Honda Civic 1996 - 2000 Service Manual

INTRODUCTION How to Use This Manual This manual contains information for the 1996- 2000 ClVlC. lt is divided into 24 sections.The first page of each section is marked with a black tab that lines up with its correspondingthumb index tab on this page and the back cover. You can quicklYfind the first page of each section without looking through a tull table ol con_ tents.The symbols printed at the top corner of each page can also be used as a quick referencesystem. Eachsectionincludesl 1. A table of contents,or an explodedview index showing: . PartsdisassemblYsequence. . Bolt torquesand thread sizes. in text . Pagereferencesto descriptaons proceduresand tools. 2. Disassembly/assembly 3. Inspection. 4. Testing/troubleshooting. 5. Repair. 6. Adjustments.

Special Information Indicates a sttong possibility of sover. perconal iniurY !@ if in3tructions are not follow€d. ol lite or loss GAUTION: Indicaiqs a possibility ot p€lsonal injury or 6quipm.nt damage il instiuc'tions are not followod

t Noncal

i-. pu.po.. ot thes6 messages is to help provent demage lo lhe vehicle, other property, or the €nvironment.

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NOTE: Giveshelpfulinformation. CAUTfON: Detaifed descriptions ol standard workshop p.oceduro3. safoty principles and servico operations are not included. Pleaso note that this manual contain3 wetnings and cautions against some sp6cific sGrvic€ methods which could cause PERSONAL INJURY, damage a vohicle or make il unsafe. Ploase undorstand that these warnings cannot covsr all conceivable weys in which service. whelher or not iocommgndod bY HONDA. mighi bo done, or ol tho possiblG hazardou3 consgquonces of ev€aYconceivablg way, nor could HONDA invqstigato all 3uch way3. AnYono using sgrvice procedures or lools, whethei or nol rGcommendod bY HONDA, must srtisty hifisetf thoroughlylhat nohher pefsonal sefety nor vehiclc satsty will be reopardi2ed. All intormationcontainedin this manual is basedon the latestprod uct information available at the time oI printing We reserve the right to make changes at any time without notice No part of this publicationmay be reproduced,stored in retrievalsystem,or trans' mitted, in any form by any means, electronic,mechanical,photo copying, recording,or otherwise,without the prior written permission of the publisher.This includestext, figuresand tables.

1848Pages FirstEdition8/99 All Right Reserved

HONOAMOTORCO.,LTD. SorvicoPublicationOffico

As sectionswith * includeSRScomponents; sDecialprecautionsare lequiredwhen servlclng

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GeneralInformation 1-2 Ghassis andPaintCodes....................... 1-32 ldentification NumberLocations......... LabelLocations.......1-33 Warning/Caution Under-hood Emissions .......1-37 ControlLabel.......... Lift and SupportPoints 1-41 LiftandSafetyStands....................... 1-42 ....................... FloorJack ......... 1-43 Towing

Chassisand PaintGodes U.S. 1996Model (2-doorHatchback)

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Vehicleldentification Number 2 H GE J 63 2 * T H I 0 0 0 0 1 Manufacturel, Make and

Type of Vehicle 2HG: HONDAOF CANADA M F G . I, N C . HONDAPassenger vehicle Line,Bodyand EngineType EJ6: CIVIC3-door/D16Y7 Body Type and TransmissionType 3: Hatchbaclds-speed M an u aI 4: Hatchbacl(4'speed Automatic Vehicle Grade 2i CX 4i DX 6: DX

D16Y7 1500001 EngineType D 16Y7:1600SOHC16-vatves SequentialMultiport Fuel-injected Engine SerialNumber

44RA: 4-speedAutomaticTransmission S40 : s-speedManualTransmission

Ch€ckDigit Model Year T: 1996 FactoryCode H: Alliston Plant, Ontario, Canada

Destinations Serial Numbel

VehicleldentificationNumber and FederalMotor Vehicle Safety Standard Certification

GY,16P NH-503P NH.583M R-97

Midori GreenPearl GranadaBlackPearl New VogueSjlver lvletallic RomaRed

O '

Paint Code

COLOR GY.l6P

o e 1-2

O O

U.S. 1996Model (4-doorSedanl ' ]500001 D16Y7-

1 H GE J 6 5 2* T L 0 0 0 0 0 1

1 H G :H O N D AO FA M E R I C A lNC. t\4FG., vehicle HONDAPassenger 2HG: HONDAOF CANADA M F G . I, N C . vehicle HONDAPassenger Line, Body and EnginsType EJ6: CIVIC4'door/D'16Y7 EJ8: CIVIC4-door/D16Yo Body Type and TransmissionTyPe Manual 5: Sedan/5-speed

Sequential D16Y7:1600SOHC16-valves Engine MultiportFuel-injected Sequential Dl6Y8: 1600SOHCVTEC16-valves Engine MultiportFuel-injected , l6Yg 1500001U . S . A : D 1 6 Y 7D

I ransmlssron

TransmissionType A4RA:4 speedAutomaticTransmission S40 : s-soeedManualTransmission

5000001A4RA(U.S.A.): S40{JAPAN): 1000001-

O O

7: LX with IVC CheckDigit Model Year T: 1996 L: EastLiberty,Ohio Plant,U.S.A. H: AllistonPlant,Ontario,Canada

Vehicleldentification Number and FederalMotor Vehicle Safety Standard Gertification

B-73M G-82P NH-538 NH-503P NH-583M R,95P

CycloneBlueMetallic CypressGreenPearl FrostWhite GranadaBlackPearl New VogueSilverMetallic lslandCoralPearl

Paint Code

COLOR 8.73M

l a 1-3

Chassisand Paint Codes U.S. 1996Model (2-doorCoupe)

o f

EngineNumber I H G E J 61 2 * T L 0 0 0 0 0 1

Line. Body and Engine Type

EJ6: CIVIC2-doorD16Y7 EJ7: ClVlC2-doorDl6Y5 EJ8: ClVlC2-door/D16Y8 Body Type and TransmissionType 1:Coupe/s-speed M an u aI 2: Coupe/4-speed Automatic,CVT

4: DX with A'lC,HX with A,,/C, EX 5: DX with ABS and A,/C,EX with ABS CheckDigit Model Year T: 1996 L: EastLiberty,Ohio Ptant,U.S.A.

Vehicleldentification Number and FederalMotor Vehicle Safety Standard Certification

1300001 EngineType D16Y5:1600SOHCWEC E 16-vatves SequentialMultiport Fuel-injected Engine D 16Y7:1600SOHC16-vatves SequentialMultiport Fuel-injected Engine D16Y8:1600SOHCWEC 16-vatves SequentialMultiport Fuel-injected Engine SerialNumber JAPAN:Dl6Y5- 130000'1U.S.A.: D16Y7,D16YB- 150000'1-

A4RA | 4-speedAutomaticTransmission S 4 0 : s - s p e e dM a n u aT l ransmission M4VA I ContinuouslyVariabte (CVT) Transmission

oa

A4RA: 5000001S40 : 1000001M4VA:1000001-

NH-503P NH-538 NH 583M R-81 R-95P

CypressGreenPearl GranadaBlackPearl FrostWhite New VogueSilverMetallic M i l a n oR e d lslandCoralPearl

Paint Code

COLOR G.82P

O O 1-4

O O

CANADA 1996Model (2-door Hatchback) VehicleldentificationNumber D16Y7 -

2 H GE J 6 3 2 * T H 0 0 0 0 0 1 Manulacturer,Make and Type of Vehicle 2HGr HONDAOF CANADA

D16Y7:1600SOHC'16-valves SequentialMultiPort Engine Fuel-injected

HONDAPassenger vehicle Line, Body and Engino Type

EJ6: ClvlC3-door/D16Y7 Body Type and TransmissionTyPe 3: Hatchbacld5-speed M a n u aI 4: Hatchbacld4-speed Automatic

VehicleGrade 2,Cx 3:CX-G

AutomaticTransmission A4RA:4-sDeed S40 : 5-sDeedManualTransmission

CheckDigit ModelYeal T: 1996 FactoryCode H: AllistonPlant,Ontario,Canada selial Number

O O

Vehicleldentification Number and CanadianMotor Vehicle Safety Standard Certification

GY-16P NH-503P NH-583M R-97

Midori GreenPearl GranadaBlackPearl New VogueSilverMetallic RomaRed

Paint Code

COLOR GY.l6P

0 0 1-5

Chassisand PaintCodes CANADA1996Model (4-doorSedanl Vehicleldentification Number lHG

r-'

Manufacturer, Make and Tvpe oI Vehicle I H G : H O N D AO FA M E R T C A M F G , I, N C . HONDAPassenger vehicle

Line, Body and EngineType EJ6: CIVIC4-door/Dt 6y7 Body Type and TransmissionType 5: Sedan/5-speed Manual 6: Sedan/4-speed Automatlc Vehicle Grade 3: LX 4: LX with ABS 5: LX with ABS and A,/C 6: EX 7: EX with ABS CheckDigit Model Year Tr 1996 FactoryCode L: EastLiberty,Ohio Plant,U.S.A. SerialNumber

Vehicleldentification Number and CanadianMotor Vehicle Safety Standard Certification

!)

EngineNumber 53 * T

800001

D 1 6 Y 7 170000'l -[

I

EngineType D16Y7r1600SOHC'16-vatves SequentialN4ultiport Fuel-injected Engine SerialNumber

TransmissionNumber A4RA 5000001

T

Transmission Type A4RA:4 speedAutomaticTransmission S 4 0 : s - s p e e dM a n u aT l ransmission SerialNumber A4RA:5000001S40 : 1000001-

B 73M G-82P NH-503P NH,538 NH.583M

t

C y c l o n eB l u eM e t a l l i c CypressGreenPearl GranadaBlackPearl FrostWhite N e wV o g u eS i l v e rM e t a l l i c

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Paint Code

COLOR 8.73M

)

1-6

O O

CANADA1996Model (2-doorCouPe) EngineNumber 1 H GE J 6 1 2 . T L 0 0 0 0 0 1

Line, Body and EngineTYPe EJ6: ClVlC2-door/D16Y7 EJ8: ClVlC2'door/D16Y8 Body Type and TransmissionTYPe

D16Y7:1600SOHCl6-valves SequentialMultiPort Engine Fuel-injected D16Y8:1600SOHCVlEC 16-valves SequentialMultiPort Engine Fuel-injected SerialNumber

A4RA- 5000001 Vehicle Glade 2: DX, Si

3: Si with ABS 5: DX with ABS CheckDigit Model Yeal T: 1996

O '

44RA:4-speedAutomaticTransmission S40 : 5-speedManualTransmission

L: EastLiberty,Ohio Plant,U S.A.

Vehicleldentification Number and GanadianMotor Vehicle Safety StandardCertification

G-82P NH-503P NH-538 NH 583M R-81 R 95P

CypressGreenPearl GranadaBlackPearl FrostWhite New VogueSilverMetallic M i l a n oR e d lslandCoralPearl

Paint Code

COLOR NH-538

O O 1-7

Chassisand Paint Codes U.S. 1997Model (2-doorHatchback)

O O

VehicleldentificationNumber 2 H G E J 63 2 * V H 1 0 0 0 0 1 Manufac-turer,Make and Type of Vehicle 2HG: HONDAOF CANADA M F G . I, N C . HONDAPassenger vehicle Lins, Eody and EngineType EJ6: ClvtC3-door/D16y7 Body Typo and TransmissionType 3: Hatchbaclds-speed Manual 4: Hatchbaclv4-speed Automatic Vehicl€ Grade 2: CX 4: DX CheckDigit Model Year V: 1997 FactoryCode H: AllistonPlant,Ontario,Canada Destinations

D16Y7:1600SOHC16-vatves SequentialMultiport Fuel-iniected Engine

A4RA:4-speedAutomaticTransmission B4RAt4-speedAutomaticTransmisston S40 : s-speedManualTransmission

44RA:6000001B4RA:6000001S40 : 1000001-

Serial Numbel

VehicleldentificationNumber and FederalMotor Vehicle Salety Standard Certification

O O NH,5O3P NH-583N4 PB-74P R-97

GranadaBlackPearl New VogueSilverMetallic DarkAmethystPearl RomaRed

Paint Code

COLOR NH-583M

O O 1-8

0 0

U.S. 1997Model (4-doorSedanl Vehicleldentification Number D 1 6 Y 7 2300001

J-tH M E J 65 2 * V S 0 0 0 0 0 1

Makeand Manulaqturer. Typeof Vehicle HONDAMOTORCO., LTD. HONDAPassenger vehicle HONDAOFAMERICA M F G . I, N C , HONDAPassenger vehicle HONDAOFCANADA M F G . I, N C , HONDAPassenger vehicle Line, Body and Engine TYPe

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EJ6: ClVlC4-door/D16Y7 EJ8: ClVlC4-door/D16Y8 Eody Type and TransmissionTYPe Manual 5: Sedan/S-sPeed 6: Sedan/4-speed Automattc Vehicle Grade 2i DX 4: EX 7: LX with A/C CheckDigit Model Yeal V: 1997 FactoryCode L: EastLibeny,Ohio Plant,U S.A Japan S: SuzukaPlant,Mie Prefecture, H: AllistonPlant,Ontario,Canada SerialNumbel

VehicleldentificationNumber and FederalMotor Vehicle Safety Standard Certification

Sequential D16Y7:1600SOHC16-valves Engine MultiportFuel-iniected Sequentral 16-valves D16Y8:1600SOHCWEC Engine MultiPortFuel-injected JAPAN:D16Y7,D16Y8- 2300001U.S.A.: D16Y7,D16Y8- 2500001-

Number Transmission A4RA- 6000001 TransmissionTYpe A4RA: 4-speedAutomaticTransmission B4RA: 4-speedAutomaticTransmission M4RA:4-speedAutomaticTransmissron S4O : s-speedManualTransmission SerialNumber A4RA(U.S.A.): 6000001^ B4RA(U.S.A.): 6000001" M4RA(JAPAN):2000001S40{JAPAN) : 1000001-

CycloneBlueMetallic CypressGreenPearl FrostWhite GranadaBlackPearl New VogueSilverMetallic lnzaRed

B 73M G-82P NH,538 NH-503P NH.583M R-96P

Paint Code

COLOR 8.73M

O O 1-9

Chassisand PaintCodes U.S. 1997Model (2-doorCoupe)

O O

EngineNumber D16Y5- 2300001

Lino. Eody and Engine Typ6

EJ6: ClVlC2-door/D16y7 EJ7: ClVlC2-door/Dl6Yb EJ8: ClVlC2-door/D16y8 Body Type and TransmissionType

Check Digit Model Yeal V: 1997 L: EastLiberty,Ohio Plant,U.S.A.

VehicleldentificationNumber and FederalMotor Vehicle Safety Standard Certification

EngineTyp6 D16Y5:1600SOHCVTEC-E16 vatves SequentialMultiport Fuel-injected Engine D16Y7:1600SOHC16-valves SequentialMultiport Fuel-injected Engine Dl6Y8r1600SOHCVTEC16 vatves SequentialMultiport Fuel-injected Engine SerialNumber JAPAN:D16Y5 2300001U.S.A.: Dl6Y7, Dl6Y8- 2500001-

A4RA: 4 speedAutomaticTransmission 84RA: 4-speedAutomaticTransmissron S40 :s-speedManualTransmission M4VA:ContinuouslyVariable Transmission(CVT)

eo

A4RA: 6000001B 4 R A :6 0 0 0 0 0 1 S40 : 1000001M4VA:2000001-

G.82P NH-503P NH,538 NH-583M R-8r

CypressGreenPearl GranadaBlackPearl FrostWhite New VogueSilverMetallic M i l a n oR e d

PaintCode

COLOR

G.82P

lo 1 - 10

eo

CANADA1997Model (2-doorHatchbackl VehicleldentificationNumber 2 H G E J 63 2 * V H 0 0 0 0 0 1 -[ Manufacturer,Make and ] Type oI Vehicle 2HG: HONDAOF CANADA M F G . I, N C . HONDAPassenger vehicle Line, Body and EngineTYPe EJ6: ClVlC3-door/D16Y7 Body Type and TransmissionTYPe 3: Hatchbacld5-sPeed lvlanual 4: HatchbaclV4-speed Automatic VehicleGrade 2i CX 3: CX-G CheckDigit Model Yeal V: 1997 FactoryCode H: AllistonPlant,Ontario,Canada

ao

'1600SOHC16-valves D16Y7: SequentialMultiPon Engine Fuel-iniected

A4RA:4-speedAutomaticTransmission B4RA:4-speedAutomaticTransmission S 4 O : s - s p e e dM a n u a l T r a n s m i s s i o n A4RA:600000184RA;6000001S40 :1000001'

Selial Number

VehicleldentificationNumbel and CanadianMotor Vehicle Safety Standard Certification

NH-503P NH.583M PB.14P R-97

GranadaBlackPearl New VogueSilverMetallic DarkAmethystPearl RomaRed

PaintCode

COLOR NH.5O3P

e o 1-11

Chassisand Paint Godes CANADA1997Modet(4-doorSedan)

]l l H G E J 65 3 * V L 8 0 0 o o l

D16Y7 2750001

1600SOHC16-vatves SequentialMultiport Fuel-injected Engine Line, Body and EngineType EJ6: ClvtC4-door/D16y7 Body Typ€ and TransmissionType 5; Sedan/5-speed Manual

4: LX with ABS 5; LX with ABS and A,/C 7: EX with ABS 8: EX with ABS and Ay'C Ch.ck Digit Model Year V: '1997

,A4RA:4-speedAutomaticTransmission B4RA:4 speedAutomaticTransmission S40 :s-speedManualTransmission

44RA:6000001B4RA:6000001S40 :1000001-

0 0

B-73M

VehicleldentificationNumber and CanadianMotor Vehicle Safety Standard Certification

NH-503P NH-538 NH-583M

CycloneBlueMetallic CypressGreenPearl GranadaBlackPearl FrostWhite New VogueSilverMetallic

Paint Code

COLOR B.73M

ea 1-12 E-

ao

CANADA1997Model (2-doorCouPel EngineNumber D16Y7 2750001

1 H GE J 6 1 2 * V L 8 0 0 0 0 1

1 H G : H O N D AO FA M E R I C A

Line, Body and EngineTYPe EJ6: ClvlC2-door/D16Y7 EJ8: ClVlC2-door/D16Y8 Body Type and Tr8nsmissionTYP8

Engins Typs D16Y7:1600SOHC16-valves SequentialMultiPort Engine Fuel-injected D16Y8:l600 SOHCVTEC16-valves SequentialMultiPort Engine Fuel-iniected SerialNumber

A4RA- 6000001

0 0

Vehicle Grado 2 : D X ,S i 3: Si with ABS 5: DX with ABS 6: DX with ABS and l'lc 7: Siwith ABS and A,/C CheckDigit Model Ysar V:1997

A4RA:4-speedAutomaticTransmission B4RA:4-speedAutomaticTransmission S4O : s-speedManualTransmission A4RA:6000001B4RA:6000001* S40 :1000001-

L: EastLiberty,Ohio Plant,U.S.A.

Vehicle ldentification Number and CanadianMotor Vehicle Safety Standard Certification

CypressGreenPearl GranadaBlackPearl FrostWhite New VogueSilverMetallic M i l a n oR e d

G-82P NH-503P NH-538 NH-583M R-81

PaintCode

COLOR

NH-538

a o 1-13

Ghassisand PaintGodes U.S. 1998Model (2-doorHatchback)

0 a

Vehicleldenti{icationNumber 2 H G E J 63 2 . W H 1 0 0 0 0 1 Manufactursr,Mak€ and Type of Vehicle 2HG: HONDAOF CANADA MFG.,INC. HONDAPassenger vehicle Lin€, Body and Engine Type EJ6: ClvlC3-door/D16y7 Body Type and TransmissionType 3: Hatchbaclds-speed Manual 4: Hatchbacl/4-speed Automatic Vehicle Grade 2i CX 4: DX CheckDigit Model Year W: 1998 FactoryCode HrAllistonPlant,Ontario,Canada Deslinations

D16Y7:'1600SOHCl6-valves SequentialMultiport Fuel-injected Engine

B4RA:4-speedAutomaticTransmission S40 : s-speedManualTransmission

Serial Numbet

Vehicleldentification Number and FederalMotor Vehicle Safety Standard Certification

NH-592P NH-583M PB,74P R-97

FlamencoBlackPearl New VogueSilverMetallic DarkAmethystPearl RomaRed

0 0

PaintCode

COLOR NH.583M

ao 1-14

eo

U.S. 1998Model (4'doorSedan) VehicleldentificationNumber

EngineNumber D 1 6 Y 7 3300001

J H M E J 65 2 * W S O O O O O 1 Manufacturer,Make and Type of Vehicle J H M : H O N D AM O T O RC O .

LTD. Passenger HONDA vehicle HONDAOFAMERICA M F G . I, N C . HONDAPassenger vehicle HONDAOF CANADA M F G , I, N C , HONDAPassenger vehicle Line, Body and Engine TYPe

ro

EJ6: ClVlC4-door/D16Y7 EJ8: ClVlC4-door/D16Y8 Body Type and TransmissionTYPe Manual 5: Sedan/5-sPeed 6r Sedan/4-speed Automatic vehicle Grade 2i DX 4: EX 7: LX with IVC Check Digit Model Yeal W: 1998 FactoryCode L: EastLiberty,Ohio Plant,U S.A Japan S: SuzukaPlant,Mie Prefecture, H: AllistonPlant.Ontario,Canada SerialNumber 000001:JAPAN,U.S.A. 500001:CANADA

EngineType Sequential D16Y7:1600SOHC16-valves Engine MultiportFuel'injected Sequential D l6Y8: 1600SOHCVTEC16-valves Engine Fuel-injected Multiport Serial Number JAPAN:D16Y7.D16Y8- 3300001U.S.A : D16Y7,D16Y8- 3500001^

B4RA 700000' I

84RA: 4-speedAutomaticTransmission M4RA:4-speedAutomaticTransmission S4O :s-speedManualTransmission B4RA(U.S.A.): 7000001M4RA(JAPAN):3000001" S40(JAPAN) : 1000001-

CycloneBlueMetallic CypressGreenPearl TaffetaWhite FlamencoBlackPearl New VogueSilverMetallic lnzaRedPearl

B-73M G 82P NH-578 NH-592P NH-583M R-96P

PaintCode VehicleldentificationNumber and FederalMotor Vehicle Sa{ety Standard Certification

COLOR B-73M

e o 1-15

Ghassisand Paint Codes U.S. 1998Model (2,doorCoupel

ea

EngineNumber l H G E J 61 2 * W L 0 0 0 0 0 1

Line, Body and Enginc Type EJ6: ClVlC2-door/D16y7 EJ7: ClVtC2-door/D16ys EJ8: ClvlC2-door/D16y8 Body Type and TransmissionType

5: EX with ABS and IVC ChockDigir Model Year W: 1998 L: EastLiberty,Ohio ptant.U.S.A.

Vehicleldentification Number and FederalMotor Vehicle Safety Standard Certification

D16Y5 3300001 EngineType D16Y5:1600SOHCWEC-El6,vatves SequentialMultiport Fuel-injected Engine D16Y7:1600SOHC16-valves SequentialMultiport Fuel-in.iected Engine Dl6Y8: 1600SOHCWEC 16-vatves SequentialMultiport Fuel-injected Engine Serial Number JAPAN:D16Y5- 3300OOtU.S.A.: D16Y7,D'16y8- 3500001-

84RA: 4-speedAutomaticTransmissron S40 :s-speedManualTransmission M4VA:ContinuouslyVariable Transmission(CVT)

0 a

B4RA:7000001S40 :1000001M4VA:4000001-

NH-592P NH-578 NH-583M R-81

CypressGreenPearl FlamencoBlackPearl TaffetaWhite New VogueSilverMetaltic MilanoRed

PaintCode

COLOR G.82P

aa 1-16

trO

CANADA 1998Model (2-door Hatchback) VehicleldentificationNumber 2 H G E J 63 2 + W H 0 0 0 0 0 1 Manulacturet, Make and Type of Vehicle 2HG: HONDAOF CANADA HONDAPassenger vehicle Line,Body and EngineTYPe EJ6: ClVlC3-door/D16Y7 Body Type and TransmissionTYPe 3: Hatchbacld5-sPeed M a nu a l 4: Hatchbacld4-sPeed Automatic Vehicle Grade 2t CX 3:CXG CheckDigit Model Year W: 1998 FactoryCode H: AllistonPlant,Ontario,Canada SerialNumber

VehicleldentificationNumber and CanadianMotor Vehicle Safety StandardCertification

1600SOHC16-valves SequentiallvlultiPort Edn g i n e Fuel-injecte

B4RA:4-speedAutomaticTransmission S40 :s-speedManualTransmission 84RA:7000001S40 :1000001'

NH-592P NH-583M PB-74P R-97

FlamencoBlackPearl New VogueSilverMetallic DarkAmethystPearl BomaRed

Paint Code

COLOR NH.592P

1-17

Chassisand Paint Codes CANADA1998Model (4-doorSedanl

A O

VehicleldentificationNumber 2HG .I

Manufacturer,Make and Type of Vehicte 2HG: HONDAOF CANADA M F G , I, N C . HONDApassenger vehicle JHM: HONDA|\4OTOR CO.,

r_rD

H 900001

I ] l I

D16Y7:1600SOHC16-valves SequentialMultiport Fuel-injected Engine 3 7 5 0 0 0 1 -U: . S . A . 370000'l-:JAPAN

] HONDApassenger I vehicte I Line, Body and EngineType EJ6: ClVlC4-door/D16y7 Body Type and TransmissionType 5: Sedan/5speedManual 6: Sedan/4-speed Automatic VehicleGrade 0: EX 3: LX 4: LX WithABS 5: LX with ABS and A"/C 7: EX with ABS 8: EX with ABS and A"/C CheckDigit Model Year W: 1998 FastoryCode H :A l l i s t o nPlant,Ontario,Canada S : S u z u k aPlant,N4iePrefecture, Japan SerialNumber 800001^:JAPAN 900001-:CANADA

VehicleldentificationNumber and CanadianMotor Vehicle SafetyStandardCertification

B4RA{U.S.A,): 700000.1M4RA(JAPAN): 3000001S40(JAPAN) : 'tOO0OO1-

0 0 B-73M NH-592P NH-578 NH-583M

CycloneBluef\4etallic CypressGreenPearl FlamencoBlackpearl TaffetaWhite New VogueSilverMetallic

Paint Code

COLOR 8.73M

ao 1-18

aa

CANADA1998Model (2-doorCouPe) Vehicleldentification Numbel

EngineNumber D16Y7

1 H GE J 61 2 * W

1 H G : H O N D AO FA M E R I C A M F G , I, N C , HONDAPassenger vehicle Line, Body and Engine TYPe

EJ6: CIVIC2 door/D16Y7 EJ8: CIVIC2 dootD16Y8 Body Type and TransmissionTYPe

EngineType 1600SOHC16-valves D'16Y7: SequentiallvlultiPort FueliniectedEngine D16Y8:1600SOHCVTEC16-valves SequentialMultiPon Engine Fuel-iniected Serial Numbel

D16Y7:375000'l' D16Y8:3780001-

Vehicle Grade 2: DX, Si

tio

3: Si with ABS 5: DX with ABS 6: DX with ABS and A,/C 7: Si with ABS and A,/C CheckDigit ModelYear W:1998

B4RA:4-speedAutomaticTransmissron S40 : s-speedManualTransmission 84RA:7000001S40 :1000001-

L: EasrLiberty,Ohio Plant,U.SA.

Vehicleldentification Number and CanadianMotor Vehicle safety StandardCertification

Cypress Green Pearl Flamenco Black Pearl Taffeta White N e w V o g u e S i l v e rM e t a l l i c MilanoRed

G-82P NH-592P NH-578 NH-583M R,81

Paint Code

COLOR NH-578

t a 1-19

Chassisand Paint Codes U.S. 1999Model (2-doorHatchbackl

aa

Vehicleldentification Number 2HGEJ632*XH100001

Manufacturer, Makeand Typeof Vehicte

T

2HG: HONDAOF CANADA

M F G .t.N C . HONDApassenger

I I

vehicle Line,Body and EngineType - _ r EJ6: CIVIC3-door/Dt6y7 Body Type and TransmissionType 3: Hatchback/b-speed M an u aI 4: Hatchbacl/4-speed Automatic Vehicle Grade 2: CX 4: DX Check Digit Model Year X: 1999 FactoryCode H: AllistonPlant,Ontario,Canada Destinations

D'16Y7: 1600SOHCl6-vatves SequentialMultipon Fuel-injected Engine

84RA:4-speedAutomaticTransmission S40 : s-speedManualTransmission B4RA:8000001S40 | 1000001-

Serial Numbel

VehicleldentificationNumber and FederalMotor Vehicle Safety Standard Certification

NH.592P NH.583M PB-14P R-97

FlamencoBIackPearl New VogueSilverMetallic DarkAmethystPearl RomaRed

1a

PaintCode

COLOR NH-583M

a a 1-20

ro

U.S. 1999Model (4'doorSedan) Vehicleldentification Number

-f

J H ME J 6 5 2 * X S 0 0 0 0 0 1 Manufacturel,Make and Type ol vehicle 1 H G : H O N D AO FA M E R I C A

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HONDAPassenger vehicle HONDAOF CANADA M F G . I, N C . HONDAPassenger vehicle HONDAMOTORCO., LTD. HONDAPassenger vehicle Line. Body and EngineTYPe EJ6: CIVIC4 door/D16Y7 EJ8: ClVlC4-door/D16Y8 Body Type and TransmissionTYPe Manual 5: Sedan/S-speed 6: Sedan/4-speed Automatic Vehicle Grade 'l: DX-V 2t DX 4: EX 7: LX Check Digit Model Year X: 1999 FactoryCode L: EastLiberty,Ohio Plant,U S.A H: AllistonPlant,Ontario,Canada Japan S: SuzukaPlant,Mie Prefecture, Serial Numbel U.S.A. 000001:JAPAN. 500001:CANADA

EngineType Sequential 1600SOHC16-valves D,]6Y7: Engine MultiportFuel-injected

D16Y8: U.S.A : D16Y7.D16Y8- 4500001-

B4RA: 4-speedAutomaticTransmission S40 :s-speedManualTransmission

B4RA(U.S.A.): 8000001M4RA{JAPAN):4000001'1000001S40(JAPAN) :

lcedTealPearl CloverGreenPearl TaffetaWhite FlamencoBlackPearl New VogueSilverMetallic lnzaRedPearl

BG.41P NH-578 NH-592P NH.583M R-96P

Paint Code

COLOR NH-s78

Vehicleldentification Number and FederalMotor Vehicle Safety Standard Certification

t a 1-21

Chassisand Paint Codes U.S. 1999Model (2-doorCoupe) VehicleldentificationNumber

aa

EngineNumber

1 H GE J 61 2 * X L 0 0 0 0 0 1 Manutacturer,Make and Type of Vehicle '1HG: HONDAOF AMERTCA M F G . I, N C . HONDAPassenger vehicle Line, Body and EngineType EJ6: ClVlC2-door/D16y7 EJ7: ClVlC2-door/D16y5 EJ8: ClvlC2-door/D16y8 EM1: CIVIC2-doorlB'1642 Body Type and TransmissionType

1:Coupe/s-speed Manual 2: Coupe/4-speed Automatic, CVT VehicleGrade 2: DX, HX 4: EX 5: EX WithABS,Si CheckDigit Model Year X:1999 FactoryCode L: EastLiberty,Ohio Plant,U.S.A. SerialNumber

VehicleldentificationNumber and FederalMotor Vehicle Safety Standard Certification

EngineType 81642:'1600 DOHCVTEC16 vatves SequentialMultiport Fuel-injected Engine Dl6Y5: 1600SOHCWEC-E16 vatves SequentialMultipon FuelinjectedEngine D16Y7:1600SOHCt6-vatves SequentialMultiport Fuel,injected Engine D16Y8:1600SOHCVTEC16-vatves SequentialMultipon Fuel-injected Engine Serial Numbel JAPAN:816A2,Dl6Y5 - 4300001U.S.A.: D16Y7,D16Y8- 4SO000t -

B4RA : 4-speedAutomaticTransmission S40,S4C:5-speedManuatTransmission M4VA : Continuously Variable (CVT) Transmission

ta

B4RA : 8000001S 4 0 ,S 4 C : 1 0 0 0 0 0 1 M4VA : 5000001-

B-95P G-95P NH-592P NH-578 NH-583M R-97

ElectronBluePearl CloverGreenPearl FlamencoBlackPearl TaffetaWhite New VogueSilverMetallic RomaRed

PaintCode

COLOR NH.592P

1-22

ea

CANADA1999Model (2-doorHatchback) Vehicleldentification Number

E n g r n eN u

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2 H GE J 6 3 2 * X H 0 0 0 0 0 1

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Manufacturer,Make and Type of Vehicl€ 2HG: HONDAOF CANADA lNC. l\4FG., HONDAPassenger vehicle Line,Bodyand EngineType EJ6: ClVlC3-door/D16Y7 Body Type and TransmissionType speed 3r Hatchbaclds M an u aI 4r Hatchbacld4-speed Automatic VehicleGrade 2: CX 3: DX CheckDigit Model Year X: 1999 FactoryCode H: AllistonPlant,Ontario,Canada Serial Number

Vehicleldentification Number and CanadianMotor Vehicle Safety Standard Certification

EngineType D16Y7:1600SOHC16-valves SequentialMultiport Engine Fuel-injected

B4RA 8000001

T

t

TransmissionType B4RA:4-speedAutomaticTransmission S40 : s-speedManualTransmission SerialNumber 84RA:800000'lS40 :1000001-

NH-592P NH-583M PB.74P R,97

FlamencoBlackPearl New VogueSilverMetallic DarkAmethystPearl RomaRed

PaintCode

COLOR NH.592P

t a 1-23

Ghassisand Paint Codes CANADA1999Model (4-doorSedanl

eo

Vehicleldentification Number J H ME J 6 5 3 * X S 8 O O O O 1 Manufaclurer,Make and Type ot Vehicle JHM: HONDAMOTORCO., LTD. HONDAPassenger vehicle 2HG: HONDAOF CANADA M F G . I, N C . HONDAPassenger vehicle Line, Body and EngineType EJ6: ClVlC4-door/D16Y7 Body Type and TransmissionType 5: Sedan/s-speed Manual 6: Sedan/4-speed Automatic

VehicleGrade 0:EX 3: LX 4: LX with ABS 5: LX with ABS and lVC 7: EX with ABS 8: EX with ABS and Ay'C Ch6ckDigit Model Year X: 1999 FactoryCode S: SuzukaPlant,Mie Prefecture, Japan H: AllistonPlant,Ontario,Canada SerialNumber 800001:JAPAN 900001:CANADA

D16Y7 4700001 EngineType D 16Y7:1 600SOHC16-valves Sequential MultiportFuel-injected Engine JAPAN:D16Y7- 4700001- 4750001U.S.A : D'16Y7

B4RA: 4-speedAutomaticTransmission M4RA:4-speedAutomaticTransmission S40 rs-speedManualTransmission B4RA(U.S.A.): 8000001M4RA(JAPAN);400000'lS40(JAPAN) : 1000001-

ro BG.41P G-95P NH-578 NH-592P NH-583M R-97

lcedTealPearl CloverGreenPearl TaffetaWhite FlamencoBlackPearl New VogueSilverMetallic RomaRed

PaintGode VehicleldentificationNumber and CanadianMotor Vehicle Safety Standard Certification

COLOR BG.41P

ta 1-24

CANADA1999Model (2-doorCouPel VehicleldentificationNumber

EngineNumber D 1 6 Y 7 4750001

1 H GE J 61 2 * X L 8 0 0 0 0 1 Manufacturer,Make and Type of Vehicle l H G r H O N D AO FA M E R I C A I M F G , I, N C . HONDAPassenger vehicle i Line. Body and EngineTyPe EJ6: ClVlC2-door/D16Y7 EJ8: ClVlC2-door/D16Y8 EMlr CIVIC2'doorlB'16,42 Body Type and TransmissionTYPe 1:Coupe/s-speed M a nu a l 2: Coupe/4-speed Automatic Vehicle Grade 2: DX,Si 4 :S i R 5: SiRwith ABS 6: DX with ABS and IVC 7: Si with ABS and A,,/C CheckDigit Model Year X:1999 FactoryCode L: EastLiberty,Ohio Plant,U.S.A. SerialNumbel

Vehicleldentification Number and CanadianMotor Vehicle Safety Standard Certification

EngineType 816,42:1 600DOHCVTEC16-valves SequentialMultiport FuelinjectedEngine D16Y7:1600SOHC16'valves SequentialMultiPort Engine Fuel-injected D16Y8:1600SOHCVTECl6-valves SequentialMultiPort Engine Fuel'injected SerialNumber

8 1 6 4 21: 7 0 0 0 0 1 D16Y7: 47500014780001' D16Y8:

TransmissionNumber B4RA

T

Type Transmission B4RA : 4-soeedAutomaticTransmission S40.S4C:5-sgeedManualTransmission SerialNumber B4RA : 8000001S40,S4C:1000001-

C ol o r B.95P G-95P NH-592P NH 578 NH-583M R97

ElectronBluePearl CloverGreenPearl F l a m e n cB o l a c kP e a r l TaffetaWhite N e wV o g u eS i l v e rM e t a l l i c R o m aR e d

PaintCode

COLOR NH-592P

t o 1-25

Chassisand PaintCodes U.S.2000Model (2-doorHatchback)

0 0

VehicleldentificationNumber 2 H G E J 6 3 2 *H 1 0 0 0 0 1 Manufacturer,Make and Type of Vehicle 2HG: HONDAOF CANADA M F G , I, N C . HONDAPassenger Vehicle Line, Body and EngineType EJ6: ClVlC3-door/D16Y7 Body Type and T.ansmissionType 3: Hatchbaclds-speed Manual 4: Hatchbacld4-speed Automatic Vohicle Grade 2: CX 4: DX Check Digit Model Yeal

Y: 2000

D16Y7 -[ 5500001 Dl6Y7: 1600SOHCI6-valvesSequenlal MultiportFuel-injected Engine

84RA:4 speedAutomaticTransmissron S40 :s-speedManualTransmissiorr 84RA:900000'lS40 | 100000'l-

FastoryCode H: AllistonPlant,Ontario.Canada SerialNumber

VehicleldentificationNumbeI and FederalMotor Vehicle Safety Standard Certification

NH-578 NH.583M NH-592P R-97

TaffetaWhite New VogueSilverlr4etallic FlamencoBlackPearl RomaRed

to

PaintCode

COLOR NH.583M

ro 1-26

t

U.S.2000Model {4-doorSedan) VehicleldentificationNumber

EngineNumber Dl6Y7, 5300001

J H ME J 6 5 2 * Y S 0 0 0 0 0 1 Manufacturer,Makg and Type of Vehicle JHM: HONDAMOTORCO., LTD. HONDAPassenger Vehicle HONDAOFAMERICA MFG.,INC. HONDAPassenger Vehicle 2 H G : HONDAOF CANADA IVIFG., INC, HONDAPassenger Vehicle Line, Body and EngineType EJ6: ClVlC4-door/D16Y7 EJ8: ClVlC4-door/D16Y8 Body Type and TransmissionTyPe Manual 5: Sedan/5-speed Automatic 6: Sedan/4-speed Vshicle Grade 2: DX 4: EX 7: LX CheckDigit Model Year Y: 2000 FactoryCode Japan S: SuzukaPlant,Mie Pretecture, L: EastLiberty,Ohio Plant,U.S.A. H: AllistonPlant,Ontario,Canada Serial Number JapanU , .S.A.:000001500001Canada:

VehicleldentificationNumber and FederalMotor Vehicle Safety Standard Certification

EngineType Sequential D16Y7:1600SOHC16-valves Engine MultiportFuel-iniected D16Y8:1600SOHCVTEC16-valves SequentialMultiportFuel-iniected Engine Sorial Numbsr Japan:5300001U.S.A.r5500001-

AutomaticTransmission : 4-sDeed S4RA : 4-speedAutomaticTransmission B4RA S40,S4C : s-speedManualTransmission S4RA{Japan) B4RA(U.S.A.) S40,S4C(Japan)

lcedTealPearl CloverGreenPearl TaffetaWhite FlamencoBlackPearl TitaniumMetallic VintagePlum Pearl

BG-41P G.95P NH-578 NH-592P YR.525M RP.32P

Paint Code

COLOR NH-578

t o 1-27

Chassisand Paint Codes U.S.2000Model (2-doorCoupe) VehicleldentificationNumber

ta

EngineNumber

l H GE J 61 2* Y 1 0 0 0 0 0 1 Manufacturer.Make and Type ol Vehicle '1HG: HONDAOF AMERICA t\4FG., tNC. HONDAPassenger Vehicle Line,Body and EngineType EJ6: ClvlC2-door/Dt6Y7 EJ7: ClVlC2,door/D16y5 EJ8: ClVlC2-door/D16Y8 EM1: CIVIC2-doorlB1642 Body Type and TransmissionType 1: Coupe/s-speed Manual 2: Coupe/4-speed Automatic,CVT Vehicle Grade 2: DX, HX 4: EX 5: EX with ABS,Si CheckDigit Model Year

D16Y5- 5300001 EnginoType Bl642; 1600DOHCWEC '16-vatves SequentialMultiportFuel-injected Engine D'I6Y5:1600SOHCWEC-E16.vatves SequentialMultiportFuel-injected Engine D16Y7:1600SOHC16-valves Sequenlal MultiportFuel-injected Engine D16Y8:1600SOHCWEC 16-vatves SequentialMultipon Fuel-injected Engine Serial Number 81642,D16Y5:5300001Dl6Y7,Dl6Y8:5500001-

Y: 2000 FactoryCode L: EastLiberty,Ohio Plant,U.S.A. Serial Number

VehicleldentificationNumber and FederalMotor Vehicle Safety Standard Certification

B4RA : 4-speedAutomaticTransmission S40,S4C:5-speedManualTransmissron M4VA :ContinuouslyVariable (CVT) Transmission

to

B4RA : 9000001* S40.S4C:1000001M4VA :6000001-

B-95P NH-578 NH.583M NH-592P R-81

ElectronBluePearl CloverGreenPearl TaffetaWhite New VogueSilverMetallic FlamencoBlackPearl M i l a n oR e d

PaintCode

COLOR NH.592P

to 1-28

ro

CANADA2000 Model (2-door Hatchbackl Vehicle ldentification Number D16Y7 -

2 H GE J 6 3 2 * Y H 0 0 0 0 0 1 Manufaqturor,Make and Type of Vehicle 2HG: HONDAOF CANADA HONDAPassenger Vehicle Line, Body and EngineType EJ6: ClVlC3-door/Dl6Yt Body Type and TransmissionType Manual 3: HatchbacUs-sDeed Automatic 4; Hatchbacld4-speed Vehicle Glade 2t CX 3: OX 5r SE CheckDigit Model Yoal Y: 2000 FactoryCode H: AllistonPlant.Ontario,Canada Serial Numb€r

VehicleldentificationNumber and CanadianMotor Vehicle Safety Standard Certification

Sequential D16Y7:1600SOHC16-valves Engine MultiportFuel-injected Number Se1i8l

B4RA:4-speedAutomaticTransmission S40 : s-speedManualTransmission 84RA:9000001S40 :1000001-

NH.583M NH.592P R-97 RP-32P

New VogueSilverMetallic FlamencoBlackPearl RomaRed VintagePlum Pearl

Paint Code

COLOR NH.592P

1-29

Chassisand Paint Codes CANADA2000Model (4-doorSedanl

ro

VehicleldentificationNumber J H M E J 65 2 * Y S 8 0 0 0 0 1 Manufaqturer, Makg and

Type ot Vehicle JHM: HONDAMOTORCO., LTD. HONDAPassenger Vehicle 2HG: HONDAOF CANADA M F G . I, N C . HONDAPassenger Vehicle Line, Body and EngineType EJ6: ClVlC4-door/D16Y7 Body Type and TransmissionTyp€ 5: Sedan/s-speed Manual 6: Sedan/4-speed Automatic Vehicle Grade 0: EX 1: LX-V 2: LX-Vwith ABS 3: LX 4: LX with ABS 5: LX with ABS and ly'C 7: EX with ABS 8; EX with ABS and A,,/C Check Digit Model Y€ar

Y: 2000 Fac'tory Code S: SuzukaPlant,Mie Prefecture, Japan H: AllistonPlant,Ontario,Canada Serial Number Japan :800001Canada:900001-

VehicleldentificationNumber and CanadianMotor Vehicle Safety Standard Certification

D16Y7 EngineType D't6Y7| 1600SOHC16-valves Sequential MultiportFuel-injected Engine J a p a n5 : 700001U.S.A.:5750001-

Transmission Number

--t

S4RA- 5000001 TransmissionType 54RA: 4-speedAutomaticTransmissron B4RA: 4-speedAutomaticTransmissron S 4 0 : s - s p e e dM a n u aT l ransmission SerialNumber

54RAlJapan) : 500000'1B4RA(U.S.A,); 900000 1S40(Japan) : '1000001,

ro

Paint Code Paint Code

G-95P NH,583M NH.592P YR-525M RP.32P

CloverGreenPearl New VogueSilverMetallic FlamencoBlackPearl TitaniumMetallic VintagePlum Pearl

PaintCode

COLOR NH.583M

ro 1-30

CANADA2000 Model (2-doorCoupel VehicleldentificationNumber l H G E J 6 ' l2 * Y 1 8 0 0 0 0 1

L

Manufacturer,Make and Type of Vehicle 1 H G : H O N D AO FA M E R I C A M F G , I, N C . HONDAPassenger Vehicle Line, Body and EngineType EJ6r ClVlC2-door/D16Y7 EJ8: ClVlC2-door/D'16Y8 EM1: CIVIC2-door/B1642 Body Type and TransmissionType Manual 1: Coupe/s-speed Automatic 2: Coupe/4-speed Vehicle Grade 2: DX,Si 4 :S i R 5: SiRwith ABS 6: DX with ABS and A,/C 7:DXG Check Digit Model Year Y: 2000 FactoryCode L: EastLibertv,Ohio Plant.U.S.A. SerialNumber

81642 5700001

816A2:1600DOHCVTEC16-valves SequentialMultiportFuel-iniected Engine '1600SOHC16-valves Sequential Dl6Y7: Engine MultiportFuel-injected D16Y8:1600SOHCWEC 16-valves SequentialMultiponFuel-injected En gi n e 81642:5700001D16Y7:575000'lD16Y8:578000'l-

B4RA :4-speedAutomaticTransmission S40,S4C:s-speedManualTransmissron B4RA :9000001S40,S4C:1000001-

VehicleldentificationNumber and CanadianMotor Vehicle Safety Standard Certification 8.95P G.95P NH-583M NH.592P R-81

ElectronBlue Pearl CloverGreenPearl New VogueSilverMetallic FlamencoBlackPearl M i l a n oR e d

PaintCode

COLOR NH-592P

ra 1-31

ldentification Number Locations

t,

Vehicle ld6ntification Numbsr(VlN)

ta

Number

1-32

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Warning/CautionLabelLocations

A: CABLEREELCAUTIONA:

'96 -99 model

TO SERVICEMANUAL FOR DETAILEDINSTRUC.

TtoNs. '00 model ALLATIONOF THE SRS CAELEREELIS CRITICALTO THE PROPEROPERATIONOF THE SRSSYSTEM.REFERTO T H E S E R V I C E M A N U A L D E T A I L E DI N S T A L L A T I O N INSTRUCTIONS. Br oRIVERMODULEWARNING WARNING THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIOENHURTOR KILLYOU. CAN SERIOUSLY TALLYDEPLOYEO, TESTEoUIPMENToR PROB. DO NOT USE ELECTRICAL ING OEVICES. DEPLOYMENT. THEYCAN CAUSEACCIDENTAL o N O S E R V I C E A B L EP A R T S l N S l D E . D O N O T DISASSEMBLE. . PLACEAIRBAGUPRIGHTWHENREMOVED. CAFEFULLY. . FOLLOWSERVICE MANUALNSTBUCTIONS

C: DRIVERMODULEOANGER DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACIO.WATER OR HEAVY METALS SUCH I.EADOR MERCURYMAY PRODUCEHARMFUL AS COPPER. AND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS, MUST NOT EXCEED2OO'F STOBAGETEMPERATURES I1(x}"CI.FOR PROPERHANDLING.STORAGEAND DISPOS. REFERTO SERVICEMANUAL. SRS SUP. AL PROCEDURES PLEMENT. POTSON CONTAINSPOISONOUSSODIUM AZIOEAND POTASSIUM NITRATE. FIRSTAID: IF CONTENTSARE SWALLOWED,INDUCEVOMITING,FOB EYECONTACT.FLUSHEYESWTTHWATERFOR15 MINUTES. IF GASES{FNOMACIOORWATEBCONTACTIAREINHALED, SEEKFRESHAIR. IN EVERYCASE,GET PBOMPTMEDICAL ATTET,ITION. KEEPOUT OF REACHOF CHILDREN.

(cont'd)

1-33

Warning/GautionLabelLocations

to

(cont'dl

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F

v7777m7na

ro D: DRIVERINFORMATION: CANADAmod6l l'96 - gtt modell

.

.

ALWAYSWEARYOURSEATBELT THIS CAR IS EOUIPPED WITH A DRIVERAIRBAGAND A FRONTSEAT PASSENGER AIRBAG' AS A SUPPLEMENTAL RESTRAINTSYSTEMISRSI. IT IS OESIGNED TO SUPPLEMENT THESEATBELT,

* Except CANADA CX E: SBSINFORMATION:U.S. model ('96.'97 model) CAUTION TO AVOIDSERIOUSINJURY: . FORMAXIMUM SAFEW PROTECTION IN ALL TYPESOF CBASHES,YOU MUST ALWAYS WEAR YOUR SAFETY BELT. . DO NOT INSTALLREARWARD-FACING CHILDSEATSlN ANY FRONTPASSENGER SEATPOSITION. . DO NOT SIT OR LEAN UNNECESSARILY CLOSETO THE AIRBAG. . DO NOT PLACEANY OBJECTSOVERTHE AIRBAGOR BETWEENTHEAIRSAGAND YOURSELF. o SEE THE OWNER,S MANUAL FOB FURTHER INFORMATION AND EXPLANATIONS. . THESRS MUST BE INSPECTED TEN YEASSAFTERIT IS INSTALLED, . THE DATEOF INSTALI-ATION I S S H O W NO F T H E DRIVER'SDOORJAMB.

1-34

U.S. model l'98, 39 model) WARNING OEATHOR SERIOUSINJURYCAN OCCUR. . CHILDREN 1 2 A N D U N O E RC A N B E K I L L E DB Y T H E AIREAG. . THEBACKSEATIS THESAFESTPLACEFORCHILDREN. o N E V E RP U T A B E A R . F A C I N G C H I L DS E A T I N T H E FRONT. . SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG. . ALWAYSUSESEATBELTSAND CHILDRESTRAINTS. . THE SRSMUST BE INSPECTED TEN YEARSAFTERIT IS INSTALLED, . T H E D A T E O F I N S T A L L A T I O NI S S H O W N O N T H E DRIVER'SDOORJAMB. U.S. model ('00 modelI WARNING DEATHOR SERIOUSINJURYCAN OCCUR, . CHILDREN12 AND UNDER CAN BE KILLEDBY THE AIRBAG. . THEBACKSEATIS THESAFESTPLACEFORCHILOREN. . N E V E RP U T A R E A R - F A C I N G C H I L DS E A T l N T H E FRONT. o SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG. o ALWAYSUSESEATBELTSAND CHILDRESTRAINTS.

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Llo

MOOULEDANGER I: FRONTSEATPASSENGER

CANADAmodel ('00 model) CAUTION TO AVOIDSERIOUSINJURYT lN ALL TYPESOF . FORMAXIMUM SAFETYPROTECTION CRASHES,YOU MUST ALWAYS WEAR YOUR SAFETY BELT. CHILDSEATSlN . DO NOT INSTALLREARWARD-FACING SEATPOSITION. ANY FRONI PASSENGER . DO NOT PLACEANY OBJECTSOVER THE AIRBAGOR BETWEENTHEAIRBAGAND YOURSELF. . SEE THE OWNER'S MANUAL FOR FURTHER ANDEXPLANATIONS. INFORMATION ExceptCx tor passengerside F: ASSISTANTINFoRMATION:US MODEL('96.

'97 mod€l)

AIRBAGSEEOTHERSIDE, U.S. model l'98 - 00 modell AIRBAGWARNING FLIPVISOROVER G: STEERINGCOLUMNNOTICE

Llo

NOTICE TO PBEVENTSRS DAMAGE, REMOVESTEERINGWHEEL BEFOREREMOVINGSTEERINGSHAFT CONNECTING BOLT. ll: MONITORCAUTION NOTICE . NO SERVICEABIfPABTSlNSlDE. . REFERTO SERVICEMANUAL FORDETAILEDINSTRUC' TtoNs.

DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVY METALS SUCH LEADOR MERCURYMAY PRODUCEHARM. AS COPPER, F U L A N D I R R I T A T I N GG A S E S O R E X P L O S I V EC O M MUST NOT EXCEED POUNDS,STORAGETEMPERATURES FOR PROPERHANOLING,STORAGEAND 2OO'FI1OO"C}. REFERTO SERVICEMANUAL' DISPOSALPNOCEDURES SRSSUPPLEMENT. POISON CONTAINSPOISONOUSSODIUM AZIDEAND POTASSIUM NITRATE. FIRSTAID IF CONTENTSARE SWALLOWEO,INDUCEVOMITING.FOR EYE CONTACT,FLUSH EYES WITH WATEB FOR 15 MINUTES. IF GASESIFROM ACID OB WATER CONTACT)ABE INHALED.SEEKFRESHAIR. IN EVERYCASE,GET PROMPT MEDICALATTENTION. KEEPOUT OF REACHOF CHILDREN, WARNING THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIDENHUBTOR KILLYOU. CAN SERIOUSLY TALLYOEPLOYED, . D O N O T U S E E L E C T R I C ATL E S T E O U I P M E N TO R PROBINGDEVICES. DEPLOYMENT' TH€YCAN CAUSEACCIDENTAL . N O S E R V I C E A B L EP A B T S l N S l D E . o O N o T DISASSEMBLE. . PLACEAIRBAGUPRIGHTWHENREMOVED CAREFULLY MANUALINSTRUCTIONS . FOLTOWSERVICE Jr SRSWARNINGIHOOD) SYSTEMISRS} RESTRAINT SUPPLEMENTAL THIS VEHICLEIS EOUIPPEDWITH DBIVERAND FRONT AIRBAGS'. SEATPASSENGER ABE WIRINGAND CONNECTORS ALL SRS ELECTRICAL COLOREDYELLOW. T A M P E R I N G W I T H , D I S C O N N E C T I N GO R U S I N G TEST EOUIPMENTON THE SRS WIRINGCAN ELECTRICAL OR CAUSEACCIDENTAL MAKETHESYSTEMINOPERATIVE FIRINGOF THEINFLATOR. WARNING AND, IF ACCIDEN. THE AIRBAGINFLATORIS EXPLOSIVE CAN SERIOUSLYHURT YOU. FOLLOW TALLY DEPLOYED, CAFEFULLY' SERVICEMANUAL INSTRUCTIONS ' ExceotCANADACX AIRBAGCAUTION K: PASSENGER u.S. model l'98 - 00 model) WARNING CAN 8E KILLEDOR INJUREOBY PASSENGER CHILDREN AIRBAG, THE BACKSEAT IS THE SAFESTPLACEFORCHILDREN12 USESEATBELTS AND UNDER.MAKESUREALLCHILDREN OR CHILDSEATS.

(cont'd)

1-35

Warning/CautionLabelLocations (cont'd)

t,

191t7CANADAMod6l

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t, 1-36

Under-hoodEmissionsControl Label (1996,1997model) EmissionGroupldentification

Families Engineand EvaPorative

Example:

EngineFamily: Model Year T: 1996 V: 1997 Manufacturer H N :H o n d a Displacem€nt

T|I

V H Nl . 6 V J G K G K

TI

VACUUMHOSEROUTINGDIAGRAM

-VEHICLE INFORMATION CONTROL Ei/ISSION E \ G \ . r r M r r v t s N r s \ J L K 6 \ D s p - A ( . M5F9N0 ( - - , . O !APOF!]V4-AV.t' !-rirorrSrMAc

CATALYST

CIVIC

fa:n \Y:/

IwcN02S{2)sFr

F l . t a r o s t q ! t M A \ u A t t o a a o o T o \ a -\ ' o F M ^ r o \ E q lA r . \ F J o ( O \ D' O \ S E \ G r \ lA I N O n M A - O o l q l l N C T M oU rS r-F\Eo0F C00ll\G-A\ 0( a-LACCESSoT N NEUTFAI TRANSM1SSION NEEDEO. NOOTHERAOJUSIMENTS

rt Tl lH i \-!-lJ O8D IICERTIFIED

IDLESPEEO ATDC

NDr(Jl6CR.L1l U S.EPAANDSTATE THSVEHCLECONfOFMSTO 1997 RECULAI ONSAPPLICA8IElO OFCALfORNIA VEHCL'S NEWMOTOR MOOET YEAR

4q!sq+HT-q4E!rL Er!4#_"E!!ifl N US€ .?2EAO2 11211

r.r-i,"

ilil]]lrl

TIEB l FULL HONDA MoTOR C0, tTD

50ST{50 States): TO U.S,EPAAND STATEOF CONFORMS THISVEHICLE TO 1996AND APPLICABLE REGULATIONS CALIFORNIA VEHICLES. 1997MODELYEARNEWMOTOR /$ST (49 States/Federall: TO U.S.EPA REGULATIONS CONFORMS THISVEHICLE ' 1 9 9 6A N D 1 9 9 7M O D E LY E A RN E W A P P L I C A B LTEO MOTOBVEHICLES, CAL (Calitornis): TO U.S.EPAAND STATEOF CONFORMS THISVEHICLE TO 1996AND APPLICABLE REGULATIONS CALIFORNIA ,1997MODELYEARNEW PASSENGER CARSPROVIDED INTOCOMIS ONLYINTROOUCED THATTHISVEHICLE MERCEFORSALEIN THESTATEOF CALIFORNIA.

Car V: Light DutyVehicle/Passenger Fuel Systsm and Number of valves J: ElectronicSequentialMultiportInjection (threeor more valvesper cylinder) Fuel Type G:Gasoline Standard F: 49 or 50 StatesTier 1 K: 49 or 50 StatesTier 1 1 : C a l i f o r n iTai e r 1 2: CaliforniaTLEV 3: CaliforniaLEV 4; CaliforniaULEV Catalyst E, F, G. H: ThreeWay Catalyst OBD K - T: OBDEquipped

Family: Evaporative

'|T

v HN1077BYMAc

Model Year T:1996 | V:1997 l Manufacturel H N :H o n d a Storage System 1:Canister CanisterWorking Capacity (grams) CanisterConfigulation A: PlasticHousing(ClosedBottom) B: PlasticHousing(oPenBottom) Fuel Systsm Y: FuelInjection Fuel Tank M: Metal Standard A: CurrentEvap E: EnhancedEvap Wild Card

1-37

Under-hoodEmissionsControl Label(lggg model) EmissionGroup ldentification

Engineand EvaporativeFamilies

Example:

EngineFamily:

oR3.'@M|LES|3,@|frlw!cs

rf

H N X v 0 ' t . 6J L 2

Model Year W: 1998 Manufacturer H N X :H o n d a

Type VEHICLE EI\4ISSION CONTROL INFORIVATION rH SVEHCLECONFOFMS IO U S EPAAND STA1EOFCALIFORNIA RE6ULAIIONS APPLICABLE IO 199AMODELYEARNEWTIEVPASSENGER CA8SPFOVOEOTI]AI 'HIS VEI CLE S OILY INIBODUCEDINTOCOMMEfiCE FORSALE N TNC

CATALYST

IWCINO?S]2)EGR6F /OBO] CEFT]F ED VALVE LASH 1C0L0l EX 0 r51002mm NOOTHTR AO.]USIMI\ISNI'TOEO

I]ONDA MOTOB CO.,ITD

OE

V: Light DutyVehicle/Passenger Car Displacement SequenceCharacters

EvaporativeFamily: Model Year W: 1998 Manufacturel H N X :H o n d a Type E :EVAP CanisterWork C.pacity (glamsl SequenceCharacters

W HNX E 0065A A D

T

50ST (50 Statosl: THISVEHICLE CONFORMS TO U,S.EPAAND STATEOF C A L I F O R N IR A E G U L A T I O NASP P L I C A B LTEO 1 9 9 8 MODELYEARNEWMOTORVEHICLES, ilgsT 149States/Federal): THISVEHICLE CONFORMS TO U.S.EPAREGULATIONS APPLICABLE TO 1998MODELYEARNEWMOTORVEHI. CLES.

LO

CAL (California): THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF C A L I F O R N IR A E G U L A T I O NASP P L I C A B LTEO 1 9 9 8 M O D E LY E A R N E W P A S S E N G E C R A R SP R O V I D E D THATTHISVEHICLE IS ONLYINTRODUCED INTOCOM. MERCEFORSALEIN THESTATEOF CALIFORNIA.

ro 1-38

(1999modell EmissionGroupldentification Example:

Families Engineand Evaporative EngineFamily: Model Yeal X:1999

X HNX V 0 t . 6J F 1

T rT T

r l

Manutacturer H N X :H o n d a

Tvpe

INFOEMATION CONTROL EMISSION VEHICLE IO U S E 13 S VEHCLECONFORMS NEWPASSENCER APPLCABLETOI999MOOELYEAR

Car V: Light DutyVehicle/Passenger Disolacement SequenceCharacters

FamilY: Evaporative ModelYear

X:1999

CATALYST IAIV€L{SH COLD SPARTPLU6CAP

E v

@o MOTOECOLTD HONDA

Manufacturer H N X :H o n d a Type R: ORVR CanisterWork CaPacitY(gramsl SequenceCharacters

_T

R 0090AAD

++

T_

I

l

TIER1: FEDERAL TO U.S,EPAREGULATIONS CONFORMS THISVEHICLE '1999MODELYEARNEW PASSENGER TO APPLICABLE CARS. TLEV: CALIFORNIA+ NLEV{RESTRICTEDI REGULATO CALIFORNIA THIS VEHICLECONFORIVIS TLEV NEW YEAR 1999 MODEL TO APPLICABLE TIONS CARSAND TO U.S.EPA NLEVPROGRAM PASSENGER TO 1999NEW TLEV PASAPPLICABLE REGULATIONS CARS. SENGER INTOCOMMAY ONLYBE INTRODUCED THISVEHICLE A STATETHAT HAS MERCEFORSALEIN CALIFORNIA, THE CALIFORNIASTANDARDSIN EFFECTTO WHICH A , S T A T ET H A T H A S B E E NC E R T I F I E D T H I SV E H I C L E OR A STATE PROGRAM, NLEV HAS OPTEDINTOTHE THERETO. CONTIGUOUS 50 STATELEV+ CFFV+ NLEV {UNRESTRICTED}: C O N F O R MT SO U . S .E P A N L E VA N D T H I SV E H I C L E A N D C A L I F O R N IR AE G U L A ' V E H I C L E CLEAN-FUEL E O G A S O L I N EF U E L E D1 9 9 9 T I O N SA P P L I C A B LT CARS/LIGHT M O D E LY E A R N E W L E V I P A S S E N G E R DUW TRUCKS]. 50 STATETLEV + NLEV (UNRESTRICTED): TO U.S.EPANLEVREGULA' CONFORMS THISVEHICLE TO 1999MODELYEARNEW TLEV TIONSAPPLICABLE AE G U L A T I O N S P A S S E N G EC RA R SA N D C A L I F O R N IR TO 1999 MODELYEAR NEW TLEV IPAS' APPLICABLE DUW TRUCKS]. SENGERCARS/LIGHT

1-39

Under-hoodEmissionControl Label (2000model) EmissionGroupldentification

Engineand Evaporative Families

Example:

EngineFamily:

Y H N X V 0 1 , 6J F 1

ro

Model Yeal

oRs'MM|LESt4,0oorml,wtscN

Y; 2000 Manufaqturer HNX:Honda

Type VEHICLE EMISSION CONTROL INFOBI\4ATION T8ISVEHCLECONFOfiMS TO U,S EPARECIJLATIONS APPLICABLE IO 'OOOMODELYEASNEWPASSENGER

V: Light DutyVehicle/passenger Car Displacoment SequenceCharaqtgrs

EvaporativeFamily:

CATALYST vAtw LcsH rN0.20:0 0?nn lcorDr EX025:00?mh SPAAKPIIJGCAP NOOTNER AD.IUSIMENIS NE€OTO

(0. Lro t0N0aM0T08

Y HNX R OO99 AAD

Model Year

Y: 2000 Manufaeturer HNX: Honda

Type R: ORVR CanisterWork Capacity (grams) SsquenceCharacters

FEDERAL TIER1: THISVEHICLE CONFORMS TO U,S.EPA REGULATIONS APPLICABLE TO 2OOO MODELYEARNEW PASSENGER CARS. CALIFORNIA+ NLEV (RESTR|CTEDt TLEV: T H I SV E H I C L E CONFORMS T O C A L I F O R N IR AE G U L A TIONSAPPLICABLE TO 2OOO MODELYEARNEW TLEV PASSENGER CARSAND TO U,S.EPA NLEVPROGRAM REGULATIONS APPLICABLE TO 2OOO NEW TLEV PASSENGERCARS. THISVEHICLE MAY ONLYBE INTRODUCED INTOCOM. MERCEFORSALEIN CALIFORNIA. A STATETHATHAS THE CALIFORNIASTANDARDSIN EFFECTTO WHICH THIS VEHICLEHAS BEENCERTIFIED, A STATETHAT HAS OPTEDINTOTHE NLEVPROGRAM,OR A STATE CONTIGUOUS THERETO.

LO

50 STATELEV + CFFV+ NLEV {UNRESTRTCTED): T H I S V E H I C L EC O N F O R M ST O U . S , E P A N L E VA N D C L E A N . F U EVLE H I C L E A N D C A L I F O R N IR AE G U L A , T I O N SA P P L I C A B L T E O G A S O L I N EF U E L E D2 O O O MODELYEARNEWLEVPASSENGER CARS. E P A C E R T I F I C A T I OTNE S T F U E L :E P A U N L E A D E D GASOLINE 50 STATETLEV+ NLEV (UNRESTRICTED}: THISVEHICLE CONFORMS TO U.S.EPANLEVREGULA. TIONSAPPLICABLE TO 2OOO MODELYEARNEW TLEV P A S S E N G EC RA R SA N D C A L I F O R N IR AE G U L A T I O N S APPLICABLE TO 2OOO MODELYEAR NEW TLEV PASSENGERCARS.

L, 1-40

Lift and SupPort Points

L,O

Lift and SafetYStands t!ffi -aE

hatch' and trunk lid are to be when heavv rear componentssuch as suspension'fuel tank' spare tire' rear before hoisting. when substantial weight is lemoved from the

removed, place additional wetght Inihe luggage arga vehicle to tip tolward on the hoisi of the vehicls. the center of gravity may change and can cause the

NOTE: 30 lbs (14kg)'placingthefrontwheelsin the luggageareacan weighsapproximately assembly . Sinceeachtire/wheel assistwiththeweightdistribution . Usethesamesupportpointsto supponthevehicleon safetystands' 1 . Placethe lift blocksas shown. and rockthe vehicleto be sure it is firmly supported' 2 . Raisethe hoista lew inches(centrmeters) 3 . Raisethe hoistto full height,and inspectlift pointsfor solidsupport

REARSUPPORTPOINT

1-41

Lift and Support Points FloorJack 1.

Apply the parkingbrakeand blockthe wheetsthat are not being lifted. When liftingthe rearof the vehicle,put the gearshift lever in reverse(Automatictransmission/Cwin E position).

t, Always use safety stands whon working on or undel any vehicle that is supported by only a iack. Never attempt to use a bumper jack for lifting or supporting the vehicle.

Raisethe vehicle high enough to insert the safety stands. 4.

Adjust and place the safety stands so the vehicle will be approxlmatelylevel,then lower the vehicle onto them.

FRONT:

LIFT PLA

Centerthe jacking bracketin the middle of the iack lift platform.

REAR:

LIFT PLATFORM

1-42

Centerthe iack bracketin the middle of the jack lift ptatform.

L,

Towing

towlf the vehicleneedsto be towed,call a professional ing service.Nevertow the vehiclebehindanothervehi cle with iust a rope or chain lt is very dangerous'

Front:

EmergencyTowing Thereare three popularmethodsof towing a vehicle: Flat-bedEquipment- The operator loads the vehicle on the the backof a truck.Thisis the bestway of transporting vehicle. Wheel Lift Equipment- The tow truck usest\ivopivoting armsthat go underthe tires {frontor rear}and liftsthem o f f t h e g r o u n d .T h e o t h e r t w o w h e e l s r e m a i no n t h e ground. Sling-type Equipment- The tow truck uses metal cables with hookson the ends.Thesehooksgo aroundpartsof the frame or suspension,and the cableslift that end of the vehicleoff the ground The vehicle'ssuspensionand body can be seriouslydamagedif this methodof towing is attemDted.

TIE DOWN HOOKS

lf the vehiclecannotbe transportedby flat-bed.it should be towed with the front wheelsoff the ground lf due to d a m a g e ,t h e v e h i c l e m u s t b e t o w e d w i t h t h e f r o n t wheelson the ground,do the following: lvlanualTransmissionand CW . Releasethe parkingbrake . Shiftthe transmissionto neutral(CW to E position)' AutomaticTransmission the Parkingbrake. . Release . Start the engine. . Shiftto LDllposition,then E position. . Turn oif the engine CAUTION; o lmploper towing preparation will damage ihe tfansmission. Follow the above procedute exaqtly lf you cannot shift the tlansmission or start the engino laulomatic transmissionl,yout vehicle must be transported on a flat-bed. . lt is best to tow the vehicle no farther than 50 mil€s (80 km), and ksop thE speedbelow 35 mph (55 km/hl . Trying to lift 01 tow your vehicle by tho bump€F will caus€setious damagg.Ths bumpers are not dEigned to supportthe vshicle'sweigh.

Rear:

TOWINGHOOK

tJO 1-43

The Special Tools Section of this manual has been omitted intentionally. Each section in the manual that requires the use of special tools has them listed separately for that section.

Specifications StandardsandServiceLimits "'.".'.""' 3-2 "...""' 3-20 ications,..'....,.'..'.... DesignSpecif "'."'." 3-23 BodySpecifications

Standardsand ServiceLimits CylinderHead/ValveTrain (Dt6y5, ( u r b Y 5 , Dt6y7, u l 6 Y 7 , D l 6 Y g e n lSines) -Section6 MEASUREMENT Compression

Cylinderhead Camshaft

D16Y5

EX IN

Secondary

EX D16Y8

IN

Primary Mid Secondary

EX Valveclearanca {Cold)

IN EX

ValvestemO.D.

IN

EX IN EX IN EX

Stem-toguideclearance Valveseat

width Steminsta ed height

Valvespring

Freelengrh

IN EX

Dt6y7 D16Y5

IN

D16Y8

IN

EX Valveguide

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

Rockerarm

Arm-toshaftclearance

L,

STANDARD INFWT

250rpm and wide openthroftle kPa{kgf/cm,,psi) Nominal Minimum Maximumvariation Warpage Height Endplay Camshaftto-holderoil clearance Totalrunout Cam lobeheight D16y7 IN

EX IN EX IN EX IN

EX

930{9.5,135) 200 120 ?R\ 92.95- 93.05{3.659 3.663) 0 . 0 5 , 0 . 1 5( 0 . 0 0 2 0 . 0 0 6 ) 0.050- 0.089(0.002_ o.oo4) 0 . 0 3( 0 . 0 0 1 ) m a x . 35.299(1.38971 31.241/.1.4678) 38.427(1.5129) 32.19311.2674l 38.784(1.5269) 36.778(1.4479) 38.274(1.5068) 37.065 .4592) 38.008(1.4964) - 0.009) 0.18- 0.2210.007 0.23 0.27(0.009 0.011) 5.48- 5.49(0.2157 0.2161) _ 0.2150} 5.45- 5.46{0.2146 0.02- 0.05(0.001_ o.oo2) 0.05-008lono2-nnn?l 0.85- 1.15(0.033- 0.045) - 0.061i 1.25- 1.5510.049 5 3 . 1 7- 5 3 . 6 4{ 2 . 0 9 _3 2 . 1 1 2 ) 53.17- 53.64(2.093_ 2.112) 57.9 (2.2a) 56.5\2.221 57.9 t2.29l 58.0 (2.2a) 58.7{2.31i 5 . 5 1- 5 . 5 3( 0 . 2 1 -7 0 . 2 1 8 ) 5.51- 5.53(0.217_ 0.218) 17.85- 18.35\0.103- 0.722) 18.65 19.t5 (0.734_ 0.754) 0.017- 0.050(0.0007 0.0020) - 0.0021) 0.018- 0.054(0.0007

0.05{0.002)

0.5(0.02) 0.15(0.006) 0.04(0.002)

=

5.45(0.2146) 5.42 tO.21341 0.08(0.003) 0 . 1 1( 0 . 0 0 4 ) 1.6(0.063) 2.0(0.079) 53.a9\2.122|j $.a9 Q.122)

5.55t0.219) 5.5s{0.219)

ra

0.08(0.003) 0.08(0.003)

LO 3-2

U n i t o f i e n g t h :m m ( ! n )

CylinderHead/ValveTrain (816A2engine)- Section STANDARD INEW) MEASUREMENT Nominal 2 5 0r p m ( m i n r i a n d 930(9.5,135) Minimum wide openthrottle 20012.0,zal variation Maximum (kqf/cm' psi) , kPa

Endplay holderoil clea€nce Camshaft-to Totalrunout lN Cam lobe height EX

Valveclearance ValvestemO.D. Stem-to-guideclearance width Stem installedheight free t*gth

LD. Installedheight

lN

0.05- 0.15(0.002- 0.006) 0.050- 0.089(0.002- 0.004) 0.0310.001)max. 33.088(1.3027i Primary 36.261{1.4278) Mid Secondary 3 4 . 9 7 (81 . 3 7 7 1 ) 32.785{1.2907) Primary 35.720(1.4063) Mid Secondary 34.691(1.3658) I N 0.15- 0.19(0.006- 0.007)* EX 0.17- 0.21(0.007- 0.008)* - 0.2159) I N 5.475- 5.48510.2156 EX 5.450- 5.460(0.2146- 0.2150) IN 0.025- 0.055(0.0010 0.0022) EX 0.050-0.080(0.0020- 0.0031) 1.25- 1.55{0.049- 0.061) IN r.25- 1.55(0.049- 0.061) EX - 1.4935) 37.465- 37.935(1.4750 IN - 1.4817) 37.165- 37.635(1.4632 EX OUTER 4 0 . 9 2( 1 . 6 1 1 ) * ' 4 0 . 9 1( 1 . 6 1 1 1 " 36.71(1.415) 4 1 . 9 6( 1 . 6 5 2 ) * r 4 r.94(1.651)*' lN 5.51- 5.53(0.217- 0.218) EX 5.51- 5.53(0.217- 0.218i lN 12.55- 13.05(0.494 0.5' j4) 12.55- 13.05(0.494- 0.514) EX

SERVICELIMIT

u*u lo.r,ool 5.420(0.2134) 0.08(0.003) 0 . 1 1( 0 . 0 0 4 ) 2.0(0.08) 2.0(0.08) 3 8 . 1 8 (51 . 5 0 3 3 ) 3 7 . 8 8 (51 . 4 9 1 5 )

- 0.052(0.00100.0020) 0.025 {0.00100.0020) o.o2s- 0.052 *: Measuringpoint betweencamshaftand rockerarm' valvespnng. *1: NTHON vatvespring. *2: CHUOHATSUJOmanutactured H;TSUJOmanufactured

3-3

Standardsand ServiceLimits EngineBlock {Dl6Y5,D16Y7,Dt6y8 enginesl- Section ,n7 _-MEASUREMENT Cylinderblock

Piston

Pistonring

Pistonpin Connecting rod

Crankshaft

Bea.ings

Warpageof decksurface Borediameter Boretaper Reboringlimit SkirtO.D. at 5 mm (0.2in) from bottomof skin Clearance in cylinder Groovewidth {for ring) Top Second oil Ringto-grooveclearance Top Second Ring end gap Top Second oil

o.D.

STANDAFOINEW} 0.0710.003) max. 75.00 75.02(2.953- 2.954)

SERVICE LIMIT 0.10(0.004) 75.07(2.956) 0.05(0.002) 0.5(0.02)

74.9A0 74.990t2.9520 2.95241

74.970(2.9516)

0.010- 0.040(0.0004 0.0016) _ 0.0406) 1.020- 1.03010.0402 - 0.0484) 1.220 1.230(0.0480 2 . 8 0 5- 2 . 8 2 0{ 0 . 11 0 4_ 0 . 1 1t O ) 0.035- 0.060(0.0014 0.0024) 0.030- 0.055{0.0012 0.0022)_ 0.15 0.30{0.006_ 0.012) 0 . 3 0- 0 . 4 5( 0 . 0 1 -2 0 . 0 1 8 ) 0.20- 0.7010.008 0.028) 18.994- 19.000(0.7478 _ 0.7480) 0.010- 0 0?2 lo oona-n dn^ol _ 0.ool6) 0.014- 0.040(0.0006 18.96- 18.98(0.746 0.747) 48.011.89) 0.15- 0.30(0.006- 0.012) - 2.1654) 54.976- s5.000(2.1644 44.91 6 - 45.0001'1.17 01 _ 1.71111 0.002510.0001) max. 0.0025(0.0001)max. 0.10- 0.35(0.004 0.014) 0.03(0.001)max.

Pin-topistonclearance Pin-torod interference Smallend borediameter Largeend borediameterNominal Endplay installedon crankshaft M a i nj o u r n a l d i a m e t e r R o di o u r n a l d i a m e t e r Taper Out of-round Endplay Totalrunout Main bearingto-lournalo't clearanceN o _l a n d5 j o u r n a l s 0.018- 0.036(0.0007 0.0014) N o .2 , 3 a n d4 j o u r n a t s 0.024 0.042(0.0009 - 0.0017) _ Bodbearingto,journatoil ctearance _ o.oo.t5) 0.020- 0.038(0.0008

L,

0.05(0.002) 1 . 0 5( 0 . 0 4 1 ) 1.2510.049) 2.85(0.112) 0 . 1 3{ 0 . 0 0 5 ) 0.13(0.005) 0.60(0.024) 0.70(0.028)

ljqql)

_

oroto.o',ur 0.005(0.0002) 0.005(0.0002) 0.4510.018) 0.04(0.002) 0.05(0.002) 0.05{0.002) 0.05(0.002)

LO

LO 3-4

Unlt of length: rnm ( n)

EngineBlock (816A2engine)- Section7 STANOARD{NEW) 0.05(0.002) 8 L 0 0 8 1 . 0 2( 3 . 1 8 9 3 . 1 9 0 )

MEASUREMENT Cylinder block

Piston

Piston ring

Warpageof decksurface Borediameter Boretaper Reboringlimit Skin O D. At 15mm (0.6in) {rom bottomof skirt in cylinder Clearance Groovewidth (for ring)

ToP Second oil Second Top

Ring end gap

Second

oil Piston pin Connectingrod

o.D. Pin to-pistonclearance Pin'torod interference Smallend borediameter Largeend borediameter Endplayinstalledon crankshaft

Nominal

Mainjournaldiameter No. 1, 2, 4 and 5 iournals No. 3 journal Rodjournaldiameter Taper Out of round Endplay Totalrunout oil clearance Main bearingto_journal Eearing N o .1 ,2 , 4 a n d5 j o u r n a l s N o .3 j o u r n a l Bod bearing'toiournaloil clearance *1: RIKENmanutactured prstonrrng pistonring *2:TEIKOKU PISTONRINGmanufactured Crankshaft

0.08{0.03) 8 1 . 0 7( 3 . 1 9 2 ) 0.05(0.002) 0 . 2 5( 0 . 0 1 )

80.980- 80.990(3.lUUz 3. rUubl

du Y/u lJ. ro/o,

- 0.0016' 0.010 0.040(o.ooo4 - 0.04091 I O3O 1.04010.0406 . 0.04881 1.230- 1.?40{0.0484

0 05 r0 002) 1 060{0 0417) 1.26010.04961

I I | 1

'*: ?:::i?l:91'::ll:l I::::::= u . u 4 5- u . u / u l u . u u r o

R i n g - t o - g r o o v ec l e a r a n c e

LIMIT SERVICE

0.040- 0.065(0.0016 0.0026)*l 0.045- 0.070(0.0018 0.0028)*' 0.20- 0.35(0.008- 0.014)*1 o.20- 0.30(0.008- 0.012)*' 0.40 0.55(0.016 0.022) 0.20- 0.50(0.008- 0.020)*' 0.20- 0.45(0.008- 0.018)" - 0.8268) 20.994- 21.000{0.8265 0.010- 0.022(0.0004 0.0009) - 0.0013) 0.013- 0.032(0.0005 - 0.8260) 20.968 20.981(0.8255

0.13(0.005) 0.1310.005) 0.60(0.024) 0.60t0.024) 0.7010.028) 0.70(0.028)

o.o''r, lliSlto?,o.oou

o.rotoo'ut

- 2.1654) 54.976 55.000(2.1644 54.970- 54.994(2.1642 2.1651) - 1.1711| - 45.00011.'1707 44.976 max. 0.005(0.0002) max. 0.004(0.0002) 0.10 0.35(0.004- 0.014) 0.020(0.0008imax.

0.010(0.0004) 0.006(0.0002) 0 . 4 5( 0 . 0 1 8 ) 0.030(0.0012)

- 0.042(0.00090.0017) 0.024 - 0.048 {0.00120.0019) o.o3o - 0.0020) - 0.050(0.0013 0.032

0.06(0.002) 0.06(0.002) 0.06(0.002)

l

l

,rr]q!4l -

ginesl- Section 8 EngineLubri,cation(Dl6Y5,Dl5Y7' Dl6Y8 enginesl STANOARD(NEW)

MEASUREMENT E n g i n eo i l

O i lp u m p

R e l i e fv a l v e

S€RVICELIMIT

4.3(4.5,3.8)Iorengineoverhaul 3.6(3.8,3.2)for oil change,includingfilter 3.3(3.5,2.9)for oil change,withoutfilter D16Y5D16Y8 3 . 7( 3 . 9 , 3 . 3 ) f oern g i n eo v e r h a u l 3.3(3.5,2.9)for oil change,includingfilter 3.0{3.2,2.6}for oil change,withoutfilter - 0.006) 0.20{0 008) 0.02- 0.14(O.OO1 rotorradialclearance lnner-to-outer (0 - 0.007) (o.oo4 0.18 0.10 i 0.20 008) Pumphousingto_outerrotor radialclearance (0006) (qool!.oo3l o 03 !.08 rotora)rialclearance _ Pumohousrnq_to settingwith oil temperature176'F(80'Ci Pressure 7 0 ( 0 . 7 1, 0 )m i n . at idle , kPa(kgf/cm'PsiI ) in 3 4 0( 3 . 5 , 5 0m at 3,000rpm

Capacity | (USqt, lmp qt)

D16Y7

-

(cont'd)

3-5

Standardsand ServiceLimits EngineLubrication(B16A2engine)(cont,d)- Section8 E n g i n eo i l

O i lp u m p

R e l i e fv a l v e

MEASUREMENT Capacity f (uS qt, lmp qt)

STANDARD INFWI

4.8(5.1,4.2)for eng;neoverhaul 4.0(4.2,3.5)for oil change,;ncludin g oilfilter 3.7 (3.9.3 3)for dil .h,nde

Inner-toouterrotorradialclearance Pumpbody-toouterrotorradialclearance Pumpbody to-rotoraxialclearance Pressure setting176"F(80.C) kPa(kgflcm,,psi) at;dte at 3,000rpm

L,

'^,irh^,,r

0.04- 0.16{0.002- 0.006) 0 . 1 0- 0 . 1 9( 0 . 0 0 4 - 0 . 0 0 7 ) ,0.003) 0.02 0.0710.001

0.20(0.008) 0.20{0.008) 0 15 {OOO6i

70 (0.7,10)min. 340(3.5,50)min.

Cooling- Section 10 Radrator

MEASUREMENT Coolantcapacity t 1USqt, tmp qt) includingengine,heater,coolinglineand reservotr Beservoircapacity: 0.4f {0.42US qt, 0.35lmp qt)

R a d i a t o rc a p Thermostat

Cooling fan

Openingpressure

kPa(kgl/cm,,psi)

Start to open .F (.C) Fully open "F ('C) Valve lift at fulty open Thermoswilch 'ON" temperature Thermoswitch "OFF' lemperature

F r.C, .F ( C)

STANOARO{NEW) 81642engine 5.0{5.3,4.4)for overhaul 4.5(4.8,4.0)for cootantchange D16Y5,D16Y7,D16Y8engines: M/T: 4.2(4.4,3.7)foroverhaul 3.1(3.3,2.7)for coolantchange A"/T:016Y7 4.1(4.3,3.6)for overhaul 3.0(3.2,2.6)for cootantchange Dl6Y8 4.3{4.5,3.8)foroverhaul 3.2(3.3,2.8)for cootantchange CW: 4.3(4.5,3.8)foroverhaul 3.2(3.3,2.8)forcootantchanqe 9 3 1 2 3( 0 . 9 5 -1 . 2 51, 4 1 8 ) 1 6 9- 1 7 6( 7 6 8 0 ) 194(90) 8 . 0( 0 . 3 1 ) m i n . 196- 203191 95) Subtract5 - 15{3 - 8) from actual,,ON,,temperature

L.

L, 3-6

Unit of length: mm (in)

Fueland Emission - Section

STANOARO(NEW)

MEASUREMENT Fuelpaessure regulator

wilh fuel pressureregulatorvacuumhose Pressure , disconnected kPa(kgvcm' Psi) D16Y5 D16Y7 D16Y8 81642

260 260260210-

Fueltank

Capacity I (USgal,lmp gal) ldlespeed rpm

4 5 { 1 1 . 99, . 9 ) M/T (neutral)

En g i n e

016Y5 D16Y7 D16Y8 816A2

310(2.7310(2.7310(2.7320 Q.A-

3.2,38 3.2,38 3.2,38 3.3, 40 -

46) 46i 46) 471

u.s.A.

Canada

670 1 50 6701 50 670150 700t 50

7 5 0 15 0 7 5 0 15 0 7 5 0 15 0

I A/T or C\.T (lE or fd positioni Canada U,S,A. 700t 50 700I 50 7 0 0 15 0

750150 750r 50

0.1max.

ldleCO %

Clutch- Serr tion12 STANDARD{NEWI

MEASUREMENT Clutchpedal

Flywheel Clutch disc

plate Pressure

Pedalheight Stroke Pedalplay D i s e n g a g e m e n th e i g h t

Clutchsurfaceruoout Rivetheaddepth Thickness Warpage Diaphragmspringfingersalignment

to floor

to floor to carpet

I

SERVICELIMIT

16s(6 1/2) 130 140(5 1/8 5 1/2) 12 -21 t1l2- 13/161 83 (3 1/4) 44 (1 3/4)min. Reference

max. 0.05(0.002) 1 . 3 -1 . 9( 0 . 0-50 . 0 7 ) - 0.36) 8.5- 9.1(0.33

0.15(0.006) 0 . 2{ 0 . 0 1 ) 5.5(0.22)

0.03(0.001)max 0.6(0.02)max

0.15(0.006) 1.0(0.04)

Lro 3-7

Standardsand ServiceLimits ManualTransmissionS40- Section 13 MEASUREMENT Capacity | (USqt, tmp qt) Mainshaft

End play Diameter of ball bearing contact area A ( T r a n s m i s s i o nh o u s i n g s i d e ) Diameterof 4th, 5th gear contact area B Diameter of 3rd gear contact area C Diameterof ball bearing contact area D ( C l u t c hh o u s i n g s i d e )

Bunout

Countershaft

Diameterof needlebearingcontactareaA

Djameterof lst gear contact area g Diameter of ball bearing contactarea C Runout

E n d p l a y ( W h e n t i g h t e n e d b y t h e s p e c i f i e dt o r q u e ) Thickness

gear

Endptay(Whentightenedby the specifiedtorque) t.D.

o .D . Length Spacercollar (Mainshaft4th and 5th gear)

Beverserdlergear

LD.

Shift arm A

MBS Shiftprece D i f f e r e n l i a lc a r r i e r

3-8

Adjust 2 1 . 9 3 (00 . 8 6 3 4 )

_ 1.0627) 26.980 26.993(1.0622 33.984 34.000(1.3380 1.3386) 25.917- 25.99011.02271.0232)

26.930('1.0602i 33.930(1.3358) 25.92011.0205)

0 . 0 2( 0 . 0 0 1m) a x . 39.009 39.025(1.5358 1.5364) 0.06 0.21(0.002 0.008) 0.06 0.19(0.002 0.007) 30.22 30.21(1.190 1.192) 3 0 . 1 2- 3 0 . 1 7( 1 . 1 8 6 1 . 1 8 8 )

0.05(0.002) 39.07('r.538) 0 . 3 3{ 0 . 0 1 3 ) 0 . 3 1( 0 . 0 1 2 ) 3 0 . 1 5( 1 . 1 8 7 ) 3 0 . 0 5( 1 . 1 8 3 )

SEBVICE LIMIT

ro

(1.4570 _ 1.4577) 3 7 . 0{71 . 4 5 9 ) 37.00937.025 - 0.007) 0.06- 0.19(0.002 0 . 3 1( 0 . 0 ' 1 2 ) - 2a.4711.119,1.1211 28.42 2 8 . 3(51 . 1 1 6 ) 3 0 . 0 0 03 - 0 . 0 1 {51 . 1 811- 1 . 1 8 1 7 ) 2 9 . 9 5 (01 . 1 7 9 1 ) 3 5 . 9 8 -4 3 6 . 0 0 (01 . 4 1 6 71 . 4 1 7 3 ) 3 s . 9 3 r0. 4 1 4 6 ) - 0.9840) 24.930(0.9815) 24.980 24.993(0.9835 0 . 0 2( 0 . 0 0 1 ) m a x . 0.0s(0.002) 4 1 . 0 0-9 4 1 . 0 2 (5' t . 6 1 4 51 . 6 1 5 2 ) 41.0111.617J 0.03 0.10(0.001_ 0.004) 0.22(0.009) 3 0 . 4 1 3 0 . 4 4( 1 . 1 9-7 1 1 9 8 ) 3 0 . 3 6( 1 . 1 9 5 )

- 44.025 44.009 (1.73261.7333) 44.0111.t35) - 0 005) 0.04- 0.12(0.002 0.24(0.009) 3 1 . 9 13 1 . 9(61 . 2 5 61 . 2 5 8 ) 3 1 . 8 5( 1 . 2 s 4 ) 33.000- 33.010(1.2992 1.2996) 38.989 39.00011.53s0_ 1.53s4) 32.03- 32.06tl.261 - 1.2621

3 3 . 0 4{ 1 . 3 0 1 ) 38.93(1.533) 3 2 . 0 1( 1 . 2 6 0 )

2 7 . 0 0 22 7 . 0 1(21 . 0 6 3_ 11 . 0 6 3 5 ) - 34.000 - 1.3386) (1.3381 33.989 (1.25941.2598) 3r.989- 32.000 - 22.86 (0.8990.900) 22.83 - 0.928) 23.53 23.56(0.926

2 7 . 0(61 . 0 6 5 ) (1.336) 33.93 3 r . 9 3{ 1 . 2 5 7 ) (0.898) 22.81 2 3 . 5(10 . 9 2 6 )

r s . 0 1 6 1 5 . 0 4(30 . 5 9 1_20 . 5 9 2 2 ) _ 0.0030) 0.032 0.077(0.0013 R i n g - t o g e a r c l e a r a n c e{ R i n g p u s h e d a g a i n s t g e a r ) 0 . 7 3- 1 . l 8( 0 0 2 9- 0 . 0 4 6 ) Forkfinger thickness lsv2nd/sth I 6.2- 6.410.244 - O.ZS2) 3rdl4th 7.4 i.6lO 2g1 O 2ggt Fork to-synchrosleeveclearance 0.35- 0.65(0.014- 0.026) Forkpawl groovewidth 1 2 . 7- 1 3 . 0( 0 . 5 0_ 0 . 5 1 ) Forkto-reverseidlergearclearance 0.5 1.t (0.020 0.043) L groovewidth - 0.2851 7.05- 7.25tO.21A Fork'to-5th/reverse shiftpiecepin clearance 0.05 0.35(0.002 0.014) tnnerdiameterof shift arm C contactffi (0.5140.517) 13.05 13.13 Shift arr14-go "L;L ".m C clearance 0.05- 0.23(0.002_ 0.009) Innerdiameterof shiftarm B shaftcontactpoint 13.973- 14.000(0.5501 0.5512) Shiftarm 8-to shaftclearance _ 0.0028) 0.013 0.070(0.0005 Shiftarm B to-shiftpiececlearance 0.2- 0.5{0.008 0.020) Diameterof shiftpiececontactpoint 1 2 . 9 1 3 . 0( 0 . 5 0 -8 0 . 5 1 2 ) Diameterof pin 6.9 7.1 \O.27 0 2A) Pinion shaft bore diameter _ 0.7098) 18.010 18.028(0.7091 C a r r i e r - t op i n i o n s h a f t c l e a r a n c e - 0.0022) 0.023 0.057(0.0009 D r i v e s h a f tb o r e d i a m e t e r 26.025 26.04s{1.0246_1.0254) C a r r i e r t o , d r i v e s h a f tc l e a r a n c e 0.045- 0.086(0.0018 0.0034) Backlash 0.05 0.15(0.002 0.006) Piniongearborediameter 1 8 . 0 4-2 1 8 . 0 6(60 . 7 1 0_30 . 7 1 1 3 ) Piniongear-topinionshaftclearance _ o.oo37) 0.055- 0.095{0.0021 0 0.110- 0.004) G e a r t o r e v e r s eg e a r s h a f t c j e a r a n c e

Beverseshittfork

STANDARDINEW} ' 1 . 9( 2 . 0 , 1 . 7 ) f oo r verhaul 1 . 8( 1 . 9 1, . 6 )f o r o i t c h a n g e 0 . 1 1 0 . 1 8( 0 . 0 0_4 0 . 0 0 7 ) 21.987- 22.000(0.8656 0.8661)

LrO

15.08(0.594) 0 . 1 4( 0 . 0 0 6 ) 0 . 4( 0 . 0 1 6 )

0.16(0.006) o.6210.02441 (0.5031) 12.78

0.095(0.004) 0 . 1 4( 0 . 0 0 6 )

Adjust with shim

LO

U n i t o f l e n g t h :m m ( i n )

ManualTransmissionS4C- Section 13 T r a n s m i s s i ooni l Mainshaft

Mainshaft 3rd and 4th gears

STANDARD{NEW)

M€ASUREMENT Capacity | (US qt, lmp qt) Fnd plaV Diameterof ball bearingcontactareaC (Clutchhousingside) Diameterof 3rd gearcontactareaB Diameterof ballbearingcontactarea'q ( T r a n s m i s s ihoonu s i n gs i d e ) Runout LD. Endplay Thickness

3rd 4th

t.D. Endplay Thickness Diameterof ball bearingcontactareaA Diameterof lst gearcontactareaI Diameterof needlebearingcontactareaC Runout

LD. torque) Endplay{Whentightenedby the specified Thickness S p a c ecr o l l a r (CoLrntershaft 2nd

LD.

gear)

Length

S p a c e rc o l l a r ( M a i n s h a f t4 t h and 5th gear)

LD.

o.D. o.D. Lengtn

LIMIT SERVICE

2 . 3( 2 . 4 , 2 . 0f o) r o v e r h a u l r i lc h a n g e 2 . 2( 2 . 3 1, . 9 ) f o o 0 . 1 1- 0 . 1 8( 0 . 0 0-4 0 . 0 0 7 ) - 1.10201 21.917- 21.990 11.1015

Adtust 2 7 . 9 3 (01 . 0 9 9 6 )

37.984 38.000(1.4954 1.4960) 2 7 . 9 8-7 2 8 . 0 0 (01 . 1 0 1 81 . 1 0 2 4 )

37 930 (1.4933) 2 7 . 9 4 (01 . 1 0 0 0 )

0 . 0 2( 0 . 0 0 1 ) m a x . 43.009- 43.025(1.6933 1.6939) 0.06- 0.21(0.002 0.008) 34.92- 34.91\1.315 1.311) 31.42- 31.41(1.237 1.239)

0.05(0.002) 4 3 . 0 8( 1 . 6 9 6 ) 0 . 3( 0 . 0 1 ) 34.3(' t.350) 31.3 11.232)

- 1.6939) 4 3 . 0(81 . 6 9 6 ) (1.6933 43.00943.025 - 0.008) 0 . 3( 0 . 0 1 ) 0.06 0.21(0.002 - 31.41 31.311.232) 31.42 \1.231 1.2391 24.980 24.993(0.9835 0.9840) - 1.4567) 36.984 37.000(1.4561 - 1.2998) 33.000- 33.015(1.2992 max. 0.02(0.0008) 4 1 . 0 0-9 4 1 . 0 2 (51 . 6 1 4-51 . 6 1 5 2 ) 0.045- 0.205(0.0018 0.0081)

24.940(0.9818) 36.930(1.4539) 3 2 . 9 5 (01 . 2 9 7 0 ) 0.05(0.002) 4 1 . 0 7( 1 . 6 1 7 ) 0 . 2 5( 0 . 0 1 )

- 1.7333) 4 4 . 0 7( 1 . 7 3 5 ) 44.00944.025 {1.7326 - 0.006) 0.24(0.009) 0.07 0.14(0.003 -' j.1405) - 28.97 (1.1386 2 8 . 8( 1 . 1 3 4 ) 28.92 36.521- 36.531(1.4378 1.4382) 4 1 . 9 8 94 - 2 . 0 0 (01 . 6 5 3-11 . 6 5 3 5 ) - 1.1453) 29.07- 29.0911.1444 31.0O2 31.01211.2205- 1.2209'l - 1.4570) 36.989- 37.000{1.4563 - 2.22641 56.45- 56.551'2.2224 26.03- 26.0A11.025- 1.021|

3 6 . 5 4( 1 . 4 3 9 ) 4 1 . 9 3( 1 . 6 5 1 ) 3 1 . 0 6( 1 . 2 2 3 ) 3 6 . 9 4( 1 . 4 5 4 )

(cont'd)

3-9

Standardsand ServiceLimits ManualTransmissionS4C(cont'd) - Section 13 MEASUREMENT Reverseidlergear

t.D. Gear-toreversegearshaftclearance

(Ringpushedagainstgear) Ringto-gearclearance (Ringpushedagainstgead Clearance Outersynchroring to gear Inner synchroring to-gear Outersynchroring-to-synchro cone Shiftfork Fork{ingerthickness Fork-tosynchrosleeveclearance Beverseshiftfork Forkpawl groovewidth Fork-to-reverse idlergearclearance L-groovewidth At 5th gearside At reverseside Fork'to-5th/reverse shift piecepin clearance At 5th gearside At reverseside Shiftpiece Shiftpiece-to-shift arm clearance Groovewidth of shiftarm contactarea Shilt'piece-to-shiftfork shaft clearance Width of shift lork contactarea Selectarm Selectarm-to-interlock clearance Selectarm to-shimclearance Interlock Width of selectarm contactarea Changepiece Changepiece-to-shilt arm holderclearance Groovewidth ot shittarm holdercontactarea Changepiece-toselectarm clearance Groovewidth of selectarm contactarea Final driven gear Backlash Differentialcarrier Pinionshattborediameter Carrierto-pinionshaftclearance Driveshaft borediameter Carrier-to driveshaftclearance Carrier-to-int6rmediate shattclearance pinion Backlash Differential gear Piniongearborediameter Piniongear-to-pinion shaftclearance Setring to bearingouterrace Synchroring Doublecone

STANDARD(NEW) -0.7891) 20.016- 20.043(0.7880 - 0.0033) 0.036- 0.084{0.0014 0.73- 1.18(0.029 0.046)

SERVICELIMIT 20.09(0.7909) 0.16(0.006) 0 . 4( 0 . 0 1 6 )

- 0.066) 0.9s- 1.6810.037 0.5- 1.0(0.02- 0.04) 0.5 1.0(0.02- 0.04) - .299i 7 . 4- 7 . 6( 0 . 2 9 1 0 0.35- 0.65(0.015 0.026) - 0.524) 13.0- 13.310.512 0.5- 1.0(0.02- 0.04) 7.4 t.1 10.29-O.30) 7.O5- 7.25 (0.21A- 0.2A5i'

0.6(0.024) 0 . 3{ 0 . 0 1 ) 0 . 3( 0 . 0 1 )

0.4 0.9(0.02 0.04) 0.05 0.45(0.002- 0.018) 0.1- 0.3(0.004- 0.012) 8 . 1 - 8 . 2( 0 . 3 1-9 0 . 3 2 3 i 0.2- 0.5 (0.008 0.020) - 0.472) 11.9- 12.010.469 0.05- 0.20(0.002- 0.008) - 0.008) 0.01- 0.210.0004 (0.390 9.9 10.0 0.394)

ua

1.0(0.04) 1 €{ 0 . 0 7 )

0.6(0.02) 0.8(0.03) 0.45(0.018)

- 0.014) 0.05- 0.35(0.002 1 2 . 0-51 2 . 1\50 . 4 7-40 . 4 7 a 1 - 0.010) 0.05- 0.25(0.002 - 12.t5 (0.474 - 0.478) 12.05

0.8{0.03)

- 0.0059) 0.090- 0.149(0.0035 - 0.7093) 18.000 18.01610.7087 0.013- 0.045{0.001 0.002) 24.000- 28.02111.1024 1.1032) - 0.0024) 0.020,0.062(0.0008 - 0.0034) 0.05- 0.087{0.0020

0.200(0.008)

0.12(0.005) 0.14(0.006)

- 0.006) 0.05-0.15(0.002 1 8 . 0 4 21 8 . 0 6( 60 . 7 1-00 . 7 1 1 ) - 0.095(0.002 - 0.004) 0.055

0 . 1 5( 0 . 0 0 6 )

0 - 0.10(0 - 0.004)

Adjust with shim

0.5(0.02)

0.10{0.004)

.'1

L,O 3-10

U n i t o f l e n g t h im m ( i n )

tssron- Section 14 AutomaticTf ansmtssron Transmission fluid Hydraulic

MEASUREMENT (US qt, lmp qti Capacity f Linepressureat 2,000rpm in E or E position

LIMIT SERVICE

STANOARD{NEWI 5.9(6.2,5.2)Ioroverhaul 2.7(2.9,2.4)for fluid chanse sgO g8ol85 SO,rzO rSO,

r A o , e ' 0I 0 ,

800- 850(8.2-8.7, 120- 124) 8 1 0 - 8 6 0( 8 . 3- 8 . 8 ,1 1 8- 1 2 5 )

7 6 0( 7 . 7 1, 1 0 ) 7 6 0( 7 . 81, l 1 )

2,100

28

1 s tc l u l c h p r e s s u r ea l 2 , O 0 O r p m i n D . p o s i t i o n

kPa (kgf/cm',psa)

2nd clutchpressureat 2,000rpm in El position 3rd and 4th clutchpressureat 2,000rpm in lFl position Stallspeedrpm (Checkwith vehicleon levelground) 1st,2nd Clutchinitialclearance Clutch 3rd,4th Clutchreturnspringfree length (A4RA,B4RATransmission) 1st 2nd,3rd,4th lst lM4RATransmission) 2nd,3rd,4th Clutchdiscthickness 1st Clutchplatethickness 2nd,3rd,4th Mark1 Ctrt"h ""d pl"t" thl"t** Mark2 (A4RA,B4RATransmission) Mark3 Mark4 Mark5 Mark6 Mark7 M a r kI MarkI M"*l Clutch end plate thickness Mark2 (M4RA Transmassioni Mark3 Mark4 Mark5 Mark6 Mark7 Mark8 Mark9 Mark 10 M a r k1 1 M a r k1 2 M a r kl 3 M a r k1 4 M a r k1 5 M a r k1 6 Mark17 Mark 18

0.65, 0.85(0.026- 0.033) 0.40- 0.60(0.016- 0.024) 3 2 . 0( 1 . 2 6 ) 30.s(1.20i 31.1 11.221 3 0 . 5( 1 . 2 0 ) 1.88- 2.00{0.074- 0.079) 1 . 5 5- 1 . 6 5 1 0 . 0 -601. 0 6 5 ) 1.95- 2.05(0.077 0.081) 2.05 2.10(0.081- 0.083) 2.15- 2.20(0.085- 0.087) 2.25- 2.30{0.089- 0.091i 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 . 7 5- 2 . 8 0( 0 . 1 0 8 0 . 1 1 0 ) 2 . 8 5 2 . 9 0( 0 . 1 1 -2 0 . 1 1 4 ) 2.3- 2.4{0.091 0.094) 2.4, 2.5{0.094- 0.098) 2.5 2.6(0.098- 0.102) 2.6- 2.7(0.102- 0.106) 2 . 7, 2 . 8( 0 . 1 0 -6 0 . 1 1 0 ) 2 . 8- 2 . 91 0 . 1 1 00 . 1 1 4 ) - .118) 2 . 9- 3 . 0( 0 . 1 1 4 0 3 . 0 , 3 . 1( 0 . 1 1 8 - 0 . 1 2 2 ) 3.1- 3.2\O.122-0.1261 3 . 2- 3 . 3{ 0 . 1 2 -6 0 . 1 3 0 } 2.0- 2.1(0.079- 0.083) 2.1- 2.2(0.083- 0.087) 2.2- 2.3(0.087- 0.091) 3 . 3- 3 . 4( 0 . 1 3 0 0 . 1 3 4 ) 3.4- 3.5(0.134- 0.138) 3.5- 3.6(0.138 0.142) 3 . 6 3 . 7{ 0 . 1 4 2 0 - .146) 3 . 7, 3 . 8 1 0 . 1 4-60 . 1 5 0 i

1_ffi9

3 0 . 0( 1 . 1 8 ) 28.5\1.12) 2 9 . 1( 1 . 1 5 ) 28.511.121 Untilgroovesworn out Discoloration Discoloration

1 I

I Discoloration Discoloration

1 I

I L I Discoloration (cont'd)

3-11

Standardsand ServiceLimits Automatic Transmission(cont'd)- Section l4 MEASUREMENT Diameterof needlebearingcontactarea On mainshaftstatorshaftbearing On mainshaft2nd gear On mainshaft4th gearcollar On mainshaft1stgearcollar (leftside) On countershaft On countershaft 3rd gearcollar On countershaft 4th gear On countershaft reversegearcollar On countershaft 1stgearcollar On reverseidlergearshaft Insidediameterof needlebearingcontactarea On mainshaft1stgear On mainshaft2nd gear On mainshaft4th gear On countershaft 1stgear On countershaft 3rd gear On countershaft 4th gear On countershaft reversegear On reverseidlergear On statorshaft(ATFpump sidei On statorshalt(statorside) Reverseidlergearshaftholderl.D. Endplay Mainshaftlst gear Mainshaft2nd gear Mainshaft4th gear Countershaft lst gear Countershaft 3rd gear Countershaft 4th gear Reverseidlergear Countershaft reversegear Selecto.hub O.D. Mainshaft4th gearcollarlength Marnshaft4th gearcollarIlangethickness Mainshaftlst gearcollarlength Countershaft distancecollarlength

,96 97 models '98 00 modets Countershaft reversegearcollarlength Countershaft reversegearcollarflange thackness Countershaft 1stgearcollarlength Countershaft lst gearcollarflangethickness Countershaft 3rd gearcollarlength

t L

a.\

STANOARD{NEW)

SERVICE LIMIT

22.980 22.99310.9047 0.9052|j 3 5 . 9 7 5 3 5 . 9 9 (11 . 4 1 6-31 . 4 1 6 9 ) 3 1 . 9 7 5 3 1 . 9 9 (11 . 2 5 8 9 _ , 1 . 2 5 9 5 ) 30.975- 30.991t1.2195 1.22011 3 6 . 0 0 4 3 6 . 0 1 (71 . 4 1 7-51 . 4 1 8 0 ) ( 1 . 4 1 6-51 . 4 1 7 2 ) 3 5 . 9 8 03 5 . 9 9 6 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 (11 . 2 5 8-91 . 2 5 9 5 ) 3 1 . 9 7 s 3 1 . 9 9 (11 . 2 5 8-91 . 2 5 9 5 ) - 14.000{0.5508 - 0.5512) 13.990 3 5 . 0 0 0 , 3 s . 0 1( 61 . 3 7 8-01 . 3 7 8 6 ) 4 1 . 0 0-0 4 1 . 0 1 16 1 . 6 1 4- 21 . 6 1 4 8 ) - 1.4967) 38.000- 38.0'16 {1.4961 - 1.4967) 38.000 38.016(1.4961 4 1 . 0 0 0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 ) 33.000- 33.016(1.2992 1.2998) - 1.4967) 38.000- 38.016(1.4961 - 0.7094) 18.007- 18.020(0.7089 -29.O1311.1417 - 1.14221 29.OO0 - 1.0638) 27.O00 27.02111.0630 '14.416 - 14.434(0.5676 0.5683) 0.08 0.19(0.003- 0.007) 0.05- 0.13(0.002 0.005) 0.075- 0.185(0.003 0.007) 0.1- 0.5{0.004- 0.020) 0.05- 0.17{0.002- 0.007) 0.10- 0.18(0.004 0.007) 0.05- 0.18(0.002 0.007) 0.10- 0.25(0.004 0.010) 51.87- 51.90{2.042 2.043) 45.00- 45.03(1.771- 1.773) - 0.1781) 4.435- 4.525(0.1746 2 7 . 0 0 -2 7 . 1 5( 1 . 0 6-3 1 . 0 6 9 ) 38.87- 38.90{1.530- 1.531) 38.92 38.95{1.532- 1.533) 3 8 . 9 7- 3 9 . 0 0( 1 . 5 3 4 , 1 . 5 3 5 i 39.02- 39.05(1.536- 1.537) 39.07- 39.10{1.538- 1.539) 3 9 . r 2- 3 9 . 1 5( 1 . 5 4 -0 1 . 5 4 1 ) 3 9 . 1 7- 3 9 . 2 0( 1 . 5 4-2 1 . 5 4 3 ) 39.22- 39.25(1.544- ' t.545) 39.27 39.30(1.546- 1.547) 21.15- 21.20(0.833- 0.835) 20.65 20.70(0.813- 0.825) 14.5 r4.6 {0.571- 0.575) 2.4- 2.610.094 0.102) 14.s- 14.6(0.571- 0.575) 2.4 2.6(0.094- 0.102)

Wear or damage

Un;t of length: mm {in)

Automatic Transmtsston Section 14 Transmission

3.97 4.024 . 0 74 . 1 24 . 1 74.224 . 2 74 . 3 24.374.42-

Thrustwasherthickness Mainshaftball bearingleftside Mainshaftlst gear '96 97 models 3rd gearsplinedwasher Countershaft '98- 00 models

2 . 9 52.43 4 . 4 54.95-

3 . 0 5{ 0 . 1 1 -6 0 . 1 2 0 ) 2.50(0.096- 0.098) 4 . 5 0( 0 . 1 7-5 0 . 1 7 7 i 5.00(0.195 0.197)

Wearor damage

One-wayclutchcontactarea 1stgearLD. Countershaft ParkgearO.D. Mainshaftfeed pipeA, O.D.(at 15 mm (0.59inlfrom

83.339- 83.365(3.2810 3.2821) - 2.6259) 66.685- 66.698(2.6254 8.97- 8.98(0.353- 0.354)

Wearor damage Wearor darnage 8.95(0.352J

- 0.2354i 5.97 5.9810.2350 - 0.3142) 7.97- 7.98(0.3138

5 . 9 5( 0 . 2 3 4 ) 7 . 9 5( 0 . 3 1 3 )

1.87- 1.97{0.074 0.078)

1 . 8 0( 0 . 0 7 1 )

- 0.2374) 6.0r8 - 6.030{0.2369 9.000- 9.01s10.3543-0.3549) - 0.3158) 8.000-8.022(0.3150 2.025- 2.015l0.0197-0.0417) 35.000 35.02511.37801.3782)

6.045(0.2380) 9.03(0.356) 8.03{0.316) 2.08(0.082) 35.050(1.3799)

5.90- 6.00(0.232- 0.236)

5.40(0.213)

Mainshaft 2nd gear thrust washer thickness

feedpipeB,O.D.(at30 mm {1.2in)from end) Mainshaft feedpipeO.D.lat 15 mm (0 59 in) from Countershaft eno) Mainshaftsealingringthickness 1 2 9m m 1 1 . 1i n i a n d3 5 m m { 1 . 4i n ) ) Mainshaftbushingl.D. MainshaftbushingLD. bushingLD. Countershaft Mainshaftsealingring goovewidth Regulator valve body

Seatingring conlact area l.D.

Shifting device and park brake control

ReverseshiftforkIingerthickness Parkbrakepawl Parkgear

Servobody

Shift fork shaft bore LD. Shiftfork shaftvalveborel.D. ATFpump gearsideclearance clearance ATFpump gear-to-body

ATFpump

Differential carrier

Differential prnrongear

LIMIT SEBVICE

STANDARDINEW) - 0.157) 4.0010.156 4.05(0.158 0.159) 4 . 1 0( 0 . 1 6-0 0 . 1 6 1 ) 4 . 1 5( 0 . 1 6 2 0 . 1 6 3 ) 4 . 2 01 0 . 1 6-40 . 1 6 5 ) 4.25(0.166- 0.167) 4 . 3 0( 0 . 1 6 8 - 0 . 1 6 9 ) 4 . 3 5( 0 . 1 7 0 0 . 1 7 1 ) - 0.173) 4.4010.172 - 0.175l 4.4510.114

MEASUREMENT

ATFpump drivengearLD. ATFpump drivengearshaftO.D PinionshaftcontactareaLD. Carrierto'pinionclearance contactare LD. Driveshaft clearance Carrierto-driveshaft Backlash

t.D. Pinion gear to-pinion shaft clearance

Set ring-to bearing outer race clearance

1 I +

Wearor damage

+ I

lWear - 0.5516) 14.000- 14.010(0.5512 - 1.4582) 37.000- 37.039(1.4567 0.03-0.05 {0.001- 0.002) - 0.0052) Drive 0.1050- 0.1325(0.0041 - 0.0025) Daiven 0.0350- 0.0625(0.0014 - 0.5525i - 14.034{0.5518 14.0' |6 13.980 13.990(0.5504 0.5508) 18.010 18.028{0.7091 0.7098) -0.0022) 0.023- 0.057(0.0009 26.025* 26.04511.0246 1.0254) - 0.0034) 0.045- 0.086(0.0018 0.05- 0.15{0.002- 0.006) - 0.7113i 18.042- 18.066(0.7103 - 0.0037) 0.055- 0.095(0.0022 0 - 0.15(0 0.006)

or otherdefect

3 7 . 0 4 (51 . 4 5 8 5 ) 0.07(0.003)

0.1{0.004) 0 . 1 2{ 0 . 0 0 5 )

ffi.oour Adjust

(cont'd)

3-13

Standardsand ServiceLimits Automatic Transmission(cont'd)

Section '14 STANDARD{NEW}

MEASUREMENT Wire Dia. Springs

CVT

Hegulator valvespringA Regulato. valvespringB Statorreactionspring Modulatorvalvespring Torqueconvenercheckvalvespring Coolerreliefvalvespring Reliefvalvespring 2nd oriticecontrolvalvespring 1-2shiftvalvespring 2-3shift valvespring 3 4 shiftvalvespring 'lst accumulator spring 4th accumulator springB 4th accumulator springA 2nd accumulator springA 3rd accumulator springA 2nd accumulator springB 3rd acc!mulatorspringB 2nd accumulator springC Lockup shiftvalvespring Lockup timing valvespring Lock-upcontrolvalvespring 3 4 ofificecontrolvalvespring Servocontrolvalvespring CPCvalvespring CPBvalvespring 4th exhaustvalvespring

1 . 8{ 0 . 0 7 1 ) 1 . 8{ 0 . 0 7 1 ) 4.5\O.117) 1 . 4( 0 . 0 5 5 ) 1.010.039) 1.0(0.039) 1 . 1( 0 . 0 4 3 ) 0.7 (0.028) 0.9 (0.035) 0.9(0.035) 0.9(0.035) 2.1(0.083) 2.3 (0.091) 2.610.102) 2.4(0.094) 2 . 8( 0 . ' 1 1 0 ) 1.6(0.063) 2.2(0.087) 2.2 t0.041) 0.9 (0.035) 0.9(0.035) 0.7(0.028) 0.7(0.028) 1.0(0.039) 0.6(0.024) 0.9{0.035) 0.9(0.035)

MEASUREMENT Capacity f {USqt, lmp. qt)

Forwardclutchpressureat 1,500rpm in E position Reversebrakepressureat 1,500rpm in E position Dr;vepulleypressureat 1,500rpm in E posrtron 1kgflcm,,psi) Drivenpulleypressureat 1,500rpm in N position pressureat 3,000rpm in E posrtron Lubrication Stallspeedfpm (Checkwith vehicleon levelground) E position E, E, El positions Clutchinitialclearance Clutchreturnspringfree length Clutchdiscthickness Clutchplatethickness

L.

No. ol Coils

87.8(3.457) 44.0i.732l' 3 0 . 3( 1 . 1 9 3 ) 35.0{1.378) 3 3 . 8( 1 . 3 3 1 ) 3 3 . 8( 1 . 3 3 1 ) 3 7 . 1( 1 . 4 6 1 ) 34.8(1.370) 4 1 . 3( 1 . 6 2 6 ) 57.0 (2.2441 51.0 \2.2441 89.1{3.508) 5 1 . 6( 2 . 0 3 1 ) 87.0(3.425) 39.011.535) 89.3(3.516) 2 0 . 7( 0 . 8 1 5 ) 3 5 . 11 1 . 3 8 2 ) 68.012.6711 73.7 12.902) 80.7(3.177) 38.0{1.496) 37.5fi.476) 52.1(2.051) 12.2(0.480) 47.2{1.858} 36.4{1.433)

STANDARDINEWI

Hydraulic pressure

3-14

FreeLongth

16.5 11.0 1.9 10.9 4.2 4.2 13.4 22.0 16.3 26.8 26.a 16.2 13.8 14.2 2.9 15.6 6.1 2.4 13.9 32.0 45.8 14.1 24.6 20.4 18.3 19.5

Section 14

Transmission fluid

Clutch

o.D. 14.7(0.584) 9.6 (0.381) 3s.4(1.407) 9.4(0.374) 8.4 (0.334) 8.4 (0.334) 8.6{0.342) 6.6(0.262) 7.6 (0.302) 7.6 (0.302) 7.6 (0.302) 16.0(0.636) 10.2lo.402l 17.0{0.676) 2 9 . 0( 1 . 1 5 2 ) 1 7 . 5( 0 . 6 9 5 1 9.0 (0.358) 3 1 . 0( 1 . 2 2 0 ) 14.5{0.576) 7.6(0.302) 8 . 1( 0 . 3 1 9 ) 6.610.262) 6.6(0.262) 8.1 (0.322) 5.6 (0.2231 8.110.322) 6.1 10.242)

Forwardclutch Start clutch Reversebrake Forwardclutch Start clutch Reversebrake Forwardclutch Startclutch Reversebrake Forwardclutch Start clutch Reversebrake

SERVICELIMIT

6.4{6.8,5.6)for overhaul 3.9 (4.1,3.4)for fluid change - 11.A,203 - 2531 1.4- 1.15114.3 1.4 1.75(14.3 11.8,203 2531 -7.1,28- 1011 o . 2- 0 . 7 1 2 . 0 r . 5 2 . 31 1 5 .-3 2 3 . 52, 1 8- 3 3 4 ) A b o v e0 . 2 1 2 , 3 0 )

2,500 3,000

- 2,650 2,350 - 3,r00 2,800

0.6- 0.8(0.024- 0.031) 0.5- 0.7(0.020 0.028) 0.45- 0.75(0.018- 0.030) 3 0 . 5{ 1 . 2 0 1 ) 4 0 . 9( 1 . 6 1 0 ) 2 9 . 4( 1 . 1 5 7 ) 1.88- 2.00(0.074-0.079) 1.88 2.00(0.074- 0.079) 1.94- 2.06(0.076- 0.081) 1.95- 2.05(0.077-0.081) 2.25 2.35(0.089- 0.093) 1.90- 2.00(0.075 0.079)

3 8 . 9( 1 . 5 3 1 ) 27.411.019l' Until groovesworn out

,*x.ar}

Untilgroovesworn out Discoloration Discoloration Discoloration

UO

cw

[Jnit of length: mm (in)

Section 14 STANDARD{NEW} - 0.138) 3.4 3.510.134 Mark 1 or 15 Forwardclutchend platethickness M a r k2 o r 1 6 3 . 5- 3 . 6( 0 . 1 3-8 0 . 1 4 2 ) 3 . 6- 3 . 7( 0 . 1 4-2 0 . 1 4 6 ) M a r k3 o r 1 7 3.7 3.8(0.146 0.150) M a r k4 o r 1 8 3 . 8- 3 . 9( 0 . 1 5 -0 0 . 1 5 4 ) M a r k5 o r 1 9 3 . 9- 4 . 0( 0 . 1 5-4 0 . 1 5 7 i Mark6 or 20 4 . 0- 4 . 1( 0 . 1 5-7 0 . 1 6 1 ) Mark7 or 21 4.1- 4.2(0.161- 0.165) Mark8 or 22 4.2- 4.3(0.165- 0.169) MarkI or 23 4.3- 4.4(0.169- 0.173) 10 or 24 Mark Mark11or 25 4 . 4- 4 . 51 0 . 1 7-30 . 1 7 7 i Mark12or 26 4 . 5 4 . 6( 0 . 1 7 7 0 . 1 8 1 ) 4.6- 4.7(0.181- 0.185) Matk 13ot 21 3.55- 3.65(0.140 0.144) plate Mark 1 thickness Reversebrakeend - 0.152) 3.75- 3.8510.148 Mark2 3.95- 4.05(0.156- 0.159i Mark3 4 . 1 5- 4 . 2 5( 0 . 1 6 3 0 . 1 6 7 ) Mark4 4.35- 4.45(0.171- 0.175) \44rk 5 4.55- 4.65(0.179- 0.183) Mark6 4.75- 4.85(0.187- 0.191) Mark7 4.95- 5.05(0.195- 0.199) Mark8 - 9.99(0.3929 0.3933) 9.98 gear shaftO.D. ATFpump drive - 0.3933) 9.98- 9.99{0.3929 ATFpump drivengearshaftO.D. 10.000- 10.015(0.3937 0.3943) Drivegearshaft ATFpump body bushingl.D. Drivengearshaft 10.000- 10.015(0.3937 0.3943) 0.01s- 0.035(0.0006 0.0014) ATFpump gearsideclearance 0.035- 0.0505(0.0014-0.0020) ATF pump gear-to-bodyclearance Drive gear 0.035- 0.0505(0.0014- 0.0020) Drivengear

MEASUBEMENT

ATFpump

Transmission

Diameterof needlebearingcontactarea Inputshaft- flywheelside Inputshaft forwardclutchside Drivepulleyshaft- startclutchside Drivepulleyshaft- flywheelside Drivepulleyshaft- forwardclutchside Thrustclearance Carrierand ring gear Drivenpulleyshaftand startclutchhub Inputshaftand ATFpump drivensprocket gearshaftand flywheelball bearing Secondary

- 0.7874) 19.987- 20.000(0.7869 - 0.7874) 19.987- 20.000(0.7869 - 1.7319) 43.981- 43.991(1.7315 24.007- 24.020(0.945- 0.946) 24.007- 24.020(0.945- 0.946)

SERVICELIMIT Discoloration

Discoloration Discoloration

1 I

Discoloration Wear or damaged Wear or damaged Wear or damaged Wear or damaged

Wear or Wear or Wear or Wear or Wear or

damaged damaged damaged damaged damaged

- 0.0043) 0.050- 0.110(0.0020 - 0.005) 0.000- 0.13010.000 0.370- 0.650(0.015- 0.026) 0.00 0.15(0.00 0.006) (cont'd)

3-15

Standardsand ServiceLimits CW {cont'd) Transmission (cont'd)

Section 14 MEASUREMENT T h r u s st h i m , 2 5x 3 1 m m t h i c k n e s s

Cottersthickness

ATFpump drivesprocketthrustshim,22 x 28 mm thickness

gearshaftthrustshim,25 x 35 rnm Secondary thickness

Input shaft feed pipe O.D. Drive pulley leed pipe Forward clutch feed pipe Input shaft bushing t.D. Drive pulley feed pipe bushing Forward clutch feed pipe bushing Driven shaft feed pipe O.D. Start clutch feed pipe (right side cover side) Driven pulley feed pipe S t a n c l u t c h f e e d p i p e ( f t y w h e e th o u s i n g s i d e ) Driven pulley shaft bushing LD. Stan clutch feed pipe (right side cover sroer Drive pulley feed pipe Start clutch feed pipe (flywheel housing side) Secondarydriven gear sealing ring groove width Start clutch end plate l.D. Input shaft sealing ring groove width Dnve pullev shaft LD. at sealing ring Shifting device ano parK brakecontrol

3-16

Parkbrake cone Parkbrake pawl Parkgear

STANDARD{NEW}

rlz-r-osr-o.o+o oolrr

1 . 0 9- 1 . 1 2( 0 . 0 4 3 0 . 0 4 4 ) 1 . 1 6 1 . 1 9( 0 . 0 4-6 0 . 0 4 7 ) 1.23 1.26(0.048 0.050) 1 . 3 0- 1 . 3 3( 0 . 0 5 1 0 . 0 5 2 ) 1.37- 1.40(0.054 0.055) 1.44- 1.47(0.057 0.058) 1 . 5 1 1 . 5 4( 0 . 0 5 9 0 . 0 6 1 ) 1 . 5 8 1 . 6 1( 0 . 0 6-2 0 . 0 6 3 ) 1.65- 1.68(0.065 0.066) 1.72 1.75{0.068 0.069) - 0.012]} 1.79 1.a2t0.O10 1 . 0 5 5 1 . 0 8 5( 0 . 0 4 1 50 . 0 4 2 7 ) 1 . 1 2 -5 1 . 1 5 5( 0 . 0 4 4 30 . 0 4 5 4 ) 1.195- ' I.225(0.0470 0.0482) - 1 . 2 9 s( 0 . 0 4 9 80 . 0 5 1 0 ) 1.265 - 0.0537) 1.335 1.365(0.0526 - 0.0565) 1.40s- 1.435(0.0553 r.475 1.505{0.0580 0.0593) 1.545 1.575(0.0608 0.0620) - 0.0648) 1.615 1.645(0.0636 1 . 6 8 5 1 . 7 1 5 1 0 . 0 6- 603. 0 6 7 5 ) 1.755- 1.785{0.0691 0.0703) 2 . 8 7- 2 . 9 0( 0 . 1 3- 0 . 1 1 4 ) 2 . 9 7- 3 . 0 0( 0 . 1 1 7 0 . 1 1 8 ) 3.07-3.10 \0.121 0.122) 3 . 1 7- 3 . 2 0( 0 . 1 2 5 0 . 1 2 6 ) 1 . 1 2 1 . 1 5 1 0 . 0 -4 4 0.045) 1.37 1.40(0.054- 0.055) 1.62- 1.65(0.064 0.065) 1 . 8 7- 1 . 9 0( 0 . 0 7 4 , 0 . 0 7 5 ) 2.12 2.15(0.083- 0.08s) 2.37 2.40(0.093 0.094) 2 . 8 0- 2 . 8 5( 0 . 1 ' t-00 . 1 1 2 ) 2 . 9 0 2 . 9 5( 0 . 1 1-4 0 . 1 1 6 ) 3 . 0 0 3 . 0 5( 0 . 1 1-8 0 . 1 2 0 ) 3 . 1 0- 3 . 1 51 0 . 1 2 20 . 1 2 4 ) , .128i 3 . 2 0- 3 . 2 5( 0 . 1 2 6 0 3.30- 3.35(0.130 0.132) 3 . 4 0- 3 . 4 s1 0 . 1 3 40 . 1 3 6 ) 3 . 5 0 3 . 5 5( 0 . 1 3-8 0 . 1 4 0 ) 3 . 6 0 , 3 . 6 5( 0 . 1 4 2 0 . 1 4 4 ) 3 . 7 0- 3 . 7 5( 0 . 1 4 6 0 . 1 4 8 ) 3 . 8 0- 3 . 8 5 1 0 . 1 5 0 . 1 5 2 )

SERVICE LIMIT I Wr"r - d-"-"g"d

ii

11

ir Wear,or damaged

I

Wearor damaoed Wearor damaged

t { Wear or damaged

Wearor damaged

w

Wearor damaqed

6.97- 6.98(0.274- 0.27s) 1 1 . 4 -7 1 ' 1 . 4(80 . 4 5 1 60 . 4 5 2 0 )

6.95(0.274) (0.451) 11.45

- 0.2762]l 7.O0O7.0t510.2156 1 1 . 5 0 0 1 1 . 5 1(80 . 4 5 2 80 . 4 5 3 5 )

7.030(0.277) 1 1 . 5 3(30 . 4 s 4 )

6.97- 6.9A\0.214 0.275:l - 1 1 . 4 8( 0 . 4 5 1_60 . 4 5 2 0 ) 11.47 - 0.354) 8.97 8.9810.353

6.95(0.274) 1 1 . 4 5( 0 . 4 5 1 ) 8 95 (0.352)

- 0.2762) 7.000 7.015(0.2756 (0.4528 - 0.4535) 11.500- '11.518 - 0.355) 9.000 9.01510.354 2.50 2.65(0.098 0.104) 88.900,88.935(3.500- 3.501) - 0.083) 2.00 2.1010.079

t.030l0.2t7l 1 r . 5 3 3( 0 . 4 5 4 ) 9.03(0.356) 2.655(0.r05) Wearor damaged 2 . 1 0 5( 0 . 0 8 3 ) Wearor damaqed

5*

rl

Wear or other defect Wear or other defect Wear or other defect

ro

cw

U n i t o f l e n g t h :m m l i n )

Section14 STANDARD{NEW) 1 8 . 0 1 0 1 8 . 0 2 8 ' 0 . 7 0-901. 7 0 9 8 ) - 0.0022) 0.023 0.057(0.0009 26.025- 26.045(.0246 1 0254\ - 0.0034) 0.045 0.086(0.0018 0 0 5 0 . 1 5i 0 0 0 2 0 . 0 0 6 ) 1 80 4 2 1 8 . 0 6{60 . 7 1 0 30 . 7 "l 3 ) - 0.0037) 0.055- 0.095(0.0022 (0 0.15 0.006) 0

MEASUREMENT Differential

Pinion shaft contact area LD. C a r r i e r - t op i n i o n c l e a r a n c e Drive shaft contact area l.D. Carrierto driveshaftclearance

Dtri"*"t"|p'.b" gear

Backlash LD. Pinion gear to-pinion shafl clearance

S"t rrg-t" b""il"s ) u t e r r a c e c l e a r a n c e MEASUBEMENT Springs

Steering

PHregulatorvalvespring PHcontrolvalvespring PL regulatorvalvespring PH'PLcontrolvalvespring c r u t l hr e d u c ' n vs d r v es p n n s valvespring LLbrication Shittvalvespring Shiftcontrolvalvespring Stan clutchcontrolvalvespring Pitotregulatorvalvespring spring Startclutchvalveaccumulator Reversecontrolvalvespring Shiftinhibitorvalvespring

WireDia 1 2 (0 047) 1 7 {0.067) 0 9 (0.035) 1 0 (0 039) ]I : 1(u 9 9]:l b ubJr 1 4 (0.055) 1 0 (0.039) 0.4(0 016) 0.6(0 024) 1 2 \0 O47) 1 2 (0.047) 1 3 (0 051)

Gearbox

0.1(0 004) 0.12(0.005)

0.15{0.006) Adjlrst

O.D.

FreeLength

9.0{0.354) 13.4(0.528) 1.2lO.2A3\ 10.0(0.394) 1 6 . 8( 0 . 6 6 1 ) 13.4(0.528) 8.2 (0.323) 1.4 t0.2911 4 . 1( 0 . 1 6 1 ) 5.7 t0.224) 8.3{0.327) 9.4 (0.370) 1 3 . 2( 0 . 5 2 0 )

2 6 . 7( 1 . 0 5 1 ) 3 9 . 4( 1 . 5 5 1 ) 1 4 . 6( 0 . 5 7 5 ) 3 1 . 4( 1 . 2 3 6 ) 44.4\1.14al 5 1 . 6( 2 . 0 3 1 ) 3 4 . 1( 1 . 3 4 3 ) 1 9 . 3( 0 . 7 6 0 ) 1 2 . 1( 0 . 4 7 6 ) 9 . 5( 0 . 3 7 4 ) 2 9 . 8( 1 . 1 7 3 ) 3 1 . 4( 1 . 2 3 6 ) 4 8 . 3( 1 . 9 0 2 )

I

No. of Coils r0.0 8.1 1.2 8.6 8.0 13.0 1.5 6.8 5.0 12.3 11.0 10.6

Section 17 STANDARD {NEWI

MEASUREMENT Steeringwheel

SERVICELIMIT

Playat steeringwheel circumference S t a r t i n g l o a d a t s t e e r i n gw h e e l c i r c u m f e r e n c e N (ksf, lbf) Manual steering Engine running Power steering

M/S Angleof rackguidescrewloosened P/S from lockedposition Preloadat piniongearshaftN m (kglcm,lbfin) M/S P u m p p r e s s u r ew i t h v a l v e c l o s e d ( o i l t e m p . / s p e e d :4 0 ' C ( 1 0 5 " F )m i n . / i d l e Do not run for more than 5 seconds). kPa (kgtcm?,psi)

0 - 1 0( 0 0 . 4 ) 1 5( 1 . 5 , 3 . 3 ) 2 9( 3 . 0 , 6 . 6 ) 20!5" 20'Max 0 . 5- 1 . 7( 5- 1 7 , 4 . 3- 1 4 . 8 i 0 . 6 1 . 2( 6- 1 2 ,5 . 2 0- 1 0 . 4 2 ) 6,400- 7,400{65- 75,920- 1,070)

HONDAPowerSteeringFluid at disassembly 0.85(0.90,0.75) Reservoir 0 . 4{ 0 . 4 2 . 0 . 3 5 }

Power steering fluid

powersteeringfluid Recommended Fluidcapacity | {US qt, lmp q0

Powersteering belt*

with 98 N (10kgf,22lbf) Deflection betweenpulleys'99 modell81642EngineTypeonly

7.5 11.0{0.30- 0.43)withusedbelt 5.0 7.0(0.20 0.28)with new belt '96 '99 models:OtherEngineTYPes 10.5- 14.010.41 - 0.55)with usedbelt 7.5 10.010.300.39)with new belt

ron.ionffi

81642EngineTvpeonly N (kgf,lbf) '99 model: '96 -'99 models:OtherEngineTYPes '99 modelr 81642EngineTYPeonlY '96 '99 models:OtherEngineTYPes

390 340740 640

540{40 490(35880(757 8 0( 6 5-

55,88 '120)wrth usedbek 50,77 - 110)with usedbelt 90, 170- 200)with new belt 8 0 ,1 4 3 - 1 7 6 ) w i t hn e w b e l t

M / S : [ , 4 a n u a ls t e e r i n g , P / S l P o w e r s t e e r i n g *: When using a ne; bett,adjust dellection or tension to new values. Run the engine for 5 minutes then turn it offR e a d j u s tt h e d e f l e c t i o n o r t e n s i o n t o u s e d b e l t v a l u e s .

3-17

Standardsand ServiceLimits Suspension- Section 18 MEASUREMENT

STANOAROINEW}

Camber algnmenl

Caster Totaltoe Frontwheelturningangle Inwardwheel Outwardwheel B i mr u n o u t A l u m i n u mw h e e l Steelwheel Wheel bearing

Endplay

Front Rear Front Front Bear

0 " 0 0 ' 11 " -1.11' 1'40'I 1" I n ' 1 . 0 12 . 0{ 1 / 1 6t 1 / ' 1 6 ) I n 2 . 0l j B( 1 / 1 6 11 / 1 6 ) 39.50' 33'10'(Reference)

Axial Badial Axial R a d l Ia Front Rear

0 000-

0.7(00 . 7( 01 . 0( 0 1 . 0( 0

0.03) 0.03) 0.04) 0.04)

SERVICELIMIT

2.0(0.08) 1 . 51 0 . 0 6 ) 2.0{0.0B) 1.5(0.06)

0 0.0s(0 - 0.002) 0 0.05(0 0.002)

Brakes- Section 19 MEASUREMENT

STANDAROINEWI

Parklngbrake

Playin strokeat 196N (20kgf,44 lbfi leverforce

To be lockedwhen pulled 6 - I notches

Footbrake peoal

Pedalheight(withfloor mat removed)

156.5 {6.16) 161(6 5/16) 1 5(1/16-3/16) 0 - 0.4(0 0.02) 20.9- 21.8(0.82- 0.86) 8.9- 9.1(0.350- 0.358)

Mastercvlinder

Freeplay Pistonto pushrodclearance

Discbrake

Discthickness Discrunout Discparallelism Padthackness

Front Rear Front Rear Frontand rear Front Rear

Rearbrake LD. drum Liningthickness *1. 5410Stampedon the caliperbody. *2. 2056Stampedon the caliperbody.

M/T A/'T, CVT

9.5 10.5*' 8.5- 9.5*' 7 . 0 8 . 0( 0 . 2 8 - 0 . 3 r ) 200 17.a7l 4 . 0( 0 . 1 6 )

SERVICELIMIT

19.0(0.75) 8 . 0( 0 . 3 1 ) 0 . 1 0( 0 . 0 0 4 ) 0.10(0.004) 0.015(0.0006) 1.6(0.06) 1 . 6( 0 . 0 6 ) 'r.6(0.06) 201 \7.911 2.0{0.08}

Air Conditioning- Section22

Conditioning SANDEN NIPPONDENSO

Compressor SANDEN

NIPPONDENSO

Compressor belt*

MEASUREMENT STANDARDINEWI Lubricanttype:SP 10 (P/N38897- Pl3 - A01AHor 3889I - P13 A0li lForrefrigerant: (R,134a)) HFC-134a Lubricantcapacity Condenser | 20\2t30.11 mf (floz, lmp oz) Evaporator I 45(12/3,1.6) Lineor hose 1 0( 1 / 3 , 0 . 4 ) Receiver 1 0t 1 / 3 , 0 . 4 ) Lubricanttype:ND'O|L8(P/N38899- PR7- 003)(ForRef.igerant:HFC,134a (R-134a)) Lubricantcapacity Condenser 25 (s/60.9) mf (floz, lmp oz) Evaporator 6 0 ( 2 , 2 . 1 1 Lineor hose 1 0( 1 / 3 , 0 . 4 ) Receiver 1 0( 1 / 3 . 0 . 4 ) Lubricanttype:SP-10 Lubricantcapacity ml lfl oz,lmp oz) 130 150(4 1/3 4.6,5.0- 5.3) Fieldcoil resistance at 68'F(20"C) O plateclearance Pulley-to-pressure 0.5r 0.1510.020 t 0.006) Lubricanttype:ND-OlL8{P/N38899- PR7,003 or P/N38899 pR7- AO1)(ForRefrigerant: HFC134a{R,134a)) L u b r i c a nc ta p a c i t y m { ( f l o z ,l r n p o z ) | 1 4 O ( 4 . 7 , 4 . -91J5 S { 5 . 2 . 5 . 4 ) S t a t o r c o i l r e s i s t a n c ea t 2 0 ' C ( 6 8 . F ) 0 3.4- 3.8 P u l l e y - t o - p r e s s u r ep l a t e c l e a r a n c e 0 . 5 1 0 . 1 5( 0 . 0 2 1 0 . 0 0 6 ) Deffection with 98 N (1Okgl.22lbll 7.5- 9.5(0.30 0.37)with usedbelt betweenpulleys 5.0- 6.5(0.20- 0.26)withnew belt Belttension N (kgf,lbf) 340 490i35 50,77 - 110)with usedbell Measuredwith belttensiongauge 690- 830(70- 85, 150 190)with new belt

*: When using a new belt,adjust deflectionor tension to new values.Run the engine for 5 minutes then turn it of{. R e a d j u s td e f l e c t i o n o r t e n s i o n t o u s e d b e l t v a l u e s .

3-18

U n i t o f e n g l h :m m { n )

Electrical Section 23

STANDARD {NEW}

MEASUREMENT Ratedvoltage V at 68'F(20'C) o Primarywindingresistance

12

HITACHI TEC windingresastance at 68'F120"C) kO Secondary HITACHI TEC Resistance at 68'F(20'C) kf) F i r i n go r d e r

0.45 0.55 0.63 0.11

Sparkplug

Type Gap

Seesection23

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

At idle ' B T D Cl R e d )

Alternator belt+

D e f l e c t i o nw i t h 9 8 N ( 1 0 k g f , 2 2 l b f ) between pulleys

lgnitioncoil

lgnitionwire

Belttension N (kgf,lbf) Measuredwith belttensiongauge

22.4- 33.6 12.A- 19.2 25 max. 1-3-4 2

1.13,(o.o€-3*.)

8.0- 10.5{0.31- 0.41}with usedbelt 6.0- 8.5{0.26- 0.33)withnew belt 340- 490(35- 50,77 110)with usedbelt 5 4 0- 7 4 0( 5 5- 7 5 ,1 2 1 . 1 6 5 ) w h hn e w b e r t SERVICELIMIT

STANDARDINEWI (MITSUBISHI)

Alternator (DENSOi

Starter

(MITSUEA 1 . 0k w 1.2kW)

Outputl3.5 V at hot A (rotor)at 68'F(20"C) kO Coalresistance S l i pr i n sO . D . Brushlength Brushspringtension g (oz) '13.5V at hot A Output (rotor)at 68'F (20'C) k0 Coil resistance S l i pr i n gO . D . Erushlength Brushspringtension g (oz)

75 3.4-3.8 Z2.j \0.A9) 19.0(0.75) 3 4 0 4 2 0( 1 2 . 0 1 4 . 8 )

Tvpe Commutatormicadepth Commutatorrunout CommutatorO.D. Brushlength Brushspringtension(new) N (ksf,lbf)

Gearreduction 0.4- 0.5(0.016- 0.020) o o.o2(o - 0.000e) 2 8 . 0 - 2 8 . 1( 1 . 1 0 2 1 . 1 0 6 ) 1 5 . 8- 1 6 . 21 0 . 6-2 0 . 6 4 ) 15.7- 11.1 {1.60- 1.80,3.5- 4.0i

80 2.2- 3.0 14.4(0.57) 10.5(0.41) 3 3 0{ 1 1 . 6 )

I

22.2\0.47) 5.0(0.20)

| 14.0(0.55) 1.5(0.06) 0.15(0.006) | o.o5(o.oo2) | 27.5(1.083) 1 1 . 0( 0 . 4 3 )

*: When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off Readiustdeflectionor tensionto usedbeltvalues

3-19

DesignSpecifications ITEM DII/IENSIONS

OverallLength 2 door Coupe/4door Sedan 2 door Hatchback

(,96 98) ('99,' 00) (,96,,97) ('98- 00)

Overallwidth Overallheight 2 doorCoupe/2doorHatchback 4-doorSedan Wheelbase FronvRear I Track GroundClearance SeatiogCapacity WEIGHT(USA) GrossVehicleWeightRaring(GVWR) 2 door Coupe HX M/T,DX M/T HX CVI ('96) HX CVT('97,'98) HX CVT('99} DX A,/T(96 98, DX A"/T('99,'00) EX Si 2 door Hatchbacl CX.DX r'96, 97, cx, DX ('98) cx (,99,,00) DXM/Ti'99,00i DX A/T ( 99, 00, 4 door Sedan DX, LX,DX-V EX WEIGHT(CANADA) GrossVehicleWeightBating(GVWR) 2-doorCoupe DX ('96) DX ('97 00) DX-G si 1,96) si ('97- 00) siR 2 door Hatchback CX,CX,G('96)

cx,cx,G1,97) cx-G(,98) cx ('98 00)

4 door Sedan ENGINE

DX M/T, SE M/I DX A,/T,SE A,/T LX,LX V EX M/I EX A/T

Type CylinderArrangement Boreand Stroke D16Y5,D16Y7,Dt6y8 B1642 Displacement D16Y5,D16Y7,Dl6Y8 81642 Compression Ratio D16Y5,D16y7 D16Y8 816A2 ValveTrain Lubrication System Oil PumpDisplacement at 6,800enginerprn D16Y5,D,l6Y7,D16Y8 81642 WaterPumpDisplacement at 6,000enginerpm 016Y5,D16Y7,D16y8 816A2 FuelRequired D16Y5,D16Y7,D16y8 816A2

STARTEB

Type/Make NormalOutput NominalVohage HourRating Directionof Rotation

METRIC

ENGLISH

4,445mm 4,450mm 4 , 1 7 0m m 4 , 1 8 0m m 1 , 7 0 5m m 1,375 mm 1,390mm 2,620mm 1,475/1,415 mm 1 5 0m m

1 7 5 . 0i n 115.2in 164.2in 1 6 4 . 6i n 6 7 . 1i n 5 4 . 1i n 5 4 . 7i n 1 0 3 . 1i n 58.1/58.1 5.9in

NOTE

3,290tbs 3,320tbs 3,330tbs 3,360rbs 3,290rbs 3 , 3 1 0t b s 3,440tbs 3,480tbs 3,285tbs 3,290tbs 3,290tbs 3,290tbs 3,330lbs 3,330tbs 3,460tbs 1,500ks 1,510 kg 1 , 5 1 0k g 1,560kg 1,570kg 1,590ks 1,495 kg 1,505kg 1 , 5 1 0k s 1 , 5 1 0k s 1,510 kg 1,530kg 1,510 kg 1 , 5 1 0k s 1,540ks Water-cooled, 4-stroke SOHC*1, SOHC VTEC"',SOHCWEC.E'3,DOHCVTEC{ gasolineengine Inline4 cylinder,transverse 75.0x 90.0mm 2.95x 3.54in 8 1 . 0x 7 7 . 4m m 3 . 1 9x 3 . 0 5i n 1,590cm3 97.0cu-in 1,595cm3 97.3cu in 9.4 9.6 10.2 Beltdriven,4 valveper cylinder Forcedand wet sump,trochoidpump

* 1 :D 1 6 Y 7 *': D16Y8 *3:D16Y5 *': 816A2

33.4f (35.3US qt, 29.4lmp qt)/minute 43.8| (46.3US qt, 38.6lmp qt)/minute 125{ {132US qt, 110lmp qt}/minute 140f {148US qt, 123lmp qt}/minute gasolinewith 86 Pump UNLEADED OctaneNumberor higher PremiumUNLEADED gasoline91 Pump OctaneNumberor higher Gearreduction/MITSUBA 1.0kw, 1.2kw 12V 30 seconds Clockwise as viewedfrom gearend

5-Z.V -

trEM MllSUBAr.u,l.z kw

SfAnff n i*nt-i-

W"'gf,t

CLUTCH

ClutchType

TRANSMISSION

ClutchFacingArea Type Transmission

I M/T CVT M/T M/T

Arr

CW PrimaryReduction

5-speedforward,1 reverse Synchronized 4 speedautomatic,1 reverse Non stagespeedforward,1 reverse Direct1 : 1 D16Y5 |

FinalReduction

3.250 1.182 1.112 0.909 0.702 3.153

Gearratio GeartYPe

3.122 13.122"11.053" 1 4.250 |

'lst

GearRatio

2nd 3rd 4th Reverse Gearratio GeartYPe

FinalReduction

cw

Low - O.D. Reverse GearRatio SecondaryReduction FinalReductionGearRatio GearRatio

AIR CONDITIONING

CoolingCapacity Type/Make Compressor No. of CYlinders CaPacitY Max.Speed LubricantCaPacitY Compressor

Type/Manufacturer No. of Cylinder Capacity Max.Speed LubricantCaPacitY

Condenser Evaporator

LubricantTYPe Type TyPe

Elower

Enginetype D16Y8 I 81642 3.230 3.250 3.250 2.105 1.909 1.182 1.458 1.250 1.112 1.107 0.909 0.909 0.875 0.102 0.702 3.000 3.153 3.153

D16Y7

1st 2nd 3rd 4th 5th Reverse

Automatictransmission

TyPe Motor Input SPeedControl Max.CaPacity

NorEs

Singleplatedry, diaphragmspring Torqueconverter Multi plateswet sanP,hYdraulic 2 5s q i n 160cm,

Manualtransmission GearRatio

ENGLISH

merntc r'4 rg

*1:2 door Hatch back + 2 r2 - d o o r C o u p e , and 4 door Sedan

4.266

S i n g l eh e l i c a l g e a r Enginetype D16Y8 D16Y7 | 2.122 2.600 1.468 0.975 0.926 0.638 0.638 1.954 1.954 4.357

1.351

2.466 0.449 2.466 1.333 4.357 14,000BTU/h 3,530Kcal/h Scroll/SANDEN 5.22cu inkev 10,000rpm 41l3tloz. 1 3 0m f 4.6imp oz | Swash-plate/DENso 10 9.4cu_in/rev 155.3mf /rev 76,000rpm 4 2l3fl oz, 140mf | 4 9 l m po z I ND'OIL8 85.7 m//rev

sP,10

Corrugatedfin

fin Corrugated

fan Sirocco 200w112v 4 speed variable 16,200 cu ft/h 460 m3/h

Temperature Control

Compressor Clutch Refrigerant

TyPe PowerConsumPtion TyPe ouantity

drive Dry,singleplate,PolY-V'belt 40 W max./12V at 68'F(20'C) HFC134a(R'134a) 22.9 isoz 650 gos |

( c o n t ' )d

4

.\t

J-Z

I

DesignSpecifications (cont'd) ITEM STEERING SYSTEM

METRIC

Tvpe

P/s M/S p/S M/S p/S M/S

OverallRatio Turns,Lock-toLock

SUSPENSION WHEEL ALIGN|\t4ENT

SteeringWheelDia. TYPe

Frontand Rear Frontand Rear

Camber

Front Rear F.ont Front Rear

Caster TotalToe EBAKESYSTEM

Type

Front Rear

PadSurfaceArea

Front

ParkingBrake TIRE WASHER

Type

Sizeand Pressure Capacity

2door Coupe/4,door Sedan 2,doorHatchback

ELECTRICAL

Baftery Starter Alternator Fuses In UnderdashFuse/Felay Box In Under-hoodFuse/Belay 8ox In UnderhoodABS FLrse/Relay Box Headlights FrontTurn Signal/Parking Lights RearTurn SignalLaghts Brake/Taillights InnerTaillights*, HighMount BrakeLight Backup Lights LicensePlateLights CeilingLight

TrunkLights GaugeLights IndicatorLights llluminationand PilotLights HeaterControlPanelLights P/S:PowerSteering M/S:ManualSteering *l: 2-doorCoupe *2: 2door Hatchback *3: 4-doorSedan *4: USA (HAM),Canada(HCM)produced *5: Japanproduced

NOTE

0.00, - 't' 1.40' ln 1 mm In 2 mm

ln 1/16 In 1/16

Powerassisted selfadjustingventilated disc Powerassisted selfadiustjngsoliddisc Powerassistedsell adjustingdr!m 37.5cm' x 4 5.8sq in x 4 44.1ctn,x4

Rear

ENGLISH

Powerassisted, rackand pinion R a c ka n dp i n i o n 1l.1 20.3 3.6 4..1 380 mm 15.0in Independent doublewishbone,coil spring Telescopic,hydraulicnitrogengas-filled

]

6.84sq-inxa

67.2cmzx 4 to.+ sq in ' I | 21.2cm, x 4 3.3 sq in x 4 Mechanical actuating,reartwo wheel brakes

5410stampedon the caliperbody 2056stampedon the caliperbody Drum Disc

Seelire intormationlabel 2.5f (2.6LJSqt, 2.2 lmp qt) 4 . 5| ( 4 . 8U S q t , 4 . 0 l m pq t ) 2.51 (2.6US qt, 2.2lmp qt) 4.5f (4.8US qt, 4.0lmp qt) 12V 38 AH/5HR 12V 1.0kW, 1.2kW 1 2 V 7 5A , 8 0A 7.5A, t0 A, 15A, 20 A 7.5A, 10A, 15A, 20 A, 30 A, 40A, 80 A 7 . 54 . 2 0 A , 4 0A 12V_60/55W 12V-2115W 1 2 V- 2 1 W 1 2 V- 2 1 / 5 W 12V-5W 1 2V 1 8W * " 2 1W + " * 3 12V 21W 12v-5w l2V-8W(Withmoonroofl 12V - 5W (Withoutmoonroof)

USAmodel Canadamodel DX ExceptDX

12V-1.4W,3W ' t 2v 1 . 1 2 W 1 . . 4W 1 2 v - 0 . 8 4 w ,1 . 4W 1 2 V 1 . 4W

L' 3-22

Body Specifications U n i t :m m ( i n )

2-doorCoupe: lt t9) gtt't

Body Specifications(cont'd)

2-door Hatchback:

Unit:mm (in)

(t t9] gre'r

3-24

Lif

Un i t :m m ( i n )

4-doorSedan: (r'tsl 06€'l

3-25

Maintenance .""."".' 4'2 LubricationPoints MaintenanceSchedulefor 1996Model '.""" 4-4 Normal Gonditions ."""" 4-6 SevereConditions MaintenanceSchedulefor 1997Model ."""' 4-8 Normal Conditions ....""' 4-10 SevereConditions MaintenanceSchedulefor 1998Model """" 4'12 Normal Conditions ."""" 4-14 SevereConditions MaintenanceSchedulefor 1999Model ."""' 4'16 Normal Conditions ."""" 4'18 SevereConditions MaintenanceSchedulefor 2000Model ."""' 4-2O Normal Conditions "'.""' 4-22 SevereConditions

I

LubricationPoints For the detailsof lubricationpointsand types of lubricantsto be applied,referto the lllustratedIndexand variouswork procedures(suchas Assembly/Reassembly, Replacement, Overhaul.Installation, etc.)containedin eachsection. No. LUBRICATIONPOINTS LUBRICANT I Engine "Energy Conserving" gradeoil, The oil containermay also displaythe Apl Certificationmark shownbelow.Makesureit says,,ForGasoline Engines.,, SAEViscosity:Seechart below, Transmission Manual GenuineHondaMTF*1 Automatic GenuineHondaPremiumFormula AutomaticTransmission Fluid(ATF)*, CVT GenuineHondaCVTFluid*3 3 BrakeLine GenuineHondaDOT3BrakeFluid*a 4 ClL,tci t""e GenuineHondaDOT3BrakeFluid*a Powersteeringgearbox Steering greaseP/N 08733- BO70E Shift leverpivots(manualtransmission) Greasewith molybdenumdisulfide 7 Releasefork (manualtrancmi
I

E -

Air conditioningcompressor

@ ComDressor oil:

SANDEN:SPlo P/N38897- p13-A01AH or 38899- p13_ A01 (R-134a)) {ForRefrigerant: HFC-134a

API SERVICELABEL

CERTIFICATION SEAL

ffi

Recommended EngineOil

Engineoil viscosityfor ambrenttemperatureranges

NorE: The itemsm arked* 1,*2, +3,*4 and +5 on abovechan are described as folows: *1: Always use GenuineHonda Manual TransmissionFluid (MTF).Using motor oil can causestiffer shifting becauseit does not containthe properadditives. *2: Always use GenuineHondapremium FormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATF can affect shift quality. +3:UseGenuineHondacVTfluid only usingotherfluidcanaffecttransmissionoperationand may reducetransmission *4: Alwaysuse GenuineHonda life. DoT3 BrakeFluid.Usinga non-Hondabrakefluid can causecorrosionand dec.easethe life of the svstem. *5: AlwaysuseGenuineHonda PowersteeringFluid.using any othertype of powersteeringfluid or automatrc transmission fluid can causeincreasedwear and poor steeringin cold weather.

4-2

NOTE:Lubricateall hinges,latchesand locksoncea year' ln corrosiveareas,more frequentlubricationis necessary' We recommendHondaWhite LithiumGrease'

4-3

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Engine 5-1 ................ EngineRemoval/lnstallation 6-1 Train ................... GylinderHead/Valve ...........7-1 EngineBfock.......... 8-1 ........... EngineLubrication 9'1 System........ IntakeManifold/Exhaust 10-1 ......... Cooling

Eng ine Removal/lnstallation Removal lnstaflation

"..'.'5'2 '.' 5-12

lgr"

EngineRemovaUlnstallation Removal

(

@@ . Make sure .

5.

Removethe batteryand batterybase.

iacks and salety stands are placedploperly and hoist brackets are attached to the correct positions on the engine. Make sure the vehicle will not roll off stands and fall while you are working underit.

8 x 1 . 2 5m m 24 N.m (2.4kgf.m, 17 lbf ftl

CAUTION: . Use fender covers to avoid damaging painted surface. . Unplug the wilin9 connectorscaretully while holding the conngstor portion to avoid damage, . Mark all wiring and hososto avoid misconnoction. Also, be sure that they do not contact other wiring or hosesor interferewith other parts, 1.

Securethe hood as open as possible. Disconnectthe batterynegativeterminalfirst. then the positiveterminal.Removethe battery. Removethe strut brace(B'16A2 engine). 8 x 1.25 mm 24 N.m {2.4kgl.m, 17 lbf.ft}

STRUTBRACE

Disconnect the connectorsfrom the ECM/pCM. 7.

Disconnect the main wire harnessconnector.

MAIN WIRE HARNESS CONNECTOR

Disconnectthe batterycablesfrom the under-hood fuse/relaybox and batterypositiveterminal. BATTERYCABLES UNDER.HOOD FUSE/RELAY BOX

ECM/PCM

5-2

8.

Removethe intakeair duct and air cleanerhousing.

016Y5,Dl6Y& 815A2engin€sl

D16Y, ongino:

a.

a.

Removethe resonatorand intakeair duct.

D i s c o n n e c t h e I A T s e n s o r c o n n e c t o r ,t h e n removethe intake8ir duct and air cleanerhousIng.

6x1.0mm 9.8 N m {1.0kgtm, 7.2 lbl'ft)

6x1.0mm 9.8 N.m (1.0kgt m, 7.2 lbf.tt)

INTAKE AIR DUCT

INTAKE AIR

AIR CITANER HOUSING

Disconnectthe intake air tempsrature (lAT) sensor connector,then r€movethg air cleanerhousIng.

AIR CI."EANER HOUSING

9.

IAT SENSOR CONNECTOR

Disconnectthe engine wire harnessconnectoron the left sideof the enginecompartment.

6x1.0mm 9.EN.m (1.0kgtm, t.2lbtft,

IAT SENSOR CONNECTOR

(cont'd)

5-3

EngineRemoval/lnstallation Removal(cont'dl 10. Relievefuel pressure(seesectionl1). Do not smokewhile working on the fuel !@ system, Keep open flame or spark away from the wolk area.Drainfuel only inlo an approvedcontainer. 1 1 . R e m o v et h e e v a p o r a t i v e m i s s i o n( E V A P c) o n t r o l canisterhoseand fuel feed hose.

12. Removethe brakeboostervacuumhose,fuel return hoseand vacuumhose. D16Y7engine:

VACUUMHOSE

D16Y7engine:

BANJOBOLT 33 N m ( 3.itlgt m, 25 lbt.ft)

FUEI-FEEDHOSE

D16Y5,D16Y8,Bt642 engines:

Dl6Y5, D16Y8,Bl642 enginos: BRAKEBOOSTER VACUUMHOSE

I 5-4

13. Removethe throftlecableby looseningthe locknut, then slip the cable end out of the acceleratorlinkage. NOTE; . Takecare not to bend the cablewhen removing it. Always replaceany kinkedcable with a new one. . Adjustthe throttlecablewhen installing(seesect i o n 11 ) .

the connectorsfrom the PCM. 1 4 , Disconnect R e m o v et h e g r o m m e t a n d w i r e h a r n e s sc l a m p s , then pull out the ECM/PCMconnectors

6x1.0mm

D16Y7engine:

LOCKNUT

16. Removethe mountingboltand lockbolt,then remove the power steering(P/S)pump belt and pump the P/Shoses. NOTE:Do not disconnect 816A2engine: Removethe adjustingbolt and mountingboits, then removethe P/Spump belt and pump

D16Y5,D16Y8,B16A2engines:

AOJUSTING

LOCKNUT

(cont'd)

5-5

EngineRemoval/lnstailation Removal(cont'dl ( Dl6Y5. DrGYr, D16Y8enginas: -1. Removethe mounting bolt and lock bolt, then removethe P/Spump beltand pump.

'18.

Removethe ransmission ground cable and hose ct8mo.

HOSECLAMP

6 x '1.0mm

MOUNTING BOLT 8 x 1.25mm 24N.m{2.4kgl.m,17tbf.ftl

LOCKBOLT 8 x 1.25mm 24 N.m 12.4kgf.m, 17 lbf.ftl

1 9 . R e m o v et h e c l u t c h s l a v e c y l i n d e ra n d l i n e / h o s e assembty(M/T). 17. Loosenthe idler pulleycenternut and adjusting bolt, then remove the air conditioning (A[/C) compressorbelt. IDI.IR PULLEYCENTER NUT 10 x 1.25mm a,l N.m {,1.5kgt.m, 33 lbf.ft)

NOTE: . Do not disconnectthepipe/hoseassembly. . Do not operatethe clutch pedal once the slave cylind€r has been removed. o Takecarenot to bendthe line. 6x1,0mm 11N.m{1.1kgt.m, I tbf.ftl

8x1.2Smm 2a N.mt2.4kgf.m, 17tbf.ftl

8 x 1.25mm 2a N'm {2,4 kgt m, 17 tbt.ftl

5-6

and splashshield. 24. Removethe front tires/wheels

20. Removethe shiftcable(CVT) CLIP

WASHER

LOCKNUT 29 N.m {3.0 kgf m,22lbf'ft}

Pt-Aslc

u x 1l.u 6 . 0mm mm

9.8Nm(10 kqt'm, 7.2lbf.ftl

SHIFTCABLE

2 1 . D i s c o n n e c t h e P o w e r s t e e r i n g p r e s s u r e( P S P ) switch connector, and r e m o v et h e w i r e h a r n e s s cramp.

l

l

I

SHIELD

25. Drain the engine coolant (see page 10-7).Loosen the drain plug in the radiator. 26. Drainthe transmissionfluid Reinstallthedrainplug usinga new washer(seesection13,14).

27. Drainthe engineoil. Reinstallthe drain bolt usinga new washer(seepage8-6). 28. Removethe shift rod and extension rod (M/T) SHIFTROD ER

EXTENSION ROD

caP. theradiator Remove usa carewhen l€movingthe tadiator !!!@ by hot coolantor steam' scalding Ap to avoid Raisethe hoist to full height.

8 x 1.25mm 't6lbtft) 22 N.m t2.2 kgf'm,

(cont'd)

EngineRemoval/lnstallation Removal(cont'dl { 29. Removethe Ay'Ccompressor.

31. RemoveexhaustpipeA.

NOTE:Do not disconnectthe Ay'Choses.

Dl6Y5. D16Y7engines: 8 x 1.25mm 22 N.m12.2ksl.m.16tbI.fr) Replace.

8x 1.25mm 24 N.m(2.{ kgf.m,t7 tbtft}

A/C A/C COMPRESSOR COMPRESSOR SELF.LOCKING 8 x 1.25mm 16 N.m (1.6kgtm,

30. Removethe shift cable(IVT). NOTE: . Takecare not to bend the cablewhen removing it. Always replaceany kinkedcable with a new one. . Adjust the shift cable when installing(see sec_ tion14).

12tbt.ftl Replace.

SELF.LOCKING NUT 10x 1.25mm 33 N.m {3.4kgt.m, 25 lbr'frl Replace.

D16Y8 ongin6; 8 x 1.25mm 22 N.m (2.2kgf.m. 16 tbf.ftl Replace.

8 x 1.25 mm 22 N.m(2.2kgf.m,16lbf.frl

GASKET Replace. SELF.LOCKING NUT 8 x 1.25mm 16 N.m 11.6kgf.m,12 lbtft) Replace. LOCKWASHER Beplace.

6x1.0mm 14 N.m (1.4kgf.m, tO tbtft)

SELF-LOCKING NUT l 0 x 1 . 2 5m m 54 N.m (5.5kgf.m, 40 lbf.ft) Replace.

5-8 t

35. Lowerthe hoist.

81642 engine: HO2SCONNECTOR

,&

36. Remove the upper and lower radiator hoses and heaterhoses,

8 x 1.25mm 22N,n 122 kdl'rn, 16rbt.ftl Replace.

GASKETS Replace.

UPPER RADIATORHOSE

Replace.

SELF.LOCKING 8 x 1.25mm 16 N.m t1.6 kg{ m, 12 lbl'ft) Replace. PIPEA

10 x 1.25 mm s4 N.m {5.5 kgf m, 40 lbf'ftl

RePlace' 32. Removethe damperforks (seesection18). D i s c o n n e ctth e s u s p e n s i o nl o w e r a r m b a l l j o i n t s (seesection18).

34. Removethe driveshafts. CAUTION: o Do not pull on th€ drivoshaft. the CV ioint may com9 apart. o Use care whgn prying out the assombly. Pull it straight to avoid damaging the differential oil seal or intermediate shaft dust seal.

37. Removsthe ATF cooler hoses,then plug the ATF cooler hosesand PiPes(A,/T)

N o T E : C o a t a l l p r e c i s i o n - f i n i s h esdu r f a c e sw i t h cleanengineoil. Tie plasticbagsover the driveshaft enos.

!^.

HOSES

(cont'd)

EngineRemovaUlnstallation Removal(cont'd) 38. Attachthe chainhoistto the engine.

HOISTINGBRACKET Installon the cylinderhead witha8x1.25mmbolt.

5-10

39. Removethe left and rightfront mount and bracket'

41. Removethe uPPsrbracket. UPPER

4 2 . R e m o v et h e t r a n s m i s s i o nm o u n t b r a c k e t ,t h e n removethe transmissionmount. TRANSMISSION

MOUNT/BRACKET

40. Removethe rearmount bracket.

Checkthat the engine/transmissionis completely free of vacuum hoses,fuel and coolant hosesand electricalwiring. (6 in)' are disconwires and hoses all that Checkonceagain nectedfrom the engine^ransmission

150mm 44. Slowlyraisethe engineapproximately

45. Raisethe engineall the way, and removeit from the car.

5-11

EngineRemovaUlnstallation Installation Brackei Bolts Torque Specifications: Dl5Y5,Dl6Y7,Dl6Y8 €nginss

10x 1.25mm 44 N.m {4.5 kgt m, 33 tbr.ftl

10 x 1.25mm 54 N.m {5.5kgf.m, 40 rbf.ftl

D16Y5,D16Y8engines(M/Tl: REARSTIFFENER

10x 1.25mm 44 N.m 14.5kgf.m, 33 tbf.frt

8 x 1.25mm 2/t N.m 12.4kgf.m, 17 tbf.ftl ALTERNATOF BRACKET

EXCEPTD16Y5, Dl6Yg engines lM/T)j STIFFENER Tightenthe boltson the stiffener in the numberedsequenceas shown

li) o).

l3l 10x 1.25mm 44 N.m {1.5kgt.m, 33 tbt.ft)

O8x1.25mm 24 N.m {2.4kg{.m, 17 tbr.ftt

10x 1.25mm 14 N.m 14.5kgt m, 33 tbf.ft) 8 x 1.25mm 24 N.m (2.4 kgf.m, 17 tbf.ft)

o16Ys,D16Y8 enginoslM/T): FRONT STIFFENER

8 x 1.25mm 2{ N.m (2.t kgtm, 17 rbtft)

5-12

10x 1.25mm 14 N.m (4.5kgf.m, 33 lbf.ftl

10 x 1.25mm 4,4N.m {4.5kg{.m. 33 tbf.ftl

1 0x 1 . 2 5m m 44 N.m {4.5kg'f.m, 33 tbtftl

816A2engine P/S PUMP BRACKET

REAR STIFFENER

SIDEENGINE MOUNT BRACKET

t0 x 1.25mm ia{ N.m (i1.5kgt rn, 33 lbt.tr)

t

1 2x 1 . 2 5n m 57 N.m {5.8 kgf,m, 12 tbl.ttl

8 x 1.25mm 24 N.m (2.4 kgl.m, 17lbf.ft)

10x 1.25mm 54 N m {5.5 kgf m, a0 lbl ft} 10x 1.25mm 4a N,m (4.5kgf.m, 33 tbf.ftt

FRONT STIFFENER

A/C COMPBESSOR BRACKET

'12x 1.25mm 57 N.m {5.8 kgt'm, 42 tbt.ft)

8 x 1.25mm 24 N.m {2.4kgf.m, 17 tbtft)

ALTERNATOR BRACKET

'10x 1.25mm ,14N.m {,1.5kgt.m, 33 rbf.ft)

(cont'd)

5-13

Engine Removal/lnstallation Installation(cont'd) Engino Inst!llation: Installthe engine in the reverseorder of removal. Beinstallthe mount bolts/nutsin the followingsequence. Failureto follow these proceduresmay cause excessive nois€and vibration,and reducebushinglife. l,

Install the transmissionmount and bracket,then tightenthe boltson the frame side, NOTE; Do not tighten the bolts/nutson the trans_ missionside. CW; 10x 1.25mm 38 N.m {3.9 kgt m. 28 lbt.ftl

I I

2,

Installthe upper bracket,then tighten the nuts in the numberedssquenceshown (O _ @).

O t2 x 1.25mm 74 N.m17.5kgf.m,

5-14

O t2 x t.2smm 74N.m17.5 kgtm, rbrft)

l a

3.

Installthe rear mount bracket,then tightenthe bolts in the numberedsequenceshown (O - @).

4.

Tighten the bolvnuts on the transmissionmount bracketin the numbe.edsequenceshown (O - O).

CVT: O 12 x 1.25mm 59 N.m (6.0 kgl'm, ilil lbf ftl Replace. 12x 1.25mm 59 N.m 16.0kgf'm, |:r tbf.tt) Replace.

@ t2 x t.2smm 7,1N.m(7.5kg{m, 54 lbfftl

O 12 x 1.25mm 59 N'm {6.0 kgf'm, /€ lbf.ftl Replace.

ExceptCVT:

/ / \

O 12r 1.25mm , @ 1 4x ' 1 . 5m m 59 N m 16.0kgt m, 8:t N.m {8.5 kgf.m, (} tbf.ftt 61 rbr.fr) Replace. Replace.

12 x 1,25mm fl N.m 16.5kgt.m, 47 tbf.ftl

Tightenthe boltson the rightfront mounvbracketin the numberedsequenceshown(O - @). GW: Olax1.5mm 83 N.m 18.5kgf.m, 61 tbf.ftl Replace.

L

O to x 1.25mm 54 N.m{5.5kgl.m. /|{}lbf.ftl

10 x 1.25mm 4,1N.m {4.5kgf.m. 33 lbf.ftl

(cont'd)

5-15

EngineRemoval/lnstallation Installation(cont'd) ExceptCVT: 7.

Performthe following: .

.

. . . . . . . 12 x 1.25mm 64 N.m (6.5kgd.m,

.

.

Tightenthe bolts/nuton the left front mount in the numberedsequenceshown {O - @). ( t 1 2 x 1 . 2 5m m 8 3 N ' m ( 8 . 5k g f . m , 6 1t b t . t r l

/+4 N.m 14.5 kgf.m, 33 lbt.trl

5-16

Cleanthe areaswhere the driveshaft(s) and the intermediateshaft contactthe transmission(dif_ ferential)thoroughlywith solvent or carburetor cteaner,and dry with compressedair. Checkthat the set rings on the ends of the drive_ shaftand intermediate shaftclickinto place. CAUTION: Use new set rings, Adjustthe shift cable(seesection14). Adjustthe throttlecable(seesection11). Adjustthe cruisecontrolcable(seesection23). Refillthe enginewith engineoil (seepage8-6). Refillthe transmissionwith fluid (seesection13, 14). Refillthe radiatorwith enginecoolant(seepage 10-7). Bleedair from the coolingsystemwith the heater valveopen (seepagej0-7). Cleanthe batterypostsand cableterminalswith sandpaper,assemblethem, then apply greaseto preventcorrosaon. Inspectfor fuel leakage(seesectionj l). After assemblingthe fuel line,turn on l) the igni_ tion switch(do not operatethe starter)so that the fuel pump runs for approximatelytwo seconds and the fuel line pressurizes. Repeatthis opera_ taontwo or three times,then checkfor fuel leak_ age at any point in the fuel line,

O 1 2 r 1 . 2 5m m 59 N.m 16.0kgt.m, 43 tbt.rtl Seplace.

\

Mount and Brackst Bohs/Nuts Torque Value Spocitications: A: '10x 1.25mm 64 N.m {6.5 kgl'm, 47 lbf'ft} B : 1 0i 1 . 2 5m m 44 N.m {4.5kgim,33 lbtft) C : 1 2x 1 . 2 5m m 83 N.m 18.5kgt'm, 61 lbf'ft) D : 1 2x 1 . 2 5m m 59 N.m (6.0ks{ m, 43 lb{ft) Replace.

REARMOUNT

SIDEENGINE MOUNT

CylinderHead/ValveTrain Dl6Y5,D16Y7,Dl6Y8engines ............. G2 SpecialTools VTECControl System TroubleshootingFlowchart .........."6-3 VTEGSolenoidValve ............" 6-6 Inspection VTECRocker Arms Manuallnspection (D16Y5engine)............................. 6-7 Inspection Manual (D16Ygenginel................'............ 6-7 Inspection Using Special Tools 6-8 {D16Y5engine}.....................""'... Inspection Using SpecialTools (D16Y8engine).........................'.'. 6-10 Valve Clearance ..."".....6-12 Adiustment Valve Seals Replacement(Cylinderhead removal 6-1tl not requiredl................................ CrankshaftPulleyand PulleYBolt ."......&16 Replacement Timing Selt 6-17 lllustratedIndex ............................... 6-18 .............. Inspection 6-1I TensionAdjustment ........................ 6-19 ......,,......... Removal ............. 6-20 lnstallation CrankshaftSpeedFluctuation(CKF)Sensor .........6'22 Repfacement

Cylinder Head 6-23 lllustratedIndex ............................... 6-27 ................. Removal 6-40 ................ Warpage ............. 6-45 lnstallation Rocker Arms 6-30 ................. Removal 6-31 ............... Disassembly/Reassambly RockerArms and Lost Motion Assemblies Inspection (D16Y5,D16Yg "..........'5-34 enginesl Rocker Arms and Shafts 6-35 GlearanceInspection....................... Camshaft 6-36 .............. Inspection Valve Seals and Valves, Valve Springs ........""..... 6-38 Removal Valve Guides 6-39 Valve Movement .............................. .........6-41 Replacement .......'......'.' 6-43 Reaming Valve Seats .'....6'40 Reconditioning Valves lnstallation Camshaft/RockerArms and Camshaft Seal/Pulley lnstallation

............. 6-tt3

............. 6-44

SpecialTools \ Ref.No.

Tool Number

I

o o @ @

o

or@-1 andO-2 @

o

(

OTHAH_ PJTOlOB 0 7 J A A- 0 0 1 0 1 0 A 07JAB- 0010204 OTLAJ_ PR3O2OB 07NAB- 0010404 07NAJ- P07010A 01406 - 0020201 OTMAJ- PY4O'114 07MAJ- PY40120 07406- 0070300 0 7 7 4 2- 0 0 1 0 1 0 0

ValveGuideReamer,5.5 mm Socket,17 mm H o l d e rH a n d l e Air Stopper HolderAttachment.50 mm PressureGaugeAdapter A/f PressureHose A/T PressureHose,2,210mm Ay'TPressureAdapter A,/TLow PressureGaugeWPanel ValveGuideDriver,5.5 mm

6-43 6-16 o- to

6-8,10 6-16 6-4 6-4 6-4 6-4 6-4 6-4't,42

-rE=-!fT----F

o

@

@

@

g-A\ o O-r

A-2

@

El

ril 6l

6-2

a

VTECControlSystem Flowchart Troubleshooting tFtrsrl #ilH:::lj1t:"J:T,?ffnostic

circuit or A probrem inthevrEcPressure switch rrouble code(Drc)Pr25e:

Reterto page 1 l-38 th rough 11-55beforetroubleshooting. The MIL has been reoortedon. DTCP1259is sto.ed. Checkthe VTECCont.olSyst6m: 1. Do the enginecontrolmodule (ECM)/powertrain control mod ule lPCM)ResetProcedure(see section11). 2. Stan the engine. 3. Warm up the engineto normal operatingtemperature(cooling fan comeson). 4. Do the BoadTest.* ls OTCP1259indicated?

* Road Test: A c c e l e r a t ei n 1 s t g e a r t o a n e n g i n es p e e do v e r 3 , 0 0 0r p m (D16Y5engine)or 6,000rpm (D'16Y8 engine). Holdthat enginespeedfor at leasttwo seconds. It DTCP1259is not repeatedduringthe first road test, repeat thistesttwo moretames. Intermittont tailura, 3y3t.m is OK at thia time. Check for ooor connoctionr o. loose wirea at VTEC oiassurc lwitch, VTECsolonoid valvo .nd ECM/PCM,

SWITCH2P VTECPRESSURE CONNECTOR

Test rhe VTECPrensureSwitch: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe VTECPressure switch2Pconnector. 3. Checkfor continuitybetween VTECpressureswitch2P connectorterminalNo. 1 and No. 2. Terminalsideof maleterminals ls there continuity?

Replacethe VTECpreasure3witch.

l1

VTM (BLu/BLK)

f;-)

{Topage6'4i

I

I

Te3t the VTEC Pressure Switch Wire: 1. Turnthe ignitionswitchON lll). 2. Measurethe voltagebetween V T E C p r e s su r e s w i t c h 2 P c o n n e c t o rN o . l a n d b o d y ground.

ls there batteryvoltage?

|

Y I

Wire sid6 ol female rermtnats

In3poct for en opon or shod to ground in thG wi.. bctwoon tho VTEC pro$ur6 switch rnd ECM/ PCM l'96 - 9a: C15,'99- 00: C101. lf tha wiro i3 OK,3ubrtitute a known-good ECM/PCM and recheck.

I VTECControl System TroubleshootingFlowchart(cont'd)

:

(

VTECPRESSURE SwlTCH2P CONNECTOR

(From page 6-3)

t

Test the VTEC Pr6suro Switch Wiro: Nleasurevoltage acrossthe VTEC pressureswitch2P connector.

I t

: . ls there bafteryvoltage?

.

Wire side of female (€rmrnats

Rcpai. opon in tho wire brtw.en VTECpr6.urc switch andG101. lf th. wir6 b OK, sub.thuto a lnown-good ECM/PCM !nd racheck.

VTECSOLENOIDVALVE lP CONNECTOR Te3tthe VTECSolonoidV.lve: 1. Turnthe ignitionswitchOFF. 2. Disconnect the VTECsolenoid valve1Pconnector. 3. Checkfor continuity between t h e V T E Cs o l e n o i dv a l v e 1 P connectorterminalNo. 1 and bodyground.

'll '- ff---r '1 I

I-L

ls there 14- 30 0?

ls pressurebelow 49 kPa (0.5kgflcm,,7 psi)?

(To page6-5)

6-4

I

Ir----'t I

Terminalsideof maleterminal

Te3ttho WEC SolonoidVatvo: '1. Remove the VTEC pressure swatchand installthe special tool as shown, then reinstall the VTECpressureswitch. 2. Reconnoctthe VTECsolenoid valve 1P connectorand VTEC pressureswitch 2P connector. 3, Connectthe tachometer(see section11). 4. Stanthe engine. 5 , W a r m u p e n g i n et o n o r m a l operatingtemperature(cool, ing fan comeson). 6. Checkoil pressureat engine speeds D16Y5engine: 1,000 and 3.000rpm, D16Y8engine: 1,000,3,000 and 5,000rpm.

t

A/T LOWPRESSURE w/PAt{EL 07406-0070300

N O T E : K e e p m e a s u r i n gt i m e a s s h o r t a s possiblebecauseengineis runningwith no load(lessthan one minute).

In.poct the VTEC aolonoid vllvo ls.c p.g. &6).

PRESSURE GAUGE ADAPTER 07NAJ - P07010A

A/T PRESSURE I{OSE 07406- 0020201 ot A/T PRESSURE HOSE. 2,210mm 07MAJ - PY&llA and A/T PRESSURE ADAPTER 07MAJ - PY,()120

I

VTECSOLENOIDVALVE 1P CONNECTOR

(Frompage6'4)

Terminalsideof maleterminal

Testthe VTECSolenoidValve: 1. Turnthe ignitionswitchOFF. 2. Disconnect the wEC solenoid valve 1Pconnector. 3 . A t t a c h t h e b a t t e r yp o s i t a v e terminalto the VTECsolenoid valveterminal. 4 . S t a r t t h e e n g i n ea n d c h e c k t h e o i l p r e s s u r ea t e n g i n e speedof 5,000rpm. ls the pressureabove390kPa (4.0kgtcm' ,57psi)?

Inspect lhe VTEC solonoid valve lseep6gem).

C {31P} ECM/PCMCONNECTOR '99 - 00:

'96 - 98:

VTM

Testthe VTECPressureSwitch: With the battery positiveterminal connectedto the VTECsolenoid valve, measurevoltagebetween connectorterminal the ECM/PCM ' 9 6 - 9 8 : C l 5 , ' 9 9 - 0 0 : C 1 0a n d bodyground. '99 - 00: ls there batteryvoltage above 5,000rpm?

VTECSOLENOID VALVE 1PCONNECTOR

'96 - 98: VTECSOLENOID VALVE CONNECTOR T6st the VTEC Solenoid Valve wire: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuitybetween t h e V T E Cs o l e n o i dv a l v e 1 P c o n n e c t o rt e r m i n a la n d t h e ECM/PCMconnectorterminal '96 - 98: A8, '99 00r B'12.

ECM/PCMCONNECTOR A {32P1 VTS {GRN/YEL) wire sideo{ female terminals

wire sideoI temale terminals Repair open in the wire between the ECM/PCM ('96 - 98: A8, '99 0o: 8l2l and VTEC solenoid v.lv6 connoc{or.

Test the VTEC Solenoid Valve Check for continuity between the V T E Cs o l e n o i d v a l v e 1 P c o n n e c t o r t e r m i n a l€ n d b o d y g r o u n d .

ls therecontinuity?

Substitute a known-good ECM/ PCM and recheck. lf symptom/ indication goes away, replace the original ECM/PCM.

ECM/PCMCONNECTOR B {25Pt

ReDair 3hort in the wire between the ECM/FCM ('96 - 98: A.8,'99 0O:Bl2l and VTECaolenoidvalve connectot,

VTECSolenoidValve Inspection 1.

D i s c o n n e ct th e 1 P c o n n e c t o frr o m t h e V T E Cs o l e noid valve. Measureresistancebetweenthe terminaland body ground.

( 4.

lf the filter is not clogged,push the VTECsolenoid valvewith your fingerand checkits movement. .

lf the VTECsolenoidvalve is normal.checkthe enganeoil pressure.

I

Resistance: l4 - 30 O 6x1.0mm 12 N.m {1.2kgt.m,8.7lbf.ft)

lf the resistanceis within specifications, removethe V T E Cs o l e n o i dv a l v e a s s e m b l yf r o m t h e c y l i n d e r head,and checkthe VTECsolenoidvalve filter for cloggrng. .

\

. I

(

lf there is clogging,replacethe engine oil filter a n dt h e e n g i n eo i l .

VTECSOLENOID VAI-VEASSEMBLY

;

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

6-6

..

VTECRockerArms (D16Y5engine) ManualInspection

ManualInspection(D16YB engine)

1 . Setthe No. 1 pistonat TDC.

1.

2.

Setthe No. 1 pistonat TDC.

Removethe cylinderheadcover.

Removethe cylinderheadcover.

NOTE:Referto page 6-46when installingthe cylinder headcover.

NOTE:Reterto page6-46when installingthe cylinder headcover.

'l

Pushthe intakemid rockerarm on the No. 1 cylind e rm a n u a l l y .

3.

Move the intakesecondaryrockerarm on the No. c y l i n d em r anually.

4.

Checkthat the intakesecondaryrockerarm moves independently of the primaryintakerockerarm,

4.

Checkthat the intakemid rockerarm movesindependently of the primary and secondaryintakerocker arms. MID ROCKER ARM

SECoNDARY ROCKERARM . P u s ha n d p u l l .

PRIMARYROCKERARM Pt

C h e c k t h e i n t a k e s e c o n d a r y r o c k e ra r m o f e a c h c y l i n d e ra t T D C .

a lf the intakesecondaryrockerarm doesnot move, removethe primaryand secondaryintakerocker armsas an assemblyand checkthat the pistonsin t h e s e c o n d a r ya n d p r i m a r yr o c k e ra r m s m o v e smoothly. a lf any rockerarm needsreplacing,replacethe primary and secondaryrockerarmsas an assembly.

5,

Checkthe intakemid rockerarm of eachcylinderat TDC, l f t h e i n t a k em i d r o c k e ra r m d o e s n o t m o v e . remove the mid, primary and secondaryintake rockerarmsas an assemblyand checkthatthe pist o n s i n t h e m i d a n d p r i m a r yr o c k e ra r m s m o v e smoothly. l f a n y r o c k e ra r m n e e d sr e p l a c i n gr,e p l a c et h e primary,mid, and secondaryrockerarms as an assemory.

6-7

VTECRockerArms (Dl6Y5enginel Inspection Using SpecialTools CAUTION: . Before using th6 Valve Inspection Tool, make 3ure that ths air pressuregaugo on the air comptsssor indicatesover iloo kPa 14kgf/cmr, 57 psi). . Inspecl th6 valv€ clearancebeforo rocker atm insDec" tion, Coverthe timing belt with a shop towel to protect tho belt. Check ths intakg primaty rocker arm of each cylindqr at TDC. '1.

3,

(

Removethe sealing bolt from the inspectionhole and connectthe an air pressureregulatorwith a 0 100psi gauge. 10x 1.0mm BOLT SEALING 20N.m{2.0kgj'm.14lblft}

Removethe cylinderheadcover. NOTE:Referto page6-46when installingthe cylinder headcover. Plugthe reliefholewith the specialtool.

l

I

'10x 1.0mm ADAPTER

YY OTLAJ- PR3O2OB

o-at

;NSp€CTTONHOLE

(Commercially available)

P u l l t h de i a a l nd turnto adlust, Loosenthe regulatorvalve on the valve inspection tool and applythe specifiedair pressure. SpocifiedAir Pressurei 250 kPa {2.5 kg,t/cm,,36 psi}

l'

5.

With the specifiedair pressureappli€d,push up the timing plate;the synchronizingpiston will pop out and engagethe intakesecondaryrockerarm. Visuallycheckthe engagementof the synchronizing prston. NOTE; pistoncan be seen in the gap The synchronizing betweenthe secondaryand primaryrockerarms, With the timing plate engagedin the groove on t h e t i m i n g p i s t o n ,t h e p i s t o n i s l o c k e d i n t h e oushedout Dosition.

6.

Stop applyingair pressureand push up the timing plate;the synchronizingpistonwill snap backto its originalposition. Visuallycheckthe disengagementof the synchronizingpistons. NOTE: . When the timing plate is pushedup, it releases the timing piston,lettingthe returnspring move pistonto its originalposition. the synchronizing

7.

Replacethe intake rocker arms as an assemblyif either does not work correctly,

TIMIT{GPLATE

TIMIiIG PLATE SPRIT{C

TIMINGPLATE oll PASSAGE--!

PRIMARYROCKER ARM

SECOI{DARY ARM ROCKER

TIMII{GSPRII{G PRIMARYROCKERARM

SECODARY ARM ROCKER

RETURI{SPRING

TIMI G PISTOI{

Removethe spscialtools. AIR PRESSURE

After inspection,checkthat the malfunctionindicator lamp (MlLl doesnot comeon.

GROOVE TIMINGSPRING

6-9

VTECRockerArms InspectionUsing SpecialTools(D16Y8enginel CAUTION: o Before using the Valve Inspection Tool. mak6 sure that the air pressuregauge on the air comprsssor indicatesovor 400 kPa {4 kgf/cm,, 57 psil. . Inspectth6 valve clearancobefore rockar arm inspection. . Cov€r th€ timing belt with a shop towel to protect the bolt. . Checktho intake prima.y rockff arm of each cylindel at TDC.

3.

Removethe sealing bolt from the inspectionhole anclconnectan air pressureregulatorwith a 0 - 100 psi gauge.

l 0 x 1 . 0m m SEALINGEOLT 20 N.m (2.0 kgf.m, 14 lbf.ft)

1 . Removethe cylinderheadcover. NOTE: Referto page6-46when installingthe cylinder neaocover, Plugthe reliefhole with the specialtool.

AIR PRESSURE REGULATOR {Commercially available) . P u l l t h ed i a l a n d turn to adjust, OTLAJ- PR3O2OB

I,^

A

IA

o- tu

(

4.

Loosenthe regulatorvalve on the valve inspection tool and applythe specifiedair pressure.

1.

Removethe specialtools.

8.

U s e a 1 0 m m d i a m e t e rr o d t o d e p r e s se a c h l o s t motionassemblythroughits full movement. Replaceany lost motion assemblythat does move smoothly.

SpecifiedAir Pressure: 250 kPa {2.5 kgf/cm', 36 psil PRIMARY ROCKER ARM

MID ROCKER ARM

SECONDARY ROCKERARM

SYNCHRONIZING SYNCHRONIZING PISTON A PISTON B 5.

Make sure that the intake primary and secondary connectedby the piston rockerarmsare mechanically and that the mid rockerarm does not move when oushedmanuallY.

ASSEMBLY

9.

After inspection,checkthat the MIL does not come on.

SECONDARY ROCKERARM

t

lf any intake mid rockerarm moves independentlyof the primary and secondaryrocker arms, replacethe rockerarms as a set.

6-11

Valve Clearance Adjustment NOTE: . Valves should be adjusted only when the cylindsr headtemperatureis lessthan 100"F(38"C). . After adjusting,retorquethe crankshaftpulley bolt (seepage6-16). 1,

Removethe cylinderheadcover. NOTE; Referto pagee46 when installingthe cytinder headcover.

2.

Removethe uppercover (seepage6-19).

3.

Set the No. 1 pistonat TDC.The "UP" mark on the c a m - s h a f tp u l l e y s h o u l d b e a t t o p , a n d t h e T D C marksshouldalignwith the cylinderheadsurface.

5.

Loosenthe locknut,and turn the adjustmentscrew until the feeler gauge slides back and forth with a sliOhtamountof drag, D16Y7engin.: CAUTION: Do not oyertighlen the locknuts; tho rockor arms are made of aluminum. INTAKE endEXHAUST VALVE LOCKNUTS 18 N.m (1.8kgI.m, 13 tbl.ftl

"UP"MARK TDCMARKS

tr

Dl6Y5, Dl6Y8 engin€3: INTAKE.nd EXHAUSTVALVE LOCKNUTS 20 N.m 12.0kstm, 14lbtft)

4.

Adjustvalveson No, 1 cylinder. Intako: 0.18- 0.22 mm {0.007- 0.009in} Exhaust:0.23- 0.27mm (0.009- 0.011inl

Adiusting screw locations: o.4

IMTAKE 1{o.3 No.2

( No.4

6- 12

nb.3 No.2 EXHAUST

No. 1

6.

Tightenthe locknut,and checkthe clearanceagain. Repeatthe adjustmentif necessary.

8.

' 1 8 0 'c o u n t e r c l o c k w i s teo R o t a t et h e c r a n k s h a f t b r i n g N o . 4 p i s t o nt o T D C .B o t hT D C g r o o v e sa r e o n c ea g a i nv i s i b l eA. d j u s tv a l v e so n N o .4 c y l i n d e r .

GAUGE

-UP'MARK

7.

(camRotatethe crankshaft180' counterclockwise "UP" mark shouldbe on shaft oullevturns 90'1.The the exhaustside.Adjustvalveson No. 3 cylinder.

to bring Rotatethe crankshaft180'counterclockwise No. 2 piston to TDC.The "UP" mark should be on the intakeside.Adjustvalveson No. 2 cylinder.

"UP- MARK

t 6-13

Valve Seals (Cylinderheadremovalnot requiredl Replacement N O T E :C y l i n d e rh e a d r e m o v a li s n o t r e q u i r e di n t h i s procedure.

Intake Valve Seals: 6.

Selectthe 7/8 in diametershort compressorattachment,and fastenthe attachmentto the No. 4 holeof the leve.arm with the speedpin supplied.

7.

lnsertan air adapto.into the sparkplug hole.pump air into the cylinderto keepthe valve closedwhile compressingspringsand removingthe valve keep ers.

8.

Put shop towels over the oil passagesto prevent t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r neao.

The procedureshown below applieswhen using the 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 Sw i t h Y48845- 2 A7/8" attachment). Alway wear approved eye protection when !@@ using ihe in-cai valve spring compressor. 1. Turn the crankshaftso that the No. I and the No. 4 pistonsare at top deadcenter(TDC). 2.

Removethe cylinderheadcoverand the rockerarm assembly.

OIL PASSAGES

NOTE: . R e f e rt o p a g e 6 - 3 0 f o r r o c k e r a r m a s s e m b l y removat. . W h e n r e m o v i n g o r i n s t a l l i n gt h e r o c k e r a r m assembly,do not remove the camshaft holder b o l t s .T h e b o l t s w i l l k e e pt h e h o l d e r s ,s p r i n g s and rockerarms on the shaft. . Referto page 6-46 when installingthe cylinder headcover.

, I

3 . Removethe fuel injectorsand the wire harness. 4.

i

Usingthe 8 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 c a m s h a f th o l d e r s .T h e u p r i g h t sf i t o v e r t h e c a m shaftas shown. OILPASSAGES Positionthe lever arm underthe crossshaft so the lever is perpendicular to the shaft and the compressor attachmentrests on top of the retainerfor the spring being compressed.Use the front position slot on the leveras shown. IN-CARSPRINGCOMPRESSOR

lnsert the cross shaft through the top hole of the two uprights.

SLOT

6 - 14

10. Using a downward motion on the lever arm, com.pressthe 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 6 . 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 spnng.

11. Removethe valveseals(seepage6-38).

't7. Removethe valveseals{seepage6-38),

12. Installthe valveseals{seepage6-43).

'18. Installthe valveseals(seepage6-43).

13. Installthe springs,the retainersand the keepersin reverseorderof removal.

1 9 . Installthe springs,the retainersand the keepersin reverseorderof removal.

ExhaustValvs Sesls:

20. Repeatsteps6 to 19 on the othercylinders.

'14.

Selectthe 7/8 in. diametershort compressorattachment,and fastenthe attachmentto the No. 2 hole of the leverarm with the speedpin supplied. Positionthe lever arm under the cross shaft so the to the shaftand the compresleveris perpendicular sor attachmentrests on top of the retainerfor the s p r i n g b e i n g c o m p r e s s e dU. s e t h e f r o n t p o s i t i o n slot on the leveras shown.

IN-CARSPRINGCOMPRESSOR

7/8 in SHORTATTACHMENT

L 6-15

CrankshaftPulleyand Pulley Bolt Replacement W h e n i n s t a l l i n ga n d t i g h t e n i n gt h e p u l l e y .f o l l o w t h e procedurebelow,

'1.

Tightenthe pulleybolt to the specifiedtorque. Torque: 20 N.m {2.0 kgf.m, 14 lbf'ft}

C l e a n ,r e m o v e a n y o i l , a n d l u b r i c a t ep o i n t s s h o w n below. O: Clean x: Bemoveany oil a: Lubricate

Use I felt tip pen to mark the pulley bolt head and washer.

MARKING

CRANKSHAFT

TIMINGBELT GUIOEPLATE Crankhaft pulley bolt size and torque value: 14 x 1.25mm 20 N.m {2.0 kgl.m, 14 lbf.ft) + 90'

\ EMBOSSINGMARKS

NOTE:Do not usean impactwrenchwhen installing. 3.

HOI.I'ERHANDTI 07JAB- 001020A HOLDERATTACHMENT.50 mm 07NAB - ootoilllA

Tightenthe pulleybolt an additional90".

EMBOSSINGMABK

MARKING

S(rc(ET,17mm 07JAA-lxtl010Aor {Co.nm.rci.lly.v.il.bl.} MARKING

6-16

I

Timing Belt Illustratedlndex NOTE: . Referto page6-20for how to positionthe crankshaftand pulleybeforeinstallingthe belt. . Markthe directionof rotationon the belt beforeremoving. a Do not usethe uppercoverand lower coverfor storingremoveditems, . Cleanthe uppercoverand lowercoverbeforeinstalling. . Replacethe camshaftsealsand crankshaftseals if there is oil leakage. . Referto page6-16beforeinstallingthe timing belt.

HEAD CYLINDER COVER Relerto page6-46 wheninstalling. HEAD COVEBGASKET Replacowhen l6akin9, domagedor deteriorated. Apply liquid gasketat th€ lour cornersof the tecessos.

TIMINGBELT page6-18 Inspection, Adjustment,page6-18 Removal,page6-19 Installation.page 6-20

d

@

I x 1.25mm 3t N.m {3.8 kgf'm, 27 lbfftl Applyengineoilto the bolt thleads. SPEEDFI.UCTUATION CRANKSHAFT

lcr(FlsENsoR Replacement, Page6-22

COVEB UPPER 6x1.0mm 9.8 N'm 11.0kgt m, 7.2 tbf.ft) NUBBERSEALS Replacewhen damaged or deledorated. LOWERCOVER FUBBER PLUG PULLEY CRANKSHAFT page6'16 Replacement, PULLEYBOLT lil x 1.25mm 20 N.m 12.0kgt.m, 14 lbt'ft) + 90" page6'16 Replacement, Do not us6 an impact wrenchwhen installing.

lnstallwith surfacefacingin.

\.-,o

TIMINGBELT DRIVEPULLEY page6_16 Replacement,

BOLT

o-RING 6 x 1 . 0 m m

10 x 1,25mm Reolace.t2 N.m 11.2kgf'm, 8.7 tbt f0 14 N.m {,1.5kgt m, 33 lbt ftl

x 1.0mm 9.EN'm (1.0 kgt.m, ?.2 tbf.ftl

6-17

Timing Belt Inspection

TensionAdjustment

Removethe cylinderheadcover.

1.

.

R e f e tr o p a g e6 4 6 w h e n i n s t a l l i n g .

2.

Removethe uppercover(seepage6 19).

3.

I n s p e ctth e t i m i n gb e l tf o r c r a c k sa n d o i l o r c o o l a n t soakrng. NOTE: . Replacethe belt if oil or coolantsoaKeo. . Removeany oil or solventthat gets on the belt.

CAUTION:lt*ays aa;j"t the timing bett rension with the enginecold. NOTE: . The tensioneris spring loadedto applytensionto the belt automaticallyafter makingthe following adjust ment. . Always rotatethe crankshaftcounterclockwise when v i e w e d f r o m t h e p u l l e ys i d e . R o t a t i n gi t c l o c k w i s e m a y r e s u l ti n i m p r o p e ra d j u s t m e not f t h e b e l t t e n sion. . lnspectthe timing belt beforeadjustingthe belt tenston. 1.

Removethe cylinderheadcover. .

Referto page6,46when installing.

2.

Removethe uppercover(seepage6,'19).

3.

Rotatethe crankshaftfive or six revolutionsto set the belt.

4.

Setthe No. 'l pistonat TDC(seepage6-21).

5.

Loosenthe adjustingbolt 180'.

\

ADJUSTINGBOLT 44 N.m {4.5kgt m, 33 rbf.ft) Rotatepulley and inspectbelt.

After inspecting,retorquethe crankshaftpullevbolt {seepage6- 16).

Rotatethe crankshaftcounterclockwise three teeth on the camshaftpulley. 7 . Tightenthe adjustingbolt. 8 . After inspecting,retorquethe crankshaftpulleybolt (seepage6-16).

o- I6

I

Removal NOTE: km) . Replacethe timing belt at 105,000miles (168.000 (normal conschedule accordingto the maintenance conditions). ditions/severe lf the vehicleis regularlydrivenin one or more of the followlngconditions,replacethe timing belt at 60.000 miles(U.S.A.)100,000km {Canada). . I n v e r yh i g ht e m p e r a t u r e( so v e r1 1 0 ' F . 4 3 ' C ) . In very low temperatures(under-20'F, -29"C)' ! Turn the crankshaftpulley so the No. 1 piston is at top dead center(TDC)beforeremovingthe belt (see page6'21). . Inspectthe water pump before installingthe timing belt {seePage10-14). 1.

Removethe splashshield(seepage5-7).

2.

Loosenthe mountingbolt and lockbolt.then remove the powersteering(P/S)pump beltand pump

5.

Removethe dipstick,then removethe upper cover and idler PulleYbracket NOTE: Do not use the upper cover to store removed items.

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

IDLER BRACKET

MOUNTINGBOLT 8 x 1.25mm 2il N m 12.4kgl m, 17 lbf'ft)

6.

I x 1.25mm 24 N.m (2.4kgl.m, 17 lbf'ft)

Removethe upperbracket{seepage6-29) NOTE: . Usea jackto supportthe enginebeforethe upper bracketis removed . Make sure to place a cushion between the oil pan and the jack.

P/S PUMP BELT

I x 1.25mm 24 N m (2.4kgfm, 17lbtft)

1.

Removethe crankshaftpulley(seepage6-16).

.'.

Removethe lowercoverand dipsticktube NOTE; Do not use the lower cover to store removed items. DIPSTICKTUBE

3.

L o o s e nt h e i d l e r p u l l e yc e n t e rn u t a n d a d j u s t i n g bolt, then remove the air conditioning(AVC)compressorbelt (seePage5-6).

LOWER

Loosenthe mountingnut and lockbolt,then remove the alternatorbelt. ALTERNATOR BELT

LOCKBOLT I x 1.25mm 24 N.m 12.4kgf.m, r? tbI.ft)

6x1.0mm 9.8 N.m (1.0kgf m, 7.2 rbt.ft) Replace. MOUNTING NUT 1 0 x 1 . 2 5m m 44 N.m 14.5kgl m, 33 rb{ ft)

(cont'd)

6-19

Timing Belt Removal (cont'd)

lnstallation

9. Removethe CKFsensorfrom the oI pump.

Installthe timing belt in the reverseorderof removal; Only key pointsare describedhere. l.

set rhe timing belt drive pulleyso that the No. 1 piston asat top deadcenter(TDC),Align the grooveon the timing belt drive pulleyto the pointeron the oil pump. TDC MARK

POINTER

I

12 N.m 11.2kgt.m, 8.7 rbf.ftl

t

I

10. Loosenthe adjustingbott lgO.. Push the tensioner t o r e m o v e t e n s i o n f r o m t h e t i m i n g b el t . t h e n retightenthe adjustingbolt.

AD.'USNNG BOLT 4{ N.m 14.5kgt m, 33 tbtftl

1 1 . R e m o v et h e t i m i n gb e l t .

6-20

TIMING BELT DBIVEPULLEY Clean.

2.

S e t t h e c a m s h a f tp u l l e y t o T D C .A l i g n t h e T D C marks on the camshaftpulleyto the cylinderhead surface.

I

3.

Installthe timing belttightlyin the sequenceshown' )@Adjusting OTiming beltdrive pullev(crankshaft) pulley-towater pump pulleyJ@Camshattpulley'

9. Checkthat the crankshaftpulleyand camshaftpulley are both at TDC. CRANKSHAFTPULLEY:

NOTE: Make sure the timing belt drive pulley and camshaftPulleYare at TDC

(wHrTE) CAMSHAFTPULLEY: "UP" MARK

Loosenand retightenthe adiustingbolt to tension the timing belt. lnstallthe lowercoverand uppercover. N O T E :C l e a nt h e u p p e r a n d l o w e r c o v e r sb e f o r e installation. lnstallthe crankshaftpulley,then tightenthe pulley bolt (seepage&16) 7.

Rotatethe crankshaftpulley about five or six turns so that the timing belt positions counterclockwise on the Pulleys.

8.

Adjustthe timing belttension(seepage6-18).

TDC MARK

lf the camshaftand crankshaftpulleysare not positioned at TDC, remove the timing belt and adjust the positionfollowingthe procedureon page 6-20' Then reinstallthe timing belt. adjustthe tensionof eachbelt 1 1 . After installation, See section23 for alternatorbelt tensionadjustment. a See section22 tot NC compressorbelt tension adjustment. . See section17 for P/Spump belt tensionadjust ment, .

L

6-21

CrankshaftSpeed Fluctuation(CKF)Sensor Replacement 1 . Removethe cylinderheadcover. NOTE:Referto page6-46when installing.

2. Removethe crankshaftpulley(seepage6_16), 3 . R e m o v et h e u p p e r c o v e r a n d d i p s t i c k / t u b e{ s e e p a g e6 - 1 9 ) .

4.

Removethe lower cover and idler pulley bracket (seepage6-19).

5.

Disconnectthe CKFsensorconnector,then remove the CKFsensor.

CKFSENSOR CONNECTOR

:

I

6x1.0mm '12N.m {1.2kgt.m, 8.7 tbf.ft)

6.

InstalltheCKFsensorin reverseorderof removal.

6-22

(

GylinderHead lllustratedIndex CAUTION: (38'C)beforeremovingthe cylinder . To avoid damage,wait until the enginecoolanttemperatuledrops below 100"F head. . When handlinga metal gasket,take carenot to fold it or damagethe contactsurface' NOTErUsenew O-ringsand gasketswhen reassembling'

WASHER when damaged Replace or deteriorated. HEAD CYLINDER COVER Referto page6 46, when installingcylinderheadcover.

6x1.0mm 9.8 N.m 11.0kgf.m,7.2lbfft) Applysoapsudsto threadsand cylinderhead contactsurfacewhen replacingthe rubber seal,then temoveany soapsudsafterinstall ing rubberseal. RUBBERSEAL Replacewhen damaged or deteriorated. CYLINDERHEADBOI-T 10 x 1.25mm 67 N.m 16.8kgf m, a9 lbt'ft) Tightening,Page6-46 Applyengineoilto the threads.

HEADCOVEBGASKET when leaking, Replace damagedor deteriorated. Apply liquidgasketat the four cornersol the recesses,

DISTRIBUTOR Seesection23.

8 x 1.25 mm 24 N.m (2.4kgf.m, 17 tbt.ft)

O.RING Replace.

CYLINDERHEAD GASKET Replace.

8 x 1.25mm 24 N.m {2.4kgf m, 17 lbf ftl

t

PINS

(cont'd)

6-23

CylinderHead lllustratedIndex(cont'dl -/) -

(

_. "or to reassembring, creanat thepartsin sorvent, drythemandappryrubricant E to anvcontactoarts.

D16Y7 engine: 8 x 1.25mm 20 N.m (2.0kgt.m, 14 tbt.ftl Applyengineoil to the

ROCK€RARM ASSEMBLY Removal,page6 30 Inspection, page6-35

6x1.0mm 12 N.m (1.2kst.m, 8.7 tbf.ft) Applyengineoit to the threads.

VALVEKEEPERS CAMSHAFT nspectron, page6-36

SPRINGRETAINER H

B

INTAKEVALVE SPRING

OILCONTROL ORIFICE Clean.

INTAKEVALVESEAL Replace. VALVESPRING SEAT

O-RING Replace.

:a

INTAKEVALVE GUIDE

VALVEKEEPERS

ti \ SPRING RETAINER EXHAUST VAL SPRING EXHAUST VALVE SEAL 8 x 1.25mm 37 N m (3.8kgt m, 27 tbtftl A p p l ye n g i n eo i l t o the threads.

VALVESPRING SEAT EXHAUSTVALVE GUIDE rnspectron, page6,39 Beplacement, page6 4l Aeaming,page6-43 VALVE INTAKEVALVE Removal,page6-38 lnstallation, page6-43

Removal,page6,27 Warpage,page6 40 Valveseatreconditioning, page6-40 Installation, page6-45

t

t t c

- A

9-2.+ L

D16Y5 engine: I x 1.25mm 20 N.m (2,0 kgf m, 14 lbf ft) Applyengineoilto the threads. ROCKEBARM ASSEMBLY Femoval,page6-30 Inspection, Page6-34

6x1.0mm 12 N.m 11.2kgf m, 8.7 lbf'ftl Apply engineoilto the threads.

CAMSHAFT page6-36 Inspection,

VALVEKCEPERS

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

SPRINGRETAINER INTAKE VALVE SPRING

B

WEC SOLENOID

VALVE

INTAKEVALVESEAL Replace. VALVESPRING SEAT INTAKE VALVE GUIDE VTECSOLENOID VALVE FILTER Replace. OIL CONTROL ORIFICE Clean.

CAMSHAFT PUL|'IY

VALVE SPRINGRETAINEB

EXHAUSTV VE SPRING EXHAUSTVALVE SEAL

8 x 1.25mm 37 N.m 13.8kgf.m, 27 tbf.frl Apply engineoilto the lhreads.

t"o'""".uoau, SEAT

Replace.

GUIDE page6-39 Inspection, Replacement, Page6-41 Reaming,page6-43

EXHAUST VALVE INTAKEVALVE Removal, page 6 38 I n s t a l l a l i o n ,P a g e 6 4 3

OIL SEAL Replace.

HEAD Removal,page6-27 Warpage,Page6 40 Valveseatreconditioning' page6-40 page6_45 lnstallation,

(cont'd)

6-25

CylinderHead lllustratedIndex(cont'dl -vp e,.io"o reassembring, creanat the partsin sorvent,dry them and appryrubricantto any contactparts. D16Y8engine:

LOSTMOTION ASSEMgLY

LOSTMOTION ASSEMBLY HOLDER

ROCKERARM ASSEMBLY Removal,page6 30 Inspection, page6-34

20 N.m 12.0kgl.m, 14 tbf.ft) Applyengineoit to the threads. 6x1.0mm 12 N.m (1.2kgt.m,8.7lbf.ftl \ Apply engineoil to the threads,

\

si l 9l l CAMSHAFT Inspection, page6-36

5xl.0mm 12 N.m {1.2 8.7 tbf.ft)

VALVEKEEPERS

SPRINGRETAINER INTAKEVALVE INTAKEVALVESEAL Replace. VALVESPRING SEAT

VTECSOLENOID VALVEFILTEB Replace.

INTAKEVAI.VE GUIOE OILCONTROL ORIFICE Clean. VALVEKEEPERS

CAMSHAFT PULLEY

SPRINGRET EXHAUSTVALVE SPRING

@

EXHAUSTVALVE SEAL VALVESPRING Replace. SEAT EXHAUSTVALVE O.RING GUIDE Replace. Inspection, page6 39 Replacement, page6 41 Reaming,page6 43

8 x 1.25mm 37 N.m 13.8kgt m, 27 tbfitl A p p l ye n g i n eo i l t o the threads. OIL SEAL Beplace.

INTAKEVALVE EXHAUST CYLINDERHEAD Bemoval,page6 38 VALVE Removal,page6 27 Installation, page6 43 Warpage,page6-40 Valveseatreconditioning, page6 40 Installation, page6-45

I I

Removal Engineremovalis not requiredfor this procedure Make sure iacks and salety stands are !!!s@ propetty and hoist brackets are attached to the ta"eata"ea f correct positions on the engine. CAUTION: . Use tender covels to avoid damaging painted sulfaces. o T o a v o i d d a m a g e ,u n p l u g t h e w i l i n g c o n n e c t o r s carefully while holding the connector portion to avoiddamage. . To avoid damagingthe cylinderhead,wait until the e n g i n e c o o l a n t t e m p e r a t u r ed r o p s b e l o w 1 0 0 " F {38"C}before loossning the tetaining bolts.

8.

Removethe throttlecableby looseningthe locknut, then slip the cableend out of the throttlelinkage NOTE: . Takecarenot to bendthe cablewhen removingit Alwaysreplaceany kinkedcablewith a new one . Adjustthe throttlecablewhen installing(seesect i o n 11 ) .

D16Y7engine: LOCKNUT

NOTE: o M a r k a l l w i r i n g a n d h o s e st o a v o i d m i s c o n n e c t l o n Also, be surethat they do not contactother wiring or hoses,or interferewith other parts. . Inspectthe timing belt before removingthe cylinder he a d . T u r n t h ec r a n k s h apf tul l e ys o t h a tt h e N o . l p i s t o n i s a t top deadcenter(seePage6-21)

.

'1. Disconnect the negativeterminalfrom the battery' 2.

D r a i nt h e e n g i n ec o o l a n (t s e ep a g e ' 1 0 - 7 ) . a Removethe radiatorcapto speeddraining.

3.

Removethe intakeair duct and air cleanerhousing (seepage5 3).

4.

R e m o v et h e m o u n t i n g b o l t a n d l o c k b o l t . t h e n r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d pump (seepage5'5).

CABLE

Dl6Y5, Dl6Y8 engines:

THFOTTLE CABLE

L o o s e nt h e i d l e r p u l l e y c e n t e rn u t a n d a d j u s t i n g bolt' then removethe air conditioning(A'lc)compressorbelt (seePage5-6). 6.

L o o s e nt h e m o u n t i n g n u t a n d l o c k b o l t . t h e n removethe alternatorbelt (seepage6-19).

1.

Removethe P/Spump bracket(seepage5-12).

(cont'd)

6-27

CylinderHead Removal (cont'd) ( 9. Relievefuel pressure(seesection11), Do not smokewhile working on tho fuel E@E system. Ke6p opgn flame or gpark away from lhe work area, Drain fuel only into an app.oved containgr. 10. Removethe evaporativeemission (EVAP)control canisterhose,fuel feed hoseand breatherhose.

1 1. Removethe brakeboostervacuumhose.fuel return hoseand vacuumhose(seepageS_4). 12. Removethe water bypasshose and positivecrank_ caseventilation(pCV)hose. 016V7engine: WATEREYPASS

D16Y7engine:

BANJOBOLT 33 N.m{3.4kgtm, 25 tbf.ftt

a

\ BREATHER HOSE PCVHOSE D16Y5, D16Y8 engines: D15Y5, Dl6YB engines: BANJOAOLT 33 N.m (3.4kgf.rn, 25 tbf.ftt

PCVHOSE

EVAP CONTROL CANISTERHOSE

I

6 -28

13. Remove the upper radiator hose' heater hose and water bYPasshose

1 5 . Removethe spark plug caps and distributorfrom the cylinderhead. Removethe uPPerbracket.

WATER EYPASS HOSE

UPPER RADIATOR HOSE

NOTE: . U s e a j a c k t o s u p p o r tt h e e n g i n e b e f o r et h e upperbracketis removed. . Make sure to place a cushion between the oil pan and the jack. 12 x 1.25mm 74 N.m {7.5 kgf m. sil lbl.ftl

UPPER BRACKET

HEATER HOSE

1 4 . Remove the engine wire harnessconnectorsand wire harness clamps from the cylinder head and the intake manifold.

o Fourfuel injectorconnectors . Engine coolant temperature(ECT)sensor connector a ECTswitch connector ECTgaugesendingunit connector a Throttlepositionsensorconnector a Manitold absolute pressure(MAP) sensor con-

'17. Removethe cylinderheadcover'

CYLINDER HEADCOVER

nector Primary heatedoxygen sensor (primary HO2S) connector S e c o n d a r yh e a t e do x y g e n s e n s o r ( s e c o n d a r y HO2S)connector(D16Y7engine) Exhaustgas recirculation(EGR)valve lift sensor connector(D16Y5engine) . VTECsolenoid valve connector(Dl6Y5, D16Y8 engrnes) . VTECpressureswitch connector(D16Y5.D16Y8 engrnes, . ldle air control(lAC)valveconnector

(cont'd)

6-29

Cylinder Head

RockerArms

Removal(cont'd)

Removal

1 8 . Removethe timing belt {seepage6-19).

\ 1.

1 9 . Removethe camshaftpulleyand backcover,

Loosenthe adjustingscrews. ADJUSTINGSCREWS

CAMSHAFT PULLEY Cleanwhen installing.

6x1.0mm

8 x 1.25mm 37 N.m (3.8 kgf.m, 21 tbtlrl Applyengineoilto the bolt threads.

Removethe exhaustmanifold{seepages9-6and 9_7). 2 1 . Removethe intakemanifold(seepages9-2thru 4). 22. Removethe cylinder head bolts, then remove the cylinderhead. CAUTION:To pr€vent warpage, unsclew lhe bohs in sequonce1/3 turn at a time; rgpeat tho sequence until all bolts are loosened. CYLINDERHEADBOLTSLOOSENINGSEOUENGE:

6-30

2.

Unscrew the camshaft holder bolts, then,remove the rockerarm assembly. NOTE: a Unscrewthe camshaftholderboltstwo turns at a t,me, in a crisscrosspattern,to preventdamao_ ing the valvesor rockerarm assembly. . When removingthe rockerarm assembly,do not removethe camshaftholder bolts.The bolts will keep the camshaftholders,the springs and the rockerarms on the shaft. CAMSHAFTHOLDERBOLTSLOOSENING SEOUENCE:

(

Disassembly/Reassembly NOTE: in originallocations' . ldentifypartsas they are removedto ensurereinstallation (see page 6-35). arms and rocker . lnsDectrockershafts . Rockerarms must be installedin the same positionif reused. . h e b o l t s w i l lk e e p t h e r r m a s s e m b l y , d o n orte m o v et h e c a m s h a fht o l d e rb o l t s T . w h e n r e m o v i n go r i n s t a l l i n g t h reo c k e a holders,springsand rockerarms on the shaft. -Zl contactpoints. prio, ,o reassemblinq, - cleanall the pans in solvent,dry them and apply lubricantto any | RocKER TNTAKE RocKER TNTAKE ARM B ARM A D16Y7engine: 14places)

(4 placesl

INTAXEROCKER

"8" is stamped Lefter on rockerarm.

I

I

I

ROCKERSHAFT COLLAR 14plac.3l B

A

fift

\

'

A

L$\ft

:l o ol ) l[ * o : l . I Jol----t No.3CAMSHAFT | | ruo.z cltusxerr 1i

T-* l=Bl-* d

I qJ?[l'-qJ'Ll ,", 'l l=^ ^l ' I ^

B A

EI

[ilH l"\ 9

ROCKERSHAFT SPRING {4 places)

t

(cont'd)

6-31

RockerArms Disassembly/Reassembly (cont'dl \

(

NOTE: . ldentifypans as they are removedto ensurereinstallation in originallocations. . Inspectrockershaftsand rockerarms (seepage6-34). . Rockerarms must be installedin the samepositionif reused. t when removingor installingthe rockerarmassembly,do not remove the camshaftholderbolts.The boltswill keepthe holders,springsand rockerarms on the shaft. I

erior to reassembring, creana the partsin sorvent,dry them and appryrubricantto any contactpoints. II{TAKEROCKERSHAFT

D16Y5engine: ROCKER ARMS TIMINGPLATE

RUBBER BANO

-]-

-P'g,rp t+.t't ll \--,?|, \2i

No.5 CAMSHAFT _ l HOLDER l

No. 4 CAMSHAFT HOLDER

l

No. 3 CAMSHAFI HOLDER

\ ra I

No.2 HOLDER

!-r I

?h'ffi*ffi' EXHAUSTROCKER ARM B /^ IOCKERSHAFT {,1plac€s)

--

EXHAUSTROCKEESHAFT

Letter "8" is stamped

6-32

Letter "A" is slamped

D16Y8engine: INTAKESOCKERSHAFT

ROCKER SI{AFT ROCKERARMS COLLAR

No. 4 CAMSHAFT HOLOER

BAND NUBBER

No. 3 CAMSHAFT HOLDER

No. 2 CAMSHAFT HOLDER

COLLAR

No. 'l CAMSHAFT HOLDER

No. 5 CAMSHAFT HOLDER

SHAFT R(rcKER SPRING

ARMB EXHAUSTROCKERSHAFT

Letter

"B"

is stamped

Letter"A" is stamped

L

6-33

RockerArms and Lost Motion Assemblies (D16Y5, Inspection Dt6Y8enginesl N O T E rW 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 , 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 t h e o i l p a s s a g eo f t h e rockerarm. 1.

Inspectthe rockerarm piston.push it manually. - lf it does not move smoothly,replacethe rocker a r ma s s e m b t y .

\

(

DI6YSengine: NOTE:Set the timing plate and returnspring as shown oerow.

RETURN

Dl6Y5 engine: ROCKERARM TIMINGPISTON TIMINGSPRING SYNCHRONTZING PISTON

CAMSHAFTHOLDER

Dl6Yg engine: SECONDARY ROCKERARM

MID ROCKERARM

PRIMARYROCKER

SYNCHRONIZING PISTON A

NOTE: . Apply oil to the pistonswhen reassembling. o Bundlethe rockerarms with a rubberbandto prevent them from separating.

6-34

2.

Removethe lost motion assemblyfrom the holder and inspectit. Test it by pushingthe plungerwith your finger. - l f t h e l o s t m o t i o n a s s e m b l yp l u n g e rd o e s not move smoothly,replaceit.

Pu3h

I

LOSTMOTION ASSEMBLY

\

a

RockerArms and Shafts ClearanceInspection Measureboth the intakerockershaftand exhaustrocker shaft. 1.

Measurethe diameterof the shaft at the first rocker locatron.

2.

Zerothe gaugeto the shaftdiameter'

3.

M e a s u r et h e i n s i d ed i a m e t e or f t h e r o c k e ra r m a n d checkfor an out of-roundcondition. RockelArm-to-ShaftClearance Standard(Newl: 0.017- 0.050mm lntake: {0.0007- 0.0020inl Exhaust: 0.018- 0.054mm (0 0007- 0 0021 in) ServiceLimit:0.08mm {0.003inl

on all the rockers. Repeatthesemeasurements - lf the clearance is overthe servicelimit,replacethe rockershaftand all overtolerancerockerarms.

I

6-35

Gamshaft Inspection

(

\ NOTE: . Do not rotatethe camshaftduringinspection. . Removethe rockerarms and rockershafts. 1.

2.

Seatthe camshaftby pushingit toward the rear of the cylinderhead.

3,

Zerothe dial indicatoragainstthe end ofthe camshaft. Push the camshaft back and fonh, and read the end ptav.

Put the camshaftand the camshaftholderson the cylinderhead.then tightenthe boltsto the specified toroue.

Camshaft End Play: Standard{New):0.05- 0.15mm 10.002- 0.006inl SorviceLimit 0.5 mm (0.02in,

Spocifiedtorqu€: 8 mm bolts; 20 N.m (2.0kgf.m t4 lbf.ft) Apply engin6 oil to tho throads, 6 mm bohs: t2 N.m (1.2 kgf'm 8.7 tbf.ft) Apply oogine oil to the thleads. 6 mm bolts: @, @ @, @

I

Removethe bolts,then removethe camshaftholders from the cylinderhead. - Liftthe camshaftout of the cylinderhead,wipe it clean, then inspect the liit ramps, Replacethe c a m s h a f ti f a n y l o b e s a r e p i t t e d . s c o r e d ,o r excessively worn, - Cleanthe camshaftbearingsurfacesin the cylinder head,then setthe camshaftbackin place. - Placea plastigagestrip acrosseachIournal. 5.

Installthe camshaftholders,and tightenthe boltsto the soecifiedtoroue.

\,l 6-36 E

6,

Removethe camshaft holders. then measurethe widest ponion of the plastigageon eachjournal. Camshaft-to-HolderOil Clearance: Standard lNew):0.050- 0.08!tmm {0.002- 0.004in} ServiceLimit : 0.15 mm {0.006in)

8.

Checkthe cam lobe heightwear.

Cam lobe heightstandard(New)

O16Y/engine D16Y5 engrne

PRI

U n i tm m ( i n )

INTAKE

EXHAUST

35.299(1.3897)

37.281(1.4678)

38.427 11.51291 38.784(1.5269) 3 2 . 1 9 3( 1 . 2 6 7 4 )

SEC

36.77811.44791

PRI D l6Y8 MID engrne

38.274(1.5068)

38.008(1.4964)

37.065(1.4592)

sEu

PRI;Primarycam lobe,SEC:Secondarycam lobe MtD:Mid cam lobe.T/B:Timing belt lN: Intake,EX:Exhaust

PRI

-7.

oil clearanceis out ot tollf the camshaft-to-holder erance: - A n d t h e c a m s h a f th a s a l r e a d yb e e n r e p l a c e d , you must replacethe cylinderhead. - lf the camshafthas not beenreplaced,first check the total runout with the camshaftsupportedon V-blocks.

sEc

a* rN Ex t/g - D16Y5engine

MIDSEC

rts - Dl6YE ongine

CamshaftTotal Runout: Standard (New): 0.03 mm (0.001inl max. ServiceLimit: 0.04 mm {0.(X)2in)

Checkthis area{or wear. Rotatecamshatt while measuring.

-

L

lf the total runout of the camshaftis within tolerance,replacethe cylinderhead. lf the total runout is out of tolerance,replacethe oil camshaftand recheckthe camshaft-to-holder clearance.lf the oil clearanceis still out of tolerance.replacethe cylinderhead.

6-37

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 each item can be reinstalledin its orioinal oosition. '1.

3.

Install the valve guide seal remover.

SEAL REMOVER

Using an appropriate-sized socketand plasticmallet. lightlytap the valve retainerto loosenthe valve keepersbeforeinstallingthe valve spring compressor.

vat vF GI nF !SEALREMOVER VALVE GUIDE LISLEP/N 57900or KD3350

PLASTICMALLET

I

SOCKET 4.

Removethe valveseal.

Installthe spring compressor.Compressthe spring and removethe valvekeeper.

VALVE SPRII{GCOMPRESSOR Snlp-onCF711or KD-383 whh #32 JAWS

L

6-38

Valve Guides ValveMovement Measurethe guide-to-stemclearancewith a dial indicator while rockingthe stem in the directionof normal thrust (wobblemethod). lniake Valve Stem-to-GuideClearance: St8ndardlNew): 0.04- 0.10mm - 0.004in) 10.002 0.16 mm 10.006in) ServiceLimit: ExhaustValvs Stem-to-GuideGlearance: Standard{New}: 0.10- 0.16mm 10.004- 0.006in) 0.22 mm (0.009in) SorviceLimit Valveextended10 mm out from seat.

lntake Valve Dimensions A StandsrdlNewl: 29.9- 30.1mm 1 1 . 1-8 1 . 1 9i n l (New): 117.42- 117.72mm B Standard (4.523- 4.635inl C Standald{Newl: 5.'18- 5.49 mm {0.2r57- 0.2r61in) 5.,[5mm (0.21,16in] C ServiceLimit: (New): 0.85- 1.15mm D Standard (0.033- 0.0'15in) 0.65mm (0.026in) D ServiceLimit: ExhaustValve Dimensions A StandardlNew): 25.9- 26.1mm (1.02- 1.03in) B Standard {Newl: 114.60- 114.90mm 11.512- 4.521in1 C Standard {New): 5.i[5 - 5.46 mm - 0.2150inl 10.21lt6 5.,12mm 10.213'lin) C ServiceLimit: D Standard {New): 1.05- 1.35mm {0.041- 0.053in) 0.95mm {0.037in} D ServiceLimit:

O /'-_)

. . .

l f t h e m e a s u r e m e net x c e e d st h e s e r v i c el i m i t , recheckusinga new valve. lf the measurementis now within the service limit, reassembleusinga new valve. l f t h e m e a s u r e m e n st t i l l e x c e e d st h e l i m i t , recheckusing the alternatemethod below, then replacethe valveand guide,if necessary.

NOTE: An alternatemethod of checkingguide to stem clearanceis to subtractthe O.D. of the valve stem, measuredwith a micrometer,from the l.D.of the valve guide, measuredwith an inside micrometeror ball gauge.Takethe measurements i n t h r e e p l a c e sa l o n g t h e v a l v e s t e m a n d t h r e e places inside the valve guide. The differencebet w e e n t h e l a r g e s t g u i d e m e a s u r e m e n ta n d t h e smalleststem measurementshould not exceedthe servicelimit. lntake Valve Stgm-to-Guidgclearance: Standard {Newl: 0.02- 0.05 mm {0.001- 0.002in) 0.08 mm (0.003in) Limit Ssrvico ExhaustValvo Stem-to-GuideClearance: Standard {New): 0.05- 0.OBmm {0.002- 0.003in) 0.11 mm (o'Ooilin) S€rviceLimit

6-39

Cylinder Head

Valve Seats

Warpage

Reconditioning

N O T E : l f t h e c a m s h a f t - t o - h o l d eori l c l e a r a n c e s( s e e page6-36)are not within specification, the cylinderhead cannotbe resurfaced.

'1. Renew the valve seatsin the cylinderhead using a valveseatcutter. NOTE: lf the guides are worn (see page 6-39). r e p l a c et h e m ( s e e p a g e 6 - 4 1 )b e l o r e c u t t i n g t h e valveseats.

lf the camshaft-to-holder oil clearancesare within sDeci, fications,checkthe cylinderheadlor warpage. lf warpageis lessthan 0.05mm (0.002in), cylinder headresurfacingis not required. lf warpage is between 0.05 mm (0.002in) and 0.2 mm {0.008in), resurfacethe cylinderhead. M a x i m u m r e s u r f a c el i m i t i s 0 , 2 m m ( 0 . 0 0 8i n ) basedon a heightof 93 mm (3.66in).

VALVESEAT CUTTER (Commercially available)

2.

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 g o n l y e n o u g h materialto ensurea smoothand concentricseat.

?

Bevelthe upperedge of the seatwith the 30. cutter and the lower edge of the seat with the 60' cutter. Checkthe width of the seatand adjustaccordingly.

4.

Makeone more very light passwith the 45"cutterto removeany possibleburrs causedby the other cutIers. Valve Seat Width: Standard (N€w): - 0.045in) Intake: 0.85- 1.15mm 10.033 Exhaust: 1.25- 1.55mm {0.049- 0.061in} SorviceLimit: Intake: 1.6mm (0.063inl Exhausl: 2.0 mm (0.079in)

Measurealongedges,and threeways acrosscenter.

Seat Width

Cylinder Head Height: Standard{Newl: 92.95- 93.05mm {3.659- 3.66:}in)

6-40

5.

After resurfacing the seat, inspect for even valve s e a t i n g r A p p l y P r u s s i a nB l u e c o m p o u n d t o t h e valve face, and insert the valve in its original location in the head, then liit and snap it closed against the seat several times.

\

ValveGuides Replacement 1 . As illustratedbelow, use a commercially-available air-impactvalve guide driver attachmentmodified to fit the diameterof the valveguides.In most cases. the same procedurecan be done using the special tool and a conventionalhammer.

VALVE SEAT

VALVEGUIDEDRIVER lCommerciallv available)

PFUSSIANBTUECOMPOUNO

The actual valve seatingsurface.as shown by the bluecomDound,shouldbe centeredon the seat. . lf it is too high (closerto the valve stem), you must make a second cut with the 60'cutter to move it down, then one more cut with the 45' cutter to restoreseat width, . lf it is too low (closerto the vslve edge), you must make a second cut with the 30" cutter to move it uD,then one more cut with the 45'cutter to restoreseat width. NOTE:The final cut shouldalwaysbe madewith the 45" cutter. 7.

lnsertthe intakeand exhaustvalvesin the headand measurethe valvestem installedheight. Intake. Exhau3tSiem Installsd Height: Standard (New): 53.17- 53.6,4mm - 2.112in) 12.093 53.89mm (2.122in) SorviceLimit:

8.

87 mm +t3.43in) |

57 mft 1224 inl

5.3 mm

tr-r

'10.8mm (0.42 inl

or VALVEGUIDEDRIVER,5.5 mm 07742- 0010100 guides.and chill them Selectthe properreplacement in the freezersectionof a refrigeratorfor about an nour. Use a hot plate or oven to evenlyheat the cylinder headto 300"F(150'C).Monitorthe temperaturewith a cookingthermometer.

lf the valve stem installed height is over the service limit. reDlacethe valve and recheck.lf its still over t h e s e r v i c el i m i t , r e p l a c et h e c y l i n d e r h e a d ;t h e valveseat in the headis too deep.

VALVESTEM INSTALLEDHEIGHT

CAUTION: . Do not use a torch; it may warp the head. Do not got the head hottel than 300"F (150"C1; excessiveheat may loosen thg valve seats. To avoid burns. use heayy gloves whon handling the heated cylinder h€ad.

\-

{cont'd)

6-41

Valve Guides Replacement(cont'd) Workingfrom the camshaftside,use the driver and a n a i r h a m m e tr o d r i v et h e g u i d ea b o u t2 m m ( 0 . 1i n ) towardsthe combustionchamber.This will knockoff some of the carbonand makeremovaleasier. CAUTION: . Always wear satety gogglesor a face shield when driving valve guides. . Hold the air hammer directly in line with the valve guide to prevent damaging the driver.

7.

Apply a thin coat of cleanengineoil to the outside of the new valve guide. Installthe guide from the camshaftside of the head; use the specialtool to drivethe guide in to the specifiedinsralledheight.lf you haveall 16 guidesto do, you may haveto reheat thehead.

I

Turn the headover, and drive the guide out toward the camshaftside of the head.

VALVEGUIOE DRIVER,5.5 mm 07742- 0010100

ll VALVE GUIOEORIVER, 5.5 mm 07742 - 001 01 00

Valve Guide lnstalled Height: Intake: 17.85- 18.35mm (0.703- 0.722inl Exhausi:18.65- 19.15mm (0.734- 0.754in)

VALVEGUIDE

It a valve guide still won't move, drill it out with a 8 mm {5/16in) bit, then try again. CAUTION: Drill guides only in extreme cases; you could damagethe cylinder head it the guide breaks. 6.

Removethe new guidesfrom the freezer,one at a time, as you needthem.

6-42

Valves Reaming

lnstallation

NOTE:For new valveguidesonly.

1 . Coat valve stems with engine oil. Insertthe valves in the valveguides.

1.

Coat both the reamerand valve guide with cufting orl.

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.

Checkthe clearancewith a valve(seepage6-391. Verifythat the valve slidesin the valve guide without exertingPressure.

T u r nr e a m e irn clockwisedireclion o nl y .

NOTE: Make sure lhe valves move up and clown smoothly. 2.

lnstallthespringseatson the cylinderhead.

3.

I n s t a l lt h e v a l v e s e a l su s i n gt h e v a l v e g u i d e s e a l installer. NOTE:Exhaustand intakevalvesealsare not interchangeable.

WHITE SPRING

INTAKEVALVESEAL

BLACK SPRING

EXHAUST VALVESEAL VALVEGUIDESEAL INSTALLER

REAMER

K D 2 8 9 9 ( C o m m e r c i a l l ya v a i l a b l e ) NOTE: Use small lD end of

o a) o , o

o

REAMER,5.5 mm O7HAH.PJ'O'IOB

P

I

(cont'd)

6-43

Valves

Camshaft/RockerArms and CamshaftSeal/Pulley

Installation(cont'd)

Installation

4.

CAUTION: . Make sure that all tockers are in alignment with their valvgs when torquing the rocket assemblybolts, . Valve locknuls should be loosened and adiusting screws backed off bofore installation. . To prevont tho rocker arm a$smbly from coming apad, l6av€the camshaft holder bohs in the holdeB.

I n s t a l lt h e v a l v e s p r i n g a n d v a l v e r e t a i n e r .t h e n installthe valve spring compressor.Compressthe springand installthevalvekeepers. NOTE:Placethe end of the valvespringwith closely wound coilstoward the cylinderhead.

1.

After wiping down the camshaft,camshaftseal and j o u r n a l si n t h e c y l i n d e rh e a d ,l u b r i c a t eb o t h s u r facesand installthe camshaft.

2.

Cleanand installthe oil control orificewith a new O-ring. OIL CONTROLORIFICE

available) lCornmercially Snap-onCFrll or KD- 3tX' with #32JAWS Lightlytap the end of eachvalve stem two or three times with a plasticmalletto ensureproperseating of the valveand valvekeepers. NOTE:Tap the valvestem only along its axisso you do not bendthe stem.

CAMSHAFTSEAL Sealhousingsurfaceshouldbe dry. Applya lightcoat of oil to camshaft a n d i n n e rl i p o f s e a l . 3.

' 6-44

Turn the camshaft until its keyway is facing up (No. piston TDC).

CylinderHead lnstallation 4.

Apply liquidgasket(PartNo. 08718- 0001or 087180003)to the head mating surfacesof the No. 1 and No.5 camshaftholders. - Apply liquidgasketto the shadedareas

lnstallthecylinderheadin the reverseorderof removal: NOTE: . Alwaysuse a new headgasket. . 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 clean. . "UP" markon the camshaftpulleyshouldbe at the top . Turn the crankshaftso the No. 1 pistonis at TDC(see page6-20). . Cleanthe oil controlorificebeforeinstalling. a Do not use the upper cover and lower cover to store removeorlems. Cleanthe upper cover and lower cover beforeinstaltaUon. 1.

Cylinderheaddowel pins must be aligned. CYUNOERHEAD

Set the rockerarm assemblYin place and loosely installthebolts. - Makesurethat the rockerarms are properlypositionedon the valvestems. Tighteneachbolttwo turnsat a time in the sequence shown belowto ensurethat the rockersdo not bind on the valves. Specitiedtorquo: 8 mm bolts: 20 N.m (2.0 kgt'm, l/t lbf'ft) Apply engine oil to the threads. 6 mm bolts: 12 N.m {1.2 kgif'm,8.7 lbf'ft) Apply engine oil to the thresds. 6 mm bolts:O, @. @, @

PINS

!

7.

Installthe backcover.then installthe camshaftpul-

(cont'd)

6-45

Cylinder Head Installation(cont'dl

(

Positionthe camshaftcorrectly(seepage6-20).

7 . Installthetiming belt (seepage6-20).

Tightenthe cylinderhead bolts sequentiallyin four steps.

8 . Adjustthe valveclearance(seepageel2),

rsr st.p: O - @ 20 N.m (2.0 kgf.m, 14 lbf'ft| 2nd srep: O - @ 49 N.m (5.0kgf.m, 36 tbtft) 3rd stop; O - @ 67 N.m {6.8 kgf.m, /r9 lbl'ft} 4th st6p: O, O 67 N.m 16.8kgf.m, 49 tbf.ftl NOTE: . W e r e c o m m e n du s i n g a b e a m - t y p et o r q u e wrench, When using a preset-typetorque wrench. be sure to tighten slowly and not to overtighten. . If a bolt makesanynoisewhileyouaretorquingit, loosenthe bolt, and retightenit from the 1ststep,

9. Installthe head cover gasketin the groove of the c y l i n d e r h e a d c o v e r , S e a t t h e r e c e s s e sf o r t h e camshaftfirst, then work it into the groove around the outsideedges. NOTE: . B e f o r ei n s t a l l i n gt h e h e a d c o v e r g a s k e t ,t h o r oughlycleanthe sealand the groove. . When installing,make sure the head cover gask e t i s s e a t e d s e c u r e l yi n t h e c o r n e r s o f t h e recesses wathno gap. COBNERS OF THERECESS

CYLINDERHEADBOLTSTOROUESEOUENCE:

I CORNERS OF THEREcEss

covEB

1 0 . Apply liquid gasketto the head cover gasketat the four cornersof the recesses.

4.

Installthe intakemanifoldand tightenthe nuts in a crisscrosspatternin two or three steps,beginning with the innernuts (seepages9-2thru 9-4). .

Alwaysusea new intakemanifoldgasket.

NOTE: . Use liquid gasket,Pan No. 08718- 0001or 08718 - 0003. . Checkthat the matingsurfacesare cleanand dry beforeapplyingliquidgasket. . Do not installthe parts if five minutesor more h a v e e l a p s e ds i n c e a p p l y i n gl i q u i d g a s k e t . Instead,reapplyliquid gasketafter removingold residue. . After assembly,wait at least 30 minutes before fillingthe enginewith oil.

Installthe exhaustmanifoldand tightenthe nuts in a crisscrosspatternin two or threesteps,beginning with the inner nut {seepages9-6 and g-7). .

Always usea new exhaustmanifoldgasket.

I n s t a l lt h e e x h a u s tm a n i f o l d b r a c k e t .l n s t a l l t h e exhaustpipe A and the bracket,then installthe cover.

6-46

\-

1 1 . W h e n i n s t a l l i n gt h e c y l i n d e rh e a d c o v e r ,h o l d t h e headcovergasketin the grooveby placingyour fingers on the camshaft holder contacting surfaces (top of the semicircles) Setthe sparkplug sealon the sparkplug tube. 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 headcovergasket.

12. Tightenthe nuts in two or thre€ steps.In the final step,tighten all bolts, in sequence,to 9 8 N'm (1.0 kgf.m,7.2 lbf.ft). NOTE: After assemblv, wait at least 30 minutes beforefillingthe enginewith oil

NOTE: . Before installingthe cylinder head cover, clean t h e c y l i n d e r h e a d c o n t a c t i n gs u r f a c e sw i t h a shop towel. . Do not touch the parts where liquid gasketwas aDolied. . T a k ec a r e n o t t o d a m a g et h e s p a r k p l u g s e a l s when installingthe cylinderheadcover, . Visuallycheckthe sparkplug sealsfor damage. . Replaceany washerthat is damagedor deteriorated.

6x1.0mm 9.8 N.m 11.0ksf.m,7.2lbfftl 1?

After installation,check that all tubes, hosss and connectorsare installedcorrectlY

\g-----*o""t' Ptl vE eE

\_

6-47

GylinderHead/ValveTrain 816A2 engine SpecialTools

............. 6'50

VTECContlol System 6-51 TroubfeshootingFlowchart ............ VTECSolenoid Valve ...""'......5-54 Inspection

VTEC RockerArms 6-54 ManualInspection........................... InspectionUsing SpecialTools .....'6-55 ValveClearance

.

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.........." 6-57 Adiustment PulleyandPulleyBolt Crankshaft ..".....6-59 Replacement Timing Belt

CylinderHead

RockerArms ...............6'72 Disassembly/Reassembly Rocker Arms and Lost Motion Assemblies .........""'6-73 Inspection Rocker Arms and Shafts 6-74 Inspection..'..."'.............. Clearance Camshafts

SpringsandValveSeals Valves'Valve """"""""' 6-77 Removal ValveSeats ......6'78 Reconditioning

lnstallation

6-82 '............

SpecialTools \ Ref.No.

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Tool Number

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o T H A HP J 7 0 1 0 B 07JAA-001020A 07JAB-0010204 07JAB- 0010404 07LAJ- PR3020A 07MAA- PR70100

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Description

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V a l v eG u i d eR e a m e r , 5 .m 5m Socket,19 mm H o l d e rH a n d l e PulleyHolderAttachment.50 mm Air Stopper TappetAdjuster - enu ozvu,r orzo TappetLocknutWrench 07MAF- PR9010A ValveSpringCompressorAttachmentExtension 0 7 7 4-2 0 0 1 0 1 0 0 ValveGuideDriver,5.5 mm 0 7 7 5 7 - P J 1 0 1 0 4 ValveSpringCompressorAttachment

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Oty 1 1 1 1 1 1 1 1 1 1

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PageRelerence 6-81 659 6-59 6-5s ] I 6-55 6-57 6-57 J 6-77 6-80,81 6-71 I

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6- 50

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VTECControl SYstem TroubleshootingFlowchart problemin the WEC PressureSwitchcircuitor The scantool indicatesDiagnosticTroubleCode{DTC)Pl259:A VTECSolenoidValvecircuit Referto page 1'l-38through 11 55 beforetroubleshooting The MIL has beenteported on. DTCP1259is siored. Checkthe VTECControl SYsiem: 1. Do the enginecontrolmodule ( E C M) R e s e tP r o c e d u r e( s e e section11). 2. Startthe engine 3. Warm uP the engineto normal operatingtemPerature(cool ing fan comeson). 4. Do the RoadTest.* ls DTCP1259indicated?

* Road Test: in 1stgearto an enginespeedover 6,000rp ' Accelerate Holdthat enginespeedfor at leasttwoseconos' lf the DTC P1259is not repeatedduring the first road test' repeatthis testtwo moretimes lntermittent failure, sYstemis OK at this time. Check for Poor connectlons or loose wires at VTEC Pressure swilch. VTECaolenoid valvo and ECM.

SWITCH2P VTECPRESSURE CONNECTOR

Test the VTECPressureSwitch: 1. Turnthe ignitionswitchOFF. the VTECPressure 2. Disconnect switch2P connector. 3. Checkfor continuitybetween VTECpressureswitch2P con n e c t o rt e l m i n a l N o 1 a n d No.2. T e r m i n a l s i d eo f male termtnals

Reolacethe VTECPre3sureswitch.

/1

WM IBLU/BLKI

/ 1 Y------r t--------- l

\1-/

| I

I

Test the VTEC Pressure Switch Wire: 1. Turnthe ignitionswitchON (ll). the voltagebetween 2. N4easure V T E C p r e s su r e s w i t c h 2 P c o n n e c t o rN o . 1 a n d b o d y ground,

YES

I

I

1

Wiresideof female terminals

Inspectlor an open or short to ground in the wire between the VTEC orassure swilch and ECM {c101. lf the wire i3 OK, substitute a known-good ECMand recheck.

{To page6 52)

(cont'd)

6-51

VTECControl System TroubleshootingFlowchart(cont,d)

( VTECPRESSURE SWITCH2P CONNECTOR

(Frompage6-5ll

Test tha VTEC P.es3uro Switch Wi.e: Measurevoltage acrossthe VTEC pressureswitch2P connector.

ls there batteryvoltage?

Wiresideof temale terminals

Ropairopon in the wiro batwoen VIEC pr...urc switch and Glot . lf the wiro is OK, 3ubltitutr a known-good ECMand rochack.

VTECSOLENOID VALVElP CONNECTOF Ir------rI

lLl.ll-r I I

Test the VTECSolenoidV.tve: 1. Turnthe ignitionswitchOFF. 2. Disconnect the VTECsolenoid valve1Pconnector. 3. Checkfor continuitybetween t h e V T E Cs o l e n o i dv a l v e 1 P connectorterminalNo, I and bodyground.

It

Terminalsideof maleterminal

I

ls there14- 30 O? OIL PRESSURE GAUGE (Comm.rciallyavail.bte) Te3tthe VTECSotonoidVatve: '1. Remove the VTEC pressure switch and installthe special tool as shown. then reinstall the VTECpressureswitch. 2. Reconnectthe VTECsolenoid valve 1P connectorand VTEC pressureswitch2P connector, 3. Connectthe tachometer(see sectio1 nl). 4. Startthe engine. 5 . W a r m u p e n g i n et o n o r m a l operatrngtemperature(cooling fan comeson). 6. Checkoil pressureat engine s p e e do f 1 , 0 0 0 , 3 , 0 0 0 and 5,000rpm.

ls pressurebelow 49 kPa (0.5kgflcm,,7psi)?

GAUGEJOINT ADAPTER SNAP.ONMT26.17 10 x 1.0ftm . Usenew washerwhen installingthe sealingbott.

N O T E : K e e p m e a s u r i n gt i m e a s s h o r r a s possiblebecauseengineis runningwitn no loadllessthan one minute).

Inipoct thg VTEC aolenoid valve l3ee P8go6-54).

(To page 6-53)

6-52

I

VTECSOLENOIDVALVE 1PCONNECTOR

(Frompage6-52)

Terminal side of male terminal

Test the VTECSolenoid Valve: 1. Turnthe ignitionswitchOFF the VTECsolenoid 2. Disconnect valve 1Pconnector, 3 . A t t a c h t h e b a t t e r YP o s r t r v e terminalto the VTECsolenoid valveterminal. 4 . S t a r t t h e e n g i n ea n d c h e c k t h e o i l P r e s s u r ea t e n g i n e speedol5,000rPm ls the pressureabove390 kPa (4.0kgt/cm?,57 Psi)?

lrcoect the VTEC solenoid valve (seepageS54)

C (31PI ECMCONNECTOR WM

Testthe VTECPressureSwitch: With the battery Positiveterminal connectedto the VTECsolenoid valve,measurevoltagebetween the ECMconnectorterminalC10 and bodyground.

ls there battery voltage above 5 , 0 0 0r p m ?

VIECSOLENOID VALVE 1PCONNECIOR Test the VTEC Solenoid Valve Wire: 1. Turnthe ignitionswitchOFF 2. Checkfor continuitvbetween t h e V T E Cs o l e n o i dv a l v e 1 P c o nn e c t o rt e r m i n a la n d t h e terminal812 ECMconnector

ECMCONNECTOR B l2sP)

Wire sideot female termrnals Repairopen in the wire between the ECMlB12| and VTECaolenoid VTECSOLENOIDVALVE 1P CONNECTOR

Test lhe VTEC Solenoid Valve Wire: Checkfor continuitybetweenthe VTECsolenoidvalve'lPconnector terminalandbodyground.

I'ft Repair short in the wiro b€'tween the ECM( 812)and VTECaolenoid

I

I

Wire sideof female termanal

Substitute a known'good ECM and recheck. lI sYmptom/indica' tion goes away. repleca the original ECM.

6-53

VTECSolenoid Valve Inspection

ManualInspection

1 . R e m o v et h e V T E Cs o l e n o i dv a l v e a s s e m b l yf r o m t h e c y l i n d e rh e a d .a n d c h e c kt h e V T E Cs o l e n o i d valvefilter for clogging. .

VTECRockerArms

lf thereis clogging,replacethe engineoilfilter and engineoil.

\

1.

Set the No. 1 pistonat TDC.

2.

Removethe ignitionwire coverand the wires.

3.

Removethe ignitionclampswhile pullingup on the Iock.

a

6xl.0mm 9.8 N.m (1.0kgl.m,7.2tbtftl IGNITION WIRECOVER IGNITION WIRE

SOLENOID

6x1.0mm 12N.m(1.2kgf.m,B,7tbf.ftl

I

lf the filter is not clogged.push the VTECsolenoid valvewith your fingerand checkits movemenr. .

lf the VTECsolenoidvalve is normal,checkthe engineoil pressure. 6x1.0mm 12 N.m (1.2kgtm,8.7 lbt.ft)

LOCK

(

6 -54 L-

InspectionUsingSPecialTools Removethe cylinderheadcover. NOTE:Referto page6-88when installingthe cylinder head cover. Pushthe mid rockerarm on the No. 1 cylindermanually. Checkthat the mid rockerarm movesindependently of the primary and secondaryrockerarms.

CAUTION: . B€fore using tho Yalvo inspeciion tool, mako suro that ths air pre3sure gauge on the air comprossor indicatos ovor /rco kPa (,1kgf/cm', 57 psi) . In3poct ths valve closranca bafore rock$ arm impoc' tion. . Cover the timing beh whh I shop towel to prcvenl gstting oil on the bolt' . Chock ths mid rocker arm of each cylindll at TDC' 1.

Removethe cYlinderhead cover. NOTE: Rsfer to page 6-86 when installing the cylinder headcover.

2.

Plug the relief hole with the special tool (Air Stopper).

OTLA'- PRSO2OA 3.

7.

Checkthe mid rockerarm ot eachcylinderat TDC' .

.

Removethe bolt and washer from the inspection hole and connoct the an air pressureregulator with a 0 - 100psi gauge.

AIF STOPPEB OTLA' - PR3O2OA

lf the mid rockerarm does not move, removs the 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 assembly.

TNSPECTIONHOIE

t0 x 1.0mrn 20 N.m{2.0kgfm, 14tbt'fr)

BEGULATORVALVE . Pullthe leverand turn to adjust.

AIRPRESSURE REGULATOR avril.bl.l {Cornm.rcirlly {cont'd}

6-55

VTECRockerArms InspectionUsingSpecialTools(cont,dl 4.

L o o s e nt h e v a l v e o n t h e r e g u l a t o ra n d a p p l y t h e specifiedair pressure.

I

SpecifiedAir Pressuro: 250 kPa {2.5 kgtlcm,, 36 psil - 490 kPa {5.0 kgtcm,, 7t psil 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 no. move wnen pushedmanually.

SECONDARY ROCKER ARM

.

lf any mid rocker arm moves independentlyof the primaryand secondaryrockerarms, replace the rockerarms as a set.

ll

Removethe tools. 7.

Checkthe operationof the lost motion assemblyby 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 ys 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 smoothlythroughits full stroke.Replacethe assem_ bly if it does not work smoothly. After inspection.check that the Malfunction Indi_ catorLamp{MlL)does not come on.

;l 6-56

ValveGlearance Adjustment NOTE: . Valves should be adjusted only when the cylinder head temperaturs is lessthan 100'F (38'C)' . After adjusting,retorquethe crankshaftpulleybolt to 177N.m (18.0kgf'm,130lbt'ft) 1.

Removethe cylinderheadcover'

Adjustvalveson No. 1 cylinder. lntako: 0.15- 0.19 mm {0'006- 0.007in) ExhaGt 0.17- 0.21 mm {0'007- 0 008 inl 4.

Loosenthe locknut, and turn the adjusting screw until the feeler gauge slides back and forth with a slightamountof drag.

NOTE:Referto pageG86 when installingthe cylinder headcover. 2.

TAPPETADJUSTER WFENCHSET 07MM - PR70110

"UP" mark on the pullsy Set No. 1 pi$on at TDC.The should be at the top, and TDC grooves on the pulley should align with the pointer on the backcover' TDC grooves{white paint) on the crankshaftpulley should align with the pointeron the timing belt lower cover'

Number I Pistonat TDC:

TAPPETLOCKNUT WRENCH 07MAA - PR70120 LOCKNUT 20 N.m {2.0 kgf'm, lil lbt'ftl

Adiusting sclaw location:

(cont'd)

6-57

Valve Clearance Adjustment{cont'd) 5.

Tightenthe locknutand recheckclearance. Repeatadjustmentif necessary.

FE€LER GAUGE

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 e (camshaftpulleyturns 90'). The "Up" mark should be on the exhaustside.Adjustvalveson No. 3 cylinder. Number 3 piston at TDC:

"UP-

7.

I

R o t a t et h e c r a n k s h a f t' 1 8 0 .c o u n t e r c l o c k w i s teo bring No. 4 piston to TDC.The ,,Up,.mark should be pointing straightdown. Adjust valves on No. 4 cylinder.

Number 4 piston at TDC:

8,

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 teo bring No. 2 pistonto TDC.The "Up., marksshould be on the intakeside.Adjust valveson No. 2 cylin_ der.

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Number 2 piston at TDC:

MARKS

I 6- 58

CrankshaftPulleYand PulleYBolt Replacement When installingand tighteningthe pulley,follow the procedurebelow' Clean,removeany oil, and lubricatepointsshown below a: Clean x : BemoveanYoll a: Lubricate CRANKSHAFT

PULLEYBOLT XXX X

x

X X

x

X X

X

X

I i

XXXXX

x

WASHER

TIMII GUID

BELT GUIOEPLATE

Crankshaftpulley bolt size and torque value: 1 4 x 1 . 2 5m m 177 N.m t18.0kgtm, 130 lbf'ftl NOTE:Do not usean impactwrenchwhen installing'

PULLEYHOLO€RATTACHMENT, 50 mm 07JAB- 0O10,OA

6-59

Timing Belt lllustratedIndex

I

NOTE: . Referto page6-59for positioningcrankshaftand pulleybeforeinstalling belt. . Markthe directionof rotationon the belt beforeremovino. a Do not usethe middlecoverand lowercoverfor storingr'emoveditems. . Cleanthe middlecoverand lowercoverbeforeinstallation.

WASHER Replace when damaged or deteriorated.

CAPNUT x 1,0mm 9.8 N.m lr.0 kgf.m,7.2lbtftl CYLINDER HEADCOVER Referto page6-86 when installing. HEADCOVERGASKET Replacewhen leaking, damagedor deteriorated. Apply liquidgasketat the four cornersol the recesses,

- -o

TIMINGBELT page6-61 Inspection, Adjustment,page6-61 Replacement,page 6-62 MIDDTECOVER 6 x 1.0mrn 9.8 N.m {1.0 kgf.m, 7.2 tbt-ltl

8 x 1.25mm N.m {5.7 kgt.m,

6 x '1.0mm 9.8 N.m {1.0kgf.m, 7.2 lbt.ftl

41tbtfr)

6x1.0mm N.m 11.0kgf.m, 7.2 tbt.ft'l

l0 x 1.25mm 5a N.m {5.5 kgl.m, 40 tbt ftt

TIMINGBELT DRIVEPULLEY Replacement, page6-59

6- 60

Installwithconcave surtacefacing out. Removeany oil and clean.

LOWER COVER

PULLEYBOLT 14x 1.25mm CRANKSHAFT PULLEY 177 N.m {18.0kgf.m. 130tbt.ft} page6-59 Replacement, page6-59 Beplacement, Do not usean impact wrenchwhen installing.

I

Inspection

TensionAdiustment

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CAUTION: Always adiust timing belt tension with the engine cold.

Removethe cylinderheadcover. NOTE:Referto page6-86when installingthe cylinder headcover. Inspectthe timing belt for cracksand oil or coolant soakrng. NOTE: . Replacethe belt if oil or coolant soaked. . Removeany oil or solventthat gets on the belt'

NOTE: . The tensioneris spring-loadedto apply proper ten after makingthe followsion to the belt automatically ing adjustment. when . Always rotatethe crankshaftcounterclockwise it clockw'se Rotating pulley side. the from viewed may result in improper adjustmentof the belt tension. 1,

Removethe cylinderheadcover. NOTE;Referto page6-86when installingthe cylinder headcover.

lnspectthrs area

2.

Setthe No. 1 pistonat TDC(seepage6-64)

3.

Rotatethe crankshaftlive or six revolutionsto set the belt.

4.

Setthe No. 1 Pistonat TDC

ADJUSTINGBOLT 54 N.m (5.5kgt.m, a0 lbtftl

I

Rotate PUlleY and inspect belt-

5.

Loosenthe adjustingbolt 180'. three teeth Rotatethe crankshaftcounterclockwise on the camshaftPulleY.

After inspecting,retorquethe crankshaftpulley bolt to 177N.m (18.0kgf'm,130lbf'ft)

7.

Tightenthe adjustingbolt.

8.

After adjusting,retorquethe crankshaftpulley bolt to 177N.m (18.0kgf'm,130lbnft)

6-61

Timing Belt Removal \ NOTE: . Replacethe timing belt at 105,000mites(168,000 km) accordingto the maintenanceschedule(normalconditions/severe conditions). lf the vehicleis regularlydrivenin one or more of the followingconditions,replacethe timing beltat 60,OOO miles(U.S.A.)100,000km {Canada). . In very high temperatures(over 110"F,43"C). . In very low temperatures(under-20.F, 29.C). . Turn the crankshaftpulley so the No. 1 piston is at top dead center(TDC)beforeremovingthe belt (see page6-57). . Inspectthe water pump before installingthe timing belt {seepage 10-14). 1.

4.

Loosenthe mountingnut and lockbolt,then remove the alternatorbelt.

a

LOCKBOLT 8 x 1.25mm 24 N.m {2.4 kgt.m. 17 rb{.ftl

Removethe splashshield(seepage5-9). Removethe adjustingbolt and mountingbolts,then r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d pump. MOUNTING 10x 1.25mm 44 N.m (4.5kgf.m. 33 rbf.ftt

5.

BELT

Removethe upperbracket(seepage6-69). NOTE: . Use a jack to support the engine before removing the upper bracket. o Placea cushionbetweenthe oil pan and the jack. Removethe P/Spump lower bracket

8xL25mm 24 N m {2.{kgf.m,17lbf.ft) Loosenthe idler pulley bracketbolt and adjustingbolt, then removethe air conditioning(A,/C)compressor belt aDJUsnNG

IOLERPULLEYBRACKET EOLT 10x 1.25mm 44 N.m 14.5kgf.m, 33 bnft)

6-62

HEATSHIELD 8 x 1.25mm 24 N.m 12.,1 kgf.m, 17 tbf.ftl

P/S PUMP LOWERARACKET l 0 x 1 . 2 5m m 44 N.m 14.5kgt.m, 33 lbf.ft)

'-f

lnstallation 7 . Removethe crankshaftpulley(seepage6-59). 8 . Removethe cylinderheadcover'

Installthe timing belt in the reverseorderof removal; Only key pointsare describedhere. 1.

NOTE:Referto page6-86when installingthe cylinder headcover.

Set the timing beltdrive pulleyso that the No. 1 pis' ton is at top deadcenter(TDC).Align the grooveon the timing belt drive pulleyto the V pointeron the oil pumP.

9 . Removethe middlecoverand lower cover. NOTE:Do not use the middle and lower coversfor storingremoveditems. COVER MIDDLE

POINTER

LOWERCOVER

9.8N.mlt.o kgfm, 7.2lw'ftl

1 0 . Loosenthe adjustingbolt 180'. Pushthe tensioner t o r e m o v e t e n s i o nf r o m t h e t i m i n g b e l t , t h e n retightenthe adjustingbolt.

set the camshaftpulleysso that the No. 1 piston is at TDC. Align the TDC marks on the intakeand exhaustcamshaft pulleys.

N.m (5.5kgt'm,

TDC MARK

11. Remove the timing belt.

(cont'd)

6-63

TimingBelt

a

lnstallation(cont'dl 3.

Installthe timing belttightlyin the sequenceshown. @ 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 )+ @ Adjusting pulley* @ Water pump pu ey + @ Intake camshaftpulley+ @ Exhaustcamshaftpulley,

9. Checkthat the crankshaftpulley and camshaftpulleys are both at TDC. CRANKSHAFT PULLEY

NOTE: Make sure the timing belt drive pulley and camshaftpullevsare at TDC,

CAMSHAFT PULLEY: "UP" MARKS

'l Loosenand retightenthe adjustingbolt to tension the timing belt. Installthe lower coverand middlecover. NOTE: Cleanthe middle and lower covers before installing. Installthe crankshaftpulley,then tighten the pulley bolt (seepage459). 7.

Rotate the crankshaft pulley about five or six turns counterclockwiseso that the timing belt positionson the pulleys. Adjustthe timing belttension(seepageA611.

1 0 . lf the camshaftand crankshaftpulleysare not positioned at TDC, remove the timing belt, adjust the positionfollowingthe procedureon page&63, then reinstallthe timing belt. 1 1 . After installation, adjustthe tensionof eachbelt. . . .

See section 23 for alternator belt tension adjustment. See section22lor NC compressorbelt tension adiustment, See section 17 for P/S pump belt tension adjustment.

I

6-64

CylinderHead lllustratedIndex CAUTION: (38"C1bofote . To avoid damaging the cylinder head, wait until the engine coolant tempsraturo drops below 100"F removing it, gasket. . when handling a metal gasket,take caro not to fold the gaskot or damagethe contact surfaceof the NOTE:Use new O-ringsand gasketswhen reassembling.

8 x 1,25 mm 27 N.m P.E kgl m. 20 tbf.fo Applyengineoil to the threads.

6x1.0mm 9.8 N.m (1.0 kgf'm,

7.2rbnftl

6 x l,omm ft) 9.8N'mtl.0 kgt'm,7.2lbf

IGNMON WIRECOVER

cr.rMp.S CAMSHAFT

fi

"o''*t*';

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CYLINOERHEAD COVER Referto page 6-86 when installing

%

CYLINDERHEAO PLUG Replace.

)@ DISTRIBUTOR 8 x 1,25mm 24 N.m {2.4 kgf'm, 1? tbf.ftl

OIL SEAL Replace.

EXHAUST

HEADCOVERGASKET when leaking,damaged Replace or deteriorated. Apply liquidgasketat the cornersof the recesses,Page6-86

SEAL RUBBER whendamaged Replace or detedorated.

10 x 1.25mm 56 N.m (5.7 kgf m, ,r1 lbl.ft)

(cont'd)

6-65

CylinderHead lllustratedIndex(cont'dl

CYLINDERHEAD BOLTS 1 1x 1 . 5m m 83 N.m {8.5kg{.m,61 Applyengineoil to threads.

INTAKEVALVESPRINGINNER VALVEKEEPERS SPRINGRETAINER INTAKEVAI.VESPRINGOUTER

valvEKEEPEBS\:""j"*'

SPRINGRETAINER EXHAUST VALVE SPRING

VALVESEAL Replace. SPRINGSEAT VALVEGUIDE INTAKEVALVE

VALVESEAL Replace. VALVE

t il

LOSTMOTION ASSEMBLY ROCKERSHAFT EXHAUSTVAL

SEALINGAOLTS.20mm 64 N.m (6.5kgt.m, 47 tbf.ft) HEAOOIL CONTROL ORIFICE C l e an .

a 6-66

Removal Engineremovalis not requiredfor this procedure.

6.

Make surejacks and safetystandsare placed !@@ properly and hoist brackels are attachedto correst position on the engine, CAUTION: o Use fender covers to avoid damaging painted surfaces. T o a v o i d d a m a g e ,u n p l u g t h e w i l i n g c o n n e c t o r s carelully while holding the connector portion. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100"F{38'Cl before looseningthe retaining bolt. NOTE: . Unspecifieditemsare common. . Markall wiring and hosesto avoid misconnection. AIso,be surethat they do not contactother wiring or hosesor interferewith other parts. o Inspectthe timing belt beforeremovingthe cylinder ne a o . . Turn the crankshaftpulleyso that the No. 1 piston is at top deadcenter(seepage6-64). 1.

the negativeterminalfrom the battery. Disconnect

2.

Drainthe enginecoolant{seepage 10-7). .

Removethe radiatorcapto speeddraining.

3.

Removethe strut brace(seepage5-2).

4.

r ousing R e m o v et h e i n t a k ea i r d u c t a n d a i r c l e a n e h (seepage5-3).

Loosenthe idler pulley bracketbolt and adjusting b o l t , t h e n r e m o v et h e a i r c o n d i t i o n i n g( A / C )c o m pressorbelt.

ADJUSTING

IDLERPULLEYBRACKET BOLT 10x 1.25mm 33 lbt.ft} 44N.m{4.5kg,l.m,

7.

Loosenthe mountingnut and lockbolt,then remove the alternatorbelt.

LOCKBOLT 8 x 1.25mm 24 N.m {2.4 kgf.m, 17 tbtftl

Removethe adjustingbolt and mountingbolt, then removethe powersteering(P/S)pump beltand pump (seepage5 5).

10 x 1.25mm ,l,l N.m {4.5 kgf.m, 33 tbf.ft,

\

ALTERNATOR BELT

(cont'd)

6-67

Cylinder Head Removal(cont'd) 8. Removethe P/Spump lower bracket. 8 x 1.25mm 24 N.m 12.4kgf.m, 17 tbtftl

11. Removethe brakeboostervacuumhose,fuel return hoseand vacuumhose(seepage5 4).

T SHIELD

12. Removethe water bypasshoseand positivecrankcase ventilation(PCV)hose. PCVHOSE

10x 1.25mm 44N.m{4.5kgf.m, 33 tbf.frl

P/S PUMPLOWER BRACKET

WATERBYPASS HOSE 1a

9 . Relievefuel pressure(seesectionl1). Do not smok6 while working on fuel @ system, keep open flam€ or spark away lrom work ar€a,Drainfuelonly into an approvedcortain€r.

1 0 . Removethe evaporativeemission (EVAP)control canisterhose,fuel feed hoseand breatherhose.

BANJOBOLT 33 N.m(3.4kgl.m.25lbf.ftl

WATEREYPASS HOSE

Removethe throttlecableand throttlecontrolcable by looseningthe locknut,then slip the cableend out of the throftlelinkage. NOTE; . Takecare not to bend the cableswhen removing them.Alwaysreplaceany kinkedcablewith a new one. . Adjustthe throttlecablewhen installing(seesectionI I ), . Adjust the throttle control cablewhen installing (seesection14).

WASHERS

BREATHER HOSE

CONTROL CABLE

6 -68

\.

14. Removethe upper radiatorhose, heater hose and water bvpasshose.

1 6 . Removethe spark plug caps and distributorform the cylinderhead. 1 7 . Removethe upperbracket.

WATERBYPASS

HEATER

NOTE: . Use a jack to supportthe engine before removing the upp€r bracketis removed. . Placea cushionbetweenthe oil panandthejack. 12x 1.25fin kgtm, 74N.m17.5 UPPERBRACKET

HOSE

andwlre 1 5 . Removethe enginewire harnessconnectors harnessclampsfrom the cylinderheadand the intake manifold.

a

a

a a a

\

Fourfuel injectorconnector Enginecoolanttemperature(ECT)sensorconnector ECTgaugesendingunit connector ECTswitchconnector ldle air control(lAC)valveconnector Manifold absolutepressure(MAP) sensor connector Throttlepositionsensorconnector Primary Heatedoxygen sensor (PrimaryHO2S) connecror VTECsolenoidvalveconnector

18. Removethe cylinderheadcover.

{cont'd)

6-69

CylinderHead Removal(cont'dl 1 9 . Removethe timing belt {seepage6-62).

24. Removethe camshaftholderplates,camshaftholders and camshafts.

20. Removethe backcoverand camshaftpulleys. CYLINDERHEAD PLUG Replace. t

BACKCOVER

\

\

CAMSHAFT HOLDERPLATE

1

€ i

\

b4

CAMSIIAFTS-

6xl.0mm 9.8 N,m (1.0kgf.m, 7.2 lbf.ft)

56 N.m (5.7kgf m, 41 tbt.f0

21, Removethe exhaustmanifold(seepage9-8). 22. Removethe intakemanifold(seepageg-5). 23. Loosenthe adjustingscrews.

Removethe cylinder head bolts, then remove the c y l i n d e hr e a d . CAUTION: To prevsnt warpage. unscrew the bolts in sequonc€1/3 turn at a tim€; lepeat lh6 sequence until all bolts aro loosened. CYLINDERHEADBOLTSLOOSENINGSEOUENCE:

No.4

6-70

INTAKE No.3 No.2

N o .1

RockerArms Removal '1. Holdthe rockerarmstogetherwith a rubberbandto preventthem from separating.

3.

S c r e w 1 2 m m b o l t s i n t o t h e r o c k e ra r m s h a f t s . Removeeach rocker arm set while slowly pulling out the intakeand exhaustrockerarm shafts.

RUEBERBAND

12 mm BOLTS

2.

Removethe intakeand exhaustrockershaftoil control orifices,then removethe VTECsolenoidvalve and the sealingbolts. ROCKERARM SHAFTS

NOTE:The shapesofthe intakeand exhaustoil control orificesare different,ldentifythe parts as they in the original are removedto ensurereinstallation locauons.

EXHAUSTROCKER SHAFTORIFICE Clean.

O.RING Replace.

O.RING

R e p l a c e ._ r

(lX

-dJ'v-l-<

-Y^\

INTAKE ROCKER ORIFIGE Clean.

/

/.

I

\

6-71

RockerArms Disassembly/Reassembly CAUTION: After installing the rocker shaft oritice, make suro thot the orifics is correctly installed in the hole of rocker shaft by trying to turn the rocker shaft. ll the orifice is in place, it should not turn. NOTE: . ldentifypartsas they are removedto ensurereinstallation in originallocations. . Inspectrockershaftsand rockerarms(seepage6-73). o Rockerarms must be installedin the samepositionif reused. . Cleanthe rockershaftorificeswhen installino. I

erior.to ,"installing,cleanarrthe partsin sorvent,dry them, and appryrubricantto any contactsurfaces.

INTAKEROCKERARM ASSEMBLIES CYLTNDERNUMBER y'///

SEALINGBOLTS20 mm 64 N m {6.5kg{.m,/t7 lbf.ftl

k r ROCKEN

a

RockerArms and Lost Motion Assemblies Inspection the primaryrockerarm,careNOTE:When reassembling fully apply air pressureto the oil passageof the rocker arm.

2.

Removethe lost motion assemblyfrom the cylinder head and inspectit. Test it by pushingthe 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 smoothly,replaceit.

PRIMARYROCKERARM MID ROCKERARM Push

I

LOSTMOTIONASSEMBLY

PISTONS

1.

Inspecteachrockerarm piston.Pushit manually -

lf it does not move smoothly. replacethe rocker arm assemDly.

PRIMARY

SECONDARY

Check prstonmovement

\

NOTE: . Apply oilto the pistonswhen reassembling. . Bundle the rocker arms with a rubber band to keepthem togetheras a set.

6-73

RockerArms and Shafts ClearanceInspection Measureboth the intakerockershaft and exhaustrocker shaft. 1.

Measurediameterof shaft at the first rockerlocatron.

3.

Measurethe insidediameterof eachrockerarm and checkfor out-of-roundcondition RockerArm-to-Shaft Clearance: Intakeand Exhaust Standard{Newl:0.025- 0.052mm {0.0010- 0.0020in) ServiceLimit: 0.08 mm {0.003in)

Surlaceshor/ldbe smooth.

Inspectrockerarm facefor wear. 2.

Zerogaugeto shaftdiameter. Repeatfor all rockers. - lf over limit, replacerockershaft and all overtolerancerockerarms. MICROMETER

6-74

NOTE:lf any rockerarm needsreplacement, replace all three rockerarms in that set {primary,mid, and seconoary).

Camshafts Inspection NOTE: . Do not rotatethe camshaftduringinspection. . Removgthe rockerarms and rockershafts. 'L

Putthe camshaftsand camshaftholderson the cylinder head.and then tightenthe boltsto the specified torque. SpecifiedTorque: O -@: 8 mm botts27 N.m {2.8kgf.m,20lbt'ft) Apply engineoil to the threads, O - @: 6 mm bolts 9.8 N.m (1.0 kgf m, 7.2 lbf'ft)

o o

o

o

o

oo

4.

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o

o o

Removethe bolts.then removethe camshaftholders from the cylinderhead. -

Lift the camshaftout of the cylinderhead,wipe c l e a n ,t h e n i n s p e c t h e l i f t r a m p s .R e p l a c et h e camshaftif lobes are pitted, scored,or excessively

-

Cleanthe camshaftbearingsurfacesin the cylin der head,then setthe camshaftbackin place, Inserta plastigagestrip acrosseachiournal.

-

Put the camshafton the cylinderhead.then install the camshaftholders,and then tighten the bolts to the specifiedtorque as shown in the left column on this page. R e m o v et h e c a m s h a f th o l d e r s ,t h e n m e a s u r et h e widestportionof the plastigageon eachjournal. Seatthe camshaftby pushingit toward the distributor end of the cylinderhead. Zerothe dial indicatoragainstthe end of the distributor drive. then push the camshaftback and fonh and readthe end play.

Camshaft-to-Hold€1Oil Clearsnce: Standard {Newl: 0.050- 0.089mm {0.002- 0.004inl S6rviceLimit: 0.15 mm 10,006inl PLASTIGAGE STRIP

CamshaftEnd Play: Standard{New}:0.05- 0.15mm {0.002- 0.006inl 0.5 mm (0.02in) Servicelimil:

\-

(cont'd)

6-75

Gamshafts Inspection(cont'dl 7.

lf the camshaft-to-holder oil clearanceis out of tolerance:

8.

Checkthe cam lobe height.

Cam lobe height standard (New):

-

And the camshafthas alreadybeenreplaced, you must replacethe cylinderhead. - lf the camshafthas not been replaced,first check the total runoutwith the camshaftsupportedon V-blocks. CamshaftTotal Runout: Standard(New):0.03mm {0.001in} max. ServiceLimit: 0.04 mm (0.002inl

INTAKE

EXHAUST

PRIMARY

33.088mm {1.3027in)

32.785mm (1.2907inl

MID

36.267mm (1.4278in)

35.720mm {1.4063in)

SECONDARY

34.978mm ( 1 . 3 7 7i1n l

3i1.691mm (1.3658in)

I Check thrs area lor wear.

-

lf the total runout of the camshaftis within toler, ance,replacethe cylinderhead. lf the total runout is out of tolerance.replacethe camshaftand recheckthe camshaftto,holderoil clearance.lf the oil clearanceis still out of tolerance,replacethe cylinderhead.

Cam Position INTAKE MID

TIB

T/B: TIMINGBELT PRI: PRIMARY MID: MID

EXHAUST SEC

MID

PRI

Valves,Valve Springs and Valve Seals Removal NOTE: ldentify valves and valve springs as they are removedso that eachitem can be reinstalledin its original Dosition. l.

3.

Installthe valve guide seal remover. VALVEGUIDESEALREMOVER COMMERCIALLY AVAILABLE ()R KD3350 Ltst-EP/N 571100

socketand plasticmalUsing an appropriate-sized retainer to loosenthe valve let, lightlytap the valve keeoers. PLASTIC

4.

Installthe valve spring compressor.Compressthe spring and removethe vSlvekeepers. VALVESPRING COMPRESSOR ATTACHMENT 07757- PJ1010A

Removethe valveguideseal.

Valve Dimensions

VALVESPRING ATTACHMENT COMPRESSOR EXTENSION OTMAF- PRgOIOA

lntake Valvo A Standsrd {Newl; 32.90- 33.10mm (1.295- 1.303in} B St ndard {New}: 101.00- 101.30mm (3.976- 3'988 in} C Stsndard (Nowl: 5./t5 - 5.,185mm (0.2156- 0.2159in) 5.445{0.21/l| in) C ServicoLimit D Siandard (N!w): 1.05- 1.35mm (0.041- O.05ilinl 0.85 mm {0.033inl D S€.vice Limit:

I COMPRESSOR Sn.p-onCFr1l

ExhaustValve A StandardlNewli 27.90- 28.10mm (1.098- 1.106in) B Stlndard {Nowl: 100.m - 1qr,90 mm {3.961- 3.972in) - 0.2150in) C Stsndard {Now}: 5.450- 5.,[60mm {0.21,16 inl 5.42010.213,0 C ServiceLimit D Standard {New): 1.65- 1.95mm (0.065- 0.077in) l.ils mm 10.057inl D SorvicoLimit:

6-77

Valve Seats Reconditioning 1.

Renewthe valve seats in the cylinder head with a valveseatcutter.

5.

NOTE:lf any guidesare worn (seepage6-79), r e p l a c et h e m ( s e e p a g e 6 - 8 0 )b e f o r ec u t t i n g t h e valveseats,

After resufacingthe 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 insertthe valve in its originallocat i o n i n t h e h e a d .t h e n l i f t i t a n d s n a p i t c l o s e d againstthe seatseveraltimes.

PRUSSIANBLUECOMPOUND

The actualvalve seatingsurface,as shown by the bluecompound,shouldbe centeredon the seat. . lf it is too high (closerto the valve stem),you must make a second cut with the 60. cutter to move it down, then one more cut with the 45. cutter to restoreseatwidth. . lf it is too low (closerto the valve edge),you must make a second cut with the 30. cutter to move it up. then one more cut with the 45. cutterto restore seatwidth. NOTE:The final cut should always be made with the 45"cutter, Carefullycut a 45oseat, removing only enough material to ensurea smooth and concentricseat. Bevel the upper edge of the seat with the 30" cutter and the lower edge of the seat with the 60. cutter. Checkwidth of seatand adjustaccordingly, Makeone more very light passwith the 45"cutterto removeany possibleburrs causedbv the other cutters. Valve Seat Width: Standard(Newl: 1.25- 1.55mm {0.0't9- 0.061in) ServiceLimii: 2.0 mm 10,08inl

7.

Insenthe intakeand exhaustvalvesin the headand measurevalvestem installedheioht. Intaka Valve Stem Installed Height: Standsrd lNaw): 37.465- 37.935mm (1./P50- r.4935inl SorviceLimit: 38.185mm 0.5033 in) Exhau3tValv€ Stem Installed Height: Standard (New): 37.165- 37.6i|5mm - 1.i1817 (1.46:t2 inl ServicoLimit 37.885(1.4915inl

SearWidrh

lf valve stem installedheight is over the servicelimit, replacethe valve and recheck.lf it is still over the service limit,replacethe cylinderhead;the valveseatin the h6ad is too deep.

6-78

(

CylinderHead

Valve Guides

Warpage

ValveMovement

oil clearances(seepage 475) NOTE:lf camshaft-to-holder the headcannotbe resurfaced. are not within specification,

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).

are within specificaoil clearances lf camshaft-to-holder tions,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), resurfacecylinderhead Maximum resurfacelimit is 0.2 mm (0.008in) based o n a h e i g h to f 1 4 2m m ( 5 . 5 9i n ) .

EDGE STRAIGHT PRECISION

lntake Valve Stem-to-GuideCl6arance: Standard(Newl:0.05- 0.11mm (0.0020- 0.0043inl ServiceLimit: 0.15 mm {0.0059inl ExhaustValve Stem-to-GuideClealance: StandardlNewl: 0.10- 0.16mm (0.0039- 0.0063inl ServiceLimit: 0.24 {0.0094in) Valveextended10 mm out from seat.

lf the measurementexceedsthe service limit, recheck usinga new valve. lf the measurementis now within the servicelimit. reassembleusingthe new valve lf the measurementstill exceedsthe limit. recheckusing the alternatemethod below.then replacethe valve and guide,if necessary.

Measurealongedges,and threeways acrosscenter'

Cylinder Head Height: - 142.05mm StandardlNewl: 1i11.95 15.589- 5.593in)

NOTE:An alternatemethod of checkingguide to stem clearanceis to subtractthe o.D. of the valve stem, measured with a micrometer,from the l.D. of the valve guide, measuredwith an insidemicrometeror ball gauge. Takethe measurementsin three placesalong the valve stem and three placesinsidethe valveguide. The differencebetweenthe largestguide measurement and the smalleststem measurementshould not exceed the servicelimit. lntake Valv€ Stem-to-GuideClsarance: Standard lNswl: 0.025- 0.055mm - 0.0022inl 10.0010 service Limit: 0.08 mm (0.003in) ExhaustValve Stem-to Guide Cl€arance: Standard {Newl: 0.050- 0.080mm {0.0020- 0.0031inl 0.ll mm (0.004in) ServiceLimit

6-79

t Valve Guides Replacement 1.

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

CAUTION: . Always wsar safety gogglesor a faceshield whsn driving valve guides. . Hold the air hammer dir€ctly in line with the valve guide to prevont damaging thg dtiver.

COMMERCIALLY AVAILABLE VALVEGUIDEDRIVER

rE-

87mm -L(3.43 inl I

sz mm tz.zrint

Workingfrom the camshaftside,use the driverand an air hammerto drivethe guideabout2 mm (0.1in) towardsthe combustionchamber.This will knockoff someofthe carbonand makeremovaleasier.

t

Turn the head over and drive the guide out toward the camshaftsideof the head.

t

10.8mm 10.42inl

ol

VALVEGUIOEDRIVER, 5.5mm 077,P- 0010100 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 t uidesand chill 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 evenlyheat the cylinder headto 300"F(150"C). Monitorthe temperaturewith a cookingthermometer. VALVEGUIOEDRIVER, 5.5mm 077{2- 0010100

-:^-,65i^q

NNSp-< CAUTION: . Do not use a torch; it may warp tho head. . Do not get tho head hotter than 300"F {150"C}; excesgiveheat may loosenthg valve seats. . To avoid burns. use haaw gloves whon handling the heatod cylinder head.

6-80

lf a valve guide still won't move. drill it out with a 8.0 mm (5/16in) bit,then try again. CAUTION: Drill guides only in extreme cases; you could damagothe cylinder head if ths guide br6aks. Removethe new guide(s)from the freezer,one at a time, as vou needthem.

Reaming 7.

Apply a thin coat of cleanengineoil to the outside of the new valve guide. Installthe guide from the camshaftside of the head; use the specialtool to drive the guide in to the specifiedinstalledheight.lf you haveall l6 guidesto do, you may haveto reheat thehead,

VALVEGUIDEDRIVER, 5.5mm - (x)l01(x) 077i12

NOTE:For new valveguidesonlY. 1.

Coatboth reamerand valveguidewith cuftingoil.

2.

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 r c l o c k w i s ew h i l e removingit from the bore Thoroughlywash the guide in detergentand water to removeany cuttingresidue. Checkclearancewith a valvelsee page6-73) .

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 ea n d exhaustvalveguideswithout exertlngpressure.

REAMERHANDLE

tr

A\

Turn r6amerin clockwisedirection

Valve Guide Installed Hoight: lntake: 12.55- 13.05mm {0.,194- 0.514in) - 0.51'lin) Exhaust:12.55- 13.05mm 10.494

a VALVEGUIDE VALVEGUIOEREAMER.5.5 mm OTHAH- PJTO1IIB

\

6-81

Valves Installation ( 1.

Coatthe valve stemswith oil. lnsertthe valvesinto the valveguides.

4.

NOTE: Checkthat the valves move up and down smoothly.

2.

l n s t a l lt h e v a l v e s p r i n g a n d v a l v e r e t a i n e r ,t h e n installthe valve spring compressor.Compressthe spring,and installthe valvekeepers. NOTE:Placethe end of the valvespringwith closely wound coilstowardthe cylinderhead.

Installthespringseatson the cylinderhead.

VALVESpRtNG COMpRESSOR ATTACHMENT 0775?_ pJlOl0A

Installthe valvesealsusingthe specialtool.

VALVESPRTNG COMPRESSORATTACHMENT EXTENSTON o?MAF- PR9010A

NOTE:Exhaustand intakevalvesealsare not interchangeable. WHITE SPRING

BRACK SPRING

VALVEGUIDESEALINSTALLER KD-28)g(Commercially available) NOTE:UsesmalllD end of tool,

5.

VALVESPRINGCOMPRESSOR lCommercially available) Snap-onCF711or KD-3tXl with #32JAWS Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and valve keepers. NOTE: Tap the valve stem only along its axis so you do not bend the stem.

VALVESEAL Replace.

VALVEGUIDESEALtNsTALLER KD-2899 NOTE:UsesmalllD end of tool

I

RockerArms lnstallation 1.

2.

l 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: . Valveadjustinglocknutsshouldbe loosenedand the adiustingscrew, backedoff before installatron. . The componentparts must be reinstalledin the originallocations. lnstallthe lost motion assemblies.

4.

Cleanand installthe rockershaft orificeswith 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 cylinderheadare not in line with each other,screw a 12 mm bolt into the rockerarm shaft and rotate the shaft. NOTE: The shapesof the rockershaft orificestor the intake and exhaust are different.The orific' must be installedin the properlocations.

3 . l n s t a l lt h e r o c k e ra r m s w h i l e i n s e r t i n gt h e r o c k e r arm shaft into the cylinderhead NOTE:Removethe rubberband after installingthe rockerarms.

ROCKER EXHAUST

ROCKER INTAKE SHAFTORIFICE Clean

SHAFTORIFICE

O.RING

O

12 mm BOLT

\

6-83

I Cylinder Head Installation lnstallthe cylinderheadin the reverseorderof removal:

2,

NOTE: . Alwaysusea new headand manifoldgasket. . The cylinderheadgasketis a metal gasket,Takecare not to bend it. . Rotatethe crankshaft, setthe No. 1 pistonat TDC(see page6-63). . 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 storangremoveditems. . Cleanthe middlecoverand lowercover beforeinstal_ lation. o Replaceany washersthat are damagedor deteriorated. 1.

Tightenthe cylinderhead bolts in two steps.In the first step, tighten all bolts in sequenceto about 29 N.m (3.0 kgf.m, 22 tbf.ftl. ln the final step, tighten in the samesequenceto 83 N.m (8.Skgf.m,6t lbf.ft). NOTE: . Apply clean engine oil to the bolt threads and underthe bolt head. . W e r e c o m m e n d u s i n g a b e a m - t y p et o r q u e wrench. When using a preset-typetorque wrench, be sure to tighten slowly and not to overtighten. . lf a bolt makesany noisewhile you are torquing it, loosenthe bolt, and retightenit from the 1ststep.

Installthe cylinderheadgasket,dowel pins and the headoil controlorificeon the cylinderhead.

CYLINDERHEADBOLTTOROUESEOUENCE

NOTE:Cleanthe oil controlorificewhen installing.

1 1 x1 . 5m m 83 N.m18.5kgf.m,61 tbf.ftl

DOWELPIN

Installthe intakemanifoldand tightenthe nuts in a cflsscrosspatternin two or three steps,beginning with the innernuts. . Alwaysusea new intakemanifoldgasket. 4.

6-84

Install the exhaust manifold and tighten the new self-lockingnuts in a crisscrosspattern in two or threesteps.beginningwith the innernuts. . Alwaysusea new exhaustmanifoldgasket.

5.

lnstallthe camshaftsand camshaftoil seals. NOTE: . lnstallthecamshaftswith the keywayfacingup. . lnstallthe oil sealwiththespring sidefacingin. . The oil sealhousingsurfaceshouldbe dry' . Set the O-ringand dowel pin in the oil passage of the No, 3 camshaftholder'

7-

lnstall the camshaftholders and camshaft holder plaIe. NOTE:The arrowsmarkedon the camshaftholders shouldpointto the timing belt. CAMSHAFT

CAMSHAFT OIL SEAL Replace.

Apply liquid gasket (P/N 08718- 0001 or 08718 1 and No. to the head mating surfacesof the 0OO3) N o . 5 c a m s h a f th o l d e r s o n b o t h t h e i n t a k e a n d exhaustside.

Tighteneach bolt two turns at a time in the sequence shown below. NOTE:Wipe off the excessliquid gasketfrom the No. 1 and No. 5 camshaftholderswith a shop towel (D - @: 8 x 1.25mm 27 N.|n (2.8ksf'm, 20 lbf'ft) Apply ongine oil to the throads. O O: 6 x 1.0 mm 9.8 N'm (1.0 kgfrm,7.2 lbf'ft) INTAKE

( Do

oo

o

o

o

NOTE:Cleanand dry the cylinderhead mating surfacesbeforeapplyingliquidgasket. - Apply liquidgasketto the shadedareas'

@

o

0

o

o o o

EXHAUST and camshaftpulleys. back cover lnstallthe {cont'd)

6-85

CylinderHead Installation(cont'dl \ 1 0 . A l i g n t h e m a r k so n t h e c y l i n d e rh e a d p l u g t o t h e cylinder head upper surface,then installthe cylin, der headplug in the cylinderhead.

14. Apply liquid gasketto the headcover gasketat the eight cornersof the recesses. NOTE: . Use liquidgasket,PartNo. 08718- 0001or 08718 - 0003. . Checkthat the matingsurfacesare cleanand dry beforeapplyingliquidgasket . Do not installthe parts if five 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 t i q u i d g a s k e t . Instead,reapplyliquid gasketafter removingold restdue. . After assembly.wait at least 30 minutesbefore f i l l i n gt h e e n g i n ew i t h o i l .

CYLINDEB HEAD

PLUG Replace. 1 1 . Installthe timing belt (seepage6-63). 1'

Adjustthe valveclearance(seepage6-61).

1 3 . Installthe head cover gasketin the groove of the c y l i n d e r h e a d c o v e r . S e a t t h e r e c e s s e sf o r t h e camshaftfirst, then work it into the groove around the outsideedges, NOTE: . Beforeinstallingthe headcovergasket,thoroughly cleanthe head cover gasketand the groove. . When installing,makesurethe headcovergasket is seatedsecurelyin the cornersof the recesses wrrn no gap. HEADCOVEB

6-86

(

15. When installingthe cylinder head cover, hold the headcovergasketin the grooveby placingyour fingers on the camshaft holder contacting surfaces (toDof 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 headcovergasket.

16. Tightenthe nuts in two or three steps.In the final step, tighten all nuts, in sequence,to 9 8 N'm {1 0 kgf.m,7.2 lbf.ft). NOTE: After assembly,wait at least 30 minutes beforefillingthe enginewith oil.

NOTE: . Be{oreinstallingthe cylinder head cover, clean the cvlinder head contacting surfaces using a shoPtowel. . Oo not touch the parts where liquid gasket was applied. . Replaceany washertaht is damagedor deter'orated.

t

1 7 . After installing,checkthat all tubes' hosesand connectorsare installedcorrectly.

\

6-A7

EngineBlock CylinderBlock ..............7-16 lnspec'tion ..........7-17 BoreHoning PistonPins ...,...........'.7-17 Removal .............7-18 lnstallation .'............7-19 Inspection ConnectingRods ................7-18 Selection Piston Rings 7'2O ..........".."' EndGap .........7-2O Repfacement 7 -21 ...........'.'. Ring-to-GrooveClearance 7'21 .......""'.. Afignment 7 -12 ................. CrankshaftOil Seal .............7-22 fnstaffation ."".........7-14 Crankshaft ..-.-..'.".'7'23 fnstaffation ......"'.....7-15 .............7-23 Oil Pan .............7-26 lnstallation

7-2 ..........." SpeciafTools 7-3 lllustlatedIndex ...................."..'.......... Flywheeland Drive Plate """'.' 7-7 Repfacement ConnectingRod and Crankshaft ..........."....7-8 End Play Main Bearings 7-9 ............... Clearance ................7-10 Selection ConnectingRod Bearings 7-11 ....'.......... clearance 7-11 ................ Selection Pistonsand Crankshaft Removaf Crankshaft Inspection Pistons Inspection fnstaffation

Oil Seals fnstaffation

r - f

....""""' 7-29

SpecialTools

Ref. No.

Tool Numbel

I

o

07LAB- PV00100 07749- 0010000 07947- SB00200 07948- SB00'101 07973- PE00200 07973- PE00310 07973- PE00320 07973- PE00400 07973- S800100 07973- 6s70500 07973- 6570600

aal

@

o @ 6'

@

o

R i n gG e a rH o l d e r Driver SealDriver DriverAttachment P i l o tC o l l a r PistonPin DriverShaft PistonPin DriverHead PistonPin BaseInsert PistonBaseHead PistonBase PistonBaseSpring

1-7 7-22,29 7.29 7-22,29 7-17,18 ' 7- 1 7 , 1a 7 - 1 1 ,1 A 7- 1 7 ,1 8 1 - 1 7 1, 8 7-17,18 7-17,18

Y(\!

a.:

ai

C a

Eg o

t0

arll \

7-2

a

lllustrated Index

I

runricateatt internalpartswith engineoil during reassembly'

NOTE: pumpcasebeforeinstallingthem' o Apply liquidgaskettothe matingsurfacesofthe right sidecoverand oil o r 0 8 7 1 8 0 0 0 3 ' . U s el i q u i dg a s k e tp, a r tN o 0 8 7 1 8 - 0 0 0 1 pan . Cleanthe oil pan gasketmatingsurfacesbetoreinstallingthe oil 81642 engine: DRAIN BOLT 44 N,m {4.5 kgf'm,33 lbt'ft)

OILPAN Reterto page7 27 when installing.

6 r 1 . Om m 12 N.m t1.2 kgl'm, 8 7 lbf'lt)

OIL PAN GASKET

6 x 1.0 mm ' 1 1N . m ( 1 . 1 k g I ' m , I tbl.ft) BUFFLEPLA

6 x 1.0 mm 1 1 N . m ( 1. 1 k g f . m , 8 tbI.fr)

12 x 1.0mm 103 N.m {10.5kgf'm, 76 tbr.ft) FLYWHEEL (M/TI

GASKET Replace. 1 1 x 1 . 5m m 76 N.m (7.9 kgf'm, 56 lbf'ft) Apply engineoil to the bolt threads. NOTE:After torqurng each cap, turn crankshaft to check for binding.

FLYWHEELCOVER IM/T) 12 x 1.0mm 74 N.m (7.5 kof.m, 54 lbf'ft)

d#*

MAIN EEARINGCAP

1^ c{Eb \%^ t*^

MAIN BEARINGS Selection,page 7_10 NOTE:New main bearingsmusl be selectedbY matchingcrank and block identificationmarkrngs

*o"rr^--(Wffi oa*,trto2,.w

CRANKSHAFT Installation, Page7'23

Check for cracks DRIVE PLATE COVER(AiT) 6x1.0mm l b f ' f t } I k g f ' m , 11 N.m {1.1

OIL JET BOLT 16 N.m 11.6 kgf'm, 12 lbl'ft) OIL JET Inspection, Page8_10 DOWEL PIN

OIL SEAL CRANKSHAFT Installation, pagesl22andl 29 ReplaceRIGHTSIDECOVER Apply liquidgasket to mating surface.

OILPUMP Overhaul,page8-'l1 Removal/lnspection, page8-13. Apply liquidgasket to matingsurlace.

8 x 1.25mm 24 N.m {2.4 kgf.m, 17 lbf'ft)

THRUSTWASHERS Groovedsidesface outward NOTE:Thrusr washer thickness is tixed and must not be changed by grindingor shimming

SEAL CRANKSHAFT O-RING Replace

11 N.m {1.1 kgf'm, a lbt.ltl

l n s t a l l a t i o n ,p a g e s 7 ' 2 9 a n d I 1 4 (cont'd) Heplace.

lllustrated Index (cont'dl I

,

Luoricateatt internalpartswith engineoil during reassembly.

NOTE: ' Apply liquidgasketto the matingsurfacesofthe rightside coverandoil pumpcasebeforeinstallingthem. . Use liquidgasket,part No. 08718- 0001or 087,18 _ OOO3. . Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit. D16Y7engine:

6 x 1.0mm DRAIN BOLT 12 N.m (1.2kgt.m. 44 N.m {4.5 kgt.m.33 tbt.ttl 8.7 tbf.tr) OIL PAN GASKET Replace. 6 x 1 . 0m m 12 N.m ('l .2 kgt.m, 8.7 tbt.trl WASHER Replace. OIL PAN Referto page7-27

FLYWHEEL COVER IM/T)

1 2 x ' 1 . 0m m 1 1 8N . m {12.0 kgt.m, 87 tbf.tr}

Apply liquidgaskerto these points. 1 1x 1 . 5m m 51 N.m 15.2kgl.m,38lbtftl Applyengineoilto the bolt threads. NOTE:Aftertorquing each cap, turn the crankshaft to checkfor binding.

MAIN BEARINGCAP MAIN BEARINGS Selection, page7-10 NOTE:New main bearingsmust be selectedby matchingcrank and blockidentification markings. CRANKSHAFT Installation, page7 23 6 r 1.0mm 1 1 N . m { 1 . 1 ksI.m, 8 lbt.ft)

Check for cracks.

CRANKSHAFT OIL SEAL Installation, pages1 22 a^d 7-29

OILSCREEN 6 x 1.0 mm 1 1 N . m 1 1 . 1kgt.m, 8 lbf.trl

\:eprace' 6 x 1 . Om m 11 N.m {1.1kgt.m, 8 rbt.frl

GASKET Replace. OILPUMP Overhaul,page8-12 Bemoval/lnspection, page8-13

DOWEL PIN

RIGHTSIDECOVER Apply liquidgasker 1o matrngsurface,

WASHERS CRANKSHAFT SEAL

l.j"Ji:l"^

pages --.S) z.2e

Replace. 6 x 1.0 mm 1 1 N . m{ 1 . 1 8 tbt.fr)

7-4

DOWELPIN

BREATHING PORTCOVER MOUNT BOLTS 6 x 1.0mm 1 1 N . m { 1 . 1 k g t . m ,8 t b f . f r } Apply liquidgaskerto the boh threads.

Grooved sides face outward. NOTE: Thrust washer thickness is fixed and must not be changed by grinding or shimming.

I I

(

D16Y5,D16Y8engines:

DRAIN BOLT 39 N.m 14.0 kgt'm, 29 lbl.tt) \

\^ 6 x 1 . 0m m

WASHER Replace.

Apply liquidgasketto these points.

q%

t 2 N . m 1 1 . 2k g f ' m , 8.7 lbl.ftl

OIL PAN Referto page7-25 when installing. FLYWHEELCOVER (M/T}

P

12 x 1.0mm 1 1 8N . m (12.0 kgt.m, 87 lbt'ft)

I

1 1x 1 . 5m m 51 N.m (5.2kgf'm, 38 lbf ftl Applyengineoiltothe bolt threads. NOTE:Aftertorquing eachcap,turn crankshaft to checkfor binding.

(M/TI FLYWHEEL

OII PAN GASKET Replace. DRIVEPLATECOVER {A/T or CVT)

MAIN BEARING

12 r 1.0mm 74 N.m 17.5 kgl.m, 54 lbf'ft)

MAIN BEARINGS page7-10 Selection, NOTE:New main bearingsmust be selectedby matchingcrank --------*-i6{\

DBIVEPLATE{A/T or CVTI Checkfor cracks

"nJ lr."i io"irriti"",ion-markings. CRANKSHAFT page7-23 Installation,

6 x 1 . Om m 11 N.m {1.1kgl'm, 8 tbl.ftl

6 r 1.0mm 11 N.m (1 1 kgf'm, I lbf'ttl

OIL SEAL CRANKSHAFT lnstallation, '1 pages7'?1 and '28 Replace.

OIL SCREEN RIGHTSIDECOVER Apply liquid gasket to mating surface.

GASKET Replace. OIL PUMP Overhaul,page8_12 Removal/lnspection, page8-13 Apply liquidgasket to mating surface.

OOWELPIN SEAL CRANKSHAFT pages7 29 Installation, O.RING and 8-14 Replace. Replace. 6 x 1.0 mm 11 N.m (1 1 kgl'm, 8 tbr.ftl

\

DOWEL PIN WASHEFS Groovedsidestace outward NOTE:Thrust washerthickness is fixed and must not be changed bV grindingor shimming.

BREATHINGPORT COVER MOUNT BOLTS 6 x 1 . Om m 11 f{..n (1.1 kgf'm, 8 lbf'fl) Apply liquidgasketto the bolt threads.

(cont'd)

7-5

lllustrated Index (cont'd) NOTE:New rod bearingsmust be selectedby matchingconnectingrod assemblyand crankshaftidentificationmarkings ( s e ep a g e7 , 1 1 ) . Lubricateall internalpartswith engineoil during reassembtv.

PISTONINSTALLATION DIRECTION: EXHAUST

4\/=\6\z\ \e/!rqrf/ INTAKE PISTONRINGS Replacement. page7-20 Measurement, pages7 20 andj-21 Alignment,page7-21 PISTONPIN Removal,page7,17 Installation, page7-18 Inspection, page7,19

CONNECTING ROD Endplay,page7-8 page7,18 Selection,

PISTON page7-15 Inspectron, NOTE:Betoreremovingthe piston,inspectthe top of the cylinderborefor carbonbuild-upor ridge.Bemoveridgeif necessary, page7-13

ENGINEBLOCK Cylinderboreinspection, page7-16 Warpageinspection, page7,'16 Cylinderbore honing,page7,17

CONNECTING ROD BEARINGS C l e a r a n c e ,p a g e 7 1 1 S e l e c t i o n ,p a g e 7 - 1 1

Inspecttop of eachcylinderbore for carbonbuild-upor ridge before removing piston. Removeridgeif necessary, page7-13

CONNECTING RODBEARINGCAP page7-23 Installation, NOTE:lnstallcapsso the bearing recessis on the samesideas the recess in the rod.

7-6

CONNECTING RODCAPNUT 816A2€ngin6: 9 x 0.75mm {0 N.m (4.1 kgt m, 30 tbf.ftl D16Y5,Dl6Y7. D16Y8engines: 8 x 0.75mm 3l N.m {3.2kg{.m, 23 tbt.fr) Applyengineoilto the bolt threads. NOTE:Aftertorquingeachbearing cap, rotate crankshaftto checkfor binding.

Flywheel and Drive Plate Replacement ManualTransmission: 816A2engine: Removethe eight flywheel bolts,then separatethe flyw 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 ' tiohtenthe bolts in the sequenceshown

Automatic Transmission: Removethe six drive platebolts,then separatethe drive tighten flange.Atter installation, olatefrom the crankshaft in a crisscross bolts the Pattern.

RINGGEARHOLDER"-i OTLAB PVOOlOO

rurS;u'.\

$..3s' RINGGEAB Inspectring gear teeth lor wear or damage.

12 x 1.0mm 74 N.m t7.5 kgl.m, 54 lbl'ltl

1 2 x 1 . 0m m 103 N.m (10.5 kgf.m, 76 lbf.tt)

D16Y5,D16Y7,D16Y8engines: Removethe six flywheel bolts,then separatethe flywheel tightenthe from the crankshaftflange.After installation, bolts in a crisscrossPattern. RINGGEAR Inspectring gear wear or teeth teetn lor wea( / danase. \ ,///.'

1 2 x 1 . om m 11 8 N , m (12.0kgI.m,87 lbf.ftl

L

7-7

ConnectingRod and Crankshaft EndPlay \ Connecling Bod End Play: Standard(Newl:0.15- 0.30mm - 0.012inl 10.006 ServiceLimit: 0.40mm (0.016inl

a lf out-of-tolerance. installa new connectingrod. a lf still out-of-tolerance,replacethe crankshaft(see

pages7-12and 7-23).

Pushthe crankshaftfirmly away from the dial indicator, and zerothe dial againstthe end of the crankshaft. Then pull the crankshaftfirmly backtoward the indicator;dial readingshouldnot exceedservicelimtr.

GrankshaftEnd Play: Standard (Newl: 0.10- 0.35 mm (0.00,f- 0.01,tinl Servic€Limit 0.it5 mm (0.018in) .

lf end play is excessive,inspectthe thrust washers and thrustsurfaceon the crankshaft.ReplaceDartsas necessary.

NOTE:Thrustwasherthicknessis fixed and must not be changedeitherby grindingor shimmrng. Thrust washersare installedwith groovedsidesfacing outward.

7-8

Main Bearings Glearance 1 . T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e . removethe main capsand bearinghalves. C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l f w i t h a cleanshop towel. Placeone strip of plastigageacrosseach main journ al . NOTE:lf the engineis still in the car when you bolt the main cap down to checkclearance,the weight of the crankshaftand flvwheelwill flaftenthe plastigage further than just the torque on the cap bolt. and give you an incorrectreading.For an accurate r e a d i n g ,s u p p o r tt h e c r a n kw i t h a j a c k u n d e r t h e c o u n t e r w e i g h t as n d c h e c ko n l y o n e b e a r i n ga t a time, 4.

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 on the next page),and rechsckthe clearance.

R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e bolts. lst step: 25 N'm (2.5kgl'm. 18 lbf'ft) FinalsteD: B16A2engine: 76 N.m (7.8 kgf.m, 56 lbf'ft) D16Y5,Dl6Y7, D16Y8engines: 51 N.m (5.2kgf'm, 38 lbf'ft) NOTE:Do not rotatethe crankshaftduring inspectron. Removethe cap and bearingagain,and measurethe widestpartot the plastigage.

CAUTION: Do nol fil€, shim, or scrapethe bearings or tho cap3to adiust cleatanc€. 7.

lf the plastigageshows the clearanceis still incorrect,try the next largeror smallerbearing(thecolor listedaboveor belowthat one),and checkagain NOTE: lf the proper clearancecannot be obtained by usingthe appropriatelargeror smallerbearings, replacethe crankshaftand start over.

Main Boaring-toJournal Oil Clearance: 816A2 engine: Standald {New}: No. l, 2, 4, 5 Journals: O.O2,l- 0.042mm 10'00(B- 0.0017in) No. 3 Journals: 0.030- 0.048mm {0'0012- 0'0019in) ServicoLimit: 0.06 mm {0.002in, Dl6Y5, Dl6\rr, Dl6Y8 engines: Standard (Nsw): No. 1,5 Journals: 0.018- 0.035mm {0.0007- 0'001'[ in) No. 2. 3, 4 Journals: 0.02,1- 0.0,(2mm {0'0009- 0.0017in} ServiceLimit: 0.05 mm (0.002in)

\

7-9

Main Bearing Selection CAUTION: lf the codes are indecipherablebecauseof an accumulationof dirt and dust, do not scrub them with a wire brush or scraper.Clean them only with solvent ol deiergent.

D16Y5,D16Y7,D16Y8engines: Lettershave beenstampedon the end of the blockas a codefor the sizeof eachof the 5 mainjournalbores. Use them, and the numbersstampedon the crankshaft (codesfor main journalsize),to choosethe correctbearIngs.

Crankshaft Bore Code Location 81642engine: Lettershave beenstampedon the end of the blockas a codefor the sizeof eachof the 5 mainjournalbores. 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 beaflngs.

\

Main Journal Code Location(Numbers) Main JournalCode Locations {Nombers or Barc)

Bearing ldentification Eearing ldentification C o l o rc o d e r s on lhe edgeof the bear ng.

B

Larger crank bore

c

a -----------""'

D

Smallerbeanngtlhrcker)

lr-l tt +#, t ll

l f '-

9""1

B':""

Black

Alack

Alue

c

D

Smaller bea ng {th'cker)

f

7-10

Ldrger crank bore

Color code on the edge of the bearing-

Smaller maan journal

4

Red

Pink

Pink

't t l

Green

Green Green

Green Brown

Brown

Brown

Black

Black

Elue

Smaller bearing {thicker)

\

I

ConnectingRod Bearings Clearance

Selection

'1.

C l e a nt h e c r a n k s h a frto d i o u r n a la n d b e a r i n gh a l f with a cleanshop towel.

CAUTION: lf the codes are indecipherable because of an accumulationof dirt and dust, do not sclub them with a wile brush or scraper.Cleanthem only with solvent or detergent,

Placeplastigageacrossthe rod journal.

ConnectingRod Code Location

the bearinghalfandcap,andtorquethe nuts. Reinstall

Numbershave been stampedon the side of each con necting rod as a code for the size of the big end Use them, and the lettersstampedon the crankshaft(codes for rod journalsize),to choosethe correctbearlngs

4.

Removethe connectingrod cap and bearinghalf

Torque Bl6A2 engine: 40 N.m (4.1 kgl.m, 30 lbf'ft) Dr6Y5,D16Y7,D16Y8enginss: 31 N'm (3.2 kgf.m, 23 lbf ftl NOTE| Do not rotatethe crankshaftduring inspection.

Half of number ls stampedon bearing cap and the other half is stampedon rod.

Removethe rod cap and bearinghalf and measure the widest part of the plastigage. ConnectingRod Bearing-to.JournalOil Glearance: 816A2engine: Standard lNewl: 0.032- 0.050mm - 0.0020in) 10.0013 inl ServiceLimit: 0.06mm 10.002 D16Y5,D16Y7,D16Y8engines: Standard lNew): 0.020- 0.038mm (0.0008- 0.0015in) 0.05 mm 10.002inl ServiceLimit

ConnectingRod Journal Code Locations(Lettels)

PLASTIGAGESTRIP

lf 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. CAUTION: Do not lile, shim, or scrapethe bearings or the caps to adiust clgarance. 7.

\

lf the plastigageshows the clearanceis still incorrect. try the next largeror smallerbearing(thecolor listed again. aboveor belowthat one),andcheckclearance NOTE: lf the Droperclearancecannot be obtained by usingthe appropriatelargeror smallerbearings, replacethe crankshaftand startover.

Bearing ldentilication Color code is on the edge of the bearing.

lfA--;T] | l l e " ' tl t;

Largerbrg end bore

----------------

l l c o r l l ll l

I lD;;ilril | l - l Smaller rod journal

2

1

Smaller bearlng (thicker)

Red

4

Smallerbearing{thrcker)

Pink

Pink

Green

3

Green Brown

Green

Green Erown

Black

Black

Blue

7-11

Pistonsand Crankshaft Removal \ 1.

Removethe oil pan assembly.

3.

Removethe oil screen.

2.

Removethe right sidecover.

4.

R€movethe oil pump.

816A2 engine

816A2engin€ OIL SCREEN

OILPUMP

D16Y5,Dl6Y7,D16Y8ongines

D16Y5,D1oyr, D16Y8engin.s

RIGHT SIDE

O-RING Replace.

5,

7-12

Remove the baffle plate (816A2 engine).

6.

Removethe boltsand the bearingcaps. CAUTION: To prevenl warpago unscrow lhe bolts in s€quence1/3 turn at a tims, r€paat the soquence until all bolts ar€ loo3ened.

q

Removethe upperbearinghalvesfrom the connecting rods and set them aside with their respective caos.

1 0 . Reinstallthe main caps and bearingson the engine in proper order,

MAIN BEARINGCAPBOLTSLOOSENINGSEOUENCE 1 1 . lf you can feel ridgeof metalor hard carbonaround t h e t o p o f e a c h c y l i n d e r ,r e m o v ei t w i t h a r i d g e reamer.Follow the reamer manufacturer'sinstrucI|ons. CAUTION; lf the ridge is not removed, it may damage tho pistons as they are pushod out. RIOGEREAMER

S:_]ILOJLOAO

7.

and main capvbearRemovethe rod caps/bearings in order. ings.Keepall caps/bearing

12. Use the wooden handle of a hammer to drive the Lift the crankshaftout of the engine,being careful not to damagejournals.

pastonsout.

1 3 . Reinstallthe connectingrod bearingsand capsafter rod assembly. removingeachpiston/connecting CRANKSHAFT

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

7-13

Crankshaft Inspection .

Cleanthe crankshaftoil passageswith pipe cleaners or a suitablebrush.

.

Checkthe keywayand threads.

Out-of-Roundand Tapet .

Alignment .

.

M e a s u r er u n o u t o n a l l m a i n j o u r n a l st o m a k e surethe crankis not bent. The differencebetweenmeasurementson each journalmust not be more than the servicelimit.

CrankshaftTotal IndicatedRunout:

Measureout-of-roundat the middle of each rod and main journalin two places.

a The differencebetweenmeasurementson each journalmust not be morethan the servicelimit. Joulnal Out-of-Round: 81642engine: Standard (New): 0.0004mm {0.0002in) max. ServiceLimit: 0.006mm {0.0002in) Dr6Y5, Dl6Y7, D16Y8engines: Standard (Newl: 0.0025mm (0.0001inl max. ServiceLimh: 0.005mm (0.0002inl

Bl6A2 engine: Standard (Newl: 0.020mm {0.0008in} max. ServiceLimit: 0.030mm {0.0012inl D16Y5,D15Y7,D15Y8engines: Standsrd{New):0.03mm (0.001in} max. ServiceLimit; 0.0i1mm 10.002in)

round at middle.

\

Support with lathe type tool or V blocks.

.

Measuretaper at the edgesof eachrod and main journal.

. The differencebetweenmeasurementson each journalmust not be more than the servicelimit. JournalTaDer: B16A2ongine: Standard lNewl: 0.005mm (0.0002inl max. ServiceLimit: 0.010mm (0.00i1inl D16Y5,D16Y7,Dl6YBengines: Standard (New): 0.0025mm {0.0001in) max. ServiceLimit: 0.005mm (0.0002in)

7-14

Pistons Inspection 1 . Checkthe pistonfor distortionor cracks, N O T E :l f a c y l i n d e ri s b o r e d .a n o v e r s i z e dp i s t o n must be used. Measurethe piston diameterat a distanceA from bottom of the skirt.

3.

Calculatethe differencebetweenthe cylinder bore diameter(seepage7-16)and the pistondiameter. Piston-to-CylinderClsarance StandardlNewl: 0.010- 0.0,10mm - 0.0016inl (0.0004 0.05 mm {0.002in} ServicoLimit:

816A2engino: A: 15 mm 10.6in) D16Y5,D16Y7,D16Y8engines: A: 5 mm (0.2inl Piston Diameter: 816A2engine: Standard lNewl: 80.980- 80.990mm - 3.1886in) 13.1882 (3.1878in) mm ServiceLimit: 80.970 D16Y5,D16Y7,D16Y8engines: Standard {New): 7,f.980- 7i1.990mm - 2.9521in! |.2.9520 ServiceLimit: 74.970mm {2.9516inl

lf the clearanceis near or exceedsthe servicelimit, inspectthe piston and cylinderblockfor excessive wear.

SKIRTDIAMETER

OversizoPiston Diametor 816A2ongine: 0.25t81.23- 81.21mm (3.1980- 3.1984inl D16Y5.D16Y7,D16Y8engines: O.25t75.23- 75.21mm (2.9618- 2.9622in) 0.50:75.i18- 75.49mm {2.9716- 2.9720in}

7 - 15

Cylinder Block Inspection 'L

Measurewearand taperin directions X andy at three levelsin eachcvlinderas shown.

lf the measurementsin any cylinderare beyond the OversizeBore ServiceLimit, replacethe block. lf the block is to be rebored.refer to piston ClearanceInspection(seepage7-15)after reboring. NOTE:Scoredor scratchedcylinderboresmust be honed. ReboringLimit: Bl642 enginc: 0.25mm (0.01in) Dl6Y5,D16Y7,D16Y8engin€s: 0.50 mm (0.02in) Checkthe top of the blockfor warpage, Measurealong the edges and acrossthe centeras shown. SURFACES TO BEMEASUREO

Cylinder Boro Size 816A2engine: Standard(Newl:81.00- 81.02mm {3.1t|:l- 3.190int ServiceLimit: 81.07mm {3.192in) D16Y5,D16Y7,D16Y8engines: Standard lNew): 75.00- 75.02mm (2.9s3- 2.954in) SarviceLimit: 75.07mm (2.956in) Oversize 816A2 engiDe: 0.25t41.25- A1.27mm {3.199- 3.200in) D16Y5,D16Y7,D16Y8Engines: 0.25t75.25-15.27 mm (2.9626- 2.963,0in) 0.50:75.50- 75.52mm 12.9721-2.9i32 inl Bore TaDet Limit: (Differencebetween first and third measure" ment) 0.05 mm (0.002inl

7-16

EngineBlockWarpage: Bl6A2 engine: Standard (Now):0.05 mm {0.002inl max. ServiceLimh: 0.08 mm (0.003in) DtOYs,D16Y7,D16Y8€nginas: Standard (N€w):0.07 mm l0.OO3inl max. ServicaLimit; 0.10 mm {0.00itin) PRECISION STRAIGHTEDGE

PistonPins

Cylinder Block

Removal

BoreHoning 1.

Measurecylinderboresas shownon page7-16.lf the block is to be reused,hone the cylindersand remeasurethe bores.

l.

Assemble the special tool as shown.

PISTONBASEHEAD 07973 - SBtx)too

f t

Honecylinderboreswith honingoil 8nd a fine (400 grit) stone in a 60 degreecross-hatchpattern.

PISTONPINBASE INSERT 01973- PE00'0)

NOTE: . Use only a rigid hone with 400grit or finer stone suchas Sunnen,Ammco,or equivalent. . Do not usestoneslhat are worn or broken.

rg\g lj*N*,"" 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 engine blockof all metal particles.Wash the cylinder bores with hot soapYwater, then dry and oil immediatelyto preventrusting. NOTE: Never use solvent.it will only redistributethe grit on the cylinderwalls.

2.

PISTONPINDRIVERHEAD 07973- PE00320 Proat

0

lf scoring or scratchesare still presentin cylinder bores after honing to the servicelimit, reborethe cylinderblock.

PISTON PIN DRIVERSHAFT 0t973 - PEqr310

NOTE:Some light verticalscoringand scratchingis acceptableif it is not deep enough to catch your fingernailand does not run the full lengthof the bore.

PILOTCOLLAR 07973 - PE00200

CYLINOESBLOCK

Emboss6dmark facing up

CYLINDER

NOTEi Us6 a hydraulic press. When pressingthe pin in or out. make sure that the recesssd portion of the piston aligns with the lips on the collar.

NOTE: . .

After honing,cleanthe cylinderthoroughlywith soapy warer. Onlv a scoredor scratchedcylinderbore must be noneo.

Assembleand adjust the length of the piston p t n driverand shaftto 53 mm (2.1inl as shown.

3.

Placethe piston on the sp€cialtool and press the pin out with the specialtools and a hydraulicpress.

7-17

ConnectingRods

PistonPins

Selection

Installation

Eachrod fallsinto one of four toleranceranges{fromOto + 0.024mm (0 to + 0.0009in), in 0.006mm (0.0002in) increments) dependingon the sizeof its big end bore.lt,s then stampedwith a number{1, 2,3, or 4) indicatingthe range. Y o u m a y f i n d a n y c o m b i n a t i o no t l , 2 , 3 , o r 4 i n a n y engrne.

1.

,

(

Usea hydraulicpressfor installation. .

Whenpressingthe pin in or out, be sureyou posi tion the recessed flat on the pistonagainstthe lugs on the baseattachment.

816A2engine

D16Y5,D16Y7,O16Y8engines The arrowmustfacethe timing beltsideo{ the engineand the connecting rod oil holemustfacethe rearof the engine.

NormalEoreSize:48.0mm (1.89in) NOTE: o Referencenumbersare for big end bore sizeand do NOTindicatethe positionof the rod in the engine. . Inspectconnectingrod for cracksand heatdamage.

The arrow must face the timing belt side of the e n gI n e .

ROD AORE CONNECTING REFERENCE NUMBER Half of numberis stampedon bearingcap, the other half on connectrngrod.

The markmustface the timing beltside o f t h ee n g i n e .

a

PISTONPIN DRIVERHEAD

Adjustthe lengthof the pistonpin driverto 53 mm (2.094n) PISTONPINDRIVERSHAFT 07973-PEOo3r0

il--Z

P,"roNPrN PILOTCOLLAR 07973-PE00200

PISTONPINBASE INSERT 07973 PEO0400 PISTONEASE HEAO 07973-5800100

7-18

lnspection 1.

Measurethe diameterof the pistonpin.

3.

NOTE:Checkthe pistonfor distortionor cracks.

Piston Pin Diametel: B16A2engine: Standard{New):20.994- 21.000mm Oversize:

clearance. Measurethe pistonpin-to-piston

lf the pistonpin clearanceis greaterthan 0.024mm ( 0 . 0 0 0 9j n ) , r e m e a s u r eu s i n g a n o v e r s i z e dp i s t o n pin.

- 0.8268in) (0.8265 20.997- 21.003 - 0.8269inl 10.8267

Piston Pin-to-PistonClearance: Standard(New):0.010- 0.022mm (0.0004- 0.0009in)

D16Y5,Dl6Y7,Dl6YBengines: StandardlNewl: 18.99,1-19.000mm (0.7478- 0.7480inl 18.997- 19.003 Oversize: {0.7479- 0.7481in) pistonpins are overslze. NOTE;All replacement

4.

2.

Zerothe dial indicatorto the pistonpin diameter'

Checkthe differencebetweenthe pistonpin diameter and the connectingrod smallend diameter' Piston Pin-to-ConnestingRod Interterence: 816A2engine: Standard(New):0.013- 0.032mm (0.0005- 0.0013in) D16Y5,D16Y7,Dl6YBengines: SiandardlNewl; 0.014- 0.040mm

- 0.0016 inl 10.0006

7-19

PistonRings EndGap

Replacement

1 . Using a piston, push a new ring into the cylinder bore 15- 20 mm (0.6- 0.8 in) from the bottom.

1.

Cleanall ring groovesthoroughly.

Measurethe pistonring end-gapwith a feelergauge: . .

Socond Ring 816A2 ongina Standard (Nowl: 0.40- 0.55 mm - 0.022inl 10.016 ServiceLimit: 0.70 mm (0.028inl D16Y5,D16Y7,Dt6Y8 engines Standard (New): 0.30- 0.ia5mm {0.012- 0.018in) SorviceLimit 0.70 mm 10.028inl Oil Ring 81642 ongine Standard {Now): 0.20- 0.50 mm (0.008- 0.020inl SorvicoLimit: 0.70 mm (0.028in) Dl6Y5. Dl6Y7, D16Y8€nginos Standard (Nowli 0.20- 0.70 mm (0.008- 0.028inl ServicaLimit: 0.80 mm 10.031in)

7-20

NOTE: . U s e a s q u a r e d - o fbf r o k e nr i n g o r r i n g g r o o v e cleanerwith bladeto fit pistongrooves. o Top ring grooveis 1.0mm (0.039in)wide. . Secondring grooveis 1.2mm (0.047in) wide. . Oil ring grooveis 2,8 mm (0.11in) wide. . Filedown the bladeif necessary.

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 page7-16, lf the bore is over the servicelimit, the cvlinder blockmust be rebored.

Pkton Ring End-cap: Top Ring 81642 engino Siandtrd (New): 0.20- 0.35 mm {0.008- 0.01,1in) ServiceLimit: 0.60 mm l0-02i1inl D16Y5.Dl6Y7, D16Y8enginos Standard lNewl: 0.15- 0.30 mm {0.006- 0.012in) Ssrvic€ Limit 0.60 mm {0.024inl

Usinga ring expander.removethe old pistonrings.

CAUTION: Do noi use a wire blush to clean ring lands. or cut ring lands deepol with cleaning tool. NOTE:lfthe pistonis to be separatedfrom the connectingrod, do not installnew ringsyet. 3.

Installnew rings in the proper sequenceand positaon(seepage7-22). NOTE:Do not reuseold pistonrings.

(Commercially available)

Clearance Ring-to-Groove

Alignment

After installing a new set of rings, measure ring-togrooveclearances:

1.

Top Ring Clearance Standard (New): B16A2angine: in) 0.045- 0.070mm (0.0018- 0.(X128 Dl6Y5, Dt6Y7, Dl6Y8 engin€s: 0.035- 0.060mm {0.0014- 0.002'lin) service Limit: 0.13 mm (o.fixi in)

Installtheringsas shown. NOTE: The manufacturingmarks must be facing upward. TOP RING(Chrome)

SecondRing Clearance Standard lNow): B16A2engine: 0.0/t0- 0.065mm (0.0016- 0.0026in) Dl6Y5, D16Y7,D16Y8onginos: 0.030- 0.055mm (0.(X)12- 0.0022in) Sewica Limh: 0.13 mm (0.005io) SECONDRING(Darkl Piston Ring Dimsnsions:

t----T

l

f

B

t---f_-L A

U n i tm m ( i n )

Top Ring (Standard)

B Bl642 engine

3 . 1( 0 . 1 2 )

1.0(0.04)

D16Y5,D16Y7, D16Y8engines

2 . 6( 0 . 1 0 )

1.0(0.04) U n i tm m ( i n )

SecondRing(Standard)

B

.,o

816A2engine

3 . 3( 0 . 1 3 )

1.2(0.05)

D16Y5,D16Y/. D16Y8engines

3 . 0( 0 . 1 2 )

1.2{0.05t

(cont'd)

7-21

PistonRings

CrankshaftOil Seal

Alignment(cont'dl

Installation

,

The sealsurfaceon the blockshouldbe dry. Apply a light coat of oil to the c.ankshaftand to t h el i po f t h es e a l .

MARK TOP RING ---.>

1. SECONDRING>

Drivethe crankshaftoil seal squarelyinto the right sidecover usingthe specialtools. HANDLEDRIVER 07749 0010000

,a-)

/\_4

o,.r^o( qffi<--sPACER \Z-.

v

Rotatethe rings in their groovesto makesure they do not bind. Positionthe ring end gapsas shown: seal with the

SECONDRINGGAP

DO NOTpositionany ring gap at pistonthrustsurfaces.

pan number side facing out.

C o n f i r m t h a t t h e c l e a r a n c ei s e q u a l a l l t h e w a y aroundwith a feelergauge. - 0.8 mm (0.02- 0.03inl Clearance:0.5 Approx.90

TOP RINGGAP DO NOTpositionany ring gap in linewith the pistonpin hole.

OIL RINGGAP

NOTE:Referto page 8-14 for installationof the oil pumo sidecrankshaftoil seal.

7-22

\

(

Grankshaft

Pistons

lnstallation

lnstallation

Beforeinstallingthe crankshaft,apply a coat of engineoil to the main bearingsand rod bearings.

B e f o r ei n s t a l l i n gt h e p i s t o n s ,a p p l y a c o a t o f e n g i n eo i l t o t h e r i n g g r o o v e sa n d c y l i n d e r bores.

Insertthe bearinghalvesinto the cylinderblockand connectingrods. 2 . Holdthe crankshaftso the rod journalsfor cylinders No.2 and No. 3 are straightdown. 3 . Lowerthe crankshaftinto the block,seatingthe rod journalsinto connectingrods No. 2 and No. 3, and installthe rod capsand nutsfinger-tight. 1.

1.

2.

lf the crankshaftis alreadyinstalled: . Setthe crankshaftto BDCfor eachcylinder. . Removethe connectingrod caps,and slip short sectionsof rubber hose over the threadedends of the connectingrod bolts. . lnstallthe ring compressor.checkthat the bearing is securelyin place,then positionthe piston in the cylinder,and tap it in using the wooden h a n d l eo f a h a m m e r . o Stop after the ring compressorpops free, and journal aligncheckthe connectingrod-to-crank ment beforepushingthe pistoninto place . Apply engine oil to the bolt threads.Installthe rod capswith bearings,and torquethe nuts to: 815A2engine: 40 N.m {,1.1kgf.m, 30 lbf'ft| D16Y5,D16Y7,D16Y8engines: 31 N.m (3.2kgf'm,23lbf'ft) lf the crankshaftis not installed: installthe ring . Removethe rod capsand bearings, then positionthe pistonin the cylincompressor, der, and tap it in using the wooden handleof a hammer. . Positionall Distonsat top deadcenter.

Groovedsidesface oulward. Botatethe crankshaftclockwise,seat journals into connectingrods No, 1 and No.4, and installthe rod capsand nutsfinger-tight. NOTE:Installcaps so the bearingrecessis on the sameside as the recessin the rod. 5.

The arrcw must face the tamingbelt side of the engine.

Checkrod bearingclearancewith plastigage(see p a g e7 - 1 1 )t,h e n t o r q u et h e c a p n u t sA. p p l y e n g i n e oil to the bolt threads. Torque: 816A2 sngine: /l{, N.m {a.l kgf.m, 30 lbf'ftl D16Y5,D16Y7,Dl6Y8 engines: 31 N.m (3.2 kgf.m, 23 lbf'ft|

ROO CONNECTING OILHOLElD16Y5,D16Y7,D16YBongines)

NOTE: Referencenumbers on connectingrod are for big-endbore toleranceand do not indicatethe positionof pistonin the engine. RUBBER

NOTE:Maintaindownwardforce on the ring compressorto preventthe rings from expandingbefore enteringthe cylinderbore.

,lll Lineup the markswhen i n s t a l l i n gt h e c o n n e c t r n g r o d cap.

6.

Installthe thrust washerson the No. 4 journal.Oil (cont'd) the thrustwashersurfaces,

7-23

Crankshaft Installation(cont'd) 7.

I n s t a l l t h em a i nb e a r i n gc a p s . Checkclearancewith plastigage(seepage7-9),then tightenthe bearingcap boltsin 2 steps.

NOTE: . Useliquidgasket,part No.08718- 0001or087180003. . Checkthat the mating surfacesare cleanand dry beforeapptyingliquidgasket. . Apply liquidgasketevenly,beingcarefulto cover all the matingsurface. . To preventoil leakage,apply liquidgasketto the innerthreadsof the bolt holes. . Do not installthe parts if five minutes or more haveelapsedsinceapplyingthe liquidgasket. Insteadreapplyliquid gasketafter removingthe old residue. . After assembly,wait at least30 minutesbefore f i l l i n gt h e e n g i n ew i t h o i l .

First step: 25 N.m {2.5 kgf.m, 18 lbf.ft) Secondstop: B1642engine: 76 N.m {7.8 kgf.m, 56 lbf.ft) D16Y5,D16Y7,D16Y8engines: 51 N.m (5.2 kgf.m, 38 lbf.ft) NOTE: Coat the thrust washer surfacesand bolt threadswith oil. MAIN BEARING CAPBOLTSTIGHTENING SEOUENCE

o

o

c

o

o L

Apply liquid gasketto the block mating surfaceof the right side cover,then install it on the cylinder block. Bl6A2 engine;

:V

fr\-/.---\-/.-

CAUTION:Whenever any crankshaft or connecting rod bearing is replaced,it is necGssaryafter reassombly to run the engine at idling spe6d until it reaches normal operating temperature,than continue to run it for approximately15 minutos.

Apply tiquid gaslet along the broken line.

D16Y5,D16Y7,D16Y8engines:

RIGHTSIDECOVER

7-24

9.

81642ongin€: RIGHTSIDE

Apply liquid gasketto the oil pump mating surtace of the block,then installthe oil pump on the cylinder block. Apply greaseto the lips of the oil seals. Thgn, align the inner rotor with the crankshaftand i n s t a l lt h e o i l p u m p . W h e n t h e p u m p i s i n p l a c e , clean any excessgreaseoff the crankshaft.Check that the oil seallips are not distorted. B16A2ongino:

DOWELPINS

D16Y5,Dl6fr, Dl6Y8 engines:

Apply liquidgasketalong the brokenline,

Dl6Y5,Dl6Y7,Dt6Y8ongino3: Apply liquid gasket alongthe broken

6 x 1.0 mm 1 1 N . m { 1 . 1 k9l.m, a rbf.ft)

OIL PUMP }{OUSING

OOWEL PIN

{cont'd)

7-25

Crankshaft

Oil Pan

(cont'd) Installation

Installation

NOTE: . Apply a light coat of oil to the crankshaftand io t h e l i po f s e a l . . U s e n e w O - r i n g sa n d a p p l y o i l w h e n i n s t a l l i n g them. 1 0 . l n s t a l l t h eo i l s c r e e n .

D16Y5,Dl6Yg engines: 1.

I n s t a ltlh e o i l p a ng a s k eot n t h e o i l p a n .

OIL PAN

816A2engine: 6 x 1 . Om m l l N ' m ( 1. 1 k g l . m , 8 tbt.Irl

,.// {

(..ao

/

cor*rt Replace.

t(^^

1 1 N . m 1 1. 1 k g f . m ,

a lbl'ltl tbt4tl ,/ .rB /

*P/

OIL PAN GASKET Replace.

& ^/t

I

O.RING Replace. OtL PutitP

24 N.m (2.4kgf.m, '17 lbl.fr)

D16Y5, D16Y7, D16Y8 engines: 6x1.0mm 1 1 N . m { 1 . 1k g f . m ,

6 x 1.0mm 1 1 N . m { 1. 1 k g f . m , a lbf.fr)

DOWELPIN

rl l Te

OIL PUMP / 6 x 1.0mm 11 N.m l l.1 kgf'm, a lbf.frl

7-26

8 tbt.rr) I

I

OIL SCREEN

2.

Apply liquid gasketto the blockmating surfacesof the oil pan,then installit. Apply liquid gasketto the shadedareas. NOTEI . U s e l i q u i d g a s k e tp a r t N o . 0 8 71 8 - 0 0 0 1 o r 08718- 0003. . Checkthat the matingsurfacesare cleanand dry beforeapPlyingliquidgasket. . Apply liquid gasketas an even bead, centered betweenthe edgesol the matingsurface' . To preventleakageof oil, apply liquid gasketto the innerthreadsof the bolt holes . Do not installthe parts if five minutes or more haveelapsedsinceapplyingthe liquidgasket lnstead,reapplyliquid gasketafter removingthe .

old residue After assembly,wait at least 30 minutes before f i l l i n gt h e e n g i n ew i t h o i l .

816A2, D16Y7engines: t n t h e o i l p u m p a n d r i g h ts i d e 1 . A p p l y l i q u i dg a s k e o covermatingareasas shown below. NOTE: . U s e l i q u i d g a s k e t ,p a r t N o . 0 8 7 1 8- 0 0 0 1o r 08718- 0003. . Checkthat the matingsurfacesare cleanand dry beforeapplyingliquidgasket . Apply liquid gasket as an even bead, centered betweenthe edgesol the matingsurface' . To preventoil leakage,apply liquid gasketto the innerthreadsof the bolt holes . Do not install the parts if five minutes or more haveelapsedsinceapplyingthe liquidgasket Instead,reapplyliquid gasketafter removingthe old residue. . Aftel assembly,wait at least30 minutes before filling the enginewith oil.

CYLINDER ELOCK

Apply liquid gasket to these pornts-

OIL PAN

3.

T i g h t e nn u t s f i n g e r - t i g h ta t s i x p o i n t s a s s h o w n below.

Apply liquid gasket to these pornts.

4.

I

Tighten all bolts and nuts, startingfrom nut @, clockwisein threesteps. tighteningcan causedistortionof NOTE:Excessive gasket oil leakage. pan and the oil Torque:12 N'm {1.2kgt'm,8.7lbf'ft|

(cont'd)

7 -27

Oil Pan lnstallation(cont'dl \ Installthe oil pan gasketand oil pan

3,

NOTE: a Usea new oil pan gasket. . I n s t a l lt h e o i l p a n n o m o r e t h a n f i v e m i n u t e s afterapplyingliquidgasket.

Tightenthe bolts and nuts finger tight at six points as shown below.

816A2 engine:

4.

OIL PAN GASKET R€place.

T i g h t e na l l b o l t s a n d n u t s , s t a r t i n gf r o m n u t O . clockwise in threesteps. NOTE:Excessive tighteningcan causedistortionof the oil pan gasketand oil leakage. Torque: 12 N.m {1.2 kgf.m, 8.7 lbf.ft)

Apply liquid gasKet to these points.

Apply liquid gasker to these points.

7-28

OIL PAN GASKET Beplace.

Oil Seals lnstallation NOTE: . Engineremovalis not required. . The crankshaftoil sealhousingshouldbe dry. Apply a light coat of greaseto the crankshaftand to the lips of the seals. 1.

U s i n gt h e s p e c i atl o o l , d r i v e i n t h e t i m i n g p u l l e y e n d s e a l u n t i l t h e d r i v e r b o t t o m sa g a i n s tt h e o i l pump. When the seal is in place,clean any excessgrease off the crankshaftand checkthat the oil seal lip is not distorted.

2.

Measurethe flvwheel-endsealthicknessand the oil sealhousingdepth.Usingthe specialtool. drive the flywheel-endseal into the rear cover to the point where the clearancebetweenthe bottom of the oil sealand the right side cover is 0.5- 0.8 mm (0.02 (see page 7-23). 0.03in) NOTE:Align the hole in the driver attachmentwith the Dinon the crankshaft.

DRIVER 07749-0010000

07947 -S800200 lnstallseal with the part numbersade facing out.

DRIVERATTACHMENT 0794a-s800101 lnslall seal with the part number side facing out.

I

7 -29

EngineLubrication "'.""".8'2 .......... SpecialTools .'..'8-3 lllustratedIndex........... EngineOil 8-6 .....'......"....."'. Inspection 8-7 Replacement........'......".'.'..."...."......" OilFilter 8-8 Rep1acement...............".'...'..'.....'.'...". Oil Pressure '.....'8-9 Testing engine) OilJet (B16A2 ...'.'......"...."'..8-10 Inspection OilPump 8-11 .....'...'..'."""' overhaul.'... ..'....8-13 Removal/lnspection/lnstallation

SpecialTools \ Ref. No.

Toot Number

I

07746- 0010400 07749- 0010000 0 7 9 1 2- 6 1 1 0 0 0 1

o

Attachment,52 x 55 mm Driver Oil FilterWrench

6\

,6

\ ll

\

8-2

a

lllustrated Index CAUTION: Do not overiighten the drain bolt.

NOTE: . Usenew O-ringswhen reassembling . Apply oil to O-ringsbeforeinstallation . Use liquid gasket,Part No 08718- 0001or 087180003. . Cleanthe oil pan gasketmating surlacesbefore installWASHER Ing. RePlace'

6x1.0mm 12 N.m (1.2kqtm,8.7 lbl.ftl

B1642 engine: DRAINBOLT 44 N.m (4.5kgl'm,33 lbt'ft) Do not overtrghten.

OIL PAN Relerto page 7'27 when installing. OIL PAN GASKET Replace-

6x1.0mm 11 N.m (1.1kgtm, 8

OIL BREATHER CHAMEER

6x1.0mm 11 N'm (1.1 kgl.m,8 lbf.ft)

otL SCREEN GASKET Replace. BAFFLEPLATE OIL JET BOLT 16 N'm 11.6kgf.m, 12lbt'ttl

€!

fl

OIL JET page8-10 Inspection,

[50

8x1+5mm 24 N.d\l2.il kgf.ft, t7 tbtft)

Replace.

OIL FILTER R e p l a c e m e n l ,p a g e 8 - 8

Replace. SWITCH ENGINEOIL PRESSURE PipeTaper)28 Threads/inch Useproperliquidsealant.

Clean

6x1.0mm 11 N.m 11.1kgt m, 8 tbt.frl Overhaul.page8'11 Removal/lnspection, Page8-13 Apply liquidgasketto matingsurfaceof engineblock

(cont,d)

8-3

lllustrated Index (cont'dl NOTE: . Usenew O-ringswhen reassembling. . Apply oil to O-ringsbeforeinstaltal|on. . Use liquid gasket,Part No. 08718 0001 or 0e719 0003. . Cleanthe oil pan gasketmatingsurfacesbeforeinstall_ ing. . Apply liquid gasketto the recessesof the oil pan gas ket (seepage7-27).

CAUTION: Do not overtighten the drain bolt. ENGINEOILPBESSURE SWITCH 18 N.m (1.8kgtm, 13 tbt.trl 1/8in. BSPT(British StandardPipeTaper) 28 threads/inch. Use properliquidsealant.

D16Y7€ngine:

OILPUMP Overhaul,page8-12 Inspection, page8 13 Apply liquidgasker to the matingsurface of the block.

O-BING OILBREATHER Replace. CHAMBER 6x1.0mm '11N.m 1.1ksnm, { 8 tbtft)

DOWELPIN

ll 6x1.0mm 1l N.m {1.1kgf-m, 8 tbf.ftl

OIL PAN

GASKET Bepiace.

OIL PAN R e f e rt o p a g e 7 - 2 7 when installing.

6x1.0mm 1 1N m ( 1 . 1k g t . m , A p p l y l i q u i d g a s k e t t o 8 tbl.ftl

6 x 1 . 0m m l2 N.m {1.2kgtm, 8.7tbf.ft)

DRAINBOLT 44 N.m {4.5kgtm, 33 tbf.ft} Do not ovenighten.

8-4

a

NOTE: . Use new O-ringswhen reassembling. . Apply oil to O-ringsbeforeinstallation. . Use liquid gasket,Part No 08718- 0001 or 08718 .

CAUTION: Do not overtightsn the drain bolt.

SWITCH ENGINEOIL PRESSURE 18 N,m l'1.8kgf.m, 13 lbf.ftl 1/8in. ESPT(British StandardPipeTaper) use 28 Threads/inch. properliquidsealant.

0003. Cleanthe oil pan gasketmatingsurfacesbeforeinstallIng.

D16Y5,D16Y8engines:

O.RING Replace.

O-RING OIL BREATHER CHAMBER

OILPUMP Overhaul,Page8 12 Inspection, Page8 13 OOWELPIN Apply liquidgasket to the matingsurface of the block.

6x1.0mm 11 N.m {1.1kgf.m, I tbt'ftl

FILTER page8_8 Replacement, 6 x ' 1 . 0m m 11 N.m ('1.1| 8 tbf.ft) BAFFL€PLATE GASKET Replace.

6x1.0mm 11N.m 11.1kgl.m, 8 tbf.ftl

OILPAN GASKET Feplace. 6x1.0mm 11 N.m 11.1kg{'m, 8 rbf.ftl

OIL PAN Relerto page7 26 when installing.

\3

BOLT 39 N.m (4.0kgf.m.29lbtftl Do not overtighten.

\

6x1.0mm 12 N.m {1.2kg{.m,8.7lbf ftl

8-5

EngineOil Inspection

Replacement

1 . Parkthe vehicle on level ground, and turn off the engine.Allow the oil a few minutes to drain back into the oil pan so the dipstickwill show the actual level. Make certainthat the oil level indicatedon the dip_ stick is betweenthe upper and lower marks. lf the level has dropped close to the lower mark. add oil until it reachesthe uppermark.

CAUTION:Removothe drain boli carefully while lho engine is hot; the hot oil may causoscalding. :1. Warm up the engine. 2.

Drainthe engineoil. 81642,D16Y7engin€s:

CAUTION: lmert thc dipstick car€fully to avoid b€nd_ ing it. Bl6A2 angin.:

,,7.fp--)*,".

rowrn-u

l

DRAINBOLT {rl N.m (4.5 kgf.m,33 tbt ft} Do not overtighten. D16Y5, Dl6Y8 6ngin93:

WASHER

D16Y5,D16Y7,Dt6y8 ongines:

DRAINBOLT 39 N.m 14.0kgfm, 29 tbf,f0 uo not overtighten.

8-6

3.

Reinstallthe drain bolt with a new washer.and rbfill the enginewith the recommendedoil.

"Energy Requirement API ServiceGrade:Use an Conserving"SJ gradeoil or an "EnergyConservingll" SH gradeoil, SAE5W - 30 preferred You canalsousean oil that bearsthe mark. APICERTIFICATION Capacity

engine: [atolz 3.7f (3.9US qt,3.3 lmp qtl I at oil change. qtl J 4.0r 9.2 US qt, 3.5 lmp filter' including change, at oil I ( 5 . 1U s q t , 4 . 2l m p q t ) | 4 . 8f overhaul engine after I I Dl6Y7 engine: 3.6f (3.8US qt, 3.2 lmP qt) filter. I at change.including (3.5US qt,2.9 lmP qtl f 3.3 I filter. I at change,without ( 4 . 5u s q t , 3 . 8l m p q t l 4 . 3 f I I afterengineoverhaul. J D16Y5,D16Y8engines: L 3.3{ {3.5US qt,2.9 lmp qt} filter. I at change,including ( 3 . 2 q t , 2 . 6 l m pq t ) U S 3.01 withoutfilter. at change, I 3.7{ (3.9US qt,3.3 lmp qt} - '1.€fter engineoverhaul.

MARK API CERTIFICATION

API SERVICELABEL

Every7,500miles(12,000km) or 12months(NormalConditions). Every3,750miles(6,000kml or 6 months (SevereConditions).

Change

Run the engine tor more than three minutes,then checkfor oii leakage

NOTE:Under normalconditions,the oil filter should be replacedat every other oil change Under severeconditions,the oilfilter shouldbe replacedat eachoil change' The numbersin the middle of the API Servicelabeltell you the oil's SAE viscosityor weight Selectthe oil for vour car accordingto this chart: Ambient Temoerature

30

20

-10

0

10

20

30

4OoC

A n o i l w i t h a v i s c o s i t y o f 5 W - 3 0 i s p r e f e r r e df o r improvedtuel economyand year-roundprotectionin the car.You may usea 10W- 30 oil if the climatein your area is limitedto the temperaturerangeshownon the chart'

8-7

Oil Filter Replacement After the engine has been run, the exhaust pipe will be hot; be careful when working around ihe exhaust pipe. Be careful when loosening the drain bolt whils the engine is hot. Burns can resuh becausethe oil temperatu16is very high. l.

Installthe oil filter by hand. Afterthe rubbersealseats,tightenthe oil filterclock_ wise with the oil filterwrench. Tighten: 7/8 tu.n clockwise. Tightening tolque: 22 N.m (2.2kgt.m, 16lbf.ft)

Removethe oil filter with the oil filter wrencn. Inspectthe threadsand rubbersealon the new filter. Wipe off the seat on the engineblock,then apply a lightcoatof oil to the new filter,srubberseal. NOTE: Use onty fitters with a built-in bypasssys, tem.

Applyoil to rubberseal beforeinstalling.

OIL FILTERWRENCH 07912- 6110001 I n s p e c tt h r e a d s a n d rubber seal surface.

8-8

Oil Pressure Testing Usethis procedureto tightenthe filter if eight numbers(1 to 8) are printedon the surfaceof the filter.

lf the oil pressurewarningIight stayson with the engine running,checkthe engineoil level.It the oil level is correct:

1) Makea markon the oil filterbaseunderthe number that shows at the bottom of the filter when the rubbersealis seated.

1.

Connecta tachometer'

2.

Removethe engineoil pressureswitch,and installan oalpressuregauge.

2l

Tightenthe filter by turning it clockwiseseven numbersfrom the markedpoint. For example,if a markis madeunderthe number2 when the rub ber seal is seated,the filter should be tightened untilthe number1 comesup to the markedpoint'

SWITCH OtLPRESSURE ENGINE HOLE MOUNTING

7/8 turn

MARK Numberwhen rubDer sealis seated

Numberaftertightening.

Numberwhen rubber sealis seated Numberaftertightening 8

7

5 1

5

GAUGE OIL PRESSURE (Commerciallv available)

1

CAUTION:Using any procedureother than those shown could rosult in serious engins damage due to oil leakage 5.

ADAPTER (1/8\28. BSPTI availablei {CommerciallY

8

fill the enginewith oil up to the specAfterinstallation. run the enginefor more than three minutes, level, ified then checkfor oil leakage

Startthe engine.Shut it off immediatelyif the gauge registersno oil pr€ssure.Repairthe problembefore continuing. Allow the engineto reachoperatingtemperature(tan The pressureshouldbe; comeson at leasttlivice). EngineOil Temperature:176"F(80"C1 EngineOil Pressulo: 69 kPa (0.7 kgf/Gm'.10 Psi) At ldle: minimum At 3.000rpm: 3/UtkPa (3.5 kgt/cm', 50 psi) minimum replace lf the oil Dressureis within specifications, recheck. and pressure switch the oil . lf the oil pressureis NOT within specifications, inspectthe oil pump (seepage8-10).

.

8-9

OilJet (B1642engine) Inspection 1 . Removethe oil jet (seepage 8-3) and inspectit as follows. M a k es u r et h a t a 1 . 1m m ( 0 . 0 4i n ) d i a m e t e dr r i l l will go throughthe nozztehole (j.2 mm (0.05in) diameter). Insertthe other end of the same 1.1mm (0.04in) d r i l l i n t o r h e o i l i n t a k e( i . 2 m m ( 0 . 0 5i n ) d i a m e _ ter). M a k e s u r e t h e c h e c kb a l l m o v e ss m o o t h l ya n d hasa strokeof approximately4.0 mm (0.16in). Checkthe oil jet operationwith an air nozzle.lt shouldtake at least200 kPa (2.0kgf/cm,,28 psi) to unseatthe checkball. NOTE: Replacethe oil jet assemblyif the nozzle rs damagedor bent.

1.2 mm (0.05inl

1 6 N . m1 1 . 6k g f , m ,t 2 t b f . f i l

CHECKBALL SPRING

Mounting torque is critical.Be very precisewhen installing. Torque:16 N.m (1.6kgt.m,12 tbt.ft)

8-10

Oil Pump Overhaul NOTE: . Use new O ringswhen reassembllng. . Apply oil to O-ringsbeforeinstallation. . Useliquidgasket,PartNo. 08718- 0001or 08718 0003 . The rotorsmust be installedto the samedirectionin order' checkthat the rolors move without binding' o After reassembly, B15A2engine:

6x1.0mm 7 N.m (0.7 kgf m, 5 lbf ft)

ROTOR OUTER page8-13 Inspection,

INNERROTOR page8-13 O-RING Replace. OOWEL PIN 6x1.0mm 1 1 N . m( 1 . 1kgf.m, 8 tbtfrl

PUMPHOUSING page8-13 Inspection, Applyliquidgasket to the matingsurfaceof the cylinderblock when installing.

RELIEFVALVE Valve mlst slide freeiy in housingbore. Replaceif scored.

SEALINGBOLT 39 N.m l4Okgt'm, 29 tbt frl

\

8 x 1.25mm 24 N,m {2.i1kgl.m. 17 tbf.ft) OIL SEAL Replace. p a g e8 - 1 4 lnstallation, SPRING

(cont'd)

8-11

O il Pu mp Overhaul(cont'dl

(

NOIE: . U s en e w O r i n g sw h e n r e a s s e m b l i n g . . Apply oil to O rings beforeinstalraUon. . U s el i q u i dg a s k e tP, a r rN o .0 8 7 1 8- 0 0 0 1o r 0 8 7 1 8 _ 0 0 0 3 . . The rotorsmust be installedto the samedirection. . After reassembly, checkthat the rotorsmove without binding.

6x1.0mm 7 N.m (0.7kgI.m, 5 lbf ftl

D16Y5,D16Y7,D16Y8engines: PUMP HOUSING I n s p e c t i o n ,p a g e 8 1 3 Apply liquid gasket to mating surfaceof the cylinder biock when installing.

INNERROTOR Inspectron, page8 13

DOWELPIN

PUMPCOVEB O-RING

_.feor,""

\ 6x1.0mm 11 N.m {1.1kgf.m,8lbl.ft)

OIL SEAL

[".?li;:;"". *,",,.rg

R E L I E FV A L V E Valve must slide freely i n h o u s i n gb o r e . R e p l a c ei f s c o r e d

""rc @.-*or"."

9''ggttt* 8 -12

Removal/lnspection/lnstallation 1.

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

2 . Turn the crankshaftand align the white groove on the crankshaftpulleywith the pointeron the lower cover. 3.

Removethe cylinderheadcoverand uppercover'

4.

Removethe power steeringpump belt, air conditioner beit and the alternatorbelt

5.

Removethe crankshaftpulleyand removethe lower cover.

6.

Removethe timing belt.

1.

Removethe drive pulley.

8.

Removethe oil pan and oil screen.

OOWELPIN

1 0 . R e m o v et h e s c r e w sf r o m t h e p u m p h o u s i n g t, h e n separatethe housingand cover' 1 1 . Checkthe inner-to-outerrotor radial clearanceon the pump rotor.lf the inner-toouter rotor clearance e x c e e d st h e s e r v i c el i m i t , r e p l a c et h e i n n e r a n d outer rotors. lnner Rotor-to-OuterRotor RadialClearance Standard{New}:815A2engine0.04- 0.16mm (0 002 - 0'006 in) D16Y5,D16Y7,D16Y8engines - 0.006in) 0.02- 0.14mm 10.001 ServiceLimit: 0.20 mm (0 008 inl ROTOR OUTER

O.RING Replace

INNERROTOR

' t 2 . Checkthe housing-to-rotoraxial clearanceon the pump rotor. lf the housing-torotor axial clearance exceedsthe servicelimit, replacethe set of inner and outer rotorsand/orthe pump housing

OILSCREEN

9.

! ' a

Housing-to-RotorAxial Clearance Standard (N€w): 816A2 engine 0.02- 0.07 mm (0.001- 0.003inl D16Y5,D16Y7,D16Y8engines 0.03- 0.08mm (0.001- 0.003inl in) S€rviceLimit: 0.15mm 10.006

Removethe oil PumP.

(cont'd)

8-13

Oil Pump RemovaUlnspection/lnstallation (cont'dl 13. Checkthe housing-to-outer rotor radialclearance. l f t h e h o u s i n g - t o - o u t erro t o r r a d i a l c l e a r a n c e exceedsthe service limit, replacethe set of inner and outer rotorsand/orthe pump housing. Housing-to-OuterRotor Badial Clearanco: Standard{Newl:816A2sngine0.10- 0.19mm (0.004- 0.007in) D16y5,Di6y7, Dt6y8 engines 0.10- 0.18mm {0.00it_ 0.007in) ServiceLimit: 0.20 mm (0.008in)

17. Reassemblethe oil pump, applyingthread lock to the pump housingscrews. 18. Checkthat the oil pump turnsfreely. 19. Apply a light coatof oilto the seallip. 20. Installthe two dowel pins and new O-ringon the oil pump. 21. Apply liquidgasketto the cylinderblockmatingsur_ faceof the oil pump. NOTE: . Use liquidgasket,PartNo.08718- oOOjor 08718 - 0003. . Checkthat the matingsurfacesare cleanand dry beforeapplyingliquidgaskel . Apply liquidgasketevenly,in a narrowbeadcenteredon the matingsurface. o To preventleakageof oil, apply liquid gasketto the innerthreadsof the bolt holes. . Do not installthe parts if five mtnuresor more h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t . Instead.reapplyliquid gasketafter removingthe old residue. . After assembly,wait at least30 minutesbefore fillingthe enginewith oil.

1 4 . lnspectboth rotors and pump housingfor scoring or otherdamage.Replacepartsif necessary.

81642engine:

1 5 . Removethe old oil sealfromthe oil pump. 1 6 . Usingthe specialtool, gentlytap in the new oil seal untilthe driverbottomsagainstthe pump. NOTE:The oil seal alone can be replacedwithout removingthe oil pump.

D16Y5,D16Y7,D16Y8engines: alongthe brokenline.

DRIVERATT 52x55mm 077a6- 0010ao0

8-14

PUMP HOUSING

\

22. Installtheoil pump on the cylinderblock. Apply greaseto the lip ot the oil pump seal. Then.installthe oil pump onto the crankshaft. Whenthe pump is in place,cleanany excessgrease off the crankshaftand checkthat the oil seal lip is not distorted.

lnstallthe oil screen. Installthe oil pan (seepages7-26or 7-27). NOTE:Cleanthe oil pan gasketmatingsurfaces.

81642engine: 8 x 1.25mm 24 N.m (2.i4kg[.m, 17 tbl.trl

6x1.Omm 11 N.m {1.1 kg{.m, 8 rbt ft)

O.RI G Replace.

DOWELPINS

GASKET Replace. OIL SCREEN 6x1.0mm rl N.m {1.1kgf'm, I tbf.ftl D16Y5, D16Y7. D16Y8 enginos: 6x1.0mm 1 1 N ' m( 1 . 1k g fm ' OOWELPIN

DOW€LPIN GASKET Replace.

O.RING Replace. 6 x 1.0 mm 11 N.m (1.1kgf.m, 8 lbf.ft)

6x1.0mm '11N'm {1 1 kgf'm, I lbf ftl

! o 8-15

lntakeManifold/ExhaustSystem lntakeManifold 9-2 ....................................... Replacement ExhaustManifold 9-6 ....................................". Rep|acement ExhaustPipeand Muffler 9-9 ...............................'.'.".. Replacement ThreeWay CatalyticConverter{TWCI 9-12 .................."'. Inspection HeatedOxygenSensor(HO2SI 9-12 ...........................'.."....." Rep|acement

r fo

L_s

IntakeManifold Replacement NOTE:Usenew O-ringsand gasketswhen reassemblinq. CAUTION: . Checktor folds or scratchoson the surfaceof tbe gasket. . Replacewith a now gasket if damaged. D16Y7engine:

8 x 1.25mm 22 N.m 12.2kgtm, 16 tbtftl

INTAKEMANIFOLD Replaceif crackedor if mating surfacesare damaged.

8 x 1.25mm 23 N.m {2,3 kgt m. 17 rbf.ftl

INTAKEMANIFOLD BRACKET 8 x 1.25mm 24 N.m {2.4kgf.m, 17 tbf.ftl

9-2

D16Y5engine:

6x1.0mm 12 N'm (1.2kgl.m,8.? lbf'ft)

EGRCHAMBER

INIAKE MANIFOLD Replaceif crackedor if mating surfacesare

8 x 1.25mm 21 N m (2.1kgf.m, 15 tbtft)

damageo,

GAS EXHAUST RECIRCULATION (EGRIVALVE

INTAKEAIB CONTROL (IAC)VALVE(M/TI

8 x'1,25mm 22 N.m (2.2kst m, 16lblftl 8 r 1.25mm 2a N.m (2.4kgt m, 17 rbt.ft) INTAKEMANIFOLD BRACKET 8 x 1.25mm 23 N.m 12.3kgf'm, 17 tbt fr)

I

8 x 1,25mm 22 N.n 12.2kol'm, 16tbftr)

(cont'd)

9-3

lntake Manifold Replacement(cont'dl NOTE:Usenew O,ringsand gasketswhen reassembling. CAUTION: . Checklor folds or scratcheson the surfaceof the gasket. . Replacewith a new gasket il damaged. D16Y8engine:

INTAKEMANIFOLD Replaceif crackedor if matingsurfacesare oamageo,

INTAKEAIR CONTROL {ract vAt_vE {M/Tl

GASKET Replace.

THROTTLE BODY

8 x 1.25mm 24 N.m {2.{ kgtm. 17 tbtftt

9-4

INTAKEMANIFOLD BRACKET

8 x 1.25mm 22 N.rn |.2.2kgl.rn, 16 tbtft)

816A2engine:

INTAKEMANIFOLD Replaceif crackedor if matingsurfacesare oamageo,

o t_-l 8 x 1.25mm 22 N.rA 12.2kgl.trr, 16 tbtftt

UH

E

n ""\--

VlCd>-^

M\G

INTAKEAIR CONTROL IIACIVALVE 8 x 1.25mm 24 N.m 12.4kgf.m, 17 tbtftl

MANIFOLD BRACKET

8 x 1.25mm 23 N.m {2.3 kg{.m, 17 tbt.ftl

Al N-m 12.2kgt.m, 16 tbt.ftl

yo 9-5

ExhaustManifold Replacement NOTE:Use new gasketsand self-locking nutswhen reassembling. CAUTION: . Checkfor folds or scratch€son the surfaceof the gasket. . Replacewith a new gasket it damaged. D16Y5.D16Y7engines:

I x 1.25mm 24 N.m {2.4kgt.m, 17 tbtft}

PRIMARYHEATED OXYGENSENSOR IPRIMAFYHO2SI 44 N.m {4.5kgf m, 33 lbtft) page9-12 Replacement,

GASKET Replace. I x 1.25mm 31 N.m (3.2kgf.m, 23 tbf.ft) Beplace.

WAY CATALYTIC CONVERTER {TWCI page9'12 lnspection,

6x1.0mm 11 N.m {1.1kgt m,8 lbf.ft)

9- 6

MANIFOLD BRACKET

SECONDARYHEATED OXYGENSENSOR (SECONDARY HO2S} 44 N.m 14.5kgf.m,33 lbf.ft) page9-13 Replacement,

D15Y8engine:

8 x 1.25mm 2,1N.m (2.akgf'm, 17 tbf.ftl

GASKET Replace.

8 x 1.25mm 31 N.m 13.2kgf'm, 23 lbf.ftl Replace.

PRIMARYHO2S 44 N.m (4.5kgf.m,33 lbtft) page9-13 Replacement,

EXHAUSTMANIFOLD BRACKET 10 x 1.25rnm /r4 N.m {4.5kgf.m,33 lbf.ft)

v

(cont'd)

9-7

ExhaustManifold (cont'dl Replacement NOTE:Usenew gasketsand self-lockingnutswhen reassembljng. CAUTION: . Checkfor folds or scratcheson the surfaceot the gask€t. . R€placewith a new gaskot if damagod, B16A2engine:

GASKET Replace.

SELF.LOCKING NUT 8 x 1.25 mm 31 N.m (3.2 kg{.m,23 lbf.ft) Replace-

10 x 1.25mm 44 N.m {4.4kgt.m, 33 tbl.ft) EXHAUSTMANIFOLD BRACKET

10x 1.25mm 4{ N.m (4.5 kgf.m.33 tbt.fil

9-8

Exhaust Pipe and Muffler Replacement nutswhen reassembling NOTE:Use new gasketsand self-locking D16Y5,D16Y7engines:

PIPE TIP EXHAUST MUFFLER

/

O

6x1.0mm 9.8 N.m 11.0kgt m, 7.2 lbf'ftl HEATSHIELO

6x1.0mm 9.8 N.m tl.0 kgf'm,7.2lbf'ft)

oP----------------

8 x 1.25mm 22 N.m 12.2kg .m, 16 tbf.f Replace. Tighlenthe boltsin steps,alternating sideto-side.

EXHAUSTPIPEB 8 x 1.25mm 22 N.m 12.2kgl'm, 16lbl'ttl Replace. Tighten the bolts in steps, alternatingside-to-side

----------"+@ neOlace.

NUT SELF.LOCKING 10 x 1.25mm 33 N.m (3.4ksd.m, 25 lbf.frl Replace.

\

GASKET Replace.

NUT SELF-LOCKING 8 x 1.25mm 16 N.m 11.6kgt m, 12 lbt'ftl Replace.

(cont'd)

9-9

ExhaustPipe and Muffler Replacement{cont'dl NOTE:Use new gasketsand self-locking nuts when reassembling. D16Y8engine: MUFFLER

d'*'ou"'"'""' 6x1.0mm 9.8N.m (1.0ksf m,7.2lbf ft)

8 x 1.25mm 22 N.rn 12.2kgl.m, 16 tbt.ft) Replace. Tightenthe boltsin steps,alternatrng side-to-side.

HEATSHIELD

6x1.0mm 9.8 N.m (1.0kgl m, 7.2 lbf.ft)

NUT SELF.LOCKING 10 x 1.25mm 33 N.m {3.4kgf.m, 25 tbtftl Replace.

EXHAUSTPIPE

SECONDARY HO25 44 N.m {4.5kgl.m, 33 lbtftl page9-10 Replacement,

TWC page9-12 inspection, GASKETS Replace. I x 1 - 2 5m m 22 N m (2.2 kgf.m. 16 lbfft)

EXHAUSTPIPEA

e) SELF-LOCKING NUT 1 0x 1 . 2 5m m 54 N.m {5.5kgl.m, 40 lbtft} Replace.

9-10

1 6 N . m { 1 . 6k g l . m , 1 2 l b f . f t } Replace-

GASKET Heplace.

Tighten the bolts in steps, a l t e r n a t i n gs i d e ' t o s a d e .

816A2 engino:

MUFFLER

-/-

_.,. EXHAUSTPIPE tlP

g

GASKET Replace.

\6r1.omm 9.8N m 11.0kgf'm,7.2lbl'ttl

8 x 1.25mm 2. N'm 12.2kgl-m, t6 tbtf0 Replace. Tighten the bolts in steps,alternatrng side-to-side.

6x1,0mm 9,8 N.m 11.0 7.2lbl4rl

NUT SELF-LOCKING l0 x 1.25mm 3:t N.m {3.4 kgf m,24lbf'ftl ReDlace.

PRIMARYIIEATED OXYGENSENSOR {PRIMARYHO2S) ll N.m (4.5kgl.m, 33 tbt f0

SECONDARY HEATED OXYGENSENSOR HO2SI {SECONDARY lrt N.m 14.5kgf.m, 33 rbl.ft) page9-13 Replacement,

Replacement,

GASKET R€place.

twc page9-12 Inspection,

GASKEIS Replace.

NUT SELF.L(rcKNG 10x 1.25mm 5,r N.m 15.5kgf.m, ,|{} lbf.ft) ReDlace.

8 x 1.25mm 16 N.m 11.6kgt.m, 12 rbf.ft) F€pl8ce.

Replaca.

8x1.25mm 22 N.m {2.2 kgt m, 16 lbf.ftl Replsce. Tight6n the bolts in st6ps, alternatingside-to-side.

I

9-11

TWC

HO2S

Inspection

Replacement

l.

PrimaryHO2S:

Usinga flashlight,makea visualcheckfor plugging, meltingand crackingof the catalyst.

1. D16Y5,D16Y7engines:

Removethe primaryHO2S. D16Y5,D15Y7engines: a.

a

D i s c o n n e ct ht e p r i m a r yH O 2 Sc o n n e c t o rt ,h e n removethe cover. 8 x ' 1 . 2m 5m 24 N.m{2.4kgl.m,

A

PRIMARYH02S CONNECTOR

816A2,D16Y8engines:

FLASHLIGI{T

b.

-\ 6{ -)\

lT

Removethe primaryHO2S.

| \l,l(

I bK/l

l llw. ( /\\

PBIMARYHO2S 44 N m (4.5kgf.m,33 tbI.ft)

9 - 12

Bt6A2, Dl6Y8 engines: a.

Disconnectthe primary HO2Sconnectorthen removethe primaryHO2S. 816A2engine

Secondsry H02S: 1.

Removethe secondaryHO2S Dl6Y5, Dt6Y7 engines: a.

D i s c o n n e c t h e s e c o n d a r yH O 2 Sc o n n e c t o r . then remove the secondaryHO2S' 02 SENSOR

PRIMARY H02S CONNECTOR

D16Y8engine

816A2, Dt6Y8 ongin6s: a.

Removethe grommet,and pull out the secondary HO2Sconnector,then disconnectthe secondary HO25connector'

H()2S SECONOARY CONNECTOR

PRIMARYHO2S 44 N.m {4.5kgt'm.33 lbf'ft)

L

2.

Installthe primary HO2Sin reverseorder of removal' {cont'd)

9-13

HO2S (cont'd) Replacement b,

Removethe secondarvHO2S.

02 SENSORWRENCH

SECONOARY HO2S 4,r N.m (4.5kgf.m, 33 tbf.ft)

I n s t a l lt h e s e c o n d a r yH O 2 S i n r e v e r s eo r d e r o f removat.

9 - 14

w a

Cooling ""' 10-2 fllustratedIndex."..."... Radiator 10-6 .'....'...."..." Replacement EngineCoolantRefillingand 10-7 Bleeding 10-9 CapTesting 10-9 Testing Thermostat 10-10 .............'.... Replacement 10-10 Testing EngineGoolantTemPerature (ECT)Switch """ 10-11 Testing WaterPumP " 10-12 Index ......'... fffustrated ' 10'14 Inspection 10-14 ..'..'...."...'.'....'..'.....'.""" Replacement

!

lllustrated Index

system is under high pressure when the @@ engine is hot. To avoid dangsr of rsleasing scalding engine coolant, removo the cap only when the engine is coot. Total Cooling System Capacityflncluding heater and foservoir (0.4f (0.42US qt, 0.35 tmp qt)ll:

Mt-|-

4 . 2 f ( 4 . 4U S q t , 3 . 7 t m p q t ) * j 5.0 / (5.3 U$ q1, 4.4 16p q11*z

CAUTION:lf any engine coolant spills on painted portions of the body, rinse it off immediately. NOTE: . Checkall cooling systemhosesfor damage,leaksor deterioration and replaceif necessary. . Checkall hoseclampsand retightenif necessary. . Usenew O-ringswhen reassembling.

4 . 1f ( 4 . 3U S q t , 3 . 6l m p q 0 * 3 4.31 (4.5US qt, 3.8 tmp qt)*a

CVT

4 . 3f ( 4 . 5U S q t , 3 . 8I m p q t ) *1i D16Y5,D16Y7,D16Y8engines *2: 81642engine *3: D16Y7engine * 4 : D 1 6 Y 8e n g i n e

UPPER RADIATOR HOSE

5x0.8mm A: ,1.4N.m {0.45kgf.m, 3.3 tbtftl g: 5.4N.m (0.55kgtm.4.0 tbf.ft)

RADIATORCAP Pressure test,page'108

RAOIATOR Enginecoolantrefillingand bleeding, p a g e1 07 Leaktest,page10-9 Inspectsolderedjointsand seamsfor leaks, Blow out dirt Irom between

6x1.0mm 9.8 N.m {1.0kgtm, 7.2 tbt.ltl UPPERBRACKET AND CUSHION

COOLANT RESERVOIR

core fins with compressed air. l f i n s e c t s ,e t c , , a r e c l o g g i n g r a d i a t o r ,w a s h t h e m o f f w i t h r o w p r e s s u r ew a t e r .

iil 6x1.0mm 7.2 N.m (0.73kgt.m, 5.3 tbtftl

RADIATORFAN FAN MOTOR SHROUD

BADIATOR FAN

DRAIN PLUG Referto section14 when installing.

Ar TOYORADIATOR manufacturedradiator B: NIPPONDENSO manufacfared raoraror

10-2

O-RING Replace.

LOWEB RADIATOR HOSE

LOWER CUSHION

Engine HoseConnections: D15Y7engine:

IAC VALVE WATEFBYPASS

THERMOSTAT HOUSING

lv

CONNECTING PIPE

HEATER HOSES

VALVE

{cont'd)

10-3

lllustrated Index (cont'd) EngineHoseConnections: D16Y5,D16Y8engines:

IACVALVE {A/T)

Replace. WATERBYPASS HOSE IAC VALVE

(M/TI

THERMOSTAT HOUSING

O.RING Replace.

\ \ \ \

h

CONNECTING PIPE

HEATER VALVE

HEATER HOS€S

1 0- 4

Engine Hose Conneqtions: 81642engine:

THERMOSTAT HOUSING

CONNECTING PIPE

O-RING Replace.

b WATERBYPASS HOSE ENGINEOILCOOLER

HEATER VALVE HEATER HOSES

10-5

Radiator Replacement 1 . Drainthe enginecoolant. 2.

5.

R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e s ,a n d ATFcoolerhoses.

3. Disconnectthe fan motor connector. Removethe radiatorupper bracket,then pull up the raotator,

RADIA

CAP

Removethe fan shroud assembliesand other parts from the radiator.

Installthe radiatorin the reverseorderof removal: NOTE: . Setthe upperand lower cushionssecurely. . F i l l t h e r a d i a t o rw i t h e n g i n ec o o l a n ta n d b l e e d the air.

Y|lT,PS:|" AND CUSHION

6x1.0mm

i.i ru-ii brgr.-, 7.2tbr.ftl

ATF COOLER HOSES(A/T) Referto section1 4 when installing. UPPERRAOIATORHOSE

6x1.0mm 7.2 N.m (0.73kgf.m. 5.3 tbf.ft)

,iiiiii

(

RESEBVOIR TANK

I RADIATOR

RAOIATORFAN/SHROUD ASSEMBLY

LOWERCUSHION

DRAINPLUG

O-RING Replace. LOWER RAOIATOR HOSE

ATFCOOLER PIPES{A/T)

10-6

EngineCoolantRefillingand Bleeding B1642 engin€:

CAUTION:when pouring engine coolant, be sure to shut the relay box lid and not to lst coolant spill on the eleqtricalparts or the paint. lf any coolant spills, rinse it off immediately. 1.

WASHER Replace.

Slide the heatertemperaturecontrol leverto maxlmum heat. Make sure the engine and radiatorare cool to the touch. Removethe radiatorcaP. Loosenthe drain plug,and drainthe coolant'

DRAINPLUG

DRAINBOLT 78N m (80 kgfm' 58lbfft) Apply liquid gasketto the drain bolt threads,then reinstallthe bolt with a new washer and tighten 't securely.

tl

6.

Tightenthe radiatordrain plug securely

1.

Remove,drain and reinstallthe reservoir'Fill the tank halfwayto the MAX mark with water, then up to the MAX mark with antitreeze.

Removethe drain bolt from the cylinderblock' D16Y5.D16Y7,Dl6Yg sngines:

0d 78 N.m {8.0kgl m.58lbt'ft)

I ro

MAX MARK

(cont'd)

10-7

Radiator EngineCoolantRefiltingand Bleeding(cont,dl \.8.

M i x t h e r e c o m m e n d e da n t i f r e e z ew i t h a n e o u a l amountof water in a cleancontainer.

9. Pourcoolantinto the radiatorup to the baseof the filler neck.and installthe radiatorcap looselv.

NOTE: o Useonly genuineHondaantifreeze/coolant. . For best corrosion protection.the coolant con_ c e n t r a t i o nm u s t b e m a i n t a i n e dy e a r _ r o u n da t 50% minimum.Coolantconcentrations lessthan 50% may not provide sufficient protection againstcorrosionor freezing. . C o o l a n tc o n c e n t r a t i o n gs r e a t e rt h a n 6 0 0 1w0i l l i m p a i r c o o l i n g e f f i c i e n c ya n d a r e n o t r e c o m _ mended. CAUTION: . Do not mix difforont brands ofar ilreeze/coolants. . Do not use additional rust inhibiiors or anti_rust produqt3; they may not be compatible with the coolant. Engine Coolent Refi Capacity Iincluding reservoir {0.4f 10.42US qr, 0.35 lmp qt),I;

M/r Att CW

3.8f {4.0US qt, 3.3 lmp qt)*1 4.5/ (4.8US qt. 4.0 tmp qt)*, 3 . 7 , ( 3 . 9U S q r , 3 . 3t m p q t ) . 3 3 . 9/ ( 4 . 1U S q t , 3 . 4 l m pq t ) * . 3 . 9/ ( 4 . 1U S q t , 3 . 4t m pq t l

*1: D16Y5,D16Y/,O16Y8 engines *2: 81642engine *3; Dl6Y7 engine *4: Dl6Y8 engine

10-8

1 0 . Startthe engineand let it run until it warms up (the radiatorfan comeson at leasttwicer. 1 1 .Turn off the engine.Checkthe level in the radiator. add coolantif needed. Put the radiatorcap on tightly,then run the engine againand checkfor leaks.

I

Testing

CapTesting 1.

Removethe radiatorcap, wet its seal with engine coolant,then installit on the pressuretester'

TESTER PR€SSURE RADIATOR (CommerciallY available) RAOIATOR

L

Wait until the engineis cool, then carefullyremove t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e coolantto the top of the tiller neck Attachthe pressuretesterto the radiatorand apply '123kPa(0.95- 1.25kgflcm' ,14 a pressureof 93 1 8p s i l . ADAPTOR (for 32 mm neck,low Profile)

PRESSURE RADIATOR TESTER available) lCommerciallY

ADAPTOR

(for32mm neck'lowPro{ile)

Apply a pressureof 93 - 123kPa (0.95 1 4 1 8p s i ) .

'l 25 kgflcm''

Checkfor a drop in Pressure. lf the pressuredrops,replacethe cap

Inspectfor enginecoolantleaksand a drop In pressure. Removethe testerand reinstallthe radiatorcap NOTE: Checkfor engine oil in the coolant and/or coolantin the engineoil.

I

t

10-9

Thermostat Replacement NOTE:Usea new O-ringwhen reassemblinq.

THERMOSTAT Install withpinup.

THERMOSTAT

THERMOSTAT HOUSING

ENGINECOOLANT TEMPERATURE {ECT)

swtTcH

24 N.m {2.4kgf.m, t7 tbf.ft)

10-10

6x1.0mm 12 N.m {1.2kgf.m,8.7tbf.frl

EGTSwitch Testing

Testing Replacethe thermostatif it is openat room temperature' To test a closedthermostat: 1,

Suspendthe thermostatin a containerof water as shown.

Romovingthe EcT swhch while lhs engine !!@ i!-ot can causethe coolant to sPrayout, seriouslyscalding you. Always lst th€ ongine and rediator cool down before removing ihe ECTswitch. NOTE:Bleedair from the coolingsystemafter installing the ECTswitch (see Page10-7) 1.

Removethe ECTswitchfrom the thermostathousing (seePage'10-10).

2.

Suspendthe ECTswitch in a containerof water as shown.

THEBMOMETER

THERMOSTAT

-f

Heat the water, and checkthe temperaturewith a thermometer.Checkthe temperatureat which the thermostatfirst opens,and at which it is fully open Heat the water, and checkthe temperaturewith a thermometer.

CAUTION: Do not let the thermometer touch the bottom of the hot Gonlainel.

CAUTION: Do not let the thermomoter touch tho bottom of the hot container'

Measure lift height of the thermostat when fully open. STANDARDTHERMOSTAT above 8.0 mm (0.31inl Lift height Starts opsning: 169' - 176'F (76' - 80'Cl 194'F {90"C1 Fully open:

4.

Measurethe resistancebetweenthe A and B terminalsaccordingto the table. Terminal

Oo"rffi 196' - 203"F

ON (91"- 95'C)

swlTcH

o- -o

5" - 15'F{3" - 8'C) OFF lower than the temPerature when t goeson

! ' o 1 0 - 11

Water Pump lllustratedIndex NOTE: . Use new O-ringswhen reassembrrng. . Use liquidgasket,PartNo. 08718- 0OOlor 087t8 _ 0003. O16Y5,D16Y7,D16Y8engines: ECTGAUGE SENDINGUNIT 9 N.m {0.9 kgI.m, 7 tbnftl Apply liquidgasket to the threads.

ENGINECOOLANT TEMPERATURE(ECT) SENSOR 1E N.m (1,8 kgf.m, 13 rbttt)

6 x 1 . 0m m 9.8N.m {1.0kgf.m, 7.2 tbt.ft'|

O.RING Replace. WATEROUTLET COVER Apply liquidgasket to matingsurface.

ECTSW1TCH 24 N.m 12.4kgf.m, 17 rbf.ftl

6xl.0mm 12 N.m {1.2kgf.m, 8.7 tbf.ft)

6x1.0mm '12N.m {1.2 kgt m, 8.7 lbt fr) 10 x 1.25mm itl N.m 14.5kgt m, 33 rbf.ftl O.RING Replace.

1 0- 1 2

815A2 engine:

WATEROUTLET COVER Apply liquidgasket to matingsurface.

6x1.0mm 9.8 N.m {1.0 kgl'm, 7,2 tbl.ftt

ECTGAUGE SENDINGUNIT 9 N.m (0,9 kgf.m, 7 rbf.ft) Apply liquidgasket to the threads.

r

ENGINE COOLANT (ECT) TEMPERATURE SENSOR 18 N.m {1.8 kgf.m, 13 tbtftl

6x1.0mm 12 N.m (1,2kgdm, 8.7 tbf.ftl

16@

aY@ t"

\lo

S X 1.0 Mrf

iiil:i'iij

WATENPUMP

rnr..,

pase10'1'r Inspection,

8.7 tbf.ftl

10-13

Water Pump Inspection

Replacement

't. Remove the timing belt (seesection6).

1.

Removethe timing belt (seesection6).

2. T u r n t h e w a t e r p u m p p u l l e yc o u n t e r c l o c k w i s e .

Removethe water pump by removingfive bolts.

Checkthat it tarnsfreely. Checkfor signsof sealleakage.

NOTE:Inspect,repairand cleanthe O-ringgroove and matingsurfacewith the cylinderblock.

NOTE:A smallamountof "weeping,,fromthe bleed h o l ei s n o r m a l .

D16Y5,D16Y7,D16Y8engines:

Dl6Y5, Dl6Y7,D16Y8engines: BLEED HOLE

6x1.0mm

12N.m{1.2kgf.m, 8.7lbt.ft)

l0 x 1.25mm {4 N.m14.5kg{.m. 33 tbt.ft) Bl642 engine: WATER PUMP

BLEEDHOLE

B16A2engine: BLEEDHOLE

d orp,

I

@;2

6x1.0mm 12 N.m 11.2kg{.m, 8.7 tbf.ft)

O.RING Replace.

3. Installthewaterpumpin the reverse orderof removal. NOTE: o KeeptheO-ringin position wheninstalling. BLEEDHOLE

10-14

.

Clean the spilled engine coolant.

Fuel and Emrsslons ldle Control System .....,...."..,.11-2 SoecialToofs 11-190 ............ SystemDoscriplion Component Locations Flowcharts Troubleshooting . . . . . . .1. .1 - 3 l n d e x. . . . . . . . . . . . . . . . . . . . . , ......11-192 ldle ControlSystem Svstem Description I 1-19i1 Va1ve .................................... ldle Air Control ......... 11-12 ................,,..,.. VacuumConnections 11'202 StarterSwitch Signal .................................... .......11-29 ElectricalConnections...............,.,.,... 11'201 Air ConditioningSignal ................................. S y s t e mC o n n e c t o r .s. . . . . . . , . , . , . . . . . . . . . . . . . .1.1. .-.5. .1. . . . . . . 11-208 .................................... Ahernator FR Signal Troubleshooting f. .1.". 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .0. . . S i g n a l 1 1 8 1 B r a k e S w i t c h . . . . . . . . . . . . . . . . . T r o u b l e s h o o t i nPgr o c e d u r e s Power Sleering ProssureSwitch Signal ......11-212 EngineControlModule/Powertrain 11-216 ControlModuleTerminal A/T GearPositionSignal............................... 11-88 ....,.,..... Afiangement 11-214 ClutchSwiich Signal ................................-.... 11.97 DiagnosticTroubleCodeChart .................,., .............11-220 ldteSpeedSetting. . 11-103 How to ReadFlowcharts.,.......................... PGM-FlSystem

!

Fuel Supply System

.,...................,.,.,.,11-221 FuelLines ......11-10,1 FuefTube/Ouick-Connect SystemDescription 11-227 Fittings..........,.,........ TroubleshootingFlowcharts ....'.... 11-230 SystemDescription EngineControlModule/Powertrain 11-230 .......,.,,........... FuelPressure ........11-107 Contlol Module ......................11-232 Fueffniectors ManitoldAbsolutePressureSensor.....'.. ... 11-115 11-231 Fu€fPressureRegulator.....,.......................'...,. . 11'121 fntakeAir TemperatuieSensor ...... . ., ............................11-235 FuefFifter Sensol.........,11-128 EngineCoolantTemperatuae . . . . . . . . . . . . . ' . . . . .1. .1' .-.2. .3 6 F u e lP u m p 11-132 ThrottlePositionSensor ...................,........... .............11'237 Relay PGM-FI Main PrimaryHeatedOrygen Sensor(Sensor1l ... 11-139 ....,...'.'.' 11'211 FuelTank ................ SecondaryHeatedOxygen Sensor ( S e n s o2r 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1 5 3 .............. IntakeAir System 11-157 HeatedOxygenSensorHeater ...................,. ....-.-.....11-243 SystemDescription ......11-164 FuelSupplySystem .11-211 ...........,......."". Air Cfeaner . . . . . . ..,. 1 1 - 1 6 6 R a n d o mM i s l i r e .....................11-211 Throttle Cable 11-167 MisfireDetectedin One Cylindsr ................. ..'.... . .,.11-211 . , . , . . . . . . . .1. 1 . .-. 1 7 0 ThrottfeBody ........ K n o c kS e n s o r 11-250 ,.,.,....-........... Air Control System Fuel Iniestion 11'172 Sensor................................... CKP/TDC/CYP 1t-176 VehicleSpeedSensor...........,......,...,.,........... Emission Control System I 1-178 BarometricPressureSensor ...............,......... .-..........11-252 Description System E l e c t r i c aLlo a dD e t e c t o r , . , , . . . . . . . . . . . . . . . . .1. .1. -. .1.7. .9. . . ...............11-252 Taifpip€ Emission . . . . . . . . . . . . . . 1 . . 1 . . . 1 . 8 3 C K FS e n s o r 11-252 ThreeWay CatafyticConvert€r............,.,,.,.,.,.... I 1-188 ECM/PCMInternalCircuit ............................. 11'254 ...,.,,,,.,.,.,.,,. System Exhaust Gas Racirculaiion I 1-189 A/T Signal{TMA/TMBI.................................. PositiveCrankcas€Ventilation System .... . . .. 11-266 11-267 EvaoorativeEmissionControls..................,,..,.,.

SpecialTools \-

SpecialTools R€f. No.

I

Tool Number

Dsscription

Oty

O

A973X_041_ XXXXX

VacuumPump/Gauge, 0 - 30 in.H9

I

@ /n @ @ @

07JAZ- 0010008 - 0010100 07PAZ 07sAz- 001000A 07406- 0040001 07406- 0040304

Vacuum/Pressure Gauge,0 - 4 in.Hg SCSServiceConnector BackprobeSet FuelPressureGauge FuelPressureAdapter,6x 15 mm

I 1 2 1 I

ta

1n \Y

11-2

I

Pagr Reference 11-251,256, 257, 273,274, 283,284, 286, 288,289, 291, 294,296,297 11-294,295 11-81 11-83 1't-230,231,234 11-230

a

GomponentLocations lndex D16Y5engine: THROTTLEPOSITIONITP) SENSOR page11-132 Troubleshooting, EXHAUSTGAS RECIRCULATION IEGRIVALVEand EXHAUSTGAS RECIRCULATION IEGRIVALVE LIFTSENSOR page'l1-254 Troubleshooting,

MANIFOLDABSOLUTE PRESSURE IMAPI SENSOR page1'l-115 Troubleshooting,

(IAC)VALVE IDLEAIRCONTROL {M/T) page11-194 Troubleshooting, EXHAUSTGAS RECIRCULATION {EGRICONTROLSOLENOID VALVE ICW) page11-254 Troubleshooting.

INTAKEAIR TEMPERATUR€ {IATISENSOR Troubleshooting,

EMISSION EVAPORATIVE IEVAPIPUNGECONTROL SOLENOIDVALVE Troubfeshooting,Page11'211, 243

LOAD ELECTRICAL DETECTOR IELD)(USA mod6l) page11 179 Troubleshooting,

POWERSTEERINGPRESSURE (PSP)SWITCH(USAI Troubleshooting, Page11-212

CRANKSHAFT POS|TTON/ TOPDEADCENTER/ CYLINDER POS|T|ON SENSOR ICKP/TDC/CYP} (Builtintothe distributor)

KNoCK SENSoR(Ks)

(cwl

Troubleshooting, Page11'170

T r o u b l e s h o o t i n g ,P a g e 11 ' 1 7 2

(CKF}SENSOR FLUCTUATION Troubleshooting, Page11-183

VEHICLESPEEDSENSOR Troubleshooting, Page11-176 ENGINECOOLANT TEMPERATURE IECT)SENSOR Troubleshooting, Page11 128

IDT.E

CONTROLIIACIVALVE

{cw)

Troubleshooting, Page11 198

WAY CATALYTIC

CONVERTER ITWCI PRIMARYTIEATED

Troubleshooting,Page 11-252

HO2SI SENSOR {PNIMARY tsENsoR1t {M/Tl

Troubleshooting, Page'l1-146 PRIMARYHEATEDOXYGEN SENSOR(PRIMARYHO2SI

1l{cw} tsENsoR

Troubleshooting, Page11-139

L

HEATEDOXYGEN SECONDARY HO2S) SENSOR{SECONDARY {SENSOR2) page11 153 Troubleshooting,

(cont'd)

11 - 3

Component Locations Index(cont'd) THROTTLEPOSITION{TPI SENSOR page11-132 MANIFOLOABSOLUTE Troubleshooting, PRESSURE {MAPI SENSOR INTAKEAIR TEMPERATURE page11-115 Troubleshooting, IIATISENSOR Troubleshooting, page11,124 IDI.EAIR CONTROLIIACIVALVE lMtfl ELECTRICAL LOAD Troubleshooting, page11-194 DETECTOR IELDI{USAI EVAPORATIVE page EMISSION Troubleshooting, 11-179 IEVAPIPURGECONTROL SOLENOIOVALVE CRANKSHAFT Troubleshooting,page 11 271. 283 POSTTTON/ TOPDEADCENTER/ POWERSTEERINGPRESSURE CYLINDER (PSPISWTTCH|USA) POStTtON page11-212 Troubleshooting, {CKP/TI'C/CYPISENSOR (Builtinto the distributor) KNOCKSENSORIKSI Troubleshooting. page11-172 page11 170 Troubleshooting,

D16Y8enginc:

CRANKSHAFT SPEED FLUCTUANONICKFISENSOR Troubleshooting, page11,183

IDI.E {A/T)

CONTROL{IACIVALVE

page11 198 Troubleshooting, ENGINE COOLANT PRIMARYHEATEDOXYGENSENSOR TEMPERATURE {PRIMARYHO2S}(SENSOR1l {'96 - 98 modolsl {ECTISENSOR page11-139 page11128 Troubleshooting, Troubleshooting,

'96 - 98 modols:

'9!t 00 modols:

THREE WAYCATALYNC CONVERTER ITWCI page11-252 Troubl6shooting,

SECONDARY HEATEDOXYGEN SENSOn (SECONDARY HO2SI(SENSOR2I page11-153 Troubleshooting,

11-4

SECONDARY HEATEDOXYGEN SENSOB ISECONDARY HO2S}ISENSOR2I page11-155 Troubloshooting,

THREE WAYCATALYNC CONVERTER ITWCI page11-252 Troubleshooting.

PRIMARYHEATEOOXYGENSENSOR IPRIMARYHO2SIISENSOR1I page11-141 Troubleshooting,

D16Y7engine:

MANIFOLDABSOLUTE (MAPI SENSOR PRESSURE Troubleshooting, r1-132 Troubleshooting, Page11-115 THROTTLEPOSITIONITPI SENSOR

(VSSI SENSOR SPEED VEHICLE 1 1-176 Troubleshooting, Page LOAO ELECTRICAL (ELD)IUSA} DETECTOR Troubleshooting, Page11'179 CRANKSHAFT POSTTTON/ TOPDEADCENTER/ CYLINDER POSITION SENSOR {CKP/TDC/CYPI (Builtintothe distributorl 't Troubleshooting, Page 1-172

INTAKEAIRTEMPERATURE IIATISENSOR page11124 Troubleshooting, PRESSURE POWERSTEERll\lG {PSP'SWTTCH {USA) Troubleshooting, Page11 212

IDLEAIR CONTROL(IAC)VALVE page11-198 Troubleshooting, l

/i

CRANKSHAFTSPEED FLUCTUATIONICKFISENSOR Troubleshooting, Page11-183 ENGINECOOLANT TEMPERATURE (ECTISENSOR page11 128 Troubleshooting, EMISSION EVAPOBATIVE (EVAPIPURGECONTROL HEATEDOXYGEN SECONDARY HO2S) SOLENOIDVALVE SENSOR(SECONDARY Troubfeshooting,page11 271, 283 (SENSOR2l Troubleshooting, Page11-153

PRIMARYHEATEDOXYGEN SENSOR(PRIMARVHO2S) {SENSOR1l page11'139 Troubleshooting, THNEEWAY CATALYTIC CONVERTERITWCI page11-252 Troubleshooting,

(cont'd)

tr , l . l -r, |

|

Component Locations Index(cont'dl

MANIFOLOAESOLUTE PRESSURE IMAPI SENSOR INTAKEAIR TEMPERATURE page11-119 Troubleshooting. IOLEAIR CONTROL{IAC)VALVE SENSOR {IAT} Bl6A2 engine: page11,196 Troubleshooting, Troubleshooting, page1'1-125 THROTTLEPOSITIONITPI ELECTRICAL LOAD SENSOR DETECTOR IELDI(USA) page11-134 Troubleshooting, page11-180 Troubleshooting, POWERSTEERINGPRESSURE CRANKSHAfi (USA) {PSPISWTTCH POStTtON/ page11-214 Troubleshooting, TOP DEADCENTER/ CYLINDER POStTtON {CKP/TDC/CYPI SENSOR (Bualtintothe distributor) Troubleshooting, page11-174

VEHICLESPEEDSENSOR{VSS} Troubleshooting, page11-177 ENGINE TEMPERATURE IECTISENSOR Troubleshooting, pageI 1-128

CRANKSHAFT SPEED (CKFISENSOR FLUCTUATION Troubleshooting, page11-t85

THREEWAY CATALYTIC CONVERTER ITWC) Troubleshooting, page11,252

S€CONOARY HEATEDOXYGEN sf rlsoR sfCoNDARY HO2SI{SENSOR2) : ? s h o o t r n pg a, g e1 1 1 5 5

1 1- 6

PRIMARYHEATEDOXYGENSENSOR IPRIMARYHO2S)ISENSOR1I Troubleshooting, page11-141

CLUTCHSWITCHlDl6Y5 ongino M,/TI page11-218 Troubleshooting,

Sell-diagnosticProcedures. p a g e1 18 1

'9!, - 0o modol3:

'96 - 98 modsls:

PGM.FIMAIN RELAY RslayTesting,page11-237 page11-238 Troubleshooting, PGM.FIMAIN RELAY RelayTesting,pagel1 237 pago1'! 238 Troubleshooting,

I

CHECKCONNECTOR ENGINCCONTROLMOOUI.T SERVICE tzPl (FCMI/POWERTRATN Self-diagnostic Procedures, page11-81

CONTROLMODULEIPCMI page11-107 Troubleshooting,

CONNECTOR SERVICE l2Pl Self-diagnosticProcedures, page11-81

ENGINECONTROLMODU1T (ECM}/POWERTRAIN CONTROLMODULEIPCMI page11 111 Troubleshooting,

{cont'd)

11-7

ComponentLocations Index (cont'dl '96 D16Y8engine(coupel, '97 D16Y7engine(coupe:KL model, sedan:KL (LXl model), '97 D16Y8engine(coupe: all models,sedan:KL modell,'98-allmodels: FUEI-VAPORPIPE FUELGAUGESENDINGUNIT FUEL FEEDPIPE Testing,seesection23 FUELFILTER Replacement,

FUELPUMP Testing,page11 236 page11 236 Replacement, FUELFILL CAP

€VAPOFATIVEEMISSION (EVAPICONTROLCANISTER VENTSHUTVALVE page l1'283 Troubleshooting, EVAPORATIVE EMISSION IEVAPICONTROLCANISTER page11 283 Troubleshooting,

FUEL TANK pageI l-241 Replacement, EVAPORATIVE EMISSION IEVAP)BYPASSSOLENOID VALVE page11-283 Troubleshooting,

FUELINJECTORS page11-232 Replacement,

EVAPORATIVE EMISSION (EVAPITWOWAYVALVE page11294 Testing, TANK PRESSURE SENSOR

FUEL REGULATOR

T r o u b l e s h o o t i n g ,p a g e 1 1 - 2 7 5

FUEL

Testing,page 11-234 R e p l a c e m e n t ,p a g e 1 1 - 2 3 4

FITTINGS

page11-227 Precautions, page11 227 Disconnection, page11-228 Connection,

'96 Dt6Y5engine,'96D16Y7engin€,'96 D16Y8engine(sedanl, '97 D16Y5engine,'97 Dl6Y7 engins (coupe: l(A, KC models, sedan:KA, KC, KL (DXl models, hatchback:all models), '97 Dl6Y8 engine (sedan:KA, KC modelsl: FUEL

VAPORPIPE

FUEL FEEDPIPE

FUELFILTER Replacement, page11-235 EMISSION EVAPORATIVE IEVAPICONTROLCANISTER page11-271 Troubleshootiog,

FUELPUMP Testing,page11-236 page11-236 Replacement,

FUELTANK page11 241 Beplacement, TIVEEMISSION {EVAP)TWO WAY VALVE Testing,page11-294 TUBE/OUICK.CONNECT FITTINGS FUELPRESSURE page11-227 Precautions, REGULATOR page11'227 Disconnection, Testing, page 11'234 page11-228 Connection, FUEL RETURN PIPE p a g e Beplacement, 11 234

11-8

'99 - 00 models:

EMISSION EVAPORATIVE IEVAP}PURGECONTROL SOLENOIDVALVE page11'288 Troubleshooting,

FUEL FEEDPIPE

UNIT FUELGAUGESENDING Testing,seesection23 VAPOR ONBOARDREFUELING R€COVERY IORVRI FUELVAPORPIPE VENT SHUTVALVE Test,page11 296

FUELFILTER page11-235 Beplacement,

FUEI-PUMP page11236 Testing, page11-236 Replacement,

EMISSION EVAPORATIVE {EVAP)CONTROLCANISTER VENT SHUTVALVE

FUELFILL CAP

T r o u b l e s h o o t i n g ,P a g e 11 _ 2 8 8

EVAPORATIVE EMISSION

{EVAPICONTROL page11_288 Troubleshooting,

EMISSION EVAPORATIVE {EVAP)BYPASSSOLENOID VALVE page11-288 Troubleshooting,

FUEL PULSATIONDAMPEB

FUELTANK PRESSURE SENSOB Troubleshooting, Page11'274

FUEL RAIL

EMISSION EVAPORATIVE IEVAPITWO WAY VALVE Testing,page11 295

FUELINJECTORS page11'232 Replacement, FUELPRESSURE REGULATOR Testing,page11-234 page11 234 Replacement,

FUEL RETURNPIPE R e p l a c e m e n t ,p a g e 11 - 2 4 1

I

FUELTUBE/OUICK.CONNECT FITTINGS page1l-227 Precautions, page11 227 Disconnection, page11-228 Connection,

(cont'd)

11 - 9

Component Locations Index(cont'd) D16Y5,D16Y8ongine: AIR CLEANERIACLI page11-244 Replacement,

THROTTLEBODY(TBI page11-247 Inspection, Removal,page11-248 page11 249 Disassembly,

THROTTLECABLE page 11-244 lnspection/Adjustment. page 11245 Installation,

RESONATOR AIR {FIA}CONTROL VAIVE {'99 modeli D16Y86ngin6) Testing,page11,250

POSITIVECRANKCASE VENTILATIONIPCV)VALVE page11-266 Inspection,

D16Y76ngin€:

AIR CLEANERIACLI page11,244 Replacement,

RESONATOR

11 - 1 0

POSITIVECRANKCASE VENTILATIONIPCVIVALVE page11-266 Inspection,

THROTTLECABIT fnspection/Adjustment. page11,244 page11-245 Installation,

.iBoov ffet

page11 247 Inspection, Removal,page11,248 page11-249 Disassembly,

816A2 engine:

THROTTLEBODY{T8) page11-247 Inspection. Removal,page1'1-248 page11-249 Disassembly, AIR CLEANER(ACLI Replacement, Page11-244

THROTTLECABLE lnspection/Adiustment,page 11-244 page11-245 lnstallation,

POSITIVECRANKCASE VENTILATIONIPCVIVALVE page11-266 Inspection,

\-

11-11

System Description VacuumConnections D16Y5engin6('96- 97 modelsl:

To EVAPORATIVE EMISSION (EVAPI TWO WAY VALVE

MANIFOLD ABSOLUTE PRESSURE IMAPI SENSOR

EXHAUSTGAS BECIRCULATION (EGR)VALVEend EXHAUSTGAS RECIRCULATION IEGR)VALVE LIFTSENSOR

\

EXHAUSTGAS RECIRCULATION (EGR)CONTROLSOLENOID

VALVE {CVT} \ .'.-' \

I

I \

€VAPORATIVE EMISSIONIEVAPI PURGECONTROLSOLENOID VALVE

)

Qo Qo FRONTOF VEHICLE

To CRUISE CONTROL DIAPHRAGM (wathcruisecontrol)

FUELPRESSURE REGULATOR

O: VacuumhoseNo.

11-12

D16Y5enginel'98 - 00 models):

EVAPORATIVE EMISSION{EVAPI CONTROLCANISTER VENT SHUTVALVE EMISSION To EVAPORATIVE tEVAPITHREEWAY VALVE{98 model) EMISSION To EVAPORATIVE IEVAP'CONTBOLCANISTER FILTER1'99- 00 modelsl

EMISSION To EVAPORATIVE l'99 - 00 modelsl {EVAP) TWO WAY VALVE EXHAUSTGAS RECIRCULATION (EGRIVALVEand EXHAUSTGAS RECIRCULATION IEGRIVALVE LIFTSENSOR

tcwl ..,.-----.-(CWontyl

EVAPORATIVE EMISSION{EVAP) PURGECONTROL CANISTER

EXHAUSTGAS RECIRCULATION IEGR}CONTROLSOLENOIO VALVEICVTI

,t'ffi,

ig

MANIFOLD ABSOLUTE PRESSURE {MAPI SENSOR

EVAPORATIVE EMISSION{EVAP) PURGECONTROLSOLENOID VALVE

Qo

To CRUISE CONTROL DIAPHRAGM (withcruisecontrol)

FRONTOF VEHICLE REGULATOR FUELPRESSURE

o: VacuumhoseNo.

L

(cont'd)

11 - 1 3

System Description VacuumConnections {cont'd} Dl6Y8 enginel'96 - 98 models):

EVAPORATIVE EMISSION(EVAPI CONTROLCANISTER VENT SHUTVALVE {'96coupe,'97coupe:all models, '97 sedan:KL model. 'g8-modelsl To EVAPOBATIVE EMISSION IEVAPITHREEWAY VALVE '97 coupe:all models. {'96 coupe, '97 sedan:KL model. 'g8-models)

To EVAPORATIVE EMISSION {EVAP) TWOWAYVALVE

EVAPORATIVE EMISSION{EVAPI PUBGECONTROL CANISTER {'96coupe,'97coupe:all models, sed6n:KL model)

FUELPRESSURE REGULATOR

MANIFOLDABSOLUTE (MAP)SENSOR PRESSURE

I

EVAPORATIVE EMISSION {EVAPIPUBGE CONTROLCANISIER '97 sodan: l'96 sadan, XA, KC mod6l3l

EVAPORATIVE EMISSION{EVAPI PURGECONTROLSOLENOID VALVE FRONTOF VEHICLE

11-14

To CRUISE CONTROL DIAPHRAGM {withcruisecontrol)

Dl6Y8 ongino ('99 - 00 modols):

(EVAP} EMISSION €VAPORATIVE CONTROL CANISTER VENTSHUTVALVE EMISSION To EVAPORATIVE {EVAPICONTROLCANISTER FILTER

EMISSION To EVAPORATIVE (EVAPI TWOWAYVALVE

EVAPORATIVE EMISSION IEVAPI PURGECONTNOL CANISTER

To CRUISE CONTROL DIAPHRAGM (with cruise control) FRONTOF VEHICI-E REGULATOR

{cont'd)

11 - 1 5

System Description (cont'dl VacuumConnections D16Y7engine('96models,'97coupe:KA. Kc models,'97 sedan:KA, Kc, KL lDx) models,'97hatchback:all modelsl:

EVAPORATIVE EMISSION(EVAPI PURGECONTROL

FUEL PRESSURE REGULATOR

To EVAPORATIVE EMISSION {EVAP} TWO WAY VALVE

MANIFOLDABSOTUTE (MAP) PRESSURE

To CRUISE CONTROL DIAPHRAGM lwith cruise

EVAPORATIVE (EVAPI EMISSION PURGECONTROL CANISTER

11-16

FRONTOF VEHICLE

model): Dl6YTengine('97coupe:KL model,'97sedan:KL ILX)model,'98model"gg model"oo

EMISSION To EVAPORATIVE {EVAP}THREEWAY VALVE l'97 coupe:KL model, '97 sedan:KL (LX) model, '98 modell EMISSION To EVAPORATIVE EMISSION(EVAP) {EVAP)CONTROLCANISTER EVAPORATIVE CONTROLCANISTER FILTER('99- 0Omodels) VENT SHUTVALVE

EMISSION{EVAP) EVAPORATIVE CONTROLCANISTER VENT SHUTVALVE EMISSION To EVAPORATIVE IEVAPI TWO WAY VALVE

PURGEJOINT EVAPORATIVE EMISSION{EVAP} PURGECONTROL CANISTER

FUELPRESSURE REGULATOR

_.\,,..,_..-. {'97coupe: KL model, '97 sedan:KL (LX) model. '98 model)

MANIFOLDABSOLUTE PRESSURE {MAP)SENSOR To CRUISE CONTROL DIAPHRAGM lwith cruisecontrol)

EVAPORATIVE (EVAP} EMISSION PURGECONTROLSOLENOID VALVE

gtt FRONTOF VEHICLE

(cont'd)

11-17

System Description VacuumGonnections(cont'd) B16A2engine:

EVAPORATIVE EMISSION(EVAPI CONTROL CANISTER VENTSHUTVALVE To EVAPORATIVE EMISSION (EVAPICONTROLCANISTER FILTER

To EVAPOBATTVE EM|SS|ON (EVAPI TWOWAYVALVE EVAPORATIVE EMISSIONIEVAPI PUBGECONTROLSOLENOID VALVE

MANIFOI.D ABSOLUIE (MAPISENSOR PRESSURE

EVAPORATIVE EMISSION{EVAPI PURGECONTROL CANISTER

2

To CRUISE CONTROL DIAPHRAGM (withcruisecontrol)

VEHICLE

FUELPRESSURE REGULATOR

11 - 1 8

Dl6Y5 engine ('96 - 97 modelsl:

:li Vacuum hose No *: CVTonly

o PRIMARY1'HEATEDOXYGENSENSOR{PRIMARYHO2S,

SENSOR HEATEDOXYGENSENSOR(SECONDARY SECONDARY HO2S.SENSOR2l ,6i MANIFOLDABSOLUTEPRESSURE {MAP)SENSOR (ECTISENSOR @ ENGINECOOLANTTEMPERATURE IIAT) SENSOR INTAKEAIR TEMPERATURE KNOCKSENSOR(KS) (CKF}SENSOR SPEEDFLUCTUATTON CRANKSHAFT (IAC} VALVE AIR CONTROL IOLE @ €) THROTTLEBODY(TBI @ FUELINJECTOR FUELPULSATIONDAMPER FUELFILTER REGULATOR @ FUELPRESSURE (il FUELPUMPIFPI (i' FUELTANK

o

o

! ' a

{DFUELTANK EVAPORATIVEEMISSTON{EVAP)VALVE AIR CLEANER o (D RESONATOR IPCVIVALVE @ POSITIVECRANKCASEVENTIL/ATION IEGR)CONTROL @ EXHAUSTGAS RECIRCULATION SOLENOIDVALVE

(EGRIVALVE @ EXHAUSTGAS RECIRCULATION IEGRIVALVELIFT @ EXHAUSTGAS RECTRCULATION SENSOR

EMISSIONIEVAPIPURGECONTROL @ EVAPORATIVE SOLENOIDVALVE

EMISSION{EVAP}CONTROLCANISTER @ EVAPORATIVE EMISSION{EVAP}TWO WAY VALVE @ EVAPORATIVE (TWCI @ THREEWAY CATALYTICCONVERTER

(cont'd)

11 - 1 9

System Description VacuumConnections (cont'd) D16Y5engine('98modet):

-: VacuumhoseNo, *: CW only

il) PRIMAFYHEATEDOXYGENSENSORIPRIMARYHO2S. SENSOR 1) O SECoNDARYHEATEooxYGEN sENsoR {sEcoNDARY HO2S.SENSOB2) iq] MANIFOLDABSOLUTEPRESSURE (MAPISENSOR O ENGINECOOLANTTEMPERATURE IECT)SENSOR 5 INTAKEAIR TEMPERATURE {IATISENSOR ! KNOCKSENSOR tKSl O CRANKSHAFT SPEEDFLUCTUATIoN{cKF)sENsoF O IDLEAIR coNTRoL {IAc) vALvE 99 THROTTLEBODYITBI @ FUELINJECToR O FUELPULSATIONDAMPER @ FUELF -TER @ FUELPRESSURE REGULAToR [4 FUELPUMPIFPI (9 FUELTANK (D FUELTANK EVAPoRATIVEEMIssIoN IEVAPIVALVE O' AIR CLEANER (D RESoNAToR

11-20

(9 POSITIVECRANKCASE VENTILATION{PCV}VALVE ?!J EXHAUSTGAS BECIRCULATION (EGR}CONTROL SOLENOIO VALVE '1 ExHAUSTGAs RECIRCULATIoN IEGRIVALVE 22 EXHAUSTGAS RECIRCULATION {EGR}VALVELIFI SENSOR €J EvApoRATtvE EMtsstoN {EvAp} puRGEcoNTRoL SOLENOIDVALVE q4 PURGEJOINT @ EVAPoRATIVEEMIssIoN {EVAP)coNTRoL CANISTER @ EVAPORATIVE EMISSIONIEVAP}BYPASSSOLENOID VALVE ?? EVAPORATIVE EMISSION{EVAP)THREEWAY VALVE ITIIEVAPORATIVE EMISSIONIEVAP}CONTROLCANISTER VENT SHUTVALVE O FUELTANK PRESSURE sENsoR QlI EVAPORATIVE EMISSION{EVAP}TWOWAY VALVE 8' THREEWAY CATALYTICCONVERTER {TWCI

D16Y5engine('99- 00 modelsl:

(PBIMARYHO2S, O) PRIMARYHEATEDOXYGENSENSOR 1) SENSOR HEATEOOXYGENSENSOR{SECONDARY O SECONDARY HO2S.SENSOR2) IMAPI SENSOR 6] MANIFOLDABSOLUTEPRESSURE IECTISENSOR COOUruT TEMPERATURE rO CruCIruC 0AT) SENSOR o rrurlxe ln ETUpERATURE .d KNOCKSENSOR(KS} (CKFISENSOR SP:ED FLUCTUATION O CN,NruXSXITT

IEGR}CONTROL @ EXHAUSTGAS RECIRCULATION SOLENOIDVALVE (EGR)VAI-VE 6 EXHAUSTGAS RECTRCULATION rf exxlust cls nectRcuLATloN IEGR)vALvE LIFT SENSOR EMISSION(EVAPIPURGECONTNOL @ EVAPORATIVE SOLENOIDVALVE O} PURGEJOINT

O THROTTLEBODY(TB) @ FUELINJECTOR E) FUELPULSATIONOAMPER t? FUELFILTER REGULATOR G) FUELPRESSURE OI FUELPUMP(FP) Gi FUELTANK G) AIR CLEANER fi? RESONATOR (PCV)VALVE Gl posmvr cnglrcAsE VENTILATION

VALVE EMISSION{EVAP)CONIROLCANISTER 6 EVAPORATIVE FILTER EMISSION(EVAPICONTROLCANISTER @ EVAPORATIVE VENTSHUTVALVE SENSOR OA FUELTANK PRESSURE er,/tlssloN tEvAPl TWO WAY VALVE 6 :vlponlnvg

0Ac)valvE @ rou an corurnoL

L

cANlsrER coNTRoL io :vaponanveeutssloN(EVAP) soL-eNolD tEvAPlBYPASS d rvlponlrtve EmtsstoN

{onvRlVENT 6 oNgoanonerueltNcvAPoRREcovERY SHUTVALVE (ORVRIVAPOR VAPORRECOVERY €!) ONBOARDREFUELING VALVE RECIBCULATION (TWCI @ THREEWAY CATALYTICCONVERTER (cont'd)

11-21

System Description VacuumConnections (cont'd) D16Y8engine ('96 sedan, '97 sedan:KA, KC modelsl:

{M/T}

i

:

@

l

F @ i

HiiFl (A/T) I

ENGINE

I

i@

l/A. (Or)l \)l#t,/

0) PRIMARYHEATEDOXYGENSENSOR(PRIMARYHO2S.

SENSOR SECONOARY HEATEDOXYGENSENSOR{SECONDARY HO2S,SENSOR2l -l MANIFOLDABSOLUTEPRESSUBE {MAPI SENSOR @ ENGINECOOLANTTEMPERATURE {ECTISENSOR INTAKEAIR TEMPERATUFE IIATI SENSOR !o, KNOCKSENSORIKSI (t CRANKSHAFTSPEEDFLUCTUATION{CKFISENSOR IDLEAIR CONTROLIIACIVALVE @ THROTTLEEODY(T8) @ FUELINJECTOR @ FUELFILTER t;

11- 2 2

I

coor-rruri

i+i

nfi |

/U[ |

,6

@ FUELPRESSURE REGULATOR @ FUELPUMP{FPI @ FUELTANK

(9 FUELTANK EVAPORATIVEEMISSIONIEVAP}VALVE

@ AIR CLEANER @ RESONATOR @ POSITIVECRANKCASEVENTILATION{PCV}VALVE

(D EVAPORATIVEEMISSIONIEVAP)PURGECONTROL SOLENOIDVALVE

@ EVAPORATIVE EMISSIONIEVAPICONTROLCANISTER

A) EVAFORATIVEEMISSIONIEVAP}TWO WAY VALVE

@ THREEWAY CATALYTICCONVERTER (TWC'

D16Y8engine l'96 coupe.'97 coup6: all models.'97 sodan: KL modol.'98 modell:

PRIMARYHEATEOOXYGENSENSORIPRIMARYHO2S, 1) SENSOR HEATEDOXYGENSENSORISECONDARY ? SECONDARY HO2S.SENSOR2l IMAPI SENSOR 3- MANIFOLDABSOLUTEPRESSURE IECTISENSOR ENGINECOOLANTTEMPERATURE (IATISENSOR INTAKEAIR TEMPERATURE 6 KNOCKSENSOR{KS) ICKFISENSOR SPEEDFLUCTUATION 7. CRANKSHAFT a IOLEAIR CONTROL{IAC)VALVE 9 THROTTLEBODYITBI ,! FUELINJECTOR FUELFILTER REGULATOR 1? FUELPRESSURE ! FUELPUMPIFPI 1 { FUELTANK EMISSIONIEVAP)VALVE r 5 FUELTANK EVAPORATIVE

a

@ AIR CLEANER

o RESONATOR

@ POSITIVECRANKCASEVENTILATION(PCV)VALVE EMISSIONIEVAPIPURGECONTROL @ EVAPORATIVE SOLENOIDVALVE

EMISSION{EVAPICONTROLCANISIER @ EVAPORATIVE EMISSIONIEVAPIBYPASSSOLENOIO @ EVAPORATIVE VALVE

EMISSION{EVAPITHREEWAY VALVE @ EVAPORATIVE EMISSIONIEVAPICONTROLCANISTER @ EVAPORATIVE VENT SHUTVALVE

@ FUELTANK PRESSUFESENSOR EMISSIONIEVAP)TWO WAY VALVE @ EVAPORATIVE ITWCI @ THREEWAY CATALYTICCONVERTER

(cont'd)

11-23

System Description VacuumConnections (cont'dl D16Y8enginel'99 - 00 modetsl:

--j

I

n

-fr

1ry|

IMTTI^

14[l(2i) l-

'-

*o'*-

-

COOLANT

]L n r

l

L * ii8'x'",

(]-i PAIMARYHEATEOOXYGENSENSOR{PRIMARYHO2S, SENSOR1) ..2rSECONOARY HEATEOOXycEN SENSOBISECONDARY HO2S,SENSOR2l i3) MANIFOLDABSOLUTEPBESSURE {MAPI SENSOR (ECTIsENsoR O ENGINEcooLANT TEMPERATURE (5) INTAKEAIR TEMPERATURE {IAT}sENsoR G] KNOCKSENSORIKSI ?r CRANKSHAFT SPEEoFLUCTUATTON {CKF)SENSOR .O IDLEAIR coNTRoL {IAc)vALvE i-9]THROTTLEBOOY{TB) (O FUELINJECToR I]'i FUELFILTER .O FUELPRESSURE REGULAToR [t FUELPUMP{FPl .D FUELTANK il' AIR CLEANER TD RESONATOR O FUELTNJEC oN AtR tFtA)coNTRoL vAt_vE .19POSITIVECRANKCASE VENTILATION{PCVIVALVE

11-24

.19)EVAPORATIVE EMIssIoN {EVAP)PURGEcoNTBoL SOLENOIDVALVE €g PURGEJorNT tj EVApoRATtvEEMtsstoN {Evap} coNTRoL cANtsTER C4 EVAPONANVEEMISSION(EVAP)BYPASSSOLENOID VALVE ?3 EVAPORATIVE EMISSION{EVAP}CONTROLCANISTER FILTER A4 EVAPoBATIVEEMIssIoN (EVAP)coNTRoL CANISTER VENT SHUTVALVE C! FUELTANK PRESSURE sENsoR EO EVAPOBATIVE EMISSION(EVAP)TWO WAY VALVE e? oNBoARD REFUELtiIGvApoR REcovERy {oRvR} VENT SHUTVALVE @ oNBoARD REFUELTNG vapoR REcovERy (oRvR) vapoR RECIRCULATION VALVE iP THREEWAY CATAI.YTIC CONVEBTER {TWCI

DI6YTengine('96mode|.,97coupe:KA,Kcmode|s,,97sedan:KA,KC,KL{Dx}modets,'gThatchback:a||models}:

COOLANT

o

l) PRIMARYHEATEDOXYGENSENSOR(PRIMARYHOzS,

1) SENSOR HEATEDOXYGENSENSOR{SECONDARY SECONDARY HOzS,SENSOR2) r.-. IMAP)SENSOR MANIFOLDAESOI-UTEPRESSURE IECT)SENSOR .t) ENGINECOOLANTTEMPERATURE (IAT}SENSOR INTAKEAIR TEMPERATURE (CKF)SENSOR SPEEDFLUCTUATION CRANKSHAFT a:!)IDLEAIR CONTROL(IACIVALVE BOOY(TB) -o THROTTLE FUELINJECTOR aroFUELFILTER a1tFUELPRESSUREREGULATOR

o

|-

FUELPUMP IFPI [3) FUELTANK

EMISSION(EVAPIVALVE @ FUELTANK EVAPORATIVE

aoAIR CLEANER (oRESONATOR IPCVIVALVE VENTILTATION a POSITIVECRANKCASE EMISSION(EVAP}PURGECONTROL @ EVAPORATIVE

SOLENOIDVALVE

(0 EVAPORATIVE EMISSION(EVAP)CONTROLCANISTER EMISSIONIEVAPITWO WAY VALVE @)EVAPORATIVE (TWCI THREEWAY CATALYTICCONVERTER

(cont'd)

11-25

System Description VacuumConnections(cont'd) Dl6Y7 angin6 ('97 coup.: KL mod€l, sedan: KL (LX) model,,9g modet):

i1] PRIMARYHEATEDOXYGENSENSOR(PRIMARYHO2S, SENSOR1) E) SECONDARY HEATEDOXYGENSENSOR{SECONDARY HO2S,SENSOR2l ABSOT_UTE €l MANTFOLD PRESSUnEtMAp) SENSOR €r ENGINECOOLANTTEMPERATURE |ECT)SENSOR €] INTAKEAIR TEMPERATURE IIAT}SENSOR 6 CRANKSHAFT SPEEDFLUCTUATION ICKFISENSOR 17 IOLEAIR CONTROLIIACIVALVE @ THRoTTLEBoDY {TBI O FUELINJEGToR (9 FUE|-FTLTEF O FUELPRESSURE REGULAToR @ FUELPUMP{FPI (D FUELTANK @ FIFL TANK EVAPoRATIVEEMIssIoN {EVAPIVALVE (, AIR CLEANER

11-26

(tORESONATOR l? PoSITIVEcRANKcAsE VENTILATIoNIPcv}VALVE IA EVAPORANVEEMISSIONTEVAPIPURGECONTROL SOLENOIDVALVE 19 EVAPORATIVE EMISSIONIEVAPICONTROLCANISTER E EVAPORATIVE EMISSION(EVAPIBYPASSSOLENOID VALVE €' EVAPoRATIVEEMIssIoN IEVAPITHREEwAY vALvE Q' EVAPORATIVE EMISSIONIEVAPICONTROLCANISTER VENTSHUTVALVE @ FUELTANK PRESSURE sENsoR {?1!EVAPORANVEEMISSIONIEVAPITWO WAY VALVE ?5 THREEWAY CATALYTICCONVERTER ITWC'

Dl6Y7 engins ('99 - 00 modelsl:

a PRIMARY1)HEATEDOXYGENSENSOR{PRIMARYHO2S, SENSOR

6t

sENsoRISECoNDARY iiconoanv neareooxYGEN

HO2S,9ENSOR2) (MAP)SENSOR MANIFOLDABSOLUTEPRESSURE (ECT}SENSOR TEMPERATURE COOLANT @ ENGINE (IATISENSOR !., INTAKEAIR TEMPERATURE ICKFISENSOR SPEEDFLUCTUATION CRANKSHAFT IOLEAIR CONTROL(IAC}VALVE @ THROTTLEBODY (TBl ao FUELINJECTOR @ FUELFILTER REGULATOR @ FUELPRESSURE FUELPUMP (FP) (} FUELTANK @ AIR CLEANER @ RESONATOR

o

VENTILATION(PCV)VALVE 6d POSITIVECRANKCASE

coNTRoL PURGE 6 rvapoamve eutssloNtEvAP) SOLENOIDVALVE COPURGEJOINT

cANlsrER coNTRoL 6 evlponnnve eutssloN(EvAPl solrNolD BYPASS i evlponnnve eussloN {EVAP} VALVE EMISSION(EVAPICONTROLCANISTEN 6) EVAPORATIVE FILTER (EVAP)CONTROLCANISTER EMISSTON @ EVAPORATIVE VENT SHUI VALVE SENSON A FUELTANK PRESSURE

rwo wAYvALvE d rvlpoamve emtsstoNtEvAPl loRvnlvENT vAPoRREcovERY 6 orueonnonerueLING SHUTVALVE {ORVR)VAPOR €) ongolno neruellNc VAPORRECOVERY VALVE RECIRCULATION (TWC) €) THREEWAY CATALYTICCONVERTER

(cont'd)

11-27

I a

System Description VacuumConnections(cont'd) 816A2engine:

(' PRIMARYHEATEDOXYGENSENSORIPRIMARYHO2S. SENSOR1l .?) SECONDARY HEATEDOXYGENSENSOR{SECONDARY HO2S,SENSOR2) 13] MANIFOLDABSoLUTEPRESSURE (MAP)sENsoB i' ENGINECOOLANTTEMPERATURE IECT)SENSOR O INTAKEAIR TEMPERATURE ITATISENSOR i6l KNOCKSENSOR{KS} O oRANKSHAFTSPEEDFLUCTUATIoN{cKF}sENsoR @ IDLEAIR coNTRoL (IAc} VALVE €) THRoTTLEBoDy trB| (D FUELINJECToR O FUELPULSATIoNDAMPER [D FUELFILTER @ FUELPRESSURE REGULAToR !I FUELPUMPIFP) f,' FUELTANK (iD ArRCLEANER t' RESONAToR '.1]iPOSITIVEcRANKcAsE VENTILATIoN{Pcv} VALVE

11-28

@ EvApoRATtvE EMtsstoNtEvAp)puRGEcoNTRoL SOLENOID VALVE JoINT @ PURGE €t EvApoRATtvE EMtsstoN(EVAptcoNTRoLcaNtsTER (EVAP) QAEVAPORATIVE EMISSION BYPASS SOLENOID VALVE @ EVApoRATtvE EMtsstoNlEvAplcoNTRoLcaNtsrER FILTER @ EvApoRATtvE EMtsstoN{EvAptcoNrRoL cANtsrER VENTSHUTVALVE @ FUELTANKPRESSURE sENsoR (EVAP} GI EVAPORATIVE EMISSION TWOWAYVALVE @ ONBOARD REFUETING VAPORRECOVERY {ORVR}VENT SHUTVALVE @ oNBoAnDREFUELING vApoRREcovERy(oRvRlvApoR VALVE .(c} RECIRCULATION THREE WAYCATALYTIC CONVERTER {TWCI

ElectricalGonnections('96- 98 Models,'99- 00 Dl6Y5 enginewith M/T)

(

To A/C PlEStUnC 6wrctt

clEc{

.2.Arr pt6rt, DraYt.nlh.t .nsrF Drar, .ndn arr .nd Drart I .a: AfI =.5 Er..d afr.nd Dla\t 6eh. r?, cvt (D,t6ys ddn.tDd Oiew d!lh. .8:'S6 Dr6Y3 dsin. td|p.), '97 Dl6Y8 {tin. o [rnEnoRUGtlTlt.s Ar lG nod.ll, sa Or6Y5 mdn', {cou9.; .ll Dod.b..r!.t:

o HoRxtr5 AF

'10: MfI lD1aV5.ncir.l rrt. Exc.orM/I (D15Y5.ntin.l r12: O16Y5.Ol6Ya.ncln.

o rcr l|o Ar

No, 13l{ Et tU[9 ll5 Al No. ri Al'ltElATOll gt l€Ntol t{o. 3l EtAatEn gc at lt.5 al

r: h tL

o.d..{ood

io/t

lt,5 Al

l.v bor

(cont'd) rt5. i9? Ot0\., ssid l6up.; (L mod.l,..d..: Kl ttxl mod.ll, 9a Dl6rr.ndn.

11-29

System Description ElectricalConnections('96- 98 Models,,99- 00 D16Y5enginewith M/Tl (cont'd)

SENSOF

PRESSURE SENSOE EGR UFT s E N s o R* 3

c-rrusren vemsrurvtvrlf;

EGR

solENotovALvE*3

uF

wec soLeton vltve'!2

SENSOR

SPEED sENsoR'2 COUNTEFSHAFI s P E E Ds E N s o R * 2

soeeloto vltve l*2

ToI|{TEFLOCK CONTBOLUNIT

ECM/PCMA(32P)

ECM/PCi/lBEsP)

ECM/PCMD(16P)

TERMINALLOCATIONS

11 - 3 0

*l: t SA model *2: A/T(DI6W,oi6y8 engine) *3:CVT(DI6Y5 6ngine) 1.4: A"/Tand Dl6Y7engine *5; ExceptA/Tand Dl6Y7engine *6: A/T(O16YO engin6) *7:CW(DI6y5 ongine)and D16y8engino *8;'96 Ol6Y8sngine(coupe),,97 D16y5 ongine(coup€:all modol!,sedan: KL modoD,'98 Dl6Y5engine,'98 ot6Y8 en9ne *9:D16Y5engin. *10: |!UT(D16Y5 engine) *ll : ExceptiUT(Dl6Y5engine) *12: D16y5,016yoengino *13:DI6YO engine *14:Dl6Y7engine *15:'97D16Y7 engine[coupe:KL modet, ssdan: KL(LX)modetl,'9gDt6y7engine

(

lSEiV|qE CHECK @NI\IECIOR

[*-

I

l-.i-*.,*,. r-Bu(

@NI\ECIOR

f-* ceor

(cont'd)

11-31

System Description ElectricalConnections('96- 98 Models,,99- 00 Dl6y5 enginewith M/T) (cont'd)

ptozs'" pozslttc*rr Ho2s(sENsoFl) c125

WHT,'RED'l

s02sHTc -BLK/WHT *12

aLKlyeL!

wrlaeo!{-L wrzneo.=r.: GFN/BLr-I FcFN,wHrJ

alvwrr'Ll

-ff ar-x,rvnr,

f--fi"-r".^'--] I LraeL*ro

;lcnr-caz

fi

Ho2s (sENsoR2) crls*'u

\ pozsntc*lu H O 2 S( S E N S O R '

:soL*3

c142

ecRcortnoL*3 SOLENOID VALVE c14o BLU/ALK VT€C PRESSURE

12: A/T (Ol6Y7, Dl6Y8 enginel '3: CvT lDt6Y5 engane) ia: A/T and Dl6Y7 enqine 15: Erc.pt A/T.nd Dr6Y7 engine '6:A/T (O16Y8.ngine) i7: CVI {Dl6Y5 Gosin.) .nd D16yo snqine r8:'96 DI6YB .ngi.. ,97 lcoup.), Dt6yl ensio. (coups: lll mod6ts, s.d6n. KL dod6ll,'98 D16y5 6ngine.,9a D16y8 o n g i n e , ' 9 9- 0 0 O t 6 Y 5 ( M / T l o n o i n e '9: Dl6Y5 ongine '10: M/T lO16Y5engine) 'l r: Ex@pt M/T (Dt6y5 engine) r'12:Ot6Y5, Ol6Y8.ngine

11-32

'15r'97 D16Y7.ngine {coupe: Kt- model, sedan: (L (l-Ximod.l), '98 Dl6y7 angins

PSPSWITCHI

c1t7 /YEL Jlr.^r'\-r

atu/wHT =..'-_

wHr---] FaMrr=ll

8r-x,--L-

I

L_id-ll

|

IT GRN/WI{T CAI\IISTERVENT

tr--+r -*' I =

calT

_

66s' l-BL!(---

_-o_ I

ctor

-

fr:-l

lf.a I CLUTCHSWTCH'X

(cont'd)

11 - 3 3

System Description ElectricalConnestions{'96- gBModels,,99- 00 Dl6yS enginewith M/T) (cont'dl

s€N90fi

I

I rDc

rDic M

sEt\tsoi

RET'

I

ct(P P

I cxP

CXPM

YEUGifl

CIG M

FIF']EE TTiT

8At{/ aR / !R|{/ AAX/

\

lhx/ ALJ(I

A& L:]

1 1-3 4

l'l

12:A/t tD16Yt,Dt0Y8.ncin.t 13: C1/t lDtOYSssin.t '4 A/T .I(| Di6Y7 .nsi.. r5: Erc.tr A/r ..d Dl6Y7 .nsin. t6: AIt lDl6Y8 .ngin.l i7:CvI lO16Y5..!ln.) ..d Dt6Y8.neln. 13: s6 Dt6Y6 ftsi..lco!p.I. 9t Dr6Y8.nqin. lcolF:.rl mo.Llr..d.n: (L no.t.l),,s Di6Y5.nsin.. '98 DI6YB.ncin.,'99 -0o O't6Y5(M/Tt.nsin.

r10: M/I {D16Y5.nsin.} 11r: Exc.pt M/T {D16V5.nsin.l '12: Or6Y5,Dl6Ya.ngin. .i5:3', O16Vt.ngin. lcoup.: X! mod.l,..d.n: (L lLXl mod.ll, 93 ol6Yt.nsin.

LCB'

NCSC'

L

(cont'd)

11 - 3 5

System Description ElectricalConnections('96- 98 Models,'99- 00 Dl6Y5 enginewith M/Tl (cont'dl

cart c5o2

Cl3i C,ta6

c5t2

t--l

o",.uonr. l| FSIX'

GA|l/OfiN

|

Orl0 GRN/BIXI. LT GRflr-

-

T

LT

8r"K/8ru

{

FYEI

g. l

C50il

l

c5t0 r I

GRN/aaX: dYEr. LrGiN' -

8rK/8ru

-

f"*

f r

- -J

BEo

I

GRN-_'-

8ru'--1

".*,".u---f -

REo--__-

Etur

YEri Gur{------Brur-

l

L ArGEAR ?O6frO

Swlrcs

IYTENLOC|( CO TROT UMI

BLu/REo,-

T' l

f

B!u/FEo,-----l

FronIAD|AtOh FAx RElAv EqtswIrEH ro a/c swrrcH

t_.1

ct3t c&t6

12:A/l (Dr5Y7,Dl6Y8.nglnel r3: CyI lOl5Y5..sinel '.: A/T.nd Dr6Y7.nsin. 15:Erc.pt A/T .nd D16Y7.ngin6 '5r A/i {Dl6Ya.ngin€l 17:CVT (D16Y5.noin.) rnd O16Ya.ngine '8r'96 015Y3.ngin. lcoup.), 9t O16Yasngin. (coop.r.llnod.l.,..d.n:KLmod.l), 98ol6Y5o.gins, '94 Di6YA .ngin., '99 - 0OD15Y5lM/Tl 6ngin.

11 - 3 6

,10: M/T {D16Y5..sin.l .11: Erc.pt M/l lOr5Y5.nginel '12: Ol6Y5,DlSYa.ngin. '15: 97 Dl5Y7.ngin. {coup.:Klmod.l, $d.n: (l lLXlmod.ll, 9A DIOYT.nsin.

UGIfI o5A)

&AMRY 60a)

ct31 WH'/ALU

-wHT/gtU

-BLVRED

A//C CIUICH

c354 -

GRN/REO

f"* u o€R.HOOD BOX FUSE/REIAY

*t*'fi

-l

-*r F*n*Aros^

I lsrc 8ru/wHr-.1 YEUGRN |i il?-\.p--lI a I ncB

|

f*-__l I

".-;"{ BtK,$rtf t

I

lll III

F I J EPLI I / | P

lt n * l ll l

n

l5-,i I Na15 l arlnrl Ton I sPsE*soaoia l<\-,o I NczsMErER I 05$

'*+

F-l

l

I | | l Ll l l lil I |

uN0€n-oAsH FTJSE/FEIAYBOX

(cont'd)

11-37

System Description ElectricalConnections('96- 98 Models,'99 - 00 Dl6Y5 enginewith M/Tl (cont'dl

atu

EVA? EVPASS

F]I " l Tf

c13r c4a6

R€D/ AED GRII

o.3a

_ lr- tr---------------

t | ll

1 |

J tt

{

t

) caQ

Lll

I |

II

lrl --

I lJ/c

.t

I| r

]-t

GRt{n'Y}rP-___-.l

i

rcrr

-

l

l

ol25

Srli$},€ 'AAXE SWIICH

'2: A/T {Dl6Y7,016Y8.ngin.) ,3: CW {Dl6Y5.nsin.l 14:A/T rnd DIGYTlnginc '5: Ex6pt A/T.nd O'l6Y7.ngin€ '6r A/T (Ol6Ygcnsin.) rtrCvI lol6Y5 .ngin€) .nd Ol6Y8€ngin. 18:'96O16Y8.ngin. lcoup.l, '97 Dl6Y8.nein. {coop.:.ll mod.l., t d.nr KL mod.t,,'98 Dr6Y5.ngin6, '98 Dr 6YE.nein., '!Xl- 0OO16Y5{M/T).ngin.

11-38

19: Dl6Y5.ngin6 rl0: M/T {Dl6Y5.ngin!) il1: Exc.pt M/r {Dr6Y5 angin€l '12: Dl6Y5, 016Y8.ngin. '13: O l6Y8 angin. '1a: Ol6Y?.ngin. '15:'97 Dl6Y7..qin. (coup€: Kl dod.t, sd.n: Kl (Lx) mod.l), 98 D16Y7 6ngin.

ElectricalConnestions('99- 00 ModelsexceptDl6Y5 enginewith M/Tl

-:

T

)

I FUEI II{JECIOBS

L ChUISECOXTnOI UNII lo CO|IPi€33OR CUrrcH BEI Y lo A/c PRESSUiEalYrc|l To FAoIAIOR FAI REL Y EcT3wllcll

SENSOF

FIJSES: (DIN1ERIOR UGHTO5A)' @ BACKUPO5A* @HonN(15A). (DSATTERY OOA* @ rcl (104*

@FrvM(r5A*

(lEA) @No.I3FUELPLMP

@ No.25MEIERCrsA) SPSEI{SOR OJA) @ ib. 15ALTERNATOR SIGML (75A) O ib. 3l STARTER ': h lhc ud.rhood lu..//rcbY box

(cont'd)

11-39

System Description ElectricalConnections('99- 00 ModelsexceptDl6Y5 enginewith M/Tl (cont'd) 0

T:I

1 c26 ECT

EVAPPURGECONTROL SoLENOtOVAIVE

c25 tAT

EVAPCOI{TROLCANISIER

ECTSENSOR

D

IATSENSOR

ta-t HO2S (sENSoFt

)w

EVAPBYPASSSOI.ENOID VALVE

cl Po2s{tc

"Eso! 87 EGFcoNTRoLsolENorovaLvE'"

c16PHO2S

vlsBr2 VTECSOLEr{O|D VATVE

H02S iSENSOR2)

,w

A23 SHO2S

VTECPFESSUFESWITCH

-t ,.1 f

BRAKE SWITCH

sEt{soR I

c7 sG1

--t SENSOB (Bulnl o

F

@E GAUGE lfil /V\ |

_r*

l -

I I

D5VBSOL

*

l-

o4tNDA14

lassEMBL

I I

N DTI SPEEOSENSOR NC DTO

SPEEDSENSOR

tr

L S +B l 7 T'I AT?04

Pr.l

03alP03

LS- a3

UNEARSOLENOID VALVE

LCA 01 LOCI LCB 03

SHE D2

P CONTBOISOIENOiDVALVE B IOI{IROLSOLENOID VAIV€ A

SHIFI COTITROL SOLENOID VALVEB To IIIT!FLOCKCONTROLUNIT

POStTtON

t---I -.._.._.._.._l

11-40

,'-J

L

-'

DRIVEPULLEY SPEEDSENSOR GAUGE ASSEMALY

ORIVENPULLEY SPEEDSENSOR SECONOARY GEABSHAFT SPEEDSENSOR

SOLENOID To INTERLOCK CONIBOL UNIT

*l : USAmodel *2: a/T(D16Y/,D16Y8engine) ,.3: CW(016Y5engine) *4: A/T and D16Wengine *5: ExceptA/Tand Dl5Y7engine *6: Cw(Dl6Y5 engine),Dl5Y8engineand 816A2engine

EcM/PcMB(25P)

EcM/PcMA(32P) 10 16 1 7 1 8 1 9 2012122 23 7

t4

I

I

11

24

ECM/PCMD(I6P)

ECM/PCMC(31P)

I

(cont'd)

TERMINALLOCATIONS

11-41

System Description ElectricalConnections('99- 00 ModelsexceptD16Y5enginewith M/Tl (cont'dl

UFTSENSOR

sEnucEcSEcK CONNEC'OR L

ABS CONTROL UNIT

_r"* -

CONI{ECTOR

"to'

aLul-_--r

".* I I

lll*,

1 1-4 2

BLX

ft *31ou..." "on"t"to"

\

llo2s (sENsoR t

SECONOARY HO2S(SENSOR 2)

I- wrrzneo'f15151 -]

FCA ,a[HT fFELWWHI.FFi/v\^F ETJVWrfT'--I l+

I I |

HO2S(gENSOR2)

\-

11-43

System Description ElectricalGonnections('99- 00 ModelsexceptDl6yS enginewith M/T) (cont'd)

Fl TI "u,

| LB|.X'--Jf-ll

cad__J

PsPswrcH'

h/wFDl

q30

t-l + l

1""

vss

VTEC soLEt{oto VALVE clia ----J----] BLTC.YEL

neozvef--l

neo,"yrr.'--{l- ---5

|

EVAP PUBGE CONTROL SOLENOIDVALVE

clat

EVAP CONTROL CANISTEFVENT SHUI VALVE

l,," I

11-4 4

-E--l qYP $rsoi

| I

^ Y

I I

I /.JrDc I Y SEr$OiI

-

l

I I

t

Il

I

I

f--Av) o' I sEr,rsoi I

|f-------l

ll

' cM

I

|

_L:_---J DIgIRIBUTOR

til |-

EiN/ ELxl

tr:-l

FI

t E l--

TI

|

CKFSENSOR

I

I AFN/ BRN/ ar-xl ELxt

BFN/

ar-xl

EFN/ aLKl BRN/ B!K'

J-

I*l

I

;q ,l o l L P I

(cont'd)

11-45,

System Description ElectricalConnections('99- 00 ModelsexceptDl6Y5 enginewith M/Tl (cont'd)

cl09

racvP*{ -

-l qt

BLK/eLu

pl

SOLENOID VALVE

--

MAINSHAFT SPEEOSENSOR clla

COUN'IERSHAFTSPEED SENSOR c121

t t

I

I

UNEAR SOL€NOIDVALVE

1 1-4 6

"f

iFx/'ORN

I

' - LI

YEL

Lll c!o4

crro

qF /ELKT

lrcnf

RED

GiN

aLuT

At c€AR PO3tllOl{ SWlrCH

wnnrd#"Si"*fi[* BLU GR+ CnXr#

BLI,IREO+

I

"

35111'o,u",,

F 'h MDIA'ORFAr{FELAY'

ToA/CSwlICH

(cont'dl

11-47

System Description ElectricalConnections('99- 00 ModelsexceptDl6Y5 enginewith M/Tl (cont'dl

DRIVEPULIEYSPEEOSENSOF

SECONDAFY GEAF SHAFTSPEEOSENSOR

PNK/BLK

YE!' SCLSM PNK/BIU

INHSOL

cnvauC

c131

GFN/Brf

CrKa

I f L_

cnvsuC

,T

11-48

GEAF POSII|ON SWITCH

;:l A/CO-UfAl

ELD'' BLtCWlfi -

T

BLK UNDER-HOOD BOX FUSE/RELAY

YEVGRI{

*tT sLrc\t/trt 1 BLvwHr 1 c501 r.. -{

UNDER-DASH FUg€/FELAY AOX

(cont'd)

11-49

System Description ElectricalConnections('gg- 00 ModelsexceptDl6y5 enginewith M/Tl (cont'd)

Elt^-l

'tF'tF

I

t L--

L

q23

r_ c446

- l l-- ,.,-,.u vever-u

| l cnrzer-rc-{f

cnnzar-x,

'-

YELI6RN BLK __1\

CsO5 -r-\ f/ P I t

\

\'----l

/

I

YEL/GRN

-

YEL/GRN

YEVELU

-

YEVBLU

lr cat'

_

qar/auC

LT GRN2

-

qaN/eud

BLVWHf

-

BLK/WiT

BLIII

-

BLul

I

Ft,EL PUMP

EVAPBYPASS SOLENOID VALVE

ft

I lJ/c T__l I t.]

I

ti-l T

I LwHr

c425__ GRN {-l

_cnnzwm'_{h\_,

I aBAKEStlflTCB

*l : USAmod6l *2: A/T(Di6W,Dt6Y8engine) *3: CW(DI6Y5engino) *4: A,rTe16 915y7"nn,n" *5: ExceB AfTand Dl6Y7engine ,16:Cyr(DI6Y5€n9ine),D16y8engineand B,tOA2 engins *7: Dl5Y8,816A2engine

11 - 5 0

SystemConnectors[FuelPumpl '95 - 98 models, '99 - 00 Dl6Y5 engine with M/T:

c792*r,.'5

c793|.,.s

c7931...15

c565

E ffi

NOTE:. . .

ffi

*1r USA mod€l '2: A/T {O16Y7,D16Y8 ensine} 13: CVT {O16Y5ensin€l *4: A/T ind D16Y7 .ngane *5: ExceFt A/T end D16Y7 engine '6: A/T lDl6Y8 enginel *7: CvT (Dl6Y5 enginoland 016Yg engine '8: ,96 Dl6YB engine {coupe),'97 Dl6Y8 sngine {coupe: sll models, s€d.nr KL modell, ' 9 8 D l 5 Y 5 . n g i n e , ' 9 8 D 1 6 Y 7e n g i n e , '99 - OODl6Y5 (M/Tl engine r9: D16Y5 ongine t 1 0 : M / T { D 1 5 Y 5e n s i n e l r 1 t : E x c e D tM / T ( D 1 6 Y 5e n g i n e ) t l 2 : D 1 6 Y 5 ,D l 6 Y g e n g i n e *13:Dl6Y8 engine r14: D16Y7 engine *15:'97 Dl6Y7 ensine {coupe: KL model, sodan: KL (LX) modeu,'98 Dt6Y7 engine

them (for example'YEUBLK1 Differentwireswith the samecolor have beengivena numbersuffixto distinguish and YEVBLK'are not the samel. O: Relatedto Fueland EmissionsSystem' - Connectorwith maleterminals(double outline):View f rom terminal side - Connectorwith femaleterminals(singleoutline):View from wire side

11 - 5 1

System Description SystemConnectorsIEngineCompartment] '96 - '98 Dl6Y5, Dl6Y8 engin€, '99 - O0Dt6y5 engine wirh M/f:

I :

ir I

\

11-52

c102

r'Trtt

:lo.

l'lrl lrl.l

_-l l6lwtr,eED' -l E|BFIvBLK l6lga-tnEcl--l

c108

c107

ffi

ffi

Cl0,r {C.nadal

r'fr] l6mrrrnru I ElilrwA----l lTltHtBtu__l

c109..

c106

c105

Etr ffi Bffiffi

c113*1

fr

r'frtr -l 16lonl l@LYEUBLK' I

bfgl-rcgtu'---l

c114

ffiffi c1a2.r

fr ,D GRN/BLK'

(9 LT GRN? BLU]

3 8

NOTE:. . .

Differentwireswith the samecolor have beengivena numbersuffixto distinguishthem and YEUBLK' arenot the same). O: Relatedto Fueland EmissionsSyst€m' - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View trom wire side

(for 6xample,YEUBLK1

(cont'd)

11-53

System Description SystemGonnectors[EngineCompartmentl(cont,d)

t

36 - 98 Dl6Y5, Dl6Y8 engine, ,99 - O0Dt6y5 engine with M/T:

I

C1,&r.3

c139r" c120

c354r1

c122 G101

11-54

I II

c112

cl11

c1t7

cl16

c1t5

fr

r'ffi] f'TBLir-l lO BLX,YEI

I

l6lEtu^tHr__-l

c120

c118"

c122

c123

i

trl-clrl---]

I

latlIBLU,

BLU5

REO!

YEL'

9 8tu 10 BLK/YEL

5

c128.'

c127*'

fr

ffi

ffi

IFFEc'--__l ftlwHn-'_l

fOTwHn-_-l I

-c,1*

:.trn .EL

[tT,l.l

v

Ii

16lwrrin+o' t liSlcFN/BLK I 16T8LK^'Er--l -.,IBaK,r/Hr. I

o

YEUGFN

8L(,

c126*'

lOlREo.

ffi

ffi

ffi

ffi

wHl/8tK

I

c125

c121*'

1618r-uf/EL-_] -l 161-cfl,avHr

cl45rrc

c141*' ___l:t_

c1a0rt

c13!,.f

E

fr

tdl cnN/YEt--l

l6lgrf,---_-l IOIREB

l-lrl I'

I

LTGRNA/VHT I

f€,]-BLK,rEf-__l

c351

Ft_

t-El-r 3l l 1 I 2 'l u l

l-,T,ITd t_-Ttli I

l.l

16lvvrrr/BtK---.l

BLF--l l g l c n N / B r KI , lETcRNi ET-YtrrrruBiu-__-l lO YEvBru I 16rlsrK'

ET-

f+plr-,

--

I

-_l

q]54't

r,f,"| I i IBLK4/VHT

I

lOlsLK I IO LGRN/REDI

NOTE:. . .

them Differentwireswith the samecolor havebeengivena numbersuffixto distinguish and YEUBLICare not the same). O: Belatedto Fueland EmissionsSystem' - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutlins):View from wire side

(for example,YEUBLK'

{cont'd}

11 - 5 5

System Description SystemConnectorslEngineCompartmentl{cont,dl

\

36 - 98 D15Y7€ngine:

'l

\,

11 - 5 6

c1o4 '1

c102

c101

ffi l3l.l

f,ftl

f

6 WHT/BLU

BLI(YEL

YEVGflN I BLU

BLK' 3 YEVBED

'4. B R N / 8 L K '

c104 lcanadal

r'ftl

c105

ffi

I. WHT/FED. I | ? lEFN/8LK' I

f3TBr--/BEo-l

BLK,A/VHT

.alY E U B L K i

l 0 BLKYEL

c108

c107

c106

ffi

EE

ffi

c112

ffi

c113*!

r=1 ,

'

l

\

\2 li

G R N -.

ftELiJ

-l

I

o

GRNELKI

o ELUT

3

1 I

givena numbersuffixto distinguishthem {for example.YEUBLKl NOTE:o Differentwireswith the samecorornavebeen and YEUBLK'are not the same). O: Relatedto Fueland EmissionsSystem (cont'd) with maleterminals(doubleoutline):View from terminalside a - Connector side wire from (single View outline): - Connectorwith femaleterminals

11-57

System Description SystemConnectorsIEngineCompartment](cont,d)

\

'96 - 98 Dl6Y7 .ngin.:

\

I 11 - 5 8

c114

c109

ffi

r'ff;t Flo-'u

I

l! veugLx' I

ftFwatu;'--l

r'ftr BLKtEt

ffi

Flrl

I O I G F N '-

fdl'.,c---_l l?

c123

cl18 {A/T}

cl17

16lBarr--

I

b]-Br.-^^,Hr-_-l

cl24 (A/Tl

c125

fr ffi

l3l.l

lTlzRN,tsril ---l I l6l-YtL,

-l lTltHr/R$' loiiED/vEr--l bfBaK/vEL- l f!]BLX,1,,iHT'-l

t

I

l

YEUGNN

8LU5 @ CRN: YELl 5

cl26 (A/Tl

fr

fol;nrr-_-l lOlREo.

o

BIK3 BLU 10 8LX]"/E! 9

c121 |AFI

cl28lA/T)

ffi

Fl,l

16lwHr--l I

lolFED/wHr I fd-cRN/8tK'_]l

BEF

lOlREp

IC ISLU/YEL

I

c141r16

ffi I

I 161-Grr.,*1/Hl

lO LTGBN,.VVHT I

161-BIK/YEL-_--l

Gt54*, F1Eh

l'l3LlJ

l6ElKl,,/Hr-l -_l

I6TBLK

R/E D IO LGRN

I

them NOTE:o Differentwireswith the samecolorhavebeengivena numbersuffixto distinguish

L

(for example,YEUBLK1

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

11 - 5 9

System Description SystemGonnectorslDashand Floor] '96 -

98 modols, 'gtl - 00 Dl6yS engine with M/T:

11-60

I

crlo tA/Tl

6 t 7

v

8 l s l r o' t l

12

!t

ffi

tffii

lEr.r.r,ll l1 lslx,^/tl' ll lsl'(^,!Hr

-]l

13 wHT,aLK

FF*

lllrlnEo' l?IBLX

I I

I I

BLX

I

5 BLU

l-r-lw'r/cFNl'l '

sdurnyAlrm sFr.m

a:2'

c125

w

l--r;-l

l! LcFN,.,vH?| lalwHrresN I lrl| hl- -

L]-]llg!N ,-l ll lcRY I l(JcRN^nH PI --.1 l6ltHrGFN

22

csto |ArIl

BLK YEL

suffix to distinguishthem (Jorexample,YEUBLKT Differentwires with the same color have been given a number and YEUBLK'are not the same) a o: Relatedto Fueland EmissionsSystem' (cont'd) side a - Connectorwith maleterminals(doubleoutline):View from terminal wire side from - Connectorwith femaleterminals(singleoutline):View

NOTE: o

11-61

System Description SystemConnectorslDashand Floorl(contd) '96 - 98 models,'99 00 Dl6Y5 engine with M/T:

c432*13

1 1-6 2

(

(O16Y5, Dl6Y8.nlin.3l

lOl6Y?.ngir.l

C134{EC[r,l/FCMal

ct33.r tFcM-B)

c t32 {ECt/r/pcM-a) 6 E 2 12 t 3 l/a 'ts t 6 1 7 1E l 9 20 21 2a 29 30 25

9

l0

tl 24

c{t3

ca3l

cr35lEcM/PCM-D)

ffi

f'Tfl'n

--Tttr-Ei ll FltEtstK

l. 9

r o l r t

7

12 t 3

@

I-IBLffiHJ-Il]l ltlcRr'r/wlr -l l-''lwHtREcp --l liELx/wNr'

FfwNr/RED''_l l lTltHr/BL(

I

l!

2 12 1 3

a l 5

8

9 t0

1 7 t8 l9

ffi

FIrt Irli I tilwHT,"Ed-l | . lcFMMr I 11 BLX^VHT'I B!x.^rHr I 11

(for example,YEUBLKT NOTE:e Differentwireswith the samecolor have beengivena numbersuffixto distinguishthem same). and YEUBLK'are not the O: Relatedto Fueland EmissionsSystem - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side

11-63

System Description SystemConnectorsIEngineCompaftment] '99 - 00 D16Y5 ICVT),D16Y8engine:

cl14

*1: USA model '2: A/T {D16Y7, O16Y8engine) *3: CVTlD16Y5engine) *4:A/T and D16Y7engine *5: ExceptA/T and D16Y7engine *6: CVT {D16Y5engine). O16YBengin€and 816A2 engine *7: D'|6Y8,81642 engine

11- 6 4

C142'3

c'r02

c101

r'fil--dl

_"1on

ffi

{Canada)

lrl2 3l

l3 {l

ffiffi

_-l lSltHr/REo" ll Fl xrvef I F]-wHrr+r/BLU

lElwHr/FED"lttl-R^r/BLrlSfBruritnEp-

c108

c'r04

A

---l

I€ IYEVBLKI

r-E--r 1 1 2 l

\^y

'-l-t_, l 1 l 23 l

lglE*

C11,t

cl13*,

c109*.

|6IcFN;--l FIBLr

I

l

|5lBwBuJ-u--l

c137r'

c138'5

c e NOTE:. . .

c112"

ffi

c302

ffi

Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1 and YEUBLK' arenot the same) O: Relatedto Fueland EmissionsSystem. - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side

(cont'd)

11 - 6 5

System Description SystemConneetorsIEngineCompartment](cont'd)

v

'9!l - 00 Dl6Y5 {CvT}, Dl6Y8 onginol

C14,0*3

c139 cl20 c1{{}

c122

11 - 6 6

c112

cl17

t1l2l

l1 2l3l

BLK'

YEVBLK]

BLKI ELKI

YEUBLKI YEUELKI

o o YEVBLK'

0,

ALKI

(9 B L K ' BLKJ

YEVBLKI

c120r3

c118*' ffil

l5l6l7lEl

a

BLU' .11

c123

a

l1 2l

m

IoFED //Hr--l 1olcnlriBirc I

o

YEUGFN

J.

c122

v

l 1 l 2 l 3 l 1 l

l1 2l

REDl

l6ELK,wHr

c128r'

C.127.'

l6TE"^r"". 1 I ItT"Eu

c140

Clitl

A

fr

f f i f f i f f i

Iij wHri FEDi_l I a IGFN/BLK, I I9 BLK,ryEL I

l1 2l

ll lolTlx,wH-r'

c126r'

trtr

F-i

t 0 8LK/YEL

5

rffil

--l FiiTwHr. l€ cnN,,srr,I

121+'

lt|sLKrElll

ALKI

o YEL' c125

|6l;LKr-----l lOlELK,^/EL ll I I tlsLU^/vHl

8 BLK

1

o YEUELKI

ffi;F---l,IRFD'

I

FlREo,-___l El;*lvr.l lr lwHr'

l6EnNta,

--.l

l e r l c R N / w H r Ir

I

w 16lBLLliBLa--l --_l I6ELK'

l6lir cFlr/wnT I]l I ITIBL/./YEL

I

c143*3

c144*3

c145'3

ffi

_,q.

,---t

/-----f

t./t2ts al lffi l5lcl7l8l

11 2l

lr t2 3J

c147r3

c145.3

fr

\-/ ldElK ^iHrr_l

I J IWHr/BLK I |-|cFN,RLr<,--1 I

trlwirmEp,I

l(1-]l68N, I l6tFtj--reDtsLu]

FIYEUR.I c351

c352

1l5l

@

(,

(9 PNVBLU

PNI(BLK

l6FEDl.ryxF_l l fdvi Hr.

GRN/YEL3

C35/a'1

Lr/H-1-_r /it El

toltrl

it] GRN/BLK]

o

f,ftf

l5l0 GRN

2 3 WHT/BLK

o

16l BLK/wHr I-l I 16lgl( 16lGBNinEol

9

i,

o

6 BLX'EL 1

aL&a€D

Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKT and YEUBLK'are not the same). o: Relatedto Fueland EmissionsSystem - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side (cont'd)

11-67

System Description SystemConnectorslEngineCompartmentl(cont'dl

\

'99 - 00 D16Y7engine:

I

I 11 - 6 8

a

c101

c106

c102

c104*,

C1oia {Canade)

c10s

f'tr]

rftr

r'ffi-a

ffi

c107

ffi

ffi

c113r'

c3o2

a

EE

c10B

ffi

c112

ffi

tu

(for example,YEUBLK' Differentwires with the same color have been given a number suftix to distinguishthem and YEUBLK'are not the samel. a O: Relatedto Fu€land EmissionsSystem. (cont'd) a - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wir€ side

NOTE: .

11-69

System Description SystemConnectors[Engine Compartmentl(cont,d] '99 - 0OD16Y7 €ngin€:

1 1-7 0

r'ft]

@

_-l

flofr-N

cl16

c115

c11a

cl10

c109

o

.!l GBN/8TKI

8TK?YEL

o

2 BLICYEL BLK/YEL BLfiEL (t BLK/YEI

ItIYEUBLK, I IEIBLvBLU' I

o

. . + ,

lOlGBN,

c123

ffi

1

l+'.1'+:l

l-l,l

@fBLK-_-l

GRN/BLK'

cl20

c11EtA/Tl

F1ftr

GRN/BLK

12 !3 GRN/BLX'

BLKJ^/EL 8LK/YEL

clr7

GffN/8TK1

@ GNN/aLK?

I

f6lBr-r,--l

I a BLKTYEL-l I

|ol-Balro/Hl

c121lAtfl

l-lrl

c125

rfrr Etr

M c n N / B L K ' __-l I I t lwHriREo' _-l I

ItrIRED/YEL,-l

f4tEr--

c126lA/Tl

fr

c128(A/Tl

c12t l[lTl

_El-

ffi

I ' l, l _l

EIwHI-__-lI l€)lFEp5

EIWHF l(?lREp,

IOIBLUryEI' -lI I

161-crNalrHr'

c141

ffi 16TLr cRN^/v-H;l 161-BrxtEL-__l

blBLK Ea ftl BLK^tHi'l

c351

c352

(xlsarr

Ftr.T l6ELffiHr-] -___-l

tr18!(

lglcRN/REp

I

(for example,YEUBLKl Differentwireswith the samecolor haveb6engivena numbersuffixto distinguishthem the same). not and YEUBLK' are a O: Relatedto Fueland EmissionsSystem. (cont'd) a - Connectorwith maleterminals(doubleoutlinel:View from terminalside - Connectorwith femaleterminals(singleoutlin€):View from wire side

NOTE:.

11-71

System Description SystemConnectors[EngineCompartment](cont'dl 816A2engins:

11-72

F1+..r l 1 2 3 l

.1' BLKYEL

6 WHT/BLU

BLKI

1 YEUGRN

e

3 YEUREO

8

5 l YEUBLKI

9 BLKryVFT 10 BLK,ryEL

C10,1 (Canadal

c104

c102

c101

l 1 2 l

l-f.l

-l 16lwHrsEo.

cl t3

c107

c108

ffi

ffi

ffi

I2 BLK/YEL

D ffi

l3 4l

C11il

ffi

c137

a

:d) GBN/BLK' GRN/8LK' GRN/BLK'

BLK,YEL rlj

ELKTYEL BLI(YEL

I

ftlwHri BLUIl'l

c123

3

ffi

Irlz 3l

--.l ffl'wHnr€D" ItrERlxBLa__l lo."llBurntotl-l

c106

BLK^/EL 2 BLK/YEL

c105

GRN/BLK'

12

rt

GFN/BLK'

!l

c138

c302

A v

tu

FTBtKiBLtr__l lZTYEuBLKi l

NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKl and YEUBLK' arenot the same). a O: Relatedto Fueland EmissionsSvstem. - Connectorwith maleterminals(doubleoutline):View from terminalside (cont'd) - Connectorwith femaleterminals(singleoutline):View from wire side

11-73

System Description SystemConnectors[EngineGompartmentl(cont'd] 81642 enginoi

11-7 4

v

c112

ffi

c122

cl17

A ,g

r'trTl 16lBLK,-__-l lO BLX,\,E[

|

l-iln'eo*r,vHr__-l l[lcRNiBLitl]l

16l Btu/wil-

Cliro

o

_-l l6l-ciN/YEL'

C1'11

ffi

c'54*1

f r lz l s l fflErKwH---l lOlBLr -lI f6lGrrunEp

NOTE:.

Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1 and YEUBLK' arenot the same). O: Relatedto Fueland EmissionsSystem, - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side

11-75

System Description

a

SystemConnectors[Dashand Floor] ('99 - fil models except D16Y5engine with M/Tl

11-76

L

a

L

a

v1 s

t5

t 2 13

8 l 7 l 6 l et 0r l ! 2 1

14 i! a L (

5 LTATU

1 E

t0 t 1

,/ ./ie /

1Al,/ 20

2 9 t0

a l 2 13111/

l6 1 7 1 8

!t t1t

' S€cuitAr.h

Sysi.m

cL5 lwithod cruir. cort?oll

elz5 {with crui*

r'ffitr

;--F-t r t 2 l

w

l-T l .

-

codrol)

1 3 r l

2 3 I 1 0 1 1 12 t3

/lr5l/

7 a 9 18 t9

12

--l lElwHT"cRN I

I

YEL

c510ta/T)

YEL 2

3LK

YEL f,ED/BLK

.!

D t!

(for example,YEUBLKl Differentwires with the same cotor have been given a number suffix to distinguishthem and YEUBLK' arenot the same). a O; Relatedto Fueland EmissionsSystem (cont'd) a - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side

NOTE: o

t-

11-77

System Description SystemConnectorslDashand Floor](cont'dl ('99 - 00 mod€ls oxc€pt Dl6Y5 ongine with M/T)

11-78

ct3r

c130

1 l z 3 l t / X 6 1 7 8 9 t o

10 I l 1 12 13 1,4 t 5 t a 1 1 t 8 t 9

cr35lPcl|.D,€

cr35 lPCM-Dr:

cr34 tEcM/PCM-C)

ca32 l r 2 3 . 1

't/ / t g

3l-1. to

'lt

5

1

lll*

Ill IiGTNiBN l5l-wxr,nol]l l:a BLXvHI

at6 2 111'12 It

lrl2l

12 l 3

tn Bs

I

E e t|0

I t It[l

-_-l I

I

c,|52tEcM/PCM-Al

c1a lr 2l

f.fil

,bl onrrwlrl.l ftlBLrwHri- l]-l Flirx,lvHJ

Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1 and YEUBLK,are not the samel. a O: Relatedto Fueland EmissionsSvstem. - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side

NOTE;.

\-

11-79

SystemDescriptions SystemConnectorslFuelPump]

\

('9!,- 00 models 6xcept Dl6Y5 ongino with M/T)

I c565

c568

E ffi

NOTE: o

c792

c793

fr

Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKI and YEVBLK,are not the same). a O: Relatedto Fueland EmissionsSystem. a - Connectorwith maleterminals(doubleoutline):View from terminalside - Connectorwith femaleterminals(singleoutline):View from wire side

11 - 8 0

(

Troubleshooting TroubleshootingProcedures How To BeginTroubleshooting problem,usethe appropr'When the MalfunctionIndicatorLamp (MlL)has beenreportedon, or there is a driveability problem' the repair ate orocedurebelowto diagnoseand A. Whenthe MIL hascome on: ,1.connectthe HondaPGMTesteror an oBD ll scantool to the 16PData Link connector(DLC)locatednearthe left kickpanel. 2. Turn the ignitionswitchON (ll) 3. Checkthe DTCand note it. Also checkand note the freezetramedata Referto the DiagnosticTroubleCode Chart and begintroubleshooting.

MALFUNCTION INDICATOR LAMP

NOTE: .SeetheoBD||scantoolorHondaPGMTesteruser,smanua|sforspecificoperatinginstructions.. .Thescantoo|oltestercanreadtheDiagnosticTroub|ecodes(DTc},freezeframedata,currentdata,andoth ControlModule(PCM)data' EngineControlModule(ECM)/Powertrain oFreezeframedataindicatestheengineconditionswhenthefirstma|function,misfireorfue|trimma|functio was detected.lt can be usefulinformationwhen troubleshooting' problem,referto the SymptomCharton page 11-84' B. Whenthe MIL hasnot come on , out thereis a d riveability

c.DTcswi|lbeindicatedbytheb|inkingoftheMa|function|ndicatorLamp(M|L)withthescsserviceconnectorco nected. shown (The 2P ServiceCheckConnectoris Connectthe SCS serviceconnectorto ServiceCheckConnectoras |ocatedunderthedashonthepassenger,ssideofthevehic|e')TurntheignitionswitchoN{||)' OBOll SCANTOOLol HONOAPGM TESTER

scs sERvlcE

Il6PI DATA LINKCONNECTOR

SERVICECHECK 07PAZ- (x)l0100 CONNECTOR I2P)

(cont'd)

11-81

Troubleshooting TroubleshootingProcedures(cont,dl ll,

EngineControlModule(ECM)/powertrain ControlModule(pCM)Resetprocedure NoTE: Resettingthe EcM/PcM will erase any stored DTcs and any freezedata. lt will also restart all readinesscode monitors. Eitherof the followingactionswill resetthe ECM/PCM. .

Usethe OBDll scantool or HondapGM Testerto clearthe EClM,s/pCM,s memory. NorE: see the oBD ll scantool or HondaPGMTesteruser'smanuals for specificoperatinginstructions.

'

Turn the ignition switch oFF. Removethe BACKuP (7.5A) fuse from the under-hoodfuse/relaybox for 10 seconds. NorE: Bemovingthe BACKuP (7 5 A) fuse cancelsthe clockand the radio presets.Make note of the customer,s presetsso you can resetthen

lll. FinalProcedure(thisproceduremust be done afterany troubleshoottng) 1. Removethe SCSServiceConnectorif it is connected. NoTE: If the Scs serviceconnectoris connectedand there are no DTcs storedin the EcMipcM,the MtL will stay on when the ignitionswitchis turnedON 0l). 2. Do the ECM/PCMResetprocedure. 3. Turnthe ignitionswitchOFF.

1-82

checksat the ECM/PCMconnectors,removethe right lf the inspectionfor a particularcode requiresvoltageor resistance ABS control unit if so equipped.unbolt the EcM/ the Remove ECM/PCM. the to expose kick panel.Pull the carpetback as describedbelow PCM bolt. Turn the ignition switch oFF, and connectthe backprobesets and a digital multimeter pages' following listed on the checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)

The illustration shows '96 - '98 models. KICK PANEL

How to Use lhe BackprobeSets to a multimeter.using the wire insulaconnectthe backprobeadaptersto the stackingpatchcords,and connectthe cords into the connectorfrom the wire side gently the tip slide adapter. tion as a guide for the contouredtrp of the backprobe wire' the end of with terminal until it comesin contact

BackProbe SET BACKPROEE lTwo 07SAZ- 001000A

DIGITALMULTIMETER (Commerciallyavail.bleI or (cont'd) Ks - AHM - 32 - oo3

11 - 8 3

Troubleshooting TroubleshootingProcedures(cont,dl \ CAUTION: . Punqturingihe insulation on a wirs can causepoor or intermiftent electricar connections. I Bring the test€r probe into contacl with the terminatlrom the terminal side of wire harnesgconncctors in the gngin€ compartment. For temale connectors,iust touch lightly with the tester probe and do not inse.t the probe.

RUBBERSEAL

TESTERPROBE

TERMINAL

Symptom Chart Listedbeloware symptomsand probablecausesfor problemsthat Do NoT causethe Malfunction indicatorLamp(MlL)to c o m eo n . l f t h e M I Lw a s r e p o r t e do n , g o t o p a g e1 1 _ 8 1 . Troubleshooteachprobabrecausein the orderristed(from reftto right)untirthe symptom is eriminated. The probablecauseand troubleshooting pagereferencecan be found berow. *: '99 - 00 models SYMPTOM PROBABLECAUSE Enginewill not start

4 , 2 , 3 ,5 , 2 0 ,1 4 ,1

Hardstarting

2, 4, 11, 16,13,'t9

Coldfast idle too low

?, s^6. 16

Cold fast idle too high

1,8,10.9

ldle speedfluctuates

7 , 8 ,1 0 . 9

Misfireor rough running

Troubleshoot for misfireon pagesl1-166,167 2,9, 10,12, 11, 16,'t8,20

LOW power E"g|*

"t"lb

Difficultto refuel*

2,4,11,7,20,8,5,15 't9, 21

Fueloverflowsduring refueling*

1r,,1

OtherProbableCausesfor an enginethat will not start: - Compression - Startingsystem - lntakeair leakage - Overheating - Enginelockedup - Battery - Timing belt

11-84

L

I

ProbableCauseList lFor th€ DTCChart, see page 11-971 ProbableGause

Page

1

11 - 1 0 7

2

11-230,231 't't-237

3

Section23

*: '99 - 00 models System

ControlModule(l'uM) EngineControlModule(ECM)/Powertrain PGM-Flmain relay l^^iti^n

cwetam

't1-124

Fosltlonsensorclrculr'Lr\Fselrsor CrankshaftPosition/fopDeadCenter/Cylinder circuit IntakeAir Temperature(lAT)sensorcircuit

7

11 - 1 9 4

ldle Air Control(lAC)Valve

I

11-220- 223

5

1' 1-172,183

ldle speedadjustment

11-241

ThrottlebodY

'10

11-244

Throftlecable

11

11-115

12

11-132 't1-178

ManifoldAbsolutePressure(MAP)sensor ThroftlePosition(TP)sensor

13 14 15 16

Barometricpressure(BARO)senso' switchsignal Section14.11-218 Mf g"a, po"itionsignal(seepage11-216)or clutch Brakeswitchsignal 11-210 't1-244 Air Cleaner lntakeair pipe

18

11-252

19

11-261

fuel Contaminated

20

21*

Three Way CatalyticConverter(TWC) emission(EVAP)control Evaporative

11-296

ORVRvent shut valvs

(cont'd)

11-85

Troubleshooting TroubleshootingProcedures (cont,dl

(

ECM/PCMData By connectingthe OBD ll scantool or the HondapGM Testerto the l6p data link connector(DLC), variousdata can be retrievedfrom the EcM/PcM.The itemsIistedin the table belowconformto the sAE recommendedpractice. The HondaPGMTesteralso readsdata beyondthat recommendedbv SAE. understandingthis datawil help to find the causesof intermittentfairuresor engineprobrems, NOTE: ' The "operatingvalues" given below are approximatevaluesand may be differentdependingon the environmentand t h e i n d i v i d u avle h i c l e . . Unlessnotedotherwise,"at idle speed,,meansidlingwith the enginecompletely warmed up, Ay'Tin position@ or E], M/T in neutral,and the Ay'Cand all accessories turnedoff. Data

Description

Operating Value

Diagnostic TroubleCode (DTC)

lf the ECM/PCMdetectsa problem,it will storeit as a code consistingof one letterand four numbers. Dependingon the problem,an SAE-defined code (poxxx) or a Honda-defined code (Plxxx)will be outDutto the rester.

lf no problemis detected, there is no output.

EngineSpeed

The ECM/PCM computesenginespeedfrom the signals sent from the Crankshaft Positionsensor. This data is usedfor determiningthe time and amountof fuel injection,

Nearlythe sameas tachometerindication.

The ECM/PCM convertspulsesignalsfrom the Vehicle SpeedSensor(VSS)into speeddata.

Nearlythe sameas speedometerindication

YES

The absolutepressurecausedin the intakemanifoldbv engineload and speed.

With enginestopped: Nearlythe sameas atmospheflcpressure At idle speed: 24 - 31 kPa(180- 280 m m H g ,7 . 1- 1 1 . 0i n H g )

YES

VehicleSpeed Manifold Absolute Pressure{MAP)

E n g i n eC o o l a n t The ECTsensorconvertscoolanttemperatureinto volt_ Temperature age and signalsthe ECM/PCM. The sensoris a thermistor (ECT) whose internalresistance changeswith coolanttemDera_ ture.The ECM/PCMusesthe voltagesignalsfrom the ECTsensorto determinethe amountof iniectedfuel. HeatedOxygen The HeatedOxygen Sensor detectsthe oxygen content Sensor{HO2S) in the exhaustgasand sendsvoltagesignalsto the (Primary, ECI\4/PCM. Basedon thesesignats,the ECM/pCMcon_ S e n s o r1 ) trols the airlfuelratio.Whenthe oxygencontentis high (Secondary (thatis, when the ratiois leanerthan the stoichiometric Sensor2) ratio),the voltagesignalis lower. Whenthe oxygencontentis low (thatis, when the ratio is richerthan the stoichiometric ratio),the voltagesignal is higher.

11 - 8 6

FreezeData

YES

With cold engine: Sameas ambienttemper, atureand IAT With enginewarmed up: 176- 194.F(80- 90.C) 0 . 0- 1 . 2 5V At idle speed: about0.1- 0.9V

YES

YES

NO ( S e n s o1r )

Data HO2S Feedback Loop Status

ShortTerm FuelTrim

LongTerm FuelTrim

lntakeAir Temperature {IAT) Throttle Position lgnition Timing

Calculated LoadValue {CLV)

Descriotion "open" or "closed"' Loopstatusis indicatedas Closed:Basedon the HO2Soutput,the ECM/PCMdeterminesthe airlfuelratioand controlsthe amountof inject-

Operating Value At idle speed:closed

ed fuel. Open:lgnoringHO2Soutput,the ECM/PCMrefersto signalsfrom the TP,MAP,and ECTsensorsto controlthe amountof injectedfuel. ! 20% The air/fuel ratio correction coefficientfor correctingthe amountot injectedfuel when H02Sfeedbackis in the closedloop status When the signalfrom the HO2Sis weak,shortterm fuel trim gets higher,and the ECM/PCM the amountof injectedfuel The airlfuelratio increases graduallygets richer,causinga higherHO2Soutput the shortterm fuel trim is lowered,and Consequently, the ECMiPCMreducesthe amountof injectedfuel This cvclekeepsthe airlfuelratiocloseto the stoichiometricratiowhen in closedloop status' ! 20% Longterm fuel trim is computedfrom shon term fuel supply the fuel in occurring changes trim and indicates svstemover a long Period lf long term fuel trim is higherthan 1.00,the amountof injecGd fuel must be increased.lf it is lower than 1 00' the amountof injectedfuel must be reduced' The IAT sensorconvertsintakeair temperatureinto voltWhen intakeair temperaage and signalsthe ECM/PCM. of the sensor ture is low, the internalresistance increases. and the voltaqesignalis higher'

F eeza Data

YES

YES

YES

With cold engine: Sameas ambienttemPer' atureand ECT

YES

pedalposition,the open'ng Basedon the accelerator is indicated valve angleof the throttle lgnitiontiming is the ignitionadvanceangleset by the gCV/eCV.tn" gCU/PCMmatchesignitiontiming to the drivingconditions.

At idle speed: approx.10 %

YES

At idle speed:12'i 2' (81642engine:16"t 2") BTDCwith the SCSservice connectorconnected.

NO

CLVis the engineloadcalculatedfrom the MAP data'

At idle speed: 15-35% At 2.500rpm with no load: 12 - 30%

YES

r o 11-87

Troubleshooting Engine/P_o,weft rain ControlModuleTerminal Arrangement ('96- 98 Models,'99- 00 Dl6ySenginewith M/T) ECM/PCMCONNECTOR A I32PI 1 2 1 I N J 6 INJ3 INJ2 I N J l

1 2 13 ACV

11

5

6

7

I

1 5 1 6 1 7 1 8 1 9 20 PCS FLR acc MIL ALTC tcM 27 2A 25 30

LG1 22

10 PGl

l1 IGPl

PG2

21 IGP2

VSVSLU ECM/PCMCONNECTOR A (32P)

Wire side of female terminals

NOTE:Standardbatteryvoltaget s 1 2 Sign.l 1

YEL BLU 8ED

2 3

88N 5

BLXAVHT

6

FED{

l N J 4 ( N o . 4 F U E LI N J E C I O B )

D ves No 4 ruel injector.

l N J 3 l N o . 3 F U E LT N J E C T O B J

D r i v e sN o . 3 l u e I n t e c l o r .

I N J 2 ( N O ,2 F U E I I N J E C T O N ) l N J l ( N o . 1 F U E LI N J E C T O B )

Drives No. 2 iuel njector. Dives No. 1 ruelinjector. Orives secondary heated oxyqen sensor

SO2SIITC(SECONDAFYHEATED OXYGENSENSOFHEATEFCON TFOL) PO2SHTC(PRIMAFYHEATEO O X Y G E NS E N S O RH E A T E R CONTROL) ESOL (EGF CONTRO! SOIENOIO VALVE)

9

With ignilion switch ON (lll: batery vo lage W i t h f ! l l y w a r m e d u p e n g i n er u n n i n q : d L t vc o n t r o l e d

Drives prihary healed oxygen sensor

W i t h i g n i t i o ns w i t c hO N l t t ) : b a n e r y v o t t a s e w l h r d l l y w d r m e d u p c n g n e , L n n r r dq u r y , o r l . o t r e d

D r i v e sE G F c o n l r o l s o l e n od v a t v e .

Wilh EGRoperating during drving wiih fu|y warmed up engrne:duty controtted W i l h E G F n o l o p e f a t i n g : OV W i t h E G F o p e r a t i n gd u . i n g d r i v o g w i l h i u t y w a r m e d u p e n 9 i n e :d u t y c o n t . o l t e d . With EGR not ooeralino; o V W i l h e n g n e a t o w e n g i n es p e e d : OV Wirh engine at h gh enqine speedr banery vohaae L e s s l h a n1 . 0V a t a t t i m e s

E.EGR 8*r/

W i l h e n g i n er u n n i n q :d d l y c o n i r o t e d

GFN/YEL

WS (VTECSOLENOTD VALVE)

Drives VTECsolenoid va ve

BflN/BLK

L G 1 ( L O G I CG R O U N D )

t0

ALK

P G 1I P O W E FG F O U N D )

G r o ! n d l o r t h e € C M / P C Mc o n l r o t c r c u i t . G r o u n di o r r h e E C M / P C Mp o w e r . t c u f .

11

YEVBLK

IGPTiPOWEFSOUFCE)

Power source forthe Ec[,l/PcM conlro

BLVBLU

IACV(IDLEAIN CONTROLVALVE)

Wilh ignition swirch ON (tt): battery voltage With gntron switch OFF:0 V W i l h e n g i n er ! n n n g : d l t y c o n t r o e d

Orives IAC vaive (posilive side).

FEO/YEL

I A C VN l I D L EA I 8 C O N T F O L VALVE NEGATIVESIOE) IACV P (IDLEAI8 CQNTROL VALVE POSITIVESIDE) PCS (EVAPPURGECONTFOT SOIENOIOVALVE)

Drives EVAP pu.ge controtsolenoid vatve.

W i l h e n g i o er u n n i n g ,e n g i n €c o o t a n ib e t o w 1 5 4 , F '68'Cr bancry vohaSe w'ln ens nc runn,.o. eng,rc

GRN/YEL

FL8 (FUELPU[4P FELAY)

O r i v e sf u e l p u m p r e l a y .

0 V {or two secoros ahe' tJ n ng 'onir or \wnch ON ,,,,,

I7

BLI(REO

ACC (A,/CCLUTCHRELAY)

Drives A/C clutch relay.

18

GFN/ONN

MIL (I\,lALFUNCTION INDICATOF

W i r h c o m p r e s s oO r Nr0 V Wilh compressof OFF:banery votrage W i t h M I L l L r n e dO N : 0 V With illl turned OFF: banery volaqe Wirh fully warmed.up engine ru.ntng: battery votlas€ During drivins wnh smatl eteclricattoad: O V w i t h i g n l t l o ns w i l c h O N ( t l ) : b 6 n € r yv o h a g e W i l h e n s i n er u n n i n s :a b o u l t 0 V ( d e p e n d i n go n

o8N

13,.

BLVBLU

19',

AITC {AITERNAIOR CONIROL)

20

YEVGRN

NO N T R O L I C M ( I G N I ' T I OC MOOU!E)

22 23

BRN/BLK

L G 2( L O G I CG A O U N D )

24

YEUBLK

BLK

WHT/FED

25*6 21'1

GFN BL! LT GRNA/VHT WHT/NED

P G 2i P O W E AG R O U N D ) lGP2 (POW€RSOUSCE)

Drivesthe IAC valve {negalive side).

se.ds ahernator controt signat.

Ground for the ECM,/PCM conrrot ci'cu L G r o ! n d l o r t h e E C M / P C Mp o w e r c i r c u i r .

Lessthan 1.0V at a tt mes

Power sou.ce lor the ECM/PCl, conrrol

Wnh ignilion swilch ON {it):battery vohage W i l h i g n i l i o ns w i t c hO F F : 0V r V W i t h i g n i t i o ns w i t c hO N ( t t ) : a b o u 5 W t h g n i t i o ns w l t c hO F F :O V

VSEFIREFEflENCEVOLTAGE)

ProvrdesreferencevoIaOe to TCM.

FANC {RAOIATORFAN CONTFOL) 2WBS (EVAPBYPASS SOLENOIOVALVE] VSV (EVAPCONTFOTCANISTEF VENT SHUT VAIVE) KO N T F O L S L U ( I N T E F L O CC UNIT)

Drives radialof fan ielay.

'2: A./T(D16Y7,016Y8 engine) 13: CvT (D16Y5enoin€) ',4: A/T and D16y7 engine *5: ExceptA/T and D16Y7€nsine '6r A/T (D16Y8ensine) '7 Cw 1D16Y5 e n g , n e la n d D 1 6 y 8e n s r n e

Orives EVAP bypass sotenotd va !e.

W i t h i g n i r i o ns w r r c hO N ( t t ) : b a r e r yv o r a s e

Drives EVAP conlfot canisrer venl shul

w n h i g n i r i o ns w ' t c hO N l r | l b a r e r y v o l a q e

Detects intenock conlrotLn t signal

W h h i g n i t i o ns w i t c hO N ( t t ) a n db r a k ep e d a depf essed: battery vollage

'"'3:Bi..I?'Jt;".'e'.!ti.?i?l'""."T8"_";btfr "fl

11 - 8 8

With radialor fan f!nn nqr O V Wilh radiato.tan stopped: battery

'10i i,4/T(D16V5engine) r 1 1 E x . e p tM / l ( D 1 6 V 5 enqinel r 1 2 : 0 1 6 Y 5 ,D 1 6 Y Be n q i n e r 1 5 : ' 9 7 0 1 6 Y 7e n g i n e l c o u p e :K L m o d e t ,s e d a n :K L ( L X l m o d e t ) , '98D16Y7 engine

B {25P) PCMCONNECTOR

Wire sideof {emaleterminals

B (25P)', FCM CONNECTOR Terminal

Wire

numoer

cotol

1

2

3

4 5 8 1l

12 13 14

RED

BLU/YEL

a

Terminal name

Description

SOLENOID Groundfor linearsolenoidvalve LS_(LINEAR VALVE- SIDE) -Drii6l linear solenoidvalve LS+(LINEARSOLENOID VALVE+ SIDE) -Drives shift controlsolenoidvalveA SHA{SHIFTCONTROL VALVEA) SOLENOID

Driveslock up controlsolenoid valveB. Driveslockup controlsolenoid

CONTROL LC B (LOCK'UP VALVEB} SOLENOID CONTROL LCA (LOCK.UP YEL VALVEA) SOLENOID ATPD3(NT GEARPOSI. PNK TIONSWITCHi SHB(SHIFTCONTROL VALVEB) GRN^lr'HT SOLENOID GRN/BLK

CON SLU (INTERLOCK WHT/RED TBOLUNIT) D4 IND(D4INDICATOR GRN/BLK LIGHT) WHT

RED

!

NOTE:Standardbatteryvoltageis 12 v'

't1

BLU

22

GRN

23

BLU

24

YEL

25

LT GRN

DetectsPy'Tgear Positionswitch signal. DnGs shift conttolsolenoidvalveB

-DlivEilite'lock control,rnit.

NMSG{MAINSHAFT GROUND) SENSOR SPEED SPEED NM {MAINSHAFT SENSOR) ATPR{M GEARPOSI TIONSWITCH) ATP2{A/T GEARPOSI TIONSWITCH) NCSG(COUNTERSHAFT GROUND) SENSOR SPEED NC (COUNTERSHAFT SPEEDSENSOR) ATPD4{M GEAFPOSITIONSWITCH) ATPNP(A"/TGEARPOSI TIONSWITCH)

DrivesD4 indicatorlight.

GZiiI'for

Wii-ignnionswitctroN {ll}:pulses With ignilionswitchuN (lll:pulses With enginerunningin 2nd,3rdgears: batteryvoltage With enginerunningin 1st,4thgears: about0 V With lock-upONI batteryvoltage With lock-upOFF:0v With lock-uPON: bafteryvoltage With lock-upOFFi0 V In [D31position: 0 V ln ;y other position: battery voltage

With enginerunningin 1st,2nd:battery vo|taqe With;ngine runningin 3rd,4th:about0 V With ignition switch ON (ll) and brake pedaldepressed:0 V With Pll indicator lrghtturneo urr: oarterv voltaoe W i t h l d i n d i c a t o r l i g h t t u r n e d O F F :0 v

mainshaftspeedsensol

Detectsmainshaftspeedsensor srgnal. DetectsM gear Positionswitch signal DetectsA/T gear Positionswitch signal. Ground for countershaftspeed sensor. Detectscountershaftspeedsensor signal. DetectsM gearPositionswitch signal. Detects A/T gear Position switch srgnal,

* 1 i U S Am o d e l *2: A/T (D16Y7,Dl6Ygengine) *3: CVT(D16Y5engine) *4: M and Dl6Y7engane *5: ExceptA.rTand 016Y7engine *6: A,/T(D16Y8engine) *7r CVT(D16Y5engine)and D16Y8engine * 8 : ' 9 6 D 1 6 Y 8e n g i n e( c o u p e ) , ' 9 7D 1 6 Y 8e n g i n e ( c o u p e : a l l m o d e l s ,s e d a n :K L m o d e l ) , ' 9 8D t 6 Y 5e n g i n e , ' 9 8 D 1 6 Y 8 engine,'99 00 Dl6Y51M/Tiengine

Signal

Withenginerunning: Pulses 0V InE position:

In any other position:batteryvoltage

I n E p o s i t i o n0:V In any other position:batteryvoltage

Vvithignition switch ON (ll), and front wheels rotating: Pulses ln E position:0V In any otherposition:5 V 0 I n E o r E p o s i t i o n :V In any other position:batteryvoltage

*9: D16Y5engine *10:M/T (D16Y5engine) *11:ExceptM/T {D16YS engine} *12i D16Y5,D16Y8engine * 13:D16Y8engine *14:D16Y7engine *15:'97 Dl6YTengine(coupe:KL model,sedan:KL (LX)model)' '98D16Y7 engine (cont,d)

11-89

Troubleshooting Engine/P_o_wgrtrain ControlModuleTerminalArrangement ('96- 98 Models'99 - 00 Dt6y5 enginewith M/T) tc'oniOi ECM/PCMCONNECTOR C {31PI 1 2 a CKFPCXPP TDCP 12 13 1 4

7

5

ACS

t5

sTsscs

1 5 17 ALTF

23 21 25 lP+ ECM/PCMCONNECTOR C (31PI

I

I

10

rMA v8u

TE

vss 29

30 TMA

Wiresideof femaleterminals

NOTE: Standard baftery voltage is 12 V To.min!l number

Wira coloa

1 2 3

BLU/RED BLU GRN YEL

4 5

BLU/FED

6

BLU/ORN 8RN LT8LU

Torminal name CKFP(CKFSENSORP SIDE) CKPP(CKPSENSOF PSIDE) TDCP{TDCSENSOR PSIDE}

10

WHT/BLU

11

WHT/RED

12 RED 14

BLK

15."

BLU/BLK

DetectsCKFsensor. DetectsCKPsensor. DetectsTDC sensor,

CYPP(CYPSENSORP SIDE)

DetectsCYPsensor.

ACS{Tr'CSWITCHSIGNAL)

Detects,ay'Csw;tch signat.

STS(STARTER SWITCH SIGNAL) SCS(SERVICE CHECK SIGNAL)

Detects staner swilch signal,

K , L I N E( D L C )

GRY

9+3

Do6criptlon

VBU(VOLTAGE BACKUP)

GRN

'17

Wirh ignition switch ON { ): about 5 V W i t h i g n i t i o ns w i t c h O N ( t t ) : p u t s e s

TDCI\4(TDCSENSORM SIDE) CYPM (CKPSENSOB M SIDE}

Groundfor TDCsensorsignal. Groond for CYP sensor signal.

OetsctsVTECpressureswitchsignal.

swtTcH)

Detects ahernator FR signal.

BLK

lP+{HO2SPUtr4P CELL+}

RED

rP-,vs- {Ho2scoMt oN)

ControlsHO2Spumpce . Reference voltagesupply.

LTGRN*'

VS+(VSCELLVOLTAGE) ATPNP(Ar'TGEARPOSI, TroN swrTcH) CLSW(CLUTCH SWITCH}

18

BLUI/VHT

23+14 24.10

25*ro 29 RED{ro

30

PNK4

TMB

OetectsVSS signal.

DetectsVS cell voltage. Deteds Ay'Tg6srposhion switch signat. Detectsclutch switch signal, Data communication with TCM: E C M c o n t r o l d a t ai n p u t

'1: USA model r 2 r A , . T( D 1 6 Y 7 O , 1 6 Y 8e n s a n e ) * 3 : C V T( O 1 6 Y 5e n g i n e ) *4: Ay'Tand O16Y7engine '5: Excepl A./T snd Dl6Y7 engine 16: Ay'T(D16Y8ensine) { 7 : C V T( D l 6 Y 5 e o s i n e )a n d O 1 6 Y 8e n o i n e "8: 96 Dl6Y8 engine(coupe),'97 D 1 6 y 8 e n g i n e ( c o u p e :a t l '99 - 00 :ed-9I t!!rnodelr,'98 D16y5ensine,,98D16y8e;sine. D 1 6 Y 5l M / T ) e n s i n e

11 - 9 0

Battery voltage at all times

Groundfor CKPsensors;gnat.

ALTF (ALTERNATORFR SIGNAL) VSS{VEHICLE S P E E DS E N SOR}

WHT/RED

W i t h e n g i n e r u n n i n g :p u l s e s With Iy'C switch ONr 0 V With Ay'Cswitch OFF:batrery vottage W i t h s t a n e rs w i t c h O N l t l t ) :b a t e r y v o h a g e With staner switch OFF:0 V

S e n d sa n d r e c e i v e ss c a ni o o l s i g n a l , D a t 6c o m m u n i c a t i o nw i t h T C M : E C M control ctat6output Power source forthe ECM/PCM control circuit. Power sourc€ lorthe DTC memory

(P/SOILPRESSURE Detects PSPswitch signal. PSPSW

16

W i t h e n g i n e r u n n i n g :p u l s e s W i t h e n g i n er u n n i n g :p u t s e s

Withthe connectorconnected: OV with the connectordisconnected: about5 v or batteryvoltage

Groundtor CKFsensorsignal.

swtTcH)

Withenginerunning: pulses

Detectsservicecheckconnectorsignal {thesignalcausing a OTCindicationl

CKFM{CKFSENSORM SIDE) CKPM(CKPSENSOR M SIDE)

VTM (VTECPRESSURE

Signal

Wrth engine at low enginespeed:0 V Wth engineathigh enginespeed:tatteryvoltase At idle with steering wheel in straight ahead p o s i t i o n : 0V At idle with stsering wheet at fult tock battery voltage With fullyw6rmed up engine running:0 V- batteryvohage (dependingon electricattoad) W h h i g n i t j o ns w i t c h O N { t t )a n d f r o n t w h e e t s rotating: cycles 0 V- 5 V W i t h i g n i t i o ns w i t c h O N ( l l ) :a b o u r 0 . 5- 5 . 3V W i t h f u l l y w a r m e d u p e n g i n ee t i d l e : a b o u t 2 . 6 - 2 . 8V W i t h i g n i t i o ns w i t c h O N t ) : a b o u r 7 V

InE orE position: OV ln any otherposition:batteryvottage Wilh clutch pedal released: about 5 V With clutch pedal deDressed: O V W i t h i g n i t ; o ns w i t c h O N ( l t ) : p u t s e s

1 9 : D 1 6 Y 5e n g i n e '10: M/T (Dl6Y5engine) * 1 1 rE x c e p tM / T 1 1 6 Y 5e n g i n e ) * 1 2 : D 1 6 Y 5 ,D 1 6 Y 8e n g i n e *13:Dl6Y8 enqine * 1 4 : O 1 6 Y 7e n g i n e i 1 5 : ' - 9 7O 1 6 Y 7e n g j n e ( c o u p e : KL modet, sedan: KL (LX) modet), '98D16Y7 enqine

D I16P) ECM/PCMCONNECTOR

Wire sideot femaleterminals

ECM/PCMCONNECTORD l16P) Te.minal numb€r

Wire color

NOTE: Standardbattery voltage is 12 V

Terminal n!me

Dor.ription

POSITIONDetectsTP sensorsignal. TPS(THROTTLE RED/BLK SENSOR} REDA/VHT 3

RED/GRN

YEURED 5

GRNMHT

6*?

RED/BLU

1

8

RED//EL

9*l

WHT/BLK

10 11

12

YEUBLU

DetectsECTsensorsignal COOLANT ECT{ENGINE SENSOR TEMPERATURE DetectsMAPsensorsignal. ABSO' MAP {MANIFOLD SENSOR} LUTEPRESSURE VOLTAGE) Power sourcelor MAP sensor. VCCl (SENSOR

BKSW{BRAKESWITCHI

Detectsbrakeswitch signal

KS {KNOCKSENSOR} PHO2S(PRIMARYHEATEDOXYGENSENSOR, 1) SENSOR

DetectsKS signal. DetectsPrimaryheatedoxygen sensor(sensor1l signal

DetectsLABELresistance LABEL DetectsIAT sensorsignal. (INTAKE AIR TEMIAT SENSOR) PERATURE DetectsEGRvalve lift sensorsignal EGRLiEGRVALVELIFT SENSOR) VOLTAGE) Providessensorvoltage, VCC2(SENSOR

GROUND} SG2(SENSOR (SENSOR GROUND) GRN,4/1r'HT SG1 GRN/BLK

(SECONDARY SHO25G

GRN/BLK*1?HEATED SEN' OXYGEN

Sensorground. Ground for MAP sensor. Ground for secondaryheatedoxygen sensor(sensor2).

2 GROUND) SOR,SENSOR 14

WHT/RED

15|3.*15

LT GRN

16*1

SH02S(SECONDARY HEATED OXYGENSEN'

Detectssecondaryheatedoxygen sensor(sensor2) signal.

2) soR,sENsoR

PTANK{FUELTANK PRES. Detectsfueltank prgssuresensor' SURESENSOR) DetectsELDsignal. EL(ELD)

GRN/RED

*1: USA model *2r A/T (D16Y7,D16Y8engine) *3: CVT(D16Y5engane) *4: A,/Tand Dl6Y7engine *5: ExceptA/T and D16Y7engine *6: A"/T(D16Y8engine) i7: CVT(Dl6Y5engine)and Dl6Y8engine * 8 : . 9 6 D 1 6 Y 8e n g i n e( c o u p e i , ' 9 7D 1 6 Y 8e n g i n e(coupe:all '98 D16Y8 m o d e l s ,s e d a n rK L m o d e l ) , ' 9 80 1 6 Y 5e n g i n e , '99 (M/T) engine 00 D16Y5 engine,

Signal With throttle fully open: about 4.8 V With throttlefully closedlabout0.5V With ignitionswitchON{ll):about0.1- 4 8 v (dependingon enginecoolantlemperature) With ignitionswitchON(ll):about3 V At idle:about1.0V on enginespeed) {depending With ignitionswitchON (ll):about5 v With ignitionswitchOFF:0 V With brakepedal released:0 v With brakepedaldepressed:bafteryvoltage With engineknocking:Pulses With throttle fullv openedfrom idle with Iully warmodup engine:above0.6V With throttle quickly closed:below 0.4 v With enginer!nning:about0.3- 4.9V With ignitionswitch ON (ll):about 0 1 4.8V {dependingon intakeair temperature) At idlewithoutvacuum:about'12 V mmHg,8in. Hg):about4 3 V With27 kPa(2OO With ignitionswitchON(ll):about5 V With ignitionswitchOFF:0V Lessthan 1.0V at alltimes Lessthan 1.0V at alltimes

With throftle fully openedlrom idle with fully warmedup engine:above0.6V With throttlequicklyclosed:below0.4V With fuelfill caDopened:about2.5V With parkinglightsturnedon at idle:about 2.5- 3.5V turnedon at With low beamheadlights idle:about1.5- 2.5V

*9: D16Y5engine *10:M/T (D16Y5engine) *11:ExceptM/T (Dl6Y5engine) * 12rD16Y5.D16YBengine *13:D16Y8engine *14: Dl6W engine *15:'97 D16Y7engine(coupe:KL model,sedan:KL lLX) model), '98D16Y7 engine:

(cont'd)

11 - 9 1

Troubleshooting Engine/P_o,wertrain ControlModuleTerminalArrangement ('99- 00 ModelsexceptDl6Y5 enginewith M/Tl ECM/PCMCONNECTOR A I32PI

ECM/PCMCONNECTOR A (32P)

Wire sideot temaleterminals

NOTE:Standardbatteryvoltageis l2 V Sign!l

3

2WSS(EVAP8YPAsSSOLENOID Drives EVAPbypass solenoid vatve,

With gn'tion swnch ON (lll banery votlage

VSV {EVAPCONTNOLCANISTER VENTSHUTVALVE]

Drives EVAPcontrot can isrer v€nt shut

Wilh ignilion switch ON {tl): b€ttery vottage

8LU/GNN

C8S (CRUISECONTSOLSIG

Oown shift signal inpot lrom c.uise conrrol

When crurss control is used:purses

Drives EVAP purge conrrol sotenoid vatve.

With engine running, enginecootant,betow r54.F (6a,C):

8ED/YEL

PCS{EVAPPURGECONTROL SOTENOIOVALVE)

BLU LT GRN/I/VIIT

6

With engine.unning, €ngine coolant, abov€ 154.F (68'C): duty conlrolled

YEL 8

BLK,IflHT

LT GRN t0

ATPD {AT GEAR POSITION SWITCH)

ootects A/T gear posnion swilch s,gnar.

(SECONDARY SO2SHTC HEAT EDOXYGEN SENSOS HEATEF CONTFOL)

Drives sscondary h€ared oxygen senso.

Wilh isn,rion swirch ON (ll):banery votrase W i t h l u l l y w a r m 6 dd p € n g i r e r u n n ' n g : d u r yc o n t r o l e d

ATPNP (AT GEAF POSITION SWITCH) EH E C KS I G N A L ) S C S( S E R V I CC

oereds A/T 9€ar position switch signat.

I n P a r r o r n e u l r s l : 0V I n a n y o t h e r p o s i t i o na p p r o x . 5 v

Oetectsssruice check connecror signal (the signalcausing a OTC indication)

with rh€ t6rminal connected:0 v With the rerm inaI disconneded: abour 5 V of ban€ry

D 4 I N D( D 4 I N D I C A T O N ]

Drives Oa indicaio. lighr.

FTF (FUELPUI\,4P SELAY)

W i t h D 4 i n d i c a t o rl i g h t t u r n e dO N : O V With D4 indicator lightturned OFF:battery vo ttage

Orivos tuel pump relay,

0V for two s€conds lfrer turnrng rgnilior swtcn ON (ll), then batt€ry voltage

ACC (Al/CCTUTCHSELAY)

Drives A./Cclutch reray.

With compressor ON:O V Wilh comp.ssor OFF;battery vottage

MI! (A,IAIFUNCTIONINDICA. TOF LIGHT) N E P( E N G I N ES P E E DP U T S E I

Oulputs6ngine speed pulse,

W i l h e n g i n 6 . u n n i n gp : utses

FANC {SADIATORFAN CON

Orives radiarortan relay.

W i r h r . d i s t o rt 6 n r u n n i n g : O V With radiatortan stopped: banery vottage With ignition switch ON (ll):p!ts€s

88N GNN/BIK

G8N/YET 11

BTI(RED

18

GFN/OFN

19

8tu

20

GFN

21

ELUA/EL

22'l

BLU

TnoL)

In otherthan @ posilion:Apprcx. 5 V

W i t h M l L t u r n e dO N : 0 V With l\,llLtornod OFF|batreryvotrsge

K LINE

Sends and r€ceivess.an lool signal.

ATP L {AT GEAS POSITION

OelocisA"/Tgear posirion switch siSnat.

23

SHO25 (SECONOARYHEATED OXYCEN SENSOR,SENSOF2)

Detectssecondsry hoar€doxygen sensor

24

STS ISTAFTENSWITCHSIG

Debcrs staner switch signat.

PSPSWiPlS PNESSURE SWITCII SIGNAL) ACS (AJCSWITCHSIGNALJ

DerecrsPSPswitch signat.

Atidle with steoringwheolin srraightaheadposition:O V At idl6with steering wheetal fult lock: barery vo ttags

Oer*ts ,ay'C swirch signat.

Wiih ty'C switch ON;0V Wilh Ay'Cswitch OFF|aboor 5V

S L U i I N T E R L O CC KO N T R O I UNIT)

Drivos interloct control unit.

With ignltion switch ON (ll)and brake pedal depresed: batlory volrage

PTANK (FUELTANK PFESSUEE SENSOR)

Oer6ds lu€l tank pr€ssura sonsor signat.

W i l h i g . r r r d s w i r c hO N r t t ra n d f u e t t i c a p o o e n 6 d .

26

GFN

27

BLU/REO

WHT/RED 29

LT GRN

swtTcH)

Er(ELOI 30

GRN/FEO

32

GRN/'WHT

AKSW (BFAKESWITCH)

' 1 : A . / T( D 1 6 Y 7 D,1 6 Ye8n g i n e ) *2: rvt/T 13:CVT(D16Y5 engine)

11- 9 2

In othfflhan E position:Apprcx. 5 V With lhronle f! lly or'6ned from idte with fu y warmod up engine: above 0.6 v Wiih th.onl6 quickb, closd:below 0,4 V Wirh srarterswitch ON (tttJ:batteryvottoge With sraftsr cwirch OFF:0 V

W i t h p a r k i n gl i g h l s r u r n e do n a r i d t e i a b o u i2 . 5 - 3 . SV Wirh low beam he€dlights turnqd on ai idts: aboul 1.5 2 . 5V Detets brak€ swrtch signEt,

With brake pedal r6l€ased:0 V Whh brake pedaldepres*d: battery voltEse

B (25PI ECM/PCMCONNECTOR

Wiresideof femaleterminals

FCM CONNECTORB {25P)

NOTE: Standardbattery voltage is 12 V Sign.l

YELtsLK BLK FED

BLU YEL 6

BLI(BIU

BED

PNKSLK

8., 9

YEUBLK

whh ignilion swilch ON (ll)ibatteryvoltage With ignition switch OFF:0 V

IGP1IPOWERSOUflCE)

Powor sou rca for the ECM/PCMconlrolcir

P G l{ P O W EG BN O U N D )

contrclcncuit' Ground fo. the ECM,/PCM

Lessthan 1.0 V at slltimes

l N J 2 ( N o 2 F U E LI N J E C I O R ) l N J 3 ( N o . 3 F U E LI N J E C T O B )

Drives No. 2 fu€l inieclor'

Wirh enqine runnin9: dulv conlroll6d

l N J , rl N o . 4 F U E LI N J E C T O F ) IACV P (IDLEAIR CONTROL VAIVE POSITIVESIDE)

Orives No.3 fuel inieclor' Drives No. 4 luel injector' O.iv€s IAC valve {Posirivoside)

Wilh engine running: duty conrrollod

ESOL {EG8 CONTROL SOLENOIDVALVE)

Drives EGF controlsolonoid valve

With EGRoperaiing during driving wirh follv warmed up onginsl dutY controlled W i l h E G Rn o l o p € r . r i n g : 0V

CONTnOL HlC tstvr(PH-PL LINEAflSOLENOIDNEGATIVE st0E) PFESSURE LS- (A/TCLUTCH SOTENOIDVALVE' CONTROL sroE) SOUFCE) rGP2{POWE8

G rcund for PH-PLcontrol linsar solsnoid

A/Tclutch prsssure conrrol sol€nod valv€ pow6r slpply negative elecrode

With ignilion swirch ON (ll):dutv controll€d

Powor $urce for lhe ECI{,'PCMcontrolc'rcuit

wnh ignirion swirch ON (ll): ban€ry voltag€ with ignirion swnch oFF:0 v

10

BLK

GSOUNDI PG2IPOWER

11

8RN

I N J l { N o , 1 F U E LI N J E q I O R )

Ground lor ths ECM/PCMcontrolctrcuil orives No. r ru6l Iniocror.

GRN,.YEL

VALVE) WS (WECSOLENOID

Orivos WEC solanoid v.lvs.

12" 13

YEUGRN

With onsino at low lpm:0V with ens,n. ar hish tpm:bsneryl9!9glWith ignition switch ON (ll)r b5n6ry volt€gs Wilh engino running: Puls6

Drivos the IAC valve lnogativ€ 3idel

With €ngin€ ru nningi dr]tv controlled

15

ORN

LS + (A,/TCIUICH PRESSURE CONTFOTSOIENOIOVALVE + SIDE} HLC LSP (PH-PI CONTROI LIN. EA8 SOLENOIDPOSITIVESIDE)

A/T clutch pr€so.6 controlsolenoid valve pow6r slpply posiliv€ oroclrode

Wirh ignition swatchON (lll: dutYcontrorled

SCLSM(STAfiTCLUTCH N€GATIVE SOLENOIO LINEAR SIDE)

Groundforstartclutchcontrol

BnN/AtK

LGI (LOGICGEOUNO) VBU IVOLTAGE8AC( UP)

22

BFN/8IK

23

8LI(BLU

LG2 (LOGICGSOUND) IACV (IOTEAIR CONTROL

Ground for lh€ EcM/PcM controlcircuit' Powet sourcetorlhe ECM/PCMcontrol circuit Power sourco tor th6 DTC m€mory' Ground iorths ECMnCM conrrol circuir'

RED

PNK/BTU 20

ICM {I6NITION CONTROLMOD ULE} IACV N (IDLEAIN CONTSOI VALVE NEGATIVESIOE)

21

25'3

YEL

r1: A/r (D16\t, D16Y8ensins)

SC LSP {STANTCLUTCHLINEAR

Orives PH-PLcontrol line€r solenoid

With qnition switch ON (lll: Pulsing srgnal

line6r

L 6 s er h a n 1 . 0v . i a l l t i m e s Battaryvoltage aitnEtrmes tsss thah 1.0 v al all times Witn ongine funning: dutv conrol!6d

Orives sran clutch control linesr solonoid.

With ignilion swilch ON (ll): Pulsing sign3r

slDE) PoSlrlvE sotENorD

'4: Ol6Y5, Dl6Y8, B164? onsina

' 3 : C V T{ O 1 6 Y 5 e n s i n o )

(cont'd)

11 - 9 3

Troubleshooting Engine/P_owertrain ControlModuleTerminal Arrangement ('99- 00 ModelsexceptDl6Y5 enginewith M/Tl (cont,d) ECM/FCMCONNECTOR C 13lPI

ECM/PCMCONNECTOR C {31P)

Wire sideof femaleterminals

NOTE;Standard

i s 1 2V .

Sig.al l

2

BLK4/VHT WHT/GFN

(PNIMARY PO2SHTC HEATEO OXYGEN SENSOB HEATES CON TROL)

Drivss primary hoated orygen sensof

With ignition switch ON (lr)rbanery volage Wrh fJly warned up €ngir. ru..i19: duty.oaro ed

ALTC (ALTESNATOBCONTSOL)

Sends aliernalo. control sig nal,

With fullywa.med upengine ronning; banery vohase D u r i n gd . i v i n gw i t h s m a l l e l e c t . i c a t i o a dO;V

3

8ED/BLU

K5 (KNOCKSENSOR)

5

WHT/RED

ATTF {AITEFNATOR FR SIGNAL'

Detects slternaror FR si9n.l.

WHT/8LK

E G R L( E G NV A I V E L I F T S E N SOR)

Dete.ts EGRvalve lrft sensorsignat.

GRN,4r'l/flT

S G l I S E N S OGEB O U N D )

Groond fo. MAP s€nsor.

8lu

CKPP(CKPSENSORP SIOE'

8

9 BLU/BLK 16

FED/GRN 18

'19

GBN/8LK

YEUNED

Ground for CKP sensor.

wlvl (wEcPREssuSE swtTcll

D€toctsVTEC pfessure switch signat,

W i t h € n g i n ea t l o w e n g i n o s p e e d : 0 V With engin€ at high engino speed : banery vo ttaae

Oetectsprimary heated oxygen s6nsor lsen-

With lhrottle f!l1y open€d from idtewith tuly, wa.med !p engin€: Ebove 0.6 V Wilh thronl€ quickly closed: b€tow 0.4 V

MAP (I\,4ANIFOLD ASSOLUIE PFESSUSE SENSOB}

Dotocrsi,4APsensor signsl.

With ignitioh switch ON (ll):about 3 V A t i d l e i 6 b o u l1 . 0V ( d e p e n d i n go n e n g i n es p e e d )

Powersourcero MAPsenso..

W i t h i g n i t i o ns w i l c h O N { l l ) : a b o u t5 V W i r h i q n i t i o ns w i t c hO F F ] 0V

S G 2( S E N S O R GSOUND) VCCl (SENSORVOLTAGEI

GNN

IDCP (TDCSENSOBP SIDEI

8ED

TDCI\,I(TDCSENSORM SIOE) C K F P( C K FS E N S O RP S I D E )

BTU/NED

25 26

8ED,ryVHT

21

NED/BLK

2a

YEVBLU

29

YEL

3o

BLK

With ongine running: pulses Ground lor TOC aensor. With engine running: p!lses W i l h i g n r t | o ns w i c h O N r l l rs n d l r o n t w l - e e 'r o t a t i n g . cycles 0 V about 5V or baneryvottage

IAT ONTAKE AIFTEi,4PEBA. TUEESENSOR)

Detects IAT senso. signat.

With ignition switch ON (ll): about 0.1 4.8 V ldepending on i.take air ternpe.ature)

ECT (ENGINECOOLANTTEI\,I. PESATUBESENSOR) TPS (THROTTLEPOSITIONSEN, SOF) VCC2(SENSORVOLTAGE)

Oelects ECT sensor signal.

W i t h i g n i r i o ns w i r c hO N { l l ) : a b o u t 0 . 1- 4 . 8 V (depending on engine coolant temperature)

DetectsTP sensor signal.

Wilh th.onle fully op€n: about 4.a V With rhronle f!lly closed: about 0.5 V

Provides s6nsor voltag€.

W i t h i g n i r i o ns w i r c hO N ( t t ) : a b o u 5t V With ignilion swiich OFF:0 V

CYPP(CYPSENSORP SIDE) CYPM (CYPSENSORM SIDE]

G,ound for CYP sonsor.

J1 WHT/FED CKFM (CKFSENSOBM SIDE) * 1 ; 4 " / Tl D 1 6 Y 7D , 1 6 Y 8e n s i n e l 4 3 :C V I ( 0 1 6 Y 5e n g i n e ) '4: D16Y5,D16Y8,81642 engin€

1 1- 9 4

L e s st h a n 1 . 0V a r a l t t i m e s

VSS {VEHIClESPEEDSENSOR)

BED/YEL

L € s sr h a n 1 . 0v a t a l l t i m e s

SIGNAI) PHO25 (PRII\,1AFY HEATED O X Y G E NS E N S O RS, E N S O R1 )

21

23

W i t h t u l l y w a r m e du p e n g i n er u n n i n g : OV - b a t t e r y v o r t a g e ( d e p e n d i n g oenr e c t f i c at to a d )

With engine running: pulses

CKPM {CKPSENSORM SIDEI

20 22

with sngine knocking: pulses

W i l h € n g r n er u n n i n g :p r u s e s Ground fo. CKF sonsorsign6i.

O {16P) ECM/PCMCONNECTOR

D {16P) ECM/PCMCONNECTOR (D16Y7,D16Y8enginel

Wire sideol temaleterminals

NOTE: Standard battery voltage is 12 V. 5i!ml

YEL

LCA (LOCK.UPCON]ROL SOLENOIDVALVEA)

Orivos look-up controlsol€noid wlv€ a.

With lock-up ON: httery vollage With lock-up OFFi 0 V

SHB {SHIFTCONTFOL SOLENOIOVALVE B)

Drivos sh ift cont.ol solanoid valv6 B

ln E posnion,in 1stlnd 2ndeoat,n E E pos' tion:Battsryvoltago I n E l p o s i r i o ni n. 3 r ds e a ti n p d , E l i n . t h s e a ri n l_d polition: o v

LC8 (IOCK UP CONTBOL SOLENOIDVALVE B) VSSOI (BATTEsYVOLTAGE FOB SOLENOIDVALVE)

Drivs locl up conttol sol€noid v6lv€ B

when fulllock-up: Banory vollaga Wnh naf locl-uP: Pulsing si9n6l wirh ignirion sitch ON (ll): battory voltaoe Wirh ignnion switch OFF:0 v

ATPR(AT GEARPOSITION swrTcH)

DetecrsAy'Tg6a. position switch signal.

SHA iSHIFI CONTROL SOLENOIDVALVEA)

Oriv€6sh ift conirol sol€noid valve A.

ATPO3(AT GEAR POSITION SWITCH)

Oot6ctsAy'TS6.r poeirioo switch siSnal

ATPD4 {AT GEAE POSITION

Oorocts A/I gs8r position switch signal.

GRN,M/HT

3''

GRN/BLK

5',

BLK/YEL

Powe. sourc€ ol solGnoidvalve

8LU/YEL

PNK

L 9''

13''

YEL

sig.als

BIU

NC (COUNTERSHAFTSPEED SENSOB)

DetocB counr€.shaftsp66d $osr

REO

NM (MAINSHAFTSPEEDSEN.

O€l€cts mainshalt sp€€d 3.nsor 3ign.ls

soR)

NMSG {MAINSHAFTSPEEO SENSORGFOUNO)

Groundfo, mainshaft sp@d sensor.

ATPNP {AT GEAF POSITION

oetscts A/T 96ar pGitaon swhch signal

ATPz{ATGEAEPOSITION swrTcHl SPEED NCSG{COUNTEBSHAFT S E N S OG ER O U N D )

Dor€cis!y'T gos. posilion swilch signal.

!T GFN

BLU 16''

swrTcH)

GAN

swrrcH)

In any olh€r position: APProx. 10 V

in 2nd€nd3rdsearin lpd, &l lntr,tr position, posirion:Batt€ryvollsgo ;n 1d soarin E, E position,in.ih se6rin E In Enyoth.r position: APPror, t0 v In any oth6t position:APProx 5 V D€p€nding on v6hicls 8pe€d;Pul.ins signal Wh6n v€hicls i5 ltoPPsd:0 v Wi$ engino rLrnninglPUls6s

In par* or n6ulral:0 V In sny olhd po3ition: APProx l0V In any oth6r Position:APProx, 10 V

Ground lor countershaii sp€3d s6nsor.

.1 A/J (Dl6Y7, Dr6Y8 engine)

rlo

(cont'd)

11 - 9 5

Troubleshooting Engine/P_oweft rain ControlModuleTerminaI Arrangement ('99- 00 ModelsexceptDl6YSenginewith M/Tl (cont,dl ECM/PCMConnectol D (16P1

ECM/PCMCONNECTON D (r6P)

Wire side of female terminats

ECM/PCMCONNECTORD {16P)(Dl6YS engine: CVTI NOTE:Standardbatteryvoltageis 12 V f€rminal Wire color numDea

Terminalname

Description

VEL(SECONDARY gearshaftspeed GEAR Secondary SHAFTSPEED SENSOR) sensor,

1+3

WHT/RED

2*3

GRN/BLK SOLENOIDCONTROL)

3+3

SHLSM(SHIFT CONTROLGroundfor shiftcontrollinear SOLENOID GRN/YEL LINEAR solenoid. NEGATIVE SIDE)

INHSOL{INHIBITOR

5*3

6*3

10*. 11*3

12*3

13*3 14*3

16*r

Inhibitorsolenoidcontrol.

(SHIFT SHLSP CONTROL Drivesshift control linear BLU^/vHT LINEAR solenoidpower. SOLENOID POSITIVE SIDE} VBSOLlBATTERY Power sourceof solenoidvalve. BLK,/YE L VOLTAGE FOR SOLENOID VALVE) (AT ATPR GEAR DetectsA,/Tgearpositionswitch WHT POSITION SWITCH) srgnal. VELSG(SECONDARY Groundfor secondary gearshaft BLKA/VHI GEARSHAFTSPEED speedsensor. SENSOR GROUND) (DRIVEN NDN Detects PULLEY drivenpulleyspeed WHT SPEED sensorsrgnal. SENSOR) (DRIVEPULLEY Detects drivepulleyspeed RED/BLU NDR SPEED sensorsrgnal. SENSOR) NDRSG(DRIVE PULLEY Ground for drive pulley speed GRN SPEED sensor. SENSOR GROUND) ATPS(ATGEAR DetectsAy'Tgear positionswitch LT GRN/RED POSITION srgnal. SWITCH) DIND1DINDICATOR LIGHT) NDNSG(DRIVEN RED^/VHT PULLEY SPEED S E N S OG RR O U N D ) GRN/BLK

*3: CVT (Dl6Y5 engine)

11 - 9 6

DrivesD indicator. Ground for driven pulley speed sensor.

Signal Dependingon vehiclespeed:pulses When vehicle is stopped:0 V With inhibitor solenoidON: baftery voltage With inhibitorsolenoidOFF:0 V

With ignition switch ON (tl):pulses

With ignition switch ON (ll):banery voltage With ignition switch OFF:0 V

InRposition:0V In anyotherposition: Approx.10V

In otherthanParkor neutral:pulses In otherthanParkor neutraltpulses

I n S p o s i t i o n :V0 In anyotherpositioniApprox,10V With D indicator turnedON:5 V WithD indicator turnedOFF:OV

DiagnosticTroubleCode(DTCIChart DTC {MlL indication*l

Delection liem

ManifoldAbsolute PressureCircuit Problem Range/Performance

P0107

(3)

P0108

(3)

. Vacuum connection . MAP sensor

Page

11 1 1 5

ManifoldAbsolute PressureCircuit Low Input

Openor short in MAP sensorcircuit MAP sensor ECMiPCM TCM*1

11

ManifoldAbsolute PressureCircuit H i g hI n p u t

Openin MAP sensorcircuit MAP sensor ECtvt/PCM

't 1 121

't1'l

. IATsensor

1 .5( 1 0 ) P 0 . 1 1 1 * 1* 4

lntakeAir Temperature Circuit Problem Range/Performance

PO112

{10}

IntakeAir TemperatureCircuit Low Input

Short in IATsensorcircuit IAT sensor ECMiPCM

P0113

(10)

lntakeAir TemperatureCircuit H i g hI n p u t

Open in IATsensorcircuit IAT sensor ECM/PCM

P0116

(86)

E n g i n eC o o l a n t TemperatureCircuit Problem Range/Performance

PO't't7

{6)

EngineCoolant TemperatureCircuit Low Input

Short in ECTsensorcircuit ECTsensor ECM/PCM

11-129

P0118

(6)

E n g i n eC o o l a n t TemperatureCircuit H i g hl n p u t ThrottlePosition Circuit Low Input

Openin ECTsensorcircuit ECTsensor ECM/PCM

11-130

Openor short in TP sensorcircuit TP sensor ECM/PCM TCM*1

11-132

?0122

t1l

P0123

(7)

P0131*'

(1)

P0132*'

('r)

PrimaryHeatedOxygenSensor CircuitHighVoltage ( S e n s o1r )

P0133*'

(61)

PrimaryHeatedOxygenSensor Slow Response ( S e n s o1r )

P0135*? (41)

! ta

ProbableCause

ThrottlePosition Circuit H i g hI n p u t PrimaryHeatedOxygenSensor CircuitLow Voltage ( S e n s o1r )

PrimaryHeatedOxygen SensorHeater CircuitMalfunction (Sensor1)

11-124

. ECTsensor . Coolingsystem

Openin TP sensorcircuit TP sensor ECM/PClvl Short in PrimaryHO2S(Sensorl) circuit PrimaryHO2S{Sensor1) Fuelsupplysystem ECM/PCM Open in PrimaryHO2S{Sensor1} circuit PrimaryHO2S(Sensor1) ECM/PCM . PrimaryHO2S(Sensorl) . Exhaustsystem . Openor short in PrimaryHO2S (Sensor1) heatercircuit . ECM

11-125 't1-126

11-124

11-136

11 - 1 3 9

11-143

11-145

11-151

*: The DTCSin parenthesis will be indicatedby the blinkingof the MalfunctionIndicatorLamp(MlL)when the SCSservice connectoris connected a1: Dl6Y5 engine(CVT) *2: ExceptD16Y5engine(M/T) * 1 4 : ' 9 7m o d e l * 1 5 : ' 9 6m o d e l * 1 6 :' 9 8m o d e l

(cont'd)

11-97

Troubleshooting

,Jla

DiagnosticTroubleCode(DTCIChat (cont'dl DTC lMlL indicationl P0137

(63)

P0r38

{63)

P0'139

(63)

P0141

(65)

Datectionhsm Secondary HeatedOxygenSensor CircuitLowVoltage (Sensor 2) Secondary HeatedOxygenSensor CircuitHighVoltage (Sensor 2) Secondary HeatedOrygenSensor SlowResponse (Sensor 2) Secondary HeatedOxygenSensor Heater CircuitMalfunction (Sensor 2) SystemToo Lean

(45)

P0171

SystemToo Rich (45)

P0172 }l? P0300*16' and some of

Random Misfire

Po3o1 P0302 P0303 P0304

/r'' \ l72l l73l \74l

P0301 P0302 P0303 P0304

/rt\ 172l l73l \74l

P0325*3

(23)

P0335

(4)

P0336

(4)

P040' r*r

(80)

P0420

(67)

- Cylinder1 - Cylinder2 - Cylinder3 - Cylinder4 Misfire Detected

KnockSensor(KS)Circuit Malfunction CrankshaftPosition SensorCircuit Malfunction Crankshaft Position Sensor Range/Performance ExhaustGas Recirculation InsufficientFlow Detected CatalystSystem Efficiency Below Threshold

*3: D16Y5engine (CVT),D16Y8engine and B1642 engine *4: D'16Y5engine *16: '98 model +17:'99 - 00 models

11 - 9 8

Probablo Cause

Shortin Secondary HO2SlSensor2) circuit Secondary H02S{Sensor 2) ECM/PCI\4 Openin Secondary HO2S(Sensor 2) circuit Secondary HO2S(Sensor 2) EC[I/PCM Secondary H02SlSensor2)

Page 11 - 1 5 3

11-154

1l-156

. Openor shortin Secondary HO2S(Sensor 2) heatercircuit . ECM/PCM Fuel supply system PrimaryHO2S(Sensor1) MAP sensor Contaminatedfuel Valve clearance Exhaustleakage

Fuelsupplysystem PrimaryHO2S(sensorl) MAPsensor Contaminated fuel Valveclearance lgnitionsystem Fuelsupplysystem MAPsensor EGRsystem IACvalve Contaminated fuel Lackof fuel FuelInjector FuelInjectorcircuit lgnitionsystem Lowcompression Valveclearance Openor shortin KnockSensor(KS)circuit KnockSensor{KS) ECM/FCtvl Crankshaft PositionSensor Crankshaft PositionSensorcircuit ECM/PCM . CrankshaftPositionSensor . Timing belt skippedteeth

11-157

11,164

11-164

r1-r66

11 167

11-170

11-172

11-172

' EGRvalve . E G Rl i n e

. Th.eeWay Catalyticconverter . Secondary HO2S

11 253

,'o DTC {MlL indication}

L

(92)

P0451'11

(91)

P0452{6

(9r)

FuelTankPressure SonsorCircuit Range/Parformance SensorCircuit FuelTankPressure LowInput

P0453*6

{91)

SensorCircuit FuelTankPressure HighInput

P0500*1,

(17)

VehicleSpeed SensorCircuit Malfunction

P0501*'3

l17l

VehicleSpeed SensorCircuit Range/Performance

P0505

(14)

P0700*r3 andsomeof P0715 P0720 P0730 P0740 P0753 P0758

(70)*

P0700*1 and P0725

(70)*

P1107

Pressure Barometric ( 1 3 ) Circuit Range/Performance Problem Barometric ( 1 3 ) Pressure Circuit Low Input Barometric ( 1 3 ) Pressure Circuit H i g hI n p u t

ldle ControlSystem lvlalfunction Automatic Transaxle

EVAPPurgeControlSolenoidVaive Openor shortin EVAPPurgeControl SolenoidValvecircuit EVAPControlCanister Vacuumlines ECM/PCM . FuelTankPressure Sensor ' ECM/PCM Sensorcircuat Shortin FuelTankPressure Sensor FuelTankPres$ure ECM/PCM Sensorcircuit ODenin FuelTankPressure FuelTankPressureSensor ECM/PCM V€hicleSpeedSensor VehicleSpeedSensorcircuit ECM V€hicleSp€edSensor VehicleSpeedSensorcircuit PCM . IAC valve . Throttle Body

P 1 1 2 1 * ' . * 1 6*. ' ?

\71

P1122'14.*16.*n

17l

P1129*1r.*16.*"(5)

Page

11-271

1 12 7 4

11-275 11-219

11-176

r 1-176 11-192

Section 14

Transaxle Automatic

15)

! l

Evaporative Emission Control SystemInsufficient PurgeFlow

P0441*5

P1108

ProbableC.use

Detoction lt€m

Section14 . ECM/PCM (Barosensor) . ECM/?CM(Baros€nsor) . ECM/PCM lBarosensor)

11 - 1 7 8

11-178

11 - 1 7 8

ThrottlePositionLower Than Expected ThrottlePositionHigherThan Expected

. I r sensor

11-138

. TP sensor

11-'138

ManifoldAbsolutePressure LowerThanExpected ManifoldAbsolutePressure HigherThanExpected

. MAPsensor

11 ' 1 2 3

. MAPsensor

't1-123

*:The E indicatorlight and the MaltunctionIndicatorLamp (MlL) may come on simultaneously. *1: D16Y5engine (CVT) "5: '96 D16Y5engine,D16Y7engine,D16Y8engine (sedan).'97D16Y5engine,Dl6Y7 engine (coupe:KA, KC models,sedan:KA. KC, KL (DX) models,hatchback:all models),D16Ygengjne (sedan:KA, KC models) *6: '96 D16Y8engine (coupe),'97Dl6Y7 engine (coupe:KL model, sedan:KL (LX) model),'97 D'16Y8engine (coupe:all models, sedan:KL model),'98-allmodels,'99-allmodels,'00-allmodels *12: ExceptA,,/T(D16Y7,D16Y8enginei *13: A"/T(D16Y7,D16Y8engine) * 1 4 : ' 9 7m o d e l (cont'd) * 1 6 : ' 9 8m o d e l '99 " 17: - 00 models

11 - 9 9

Troubleshooting DiagnosticTroubleCode(DTGIChart(cont'dl DTC (MlL indicationl

Detection lt6m

PrimaryHeatedOxygenSensor (Sensor1) Circuit Malfunction PrimaryHeatedOxygenSensor (Sensor'1)Circuit SlowResponse

Probablc Cause

Page

Openor shortin PrimarvHO2S(Sensor1 PrimaryH02S(Sensor1)

11-146

P1162+1

(48)

P]163'

(61)

Pl164*r

(61)

P1165*?

(61)

P1166'

(41i

P1167*'

(41)

P1168*'

(48)

. PrimaryHO2S(Sensor1) PrimaryHeatedOxygenSensor (Sensor1) CircuitRange/ Performance Problem PrimaryHeatedOxygenSensor Openor shortin PrimaryHO2S(Sensor1) (Sensor'1)HeaterSystemElectrical heatercircuit Problem PrimaryHO2S(Sensor1) ECM/PCM PrimaryHeatedOxygenSensor Openin PrimaryHO2S(Sensor1)VS+circuit PrimaryHO2S(Sensor1) Heater lSensor1) HeaterSystem Malfunction PrimarvHO2S{Sensor1) . Shortin PrimaryHO2S(Sensor1) LABEL PrimaryHeatedOxygenSensor (Sensor1) LABELLowInput circuit

Pl169*?

(48)

PrimaryHeatedOxygenSensor (Sensor1)IABELHighInput

PrimaryHeatedOxygenSensor (Sensorl) CjrcuitRange/ Performance Problem

WEC System Malfunction

P1259*3

(221

P1297*s

(20)

ElectricalLoad DetectorCircuit Low Input

Pr298+'

l20l

Electrical Load Detector Circuit H i g hI n p u t BandomMisfire

ano someof P0301 l71l P0302 l72l P0303 l73l P0304 l74l *7: D16YS engine(M/T) *8: D16Y5, D'16Y8 engine *9: USAmodel * 1 4 r ' 9 7m o d e l *15r'96 model

11 - 1 0 0

. PrimaryHO2S(Sensor1) 11-145

. PrimaryHO2S(Sensor1) 11-150

. Openin PrimaryHO2S(Sensor1)IABEL circuit . Shortin groundcircuit WEC SolenoidValve Openor shortin WECSolenoid Valvecircuit VTECPressureSwitch Openor short in VTECPressureSwitch circuit ECM,FCM ElectricalLoadDetector ElectricalLoadDetectorcircuit ECM/PCM ElectricalLoadDetector ElectricalLoadDetectorcircuit ECM/PCM lgnitionsystem Fuelsupplysystem MAPsensor EGRsystem IACvalve Contaminated fuel Lackol fuel

11-150

11 - ' 1 6 1

11-163

11-151

11.152

Section6

11-179

11 - 1 8 1

11-166

DTC (MlLindicationl P1336

(54i

P1337

(54)

P13s9

(8)

P1361

(8)

P1362

(8)

P1381

{9)

P1382

(9)

CrankshaftSpeed FluctuationSensor IntermittentInterruption

. CKFsensor

CrankshaftSpeed Fluctuation Sensor N oS i g n a l CrankshaftPosition/Top DeadCenterSensor Disconnected Top DeadCenter SensorIntermittent Interruptron Top DeadCenter SensorNo Signal

CKFsensor CKFsensorcircuit ECM,PCM ' CKP/TDC sensorcircuit

CylinderPositionSensor IntermittentInterruption CylinderPositionSensor No Signal

Control Evaporative Emission SystemLeakDetected {FuelTank Area) P1456*5

(90)

L Evaporative EmissionControl SystemLeakDetected(EVAP Area) ControlCanister P1457*6

(90)

Probable Cause

Detection ltem

Page 11183

11-'183

11-187 . tuL sensor

11-172 TDCsensor TDCsensorcircuit ECIV/PCM . CYPsensor

11-172 11-172

CYPsensor CYPsensorcircuit ECM/PCM

11-112

Fuelfillcap Vacuum connection Fu€ltank Fueltank pressuresensor EVAPbypasssolenoidvalve EVAPtwo way valve EVAPcontrol canistervent shut valve EVAPcontrol canister EVAPpurge control solenoidvalve

11-283

Vacuum connection EVAPcontrol canister Fueltank pressuresensor EVAPbypasssolenoidvalve EVAP two way valve EVAPcontrol canistervent shut valve Fuel Tank EVAPpurge control solenoidvalve

11-283

*6: '96 D16Y8engine(coupe),'97 Dl6Y7engine(coupe:KL model,sedan:KL (LXlmodel),'97D16Y8engine(coupe:all models, models. models,'99-all models,'00-all sedan:KL model),'98-all

I ta

(cont'd)

1 1 - 10 1

Troubleshooting DiagnosticTroubleCode(DTCIGhart(cont'd) DTC lMlL indicationl

Detegtion hom EGRValve Lift Insufficient Detected

EGRvalve(withlift sensor) EGRvalvelift sensorcircuit EGRcontrolsolenoidvalve(A,/I) EGRcontrolsolenoidvalvecircuit E G Rl i n e EGRvalvecircuit(M/T) ECM

EGRValve Lift Sensor High Voltage

EGRvalve (with lift sensor) EGRvalve lift sensorcircuit ECM

IACvalve IACvalvecircuit ECM Openor shortin IACvalvecircuit IACvalve ECM/PCM

P1491*!

\12J

P1498*.

112)

Pl508*10

(14)

ldleAir ControlValve CircuitFailure

{14)

ldleAir ControlValve CircuitFailure

P1607

1-)

Probablo Csuss

EngineControl Module/Powertrain Control lvlodule lnternal CircuitFailureA

't1-256

11-265

'11-194

1l-198

. ECM/PCM

TMA,/TMB SignalLineFailure ODenor sho.t in TMA,/TMB circuit P1655*1 (30) Automatic Transaxle P1705 P1706 P1753 P1758 P1768 P1785 P1790 P1791 (70)* P1793 P1870 P1873 P1879 P1885 P1886 P1888 P1890 P1891 *: The E indicatorlightandthe Malfunction Indicator Lamp{MlL)maycomeon simultaneously. *4: D16Y5engine(M/T) +10:ExceptA/TandDl6Y7engine *11:A,/TandD16Y7engine *18:D16Y5engine(CW)(except'99- 00 models)

11-102

Page

11-188 11-189

Section14

How to ReadFlowcharts A flowchartis designedto be usedfrom startto final repair.lt's likea map showingyou the shortestdistance.But beware: "map" anywherebut a "stop" symbol,you can easilyget lost. lf you go off the

tSrARTl

flowchart. the conditionsor situationto starta troubleshooting Describes

FanoNl

Asksyou to do something;performa test,set up a conditionetc.

(boldtype)

@ tsroPI {boldtype)

direction. Asksyou aboutthe resultof an action,then sendsyou in the appropriatetroubleshooting The end of a seriesof actionsand decisions.describesa final repairactionand sometimesdirectsyou to an earlierpart of the flowchartto confirmyour repair,

NOTE: . The term "lntermittentFailure"is used in thesecharts,lt simply meansa systemmay have had a failure.but it checks out OK at this time. lf the MalfunctionIndicatorLamp(MlL)on the dash does not come on, checkfor poor connections or loosewires at all connectorsrelatedto the circuitthat you aretroubleshooting(seeillustrationbelow)' ControlModule . Most of the troubleshootingflowchartshave you resetthe EngineControlModuls (ECM)/Powertrain you (DTC). problem can't duplicatethe is intermittent and (pCM)and try to duplicatethe DiagnosticTroubleCode lf the possibly, replaced needlessly and, a result in confusion To so will only flowchart. do code,do not continuethoughthe ECM/PCM. . ,,Open"and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an accidentalconnectionof a wire to ground or to anotherwire. In simple electronics,this usuallymeanssomethingwon't this can sometim€smean somethingworks,but not the way it's work at all. In complexelectronics(likeECM's/PCM'sl. to. suDDosed

toosE

11 - 1 0 3

PGM-FISystem SystemDescription INPUTS

ENGINE C O N T R OM L O D U L E( E C M Y POWERTRAIN CONTROL MODULE(PCM)

OUTPUTS

CKP/TDC/CYP Sensor MAPSensor IATSensor TP Sensor EGRValveLiftSensor*' PrimaryH02S SecondaryHO2S VSS BAROSensor ELD*' KS€ StarterSignal ALT FRSignal Air Conditioning Signal A/T GearPositionSignal BatteryVoltage{lGN.1} ErakeSwitchSignal PSPSwitchSignal FuelTankPressure Sensor*i VTECPressure Switch*5 ClutchSwitchSignal*6 Countershaft SpeedSensornB MainshaftSpeedSensorrs

F ; i l r rj " - - - - - f i - t r i - ' r . ; l

Fb"t."'i"d" c;;il

- \ ----t

/

F,h"'c;;tr*".io";-l @."r.l"sc;;ll B""k-pF"""till EaM/PcM

r\ -:/

FuelIniectors PGM-FlMain Belay{FuelPump) MIL IACValve !y'CCompressor ClutchRelay RadiatorFanRelay*, CondenserFanRelay ALT*' lcM EVAPPurgeControlSolenoid PrimaryHO2SHeater SecondaryH02SHeater EGRControlSolenoidValve*r EGRvalve*6 EVAPBypassSolenoidValve*' EVAPControlCanisterVentShut VTECSolenoidValve*5 DLC Lock-upControlSolenoidValve*a ShiftControlSolenoidValve*3 LinearSolenoidValve*3

*1: Dl6Y5engine *2: USAmodel *3: CW (D16Y5 ensine),D16Y8engineand 81642ensine *4: '96 D16Y8enginelcoupe),'97Dl6Y7engine(coupe:KL model,sedan:KL (LX)model),'97D16Y8engine{coupe:all models,sedan:KL model),'98-all models,'99'allmodels,'00-all models +5:D16Y5,D16Y8,816A2 engine *6: M/T (D16Y5enginei *7: CVT1D'l6Y5 engine) +8:A/T (D16Y7, D16Y8engine) *9: '96 D16Y5engine,'96D16Y7engine,'96Dl6Y8 engine(sedan),'97D16Y5engine,'97Dl6Y7 engine(coupe:KA, KC models,sedan: KA, KC,KL (LX)models,hatchback: all models),'97D16Y8engine(sedan:KA,KC modelsi PGM-FI Sy3lem The PGM-Fl system on this model is a sequential multipon fuel injection system. Fuel iniector Timing and Duration The ECM/PCM contains memories for the basic discharge durations at various engine speeds and manifold air flow rates. The basic discharge duration, after being read out from the memory. is further modified by signals sent from various sensors to obtain the final discharge duration. ldle Air Control ldle Air Control Valve llAC Valve) When the engine is cold. the A,/Ccompressor is on, the transmission is in gear, the brake pedal is depressed,the P/S load is high, or the alternator is charging, the ECM/PCMcontrols current to the IAC Valve to maintain the correct idle speed. lgnition Timing Control . The ECM/PCM contains memories for basic ignition timing at various engine speeds and manifold air flow rates. lgnition timing is also adjusted for engine coolant temperature. . Aknockcontrol system was adopted which sets the ideal ignition timing for the octane rating ofthegasoline used.*3 Othgr Control Funqtions 1. Starting Control When the engine is started, the ECM/PCM provides a rich mixture by increasing fuel injector duration. 2. Fuel Pump Control . When the ignition switch is initially turned on, the ECM/PCM supplies ground to the PGM-Fl main relay that supplies current to the fuel pump for two seconds to pressurizethe fuel system. . When the engine is running, the ECI\4PCM supplies ground to the PGM-FI majn relay that supplies current to the fuel oumo. . When the engine is not running and the ignition is on, the ECM/PCM cuts ground to the PGM-FI main relay which cuts current to the fuel pump.

11-104

FuelCut-offControl . Duringdeceleration with the throttlevalveclosed,currentto the fuel injectorsis cut off to improvefuel economyat speedsover the followingrpm: . D 1 6 Y 5e n g i n e( M / T ) : 8 5 r0p m . D]6Y5engine(CVT),D'16Y8 engine(USAM/T):920 rpm . Dl6Y8 engine(USAA,/I),D16Y7engine(USAA,/T);910rpm . D16Y8engine(CanadaM/T),D16Y7engine(canada):990 rpm ' D16Y8engine(CanadaM/T):1,000rpm . 8 1 6 A 2e n g i n e9: 7 0r p m . Fuelcut-offactionalso takesplacewhen enginespeedexceeds6,900rpm (D16Y5,D16Y7engine;D'16Y8engine: 7,000rpm. 816A2engine:8.100rpm), regardlessof the positionof the throttlevalve,to protectthe enginefrom '99 Dl6Y7 engine(A,/T)and '99 D16Y8engine(A./T), the PCMcutsthe fuel at enginespeedsover over-rewing.With 5,000rpm when the vehicleis not moving. IVC CompressorClutchRelay When the ECM/PCMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorfrom and enrichesthe mixtureto assuresmoothtransitionto the A,/Cmode beingenergized, Emission(EVAP)PurgeControlSolenoidValve*' 5 . Evaporative When the enginecoolanttemperatureis above 154'F(68'C).the ECM/PCMcontrolsthe EVAPpurgecontrolsolenoid valvewhich controlsvacuumto the EVAPpurgecontrolcanister. Emission(EVAP)PurgeControlSolenoidValve*a Evaporative When the enginecoolanttemperatureabove 154"F(68"C),intakeair temperatureabove32"F(0'C)and vehiclespeed above 0 mile (0 km/h)or [Ay'Ccompressorclutch on and intakeair temperatureabove 160"F(41'C)],the ECM/PCM controlsthe EVAPpurgecontrolsolenoidvalvewhich controlsvacuumto the EVAPpurgecontrolcanister. (EGR)ControlSolenoidValve*? 6. ExhaustGasRecirculation When EGRis requiredfor controlof oxidesof nitrogen(NOx)emissions.the ECMcontrolsthe EGRcontrolsolenoid valvewhich suppliesregulatedvacuumto the EGRvalve 1 . AlternatorControl with the electricalload and driving mode, The systemcontrolsthe voltagegeneratedat the alternatorin accordance fuel economy. improve the engine load to which reducesthe

3.

.1.

ECM/PCMFail-safe/Back-upFunctions 1. FailsafeFunction When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMignoresthat signal and assumesa pre-programmedvaluefor that sensorthat allowsthe engineto continueto run. Function 2. Back-uD When an abnormalityoccursin the ECM/PCMitself,the fuel injectorsare controlledby a back-upcircuitindependent of the systemin orderto permitminimaldriving. 3. Self diagnosisFunctionlMalfunctionIndicatorLamp(MlL)l When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMsuppliesgroundfor the lvllLand storesthe DTC in erasablememory.When the ignition is initiallyturned on, the ECM/PCMsuppliesground for the MIL for two secondsto checkthe MIL bulb condition. 4. Two Trip DetectionMethod idle control To preventfalse indications,the Two Trip DetectionMethodis usedfor the HO2S,fuel metering-related. functions.When an abnormalityoccurs, system,ECTsensor,EGRsystemand EVAPcontrol systemself-diagnostic the ECM/PCMstoresit in its memory.When the same abnormalityrecursafterthe ignitionswitch is turned OFFand this functionis ON 0l) again,the ECM/PCMinformsthe driver by lightingthe MlL. However,to easetroubleshooting, an abnormality jump immediately when will then blink you The MIL check connector. the service cancelledwhen occurs, 5. Two (or Three)DrivingCycleDetectionMethod A "DrivingCycle"consistsot startingthe engine.beginningclosedloop operation,and stoppingthe engine.lf misfiring that increasesemissionsis detectedduringtwo consecutivedrivingcycles,or TWCdeteriorationis detecteddurthis function ing three consecutivedrivingcycles,the ECM/PCMturns the MIL on. However,to easetroubleshooting, is cancelledwhen you jump the servicecheckconnector.The MIL will then blink immediatelywhen an abnormality occurs. (cont'd)

1 1 - 10 5

PGM-FISystem SystemDescription(cont'dl Lean Burn Control {D16Y5engine: CvT)

TOC/CKP/CYP SENSOR

MAP SENSOR

CKF SENSOR

Comparison oI currentair fuel ratio to target ratio

ECM

The lean burn control system is basedon the characteristic increasein crankshaftangularacceleration which occursin when the air-fuelratiogetsleaner. The CKFsensor,which is mountedon the crankshaft,monitorssnginespeed,lf crankshaftangularacceleration falls below a certainlevel(targetair-fuelratiolevel),the amountof injectedfuel is reouceo. lf crankshaftangularacceleration exceedsthis level.the amountof fuel is increased. This system improvesfuel economyand driveabilityby controllingthe amount of injectedfuel in the lean burn range immediatelvbeforecombustionstartsto deteriorate.

1 1 - 10 6

I

EngineControlModule/PowertrainControlModule(ECM/PCM) t'96- 98 Models,'99- 00 Dl6Y5enginewith M/Tl The Malfunc{ion Indicator Lamp {MlLl never comes on (evenlor two secondsl atter ignition is turned on.

7.5A) in the checkfor a loosefuse No. 25 {METER NOTE:lf this svmptomis intermittent, terminalA18,or an intermit underdash{use/relaybox, a poor connectionat ECM/PCM (A18)and the gaugeassemblv. wire betweenthe ECM/PCM tent ooenin the GRN/ORN

Turnthe ignitionswitchON (ll). ls the low oil pressurelighton? -

Repair short or open in the wile botwoen No. 25 {M€TERI 17,5Altus€ and gau99 assem' bty. ReplacoNo.25 IMETERI(7,5 A)tuse.

Try to start the engine. A I32PI ECM/PCMCONNECTOR PGl {BLKI Doesthe enginestan? Checklor an open in the wiles {PGlinosl: 1. Turnthe ignitionswitchON (ll). 2 . l d e a s u r ev o l t a g e b e t w e e n b o d y g r o u n da n d E C M / P C M connectorterminalsA10 and A23 individually.

L

Check tor an open in the wire ot bulb (MlL line): 1. Turnthe ignitionswitchOFF. 2 . C o n n e c t h e E C M / P C Mc o n nector terminal A'18to body groundwith a jumperwire. 3. Turnthe ignitionswitchON (ll).

Wire sideot femaleterminals Repair open in the wire(s) b e t w e e n E C M / P C Ma n d G 1 0 1 (localod at the thetmostat hous_ ingl that had morethan 1.0V.

ls thorelessthan 1.0V?

Substituto . known-good ECM/ PCM and recheck.It symptom/ indication go6s away, roPlace the origin.l ECM/PCM.

ls the MIL on? -

Substitute a known-good ECM/ PCM and .echeck.lf symptom/ indication goes away, replaco the origin.l ECM/PCM.

! 1 ,

Repair open in th€ wires betwoen ECM/PCMlAl8l and gaug6 a$embly. Replacethe MIL bulb,

A (32P} ECM/PCMCONNECTOR

8

6

2 12 l 3

t 5 t 6 1 t I t 19 20

25

MrL

22

l0

11

23

2a

xt 30

27

I luanpenwrnr

IGRN/ORN) I

Wire sideof femaleterminals

(cont'd)

11-107

PGM-FISystem EngineControlModule/PowertrainControlModule(ECM/PCMI ('96- 98 Models,'99- 00 Dl6Y5enginewith M/Tl (cont'd) The Maltunction Indicator Lamp (MlLl stays on o. comes on eftar two s€conds,

Check the Oiagnoslic Trouble Code{DTC}I 1. Connecta scantool or Honda PGMTester. 2. Turnthe ignitionswitchON (ll). 3. Read the DTC with the scan tool or HondaPGMTester.

Are any DTC{s)indicated?

NOTE: . Whenthereis oo Diagnostic TroubleCode(DTC)stored,the MtL wi stay on if the SCS servace connectoris connected andthe ignitionswitchis on, . lf this symptomis intermittent, checklor: - A looseFl E/M115A) fuse in the underhoodluse/relaybox - A looseNo. 13 FUELPUMPfuse(15A) in the underdashfuse/relay box - An intermittentshon in the wire betweenthe ECM/PCM(C7)and the servicecnecK connector - A n i n t e r m i t t e nst h o r t i n t h e w i r e b e t w e e nt h e E C M / P C M( A 1 8 )a n d t h e g a u g e assembly - An intermittentshon in the wire betweenthe ECM/PCM{D4)and the MAp sensor An intermittentshort in the wire betweenthe ECM/PCM(D10),the Tp sensor,the EGRvalve l:ft sensor (D16Y5engine)and/or the Fuel tank pressuresensor (,96 Dl6Y8 engine(coupe),'97 016Y7engine(coupe:KL model,sedan:KL (LX)modeli, '97 016Y8 engine{coupe:all models,sedan:KL modeti,'98,allmodels} - PGM-FImain relay . Seethe OBD ll scantool or HondaPGMTesteruser'smanualslor speciticoperating instructions.

Go to troubleshooting p.oc€dur€s (se€pago 11{11.

Checkthe DTCby MIL indication: 1. Turnthe ignitionswitchOFF. 2. Connectthe SCSservicecon, n e c t o rt o t h e s e r v i c ec h e c k connector. 3. Turnthe ignitionswitchON (lli.

Doesthe MIL indicateany DTC?

Repair opon ol short in wire botwoen the ECM/PCM (C8) and Data Link Connector. Go to troublelhooting procedure ls6epage11-811.

ECM/PCMCONNECTOR C 13lPI

scs tBRNI

Try to startthe engine.

Doesthe engine start? Wire side of female terminals

Check for a short in the wire (SCSlin€l: 1 . D i s c o n n e ctth e S C S s e r v i c e connector. 2. Stop the engineand turn the ignitionswitchON {lli. 3. Measurevoltagebetweenthe ECM/PCMconnectorterminal C7 and body ground.

ls thereapprox.5 V?

(Topage11,109)

11-108

(To page11 109)

Ropair short to body Iround in the wire betweon ECM/PCMlCTl and sorvicecheckconnector.

l F r o mp a g e1 1 1 0 8 )

Checkfor a short in the wire {MlL linell 1. Turnthe ignitionswitchOFF. 2. Disconnectthe Eclvl/PCMconnectorA (32P). 3. Turnthe ignitionswitchON {ll).

ls the MIL ON?

Ropair short to body gtound in the wir. between the ECM/PCM lA18)and MlL.

Substitute a known-good ECM/ PCM and recheck.lt 3ymptom/ indicaiion goes away, rePlace ihe original ECM/PCM.

( F r o mp a g e1 1 1 0 8 )

InspectFl E/M (10 A) fuse in the undeFhoodIuse/relaybox. -

-

Repair short in the wirg b€tweon Fl E/M (15 A) luse and PGM-FImain rolay. ReplaceFl E/M (15 Alfuse.

InspectNo. 13 FUELPUMP(15A) fuse/relaY fuse in the under-dash -

-

Repait lhort in the wire botween No. 13 FUEL PUMP 115Al fuse and PGM-FImain reray. RoplaceNo. 13 FUELPUMP 115Al tu3o.

Checkfor a short in a 3€nsor: 1. Turnthe ignitionswitchON (lli. 2. Disconneclthe 3P connector from eachsensorone at time: . TP sensor . EGRvalvelift sensor(D16Y5 engrne) . F u e l t a n k p r e s s u r es e n s o r ( ' 9 6 D 1 6 Y 8e n g i n e( c o u p e ) , ' 9 7 D 1 6 Y 7e n g i n e ( c o u P e : K L m o d e l , s e d a n :K L ( L X ) m o d e l ) , ' 9 7D 1 6 Y 8e n g i n e l c o u p e :a l l m o d e l s ,s e d a n : KL model,'98-allmodels)

!

{To page11 110)

(cont'd)

11 - 1 0 9

PGM-FISystem EngineControlModule/Powertrain ControlModule(ECM/pCMl ('96- 98 Models,'99 - 00 D16Y5enginewith M/Tl (cont,dl ( F r o mp a g e 1 1 - 1 0 9 )

ECM/PCMCONNECTOR D {16P} Doesthe N4lLgo OFF?

Replacethe sensor that caused the light to go out.

Check fo. a short in the wi.os (VCClines): ':. Turnthe ignition switchOFF. 2 . D i s c on n e c t t h e E C M / P C M connectorD (16P). 3. Checkfor continuitybetween b o d y g r o u n da n d E C M / P C M c o n n e c t o tre r m i n a l sD 4 a n d D10individually.

Ropair short to body ground in the wire betweon ECM/ PCM{O4)and MAP s6n3or. Repair short to body ground in the wire between ECM/ PCMlD10l,the TP sensor,the EGRvalve lift sensor{D16Y5 engine) and/or the Fuel tank pressuresensor {'96 Dl6Yg enginelcoupe),'97 D16Y7 e n g i n e ( c o u p e :K L m o d e l , s e d a n : K L ( L X l m o d e l ) ,' 9 7 D16Y8 engine (coupe:all models,sedan:KL model. €8allmodelsl.

ls therecontinuity?

Checktor rn open in the wires (lGPlines): 1. Disconnectthe fuel injectors and IACvalveconnectors, 2. Turnthe ignitionswitchON (ll). 3 . M e a su r e v o l t a g e b e t w e e n b o d y g r o u n da n d E C M / P C M c o n n e c t otre r m i n a l sA 1 1 a n d 424 indivjdually.

ls therebatteryvohage?

ls therelessthan 1.0V?

Substitute 6 known-good ECM/ PCM and r€check.lf symptom/ indication 9o€s away, replace the original ECM/PCM.

11-110

Wire sideof femaleterminals

ECM/PCMCONNECTOR A (32P}

IGP 1 {YEL/BLKI 2

I l 5 t 6 I t t 8 t 9 20

12 1 3

25

27

11

23

-

-

Repair open in the wirels) between ECM/PCM (A11, A24land PGM-Flmain relay. Check for poor connections or loose wiras at the PGM-FI main relay, Test the PGM-FImdin relav lseepag611-237).

v) (l

Wire sideof femaleterminals

LG1 {8RN/ BLK) I 2 5 8 '12 t t 1 1 t 5 l 6 1 7 t 8 t 9 20

2A 23 30

LG2 {8RN/ 8LK}

Repair open in the wirolgl b€twe€n ECM/PCM {A9, A22} and G101that had more than 1.0V.

21

2a 29 3 0 IGP2 (YEL/BLKI

Checkfor an open in the wires (LGline3): 1. Reconnectall sensorconnec tors. 2. Reconnect the ECM/PCM connectorD (16P). 3. Turnthe ignitionswitchON (ll). 4. Measurevoltage between b o d y g r o u n da n d E C M / P C M c o n n e c t o tr e r m i n a l sA g a n d A22individually.

VCCl {YEL/RED}

to

l1

23

2a

ControlModule(ECM/PCM) EngineControlModule/Powertrain ('95- 00 ModelsexceptDl6Y5 enginewith M/T) The Mrlfunction Indicator LamP {MlL) never comes on {even tor two seconds) after ignition is turnedON lll).

Turnthe ignitionswitchON lll).

NOTE: . Whenthere is no Diagnostic TroubleCodelDTC)stored,the MIL will staYon if the SCS seruiceconnectoris connectedandthe ignitionswitchis on. . lf this symptomis intermittent, checkfor: box - A looseNo. 25 (METER) {7.5A) fusein the underdashfuse/relay box - A looseFl E/M(15Alluse in the undeFhoodfuse/relay box fuse/relay - A looseNo. 13 FUELPUMPfuse(15A) in the under-dash (A18)and the gaugeassem' - An intermittentshon in the wire betweenthe ECM/PCM an intermittentshort in the wire betweenthe ECM/PCM(C19)and the MAP sensor An intermittentshort in the wire betweenthe ECM/PCM{C28),the TP sensor,the EGRvalvelift sensor(D16Y5engine)and/orthe Fueltank pressuresensor('96D16Y8 engine (coupe),'97D16Y7engine lcoupe: KL model, sodan:KL (LX) model)"g7 Dt6Y8 engine(coupe:all mod;ls, sedanlKL model),'98-allmodels,'99-al'models' '00-allmodels. - PGM'FImain relay . See the oBD ll scantool or HondaPGM Testeruser'smanualsfor specificoperating instructrons, -

ls the low oil pressurelighton? -

Repair shott or open in tho wire bstwoon No. 25 IMETER) l?.5A)tuse and gaugatsom_ blv. ReolaceNo. 25 (METERI(7.5 Alluse. A I32PI CONNECTOR ECM,/PCM

Try to start the engine.

Doesthe enginestart?

Checkfor an opon in the wire or bulb (MlL line): 1. Turn the ignitionswitchOFF. 2 . C o n n e c t h e E C M / P C Mc o n ' nectorterminal A18 to body groundwith a iumperwire. 3. Turnthe ignitionswitchON (ll) Wiresideof {emaleterminals -

-

Turn the ignitionswitchOFF. InspectFl E/M(15A)fuse in the underhood Iuse/relaybox.

Repair open in tho wire3 betwoon ECM/PCM (A18) and gaugo .*tembly. Rool.ce the MIL bulb.

Substitute a known-good ECM/ PCM and rochoc&. lf sYmptom/ indication goes sw6y, repl.ce tho original ECM/PCM.

Rop.ir short in the wirc betwo€n Fl E/M (15 A) luso and PGM-Flmrin rGl.y. Reol.ce Fl E/M (15 A)tusa.

lnspectNo. 13 FUELPUMP{15A} luse in the under-dashfuse/relay -

.f,

-

Reoair short in the wiro between No. 13 FUEL PUMP 115Al luse sod PGM-FImain relay. ReolaceNo. 13 FUEL PUMP 115A) tuse.

(cont'd)

(Topage11 112)

11-111

PGM-FISystem EngineControlModule/Powertrain ControlModule(ECM/PCM) ('99- 00 ModelexceptDl6Y5 (M/Tl engine)(cont'd) ( F r o mp a g e ' 1 1 - 1 1 1 )

Checkloi an open in the wires (lGPlinesl: 1. Disconnect thelueliniectorand IACvalveconnectors. 2. Turnthe ignitionswitchON (ll). 3 , M e a s ur e v o l t a g e b e t w e e n b o d y g r o u n da n d E C M / P C M c o n n e c t o tr e r m i n a l s8 1 a n d Bg individually. Wiresideof femaleterminals -

ls there batteryvoltage?

-

R e p a i ro p e n i n t h e w i r o ( 3 ) between ECM/PCMlBl, B9l and PGM-Flmain relay. Check tor poor connections or loose wires al the PGM-FI main relav. Test tho PGM-FImain rehy (3.e page 11-237). ECM/PCMCONNECTOR B {25P)

Checktor an open in the wires (PG,LG lines): 1 . R e c o n n e ctth e f u e l i n i e c t o r and IACvalveconnectors. 2. Measurevoltage between body ground and ECM/PCM connectorterminals82, 810, 820 and 822 individually.

ls therelessthan1.0V?

Check for a short in the wires {VCCI,VCC2lin6s}: Measurevoltage between body ground and ECM/PCMconnector terminals C19andC28individually.

ls thereapprox.5V?

Repair open in the wirels) b e t w e e n E C M / P C Ma n d G 1 0 1 llocated ai the l6ft side of tho intaks m.nifoldl thrt h.d more than 1.0V.

Checktoa a 3hort in s 3ensor: While measuring voltage betweenbody ground and ECM/ P C [ / tc o n n e c t o rt e r m i n a l sC 1 9 and C28 individually,disconnect the 3P connectorof each sensor one at time: . MAPsensor . TP sensor . EGRvalve . Fueltankpressuresensor

ls thereapprox.5 V? Substiiute a known-good ECM/ PCM and racheck. ll symptom/ indicetion goes eway, replace th6 original ECM/PCM.

11-112

Replace tho sansor that had .pprox. 5 V.

LG1(BRN/BLKI Wiresideof femaleterminals ECM/PCMCONNECTOR C (31P)

vcc2 f e m a l e t e r m i n a l s IYEL/BLUI

vccl {YEL/RED)

Reoairshort in lhe wire betwe.en M A P 3 a n s o r ,T P s e n s o r , E G R valve, Fuel tank pres3ure3ensor and ECM/PCM{Cl9, C28).

The Malfunction Indicator LamP lMlL) staYson or comes on after

NOTE: "in-"n tf'"r" is no DiagnosticTrouble Code (DTCistored,the MIL will stav on ;{ the scs andthe ignitionswitchis ON (ll) is connected serviceconnector . lf this symptomis intermittent, checkfor: (A10)and the servicecheck - An intermittentshortin the wire betweenthe ECM/PCM -

C h e c kt h e D i a g n o s t i cT r o u b l e Code(DTC): 1. Connecta scantool or Honcla PGMTester. 2. Turnthe ignitionswitchON (ll) 3. Read the DTC with the scan tool or HondaPGMTester.

indicated? Are any DTC(S)

'l

connector ( A 1 8 1a n d t h e g a u g e A n i n t e r m i t t e nst h o r t i n t h e w i r e b e t w e e nt h e E C M / P C M

. s"" it'" Oab ll scantool or HondaPGMTesteruser'smanualsfor specificoperating instructions.

Go to troubloshooting Proc€dures (seepage 1141).

check the DTCby MIL indic.tion: 1. Turnthe ignitionswitchOFF 2. Connectthe SCSservicecon_ n e c t o rt o t h e s e r v i c ec h e c k 3. Turnthe ignitionswitchON (ll)

Doesthe MIL indicateanYDTC?

Repair open or 3hort in wiro between ihe ECM/PCM(A21) and Data Link Connector. Go to troubleshooting Ploce_ du.es (seepage 11-811.

Try to start the engine

Substitute . known-good ECM/ PCM and recheck lt sYmptom/ indication goes awaY, rePlaca th. original ECM,/PCM. A I32P) ECM/PCMCONNECTOR C h e c kf o r a s h o r t i n t h e w i . e (Scs line): 1. Turn the ignitionswitch OFF and turn the ignition switch

o N1 ) .

2 - M e a su r e v o l t a g e b e t w e e n body groundand the ECM/ PCMconnectorterminalA10

ls there batteryvoltage?

Wire side of female terminals

Reoair short to body ground in the wiro bstwaen ECM/PCM (A101 and service ch€ck connoctot.

(cont'd) (Topage11-'114)

1 1 - 11 3

PGM-FISystem EngineGontrolModule/PowertrainControlModule(ECM/PCMI ('99- 00 ModelsexceptDl6Y5 enginewith M/T) (cont'dl { F r o mp a g e 1 1 1l 3 )

Checkfor a short in the wi.e lMlL linelr 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMcon nectorA (32P). 3. Turnthe ignitionswitchON (ll).

l s t h e M I LO N ?

Substituto a known-good ECM/ PCM and r€check.lf symptom/ indication goes away, roplace the o.iginal ECM/PCM.

11-114

Repairshorl to body ground in the wire between the ECM/PCM {A18}andMlL.

ManifoldAbsolutePressure(MAP)Sensor('96Models) problem (vacuumleak) in the The scan tool indicatesDiagnosticTrouble Code (DTC)P0106:A mechanical ManifoldAbsolutePressure(MAP)Sensorsystem' TheMAPsensorconvertsmanifoIdabsoIutepressureintoeiectricaIsigna|sandinpUtstheEcM/PcM' OUTPUT VOLTAGE (v13.5 3.0 2.5 2.0 1.5 1.0 0.5 0 -

The MIL has been reported on OTCP0106is storod. Or from PtobableCauseLisl.

300

lin. Hgl GAUGE READING (mm Hgl

Problomverificetion: 1. Do the ECM/PCMResetProcedure. 2. Start the engineand keep enginespeedat 1,000rpm for one minutewith the transmis' sion in @ or I Position{Mff in neutral).

ls DTCP0106indicated?

Checkthe MAP sensoroutPut: 1. Turnthe ignitionswitchOFF 2. Turnthe ignitionswitchON (ll). 3. Checkthe MAP with the scan tool.

C h e c kt o r v a c u u m l e a k a g eo r blockagebetweenthe MAP sen' sor and throftlebody

ls thereleakageor blockage? Chockthe MAP s€nsol output: 1. Stopthe engane. 2. Turnthe ignitionswitchON (ll). 3. Checkthe MAP with the scan tool.

l l ,

( T op a g e1 1 - 1 1 6 )

(Topage11 116)

{cont'd)

1 1 - 11 5

PGM-FISystem ManifoldAbsolutePressure(MAP)Sensor('96Modelsl(cont'dl ( F r o mp a g e1 1 - 1 1 5 i

Chockto. poor response: 1 . S t a r t t h e e n g i n e .H o l d t h e engineat 3,000rpm with M in E or E position, M/T in neu tral untiltheradiator tan comes on, then turn the ignition switchOFF. 2. Startthe engine. 3. Checkthe MAP with the scan tool.

{ F r o mp a g e1 1 - 1 1 5 )

Checklor poor response: 1 . S t a r t t h e e n g i n e .H o l d t h e engineat 3,000rpm with M in E or E position,M/T in neutral until the radiatorfan comes on, then turn the ignition switchOFF. 2. Startthe engine. 3. Checkthe MAP with the scan tool.

ls a N4APot 40.0kPa {300mmHg, 12.0in.Hg)or lessindicated within one secondafter staning the engine?

The MAP sensor is OK st this time.

ls a MAP of 40.0kPa(300mmHg, 12.0in.Hg)or lessindicated within one secondafterstartingthe engine?

Substitute a known-good ECM/ PCM and rechock. lt symptom/ indication go6s .way. .6plrce th€ original ECM/PCM.

11-116

ManifoldAbsolutePressure{MAP}Sensor ('96- 98 Models,'99- 00 D16Y5enginewith M/T) (high vacuum) problem in the The scan tool indicatesDiagnosticTrouble Code (DTC)PO107:A low voltage ManifoldAbsolutePressure(MAP)sensor. Tho MIL has been roport€d on. DTCP0107is storod.

Problamverification: 1. Turnthe ignitionswitchON (ll). 2. Checkthe MAP with the scan lool.

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

lntormittont failuro, sYatgmia OK al thb timo. Chocklor Pool con_ noqtiona or looso wirca at C111 {MAP !6nsor) ond ECM/PCM. (C111) MAP SENSOR3P CONNECTOR

Chockfor an opon in wiJe (VCCI lino): 1. Turn the ignitionswitchOFF. 2. Disconnectthe MAP sensor

vccr

(YEL/BEDI

3. Turn the ignitionswitchON (ll). 4. Measurevoltagebetweenthe MAP sensorconnectorNo l terminaland No 2 terminal

I

Wiresideof femaleterminals ls thereapprox.5 V?

Ropair open in tho wit b€twocn ECM/PCM(Dill tnd MAP !enso].

Checkfor .n open or ahort in the MAP 3€naor: C h e c kt h e M A P w i t h t h e s c a n tool.

ls approx.2 kPa(15mmHg, 0.6in.Hg)or lessindicated? (D16Y5engine (with YES

cw))

T

Chsckto. a short in the TCM: 1. Turn the ignitionswitchOFF. the 22Pconnector 2. Disconnect from the TCM. 3 . T u r n t h e i g n i t i o ns w i t c hO N

0r).

4. checkthe MAP with the scan tool.

( T op a g e1 1 - 1 1 8 )

(cont'd)

11-117

PGM-FISystem ManifoldAbsolutePressure(MAp)Sensor ('96- 98 Models,'99- 00 D16Y5enginewith M/Tl (cont,d) ( F r o mp a g e1 1 - 1 1 7 )

ls approx.2 kPa('15mmHg,0.6 in.Hg)or lessindicated?

MAP SENSOR3P CONNECTOR IC1l1I Check for a short in ihe wire {MAPline)l 1. Turnthe ignitionswitchOFF. 2 . D i s c on n e c t t h e E C M / p C M connectorD (16P). 3. Checkfor continuitybetween the MAPsensorconnectorNo.3 terminalandbodyground.

MAP (RED/GRNI

Wiresideof femate;rminats

R6pairlhort in tha wire b€twaen ECM/PCM {D3l .nd MAP !6ru0r.

Substitute a known-good ECM/ PCM..nd recheck. normal MAP is indiceted, .eplsce lhe original ECM/PCM,

11-118

|'

ManifoldAbsolutePressure(MAP)Sensor (;gg- OOModelsexceptDl6Y5 enginewith M/T) A low input (high vacuuml problem in the The scan tool indicatesDiagnostrcTrouble Code (DTC)PO1O7: ManifoldAbsolutePressure(MAP)sensor' signalsand inputsthe ECM/PCM' The MAp sensorconvertsmanifoldabsolutepressureinto electrical OUTPUT VOLTAGE lvl3.5 3.0 2.5 2.0 1.5 1.0 0.5 0 lq,

.-l

-

2oo 3q, (x,

5q)

6q) 700

(in.Hgl GAUGE REAOING (mmHgl

The MIL h'3 been reported on OTCP0107b stor€d.

Problemverilication: 1. Turnthe ignitionswitchON {ll) 2. check the N4APwith the scan tool.

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

lntermittent failuro,3Ystomis OK at this time. Ch€ckfor Poor con' nection3 or loose wiros at C111 IMAP sonsorl and ECM/PCM. IC114) MAP SENSOR3P CONNECTOR

Ch.ck for an opcn in wit. {vCC1 linel: 1. Turnthe ignitionswitchOFF 2 . D i s c o n n e ctth e M A P s e n s o r connector. 3. Turn the ignitionswitchON (ll). 4. Measurevoltagebetweenthe MAP sensorconnectorNo. 1 terminaland No 2 terminal

vccl tYEL/RED)

Wire sido of fomalg tormin6ls

ls thereapprox.5 V?

Repairopsn in the wirg botween ECM/PCM(C19)rnd MAP seGor.

(To page 11-120)

{cont'd)

1 1 - 11 9

PGM-FISystem ManifoldAbsolutePressure(MApl Sensor ('99- 00 ModelsexceptDl6yS enginewith M/T) (cont,dl ( F r o mp a g e1 1 1 1 9 )

Checkfor an open or shon in the MAP s€nsor: C h e c kt h e M A P w i t h t h e s c a n tool.

ls approx.2 kPa(15mmHg, 0.6in.Hg)or lessindicated?

MAPSENSOn 3PCONNECTOB tcllilt Check tor a sho.t in lhe wire {MAPline): 1. Turnthe ignitionswitchOFF. 2 . D i s c o nn e c t t h e E C N 4 / p C N 4 connectorC (31P). 3. Checkfor continuitybetween the MAPsensorconnectorNo.3 terminalandbodyground.

MAP (RED/GRNI

Wire side of female terminals Repairshort in the wire between ECM/PCM{Cl7} and MAp s€nsor.

Substitute a known-good ECM/ PCM and rech6ck.lf no.mal MAp is indicated, replace the o.iginal ECM/rcM.

1 1-120

!

ManifoldAbsolutePressure(MAPISensori;idlga lil;dels,'99- 00 Dl6Y5ensinewith M/T) voltage (low vacuum) problem in the The scan tool indicatesDiagnostrcTrouble code (DTC)Po108:A high ManifoldAbsolutePressure(MAP)sensor. The MIL has beenreportedon OTCm108 is stolod. Problemvetitication: 1 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rPm with no load (in Parkor neutral)until the radiatorfan comeson, then let it idle. 2. Checkthe MAP with the scan tool. ls 101kPa(760mmHg,300 in.Hg) or higherindicated?

lntormittent lailure, sFtom k OK .t thb time. Chocklor Poor con' nections or loorg wires at Cll'l |MAP sensorl snd ECM/PCM.

ICl11} MAP SENSOR3P CONNECTOR

Check tor an open in the MAP 36nSOt:

l l

1. Turnthe ignitionswitchOFF 2 . D i s c o n n e ctth e M A P s e n s o r 3P connector. 3. Installa jumperwire betlveen the MAP sensor3P connector No 3and No 2. terminals 4. Turnthe ignitionswitchON (ll). 5. Checkthe MAP with the scan tool.

MAP IRED/GRNI JUMPERWIRE Wire sideol femaleterminals

ls 101kPa(760mmHg,30 0 in.Hg) or higherindicated?

vccl IYEL/RED)

Checkfor an open in wire (SG1 line): 1. Removethe iumperwire. 2. Measurevoltagebetweenthe MAP sensor3P connectorte. minalsNo. 1 and No 2 ls thereapprox.5 V?

Rapai. open in the wito batwoen ECM/PCM(D12).nd MAP !en.or.

D (16PI ECM/PCMCONNECTOR JUMPERWIRE

Check for an oPon in the wiie (MAPlinel: 1. Turnthe ignitionswitchOFF. con2 . C o n n e c tt h e E C M / P C M nectorterminalsD3 and D12 with a iumPerwire. 3. Turnthe ignitionswitchON (ll). 4. Checkthe MAP with the scan tool.

MAP (RED/GRN)

sG1 (GRN/WHT) Wire sideof femaleterminals

ls 101kPa(760mmHg,30 0 in.Hg) or higherindicated?

lr,

Repairopon in the wiles bstlt oon ECM/PCM(D3l and MAP 3oGor.

(cont'd) Substituto a known'good ECM/ PCM and rochock.ll normal MAP is indicated, replace tho original ECM/PCM.

11-121

PGM-FISystem ManifoldAbsolutePressure(MAPISensor ('99- 00 ModelsexceptD16YSenginewith M/T) (contd) The scan tool indicatesDiagnosticTrouble Code (DTC)P0108:A high voltage flow vacuum)problem in the ManifoldAbsolutePfessure(MAp)sensor, Tho MIL has boon rcDortodon. DTC ml 08 b stolod. Problemverification: '1.Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson, then let it idle. 2. Checkthe MAP with the scan toot, ls 101kPa(760mmHg.30 in.Hg)or higherindicated?

Intormittent f.ilu.e, rystom is OX at thi! time. Chocktor poor conn6ction3 or looso wirea at C111 (MAP 3en.or) and tho ECM/ PC-M.

Check for an open in the MAP aon5('r: 1. Turnthe ignalionswitchOFF. 2 . D i s c o n n e ctth e M A P s e n s o r 3P connector. 3. Install a jumper wire betwesn the MAP sensor3P conn6ctor terminals No.3 and No.2. 4. Turnthe ignitionswitchON {ll). 5. Checkthe MAP with the scan tool.

(C111I MAP SENSOR3P CONNECTOR

MAP IRED/GRNI

JUMPERWIRE Wiresideof femaleterminals

ls 101kPa(760mmHg,30 in.Hg)or higherindicated?

vccl IYEL/RED)

Check fo. an opcn in wiro (SGl line): 1. Removothe jumperwire. 2. Measurevoltage between the MAP sonsor3P connectorter m i n a l sN o . 1 a n d N o . 2 . ls there approx. 5 V?

Roprir opon in tha wiJo bctwoen thc ECM/FCM(C7l rnd the MAp sonln t.

Chsck for an open in tho wi.e {MAPlino}: 1. Turnthe ignitionswitchOFF. 2. Install a jumper wire on the ECM/PCMconnectorsbetween C7andC17. 3. Turnthe ignitionswitchON (ll). 4. Checkthe MAP with the scan tool, ls 101kPa(760mmHg,30 in.Hg)or higherindicated?

Substituto a known-good ECM/ PCM and rechcck,It normal MAP is indiceted. r.place tho original ECM/PCM.

11- 1 2 2 --

ECM/PCMCONNECTOR C (31PI

Repairop€n in the wir6a bstwoon tho ECM/FCM(C171and rh6 MAp scnltoa.

JUMPERWIRE Wiresideof femaleterminals

ManifoldAbsolutePressure(MAP)Sensor(cont'dl (MAP)lower than The scan tool indicatesDiagnosticTroublecode (DTc) P1128:ManifoldAbsolutePressure exoected. -

Tho MIL has been t€Portedon. DTCP1128is stored.

Problemverification: 1. Turnthe ignitionswitchON (ll). 2. Checkthe MAP with the scan tool.

ls 54.1kPa(406mm Hg, 16.0 in. Hg)or higherindicated?

lntermitteni failu.e, sYstomi! OK at thb time.

higherthan The scantool indicatesDiagnosticTroublecode (DTC)P1129:ManifoldAbsolutePressure{MAP) exoected,

L -

The MIL has beenroportedon. DTCP1129is slorod

Problemv6rilicaiion: 1 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 2. Checkthe MAP with the scan tool.

ls 43.3kPa(325mm Hg, 128 in. Hg)or lessindicated?

Int6rmittent failuto, sy3tem i3 OK at thi3 time.

11-123

PGM-FISystem IntakeAir Temperature(lAT)Sensor('96- 97 Models) The scan tool indicatesDiagnosticTroublecode (DTC)P0111:A range/performance problemin the lntakeAar Temperature(lAT)Sensorcircuit. The IAT sensor is a temperaturedependantresistor(thermistor). The resistanceof the thermistordecreasesas the intake air temperatureincreasesas shown below. -

The MIL hss beon reportedon. DTCP0111is stored. Or from ProbableC.use List.

RES|STAI{CE {tol

Problemverification: 1. Turnthe ignitionswitchOFF. 2. Disconnect the IAT sensor2P connector, 3. Removethe IATsensor. 4. Reconnectthe IAT sensor2p

. 32 .. ro. tr. 2r, zaa r..l -20 o 20 /|o ao ao 100 rrotlcl

5. Leavethe IAT sensorexposed to ambaent temperature, 6. Turn the ignitionswitch oN fll). 7. Checkthe IAT with the scan tool.

INTAIG AIR TEMPEMTURE

Rsplscgthe IAT sensor.

Checktho IAT sensoroutput: 1. Warm the IAT sensorwith a hair dryer2. Checkthe IAT with the scan tool.

Didthe IATrise2"F(1.C)or more from the ambienttemperature?

Replscethe IAT sensor.

1 1-124

Int€rmittont failu.e, system is OK at this time.

I

IntakeAir Temperature(lATl Sensor The scantool indicatesDiagnosticTroubleCode{DTC)P0112:A low voltage(hightemperature)problemin the lntakeAir Temperature(lAT)sensorcircuit. The MIL has beenTeportedon. DTCP0112is stored.

RESISTANCE IKOI

Problemverification: 1. TurntheignitionswitchON 1ll) 2. Checkthe IAT with the scan tool. a2 .. toa rra rrl l:rt t.al 20 0 20 ro ao ao too t2ot.cl

AIRTEMPEFATURE INTAXIE ls 302'F(150"C)or hagher(or H Limit in Hondamode ot PGMTester)or 0 V indicated? ls the correctambrenttemper atureindicatedi' ?

Roolac€tho IAT 3ensor. *2: lf the engineis warm, it will be higherthan ambienttemPerature.

.-l

lntermittent failure, svstom is OK 6t this tim€. Checkfor Poor Gonnections or loos€ wires st C112 {lAT.en3orl and ECM/PCM. Checktor a shon in the IAT sensor: 1. Disconnectthe IAT sensorcon nector. 2. Checkthe IAT with the scan tool. l s 3 0 2 " F( 1 5 0 ' C ) ohr i g h e (r o r H'Limitin Hondamodeof PGMTester)or 0 V indicated? {C112) IAT SENSOR2P CONNECTOR

-+-r

Ch6ckfor s short in the wira (lAT lin€): 1. Turn the ignitionswitchOFF 2. Disconnectthe ECM/PCMconnectorD (16P)(C(31P))*'. 3. Checkfor continuitybetween the IATsensor2PconnectorlerminalNo.2 andbodyground.

I-_T' l ' l

I

IAT {RED/YEL)

=

Wire sideof femalet e r m r n a r s Reoairshort in the wire bstween ECM/PCMtD8 (c25)'1) and IAT

rf,

Substitute a known-good ECM/ PCM and recheck. It normel IAT is indicated, replace the original ECM/PCM. * l: '99 - 0Omodels except Dl6Y5 engine with M/T-

11-125

PGM-FISystem IntakeAir Temperature(lAT)Sensor ('96- 98 Models,'99- 00 D16Y5enginewith M/Tl The scantool indicatesDiagnosticTroubleCode(DTC)POl13:A high voltageflow temperature)problem in the IntakeAir Temperature(lAT)sensorcircuit, The MIL has beenreportedon. DTCP0113b sto.6d.

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

ls -4'F 1-20"C)or less(or L Limit in Hondamodeof PGNITester)or 5 V indicated?

Intermittent tailuJe,systom is OK at this time, Check to. poor connections or loose wir.s at C112 {lAT senso.l .nd ECM/PCM,

Checkfor an open in the IAT sensol: 1. Disconnect the IAT sensor2p connector, 2. Connectthe IAT sensor2P conn e c t o rt e r m i n a l sN o , 1 a n d No.2 with a jumperwjre. 3. Checkthe intakeair tempera, ture with the scantool.

ls -4"F ( 20'C)or less(or L-Limit in Hondamodeof PGMTester)or 5 V indicated?

taT sENsoR2PCONNECTOn (Cl12l

I ' j r l

'---.]__+ SG2 (GRN/BLKII

I

tAT IRED/YEL}

JUMPER WIRE Repbcethe IAT sensor.

Wire sideof femaleterminals

ECM/PCMCONNECTOR D (16PI

Check tor an open in th6 wires {lAT.SGzline!): 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsD8 and D11 with a 3. Turn the ignitionswitchON (ll). 4. Checkthe IAT with the scan tool.

IAT IRED/YEL)

sG2 (GRN/BLK)

JUMPERWIRE ls -4"F ( 20'C)or less(or L-Limit io Hondamode ol PGMTester)or 5 V indicated?

Substitute a known-good ECM/ PCM end recheck. lf normal IAT is indic.ted, replace the original ECM/PCM.

11- 1 2 6

R€p6ir opan in the wiro! hween EC-M/PCMlD8. 011l and IAT sen-

Wiresideof femaleterminals

L

IntakeAir Temperature(lAT)Sensor ('99- 00 ModeisexceptD16Y5enginewith M/Tl (low temperature)problemin the The scantool indicatesDiagnosticTroublecode (DTC)P0113:A high voltage IntakeAir Temperature(lAT)sensorcircuit. The MIL has be€nrePortedon. DTCP0113i3 stored.

Probl€mvetification: 1. Turnthe ignitionswitchON (ll). 2. Checkthe IAT with the scan tool.

ls -4"F (-20"C)or less(or L-Limit in Hondamodeof PGMTester)or 5 V indicated?

I

Intormittont .t thi! tim.. nactions or tlAT ..n!or)

f.iluro, tyrtom i. OK Chocl for Poor con' looso wit6 !t C112 rnd ECM/PCftl,

r-+-r

Checktor an open in tho IAT son' 304: the IAT sensor2P 1. Disconnect connector, 2. Connectthe IATsensor2Pcon_ n e c t o rt e r m i n a l sN o . 1 a n d No.2 with a jumPerwire. 3. Checkthe intakeair temperature with the scantool.

I t l , llAr

L1__f sG2 IGRN/BLK} I

I

(RED/YELI

JUMPER WIRE Wire sideof femaleterminals

ls -4"F {-20"C)or less(or L-Limit in Hondamodeof PGMTester)or 5 V indicated?

C (31PI ECM/PCMCONNECTOR

Check lor an open in iho wirg3 {lAT,SG2 linesl; 1. Turnthe ignitionswitchOFF 2. ConnectECM/PCMconnector terminalsC18and C25with a iumperwire. 3. Turnthe ignitionswitchON (ll) 4. check the IAT with the scan tool.

ls -4"F (-20"C)or less(or L-Limit in HondamodeoI PGMTesterlor 5V indicated?

IAT SENSOR2P CONNECTOBIC112'

JUMPERWIRE Wiresideof lemaleterminals

Roprir opan in tho wilaa brlwocn ECM/PCM (C18, C25l .nd IAT !on30r.

substituts a known'good ECM/ PCM and recheck. ll normal IAT is indicated, replace the otiginal ECM/PCM.

11-127

PGM-FISystem EngineCoolantTemperature(ECTISensor The scan tool indicatesDiagnosticTrouble code (DTC)P0116;A range/performance problem in the Engrne CoolantTemperature(ECT)Sensorcircuit. The ECTSensoris a temperaturedependantresistor(thermistor). The resistance of the thermistordecreases as the engine coolanttemperatureincreases as shown oetow. RESISTANCE (ko)

THERMISTOR

- a 3 2 6 8r 0 al a 0 l ? 62 t 22 4 8 1 ' r r -20 o 20 ao o D r@ Il, r'c) ENGINE COOLANT IEMPERATURE

NOTE:lf DTCP0117and/orP01'18 are storedat the sametime as DTCP0116,troubleshootthose DTCSfirst. then recheck for DTCP0116. PossibleCause . ECTsensordeterioration . Malfunctionin the thermostatand coolingsystem TroubleshootingFlowchart -

The MIL has bognreportedon. DTCP0116is stored.

Problemverification: 1. Start the engine.Hotd the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 2. With the scantool, checkthe

is 176 200'F{80- 93'C)or 0.0-0.TVindicated?

Check the thermostat and the cooling system. ll they als OK, raplacethe ECTsensor.

11- 1 2 8

Intermiftent lailure. system is OK ai thi. time. Ch.ck the thc.mostat 6nd thc cooling system.

|. fD;r.tt |jg

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

The MIL has been,eported on. DTCml 17 is storod.

Problomvorification: 1. Turn the ignitionswitchON (ll). 2. Checkthe ECTwith the scan tool.

or higher{or ls 302"F(150"C) H-Limitin Hondamodeof PGMTester)or 0 V indicated?

Intermittont failulo, sy3tom it OK at thk tim., Chockfor Poor oonn.ctions or loo!. wiraa at C122 IECT3en orl and ECM/FCM.

ChecktoJ a short in the ECTs.n5('t:

the ECTsensor2P 1. Disconnect connector. 2. Checkthe ECTwith the scan rool.

' f

ls 302"F(150"C) or higher{or H-Limitin Hond6modeof PGMTesterl or 0 V indicated?

(C122I ECTSENSOR2P CONNECTOR

Check for a 3hort in tho wiro IECTlinel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMconnectorD (16P)(C{31P))*. 3. Checkfor continuity between the ECTsensor2PconneclorterminalNo,1 andbodyground. Wiresideof femaleterminals B.gair short in the wiro bltween ECM/PCM(D2 (C261'l.nd ECT

Substitute . lnown-good ECM/ PCM .nd rocheck.It normrl ECT is indic.ted, replaco the original ECM/PCM, *:'99 -Oo modelsexceptD16Y5enginewithM/T

.1,

(cont'd)

11-129

PGM-FISystem EngineCoolantTemperature(ECT)Sensor ('96- 98 Models,'99- 00 D16YSenganewith M/T) (cont'd) The sc€ntool indicatesDiagnosticTroubleCode(DTC)P0118;A high voltage(low temperature)problemin the EngineCoolantTemperature(ECT)sensorcircuit. -

Tho MIL ha3bcen r€oortedon. OTCm118 b stored.

Problomvorificttion: 1. Turnthe ignitionswitchON (ll). 2. Checkthe ECTwith the scan tool.

ls -4"F (-20'C) or less(or L-Limit in Hondamode ol PGMTester)or 5 V indicated?

Intcrmitt.nt failui.. rydom is OK at thir timc. Chackfor Door connaction! or loor! wiaar at C122 IECT..n.orl .nd ECM/rcM, ECt SENSOR2P CONNECTOR {C1221

Chscklor sn open in thc ECT3ansoa: 1 . D i s c o n n e ct h e E C Ts e n s o r 2P connector. z . L o n n e c rr n e E L t s e n s o rz F connectorterminalsNo. 1 and No.2 with a jumperwire. 3. Checkthe ECTwith the scan tool.

ECT IRED/WHTI JUMPERWIRE

sG2 (GRN/BLK) Wire side of female terminals

ls -4'F (-20'C) or loss(or L-Limit in Hondamode ol PGMTesterlor 5 V indicated?

ECM/PCMCONNECTOR D Il6PI JUMPERWIRE

sG2tGRN/81r0 Chack for an opon in the wire. {ECT,SG2lin..l: 1. Turnthe ignitionswitchOFF. 2. Connect ECM/PCMconnector terminals D2 and D11 with a jump€rwire. 3. Turn the ignitionswitchON (ll). 4. Checkthe ECTwith the scan tool.

ls -4'F 1-20'Clorless(o. L-Limit in Hondamode ol PGMTester)or 5 V indicated?

Sub3titut. s known-good ECM/ FCM and r.chcck, It normel ECT i! indicatod, roplaco tho origin.l ECM/PCM.

11 - 1 3 0

Wire side of Iemale terminals

Repriroprn in tha wirar bstwoon CCM/PCM IDZ Dl1) .nd EGTrcnaor.

PGM-FISystem t

EngineCoolantTemperature(ECT)Sensor ('99- 00 ModelsexceptDl6Y5 enginewith M/Tl The scantool indicatesDiagnosticTroubleCode(DTC)P0118:A high voltage(low temperature)problemin the EngineCoolantTemperature(ECT)sensorcircuit. The MIL has been reportedon, oTC P0118is stored.

Problemverilication: 1. Turnthe ignitionswitchON (ll). 2. Checkthe ECTwith the scan tool.

ls -4'F (-20"C)or lesslor L-Limit in Hondamodeo{ PGMTester)or 5 V indicated?

I

lntormittent failuro, systom is OK at thb timo. Checklor poor con' nections or 10036wiraa at C122 {ECTssnsorl and ECM/rcM.

{C122) ECTSENSOR2P CONNECTOR ECT (RED/Wr{T)

Checkfor an open in the Efi sen' sori the ECTsensor2P 1. Disconnect connector, 2 . C o n n e c tt h e E C Ts e n s o r2 P connectorterminalsNo, 1 and No.2 with a jumperwire. 3. Checkthe ECTwith the scan tool.

JUMPERIVIRE sG2 {GRN/BLK) wire side of female terminals

ls -4"F 1-20"C)or less(or L-Limit in Honda mode of PGMTester)or 5 V indicated? C 131PI ECM/PCMCONNECTOB Check for sn open in the wires IECT.SG2 linesl: 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsC18and C26with a jumperwire. 3. Turn the ignitionswitchON (ll). 4. Checkthe ECTwith lhe scan tooi.

ls -4'F {-20"C)or less(or L-Limit Tester)or in Hondamodeof PGN4 5 V indicated?

JUMPERWIRE Wiresideof femaleterminals

Rspair opon in th6 wiros bstwoon ECM/PCM (Cl8, C26l and ECT 3ensot.

Substitute 6 known-good ECM/ PCM and recheck.l{ no.mal EcT is indicatod, .eplace the original ECM/PCM.

11-131

PGM-FISystem ThrottlePositionITP)Sensor('96- 98 Models,'99- 00 D16Y5enginewith M/Tl The scantool indicatesDiagnosticTroubleCode (DTC)P0122:A low voltageproblemin the ThrottlePosition (TP)sensorcircuit. The TP Sensor is a potentiometer. lt is connectedto the throttle valve shaft. As the throttle position changes,the throttle positionsensorvariesthe voltagesignalto the ECM/PCM.

-

OUTPUTVOLTAGEIVI

Tho MIL h63 boon roportod on. DTCm122 i. storcd.

1 2 1 0

Probl6mvoritic€tion: 1. Turn the ignitionswitchON (ll). 2 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.

ls there approx..49V when the throttle is fully closedand approx.4.5V when the throttle is lully op6ned?

Int..mittent tailura, rFiem ir OK at thit tima. Chocktor Door connections or loorc wires !t C110 ITPlonrorl .nd ECM/FCM.

OPENING

FULL THROTTLE

TP SENSOR3P CONNECTOR ICllOI

s{i2 (GRN/BLKI

Ch6ck lor rn opon in the wire (VCC2linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectths TP sensor3P connector. 3. Turnthe ignitionswitchON lll). 4, Measure voltage between the TP sensor3P conn€ctorterminalsNo.l and No.3.

THROTTLE

vocz

(YEL/BLUI

Wire sideot femal6terminals

ECM/PCMCONNECTOR D IT6PI

ls thereapprox.5 V? Checkfor rn opcn in wire IVCC2 line): Measurevoltage betweenECM/ PCMconneclorterminalsD10and 011. Chockfor rn open or 3hort in TP lon30t: 1. Turnthe ignitionswitchOFF. 2. At the s€nsor side, measure resistancebetweenthe TP sensor terminals No. 1 and No. 2 with the throttle fully closed.

{ T op a g el 1 - 1 3 3 )

ls thereapprox.5V?

SG2 IGRN/ALKI Wire sideof femaleterminals

Roplir op€n in thg wiro batwcsn ECM/PCM{DlO) rnd TP ren3or.

Substitut6 r known-good ECM/ PCM and rach6ck. lf pro$ribod vohrge i! now avrilablc, replac€ tho o.iginel €CM/FCM.

Terminalsideof maleterminals

11-1 3 2

t {Frompagel1'132}

ls thereapprox.0.5- 0.9k0?

'P SENSOR3P CONNECTOR

Checkfor an opsn or 3hort in tho TP sensor: Measureresislancebetweenthe T P s e n s o rt e r m i n a l N o . 2 a n d No. 3 with the throttlefully closod.

ls thereapprox.3.6- 5.4k0?

Terminalsideof maleterminals

Chock lor an open in the ECM/ PCMITPSlin6l: 1. Reconnectthe TP sensor 3P connector. 2. Turn the ignitionswitchON {ll}. 3. Measurevoltage between ECM/PCMconnectorterminals D l a n dD 1 1 .

ls there approx.0.5Vwhen the throttleis fully closedand approx.4.5Vwhen the throttle is fully opened?

D {16PI ECi'/PCM CONNECTOR

t-

sG2IGRN/BLK)

TPSIRED/ Btx)

hm

Substitut. r known-good ECM/ PCM and r.ch.ck. lf pt6crib.d vohrga i. now !Y!il.blo, lcpl.co tho odginal ECM/PCM.

6

I

tl

t5

t

to

tl

12

ta

Wire side ol lemale terminals

lDl6Y5 engine f Checktor . short in tha TCM: 1. Turn the ignitionswitchOFF. 2. Disconnectthe 22P connector from the TCM. 3. Turn the ignitionswitchON (ll). /t. MeasurevoltagebetweenECM c o n n e c t o rt e r m i n a l sD 1 a n d D11.

TPSIR€O/ BLKI

SG2IGRN/BLKI

V whenthe ls thereapprox.0.5 throftleis tully closedand approx.4.5V whon the throttle is fully opened?

Ropairrhort in the wir€ bdtwcon ECM/PCM(D11,TCM and TP i.n. 30r,

11 - 1 3 3

PGM-FISystem Throttle Position(TPlSensor('99- 00 ModelsexceptD16Y5enginewith M/T) scantool indicatesDiaqnosttcTroubleCode (DTC)P0122:A low voltageproblem in the Throttleposition lTO12Z _TI { | r, sensoacrrcurl. The TP Sensor is a potantiometer.lt is connectedto the throttle valve shaft. As the throttle position changes,the throttle position sensor varies the voltage signal to the ECM/PCM.

-

ERUSH HOI.DEN Th. MIL har boon.6portcd on. DTCP0122b siored.

OUTPUTVOLTAGE(VI

BRUSH

BESIS?OF Problemverification: 1. Start the engine,Hold the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n . then turn the ignition switch OFF, 2. Turnthe ignitionswitchON (ll). 3 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.

5 4 3

TERi'I AL

2 1

INNER BUS}IING

THROTTLE OPE II{G

o

FULL THROTTLE TP SENSOR3P CONNECTOR {Cl1OI

ls there approx..49V when the throttle is fully clos€dand approx,4.5 V when the throttle is fullyopened?

l||t rmittont failura, lyrtom b OK at thi! tima. Chocktor poor connactionr o. looao wires rt C110 {TP3.n!or} rnd ECM/PCM.

vcc2

sG2 IGRN/8LKI

Checkfor an opan or 3hort in tho wi.c (VCC2linc): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe TP sensor3P connector, 3. Turn the ignitionswitchON (ll). 4. Measure voltago between the TP sensor3P connectorter minalsNo. 1 andNo.3.

(YEUBLUI

Wiresideof temaleterminals

ECM/PCMOONNECTOR C 131P)

ls theroapprox.5 V?

Chccl tor .n opln in wiro IVCC2 lin€l: Mgasurevoltago betweenECM/ PCMconnectorterminalsC18and Ch.Gkfor rn opan or 3hort in TP 36nlot: 1. Turnthe ignitionswitchOFF. 2, At the sensor side, moasure r e s i s t a n c eb e t w e e n t h e T P sensor3P connectorterminals No. 1 and No. 2 with th€ throt, tle fullyclosed.

(To page11-135)

ls thereapprox.5 V?

Wire sideol femaleterminrls

R.prir opcn in the wiro bctw.en ECM/PCM(C281and TP 3€nror.

Subrtituto r known-good ECM/ PCM .nd rochcck. lf pro.c.ibed voltaga i! now available,roplaco tho origin.l ECM/PCM.

Terminal side of male terminals

11-134 L

L (Frompage11-134) TP SENSOR3P CONNECTOR lsrhereapprox.0.5- 0.9ko?

Chockfor an open or 3hort in the TP 3en30r: Measure resistancebetween the TP sensor3P connectorterminals No. 2 and No. 3 with the throttle tully closed. Terminalsideol maleterminals ls thereapprox.4.5k0?

Check for .n opon in th€ ECM/ PCM(TPSlino): 1. Reconnectthe TP sensor connector. 2. Turn the ignitionswitch ON {ll). 3. Measurevoltago between Cl8 terminaland C27terminalon the ECM/PCMconneclor.

I

ls there approx.0.5V when the throttleis fully closedand approx.4.5V when the throttle is fully open€d?

C (31PI ECM/PCMOONNCCTOR

Sub.lltut. . known-good ECM/ PcM lnd r.chock. ll pr6cribod vohago b now lvallabla, aeplrca tho originrl ECM/PCM,

Wire sideoI femaleterminals

Ropairahort in th. wiro b€{ween ECM/FCMlC18l .nd TP ..n.o].

.1, 11-135

PGM-FISystem ThrottlePosition(TP)Sensor(€6 - 98 Models,39 - 00 D16Y5enginewith M/T) The scantool indicatesDiagnosticTroubleCode (DTC)P0123:A high voltageproblemin the ThrottlePosition (TP)sensorcircuit. The MIL has been reportodon. DTCP0123is sto.ed.

Problomveritication: 1. Turnthe ignitionswitchON {ll). 2 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.

ls thereapprox.10%whenthe throttleis fully closedand approx.90o/o when the throttle is lully opened?

Intermittont tailuro, system is OK at thb timo, Checkfor ooor connociion3 or loos6 wiros at C110 ffP s€nsor)and ECM/PCM.

Chgckto. an opan in the TP sonsot: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe TP sensor3P connector. 3. Turn the ignitionswitch ON (ll). 4. At the harnessside,measure voltagebetweentho TP sensor 3P connecterterminalsNo, 1 a n dN o . 3 .

TP SENSOR3P CONNECTOR IC1lOI

sG2 IGRN/BLKI

vcc2 {YEL/BLUI

Wire sideof femaleterminals

ls thereapprox.5V? ECM/PCMCONNECTOR D (16P) Ch.ck tor .n open in the wira (SG2linel: Measurevoltage betweenECM/ PCMconnector terminalsD10and D11. SG2 (GRN/BLKI ls thereapprox.5 V?

Repairop6n in the wire betwoen ECM/PCM(D11)rnd TP s6nsor. Wire sideof femaleterminals

Substitute a known-good ECM/ PCM snd rech.ck. lf pra3cribed voltago is now available,replsce tho original ECM/PCM,

11 - 1 3 6

ThrottlePosition(TP)Sensor('99- 00 ModelsexceptD16Y5enginewith M/Tl I

The scantool indicatesDiagnosticTroubleCode{DTC)P0123:A high voltageproblemin the ThroftlePosition {TP)sensorcircuit. The MIL has been reportedon DTCP0123is slored.

Problemverification: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n then turn the ignition swatch OFF, 2. Turnthe;gnitionswitchON (ll). 3 . C h e c kt h e t h r o t t l e P o s i t i o n with the scantool.

ls thereapprox.10%whenthe throttleis fullyclosedand approx.90%when the throttle is fullyopened?

'l'

lntormittenl tailure, 3ystom is OK at this time. Check tor Poor con' neqtions or loo3€ wires at C'110 (TPsensorltnd ECM/PCM.

Ch€ckfor an open in the TP s6nsoJ: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe TP sensor3P

TP SENSOR3P CONNECTOR {C11OI

sG2 {GRN/BLKI

voc2 {YEUBLU}

Wiresideof femaleterm;nals

3. Turnthe ignitionswitchON (ll). 4. At the wire harnessside, measure voltagebetweenthe TP sensor3P connectorterminals N o .1 a n dN o . 3 .

ls there approx. 5 V? C (31PI ECM/PCMCONNECTOR Check tor an open in the wire (SG2lino): Measurevoltage betweenECM/ PCMconnectorC (31Piterminals C18and C28.

ls thereapprox.5 V?

Repairopen in the wite betwe€n ECM/PCM(Cl81and TP son.or.

Wiresideof femal€terminals

Substitute a known-good ECM/ PCM and recheck. lf Pr$cribed voltage is now aveilabl6. replace the original ECM/PCM.

(cont'd)

11-137

PGM-FISystem ThrottlePosition(TP)Sensor(cont'd) I Pl 121 | The scan tool indicatesDiagnosticTroubleCode(DTC)Pl 121:ThrottlePosition(TP)lowerthan expected. -

The MIL hss been.eportedon. DIC P1121i. stored.

Problemvedficatiod: 1. Turnthe ignitionswitchON (ll). 2 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.

ls TP *% or higherindicated when the throftle is tully openod?

Intermittent tailure, ryttem i! OK rtthistimo.

* : 1 1 . 8{ D 1 6 Y e5 n g i n e i 12.9{016Y7engine) 12.2(D16Y8engine) 13.7(816A2engine)

TroubleCode(DTC)P1122:ThrottlePosition(TP)higherthanexpected. I P1122 I The scantool indicatesDiagnostic -

The MIL ha3 be6n repoJted on. DTCPl122 i. llorod.

P.oblomv6dfication: 1. Turnthe ignitionswitchON (ll). 2 . C h e c kt h e t h r o t t l e p o s i t i o n with the scantool.

ls TP'70 or l€ssindicatedwhen the throttleis fullyclosed?

*: 16.5{Dl6Y5,Dl6Y8engine} 16.9(D16Y7engine) 16.5(81642engine)

11 - 1 3 8

Intormitt6ot frilu.o, aFtom b OK at thb timo.

t

PrimaryHeatedOxygenSensor{PrimaryHO2SI(Sensor1) ('96- 98 ModelsexceptDl6Y5 enginewith M/Tl In operation, The HeatedOxygenSensor(HO2S)detectsthe oxygencontentin the exhaustgas and signalsthe ECM/PCM. the ECM/PCMreceivesthe sjgnalsfrom the sensorand variesthe durationduring which fuel is injected To stabilizethe sensor,soutput,the sensorhasan internalheater.The PrimaryHO2S(Sensor1) is installedin the exhaustmanifold. HO2S: SENSOR

VOLTAGE{VI

ztRcoNlA

- LEAN R|cH-AIRFUEL RANO

The scan tool indicatesDiagnosticTrouble Code (DTC)P0131;A low voltage problem in the Primary Heated OxygenSensor(H02S)(Sensor1) circuit. The MIL has be€nteportedon. DTCP0131is siorcd.

Problomverificalion: 1. Do the ECM/PCMResetPro' cedure. 2. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson, 3. Test-drivewith the A/T in E position(M/Tin 4th gear) 4. Check the Primary HO2S (Sensor1) output voltagewith the scantool duringacceleration usingwide openthrottle. lntcrmift€nt failura, 3Y3temis OK at this tims. Checkfor Poor connections or loo3e wi.o3 at C123 (Primlry HO2S, 3sn3or 1) and ECM/PCM,

(To page1I-140)

{cont'd)

11 - 1 3 9

PGM-FISystem PrimaryHeatedOxygenSensor(PrimaryHO2S)(sensor1l ('96- 98 ModelsexceptDl6Y5 enginewith M/T) (cont'dl ( F r o mp a g e1 1 - 1 3 9 )

Checkfor a shon in the HO2S: 1. Turnthe ignitionswitchOFF. 2. Disconnect the PrimaryHO2S (Sensor1) 4Pconnector. 3. Startthe engineand let it idle. 4. Check the Primary HO2S (Sensor1)outputvoltagewith the scantool,

Doesit stayat 0.1V or less?

PRIMARYHO2Slsonsor 1l ,tP CONNECTOR lC123l

Check for a short in lhe wire (PHO2Slinel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMconnectorD ('l6P). 3. Checkfor continuitybetween the PrimaryHO2Slsensor 1) 4 P c o n n e c t o tre r m i n a lN o . 1 and body ground.

Wire sideof femaleterminals

Repairshort in lhe wire b6tw6en ECM/rcM (D7)and PrimaryllO2S {Sensor1}. Substitute a known-good ECM/ PCM and recheck.ll symptom/ indicationgoes awry, replacothe original ECM/PCM.

1 1-1 4 0

Fjq?S)(Sensor1l PrimaryHeatedOxygenSensor(Primary('99- 0b Modelsexiept D16Y5enginewith M/T)

T h e H e a t e d o x y g e n s e n s o r s ( H o 2 S ) d e t e c t t h e o x y g e n c o n t e n t i n t h e e x h a u s t g a s a n d s i ginjected. n a | s t h eTo E cstabilize M / P c Mthe '|noperati variesthe durationduring which fuel is the EcM/pcM receivesthe signarsfrom the sensorand sensor,soutput,thesensornasaninternaIheater.ThePrimaryHo2S(sensorl)isinsta|ledinexhaustmanifo 81642engine:exhaustPiPeA)

SENSOR TERMINALS

VOLTAG€(VI

HEATER

HEATER TERMINALS The scan tool indicatesDiagnosticTrouble Code OxygenSensor(HO2S)(Sensor1) circuit -

RICH+ AIR- - LEAN FUEL RATIO

(DTC)P0131:A low voltage problem in the Primary Heated

The MIL has been t€Ported on. DTC P013'l is stored.

Problemveritication: 1. Do the ECM/PCMResetPro2. Start the engine.Hold the engine at 3,000rpm wrth no load (in Parkor neutral)until the radiatorfan comeson 3. Check the PrimarY HO2S lSensor 1) output voltagewath the scantool during accelera tion usingwide openthrottle

Doesthe voltage stay at 0 5 v or less?

lntermittont f.ilure, 3ystem i3 OK at thi3 time. Check tor Poor con' nections or loose wires el C123 {Primary HO2S, Sensor 1) and ECM/PCM.

C h e c k t h e f u e l p r e s s L l r e( s e e P a g e 11,109).

(cont'd) (To page 11 142)

11-141

PGM-FISystem PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1) ('99- 00 ModelsexceptDl6Y5 enginewith M/T) (cont'd) ( F r o mp a g e 1 1 1 4 1 )

Chockfo. a shori in the HO2S: 1. Turnthe ignitionswitchOFF. 2. Disconnect the PrimaryHO2S (Sensor1i 4Pconnector. 3. Stanthe engineand let it idle. 4. Check the Primary HO2S (Sensor1) outputvoltagewith the scantool.

Doesit stayat 0.5V or less?

Roplacothe HO2S(Sensor1). PRIMARYHO2S{S€oror 1} 4P CONNECTOR lc123l

Check tor a short in the wire {PHO2Slinel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe EcltI/PcM connectorC {31P). 3. Checkfor continuitybetween the PrimaryHO2Slsensor 1) 4P connectorterminal No. 1 and body ground.

PHO2S

f----l ,wHl_l:-f;-l

0ffi _L Wire side of femaleterminals ReDairshorl in the wi.e between E C M / P C M( C l 6 1 a n d P r i m a r y HO2S(Sercor 11.

Substitute a known-good ECM/ PCM and recheck. lf symptom/ indication goes away, replace the original ECM/PCM.

1 1-1 4 2

PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1) ('96- 9b ModelsexceptDl6Y5 enginewith M/Tl The scantool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltageproblemin the PrimaryHeated OxygenSensor(PrimaryH02S)(Sensor'l)circuit.

Probl€mverification: 1. Do the ECM/PCMResetProcedure. 2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson 3. Test-drivewith the A/T in E position(M/Tin 4th gear) 4. Check the PrimarY HO2S (Sensor1) oLltPut voltagewith the scantool duringdecelera' tion using completelyclosed throttle.

Doesthe voltagestay at 1.0V or more?

Int.rmittont fiilur., system it OK at thb timo. Chockfor Poot connections or loo3a wir63 at Cl23 lPrimarY HO2S,SensoJ 1l .nd ECM/PCM.

HO2S(Sonso.'ll 4PCONNECToR PRIMARY tc123t PHO29 IWHT}

Checkfor an open in the Primary HO2S: 1. Turnthe ignitionswitchOFF. the PrimaryHO2S 2. Disconnect (Sensor1) 4P connector' 3 . C o n n e c tt h e P r i m a r YH O 2 5 lSensor l) 4P connectortermin a l sN o . 1 a n d N o . 2 w i t h a

sG2 IGRN/ BLKI

Wire sideot femaleterminals

4. Turnthe ignitionswitchON (ll). 5. Check the PrimarY H02S (Sensor1i outPutvoltagewith the scantool. lsthere1.0V or more?

Check for an open in the wiro {PHO2Sline): 1. Turnthe ignitionswitchOFF. 2. ConnectEcM/PcMconnector t e r m i n a l sD 7 a n d D 1 1w i t h a jumperwrre, 3. Turn the ignitionswitchON lll) 4. Check the PrimarY HO2S (Sensor1) output voltagewith the scantool, ls there1.0V or more?

D I16PI ECM/PCMCONNECTOR JUMPERWIRE SG2 IGRN/BLKI PHO2S(WHT}

Replir open in tho wirc b€twccn ECM/PCM lo?) and Prim!.Y HO2Slsonsor 1). Wiresideof tem6leterminals

Substitute a known-good ECM/ PCM and recheck. lf 3ymptom/ indicetion goos awey, roplace the oliginal ECM/PCM.

11-143

PGM-FISystem PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1) ('99- 00 ModelsexceptD16Y5enginewith M/T) The scan tool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltageproblemin the primary Heated OxygenSensor(PrimaryHO2S){SensorI ) circuit. The MIL has beenreportedon. OTCP0132 is stored.

Problemvorificalion: 1. Do the ECM/PCMResetPro cedure, S t a r tt h e e n g i n e .H o l d t h e enganeat 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson. C h e c kt h e P r i m a r y H O 2 5 {Sensorlioutput voltagewith the scantool duringdecelerataonusing completelyclosed throttle. Intermittent tailure, systom k OK at this time. Chocktor poor connections or looso wir* at Cl23 (Primaly HO2S,Sonsor 1) and ECM/PCM. Checklor an open in the Primary H02S: 1. Turnthe ignitionswitchOFF. 2. Disconnect the PrimaryHO2S lSensor1)connector. 3 . C o n n e c tt h e P r i m a r yH 0 2 S (Sensor1)4P connector termi n a l sN o . 1 a n d N o . 2 w i t h a

PRIMARYHO2Sls€n3or 1' 4P CONNECTOR (c123t

PHO2S IWHTI

sG2 (GRN/ BLK)

Wiresideof temaleterminals

4. Turnthe ignitionswitchON (ll). 5. Check the Primary H02S {Sensorl) output voltagewith the scantool.

ls there1.5V or more?

Check lor an open in th€ wire (PHO25lin€l: 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsC16and C18with a jumperwire. 3. Turnthe ignitionswitchON {lli. 4. Check the Primary HO2S (Sensor1i output voltagewith the scantool, ls there1.5V or more?

Subsiitute a known-good ECM/ PCM and r.check. lf symptom/ indication goos away, replece the original ECM/PCM.

11- 1 4 4

ECM/PCMCONNECTOR C 131PI

Roptir op.n in tho wire betweon E C M / P C Ml C l 6 l a n d P r i m . r y HO2Slsensor 11. SG2 IGRN/8LK} Waresideof femaleterminals

PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1l Heated tool indicatesDiagnosticTroubleCode(DTC)P0133:A slow responseproblemin the Primary

scan tFol3alThe OxygenSensor{PrimaryH02S)(Sensor1) circuit.

Heated The scantool indicatesDiagnosticTroublecode (DTC)Pl163:A slow responseproblemin the Primary

I P 1 1 6 3 OxygenSensor(PrimaryHO2S)(Sensor1)circuit

Description 2), the deteriorationof the By controllingthe airlfuelratiowith a PrimaryHo2S {Sensor1) and a secondaryHO2S{Sensor period the Ho2s exceedsa cerof primaryHO2S(Sensor1) can be evaluatedby its feedbackperiod.when the feedback judged deteriorated as tain valueduringstabledrivingconditions,the sensorwill be and DTCP0133or P1163*will be stored' when deteriorationhasbeendetectedduringtwo consecutivetrips.the MIL comeson P0133,troubleshootthose DTCSfirst' then NOTE:tf DTCP0131,P0132and/orP0135are storedat the sametime as DTC the sametime as DTCP1163,troubleshootthose troubleshootDTCP0133.lf DTCPl 162,P1168and/orP1169are storedat DTCSfirst,then recheckfor DTCPl163. PossibleCause 'l) o PrimaryHO2S(Sensor Deterioration (Sensor 1)Deterioration o PrimaryHO2SHeater . Exhaustsystemleakage Troublsshooting Flowchart -

The MIL has been reportedon DTC P0133and/or Pl163* is stored,

ProblemVerilication: 1. Do the ECM/PCMResetPro cedure2. Connectthe scantool 3 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson 4. Connectthe SCSserviceconnector. 5 . T e s t - d r i v eu n d e r I o l l o w i n g conditions. - 55 mph (88 km/h) steady speed - A/f in D position {M/T in 5th gear) codecomes Untilreadiness

lntermittent failure, 3Y3tem i3 OK at thi3 time. Ch.ck lol Poor conncctions or loosc wiros at C123 {C145)!lPrimaryHO2S,Sensor1l and ECM/PCM.

Replaceth6 Prim.ry HO2S (Sen' sor 11. *: P'l163(D16Y5enginewith M/T)

11-145

PGM-FISystem HeatedOxygenSensor(primaryHO2S)(sensor1l Itil-"w (Dl6Y5enginewith M/Tl The scan tool indicatesDiagnosticTrouble Code (DTC)p1162:A malfunctionin the primary HeatedOxygen Sensor(PrimaryHO2S)(Sensor1) circutt.

Doscription ThePrimaryHeatedorygen sensor(Primary Ho2s){sensor1) operates overa wideairlfuelrange.The primaryHo2S (Sensor 1)is installed in theexhaust manifold. SEI{SOR ELEMENT

SENSOR TERMINALS

NOTE:lf DTCPl162 is storedat the sametime as DTCPl167,troubteshootDTCp1162first,then recheck for DTCp1167. -

lh6 MIL hes b6on reDortedon. DTCPl162 ir 3tored.

Problomv6rificationi 1. Do the ECMResetProcedure. 2. Startthe engine. 3. Wait at leasttlvo minutes. ls DTCP1162indicatod?

Test drive tor severalmiles with the transmission in 3rd gear.Hold the enginespeedat 1,500rpm. ls DTCP1162indicated?

Chock for an open in the wire (lP+lins): 1. Turnthe ignitionswitchOFF. 2. DisconnectECM connectorC {31P)from the ECM. 3. Disconnectthe 8P connector from the PrimaryHO2S{Sens o r1 ) . 4. Checkfor continuity between the PrimaryHO2S(Sensor1) 8P connectorterminal No. 7 and ECM connectorterminal c23.

Intermittent tailuro,systom is OK at this timo. Checktor poor connections or loose wires at C145 (Plimr.y HO2S, Senso. t) and ECM,

ECMCONNECTOR C (31PI PRIMARYHO2S (SENSOR 1)8P CONNECTOR {Clir5)

femaleterminals

of female terminals

Repairopen in the wire betwaon ECM (C231end Prim.ry HO2S lsen3orl). Inspectlor poor terminal to terminal contact at the Primary HO2S lsensor 'l I connoctorand ECM. It terminal contect is OK, roplace lh6 Primrry HO2S{Sensor1}. (To page 11-147)

1 1-146

ECMCONNECTORS l F r o mp a g e ' 1 1 - 1 4 6 )

Checkthe ECMinput vottage{lP-/ VS- lino): 1. Turnthe ignitionswitchOFF. 2 Turnthe ignitionswitchON (ll) 3. Measurevoltage between ECMconnectorterminalsC24

D {15P)

c (31Pl

sG2 (GRN/BLKI tP-/vs-tREol

femaletermrnals

ls theremorethan 0.5V?

6 '17 16 1 1 12 1 3 l a 1 5 t 6

Ch.ck the ECM: 1. Turnthe ignitionswitchOFF 2. DisconndctECM connectorC {31P){romthe ECM. 3. Checklor continuity between b o d y g r o u n da n d E C M c o n nectorterminalC24

23 2a 25

9 10

22 29 30

27 2a

O\ rP-/vs:Z taeot -

Checkto. r short in the wi.e {lP-/ VS- lin6l: 1. Disconnectthe 8P connector from the PrimaryHO2Slsens o r1 ) . 2. Checktor continuity between body ground and ECMconnector terminalC24

8

3 a

2

I

,l

Repair open in the wire betw€en ECM {C2{l and Prima.y HO2S{S€nsor1l. Substitute a known-good ECM and recheck.It symptom/indi cation goes away. replacethe odginalECM.

5 5 3 a 1 1 1 2 13 1 a 1 5 1 6 1 7 t 8 21 2A 23 21 25 2

9 10

I

22 E 30

0) {REDr

Ropairshort in the wire bstween the Primary HO2Slsensor 1) and ECM (C24).

Check the ECM output voltage {VS+linel: voltage between ECM N4easure C25and D11. connectorterminals

ls theremote than 0.5V?

Checkfor a short in the wire (VS+ line): 1. Turnthe ignitionswitchOFF. 2. DisconnectECM connectorC {31P)Irom the ECM. 3. Check{or continuitybetween b o d y g r o u n d a n d E C Mc o n nectorterminalC25.

1 5 't6 '15 17 18 l 1 12 13 ta 27 2A 23 21 E 2

3

a

8

9

10 22

29 30

[]) vs* I rwsrt (cont'd)

( T o p a g e 1 1 -1 4 8 )

(To page 11 148)

11-147

PGM-FISystem PrimaryHeatedOxygenSensor(PrimaryHO2SI(sensorl) (Dl6Y5enginewith M/T) (cont'd) ( F r o mp a g e 1 l - 1 4 7 )

( F r o mp a g e1 1 1 4 7 )

Substitute a known-good ECM and rechock. tf symptom/indicrtion goes away, replacethe originalECM. Checkfor a short in the wire llP+ lin6): 1. Disconnectthe 8P connector Irom the PrimaryHO2S(Sens o r1 ) . 2. Checktor continuitybetween body ground and ECMconnector terminalC25.

|

2 3 r a

tl 12

a

1

to

9

t 5 16 1 1 1 a

p ffi;r,w''.""i0"or. I

lemate lerml

Repairshort in the wiro botween the Primarv HO2S{Sensor1} and ECM {C25}. Replaceth€ Primary HOzS {Sensor 11. a

7 It

ls theremorethan 5.0V?

t 6 '11

1 2 t3

check the EcM: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 8P connector from the PrimaryHO2S(Sensor 1). 3. Turnthe ignitionswitchON (ll). 4. MeasurevoltagebetweenECN4 connector C25andD11.

9 t0

ta

VS+ {WHT}

sG2 {GRN/BLK} 2

3

5

,

9 ,10 1l

12

l 3 'ta t 5

15

ls theremorethan 5.0V?

Check the ECM input voltage llP-/ vS-linel: 1 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (transmission in neutral) untiltheradiator fan comeson, then letit idle. 2. MeasurevoltagebetweenECM connectorterminalsC24 and Dt1.

Subslitute a known-good ECM and rgcheck. It symptom/indication goes away, repl.ce the original ECM.

ls there2.6 2.8V?

Checkth6 ECM output voltage (VS+linel: Measurevoltage between ECM connectorterminalsC25and D11.

1

2 i 3 't2 'tt

11- 1 4 8

13

9 t0 22

sG2 (GRN/8I-K}

6 l t

(Topage 11 149)

rl

VS+ {WHT) 2

(Topage11-149)

a

5 t5 t t

3 9

15

ll

( F r o mp a g e 1 1 1 4 8 )

( F r o mp a g e1 1 ' 1 4 8 )

Roplac€th€ Primary HOzS (Sen' sor 11.

ls therelessthan2.8V?

Substitute a known-good ECM and recheck. lf symptom/indica' tion goes awav, replaceth€ odgi' nalECM.

Check the ECM oulput voltage (lP+linel: Measurevoltage between ECM terminalsC23and D11 connector

ls theremorethan 0.4V?

sG2 (GRN/BLKI

Substitute a known-good ECM and recheck f symptom/indication goes awaY,replacethe origi_ nal ECM.

Wire sideof femaletermanals 8

6

2 3 a

1

22

a 30

21 25 Checkthe ECM: 1. Turnthe ignitionswitchOFF. 2. DisconnectECM connectorC (31Plfrom t h eE C M . 3. Checkfor continuitybetween b o d y g r o u n d a n d E C Mc o n nectorterminalC23

I

Check fot an oPen in tha wire llP+ linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 8P connoctor from the PrimaryHO2S(Sensor'l). 3. Checkfor continuitybetween the PrimarYHO2S(Sensor1) 8P connectorterminal No. 7 and ECM connectortermrnal c23.

lP+

6) tBrK) C {31P} ECMCONNECTOR PRIMARYHO2S (SENSOR 1l8P coNNECTORlC1a5l

lP+ (BLK)

Wire sideof femaletermrnals

Substitute a known_goodECM and r6check. lf symPlom/indica' tion goos away, replacethe odginalECM. 2

3

a

6

7

1 1 1 2 1 3 1 l 1 5 16 1 1 1 8 23 2a 25 Repairshort in lhe wire belween 'l) the Primary HO2S(Sensor dnd ECM{C23).

Replacethe Primary HO2S (Sen' s o r1 ) .

of female terminals

Repairopen in the wire belween E C M { C 2 3 1a n d P r i m a r y H O 2 S {Sensor11.

NO

Checkfor a short in the wire llP+ line): 1. Disconnectthe 8P connector from the PrimaryHO2S{Sen' s o r1 ) , 2. Checkfor continuitybetween b o d y g r o u n da n d E C M c o n nectorterminalC23.

9 10

1 1 12 1 3 1 4 1 5 1 6 1 7 1 8

I

I

,4

10 22

A

30

A\ lP+ Ij/ IBLK)

(cont'd)

11-149

PGM-FISystem HeatedOxygenSensor(primaryHO2SI(sensor1l l:in1.".fy (D16Y5 enginewith M/D (cont'd) The scan toor indicatesDiagnosti" code (DTC)pl164: A range/performance probremin the primary -Tl:y|* HeatedOxygenSensor(primaryHO2S) (Sensor1)circuit. The MIL has beonreponed on. DTCP1164is stored.

ProblemVerilication: 1. Do the ECMBesetProcedure. 2 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (transmission in neutral) untiltheradiatorfan comeson. 3. Connectthe SCSserviceconnector. 4. Test-drivein 4th gear. Starting at 1,600rpm, accelerate using wide openthrottlefor at least5 seconds.Thendeceleratetor at least 5 secondswith the throt tle completelyclosed.

ls DTCPl164indicatedT

Intgrmittent failure, syrtem b OK at this time. Checktor Door connoctions or loose wires at C1a5 (Primary HO2S. Senso. and ECM.

The scan tool indicatesDiagnosticTrouble Code (DTC)p1165:A range/performance problem the pnmarv HeatedOxygenSensor(primaryHO2S)(sensor1) circuit. -

The MIL has been reoortedon. DTCP1165is stored.

ProblemVo.ification: 1. Do the ECMResetProcedlre. 2 . S t a r t t h e e n g i n e .H o t d t h e engine at 3,000rpm with no load (transmission in neutral) u n t i l t h e r a d i a t o rf a n c o m e s 3. Connectthe SCSservicecon, nector. 4 . T e s t - d r i v eu n d e r f o l l o w i n g conditions. - 55 mph steadyspeed Transmission in 5th gear Until readinesscode comes

ls DTCP1165indicated?

Replace the P.imary HO2S (S6nsor 11.

11 - 1 5 0

Intermittent l.iluro, system b OK at lhis time. Ch€cktor poor connoctions or loose wir6 at Ci45 (Prioary HO2S, Sen3or 1l .nd ECM.

t

(DTC)P1168;A low voltageproblem in the PrimaryHeated The scan tool indicatesDiagnosticTroubleCode OxygenSensor(PrimarvHo2S)(Sensor1) LABELcircuit' -

The MIL has b6€nreponed on' DTCP1168is storcd

Problemvedfication: 1. Do the ECMResetProcedure 2. Startthe engine. 3. Wait at leasttwo minutes

ls DTCP1168indicated?

lntalmittent failure' aYstomb OK at thi3 time. Chocklor Poor connection3 or loo3o wiro3 at C145 (Primary HO2S,S.n.or 1l and ECM. D {16PI ECMCONNECTOR LABEL{WHTI

Chockth. ECM: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM connec' torD 116P). 3. Check for continuity between ECM connectorterminal D7 and body ground

wire side of female terminals Sub3titut. e known-good ECM 6nd r.chock. lf rymptom/indication gocr away, r.Placs the origi_ nal ECM.

LABEL(WHTI

Check for t shott in lhg wire3 ILABELline): the PrimaryHO2S 1. Disconnect (Sensor1) 8P connector' 2. Check for continuitv between ECM connectorterminal D7 and body ground

Reoair short in the wir63 botlvoon lhe Primary HO2S{Sensor1} end ECM(O71. (cont'd)

PGM-FISystem Heated9{ygglSensor(primaryHO2SI(Sensor1) IiT-"-w (Dl6Y5enginewith M/Tl lconr'd) scan tool indicatesDiagnosticTroublecode (DTc) P1169:A high volrageprobtemin the pnmary Heated -1T1163 Ih" UxygenSensor{primaryHO2S)(Sensor.l) LABELcircuit. -

The MIL hrs been reported on. DTCPl169 i3 stored.

Problemverification: L Do the ECMResetProcedure. 2. Startthe engine. 3. Wait at leasttwo minutes.

PSTMARY HO2S(SENSOR (145) 1l8p CONNECTOR

ls DTCP1169indicated?

LABELIWHTI

Intormittent f.ilure, sv*em b OK at this time. Checkfor poor conn.ctions or loose wires at C145 (Prim.ry HO2S, Sensor 1l and ECM.

Ch€ck Ior an op6n in th€ wire (LABELline): 1. Turnthe ignitionswitchOFF. 2. Disconnect the PrimaryHO2S (Sensor1) 8P connector. 3. Turn the ignitionswitchON (ll). 4. Measurevoltage between Primary HO2Slsensor 1) 8P connectorNo, 4 terminaland body ground.

ECMCONNECTOR O {16P}

1

2

3

6

8

9 10 1 t

Ropairopon in the wires betweon lhe P.imary HO2S{Sensor't} and ECMtD7l.

Check lor an open in the wire {SG2linel: 1. Turnthe ignitionswilchOFF. 2. DisconnectECM connectorD (16P)tromthe ECM. 3. Check for continuity betlveen ECM connectorterminal D1l and PrimaryHO2S(Sensor1) 8P connectorterminalNo.3.

ls therecontinuity?

Roplacethe Primary HO2S (Sensor 1).

11-152

5 12

sG2

16

t3 1 4 15 ls there approx. 5 V?

a

(GRN/BLK)

sideof female e terminals

tll I

I

;G2

-- rl I IGRN/BLKI 2 3 4 6

8

R€pairopen in th6 wire between the Primary HO2Slsensor 1) and ECM(011).

(Sensor2l SecondaryHeatedOxygenSensor{secondaryHO2S) problemin the SecondaryHeated The scantool indicatesDiagnosticTroubleCode(DTC)P0137:A low voltage OxygenSensor(SecondaryHO2S)(Sensor2) circuit' -

Tho MIL has beenreportedon DTCP0137is stored.

Problemverification: 1. Do the ECM/PCMResetPro cedure. 2 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm wlth no load (in Parkor neutral)until the radiatorfan comeson 3. With the scantool, checkthe S e c o n d a r yH O 2 S( S e n s o r2 ) outputvoltageat 3,000rPm

Doesthe voltage staYat 0.3 V or less?

lntermittent frilure, sYdem is OK at this tim6. Checkfor Poor con' nections or loolo wir.3 at C131t (locatodundor right.ido of desh)' C432. {located under middle of dashl, cl25 lc782lr {Secondary HO2S)tsensor 2l .nd ECM/PCM.

Ch6cktot a sho.t in the S€condery HO23: '1. Turnthe ignitionswitchOFF. 2 , D i s c o n n e c tt h e S e c o n d a r Y HO2SlSensor2)4Pconnector. 3. Startthe engine. 4 . C h e c kt h e S e c o n d a r YH O 2 S lsensor 2) outputwith the scan tool,

SECONDARYHO2S ls.n.ot 2) (C125,C782') ,rPCONNECTOR

C h e c kt o r a s h o r t i n t h e w i r e {SHO2Slinel: 1. Turnthe ignitionswitchOFF. 2 . D i s c o nn e c t t h o E c M / P C M connectorD {16P){A (32P))*' 3. Checkfor continuitybetween the SecondarYH02S (Sensor terminalNo 1 2) 4P connector and body ground.

Wire side oI temale terminals

R€pairshort in tho wire bstwoen E C M / P C M l D 1 4 ( A 2 3 1 * ' |a n d SecondarvHOzS(Sensor2).

Substitute a known-good ECM/ PCM and recheck lf 3ymptom/ indicalion go€s awaY, tePltco the oiigin.l ECM/PCM.

(cont'd)

*'t: D16Y8engine *2:'99 - O0m;dels except D16Y5enginewith M//T

11 - 1 5 3

PGM-FISystem Heated OxygenSensor(Secondary HO2S){sensor2l 9ggoqOfry '99 ('96 98 Models; - 00 D16YS enginewith M/Tl

I

The scantool indicatesDiagnosticTroubleCode(DTC)PO'138: A high voltag€problemin the SecondaryHeated OxygenSensor(Secondary HO2SI(sensor2) circuit. -

Ths MIL ha3 bcen r6port.d on. DTCm138 i. 3tored.

Problemvorilication: 1. Do the ECM/PCMResetProcedure. 2 . S t a r t t h e e n g i n e .H o l d t h e engine at 3.000rpm with no load (in Parkor neutral)until the radiatorfancomeson. 3. With the scan tool, ch€ckthe S e c o n d a r yH O 2 S{ S e n s o r2 ) outputvoltageat3,000rpm. Into.mittant failurc, sy3tem b OK rt thi3 tims. Ch6cktor poor conn6clionr or loo3€ wiroa at C13'l* (locat d und6r right lido of dr'h), C/€2r (loc.tod und€r middle ol d.rhl, C125 {C782lr (Socond.ry HO2SS6n3or2) .nd ECM/PCM.

SECONDARY HO2Sls.nsor 2l 4P CONNECTOR C125tc782t* JUMPERWIRE

sHo2s IWHT/RED}

Chcd( for rn open in the Socond!ry

f|o2s:

1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e c tt h e S e c o n d a r y HO2S(Sensor2) 4P connector. 3. Connectthe SecondaryHO2S (Sensor2) 4P connectorterminalsNo. 1 and No.2 with a JUmperwire. 4. Tu.n the ignitionswitch ON (ll). 5 . C h o c kt h e S e c o n d a r yH O 2 S (Sensor2) output vollage with the scantool.

sHo2sG (RED/YEL) (GRN/WHT)* (GRN/BLK)*'

Wiresideof femaleterminals

a

ECM/FCMCONN€CTORD Il6PI

ls there0.6V or more?

sH()2sG {YEL/RED) {GRN/BLK}' JUMPERWINE

Check tor an open in the wiro (SHO2Slin6l: 1. Turnth6 ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsD14 and D13with a jumperwire. 3. Turn the ignitionswitch ON {ll}. 4 . C h e c kt h e S e c o n d a r yH O 2 S ( S e n s o r2 ) o l t p u t v o l t a g e with the scantool. ls thore0.6V or more?

Subslituto a known-good ECM/ PCM .nd rccheck. lt symptom/ indication goe! rway, replace the original ECM/PCM. 'i D16Ygengine *1i Dl6Y5 engine

1 1- 1 5 4

Wire sideof femaleterminals

Rapairop.n in the wiio botw.on ECM/PCMlD13 and/or Dlal and S.cond.ry HO2Sls€nsor 21.

a

(Sensor2l SecondaryHeatedOxygenSensor(SecondarytlO2S) ('99- 00 lilodelsexceptDtGYSenginewith M/T) problemin the secondaryHeated The scantool indicatesDiagnosticTroublecode (DTC)P0138:A high voltage (Sensor 2) circuit. (Secondary H02S) OxygenSensor -

The MIL has beon reportod on. DTCm138 is.tored.

Ploblem vorification: ResetPro1. Do the ECM/PCN4 cedure. 2. Start the engine Hold the engine at 3,000rpm with no load (in Parkor neutral)until the radiator{ancomeson 3 . C h e c kt h e S e c o n d a r YH 0 2 S (Sensor2) output voltage at 3,000rpm with the scantool

Does the voltage stay at 0 6 V or more?

lntormittont failuio, sYstom b OK st thir timo. Checkfor Poor con_ nections ot loo39 wiJo3 af Cl3lr (locatedunder right ride ot desh), C432' (locatod undot middle of dashl, Cl25 {C782lr (Secondaiy HO2SSon3or2l and ECM/PCM.

Ct€d( tor an opan in the Secondary

HO2S{S€nsot2} SECONDARY Cl25 lc782l' 4P CONNECTOR

l|o2s:

1. Turn the ignitionswitchOFF 2 . D i s c o n n e c tt h e S e c o n d a r Y HO2S(Sensor2) 4Pconnector. 3. Connectthe SecondaryHO2S (Sensor2) 4P conneclorter_ minalsNo. 1 and No.2 with a iumperwire. 4. Turnthe ignitionswitchON (ll) 5. Check the SecondarYHO2S lSensor2) outptltvoltagewith the scantool,

JUMPERWIRE

sH02s (WHT/RED)

sG2 {GRN/BLKI

Wire sideof femaletermanals

lsthere0.6V or more?

ECM/PCMCONNECTORS A (32P1

Check lor an open in the wiro (SHO2Sline): 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalsA23 and C18with a jumperwrre, 3. Turn the ignitionswitch ON (ll). 4 . C h e c kt h e S e c o n d a r YH O 2 S { S e n s o r2 ) o u t P u tv o l t a g e with the scantool.

ls there0.6V or more?

gs92g 111yp17p5py | .lutuPeawtne

Repairopon in tho wire betwecn ECM/PCM (A23) and SocondarY HO2S{Sansor2). Wire sideot femaletermlnals

I

r

Substitut€ a known'good ECM/ PCM and recheck. It symptom/ indication goes awey, JePlaco the otiginel ECM/PCM *i 016Y8 engine

11 - 1 5 5

PGM-FISystem SecondaryHeatedOxygenSensor(SecondaryHO2S){sensor2l The scantool indic€tesDiagnostic TroubleCode{DTC)P0139:A slow responseprobtemin the SecondaryHeated -[FO13a]l UxygenSensor(HOzS)(Sensor 2) circuit. -

The MIL has beenreportedon. DTCP0139is stored.

Problemverification: 1. Do the ECM/PCMResetPro2. Start the engine.Hold the engine at 3,000rpm with no load {in Parkor neutral)until the radiatorfan comeson. 3. With the scantool, checkthe S e c o n d a r yH O 2 S( S e n s o r2 ) outputat 3,000rpm.

Doesthe voltagestaywithin 0.3- 0.6V for two minutes?

*: D16Y8 engine

11 - 1 5 6

Intermiftent failure, system i! OK at this tims. Check for pool connections or loos6 wiles at C131. {locatedundor ght lide of dash), C432' (locrted under middle ot d.shl Cl25 (C782lr (Socondary HO2S)(Sonsor2) and ECM/FCM.

HeatedOxygenSensor(HO2SIHeater ('96- 98 Mbdels,'99- 00 Dl6Y5enginewith M/Tl probl€m in the Primary Heated The scan tool indicatesDiagnostrcTrouble code (DTC)P0135:An electrical

tFo135l OxygenSensor(PrimaryHOiS) (Sensor1) Heatersystem(ExceptD16Y5enginewith M/T)'

Heatedoxygen sensor The;can tool indicatesDiagnosticTrouble code (DTC)P0141:A problem in the secondary

iPol4tl(secondarvHO2S)(Sensor2) Heatercircuit. -

The MIL h.s boenJeponedon. DTC P0135,and/or Polal .re stoled.

Problemverificationl 1. Do the ECM/PCMResetProceduae, 2. Startthe engine

Checkfor an open or 3hort in tho HO25: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe HO2S(Primary or Secondary*)(Sensor1 or Sensor2) 4Pconnector' 3 . A t t h e H o 2 s s i d e ,m e a s u r e resistancebetween the HO2S 4P connectorterminalsNo. 3 a n dN o . 4 .

lniermittent tailura, sYttam i! OK at thi3 time, Chsck for Poor con' neciion3 or loose wilG3 at C131** (locat.d undo. right sido ot dashl, C{32** (loc.ted under middle ol dashl, C123 (PrimarY HO2S.Sansor 1) C125 lc782l*r {Socondery H02S, Sonsor 2l' and EcM/PcM.

PRIMARYHO2S(Son.or 1l aP CONNECTOR SECoNDARYHO2Stsensor 2l ilP CONNECTORT

Terminalsideof maleterminals

ls there10- 40 0?

C h e c kf o r c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d t h e H O 2 S4 P c o n n e c t o rt e r m i n a l sN o . 3 a n d N o . 4i n d i v i d u a l l y

ICl23I PRIMARYHOzS (SENSOR1) 4P CONNECTOR {C125I* HO2SISENSOR2) 4P CONNECTOR SECONDARY

PO2SHIC,SO2SHTC IBLK/WHT)

Wire sideof femaleterminals

Chockfor an oPen ot short in tho wire |PO2SHTC,SO2SHTC*linol: 1. Turnthe ignitionswitchON (ll). 2. Measurevoltage between the HO2S4P connectorterminals N o . 3a n dN o . 4 .

HO2SISENSOR2) SECONDARY ,tP CONNECTOR 1C782)'*

so2sHTC {BLK/WHT)

Wire sideoI femaleterminals

I

( T op a g e1 1 ' 1 5 8 )

*: p0141 (To page11-158) **: D'16Y8 engane

(cont'd)

11-157

PGM-FISystem

a

HeatedOxygenSensor(HO2S)Heater ('96- 98 Models,'99- 00 D16Y5enginewith M/T) (cont'dl ( F r o mp a g e1 1 - 1 5 7 )

Checktor an op6n or 3hoft in the wire {lGl lin6): M e a s u r ev o l t a g e b e t w e e nt h e HO2S4Pconnector terminals No.3 (D16Y8engine:No. 4) and body ground.

PRIMARY HO2S{SENSOR 1I 4PCONNECTOR {c1231 SECONDARY HO2S{SENSOR 2}4P coNNECTOR 1C125)r

r-l --'1 l l i 2 l

f;T;t

-

Check for an open in the wire SO2SHTC'linel: IPO2SHTC, 1. Turnthe ignitionswitchOFF. 2. Reconnectthe HO2S4P connector. 3. Disconnectthe ECM/PCMconnectorA (32P). 4. Turnthe ignitionswitchON (ll). 5. Measurevoltage between the ECM,/PCM connectorterminals 46 and410 {A5andA10)*. ls there0.1V or less?

tcl |BLK/ &) YELI Y

Repair open or shon in the wire between Primary HO2S lson.or 1), {No. 15 ALTERNATOR SP SENSORI(7.5 Al fuse and SecondaryHO2S,Sonsol

Wiresideof fomalelerminals

2t,.

Replacethe No. 15 ALTERNATOR SP SENSOR17.5A) tuse. SECONDARYHO2S ISENSOR2) 4P CONNECTOR {c78ilf

IBLK/WHT)

Ropail opan in the wire b€twoen ECM/PCMlA6, A5l* and HO2S {Primary,Secondary+1.

a

Wire sideof lemaleterminals

ECM/PCMCONNECTOR A I32P)

Substitute a known-good ECM/ PCM and recheck. ll symptom/ indication goes awry, repbce tho origin.l ECM/PCM.

pozsxtc E/ ^ so2sHrcI IBI-K/WHTI ,-----{v}tBLK/WH0.J

|

(Frompage11-157)

3 12 r3

. = , | I uI JsTgTro

t 5 t 6 I t ta r9 20 25 27 2A 2i 3o

z2l 23

PG1 IBLK} ll

21

Wire sid€ ot temale terminals

Check tor a short in the wire SO2SHTC*line): {PO2SHTC. '1. Turn the ignitionswitchOFF. 2. Disconnectthe ECM/PCMconnectorA (32P1. 3. Checkfor continuitybetween the ECM/PCMconnectorterminal46 (A5)*and bodyground.

SO2HTC(BLK/WHTI* PO2SHTC{BLK/WHTI Repairshort in thg wire betwe€n ECM/PCMlA6, A5*l .nd HO2S (P.im.ry, Socondary*). Substitute a known-good ECM/ PCM and recheck. It symptom/ indicetion goes away, rophce the original ECM/PCM. *: P0141 *+: Dl6Y8engine

11-158

I

HeatedOxygenSensor(HO2S)Heater i'ss - oo Mb-delsexceptD16Y5enginewith M/Tl problem in the Primary Heated The scan toot indicatesDiagnosticTrouble Code (DTC)P0135:An electrical

Fo13slOxygen Sensor(PrimaryttOiS) (Sensor1) Heatersystem{ExceptD15Y5enginewith M/T)' -scan The

TroubleCode(DTC)P0141;A problemin the SecondaryHeatedOigen Sensor tool indicatesDiagnostic

Fol11l(SecondarvHO2S){Sensor2) Heatercircuit -

The MIL has been reponed on. DTC P0135.and/or P0141are storod.

Problemvorification: 1. Do the ECM/PCMResetProcedute. 2. Stanthe englne.

Chockfoi an open or short in the HO25: 1. Turnthe ignitionswitchOFF 2. Disconnectthe HO2S(Primary or Secondary*)lSensor 1 or Sensor2) 4Pconnector' 3 . A t t h e H 0 2 S s i d e ,m e a s u r e resistancebetween the HO2S 4P connectorterminalsNo. 3 a n dN o . 4 .

lntermiftent failuro, sYstomb OK at thit limo. Ch6ck lor Poor oon' nectiont or looso wita! at C131'* {loc.tod und.t right ido ol drshl, C432'* (located undel middlo of dashl, C123 (PrimarY HOzS,Sensor 1) C125 (Ct82lr' (socondary HO2S, Sensor 2)t .nd ECM/PCM.

PRIMAFYHO2Sls.n.or ll rrPCONNECTOR HO2S(Srn.ol214PCONNECTOR' SECOITIDARY

Terminalsideof maleterminals

ls there10- 40 n?

C h e c kf o r c o n t i n u i t y b e t w e e n b o d y g r o u n d a n d t h e H O 2 S4 P c o n n e c t o rt e r m i n a l sN o . 3 a n d No.4 individuallY.

PRIMARYHO2S{SENSOR1} ilP @NI{ECTOR lc123l sEcoNDARY HO2SISENSOR2) aP @NNECTOR(C125)'

3l-, l-tl-t

so2sHrc Fo2sHrc.

ver.t l ^-1 .'l {BLK/wHrl 11'!'l-l

--=|u----{v)'---..-'I

Wire side of {emaleterminals

Checkfor an opon or short in lho SO2SHTC+line): wire (PO2SHTC, '1. Turnthe ignitionswitchON (ll). 2. Measurevoltage between the H02S 4P connectortermlnals N o . 3a n dN o . 4 .

Ho2S (SENSOR2, SECO'TIDARY {C7&llt' 4P CONNESTOR

so2sHTc (BLKnflHTl

IBLK/WHT)

Wire sideoI femaleterminals {To page11-160}

r: p0141 {To page 11-160} * * : D 1 6 Y ge n g i n e

(cont'd)

11 - 1 5 9

PGM-FISystem HeatedOxygenSensor(HO2S)Heater ('99- 00 ModelsexceptD16Y5enginewith M/T) (cont'dl PRIMARYHO2SISENSOR1I 4P CONNECTOB

( F r o mp a g e1 1 - 1 5 9 )

{c123) SECONDANY HO2SISENSOR 2} 4P (C125)* coNNECTOR Checkfor an open in the wires {lGl* line}i Measurevoltagebetweenthe pri mary HO2S4P connectorterminal No. 3 (D16Y8engine:No. 4) and body ground.

-r--r , lr zl -

ls there batteryvoltage? Check,or an open in the wires (PO2SHTC, SO2SHTC'linel: 1. Turnthe ignitionswitchOFF. 2. Reconnectthe HO2S4P connector, 3. Disconnectthe ECN4/PCM con nectorC (31Pi(ECM/PCM connectorA (32P))i. 4. Turnthe ignitionswitchON (lli. 5. Measurevoltagebetweenthe ECM/PCM connectorterminals 82 andCl 182andAB)*. ls there0.1V or less?

lc'l Repeir open or shon in the wire between Primary HO2S lsensor 1), {No. 15 ALTERNATOR SP SENSOR)(7.5 A) fus€ and SecondaryHO2S,Sensor

-f1 3 4 l L--r-J-r

relxr p1 YELI

Y

Wiresideof temaleterminals

2t,. ReDlacethe No. 15 ALTERNATORSP SENSOR{7.5 A tuse.

SECONDARY HO2S (SENSOR214P CONNECTOR {c782}rr

IG1 IBLK/WHT)

Wiresideof femaletelminals Reprir open in the wirc betwo€n ECM/PCM(Cl, A8i) and HO2S (Primary,Secondary+).

ECM/PCMCONNECTORS

NO Substitute a known-good ECM/ PCM and recheck.lf symptom/ indication goes away, replace the origin.l ECM/PCM.

(Frompage11 l59i

Check tor a short in the wires SO2SHTC*linel: IPO2SHTC, 1. Turnthe ignitionswitchOFF. 2. Disconnect the ECM/PCM connectorC (31Pi(ECM/PCM con nectorA (32P)i*. 3. Checktor continuitybetween the ECM/PCMconnectortermi nalC1{A8)*and bodyground.

Wiresideof femaleterminals ECM/FCMCONNECTORS Repai. short in the wire b€tween ECM/PCMlcl, A8.l and HO2S (Pdmery,Secondary*1.

Substitute a known-good ECM/ PCM end recheck.lf symptom/ indication goes away, replace the o.iginal ECM/PCM. *: P0141 **: Dl6Y8engine

1 1 - 16 0

Wire side of female terminals

HeatedOxygenSensor(HO2SIHeater(Dl6Y5enginewith M/Tl The scan tool indicatesDiagnosticTrouble Code (DTC)P1166:An electricalproblem in the Primary Heated OxygenSensor(PrimaryH02S)Heatersystem. -

The MIL has been lePorted

-

DTCPl166 b stored.

Problemverilication: 1. Do the ECMResetProcedure. 2. Startthe engine.

ls DTCP'l166indicated?

Intermitlent failura, sYstemb OK at this time (te3t drive maY be ngcessary).Check for poor connections or loose wires between C145 (PrimaryHO2S,Sen3or1l end ECM.

Checkthe Primary HO2S(Sensot 1l resistence: 1. Turnthe ignitionswitchOFF the PrimaryHO2S 2. Disconnect (Sensor1) 8P connector. 3 . A t t h e P r i m a r yH O 2 S( S e n s o r 1 ) , m e a s u r er e s i s t a n c e betweenNo. 1 and No. 2 ter_

ls there2 13 O?

PRIMABYHO2SISENSOR1I 8P CONNECTOR

Terminalsideof maleterminals

Replacelhe Primery HO2S (Sensor 11.

Checkfor a shorted PrimarY HO2Slsensor 1): C h e c kf o r c o n t i n u i t y b e t w e e n bodygroundand eachterminal.

ls there conlrnuily?

Checkfor a shorted PrimarY HO2S{S€nsor1l: Checkfor continuity betweenter' s o.3, m i n a lN o . 1 a n d t e r m i n a l N 4, 6, 7 and 8 individually.

I

(cont'd) (Topage11'162)

11-161

PGM-FISystem HeatedOxygenSensor(HO2S)Heater(Dl6Y5enginewith M/Tl (cont'd) \. PRIMARYHO2S(SENSOR1} 8P CONNECTOR {Cl45I

( F r o mp a g e1 1 - 1 6 1 )

I

PO2SHTC {BtK/WHT) Ch6ckthe PO2SHTCcircuit: 1. Start engineand keepengine rpm at idle. 2. At the engine wire harness, m e a s u r ev o l t a g e b e t w e e n PrimaryHO2S(Sensor1) 8P connectorterminalNo. 1 ter minaland bodyground.

ls theremorethan5 V?

Check for an open in the wire (PGlinell MeasurcvoltagebetweenPrimary HO2S(Sensor1) 8P connectorterminalsNo. l and No.2.

Repairopon in the wi.o bEtwoon the HO2S.nd G101 (locatedat th.rmonat housingl.

ls theremorethan 5 V?

C h e c kl o r a s h o r t i n t h e w i r e line): {PO2SHTC 1. Turnthe ignitionswitchOFF. 2. DisconnectECMconnectorA (32P)tromthe ECM. 3. Checkfor continuitybetween E C Mc o n n e c t o rt e r m i n a l4 6 and body ground.

Substitule a known-good ECM .nd .echeck. lt 3ymptom/indication 906! rwry, roplacethe original ECM,

PO2SHTC IALK/WHTI

!

o

a

ECMCONNECTOR A {32P} 6 1 2 t3

l 5 t6 1 ' t 8 t 9 25

2'

9l ro

It

221 23

2a

I

a

2a E ito

,1 | ---

femaleterminals Ropair3hort in tho wire betwoen the ECM {46} and the Prim.ry HO2Slson3or 11.

Check for an open in the wire (PO2SHTC linel: C h e c kf o r c o n t i n u i t y b e t w e e n ECM connectorterminal46 and the PrimaryHO2S(Sensor1)8P connectorterminalNo. 1. Repairopsn in the wir6 botween ECM {A6} .nd the Primary HO2S lsonror 1).

Substituto a known-9ood ECM and rech6ck. lf symptom/indication goes away, replace the original ECM.

1 1- 1 6 2

\

a

The scan tool indicatesDiagnosticTrouble Code (DTC)Pl167: A system malfunctionin the Primary Heated Orygen Sensor{PrimaryHO2S)(Sensor1) Heatercircuit -

The MIL has be€nreportedon. DTCPl167 i3 3tored.

ProblemVeritication: 1. Do the ECMResetProcedure. 2 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000mm with no in neutral) load (transmission until the radiatorfan comes on.

indicated? ls DTC1167

Intormittont failure, system i3 OK at thia time. Chock for Poor con_ noction3 or looso wilgt ai Cl45 (Primary HO2S, Son3or 1l and ECM.

Check lor sn open in the wire (VS+linel: 1. Turnthe ignitionswitchOFF the PrimaryHO2S 2. Disconnect {Sensor1)8P connector. 3. Turnthe ignitionswitchON (ll). the 4. Measurevoltage betwe€n '1) Primary HO2S(Sensor 8P connectorterminalNo 6 and body ground. ls theremorethan 5 V?

PRIMABYHO2SISENSOR1} 8P CONNECTOR tc145l

C (31P) ECMCONNECTOR

,l

Ch.ck the ECM: M e a s u r ev o l t a g e b e t w e e nt h e ECM connectorterminsl C25 and body ground.

2

3

a 21 25 VS+ {WHTI

ls theremorethan 5 V? Replacothe Primary HO2S (Sonsor 11.

4

8

5

9 10

1 1 12 1 3 t 4 1 5 1 6 1 7 1 8

a 30 Wire sideof female terminals

Repairopon in the wite ECM(C25) and P m.ry HO2S(S€n3or11.

Substitute ! known-good ECM and r6check.lf symptom/indication gos6 away, r.place tho origi' nd ECM,

11 - 1 6 3

PGM-FISystem FuelSupplySystem D017-il

Th""""ntool indicatesDiagnosticTroubteCode{DTC)p0171;Thefuetsystemistoo lean.

1P0172 | fne scantool indicatesDlagnosticTroubleCode(DTC)P0172:Thefuelsystemistoo rich. Description By monitoringthe LongTerm FuelTrim, long term malfunctionsin the fuel systemwill be detected. lf a malfunctionhas beendetectedduringtwo consecutive trips,the MIL will come on and DTCP0171and/orP0172will be stored. NOTE:lf some of the DTCSlistedbeloware storedat the sametime as DTCP0171andlot P0172,ltouhleshootthose DTCS first.then recheckfor DTCP0l7l andlotP0172. P 0 1 0 6 - 8P,1 1 2 8 **35. ,P 1 1 2 9 **35 M A PS e n s o r P0135;PrimaryHO2SHeater P0137.P0138:SecondaryHO2S P0'141: SecondaryHO2SHeater P0401:EGRFlow Insufficient*1 P0441:EVAPSystemInsufficientPurgeFlow*6 P1259:VTECSystem*, P1491:EGR ValveLift Insufficient*r P1498:EGRValveLift SensorHjghVoltage*r *r: D16Y5engines *' : Dl6Y5, D16Y8,81642engine *3:'97 models * a : ' 9 6m o d e l s f 5:'98 - 00 models *6:'96 D16Y5engine,'96D16Y7engine,'96D16Y8engine(sedan),'97D16y5engine,,97D16y7 engine(coupe:KA,KC mo+ els,sedanKA.KC,KL (DX)models.hatchback; all models),'97D16Y8engine(sedan:KA,KCmodels) PossibleCause DTCP0'171 loo lean

DTCP0172 too rach

11-164

FuelPumpinsufficientf lovpressure FuelFeedLineclogged,leaking FuelPressureRegulatorstuckopen FuelFilterclogged FuelInjectorclogged,air inclusion Gasolinedoesn'tmeet Owner'sManualspec. PrimaryHO2S(Sensor1) deteriorated MAP Sensorrange/performance*. EGRSystemmalfunction(too much flow)*1 ValveClearance Exhaustleak FuelPressureRegulatorclogged,stuckclosed FuelReturnPipeclogged FuelInjectorleaking Gasolinedoesn'tmeet Owner'sManualspec. PrimaryHO2S(Sensor1) deteriorated MAP Sensorrange/performance*a EGRSysteminsufficientflow*1 EVAPPurgeControlSolenoidValveleaking,stuckopened ValveClearance

t Troubleshooting Flowchart -

The MIL ha3 b€onrePorledon. DTC P0171a^dlot P0172arc stored,

is the fuel pressureOK? ls the fuel pressuretoo high ortoo low? Checkthe Primary HO2S: 1 . S t a r tt h e e n g i n e .H o l d t h e engine at 3,000rpm with no Ioad (in Parkor neutral)until the radiatorIan comeson 2 . C h e c kt h e P r i m a r y H O 2 S ( S e n s o r1 ) o u t p u t w i t h t h e scantool,

Checkthe fuel pt€ssureregulator and fusl re{urn pipe.

Check the tu6l pump. fuel leed pipe, fu€l fiher, and Iuel Pressure regulator.

Doesit stayat lessthan 0.3V or morethan 0.6V?

'l

NO Check lor a sticking or leaking EVAPpurge control solenoid vacuWitha vacuumPumP,aPPIY u m t o t h e E V A Pp u r g e c o n t r o l s o l e n o i dv a l v e f r o m t h e i n t a k e manifoldside. Does it hold vacuum?

a-,-:- Checkthe MAP sensoroutputr 1. Turnthe ignitionswitchON (ll) 2. Checkthe MAPwith the scan tool. YES Check th6 response of the MAP sensoa: 1. Startthe engine. 2. Checkthe MAP with the scan tool. l s a M A P o f 4 0 . 0 k P a 1 3 0 0m m H g , 1 2 . 0i n H g ) o r l e s s i n d i c a t e dw i t h i n one second after starting the engine?

-

Checkth€ valve cloarance. Checkthe EGRrystem lD16Y5 enginel. lf they are OK, r€placethe tuel iniocto]3.

11 - 1 6 5

PGM-FISystem RandomMisfire lFoiool*uo,[FTiool*' *' and

P0304

The scan tool indicatesDiagnosticTrouble Code (DTC) P 0 3 0 0 * 5o r P 1 3 0 0 * 3* 1 a n d s o m e o f P 0 3 0 1- P 0 3 0 4 : Randommisfire.

Description Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor which is attachedto the crankshaft. lf misfiringstrongenoughto damagethe catalystis detected.the MIL will blinkduringthe time of its occurrence, and DTC P0300*5 or P1300*3'*'and some of DTCsP0301through P0304will be stored.Then,after misfirehas ceased,the MIL will come on. lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles,the MIL will come on, and DTC *a and some of DTCSP0301through P0304will be stored. P0300*5 or P1300*3 NOTE:lf some of the DTCSlistedbeloware storedat the sametime as a misfireDTC.troubleshootthose DTCSfirst,then recheckfor the misfireDTC. *5,Pl129*3*5;MAP sensor P0106*4. P0107.P0108,P1128*3 P 0 1 3 1P. 0 1 3 2H: O 2 S P0171,P0112iFuelmetering P0401,P 1491,P1498:EGRsvstem*1 P0505:ldle ControlSystem P1253:VTECSystem*, P 1 3 6 1P, 1 3 6 2T: D Cs e n s o r P1381,Pl382:CYPsensor P1508:IACvalve PossibleCause . Fuelpump insufficientfuel pressure,amountof flow . Fuelline clogging,blockage,leakage . Fuelfilter clogging . Fuelpressureregulatorstuckopen . EGRsystemmalfunction*1 . Distributormalfunction . lgnitioncoil wire open.leakage . lgnitioncontrolmodulemalfunction . MAP sensorrange/performance, poor response*r . Valvescarbondeposit . Compressionlow . IACvalvemalfunctionr. . VTECsystemmalfunction*, . Fueldoes not meetOwner'sManualspec.,lackoffuel . HO2S . HO2Scircuit

*l: D16Y5engine *2: D16Y5,D16Y8,Bt6A2 engine *3: '97 models *4;'96 models *5: '98 - 00 models

Troubleshooting By test-driving,determinethe conditionsduring which misfireoccurs,Dependingon these conditions,test in the order describedin the table below. Possible cause

- --^ ---

\

\

\

rage

Only low rpm and load

EGR*1 system

o

Crankshaft Fuel Distributorand position(CKP) pressure lgnitionwires sensor

tcM

section6

11-230, 231

section 23

@

@

Only accelerating

@

Only high rpm and toao

o

Not specific

o

section 23

Clearance

tAc MAP Valve sensor

section 6

1 1 - 1 9 4 11

o o o

@

@

o

@

@

NOTE:lf misfiredoesn'trecur,some possiblecausesare fuel that doesn'tmeet owne/s manual spec,lackof fuel, carbondepositson sparkplug,etc.

1 1 - 16 6

o

I

MisfireDetectedin OneCylinder P0301 | The scantool indicatesDiagnosticTroubleCode(DTC)P0301:Cylinder1 misfiredetected. [F03O2l 16"""untool indicatesDiagnosticTroublecode (DTc)P0302:Cylinder2misfiredetected. [FO3Ofl 16" ".un toot indicatesDiagnosticTroubte Code (DTC)P0303;Cylinder3 misfire detected.

4 misfiredetected. Cylinder I P0304I ths..rr toolindicates Diagnostic TroubleCode(DTC)PO3O4: D€scription lMisfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor which is attachedto the crankshaft, and DTC lf misfiringstrongenoughto damagethe catalystis detected,the MIL will blinkduringthe time of its occurrence, MIL will come on. the or P0304will be stored.Then,afterthe misfirehasceased, P0302,PO3O3 PO3O1, lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cyclss,the MIL will come on, and DTC P0301,P0302,P0303or P0304will be stored. NOTE:lf some of the DTCSlistedbelow are storedat the sametime as a misfireDTC,troubleshootthose DTCSfirst,then recheckfor the misfireDTC.

I

P1129*3'*5: MAP sensor P0107,P0108.P1128*3'*5, PO106*1, P 0 1 3 1P, 0 1 3 2H: O 2 S P0171,P0172iFuelsuppiy system P0335,P0336:CKFsensor P0401.P1491,P1498:EGRsystem P0441:EVAPsystemInsufficientpurgeflow*6 Pl359.P1361.Pl362:TDCsensor P1381.Pl382:CYPsensor *o:'96 models *6:'96 D16Y5engine,'96D16Y/engine,'96D16Y8engine{sedan),'97D16Y5engine,'97D16\4,engine(coupe:KA, models),'97D16Y8engine(sedan:KA,KCmodels) KCmodels,sedanKA.KC,KL (DX)models,hatchback:all

PossibleCause . Fuelinjectorclogging,fuel leakage,air leakage . Fuelinjectorcircuitopen or shorted . Sparkplug carbondeposits,fouling,malfunction . lgnitionwires open.leaking . Distributormalfunction . ComDression low . Valveclearanceout of spec . VTECsystemmalfunction(D16Y5,D16Y8.81642engine) . HO2S . HO2Scircuit

r'a

(cont'd)

11-167

PGM-FISystem Misfirein DetectedOneGylinder(cont'dl Troubleshooting Flowchart -

The MIL has beenreoortedon. DTC P0301.P0302.P0303,or P030ilis indicated.

Checkthe fuel iniecto. lunction: Stan the engine,and listenfor a clickingsoundat the fuel injector in the problemcylinder.

Checkfor an openor short in the harnessbetweenECM/PCMand the fuel iniector.

Repairopen or short in the wir€.

Replacethe fuel iniector. Sub3titute a known-good E C M / P C Ma n d r e c h e c k .I t symptom/indication goes away, replacethe original ECM/ PCM.

Problemverification: 1. After checkingand recording the freezedata,do the ECM/ PCMResetProcedure. the sparkplug from 2. Exchange the problemcylinderwith one from anothercylinder, 3. Connectthe SCSservicecon' nector, 4. Test-drivethe vehicleseveral timesin the rangeofthe free2e data.

( T op a g e1 1 - 1 6 9 )

1 1 - 16 8

NOTE: . lf there is no treezedata of misfiring, just clearthe DTC. . It there is no freezedata of misfiring, t e s t d r i v e su n d e rv a r i o u sc o n d i t i o n s

I ( F r o mp a g e 1 1 ' 1 6 8 )

ls DTCP0301,P0302,P0303, or P0304indicated?

Intermittent misfire due to spark plug fouling, etc. (firing is OK ar this time).

Doesthe misfireoccurin the othercylinder?

Replacethe faulty spark plug.

Check for fuel iniector malluncl|on: 1. Exchange the fLrelinjector from the problem cylinder with one from another cylin der. 2 . L e t t h e e n g i n e i d l e f o r t r r v om i n utes. 3. Test-drive the vehicle several times in the range ot the freeze data.

l

l

NOTE:lf there is no freezedata of mis_ firing, test drives under variouscondi tions are necessary.

ls DTCP0301,P0302,P0303, or P0304indicated?

lntermitt€nt mistire due to bad contact in the fuel iniector connector (firing is OK at this time).

Doesthe mistireoccurin the othercylinder?

Replacethe taulty fuel injector.

Checklhe following items: . Cylinderleak-down . Compression . Crankshattspeod tluctuation {CKF)sensoi

t 1 1 - 16 9

PGM-FISystem KnockSensor(KSl('96- 98 D16Y5enginewith CW and'96- 98 D16Y8 engine) Forr-l

tool indicates Diagnostic TroubleCode(DTC)P0325: A malfunction in the circuitof the Knocksensor I,3,.""""

The MIL has bgenroportsdon. DTCPO:t25is stored. Problomveiilication: 1. Do the ECM/PCM ResetProceoure, 2. Start the engine.Hold the engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rt a n c o m e s o n , then let it idle. 3 . H o l d t h e e n g i n e a t 3 , 0 0 04,000 rpm tor at least 60 seconds.

ls DTCP0325indicated?

DIAPHRAGM

Intermittenl fsilu16,3y3l6m b OK at thi3 timg lteat drivo mav ba noc63saryl. Chock tor poor conneclioni or loose wire3 b€twccn C137{knock len3or (KS)land ECM/PCM.

Checkfor a short in tho wire {KS linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe knock sensor 2Pconnector, 3 . D i s c o nn e c t t h e E C M / P C M connectorO (16P). 4. Check for continuity between E C M / P C Mc o n n e c t o rt e r m i nalsD6 and body ground.

ECM/PCMCONNECTOR D {16PI

Wire sideof femaleterminals

Reo.ir 3hort in the wire between ECM/PCM{DG).nd knock 3.n-

(Cl371 KS 2P CONNECTOR KS

Chock for an open in the wire (KSlinel: C h e c kf o r c o n t i n u i t y b e t w e e n ECM/PCM connectortorminalD6 and knock sensor 2P connector terminalNo. l.

ls therecontinuity?

(RED/BLUI 1

I Ropairopen in the wire bgtweon ECM/PCMlD6l and knock sen-

\

,_- ,--tl

e s l le oI temal€ tertn i n irls

3('t.

Substitutea known-goodknock sensorand recheck.

Rsplaceth. o.igin.l knock s€nsor.

Substitute a known-good ECM/ PCM end recheck. lf 3ymptom/ indication goes rway, replace rhe original ECM/PCM.

11-170

KS IRED/ BLU)

1

1

2

1

8

9 't0 1 t

13 l4 t5

t6

12

'99- 00D16Y8 engineand enginewith cw, Knocksensor(Ks)r99- 00D16Y5 816A2engine The scantool indicatesDiagnosticTroubleCode(DTC)P0325:A malfunctionin the circuitof the KnockSensor {KS}. The MIL has beenreportedon. DTCm325 is stored

OIAPHRAGM Problemverification: 1. Do the ECM/PCMResetPro cedure, 2 . S t a r tt h e e n g i n e H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 3 . H o l d t h e e n g i n e a t 3 . 0 0 04,000 rpm for at least 60 sec' onds.

ls DTCP0325indicated?

lntermittent failure, system is OK at thi3 time lt€3t drive maY b€ nocessaryl. Chsck tor poor connectionsor loose wiros at C137 {knock sen' sor {KSll and ECM/PCM.

C (31P) ECM/PCMCONNECTOR

Ch€ckfor a short in tho wire (KS linel: 1. Turnthe ignitionswitchOFF. 2, Disconnectthe knock sensor 1Pconnector. 3. Checkfor continuitybetween E C M / P C Mc o n n e c t o rt e r m i _ nalsC3 and body ground. Wire side of female terminals

ls therecontinuity?

Repri. short in the wiro bqtwecn ECM/PCMlc3l and knock 3ensor. (C1371 KS 2P CONNECTOR KS

Check for an open in lhe wire {KS linc): C h e c kf o r c o n t i n u i t y b e t w e e n ECM/PCMconnectorterminalC3 and knock sensorconnectorterminalNo. 1.

Replir open in the wire bdtweon ECM/PCM{Ctl and knock sensor'

ECM/PCMCONNECTOR

S u b s t i t L r t ea k n o w n ' g o o d k n o c k sensor and recheck, Wire side of female terminals

Replacetho otiginal knock sensor.

t

substitute a known-good ECM/ PCM and recheck. ll symptom/ indication goes awaY, rePl6co tha o.iginal ECM/PCM.

11-171

PGM-FISystem CrankshaftPosition/TopDeadGenter/Gylinder Position(CKP/TDC/CYP) Sensor ('96- 98 Models,'!n - 00 D16Y5enginewith M/Tl scantool indicatesDiagnosticTroubleCode(DTC)P0335:A malfunctionin the Crankshaftposition(CKp) tFos3slThe sensorcircuit.

tFffi6l

The scantool indicatesDiagnosticTroubleCode(DTC)P0336:A range/performance problemin the Crankshaft Position(CKP)sensorcircuit.

The scantool indicatesDiagnosticTroubleCode tPr361I (TDC) sensorcircuit.

fPfi62l

(DTC)P1361:Intermittentinterruotionin the Too DeadCenter

The scan tool indicatesDiagnosticTroubleCode {DTC)P1362:No signalin the Top DeadCenter(TDC}sensor circuit.

The scantool indicatesDiagnosticTroubleCode fFr38il{CYP) sensorcircuit.

(DTC)P1381:Intermittentinterruptionin the CvlinderPosition

The scantool indicatesDiagnosticTroubleCode {DTC)Pl382: No signal in the CylinderPosition(CYP}sensor tF13s2-l circuit. Description The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC Sensordeterminesignitiontiming at start-up(cranking)and when crankangle is abnormal.The Cyp Sensordetectsthe positionof No. 1 cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP Sensoris built into the distriburor. NOTE:lf DTCP1359is storedatthesametime as DTCP0335.P0336,P1361,Pl362,P1381and/orP1382,troubteshoorDTC P1359first,then recheckfor those DTCS. Ot6y56ngine: Dt6y7,ot6y8enqin6s:

-

The MIL hrs beenreportedon. D T C P 0 3 3 5 ,P 0 3 3 6 ,P 1 3 6 1 , P1362,P1381and/or Pl382 6re stored,

Problemverification: 1. Do the ECM/PCM ResetProcedure. 2. Stanthe engine. ls DTCP0335,P0336,P1361,P1362, P1381and/orP'l382indicated?

TDC CKP SENSORSENSOR

SENSOR ROTOR BOTOR

ROTOR

Intermittent hilu.e, system b OK at this time. Checktor poor conn€ctions or 10036wiros at C120 {distributor}and ECM/PCM.

SENSOR ROTOR

SENSOR SENSOR ROTOR ROTOR DISTRIBUTOR 1OP coNNECTORtC120t TDC P

Check for an open in the CKP/ TDC/CYPsensor: 1. Turnthe ignitionswitchOFF. 2. Disconnect the distributor10P

CYPM {BLK}

3. Measureresistancebetween the terminalsof the indicated sensor(*seetable). SENSOR DTC

ls there350- 700 0?

Replacethe distributor ignition housing (soesection23).

CKP TDC CYP

11-172

SENSOR ECMfCM IERMINATTERMINAT COLOR

P033s

2

c2

m336

6

c12

BLU

P1361

3

P1362

7

cl3

RED YEL

8

c4 c14

P!381 P't382

GRN

8LK

(Frompage | 1-172)

DISTRIBUTOR 10PCoNNECTOR{C1201

Check fo. a sho.t in the CKP/ TDC/CYPsensor: C h e c kf o r c o n t i n u i t yt o b o d Y ground on both terminalsof the i n d i c a t e ds e n s or i n d i v i d u a l l y 1*seetable).

ls therecontinuity?

TDCP (GRNI

Replacothe di3tributorignition hoGing lsee section23).

Checkfor an open in the wires line3): ICKP/TOC/CYP the distributor10P 1. Reconnect connecaor. the EcM/PCMcon2. Disconnect nectorC {31P}. resistancebetween 3. N4easure the terminalsof the indicated consensoron the ECIM/PCM nector{*seetabie}.

ls there 350 - 700 o?

Terminalsideof maleterminals

Repairopen in the indicated sensor wires lrsee tablel.

C 131P) ECM/PCMCONNECTORS CI(P P TDC P

CYP P (YEL)

Chock lor. short in the wires lines): ICKP/TDC/CYP C h e c kf o r c o n t i n u i t y b e t w e e n conbody ground and ECM/PCM nectorterminalsC2, C3 and/or C4 individually. M

ls therecontinuity?

Substitute e known-good ECM/ PCM, and iecheck. ll sYmptom/ indication goes awev, r€Place the original ECM/PCM.

Repai.short in the indic.ted sen_ sor wire3 ('soe tablol,

M CKPM (WHT) (REDI

CKP P (BLU}

IBLKI Wiresideof femaleterminals

TDC P CYPP (GRN) IYELI

t 11-173

PGM-FISystem CrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYPI Sensor f99 00 ModelsexceptD16Y5enginewith M/T) The scantool indicatesDiagnosticTroubleCode l-Fos3sl sensorcircuit. The scantool indicatesDiagnosticTroubleCode tFos36l Position(CKP)sensorcircuit.

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

(DTC)P0336:A range/performance problemin the Crankshaft

The scantool indicatesDiagnosticTroubleCode l {TDC) tF1361 sensorcircuit.

(DTC)P1361:Intermittentinterruptionin the Top DeadCenter (TDC)sensor

The scantool indicatesDiagnosticTroubleCode {DTC)P1362:No signalin the Top DeadCenter Fr362-1 circuit. The

indicatesDiagnosticTroubleCode(DTC)P1381:Intermittentinterruptionin the CylinderPosition

scantool tF13sil(CYP) sensorcircuit. lTiaSt :

The scantool indicatesDiagnosticTroubleCode (DTC)P1382;No signal in the CylinderPosition(CYP)sensor circuil.

DoscriDtion The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC Sensordeterminesignitiontiming at start-up(cranking)and when crankangle is abnormal.The CYPSensordetectsthe positionof No. 1 cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP Sensoris built into the distributor. NOTE;lf DTCP1359is storedat the sametime as DTCP0335,P0336,P1361.P1362,P1381and/orP1382,troubleshootDTC engino: P1359first,then recheckfor thoseDTCS. D16Y5

-

The MIL has beenreportodon. DTC P0335, P0336. P1361, P1362,P1381rnd/or P1382.re stored.

Problemverific{tion: 1. Do the ECM/PCMResetProcedure. 2. Startthe engine. ls DTCP0335,P0336,P1361,P1362, P1381and/orPl382 indicated?

TDG CKP SENSORSENSOB SENSORROTOR BOTON ROTOR Intormittcnt failure, systom b OK at thb time. Check to. poor connections or loose wires at C120 (dktributorl and ECM/PCM.

Check tor an open in the CKP/ TDC/CYP3enior: 1. Turnthe ignitionswitchOFF. 2. Disconnect the distributor10P connector, 3. Measureresistancebetween the terminalsof the indicated sensor(*seetable). ls there 350 700 0?

TDC CKP CYP SENSOB SENSOB s€Nson ROTOR ROTOR BOTOR D16Y7, D16Y8ongine:

S E N S O R DTC CKP

TDC

Replrce the distributor ignition hou3ing (!ee section 231.

CYP

P0335

2

c8

P0336

6

c9

P1361

3

c20

GRN

P1362

7

c21

BED YEL

I

c29 c30

P1381 P1342

(Topage11-175)

1-1 7 4

S E N S O R ECM/PCM T E B M I N A I TERI\,4INAI C O L O R

8LU

BLK

Dl6Y5.816A2engine: DISTRIEUTOR

l0PcoNNECTOR {C120)

(Frompage11-174)

C h o c kf o r . 3 h o r t i n l h o C K P / Tlrc s6n3o.: C h e c k{ o r c o n t i n u i t y t o b o d y ground on both tsrminalsof the indicatedsensorindividuallY.

Terminalsideol maleterminals 016Y7,Dt6Y8 engine: Chsck for an open in the wile3 ICKP/TIrcline6l: 1. R€connectthe CKP/TDCsonsor 4P connector. 2. Disconnectthe ECM/PCMconnectorC 131P). 3. Measureresistancebetween the terminalsol the indicated sensoron the ECM/PCMconnector1*seetablel.

ls there 350- 700 o?

DISTRIBUTOR (Cl201 8P CONNECTOR

Terminalsideol maleterminals Ropsiropon in tho indiclted sonior wiro3 l*!sa tabla).

C (31P) ECM/PCMCONNECTOR

CKPM IWHT}

Chack for a .ho in th6 wiros {CKP/TDClino3l: C h e c kf o r c o n t i n u i t y b e t w e e n body ground and ECM/PCMconnectorterminalsC8, C20 and/or C29individually.

lDC M (REDI

Rcpairrhort in th. indicat.d 36n_ lor wirar {'3ac trblol.

Substituto . known-good ECM/ PCM lnd rechock. lf 3ymptom/ indicatlon go6s aw.y, ropllc. tho origin.l ECM/PCM.

Wiresideof femsleterminals ECM/PCMCONNECTOR c l31P) CKPP

wire sideof femaleterminals

t 11-175

PGM-FISystem VehicleSpeedSensor(VSSI('96- 98 Models,'99- 00 D16Y5enginewith M/Tl @

The scan tool indicatesDiagnosticTrouble Code (DTC)P0500:A malfunctionproblem in the VehicleSpeed Sensor(VSS)circuitIexceptA!/T(D16Y7,D16Y8engine)1. The scan tool indicatesDiagnosticTrouble Code (DTC)P0501:A range/performance problem in the Vehicle SpeedSensor (VSS)circuit [A,rT{D16Y7,D16Y8engine)]. The MIL has been reDortedon. DTCP0500or P0501is stored.

ECM/PCMCONNECTORS A {32P}

Problemverification: 1- Testdrivethe vehicle. 2. Checkthe vehiclespeedwith the scantool.

ls the correctspeedindicated?

2

LG.t {BRN/BLK}

3

9

12

1 6 1 1 t 8 t 9 20

l0

lt

23

21

2A 29 30

Intermittent tailure, system is OK at this time. Checktor Door connectionsor loose wires at C117 {VSSlandECM/PCM.

Checkfor an open in the ECM/ PCM: 1. Turnthe ignitionswitchOFF. 2. Elockthe rearwheelsand set the parkingbrake. 3. Jackup the frontof the vehicle and supportit with safety stands. 4. Turnthe ignitionswitchON (ll). 5. Blockthe righttrontwheeland s l o w l y r o t a t et h e l e f t f r o n t

c {31P} 3

I

12

tl

8 1 9 1o

ialr5 i6l

1 0 ./

VSS IBLU/WHT} Wiresideot temaleterminals

6, Measurevoltagebetweenthe E C M / P C Mc o n n e c t o rt e r m i nalsC18and A9. Doesthe voltagepulse0 V a n d5 V ?

Subslitute a known-good ECM/ PCM and recheck.lf symptom/ indic.tion goes away, replacethe orisinal ECM/PCM. LGI (BRN/8LK}

Check tor a short in ihe ECM/ PCM: 1. Turnthe ignitionswitchOFF. 2 . D i s c on n e c t t h e E C M / P C M connectorC (31P). 3. Turnthe ignitionswitchON {ll). 4 . B l o c kt h e r i g h t f r o n t w h e e l and slowlyrotatethe leftfront

I

3

2

5

a

6

l 5 t 6 1 t l 8 t 9 20

12 l 3

27

9

l0

22

11

2a

20 29 30

5. Measurevoltagebetweenthe ECM/PCM connectorterminals C18andA9. Does the voltage pulse 0 V and s V?

-

Repair short in the wire betwGenECM/PCM{C18}end

vss, TcM. -

-

Repair open in the wire between ECM/PCM {Cl8} and

vss.

lf wire is OK, test the VSS lsee section 23).

11-176

Substitute a known-good ECM/ PCM and recheck. lI symptom/ indication goes away. replace the original ECM/PCM.

1

2 t 2 l 13l . l 2 3 1r . l s l

9 10 7

I l ,/

t. , ) ,rl

1,/ L

VSS {BLU/WHT}

VehicleSpeedSensor(VSS)('99- 00 ModelsexceptDl6Y5 enginewith M/T)

Thescantoo|indicatesDiagnosticTroub|ecode(DTc)Po5o0:Ama|functionproblemintheVehic|es

fFosoo-l Sensor(VSS)circuitlexceptA//T(D16Y/,D16Y8engine)l'

Thescantoo|indicatesDiagnost|cTroub|eCode(DTC)Po5o1:Arange/performanceprob|eminthe

lFosoilSDeedSensor{VSS)circuittA,/T(D16Y7,D16Y8engine)1. The MIL has beenreportedon OTCP0500or P0501is stored. Problemveritication: the vehicle. 1. Test-drive 2. Checkthe vehiclespeedwith the scantool ls the correctsPeedindicated?

I

ECM/PCMCONNECTORS B {25P) lntermitt6nt failure, sYstemis OK at thb time. Checktor Poor connections or loose wir6 at C117 {vss} .nd ECM/PCM

Check for an open in the ECM/ PCM: 1. Turnthe ignitionswitchOFF. 2. Blockthe rearwheelsand set the parkingbrake 3. Jack uP the front ofthe vehicle and supportit with safety stands. 4. Turnthe ignitionswitchON (ll). 5. Blockthe right front wheel and s l o w l y r o t a t et h e l e f t f r o n t 6, Measurevoltagebetweenthe E C M / P C Mc o n n e c t o rt e r m i _ nalsC23and 820. D o e s t h e v o l t a g e P u l s e0 V and 5 V or batteryvoltage?

Wire sideol lemaleterminals Substituto a known'good ECM/ PcM and rech€ck. ll sYmptom/ indic€tiongoes awaY,lsplace the originalECM/PCM. ECM/PCMCONNECTORS

Check for a short in the ECM/ PCM: 1. Turnthe ignitionswitchOFF. 2 . D i s c on n e c t t h e E c M / P c M connectorC (31P). 3. Turnthe ignitionswitchON (ll) 4 . B l o c kt h e r i g h t f r o n t w h e e l and slowlyrotatethe leftfront

B E5PI

5. Measurevoltagebetweenthe terminals connector ECM/PCM C23and 820. D o e s t h e v o l t a g e P u l s e0 V and 5 V or battery voltage?

-

t

-

Reoair short in the wire between ECM/PCM{C23}and

vss. TcM.

Substiiute . known-good ECM/ PCM and r6check. lf symptom/ indication goes awaY, rePlace the origin.l ECM/PCM.

Wire sideoI femaleterminals

Repai. open in the wire between ECM/PCM{C231and

vss.

lf wire is OK, tesr the VSS {seesestion23).

11-177

PGM-FISystem BarometricPressure(BAROISensor The scantool indicatesDiagnosticTroublecode (DTC)Pi106:A range/performance problemin the Baromerrrc Pressure(BARO)Sensorcircuit. The MIL ha3 beenr€Dortsdon. DTCPl106 is stored.

Problemverification: 1 . D o t h e E C M / P C Mr e s e tp r o cedure, 2 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)until the radiatorfan comeson, then let it idle. 3. Connectthe SCS servicecon nector. 4. Test drive with the A/T in E position,M/T in 4th gear. 5 . A c c e l e r a t ef o r f i v e s e c o n d s usingwide openthrottle.

ls DTCP1106indicated?

Intormittont tailure, system is OK at this time.

Substitut€ e known-good ECM/ PCM and recheck.ll symptom/ indicationgoes .way, .oplscethe o.iginal ECM/PCM.

fF1lot

The scantool indicatesDiagnosticTroublecode (DTc)P1107:A low voltageprobtemin the Barosensorcircurr.

scan tool indicatesDiagnosticTroubrecode {DTC)p1108:A tPlloal The circuit. The MIL has been.oported on. DTCP'l107o. Pl108 is stored.

P.oblemveritication: 1. Do the ECM/PClvl Resetpro cedure, 2. Turnthe ignitionswitchON (ll).

ls DTCP1107or Pl108indicated?

Substitute a known-good ECM/ PCM and rechock. It symptom/ indication goes away, .6place the original ECM/PCM.

11-178

Intormittent frilure, syitem i3 OK at this time.

high vortageprobrem in the Baro sensor

with M/T} ElectricalLoadDetector(ELDI{'96- 98 Models,'tn 00 D16Y5engine (DTC)P1297:A low voltage problem in the ElectricalLoad The scan tool indicatesDiagnosticTrouble code Detector(ELD)circuit.

Problemverification: '!. Do the ECM/PCMResetProcedure. 2. Start the engine 3. Turn on headlights ls DTCP1297indicated?

lntermittent tailure,sYstemis OK at this time. Checkfor Poor connection3 or loose wires at C131 tlocatedunder righl side of da3h). C354(ELDIandECM/PCM.

(c35'rl ELD3PCONNECTOR

l--

Ch.ck lor short in the ELD: Measurevoltage betweenbody groundand the ELD3Pconnector t e r m i n aNl o . 3 .

--f

,

l l l 2 l 3 l

..

ao (GRN/REDI

Y

ls thereapprox.45 V?

O I16PI ECM/PCMCONNECTOR

Checkfor a short in tho wile (EL linel: 1. Turnthe ignitionswitchOFF' con the ECM/PCM 2. Disconnect nectorD (16P) 3. Checkfor continuitybetween b o d y g r o u n da n d E C M / P C M connectorterminalD16 R6pairshort in the wire between ELD. ECM/PCM(D161and

Wire sideof femaleterminals

Substitute a known-good ECM/ PCM and recheck lf symplom/ indication goes awaY, rePlace the original ECM/PCM

r a 11-179

PGM-FlSystem ElestricalLoadDetector|ELD)t'glf- 00 ModelsexceptD16y5enginewith M/Tl The scan tool indicatesDiagnosticTrouble Code (DTC)P'1297; A low voltage probtem in the ElectricalLoad Detector(ELD)circuit.

Problemverilication: 1. Do the ECM/PCMResetProcedure. 2. Start the engine. 3. Turn on headlights. Inlermittont failur6. systom i3 OK at this time, Chocktor ooor connestions or loose wires at C131 (locrted undor ight side ot d.shl, C354(ELDIand ECM/PCM. Checkfor short in th6 ELD: Measurevoltage between body groundand the ELD3P connector t e r m i n aNl o . 3 .

ELD3PCONNECTOR tC354)

EL {GRN/REOI

ls thereapprox.4.5V?

ECM/PCMCONNECTOB A I32PI

Check to. a short in the wne (EL linel: 'L Turn the ignitionswitchOFF. 2. Disconnect the ECM/PCM connectorA (32P). 3. Checktor continuity betlveen b o d y g r o u n da n d E C M / P C M connectorterminalA30.

ls therecontinuity?

Sub3titute a known-good ECM/ PCM and rech€ck. It symptom/ indication goes away. replace the o.iginal ECM/PCM.

11 - 1 8 0

Repairshort in the wile between ECM/PCMlA30) and ELD.

Wire side of lemale terminals

- 00 D16Y5enginewith M/T) ElestricalLoadDetector(ELD)f96 98 Models''99

ThescantoolindicatesDiagnosticTroubleCode(DTC)P1298:AhighvoltageproblemintheElectrical Detector(ELD)circuit

Problomvcrificttion: ResetPro1. Do the EcM/PClVl cedure, 2. Startthe engine. 3. Turnon headlights. ls DTCP1298indicated)

Ch.ck lor tn oPan in tho wir' (lGl linol: 1 . T u r n t h e i g n i t i o na n d h e a d ' liohtsOFF 2. D]""onn""t the ELD 3P con_ nector3. Turnthe ignitionswitchON {ll)' 4. Measurevoltagebetweenbody groundandthe ELD3Pconnec '1. tor terminalNo.

lntarmitt..rt l.ilur., ryttcm b OK .t thia tim. Ch.ck lor Poo' connections or looaa wir.3 at C131 lbcd.d und.r right ide ol dalhl' Gl5a {EU)} .nd ECM/PCIYI

{G's'I ELD3PCONNECTOR

Wire side ol femaleterminals

R.oair ogan in tha wira Mw"n

ru".rs ltTEnrlton SPSelSOn

t?.5 A, fu!. in th. undcr-dr3h tu3e/r.l!Y box .nd ELD. Chcck lor tn oP.h in thc wire {GND lincl: 1. Turn the ignition switch and h e a d l i g h t sO F F . 2. Disconnect the ELD 3P con_ nector' 3. Check for continuity between body ground and the ELD 3P c o n n e c t o .t e r m i n a l N o 2

EL IGFN/REDI

Raprir opcn in the wira bstwt€n ELD conncctor lnd G/O2.

Ch.ck lor !n oplo in tha wirc IEL lin.l: Check for continuity between the ELD 3P connectorterminal No 3 and ECM/PCM connector termi nal D'16. Rapaii opcn in the wira b€tw"n ECM/FCM (I)161.nd th. ELD'

wire side of lemale termrnals

Ch.d( fo. r m.llunction in thc ELD: 1 . R e c o n n e c tt h e E L D 3 P c o n ' 2. Start th€ engine and allow it to idle. 3. Wh ile measuring voltage beNveen ECM/PCM connector terminals D16 and A9, turn t h e h e a d l i g h t so n { l o w ) .

t'a

Doesthe voltage droP?

Sub3titut. . known_good ECM/ PCM .nd rcch.ct. lt sYmptom/ indication goas away/ iapllc' thc origin.l ECM/PCM

)

Wire side of Iemale terminals

11 - 1 8 1

PGM-FISystem ElestricalLoadDetector(ELDI('99- 00 ModelsexceptD16y5enginewith M/Tl The scan tool indicatesDiagnosticTroublecode (DTCIPl298: A high vottageproblem in the EtectricalLoad Detector(ELD)circuit.

Problemve.itication: 1. Do the ECN4/PCM Resetpro cedure. 2. Startthe engine. 3- Turn on headiights. ls DTCP1298indicated?

Inte.mittent teilu.e, svstem is OK at this lime. Chockfor Door connections or loose wires at Ci31 {located under Jight side ot daihl, C354(ELD)and ECM/PCM.

ELD3P CONNECTOR (65/0

Check for an open in the wire {lG1line}: 1 . T u r n t h e i g n i t i o na n d h e a d lightsOFF. 2 . D i s c o n n e ctth e E L D 3 P c o n Wiresideof fernaleterminals

3. Turnthe ignitionswitchON (ll). 4. Measurevoltagebetweenbody groundand the ELD3P connectorterminalNo. 1. ls there battery voltage?

Repairopon in tho wiro batwe€n No. 15 ALTERNATOR Sp SENSOR {7.5 A} fuse in th6 undor-dash Iuse/releybox and ELD.

Check for an open in the wiro {GNDlinel: 1. Turn the ignition switch and headlights OFF. 2 . D i s c o n n e ctth e E L D 3 P c o n nector. 3. Checkfor continuitybetween body ground and the ELD3P connectorterminalNo.2,

ls therecontinuity?

Repsir op€n in the wire between ELD connector and ECM/PCM.

Substitute a known-good ECM/ PCM and recheck.lf symptom/ indication goes away. replace lh6 original ECM/PCM.

11-182

TI

r l 2 l 3 l

I crvo (o) (BrKr

Y

Wire sideof lemaleterminals

Repairopen in the wire bstwoen ELDconnsctorand Gia02. Check ,or an open in the wire IEL linel: 1. Disconnect the ECM/PCM connectorA (32P). 2. Checkfor continuitybetween the ELD3P connectorterminal No. 3 and ECM/PCMconnector terminalA30.

ELD3P CONNECTOR (CA54I

EL {GRN/REOI

ECM/PCMCONNECTORS A (32P1

Chockfo. a malfunctionin the ELD: '1. Reconnect the ELD connector and ECM/PCMconnector A (32P). 2. Stan the engineand allow it to idle. 3 . W h i l e m e a s u r i n gv o l t a g e between ECM/PCMconnector terminals A30 and B2O,turn the headlighrs on ow).

Wiresideof lemale EI-IGRN/RED) terminals ECM/PCMCONNECTORS A {32P)

Doesthe vokagedrop?

Wire side of f€male terminals

\

Fluctuation(GKFISensor CrankshaftSpeed '99 - 00 D16Y5enginewith .M/Tl firC- 48 Models, fPrk6l

Speed (DTC)P1336;Intermiftentinterruptionin the Crankshaft The scantool indicatesDiagnosticTroubleCode Fluctuation(CKF)sensorcircuit.

ThescantooIindicatesDiagnosticTroub|ecode{DTC)P1337:NosignaIinthecrankshaftspeedF|uctuatio

lFr3g7-lsensorcircuit.

D6scription T h e d i a g n o s t i c s y s t e m h a s a p u | s e r r o t o r o n t h e c r a n k s h a f t a n d a p u | s e p i judges c k - u p s e n s8n o r oengine n t h e emisfire n g i n e boccurred l o c k . T hife E c M / P that sensorsignal,and monitorsthe crankshaftspeedftuctuationbasedon the cKF limit' the fluctuationgoes beyonda predetermined

-

I

The MtL hds been reported on. DTC P1336and/or P1337a.e stored.

P.oblem v€rific.tion: 1. Do the ECM/PCMResetProcedure. 2. Stanthe engine

lntormittont lailur6, tY3tom b OK at thit tima. Chock tor Poor con' nactions or loota wito! at C102 IC-KFson$rl .nd ECt /PCM, and mrka suro CKFtonaor mounting boh ittigM.

Chockfor .n open in tho CKFaen30t:

1. Turnthe ignitionswitchOFF 2. Disconnectthe CKFsensor 3P connector, 3 . M e a s u r e t h e r e s i s t an c e between the CKF sensor 3P connectorterminalsNo. 1 and No.3.

CKF SENSOR 3P CONNECTOR L:l .)l l.' Ir-T--T---.]

l- 1 l 2 l 3 l l L ''---r C K F MI I CKFP twrfit 1,.^\ | lsLul \.7

ls there1.6- 3.2kO?

Terminalsideof maleterminals

Ch€cktor a short in the CKFson' 30ti

C h e c k{ o r c o n t i n u i t Yb e t w e e n body groundand the CKFsensor 3P connectortermin6lsNo. 1 and N o . 3i n d i v i d u a l l Y .

I

CKF M IWHT}

CKF P IBLUI

(cont'd) (To page 11 184)

11 - 1 8 3

PGM-FISystem CrankshaftSpeedFluctuation(GKFISensor ('96- 98 Models,'99- 00 D16V5enginewith M/Tl (cont,d)

\

(Frompage11 183)

Checklor an open in the wires ICKFlines): 1. Reconnect the CKFsensor3p 2. Dlsconnect the ECM/PCM connectorC (31P). 3, Measureresistancebetween E C M / P C Mc o n n e c t o rt e r m i n a l sC l a n dC l 1 .

ECM/PCMCONN€CTOR C (31P} CKFP (8LU/REO)

6rl-i ls there1.6 3.2kO?

Repairopen in the wire between ECM/PCM{C1,C11}and the CKF

Repairshort in the wiro bstwoen ECM/PCM{Cl) and the CKFson-

11-184

tl

21

CKFM (WHT/REO)

C h e c kf o r a s h o r t i n t h e w i r e {CKFline}: C h e c kf o r c o n t i n u i t y b e t w e e n body ground and ECM/PCMcon, nectorterminalC1.

Substitute a known-good ECM/ PCM,and recheck.lf symptom/ indicationgoes awry, replacethe original ECM/PCM.

rF

a

6

7

8

9 10

1 2 13 1 1 1 5 t 6 1 7 1 8

CKFP (BLU/RED)

27 2A

29 30

Wire side of female termtnats

a

t

CrankshaftSpeedFluctuation(CKF)Sensor ('99- 00 MocielsexceptD16Y5enginewith M/T) DiagnosticTroublecode (DTC)P1336:Intermittentinterruptionin the crankshaftspeed

scantool indicates Ftu6l The Fluctuation(CKF)sensorcircuit

Fluctuation(CKF) The scantool indicatesDiagnosticTrouble Code (DTC)P1337:No signal in the CrankshaftSpeed

tF13g7lsensorcircuat,

Description T h e d i a g n o s t i c s y s t e m h a s a p u l s e r r o t o r o n t h e c r a n k s h a f t a n d a p u | s e p i c k - u p s e n s o r o n t h e e n g i n e b | o c k . T hife E c M / P judgesthat an enginemisfireoccurred monitorsthe crankshaftspeedfluctuationbasedon the cKF sensorsignal.and limit' the fluctuationgoesbeyonda predetermined

-

I

The MIL has b€onreportadon. DTC P1336and/or P1337are stored.

Problemverification: 1. Do the ECM/PCMResetProce' dure. 2. Startthe engine

lntermittcnt failuro, sydcm is OK ai this time. Checklot Poor con_ noctions or loo3e wiros at C102 ICKFs€nsor) and ECM/FCM,and make suro CKF sansor mounting bolt b tight.

Checktor an open in the CKFsen_ 1. Turnthe ignitionswitchOFF the CKFsensor3P 2. Disconnect 3. Measure the resistance b e t w e e nt h e C K Fs e n s o r3 P connectorterminalsNo. 1 and No.3.

ls there1.6 3.2kO?

Check for a short in ihe CKF sen_ sot: Check for continuity between body ground and the CKF sensor 3P connector terminals No 1 and No.3 individuallY.

t

CKFSENSOR3P CONNECTOR

r--r t |-.r-r'--]l

l l ll 2 l 3 l l .l---'.-T_

C K F MI t w H T l --\9|/Ai

I CKFP i lBlul

Terminal side oI male terminals

CKF M (WHT)

CKFP (BLU)

(cont'd) (To page 11-186)

11 - 1 8 5

PGM-FISystem CrankshaftSpeedFluctuation(GKFISensor ('99- 00 ModelsexceptD16YSenginewith M/Tl (cont,d)

\

I

(Frornpagel1-185)

Check Ior an opsn in the wires (CKFlines): 1. Reconnect the CKFsensor3p connector. 2. Disconnectthe ECM/PCMconnectorC {31P}. 3. Measureresistancebetw€en E C M / P C Mc o n n e c t o rt e r m i nalsC22and C31.

l s t h e r e1 . 6 - 3 . 2k 0 ?

ECM/PCMCONNECTOR C 13lPI

Repair opqn in th. wire bo{ween ECM/PCM(CZ, Ctll and th. CKF lon30r. Wire sideof female terminals

Check tor a short in the wire ICKFline): C h e c kf o r c o n t i n ! i t y b e t w e e n body groundand ECM/PCMconnectorterminalC22.

Roplir thort in tho wirg b.iwoon ECM/FC'ftllc22l and tho CKF3€n-

I Substituto a known-good ECM/ PCM, and r.ch.ck. It symptom/ indication90o. aw!y, 6pbco the originalECM/PCM.

11 - 1 8 6

a

Sensor Position(CKP/TDC/CYPI DeadCenter/Cylinder Position/Top Crankshaft

Thescantoo|indicatesDiagnosticTroub|ecode(DTc)P1359:Aprob|eminthecrankshaftPosjtion/TopDe sensorcircuit' Position(CKP/TDC/CYP) Center/Cvlinder -

The MIL has been reportedon DTCP1359is stored

Problemveritication: 1. Do the ECMResetProcedure 2 . S t a nt h e e n g i n el f t h e e n g i n e won't start,crankit for at least 10seconds-

ls DTCP1359indicated?

lntermittent failure, sYstem is OK Check for poor connecllon3or loose wires at C120 {distributor} and ECM,/PCM.

C h e c kf o r p o o r c o n n e c t i o n so r loose wires betweenthe distribu tor and the ECM/PCM

l , a

Substitute a known'good ECM/ PCM, and rccheck. lt 3ymPtom/ indication goes awtY, rePlace the original ECM/PCM.

rta 11-1A 7

PGM-FISystem ECM/PCMlnternalCircuit [Fi6oil -

th" """n tool indicates Diagnostic Troublecode(DTc)p1607: An EcM/pcMlnternal circuitprobtem.

The MIL has beenreportedon. DTCP1607is stored.

Problernverification: 1. Do the ECN4/PCM Resetprocedure. 2. Turnthe ignitionswitchON t). 3. Wait 10 seconds.

ls DTCP1607indicated?

Substitule a known-good ECM/ PCM and recheck.lf symptom/ indicationgoes away, .epl.ce the origin.l ECM/PCM.

11-188

J

I

A/T Signal(TMA/TMBI('96- 98 Dl6Y5enginewith GW) signallinefailure Code(DTC)P1681:TIVA,/TMB [F16551lTh" ""un toot indicatesDiagnosticTrouble C 131P} ECMCONNECTOR

TMA IGRYI

Problemverification: 1. Dothe ECMResetProcedure. 2. Drive the vehicleIor several milesat varyingspeeds

ls DTCP1655indicated?

Check lor an oPen in the wire (TMAline): 1. Turnthe ignitionswitchOFF 2. DisconnectECM connectorC (31P)from t h eE C M 3. Turnthe ignitionswitchON (ll). 4 - M e a s u r e v o l t a ge b e t w e e n E C M c o n n e c t o rt e r m i n a lC g and bodyground.

l

l

ls therebatteryvohage?

lnt.rmittent failure, system is OK at ihis time. Checktor Poor connections or loos€ wires at C131 llocated under right side of dash), C438ITCM)and ECM.

C h e c kf o r a s h o r t i n t h e w i r e ITMA line,: Measurevoltage between TCM 22PconnectorterminalNo 7 and body ground. ls there batteryvoltage?

Check for an open in the wire {TMBline}: 1. Turnthe ignitionswitchOFF 2. ReconnectECM connectorc (31P). the 22Pconnector 3. Disconnect from TCM. 4. Turnthe ignitionswitchON (ll). 5. Measurevoltage between TCM 22P connectortermlnal No.6 and body ground.

ls there batteryvoltage?

fcu22P CONNECTOR

Ropairshod in the wire bstwe€n the EcM (C!l)and the TcM.

Repairopen in the wire between th€ EcM {Ca)and the TcM.

Check for a 3ho.t in the wire {TMB lin6,: Measurevoltage between ECM connectorterminalC30and body ground,

6 7 2 3 1 '12 1 5 1 6 1 7 18 1t 13 1 4

8

29 30

23 2a 25 Substitute a known'good ECM and recheck. It symPtom/indica' tion goes away, teplace the original ECM.

Wire side oI temale terminals

ls there bafteryvoltage?

t l ,

9 10

TMB* {PNK}

Reoairshort in the wile b6tween the ECM{C30}and the TCM.

f,epair open in the wire between the EcM (C30) and the TcM.

11 - 1 8 9

ldle Control System SystemDescription The idle speedot the engineis controlledby the ldle Air Control(lAC)Valve. The valve changesthe amount of air bypassinginto the intakemanifoldin responseto electriccurrentcontrolledbv the ECM/PCM. Whenthe IACValveis activated,the valveopenslo maintainthe properidle speed. D16Y5,D16Y8,Br6A2engine(M/T):

VARIOUS sEI{SORS

(ROTARYI

tac vat-vE

Dl6Ys {CVTl,D16Y8enginelA/T):

EI{GINE cooLAI{T

INTAKEMANIFOTD

;iy--, - ---
VARIOUS SENSORS

D16Y7engine:

{ROTABY)

INTAKE MANIFOLD

1 1 - 190

of air is increasedto raisethe idle speed 1 . After the enginestarts,the lAc valve opensfor a certaintime. The amount about 150 300rpm. properfast idle speed.The amount of When the coolanttemperatureis tow, the IAC valve is openedto obtain the bypassedair is thus controlledin relationto the enginecoolanttemperature'

IOLESPEED lrpml

176 80

ENGI E COOLANI TEMPERATURE t" Fl toc)

l l

't. W h e n t h e i d | e s p e e d i s o u t o f s p e c i i i c a t i o n a n d t h e s c a n t o o | d o e s n o t i n d i c a t e D i a g n o s t i c T r o u b | e c o d e ( D T c ) P 0 5 or P1508.checkthe followingitems: . Adiustthe idle speed{seepage11-220} . Starterswitchsignal(seepage11-202) . Air conditioningsignal(seepage l1-204) . ALT FRsignal(seePage11-2081 ' Brakeswitchsignal(seepage 11-210) . PSPswitchsignal(excaptCanadamodel)(seepage11-212) . A,/Tgear position signal {seesection 14, Dl6Y5 engine (CVT): p a g e1 1 - 2 1 6 ) . Clutchswitchsignal(D16Y5enginewith M/T)(seepage11-218) . Hosesand connections ' IACvalveand its mountingO-rings the idle speed(seepage11-220) lf the aboveitemsare normal,substitutea known-goodIACvalveand readjust

| f t h e i d | e s p e e d s t i | | c a n n o t b e a d j u s t e d t o s p e c i f i c a t i o n ( a n d t h e s c a n t o o | d o e s n o t i n d i c a t e D T cthe P0505or lf symptom goes away, replace after IAC valve replacement.substitutea known-goodECM/PCMand recheck. originalECM/PCM.

ldle Control System ldleControlSystem lF0505 l Th" """n tool indicatesDiagnosticTroubleCode(DTC)PO5O5: tdtecontrotsystemmalfunction. NOTE: lf DTC P1508or P1509is stored at the same time as DTC P0505,troubleshootDTC p1508or p1bogfirst. then recheckfor DTCP0505. PossibleCause . IACvalvemechanicalmalfunction . Throttlebody cloggedpon, improperadjustment . Intakemanifoldgasketleakage . Intakeair hoselooseleakage . Vacuum leak . ECTsensorincorrectoutput . ThrottlePositionsensorincorrectoutput*r TroubleshootingFlowchart The MIL has beenreoortedon. DTCP0505is stored.

Problem verification: 1. Start the engine. Hold the eng;ne at 3,000 rpm with no load (jn Park or neutral) until t h e r a d i a t o rf a n c o m e s o n , t h e n *r let it idle.

t2. with rhe scantoot, ct'eit Ge l Throttle position should be approx. 10%with the throt tle fully closed. En g i n e c o o l a n t t e m p e r a ture should be 194 205'F (90 96.Ci. lf they are not within the s p e c . ,r e p a i rt h e f a u l t y s e n L._ _9oI9[cr]41 l 3. Chec&the engine speed at i d l e w i t h n o - l o a dc o n d ; t i o n s i h e a d l i g h t s ,b l o w e r f a n , r e a r defogger, radiator fan, and air conditioner are not operating \see page l1-22O - 223).

ls the idlespeedOK?

Intermittent tailure, system is OK at this time.

ls it 550 rpm or less?

(Topage 11,193) * 1 r ' 9 6 m o d e l so n l y

11-192

(Topage ll-193)

I

{ F r o mp a g e1 1 - 1 9 2 )

Checkthe IAC valve: the 3P connectorfrom Disconnect the IACvalve.

D16Y8enginewith M/T 81642engine) 1D16Y5, I Checkthe IACvalve: D i s c o n n e c tt h e 2 P c o n n e c t o r from the IACvalve.

Doesthe enginespeeddrop or the enginestall?

L

Adiust the {base}idle speod (see page 11-220- 2231.It it's imposaible,clean the ports in lhe throt' tle bodv,

( F r o mp a g e 1 1 - 1 9 2 i

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

Does the engine speed droP?

Adiust the idle speed (see page 11-220- 2231.lf it's impossible, reolacethe IAC velve.

D16Y7engine:

Ch€ck tor vecuum loaks, m.ke sure the throttle valve is com_ pletaly closed,end repair as nec-

UPPER PORT

1 1 - 19 3

ldle Control System ldle Air Control(lAClVatve('96- 98 Dl6ys, Dl6yB enginewith M/Tl The scan tool indicatesDiagnosticTrouble Code (DTC)P1508:A problem in the ldle Air ControtflAC)varve circuit. The IAC Valve changesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM in orderto maintainthe properidle speed.

The MIL hss b€on repo.ted on. DTCP'l508i. itorod.

Problemvorification: 1. Do the ECM/PCMResetProcedure, Startthe engine,and warm it uP to normal operatingtemperature.

ls DTCP1508indicated?

VALVE

Intormittont t!llur., sy.tcm b OK at thb tim6. Chsck fol poor conncctionr or loo3e wirot at C138 (lACvalv.l.nd ECM.

Check for an opcn in the wiro (lGPlline): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe IAC valve 2P connector. 3. Turnthe ignitionswitchON (ll). 4. Measurevohagebetweenbody ground and the IAC valve 2P connectorterminal No. 2.

IAC VALVE2P CONNECTOR ICl3A)

,flrcer

h-:J

iYEL/BLKI

!.__-,/

-lt (v)

-T -=

Wiresideof femaleterminals R.prir opan in the wiro botwa.n IAC valv..nd PGM-FImain r.l.y.

Chockfor an opon or sho in the wire (IACVlinal: 1. Turn the ignition switch OFF and reconnectthe IAC valve connector. 2. Disconnectthe ECMconnector A (32P). 3. Turnthe ignit;onswitchON (ll). 4. Measurevoltage between b o d y g r o u n da n d E C M c o n nectorterminalA12.

ECMCONNECTOR A I32PI

6

r5 t 6

12 t 3

tAcv (BLK/ ELUI

t*

25

&

l 7 t 8 t 9 20

a

10

ll

23

2a

a 2A 3o

Wire sideoI lemal€terminals (To page1l-195)

11-194

I ( F r o mp a g e1 1 - 1 9 4 )

Repair open or short in the wire between ECM lAl2l and IAC

Checkthe IAC valve Iunction: MomentarilyconnectECM conn e c t o rt e r m i n a l sA 1 2 a n d A 1 0 with a jumPerwire severaltimes. Wire sideof femaleterminals Doesthe IACvalveclick?

Substitute a known-good ECM and recheck. It symPtom/indication goes away, replacethe original ECM.

I

ldle Gontrol System ldle Air Control(lAG)Valve('99- 00 Dl6Y8 enginewith M/T, Bt6A2 enginel -[Fl50g

l ]h"

scan tool indicatesDiagnosticTrouble Code (DTC)P1508:A problem in the ldle Air Controt AC) vatve

CtrCUtt.

The IAC Valve changesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM in orderto maintainthe properidle speed.

The MIL has boon r€oorted on. DTCP1508is srored.

Probl6mverification: 1. Do the ECM/PCMResetProcedure. 2. Startthe engine,and warm it up to normal operatinglemperature.

VALVE ls DTCP1508indicated?

Intermittent tailure, system is OK at this timg. Check to. poor connoctions or loose wires at C138 {lAC valvel and ECM.

Ch6ck for an open in the wir€ {lGPllino}: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe IAC valve 2P connector. 3. Turnthe ignitionswitchON (ll). 4. Measurevoltagebetweenbody ground and the IAC valve 2P conneclor termina I No.2,

IAC VALVE2P CONNECTOR IC138'

la

I \

-

- d2 t,-

rcpr

{YEL/8LKI

Y-= Wire side ot female terminals

Repairopon in the wire bgtwoen IAC valve and PGM-Flmain relay.

Checktof an open or short in the wire {IACVline}l 1. Turn the ignition switch OFF and reconnectthe IAC valve 2. Disconnectthe ECMconnector B {25P). 3. Turnthe ignitionswitchON (ll). 4. Measurevoltage between b o d y g r o u n da n d E C M c o n n€ctorterminal823. Wire side of lemale terminals (Topage11-197)

1 1 - 19 6

t { F r o mp a g e1 1 - 1 9 6 )

ls therebatteryvoltage?

Repair opon or short in lhe wire between EcM lBzl) and lAc valve.

Checkthe IAC valve fundion: MomentarilyconnectECM connectorterminals823 and 82 with a iumpe.wire severaltames. Wire sideof femaleterminals Doesthe IACvalveclick?

Substitute a known-good ECM and rocheck. ll symptom/indicdtion go€s away, rePlacetho origi_ nal ECM.

I

11-197

ldle Control System ldle Air Control(lAC)Valve('96- 98 A/T and Dl6Y7 enginel TroubleCode(DTC)P1509:A problemin the idleAir Control(tAC)valvecircuit. 1P1509 ThescantoolindicatesDiagnostic The (Rotary)IAC Valvechangesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM/PCMin orderto maintainthe properidle speed,

BIMETAL The MIL has b€€nroportedon. DTCP1509is stored. Problemverification: 1. Do the ECM/PCMResetProceoure. 2. Turnthe ignitionswitchON (ll). ls DTCP1509indicated?

SHAFT

STOPPER

Intermittent failura, systom ia OK at this time. Checktor poo. connoctions or loose wires at C109 llAC valve) and ECM/PCM. ECM/PCMCONNECTOR A I32PI PGl IBLKI

Checkfor an opon in the wirer {PGlines): Measurevoltage between bodv ground and ECM/PCIIconnector terminalsA10 and A23 individu

ls theremorethan 1.0V?

VALVE

Repairop€n in the wires betwoen ECM/PCMand G101llocatedat tho thermostat housing). Wire sideof lemaleterminals

Chock th€ ECM/PCM inpui voltagel 1. Turnthe ignitionswitchOFF. 2. DisconnectECM/PCMconnector A (32P)fromthe ECM/PCM. 3. Turnthe ignitionswitchON (ll). 4 . M e a s ur e v o l t a g e b e t w e e n b o d y g r o u n da n d E C M / P C M connectorterminalsA14 and A13* individually.

1 2 3 a 5 6 E l0 12 1 3 1 4 r 5 1 6 1 7 1 8 t9 20 2:2 23 27 2A A 30

rAcvN loRNl*

IACVP {BLK/BLUI

(To page 11-199)

Ch6ckth6 IAC valve: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe IAC valve 3P connector, 3, Measureresistancebetween IACvalve3P connectortermin a l N o . 2 a n dt e r m i n a l N s o.1 a n d3 i n d i v i d u a l l y . ls there 16- 28 g?

Substitute a known-good ECM/ PCM and recheck. lf symptom/ indication goos away, replace th€ origin.l ECM/PCM. *: IACV N line

11 - 1 9 8

IAC VALVE3P CONNECIOR

IACV N

IACV P

IGP Terminalsideof male terminals

11

21

t

lFrompage11-198)

IAC VALVE3P CONNECTOR IClG'} Chock for an opon in tho wilo (lGPlins): '1. Turnthe ignitionswitchOFF. 2. Disconnectthe IAC valve 3P connector, 3. Turn the ignitionswitchON (ll), 4. At the wire hamess, measure voltage between IAC valve 3P connectorterminalNo. 2 and body ground. ls there bafteryvoltage?

l l

IGPIYEL/BIX)

Raprir op€n in th€ wirc botw.€n th. IAC vrlv6 and PGM.FI mtin rehy.

Check for rn open in tho wil.s (IACVP,IACV Nr linesl: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/rcM connecrorA (32P). 3. Checkfor continuity between IAC valve 3P connecto.terma_ nal No. 3 and ECM/PCMconn e c t o r t e r m i n a l A 1 4 ( an d betweenIAC valve 3P connector terminal No. 1 and ECM/ rcM connectorterminalA13l*.

IACV N

toRNt*

t

IACV P (BLK/8LU}

I

ECM/PCM CONNECIOR A (32P)

Ropairopan in tha wito bgtwoon ths IAC vrlv! rnd ECM or PCM {A14,413.1.

Checkthe IACV.lvo: 1. Disconnectthe IAC Valve 3P 3. Measureresistancebetween IAC Valve 3P connectorterminai No. 2 and terminalsNo. 1 and No.3 individuallY.

o ,

I

Check for e lhort in tho wiros (IACVe nCV Nr linc): C h e c kf o r c o n t i n u i t y b e t w e e n body ground and ECM/PCMconn e c t o rt e r m i n a l sA 1 4 a n d A 1 3 * individually. ls therecontinuity?

IACV P (BLK/BLU} t

m a 3o

1Z 13 ta 1 5 l 6 1 7 ta l 9 25

21

i6

x2

l0

't1

23

21

Wirc sideof lemaleteaminals Rapair rhort in thr wi]. batwaon th. IACv.lvc .nd ECM/PCfvl{A14,

,|

31.

Ar3.t.

12 t3

r .l r st5

1 1 r8 t 9 20

27

2a A 30

tAcv N (oRNt*

5

7

a

I

l0

tl

22

23

2a

IACVP (BLK/SLU}

IAC VALVE3P CONNECTOR

IACVP ls there16- 28 O?

rla

Subrtituto a known-good ECM/ PCMand r€ch€d( lt .vmptom/indi calioo gp€. .way, ruplacetho odgi ml Eqvt/FCM. -: IACVN line

Terminalsideof mal6 tetmtnats

11 - 1 9 9

ldle Gontrol System ldle Air Control{lAClValve('99- 00 A/T and Dl6Y7 enginel TroubleCode(DTC)P1509:Aprobleminthe idleAirControl(lAC)valvecircuit. 1P1509 lThescantool indicatesDiagnostic The (Rotary)IAC Valvechangesthe amount of air bypassingthe throttle body in responseto a currentsignalfrom the ECM/PCMin orderto maintainthe properidle speed. BIMETAL HOLDER

BIMETAL Tho MIL has b€enreportedon. OTCP1509is sto.ed. Problemverilicationr 1. Do the ECM/PCMResetProcedure. 2. Turnthe ignitionswitchON (ll). ls DTCP1509indicated?

SHAFT Intermittont tailure, sy3tem i3 OK at thb time. Checkfor poor con' noctions or loose wiros at C109 (lAC velvel and ECM/PCM.

VALVE

STOPPER

ECM/PCMCONNECTOR B {25P}

Checkfor an oDen in the wilos IPG linesl: Measurevoltage between body ground and ECM/PCMconnector terminals82 and 810 individually. ls theremorethan 1.0V?

Ropail open in the wires be'tw€en ECM/PCM .nd G101 llocated .t the the.mostat housingl. Wire sideof femaleterminals

Check tho ECM/PCM input voltage: 1. Turnthe ignitionswitchOFF. 2. DisconnectECM/PCMconnector A (32P)tromthe ECM/PCM. 3. Turn the ignitionswitchON (ll). 4, Measurevoltage between body ground and ECM/PCM c o n n e c t o tr e r m i n a l s8 6 a n d 815* individually. (To page11-201)

Chockthe IACv.lve: 1. Turnthe ignitionsw;tchOFF. 2. Disconnectthe IAC valve 3P connoctor. 3. Measureresistancebetween IACvalve3P connectortermi' nal No. 2 and terminalsNo. 1 and 3 individually. ls there16- 28 O?

YES Sub3titute e known-good ECM/ PCM .nd recheck. lf 3vmptom/ indicalion goos away, replac6 thc original ECM/PCM. *: IACV N line

11-200

IAC VALVE3P CONNECTOR

IACV N

IACVP

IGP Terminal side of male terminals

I (Frompage11 200)

{C1O9I IAC VALVE3P CONNECTOR Check toi an open in thg wire {lGPline): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe IAC valve 3P connector. 3. Turnthe ignitionswitchON (ll) 4, At the wire harness,measure voltage between IAC valve 3P connectorterminalNo. 2 and body gro!nd.

IGP(YEL/BLK)

Wire sideof femaleterminals

Repairopen in the wire between the IAC valve and PGM-FI main reraY.

I

Checkfor an open in the wires IIACVP. IACVN' lines): 1. Turnthe ignitionswitchOFF. conthe ECM/PCM 2. Disconnect nectorA (32P). 3. Checklor continuitybetween IAC valve 3P connectortermi' nal No. 3 and ECM/PCMconn e c t or t e r m i n a l B 6 ( a n d beNveenIAC valve 3P connec t o r t e r m i n a lN o . 1 a n d E C M / terminal815)*. PCMconnector

IACV N (oRN)*

ECM/PCM B (25PI CONNECTON Repairopen in the wiro ltstwcen the IAC valvo and €CM/PCM (86, 815'1.

Check for a shon in the wires (IACVP, lACv N* linesl: C h e c kf o r c o n t i n u i t y b e t w e e n conbody ground and ECM/PCM n e c t o r t e r m i n a l s8 6 a n d 8 1 5 * individually. ls therecontinuity?

IACVP {BLK/BLU'

IACV N (oRNt.

IACV P IBLK/BLUI

Wire sideof femaleterminals

Reoairshort in the wiro Mweon the lac valve end ECM/FCM(86, 815*).

Checkthe IAC valv€: l. Disconnectthe IAC Valve 3P connector, 2. Measureresislancebetween IAC Valve 3P connectortermi nal No. 2 and terminalsNo 1 and No.3 individually

N

IACVALVE3P CONNECTOR ls there16- 28 O? IACV N

L

Substituta . known-good ECM/ PCM and rochcdc f 3ymptom/indi cation go€a away, r€dace the origi nal ECM/Pqvl.

IACV P

IGP Terminal side of male

"r IACVN line

11-201

ldle Control System StarterSwitch Signal('96- 98 Models,'99- 00 D16Y5enginewith M/Tl when the engineis cranking. Thjs signalsthe ECM/PCM NOTE: . A/T:Transmission in E or E position . M/T:in neutral ECM/PCMCONNECTORS Checktor an open or short in the wire ISTSlinel: Measurevoltage betweenECM/ PCMconnectorterminalsA9 and C6 with the ignitionswitchin the startlllli position.

a l32Pl LGl {BRN/BLKI 1

2

l 2 l 3 l a 1 5 ! 6 1 7 1a 1 9 20

25

2l

6

STS IBLU/ORNI

9

10

22

It

2a

3

5

6

7

a 9 l0

t t 12 t3 l 4 t 5 t 6 1 7 1E

2A 7t 30

23 2a

29 30

Wire sideot femalelerminals

Inspectthe No. 31 STARTERSIGNAL (7.5A) fuse in the underdash fuse/relaybox.

Staner 3witch signal is OK. -

Repair opon in th6 wiro botwean (C6)and the No.31 ih. ECII4/PCM STARTERSIGNAL{7.5Al tulo.

11-202

Repair .hort in the wire botwoen tha ECM {C6l and tho No, 31 STARTERSIGNAL { 7 . 5A l t u s s o r t h e P G M - F I main relay, Roolac. the No. 3'l STARTER SIGNALl?.5 Al tu3€.

StarterSwitch Signal('99- 00 ModelsexceptDl6Y5 enginewith M/T) \ when the engineis cranking This signalsthe ECM/PCM NOTE: . M/f: Clutchpedalmust be depressed. . A,/T:Transmission in E or E position ECM,/PCM CONNECTORS Ch€ckfor an open or short in the wire {STSlinel: Measurevoltage betweenECM/ P C [ / |c o n n e c t o rt e r m i n a l sA 2 4 and 820 with the ignitionswitch in the startposition(lll).

SIGInspectthe No.31 STARTER NAL(7.5Alluse in the under-dash W;resideof femaleterminals Staner 3witch signal is OK. -

I Repairopen in the wirc betwean the ECM/PCMlA24) and the No. 31 STARTERSIGNAL{7.5Alfuse.

Repair3hort in tho wire be' tween tho ECM/PCM lA24) and tho No. 31 STARTERSIGNAL 17.5Al fuse or the PGM-FI mein relay. ReDlacothe No. 31 STARTER SIGNAL17.5Al fuse.

ldle Gontrol System Air GonditioningSignal('96- 98 Models,'99 - 00 Dl6Y5 enginewith M/Tl This sjgnalsthe ECM/PCM when there is a demandfor coolingfrom the air conditioningsystem.

ECM/PCMCONNECTORS

a {32P1

c l3lPl

LGl IBRN/8LKI

C h e c kf o r a s h o r t i n t h e w i r e {ACSline): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe A/C pressure switch 2P connector {see sec tion 22). 3. Turnthe ignitionswitchON (ll). 4 . M e a s u r e v o l t ag e b e t w e e n E C M / P C Mc o n n e c t o rt e r m i nalsC5 and A9.

ls thereapprox.5 V?

2 3 6 1 I 12 't3 1 a l 5 l 6 1 7 t 8 t 9 20 25

2l

ACS {BLU/RED)

9

't0

It

t

3

a

23

2a

ll

12 l 3

l!a

2A 29 30

t0

29 30

ACS(BLU/BEDI

Checkfor a .hort in the wi.e {ACS line): 1. Turnthe ignitionswitchOFF. 2. Disconnect the ECM/PCM connectorC (3lPi. 3. Checktor continuitybetween b o d y g r o u n da n d E C M / P C M connectorterminalC5,

Reotir short in the wi.e between the ECM/PCMlc5l and rhe A/C pressureswitch.

-

-

Substitute a known-good ECM/rcM .nd re.fieck. f Drescribed voltage is now avail tble, replace the original ECft4/ PCM, See the air conditioner inspetion ls€e s€ction 221. 1

2

LGl IBRN/BLKI

a

3 25

s l s l r l l o l g lr o l r r I 16 y ) n l t s l n l / @ ) z r I z r I 27

1!M1

1-/r

ACC

IBLK/RED)

11-204

9

'tE

Wire sideof femaleterminals

1 2 1 3 1 4 l5 (To page11-205)

17

23 2a 25

ls there continuity?

Check tor an op€n in the wire IACClin6l: 1. Turnthe ignitionswitchOFF. 2. Reconnectthe A/C pressure switch 2P connector. 3. Turnthe ignitionswitchON (ll). 4 . M o m e n t a r i l yc o n n e c tE C M / PCM connectorterminalsA9 a n d A 1 7 w i t h a j u m p e rw i r e

8 i 5 !6

JUMPERWIRE

(Frompage11-204) UNDER.HOODFUSE/BELAY BOX 9P CONNECTOR 1C352) Check for an open in the wir€ (ACClinel: Momentarilyconnectunderhood fuse/relaybox 9P connectorteF minal No. 5 to body groundwith a iumperwire severaltimes.

ls therea clickingnoisefrom clutch? the IVCcompressor

1

2 5

JUMPER WIRE

I

a

8

9

(BLK/RI ACC(BLK/REDI Wiresideof female terminals

See air conditionor inspection (see3oction221.

ls therea clickingnoisefrom the Py'Ccompressorclutch?

Repairopen in the wire between r h e E C M / P C Ml A l 7 l a n d t h 6 under-hood fu3e/rolaY box 9P connectorlC352l.

r f

ECM/PCMCONNECTORS

A t32P) Check for the oPeration of the Alcl 1. Startthe engine. 2. Turnthe blowerswitchON 3. Turnthe AJCswitchON.

c {31Pl ACSIBLU/RED)

LGl (BRN/BLK) I

2

a

3

9

12 1 3 1 5 l 6 1 1 l a 1 9 20 2A 29 30 27 25

10

1t

23

2a

I 3 t t 12 't3 l a 't5 t 6 1 7 t a 23 2a

8

9 t0

29 30

Wire sideof lemaleterminals

Doesthe Ay'Coperate?

Chock tor an open in the wire IACSlinel: Measurevoltage betweenECM/ PCMconnectorterminalsA9 and c5.

Air conditioning signal is OK. l s t h e r e l e s st h a n 1 . 0 V ?

-

t

-

Substiiute a known-good ECM/PCM and recheck ll symptom/indication 9oes a w a y , . o p l a c et h e o r i g i n a l ECM/PCM. Seethe air condhionerinsP€c_ tion {sees€c{ion22).

Repair open in the wire b€tween the EcM/PcM lC5) and the A/c 3witch.

ldle Control System Air ConditioningSignal('99- 00 ModelsexceptDl6Y5 enginewith M/Tl This signalsthe ECM/PCM when there is a demandfor coolingfrom the air conditioningsystem. ECM/PCMCONNECTORS a l32P)

C h o c kt o r a s h o r t i n i h e w i . e (ACSlin6): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe A/C pressure switch2Pconnector. 3. Turn the ignitionswitchON (ll). 4. Measurevoltage between E C M / P C Mc o n n e c t o rt e r m i nalsA27 and 820.

ECM/PCMCONNECTOR A {32P) Checkfor a short in the wire (ACS linel: '1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMcon nectorA (32P). 3. Checklor continuitybetween body ground and ECM/PCM connectorterminalA27. Wire sideof femaleterminals

Reoairshort in lhe wi.e botweon the ECM/PCM(A271and rhe A/C pressureswilch.

Check to. an opon in tho wi.e (ACClinel: 1. Turnthe ignitionswitchOFF. 2. Reconnectthe A/C pressure switch 2P conneclor. 3. Turnthe ignitionswitchON (ll). 4 . M o m e n t a r i l yc o n n e c tE C N 4 / PCMconnectorterminalsA17 a n d 8 2 0 w i t h a j u m p e rw i r e

Srr66titutoa known{ood ECM/ PCt4tnd rechock. It prascrib€d voltage is now available, replac€the originalECM/rcM. Soothe air conditionerinsoection {see s€ction 22}.

ECM/PCMCONNECTORS A (32P1

(To page '!1-207)

LGl {BRN/BLK)

11-206

I (Frompage11-206) FUSE/RELAY UNDER-HOOO

sox 9PcoNNEcroR lca52l ls therea clickingnoisefrom the Iy'Ccompressorclutch?

Check for an open in the wite IACClino): Momentarilyconnectunder_hood luse/relaybox 9P connectorteF minal No. 5 to body groundwith a jumperwire severaltimes.

JUMP€R WIRE

1

2

3 a

5

6

8

9

ACC(8LK/REDI Wire sideof f e m a l e terminals

ls therea clickingnoiselrom the ly'C compressorclutch?

Ropairopen in tho wilo betwg€n the ECM/PCMlA17) and the A/C clutch rolay.

S6e air conditioner insPoction l3oasection221

ECM/PCMCONNECTORS A (32P1

Chock for the oporation of lho AIC: 1, Startthe engine. 2. Turnthe blowerswitchON switch ON. 3. Turn the ray'C

Doesthe Iy'Coperate?

Check lor an open in the wiro (ACSlino): Measurevoltage betweenECM/ P C M c o n n e c t o rt e r m i n a l sA 2 7 and 820.

Air conditioningsignal is OK. ls voltagelessthan1.0V?

-

-

Wiresideof {emaleterminals

Repair op6n in the wiro bctwoon lhe ECM/PCMlA27l and tho A/C 3witch.

Sub6iitut€ r known€ood ECtt / PCM and rccheck. ll sYmPt o m / i n d i c a t i o n9 o e 3 . w a Y , replacathe originalECM/PCM Seethe ai. condhionGrin3p€ction lseesoc{ion221.

11-207

ldle Control System Alternator(ALTIFRSignal{'96- 98 Models,'99- 00 Dl6y5 enginewith M/Tl This signalsthe ECM/PCM when the Alternator(ALT)is charging. ECM/PCMCONNECTORS

Inspoctionof ALT FRSignal.

a {32P) LGl (BRN/BLK) Check tor a short in tfte wire (ALT F linel: 1. oisconnectthe 4P (3P)*connectorfrom the ALT. 2. Turnthe ignitionswitchON (ll). 3 . M e a s ur e v o l t a g e b e t w e e n E C M / P C Mc o n n e c t o rt e r m i nalsC17and A9.

ls thereapprox.5 V?

Checkth€ operation of the ALT: 1. Turnthe ignitionswitchOFF. 2. Reconnectthe ALT 4P (3P)* connectorto the ALT. 3 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutral)untjl the radiatorfancomeson,then letit idle. 4. [,4easu re voltage between ECM/PCMconnectorterminals C17andA9.

Does the voltage decrease when h e a d l i g h t sa n d r e a r d e f o g g e r a r e turned on?

c {31P)

ALT F {WHT/REO)

Wire sideof femaleterminals

Checklor a sho.t in the wire {ALT F line): r. I urn rne tgn|ltonswtlchul-f, 2. Disconnectthe negativebattery cablefrom the baftery. 3. Disconnectthe ECM/PCMcon nectorC {31P). 4. Checkfor continuitybetween b o d y g r o u n da n d E C M / P C M connector terminalC17.

1

7

1

11

12 1 3

8

I

a

30

10

14 15 16 17 18

23 21 25

ALTF IWHT/REDI

o

Repairshort in the wire betwe€n the ECM/PCM{Cl71andth€ ALT.

Substitute a known-good ECM/ PCM and recheck. It prescribed voltage is now available,roplace the originrl ECM/PCM.

ALT FRsignal is OK. ALT CONNECTORS IC1O4I 4P

Checktor an open in the wire (AlT F linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe negativebattery cablefrom the battery. 3 . D i s c on n e c t t h e E C M / P C M connectorC (31P). 4. Disconnectthe 4P (3P)*con, nectorfrom the ALT. 5. Connectthe ALT 4P 13P)lcon nectorterminalNo. 4 (No. 1)' to body groundwith a iumper

1

*: Canadamodel

11-208

2 l

Flr

rr-ri-f

rwHr/(V) neor Y

JUMPER WIRE

JUMPER WIRE

Wire sideof femaleterminals

6. Checklor continuitybetween b o d y g r o u n da n d E C M / P C M connectorterminalC17, ls therecontinuity?

3P*

3

Repair op6n wire botween th€ ECM/PCM(C171rndth€ ALT.

7

I

1 l 12 13 l4

15 16 17 18

23 21 25

o

8

9 10

E

30

/l

ALTF IWHT/REDI

t

M/T) Alternator(ALT)FRSignal('99- 00 ModelsexceptDl6Y5 enginewith when the Alternator{ALT)is charging This signalsthe ECM/PCM

ECM/PCMCONNECTORS

lnsoeclionoI ALT FB Signal.

Check{or a short in the wire {ALT F line): 1. Disconnectthe 4P (3P)+con nectorfrom the ALT 2. Turnthe ignitionswitchON (ll) 3. MeasurcvoltagebetweenEcM/ PCM connectorterminalsC5 and820.

ls thereaPProx.5 V?

l t

Checkthe operation otthe ALT: 1. Turnthe ignitionswitchOFF. 2 - R e c o n n e ct th e A L T 4 P ( 3 P ) * connectorto the ALT 3 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm wrth no load {in Parkor neutraliuntil t h e r a d i a t o rf a n c o m e s o n , then let it idle. 4- MeasurevoltagebetweenECM/ PCM connectorterminalsC5 and820.

D o e s t h e v o l t a g e d e c r e a s ew h e n h e a d l i g h t sa n d r e a r d e l o g g e r a r e turned on?

Check tor a short in the wirc (ALt F line): 1. Turnthe ignitionswitchOFF 2. Disconnectthe negativebat_ tery cablefrom the baRery' 3. Disconnectthe ECM/PCMcon' nectorC (31P). 4. Checkfor continuitybetween b o d y g r o u n da n d E C M / P C M connectorterminalC5

Wire sideof femaleterminals C (31P} ECM/PCMCONNECTOR ALT F (WHT/RED)

Wire sideof temaleterminals Repairshort in the wire between the EcM/PCM {C5land the ALT.

Substitute a known-good ECM/ PCM and rechock.lf P.esc.ibed voltage is now availabl€,ieplace tho original ECM/PCM

ALT FF signal is OK. IClO4I ALT CONNECTORS

3P*

lP

NO

--?-1 l 2 l |# i 3 l . l JUMpER otriJ rwxrr(V) WIRE neor Y

Checklor an op€nin the wire (ALT F line,: switchOFF 1. Turnthe agnition 2. Disconnectthe negativebattery cable{rom the battery. con' the ECM/PCM 3. Disconnect nectorC (31P). 4. Disconnectthe 4P (3P)*con' nectorfrom the ALT. 5. Connectthe ALT4P (3P)*connectorterminalNo 4 (No. 1)* to bodYgroundwith a iumper

JUMPER WlnE

Wire sideof femaletermlnals

C (31PI ECM/PCMCONNECTOR

6. Checklor continuitybetween b o d y g r o u n da n d E C M / P C M connectorterminalC5 Repair oPen wire betwoen t|lo ECM,/PCM{C5)and the ALT.

*: Canadamodel

Wire sideof femaletermrnals

ldle Control System BrakeSwitch Signal('96- 98 Models,'99 - 00 Dl6YSenginewith M/Tl This signalsthe ECM/PCM when the brakepedalis deoressed. Inspectionof BrakeSwitch Signal.

Are the brakelightson without depressing the brakepedal?

Depressthe brakepedal.

Inspectthe HORN(15 A) fuse in the under-hoodfuse/relaybox.

Do the brakelightscomeon?

-

Repair short in the wire betweenthe brake3whch and rhe HORN115At lu3e. Replacethe I|oRN 17.5A) tus€.

Repair open in the wire betweenthe brakeswitch and the HORN115Al fuse. Inspect th6 br.ke switch {s6€ section l9l. Check tor an open in the wire IBKSWline): 1. Oepressthe brakepedal. 2. Measurevoltage between ECM/PCNI connectorterminals Ag and D5with the brakepedal oepresseo.

ECM/PCMCONNECTOFS LGl

A (32Pt ,l

a

6

7

12 1 3 1 1 1 5 1 6 1 7 t 8 1 9 20

25

ls there battery voltage?

Brakc switch sign.l is OK.

11- 2 1 0

21

2A

D {16P)

IBRI\v 8 22

a 30

Repairopen in the wire b€tween the ECM/PCM{Dsl and the brake switch.

10

11

23

2a

1

2 I

13 14 1 5

BKSW (GRN/ WHTI

I

9 10 1 1 16

Wire sideof femalet€rminals

12

I

J

M/Tl BrakeSwitch Signal('99- 00 ModelsexceptDl6Y5 enginewith when the brakepedalis depressed This signalsthe ECM/PCM lnsoectionot BrakeSwitch signal.

Are the brakelightson without the brakePedal? depressing

Depressthe brakePedal

Do the brakelightscomeon?

Inspectthe HoRN {15 A} fuse in the underhood fuse/relaybox'

-

I

-

-

R.pair short in the wiro be' tween the brake switch and the HORN(15Alfuse. Replac€the HORN(15A) tuse.

Repair open in the wite be' tween the brako switch and the HORN(15Alfuse. lnsoect the brake switch (3ec section tgl. ECM/PCMCONNECTORS

Check fot an oPen in the wire {BKsw linel: 1. Depressthe brakePedal. 2. Measurevohagebeween ECM/ PCMconnectorterminalsA32 and 820 with the brakePedal depressed.

BKSW(GRN/WHTI

Bepair open in the wire between t h e E C M / P C M( A 3 2 ) a n d t h e brake switch.

LG1 {BRN/BLK) Wire side o{ female terminals

Brakeswitch signal i5 OK

ldle Control System (PSPISwitchSignal Pressure lgy"t9!"_"ring ('96- 98 Models,'99- 00 DlGy5enginewitn fU/f) (USAI This signalsthe ECM/PCN4 when the power steeringload is high. Inspectiono{ PSPswitch signal.

ECM/PCMCONNECTORS

Checkfor an opon in the wire {PSP SW linelr 1. Turnthe ignitionswitchON (ll). 2. Measurevoltage between E C M / P C Mc o n n e c r o rt e r m i n a l sA 9 a n dC 1 6 .

WiresideoI temaleterminals Checklor an open in the wire (PSP SW line): 1. Turnthe ignitionswitchOFF. 2. Disconnecl the PSPswitch2p

ls therelessthan1.0V?

3. Turnthe ignitionswitchON (ll). 4. At the harnessside, connect the PSPswitch 2P connector terminalN s o.l andNo.2 with a jumperwire. 5. Measurevoltage between ECM/PCMconnectorterminals Ag andC16.

PSPSWITCH2P CONNECTOR PSPSW IGRNI

JUMPER l--L w f R E- 2 /

GND(BLKI Wiresideol femaleterminais

Check the operation of the PSP switch: '1. Start the engine 2 . T u r n s t e e r i n gw h e e l t o f u l l

ls therelessthan 1.0V?

3 - M e a s ur e v o l t a g e b e t w e e n ECM/PCMconnectorterminals A9 andC16.

ls therebatteryvoltage?

PSP switch signel is OK.

11- 2 1 2

(To page 11'2'13)

II

-

Repair open in the wiro between the ECM/PCMlc16l and the PSPswitch. Repair open in BLK wire betwoen the PSP switch and G101.

t ( F r o mp a g e1 1 2 1 2 )

C h e c kl o r a 3 h o r t i n t h e P S P switch: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector from the PSPswitch. 3. Turnthe ignitionswitchON (ll) 4. Measurevoltage between E C M / P C Mc o n n e c t o rt e r m i nalsAg and C16.

ECM/PCMCONNECTORS

Wire sideof temaleterminals

'l

ls there batteryvohage?

Checktor a short in the wiro {PSP SW linel: '1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMcon nectorC (31P). 3. Checklor continuity between b o d y g r o u n da n d E C M / P C M connectorterminalC16.

1

tl

2

a

6

1

8

9 t0

12 1 3 1 4 1 5 16 17 18

a 30

23 21 25

o

PSPSW (GRNI

Repairahort in the wire between the ECM/PCM(C16)and th6 PsP switch.

Substitute a known_good ECM/ PCM end rechock. lf Prescribed voltage b now avsilable. rePlace the original ECM/PCM.

1 -213

ldle Control System PowerSteeringPressure(PSP)Switch Signal ('99- 00 ModelsexceptDl6y5 enginewith M/T) (USAI This signalsthe ECM/PCM when the powersteeringload is high.

ECM/PCMCONNEgTORS

Inspoctionot PSPswitch signal.

Checkfor an op€n in the wire (PSP SW linel: 1. Turnthe ignitionswitchON (ll). 2. MeasurevoltagebetweenECN4/ PCMconnectorterminals426 and 820.

ls therelessthan1.0V?

Checkfor .n open in tho wire IPSP SW line): 1. Turnthe ignitionswitchOFF. 2. Disconnoct the PSPswitch2P connector. 3. Turn the ignitionswitchON (ll). 4. At the wire side,connectthe PSP switch 2P connector term i n a l sN o . 1 a n d N o . 2 w i t h a jumperwire. 5. MeasurevoltagebetweenECM/ PCNIconnoctorterminals 426 and 820.

Wiresideof femaleterminals (qts6) PSPSWTTCH 2P CONNECTOR PSPSW (GRN) JUMPERT---7

wlRE LJ-

1

\

2-l

GNDIBLK) Wi16sid6 of temale terminals -

Check the operation ot the PSP sw;tch: '1. Start the engine 2. Turn steeringwheelslowly. 3. MeasurevoltagebetweenECM/ PCM connectorterminals 426 and 820.

ls therelessthan 1.0V?

ls there batteryvoltage?

PSP switch sign8l i3 OX.

1 1-2 1 4

( T op a g e1 1 - 2 1 5 )

-

Ropai. opgn in ths wire betw.€n the ECM/PCM {A261 rnd th6 PSPswitch. Ropsir opon in BLK wi.o botwoen tho PSP switch and G101.

\ (Frompage11'2141

ECM/PCMCONNECTORS

C h e c kl o r a s h o r t i n t h o P S P swhch: 1. Turnthe ignitionswitchOFF 2. Disconnectthe 2P connector from the PSPswitch 3. Turn the ignitionswitchON {ll) 4. MeasurevohagebetweenECW PCMconnectorterminalsA26 and 820. Wire sideof femaleterminals A I32P) ECM/PCMCONNECTOR

'l'

Ch6ckfor a short in tho wiro IPSP SW lino,: 1. Turnthe ignitionswitchOFF 2. Disconnectthe ECM/PCMconnectorA (32P). 3. Check for continuity betweon body ground and ECM/PCM connectorterminalA26 Wiresideof lemaleterminals Rogair short in the wiro b€{woon the ECM/PCM(A26)and the PSP switch.

Substitute a known_good ECM/ PCM rnd r.check. lf Prdcribod vohago is now avaihblo' rcPl.co the original ECM/PCM

-215

ldle Control System AutomaticTransaxle(CVTIGearPositionSignal ('96-98 D16Y5enginewith CW) This signalsthe ECMwhen the transmissionis in @ or @ position.

Checkthe operationoI the A/T gear position switch: 1. Turnthe ignitionswitchON flt). 2. Observethe A/T shift position indicatorand selecteachposi tion separately.

See lhe A/T gear position indicator insp€ction{seesec{ion l/tl.

Check tor a short in the wir6 (ATp NPline): 1. Turnthe ignitionswitchOFF. 2. Disconnect the 14Pconnector Irom the gaugeassembly. 3. Disconnect the 26Pconnector from the TCM. 4. Turnthe ignitionswitchON fll). 5. MeasurevoltagebetweenECM c o n n e c t o tr e r m i n a l sA 9 a n d c29.

ls thereapprox.5 V?

Check for an open in the wire lATp NP lina): 1. Turn the ignition switch OFF_ 2. Beconnect the 14P connector to the gauge assembly. 3. Reconnectthe 26P connector to the TCM. 4 . S t ar t t h e e n g i n e . 5. Measure voltage between ECM connector terminals A9 and C29 with the transmis sion in E and E posationt

( T op a g e1 1 ' 2 1 7 )

11-216

Wire side ot female terminals

Checkfor a short in the wire lATp NPlinell 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM connec tor C (31P). 3. Checkfor continuitybetween b o d y g r o u n da n d E C M c o n nectorterminalC29.

2

4

ATP NP {LT GRNI

5

7

t 1 12 1 3 1 a 1 5 1 5 1 7 1 8 23 21 25

I

9 10

29 30

o

ATPI N P (LT G i BN)

Repairshort in the wire between t h e E C M { C 2 9 1a n d t h e g a u g e assemblv,

Substitute a known-good ECM and recheck. lf prescribed voltage is now avrilable, replace the o.iginalECM.

t ( F r o mp a g e1 1 - 2 1 6 )

ls therelessthan 1.0V?

-

-

Repair open in the wire between the ECM {C291and lhe Ituge assomblv. Repair open in the wire betwoen the gauge assembly and the A/T gea. Position switch.

ECMCONNECTORS

LG1 IEBN/BLK) Chockfor a short in the wite (ATP NP line): Measurevoltage between ECM connectorterminalsAg and C29 in gear. with the transmission

ls there batteryvoltage?

A/T g€ar position signal is OK

L

ReDairshort in the wire be'tween ECM(C291and gauge a3somblY.

Wire sideof femaleterminals

ATP NP (LTGRN)

ldle Control System ClutchSwitch Signal(Dl6YSenginewith M/Tl { This signalsthe ECMwhen the clutchis engaged. Inrpactionot dutch rwitch signal.

ECMCONNECTORS

A {32P}

LGl (BRN/BLK)

Check for on opon in the wiro (CLSWlinel: '!. Turnthe ignition switchON (ll). 2. MeasurevoltagebetweonECt!4 connectorterminalsC29 and A9. Wire sideof femaleterminals

ls thare approx. 5 V?

Ch.ck tho clutch switch: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector from the clutch switch. 3. Turn the ignitionswitch ON (ll). 4. Measurevoltageb€tweenECM connectorterminalsC29 and

\-

(

ls thereapprox.5 V?

Chcck for an open in thg wire {CLSWlinel: 1. Depressthe clutchpedal. 2. MoasurevoltagebetweenECM connectortorminalsC29 and A9.

Check for a short in th6 wire (CLSWline)l 1. Turnthe ignitionswirchOFF. 2. Disconnectthe ECM connec tor C (31P)tromthe ECM. 3. Checklor continuitybetween ECM connectorterminal C29 and body ground.

2 1 l 12 t 3

6

'ta t 5

l6

1

8

1 7 l8

9 10 22

o

cLsw (RED}

Repairshort in the wirc between t h o E C M { C 2 9 1a n d t h o c l u r c h switch.

(Topage11-219)

Sub3titutg a known-good ECM and rechock, It p.e3cribed vohago i! now available,roplacethe original ECM.

! 11- 2 1 8

a

{ F r o mp a g e1 1 - 2 1 8 ) CLUTCHSWITCH2P CONNECTOR

ls voltagelessthan 1.0V?

j-t

Checklho clutch switch: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector from the clutch switch. 3. Checklor continuitybetween the clutch switch connector terminalsNo. 1 and No.2 with the clutchpedaldepressed

-

Terminalsideof male termrnals

-

Adiu3t the clutch swiich. Reolacelhe clutch switch.

{C41', CLUTCHSWITCH2P CONNECTOR

-f--r Checkfor an open in tha wiie: 1. Turnthe ignitionswitchON lll) 2. Measurevoltage between the clutch switch connectorterml' nal No. 1 and body groundwith the clutchpedaldepressed.

I

ls thereapprox.5 V?

I-l_' l ' l clsw 1;1 tREDr Y Wire 6ide of lemale terminals

Repairop€n in the wire betwoen the EcM (C291and thc clutch swilch.

Repairopen in BLKwire between the clutch switch and Gircl.

Clutch switch signal is OK.

l r , 11-219

ldle Control System ldle SpeedSetting Inspection/Adiustmenl '96, '97 Dl6Y5. '96 - 00 Dl5Y8 sngine with M/T NOTE: . B e f o r es e t t i n gt h e i d l e s p e e d ,c h e c kt h e f o l l o w i n g items: - The MIL has not beenreportedon. - l g n i t i o nt i m i n g - Sparkplugs - Aircleaner - PCVsystem ) u l l t h e p a r k i n gb r a k el e v e r u p . S t a r tt h e o ( C a n a d aP engine,then checkthat the headlightsare off. 1.

Startthe engine.Hold the engineat 3.000rpm with no load (taansmission in neutral)until the radiator fan comeson, then let it idle.

2.

Connecta tachometer.

3.

Disconnect the IACvalveconnector.

Adjustthe idle speed,if necessary, by removingthe cap and turningthe idle adjustingscrew. NOTE; After adjustingthe idle speed in this step, recheckthe ignitiontiming (seesection23). lf it is out of spec,go backto step4. IDLE

6. Turnthe ignitionswitchOFF. 7. Reconnectthe 2P connectoron the IAC valve,then do the ECMresetprocedure. 8. Restartand idle the enginewith no-loadconditions for one minute,then checkthe idle speed. ) u l l t h e p a r k i n gb r a k el e v e r u p . N O T E :( C a n a d a P Startthe engine,then checkthat the headlightsare off. ldle sp€sd should b€: 670 i 50 rpm IUSA) 750 t 50 rpm {Canada} 9. ldle the enginetor one minutewith headlights{Low) ON.and checkthe idlespeed.

4.

lf the enginestalls,restartthe enginewith the acceleratorpedalslightlydepressed.Stabilizethe rpm at 1,000,then slowly releasethe pedaluntil the engine idles.

ldle speed should be: 750 :r 50 rpm 1 0 . T u r n t h e h e a d l i g h t so f f . l d l e t h e e n g i n ef o r o n e minutewith heaterfan switchat Hl and air conditioner on,thencheckthe idlespeed.

Checkidlingin no-loadconditionsr headlights. blower fan. rear defogger,radiatorfan, and air conditioner are not operating.

ldle speed should be: 8 1 0 1 5 0r p m

ldle spsedshouldbe: 450 1 50 rpm

NOTE:lf the idle speed is not within specification, seeSymptomChan on page 11-84.

11-220

t '96.'97 D16Y5enginewith CVT,'96 - 00 D16Y8ongins with A/T and'96 - 00 Dl6Y7 €ngine

D16Y5,D16Y8engine: IDLE ADJUSTING

Adiustthe idle speedusing a HondaPGM Testerif possible.lf not, usethe followingprocedure: NOTEI . Leavethe IAC valve connected . Betore setting the idle speed. check the following items: - The MIL has not beenreportedon' - lgnitiontiming - SparkPlugs - Air cleaner - PCVsystem 1.

Connecta tachometer.

2.

Startthe engine.Hold the engineat 3,000rpm wirh n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n comeson, then let it idle.

3.

I

Checkthe idle speedwith no-loadconditions:headiights, blower fan, rear defogger,radiatorfan, and air conditionerare not operatlng

Dl6f, ongine: NOTE:When you removethe ACL housing,do not disconnectthe IAT sensorconnector

ldl€ spoed should be: USA: D16Y5engine with CVT, D16Y7engine with A/T' Dl6YB engine with A/T: 700 :r 50 rpm (in E or El Positionl D16Y7engine with M/T: 670 i 50 rpm Canada: Dl6Y8 sngin€, Dl6Y7 engins: M/T

750t 50 rpm

NT

7501 50 rpm (in E or El Position)

by removingthe Adjustthe idle speed,if necessary, screw 1/2-turn adiusting idle the turning and cap clockwiseor counterclockwise

A f t e r t u r n i n g t h e i d l e a d j u s t i n gs c r o w 1 / 2 - t u r n ' checkthe idle speedagain.lf it is out of spec,turn the idle adjustingscrew1/2-turnagaan' NOTE: Do not turn the idle adjustingscrew more than 1/2-turnwithout checkingthe idle speed' l d l e t h e e n g i n e f o r o n e m i n u t e w i t h h e a t e rf a n switch at Hl and air conditioneron, then checkthe idle speed. ldle speed should be: M/T

8 1 0 1 5 0r p m

A/T. CvT 810t 50 rpm (in El or E Position)

t

NOTE: . Do not turn the idle adjustingscrewwhen the air conditioneris on. see . lf the idle speed is not within specification. (cont'd) SymptomCharton page 11-84

11-221

ldle Control System ldle SpeedSetting (cont'dl Inspeqtion/Adiustment 38 D16Y5engine whh M/T,'99 - 00 81642 engine NOTE:Beforesettingthe idle speed,checkthe following items; - The MIL has not beenreportedon. - lgnitiontiming - Sparkplugs - Air cleaner - PCVsystem '1.

lf necessary, adjustthe idle speed,by removrnglne cap and turningthe idle adjustingscrew. After adjustingthe idle speed recheckthe ignitlon timing (seesection23). lf it is out of spec,go back to step 4. |DLE

Startthe engine.Hold the engineat 3,000rpm with no load (transmissionin neutral)until the radiator fan comeson, then let it idle. Connecta tachometer. Disconnect the IACvalve2Pconnectorand the EVAP purgecontrolsolenoidvalve2P connector.

6. Turnthe ignitionswitchOFF. 7. Reconnectthe 2P connectorsto the IAC valve and the EVAPpurge controlsolenoidvalve,then do the ECM reset procedure.

EVAPPURGE CONTROL SOLENOIDVALVE

lf the enginestalls,restartthe enginewith the acceleratorpedalslightlydepressed.Stabilizethe rpm at 1.000,then slowly releasethe pedaluntil the engine idles. Checkidlingin no-loadconditions:headlights, blower fan, rear defogger,radiatorfan, and air conditioner are not operating. ldl€ speed should be: 450 i 50 rpm

8. Restartand idle the enginewith no-loadconditions for one minute,then checkthe idle sDeed. ldle speed should bo: USA: D16Y5engine: 670 i 50 rpm 81642 engine: 700 i 50 rpm Canada: 81642 engine: 750 t 50 rpm NOTE:lf the idle speedincreasesto 8lO t 50 rpm, this meansthe EVAPsystemis purgingthe canister. To stop the purging temporarily,raise the engine speedabove 1,000rpm with the acceleratorpedal, then slowly releasethe pedal. 9 . l d l e t h e e n g i n ef o r o n e m i n u t e w i t h h e a d l i g h t s (Low)ON. and checkthe idle speed. ldle speed should be: 750 i 50 rpm 1 0 . T u r n t h e h e a d l i g h t so f f . l d l e t h e e n g i n e f o r o n e minute with heaterfan switch at Hl and air conditioneron, then checkthe idle soeed. ldls speed should be: 810t 50 rpm l f t h e i d l e s p e e d i s n o t w i t h i n s p e c i f i c a t i o ns, e e SymptomCharton page 11-84.

11-222

\ '98 - 0OD16Y5ongine with CvT

6.

Removethe cap and turn the idle adiustingscrew 1/2-turnclockwiseor counterclockwlse IDLE

7.

After turning the idle adjusting screw 1/2-turn,check the idl€ speedagain.lf it is out of spec,turn the idle adjustingscrew 1/2-turnagain.

Adjustthe idle speedusing a HondaPGM Testerif possible.lf not, usethe followingprocedure: NOTE: . Leavethe IACvalveconnected. . Before s€tting the idle speed, check the following rtems: - The MIL has not beenreportedon. - lgnitiontiming - SparkPlugs - Air clean€r - PCVsvstem '1. Connecta tachometer. 2.

Stan the engine.Holdthe engineat 3,000rpm w'th in E or E] position)until the no load (transmission radiatorJancomeson, then let it idle.

3.

C h e c kt h e i d l e s p e e d u n d e r n o - l o a dc o n d i t i o n s : head lights, blower fan, rear defogger, radiator fan, and air conditionerare not operatlng. ldlo spaod ehould bo: 700 t 50 rpm

I

. . 4.

5.

NOTE: Do not turn the idle adjustingscrew more than 1/2-turnwithout checkingthe idle speed.

the lf the idle speed is within the specification, procedureis comPlete. lf the idle sDeedis out of specitication,9o to step 4'

tf the idle speed is 810 1 50 rpm, this means the EVAPsystem is purging the canister.To stop the purgingtemporarily,raisethe enginespeed above l,OO0rgm with the accelsratorpedal. Slowly release the pedal.and rscheckthe idl€ speed. . tf the idle speed is within the specificstion,the is comPlete. Drocedure . lf the idle sp€edis out of spocification,go to step 5. Disconnectth€ EVAPpurgs control solenoidvalve 2P connector.

Turn the ignition switch OFF.Reconnectthe EVAP purge control solenoidvalve 2P connector'then do the ECM reset Procedure. 9.

Startthe engine.ldlethe enginefor one minutewith heaterfan switch at Hl and air conditioneron, then checkthe idle speed. ldle spaed should be: 810 t 50 rpm (in El or E Posiiion) lf the idle speed is not within specification,see SvmptomCharton Page11-84.

EVAPPURGE CONTROL SOLENOIDVALVE

11-223

Fuel Supply System FuelLines NoTE: Checkfuel systemlines,hoses,fuel filter,and other componentslor damage,leaksand deterioration, and replace if necessary.

t/ ,ee.-

4/

;

Tl

/.,/

...,.'

..4,/

i,/ I

22 N.m (2.2kgt.m,16lbf.ft) (D16Y5engine:28 N.m 2.8 kgtm, 21 lbf ft) The illustration shows'99 00 models.

11-224

I

'96 - 98 models: NOTE:Checkall hoseclampsand retightenif necessarY.

M /v

FUEL FILTER

PRESSURE REGULATOR

I

FUEL TANK FUEL GAUGE SENDING UNIT

BASEGASKET Replace.

C l a m pI n r h e m i d d l e

@ C l a m pi n t h e m i d d l e

10-14mm (0.39- 0.55inl (cont'd)

11-225

Fuel Supply System FuelLines(cont'dl .99 - 00 models: NOTE:Checkall hoseclampsand retightenif necessary. : Do not disconnectthe hosefrom the pipe.

VAPOR ONBOARDREFUELING BECOVERY IORVRI VENT SHUTVALVE

FUEL GAUGE

lt N.rn l1.a kgt.m, r0 lbt ftl

B

ftr, n'fo'

PRESSURE REGULATOR

Clampin the middle

Clampin the middle

11-226

I

I

Fittings FuelTube/Ouick-Gonnect Precautions

Disconnestion

Do not smoke while working on the fuel !@ system, Keepopen flames away from your work a.ea'

Do not smoke while working on the luel !@ system. Keep open llames away lrom youl work area.

fittings assemblyconnects The fuel tube/quick-connect the in tank fuel pump with the fuel feed pipe.For removi n g o r i n s t a l l i ntgh e f u e l p u m p a n df u e lt a n k ,i t i s n e c e s fittings. sary to disconnector connectthe quick-connect Payattentionto lollowing:

1.

Relievefuel pressure(seepages11'230,2311.

2.

C h e c kt h e t u e l q u i c k - c o n n e ct itt t i n g sf o r d i r t , a n d cleanif necessary.

3.

Hold the connectorwith one hand and pressdown the retainertabs with the other hand,then pull the connectoroff.

.

fittings assemblyis not The fuel tube/quick-connect h e a t - r e s i s t a nbt ;e c a r e f u ln o t t o d a m a g ei t d u r i n g procedures weldingor other heat-generating

.

fittings assemblyis not The fuel tube/quick-connect acid-proof;do not touch it with a shop towel which was used for wiping batteryelectrolyte.Replacethe fitlings assemblyif it came fuel tube/quick-connect into contactwith electrolyteor somethingsimilar.

.

W h e n c o n n e c t i n go r d i s c o n n e c t i n gt h e f u e l t u b e / q u i c kc o n n e c tl i l t i n g s a s s e m b l y ,b e c a r e f u ln o t t o Replaceit if damaged bendor twist it excessively.

NOTE: o Be carelulnot to damagethe pipe or other pans Do not usetools. . lf the connectordoes not move,keepthe retainer tabs presseddown, and alternatelypull and push the connectoruntil it comesoff easily. . Do not removethe retainerfrom the pape;once removed,the retainermust be replacedwith a new one. LOCKINGPAWL

quick-connect fittingcan be reconnecled, A disconnected b u t t h e r e t a i n e ro n t h e m a t i n g p i p e c a n n o tb e r e u s e d once it has been removed from the pipe. Replacethe retatnerwnen . R e p l a c i ntgh e f u e lp u m p . . Replacingthe fuel leed pipe. . lt has beenremovedlrom the PiPe. . lt is damaged. PANEL ACCESS

TAB BETAINER

CONNECTOR

4.

Checkthe contactareao{ the pipefor dirt and damage. . lf the surfacels dirty,cleanit. . lf the surface is rusty or damaged,replacethe fuel pump or fuel feed piPe.

PIPE

(cont'd)

11-227

Fuel Supply System FuelTube/Ouick-Connect Fittings(cont'd) 5.

To prevent damage and keep out toreign matter, c o v e r t h e d i s c o n n e c t e dc o n n e c t o ra n d o i o e e n d with plasticbags.

Connection

!s@

Do not smokewhile workingon the fuel

system. Keep open llames away from your work area. 1.

Checkthe pipe contact area for djrt and damage, and cleanif necessary,

CONTACTAREA

PI.ASIICBAGS

Insert a new retainer into the connector if the retainer is damaged, or after . replacing the fuel pump. . replacing the fuelfeed pipe. . removing the retainer from the pipe.

N.w RETAINER (lnsertinto the connector.)

11-228

t

fining Beloreconnectinga new fuel tube/quick-connect assembly,removethe old retainerfrom the matingpipe

4.

Make sure the connectionis secureand the pawls are firmly lockedinto place;checkvisuallyand by pullingthe connector.

with the tabs pulled apan,remove and discardthe retarner

RCTAINER

New FUELTUBE/ OUICK.CONNECT FITTINGASSEMELY

3.

I

Reconnectthe batterynegativecable,and turn the i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l r u n f o r a b o u t t w o s e c o n d s ,a n d f u e l p r e s s u r ew i l l r i s e . Repeattwo or three times, and checkthat there is no leakagein the fuel supplvsystem

Align the quick-connectfiftings with the pipe, and align the retainerlockingpawls with the connector fittings onto grooves.Then pressthe quick-connect the pipe until both retainerpawls lock with a clicki n gs o u n d . NOTE:lf it is hard to connect,put a small amount of new engineoil on the pipe end.

Connectionwith new retainer:

11-229

Fuel Supply System SystemDescription The fuel supply system consistsof a fuel tank, in-tank high pressurefuel pump,PGM-FImain relay,fuelfilter, fuel pressureregulator,fuel injectors.and fuel delivery and return lines. This system delivers pressure-regulatedfuel to the fuel injectorsand cuts the fuel delivery when the engineis not running.

Inspoction 1.

Relievefuel pressure.

2.

Removethe service bolt on the fuel filter while holding the banjo bolt with anotherwrench.Attachthe specialtool.

FuelPressurel'96 Modelsl Relieving Beforedisconnectingfuel pipes or hoses,releasepressure from the system by looseningthe 6 mm service bolt on top of the fuel filter.

.

. 1. 2. 3. 4.

5. 6,

Do not smoke whil6 working on the fuel system. Kgsp opon flames or sparks away from youl work area. Be sure to relieve fuel pressurewhile the ignition switch is off. Write down the frequenciesfor the radio's preset buttons. Disconnectthe batterynegativecablefrom the battery negativeterminal. Removethe fuelfill cap, Use a box end wrench on the 6 mm servicebolt at the fuel filter while holding the specialbanjo bolt with anotherwrench, Placea rag or shop towel over the 6 mm servicebolt. Slowly loosenthe 6 mm servicebolt one complete rurn.

FUEL PRESSURE GAUGE 07406 - 00ir0(x)1

REGULATOB Startthe engine.Measurethe fuel pressurewith the engineidling and the vacuumhoseof the fuel pressure regulatordisconnectedfrom the fuel pressure regulatorand pinched.lf the engine will not start, turn the ignition switch ON (ll), wait for two seconds, turn it off, then back on again and read the fuel pressure. Pr€3sureshould bo: 260 - 310 kPa (2.7- 3.2 kgt/cmr, 38 - 46 psi) Reconnectvacuumhoseto the fuel pressureregulator, Pressureshould bo: 200 - 25OkPa l2.O- 2.5 kgf/cm', 28 - 36 psil lf the fuel pressureis not as specified,first checkthe fuel pump {seepage 11-2361. lf the fuel pump is OK, checkthe following: .

. .

.

A fuel pressuregaugecanbe attachedat the 6 mm servicebolt hole. Always reDlacethe washer betweenthe service bolt and the specialbanjo bolt wheneverthe service bolt is loosened. R e p l a c ea l l w a s h e r s w h e n e v e r t h e b o l t s a r e removeo.

11-230

.

l f t h e f u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d , inspectfor; - Pinchedor cloggedfuel returnhoseor line. - Faultyfuel pressureregulator(seepage 11-234). lf the fuel pressureis lower than specified,inspect for: - Cloggedfuelfilter. - Faultyfuel pressureregulator{seepage 11-234). - Fuelline leakage.

t

J

FuelPressure{'97and later Models) ReliGving Beforedisconnectingtuel pipes or hoses,releasepressure from the system by looseningthe 12 mm banjo bolt on top of the fuel filter.

Inspaqtion 1.

Relievefuel pressure.

2.

Removethe 12 mm banjo bolt from the fuel filter while holding the fuel Jilter with another wrench Attachthe specialtools. CLAMP

@ o Do not smoke whilo working on the fuel sy3lom. .

Ksgp op€n flames or sparks away tlom Your work arga. Be sure to relievefuel pressule while the ignition swhch is off.

1.

Write down the frequenciesfor the radio's preset buttons,

2.

Disconnectthe batterynegativecablefrom the battery negativeterminal.

3.

Removethe fuel fill cap.

4.

Use a box end wrench on the 12 mm banjo bolt at the fuel filter while holdingthe fuel filterwith another wrench. Placea rag or shoptowel overthe 12 mm banio bolt.

I

FUELPRESSURE BOLT,12mm ADAPTER tguxt8-PD6-0101

REGULATOR 3.

the fuel Pressurewith the Start the engine engine idling and the vacuum hose of the fuel pressure regulator disconnectedfrom the fuel pressure regulatorand pinched lfthe enginewill not start,turn the ignition switch ON {ll), wait for two seconds,turn it off, then backon againand readthe fuel pressure' Pr$3uro ehould be: excepi 816A2 sngine: 260 - 310 kPa {2'7 - 3.2 kgf/cm" 38 - {6 Fi} B16A2engine: 27O-32O kPa P.8 - 3'3 kgf/cm', '10- 47 psi)

4.

Reconnectvacuumhosoto the fuel pressureregulator' Pre33ure3hould be: except B16A2engin€: 2OO- 250 kPa {2.0- 2'5 kgf/cm', 28 - 36 psi) B16A2engino: 210- 260 kPa 121- 2.6 ksf/cm', 30 - 37 psi) lf the fuel pressureis not as specified,first checkthe f u e lp u m p( s e ep a g e1 1 - 2 3 6 l)f t h e t u e l p u m p i s o K , checktho following: . l f t h e f u e l p r e s s u r ei s h i g h e r t h a n s p e c i f i e d , inspectfor: - Pinchedor cloggedfuel returnhoseor line. - Faultyfuel pressureregulator(see page 112341. . lf the fuel pressureis lower than specified,inspect for: - Cloggedfuel filter. - Faulty fuel pressureregulator(see page l12341. - Fuelline leakage.

Slowly loosenthe 12 mm banjo bolt one complete turn. 12 mm BAtt O BOLT 33 N.m (3.i1kgf m, 25 tbf.f0

N O T E :R e p l a c ea l l t h e w a s h e r sw h e n e v e rt h e 1 2 mm banio bolt is loosenedor removed.

11-231

Fuel Supply System FuelInjectors Replacement Do not smoke when working on the tuel systgm, Keepgp6n flames away from your work area

@ 'f.

Relievethe fuel pressure(seepages11-230,231J. 2. Disconnect the connectorsfrom thefuel injectors(D16Y7engine:Removethe air cleaner). 3. Disconnect the vacuumhosesfrom thefuel pressureregulator.Placeashoptoweloverthefuel returnhose,then disconnectit from the fuel pressureregulator.Disconnectthe vacuum hosesand 2P connectorfrom the EVAp purge controlsolenoidvalve. 4. Removethe retainernuts on the fuel rail. 5. Disconnect the fuel rail. 6. Removethefuelinjectorsfrom the intakemanifold. D16Y5,D16Y8engine: NOTE:lllustrationshows D16Y8engine. D 1 6 Y 5e n g i n ei s s i m i l a r . 12 N.m 11.2kgl.m, 8.7 rbt.ft)

12 N.m 11.2lgl.m, 8.7 rbt.ftl

FUEL

.q

e EVAP PURGECONTNOL SOLENOIDVALVE

11-232

w Y E4

V

ffi

}Y g

E

O.RING Replace. CUSHION RING Replace.

ffi V

E E

R

w t Y

O.RING Replace.

cusl{toN RING Replace. SEAL RING Replace.

\

J 81642engine:

12 N.m {1.2kgl m; 8.? lbt.ft)

FUEL PRESSURE REGULATOR

O.RING Replace.

cusHloN RING Replace.

EVAP PURGECONTROL SOLENOIDVALVE

\

7. 8. 9. 10. 11.

SEAL RING Replace.

Slidenew cushionringsonto the fuel injectors. CoatnewO-ringswithcleanengineoil,and putthem onthefuel injectors. Insertthe fuel injectorsinto the fuel railfirst. Coatnewsealringswith cleanengineoil,and pressthem intothe intakemanifold. To preventdamageto the O-rings,installthefuel injectorsinthefuel railfirst,then installthem inthe intakemanifold.

'12. Installand tightenthe retainernuts.

13. Connectthe vacuum hosesand fuel return hose to the fuel pressureregulator,Connectthe vacuum hosesand 2P connectorto the EVAPpurgecontrolsolenoidvalve. (D16YIengine;Installthe air cleaner). 14. Installthe connectorson the fuel inl'ectors two seconds, 15. Turnthe ignitionswitchON (ll),butdo not operatethe starter.Afterthe tuel pump runsfor approximately the fuel pressurein the fuel linerises.Repeatthis two or threetimes,thencheckwhetherthereis anyfuel leakage.

11-233

Fuel Supply System FuelPressureRegulator Te3ting

Reolacement

Do not smoke during the tast. Keep open @ flamcs away from your work arsa.

Do not smoke while working on luel sys@@ tem. Keepopen flame away from your work area,

1. Attachthe specialtool(s)to the serviceport on the fuel filter (seepages11-230,231).

1.

Placea shop towel underthe fuel pressureregulator, then relievefuel pressure(seepages 11-230,231l..

2.

Disconnect the vacuumhoseand fuel returnhose.

3.

Removethe two 6 mm retainerbolts and the fuel pressureregurator.

Pressureshould bo: except 81642 engine 260 - 310 kPa |'2.7- 3.2 kgllcrn2,38 - /t6 psil 816A2engine: 27O- 320 kPa 12.8- 3.3 kgf/cm,, 40 - 47 psi) {with the tuel pressureregulator vacuum hose disconnestedand pinched)

CLAMP

REGULATOR

Reconnectthe vacuum hose to the fuel pressure regulator. Checkthat the fuel pressureriseswhen the vacuum hosefrom the fuel pressureregulatoris disconnected again. l f t h e f u e l p r e s s u r ed i d n o t r i s e , r e p l a c et h e f u e l pressureregutalor.

Applycleanengineoil to a new O-ring.and carefully installit into its properposition. I n s t a l lt h e f u e l p r e s s u r er e g u l a t o ri n t h e r e v e r s e orderof removal.

11-234

I

FuelFilter Replacement

r@ . .

Do not smoke whilc working on fuel system. Keep open flame away from your work arsa. While replacing the tuel filter, be catelul to koep a sale distance betwoen battery torminals and any tools.

,96MODELS: 12 mm BANJO BOLT 33 N.m (3.4 kgl.m, 25 rbf.ftl

T h e f u e l f i l t e r s h o u l d b e r e p l a c e dw h e n e v e rt h e f u e l pressuredrops belowthe specifiedvalue [260- 310 kPa 12.7- 3.2 ksl/cm',38 - 46 psi), |270 - 320 kPa (2.8 - 3 3 kgf/cm,,40 - 47 psi))* with the fuel pressureregulator vacuum hose disconnectedand pinchedl after making sure that the fuel pump and the fuel pressureregulator are OK. *: 81642engine 1.

Placea shop towel underand aroundthe fuelfilter.

2.

Relievefuel pressure(see pages 11-230,231]R e m o v et h e 1 2 m m b a n j o b o l t a n d t h e f u e l f e e d pipefrom the fuel filter,while supportingit with the anotherwrench,as shown.

I

Removethe fuel filter ciamp and fuel filter' l n s t a l l t h e n e w f u e l f i l t e r i n t h e r e v e r s eo r d e r removal,and notetheseitems: a When assembling,use new washersas shown . C l e a nt h e f l a r e d j o i n t o f h i g h p r e s s u r eh o s e s them. thoroughlybeforereconnecting

,97 AND LATERMODELS:

1 2m m BANJO BOLT 33 N.m t3.4 kgf m, 25 lbf.fr)

\\i(o-r

\)

11-235

Fuel Supply System FuelPump Testing

Replacement

Do not smoke during the test, Keep open !@ flame away from your work atea,

Do not smoke while working on tuel svs@E tem. Keepopen llames away from your work area.

lf you suspecta problemwith the fuelpump,checkthatthe fuel pump actuallyruns;when it is ON (ll),you will hear somenoiseif you holdyour earto the fuelfill portwith the fuel fill cap removed.The fuel pump should run for two secondswhen ignitionswitchis firstturnedON (ll).lf the fuel pumpdoesnot makenoise,checkit asfollows:

1.

Removethe seatcushion(seesection20).

2.

Removethe accesspaneltrom the floor.

L

Removethe seatcushion{seesection20).

2.

Removethe accesspanelfrom the floor.

3.

Make sure the ignition switch is OFF,then disconnectthe Iueltank 2P connector.

4.

Connectthe PGM-FImain relay7P connectortermin a lN o .4 a n d N o . 5 w i t h a j u m p e rw i r e .

ACCESSPANEL

i

PGM-R MAIN RELAY7P CONNECTOR lC4,(|l

FUELPUMP IYEL/ GRN}

IGN 1 (YEL/GRNI

JUMPERWIRE

Wiresideof temaleterminals

Checkthat batteryvoltageis availablebetweenthe fuel pump connectorterminalNo. 1 and bodyground whenthe ignitionswitchis turnedON (ll).

CONNECTOR tcs6s) FUELPUMP (YEL/GRNI

=

[t

L3l .i)

T

Wire side of temaletorminals

lf batteryvoltage is available,checkthe fuel pump ground.lf the groundis OK,replacethe fuel pump. lf there is no voltage,checkthe wire harness(see p a g e1 1 - 2 3 8 ) .

11-236

3.

Disconnect the 2P connectorfrom the fuel pump.

4.

Removethe fuel pump mountingnuts.

5.

Removethe fuel pump from the fuel tank.

6.

Installpans in the reverseorderof removal.

I

J

Relay PGM-FlMain Description T h e P G M - Fm l a i n r e l a va c t u a l l vc o n t a i n st w o i n d i v i d u a l relays.This relay is locatedat the right side of the cowl. One relayis energizedwheneverthe ignitionis on which suppliesthe batteryvoltageto the ECM/PCM,power to the luel iniectors,and power for the secondrelay.The secondrelayis energizedlor two secondswhen the ignit i o n i s s w i t c h e dO N ( l l l ,a n d w h e nt h e e n g i n ei s r u n n i n g , to supplypowerto the luel pump.

PGM-FI MAIN RELAY

RelayTesting NOTE: . It the enginestartsand continueslo run. the PGM Fl m a i nr e l a yi s O K . . U s et h e t e r m i n anl u m b e r sb e l o w ; ignorethe terminalnumbersmoldedinto the relay, 1 . R e m o v et h e P G MF l m a i nr e l a y . 2. Attachthe batterypositiveterminalto the No. 2 terminal and the batterynegativeterminalto the No 1 terminal of the PGM-Flmain relay.Then checkfor continuitb y e t w e e nt h e N o . 5 t e r m i n aal n d N o 4 t e r t h m i n a lo f e P G MF l m a i nr e l a y . . lf there is continuity,go on to step3. P G M - Fm l ain . l f t h e r ei s n o c o n t i n u i t yr,e p l a c e t h e relay and retest.

No.3

No. 1

FUEL PUMP

I

To lGN.1

To GROUND

To 8AT O

To ECM/PCM {(a11,A241,(81.B9l*l

To ST. SWITCH

To ECM/PCM{A161

3.

4.

t

To FUELPUMP .r '99 model

Altachthe battervpositiveterminalto the No.5 terminal and the batterynegativeterminalto the No. 3 terminalof the PGM-Flmain relay.Then checkthat there is continuitybetweenthe No. 7 terminaland No. 6 terminalof the PGM-Flmain relay. . lf thereis continuity,go on to step4 . l f t h e r ei s n o c o n t i n u i t yr,e p l a c e t h e P G M -m F la i n relayand retest. Attachthe batterypositiveterminalto the No. 6 terminal and the batterynegativeterminalto the No. 1 terminalof the PGM Fl main relay.Then checkthat there is continuitybetweenthe No. 5 terminal and No. 4 terminalof the PGM-Fimain relay. . lf thereis continuity,the PGM-Flmain relayis OK. lf the fuel pump still does not work,go to Harness Testingon the nextpage. . lf there is no continuity,replacethe PGM Fl main relay and retest.

(cont'd)

11-237

Fuel Supply System PGM-FIMainRelay(cont'dl Circuit Troubleshooting -

Enginewill not start. lnsoection of PGM-FI main relay and relay harne$. PGM.FIMAIN RELAY7P CONNECTOR {C443)

Check for an open in the wire {GNOline}: l. Turnthe ignitionswitchOFF. 2. Disconnectthe PGM-Flmain relay7P connector. 3. Checkfor continuitybetween the PGMFl main relay7P connectorterminalNo.3 and body ground.

1

a

2 5

GND {8LK) 6

7

[,

Wire sideof femaleterminals Ropai. open in the wir€ between the PGM-FImain .elavand G101.

Checkfor an open or short in the wire {BATlin€}: N 4 e a s u rveo l t a g e b e t w e e nt h e PGM-FImain relay 7P connector terminalNo. 7 and body ground. -

ls lhere battery voltage?

-

Repair open or sho.t in the wire betweenthe PGM-FImain r e l a ya n d t h e F l E / M { 1 5 A } fus€. Replace the Fl E/M (15Allu3e in the under-hoodfuse/relay oox.

Checktor an open or short in the wire {lGl line): 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltage between the PGM-Flmain relay7P con' nectorterminalNo.5 and body ground. -

ls there batteryvoltage? -

Ch.ck for an open or short in the wire {STSlino}r 1. Turnthe ignitionswitchto the START(lll)position. NOTE: . M/T: Clutch pedal must be oepresseo. . A/T: Transmissionin E or E position. 2, Measurethe voltagebetween t h e P G M - F lm a i n r e l a y 7 P connectorterminalNo, 2 and body ground.

'96 98 models:(To page1l 239) '99 - 00 models:(To page I l-240)

11-238,

Repair open or short in the wire betwoenthe PGM-FImain relavand the No. 13 FUEL PUMP(15A)tuse. R € p l a c et h e N o . 1 3 F U E L PUMP{15A} tus€ in the underd.sh fus€/relaybox.

1

2

a

5

6

3 BAT {WHT/BLK}

,

I

J

('96- 98 models) -

ls there bafteryvoltage?

-

Repair open or 3hort in the wire bstw€er the lGM-Fl main rolsy .nd the No. 31 STARTER SGNAL 17.5A) tuse. Reolacethe No. 31 STARTER SIGNAL (7.5 Al fu3o in the unde.-dashtusg/rolavbox.

Chock lor !n open in the wit. lFLn line)l 1. Turnthe ignitionswitchOFF conthe ECM/PCM 2. Disconnect nectorA (32P). 3. Check for continuity between the PGM-FImain relay 7P connectorterminalNo. 1 and ECM/ PCMconnectorterminalA16.

{GRN/YELI

()

FLR (GRN/YELI

A t32Pt ECM/PCMCONNECTOR

I

l0

t1

ml,/ x2 3ol./

23

2a

Wiresideof femaleterminals

Ropair op6n in th. walo betwoan t h e E C M / P C Ml A 1 6 ) a n d t h c PGM-FImain rolaY.

I

6

1 2 12 r3 1'a l 5 't6 1 ' t t i 9 2e 29 21 25

Ch6ckfor an opon in th. wi.e3 llcPl,lGP2linesl: con1. Reconnectthe ECM/PCN4 nectorA (32P). 2. Reconnoctthe PGM-Flmain relay connector, 3. Turn the ignitionswitchON (ll) 4. Measurevoltage between ECM/PCMconnectortermanals A 1 1 a n d A 1 0 ,a n d b e t w e e n A246nd A10.

3 t

2

a

PGl (BLK) 1

12

't/t 1 5 t 6 1 7 t 8 t 9 zi 25

27

2A 4t 30

I

4l IGP2 {YEL/BLKI

Repeir opon in th6 wire between ttre ECiA/PCM (A11,A24) and tho PGM-FImsin r.lty. R€plac. tho FGM-FImain rc|.Y.

Checktor an open in the ECM/ PCM: 1. Turn the ignitionswitchOFF. 2, Measurevoltage between ECM/PCMconnectorterminals A16and A10whenthe ignition switch is lirst turned ON (ll) for two seconds.

ls thero1.0V or less?

FLR IGRN/YELI 3 12 1 3 'ta l 5 25

PGl

l5 6 7l lslel tl 221 23 t 6 't7 t 8 t 9 20 27

IBLK) 1l

2a

28 4t

Substituta a known-good ECM/ PCM and rechcck. lf proacribod voltege is now availablc,r.Place the originll ECM/PCM.

C h 6 c kt h . P G M - F Im . i n l o l a y (.ee pagc 11-2371.

(cont'd)

11 - 2 3 9

Fuel Supply System PGM-FIMain Relay(cont'd) _._(9x.qq-gqerll _ -

ls there batteryvoltage? -

Repair op€n or short in the wir€ betlveen the PGM-FImain relay and the No. 31 STARTER SIGNAL17.5A) fuse. RoDlacethe No. 31 STARTER S I G N A L{ 7 , 5 A l t u s e i n t h e under-dashluse/rolay box.

I J

PGM.FIMAIN FELAY7P CONNECTOR {C4€} FLR IGRN/YEL}

Check tor an open in the wire (FLRlinel: 1. Turnthe ignitionswitchOFF. 2. Disconnect the ECM/PCM connectorA (32P). 3. Checkfor continuitybetween the PGM-FImain relay 7P connectorterminalNo. 1 and ECM/ PCMconnectorterminalA16. Wire sideot femaleterminals Repairopen in the wir6 botween t h e E C M / P C M ( A 1 6 1a n d r h e PGM-FImain relay. ECM/PCMCONNECTOR B {25PI IGP2{YEL/BLKI Checkfor an open in the wires {lGPl, lGP2line3): 1. Reconnect the ECM/PCM connectorA {32P). 2 . R e c o n n e ct th e P G M - F m l ain relay connector. 3. Turn the ignitionswitch ON (ll). 4. Measurevoltage between ECN4/PCM connectorterminals 81 and 820, and between Bg and 820.

IGP2 (YEL/BLKI

Wire side of female terminals

-

-

Repair open in the wire between th. ECM/PCM(81, Bg) snd the PGM-Fmain rolay. Roplaceth€ PGM-FImain relav.

ECM/PCMCONNECTORS A (32P1

Chocktor an open in th6 ECM/ PCM: 1. Turnthe ignitionswitchOFF. 2. Measurevoltage between ECM/PCMconnectorterminals A16 and 82 when the ignition switch is first turned ON lll) for

ls there1.0V or less?

Chock the PGM-Fl m.in r6lay {see p.ge 11-2371.

11-240

Sub3titute . known-good ECM/ PCM and rochock. lf prescribed vohege is now available,replace the original ECM/PCM.

Wire side of fem6le terminals

'l'

I

FuelTank '96 - 98 models: Replacement !@@ 1. 2. 3. 4.

Do not smokewhile working on fuel system'Keepopen flame away

from your work ar'a'

Relievethe fuel pressure(seepages\1-230'23'll' Removethe seatcushion(seesection20). Removethe accesspanelfrom the floor' '97 D16Y/ engine(coupe: KL model' ('96 D]6Y8 engine (coupe) Disconnectthe 2P (C565)and 3P (C564)connectors

sedanKL(LX)model).'97D'l6YSengine(coupe:allmodels'sedan:KLmodel'98-allmodels):and6P(C568)con tor), (see pages'l'l-225' 2271 5. Disconnectthe hose and quick-connectfittings jackstands' with it and support vehicle, the 6. Jackup joint protector' 7. Removethefueltank cover('96,'97model)orthefuel hose container' 8. Bemovethedrainbolt,and drainthefuel into an approved as you pull,to avoiddamagingthem' the hoses{seepager i-izst. Sria" nu"i ihe clamps,then twist hoses 9. Disconnect 10. Placea jack.or othersupport,underthe tank' 11. Removethe strapnuts,and let the strapsfall free' mount' carefully pry it off the mount' 12. Removethefueltank lf it stickson the undercoatappliedto its 13.|nsta||thedrainbo|twithanewwasher.thencoatthedrainbo|twithNoxrustl24B,A||owtheNoxrustdryfor20min ules. 14. Installtheremainingpans in the reverseorderof removal'

I SASEGASKET Replace.

BASEGASKET Replace.

TANK STRAPS DRAINBOLT ,19N.m {5.0 kgt m, 36 lbf.ftl

(cont'd)

11-241

FuelSupplySystem FuelTank {cont'dl 39 - (xt models: Replac6ment @

Do not smokewhire working on fuer system.Ke€popenframaaway trom your work area.

1. Relievethefuelpressure(seepages11-230,23'll. 2. Removethe seatcushionlseesection2O). 3, Removethe accesspanelfromthefloor. 4. Disconnectthe2P(C565)and3P(CS64)connectorsand 6p (C569)connecror. 5. Disconnect the hoseand quick-connect fiftings(seepages1l-226,22j), 6. Jackup the vehicle,and supportit with jackstands. 7. Removethefuelhosejoint protectorand heatshield. 8. Removethedrainbolt.and drainthefuel intoan aporovedcontainer. 9 Disconnect the hoses(seepage11-226). Slidebackthe clamps.then twist hosesas you pull,to avoiddamagtngrnem. 10. Placea jack,or other support,underthe tank, 11. Removethe strapnuts,and let the strapsfallfree, '12. Removethefuel tank.lf itsticksonthe undercoatappliedto its mount,carefullypry itoffthe mount. 13. Installthedfain boltwith a new washer.then coat the d rain bolt with Noxrust124B,AllowtheNox.ustdrv for 20 minutes. 14. Installtheremainingpartsin the reverseorderof removal,

o

Replace.

DRAINBOLT ,19N.m (5.0 kgf.m,36lbf.ft)

11-242

Intake Air System \

J

SystemDescriPtion pipe' Air C|eaner(ACL},intakeair duct, Thrott|e The systemsupp|iesair for a|| engineneeds'|t consistsof the intakeair intakeair pipe providesadditionalsilencing Body (TB),ldle Air control (lAc) valve and intakemanifold.A resonatorin the as air is drawn into the system. D16Y5,D16Y8,816A2 engine {M/Tl YEL/ aLK -

- FromPGM-FI MA|NRELAY

IAC VALVE

BLK/ BLU -INTAKE AIR DUCT

IROTARYI IAC VALVE

D16Y5engine (CVT),D16Y8engine (A/T)'

ORN

BLK/

Iaru ENGINE COOLANT

INTAKE AIRDUCT

f'ttlxr ,tla"tpoto

I

VARIOUS SENSORS

D16Y7engine:

BLK

INTAKE AIR PIPE {ROTARY) IACVALVE

tr RESONATOR

! r , 11-243

lntake Air System Air Cleaner(ACLI NOTE: Do not cleanthe ACL elementit with compressedair {exceptdry type). D16Y5,D16Y8,816A2engine: ACL ELEMENT Normal conditions: Replaceair cleanerelementevery 30,000miles(48,000 km) or 24 monthswhichevercomesfirst. S€voaeconditions: (Usenormalschedule exceptin dusty conditions) Replaceevery 15,OOO miles(24,000km)or 12 months whichevercomesfirst.

ThrottleCable Inspection/Adiustment 1. Startthe engine.Hold the engineat 3,000rpm with n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n comeson, then let it idle. 2.

Checkthat the throftlecableoperatessmoothlywith no bindingor sticking.Repairas necessary.

3.

Checkcable free play at the throttle linkage.Cable deflectionshoutdbe 10- l2 mm (3/B- 112in.l.

D16Y5,D16Y8engine: CABLE BRACKET

LOCKNUT

DEFLECTION 10-12mm BIA- 112inl

D16Y7engine: D16Y7engine:

ACL ELEMENT Normal conditions: Replaceair cleanerelementevery 30,000miles(48,000km) or 24 monthswhichevercomesfirst, Seve.s conditions: (Usenormalscheduleexcept in dustyconditions) Replaceevery l5,000 whichever comes first.

11-244

LOCKNUT

DEFLECTION 1 0 - 1 2m m l3lA - lninl

\

J lnstallation

816A2 engine:

Dl6Y5,Dr6Y8,D16Y,€ngine: 1. LOCKNUT

Openthe throttlevalvefully, then installthe throttle cable in the throttle linkage,and install the cable housingin the cablebracket.

D16Y5,D16Y8engins: LOCKNUT

DEFLECTION CABLE 10-12mm BRACKET Bla- 112inl

ADJUSTING NUT

t lf deflectionis not within specs'loosenthe locknut' turn the adjustingnut untilthe deflectionis as specified,then retightenthe locknut. With the cable properlyadiusted,checkthe thronle valve to be sure it opens fully when you push the acceleratorpedalto the floor. Also checkthe throttle valve to be sure it returns to the idle position pedal' wheneveryou releasethe accelerator

Startthe engine.Hold the engineat 3,000rpm with n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n comeson, then let it idle. Hold the cable sheath.removingall slackfrom the caDle (cont'dl

11-245

IntakeAir System ThrottleCable(cont'dl 4.

S e t t h e l o c k n u to n t h e c a b l e b r a c k e t .A d j u s t t h e adjustingnut so that its free play is Omm.

5.

Bemovethe cable sheathfrom the throttle bracket, resetthe adjustingnut and tightenthe locknut.

816A2 engine: 1.

Openthe throttlevalvefully, then installthe throttle c a b l ei n t h e t h r o t t l el i n k a g e a . n d i n s t a l lt h e c a b l e housingin the cablebracket,

O16Y5,D16Y8engino: THROTTLELINK ADJUSTINGNUT

9.8N.m {1.0 kgl.m, 1.2 tbt.ttl

DtGYT6ngine:

LOCKNUT

ADJUSTING NUT

Startthe engine.Hold the engineat 3.000rpm with n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n comeson, then let it idle. H o l d t h e t h r o t t l e l i n k t o t h e t h r o t t l e l e v e r ;t h e r e should be no clearance. Hold the cable sheath,removingall slackfrom the cable. Turn the adjustingnut untit it is 3 mm {1/8in.)away from the cable bracket,

3 mm 11/8in.)

LOCKNUT 9.8 N.m (1.0kgt m, 7.2 tM.ttl

ADJUSTINGNUT

T i g h t e nt h e l o c k n u t .T h e c a b l e d e f l e c t i o ns h o u l d n o w b e 1 0 - 1 2 m m l 3 / B- 1 / 2 i n . ) . l f n o r . s e e Inspection/Adjustment.

11-246

I

Throttle BodY Description side-drafttype The throttlebodYis eithera single-barrel type a down-draft or (D16Y5,D16Y8,816A2 engine) (D16Y/engine).The lower portionot the throttlevalveis heatedby engine coolantfrom the cylinder head' The idle adjustingscrew which regulatesthe bypassair is locatedon the top of the throttlebody THROTTLE POS|T|ONlTPl SENSOR

Dl6Y7 ongine:

IDLEAD.'USTING SCREW

STOPSCREW {Do not adjust.)

816A2 engins: LINK THROTTLE

t In3pection 1 . C h e c kt h a t t h e t h r o t t l e c a b l e o p e r a t e ss m o o t h l y without bindingor sticking. checkfor: lf there are any abnormalities, . Excessivewear or play in the throttle valve shaft' . StickYor binding throttle lever at the fully closed .

Position. Clearancebetweenthrottle stop screw and throttle leverat the fully closedposition'

STOPSCREW THROTTTE (Do not adjust.)

Replacethe throftle body if thsre is excessiveplay in the throttlevalveshaftor iJthe shaftis bindingor sticking'

D16Y5,Dl6Y8 engine:

THROTTLESTOP SCREW {Do not adjust.)

(cont'd)

11-247

Intake Air System ThrottleBody (cont'dl

\rJ

Removal D16Y5,Dl6Y8,81642engine:

D15Y7engine:

IAT SENSOR

AIR CLEANER {ACLI MAP SENSOR 22 N.m 12.2kgl.m, 16 rbf.ftl

GASKET Replace.

THROTTLECABLE

NOTE: . Do not adjustthe throttlestop screw. . After reassembly, adjustthe throttlecable{seepage l l-244). . The TP sensoris not removable.

11-248

\ Disasssmbly Dl6Y5,Dl6Y8 engine: 2.1N.m (0.21ksf.m,1.5lblftl\

MAP SENSOR page11'115 Troubleshooting,

b Y TPSENSOR IDLEAOJUSTING

3.5N.m t0.35kgl m,2.5 lblftl

B16A2sngine:

MAP SENSOR Troubleshooting, Page11-119

z.'t N.m kgf'm, 10.21 1.5tbf.frl

MAP SENSOR Troubleshooting, Page11 115

TP SENSOR

11-249

IntakeAir System FuelInjectionAir (FlA)ControtSystemI'99- 00 Dl6yg enginel Dsscription Whenthe enginerunninglenginecoolantbelow 149oF(6S"C)], the fuel InjectionAir (FtA)ControlValvesendsintakeair to the fuel iniectors.

FUEL INJECTOB

E>

: INTAKE AIR

11-250

\

J Fuol Iniection Air {FlA)Contlol Valve T$ting 1.

Startthe engine.

2.

Removethe vacuum hose from the fitting on the intakeair duct, and connecta vacuumgaugeto the nose. NOTE:Enginecoolanttemperaturemust be below 149"F(65"C). VACUUMPUMP/GAUGE, 0-30 in.Hg. A973X- 041-XXXXX

Raiseand lower the engine speed,and make sure the vacuum gauge readingchangesas the engine speed changes. lf vacuum reading does not change check these rtems: . The vacuum lines of FIA systemfor misrouting, leakage,breakageand clogging. . The FIA controt valve for cracksor damage . The cooling system (seesection 10). rpm with no load (in Park Hold the engineat 3,OOO or neutral)until the radiatorfan comes on, th€n let it idle and recheck. lf vacuumreadingchangeschecktheseitems: a The FIAcontrolvalvefor cracksor damage. . The coolingsystem(seesection10).

11-251

EmissionGontrolSystem SystemDescription

ThreeWay CatalyticConverter

The emissioncontrol system includesa Three Way Catalytic Convener(TWC),ExhaustGas Recirculation (EGR) system,. PositiveCrankcaseVentilation(pCV)system and EvaporativeEmission(EVAP)Controlsystem.The emission control system is designedto meet federaland state emissionstandards. *: D16Y5engine

Doscription The Three Way CatalyticConverter (TWC) is used to conven hydrocarbons(HC),carbonmonoxide(CO),and oxides of nitrogen(NOx) in the exhaustgas to carbon dioxide(COr),dinitrogen(N,)and watervapor.

(TWCI

D15Y5,D16\r, engine: ENGINESIDE

t

TailpipeEmission Inspestion Do not smoke during ihis procedure.Keep @@ any open flame away from your work area. 1.

Startthe engine.Hold the engineat 3,000rpm with n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n comeson. then let it idle.

2.

Connecta tachometer. Checkand, if necessary,adjustthe idle speed (see page 11-220- 223). Warm up and calibratethe COmeteraccordingto the metermanufacturer's instructions. Checkidle CO with the headlights,heater blower, rearwindow defogger,coolingfan,and air conditioner off. ) u l l t h e p a r k i n gb r a k el e v e r u p . N O T E : ( C a n a d aP Startthe engine,then checkthat the headlightsare off.

'99 -

00 D16Y8,81642 engine:

CO mete.shouldindicate0.1%maximum. NOTE:'98 Dl6Y5 engine- lf the idle speedincresses to 8101 50 rpm, this meansthe EVApsystemis purgingthe canister.To stop the purgingtemporarily. raisethe enginespeedabove 1,000rpm with the pedal,then slowly releasethe pedal. accelerator FORWARD

11-252

e -

\ (DTc)p0420:catatystsysremefficiencybelowthreshold. lTo420l Th" """n toot indicatesDiagnosticTroubtecode Description outputduringstabledriving This systemevaluatesthe catalyst'scapacityby meansof the Ho2s {Primaryand secondary) on and DTCP0420will MIL comes the cycles. driving two consecutive during been detected has conditions.ll deterioration be stored. those DTCSfirst. then NOTE:lf some of the DTCStistedbelow are storedat the same time as DTCP0420,troubleshoot recheckfor DTCP0420 P0137,P0138:SecondaryHO2S(Sensor2) H02S {Sensor2) Heater Po14'1:Secondary Possibl€Cause . TWCDeterioration . Exhaustsystemleakage TroubleshootingFlowchart The MIL has beenreportedon. DTC P0420 is stored

I

Problemverilication: ResetProce 1. Do the ECM/PCM dure. 2 . S t a r tt h e e n g i n e H o l d t h e engine at 3,000rpm wath no load {in Parkor neutral)until the radiatorfan comeson. 3. Connectthe SCSservicecon 4. Testdrive 40 - 55 mph for a p p r o x ,t w o m i n u t e s T h e n deceleratefor at least 3 sec_ o n d s w i t h t h e t h r o t t l ec o m ' pletely closed-Then reduce the vehiclespeedto 35 mph, a n d t r y t o h o l d i t u n t i lt h e codecomeson readiness

l s D T C P 0 4 2 0i n d i c a t e d ?

Checkthe TWC {seesection 9l lf necessary,replacethe TwC

Intermittent Iailure, system is OK at this time.

EmissionControl System (EGR)System(D16ySengine) ExhaustGasRecirculation Doscription The EGRsystemis designedto reduceoxidesof nitrogenemissions(NOx)by recirculating exhaustgas throughthe EGR valveand the intakemanifoldinto the combustionchambers.lt is composedof the EGRvalve.EGRvacuumconrrotvatve. EGRcontrolsolenoidvalve.ECMand varioussensors. The EcM containsmemoriesfor ideal EGRvalve lifts for varyingoperatingconditions,The EGRvalve lift sensordetects the amountof EGRvalvelift and sendsthe informationto the ECM.The ECMthen comparesit with the ideatEGRvalvelift which is determinedby signalssent from the other sensors.lf there is any differencebetweenthe two. the EcM cuts currentto the EGRcontrolsolenoidvalveto reducevacuumappliedto the EGRvalve. EGRCONTROL CVT: SOLENoID vALvE

EGNVALVELIFTSENSOR

BLK

I

I 11-254

4 The scantool indicatesDlagnosticTroublecod€ {DTc}Po4ol:lnsufficientflow in the ExhaustGas Recirculation (EGR)svstem. Doscription the changesin MAP before Deterioration(clogging,leakage,etc.)in the EGRline or EGRvalve is detectedby meansof and afterthe operationof the EGRvalve. DTC P0401will be lf deteriorationhas been detectedduring two cons€cutivedriving cycles,the MIL will come on and stored. Po$ible Causeg . Clogging.leakagein the EGRline . FaultyEGRvalve TroubleshootingFlowchart -

\

Tho MIL ht! bacn rgportodon. DTCm40l is 3torod.

Problomvorification: 1. Do the ECM/PCMResetProcedure. 2. Connectthe SCS serviceconnector, underthe following 3. Tost-drive conditions. - Without any electricalload - Deceleratelrom 55 mPh (88km/h)lor at least5 seconos

lntormiftam f!ilu.a, ayltam ia OK .t thb time,

-

Clo.n tho inttkc mlnifold EGR port wittr carbursto. clotner. Cl.an the pa$lgo insido tho EGR valvo with crrburator cloanol or aoglacatha vllvo.

EmissionControl System ExhaustGasRecirculation(EGR)System(D16Y5enginewith GWI (cont'dl lTl49il -

T_hescantool indicatesDiagnosticTroubleCode(OTC)P1491:A malfunctionin the ExhaustGas Recirculation l E g h )s v s t e m .

CvT lM/T seepage 1l-2611: The MIL has been reoortedon. DTCP1491is stoled.

Problemverification: 1. Do the ECM/PCM ResetProcedure. 2. Connectthe SCSservicecon' 3 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load {in Parkor neutral)until the radiatorfan comeson, 4. Drivethe vehicleon the road for approx.10 minutes.Try to keepthe enginespeedin the 1,700- 2,500rpm range.

l s D T CPl 4 9 l i n d i c a t e d ?

Intermittonl failure, system is OK at this time. Checkfor Door connections or loose wires at, C144 {EGRvelve}and ECM/PCM.

Check fo. vacuum to ihe EGR 1. Disconnectthe No. 16 hose from t h e E G Rv a l v e . 2. Connect a vacuum pump/ gauge to the hose. 3. Start the engine and let it idle.

EGRVALVE LIFTSENSOR

#16 HOSE

ls thereany vacuum?

Check tor a malfunction in the EGR control solenoid valve: '1. D i s c o n n e c tt h e E G R c o n t r o l solenoid valve 2P connector, 2 . B e c h e c kt h e N o . 1 6 h o s e f o r

(To page11 257)

PUMP/GAUGE,0-30 in.Hs A973X-041-XXXXX

ls there any vacuum?

Substitute a known-good ECM/ PCM and recheck. It symptom/ indicalion goes away, replace the original ECM/PCM.

11-256

Check vacuum hose routing o, the entire EGR svstem. lf hose routing is OK, replac€the EGR control solenoidvalv6.

EGR VALVE

J

\

EGRVALVE LIFTSENSOR

(Frompage11-256)

#16HOSE

Check fo. a mallunction in the EGFvalv€: 1. ldove the vacuumpump/gauge to the EGRvalve. 2. With the engineat idle,apply 26.7kPa(200mmHg,8.0in.Hg) ofvacuumto the EGRvalve.

- 30 in.Hs PUMP/GAUGE,0 4973X-041-XXXXX

Doesthe enginestallor run roughand doesthe EGRvalve holdvacuum? EGRVALVELIFTSENSOR 3P CONNECTOR lC14.l)

I

vccz

zF\

Check for an open in the wire IVCC2linel: 1. Turnthe ignitionswitchOFF. the EGRvalve lift 2. Disconnect sensor3Pconnector. 3. Turnthe ignitionswitchON (ll). 4. Measurevoltagebetweenthe EGRvalve lift sensor3P con' n e c t o rt e r m i n a l sN o . 3 a n d No.2.

Ill

-r_

. ] IYEL/BLU) 2l3l---l 7

|

v-,, I

SG2IGRN/BLK) I ^

I{Vts

I

D {16P) ECMCONNECTOR

ls lhere approx.5 V?

vcc2 IYEL/BLU}

sG2

(GRN/BLKI

Wire sideol temaleterminals

C (31P}' PCMCONNECTORS

Check for an oDen in the wire {VCC2line}: M e a s u r ev o l t a g e b e t w e e nt h e E C M / P C Mc o n n e c t o rt e r m i n a l s D10and Dl1 (C18and C28)*.

Wire side of female terminals

YES l s t h e r ea p p r o x . 5V ?

(To page 1l-258)

Sub3titute t known-good ECM/ PCM end recheck. lt 3ymptom/ indication goos eway, replace th6 original ECM/PCM.

Rep.ir open in the wire between r h e E G Rv a l v e s n d E C M / P C M {Dl0 {C28)*).

(cont'd) *: '99 - 00 models

1 1-257

EmissionGontrolSystem (EGRISystem(Dl6Y5enginewith CW) (cont'dl ExhaustGasRecirculation {Frompage11-257}

Chocklor an opcn or short in th. EGRv.lve lift .€nsor '1. Turnthe ignitionswitchOFF. 2. At the sensorsid€, measur€ resistancebetween the EGR valve lift sensor 3P connector terminalsNo. 1 and No.2.

EGRVALVELIFTSENSOR 3P CONNECTOR {Cl251 EGRL

(WHT/BLKI

ls there continuity or resis' tanceot 100k0 or higher?

sG2 {GRN/BLK} Terminalsideol maleterminal

Chocktor sn op€n or lhort in the EGRvalve lift lonror: Measureresistancgbetweenthe EGRvalve lift s€nsor3P connector terminalsNo. 1 and No.3.

EGRL IWHT/BLKI

ls there100k0 or higher?

ECIT'I CONNECTOR D II6PI

Ch.ck tor an ooon or rhon in thc wiro IEGRLlinc): 1. Beconnecttho EGRv6lve lift sensor3P connector. 2. Turn tho ignitionswitchON (ll). 3. Measurevoltage between the ECM/PCMconnectorterminals D9and Dl1 (C6and C18l*.

EGRL {WHT/BLKI

sG2 {GRN/BLK}

Wir€ side of f€maleterminals

PCMCONNECTORS C (31PI*

ls thereapprox.1.2V?

Wire sideof femaleterminals

{Topage11-259)

11-258

(To page11-259)

./

I

(Frompage11-258) ECMCONNECTOR O {I5PI

Check for a 3hort in the wire {EGRLlinel: C h e c kf o r c o n t i n u i t y b e t w e e n ECM/PCMconnectorterminalDg

Repairop€n in the wire between th6 EGRvalve and the ECM/PCM (D9 tc6trt.

Wire sideof lemaleterminals PCMCONNECTORS C (31P)*

ReDairshort in the wirc batweon the EGRvalve and ECM/PCM{Og

(c5t*).

Wire sideof temaleterminals

(From page 11-258)

I EGRCONTROLSOLENOIDVALVE 2P CONNECTOR

Checkths vacuum routing: ' 1 . R e c o nn e c t t h e v a c u u m p u m p / g a u g et o t h e N o . 1 6 hose. 2. Startthe engineand let it idle. 3. At the EGR control solenoid valve side, connect the battery positiveterminal to the E G Rc o n t r o l s o l e n o i dv a l v e connectotterminalNo. 1. 4 . W h i l e w a t c h i n gt h e v a c u u m g a u g e ,c o n n e c tt h e b a t t e r y negativeterminalto the EGR controlsolenoidvalve2P connectorterminalNo.2,

Terminal side oI malelerminals

ls thereapprox.26.7kPa 1200mmHg,8.0in.Hg)of vacuumwithin 'l second? Chockthe vlcuum hos6s: 1. Turnthe ignitionswitchOFF. 2. Inspectthe No. 16 and No. 10 hosesfor leaks,restrictionsor mtsrouUng.

t

(cont'd) 11,260)

11-259

EmissionControlSystem ExhaustGasRecirculation(EGR)System(Dl6Y5enginewith CW) (cont'dl (Frompage11-259)

Chocklor an open in the wire (E SOL linsl: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector Irom the EGRcontrolsolenoid 3. Disconnectthe ECN4/PCM connectorA (32P)(B (25P))*from the EcM/PCM. 4. Checktor continuitybetween ECM/PCl,connectorterminal 47 (86)* and the EGRcontrol solenoid valve 2P connector t e r m i n aNl o . 2 .

EGRCONTROLSOLENOID VALVE2P CONNECTOR {C142} Wire side ESOL of lemale IRED) terminals

ECM CONNECTOR a t32Pl

-

ESOL IRED)

-_-] EGRCONTROLSOLENOID VALVE2P CONNECTOR ICl'2} Wireside of female i terminals ECM CONNECTOR B l25P)

I

l

ESOL (REDI Wireside of female rermtnats

ls therecontinuity?

Repair opon in th. wir. bstwocn tha EGR control 3ol€noid valvo and tho ECM/PCM(A7 186l'1.

Check for . rhort in the wire (ESOLlinel: Checkfor continuity between the EGRcontrolsolenoidvalve2P connectorterminal No. 2 and body ground, R.p.ir ahort in tha wi.c b.twecn the EGR control iolonoid vllye and th. ECM/FCM{A7 (46}rl. Check for an opon in the wiro IGNDlinel: Checkfor continuity between the EGRcontrolsolenoid vaive2Pconnectorterminal No. I and body ground, Rcpai. op€n in the wir6 b6'twoen the EGR control rol.noid valve and G101. Sub3titule a known-good ECM/ PCM and rechock. lf symptom/ indication goes away, replac€ the original ECM/PCM.

*: '99- 00 models

11-260

Wireside of female terminals

t J

\

J

System(D16Y5enginewith M/T) ExhaustGasRecirculation M/T: -

Th6 MIL ha3b€onreponed on. DTCPl,{tl is 3tored.

Prcblem verification: 1. Do the ECMResetProcedure. 2. Connectthe SCSservicecon_ nector. 3 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no in neutral) load (transmission fan comeson. untiltheradiator 4. Drivethe vehicleon the road for approx. 10 minutes.Try to keep the enginespeedin the 1,700- 2,500rpm range.

ls DTCP1491indicated?

I

(C14'rl EGRVALVE6PCONNECTOB lnlermittont tailure, svalem is OK at thi3 tim6. Checkfoi Poor con' nections or looso wiro3 at Cl/K IEGRvalvsl and ECM.

1

a G10l IBLK}

Check tor a malfunction in the EGRvalv6: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe EGRvalve 6P connector. 3. Stantheengineandletit idle 4. Measurevoltage between the termi' EGRvalve6P connector n a l sN o . 4 a n dN o . 6 .

Wi16sideof maleterminals

sG2 ls there batteryvoltage?

PNK IE.EGRI

Checkthe EGRvalve: 1. Turnthe ignitionswitchOFF 2. Turnthe ignitionswitchON lll). 3. Measurevoltage between the EGRvalve 6P connectortermi n a l sN o . 2a n dN o . 3 .

Substitute a known-good ECM and recheck. It symptom/indica_ tion goes away, replaceth€ original ECM.

ls thereapprox.5V?

(To page11-262)

{GRN/ BLK}

vcc2 {YEL/ BLU)

EmissionControl System ExhaustGasRecirculation System(D16Y5enginewith M/T) (cont'dl

\ v

( F r o mp a g e1 1 - 2 6 1 )

ECMCONNECTOR D {16P) Check tor open in the wire (SG2 linel: M e a s u r ev o l t a g e b e t w e e nt h e E C Mc o n n e c t otre r m i n a l sD 1 0 a n dD 1 1 .

vcc2 (YEL/BLU)

ls thereapprox.5 V?

Repsir open in lhe wire beiween E C Ml O l l l a n d E G Rv a l v e .

sG2 IGRN/BLK)

Wire sideof femaleterm;nals

EGRVALVE6P CONNECTOR

Checkthe EGRvalve: 1. Turnthe ignitionswitchOFF. 2 , A t t h e s e n s o rs i d e ,m e a s u r e resistancebetweenthe EGR valve 6P connectorterminals No. 1 andNo.2.

EGRL (WHT/ BLK}

SG2 (GRN/BLK)

Termanal sideof maleterminals

l s t h e r e c o n t i n u i t yo r r e s i s tanceof 100k0 or higher?

Checkthe EGRvalve: Measureresistancebetweenthe E G Rv a l v e 6 P c o n n e c t o tr e r m i n a l sN o . 1 a n d N o . 3 .

ls there100k0 or higher?

(To pase 11 263)

1 -262

EGRL {WHT/ BLK}

vcc2 {YEL/BLU}

'l'

T lFrompage11-262) ECMCONNECTOR D I16P' Chock for rn opon in the wire {EGRL linel: the EGRvalvecon 1. Reconnect nector. 2. Tu.nthe ignitionswitchON (ll). 3. Measurevoltage betweon the PCM connectorterminalsDg a n dD l 1 . WiresideoI femaleterminals

ls thereapprox.1.2V?

Checktor th€ wirc (EGRL line): C h e c kf o r c o n t i n u i t y b e t w e e n ECM connectorterminal Dg and body ground.

Roprir op6n in the wirs botwean the EGRvalvo.nd th. ECMlD9).

t Rooair ahort in tho wiro baftr,otn tho EGRv.lv..nd the ECM lDgl.

EGRVALVE6P CONNECTOR Ch€ckthe EGRvalve: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe EGRvalve 6P connector. 3. Connectthe battery positive terminal to EGRvalve 6P connectorterminalNo. 6. 4. Stan the engineand let it id'e, then connectthe batterynega_ tive terminalto EGRvalve 6P connectorterminal No, 4, wire sid6 of lemale te.minals

(cont'd)

EmissionGontrolSystem ExhaustGasRecirculation System(Dl6Y5enginewith M/Tl (cont'dl lFrompage11 263)

Checklor an op€n in the wire (EEGRline): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECMconnector, A (32P)trom the ECM. 3. Checklor continuitybetween E C Mc o n n e c t o rt e r m i n a lA 7 and the EGRvalve6P connectorterminalNo.6.

J

EGRVALVE 6P CONNECTOR {C144}

CONNECTOR A l32P)

Wire side of female termtnals

Repairopen in the wiro botween the EGRvalv6.nd th€ ECM{A71.

Check tor a short in the wire {EEGRlin6l: C h e c kf o r c o n t i n u i t y b e t w e e n ECM connectorterminalA7 and body ground.

J ls therecontinuity?

Reoairshorl in tho wiro belwe€n the EGn vake rnd the ECMlA7l.

Check fo. an open in tho wiro IGNDline): Checkfor continuity between the EGRvalve6P connectorterminal N o . 4 a n db o d yg r o u n d .

2 R6pai. open in th€ wir. between th6 EGF control solenoid v6lve and G101.

Substitute 8 known-good ECM and recheck. It symptom/indication goes away, roplacethe originalECM.

-264

a I

G101

Q) raur

\

J

System(D16Y5enginel ExhaustGasRecirculation The scan tool indicatesDiagnosticTrouble Code {DTC)P1498:A high voltage problem in the ExhaustGas (EGRlvalvelift sensorcircuit. Recirculation -

The MIL has beenreportodon. DTCP1498is storod.

Probl€mverification: ResetProce 1. Do the ECM/PCM dure. 2. Stanthe engine.

ls DTCP1498indicated?

C h e c kf o r a n o p e n i n t h o E G R valv6 lift sen3or: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe EGRvalve lift sensor3P (M/T:6Plconnector. 3. Turnthe ignitionswitchON (ll). 4. Measurevoltagebetweenthe EGRvalve litt sensor 3P lM/T: 6P)connectorterminalsNo. 3 a n dN o . 2 .

I

Intermittent tailure,sy3lem is OK at lhis time. Check tor poor con' nections or loose wire3 at C144 |EGRvalveland ECM/PCM. (C1441 EGRVALVELlFf SENSOR3P {M/T: 6Pl CONNECTOR

cvT:

vcc2 {YEL/BLUI

SG2 IGRN/BLK)

M/T: ls thereapprox.5V?

Check lor op€n in th€ wire (SG2 line): Measurevoltage betweenECM/ terminals010 and PCMconnector D1l (C18and C28)*.

ls thereapprox.5 V?

Substitute . known-good ECM/ PCM and recheck.ll symptom/ indicrtion goes away, replaco the original ECM/rcM.

sG2 {GRN/ BLKI

Wir€ side ol lemale terminals

Repairopen in tho wiro betwoen ECM/PCMlDl1 (Cl8)r) and EGR valvo lift sensor.

D (16P) ECMCONNECTOR

vcc2

(YEL/BLUI

sG2 (GRN/BLK)

*:'99 - 00 D16Y5enginewith CVT Wir€ sideof femaleterminals

C 131P)' PCMCONNECTORS

Wire sideoI femaleterminals

11-265

EmissionControl System VentilationIPCVISystem PositiveCrankcase

tJ

Descripiion

lrcpection

T h e P o s i t i v eC r a n k c a s eV e n t i l a t i o n( P C V )s y s t e m i s designedto preventblow-by gas from escapingto the atmosphere.The PCVvalve contains a spring-loaded plunger.When the enginestarts,the plungerin the PCV valve is lifted in proportionto intakemanifoldvacuum and the blow-by gas is drawn directly into the intake manifold.

1. 2.

Checkthe PCVhosesand connectionsfor leaksand clogging. At idle,makesurethere is a clickingsoundfrom the PCVvalve when the hose betweenthe PCVvalve and the intakemanifoldis lightly pinchedwith your fingersor pliers,

D16Y5,D16Y8ongins: D15Y5,D16Y8,816A2 ongins:

BREATHER HOSE

BREATHER HOSE

PCVVALVE Gentlypinchhere.

Dl6'|116ngin6:

Bl6A2 engins:

-: aLOW-BYVAPOR -: FnESHAIF

VALVE

PCV

lf there is no clickingsound, checkthe PCVvalve grommetfor cracksand damage.If the grommet is OK, replacethe PCVvalveand recheck.

11-266

\

1

EvaporativeEmission(EVAPIControls Description The evaporativeemissioncontrolsare designedto minimizethe amount of fuel vapor escapingto the atmosphere.The systemconsistsof the foliowingcomponents: EvaporativeEmission (EVAP)Control Canisto] An EVAPcontrolcanisteris usedfor the temporarystorageof fuel vapor until the fuel vapor can be purgedfrom the EVAPcontrolcanisterinto the engineand burned.

A.

B. Vapor PurgeControl System EVAPcontrolcanisterpurgingis accomplishedby drawingfreshair throughthe EVAPcontrolcanisterand into a port on the intakemanifold.The purgingvacuumis controlledby the EVAPpurgecontrolsolenoidvalve.

VALVEDUTYCONSOLENOID EVAPPURGECONTROL ENGINE AFTER STARTING TROLLED I ' 9 6D 1 6 Y 5e n g i n e , ' 9 6D l 6 Y 7e n g i n e , ' 9 6D 1 6 Y 8 7 1 6 Y 5e n g i n e , ' 9 7D 1 6 Y 7 e n g i n e( s e d a n ) , ' 9 D r A , K C m o d e l s ,s e d a n :K A , K c ' e n g i n e( c o u p e K '97 K L i D X ) m o d e l s ,h a t c h b a c ka: l l m o d e l s ) , D 16Y8engine(sedan:KA, KC models)l

ABOVE154'F(68'C) ENGINECOOLANTTEMPERATURE

I

I ' 9 6 D 1 6 Y 8e n g i n e ( c o u p e ) , ' 9 7D 1 6 Y 7e n g i n e ( c o u p e :K L m o d e l ,s e d a n :K L ( L X ) m o d e l ) " 9 7 D16Y8engine(coupe:all models,sedan:KL model) '98-allmodels,'99-allmodels,'00-allmodelsl

ABOVE154'F{68"C) ENGINECOOLANTTEMPERATURE ABOVE32'F (O'C) INTAKEAIRTEMPERATURE and SPEEDABOVEO MILE(OKM/h} VEHICLE

or CLUTCHON l'lc COMPRESSOR and ABOVE160"F(41'C) INTAKEAIRTEMPERATURE

c.

FuelTank Vapor Control System Whenfuel vapor pressurein the fuel tank is higherthan the set valueof the EVAPtwo way valve,the valveopensand regulatesthe flow of fuel vaporto the EVAPcontrolcanister.

D. Onboard RefuelingVapor Recovery(ORVRISystem {'99 - 00 models}

Duringrefueling.the oRVR {onboard RefuelingVapor Recovery)vent shut valve openswith the pressurein the fuel tank.and feedsthe fuel vaporto the EVAPcontrolcanister.

t

(cont'd)

11-267

EmissionControlSystem EvaporativeEmissionIEVAPIControls(cont'd) '96 D16Y8ongins (coupol.'97 D16Y8€ngino (coups:all mod€ls,sedan:KL model),'98 D16Y5engine (all mod6lsl,'98 Dl5YB engine {all modols): BLK/ YEL

{

<

EVAPPURG€ CONTROL SOLENOIDVALVE

FUEL TANK

From No. 15 ALTERNATOR SP SENSOR (7.5A)

YEL/ BLU

PRESSURE SENSOR

. V€NT SHUT

EVAP BYPASS SOLENOID VALVE

LT GRN GRN/ BLK

L

L

__

EVAP TWO WAY VALVE

BLU

VARIOUS SENSORS

L TG R N /

WHT RED/ YEL

INTAKE MANIFOI.I' '97 D16Y7engin. (coupa:KL model, sedan: KL {LX) model},38 Dl6\r/ engine:

YEL/ BLU LT G] GRN/ BLK

FUEL TANK PRESSURE SENSOR

BLU LT GRN/ WHT

EVAP BYPASS

RED/ YEL BLK

VALVE EVAPCONTROL CANISTER

EVAP TWO WA VALVE

FUEL FILL CAP

FUELTANK

11-268

?:y- -<

From No. 15 ALTERNATOR SP SENSOR 17.5A)

J '96 Dl6Y5 engine,'96 D16Y8engine (sodanl,'97 Dl6Y5 sngino,'97 Dl6Y8 sngine (sedan:KA, KC modols): EVAP PURGE CONYROL SOLENOID VALVE

EVAP TWOWAY VAL

From No.15 < - ALTERNATOR SPSENSOR

BLK/YEL__ _

VARIOUS SENSORS

FUEL FILL CAP

I '96 D16Y' engin.,.9?

D16Y7 engine {coupe: KA, KC models, sedan: KA. KC, Kl- IDX) modols, hatchback: all models}:

3lI/EVAP PUBGE CONTROL SOLENOID VALVE

-

-{

ALTERNAT'R SP SENSOR

RED/ YEL

FUEL

8LK

FILL CAP

t

-

From No. 15

+

\,"ro*,

(cont'd)

MANIFOLD

11-269

EmissionControlSystem EvaporativeEmission(EVAPIControls(cont'd) '99 - 00 Dl6Yg engine,'99- 00 Dl6Y5 €ngine,'99- 00 81642engine: From - No. 15 ALTERNATOR SP SENSOR {7.5A)

BLK/ YEL _

FUEL TANK PRESSURE SENSOR

YELI EVAP BYPASS SOLENOID VALVE

ONBOARDREFUELING VAPORRECOVERY IONVR)VENT SHUTVALVE

BLU LT GRN/ *=ol WHT YEL EVAPPURGE CONTROL SOLENOIDVALVE

8LK

FUELTANK

ONBOARDREFUELING VAPORRECOVERY IORVN}VAPOR RECIRCULATION VALVE EVAPCONTROL CANISTER '99 00 D16Y7 engine:

GRN/ BLK

-

EVAPORATIVE EMISSION{EVAP) CONTROL CANISTER FILTER

BLK/ YEL FUEL TANK PRESSURE SENSOR

LT GRN

EVAP EYPASS SOLENOID VALVE

EVAP TWOWAY VALVE

EVAPPURGE CONTROL SOLENOIOVALVE

FUELTANK ONBOARDREFUELING EVAPCONTROL VAPORRECOVERY {ORVRIVENT CANISTER SHUTVALVE ONBOARDREFUELING VAPORRECOVERY IORVRIVAPOR RECIRCULATION VALVE

1 1-2 7 0

BLU LT GNN/ WHT

INTAKE MANIFOLD EVAPORATIVE EMISSION{EVAPI CONTROL CANISTER FILTER

From No. 15 < ALTERNATOR SP SENSOR {7.5A}

\

J ,96 D16Y5engine,,96 D16r,gngino,,96 Dt6Y8 engine {3edan)'37 D16Y5engino..97 D16r, engine {coupe:KA, Kc mod(s€dan:KA' KC mod€lsl: els. sedan:KA, KC, KL {DX} models. hatchback:all modols}''97 Dl6Y8 ongine (EVAP)control system The scan tool indicatesDiagnosticTrouble code (DTC)P0441:EvaporativeEmission insufficientpurgeflow. Description insufficientEVAPcontrol system By monitoringthe purge line vacuumwith the MAP sensor,the ECM/PCMcan detect purgeflow. PossibleCau3e . EVAPPurgeControlSolenoidValve . EVAPPurgeControlSolenoidValveCircuit . EVAPControl Canister . VacuumLines . ECM/PCM Troubl93hootingFlowchart -

\

The MIL has bsGn.eportadon. DTC milal k rtored.

Pioblem vsrificJtion: 1 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rPm with no load {in Parkor noutral)until the radiatorfan comeson. 2. Do the ECM/PCMResetProce' dure, 3. Connectthe SCS serviceconnector. 4. Test-driveunderfollowingconditionson the road - Withoutany electricalload - A/T in E or E Position (M/Tin 3rd-sthgear) - Engine sPeed betweon 1,200- 2.400rpm. - Decelerate {rom 50 mph (80 knl/h)to 15mph (24km/h) ls DTCP0441indicatod?

lntormittont lailuro, sFtorn b OK at thi. timo. Ch€cktor Poor con' ncction3 or looac wir.3 at C144 {EVAP purgo control tolonoid vrtv.l .nd ECir/FCttl.

EVAPPURGECONTROIsottNotD vALvE2P (Cl1al CoNNECTOR

r-+-r

I ' l ' l

Ch.ck fo. !n op€n in the wiro l|(il linel: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe EVAP Purge controlsolenoidvalve2P con_ neclor, 3. Turn the ignitionswitchON (ll) 4. Measur€voltagebetweenbody ground and the EVAPPurge control solenoidvalve 2P connectorterminal No 1.

lG-ro.*l'rr"r

O)

Y

Wire side of female terminals

Rop.ir opor in tho wir6 b€two€n the EVAP purgo codtiol tolonoid v.lvo rnd tho No 15 ALIERNA' TORSP SENSOR17.5A)lu.o. {To page11-272)

(cont'd)

11-271

EmissionGontrolSystem EvaporativeEmission(EVAPIControls(cont'dl

I

(Frompage11-271)

ECM/PCMCONNECTOR D I32P} PGl IBLKI

Check the EVAP purge control solenoidvalvei 1 . R e c o n n e c t h e E V A Pp u r g e controlsolenoidvalve2P connector. 2. ConnectECM/PCMconnector terminalsA15 and 410 with a

PCS{REO/YEL)

t

Doesthe solenoidvalveclick when the jumperis connected?

Checkfor an open or short in the wire (PCSline): Measurevoltage betweenECM/ PCMconnectorterminalA15 and body gro!nd.

3 8 12 l 3 'I't t 5 t 5 '11 I E 1 9 20 ?5

21

9

t0

'tt

23

2a

2A 29 30

PCS{RED/YEL)

Che'ckfor a short in the wir6 {PCS line): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMconnectorA (32P). 3. Disconnectthe EVAP purge controlsolenoidvalve2P con nector. 4. Checklor continuitybetween body ground and ECM/PCM connectorterminalA15.

Repai. short in the wir6s betwoon the EVAP purge control solanoid valveand ECM/rcM lA15l.

R€pair op€n in the wir$ betwo€n tho EVAP purge control solenoid valve and ECM/rcM lA15l.

Checkthe vacuum lin€3: Checkthe vacuumlinesol EVAP systemfor misrouting,leakage, breakage and clogging.

Are the vacuumlinesOK?

2 3 a 6 7 E 9 12 t 3 'ta 't5 l 6 1 7 ta 1 9 20 22

2a

27

28 A

30

0) Pcs{REo/YELI

-272

t0

It

23

21

\

J D16Y7,D16Y8engine

D16Y5engine:

(Frompage11-272)

Check lhe EVAP Purge control solsnoid valve: 1. Disconnectthe vacuum hose from the EVAPcontrolcanister' 2. Connectthe vacuumPumPto vacuum the hoseandaPPIY

VACUUM PUMP/ GAUGE,

0 - 30 in.Hg A973X-

otl -

VACUUM PUMP/ GAUGE, 0 - 30 in.Hg As73x - 0il1 -

xxxxx

xxxxx

Doesit hold vacuum? EVAPCONTROL CANISTER D I32PI ECM/PCMCONNECTOH

I

Checkthe EVAPcontrol canister: 1. Reconnectthe vacuum hoseto the EVAPcontrolcanlster. 2. Connectthe vacuum/Pressure gaugetothe Purgeaarhose 3. ConnectECM/PCMconnector terminalsA15 and A10 with a iumperwire. 4. Startthe engine 5. Checkthe vacuum

PGl IBLKI

JUMPERWIRE Wire sideotfemaleterminals

D16Y7, Dl6Y8 engine:

Checkthe EVAPtwo way valve (seepage11-193)

Doesthe EVAPtwo waY valve

Replacethe EVAPtwo wsY valve.

D16Y5sngin€: VACUUM/ PBESSURE GAUGE0-4in.Hg 07JAZ- 0010008 Sub3titute a known-good ECM/ PCM .nd recheck.lt symPtom/ indicrtion go6s away, rePlacethe original ECM/PCM.

t

VACUUM/PRESSURE GAUGE 0-4 in.Hg o?JAZ- 001fl)OB

(cont'd)

11-273

EmissionControlSystem EvaporativeEmission(EVAP)Gontrols(cont'd)

I J

'99 - 0O models only: The scantool indicatesDiagnosticTroubleCode(DTC)P0451:The FuelTankPressuresensorcircuitrange/ oerformanceDroblem. Ths MIL has been reDortgd on. DTCm/$1 i3 stored.

ECM/PCMCONNECTORS

A (32P)

Checkthe tuel tank pros3ureser|sor: 1. Do the ECM/PCMResetProcedure. 2. Removethetuellillcap. 3. Turnthe ignitionswitchON (ll). 4. N4onitor the FTPSensorvolta g e w i t h t h e H o n d aP G M T e s t e r ,o r m e a s u r ev o l t a g e b e t w e e nb o d y g r o u n d a n d ECN4/PCM connectorterminals A29and C18. wire sideot femareterminars

sG2 IGRN/BLK)

ls thereapprox.2.5V7

Checktho tuel tank pressure!onsoa: 1 . R e m o v et h e f u e l t a n k ( s e e page 11 2421. 2 . R e m o v et h e f u e l t a n k p r e s s u r e s e n s o ra s s e m b l yf r o m the fueltank. 3. Connectthe fueltank Pressure S e n s o rs u b - h a r n e s6sP c o n n e c t o r t o t h e a c c e s sp a n e l sideconnector, 4. Disconnectthe hose between the EVAPtwo way valvg and the fuel tank pressuresensorat the EVAPtwo way valveend. 5 . C o n n e c ta v a c u u mp u m p t o the openend ofthat hose. 6. Turnthe ignitionswitchON (ll). 7. Monitor the FTPSensorvolt, age with the Honda PGM T e s t e r ,o r m e a s u r ev o l t a g e between ECM/PCMconnector t e r m i n a l sA 2 9 a n d C 1 8 ,a n d carefullypump vacuum on the hoseone strokeat a time. 8. The voltagesho!ld smoothly drop from the stading approx. 2.5 V down to approx. '1.5V. STOPapplyingvacuumwhen the voltagedropsto approx.1.5 V or damageto the fuel tank pressuresensormay occur. Doesthe voltagedrop to approx.1.5V and hold?

Sub3titute a known-good ECM/ PCM and r6check.It symptom/ indicltion 90e3aw.y, replac\.th€ original ECM/PCM.

11- 2 7 4

tl' FUELTANK PRESSURE SENSOR

VACUUM - 30 in.Hg PUMP/GAUGE,0 A973X- 041 -

xxxxx

FUELTANK PRESSURE SENSOR ASSEMBLY

EVAP TWO WAY VALVE

\

J engine {coupe:KL model, sedan:KL (LX) modeu,'97 FuelTank Pro3suresensor 196 D16Y8engine (coupe).'97D15Y7'99 '98-all - 00 D16Y5engine with M/Tl: models) D16Y8engine (coupe:all models, sedan: KL model,

Foc2l::il":"toolindicatesDiagnosticTroublecode(DTc)P0452:A|owvo|tageprob|emintheFue|TankPre EcM/PCM. The fuel tank pressuresensorconvertsfuel tank absolutepressureinto electricalsignalsand inputsthe OUTPUT VOLTAGE tvt 4.5

-

The MIL has beenreportedon DTCP0452is stored.

Checkthe vacuum lines: C h e c kt h e v a c u u m l i n e s o f t h e fuel tank pressuresensorfor misr o u t i n g ,l e a k a g eb, r e a k a g ea n d cloggrng.

+7 kPs 150mmHg, 2 in.Hg)

-? kPa (-50 mmHg, -2 in.Hg)

PRESSURE

\ Are the vacuumlinesOK? O I16P) ECM/PCMCONNECTOR Problemv€ritication: ResetProce 1. Do the ECM/PCM dure. 2. Removethe luel fill caP. 3. Turnthe ignitionswitchON lll) 4. Monitor the FTPSensorvolt_ a g e w i t h t h e H o n d aP G M T e s t e r ,o r m e a s u r ev o l t a g e b e t w e e nb o d Yg r o u n d a n d terminalDl5. ECM/PCM ls thereapprox.2.5V?

Checktol an op€n in wite (VCC2 line): 1. Turn the ignitionswitchOFF fuel fill caP. 2. Reinstallthe the fuel tank Pres' 3. Disconnect suresensor3P connector4. Turnthe ignitionswitchON (ll) 5, Measurevoltage between the fuel tank pressuresensor3P connectorNo. l terminaland No.2 terminal. ls thereapprox.5 V?

(Topage11'276)

PTANK {LTGRNI lntermittent tailuro, sYstemi5 OK dt this timo. Chockfor Poot conneciion3 or loose wir* at C131 llocatod under right side ot dashl, C4O1(located .bove under'da3h tuso/ielay box), C574 1C568)* {located under acc€ss Panell. C792 lfuel tank pressule sen3or) and EcM/PCM.

Wire sideoI femaleterminals

FUELTANK PRESSURE SENSOR (C7921 3P CONNECTOR

vcc2 (YEL/BLU}

sG2 IGRN/8LK) Wiresideof femaleterminals Repairopen in the wite between the fuel tank Pr€s3urea€n3orand th6 EcM/PcM (D1ol.

(cont'd)

11-275

EmissionControlSystem EvaporativeEmission(EVAP)Controls(cont'dl ! {Frompage11-275) FUELTANK PRESSURE SENSOR 3P CONNECTOR {C7921 PTANK {LT GRN)

Check to. ! short in the wiro IPTANKlinol: M e a s u r ev o l t a g e b e t w e e nt h e firel tank pressuresensor 3P connector No. 3 terminal and No. 2 terminal,

sG2 {GRN/BLK) Wire side of f€mal€ terminals

ls thereapprox.5V?

Check fo. a Short in the wire IPTANKIinoI: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ECM/PCMcon, nectorD 116P). 3. Checkfor continuity between the fuel tank pressuresensor 3P connectorNo.3 terminals and body ground.

ls there continuity?

Substitute ! known-good ECM/ PCM and recheck. lf .ymptom/ indication go6s awry, replecoth6 origin.l ECM/PCM.

-276

PTANK {LT GRNI

Repairthort in thc wire betwean tho fuel iank pre$uro 3€naorand ECM/FCMtDl5t.

\ '99 - 00 models excepi Dl6Y5 engine with M/T: problemin the FuelTank Pressure The scantool indicatesDiagnosticTroubleCode(DTC)P0452:A low voltage sensor. signalsand inputsthe ECM/PCM The fuel tank pressuresensorconvertsfuel tank absolutepressureinto electrical OUTPUT VOLTAGE (vl t.5

The MIL has been.eported on. DTCP0452is stored Checkthe vacuum lines: C h e c kt h e v a c u u m l i n e s o f t h e fuel tank pressuresensorlor misr o u t i n g ,l e a k a g eb, r e a k a g ea n d cloggrng.

I

ls thereapprox.25 V?

Checkfor an open in wire {VCC2 line): 1. Turnthe ignitionswitchOFF. theltrelfill caP 2. Reinstall 3, Removethe accessPanelfrom the floor. the fuel tank Pres' 4. Disconnect s u r e s e n s o rs u b - h a r n e s6s P

I

PRESSURE

A (32P) ECM/PCMCONNECTOR

PTANK{LT BLUI

lntermitlent tailure,3Ystemb OK at this time. Checkfor Poor con' nections or loose wire3 at C131 {locatedunder right side of dash}, C401 {located above under'dash tuse/relay box), C574 (C568)* l l o c d t e d u n d e r a c c e s sP a n e l ) , C792 (tuel rank Prcssuresensorl and ECM/PCM.

5. Turnthe ignitionswitchON (ll). 6. At the accessPanelside, mea_ sure voltage betweenthe fuel tank Pressuresensorsub-narNo 5termi ness6P connector nalandNo.6 termlnal. ls there approx 5 V?

(Topage'11-278)

+7 kP. 150mmHg, 2 in.Hgl

-7 kP. (-g) mmHg, -2 in.Hgl

Are the vacuumhnesOK?

Problemveritication: ResetProce1. Do the ECM/PCM dure, 2. Bemovethe fuel fill caP. 3. Turnthe ignitionswitchON {ll) 4. Monitorthe FTPSensorvoltage with the HondaPGMTester'or measurevoltagebetweenbody groLrndand ECM/PCMconnec_ tor terminalA29.

l l

0.5

Wire sideof lemaleterminals

FUELTANK SENSOR PRESSURE SUB.HARNESS (C574(C568)rl 6P CONNECTOR

vcc2 (YEL/BLUI

sG2 {GRN/BLK}

Wire sideo{ temaleterminals Repair open in tho wire between th6 fu€l tank Prossuro sen3oa and the ECM/PCM lc28).

(cont'd)

EmissionControlSystem EvaporativeEmission(EVAPIControls{cont,dl (From page 11-277)

J FUELTANK PRESSURE SENSOR SU8-HABNESS 6P CONNECTOR 1C574tC568)rt PTANK {LTGRN}

C h e c kf o r a s h o r t i n t h e w i r e {PTANKline): A t t h e a c c e s sp a n e ls i d e , m e a s u r e v o l t a g eb e t w e e nt h e f u e l tankpressuresensorsub-harness 6P connectorNo. 2 terminaland N o .6 t e r m i n a l .

Wire sideof femaleterminals ls thereapprox.5 V?

C h o c kl o r a S h o r t i n t h e w i . e (PTANKline): 1. Turn the ignitionswitchOFF. 2. Disconnect the ECM/PCM connectorA (32P). 3. Checkfor continuitybetween the fuel tank pressuresensor sub-harness 6P connectorNo. 2 terminalsand body ground.

PTANK ILT GRN}

Repairshort in the wi.e betwsen the luel tank pressuresensorand ECM/PCM{A291.

Subsiitute a known-good ECM/ PCM and rechock.lf symptom/ indicationgoes away, replac€the original ECM/PCM.

1 1- 278

\ (coupo: KL mode|' 3edan: KL (Lxl modg||',97 Fue| Tank Pr€ssuresensor 196 Dr6Y8 engine (coupe},,97 D16Y7angino ongins with M/Tl: Dl6Y5 0O 39 Dl6Y8 engine (coupe:all modeb, sedan: Ki model.'98'all modols)

rFoG'l::;Jl"too|indicatesDiagnosticTroub|ecode(oTc)P0453;Ahighvo|tageprob|emintheFue|TankPr The MIL has beon reponed on DTCP0453b stored. Checkthe vacuum lines: C h e c kt h e v a c u u ml i n e s o I t h e fueltankpressuresensorfor misr o u t i n g ,l e a k a g eb, r e a k a g ea n d clogging. Are the vacuumlinesOK? D Il6PI ECM/PCMCONNECTOR

\

Problemverification: 1. Do the ECM/PCMResetProcedure. 2. Femovethe fuel fill cap 3. Turnthe ignitionswitchoN (ll). 4. Monitor the FTPSensorvolta g e w i t h t h e H o n d aP G M T e s t e r ,o r m e a s u r ev o l t a g e b e t w e e nb o d Y g r o u n d a n d ECM/PCMconnectortermrnal D15. ls thereapprox.2 5 V?

Check for an oPen in the wire (SG2line): 1. Turnthe ignitionswitchOFF. the fuellill cap 2. Reinstall the fuel tank Pres3. Disconnect suresensor3P connector. 4. Turn the ignitionswitchON (ll) 5. Measurevoltage between the fuel tank Pressuresensor3P connectorterminalsNo. 1 and No.2. ls thereaPProx.5 V?

Check for an open in the wire (PTANKline): M e a s u r ev o l t a g e b e t w e e nt h e fueltank Pressuresensor3P connectorNo. 3 terminaland No. 2 termrnal,

I

PTANK ILT GRNI lntormittont t iluro, 3Ystem is OK at this time. Checklot Poor con_ noctiona or loo3e wirat at C131 {loc.ted undor right 3id6 of d8hl, CaOl llocatod rbov. under-dalh fus6/relay boxl, C574 (C568lr llocatod und6l accoss Pan6ll, C792 lfuel tank Preasuloaonlorl end ECM/PCM. *: coupe

Wiresideof tgmaletorminals

FUELTANK PRESSURE SENSOR (C792) 3PCONNECTOR

vcc2 (YEL/BLU}

sG2 (GRN/BLKI Wire sid€ of female terminals

Ropairopon in the wira b€tw€sn the fuel tank prasure sonlor and ECM/PCM(Dl1).

sG2 IGRN/BLKI

PTANK IGBN/RED}

ls thereapprox.5 V?

(cont'd) {To page 11-280)

11-279

EmissionControl System EvaporativeEmission(EVAPIControls(cont'dl

\ v

l F r o mp a g e1 1 - 2 7 9 1

ECM/PCMCONNECTOR D {16PI

Check for an open in the wire {PTANKline): Measurevoltage betweenECM/ P C Mc o n n e c t otre r m i n a l sD 1 5 a n dD ] 1 .

ls thereapprox.5 V?

Substitute a known'good ECM/ PCM end recheck.lt symptom/ indication goes awav, replacethe original ECM/PCM.

-2AO

Repairopen in the wire between E C M / P C Ml D 1 5 ) a n d l u e l t a n k pressuaesensor.

PTANK {LTGRN)

SG2 (GRN/BLK}

Wire sideof femaleterminals

\ '99 - 0Omodols except Dl5Y5 engine with M/T:

rFo45'::n":"tooIindicatesDiagnosticTroub|ecode(DTc)P0453:Ahighvo|tageprob|emintheFUelTankP The MIL has beenreportedon. DTCP0453is stored. Checkthe vacuum lines: C h e c kt h e v a c u u ml i n e s o t t h e fueltank pressuresensorfor misr o u t i n g ,l e a k a g eb, r e a k a g ea n d clogging. Are the vacuumlinesOK? A {32P) ECM/PCMCONNECTOR Problemverilication: ResetProce1. Do the ECM/PCM dure, 2. Removethe fuel fill caP 3. Turnthe ignitionswitchON (ll). 4. Monitor the FTPSensorvolt' a g e w i t h t h e H o n d aP G M T e s t e r ,o r m e a s u r ev o l t a g e b e t w e e nb o d y g r o u n d a n d ECM/PCMconnectorterminal A.29. ls thereapprox.2.5V?

Ch€ck for an open in the wira {SG2line): 1. Turn the ignition switch OFF. 2 . R e i n s t a l lt h e f u e l f i l l c a P 3. Remove the access Panel lrom the floor. 4 . D i s c o n n e c tt h e f u e l t a n k P r e s s u r e s e n s o r s u b - h a r n e s s6 P

PTANK{LTGRN)

lntermittent failuro. svstem b OK at this time. Checkfor Poor con_ noctionsor loo3€wire3 at C131 {locatedunder tight side of dash), C4Ol {located above underdash fuse/relay boxl, C57{ (C5681' l l o c a l e d u n d e . a c c e s sP a n e l l , C792 {fuel tank Pressuresensorl aod ECM/PCM.

Wiresideof temaleterminals

FUELTANK SENSOR PRESSUNE SUB.HARNESS 6P CONNECTOR {C574(C568)}}

vcc2 {YEL/BLUI

sG2 IGRN/BLK)

Wiresideof femaleterminals

5. Turn the ignition switch ON (ll) 6 , A t t h e a c c e s sP a n e l s i d e , m e a sure voltage between the fuel tank pressuresensor sub_harness 6P connector termlnals N o . 5 a n dN o . 6 .

ls thereapprox.5V?

Check lor an oPen in the wire {PTANKlinel: At the accessPanel side, mea s u r e v o l t a g eb e t w e e nt h e f u e l tank pressuresensorsuo_harness 6P connectorNo. 2 terminaland No. 6 terminal.

Repairopen in the wire between the fueliank Pres3ure3ensorand ECM/PCM{Cl8). PTANK {LTGRNI

(cont'd) ls there approx. 5 V?

(Topage11.282)

11-281

EmissionGontrol System EvaporativeEmission(EVAP)Controls(cont'd) (Frompage11-281)

I J ECM/PCMCONNEfiORS a {32P)

Check tor an open in th€ wire (PTANKline): Measurevoltage betweenECM/ P C i / lc o n n e c t o rt e r m i n a l sA 2 9 a n dC 1 8 .

ls thereapprox.5 V?

PTANK ILT GRNI

Repsir open in tho wire between ECM/PCM {A29} .nd fuol tank oao!3urotensor. SG2 IGRN/BLK)

Substitute a known-good ECM/ PCM and rscheck. It symptom/ indicationgoes aw.y, ..plsc. the original ECM/FCM.

Wiresadeof femaleterminals

t

\"

11-282

I

a

\ t,96 D16Y8engine (coup6l,'9? Dl6Y7 engine (coupe:KL model, sedan: KL els, sedan:KL model,'98-8ll modelsl 39 - 00 Dl5Y5 engine with M/Tl:

(LX) model)"g7 Dl6Y8 ongine (coupe:all mod-

(EVAP)controlsystemleak The scantool indicatesDiagnosticTroublecode (DTc)P1456:EvaporativeEmission detected(fuel tank sYsteml

Fr4t6l

(EVAP)controlsystemleak The scantool indicatesDiagnosticTroubleCode(DTC)P1457:EvaporativeEmission

fF14s7detected(EVAPcontrol canistersystem). PossibleCauss . Fuelfill cap . VacuumConnections . FuelTank . EVAPControlCanisterVent ShutValve . EVAPControlCanisterVentShutValveCircuit . EVAPPurgeControlSolenoidValve . EVAPPurgeControlSolenoidValveCircuit . EVAPBypassSolenoidValve . EVAPBypassSolenoidValveCircuit . FuelTankPressureSensor . FuelTankPressureSensorCircuit . EVAPControl Canister . Throttle Body

VACUUM - 30 in.Hg PUMP/GAUGE,0 A973X- 041 -

xxxxx

Troublsshooting Flowchart

I

-

EVAP CONTROL

Check the EVAP control canbtol vent shut valve: 1. Disconnectthe vacuum hose I r o m t h e E V A Pt h r e e w a Y valve and connecta vacuurn pump to the hose. 2 . R e m o v e t h e E V A Pc o n t r o l canistervent shut valveIrofi the canrster. 3. Turnthe ignitionswitchON (lli 4. Applyvacuumto the hose.

cANrsrER

.4,

The MIL ha3 been rePofted on. DTCP1456or P1457is stored.

re

VALVE

./

{S----r*::n Chock for . shon in the wire (VSv linel: Disconnectthe 2P connector{rom the EVAP control canister vent

Does the valve hold vacuum?

Repairshort in the wir€ betwcen the EVAP control canister vent shut v.lve and tho ECM/PCM tA29|.

Doesthe valvehold vacuum? Check the EVAP control canister vent shui valve: 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalA29 to body ground with a iumPerwire. 3. Turn the ignitionswitchON (ll). 4. Applyvacuumto the hose

A {32P) ECM/PCMCONNECTOR

Reohce the EVAP control canister vent shttt valve.

7

3

't2 t 3

t5 t 6 I t

25

ILT GRN/W{T)

It

t 9 20

a

A

I

I

9

t0

1t

2a

2a

JUMPERWIRE

Doesthe valveholdvacuum? Wiresideof femll terminals

\

(cont'd)

(To page11-284i

(To page 11 284)

11-283

EmissionControlSystem EvaporativeEmission(EVAPIControls(cont'dl (Frompage1l-283)

1

(Frompagel1-283) EVAPCONTROL CANISTERVENT SHUT VALVE2P CONNECTOR IC141} l l t r t

Check for an open in tho wire (lGl line): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector lrom the EVAPcontrolcanister vent shutvalve. 3. Turnthe ignitionswitchON (ll). 4. Measurevoltage between the EVAPcontrolcanistervent shut v a l v e2 P c o n n e c t o tre r m i n a l No. 2 and body ground.

+

rcl

o) (8LK/YErl

I

Wire sideot temaleterminals

Repairopen in the wire betwe€n the EVAP control c.ni3tei vent shut valve and th6 No. 15 ALTERNATORSP SENSOR17.5Al fuse.

Cfisck tor an opon in the wire (VSV line): 1. Turnthe ignitionswitchOFF. 2. Beconnectthe 2P connector to the EVAPcontrol canister vent shut valve. 3. Turnthe ignitionswitchON (ll). 4. Measurevoltage between E C M / P C Mc o n n e c t o rt e r m i nalsA29 and Al0.

ECM/PCMCONNECTOR A (32PI

PGT(BLKI

I

2

:

3

12 13

t6

25

VSV ILTGRN/WHT}

ls there battery voltage?

l

l ' l t l ' l l e l s lr oI r I €lnltlr@/lzzl zs f il

Wiro side of lemale tgrminals

Rep.ir open in the wire betwoon the EVAP control canister vent shut valve and th€ ECM/PCM tA29t.

Replaceth6 EVAP control canister vent 3hut valve.

Checkthe vacuumwhon cold: 1. Disconnectthe vacuum hose shown from the EVAPcontrol canrsterand connecta vacuum gaugeto the hose, 2. Start the engineand allow it to idle. N O T E :E n g i n ec o o l a n tt e m peraturemust be below 154oF (68'C)or lVC switch OFF. 3. Ouicklyraisethe enginespeed to 3,000rpm.

{Topage1l-285}

11-284

VACUUM PUMP/ GAUGE,0- 30 in.Hg 4973X 041- XXXXX

'l'

\ (Frompage11-284)

ls therevacuum?

Check the EVAP pirrge control solenoidvalvei 1. Disconnectthe 2P connector lrom the EVAPpurge control solenoidvalve. 2. Ouicklyraisethe enginespeed to 3,000rpm. InsDectvacuum ho56routing. ll OK, replacethe EVAP Purge control solenoidvalve.

\

Checkthe vacuum when hot: 1. Turn the ignitionswitchOFF 2. Blockthe rearwheelsand set the parkingbrake. 3. Jack up the front o{ the vehicle and supportit with safety stands, 4 . S t a r t t h e e n g i n e .H o l d t h e engine al 3,000rpm wlth no load (in Parkor neutral)until the radiatorfan comeson, then letit idle. 5, Checkfor vacuumat the vacuum hose with transmissaon i n g e a r ( A / Ti n B P o s i t i o n , M/T in lst gear) after starting the engrne. 6. Ouicklyraisethe engine speed to 3,000rpm.

Chock for a short in the wire (PCSlinel: 1. Turnthe ignitionswitchOFF connec' ECM/PCM 2. Disconnect tor A (32Pi. 3. Checkfor continuitybetween the EVAPPUrgecontrol sole noid valve 2P connectortermi nalNo.2 andbodyground. ls therecontinuity?

EVAPPURGECONTROLSOI.INOID IC114I VALVE2P CONNECTOR

Wiresideot female terminals Reoairshort in the wire botween the EVAP purg€ cor|t]ol solenoid valve and the ECM/pcM lA15l.

Substitute a known-good ECM/ PCM and recheck. lf sYmPtom/ indication goes eway. repl.c€ the original ECM/PCM.

Check the EVAP Purg€ control solenoidvalve: 1. Turnthe ignitionswitchOFF 2. Disconnectthe 2P connector from the EVAP Purge control s o l e n o i dv a l v e a n d w a r m l t up to normal operatingtem_ peratureagain if necessary 3. Stanthe engine. 4. At the harnessside, measure v o l t a g e b e t w e e nt h e E V A P Purge control solenoidvalve 2P connectorterminal No. 1 and No. 2 with the transmis sion in gear (A,/Tin E Position, M/T in 1stgear).

?

,

I,l,lil?"",,, EL,TW YEL)

In3pectvacuum ho3€touting. ll OK, replace EVAP Purge conlrol aolenoidvtlv€.

Check lo. an open in the wire llGl linel: At the harnessside, measurevolt age betweenthe EVAPPurgecontrol solenoidvalve 2P connector terminalNo. 1 and bodyground

\

IBLK/YELI

Repeiropen in tho wire between EVAP purge conttol solenoid valv€ and the No. 15 ALTERNATORSP SENSOR(7.5A fu3e (cont'd)

lTo page 11 286i

(To page11-286)

11-285

EmissionControl System EvaporativeEmission(EVAPIControls(cont'd) (Frompage11'285)

\

(Frompage11 285) ECM/PCMCONNECTOR A {32P} PGl

{BLK) Check lor an op€n in the wire {PCSline}: 1. Turnthe ignitionswitchOFF. 2, Reconnectthe 2P connectorlo the EVAPpurge controlsolenoidvalve. 3. Turnthe ignitionswitchON (lll. 4. Measurevoltage between ECM/PCM connectorterminals 4 1 5 a n dA ] 0 .

PCS {RED/YEL)

Wire side of temale terminals

Repai. op€n in the wire bGtween the EVAP purge control solenoid valveand the ECM/PCM{A151.

EVAPIWO WAY Substitute a known-good ECM/ PCMand retest. tf sympiom/indication goes away, replac6 the original ECM/PCM.

Checkthe EVAPtwo way valvo: See EVAPtwo way valve test (see p a g e1 1 ' 2 9 4 ) .

Replace tho EVAP two way valve.

Check the EVAP bypr$

xxxxx

EVAPBYPASS SOLENOIDVALVE

3olenoid

1. Disconnect the vacuum hose from the EVAP two way valve and connect a vacuum pump to the hose. 2 . T u r n t h e i g n i t i o ns w i t c h O N l l l ) . 3. Apply vacuum to the hose.

Doesthe valvehold vacuum?

C h e c kt o r a s h o r t i n t h e w i r e {2WBSlinel: Disconnect the 2P connectorfrom the EVAPbypasssolenoidvalve.

Does the valve hold vacuum?

(To page'l1 287)

11-286

PUMP/ GAUGE,0- 30 in.Hg A973X041 -

O.RING Beplace. EVAP TWO WAY VALVE Repairshort in the wire betwe€n EVAP bypass sol€noid valve and rhe ECM/PCMlA28).

.

I (Frompage11-286)

A (32P) ECM/PCMCONNECTOR Checkthe EVAP bypa3s3olenoid 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalA28and bodyground with a jumperwire. 3. Turn the ignitionswitchON (ll).

I 2 '12 t t

ChGcktor an opon in lho wite (lGl lin6l: 1. Turnthe ignitionswitchOFF 2. Disconnectthe 2P connector trom the EVAPbypass solenoid valve. 3. Turnthe ignitionswitchON (ll). 4. Measurevoltage between the EVAPbypasssolenoidvalve 2P connectorterminal No- 1 and body ground.

7

5

8

1 5 t6

t 8 t 9 20

27

26 29 3o

2WBS (BLUI _ JUMPER WIRE

t0

11

23

21

Wiro sideol Iemale terminals

SOLENOID EVAPBYPASS VALVE2PCONNECTOR {C793I Wire side of femal€ terminals

R.pair open in tha wil€ botwoon EVAPpurg. cor|trol 3olenoid valve .nd tho No. 15 ALTERNATORSP SENSOR17.5Al tu3e.

\

a l32Pl CONNECTOR ECM/P,CM Check lor an open in the wire {2WBSline): l. Turnthe ignitionswitchOFF. 2. Reconnsctthe 2P connector to the EVAPbypasssolenoid 3. Turnthe ignitionswitchON (ll) 4. Measure voltage between ECM/rcM connectorterminals A28andAl0. Ch6ck the following P..ts for l 6 a k a g e t o a t m o s P h e r e ,a n d roplir or rephco if neca3aary: ' fuel fill c.D . tu6l t.nk . tuel vapor pipe . EVAPtwo way v3lvo . EVAPbypa3! solanoidvtlY. , fuel tlnk pra63uro3on3or . EVAPcontrol canBte. . EVAP control crnistor vent shut vtlvo . EVAP purgo control lolonoid

ls there batteryvoltage?

PGl (BLKI

I

I 7 l l s l e lr o l r ' I

I

,"l!j'"EBUP)._3)_!J

't2 r3 E

nt ll 4al*l 4 l,-'l

2WaS{BLUI Wir€ side of female terminals

Roprir opon in tho wiro betwoen th. EVAP byp.$ 3ol6noid valve rnd tho EcM/PcM lA28l.

. vscuum hoseSand connoction3

\

(cont'dl

11-2A7

EmissionControl System EvaporativeEmission{EVAP)Controls(cont'dl

\ J

'99 - 00 modols except Dl6Y5 engine with M/T: The scantool indicatesDiagnosticTroubleCode(DTC)P1456:EvaporativeEmission(EVAP)controlsystemleak

tF1456-ldetected(fueltanksvstem).

The scantool indicatesDiagnosticTroubleCode(DTC)P1457:Evaporative Emission(EVAP)controlsystemleak

tP14sz-ldetected(EVAPcontrolcanistersystem). PossibleCause . Fuelfill cap . VacuumConnections . FuelTank . EVAPControlCanisterVent ShutValve . EVAPControlCanisterVent ShutValveCircuit . EVAPPurgeControlSolenoidValve o EVAPPurgeControlSolenoidValveCircuit . EVAPBypassSolenoidValve . EVAPBypassSolenoidValveCircuit . FuelTankPressureSensor . FuelTankPressureSensorCircuir . EVAPControlCanister . ORVRvent shut valve . ORVRvapor recirculation valve . ThrottleBody

VACUUM PUMP/GAUGE, 0 -30 in,Hg A973X- oal -

xxxxx

EVAP CONTROL CANISTER VENT SHUT VALVE

T-t t

\

TroubleshootingFlowchart The MIL has beenreportedon. DTCP1456o. P1457is stored.

Check the EVAP cont.ol canister vent shul valve: 1. Disconnectthe vacuum hose f r o m t h e E V A Pt h r e e w a y valve and connecta vacuum pumpto the hose. 2 . R e m o v et h e E V A Pc o n t r o l canistervent shut valve from tne canrster. 3. Turnthe ignitionswitchON (ll). 4. Applyvacuumto the hose.

O.RING Replace.

EVAP CONTROL CANISTER

Check for a short in the wiro (VSV linel: Disconnectthe 2P connectorfrom t h e E V A Pc o n t r o lc a n i s t e rv e n t

Does the vaive hold vacuum?

Doesthe valvehold vacuum? Check the EVAP cont.ol canister v€nl shut valve: 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector t e r m i n a lA 4 t o b o d y g r o u n d with a jumperwire. 3. Turnthe ignitionswitchON (ll). 4. Applyvacuumto the hose.

Reolacethe EVAP control canister veni shut valve.

RoDair3hort in the wire botwe€n the EVAP control canilter vent shut valve and the ECM/PCM {A4t. ECM/PCMCONNECTOR A I32PI

Doesthe valvehold vacuum?

Wire side of female terminals

(To page 11'289)

11-288

lTo page11-289)

\ {Frompagel1 288}

(Frompage11-288) EVAPCONTROL CANISTERVENT SHUT VALVE2P CONNECTOR IC141I Check for an open in tha wire (lGt linol: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector from the EVAPcontrolcanister vent shutvalve. 3. Turnthe ignitionswitchON lll). 4. Measurevoltage between the EVAPcontrolcanistervent shut valve 2P connectorterminal No.2 andbodyground.

ls there batteryvoltage?

tG1 IBLK/WHT}

Wiresideof temaleterminals Repairopen in the wire between the EVAP control canister vent shut valve .nd the No. 15 ALTERNATORSP SENSOR{7.5A)fu3e. CONNECTORS ECM,/PCM

a t32P) Ch€d( for an op€n in the wiie IVSV linel: 1. Turnthe ignitionswitchOFF. 2. R€connectthe 2P connector to the EVAPcontrol canister vent shutvalve, 3. Turnthe ignitionswitchON (ll). 4. Measurevoltage between E C M / P C Mc o n n e c t o rt e r m i nalsA4 and 82.

\

Wire sideof female termrnats

ls there batteryvoltage?

Repairopen in the wire bctween the EVAP control canistorvent shut valve and lhe ECM/PCM {44t.

Rcolacotho EVAP control canis. t6r vent shut valvo.

Ch€ckthe vac[um when cold: 1, Disconnectthe vacuum hose shown from the EVAPcontrol canisterand connecta vacuum gaugeto the hose. 2. Start the engineand allow it to idle. N O T E i E n g i n ec o o l a n tt e m peraturemust be below 154"F (68'C)or Ay'Cswitch OFF. 3. Ouicklyraisethe enginespeed to 3,000rpm.

?, T-t fl VACUUM PUMP/ GAUGE,0 -30 in.Hg A973X0/r1- XXXXX

{Topage11-290)

\

(cont'd)

11-289 -

EmissionControlSystem EvaporativeEmission(EVAPIControls(cont'dl

I J

(Frompage11-289) Ch€ck the EVAP purge control solenoidvalv6: 1. Disconnectthe 2P connector from the EVAPpurge control solenoidvalve. 2. Ouicklyraisethe enginespeed to 3,000rpm. Insped vacuum hose routing. lf OK. roplace the EVAP purge control solonoidvalve.

Checkthe vacuum when hot: 1. Turnthe ignitionswitchOFF. 2. Blockthe rearwheelsand set the parkingbrake. 3. Jack up the lront of the vehicle and supportit with safety stands. 4 . S t a r t t h e e n g i n e .H o l d t h e engine at 3,000rpm with no load (in Parkor neutraliuntil the radiatorfan comeson, then let it idle. 5. Checkfor vacuumat the vacuum hose with transmission in gear (A/Tin E position, lvl/T in 1st gear) after starting the engine. 6. Ouicklyraisethe enginespeed to 3,000rpm.

Chock tor r short in the wir€ {PCSline): 1. Turnthe ignitionswitchOFF. ECM/PCM connec2. Disconnect tor A (32P). 3- Checktor continuitybetween the EVAPpurge controlsolenoid valve 2P connectorterminalNo.2 andbodyground. ls therecontinuity?

EVAPPURGECONTROLSOLENOID VALVE2P CONNECTOR IC114I PCS IRED/YEL) of

temale termrnars Rooairshoft in the wire belwegn the EVAP pulg6 control solenoid valvs and tho ECM/PCM{A61.

Substitute a known-good ECM/ PCM and rech6ck. lt 3ymptom/ indicrtion 90e3 rway, r6plac6 th€ o.iginalECM/FCM. Check th€ EVAP purge control solenoidvalve: 1. Turnthe;gnitionswitchOFF. 2. Disconnectthe 2P connector from the EVAPpurgecontrol solenoid valve and warm it up to normal operatingtemperatureagain if necessary. 3. Startthe engine. 4- At the harnessside, measure v o l t a g e b e t w e e nt h e E V A P purge control solenoidvalve 2 P c o n n e c t o tre r m i n a lN o . 1 and No.2 withthetransmission in gear {A/T in E position, M/T in lst geari. ls therebatteryvoltage?

PCS (RED/YEL) tGl IBLK/ YEL)

In3pectvacuum hoaerouting. lf OK, repl.ce EVAP purge control solonoidvalve.

Chock for an open in the wire (lG1lina): At the harnossside, measurevoltage beNveenthe EVAPpurge control solenoidvalve 2P connector terminalNo. 1 and bodyground. ls there batteryvoltage?

( T op a g e1 1 - 2 9 1 )

11-290

{ T op a g e1 12 9 1 )

Repairopen in the wire b€lwe€n EVAP purge contrl 3olenoid valv6 and lhe No. 15 ALTERNATORSP SENSOR17.5A, fu3e.

I

ECM/PCMCONNECTOR (Frompagel1 290)

(Frompage11-290)

Check for an open in the wire {PCSlin6): 1. Turn the ignitionswitchOFF the 2P connectorto 2. Reconnect the EVAPpurge controlsole3. Turnthe ignitionswitchON {ll). 4 . M e a s ur e v o l t a g e b e t w e e n EClr/PCMconnectorterminals A6 and 82.

ls there batteryvoltage?

Wire sideof temale terminals Ropairopen in the wire between the EVAP purge Gontrolsolenoid vrlve and th6 ECM/PCMlA6l

Substitute a known-good ECM/ PCMrnd re{61. lf symptom/indi' cation goes away, rePlacethe oiiginal ECM/PCM.

I Checkthe EVAPtwo way valve: See EVAPtwo way valve test (see p a g e1 1 - 2 9 5 ) . Roplace the EVAP two way valve

FUEL TANK

Checkthe EVAP bypa$ solenoid 1 . R e m o v et h e f u e l t a n k ( s e e page11-242J. 2. LiIt up the fuel tank with a transmissioniack,and connect the fuel tank pressuresensor sub harness6P connectorto the accesspanelside connec_ tor, 3. Disconnectthe vacuum hose from the EVAPtwo way valve and connecta vacuumPumP to the hose, 4. Turnthe ignitionswitchON (ll) 5. Applyvacuumto the hose.

tn VACUUM - 30 in Hs PUMP/GAUGE,0 A973X- 041 -

xxxxx

(To page 11 292)

EVAP TWO WAY VALVE

(cont'd)

11-291

EmissionControl System EvaporativeEmission(EVAPIGontrols(cont'd)

EVAPBYPASS SOLENOIDVALVE

Y

( F r o mp a g el 1 ' 2 9 1 )

Doesthe valvehold vacuum?

C h e c kf o r a s h o r t i n t h e w i r e {2WBSlinel: Disconnectthe 2P connector{rom the EVAPbypasssolenoidvalve.

Repairshort in the wire between EVAP bypass solenoid velve and rhe ECM/PCM{A3).

O o e st h e v a l v e h o l d v a c u u m ?

Checkthe EVAP bvpr$ 3olenoid 1. Turnthe ignitionswitchOFF. 2. ConnectECM/PCMconnector terminalA3 and body ground with a jumper wire. 3. Turnthe ignitionswitchON (ll).

Doesthe valvehold vacuum?

Ch€ck lor an op.n in the wire llcl linol: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector from the EVAP bypasssolenoid valve. 3. Turnthe ignitionswitchON (lll. 4, Measurevoltage between the EVAP bypasssolenoidvalve 2P connectorterminal No. 1 and body ground.

Wire sideol femaleterminals

EVAPSYPASSSOLENOIO VALVE2P CONNECTOR IC793}

tG1

{BLK/WHT)

Wire sideof female terminals

Repair open in the wir6 b€tw€€n EVAPpurg6 control 3olanoid valve and the No. 15 ALTERNATORSP SENSOR{7.5A) Iuse.

{To page 11 293)

11-292

(To page11 293i

I

(Frompage11-292i

(Frompage11 292)

Check toi an opon in the wiro (2wBS linol: 1. Turnthe ignitionswitchOFF. 2. Reconnectthe 2P connector to the EVAPbypasssolenoid 3. Turn the ignitionswitchON (ll). 4. Measurevoltage between ECM/PCMconnectorterminals 43 and 82.

\

Chock the tollowing parts tol leakageto aimosphero,and ropaii or replacoif necess6.y: . fuel fill cap . fuel tank . fuel v.por pipe . EVAPtwo way valve . EVAPbypas solonoidvalve . tuel tank pre3suaesen3or . EVAPcontrol cankter . EVAPcontrol canisier veni 3hut valve . EVAP purge conttol solenoid

ls there bafteryvoltage?

Reprir opan in tho wire be(wean th. EVAP byp.is solonoid valve rnd rhe EcM/PcM (A31.

. ORVRvent 3hut valve . ORVBvaoor recirculationvalve . vacuum hoses tnd connactions

\l

(cont'd)

11-293

EmissionControlSystem EvaporativeEmission(EVAPIControls(cont'd) EvaporativeEmission(EVAPITwo Way Valve Testing l'96 DIGYSenginelcoupel,'97Dl6Y7 engine(coupe:KL model,sedan:KL (LX)modoll,'97 Dl6Y8 engine{coup€: '98-all modelsll: alt models, sedan:KL model, 1. Removethe fuel fill cap. 2.

R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y valve. and connectit to a T-fittingfrom a vacuum gaugeand a vacuumpump as shown.

VACUUM/PRESSURE GAUGE 0- 4 in.Hg

I J

f96 D16Y5engine,'96D16Y7engine,'96D16Y8ongine (sedanl,'97D16Y5engine,'97Dl6Y7 engine{coupe:KA, KC models, sedan: KA, KC, KL {DX} models, hatchback: all modsls),'97D16Y8engine{sedan:KA, KC models}l: 1.

Removethe fuel fill cap,

2.

R e m o v et h e v a p o r l i n e f r o m t h e E V A Pt w o w a y valve on the fuel tank, and connectit to a T-fitting f r o m a v a c u u mg a u g e a n d a v a c u u m p u m p a s snown. VACUUM/ PRESSURE GAUGE, 0 - 4 in.Hg 07JAZ- 0010008 VACUUM PUMP/GAUGE. 0 -30 in.Hg A 9 7 3 X - 0 4 1- X X X X X

T-FITTING T-FITTING

while watchApply vacuumslowly and continuously ing the gauge.The vacuumshouldstabilizemomentarilyat 0.8- 2.1kPa(6 - 16 mmHg,0.2- 0.6in.Hg). l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w 0 . 8 k P a { 6 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 1 k P a (16 mmHg,0.6 in.Hg),installa new valveand retest. 4.

Move the vacuum pump hose from the vacuumfitting to the pressurefitting, and move the vacuum gauge hose from the vacuum side to the pressure sideas shown.

A p p l y v a c u u m s l o w l y a n d c o n t i n u o u s l yw h i l e watching the gauge.The vacuum should stabilize momentarilyat 0.7- 2.0 kPa(5 - 15 mmHg,0.2- 0.6 i n . H g) . l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w 0 . 7 k P a ( 5 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 0 k P a (15 mmHg,0.6 in.Hg),installa new valveand retest.

'l'

Move the vacuum pump hose from the vacuumfitting to the pressurefitting, and move the vacuum gauge hose from the vacuum side to the pressure sideas shown.

PRESSURE SIDE

5.

the vapor line while watchingthe Slowlv pressurize gauge.The pressureshouldbe stabilizemomentari l y a b o v e 1 . 0k P a( 8 m m H g .0 . 3i n . H g ) . . l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e ' 1 . 0k P a ( 8 m m H g ,0 . 3 i n . H g ) t, h e o p e n s )a b o v e valveis OK. . lf the pressurestabilizesbelow 1.0kPa(8 mmHg, 0.3 in.Hg),installa new valveand retest.

11-294

Slowly pressurize the vapor line while watchingthe gauge.The pressureshouldstabilizeat 1.3- 4.7 kPa ( 0 - 3 5 m m H g ,0 . 4- 1 . 4i n . H g ) . . I t t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e o p e n s )a t 1 . 3- 4 . 7 k P a( 1 0- 3 5 m m H g ,0 . 4- 1 . 4 in. Hg),the valveis OK. . lf the pressurestabilizes below1.3kPa(10 mmHg, 0.4 in.Hg)or above4.7 kPa(35 mmHg. 1.4 in.Hg), installa new valve and retest.

\,

\ EvaporativeEmission(EvAPl Two Way Valve T6ting '99 - 00 modols: 'L

Removethe fuel tank (seepage 11-242).

2.

Remove the vapor line {rom the EVAP two way valve(locatedabovethe EVAPcontrolcanister),and connect it to a T-fitting from vacuum gauge and vacuumpumo as snown,

5.

the vapor lin€ while watchingthe Slowly pressurize gauge. T h e p r e s s u r es h o u l d b e s t a b i l i z em o m e n t a r i l y above1.0kPa(8 mmHg,0.3 in.Hg). . l f t h e p r e s s u r em o m e n t a r i l ys t a b i l i z e s( v a l v e opens)above 1.0 kPa (8 mmHg, 0.3 in.Hg),the valveis OK. . ll the pressurestabilizesbelow 1.0kPa(8 mmH9, 0,3 in,Hg),installa new valveand retsst.

VACUUM/PRESSURE GAUGE 0 - il in.Hg

07JAZ- 001(x)08

r y ( L T.FITTING

"*'"""_,";f1 GAUGE,0- 30 in.Hg 4973X - (Xl -

xxxxx J.

Apply vacuumslowlyand continuouslywhile watching the gauge. The vacuum should stabilizemomentarilyat 0.8 2.1kPa{6 - 16 mmHg,0.2- 0.6 in.Hg). l f t h e v a c u u m s t a b i l i z e s( v a l v e o p e n s ) b e l o w 0 . 8 k P a ( 6 m m H g , 0 . 2 i n . H g )o r a b o v e 2 . 1 k P a (16mmHg,0.6 in.Hg),installa nsw valveand retest. Move the vacuum pump hosefrom the vacuumfitting to the pressurefitting, and move the vacuum gauge hose from the vacuum side to the pressure sideas shown.

(cont'd)

11-295

EmissionGontrolSystem EvaporativeEmission(EVAP)Controls(cont'dl ORVRVent Shut Valve Test

Vatve Tcst

Float Test

1.

Makesurethe fueltankis lessthanhalffull.

1.

Makesurethe fuel tank is lessthan halffull.

2.

Removethe fuelfill cap.

2.

Removethe fuel fill cap to relievethe fuel tank pressure,then reinstallthe cap.

3.

Removethe fuel hose joint protector.Disconnectthe ORVRsignalhose.

3.

Removethe fuel hose joint protector.Disconnect the ORVRvapor recirculationhose, and connecta vacuumpump to the vaporrecirculation hose.

ORVR SIGNAL HOSE

ORVRVAPOE RECIRCULATION

VACUUM PUMP/ GAUGE,0- 30 in.H9 A973X- 041 -

xxxxx

Disconnectthe vacuum hose from the EVAPcontrol canister. andthen plugthe portwith a plug. VACUUM PUMP/GAUGE, 0 - 30 in,Hg A973X-041-XXXXX

4.

Plugthe hoseport. A p p l y v a c u u m t o t h e O R V Rv a p o r r e c i r c u l a t i o n nose. . lf the vacuumholds,replacethe ORVRvent shut valve{seepage 11-297). . lf the vacuumdoesnot hold,the float is OK.

CONTROL CANISTER VENT SHUT VALVE

Disconnectthe vacuum hose from the EVAPcontrol canistervent shut valve,and connecta vacuum pump to the vacuumhose, Pumpthe vacuumpump 80 times. . lf the vacuumholds,go to step7, . lf thevacuumdoesnot hold,goto step9.

11-296

\ 7.

Connecta secondvacuumpump to the OBVRsignal nose.

VACUUM PUMP/ GAUGE.0- 30 in.Hg A973X- 041 -

ORVRVent Shut Valve Replacement 1.

Removethe fueltank(seepage11-242).

2.

Removethe ORVRventshutvalvefrom the fueltank.

3.

lnstalloarts in the reverseorder of removal.

xxxxx

\ Apply vacuum (1 pump) to the ORVRsignal hose, then checkthe vacuumon the pump in step6. . lf the vacuumholds,replacethe ORVRvent shut valve. . lf the vacuum is released,the ORVRvent shut valve is OK. Disconnectthe ORVRquickdisconnectfrom the EVAP canister,then plug the port on the canister. Reapplyvacuum(80pumps). . lf the vacuumholds,reDlacethe ORVRvent shut valve, . lf the vacuum does not hold, inspectthe EVAPcanister vent shut valve O-ring.lf the O-ring is OK, replacethe EVAPcanisterand repeatstep 4.

\

11-297 I

J

Transaxle .""""" 12'1 cf utch 13-1 ............"'.'..".'...'. ManualTransmission " ". 14-1 "........ ........ AutomaticTransmission ...15-1 Differential ." 16-1 Driveshafts

J

Clutch

t

\

...........12-2 Tools.......... Speciaf ......12-3 flfustrated Index.......... clutch Pedal 12'4 .................... Adjustment ClutchMasterCylinder .....12-5 Removal/lnstallation SlaveCylinder .....12'6 Removal/lnstallation PressurePlate ......12-7 Removal/lnspection ClutchDisc ......12-8 Removal/lnspection Flywheel 12-9 ....................... Inspection 12-9 ....................................... Replacement ClutchDisc,PressurePlate 12-10 ..................... lnstallation ReleaseBearing ......12-11 Removal/lnspection 12-12 .................,... fnstalfation

SpecialTools I t J Ref. No.

o \31

(

@ !o/

Description

Tool Number

O T J A_FP M 7 O 1 1 A _ PM70124 OTJAF or 07LAB- PV00100 07924,PD20003 - 0010100 07746 07749- 00' ]0000 0 7 9 3-6 3 7 1 0 1 0 0

PageReterence

ClutchAlignmentDisc ClutchAlignmentShaft RingGearHolder

12-7 12-7 , 8 , 1 0 ,1 1 't2-7,9,10,11

Attachment,32 x 35 mm Driver H a n dl e

1 21 0 12-'tO 1 2 - ,18 , 1 0 ,1 1

(r\

2-2

Oty

U

a

lllustrated Index \ NOTE: . Wheneverthe transmissionis removed,cleanand greasethe releasebearingslidingsurface . lf the partsmarkedwith an asterisk(*) are removed,the clutchhydraulicsystemmustbe bled (seepage12-6) and twisting . Inspectthe hosesfor damage,leaks,interference,

'RESERVOIFTANK ASSISTSPRING LOCKPIN 5x1,0mm 9.8 N.m (1.0kgf.m, 7.2 tbtftl

*CLUTCHLINE 15 N.m {1.5kgJm, 11 tbt.ft)

*CLUTCHMASTERCYLINDER page12 5 Removal/lnstallation,

RELEASEBEARING page12-11 Removal/lnspection, page12-'12 Installation, FLYWHEEL I n s p e c t a opna,g e1 2 I Replacement, Page12-9 CLUTCHDISC page12-8 Removal/lnspection, page12-'10 lnstallation, '12x 1.0mm 118N.m {12.0kgt'm,86.8lbfft) PLATE PBESSURE page12 7 Bemoval/lnspection, page12''10 Installation, 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbf.ft) 8 x 1.25mm 22 N m (2.2kgf.m, 16lbf ft) ISLAVE CYLINDER page12_6 Removal/lnstallation,

12-3

Glutch Pedal Adjustment

J

NOTE: . T o c h e c kt h e c l u t c h i n t e r l o c ks w i t c h a n d c l u t c h switch,seesection23. . The clutchis self-adjusting to compensatefor wear.

5 . T u r nt h e c l u t c hs w i t c h( o r a d j u s t i n gb o l t )i n a n a d d i tional3/4to 1 full turn. TightenlocknutA.

CAUTION:lf there is no clearancebetween the master cylinder pislon and push rod, the releasebearing is held against the diaphragm spring, which can result in clutch slippage01other clutch problems.

7 . LoosenlocknutB on the clutchinterlockswitch.

1.

LoosenlocknutA, and backoff the clutchswitch(or adjustingbolt) until it no longertouchesthe clutch peoar.

2.

LoosenlocknutC, and turn the push rod in or out to get the specifiedstroke {@} and height (@) at tne c l u t c hp e d a l .

9 . Releasethe clutchpedal 15 - 20 mm {0.59- 0.79in) from the fully depressedpositionand hold it there. Adjustthe positionof the clutchinterlockswitchso t h a t t h e e n g i n ew i l l s t a r tw i t h t h e c l u t c hp e d a li n t h i sp o s i t i o n .

3.

TightenlocknutC.

4.

Threadin the clutchswitch {or adiustingbolt) until it contactsthe clutchpedal.

8 . Measurethe clearancebetweenthe floor boardand clutchpedalwith the clutchpedalfully depressed.

1 0 . Threadthe clutch interlockswitch an additionalin 3/4to 1 full turn. 'lL

TightenlocknutB.

ASSIST SPRING

-Atl 9002)

LOCKNUTB 9 . 8 N . m ( 1 . 0 k 9 1 . m , 7 . 2l b t . t t ) INTERLOCKSWITCI{

CLUTCH SWITCH lo. ADJUSTING BOLTI

LOCKNUTA 9.8 N'm (1.0 kgI.m, 7.2 lbf,ft) LOCKNUTC 18 N.m {1.8kql.m,13lbf.ft}

@ @ @ @

( S T R O KaEt P E D A L )1:3 0- 1 4 0m m ( 5 . 1 2- 5 . 5 1i n ) (TOTALCLUTCHPEDALFREEPTAYI:12- 21 mm (0.47- 0.83in) includethepedalplay 1 10 mm (0.04- 0.39in) ' ]65mm (CLUTCH PEDALHEIGHT): {6.50in) to the floor (CLUTCP H E D A LD I S E N G A G E M EH NE T I G H T8) :3 m m ( 3 . 2 7i n ) m i n i m u mt o t h e f l o o r

12-4

Glutch Master Gylinder

I

RemovaUlnstallation CAU'NON: . Do not sDillbrakelluid onthevehicle;it may damage the paint; if brake fluid does contact the paint, wash it off immediatelYwith water. . Plug the end ofthe clutch line and reservoirhos€ with a shop towelto preventbraketluid from coming out

4.

Removethe clutchmastercylinder.

1 . T h e b r a k et l u i d c a n b e r e m o v e df r o m t h e c l u t c h mastercylinderreservoirwith a syringe 2.

Disconnectthe clutch line and reservoirhose from the clutchmastercylinder. CLUTCHLINE 1 9 N . m1 1 . 9k g f . m , 14 tbf.ttl

CYLINDER MASTER CLUTCH

l n s t a l lt h e c l u t c h m a s t e rc y l i n d e r i n t h e r e v e r s e orderof removal. NOTE:Bleedthe clutchhydraulicsystem{seepage 12-61,

) [. 3.

Pry out the lock pin, and pull the pedal pin out of the yoke.Removethe nuts NUTS 8 x 1.25 mm 13 N.m {'1.3kgt.m,9.4lbfft)

iffi,

12-5

Slave Gylinder Removal/lnstallation CAUTION: . Do not spill brake tluid on the vehicle;it may damage the paint; if brake fluid does contact th€ paint, wash it off immodiatoly with water, . Plug the end ot the clutch line with a shop towel to prevsnt brakefluid from coming oul.

-61'srp",

3.

I n s t a l lt h e s l a v ec y l i n d e ri n t h e r e v e r s eo r d e r o f removal. NOTE:Makesure the boot is installedon the slave cvlinder. . CLUTCH LINE 15 N.m (1.5 kgf.m,11 lbf.It)

High Temp Urea crease(p/N

08798- 90021. : BrakeAssembly Lube or equivalentrubber grease. 1.

SLAVECYLINDER

Disconnect the clutchlinefrom the slavecvlinder.

-G4

(P/N08798- 90021

8 x 1.25mm 22 N.m 12.2 kgl.n, 16 lbl.lt)

:^.

:l .:i!!!!! (Brak€Assembly Lubol Bleedthe clutchhydraulicsystem.

2.

Removethe slavecylinderfrom the clutchhousing.

12-6

a Attacha hoseto the bleederscrew,and suspend the hosein a containerof brakefluid. . Makesurethere is an adequatesupplyof fluid at the clutchmastercylinder,then slowly pump the clutchpedaluntil no more bubblesappearat the bleederhose. . Refillthe clutch mastercylinderwith fluid when done. . Always use GenuineHonda DOT 3 BrakeFluid. Using a non-Hondabrakefluid can causecorrosion and decreasethe life of the system. . Confirmclutch operation,and checkfor leaking fluid.

PressurePlate Removal/lnsPection

\

1 . Inspectthe fingersof the diaphragmspringfor wear at the releasebearingcontactarea.

lnspectthe pressureplate surfacefor wear' cracks, a n db u r n i n g .

Checkthe diaphragmspringfingersfor heightusing the specialtools and a feelergauge.

Inspectfor warpageusinga straightedgeand leeler g au g e .

Standard{New}:0.6 mm (0.02inl max. SeruiceLimit: 1.0 mm {0.04in}

NOTErMeasureacrossthe pressureplate at three pornrs.

FEELER GAUGE

Standard (Newl: 0.03 mm (0.001inl max. ServiceLimit: 0.15 mm (0.006inl

STBAIGHTEDGE

CLUTCH ALIGNMENT DISC OTJAF_PM7O11A CLUTCH ALIGNMENT SHAFT

OTJAF-PM7012A HANDLE 07936-37tOtOO lf the height exceedsthe servicelimit, replacethe pressurePlate. 3.

Installthespecialtools PLATE PRESSURE MOUNTING BOLT

lf the warpageexceedsthe servicelimit, replacethe pressureplate.

07LA8-PVOOIOO ot

o7924-PD20003

ALIGNMENTSHAFT OTJAF-PM7012A HANDLE 07936-371010O GEARHOLDER

ENGINE BLOCK

BOLT ADJUSTER BOLT

\rf

4.

To prevent warping, unscrew the pressure plate m o u n t i n gb o l t s i n a c r i s s c r o s sp a t t e r ni n s e v e r a l steps,then removethe pressureplate.

12-7

Clutch Disc RemovaUlnspection U '1.

Removethe clutchdiscand specialtools.

4.

M e a s u r et h e d e p t hf r o m t h e l i n i n gs u r f a c et o t h e rivets,on both sides. Rivet Depth: StandardlNewl: 1.3- 1.9mm {0.05- 0.07in} min. ServiceLimit: 0.2 mm (0.01in)

CLUTCH

CLUTCH DISC

CLUTCH ALIGNMENTSHAFT

oTJAF-pM7012A

xltori 07936-3710100

2.

Inspectlining of the clutchdiscfor signsof slipping or oil. lf it is burnedblackor oil soaked,replaceit. Measurethe clutchdiscthickness. Clulch DiscThickness: Standard(Now):8.5- 9.1 mm (0.33- 0.36in) Servic€Limit: 5.5 mm (0.22inl

CLUTCH

lf the depth is lessthan the servicelimit, replacethe clutchdisc.

lf the thickness is less than the service limit. .eolace the clutch disc.

12-8

Flywheel \

Inspection

Replacement

1 . Inspectthe ring gearteethfor wear and damage

1.

2.

I n s p e c t h e c l u t c h d i s c m a t i n g s u r f a c eo n t h e flywheelfor wear,cracks,and burning.

3.

Measurethe flywheelrunout using a dial indicator t h r o u g h a t l e a s tt w o f u l l t u r n s P u s h a g a i n s tt h e f l y w h e e le a c ht i m e y o u t u r n i t t o t a k e u p t h e crankshaftthrustwasherclearance.

Installthespecialtool.

FLYWHEEL

t\

N O T E :T h e r u n o u tc a n b e m e a s u r e dw i t h e n g i n e installed.

m\J

Standard (New): 0.05 mm (0.002inl max. ServiceLimit: 0.15mm {0.006in)

FLYWHEEL MOUNTING BOLTS RITIGGEAR HOLDER oTLAB-PV00100 ot o7924-PD20003

I J

2. OIAL INOICATOR

lf the runout exceedsthe servicelimit. replacethe flywheel. 4.

Removethe flywheelmountingbolts in a crisscross patternin severalstepsas shown, and removethe flywheel, Removethe ball bearingfrom the flywheel

Turn the inner raceo{ the ball bearingwith your tinger. The ball bearingshouldturn smoothlyand qui etly. lf the inner race does not turn smoothly and q u i e t l y ,r e p l a c et h e b e a r i n g .C h e c kt h a t t h e b a l l bearingouter racefits tightly in the flywheel.lf it is loose.replacethe ball bearing FLYWHEEL

\ tO

BALL BEARING

(cont'dl

12-9

Flywheel

Clutch Disc,PressurePlate

(cont'dl Replacement

Installation Y

4.

Drivethe new ball bearinginto the flywheel using the specialtools as shown.

1.

I n s t a ltlh e s p e c i atlo o l .

DRIVER 07749-0010000

CLUTCH DISC

07936-3710r00

ATTACHMENT, 32x35mm 07746-OOIOTOO

FLYWHEEL

{P/N08798-90021 RINGGEARHOLDER 07LAB-PVOO100 ot 07924-PD20003

CLUTCHALIGNMENTSHAFT OTJAF_PM7012A

BEARING

5.

6.

Align the hole in the flywheel with the crankshaft d o w e l p i n a n d i n s t a l lt h e f l y w h e e l .I n s t a l lt h e mountingboltsfinger-ti9ht.

2.

Installtheclutchdisc usingthe specialtools.

3.

Installthe pressureplate.

Installspecialtool, then torquethe flywheelmounting bolts in a crisscrosspatternin severalstepsas snown.

MOUNTING BOLTS 1 1 8N . m ( 1 2 . 0k g l . m , 87 tbf.ft)

WV a// , RING GEAR HOLDER oTLAB PV00'l OO 07924

RINGGEARHOLDER 07LAB-PV00100 ol

07924 -PO20003

12-10

PD20003

OTJAF_PM70124 HANOLE 07936-3710100

ReleaseBearing Removal/lnspection ) 4.

Torquethe mountingbolts in a crisscrosspatternas s h o w n .T i g h t e nt h e m i n s e v e r a sl t e p st o p r e v e n t warpingthe diaPhragmsPring.

1.

Removethe releasefork boot from the clutchhousIng.

2.

Removethe releasefork from the clutchhousingby squeezingthe releasefork set spring with pliers Removethe releasebearing.

MOUNTING BOLTS 8 x 1.25mm 25 N.m (2.6 kgl'm. 19 rbf.ft)

RELEASEFORK

Checkthe releasebearingfor play by spinningit by hand.

\

CAUTION: The releass bearing is packed with grease.Do not wash it in solvent.

RINGGEARHOLDER CLUTCH ALIGNMENTSHAFT OTJAF_PM7O12A oTLAB-PV00100 ot

07924-PD20003

HANOLE 07936-3710100

lf there is excessiveplay, replacethe releasebearing with a new one.

12-11

ReleaseBearing Installation

I J

NOTE:Use only Super High Temp Urea Grease (P/N08798- 9002). 1.

3.

Move the releasefork right and left to make sure that it fits properlyagainstthe releasebearing,and that the releasebearingslidessmoothly.

4.

Install the releasefork boot; make sure the boot sealsaroundthe releasefork and clutchhousino.

With the releasefork slid betweenthe releasebearing pawls, installthe releasebearingon the mains h a f tw h i l e i n s e r t i n gt h e r e l e a s ef o r k t h r o u g ht h e h o l ei n t h e c l u t c hh o u s i n g .

RELEASEFORKBOLT 1 2 x ' l. 2 5 m m

-Gr

08798-9002)

tP/N0a79a-90021 O . 3 - 0 . 9s 1 0 . 0 -1O . 0 3 o z l

2.

Align the detentof the releasefork with the release f o r k b o l t , t h e n p r e s s t h e r e l e a s ef o r k o v e r t h e releasefork bolt sequarely.

12-12

J

ManualTransmission S40 Model (All except'99- 00 2-doorSi' SiR) . . . . . " . . . . . . ' . ' . . " . . .1. .3"-. 1 M a n u a lT r a n s m i s s i o n S4C Model ('99 - 00 2-door Si, SiRl . . . . . . . . . . . . . . . . . . . . .1. .3. -. 4 . .5' M a n u a lT r a n s m i s s i o n

\

\ ta

S40Model (All except'99- 00 2-doorSi' SiR) ManualTransmission 13-2 ..'.......... SpecialTools Maintenance 13-3 Oil .............................. Transmission Back-upLight Switch 13-3 ......... Replacement '.......13-4 Troubleshooting

\

TransmissionAssemblY 13-5 ................. Removal 13-8 ............. lnstallation 13-10 lllustratedIndex ...............'........."........ TransmissionHousing .."""""""' 13-12 Removaf I J R"rr"r"" Shift Holder 13-13 lnspection....................... Clearance Reverseldler Gear 13-14 ....'.........." Removal Mainshaft, Countershaft, Shift Fork 13-14 ......'... Disassembly MainshaftAcsemblY .......13-15 Index ............... 13-16 Inspection..'.................... Clearance 13-17 .......... Disassembly 13-18 ....'......... Inspection 13-19 ........... Reassembly Countershaft AssemblY ......13-20 lndex ................ 13-21 lnspection."..........'......." Clearance 13-22 ..."""' Disassembly 13-23 .............. Inspection ..'.""...13-23 Reassembly

\

Shift Fork AssemblY ."'...13-25 lndex ............... 13'26 lnspection."......."........'.. Clearance 13'27 MBS Shift PieceInspection....-.....'.. Synchro Sleeve,Synchro Hub ".... 13'27 fnspection/lnstallation.......'...... SynchroRing,Gear 13'28 '....'..".... Inspection Shift Rod .'......"."""13'29 Removal Differential .'."' 13-30 lndex ......."'...... 13-30 BacklashInspection..........."......."... 13'31 BearingBeplacement'.............'.".... FinalDrivenGear Replacement'.....13-31 13-32 Thrust Shim Adiustment ..."........... Clutch HousingBearing Replacement MainshaftThrust Shim Adiustment Transmission Reassembly Oil Seals Replacement GearshiftMechanism Overhaul

.......'.13-34 '....'.."..13-36 13-39 ........... .........13-43 13-44 ................

SpecialTools

ly tr Ref. No.

I

o o .@

@

!'5,

@

o

@ 6

@ @ @

(3

Tool Numbet

(Xy

Description

OTGAJ PG2O11O OTGAJ PG2012O 07GAJ- PG20130 07736- A010004 07746- 0010300 07746- 0010400 07746- 0030100

MainshaftHolder C ol l ar MainshaftBase AdjustableBearingPuller,25 - 40 mm Attachment.42 x 47 mm Attachment,52x 55 mm Driver,40 mm LD.

1 1 1 1 1 1 1

07746- 0030300 07746- 0030400 07749- 0010000 0 7 J A D- P H 8 0 1 0 1 07JAD- PH80200 0 7 9 4 7- 6 1 1 0 5 0o1r 07947- 6110500

Attachment,30 mm I.D. Attachment,3Smm LD. Driver DriverAttachment Pilot.26 x 30 mm SealDriverAttachment

1 1

r 1 1 1

I

I

|

I I

PageReference 13-38 13-37 13-37 13-34,35 13-34.35 13-34,35 13-19,24 31,32 13-19,24 13-19,24

t3-34,35, 43 13-43 13,43 13-43

* Must be usedwith commercially-available 3/8"-j6 SlideHammer.

I

o

aa

v

al

o

\91

ai

f!

o

I

Back-upLight Switch

Maintenance Oil Transmission

Replacement

NOTE:Checkthe transmissionoil with the engine OFF a n dt h e v e h i c l eo n l e v e lg r o u n d .

NOTE:To testthe back-uplight switch,seesection23

1.

1.

the connector,then removethe back-up Disconnect light swirchconnectorfrom the connectorclamp.

2.

Removethe back-uplight switch.

Removethe oil filler plug, then checkthe level and conditionof the oil. PLUG OILFILLER /14N.m (4.5 kgl.m,33 lbl.ft)

ProperLevel

WASHER Replace.

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 reinstallthe oil filler plug with a new washer. lf the transmissionoil is dirty, removethe drain plug a n dd r a i nt h e o i l . 4.

\

Reinstall the drainplug with a new washer,and refill the transmissionwith the recommendedoil to the properlever. NOTE:The drain plug washershouldbe replacedat everyoil change.

25 N.m (2.5 kgf'm, 18lbf'ltl

ASHER

Installthe new washerand back-uplight switch Connectthe back-uplight switchconnector.

Reinstall the oil filler plug with a new washer. OilCapacity 1.8f (1.9US qt. 1.6lmp qtl at oil change 1.9{ (2.0US $, 1.7lmp qt) at overhaul A l w a y su s e G e n u i n eH o n d aM a n u a lT r a n s m i s s i o n Fluid {MTF).Using motor oil can causestiffershifti n g b e c a u s ei t d o e s n o t c o n t a i nt h e p r o p e ra d d i t|ves.

\

13-3

Troubleshooting ReverseGearNoiseReductionSystem Wheneverthe clutchpedalis depressedto shift into reverse,the mainshaftcontinuesto rotatebecauseof its inertia. The resultingspeeddifferencebetweenmainshaftand reverseidlergear producesgear noise. The reversegear noisereductionsystememploysa cam platewhich was addedto the reverseshift holder.When shifting shjft piece,connectedto the shift lever,rotatesthe cam plate.This causesthe sth synchroset into reverse,the sth/reverse to stop the rotatingmainshaft.As there is no speeddifferencebetweenmainshaftand reverseidler gear,therewill be less gear norse. gear noisereductionsystem. NOTE:This systemis not a fully-synchronized Therefore,you may heargear noisewhen O you shift into reversewith the vehiclenot yet completelystopped. @ you shift quicklyinto reverseduringfast idling.

Gear noise is oresent when shifting into reverce after the engine is started.

T e s t - d r i v et h e v e h i c l e .

ls the gearnoisepresentwhen shiftinginto 5th gear?

Beplacethe 5th synchro hub and 3leevee3 a set,

Measurethe clearancebetween 5th shift fork and 5th synchro sleeve{seepage13'26).

ls the clearance 1.0mm (0.04 in) or less?

Measurethe MBS shift piecepin (seepage13-27).

ls ( 6.8mm (0.27in) or more?

ReDlace the reve6e ahift hold.r.

13-4

Replacethe MBS shift piece.

-

TransmissionAssembly

I

Removal 6.

@ . Make sure

iacks and safety stands are placed prop€dy, and hoist brackets are atlach€d to correct position on the enginc. . Apply parking brake and block rear whosls so car will nol roll olf stands and lall on you while working under it.

Disconnectthe vehiclespeedsensor(VSS)connecror.

vss CONNECTOR

CAUTION:Use fender coversto svoid damaging painted surfaces. the negative{-) cablefirst,then the posDisconnect itive (+) cable from the battery'

1.

Draintransmissionoil {seepage 13-3). Removethe intakeair tube. intakeair duct and air cleanerhousingassembly(seesection5). Disconnectthe starter motor cables,transmission groundwire and back-uplight switchconnector. 7. 6x1.0mm 9.8 N.m (1.0 ksf.m,7.2 lbI.ft)

LIGHT BACK-UP swlTcH CoNNECTOR

Removethe clutch line bracket,clutch line clamp, and slavecvlinder. CAUTION: . Do not opsr.te tho clutdh pedal once the 3lavc cylindor has b6on romoved. . Tske care not to bend tha clutch lin6.

\

ARTER

8 x 1. 2 5 m m 8.8 N.m {0.9kgt.m,6.5 lbf.ftl

5.

Removethe wire harnessclamps.

(cont'd)

13-5

TransmissionAssembly Removal(cont'dl 8.

v '10. Remove the shift rod and extensionrod.

Removethe driveshafts(seesection161. NOTE:Coat all the precisionfinishedsurfaceswith cleanengineoil or grease.Tie plasticbags over the driveshaftends,

SI'IIFT BOD

SET RING

10 x 1.25mrn 43 N.m 14.4 kgt.m,

DRIVESHAFT 32 rbf.frl

8x22mm SPRINGPIN Replace.

f-

EXTENSIONROD

PIN PUNCH,8.O mm (Commercially available)

'1'1. Removethe enginestiffenersand clutchcover. D16Y5,D16Y8engines: COTTERPIN Replace. SELF 1 2 x 1 . 2 5m m Replace. 4 9 - 5 9 N . m ( 5 . 0- 6 . 0 k g t . m , 1 2 x 1 . 2 5 m m 36-43 lbf.ft) 64 N.m {6.5 kgt.m,47 lbf.tr) 9.

10 x 1.25mm 44 N.m (4.5 kgt.m,

33 tbf.tr)

I x 1.25mm 24 N.m (2.4 kgf.m 17 lbt.frl

Remove exhaust pipe A. GASKETS Replace.

COVER IF\

sELF-LocKtNGNUT.''1/ EXHAUST Replace. PIPEA 8 x 1.25mm SELF-LOCKING NUT 16 N.m {1.6kgf'm, Replace. 12 tbf.ft) D16Y5, D16Y7 engines: NUT SELF-LOCKING Replace. 33 N.m {3.4 kgf.m,25 lbt.ft) I x 1.25mm D16YB engine: 22 N.m (2.2 kgf.m, 1 0 x 1 . 2 5m m 16 tbt'fr) 54 N.m 15.5 kgl'm,40 lbf.ttl

13-6

8 x 1.25mm 24 N.m 12.4 kgf'tn, 17 tbt.tr)

14. Removethe rightfront mounvbracket.

D16Y7engine:

'lOx 'l.25mm 44 N'm (4.5 kgl.m, 33 rbf.frl 8 x 1.25mm 24 N.m {2.4 kgl.m,

ENGINE STIFFENER

1 0 X 1 . 2 5m m It4 N'm (4.5 kqf'm,33 lbf'ltl

12. Installthe bolts in the cylinder head and attach a chain hoist to the bolts,then lift the engineslightly to unloadthe engineand transmissionmounts.

Replace. 1 2 x 1 . 2 5m m 64 N.m t6.5 kgf.m,47 lbf'ft)

CHAINHOIST Placea jack underthe transmission.

\

1 6 . Removethe transmissionmount bracketand mount. TRANSMISSION MOUNT

TRANSMISSION

BRACKET

13. Removethe sDlashshield,

SPLASH SHIELD (cont'd)

13-7

TransmissionAssembly Removal(cont'd)

Installation

1 7 . R e m o v et h e t h r e e u p p e r t r a n s m i s s i o nm o u n t i n g boltsand the lowerstartermountingbolt,

Installthe transmissionassemblyin the reverseorderof removal.

J

Beforeinstalling,checkthat the two dowel pins are installedin the clutchhousing. When installingthe startercable,make sure that the crimped side of the ring terminal is facing out (see section23). Apply greaseto the parts as shown, then installthe releasefork and releasebearing, NOTE: Use only Super High Temp Urea Grease (P/N 08798- 9002).

STARTER MOUNTING BOLT 1 0 x 1 . 2 5m m 44 N.m (4.5 kgf.m, 33 rbnftl

TRANSMISSION MOUI{TING EOLTS 1 2 x 1 . 2 5m m & N.m (6.5 kgt'm,47 lbl.ftl

18. Removethe rear mount bracketbolts and transmission mountingbolts.

1 2 x 1 . 2 5m m 64 N.ft 16.5 kgl.m,47 lbl.ftl

RELEASEFORK BOLT 1 2 x 1 . 2 5m m 29 N'm 13.0 kgt,m,

22 tbl.ttl

(P/N08798-90021 R€LEASE BEARING

RELEASE FORK 8()07

r a

SPECIALBOLT Replace. 'll x 1.5mm 84 N.m (8.5 kgf.m,61 lbf.ftl {PiN 08798-9002)

tP/N08798-90021 0.3-0.9 g 1 0 . 0 1 - 0 . 0 3o z l

REAR

WASI{ER MOUNT SPECIALBOLT BRACKET Replace. 14 x 1,5 mln 84 N.m (8.5 kgl.m, 61 rbl.ftt

1(|

Pull the transmissionaway from the engineuntil it clearsthe mainshaft.then lower it on the transmission jack. CAUTION: Take caro not to b6nd tho clutch lin€.

. Torque the mounting bolt and nuts in the sequence shown. 'l.25 mm O 12 x 1.25mm O) 12 x 64 N.m {6.5 kgt.m, 64 N.m 16.5kgl.m, 47 lbf.fr) 47 tbt.ft)

NOTE: Use only Super High Temp Urea Grease {P/N08798- 9002}. 6 x 1.0mm 9.8 N.m (1.0kgl.m. 7.2 tbf.tr)

.

a Check that the bushings are not twisted or offset. a Install the clip as shown. SHIFTROD

Apply greaseto the slavecylinderpush rod.

CLUTCH UNE

@ 1 2 x 1 . 2 5m m 74 N.m (7.5 kgl'm, 54 tbt.fr)

I

.

8 x 1.25mm N.m t2.2 kgt.m, l6 lbl'tt)

a Turn the boot so the hole is facingdown. a Makesurethe boot is installedon the shift rod.

-6tl (P/N08798-9002)

8 x 1.25mm 22 N.m 12.2 kgl.n. 16 tbf.frl

Turn the breathercap so that the the front of the car as shown.

"F" mark points at

FRONT

Refill the transmissionwith the recommendedoil (seepage 13-3). Connectthe positive (+) cable first, then the negative (-) cable to the battery. a Checkthe clutchoDeration, a Shift the transmissionand checkfor smooth operation. Checkthe front wheelalignment(seesection18).

13-9

lllustrated lndex ! Referto the drawingbelowfor transmissiondisassembly/reassembly, Cleanall the partsthoroughlyin solventand dry with compressedair.

I

luuricateattthepartswithoil beforereassembty.

NOTE: . Thistransmissionusesno gasketsbetvveen the majorhousings;useliquidgasket(PiN08718-0001or08718-0003) (seepage 13-41). . Alwayscleanthe magnet@ wheneverthe transmissionhousingis disassembled. . Inspectall the bearingsfor wear and operation. a6_

'%/t'*.

k+-o -{-g}.-_a

13-10

TorqueValue A - 15 N.m (1.5kgf.m,1'1lbf.ft) B - 27 N.m (2.8kgf.m.20 lbift) C - 31 N.m {3.2kgnm,23 lbift)

\

\ t

O BALLBEARING(*T) ANGULAR BALL BEARING{*2I HUB O 5THSYNCHRO O 5TH SYNCHROSLEEVE €) SYNCHROSPRING B|NG o SYNCHRO @ 5TH GEAR @ gz xgt x 23.5mm NEEDLEBEARING @ SPACERCOLLAR @34x39x23mm NEEDLEBEARING (D 4TH GEAR O SYNCHRORING C) SYNCHROSPRING CO3RD/4THSYNCHROSLEEVE HUB @ 3RD/4THSYNCHRO (} 3RD GEAR @34x39x27.5mm NEEDLEBEARING G) MAINSHAFT G) WASHER @ SPRINGWASHER @ BALL BEARING Checkfor wear and operation. (E 26x42x7 mm OILSEAL Replace. @ 28 mm PLUGBOLT 5,1N.m {5.5 kgf'm, /t0 lbt'ft) SPRING @ lsT/zND SELECT L. 36.26mm (1./P8in) @ SHIFTARM SHAFT @ CLUTCHHOUSING @ INTEELOCKGUIDEBOLT 39 N.m (4.0 kgf.m, 29 lbf.ftl @ REVERSESHIFTHOLDER @ REVERSEIDLERGEAR @ REVERSEIDLERGEARSHAFT @ 5 x 22 mm SPRINGPIN Replace. @ 3RD/4THSHIFTPIECE SHIFTPIECE @ 5TH/REVERSE PIECE MBS SHIFT @ @ 1ST/2NDSHIFI FORK

3RD//|THSHIFTFORK 5TH/REVERSE SHIFTFORK 52 mm SNAPRING 65 mm THRUSTSHIM(*11 70 mm THRUSTSHIM(*21 Selection,page 13-36 @ OIL GUIDEPLATE @ wASHERReplace. @ BACK.UPLIGHTSWITCH 25 N.m (2.5 kgf'm, 18 lbf'ft) @ sET SCREW 22 N.m {2.2 kgf.m, 16 lbl.ft} @ WASHERReplace. 1 . 3 1 . 6m m ( 1 . 2 , 1 i n l @ DS P R I N G @ STEELBALL15/16in) @ BACK-UPLIGHT SWITCHHARNESSBRACKET HANGER TRANSMISSION @ @ 32 MM SEALINGBOLT 25 N.m (2.5 kgf.m, 18 lbt'ft) @ OIL SEAL Replace. @ OILDRAINPLUG 39 N.m (4.0 kgf.m, 29 lbf.ft) @ WASHERReplace. @}OILFILLERPLUG 44 N.m (4.5 kgf.m, 33 lbf'ftl @ WASHERReplace. @)TRANSMISSIONHOUSING €) CLUTCHLINEBRACKET @ OIL GUTTERPLATE @ REVERSELOCKCAM @ REVEBSESELECTSPRING L. 63.4 mm {2.,196in) @ REVERSESELECTRETAINER @ SHIFTARM C @ SHIFTARM B @ INTERLoCK @ COLLAR @ SHIFTARM A @ SPRINGWASHER @ MAGNET @ sET BALL SPRINGBOLT 22 N.m (2.2 kgf.m, 16 lbf.ftl @ 14 x 20 mm DOWELPIN

@ @ @ @

@ 72 mm THRUSTSHIMl*11 80 mm THRUSTSHIM(*21 '13-33 Selection,page ASSEMBLY @ DIFFERENTIAL Seepage 13-30 @ 14 x 25 x 17.5mm OILSEAL Replace. @ 35 x 56 x 8 mm OILSEAL Replace. @ SHIFTROD @ BOOr @ OILGUIDEPLATE @ 3 0 x 4 7 x 2 1m m NEEDLEBEARING(* 1} 3 0 x 5 5 x 2 1m m NEEDLEBEARING {'2) COUNTERSHAFT @ @ 3 6 x 4 1 x 2 5 . 5m m NEEDLEBEARING Checkfor wear and operatron. @ lsT GEAR @ FRICTIONDAMPER @ SYNCHRORING @ SYNCHROSPRTNG HUB @ lST/2ND SYNCHRO @ REVERSEGEAR SPRING @ SYNCHRO @ SYNCHRORING @ FRICTIONDAMPER @ SPACER @39x4lx27mm NEEDLEBEARING @ 2ND GEAR @ 3RDGEAR @ 4TH GEAR @ sTH GEAR @)BALLBEARING{* 1} NEEDLEBEARING(*2} @ BALL BEARING @)SPRINGWASHER @ LoCKNUTReplace. 1 0 8- 0 - 1 0 8N . m

ftt.o* o- 1r.okst.m,l 179.6- 0- 79.6rbtft I

* 1 : D 1 6 Y 7e n g i n e *2: D16Y5,D16Y8engines

1 3 - 11

TransmissionHousing Removal NOTE:Placethe clutch housingon two piecesof wood t h i c k e n o u g ht o k e e p t h e m a i n s h a f tf r o m h i t t i n g t h e workbench. 1.

Removethe back-uplight switch.

2.

Removetransmissionhanger.

4.

Loosenthe transmissionhousingattachingbolts in a crisscrosspattern in severalsteps,then remove them. Removethe 32 mm sealingbolt.

6.

TRANSMISSION HANGER

Expandthe snap ring on the countershaftball bearing, and remove it from the groove using a pair of snap ring pliers. 32 mm SEALINGEOLT

BACK-UPLIGHTSWITCH Removethe settingscrews.washers.springs,and steelballs.

SNAP RING

7.

Separatethe transmissionhousingfrom the clutch housing,and wipe it cleanof the sealant. Removethe thrust shim,oil guide plate.and oil gutter platefrom the transmissionhousing.

otL GUTTER TE

STEELBALLS O. 5/16 in SPRING L . 3 1 . 6 m m I 1 . 2 4i n l SETTINGSCREW

(o TRANSMISSIONHOUSING

1 3-1 2

ReverseShift Holder Inspection Glearance ) 1.

Measurethe clearancebetween the reverseshift shift piecepin. fork and sth/reverse 0.05- 0.35 mm 10.002- 0.01,1inl Standard: ServiceLimit 0.5 mm (0.02in)

3.

Measurethe clearancebetween the reverseidler gearand the reverseshiftfork. 0.5- 1.1mm {0.02- 0.0,1in) Standard: ServiceLimii: 1.8 mm 10.07inl IDLERGEAR REVERSE

REVERSE

REV€RSESHIFTFORK

\

lf the clearancesare more than the service limit. measurethe widths of the groove in the reverse shifi fork.

is morethan thg servicelimit, mealf the clgarances sure the width of the reverseshift fork. - 0.512in} Standlrd: 12.7- 13.0mm {0.5110

Standard:7.05- 7.25 mm (0.278- 0.285inl REVERSE SHIFTFORK

REVERSESHIFT HOLDER REVERSESHIFT HOLOER

lf the widths of the grooves are not within the standard,replacethe reverseshift holderwith a new one. lf the width of the groovesare within the standard, replacethe sth/reverseshift piece with a new one,

lf the width is not within the standard,replace the reverseshift holderwith a new one. lf the width is within the standard,replacethe revsrseidlergearwith a new one.

t 13-13

Reverseldler Gear

Mainshaft,Countershaft, Shift Fork

Removal

Disassembly

1.

1.

Removethe reverseshift holder. SHIFT REVERSE HOLOER

R e m o v et h e i n t e r l o c kg u i d e b o l t f r o m u n d e r t h e clutchhousing. SHIFTARM8 ATTACHING BOLT

CLUTCH HOUSING

Remove the reverse id ler gear shaft and reverse idlergear.

INTERLOCK GUIDEBOLT Removethe shift arm B attachingbolt.

REVERSE IDLER GEARSHAFT

Removethe mainshaftand countershaftassemblies with the shiftfork from the clutchhousinq. NOTE:Beforeremovingthe mainshaftand countershaft assemblies, tape the mainshaftsplinesto protectthe seal.

Tape the mainshaft splines. WASHER SPRING WASHER

1 3- 1 4

Mainshaft Assembly

I

lndex Notethe followingduring reassembly: . The 3rd/4thand sth svnchrohubs are installedwith a press . Installthe angularball bearingwith the thin-edgeouter racefacingthe sth synchrohub . Installthe ball bearingwith the ball cagefacingup prior to reassembling, cleanall the partsin solvent,dry them and apply lubricantto all contactsurfacesthe 3rd/4th and sth svnchrohubs.

BallcagefacesuP.

Thin edgeof outer racelaces down. BALLBEARING{*1) ANGULARBALLBEARING('2)

3RD/4TH SYNCHROSLEEVE page 13'27

Checkfor wear and operataon. Note the directionot installation

SYNCHROHUB 5TH SYNCHRO SLEEVE lnspection,page 13-27 SYNCHROSPRING SYNCHRORING Inspection, p a g e1 3 - 2 8

SYNCHRORING Inspection,pase 13 28

sTHGEAR I n s p e c t i opna, g e1 3 - 1 7

3RD GEAR lnspection,page 13-16 34 x 39 x 27.5 mm NEEDLEBEARING Checkfor wear ano opetaflon,

MAINSHAFT I n s p e c t i o np,a g e 1 3 - 1 8

CHAMFEB

32 x 37 x 23.5 mm NEEDLEBEARING Checkfor wear and operation. SPACERCOLLAB I n s p e c t i o np,a g e 1 3 1 6 34x39x23mm NEEDLEEEARING Checkfor wear and operation, 4TH GEAR rnspeclron,p a g e1 3 ' 1 6 RING page 13 28 Inspectaon, SPRING

*1: D16Y7engine *2: D16Y5,D16Y8engines

13-15

MainshaftAssembly ClearanceInspection NOTE: lf replacementis required,always replacethe synchrosleeveand hub as a set. 1.

Measurethe clearancebetween2nd and 3rd gears, Standard: 0.06- 0.21 mm 10.002- 0.008in) ServiceLimit: 0.33mm (0.013inl

3.

Measurethe clearancebetween 4th gear and the spacercollar. Standard: 0.06- 0.19 mm 10.002- 0.007in) ServiceLimit: 0.31 mm 10.012in)

+ 4TH GEAR

/

-J-

i l f r

TI

l

"

- ) -

2ND GEAR

Hl I 3RO GEAR

INDICATOR

di

I

f

-r

''==f{'

5TH GEAR

lf the clearanceis more than the servicelimit, measuredistance@ on the spacercollar. ?2.V. - 22.86mm 10.8!t8- 0.900in) SorvicaLimii: 22.81mm {0.8t8 inl Standard:

lf the clearanceis more than the servicelimit. measurethe thicknessof 3rd gear,

4TH GEAR SIDE

3O.22- 3O.27mm {1.190- 1.192in} ServicaLimit: 30.15mm (1.187inl Standard:

3RD GEAR

SPACER COLLAR

lf distanc€@ is lessthan the servicelimit, replace the spacercollarwith a new one, lf distance@ is within the servicelimit, measure the thicknessof 4th gear. 30.12- 30.17mm (1.186- 1.188inl Servic6Limh: 30.05mm (1.1&linl Standard:

4TH 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 3rdl4thsynchrohub with a new one.

13-16

lf the thicknessof 4th gear is lessthan the service limit, replace4th gearwith a new one. lf the thicknessof 4th gear is within the service limit, replacethe 3rdl4thsvnchrohub with a new one,

T

Disassembly 6.

Measurethe clearancebetweenthe spacer collar and sth gear. 0.06- 0.19 mm 10.002- 0.007inl Standard: ServiceLimit: 0.31mm (0.012inl

1.

Removethe ball bearingusing a bearingpuller as shown. BEARINGPULLER (Commercially availablel

4TH GEAR DIAL

INDICATOR

I -<=q,

5TH GEAR

7.

lf the clearanceis more than the servicelimit, measuredistance@ on the spacercoilar 23.53- 23.56mm 10.926- 0.928in) Sowice Limit 23.51mm {0.926in}

Standard:

SPACER COLLAR

CAUTION: Remov€ths synchro hubs using a press and steel blocks as shown. Us€ of a iaw-type pullel can caus€damagelo the gear teeih.

sTH GEAR SIDE lf distance@ is lessthan the servicelimit, replace the spacercollarwith a new one, lf distance@ is within the service limit, measure thicknessof 5th gear.

S u p p o r t 4 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 sth svnchrohub as shown.

28.1:2- 28.17 mm 1 1 . 1 1-91 . 1 2 1i n ) ServicaLimit: 28.35mm (1.116inl

Siandatd:

sTH GEAR

lf the thicknessof 5th gear is lessthan the service limit, replacesth Oearwith a new one. lf the thicknessof sth 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.

{cont'd)

13-17

MainshaftAssembly Disassembly(cont'd)

Inspection Y

3.

Supportthe 3rd gear on steelblocks,and pressthe mainshaftout of the 3rd/4thsynchrohub as shown.

'1. Inspect h e g e a r s u r f a c ea n d b e a r i n gs u r f a c ef o r wear and damage.then measurethe mainshaftat pointsA, B, C, and D. A: 21.987- 22.000mm - 0.8661inl 10.8656 B: 26.980- 26.993mm 11.0622- 1.0627inl C: 33.98,1-34.000mm (1.3380- 1.3385in) D: 25.977- 25.990mm |.1.0227- 1.0232inl ServiceLimit: A: 21.930mm 10.8634inl B: 26.930mm {1.0602in} C: 33.930mm (1.3358in) D: 25.920mm (1.0205in) Siandard:

Checkfor wearanddamage lf any part of the mainshaftis lessthan the service limit,replaceit with a new one. 2.

Inspectfor runout. Standardi 0.02 mm (o.(Xtlin) max. S€rviceLimii: 0.05 mm (0.002in) N O T E : S u p p o r t t h e m a i n s h a f ta t b o t h e n d s a s snown.

lf the runout is more than the servicelirnit,reolace the mainshaftwith a new one.

13-18

I

)r'

Reassembly CAUTION: When installing the 3rd/4th and 5th synchro hubs, support th€ shaft on steel blocks, and insiall the synchro hubs using a press.

3.

Installthe sth synchrohub using the specialtools ano a press.

NOTE:Referto page13-15for reassemblysequence. 1.

Support 2nd gear on steel blocks'then install the 3rd/4thsynchro hub using the specialtools and a oress.

DRIV€R,40 mm I O. 07746 -0030' 100

ATTACHMENT, 30 mm l.D. 07746-O030300 sTH SYNCHROHU8

ATTACHMENT, 35 mm LO. 07746-OO3O/+OO

\r' ,

Installthe ball bearingin the directionshown using the specialtools and a Press.

2I{D GEAR

DRIVER,iO mm l.D. 07746 - lxxlollx'

Install the 3rd/4th synchro sleeve by aligning the stops of the 3rdl4th synchro sleeveand hub. NOTE; After installing,checkthe operationof the 3rd/4thsvnchrohub set

BAI-LBEARING BallcagefacesuP

30 mm l.D. ATTAGHMENT, 077i16- 00303qt

SYf{CHRO SLEEVE

*1: D16Ytengane *2: Dl6Y5,D16Y86ngines

13-19

CountershaftAssembly Index

I.r

NOTE:The 3rd, 4th,and sth gearsare installedwith a press.

-re

Prior_to reassembling, cleanall the partsin solvent,dry them and apply lubricantto all contactsurfacesexceptthe 3rd, 4th,and 5th gears.

Snapring groovefacesup. LOCKNUTReplace. 108-O- 108 N.m I 11.0-O-11.0kst.ml I 79.6-0- 79.6 lbt.ft I

Thin edgeol outer racefacesdown. SYNCHROSPRING

SYNCHRORING I n s p e c t a opna, g e1 3 - 2 8 FRICTIONDAMPER 1ST GEAR l n s p e c t i o np,a g e 1 3 2 1 , 2 8

WASHER BEARING Check for wear and operatron, / BALL EEAR|NGt*1) (.2) t NEEDLEBEARTNG Check for wear and operatron, GEAR 4TH GEAR 3RD GEAR 2ND GEAR lnspection,page 13-21, 28 39x44x27m m NEEDLEBEARIfI'G Check for wear and operation. SPACERCOLLAR Inspection,page 13-21 FRICTIONDAMPER

36 x 41 x 25.5 mm NEEDLEBEARING Check for wear and operataon. Inspection,page 13-23

SYNCHRORING Inspection,page 13-28 SYNCHROSPRING REVERSE GEAR lnspection,page 13 27 1ST/2NDSYNCHROHUB

*1: D'16Y7 engine *2: D16Y5,D16Y8engines

13-20

ClearanceInspection NOTE: lf replacementis required,always replacethe synchro sleeveand hub as a set. 1.

Measurethe clearancebetween2nd and 3rd gears.

3.

0.04- 0.12 mm (0.002- 0.005in) Standard: ServicoLimit: 0.2,1mm 10.009in)

Measurethe clearancebetween the countershaft and lst gear. 0.03- 0.10 mm (0'(X)l- 0'qt4 in) Standard: Sorvic. Limit: 0.22 mm (0.009inl

4.

32.G1- 32'06 mm {1.261- 1.262in} S6rvicaLimh: 32'01 mm (1'260in) stlndard:

GAUGE

I)t

2.

lf the clearanceis more than the servicelimit, measureth€ thicknessof the spacercollar'

lf the clearanceis more than the servicelimit, measurethe thicknessof 1stgear. 30./tl - 30.'l'l mm - 1.198in) 11.197 Servics Limit 30.36mm (1.195in)

Standard:

1ST GEAB

SPACER COLLAR

lf the thicknessis lessthan lhe servicelimit, replace the sDacercollarwith a new one. lf ths thicknessis within the servicelimit, measure the thicknessof 2nd gear. 31.91- 31.96mm - 1.258inl 11.256 (1.25,1inl mm 31.85 Limit Soryice

Standard:

/

j'T

z4:_l- \

2I{D GEAF \

\

/

"b/

P-

1^'.-1r.--l --f lf the thicknessof 1stgear is lessthan the service limit, replacelst gearwith a new one. lf the thicknessof 1st gear is within the service limit, replacethe lsv2nd synchrohub with a new one.

lf the thicknessof 2nd gear is lessthan the service limit, replace2nd gearwith a new one. lf the thicknessof 2nd gear is within the servace limit, replacethe lsv2nd synchrohub with a new one,

13-21

CountershaftAssembly Disassembly \ CAUTION:Removethe gears using a press and steel blocks as shown. Use of a iaw-type puller can damage the gear teeth.

4.

Support4th gearon steelblocks,and pressthe countershaftout of 5th and 4th gearsas shown.

5.

Support1stgearon steelblocks,and pressthe countershaftout of 3rd gearas shown.

1 . S e c u r e l yc l a m pt h e c o u n t e r s h a fats s e m b l yi n a benchvisewith wood blocks. 2.

Raisethe locknuttab from the groove of the count e r s h a f t t, h e n r e m o v et h e l o c k n u ta n d t h e s p r i n g washer.

I./ 3.

R e m o v et h e b e a r i n g su s i n ga b e a r i n gp u l l e ra s shown. 3RD GEAR

EEARINGPULLER

1ST GEAR

Inspection

Reassembly

1 . Inspectthe gear surfacesand bearangsurfaceslor w e a r a n d d a m a g e t, h e n m e a s u r et n e countershaft at pointsA, B, and C.

CAUTION: . Pressthe 3rd,4th, and sth gears on the countershaft without lubrication. . When installing the 3rd. 4th, and 5th geals, support the shaft on steelblocksand installthe gearsusinga pless.

A: 30.000- 30.015mm ( 1 . 1 8 1 11- . 1 8 1i7n l B: 35.984- 36.000mm ( 1 . i 1 1 6- 71 . 4 1 7 i3n l C: 24.980- 2i1.993mm {0.9835- 0.9840in) SeryiceLimit:A: 29.950mm (1.1791inl B: 35.930mm (1 '1146in) in) C: 24.930mm 10.9815

Standard:

NOTE:Relerto page 13-20for reassemblysequence' 1.

lnstallthe needlebearingon the countershaft' ,

36x41 x 25.5mm NEEDLEBEARING

COUNTERSHAFT

Check oil passages for cloggrng-

I

2. Check for wear ano oamage.

2.

NOTE:Checkthat the fingersof the frictiondamper are securelyset in the groovesof the 1sv2ndsynchro hub.

lf any part of the countershaftis less than t h e servicelimit, replaceit with a new one.

.

Assemblethe pans belowas shown.

2ND GEAR

Inspectfor runout.

39x/+4x27mm NEEDLEBEARING

Standard: 0.02mm (0.001inl max. SeryiceLimit: 0.05 mm {0'002in)

SPACERCOLLAR FRICTIONDAMPER SYNCHRORING SYNCHROSPRING REVERSEGEAR lST/2NO SYNCHROHUB SYNCHROSPRING SYNCHRORING FRICTIONDAMPER 1ST GEAR

t ,

.

lf the runoutis morethanthe servicelimit.replace with a new one. the countershaft

3.

Installthe partson the countershait

(cont'd)

13-23

CountershaftAssembly (cont'd) Reassembly 4.

.g

Suppon the countershafton a steel blockas shown and install 3rd gear using the specialtools and a press.

7.

Installthe bearingsin the directionshown usingthe sDecialtoolsand a oress. CAUTION: Install ths bearings with a maximum pressureot 7.8 kN {800 kgt, 5,786lbfl.

PRESS

sry /rt-\

DRIVER,40 mm LO. 07746 -0030100 ATTACHMENT,

35 mml.o. 07746-0030400

\

5.

Snapring lacss up.

ATTACHMENT, 30 mm l.D. 07745 - q'303tl)

Install4th gear usingthe specialtools and a press.

DRlvER. 40 mm 07746- 0030100

*1: 016Y7engine *2: D16Y5,D16Y8engines

ATTACHMENT, 35 mm LO.

07746-0030400 8.

Thin edgeof outer racefaces down,

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 a t s s e m b l vi n bench vise with wood blocks. LOCKNUT 108+0r108N.m (11.0* 0 - 11.0kgt m. 79.6 - 0 * 79.6 tbf.ft)

6.

Install5th gear usingthe specialtools and a Dress. DRIVER,40 mm l.D. 07746-0030100 ATTACHMENT, 30 mm l.D.

07746-0030300

5TI{ GEAR

Installthe spring washer,tighten the locknut,then stakethe locknuttab into groove.

\ J

Shift Fork AssemblY lndex I

parts' cleanall the partsin solvent,dry them, and applylubricantto any contact erio, ,o reassembling,

3RD/4THSHIFTFORK

5THiREVERSE SHIFTFORK

1ST/2NDSHIFTFORK

I M8S SHIFT PIECE

5TH/REVERSE SHIFTPIECE

3RD/4TH SHIFTPIECE

\a 13-25

Shift ForkAssembly ClearanceInspection J NOTE:The synchrosleeveand the synchrohub should be replacedas a set. l.

3.

Measurethe clearancebetweeneach shift fork and its matchingsynchrosleeve.

Measurethe clearancebetweenthe shift piece or shiftfork and the shift arm B. Standard: 0.2 - 0.5 mm {0.008- 0.02 in} SarviceLimit: 0.62 mm 10.0244inl

Standard: 0.35- 0.65 mm {0.014- 0.026int ServiceLimit 1.0 mm (0.04in)

4. 2.

lf the clearanceis more than the servicelimit, measurethe thicknessof the shiftfork fingers.

lf the clearanceis more than the servicelimit, measurethe grooveof the shift pieceor shiftfork, Standard: 13.2- 13.4mm (0.520- 0.b28inl

Standard: 3rd/ilth: 7.il - 7.6 mm {0.291- 0.299in} lst/2nd, 5th: 6.2 - 6.il mm (O.2,tt- 0.252in)

SHIFTFORK

lf the thicknessof the shift fork finge.s is not within the standard,replacethe shift fork with a new one. lf the thicknessof the shift fork fingers is within the standard.replacethe synchrosleevewith a

13-26

lf the grooveof the shift pieceor shift fork is not within the standard, replacethe shift piece or shiftfork with a new one. lf the groove of the shift piece or shift fork is within the standard,replacethe shift arm B with a new one.

\ J

Synchro Sleeve, SynchroHub MBSShift PieceInsPection 1.

Measurethe width of the MBS shift piece. 6.9 - 7.1 mm 10272 - 0.280inl Standard; ServiceLimit: 6.8 mm {0.268inl

Inspection/lnstallation ' 1 . lnspectgear teeth on all synchrohubs and synchro

s l e e v e st o r r o u n d e do f f c o r n e r s ,w h i c h i n d i c a t e

I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o sleeve,and checkfor freedomof movement. NOTE: lf replacementis required,always replace the synchrosleeveand synchrohub as a set. SYNCHRO SLEEVE

lf the width of the MBS shift pieceis lessthan servicelimit, replacethe MBS shift piece'

When assemblingthe synchrosleeveand synchro hub, be sureto matchthe three setsof longerteeth (120degreesapart)on the synchrosleevewith the three setsof deepergroovesin the synchroHub CAUTION: Do not install th€ sYnchro sleeve with its longsr t€sth in the synchro hub slots bocauseii will damageths spring ring. LONGERTEETH

t 13-27

SynchroRing,Gear Inspection 1.

\a

Inspectthe synchroring and gear.

SYNCHRO

A: Inspectthe insideof the synchroring for wear. B: Inspectthe synchro sleeveteeth and matching teethon the synchroring for wear (roundedoff).

r-\ /-\

SYNCHRO

oioi *-o* C: Inspectthe synchro sleeveteeth and matching teethon the gearfor wear (roundedoff).

, \ n

UtJ

GOOOWORN D: Inspectthe gear hub thrustsurfacefor wear. E: Inspectthe cone surfacefor wear and roughness. Fr Inspectthe teeth on all gears for unevenwear, scoring,galling,and cracks. 2.

Coatthe cone surfaceof the gearwith oil. and place the synchroring on the matchinggear. Rotatethe synchroring.makingsurethat it does not slip. Measurethe clearancebetweenthe synchro ring a n dg e a ra l l t h e w a y a r o u n d . NOTE:Holdthe synchroring againstthe gearevenly while measuringthe clearance. Synchro Ring-to-GearClearance Standard: 0.73- 1.18mm {0.029- 0.046in} ServiceLimit 0.4 mm {0.02in) lf the clearanceis lessthan the servicelimit, replace the synchroring and synchrocone.

13-28

r /

Shift Rod Removal 6. Removeshift arms C and B, and the interlock,then removethe reverseselectspringand retainer'

(5/16in)' NOTE:The steelbatlsareallof the samesize 1.

Removethe differentialassembly'

2.

R e m o v et h e 2 8 m m p l u g b o l t a n d l s t / 2 n d s e l e c t spring.

3.

Removethe shift arm C attachingbolt'

4.

Removethe shift arm shaft'

7. Removethe shift arm A attachingbolt, the set ball springbolt, set spring,and steelball' 8. Removethe shift rod' then removethe shift arm A' 9. Removethe reverselockcam' 10. Removethe magnet.

NOTE:Be carefulnotto losethe steelball' 5.

Removethe steelball,spring,and collar'

LOCKCAM REVERSE

l

SHIFTARM C

I V /

REVERSESELECTRETAINER

' l J

\s

SHIFTARM B

REVERSESELECTSPRING L. 63.4 mm {2.50 inl

INTERLOCK

&-"onn"

SPRINGL. 21.4 mm (0.843 in)

BALL SPRINGEOLT

SI{IFT ARM A

SPRING L . 2 5 . 6 m m 1 1 . 0 1i n l

COLLAR 14x20 OOWELPIN

ASSEMBLY DIFFERENTIAL

,*(S* 6S* \ \

\

\ srtrr ran,tsrarr

\ ',)r,r"o r..."r "rr,*n

t. 36.26 mm {1.428 in,

\ 28 mm PI-UGBOLT

OIL SEAL Replace. SHIFTROD

Differential BacklashInspection '1.

Placedifferentialassemblyon V-blocks,and install both driveshafts.

OIAL THRUSTSHIM Selectivepart

BALL BEARING Check for wear and damage.

DIFFERENTIAL C h e c kl o r c r a c k s .

ffi

SPEEDOMETER DRIVEGEAR

cFrNAL ' eDRTvEN c ' oo*^r'@ wea' -Zl Measurebacklashof both piniongears. BALL BEARING Checkfor wear and damage. 10 x 1.0mm 101 N.m (10.3 ksf.m. 74.5 lbt.ftl Left-handthreads

13-30

Standard {New); 0.05- 0.15 mm {0.002- 0.006in) lf the backlashis not within the standard,reDlace the differentialcarrier.

S I

BearingRePlacement NOTE: Checkbearingsfor wear and rough rotation lf the bearingsare OK,removalis not necessary' '1. Removethe ball bearingsusing a bearingpuller as shown.

FinalDrivenGearRePlacement 1,

Removethe bolts in a crisscrosspatternin several steps,then remove the final driven gear from the ditferentialcarrier' NOTE: The final driven gear bolts have left-hand threads.

EALL B€ARING

I lnstall new ball bearingsusing the specialtool as shown.

1 0 x 1 . 0m m B O L T 1 o 1 N . ml l O . 3k g f ' m , 7 45 l b f ' f t ) Lelt'handthreads

NOTE: Drive the bearingssquarelyuntil they bottom againstthe carrler. DRIVER,40 mm LD.

?746-0030100

lnstallthe final driven gear by tighteningthe bolts in a crisscrosspattern in severalsteps'

\1,

Differential ThrustShim Adjustment Y 1.

Installthe differentialassembly,makingsure it bottoms in the clutchhousing,usingthe specialtool as shown.

Installthe transmissionhousing(seepage l3-41). NOTE:Do not apply liquidgasketto the matingsurfaceof the clutchhousing. T i g h t e nt h e t r a n s m i s s i o nh o u s i n ga t t a c h i n gb o l t s (seepage13-42).

DRIVER, 40 mm LD. 07746 0030100

I x 1,25mm 27 N.m (2.8 kgt'm, 20 lbf'ft} Usethe specialtool to bottom the differentialassembly in the clutchhousing.

Installthe thrustshim.

t J

NOTE: Installthe same size thrust shim that was removed.

6.

13-32

Measureclearancebetweenthrust shim and bearing outer racein transmissionhousing.

7.

lf the clearanceis more than the standard,selecta new thrustshim from the followingtable

Part Numbel

Thickness

NOTE:It the clearancemeasuredin step 6 is within the standard.go to step 10.

41441- PL3- B00

1 . 0m m ( 0 . 0 3 9 i4n )

41442-PL3-800

1 . 1m m ( 0 . 0 4 3i3n )

Standard:0 - 0.10 mm l0 - 0.00/tinl

41443-PL3-800

1 . 2m m ( 0 . 0 4 7 i2n )

41444-PL3-800 41445-PL3-800

1 . 3m m ( 0 . 0 5 1i2n l 1 . 4m m ( 0 . 0 5 5 i1n )

Part Number

Thickness

41446-PL3-800

1 . 5m m ( 0 . 0 5 9I1n )

41441- PL3- A00

1.0mm (0.0394in)

41447-PL3-800

1.6mm (0.0630in)

41442-PL3-A00

'1.1 mm {0.0433 in)

4r 448- PL3- 800

1.7mm (0.0669in)

41443-PL3-A00

1.2mm {0.0472in)

4 t449- PL3- 800

41444-PL3-A00 41445-PL3-A00

1 . 3m m ( 0 . 0 5 1i2n ) 1 . 4m m ( 0 . 0 5 5i1n )

41450-PL3-800 41451- PL3- 800

1.8mm (0.0709in) '1.0m 5 m ( 0 . 0 4 1 i3n )

41446-PL3-A00

1 . 5m m ( 0 . 0 5 9 i1n )

41452-PL3-800

'1.15mm (0.0453in) 1.25mm (0.0492in)

41447-PL3-A00

1 . 6m m ( 0 . 0 6 3i0n )

41453-PL3-B00

1 . 3 5m m ( 0 . 0 5 3 i2n )

41448-PL3-A00

1.7mm (0.0669in)

41454-PL3-B00

1 . 4 5m m ( 0 . 0 5 7 i1n )

4r449-PL3-A00

1.8mm (0.0709in)

41455-PL3-B00

1 . 5 5m m ( 0 . 0 6 1i0n )

41450-PL3-A00

41456-PL3-800

1.65mm (0.0650in)

41451-PL3-A00

1 . 0 5m m { 0 . 0 4 1 i3n ) 1 . 1 5m m ( 0 . 0 4 5i3n )

41457-PL3-800

1.75mm {0.0689in)

41452-PL3-A00

1.25mm (0.0492in)

41453-PL3-A00

in) 1.35mm (0.0532

41454-PL3-A00

'1.45mm (0.057'lin)

72 mm THRUSTSHIM:D16Y7engin€

\

80 mm THBUSTSHIM:D16Y5.D16Y8engines

41456-PL3-A00

1 . 5 5m m ( 0 . 0 6 1i0n ) 1.65mm (0.0650in)

41457-PL3-A00

1 . 7 5m m ( 0 . 0 6 8i9n )

41455-PL3-A00

8 . Removethe boltsand transmissionhousing. 9 . R e p l a c et h e t h r u s t s h i m s e l e c t e di n s t e p 7 , t h e n recheckthe clearance. 1 0 . Removethe bolts and transmissionhousing.Apply l i q u i d g a s k e tt o t h e s u r f a c eo f t h e t r a n s m i s s i o n housingand reassemble

Clutch HousingBearing Replacement l.

Mainshaft 1.

3,

Removethe ball bearing using the special tool as shown.

Drivethe new oil seal into the clutchhousingusing the specialtoolsas shown.

3i8 " -16 SLIDEHAMMER (Commercially available)

ATTACI{MENT, 42 x 47 mm 07746 -0010300

07749-0010000

CLUTCH HOUSING

ADJUSTAELEBEARING PULLER,25-40 mm 07736-AO10004

2,

t./ Drivethe ball bearinginto the clutchhousingusing the specialtools as shown.

Remove the oil seal from the clutch housing,

CLUTCH

ATTACHMENT,52 x 55 mm DRIVER

07746 0010400

Replace.

13-34

07749-0010000

2.

Countershaft 1.

Removethe needlebearingusingthe specialtool as shown.then removethe oil guide plate

I n s t a l lt h e o i l g u i d e P l a t e ,t h e n d r i v e t h e n e e d l e b e a r i n gi n t o t h e c l u t c hh o u s i n gu s i n gt h e s p e c i a l tools as shown.

3/g " -16 SLIDEHAMMER available) {Commercially

NEEOLEBEAFING

GUIDEPLATE

PULLER,25-40 mm 07736-AO1000A

'1: ATTACHMENT,42 x 47 mm 07746-0010300 *2: ATTACHMENT,52 x 55 mm 07746 -0010400 ORIVER 07749 -0010000

CLUTCH HOUSING

NEEOLEBEARING OIL GUIDEPTATE * 1 : D 1 6 Y 7e n q i n e *2: D16Y5, D16Y8 engines

\

13-35

MainshaftThrust Shim Adjustment \ 1 . R e m o v et h e t h r u s ts h i m a n d o i l g ui d e p l a t ef r o m the transmissionhousing.

5.

THRUSTSHIM

NOTE:Useonly one thrustshim. (BasicFormula) ( B )+ { C ) . 0 . 9 5= s h i mt h i c k n e s s

OIL GUIDE PLATE

Exampleof calculation: D i s t a n c e@ ( 2 . 0 0m m ) + D i s t a n c e@ ( 0 . 0 9m m ) = 2.09mm subtractthe spring washer height (0.95m m ) = tne required t h r u s ts h i m( 1 . 1 4m m )

TBANSMISSION HOUSING

Installthe 3rd/4th synchro hub, spacer collar, 5th synchrohub, ball bearing,and thrust washeron the mainshaft.Installthe assemblyin the transmission ho u s i n g . @

gnol+lx syNcHRoHUB

65 mm THRUSTSHIM:D16Y7engine:

c D E

THRUSTWASHER SPACERCOLLAR

F G I

sTH SYNCHROIIUB

J

L BALL EEARING N

M e a s u r et h e d i s t a n c e@ b e t w e e nt h e e n d o f t h e transmissionhousingand thrustwasher. NOTE: . Usea straightedgeand verniercaliper. . Measureat three locationsand averagethe readIngs. 4.

Measurethe distance@ betweenthe surfacesof the clutchhousingand bearinginnerrace. NOTE: . Usea straightedgeand depthgauge. . Measureat three locationsand averagethe readIngs. ENOOF CLUTCHHOUSING

L

o o R

s T U

X

z AB AC

AD

AG AH AI AK

INNERRACEOF BALL AEARING AN AO

13-36

Selectthe propershim on the basisof the following calculations:

Part Numbor 23931- PL3 A10 23932- PL3 A10 23933- PL3 A10 23934 PL3- A10 23935-PL3-410 23936-PL3-410 23937-PL3-A10 23938 PL3- A10 23939- PL3 At0 23940-PL3-Ar0 23941- PL3- A10 23942- PL3 A10 23943-PL3-A10 23944 PL3- A10 23945-PL3-A10 23946- PL3 A10 23947 PL3- 410 23948-PL3-A10 23949 PL3- A10 23950-PL3-A10 23951 PL3- A10 23952-PL3-Ar0 23953-PL3-A10 2 3 9 5 4- P 1 3 , A 1 0 23955- PL3 A10 23956-PL3-Ar0 23957-PL3-A10 239s8- PL3 A10 23959 PL3- A10 23960- PL3 A10 23961- PL3 410 23962 PL3- A10 23963-PL3-410 23964- PL3 A10 23965-PL3-A10 23966 PL3- A10 23967-PL3-A10 23968 PL3- A10 23969-PL3-A10 2 3 9 7 0 -P L 3- A 1 0 2 3 9 7 1- P L 3 - A 1 0

Thickness 0.60mm (0.0236 in) 0.63mm 10.0284 in) 0.66mm {0.0260ini 0.69mm (0.0272 in)

0.72mm 10.0283 in) 0.75mm 10.0295 in) 0.78mm {0.0307in} 0.81mm (0.0319 in) 0.84mm (0.0331 in) 0.87mm (0.0343in) 0.90mm (0.0354in) 0.93mm (0.0366 in) 0.96mm (0.0378 in) 0.99mm 10.0390 in) 1.02mm {0.0402 in} 1 . 0 5m m ( 0 . 0 4 1i3n ) 1.08mm (0.0425 in) 1 . 1 1 m m( 0 . 0 4 3i7n ) 1 . 1 4m m { 0 . 0 4 4i9n } 1 . 1 7m m ( 0 . 0 4 6i1n ) 1.20mm (0.0472 in) 1.23mm {0.0484in) 1.26mm {0.0496in} 1.29mm (0.0508 in) 1.32mm (0.0520 in) 1.35mm {0.0531in) 1.38mm (0.0543 in) 1.41mm (0.0555 in) 1.44mm (0.0567 in) 1.47mm (0.0579in) 1.50mm (0.0591in) 1.53mm (0.0602 in) 1.56mm (0.0614 in) 1.59mm (0.0626in) 1.62mm {0.0638in) 1.65mm (0.0650 in) 1.68mm {0.0661in) 1.71mm {0.0673in) 1.74mm (0.06a5 ini 1 . 7 7 m m ( 0 . 0 6 9 7i n )

1.80mm 10.0709 in)

r 1

70 mm THRUSTSHIM:Dl6Y5, Dl6Y8 engin€s Part Number 23931- PL3- 800 23932-PL3-800

c

23933-PL3-800 23334-PL3-800

D E

23935-PL3-800 23936- PL3 800 23937-PL3-B00 23938-PL3-800 23939-PL3-800

F

23940-PL3-800 23941- PL3- 800

23942-PL3-800 23943-PL3-800

L N

23944-PL3-800

o

2394s-PL3-800

P

23946-PL3-800 23947-PL3-800 23948- PL3 800

o

23949-PL3-800 23950-PL3-800

T

X

z A8 AC

AD

AG AH

AK

AN

AO 6.

23951- PL3- 800 23952-PL3-800 239s3-PL3-800 23954-PL3-800 2395s-PL3-800 23956-PL3-800 23957-PL3-800 23958-PL3-800 23959-PL3-800 23960-PL3-800 2396' t-PL3-800 23962-PL3-800 23963-PL3-800 23964-PL3-800 23965-PL3-800 23966-PL3-800 23967-PL3-800 23968-PL3-800 23969-PL3-800 23970-PL3-800 2 3 9 7 1 -P L 3 8 0 0

Thickness

7, Installthe thrust washer and spring washer in the mainshaft.

in) 0.60mm 10.0236 0.63 mm (0.0284in) in) 0.66mm (0.0260 in) mm 0.69 10.0272 in) 0.72mm (0.0283 in) 0.75mm (0.0295 0.78mm (0.0307in) 0.81mm (0.0319inl in) 0.84mm (0.0331 mm 0.87 {0.0343in) in) 0.90mm (0.0354

in) 0.93mm (0.0366 in) 0.96mm (0.0378 0.99mm i0.0390in) in) 1.02mm (0.0102 in} 1.05mm {0.0413 1.08mm (0.0{25in) '1.1'1 4n) mm (0.0437 inl 1.14mm (0.0449 in) 1.17mm (0.0461 in) 1.20mm (0.0472 in) 1.23mm (0.0444 in) 1.26mm {0.0496 1.29mm (0.0508in) in) 1.32mm (0.0520 in) 1.35mm (0.0531 1.38mm (0.0543in) in) 1.41mm (0.0555 in) 1.44mm {0.0567 in) 1.47mm (0.0579 1.50mm (0.0591in) in) 1.53mm (0.0602 in) 1.56mm (0.0614 in) 1.59mm (0.0626 in) 1,62mm (0.0638 in) 1.65mm (0.0650 1.68mm (0.0661in) in) 1.71mm (0.0673 1.74mm (0.0685in) 1.77mm (0.0697in) inl 1.80mm (0.0709

Installtheoil guide plateand selectedthrustshim in ths transmissionhousing NOTE: . C l e a nt h e t h r u s t w a s h e r , s p r i n g w a s h e l a n d thrustshim thoroughlybeloreinstallation. . l n s t a l l t h e t h r u s t w a s h e r ,s p r i n g w a s h e r a n d thrustshim proPerlY.

THRUSTWASHER WASI{ER SPRING

8 . lnstallthe mainshaftin the clutchhousing o

Placethe transmissionhousingover the mainshaft and onto the clutchhousing.

1 0 . Tightenthe clutch and transmissionhousingswith several8 mm bolts. N O T E : l t i s n o t n e c e s s a r yt o u s e s e a l i n ga g e n t betweenthe housings' 8 x 1.25mm 27 N'm t2.8 kgf.m. 20 lbf'ft) 1 1 . Tap the mainshaftwith a plastichammer. lz.

Checkthe thrust clearancein the manner doscribsd below. CAUnON: Mc.suromont 3hould bo mlde !t room tomp9laturs. a. Slidethe mainshaftbase and the collarover the mainshaft.

CLUTCH HOUSING

MAITISHAFTBASE 07GAJ-PG20130 COLLAF 07GAJ-PG20120

THRUSTSHIM

I

OIL GUIDE PLATE

{cont'd}

TRANSMISSION HOUSING

13-37

MainshaftThrust Shim

I I

Adjustment(cont'dl b.

u

A t t a c ht h e m a i n s h a f th o l d e rt o t h e m a i n s h a f ta s follows:

e.

Zero a dial gaugeon the end ofthe mainshaft.

NOTEI . B a c k - o utth e m a i n s h a f h t o l d e rb o l t a n d l o o s e n 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 towardthe 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 f t h e m a i n s h a f st p l i n e s , then tightenthe hex bolts. MAINSHAFTHOLOER BOLT

MAINSHAFT HOLDER 07cAJ_PG20110

t. MAINSIIAFT HOLDER 07GAJ-PG20110

Turn the mainshaftholderbolt clockwise:stop turn, ing when the dial gange 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 olav. CAUTION: Turning the mainshaft holder bolt more than 60 degre€s after the needle ot the dial gauge stops moving may damagethe iransmission.

Seatthe mainshaftfully by tappingon the end with a plastichammer. d.

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 contactsthe wide surfaceof the mainshaftbase.

lf the readingis within the standard.the clearanceis correcl. lf the readingis not within the standard,recheckthe shim thickness. Standard:0.11- 0.18mm {0.00it- 0.007in}

\,J

Transmission Reassembly NOTE:The steelballsare all ofthe samesize(5/16in).

Insertshift arm shaft in the clutchhousing. 1 . Installthe collar,spring.and steelball into the case. Compressthe ball and insertthe shift arm shaft,

1.

Installthe magnetand reverselockcam.

2.

Set shift arm A on the clutch housing,then install the shift rod.

3.

Installthe spring washerand shift arm A attaching bolt.

8 . Installshift arm C in shift arm A, then insertthe shift arm shaft. 9. Install the reverseselect retainer and reverse select springonto shift arm shaft.

Installthesteelball,spring,and set ball springbolt.

1 0 . Installthe differentialassembly. 5.

Installshift arm B in the interlock,then set it on the clutchhousing.

A:8x1.0mm 3'l N,m (3.2 kgt.m,23 lbf.ft)

SI{IFT ARM C

6 x 1.0 mm 15 N.m 11.5 kgt.m, 11 lbt'ftl REVERSELOCK CAM REVERSESELECTRETAINER REVERSESELECTSPRING L. 63.4 mm 12.50in)

sHtFTARM ' ___\.*^

rNrERLocK

p

MAGNET

|Jiiill---=l@

SET BALL SPRINGBOLT 22 N.m 12.2 kgl.m, 16 lbf'ftl

SHIFTAFM A COLLAR

SPRING L . 2 5 . 6 m m ( 1 . O 1i n )

CLUTCH HOUSING

OIL SEAL Replace. SHIFTARM SHAFT SHIFTROD BOOT

\rl

(cont'd)

13-39

Transmission Reassembly lcont'dl 11. Positionthe 36 mm springwasherand washeronto the mainshaftbearing.

15. Installthe reverseidler gear and reverseidler gear shaft.

MAINSHAFT/COUNTERSHAFT SHIFTFORKASSEMELIES

REVERSE IDLER GEARSHAFT Tape the mainshaft splines.

12. Installthe mainshaft,countershaft,and shift fork assemblies.

GEAR

N O T E ;A l i g n t h e f i n g e r o f t h e i n t e r l o c kw i t h t h e groove in the shift fork shaft, 16. Installthe reverseshift holder.

1 3 . lnstallthe spring washerand shift arm B attaching bolt. I x 1 . 0m m 31 N.m (3.2 kgl.m,23 lbt.ft) IST/2ND SELECTSPRING L. 36.26 mm 11.428in)

54 N.m 15.5 kgf.m, 40 tbt.ftl

SPf,ING WASHER

GUIDE BOLT 39 N.m 14.0 kgf.m, 29 lbf.frl

1 4 . Installthe 1sv2ndselect spring, 28 mm plug bolt.

and interlockguidebolt, NOTE: Apply Iiquid gasket (P/N 08718- 0001 or 08718- 0003)to the threadsof the 28 mm plug bolt and interlockguide bolt.

13-40

REVERSE SHIFT

6 x 1.0mm l5 N.m (1.5kgf.m, 11 lbt.trl

L J

20. lnstallthe dowel pins and the transmissionhousing.

17. Instalithe oil gutterPlate.

OIL GUTTERPTATE

Lowerthe transmissionhousingwith the snap ring pliers,and set the snap ring into the groove of the countershaftbearing. NOTE:Checkthat the snap ring is securelyseated in the grooveof the countershaftbearing 32 mm SEALINGEOLT 25 N.m (2.5 kgf.m, 18lbf.ftl

TRANSMISSION HOUSING

1 8 . I n s t a l lt h e o i l g u i d e p l a t ea n d t h r u s t s h i m o n t h e transmissionhousing. 1 9 . Apply Iiquid gasketto the surfaceof the transmiss i o n h o u s i n gm a t i n g w i t h t h e c l u t c h h o u s i n ga s shown. NOTE: . Use liquid gasket {P/N 08718- 0001 or 08718- 0003). . Removethe dirty oil fromthesealingsurface. . lf 5 minutes have passedafter applying liquid gasket,reapplyit and assemblethe housings. . Allow it to cure at least20 minutesafter assembly beforefillingthe transmissionwith oil.

4 . 6- 8 . 3 m m 1 0 . 1 4 - 0 . 3 3i n l

Liquid gasket

22. Installthe 32 mm sealingbolt. N O T E :A p p l y l i q u i d g a s k e t( P / N0 8 7 1 8- 0 0 0 1 08718- 0003)to the threads.

\

(cont'd)

13-41

Transmission (cont'd) Reassembly 23, Tightenthe transmissionhousingaftachingbolts in t h e n u m b e r e ds e q u e n c ei n s e v e r a ls t e p s s h o w n Delow.

2 5 . I n s t a l lt h e b a c k - u pl i g h t s w i t c ha n d t r a n s m i s s i o n hanger.

8 x 1.25mm Tolque: 27 N.m 12.8kgf.m. 20 lbf.ft)

8 x 1.25mm 27 N.m 12.8 kgl.m, 20 lbt.lrl TRANSMISSION HANGER

EACK.UPLIGHTSWITCH HARNESSBRACKET

//-',, \

/I

o

.--"-4

;'c'-9,/t-)

25 N.m (2.5 kgt.m, 18 lbf.ft)

24. Installthe steelballs,springs,and set screws.

K)w

s

WASHER Replace.

STEELEALLS D. 5i16 in

L . 3 1 . 6 m m 1 1 . 2 4i n ) SETTINGSCREW 22 N.m 12.2kgf.m, 16 lbf.ftl

13-42

I./

Oil Seals Replacement ClutchHousing:

TransmissionHousing: 1.

Removethe oil sealfrom the transmissionhousing.

l n s t a l lt h e o i l s e a l i n t o t h e t r a n s m i s s i o nh o u s i n g usingthe specialtools as shown.

SEAL ORIVER ATTACHMENT 07947-6110501 or 07947-6110500

1.

Removethe oil sealfrom the clutchhousing.

lnstallthe oil seal into the ciutchhousingusingthe specialtoolsas shown.

ORIVERATTACHMENT oTJAO-PXaO101 OIL SEAL Replace.

OIL SEAL Replace.

\t,

,26x30mm OTJAD PHAO2OO

13-43

GearshiftMechanism Overhaul NOTE: .Inspectrubberpartsforwearanddamagewhendisassembling;replaceanywornordamagedparts. . Installthe clip as shown. . Turn the boot so the hole is facingdown as shown. . Makesurethe boot is installedon the shift rod.

16 tbf.trl

EXTENSION BOLT SHIFTLEVERKNOE 7.8 N.m {0.8kgf.m,5.8 lbt.tt)

)

EXTENSION

MOUNT

/,1:\

l': I cusHroN ,€ \l / / \ \ / -/ - s

SHIFT

\,

LEVER

\5 lW

-"or.o* "ot'o' p f*** -o-E \\-ii,,l?'"

PY:,'\1^l searr'p)) ".o.o)@1 sHlFr

\:/

Q,gD

ii,".i'----....-.9

sEAr

ffi

et-

.-\

Dusr\

'6

/ g-ia',rf,',,"' \\

.rrr*(,o"" tlourur

-Vvvvvvvvvvvvvvvvl IiUei__-.....p anecxer SHIFT

"r^r" ?!il, e* t @ 7****r t 1 t \ sHrFTLEVER BALLHOLDER

I

\

22 N.m

o-","o,\ \ ;":'i:;u -Replace. | 1

22 N'm 12.2ksf'm, 16 lbt.ftl

,-/n

""'%ilfI I JI ^.-.-n{wl\^fr REAR JorN*lr,""17E@

_6, L\ -6r

SELF-LOCKING NUT Replace. ' 1 . 0 6 x mm 9 . 8 N . m { 1 . 0 k g f . m ,7 . 2 l b f . l r }

13-44

sELF-LocKrNG Nur

SPRINGPIN Replace.

t J CLIP

d ul/

S4CModel ('99- 00 2-doorSi, SiR) ManualTransmission 13-46 Countershaft Assembly ............' SpecialTools "....13-71 fndex ................ Maintenance 13'75 Inspection'......'...........'... Glearance 13-47 Oi1...................'.......... Transmission ..........13-76 Disassembly Back-up Light Switch .'............13'77 fnspection ...""" 13'47 Repfacement ".........13'78 Reassembly TransmissionAssembly 13-/tB SynchroSleeve,SynchroHub ......'.......... Removal 13'8C .............. Inspection 13-52 ............. lnstallation 13-80 ............. Installation 13-54 lllustratedlndex ................................... SynchroRing,Gear TransmissionHousing 13-81 .'............ Inspection 13-55 ................. Removal Differential BeverseShift Holder, Reverseldler Gear ......13-82 lndex ................ 13-57 Clearancelnspection ...................".. 13-82 BacklashInspection..."..........."'...... 13-58 ................. Removal ...... 13-83 FinalDrivenGearReplacement ChangeHolderAssembly 13-83 BearingReplacement....."'.......""'.. 13-59 lnspection.................".... Clearance Thrust Shim Adiustment ......""'.....13-84 13-61 ....,,........... Removal Clutch HousingBearing 13-62 ............... Disassembly/Reassembly ..'......13-86 Replacement Mainshaft, Countershaft, Shift Fork 13-63 Mainshaft Thrust Glearance ................. Removal '.........'.13-88 Adiustment Shift Rod 13-64 Transmission .........."'.... Removal ."'.......13-91 Reassembly Shift Fork Assembly ......13-65 Oil Seals lndex ................ ..'......13-96 Replacement 13'66 lnspection.............'......... Clearance Gearshift Mechanism Mainshaft Assembly 13-97 ................ Overhaul ......13-67 lndex ............"" 13-68 lnspection....................... Clearance ..........13-71 Disassembly '."'.......',13'72 fnspection .......'...13-73 Reassembly \

SpecialTools

I

I I

SpecialTools Ref. No.

Tool Number

o

D€scription

0 7 G A J- P G 2 0 1 1 0 07GAJ- PG20l30 07JAD- PH80l0'1 07736- A010004 07746- 0010300 07746- 0010400 07746- 0030100 07746- 0030300 07746- 0030400 0 7 7 4 6- 0 0 4 1 1 0 0 07749- 0010000 07947- SD90200

@

o

-@ @

o

@ @ @

o

@

Oty

MainshaftHolder MainshaftBase DriverAttachment AdjustableBearingPuller,25- 40 mm Attachment,42 x 47 mm Attachment,52 x 55 mm Driver,40 mm LD. Attachment,30 mm LD. Attachment,35 mm LD. Pilot,28 mm H a n dl e DriverAttachment

I 1 1 1 I 1 'l I 1 1 1 'I

Remark

I

13-90 13-90 13-96 13-86,87 13-86 13-86,87 13-73,79,83,84 13-73,19 13-73,79 13-86 13-86,87,96 13-96

* Must be usedwith commercially-available 3/8,,-16 SlideHammer.

./

o

aol

@

(t

4^

Back-upLight Switch

Maintenance Oil Transmission

Replacement

NOTE:Checkthe oil with the engineOFF.and the vehicle on levelground.

NOTE:To checkthe back-uplight switch,seesection23.

1.

1.

Disconnect the connector,then removethe back-up light switchconnectorfrom the connectorclamp.

2.

Removethe back-uplighr switch.

Removethe oil filler plug, then checkthe level and condition of the oil. PLUG OILFILLER ia4N.m {{.5 kgf'm,

33tbtfrl

ProperLevel

Replace.

T h e o i l l e v e l m 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 reinstallthe oil filler plug. lf the transmissionoil is dirty, removethe drain plug and drainthe oil. Reinstallthe drainplug with a new washer.and refill the transmissionoil to the properlevel.

\

AACK.UP 25 N.m 12.5kgf.m, 18 lbf'tt)

lnstallthe new washerand the back-uplight switch.

NOTE:The drain plug washershouldbe replacedat everyoil change. 4.

Reinstalltheoilfiller plug with a new washer. Oil Capacity 2.2 f {2.3US. qt, 1.9 lmp. qtl at oil change. 2.3 f {2./fUS. qt. 2.0 lmp. qt} at overhaul. A l w a y su s e G e n u i n eH o n d aM a n u a lT r a n s m i s s i o n Fluid (MTF).Using motor oil can causestiffershifting becauseit does not contain the proper additives. PLUG OILFILLER ila N.m{4.5kgf.m,33 lbt'ftl

\1,

Replace.

Checkthe transmissionoil level.

l , {

TransmissionAssembly Removal

@Make sure

iacks and safoty stands are placad ploperly (3eesection l). Apply parking braks and block rear wheels so car will not roll off stands and fall on you while working under il.

Bemovethe wire harnessclamps. 7.

Disconnect the startermotor cablesand the vehicle speedsensor(VSS)connector.

CAUTION:Us6 fonder cove6 to avoid damaging painted sudaces. L

8 x 1.25mm 8.8 N.m (0.9kgf.m, 6.5 tbtftl

Disconnectthe negative(-) cable from the battery, then the positive(+l cable. Drain the transmissionoil. then reinstallthe drain plug with a new washer(seepage13-47). Removethe intakeair duct and the air cleanerhousing assembly(sees€ction5). Disconnectthe back-uplight switch connectorand the transmissiongroundwire. Remove the lower radiator hose clamp from the transmissionhangerB.

STARTER MOTOR CABLES

LOWERRADIATOR HOSECLAMP 8 x 1.25 mm 22Nm12.2kgl'm,

16rbtft)

8.

Removethe clutchline bracketand the slav6cylinoer. NOTE: Do not operate the clutch pedal once the slavecylinderhas beenremoved.

13-48

\ J

9 . R e m o v et h e t h r e e u p p e r t r a n s m i s s i o nm o u n t i n g boltsand lowerstartermotor mountingbolt.

11. Disconnectthe heatedoxygen sensor(HO2S)connector,then removeexhaustpip€ A. H02S CONNECTOE

STARTER MOTOR MOUNTING BOLT 10x 1.25mm a,tN.m14.5kgl.m. 33 tbf.trl

TRANSMISSION MOUNTING BOLTS 12 x 1.25mm 6,1N.m (6.5kgdm, 47 lbf'ft|

'10. Removethe enginesplashshieid.

NUT SELF.LOCKING Replace. 8 r 1.25mm 16 N.m (1.6 kgf.m, 12lbf'ft)

Replace. 10 x 1,25mm 54 N.m {5.5 kgf.m, 'lll lbf.ft)

12. Removethe cotter pins and loosenthe castlenuts, then separatethe ball joints from the lower arm (seesection18). 13. Removethe right damPerfork. 10x 1.25mm a3N.mlil.akgf.m,32lbf'ft|

,

!-

ria

:

-11

\/-/

'-a

't''

SPLASHSHIELD

NUT SELF.LOCKING R6place. 12 x 1.25mm 6a N.m (6.5 kgl.m, RIGHT CASTI.TNUT DAMPER 12x 1,25mm 47 rbf ft) FORK a9 - 59 N.m (5.0- 6.0 kgtm, 36 - i(t lbf.ftl

(cont'd)

13-49

TransmissionAssembly Removal(cont'd) 14. Remove the driveshafts and the intermediate shaft (seesection16).

17. Removethe front and the rearenginestiffensrs.

NOTE:Coat all precisionthe finishedsurfaceswith cleanengineoil or grease.Tie plasticbags over the driveshaftends,

t J 1 5 . Removethe bolt, then disconnectthe change eldension.

18. Removethe clutchcover.

Removethe clip and the spring pin,then disconnect the changerod. 8x22mm SPRING PIN CLIP Replace. CLUTCHCOVER

6x1.0mm 12 N.m (1.2kg{.m, 9 tbf.ftl

x 'l .25 mm 24 N.m {2.4 kgt m, 17 rbt ftl

13-50

19. Removethe rightfront mounvbracket.

22. Removethe rear mount bracketbolts and the transmissionmountingbolts

10 x 1.25mm ,14N.m {4,5kgf.m,

12 x 1.25mm 5{ N.m 16.5kgf.m, 47 lbl.ft)

SPECIALBOLT Replace. 1 4x 1 . 5m m 8il N.m (8.5kgtm, 61

WASHER

SPECIALBOLT Replace. 12 x 1.25mm 64 N.m 16.5kgl'm, 47 lbf ftl

)

WASHERS

20. Placea transmissionjack under the transmission and a jackstandunderthe engine.

23. Pull the transmissionaway from the engine until it clearsthe mainshaft,then lower it on the transmissionjack.

21. Removethe transmissionmount

TRANSMISSION

3-51

TransmissionAssembly lnstallation

L f;

Installthe transmissionassemblyin the reverseorder of removal. . .

.

Beforeinstalling,checkthat the two dowel pins are installedin the clutchhousing. When installingthe startercable.make sure that the crimped side of the ring terminal is facing out (see section23). Apply greaseto the parts as shown, then installthe releasefork and releasebearing.

Torquethe mounting bolt and nuts in the sequence shown. Checkthat the busingsare not twistedor offset. @ t2 x 1.25mm 6,tN.m16.5kgtm, 47 lbf.ft)

O t2 x 1.25mm 6,rN.m(6.skg{.m, 17 tbf.ft)

NOTE; Use only Super High Temp Urea Grease (P/N08798-9002).

RELEASEFORKBOLT 29 N.m 13.0kgf.m, 22 tbllrl

-R1

tP/N 08798-

O 12 x 1.25mm 7ilNm17.5kgf.m, 5it lbt ft)

(P/N 08798- 9rD2l

I

Installthe alip and the spring pin on the changejoint as snown. Turn the shift rod boot so the hole is facingdown as snown. Make sure the shift rod boot is installedon the change rod. CHANGEROO

FL.ll

SPRING PIN heptace,

8 mm PIN PUNCH

CHANGE ./ "*,* EXTENSfoN (/ ^ st

l?rffi lo,iD(

l\K

CLIP

13-52

.

Apply greaseto the slavecylinderpush rod. N O T E : U s e o n l y S u p e rH i g h T e m p U r e a G r e a s e (P/N08798- 9002). 6x1.0mm 9.8N'm(1.0kglm, 7.2tbl.ft)

-6,4

(P/N 08798- 9m2)

8 x 1.25 mm 22N.n 12.2kgl'm, 16 tbf.ftl

with oil (seepage13-47). a Refillthetransmission a Connectthe positive(+) cablefirst, then the negative ( - ) cable to the battery. a Checkthe clutchoPeration. and checkfor smooth operaa Shift the transmission, tion. Checkthe front wheelalignment(seesection181.

lllustrated Index t Referto the drawingbelowfor transmissiondisassembly/reassembly. Cleanall the partsthoroughlyin solventand dry with compressedair.

I

attthe panswithoil beforereassembly. Luoricate

NOTE: . Thistransmission usesno gasketsbetweenthe majorhousings;useliquidgasket(P/N08718-0001or08718-0003) (seepage '13-93). . Alwayscleanthe magnet@ wheneverthe transmissionhousingis disassembled. . Inspectall the bearingsfor wear and operation.

\ I ir

6d

a h P i a .l t f l t

@

I ) K1T\A R l,l 1r @ r t ? uh "ii L6q Br

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E,M A # & f

o-*ffiX,

'F@ , €D

13-54

c n

E F

I

Bolt Size

TorqueValue

6x1.0mm 6x1.0mm 8 x 1 . 0m m '1.2m 5m 8x 8 x 1 . 2 5m m 8 x 1 , 0m m

12 N.m (1.2kgnm,8 lbf'ft) 1 5 N . m( 1 . 5k g f ' m ,1 1 l b ff t ) , 1l b i f t ) 1 5 N . m( l . 5 k g f . m 1 24 N'm (2.4kgim, 17lbift) 27 N.m (2.8kgf.m,20lbf'ft) 30 N.m (3.1ksf m. 22 lbift)

:!, ANGULARBALLBEABING :2, STOPRING :3] TAPERRING ..-I NEEOLEBEARING l!-- SPACER O SYNCHRORING ? SYNCHROSPRING SYNCHROSLEEVE E 5TH/REVERSE SYNCHROHUB ...] sTH/REVERSE O SYNCHBOEING .11-r sTH GEAR 1A 38 x 43 x 26 mm NEEDLEBEARING I13)SPACERCOLLAR [!] /ITHGEAR .T5)SYNCHRORING O SYNCHROSPRING 17 3RD/4THSYNCHROHUB O 3RD/4THsYNcHRo SLEEVE ii9 38D GEAR 8I MAINSHAFT 2i WASHER A SPRINGWASH€R ?I BALLBEARING .a4,28 x 41 x 7 mm OIL SEALReplace. .2i 35 x 56 x 8 mm OIL SEALReplace. t-t 14 x 20 mm DowEL PIN .'] OIL CHAMBERPLATE IDLERGEARSHAFT O REVERSE IDLERGEAR .iI..,REVERSE SHIFI HOLDER 'd REVERSE sHIFTPIECE ait '34 srH/REVERSE 5 x 22 mm SPRINGPIN Replace. 3' 1ST/2NDSHIFTFORK ,34' 3RD/4THSHIFTFORK

sstrr ronx i9t)srH/nevense

33 OIL GUTTERPLATE !' SNAPRING 3d 72 mm THRUSTSHIM @ OIL GUIDEPLATE 4t 10 mm WASHERReplace GEARSHAFTBoLT ti REVERSE TDLER 54 N.m {5.5kgf m, 40lbIft) 4N TBANSMISSIONHANGERB CAP 43]BREATHER A,JTRANSMISSIONHANGERA IT' BACK-UPLIGHTSWITCH 25 N.m {2.5kgl.m,18lblftl 14 mm mm WASHERRePlace aO14 16 mm mm SEALINGBOLT tt 16 29 N.m (3.0kgf m,22 lbf ft) :4s)32 mm SEALINGBoLT 25 N m 12.5kgl m, 18 lbl'ft) .!rl 40 x 62 x I mm OIL SEALReplace 00 STEELBALLD.5/15 iN SPRINGL. 30 mm {1.2in) 12 mm WASHERReplace. SETSCREW 22 N.m {2.2kg{ m, 16 lbl ftl @l OILDRAINPLUG 39 N.m {4.0kgf m, 29lbtftl WASHERReplace. PLUG OILFILLER 4,t N.m {4.5kgl m, 33 lblftl

5i 6 !9 @ (6'

WASHERReplace. TRANSMrssioN HouslNG 80 mm SHIM SHIFTPIECESHAFT INTERLOCK

@ sHrFrPECE

6} SHIFTARM HOLDER

@ seucr nnrvt

I9 SELECTRETURNSPRING @ 10 mm SHIM 6, 10 mm WASHER @ LOCKCOLLAR i6sl3 x l5 mm SPRINGPIN Replace. t0 8 mm SPRINGWASHER A) CHANGEPIECE L.25.6mm (1.01in) ll SPRING '' MAGNET ?4)CLUTCHHOUSING ta. 14x 25 x 16 mm OILSEALReplace.

Boo A sHrFT ASSEMBLY O D|FFERENT|aL

Seesection15 iIO SHIFTRODBOOT 6 OIL GUIDEPLATE @ 33 x 60 x 20 mm NEEDLEBEASING PLATE O BEARINGRETAINER lD LocK WASHERReplace. .0 couNTERSHAFI A DISTANCECOLLAR 6 & x 4I x 22 mm NEEDLEBEARING

6. 1sr GEAR

@ FRICTIONDAMPER O SYNCHRORING .d SYNCHROSPRING @ 1ST/2NDSYNCHROHUB ..9i.REVERSEGEAR C) DOUBLECONESYNCHRO O FRICTIONDAMPER S SPACER 6 T2 x TI x 24 mm NEEDLEBEARING (!' 2ND GEAR 61 3RDGEAR iD 4TH GEAR @ 5TH GEAR (O NEEDLEBEARING (10BALLBEARING @ SPRINGWASHER f,o LoCKNUTReplace. 108- 0- 108N'm 1 1 1 . 0 - 0 * 1 1 . 0k g fm , 80* 0- 80lbI.ft) IO CLUTCHLINEBRACKET .d BACK.UPLTGHTSWITCHHARNESSBRACKET

13-55

TransmissionHousing Removal NOTE:Placethe clutch housingon two piecesof wood t h i c k e n o u g ht o k e e p t h e m a i n s h a f tf r o m h i t t i n g t h e workbench. '1.

5.

Loosenthe transmissionhousingattachingbolts in a crisscrosspattern in severalsteps,then remove them. TRANSMISSION HANGERA

Removethe back-uplight switch.

2.

RemovetransmissionhangerB.

3.

Removethe set screws,the springs,and the steel balls. BACK.UPUGHT

swrTcH

ATTACHINGBOLT

SETSCREW

4.

o.

R€movethe 32 mm sealingbolt.

1.

Expandthe snap ring on the countershaftball bearing, and removeit from the groove using a pair of snap ring pliers,

Removethe reverseidler gearshaftbolt.

32 mm SEALINGBOLT

WASHER Replace.

REVEBSE SNAPRING

13-56

I {

ReverseShift Holder, Reverseldler Gear ClearanceInspection Separatethe transmissionhousingfrom the clutch housing,and wipe it cleanof the sealant. Removethe 72 mm thrust shim and the oil guide platefrom the transmissionhousing

1 . Measurethe clearancebetween the reverseshift shift piecepin holderand the 5th/reverse Standard: Revsrs. Sids: 0.05- 0./t5mm {0'002- 0.018in} 0.4 - 0.9 mm (0.02- 0.0'l in) 5th Side:

72fifi

THRUSTSHIM

PIN SHIFTPIECE sTH/REVERSE

fi HOUSING TRANSMISSION Removethe 16 mm sealingbolt and the oll gutter plate.

lf the clearanceare not within the standard,measure the width of the grooves in the reverseshift holder. Standard: Rsvers€Side: 7.05- 7.25 mm (0'278- 0.285in) 7.,1- 7.7 mm (0.29- 0 30 inl 5th Sid6: SIDE REVERSE

OIL GUTTERPLATE

lf ths width of the grooves are not within the standard, replacethe reverseshift holder with a new one. lf the width of the groovesare within the standard, replacethe sth/reverseshift piece with a new one {cont'd)

13-57

ReverseShift Holder,Reverseldler Gear ClearanceInspection(cont'dl 3.

Measurethe clearancebetween the reversei d l e r gearand the reverseshift holder. - 0.04inl Standard: 0.5- 1.0mm 10.02 ServiceLimit: 1.8 mm (0.07inl

Removal 1.

Removethe reverseshift holder.

REVERSE SHIFTHOLDEB

REVERSE SHIFTHOLDER

Removethe reverseidler gear and the reverseidler gearshaft. lf the clearanceis more than the servicelimit. mea, surethe width of the reverseshift holder. Standard:13.0- 13.3mm (0.512- 0.524in)

REVERSE IDLER

lf the width is not within the standard,replace the reverseshift holderwith a new one. lf the width is within the standard,replacethe reverseidlergearwith a new one.

13-58

ChangeHolderAssemblY ,

InsPection Glearance 1 . Measurethe clearancebetweenthe shift pieceand the shift arm holder.

3.

Measurethe clearancebetweenthe selectarm and the interlock. 0.05- 0.20 10002 - 0.008inl Standard: ServiceLimit:0.45mm (0.018inl

Standard: 0.1- 0.3 mm {0.004- 0.012in) service Limit: 0.6 mm {0.02in) SHIFTPIECE

INTERLOCK

SHIFTARM HOLDER

lf the clearanceis more than the servicelimit, measurethe width of the groovein the shift piece' Standard:8.1- 8 2 mm {0'319- 0.323in}

4.

lf the clearanceis more than the servicelimit, measurethe width of the interlock. Standatd: 9.9 - 10.0mm (0.390- 0.39'tin)

SHIFTPIECE

lf the width of the groove is not within the standard,replacethe shift piecewith a new one' lf the width of the grooveis within the standard, replacethe shift arm holderwith 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)

13-59

ChangeHolder Assembly ClearanceInspection(cont'd) 7.

Measurethe clearancebetweenthe selectarm and t h e 1 0m m s h i m . Standard:0.01- 0.2 mm (0.0004- 0.008in)

I 9. Measurethe clearancebetweenthe shift arm holder and the changepiece. Standard; 0.05- 0.35 (0.fi)2 - 0.014inl ServiceLimit: 0.8 mm (0.03in)

SELECTARM SHIFTARM HOLOER

vo

l0 mm SHIM

8.

lf the clearanceis not within the standard,select and installthe appropriatel0 mm shim for the correctclearancefrom the chartbelow.

lf the clearanceis more than the servicelimit. mea_ surethe grooveof the changepiece. Standard: 12.05- 12.15mm {0.i[7it4- 0.47txtinl

mm Shim Part Number

Thickness

24435-689-000

0.8 mm (0.031in)

B

24436-589-000

1.0mm (0.039in)

c

24437-689-000

1.2mm (0.047in)

D

24438-689-000

1 . 4m m ( 0 . 0 5 5i n )

E

24439-689-000

1 . 6m m { 0 . 0 6 3i n )

CHANGEPIECE

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.

13-60

Removal 11. Measurethe clearancebetweenthe selectarm and the changePiece.

1.

Bemovethe shift pieceshaft.then removethe shift pieceand the interlock. SHAFT SHIFTPIECE

0.05- O'25mm 10'002- 0'010 in) Standard: ServicaLimii: 0.5 mm {0.02in)

SELECTARM

INTERLOCK

2.

Remove the change holder assembly'

U O 't2. lf the clearanceis more than the servicelimit, measurethe width of the changePlece. Standard: 12.05- 12.15mm {0.47'|{ 0 47tI| inl

PIECE CHANGE

a lf the width is not within the standard,replace

the changePiecewith a new one'

a lf the width is within the standard,replacethe

selectarm with a new one.

13-61

ChangeHolder Assembly Disassembly/Reassembly I

P'io' to '"""sembring,creanaI the pans in sorvent,dry them and apprylubricantto any contactsurfaces.

l0 mm SH|M R€TURNSPRING

I

,omm wAsHEF

t /

@@d.

r]7 | I

SELECTARM

13-62

3 x 16 mm SpRtNG Replace.

Mainshaft,Countershaft,Shift Fork Removal 1 . Removethe mainshaftand the countershaftassemblieswith the shiftforksfrom the clutchhousing. NOTE:Tape the mainshaftspline beforeremoving assemblies. the mainshaftand the countershaft

4.

Removethe chamberPlate. CLUTCHHOUSING

Removethe springwasherand the washer'

MAINSHAFT

COUNTERSHAFT

Tapethe

CHAMEEFPLATE

splrnes. WASHER

v

Removethe differentialassemblyfrom the clutch housing. DIFF€RENTIALASSEMBLY

CLUTCH HOUSING

13-63

Shift Rod Removal

l_

1.

Removethe shift rod boots.

2.

R e m o v et h e c h a n g ep i e c ea t t a c h i n gb o l t a n d t h e springwasher.

3,

Bemovethe set screw.then removethe spring and the steelball.

4,

R e m o v et h e s h i f t r o d , t h e n r e m o v e t h e c h a n g e piece,

5.

Removethe oil seal.

SETSCREW OIL SEAL R€placs.

CHANGEPIECE

*ry

SPRING L. 25.6 11.01inl

STEEL (D.s/16

SHIFT

noD

BOOTS

\,,rl SPRINGWASHEN ATTACHINGAOLI

13-64

Shift Fork AssemblY lndex -A I

cleanall the partsin solvent,dry them and applylubricantto any contactpans eriorro reassemblinq.

mm PINPUNCH

sTH/REVERSE SI{IFTFORK

3RD/4THSHIFTFORK

Shift Fork Assembly ClearanceInspection NOTE:The synchrosleeveand the synchrohub should be replacedas a set. 1.

Measurethe clearancebetweeneach shift fork and its matchingsynchrosleeve.

3.

Measurethe clearancebetweenthe shift pieceand the shiftfork shafts. Standard: 0.2- 0.5 mm (0.008- 0.02inl ServiceLimit: 0.8 mm {0.03in)

Standard: 0.35- 0.65mm {O.Olit- 0.026inl ServiceLimit: 1.0mm t0.04inl

SHIFTFOBK

lf the clearanceis more than the servicelimit. mea_ surethe thicknessof the shittfork finoers.

lf the clearanceis more than the servicelimit. measurethe width of the shift Diece.

Standard:7.4- 7.6 mm (0.291- 0.299in)

Standard:11.9- 12.0mm (0.469- 0.it72in)

SHIFTPIECE

l f t h e t h i c k n e s so f t h e s h i f t f o r k f r n g e r sr s n o t within the standard,replacethe shift fork with a new one. lf the thicknessof the shift fork fingersis within the standard,replacethe synchrosleevewith a

13-66

lf the width of the shift piece is not within the standard,replacethe shift piecewith a new one. lf the width of the shift piece is within the stan_ dard,replacethe shift fork with a new one.

t ,

Mainshaft AssemblY lndex Notethe follow . The 3rd/4thand the 5th synchrohubsare installedwith a press . Installthe angularballbearingwith the thin-edgedcuterracefacingthe stop rrng' cleanall the partsin solvent,drythem,and apply lubricant to any contactsurfacesThe Priorto reassembling. them' 3rd/4thand the sth synchrohubs,however,shouldbe installedwith a pressbeforelubricating

ANGULARBALLBEARING Inspectlor wear and operation. Notethe drrectlon oI installatton. STOPRING TAPERRING

v

SYNCHRO SPRING

NEEOLEEEARING Inspectfor wear and operation.

3RO/4THSYNCHROHUB

SPACER

3RO/4THSYNCHROSLEEVE

SYNCHRORING Inspection. page13-81 SYNCHRO SPRING

SYNCHRO SPRING Inspection, page13-81

3RDGEAR Inspection, page13-68,81 NEEDLEBEARING and operation.

SYNCHROHUB 5TH/REVERSE SYNCHROSLE€VE SYNCHEO SPRING SYNCHRORING Inspection, page13 8'1 GEAR Inspeclron, page13-70,81

NEEDLEBEARING InspectIor wear and operation.

COLLAB 4TH GEAR Inspection, p a g e1 3 ' 6 9 , 8 1

13-67

Mainshaft Assembly ClearanceInspection N O T E :l f r e p l a c e m e ni ts r e q u i r e d a, l w a y sr e D l a c et h e synchrosleeveand the synchrohub as a set. 1.

Measurethe clearancebetween2nd and 3rd oears, Standard: 0.06- 0.21mm (0.002- 0.008inl ServiceLimit:0.3 mm (0.01inl

2.

lf the clearanceis more than the servicelimit, measurethe thicknessof 3rd gear. Standard: 34.92- 3it.97mm t1.375- 1.377int ServiceLimit: 3,1.3mm (1.350inl

I d 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.

3.

Measurethe clearancebetween 4th gear and the spacercollar. 0.06- 0.21 mm (0.002- 0.008inl Standard: Servic€Limit: 0.3 mm (0.01inl

5.

lf distance@ is not within the standard.replacethe spacercollarwith a new one. lf distanceO is within the standard.measurethe thicknessof 4th gear' Standard: 31.12-31'17mm {1.237- 1.239inl ServiceLimh:31.3mm (1.232in)

It the clearanceis more than the servicelimit, measuredistance@ on the spacercollar Standard:26.03- 26.08mm {1.025- 1.027in} lf the thicknessof 4th gear is less than the service llmit, replace4th gearwith a new one. lf the thicknessof 4th gear is within the service limit, replacethe 3rd/4thsynchrohub with a new one, 4TH GEAR SIDE

SPACERCOLLAE

(cont'd)

13-69

Mainshaft Assembly Inspection(cont'dl Clearance 6.

Measurethe clearancebetween sth gear and t h e spacercollar. Standard: 0.05- 0.21mm (0.002- 0.008inl inl Servicelimit: 0.3 mm 10.012

\ 8.

lf distance(E is not within the standard,replacethe spacercollarwith a new one. lf distance@ is within the standard,measurethe thicknessof 5th gear. Standard: 31.12-31.47mm {1.237- 1.239in} ServiceLimit:31.3mm {1.232in)

5TH GEAR

5TH GEAB

u,a 1.

lf the clearanceis more than the servicelimit, measuredistance€) on the spacercollar. Standard:26.03- 26.08mm {1.025- 1.027inl

SPACERCOLLAB

3-70

lf the thicknessof 5th gear is lessthan the service limit, replacesth gearwith a new one. lf the thicknessof 5th gear is within the servace 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 1.

Removethe ball bearingusing a bearingpuller as shown.

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/4thsvnchrohub, as shown.

BEABINGPULLER

BALLBEARING

CAUTION: Remove the synchro hubs using a ptess and the sts€l blocks as shown. Use of a i8w'type puller can causedamageto th€ gear teeth. S u p p o r ts 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 sth synchrohub, as shown.

13-71

MainshaftAssembly Inspection 1.

(

Inspectthe gear surfacesand the bearingsurfaces for wear and damage.then measurethe mainshaft at points A, B, and C. lf any partsof the mainshaft are less than the service limit, reDlacemainshaft with a new one.

2.

Inspectfor runout. lf the runout is more than the servicelimit, replacethe mainshaftwith a new one, Standard: 0.02 mm 10.0008inl max. Ssrvice Limit: 0.05 mm 10.002inl t

Standard: A: 27.987- 28.000mm {1.1018- 1.1024in} - 1.4960inl B: 37.98i1- 38.fi)0 mm (1.,|!t5,0 - 1.1020inl Ci27.977- 27.990mm 11.1015 ServiceLimit: A; 27.940mm {1.1000in} B: 37.930mm (1./{133 in) C:27.930mm (1.0996inl

Inspectfor wear ano oamage.

Inspectoil passages tor clogging.

1 3-7 2

N O T E : S u o o o r t t h e m a i n s h a f ta t b o t h e n d s a s shown.

Reassembly CAUTION: . Press the 3rd/4th and the 5th synchro hubs on the mainshaft without lubrication. o When installing the 3rd/,lth and the sth synchro hubs, support the mainshaft on steel blocks, and installthe synchro hubs using a prsss. . Install the 3rd/4th and the sth synchro hubs with a maximumplessur€of 19.6kN (2,000kg, 14,466lbl.

2.

{0 mm l.O. DRIVER, 07746- 0030100

NOTE:Referto page13-67for reassemblysequence. 1,

Installthe sth synchrohub using the specialtools and a pressas snown.

ATTACHMENT, 35 mm LD. 07716 - 0030,100

Support 2nd gear on steel blocks,then install the 3rd/4thsynchro hub using the specialtools and a press,as snown.

PRESS

+ sTH SYNCHROHUB

NOTE: . A f t e r i n s t a l l i n g c. h e c kt h e o p e r a t i o no f t h e 3rd/4thsynchrosleeveand hub. . Assemblethe 3rd/4th synchro hub and sleeve togetherbetoreinstallingthem on the mainshaft.

3RD/4TH SYNCHROHU3 Closedend

DBIVER,10 mm l.O. 07746- 00301U)

3.

l.

I n s t a l lt h e a n g u l a rb a l l b e a r i n gu s i n g t h e s p e c i a l tools and a pressas shown.

/ lrrlcHlileNr. ss .- t.o. 07746- 0030,100 DRIVER,40 mm LD. 0?7a6- It030100

3RD/{TH SYNCHRO SLEEVE 2ND GEAR

GountershaftAssembly Index NOTE:The 4th and sth gearsare installedwith a press.

3

Priorto reassembling, cleanall the partsin solvent,dry them and applylubricantto any contactsurfaces.The 4th and 5th gears.however,shouldbe installedwith a pressbeforelubricatingthem.

SYNCHROSPRING LOCKNUT Replace 108"0-108N.m i11.0 0- l1.0kgtm, 180-0-80lbttr

REVERSE GEAR

WASHER EALLEEARING and operation. NEEDLE BEARING lnspectfor wear ano operaton. 5TH GEAR DAMPER 4THGEAR

ST GEAR Inspection,page 13-75

3RDGEAR

Inspection, page13-75 DISTANCE COLLAR

NEEDLEBEARING and operatron,

COUNTERSHAFT page13-77 Inspection,

NEEDLEBEARING ano operatron,

SPACER FRICTIONDAMPER DOUBLECONE page13 81 Inspection,

13-74

I I

I Inspection Clearance 1.

M e a s u r et h e c l e a r a n c eb e t w e e nt h e 1 s t g e a r a n d distancecollar. Standard: 0,045- 0.205mm 10.002- 0.008in) ServiceLimit: 0.25 mm (0.01inl

3.

M e a s u r et h e c l e a r a n c eb e t w e e nt h e 2 n d a n d 3 r d gears. 0.07- 0.14mm (0.003- 0.006inl ServicoLimii: 0.24 mm (0.009in) Standard:

'-. -=Jl

ll

71 il

3RD GEAR

2NDGEAR

,

' I

2.

lf the clearanceexceedsthe servicelimit. measure of 1stgear. the thicknesses lST GEAR Standard:29.45- 29.50mm {1.159- 1.161in}

DISTANCECOLLAR Standard:@36.5mm (1.4i1in) @ ,12.0mm (1.65in) @ 3 0 . 0m m ( 1 . 1 8i n )

lf the thicknesses of 1st gear and distancecollar are less than the standard,replacewith a new one. of 1st gear and distancecollar lf the thicknesses are within the standard,replacethe lsv2nd synchro hub with a new one.

4.

lf the clearanceexceedsthe servicelimit, measure of znd gearand spacer. the thicknesses 2ND GEAR Standard:28.92- 28.97mm (1.139- 1.1't1inl

SPACERCOLLAR inl Standard:29.07- 29.09mm {1.1it4- 1.1,15

lf the thicknesses of 2nd gearand spacerare less than the standard,replacewith a new one. l f t h e t h i c k n e s s eo s f 2 n d g e a r a n d s p a c e ra r e within the standard,replacethe lsv2nd synchro hub with a new one.

13-75

GountershaftAssembly Disassembly . 1 . S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l vi n a benchvisewith wood blocks. 2.

4,

Removethe bearing outer race,then remove the needlebearingusinga bearingpulleras shown.

Raisethe locknuttab from the groove in the countershaft,then remove the locknut and the spring washer.

I

BEARINGPULLEF

BEARING

CAUTION: Romovethe gears using a pr63 and the stesl blocks as shown, Use of a ,aw-typo puller can causedamagelo lhe gear tooth. Removethe ball bearingusing a bearingpulle. as shown.

Support 4th gear on steel blocks, and press the countershaft out of sth and 4th gears,as shown.

BEARINGPULLER

sTHGEAF BALLBEARING

13-76

a It

{TH GEAR

(

Inspection 1.

Inspect the gear surfaces and the bearing surfaces for wear and damage,then measurethe countershaft at points A, B, and C. lf any parts of the countershaftare lessthan the servicelimit. reDlacecountorshaft with a new one. Standard: A: 2/t.980- 2{.993 mm (0.9835- 0.9&O in} B: 35.984- 37.000mm {1.4561- 1.4567in) G:33.fiD - 33.015mm {1.2992- 1.2998in) Sorvicc Limit: Ar 2/t.9't0mm 10.9819inl B: 36.930mm {1.'l5qt in} C: 32.950mm {1.2972in}

2.

Insoectfor runout. lf the runout is more than the service limit, reolacethe countershaftwith a new one. 0.02 mm {0.(x)08in) max. Strndard: Servic. Limit 0.05 mm (0.002in) NOTE: SuoDortth€ countershaftat both ends as shown.

Rotatelwo complele revotutons.

Insp€ctfor wear

t Inspectoil passagefor clogging.

13-77

GountershaftAssembly Reassembly { CAUTION: . Pross4th and sth gears on the countershaft without lubrication. . When installing ilth and sth geafs, support the shaft on steel blocks, and install the gears using a press. . Install ilth and sth gear with a maximum pressureof 25.5 kN (2,600ksf, 18,806lbf).

4.

lnstallthe 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 synchroas shown.

NOTE;Referto page13-74for reassemblysequence. '1. Installthe distancecollar and the needle bearinos on the countershaft.

COUNTERSHAFT

Installthe frictiondamper,the synchroring,and the synchrospringon 1stgear.

;

Assemblethe friction damper,the needlebearing, and 2nd gear,then installthem by aligningthe fingers on the frictiondamperand the groovesin the 1sv2ndsynchrohub with the fingersof 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 snown. Installthespacer.

Installthe 1sv2ndsynchrohub by aligningthe fingers on the frictiondamperand the groovesin the 1sv2ndsynchrohub,as shown.

2ND GEAR

lST/2NO

FRICTIONDAMPER

Install the parts assembledi n s t e p s 2 - 6 o n t h e countershaft. lSI GEAR

13-78

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 5nown.

'1'1.

Install the needle bearing, then install the ball bearing using the special tools and a press as shown. PRESS

DRIVER,40 mm LD. 07746- 0030100

ATTACHMENT,30 mm LD. 07746- 0030300

mm LD. ATTACHMENT,35 07746- 0030400

1 0 . 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 install5th gear using the specialtools and a press, as shown.

J.-

1 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. lnstallthe spring washer,tighten the locknut,then stakethe locknuttab into the groove. LOCKNUT 1 0 8 - 0 - 1 0 8 N . m1 1 1 . 0 -0 - 1 1 . 0 k g t . m , 80+ 0* 80 lbf'ftl

ATTACHMENT,30 mm I,D, 07746- 0030300

WOOD BLOCKS

\

13-79

Synchro Sleeve,Synchro Hub Inspection

Installation

1 , Inspectgear teeth on all synchrohubs and synchro sleevesfor rounded off corners. which indicates

When assemblingthe synchrosleeveand synchrohub, b e s u r e t o m a t c h t h e t h r e e s e t s o f l o n g e rt e e t h ( 1 2 0 degreesapart)on the synchrosleevewith the three sets of deepergroovesin the synchrohub.

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 freedomof movement. NOTE: lf replacementis required,always replace the synchrosleeveand synchrohub as a set.

SYNCItRO SLEEVC

13-80

CAUTION:Do noi install tho synchro sleevewith its longer toeth in the synchro hub slots, because it will damage the spring ring.

LONGER TEETH

SynchroRing,Gear Inspection

SYNCHROSPRING

'1. Inspectthe synchroring and gear. A: Inspectthe insideof the synchroring for wear' SYNCHRORING

B: Inspectthe synchro sleeveteeth and matching teethon the synchroring for wear (roundedoff).

oo

GOODWORN C: Inspectthe synchro sleeveteeth and matching teethon the gearfor wear (roundedoff).

n n

U WORN U

GOOO D: Inspectthe gear hub thrustsurfacefor wear.

E: Inspectthe cone surfacefor wear and roughness. F: Inspectthe teeth on all gears for unevenwear, scoring,galling,and cracks' 2.

t

Coatthe cone surfaceof the gearwith oil, and place the synchroring on the matchinggear. Rotatethe ring,makingsurethat it does not slip Measurethe clearancebetweenthe 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-GearClearance Standard: 0.73- 1.18mm (0.029- 0.0'16in) Ssrvice Limit:0.,0mm {0.02in} Double Cone Synchro-to-GealClearanc€ Standald: @: (Outer Synchro Ring to Synchro Con6l - 0.04in) 0.5- 1.0mm 10.02 @: (Synchrocone to Gearl 0.5- 1.0mm (0.02- 0.04inl O: {Outer Synchlo Ring to Gear) 0.95- 1.68mm (0.037- 0.066in) ServiceLimit: @: 0.3 mm {0.01in} @: 0.3 mm {0.01in) O: 0.6 mm t0'02inl

SYNCHROCONE

lf the clearanceis lessthan the servicelimit, replace the synchroring and sYnchrocone.

13-81

Differential Index

BacklashInspection 1.

Placethe differential assemblyon V-blocksand install both axles. M e a s u r et h e b a c k l a s ho f b o t h p i n i o ng e a r s .l f t h e backlashis not within the standard,replacethe dif, ferentialcarrier. Standard(New):0.05- 0.15mm (0.002- 0.006inl

80 mm SHIM page'13,84 Selection,

FINALDRIVENGEAR Inspecttor wear and damage.

101 N.m {10.3kgtm,74.5 lbf.ft) BALLBEAFING threads Inspectfoawear and ooeration. Left-hand

13-82

DIAL INDICATOR

FinalDrivenGearReplacement

BearingReplacement

'1. Removethe bolts in a crisscrosspatternin several steps,and removethe final drivengearfrom the differentialcarrier.

NOTE:Checkthe ball bearingsfor wear and rough rotation. lf bearingsare OK, removalis not necessary. 1.

N O T E :T h e f i n a l d r i v e ng e a r b o l t s h a v e l e f t - h a n d threads,

Removethe ball bearingsusing a standardbearing pullerand bearingseparatoras shown.

BEARINGPULLER 12x 1.0mm 101N.m {'10.3kgf.m,74.5lbf.ftl Left hand

BEARINGSEPARATOR lCommercially availab16)

FINALDRIVENGEAR Chamferon insidedaameterof final drivengear faces carrier. BALL BEARING

rla 2. 2.

Installthe final driven gear by tighteningthe bolts in a crisscrosspatternin severalsteps.

I n s t a l ln e w b a l l b e a r i n g su s i n gt h e s p e c i a tl o o l a s shown. NOTE: Drive the bearingssquarelyuntil they bottom againstthe carrier.

BALL BEARING

13-83

Differential ThrustShim Adjustment 1.

(

Installthe differentialassembly,makingsure it bot toms in the clutchhousing,usingthe specialtool as shown.

Installthe transmissionhousing(seepage13-94). NOTE:Do not apply liquidgasketto the matingsurfaceof the clutchhousing. 4.

ORIVER,40 mm LO. o7746-0030100

T i g h t e nt h e t r a n s m i s s i o nh o u s i n ga t t a c h i n gb o l t s (seepage 13-94). I x 1.25mm 27 N'm (2.8 kgf.m, 20 lbf.ftl Usethe specialtool to bottomthe differentialassem. bly in the clutchhousing. Measureclearancebetweenthe 80 mm shim and bearingouter racein the transmissionhousing.

l n s t a ltlh e 8 0 m m s h i m . NOTE:lnstallthe 80 mm shim that was removed.

mm SHIM

13-84

7.

lf the clearanceis not within the standard,selecta new 80 mm shim from the followingtable. Standard:0 - 0.10mm (0 - 0.004inl

t

missionhousing.

41441- PL3- 800

Thickn6ss '1.0mm (0.0394in)

B

41442-PL3-B00

1.1mm (0.0433in)

c

41443-PL3-800

1.2mm (0.0472in)

D

41444-PL3-800

1 . 3m m ( 0 . 0 5 1i2n )

41445-PL3-800

1 . 4m m ( 0 . 0 5 5 i1n )

41446-PL3-800

1 . 5m m ( 0 . 0 5 9 i1n )

41447-PL3-800

1.6mm (0.0630in)

41448-PL3-800

1.7mm (0.0669in)

41449-PL3-800

1.8mm (0.0709in)

H K

4 1 4 5 0 - P L 3 - B 0 0 1 . 0 5m m ( 0 . 0 4 1 i3n ) 1.'15mm (0.0453in) 41451- PL3- 800

IV N

4 1 4 5 2 - P L 3 - 8 0 0 1.25mm (0.0492in) 4 1 4 5 3 - P L 3 - B 0 0 1.35mm (0.0532inl

P

41454-PL3-800

1.45mm (0.0571in)

41455-PL3-800

1 . 5 5m m ( 0 . 0 6 1i0n )

R

Beplacethe 80 mm shim selectedin step 7, then recheckthe clearance. the transmissionand installthe trans1 0 . Reassemble

80 mm Shim Part Number

8 . Removethe boltsand transmissionhousing.

4 1 4 5 6 - P L 3 - 8 0 0 1.65mm (0.0650inl 4 1 4 5 7 - P L 3 - 8 0 0 1.75mm (0.0689in)

NOTE;lf the clearancemeasuredin step 6 is within the standard,it is not necessaryto 9o to step 9.

13-85

Clutch HousingBearing Replacement Mainshaft: L

( 3.

Drivethe new oil seal into the clutchhousingusing the specialtools as shown.

Removethe ball bearingusing the specialtools as shown.

HAMMER 3/81_16SLIDE { c o m m e r c i a l l ya v a i l a b l e )

HANOLE 07749- 0010000

OIL S€AL Replace.

ADJUSTAELEBEARING PULLER,25 - 40 mm 07736- A01000A

4.

2.

Removethe oil sealfrom the clutchhousino.

ATTACHMENT,42 x 47 mm 07746- 0010300

Drivethe ball bearinginto the clutchhousingusing the specialtoolsas shown.

HANDLE 07749- 0010000

ATTACHMENT,52 x 55 mm 07746- 0010il{)0

CLUTCHHOUSING

BALLBEARING PILOT,28 mm 07746- 0041100

13-86

3.

Countershaft: 1.

Bendthe tab on the lockwasherdown,then remove the bolt and bearingretainerplate.

Positionthe oil guide plateand new needlebearing in the bore of the ctutchhousing,then drive in the needlebearingusingthe specialtools as shown NOTE:Positionthe needlebearingwith the oil hole facingup.

NEEDLE BEARINGRETAINERPLATE

^ g

OIL HOLE

LOCKWASHER Reolace.

d---""-

cLutcHtlouslNG

t Removethe needlebearingusing the specialtools as shown,then removethe oil guide plate' NEEDLE BEARING HAMMER 3/8' - 16SLIOE (CommerciallY available)

Installthe bearingretainerplateand new lockwasher, then bendthe tab againstthe bolt head' 8x10mm 15N'm (1.5kgt'm,rl |bt'ft)

LOCK WASHER Replace.

ADJUSTABLEBEARING - {o mm PULLER,25 07736- Aolmo A

13-47

Mainshaft Thrust Clearance Adjustment 1.

V .

Removethe 72 mm thrust shim and oil guide plate from the transmissionhousing.

5.

Measuredistance@ betweenthe end of the clutch housingand bearinginnerrace. NOTE; . Usea straightedgeand depthgauge. . Measureat three locationsand averagethe readings.

72 mm THRUSTSH|M TRAt{SMtSStON HOUSING

OIL GUIOEPLATE

o

B INNERRACEot EALLBEARING

lnstall the 3rd/4th synchro hub. spacer collar,5th synchrohub. spacer,and ball bearingon the main_ shaft,then installthe above assemblyin the trans_ missionhousing.

4.

Selectthe prcpet72 mm thrust shim from the chart by usingthe formulabelow.

lnstallthe washe[on the mainshaft,

NOTE:Us€only one 72 mm thrustsntm.

Measuredistance@ betweenthe end of the transmissionhousingand washer.

Shim Selection Formula:

NOTE; . Usea straightedgeand verniercaliper. . Measureat three locationsand averagethe read_ ing. ENOot lnA sMtsstoN

Fromthe measurements you madein steps4 and 5: . Add distanceO lstep5) to distance@ (step4). .

From this number, subtract 0.93 (which is the midpointof the flex rangeof the clutch housing bearingspringwasher).

.

Takethis numberand compareit to the available shim sizesin the chart.

HOUSING MAINSHAFT

{Forexample)

B;2.39 + C:0.22

- 0.93

3RD/irTHSYNCHROHUB

2.61

= 1.68

SPACCRCOLLAR

Try the 1.68mm (0.0661in) shim.

5TH SYNCHROHUB

AALL BEARING TFANSMISSION HOUSING

13-88

7. lnstallthethrustshim selectedand oil guide platein the transmissionhousing.

72 mm Thrust Shim

c D E F G

J

K L N

o P

o R S T

t

X

z AB AC

AE AG AH

AK

AN

AO

Part Number 23931- P21 000 2 3 9 3 2 - P 2 -10 0 0 23933 P21- 000 23934- P21 000

2393s-P21-000 -000 23936-P21 23937-P21-O00 2 3 9 3 8 - P 2 -10 0 0 2 3 9 3 9 - P 2 -10 0 0 -000 23940-P21 23941 P21- 000 23942- P21 000 2 3 9 4 3 - P 2 -10 0 0 23944- P21-000 23945- P21 000 23946- P21 000 23947- P2l 000 2 3 9 4 8 - P 2 -10 0 0

23949- P21 000 23950- P21 000 23951- P21-000 23952- P21-000 2 3 9 5 3 - P 2 -10 0 0 2 3 9 5 4 - P 2 -10 0 0 23955- P21-000 2 3 9 5 6 - P 2 -10 0 0

2 3 9 5 7 - P 2- 0 100 23958- P21-000 23959 P21- 000 23960- P21 000 23961- P21-000 23962 P21- 000 -000 23963-P21 2 3 9 6 4 - P 2 -10 0 0 2 3 9 6 5 - P 2 -10 0 0 - 000 23965-P21 2 3 9 6 7 - P 2 -10 0 0 23968- P21-000 23969 P21- 000 2 3 9 7 0 - P 2 -10 0 0 23971- P21-000

Thickness in} 0.60mm {0.0236 in) 0.63mm 10.0248 in) 0.66mm (0.0260 in) 0.69mm (0.0272 in) 0.72mm (0.0283 in) 0.75mm (0.0295 0.78mm (0.0307in) 0 . 8 1m m ( 0 . 0 3 1i9n ) in) 0.84mm (0.0331 (0.0343 in) mm 0.87 ini 0.90mm (0.0354 in) 0.93mm (0.0366 in) 0.96mm 10.0378 in) 0.99mm (0.0390 1.02mm (0.0402in) in) 1.05mm (0.0413 in) 1.08mm (0.0425 'l 1.'1 mm (0.0437in) in) 1.14mm (0.0449 1 . 1 7m m ( 0 . 0 4 6i1n ) 1.20mm (0.0472in) in) 1.23mm (0.0484 in) 1.26mm (0.0496 in) 1.29mm (0.0508 in) 1.32mm (0.0520 in) 1.35mm (0.0531 in) 1.38mm 10.0543 in) 1.41mm (0.0555 1.44mm {0.0567in) in) 1.47mm (0.0579 in) 1.50mm {0.0591 1.53mm {0.0602in) 1 . 5 6m m ( 0 . 0 6 1 1 i n ) in) 1.59mm {0.0626 '1.62mm {0.0638in) in) 1.65mm (0.0650 in) 1.68mm {0.0661 in) 1.71mm 10.0673 in) 1.74mm {0.0685 1.77mm {0.0697in) in) 1.80mm (0.0709

OIL GUIDEPLATE

72 mm THRUST TRANSMISSION HOUSING

8 . I n s t a l lt h e s p r i n gw a s h e ra n d w a s h e ro n t h e b a l l beaflng. NOTE: . Cleanthe springwasher,washerand thrust shim throughlybeforeinstallation. . 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. -WASH€R -<]>-.-' x

(-.-sK (9r'

-sPRtNGWASHER

9 . lnstallthemainshaftin the clutchhousing. 1 0 . Placethe transmissionhousingover the mainshaft and onto the clutchhousing. ' Il . Tightenthe clutch and transmissionhousingswith several8 mm bolts. N O T E : l t i s n o t n e c e s s a r yt o u s e s e a l i n g a g e n t betweenthe housings. 8 x 1.25mm 27 N.m (2.8 kgf.m. 20 lbf'ft) 12. Tap the mainshaftwith a plastichammer.

(cont'd)

13-89

MainshaftThrustClearance Adjustment(cont'd) 13. Checkthe thrust clearancein the mannerdescribed oetow. CAUTION: Measuremenl should be made at room tempetature. a. Slidethe mainshaftbaseover the mainshaft. MAINSHAFT

c. Seatthe mainshaftfully by tappingits end with a plastichammer. d. Threadthe mainshaftholder bolt in untjl it just contactsthe wide surfaceof the mainshaftbase. e. Zeroa dial gaugeon the end ofthe mainshaft. f. Turn the mainshaftholder bolt clockwise;stoo t u r n i n g w h e n t h e d i a l g a u g e h a s r e a c h e di t s m a x t m u mm 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 gaugersthe amountof mainshaftend Dlav. CAUTION: Turning tho mainshaft holder bolt more than 60 degreesafter the needle of the dial g€uge stops moving may damage the transmis_ ston. DIALGAUGE

MAINSHAFTEASE 07GAJ- PG20.130

b. Attach the mainshaftholderto the mainshaftas follows: NOTE: . Back-outthe mainshaftholderbolt and loosen the two hex bolts. . Fit the holder over the mainshaftso its lip is towardsthe transmission. . AIignthe mainshafh t o l d e r . sI i p a r o u n dt h e groove at the insideof the mainshaftsplines, then tightenthe hex bolts. MAINSHAFT HOLOER BOLT

g. lf the reading is within the standard,the clearance is correct. lf the readingis not within the standard.recheck the shim thickness. Standard:0.11- O.18mm {0.004- 0.007in}

[--F-e

l6fffi |

ff

\-/

l\nrx

I/ Borrs

MAINSHAFT HOLDER 07GAJ- PG20110 MAINSHAFTBASE 07GAJ- PG20130

13-90

07cAJ_ PG20110

Transmission ReassemblY 1.

Installthe new oil seal

2.

Setthe changePiece.

3.

Installthe shift rod

4.

Installthe steelball'the spring,and the set screw'

5.

Installthe spring washer and changepiece attaching bolt.

6.

Installthe shift rod boots.

8x1.0mm 31 N.m 13.1kg-m, 22lb-ltl CHANGE PIECE

SPRING ,

@

/L.256fim

/

t't o'ti"l

B()(

I

{zw"y-6@

@:4

OIL SEAL Replace.

SPRING WASHER

q

Setthe springwasherand the washer'

and the shift 1 0 . lnstallthe mainshaft,the countershaft, fork assemblies. N O T E :A l i g n t h e f i n g e r o f t h e i n t e r l o c kw i t h t h e groove in the shift fork shaft.

7.

Installthe oil chamberPlate' 6 x '1.0mm 12 N.m (1.2kg-m,9lb-ft| SHIFTFORKS

13-91

Transmission (cont'd) Reassembly 11. Installthe c h a n g eh o l d e ra s s e m b l y .

( 13. Measurethe distance@ after mounting the shift pieceshaft.lf it's incorrect.checkthe installation.

6x1.0mm 15 N.m {1.5kgf.m,

CHANGE HOLDER ASSEMBLY

Distance@: 11.9- 12.3mm {0./t7- 0.48inl

12 N.m {1.2kgf.m,9lbtftl

1 2 . Installthe shift pieceand the interlock.then install the shift pieceshaft. 14. Installthe .everseidler gear and the reverseidler gearshaft.

REVERSE IDLERGEAR

REVERSE IDLE

13-92

15. Installthe reversechangeholder.

1 7 . Installthe oil gutterplate. 1 8 . Bendthe hook of the oil gutterplate,then installthe 16 mm sealingbolt.

6x1.0mm '15N.m 11.5kgim, 11 lblftl

NOTE: Apply liquid gasket {P/N 08718 0001 or 08718- 0003)to the threads. BOLT 16mm SEALING 29 N.mt3.0kgl'm,22 lbt'ft}

tl Instsllthe oil guide plateand the 72 mm thrustshim into the transmissionhousing.

1 9 . Apply liquid gasketto the surfaceof the transmission housingas shown' NOTE: . U s e l i q u i d g a s k e t ( P / N 0 8 7 ' 1 8- 0 0 0 1 o r 08718- 00031. . Removethe dirty oilfrom the sealingsurface' . lf 5 minut€s have passedafter applying liquid gasket,reapplyit and assemblethe housings' . Allow it to cure at least 20 minutes after assemblv bsforefitlingthe transmissionwith oil'

---

Liqui.lgask€t

(cont'd)

13-93

Transmission (cont'dl Reassembly Installthe dowel pins. 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 housingwith the finger on the stop fl ng.

( 23. Checkthat the snap ring is securelyseated in the grooveof the countershaftbearing. Dimension6) as instalt6d:4.6- 8.3 mm (0.181- 0.327inl

GROOVE

24. Installthe clutch line bracket,transmissionhanger Lowerthe transmissionhousingwith the snap ring p l i e r s ,a n d s e t t h e s n a p r i n g i n t h e g r o o v eo f t h e countershaftbearing. TRANSMISSION HOUSING

A and back-uplight switch ctamp,then tighten the transmission h o u s i n ga t t a c h i n gb o l t s i n t h e n u m _ beredsequenceshown below.

ATTACHING BOLTS 8 x 1.25mm 27 N m 12.8kgtm, 20tbt.trl

lar---'o

"W

TRANSMISSION HANGERA

o

BACK.UPLIGHT SWITCHCLAMP

13-94

l n s t a l l t h e s t e e l b a l l s ,t h e s p r i n g s ,a n d t h e s e t screws.

25. Installthe 32 mm sealingbolt N O T E :A p p l y l i q u i d g a s k e t( P / N 0 8 7 1 8- 0 0 0 1o r 08718- 0003)to the threads.

Installthe back-uplight switchand the transmission hangerB.

32 mm SEALINGBOLT 25 N.m {2.5 kgl'm, BACK.UPLIGHTSWITCH 25 N.m 12.5kgt m, 18 lblttl

EALL

\

\ \

8 x 1.25mm 21 N.m (2.4 kgf m, 1 7lbf.ftt

TRANSMISSION HANGERB

I

I

I

I

\

SETSCREW '12x 1.0mm 22 N.m (2.2kgf'm, 16 tbt.trl

26. Tightenthe reverseidler gearshaft bolt'

REVERSEIDLERG€AR SHAFTBOLT 10 x 1.25mm 5a N.rn t5.5 kgl m, {0 lbtftl

13-95

Oil Seals Replacement { Trrn3mirdon Housing:

Clutch Housing:

1.

1.

Removethe oil sealfrom the transmissionhousing.

Removethe oil sealfrom the clutchhousing.

OIL SEAL Replace.

Install the oil seal into the transmissionhousing usingthe sp€cialtools as shown,

Installthe oil seal into the clutchhousingusing the specialtoolsas shown.

HANDLE 07149 - d)l(xxto HANDTI

0t?a9- 001o(xto

OILSEAL Replace. HOUSING

13-96

OIL SEAL Replace.

GearshiftMechanism Overhaul NOTE: reDlaceany worn or damagedParts. . Inspectrubberpartsfor wear and damagewhen disassembling; joint as shown' . Installthe springpin and the clip on the change . Turn the shift rod boot so the hole is facingdown as shown' . Makesurethe shift rod boot is installedon the shift rod'

I x 1.25mm 22 N.m 12.2kgf.m, 16 lbf.ft)

ffi-:t't:il1ii51i?"'*, TU /g3i'51!Exii V

ExrENsroN

EXTENSfON

ilr'eol.T

MOUNT

\

@2'

\

h

V\

END EXTENSION BUSHING

-_.--_-_---

--1'>=2v/,,/ -:liT.i'ff" BALL SEAT

EXTENSIONEND WASI{ERB EXTENSIONROD

.o,-.o*&--ffi{---*, g

N: MOUNTING

LEvER sHrFr

V-oiliiSi[a

.*rr"r,o"-tf I

BRAcxEr

/ 8 x 1.2smm

"u, / ,rar-aoa*,"o Replace. 6x1.0mm 9.8N.m ('1.0kgt'm, 7 tbr.ftt

xoloen

€9-l--enr

I

u :-,rro""a,

ii-ri- ri.zrsr.-, 16 tbf.ft)

8x22mm SPRINGPIN Replace.

SHIFTI"EVER

--::=t

I

t

-.Q ,,,.

E ,",t.ruaa

9.a-"t't

SHIFTROD

8 x 1.25mm 22 N.m 12.2kgf'm, 16lblftl

,

SHIFTRODBOOT

SPRINGPIN

@

ZW €lt#

@ CLIP

/

-,\

HOLE

13-97

AutomaticTransmission "'..'.."...'..'14-1 AutomaticTransmission'.... VariableTransmission Continuously 14-193 (Cy1l ..........

t ro

AutomaticTransmission

L

Valve Body 14'2 .....'."".'-.-.' SpecialTools ......... 14-139 ........'.... Repair.................... 14-3 .,....................-...... Description power Flow Valve 14"6 ......,................. 1,1-1i10 Assembly 14-13 ElestronicControlSystem ..... ................'..'.'.. ATF Pump 1'l-19 .....'......" HvdraulicControl . . . . . . . . . . . ' . . . . . . .1.4. .- 1 4 1 Inspection .'.'.".'....11-21 HydraulicF|ow...... Body Main Valvs t/t'33 '............ ... Lock-upSystem y/lnspoction/R.sssembly .'.'.'.'..-.-. 11-112 Disass€mbf ElectricalSystem BodY Valve Secondsry 14'39 Locations....,.............'......'.............'.,. Component Disa$embfy/lnspoction/Rsassembly......'.'.'.'.11-111 PCMCircuit Diagram '96 - 98 Models) .........'..1/t-40 RegulatorValve Body lA/T Control Syst€m: Disa$embly/lnspoction/Rea3sembly..........'...14-1{5 PCMTarminal Volt8ge/MeasuringCondhions {'96 - 98 Modebl Servo Body A/T Control System ............ .".'........ 14-146 Disassombly/lnsp€ction/Reassembly PCMCircuit Disgram Lock-upValv6 Body (A/T Conlrol System: '99 - 00 Modsls) '..........'14-44 Dis$s.mbf y/ln3poction/Rea$embly .'..-.-..'.'.' 11-117 PCMTerminal Voltage/MeasuringConditions Mainsh!ft ('99 - 00 Models) til-46 Dkassembly/lnep€ctionReassembly..'...'........14'148 A/T Control System ... l it-149 rl-48 .............'..........'. I Inspoction .... Proceduros Troubleshooting Countsrshaft Symptom-to-ComPonentChari '96 - 98 Models'..-.-..."'.'..11-52 Disa$embly/lnspeqtion/Rea3sembly.......'...'..1a-l51 SFiem Efectricaf 11-152 -'99 1+54 .........". ... Dba$ombly/Re$s.mblY 00 Modols EloqtricalSystem 14-153 ...................... ('96 Models) Inspestion 98 EleclricatTroubl$hooting 14-56 Clutch Ona-way Flowcharts Troubleshooting Disassembh/lrupoction/Rca$embly .. "'........l4-155 ElectricalTroubleshooting('9!t- 00 Models) 1+81' Clutch Troublsshooting Flowchart3 lllustlttcd Ind.x {A48A,B4RATransmlssion)..' 14-156 Lock-upControl Solenoid vslvo A/B AssemblY 14-105 tustr.tod Index (MrnA Transmi$ionl ............til-158 14-160 1+105 RePlacoment 11-162 Rea$emblY Shift Cont.ol SolenoidValve A/B A3sembly 14-106 Difforrr ial Test.....,...... ........t4-156 14-106 llhdraied Index Replacement . 14-167 ln3poction B.ckhrh AsssmblY LinearSolenoid ..-..........11-167 14-107 BoaringRoplacemont Test.....,.,.......... lil-168 .....14-108 Diftrrsniial CarriorRepl8cemeni .'.-.............'...' Replacoment...... t4-t 59 Romoval Oil Sall Mainshaft/CountorshaftSpo€dSonsors 1'l'169 Clearance'......'.....'... lit'108 ln3tallstion/Sidc ......'."'........... Oil Soal Replacemsnt Torqua Convertcr Housing Boarings HydraulicSystem Mlin3haft Besring/Oil Scal Roplac.ment ."..'.. lil-172 Symptom-to-ComponeniChart r+109 Counio6hatt Betring R.plscem.nt ..'.............14-173 HydraulicSydem t 4 1 1 3 Tranlmission Housing Boarings RoadTe3t Msinsh.ft /CounteEhaft Bearings Stall Speed 11-171 B!pltcomgnt 1+116 Test Gear Rcvo.3s ldlor Fluid Level 11-175 lnrtallation 11-117 Checkin9.........."..'.'..... ParkStop 14-itB Changing In3pection/Adiustmsnt...'......'.'............'...."""'14-175 1+119 Testing Pressure Transmbgion Transmission lil-176 Reassombly Transmission . l4-182 ............'.'............'.. Plsie Torquo Convertet/Drivr 11-122 Rgmoval .. Transmission lllustrated Indax 1'l-183 .'..........'.'.'..... Inrtallation 11.726 Cover'. .... Transmission/End .... lil-187 .. Flushing Cooler 11-128 Hou3ing,.............'.'......'....""..-.-.. Transmission Torque Conve.ter Housing/ValvoBody ...........14-130 Shift Cabls RemovaUlnttallation End Cover 1,1-190 Adiustmont 11-132 lit-191 Lever .,........ Shift TransmisgionHousing Panel Shift lndicator 1 4 l 3 i l . . . . . . ' . . . . . R e m o v a .l . . ' . ' . . . . . . . . ' . . . . . . . . . . . . . .1. .4. .- 1 9 2 Adiu3tmant Tolque Convgrter Housing/valvs Body Hoses ATF Coolor 14-136 ............. Rsmoval .........,...... l'l-192 ..,............,.,....... Connection Valve CaDs t 4'138 .......'................. Description

SpecialTools

l.- a Ref. No.

Tool Number

o

07GAB- PF50101 07GAE- PG40200 or - PG4O2OA OTGAE 07HAC- PK4010A 0 7 J A D- P H 8 0 1 0 1 07JAD- PH80200 07LAE- PX40100 07PM - 0010100 07sM - 0010004 OTMAJ- PY4O1 1A 07MAJ- PY40120 07406- 0020400 07406- 0070300 07736- A010004 07746- 0010500 07746- 0010600 07746- 0030100 07749- 0010000 0 7 9 4 7- 6 1 1 5 0 1

,6'\

€) @) @@ @

o

@ @ @ @.. @ @ @ @ @

MainshaftHolder ClutchSpringCompressorBoltAssembly HousingPuller Driver Attachment Pilot,26 x 30 mm ClutchSpringCompresso.Attachmenr SCSServiceConnector BackprobeSet IVT Oil PressureHose,2210mm Ay'TOil PressureHose,Adapter Ay'TOil PressureGauge Set dpanel A,/TLow PressureGaugeWpanel AdjustableBearingPulter,25 - 40 mm Aftachment,62 x 68 mm Aftachment,72 x 75 mm Driver40 mm l.D. Driver Driver Attachment,68 mm

*07HAE- P150101 can be usedas a substitute. **Must be usedwith commercially-available _ 3/8,, 16slidehammer.

ry

=k

E-E

g

@

I 1 1 1

I 1 ,l 'l 1 I 1 1

14-135 14-171 14-' t7'l 14-160,163 14-49 1 4 - 5 01, 1 3 r4-119 1 4 -11 9 14-119 '14-1 19 14-172,173 14-172,'t73,114 14-172,174 14-153, 167.169,170 1+171, 172, 173,17 14-'t7'l

@

lal

o

1 4 - 1 3 31, 8 0 14-160,163

o

€)

e 4

w

o

@

14-2

----a\ /

\<-t-'\26

@

@

@

@

@

@

@

L

a

Description

controlledunit which provides The automatictransmissionis a 3-elementtorque converterand a dual-shaftelectronically 4 soeedsforward and 1 reverse. Torque Convertel, Geats,and Clutches The torqueconverterconsistsof a pump,turbineand stator,assembledin a singleunit.They are connectedto the engine crankshaftso they turn togetheras a unit as the engineturns.Aroundthe outsideof the torque converteris a ring gear which mesheswith the starterpinionwhen the engineis being started.The entiretorqueconverterassemblyseryesas a flywheelwhile transmiuingpowerto the transmissionmainshaft. The mainshaftis in Iine with the engine The transmissionhas two parallelshafts:the mainshaftand the countershaft. The mainshaftincludesthe 1st,2nd and 4th clutches,gearstor 2nd, 4th, reverseand lst (3rd gear is integral crankshaft. with the mainshaft,while the reversegear is integralwith the 4th gear).The countershaftincludesthe 3rd clutch,and gearsfor 3rd,2nd,4th, reverse.1stand park.The gearson the mainshaftare in constantmeshwith those on the countershaft.When certaincombinationsof gearsin transmissionare engagedby clutches.power is transmittedfrom the mainto provideE, ld, E, and E positions. shaftto the countershaft ElectronicControl The electroniccontrol svstem consistsof the PowertrainControl Module {PCM),sensors,a linear solenoid and four controlledfor comtonabledrivingunderall conditions.The PCMis solenojdvalves.Shiftingand lock-upare electronically panel side lower on the passenger's the front locatedbelowthe dashboard,under HydraulicControl The valvebodiesincludethe main vatvebody,the secondaryvalvebody,the regulatorvalvebody,the servobody and the lock-upvalvebody throughthe respectiveseparatorplates,Theyare boltedon the torqueconverterhousang The main valve body containsthe manualvalve,the 1-2shift valve.the 2nd orificecontrolvalve,the CPB{ClutchPressure Back-up)valve,the modulatorvalve.the servo controlvalve,the reliefvalve,and ATF pump gears The secondaryvalve (Clutch body containsthe 2-3 shiftvalve.the 3-4shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalveand the CPC pressureControl)valve.The regulatorvalve body containsthe pressureregulatorvalve,the torqueconvertercheckvalve, the coolerreliefvalve,and the lock-upcontrolvalve.The servobody containsthe servovalvewhich is integratedwith the The lock-upvalve body containsthe lock-upshift valve and the lock-uptiming reverseshift fork, and the accumulators. valve.The linearsolenoidand the shift controlsolenoidvalveAy'Bare boltedon the outsideof the transmissionhousing, and the lock-upcontrolsolenoidvalveAy'Bis boltedon the outsideof the torque converterhousing.Fluidfrom regulator passesthroughthe manualvalveto the variouscontrolvalves.The clutchesreceivefluid from their respectiveteed pipes or internalhydrauliccircuit. Shift Control Mechanism Inputfrom varioussensorslocatedthroughoutthe car determineswhich shiftcontrolsolenoidvalvethe PCMwill activate a line Activatinga shift controlsolenoidvalvechangesmodulatorpressure,causinga shift valveto move.This pressurizes and B are convalves A gear, solenoid control The shift and its corresponding that clutch clutches, engaging of the to one trolledby the PCM. Lock-upMechanism fluid is drainedfrom the backof the torqueconverter position,in 3rd and 4th.and in E positionin 3rd, pressurized In ,Dt1 through a fluid passage,causingthe lock-uppistonto be held againstthe torque convertercover.As this takesplace,the Togetherwith hydrauliccontrol,the PCMoptimizesthe timing of mainshaftrotatesat the same as the enginecrankshaft. the lock-upmechanism.The lock-upvalvescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and linearsolenoid.When lock-upcontrolsolenoidvalvesA and B activate,the modulatorpressurechangesThe lockup controlsolenoidvalvesA and B and the linearsolenoidare controlledby the PCM.

(cont'd)

14-3

Description (cont'dl Gear Selection The shift leverhassix positions:E PARK.E REVERSE, N NEUTRAL,E 1stthrough 4th gear ranges,E 1stthrough3rd gear ranges,@ 2nd gear. Position

De3cription

E PARK

Frontwheelslocked;parkpawl engagedwith pa* on countershaft. All clutchesreleased.

E REVERSE

Reverse;reverseselectorengagedwith countershaftreversegear and 4th clutchlocked.

N NEUTRAL

All clutchesreleased.

E DRIVE {1stthrough4th)

Generaldriving;startsoff in 1st,shiftsautomatically to 2nd,3rd,then 4th,dependingon vehicle speedand throttleposition.Downshiftthrough3rd,2nd and 1ston deceleration to stop.The lock-up mechanismcomesinto operationin @ positionin 3rd and 4th gear.

Ei DRtvE ('lstthrough3rd)

Usefor rapidacceleration at highwayspeedsand generaldriving;up-hilland down,hilldfiving;stans otf in 1st,shiftsautomaticallyto 2nd, then 3rd, dependingon vehiclespeedand throttle position. Downshiftsthrough 2nd to lst on decelerationto stop.The lock-upmechanismcomes into operation in 3rd gear,

B SECOND

Usefor enginebrakingor bettertractionstartingoff on looseor slipperysurfaces;staysin 2nd gear,does not shift up and down.

Startingis possibleonly in E and E positionsthroughthe useof a slide-type,neutral-safety switch. Automatic Transaxle(A/f, Gear Position Indicator The Ay'Tgear positionindicatorin the instrumentpanelshowswhich gear has beenselectedwithout havingto look down at the console. Clutch€s The four-speedautomatictransmissionuseshydraulically-actuated clutchesto engageor disengagethe transmission gears. When hydraulicpressureis introducedinto the clutchdrum, the clutchpiston moves.This pressesthe frictiondiscsand steel platestogether,lockingthem so they don't slip. Poweris then transmittedthroughthe engagedclutch packto its hub-mountedgear.Likewise, when the hydraulicpressureis bledfrom the clutchpack,the pistonreleases the frictiondiscs and the steelplates,and they are free to slide past each other.This allowsthe gear to spin independentlyon its shaft, transmittingno power. lst Clutch The 1stclutchengages/disengages 1stgear,and is locatedat the end of the mainshaft,just behindthe right sroecover. The 1stclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the mainshaft. 2nd Clulch The 2nd clutchengagegdisengages 2nd gear,and is locatedat the middle of the mainshaft.The 2nd clutchis joined back-to-back to the 4th clutch.The 2nd clutchis suppliedhydraulicpressurethroughthe mainshaftby a circutrconnected to the internalhvdrauliccircuit, 3rd Clutch The 3rd clutchengages/disengages 3rd gear,and is locatedat the end of the countershaft. The 3rd clutchis suoolied hydraulicpressureby its ATFfeed pipewithin the countershaft. ilth Clutch The 4th clutchengages/disengages 4th gear,as well as reversegear,and is locatedat the middleof the mainshaft.The 4th clutchis joined back-to-back to the 2nd clutch.The 4th clutch is suppliedhydraulicpressureby its ATF feed pipe within the mainshaft.

14-4

\-a

One-way Clulch The one-wayclutchis positionedbetweenthe countershaft1stgearand the parkgea.,with the parkgear splinedto the countershatt,The 1st gear providesthe outer racesurface,and the parkgear providesthe inner racesurface.The one-wayclutch locksup when power is transmittedfrom the mainshaft1st gear to thetountershaft 1st gear.The lst clutchand gears remainengagedin the 1st,2nd.3rd,and 4th gear rangesin the p!1,p! or L?lposition. are appliedin the E, E or @ position. when the 2nd,3rd, or 4th clutches/gears However,the one-wayclutchdisengages "speedrange"of the gears overrides the locking on the countershaft This is becausethe increasedrotationalspeedof the the one-wayclutchfree-wheelswith the 1stclutchstill engaged. one-wayclutch.Thereafter, zNO CLUTCH

,lTH CLUTCH

1STCLUTCH MAINSHAFT

COUNTERSHAFT

ONE.WAYCLUTCH

PANKGEAR

3ROCLUTCH

OUTSIDEOF ONE.WAY CLUTCH The sprags engage/

disengage outside and insideoI the

INSIDEOF ONE.WAY CLUTCH Splaned with counter shaft

LOCKINGCONDITION

OVER-RIDING LOCKINGSPEEDCONDITION

14-5

Description PowerFlow

\ART POSMON\

E E E 1ST

2ND

D]

3RD 4TH

tr

2ND 3RD

E

TOROUE CONVERTER

o o o o o o o o o o o

1STGEAR 2ND GEAR 3RDGEAR 2ND 3RD CLUTCH CLUTCH CLUTCH

4TH CLUTCH

REVERSE GEAR

o o o*, o*,

o o

o*1

o

o*1

o

O*r o+r

o o

o*1 o*1

o

O: Operates, x: Doesn'toperate. *1: Althoughthe 1stclutchengages,drivingpower is not transmittedas the one-wayclutchslips. *2: The one-wayclutchengageswhen accelerating, and slipswhen decelerating.

14-6

PARK GEAR

o

lXl Position Hydraulicpressureis not appliedto the clutches.Poweris not transmiftedto the countershaft. E Position Hydraulicpressureis not appliedto the clutches.Poweris not transmittedto the countershaft. The countershaftis lockedby the parkpawl interlockingthe parkgear.

TOROUECONVERTER

rST CLUTCH

COUNTERSHAFT

FINALDRIVE

3RD CLUTCH

14-7

Description PowerFlow (cont'dl

L

lst Gesr(E or @ position) In lE or E position, theoptimumgearis automatically selected from 1st,2nd,3rd and4thgears,according to conditions suchasthe balance between throttleopening(engineload)andvehiclespeed. pressure 1. Hydraulic is appliedto the 1stclutch,whichrotatestogetherwiththe mainshaft, causingthe mainshaft 1st gear to rotate.

Poweris transmittedto the countershaft1stgear,which drivesthe countershaft via the one-wayclutch. Poweris transmittedto the final drive gear,which drivesthe final drivengear.

TOROUE CONVERTER MAINSHAFT1ST GEAR

lST CLUTCH

MAINSHAFT

AY CLUTCH FINALDRIVEGEAR PARKGEAR COUNTERSHAFT 1ST GEAR

14-8

2nd Gear {8, E or E position) E Positionis providedto drive only 2nd gear. 1.

Hydraulicpressureis appliedto the 2nd clutchon the mainshaft,and power is transmiftedvia the 2nd clutchto the mainshaft2nd gear.

2,

Powet transmitted to the mainshaft 2nd gear is conveyed via tho countorshaft 2nd gear, which drivos the countershaft.

3.

Poweris transminedto the final drivBgear,which drivesthe final drivenge8r. NOTE: Hydraulic pressureis also applied to the 1st clutch, but since the rotation speed of ths 2nd gear excaadsthat 'lst gear is cut off at the one-way clutch. of lst gear, power from TOROUECONVERTER 2ND CLUTCH

MAII'ISHAFT

2I{D GEAR COUNTEBSHAFT

(cont'd)

14-9

Description PowerFlow (cont'dl 3rd Gear (bl or bd positionl 1.

Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshaft3rd gear is transmittedto the countershaft 3rd gear.

2.

Poweris transmittedto the final drive gear,which drivesthe tinal drivengear. NOTE:Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceedsthat of 1st gear,powerfrom lst gear is cut off at the one-wayclutch.

TOROUECONVERTER

MAINSHAFT3RD GEAR

MAINSHAFT

COUNTERSHAFT

3RD GEAB 3RD CLUTCH

DRIVENGEAR

14-10

4th cear lE position) 1.

mainshaft4th Hydraulicpressureis appliedto the 4th clutch,which rotatestogetherwith the mainshaft,causingthe gearto rotate.

2.

Poweris transmittedto the countershaft4th gear'which drivesthe countershaft'

3.

Poweris transmittedto the final drive gear,which drivesthe final drivengear' gear exceedsthat of 1st NOTE:Hvdraulicpressureis alsoappliedto the lst clutch,but sincethe rotationspeedof 4th gear,powerfrom 1stgear is cut off at the one-wayclutch TOROUE MAINSHAFT4TH GEAR

COUNTERSHAFT

FINALORIVENGEAR

14-11

Description PowerFlow (cont'd) El Po3ition 1,

Hydraulicpressureis switchedby the manualvalve to the servo valve,which moves the reverseshift fork to the reverse position. The reverseshift fork engageswith the reverseselector,reverseselector hub, and the countershaft reversegear. Hydraulicpressureis also appliedto the 4th clutch.Power is transmitt€dfrom the mainshaftreversegear via the reverseidler gear to the countershaftreversegear. The rotation direction of the countershaftreversegear is changedvia the reverseidler gear, Poweris transmittedto the final drive gear,which drivesthe final drivengear. TOROUE

MAINSHAFT

COU TERSHAFT

REVERSE IDLER

REVERSE SELECTOR HUB REVERSE SETICTOR

FINALON|VENGEAR

14-12

REVERSE SHIFT FORK

ElectronicControlSYstem four solenoid controtsystemconsrstsof a Powertraincontrol Module(PcM),sensors,a Iinearsolenoidand The electronac is located PCM The conditions all under driving for comfortable controlled electronically valves,shifting and lock-upare side belowthe dashboard,underthe front lower panelon the passenger's

PGM-FI Control Sy3tem

A/T Control SYstom

Shift Control

Lock-uDControl

14-13

Description ElectronicControlSystem(cont'd) Shift Control The PCM instantaneously determineswhich gear should be selectedby varioussignalssent from sensors,and actuates the shift controlsolenoidvalvesA and B to controlshifting.Also.a GradeLogicControlSystemhas beenadoptedto control shiftingin E positionwhile the vehicleis ascendingor descendinga slope,or reducingspeed. Poshion

8,tr E

tr

Gear

Shift Control Solenoid Vslve A

Shift Control Solenoid Valve B

1st

OFF

ON

2nd

ON

ON

3rd

ON

OFF

4th

OFF

OFF

2nd

ON

ON

Reverse EON *See page 14-31for reverseinhibitorcontroldescription.

OFF

Lock-upControl From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol solenoidvalveA and/orB accordingly.The combinationof drivingsignalsto lock-upcontrolsolenoidvalvesA and B and the linearsolenoidpressureis shown in the table below. Lock-upControl Solenoid Valvo A

Lock-upControl SolenoidValve B

Linoar Solonoid Prggguro

Lock-upOFF

OFF

OFF

High

Lock-up,Half

ON

Duty operation OFF* ON

Low

Lock-up,Full

ON

ON

High

ON

Duty operation OFF- ON

Lock-upConditions

LOCK-Up

duringdeceleration

14-14

a

GRADELOGICCONTROLSYSTEM How it works: The pCM comparesactualdrivingconditionswith drivingconditionsmemorizedin the PCM,basedon the input from the vehiclespeedsensor,the throttlepositionsensor,the barometoricpressuresensor,the enginecoolanttemperaturesensor, the brakeswitchsignal,and the shift leverpositionsignal,to controlshiftingwhile a vehicleis ascendingor descendinga slope,or reducingspeed.

SIGNALSOETECTED

Judgemenl ot Conirolling Arca O.iving Resi3lence

. Ascendingmod€ lFuzzyloqicl . GradualAscendingmode ' Ste€p Ascendingmode . Oescendingmode . Gr.du.l Descendingmode . Steep D6cending mode

14-15

Description ElectronicControlSystem{cont'dl

L

AscendingControl When the PCMdeterminesthat the vehicleis climbinga hill in E position,the systemoxtendsthe sngagementareaof 2nd gear and 3rd gear to prevent ths transmissionfrom fr€quently shifting between 2nd and 3rd gears, and between 3rd and 4th gears,so the vehiclecan run smooth and have more power when needed.Thereare two ascendingmodeswith different3rd geardrivingareasaccordingto the magnitudeof a gradientstoredin the pCM. NOTE: . The PCMmemorycontainsshift schedulesbetween2nd and 3rd gears,and between3rd and 4th gearsthat enablethe PCM'sfuzzylogicto automatically selectthe most suitablegearaccordingto the magnitudeof a gradient . Fuzzylogic is a form of artificialintelligencethat lets computersrespondto changingconditionsmuch like a human mind would, DsscondingControl When the PCM determinesthat the vehicleis going down a hilt in E position,the shift-upspeedfrom 3rd to 4th gear when th€ throftle is closed becomesfaster than the set speed for flat road driving to widen the 3rd gear driving area. This, in combinationwith engine brakingfrom the decelerationlock-up,achievessmooth driving when the vehicle is descending. Thereare two descendingmodeswith differentdownshift(4 - 3) schedulesaccordingto the magnitudeof a gradientstoredin the PCM.When the vehicleis in 4th gear,and you are deceleratingon a gradualhill, or when you are applying the brakeson a steep hill, the transmissionwill downshift to 3rd gear. When you accel6rate,the transmissionwill then return to 4th gear.

ASCENDINGMODE

DESCENDING MODE

F

4TH SHIFTING CHARACTERISIICS CONTROLAREA

3pe€d ff.1"11", vehicr. GRADUAL ASCENOING CONTROL AREA

ff;Tlr.,

vohicre speed

Docel6rationControl Whenthe vehiclegoes arounda corner.and needsto first decelerateand then accelerate. the rcM setsthe datafor deceleration control to reducethe number of times the transmissionshifts.When the vehicle is deceleratingfrom speedsabove 26 mph (41km/h),the rcM shiftsthe transmissionfrom 4th to 2nd earlierthan normalto copewith upcomingacceleration.

14-16

.

Circuit Diagram and Terminal Locations-'96

- 98 Modols

IGNITIONSWiTCH

tc1 IOCI(- UPCONTBOL SOTENOID VALVEA IGPl IGP2

vcc2 TPS

LOCK-UPCONTSOT soLtNoto valvE I

sG2

SIIIFTCONTFOL

sHrFrc0mioL

B SOLENOIDVATVE

UI{EARSOLENOIO

14-17

Description ElectronicControlSystem(cont'dl

L I

CircuitDiagramand TerminalLocations-'99 - O0Models GNTONSWICH rcj ,,--b. PG2 LOCK.UPCONIFOL SOLEI\Q D VALVEA

IGP2 v3u

vcc2 sc2

LOCKUPCON'IROL SOLENODVALVEB

SHFI CONTROL

SHIFTCONTFOL SOLENOIDVALVEE

L NEAFSOLEIOIO 6NII ONSWICH

14- 1 8

HydraulicControl

controlledsolenoids' and electronically The hydrauliccontrolsystemis controlledby the ATF pump,valves,accumulators, TheATFpUmpisdrivenbysp||nesontheendofthetorqueconverterWhichisattachedtotheengine.F|uidfrom pumpf|owsthroughtheregu|atorva|vetomajntainspecifiedpressurethroughthemainva|vebodytothemanuaIva| directingpressuretoeachofthec|utches.Theva|vebodyinc|udesthemainvaivebody,theregu|atorvalveb |ock-upva|vebody,thesecondaryVa|vebody,theservobody,theIinearso|enoid,theshiftcontro|so|enoid valveAy'Bassemblyand the linassembly,and the lock up controlsolenoidvalveA/B assembly.The shift controlsolenoid valve A,/Bassemblyis solenoid control lock-up The housing. transmission ear solenoidare boltedon the outsideof the housing converter boltedon the outsideof the torque

SHIFTCONTROL SOLENOIOVALVEA/8 ASSEMBLY LINEARSOLENOID

SERVOBOOY

VALVE

REGULATOR VALVEBODY

VALVEBOOY

CONTROL SOLENOIDVALVEA/B ASSEMBLY

ATF PUMPGEARS

(cont'd)

14-19

Description HydraulicControl(cont'dl Msin Valve Body The main valvebody housesthe manualvalve,the 1-2shift valve, the 2nd orificecontrolvalve,the cpB valve,the modulator valve'the servocontrolvalve,and the reliefvalve.The primary functionsof the main valve body are to swatchfluid pressureon and off and to controlthe hydraulicpressuregoing to the hydrauliccontrolsvstem. 2ND ORIFICECONTROT VALVE

1-2 SHIFT VALVE

RELIEFVALVE

VALVE

CONTROL VALVE

SocondaryValve Body The secondaryvalvebody is locatedon the main valvebody.The secondaryvalvebody housesthe 2-3shift vatve,the 3-4 shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalve,and the CpCvalve. 3-4 SHTFTV 2.3 SHIFTVALVE

4TH EXHAUSTVALV€ CPCVAL

VALVE

14-20

\ RegulatorValve BodY valve body consistsof the regulatorvalve'the The regulatorvalve body is locatedon the main valve body.The regulator checkvalve,the coolerreliefvalve,and the lock-upcontrolvaive' torque-converter VALVE REGULATOR VALVE REGULATOR

BODY

CONVERIER CHECKVALVE

COOLERRELIEFVALV€ CONTROLVALVE

Lock-upValve BodY valveis locatedon the regulatorvalvebodv The lock-upvalvebody with the lock-upshift valveand the lock-uptiming

LOCK,UPSHIFTVALVE

LOCK-UPNMING VALVE

icont d

1+21

Description HydraulicControl(cont'dl RegulatorValve The regulatorvalve maintainsa constanthydraulicpressurefrom the ATF pump to the hydrauliccontrol system,white alsofurnishingfluid to the lubricatingsystemand torqueconverter.The fluid from the ATF pump flows through B and 8,. The regulatorvalve hasa valveorifice.The fluid enteringfrom B flows throughthe orificeto the A cavity.This pressure of the A cavitypushesthe regulatorvalveto the right side,and this movementof the regulatorvalve uncovers the fluid port to the torqueconverterand the reliefvalve.The fluid flows out to the torqueconverter,and the relief valveand regulator valvemovesto the left side.Accordingto the levelof the hydraulicpressurethrough B, the positionof the regutator vatve changesand the amountof the fluid from B' through D and c also changes.This operationis continued. maantaining the line pressure, NOTE:When used."|eft" or "right" indicatesdirectionon the illustrationbetow. ENGINENOTRUNNING

ENGINERUNNING To TOROUECONVERTER Lubrication STATORSHAFTARM

Stator RoactionHydraulicProssur6Control Hydraulicpressureincreasesaccordingto torque,are performedby the regulatorvalve using the stator torque reaction. The stator shaft is splined with the stator in the torque converter,and its arm end contactsthe regulator sprangcap. when the vehicleis accelerating or climbing(TorqueConvert€rRange),the statortorque reactionacts on the statorshaft,and the statorarm pushesthe regulatorspringcap in the directionof the arrow in proponionto the reaction.Jne stator reaction spring compresses, and th€ reoulatorvalve movesto increasethe line pressurewhich is regulatedby the regulator valve. The line pressurereachesits maximum when the stator torque reaction reachesits maximum. TOROUE CONVERTER

REGULATOR VALVE

SPRINGCAP

STATOR

14-22

ATORSHAFTARM

\ Servo Body valvewhich is integratedwith The servo body is locatedon the secondaryvalve body.The servo body containsthe servo the reverseshiftfork,and the accumulators

2NO ACCUMULA

SERVOBODY

1STACCUMULATOR

3RDACCUMULATOR

SERVOVALVE/SHIFT FORKSHAFT

NoTE: The illustrationshowsthe'96 -

'98 models;the '99 - 00 modelsare similar'

14-23

Description HydraulicFlow GeneralChart ol Hydraulic Pressure peguratorvarve-_lATFPump-

lra Linepressure-f-

Moduratorpressure-Clutch pressure

Linearsorenoid

| pressure -Torque Converter t-Lubrication Pressure Distribution of HydraulicPressur€ . RegulatorValve -]TorqueConverterpressure Lubricationpressure F_ iTo regulateLinepressure .

Manualvalve _

To selectLine pressure_

clutch pressure

'

ModulatorValve

i/odulator pressure_

Shift ControlSolenoidValves Lock_up ControlSolenoidValves LinearSolenoid

___f_ F_ L_

. . .

1-2Shift Valve2-3 ShiftValve 3-4 ShiftValve

l 1-

Ctutchpressure

PORTNO. DESCRIPTION OF PRESSURE P ORTNO. DESCRIPTION OF PRESSURE P ORTNO. DESCRIPTION OF PRESSURE 1

LINE

6B

LINE

MODULATE (SHIFTCONTROL SOLENOID VALVEB)

41

4THCLUTCH

MODULATE (LOCK-UP CONTROL SOLENOID VALVEA)

56

LINEARSOLENOID

LINE

6D

MODULATE (LOCK-UP CONTROL SOLENOID VALVEB)

90

TOROUECONVEBTER

LINE

6D'

MODULATE (LOCK-UP CONTROL SOLENOID VALVEB)

91

TOROUECONVERTER

LINE

7

LINE

92

TOROUECONVERTER

LINE

8

LINE/CPC

93

ATF COOLER

3"

LINE

94

TOROUECONVERTER

LINE

9 '10

LINE

4

1STCLUTCH

95

LUBRICATION

LINE

20

2ND CLUTCH

YO

LINE

20A

2

5

6A

14-24

2NDACCUMULATOR

97

TOROUECONVERTER TOROUECONVERTER

LINE

99

SUCTION

X

DRAIN

MODULATE

30

3RDCLUTCH

MODULATE (SHIFT CONTROL SOLENOID VALVEA)

40

4THCLUTCH

\ @ Position (ATF)is drawn from (99)and disAs the engineturns,the ATF pump also startsto operate,Automatictransmissionfluid (1). pressure The line pressure(1) is regulated line pump the becomes chargedinto (1).Then,ATF flowing from the ATF (94) converter through the lock-up (92) torque of the pressure enters inlet by the regulator valve. The torque conv€rter pressurefrom rising' prevents converter the torque valve (901. ch€ck converter torque The shift valve and dischargesinto Underthis condition,the hydraulicpressureis not appliedto the clutches' "1eft"or "right" indicatesdirectionon the hydrauliccircuit' NOTE:When used,

14-25

Description HydraulicFlow (cont'd) L?jPosition The line pressure(1) flows to the manualvalve and the modulatorvalve.The line pressure(1) changesthe trnepressure (4) and (25)at the manualvalve.and changesto the modulatorpressure at the modulatorvalve.But the moouratorpressure (6) does not flow to each shift valve becauseshift control solenoidvalvesA and B are turned oN by the pcM. The line pressure(4) passesthroughthe cPB valveand the cPc valve.and changesto the line pressure(s), th;n flows to the 1-2shift valve.The line pressure{S)from the l-2 shift valvechangesto the 2nd clutchpressure(20) at the 2-3 shift valve. The 2nd clutch pressure(20) is appliedto the 2nd clutch.and the 2nd clutch is engaged.The line pressure(4) passes throughthe 1-2shift valve and the orifice,and changesthe lst clutchpressure,The 1stclutchpressure(10) atsoflows to the 1stclutch.However,no power is transmittedbecauseof the one_wayclutch. NOTE:When used,"Ieft" or "right" indicatesdirectionon the hvdrauliccircuit.

14-26

E! or l8! Position 1.

lst Gear The flow of fluid throughthe torqueconvertercircuitis same as in E position,The line pressuretlows to the manual valveand the modulatorvalve.The line pressurechangesto the modulatorpr€ssure(6)at the modulatorvalveand to the line pressure(4)at the manualvalve.The modulatorpressure(61flows to the lsft end of the 1-2shift valveand the 3-4 shiftvalvebecauseshift controlsolenoidvalveA is turnedOFFand B is turnedON by the PCM.The 1-2shiftvalve is moved to the right side.The line pressure(4) changesto the lst clutchpressure(10)at the 1-2shift valve and the oritice.The lst clutchpressure(10)is appliedto the 1st clutchand tho 1st accumulator;consquently,the vehiclewill move as the enginepower is transmitted. "|eft" or "right" indicatesdirectionon the hydrauliccircuit' NOTE:When used,

(cont'd)

14-27

Description HydraulicFlow (cont'd) 2nd G.!r As tha speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalve A is turnedoN by meansof the PCM The modulatorpressure{64} in the left end of the 1-2 shift valve is r€leased by turning shift controtsotenoid valve A oN The 1-2 shift valve is moved to the left side and uncoversthe port to allow line pressure{5) to the z-3 shift valve. The line pressure(5) changesto the 2nd ctutch pfessure l2O)at the 2-3 shift valve. The 2nd clutch pressure (20)is appliedto the 2nd clutch,and the 2nd clutchis engaged. Fluid flows by way of: - Line Pressure(4) + cPB varve - Line pressure(s) * 'r-2 shift varve - Line pressure(5) * 2-3 shift varve - 2nd ClutchPressure(20)+ 2nd Clutch The hydraulic pressurealso flows to the 1st clutch. However,no power is transmittod NOTE:When used,"|eft" or ,,right,,indicatesdirectionon the hydrauliccircuit.

14-28

becauseof the one-way ctutch.

I 3.

3rd Gear As the soeedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalveB is turned OFFby meansol the pCM. Shift controlsolenoidvalve A remainsON. The modulatorpressure(6) flows to the right end of the 1-2 shift valve and the left end oJ the 2-3 shift valve. The 2-3 shift valve is moved to the right side by the modulator pressure (68).The 2-3 shift valvecoversthe port to stop line pressure(5)to the 2nd clutchand uncoversto the 3-4 shift valve (30)at the 3-4 as the 2-3 shift valve is movedto the right side.The line pressure(5) becomesthe 3rd clutchpressure is engaged' (30) 3rd clutch pressure and the to the 3rd clutch, is applied shiftvalve.The 3rd clutch Fluid flows by way of: - Line Dressure(4)* CPBValve- LinePressure(5)* 1-2ShiftValve- LinePressure(5)* 2-3ShiftValve - Line Pressure(5)* 3-4 ShiftValve- 3rd ClutchPressure(30)- 3rd Clutch The hvdraulicpressurealso flows to the 1st clutch.However,no power is transmittedbecauseof the one-wayclutch as in 2nd gear. "|eft" or "right" indicatesdirectionon the hydrauliccircuit. NOTE:When used,

14-29

Description HydraulicFlow lcont'dl 4th Goar {E Position} As the speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalveA is turned OFFbymeans ofthe PCM Shift control solenoidvalve B remainsoFF. The modulatorpressure(6) flows to the left end of the t-2 shift valve and the left end of the 3-4 shift valve.The modulatorpressure(64) in the left end of the 1-2shift valve equals the modulatorpressure{68) in the right end of the 1-2shift valve,the 1-2 shift valve remainsat left side by the tension of the valvespring. The 3-4 shift valveis movedto the right side by the modulatorpressure(64).The 3_4shift valve coversthe port to the 3rd clutchand uncoversthe port to the 4th clutchas this valve is movedto the right side.The 4th clutchpressure(4.1) from the 3-4 shift valve becomesthe 4th clutch pressure(40) at the manual valve.The 4th clutch pressure(401 is appliedto the 4th clutch,and the 4th clutchis engaged. Fluidflows by way of: - Linepressure(4)* CPBValve- Line Pressure(5)+ 1-2Shift Valve- Linepressure(5)* 2-3 ShiftValve - LinePressure(5)- 3-4 ShiftValve- 4th Clutchpressure(41)+ ManualValve_ 4th Clutchpressure(40) * 4th Clutch The hydraulicpressurealso flows to the lst clutch.However,no power is transmittedbecauseof the one-waycrutch as in 2nd and 3rd gear. NOTE:When used,"|eft" or "right,,indicatesdirectionon the hydrauliccircuit.

14-30

L E Position pressure(1) changesto the The flow of fluid through the torque conveftercircuitis the same as in E position The line (3')at the 'l-2shift valve pressure (3) line to the line pressure(3)and flows to the l-2 shift valve.The iine pressure changes (Reverserangeposition)and uncoversthe port to and flows to the servovalve.The servovalveis movedto the right side 1-2shiftvalveflows throughthe servovalveto pressure the from The line {3') allow line pressure{3") to the manualvalve, pressure(40)is appliedto the 4th clutch,and (40). 4th clutch pressure The clutch the manualvalve and changesthe 4th the 4th clutchis engaged, ReverseInhibitor Control (10 km/h)'the PCMoutputsthe Whenthe E positionis selectedwhile the vehicleis movingforwardat spe€dsover 6 mph oFF,shift controlsolenoid 1stspeedsignalto shift controlsolenoidvalvesA and B; shiftcontrolsolenoidvalveA is turned port line pressure(3') to the stop to valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe (40) pressure is not appliedto the servovalve.The line pressure(3' )is not appliedto the servovalve,and the 4th clutch 4th clutch, as a result, power is not transmitted to the reversedirection' 'left" or "right" indicatesdirectionon the hydrauliccircuit' When used.

14-31

Description HydraulicFlow (cont'd) lll Position The flow of fluid through the torque convertercircuitis the same as in E position.The line pressure(1) changes to the line pressure(3)and flows to the l-2 shift valve.The line pressure(3)changesto the line pressure(3,)at the 1-2shift valve and flows to the servovalve.The servovalveis movedto the right side (Reverserangeposition)and uncovers port the to allow line pressure(3") to the manualvalveas in @ position.The line pressure(3") from the servovalveis Intercepted by the manualvalve.However,hydraulicpressureis not suppliedto the clutches,and the power is not transmitted. NOTE:When used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.

14-32

Lock-upSystem \ Lock-upClutch 1.

Ooeration(clutchonl with the lock-upclutch on, the fluid in the chamber betweenthe torque convertercover and the lock-uppiston is drained off, and the converterfluid exertspressurethrough the pistonagainstthe torque convertercover,As a result,the convener turbine is lockedto the conveftercover.The effect is to bypassthe converter,therebyplacingthe vehiclein direct drive PISTON LOCK.UP

DAMPERSPRING

The power flows by way ot: Engine { Driveplate

i Torqueconvertercover I Lock-uppiston Damperspring I Turbine Mainshaft

ODeration{clutch off} "clutch on." As a result,the lock-uppiston moves away from With the lock-upclutch off, the fluid flows in the reverseof the convertercover,and the torque converterlock-upis releassd. TURBNE Engine

t Driveplate I Torqueconvenercover { Pump I Turbine

TOROUECOI{VERTER COVER

\

Mainshaft

(cont'd) MAINSHAFT

14-33

Description Lock-upSystem(cont'd) In B.rlposition,in 3rd and 4th, and lDl_positionin 3rd. pressurized fluid is drajnedfrom the back of the torque converterthrough a fluid passage.causingthe lock-up pistonto be held againstthe torque convenercover.As this takesplace,the mainshaftrotatesat the samespeed as the engine crankshaft,Togetherwith the hydraulic c o n t r o l ,t h e P C M o p t i m i z e dt h e t i m i n g o f t h e l o c k _ u p system.Under certainconditions,the lock_upclutch is appliedduringdeceleration, in 3rd and 4th gear. The lock-upsystemcontrolsthe rangeof lock_upaccord_ ing to lock-upcontrol solenoidvalvesA and B. and the linearsolenoid.When lock-upcontrolsolenoidvalvesA and B activate,modulator pressurechanges.Lock_up controlsolenoidvalvesA and B and the linearsolenoid a r e m o u n t e do n t h e o u t s i d eo f t h e t o r q u e c o n v e r t e r housing.and are controlledby the pclvl.

TOROUECONVERTER

.

LOCK.UPCONTROL VALVE

Lock-upConditions/Lock-upControl SolenoidValves/ LinearSolenoid Pressure

A

B

OFF

OFF

High

Lock-up.Half

ON

Dutyoperation OFF- ON

Lock-up.Full

ON

ON

High

Lock-up during deceleration

ON

Dutyoperation OFF* ON

Low

Lock-up Conditions Lock-upOFF

TOROUECONVERTER CHECI(VALVE

RELIEFVAI-VE

Lock-upControl Solenoid Valve

Lineal Solenoid Pressure

LOCK.UPCONTROL SOLENOIDVALVE

MODULATORPRESSURE

LOCK.UPTIMING VALVE

^ VALVE r______rr r cooLER RELTEF

.--

LINEARSOLENOIDPRESSURE

ATFPUMP

14-34

I No Lock-up . . .

Lock-upControlSolenoidValveA: OFF Lock-upControlSolenoidValveB: OFF High LinearSolenoidPressure:

fluid regulatedby the modulatorworks The pressurized on both endsof the lock-upshiftvalve.Underthis condition, the pressuresworking on both ends of the lock-up shift valveare equal,the lock-upshift valve is movedto the right side by the tensionof the valve spring alone. The fluid from the ATF pump will flow through the left side of the lock-upclutchto the torqueconvener;that is, the lock-upclutchis in OFFcondition.

TOROUE CONVERTER

"left" or "right" indicatesdirection NOTE:When used, circuit. on the hydraulic

LOCK.UPCONTROL SOLENOIDVALVE

MOOULATORPRESSURE RELIEFVALVE

LOCK-UPTIMING VALVE

LINEARSOLENOIOPRESSURE 9

L

] I COOLER RELIEF VALVE

ATFPUMP

(cont'd)

14-35

Description Lock-upSystem(cont'dl Half Lock-up .

Lock-upControlSolenoidValveA: ON Lock-upControlSolenoidValve8: DutyOperation OFF- ON LinearSolenoidPressure: Low

The PCMswitchesthe solenoidvalveA on to releasethe modulatorpressurein the left cavityof the lock_upshift valve.The modulatorpressurein the right cavityof the lock-upshift valve overcomesthe springforce;thus the lock-upshift valveis movedto the leftside. The line pressureis then separatedinto the two pasTOROUE CONVERTER sagesto the torque converter: Torque ConverterInner pressure:enters into right sadeto engagelock-upclutch TorqueConverterBackpressure:entersinto left side LOCK.UPCONTROL to diseogagelock-upclutch VALVE The back pressure(F2)is regulatedby the lock-upcontrol valve, whereasthe position of the lock-uptiming valve is determinedby the linearsolenoidDressureand tension of the valvespring.Also the positionof the lock_ LOCK.UP CONTROL SOI.TNOID up control valve is determined by the back pressureof VALVE the lock-upcontrol valve, torque converter pressurereg_ A 8 ulatedby the torqueconvertercheckvalve,and modula_ tor pressuredeterminedby the lock-upcontrolsolenoid valve B. The PCMswitchesthe lock-upcontrolsolenoid valve B on and off rapidly{duty operation}undercertain conditions to regulate the back pressure(F2)to lock the torque convener properly.

TOROUECONVERTER CHECKVAI-VE

NOTE:When used, "left" or "right" indicatesdirection on the hvdrauliccircuit. MODULATOR PRESSURE

RELIEF VALVE

LOCK-UPTIMING VALVE

^ cooLERRELTEF valvE L____J'r

LINEARSOLENOTD PRESSURE

ATF PUMP

14-36

Full Lock-up . Lock-upControlSolenoidValveA: ON . Lock-upControlSolenoidValveB: ON o LinearSolenoidPressure: High W h e n t h e v e h i c l es p e e df u r t h e r i n c r e a s e st.h e l i n e a r s o l e n o i dp r e s s u r ei s i n c r e a s e dt o h i g h i n a c c o r d a n c e with the linearsolenoidcontrolledbv the PCM. T h e l o c k - u pt i m i n g v a l v e o v e r c o m e st h e s p r i n g f o r c e and moves to the left side. Also, this valve closesthe fluid port leadingto the left side of the lock-upcontrol Under this condition.the modulatorpressurein the left s i d e o f t h e l o c k - u pc o n t r o l v a l v e h a d a l r e a d y b e e n releasedby the lock-upcontrol solenoid valve B; the lock-upcontrol valve js moved to the left side. As this t a k e s p l a c e ,t h e t o r q u e c o n v e r t e r b a c k p r e s s u r ei s releasedfully. causingthe lock-upclutchto be engaged fully.

TOROUECONVERTER

LOCK.UPCONTROL SOLENOIDVALVE

"|eft" or "right" indicatesdirection NOTE:When used, on the hvdrauliccircuit.

MODULATORPRESSURE RELIEFVALVE

LOCK.UPTIMING VALVE

'r

LINEARSOLENOIOPRESSURE

vALvE ,-.r' cooLERRELTEF

ATFPUMP {cont'd)

14-37

Description Lock-upSystem(cont'dl DecelerationLock-up . .

Lock-upControlSolenoidValveA: ON Lock-upControlSolenoidValveB: DutyOperation OFF- ON a LinearSolenoidPressure: Low The PCM switchessolenoidvalve B on and off rapidly u n d e r c e r t a i nc o n d i t i o n sT . h e s l i g h t l o c k - u pa n d h a l f lock-upregionsare maintainedso as to lock the torque converterproperly. NOTE:When used, "left" or "right" indicatesdirection on the hydrauliccircuit,

TOROUECONVERTER

LOCK-UPCONTROL SOLENOIDVALVE

MOOULATORPRESSURE RELIEFVALVE

LOCK.UP TIMING VALVE

LINEARSOLENOIDPRESSURE COOLERRELIEFVALVE

ATF STRAINER ATFPUMP

1434

ComponentLocations

CONTROL POWERTRAIN MODULE(PCM)

TRANSAXLE{A/TI GEARPOSITIONSWITCH

COUNI€RSHAFT SPEEDSENSOR

SOI,TNOIDVALVE ASSEMBLY SOLENOIDVALVE ASSEMBLY

SPEEDSENSOR

1+39

PGMGircuitDiagram(A/T ControlSystem:'96 - 98 Modelsl -HOODFUSE/RELAY UNDEfl BOX

U N D E RD A S H N o . l 3( 1 5 A ) FUSE/REIAY 8OX

(80A1N0.42 No.41 l40A) No.47{7.5A)

/8LU

YEUBLK

c10

424

Arp Np

BtK At0

Btx 423

lon,^o l r,, lotrr

'96:BLU/BED '97,'98rGFN/BLK

l 6lt l 3]t lot* 824 t88 tB17 '96:GRN 8LU

GAUGE ASSEMBTY A,TGEAR POSITION INDICATOR

'96:BLU/RED al -'97,'98: GRN/8LK

LTGRN BLK/BTU

F-

BTK/BI.U

F_wHr F-

GRN

GRN

f-

GRN

BLU

F-

Bru

RED

GRNiELK

NorE: :ro5v t : r o1 2 v T

T T T

YEL

GRN BLU

CONNECTOR SERVICE CHECK

NCSG ILS-

l

ISHA

ISHB

ltc A

ltc B

WHT

RED

t

ILS+

l

l '

It Tl l

l

T II

Lo-l

MAINSHAFT SENSOR SPEED

BRNiBLK -UP CONTROL SHIF'CONTROL LOCK VALVE VALVE SOLENOIO SOTENOID ASSEMELY ASSEMEI-Y

I -

G1 0 1 PCMTerminelLocations

14-41

PCMTerminalVoltage/MeasuringGonditions('96 - 9g Models) A/T ControlSystem The PCMterminalvoltageand measuringconditionsare shown for the connectorterminalsthat relateto the A"/Tcontrol system.The other PCMterminalvoltageand measuringconditionsare describedin sectionI l.

A l32P)Conn€ctot

B I25P)Connector

C (31P)Conngctor

D (16P)Connector

PCMCONNECTOR A I32P} Terminal Numbor

Signal

Dcacription

MoasuringConditions/Te.minalVoltage - see section 1I -

A1 to A8 A9

LG1

Ground

A10

PG1

Ground

A11

IGPl

Power supply system

412 to A2l

With ignitionswitchON (ll):8atteryvoltage With ignition switch OFF:0 V - see section I I -

Ground

423

PG2

Ground

A'24

IGP2

Power supply system

A25 to A32

With ignitionswitchON (ll):Batteryvoltage With ignition switch OFF:0 V - seesectionl1 -

PCMCONNECTORB (25P} Terminal Number

Signal

B1

LS-

Description

MeasuringConditions/T6rminalVoltage

Linearsolenoidpower supply negativeelectrode

lgnitionswitchON (ll):Pulsingsigna.

Linearsolenoidpowersupply positive electrode

lgnitionswitchON (ll):Pulsingsignal

SHA

ShittcontrolsolenoidvalveA control

In 2nd gear and 3rd gear in E, E position, and in @, @ position:Batteryvoltage In lst gearand 4th gear in E. E position:0 V

B4

LCB

Lock-upcontrol solenoid valve B control

Whenfull lock-up:Batteryvoltage When half lock-up:Pulsingsignal

B5

LCA

Lock-upcontrolsol€noidvalveA control

When lock-upis ON: Batteryvoltage With no lock-up:0 V

82

86 to 87

B8 B gt o 8 1 0

14-42

Not used ATP D3

IVT g6ar positionswitch@ position signalinput Not used

l n E p o s i t i o n ;O V In otherthan E position:Batteryvoltage

I PCMCONNECTORB {25P1{cont'dl Measuring Conditions/TerminalVohage

Description

TerminalNumber

Signal

811

SHB

Shift controlsolenoidvalveB control

B't2

SLU

Interlockcontrol

813

D4 IND

D4 Indicatorlight control

When ignitionswitchis firstturnedON (ll): Batteryvoltage for two seconds In E position:Bafteryvoltage

B't4

NMSG

Mainshaftspeedsensorground

Always:0 V

E tc

NM

Mainshaftspeedsensorsignal input

Dependingon enginespeed:Pulsingsignal When engineis stopped:0 V

816

ATP R

Ay'Tgear position switch E positionsignalinput

I n E p o s i t i o n0: V In otherthan E position:Batteryvoltage

817

ATP 2

A/T gear position switch E position signalinput

I n E p o s i t i o n0 :V Battery voltage In orherthanE position:

position, In 1stgearand 2nd gear in -q1,q11 and in E] position:Batteryvoltage [Dr-position:0 V In 3rd gearand 4th gear in lD.J, When ignitionswitchis ON (ll),brakepedal deoressedand accelerator Dedalreleased:0 V

Not used

8 1 8t o 8 2 1

s22

NCSG

Countershattspeedsensorground

Alwaysr0 V

B23

NC

speedsensorsignal Countershaft input

Dependingon vehiclespeed:Pulsingsignal Whenvehicleis stopped:0 V

B24

ATP D4

Ay'Tgear position switch lor position signalinput A,/Tgear position switch E and N positionsignalsinput

InEposition:0V In otherthan 6 position:5 V

ATP NP

: I n E a n dE p o s i t i o n0sV Batteryvoltage In otherthanE andN] positions:

C {31P) PCMCONNECTOR TerminalNumber

Signal

Description

- seesection11 -

Cl to C6

c1

Servicechecksignal

With ignition switch ON (ll) and servicecheck connectoroDen;5 V With ignition switch ON (ll) and servicecheck connectorconnectedwith sDecialtool: 0 V - seesection11-

Back-uppower system

Always batteryvoltage - seesection'11-

C8 to Cg

c10

Measuring Conditions/TerminalVoltage

VBU

C 1 1t o C 3 1 D (16P} PCM CONNECTOR TerminalNumber

Signal

Description

- seesection11-

Dl to D4

D5 D 6t o D 1 6

MeasuringConditions/TerminalVoltage

STOPSW

Brakeswitchsignalinput

Batteryvoltage Brakepedaldepressed: 0V Brakepedalreleased: - seesection1 l -

14-43

PCMGircuitDiagram(A/T GontrolSystem:'99- 00 Models)

UNOEF DASI FL]SE/FELAY BOX

ta T06 TDr. UISEF,DASH FISSIELYmX r,Jo 25(75A)

GAUGE ISSEMBLY

Lr GRN -----l

L

l"--

eultru----iF

LTGRll INT€RLOCK CCNTFOL uN|l

erk€Lu

ert*rll

r-->l

l__

14-44

sL!

I

I

I STARTEF

CONNECTOF 1r6P)

Y II

I

SPEEO SENSOF

f7 II I

I ECI

"*ttot**" 1*u) ttt*'"

,5-,

I

II

SHIFICONTFOL solEt€to vALvE ASSEMSLY

fl**',*" I BLK

I G401

PCMTerminalVoltage/Measuring Conditions('99- 00 Models) A/T ControlSystem The PCMterminalvoltageand measuringcondjtionsare shownfor the connectorterminalsthat are relatedto the A//Tcontrol system,The other PCMterminalvoltageand measuringconditionsare describedin section,11.

PCMConnoctorTgrminrl Locations

PCMCONNECTOR A {32PI Terminal Numbel A10

Signal 5L5

A14

D4 IND

428

ILU

A.32

STOPSW

Description

M€asuring Conditions/TerminalVoltage

Servicechecksignal

With ignitionswitchON (ll)and servicecheck connectoropen:Approx, 5 V With ignitionswitchON (ll)and servicecheck connectorconnectedwith sDecialtool: 0 V

E indicatorlight control

When ignitionswitchis first turnedON (ll): ApDrox. 10 V for two seconds In E position:Approx.1OV

InterlockControl

When ignitionswitchON (ll),brakepedal pedalrereaseo: depressed, and accelerator Batteryvoltage

Brakeswitchsignalinput

Brakepedal depressed:battery voltage Brakeoedalreleased:0V

PCMCONNECTOR 8 (25P} Terminal Number

Signal

B1

!GP1

Power supply system

PGl

Ground

B8

LS AM

B9

Descdption

MeasuringCondhions/TorminalVoltag6 With ignitionswitchON (ll):Batteryvoltage With ignition switch OFF:0 V

Linearsolenoidpowersupply negativeelectrode

With ignitionswitchON (ll):Pulsingsignal

IGP2

Power supply system

With ignition switch ON (ll): Bafteryvoltage With ignition switch OFF:0 V

810

PG2

Ground

917

LS AP

B20

14-46

With ignitionswitchON (ll):Pulsingsignal

Ground

VBU 822

Linearsolenoidpower supply positiveelectrode Back-uppowersupply Ground

Always battery voltage

D {16P) FCM CONNECTOR

D1

LCA

Lock-upcontrolsolenoidvalveA control

When lock-upis ON: Batteryvoltage With no lock-up:0 V

SHB

ShiftcontrolsolenoidvalveB control

In E position,in 1stand 2nd gearin E, E position: Batteryvoltage ln 3rd gear in E, E, in 4th gear in E posit i o n ; 0V

LCB

Lock-upcontrolsolenoidvalveB control

Whenfull lock-up:Batteryvoltage With half lock-up:Pulsingsignal

Not used

D4 D5

VB SOL

D6

ATP R SHA

o

Measuring Conditions/TorminalVohage

Signal

D3

\

Do3cription

Terminal Number

Lock-upcontrolsolenoids,shift controlsolenoidsand linear solenoidpower supplyelectrode

with ignitionswitchoN (ll):Batteryvoltage With ignitionswitchOFF:0 V

Ay'Tgear position switch E positioninput

tnEposition:0V Approx.10V In otherthanE position:

ShiftcontrolsolenoidvalveA control

In E] position,in 2nd and 3rd gearin p!, [Q] position: Batteryvoltage In 1stgear in E, @ position,in 4th gear in El Dosition:0 V

D8

ATP D3

A/T gear position switch E positioninput

In E position:0V In otherthan @ position:Approx.10 V

D9

ATP D4

Ay'Tgear position switch E position switch

0V In El position: Approx.5 V In otherthanE position:

D10

NC

Countershaftspeedsensorsignal input

Dependingon vehiclespeed:Pulsingsignal Whenvehicleis stooped:0 V

D11

NM

Mainshaftspeedsensorsignal Inpur

Dependingon enginespeed:Pulsingsignal When engineis stopped:0 V

D't2

NMSG

Mainshaftspeedsensorground

D13

ATP NP

Ay'Tgear position switch E and E positioninput

: I n E a n dE p o s i t i o n0sV Approx.10V In otherthanE andE positions:

D14

AfP 2

Ay'Tgear position switch E positioninput

tnEposition;0V Approx.10V In otherthanE position:

D16

NCSG

Countershaftspeed sensor ground

14-47

Troubleshooting Procedures

Chcckingthe DiagnosticTrouble Code IDTC) with an OBD ll Scan tool or Honda PGM Tester when the PCMsensesan abnormalityin the input or output systems,the pl indicatorlight in the gauge assemblywill blink.When the 16PData Link Connector(DLC)(locatedunder the dash on the driver,sside) is connectedto the OBD ll ScanTool or HondaPGM Testeras shown,the scantool or testerwill indicatethe DiagnosticTroubleCode (DTC)when the ignitionswitchis turnedON{ll). OBD ll SCANTOOLor HONDAPGMTESTER

DAYALINKCONNECTOR {16P}

lf the El indicatorlight or the MIL hasbeenreportedon, or lf a driveabilityproblemis suspected, follow this procedure: 1. Connectthe OBD ll ScanTool (conformingto SAE J19781or HondaPGMTesterto rhe 16p DLC.(Seethe OBD ll Scan Tool or HondaPGMTesteruser'smanualfor specificinstructions.lf you are usingthe HondaPGMTester,makesure it is set to the SAE DTCtype.) 2. Turn the ignitionswitchON (lll, and observethe DTCon the screen, 3, Recordall fuel and emissionDTCS,A/T DTCS,and freezedata. 4 lf there is a fuel and emissionsDTC,first checkthefuel and emissionssystemas indicatedbythe DTC(exceptfor DTC P0700).DTCP0700meansthere is one or more A,/TDTC,and no problemswere detectedin the fuel and emissionscircuit of the PCM. 5. Write down the radiostationoresets. 6. Resetthe memorywith the PGMTesteror by removingthe BACKUP fuse in the passenger's under-dashfuse/relaybox for more than 10 seconds. 7. Drivethe vehiclefor severalminutesat speedsover 30 mph (50 km/hr),and then recheckfor DTCS.lf the A"/TDTC returns,go to the Symptom-toComponentCharton pages14-52and 14-53for'96 - 98 models,and pages14-54and 14-55for the'99 - 00 models,lf the DTCdoes not return,there was an intermittentproblemwithin the circuit.Make sureall pins and terminalsin the circuitare tight, and then go to stepg. 8. Resetthe radiopresetstations,and setthe clock.

14-44

Chockingth€ DiagnosticTroubleCode (DTCI with the ServicoCheckConneqtorand Sp€cialTool Whenthe PCMsensesan abnormalityin the inputor outputsystems,the @ indicatorlight in the gaugeassemblywill blink When the Service CheckConnector(locat€d under the dash on the passengsrside) is connectedwith the special tool as TroubleCode(DTC)when the ignitionswitchis turnedON (ll). shown,the E indicatorlightwill blinkthe Diagnostic When the E indicator light has been reported on, connectthe ServiceCheckConnectorwith the specialtoo'. Thenturn ON (ll)the ignitionswitchand obssrvethe E indicatortight. GAUGEASSEMBLY

SERVICE CHECK CONNECTOR I2PI

CONNECTOB

07PAZ-0010100

Codes 1 through 9 are indicated by individual short blinks, Codes 10 and above are indicat€d by a sories of long and short blinks.One long blink equals1Oshort blinks.Add the long and short blinkstogetherto determineth€ code.After determining the code, refer to the electricalsystem Symptom-to Component Chart on pages 1+52 and 1+53 for'96 98 mod'99 00 models. els,and 14-54and 14-55for the Short blink loncel

S€r DTC1

s.. DTC2 Long blink

Short blink

lfiYa tim.!,

S€c DTC 15

(cont'd)

14-49

TroubleshootingProcedures (cont'dl 1.

Removethe kickpanelon the passenger's side {seesection20}.

2.

Removethe PCM.and turn the PCMover.

Inspectthe circuit on the PCMaccordingto the troubleshootingflowchart with the spocialtools and a digital multimeter as shown. How lo Use tha BackprobeSet Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cords to a multimeter.Usingthe wire insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the wire side until it comesin contactwith the terminalend ofthe wire.

BACKPROSE

BACKPROBE SET

07saz- (xtl(xtoA {two required)

DIGITALMULNMEIER (Comm€rcially6vailabl€l -aHM-32-003 or equival€nt

14-5 0

PCMResetProcedure 1. Turn the ignitionswitchoff. 2.

Removethe BACKUPfuse (7.5A) from the under-hoodfuse/relaybox for

'10secondsto resetthe PCM'

NOTE: the radio . Disconnecting the BACKUP fuse also cancelsthe radio presetstationsand clock setting Make note of you them reset can presetsbeforeremovingthe luse so . in" gCfUmemorycan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester'

Final Procedure NOTE:This proceduremust be done afterany troubleshooting. 1. Turn the ignitionswitchOFF. 2.

Resetthe PcM.

3.

tool from the oBD ll scan Tool or HondaPGMTesterfrom the DataLinkconnector,or removethe special Disconnect the ServiceCheckConnector.

4.

Turn the ignitionswitchON (ll),and setthe radiopresetsand clocksetting'

5'ToVerifytheprob|emisrepaired,test.drivetheVehic|eforseveralminutesatspeedsover30mph(48km/h).

14-51

Symptom-to-Component Ghart ElectricalSystem-'gG - 98 Models E Indicaior Light

MIL

P1753 fl)

Blinks

ON

Lock-upcontrolsolenoidvalveA

P1758 \21

Blinks

ON

Lock-upcontrolsolenoidvalveB

P1705 (51

Blinks

ON

Ay'Tgear position switch (short to groundl

P1706 (6)

OFF

ON

A,/Tgear position switch (open)

P0753 l7l

Blinks

ON

ShiftcontrolsolenoidvalveA

P0758 {8)

Elinks

ON

ShiftcontrolsolenoidvalveB

POl20 (9)

Blinks

ON

Countershaftspeed sensor

P0715 {15)

'96 - 97 models: OFF '98 model: Blinks

ON

P1768 {16)

Blinks

ON

P0740 (40)

OFF

ON

P0730 (41)

OFF

ON

DTCII

Dotection ltem

Page 14-56 14-58 14-60 14-62 14-64 14-66 14-68

Mainshaftspeedsensor

P0700*, (none) *1: The DTCin the parentheses is

14-70

Linearsolenoid Lock-upcontrol system Shift control system

't4-72 14-74 14-75

Automatictransmissioncontrolsvstemin the pGM-Fl control svstem

the code E indicatorlight indicateswhen the DataLinkconnectoris connectedto the Honda PGM Tester. *2: Wheneverthe HondaPGM Testeror ScanTool detectsan automatictransmissioncontrolsystemDTC,p07OO will be set in the PGM-FIcontrol svstem.

14-52

lf the self-diagnostic l-d indicatorlight does not blink,performan inspectionaccordingto the table below. SYmPtom

Inspection

E indicatorlight does not come on tor two secondsafterignition switchis first turnedON {ll}. E indicatorlight is on constantly(not blinking)wheneverthe ignition switchis ON (ll). Shift levercannotbe movedfrom @ positionwith the brakepedal depressed.

Ref.Page 11-16 14-78

Inspection

't4-79

to recreatethe symptom by test-drivNOTE:lf a customerdescribesthe symptomfor code Pl706 {6),it will be necessary DTC. recheck the then ing,

14-53

Symptom-to-Component Chart ElectricalSystem-'99 - 00 Models DTC*I

E Indicator Light

MIL

P1753 fi)

Blinks

ON

Lock-upcontrolsolenoidvalveA

P1758 t2l

Blinks

ON

Lock-upcontrolsolenoidvalveB

P1705 {5}

Blinks

ON

Ay'Tgear position switch {short to ground)

P1706 (6)

OFF

ON

y'VTgear position switch {open)

P0753 \71

Blinks

ON

ShiftcontrolsolenoidvalveA

P0758 (8)

Blinks

ON

Shift control solenoid valve B

P0720 (9)

Blinks

ON

Countershaftspeed sensor

P0715 (15)

Bl i n k s

ON

P1768 (16)

Blinks

ON

PO740 (40)

OFF

ON

Lock-upcontrol system

P0730 (41)

OFF

ON

Shift control svstem

P0700*, (none)

OFF

Dotostion ltem

Mainshaftspeedsensor Linearsolenoid

Page '14-80

14-82 14-84 14-81 14-89

14-9r r4-93 14-95 't 4-97 14-99 14-100

Automatic transmissioncontrol system in the pGM_Fl controt svstem

*1: The DTc in the parentheses is the code E indicator tight indicateswhen the Data Link connector is connected to the Honda PGM Tester. *2: Whenever the Honda PGM Tester or scan Tool detects an automatic transmission control system DTc, p07oowill be set in the PGM-FIcontrol svstem

14-54

E indicatorlight does not blinkand followingsymptomsappear,performan inspectionaccordingto lf the self-diagnostic the table below. page Reference

1."""". y{*fu fiSh, E i"dl.r."

14-101

oN (ll). lE indicatorlight does not come on for two secondsafterignitionswitchis first turned Shift levercannotbe movedfrom E positionwith the brakepedaldeprsssed'

14-102 14-104

14-55

ElectricalTroubleshooting(,96- gg Models) Troubleshooting Flowchart- Lock-upcontrorsorenoidVarveA NOTE:Recordallfreezedata beforeyou troubleshoot. . OBD ll Scrn Toot indicatesCode P1753. . S e l f - d i a g n o s i s@ i n d i c a t o r light blinks once.

Po$ible Cau3e

. Disconnecledlock-up control solenoidvalvo A connector . Short or open in lock-uDcontrol solenoidvalv€ A wire . Fauliy lock-up contlol solonoid valve A PCMCONNECTORS

Checkfor a Short to Powo.: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (32p)and B ( 2 5 P )c o n n s g l 6 p s1 r q - t h a PCM. 3. Turnthe ignitionswjtchON 0t). 4, Measurethe voltagebetween the 85 and Ag or A22 termi nals.

A l32P)

Wire sideof femaleterminals

Repair shoit to power in the wire betw€en the 85 terminal and thg lock-up coDtrol tolenoid valve A.

Mea3ureLock-upControl Solenoid Valve A RGislance: '1. Turn the ignitionswitchOFF. 2. Measure the resistance betweenthe 85 and A9 or A22 terminals.

ls the resistance 12- 25 O?

To page'14-57

Checklor looso PCM conn€ctoB. lf nece$.ry, substituto a knowngood aolonoid valve ass€.nblvol PCMend rech6ck.

Frompage14-56

PCMCONNECIOBS

Ch6ck Lock-up Control Solenoid Valve A tor a Short Cilcuiti 1. Disconnectthe 2P connector lrom the lock-upcontrol solenoid valveassemblY. 2. Check for continuity between the 85 and Ag or A22 terminats. Wire sideof lem6leterminals Ropair 3hort to giound in iha wila b.twoqn th6 85 terminrl rnd tho locl-up control 3olanoid valvo A. LOCK.UPCONTROL SOrINOID CONNECTOR

lml -,f (o)

Mo..ura Lock-up Control Sole' noid Velve A Reri3tanc. at tho SolenoidConn6cto.: Measure the resistancebetween the No. 2 terminalof the lock-up control solenoidconnectorand body ground.

ls the resistance12_ 25 O?

YEL

I

Teaminalsideof maloterminals

Chock for opan in tha wit. ba(w.an tha 85 torminll lnd the lock-uocontrol lolanoid vtlYa A.

Roplscetho lock"up cont.ol 3ol€_ noid vllvo arsembly.

14-57

ElectricalTroubleshooting('96 - 9g Modelsl TroubleshootingFtowchart- Lock-upcontrol sorenoidVarveB NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanTool indicrtes Code P1758. . Self-diagnosisE indicrtor light blinkstwice.

PossibleCause . Disconnectedlock-up control solenoid valve B connector ' Short or open in lock-upcontrol solonoid valve B whe . Faulty lock-up control solenoid valve B

PCMCONNECTORS Checkfor a Shon to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (32p)and B ( 2 5 P )c o n n e c t o r sf r o m t h e PCM, 3. Turnthe ignitionswitchON t). 4. Measurethe voltage between the 84 and A9 or A22 terminals.

A {32P)

Wire sideof femaleterminals

Repeir short to power in the wire between the 84 teiminal and the lock-up control solenoid valve B.

MoasureLock-upControl Solenoid Valve B Resistance: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance b e t w e e nt h e 8 4 a n d A g o r A22terminals.

ls the resistance 12- 25 O?

To page 14-59

Check for loose FCM connectors, lf necessary, substitute a knowngood solenoid valve assembly ol P1CMand rech6ck.

Frompage14 58

PCMCONNECTORS

Check Lock-up Control Solenoid Valve B for a Short Circuh: 1. Disconnectthe 2P connector from the lock-uPcontrolsole' noid valveassefibly. 2. Checkfor continuitybetween the 84 and A9 or A22 termanals, WiresideoI lemaleterminals

ls therecontinuity?

Rgprir 3hort to ground in tho wite Hwoon the 84 torminal and the lock-uocontlol solonoidvalvs B.

LOCK.UPCONTROL SOLENOIDCONNECTOR

IFl;II -r:-]

Measu.o Lock-uP Control Sole' noid Valve I Resistance at tho SolenoidConnector: Measurethe resistancebetween the No. 1 terminalo{ the lock-up control solenoid connectorand body ground.

12- 25 O? ls the resistance

6nn/eLKfi

I Terminalsidoot maleterminals

Chcck tor opcn in the wirs b€tlve.n the 84 ierminal and tho lock-upconttol solonoidvllvc B.

Reolacethe lock'up control solenoid valve assemblY.

14-59

ElectricalTroubleshooting('96 - 9g Models) TroubleshootingFlowchart- A/T GearpositionSwitch (Shortl NOTE:Recordallfreezedatabeforeyou troubleshoot. ' OBD ll Scln Toot indic.tes Cod6 P1705. . Sofidi.gno3b E indicato] tighr blinksfivatim...

Observo th. A/T Go.r po3ition Indicator: 1. Turnthe ignitionswitchON l). 2. Observethe A"/Tgear position i n d i c a t o r ,a n d s h i t t t o e a c h posttron,

Do any indicatoGstay on when the shift lever is not in those positions?

Poiriblo Caus6 . Short in A/T go.. position awhch wira . FauhyA/T goa. position swhch NOTE:Code P1705(5) is causedwhen the PCM receives two g e a r p o s i t i o n inputsat the sametime.

Tho sy3tem b OK.t this timo. Checkth6 wilc harnari for damrga.

PCMCONNECTORS

M.r.ur. ATP R Vohlge: 1. Shiftto all positionsotherthan

E.

2. Nileasurethe voltage between the 816 and Ag or A22 torminats,

ls there batteryvoltage?

Check for short in tha wiro bstwacn the 816 tcrminal and th6 A/T go.r porition rwitch or A/T g..r position indicltor. It wira i3 OK, ch.ck for loo!€ FCfit connocto13. lf nacetaary, subrtitute a known€ood Pcllt and roa|rsck.

Meesur. ATP NP Vohage: 1. Shiftto allpositionsoth€rthan

EorE.

2. Moasurethe voltage between the 825 and A9 or A22 termi nats.

M.Gur. ATP D4 Voltago: 1. Shiftto allpositionsotherthan lD.l. 2. Measurethe voltage betw€en rhe 824 and Ag or A22 terminals.

ls there approx. 5 V? YES To page14-6':

1 4- 60

Check for short in the wire b.tw..n th6 B:I5torminrt and th. A/T gclr poahion indicator. o. . short in tha wirrs between th. A/T gclr position indicator rnd the A/T gerr poiition switch. lf wir.3 r.o OK, chack tor looso PCM conn.ctorr. It n.cosarry. sub.tituto a known-good pCM .nd r.chock.

Check tor 3hort in tho wiro bc{wocn the 824 terminrl and tho A/T ge.r poiition switch. lI wile ia OK, chock tor loo3o plCM conncctoaa. It nacossarv,sublthute a known-good PCMand rech€ck.

Wiresideof femaleterminals

PCMCONNECTORS

From page 14-60

'96:GRN'97- 98:PNX

MeasuroATP D3 Voltage: 1. Shiftto all positionsotherthan

tr.

2. Measurethe voltage between the 88 and A9 or A22 terminals.

B (25P1 Wire sideot femaleterminals

ls there batteryvoltage?

Ch.ck tor short in the wire botwoen tho 88 terminal and ihe A/T goar position 3witch ol A/T gosr position indicator, ll wirc is OK, chock for loo3€PCM connector3. lf nece3rary, substituta a known-good PCMlnd roch€ck

Morsuro ATP2Voltage: 1. Shiftto all positionsotherthan 6t 2. Measurc the voltage between the 817 and Ag or A22 termln6ls.

ls there batteryvoltage?

Check for short in the wile b€twesn the B'l 7 terminal and the A/T ge.r pGition switch or A/T gear po3ition indicator. lf wire i3 OK, check for loo3o rcM connec' to13. lf necossarY, substitute a known-goodPICMand recheck.

check for loose PCMconnectors. lf noc*sarY. sub3titute a known_ good PCMand r.chock.

14-61

ElectricalTroubleshooting('96- gg Modelsl TroubleshootingFlowchart- A/T GearpositionSwitch (Open) NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanTool indicatesCode P1706. . Self-di.gnosk E indicatortight blinks six timos.

PossibleCauso . DisconnectedA/T gear position switch conn€ctor . Open in A/T gear position switch wire . FaultyA/T gear position switch PCMCONNECTORS

MoasureATP I Voltage: 1. Turnthe ignitionswitchON 1 ). 2. Shiftto E position. 3. Measurethe voltagebetween the B'f6 and Ag ot A22 tetminats.

Wire side of female terminals

Ropai. op€n in the wire betwe€n the Bl6 terminal.nd the A/T gear position swhch.

Measur€ATP NP Voltage: 1. Shiftto E or E position. 2. Measurethe voltagebetween the 825 and A9 or A22 termi, nals,

Repeir open in the wir€ between tho B25terminal and th6 A/T geer position indicator or tho A/T 96.r position 3witch.

MeasureATP 04 Voltege: 1. Shiftto E position. 2. Measurethe voltagebetween the 824 and A9 or A22 termi nals,

ls there voltage?

NO

To page 14 63

1+62

Rcpair open in the wire between tto 82{ to.minal and th6 A/T geat lrosition 3witch.

Frompage14-62 PCMCONNECTORS '95: GRN37 -'98: PNK MeasureATP 03 Voltagei 1. Shiftto E Position. the voltagebetween 2. lvteasure the 88 and A9 or A22 terminals.

Wire sideof femaleterminals

Ropairopen in tho wils between the 88 terminal .nd tho A/T goar oosition switch

Mea3ur. ATP2Vohage: 1. Shiftto E Position. 2. Measurethe voltage between the 817 and Ag or A22 termi' nals,

Repairopen in the wirc botweon the B17terminalrnd the A/T geer poaition 3witch.

Chockfor loose PCM conn€ctoB. lf nec*sary, sub3titute e known' good PCMand rocheck.

14-63

ElectricalTroubleshooting('96 - 98 Modelsl TroubleshootingFlowchart- Shift GontrolSolenoidValveA NOTE:Recordall freezedata beforeyou troubleshoot. ' OBD ll ScanTool indicatesCode P0753. . Sett{iagnosis E indicatorlight blinks seventim6.

Po$ible Cau3e

. D i s c o n n e c t e ds h i f t c o n t r o l solenoidvalve A connector . Short oi open in shift control solenoidvalve A wire . Faulty shirt control solenoid

PCMCONNECTORS

Checktor a Short to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (32P)and B { 2 5P i c o n n e c t o r st r o m t h e PCM. 3. Turnthe ignitionswitchON {ll). 4. Measurethe voltage between the 83 and A9 orA22 terminals.

A t32Pl

Wire sideol femaleterminals

Repairshort to powe. in the wir6 between the 83 terminal .nd the shift control solonoid valvo A.

Moa3ure Shift Control Solenoid Valve A Resistanc€: 1. Turnthe ignitionswitchOFF. 2, Measure the resistance betweenthe 83 and A9 or A22 terminals.

ls the resistance 12- 25 0?

To page14-65

Ch€ckfor loose PCMconnectors. lf n€c6srry, subatitute a knowngood solenoid valve a3,semblyor PCMend rocheck.

Frompage14-64 PCMCONNECTORS Check Shift Control Sol.noid v.lve A loi a Short Circuh: '1. Disconnectthe 2P connector from the shift control solenoid valveassemblY. 2. Checkfor continuitybetween the 83 and Ag or A22terminals.

Wiresideo{ femaleterminals

Roprir shon to ground in th. wil. b.tw€on th. B:t t.rmin.l rnd tho ihift conLol aolonoid valvc A SHIFTCONTROLSOLENOID CONNECTOR ----!=--

FI-I1 =r==--

Mea3ur. Shift Control Solonoid v.lvo A Rgistance !t tho solendd Connoc'tor: Measurethe resistancebetween the No. l terminalofth€shiftcon_ trol solenoid connectorand body ground.

alurvEL5f

II Terminalsideol maleterminals

12- 25 O? ls the resistance

Chack to. open in th. rtir. b.t^raan tha 8:l Lrtnlnll tnd tho thift conlrol 3olanoid valva A.

14-65

ElectricalTroubleshooting('96 - g8 Modelsl TroubleshootingFlowchart- Shift ControlSolenoidValveB NOTE:Recordallfreezedatabeforeyou troubleshoot, . OBD ll ScanTool indic.tes Code P0758. . Solt-diagnosisE indicatorlight blinks eight times.

PossibleCause ' Disconnected shift control solenoidvalve I connectol . Short or open in shift control solenoidvalve B wire . Faulty shift control 30lenoid valve B

PCMCONNECTORS

Chockfor a Short to Power: 1. Turnthe ignitionswatchOFF. 2. Disconnect the A (32P)and B (25P)connectors from the PCM. 3. Turnthe ignitionswitch ON (ll). 4. Measurethe voltagebetween the 811 and Ag or A22 terminals,

A t32P)

Wire sideot femaleterminals

Repairshort to powar in the wire botwcen the 811 torminal and the shift control solenoidvalve 8.

Measure Shift Cont.ol Solenoid Valve B Resktance: 1. Turnthe ignitionswitchOFF. 2 , M e a su r e t h e r e s i s t a n c e b e t w e e nt h e B l l a n d A 9 o r A22terminals.

ls the resistance 12- 25 O?

To page 14 67

Checl for loose PiCM connector3. lf nec€ssary, sub3titute a knowngood solenoid v.lve assembly ol PCM and recheck.

Frompage14-66 PCMCONNECTORS

C h e c kS h i f t C o n l r o l S o l € n o i d valve B tor a Short Circuit: 1. Disconnectthe 2P connector trom the shift control solenoid valveassembly. 2. Checkfor continuitybetween the 811 and Ag or A22 terminals,

, 2 ll r .

5

Wire sideof femaleterminals

ls therecontinuity?

Replir shon to ground in th€ wire betwe.n the 811 terminal and the 3hift control solenord valvo B. SHIFTCONTROLSOLENOID CONNECTOR

GRN/WHT Measure Shift Control Solenoid vrlve B Resistanceat the Solenoid Connector: Measurethe resistancebetween the No.2 terminaloftheshiftcon trol solenoid connectorand body ground.

12 25 O? ls the resistance

Terminalsideol maleterminals

Check tor ooen in the wire betw..n thc 81 1 t€tminal ard tha shift control solonoidvrlv6 B.

14-67

ElectricalTroubleshooting('gO- 98 Modelsl TroubleshootingFlowchart- CountershaftSpeedSensor NOTE;Recordallfreezedata beforeyou troubleshoot. . OBOll Scln Tool indicat6 Code

m7z).

. S6lt-dirgnosis E indic.tol light blink! nin. tim6,

Po$iblo Causa ' Loosg or laulty conncction botwocn tho PCM and c.i hrrn1't! ' Disconnoctad countorahott lpo€{ san3or oonnoctot . Short or opon in countorshaft speed lonsor wire . F ulty counte.lhalt spe6d s6nsol

ls the countershaftspoedsensor installedproperly? COUNTERSHAFT SPEEDSENSOR CONNECTOR

lFI,]1 -F=r

9 l

Moa3ureCountoEhaft Sp€ed S6nsor Reaktanc€ at tho Son3or Connoctor 1. Disconnectthe 2P connector trom the countershaftspged sensorconnector, 2. Measurethe resistanceof the countershaftsDeedsensor,

L_l

Terminalsideol maleterminals

ls the resistance400 - 600 0?

PCMCONNECTOR B I25P}

Chock Countersh.ft Spood Scr|3ol for a Shoft Circuit: 1. Disconnectthe B {25P)con nectorfrom the PCM. 2. Check for continuity between the body groundand the 823 t e r m i n a la n d 8 2 2 t e r m i n a l individually. Wiresideof temaleterminals Repai. .hort in th. wiroa b.t$re€n tho 823 lnd 822 torminals .nd lho counteBhaft lpocd aenro..

To page 14-69

14-68 l'

PCMCONNECTOR 8 I25PI MeasureCounteFhaftSp€€dS6nsor Resistance: 1. Connect the countershaft speedsensor2P connector, 2, Measure the resistance between the B23 and 822 tel mtnals.

Wire sideoI femaleterminals ls the resistance400- 600 0?

Repair looso terminal ol opon in the wiro3 between th6 823 and 822 terminal3 and the countershaft soeedaen3or.

Checktor looscrcM connestors. ll nocessary, sub3titutea knowngoodPCMandrecheck.

14-69

ElectricalTroubleshooting('96 - 98 Modelsl TroubleshootingFlowchart- MainshaftSpeedSensor NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanTool indicatesCode m715. . S e l f - d i r g n o s i 3E i n d i c a t o r light indicstesCode 15.

Po$ible Cause . Disconnect€dmainshaft sD€ed Sensor@nnoctot . Short or open in mainshatt sJt€eds6nsoawire . Faulty mainshaftlpeed s6nso.

N O T E :C o d e P 0 7 1 5( 1 5 )o n t h e P C M doesn'talwaysmeanthere'san electrical problemin the mainshaftor countershaft s p e e ds e n s o rc i r c u i t ;c o d e P 0 7 1 5( 1 5 ) may also indicatea mechanicalproblem in the transmission.

Checkthe mainshaftand countershaftspeedsensorinstallation.

Are the mainshaftand countershaft speedsensorinstalledproperly? MAINSHAFTSPEEO SENSORCONNECTOR

MoasureMainshaftSpoedSgnsol Rosistanceat the Sensor Conn€ctor: 1. Disconnectthe 2P connector from the mainshaftspeedsensor connector. 2. Measurethe resistance ot the mainshaftspeedsensor.

Terminalsideof maleterminals

ls the resistance400 600 O?

PCMCONNECTOR B I25PI Check Mainshaft Sp6ed Sensor for a Short Circuil: 1. Disconnect the B {25P)connec' tor lrom the PCM. 2. Checkfor continuitybetween bodygroundand 815terminal and the 814terminalindividu,

ls therecontinuity?

To page 14-71

14-70

Repai. shon in the wi.os bstwoen the 815 and 814 te.minals and the mainshatt .Dood 3ensor.

Wiresideof femaleterminals

Frompage14-70

B I25PI PCMCONNECTOR Mea3uroMain3haftspeed sensor Resistance: 1. Connectthe ma;nshaftsPeed sensol2Pconnector, 2 . [ / l e a s ur e t h e r e s i s t a n c e betweenthe 815 and 814 ter_ minals.

ls the resistance400- 600 O?

Run the Electical TrouH€.hooting Flowcirrt for cod. P0720l9l. Check for loose P1CMconnoctors. ll n€cesslrY,3ubstitute a known' good PCMand racheck.

Wire sideoI femaletermlnals

MAINSHAFTSPEEDSENSOR CONNECTOR

CheckNM wire Continuityl 1. Disconnectthe 2P connector from the mainshaftspeedsen' sor connector. 2. Checkfor continuitybetween the 815terminaland the No. 1 terminal of the mainshaft speedsensorconnector.

Rgpsi. opon in thc wira bctwg€n the 815 torminrl and th6.tain_ shatt soeodlensoa,

CheckNMSGWire ContinuitYr Checkfor continuity between the 814 terminaland the No.2 termi nal of the mainshaftsp€edsensor connector,

Repairopen in the wira botwGon the 814 terminal and lhe main' shsft spo€d 3en3or.

Checkfor loo3o PCMconnoctoB. ll neca$8ry, subditute a knowngood PCMand rgchock.

14-71

ElectricalTroubleshooting('96 - 98 Modelsl TroubleshootingFlowchart- LinearSolenoid NOTE:Recordall freezedata beforevou troubleshoot, OBOll ScanTool indicatesCode P176a. S e l f - d i a g n o s i 3E i n d i c a t o r light indicatesCode 16,

Po$ible Caus6

. DisconnoctodlineaJ solonoid connectot . Short or open in linoar solenoid ' Faultylinoar solonoid

LINEARSOLENOID CONNECTOR

l;r]l

TT

Measure Linear Solenoid Resistance at the SolenoidConnecto.: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 2P connector lrom the linearsolenoidcon nector, 3. Measurethe resistance ofthe linearsolenoid.

YL I I

Terminalsideol maleterminals

ls the resistance approx.5.0O? PCMCONNECTOR B I25PI WHT

RED

CheckLinearSolenoidfor a Shon Circuit: 1. Disconnect the B 125P) connector from the PCM. 2. Checkfor continuitybetween the body ground and the B1 terminaland 82 terminalindavidually. Wiresideof femaleterminals

Repair short in the wires bgtwoen the Bl and 82 terminab and the lineti solsnoid.

Meaaure Linoar Solenoid RGi3tanc€: 1 . C o n n e c t h e l i n e a rs o l e n o i d connector. 2 , M e a su r e t h e r e s i s t a n c e betweenthe 81 and 82 terminals,

ls the resistance approx.5.0O?

To page14-73

14-72

Ropair looso terminal or open in the wires botwe€n the 81 and 82 telminals end the linear solenoid.

Ftom page 14-72

PCMCONNECTOR A I32P} Checkthe G.ound Circuit: Checkfor continuitybetweenthe A9 and A10terminals.

. Rapair opan in the wiro botweon th6 tormin.b Ag rnd A10and G101. . Raprir looc€ iunction connrc{or. . R.p.ir poor ground {G101}.

Wirosideof t6maleterminals

Chock tor 100!6 PCM connectors. ll nocessary,substituto a knowngood PCMand r6ch6ck.

14-73

ElectricalTroubleshooting('96 - 98 Models) TroubleshootingFlowchart- Lock-upControlSystem NOTE:Recordall freezedata beforevou troubleshoot. . OBD ll Sc6n Tool indicatG Code

PossibleCause

m7{0. . Self-diagnosis E indicatorlight indicatesCode40.

Faulty Lock-upcont.ol system

Checktor Another Code: Checkwhether the OBD ll scan tool or the E indicato,light indicates anothercode.

Doesthe OBDll scantool or the E indicatorlight indicate anothercode?

Tast Line Pressure: M e a s u r et h e l i n e p r e s s u r e( s e e page14-119and 14-120).

Perform lhe Troublo3hooiing Flowchart tor the indicated Code(s).Recheckfor cod. P07il0 lilol aftor iroubl€3hooting. NOTE:Do not continuewith this troublesnoonno until the causesof any otherDTCShavebeencorrected.

Repairtho hydreulicaystem a3 necessary{3eepage 14-119).

R e p l a c et h e L o c k - u p C o n t r o l Solenoid Valve Assembly and R6check; 1 . B e p l a c et h e l o c k u p c o n t r o l solenoidvalve Ay'Bassembly (seepage14-105). 2. Turn the ignitaonswitch OFF and reset the PCM by remov ing the BACKUP (7.5A) fuse in the underhood fuse/relay box for morethan 10seconds, 3. Usingthe scantool, checkto be sure that the enginecool a n t t e m p e r a t u r ei s i n 1 7 6 ' F (80'C)and above. 4 . D r i v et h e v e h i c l ea t 5 5 m p h (88 km/h)constantlyfor more than one minute. 5. Recheck for codeP0740(40).

Doesthe OBDll scantool indicatecode P0740{40)?

14-74

The systom k OK at this time.

TroubleshootingFlowchart- Shift ControlSystem NOTE:Recordall freezedata beforevou troubleshoot. . OBD ll ScanTool indicatesCode P0730. . S e l l - d i a g n o s i sE i n d i c a t o r light indicatesCodeill.

PossibleCause Faultyshift control system

Checktor Another Coder C h e c kw h e t h e rt h e O B D l l s c a n t o o l o r t h e E , i n d i c a t o rl i g h t indicateanothercode.

Doesthe oBD ll scantool or tightindi the E indicato'. cateanothercode?

Perlorm ths Troubleshooling Flowch.rt for the indic.t.d Code(sl.Rechecktor code m730 l4'lI atter troubleshooting. until the causesot any NOTE:Do not continuewith this troubleshooting other DTCShave beencorrected.

Test lst, 2nd, 3rd and 4th Clutch Pressure: Measurethe 1st,2nd,3rd and 4th clutchpressure(seepage 14119 t h r u1 4 - 1 2 1 ) .

ls eachclutchpressurewithin the servicelimit?

Ropair the hydrlulic systom !s necessary{see page 14-119 and 11-1211.

ReplaceShift Control Solenoid valve Assembly,Linear Solenoid Assamblyand Rechock: 1 . R e p l a c et h e s h i f t c o n t r o l solenoidvalve A'/Bassembly (seepage14-106). 2 . R e p l a c et h e l i n e a rs o l e n o i d assemblylseepage14 108). 3. Turn the ignition switch OFF and resetthe PCMmemory by removingthe EACKUP (7.5A) tuse in the under hood fuse/ relaybox for more than l0 seconds, 4 . D r i v et h e v e h i c l ea t o v e r 1 2 mph (20 km/h)in 1st,2nd,3rd and 4th gearfor morethan 30 secondsat P1 position. tor codeP0730(41). 5. Recheck

Doesthe OBDll scantool or the Ed indicatortightindi catecodeP0730{41)?

The swt6m is OK et this time.

ElectricalTroubleshooting('96 - 98 Models) TroubleshootingFlowchart- E IndicatorLight DoesNot GomeOn Tha E indicator light does nol come on when the ignition swhch is first turned ON (lll. {lt should come on tol about two s€conds.l

Chockthe SeJvicoCheckConnector: Make sure the specialtool (SCS SeryiceConneclor)is not connected to the servicecheckconnector.

ls the specialtool (SCSService Connector)connectedto the ser vice checkconnector?

Disconnectthe special tool trom thc sarvice check connoctor and rocheck.

Checkth6 E indicator Light: Shift to lD.l oosition.

Checktor loose PCM connecto6. ll nece3sary, sub.titute a knowngood FCM and r.chock.

PCMCONNECTOR A I32PI Checkthe Ground Circuit: '1. Turnthe ignition switchOFF. 2. Disconnecrthe A {32P}connector lrom the PCM. 3. Check for continuity between the A9 terminal and body ground and the A22 terminal and body ground.

Wire sideof femaleterminals Repair op6n in tho wirgs between tho A9 ot M2 torminalsand G101. Rcpairpoor glound {G101).

To page14-77

14-76

Frompage14-76

A I32PI PCMCONNECTOR

Measure Powor Supply Cilcuit Voltage: 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltagebetween t e r m i n a l sA 9 a n d A 1 1 a n d b e t w e e nt e r m i n a l sA 2 2 a n d 424.

Wiresideof {emaleterminals RGpairopon or short in the wire boiween the A11 andlot Ml lor' minals,the PGM-Flm.in rel.Y, end the tu36 box.

Mo.sure D4 IND Voltago: 1. Turn the ignitionswitchOFF. 2. Connectthe A {32P}connector to the PCM. 3. Connecla digital multitester to the B13and Ag or A22 terminals, 4. Turn the ignition switch ON (ll) and makesure that the voltage is availablefor two seconds.

BRN/BLK

BRN/BLK

'96:BLU/RED ,97,'98:GRN/BLK

Chack tor opan in thc wita bctwoon tha 813 larminal and th. gauge ar!.mbly. lf wi.c i! OK, chock for . frulty E indicator light bulb or a l.uhy g.ug. a.!.mbly printod circuit bolrd.

Chock for loose PCM connoctort. Chocktho A/T gGatpolition switch. lI n6ca$sry, substitute a known-good PCMand rochock.

14-77

ElectricalTroubleshooting('96 - 98 Models) TroubleshootingFlowchart- E IndicatorLight On Constantly Th6 E indicstor light is on const.ntly {not blinkingl whenevei the ignition switch is ON lll).

PCMCONNECTOR B (25P)

Measure04 IND Voltage: 1. Turnthe ignitionswitchOFF. 2. Disconnect the B 125P) connector from the PCM. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween t h e 8 1 3 t e r m i n a la n d b o d y ground,

Wire sideof lemaleterminals Repair3hort to pow€. in the wiro between the 813 terminal end thc gauge asiombly.

Meaiure ATP Dil Voltage: 1. Turnthe ignitionswitchOFF. 2. Connectthe I (25P)connector to the PCM. 3. Turn the ignitionswitchON (ll). 4. Shifttoany positionotherthan 5. Measurethe voltagebetween t h e 8 2 4 t e r m i n a la n d b o d y ground.

Checkfor a short to ground on tho wir6. It wire i3 OK, .eplac6 the A/T goar po3ition indbator,

14-7 A l.

!

a

TroubleshootingFlowchart- BrakeSwitch Signal Symptom Shift lever cannol b€ moved f.om B pGition with the brako podrl depr8sed.

CheckBrako Light Operation: Deoressthe brakepedal.

Are the brakelights ON?

Rop.ir faulty braks switch cilcuit lsos soction231.

PCM CONNECTORS MeasureSToP SW Vohag€: 1. Turnthe ignitionswitchOFF. the A l32P)and D 2. Disconnect { l 6 P ) c o n n e c t o r sf r o m t h o PCM. 3. Measurethe voltage belween the D5 and A9 or A22 terminals with the brake Pedal depressod.

Wire sideof lemaleterminals

ls there batteryvoltage?

. Brakeswitch 3ign.l is OK. . Ch6cklor looao PCMoonnoctors. It nocassary,aubctilute a knowngood PCM and r€check. . Inspoctthe brake switch circuit {s6esection 231.

Rap.i. opon in the wira bctn oen tha 05 terminal and tho btrkc lwitdr.

ElectricalTroubleshooting('99 - 00 Models) TroubleshootingFlowchart- Lock-upControlSolenoidValveA \ NOTE: Recordall freezedata before vou troubleshoot. . OBD ll ScanTool indic.t6 Code P1753. . S e l f - d i a g n o s i s@ i n d i c a t o r light blink3 once.

Checklor a Short to Power: L Turnthe ignitionswitchOFF. 2. Disconnect the B (25P)and D ( 1 6 P )c o n n e c t o r sl r o m t h e PCt\4. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltage between the Dl and 820 or 822 terminats.

PossibleCause . Disconnoctedlock-uD control solenoid valve A/B alsembly connector . Short or opon in lock-upconkol solenoid valv6 A wire . Faulty lock-up control solenoid valva A ' Open in VB SOLwire

FCM CONNECTORS

LGl IBRN/BLXI

B (2sPt

Measu.e Lock-up Cont.ol Solenoid V.lvo A R63btanc6: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance between the Dl and 820 or 822terminals.

LGl (BRN/BLKI

MeasureVB SOLVohage: 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltage between the D5 and 820 or 822 terminals.

Check for blown No. 15 17.5Al fu3€ in the undordash fuse/raby box. l{ th€ tusa ii OK, r.pair opon in the wira b€twoen th€ 05 torftinal and thc und€r{ash fuso/r€lay box.

14-80

ll D {16P1

LG2 IBRN/8LK)

To page 1+81

I t25Pt

Checkto.loose tarminalfit in the PCM connecloa3.ll necessary, substilute a known-good PCM and rocheck.

LG2 (BRN/BLK)

Wire sideot femaleterminals

Ropairshort to powcr in the wire bstwoon tho Dl tolminal and the lock-upcor|lrol lolonoid valvo A.

ls the resistance 12- 25 O?

ll D {16P1

B (25Pt

D (16P1

a

B {25P} PCMCONNECTOR

Frompage14-80

Checklor continuity between the 8 2 0 t e r m i n a la n d b o d y g r o u n d , a n d b e t w e e nt h e B 2 2 t e r m i n a l and body ground.

I.G1(BRN/BLKI

Wiresideof l6maleterminals Ropair opon in thc wircs betwe6n the 820 lnd 822 tolminals .nd ground {G10ll, and tepair Pool ground (G10'l).

PCM OONI{ECTORS Check Lock-up Cont.ol Solonoid valve A for a Shon Cilcuit: 1. Disconnectthe 2P connector trom the lock-upcontrol solenoid valve ry'Bassembly. 2. Check for continuity betlv€en th6 D1 and 820 or 822 terminals.

ll o l16P)

B (25p)

IBRN/BLK}

LG2IBRN/BLK}

Wire side ot femaleterminals R6p.ir 3hort to glound in thc wir. b.two.n the Dl torn|in.l ard th. lock-up conttol iol.noid valva A.

LOCK.UPCO TROLSOTINOIDVALVE A/B ASSEMBLYCON]TECTOR I2P}

Maasuro Lock-up Control Sol.noid Vllve A Ro.istance at tho SolanoidConn6ctor: Measure the resistancebetween the No. 2 terminal of the lock-up control solenoidvalve y'y'Bassembly connectorand body ground.

]F]AL r-f-

I

LCA {YEu

(o) Y

I

'12 ls the resistance - 25 O?

R6placotho lock-up control solo_ noid valve A/B.$6mblY.

Terminalsideof maleterminals

Chack for opon in tho wiro botweon the Dl t..minal and tho lock-upcontrol solenoidYalvaA.

14-A1

ElectricalTroubleshooting('99 - 00 Models) TroubleshootingFlowchart- Lock-upControlSolenoidValveB NOTE|Recordallfreezedata beforeyou troubleshoot. ' OBD ll ScanTool indic.tes Code P1758. . S e l f - d i a g n o s i sE i n d i c a t o r light blinks twice.

Chackfor a Short to Power: 1. Turnthe ignitionswitchOFF. 2. Disconnect the I (25P)and D ( 1 6 P )c o n n e c t o r sf r o m t h e PCM. 3. lurn the ignitionswitchON (ll). 4. Measurethe voltage between the D3 and 820 ot 822 tetminals,

PossiblaCause . Oisconnectedlock-uD control solenoid velve A/B assembly connector . Short or open in lock-upcontrol solenoid valv€ B wire . Faulty lock-up control solenoid valve B ' Open in VB SOLwire

B t2sP)

Repairshort to power in the wire between the D3 terminal and the lock-upcontlol solenoidvalve B. MeasureLock-upControl Solenoid Vdlve I R8i3tance: 1. Turnthe ignitionswitchOFF. 2, Measure the resistance between the D3 and 820 or 822terminals.

ls the resistance 12- 25 O?

rcM CONNECTORS

Wiresideol femaleterminals

I {2sPt

B (25P1

Chockfor loose te.minal fit in the PCM connectors. It necessary, substitute a known-good PCM end recheck.

14-82

ll D (16Pt

To page 14-83

MeasureVB SOLVoltago: 1. Turnthe ignitionswitchON lll). 2. Measurethe voltage between the D5 and 820 or 822 terminals.

ls there batteryvoltage?

ll D t15P)

Checkfor blown No. 15 {7.5 Al fus€ in the under-dashluse/reley box. It the fuse is OK, repair open in the wir6 between th6 DStermi nal and the under-dashfuse/reby oox,

D t16Pt

B (25PI PCMCONNECTOR

Frompage14-82

51 6

2 3 l0 1 1 /

Checkfor continuitYbetweenthe 8 2 0 t e r m i n a la n d b o d y g r o u n d , a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground

LG2 (BRN/BLKI

LG1 (BRN/BLK)

o

I

15

o

Wiresideof femaleterminals Repairopen in the wires between the 820 and 822 terminals and ground |G101),and repair Pool ground(G1011.

Check Lock-up Control Solenoid Valve B lor a Short Cilcuit: 1. Disconnectthe 2P connector controlsolefrom the lock_uP noid vaiveA/B assemblY. 2. Checkfor continuitybetween the D3 and 820 or 822 termi nals.

B (25P1

Rep.ir short to ground in lho wire between lhe D3 terminal and the lock-up contlol solenoid valve B.

-

llo t16Pt

Wire sideof femaleterminals

LOCK.UPCONTROLSOLENOIDVALVE (2PI A/B ASSEMBLYCONNECTOR

MeasureLock-upControl Sol6' noid Valve B Resistanceat the Sol6noidConn€ctor: Measurethe resistancebetween the No. 1 terminalof the lockuP control solenoidvalve A'lBassem_ bly connectorand body ground-

t;T J llt z ! ] 4

LC B (GRN/BLKII

t

(o)

YI

12- 25 0? ls the resistance

Repl.ce the lock-up control 3olc noid valve A/B a$emblY.

Terminalsideof maletermrnals

Ch6ck {or open in the wire between the D3 terminal dnd ihe lock-upcontrol sol€noid valve B.

14-83

ElectricalTroubleshooting('gg - 00 Models) TroubleshootingFlowchart- A/T GearpositionSwitch (Short) NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanTool indicrtB Code P1?05. . S o l t - d i a g n o 3 i 3E i n d i c a t o r light blink. tive times.

Observothe A/T Gear Position Indicetori 1. Turnthe ignitionswitchON fit). 2. Observethe lVT gear position indicator,and shift each posi, !on separately.

Doesany indicatorstayon when the shiftleveris not in that position?

Po$ible Cause ' Short in A/T go.r position swhch wire . FaultyA/T goar position switch NOTE:Code P1705(5) is causedwhen t h e P C M r e c e i v e dt w o g e a r p o s i t i o n inputsat the sametime.

The sFtom is OK at thi3 time. Check the wi.e harnessfor damaga.

Do all gearpositionindicators go out? PCM CONNECTORS

B {25P1

MoasureATP R Voltage: 1. Shiftto all positionsotherthan

E.

LGl (BRN/BLK)

2. Measurethe voltagebetween the DGand 82Oo( 822 terfiinats.

ls there batteryvoltage?

To page14-85

14-84

llD (16P1

LG2 (BRN/BLKI

Wiresideof femaleterminals

Check tor short in the wire batwoen tha DB terminal and the A/T go.r porhion switch or A/T g6ar po3ition indicator, and chock for opon in the wires between the B20 and B22 t€rmin.ls and body ground (G10 . tf wir€c rro OK, chsck fo. loo3e telftinal fit in the FCM connectors.ll noceisary, substiiute e knowngood FCM and r€check.

Frompage14-84

B {25P)

Measule ATP NP Voltage: 1. Shiftto all positionsotherthan

31115 2 l6 8 1 1 2 tV-st7 / \ 1 67 I 9 1 0 t 1 2 10n\/

pl orE.

2. Measurethe voltage between the D13and 820 or 822terminals.

PCMCONNECTORS o t16Pl

o zlzz /l/1,/ L---{O--l

I LGl (BRN/BLK)

113 \a TI

t9

ATP NP (LT GRN)

\=/

LG2 {BRN/BLKI

ls there bafteryvoltage?

,/t\_

Check for ahott in lhe wire between ths D13 torminal and tho A/T go.r PGition iwitci, and in rho E .nd E polition signal wires Mwgon tho A/T gsar Posi' tion indicrtor and th. A/T gGar po3ition 3witch. ll wiJ.! .ro OK, check lor loose torminal fit in the PCM connoctor3.lf nocet3.rY, substitute . known-good PCM and r6check.

Wirc sideo{ femaletermlnals

g t25P)

MeasureATPD4voh.g€: otherthan 1. Shifttoallpositions

E

9 10

2. Measurethe voltage between the Dg and 820 or 822 terminals.

8l 3 115 111/ t6l/ 17

) W

20 (BRN/8IJ() LGl

D t16P)

Wl/l

+

5

l2

l sl t l a

1 12

'3111/ll ATP D4 IYEL)

LG2(BBN/BLKI

-<_

ls there approx. 5 V?

Ch.ck lor 3hort in ths wilo betweon tho lxl termin.l and tho A/T ge.r pGhion switch. It wites are OK. chock fo. looao t€rminal fit in the PCM conn.ctoB. lf noc_ .*sary, sulFtitute a known-good PCM.nd rechock.

Moa3ureATP D3 Vohsge: 1. Shiftto all positionsotherthan

tr.

2. Measurethe voltage between the D8 and 820 or 822 terminals.

ls there batteryvoltage?

LGl IBRN/BLK) LG2 (BRN/BLK}

Check tor 3hort in the wits betweon the D8 torminal and the A/T goer position switch or A/T gcar position indicltor. It wires are OK, check for loo3€ torminal fit in tho FCM conn€ctoG. lf nec_ a3$ry, 3ubatitute e known'good PCM and r.check.

To page l4'86

14-85

ElectricalTroubleshooting('gg - 00 Models) TroubleshootingFlowchart- A/T GearpositionSwitch (Short)(cont,dl FCM CONNECTORS

B {25P) MeasuleATP 2 Vohage: 1. Shiftto all positionsotherthan l 2. Measurethe voltage between the D14and 820 or 822terminals,

1 2 8 [Ll 9 1 0 1 / 1 1 3/ 151/)11 ,/ 20 LGl (BRN/BLK}

D l16Pl 1

2 3 5 7 8 9 t 0 1 12 ATP 2 {BLUI

Wiresideof femaleterminals

ls there batteryvoltage?

Ch6ckfor loose terminal fit in the PCM connoctors. lf necessary, substitute a known-good PCM and recheck.

14-86

Check for short in the wire between the D14 terminal and the A/T gear position switch or A/T ge.r position indicator. It wires aaeOK, checkloa loose terminal th in ths PCMconnectors.ll necessary,substitute a knowngood FCM and recheck.

TroubleshootingFlowchart- A/T GearPositionSwitch (Open) NOTE:Recordallfreezedata beforeyou troubleshoot. . OBOll ScanTool indicatd Codc P1706. ' S s l f - d i a g n o s i sE i n d i c a t o r light blink3 six tim6.

Po$ible Cause . DisconnectodA/T goar position switch conngdor . Open in A/T gear position switch wire . Fautty Aft gear poshion switch

Test the Ay'Tgear position switch (seesection23).

PCMCONNECTORS

B(25Pt

MoasureATP R Volt.ge: '1. Turnthe ignitionswitchON ('l). 2. Shift to E position. 3. Measurethe voltage between the D6 and 820 ot 822 termi' nals.

IARN/BLK)

llDtl6Pl

LG2IBRN/BLKI

Wire sideof lemaleterminals

Repoiropon in the wire bitween the D6 torminll and the A/T go.r position switch.

D (16P1 MeasuroATP NP Volt ge: 1. Shiftto E or E position. 2. Measlre the voltage between the D13and 820 or 822 terminals,

I

2 { 't0 1 1 /

LG1 {BBN/BLKI

6 t5l/

,|

2 3 1 8 9

5 12

ATP NP (LTGRNI

Ropairop€n in thc wire betwoon the D13terminrl and the A/T ge.r position switch.

(cont'd) Io page14-88

ElectricalTroubleshooting('gg - 00 Models) TroubleshootingFlowchart- A/T GearpositionSwitch Open{cont,d) Frompage14-87 PCMCONNECTORS

B l2sPl

Moalure ATP 04 Vohago: 1. Shiftto pll position. 2. Measurethe voltage between the Dg and 820 or 822 termi nals.

D {16P)

1 2 415 6 I 9 10 11)./ t5l/ 11

zo ztzzll//l

fj r-cz]_c;l tgaNlelxr

1 8 9

LGl {BRN/BI.KI

12

ATP D4 (YEL}

Wire sideof lemaleterminals

Repair opon in the wire betweon the lrg terminal and the A/T goat poshion switch.

MeasureATP D3 Vohage: 1. Shiftto l& position. 2. Measurethe voltagebetween the D8 and 820 or 822 terminats.

1

hsr),41

I.G1IERN/BLKI LG2IBRN/BLKI

Reprir opcn in the wirc b?twoen the D8 terminrl and tho A/T goar Dositiontwitch.

B (25P1 Mersurc ATP 2 Voltage: 1. Shiftto E position. 2. Measurethe voltage between the Dl4 and 820 or 822 terminals,

I

2

9 10 11)/ LGl IBRN/BLKI

Reprir opon in the wire betweon tho Dl4 te.minal rnd the A/T go.r position switch.

Ch6cktor loose terminal tit in the PCM connectors. ll necossery, subslitute . known-good pCM and recheck.

1 4- 88

D {16P} 5l l6l/ 8

Itsln

7 8 9

12

ATP 2 IBLUI

TroubleshootingFlowchart- Shift ControlSolenoidValveA NOTE:RecordallJreezedata beforeyou troubleshoot. . OBD ll ScanTool indic.ts6 Code Pot53. . Solt-diagno.isE indicrtot light blinks seven time6.

Chock tor a Short to Power: 1. Turnthe ignitionswitchOFF. the g (25P)and D 2. Disconnect ( 1 6 P )c o n n e c l o r sf r o m t h e PCM, 3. Turn the ignirionswitchON (ll) ,1. Measurethe voltage between the D7 and 820 or 822 termi nals,

PossibleCru3. ' Disconnectod 3hift control solonoid valva A/B a33emblY connactot . Short or opon in shift cont.ol solonoidvalvo A wits . Faulty shift control .olenoid . op.n in vB SOLwi.e

PCM CONNECTOBS

ll D {16P)

I t25Pt

LG1{BRN/BLK} LG2IBRN/BLKI Wire side of female terminals Rcpairshort to powet in the wile b€t^reen tho D7 termin.l .nd the shift control aolonoid valve A.

Mee3ur. Shift Control Solonoid Valve A Roaisttnce: 1. Turnthe ignitionswitchOFF. 2. Measure the resistance between the D7 and 820 or 822 terminals. LGl IBRN/BI-K) ls the resistance12 - 25 O?

LG2IBBN/BLK)

To page 14-90

BrzsPt

o trQil

Me.3uro vB SOLVoh.ge: 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltage between the D5 and 820 or 822 terminals.

ls there bafteryvoltage?

Checkfor loose t6tminalfit in th€ PCM connoctors. It necessary, substitute e known-good PCM and rechock.

Check tor blown No. 15 17.5A) fuse in tho underdaah fula/rol.Y box. ll the tusr is OK, .epair oPen in th. wiio betwe.n the D5 ter' min.l and th. underdssh tuso/ relav box.

(cont'd)

14-89

ElectricalTroubleshooting('gg - 00 Models) TroubleshootingFlowchart- Shift ControlSolenoidValveA (cont,O) Frompage14-89 PCMCONNECTOR B {25P} Checklor continuitybetweenthe 820 terminal and body ground, a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground. LGl (BRN/BLKI Repair open in ihe wires between th€ 820 and 822 termin a l s e n d g r o u n d { G 1 0 l l .a n d repa,rpoor ground{G101}. Wiresideof femaleterminals Check Shitt Control Solenoid Valve B for a Short Circuit: 1. Disconnectthe 2P connector from the shiltcontrolsolenoid valve A,/Bassembly. 2. Checklor continuitybetween the D7 and 820 or 822 termi, nals.

rcM CONNECTORS

Bt25Pt

LGl {BBN/BLKI ls therecontinuity?

R€pairshort to ground in the wiie bartwe€nthe D7 te.minal and the shift control solonoidvalveA.

Meesuro Shift Control Solenoid Valve A RGistance at the Solenoid Connector: Measurethe resistancebetween t h e N o . 1 t e r m i n a lo f t h e s h i f t c o n t r oI s o l e n o i d v a l v e A / B a s s e m b t yc o n n e c t o ra n d b o d y grounct,

ls the resistance 12 25 O?

Check for open in the wire between the D7 termindl and the shift control 3olonoidvalve A.

14-90

llD t16Pt

LG2 (BRN/BLKI

Wiresideof femaleterminals

SHIFTCONTROLSO|'INOID VALVE A/B ASSEMBLYCONNECTOR I2PI

SHA {BLU/YELI

Repl.cetho shift control solenoid valve A/B rss€mblv.

TroubleshootingFlowchart- Shift ControtSolenoidValveB NOTE:Recordall freezedatabeforeyou troubleshoot. . OBD ll ScanTool indic.l6 Code P0758. ' Self-diagnosbEl indicatorlight blinkseighl tim6.

Checktor a Shortto Power: 1. Turnthe ignitionswitchOFF the B (25P)and D 2. Disconnect ( 1 6 P )c o n n e c t o r fsr o m t h e PCM. 3. Turnthe ignitionswitchON (lli. 4. Measurethe voltage between the D2 and 820 or 822 termi nals,

PossiblgCause . Disconnectgd ihilt control solenoidvalve A/B conneciot r Short or oDen in shift conlrol 3olgnoidvrlve B wito . Faulty 3hift control solenoid velve B . Op€n in VB SOLwire

B (25Pt

rcM CONNECTORS

-

I lD {16P)

LGl IBRN/BLKI LG2IBRN/BLK)

Wiresideof {emaleterminals Repaft3hon to Powor in the wir€ b€tirvoonthe D2 termin.l and the 3hift control solenoid valve B.

M€asure Shift Control Solenoid Valve B R6isttnce: 1. Turnthe ignitionswitchOFF 2. Measure the resistance between the D2 and 820 or 822 terminals.

LGi (BRi|/BLKI LG2IBRN/8LK)

12- 25 O? ls the resistance

To page14-92

B {25P1

D (t6Pl

Me.sure VB SOLVohage: 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltage between the D5 and 820 or 822 termi' nars.

ls there battery voltage?

Checkfor loo3eterminal fit in the PCM connectols. lf necossarY, substitute a known_goodPCM and rocheck,

Checklol blown No 15 {7.5 Al fuse in the under-d.sh luae/rolav box. ll the fuse is OK, repair open in ihe wire between tho D5 terminal and the under'dashfus€/ relav box.

(cont'd)

14-91

ElectricalTroubleshoot:ng('gg - 00 Models) TroubleshootingFlowchart- Shift ControlSolenoidValveB (cont,dl Frompage'14-91

PCMCONNECTOR A {25PI Checkfor continuity between the 8 2 0 t e r m i n a la n d b o d y g r o u n d , a n d b e t w e e nt h e 8 2 2 t e r m i n a l and body ground. LGl (BRN/BLK) Ropair opan in the wirgs b.twocn the 820 rnd 822 te.mi, n.ls and ground lG10t), and ..p.ir poor ground lG10t). Wiresid€ot femaleterminals Check Shift Control Sol.noid Vrlve B tor a Short Ci.cuit: 1. Disconnectthe 2P connector from the shift control solenoid valve A/B assembly. 2. Checkfor continuitybetween the D2 and 820 or 822 terminals.

FCM CONNECTORS SH B (GRN/WHTI

B(25P1

IBRN/BLKI Repair3hort to ground in tho wire botw.en tha 02 torminsl and the shift com.ol rolonoid v.lv. B.

Meaiuro Shift Cont.ol Solonoid Vrlve B Raailtrnca at the Solonoid Conn€c,toa: Messure the r€sistancebelween t h e N o . 2 t e r m i n a lo f t h e 6 h i f t control solenoid valve A/B a s s e m b l yc o n n e c t o ra n d b o d y ground.

-

llDt

LG2IBRN/BLK) Wire sideof temaleterminals

SHIFT@NTROL SOENOID VALVE (2PI A/A ASSEMBLYCONNECTOR

. - _ 1 ) 2 -.T-

I sne tcanlwxrt

(o YI

ls the resistance 12- 25 O?

Chack for open in the wi.e betwoon th€ D2 termin.l and the 3hift control lolanoid valv6 8.

14-92

R.pl.co th. 3hift control lolenoid v!lv. A/8.lsombly.

Terminal sideoI maleterminals

TroubleshootingFlowchart- CountershaftSpeedSensor NOTE: Recordall freezedata beforeyou troubleshoot . OBD ll ScanTool indicat6 Code PO720. . Self-diagnosisE indicatorlight blinks nin6times.

C h e c kt h e c o u n t e r s h a f st P e e d sensorinstallation,and check it lor damage.

ls the countershaftspeedsensor installedproperly,and not damaged?

Po$iblo Cause . Loos€ or fsulty conneclion between the PCM and vehicle hainoss ' Disconnectod countersh.ft spoed senaof connoctor . Short or opgn in counteBhaft 3Deedaensorwire . Faulty counloEhaft 3p€ed sen' soa

Reinstallor replaceand rechock.

COUNTERSHAFfSPEED SENSORCONNESTOR Measurg Counlershatt SPeed Sgn3ol R6istance at tho Son3ol Connector: 1. Disconnectthe 2P connector from the countershaftsPeed sensor. 2, MeasurocountershaftsPeed sensorresistancaat the sensor connector.

TerminalsideoI maleterminals

ls the resistance400- 600 O?

D I16PI FCM CONNECTOR Chcck CounteEh.tt SPeed Sen' sor lor a Short Circuit: 1 . D i s c o n n e ct th e D { 1 6 P )c o n nectortrom the PCM. 2. Checklor continuitybetween body groundand the D10ter_ minal and D16 terminal individ!ally.

NCIBLUI

Wire sideof temaleterminals R6oai. short in tl|€ wi.6a bstwa€n the D10 and D16 t.rminali end tho countdthatt rP€od senaor.

rconl c To page 14 94

1+93

ElectricalTroubleshooting('gg - 00 Modelsl TroubleshootingFlowchart- CountershaftSpeedSensor(cont,d) Frompage14-93

Measure CounteJahaft Speed SensorCircuittor an Open: 1. Connect the countershalt speedsensorconnector, 2. Measure the resistance betweenthe Dl0 and D16ter mtnats.

PCMCONNECTOR D I16PI

Wiresideof femaleterminals ls the resistance400 - 600 O?

Checkfor loose t.rminal frt in the PCM connectors. It necalsary, 3ubstitute a known-good PCM and recheck.

14-94

Roptir loo.€ t6.minal or opan in th6 wir€! betwo€n lho D10 lnd D16 t.rmina13and the count.rshatt apaadaaNor.

TroubleshootingFlowchart- MainshaftSpeedSensor NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanTool indicatesCode m715. . Sell-diagno3isE indicator indicatesCode 15.

PossibleCausg . Diaconn€ctedmainshaft spoed sen3orconnector 'Short or open in mainshaft sDeed sen3or wile . Faulty main3haltspeedsensor

NOTE:Code P0715(15)on the PCMdoesn't problemin alwaysmean there'san electrrcal the mainshaftor countershaftspeed sensor circuit;code P0715{15) may also indicatea problemin the transmissjonAny mechanical p r o b l e mc a u s i n gi r r e g u l a rc o u n t e r s h a ft to mainshalt speed differencecan cause thls code.

Checkthe mainshaftand countershatt speedsensorsinstallation, and checkthem for damage.

Are the mainshaftand countershaft speedsensorinstalledproperly, and not damaged?

Rsinalallor replaceand rocheck.

MAINSI{AFTSPEED SENSORCONNECTOR

Mea3u.e Meinshalt SPeod Sensor Residance al the Sen3or Connector: 1. Disconnectthe 2P connector f r o m t h e m a i n s h a f ts P e e d sensor. 2, Nreasuremainshaftspeedsen_ sor resistanceat the sensor connector.

l.TT ll ,.

(- io- l l t

l

TerminalsideoI maleterminals ls the resistance400- 600 O?

D (16P) PCMCONNECTOR Check Mainshaft Sp.ed Sen3o. for a Short Circult: 1. Disconnectthe D (16P)connectortrom the PCM. 2. Checklor continuitybetween body groundand the D11ter' m i n a la n d D 1 2t e r m i n a il n d i vidually.

NMSG (WHT)

Wiresideof femaleterminals

ls therecontinuity?

Bopair 3hort in the wiros b€twe€n the 011 and D12 termin.ls rnd th€ main3hett sp€€d aensoa.

(cont'd) To page 14 96

14-95

ElectricalTroubleshooting('gg - 00 Models) TroubleshootingFlowchart- MainshaftSpeedSensor(cont,dl Frompagel4-95

PCMCONNECTOR D {16PI Measure Mainshatt Speed SensorResistance: 1. Connectthe mainshaftspeed sensorconnector. 2. Measurethe resistancebetween the Dl1 and D12terminats.

/)

2 3

NMSG {WHTI

6 18

rghrll [e]

(

NM IREDI

I

Wire sideof femaleterminals

ls the resistance400- 600 0?

Run the Electricel Troubl€shooting Flowchart lor cod6 m?m l9). Ch€ck lor loo.o te.minol fit in th6 PCM connectors. lf necossary, substitute r known-good PCM end .echeck.

CheckNM Wire Continuity: 1. Disconnectthe 2P connector from the mainshaftspeedsensor. 2. Checkfor continuitybetween the D11terminaland the No.2 terminal ot the mainshaft speedsensorconnector,

23

1

5

6 7 8

t1v

NM (REDI

o

MAINSHAFTSPEED SENSOROONNECTOR

Ropair opon in the wiro lratwoen tho Dll tsrminal and tha main3hatt spe€d sensor.

CheckNMSG Wire Continuity: Checkfor continuity betweenthe Dl2 terminaland the No. 1 terminal of the mainshaftspoedsen-

RED

Wire sideof femaleterminals

6 1 78 t1v

9

ll

12

Io

NMSG IWHTI

WHT 1

Repai. open in the wire betwoen the D12 terminal and the meinshaft 3peodsansor.

CheckIor loose terminal fit in the PCM connectors. lf necesaary. substitute a known-good PCM and recheck.

14-96

TroubleshootingFlowchart- LinearSolenoid NOTE: Recordall freezedata before you troubleshoot. . OBD ll Scln Tool indic.t.t Codo P1768. . Self-diagnosisE indicltol indicat6 Cods 16.

Moasur. VB SOLVoltago: 1. Turnthe ignitionswitchOFF. the B {25P)and D 2. Disconnect ( 1 6 P )c o n n e c t o r sf r o m t h e PCM. 3. Turn the ignitionswitchON (lll. 4. Measurethe voltage between the D5 and 820 or 822 terminals.

Poitibl. Cau3. . DisconnactedlinoaJ tolanoid connaclol . Shorl or opon in linolr solonoid . Flulty linoar 3olenoid . ODonin VB SOLwit. . ODenin PG lino

PCftI @NNECTORS

D {16P1

B t25Pl

Wire side ol female terminals Ropair opan or thort in dla wi.9 hrw..n th. D5 t.rminrl .nd th. und.r-d.rh fu ta/r.l.y box.

PCM OONNECTORB I25PI Ch.ck th. Ground Circuit: 1. Turnthe ignitionswitchOFF. 2. Checklor continuity betwoen the terminals82 and 822 and b e t w e e nt e r m i n a l s8 1 0 a n d 820.

Rapair opal| in tfr wi|! batlwao th. tcrrnln.l. 82, B10, B:20..nd BZI .id Gt01. R.p.ir poor ground tG10rl.

Linea. Solenoid M.!sure Rcai3tancc rt tha Solanoid Conn6ctor: the linearsolenoid 1. Disconnect connectol, 2. Measurethe resistanceof the linearsolenoid.

LGT(BNN/BLKI

LG2 {BBN/BLKI

Wir6 side of Iemale terminals

LINEAFSOITNOIDOONNECTOR

Flr-11 =T=T o l Y

I

L_l

ls the resistanceapprox. 5 O?

Terminalsideof mal€termanals

To page 14-98

(cont'd)

1+97

ElectricalTroubleshooting('99 - 00 Modelsl TroubleshootingFlowchart- LinearSolenoid(cont'dl Frompage14 97

Check Linea. Solenoid tor a Short Ci.cuit: Checkfor continuitybetweenthe body groundand the 88 terminal and B17terminalindividually.

PCMCONNECTOR A {25PI

Repairshon in the wir6 between th€ 88 and 817 terminals and the lin€arsolenoid, Wire sideof femaleterminals

Measure Linear Solenoid Resistance: 1 . C o n n e c t h e l i n e a rs o l e n o i d connector, 2 . M e a su r e t h e r e s i s t a n c e betweenthe Bg and 817 ter mtnals,

ls the resistance approx.5.0O?

Checkfor loose terminal tit in the PCM conn€ctors, lf necessary, substitut6 a known-good PCM and recheck.

14-9 8

LSAM(WHTI

Repair loose te.minal or open in the wire botwoenthe 88 .nd Bl7 t.rmin.b end the linoar3olenoid.

TroubleshootingFlowchart- Lock-upControlSystem NOTE:Recordall freezedata beforevou troubleshoot. OBD ll ScanTool indicatesCode m14/J. S€lf-diagnosis.D4lindicalorlight indicatesCode40.

Possibl€Cause Faulty Lock-upcontrol sy3tem

Checkfor Another Code: C h e c kw h e t h e rt h e O B D l l s c a n t o o l o r t h e : E i n d i c a t o rl i g h t indicatesanothercode,

ooesthe OBDll scantool or rhe E indicatorlight indicate anothercode?

Test Line Pressure: M e a s u r et h e l i n e p r e s s u r e( s e e p a g e1 4 1 1 9a n d 1 4 - 1 2 0 ) .

ls the lanepressurewithinthe servicelimit?

P e r f o r mt h e T r o u b l e s h o o t i n g Flowchart tor the indicated Codels|. Rocheckto. code P0740 (40).fter troublBhooting. until the causesof any NOTE:Do not continuewith this troubleshooting other DTCShave beencorrected.

Repairthe hydrrulic sy3tem as n6c6ssary(seepage 14-1191.

R e p l a c et h e L o c k - u p C o n t r o l Solenoid Valve Assembly and Recheck: 1 . R e p l a c et h e l o c k - u pc o n t r o l solenoidvalve A/B assembly (seepage14-105). 2. Turn the ignition switch OFF and reset the PCM by remov ing the EACKUP (7.5A) fuse in the underhood {use/relay box for morethan 10seconds. 3. Usingthe scantool, checkto be sure that the enginecoola n t t e m p e r a t u r ei s i n 1 7 6 ' F (80'C)and above. 4 . D r i v et h e v e h i c l ea t 5 5 m p h (88 km/h)constantlyfor more than one minute, for codeP0740{40). 5. Recheck

Doesthe OBDll scantool indicatecodeP0740(40)?

The svstem i3 OK .t this time.

14-99

ElectricalTroubleshooting('99 - 00 Modelsl TroubleshootingFlowchart- Shift ControlSystem NOTE:Recordallfreezedata beforeyou troubleshoot. . OBD ll ScanTool indicrtd Code

m730.

. S e l f - d i r g n o s i sE i n d i c a t o r light indicst€. Codo41.

Po33ibl.Crus6 Frulty 3hift control ryrtom

Checkfor Anoth€. Code: C h e c kw h e t h e rt h e O B D l l s c a n t o o l o r t h e E i n d i c a t o rl i g h t indicateanothercode.

DoestheOBDllscantool or the E indicatorlight indicate anothercode?

Prrf orm tho Troublc!hooting Flowch.rt for th. indicrt.d Cod.l3l. R.ch.ck tor cod. m730 141|.tt r troubldhootlng. NOTE:Do not continuewith this lroubleshootinguntil the causesot any other OTCShave beon corrected.

Test 13t, 2nd, 3rd .nd 4th Clutch Prglture: Measurethe 1st,2nd,3rdand 4th clutchpressure(seepage 14-119 t h r u1 4 1 2 1 ) .

ls each clutch pressurewithin the servicelimit?

R.prir tho hydrlulic ayrtam aa n.c.3t..y lr.o p!9. lil-119 rnd 1+1211.

Roplace Shift Control Solenoid Valve Asembly. Linoar Sol.noid Assembly.nd Recheck: 1 . R e p l a c et h e s h i f t c o n t r o l solenoidvalve A/B assembly (seepage14-106). 2 . R e p l a c et h e l i n e a r s o l e n o i d assembly{seepage14-108}. 3. Turn the ignitionswitch OFF and resetthe PCMmemory by removingthe BACKUP (7.5A) fuse in the under-hoodfuse/ relaybox for more than 10 seconds, 4 . D r i v et h e v e h i c l ea t o v e r 1 2 mph (20 kn/h) in 1st,2nd, 3rd and 4th gear lo. more than 30 secondsat lPll position. 5. Recheck for codeP0730(41).

DoestheOBDIlscantool or the E ;ndicatorlight indicatecodeP0730(41)?

14-100

Th. sFtcm b OK .t this time.

TroubleshootingFlowchart- El IndicatorLight On Constantly The Dll indicator lighi is on constantly {not blinking)whenever the ignition switch is ON (lll.

A I32P) PCMCONNECTOR MoasureD4 IND Voltage: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e A { 3 2 P }c o n nectorfrom the PCM. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween t h e A 1 4t e r m i n a a l ndbody ground.

Repsirshort to power in the wire between the A14 torminal and the gauge assembly.

MeasureATP D4 Voltagel 1. Turnthe ignitionswitchOFF. 2. Connectthe A (32P)connec tor to the PCM. 3. Turnthe ignitionswitchON (ll). 4 . S h i t t t o a n y p o s i t i o no t h e r than [ql. 5. Measurethe voltagebetween t h e D 9 t e r m i n a la n d b o d y ground.

ls thereapprox.5 V?

Test the A/T gear position switch ( s e es e c t i o n 2 3 ) .

CheckIor a short to ground in the wire betweon the D9 terminal and A/T gear position switch. It wire is OK, substitute a knowngood PCMand recheck.

Wiresideof lemaleterrnanals

D {16P) PCMCONNECTOR 2 6 1 t{

e11(

5 12

Iro

ATPD' (YELI

Wire sideof femaleterminals

ElectricalTroubleshooting('99 - 00 Models) TroubleshootingFlowchart- E IndicatorLight DoesNot ComeOn The Pll indicator light does not come on when the ignition switch is fi.st turned ON (ll). llt should come on for about two seconda.l

Check the Service Check Connector: Makesure the specialtool (SCS ServiceConnector)is not connected to the servicecheckconnector? ls the specialtool{SCSService Connector) is not connected to the seNicecheckconnector.

Disconnectthe special tool from the service check connector and r6check.

Checkthe Dll lndicator Lighti Shiftto d position. Doesthe @ indicatorlight comeon?

Checkfor looseterminal fit in the PCM connecto13.It necessary. sub3titute a known-good PCM and recheck. FCM CONNECTOR B (25P}

Checkthe Ground Circuit: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e B ( 2 5 P )c o n nectorfrom the PCM. 3. Checkfor continuitybetween t h e 8 2 0 t e r m i n a la n d b o d y ground,and betweenthe 822 terminaland body ground.

i 2 9 10

t 5

q

6

t7

LGl {8RN/ALKI

LG2 {BRN/8LK}

o) (o Repair open in the wires between the B20 rnd 822 termi, nd n a l sa n d g r o u n d( G 1 0 1 ) a rep.ir poor ground (G1011.

Wire sideol temaleterminals

Measure Power Supply Circuit Voltage: 1. Turnthe ignitionswitchON {ll}. 2. Measurethe voltagebetween terminals B1 and 822 and b e t w e e nt e r m i n a l s B g a n d 820. LGl IBNN/BLK} Repair open or short in the wi.o between th6 81 and/or 89 terminals and the PGM-FImain relav, and between th€ PGM-FImain r€ley rnd the under-hoodtus€/ relay box. To page14''103

14-102

LG2 {BRN/BLK)

Frompage14-102

PCMCONNECTORS

Measu.e D4 IND Voltago: 1. Turnthe ignitionswitchOFF. 2. Connectthe B (2SPiconnector to the PCM. 3. Connecta digital multimeter to the A14 and 820 or 822 ter4. Turnthe ignitionswitchON (ll), and makesurethat voltageis for two seconds. available

Wire sideol femaleterminals Chock for ooon in tho wite between the A't4 tsrminal .nd the gauge.3s.mbly. ll wite i3 OK, chock to. a t.ulty indicator light bulb or. feulty gaugc e336mblyp.inted circuit board.

CheckD4 IND lor a Short Citcuit: Checklor continuity betweenthe A14terminaland bodyground.

ls therecontinuity?

Rop.ir short in thc wirg b€twoen th. Al4 tormin.l .nd tho gaugo a$ombly. ll wiro is OK. chock tho gsugo a3rambly.

Checkfo. loose terminal tit in thc PCM connectoB. Chock the A/T gear position switch. It ncce3sary, substitute a known-good PCMand rechock.

14-103

('99- 00 Modelsl ElectricalTroubleshooting TroubleshootingFlowchart- BrakeSwitch Signal Shift lever cannot be moved trom E position with tho b.ake pedal depressod.

CheckBrake Light Operation: Depressthe brakepedal.

Are the brakellghtsON?

Repairt ulty brake switch circuit {sees€ction23}.

PCMCONNECTORS B {25P)

Mea3ureSTOPSW Vohage: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (32P)and B { 2 5 P }c o n n e c t o r sf r o m t h e PCM, 3. Measurethe voltagebetween the A32 and 820 or 822termin a l s w i t h t h e b r a k ep e d a l depressed.

Wire side of female terminals

ls therebatteryvoltage?

. Brak€switch sign.l is OK. . Check for loose terminal fil in lhe PCM conn€ctors. lf necessary. substitute a known-good PICMand recheck. . InsDectthe breke 3witch circuit lsee section231.

14-104

Repairopen in the wire betwsen the A32 terminal rnd tho brrk6 switch.

Lock-upGontrol SolenoidValve A/B Assembly Test

Replacement

'1, Disconnectthe 2P connectorfrom the tocK-upcontrol solenoidvalve1y'8assembly.

NOTE:Lock-upcontrolsolenoidvalvesA and I must bs removed/replacedas an assembly.

TERMINAL SIOEOF MALETERMINALS

1.

R e m o v et h e m o u n t i n gb o l t s a n d l o c k - u pc o n t r o l solenoidvalveAy'Bassemblv.

6 r 1 . 0m m 1 2 N . m( 1 . 2k g f . m , 8 . 7l b l . f t l

/:'-

Cleanthe mountingsurface and fluid psssages.

LOCK.UP CONTROL VALVEA/B SOLENOID ASSEMBLY Measurethe resistancebetween the No. 2 terminal (solenoidvalve A) of the lock-upcontrol solenoid valveconnectorand body ground,and betweenthe No. 1 terminal(solenoidvalveBl and body ground. STANDARD:12 - 25 O

Cleanthe mounting surfaceand fluid passagesof th6 lock-upcontrol solenoid valve assembly,and instsll a new lock-upcontrol sol€noid valve Ay'Bwith a new filtsr/gask€t. Checkthe connector for rust, dirt or oil, and raconnect it securely.

Replacethe lock-upcontrol solenoidvalve assembly if the resistanceis out of specification. lf the resistanceis within the standard,connectthe No. 1 terminalof the lock-upcontrolsolenoidvalve connectorto the battery positiveterminal. A clicking soundshouldbe heard.Connsctthe No. 2 terminalto the batterypositiveterminal.A clickingsound should be heard. Replacethe lock-upcontrol solenoid valve assemblyif no clickingsoundis heard.

1+105

Shift Control SolenoidValve A/B Assembly Test

Replacement

1.

NOTE: Shift control solenoid valves A and B must be removed/replaced as an assembly.

Disconnectthe 2P connectorfrom the shift control solenoidvalveA,/Bassemblv.

1.

Removethe mountingboltsand shiftcontrolsolenoid valveA,/Bassembly.

5xL0mm 12 N.m (1.2kgf.m,8.7lbf.ft)

SHIFTCONTROL VALVEA/B SOLENOID ASSEMBLY

N4easure the resistancebetweenthe No. 1 terminal (solenoidvalveA) of the shift controlsolenoidvalve connectorand body ground,and betweenthe No. 2 terminal(solenoidvalveB) and body ground. STANDARD:12 - 25 O Replacethe shift controlsolenoidvalve assemblyif is out of specification, the resistance lf the resistanceis within the standard,connectthe No. 1 te.minal of the shift control solenoid valve connectorto the batterypositiveterminal.A clicking sound should be heard.Connectthe No. 2 terminal to the battery positive terminal. A clicking sound should be heard.Replacethe shift control solenoid valveassemblyif no clickingsound is heard.

14-106

CONNECTOR BRACKET

FILTER/GASKET Cleanthe mountingsurface Beplace. and fluid passages.

Cleanthe mounting surfaceand fluid passagesof t h e s h i f t c o n t r o l s o l e n o i d v a l v e a s s e m b l y ,a n d installa new shift controlsolenoidvalveAy'Bwith a new filter/gasket and the clamp bracket. Checkthe connectorfor rust. dirt or oil. and reconnect it securelv,

LinearSolenoid Assembly Test 1.

lf not, removethe linearsolenoidassembly.

the linearsolenoidconnector. Disconnect

Checkthat the linearsolenoidfluid passageIor dust or dirt. LINEARSOLENOID

1.

C o n n e c t h e N o . 2 t e r m i n a lo f t h e l i n e a rs o l e n o i d connectorto the batterypositiveterminaland connectthe No, 1 terminalto the batterynegativetermanal.Checkthat the valvemoves. Disconnectone of the batteryterminalsand check that the valvereleases. NOTE:You can see the valve movementthrough the fluid passagein the mountingsurfaceof the linear solenoidassembly.

LINEAR SOLENOID

Measurethe resistancebetweenthe No. 1 and the No. 2 terminalsof the linearsolenoidconnector. STANDARD:applox. 5 O replacethe lf the resistanceis out of specification, linearsolenoidassembly. 4.

Connectthe No. 2 terminalof the linsarsolenoidconnector to the batterv positive terminal and connect the No. 1 terminalto the batterynegativeterminal A clickingsoundshouldbe heard.

VALVE

lf the valvebinds,or movessluggishly,or the linear solenoiddoesnot operate,replacethe linearsolenoid assembly.

14-107

LinearSolenoidAssembly

Mainshaft/Countershaft Speed Sensors

Replacement

Replacement

1.

't. Removethe mm 6 bolt and the countershaftspeed

Removethe mountingbolts and the linearsolenoid assemory.

themounting surface Clean andfluid passages.

sensorfrom the rightside cover. 6 x 1 . 0m m 1 2N.m (1.2kgf.m, COUNTERSI{AFT 8.7rbf ft) SPEEDSENSOR

6x1.0mm 12 N.m 11.2kgl m, 8.7 tbf.ftl

\

\

O.RING Replace.

\

/ ,

%/E:)

MAINSHAFT SPEED SENSOR

@ @ GASKET

LINEAR SOLENOID ASSEMELY

MAINSHAFTSPEED SENSOBWAS}IER (D16Y7enginel

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

Cleanthe mountingsurfaceand fluid passageof the linearsolenoidassemblyand transmissionhousing.

Removethe 6 mm bolt and the mainshaftsDeed sensorfrom the transmissionhousino.

Installa new linear solenoidassemblywith a new gasl(et.

Replacethe O-ringwith a new one beforeinstalling the countershaftspeedsensoror th€ mainshaftspeed sensor.

NOTE;Do not pinch the gasketwhen installingthe linearsolenoid;makesurethat the gasketis installed properlyin the mountinggrooveof the linearsolenoid. Checkthe linearsolenoidconnectorfor rust,dirt or oil, and connectit securely,

14-108

NOTE:Installthemainshaftspeedsensorwasheron the mainshaftspeed sensor.The mainshaftspeed sensorwasher is used on models with the D'|6Y7 engine.

Symptom-to-ComponentChart HydraulicSystem C h e c kt h e s e i t e m s o n t h e P R O B A B L EC A U S E L i s t

SYMPTOM Engineruns,but vehicledoesnot move in any gear. Vehiclemovesin E, E, but not in lrl, pr-, position.

movesin Dl, E, El,lut notin E position. Vehicle Vehiclemovesin -o1],@, @, Uutnot in E position. Vehiclemovesin E position. idlevibration. Excessive flareson startingotf in E, [Dl]position Pooracceleration; Stallrpm hiqh in !!1, p!1,E position.

C h e c kl h e s e l e m s o n the NOTESLIst

1.2,3,5,6,7.36,38

K , L ,R ,S

6, 8, 9, 10,30, 54

c,M,o

6,11,12.24 4 , 6 , 1 4 ,1 5

C,L

10,12,13,14,16,29,33,34,35

C,D

c,L,o

4 ,5 ,4 1 4 ,a 1 . 2 ,1 9 , 3 2 , 3 6 1 , 2 , 3 , 6 , 3 44,1 6. 8. 10

K,L,R

6,12

C,D C,D

14

N

No shift

11, 32. 45,41, 48 19,20,40,48,49

G,L

Failsto shiftin 81, pll position;from lst to 3rd gear

22,49

F a i l st o s h i f t i n 0 3 , D . o o s i t i o n ; f r o m l s t t o 4 t h q e a r

22.23,48

Erraticupshifting. 1'2 upshift,2-3 upshift,3-4 upshift

58

stall rom hioh in D.r, lD,loosition. 5t"[ rprnrsn ^ a"t"t-at

1-2upshift 3'4 upshift Harshupshift{1 2). Harshupshift(2'3). Harsh upshift (3'4).

21,48 22,t9

23,la 12,19,20,29.50,51,57.54 13,19,20,24,27, 29,50.51, 51, 58 14,19,20,25,28,29.50,51, 51, I

C,D,E,H,L C , D ,E ,I , L

19, 20. 24, 43,54, 57, 58 12,19,20,25,43,55,57,5A 13,19,20,26,43,56,57,58

o

Flareson 2-3 upshift. Flareson 3-4 upshift. Excessive shockon 2-3uPshift. Excessive shockon 3-4 uPshift. Lateshiftfrom El positionto Lq! or &l position. Lateshiftfrom E positionto E position.

1 3 ,1 9 , 2 0 , 2 4 . 2 1 , 5 1 14,19. 20,25.24,51 13.19,20,24,27. 43.50.51, 58 14,19,20,25.2A,8, 50,51, 58

F I

10,30 4 , 1 4 ,2 1 , 5 3

o

in all shiftleverpositions Noisefrom transmission

2,31

K,L,O

V e h i c l e d o e s n o t a c c e l e t a t em o r e t h a n 3 1 m p h { 5 0 k m / h )

17

shift lever does not operate smoothly.

P

will not shiftintoparkin [a]position Transmission

6, 39 19,48,49 6, 18,39

S t a l l r p m h i g h ; a l l c l u t c h p r e s s u r e sa r e i n s p e c i f i c a t i o n .

41

D,K,O

Lockup clutchdoesnot disengage. Lockup clutchdoesnot operatesmoothly.

19,44,45,46.41,50,51.54 19,41,44,45,46,47,50,51,58

L

Lock-upclutchdoesnot engage. Vibrationin all positions

19,41,4t, 15,46,41,50, 51,57,58

Harshdownshift(2-1) Harshdownshift(3-2). Harshdownshift(4-3).

F a i l st o s h i f t ; s t u c k i n 4 t h g e a r .

C,D,E,H C, D, E, I E,L,N

E,L,N E,L,N

F I

(cont'd)

The followingsymptomscan be caused by improperrepairor assembly

Checktheseitems,onth€^ CAUSEDUETO PROBABLE List IMPROPER REPAIR

Vehiclecreepsin N position.

R 1 ,R 2

Vehicledoes not move in &l or Pll position. locksup in E position. Transmission

R4

drag in transmission. Excessive

R6

vibration,rpm related. Excessive

R7

Noisewith wheelsmovingonlY.

R5

Main sealpops out.

R8

Variousshiftingproblems.

R 9 ,R l O

ltemson the NOTESList

R 3 ,R 1 1 K,R

REPAIR CAUSEDUETO IMPROPER PROBABLE lmproperclutchclearance. lmpropergearclearance. Parkleverinstalledupsidedown. one-way{sprag)clutchinstalledupsidedown. Reverseselectorhub installedupsidedown. ATF pump binding. Torqueconverternot fully seatedin ATF pump. Main sealimproperlyinstalled. Springsimproperlyinstalled. Valvesimproperlyinstalled. Shiftfork bolt not installed.

14-11

Symptom-to-ComponentChart HydraulicSystem(cont'dl Seeflushingprocedure,page 14-187and 188. set idle rpm in gearto specifiedidle speed.lf still no good,adjustmotor mountsas outlinedin engine sectionof this manual. lf the largeclutchpistonO-ringis broken,inspectthe pistongroovefor rough machining. lf the clutchpackis seizedor is excessively worn. inspectthe otherclutchesfor wear,and checkthe orifice controlvalves,CPCvalveand linearsolenoidfor free movement. lf the linearsolenoidis stuck,inspectthe clutchesfor wear. G.

lf the l-2 shift valveis stuckclosed,the transmissionwill not upshift.lf stuckopen,the transmissionhas no 1stgear.

n,

lf the znd orificecontrolvalveis stuck.inspectthe 2nd and 3rd clutchoacksfor wear. lf the 3-4 orificecontrolvalveis stuck,inspectthe 3rd and 4th clutchoacksfor wear. lf the clutchpressurecontrolvalveis stuckclosed,the transmissionwill not shift out of 1stgear. lmproperalignmentor main valvebody and torqueconverterhousingmay causeATF pump seizure.The symptomsare mostlyan rpm-related tickingnoiseor a high-pitchedsqueak. lf the ATF straineris cloggedwith particlesof steelor aluminum,inspectthe ATF pump and differential pinionshaft.lf both are OK and no causefor the contaminationis found,replacethe torqueconverter. lf the l st clutchfeed pipe guide in the end cover is scoredby the mainshaft,inspectthe ball bearingfor excessivemovementin the transmissionhousing.lf oK, replacethe end coveras it is dented.The o-rino underthe guide is probablyworn. Replace the mainshaftif the bushingfor the 4th feedpipeis looseor damaged.lf the 4th feedpipeis danF aged or out of round, replacethe right side cover. Replace the mainshaftif the bushingfor the 1stfeedpipeis looseor damaged.lf the 1stfeedpipe is darnagedor out of round,replaceit. A worn or damagedspragclutchis mostlya resultof shiftingthe transmissionin the wheelsrotatein reverse,suchas rockingthe vehiclein snow.

or E positionwhile

Inspectthe framefor collisiondamage. Inspectfor damageand wear: 1. Reverseselectorgearteethchamfers. 2. Engagement teethchamfersof countershaft4th and reversegear. 3. Shiftfork for scuffmarksin center. 4. Differentialpinionshaftfor wear u nder pinion gears. 5. Bottomof 3rd clutchfor swirl marks. Replaceitems1,2,3 and 4 if worn or damaged.lf transmission makesa clicking,grindingorwhirringnoise, alsoreplacemainshaft4th gear,reverseidlergear.and countershaft 4th gearin additionto 1, 2, 3 or 4. lf differentialpinion shaft is worn, overhauldifferentialassembly,and replaceATF strainer,and thoroughly cleantransmission, flushtorqueconverter, coolerand lines. lf bottom of 3rd clutchis swirled and transmissionmakesgear noise,replacethe countershaftand final driven gear. Be very carefulnot to damagethe torqueconverterhousingwhen replacingthe main ball bearing,you may also damagethe ATF pump when you torquedown the main valvebody.Thiswill resultin ATF pump seizureif not detected.Usethe oroperroors. Installthe main sealflush with the torqueconverterhousing.lf you push it into the torqueconverter housinguntil it bottomsout, it will blockthe fluid returnpassageand resultin damage.

14-1 1 2

Road Test

NOTE:Warm up the engineto normaloperatingtemperature (the radiatorfan comeson)' 1. Apply parkingbrakeand blockthe wheels.Start the engine,then shift to E positionwhile depressingthe brake pedaland releaseit suddenly.The engineshouldnot stall' Dedal,Depressthe accelerator 2. Repeatsametest in E Position. 3. Test-drivethe vehicleon a flat road in the E position.Checkthat the shift pointsoccurat approximatespeedsshown in the table.Also checkfor abnormalnoiseand clutchslippage. the throttleopening NOTE:Throttlepositionsensorvoltagerepresents a. Unboltthe PCMfor roadtesting;referto page14-50. b. Setthedigitalmultimeterto checkthe th rottlepositionsensorvoltagebetweenPCMterminals; . '96 - 98 models:D1 {+)and A9 (-) or 422 (-}. . ' 9 9- 0 0 m o d e l sC : 2 7( + )a n d B 2 0 t - )o r B 2 2 { - } .

BACKPROBE ADAPTER

SET BACKPROBE 07sAz- 001oq)A {tworequiredl

DIGIIAL MULTIMETER lCommerciallyavailable) KS-AHM-32-003, or equivalenl

'96 - 98 Modelsr

c (31P}

I (25P1

Wire sideol temaleterminals '9!t - 00 Models:

A t32Pt

PCMCONNECTORS c (31P)

B t25Pl

D (16P)

LG1IBRN/BLK)

Wire side ol female terminals

1+113

Road Test (cont'dl .91Position:Dl6Y7 engine .

Upshift Throttle Opening Throttlepositionsensor voltage:0.75V Throttlepositionsensor v o l t a g e : 2 . 2V5 Fully-opened throttle Throttlepositionsensor voltage:4.5V

Unit of speed

lst + znd

2nd * 3rd

mph

9-12

20-23

28-32

21-24

km/h

15-19

32-37

45-52

34-39

mph

3rd t

Lock-upON

4th

40-45

62-67 't08 99 -

95 - 104 1 0 1- ' t 1 2

km/h

34-40

mph

33-38

km/h

53-61

Unit of speed

Lock-upOFF

'lth + 3rd

mph

't9 - 22

1 7- 2 0

6-9(3rd+lst)

km/h

30-35

27-32

10- 15 (3rd+ 1st)

mpn

95 - 105

85-95

54-61

25-30

km/h

153- 169

1 3 7- 1 5 3

87-98

40-48

Unit of speed

lst + 2nd

2nd - 3rd

3rd + 4th

Lock-up ON

mph

9-12

20-23

2A-32

2 1- 2 4

km/h

32-37

45-52

34-39

mpn

15-19 2 1- 2 5

40-45

km/h

34-40

59-65 9 5- 1 0 4

99 - 108

mph

32-37

6 2- 7 0

96 - 107

9 5- 1 0 6

km/h

52-60

1 0 0- 1 1 3

't55-

't53- '170

Unit ot speed

Lock-upOFF

'lth + 3rd

mph

19-22

1 7- 2 0

6-9(3rd+ 1st)

km/h

30-35

27-32

l0 - 15 (3rd+ lst)

mpn

9 1- 1 0 1

km/h

'147- 163

102-115

99 - 109 '159- 176

163- 180

Downshift Throftle Opening Fullyclosedthrottle Throttlepositionsensor voltage:0.5V Fully-opened throttle Throttlepositionsensor voltage:4.5V

3rd + 2nd

2nd t

lst

-q1Position: DI6YBengine .

Upshift Throttle Opening Throftlepositionsensor voltage:0.75V Throttlepositionsensor v o l t a g e : 2 . 2V5 Fully-opened throttle Throttlepositionsensor voltage:4.5V

112

Downshift Throttle Opening Fully-closed throttle Throttlepositionsensor voltage:0.5V Fullyopenedthrottle Throttlepositionsensor voltage:4.5V

NOTE: . Lock-upON:The lock-upcontrolsolenoidvalveA turns ON. . Lock-upOFF:The lock-upcontrolsolenoidvalveA turns OFF.

14-114

3rd+2nd

I

54-61 1 3 7- 1 5 3

87-98

2nd+lst

25-30 I

40-48

then shift from Dl positionto Z position The Accelerateto about 35 mph (57 km/h)so the transmlssionis in 4th, braking' engine vehicleshouldimmediatelybeginslowingdown from CAUTION: Do not shift from -91or the transmission.

-Ddposition to damage E position at speeds ov6r 63 mph {100 km/hl; You mav

positions' Checkfor abnormalnoiseand clutchslippagein the following E (2ndGear)Position clutchslippage. from a stop at full throttle.checkthat there is no abnormalnoiseor ll Accelerate posirion' in this the selector with not occur should b. Upshiftsand downshifts Position E (Reverse) and clutchslippage' i"cceleratefrom a stop at fullthrottle,and checkfor abnormalnoise Test in B (Park)Position into E position Beleasethe brake;the veh' Parkthe vehicleon slope(approx.l6'), applythe parkingbrake'and shift cle shou,dnol move

1+115

Stall Speed Test CAUTION: . To prev€nt transmissiondamage,do not t6st stall speedfor more than ro sgcondsat a time. . Do not shift the levor while raising the engine speed. . Bo sule lo remove the pressuregauge betoro testing stall speed. '1.

Engagethe parkingbrake,and blockthe front wheels.

2.

Connecta tachometerto the engine,and startthe engine.

3.

Makesurethe Ay'Cswitchis OFF.

4.

After the enginehaswarmed up to normaloperatingtemperature(the radiatorfan

5.

Fullydepressthe brakepedaland accelerator for 6 to g seconds,and noteenginespeed.

6.

Allow two minutesfor cooling,then repeatthe test in @ and @ positions.

comeson). shift into E position.

NOTE: . Stallspeedtestsshouldbe usedfor diagnosticpurposesonly, . Stallspeedshouldbe the samein o., E and positions. E Stall Spsed RPM: Specification:2.700rpm ServiceLimit: 2,550- 2,850rDm

TROUBLE

PROBABLECAUSE

Stallrpm high in D., E and E positions

. . . .

Stallrpm high in El position Stallrpm high in E posirion

. Slippageof 4th ctutch . Slippageof 2nd clutch . Slippageof lst clut"tr or. t"t g""io*-*"y "lut"h . Engineoutput low . Torqueconverterone-wayclutchslipping

Stallrpm high in E position Stallrpm low in LDa . El and E positrons

1 4-1 1 6

Low fluid levelor ATF pump outDur CloggedATF strainer Pressureregulatorvalvesluckcloseo Slippingclutch

Fluid Level Ghecking NOTE: Keep all foreign particlesout of the transmissron. 1.

7.

Insertthe dipstickbackinto the transmissionin the directionshown.

Warm up the engineto normal operatingtemperature (the radiatorfan comeson) FRONT

Parkthe vehicleon the level ground, then turn off the engrne. Removethe dipstick(yellow loop) from the transmission.and wipe it with a cleancloth. Insertthe dipstickinto the transmrssron

Installthedipstickin the extent of the directionshown.

DIPSTICKIYELLOWLOOPI

R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l l t s h o u l d b e b e t w e e nt h e u p p e r m a r k a n d l o w e r marks.

K L

UPPERMABK LOWERMARK

lf the levelis belowthe lower mark,pour the recomm e n d e df l u i d i n t o t h e t i l l e r h o l e t o b r i n g i t t o t h e upper mark. Always use GenuineHonda Premium FormulaAutomaticTransmissionFluid (ATF).Using a non-HondaATFcan affectshift quality

14-117

Fluid Level Changing NOT€: Keep all foreign particlesout of the transmission. '1.

Bringthe transmissionup to operatingtemperature (the radiatorfan comeson) by drivingthe vehicle. Parkthe vehicleon the level ground, and turn the engine off. R e m o v et h e d r a i n p l u g . a n d d r a i n t h e a u t o m a t i c transmissionfluid (ATF). NOTE:lf a coolerflusheris to be used,seepage 14187and 14-188.

TRANSMISgION ENDOOVER

DNAINPLUG 1 8x 1 . 5m m 49 N.m (5.0kgtm, 36lbf.ftl

SEALINGWASHER Replace.

Reinstallthe drain plug with a new sealingwasher, then refill the transmissionwith the recommended fluid into the filler hole to the upper mark on the d i p s t i c k .A l w a y s u s e G e n u i n e H o n d a p r e m i u m FormulaAutomaticTransmissionFluid (ATF).Using a non-HondaATFcan aftectshift quality. Automatic TransmissionFluid Capacity: 2.7 | |'2.9US ql,2.a lmp qtl at Ghlnging 5.9 f 16.2US qt. 5.2 lmp qt) at overhaul

1 4- 1 1 A

PressureTesting

@ I While testing, be caroful of th€ rotating front wheels. .

Make sure lifts, iacks, and satoty stands are placod properly (seesection 1)'

CAUTION: . Beforoiesting, be sure the transmissionfluid is tilled to tho proper level' . Warm up tho engine before testing' 1.

Raisethe vehicle(seesection1).

2.

Warm up the engine,then stopthe engineand connecta tachometer'

3.

Connectthe oil pressuregaugesto eachinspectionhole. TOROUE:18 N.m (1.8 kgf'm, 13 lbnft) to entel cAUTloN: connact the oil pressurogauges securely;be suro not to allow dust and other foreign Parlicles the inspestion holos'

GAUGE A/T OILPRESSURE SETw/PANEL 07t06- 0020400

HOSE A/T OIL PRESSURE ADAPTER 07Mru - PY0120 (4 requiJedl

GAUGE A/T LOWPRESSURE SETWPANEL 07406- 0070300

HOSE A/T OIL PBESSURE 2210mm OTMAJ- PY4{)llA 14roquircdl

Startthe engine,and measurethe respectiveptessureas follows' a Line Pressure . 1st Clutch Pressure . 2nd,3rd and 4th ClutchPressure Installa new washerand the sealingbolt in the inspectionhole.and tightento the specifiedtorque' TOROUE:l8 N.m (1.8 kgf'm,13lbf'ft) NOTE:Do not reuseold sealingwashers;alwaysreplacewashers'

(cont'd)

14-119

PressureTesting (cont'd) Line Pressure/1stClutch PressurcMeasurement 1.

Setthe parkingbrake,and btockboth rearwheelssecurely.

2.

Startthe engine,and run it at 2,OOO rpm.

3.

Shiftto N or E position,then measureline pressure. NoTE: Higherpressuremay be indicatedif measurements are made in shift leverpositionsotherthan @ or @ posi tron.

4.

Shiftto tq;lposition,hold the engineat 2,000rpm, and measure1stcrutchpressure.

1STCLUTCHPRESSURE INSPECTION HOLE (Markedwith "1")

LOCK.UPCONTROL SOLENOIDVALVEA/8 ASSEMBLY VALVEA/B ASSEMBLY

PRESSURE Line

1stClutch

14-120

SHIFTLEVER POS|TtON

SYMPTOM

PROBABLE CAUSE

FLUIDPRESSURE Standard

N orE

No (or low) lrne pressure

Torqueconverter, ATF pump,pressure regutator. torqueconverter checkvalve

D;l

Noor low 1st pressure

1 s tC l u t c h

830 - 880 kPa {8.5- 9.0 kgf/cm?, 120- 130psi)

ServiceLimit 780 kPa (8.0kgf/cm' ,110psi)

2nd, 3rd and 4th Clutch PressureMeasurement 1. Setthe parkingbrake,and blockboth rearwheelssecurely' 2. Startthe engine,and run it the engineat 2,000rpm' pressure 3. Shiftto E position,then measure2nd clutch pressure 4. Shiftto El position,then measure3rdclutch pressure' 5. Shiftto E position,then measure4th clutch pressure' 6. Shiftto E position,then measure4th clutch

2ND CLUTCHPR€SSURE HOLE INSPECTION

HOI'E INSPECTION (Markedwith "3")

FLUIDPRESSURE SHIFTLEVER PRESSURE POStT|()N

SYMPTOM

PROBABLECAUSE

2nd Clutch

tr

No or low 2nd pressure

2nd Clutch

3rd Clutch

tr

No or low 3rd pressure

3rd Clutch

p.l

No or low 4th presSure

4th clurch

4th clutch

E

standard 800 (8.21208'10(8.3120-

I

sorviqe Limit

850 kPa 8.7 kgflcm', 120psi)

760 kPa (7.7kgf/cm' ,110Psil

860 kPa 8.8 kgt/cm', 130psi)

760 kPa (7.8kgt/cm',110Psi)

Servo Valve or 4th Clutch

1+121

Transmission Removal @

Maks sure lifts, iacks and safety stands are placed properly, and hoist bracket ate aftached to the cor_ rec{ position on the engine lsee section 1). Apply parking brake and block rear whoels so vehicle will not roll off stands and fall on you while working under it.

4.

Removethe transmissiongroundcable,and discon_ nectthe lock-upcontrolsolenoidconnector.

CAUTION: Use tender covers to avoid damaging painted surfaces. 1,

Disconnectthe battery negative(_) terminal from the battery,then removethe positive(+)terminal.

2.

Removethe intakeair duct. D16Y7engins: Removethe intakeair duct and resonator. LOCK.UPCONTROL SOLENOIDCONNECTOR

D16Y8engine: Removethe intakeair duct and the air cleanerhousing assembly, 3.

Removethe starter cables and cable holder from the starter motor. 5,

Disconnectthe vehiclespeedsensor(VSS)connec_ tor and the countershaft speedsensorconnector.

MOTORCABLE

VEHICLE SPEED

MOTORCABLE

14-122

6.

Removethe transmissionhousing mounting bolts and the rearenginemountingbolt.

8.

DRAINPLUG 18 x 1.5mm '9 N m t5 o kgf'm' 36 lbf'ft|

MOUNTINGBOLTS

7.

the shiftcontrolsolenoid,the linearsoleDisconnect noid,and the mainshaftspeedsensorconnectors' 9. SHIFTCONTROL SOLENOIDCONNECTOR

R e m o v et h e d r a i n p l u g , a n d d r a i n t h e a u t o m a t i c t r a n s m i s s i o nf l u i d ( A T F ) .R e i n s t a ltlh e d r a i n p l u g with a new sealingwasher.

Replace.

Remove the splash shield.

LINEARSOLENOID CONNECTOR

SPLASHSHIELD BRACKET

{cont'd)

14-123

Transmission Removal(cont'd) '10. Remove the cotter pins and castlenuts, th€n separate the balljoints from the lower arms (seesection 1gl.

16. Removethe shift cablecover.then removethe shift cableby removingthe controllever,

DAMPERPINCHBOLT

CAUTION: Take car6 not to bond the shift cable.

NUT FORK BOLT

FORI(

COTTER PIN Replace. WASHER

11. Removethe right damper fork bolt. th€n separate right damperfork and dampor. 1 2 . Prythe right and left driveshaftsout ofthe differential. 1a

Pullon the inboardjoint to removethe right and left drivsshafts(seesection 16).

1 4 . Tie plastic bags over the driveshaftonds. NOTE: Coat all precisionfinished surfaceswith clean engineoil. t9.

1 7 . Removethe right front mounvbracket. 1 8 . Remove the ATF cooler hoses at the ATF cooler lines.Tufn the ends of the ATF cooler hosesuo to preventATF from flowing out, then plug the ATF cooler hosgsand lines. NOTE: Checkfor any sign of leakageat the hose ioints.

Removethe exhaustpipe A, NOTE: Dl6YB engine is shown; D16y7 engine is similar.

SELF-LOCKING NUT Replace.

14-124

EXHAUSTPIPEA

MOUNT/BRACKET

19. Removethe engine stiffener and the torque converter cover.

23. Placea jack under the transmission.and ra6a :'. transmissioniust enoughto take weight otf ol tF. mounts.then removethe transmissionmounl TRANSMISSION MOUNTBRACKET

COVER

20. Removethe eight drive plate bolts one at a tlme while rotatingthe crankshaftpulley.

2 1 . Removethe distributor. Attacha hoistingbracketto the engine,then lift the engineslightly.

24. Removethe transmissionhousing mounting bolts and the rearenginemountingbolts.

25. Pull the transmissionaway from the engineuntil it clearsthe 14 mm dowel pins, then lower it on the transmissionjack.

TRANSMISSIONHOUSING

HOIST BRACKET

lf necessary,removethe torque converteranc:" startermotor.

1+16

lllustrated Index Transmission/End Cover a-'tEO

14-126

O ROLLER O COLLAR O o-RINGReplace. @ FEEDPIPEFLANGE @ O-RINGReplace. @ SNAP RING €) 3RD CLUTCHFEEDPIPE LOCKNUT(FLANGENUT) €) COUNTERSHAFT 23 x 1.25mm Replace. o coNlcAL SPRINGWASHERReplace. @ PARKGEAR @ ONE.WAYCLUTCH lST GEAR @ COUNTERSHAFT @ NEEDLEBEARING lST GEARCOLLAR @ COUNTERSHAFT @ o-RlNGs Replace. @ ENDcovER GASKETReplace. E) DOWELPINS @ PARKPAWLSTOP @ LocK WASHERReplace. @ PARKSTOPSelectivepart €D PARKLEVER @ PARKLEVERSPRING €D DRAINPLUG €) SEALINGWASHERReplace @ o-RINGReplace. SPEEDSENSOR @ COUNTERSHAFT PAWL PARK @) @ PARKPAWLSPRING @ PARKPAWLSHAFT @ LINEARSOLENOIDASSEMBLY @ LINEARSOLENOIDGASKETREPIACE.

@)END COVER @ lsT CLUTCHFEEDPIPE @ O-RINGSReplace. @ FEEDPIPEFLANGE C) SNAP BING @ MAINSHAFTLOCKNUT(FLANGENUTI 21 x 1 25 mm Replace. @ CONICALSPRINGWASHERRePlace @)lST CLUTCHASSEMBLY @ o-RlNGs Replace. €) THRUSTWASHER @)THRUSTNEEDLEBEARING @ NEEDLEBEARING @ MAINSHAFTlST GEAR @ MAINSHAFTlST GEARCOLLAR @)ATF COOLERLINE @ SEAUNGWASHERSReplace. @ LINEBOLT @ ATF DIFSTICK @ ATF COOLERLINE @ UNE BOLT @ SEALINGWASHERSReplace. @ VEHICTTSPEEDSENSOR @ O-RINGReplace.

TOROUESPECIFICATIONS Bolt/Nut No. 6B 8F 12A. 'l8D 2'tM 23C

Torque Value

Size

'12N'm (1.2kgim,8.7 lbift) 14 N.m (1.4kgf.m,10 lbf'ft) 22 N.m (2.2 kgf.m, 16 lbf'ft) 28 N.m (2.9 kgf.m, 21 lbf'ft) 49 N.m (5.0 kgf.m, 36 lbf'ft) 78 N.m (8.0 kgf'm, 58 lbf'ft) 103N.m {10.5kgf'm,75.9lbift)

6x1.0mm 6x1.0mm 8 x 1 , 2 5m m 1 2x 1 . 2 5m m 1 8x 1 . 5m m 2 1 x 1 . 2 5m m 2 3 x 1 . 2 5m m

Remarks

Linebolt Drainplug Mainshattlocknut:Left-handthreads locknut: Countershaft Left-handthreads

14-127

lllustrated Index Transmission Housing

6A

I e

:!_..

14-128

Replace, O LocKWASHER SHIFTFORK O REVERSE REVERSE GEARCOLLAR O COUNTERSHAFT REVERSE GEAR G) COUNTERSHAFT BEARING @ NEEDLE SELECTOR @ REVERSE HUB SELECTOR REVERSE O 4THGEAR @ COUNTERSHAFT BEARING O NEEDLE 28 mm Selectivepart GOLLAR, @ DISTANCE 2ND O COUNTERSHAFT GEAR @ THRUSTNEEDIEBEARING 3RDGEAR @ COUNTERSHAFT BEARING @ NEEDLE 3RDGEARCOLLAR @ COUNTEBSHAFT NEEDLE BEAFING @ THRUST WASHER O SPLINED ASSEMBLY @ 3RDCLUTCH Replace. @ O-RtNGs @ COUNTERSHAFT @ SNAPRING WASHER @ THRUST BEARING NEEDTE €) THRUST GEAR 4TH GEAR/REVERSE MATNSHAFT @} BEARINGS @iNEEDLE EEARING @ THRUSTNEEDLE 4THGEARCOLLAR @)MAINSHAFT ASSEMBLY @ 2ND/4THCLUTCH @ o-RlNGsReplace. x 55 mm Sel€ctivepart WASHER,36.5 @ THRUST BEARING @ THRUSTNEEDLE zNDGEAR @ MAINSHAFT BEARING @ NEEDLE

BEARING NEEDLE @ THRUST @ MAINSHAFI @ S€ALINGRINGS,35 mm RING,29mm @ SEALING @}NEEDIEBEARING @ SETRING VALVEA/B ASSEMSLY SOLENOID @ sHrFTCONTROL CLAMPBRACKET @ HARNESS Replace. FILTER/GASKET SOI"ENOID @ SHIFTCOI,ITROL BFACKET CONNECTOR @ HANGER TNANSMISSION @D CAP @ BREATHER SPEED SENSOR @ MAINSHAFT WASHER SPEED SENSOR {Dl6Y' ongine} @ MATNSHAFT O-RING Replace. @ @ SNAPRING BEARING HOUSING TRANSMISSION @ MAINSHAFT HOUSING BEARING TRANSMISSION @ OOUNIERSHAFT ASSEMBLY IDLERGEARSHAFTHOLDER @ REVERSE BEARING @ NEEDI.E SEAL Replace. olL @ @ SETRING,fll mm Selectivepart

HouslNG @rnANsMrssloN

IDI."ER GEAR @ REVERSE @ DowELPINS Replace. HOUSING GASKET @ TRANSMISSION ASSEMBLY @ DIFFERENfIAL @ OILSEALReplace. HOUSING @ TOROUECONVERTER

TOROUESPECIFICANONS Boh/Nut No.

Torquovalue

Size

6B 10A

12 N.m {1.2kgf.m,8.7lbf.ft) 14 N.m (1.4kgf'm,10lbf'ft) 44 N.m (4.5 kgf.m, 33 lbf'ft)

6x1.0mm 6x1.0mm 1 0x 1 . 2 5m m

Romarks

14-129

lllustrated lndex TorqueConverterHousing/ValveBody

to\ \*

14-130

O ATF FEEDPIPE O ATF STRAINER O SERVOBODY '99 - 00 modelsservobody has integrallymolded servodetent. @ SERVOSEPARATORPLATE (' SECONDARYVALVE BODY @ DOWELP|NS O SECONDARYSEPARATORPLATE @ SERVODETENTBASE('96 -'98 models) O ATF FEEDPIPES (D ATF FEEDPIPES O SHAFTSTOP @ CONTROLSHAFT €D DETENTARM SPRING @ DETENTARM (9 DETENTARM SHAFT @ FILTERReplace. (? CHECKBALLS CHECKVALVE @ TOROUECONVERTER CHECKVALVE SPRING CONVERTER TOROUE @ @ DOWELPINS @ LOCK.UPVALVE BODY @ LOCK-UPSEPARATORPLATE VALVE BODY @ REGULATOR PINS DOWEL @} @ COOLERRELIEFVALVE SPRING @ COOLERRELIEFVALVE @ O-RINGReplace. @ STATORSHAFT @ STOPSHAFT @ ATF FEEDPIPE @ MAIN VALVE BODY @ ATF PUMP DRIVENGEARSHAFT @ ATF PUMP DRIVENGEAR @ DOWELPINS 65)ATF PUMP DRIVEGEAR

MAIN SEPARATORPLATE SUCTIONPIPECOLLAR ATF MAGNET HOUSING TOROUECONVERTER COUNTERSHAFT BEARING @ ATF GUIDEPLATE HOUSING @ ToRoUE CONVERTER @ OILSEALReplace. HOUSING @ MAINSHAFTTOROUECONVERTER BEARING @)olL SEALReplace. @ LOCK-UPCONTROLSOLENOIDFILTER/GASKET Reolace. @ LOCK-UPCONIROL SOLENOIDVALVEA/B ASSEMELY @ CONNECTORBRACKET

@ @ @ @

TOROUESPECIFICANONS Bolt/Nut No.

Torque Valug

Siz€

12 N.m (1.2kgf.m,8.7lbnft)

6x1,0mm

Remarkg

14-131

End Cover Removal NOTE: . Cleanallpartsthoroughlyin solventor carburetorcleaner,and drywith compressedair, . Blow out all passages, . When removingthe right sidecover,replacethe following: - O-rings - Mainshaftand countershaftlocknuts - Conicalspringwashgrs - End cover gasket - Lockwasher - Sealingwashers 6 x 1.0mm BOLT 13 Bolts

ENDCOVER

PARKITVER LOCKWASHER

PARKPAWL

tST GEAFCOLLAR

LINEAOLT

COUI{TERSI{AFT

SEALINGWASHERS

14-132

1.

Removethe 13 bolts securingthe end cover,then removethe cover.

5 . Removethe specialtool from the mainshaftafter removingthe locknuts.

Slipthe specialtool onto the mainshaftas shown.

6 . Removethe 1stclutchand mainshaft1stgearassem bly and mainshaft1stgearcollarfrom the mainshaft.

HOLOER MAINSHAFT - PFs0101 07GAB

7. Removethe parkpawl.springand shaft. 8. Removethe parkleverfrom the controlshaft. 9. Using a universaltwo-jaw puller, removethe park g e a r , o n e w a y c l u t c h a n d c o u n t e r s h a f t1 s t g e a r assemory.

PULLER (CommerciallYavailable)

PARKGEAR

Engagethe parkpawl with the parkgear. 4.

Cut the locktabs of the mainshaftand countershaft locknutsusing a chiselas shown. then removethe locknutsand conicalspringwashers CAUTION: Keep all of lhe chiseled particles out of the transmission. NOTE: . Mainshaftand countershaftlocknuts have lefthandthreads. . Alwayswear safetyglasses.

1 0 . Removethe needle bearing and the countershaft 1stgearcollarfrom the countershaft 1 1 . Removethe ATF coolerlinesand ATFdipstick.

cHrs€L

LOCKNUT

LOCKTA8

14-133

Transmission Housing Removal

TRANSMISSIONHOUSING MOUNTINGBOLTS 1 8B o l t s TRANSMISSION HANGER

TRANSMISSION HOUSING

MAINSHAFT SUB.ASSEMBLY

MAINSHAFT SENSORWASHER lD16Y7engine) SUB.ASSEMBLY MAINSHAFT SPEEDSENSOR

TRANSMISSION HOUSINGGASKET

DIFFEBENTIAL ASSEMBLY

TOROUE CONVERTER HOUSING

14-134

Torque ConverterHousing/ValveBody Removal

ATF FEEOPIP€

PIN LOCK-UPVALVE BODY

6x1.0mm

SERVODETENT BASE

LOCK-UPSEPARATOR PLATE

ATFFEED PIPES

REGULATOR VALVESODY DOWELPIN COOLERRELIEFVAL

STRAINER

CONTROL SHAFT DETENT ARM SHAFT

DETENT ARM SERVOEODY SEPARATON ATF FEEDPIPE 6x1.0mm 5 Eolts MAIN VAL BODY ATFPUMP GEARSHAFT ATF PUMP DRIVEN MAIN SEPARA PLATE

6x1.0mm 3 Eolts VALVEBODY PIN SECONDARY SEPARATOR PLATE

NOTE:The illustrationshowsthe '96 - 98 models,the '99 - 00 modelsdo not havethe servodetentbase;the servodetent is integralwith the servobody.

14-136

NOTE; . Clean all parts thoroughly in solvent or carburetor cleaner,and dry with compressedair. . Blow out all passages. . When removingthe valvebody,replacethe O-ring.

1 3 . C I e a nt h e i n l e t o p e n i n go f t h e A T F s t r a i n e rt h o r oughly with compressedair. then checkthat it is in good condition,and the inletopeningis not clogged.

l, Removethe ATF feed pipes from the servo body, secondaryvalvebody and main valvebody. For'96 - 98 models:Removethe ATF strainerand servo detent base (two bolts). For'99 - 00 models:Removethe ATF strainer(one bolt). Removethe servo body and servo separatorplate {'96- 98 models:sevenbolts,'99- 00 models:eight bolts).

INLETOPENING

Removethe secondaryvalve body, shaft stop and secondaryseparatorplate(threebolts). Removethe lock-upvalve body and separatorplate {sevenbolts). Removethe regulatorvalvebody (one boltl. 7 . Removethe stator shaft and stop shaft.

1 4 . Test the filter by pouring clean ATF fluid through the inlet opening. Beplacethe ATF strainerif it is cloggedor damaged. NOTE:The ATF str8inercan be reused if it is not clogged.

Removethe detentspringfrom the detentarm. then remove the control shaft from the to.que converter housing. Removethe detentarm and detent arm shaft from the main valvebody. 1 0 . Removethe main valvebody (five bolts). NOTE:Do not let the eight checkballsfall outofthe m a i n v a l v e b o d y w h e n r e m o v i n gt h e m a i n v a l v e body. 't'1. Removethe ATF pump drivengear shaft,then remove the ATF pump gears. 12. Removethe main separatorplate and two dowel pins.

14-137

Valve Caps Description C a p sw i t h o n e p r o j e c t e dt i p a n d o n e f l a t e n d a r e installedwith the flat end toward the inside of the valve body. Capswith a projectedtip on each end are installed w i t h t h e s m a l l e rt i p t o w a r d t h e i n s i d eo f t h e v a l v e body.The smalltip is a springguide.

Toward outside of valvo body.

Capswith hollow ends are installedwith the hollow end awayfrom the insideofthe valvebody. Capswith notchedends are installedwith the notch towardthe insideof the valvebody. Capswith flat ends and a hole throughthe centerare installedwith the smaller hole toward the inside of the valvebodv.

Toward outsido of valve bodv.

Efla Toward insido ot valvo body.

C a p s w i t h o n e p r o j e c t e dt i p a n d h o l l o w e n d a r e installedwith the tip toward the inside of the valve body.The tip is a springguide.

Towa.d outside o, valv6 bodv.

Toward inlido ot valve bodv,

Capswith flat ends and a groovearoundthe cap are installedwith the groovedside toward the outsideof the valvebody.

Toward oulsido of valv6 body.

"-\"h

,A

\za9 Sectional view.

Toward insid€ of valv6 bodv.

14-138

Toward insido ol valvo body.

Valve Body Repair NOTE:This repair is only necessaryif one or more of the valvesin a valve body do not slidesmoothlyin their bores.You may use this procedureto free the valvesin the valvebodies.

5.

Coatthe valvewith ATF,then drop ir into its bore. It should drop to the bonom of the bore under its own weight.lf not, repeatstep4, then retest.

1 . S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r about30 minutes. 2.

Removethe #600 paper and thoroughly wash the entirevalve body in solvent.then dry it with compressedair.

Carefullytap the valve body so the stickingvalve dropsout of its bore. C A U T I O N :l t m a y b € n e c e s s a r yt o u s e a s m a l l screwdriver to pry the valve free. Be careful not to scratchthe bore whh the screwdriver.

3.

4.

Inspectthe valvefor any scuff marks.Use the ATFsoaked#600 paper to polishoff any burrs that are on the valve,then wash the valvein solventand dry it with compressedair.

VALVE BODY

-M W

paper,and insert Roll up half a sheetof ATF-soaked it in the valvebore of the stickingvalve. Twistthe paperslightly,so that it unrollsand fits the b o r e t i g h t l y ,t h e n p o l i s ht h e b o r e b y t w i s t i n gt h e paperas you push it in and out. CAUTION: The valve body is aluminum and doesn't require much polishing to remove any burrs,

ATF-soaked #600 abrasive Paper 7.

Removethe valve.then thoroughlyclean it and the valve body with solvent. Dry all parts with compressedair. then reassembleusing ATF as a lubri cant.

14-139

Valve Assembly NOTE: Coat all parts with ATF before assembly. .

.

Set the spring in the valve and installit in the valve body. Push the spring in with a screwdriver,then installthe springseat.

Installthe valve, valve spring and cap in the valve body and securewith the roller.

-_^?=w_ 5-'--------P/ =/

/-\ (-,.1\) ,. l_/1

) SPRIITGSEAT

VALVE BODY

VALVE BODY

Installthe valve,springand cap in the valvebody. Pushthe cap,then installtheclip.

VALVE AODY

VALVE

SPRING

14-140

ATFPump Inspection 1.

Installthe ATF pump gears and ATF pump driven gearshaft in the main valve body

2.

Measurethe side clearanceof the ATF pump drave and drivengears. ATF Pump GearsSide {Radial)Clearance: Standard (New): ATF Pump Drive Gear 0.105- 0.1325mm {0.004- 0.q)5 in} ATF Pump Drivsn Gear 0.035- 0.0625mm (0.0014- 0.0025inl

NOTE: . Lubricateall partswith ATF during inspection. . Installthe ATF pump drivengearwith its grooved and chamferedsidefacingup as shown.

GEAR ATFPUMPORIVEN Groovedand chamfe.edside

MAIN VALVESOOY

YZ] o?

ATF PUMP DRIVEGEAR

ATF PUMP DRIVENGEAR Inspectteethfor wear and damage

lnspect teethforwearanddamage. 3.

MAIN VALVE BODY

Removethe ATF pump driven gear shaft. Measure the thrust clearanceof the ATF pump driven gearto-valve bodY. ATF Pump Drive/Drivon Gear Thrust {Axial} Cloarance: Standard (Now): 0.03- 0.05 mm 10'001- 0.002inl SorviceLimit: 0.07 mm (0.003in)

1+141

Main Valve Body Disassembly/lnspection/Reassembly NOTE: . Cleanallpartsthoroughlyin solventor carburetorcleaner,and drywith compressedair. Blowoutall passages. . Replacethe valvebody as an assemblyif any pans are worn or damaged. . Checkall valvesfor free movement.lf anyfail toslidefreely,seeValveBody Repaironpage,l4-139. . Coatall partswith ATF duringassembly. CAUTION: Do not use a magnet to removs tha check balls; it may magnetizothe balls.

I.2 SHIFTVALVE CPBVALVE

VALVECAPCLIP ORIFICE CONTROLVALVE

BALLS,8

lST ACCUMULATOR CHOKE

MODULATOR VALVE

RELIEFVALVE

VALVE

MAIN VALVEEODY Inspectfor wear,scratches and scoring.

SEBVOCONTROLVAL

VALVECAP

14-142

CHECKBALL

CHECKBALLS

w

CHECKBALLS

MAIN VALVEBODY (Sectionalviewl

SPRINGSPECIFICATIONS

U n i t :m m ( i n ) Standard (New)

No.

o @ @ @ @ @

Springs Reliefvalvespring Modulatorvalvespring CPBvalvespring 1-2shiftvalvespring 2nd orificecontrolvalvespring Servocontrolvalvespring

Wire Dia. 1 . 1( 0 . 0 4 3 ) '1.4(0.055) 0.9 (0.035) 0.9 (0.035) 0.7 (0.028) 1.0(0.039)

o.D. 8.6 (0.342) 9.4 (0.374) 8.1 t0.3221 7.6 {0.302) 6.6 (0.262) 8.'t to.322l

Free Length 3 7 . 1( 1 . 4 6 1 ) 35.0(1.378) 47.2(1.8s8) 4 1 . 3( 1 . 6 2 6 1 34.8(1.370) 52.1t2.O51l

No. ot Coils 13.4 10.9 1C?

'15.3 22.0 20.8

1+143

SecondaryValve Body Disassembly/lnspection/Reassembly NOTE: . Cleanallpartsthoroughlyin solventor carburetorcleaner.and drywith compressedair, Blowoutall passages. . Replacethe secondaryvalvebody kit. P/N27700- P4R- 315 (Thesecondaryvalve body kit includesthe linearsolenoid assembly)if any partsare worn or damaged. . Checkallvalvesfor free movement.lf anyfailto slidefreely,seeValveBodyRepaironpage14-139, . Coatall partswith ATF duringassembly. . The CPCvalveis installedin the secondaryvalvebody, held in placeby the lockbolt.

2.3 SHIFTVALVE

3.4 SHIFTVAL .TH EXHAUSTVALVE

LOCKBOLT CAUTION:Do not move.

SECONDARY VALVEBODY Inspectfor wear,scratches 6nd scoring. 3-'l ORIFICE CONTROLVAL

VALVE

SPRINGSPECIFICATIONS

U n i t :m m ( i n ) Standard {New)

Springs

No.

Wire Dia.

o ra, .n

3-4shift valvespring 2-3shift valvespring 4th exhaustvalvespring 3-4orificecontrolvalvespring

14-144

0.910.035) 0.9{0.035) 0.9{0.035) 0.7{0.028)

o.D. 7.6 (0.302) 7.6 (0.302) 6.1 10.2421 6.6 (0.262)

FreeLongth 57.O12.2441 57.O12.2441 36.4(1.433) 37.5(1.476)

No. of Coils 26.8 26.8 24.6

RegulatorValveBody Disassembly/lnspection/Reassembly NOTE: . cleanall partsthoroughlyin solventor carburetorcleaner,and drywith compressedair. Blowoutall passages . Replacethe valvebody as an assemblyif any partsare worn or damaged. . checkallvalvesfor free movement.lf anyfail toslidetreely,seevalve Body Repaironpage1+139. 1.

Holdthe regulatorspringcap in placewhile removingthe stop bolt. once the stop bolt is removed.releasethe spring cap slowly. CAUTION: The regulator 3pring cap can pop out when the stop boh is removod'

2.

is the reverseorderofths disassemblyprocedure. Reassembly NOTE: o Coatall partswith ATF duringassembly. . Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe springcap into the valve body,and tightenthe stop bolt.

\ STOPBOLT 6x1.0mm 12 N.m 11.2

^/^'ou*'oRsPRrNGcAP

*N@

8.7 tbf.lrl

VALVEBODY REGULATOR Inspectlor wear, scratches and scorlng.

REGULATOR VALVE

\=f

-.-*

*fi

/F cooLERRELlEFvALVr"r? ^LvE// cHEcKv roRouEcoNvERrER

{

a-tLocK.uPcoNrRoLvALVE ry

v^r* "r**::f\

vi{LvEcAp

SPRINGSPECIFICANONS

Unit:mm (in) Standard (Now)

No,

o o

@ @ @

Springe RegulatorvalvesPringA RegulatorvalvespringB Statorreactionspring Coolerreliefvalvespring Torqueconvertercheckvalvespring Lock-upcontrolvalvesPring

Wire Dia. 1.8{0.07' r) 1.8(0.071) 4.5(0.177) 1.0(0.039) 1.0(0.039) 0.7 (0.028)

o.D. 'r4.7(0.584) 9.6 (0.381) 35.4(1.407) 8.4{0.334) 8.4 {0.334} 6.6{0.262}

Free Lengrth 87.8(3.457) 44.0(1.732) 30.3(1.193) 3 3 . 8( 1 . 3 3 1 ) 33.811.3311 38.0{1.4961

No. of Coils 11.0 1.9 8.2

a.2

't4.1

14-145

Servo Body Disassembly/lnspection/Reassembly NOTEI . clean all partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Blow out all passages. . Replacethe valvebody as an assemblyif any partsare worn or damaged. . Coatall partswith ATFduringassembly. . Replacethe O-rings. . The servobody showsthe '96- 98 models:the '99 - 00 modelshavean integrallymoldedservodetent. SERVO BODY I n s p e c tf o r w e a r , s c r a t c h e sa n d s c o r i n g .

,______.g 1l

v "-------'g I

ZruO lCCUr,irUr-nrOn ---rrr___-p

O.RING Replace.

n\='l

3,ii11---------*5 1STACCUMULATOR PISTON

^rrr4 3ROACCUMULATOR PISTON

4TH ACCUMULATOR PISTON SNAPRINGS

SPRINGSPECIFICATIONS

No.

U n i t :m m ( i n ) Standard {New)

Springs Wire Dia.

o (a @)

o @

'Ist accumulatorspring 4th accumulatorspringA 4th accumulatorspringB 3rd accumulatorspringA 3rd accumulatorspringB 2nd accumulatorspringC 2nd accumulatorspringA 2nd accumulatorspring B

14-146

2.1(0.083) 2 . 6( 0 . 1 0 2 ) 2 . 3( 0 . 0 9 1 ) 2 . 8( 0 . 1 1 0 ) 2.210.0871 2.2 t0.0a7l 2.4 (0.094) '1.6(0.063)

o.D. 16.0(0.636) 17.0(0.676) 10.2lo.402J 1 7 . 5( 0 . 6 9 5 ) 31.0 11.220) 14.5(0.576) 2 9 . 0( 1 . 1 5 2 ) 9.0 (0.358)

FreeLength 89.1(3.s08) 87.0(3.425) 5 1 . 6( 2 . 0 3 1 ) 89.3(3.516) 3 5 . 1( 1 . 3 8 2 ) 68.012.677) 39.0(1.535) 20.7(0.815)

No. of Coils 14.2 13.8 '13.9

Lock-upValve BodY Disassembly/lnspection/Reassembly NOTE: with compressedair' Blow out all passages' . Cleanall pans thoroughlyin solventor carburetorcleaner'and dry a Replacethe valvebody as an assemblyif any partsare worn or d€maged' ValveBody Repaironpage14-'139' . Checkallvalvesfor free movement ttanytaitio stlaefreely'see . Coatall partswith ATF duringassembly

LOCK.UPVALVEBODY Inspectfor wear,scratches and sconng.

VALVECAP

LOCK-UPTIMINGVAL

U n i t :m m ( i n )

SPRINGSPECIFICATIONS

Lock-upshiftvalvesPrang Lock-uptiming valvesPrlng

7.6 (0.302) 8 . 1( 0 . 3 1 9 )

73.1 t2.902J ao.7 13.'1771

14-147

Mainshaft Disassembly/lnspestion/Reassembly NOTE: . Lubricateall partswith ATF during reassembly. .Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement, . Beforeinstallingthe O-rings,wrap the shaftsplineswith tapeto preventdamagingthe O_rings. . Locknuthasleft-handthreads.

LOCKNUT{FLANGENUTI 21 x 1.25mm 78 N.m (8.0 kgl.m,58 lbt.ftt Replace. Left-handthreads CONICALSPRINGWASHER Reolace.

SNAP RING

THRUST WASHER

MAINSHAFT Checksplinesfor excessive wear and oamage. Check bearingsurtacefor scoring, scratchesand excessivewear.

THRUSTWASHER

4TH GEAN

THRUST NEEDLE BEARING BEARING

BEARINGS 1ST GEAR THRUST NEEDLE BEABING

1ST GEAR COLLAR

4TH GEAR COLLAR

TRANSMISSION HOUSINGBEARING

O-RINGS Replace. THRUSTWASHER,36.5 x 55 mm Selectivepart.

THRUSTNEEDLE EEARING

Install the sealing ring mating faces as shown,

RING,

29 mm NEEDLEBEARING SETRING

14-148

O-RINGS Replace.

THRUST NEEOI.E BEARING

2ND/4TH CLUTCH ASSEMBLY

SEALINGRINGS, 35 mm

lST CLUTCH ASSEMBLY

2NO GEAB NEEDLEBEABING THRUSTNEEDLE BEARING

Inspection 3.

a ClearanceMeasurement NOTE: Lubricateall parts with ATF during assembly. 1,

Removethe mainshaftbearingfrom the transmission housing(seePage14-1741.

2.

Assembleths parts below on the mainshaft.

Torquethe mainshaftlocknutto 29 N'm (3.0kgf'm, 22 tbt,ftl. NOTE:Mainshaftlocknuthas left-handthreads.

NOTE:Do not assemblethe O-ringsduring inspectlon.

LOCKNUT

CONICAL SPRIIIGWASHER

lST CLUTCHASSEMBLY TXRUSTWASHER

SNAP RING

29 N'm t3.0 kgl'm, 22 lbt'ft) Hold 2nd gear againstthe 2nd clutch'then measure the clearancebetween 2nd gear and 3rd gear with a feelergauge.

1STGEARCOLLAR

NOTE: Take measurementsin at least three places, and use the av€rageas the actual clearance'

TRA SMISSION HOUSII{GBEARING

STANDARD:0.05- 0.13 mm 10.002- 0.005in)

THRUSTWASHER 4TI{ GEARCOLLAR 2ND/4THCLUTCH ASSEMBLY THRUSTWASHER 36.5 x 55 mm Selectivepart. THBUSTNEEDLE BEARING 2ND GEAR AEABII{G

IHRUST NEEDLE BEARING

THRUST WASHER, 36.5 x 55 mm

MAINSHAFT

(cont'd)

1+149

Mainshaft Inspection(cont'd) 5.

l f t h e c l e a r a n c ei s o u t o f t o l e r a n c e ,r e m o v e t h e thrustwasherand measurethe thickness. THRUST WASHER

6.

Selectand installa new washer,then recheck.

THRUSTWASHER36.5 x 55 mm No. 1

4

Part Number

Thickness

90441- P4P- 010

4.00mm (0.157in)

90442-P4P-010

4 . 0 5m m ( 0 . 1 5 9 in)

90443-P4P-010

4 . 1 0m m ( 0 . ' 1 6i1n )

90444-P4P-010

4 . 1 5m m ( 0 . 1 6 3 in)

90445-P4P-010

4.20mm (0.165in)

90446-P4P-010

4.25mm (0.167in)

7

90447-P4P-010

4.30mm (0.169in)

8

90448-P4P-010

4 . 3 5m m ( 0 . 1 7 1i n )

90449-P4P-010

4 . 4 0m m ( 0 . 1 7 3 in)

90450-P4P-000

4 . 4 5m m ( 0 . 1 7 5 in)

10

7 . After replacingthe thrust washer, make sure the clearanceis within tolerance.

14-150

Countershaft Disassembly/lnspection/Reassembly NOTE: . Lubricateall partswith ATF beforereassembly' gallingand rough movement' . tnrp"",,n",t -"t needlebearingsand the needlebearingsfor preventdamagingthe O-rings to tape with splines the shaft wrap . Beforeinstallingthe O-rings. . Locknuthas left-handthreads LOCKNUT(FLANGENUT} 23 x 1.25mm 103 N.m {10.5 kgf'm, 75.9 lbf'tt) Replace. L e f t ' h a n d lhreads SPRING CONTCAL WASHER Replace.

GEAR REVERSE

GEAR

CLUTCH

NEEDLEBEARING SELECTOR

1ST GEAR

SELECTOR BEARING 4TH GEAR NEEDLEBEARING

lST GEAR COLLAR

DISTANCECOLLAS, 28 mm Selective pa .

TRANSMISSION HOUSINGBEARING

2'{D GEAR

COUNYERSHAFT Check splineslor excesslve wear and damage Checkbearingsurfacefor scoring' scratchesand excessivewear'

THRUST NEEDLE BEARING 3RD GEAB

NEEDLEBEARING 3RD GEAR COLLAR THRUST NEEDLEEEARING SPLINEOWASHER 3RD CLUTCH ASSEMBLY

Replace.

1+151

Countershaft Disassembly/Reassembly 1.

Using a hydraulicpress,pressout the countershaft while supporting4th gear. NOTE:Placean attachmentbetweenthe pressand the countershaft to preventdamageto the shaft. CAUTION: Do not allow the countershaftto fall and hit the g.ound when pressedclear.

2.

Assemblethe parts on the countershaftas shown oetow. NOTE; . Lubricateall partswith ATFduringassembly. . Beforeinstallingthe O-rings,wrap the shaft splines with tapeto preventdamagingthe O_rings.

4TH GEAR NEEDLEEEARING DISTANCECOLLAR, 28 mm Selective part.

2ND GEAR THRUSTNEEOLEBEARING

3RD GEAR

NEEDI.EEEARING 3RO GEAR COLLAR THRUST NE€OLEBEARING SPLINEDWASHER 3RD CLUTCH ASSEMBLY

O.RINGS Replace.

COUNTERSHAFT

14-152

Inspection 3.

Installthe reverseselectorhub on the countershaft sub-assembly,and then pressthe reverseselector hub usingthe specialtool and a pressas shown'

Measurement r Clearance NOTE;Lubricateall partswith ATFduringassembly 1.

Removethe countershaftbearingfrom the transmissionhousing(seepage l4-174)

2.

Installthepartsbelowon the countershaftusinglhe specialtool and a pressas describedon this page NOTE:Do not assemblethe O-ringsduring inspection.

REVERSESELECTOR HUB 4TH GEAR NEEDLEBEARING DISTANCECOLLAR, 28 mm SelectavePart. 2ND GEAR THRUST NEEDLEBEARING 3RD GEAR BEARING 3RD GEAR COLLAR THBUST NEEDLEBEARING SPLINEOWASHER 3RD CLUTCH ASSEMBLY

(conl'd)

14-153

Gountershaft (cont'dl Inspection 3.

I n s t a l lt h e p a r t s b e l o w o n t h e c o u n t e r s h a fst u b a s s e m b t yt,h e n t o r q u et h e l o c k n u t o 2 9 N . m ( 3 . 0 kql.m , 22 blf.ftt .

4.

Measurethe clearancebetweenthe 2nd gear and the 28 mm distancecollarwith a feelergauge. NOTE:Takemeasurements in at leastthree places. and usethe averageas the actuarctearance.

NOTE:Countershaft locknuthas left handthreads.

STANDAFD: 0.10- 0.18mm {0.004- 0.002inl LOCKNUT Left hand threads CONICALSPRING WASHER PARKGEAR/ONE.WAY CLUTCH/1ST GEAR ASSEMBLY NEEOLE BEARING OISTANCECOLLAR,28 mm

.IST GEAR COLLAR TRANSMISSION HOUSING BEARING

(=)-----' v

REVERSE GEAR COLLAR

lf the clearanceis out of tolerance.removethe 2g mm distancecollarand measurethe width. S e l e c ta n d i n s t a l la n e w d i s t a n c ec o l l a r ,t h e n recheck. DISTANCECOLLAR,28 mm No.

Part Numb€r

widrh

1

90503-PCg-000

3 9 . 0 0m m ( 1 . 5 3 5i n )

2

90504-PCg-000

3 9 . 1 0m m { 1 . 5 3 9i n )

90505-PCg-000

3 9 . 2 0m m ( 1 . 5 4 3 in)

7.

14-154

90507-PCg-000

3 9 . 3 0m m { 1 . 5 4 7i n )

90508-PC9-000

3 9 . 0 5m m ( 1 . 5 3 7 in)

90509-PCg-000

39.15 m m ( 1 . 5 4 i1n )

7

90510-PCg-000

3 9 . 2 5m m ( 1 . 5 4 5 in)

I

90511-PCg-000

3 8 . 9 0m m ( 1 . 5 3 1i n )

90512-PCg-000

3 8 . 9 5m m ( 1 . 5 3 3 in)

Afret selectinga new distancecollar, recheckthe clearanceand makesure it is within tolerance.

One-way Clutch Disassembly/lnspection/Reassembly 1.

Separatecountershaft1st gear from the park gear by turningthe parkgear in the directionshown

3.

Inspectthe partsas followsl PARKGEAR

Inspeclthe parkgear for wear and scorrng.

lST GEAR COUNTERSHAFT

2.

Removethe one-wayclutchby prying it up with the end of a screwdriver.

1STGEAR COUNTERSHAFT

ONE-WAYCLUTCH Inspectthe one-way clutch for damageand laulty movement.

ONE-WAY CLUTCH NOTE:lnstallin this direction. lST GEAB

Inspectcountershaltlst gear for wearanclscorlng. After the partsare assembled,hold countershaft1st gear and turn the park gear in the directionshown to be sure it turns freely.Also make sure the park gear does not turn in the oppositedirection.

ONE'WAY CLUTCH COUNTERSHAFTlST GEAR

SCREWORIVER

14-155

Clutch lllustratedIndex(A4RA,B4RATransmission) 3RDCLUTCH CLUTCH DRUM

O-RINGS Beplace. CLUTCHptSTON

CLUTCHEND PLATE

SNAPRING

lST CLUTCH

CLUTCHEND

SNAPRING SPRINGRETAINER RETUNNSPRING

CLUTCHDRUM CLUTCHPLATES Standardthickness: 1.6mm (0.063in)

CHECKVALV€

14-156

2NDi4TH CLUTCH SNAPRING

CLUTCHPISTON DISCSPRING

SNAP RING

SPRINGRETAINER RETURNSPRING

CHECKVALVE O.RINGS Replace.

4TH CLUTCHDRUM CLUTCHPLATES Standardthickness:O-RINGS 2.0mm {0.079in) Replace.

SNAPRING

14-157

Clutch lllustratedIndex(M4RATransmission) 3RD CLUTCH CLUTCH DRUM CLUTCHPISTON DISCSPRING

CLUTCIIEND

rST CLUTCH CLUTCHE D

SI{AP RIiIG

CLUTCHPLATES Standardthickness: 1.6mm (0.063in)

CHECKVALVE

14-158

SNAPRING

2ND/4THCLUTCH

CLUTCH PISTON

VALVE

2.0mm (0.079in)

2ND CLUTCH

DRUM CLUTCHPISTON RETURNSPRING RETURNSPRING

\l-.

SNAPRING

14-159

Clutch Disassembly 1 . Removethe snap ring. then removethe clutchend plate,clutchdiscsand plates.

3.

Installthespecialtools as shown. CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE-PX40,t 00

SCREWDRIVER

SNAP RING

2.

Removethe discspring. NOTE:Except2nd clutch.

DISC SPRING

CLUTCH COMPRESSOR AOLTASSEMBLY 07GAE- PG4tt200

CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX()100 o1 07HAE- P150100

ol

O'GAE - FG4O2OA

CLUTCH SPRING COMPRESSOR ATTACIIMENT oTLAE-PX40100

1

CLUTCI{ DRUM

CLUTCH COMPRESSOR BOLTASSEMBLY 07GAE - PG/O200 OTGAE- PG4O2OA

14-160

CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- Px/Ol00 ot 07HAE- PLs0100

CAUTION: lf eithd end of the 3pocialtool issotoveran area ot the spring rstainer which is unsupport€d by tho return spring, tho r€tain€l may be damagod. Bo eure the special tool is adiusted to have full contact with tha spring retainor.

5.

Removethe snap ring. Then removethe specialtools, spring retainerand returnspring.

Do not sat horo.

SPRINGRETAIItIER

Wrap a shop rag aroundthe clutchdrum, and apply air pressureto the ATF passageto remove the pisron. Placea finger tip on the other end while applying air pressure. OSHA.APPROVED SPRINGRETAINER

4.

Compfessthe returnsprang.

PISTON

14-161

Clutch Reassembly NOTE: . C l e a na l l p a r t st h o r o u g h liyn s o l v e not r c a r b u r e t o r cleaner,and dry them with compressedair. Blow out all passages. a Lubricateall partswith ATF beforereassembly. 1 . Inspectthe checkvalve;if it's loose,replacethe pisto n.

3.

Installthe pistonin the clutchdrum, Apply pressure and rotateto ensureproperseating, NOTE:Lubricatethe pistonO-ringwith ATF before installing. CAUTION: Do not pinch the O-ring by insta ing the piston with too much force. CLUTCIIDRUM

CHECKVALVE

2.

Installnew O-ringson the clutchpiston. I n s t a l lt h e r e t u r ns p r i n g a n d s p r i n g r e t a i n e r a , nd positionthe snap ring on the retainer.

O RINGS

CLUTCI{DRUM

PISTON

14-162

5.

CAUTION:lf eithe. end of the sDecialtool is set over an area of the spring retainer which is unsupported by the rsturn spring, the ietainer may be damaged. Bs sure the specialtool is adjusted to have full contact with the spring retainer.

Installthe specialtools as shown. CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40100

SPRING

CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40100 or 07HAE- P150100

Sot hsro.

Do not sot hore.

SPECIAL TOOL

CLUTCH SPRING COMPRESSOR ATTACHMENT 07LAE-PX40100

RETAINER

6.

Compressthe returnspring.

CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX4010o CLUTCHSPRING COMPRESSOR BOLTASSEMBLY 07GAE- PG40200

07HAE- PL50100

O7GAE. PG4O2OA (cont'd)

14-163

Glutch (cont'd) Reassembly 7.

Installthe s n a pr i n g .

1 0 . Soakthe clutchdiscsthoroughlyin ATF for a minimum of 30 minutes. l l . Startingwith a clutch plate, alternatelyinstall the

clutch platesand discs.Installthe clutch end plate with flat side toward the disc. NOTE:Beforeinstallingthe platesand discs,make sure the insideof the clutchdrum is free of din or other foreign mafter.

CLUTCHENDPLATE Installin this direcrion.

SNAP RING

8.

Removsthe specialtools.

o

Installthe discspring. NOTE: Installthe disc spring in the direction shown, except 2nd clutch.

12. Installthesnap ring.

SCREWDRIVER

SNAP RING

14-164

13. Measurethe clearancebetweenthe clutchend plate and top discwith a dial indicator'Zero the dial indicatorwith the clutchend plateloweredand lift it up to the snap ring. The distancethat the clutch end platemovesis the clearancebetweenthe clutchend plateand top disc. in at leastthree places, NOTE|Takemeasurements and usethe averageas the actualclearance. Clutch End Plste-to-TopDisc Clearance: SerYiceLimit

Clutch 0.650.650.400.40-

1st 2nd 3rd 4th

0.85mm (0.0260.85mm (0.0260.60mm (0.0160.60mm (0.016-

0.033in) 0.033in) 0.024in) 0.024in)

OIAL INDICATOR

CLUTCHEND PLATE A4RA, g4RA Transmission: Plate No. ,l 2 J

4 5 6 1 8 q

Plate No.

3

'l

.' q

10 11 't2 Clearance

13 14 15 '16

CLUTCHDISC

17 18

1 4 . l f t h e c l e a r a n c ei s n o t w i t h i n t h e s e r v i c el i m i t s , select a new clutch end plate from the following table.

22551- P4R- 003 22552-P4R-003 22553-P4R-003 22554-P4R-003 22555-P4R-003 22556-P4R-003 22557-P4B-OO3 22558-P4R-003 22559-P4R-003

Thickness in) 2 . 1m m ( 0 . 0 8 3 2.2 mm (0.087in) 2 . 3m m ( 0 . 0 9 1i n ) 2.4 mm (0.094in) 2.5 mm (0.098in) 2 . 6m m ( 0 . 1 0 2i n ) 2 . 7m m { 0 . 1 0 6i n ) 2 . 8m m { 0 . 1 1 0i n ) '14 2 , 9m m ( 0 . 1 i n )

M,IRATransmi$ion:

1

CLUTCHEND PLATE

Part Number

Part Number 22551- PCg- 000 22552-PCg-000 22553-PCg-000 22554-PCg-000 22555-PCg-000 22555-PCg-000 22557-PCg-000 22558-PCg-000 22559-PCg-000 22560-PCg-000 22561- PCg- 000 22562-PCg-000 22563-PCg-000 22574- P4V- 003 22561- P4V- 003 22562- P4V- 003 22563-P4V-003 22564-P4V-003

Thickness 2.4 mm (0.094in) 2.5 mm (0.098in) 2 . 6m m { 0 . 1 0 2i n ) in) 2 . 7m m ( 0 . 1 0 6 2 . 8m m ( 0 . 1 1 0i n ) 2 . 9m m ( 0 . 1 1 4i n ) 3 . 0m m { 0 . 1 1 8i n ) in) 3 . 1m m ( 0 . 1 2 2 in) 3 . 2m m ( 0 . 1 2 6 3 . 3m m ( 0 . 1 3 0i n ) 2 . 1m m ( 0 . 0 8 2i n ) 2.2 mm {0.086in) 2.3 mm (0.090in) in) 3 . 4m m ( 0 . 1 3 4 3 . 5m m ( 0 . 1 3 8i n ) 3 . 6m m ( 0 . 1 4 2i n ) in) 3 . 7m m ( 0 . 1 4 6 in) 3 . 8m m ( 0 . 1 5 0

15. After replacingthe clutchend plate.make sure that the clearanceis within tolerance.

NOTE: lf the thickestclutch end plate is installed, but the clearanceis still over the standard,replace the clutchdiscsand clutchplates. PLATENUMBER

Thickn6ss

CLUTCHENO PLATE

14-165

Differential lllustratedlndex

SET RING, 80 mrrt

efef

BOLT 1 0 r 1 . 0m m '10'l N'm (10.3 k91.m,74.5 lbf.ftl Left-hand threads

FINALDRIVENGEAR Inspecttor excessivewear. Installin this direction.

BALL BEARING Inspectfor faulty movement.

DIFFERENTIALCARRIER Insoectfor cracks,

ROLLER,5x10mm ORIVE SPEEDOMETER GEAR lnstallin this direction.

SNAP RING Installin this direction.

EALL BEARING Inspectfor faulty movement-

14-166

Backlashlnspection 1.

Placedifferentialassemblyon V-blocksand install both axles.

BearingReplacement NOTE: Checkbearingsfor wear and rough rotation.lf bearingsare OK, removalis not necessary. 1,

Removebearingsusinga bearingpuller. BEARINGPULLER (Commerci6lly available)

Checkbacklashof both piniongears Standard {Now): 0.05- 0.15 mm {0.002- 0.006in) lf backlashis out of tolerance,replacethe differential carrier.

2.

Installnew bearingsusingthe specialtoolas shown.

14-167

Differential DifferentialCarrierReplacement L

Removethe final driven gear from the differential carrier.

5.

NOTE: The final driven gear bolts have left-hand threads.

Align the hookedend of the snap ring with the pinion shaft as shown,then installthe snap ring in the differentialcarrier groovs. Hookedend

SNAPRING Installin this Install thisdireclon. direction.

Pry the snap ring off differentialcarrier,then remove the speedometer drivegearand 5 x 10 mm roller.

SNAP RING

SPNI G PIN

Installthe final drivengear,then tightenthe boltsto the specifiedtorque. TOROUE:101 N.m (10.3kgf'm, 74.5 lbf.ftl NOTE: The final driven gear bolts have left-hand threads. 3.

Installthe 5 x l0 mm rollerin the differentialcarrier, BOLTS 1 0 r 1 . Om m 1Ol t{.m 11O.3kgf.m, 74.5 lbl.frl Left-hand rhreads

FINALDRIVEN GEAR lnstallin this direction.

DIFFERENTIAL CARRIER

Installthe speedometerdrive gear with its chamfered side facingthe carrier.Align the cutouton the bore of the speedometerdrive gear with the 5 x 10 mm roller.

14-168,

7.

Install a new ball bearing (se€ page 14-157).

Glearance Oil SealInstallation/Side

OilSealRemoval

1.

1.

Remov€the differentialassembly.

2,

Removethe oil sealfrom the transmissionhousing,

Installa 2.50mm (0.098in) set ring,80 mm in transmissionhousing. NOTE:Do not installthe oil sealvet.

RING,80 mm TRAITISMISSlON HOUS|l{G

OIL SEAL Roplace.

R e m o v et h e o i l s e a l f r o m t h s t o r q u e c o n v e r t e r housing.

OIL SEAL Replace.

TOROUECONVERTEF HOUSING

Installthe differentialassemblyinto the torqueconverterhousingusingthe specialtoolas shown.

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 ga n d t i g h t e nt h e bolts{seepage 14-178and 14-179).

{cont'd)

14-169

Differential (cont'd) Oil SealInstallation/Side Clearance 4.

Tap on the transmissionhousingside of the differentialassemblywith the specialtool to seatthe differentialassemblyin the torqueconverterhousing.

5.

N4easure the clearancebetweenthe 80 mm set ring and outer race of the ball bearinoin the transmiss i o nh o u s i n g . STANDARD: 0 - 0.15mm (0 - 0.006inl

DRIVER40 mm l.D. SET RING,80 mm BALL BEARING

lf the clearanceis more than the standard,selecta new set ring from the table,and install: SETRING,80 mm Part Number 90414-689-000 904r5-689-000 90416-689-000 90417-689-000 90418-689-000 904r9-PH8-000

Thickness 2.50mm (0.098in) 2 . 6 0m m { 0 . 1 0 2i n ) 2 . 7 0m m { 0 . 1 0 6i n ) 2 . 8 0m m ( 0 . 1 1 0i n ) 2 . 9 0m m ( 0 . 1 1 4i n ) 3 . 0 0m m ( 0 . 1 1 8i n )

NOTE:lf the clearancemeasuredin step 5 is standard, it is not necessaryto perform steps 7 and 8. 7.

Removethe transmissionhousing. Replacethe 2.50mm (0.098in) 80 mm set ring with the one of the correctthicknessselectedin step6.

14-170

9. lnstallthe new oil seal flush with the transmission housjngusing the specialtools as shown DRIVER 077i(} - 0010000

PILOT. 26x30mm 07JAO- PH80200

DRIVERATTACHMENT,68 mm 079i17-6110501

10. lnstall the new oil seal flush with the torque converterhousingusingthe specialtoolsas shown

DRIVER 07749- 0010000

14-171

TorqueConverterHousingBearings MainshaftBearing/OilSealReplacement 1.

Removethe mainshaftbearingand oil seal using the specialtools as shown.

2.

Drive in the new mainshaft bearing until it bottoms in the housingusingthe specialtools as shown.

DRIVER 077€ - 0010000

3/8"16 SLIOE HAMMER

ADJUSTAELEBEARING PULLER,25 - ilo mm 07736- A01000a

lnstallthe new oil sealflush with the housingusing the specialtools as shown.

DBIVER 07749 - 0o l0(xt0

ATTACHMENT, 72x75 mfi 07746- 0010600

1 4-1 7 2

CountershaftBearingReplacement '1. Removethe countershaftbearingusing the special tools as snown.

3,/8'.16SLIDEHAMMER {Commerciallv available)

AOJUSTABLE BEARING PULLER, 25-{Omm 07736- A0'1000A

2. 5.

Installthe ATF guide plate. Drive the new bearing into the housing using the specialtools as shown.

ATTACHMENT, 62x68mm

0 - 0.03 mm (0 - 0.001inl

14-173

TransmissionHousingBearings Mainshaft/Countershaft BearingsReplacement L

To removethe mainshaftand countershaftbearings from the transmissionhousing,expand each snap ring with snap ring pliers,then pushthe bearingout usingthe specialtools and a pressas shown.

Expandeach snap ring with snap ring pliers,insert t h e n e w b e a r i n gp a r t - w a yi n t o t h e h o u s i n gu s i n g the specialtools and a press as shown, Installthe bearingwith the groovefacingoutsidethe housing.

N O T E : D o n o t r e m o v et h e s n a p r i n g s u n l e s si t ' s necessary to cleanthe groovesin the housing.

NOTE:Coatall partswith ATF. Releasethe pliers,then push the bearingdown into the housinguntil the ring snapsin placearoundit.

PRESS

07749- 0010000

\ DRIVER 07749- 0010000

ATTACHMENT, 62x68mm 07746-

IRN {L{r.)n \bZ

MAINSHAFTBEARING DFIVEB 07749- 0010000 TTACHMENT

ATTACHMENT . Mainshaft Bearing Removaluse: ATTACHMENT,72 x 75 mm 077/16- 0010600 . Counte6haft Bsaring Removaluse: ATTACHMENT,62 x 68 mm 07746- 0010500 After installingthe bearingverifythe following: . .

The snap ring is seatedin the bearingand housing grooves. The ring end gap is correct.

ENDGAP:0-7mm

(0- 0.28in)

ATTACHMENT . Mainshaft BearingInstallation us€: ATTACHMENT.72 x 75 mm 07746- 0010600 . Countershaft Bearing Installation use: ATTACHMENT,62 x 68 mm 077/16- 0010500

14-174

SNAP RING

Park Stop

Reverseldler Gear

Inspection/Adiustment

lnstallation 1,

'1.

lnstallthe reverseidler gear.

Setthe parkleverin the E position. Measure the distance between the park pawl shaft and the parkleverrollerpin as ahown. STANDARD:72.9- 73.9 mm 12.87- 2.91 inl

/A\ Measuring \v

Installthe reverseidler gear shaftholderand needle bearinginto the transmissionhousing,then tighten the bolts. 6 x 1.0 mm 12 N.m ll .2 kgf'm, 8.7 tbf.ftl

PARKPAWL SHAFT

lf the measurementis out of tolerance,selectand i n s t a l lt h e a p p r o p r i a t ep a r k s t o p f r o m t h e t a b l e Delow. PARKSTOP

PARKSTOP Mark I

GEAR

Part Numb€r

Lr

12

2 4 5 3 7 - P A g - 0 0 3 1 1 . 0 0m m (0.433in)

11.0m 0 m (0.433 in)

2 4 5 3 8 - P A g - 0 0 3 1 0 . 8 0m m (0.425in)

10.65mm (0.419 in)

2 4 5 3 9 - P A g - 0 0 3 1 0 . 6 0m m (0.417 in)

1 0 . 3 0m m (0.406in)

After replacingthe park stop, make sure the distanceis within tolerance.

14-175

Transmission Reasembly NOTE; . Coat all parts with ATF. . Beplacethe followingparts: - O-rings - Lockwashers - Gaskets - Mainshaftand countershaftlocknutsand conical springwashers - Sealingwashers TOROUE:l2 N.m (1.2 ksf'm,8.7 lbf.ft) 6 x 'l.0 mm 7 Bolts

LOCK.UPVALVE BODY LOCK.UPSEPARATOR PLATE

FEEDPIPE:A

DOWELPINS.2 6xl.0mm 1 Bolt

ATF STRAINER

ATFFEED PIPES:

a REGULATOR VALVE BODY DOWELPINS. 6x1.0mm 7 Bolts

COOIERRELIEFVALVE

SERVOBODY TOROUECONVENIER CHECKVALVE STATORSHAFT

SERVOSEPARATOR PLAYE

O.RING STOPSHAFT ATF FEEOPIPE:H 5x1.0mm 5 Bolts MAIN VALVEBODY ATF PUMP GEARSHAFT

SECONOARY SEPARATORPLATE

ATF PUMPDFIVEN GEAR MAIN SEPARATOR PLATE

'

DOWELPINS,

TOROUECONVERTER HOUSING

/

-

CONTROL SHAFI

t'se- oo^od"t"t

7r(

lli tri

NOTE:The illustrationshows the'96 - 98 modsls,the'99 - 00 modelsdo not havethe servo detentbase;the servo detentis integralwiththe servobodv.

1 4-1 7 6

1 . Installthe ATF magnetand suctionpipe collarin the torqueconverterhousing.if necessary. lnstallthe main seDaratorplate and the two dowel pins on the torqueconverterhousang. Installthe ATF pump drive gear,ATF pump driven gear and ATF pump driven gear shafton the torque converter housing. NOTE; Install the ATF pump driven gear with its groovedand chamferedsidetacingdown. ATFPUMP

a

For '96 - 98 models: Installthe servo detent base and the ATF strainer(two boltsl. For'99 - 00 models: Installthe ATF strainer (one bolt).

1 0 . Tightenthe five bolts on the main valve body to 12 N.m ('1.2kgf.m,8.7lbf.ft). Makesure the ATF pump drive gear and ATF pump drivengearshaft move smoothlY' 1 1 . lf the ATF pump drive gsar and ATF pump driven gear shaft do not move freely, loosen ths five bolts the valve on the main valve body, and disassemble bodies. Realignthe ATF pump driven gear shaft and reassemble the valve bodies,then retighten the bolts to the specifiedtorque,

ATF PUMPDRIVEN GEARSHAFT ATF PUMP DRIVENGEAR Groovedand chamfered side taces separalor plate.

4.

Installthe servo body and separatorplate on the secondaryvalve body ('95 - 98 models: seven bolts. '99 - 00 models:eight boltsl.

MAIN SEPARATOR PLATE

CAUTION: Fsilule to align tho ATF pump driven goar shaft corr.ctly will rscuh in a s€izedATF pump drive goar or ATF pump d ven gear shaft.

Loosely install the main valve body with five bolts. Make sure the ATF pump drive gear rotatessmoothly in the normal operating direction and the ATF pump driven gear shaft moves smoothly in the axial and normaloperatingdirections. Install the secondaryvalve body, separatorplate and two dowel pinson the main valvebody. NOTE:Do not installthebolts.

6. 7.

Installthe controlshaft in the housingwith the control shaftand manualvalvetogether. lnstall the detent arm and arm shaft in the main valve body, then hook the detentarm springto the detent arm, PLATE SERVOSEPARATOR

PUMP

1 2 . Installthe stator shaft and stop shaft.

't3. Installthe bolts and the shaftstop on the secondary valve body, then tighten the bolts (three boltsl.

DETENTARM SPRING DETENT

MANUAL VALVE

1 4 . Installthe torqueconvertercheckvalve,coolerrelief valveand valvespringsin the regulatorvalve body. then install the regulatorvalve body on the main valve bodv (one bolt). 1 5 . Installthe lock-upvalve body on the regulatorvalve bodv (sevenbolts). Installthe ATF feed pipes in the main valve bodY, the threeATF feed pipesin the secondaryvalveand the four ATFfeed pipesin the servobody. (cont'dl

14-177

Transmission (cont'd) Reassembly

TRANSMISSION HANGER

*''

TRANSMISSIONHOUSING MOUNTINGBOLTS 10 x 1.25mm 4{ N.m {4.5 kg{.m,33 lbI.ft)

Ufln

MAINSHAFT SUB.ASSEMBLY

TRANSMISSION HOUSING

REVERSE GEAR COLLAR

$*U./

REVERSE GEAR

_\,]ffil

MAINSHAFTSPEED SENSOR WASHER (D16Y7engine)

LOCKWASHER SHIFTFORK

COUNTERSHAFT SUB.ASSEMBLY

MAINSHAFT

SPEED OIFFER€NTIAL ASSEMBLY

TRANSMISSION HOUSINGGASKET TOROUECONVERTER HOUSING

14-178

1 7 . l n s t a l lt h e r e v e r s ei d l e r g e a r a n d t h e g e a r s h a f t h o l d e r( s e ep a g e1 4 - 1 7 5 ) .

reversegear 2 1 . lnstallthe needlebearing,countershaft and reversegearcollaron the countershaft.

1 8 . lnstallthe differentialassemblyin the torque converterhousing.

22. Align the spring pin on the control shaft with the

1 9 . A s s e m b l et h e m a i n s h a f ts u b - a s s e m b l ya n d t h e c o u n t e r s h a fst u b - a s s e m b l yt ,h e n i n s t a l lt h e m togetherin the torqueconverterhouslng

transmissionhousinggrooveby turningthe control shaft. SPRINGPIN CONTROLSHAFT

MAINSHAFT SUB-ASSEMBLY COUNTERSHAFT SUB.ASSEMBLY

Installthe two dowel pins and a new gasketon the torqueconverterhousing. 24. Placethe transmissionhousingon the torque converterhousing.

20, Turn the shift fork so the large chamferedhole is tacing the fork bolt hole, then install the shift fork with the reverseselector,and tighten the lock bolt' Bendthe locktab againstthe bolt head

SHIFTFORK LOCKWASHER Replace.

CAUTION: Make sure that lhe mainshaft speed sensor is not installed on the transmission housing before installing the transmission housing on the torque conv€rter housing. l 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 gm o u n t i n g b o l t s a l o n g w i t h t h e t r a n s m i s s i o nh a n g e r ,t h e n t i g h t e n the bolts in two or more steps in the sequenceas shown. TOROUE:,l,t N'm l{.5 kgf'm, 33 lbf'ft} TRANSMISSION HANGER

6 x 1.0mm 4 N.m ('l.4 kgl'm, 1O lbt'ft)

Large chamtered hole

o (cont'di

14-179

Transmission (cont'dl Reassembly 26. Slipthe specialtool onto the mainshaftas shown, MAINSHAFTHOLDER 07GAB- PF50101

3 1 . I n s t a l lt h e m a i n s h a f t1 s t g e a r c o l l a ro n t h e m a i n _ shaft. 32. Wrap the shaft splineswith tape to preventthe Orings,then installnew O-ringson the mainshaft, 33. Assemblethe thrust washer,thrust needlebearing, needle bearing,and mainshaft?st gear in the lst clutchassembly,then installthem on the mainshaft. 34. Installnew conicalspring washersand locknutson eachshaft.

27. Installtheparkleveron the controlshaft. 28. A s s e m b l et h e o n e - w a yc l u t c h a n d t h e p a r k g e a r with the countershaftlst gear(seepage l4-1S5).

CAUTION: Install the conical spring washers in the direction shown. MAINSHAFT LOCKNUT Left handthreads

29. Installthe countershaftlst gear collar.needlebear_ ing, and the countershaft1stgearlparkgear assembly on the countershaft. lSTCLUTCH ASSEMBLY

PARK GEAR

CONICAL SPRING WASHERS installin thisdirection. 35. Tightenthe locknutsto the specifiedtorque.

30. Installthe park pawl shaft, spring, pawl, and pawl stop on the transmissionhousing,then engagethe parkpawlwith the parkgear.

NOTE: . D o n o t u s e a n i m p a c t w r e n c h .A l w a v s u s e a torque w.ench to tighten the locknut. . Mainshaftand countershaftlocknuts have left_ handthreads. TOROUE: MAINSHAFT 78 N.m (8.0 kgf.m, 58 tbf.ft) COUNTERSHAFTt03 N.m 1r0.5kgf.m, 75.9 tbt.ftl

14-180

36. Removethe specialtool from mainshaft,then stake eachlocknutusinga 3.5 mm punchas shown'

40. Instslltheend coverwith two dowel pinsandanew gasket(thirteen bolts)' TOROUE:12 N'm (1.2tgf'm. 8.7 lbf'ft}

COUNTERSHAFT LOCKNUT

0.7- 1.2mm (0.03- 0.05 in)

ENDCOVER a'f

Set the park lever in the El position, then verify that the park Pawl engagesthe Parkgear

38. lf the Dawl does not engagefully, checkthe park ao

4 1 . lnstall the ATF cooler lines with new sealing wash9rs.

pawl stop clearance(see page 14-175).

TOROUE:28 N.m {2.9 kgf'm. 21 lbt'ft1

Tighten the lock boll and bend the lock tab'

Installthe ATF diPstick.

Erl.Omm

14 t{.m (1.4 kgf'm, 10 tbl.ftl

\.-

(o)

LOCK WASHEF

14-181

Torque Converter/Driveplate

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

74 N.m 17.5 kgl.m, 54 lbf.ftl Torque in a ctisscaossoattern.

@ @ /

E PLATE

14-182

Transmission lnstallation 1.

Flushthe ATF cooler as describedon page l4-187 and 14-188.

Installthe transmissionmount bracket.

6.

12 x 1.25mm 6il N.m {6.5 kgf.m, a7 lbf'ft)

Install the torque converter assembly securely with a new O-ringon the mainshaft 45 N.m {4.5 kgf.m,

MOTOR STARTER 14 mm DOWELPIN

TOROUE CONVERTER

O-RING Replace

PIN lil mm DOWEL

lnstall the starter motor on the torque converter housing,then installthe two 14 mm dowsl pins in the torqueconverterhousing. Placethe transmissionon a jack,and raiseit to the engineassemblylevel. Attach the transmissionto the engine,then install two transmissionhousingmounting bolts and two rearenginemountingbolts. REARENGINE BOLTS MOUNNNG 1,1r15mm TRANSMISSIONHOUSING MOUNTINGBOLTS 12x 1.25mm 47 tbf frl 64 N.m {6.5

12 x 1.25mm 74 N.m (7.5 kgf.m, 54 tbt.fr)

TRANSMISSIONMOUNT

Installthe remainingtransmissionhousing mounting boltsand remainingrearenginemountingbolt.

7.

REARENGINE MOUNTINGBOLT 14 x 1.5mm el N.m (8.5 kgt'm, 61 tbl.ft) Replace.

&| N.m 18.5kgf m, 61 lbf'ft] Replace. WASHER

HOUSING MOUNTINGBOLTS 12 x 1.25mm g N m (6.5kgf m, 'l? lblftl

ENGINE MOUNTING BRACKET 8.

Remove the transmission jack. (cont'd)

JACK

14-183

Transmission Installation(cont'dl 9. Attach the torque converter to the drive plate with eight drive plateboltsand torqueas follows: Rotatethe crankshaftpulleyas necessaryto tighten the bolts to 1/2 of the specified torque. then to the final torque, in a crisscrosspattern. After tighteningthe last bolt, checkthat the crankshaft rotatesfreely.

14. Installthe control lever with a new lock washerto the controlshaft,then installthe shift cablecover. CAUION: Taks care not to bend the shift cable. SHIFTCABLE

TOROUE:12 N.m {1.2 kgl.m, 8.7 tbt{r} 10x 1.25mm 4,r N.m 14.5kgf.m,33 lbtft)

L(rcK WASHER Replace.

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

8 x 1,25r'|m

22N-m 12.2tgt m. 16lbnftl SHIFT CAAE COVER

x 1.0mm

tit N.m11.4kgtm, 10tbr,ft,

I \ 1.25mm 2/t N.m {2.4kg{.m, 17 tbt ftl

CONVERTEB COVER

10. Installthe torque convener cover and the €ngine stiffener. '11. Tighten the crsnkshaft pull€y bolt, if necessary(see section61. 12. Connectthe ATF cooler hosesto the ATF cooler lines (seepage1,t192).

15. lnstallthe exhaustpipeA. NOTE: D16Y8engine is shown; D16y/ engine is sim_ ilar.

ATF COOIIR UNE

Replace.

10 x 1.25mm a,l N.m {4.5kgl.m, 33 rbt.ftt RIGHTFRONT 12 x 1.25mm MOUNT/BRACKET6.t N.m (6.5kg{.m, 47 tbt ftl

13. Installthe rightfront mounvbracket.

14-1A4

GASKET Replace. SELF.LOCKING NUT Replace. 8 x 1.25mm 22 N.m {2.2 kgl.m, 16lbtfrl

SELF.LOCKING NUT Replace. 10 x 1.25mm 54 N.m (5.5 lgf.m, 40 tbt ftl NUT Replace. 8 x 1.25mm 16 N.m {1.6kgI.m, 12 tbf.ft)

16. Installa new set ring on the end of eachdriveshaft' 17. Installtheright and left driveshafts(seessction16) CAUTION: Whil6 installing the driveshafE in the diffarential, be surs not lo allow du3t and othor foreign particl€s to enler into the transmission. NOTE: . Cleanthe areaswhere the driveshaftscontactthe transmission(differential)thoroughly with solvent or carburetorcleaner,and dry with compressedair. . Turn the right and left steeringknucklefully outward, and slide each driveshaft into the differential until you feel its set ring clip engagethe side gear. 18. Installthe damperfork,then installthe rightand left ball jointsto the eachlower arm with the castlenuts and new cotter Plns.

20. Connectthe mainshaftspeedsensor,the linearsolenoid and the shift controlsolenoidconnectors.

SOLENOIO SHIFTCONTROL CONNECTOR

LINEAR SOITNO|o CONNECTOR 6 r 1.0mrn 12 N.m (1.219f.m, E.7lbf.frl

DAMPERPINCHBOLT 10 x 1.25 mm a3 N.m l4.iakgf.m, 32 tbl.ftl CONNECTOR

21. Connectthe countershaftspeed sensor and the vehicle speedsensor (VSS)connectors. SPEED VEHICI..E CONNECTOR SENSOR 4l NUT SELF.LOCKING 12 x 1.25mm 6il N.m t6.5 kgf'm, il7 lbf ftl Replace.

COTTER

CASTLENUT Replace. 12 x 1,25mm 49 59 N.m {5.0- 6.0 kgf m, 36 - iB lbf'ft|

19. Install the splash shield.

COUNTERSHAFT SPEEDSENSOR CONNECTOR

(cont'dl

14-185

Transmission Installation{cont'd) Connectthe lock-upcontrolsolenoidconnector.and installthe transmissiongroundcable.

24. Installtheintakeair duct. D16Y7engine: Installthe intakeair duct and the resonaror.

6 x '1.0mm 12N.m{1.2kgf.m,8.7lbl.ft}

D16Y8engine: lnstallthe intakeair duct and the air cleanerhous_ angassembly. 25. Refillthe transmissionwith ATF (seepage 14_1.18). 26. Connectthe positive(+) cable first. then the negative (-) cable to the battery. 27. Checkthe ignitiontiming (seesection23). 28. Startthe engine.Setthe parkingbrake,and shift the transmissionthrough all gears.three times. Check the shift cableadjustment(seepage14_190).

TRANSMISSION GROUNDCABLE

LOCK.UPCONTROL SOLENOIDCONNECTOR

Connectthe stanercableson the stanermotor.and installthe cableholder. NOTE; When installingthe starter cable terminal. makesurethat the crimpedside of the ring terminal is facingout (seesection23).

6x1.0mm 12 N.m 11.2kg{.m.8.7tbtftl {0.9kg'f.m,7 lbf.ftl

STARTERCAELE

14-186

29, Checkthe front wheelalignment(seesection1g). 3 0 . L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e cooling fan comes on) with the transmissionin N or @ position,then turn it off and checkthe fluid level(seepage 14- 7). 31. Roadtest as describedon pages14-113thru ,14_116.

CoolerFlushing To prevent iniury to.face and eyas, always !!!@ glasses ot a face shield when using the safetv -ea. transmissionflusher.

7. With the water and air valvesoff, attachthe water and to the flusher'lHotwaterif available.) air suDolies

NOTE:This procedureshouldbe performedbeforereinstallingthe transmission. 1.

Checkthe tool and hosesfor wear and cracksbefore using.lf wear or cracksare found,replacethe hoses beforeusing. Usingthe measuringcup,fill the tankwith 2'l ounces (approximately2/3 full) of biodegradableflushing fluid (J35944- 20).Do not substitutewith any other f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d contarner. the tank Securethe flusherfiller cap, and pressurize (5 6 kpa 829 550 between with compressedair to 120Psi). 80 8.45kgflcm' .

8, Turn on the flusherwater valve so water will flow throughthe coolerfor 10 seconds.

NOTE:The air line shouldbe equippedwith a water trap to ensurea dry air system.

NOTE;lf water does not tlow throughthe cooler,it is completelyplugged.cannotbe flushed,and must be replaced.

Hangthe tool underthe vehicle. Attach the tank's dischargehose to the return line of the transmissioncoolerusinga clamp. Connectthe drain hoseto the inlet line on the transmissioncoolerusinga clamP IMPORTANT: Securelyclampthe oppositeend oJthe drain hoseto a bucketor floor drain. TRANSMtssroN

I

9. Depressthe trigger to mix the flushing fluid into the water flow. Usethe wire clip to hold the trigger down'

1 0 . While flushingwith the water and flushingfluid for two minutes,turn the air valve on for five seconds everv 15- 20 secondsto createa surgingaction' MAX 845 kpa{8.45kgf/cm' ,120psi) AIR PRESSURE: ' 1 1 .Turn the water valve off. Releasethe trigger,then reversethe hosesto the coolerso you can flush in the oppositedirection.Repeatsteps8 through 10' 12, Releasethe trigger,and rinsethe coolerwith water onlv for one minute 13. Turn the water valveoff, 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: Residualmobturo in tho cooler or pipas can damagethe transmksion'

{r Water TRANSMISSIONCOOLER FLUSHER {Commcrci.llYavail.blel Kent-MooreJ384O5'A or equivelent

15. Removethe flusherfrom the coolerline.Attachthe drain hoseto a contalner. 16. Installthe transmission,and leavethe drain hose attachedto the coolerline {cont'd)

14-187

Transmission CoolerFlushing(cont'dl 1 7 . Makesurethe transmissionis in the E position. Fill the transmissionwith ATF, and run the engine for 30 secondsor until approximately0.95f (1.0US qt.,0.8lmp qt.) is discharged.

TOOL MAINTENANCE 1.

1 8 . Removethe drain hose, and reconnectthe cooler returnhoseto the transmission(seepage l4-192).

Empty and rinseafter each use.Fill the can with water and pressurizethe can. Flushthe dischargeline to ensurethat the unit is clean.

2.

1 9 . Refillthe transmissionwith ATF to the oroDerlevel (seepage 14-118).

lf dischargeliquiddoes not foam,the orificemay be blocked.

3.

To clean,disconnectthe plumbingfrom the tank at the largecouplingnut.

FILLERCAP

ORIFICE GRT{G

Removethe in-line filter from the dischargeside and clean if necessary. The fluid orifice is tocatedbehind the filter. Clean it with the pick stored in the bottom of the t a n k h a n d l e ,o r b l o w i t c l e a n w i t h a i r . S e c u r e l v reassembleall Darts.

14-18A

Shift Cable Removal/lnstallation !@@ seqtion1).

Make sure lifts are placed properly (see

1.

Removethe front console(seesection20).

2.

Shift to E position,then removethe lock pin Jrom the adjuster.

4.

Removethe shift cableholder.

5.

Bemovethe shift cablecover.

6.

Removethe control Iever from the control shaft, then remove the shift cable. Take care not to bend it the cablewhen removing/installing I x '1.25mm 22 N.m 12.2kgl'm. 16 tbl.ftl

SHIFTCABLEHOLDER SHIFTCABLE

LOCKWASHER Replace. CONTBOLLEVER

7.

SHIFTCABI.f 7 N.m (07kst'm,5lbl'ftl

3,

6x1.0mm 12 N.m ('1.2ksf.m, 8.7 rbtftl

6 x 'l.0mm 14 N.m (!.il kgt.m. 10lbl.ftl

lnstall the shift cable in the reverseorder of removal' C h e c kt h e c a b l e a d j u s t m e n to n r e a s s e m b l y( s e e page 14-190).

Remove the shift cable bracket.

SHIFTCABLE BRACKET

6x1.0mm 9.8 N.m {1.0kgf m, 7.2

14-189

Shift Cable Adjustment @ section1).

Make sure lifts are ptaced properly (see

1.

Removethe front console(seesectionZ0l.

2.

Shift to @ position.then removethe lock pin from the adiuster.

3 . C h e c kt h a t t h e h o l e i n t h e a d j u s t e r i s p e r f e c t l y alignedwith the hole in the shift cable.There are two holes in the adjuster.They are positioned90. apart to allow cable adjustmentin 1/4 turn increments.

Cable Too Short

Cable Too Long

Exact Alignment

4. lf the hole is not perfectly aligned, loosen the locknut on the adjusterand adjustas required. 5. Tightenthe tocknutto 7 N.m (0.7kgf.m,5 tbf.ft). 6. Installthe lock pin on the adjuster.lf you feel the lock pin binding as you reinstallit, the cableis still out of adjustmentand must be readjusted. 7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d j u s t e r securetv.

7 N.m (0.7kgtm. 5 tbtftl

8. Move the shift lever to each gear, and verify that the shift positionindicatorfollows the automatictransaxlegear positionswitch. 9 . S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l gears. lf any gear does not work properly, refer to (seepage 14-109thru 1'4-'112). troubleshooting 10. Insertthe ignition key into the key cylinderon the Ay'Tgear positionindicatorpanel,and verifythat the shift lock leveris released.

14-190

Shift Lever

PUSHKNOBSPRING

SCBEW N.m {0.3kgtm.2 lbf ft) threadlocksealant Apply non-hardening SCREW 3 N.m {0.3kgifm,2 lblft)

SILICONEGREASE

GEARPOSITIONINDICATORPANEL COVER BUSHING

-61

SHIFTINDICATOR

SILICONEGREASE

LEVER

SHIFTLOCK

SCREW 3 N.m {0.3

SHIFTLEVERASSEMBLY

g

2/""*" ,.@ *

6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ft)

-Rt

_.\__r.\

\ooru.r.,

A/T GEARPOSITION PLATE A/T GEARPOSITIONSWITCH

SHIFTLEVERBRACKETBASE

SHIFTLEVER BASECOLLAA 6x1.0mm 9.8 N.m 11.0kgf.m.7.2lbf.ft)

14-191

Shift Indicator Panel Adiustment '1.

Checkthat the index mark on the indicatoralions with the N mark on the shift indicatorpanelwhen the transmissionis in NEUTRAL.

ATFCoolerHoses Connection 1.

Connectthe ATFcoolerhosesto the ATFcoolerlines and ATF cooler,and securethem with the clips as shown.

INDEXMARK

TRANSMISSION

3 N.m {0.3 kgf.m, 2lbt.ftl

lf not aligned.removethe front console{seesection 20t. Removethe shift indicatorpanel mounting screws and adjustby movingthe panel, NOTE:Wheneverthe shift indicatorpanelis removed, reinstallthepanelas describedabove,

14-192

CLIP

ContinuouslyVariableTransmission(CVTI . . . . . . . . . . . . . .1. 4 . -194 S p e c i aTlo o l s . . . . . . . . . . . . . . . . .1. 4 . .- 1 9 5 Description Brake/Planetary Clutches/Reverse . . . . . . . . . .1 4 - 1 9 8 Gear/Pulleys p o w e rF l o w ..............1 , .4. .-.2. 0 0 ElectronicControlSYstem ......14-203 (,96- 98 Modets) ElectronicControl System " 14-205 ('99- oo Models) 14-208 '....... HydraulicControl '14-212 .'..-.....'... HydraulicFlow .....-...'.' 14-222 ParkMechanism EleqtricalSystom ComponentLocations '96 - 98 Models """"""' 14-224 ,99- 00 Modets 14-225 ............. 14-226 TCM CircuitDiagram('96- 98 Models)............. TCM Terminal Voltage/ MeasuringCondiiions('96- 98 Models) '....14-228 PcM CircuitOiaqram '99 14-230 {A/TControlSystem: - 00 Models}...--.... Conditions PCMTerminalVoltage/Measuring ('99- 00 Models) .'.'...14-232 A/4 ControlSystem '14-234 ... . .........',........."' Procedures Troubleshooting Chart Symptom-to-ComPonent '14-234 '96 - 98 Models......'..... ElectricalSystem'11-210 ElectricalSystem-'99 - 00 Models..'....-..-. Troubleshooting Electrical Flowcharts Troubleshooting """'11-242 ('96- 98 Models) Flowchart Troubleshooting ......14-265 ('99- 0OModets) Solenoid LinearSolenoids/lnhibitor . . . . . .1. 4 - 2 9 f T e s t. . . . . . . . . . . . . . . . . . . . . . . . . Gear Pulley/Secondary DrivePulley/Driven Shaft Speed Sensors .14-292 .........'...... Replacement Start Clutch Control StartClutchCalibrationProcedure...........,. 14-293 HydraulicSYstem Chart Symptom-to-ComPonent '.'.......14-294 HydraulicSystem . . . . . . . . . . . . . . . . . . . .1. 4 . .-.2. .9. .6 R o a dT e s t StallSpeed ......14-294 Test......................... FluidLevel .......14-299 Checking/Changing 14-300 ................. Testing Pressure LowerValveBodYAssemblY . . . . . . . . . . , . .1.4 - 3 0 2 Replacement ATF Filter .....14-303 Removal/lnstallation Transmission Transmission 14-304 . R e m o v a.l . . . . . . . . . .

lllustratedIndex ValveBodY Transmission/Lower . . . . . . . . . . . . .1. .4. -. 3 0 8 Assembly ... 14-310 Housing Housing/Flywheel Transmission 14-312 ntermediateHousing ..........'.'.... EndCover/f TransmissionHousing/ Lower Valve Body Assembly .. " 14-314 R e m o v a l. . . . . . . . . . ' . . . . Housing TransmissionHousing/Flywhesl ........1+316 Removal................. Housing EndCover/lntermediate 14-318 Removal.........,............... Body Valve Manual .'.'.'.....14-320 Disassembly/lnspection/Reassemblv Forward Clutch . .2. .1. l l t u s t r a t eIdn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .4.-. 3 14-322 .................. Disassemblv , ,, . ',','......14-324 Reassemblv SecondaryGear Shaft 25 x 35 mm ThrustShim Selection..'.'....-...14-324 Differential 14-329 lllustratedlndex ...,.....................,.,...-.-.-...'... .-....14-329 BacklashInspection ....'...14-330 BearingReplacement......'........'....'... 14-330 DifferentialCarrierReplacement........'........ 14-331 ........... Oil SealRemoval 14-331 . . ....... Clearance Oil SealInstallation/Side FlywheelHousingInputShaftOil Seal ...'.'..14-333 .....,.... Replacement TransmissionHousingBearings Driven Pulley Shaft Bearing 14-334 . ...................'.. ...................'. Replacenient Bearing Shaft SecondaryGear . ........14-335 . .......... ...................... Reolacbment FlywheelHousing Beating SecondaryGear Shaft Bearing R e o 1 a c e m e n t . . . . . . . . . . . . . . . . . . , . . . . . . . . .1. .4.-. 3 . .3. .5. . . . . . . . . . Bearing RingGear . . . . . . .1.4 - 3 3 6 Replacement......... Control Shaft Assembly .................'.....1 . .4. .-.3. 3 6 R e m o v a l / l n s t a l l a t.i .o. n Transmission 14-338 .................. Reassembly Plate .. . ....... ......... . ....-.....'.'...14-341 Flywheel/Drive Transmission 14-348 ..................... lnstalation .'.........14-352 CoolerFlushing shift cable Removal/lnstallation....'........." """ 14-354 . . . . . . . ' . . . . . . .1. 4 - 3 5 5 Adjustment . . . . . . . . . . . . . . . . . .1 . .4. .' .3.5, .6 S h i f tL e v e r Shift IndicatorPanel ..............1 . .4 - 3 5 7 Adjustment ATF Cooler/Hoses .... 14-357 l n s t al l a t i o n. . . . . . , , . . . . . .

SpecialTools

Ref. No.

Tool Number

I

o @

alr *

@

o @ 6l

@

o

@ @-" @ @ @

o

@

07GAE- PG40200 07JAD- PH80200 07LAE- PX40100 07PM- 0010100 07sM- 0010004 07TAE- P4V01l0 07TAE- P4V0120 07TAE- P4V0130 07tvlAJ- PY4011A 07MAJ- PY40l20 07406- 0020400 07406- 0070300 07736- A0r 0004 07746- 0010100 07746- 0010500 07746- 0010600 07746- 0030100 07749- 0010000

ClutchSpringCompressorBoltAssembly Pilot.26 x 30 mm ClutchSpringCompressorAttachment SCSServiceConnector BackprobeSet ReverseBrakeSpringCompressor Stan ClutchRemover Stan ClutchInstaller A/T Oil PressureHose,2210mm Ay'TOil PressureHose,Adapter Ay'TOil Pressurecauge Set Wpanel Ay'TLow PressureGaugew/panel AdjustableBearingPuller,25 - 40 mm Attachment,32 x 35 mm Attachment,62 x 68 mm Attachment,72 x 75 mm Driver40 mm l.D. Driver

0 7 9 4 7- 6 1 1 0 5 0 1 01947 - 6340201

Driver Aftachment,68 mm DriverAttachment,58 x 72 mm

't4-322,325

I 1 2 I a ,l

14-333 14-322,325 't4-235,293 14-236, 296 r4-319,339 't 4-311 14-342,343 't4-300

1 1

14-300 14-300 14-300 14-335 14-333, 336 14-335 14-334, 335 14-330, 331 14-333, 334,335, 336 14-333 14-333

1 ,1 1 1 '1 I 1 1

*07HAE- PL5010lcan be usedas a substitute. **Must be usedwith commercially-available 3/8.,- 16 slidehammer.

E*E o

e

1:,'Jt* dAt:-

@

IR

>.'.--t-'- t'

\;4

aio

@

14-194

o

e'

18l

io(313

@

@

@

@

Description

controlledautomatictransmissionwith drive and driv The ContinuouslyVariableTransmission(CVT)is an electronically en Oullevs,and a steelbelt.The CVTprovidesnon stagespeedsforward and one reverse.The entireunit is positionedin l i n ew i t ht h e e n g i n e . Transmission Aroundthe outsideof the flywheelis a ring gear which mesheswith the starterpinion when the engineis being staned. The transmissionhasfour parallelshafts:the input shaft,the drive pulleyshaft.the drivenpulleyshaft,and the secondary The drive pulleyshaftand the drivenpulleyshaftconsistof gearshaft.The input shaftis in linewith the enginecrankshaft. pulleys. pulleys steel belt. are linkedby the Both movableand fixed face The input shaft includesthe sun gear.The drive pulleyshaft includesthe forwardclutchwhich mountsthe carrierassembly on the forwardclutchdrum. The carrierassemblyincludesthe piniongearswhich meshwith the sun gearand the ring gear.The ring gear hasa hub-mountedreversebrakedisc. The drivenpulleyshaft includesthe startclutchand the secondarydrive gearwhich is integralwith the parkgear'The secondary gear shaft is positionedbetweenthe secondarydrive gear and the final driven gear.The secondarygear shaft includesthe secondarydriven gear which servesto changethe rotationdirection.becausethe drive pulleyshaft and the driven oullev shaft rotate the same direction.When certain combinationsof planetarygears in the transmissionare engagedby the clutchesand the reversebrake,power is transmittedfrom the drive pulleyshaftto the driven pulleyshaft to provideE, E, E, and El. ElectronicControl '96 - 98 Models: The electroniccontrolsystemconsistsof the TransmissionControlModule (TCM),sensors,three linearsolenoids,and a controlledunderall conditions' inhibitorsolenoid.Shiftingis electronically the dashboard, behind the kickpanelon the driver'sside. is located below The TCM '99 - 00 Models: The electroniccontrol svstem consistsof a PowertrainControl Module (PCM),sensors,three linear solenoidsand an controlledunderall conditions.A GradeLogicControlSystemto controlshiftinhibitorsolenoid.Shiftingis electronically position or descendinga slope. vehicle is ascending while the ing in E side. The PCMis locatedbelowthe dashboard,underthe kickpanelon the passenger's HydraulicControl The lower valve body assemblyincludesthe main valve body,the PressureLow (PL)reguiatorvalvebody,the shift valve body, the start clutch control valve body, and the secondaryvalve body. They are positionedon the lower part of the t r a n s m i s s i ohno u s i n g . The main valvebody containsthe PressureHigh (PH)controlvalve,the lubricationvalve,and the pitot regulatorvalve. The secondaryvalve body containsthe PH regulatorvalve,the clutchreducingvalve,the startclutchvalve accumulator, and the shift inhibitorvalve.The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrol valve which is ioinedto the PH,PLcontrollinearsolenoid.The inhibitorsolenoidvalveis boltedon the PLregulatorvalvebody. The shift valvebody containsthe shiftvalveand the shift controlvalve.which is joinedto the shift controllinearsolenoid. The startclutchcontrolvalve body containsthe startclutchcontrolvalve,which is joinedto the startclutchcontrollinear solenoid.The linearsolenoidsand the inhibitorsolenoidare controlledby the TCM or PCM.The manualvalvebody which containsthe manualvalveand the reverseinhibitorvalve,is boltedon the intermediatehousing. The ATF pump assemblyis locatedon the transmissionhousing,and is linkedwith the input shaft by the sprocketsand feed pipes,and the reversebrakereceives the sprocketchain.The pulleysand the clutchreceivefluid from their respective fluid from internalhydrauliccircuit. Shift Control Mechanism Inputfrom varioussensorslocatedthroughoutthe vehicledetermineswhich linearsolenoidthe TCM or PCMwill activate. Activatingthe shift controllinearsolenoidchangesthe shift controlvalve pressure,causingthe shift valveto move.This pressurizes the drive pulley pressureto the drive pulleyand the driven pulley pressureto the driven pulleyand changes their effectivepulleyratio.Activatingthe startclutchcontrollinearsolenoidmovesthe startclutchcontrolvalve.The start clutch control valve uncovers the port, providing pressure to the start clutch to engage it

(cont'd)

14-195 ,!

Description (cont'd) Gear Sel€stion The shift leverhassix positions:@ pARK,E REVERSE, g SECOND, E NEUTRAL, and El LOW. E DR|VE, Poshion

De3cription

E PARK

Frontwheelslocked;parkpawl engagedwith the parkgearon the drivenpulleyshaft.The start clutch and the forward clutch released.

E REVEBSE

Reverse;reversebrake engaged.

E NEUTRAL

Neutral;the start clutch and the forward clutch released.

D DRIVE

Generaldriving;the transmissionautomatically adjuststo keepthe engineat the bestspeedfor drivingconditions.

E SECOND

For rapid accelsrationat highway speeds;the transmissionshifts into a lower range of ratios for better accelerationand increasedengine braking.

E LOW

Forenginebrakingand powerfor climbinO;the transmissionshiftsinto the lowestrangeof the ralros.

Staning is possibleonly in E and E positionsthrough the use of a slid6-type,neutrafsafety switch. Automrtic Transaxle{A/T} Gear Position Indicltor The A-lTgear position indicator in the instrument panel shows which gear has been selectedwithout having to look down at the console.

14-196

STEELBELT STARTCLUTCH

INPUTSHAFT

DRIVEPULLEY

ATF FILTER

14-197

Description Clutches/Reverse Brake/Planetary Gear/Pulleys Clulches/ReverseBrake T h e C V T u s e st h e h y d r a u l i c a l l y - a c t u a tcel u d t c h e sa n d b r a k et o e n g a g eo r d i s e n g a g et h e t r a n s m i s s i o n g e a r s .W h e n hydraulicpressureis introducedinto the clutchdrum and the reversebrakepistoncavity,the clutchpistonand the reverse brakepiston move.This pressesthe frictiondjscsand the steelplatestogether,lockingthem so they don't slip. Poweris then transmittedthrough the engagedclutch packto its hub-mountedgear. and through engagedring gear to pinion gears. Likewise,when the hydraulicpressureis bled from the clutchpackand the reversebrakepistoncavity,the pistonreleases the frictiondiscsand the steelplates,and they are free to slidepasteach.This allowsthe gearto spin independently on its shaft,transmittingno power. Start Clutch The startclutch,which is locatedat the end of the drivenpulleyshaft,engages/disengages the secondarydrive gear. The startclutchis suppliedhydraulicpressureby its ATFfeed pipeswithin the driven pulleyshaft. Forward Clutch The forwardclutch,which is locatedat the end of the drive pulleyshaft,engages/disengages the sun gear. The forwardclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the drive pulleyshaft. ReverseBrake The reversebrake,which is locatedinsidethe inte.mediatehousingaroundthe ring gear,locksthe ring gear in E position. The reversebrakediscsare mountedto the ring gear and the reversebrakeplatesare mountedto the intermediate housing.The reversebrakeis suppliedhydraulicpressureby a circuitconnectedto the internalhydrauliccircuit. PlanetaryGear The planetarygearconsistsof a sun gear,a carrierassembly,and a ring gear.The sun gear is connectedto the input shaft with splines.The pinion gearsare mountedto the carrierwhich is mountedto the fo.ward clutchdrum. The sun gear inputsthe enginepower via the input shaftto the planetarygear,and the carrieroutputsthe enginepower.The ring gear is only usedfor switchingthe rotationdirectionof the pullevshafts, In E. E, and E positions(forwardrange),the pinion gearsdon't rotateand revolvewith the sun gear, so the carrier rotates.In E] positjon{reverserange),the reversebrakelocksthe ring gear and the sun gear drivesthe pinion gearsto rotate.The pinion gearsrotateand revolvein the oppositedirectionfrom the rotationdirectionof the sun gear,and the carrierrotateswith piniongear revolution. Pulleys Eachpulley consistsof a movableface and a fixed face, and the effectivepulley .atio changeswith engine speed.The drive pulleyand the drivenpulleyare linkedby the steelbelt. To achievea low pulley ratio, high hydraulicpressureworks on the movableface of the driven pulleyand reducesthe effectivediameterof the drive pulley.and a lower hydraulicpressureworks on the movableface of the drive pulleyto eliminatethe steelbelt slippage.To achievea high pulleyratio,high hydraulicpressureworks on the movablefaceof the drive pulleyand reducesthe eifectivediameterof the driven pulley,and a lower hydraulicpressureworkson the movable faceof the drivenpulleyto eliminatethe steelbelt slippage.

14-198

ATF PUMP DRIVENSPROCKET

ATF PUMP DRIVEPULLEY

RING GEAR

REVERSE BRAKE PISTON

FORWARDCLUTCH BEVERSEBRAKE CARRIER

FLYWHEEL

RINGGEAR DRIVEPLATE PLANETARY PINIONGEARS

INPUTSHAFT

ATFPUMP DRIVECHAIN

ATF PUMP DRIVESPROCKET

DRIVENPULLEY SHAFT

STARTCLUTCH FINALDRIVEGEAR

DRIVENPULLEY GEAR SECONDARY SHAFT

a-i___

STEELBELT

il

DRIVEGEAR SECONDARY

PARKGEAR

14-199

Description PowerFlow E Position . . .

StartClutch:released ForwardClutch:released ReverseBrake:released

Hydraulicpressureis not appliedto the startclutch.forwardclutch,and the reversebrake.Poweris not transmittedto the secondarydrive gear. E Position . StartClutch:released . ForwardClutch:released a ReverseBrake;released Hydraulic pressureis not applied to the start clutch, forward clutch, and the reversebrake.Power is not transmitted to the secondarydrive gear. The secondarydrive gear is locked by the park pawl interlockingthe park gea.. FI-YWHEEL

FORWARD

INPUTSHAFT

SUN GEAR

STARTCLUTCH ORIVENPULLEY

FINALORIVE GEAR PARKGEAR

FINALDRIVENGEAR

14-200

E, E, and E Positions{Forward Rangel . Start Clutch:engaged . ForwardClutch:engaged o ReverseBrake:released 1, The hydraulicpressureis appliedto the forward clutch and the start clutch,and the sun gear drives the torward clutch. 2.

The torwardclutchdrivesthe drive pulleVshaft.which drivesthe drivenpulleyshaft linkedby the steelbelt.

3,

The drivenpulleyshaftdrivesthe secondarydrive gear,via the startclutch.

4.

Poweris transmittedto the secondarydrivengear,which drivesthe final drivengear.

NOTE:The working hydraulicpressureon the movablefaceof eachshaftdependson the throttleopeningposition. FLYWHEEL

DRIVEPULI.fY STEELAELT

CLUTCH

INPUTSHAFT

STARTCLUTCH

DRIVEN SECONDARY GEAR

(cont'd) FINAL DRIVENGEAR

14-201

Description Power Flow (cont'd) E Position . . .

Start Clutch:engaged ForwardClutch:released ReverseBrake:engaged

1. The hydraulicpressureis appliedto the reversebrakeand the startclutch.The sun gear drivesthe piniongears,and the piniongearsrevolvearoundthe sun gear.The carrierassemblyrotatesin the oppositedirectionfrom the rotation directionof the sun gear. 2.

The carrierassemblydrivesthe drive pulleyshaft via the forward clutchdrum, and the drive pulleyshaft drivesthe drivenpulleyshaftlinkedby the steelbelt.

3.

The drivenpulleyshaftdrivesthe secondarydrive gearvia the startclutch.

4.

Poweris transmittedto the secondarydrivengear,which drivesthe final drivengear. DRIVEPULLEY

STEELEELT REVERSE BRAKE

DRIVE PULLEY

CARRIER ASSEMBLY

INPUTSHAFT

SUN GEAR PINIONGEAB RINGGEAB

STABTCLUTCH DRIVENPULLEY SECONDARY DRIVE GEAR FINAL

GEAB SECONDARY ORIVEN GEAR

FINALORIVEN GEAR

14-202

ElectronicControlSystem('96- 98 Modelsl (TcM),sensors,three linearsolenoids,and an The electroniccontrolsystemconsistsof the Transmissioncontrol Module controlledunderall conditions inhibitorsolenoid.Shiftingis electronically The TCIMis locatedbelowthe dashboard,behindthe kickpanelon the driver'sside' when the vehicleis The TcN4controlsthe transmissionto reduceenginespeedand retainthe engine'scoolingefficiency drivenwith Iull throttleacceleration t h, e T C M r e g u l a t e st h e p u l l e yh y d r a u l i cp r e s s u r et o y r i v e na t f u l l t h r o t t l ea c c e l e r a t i o n l f t h e v e h i c l ei s c o n t i n u o u s l d and retainsthe designedcoolingefficiencyAfter speed increasethe pulleyratio,which,as the result.reducesthe engine the pulleyratioto the originalratio. increases the TCM for a while, the vehiclehas beendrivenat a lower enginespeed cut off the rvc clutch{if the A!/cis on) and EcM to to the a signal sends position, the TcM For smooth startingin the E position' to the is shifted E the transmission rpm when 900 speed to engine the increases properly.the TCM regulates The start clutchfunctionsto make smooth startingpossible.To let the start clutchfunction position' in the pressure memorized E negative entine's the startclutchhydraulicpressurebasedon the

:

: z z z

S*ond.ry

G..r Sh:ft

(cont'd)

14-203

Description ElectronicControlSystem('gG- 98 Modelsl(cont'dl Circuit Diagramand Terminal Locations GNITIONSWITCN

Pri- PtcoNTnoL LrN ns0LtN0t0

SIAiT CLUTCH CONTSOL LINEAFSOLENOID

:

MAP(PBI

g

s61

E

rtDiRxo

g

sHtFT CONmOI LINIAftSOLENOID

TM8

scs

i\\c-...............-+B BFAXELIGHT PAS|(ING 8MI(E SWITCH

i\--------.--_ rcr

1 14

14-204

2

3

5 17

1

20

8

I

1 0 1 1 't2 23

2 26 12 1 3 t 4

5

7

t6 17 18

8

9

20

10

ElectronicGontrolSystem('99- 00 Modelsl (PCM).sensors,three linearsolenoidsand an The electroniccontrotsystemconststsof a Powertraincontrol Module controlledunderall conditionsA GradeLogiccontrol systemto controlshiftinhibitorsolenoid.shifting is electronically ing in E positionwhile the vehicleis ascendingor descendinga slope' fn"pCVirlocatedbelowthedashboard,underthekickpanelonthepassenger'sside' is to reduceenginespeedand retainthe engine'scoolingefficiencywhen the vehicle The pCM controlsthe transmassion drivenwith full throftleacceleration the pulley hydraulicpressureto lf the vehicle is continuouslydriven at lull throttle acceleration,the PCM regulates the designedcoolingefficiencyAfter retains and increasethe pulleyratiowhich. as the result,reducesthe enginespeed pulley ratioto the originalratio' the increases PCM while, the the vehiclehas beendrivenat a lowerenginespeedfor a the enginespeedto (if increases on) and A/c is the ,Vc clutch off the PcM cuts position, the i"i ".nl",rr startingin the E 900 rpm when the transmissionis shiftedto the E position' functionproperly,the PcM regulates The start clutchfunctionsto make smooth startingpossible.To let the start clutch in the E position' pressure memorized the startclutchhydraulicpressurebasedon the engine'snegative FCM

s*o.d.ry

G..t Sh.h

(cont'd)

14-205

Description ElectronicControlSystem('99- 00 Modelsl(cont'dl Grade Logic Control System How it works: The PcM comparesactual driving conditionswith memorizeddriving conditions.basedon the input from the vehicle speedsensor,the throttlepositionsensor,the manifoldabsolutepressuresensor,the enginecoolanttemperaturesensor, the brakeswitchsignal,and the shift leverpositionsignal,to controlshiftingwhile the vehicleis ascendingor descending a slope. AscendingControl When the PCM determinesthat the vehicleis climbing a hill in E position,the system selectsthe most suitableshift schedule(pulleyratio)accordingto the magnitudeof a gradient.so the vehiclecan run smooth and have more power when needed.Thereare threeascendingmodeswith differentshift schedulesaccordingto the magnitudeot a gradientin the PCM. DescendingControl when the PCMdeterminesthat the vehicleis going down a hill in E position.the systemselectsthe most suitableshift schedule(pulley ratio) accordingto the magnitudeof a gradient.This, in combinstionwith engine braking,achieves smoothdrivingwhen the vehicleis descending,Thereare three descendingmodeswith differentshift schedulesaccording to the magnitudeof a gradientin the PCM.

14-206

-'99 Circuit Diagram and Terminal Locations

- 00 Models

IGN1TIONSWTCH PH.PLCOiTSOL SOLEI€ID LINEAF

IGPl SIAFTCLIJICHCOTITROL LINEiFSOLET€IO

vcc2 TPS SHIFICONTNOT SOLEI{OIO LINEAR

INNIBTOFSOLETIOIO

14-207

Description HydraulicControl The hydrauliccontrolsystemis controlledby the ATF pump.the valves,and the solenoids.The ATF pump is drivenby the input shaft.The ATF pump and the input shaft are linkedby the ATF pump drive chain and the sprockets,The inhibitor solenoidvalve and the linearsolenoids.which are locatedon their valve body, are controlledby the TCM or pcM. Fluid from the ATF pump flows throughthe PH regulatorvalveto maintainspecifiedpressureto the drive pulley, the driven pulley,and the manualvalve, The lower valve body assemblyincludesthe main valve body,the PL regulatorvalve body,the shift valvebody,the start clutchcontrolvalvebody,and the secondaryvalvebodv. Main Valve Eody The main valvebody containsthe pH controlvalve,the rubricationvalve,and the pitot regulatorvalve. PH Control Valve The PHcontrolvalvesuppliesPHcontrolpressure(PHCIin accordance with the pH-pLcontrolpressure(HLc),and supplies PH control pressureto the PH regulatorvalve,which also regulatssPH pressure. At kick-down,it increasespH controlpressurewhich increases the high (PH)pressure.This shortensthe shift speedby releasingthe reverseinhibitor pressure(Rl)fromthe inhibitorsolenoidvalve. LubricationValve The lubricationvalvecontrolsthe lubricationpressureto eachshaftand maintainslubricationpressure. Whenrne pressure is too high,the spring is compressed. This movesthe lubricationvalveand opensthe fluid leakpassage. Pitot Regulalor Valv6 The pitot regulatorvalvecontrolsthe startclutchpressure(SC)in accordance with the enginespeed,when the electronic controlsystemis faulw.

MAIN VAIVE BODY

14-208

SecondaryValve Body valve accumulator' The secondaryvalve body containsthe PH regulatorvalve.the clutchreducingvalve' the start clutch and the shift inhibitorvalve PH RegulatorValve pump. and suppliesPH pressureto the The pi regulatorvalve maintainshydraulicpressuresuppliedfrom the ATF PH regulatorvalveby the PH control the pressure at is regulated hvdrauliccontrolcircuitand the lubricationcircuit.PH pressure(PHC)from the PH controlvalve. Cluteh ReducingValvo the clutch reducing pressure The clutch reducing valve receivesPH pressurefrom the PH regulator valve and regulates clutchcontrolvalve'and the start (cR) and valve pressure manual to the (cR).The clutchreducingvalvesuppliesclutch solenoidvalve' inhibitor the and valve, control shift pressure valve. the control suppliessignalpressureto the PH-PL Start Clutch Valv€ Accumulator the hydraulicpressurethat is suppliedto the startclutch' The startclutchvatveaccumutatorstabilizes Shift Inhibitor Valve from electroniccontrol to hydraulic The shift inhibitor valve switchesthe fluid passageto switch the start clutch control pressure(cR) to the pitot regulator reducing clutch suppliss lt also is faulty. system control control when the electronic valveand the pitot lubricationpipe.

START CLUTCHVALVE

SECONDARYVALVE BODY

SHIFTINHIBITOEVALVE

VALVE REDUCING VAL PH REGULATOR

(cont'd)

14-209

Description HydraulicControl{cont'dl PL RegulatorValve Body The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrolvalve.which is joined wirh the pH-pL controllinearsolenoid.The inhibitorsolenoidis boltedon the pL regulatorvalvebody. .

PL RegulatorValve The PL regulatorvalvesupplieslow p.essure(pL)to the pulleyto eliminatesteelbelt slippage. The PL pressureis controlledby the pH-pLcontrolpressure(HLC).

.

PH-PLControl Valve The PH-PLcontrolvalve controlsthe PL regulatorvalve accordingto enginetorque.The PH-PLcontrolvalvesuoolies PH-PLcontrolpressure(HLC)to the PH controlvalveto regulatePH pressurehigherthan pL pressure.The pH-pLcontrol valveis controlledby the PH-PLcontrollinearsolenoid.which is controlledby the TcM or pcM,

.

InhibitorSolenoid The inhibitorsolenoidcontrolsthe reverseinhibitorvalveby turningon and off. Also,the inhibitorsolenoad controlspH controlpressure(PHC)by applyingreverseinhibitorpressure(Rl)to the PHcontrolvalve.The inhibitorsolenoidis controlledby the TCM or Pclvl.

Start Clutch Control Valv€ Body The startclutchcontrolvalve body containsthe startclutchcontrolvalve.Both are joinedto the stan clutchcontrollinear solenoid. .

Start Clutch Control Valve The startclutchcontrolvalvecontrolsstartclutchengagementaccordingto the throttleopening.The start clutchcon, trol valveis controlledby the stan clutchcontrollinearsolenoid,which is controlledbv the TCM o. pCM.

STARTCLUTCHCONTROL vAt-vE

LOWERVALVEBODY ASSEMBI-Y PH.PLCONTROL LINEARSOLENOID

14-210

Shift Valve BodY linearsolenoro. shift controlvalve.Bothare ioinedto the shiftcontrol The shiftvalvebody containsthe shift valveand the

r tl'ft1il1rf"",""

pH Theshiftvarvedistributes varve. (sV)fromtheshiftcontror by shiftvarvepressure is controred

pi""aur" "nO PL pressureto drive pulleyand the driven t

pulley'to shiftthe transmission'

t*"rilf:::lr';ivarve

opening and vehicle speed rhe shift contrors the shift varve in accordancewith the throttre When the elecsolenoid,which is controlledby the TcM or PcM controlvalveis convorr"ouv ti" "iirt "ontrol linear port leadingthe the uncover to valve "witchesthe shift inhibitor tronic controlsystemis faulty,t;; snift controtuutue pitot regulatorpressureto the startclutch SHIFTCONTROL CONTROLVALVE

VALVEBODY

inhibitorvarve.Themanuatvarvebodvis bortedto the varveandthe reverse the manuar T;J:"i"""1ff"t""ilody contains intermediatehouslng .

ManualValve position' the fluid passageaccordingto the shift lever uncovers/covers The manualvalvemechanicallY

'

(Rl). lt interceptsthe hvdraulic circuit to the is contro ed by the reverse inhibitor pressure ff:e;;;.'::'?Xftl::T",* at speedsover approximatelv6 mph (10 km/h)' reversebrakewhile the vehicleis movingforward REV€RSEINHIBITOR VALVE MANUAL VALVE BODY

MANUALVALVE

14-211

Description HydraulicFlow GeneralChart of Hydraulic prossure

'Shift Valve . ShiftinhibitorVatve

PH REGULATOR VALVE

NO.

cc coL

DESCRIPTION OF PRESSURE

NO.

DESCRIPTION OF PRESSURE

CLUTCHCONTROL

PP

PITOTPIPE

ATF COOLER

PR

PITOTREGULATOR

CLUTCHREDUCING

RCC

RECIRCULATION

DN

DRIVENPULLEY

DR

DRIVEPULLEY

RVS

REVERSE BRAKE

FWD

FORWARD CLUTCH

sc

STARTCLUTCH

HLC

PH-PLCONTROL

sl

SHIFTII"IHlBITOR

LUB

LUBBICATION

PH

PRESSURE HIGH

PHC PL

14-212

PHCONTROL PRESSURE LOW

RI

SUC

REVERSE INHIBITOR

SUCTII'N SHIFTVALVE

X

LEAK

E Position

Astheengineturns.theATFpumpa|sostartstooperate.F|uidfromtheATFpumpf|owstothePHregu|atorva|veandt c|Utchreducingva|ve.ThePHregu|atorva|veregu|ateshighpressure(PH).andsendittotheshiftVa|veandthePLr latorvalve.Thehighpressure(PH)flowstothemovablefaceofthedrivenpulleyviatheshiftvalve'andturnsintolow pressure(PL)atthePLregu|atorva|ve.Thelowpressure(PL}f|owstothemovab|e'aceofthedrivepu||eYviatheshif valve.At this time, the pulleyratio remarnslow'

T h e h i g h p r e s s u r e ( p x ) u e c o m e s t t r e c t u t c h r e d u c i n g p r e s s u r e ( C R ) a t t h e c | uvalve' t c h r eand d u cthe i n gshift va|V e . T h evalve' c | u t cand hreducing control valve'the PH-PLcontrol sure (CR)flows to the startclutchcont'oi uatt". tn"lt"n'al is interceptedbYthose valves pressureis not appliedto the clutchesand reversebrake' Underthis condition,hydraulac

(cont'd)

14-213

Description HydraulicFlow(cont'dl lll position, at low spo€d range The flow of fluid up to the drive pulley,the driven pulley,and the clutchreducingvalve is the same as in El position.The pulleyratio is low becausethe drivenpulleyreceiveshigh pressure(PH), and the drive pulleyreceiveslow pressure(pL), The clutchreducingpressure{cR) flows throughthe manualvalve to the forwaroclutch,ttrenforwardciulcn is engaged. The forwardclutchthen drivesthe drive pulleyshaft,which drives the d(ven pu ey shaft. Also' clutch reducingpressure{cR) flows to the start clutch control valve, and becomesclutch control pressure {cc). clutch control pressure(cc) becomesstart clutch pressure(sc) at the shift inhibitorvalve.stan clutchpressure{sc) is appliedto the startclutchto engagethe startclutch.

14-214

E position, at middle sPeedrange

Asthespeedofthevehic|ereachestheprescribedVa|ue,theshiftcontro||inearsolenoidisactivatedbytheTcMorPc T h e s h i f t c o n t r o | | i n e a r s o | e n o r o c o n t r o I s t t r e s n i f t c o n t r o I V a | v e(SV) t o a c t i v a t shift e s h icontrol ftVa|ve p r e sShift s u r evalve ( S V ) 'pressure c|utchreducing valve at the shift valve pressure sure (CR)trom the clutchreduclngvalve becomes ( S V ) f l o w s t o t h e | e f t " n o o t t r ' " s t ' i t t u " t u e . t h e s h i f t V a | V e t o t h e r i g h t s i d e a n d p oport s i t i o n i n g i tlow i n t hpressure e m i d d |(PL) e o f ito t sthe trave|.The leading tiHl a ,tr" pulleys,and uncoversthe shiftvalvecoversth" pon ao",oo nLior".irr" middle' in the pulley is ratio pressure(PL).At this time, the pu eys.The drive pu ey and tne oriJenpriLy |."""iu" to* clutch' start the Pressureremainsto applythe forwardclutchand "|eft" or "right" indicatesdirectionon the hydrauliccircuit' NOTE:When used,

(cont'd)

14-215

Description HydraulicFlow (cont'd) @ position, at high spe6d range As the speedof the vehiclereachesthe prescribedvalue,the shift controllinearsol€noidmovesthe shift controrvatveto increaseshift valve pressure(SV)at the left end of the shift valve. ttre srrit vatvemovesto the right side comparedto its positionat the middle pulley ratio.The shift valve uncovers the port leadinghigh pressure(pxito ttre d.ve puley and uncoversthe port leadinglow pressure(PL)to the drivenpulley. The drive pu|ey receiveshigh pressure(pH)and the driven pulleyreceiveslow pressure(pL).The pulleyratiois high. Pressureremainsto applythe forwardclutchand the startclutch, NOTE:When used,"left,,or,,right" indicatesdirectionon the hydraulic circuit.

14-216

E position pulley'and the clutchreducingvalve is the sameas in E position The The flow of fluid up to the drive pulley,the driven and the drive pulleyreceiveslow pressure{PL). pulleyratio is low b"car"" tt " o riu",i'prti"vi"""v"" t'igtrpressure.(pH) (RVS)to the the port that leadsreversebrakepressure The manualvalve is shiftedinto the B position,and it uncovers (Rl)is pressure inhibitor reverse and PcM, meansof the TcM or reverseinhibitorvalve.The inhibitoiJenoid turns off by

a p p l i e d t o t h e r i g h t e n d o f t h e , " u " , " " i n t , i u i . o , u , | v e . T h e r e v e r s e i n h i b i t o r v a |pressure v e m o v e(cR) s t o tbecomes he|eftsid e , a n dbrake uncoversth reverse clutch reducing port that leadsreversebrakepr"a"ur" tivst,o,he reversebrake. ring the The reversebrakeis engaged,and it locks pressure(RVS)at the manuat*r"-, "nJ tro*" to the reversebrake. gear. "|eft" or "right" indicatesdirectionon the hydrauliccircuit' NOTE:When used,

(cont'd)

14-217

Description HydraulicFlow(cont'dl E position ReverseInhibitor Conirol lf the E positionis selectedwhile the veiicle is moving forward at speedsover 6 mph (10 km/h),the inhibitorsolenoid doesn'tturn off by meansof the TcM or PCM Reverseinhibitorpressure(Rl) is not appliedto the reverseinhibitorvalve as the reverseinhibitorsolenoidturns on. The reverseinhibitor valve is kepton the right side,and coversthe pon ro srop reversebrakepressure{RVS}to the reversebrakefrom the manualvalve.Reversebrike pressure(RVs)i; not appried to the reversebrake,and power is not transmittedto the reverse direction. NOTE:When used,"left,' or,,right,,indicatesdirectionon the hydraulic circuit.

14-218

E position position' pulley' and the clutch reducingvalve is the same as in E The flow of fluid up to the drive pulley,the driven and is valve' controlvalve,the manualvalve,and the shift control Clutchreducingpressure(CR)t'"*" i" ii" startclut;h interceptedbYthosevalves. to the clutchesand reversebraKe' Underihis condition,hydraulicpressureis not applied

fr

--l

-

4t1.1 'rltll

,

1

(cont'd)

14-219

Description HydraulicFlow (cont'd) lll position, when th€ electroniccontrol system is fauhy. when the electroniccontrolsvstem(linearsolenoidsand sensors)is faulty, the transmissionusesthe pitot pipe pressure (PP)to 311o-rh" u"hicleto drive. when all linearsolenoidsand sensorsare off becauseof a faulty electronrc controlsystem,clutchreducingpressure(cR) flows to the startclutchcontrolvalve,the manualvalve,the PH-PLcontrol valve,and the shift controlvalve.clutch reducing pressure(cR) becomesshift varvepressure(sV) at the shift contror varve,and shift varvepressure{sv) is appriedto the left end of the shift valve and the right end of the shift inhibitorvalve. The shift valve movesto the right side.and uncoversthe pon that leadshigh pressure(PH)to the drive pulleyand uncoversthe po.t tlr"t r""1" ro,,"-pressure (pL)to the driven pulley At this time, the pulley ratio is high, The shift inhibitorvalve movesto the left side,and uncoversthe port that leadsshift inhibitorpressure(Sll to the pitot lubricationpipe and the pitot regulatorvalve.tne prtot lubrication pipe dischargesfluid insideof the pitot flange,and discharged fluid entersinto the pitot pipe and it is appliedto the left end of the pitot regulatorvalve.The pitot regulatorvalve moveslo the right side,and uncoversthe port that leadspitot regulatorpressure(PR)to the shift inhibitorvalve.Pitot regulatorpressure {pR)becomesstartclutchpressure{sc1at the shift inhibitorvalve,and is appliedto the stan clutch.The stan clutch rs engaged.The forwardclutch pressure(FWD)is appliedto the forwardcrutch,and the forwardcrutchis engaged.This alows the vehicreto drive. NOTE:When used."|eft" or ,,right',indicatesdirectionon the hydraulic circuit.

14-220

system is faulty' E] position, when the elestronicGontrol pulley'and the startclutchis the sameas in El position The flow of tluid up to the drive pulley,the driven pressure{RVS}to the it uncoversthe port that leadsreversebrake The manualvalve is shiftedinto the lE position'and valve becauseof inhibitor reverse (Rl)is appliedto.the right end of the reverseinhibitorvalve.Reverse,"nlu-i,"ip*r""i" a f a u l t y i n h i b i t o r s o l e n o i d . T h e ' " t ' " , " " i n f t i U i t o ' v a l v e m o v e s t o t h(cR) e l e fbecomes t s i d e ' a nreverse d u n c o vbrake e r s t hpressure e p o r t t h(RVS) a t l e aat d sthe reverse reducingpressure brakepressure{RVS)to the ,"u"r." ir"t"- cru,ch vehigear'This allowsthe reversebrakeis engagedand locksthe ring manualvalve,and,lows to the ,e\r"rs" lr"re. ttre cle to drive in reverse. "left" or "right" indicatesdirectionon the hydrauliccircuit' NOTE:When used,

14-221

Description ParkMechanism The park mechanismlocksthe transmissionby engagingthe park pawl with the park gear which is integralwith the secondarydrive gear'The secondarydrive gear engageswith the secondarydrivengear which engageswit-hthe final driven gear. shiftingto E positioncausesthe parkcone (installedat the end of the parkrod) press to the park pawl onto the parkgear. Evenif the end of the park pawl rideson the top of the parkgearteeth,slight movementof the vehiclewill causethe park pawl and the parkgearto mesh with eachother completely becausethe parkcone receivesthe tensionfrom the parkrod spring The park pawl receivesthe tension(whichactsto separatethe park pawl from the park gear)from the park pawl spring.

STARTCLUTCH PARKPAWI-

PABKGEAR

PARKCONE

PARKPAWL

PARKROO SPRING

1 4-222

PARK ROD

Component Locations

36 - 98 Models

BRAKESWITCH

ENGINECONTROL MODULEIECMI

AUTOMATICTRANSAXLE(A/T} GEARPOSITIONSWITCI{

SECONDARY GEARSHAFT SPEEOSENSOR

MANIFOLDABSOLUTE IMAPI SENSOR THROTTI.IPOSITION{TPI SENSOR

VEHICLESPEEOSENSOR

{vss}

/i/ i

DRIVENPULLEY SPEEDSENSOR

,' / ,','4

$r,

,i/:1

i,,

t"--.---.-

-_,-:-_a.--: il

INHIBITOR SOLENOID

STARTCLUTCHCONTROL LINEARSOLENOID

PH.PLCONTROL LINEARSOLENOID PULLEY SPEEDSENSOR

SHIFTCONTROL LINEARSOLENOTD

14-224 h

'99 - 00 Models

CONTROL

AUTOMATIC TRANSAXLE IA/TI GEARPOS]TIONSW]TCH

SECONDANYGEAR SHAFT SPEEDSENSOR

MANIFOLDABSOLUTE IMAPI SENSOR THROTTLEPOS]TIONITP) SENSOR

VEHICLESPEEDSENSOR

tvss)

DNVENPUL]-EY SENSOR SPEED

STARTCLUTCHCONTROL LINEARSOIENOID

PH.PLCONTBOL LINEABSOLENOIO

PULLEY SPEEDSENSOR

SHIFTCONTROL LINEARSOLENOIO

14-225

TCM CircuitDiagram('96- 98 Modelsl U N D E NH . O O DF U S E ] R E LBAO YX

No.521l5A)

l

N o . 4 ll 8 0 A ) N o . 4 7 ( 7 . 5 A )

PARKING BRAKE

I

swrTcH

lG1

sToP swT

A / TG E A R POSITION INDICATOR

YI

I

I

i

I I

GnN,4,vHT

Tot 2v

V I

I

I

UNDER OASH FUSE/RELAY 80X

I G N I T I OCNO I L

GRN/REO

, t ,I HBR( sw-

-

I

BI-U

rsl rur

LTGRN ELKiBI-U

RED

GRN/BLK

8LK

I

I

Tl G401 G404

14-226

cRN---l

F-----

GnN

Bru-J

F------

61U

NoTEiif

T

:ro 5V

: T ot 2 v

^ A ',o

J'

I

GRY

WHT/REDELUMHT B2O

I

T

I

I

I

I

l

wirr , 'r-|

l

wHTqED I

l

PNUSLK I

PNK,BLU 1

T

T

T

J wxitnro I eruxialrI r-T' _ r r -r_ -T

L -T-

-T-r

T

nro,wHr

I

nroieru _ L

I

T

T

cnN --

B6

B7

LB5

wHT

T

PNK

T

T

BLKMHTI

T

I

|

|

|

|

l

l

T -.T-. T

'i| Lli:"*l

BLUIEL^^.,1,. YFt -_..1_.-. GRN{WHT-...1_... GRNiBIK PNKiBLU GBN,^vEt

T

I

GRN/BLK

G8N/YEL J

I

| c*Hl**t I

pr'rxisLr I

l

t

l

J l

T

'i'

I sLU'i^'Hr I

l

l

PNK7BLU I GBN/YEI I

l

+. L' il

GRN/BIK

t l

-t P-

BRN/BLK

l

d s t g @ @ @ l e ] SEigY#ISBniho, 3FIYE,',X!b'J SFiYbtt"','J8i0ft 3il[ip' T

BLK

rNHrBlT0R I SOLENOID I

I

5PEE'sENsoR !8[$fo,o !'$,'Afl]: !'8$nlo'ol

I

n-:

I

G1 0 1

G1 0 1

-

TCMTeflnlnalLocations

X

>< 2 14

3

5 17

TCM-A (26P)Connertor

7 20

10

'11

2 2 5 26

5

14

6

7

17 18

10

8 20

,/1,/

T C M- B l 2 2 P ) C o n n e d o r

14-227

TCMTerminalVoltage/Measuring Gonditions ('96- 98 Modelsl

TCM Terminal Loc.tions 2

1

4

1 1 1 5 16 1 7

20

8

9 1 0 1 1 12 1 3 23 25 26

TCM-Al25P)Connecto.

TCM-B(22P)Connectot

TCM CONNECTOR A (26P}

TerminalNumbet

Signal

A1

SCLS_

Stanclutchcontrollinearsolenoid powersupplynegativeelectrode

Engineidling,E position: Approx. 0.4 V

HLC LS-

PH-PLcontrol linearsolenoidDower supply negative electrode

Engineidling,E position: Approx.0.7V Engineidling,E position: Approx.0.8V

A4

LG1 NE

A6 A7

ATP L

A8

ATPS

A9

ATP D

Ar0

ATP NP

A11

ATP R

A.12

tGl

A13

PG1

414

A15

HLCLS+

A16

SH LS+

417

Dsscription

Shiftcontrollinearsolenoidoower supplynegativeelectrode Ground Enginespeedsignalinput Not used A/f gear positionswitchEl position signalinput ly'T gearpositionswitchE position signalinput A{/Tgear positionswitchE position signalinput A,/TgearpositionswitchE or E positionsignalsinput A,/Tgear positionswitchE position signalinput Powersupplysystem Ground Startclutchcontrollinea.solenoid powersupplypositiveelectrode PH-PLcontrolline8|.solenoidpower supplypositiveelectrode Shift control linear solonoid oower supply positive electrode

A18

Ground Not used

A19

Not used

420

D IND

A2'l

VBU

Not used Back-uppower system Not used

tG1

Powersupplysystem

PG1

Ground

424

14-228

Withenginerunning:Pulsingsignal InEposition:OV In otherthanEl position:Approx.1OV In lg position:0 V In otherthanE position: Approx.10V In lll position:0 V In otherthanE position: Approx.10V InEorEposition:oV In otherthanE orE position: Approx.1OV In lE position:0 V In otherthanE position: Approx.1OV With ignitionswitchON (ll):Baneryvoltsge With ignitionswitchOFF:0 V Engineidling,E position: Approx.2.5V Engineidling,El position: Approx.5.0V Engineidling,E position: Approx.6.0V

When l9l indicator light comes on: Approx. jO V When lll indicatorlighr OFF:0 V

Not used

422

A.25

E indicatorlight control

MoasuringConditions/Torminsl Vohrgo

Alwaysbatteryvoltage

With ignition switch ON (lt):Bafteryvoltage With ignitionswitch OFF:0 V

TCM CONNECTORB (22P} Terminal Numbel

Signal

B1

S O LI N H

82

MAP(PB)

B3 B4

TPS

VSS

TMB 81

TMA

B8

N D NS G NDN

B9 810

NDR

811 812 813

STOPSW

Inhibitorsolenoidcontrol

-M

Pressure IMAP) anifold Absolr-rte sensorsignalinPUt

Not used -Throttle Position(TP)sensorsignal input

VehicleSpeed Sensor(VSS)signal Inpur Data communicationwith ECM: Transmissioncontrol data outpUt Data communicationwith EClvl: PGM Fl control data inPut Driven pulley speedsensorground Driven pulley speedsensorsignal input

Drivepulleyspeedsensorsignal Input Not used BrakeswitchsignalinPut

Datacommunication: DIAG-H (TXD/RXD) Diagnostictrouble code outPut

814

816

VEL SG

Secondarygear shaft speedsensor grouno Drive pulley speedsensorground Parkingbrakeswitch signal inPut

N D RS G

819 B20 821

VREF

With ignition swltch uN {ll,: l-ulslng slgnal

ln other thTnE and E position:Pulsingsignal

-tn

ottrerttranE anaE position:Pulsingsignal

With brakepedaldepressed:Batteryvoltage 0V With brakepedalreleased: Wittr ignitio.rs*itct' ON (ll):Approx 5.0 V

on vehiclespeed:Pulsingsignal Depending 0V Whenvehicleis stoPped:

gearshaftspeedsensor Secondary signalinput

HBRKSW

With ignitionswitch ON (ll) and throftlefully open: 4 . 1 4- 4 . 4 2V With ignition switch ON (ll) and throttle fully closed:0.44- 0.56V With ignition switch ON (ll) and rotatingfront wheels0 r -5Vcycle With ignilion swltch UN lll): rulslng slgnar

With ignition switch ON (ll) and servicecheck connectoroPen:APProx.5 V With iqnition switch ON (ll) and servicecheck "onn"itot. connect"dwith specialtool: 0 V

VEL

818

With inhibitorsolenoidON: Bafteryvoltage With inhibitorsolenoidOFF:0 V With iqnition switch ON (ll):Approx.2.5 V With e;gine adling:Approx. 1.0V (dependingon enginespeed)

Se-ice ctrectsignat

815

817

Measuring Conditions/Terminal Voltage

Description

Not used +5 V relerence

Not used Not used

With parkingbrakelever pulledr0 V With parking brakelever released:Batteryvoltage

With ignitionswitchON (ll):Approx 5 V

PCMCircuitDiagram(A/T ControlSystem:'gg - 00 Models)

tGNtTtc{l SWTCH

UNDER.OASN FUSF]NEUY 8OI

UADEFD'SI FUSSFEUY 8OX r{o.2s(7 5A)

iPrE: T

rosv I N

lD

,:-^1 GETBPOSITIoi{

14-230

EI€INE COOLTI'II TEUPEFATUFE SENSOF

SPEED SEllsoF

Y

I I

I

T I .-l-

tI

GFN8U

l

t

u00u

t

I

t

l

EE

l

iflfl.S$' ilillfSIft,' *fl&'u''!l^" soLEl€|0

l

J-

H

I NHIEITOR

I soLEr,roro

I :

14-231

PGMTerminalVoltage/Measuring Conditions('99- 00 Modelsl A/T ControlSystem The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the A/T control system.The other PCMterminalvoltageand measuringconditionsare describedin section11. PICMConnoctorTerminrl Location3

Terminal Number

Signal

A7

ATP D

A,/Tgear position switch E positioninput

InEposition:OV In otherthan E] position:Approx.1OV

A9

ATP NP

A/T gear position switch @ and S positionsinput

In E andEl positions: 0V In otherthanE] andE position: Approx.1OV

Timing and adjustmentservice checksignal

With ignitionswitchON {ll} and servicecheck connectoroDen:5 V With ignitionswitchON (ll) and servicecheck connectorconnectedwith soecialtool:0v In E position;OV In otherthan E position:Approx.10 V

A10

ATP L

STOPSW

Descriplion

A,/Tgear position switch I positioninput Brakeswitchsignaloutput

MeasuringCondhions/TorminalVoltage

Brakepedal depressed:Batteryvoltage Brakepedalreleased:0 V

PCMCONNECTORB I25P} Terminal Number

Signal

B1

IGPl

Powersupplycircuitfrom main relay

82

PG1

Ground

B8

HLCLSM

B9

IGP2

Powersupplycircuitfrom main relay

810

PG2

Ground

817

HLCLSP

PH-PLcontrollinearsolenoid power supplypositiveelectrode

818

SC LSM

Startclutchcontrollinear solenoidpower supplynegative electrode

Description

LGI

Ground

821

VBU

Back-uppowersupply

825

14-232

With ignitionswitchON (lll: Batteryvoltage With ignitionswitchOFF:0 V

PH-PLcontrollinearsolenoid power supply neqativeelectrode

s20 B22

MoasuringCondhions/TerminalVohage

With ignitionswitchON (lll: Batteryvoltage With ignitionswitchOFF:0V

With ignitionswitchON {ll):Pulsingsignal

Always battery voltage

Ground SC LSP

Stan clutchcontrollinear solenoidpowersupplypositive electrode

With ignition switch ON (ll): Pulsing signal

\

a D {16P) PCMCONNECTOR TerminalNumbs]

Signal

D1

VEL

02

Description

Measuring Conditions/TerminalVoltage

Secondarygearshaftspeed sensorsignalinput

Dependingon vehiclespeed:Pulsingsignal APProx.0 V Whenvehicleis stoPPed:

S O LI N H

lnhibitorsolenoidcontrol

With inhibitorsolenoidON: Batteryvoltage With inhibitorsolenoidOFF:0 V

D3

SH LSM

Shift controllinearsolenoid power supplynegativeelectrode

D4

SH LSP

Shift controllinearsolenoid power supplypositiveelectrode

With ignitionswitchON (ll):Pulsingsignal

D5

VB SOL

Powersupplyfor solenoidvalves

With ignitionswitchON (ll):Bafteryvoltage With ignitionswitchOFF:0V

D6

ATP R

A,/Tgear position switch E positioninput

InEposition:0V In otherthan B position;Approx.10 V

D]

V E LS G

SecondarygearshaftsPeed sensorground Not used

D8

Not used

D9 D10

NDN

Drivenpulleyspeedsensorsignal anput

In otherthan E and E position:Pulsingsignal

D11

NDR

ln otherthan E and E position:Pulsingsignal

D12

N D RS G

Drivenpulleyspeedsensorsignal input Drivepulleyspeedsensorground

D13

ATPS

A,/Tgear position switch E positioninput

D14

D IND

D indicatorlight control

I n E p o s i t i o n0: V In otherthan E position:Batteryvoltage When ignitionswitchis firstturnedON (ll): Batteryvoltage for two seconds In E position:Batteryvoltage

Not used

D15 D16

NDN SG

Drivenpulleyspeedsensor ground

14-233

TroubleshootingProcedures

l. How To BeginTroubleshooting When the E indicatorlight has been reportedon, use the appropriateprocedurebelow to diagnoseand repatrthe proDlem. A . W h e nt h e @ i n d i c a t olri g h th a sc o m eo n : l

connectthe HondaPGM Testeror an oBD ll ScanTool to the 16PData Link Connector(DLc) locatednearthe left kickpanel.

2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 3 . Checkthe DTC and note it. Also checkand note the freezeframedata. R e f e rt o t h e D i a g n o s t i T c r o u b l eC o d eC h a r ta n d b e g i nt r o u b l e s h o o t i n g .

o0\e--loo

INOICATOR LIGHT

NOTE:SeetheOBDll ScanTool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions. Some PGM-FIproblemswill also makethe E indicatorlight come on. After repairingthe pGM-Flsystem,disconnectthe BACKUP fuse (7.5Al in the under-hoodfuse/relaybox for more than l0 secondsto resetthe TCM or PCMmemory,rnen recheck. NOTE:Disconnecting the BACKUP fuse also cancelsthe radio presetstationsand the clock setting.Make note of the radiopresetsbeforeremovingthe fuse so you can resetthem,

OATALINKCONNECTOB I16P}

14-234

connectedto the B. DTCSwill be indicatedby the blinkingof the E indicatorlight with the SCSserviceconnector (2P) on the passen the dash under is located (The Check Connector Service ServiceCheckConnectoras shown. (ll). ON switch ger'ssideof the vehicle.)Turn the ignition

i

i

i:j ,,,/

CONNECTOR {2PI

CONNECTOR

07PAZ- 00101(x)

aboveare indicatedby a seriesof long and short codes 1 through9 are indicatedby individualshon btinks.codes 10 and b|inks.one|ongblinkequa|sloshortb|inks.Addthe|ongandshortb|inkstogethertodeterminethecode.After m i n i n g t h e c o d e , r e f e r t o t h e e | e c t r i c a | s y s t e'99 msymptom-to-componentchartonpagesl4-238and14.239forthe,96_9 - 00 models models,and on pages14-240and 14'241for the Shorl blink (oncc)

Soc DTCI

Sor DTC2

Long blink

Short blinks |tive tim€sl

Scc DTCI5

the PGM-FIsystem,disconnectthe some pGM-Ftproblemswi atso makethe E indicatorlight come on. After repairing BACKUPfuse(7.5A)intheUnder.hoodfuse/re|ayboxformorethanl0secondstoresettheTcMorPcMmemory recheck.

(cont'd)

14-235

TroubleshootingProcedures (cont'd) C. lf the inspectionfor a particularcode requiresvoltageor resistance checksat the TCM or PCMconnectors,remove the driver'sside kick panel,and unbolt the TCM, and at the PCMconnectors,removethe passenger'sside kick panel,and unbolt the PCM.Turn the ignitionswitchOFF,and connectthe backprobesetsand a digitalmultimeter as describedbelow.Checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)listedon the followingpages. 6x1.0mm 9.9N.m{1.0kgt m, 6 x 'l,0 mm 9.EN.m (1.0 kgf.m, 7.2 rbtftt

How to use lhe Backprob€SE{ Connect the backprobeadaptersto the stacking patch cords, and connect the cords to a multimeter, Using the wire insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the wire side until comesin contactwith the terminalend of the wire.

BACI(PROBESET

07saz- 001txtoa Itwo requirodl

ADAPTER

coRo

14-236

DIGITALMULTIMETER (Commarciallyavsibblel KS-AHM-32-(x)3, or oquivalent

ll. TCM ResetPlocedure 1. Turn the ignitionswitchoff. 2. Removethe BACKUp fuse (7.5A) from the under-hoodfuse/relaybox for 10 secondsto resetthe TCM or PCM. NOTE: . Disconnecting the BACKUPfuse also cancelstheradio presetstationsand the clocksetting Makenole ofthe radio presetsbeforeremovingthe fuse so you can resetthem BACKUP

t7.sAl FusE

.

The TCM or PCMcan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester' OBD ll SCANTOOLo. PGMTESTER

{16PI DATALINKCONNECTOR lll. Final Procedut€ NOTE:This proceduremust be done afterany troubleshooting '1.Turn the ignitionswitchoff. 2. Resetthe TcM or PCM. the OBD ll ScanTool or HondaPGMTesterfrom the DataLink Connector(16P),or removethe specialtool 3. Disconnect from the ServiceCheckConnector. 4. Turn the ignitionswitchON (ll),and setthe radiopresetsand clocksetting.

14-237

Symptom-to-Component Chart ElectricalSystem-'96 - 98 Models DTC*

O Indicator Light

MIL

P1790 (3)

Blinks

ON

P179'l (4)

Blinks

ON

Vehiclespeedsensor

P1705 (5)

Blinks

ON

Ay'Tgear position switch (short to groundl

P1706 (6)

OFF

ON

A/T gear position switch {open)

P0725 (11)

Blinks

ON

P1793 112l

Blinks

ON

Manifoldabsolutepressuresensor

P1 8 7 0 (30)

Blinks

ON

Shiftcontrollinearsolenoid

P'1873 (311

Blinks

ON

PH-PLcontrollinearsolenoid

P1879 (32)

Blinks

ON

Startclutchcontrollinearsotenoid

Blinks

ON

Blinks

ON

Drivepulleyspeedsensor

P1886 (35)

Blinks

ON

Driven pulley speed sensor

P1888 (36)

Blinks

ON

Secondarygear shaftspeedsensor

(37)

Blinks

ON

P1890 l42l

Blinks

ON

P1891 (43)

Blinks

ON

P1882 P1885

(34)

T to55

Detectionltem Throttlepositionsensor

lgnitioncoil

Inhibitorsolenoid

ECMor TCM Shift controlsystem Start clutch control svstem

Page 14-242 14-243 't

4-244

14-246 14-248 14-249 14-250 14-25'l 14-252 14-253

1l-Zb4 14-255 14-256 14-257 14-259 14-260

*: The DTCin parentheses is the code @ indicatorlight indicateswhen the DataLinkConnectoris connectedto the Honda PGMTester.

14-23a

lf the self-diagnostic E indicatorlight does not blink,performan inspectionaccordingto the table below. Symptom E indicatorlight does not come on for two secondsafterignitionswitch is firstturn on (ll). E indicatorlight is on constantly(not blinking)wheneverthe ignition switchis on (ll).

Inspection

Ref.page 14-262 14-264

NOTE: . lf a customerdescribedthe symptomfor code P1706(6),it will be necessaryto recreatethe symptom by test driving, then recheckthe DTC. lf so, repairthe . Sometimethe E indicatorlight and the MalfunctionIndicatorlamp (MlL)may come on simultaneously. pGM-Flsystem accordingto the DTc, then reset the memory by removing the BACK uP fuse in the under-hood (50 km/h)'then fuse/relaybox for more than 10 seconds.Drivethe vehiclefor severalminutesat a speedover 30 mph recheckthe DTC.

14-239

Symptom-to-Com ponentChart ElectricalSystem-'99 - 00 Models E Indicatot Lighr

MIL

P1705 (5)

Elinks

ON

A,/Tgear positionswitch(shortto grouno,

P1706 (6)

OFF

ON

A"/Tgear position switch (open)

P1870 (30)

Blinks

ON

Shiftcontrollinearsolenoid

P1873 (31)

Blinks

ON

PH-PLcontrollinearsolenoid

P1879 t32l

Blinks

ON

Stan clutchcontrollinearsolenoid

P1882 (33)

Blinks

ON

Inhibitorsolenoid

P1885 (34)

Blinks

ON

Drivepulleyspeedsensol

P1886 (35)

Blinks

ON

Drivenpulleyspeedsensor

P1888 (36)

Blinks

ON

Secondarygear shaft speed sensor

P1890 \421

Blinks

ON

Shift control system

P1891 (43)

Blinks

ON

Start clutch control system

DTCT

r: The DTc in parentheses is the PGM Tester.

14-240

Detostion ltem

Page 14-265 14-26€ 14-271 14-213 14-215 't4-277 't

4-279

14-281 14-283 14-245 14-286

codeE indicatorlight indicateswhen the DataLinkconnectoris connectedto the Honda

table below. lf the self-diagnostic E indicatorlight does not blink.performan inspectionaccordingto the SYmPtom IDIindicatorlight does not come on for two secondsafter ignitionswitch is firstturnedON (ll). lE1indicatorlight is on constantly(not blinking)wheneverthe ignition switchis ON {ll).

Inspection

Ref.page 14-284 14-290

NOTE: by test driving, . lf a customerdescribedthe symptomfor code Pl706 (6),it will be necessaryto recreatethe symptom then recheckthe DTC. lf so, repair . iometimes, tfre E indicatorlight and the MalfunctionIndicatorlamp (MlL) may come on simultaneously in the underfuse RADIO BACK UP the removing by the PGM-Flsystemaccordrngto the DTC,then resetthe memory km/h)' then mph 30 {50 over at a speed minutes for several the car Drive hood fuse/relaybox for more than 10 seconds. recheckthe DTC.

14-241

ElectricalTroubleshooting('96- 98 Modelsl TroubleshootingFlowchart- Throttleposition(Tpl Sensor NOTE:Recordall freezedata beforeyou troubleshoot. . OBOll ScanTool indic.tes Code P1790. . Self-diagnosisE indicator light blinks three times.

PossibleCause . Disconnectedthroftle position (TPl3ensorconnoctol . Short or open in TP sensorwire . FauhyTP sensol

Checklor Anothar Code or MIL Blinking: 1. Turnthe ignitionswitchON 1 ). 2. Checkwhetherthe OBD ll scan tool indicatesanothercode or the MalfunctionIndicatorLamp (MlL)blinks(seesecrion11).

Doesthe OBDll scantool indicate anothercode oristhe MILblinking?

Repairthe PGM-FIsystom (3ee section 111.

TCM CONNECTORS

MeasureVREFVoltage: 1. Turnthe ignitionswitchOFF. 2. Disconnect the A (26P)and B { 2 2 P }c o n n e c t o r sl r o m t h e TCM. 3. Turn the ignition switch ON {fl). 4. Measurethe voltage bet\iveen the 820 and A13 or 426 terminals,

ls lhereapprox.5 V?

BLK

WHT/RED Wire s;deof femaleterminals

Repairopen or short in thc wire b,stween the Bao tcrminal rnd the ECM.

MeasureTPS Voltago: Measurethe voltagebetweenthe B4 and A13 or 426 terminals.

ls there0.4- 0.6V?

Checkfor loose TCM connectors. lf necessary,substitute a knowngood TCM and r6check.

A {26P1

Repail open in the wire tr€tweon the Erl t6.minal ind the TP sen3o..

(VSS) TroubleshootingFlowchart - Vehicle Speed Sensor NOTE:Recordall freezedata beforeyou troubleshoot' . OBD ll ScanTool indicatesCode P1791. . Setf-diagno3isE indicato. light blinks tour times.

Po$ribleCtuse . D i s c o n n e c t e dv e h i c l e s p e e d sensor (VSS)connectol . Short or open in VSS wire ' Faulty VSS

Refer to seclion 23 for vehicle soeedsensor IVSSItest

Check the VSS Voltage: 1 . R a i s et h e v e h i c l e 2 . S h i f t t h e t r a n s m i s s i o nt o l E posrtlon. 3 . D i s c o n n e c tt h e A ( 2 6 P )a n d B (22P) connectors from the

@

. Make sure lifts, iacks,and sal€tYstands are placedproperly lsoe section 1)' . Set the parking brake securelv,and block the rear wheels' . iacr upile rront or the vehicle,and support it with safety st'nds' TCM CONNECTORS

TCM. 4 . T u r n t h e i g n i t i o ns w i t c h O N { l l ) . 5. Rotate the front wheel and check for the voltage between the 85 and 413 or A26 terminals. Blockthe other wheel so at does not turn

Wire sideof femaleterminals

D o e s 0 V a n d a p p r o x5 V o r m o r e appearalternatelY?

Check for oP€n in the wire between the 85 terminal and the vehicle speed sensor {VSS}. lf wire is OK, check the vSS (see soction23).

Checkfor loos€ TCM connedors lI nec€ssary,substitute a known' good TCM and recheck.

14-243

ElectricalTroubleshooting('96- 9g Models) TroubleshootingFlowchart- A/T GearpositionSwitch (Short) NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanTool indicatesCode P1705. . Seif-diagnosis@ indicator light blinksfive times.

Obsorvethe A/T gear position indicetor: 1 . T u r n t h e i g n i t i o ns w i t c hO N 1[). 2. Observetho Ay'Tgear position i n d i c a t o r ,a n d s h i f t t o e a c h positionseparately.

Do any jndicatorsstayon when the sh;ft leveris not in that position?

PosribleCause . Short in A/T go.r position switch wire . Faulty A/T g€ar polition switch NOTE: Code P1705(5)is causedwhen t h e T C M r e c e i v e st w o g e a r p o s i t i o n Inputsat the sametime.

Th6 lyrtcm i3 OK at thi. tima. Check the wi.s hamels for drm. ag9.

TCM CONNECTOR A {26P}

MeasureATP R Vohage: 1. Shiftto all positionsotherthan

E.

2. Measurethe voltage between the 411 and A13 or A26terminats.

ls thereapprox.10V?

MeasureATP NP Volt.ge: 1 . S h i f t t o a l l p o s i t i o n so t h e r than @ or @. 2. Measurethe voltage between the A10 and 413 or 426 terminals,

ls thereapprox.10V?

Check for sho.t in tho wire b€twoonthe Al1 t rminaland th6 A/l ge.r polhion switch or A/T gear position indicstor. lf wilo is OK check for loos6 TCM conncctora. It nocassery, subrtitute a known-good TCM and r€chsck.

Ch.ck tor 3hort in th€ wirc b€twe€n thc Al0 termin.l and the A/T 96r. porition indicrtor, or a short in the wilea b?twecn tho A/T gerr porition indic.to. and the A/T geer position switch. It wires ar6 OK, chsck for loose TCM conn.clols. ll nccNe3sa.y, substituto a known-good TCM rnd locheck.

Measure ATP O Vohage: 1 . S h i f t t o a l l p o s i t i o n so t h e r t h a n

E,

2. Measurethe voltagebetween the Ag and A13 or 426 termi nals.

l s t h e r e a p p r o x . ' 1 0V ?

To page14-245

14-244

Checl tor short in the wire lr€tweon tho A9 terminal and the A/T g6a. position 3witch. lf wire b OK. check tor loos€ TCM connectors. lf nocelsary, substhute a known-goodTCM and rechack.

Wire sideof femaleterminals

A (26P) TCM CONNECTOR From page l4-244

Measure ATP S Vollage: 1 . S h i f t t o a l l P o s i t i o n so t h e r t h a n 2. Measure the voltage between the A8 and A13 or A26 termi nals.

Wire sideof femaletermanals

ls thereapprox.10V?

Check lor shott in the wire between the A8 terminal and the A/T gea. Position switch or the A/T gearpositionindicator.lf wire is OK, check for loose TCM con_ nectors. lI necessary,substitute a known-goodTCM and recheck.

MeasureATP L Voltage: '1. Shiftto all positionsotherthan

E-

2, Measurethe voltagebetween the A7 and A13 or A26 terminals.

ls thereapprox.10V?

Check for short in the wi.e between the A7 terminal and the A/T gear position switch or the A/T gear position indicator. lf wire b OK. check for loose TCM connectors. ff necessary,substilute a known-goodTCM and recheck.

Checklor loose TCM connectors. lf necessary.substitute a known' good TCM and recheck.

14-245

ElectricalTroubleshooting(,96- 9g Models) TroubleshootingFlowchart- A/T GearpositionSwitch (Openf NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanToot indicat* Code P1706, . Solf-diagnosisE indicator tight blinb six times.

Pos.riblsCause . DisconnoctedA/T gear position switch connector . Open in A/T gear position switch . Faulty A/T gear position switch TCM CONNECTOR A I26PI

Measule ATP R Volt.gei 1. Turn the ignitionswitch ON l). 2. Shifito E position. 3. Measurethe voltage between the A11 and 413 or ,426terminals.

Repairopen in tho wire betwoen lhe A11 terminaland the A/T goar po3ition switch.

MeasureATP NP Volt.gei 1. Shifrto E orE position. 2. Measurethe voltage betlveen the A10 and A13 or 426 termi nals.

Repairopen in the wiro between the A10 terminal.nd tho A/T gea. poshion swhch.

MeasureATP D Vohage: 1. Shiftto E position. 2. Measurethe voltagebetween the Ag and A'13or 426 termi-

Repairopen in the wire lretween the A9 terminel and the A/T gear position 3witch.

To page14-Z4j

14-246

Wiresideof femaleterminals

A l26p) TCM CONNECTOR

From page 14 246

MoasureATP S Voltage: 1. Shiftto E Position 2. Measurethe voltagebetween the A8 and 413 or 426 termi nals,

Bepair open in the wir€ between the A8 t€rminal and the A/T gear position switch.

Wire sideof femaleterminals

MeasureATP L Vohage: 1. Shiftto E Position 2. Measurethe voltagebetween the A7 and A13 or 426 terminals.

Repairopen in the wire between the A7 terminal and the A/T geal Dositionswitch

Chocktor loose TCM connectors. lf necessary,substitute a l(nowngood TCM and recheck,

14-247

ElectricalTroubleshooting('96- 9g Models) TroubleshootingFlowchart- lgnitionCoil NOTE:Recordall freezedata beforeyou troubleshoot, . OBD ll ScanTool indicatesCode POl25. . Soll-diagnosisE indicarol light indicatesCode 11.

Po3ribleCause . Dbconnected ignition coil connectol . Short o. op6n ignition coil wire ' F.ulty ignition coil

MeasureNE Voltrge: 1. Disconnectthe A {26p) con nectorfrom the TCM. 2. Startthe engine. 3. Measurethe voltagebetween the A5 and 413 or A26 terminals, Wire sideot femaleterminals

ls there battery voltage?

Check for loose TCM connector. It nec$sery. substilute a knowngood TCM and .echeck.

R6p.i. open or short in the wire b€lween the A5 te.minsl and tho ignhion coil. It wir€ b OK, check the ignition coil test lsoc aoction 23t.

Sensor TroubleshootingFlowchart- ManifoldAbsolutePressure{MAPI NOTE:Recordall freezedata beforeyou troubleshoot . OBD ll ScanTool indicatesCode P1793, . self-diagno3b E indicato. light indicat€sCode 12.

PG.iblo Cau3€ . Dkconnoctodmanilold .bsoluto ore33urcIMAP) sensor connoc' lor . Short or opcn in MAP s.nsor MAP sen3or

Chock tor Another Cod€ or MIL Blinking: 1. Turnthe ignitionswitchON (ll). 2. Checkwhetherthe OBD ll scan tool indicatesanother code or the Mal{unctionIndicatorLamP (MlL)blinks(ssesection11).

Doesthe OBDllscan tool indicate anothercodeor isthe lVlLblinkin9?

TCM CONNECTORS

MeasureVREFvoltage: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe A (26P)and B ( 2 2 P )c o n n e c t o r st r o m t h e TCM. 3. Turn the ignitionswitchON (ll). 4, Measurethe voltage between the B2Oand A13 or A26termr nals.

WHT/RED Wire sideof femaleterminals

lsthereaPprox.5V?

R€pair opon or 3hort in the wire botwoan the 820 t€.minal and the EcM.

MsasureMAP IPB)volt.ge: Measurethe voltage betlveenthe 82 and A13 or 426 terminals.

ls thereapprox.3 V?

Repair opon ot shorl in the wiro betwesn the 82 torminal end th€ MAP sensol.

Checkfor loo3eTCM conn€stors. lf nec*sarY, sub3titute a known' good TCM and rechock.

14-249

ElectricalTroubleshooting(,96- 9g Modelsl TroubleshootingFlowchart- Shift ControlLinearSolenoid NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanToot indicatesCode P1870. . Selt-dirgnosis[d indic.tor tight indicatosCode30.

PossibleCause ' Disconnected3olenoid h.rn€is connoctor . Short or open in 3hift control linear solenoidwire . Faulty shift control linear solenoid

SOLENOIDHARNESS 8P CONNECTOR BLU/WHT

MeasureShift ControlLinoarSolenoid Resistanceat the Solenoid HarnessConnector: 1. Disconnectthe 8p connector fromthe solenoidharnesscon nector. 2 , M e a s ur e t h e r e s i s t a n c e betlveenthe No. 3 and the No. 7 terminalsofthe solenoidhaF nessconnector.

GRN/YEL Terminal stde of male terminals

ls the resistance 3.8- 6.8O? TCM CONNECTOR A I26PI

Check Shift Controt Linear Sotenoid for a Short Circuit: 1 . D i s c o n n e ct th e A ( 2 6 p )c o n , nectorfrom the TCM. 2. Checkfor continuitybetween body ground and the A3 ter minal and the A16 terminal individually. Wiresideof femaleterminals

Repair shon in tho wire6 betweon the A3 and A16 termin.ts lnd tho body ground. GRN/YEL M e a s u r eS h i t t C o n t r o l L i n e . r SolenoidResistance: 1. Connectthe 8P connectorto the solenoidharnessconnec, tor. 2 , M e a su r e t h e r e s i s t a n c e betweenthe 43 and A16 ter-

ls the resistance 3.8 6.8O?

Chockfor loose TCM connectorc. ll necessary,substitute a knowngood TCM and recheck.

14-250

l l 1 2 l :1

5

IriGlx 1 7 8LU/YEL

Repairloose terminal oa open in the wires between the 43 and A16 terminal3and the solenoid harnessconnector.

7

2t)

8

9 10 1 1 12 13

23

25 26

Troub|eshootingF|owchart_PH-PLControJLinearSo|enoid NOTE| Recordall treezedata beforeyou troubleshoot . OBD ll ScanTool indicatesCodo P1873. . sef-diagnosis E indicalor light indicat6 Code 31.

Possiblecause ' Disconnectedsolenoid harness connectof . Short or oPen in PH_PLcontrol linear solenoidwire . FaultyPH-PLcontrol linear sole_ noid

SOLENOIOHARNESS 8P CONNECTOR

Measure PH-PLControl Linear Solenoid Resistanceat the Sole_ noid HatnessConnectot: 1. Disconnectthe 8P connector confrom the solenoidharness nector, 2. Measure the resistance betweenthe No 2 and the No. 6 terminalsofthe solenoidhar nessconnector'

GRN/WHT

PNK/BLK Terminalsideof maletermlnals

3.8- 6.80? ls the resistance A (26P) TCM CONNECTOR

o Check PH-PLControl Lineer Solenoidfor a Short Circuit: 1 . D i s c o n n e ct th e A 1 2 6 P c) o n nectorlrom the TCM 2. Checkfor continuitybetween body ground and the A2 ter minal and the A15terminal individually.

I

PNK/BLK 2

3

5

4

1 1 't5 1 6 1 7

I

7

8

20

/,,/

10 l 1 1 2 13

23

25 26

IGRN/wHr

o

Wire side ol female terminals

Repair short in th€ wires between the A2 and A15 lermi_ nals and the body glound.

*r}l

Measute PH-PLControl Linear SolenoidResi3tance: 1. Connectthe 8P connectorto the solenoidharnessconnector, 2 , M e a su r e t h e r e s l s l a n c e betweenthe ,q2 and A15 ter_

3.8-6 8 O? lsthe resistance

PNK/8LK

t'T, E[

3

a 5

16

I

20

9 1 0 1 1 12 1 3

23

25 26

GRN/WHT

Rep.il loose tetminal or oPen in th6 wires betwccn the A2 and A15 lerminals and the solenoid harnessconn€ctol.

Checkfor loose TCM connactors lf neceasery,Substitutea knowngood TCM and rechock.

14-251

ElectricalTroubleshooting('96- gg Modelsl Troubleshooting Flowchart- start clutchcontrolLinearsolenoid NOTE: Recordall freezedata before you t.oubleshoot. . OBOll ScanTool indicatG Code P1879. . Self-dilgno.is E indicator light indiclt$ Code32.

Po$iblo C.u.o ' Di3aonnoctodsolanoid harncat connactol . Short or opon in start clutch control linoar tolanoid wira . Faulty ttart clutch control lino.r solanoid

Me.suro Sta.t Clutch Control LinearSolenoid Rosirtrnco st th. SolenoidHrrn6rs Connecto.: 1. Disconnectthe 8P connector from the solenoidharnessconnector. 2, Measure the resistance betweenthe No. 4 and the No. 8 terminalsotthe solenoidharnessconnectot.

SOLENOIDHARNESS 8P CONNECTOR

YEL

PNK/BLU Terminalsideof maleterminals

ls the resistance 3.8- 6.80?

TCM CONNECTOR A I26P} Chock Start Clutch Control Linoar Solenoidtor a Short Circuit: 1. Disconnectthe A (26p) con, nectorfrom the TcM. 2. Checklor continuity between body ground and the A1 terr n i n a la n d l h e A l i l t e r m i n a l individually.

Wiresideof femaleterminals

Raprir 3hort in tha wira3 b.ftvcen tho A1 .nd Atil t .mi. n.l. .nd thr body ground.

-{r-

Measure Stan Clutch Cont.ol LineerSolenoidF6aist.ncei 1. Connectthe 8P connectorto the solenoidharnessconnector. 2 . M e a su r e t h e r e s i s t a n c e betweenthe 41 and Al4 terminals,

ls the resistance 3.8- 6.8O?

Checkfor loose TCM connecto.s. lf necessary, substitute a knowngood TCM and iecheck.

14-252

PNK/BLU

E

2 3 a 5 a 15 t 6 1 ' YEL

Rcplir loose tcrminal or oDcn in thG wiras b.tween the Al rnd Ala torminal3 rnd tha 3olanoid hamaas connactor.

1

20

I

9 1 0 l l 12 13

a

25 2G

TroubleshootingFlowchart- InhibitorSolenoid NOTE:Recordall treezedata betoreyou troubleshoot . OBD ll ScanTool indic.td Code P1882. . Selt-di.gnGis E indicator lighl indic.tos Code 33.

Po$ibls Cause . Dbconnected solenoid hatness connedor ' Short or opon in inhibitor sole' noid wire . Faultv inhibitor solenoid SOLENOIDHARNESS 8P CONNECTOR

Mea3ureInhibhorSolenoidResidance at the sol€noid Harness Connector: 1. Disconnectthe 8P connector f r o m t h e s o l e n o i dh a r n e s s connector. 2. Measure the reslstance betlveenthe No 5 terminal of the solenoidharnessconnector and body ground.

Terminalsideof maleterminals

11.7- 21 0 0? ls the resistance

Check Inhibitor Solenoid lor a Short Circuii: 1 . D i s c o n n e ctth e B ( 2 2 P )c o n nectorfrom the TCM. 2. Check for continuity between t h e B 1 t e r m i n a la n d b o d y gro!no. Wire sideof femaleterminals

Repairrhort in the wire ltetwegn the 81 dnd the bodY ground.

Mea$rr€ Inhibitor Solenoid ResBt' anoe: 1. Connectthe 8P connectorto the solenoidharnessconnec_ IOr. 2. Measure the resistance betweenthe Bl and body ground.

11.7- 21.0O? ls the resistance

Reoair loose terminal or open in the wire betwean the 81 and the solenoid hame3sconnector'

Ch6ckfor loose TCM connectors. ll necessary, substhule a known_ good TCM and techeck.

14-253

ElectricalTroubleshooting{'96 - 9g Models) TroubleshootingFlowchart- DrivepulleySpeedSensor NOTE:Recordall freezedata beforeyou troubleshoot, ' OBD ll ScanTool indicatesCode P1885. . Self-diagnosisE indicator tight indicatesCode34.

Po$ible Cause . Oisconn€cted drive pulley speed sensorconnector . Shon or op€n in drive pulley spgedsonsorwire . Faulty drive pulley spoed s.nsot

C h e c kt h e d r i v e p u l l e y s p e e d s e n , sor installation.

ls the drivepulleyspeedsensor installedproperly?

ORIVEPULLEYSPEED SENSOR2P CONNECTOR

M6a3ureDrive PulleySp€ed S€nsor Resistanceai the Seosor Connectot: 1. Disconnectthe 2P connector from the drive pulley speed sensorconnector. 2. Measurethe resistance of the drivepulleyspeedsensor.

lT_ T---_l

-rr lt 9l

1 | 2 tl

t| ]--+i

L_t

TerminalsideoI maleterminals ls the resistance350 - 600 O? TCM CONNECTOR 8 I22PI REO/BLUJ ( l

Check Orive Pulley Speed Sensor tor a Short Circuit: 1. Disconnect the B (22P)connectortromthe TCM. 2. Checkfor continuitybetveen body groundand the 810 term i n a la n d 8 1 7 t e r m i n a il n d i vidually.

2 4 5 6 8 9 10 1 2 1 3 t 4 15 1 6 1 7 1 8 20 GRN

o Rspair shon in the wi.es botwoen the Bl0 and 817 te.minals and the driva pulloy 3peod 3eniol.

Wiresideof femaleterminals

Measure Drive Pulley Sp€€d Sensor Re3istance: 1. Connectthe drivepulleyspeed sensor2P connector. 2 , M e a su r e t h e r e s i s t a n c e betweenthe 810 and 817 termtnals.

REO/8LU

1 ls the resistance 350- 600O?

Check tor looso TCM connoctor. ll necessary,substituto a knowngood TCM and recheck.

14-254

Repair loos6 t.rmin.l or open in th. wiros botweon tho Bl0 and 817 torminals and thg driva pulley sp€gd sensor.

2

1

5

12 1311 15 1 6

iliI;W1M tdil)lil/l

GRN

v

TroubleshootingFlowchart- DrivenPulleySpeedSensor NOTE:Recordall freezedata beforeyou troubleshoot' . OBD ll ScanTool indicatesCode P1886. . Sell-diagnosisE indicator light indicatesCode 35.

Po3sibleCause . D i s c o n n e c t e dd t i v e n P u l l e Y so6edsensorconnector . Short or open in driven PulleY apeedsen3orwire . Faulty driven PulloYsPeod 3en-

DRIVENPULLEYSPEEO SENSOR2P CONNECTOR

ls the drivenPulleyspeedsensor installedproPerlY?

l-_r| 1 2 l :-

M€asure Driven Pulley SP€edSen_ sor Resbt nce at the SensorConneclof: 1. Disconnectthe 2P connector from the driven PUlleyspeed sensorconnectol. ot the 2. Measurethe resistance drivenpulleyspeedsensor.

tt 9t

L_.1

Terminalsideof maletermrnals

350 6000? ls the resistance I l22p) TCM CONNECTOR WHT REO/BLU ^\, Check Driven Pulley Speed Sensor {or a Short Circuit: 1. Disconnectthe B (22P)connec_ tor from the TCM. 2. Checkfor continuitybetween body ground and the BB ter minaland 89 terminalindivid'

8 9 10 6 '17 '16 20 18 12 13 1 a 15 1

Repair sho.t in the wiles between lhe 88 and Bg lerminals tnd the driven pulleY3Peed3€nsor.

2

a

Wire side oI female terminals

RED/BLU] WHT

o

Measure Driven Pulley SPeedS€nsor Reistance: 1 . C o n n e c t h e d r i v e nP u l l e Y speedsensor2P connector' 2 . M e a s ur e t h e r e s i s t a n c e betweenthe 88 and Bg terml_ nals.

350- 600O? ls the resistance

o

1

2

1

6

12 1 3 1 a 1 5 1 6 1 7 1 8

10

8 20

Repair loos€ terminal or oPen in the wires between the Bg and Bg torminals and the dtiven Pulley 3D6eO S6n50a,

Check lor loose TCM connector. lf necessary,substitute a known_ good TCM and rechack.

14-255

ElectricalTroubleshooting('96 - 98 Modelsl TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor NOTE:Recordall freezedata beforeyou troubleshoot. . OBD ll ScanTool indicatesCode P1888. . Selt-diagnosisIq indicator light indicatesCode 36.

Po$ible Cause

. Disconnectedsecondarygeal shaft speodsen3orconnectol . Short ol open in s€condary gear shaft spe€d sen3or wiro . Faulty secondary gear shatt speeds€nsor

Checkthe secondarygear shaft speedsensorinstallation.

SECONDARY GEARSHAFTSPEED SENSOR2P CONNECIOR

ls the secondary gearshaftspeed sensorinstalledproperly?

llll;ll

MeasureSecondaryGear Sheft Speod Sensor R8istance at the SensorConnector: 1. Disconnectthe 2P connector from the secondarygearshaft speedsensorconnector. 2. Measurethe resistance ol the secondarygear shalt speed

T_T

l @ t

l

LJ

Terminals i d e o f m a l e t e r m i n a l s

ls the resistance 350- 6000? TCM CONNECTOR B {22P} Check Counterchaft Speed Sonsor for a Short Circuit: 1. Disconnectthe B 122P)connec torfromtheTCM. 2. Checkfor continuitybetween body groundand the 815 ter m i n a la n d 8 1 6 t e r m i n a il n d i vidually.

ls therecontinuity?

I

14-256

5

6

9 10 20

ORN/BLU

-

D (o. Repair short in the wir€6 bctuveen th. 815 and 816 torminrls.nd the s€condary ge.r shaft speod

Wire sideof femaletermanals

1 a 5 6 7 8 I 10 1 2 13 1 4 1 5 1 5 1 7 1 8 20

A I

2 . M e a su r e t h e r e s i s t a n c e betweenthe 815 and 816 te. mrnals.

Check lor loose TCM connector. lf n€cessary, substitute a knowngood TCM and recheck.

1

WHT/REDT

Measu.e Secondary Gear Shatt Speed Sensor Resistance: 1. Connectthe secondarygear shaftspeedsensor2P connec-

ls the resistance 350 600O?

2

12 131 a 15 16 1 7 18

WHT/REI

Reprir loose terminal or opcn in the wires between the 815 and 8'16terminals and the secondary g€ar shaft sp€ed s€nsor,

ORN/BLU

TroubleshootingFlowchart- TMA and TMB Signals NOTE:Recordall freezedatabeforeyou troubleshoot' . OBD ll Scsn Tool indicate3Codo P1655. . Self-diagnosbE indicator light indicalesCod6 37.

PossibleCause . Shorl or op.n in TMA wi.o botwo6n 87 terminal and ECM . Short or open in TMB wiro bdtwoon BGto.min.l .nd ECM . F.ulty ECM . FaultyTCM

CheckTMA Wire Continuity: 1. Turnthe ignitionswitchOFF. 2- Disconnectthe I (22P)connectorlrom the TCM 3 . D i s c o n n e ct th e c ( 3 1 P )c o n ' nectorfrom the ECM 4. Checkfor continuitybetween t h e 8 7 t e r m i n a lo f t h e T C M and the Cg terminaloI the ECM,

B (22P) TCM CONNECTOR GRY

a

2

I

o 9 10

8

5

12 1311 1 5 16 17 18

20

C 13lPI ECMCONNECTOR GRY 1

2 3 a

1 112 t 3 l a

l8 9r0

5 6 18/

16

/ 29130/

WiresideoI temaleterminals

Ropail open in the wire betwcen the TCM and the ECM.

::) Check TMA Wir€ for a Short Circuit: Checkfor continuitybetweenthe 87 terminalof the TCM or the Cg t e r m i n a lo l t h e E C M a n d b o d y ground.

I

2

a 5 6

12 t 3 1 4 1 5 1 6 1 7 1 8

8

9 10

20

check rhe EcM: 1 . R e c o n n e ctth e C ( 3 1 P )c o n ' nector to lhe ECM, and the B (22P)connectorto the TCM 2. Turnthe ignitionswitchON (ll). 3. Measurethe voltage between t h e C 9 t e r m i n a lo I t h e E C M and body ground.

ls thereapprox.10V?

Chocktor loose ECMconnectors. lf nscossary,subdituta a known' good ECM.nd lecheck.

(cont'd) To page14 258

14-257

ElectricalTroubleshooting('96- 98 Models) TroubleshootingFlowchart- TMA and TMB Sigrrals(cont,d) from page14 257

TCM CONNECTOR 8 {22P}

CheckTMB Wire Continuity: 1. Turnthe ignirionswitchOFF. 2. Disconnect the C (31P)connec, tor from the ECM,and the I (22P)connectorfrom the TCM. 3. Checkfor continuitybetween t h e 8 6 t e r m i n a lo l t h e T C M a n d t h e C 3 0 t e r m i n a lo f t h e ECM,

PNK

2

6

I

12 1314

o 7 t 8

16 17 18

10

I

20

ECMCONNECTOR C 131P} 2

a

5 6 7

12 1 3 l a

ll

Repairopen in the wire betwe€n rhe TcM and the EcM.

8 I 10

17118

/l/l

)/)/l/l )aol'ol/ PNK

Wire sideof femaleterminals Check TMB Wire tor a Short Circuit: Checkfor continuitybetweenthe 8 6 t e r m i n a lo t t h e T C M o r t h e C 3 0 t e r m i n a lo t t h e E C M a n d body ground.

PNK

2

4

5

6

o ,

12 1 3 1 1 1 5 1 6 1 1 1E

8

9 10

20

ls therecontinuity?

Checkthe TCM: 1 . R e c o n n e ctth e B ( 2 2 p )c o n nectorto the TCM, and the C (31P)connectorto the ECM. 2. Turnthe ignitionswitchON (ll). 3. Measurethe voltage between t h e B 6 t e r m i n a to f t h e T C M and body ground.

ls thereapprox.S V?

Checkfor loose TCM connoctors. lf necessary,substitute e lnowngood TCM and recheck.

PNK

2 1 5 7 8 10 1 2 13 1 4 1 5 1 6 1 7 1 8 20

TroubleshootingFlowchart- Shift ControlSystem NOTE:Recordall freezedata beforeyou troubleshoot. OgD ll ScanTool indicatesCode P'1890. Self-diagnosi3E indicator light indicatesCode 42.

Po$ible Cause Faulty 3hift control system

Checkfor Anolhet Code: C h e c kw h e t h e rt h e E i n d i c a t o r lightindicatesanothercode.

ls the E indicator light indi cate another code?

P e r t o r mt h e T r o u b l e s h o o l i n g Flowchrrt to. th€ indicet.d Codelsl.

CheckStall SpeedRPM: M e a s u r et h e s t a l l s p e e dR P M (seepage14-298).

ls the stallspeedover 3,500rpm?

l s t h e s l a l l s p e e d b e l o w 2 . 0 o 0r p m )

T e s t - d r i v ea n d C h e c k En g i n e Speed: 1 . D r i v et h e v e h i c l ea t 3 0 m P h (50 km/h) constantlYfor sev_ eral manutes. 2. Checkthe enginespeed

ls the engine speed within the s p e c i f i c a t i o n( s e e p a g e 1 4 2 9 6 and 14 297\?

14-259

ElectricalTroubleshooting('96 - 98 Models) TroubleshootingFlowchart- Start ClutchControlSystem NOTE:Recordall freezedata beforeyou troubleshoot. OBOll ScanTool indic.le3 Cod6 P1891. Solt-diagnosisE indicator light indicatesCode(1.

Po$ible Ceuaa Frulty start clutch cont.ol 3ystem

Checkfor Another Codo: C h e c kw h e t h e rt h e @ i n d i c a t o r light indicatesanothercode.

ls the E indicatorlightindicateanothercode?

Poiform tho Troublcahootlng Flowchrrt lor the indicat.d Code(sl.

Test Strrt Clutch Oper.tion: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 8P connector from the solenoidharnesscon, nector. 3. Start the engine,and shift to E position. 4 . C h e c kw h e t h e r t h e v e h i c l e moves.

Rcplacath. strrt dudt r$amt ly.

CheckCreepingSpe€d: 1. Turnthe ignitionswitchOFF. 2. Reconnectthe 8P connectorto the solenoidharnessconnector, 3. Start the engin6,and shift to E position. 4 . C h e c kw h e t h e r t h e v e h i c l e creeps,and chockthe creepIng speed.

Does the vehicle move and is the creepingspeed approx.3 mph (5 km/h)?

To page 14-261

14-260

From page 14 260

CheckStall Speed RPM: Measurethe stallspeedRPM(see page14'298).

ls the stallspeedover3,500rpm?

Warm Up Engine and Recheck Failure: 1 . W a r m u P t h e e n g i n et o n o r ' m a l o p e r a t i n gt e m P e r a t u r e (theradiatorfan comeson) 2. Checkwhetherthe startclutch problemappearsagain.

Doesthe problemappear?

The svstem is OK at this time.

rl, 14-261 J

ElectricalTroubleshooting('96- 98 Modelsl TroubleshootingFlowchart- Pl IndicatorLight DoesNot GomeOn The E Indicator light does not come on when the ignition switch is tirst turned ON {ll). {lt should come on for aboul two s€conds,)

Chockthe ServiceCheckConneclot:

Make sure the specialtool (SCS S e r v i c eC o n n e c t o ri)s n o t c o n nectedto the seryicecheckcon nector,

ls the specialtool (SCSService Connector) connected to the servicecheckconnector?

Disconn€ctthe sDecialtool from the seruicecheck connector and recheck.

Checkthe E IndicatorLight: Shift to [5] oosition.

Doesthe E indicatorlight comeon?

Checkfo. loose TCM connectors. lf neceasary, substitute a knowngood TCM .nd rochock. A {26P) TCM CONNECTOR BLI

Ch€ckth6 Ground Circuit: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e A 1 2 6 P c) o n nectorfrom the TCM. 3. Checktor continuitybetween t h e A 1 3 t e r m i n a la n d b o d y ground and the 426 terminal and body ground.

I

1

2

3 a 5

1a 15 16 17

8 9 1 0 1 t 12

20

23

rt o

.Repair open in the wires betwoon lhe A13 or A26 terminel3and G101. . Repai.poorground{G1011.

14-262

25

nl

8LK

Wire side of female terminals

To page14-263

l-

Ftom page14 262 A I26P) TCM CONNECTOR BLK/WHT

Measure Powet SUPPIYCi.cuit Voltage: 1. TurntheignitionswitchON (ll) 2. Measurethe voltagebetween t e r m i n a lA s 1 2a n d A 1 3a n d b e t w e e nt e r m i n a l sA 2 5 a n d 426.

a

2

r

BLK

1 0 1 1 12 13 25 26 23

7

20

14 t5 16 17

I

A BLK/WHT

I

BLK

I

Wire sideof femaleterminals ls there batteryvoltage?

Repair open or short in the wire between the A'12andlor Ms lerminrls and the under-dashfuse DOX,

MeasureD IND Voltage: 1. Turnthe ignitionswitchOFF 2. connect the A (26P)connec tor to the TcM. 3. Connecta digkal multitester to the A20and A'13or A26ter minals. 4. Turnthe ignitionswitchON (ll), and makesure that the voltage for two seconds. is available

GRN/BLK

Check tor opon in the wire between the A20 l6rminal and the gaug€ assembly. It the wite is OK, check tor a faultY ipl indicalor light bulb or a faulty gauge assemblyprir ed circuit boatd. CheckD INOfor an Shott Circuit: 1. Turnthe ignitionswitchOFF 2 . D i s c o n n e ct th e A ( 2 6 P )c o n nectorfrom the TCM. 3. Checkfor continuitybetween the A20terminalandthe No.I terminalof the gaugeassembly connector(seesection23).

A (25P} TCM CONNECTOR 1

2

8

a 5

20

1 l 15 16 1 7

9 1 0 1 1 12 1 3

25 26

23

GRN/BLK GAUGEASSEMBLY 14PCONNECTOR Bepair open in the wire between the A20 terminal and the gauge assembly.

o

a 5 7

8

9 10

1 1 12

GRN/BLK

Checktor looso TCM connecto.s. C h e c kt h e A / T g e . r P o s i t i o n switch. lf nec6ssary,substitute a known-goodTCM and r€check

Wire side of female terminals

14

ElectricalTroubleshooting('96 - 98 Modelsl TroubleshootingFlowchart- lq IndicatorLight On Constantly The E indic.tor light is on constantly {not blinking}whonever the ignilion switch is ON llll.

TCM CONNECTOR A {26PI MeasureD INOVoltage: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e A ( 2 6 P )c o n ' nectorfrom the TCM. 3. Turnthe ignitionswitchON (ll). 4, Measurethe voltagebetween t h e A 2 0 t e r m i n a la n d b o d y ground,

2 3 4 1a 15 16 1 7

7

1 0 l l 12 13 23 25 26

8

20

GRN/BLK

Wiresideof femaleterminals Repeir3hort to power in thc wire between tho A20 terminal and ihe gauge ass€mbly.

MeasureATP DVohage: 1. Turnthe ignitionswitchOFF. 2. Connectthe A (26P)connector to the TCM. 3. Turnthe ignitionswitchON (ll). 4. Shift to any positionotherthan

YEL

1

E,

5. Measurethe voltagebetween t h e A 9 t e r m i n a la n d b o d y ground.

Check tor a short to ground on the wire. ll wire is OK, .epl.ce the A/T gear position indic.tor.

14-264

2

3

a

1a t5 16 17

5

7

20

8 9 1 0 1 t 12 1 3

a

25 26

ElectricalTroubleshooting('99- 00 Models) TroubleshootingFlowchart- A/T GearPositionSwitch (Short) NOTE:Recordall freezedata beforeyou troubleshoot. . oBD ll scln lool indicats code P't705. . Self-diagnosbE indicator light blinksfivetim€s.

Obseive tho A/T Gear Polition lndicetor: 1. Turnthe ignitionswitchON (ll). 2. Observethe A,/Tgear positaon indicator,and shift oach Position separately.

Doesany indicatorstay on when the shiftleveris not an that position?

Po3sibleCause . Short in A/T gear po3ition 3witch . F.ulty A/T ge6r Positionswitch NOTE: Code P1705(5)is causedwhen t h e P C M r e c e i v e dt w o g e a r P o s i t i o n inputsat the sametime.

Tho ry3t6m is OK at this tims. Check th€ wiro hsrno!! tor damage.

PCMCONNECTORS

Bt25Pt

llO(16P1

M.Furo ATP R Vohtge: 1. Shift to all positionsother than

E.

2. Measurethe voltage between the D6 and 820 or 822 termi' nals,

ls thereapprox.10V?

LGl (BRN/8LKI LG2(BRN/8LKI Wire sideof femaleterminals

Chock for lhort in tho wit€ betwe€n the D6 telminal and thg A/T ge.r position 3witch or A/T gear po3ition indicttoi, !nd chcck for open in the witgs botwo€n the 820 lnd 822 tetmi_ F n.ls and body g.ound (G1011. wiro3 ere OK, checktor loo3oter' minal fit in the PrCMconnoctors. ll n6c€3sary, 3ubstitute a knowngood PCMand rochock.

(cont'd) To page14 266

14-265

ElectricalTroubleshooting('99- 00 Models) Troubfeshooting Flowcharl -

AIT Gear Position Switch {Short) {cont,d}

Frompage14 265

MeasureATP NP Voltage: '1. Shiftto all positions otherthan EorI 2. Measurethe voltagebetween the A9 and 820 or 922 te(minals.

jl

A t32Pl

B {25P)

LGl IBRN/BLK)

LG2 {BRN/BLK}

Wire sideof femaleterminals

ls thereapprox.10V?

Me.sure ATP D Vohago: 1 . S h i f t t o a l l p o s i t i o n so t h e r t h a nE . 2. Measurethe voltage between the 47 and 820 ot 822 tet-r'inals,

Check for short in the wire betwoen ths Ag terminal and the A/T gerr position switch, .nd in the E .nd E position3ignal wiros botween the A/T gear position indic.tor and the A/T gear positaonswitch. lf wircs .re OK, checktor looseterminal tit in the PCM connectols. lf n€ces3ary, substitute a known-good PCMand rocheck.

ATPD (YEL) a l32Pl

ll

B (25P1

LG1 {BRN/ALKI

ls thereapprox.10V?

To page 14-267

14-266

Check tor 3hort in lhe wire b€twaen thc A7 terminel and the A/T g6ar position switch. lf wir.s are OK, ch.rckto. loose terminal fit in th6 PCM connectoF. lf nscossary.substhute a known-good PCM and ..check.

LG2 IBRN/BLK)

Frompage14-266

PCMCONNECTORS M6asureATP S Voliag€: 1 . S h i f t t o a l l p o s i t i o n so t h e r than E. 2. Measurethe voltagebetween the D13and 820 or 822 termi nals.

D (16P1

B t2sP)

ATP S {LT GRN/RED)

LG1{BRN/BLKI LG2 (BRN/BLKI

Wire sideof Iemaleterminals

'10 ls thereapprox. V?

Check for short in the wire between the D13 terminal and the A/T gear position lwitch or A/T goar position indicator. It wir6s are OK, checklor loose l€rminal fit in the PCM connectors. ll nec*3arv, substitute a known' good PCMand r6check.

PCMCONNECTORS MeasureATP L Voltage: 1 . S h i { t t o a l l p o s i t i o n so t h e r than E. 2. Measurethe voltagebetween the A22 and 820 or 822 terminals.

ls thereapprox-10V?

Checktor loos€ terminalfit in the PCM connectors, It nec6s3arY, substitute a known-good PCM and rech6ck.

t32Pl

Check lor sho.t in ihe wire betwgon the A22 terminal and th. A/T geat position switch or A/T gear position indicator. It wires are OK, ch€ckfor 10036terminal fit in the PCM connectors. lf n6cessery,substitute a known_ good PCMand recheck.

B t25Pl

ElectricalTroubleshooting{'99- 00 Models) Troubfeshooting Flowchaft- AIT GearPositionSwitch (Openl NOTE:Recordallfreezedata beforevou troubleshoot. . OBD ll Scan Tool indicstE Code P1706. . Selt-diagnGi! E indicato. light blinks six tim€a.

Po$ible Cau3e . OilconnectedA/T goar position switch . Op€n in A/T go.r po.ition switch wi?o . Faulty A/T gear polition switch

Test the IVT gear position switch (seesection23).

PCM@NNECTORS Measu.eATP R Voltage: 1. Turnthe ignitionswitchON (ll). 2. Shiftto E position. 3. Measurethe voltage between the D6 and 820 or 822 terminals,

(BRN/BI.XI Ropair opcn in the wi.. hr.raGn th6 DOtorminrl lnd the A/t g..r position awitch.

MeasureATP NP Vohage: '1. Shiftto E or N position. 2. Measurethe voltage between the A9 and 820 ot 822 letminals,

I tO (16P1

B {25P)

LG2IBRN/BLKI

wire side of fomale terminals

ATP NP ILT GRNI

A t:r2Pt

Il

s tzspt

I-G1(BRN/BLKI

Ropair op6n in th€ wiro b€{woan the Ag t.rminal and the A/T go.. position .witch.

To page14 269

14-264

LG2 {BRN/BLK)

Frompage14-268

Moasule ATP D voltago: 1. Shiftto El position. 2. Measurethe voltage between the A7 and 820 or 822 termi nals.

A {32P}

ll

B l25Pl

LGl IBRN/BLK)

LG2 (BRN/BLKI

Repairopen in the wira betwo6n the A7 torminal and the A/T ge.r po3ition switch.

MeasureATP S Vollag6: '1. Shiftto position. E 2. Measurethe voltage between the D13and 820 or B22termi nals. LGl IBRN/BLK}

Repairop€n in tho wire between ihe D13 terminal .nd the A/T gear position switch,

To page14-270

(cont'd)

14-269

ElectricalTroubleshooting{'99- 00 Models} TroubleshootingFlowchart- A/T GearPositionSwitch (Openl(cont'dl Frompage14-8-269

PCMCONNECTORS

B (25P1 MsasuroATP L Voftage: 1. Shiftto E position. 2. Measurethe voltagebetween the A22 and 820 or 822 terminals,

Wiresideof femaleterminals

Bepair opon in the wiro bgtw€en lho A22 torminal and the A/T goar poihion lwitch.

PCMCONNECTOR B I25PI Check LG Wiro for .n Open Circuit: '] Turnthe ignitionswitchOFF. 2. Checklor continuitybetween the 820 t€rminaland body ground,and betweenthe 822 terminaland body ground.

1 2 9 't0 l 1

LGT(BFN/ALK} ll

.15 / 7

I

Br1/l/41it8 l L G 2IBRN/BLKI

o) (o)

Wire sideof femaleterminals

Ropai' op.n in the wir€a botw.€n the 820 rnd 822 toJminals .nd body ground, and .opsi. pool ground(Gl01l.

Check tor loose te.minal frt in th6 PCMconn€ctors, lf n€cessary,substitut€ a knowo-good PCM and a6check,

14-270

J

TroubleshootingFlowchart - Shift Control Linear Solenoid NOTE:Recordall freezedata beforeyou troubleshoot .OBD ll Scan Tool indicatos Code P1870. . Solf-diagnosisE indic.lor light indic.t€s Code 30.

PossiblcCause . Disconn€ctedsolenoid harnos3 connectol . Short or oDen in shilt control linetr solonoidwiro . Faulty shift control linear sole_ noid . Op€n in VB SOLwite . ODen in PG'l and PG2 wires or poor ground {G10'l) PCMCONNECTORS

M6a3ureVB SOLvoltage: 1. Turnthe ignitionswitchOFF. the B 125P)and D 2. Disconnect ( 1 6 P )c o n n e c t o r sf r o m t h e PCM, 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltage between the D5 and 820 or 822 termi nals.

B(25P)

-

Dll6P)

LG1IBRN/BLKI wire sideot femaleterminals

f,

Repairopen or shod in the wire between the D5 terminal and the under-dashtuso/telay box.

B PsPI PCMCONNECTOR PG,IIBLK)

Checkthe Ground Circuitl 1. Turnthe ignitionswitchOFF. 2. Checklor continuity between the terminafs 82 and 822 and b e t w e e nt e r m i n a l s8 1 0 a n d 820.

LG1 IBRN/BLKI

LG2IBRN/BLK)

Repairopen in the wi.e betwoen the termin.ls 82, B10, B20,and 822 and G101. Repair Pool ground(G101).

a

{cont'd) 10 page14-272

14-271

('99- 00 Models) ElectricalTroubleshooting TroubleshootingFlowchart- Shift GontrolLinearSolenoid(cont'dl tuom page14 271 HARNESS8P CONNECTOR SOI."ENOID SH LSP

M e a s u r eS h i f t C o n t r o l L i n e a r Solenoid R6sistanceat the Solenoid Hrrness Connector: 1. Disconnectthe solenoidhar ness8P connector. 2. Measure the resistance betweenthe No. 3 and No- 7 terminalsoI the solenoidhar ness8P connector,

SH LSM Terminalsideof maleterminals

ls the resistance 3.8- 6.8o?

PCMCONNECTOR D {16P} SHLSMIGRN/YELISHLSP{BLU/WHTI

Check Shift Control Lin€ar Solenoid tor a Short Circuit: Checkfor continuitybetweenthe body groundand the D3terminal and D4terminalindividually.

Rep.ir short in th€ wir€ tr€twlren ihe D3 and D4 torminab .nd the shift cont.ol line.. solenoid.

Wire side oI temale terminals

SH LSM {GRN/YELI SH LSP IALU/WHT} Measure Shitt Conirol Lineer SolenoidResbtance: 1. Connectthe solenoidharness 8P connector. 2. Measure the resistance betweenthe D3 and D4terminats.

ls the resistance 3.8- 6.8O?

Checktor loose terminal fit in the PCM connector3,It necessary, substitute a known-good PCM and recheck.

14-272

Repeir loose ierminrl or open in the wire3 between tho D3 and D4 terminals end the shift control linear solenoid.

TroubleshootingFlowchart- PH-PLControlLinearSolenoid NOTE: Recordall freezedata before you troubleshoot. . OBD ll Scan Tool indicates Codo P1873. . sslt-disgnosisE indicltor light indicatesCode 31.

Possiblsc.use . Oisconn6dod solenoid harness conn6ctol . Short or ooen in PH-PLcontrol linear solenoidwire . F.ulty PH-PLcont.ol linear solenoid . ODenin VB SOLwire . Op€n in PGl and PG2 wires or poor groundlG101l PCM CONNECTORS

Mo.surevB SOLVohagg: 1. Turnthe ignitionswitchOFF. the 8 (25P)and D 2. Disconnect ( 1 6 P )c o n n e c t o r sf r o m t h e PCM, 3. Turn tho ignitionswitchON (ll), 4. Measurethe voltage between the D5 and 820 or 822 terminals,

B (25P1

D {16P}

(BRN/BLX) Wire sideof femaleterminals Ropairopen or shod in the wiJe bstwaon tho D5 terminal and the under-dalh tuso/relaybox.

B (25P| PCMCONNECTOR Checkthe Ground Circuh: 1. Turnthe ignitionswitchOFF 2. Checktor continuity between the terminals82 and 822 and b e t w e e nt e r m i n a l s8 1 0 a n d 820.

LGT IBRN/BLKI

LG2IBRN/BLK)

Fepair open in tho wiro b€tw€en tho torminds 82, 810, 820, and 822 and G101. Repair Poor ground(G1011.

(cont'd) Fo page 14-274

14-273

('99- 00 Models) Electrical Troubleshooting TroubleshootingFlowchart - PH-PLGontrol Linear Solenoid (cont'd) Frompagel4-273 SOLENOIDHARNESS8P CONNECTOR Mea3ure PH-PLControl Linear Solenoid Rosistanceat lhe Solenoid HarnessConnector: 1. Disconnectthe solenoidharness8P connector. 2 . M e a s ur e t h e r e s i s t a n c e betweenthe No. 2 and No. 6 terminalsoI the solenoidhar ness8P connector.

HLCLSP

HLCLSM Terminal side of male terminals

ls the resistance 3.8- 6.8O?

PCMCONNECTOR B (25PI HLCI.SM (PNK/BLK) CheckPH-PLControl LinearSolenoid lor a Short Circuit: Checkfor continuitybetweenthe body groundand the 88 terminal and 817 terminalindividually.

Rep.i. 3hort in the wiro bsh^,een lhc 88 and 817 terminals and the PH-PLcont.ol linear solenoid.

Wiresideof femaleterminals

HLCLSM {PNK/BLKI Measure PH-PLControl Linear SolenoidResistance: 1. Connectthe solenoidharness 8P connector, 2. Measure the resistance betweenthe 88 and 817 terminals.

3 I

l0 20

5

-j-

/ 1 1i 8

A/'.nlisl

i.((

HLCLSP IGRN/WHT}

ls the resistance 3.8-6.8 O?

Checklor loose ierminal fit in the PCM connectoTa.lf necessary, substitute a known-good PCM .nd recheck.

1 4- 2 7 4

Repair loose te.minal or open in the wires between the 88 rnd 817 te.minlb .nd the PH-PLcontrol linear solenoid.

TroubleshootingFlowchart- Start ClutchControlLinearSolenoid NOTE:Recordall freezedata beforeyou troubleshoot' 'OBD ll Scan Tool indicates Code Pl879. . self-diagnosisE indicstor light indicatesCode 32.

Po$ible Cause . Disconnectedsolenoid harness connedol . Short or open in sta.t clutch control linear solenoidwiro . Faulty3tart clutch conttol lin€ar solenoid ' Ooen in VB SOLwire . Open in PGI and PG2 wires or poor ground{G101) PCMCONNECTORS

MeasureVB SOLVoltag6: 1. Turnthe ignitionswitchOFF the B {25P)and D 2. Disconnect ( 1 6 P ) c o n n e c t o r s{ r o m t h e PCM. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween the D5 and 820 or 822 terminals,

o l16P)

B l25P) --

LGl IBRN/BLK) Wire sideof lemaleterminals

ls there batteryvoltage?

Reprir opon or short in the wire between the D5 terminal and the undei-d.sh luse/relaYbox.

B {25PI PCMCONNECTOR Checkthe Ground Ciicuit: '1. Turnthe ignitionswitchOFF. 2. Checkfor continuitybetween the terminafs 82 and 922 and b e t w e e nt e r m i n a l s8 1 0 a n d 820.

LGl (BRN/BLKI

ls therecontinuity?

Rep.ir open in the wire betwesn the terminab 82, 810, 820. tnd 822 and G101. RePair Poor groundlG101l.

(cont'd) To page14-276

14-215

Electrical ('gg- 00 Modelsl Troubleshooting TroubleshootingFlowchart- start clutch control Linearsolenoid(cont,d) Frcmpage14.275

Measurs Start Clutch Control Linear Solenoid R€aistanceat ths Solenoid Harne€sConnector: 1. Disconnectthe solenoidharness8P connector. 2 , M e a s ur e t h e r e s i s t a n c e betweenthe No. 4 and No. I terminalsof the solenoidharness8P connector,

SOLENOIDHARNESS8P CONNECTOR SC LSP

SC LSM T6rminalsideof maleterminals

ls the resistance 3.8- 6.80?

Check Start Clutch Control Line.r Solenoid tor a Short Circuit: Checkfor continuity between tho body ground and the 818 terminal and B2Sterminal individually.

R€p.ir short in th. wire bctw.on th6 818 and 825 termin.lr rnd the 3hift cont ol linc.r solonoid.

Measure Start Clutch Control LinearSolenoidR6ist.nco: 1. Connectthe solenoidharness 8P conn€clor. 2. Measure the resistance betlveenthe 818 and 825 ter, mtnats,

ls the resistance 3.8-6.8 O?

Checkto. loose tarminal fit in tho PCM connactors. It necessary, substitute a known-good PCM and recheck.

14-276

Wire side of f6maleterminals

SC LSM (PNK/BLU)

Raprir looa. t€.minal or opan in tha wirars lratwe.n the B18 and 825 terminal3 and tha st!rt clutch control linoar 3olanoid,

TroubleshootingFlowchart- lnhibitorSolenoid NOTE:Recordall freezedata beforeyou troubleshoot' .OBD ll Scan Tool indicaies Codo P'l882. . Self-diagnosisE indicttor light indic.tes Code 33.

Po3sibleCause . Oi3connec'tedsolenoid harn6s connectoa . Shorl or open in inhibitor 3olenoid wir€ . Faulty inhibitor solenoid . ODenin vB SOLwire . Open in PGl and PG2 wires or poor ground{G101} PCM CONNECTORS

Me'sure VB SOLvoltagel '1. Turnthe ignitionswitchOFF. the B (25P)and D 2. Disconnect ( 1 6 P )c o n n e c t o r sf r o m t h e PCM. 3. Turnthe ignitionswitchON (ll) 4. Measu.e the voltage between the D5 and 820 or B22terminals. (BRN/BLKI Wire sideot femaleterminals

ls there bafteryvoltage?

Repair open or short in the wire between the D5 tolminal and the undor-dashlu36/relay box.

B {25P} PCMCONNECTOR Ch€ckthe Ground Circuit: 1. Turnthe ignitionswitchOFF. 2. Checktor continuitybetween the terminals82 and 822 and b e t w e e nt e r m i n a l sB ' 1 0a n d 820.

LGl IBRN/BLKI

LG2(BRN/BLKI

R€pairopen in the wire between the torminal3 82, 810, B20, and B 2 2 . n d G 1 0 1 . R e P a i rP o o r ground{G101).

(cont'd) To page14-278

14-217

('99- 00 Models) Troubleshooting Electrical TroubleshootingFlowchart - Inhibitor Solenoid (cont'dl Ftom page 14-277

SOLENOIDHARNESS8P CONNECTOR Mersure Inhibitor SolenoidR6bt.nce at the Solenoid Harne3s Conn€ctor: 1. Disconnectthe solenoidhar, ness8P connector, 2. Measure the resistance betweenthe No.5 terminalof the solenoidharness8P connectorand bodyground.

SOL INH

Terminalsideof maleterminals ls the resistance 11.7- 21.0O?

B t25P)

Check Inhibitor Solonoid fo. . Short Ci.c!it: Checkfor continuity between the D2 and 820 or 822terminals.

ll

D t16P)

LGl IBRN/BLKI Wire sideoI temaleterminals R.p.ir 3hort in thc wire botwaan th€ 02 t.rminal and the inhibhot solenoid.

Measur6 Inhibitor Solenoid Re3istance: 1, Connectthe solenoidharness 8P connector. 2, Measure the lesistance between the D2 and 820 or 822terminals.

B t25Pt

LGl {BRN/ALKI

ls the resistance 11.7- 21.0O?

Checkfol looso torminal fit in the PCM connectors. lf n€cessaay, substitute a known-good PCM and r€check.

14-274

Rcpair loo3. tarminal or opan in tho wha brtw.€n tho D2 to.minal .nd tho inhibitor lolonoid.

otl6Pt

Troubleshooting Flowchart - Drive Pulley Speed Sensor NOTE:Recordallfreezedata beforeyou troubleshoot' .OBD ll Scan Tool indicates Code Pl885. . Selt-diagnosbE indicator light indicatosCode 34

PossibleCau3€ . Disconnected diive PulleY soeeds6n3orconnectol . Short or open in drive Pull.Y sooed sonsor wire . FaultY drive PulleY spo€d sen' 301

checkthe drive pulleYsPeedsensor installation,and check it for damage.

ls the drive PulleYspeedsensor installedproperly,and not damaged?

Rein3tallor roplaceand techeck

DRIVEPULEY SPEED @NNEfiOR SENSOR

Measuro Drive PulleY Speed Sen_ sor Ro3istanco at the Sonsol Connector: 1. Disconnectthe 2P conneclor from the drive Pulley speed sensor, 2. Measuredrive Pulley speed sensor resislanceat the sensor connecror.

Terminalsideof maleterminals

ls the resistance350 - 600 O?

D (16PI PCMCONNECTOR

CheckDrivo PulleYSP6€dSen3o. lor . Short Circuit: 1. Disconnectthe D {16P)connectorlrom the PCM. 2. Checklor continuitybetween body groundand the D11ter minal and D'l2 terminal indi vidually.

NDR SG IGRNI

Wire sideo{ Iemaleterminals

Repai. short in the wiles between the Dll lnd D12 terminals and iho drive Pull.Y speed

(cont'd) To page14-280

14-279

Electrical ('gg- 00 Models) Troubleshooting TroubleshootingFlowchart- DrivepulleySpeedSensor(cont,d) Frompage14-279

PCMCONNECTOR D {16P}

MeasureDrivo PulleySpeed Sensor Circuit tor an Open: 1 . C o n n e c tt h e d r i v e p u l l e y speedsensorconnector, 2 . l v l e a s rue t h e r e s i s t a n c e betweenthe Dl1 and Dl2 terminals.

Wire sideof temaleterminals

ls the resistance350 - 600 O?

Ch6ckfor loose lerminal tit in the PCM connectors, ll nece3saay, substituto a known-good PCM 6nd r€check.

14-280

R6pair loose tgrminal or opan in the wiros betwo€n tho D1,l .nd Ol2 tarminrl! .nd th. drivs pulley speed *n3or.

TroubleshootingFlowchart- DrivenPulleySpeedSensor NOTE: Recordall freezedata betore you troubleshoot' 'OBD lt Sc.n Tool indicates Code Pl886. . Self-diagnosbE indicator light indicrt€. Codo35.

Po3sibleCaus€ ' O i s c o n n e c t e dd r i v e n P u l l e Y speeds6nlor connoctor . Short or opon in d.iven Pulley soeedsonsol wirc . Faulty driven Pulley speed sen_ sor

C h e c kt h e d r i v e n P u l l e ys p e e d sensorinstallation,and check it Ior damage.

lsthe drivenpulleYspeedsen' and not sor installedProPerly, damaged?

Boin3tallor ropl.ca and recheck.

DRIVENPULLEYSPEED CONNECTOR SENSOR M..sure Drivon PulloY SPoed Sonsor Rosblanco at the S6n3or Conn6ctori 1. Disconnectthe 2P connector trom the driven PUlleysPeed sensor, 2. lveasuredriven Pulleyspeed sensorresistanceat the sen_ sor connector.

Terminalsideol maleterminals

ls the resistance350 - 600 0?

D If6P) FCM CONNECTOR NDN IWHTI Check Dtivon Pulloy SP€ed Sen' sor for a Short Circuit: 1. Disconnectthe D (16P)connectorfrom the PCM. 2. Check tor continuity between body groundand the D10ter' minal and Dl6 terminal individually.

Wire sideof femaleterminals Raoair shott in tho wi.6s betwoon th. Dlo end D16 tormi' nak .nd the ddven Pulley spo€d

(cont'd) Fo page 14'282

14-2A1

ElectricalTroubleshooting['gg - 00 Models) TroubleshootingFlowchart- DrivenpulleySpeedSensor(cont,dl Frompagel4 281

M6asure Driven Pulley Speed SensorCircuit Ior an Op€n: 1 . C o n n e c t h e d r i v e np u l l e y speedsensorconnector, 2, Measure the resistance betweenthe D10and Dl6 terminals. NON SG IRED/WHTI

Wire sideof femaleterminals

ls the resistance350 - 600 O?

Checktor loose terminal tit in the PCM connectors, lf necessary, sub3titute a lnown-good PCM and rech6ck.

14-282

Rgpair loose terminal or open in the wires botwosn the Dlo and 016 torminab rnd the drivon Dulley speed3ensoa,

TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor NOTE:Recordall freezedata beforeyou troubleshoot ' OBD ll Scan Tool indicates Code P1888. . Self-diagnosisE indicalor light indicats Code 35.

Po$ible Causo . OisconnectodsecondarYgear shaft speedsensorconn66or ' short or open in secondarygear shaft spe€dsensorwiro . Faulty secondarY gear 3haft sPeedsensor

Checkthe secondarYgear shaft s p e e ds e n s o ri n s t a l l a t i o na, n d checkit for damage.

gearshaft ls the secondary speedsensorinstalled properly,and not damaged?

Reinatallor replaceand rocheck. GEARSHAFT SECONDARY SPEEOSENSORCONNECTOR

Measure SocondarY Gear Sh.ft Speed Sen3or Resistanceat the SensorConnector: 1. Disconnectthe 2P connector trom the secondarygearshaft speedsensor. gearshaft 2. Measuresecondary speedsensor resistanceat the sensorconnector.

Terminalsideof maleterminals

350- 6000? ls the resistance

D I15P) PCMCONNECTOR VEL (WHT/REO) VEL SG IALK/WHTI Check SecondarY Gear Shaft SpeedSensorlor a Short Circuit: 1. Disconnedthe D (16P)connector from the PCM. 2. Checkfor continuitybetween body ground and the D1 term i n a l a n d D 7 t e r m i n a li n d i vidually. Wire side oI female terminals

Repair short in the wiros b.tween the Dl and D7 termi_ n e 1 3a n d t h € s e c o n d a r Yg e a l 3haft lpeed sonsor.

(cont'd) To page14-284

14-243

ElectricalTroubleshooting('gg - 00 Modelsl TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor(cont'd) Frompage14 283

Moasu.€ Secondary Gaar Shaft Spo6d Sonsor Circuit tor an Openi 1. Connectthe secondarygear shaftsp6edsensorconnector, 2 . M e a s ur e t h e r e s i s t a n c e betweenthe Dl and D7 termi nals, Wi16side of femalet6rminals

ls the resistance350 - 600 O?

Checkfor loosoterminal lit in the PCM connectors. lf necessary, substilute a known-good PCM .nd recheck.

14-284

Repair looao terminal or opon in the wiraa batuvacn the Dl and D7 t.rminrls snd the second!ry geer rhatt 3peod 3.nior.

TroubleshootingFlowchart- Shift ControlSystem NOTE:Recordallfreezedata beforeyou troubleshoot ' OBD ll ScanTool indicatesCodo P1Ato. . Self-diagnosisE indicator light indicatosCode 42.

Possiblecause Faultvshift control svstem

Checkfor Anoth€r Code: Checkwhether the E indicator light indicatesanothercode.

ls the E indicatorlightindi cateanothercode?

P€rform the Tloubleshooting Flowchart for the indicated Code(sl.

CheckStall SpeedRPM: M e a s u r et h e s t a l l s P e e d R P M (seepage14-298).

ls the stall speedover 3,500rpm?

ls the stallspeedbelow 2,000rpm?

T e s t - d r i v ea n d C h e c k E n g i n e Speed: L Drive the vehicle at 30 mph 150km/h) constantlyfor several mlnutes. 2. Checkthe enginespeed

ls the enginespeedwithinthe (seePage14'296 specification and 14'297)?

14-245

ElectricalTroubleshootang ('gg- 00 Models) TroubleshootingFlowchart- Start ClutchControlSystem NOTE:Recordallfreezedata beforeyou troubleshoot. . OBD ll ScanTool indicatesCode P1891. . Self-diagnosisE indicator tight indicatesCode 43.

Possibl€Cause Faultv start clutch control syslem

Checkfor Another Codel C h e c kw h e t h e rt h e E i n d i c a t o r light indicatesanothercode.

ls the E indicatorlight indicateanothercode?

Perform the Troubleshooting Flowchart tor the indic.ted Codelsl.

Test Stsn Clutch Operation: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 8P connector from the solenoidharnesscon nector. 3. Start the engine,and shift to E position. 4 . C h e c kw h e t h e r t h e v e h i c l e moves.

Repl.c€ the stan clutdt rasemHy.

Check Croeping Sp€6d: 1. Turn the ignition switch OFF. 2 . R e c o n n e c tt h e 8 P c o n n e c t o r t o the solenoid harness connec 3. St€rt the engine, and shift to E posation. 4. Check whether the vehicle creeps, and check the creep ing speed.

Does the vehicle move and is t h e c r e e p r n gs p e e d a p p r o x , 3 mph (5 km/h)?

fo page14 287

14-2A6

t a Frompage14'286

CheckSrall Speed RPM: Measurethe stallspeedRPM(see page14-298).

ls the stallspeedover 3,500rPm?

Warm Up Engine and Becheck F ilure: 1 . W a r m u p t h e e n g i n et o n o r m a l o p e r a t a n gt e m P e r a t u r e (theradiatorfan comeson). 2. Checkwhetherthe stan clutch problemappearsagain.

I a

Doesthe problemappear?

The 3v3tem ia OK at thi! iime.

14-2a7

ElectricalTroubleshooting('99- 00 Models) TroubleshootingFlowchart- El IndicatorLight DoesNot ComeOn The D indicator light does not come on whon ths ignhion switch is tirst turned ON {lll. llt should come on tor abouttwo s€conds.) Checkthe ServiceCheckConnector: Makesure the specialtool {SCS S e r v i c eC o n n e c t o rils n o t c o n nectedto the servicecheckconnector, l s t h e s p e c i a lt o o l ( S C S Service Connectorl connected t o t h e s e r v i c ec h e c k c o n n e c tor?

Disconnectthe sp€cial tool f]om the seruice chcck connoclor and aecheck.

Checkthe E Indicalor Light: Shiftto E posjtion. Doesthe E indicatorlight

Checktor loose te.minal fit in the PCM connectors, lf nocessary, substitute a known-good PCM and aecheck.

Checkthe Ground Circuit: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e B ( 2 5 P )c o n nectorfrom the PCM. 3. Checktor continuitybetween t h e 8 2 0 t e r m i n a la n d b o d y ground,and betweenthe 822 terminaland body ground.

ls therecontinuity?

PCMCONNECTOR B I25PI

LGl {BRN/BLK)

Fepair open in th. wiros b€tw.en the 820 end 822 termin a l s a n d g r o u n d { G 1 0 1 1 !, n d repair poor ground {G1011.

Wire sideot femaleterminals

Measure Power Supply Circuit Voltage: 1. Turnthe ignitlonswitchON (ll). 2. Measurethe voltagebetween terminals Bl and 822 and b e t w e e nt e r m i n a l s B 9 a n d 820.

ls there batteryvoltage?

To page14-289

14-2AA

Ropairop€n or short in tho wire b€tween the Bl and/or B!| tarminds and the PGM-FImain .ohy, and between tho PGM-FImain relay and the under-hood fuso/ r€lav box.

LGlIARN/BLK)

LG2IBRN/BLKI

Frompage14-289

PCMCONNECTORS

D {16P1 1

MsaaureD IND Volt.ge: 1. Turnthe ignitionswitchOFF. 2. Connecttho B (25Plconnector to the PCM. 3. Connecta digital multimeter to the D14and 820 or 822termtnals. il. Turn the ignition switch ON (lll, and makesure that voltage is availablefor two seconds

2

3

r s 1 / 7I

2

nn fT /fl o lzlzz ,rl/zs

1

5 l 1 12

6

9 10

1311 - -T---=4'+:l LG2IBRN/BLKI\=/

(BRN/BI.X) Check for open in the wire between tha D14 terminal rnd the gauge a33emblY.lf wiro ia OK, chock for . frulty indicator light bulb or a Iaulty gaug. a3r6mblyprintod circuit board.

|

D4 IND (GRN/BLK}

Wiresideof femaleterminals

r l z3

5

6 i / l / t0 1112

CheckD IND for a Short Circuit: Checklor continuitYbetweenthe D14terminaland body ground.

l0

D' INDIGRN/BLKI

o Rgpair3hort in the wire b.tween the D14 tcrminal and tho gauge a*somblY.

Checkfor loose terminsl fh in the PCM connectors Check tho A/T goar posilion switch. It neces' saiy, iubstitute a known_good PCMrnd rochock.

4-289

('gg- 00 Models) ElectricalTroubleshooting TroubleshootingFlowchart- E IndicatorLight On Constantly The E indicator light is on constantly {not blinkingl whenever the ignition switch is ON lll|. FCM CONNCCTOR D tl6PI Mersure D IND Voltage: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ct th e D ( 1 6 P )c o n nectorfrom the PCM. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween the 014terminaa l ndbody ground,

2 3

5

t0

12

tsll /

rc

II D4rND(GRN/BLK)

o Repairshort to power in tho wire bstween the Dl4 termin.l snd the gaug€ r3sembly.

MeasureATP DVoltage: 1. Turnthe ignitionswitchOFF. 2 . C o n n e ctth e D ( 1 6 P ic o n n e c tor to the PCM. 3. Turnthe ignitionswitchON lll). 4. Shiftto any positionotherthan

I

6 1

Wiresideof femaleterminals

rcM CONNECTOR A I32PI ATP Dil {YELI

E,

5. lMeasure the voltagebetween t h e 4 7 t e r m i n a la n d b o d y ground.

ls thereapprox.10V?

Test the A/T gear position switch {seesection23).

Checkfor a shorl lo ground in the wire between tho A7 terminal and A/T ge.r polition switch. l, wire is OK, substitute a knowngood PCMand recheck.

14-290

Wire sideof lemaleterminals

Solenoid LinearSolenoids/lnhibitor )

Test 1.

Disconnectthe 8P connectorfrom the solenoidharnessconnector.

7.

lf all ot the resistancesare within the standard,a c l i c k i n gs o u n d s h o u l db e h e a r dw h e n c o n n e c t r n g the battervterminalsto the solenoidharnessconnectorterminalsbelow: Shift control linear solsnoid No.3: BattervPositiveterminal No. 7: Batterynegativeterminal PH-PLcontrol linear solenoid No.2: Battervoositiveterminal No. 6: Bafterynegativeterminal Start clutch control linear solenoid No. 4: BatteryPositiveterminal No.8: Batterynegativeterminal lnhibitor solsnoid No,5: BattervPositiveterminal Body ground:Batterynegativetermrnal

HARNESS SOLENOID CONNECTOR

SOLENOIDHARNESSCONNECTOR

ATF OIPSTICK Terminalsideof maleterminals

Measurethe resistanceof the shift control linear solenoidbetweenthe No. 3 and No. 7 terminalsof the solenoidharnessconnector. Measurethe resistanceof the PH-PLcontrol linear solenoidbetweenthe No. 2 and No. 6 terminals

l f n o c l i c k i n gs o u n d i s h e a r d , r e p l a c et h e l o w e r valvebody assemblY, NOTE: lf the lower valve body assemblyreplacement is required,see Lower Valve Body Assembly (page14-302). Replacement

Measurethe resistanceof the start clutch control linearsolenoidbetweenthe No 4 and No. 8 terminats, STANDARD:38-6.8O M e a s u r et h e r e s i s t a n c eo f t h e i n h i b i t o rs o l e n o i d betweenthe No. 5 terminaland body ground 2 1 . 0O S T A N D A R D : 1 1-. 7 R e p l a c et h e l o w e r v a l v e b o d y a s s e m b l y i f a n y is not within its standard. solenoidresistance

14-291

DrivePulley/DrivenPulley/Secondary GearShaft Speed Sensors Replacement CAUTION: While replacingthe speed sensor,be sure not to allow dust and other foreign parliclos to enter into the transmission. '1.

Disconnect the connectorsfor the drive pulley,the drivenpulley,and the secondarygear shaftspeedsensor.

2.

Removethe 6 mm bolt from the transmissionhousing,and removethe drive pulley.the driven pulley,and the secondarygearshaftspeedsensors.

3.

Replacethe O-ringsbeforereinstallingthe drive pulley,the driven pulley,and the secondarygear shaft sp€edsensors.

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

DRIVENPULLEYSPEEDSENSOB

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

14-292

@

Start ClutchControl

T

Start ClutchCalibrationProcedure Shift into E o|. E position.To store the engine negativepressurein memory.Iet the engine idle in E or E positionfor one minute underthe following conditions:

NOTE:When the following parts are replaced,the TCM must memorizethe feedbacksignalfor the start clutch control. . TCM . Transmissionassembly . Stan clutchassembly . Lowervalvebodv assembly . Engineassemblyor overhaul

. With the brakepedaldepressed, . with the y'\/cswitch oFF. . With the combinationlight switchOFF. . With the heaterfan switchOFF. . Turn OFFall otherelectricalsystems

'96 Model Only

NOTE: Start step 5 within 60 secondsafter the radiator fan goes off.

CAUTION: Do not uso this procsdure on'97 - (X)mod'97 - 00 els or you will damage the transmission. On models, the TCM or PCM memorizes ths loodback sig' nals when you drive the vehicle. 1.

2.

rl ,

E n g a g et h e p a r k i n g b r a k e , a n d b l o c k t h e f r o n t wheelssecurely. Connectthe SCS serviceconnectorto the Service C h e c kC o n n e c t o ra s s h o w n . ( T h e S e r v i c eC h e c k connector (2P) is located under the dash on the passenger's sideof the vehicle.)

Shift into E position,and let the engineidle for two minutes to store the feedbacksignal in memory underthe sameconditionsas in step5. 7.

Connectthe HondaPGMTester.Checkthat the TCM hascompletedthe startclutchcalibration. NOTE: . The TCM will not storethe feedbacksignalwhen the CVT fluid temperatureis below 40"C(104'F) even if the engine coolanttemperaturereaches the normaloperatingtemperature. . Repeatthese proceduresuntil the start clutch calibrationis completedD i s c o n n e c t h e S C S s e r v i c ec o n n e c t o rf r o m t h e ServiceCheckConnector. '97 - 00 Models The TCM ('97- 98 models)and PCM('99- 00 models) memorizethe feedbacksignal when you drive the vehicleas follows:

CONNECTOR I2PI

CONNECTOR

07PAZ- lDl01(xt

Startthe engine,and warm it up to normal operating temperature(the radiatorfan comeson twice).

After warming up the engine (the radiator fan comesonl. . Shift into E position. . Turn OFFall electricalsystems, . Drive the vehicle up to the speed 37 mph (60 km/h). . A f t e r t h e s p e e d r e a c h e s3 7 m p h ( 6 0 k m / h ) , releasethe acceleratorfor 5 seconds. .

for 20 Fullydepressthe brakepedaland accelerator secondsin the E] position.

14-293

Symptom-to-Component Chart HydraulicSystem SYMPTOM Engineruns,but vehicledoes not move in any position. Vehicledoes not move in @, [. p positions.

Checktheseitemson the PBOBABLE CAUSEList 't,2,3,4,5,6,7,8,9, 1 0 ,2 0 ,3 4 ,3 5 ,3 6 ,3 8 ,4 1

Vehicledoes not move in E position.

1 0 ,1 1 ,1 2 ,2 0 ,4 1 5, 'to,11, 12,17,1A,19,20,39,41

No shift to higherratio,

9 , 1 3 ,1 4 .1 5 ,1 6 , 3 5 , 3 7 , 4 0

Pooracceleration.

9, 13,' t4,'t5,16.20,35,37, 38, 40

Flareson moving.

9,'t0,20,2't,35,36,38,40,42

Excessive shockwhen depressingand releasing .^^alA/.r^r

^A.1. I

9, 10, 20, 2'1,35, 36, 3A,42

N o e n g i n eb r a k i n g .

9,20,21,35,36,38

Vehicledoes not accelerate in lll position.

9, 17, 18,19,20. 35,36,38

Vehiclemovesin E position. (Shiftcableadjustmentis proper).

1 0 ,2 2 , 2 3

Lateshiftfrom N positionto E position,and from E positionto E position.

'10,1 1 ,1 2 , 2 24, 1

Lateshift from E positionto E position.and from E positionto N position.

1 l , ' t 2 , 1 7 ,1 8 , 2 2 4 ,1

Enginestopswhen shiftedto E positionfrom E position.

9, 10,20,35,37,34, 42

Enginestopswhen shiftedto E positionfrom I Noisefrom transmissionin @ position.rl

9, 18,19,20,25,26,35,37,38,42 5, 17, 18,'t9,25,26

Excessive idle vibration.

2,3,4,21,24

Noisefrom transmissionin @ and @ positions.

2,3,19,24,25,2A

Huntingenginespeed.

16,35,37,38

Vibrationin all position.

8, 2a

Shift leverdoes not operatesmoothly.

11,29,4'l

Transmission will not shift into lll positionor transmission cannotbe removedfrom E position.

11, 29,30, 31,32,33

Vehicledoes not accelerate to more than a certainspeed.

9 , 1 0 ,1 4 ,1 5 , ' t 6 , 2 0 , 3 5 , 3 7

Excessive shockon startingoff.

38,42

Flareson accelerating at low speed.

20,21,38, 42

Excessive vibration in E, E, tr, E positions. Lowenginespeedin E. E. tr. E positions.

20,21,38,42 20,21,38,42

Stall speed high.

10,20,38

Stallspeedlow.

9, 20,27,37, 38

position.

Judderon startingoff. 20,43 *1: Somegear noiseis normalin the Lll positiondue to planetarygearaction.

14-294

t .

CAUSELIST PROBABLE Low CVTfluid level ATF pump worn. AT gearsworn or damaged.Foreignmaterialin ATF pump. ATF pump chain/ATFpump sprocketworn or damaged. Inputshaftworn or damaged. 5

S u ng e a rw o r n o r d a m a g e d .

6

Finaldrivenoearworn or damaqed,

1

drivengearworn or damagedSecondarydrive gear/secondary

8

plateworn or damaged. Flywheel/drive housingassemblyworn or damaged. Intermediate

9 '10

Forwardclutchdefective.

1'r

Shift cablebroken/outof adiustment.

't2

M"nu"t t"uffi

13

ATFfeed pipe (pulleypressure)worn or damaged.

14 Vchiclcspeedsensordefective. 16 '11

rl,

TCM or PCMdefective. Reversebrakedetective.

'18 1q

Planetarygearworn or damaged.

20 t't

Start clutchdefective. ATFfeed pipe (startclutchpressure)worn or damaged

23

brakeclearanceincorrect. Clutchclearance/reverse worn or damaged Reversebrakereturnspring/retainer

24 25

Needlebearingon input shaftworn or damaged. Thrustneedlebearingon carrierworn or damaged. Thrustwasheron carrierworn or damaged.

27

Enoine outout low.-----------------------Flvwhcelassemblvdefective.

29 30

Controlleverworn or damaged. Parkpawl/parkpawl shaftworn or damaged Detentlever/parkbrakerod assemblyworn or damaged

32

Parkgearworn or damaged.

33

Parkpawl springworn or damaged.

34

filter clogged. ATFstrainer/ATF

50

Lower valve body assemblydefective. Lowervalvebodv assemblvdefective(PLregulatorvalvebody assemblydefective)' Lowervalvebodv assemblydefective(shiftvalvebody assemblydefective). Lowervalve bodv assemblvdefective(startclutchcontrolvalvebody assemblydefective)'

fl,

39

Lowervalve bodv assemblvdefective{inhibitorsolenoiddefective}

40

Solenoidharnessworn or damaged.

41

Manualvalvebody worn or damaged. PBfeedbacksystem defective.

43

CVTfluid deteriorated.

14-295

RoadTest

NOTE:Warm up the engineto normaloperatingtemperature(the radiatorfan com6son). 1.

Apply the parkingbrakeand blockthe wheels.Start the engine,then shift to the E positionwhile depressingthe pedaland releaseit suddenly.The engineshouldnot stall. brakepedal.Depressthe accelerator

2.

Testin E position Parkthe vehiclein a slope (approx.16'). apply the parkingbrake,and shift into E position.Releasethe brake;the vehicleshouldnot move.

3.

Test-drivethe vehicleon a flat road in the positionshown in the table.Checkthat the enginespeedsmeetthe approximatevehiclespeedsshown in the table. NOTE: Throttle position sensor voltage representsthe throttle opening. To monitor the throttle position sensor voltage,useone of the followingmethods: A. Connectthe HondaPGMTester,and go to the PGM-FIDataList. OBDll SCANTOOLor HONOAPGMTESTER

A

1

For road testing on '96 - 98 models, remove the drive/s side kick panel to exposethe TCM; on '99 - OOmodels, removethe passenger'sside kick panel to exposethe PCM (see page l,[-236), Set the digital multimeter to checkthrottle position sensor voltage betweenterminals: . '96 - 98 modols: TCM 84 {+} and Aa (-) or A17 (-1. . '99 - 0Omodels: FCM C27 {+l and 820 (-l ot 822 l-1.

DIGITALMULTIMETER (Commerci.llyrvrilabl.l KS-AHM-32-003 or oquivalant

BACKPROBE ADAPTER

'96 - 98 Models: BRN/BLK

D{16Pt

A {26P1 TPS {BED/BLK} BRN/BLK Wire side of female terminals

14-296

Waresideot femaleterminals

o @ position: EnginoSpeed rPm

VehicloSpeed Throttle Opening

25 mph l/() km/h)

|

37 mph {60km/h)

| 62 mph {100km/h}

Throttlepositionsensorvoltage:0.75V

1,250- 1,650

Throttlepositionsensorvoltage:2'25V Throttlepositionsensorvoltage;4 5 V Fullthrottleposition

2,500- 3,100

2,650- 3,250

2,700- 3,300

3,950- 4,550

4,650- 5,250

5,200- 5,800

o $l position:EngineSpeedrPm VehicleSpoed Throttle Oponing Throttlepositionsensorvoltage:0.75V ThrottleDositionsensorvoltage:2.25V Throftlepositionsensorvoltage:4.5v Fullthroftleposition

2s mph(40km/hl - 2,200 1,800

|

37 mph(60km/hl 2,200- 2,800

| 62 mph{r00km/h}

2,950- 3.550

3,250- 3,850

3,550- 4,150 4,050- 4,650

4,100- 4,700

5,100- 5,700

5,900- 6,500

o E position: Engin€Sp6ed rPm Vehiclo Spoed Throttle Oponing

25 mph (40km/hl

|

37mPh{60km/h)

ThrottleDositionsensorvoltage:0.75V Throttlepositionsensorvoltage;2.25V

3,100- 3,700 3,500- 4,100

3,650- 4,250 4,050- 4,650

Throttlepositionsensorvoltage:4.5V Fullthrottleposition

4,100- 4,700

5,100- 5.700

J 62 mph 1100km/h} 4,450- 5,050 4,800- 5,400

5,900- 6,500

14-297

Stall Speed Test CAUTION: . To prevent transmission damage,do not test stall sp€€d for mole than 10 secondsat a time. . Do not shift the lsver whils raising the engine speod. . Be sure lo remove the pressuregauge before tosting stall speed. . Stall speed tssts should be used tor diagnostic purposesonly, 1.

Engagethe parkingbrake,and blockthe tront wheels.

2.

Connecta tachometerto the engine,and stan the engine.

3.

Makesurethe A/C switchis OFF.

4.

After the enginehaswarmed up to normaloperatingtemperature(the radiatorfan comeson), shift into E position.

5.

Fullydepressthe brakepedaland accelerator for 6 to 8 seconds,and note enginespeed,

6.

Allow two minutesfor cooling,then repeatthe test in E, E, and E positions.

Stall SpeedBPM in E poshion: Specification:2,500rpm Servic€Limit: 2,350- 2.650rpm Stall Speed RPM in E, E and E positions: Specitication:3,000rpm ServiceLimit: 2,800- 3,100rpm TROUBLE Stallrpm high in @. p. [, and @ positions

Stallrpm high in E position Stallrpm low in E, P, [, and @ positions

14-294

PROBABLECAUSE Low fluid levelor ATF pump output CloggedATF strain€r PH regulatorvalve stuck closed Slippageof forwardclutch Faultystartclutch . Slippageof reversebrake . Faultystartclutch Engineoutput low Faultystan clutch Stuckshiftvalve

FluidLevel

l .

Checking/Changing CAUTION: while chscking and changing, be sure not to allow dust and other toreign particles to ent€l inlo the transmission.

Changing 1.

Bringthe transmissionup to normaloperatingtemperature(the radiatorfan comeson) by driving the vehicle.Parkthe vehicleon the level ground, and turn off the engine.

2.

Bemovethe drain plug,and drainthe CVTfluid.

Checking NOTE: Checkthe fluid level with the engine at normal operatingtemperature(theradiatorfan comeson). ' 1 . P a r kt h e v e h i c l eo n t h e l e v e lg r o u n d .T u r n o f t t h e engrne. 2.

Removethe dipstick(yellow loop) from the transmission,and wipe lt with a cleancloth. NOTE: Checkthe transmissionfluid 50 to 90 seconds aftershuttingoff the engine.

3.

Insertthe diDstickinto the transmission. DIPSTICK(YELLOWLOOPI

NOTE| lf a coolerflusheris to be used,see page14352and 14-353. Reinstallthe drain plug with a new sealingwasher, t h e n r e f i l l t h e t r a n s m i s s i o nw i t h G e n u i n eH o n d a CVTFluidto the uppermarkon the dipstick. Automatic TransmissionFluid CaPacity: 3.9 i (4.r US qt. 3.4 lmp qt) 8t chlnging 6.4 I (6.8 US qt, 5.6 lmp qt) 8t ov€lhaul RscommendedAutomatic TransmissionFluid: GenuineHonda CVT FluidUse GenuineHondaCW fluid only. Usingotherflui d s c a n a f f e c t t r a n s m i s s i o no p e r a t i o n a n d m a y reducetransmissionliJe.

R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l . shouldbe betweenthe uDDerand lower mark. DIPSTICK

5.

6.

lf the level is below the lower mark, add fluid into t h e f i l l e r h o l e t o b r i n g i t t o t h e u p p e r m a r k .U s e G e n u i n eH o n d aC W F l u i do n l y . Insertthe dipstickinto the transmission.

ChangeInterval: Normal Condition: 30, 000 miles 148,000km) SevereCondition: 30,000 miles (48,000km), but it you drive at high sPeedsin high t90"F (32'C) and abovol temperatures, the ttansmission fluid should be changed evsrY 15,000 miles 124,000km).

{-]lr ORAINPLUG 18 x 1.5mm a9 N.7n(5.0kgl.m, 36 lb{'ftl

SEALINGWASHER Replace.

14-299

PressureTesting

. .

While testing, be careful of the rot8ling front wheels. M8k6 suro lifts, iacks, and satety stands are placed properly lsee section 11.

CAUTION: . Beforetesting, be sur. the transmb3ion fluid is fillod to the propor lcvel. . Warm up the engin€ to nolmal operating tsmperature bofore testing . While t€sting, be 3ure not to allow dust and other loreign particles to onler into the transmi$ion. 1.

Raisethe front of the vehicle,and supportit with safetystands(seesection1).

2.

Setthe parkingbrake.and blockboth rearwheelssecurely.

3.

Allow the front wheels to rotate freely.

4.

Warm up the engine(the radiatorfan comeson),then stop aridconnecta tachometer.

5.

Connectthe specialtool to eachinspectionhole. TOROUE:18 N.m (1.8 kgt'm, 13 tbtfr) GAUTION: . Connectthe oil pressurogauge !!€curoly,bs sur6 not to allow dust and other foroign particlG3to ontar the inspsction hole. . Whon troubleshooting by tho E indicltor light indic.t6 a problam. you mu3t u3e an oil p.essure gluge that moa, sures 4,9(X)kPa (a.90MPa,50.0 kS cr*,771psi) or more when molsuring driv. pulley pressureand driven pullcy pre33ure. NOTE: . D.ive pulley pressuremay be above 3,430kPa (3.i8 MPa,35.0 kgf/cmr,498 psi) wh€n there is a transmissionproblem that causesthe TCM or PCMto go into the fail-safemode, . Use a commerciallyavailableoil pressuregauge that measures4,900kPa {4.90MPa, 5O.Okgf/cmr,711 psi) or more,and the Ay'TOil PressureHose,2210mm (07MAJ- PY4011A). A/T OIL PRESSURE GAUGE SETW/PANEL 0ta{r6 - oO2Oi|(Xt

A/T LOW PRESSURE GAUGEW/PANEL 0706 - qt7o:t{ro

FORWARDCLUTCHPRESSURE INSPECTION "F") lMarkedwith

DRIVEPULLEYPRESSURE INSPECTIONHOI.E (Markedwith "DR")

A/T PRESSURE HOSE ADAPTER 07MAJ- PYar'120 lil R.qulr.d)

A/T PRESSUBE HOSE 2210mm 07MAJ- PYitollA la R.quir.d)

REVERSE BRAKEPRESSURE INSPECTION I.IOLE

(

ATF DIPSTICK INSPECTION HOLE (Markedwith "LUB")

14-3 0 0

DRIVENPULLEYPRESSURE INSPECTION HOLE lMarkedwith "DN")

CLUICH PRESSURE INSPECNONHOLE (Markedwith "SC")

Startthe engine. pressuresat 1'500rpm' 1 . Shiftto the respectiveshift leverpositionsin the table,and measurethe following . . . .

ForwardClutchPressure ReverseBrakePressure DrivePulleyPressure DrivenPulleyPressure

8. Shiftto E posltion,and measurethe lubricationpressureat 3,000rpm' SHIFTLEVER PBESSURE POSmON Forward Clutch Reverse Brake Drive Pulley

FLUIDPRESSURE SYMP{OM

Lubrication

Standard/SsrviceLimit

E

No or low forward clutch pressure

ForwardClutch

1 . 4- 1 . 7 5M P a (14.3- 17.8kgtcm' , 203- 253Psi)

ts

No or low reversebrake pressure

ReverseBrake

1 . 4- 1 . 7 5M P a (14.3- '17.8kg7cm' ,203- 253Psi)

N

No or low drive pulley pressure

ATF pump, PH regulatorvalve,PL regulatorvalve, Shiftvalve

0.2- 0.7 MPa (2 - 7.1 kgflcm' ,28 - 101Psi)

Drivepulley pressure roo

PH regulatorvalve, PL regulatorvalve, Shift valve.Shift controllinear solenoid

high

Driven Pulley

PROBABLECAUSE

No or low drivenpulley pressure

ATF pump, PH regulatorvalve,Shift valve,Shift control linearsolenoid

Drivenpulley pressuretoo hi g h

PH regulatorvalve

No or low lubrication pressure

ATF pump, Lubricationvalve

1 . 5- 2 . 3M P a (15.3- 23.5kg?cm' ,218- 334 Psi)

Above0.2 MPa (Above 2 kgf/cm'. 30 Psi)

the specialtool afterpressuretestlng 9 . Disconnect the bolts to the specified 1 0 . Installthe sealing boits in the jnspectionholes with new sealingwashers,and tighten toroue. TOROUE:18 N.m {1.8 kgf'm, 13 lbf'ft} CAUTION: Keepall foreign particles out of the transmission'

14-301

LowerValveBodyAssembly Replacement Make sure lifts, iacks, and saf€ty stands @ are placsd prop€rly {seasection 1). CAUTION: While removing and installing th6 lower valve body asssmbly, b€ sule not to allow dust and other for€ign particlesto entsr inio the transmksion. 1.

2.

Raisethe front of the vehicle,and support it with safetvstands(seesection1). Set the parking brake,and block both rear wheels securetv.

7. 8. 9. 10. 1l.

Removethe ATFcooleroutlet line. Removethe ATFcoolerline bracketbolt. Removethe ATF pan (fourteen bolts). Removethe ATF strainer(two bolts). Removethe one bolt securingthe solenoidharness connector, 1 2 . R e m o v et h e l o w e r v a l v e b o d y a s s e m b l y( e i g h t bolts). LINEBOLT SEALING Replace.

28 N.m (2.9kgtm,21 lbtft)

ATF COOI.-ER

OUTLET R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d . Reinstallthe drain plug with a new sealingwasher (seepage 1+299). O.RING Feplace.

CAUTION: Keop all of other toreign parliclos out of the transmission. 4.

the 8P connectorfrom the solenoidharDisconnect ness connector. Remove the ATF cooler hoses at the ATF cooler lines.Turn the ends of the ATF cooler hosesup to preventATF from flowing out, then plug the ATF coolernoses.

SOLENOIOHARNESS CONNECTOR OOWELPIN

O.RING

ATF Replace. STNAINER

CAUTION: Keep all of other foroign particlo3out of tho transmission. 6.

6x1.0mm 12 N.m 11.2kgt m, E.7 tbt'ft) OOWELNN

RIGHTFRONT MOUNT/BRACKET

ATF COOLERLINE

10x 1.25mm sil N.m 15.5kgf.m, 40 rbr.ft)

ATF COOLERHOSE

14-302

VALVE BODYASSEMBLY 6x1.0mm 12 N.m 11.2kgf.m, 8.7 rbf.ft)

Removethe right front mounvbracket. 10 x 1.25mm ila N.m (,1.5kgf.m,33 lbtft)

5x1.0mm 12 N.m 11.2kgt.m, 8.7 tbt.ftl

ATF PAN

ATF PAN GASKET Replace. ATF COOLERINLET UNE BRACKETBOLT 8 x 1,25mm 26 N.m {2.7 kgf.m, 20 tbf.frl

x 1.0mm 12 N.m 11.2kgf.m,E.7lbf.ftl

1 3 . Install the new lower valve bodv in the reverse ordgrof the removalorocedure. CAUTION: Koep all ot other fo.oign particles out of ths transmission. NOTE: . Replacethe followingparts: - O - r i n g so n t h e s o l e n o i dh a r n e s sc o n n e c t o r and the ATFstrainer - ATF pan gasket - Sealingwashers . l f t h e A T F c o o l e r i n l e t l i n e b r a c k e ti s b e n t o r warped,put it backto the originalposition. 1 4 . Perform the start clutch calibrationorocedureon page14-293.

ATFFilter

l .

Removal/lnstallation Make sure lifts, lEcks, snd safoty stands !@ ara pl8ced properly {saesection 1). CAUTION: While removing and installing the ATF tilier, be sure not to allow dust or other for6ign particle3 to enter thg transmission. 1.

Raisethe front of the vehicle,and support it with safetystands(seesection1).

2.

Set the parking brake,and block both rear wheels securely.

3.

R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d . Reinstallthe drain plug with a new sealingwasher {seepage 14-299). CAUTION: Keep all toreign particles out ot the transmission.

Removethe ATF cooleroutletline. Removethe ATF coolerline bracketbolt. Removethe ATF pan (fourteen bolts) Removethe ATF cooler inlet line from the ATF pan (threebolts). 10. Removethe ATFfilter,and cleanit. 11. Checkthat the ATFfilter is in good condition. 12. Replacethe ATFfilter if it is clogged. 6. 7. 8. 9.

LINEBOLT 28 N.m {2.9 kgf.m,21 lbt.ft)

ATF COO1TROUTIET 6x1.0mm 12 N m (1.2kgf m,

ATF COOLERINI-ET LINEERACKETBOLT 8 x 1.25mm 26 N.m (2.7kgt.m,

20rbtftt

Remove the ATF cooler hoses at the ATF cooler lines.Turn the ends of the ATF cooler hosesup to preventATF from flowing out, then plug the ATF coolernoses.

fl,

CAUTION: Keep all foreign particles out of the transmission.

O.RING Replace. ATF FILTER

5.

Removethe rightfront mounvbracket. 10 x 1.25mm 4{ N.m {i1.5kgf.m,33 lbf ft)

ATF GASKET Replace.

ATF PAN

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

'13. l n s t a l lt h e A T F f i l t e r i n t h e r e v e r s eo r d e r o f t h e removalprocedure. 10 x 1.25mm 54 N.m {5.5 kgt'm, 40 rbl.ft)

(|'t

ATF COOLERHOSE

GAUTION: Keep all foreign particles out ot the transmission, NOTE: R e p l a c et h e O - r i n g s ,t h e A T F p a n g a s k e ta n d sealingwashers. l f t h e A T F c o o l e r i n l e t l i n e b r a c k e ti s b e n t o r warped.put it backto the originalposition

14-303

Transmission Removal

@ . Mako .

4,

suro lifts. iacks, and satety stands are placod properly, and hoi3t bracket are attached to lhe correct position on the engine {seesoction 1}. Apply parking brake and block r€ar wheels so tha vehicle will not roll off stands and fall on you while working undor it.

Disconnect the solenoidharnessconnector, the drive pulleyspeedsensorconnector,and the groundcable terminals. GROUNDCABLE

GROUNDCAELE

CAUTION:Use tender coversto avoid damaging painted surfaces. 1.

Disconnectthe battery negative(-) terminal from the battery,then removethe positive(+)terminal. Removethe intakeair duct and air cleanerhousing assembly.

3.

Removethe starter cables and cable holder from the starter motor.

DRIVEPULI.-EY SPEEDSENSOR CONNECTOR

STARTERMOTOR

SOLENOIOHARNESS CONNECTOR

Removethe clip, then separatethe shift cablefrom the controllever, CAUTION: Take care not to bend the shift cable. S}IIFT CABLE

WASHER

WASHER

STARTERCABLE

CONTROLLEVER

14-304

I 6.

Disconnectthe vehiclespeedsensor(VSS)connector, the driven pulley speed sensorconnector,and the secondarygearshaftspeedsensorconnector.

GEAR SECONDARY SHAFTSPEED SENSOR

8.

R e m o v et h e d r a i n p l u g , a n d d r a i n t h € C V Tf l u i d Reinstallthe drain plug with a new sealingwasher. CAUTION:While installing the drain plug' bo 3ur. nol io allow du3l 8nd other toreign particles to enter into th€ trsnsmi$ion.

ORIVENPULLEY SPEEDSENSOR CONNECTOR

DRAINPLUG 18 x 1.5rnm (, N.m (5.0 kgfm, 36 lbf'ft|

7.

SEALINGWASHER Replaco.

Removethe transmissionhousingmountingbolts. 9.

Removethe splashshield.

14-305

Transmission Removal(cont'd) 10. Removethe cotte. pins and castlenuts,then separate the balljointsfrom the lowerarm (seesection1g).

-=V, SELF-LOCKING \ NUT \ CASTLEI{UT COTTER Replace. oitupea rOax Replac6.

'16,

Removethe rightfront mounvbracket,

/\<,\

't1. Remove the right damper fork bolt, then separate right damperfork and damper.

't2. Pry the right

and left driveshaftsout of the differen-

ATFCOOLER HOSE 17. Remove the ATF cooler hoses at the ATF cooler lines.Turn the ends of the ATF cooler hosesuo to preventCVT fluid from flowing out, then plug the ATF coolerhosesand lines,

tial. tJ.

Pullon the inboardjoint to removethe right and left driveshafts(seesection16).

1 4 . Tie plasticbagsoverthe driveshaftends.

NOTE: Checkfor any sign of leakageat the hose joints. 18. Removethe engine stiffenersand the flywheel cover.

NOTE:Coatall precisionfinishedsurfaceswith clean e n g i n eo i l . Removethe exhaustpipe A.

q. SELF.LOCKING NUT Replace. SELF.LOCKING NUT Replace.

1 4- 3 0 6

EXHAUSTPIPEA

ENGINESTIFFENER

1 9 . Removethe eight drive plateboltsone at time while rotatingthe crankshaftpullev.

Removethe distributor'

2 3 . R e m o v et h e t r a n s m i s s i o nh o u s i n gm o u n t i n gb o l t and rearenginemountingbolts

Atach a hoistingbracketto the engine,then lift the e n g i n es l i g h t l y .

REARENGINEMOUNTING TRANSMISSIONHOUSING MOUNTINGBOLT

WASI{ER

22. Placea iack under the transmission.and raisethe

transmissionjust enoughto take weight off of the mountbracket mounts,thenremovethe transmission

Pull the transmissionaway from the engine until it clearsthe l4 mm dowel pins, then lower it on the transmissionjack

MOUNT TRANSMISSION

TRANSMISSIONMOUNT

14-307

lllustratedIndex Transmission/Lower ValveBodyAssembly

14- 3 0 8

O ATF DIPSTICK O o-RINGReplace. .' SOLENOIDHARNESSCONNECTOR @ LOWERVALVEBODYASSEMBLY O DOWELPIN O LINEBOLT .i ATTfCOOUR IruIETLINEB8ACKETBOLT €] lrr cooua truler LINEASSEMBLY O SEALINGWASHERRePIACE' G, ATF COOLEROUTLETPIPE 6) o-RINGReplace. @ ATF FILTER fO o-RINGReplace. @ ATF PAN (3 DOWELPIN (D O-RINGReplace. E) ATF STRAINER @ ATF MAGNET (9 ATF PAN GASKETRePIACE' O ATF MAGNET €t oRAIN PLUG @ SEALINGwAStlER Replace.

TOROUESPECIFICATIONS Bolt/Nut No.

Torque Value

Size

8F 12J 18D

12 N.m {1.2kgf m, 8.7 lbf'ft} 26 N.m (2.7kgim,20 lbf'ft) 28 N.m (2.9kgf'm,21lbf'ft) 49 N.m (5.0 kgf'm, 36 lbf'ft)

6x1.0mm 8 x 1 . 2 5m m 1 2x 1 . 2 5m m 1 8x 1 . 5m m

Remarks

Linebolt Drainplug

14-309

lllustratedIndex Transmission Housing/Flywheel Housing 8G

I

)

H

14-310

C e) .' O 6

O-RINGReplace. OIL SEALRePlace HOUSING FLYWHEEL flVWneel }|OUSttttGGASKETReplace DIFFERENTTALASSEMELY

@lrr plsslce uruEASSEMBLY

Replace O O-RING PIN @ DOWEL €) ATFPUMPASSEMBLY (ODowELPlN,18x 10mm Replace. O O-RING o DowELPlN,22x 10mm lrr puup oRve cxltttt iA SNAPRING part f3 fxaUst St|t|l, zz t 28 mm Selective

Gtlrr punpontvespaocxer O PITOTFLANGE

HUB ontveSPRoGKET itonTFpurrap (O THRUSTWASHERS @ PITOTPIPEBRACKET PIPE O PITOTLUBRICATION @ PITOTPIPE t3 OIL SEALReplace. OaSEt AtitC, SOmm SelectivePart

ASSEMBLY o3lrr passlce ltnE HoLOER

6) o-RING Replace. €) STARTCLUTCHATF FEEDPIPE COO-RINGReplace. €I FEEOPIPEFLANGE @ SNAPRING BRACKET O' CONNECTOR @ BALLBEARING 6} SNAPRING 64 COTTERRETAINER 6DCoTTERS,25.5mm selectivePart

6t stlnt cLutcHasseMsLv ASSEMBLY @secoruomvontvEGEAR @ o-RINGSReplace COVER 6) DIFFERENTIAL rO ttaUSr SntU, zs t 35 mm Selectivepart GEARSHAFT @ SECONDARY @ PARKPAWLSHAFT @ PARKPAWLSPRING .1i PARK PAWL @ TONGUEDWASHERREPIACE, @ PARKROOHOLDER @ BALLBEARING @ o-RINGReplace. @ VEHICLESPEEDSENSOR @ OIL SEALReplace.

TOROUESPECIFICATIONS

12 N.m (1.2kgnm,8.7lbf'ft) 22 N.m (2.2kgf'm.16lbf'ft) 26 N.m (2.7 kgf'm, 20 lbf'ft) 29 N.m {3.0 kgf'm, 22 lbift)

6x1.0mm 8 x 1 . 2 5m m 8 x 1 . 2 5m m 8 x 1 . 2 5m m

ft, 14-311 )

lllustratedIndex RightSideCover/lntermediate Housing 88

I

.Fi.

O ENDCOVER O ATF FEEDPIPE O DOWELPIN @ O-RINGReplace. G) FEEDPIPEFLANGE

@reeopperurucepuru

O] ROLLER ASSEMBLY XOUSING O IruTENMEDNTE

sxlrr lsseugLv aocorutnoL ttoustt'tc @tnlrusmtsstottt

@ SHIFTCABLEBRACKET CAP c) BREATHER @ oll- SEALReplace. LEVER @ CONTROL Replace. G LoCKWASHER sENsoR (D secololaY ceaR SHAFTSPEED o) onvel put-uv sPEEDSENSOR Replace. @ O-RING (OSNAPRING 6 rnmrsutsstoru xouslNc oRlvENPULLEY BEARING SHAFTROLLER REPIACE' GASKET @ ENDCOVER Replace @ o-RING 6omnruulL vnLVe goDYLINEA 64 MANUALVALVEBODYLINEB Replace. @ O-RING SPRING @ DETENT O ATFFEEDPIPE Replace. @ O-RING @ MANUALVALVEEODY PIN @ DOWEL goDYSEPARAToR PLATE @ r'rllull valve 6DSNAPRING @troRwlno cturcx ASSEMBLY @ o-RINGReplace @ SNAPRING ASSEMBLY o3spnlrucaetlrupn/RETURNSPRING @ nevenseennr eBtottt Feplace. @ o-RING @ SNAPRINGRE'AINER @ ATFFEEDPIPE

.1,

Replace' GASKET HOUSING 6) TRANSMISSION PIN @ DOWEL PIPE @)ATFFEED Replace. @ o-RING 60o-RINGReplace. SENSOR SPEED @)DRIVEPULLEY HANGER @ TRANSMISSION @ SNAPRING part @ txaust Sxtfu,zs t 31mm selective BEARING SALL @ 6J RINGGEAR 6DSNAPRING part Selective @ aevenseaRlxe rND PLATE DISC BRAKE @ REVERSE PLATE BRAKE @ REVERSE @ DISCSPRING WASHER 6} THNUST

eelnNc @}finusr NeeoLr

WASHER @ THRUST ASSEMBLY @ GARRIER WASHER @ THRUST BEARING NEEDLE @ THRUST @}SUNGEAR RINGREPIACE' @ SEALING BEARING @ NEEDLE @ INPUTSHAFT BEARING @ NEEDLE RINGFEPIACE' @ SEALING Replace' RING{RUBBERI @ SEALING PIPE @ ATFFEED

TOROUESPECIFICATIONS

6B 8B 8F 8G

12 N.m (1.2kgf'm,8.7lbf'ft) 14 N.m {1.4kgf'm,10 lbift) 37 N.m (3.8 kgf'm, 27 lbf'ft) 26 N.m (2.7kgf'm,20lbf'ft) 29 N.m (3.0 kgf'm, 22 lbf'ft)

6x1.0mm 6x1.0mm 8 x 1 . 2 5m m 8 x 1 . 2 5m m 8 x 1 . 2 5m m

rl, 14-313

TransmissionHousing/LowerValveBodyAssembty Removal NOTE: . Cleanall partsthoroughlyin solventor carburetorcleaner, and dry with compressedair. . Blow out all passages. . When removingthe lowervalvebody,replacethe followingl - O-rings - ATF pan gasket - Sealingwashers

O.RING Replace. SOLENOIOHARNESSCONNECTOR DOWELPIN

6 x'1.0mm BOLT

LOWERVALVEBODYASSEMBLY

6 x 1.0mm BOLT

ATF PAN GASKET Replace.

ATF STRAINER

ATF COOLERINLET LINE BRACKETBOLT 8 x 1.25mm ATF COOI..ERINLET LINE

6 x 1.0mm BOLT

6 x 1.0mm EOLT

14-314

l .

'1. Removethe ATFcoolerinlet iine bracketbolt' 2.

Removethe ATFcooleroutlet line Removethe ATF pan (fourteenbolts). Removethe ATFstrainer{two bolts)

5.

Removethe one bolt securingthe solenoidharness connector,then pushthe connector.

6.

Removethe lowervalvebody (eightbolts)

7.

Cleanthe inletopeningof the ATFstrainerthoroughly with compressedair, then checkthat it is in good condition,andthe inletopeningis not clogged'

ATF STRAINER

2

c

c;2

'

ar\

INLETOPENING the ATFstrainerif it is cloggedor damaged Replace NOTE:The ATF strainercan be reusedit it is not clogged.

14-315

TransmissionHousing/Flywheel Housing Removal NOTE: . Cleanallpartsthoroughlyin solventor carburetorcleaner,and dry with compressedair. . Blow out all passages. . When removingthe transmissionhousing/flywheel housing,replacethe following: - O-rings - Secondarydrive gear assembly - Start clutch assemblv - Flywheelhousinggasket ATF PASSAGELINE HOLD€RASSEMBLY

8 x 125 mm BOLT

VWHEELHOUSING

IX)WEL PIN OIFFERENTIAL ASSEMBLY

EYWIIEELHOUSINGGASKET Roolace.

SNAPRING

COTTER RETAINER ATF PA$gAGE UNE ASSEMBLY

COTTERS, 25.5 mm Selectivepart

O.RING Rsplaco.

STARTCLUTCH ASSEMBLY Replace.

6 x 1,0 mm BOLT O.RING Replace.

THRUSTSHIM, 25x35mm Seloctivepart

ATF PUMP DRIVECHAIN SNAP RING

THRUSTSHIM,22 r 28 mm part Seloctive SECONDARY GEARSHAFT SECONDARY DRIVE GEARASSEMBLY Replace. PARK PAWL SHAFT

GRII{GS Replac€.

6 x 1.0 mm BOIT ATF PUMP DRIVE SPROCKET PfTOTFLANGE ATF PUMP DRTVE SPROC|(ETHUB THRUSTWASHERS

PARKPAWL SPRING

INPUTSHAFT

InANSMISS|O]{ HOUSTNG DRIVENPULLEYSHAFT

14-316

) 1 . Removethe ATF passageline holderassembly' Removethe flywheelhousing(twentybolts)' Removethe ATF passageline assembly(onebolt) Removethe ATF pump drive sprocket (three bolts), then removethe ATF pump drive chaan. Move the pitot flange toward its cutout, then remove the pitot flange.

10. Setthe specialtool on the startclutch'and attachthe oawl of the specialtool to the parkgear securelyas shown. CAUTION: . Do not place tho pawl of the spocial tool on the start clutch guidc. ll the pawl ot the spocial tool contacts the 3tart clutch guid€, the start clutch guido may be damaged. . Be sure not to allow dust and other foreign particles to enter into the drivon pull6y shaft' STARTCLUTCH REMOVER 07TAE- P4V0120

STARTCLUTCH ASSEMBLY Replace.

PAWL

PITOTPIPE

Removethe snap ring securingthe ATF pump drlve sprockethub. then remove the 22 x 28 mm thrust shim, the ATF pump drive sprockethub and the thrust wasners, 7.

STARTCLUTCH REMOVER 07TAE- P4V0120

Removethe differentialassemblY. Removethe park pawl shaft,the park pawl spring, and the parkPawl'

9.

1 1 .Removethe start clutch and the secondarydrive gear assemblyusing the specialtool, then remove the secondarygearshaft.

STARTCLUTCH ASSEMBLY

Removethe snap ring securingthe startclutch,then remove the cotter retainerand the cotters.

J

14-317

End Cover/lntermediate Housing Removal NOTE: . Cleanallpartsin solventor carburetorcleansr,and drywith compressedair, . Blow out all passages. . When removing the end cover/intermediatehousing, replacsthe following parts: - O-rings - End cover gasket - Transmissionhousinggasket - Sealingrings - Sealingwashers 8 x 1.25 mm BOLT

6 x 1.0mm BOLT REVERSEBRAKE END PLATE

{ u

Dtsc PLATE DISCSPRING SNAP

ENDCOVER GASXET Feplac€.

THRUST 2 5 x 3 1m m Selectivepart RINGGEAR THRUSTWASHER THRUSI NEEDLE BEARING

8 x 1.25mm BOLT

THRUSTWASHER CARRIER ASSEMBLY

sNAP / R|NG I

INIERMEDIATE HOUSING ASSEMSLY

THRUSTWASHER THRUSTNEEDLE BEARING SUN GEAR INPUTSHAFT

o.BING Replace.

TRANSMISSTON HOUSINGGASKET Replace.

SNAPRING CLUTCHEND PLATE FORWARDCLUTCH ASSEMBLY

SEALINGRING(RUBBER} Replace.

DOWELPIN

SNAPRING HOUSING

SPRINGRETAINER/ RETURNSPRINGS SNAPRING RETAINER

14-318

l .

1 . Removethe end cover {three6 mm bolts,eleven8 mm bolts). 2. Removethe manualvalvebody linesA and B 3. Removethe snap ring securingthe ring gear,then removethe thrustshim and the ring gear'

11. Compressthe returnsprings.then removethe snap ring C A U T I O N :l f t h e s p r i n g r e t a i n e r t a b i s o n t h e rsverse braks piston, tho spting letainer may be damaged. Be surs the spring letainer tab is not on the piston. SPECIALTOOL

4. Removethe snap ring securingthe reversebrake discsand plates,then removethe reversebrakeend plate.brakediscs,brakeplates,and discspring' 5. Removethe carrierwith the thrust washersand the thrust needlebearingfrom the forwardclutch 6. Removethe sun gear and the input shaft as a sub assemblybY Pullingit The sun gear is pressfittedtightly into input shaft' 7. Removethe snap ring securingthe forward clutch, and removethe snapring securingthe forwardclutch end plate,then removethe forward clutchend plate' 8 . R e i n s t a ltl h e c a r r i e ro n t h e f o r w a r d c l u t c h ,t h e n securethe carrierwith the snap ring on the forward clutchend Plate.

SPfiINGFETAIiGR TAB 12. Removethe specialtool, then remove the spring springassembly. retainer/return 1 3 . Removethe sealingbolt securingthe reversebrake pressureinsPectionhole. 1 4 . Apply air pressureto the inspectionholeto remove the reversebrakePiston SPBINGREYAINER/ RETURiI SPRIiIG ASSEMALY

9. Remove the forward clutch and carrier assembly together.

REVERSEBNAXE PISTON

' 1 0 .l n s t a l lt h e s p e c i a lt o o l t o r e m o v e t h e s n a p r i n g securingthe reversebrakereturnspring retaineras snown.

o-Rrllcs Replace.

BBAKE REVERSE COMPRESSOR SPRING 07TAE- PaV0110

FCVERSEBRAKE PRESSUREINS?ECTK)N HOtl

SEALING WASHER Replace. 8 x 1.25mm 18 N.m 11.8kgf.m, 13 lbf.ttl

Removethe snap ring retainerfrom the drive pulley shaft. 1 6 . Removethe manualvalvebody (fivebolts)' 't7 Removethe rollerand pushthe controlshaftassembly toward the outsideof the transmissionhousing, housing(fourbolts)' then removethe intermediate

14-319

ManualValveBody Disassembly/lnspection/Reassembly NOTE: . Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Elow out all passages. . Coatall partswith CVTFluidduringassembly.

SPRINGSEAT INHIBITOR REVERSE VALVESPRING

REVERSE INHIBITOR VALVE

MANUAL VALVE

MANUAL VALVEBODY Inspectfor wear, scratches and sconng,

14-320

ForwardClutch

l .

lllustrated Index

CLUTCHORUM

\ \

DISCSPRING

\_

CLUTCHEND PLATE

CLUTCHPISTON

SNAPRING

14-321

ForwardClutch Disassembly 1.

Removethe snap ring, then removethe clutchend plate,clutchdiscs,and plates.

3.

Installthe specialtoolsas shown. CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40100

SNAPRING

CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PXa0100or 07HAE- P150100

2.

Removethe disc spring.

CLUTCHSPRING COMPRESSOR BOLT ASSEMBLY o7R{E-PG402OO

OISC SPRING

CAUTION: lf €ither ond of the sp€cial tool is sst over an aroa of the spring retainer which is unsupported by th€ retum spring, the rotainer may be damaged. Be sure the spccialtool is adiustedto hava tull contaqt with the sp.ing retainer.

t

CLUTCHDRUM

Do not B€t here.

SPECIALTOOL

SPRINGRETAINES

14-322

4.

Compressthe returnsprlng.

6.

Wrap a shop rag aroundthe clutchdrum, and apply air pressureto the fluid passageto removethe piston. Placea fingertip on the otherend while applyingair pressure. OSHA-APPROVED 30 psi NOzzLE

Removethe snapring.Thenremovethe specialtools, and returnspring. springretainer,

SPBINGRETAIT{€R

14-323

ForwardGlutch Reassembly NOTE: . Clean all parts thoroughly in solvent or carburetor cleaner,and dry them with compressedair. . Blow out all passages. . Lubricateall partswith CW Fluidbeforereassembly. 1.

Inspectthe checkvalve;if it's loose,replacethe piston. CHECKVALVE

3.

Installthe pistonin the clutchdrum. Apply pressure and rotateto ensureproperseatang, NOTE: Lubricatethe piston O-ring with CVT Fluid beforeinstalling. CAUTION: Do not pinch thc O-ring by installing the pistoo with too much torqo. CLUTCHDRUM

InstallnewO-rings on theclutchpision. Install the return spring and spring retainer,and positionthe snap ring on the retainer.

CLUTCHDRUM

PISTON

14-324

l . 5.

lnstallthesDecialtoolsas shown.

6.

Compressthe returnsPrlng'

7.

Installthe snap ring.

CLUTCHSPRING COMPRESSOR ATTACHMENT 07LAE- PX40100

CLUTCI{ SPRING COMPRESSOR BOLT ASSEMBLY oTGAE-PG40200

CLUTCHSPNING COMPRESSOR ATTACI{MENT 07LAE- Pxil010oo. 07HAE- P150100

CAUTION: lf either end of the specialtool is set ovel an area of lhe spring retain€r which is unsupported by the return spring, tho retainsr may be damaged' Be sure the speciallool is adiusted to have full contact with the spring tetainer.

SIIAP RING

8.

Removethe specialtools.

Sgt h6r6.

Do not sat hore. SPECIALTOOL

RETAINER

(cont'd)

14-325

ForwardClutch Reassembly {cont'd) 9. Installthe discspring.

12. Installthesnap ring.

NOTE:Installthediscspringin the directionshown.

DISC SPRING

SNAPRING

-\

"arr"" o"u*

1 0 . Soakthe clutchdiscsthoroughlyin CW Fluid for a minimumof 30 minutes. 1 1 . Starting with a clutch plate. alternatelyinstall the clutch platesand discs.Installthe clutch end plate with flat sidetoward the disc. NOTE:Beforeinstallingthe platesand discs,make sure the insideof the clutch drum is free of dirt or other toreign matter.

13. Verify that the snap ring end gap is correct. CLUTCH

CLUTCHENDPLATE Installin this dir€ction. Minimum7.9mm (0.31ini

14-326

14. Measurethe clearancebetweenthe clutchend plate Zeroth€ dial indicaand toDdiscwith a dial indicator, tor with the clutch end plate lowered,and lift it up to the snap ring. The distancethat the clutch end plate moves is the clearancebetweenthe clutch end plate andtoDdisc.

15. It the clearanceis out of tolerance,selecta new ciutch end platefrom the followingtable,thenrecheck. NOIE: lf ihe thickestclutchend plateis installedbut the clearanceis still over the standard,replacethe clutchdiscsand clutchPlates.

in at leastthree places, NOTE:Take measurements and usethe averageas the actualclearance.

PTATEI{UMBEN

Clutch End Plate-to-TopDisc Clesranc€: STANDARD:0.6 - 0.8 mm 10.024- 0.031inl

FORWARDCLUTCHEND PLATE Plate No.

Part Number

Thickn€ss

1or15

22561- P4V- 003 3 . 5m m ( 0 . 1 3 8i n )

2or16 3or17

in) 22562- P4V -OO3 3 . 6m m ( 0 . 1 4 2 2 2 5 6 3 - P 4 V - 0 0 33 . 7m m ( 0 . 1 4 6i n )

4or18

22564- P4V- 003 3 . 8m m ( 0 . 1 5 0i n )

5or19

2 2 5 6 s - P 4 V - 0 0 33 . 9m m ( 0 . 1 5 4i n )

6ot20 7 ot 21

2 2 5 6 6 - P 4 V - 0 0 34 . 0m m ( 0 . 1 5 7i n ) 22567-P4V -003 4 . 1m m ( 0 . 1 6 1i n )

8ot22

2 2 5 6 8 - P 4 V - 0 0 3 4 . 2m m ( 0 . 1 6 5i n )

9ot23

2 2 5 6 9 - P 4 V - 0 0 3 4 . 3m m { 0 . 1 6 9i n ) in) 22570-P4V-OO3 4 . 4m m ( 0 . 1 7 3

1 0o r 2 4 'll

or 25

2 2 5 7 1 , P 4 V - 0 0 34 . 5m m ( 0 . 1 7 7i n )

12ot 26

2 2 5 7 2 - P 4 V - O O 34 . 6m m ( 0 . 1 8 1i n ) 22573-P4V-OO3 4 . 7m m { 0 . 1 8 5i n )

1 3o t 2 7

1 6 . After replacingthe clutchend plate,makesure thal the clearanceis within tolerance.

14-327

SecondaryGearShaft 25 x 35 mm ThrustShim Selection 1.

Measurethe distancebetweenthe flywheelhousing surfaceand the ball bearing as shown, then note the measurement(Measurement A).

Calculate25 x 35 mm thrust shim thicknessbv followingformula. FORMULA; 25 x 35 mm Thrust Shim Thicknoss = Measurement A - Measurement B + Flywheel Housing GasketThickness:0.5 mm {0.020in}

FLYWHEEL HOUSING

>dt?'

Example: MeasurementA: 32.7 mm (1.287in) Moasurem.nt B: 30.! mm {1.185in}

O

25 x 35 mm Thrust Shim Thickness = 32.7mm (1.287in) - 30.1mm (1.185in) + 0.5 mm {0.020in) = 3.1 mm (0.122inl

BALLBEARING

Select 25 x 35 mm Thrust Shim D. A MeasuringDistance

Selectthe 25 x 35 mm thrust shim from the following the table. THRUSTSHIM, 25 x 35 mm

EALL BALL BEARING

FLYWHEEL HOUSTNG

Installthe secondarygear shatt in the transmission housing. Measure the distance between the transmission housing surface and the thrust washer mounting surfaceof the secondarygear shaft as shown,then notethe measurement(Measurement B).

No.

Part Number

Thickne3s

90551- P4V- 000 2 . 8m m ( 0 . 1 1 0i n ) B

9 0 5 5 2 - P 4 V - 0 0 02 . 9m m ( 0 . 1 1 4i n )

c

9 0 5 5 3 - P 4 V - 0 0 03 . 0m m ( 0 . 1 1 8i n )

D

9 0 5 5 4 - P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2 2 in)

E

9 0 5 5 5 - P 4 V - 0 0 0 3 . 2m m ( 0 . 1 2 6i n ) 9 0 5 5 6 - P 4 V - 0 0 0 3.3 mm (0.130in)

G

9 0 5 5 7 - P 4 V - 0 0 0 3 . 4m m ( 0 . 1 3 4i n )

H

9 0 5 5 8 - P 4 V - 0 0 0 3 . 5m m ( 0 . 1 3 8i n )

9 0 5 5 9 - P 4 V - 0 0 03 . 6m m { 0 . 1 4 2i n ) K

14-328

9 0 5 6 0 - P 4 V - 0 0 0 3 . 7m m ( 0 . 1 4 6i n ) 90561- P4V- 000 3.8 mm (0.'150 in)

Differential

l .

Bacl(lashInspection

lllustratedIndex BOLTS 1 0x 1 . 0m m 98 N.m 110.0kgf.m, 72 tbl.ltl Left-handthreads

1.

Placethe differentialassemblyon V-blocks,and install both axles.

2.

Checkthe backlashof both piniongears. Standard (Newl: 0.05- 0.15 mm 10.002- 0.006in)

PINIONGEARS

FII{AL ORIVENGEAR

BAIT EEANIM;

SET RING. 8() tnm Soloctivopan

lf the backlashis out of tolerance,replacethe differentialcarrier.

14-329

Differential BearingReplacement

DifferentialCarrierReplacement

NOTE:Checkthe bearingsfor wear and rough rotation. lf the bearingsare OK, removalis not necessary.

1.

'1. Removethe ball bearingsusinga bearingpuller.

Removethe final driven gear from the differential carner. NOTE: The final driven gear bolts have left-hand threads. BOLTS 1 0x 1 , 0m m 98N'm 110,0 kgf.m, 72 tbl.ttl Left-hand threads

BAI-LBEARING

Installthe new ball bearingsusing the special tool with a pressas shown.

DIFFERENTIAL CARRIER Installthe final driven gear with its chamferedside on the innerborefacingthe differentialcarrier.

ORIVER10 mm l.O. 07746- 0030100

Tightenthe boltsto the specifiedtorque in a crisscross Paftern. TOROUE:98 N.m (10.0kgt.m, 72 lbf.ft)

BALLBEARING

14- 3 3 0

l .

Clearance Oil SealInstallation/Side

Oil SealRemoval 1.

Removethe differentialassembly.

2.

Removethe oil sealfrom the transmissionhousing.

1.

lnstall a 2.50 mm (0.098in) thick 80 mm wide set r i n gi n t h e t r a n s m i s s i ohno u s i n g . NOTE:Do not installtheoil sealyet.

TRANSMISSION HOUStl{G TRANSMISSON HOUSING

3.

OIL SEAL R€placa.

Removethe oil sealfrom the flywheelhousing.

lnstallthe differentialassemblyinto the transmrssion housingusingthe specialtoolas shown

DIFFEREI{NAL ASSEMBLY (cont'd)

14-331

Differential Oil SealInstallation/Side Clearance(cont'dl 3.

Installtheflywheelhousing,and tightenthe bolts.

4.

8 x 1.25 mm 29 N m (3.0kgt m,22 lbf.ttl

Measurethe clea.ancebetweenthe 80 mm set ring and outer race of the ball bearingin the transmission housing. STANDARD: 0 - 0.15mm (0 - 0.006in)

ug Ei

DOWELPIN

lf the clearanceis more than the standard,selecta new set ring from the table,and installit. SETRING,80 mm Part Number 904' r4-689-000 90415-689-000 90416-689-000 90417-689-000 90418-689-000 90419-PH8-000

Thickness 2.50mm (0.098in) 2 . 6 0m m ( 0 . 1 0 2 in) 2 . 7 0m m ( 0 . 1 0 6 in) 2 . 8 0m m ( 0 . 1 1 0 in) 2 . 9 0m m ( 0 . 1 1 4 in) 3 . 0 0m m ( 0 . 1 1 8i n )

NOTE:lf the clearancemeasuredin steD4 is standard, it is not necessaryto perform steps 7 and 8.

14-332

6.

Removethe flywheelhousing.

7.

Replacettle 2.50mm (0.098in) set ring, 80 mm with the one ot the correctthicknessselectedin steD5.

FlywheelHousing Input Shaft Oil Seal

l .

Replacement 8.

Installthe oil sealin the transmissionhousingusing the sDecialtools as shown.

1.

Removethe input shaft oil seal from the flywheel housing.

DRIVER 07749- 0010d)0

OIL SEAL

9.

Installthe oil seal in the flywheelhousingusingthe soecialtools as shown.

Instalithe oil seal in the flywheelhousingusingthe soecialtoolsas shown.

FLYWHEEL

DRIVER ATIACHMENT,58 x 72 rnin 0?947- d'40201

PILOT, 26x30mm oTJAD- PH80200

lmtalled depth: 2 . 5 - 3 . 5m m

ro"nri':,ilii.rl

t@

14-333

Transmission HousingBearings DrivenPulleyShaft BearingReplacement 1.

To removethe driven pulleyshaft b'earingtrom the t r a n s m i s s i o nh o u s i n g ,e x p a n dt h e s n a p r i n g w i t h s n a p r i n g p l i e r s ,t h e n p u s h t h e b e a r i n go u t u s i n g the specialtoolsand a pressas shown.

Expandthe snap ring with snap ring pliers,insert the new bearing part-way into the housing using the specialtools and a press as shown. Installthe bearingwith the groovefacingoutsidethe housing.

NOTE: Do not removethe snap ring unlessit's necessaryto cleanthe groovein the housing.

N O T E :C o a ta l l p a n sw i t h C W F l u i d . R e l e a s et h e p l i e r s ,t h e n u s i n g t h e s p e c i a lt o o l s , push the bearingdown into the housing until the snap ring snapsin place.

07749- 001(xDo

BEARING

ATTACHMENT, 72x75mm 07746 - OO1 0600

GROOVE

SNAP RING

ATTACHMENT, 72x75mm 07746 - (x'l05U)

After installingthe bearingverifythe following: o The snap ring is seatedin the bearingand housing grooves. . The ring end gap is correct.

ENDGAP|0 -9 mm l0 - 0.35 inl

077i()- 001(xrco

SNAPRING

14-334

FlywheelHousing Bearing SecondaryGearShaft Bearing Replacement 1.

Removethe secondarygear shaft bearingusingthe specialtools as shown.

Replacement 1.

Removethe secondarygear shaft bearingusingthe soecialtool as shown.

3/8" - 16 SLIDEHAMMER lCommorciallyaY.ilabl6l

3/8" - 16 SLIDEHAMMER {Comm6rciallYavailablel

BEARING ADJUSTABI.T - 40mm PULLER.25 07736- A01000A

SecondaryGear Shaft Bearing

GEAR SECONDARY SHAFTBEARING

Installthe new secondarygear shaft bearinguntil it bottomsin the transmissionhousing.usingthe specialtools as shown.

2.

lnstallthe new secondarygear shaft bearinguntil it bottoms in the flywheel housing,using the special tools as shown. DRIVER 07749- (x)10000

ATTACHMENT. 62xGgmm 07745- 0010500

14-335

RingGearBearing

ControlShaft Assembly RemovaUlnstallation

Replacement 1.

Remove the ring gear bearing.

1.

Removethe bolt and lockwasher.

CONTROLSHAFT ASSEMBLY

TRANSMISSION

RING

RINGGEAR

Installthe new ring gear bearinguntil it bottoms in the ring gear.usingthe specialtoolsas shown, 6r1.0mm 14 N.ft 11.4kg{.m, 10 rbf.ftl

CONTROL LEVER LOCKWASHER Replace.

DRIVER 07?{9 - 001(xxxt

2.

Removethe control lever from the control shaft.

3.

Removethe control shaft assembly.

4.

Installthe controlshaftassemblyin the transmission housing. Installthe controlleverto the controlshaft. Installand tightenthe bolt with a new lockwasher.

1 4- 3 3 6

Transmission Reassembly CAUTION:While reassembling.be sure not to sllow dust and othor foreign particlesto enter into the transmission. NOTE: . Coatall partswith CVTFluid. . Replacethe followingparts: - O-rings - S e a l i n gr i n g s - Sealingwashers - Gaskets - Startclutchassemblyand secondarydrivegear assembly 8 x 1.25mm 37 N.m {3.8kgf.m,27 lbtftl SNAPRING

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

MANUAL VALVE LINES

REVERSE BRAKE END PLATE

ENDCOVEB DOWEL PIN

Dtsc PLATE

ENDCOVERGASKET

DISCSPRING

6x1.0mm 12 N.m 11.2kgtm,8.7 lbtft)

THRUSTSHIM,25x 31 mm Selectivepart

SNAP RING

RINGGEAR THRUSTWASHER

MANUAL VALVE BOOY

THRUST BEARING

eB

8 x 1.25mm 29 N.m 13.0kgl m, 22 lbtftl

H^c

INTERMEDIATE HOUSINGASSEMBLY

THRUSTWASHER CARRIERASSEMBLY THRUSTWASHER

ROLI.IR

THRUSTNEEDLE BEARING SUN GEAR

ATF FEEDPIPE

INPUTSHAFT

O-RINGS

TRANSMISSION HOUSINGGASKET

SNAPRING FORWARDCLUTCH

SHAFT ASSEMALY

(RUBEERI SNAPRING SPRINGRETAINER/ RETURNSPRING ASSEMBLY

DOWELPtN

REVERSE BRAKEPISTON O.RINGS

TRANSMISSION HOUSING

SNAPRINGRETAINER ATF FEEDPIPES

14-338

lnstallthe ATF feed pipe in the transmissionhousing, and installthe three ATF feed pipeswith new O - r i n g si n t h e t r a n s m i s s i ohno u s i n g , Installthe two dowel pins and new transmissionhousing gasketon the transmissionhousing. Pushthe controlshaft assemblytoward the outside of the transmissionhousing,then installthe intermediatehousingassembly(four bolts). lnstall the manual valve body separatorplate and housing, the two dowelpins on the intermediate the detent with body then installthe rnanualvalve (five bolts). spring Put the controlshaft assemblyback,then installthe rollerin the intermediatehousing. 6 . lnstallthe reversebrakepiston in the intermediate housing. springassemblyon 7 . Installthe spring retainer/return brake the reverse Piston.

1.

NOTE:Installthereturnspringson the springguides of the reversebrake piston securely L

1

tnstallthe specialtool to compressthe returnspring as shown. REVERSE BRAKE COMPRESSOR SPRING

07TAE- P4V0110

9 . Compressthe return springs,then installthe snap ring in the intermediatehousing above the spring retainer. 1 0 . Verifythat the snap ring end gap is correct' M i n i m u m 1 5m m 1 0 . 5 i9n ) '-t,,,,.

///,,-

\\',r

i/ '/.

.r'

'1

,

.-J?

//

SNAPR I N G

1 1 . S o a k t h e r e v e r s eb r a k ed i s c s t h o r o u g h l yi n C V T F l u i df o r m i n i m u m3 0 m i n u t e s .

12. Installthedisc springon the reversebrakepiston' 1 3 . S t a r t i n gw i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y installthe reversebrakeplatesand discs lnstallthe reversebrakeend plate,and the snap ring' 1 4 . Measurethe clearancebetweenthe reversebrake end plateand the top discwith a dial indicator'Zero plate the dial indicator with a reversebrake end distance The ring snap the to it up lift and lowered, that the reversebrakeand platemoves is the clearance between the reverseend plate, and the top disc. in at leastthree places' NOTE:Take measurements and usethe averageas the actualclearance' STANDARD:0.45- 0.75 mm (0.018 0'030 in)

CAUTION:lf the spring retainertab is on the reverse brakc piston, the spring rstainer may be damaged' Be sure the spring retainertab is not on the piston' SPECIALTOOL REVERSEBRAKE

rp

{cont'd)

14-339 -^

Transmission (cont'dl Reassembly lf the clearanceis not within the standard,removethe reversebrakeend plateand measureits thickness. 1 6 . Select and install a new reversebrake end Dlate. then recheck.

22. Veritythat the outsidediameterol the snap ring is correct. Msximum41.4mm11.63 in)

N O T E : l f t h e t h i c k e s tr e v e r s eb r a k ee n d o l a t e i s installed,but the clearanceis still over the standard, replacethe reversebrakediscsand plates. REVERSEBRAKEEND PLATE SI{APRIiIG Plat6 No. 1

Part Number

Thickness

22551 - P4V- 003 3 . 6m m ( 0 . 1 4 2i n ) 22552-P4V-003 3 . 8m m ( 0 . 1 5 0 in) 2 2 5 5 3 - P 4 V - 0 0 3 4 . 0m m ( 0 . 1 5 7i n )

4

2 2 5 5 4 - P 4 V - 0 0 3 4 . 2m m ( 0 . 1 6 5i n )

5

2 2 5 5 5 - P 4 V - 0 0 3 4 . 4m m ( 0 . 1 7 3i n )

6 7

2 2 5 5 6 - P 4 V - 0 0 3 4 . 6m m ( 0 . 1 8 1 in) 22557-P4V -OO3 4 . 8m m ( 0 . 1 8 9i n )

8

2 2 5 5 8 - P 4 V - 0 0 3 5.0 mm (0.200in)

1 7 . After replacingthe reversebrake end plate, make surethat the clearanceis within the standard. 1 8 . R e m o v et h e s n a p r i n g , r e v e r s eb r a k ee n d p l a t e , discs,plates.and discspring. 1 9 . I n s t a l lt h e s n a p r i n g r e t a i n e ro n t h e d r i v e p u l l e y shaft. 20. Wrap the drive pulleyshaftsplineswith tapeto prev e n t d a m a g et o t h e O - r i n g s ,t h e n i n s t a l ln e w O nn g s . 2 1 . Installthe forwardclutchassemblyon the drive pulley shaft,then installthesnap ring.

Install the input shaft and the sun gear as a sub assemDry. I n s t a l lt h e t h . u s t n e e d l e b e a r i n ga n d t h e t h r u s t washeron the sun gear. CARRIER ASSEMBLY

IHruST

THFUST I'IEEDI! EEARIT{G

SITAP

O-RINGS SI{AP RIM; BETA EB

25. Installthecarrierassemblyon the forwardclutch.

DRIVEPUI.IEY SHAFT

14-340

26. Installthe thrust washer,the thrust needlebearing' and the thrustwasheron the carrierassembly' THRUSTSHIM, 2 5 x 3 1m m Selective Pan

SNAPRING

30. lf the clearanceis out of tolerance,removethe 25 x 31 mm thrust shim and measureits thickness'

3 1 . Selectand install a new 25 x 31 mm thrust shim. then recheck. THRUSTSHIM, 25 x 31 mm

RINGGEAR No.

Part Numb.l 90451- P4V- 000

THRUSTWASHERS

THRUSTNEEDLE EEARING

Thickne*3 1.05mm (0.041in)

B

9 0 4 5 2 - P 4 V - 0 0 0 1.12mm (0.044in)

c

90453-P4V-000

D

90454- P4V- 000

F

9 0 4 5 5 - P 4 V - 0 0 0 1.33mm (0.052in) 90456-P4V-000 1.40mm (0.055in)

'1.19mm (0.047in) 'l.26mm (0.050in)

904s7-P4V-000 1.47mm (0.058in) 90458-P4V-000

90459-P4V-000 CARRIER ASSEMBLY

21. lnstallthering gear and the 25 x 31 mm thrustshim, then installthesnaPrrng.

J

90460-P4V-000 1.68mm (0.066inl

K

9 0 4 6 1 - P 4 V - 0 0 0 1.75mm (0.069in) 90462-P4V-000 1.82mm (0.072in)

M

24. Verifythat the outsidediameterof the snap ring is correct,

1.54mm (0.06'lin) '1.61mm (0.063in)

N

o

904a0-P4V-000

in) 1.085mm (0.0427

9 0 4 8 1 - P 4 V - 0 0 0 1.155mm (0.0454in) 901a2-P4V-000 1.225mm (0.0482in) in) 90483-P4V-000 1.295mm (0.0510

Maximum30.7mm (1.21in)

o R

T

9 0 4 8 4 - P 4 V - 0 0 0 1.365mm (0.0537in) 904a5-P4V-000 1.435mm (0.0565in) 90486-P4V-000

1.5O5mm (0,0593in)

90487-P4V-000

1.575mm (0.0620in)

90488-P4V-00{) 1.645mm {0.0648in) in) 90489-P4V-000 1.715mm (0.0675

SNAPRING

29. Measure the clearancebetween the 25 x 31 mm thrustshim and the snaPrlng.

90490-P4V-000

1.785mm (0.0703in)

STANDARD:O.O5- 0.11 mm (0.0020 0.00'8 in)

32. After replacingthe 25 x 31 mm thrust shim, make sure that the clearanceis within toleranceand the snap ring outside diameter is correct'

NOTE:Takemeasurementsin at leastthree places' and usethe averageas the actualclearance

33. Installthe discspringin the directionshown' 34. S t a r t i n gw i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y install the reverse brake plates and discs lnstall selectedreversebrake end plate, then install the snap nng. RING

REVERSE END PLATE

BRAKE

Dtscs SPRING

,**r#*,".

REVERSE PI-ATES

'- t ) RINGGEAR

lnstall in this direction.

(cont'd)

14-341

Transmission (cont'd) Reassembly 35. Verifythat the snap ring end gap is correct. M i n i m u m1 8m m ( 0 . 7 1i n )

39. Installthe park pawl,spring,and shaft on the transmissionhousing,then move the controlleverto anv gear otherthan E position. SNAPRING THBUST SHIM, 25x35mm

,/\,

."or**ol!/'

SECONDARY GEARSHAFT

Install the manual valve body lines A and B wkh new O-ringson the manualvalvebody and the intermediatehousing. 8 x 1.25mm 37 N.m 13.8kgf.m,27 lbf.ftl

END COVER

COTTER RETAINER COTTERS, 25.5mm pan Selective

STARTCI.UTCH ASSEMBLY

6x1.0mm 12 N..n (1.2kgt m, 8.7 rbtft)

SECONDARY ORIVEGEAF ASSEMBLY

fl g

O.RINGS

PARK PAWL SPRING PARKPAWL

END COVERGASKET DOWELPINS O-RINGS

,10, Install the secondary gear shaft with setected25 x 35 mm thrust shim (seepage ,14-328). MANUAL VALVE BODYLINEA

uaNYuAL VALVE 37. Install the two dowel pins and new end cover gas_ ket on the intermediatehousing,then install new O_ rings on the ATF feed pipes. Installthe end cover (three 6 mm bolts, eleven g mm bolts). NOTE:Installthe nine 8 mm bolts in the end cover ( t w o 8 m m b o l t s r e m a i n i n t h e e n d c o v e r )t h e n tightenthe eleven8 mm bolts.

14-342

41. Wrap the driven pulley shaft splines with taDe to prevent damage to the O-rings, then install new O_ rings. 42, Assembleths secondarydrive goar assembly in the start clutch assembly,then installthem on the driven pulley shaft, 43. Pull the handle of the specialtool up, then install the tip of it into the driven pulley shaft hole, and set the specialtool on the stan clutch. CAUTION:Whib in3trling thc st rt ctutch and rh. 3ocondlry driye g.!r a3sombly using lh€ special tool, bo 3urc nol to sllow du3t or olher foraign par_ ticlos to ontq into tho iransmbsion. STARTCLUTCH INSTALLER 07TAE - P4V0r30

I c,rrr,unar".

44. Pushthe handleof the specialtool, then tightenthe nut to seal the secondarydrive gear assemblyon the drivenpulleYshaftsecurelY. STAAT CLUTCHIi'ISTALIIR 07TAE- PaV0130

47. lf the clearanceis not within the standard,remove the cottersand measuretheirthickness

48. Selectand installnew cotters,then recheck. COTTERS,25.5 mm Part Number

No.

Thickness

B

9 0 4 2 9 - P 4 V - 0 0 0 2.9m m ( 0 . 1 1 4i n ) 9 0 4 3 0 - P 4 V - 0 0 03.0m m ( 0 . 1 1i8n )

c

9 0 4 3 -1P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2l2n )

D

in) 9 0 4 3 2 - P 4 V - 0 0 0 3 . 2m m ( 0 . 1 2 6

49. After replacingthe 25.5mm cotters,make surethat the clearanceis the standard

50. lnstallthe cotterretainerand the snaprlng Verify that the outsidediameterof the snap ring is correct. Minimum33.9mm (1.33in)

OF HA'{DI,-E

SHAFT

Pull the handleof the specialtool up, and remove the specialtool. 46. lnstallthecotters,then measurethe clearanceDelween the cottersand the startclutchguide 0 - 0.13mm (0 - 0.005inl STANDARD:

SNAP RII{G

52. l n s t a l l t h e t h r u s t w a s h e r s .t h e A T F p u m p d r r v e sprockethub and the 22 x 28 mm thrustshim on the inDUtshaft,then installthe snap ring. SNAPRING\

in at leastthree places, NOTE:Take measurements and usethe averageas the actualclearance

THFUST SHIM, 22 x 2a mm Selectivepan ATF PUMP DRIVE SPROCKETHUB THRUSTWASXERS

25.5mm COTTERS,

GAUGE INPUTSHAFT

lil START 1 GAUGC

(il START CLUTCH

(cont'd)

14-343

Transmission (cont'd) Reassembly 53. Verifythat the outsidediameterof the snap ring is correct. M a x i m u m2 6 . 3m m ( 1 . 0 4i n )

After replacingthe 22 x 28 mm thrust shim. make sure that the clearanceis within toleranceand the snap ring outsidediameteris correcr. 58. Installthe pitot flange using its cutout as shown to clearthe pitot pipes.

SNAP RING

54. Measurethe clearancebetween the 22 x 28 mm thrustshim and the snap ring. STANDARD:0.37- 0.65 mm (0.015- 0.026inl NOTE:Takemeasurementsin at leastthree places, and usethe averageas the actualclearance.

59. Install the ATF pump drive sprocket.and put the ATF pump drive chain on the ATF pump drive and driven sprockets,then install8nd tighten the bolts (three bolts). TF PUMPDRIVECHAIN

55. lf the clearanceis out of tolerance,removethe 22 x 28 mm thrustshim and measureits thickness. co.

Selectand install a new 22 x 28 mm thrust shim, then recheck.

6x1.0mm 12 N.m 11.2kg{.m,8.7 lbf.ftl ATF PUMPORIVE SPROCKET PITOTFLANGE

THRUSTSHIM,22 x 28 mm No.

Part Numb€r

Thicknsss

c

9 0 5 7 3 - P 4 V - 0 0 01 . 1 5m m ( 0 . 0 , {i5n )

D

9 0 5 7 4 - P 4 V - 0 0 0 1.40mm {0.055in)

E

9 0 5 7 5 - P 4 V - 0 0 0 1.65mm (0.065in)

F

9 0 5 7 6 - P 4 V - 0 0 0 1.90mm (0.075in)

ATF PUMP

9 0 5 7 7 - P 4 V - 0 0 0 2 . 1 5m m ( 0 . 0 8 5i n ) 9 0 5 7 8 - P 4 V - 0 0 0 2.40mm (0.095in)

14-344

INPUTSXAFT

l . 60. Installthe ditferentialassembly (oneboltl' 61. InstalltheATF passageline assemblywith new O-rings housing' 62. Installthethreedowel pinsand new flywheelhousinggasketon the transmission (twentybolts)' 63. Installthe flywheelhousingand connectorbracket 64. InstalltheATF passageline holderassembly(two bolts)' 6x1.0mm 12 N.m {1.2 ksf'm, 8.7 tbf.ftl

L|NE ATFPASSAGE

"o.o.'o{

I

I

8 x 1.25mm 29 N.m t3.o kg['m, 22 lbf'ttl

/ g u s

g l l

FLYWHEELHOUSING

d \n rm \A

o-nrnc--.-..ff ATF PASSAGELINE ASSEMALY

BRACKET CONNECTOR

DOWELPIN

6x1.0mm 12 N.m 11.2kgd'm,

8.7tbr.tr) ASSEMBLY DIFFERENNAL O.RING DOWELPIN

DOWELPIN FLYWHEELHOUSING GASKET

TRANSMISSION

ItousrNG ATF PASSAGE LINEASSEMBLY

PASSAGELINE GUIOE

TRANSMISSIONHOUSING (cont'd)

14-345

Transmission (cont'dl Reassembly 65 lnstallthe solenoidharnessconnectorwith a new O-ring(one bolt),then installthe lower valve body assemblywith threedowel pins (eightbolts). 66. Installthe ATFstrainerwith a new O-ring(two bolts). 67. lf necessary, assemblethe ATF pan,ATFfilter,and the ATFcoolerinlet line (seepage14_303). 68. Installthe ATF pan with the two dowel pinsand a new ATF pan gasket(fourteenbolts). 69. Installthe ATF coolerinlet line bracketbolt. 70. InstalltheATFcooleroutletlinewith the line bolt and new sealingwashers.

6x1.0mm 12 N.m 11.2kgf.m, 8.7 rbtft) DOWELPINS ATF STRAINER

ATF COOLEROUTI.IT LINE DOWELPINS ATF PAN,/ATFFILTER/ ATF COOLERINLET LINEASSEMELY

@ @ C4

6x1.0mm 12Nm11.2kgl.m, 8.? tbf.ft)

CONNECTOE 6x1.0mm 12 N.m {1.2kgf.m, 8.7 tbtftl

LOWERVALVEBODY ASSEMBLY 6x1.0mm 12 N.m 11.2kgf.m, 8.7 tbt.ft) ATF COOI.ERINI.IT LINEBRACKETBOLT I x 1.25mm 26 N.m (2.7kgt.m,20 lbf.ft)

14-346

Flywheel/DrivePlate

WASHER Installin this direction.

DRIVEPLATE

o0

/,1 vl

. . /

a9a

.t FLYWHEEL wear' lnspectthe teethof the ring gearfor excessive

1 2x 1 . 0m m 74 N.m (7.5kgf.m, 54lbfft) Torque in a crisscrossPattern

Transmission Installation L

Flushthe ATF cooleras describedon pages14-352 and 14-353.

6.

Placethe transmissionon s jack,and raiseit to the engineassemblylevel.

Removethe used greasein the flywheel hub caD and flywheelsplines.

7.

Anach the transmissionon the engine,then install the transmissionhousing mounting bolt and rear enginemountingbolts.

Fill the insideof the flywheelhub cap,and coatthe flywheel hub splineswith SuperHighTemp Urea Grease (P/N08798- 9002)as shown.

TRANSMISSION HOUSING MOUNTING BOIT 6,1N.m 16.5kgl.m,

47 tbtttl

REARENGINEMOUNTING BOLT Replace. 12 x 1.25mm 59 Nrn {6.0 kgl.m. ,€ lbt ftl

SPLINES Apply SUPEBHlcH TEMP UREAGREASE lPlN 08798- 90O2t

WASHER

SUPERHIGHTEMP UREAGREASE (P/N 08798 - !)0021 1.5-2.5 g 10.05-0.t9oz)

I n s t a l la n e w s e a l i n g r i n g ( r u b b e r )o n t h e i n o u t shaft,and installtwo '14x 20 mm dowel Dinsin the flywheelhousing. Installthe flywheelsecurelyon the input shaft,then installthestartermotor on the flywheelhousing.

lnstallthe transmissionmount bracket.Tightenthe long bolt loosely,and tighten the nuts and bott on the mount bracket to the specified torque. Then tighten the long bolt to the specifiedtorque. 12x 1.25mn 6,r N'm 16.5kgtm,47 tbtftl

l-".--..-,^

4,1Nm la.5 kgt.m,33 tbt.ft)

G

\

V

TRANSMISSON MOUNT BRACKET

INPUTSHAFT STARTER

.4;i "lrj ,i rr,"r.,., a

SEALINGRING {RUEBER)

MOUI{T

l4 x 20 mm DOWELptN FLYWHEEL

14-348

12 x 1.25mn

74N.m(7.5tstm,5a tbtftt

l . 9. Installthe remainingtransmissionhousing mounting bolts. PRIMARYOXYGENSENSOR

(see 1 3 . Tighten the crankshaftpulley bolt, if necessary section6). 1 4 . Connectthe ATF cooler hosesto the ATF cooler lines (seepage 14-357). CAUTION: Whilo connecting the ATF cooltr hGes, b€ sure not lo allow dust and other loreign particles to entg. into the transmission. 15. Installtherightfront mounvbracket' 10 x 1.25mm a,r N.m {4.5 kgf'm,33 lbt ftl RIGHTFRONT MOUNT/BRACKET

ATF COOLERLINE HOUSING TRANSMISSION MOUNNNG BOLT 6il N.m {6.5 kgf.m,47 lbf'ftl

1 0 . Removethe transmissionjack and the hoist. then remove the hoist bracketfrom the engine' 1 1 . Attach the flvwheel to the drive plate with eight boltsand torqueas follows: Rotatethe crankshaftpulley as necessaryto tighten rhe bolts to half of the specifiedtorque,then to the final torque,in a crisscrosspattern. After tightening the last bolt. check that the crankshaftrotatesfreelY.

10 x 1.25 mm 54 N.m {5.5 kgt'm, 4{) tbl.ftt

ATF COOI,TRHOSE 16. Installthe exhaust PiPeA. EXHAUSTPIPEA

12. Installthe flywheelcoverand the enginestiffeners

DRIVE

6xl.0mm 12 N.m ENGINE 10x 1.25mm -rE l12 kgf'm' STIFfENEB artN.mla.skgt.m, 8.7 tbf.ftl

33tbtftt

*s$o

8 x 1.25mm 24 N.m (2.1kgf'm, 17 tbt.ftt

oor*rr-@ DRIVEPI.ATEBOLT 6x1.0x14mm 12 N.m {1.2kgt m. 8.7 lbf,ftl

FLYUTHEEL ENGINESTIFFENER 8 x 1.25mm '17 24 N.m (2.4 kgt'm, lbf'ftl

Replace. 8 x 1.25mm 26 N.m 12.7kqfin, 20 rbt'ftl 10 x 1.25mm r,a N.m {4,5kgf m, 33 tbf.ftl

SELF.LOCKING Replace. 8 x 1.25mm 22 N.m t2.2 kgl m, 16lbf'ftl

GASKET Replace.

@ \

NUT SELF.LOCKING Replace. 10 x 1.25mm 5/aN.m {5.5kgt m, irc lbf.ft) NUT SELF.LOCKING Replace. 8 x 1.25mm 16 N.m {1.6kgl'm, 12 tbl.ftt (cont'dl

14-349

Transmission Installation(cont'd) 1 7 . InstallI new set ring on the end of eachdriveshaft.

20. Installthe splashshietd.

Installthe right and left driveshafts(seesection16). CAUTION:While instatlingthe drive3haftsin the differential,be sure not to allow dust and olher foraign particles to enter into tho transmission. NOTE: . Cleanthe areaswherethe driveshaftscontactthe transmission{differential}thoroughly with solvent or carburetorcleaner,and drv with comDressedair. . Turn the right and left steeringknucklefully outwa.d, and slide each driveshaftinto the differential until you feel its set ring clip engagethe side gear. 1 9 . Installthe damperfork,then installthe right and left ball joints to each lower arm with the castleouts and new cotter pins.

I

6

I

"a,a

6* s

a

a

6 x 1 . 0m m 9.8 t{.m 11.0kgt.m, 7.2 tbf.trl

2 1 . Connectthe vehicle speed senso. connector.the driven pulley speedsensorconnectorand the secondary gear shaft speed sensor connector,

10 x 1.25mm 43 N.m {4.4 kgf.m,32 lbf.ftl

6x1,0mm 12 N.m {1.2kg{.m,8.7 tbf,ft) DRIVENPULLEY SPEEDSENSOR CONNECTOR

SELF-LOCKING NUT Replace. CASTI.I 12x 1.25mm '12x 1.25 mm 6l N.m

ksr.m. {6.s 47tbr.ftrl! _ll

ffiteo

- s.otet'.,

E. SECONOARY GEAR SHAFTSPEED SENSOBCONNECTOR

1 4- 350

6 x 1.0 m.rl '12N.m {1.2 kg{.m,8.7tbf.fo

22. Installthe shift cable end on the control lever,and installthe shiftcableon the shift cablebracket' CAUTION: Take care not to bend the shift cable' 23. lnstallthe clip in the directionshown.

SHIFI CABLE

25. Connectthe startermotorcableon the startermotor. and installthe cableholder. NOTE:When installingthe stanermotor cable.make s u r e t h a t t h e c r i m p e ds i d e o f t h e r i n g t e r m i n a li s facingout (seesection23).

LOCKNUT 29 N m {3.0kg{ m, 22lblftl

STARTERMOTOR

SHIFTCABLE ERACKET

WASHER IPLASTIC)

STARTEB

MOUNTINGNUT B 9 N.m (0.9 kgf m,7 lbf ft)

LEVER CONTROL 24, Connectthe solenoidharnessconnector.the drive p u l l e y s p e e d s e n s o rc o n n e c t o r .a n d t h e g r o u n d cableterminals. 6x1.0mm 12 N.m {1.2kgf.m. 8,7 rbtft)

GROUNDCABLE 6x1.0mm TERMINAL 12 N.m {1.2kgf'm, 8.7lbtfrl

26. Installall removedconnectorsand clamps' 27. Installthe distributor. 28. Installthe intake air duct and air cleaner housing assemDly. 29. R e f i l l t h e t r a n s m i s s i o nw i t h t h e r e c o m m e n d e d GenuineHondaCVTFluid(seepage14-2991 CAUTION:While filling the CvT Fluid,bs surs not io allow dust and other fotoign particles to entor into the transmission.

30. Connect the battery positive (+) terminal first, then

GROUND TERMINAL DRIVEPULLEY SPEEDSENSOR CONNECTOR

SOLENOIDHARNESS CONNECTOR

the negative(-l terminal to the battery' 3 1 . Checkthe ignitiontiming (seesection23). Startthe engine.Setthe parkingbrake,and shift the transmissionthrough all gears three times Check shiftcableadjustment(seepage 14-355). Checkthe front wheelalignment(seesection18) 34. L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e radiatorfan comes on) with the transmissionin lXl or E position,then turn it off and checkfluid level' Perform the start clutch calibration procedureon page14-293. 36. Roadtest as describedon pages14-296and 14-297

14-351

Transmission GoolerFlushing To prevent iniury to face and eyes,always @ wear safety glassesor a tace shield when using the transmissionflusher.

7. With the water and air valvesoff, attachthe water and air suppliesto the flusher.(Hotwaterif available.)

NOTE:This procedureshouldbe performedbeforereinstallingthe transmission. '1.

Checkthe tools and hosesfor wear and cracksbefore using.lf wear or cracksare found, reDlacethe hoses beforeusing. Usingthe measuringcup.fill the tankwith 2,1ounces (approximately2/3 full) of biodegradableflushing fluid (J35944- 20).Do not substitutewith any other f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d contatner.

4.

Securethe flusherfiller cap,and pressurize the tank with compressedair to between5S0- 829 kpa (5.68.45kgf/cm' ,80 - 120psi).

8. Turn on the flusherwater valve so water will flow throughthe coolerfor 10 seconds.

NOTE:The air line shouldbe equippedwith a water trap to ensurea dry air system,

NOTE:lf water does not flow throughthe cooler,it is completelyplugged,cannotbe flushed,and must be replsced.

Hangthe tool underthe vehicle. Attach the tank's dischargehose to the return line oi the transmissioncoolerusinga clamp. Connectthe drain hoseto the inlet line on the transmissioncoolerusinga clamp. IMPORTANT: Securelyclampthe oppositeend ofthe drain hoseto a bucketor floor drain,

9. Depressthe trigger to mix the flushing fluid into the water flow. Usethe wire clip to hold the trigger down. '10.

While flushingwith the water and flushingfluid for two minutes.turn the air valve on for five seconds every 15- 20 secondsto createa surgingaction. AIR PRESSURE: MAX 845 kpa (8.45kgflcmr, 120 psi)

11. Turn the water valve off. Releasethe trigger,then reversethe hosesto the coolerso you can flush in the oppositedirection.Repeatsteps8 through 10.

TRANSMISSION

12. Releasethe trigger.and rinsethe coolerwith water only for one minute. 13, Turn the water valveoff, 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: Rosidual mobturo in the qooler or lines cln damagethe transmission,

t TRANSMISSION COOLER FLUSHER {Commerciallyavailable) Kent-MooreJ384O5-A or oouivalent

14-352

15. Removethe flusherfrom the cooler line.Attachthe drain hoseto a container. 16. Installthe transmission.and leave the drain hose attachedto the coolerline.

l . 1 7 . Makesurethe transmissionis in the E] position. w i t h c v T F l u i d ,a n d r u n t h e F i l lt h e t r a n s m i s s i o n enginefor 30 secondsor until approximately0 95 { ( 1 . 0U S q t . , 0 . 8l m p q t . )i s d i s c h a r g e d .

TOOL MAINTENANCE 1.

Emptyand rinseaftereachuse.Fillthe canwith water and pressurizethe can. Flushthe dischargeline to ensurethat the unit is clean.

1 8 . Removethe drain hose, and reconnectthe cooler returnhoseto the transmission(seepage14-355)

2,

lf dischargeliquiddoes not foam,the orificemay be blocked.

'19. Refillthe transmissionwith CVTFluidto the proper level(seepage 14-299).

3.

To clean,disconnectthe plumbingfrom the tank at the largecouPlingnut.

FILLERCAP

FILTER

COUPLING NUT

I - 0--D -@q \

\

i

I

I

\ ORIFICE

O.RING

.l,

Removethe in-linetilterfrom the dischargesideand cleanif necessary' The fluid orificeis locatedbehindthe filter. Cleanit with the pick storedin the bottom of the tank handle. or blow it cleanwith air. Securelyreassemble all parts.

14-353

Shift Cable RemovaUlnstallation Make sure lifts, iacks and safety stands are @ placedproperly(seeseqtion11, 1.

Removethe front console(seesection20).

2.

Shift to E position,then removethe lock pin from the adiuster.

Removethe air cleanerhousingassembly. Removethe clip from the control lever,and loosen the locknut. CLIP

SHTFT CABLE LOCKNUT 29 N.m 13.0kgf m,22 lbf.ft)

\. *o"ra"

\

SHIFTCABI-E BRACKET

CONTROLLEVER

Removethe shift cablefrom the control lever,the shiftcablebracket,and the clamp. Removethe shift cablebracketbolts and nuts,then remove the shift cable.Take care not to bend the shift cablewhen removing/installing it. SHIFTCABLEBRACKET

ADJUSTER

{1.2kgI m, 8.7lblft)

14-354

7.

lnstallthe shift cable in the reverseorder of removal.

8.

Checkthe cableadjustment(seepage14-355).

t

Adjustment Make sure lifts, jacks and safety stands are !@ placed properly (seesection 1). l.

Removethe front console(seesection20).

2.

Shift to I posirion,then removethe lock pin from the adjuster.

3. Checkthat the holein the adiusteris perfectlyaligned with the holein the shiftcable.Therearetwo holesin the adjuster.They are positioned90" apartto allow cableadjustmentin 1/4turn increments.

lf the hole is not perfectlyaligned,loosenthe locknut on the adjusterand adjustas required. Tightenrhe locknutto 7 N.m (0.7kgim,5 lbf'ft). Installthe lock pin on the adjuster'lf you feel the lock pin binding as you reinstallit. the cable is still out of adjustmentand must be readjusted SHIFTCAELE

7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d i u s t e r { 0 . 7 k g f . m ,5 l b f ' l t l

securery. lMovethe shift leverto eachposition,and verifythat t h e s h i f t p o s i t i o ni n d i c a t o rf o l l o w st h e a u t o m a t l c transaxlegear positionswitch. S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l positions.lf any gear does not work properly,refer (seepage 14-294and 14-295). to troubleshooting 1 0 . Insertthe ignition key into the key cylinderon the Aff gear positionindicatorpanel,and verifythat the shift lockleveris released.

l, 14-355 ,l

Shift Lever

PUSHKNOB

\

PUSHKNOESPRING

X ,l \2

\re ./ ,/

-6r

SILICONEGREASE SHIFTINDICATORLAMP.

a,-,/

SHIFTLEVER KNOB

/

Jl

/

SCREW tn rn I 3 N.n l0.3xgtm, 2 lbf ftl Applynon-hardening non-hardening th' thread locksealant. / Apply

I

SCREW 3 N.m{0.3kgf'm,2 lbl.ft) A/T GEARPOSTTONINDICATORPANEL

LEVERCOVER SHIFTLOCK

sotENolD

BUSHING

-611 SII.'|CONEGREASE

SCREW 3 N.m10.3kgl.m.2lbf.ttl

SHIFTI.TVEBASSEMBLY

L@KP'N dE("""--

n2

6x1.0mm 9,8 N.m 11.0kgf.m, 7.2 tbtft)

-
A/T GEARPOSITION PLAYE

A/T GEARPOSMON SWNCH

3 N.m 10,3kqf.m, 2tbfitl

SHIFTLEVENBRACKETBASE SHIFTLEVER BASE COLLAR

6x1.0mm 9.8 N.m {1.0 kgf.m,7.2 lbf ftl

14- 3 5 6

Shift Indicator Panel

ATF Gooler/Hoses

Adjustment

lnstallation

r ligns 1 . C h e c kt h a t t h e i n d e x m a r k o n t h e i n d i c a t o a with the E mark on the shift indicatorpanelwhen the transmissionis in NEUTRAL.

1.

InstalltheATF cooler,ATF coolerline assemblyand the ATFcoolerhoses.

6x1.0mm 11 N.m ('l 1 kgf.m,8.0lbl'ftl

ATF COOLERLINEASSEMBLY ATF COOLERHOSE RADIATOR 6x1.0mm 9.8 N.m 11.0kgf'm, 7 8 lbf'ft)

ATF COOLER

HOSES ATF COOI..ER

lf not aligned,removethe front console{seesection 20).

Connectthe ATF cooler hoses to the ATF cooler linesand ATF cooler.and securethem with the clips as shown.

Removethe shift indicatorpanel mounting and adjustby movingthe panel. NOTE: Wheneverthe shift indicatorpanel is removed, reinstalltheDanelas describedabove.

1 l l

Tf

{ i

l.T

6-8mm 10.2- 0.3 in) 33-35mm 11.3- 1.4inl

2-1mm 10.1- 0.2 in)

2-ilmm { 0 . 1- 0 . 2 i n )

It, 14-357

There is no chapter 15 in the printed version of this manual. I actually went to a Honda dealership and asked if I could look at the manual. The mechanic told me Honda probably used chapter 15 for something in another market with a different transmission option.

I

SpecialTools

Ref. No.

o @ ,a \9'

o

@ @

I

Tool Number

07JAF- SH20400 07LAD- PW50601 07MAC- S100200 - 0010300 07746 - 0010400 07746 07746- 0030400 - 0010000 07749 - SD90100 07965 07xAc- 0010100

SupportBaseAttachment InnerRaceDriver BallJoint Remover,28 mm Driver Attachment,42 x 47 mm Driver Attachment,52 x 55 mm DriverAttachment,35 mm l.D. HandleDriver SupportBase ThreadedAdapter,22 x 1.5mm

Oty

I

1 1 1 1 I I 1 I 1

@

e

&

@

c

@ \r'

g

e

@

c[G) 8-)

16-2

Description

@

6

w lo,

l..---,l G)

Remark

Driveshafts Inspection

Removal

DriveshaftBoot Checkthe boots on the driveshaftfor cracks,damage, leakinggreaseand loose boot bands.lf any damageis found,replacethe boot and boot bands,

1.

Loosenthe wheel nuts slightly. Raisethe front of the vehicle,and support it with 'l). safetystandsin the properlocations(seesection Removethe wheel nuts and front wheels.

LooseSplines Turn the driveshaftby hand and make sure the splines a n d j o i n t a r e n o t e x c e s s i v e llyo o s e .l f a n y d a m a g ei s found,replacethe inboardjoint. Twisied or Cracked Makesurethe driveshaftis not twistedor cracked. Reolaceit if necessarv.

DRIVESHAFT

Drainthe transmissionfluid (seesection13 or 14). 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. nut and flangebolts. Removethe selJ-locking FLANGEBOLT 10 x 1.25mm BOOTBANDS

1.

(cont'd)

16-3

Driveshafts Removal(cont'd) 8. Remove the cotter pin from the lawer arm ball joint castle nut. and remove the nut.

1 2 . P u l l t h e i n b o a r dj o i n t , a n d r e m o v et h e d r i v e s h a f t from the differentialcase as an assembly.Do not pull on the driveshaft;the inboardjoint may come apart.Use carewhen prying out the assembly,and pull it straightto avoid damagingthe differentialoil seat.

07MAC- SL00200

I n s t a l la 1 2 m m h e x n u t o n t h e b a l l j o i n t . B e s u r e that the hex nut is flush with the ball joint pin end, or the threadedsectionof the ball joint pin might be damagedby the specialtool. 1 0 . Usethe specialtool as shown in section18,to separate the ball joint and lower arm. Be carefulnot to damagethe balljoint boot.

SCREWDRIVER

13. Pullthe knuckleoutward,and removethe driveshaft o u t b o a r dj o i n t f r o m t h e f r o n t w h e e l h u b u s i n g a plastichammer.

NOTE: lf necessary,apply penetratingtype lubri, cantto loosenthe balljoint. 1 1 . Pry the driveshaftassemblywith a screwdriver,as shown, to force the set ring at the driveshaftend pastthe groove.

SCREWDRIVER 3.5mm

DRIVESHAFT

16-4

t

Disassembly lnboard Joint Side:

Crimping Type

1 . C a r e f u l l yc l a m p t h e d r i v e s h a f itn a v i s e w i t h s o f t j a w s , t h e n r e m o v et h e s e t r i n g f r o m t h e i n b o a r d joint. 2.

Removethe boot bands.Take care not to damage the boot. . lf the boot band is a lockingtab type, pry up the l o c k i n gt a b s w i t h a s c r e w d r i v e ra, n d r a i s et h e end of the band. . It the boot band is a welded type, cut the boot band. . lf the boot band is a crimping type, pry up the end of the bandwith a screwdraver. . lf the boot band is a double loop type, lift up the band bend.

DoubleLoopType

Locking Tab Typs

J M a r k e a c h r o l l e ra n d i n b o a r dj o i n t t o i d e n t i f yt h e locationsof rollersand groovesin the inboardjoint. Then removethe inboardjoint on the shop towel. Be carefulnot to drop the rollerswhen separating them from the inboardioint. JOINT INBOARD forwearor damage, Check splines Check insideboreforwear. Inspectfor cracks. Replace.

Welded Type

l ,

(cont'd)

16-5

Driveshafts (cont'dl Disassembly 4. Mark the rollersand spiderto identifythe locations of the rollerson the sDider,then removethe rollers.

Outboard Joint Side: 1.

B€ARING REMOVER available} {Commerciallv

L i f t u p t h c t h r e e t a b s w i t h a s c r e w d r i v e r ,t h e n remove the boot bands,Take care not to damage the boot. NOTE: . lf the boot band is a double loop type, lift up the band bend. . lf the boot band is a welded type, cut the boot band. . lfthe boot band is a locking tabs type, pry up the tabs with a scr€wdriv€rand lift uo the snd of the band.

TAB

STOPRING (Applicable to '96- 98modols and Erazil-produced driveshafts) Removethe circlip. Mark the spiderand driveshaftto identifythe position ot the spideron the shaft. 1 . Removethe spiderusinga bearingremover. Removethe stop ring (Applicableto '96 - 98 models and Brazil-produceddriveshafts). Wrap the splineson the drivsshaftwith vinyl tapeto preventdamageto the boot and dynamicdamper.

2.

Slide the outboard boot to the inboardioint side.

DRIVESHAFT VINYL TAPE

INBOAROAOOT Inspectfor cracking, splitting and wear.

DYNAMIC DAMPER Check for damage. R e m o v et h e i n b o a r d boot, and if necessary,the dynamicdamper.

16-6

OUTBOABD BOOT

1

Wipe off the greaseto exposethe driveshaftand the outboardioint inner race.

4.

Markthe driveshaftat the same positionof the outboardjoint end with paint.

7.

Removethe driveshaftfrom the vise

8.

Removethe stop ring from the driveshaft.

DRIVESHAFT

Feplace.

5.

Carefullvclampthe driveshaftin a vise.

ADAPTER,24 x 1.5 mm THREADED

07xac- (x)102(x)

Removethe outboardjoint using a specialtool as snown.

16-7

Driveshafts Reassembly U.S. and Canada-ProducadDriv€shafts Notetheseitemsduring reassembly' . Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair, Do not wash the rubber pans with solvent. o ;..jl@l

: Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft ser,

Greasequantity: lnboardJoint OutboardJoint

1 1 5- 1 3 5g ( 4 . 0- 4 . 8o z ) 1 1 5- 1 3 5g ( 4 . 0- 4 . 8o z )

. The'98 Canadamodel and all '99 - 00 modelsusesa TPE(Thermoplastic PolyesterElastomerloutboardjoint boot. Use the ear clamptype boot band in the outboardjoint boot set. CIRCLIP STOPRING ('96- 98 models)

INBOARDBOOT

-6l Packcavitywith grease.

-6r

EABCLAMPBAND Replace.

Packcavitywith grease. DYNAMICDAMPER OOUBI.SLOOPBAND Replace. EARCLAMPBAND Replace. DRIVESHAFT

STOPRING Replace. OUTBOARDBOOTITPE)

-6ll ,

Pack cavity with grease.

EARCLAMPBAND Replace.

-G.1 OUTBOARDJOINT

16-8

l / Brazil-ProducedDriveshafts Notetheseitemsduring reassembly . clean the disassembledparts with solvent,and dry them thoroughlywith compressedajr. Do not wash the rubber partswith solvent. .

.fut

:Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft ser.

Greas€quantity: lnboardJoint OutboardJoint

1 1 5- 1 3 5g ( 4 . 0- 4 . 8o z l 1 1 5- 1 3 5g { 4 . 0- 4 . 8o z ) INSOARDJOINT

t t

DRIVESHAFT

BOOTBANDS Replace.

l,z

(cont'd)

-6.l

Pack cavity w r t h g r e a s e ,

16-9

Driveshafts (cont'dl Reassembly Japan-ProducedDriveshafts Notetheseitemsduring reassembly. . Cleanthe disassembledpans with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber parts with solvent. o r@l

: Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft set.

Greasequantity: 1600DOHCWEC engine InboardJoint

Except1600DOHCVTECengine

OutboardJoint

Splines(Al '1600DOHCWEC

engine

Except1600DOHCVTECengine

130- 1409 (4.6- 4.9oz) 1 1 0- 1 2 0g ( 3 . 9- 4 . 2o z ) 0.5- 1.0g (0.018- 0.035oz) Rubberboot 90- 'l00g (3.2- 3.5oz) TPEboot;105- 1159 (3.7- 4.1oz) Rubberboot 70- 80 g |'2.5- 2.8 ozl TPEboot 95 - 105g (3.4- 3.7 oz) {1600DOHCVTECangine)

],*"u, ,"^S '/ t'.t$-'-,' ,/s

SETRING Replace.

-6{@

Packcavity with grease.

INBOARD BOOT

-6;

Packcavity with grease.

DYNAMICDAMPER DYNAMIC Replace. DOUA|.I Lq)P BAND Replace.

LOOPBAND Replace.

(Rubbertypc)

tttt t*'

OUTBOARD BOOT IRUEBER)

-----_.r...._

Packcavity with greaseCLAMPBAND Replace.

16-10

6.

lnboard Joint Side: 1,

Wrap the splineswith vinyl tapeto preventdamage to the bootsand dynamicdamPer.

Fit the rollersonto the spiderwith their high shouldersfacingoutward,and notetheseitems: . Reinstallthe rollersin their originalpositionson the spiderby aligningthe marks . Hold the driveshaft pointed up to prevent the rollersfrom fallingoff.

VINYLTAPE INBOARDBOOT

-\r/

-

-<@

Highshoulderfaces

DAMPER DYNAMIC Installthe dynamicdamperand inboardboot to the driveshaft,then remove the vinyl tape. Take care not to damagethe boots. I n s t a l lt h e s t o p r i n g i n t o t h e d r i v e s h a f tg r o o v e (Applicsbleto '96 - 98 modelsand Brazil- Produced driveshafts)A . lways rotatethe stop ring in its grooveto be sureit is fully seated.

@--c't"t't

STOPRING (ApplicablGto'96- 98 modob and Brrzil-Producrddrivoshaftrl

7.

Packthe inboardjoint with the joint greaseincluded in the new driveshaftset. Greasequantity: Japan-Produced: 1600DOHCVTECongine: 130- 1/t0g 14.6- '[.9 oz) Except 1600DOHCVTECangine: 110- 120I {3'9 - il'2 oz} splines O: Left inboard ioint 0'5 - 1.0s (0.018- 0'035oz) U.S,,Canada,and Brazil'Produced: 1 1 5- 1 3 5g ( 4 0 - 4 . 8 o z l

Installthe spiiler on the driveshaftby aligningthe markson the sDiderand the end of the driveshaft. Fit the circlip into the driveshaft groove. Always rotatethe circlip in its groove to be sure it is fully seated.

lr;

6

-6.l

(cont'd)

1 6 - 11

Driveshafts (cont'dl Reassembly 8.

Fit the inboardjoint onto the driveshaft,and note theseitems: . Reinstallthe inboardjoint onto the driveshaftby aligningthe marks on the inboardjoint with the markson the rollers. . H o l d t h e d r i v e s h a f ts o t h a t t h e i n b o a r dj o i n t pointsup to preventit from fallingoff.

10. lf necessarypositionthe dynamicdamperas shown Detow. . Installa new dynamic damper band. and bend down both setsof lockingtabs. . Lightly tap on the doubled-overponjon of the bandto reduceits height. Loft: 1600DOHCVTECmodel: 26i 2 mm (1.0t 0.1inl All other models: 9,1t 2 mm (3.710.1 inl With "SR1" mark: 7512 mm 12.9! 0.1inl Right: 16dl DOHCVTECmodels:2612 mm 11.0t 0.1inl All other modelii 5 5 1 2 m m ( 2 . 2t 0 . 1i n l

INBOARO JOINT

DYNAMIC DAMPER

Adjust the length of the driveshaftsto the figure below, then adjust the boots to halfway between full comDression and full extension.The ends of the bootsseatin the grooveof the driveshaftand joint.

-SR1" MARK DYNAMICDAMPERBAND

Left driveshaft.1600DOHCWEC model: - 18,9inl 475- 480mm 118.7

U.S. and Canada-ProducedITPEBOOTI Left 53612 mm {21.110.1 in} Right:2txt12 mm {10.it1 0.1in}

Right driveshaft,1600OOHCVTECmodel: 475- 480mm (18.7- 18.9in) Left driveshaft,all othei models: 774-779 mm (30.5- 30.7in) Right driveshaft,all other models: -'19.9inl 501- 506mm 119.7

OYNAMICDAMPER

16-1 2

OUTBOARDJOINT

l .

11. Setthe doubleloop band onto the boot and dynamic damperwith the band end toward the front ot the vehicle.

DOUBLELOOPBANO

1 4 . Threadthe free end of the band through the nose

sectionof the boot band tool and into the slot on t h e w i n d i n gm a n d r e l . 1 5 . Placea wrenchon the winding mandrelof the boot band tool, and tightenthe band until the mark you madeon the band meetsthe edgeof the clip.

, (KD-3191 or equivalent)

1')

Markon band.

Pullup the slackin the band bY hand

1 3 . Mark a positionon the band 10 - 14 mm {0 4 0 6 i n )f r o m t h e c l i P .

1 6 . Lift up the boot band tool to bend the free end the clip' the band90 degrees,then center-punch

CLIP HAMMER

Ip

(cont'd)

16-13

Driveshafts (cont'dl Reassembly 1 7 . Unwindthe boot bandtool, and cut off the excess5 - 10 mm (0.2- 0.4 in) from the clip. 5-10mm 10.2- 0.a inl

Outboard Joint Sid.: 1. Wrap the splineswith vinyl tapeto preventdamage to the boot. TPE tvDe: -.

OUTBOARO BOOTITPE) BOOTBAND Replac€,

VINYLTAPE

1 8 . Securethe end of the boot band by tappingit down with a hammer, Rubbertyp.:

> V INYLTAPE

I n s t a l lt h e b o o t b a n d a n d o u t b o a r d b o o t , t h e n remove the vinyl tape. Take care not to damage the boot, 19. Installthenew set ring,

Installthe stop ring into the driv€shaftgroove. DRIVESHAFT

Note these items after reassembly: . Make sure the band and clip does not interfere with anythingand the band does not move. a Removeany grease remaining on the surrounding surfaces.

1 6- 14

4.

lnsert the driveshaft into the outboard joint until the stop ring is closeon the ioint.

6.

Checkthe alignmentof the paint mark with the outboardjoint end.

DRIVESHAFT

7.

)

J To completelyseat the outboardjoint, pick up the driveshaftand joint, and drop them from about 10 cm (4 to 5 inches)onto a hard surface.Do not use a hammer as excessiveforce may damagethe driveshaft.

Packthe outboardjoint with the joint greaseincludsd in th€ new ioint boot set. Gleaso quanlity U.S.,canada, and Brazil'Ploducod: 115- 135g {4.0- 4.8oz} Japan-Producod: DOHCVTECangino: 161X, Rubborboot: 90 - 100g 13.2- 3.5oz) TPEboot: 1tl6- 115I {3'7- tl'l oz} Excapt 1000DOHCVTECengine: Rubbel boot: 70 - 80 g l.2.5- 2.8 ozl TPEboot: 95 - 105g {3.4- 3.7 oz} DRIVESHAFT

J

(cont'd)

16-15

Driveshafts Reassembly lcont'd) 8 . Installtheoutboardboot and the boot bands. . lf the boot is the rubber type. go to step 13. . lf the boot is the TPEtype, go to step 9.

11. Closethe ear portion of the band with a commerciallyavailableboot band Dincerc.

Fit the boot endsonto the driveshaftand outboard ioint.

BOOTBAND PINCERS KENT-MOORE J,35910 or eouivalent EAR FOFNON

10, Set the ear clamp band by threadingthe tab into the holesof the band.

Chsckthe clearancabetween the closed ear oonion of the band. lf the clesranceis not within the standard, close the ear portion of ths band further.

6.0 mm (0.24in) MAX

3.0 mm 10.t2inl MAX

EARCLAMPBAND Reolace.

16-16

I 13. Fit the boot ends onto the driveshaftand the outboardjoint

17. Threadthe free end of the band through the nose sectionof a commerciallyavaiiableboot band tool KD-3191or equivalentand into the slot on the winding mandrel. BOOTBANDTOOL available) lCommerciallY or equivalent KD-3191

Mark spot.

MANDREL

1 4 . Fit the doubleloop boot bandsonto the boot ends' Pullup the slackin the band by hand' 1 6 . Mark a positionon the band 10 14 mm {0 4 0 6 in,)from the cliP.

1 8 . Placea wrench on the winding mandrelof the boot band tool, and tighten the band until the marked spot on the band meetsthe edgeof the clip' 1q

CLIP

lrz

Lift uo the boot band tool to bend the free end of the band 90" to the clip Centerpunchthe clip, then fold overthe remainingtail onto the clip

(cont'd)

16-17

Driveshafts (cont'dl Reassembly

Installation

20. Unwind the boot band tool, and cut off the excess free end of the band to leave a 5 - 10 mm (0.2- 0.4 in.)tail protrudingfrom the clip.

1,

Installthe new set ring onto the driveshaftgroove. Always use a new set ring whenever the driveshaft is beinginstalled.

INBOARD JOiIT

21. Bendthe bandby tappingit down with a hammer. NOTE:Maks sure the band and the clip does not interferewith anything, and the band does not mov6. Removeany greaseremaining in the surroundingsurtaces.

SET RII{G GR(X)VE

2.

Installthe outboardjoint into the knuckte.

AANOEND

KNUCKI.E

OUTBOARDJOINT

16-18

3.

lnsertthe inboardend of the driveshaftinto the dift 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 NOTE: Cleanthe areaswhere the driveshaftcontact the transmission(differential)thoroughlywith solvent or carburetorcleaner,and dry with compressedair'

5. lnstallthe dampertork 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 aligningtab is alignedwith the slot in the damPerfork. FLANGEBOLT l0 r 1.25mm rit N.m t4.akgf.m,32 lbf.ft)

AIIGN|NGTAB

JOINT INBOARD

INBOARDJOINT

Replace.

GROOVE

an

NUT SELF-LOGKING 12x 1.25mm 6,1N.m16.5kgi.m,a7 lbfftl Replace. Loosely install the flange bolts and the new selflockingnut. 1 . Apply oil to the seatingsurfaceof the new spindle nut.

DIFFERENTIAL

FRONTWHEEL

lnstall the knuckieon the lower arm. then trghten the castlenut and installa new cotterpin

WHEELNUT 12 x 1.5 mm 108N.m (11.0kgl'm, g) lbl ftl

NOTE: wipe off the grease before tightening the nut at the ball ioint. CAUTION: . Be careful not to damagothe ball ioint boot' . Torque the castle nut to the lower torque sp€cification, thsn tighten it only far enough to align the slot with th€ pin hol6. Do not align the nut by loosening.

J

CASTLENUT 12 x 1.25 mm i$ - 59 N.m 15.0- 6.0 kgl m,35 - 43 lbf ftl

COTTERPIN Replace. On reassemblY, bendthe cotterpin

SPINDLENUT 22 x 1.5 mm

kgt'm,13illbt'ftl 181N m 118.5 usea driftto NOTE:Aftortightening, stakethespindlenutshoulderagainstthe drivoshaft' 8. Installa new spindlenut,then tightenthe nut' 9. Cleanthe mating surfacesot the brakedisc and the wheel. then install the front wheel with the wheel nuts. 10. Tighten the flange bolts and the new self-locking nut with the vehicle'sweighton the damper. fluid (see 11. Refillthe transmissionwith recommended section13 or 14). 't2. Checkthe front wheel alignmentand adjust if necessary(seesection18),

16-19

IntermediateShaft Removal '1.

Disassembly

Drainthe transmissionoil or fluid {seesection13 or

r4).

NOTE: Be carefulnot to damagethe metal rings on the intermediate shaftduringdisassembly.

Removethe left driveshaft(seepage 16-3).

1.

Removethe set ring.

3 . Removethe threedowel bolts.

2.

Removethe intermediateshaft outer seal from the Deaflngsuppon.

OOWELBOLTS '10x 1.25mm

3.

Removethe externalcirclip,

2.

Removethe intermediate shaftfrom the differential. CAUTION: Hold the intermsdiate shaft horizontal until it is clear of lhe dilterential to prevent damage to the differential oil seal. INTERMEDIATE SHAFT

16-20

Disassembly shaft bearingout ot the bearPressthe intermediate ing support using the specialtools and a pressas shown.

6.

Pressthe intermediateshaftout of the shaft bearing usingthe specialtools and a pressas shown. Removethe internalcircliP

Press INTERNALCIBCLIP

I

Press HANOLEDRIVER 0?749- 00'10000

SUPPORTBASE ATTACHMENT 07JAF- SH20400

RING SUPPORT BEARING or distortion for damage Check

I DRIVERATTACHMENT, 12x47 mm 07746- 0010300

FLOATINGRUBBEB DAMPER Checkfor deterioration and oamage.

BASE SUPPORT ATTACHMENT 07JAF_ SH20it00

BEARINGSUPPORT Checkfor damage

ReassemblY NOTE: compressedair' Do not wash the rubber . clean the disassembtedparts with solvent,and dry them thoroughlywith partswith solvent. reassembly' . Becarefulnot to damagethe metalringson the intermediateshaftduring BEARINGSUPPORTRING

DOWELBOLTS 1 0x 1 . 2 5m m 39 N.m 14.0kgf.m,29lbIftl

EXTERNALCIRCLIP Packthe interior of the outerseal. 2.0-35s10.07-012oz)

SHAFTRING INTERMEDIATE

I

INTERNALCIRCLIP

A4\ SHAFTBEARING INTERMEDTATE Replace,

l J

sErR'NG Reolace

VU

OUTERSEAL Replace. (cont'd)

16-21

lntermediateShaft (cont'd) Reassembly 1.

Pressthe intermediateshaft bearinginto the bearing support using the specialtools and a press as shown.

Seatthe externalcirclip in the groove of the intermediateshaft. Installthe outer seal into the bearingsupportusing the specialtools as shown.

Prass

I

NOTE: Installthe seal ftush with the bearingsupport.

Pre$

t

DRIVER ATTACHMENT, 52x55mm 07746- 0010(X)

Packthe Interior of the ouler seal. 2.0- 3.5g {0.07-0.12 ozl

HANDr.r DRTVER - 0011r(x)0

ORIVERATTACHMENT, 52x55mm 077i16- 0010/O0

OUTENSEAL

Seatthe internalcirclipin the grooveof the bearing suppon. Pressthe intermediateshaft into the shaft bearing usingthe specialtools and a press. Praa.r

I

@--LJ

INTERMEDIATE SHAFT

Install the new set ring in the intermediateshaft groove.

DRIVERATTACHMENT,35mm LD.

16-22

lnstallation 1.

lnsertthe intermediateshaft assemblyinto the differential. CAUTION:Hold the intermodiateshaft horizontal to prevent damag€to the difterential oil seal' shaft NOTE:Cleanthe areaswherethe intermediate (differential) thoroughly transmission the contacts with solvent or carburetorcleaner,and dry with comair, Dressed

2.

Installthe three dowel bolts,then tightenthem' DOWELBOLTS 10x 1.25mm 39 N.m {i1.0kgf'm, 29 lbf'ftl

l z 16-23

l . Steering Tools Speciaf

t

Ir/

....."'.....17-2 Inspection and Adiustment

17-30 SteeringOperation'......."'........'...... Power Assist Check ManualSteering 17-30 With VehicleParked.."................ ComponentLocations 17-31 ....." SteeringLinkageand Gearbox .......17-3 lndex ................ ...--."""..17-32 Pump Beft Inspectionand Adiustment 17'33 RackGuide Adiustment .'.......'.......'. 17-4 SteeringOperation"'......"............... 17-33 FluidReplacement.....'.."................. 17-5 RackGuideAdiustment................... " 17-34 Pump PressureCheck .............'....-. *SteeringWheel 'Steering Wheel (Seepower steering section) 17-35 .."'........'... *SteeringColumn Removal 17-35 ............. (Seepower steering sectionl lnstallation 17-36 ......'.....'.' Disassembly/Reassembly SteeringGearbox *Steering 17-5 ................. Column Removal 17'37 ---.... .......""17-7 Removal/lnstallation....'........... Disassembly 17'38 17-9 .............. ..'......... lnspection ReassemblY 17-13 Power Steering Hoses,Lines ............. lnstallation 17-39 FluidLeakageInspeetion............'.... ......"..17-39 Replacement PowerSteering Component Locations """' 17-15 lndex "......."..... System DescriPtion 17'16 FluidFlow Diagram.........""............. 17-17 "........"'...-SteeringPump ............'... 17-20 SteeringGearbox.".................'...'.'.'

Power Steering PumP 17-40 .'.'..'..'............. Removal/lnstallation ".........17-41 Disassembly 17'42 .......---'." fnspection ..'.........17-44 Reassembly

SteeringGearbox 17'47 ....'........."' Removal Troubleshooting 17'22 ..........'17-49 DisassemblY GenerafTroubleshooting..........--.... -26 17-55 17 '........... Reassembly Noiseand Vibration......................... 17-65 ............. .............17-28 lnstallation FfuidLeaks Ball Joint Boot Replacement.......'..17-68

lp

Ref. No

I

o

@ @ @ @ fof

@ @ @ @ @ @ @ @ @ @ @ @

Tool Number

- PH70100 07GAF - SD4010A 07GAG or - SD40100 07GAG - SD4020A 07GAG or - S040200 07GAG *07JGG - 00r010A 07MAC- 5100200 - SR3O2OA OTNAD - SR3090A 07NAG or 07NAG- SR30900 - 5040110 07RAK - 5040121 07RAK or - 5040t20 07RAK - 0010004 07406 or - 001000r 07406 07725- 0030000 - 0010100 07746 - 0020100 07746 07746- 0030300 - 0010000 07749 - SA50001 07916 07965- SA50500 07974- SA5020A or 07974- SA50200 07974- SA50800

Description

Oty

I Pag€Reterence

PilotCollar PistonSealRingGuide

1 1

11-54 17-59

PistonSealRingSizingTool

'I

'17-59

BeltTensionGauge BallJoint Remover,28 mm CylinderEndSealBemoverAttachment PistonSealRingSizingTool

1 'I 1 I

17-32 17-6,47 17-51 | /-ao

P/SJoint Adaptor(Pump) P/SJoint Adaptor (Hose)

1 1

17-34 17-31 't7-34

P/S PressureGauge UniversalHolder Attachment,32x 35 mm Driver,22 mm l.D. Attachment,30 mm l.D. Driver LocknutWrench, 40 mm FrontHub DiVAssemblyTool SleeveSealRingSizingTool

@ BsllJoint BootClip Guide * lncludedin the BeltTensioncauge Set,07TGGOO10OOA.

I 1 1 I 1 1 I 1

't7-42,16 17-57,58 17-10 17-44 't7-57 17-5,33 17-68 17-57

I

17-57,6A

p

v o

€_ ts7-

(o)

F=1

dysB @

aal

@

@

@

@

17-2

o

@

@

@

@

ComponentLocations

t

lndex ManualSteering NOTE: beenfound defectiveor damageddur. lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has (see 24)' section be deployed ing transit.storageor service,it should o Beforeremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel . After installingthe gearbox,checkthe wheelalignmentandadjustif necessary precautions, and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations, section124)beforeperformingrepairsor service'

WHEEL STEERING Removal/lnstallation, Page17'35 page17-36 Disassembly/FeassemblY, DRIVER'SAIRBAGASSEMBLY seesection24 Removal/lnstallation,

J

STEERINGCOLUMN Removal/lnstallation, Page17-37 page17'38 Inspection, CABLEREEL seesection24 Removal/lnstallation, SWITCH IGNTTION See section23

t,

STEERINGGEARBOX RackGuideAdiustment,Page17-5 Removai,page17'5 Disassembly, Page17_7 page17_9 Reassembly, page17 13 Installation,

TIE.RODEND BALLJOINT page17-68 BallJoint BootReplacement,

17-3

Inspectionand Adjustment SteeringOperation SteeringWheelRotationalPlay Placethe front wheels in a straightaheadpositionand measurethe distancethe steeringwheel can be turned without movingthe front wheels.

Ste€ring Effort Check Raisethe front wheelsoff the ground. Turn the steeringwheelwith a springscaleand checkits reaorng,

ROTATIONAL PLAY:0 - 10 mm (0 - 0.4 in)

Standard:15 N (1.5kgf,3.3 lbll maximum

lf the play exceedsthe servicelimit, perform rackguide adjustment(seepage lT-5). lf the play is still excessiveafter rack guide adjustment, inspectthe steeringlinkageand gearbox as descrjbed Detow.

l f i t r e a d sm o r e . p e r f o r m r a c k g u i d e a d j u s t m e n (t s e e p a g e1 7 - 5 ) .

a o \---------U

Steering Linkageand Gearbox

TIE.ROOLOCKNUT Checkfor looselocknut.

BOOT I n s p e c tf o r d a m a g e a n d d e t e r i o r a t i o n .

STEERING JOINTS Checkfor loosejoint

COLUMN Inspectfor loosecolumn mountingboltsand nuts. PINIONSHAFTGROMMET for damageand deterioration.

END BALLJOINT I n s p e c tf o r f a u l t y m o v e m e n t ano oamage.

GEABBOXMOUNTING Inspectf or deterioration. GEABBOXASSEMBLY I n s p e c tf o r l o o s e m o u n t i n g b o l t s .

1 7-4

BALLJOINT BOOT Inspectfor damageand deterioration. See pago 17-68tor replacement.

SteeringGearbox RackGuideAdjustment

Removal

N O T E : P e r f o r mt h e r a c k g u i d e a d j u s t m e n tw i t h t h e wheelsin the straightaheadposition.

NOTE:Using solventand a brush,to wash any oil and dirt off the gearbox.Blow dry with compressedair.

1.

Loosenthe rack guide screw locknutwith the specialtool, then loosenthe rackguidescrew.

1.

Raisethe front of vehicle,and supportit on satety standsin the properlocations(seesectionI ).

2.

Removethe front wheels.

3.

Removethe steeringwheel(seepage 17-35).

4.

Removethe steeringloint cover

RACKGUIDESCREW

JOINTCOVER STEERING

WRENCH, 40mm LOCKNUT 07916- SA5000r

l.r

the Tightenthe rackguide screwuntil it compresses springand seatsagainstthe rackguide,then loosen rt. Retightenthe rackguide screwto 4 N'm (0.4kgf m, 2.9 lbf.ft),then backit off to specifiedangle. SpeciliedReturn Angle: 30' max. 4.

Removethe steeringjoint lower bolt, and disconnect the steeringjoint by moving the joint toward t h ec o l u m n .

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 JOINT STEERING

Checkfor tight or loose steeringthrough the completeturningtravel. Rechecksteeringeffort(seepage17-4).

l,z

LOWERBOLT (cont'd)

17-5

SteeringGearbox Removal(cont'd) Removethe cotter pin from the castle nut ('96 - '97 models)or nut ('98- '00 models)and removethe nut.

13. Removethe mountingbracket,

Replace.

7 . Installthe10 mm hex nut on the ball joint. Be sure that the 10 mm hex nut is flush with the ball joint pin end, or the threadedsectionof the ball joint pin mightbe damagedby the balljointremover. NOTE:Removethe ball joint usingthe specialtool, Refer to section 18 for how to use tho ball joint remover. Separatethe tie-rodball joint and knuckleusingthe specialtool. CAUTION: Avoid damaging the ball ioint boot.

Pullthe steeringgearboxall the way down to clear th€ pinionshaftfrom the bulkhead,then removethe pinionshaftgrommet, t5.

Move the steering gearbox to right so the left rack end clearsthe rearbeam,then tilt the left side down to remove it from the car.

Removethe left tie-rod end, then slide the rack all the way to the right.

'10.Separatethe exhaustpipeA

or TWC (seesectiong).

PINIONSHAFTGROMMET

1 1 . Disconnectthe shift linkage(seesection13 or section14). 12. Removethe stiffener plate.

STEENINGGEARBOX

17-6

Disassembly )

'1.

2.

Placethe gearboxin a vise with a soft jaws, then c l a m p t h e g e a r b o xa t t h e m o u n t b r a c k e to r g e a r housing.

Pushthe right end of the rack backinto the cylinder housing so the smooth surfacethat rides against the sealwon't be damaged.

CAUTION: Be carcful not to distort the gear housin9 by clamping it too iight in the vise incorrectly.

L o o s e nt h e l o c k n u t ,a n d r e m o v e t h e r a c k g u i d e screw. 7.

Removethe tie-rodend and locknut.

R e m o v et h e d i s c w a s h e r ,s p r i n g a n d r a c k g u i d e from the gear housing.

Removethe boot bands and tie-rod clips. Pull the bogtsawayfrom the ends of the gearbox.

RACKGUIOE SPRING DISCWASHER LOCKNUT TIE.RODCLIP

/

4.

H o l d t h e s t e e r i n gr a c k w i t h o n e w r e n c h , a n d unscrewthe rackend with anotherwrench. CAUTION: Be caleful not to damagc the rack sur' facs with the wrench. STEERINGRACKENO

RACKGUIDESCREW

8.

Removethe pinion dust seal and the 35 mm snap nng.

9.

Holdthe pinionshattwith a visesecurely Removethe pinion by tapping evenly around the flangedsectionof the gearboxwith a plastichammet. CAUTION: Do not tap on tho steering rack. NOTE| Do not reusethe removedpinion.

9._ ViF=\_

PINIONDUSTSEAL Replace. SNAPRING,35mm STEERINGPINION Feplace.

l , 17-7

SteeringGearbox (cont'dl Disassembly 10. Slidethe steeringrackout of the cylinderhousing. CAUTION: Be carelul not to damage the bushing in the cylinderhousing.

12. Replace the gearboxmountingcushionif necessary: .

.

To removethe cushion,usea sharpknifeand make a cut downthe lengthof the cushion.Becarefulnot to damagethe painton the outsideof the cylinder housing.Removethe old cushion. Apply weatherstripadhesiveto the insideof the new cushion.Installthe cushiononto the cylinder housingand positionit 20 - 22 mm (0.79- 0.87in) from the end of the cylinderhousingas shown.

N O T E :A f t e r i n s t a l l i n gt h e c u s h i o n ,w i p e o f f a n y e x c e s sa d h e s i v et h a t m a y h a v e d r i p p e d i n t o t h e i n s i d eo f t h e c y l i n d e hr o u s i n g .

1 1 . R e m o v et h e r a c ke n d b u s h i n g .

GEARBOXMOUNTINGCUSHION 20 - 22 mm 10.79- 0.87 in)

Inspectinnerwall tor wear or damage.

17-8

Reassembly NOTE: partswith solvent,and dry them with compressedair. Do not dip the rubberpartsin solvent. . Cleanthe disassembled . Alwavsreplacethe non reuseablepartswith new ones beforeassembly . Do not allow dust,dirt, or otherforeignmaterialsto enterthe steeringgearbox.

PINIONOUSTSEAL Replace.

-6,1

RACKENOBUSHING MOUNTINGCUSHIONS GEARBOX

\

^lr

-6i

t r

r@

V."^pR,NG,3smm

a

/

^$'q0 ")*o''o"'"'* \

DISCWASHER RACKGUIDE

t J

(cont'd)

17-9

Steering Gearbox (cont'dl Reassembly L

Apply a thin coat of greaseto the insidesurfaceof t h e r a c ke n d b u s h i n g .

Drivein the steeringpinion in the gear housingwith the soecialtools.

Greasequantity:1 - 3 S 10.04-0.1ozl CAUTION:Do not till the slots with greas€;th€y must remain open to serve as air passages,

ORIVER. 22 mm l.D. o7716qr20100

I n s t a ltl h e r a c ke n d b u s h i n gb y a l i g n i n gt h e r o u n d projectionon the bushingwith the hole in the cylind e rh o u s i n g

PINIONDUST SEAL Replace.

SNAPRING,35 mm Vinyltape STEERING PINION

I n s t a l lt h e 3 5 m m s n a p r i n g s e c u r e l yi n t h e g e a r housinggroove. 7 . Apply vinyl tape to the pinion shaft,then coat the vinyltapewith grease. Installthe piniondust sealon the gear housinguntil it seatsproperly,then removethe tape. Greasethe steeringrackteeth. 4.

I n s t a l lt h e s t e e r i n gr a c k i n t o t h e c y l i n d e rh o u s i n g carefullyto avoiddamagingthe rackend bushing.

G r e a s et h e s l i d i n gs u r f a c eo f t h e r a c k g u i d e ,a n d installit on to the gear housing. 1 0 . Installthe spring,discwasherand rackguide screw on the gear housing. NOTE:Installthe disc washerwith its convexside facingin.

Dtscw,

a(-\ \ l 1* l \,

,/

\

SPRING LOCKNUT CYLINDERHOUSING

17-10

RACKGUTDE

RACKGUIOESCREW

11. Adjustthe rackguidescrew(seepage 17-5).

I t 12. l n s t a l lt h e n e w l o c k w a s h e r i n t h e g r o o v e i n t h e steeringrack. 1 3 . Installthesteeringrackend into the rack LOCKWASHER Replace.

16. Apply grease around the outside ot the rack end housing.

RACKEND 54 N m ts.s kgf'm, 40 lbtft)

=-.

.r=-q!q!!.n SILICONEGREASE

TAB RACK END

(l*v

1 4 . Hold the steering rack with a wrench and tighten the rackend with another. CAUTION: Be careful not to damage the tack surfac€ with the wrench. 1 5 . After tighteningthe rack ends, stakethe four sections of the lock washer with a roll pin drift and a mallet. . Placethe wood blockon the presstable.then set the lock washer section of the rack end on the wood blocksecurelY. . Be sure the tool is alignedwith the flat sections of the steeringrackend beforepressing . Stakethe lock washer in the center of the flat section of the steering rack end.

1 7 . Apply a light coat of silicone grease to the boot grooveson the rackends. lnstall the boots in the rack end with the tie-rod clips. NOTE: Install the boot band with the rack in the straight ahead position (right and left tie-rodsare equalin length).

NOTE| WiPe greaseoff the threadsectlon

ROLLPIN DnlFTl (Commorci.lly.Yril.blol Snap-OnNo. PPRSor oquival.nt

rl,

NOTE: This drift has a flat tip, to prevent puncturing of metalwasher.

nlCr/ srEEatruG WOODENBLOCK

TIE.ROOCLIP

(cont'd)

17-11

SteeringGearbox Reassembly(cont'd) '19.

Installthe boot band so that the lockingtabs of the band(stakepoints)are in the rangeshown below. { T a b ss h o u l df a c eu p a n d s l i g h t l yf o r w a r o . ,

2 2 . S l i d et h e r a c kr i g h t a n d l e f t t o b e c e r t a i nt h a t t h e bootsare not detormedor twisted.

20. Bendboth setsof lockingtabs. 2 1 . Lightlytap on the doubled-overportionsto reduce t h e i rh e i g h t . CAUTION:Stakethe band lockingtabs firmly.

Stakepoints

+

Lett Boot Band (Viewedfrom the left side)

17-12

Right Boot Bend (Viewedfrom the right side)

Fronr

lnstallation ) 1.

Slidethe rackall the way to the righl

2.

Installthe pinion shaft grommet,and insertthe pin i o n s h a f tu p t h r o u g ht h e b u l k h e a d .

4.

I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x mountingboltsand stiffenerplateattachingbolts. N O T E rI n s t a l lt h e b o l t s l o o s e l yf i r s t . t h e n t i g h t e n them securely. PLATE STIFFENER

NOTE|Align the notch in the pinion shaft grommet w i t h t h e t a b o n t h e g e a rh o u s i n g .

ATTACHINGBOLTS 38 N.m (3.9kgf.m.28lbf.ftl

STEEBINGGEARBOX

J

3.

Installthe mountingbracketswith the two gearbox m o u n t i n gb o l t so n t h e c u s h i o n .

EOLTS MOUNTING GEARBOX 43N.m{4.4kgf.m,32lbf'ftl 5. 6.

Centerthe steeringrackwithin its stroke Slip the lower end ot the steeringjoint onto the pin ion shaft(line up the bolt hole with the groove aroundthe shaft),and tightenthe lower bolt. NOTE: . Connectthe steeringshaft and pinion with the steeringwheeland steeringrackcentered 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 s e c u r e l yi n t h e g r o o v ei n t h e s t e e r i n gg e a r b o x p i ni o n . lf the steeringwheel and rack are not centered, r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e steeringioint. JOINT STEERING

{4.0 kgt.m,29 lbf.ftl NOTE:The arrowon the bracket pointtowardthe front.

J

JOINT STEERING LOWERBOLT 22 N.m {2.2kgf.m,16lbf'ft}

(cont'd)

I t- t5

SteeringGearbox Installation(cont'dl 7.

Centerthe cable reel by first rotating it clockwise until it stops.Then rotate it counterclockwise (approximatelytwo turns) until the arrow mark on the label points straight up. Reinstallthe steering wheel(seepage 17-35).

9. Reconnsctthe ti€-rod ends to the steering knuckles, thon tightsn th€ castlenut ('96-'97 models)or nut ('98-'00 models)to the specifiedtorque,and install new cotter pins. NOTE: Before connecting the tie-rod ends, wipe off a n y g r e a s ec o n t a m i n a t i o nf r o m t h e b a l l j o i n t tapered section and threads.

Installthe steeringjoint cov€r with the clampsand clrps.

CAUTION: Torque lhe ct3tle nut to thr lowsr torque spocification,th€n tighton it only tar anough to align the 3lot with tho pin hob. Do not align the nut by loosening ('96 - '97 modcls onlyl. STEERING JOINI COVER

TIE.ROD

'96 - 37 model3:

CAST1TNUT ,O - ilt N'm {4,0 - 4.8 kgf.m. 29 - 35 tbtftl

COTTERPINS R6plac6. On rgassombly,b6nd cotter prn as shown. '98 - '00 modol3:

NUT 4a N.m (4.5kgf.m, 33 lbr.ftl

10. Installthe exhaustpipe A or TWC (seesection9). l l . Connectthe shift linkage (see section 13 or section

14). Installthe front wheels. After installation,perform the following checks. . .

Adjust the front toe (seesection 18). Checkthe steering wheel spoke angle. Adjust by turning the right and left tie-rods, if necessary.

NOTE:Turn the right and lefttie-rodsequally.

17-14

ComponentLocations

I

lndex Power Steering: NOTE: . li an intactairbagassemblyhas been removedtrom a scrappedvehicleor has beenfound defectiveor damagedduring transit.storageor service,it shouldbe deployed(seesection24). . Beforeremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel. . After installingthe gearbox,checkthewheelalignmentandadjustif necessary. and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions, section{24}beforeperformingrepairsor service.

WHEEL STEERING page17-35 Removal/lnstallation, page17-36 Disassembly/Feassembly, DRIVER'SAIRBAGASSEMBLY seesection24 Removal/lnstallation,

/

STEERINGGEAREOX page17'33 RackGuideAdiustment, Removal,page17 47 page17-49 Disassembly, page17-55 Reassembly, page17-65 Installation, VALVEEODYUNIT Overhaul,page17 52

COLUMN page17-37 Femoval/lnstallation, page17-38 Inspection, CASLEREEL see section24 Removal/lnstallation, IGNITIONSWITCH Seesection23

1,,

POWEFSTEERINGPUMP page11-32 PumpBeltInspection, PumpBeltAdiustmenl,page11'32 PumpPressure Check,page17 34 page17'40 Removal/lnstallation, page17-41 Disassembly/Reassembly,

TIE.RODEND BALLJOINT page17-68 BallJointBootReplacement,

17-15

System Description FluidFlow Diagram power steering,connectedto the steeringgearbox.The fluid pressureis proThe system is a compactrotary-valve-type vided by a vane-typepump which is driven by the enginecrankpulley.The amount of fluid and pressureis regulatedby the flow controlvalvebuilt into the pump.The fluid pressurefrom the pump is deliveredto the valvebody unit aroundthe pinionof the steeringgearbox.The valveinsidethe valvebody unit controlsthe hydraulicpressureand changesthe direction of the flow. The fluid then flows to the powercylinder.where rackthrust is generated.Fluid returningfrom the power cylinderflows backto the reservoir,wherethe fluid is "filtered"and suppliedto the pump again.

RESERVOIR

VALVEBOOYUNIT

SUB.VALVE

FLOWCONTROLVALVE

17-16

STEERINGGEARBOX

SteeringPump )

Construction The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is drivenby a POLY-V-belt operationsfor every rotafrom the crank pulley.The pump features10 vanes.Eachvane performstwo intake/discharge discharge. small during pulse pressure becomes extremely hydraulic fluid that the tion of the rotor.This means

FLOWCONTROLVALVE

ROTOR

/

VANE

CAM RING

Operation The belt-drivenpulley rotatesthe rotor through the drive shaft.As the rotor rotates,the hydraulicpressureis appliedto of the cam ring. the vanechamberof rhe rotor and the vaneswill rotatewhile beingpushedonto the innercircumference so the vanes of the shaft, center portion respect to the with The inner circumferenceof the cam ring has an extended volume of the internal the movement. this roller As a result of rotates. as the rotor direction in the axial move downward vanechamberwill change,resultingin fluid intakeand discharge

J

FLUIDMOVEMENT:

STARTOF FLUIDINTAKE:

FLUIDINTAKE:

The vanes are pushed onto the inner circumferenceol the cam ring,

l h e v o l u m eo f t h e v a n ec h a m - T h e s u c k e d - i nf l u i d m o v e s ber increasesso that fluid is towardthe dischargeport. suckedin.

FLUIDDISCHARGE:

As the vanes return to the t h e i r o r i g i n a lP o s i t i o no n t h e inner side,the volume of the v a n e c h a m b e rd e c r e a s e s o t h e f l u i d i s d i s c h a r g e df r o m the dischargeport.

(cont'd)

a - t

I I-

4 -

| t

SystemDescription SteeringPump(cont'dl The flow control valve and sub-valvein the pump performs the following steps @ through @ to control the flow of fluid, that is to increasethe dischargevolume when enginespeedis low, and to decreaseit when the engine speed increases.The assistancethrust of the s t e e r i n gg e a r b o xc h a n g e si n c o m p l i a n c ew i t h t h e changein the dischargevolume.

FLOWCURVE

l o t r r t r r

l o 3 J

PUMP R.P.M.

o

When the engine starts,fluid dischargedfrom the dischargeport startsto flow through oil passageA, the fixed orificeand the variableorificeto the steering gearbox.When the engine speed is extremely low, the return port is closed by the flow control

To STEERING GEARBOX

Fluid pressuredischargedfrom the dischargeport is appliedto the top of the sub-valve,and the fluid pressurethat passedthrough oil passageA is applied to the bottom of the sub-valve.When this happens, the pressuredifferencebetweenthe ends of oil passageA, which is causedby the resistanceoil passage A w h e n t h e f l u i d f l o w s t h r o u g h t h e p a s s a g e .i s appliedto the sub-valve,However,the pressuredifferenceapplied to the sub-valve.that is the force that pushes the sub-valve down, is too small to overcomethe spring force, and the variableorifice is fully openwhen the enginespeedis extremelylow. Becausethe fluid volume flowing throughthe fixed orificeand variableorificeincreases, a pressuredifterence is createdbetweenthe ends of these orifices, and it increasesin proportionto the engine speed.As the fluid pressurethat passedthe fixed orificeand variableorificeis directedto the bottom of the flow control valve. a pressuredifferenceis created between the top and bottom of the valve, w h i c h p u s h e sd o w n t h e f l o w c o n t r o l v a l v e a n d opens the return port. As a result,pan of the fluid dischargedfrom the dischargeport feturns to the pump suction port, keepingthe dischargevolume constant. In this condition,the sub-valvedoes not move. and the variableorificestaysfully open.

SUB.VALVE

!rs+/f/ffih\\ o,,-i^"l^tKzYt)9 1y ul3Yl

FLOW CONTNOLVALVE To STEEnINGGEARBOX

su8-vALvE

ORIFICE

ToP

FLOWCONTROLVALVE

17-1 8

t

To STEERINGGEARBOX

@ The fluid volumethat flows thoroughoil passageA and the pressuredjfferenceappliedto the sub-valve i n c r e a s ei n p r o p o r t i o nt o t h e e n g i n e s p e e d .T h e sub-valvelowers overcomingthe spring force,and it stans to closethe variableorificeto regulatethe dischargevolume,Whenthis happens,the fluid volume flowing to the steeringgearboxdecreasesas the engine speed increases.At the same time, the flow controlvalvecontinuesto controlthe fluid volume to the returnPort,

To STEERINGGEAREOx SUB.VALVE

@ As the enginespeedincreasesfunher, the pressure differenceat the sub-valveincreasesfurtheras well. The sub-valvethen closesthe variableorificecomp l e t e l y ,r e g u l a t i n gt h e d i s c h a r g ev o l u m e f u r t h e r . W h e n t h i s h a p p e n s t, h e f l u i d v o l u m e d i s c h a r g e d from the pump to the steeringgearboxis regulated a n d m a i n t a i n e da t a g i v e n l e v e l u n t i l t h e e n g i n e speedreachesthe high speedrange The flow control valve functions continuesto control the fluid volumeto the returnPort.

/F

ft>..\ '-€/K\A/A o'.'to"5lo'#2"n af 11\D7

FLOWCONTROLVALVE

PressureRelief P r e s s u r ea t t h e d i s c h a r g es i d e o f t h e f i x e d o r i f i c ei s directedto the bottom of the flow control valve.When the pressurebuilds up, the reliefvalve in the flow control valveopensto releasethe pressureat the bottomof the valve.This allows the flow control valve to be pushed back by the pressuredifference,and the fluid volumeto the pump returnport increases. As explainedabove. the system keepsthe pump disc h a r g ep r e s s u r e( r e l i e fp r e s s u r ef)r o m e x c e e d i n gt h e given level by controllingthe volume of the fluid to the pump relurn pon,

1.,

FLOWCONTROLVALVE DAMPINGORIFICE {Docreasesexcessiv€ vibration in the valv6.)

RELIEFVALVE {Opan)

17-19 )

System Description Steering Gearbox The rack-and-pinion type steeringgearboxhas a valvebody unit incorporatedwith the pinionto controlthe steeringfluid pressure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve body unit and is sentthroughthe cylin, der line to the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylin, der returnsthroughthe cylinderline and valvebody unit to the reservoii.

VALVEEODYUNIT CYLINDERLINE

To RESERVOm +FromPUMP -;

POWERCYLINDER

Valve Body Unit Insidethe valve body unit is the valve,which is coaxialwith the pinion shaft,and controlsthe steeringfluid pressure.The valve housingis connectedwith the fluid line from the pump,the returnline to the reservoir,and the two cylinderlines from the respectivepower cylinder.The pinion shaft is double- structuredwith the input shaft connectedto the pinion gear,both of which are interconnected with the torsionbar. The pin insertedin the valve and the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the valve.Becauseof this construction, the differencein angle in the circumferential directionbetweenthe input shaftand the valve becomeslargeraccordingto the torsionalstrengthof the pinionor steeringresistance. However,maximumtorsion betweenthe shaftsis regulatedby the engagedsplinesof the shaftsat the pin engagementsectionto hold the torsionbar within the set value, This allowsthe steeringsystemto functionas an ordinaryrack-and-pinion type steeringif the steeringfluid is not pressurizedbecauseof a faulty pump,

VALVE Difforencein angle botwoon the input shaft and pinion shsft

PINIONSHAFT

lo -l INPUTSHAFT

17-20

a

INPUTSHAFT

Control Pressure

Low assistat higherspeeds: W h e n s t e e r i n g r e s i s t a n c e I s I o w , s u c h a s w h e n d r i v i n g a t h i g h s p e e d s , o r w h e n d r i v i n g soIt rthe a i gfeed h t a pressure head,theinpu power cylinderorifices.Most nearor in the neutralposition,so there is little or no fiow ro any of the fromthepumpisbypassedtothereservoir.Becauseofthis,thepressurestaysthesameinbothsidesofthepo der, resultingin low or no asslst VALVE

From PUMP

RESERVOIR

RETURNPASSAGE lTo RESERVOIRI

SECTIONA-A

POWERCYLINDER STEERINGGEARBOX

Highassistat lower speeds: low speeds'or when turning the wheel wirh the vehicle When steering resistanceis high. such as when driving at stopped,thedifference|nang|ecreatedbetweentheinputshaftandtheVa|veopensthef|uidpassageonon c|osesthefluidpassageontheotherside,ateachpairoforifices'Thef|uidpressureincreasesinthesideo|th c y | i n d e r | e d b y t h e | a r g e r f | u i d p a s s a g e ' T h i s i n c r e a s e d p r e s s u r e p u s h e s o n t h e r a c k p i s t o n , athe | l osteering wingthe s t eto eringwh tluid the returnpassageopensallowing be turnedwith light effort.on the other sideof the powercylinder,

r e t u r n t h r o U g h t h e i n p u t s h a f t t o t h e r e s e r v o i r ' T h e f | u i d p a s s a g e s t o t h e p o w e r c and y | i npower d e r a uassist t o m aincreases tica||ychang increases.In other words, the passagesbecomelarger increasingas the steeringresrstance (for example'when parkingor makinglow speedturns)' and the paswhen the steeringeffort would normallybe high, sagesbecomesma||erandpowerassistdecreaseswhenthesteeringeffortwou|dnorma||ybe|ow,(forexamp|e,w drivingat high speedsor straightahead). FLUIOPASSAGETO POWERCYLINDER

/t=\

\a!-4,)) =YjJ

SECTIONA-A

l'

{High fluid Pressure}

Troubleshooting GeneralTroubleshooting Checkthe followingbeforeyou begin: . Hasthe suspensionbeenmodifiedin a way that would affectsteering? . Are tire sizes,tire varietyand air pressurecorrect? . lsthe steeringwheeloriginalequipmentor equivalent? . lsthe powersteeringpump belt properlyadiusted? . ls steeringfluidreservoirfilledtoproperlevel? . ls the engineidle speedcorrectand steady?

HardSteering(Checkthe poworassist.se€page17-3o.lfthe torce is over 29 N (3.0kgf,6.6lbo, Procedewith this troubleshootinq.)

Checkthe pump fluid pressure (soepage17-34). l/easure steady-state tluid press!re while idling with the both valvestully open. It should be 1.500kPa(15 kgf/cmr, 213psi)or below.

Abnormal lluid pressure {fluid pressure is too high)

C h € c kt h e f e e d s n d r e t u r n c i r c u i t l i n € s a n o n o s e betw6€n the gearbox and pump for clogging and d€lormation.

Normallineand hose

Normal Faultyvalve body unit

Checkthe pump fluid pressure {seepage 17-34). 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 pressurecontrol valveIully closed. It should be 6,400- 7,400kPa(6575 kgflcm,,920- 1,070psi)

Reliefpressure too low

Checkth€ flow control vslve (see page 17-42). . Chockthe valvo lor smooth movement in the housing. . Checkthe reliefvalve for leaks.

Normalrelisfpressure

Go to page 17-23

17-22

Abnormal

Faultypump assembly

Faultyllow control valve (Replace the pump es an assembly)

I Checkthe force requiredto turn the wheel(seePage17 30i Startthe engineand measurethe force requiredto turn the wheel of to the right and left.Difference t h e l o r c e r e q u i r e dt o t u r n t h e wheel to the right and to the Ieft should be 2.9 N 103 kgf, 0.7 lbf) or below.

Normal

Deformed

Abnormal

Faultycylinderlines

Checkfor bent rack shaft

II Compairthe steeringto another alike vehicle.

Checkrackguideadiustment(see page17-33).

AdiustmentOK

Faultyvalvebody unit

/

1,,

(cont'd)

17 -23

Troubleshooting GeneralTroubleshooting(cont'd) Assist(excessively lightsteering)at high speed.

Shockor vibrationwhen wheelis turnedto {ull lock.

Checkthe rack guide for proper adiustment(seepage17 33).

lf the problem is not correctedby adiustingthe rack guide, adjust t h e f r o n t w h e e l a l i g n m e n tl s e e section181.

Checkthe rack guide for proper adjustment(seepage17-33).

Rackguideis adjustedproperly.

Checkthe belt for slippageand a o l u s t a s n e c e s s a r y{ s e e p a g e 11 32).

lfthe problemis not correctedby adjustingthe rackguide,replace the gearbox.

Steeringwheelwill not return smoothly.

A a n d B c y l i n d e rl i n e sa r e n o r mal, checkwheel alignment(see section18).

W h e e l a l i g n m e n ti s a b n o r m a l , adjust as needed.

Wheelalignmentis normal. Checkthe steeringwheel operation and power assistcheck{see page lT-30).

It the measurementsare out of s p e c i f i c a t i o n sa, d j u s t t h e r ac k guide.

lf the problemis not correctedby adjustingthe rackguide,replace the gearbox.

1 7- 2 4

Adjustthe rac*guide(seepage17-3).

Unevenor roughsteering

lf the problemis not correctedbY adjustingthe rackguide,replace the gearbox.

Adiustthe belttension.Feplacethe (seePage1732). belt,il necessary

ldle speedlow or erratic.

lfthe enginestallswhenthe wheel is turnedwhile car is stoppedor moving at low speed,adjustthe idlespe€d(seesection11)

Air in reservoir,or check Power steeringIluid level.

Checkpower sleeringfluid level lf the level is excessivelylow, check lor leaksin the system.Add lluid to the specifiedlevel.

lf ltuid level is OK, checkO-rings a n d s e a l so n b o t h e n d s o f t h e pump inlet hose,and the P/S pump housing mating surfaces and the pumP shaft oil seal for suction leaks. RePlaceParts as nocessary.

/

Steeringwheel kicksback duringwide t!rns.

P u m p b e l t s l i P P i n go n P L r l l e Y (pumpstopsmomentarilY)

Adjust the belt tension (see Page belt. 1732)orreplace

Installthe power steeringpressure gauge,Closethe Pressurecontrcl valve fully and m6ssurethe PumP pressure{s€epage17-34}.

Checkif pump press{rreis normal and the gaugeneedletravel is 500 k P a ( 5 k g l / c m ?7, l P s i ) o r l e s s . Chockthe flow control valve if the needletravel exceeds500 kPa (5 kgflcm',71 Psi).l{ the flow control valve is normal, replacethe PumP as an assemoly.

ll, 17 -25, )

Troubleshooting Noiseand Vibration NOTE;Pump noisein first 2 - 3 minutesafterstartingin cold weatheris normal.

Humming

Rattleor chattering

Humming due to pulsationof fluid is normal, particularlvwhen the wheel is turned with the vehicle stooDed.

lf equipped with automatictransmission, the hum could be the torque conveateror pump noise.

Confirm by temporarily removing the pump belt.

High-pressureline touching the frame.

Repositionthe line.

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 paatsas necessary.

Columnshaftwobbling.

Replacethe columnassembly.

Checkthe rack guide tor proper adjustment(seepage 17,33).

Adiusi,if necess€ry.

Rattlingsoundand feelingwhen turningthe steeringwheelraghtand leftwith the engineOFFis normal.

Pump noise,though not loud.trom the valvebody unit can be heardwhon turning the steeringwheel rightor left.This is normat.

CAUTION: When imp€sting, do not hold the steering wheet a[ the way to the right or the left.

17-26

)

Pumpnoase

Gratingnoise from pump

Cavitationcaused bY air bubbles in the fluid.

Checkthe tluid level. l f l o w , f i l l t h e r e s e r v o i rt o t h e proper level,and checklor leaks. Tighten or replaceas nocessary.

Checklor a crushed suction hose or a loose hose clamp allowing air into the suction side of the sy$em. Tighton or roplaceas necossary.

Pumpgearnois€

l z / Rattleor chattgring

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 weatheris normal ComparepumP noiseat operating temperatureto simularvehicle.

loud, lf pump nois€is abnormallY remove and inspectthe PUmPfor w6ar and damage(seePage 1741).

Tightenor replacethe Pulley. l f s h a t t i s l o o s e , r e P l a c et h e pump.

t r 17-27

Troubleshooting FluidLeaks Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points.dependingon location of the faultyoil seals/seal rings.Checkthe followingbeforeremovingthe gearboxfrom the frame_

SteeringGearbox

Leakingfrom the oil seal on the top of the valvehousing.

Replacethe valve oil seal from the valvehousing.

Leakingfrom cylinder end into left tie rod boot.

Replacethe valve oil seal trom the pinionshaft.

Replacethe cylinderend sealon the gearhousingside.

17-2a

Leakinglrom cylinder end into right tie-rod boot.

Replacethe cylinderend seal on the cylinderend side.

Leakinglrom the shaftupperend sectronor pin engagementsec, tion ol the pinionshaft.

Replacethe valvebody unit.

Leakingfrom cylinderlineA or B connections{at tlare nut}.

Tightenthe connector.lf it's still leakinO, replacethe Iine,cylinder or valvehousingunit.

L e a k i n gc a u s e db y a d a m a g e d cylinde.lineA or B.

ReplacecvljnderlineA or B.

Leakingfrom feed line and return lineioint fittingon the valvebody unit (atflarenut).

Tighten the connector. ll it's still leaking,replacethe line,,ointfit, ting or valv6housing.

the housingO-rings Replace lf the housingstill leaks,rePlace the pumP.

Reservoiris overfilled Pull off the hose and drain the reservoitto the Properlevel.

Air leakin suctionsideofthe sys' tem (reservoir,inlet hose,tront pump seal).

Pumpoutletline (highpressure,

L e a k i n ga t t h e t h r e a d e d f i t t i n g

Tighten the fifting. lI it's still leaking, replacethe O-ringor feed line.

Leakingat the swaggedjoint.

/ PumpinletIine (low-pressure)

Leakingbecauseol damage,dete_ assemblY. or imProPer rioration,

Reolaceor rePairas necessarY.

t J 17-29

Inspectionand Adjustment SteeringOperation Placethe front wheels in the straight ahead position, and measurethe distancethe steering wheel can be turnedwithout movingthe front wheels.

PowerAssist Gheckwith VehicleParked 1.

Checkthe power steeringfluid level (see page 1733) and pump belttension(seepage17-32).

ROTATIONALPLAY:0 - 10 mm l0 - 0.39 inl

2.

lf the play exceedsthe servicelimit. perform rack guide adjustment(seepage 17-33). lf the play is still excessiveafter rack guide adjustment. inspectthe steeringlinkage and gearboxas described on the nel(t pag€.

Startthe engine,allow it to idle.and turn the steering wheel from lock-tolockseveraltimes to warm up the fluid.

3.

Attach a spring scaleto the steering wheel. With the engine idling and the vehicleon a clean,dry floor, pull the scaleas shown and read it as soon as the tires beginto turn.

ROTATIONALPLAY

D 0

The scaleshould read no more than 29 N (3.0 kgf. 6.6 lbf). lf it reads more, check the gearbox and pump,

17-30

I

SteeringLinkageand Gearbox

COLUMN STEERING Inspectfor loosecolumn mountingboltsand nuts

TIE-RODEND BALLJOINT Inspectfor faultymovement and damage.

BOOT Inspect

damageand deteriorataon JOINTS STEERING Checkfor loosejoint bolts.

l./

SHAFTGROMMET I n s p e c tf o r d a m a g e a n d d e t e r i o r a t a o n .

TIE-RODLOCKNUT for looselocknut

STEERINGGEARBOX lnspectfor loosemountingbolts. MOUNTINGCUSHIONS GEARBOX Inspectf or deterioration

BALLJOINT BOOT Inspectfor damageand deteriorataon' Seepage17-68lorreplacement.

lrz 17-31

Inspectionand Adjustment PumpBelt NOTE:When usinga new belt,first adjustthe deflection or tensionto the valuesfor the new belt, then readjust the deflectionor tensionto the valuesfor the used belt afterrunningenginefor five minutes.

Adiustment

Inspection

1.

Loosenthe powersteeringpump mountingbolts.

2.

Adjustthe belttension.

'99 - '00 Attachthe specialtool to the belt and measurethe tension of the belt. Tension: '99 -'00 mod€ls:B1642 Engin. Type only Used Bsh: 390 - 540 N lao - 55 kgt.88 - 120 tbf) New Belt: 740- 880N {75- 90 kgf, 170- 200tbt} '96 - '00 models:Other EngineTypes Used Beh: 340 - 490 N (35 - 50 kgf, 77 - ilO tbfl New Belt: 640- 780N 165- 80 ksf, 1& - 176tbf) NOTE: . lf thereare cracksor any damageevidenton the belt, reDlaceit with a new one. . Followthe manufacturer's instructionsfor the tension gauge. BELTTENSION GAUGE 07JGG_ 001010A

.

mod€ls: 816A2 Engin€Typo only

Turn the adjustingbolt by handto get the properbelt tension,then retightenthe mountingbolts, ADJUSNNG BOLT

PUMP MOUNNNG BOLTS 24 N.m (2.4kgf'm, 17 tbtftl

'96 -'00 .

Inspectthe pump beltfor cracksor any damage. Replacethe belt with a new one if necessary.

POWERSTEERING PUMP

modek: Othcr Engins Typos

Pry power steering pump away from the engine with a wrench to get the proper belt tension, then retighten the mountingbolts. PUMPMOUNTINGBOLT 24 N.m (2,4kgf.m, 17 lbl.ftl

Measuremontwithout Beh Tension Gauga: Apply a force of 98 N (10 kgt,22 lbfl and measurethe deflectionbetweenthe power steering pump and the crankshaftpulleys. Dsflectior: '99 -'00 model3:816A2 Engine Typ€ onty Used Beh: 7.5 - 11.0mm t0.30- 0.43 inl New Beh: 5.0 - 7.0 mm (0.20- 0.28 in) '96 - '00 models:Othor Engine Typos Used Behi 10.5- 14.0mm (0.ial- 0.59 inl Now Beh: 7.5- 10.0mm (0.30- 0.39inl POWERSTEERINGPULUY

PUMPMOUNTING BOLT 24N.m{2.akgtm, 17tbtftl Start the engine and turn the steeringwheel from lock-to-lock severaltimes,then stop the engineand recheckthe deflectionof the belt, CRANKSHAFT PULLEY

17-32

I

RackGuideAdjustment

FluidReplacement

NOTE:Performrack guide adjustmentwith the wheels in the straightaheadPosition.

Checkthe reservoirat regularintervals,and add fluid as necessary. CAUTION: Always us€ Genuine Honda Power Stearing Fluid-V or S. Using any other type of power sto€ring tluid or automatic transmission lluid can cause increasedwear and poor steering in cold weathor. SYSTEMCAPACITY: 0.85liter 10.90US' qt,0.75 lmp'qt) at disassembly CAPACITY: RESERVOIR 0.4 liter (0.42US. qt, 0.35 lmP.qt)

1.

Loosenthe rack guide screw locknutwith the cialtool. '96 - '97 models: Loosenthe rackguidescrew

LEVEL LINE

LOWERLEVELLINE LOCKNUTWRENCH,40 mm

'98 - '00 models: Removethe rack guide screw and remove the old sealantoff of the threadedsection. Apply new sealantall around the threads.Loosely installtherackguidescrew

1. 2.

Raisethe reservoir,then disconnectthe returnnose. Connecta hose of suitablediameterto the disconnectedreturn hose,and put the hose end in a suitablecontainer. CAUTION:Take care not to spill tho fluid on the body and parts. Wipe off any spill€d fluid at oncs'

Tightenthe rack guide screwto 25 N'm (2.5 kgf'm. 18 lbf.ft),then loosenit. Retightenthe rackguidescrewto 3 9 N'm (0.4kgim, 2.9 lbf.ft),then back it off to specifiedangle. SpecifiedReturn Angle: 20" max. 4.

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. Checkfor tight or loose steeringthrough the completeturningtravel. PerformfollowinginsPections: . .

l r

Steeringoperation(seepage 17-30). Powerassistwith vehicleparked.

HOSE

3.

4. 5. 6.

7.

Startthe engine,let it run at idle,and turn the steering wheel from lock-to-lockseveral times When f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e engine,Discardthe fluid. Reinstallthe returnhoseon the reservoir' Fillthe reservoirto the upperlevelline. Startthe engineand run it at fast idle,then turn the severaltimes to bleedair steeringtrom lock-to-lock trom the system. Recheckthe fluid leveland add some it necessary. CAUTION: Do not fill the reservoir beYond the upper l€vel line.

17-33

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. CAUTION: Disconnectthe high pr$sure hos€ with care so as not lo spill the power sieering tluid on tha frame and other parts. 1.

2.

3.

Disconnectthe outlet line from the Dumooutlet fitting, then installtheP/Sjoint adaptor(pump)on the Dumooutlet. Connectthe P/Sjoint adaptor (hose)to the power steering pressuregauge, then connect the outlet hoseto the adaptor. Installthe power steeringpressuregaugeto the P/S joint adaptor(pump)as shown.

ourlErHosE FnrNo

,t"ll lrilu"ott

Startthe engineand let it idle. 7 . Turn the steeringwheel from lock-to-lockseveral timesto warm the fluid to operatingtemperature. Measuresteady-state fluid pressurewhile idling. If t h e p u m p i s i n g o o d c o n d i t i o nt,h e g a u g es h o u l d readlessthan 1500kPa(15kgf/cmr,213 psi). lf it readshigh, checkthe outlet line or valve body unit (seeGeneralTroubleshooting 17-22). 9 . C l o s et h e p r e s s u r ec o n t r o l v a l v e ,t h e n c l o s et h e shut-off valve gradually until the pressuregauge needleis stable.Readthe oressure. lmmediatelyopenthe pressurecontrolvalvefully. GAUTION: Do not keep lhe prossure control valve clos€d more then 5 soconds or the pump could be damagod by over-heating. lf the pump is in good condition,the gaugeshould read at least 6,400- 7,400kPa (65 - 75 kgflcm,,920 1,070psi).A low readingmeanspump outputis too low for full assist.Repairor replacethe pump,

P/S JOINT ADAPTOBIHOSEI 07RAK- S0i10l2r ol 07RAK- 50{{)120

P/S PRESSURE GAUGE 07406- 001000A or 07406- 0010001

P/S PBESSURE GAUGE 07{16 -@1@OA oi (Pa.t of tooll 11 N.m 11.1kgt m, 8 lbf.ftl PRESSURE CONTROLVALVE SHUT.OFF VALVE

PUMPOUTLET FITTING

6 x 1.0 mm BOLT lPart of tool) 11 N.m 11.1kgf m, 8 lbtftl

4. 5.

Openthe shut-offvalvefully. Openthe pressurecontrolvalvefully.

17-34

SI{UT.OFFVALVE

Steering Wheel Removal

lnstallation

S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a R e v i e wt h e SRScomponentlocations,precautions,and procedures in the SRSsection(24)beforeperformingrepairsor service.

CAUTION: Do not tap on the steering wheel or steering column shaft when installing the stsering wheel.

N O T E :B e f o r er e m o v i n gt h e s t e e r i n gw h e e l .a l i g n t h e front wheelsstraightahead. 1.

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 steeringwheel(seesection24)

2.

Disconnectthe horn connectorand cruise control switchesconnector.

CRUISE SWITCHESCONNECTOR

l,/ 3.

Removethe steeringwheelnut

N O T E :B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,a l i g n t h e front wheelsstraightahead. 1.

B e f o r ei 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 cable reel, Do this by first rotating the cable reel clockwiseuntil it stops.Then rotateit counterclockwise approximatelytwo turns The arrow mark on the cablereellabelshouldpointsstraightup. CAELEREEL

Installthe steeringwheel with the steeringwheel nut. NOTE: Be sure the steering wheel shaft engages the cablereeland cancelingsleeve.

WHEELNUT STEERING Replace. ag N.m {5.0kgt rn, 36lbfft)

Attachthe cruisecontrol switchesconnectorio the steeringwheelcliP, Connectthe horn connector. I n s t a l lt h e d r i v e r ' sa i r b a ga s s e m b l y a, n d c o n f i r m propersystemoperation(seesection24).

1.,

Removethe steeringwheelby rockingit slightlyfrom as you pull steadilywith both hands. side-to-side

C h e c kt h e h o r n a n d c r u i s e c o n t r o l s w i t c h e sf o r properoperatrons.

17-35

Steering Wheel Disassembly/Reassembly

STEERING WHEEL

*@*&*W @,

17-36

SteeringColumn

I

Removal/lnstallation S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e SRScomponentlocations,precautions,and proceclures r e p a i r so r s e r i n t h e S R Ss e c t r o n( 2 4 )b e f o r ep e r t o r m i n g vice. N O T E :B e f o r er e m o v i n gt h e s t e e r i n gc o l u m nf o r S R S , removethe driver'sairbagassemblyand cablereel lsee s e c t i o n2 4 ) . w h e e l( s e ep a g e1 7 3 5 ) . 1 . R e m o v et h e s t e e r i n g 2 . R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d driver'skneebolster(seesection20). 3. Removethe combinationswitchassemblyfrom the s t e e r i n gc o l u m ns h a { tb y d i s c o n n e c t i nt hg e c o n n e c tors. the ignitionswitchconnectors. 4. Disconnect 5 . R e m o v et h e s t e e r i n jgo i n tc o v e r . 6 . B e m o v et h e s t e e r i n jgo i n tb o l l s . 7 . D i s c o n n e ct th e s t e e r i n gi o i n t b y m o v i n gt h e j o i n t toward the column,and removeit from the column shaft. 8 . R e m o v et h e s t e e r i n gc o l u m n b y r e m o v i n gt h e attachinn g u t sa n d b o l t .

UPPER

9. Installationis the reverseof the removalprocedure NOTE: . Makesurethe steeringjoint is connectedas follows: a. Insertthe upper end of the steeringioint onto the steeringshaft (lineup the bolt holewith the flat on the shait),and looselyinstallthe upperjoint bolt. b . S l i p t h e l o w e r e n d o f t h e s t e e r i n gj o i n t o n t o t h e pinion shaft (line up the bolt hole with the groove a r o u n dt h e s h a f t ) ,a n d l o o s e l yi n s t a l lt h e l o w e r joint bolt. Be sure that the lowei joint bolt is securelyin the groovein the pinionshaft. c . P u l l o n t h e s t e e r i n gj o i n t t o m a k e s u r e t h a t t h e steeringjoint js fully seated.Then tightenthe ioint bolts. . 8e sure the wires are not caught or pinchedby any partswhen installingthe column . Make sure the wire harnessis routed and fastened properly. . Makesurethe connectorsare properlyconnected.

STEERINGCOLUMN COMBINATIONSWITCH ASSEMBLY

RETAININGCOLLAB NOTE:Takecarenot to let the retainingcollarfall out of positionduringinstallation. JOINTBOLTS STEERING 22 N.m {2.2kgf.m,16lbtft}

FLANGEBOLTS 22Nm12.2kgl'm,

FLANGENUT 13 N.m {1.3kgl.m.9 lbf ft)

16tbt.tr) UPPERJOINT BOLT Bolt musl line up

COLUMNCOVER

on shaft.

Groove.

JOINTCOVER CLIP

J

LOWERJOINT BOLT 8oh must line up wrth groovearoundon shaft.

17-37

SteeringColumn Inspection NOTE:The tilt steeringcolumn type is shown;the conv e n t i o n asl t e e r i n gc o l u m ni s s i m i l a re x c e p tf o r t h e t i l t mechantsm. Checkthe steeringcolumn ball bearingand the steering joint bearingsfor play and proper movement.lf there is noiseor if there is excessiveplay,replacethe steeringcolumnas an assembly. Checkthe retainingcollar for damage.lf it is damaged,replacethe retainingcollar. Checkthe absorbingplates,absorbingplate g u i d e s and slidingcapsulesfor distonionor breakage. Replacethe steeringcolumn as an assemblyif they are distortedor broken.

ABSORBINGPLATEGUIDES

COLUMNBALL

BEARINGS

SLIDING This part is attachod to the column bracket with the plasticinjections.

1 . Move the tilt lever from the loose positionto lock position 3 to 5 times; then measurethe tilt lever preloadl0 mm {0.4in) from the end ofthe tilt lever. Preload: 70 - 90 N (7 - 9 kgf. 15 - 20 lbf) l f t h e m e a s u r e m e n ti s o u t o f t h e s p e c i f i c a t i o n , adjustthe pfeloadusingthe followingprocedures.

TILTLOCKBOLT Tighten the lock bolt with

a. Loosenthe tilt lever,and set the steeringcolumn in the neutralposition. b. Removethe 6 mm lockbolt and removethe stop. c. Adjustthe preloadby turningthe tilt lock bolt left or flgnr. d. Pullup the tilt leverto the uppermostpositionand install the stop. Checkthe preloadagain. lf the measurementis still out of specification,repeat the aboveprocedures"a" through"c" to adjust. CAUTION:Be caretul not to loosen tho tilt lever when installingthe stop or tightening the 6 mm lock bolt.

1 73 a

the tilt leverraised.

10 mm (0.4inl

9.8N.m (1.0kgl.m,7lbf.ft)

Power Steering Hoses,Lines Fluid LeakageInspection HOSESand LINES . I n s p e c th o s e sf o r d a m a g e ,l e a k s ,i n t e r f e r e n c eo r twisting. . Inspecttluid linesfor damage,rustingand leakage. . Inspectfor leaksat hose and line joints and connections. POWERSTEERING 12 N.m {1.2kgt.m,9lbt.ft}

swtTcH

LINES VALVEBODYUNIT-to-CYLINDER '17N.m 12 tbl.ftl {1.7 LINES VALVEBODYUNIT-Io-FEED/RETURN Feedline:14 x '1.5mm llare nut 37 N.m {3.8 kgJ.m,27 lbf'tt) Return Line Joint 16 x 1.5 mm flare nut 28 N m 12.7kgf.m,20lbtft)

LINES CYLINDERHOUSING-to.CYLINDER 28 N.m (2.7 kgf.m,20 lbf.ft) 8()07 Checkfor leaks.

G€AR8OX andVALVEBODYUNIT for leaksatthematingsurface Check andflarenutconnections, OUTLETHOSE 11 N.m ( 1 . 1k g f . m , 8

tbt (Double RingTypei

PUMPASSEMBLY Checkfor leaksat the pump seal,inletand outletfiftings.

Replacement

1.,

NOTE: pipesecurely . Connecteachhoseto the corresponding until it contactsthe stop on the line.Installthe clamp or adiustableclampat the specifieddistancefrom the hoseend as shown. . Add the power steeringfluid to the specifiedlevelon the reservoirand checkfor leaks.

CAUTION: Check all clamps for deterioration or delormation; replacewith the clamps new ones il necessary.

ADJUSTABLEHOSECLAMP: . P o s i t i o nt h e a d i u s t a b l eh o s e c l a m p s a t t h e p o i n t s indicated(a)in the drawingabove. . Slidethe hoseoverthe line until it contactsthe stop.

HOSECLAMP: . Positionthe hoseclampsat the pointsindicated(b) in the drawingabove. . Slidethe hoseoverthe line until it contactsthe stop.

2.5- 5.5 mm {0.01- 0.22in)

2.0 - 4.0 mm (0.08- 0.16in)

2.5- 5.5mm (0.01- 0.22in)

17-39

PowerSteeringPump RemovaUlnstallation NOTE: Eeforedisconnectingthe hosesfrom the pump, Dlacea suitablecontainerunderthe vehicle.

Connectthe inlet hose and the outlet line. Tiqhten the pump fittingssecurely.

Removethe belt by looseningthe pump mounting b o l t s a n d a d j u s t i n gb o l t ( ' 9 9- ' 0 0 m o d e l s :8 1 6 4 2 EngineTypeonly).

Looselyinstallthe pump in the pump bracketwith mountingbolts and adjustingbolt ('99-'00 models: 81642EngineTypeonly).

1.

OUTLETLINE

11 N.m {1.1kgf'm, 8

1.

Installthepump belt. CAUTION: . Make sure that the power steering belt is proporly positioned on the pulleys. . Do not get power stoering tluid or grease in the power steering bsh or pulley faces.Cleanoff any fluid or greasebefore installrtion.

L

8.

Adjustthe pump belt (seepage 17-32). Fill the reservoirto the upper level line (see page

PUMPMOUNTING BOLT 24 N.m(2.4kgl.m,17lbfft) 2.

Coverthe Ay'Ccompressorwith severalshop towels to protectit from spilledpowersteeringfluid.

3.

Disconnectthe inlet hose and the outlet line from the pump,and plug them. NOTE:Takecare not to spill the fluid on the body or parts,Wipe off any spilledfluid at once.

4.

R e m o v et h e p u m p m o u n t i n gb o l t s a n d a d j u s t i n g b o l t ( ' 9 9 - ' 0 0 m o d e l s :8 1 6 A 2E n g i n eT y p e o n l y ) , then removethe pump. NOTE: . Do not turn the steeringwheel with the pump removeo. . Wrap the opening of the pump with a piece of tape to preventforeign material from entering thepump.

17-40

Disassembly CAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly. NOTE: . Cteanthe disassembledpartswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a solvent. . Alwavs replacethe O-ringsand rubbersealswith new ones beforeassembly. . Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures' . Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem. . Replacethe pump as an assemblyifthe partsindicatedwith asterisk(*) are worn or damaged' FLANGEBOLTS 20 N.m {2.0kgf.m, 14 rbf ft) 4.5mm ROLLER

*OUTERSIOEPLATE

5 mm ROLLER

.PUMP NOTOR }SIDE PLATE

l,/

13 x 1.9mm O-RING Replace.

SNAPRING

*SUB-VALVE 51 x 2.4 mm O-RING Replace. 15.2x 2.4mm O-RING Replace.

PUMPSEAL Replace. PUMPSEALSPAC€R

INLETJOINT

.PUMP DRIVESHAFT BALL BEARING lnspectionand RePlacement, seepage17-43

FLANGEBOLTS 11 N m 11.1kgf.m, 8 rbf.ftl

10 mm CIRCLIP *FLOWCONTROI-VALVE Inspection and Overhaul,

se[ pasett.tz

g

4 seatuc/ J

mm O-RING

--{;'rX!;' $

FI-OWCONTROLVALV€ CAP 49 N.m {5.0 kgt m, 36 rb{.ft)

PULLEYNUT 6il N.m {6.5 kgf.m, 47 tbf.frl

(cont'd)

17-41

PowerSteeringPump Disassembly(cont'dl

Inspection

' t . Drain the fluid from the pump.

Flow Control Valve:

2 . Hold the steering pump in a vise with soft jaws, hold the pulley with the specialtool, and remove the pulleynut and pulley.

1.

Checkthe tlow control valve for wear. burrs, and other damage to the edges of the grooves in the vatve, FLOW VALVE CONTROL

CAUTION: Be careful not to damage the pump housing with the iaws of the vise and extension bar. UNIVERSALHOLDER

for Check to edges. damage Inspectthe bore the flow control valve for scratches or wear. Slip the valve back in the pump, and checkthat it moves in and out smoothly.

Loosenthe flow control valve cap with a hex wrench and removeit. 4. Removethe O-ring,flow controlvalveand spring. 5. Removethe inletjoint and O-ring. 6. Removethe pump coverand pump coverseal. 7. Removethe outer side plate,pump cam ring, pump rotor,pump vanes,side plateand O-rings. lf OK, go on step 4; if not, replacethe pump as an assembly.The flow control valve is not available separately.

8. Removethe snap ring, then removethe sub-valve from the pump housing. 9. Remove the circlip, then remove the pump drive shaft by tappingthe shaft end with the plastichammer. 10. Removethe pump sealspacerand pump seal.

17-4 2

4.

Attach a hose to the end of the valve as shown. VALVE FLOWCONTROL

TIOSE

I

5,

Submergethe valve in a containerof power steering fluid or solvent.and blow in the hose.lf air bubbles leakthrough the valve at lessthan 98 kPa (1.0kgf/cm' ,14.2psi),repairit as follows.

?

i--

,

Ball Bearing: 1.

Inspectthe ball bearingby rotatingthe outer race slowly. lf any play or roughnessis felt, replacethe ball bearing.

AIR PRESSURE

BALLBEARING

POWERSTEERTNG FLUIDor SOLVENT

Hold the bottom end of the valve with a open end wrench. 7.

l./

Unscrewthe seat in the top end of the valve. and removeany shims,the reliefcheckball. reliefvalve and reliefvalvespring.

Removeand discardthe ball bearingusing a press as snown. Installthenew ball bearingusinga pressas shown.

RELIEFVALVE

Ball Boaring Rsplaccmont:

RELIEFCHECKBALL

{W-*"'

Prcrt

SEAT 9 N.m {0.9kgf'm, 6.5 lbt'ftl

RELIEFVALVE SPRING Clampthis end in a openend wrench,

8.

1.,

FLOWCONTROLVALVE

Clean all the parts in solvent, dry them off, then reassembleand retest the valve. lf the flow control valve tests OK, reinstallit in the pump. lf the flow control valve still leaksair, replacethe pump as an assembly.The flow control valve is not available separatelY. NOTE: 11necessary,relief pressureis adjustedat the factorv by adding shims under the check ball seat.lf you found shims in your valve,be sure you reinstallas many as Youtook out.

lnstallwith the red shielded side facing down.

NOTE:Supportthe innerrace with the tool securely.

17-43

PowerSteeringPump Reassembly Coat the pump cover seal and the cover bushing with the power steeringfluid, then installthe pump coverseal into the groovein the pump cover.

1 . Align the pin of the sub-valvewith the oil passage in pump housing.and push down the sub-valve. Installthesnap ring properly. OIL PASSAGE Alignthe pin of

lnstallthe outer side olateover the two rollers.

the oil passage.

ROL1IR

OUTERSIDEPLATE

4.5 mm ROLLER

5 mm ROLLER PUMP HOUSING

SNAPRING

Installthe new pump seal in the pump housingby hand,then installthepump sealspacer. NOTE: Insertthe pump seal with its grooved side facingin. Positionthe pump drive shaft in the pump housing, then drive it in usinga specialtool as shown. Installthe 40 mm circlip with its radiusedside facing out, 40 mm CIRCLIP ATTACHMENT, 30 mm

d

BALL BEARING

gf'uMP

PUMPCOVER

7.

Set the pump cam ring over the two rollerswith the " o " markon the cam ring upward.

PUMPCAM RING

oRrvE sHAFr

/ffi\

ROI,IIR SET HO'"ES

f.\'vj H

PUMPSEALSPACER

n,/ /:K /ZA\.-V

PUMPSEAL Reptace.

ROLl.ERS

17 -44

BUSHING

I

8 . Assemblepump rotor to the pump cover with the " " " markson the rotor facingdown.

't2. Coatthe O-ringwith power steeringfluid. and posi tion it into the pump housing. Installthe pump cover assemblyin the pump houstng.

9 . Setthe 10vanesin the groovesin the rotor. NOTE:Be surethat the round ends ot the vanesare in contactwith the slidingsurfaceof the cam ring.

FI.ANGEEOLTS 20 N.m (2.0 kgf.m, 14 tbf.ft)

PUMPROTOR

PUMPCOVER ASSEMBLY

0 E

51 x 2.4mm Replace.

gn

't4. C o a t t h e f l o w c o n t r o l v a l v e w i t h p o w e r s t e e r l n g fluid.

1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d installit into the groovesin the side plate. 1 1 . Installthe side plateon the cam ring by aligningthe rollerset holesin the side platewith the rollers. r

1 6 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d installit on the Jlowcontrolvalvecap. 1 7 . Installthe flow controlvalvecap on the pump housing, and tighten it.

E

SIDE PLATE

15. lnstall the flow control valve and spring on the pump housing.

15.2x 2,1 mm O-RING Replace.

ROLIIR SETHOTT SET HOI.^E

FLOWCONTROL VALVECAP 49 N.m (5.0 kgj m, 36 tbf.ft)

l ,

ROI.I.ERS

{cont'd)

17-45

PowerSteeringPump (cont'dl Reassembly C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d installit into the groovesin the inletjoint. Installthe inletjoint on the pump housing.

'11N.m (1.1kgt.m, 8 |bnft)

UNIVERSALHOLDER

PULLEY NUT 64N.m{6.5kgf.m,

15.2x 2.4 Replace.

-

EI

I n s t a l lt h e p u l l e y a s s h o w n b e l o w , t h e n l o o s e l y installthe pulley nut. Hold the steeringpump in a vise with soft jaws. CAUTION:Be car€fulnot io damagethe pump housing with the jaws ot the vise.

17-46

21. Holdthe pulleywith the specialtool,and tightenthe pulleynut.

Checkthat the pump turns smoothlyby turning the pulleyby hand.

SteeringGearbox Removal ) NOTE:Usingsolventand a brush,wash any oil and dirt off the valve body unit its lines.and the end if the gearair. box. Blow dry with comPressed 1.

Drainthe power steeringfluid as describedon page

2.

Raisethe front of vehicle, and support it on safety stands in the proper locations(seesection 11.

3,

Removethe front wheels.

4.

Removethe driver'sairbagassembly,and steering wheel(seepage17-35)

5.

Bemovethe steeringjoint cover.

7. Removethe cotter pin from the castle nut {'96 -'97 '00 modslsl and removethe nut. models)or nut ('98-

TIE.RODEND

BALLJOINTREMOVER. 28 mm 07MAC- SLqI2|X)

'98 - '00 mod.b: NUT COTTERPINS Repl6ce.

8 . lnstallthe t0 mm hex nut on the balljoint. Be surethat the 10 mm hex nut is flushwith the ball joint pin end, or the threaded section of the ball joint pin might be damagedby the specialtool. NOTE:Removethe ball joint usingthe specialtool. Refer to section 18 for how to use ths ball joint remover.

6.

Removethe steeringjoint lower bolt, and loosen the steeringjoint upper bolt. Disconnectthe steering joint by movingthe ioint towardthe column

9 . Seoaratethe tie-rodball joint and knuckleusingthe specialtool. CAUnON: Avoid damaging tho ball ioint boot.

1 0 . Removethe left tie-rod end, then slide the rackall the way to the right. 1 1 . Separatethe exhaust pipe A or TWC (seesection 9).

12. Disconnectthe shift linkage(seesection13 or section 14).

t J

(cont'd)

17-47

SteeringGearbox Removal{cont'dl 1 3 . Loosenthe 14 mm flare nut and disconnectthe feed

17. Removethe mountingbrackets.

line. 1 4 . Loosenthe adjustablehose clamp and disconnect the returnhose. t9.

Loosenthe 16 mm flare nut and removethe return hosejoint trom the valve body unit. CAUTION: After disconnecting lhe hos6 and lin6. plug or seal the hose and line with a pioca ol tapa or equivalent to prevenl foreign matorials trom entsring the valve body unit. N O T E : D o n o t l o o s e nt h e c v l i n d e r l i n e A a n d betweenthe valve body unit and cylinder. ADJUSTABLE HOSE CLAMP

1 8 . Pull the steeringgearboxall the way down to clear the pinionshaftfrom the bulkhead.then removethe pinionshaftgrommet. Move the steering gesrbox to right so the left rack end clearsthe rearbeam,then tilt the left side down to remove it from the vehicle,

1 6 . Removethe stiffenerDlate.

CAUTION: Be careful not io bend or damage the fagd ling and cylindsr lin99 whgn rgmoving thg ggarbox,

NOTE: Some stiffener plate attaching bolts are also used as gearboxmounting bolts.The gearboxwill tilt to sidewhen theseboltsare removed.

STEERINGGEANEOX

17-48,

Disassembly )

Holdthe steeringrackwith a wrench('98-'00 models: left end only), and unscrewthe rack end with anotherwrench.

Steering Rack DisassemblY NOTE: the gearbox,wash it off with sol r Beforedisassemble vent and a brush. . Do not dip sealsand O-ringsin solvent. 1.

Removethe steeringgearbox(seepage 17-47]..

2.

Removethe tie-rodend and locknut.

3.

Removeair tube and cliPs.

CAUTION: Be caroful not to damage the rack 3urfaco whh the wrench. NOTE:'96 -'97 modelsis shown. LOCKWASHER

STEERINGRACK END

STEERINGRACK

t ) Loosen the locknut, then remove the rack guide screwand O-ring('96-'97 modelsonly)

Removethe boot bands and tie-rod clips Pull the bootsawayfrom the endsof the gearbox. 7.

Removethe springand the rackguidefrom the gear housing.

BOOT

(|-,

TIE.RODCLIP

{cont'd}

17 -49

SteeringGearbox Disassembly(cont'd) 8. RemovecylinderlinesA and B from the gearbox.

11. Drill a 3 mm (0.12in) diameterhole approximatety 2.5 - 3.0 mm (0.10- 0.12 in) in depth in the staked point on the cylinder.

cAunoN: o Do nol allow metal shavings to onter the cylin. der housing. . After romoying iha cylinder end, remova any bur6 at the staksd point.

Dcpthi 2,5 - 3.0 mm {0.10- 0.12in}

CYLINDERLINEg

CYLINOCR LINEA

Drain the fluid from the cylinderfittings by slowly moving the steering rack back and forth,

CYUNDER

1 0 . Removethe two flange bolts, then remove the valve body unit from the gearbox. (See page 17-52for valve body unit disassembly.)

VALVEBOOYUNIT

FLANGEBOLT

1 2 . H o l d t h e s t e e r i n g g e a r b o x u s i n g a C - c l a m pa s snown.

'96 - '97 mod.ls: 32 mm SHIMS '00 98 modok: WAVE WASHER

13. Loosenand removethe cvlinderend.

17-50

t

14. Assemblea 12 x 1.25mm flangenut onto a 12 x 175 mm grade 10flangebolt as shown. N O T E :W r a p t h e t l a n g e p o r t i o n o f t h e b o l t w i t h vinyl tapeto protectthe cylinder.

18, Removethe 12 mm bolt and nut from the steering rack, 1 9 . R e m o v et h e c y l i n d e re n d s e a l f r o m t h e s t e e r i n g racK. HOUSING CYLINDER

Replace. | | mm FLANGE 12, BOLT

VINYLTAPG {p/N 90i77 - SLo- 000} 12 mm FLANGENUT

Installthe flange bolt into the end of the steering r a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h e 'll4 turn. Hold the flange bolt, and flange bolt out tightenthe flangenut againstthe rackby hand. 1 6 . Installthe bearingseparatoron the gearboxhousing a5snown. t5.

12 x 175 mm

Ptess

FLANGEBOLT

t./

BEARINGSEPARATOR 0 - 1112"I lCommerciallyavailablo)

J__--',----)t' ,-----'" ,-,-'-' fiN\\ ----'

| .Wl'---t

I|

-'4a

^--.'--4

A ooY----\ * srerhtncnact Q)

20. lnserta 24" long,3E" drive extensionand the specialtool into the cylinderfrom the gearboxsrcle. NOTE: Make sure that the specialtool is securely positionedon the backupring edges' CAUTION: Be caroful not damago to inner surfaco of the cylinder housing with the specisltool' 21. Set the gearboxin a press,then pressout the cYlinder end sealand backupring from the gearbox, GAUTION: . Keepthe tool sttaight to avoid damagingthe cylin' der wall. Checkth€ tool angls, and corr€st it if nec€ssary,whon rsmoving the cylinder snd seal. . Uss a pross to removs tho cylinder end seal. Do not try to removo ths seal by striking the tool h will br€ak the backup ring. and the cylinder snd s€alwill lemain in tho gearbox. Pross

STEERINGRACK CYLINDEREND SEAL

1 7 . Set the gearboxin a pressso the gear housingpoint upward,then pressthe cylinderend seal and steering rackout of the gearbox NOTE:Hold the steeringrackto keep it from falling when pressedclear.

1.,

CAUTION: . Be carsful not damage to inn6l surfaceot the cylinder housing with the flange bolt. . Do not place your lingers under th€ ste€ring rack.

BACKUPRING CYLINDEREND SEAL

CYLINDEREND SEAL REMOVERATTACHMENT 07NAD- SR3020A

(cont'd)

17-51

SteeringGearbox (cont'dl Disassembly 22. Carelullypry the pistonseal ring and O-ringoff the prslonrack. CAUTION| Be caletul not to damage the inside of seal ring groove and piston edges when removing the sealrin9,

Valve Body Unii Disassembly 23. Eeforeremovingthe valvehousing,applyvinyl tape to splinesof the pinionshaft. 24. Separatethe valve housingfrom the pinion shaft/ valveusinga press.

VALVEHOUSING

Vinylt.pe

PINIONSHAFT Replace.

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. NOTE: T h e r em a y b e t h e s l i d i n gm a r k sf r o m t h e s e a l r i n g o n t h e w a l l o f t h e v a l v e h o u s i n g .R e p l a c e the valvehousingonly if the wall is stepped. When the valve housingis replaced,jnstallnew shim(s)on the bearingsurfaceof the housingto adjustthe thickness. Checkthe inside of valve housing whether the wall is stepped.

17-52

I 2 6 . C h e c kf o r w e a r . b u r r s a n d o t h e r d a m a g et o t h e edgesof the groovesin the sleeve' NOTE:The pinion shaft and sleeveare a precision m a t c h e ds e t l f e i t h e rt h e p i n i o n s h a f t o r s l e e v e must be replaced,replaceboth partsas a set' SLEEVESEALRINGS Checkfor Peeloff or damage.

28. Usinga cutteror an equivalenttool, cut and remove the lour seal ringsfrom the sleeve' CAUTION: Be careful not to damage the edges of the slgevs grooves and outer surface whsn lemoving the seal rings. SLEEVE

29. Using a cutter or an equivalenttool, cut the valve

l./

27. Removethe circliPand Pinion shaft sleevefrom the pinionshaft.

seal iing and O-ringat the groovethe pinion shaft' Removethe valvesealring and O-ring' CAUTION: Be careful not to damage the edges oI the pinion shaft gloove and outer surface when removing the valve seal ling and O-ring'

Cutting slot Posrtlon.

1.,

VALVESEALRING Replace.

(cont'd)

-r l

rt t r -99

.<

SteeringGearbox Disassembly(cont'd) 30. Bemovethe valveoil sealand backupring {'96-'97 models)or wave washer('98-'00 models)from the oinionshaft. NOTE: . Inspectthe ball bearing by rotating the outer race slowly. lf there is any excessiveplay, replacethe pinionshaftand sleeveas an assembly. . The pinion shaft and sleeve are a precisefit; do not intermix old and new pinion shaftsand steeves. BALLBEARING

'98- '(x) mod.lr: WAVEWASHER

Replace.

3 1 . Pressthe valve oil seal and roller bearing{'96 -,97 m o d e l s lo r b u s h i n g( ' 9 8 - ' 0 0 m o d e l s lo u t o f t h e valve housing using a hydraulicpress and special tool shown below. NOTE: Do not use a hammer; it will damage the specialtool. '96 - '97 modob: PILOTCOLLAR 07GAF- PH70100 VAI.VE OIL SEAL Replace. BOI.I"ERBEARING Replace. '96 - '00 mod.b:

PILOTCOLLAR 07GAF- PHtoroo VALVEOII.SEAL Replace. BUSHING Beplace.

17-54

Reassembly

)

NOTE: parts in a solpartswrth a solvent,and dry them with compressedair. Do not dip the rubber . clean the disassembled vent. . Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly' in the assemblyprocedures' . Applythe recommendedpowersteeringfluid to the parts+ndicated power steeringsystem. the to enter materials foreign o Do not a||owdust,dirt, or other necessary' where tools a Usethe appropriatespecial CYLINDERLINE A FLANGEBOLTS 20 N.m (2.0kgt'm, 14lbf ftl CYLINDERLINEB VALVEHOUSING

FLARENUTS 28 N.m (2.7ksf m,20 lbf ftl

VALVEOILSEAL Replace.

--, ''*^'*-1$*€-/s6-,,mode,3: *--fitllTllli".",'r'o,.n,ft EUSHING Replace ..-------...... SLEEVESEAL RINGS

'P'\--

l./

Replace.

lss-,

"o. Xll,Y5"l'.--r...- gY------..r.u,

CYLINDEREND SEAL Replace.

,-f-..-S:

_

--€l€--------=- 'oo ,,iod"t., -s-'---------

BACKUP Replace.

I ,

",a"a,,

SS

Replace.

BEARING

.----

HOUSING CYLINDER , / GEARHouslNG _\-j

d

// AJ ,S-'..l.g

.,_-\ t\

-\--'\-

F

s

ircriip'ii.rt'-

vALvE SEALR'NG

-.-.-r_

wAvEwAsHER

,96 _,9? models:

i"pru"". -\

O.RING ReDtace.

\ntonsrnrr 97 models onlY:

S_.<---,tj-

n"prac".

)@OOD m\ CYLINDEREND SEAL

/'\N,."._

nrNG

I

'98- 'oo models:

-

RACKGUIDE

\

:scREw I O.RING Replace. .98- '00 models: CYLINDEREND 69 N.m {?.0kgt'm,51 lbl'ft)

t J

(cont'd)

17-55

SteeringGearbox (cont'd) Reassembly Valve Body Unit Reassembly 1. Apply vinyl tape to the steppedportion of the pinion shaft,and coatthe surfaceof the vinyl taoe with the powersteeringfluid. 2. Installthe backup ring ('96 -'97 models)or wave washer ('98 -'00 models)with its taperedside as shown below. 3. Coat the inside surface of the new valve oil seal with powersteeringfluid. 4. Slidethe valve oil seal over the pinion shaft,being carefulnot to damagethe sealinglip. Vinyl t.po {Steppedponion}

'96 - '97 models:

8. Apply power steering fluid to the surface of the v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n shaft. 9. Apply power steeringfluid to the insideof the special tool. Set the largerdiameterend of the special tool overthe valveseal ring. 10. Move the specialtool up and down severaltimes to makethe valvesealring fit in the pinionshaft. 11, Removethe soecialtool. 12. Turnthe specialtool over,and set the smallerdiameter end of the specialtool over the valve seal ring. Move the specialtool up and down severaltimes to m a k et h e v a l v e s e a l r i n g f i t s n u g l y i n t h e p i n i o n shaft.

Tap6redposition.

BACKUP

PISTONSEALBING SIZINGTOOL 07NAG - SR:togoA

Grooveside.

ol

surethe springis seatodin the oil seal.

07NAG - SR3|X)00

lip

'98 - '00 mod.b:

CAUTION: InstEllihe valve oil seal whh its groov.d 3ide tacing opposite tho boaring.

7.

Apply vinyl tape to the splinesand steppedportion of the shaft, and coat the surface of the vinyl tape with the powersteeringfluid. Fit the new O-ringin the grooveof the pinionshaft. Then slide the new valve seal ring over the shaft and the groovein on the pinionshaft. Removethe vinyl tapefrom the pinionshaft,

VALVESEALRIiIG Replace. Do not over-expand.

17-56

(g(m Usethe larger diameter end of the special tool first to make the valve seal ring fit in the pinion shaft.

Makethe valvesealring fit snuglyin the pinion shaftusingthe otherend (smallerdiameterend)of the specialtool.

I Apply power steeringfluid to the surfaceof the specialtool. Setthe new sealrings over the 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; the sealring. Installtheresin . Do not over-expand 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 sleeveseal rings: black and brown. Do not mix the different types of sleevesealringsas they are not compatible

pin18. Apply power steeringfluid to the surfaceo{ the pinion shaft the ion shaft.Assemblethe sleeveover b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e sleevewith the cutout in the shaft.Then installthe new circlipsecurelyin the pinionshaftgroove' NOTE: B e c a r e f u l n o t t o d a m a g et h e v a l v e s e a l r i n g when insertingthe sleeve. Installthecirclipwith its radiusedsidetowardthe sleeve.

1 4 . Setthe specialtool in the groovesin the sleeve,and set eachring in eachgroovesecurely. NOTE: After installation,compressthe seal rings with your fingerstemPorarilY BALLJOINT BOOI CLIPGUIDE 07S7,1-SA50800 SLEEVE

'19. Apply power steeringfluid to the seal ring lip of the valveoil seal.then installthe sealin the valve housi n g u s i n g a h y d r a u l i cp r e s s a n d s p e c i a lt o o l s a s shown. CAUTION: Install the valve oil seal with its grooved side facing the tool. 15. Apply power steeringfluid to the seal rings on the sleeve,and to the entire insidesurfaceof the specialtool. 16. lnsertthe sleeveinto the specialtoolslowly' 1 7 . M o v e t h e s l e 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'

Pre3s

DRIVER 07749- 0010000

ATTACHMENT. 32x35mm 0774.6- q)101(x)

I

NOTE: Be surethat the seal ringsare not turned uP. SITEVESEALRING SIZINGTOOL or 0797a- SA5020A 07974- SA50200

fr

J

VALVEOIL SEAL Replace. Makesurethe springis in the oil seal. (cont'd)

17-57

SteeringGearbox (cont'd) Reassembly 20. Pressthe new bearing ('96 - '97 models) or new

bushing ('98 -'00 models)into the valve housing usinga hydraulicpressand specialtool as shown,

NOTE:Placethe rollerbearing('96-'97 models)on the valve housingwith the stampedletterfacingup towardsthe valveside. DRIVER Pr033 077itg-001tXlOO

+

ATTACHMENT, 3:Ix35mm 07746- 0010,t(x)

'96 - '97 models: ROLLERBEARING Letterstampedtace upward.

'98 - '00 modob:

?/_vusHrNG ['---v-lt \4) 21. Apply vinyl tape to the pinion shaft.then coat the vinyltape with power steeringfluid. Sealing lip face.

VALVEOIL SEAL

VALVEHOUSING

PINION

SLEEVESEALRINGS Replace. 8e surethat the sealnngs are not turnedup, then install.

E

22. Insertthe pinionshaft into the valvehousino. CAUTION: Be careful noi to damage th€ valve seal rings. 23. Removethe vinyltapefrom the pinionshaft.

17-5A

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 pressas shown. N O T E : C h e c kt h a t t h e p i n i o n s h a f v s l e e v et u r n s smoothlyby turningthe pinionshaft.

) Steering RackReassembly 25. Coatthe pistonseal ring guide with power steering fluid,then slideit onto the rack,big end first'

31. Wrap vinyl tape aroundthe rackteeth and rackend edges,then coat the surfaceof the tape with the powersteeringfluid NOTE: Make sure that the vinyl tape is wrapped carefullyso that thereis no steppedportion

26. Positionthe new O-ringand new pistonsealrlng on the specialtool, then slide them down toward the big end of the tool NOTE: . Do not over expand the resin seal rings lnstali the resin ;eal rings with care so as not to damage them. After installation,be sure to contract the seal ring usingthe specialtool(sizingtool) . Replacethe piston'sO-ringand sealring as a set' 27. Pull the O-ringoff into the piston groove,then pull the pistonsealring off into the pistongrooveon top ol the O-ring PISTON

PISTONSEALRING GUIDE 07GAG- SD4O10Aol 07GAG- SD,ol(xt

Coatthe insidesurfaceof the new cylinderend seal with power steeringfluid. Installthe cylinderend seal onto the steeringrack with its groovedsidetowardthe piston. CAUTION:When installingthe cylinder end seal, be caieful not damagethe sealing lip face of tho seal with the edgss or teeth of th€ ste€ring rack' CYLINDEREND SEAL

Coatthe piston seal ring and the insideof the specialtoolwith powersteeringfluid. Carefullyslide the tool onto the rack and over the pistonsealring. Move the specialtool back and forth severaltimes to makethe pistonsealring fit snuglyin the piston'

PISTON Replace.

E

Make sure the sPring is in the cylinder end soal

Removethe vinyl tapefrom the steeringrack NOTE:Removeany residueoftape adhesive (cont'dl

17-59

SteeringGearbox Reassembly{cont'd) 3 5 . I n s t a l lt h e n e w b a c k u pr i n g o n t h e s t e e r i n gr a c k , then placethe cylinderend sealto piston. BACKUPRING

37. Installthe flange bolt into the end of the steerino r a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h l f l a n g e b o l t o u t 1 / 4t u r n . H o l d t h e f l a n g eb o l t a n d tightenthe flangenut againstthe rackby hand. 38. Installthe cylinderend seal into the bottom of the c y l i n d e rb y p r e s s i n go n t h e b o l t w i t h a p r e s sa s shown. CAUTION: Do not push on the boh with excessive force as it may damage tho cylinder end seal. Preas

12 x 175mm FLANGEBOLT {P/N 90177- SLo - 000}

36. Greasethe steeringrackteeth,then Insenthe steer-

12 mm FLANGENUT

ing .ack into the gear housing.

CAUTION: Be careful not to damage to inner surface of the cylindsr housing with the rack edges.

?q

R e m o v et h e f l a n g e b o l t . a n d c e n t e rt h e s t e e r i n g rack. W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s .a n d coatthe surfaceof the tape with the power steering fluid. NOTE: Make sure that the vinyl tape rs wrapped carefully so that there is no stepped portion.

17-60

) 4 1 . Coatthe insidesurfaceof the new cylinderend seal with power steeringfluid. Installthe cylinderend seal onto the steeringrack with its groovedsidetowardthe piston' Pushin the cylinderend sealwith your finger' CAUTION:When installing the cylinder end sesl' be carelul not damage the sealing face ot the seal with the threads and burrs at the staked position oI the cylinder housing.

tr

ENDSEAL CYLINDES Replace. Makesurethe sPring end seal is in the cylincler

CYLINDEREND SEAL

Removethe vinyl tapefrom the steeringrack' NOTE:Removeany residueoftape adhesive Holdthe steeringgearboxusinga C-clampas shown' C-CLAMP:

GEARBOX

46. C o a t t h e i n s i d es u r f a c eo f t h e c y l i n d e re n d w i t h power steeringfluid,then installthecylinderend by screwingit into the cylinderhousang. 4 7 . Removethe C-clampfrom the steeringgearbox' After tighteningthe cylinderend' stakethe point of -'00 t h e c y l i n d e rh o u s i n gs h o w n b e l o w F o r ' 9 8 modelsgo to step51. NOTE: Stakethe cylinder in the position opposite from where the stake was removed during disassemoly. Stake point. Depth: 1 0 mm (0.04in)

Be carefulnot to damage the bushingwhen inserting the cylinderend.

-'97 model only)' 49. Selectthe 32 mm shim(s)('96 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 steeringgearboxis reassembledwithout replacingthe pinionshatt,valve housing,and gear box housingwith new ones. l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x housingare replaced,selectthe new shim{s)as follows. Shim selection: a. Set the four 32 mm shims on the bearingsurfaceof t h e g e a r b o xh o u s i n g .T o t a l t h i c k n e s so f t h e f o u r shimsshouldequalno more than 0 70 mm' 010 mm' Shim set: four 32 mm shims (Thickness: 0.15mm, 0.20mm, 0.25mm respectivelyl CAUTION: Th€ four 32 mm shims do not have thickness identification marks Measure the thickness of each shim using a micrometsr, and mark the shim lor identification.

l-,

(cont'd)

17-61

SteeringGearbox (cont'd) Reassembly b.

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 specifiedtorque.

VALVEBODYUNTT

FLANGEBOLT 20 N.m {2.0ksl.m, 14lbI.ftl

Example: Measurementis 0.28mm (0.011in): 0.70- O.28= 0.42mm (0.028- 0.011= O.Ot7inl The selectedshims should be 0.28 mm lO.OtOin) and 0.15mm {0.006in} in thickness. lf the r€quired shim thicknessis 0.10 mm or less, no shims are necessarv. 50. Sot the selected32 mm shims (,96 - ,97 models only) on the bearingsurfaceofthe gearbox housing. FLANGE BOLT 20N.m12.0ksf.m,1l lbtftl VALVEBODYUNIT

O-RING Replace.

Measurethe clearancebetween the gearbox and valvebody unit usinga feelergaugeas shown.

-A-l

NOTE:Measurethe clearanceat the point midway betweenthe two mounting bolts. '96 - 37 modsl3 only: 32 mm SHIMS {S.loctod numb.r of 3him!l NEEDLEBEARING

-R1 5 1 . Coat ths new O-ring with grease,and carefully fit it on the valvehousing. Apply greaseto the needlebearingin the gearbox housing. D e t e r m i n et h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m shims by subtractingthe clearanceobtainedin the step "c" from the total thicknessof the four shims. ( T o t a lt h i c k n e s so f t h e 4 s h i m s )- ( C l e a r a n c e=) Requiredthicknessof the shims

EA

NOTE:Selectthe shims so that the total thickness is closeto. but lessthan,the requiredthickness,

54. Tighten the flange bolts to the specifiedtorque.

17-62

Installthe valve body unit on the gearboxhousing by engagingthe g€ars. NOTE: Note the valve body unit installationposition (directionof line connection).

) 55. InstallthecylinderlinesA and B. NOTE: . C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e s A a n d B thoroughly. The joints must be free of foreign materlal. . Installthe cylinderlinesA and B by tightingthe flare nuts by hand first, then tighten the flare nutsto the specifiedtorque. 17 N.m {1.7 kgt'm, 12 lbl.ft)

6 0 , l n s t a l lt h e n e w l o c k w a s h e ri n t h e g r o o v e i n t h e steeringrack. 61. Screweachrackends into the rack' -'00 mod62. Holdthe steeringrackwith a wrench('98 ends' rack els:left end onlY),and tightenthe CAUTION: Bo cateful nol to damage ihe rack surface with the wranch. '96 -'97 model is shown. NOTE: LOCKWASHER

RACKEND STEERING 54N'm t5 5 kgtm' 40lbl'ft)

28 N.m (2.7 kgf m,20 lbf ftl

CYLINDERLINE8

STEERINGRACK

CYLINDERLINEA

56. Greasethe sliding surface of the rack guide, and installit onto the gear housing '97 models: 5 7 . 36 Apply a thin coat of greaseto the new O-ring,and installit on the rackguidescrew. 38 - '00 models: Remove the old sealant off of the threaded section, then apply new sealantall aroundthe threads 58. Installthe spring, rack guide screw and locknuton the gear housing. Adjustthe rackguide screw(seepage17-33)' NOTE:After adjusting,checkthat the rack moves smoothlyby slidingthe rackright and left'

-Gl

'1 r

After tighteningthe rack ends, stakethe four sections of lockwasherwith a drift and a mallet. Placethe wood block on the presstable. then set the lock washer section of the rack end on the wood block securelY. Be sure the tool is alignedwith the flst sections of the steeringrackend belorepressing. Stake the lock washer in the center ot the flat section of the steering rack end.

l:. 1

O.BING Replace.

NOTE:Thisdrift hasa flat, to preventpuncturing

l /

WOODENBLOCK

LOCKNUTS {cont'd}

17-63

SteeringGearbox (cont'dl Reassembly 64. Apply greaseto the circumferenceof the rack end housing.

67. Adjust the air hose fitting positionof the boots bv turningit as shown below.

LEFTBOOT (Viewedfrom the left side)

RIGHTBOOT {Viewedfrom the right side)

RACKEND GROOVE

=^.

#-q!:s!!H SILICONEGREASE

AIR HOSEFITTING

A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t grooveson the rackends. 66. lnstall the boots in the rack end with the tie-rod clips. NOTE:Installthe boots with the rack in the straight ahead position (right and left tie-rodsare equal in length).

Install new boot bands on the boot, and bend both sets of locking tabs. CAUTION: Stlke ths band locking tabs firmly.

RACK END

NOTE: Wipe the greaseoff the threadsection.

Lightlytap on the doubled-overportionsto reduce their height. Slide the rack right and left to be certainthat the boots are not deformed or twisted. TIE.RODCLIP

17-64

lnstallation 7 1 . C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t boot. lnstallthe clipson the cylinderlines'then clampthe air tube with the cliPs.

CAUTION: Be carelul not to bend or damage the feed line and cylinder lines when installing the gearbox' 1,

Beforeinstallingthe gearbox,slide the rack all the way to right.

2.

Installthe mounting cushion on the steeringgearDOX.

CYLINDERLINE A

Installthe pinionshaftgrommet,then insertthe pinion shaft up throughthe bulkhead. NOTE:Align the notch in the pinion shaft grommet with the tab on the valvehousing.

CLIP

l./ I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t t n g cushion,then installtwogearboxmountingbolts' MOUNTINGBRACKET

cusHroN

l-,

NOTE:Installthe bracket with the arrow Pornllng towardthe front.

39 N.m (4.0kgj m, 29 lbtftl

(cont'd)

17-65

SteeringGearbox (cont'dl Installation 5.

I n s t a l l t h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x mountingboltsand stiffenerplateaftachingbolts. CAUTION: Be sure the air tube is not caught or pinched by stiffener plate, N O T E :I n s t a l lt h e b o l t s l o o s e l yf i r s t , t h e n t i g h t e n them securely.

9 . Centerthe steeringrackwithin its stroke. 1 0 . Slip the lower end of the steeringjoint onto the pinion shaft (lineup the bolt holewith the groove aroundthe shaft),and tightenthe upper and lower steeringjoint bolt. NOTE: . Connectthe steeringshaft and pinion with the cablereeland steeringrackcentered. . Be surethat the lower steeringjoint bolt is securely in the groovein the steeringgearboxpinion. . lf the steeringwheel and rack are not centered, r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e steeringjoint. STEERING JOINT UPPERBOLT 22 N.m (2.2kgf.m, 16 tbt.ftl

ATTACHINGAOLTS 38 N.m 13.9kgf.m, 28 lbf.ftl MOUNTINGBOLTS (} N.m (4.a kgt m, 32 lbf.ftl

6.

Installthe returnhosejoint by tighteningthe l6 mm f l a r en u t .

7.

Connectthe relurn hose securely,and tighten the a d j u s t a b l eh o s e c l a m p f r o m t h e e n g i n ec o m p a r t ment.

8.

C o n n e ctth e f e e d l i n e a n d t i g h t e nt h e 1 4 m m f l a r e nut. NOTE:Makesure that there is no interference betweenthe fluid lines,the rear beam or any other parts. ADJUSTABLEHOSE CLAMP (seepage17-39)

16 mm FLARENUT 28 N.m {2.9 ksl.m. 20 lbf.ft)

RETURN

1a mm FLARENUT 37 N.m (3.8kg{.m,27 lbt.ftl

17-66

PINIONSHAFT

Groove, STEERINGJOINT LOWERBOLT 22 N.m (2.2kgt.m,16lbtttl

1 1 .Centerthe cable reel by first rotating it clockwise u n t i l i t s t o p s .T h e n r o t a t ei t c o u n t e r c l o c k w i s e (approximatelytwo turns) until the arrow mark on the label points straight up. Reinstallthe steering wheel (seepage17 35).

) 12, Installthe steeringjoint coverwith the clampsand a clrp.

1 4 . Installthe exhaustpipeA or TWC (seesection9). 1 5 . Connectthe shift linkage(seesection13 or section 14). 1 6 . lnstallthe front wheels 1 7 . Fill the systemwith power steeringfluid, and bleed air from the system(seepage17-331

1?

the tie-rodendsto the steeringknuckles, Reconnect tightenthe castlenut ('96-'97 models)or nut ('98 'OOmodels)to the specifiedtorque,and installnew cotter plns.

performthe followingchecks 1 8 . After installation, . S t a r t t h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e steeringwheel from lock-tolockseveraltimes to warm up the fluid. Checkthe gearboxfor leaks (seepage17-39). . Adjustthe front toe (seesection18). . Checkthe steeringwheel spokeangle.Adjust by turningthe right and lefttie-rods,if necessary. NOTE:Turn the right and lefttie-rodsequallv

NOTE: Before connectingthe tie-rod ends, wipe off from the ball joint tapered any greasecontamination sectionandthreads.

t r

CAUTION: Torquo the castle nut to the lower torque sp€cification, then tighten it only tar enough to align the slot with the pin hole. Do not align the nut by loosening{,96-'97 modelsonly). NE-RODEND

'96 -'97 models:

CASTLENUT 40 - a8 N'm (4.0- 4.8 kgf'm, 29 - 35 lbf.ftl

\

COTTERPINS Replace. On reassembly,bend the cotterPin6s shown. '98 -'00 mod€ls:

NUT &l N.m {a.5kgf'm,33lbl'ftl

(l-, 17-67

Balljoint Boot Replacement '96 - '97 models:

'98 - '00 models:

1.

CAUTION:Do not contaminatothe boot installation section with grease.

Removethe boot set ring and the boot. CAUTION:Do not contaminatethe boot installa. tion section with grsase.

2.

Packthe interiorof the boot and lip with grease.

3.

Wipe the greaseoff the sliding surfaceof the ball pin,then packthe lower areawith freshgrease. CAUTION: . Keep greaseoff the boot installation seciion and the tapered s€ction ot the ball pin. . Do not allow dust, dirt, or oth6r foreign materials to 6nt8r the boot. LIP

EALLPIN TAPERED SECTION Wipe off the grease.

-6lr SECTION Wipe off the grease.

4.

BOOTINSTALLATION SECTION Wipeoff the grease

1.

Removethe boot from the tie-rodend, and wiDethe old greaseoff the ball pin.

2.

Packthe lower area ofthe ball pin with fresh grease.

3.

Packthe interiorof the new boot and liD with fresh grease. CAUTION: . Keop groasc ott tho boot installalion sestion and th. iapored s.ction if th€ ball pin. . Do not allow dust. dirt, or other foreign materials to entor tho boot.

LtP .6r

J_/

ru BOOT INSTALLA SECTION Wipe off the gr€ase,

Installthe boot in the grooveof the boot installation sectionsecurely,then bleedthe air from the boot. Installthe new boot usingthe specialtool as shown below.

ADJUSTINGBOLT Adjustthe depth by turningthe bolt.

NOTE: The boot must not be a gap atthe boot instal lation sections. FRONTHUB DIS/ASSEMBLYTOOL 07965 - SA5o500

SETRING

Adjust the specialtool with the adjustingbolt until the end of the tool aligns with the groove on the boot. Slidethe set ring over the tool and into posiUOn.

CAUTION: After installing the boot, qhsck the ball pin tapered section for grease contamination and wipe it it necGsary.

17-68

CAUTION: Aftor installing the boot, chock the batl pin tapgred section tor grgase cortamination. and wipe it it n€ces3ary.

Suspension

)

l r

18-2 ............. SpecialTools ComponentLocations ......f8-3 lndex ,,.............. Alignment Wheel .......18-4 Caster.............. .................. l8-4 Camber Front Toe Inspection/ ........18-5 Adiustment RearToe lnspection/ ........18-5 Adiustment 18-6 TurningAngleInspection................ Wheel/HubInspection l8-7 BearingEnd P|ay.............................. .......18-7 WheelRunout Front Suspension SuspensionArms Replacement ('96- 99 modelsl.......................... 18-8 SuspensionArms Replacement ('992D Si and Si-Rmodels) ........18-9 18-10 Knuckle/HubReplacement............. Lower Ball Joint Replacement.......18-16 .......... 18-17 BallJoint Boot Replacement

Front Damper 18-17 ................. Removal 18-18 .................. Disassembly/1nspection ........... 18-19 Reassembly 18-19 ............. lnstallation RearSuspension SuspensionArms Replacement ('96- 99 models)....................,..... 18-21 SuspensionArms Replacement ('992D Si and Si-Rmodels) ........1A-22 Hub BearingUnit Replacement......18-23 UpperArm Eushing .....18-25 Replacement RearDamper ................. 18-26 Removal .....1A-27 ............. Disassembly/|nspection ........... 18-28 Reassembly 18-29 ............. lnstallation

SpecialTools

Ref. No.

Tool Numbor

o

07GAF- SE00200 07GAF- SE00401 07GAG- SD40700 07JAF- SH201l0 07JAF- SH20120 07JAF- SH20200 07MAC- S100200 07746- 0010500 07749- 0010000 07947- 6340201 07965- SB00100 07965- 5800200 07965- SD90100 07974- SA50700

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Description Hub AssemblyGuideAttachment Hub DivAssemblyBase BallJoint BootClip Guide Hub Dis/Assembly Pilot,38 mm Hub Dis/Assembly Shaft,22.4x25.4 mm BallJoint RemoverBase BallJoint Remover,2Smm Attachment,62 x 68 mm Driver Driver Attachment EallJoint Remover/lnstaller BallJoint InstallerBase SupportBase BallJoint BootClip Guide

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1a-2

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Oty

PageReteronc€

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1 1 1 1 1 1 1 1 1 1 1 I 1

1 8 -1 4 18-17 1 8 -1 4 1 8 -1 4 18-16 1 8 - 1 21, 3 18-14 1 8 -1 4 1 8 -1 5 1 8 -1 6 1 8 -1 6 18-15 1 8 - 1 61, 7

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ComponentLocations lndex ) W h e e l A l i g n m e n t ,p a g e l 8 4

Front Suspension: FBONTDAMPER . Removal,page18-17 . Disassembly/lnspection, page18-18 . Reassembly, page18'19 . Installation, page18-19

UPPERARM ' Replscement, page18-8

KNUCKLE/HUB . Replacement, page18'10 . WheelBearingReplacement, page18-14 . LowerEallJointReplacement, page18-16

BAR STABILIZER ' Replacement, page18-8

LOWERARM . Replacement, Page18-8

Rear Suspsnsion: REARDAMPEB . Removai.page18-26 . Disassembly/lnspection, page 18-27 . Feassembly, page lS-28 . Installation, page18-29 UPPERARM ' Replacement, page18 20

LOWERARM . Replacement,page 18-20

l-,

ARM . Feplacement, page18 20

TRAILINGARM ' Replacement, page18-20

18-3

WheelAlignment Caster

Camber

N O T E :F o r p r o p e ri n s p e c t i o n / a d j u s t m eonf t h e w h e e l alignmentcheckand adjustthe following beforechecki n gt h e a l i g n m e n t .

lnspection

. . . .

Checkthat the suspensionis not modified. Checkthe tire sizeand tire pressure. Checkthe runoutof the wheelsand tires. Checkthe suspensionball ioints.{Hold a wheel with your hands and move it up and down and right and leftto checkfor wobbling.)

N O T E :U s e c o m m e r c i a l l y - a v a i l a b l em p u t e r i z efdo u r co w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w the equipmentmanufacturer's instructions. 1 . C h e c kt h e c a m b e ra n g l e . Camberangle: Front: 0'00' j 1" Rear:-1"11" 2.

Inspection N O T E :U s e c o m m e r c ilal y - a v a i l a b lceo m p u t e r i z efdo u r w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t { c a s t e rc. a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w the equiDmentmanufacturer's instructions. 1 . Checkthe casterangle. Casterangle: 1',10'I 1' 2.

lf out of specification,checkfor bent or damaged suspensron components.

18-4

lf out ol specification,checkfor bent or damaged suspensron components.

,f,

Front Toe Inspection/Adiustment

RearToe Inspection/Adiustment

N O T E :U s e c o m m e r c i a l l y - a v a i l a bc loem p u t e r i z efdo u r w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n g a n g l e ) .F o l l o w instructions. the equipmentmanufacturer's

co l em p u t e r j z e Ido u r N O T E :U s e c o m m e r c i a l l y - a v a i l a b w h e e l a l i g n m e n te q u j p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w instructions. the equipmentmanufacturer's

1.

Checkthe tire pressure.

1.

NOTE: slth a M e a s u r ed i f f e r e n c ei n t o e m e a s u r e m e n tw the wheelspointedstraightahead. . if the parkingbrakeis engaged,you may get an incorrectreadang,

Centersteeringwheel spokes. ?

C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t ah e a d . Fronttoe: lN 1 1 2 mm llN l/16 r 1/16 inl

4.

-

lf adjustmentis required,go on to step 4.

-

lf no adjustmentis required,remove alignment equrpmenr.

Loosenthe tie-rod locknuts,and turn both tie-rods in the same directionuntil the front wheels are in straightaheadposition.

Reartoe-in:2 11mm ttltollllS int

2.

4,1N.m {4.5 kgf.m,33 lb{.ft)

6.

lf adjustmentis required,go to step2.

-

lf no adjustmentis required,remove alignment equipment.

Beforeadjustment,note the locationsof adiusting boltson the right and left compensatorarms

ADJUSTINGBOLT 10 x 1.25mm 64 N.m 16.5ksf m, 47 lbtft)

In

Turn both tie-rodsequally until the toe readangon the turningradiusgaugeis correct.

4.

After adjusting,tightenthe tie-rodlocknuts.

.

NOTE:Repositionthe tie-rodboot if it is twistedor displaced.

-

Loosenthe adjustingbolts, and slide the compen satorarm in or out. as shown,to adjustthe toe

TIE.ROD LOCKNUT '14x 1.5mm

t J

R e l e a spea r k i n gb r a k e .

ARM CoMPENSAToR

Tightenthe adiustingbolts

Example: A f t e r t h e r e a r t o e i n s p e c t i o n t, h e w h e e l i s 2 m m (0.08in) out of the specification. - M o v e t h e a r m s o t h e a d j u s f i n gb o l t m o v e s 2 m m (0.08in) inwardtrom the positionrecordedbeforethe adjustment. - The distancethe adjustingbolt is moved should be equalto the amountout-of-specification.

18-5

WheelAlignment TurningAngle Inspection N O T E rU s e c o m m e r c i a l l y - a v a i l a b co l em p u t e r i z e fdo u r w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w the equipmentmanufacturer's instructions. '1. Turn t h e w h e e l r i g h t a n d l e f t w h i l e a p p l y i n gt h e b r a k e ,a n d m e a s u r et h e t u r n i n g a n g l e o f b o t h wneets. Turningangle: lnward wheel: 39'50' Outwald wheel (referencel:33'10'

2.

l f t h e t u r n i n g a n g l e is not within the specifications, c h e c k f o r b e n t o r d am a g e d s u s p e n s i o nc o m p o nents,

18-6

Wheel/HubInspection WheelRunout

BearingEnd Play \ 1.

Raisethe vehicleoff the ground,and suppon it wjth safetystandsin the properlocations(seesection1).

1.

Raisethe vehicleoff the ground,and supportit with safetystandsin the properlocations(seesectionI I

2.

Removethe wheels,then reinstallthewheel nuts

2.

Checkfor bent or deformedwheels.

3.

Attachthe dial gaugeas shown.

3.

Attachthe dial gaugeas shown.

4.

the bearingend play by movingthe disc in N4easure or outward.

4.

Measurethe wheel runoutby turningthe wheel.

Front/R€ar: Standard:0 - 0.05mm l0 - 0.002inl

Front and RearWheel Axisl Runout: Standard: 0 - 1.0 mm (0 - 0.0,1inl Steel Whoel: Aluminum Wheel: 0 - 0.7 mm (o - 0.03 in) ServicaLimit:

2.0 mm (0.08inl

t./ Measureend playat hub flange.

Bear:

Front and RearWheel Radill Runout: Standard: 0 - 1.0 mm (0 - 0.04 in) Steol Wheel: AluminumWheol:0 - 0.7 mm (0 - 0.03in) ServiceLimit:

1.5mm {0.06in}

M e a s u r e e n d P l a Ya t c e n t e r o f the hub cap.

l J

lf the bearingend play measurementis more than the standard,replacethe wheelbearing.

lf the wheel runout is more than the servicelimit, replacethe wheel.

1A-7

FrontSuspension ('96- 99 models) SuspensionArms Replacement CAUTION: . Replacethe selt-lockingnuts after removal. . The vehicle should be on the ground betore any bolts or nuts connectedto rubber mounts or bushings are tightened. NOTE: . Wipe off any dirt, oil or greaseon the threadsbeforetighteningthe fasteners. . The right and left damper forks are not interchangeable. The left damper fork is markedwith "AL" while the right "AR' damperfork is markedwith . The right and left upperarmsare not interchangeable. The left upperarm is markedwith "SO1-L"while the right upper arm is markedwith "SOl-R". . Beforetighteningthe upperand lower mountingnuts on the stabilizerlink,adjustthe locationof the link with the suspensionundervehicleload. . When installingthe radiusarm washers,the "FR" markfacesthe front ofthe vehicle. . After installingthe suspensionarm, checkthe front wheelalignment,and adjustif necessary (seepage18-4). FLANGEBOLTS 1 0x 1 . 2 5m m 54 N.m 15.5kgl.m, 40 tbf.ftl

STAEILIZER END RUBBER BUSHING Checkfor deterioration and damage,

BALLJOINT BOOT - ---\--

. C h e c kf o r d e t e r i o r a t i o n a n d d a m a g e . . S e e p a g e 1 8 - 1 6f o r b o o t r e p l a c e m e n t .

-\ STABILIZER BAR Checkfor bendingand damage.

FLANGEBOLT 1 4x 1 . 5m m

103N.m{10.5kg{.m,. 76lb{.ft) \ FLANGEBOLT-

/)l

t,t,,"-iV ,/4,

v:\

;iffillr-"ilHitffi*::,"*"

c

LOWERARM Checkfor Jl TT da

and damaoe,

o.'-----------

1 4x 1 . 5m m Replace. 83 N.m {8.5kgf.m, 61 lbf.ftl

1 { x 1 . 5m m 89 N.m {9.1 kgt m. 66 lbtft)

-6; SILICONEGREASE RUBBERBUSHING

DAMPERFORK Checkfor damage. FLANGEBOLT 10x 1.25mm € N.m {4.6 kgt m. 32 tbf.ft)

SELF-LOCKING NUT I x 1.25 22 N.m (2.2kg{.m, 16lbf.ftl Replace.

SELF-LOCKING NUT 12x 1.25mm Replace. 6it N m {6.5 kgf.m, 47 lbf.ftl RUEBERBUSHING . Checkfor deterioration and damage.

.6t",.,"o".c"Ke STAAIL|zER ENDRUBBER EUSHINGS Notethe direction of the bushings.

18-8

SuspensionArms Replacement('992D Si and Si-Rmodels)

I

CAUTION: . Replacethe selt-lockingnuts after removal. . The vehicle should be on the ground belore any bolts or nuts connectedto rubber mounts or bushings are tightened. NOTE: . Wipe off any dirt, oil or greaseon the threadsbeforetighteningthe fasteners "AL" while the right The left damper fork is markedwith . The right and ieft damper forks are not interchangeable. "AR" damperfork is markedwith "SOl-L" while the right upper The left upperarm is markedwith . The right and left upperarms are not interchangeable. "SO1-R". arm is markedwith . Beforetighteningthe upper and lower mountingnuts on the stabilizerlink,adiustthe locationof the link with the susp e n s i o nu n d e rv e h i c l el o a d . "FR" markfacesthe front of the vehicle. . When installingthe radiusarm washers,the (seepage18-4). . After installingthe suspensionarm, checkthe front wheelalignment,and adjustif necessary FLANGEBOLTS 10 x 1.25mm sit N.m 15.5kgf.m, 40 tbtftl

UPPERARM ' Checkthe balljointbootfor deterioration anddamage. . Checkthe bushingfor deterioration anooamage, . C h e c kt h e b a l l i o i n t f o . f a u l t y BUSHING STABILIZER movement and clamage.

Alignthe stabilizermark with the end of stabilizerbushing

FLANGEBOLT 1 4x 1 . 5m m 103N.m (10.5kgf.m,

l./

76tbr.ftl BAR STABILIZER Checkfor bendingand damage. FLANGEBOLT8 x 1.25mm 22 N.m (2.2 kgf.m, 16lbf.ft)

LINK STABILIZER . Checkthe balliointbootfor deteriorationand damage. . Checktheballiointtor faulty LOWERARM movementanddamage. Checkfor damage.

-.6r

NUT SELF-LOCKING 1 4x 1 . 5m m Replace. 83 N.m 18.5kgf m, 61 lbf.ft) FLANGEBOLT 1 4x 1 . 5m m 89 N.m 19.1kgf.m,66 lbf.ft)

hSHrtlrT.[*"u srr-,co", Checkfor deterioration

6g619g

ano oamage.

NUT SELF.LOCKING 10 x 1.25mm 29 N m 13.0kgf m, 22 lbf ftl Replace. Holdthe ballioint pin usinga hex wrench, nut. the self'locking and taghten

FLANGEBOLT 10x '1.25mm 43 N.m {4.4kgf.m, 32 tbtft)

FLANGENUT l0 x 1.25mm 29 N.m 13.0kgI m,2.2 lbf ft) Beforetighteningthe {langenut, positionthe balljoint Pin in the middleof its rangeof travel, undervehicleload with the suspension

DAMP€RFORK Checklor damage. DAMPERFORK RU88ERBUSHING Checkfor deterioration and damage.

RANGE

4@lsrlrcoNE

NUT SELF.LOCKING 12 x 1.25mm Replace. 64 N m 16.5kgl.m, 47 lblft)

GREASE

J

18-9

FrontSuspension Knuckle/Hub Replacement CAUTION: . Replacotho salf-lockingnuts after romoval. . The vehiclo should be on tho ground bsfore any bohs or nuls connectedto rubber mounb or bushings are tightened. . Torqu€ th€ castle nut to the lowor torque specification,ihen tighton it only far enough to align th€ slot whh the pin hole. Do not align the nut by loosening. NOTE: . Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weights may corrodeand damage the aluminumwheels. . On the aluminumwheels,removethe centercap from the insideof the wheelafter removingthe wheel, . Beforeinstallingthe brakedisc,cleanthe matingsurfacesof the front hub and brakedisc, . Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakediscand wheel. o Wipe off the greasebeforetighteningthe nut at the ball joint. CALIPERMOUNTINGBOLT 1 2x 1 . 2 5m m 108N.m {11.0kgl.m,80lbf.ft)

CASTLENUT 10 r 1.25mm 39 - ia7N.m (4.0- 4.8 kgf.m,29 - 35 lbf,ftl COTTERPIN Replace. WHEELBEARING Replace. page18-14 Replacement, CIRCLIP

LOWERBALLJOINT Inspectfor faulty movementand wear. Replacement, page18-16 SETRING BALLJOINT BOOT Checkfor deterioration and damage.

CASTLE NUT 12x 1.25mm 49- 59N.ml5.O- 6.0kg{.m.36- /(} lbf,ftl

SCREW 5x0.8mm 5 N.m {0.5 ksl.m, 4 lbf.ftl FRONTHUB Checkfor damageand cracks. Replacement, page18-10 SPINDI.T]{UT 22 r 1.5 mm lEl N.m {18.5kgf.rn,13{ lbl.ttl Replace. NOTE: . Beforeinstellingthe spindle nut. apply 6n9ineoilto th6 seatingsurfaceofthe nut. . Atter tightening, uso a drift to stakethe spindle nut should6ragainstthe driveshaft.

BRAKEDISC Checkfor wear and rust. page18-11 Replacement, lnspection, section19. WHEELNUT 12 x 1.5mm '108N.m 1r1.0kgf.m, 8lt lbf.ft) 6 mm BRAKEDISCRETAININGSCREW 9.8 N.m 11.0kgf.m, 7 lbtft)

18-10

) 1.

7. Removethe 6 mm brakedisc retainingscrews.

Loosenthe wheel nuts slightlY. Raisethe front of the vehicle,and support it with safety standsin the properlocations(seesection1).

3 . Removethe wheel nutsand wheel.

6 mm BRAKEOISC RETAININGSCREWS 9.8 N.m t1.0 kgf.m, 7 lbf'ft)

WHEEL NUT '108N.m {11 kgf m, 80 lbl.ft)

I x 1.25mm BOLTS 8 . Screwtwo 8 x 1.25mm bolts into the discto push it awayfrom the hub, 18'lN.m 118.5kgf m, 134lblfti Replace. NOTEIBeforeinstallingthe spandlenut, apply engineoil to the seatingsurfaceof the nut After tightening,use a drift to stakethe spindlenut shoulderagainslthe driveshaft

l )

Raisethe locking tab on the spindle nut, then remove the nut. Remove the brake hose mounting bolts. BRAKEHOSEMOUNTINGBOLT I x 1.25mm 12 N.m (1,2kgtm,8,7 lbf'ftl

NOTE: Turn each bolt two turns at a tameto prevent cockingthe disc excessivelY. Removethe brakediscfrom the knuckle.

1 0 .Checkthe front hub for damageand cracks. 1 1 . R e m o v et h e w h e e l s e n s o rf r o m t h e k n u c k l e( f o r

vehicleswith ABS). NOTE:Do not disconnectthe wheel sensorconnector.

N.m {'1.0kgf m, 7 tbf.ft)

CALIPERMOUNTINGBOLTS 12 x 1.25mm 108 N.m {'11.0kgtm, 80 lbt.ft)

6.

Removethe caliper mounting bolts and hang the caliperassembiyto one side CAUTTON:To prevent accidentaldamage to the caliper assemblyor brake hoso' use a short piece of wire to hang the caliPertlom lhe undelcarriage.

WHEEL

MOUNTING BOLTS 9.8 N.m 11.0kgf,m, 7 lbf'ft) (cont'd)

FrontSuspension (cont'dl Knuckle/HubReplacement NOTE: Use the specialtool to separatethe ball joints from the suspensionor steeringarm, CAUTION: 86 careful not lo damagethe ballioint boot.

17. Oncethe specialtool is in place,turn ths adjusting bolt as necessaryto make the jaws parallel.Then hand-tighten the pressure bolt, and recheckthe jaws to makesurethey are still parallel.

12. Cleanany din or greaseoff the balljoint. 13. Removethe cotter pin from the steeringarm, and removethe nut. 14. Apply greaseto the specialtool on the areasshown, This will ease installationof the tool and prevsnt damageto the pressurebolt threads. AI\IUSTING BOLT

PRESSURE AOLT

NOTE: After making the adiustment to the adiusting bolt, be sure the head of the adjusting bolt is in this position to the allow the jaw to pivot.

1 5 . Installa 10 mm hex nut onto the ball joint. Be sure that the hex nut is flushwith the balljoint pin end to prevent damage to the threaded end of the ball joint. 1 6 . Install the special tool as shown. Insert the jaws carefully,makingsure you do not damagethe ball joint boot. Adiust the iaw spacing by turning th6 pressurebolt. NOTE: lf necessary,apply penetratingtype lubricantto loosenthe balljoint. COTTER.PIN Replace. On reassembly, bend the cofter pin

CASTI.TNUT 10 x 1,25mm 39 - 47 N.m 14.0- 4.8 kgf.m, CASTLENUT 29 - 3s tbl.ftt 10 r 1.2smn--]*-

corrcn nn Replace-

18-12

.\

1 8 . With a wrsnch, tighten the pressurebolt until the ball joint shaft pops loose from the steering arm. we.r cye plotection. Thc brtt ioint E@ cln brcrk loose suddenly and sclt'tol dirt or other d.brb inio youl .ye.. 10

Rsmov€the tool, then remove th€ nut from the end of the ball ioint and pull the ball joint out of the stoering/suspensionarm. Insp€ctthe ball joint boot and replaceit if damaged.

) 20, Removethe cotter pin from the lower arm ball joint castlenut. and removethe nut.

Removethe cotterpin from the upper ball joint castle nut, and removethe nut.

COTTER.PIN Replace. On reassembly, bend the cotter Pan

NUT CASTLE 12x 1.25mm 49- 59 N.m(5.0- 6.0kgl m,36-,13lbf'ft|

'12x 1.25mm 39 - 47 N.m 14.0- 4.8 kgf m, 29 - 35 tbf.ft)

12mm HEXNUT

07MAC- SL00200

lnstallthe 12 mm hex nut onto the balljoint Be sure that the hex nut is flush with the ball joint pin end, or the threadedsectionof the ball joint pin mlght be damagedby the balljoint remover'

l r

25. Usethe specialtool as shown on page l8-12to separatethe balljoint and knuckle. NOTE: lf necessary,apply penetratingtype lubri cantto loosenthe ball joint. BALLJOINT REMOVER,28 mm 07MAC- SL00200

21. lnstalla 12 mm hex nut onto the ball joint. Be sure that the hex nut is flush with the ball joint pin end' or the threadedsectionof the ball joint pin might be damagedby the balljoint remover.

26. Putl the knuckteoutward and remove the driveshaft outboardjoint from the knuckleby tapping the driveshaft end with a plastichammer,then removethe knuckle. KNUCKLE Checkfor damage.

22. Usethe specialtool as shown on page l8-12to separatethe ballioint and lowerarm. NOTE; lf necessary,apply penetratingtype lubricantto loosenthe ball joint.

l J 18-13

FrontSuspension (cont'dl Knuckle/Hub Replacement NOTE: Replacethe bearingwith a new one after removal.

29. Pressthe wheel bearingout ofthe knuckleusingthe specialtools and a Dressas shown,

27. Separatethe hub from the knuckleusingthe special tools and a hydraulicpress. CAUTION: o Take cale not to distort the splash guard. . Hold onto the hub to keep it from falling whon pr$sed clear, . To prevenl damage to the tool. mak€ sure the threads are fully engagedbelore pressing. Press HUBDIS/ASSEMBLY PILOT,38 mm BEARTNG t - SH20110 07JAF SEPARATOR -

DRIVER 07749- (X)l0000

KNUCKLE

Pross

t ATTACHMENT, 62x68mm 07746- 0010500

O- 1112in. (Commercially available)

HUB DIS/ASSEMBLYBASE 07GAF- SEoo4Ol

WHEEL BEARING Replace.

Pressthe wheel bearing inner race from the hub using the specialtools, a bearingseparator,and a press as shown. HUB DIS,/ASSSMBLY PILOT,38 mm 07JAF- SH20110

KNUCKLE HUB DIS/ASSEMALY SHAFT.22.{x 25.4mm 07JAF- SH20120

FRONT I{U8

28. Removethe circlip and the splash guard from the knuckle. Checktor bendingand damage. HUB DIS/ASSEMBLY SHAFT,22.4 x 25.4mm 07JAF- SH20120

18-14

I

N O T E :W a s h t h e k n u c k l ea n d h u b t h o r o u g h l yi n highflash point solventbeforereassembly. 31. Pressa new wheel bearing into the knuckleusing the specialtoolsand a pressas shown

34. lnstallthe hub on the knuckleusingthe specialtools shown and a hydraulicpressas shown. CAUTION:Take care not to distort tho splashgusrd'

N O T E :P l a c et h e w h e e l b e a r i n go n t o t h e k n u c k l e with the pack seal (metalcolor) toward the inside Be careful not to damage the sleeve of the pack seal. Press HANOI.E 07749- 001

HUB/ASSEMBLY GUIDEATTACHMENT 07GAF-SEflt2d)

KNUCKLE

DOUBLELIPSEAL COLOR) {BLACK

DRIVER ATTACHMENT 58x72mm 07947- 6340201

FRONTHUB SUPPORTBASE 07966- StXx)100

SPLASHGUARD

KNUCKLE BASE SUPPORT 07965- SD90100

32. Installthecirclipsecurelyin the knucklegroove' 33. Installthesplashguard,and tightenthe screws. scREws 5 N.m(0.5kgdm, 4lbt'ft)

tnstall the knuckle in the reverse order of removal' and pay particularattentionto the followingitems: . . .

. . .

.

l-,

.

Be careful not to damage the ball joint boots when installingthe knuckle. Torque all mounting hardwareto the specified torque valugs. Torquethe castlsnuts to the low€r torque speclfications,then tighten them only far enough to align the slot with the pin hole. Do not align the castlenut by loosening. lnstall new cotter pins into the castlenuts after torquing. Avoid twistin0 the sensorwires when installing the wheelssnsor. Beforeinstallingthe brakedisc,cleanthe mating surfacesof the front hub and the inside of the brakedisc. Beforeinstallingthe wheel,cleanthe matingsurfaceofthe brakediscand the insideof the wheel Checkthe front wheel alignment,and adjustit if (seepage18-4). necessary

18-15

FrontSuspension Lower BallJoint Replacement L

Removethe knuckle(seepage18-11).

Installthe ball joint boot and set ring usingthe specialtool (seepage18-16).

8.

Removethe boot by pryingthe set ring off. C h e c kt h e b o o t f o r d e t e r i o r a t i o na n d d a m a g e . replaceif necessary.

ADJUSTINGBOLT Adjustrhe depthby turningthe bolt.

Installthe specialtools onto the ball joint and tighten the casflenut. P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s shown. then set the assemblyin a vise. Pressthe ball joint out of the knuckle, BALLJOINTREMOVER/INSTALLER 07965- SB00r00

CASTLENUT

l

f

BALLJOINTREMOVER BASE 07JAF- SH20200 Placethe balljoint in positionby hand. 7.

Installthe specialtools over the ball joint as shown, then pressthe ball joint in. BALLJOINT INSTALLEBBASE 07965- 5800200

Installthe knucklein the reverseorder of removal, and pay particularattentionto the followingitems: . . .

. . .

. BALLJOINT HOUSINGSURFACE

18-16

.

Be careful not to damage the ball joint boots when installingthe knuckle, Torque all mounting hardwareto the specified torquevalues. Torquethe castlenuts to the lower torque specifications.then tighten them only far enough to align the slot with the pin hole. Do not align the castlenut by loosening. Installnew cotter pins into the castlenuts after torquang. Avoid twisting the sensorwires when installing the wheelsensor. Beforeinstallingthe brakedisc.cleanthe mating surfacesof the front hub and the inside of the brakedisc. Beforeinstallingthe wheel,cleanthe matingsurfaceof the brakediscand the insideof the wheel. Checkthe front wheel alignment,and adjustit if necessary{seepage18-4).

FrontDamper

!

BallJoint BootRePlacement 1.

Removal

Removethe set ring and the boot.

l.

Removethe front wheels(seepage18-11).

CAUTION:Do not contaminatethe boot installation section with grease.

2,

R e m o v et h e d a m p e r p i n c h b o l t t r o m t h e t o p o f damperfork.

Packthe interiorof the boot and lip with grease

DAMPERFORK

EALLPIN TAPEREDSECTION OAMPER FORK BOLT

EOOTINSTALLATIONSECTION BOOTINSTALLATIONSECTION Wipeoff the grease. Wipe off the grease.

3.

Wipe the greaseoff the sliding surfaceof the ball pin and packwith freshgrease. CAUTION: . Keep greaseoff the boot installation section and the tapeled section of the ball pin. . Do not allow dust, dirt, or other toreign materials to enterthe boot.

l J 4.

Installthe boot into the grooveof the boot installation sectionsecurely,then bleedthe atr.

5.

Installthe upper and lower ball joint boot set rings usingthe specialtools as follows:

OAMPER PINCH AOLT 1 0x 1 . 2 5m m

NUT SELF-LOCKING 1 2x 1 . 2 5m m Replace.

Removethe damper fork bolt and self-lockingnut from the bottom of the damper fork, then remove damperfork. Removethe damperby removingthe two nuts

DAMPER

L o w e r b a l l j o i n t : A d i u s t t h e s p e c i a lt o o l w i t h t h e adjustingbolt until the end of the tool alignswith the groove on the boot. Slide the set ring over the tool and into Position. BALLJOINT BOOTCLIP GUIDE

AOJUSTINGBOLT Adjust the depth by turningthe bolt.

UPPEREALL JOINT EOOT: 07GAG- SD40700 LOWERBALL JOINT BOOT: 07974- SA50700

l t

CAUTION: After installing the boot, check the ball pin tapsrod section fol grease contamination and wipe it if necessary.

18-17

Front Damper Disassembly/lnspection Disassembly '1. Compressthe damper spring with the spring compressor accordingto the manufacturer,sinstructions,then removethe self-lockinonut.

Replace.

DAMPER MOUNTING WASHER

CAUTION: Do not compress the spring more than n€cessaryto remove the nut.

10 mm SELFLOCKINGNUT Replace.

BASE DAMPER MOUNTING BUBBER Checkfor deterioration and damage.

STRUTSPRING COMPRESSOR: (Commerci.llyavailabl.l BRANICKO T/N MST.s8I}A, T/N 7200, or eouivalent

Releasethe pressurefrom thg spring compressor, then disassemble the damperas shown in the next column. Inspostion 1. Reassemble all parts,exceptthe spring. 2. Pushon th€ damperassemblyas shown.

DAMP€R SPf,ING Checktor weakenedcompression and damage. SPBINGMOUNTINGRUBBER Checkfor deterioration and damage, BUMP STOP Checkfor damage.

DUSTCOVER PLATE

OUSTCOVER Checkfor bendingand damage.

Checkfor smooth operationthrough a full stroke, both compressionand extension, N O T E :T h e d a m p e r s h o u l d m o v e s m o o t h l v .l f i t does not (no compressionor no extension),the gas is leaking,and the dampershouldbe replaced. Checkfor oil leaks,abnormalnoises,or bindingduring these tests.

18-18

DAMPERUNIT

and

BUMPSTOPPLATE

\

Reassembly

lnstallation

't. Installthe damperunit on a springcompressor.

1.

2.

Assemblethe damper in reverseorder of removal exceptthe damper mountingwasherand self lockingnut. NOTE:Align the bottom of the damper spring and springlower seatas shown.

Looselyinstallthe damperonto the frame with the aligning tab facing inside.then loosely install the two flangenuts. NUTS FLANGE 10x 1,25mm 49 N.m(5.0kgt'm,36 lbf'ftl

DAMPERASSEMBLY

STRUTSPRINGCOMPRESSOR: lcommercially availablel T/N MST.58OA,T/N 7200, BRANICK@ or 6quival€nt

l r SPBINGLOWERSEAT

3.

P o s i t i o nt h e d a m p e r m o u n t i n g b a s e o n t o t h e damperunit as shown.

4.

Compressthe damPersPring. Installthe dampermountingrubber,dampermounting washer,and a new 10 mm self-lockingnut. Hold the dampershaft.and tightenthe 10 mm selflockingnut. NUT SELF-LOCKING 10x 1.25mm 29 N.m 13.0kgf m, 22 lbf ft) Replace.

DAMPER MOUNTINGWASHER

(l-t {cont'd)

18-19

Front Damper Installation(cont'd) 2. Installthe damperfork over the driveshaftand onto t h e l o w e r a r m . I n s t a l lt h e f r o n t d a m p e r i n t o t h e damperfork so the aligningtab is alignedwith the slot in the damperfork.

ALIGNINGTAB

DAMPER PINCH EOLT 10 x 1.25mm 43 N.m 14.4kgf.m,32 lbtftl

12x 1.25mm 64 N.m 16.5kgl.m, 47 lbtftl Replace.

Looselyinstallthe damperpinch bolt into the top of the damperfork. Looselyinstallthe damperfork bolt and a new selflockingnut into the bottomof the damperfork. Raisethe knucklewith a floor jack until the vehicle just lifts off the safety stand. The ftoor ilck must be sscuroty posi@E lionsd or personal iniury may r€€uh. Tightenthe damperpinchbolt. 7 . Tightenthe damperfork bolt and self-locking nut. 8 . Tightenthe flangenutson top of the damper. 9 . Installthe brake hose mounts with the brakehose mountingbolts.

1 0 . Installthe front wheel.

1a-20

RearSuspension

I

SuspensionArms Replacement('96- 99 modelsl bafore hoisting' Wh€n tffi Whsn ths suspensionarms ar6 to be removed. place additionsl weight in the trunk gravity may change causing ths cat to tip tor' substantial weight is removed ftom th6 teal of ths vehicl6, the center of ward. CAUTION: . Replacethe selt-lockingnuts after removal. .Thgvehic|eshouldb€onthggroundboforeanybohsornutsconnectodtorubbelmountso]bughingsaretighton. NOTE: . Makesurethe toe adjustingboltson the compensatorarm are installedin the samedirection' ,.t UP LK,,or "t UP LS'.is stampedon the |eft upperarm and ,,t UP R" or "t UP RH G.,or . ,,t UP 1,, or ,,t UP LH G,. or "t UP RK" or "t UP RS" on the right upperarm' "t UP" stampedsidefacesforward' . The rightand left "ornp"n""to, uitt rre symmetricallnstallsothe .Afterinsta||ingthesuspens|onarm,checktherearwhee|alignment,andadjustifnecessary(seepagelS-4). FLANGEBOLT 10 x 1.25mm 54 N.m (5.5kgf'm, 40 lbf'ftl ADJUSTINGBOLT (FLANGEBOLTI 10x 1.25mm

UPPERARM INNER BUSHING Checkfor deterioration and oamage.

47 tbf.ftl

DAMPERMOUNTINGBOLT (FLANGEBOLT} 10 x 1.25mm 54Nm (5.5kgd.m,iro lbf'ft)

t J l0 mm FLANGEBOLT

N.mt4.0kstm, 29lblftl UPPERARM Checkfor bendang damage-

FLANGEBOL 10 x 1.25mm ARM COMPENSATOR Checkfor bending ano oamage,

TRAILINGARM FI.ANGEBOLT 10 x 1,25mm 54 N.m (5,5ksrf.m,4{}lbf'ft}

I 54 N.m

(5.5ksrm, aolbf'ftl

\

ARM COMPENSATOR INNERBUSHING SILICONE .GREASE .@] Checktor deteriorataon and damage. FLANGEBOLT 10 x 1.25mm 64 N.m {6.5 kgt'm, 47 lbf.ft)

FLANGEAOLT 12 x 1.25mm 64 N.m {6.5 kgf m, 47 tbf.ftt

LOWERARM Checkfor cracks ano damage.

LOWENARM BUSHING SILICONE .,..i@l GREASE Checkfor deterioration and oamage,

1A-21

RearSuspension SuspensionArms Replacement ('gg2D Si and Si-Rmodels) CAUTION: . Roplacethe self-lockingnut after removal. ' The vehicle should be on the gtound before any bohs or nuls connectedto rubber mounts or bushing are tightened. NOTE: ' Makesurethe toe adjustingbortson the compensatorarm are insta|edin the same direction. . "t UP L" or "t UP LH G" or "t Up LK" or "l Up LS,,is stampedon the left upperarm and ,,t Up R,,or "t Up RH G,, " i U PR K " " t o r U P R S " o n t h e r i g h tu p p e ra r m . . T h e r i g h ta n d l e f tc o m p e n s a t oarr m a r es y m m e t i c aIrn. s t a lsl o t h e " u p r " m a r k p o i n t s t o t h e f r o n t . . After installingthe suspensionarm, checkthe wheelatignmentand adiustif necessary, FLANGEBOLT '10x 1.25mm 54Nm155kgl.m,

8 rhm BOLTS 22 N.m {2.2 kgf.m, 16 tbtfrl

,rc lbf.ftl

STABILIZER BUSHTNG

STAEILIZER BAR Checkfor bendingor damage.

FLANGEBOLT 10 x 1.25mm 64 N m {5.5 kgf.m,47 lbtftl UPPERARM BUSHING Checkfor deterioration and

Alignthe stabitizer mark with the end ot the stabilizerbushing.

FLANGEBOLT '10x 1.25mm 54 N.m 15.5kgt.m, a0 lbtftl FLANGEBOLT 10x 1.25mm 54 N.m 15.5*gf.m,

stLrcoNE UPPERARM BUSHING

iO lbf.ftl

EOLTS TRAILINGARM Checkfor bendingand

10x 1.25mm 39 N m ll kgf.m, 29 lbf.ft) UPPERARM Checkfor b€ndingor damage.

#@l stLtcoNE COMPENSA TORARM BUSHING

FLANGENUT r '1.25mm 29 N.m {3.0 ksl.m,22 lbtft} Beloretightening the flange nut, positionthe balljoint pin in the middleol its rangeof travel,with the suspension under vehicleload.

COMPENSATOR ARM BUSHING Checkfor deterioration and damage. FLANGEBOLT l0 x 1.25mm 6l N.m 16.5kg{.m,a7 lbt.ftl

LOWERARM Checkfor damage-

FLANGEBOLTS 10 x 1,25mm 64 N.m {6.5kgf.m, 47 lbf.ftl

LOWERARM BUSHING

-Gr

SELF.LOCKNGNUT 10 x 1.25 mm 29 N.m (3.0 ksl.m, 22 tbtfrl Replace. Hold the ball ioinl pin using a hex w.enct. and tighten the selfjocking nut.

STABILIZEBLINK

stltcoNE LOWERARM BUSHING . Checkfor deteriorationand damaoe. ' Seepage18 25 for bushingreplaciement.

' C h e c kf o r b e n d i n g a n d d a m a g e . . C h e c kt h e b u s h i n g f o r d e t e r i o r a t i o na n o oamage.

18-22

FLANGEBOLT 10 x 1.25rnm 54 N.m {5.5 kgt m, iro lbf.ft)

I

HubBearingUnit RePlacement NOTE: weightsmay corrodeand damage o Use only genuineHondawheel weightsfor aluminumwheels Non-genuinewheel t h e a l u m i n u mw h e e l s . . o n t h e a | u m i n u m w h e e | s , r e m o v e t h e c e n t e r c a p f r o m t h e i n s i d e o f t h e W h e e | a f t e r r e m o v i n g t h e w h e e |(or ' brake hub and the brakedisc . Beforeinsta||ingthe brakedisc (or brakedrum),c|eanthe mating surfacesof the rear orum,. andwheel' . Beforeinstallingthe wheel,cleanthe matingsurfacesofthe brakedisc(or brakedrum) * 1 :Forvehicleswith drum brakes. *2'.'99 2D Si and Si-Bmodels

12 6 mm FLANGEBOLT 9.8 N.m {1.0kgf m, 7 lbf'ft| SPINDLEWASTIER

TRAILINGARM Checkfor cracking and oamage,

SPINDLENUT 22 x 1.5mm 181N,m (18.5kgt'm.134lbfft) Replace. NOTE: ' Beforeinstallingthe spindlenut,apply engineoil to the seatingsurfaceof the nut, ' Aftertightening,usea drift Punch to lockthe spindlenut shoulderinto the spindle.

*2 SPLASHGUARO Checkfor cracking and damage.

HUBCAP Beplace. 12 BRAKEDISC Checkfor wear and rust, '2 6 mm BRAKEDISCRETAININGSCREW 9.8 N'm 11.0kgt m, 7 lbf'ft| \

l r

)

*1 BACKINGPLATE

/\

*1 BRAKESHOE

r1 FLANGEBOLT 10 x 1.25mm 6,0N.m (6.5ksl.m,47 lbl'ftl

'1 BRAKEORUM

REAB HUB UNIT BEARING Checkfor cracking and damage.

l-t

NUT WHEEL 1 2x 1 . 5m m kgt'm.80lbt'ft) 108N.m{11.0

(cont'd)

1A-23

RearSuspension Hub BearingUnit Replacement(cont'dl NOTE:Disctype {'992D Si and Si-Rmodets)

8 . Release the parkingbrakelever.

1.

Loosenthe wheel nuts slightly.

2.

Raisethe rear of vehicle,and supportit with safety standsin the properlocations{seesection1).

9 . R e m o v et h e b r a k e d r u m , h u b u n i t b e a r i n g ,a n d spindlewasherlfor vehicleswith drum brakes).

3.

Removethe wheel nuts and rearwheel.

4.

Pullthe parkingbrakeleverup.

5.

R e m o v et h e h u b c a p .

6.

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. SPINDLE NUT 22x 1.5mrn

lFor vehictes \ \with drumbrakes;/

181N.m (18.5kgf'm,134lbf.fi) Replace. NOT€: . Eeforeinstallingthe spindlenut, applyengineoil to the seating surfaceof the nut. . Aftertightening,usea drift to stakethe spindlenut shoulder againstthe spindle.

BRAKEDRUM

SPINDI-E WASHER

10. Removethe 6 mm flangeboltsand calipershield. WHEELNUT 12x 1.5mm 108N.m I I 1 kgt m, 80 lbf.ftl

CALIPER SHIELO C h e c kf o r b e n d i n g a n d d a m a g e .

6 mm FLANGEBOLTS 9.8 N.m {1.0kgf.m, 7 lbf,ft) HUBCAP ReplaceNOTE:Takecarenot to damagethe hub untt on disassembly. 7 . Remove the 6 mm brake disc retaining screws.

6 mm BRAKEDISC RETAININGSCBEWS 9.8 N.m 11.0kgl.m, 7 lbf.frl

1A -2 4

T

UpperArm BushingRePlacement 1 1 . Removethe two brakehose mountingbolts 1)

R e m o v et h e c a l i p e rb . a c k e tm o u n t i n gb o l t s ,a n d hangthe caliPerto one side

1.

R e m o v et h e u p p e r a r m b u s h i n g a n d u p p e r a r m j n n e rb u s h i n ga s s h o w n

ARMINNERBUSHING UPPER

CAUTION:To prevent accidentaldamage to the caliper or brake hose, use a short piece of wile to hang the caliperfrom the undercarriage. BOLTS BRAKE HOSEMOUNTING 22 N'm{2.2kgf'm,16lbt"ft}

ARMBUSHING UPPER

t t

I

ARM REARUPPER Scribea line on the upperarm innerbushingso that it is in linewith the bolt mountingsurface Markto pointson the upper arm so that they are In line and make a right anglewith the arm as shown in the drawing.

l r

CALIPER

10x 1.25mm 38N'm (3.9kgf'm,28lbf'ftl

Screwtwo 8 x 1.25mm bolts into the discto push it awayfrom the hub. NOTE:Turn each bolt two turns at a time to prevent cockingthe discexcessively.

BOLTMOUNTING SURFACE Drivein the upperarm innerbushingwith the marks aligned.

1 4 . Removethe brakedisc. 1 5 . Removethe hub unit bearingfrom the spindle

5.

Drivethe upperarm bushingintothe upperarm NOTE: Drive in the upper arm bushingand upper a r m i n n e r b u s h i n g u n t i l t h e i r l e a d i n ge d g e s a r e flush with the uPPerarm UPPER ARM

SPINOLEWAS}IER

l t

16. lnstallin the reverseorderof removal.

1A-25

RearDamper Removal 1.

Bemovethe rearwheels(seepage1g-22).

2.

Removethe speakercoverand speaker(Hatchback). Sedanand Coupe:Removethe trunk side panel(see section20).

3.

Removethe two flange nuts. FLANGENUTS 10x 1.25mm

4.

Removethe flangebolt from the damper.

FLANGEBOLT '10x 1.25mm FLANGE BOLT 10x 1,25mm Removethe flangebolt that connectsthe lower arm to the trailingarm.

18-26

6.

Lowerthe rearsuspension, and removethe damper.

I

Disassembly/lnsPection Disassembly 1.

Compressthe damper spring with the spring comp r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r ' isn s t r u c tions,then removethe self-lockingnut.

lnspection 1.

all parts,exceptthe sprlng. Reassemble

2.

Pushon the damPeras shown.

GAUTION: Do not compress the spring more than necessaryto remove the sell-lockingnut.

WOODENBLOCK

l r STNUTSPRINGCOMPRESSOR: lComm6rcially.vailablel ERANICKoT/N MST-580A,T/N 7200,or equivalent Release the pressure from the spring compressor. then disassemblethe damper as shown on page 18-

Checkfor smooth operationthrough a full stroke, both compressionand extension. N O T E :T h e d a m p e r s h o u l d m o v e s m o o t h l y l f i t does not (no compressionor no extension),the gas is leaking,and the dampershouldbe replaced. CheckJor oil leaks,abnormal noises,and binding duringthesetests.

(|-r {cont'd)

18-27

RearDamper (cont'dl Disassembly/lnspection SELF-LOCK|NG NUT 10x 1.25mm

- el v

29 N.m{3.0kst'm,22 lbf.ftl Replace. DAMPEB MOUNTING WASHER

DAMPER MOUNTING 8U8BER Checktor deterioration ano oamage. DAMPER COLLAR

Reassembly 1.

Installthe damperunit onto a springcompressor. NOTE:Followthemanufacturer's instructions. Assemblethe rear damper in the reverseorder of disassemblyexceptthe damper mounting washer and self-lockingnut. NOTE:Align the bottom of the damper spring and springlower seatas shown.

DAMPER MOUNTINGBASE OAMPERMOUNTING BUBBES Checkfor deterioration ano oamage. DAMPERSPRING Checklor weakness, compression, and damage. SPRINGMOUNTING RUBBER Checkfor deterioration ano oamage.

P o s i t i o nt h e d a m p e r m o u n t i n g b a s e o n t o t h e damoerunit as shown. SIRUTSPRING COMPRESSOR: (Commerciattyavaitabtel DAMpERMOUNTTNG

BRANICKO T/N MST-580A,T/N 7200. or cquivalont

BUMP STOP Checkfor weakness and damage, OUSTCOVERPLATE DUSTCOVER Checklor bending

Compressthe damperspring with the spring compressor. Installthe damper mounting washer, and loosely installa new self-locking nut. DUSTCOVERBOOT Checkfor deterioration and damage.

Holdthe dampershaftwith a hex wrench,and tighten the self-locking nut. SELF-LOCKING NUT 10 x 1,25mm 29 N m 13.0kgt.m, 22 lbtftl Replace.

OAMPERUNIT

18-2A

:

DAMPER MOUNTING WASHER

RearDamper

I

lnstallation ' 1 . L o w e r t h e r e a r s u s p e n s i o n a, n d p o s i t i o n t h e damperwith the springstop pointedtoward the left

SPRINGSTOP

2.

Looselyinstallthetwo flangenuts FLANGENUTS 10x 1.25mm 49 N.m (5 kgf.m, 36 lbt'ft) Tightenthesenuts in step7.

l r 3.

Looselyinstallthe flangebolts. FLANGEBOLT 10 x 1.25mm 54 N.m {5.5 kgf m, 40 lbt'ft1

FLANGEBOLT 10 x 1.25mm 54 N.m {5.5 kgf.m, /r0 lb{.ft|

Raisethe rear suspensionwith a floor jack until the vehicle just lifts off the safety stand. Tne floor iacx must be securelYPosi!@@ tionod or peFonal iniury may rssull Tightenthe flangebolts. Tightenthe two flangenuts on top of the damperto the specifiedtorque. 7.

Checkthe rearwheel alignmentand adjustif necessary (seepage18-4).

1A-29

t Brakes ..."...19-1 Brakes Conventional Anti-lockBrakeSystem(ABS)."......"..19-43

It-,

l t

t Brake Conventional .............19'2 SpeciafTools ComponentLocations ......19-3 lndex ................ Inspectionand Adiustment BrakeSystem RubberParts 19-4 and BrakeBooster...........,.,............. 19-5 ............ BrakePedal ........ 19-6 ParkingBrake ................. 19-7 Bleeding Front BrakePads Inspectionand Replacement..........19-8 Front ErakeDisc 19-12 DiscRunoutInspection................... DiscThicknessand Parallelism .......... 19-12 Inspection Front BrakeCaliper 19'13 .......... Disassembly ........... 19-16 Reassembly MasterCylinder/BrakeBooster 19-21 ....................... Removal/lnstallation PushrodClearanceAdiustment ......19-22 19-23 BrakeBoosterInspection................

l-l

RearBrakePads Inspectionand Replacement,,........19-24 RearBrakeDisc 19-26 DiscRunoutlnspection................... DiscThicknessand Parallelism ..........19-26 Inspection RearBrakeCaliper ...........19-27 Disassembly ........." 19-31 Reassembly RearDrum Brake 19-35 .............................. Index/lnspection 19-36 ....,.,....... Inspection 19-37 BrakeShoe Disassembly..............." 19-37 ...............'.. BrakeShoeReassembly BrakeHoses/Lines Inspection/TorqueSpecifications..... 19-39 19-40 ........................... HoseReplacement ParkingBrakeCable lnspectionand Replacement........,.19-41

SpecialTools

Ref. No.

o

I

Tool Numbo]

- SG00100 07HAE 07JAG- SD40100 - SA50001 07914

o

19-2

Descriplion BrakeSpringCompressor PushrodAdjustmentGauge SnapRingPliers

@

Oty

I

PageReference

19-28, 33 19-22

ComponentLocations

I

lndex

ERAKE PEDAL Inspectron and page195 Adjustment,

HOSES LINES BRAKE page19-39 ications, Inspection/Torque specif page19-40 HoseReplacement,

BOOSTER MASTERCYLINDER/BRAKE page19 21 Removal/lnstallation, Adjustment,page19_22 PushrodClearance BrakeBoosterInspection,page 19-23

l J

PARKINGBRAKECASLE inspectionand Replacement, p a g e1 9 4 1

BBAKE Adiustment,page19-6 FRONTBRAKES NOTE: There are two types offront brakecalipers: "5410" The calipertypescan be identitiedby the or "2056"stampedon the caliperbody.Checkthe type ot the brakecaliperbetore servicing. FrontBrakePads 5410Type:page19-8 2056Typerpage19 10 FrontBrakeDisc,page19-12 FrontBrakeCaliper 5410Type:page19-13 2056Type:page19-14

REARORUMBRAKES page19-36 Inspection, page19'37 BrakeShoeBeplacement, REARDISCBRAKES RearBrakePads,page19 24 RearBrakeDisc,page19 26 RearBrakeCaliper,page19'27

l J 19-3

Inspectionand Adjustment BrakeSystemRubberPartsand BrakeBooster @ Brake Boostet Checkbrakeoperationby applyingthe brakes. lf the brakesdo not work properly,checkthe brake booster,Replacethe brakeboosteras an assembly if it does not work properlyor if there are signs of leakage.

€) Piston Cup and PressureCup Inspeqtion .

Checkbrakeoperationby applyingthe brakes. Visuallycheckfor damageor signs of fluid leakage. R e p l a c et h e m a s t e rc y l i n d e ra s a n a s s e m b l yi f the pedal does not work properly or if there is damageor signsof fluid leakage.

.

C h e c kf o r a d i f f e r e n c ei n b r a k e p e d a l s t r o k e b e t w e e nq u i c k a n d s l o w b r a k e a p p l i c a t i o n s . Replacethe master cylinder if there is a differencein oedalstroke.

Brake Hoses Visuallycheckfor damageor signsof fluid leakage. Replacethe brakehose with a new one if it is dama g e do r l e a k i n g .

@ CaliperPiston Seal and Piston Boots Checkbrakeope.ationby applyingthe brakes. Visuallycheckfor damageor signsof fluid leakage. lf the pedal does not operateproperly,the brakes drag. or there is damageor signs of fluid leakage, disassembleand inspectthe brakecaliper.Replace the boots and seals with new ones wheneverthe brakecaliDeris disassembled.

@ Wheol Cylindor Piston Cup and Dust Cover

19-4

Checkbrakeoperationby applyingthe brakes. Visuallycheckfor damageor signsof fluid leakage. lf the pedal does not operate properly,the brakes drag, or there is damageor signs of fluid leakage, disassembleand inspectthe wheel cylinder.lf necessary,replacethe wheelcylinderas an assembly.

BrakePedal ) PedalHeight 1. Disconnectthe brakeswitch connector,loosenthe brakeswitch locknut,and backoff the brakeswitch until it is no longertouchingthe brakepedal, 2.

4.

At the carpetcutout,measurethe pedalheightfrom the right sidecenterof the pedalpad.

Screw in the brake switch until its plunger is fully depressed(threadedend touching the pad on the pedal arm). Then back off the switch 1/4 turn to m a k e 0 . 3 m m ( 0 . 0 1i n ) o f c l e a r a n c eb e t w e e nt h e threadedend and pad. Tighten the locknutfirmly. Connectthe brakeswitchconnector. CAUTION: Make sure that the brake lights go off when the pedal is released.

PUSHROD LOCKNUT

)

LOCKNUT

* 5.

I t POINTICUTOUTI

Standard PedalHeight (with carpet removed): 156.5mm 16.16inl M/T: A/T, CVT:161mm (5 5/16 in) 3.

Loosenthe pushrodlocknut,and screwthe pushrod in or out with pliersuntil the standardpedal height from the floor is reached.After adjustment,tighten the locknutfirmly.

0.3mm (0.01in)

Checkthe brakepedalfree play as describedbelow.

PedalFreePlsy 1. With the engine off, inspectthe play on the pedal pad by pushingthe pedalby hand. FreePlay:1 - 5 mm (1/16- 3/16 inl 2.

adjust lf the pedal free play is out of specitication, the brakeswitch. CAUTION: lf the pedal free play is insufficient, it may result in brake drag.

N O T E : D o n o t a d i u s tt h e p e d a l h e i g h tw i t h t h e Dushroddepressed.

BRAKEPEDALPAO

PUSHROOLOCKNUT 15 N.m (1.5kgf.m. 11 lbI.ft)

19-5

Inspectionand Adjustment ParkingBrake Removethe rearconsole(seesection20).

Inspection 1. Pullthe parkingbrakeleverwith 196N {20kgf.44 lbf) force to fully apply the parkingbrake.The parking brake lever should be locked within the sDecified numberof clicks.

Pullthe parkingbrakeleverup one click, Tightenthe adjustingnut until the rearwheelsdrag slightlywhen turned.

Lever Lockedclicks: 6 - I

Pulledup w i t h 19 6 N 1 2 0k g f , 4 4 l b f )

\

ADJUSTING NUT 2.

Adjustthe parkingbrakeif the leverclicksare out of specification. Beleasethe parkingbrakeleverfully, and checkthat the rear wheelsdo not drag when turned.Readjust if necessarv.

Adiusiment NOTE:After servicingthe rear brakepadsor calipers,or the rear brakeshoe, loosenthe parkingbrakeadjusting nut, startthe engine,and depressthe brakepedalseveral times to set the self-adjusting brakebeforeadjusting the parkingbrake. 1.

Raisethe rear wheels off the ground, and support the vehicleon safetystands. Elock the front wheels bofore iacking l@ uDthe rear ot the v6hicle.

2.

On vehicleswith rear disc brakes,make sure the parkingbrakearm on the rearbrakecalipercontacts the brakecalioerDin.

19-6

7.

Make sure that the parkingbrakesare fully applied when the parkingbrakeleveris pulledup fully.

8.

Reinstallthe rearconsole.

I

Bleeding CAUTION: . Always use GenuineHondaDOT3 BrakeFluid.Using 8 n o n - H o n d ab r a k € f l u i d c a n c a u s e c o r r o s i o n a n d docrea3ethe life of the system. . Make surs ||o dirt or other foteign matter is allowed to contaminate the brake fluid, . Do not spill brake lluid on the vehicle, it may damago the paint; if brake lluid doos contac{ the paint, wash it ofl imm€diately with water.

FRONTT

NOTE:The reservoiron the mastercylindermust be at the MAX (upper)level mark at the start of the bleeding p r o c e d u r e a n d c h e c k e da f t e r b l e e d i n g e a c h b r a k e caliper.Add fluid as required. 1.

Makesure the brakefluid levelin the reservoiris at the MAX lupper)levelline.

MAX {UPPER)LEVEL

REARlDrum Brakel:

CYLINDER

Havesomeoneslowly pump the brakepedslseveral times,then applysteadyPressure. Loosenthe brakebleedscrewto allow air to escape f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w securely. Repeatthe procedurefor eachwheelin the sequence shown below until air bubblesno longerappearin the fluid.

REAR(DiscBrake):

Refillthe mastercylinderreservoirto the MAX (upper)levelline. ELEEDINGSEOUENCE:

1,,

O Front Right

(D Bo.r Right

O Front Left

O Rear Left

AIEEDSCREW

9 N.m (0.9ksf m, 6.5 lbf'ft)

19-7

Front BrakePads Inspectionand Replacement NOTE:Therearetwo typesof front brakecalipers: T h e c a l i p e rt y p e s c a n b e i d e n t i f i e db y t h e " 5 4 1 0 " o r "2056" stamped on the caliper body as shown below. Checkthe type of the brakecaliperbeforeservicing.

4.

Removethe pad shim. pad retainers,and pads. NOTE:When the caliperis equippedwith an outer pad shim, replacethe shim togetherwith the pads

5i110Type: NOTE:For 2056type disassemblyprocedures. see page 19-'10.

Never use an air hose or dry brush lo clean brake assgmblios. Use an OSHA approved vacuum cleaner to avoid breathing brake dust. 1 . Loosenthe front wheel nuts slightly,then raisethe vehicle,and support it on safety stands.Remove the front wheels. 2 . Removethe brakehosebracketfrom the knuckle. Removethe caliper bolt, and pivot the caliper up out of the wav.

5.

U s i n g v e r n i e rc a l i p e r s m , e a s u r et h e t h i c k n e s so f each brakepad lining.The measurementdoes not includethe pad backingplatethickness. Brake PadThickno$: Standard:9.5 - 10.5mm 10.37- 0.41 in) SerYicoLimit 1.6 mm {0.06in}

CALIPERBOLT

NOTE:Checkthe hosesand pin boots for damage and deterioration.

19-8

lf the brake pad thicknessis less than the service limit, replacethe front Dadsas a set.

) 7. Cleanthe caliperthoroughly;removeany rust,and checkfor groovesand cracks. 8. Checkthe brakediscfor damageand cracks. 9. lnstallthe pad retainers,

'12. Pushin the pistonso that the caliperwill fitoverthe pads, Make sure that the piston boot is in position to prevent damaging it when pivoting the caliper down. CALIPERBOLT N m (3.3kgf m,2a lbf.ft)

10. Apply greaseto the points indicatedby the arrows in the followingillustration: NOTE:Use the pad greaseincludedin the pad set or Molykote Nl77grease,and apply a thin coat of greaseevenlyto the designatedpoints.

I t

o . . . .

Pistonend and innerDadcontactsurface Padand calioerbracketcontactsurface Outerpad and caliperbody contactsurface Outer pad shim and outer pad contact surface Outerpad shim and caliperbody contactsurface

1 3 . Pivotthe caliperdown into position,then installthe caliperbolt and tightenit. CAUTION: Be caretul not damage the pin boot when pivoting the caliper dowr. 1 4 . lnstallthe brakehosebracketon the knuckle NOTE: Inspectthe brake hose for interferenceor twisting.

WEARINDICATOB

1 5 . Depressthe brakepedalseveraltimes to makesure the brakeswork. then test-drive. INNER PAD OUTERPAD

11. Installthe brakepadsand pad shim correctly.

.

.

l.t

Whon reusing the pads, always reinstall the brake pads in their original positions to prevont loss of braking efticiency. Contaminated brake discs or pads teduce stopping ability. Keep greaseoft the discs and pads'

NOTE: lnstall the Dad with the wear indicator on the inside.

N O T E :E n g a g e m e n o t f t h e b r a k e m a y r e q u i r ea greater pedal stroke immediately after the brake pads have been replacedas a set. Severalapplicat i o n s o f t h e b r a k e p e d a l w i l l r e s t o r et h e n o r m a l Dedalstroke. 1 6 . After installation.checkfor leaksat hose and line jointsor connections, and retightenif necessary.

(cont'd)

19-9

Front BrakePads (cont'dl Inspectionand Replacement 2056Type:

5.

@ . Never use an air hose or dry brush to

clgan brake assemblies. Use an OsHA-approvedvacuum cleanor lo avoid breathing broke dust.

.

1.

2. 3.

U s i n g v e r n i e rc a l i p e r s m . e a s u r et h e t h i c k n e s so f each brake pad lining.The measurementdoes not includethe pad backingplatethickness. Brake PadThicknsss: Standard; 8.5 - 9.5 mm 10.33- 0.37 in) ServicaLimh: 1.6 mm {0.06in}

Loosenthe front wheel nuts slightly.then raisethe vehicle, and support it on safety stands. Remove the front wheels. Removethe brakehosebracketfrom the knuckle. Removethe caliperbolt B, and pivot the caliperup out of the wav,

lf the brake pad thicknessis less than the service limit, replacethe front pads as a set,

EOLTB NOTE:Checkthe hosesand pin boots for damage and deterioration. Removethe pad shim, pad retainers,and pads. NOTE:When replacingthe pads, replac€the shim togetherwith the padsas a set,

OUTER PADSHIM C h e c kf o r w e a r .

INNER PAD PAORETAINERS Checkfor weaknessand damage, OUTERPAD

19-10

7.

Cleanthe caliperthoroughly;removeany rust. and checkfor grooves and cracks.

8.

Checkthe brakediscfor damageand cracks,

9.

Installthe pad retainers.

) lO. Apply greaseto the points indicatedby the arrows in the followingillustration:

12. Pushin the pistonso that the caliperwill fit over the pads.Make sure that the piston boot is in position t o p r e v e n td a m a g i n gi t w h e n p i v o t i n gt h e c a l i p e r

NOTE:Use the pad greaseincludedin the pad set or Molykote M77 grease,and apply a thin coat of greaseevenlyto the designatedpoints. . o . . .

Pistonend and innerpad contactsurface Padand caliperbracketcontactsurface Outerpad and caliperbody contactsurface Outerpad shim and outer pad contactsurface Outerpad shim and caliperbody contactsurface

PISTON

CALIPERBOLTB 26 N.m {2.7kgt m, 20 rbl.ftl

WEARINDICATOR

OUTERPAD OUIER PADSHIM

1 3 . P i v o tt h e c a l i p e rd o w n i n t o p o s i t i o n ,t h e n i n s t a l l caliperbolt B and tightenit. 1 4 . lnstallthebrakehosebracketon the knuckle.

NOTE:Inspectthe brakehose for interferenceand twisting. Depressthe brakepedalseveraltimes to makesure the brakeswork,then test-drive

I 1. Installthe brakepadsand pad shim correctly

@ o When reusing the pads, always reinstall the .

brake pads in their original positions to plevent loss of braking etticiencY. Contaminated brake discs ol pads reduce stopping ability. Keep greaseoft the discs and pads.

t f t h e b r a k e m a y r e q u i r ea N O T E :E n g a g e m e no greater pedal stroke immediately after the brake pads have been replacedas a set. Severalapplicat i o n s o t t h e b r a k e p e d a l w i l l r e s t o r et h e n o r m a l pedal stroke. 1 6 . After installation,checkfor leaksat hose and line jointsand connections, and retightenif necessary.

N O T E :I n s t a l lt h e p a d w i t h t h e w e a r i n d i c a t o ro n the inside.

1 9 - 11

Front BrakeDisc DiscRunoutInspection L

2.

Loosenthe front wheel nuts slightly,then raisethe vehicle,and support it on safety stands. Remove the front wheels.

DiscThickness and Parallelism Inspection 1 . Loosenthe front wheel nuts slightly,then raisethe vehicle,and support it on safety stands.Remove the front wheels.

Removethe brakepads(seepage19,8). Removethe brakepads(seepage 19-8). I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s . Cleanthe discthoroughlyand removeall rust. Use wheel nuts and suitableplain washersto hold the disc securelyagainstthe hub,then mount a dial i n d i c a t o ra s s h o w n , a n d m e a s u r et h e r u n o u t a t 10 mm (0.4in) from the outeredgeof the disc.

U s i n g a m i c r o m e t e r ,m e a s u r ed i s c t h i c k n e s sa t eight points, approximately45" apart and 10 mm (0.4in) in from the outeredgeof the disc.

Brake Disc Runout: ServiceLimit: 0.10 mm (0.004inl

WHEELNUT ANO PLAINWASHER '108N.m (11 kg{.m,80 lbf.ft)

BrakeDbc Thickn6s: Standlrd: 20.9- 21.8 mm (0.82- 0.86 in) Max. RefinishingLimit: 19.0mm 10.75inl NOTE:Replacethe brakedisc if the smallestmeasurementis lessthan the max. refinishinqlimit. Brake Disc Parallelism:0.015mm (0.fit06 in) max.

lf the disc is beyond the servicelimit, refinishthe brake disc with an on-car brake lathe, The KwikLathe produced by Kwik-way Manufacturing Co. and the "Front BrakeDisc Lathe" offeredby Snapon ToolsCo.are approvedfor this operation. Max. RefinishLimit: 19.0mm (0.75in) NOTE:A new disc shouldbe refinishedif its runout is greaterthan 0.10mm (0.004in)

NOTE:This is the maximum allowabledifference betweenthe thicknessmeasurements. lf the disc is beyondthe servicelimit for parallelism, refinishthe brake disc with an on-car brake lathe. The Kwik-Latheproduced by Kwik-WayManufacturing Co. and the "Front BrakeDisc Lathe"offered by Snap-onTools Co. are approvedfor this operation. NOTE:Seesection18for brakedisc reDlacement.

19-12

Front BrakeCaliper Disassembly NOTE:Therearetwo typesof front brakecalipers: "5410"or T h e c a l i p e rt y p e s c a n b e i d e n t i f i e db y t h e "2056" stamped on the caliper body as shown below. Checkthe type of the brakecaliperbeforeservicing.

R e m o v et h e c a l i p e rp i n s a n d p i n b o o t s f r o m t h e calioerbracket, PINB CALTPER BRACKET CAL|PER

3.

5410Type: see page NOTE:For 2056type disassemblyprocedures, 19-14.

CALIPERPIN A

4,

@ o Never use an air hose ot dry brush to clean brakg .

I t

assemblies. Use an OSHA approved vacuum clganer to avoid breathing brake dust.

CAUTION: . Do not spill brake lluid on the vehicls; it may damage the paint; if brake fluid does conlact the paint, wash it off immedistely with waier. . To prevenl spills, covet the hose ioin$ with rags or shop towels. . Clean all parts in brake fluid and air dry; blow out all passageswith compressedair. L

lf necessary.apply compressedair to the caliper fluid inlet to get the piston out. Placea shop rag or wooden blockas shownto cushionthe pistonwhen it is expelled.Uselow pressureair in shortspurts.

@ . Do not place your iingers in tront ol the piston. .

Do not use high air pressure; use 8n OSHA approved 30 PSInozzls,

Removethe banjo bolt, and disconnectthe brake hosefrom the caliDer. CALIPER BANJO EOLT

Removethe pistonfrom the caliper,and checkthe pistonfor scoring. Removethe boot clip,pistonboot and pistonseal. CAUTION:Take care not to damage the cylindcr PISTONSEAL Replace. SEALING Replace.

BOLTS

Removethe caliperbolts,then remove the caliper from the bracket.

l J

BOOTCLIP Replace.

\

,

,t. ( \)

CALIPERBODY Checkfor scoring PISTONBOOT Replace.

(cont'd)

19-13

Front Brake Caliper Disassembly(cont'dl 2056Type:

4.

@Nevor u3e an air hos€ or dry brush to clgan brake

R e m o v et h e p i n b o o t , s l e e v eB a n d s l e e v eb o o t from the caliperbody. CALIPER EODY Check for scoring on cytinder wa .

assomblios. Use an OSHA approved vacuum cl6aner to avoid braathing braks duet. CAUTION: . Do not spill brakefluid on ths vchicle; it may damage the paint; if brako fluid does contact the p.int. wash it olt immediately with wato.. . To prevsnt spills, cover the ho3o ioints whh rag3 or shop towels. . Cl€an all parts in brake fluid and air dry; blow out 8ll passagsswith compr63€d air. 1.

Removethe banjo bolt, and disconnectthe brake hosefrom the caliper. SEALINGWASHERS

SLEEV€B Checkfor damage. lf necessary,apply compressedair to the csliper fluid inlet to get the pistonout. Placea shop rag or woodenblockas shownto cushionthe oistonwhen it is expelled.Use low pressureair in shortspurts,

a Do not placo your lingers in ftont ol tho pkton. a Do noi usa high air prsssure; uso an OSHA

approved 30 PSInozzle. WOODENALOCK

Removecaliper bolt B, pivot the caliper up out of the way,then removethe caliperfrom the bracket. Removethe guide pin boot from sleeveA on the caliDerbracket. C h e c kf o r d a m a g e .

GUIDEPIN BOOT Replace.

GALIPERBRACKET Checktor cracks.

1 9- 1 4

Removethe pistonfrom the caliper,and checkthe pistonfor scoring.

7.

Removethe boot clip, pistonboot and pistonseal. CAUTION;Take care not to damage the cylinder bore.

goor cLtP Replace.

SEAL NSTON BOOT Replace.

I

l.t 19 - 1 5

Front BrakeGaliper Reassembly 5410Type: NOTE:For 2056type reassemblyprocedures, see page19-18.

o . . .

Never use an air hose or dry brush to clean brako assemblies. Use an OSHA approved vacuum cleanerto avoid breathing brake dust. Contaminatedbrake discs or pads reducestopping abilhy. when reusing the pads, always reinstall the brake pads in their original positions to pr€vent loss of braking €fficiency.

CAUTION: . Do not spill brake fluid on the vehicle;it may damagethe paint; if brake fluid do€s contaci the psint, wash it oft imme" diately with water. . Cleanall parts in brake fluid and air dry; blow out all passag€swhh comp.€ssedair. . Betorereassembling,checkthat all parts are free ol dust and othor toreign particlos. . Replaceparts wilh new ones whenever specifiedto do so. . Make sure no dirt or other toreign matt€r is allowed to contaminate the brake fluid. . Always use Genuine Honda DOT 3 Brake Fluid. Using a non.Honda brake tluid can cause corrosion and decressethe life of th€ system. NOTE: . Coatthe piston,pistonseal,and caliperborewith cleanbrakefluid. . Replaceall rubberpartswith new oneswheneverdisassembled.

z_.

.=-.q8! .9!,H: Use recommendedrubber greasein the caliper seal set. -.61'

use recommendedsealgreasein the catipersealset. BRAKEPADS

CALIPERBRACKEIMOUNTINGBOLT 108N.m {11.0kgt m,80lbf.ft)

PIN BOOTS

"k..6

Replace.

tilfliltn

prr'r e-....,-q\, t w t\J fl iJI Il car-rpen -

WEAB WEAB INDICATOR rNDrcAroR

l n s r a l li n n e r p a d w i t h irs weat indicatot !pwatd/,.

lAV

@{

\

*

*/

W

q

1 CALIPERBRACKET

OUTERPADSHIM

-o

CAI-IPER PIN A -

-'''---&@ PAD RETAINERS

PISTONSEAL PISTONBOOT Replace. Replace.

-6r / BLEEDSCREW S N.m (0.9kgt.m, 6.5 tbf.ftl CALIPERBODY

19-16

I

6 v o/

eoorcr-re neptace.

'1.

Cleanthe piston and caliperbore with brakefluid, and inspectfor wear and damage. C o a tt h e n e w p i s t o n s e a l w i t h t h e r e c o m m e n d e d rubbergreasein the caliperseal set.and installthe sealin the cylindergroove. Apply the recommendedseal greasein the caliper sealset to the sealinglips and insideof a new piston boot,and securelyinstallit in the caliperwith the new bootclip. CAUTION: Be careful nol to damage the caliper cylinderwall.

Apply the recommendedseal greasein the caliper seal set to the sliding surfaceof the pins and the lnsideof the new pin boots. lnstallthe pin boots into the groovesin the caliper bracketproperly. CALIPERERACKET

CALIPER

-6l CALIPEBPIN B

-6.l PIN BOOTS Replace. PISTONSEAL Replace.

--^.

,:=-qE!!!-H RUBBER GREASE

-6l CALIPERPIN

I J

PISYONBOOT Replace. j@i SILICONEGREASE

7. Insertpin A and pin B into the caliperbracket. 8. Install the pin boots into the grooves in the pans propeny. 9. Installthe brakepads in their originalpositions(see page 19-9). 10. Pushin the pistonso that the caliperwill fit overthe pads,and installthe caliPer. 11. Tightenthe caliperbolts. 12. Connectthe brakehoseto the caliperwith new sealing washers,and tightenthe banjobolt. BANJO EOLT 34 N.m (3.5kg{ m, 25 lbflt}

SEALINGWASHERS Replace.

L u b r i c a t et h e c a l i p e ra n d p i s t o nw i t h b r a k ef l u i d , then installthe pistonin the cylinderwith the dished end facingin.

CALIPERBOLT 32 N.m 13.3kgt.rn,24lblft)

'13. Fill the brakereservoitand bleedthe brakesystem {seepage19-7). 1 4 . Performthe following checks: . Checkfor leaksat hose and line joints and connections.and retightenif necessary. . Checkfor brakehosesfor interferenceand twisting. (cont'd)

19-17

Front BrakeCaliper Reassembly(cont'd)

I

2056Type:

. Never use an air hose or dry b.ush to clean brake assemblies. . Uso an OSHA approved vacuum cleansrto avoid breathing brake dust. . Contaminatedbrake discs or pads reducestopping ability. t when reusing the pads, always r6instsll the brake pads in their original positioos to prevent loss ol braking efficiency. CAUTION: ' Do not spill brake tluid or th€ vehicle; it m8y damage the paint; if brake fluid does contact the paint, wash it off immediately with water. . Cleanall parts in brake tluid and air dry; blow out all passageswith compr63ed air. . Beforo reassembling,checkthat all parts are fr€e of dust and other foreign particles, . Replaceparts with new ones wheneveaspecifiedto do so. . Make sure no dirt or other foreign matter is allowad to contaminato the brake fluid, ' Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Hondabrake fluid can caus€ corrosior and decreasethe life ol the system. NOTE: . Coatthe piston,pistonseal,and caliperborewith cleanbrakefluid. . Replaceallrubberpartswith new oneswheneverdisassembled. .'=5@: -6l

Use recommendedrubbergreasein the calipersealset, ' Use recommendedsealgreaseIn the calipersealset.

@6--i#i['i,?li"..;:l]l?Y]li"'"'

BRAKEPAOS

-/ffr r""'"rr r"""ip"autr,

WEAR,INDICAToR.

,ffi

\

CALIPERBRACKET

OUTERIPAD

i t s w e a r n d c a t o r u ' w\a r d

\

e"6ft

'ADRETATNERS

pr MffiA GUIDE PIN BOOT \\ ) {I I II ) I I \I\d/ tt\' id 6 % '---r..'.* caL,PER u -es **=*t ".-,."oo*'J.l, ru,oonW U

BLEED SCREW 9 N.m(0.9kgf.m,6.5lbf.ft) \

o@

-"-41

q.-

SLEEVE8

t\

r{.i'""Jg*' a,t/

CALIPERBOLTB 2 6 N m { 2 . 7 k g f . m20 , tbf.ftl

c'f3!@

PISTONEOOT Replace. CALIPERBODY PIN BOOT Replace.

19-18

SLEEVE A

.&l

BOOTCLIP Replace.

1.

Cleanthe piston and caliperbore with brakefluid, and inspectfor wear and damage.

4.

Lubricatethe caliper and piston with brake fluid, t h e n i n s t a l lt h e p i s t o n i n t h e c y l i n d e rw i t h t h e dishedend facingin.

Coat a new Distonsealwith the recommendedrubber greasein the calipersealset,and installtheseal in the cylindergroove. Apply the recommendedseal greasein the caliper seal set to the sealinglips and insideol a new piston boot, and securelyinstallit in the caliperwith a new boot clip. CAUTION: Be carelul not to damage ths calipor cylinder wall.

Apply the recommendedseal greasein the caliper seal set to the sliding surfaceoJ sleeveB and the insideof the new pin and sleeveboots. lnstallthe new sleeveand pin boots 8nd sleeveB on the caliDer.

I J

NOTE: Makesure to installthe boots into the grooves in the caliperand sleeveB properly. BOOT SI.EEVE Replace.

Replace.

-6, SILICONEGREASE

-1!!4!!n RUBEERGREASE

=_.

SLEEVEB

Y

P IN BOOT Replace.

t./

(cont'd)

19-19

Front BrakeCaliper (cont'dl Reassembly 7 . Apply the recommendedseal greasein the caliper seal set to the sliding surfaceof sleeveA and the insideof a new guide pin boot. I n s t a l lt h e g u i d e p i n b o o t i n t o t h e g r o o v e i n t h e sleeveA.

1 1 .Connectthe brakehoseto the caliperwith new sealing washers,and tightenthe banjobolt. Tightenthe caliperbolt B. BANJOBOLT

Make sure that the brake pad retainersand brake padsare in their originalpositions(seepage 19-10).

26 N.m (2.7 kgl.m, 20 lbtftl

1 3 . Fill the brake reservoir and bleed the brake svstem (seepage 19-7).

Installthe caliperonto sleeveA, and pivot it down into position. NOTE:Installthe guide pin boot into the groove in the caliperproperly.

BRACKET

SLEEVEA

19-20

1 4 . Performthe following checks. . Checkfor leaksat hose and line ioints and connectaons,and retighten if necessary. . Checkfor brake hoses for interferenceand twistIng.

MasterCylinder/BrakeBooster

I

RemovaUlnstallation CAUTION: . Be care{ulnol to bend or damagethe brake lineswhen rsmovingthe mastsr cYlinder. . Do not soill brakefluid on the vehicle; it may damage the paint; if brake fluid does contact the paint, wssh it off immediatelYwith water' . To prevent spill3, cover the hose ioints with rags or shop towels. the brakefluid levelswitchconnectors' 1 . Disconnect the 2 . Remove reservoircap from the mastercylinder' 3 , The brakefluid may be suckedout through the top of the mastercylinderreservoirwith a syrlnge. the brakelinesfrom the mastercylinder' Disconnect 5 . R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d washers. 6. Removethe mastercylinderfrom the brakebooster' 7. Disconnectthe vacuum hose trom the brakebooster' 8. Removethe cotterpin and clevispin from the clevis' CAUTION: Do not disconnect the clevb by removing it from the operating rod of the brako booster' lf the clevis is loosened, adiust the pushrod length before installingth€ brake booster (seepage 19-221'

9. Removethe four boostermountlngnuts 10. Pull the brake booster forward until the clevis is clearof the bulkhead. 1 1 . R e m o v et h e b r a k eb o o s t e rf r o m t h e e n g i n ec o m panmenr. '12. Installthe brakeboosterand mastercylinderin the reverseorderof removal. CAUTION: . When connecting the brake lines. make sure that there is no inte erence between the brake lines and oth6r Parts. r Be careful not to bend or damage the brake lines when installing the master cylinder. N O T E : l f r e p l a c i n gt h e m a s t e rc y l i n d e ro r b r a k e b o o s t e r ,c h e c ka n d a d i u s tt h e p u s h r o dc l e a r a n c e be{oreinstallingthe mastercylinder(seepage 19-221' , n d b l e e dt h e F i l l t h e m a s t e rc y l i n d e rr e s e r v o i r a (see 19-7). brake svstem Page 1 4 . After installation.checkthe brakepedal height and brake pedaltree play (see page l9-5) and adjust if necessary. BOOSTER BRAKE (WithABS:7" + 8" tandembrakebooster)

\l/ -6.4 CLEVISPIN

BRAKEFLUIOLEVEL SWITCHCONNECTORS MASTERCYLINDER

COTTERPIN Replace.

VACUUM HOSE

To RearWheelCylinders

t'N't'ttrnt'-''

To FrontCaliper (WithoutABS)

$ To FrontCaliper lWithoutABSi

15 N.m {1.5kgl m, 11 tbtft) CONTROLVALVE PBOPORTIONING

l r

1 5 N . m { 1 . 5 k g i f . m ,1 1 l b t f t } (With ABS: To modulator unit)

19-21

MasterCylinder/BrakeBooster Pushrod GlearanceAdjustment NOTEr . T h e m a s t e rc y l i n d e r p u s h r o d - t o - p i s t o cn l e a r a n c e must be checkedand adjustmentsmade, if neces_ sary,beforeinstallingthe mastercylinder. . ABS type is shown, conventionalbraketype is similar. 1.

Setthe specialtool on the mastercylinde.body;push in the centershaft until the top of it contactsthe end ofthe secondarypistonby turningthe adjustingnut.

N O T E :l f t h e c l e a r a n c eb e t w e e nt h e g a u g e b o d y and adjustingnut is 0.4 mm (0.02in), the pushrodto-pistonclearanceis 0 mm. However,if the clear_ ance betweenthe gauge body and adjustingnut is 0 mm, the pushrod-to-piston clearanceis 0.4 mm (0.02in) or more.Therefore,it must be adjustedand rechecked. 6. lf clearanceis incorrect,loosenthe star locknut,and turn the adjusterin or out to adjust. NOTE; . Adjustthe clearancewhile the specifiedvacuum is appliedto the booster. . Holdthe cleviswhile adjusting. 7 . Tightenthe star locknutsecurely. Removethe specialtool. 0 - 0.4mm (0- 0.02in) STARLOCKNUT 22 N.m {2.2kg,f.m,16lbtft)

Withoutdisturbingthe centershaft'sDosition,install the specialtoolupsidedown on the booster. Installthe mastercylinder nuts, and tighten to the specifiedtorque. Connectthe boosterin-linewith a vacuumgaugeO_ 101 kPa (0 - 760 mmHg, 30 in.Hg)to the booster,s e n g i n e v a c u u m s u p p l y , a n d m a i n t a i na n e n g i n e speedthat will deliver66 kpa (500mmHg,20 in.Hg) vacuum. With a feelergauge.measurethe clearanceDetween the gaugebody and the adjustingnut as shown. Clearance:0 - 0.4 mm {0 - 0.02 in)

PUSHROD ADJUSTMENTGAUGE

ADJUSTER

07JAG- SD('1(x) 9. Adjust the pushrodlength as shown if the booster rs removed. 11610.5 mm {{.571 0.02in)

VACUUM GAUGE (Comm€rciallyavaileblel 0 - 101kPa {0 - 760 mm Hg, 30 in.Hg)

AOJUSTINGNUT

FEELER GAUGE

PUSHROD LOCKNUT 15 N.m 11.5kgf.m,11 tbtftl

1 0 . Install the master cylinder {see page l9-21).

19-22

BrakeBoosterInsPection FunctionalTest 1. With the engine stopped,depressthe brake pedal severaltimes to depletethe vacuumreservoir,then depressthe pedalhard and hold it for 15 seconds lf t h e p e d a l s i n k s ' e i t h e r t h e m a s t e rc Y l i n d e ri s bypassinginternally,or the brake system (master c y l i n d e r .l i n e s .m o d u l a t o r ,p r o p o r t i o n i n gc o n t r o l valve,or caliPer)is ieaking. 2. Start the engine with the pedal depressed lf the pedalsinksslightly,the vacuumboosteris operating n o r m a l l y .l f t h e p e d a l h e i g h t d o e s n o t v a r y , t h e boosteror checkvalve is faultY. 3. With the engine running.depressthe brake pedal l i g h t l y .A p p l y j u s t e n o u g hp r e s s u r et o h o l d b a c k a u t o m a t i ct r a n s m i s s i o nc r e e p .l f t h e b r a k ep e d a l s i n k sm o r e t h a n 2 5 m m ( 1 . 0i n . ) i n t h r e e m i n u t e s , t h e m a s t e rc v l i n d e ri s f a u l t y . A s l i g h t c h a n g ei n pedal height when the A'lCcompressorcycleson a n d o f f i f n o r m a l . ( T h e A / C c o m p r e s s o rl o a d changesthe vacuumavailableto the booster')

Booster CheckValve Test 1. Disconnectthe brake boostervacuum hose at the booster. 2. Stan the engineand let it idle.Thereshouldbe vacuum. lf no vacuum is available,the checkvalve is not working properly. Replacethe brake booster vacuumhoseand checkvalve,and retest. BRAKEBOOSTER VACUUMHOSE ( C h e c kv a l v e built-in)

LeakTest 1 . D e p r e s st h e b r a k ep e d a lw i t h t h e e n g i n er u n n i n g . then stop the engine.lf the pedal height does not vary while depressedfor 30 seconds,the vacuum b o o s t e r i s O K . l f t h e p e d a l r i s e s .t h e b o o s t e ri s faulty. 2, With the engine stopped,depressthe brake pedal s e v e r a lt i m e s u s i n g n o r m a l p r e s s u r e W h e n t h e Dedalis first depressed,it should be low On conthe pedalheightshouldgradsecutiveapplications, uallv rise. lf the pedal positiondoes not vary, checK the boostercheckvalve.

l./ 19-23

Rear Brake Pads Inspection and Replacement Never use an air hose or dry brush to clean brake assemblies. Use an OsHA-apptoved vacuum cl€aner to avoid breathing brake dust, 'L

4.

Removethe outerpad shim,pads,and pad retainers.

PAORETAINERS

Blockthe front wheels,loosenthe rear wneet nuts s l i g h t l y ,s u p p o r tt h e r e a r o f t h e v e h i c l eo n s a f e t y stands,then removethe rearwheels. Releasethe parkingbrake,and removethe calioer s hi e l d .

OUTERPAO SHIM Checkfor

REARBRAKE PADS Check for wear.

CALIPER SHIELD Removethe brakehose clamp bolt from the trailing arm first, then remove the two caliper mounting boltsand the caliperfrom the bracket. CAUTION: . Thoroughly clean the outside of the caliDerto prevent dust and dirt trom entering inside. . Support the calipor with a pieco of wire so that it does not hang fuom the brake hose.

U s i n g v e r n i e rc a l i p e r s m , e a s u r et h e t h i c k n e s so f each brakepad lining.The measurementdoes not anclude the pad backingplatethickness. BrakePad Thickness: Standard: 7.0 - 8.0 mm {0.28- 0.31 in} ServiceLimit: 1.5 mm {0.06in}

NOTErCheckthe hosesand pin boots for damage or deterioration. PARKING BRAKE CABLE ^.. ._-_ ---.

BACKINGPI-ATE

lf the pad thicknessis less than the service limit, replacethe padsand shimstogetheras a set.

19-24

I 7 . Cleanthe caliperthoroughly;removeany rust, and

checkfor groovesand cracks. Checkthe brakediscfor damageand cracks. l v l a k es u r e t h a t t h e p a d r e t a i n e r sa r e i n s t a l l e di n their correctpositions.

12. Rotatethe caliperpistonclockwiseinto the cylinder' then align the cutout in the piston with the tab on the innerpad by turningthe pistonback CAUTION: Lubricate ths boot with rubber grease to avoid twisting the piston boot. lf the piston boot is twisted, back it out so it sits properly. CALIP€RMOUNTING BOLTS 23 N,m {2.3kg{.m, 17 lbt'ft)

CUTOUT BRAKECALIPER PAD RETAINERS

Apply greaseto the pointsindicatedby the arrow in the followingdrawing: NOTE:Use the pad greaseincludedin the pad set or lMolykoteM77 grease,and apply a thin coat of greaseevenlyto the designatedpoints. . Pistonend and inner pad contactsurface . Padand caliperbracketcontactsurface . Outerpad shim and outer pad contactsurface . Outerpad shim and caliperbody contactsurface

1 3 . Installthe brakehoseclampon the trailingarm. 1 4 . Installand tightenthe calipermountingbolts. 1 5 . Installthe calipershield.

1 6 . After installation.checkfor leaksat hose and line jointsand connections, and retightenif necessary. 1 1 . l n s t a l lt h e b r a k ep a d s a n d o u t e r p a d s h i m o n t h e

caliper bracket.Installthe inner pad with its wear indicatorfacingdownward.

@ iwhen

t./

.

reusing the pads, always reinstall the brake pads in iheil original posiiions lo prevont loss ol braking efficiency Contaminaled brake discs or pads reduce stopping ability. Keepgreaseoff the discs and pads.

1 7 . Depressthe brakepedalseveraltimes to makesure

the brakeswork,then test-drive of the brakemay requrregreater NOTE:Engagement pedaltravel immediatelyafter the brakepads have of been replacedas a set. Severallight applications pedal travel. pedal the normal will restore the brake Greaterthan normal pedaltravel may damagethe mastercylinder.

19-25

RearBrakeDisc DiscRunoutInspection 1 . Loosenthe front wheel nuts slightly,then raisethe vehicle, and suppon it on safety stands. Remove the front wheels.

DiscThickness and Parallelism Inspection 1.

Loosenthe front wheel nuts slightly,then raisethe vehicle,and support it on safety stands. Remove the front wh6els.

2.

Removethe brakepads(seepagej9-24).

3.

U s i n g a m i c r o m e t e r .m e a s u r ed i s c t h i c k n e s sa t erght points, approximately45" apart and 1o mm {0.4 in) in from the outer edge of the disc. Replace the brakedisc if the smallestmeasurementis less than the max. refinishinglimit.

Removethe brakepads(seepage 19-24). I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s . Cleanthe discthoaoughly,and removea rust. Use wheel nuts and suitableplain washersto hold the disc securelyagainstthe hub. then mount a dial i n d i c a t o ra s s h o w n . a n d m e a s u r et h e r u n o u t a t 10 mm (0.4in) from the outeredgeof the disc. Brake Disc Runout: ServiceLimit:0.10mm {0.00,tin)

BrakeDisc Thickness: Standard:8.9 - 9.1 mm (0.350- 0.358in) Max. RsfinishingLimit: 8.0 mm {0.31in}

5.

Brake Disc Parallelirm:0.015mm (0.0006inl msx.

lf the disc is beyond the servicelimit, refinishthe brakedisc,

NOTE;This is the maximum allowabledifference betweenthe thicknessmeasurements.

Max. RetinishingLimit: 8.0 mm {0.31in) 4. NOTE:A new disc shouldbe refinishedif its runout is greaterthan 0.10mm (0.004in).

lf the disc is beyondthe servicelimit for Darallelism. refinishthe brakedisc. NOTE;Seesection18for brakedisc replacement.

19-26

Rear BrakeCaliper Disassembly

@ f l',leveruse an air hose or dry brush to clean brake

5,

R e m o v et h e p i n s a n d p i n b o o t s f r o m t h e c a l i p e r bracket.

assemblies. Use an OsHA-approvedvacuum cleaner to avoid breathing brake dust. . Contaminated brake discs or pads reduce stopping ability.

.

CAUTION: . Do not spill brake tluid on the cal; h may damagethe paint; if brake fluid does contact the paint, wash ii ofl immediatelYwith water. . To prevent spills, cover the hose ioints whh rags or shop tow€ls. . Clean all parts in brake fluid and air dry; blow out all passagsswith complessedair. 1.

Removethe calipershield(seepage 19-24).

2.

R e m o v et h e l o c k p i n a n d c l e v i sp i n . R e m o v et h e cableclip,and disconnectthe cablefrom the arm CABLECLIP

PIN A

6.

Removethe pad springfrom the caliperbody

Removethe banjobolt and two sealingwashers Removethe two calipermountingbolts and caliper body from the bracket. CALIPERMOUNTNG AOLTS

CALIPERBRACKET Checkfor cracks

SEALING WASHERS Replace.

BANJO BOLT

(cont'd)

19-27

RearBrakeGaliper Disassembly(cont'd) 7.

Removethe piston by rotatingthe piston counterc l o c k w i s ew i t h t h e t o o l , a n d r e m o v et h e p i s t o n boot. CAUTION: Avoid damaging the piston.

PISTONBOOT Replace.

Removethe pistonseal. CAUTION: Take care not to damage the cylinder bore.

CALIPERBODY Check for scoring on

9. Installthe specialtool betweenthe caliperbodv and spnng cover. CAUTION: Be caretul not to damags the inside of the caliper cylinder during caliper disassembty. BRAKESPRING COMPRESSOR 07HAE- SG00100

LOCKNUTS

Positionthe locknutsas shown.then turn the shaft untilthe platejust contactsthe caliperbody. N O T E : D o n o t c o m p r e s st h e s p r i n g u n d e r t h e springcover. 1 1 . Turn the shaft clockwise1/4-'ll2 tu.n to comoress adjustingspringB in the caliperbody. CAUTION: To preyant damage to the inner compononts. do not turn the shaft mor€ than 1/2 turn. SHAFT

LOCKNUTS

PISTONSEAL Replace.

ADJUSTII{G SPRING8

19-28

\ Lowerthe locknutsfully,and tightenthem securely.

15. Removethe adjustingbolt.

NOTE:Keepthe locknutsin this positionuntil you r e i n s t a l l t hcei r c l i p .

1 3 . Removethe circlipwith snapring pliers. SNAPRING PLIERS 07914- SA50001

't4. Hold the platewith your fingers,and turn the shaft Removethe specialtool from the counterclockwise. calioer.

LOCKNUTS

Removethe springcover,adjustingspringB, spacer, bearingA, and cup from the adjustingbolt. '17. Removethe sleevepiston,and removethe pin from the cam in the caliperbody.

SLEEVEPISTON Checklor wear and damage,

i

I

I

6-50-a w l \

I

O-RIITG Repl6ce.

l./

(cont'd)

19-29

RearBrakeGaliper (cont'dl Disassembly 18. Removethe returnspring. RETURN SPRING PARKINGLEVER/ CAM ASSEMBLY Checklor damage.

1 9 . Removethe parkinglever and cam as an assemblv from the caliperbody. CAUTION: Do not loosen the parking nut with the cam inslalled in the caliper body, lf the leyer and shaft must be separated, hold the lever in a vise, and loosenthe parking nut, Removethe cam boot.

19-30

I

Reassembly "n ",, hos6 or drv brush to ctoan brake assemblies. HP* o Use an OSHA-approvedvacuum cleanel to avoid brealhing brake dust' . Contaminatedbrake discs or pads reducestopping sbility. . When reusing the pads, in3tall thom in thoil original positions to prevent loss of braking efficiency' CAUTION: . Do not soill brake fluid on the vehicle; lt may damagelhe paint; if brake fluid does contacl the paint' wash it oft immediately with water. . Cl€anall Darts in brake fluid and air dry; blow out all passagsswith comPressedair' . Belore rsas3embling,checkthat all parts ars free ot du3t and othor tor€ign particles' . Replaceparts with new ones whenever spscifiodto do so. o Make sur€ no dirt or othor foreign matter is allowed to contaminate the brake tluid' . Always use Genuine Honda DOT 3 Brake fluid. Using a non-Hondabrake fluid can Gtuse corrosion and decreasethe lif€ of ths system. NOTE: . Coatpiston,pistonseal,and caliperborewith cleanbrakefluid . Replaceall rubberpartswith new oneswheneverdisassembled. Userecommendedsiliconeand pin greasesin the calipersealset.

o .-'{@]:

. -ffi,Use

rubbergreasein thecalipersealset. recommended -"'9 sPRTNG RETuRN

iiilji:ll;;

__X.,,..".^

8 mm FLANGEBOLT 23 N.m (2.3kgt'm, 17lbf ftl BLEEDSCREW 9 N.m (0.9kgtm,6.5lbf'ft|

@

BEARINGA

PAOSPNING

=^.

\

F

PISTONBOOT

-61

@@-t-.

CUP r---

Replace.

.ffi PINBOOTS Replace.

OUTERPAD SHIM BRAKEPAOS

I "l-r,r.,"or"'*o" orr" 23N.m{2.3kgtm,17lbf.ftl

l /

PISTONSEAL Replace.

@., \@

CALIPERBMCKET \ ----.-,o, MOUNTINGEOLTS q% 54 N.m (5.5 kgf.m,40lbl.ft)

CALIPEB BRACKET

PISTON

(cont'd)

19-31

RearBrakeCaliper (cont'dl Reassembly L

Packall cavitiesof the needlebearingwith the rec, ommendedrubbergreasein the calipersealset,

5.

I n s t a l l t h ep i n i n t h e c a m . O.RING Replace.

Coat a new cam boot with recommendedrubber grease in the caliper seal set, and install it in the caliperbody.

PARKINGNUT 28 N.m (2.8 kgt m,

20rbr.trt SLEEVE PISTON SPRII{G WASHEN

Installa new O-ringon the sleevepisron.

z.

.-_e!!!9!.{

RUBBER GREASE

7.

Installthe sleevepistonso that the hole in the bottom of the pistonis alignedwith the pin in the cam, and the two pins on the pistonare alignedwith the holesin the calioer. Coat a new cup with recommendedrubbergrease in the caliperseal set, and installit with its groove facingthe bearingA side of the adjustingbolt.

€8.--:BTif @'-.-3nfi""'i"

Apply recommendedrubber greasein the caliper seal set to the pin contactingarea of the cam, and installthe cam and lever assemblyinto the caliper bodv.

@--seacrn eeenrne a $

fi,*,*^"

lnstallthe returnspring. CAUTION: . When the cam and lever wgre separatod.b€ surg to assemble them bofore installing the cam in the caliper body, Install the lev€r and spring washer. apply locking agent to the threads, and tighten the parking nut while holding the l.vor whh a vise, . Avoid damaging the cam boot since it must bs installed before thg cam. . When installing the cam, do nol allow the cam boot lips lo turn outside in.

GF-

=^.

#-g!!!!!Jl

RUBBER GREASE

o

19-32

CUP Replace.

Fit the bearingA, spacer.adjustingspring B, and springcover on the adjustingbolt, and installthem in the caliDercvlinder.

1 0 . l n s t a l lt h e s p e c i atl o o l o n t o t h e s p r i n gc o v e r ,a n d turn the shaft untilthe locknutcontactsthe plate.

13. Coat a new piston sealwith recommendedsilicone greasein the calipersealset,and installit in the cali-

per.

PISTONSEAL Replace.

-6l

PISTONBOOT Replace. RUBBER GREASE

1 4 . Apply recommendedrubber greasein the caliper seal set to the sealinglips and insideof a new piston boot,and installit in the caliper. Coatthe outsideof the pistonwith brakefluid, and i n s t a l li t o n t o t h e a d j u s t i n gb o l t w h i l e r o t a t i n gi t clockwisewith the tool. 1 1 . Checkthat the flaredend of the springcoveris below the circlipgroove.

CAUTION: Avoid damaging the piston and piston boot.

12. Installthe circlip into the groove.then removethe specialtool. NOTE:Checkthat the circlipis seatedin the groove properly.

PISTON CIRCLIP

SPRINGCOVER

t.t

(cont'd)

19-33

RearBrakeCaliper (cont'dl Reassembly '16. Installthepad

springonto the caliper.

21. Installthe brakepad retainersand brakepads (see page19-25). 22. Align the cutout in the piston with the tab on the innerpad (seepage 19-25). Installthe caliperonto the caliperbracket.and tighten the calipermountingbolts.

PAD SPRING

CALIPERMOUNTINGBOLTS 23 N.m {2.3 kg{.m. 17 lbf.ft)

1 1 . Apply the recommendedpin groasein the caliper sealset to the slidingsurfaceof the pins and inside of the new pin boots. Installthe pin boots into the groovesin the caliper bracketproperly. PINBOOTS Replsce.

BANJO BOLT 34 N.m 13.5kg{.m. 25 rbtft)

WASHERS Replace.

24. Connectthe brakehoseto the caliperwith new seal, ing washers,and tightenthe banjo bolt, Insertths cable through the arm, and connectthe cabls to the lever with the clevis pin and lock pin. Installthe cableclip securely.

CLEVISPIN

-t (Bl.ck Colorl

//t

LOCKPIN Roplace.

PIN Repl6ce.

PIN GREASE

19. Insertpin A and pin B into the caliperbracket. 20. Installthe pin boots into the grooves in the p rn s propefly.

19-34

26. Installthe caliDershield. 27. Fill the brakereservoir,and bleedthe brakesvstem (seepage19-71. 28. Operatethe brake pedal severaltimes, then adjust the parkingbrake(seepage 19-6). performthe followingchecks: 29. After installation, . Checkfor leaksat hose and line joints and connections,and retightenif necessary. . Checkthe parkingbrakeleverfor operation,and adjust it if necessary. . Checkfor brakehosefor interference or twistinq.

RearDrum Brake Index/lnspection Never use an air hose or dly brush to clean brake assemblies, Use an OSHA approved vacuum cleanarto avoid breathing brake dust, a Contaminatedbrake linings or drums reducestopping ability. a Block the tront wheels before iacking up ths r€ar of lhe vehicle. '1.

Blockthe front wheels,loosenthe rear wheel nuts slightly,supportthe rear of the vehicleon safety stands,then removethe rearwheels.

2.

Release the parkingbrake,and removethe rearbrakedrum.

WHEELCYLINDER Inspectfor leakage. lf necessary, replaceas an assembly.

I N m 10.9kgtm, 6.5 lbf.ftl

PARKINGBRAKELEVER Markedleftand right.

u-cLrP

WAVE WASHER

Replace.

I

UPPERRETURNSPRING Checkfor weakness ano oamage,

@

J

PIVOTPIN

/ €f-l .^ *'t")

TENSIONPIN

10 mm BOLT 6,1Nm 15.5kgf m, 47 tbf.ft)

BACKINGPLATE Markedlelt andright-

II

ctEv'sB / ADJUSTERBOI-T

|

d " /

/

, Installsecurelyon tensionpin.

IU

(t

Checkratchetteeth for wear and damage.

LOWERRETURN SPRING Checkfor weakness and oamage.

BRAKESHOE Inspection, seepage19-36 lf brakeshoes are to be r e u s e d ,m a r k a n d r e a s s e m b l e in same position.

,.ro,".r r.*,"n

/ /

SELF.ADJUSTER LEVEB SELF-ADJUSTER SPRING Checkfor weakness ano oamage.

BRAKEDRUM Inspection, seepage'1936

t

19-35

RearDrum Brake Inspection 1 . Checkthe wheelcylinderfor leakage.

6.

Checkthe brakeliningsfor cracking,glazing,wear, and contamination.

Measure the inside diameter oJ the brake drum usingthe insideverniercalipers. Drum Inside Diameter: Standard: 199.9- 200.0mm {7.870- 7.874in) Servic€Limit: 201.0mm (7.913inl

Measurethe brakeliningthickness. Brake Lining Thickness: Standard: 4.0 mm {0.157in} ServiceLimit: 2.0 mm 10.08in)

INSIDEVERNIERCALIPERS

WHEELCYLINDER

BRAKEORUM

LININGS

NOTE; Measurementdoes not include brakeshoe thickness. 4.

lf the brakelining thicknessis lessthan the service limit, replacethe brakeshoesas a set. Checkthe bearingsin the hub unit for smooth operation. lf defective,refer to section 18

19-36

7.

l f t h e i n s i d ed i a m e t e ro f t h e b r a k ed r u m i s m o r e than the servicelimit, replacethe brakedrum.

8.

C h e c kt h e b r a k ed r u m f o r s c o r i n g ,g r o o v e s ,a n d cracks.

t

BrakeShoeDisassembly 1.

R e m o v et h e t e n s i o np i n s b y p u s h i n gt h e r e t a i n e r springsand turningthem. TENSIONPINS

6.

Removethe wave washer,parkingbrakelever,and pivot pin from the brakeshoe by removingthe Uclrp.

PARKINGERAKE I-EVER

WAVEWASHER

/

@@

I

I U-CLIP Replace.

RETAINER SPRINGS Lower the brake shoe assembly,and remove the lower returnspring. NOTEi Be carefulnot to damagethe dust cover on the wheelcylinder.

t

1 . Apply brakecylindergrease(P/Nr08733- B020E)or equivalentrubber greaseto the sliding surfaceof the pivot pin,and insertthe pin into the brakeshoe.

3.

Removethe brakeshoeassembly.

4.

the parkingbrakecablefrom the parking Disconnect brakelever.

Installthe parkingbrakelever and wave washeron the pivot pin and securethem with the U-clip,

lever, Removethe upper returnspring,self-adjuster a n d s e l f - a d j u s t esrp r i n g ,a n d s e p a r a t et h e b r a k e snoe5.

NOTE: Pinchthe U-clip securelyto preventthe pivot pin from comingout of the brakeshoe.

ADJUSTEBBOLT Checkratchetteethfor wearano oamage.

UPPERRETURNSPRING Checkfor weakness a n oo a m a g e .

N r ll

//

t

BrakeShoeReassembly

,6;::"' LEVER

,'/

(cont'd)

19-37

RearDrum Brake BrakeShoeReassembly {cont'dl C o n n e c tt h e p a r k i n g b r a k ec a b l e t o t h e p a r k i n g brakelever.

5. Cleanthe threadedportionsof clevisesA and B. Coat the threads of the cleviseswith grease.To shoften the clevises, tun the adjuster bolt.

Apply greaseon eachslidingsurface. contaminated brake linings reduce !@ stopping ability. Keep greaseor oil off the blake linings. Wipe any excessgreaseoff the parts, .

Apply brakecylindergrease{P/N:08733- 8020E) o r e q u i v a l e nrt u b b e rg r e a s et o t h e s l i d i n gs u r facesas shown.

6. Hook the self-adjusterspring to the self-adjuster leverfirst,then to the brakeshoe 7. Installthe clevisesand upper return spring. noting the installationdirection. NOTE:Be carefulnot to damagethe wheel cylinder dustcovers, 8. Installthe lower returnspring.

+a

Slidingsurlace

9. Installthe tensionpins and retainingsprings.

SpRtNG uppERRETURT{

CLEVISB CLEVISA

Apply Molykote44MAto the brakeshoeendsand oppositeedgesofthe shoesas shown.

_' o +O

Opposite edge of the shoe Brake shoe ends

LOWERRETURNSPRING

't0. Installthebrakedrum. 1 1 . lf the wheel cylinderhas been removed,bleed the

brakesystem(seepage 19-7),and checkfor leaksat brakeline connections, and retightenif necessary. 12. Depressthe brake pedal severaltimes to set the self-adjusting brake. 1 3 . Adjustthe parkingbrake(seepage19-6).

19-38

Brake Hoses/Lines

L

J

Specifications Inspection/Torque and twisting. leaks,interference, t. Inspectthe brakehosesfor damage,deterioration, 2. Checkthe brakelinesfor damage,rusting.and leakage.Also checkfor bent brakelines. and retightenif necessary' 3. Checkfor ieaksat hoseand line iointsand connections, 4. Checkthe mastercylinderand ABS modulatorunit for damageand leakage CAUTION: Replacetho brake hose clip whenev€r the brake hose is serviced.

l-lNE ABS MODULATORUNIT-Io-BRAKE 19 N.m (1.9 kgf.m, 14lbl.ftl CONTROLVALVE. PROPOBTIONING io-BRAKELINE 11 tbf.ftl l5 N.m (1.5 MASTERCYLINDER-Io-BMKELINE 15 N.m (1.5ksrf.m,11 lbf'ft)

J

REARDISGBRAKE: BRAKEHOSE-to4ALlPER {BANJOBOLT} 34 N.m (3.5kgtm,25 lbf ftl BLEEOSCREW 9 N'm (0.9kgf.m, 6.5 lM.ftl CYLINDER BRAKELINE-to-WHEEL 15 N.m (1.5kgl.m, 11 lbf.ftl BLEEDSCREW 7 N.m {0.7kst m, 5 lbf,ttl

HOSE BRAKELINE-io-aRAKE 15 N.m {1.5

11 tbtft)

HOSE BRAKELINE-Io-BRAKE 15 N.m (1.5kgt.m, 11 lbf'ft)

(BANJOBOLT} 3,1N.m 13.5kgf.m, 25 lbf.ft)

J

19-39

BrakeHoses/Lines HoseReplacement CAUTION: . Bgfore reagsembling,chgck that all parts are free of dust and othor foroign particles. . Repl8ceparts with new ones whenever specified to do so, . Do not spill brake fluid on th6 vehicle; it may damage tho paint; if brake fluid does contact the paint, wash it off immediately with water.

6. Installthe brakehose bracketand brakehose onto the knucklefirst.then connectthe brakehoseto the caliperwith the banjobolt and new sealingwashers. BRAKEHOSE

1 . Replacethe brakehose if the hose is twisted,cracked, or if it leaks. Disconnect the brakehosefrom the brakeline using a 10 mm flarenut wrench. FLARENUT WRENCH lCommercially available)

6 mm HOSEBRACKET BOLTS 9.8 N.m {1.0kgf m, 7 lbtfr}

BRAKELINE

BANJOBOI.T 34N.m {3.5kgf.m,25lbt.ftl 7 . I n s t a l lt h e b r a k eh o s e o n t o t h e u o o e r b r a k eh o s e bracketwith a new brakehoseclip 15 N.m (1.s ks{.m, 11 lbl.ftl

BRAKEHOSE

Removeand discardthe brake hose cliD from the brakehose.

8 . Connectthe brakelineto the brakehose. After installingthe brakehose,bleedthe brakesystem (seepage 19-7). Removethe banjo bolt, and disconnectthe brake hosefrom the caliper.

1 0 . Performthe followingchecks: .

Removethe brakehose bracketfrom the knuckle. .

Checkthe brakehoseand line joint for leaks,and tightenif necessary. Checkthe brakehosesfor interference and twistIn g .

19-4 0

ParkingBrakeCable and Replacement Inspection

L

CAUTION: The parking blake cables must not be bent or distorted. This will lead to stiff operation and premature cable failure.

PARKINGBRAKECABLE Checkfor faultymovement. PARKINGBRAKELEVER Checkfor smooth operation.

DISCBRAKETYPE: CLEVISPIN

EOUALIZER

\ i

,

PARKINGBRAKESWITCH

Disc BrakeType: the parkingbrakecablefrom the leveron the Disconnect caliperby removingthe lockpin and clevispin, and remove the cablefrom the arm by removingthe clip

Drum BrakeType: Removethe parkingbrakecablefrom the backingplate usinga 12 mm offsetwrenchas shown.

PARKINGERAKECABLE BACKINGPLATE

CLEVISPIN

/

{tt

12 mm OFFSETWRENCH (Commercially available)

19-41

L

-

Anti-lockBrakeSystem(ABSI SpecialTools ............. 19-44 ComponentLocations......................... 19-45 Anti-lockBrakeSystem (ABS)

t

t /

Wheel Sensor ........19-64 Solenoid ................. 19-60 ABS PumpMotor ............................. 19-68 Main Relay ............. 19-71 lgnition Voltage .... 19-73 CentralProcessingUnit {CPU}........19-74 Modulator Unit Removal/lnstallation....................... 19-75 ABS Control Unit Replacement .........19-76 Pulsers/WheelSensors Inspection .............. 19-76 Wheel SensorReplacement............ 19-77

Features/Construction..................., 19-46 Operation ............... 19-47 Circuit Diagram .........19-50 ABS Control Unit Terminal Arrangement .........19-52 TroubleshootingPrecautions............. 19-54 DiagnosticTroubleCode (DTCI DiagnosticTroubleGode(DTCI Indication ........... 19-56 DTCErasure ........... 19-57 Symptom-to SystemChart ............. 19-58 Troubleshooting ABS IndicatorLight DoesNot ComeOn ............ 19-60 ABS IndicatorLight DoesNot Go Off ............................................ 19-62

SpecialTools

Ret.No. (!)

19-44

I I

Tool Number 07PM- 0010100

I I

Description SCSService Connector

I

O,V I pageReference t I 19_s6

ComponentLocations

t a SERVICECHECKCONNECTOR {2PI MOOULATORUNIT

ABS CONTROLUNIT

BIGHT.REAR WHEEL SENSORCONNECTOR RIGHT-REAR WHEELSENSOR

LEFT.R€AR WHEEL SENSOR CONNECTOR UNDER.DASHFUSE/RELAY8OX LEFT.FRONT WHEELSENSOR

J

FUSE/RELAY BOX UNDER.HOOD lcl lilo Al FUSE

E

o

ABS INDICATORLIGHT

UNOEF.DASI{FUSE/RELAYBOX METEBI7.5 AI FUSE

t

HORN/STOPI15 A) FUSE

ABS FUSE/RELAYBOX UNDER.HOOO ABS +B (20 A) FUSE

PUMP MOTOR{'O A} FUSE

0 00000 n u 0 00000 0 BR DEFRLY 17,5A) FUSE

MTRCHECK(7.5AI FUSE

PUMPMOTORBELAY

19-45

Anti-lockBrakeSystem(ABSI Features/Construction When the brakepedalis depressedduring driving,the wheelscan lock beforethe vehiclecomesto a stop, In such a case, the maneuverability of the vehicleis reducedif the front wheelsare locked,and the stabilityof the vehicleis reducedif the rearwheelsare locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate of the wheelsto ensurethe grip forceof the tires.and it therebyensuresthe maneuverbility and stabilityof the vehicle. Judgingthe vehiclespeed.the ABS calculatesthe slip rateof the wheelsbasedon the vehiclespeedand the wheel speed, then it controlsthe brakefluid pressureto attainthe targetslip rate.

Grip Force of Tire and Road Surlace

Slip Rate

COEFFICIENT OF FRICTION

BRAKING STARTPOINT

TARGETSLIPRATE ROTATIONAL DIRECTION

RADIAL DIRECTION OF THE ROTATIONAL OIRECTION SLIPRATE

19-46

A: Distancewithout slio 8: Slippsd distance C: Actuel distance VEIIICLESPEED- WHEELSPEEO sr-rrmre=f= VEHICLESPEED

t

-

Operation ABS Control Unit Main Control The ABS control unit detectsthe wheel speedbasedon the wheel sensorsignalit received,then it calculatesthe vehicle speed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring decelerationbasedon the rateof deceleration. The ABS control unit calculatesthe slip rate of each wheel. and it transmitsthe control signal to the modulator unit solenoidvalvewhen the slip rateis high. The pressurereductioncontrolis a three-modesystem,that is pressurereduction,pressureretainingand pressureintensifying modes.

t

Self-diagnosisFunqtion The ABS controlunit is equippedwith a main CPUand a sub CPU,and the CPUScheckeachother' The CPUscheckthe circuitof the svstem. "systemdown mode" or the "controlinhibitionmode" Whenthe CPUSdetectfailure,they shiftto the

SOLENOID VALVE

LIGHT ABS INDICATOR

MAIN RELAY

SYSTEIV DOWN

ON

No operation

Drive inhibition

CONTROL INHIBITION

ON

No operalron

Drive inhibition

MODE

CPU Operation*r

Operation

Restartcondition lgnition switch

OFF + ON

Automatic

DTC Memory

Memory

*1: ExceptCPUfailure can be classifieldinto thesefour categories: The self-diagnosis Initial diagnosis O: @: ExceptABS control @: DuringABS control @: Duringwarning On-board DiagnosisFunstion The ABS controlunit is connectedto the data link connector{16P). The ABS systemcan be diagnosedwith the HondaPGMTester.

/

(cont'd)

19-47

Anti-lockBrakeSystem{ABS) Operation(cont'dl ABS Modulator The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and the dampingchamber. The modulatorreducesthe caliperfluid pressuredirectly,and it is also referredto as a circulatingtype becausethe brake fluid circulatesthrough the caliper,reservoirand the mastercylinder. The hydrauliccontrolhasthree modes:pressurereducing,pressureretaining,and pressureintensifying. The hydrauliccircuitis the independent four channeltype, one channelfor eachwheel.

PUMPMOTOR

RF

LR

rN: INLETVALVE Pressureintensifyingmode:Inletvalveopen,outletvalveclosed { N O R M A L t YO p E N I OUT: OUTIET VALVE {NORMALIY CTOSED) Mastercylinderfluid is pumpedout to the caliDer. Pressureretainingmode: Inletvalveclosed,outletvalveclosed Caliperfluid is retainedby the inletvalveand outletvalve. Pressurereducingmode: Inletvalveclosed,outletvalveoDen Caliperfluid flows throughthe outletvalveto the reservoir. Motor operationmode: When startingthe pressurereducingmode,the pump motor is ON. WhenstoppingABS operation,the pump motor is OFF. The reservoirfluid is pumpedout by the pump,throughthe dampingchamber,to the master cvlinder.

19-48

L Wheel Soeed and Modulator Contlo

EELSPEED

OUTLET VALVE ON OFF

t

INLET VALVE ON OFF t\,40ToR ON OFF pressure when the wheelspeeddropssharplybelowthe vehiclespeed,the inletvalveclosesto retainthe caliperfluid pressure. The pump fluid caliper reduce the to momentarily opens valve the outlet further, speed drops When the wheel motor startsat this time. As the wheelspeedis restored,the inletvalveopensmomentarilyto increasethe caliperfluid pressure. WheelSensoJ type The wheelsensorsare the magneticcontactless frequencychanges As the gear pulserteeth rotatepastthe wheel sensor'smagneticcoil,AC currentis generatedThe AC and therebydetects frequency signal wheel sensor the unit detects with the wheel speed.The ABS control in accordance the wheelspeed. Thereare four wheelsensors,one for eachwheel The gear pulserhas50 teeth. GEARPULSEB

at HIGHSPEED

WHEELSENSOB gl

/

at LOWSPEED

= o

19-49

GircuitDiagram

AA DEFBLYI7.5AI

-

E8l{'Ytr LEFT.FSONT SOLENOIO

_@f_u, n4@f-n,

UNDER.HOOO A8S FUSE,/FELAY BOX 3P CONNECTOR(O number) |

UNDER-OASH FUSSRELAY 8OX (O numbe, ZoPCONNECTOR 2 3

2 3 l

UNDER.HOODAAS FUSE/RELAYBOX 2P CONNECTOR(! number) |

5 6

t3 / i 1 5 /

t0 tl

MOOULATORUNIT IOP CONNECTOR

7 8 I t8

20

UNDER.OASHFUSE,/RELAY BOX 1 8 PC O N N E C T O R( E n u m b € r ) 2 3

- l

9

ll

5 6 2 13)t4 /

1617

GAUGEASSEMELY5P CONNECTOR

---t-t 1 t / 1 3) / l 5 l Wiresideot temaleterminals

19-50

zrJrF!_

l l l 2 3 l l

14TiEltl

c@4

PIMP MOTOR2P CONNECTOR (Ll number) fFl

GTN

t

ABS CONIROLUN]T

ECM/ PCMISCS'

V

+B

Y

WHTNED

,,,+-{l-, [,b.,,,,, B6li! -F- ?,,] 8U(

JG,Ol, Ga02

SENSOR LEFT.

RIGHT,

\EWIK

l

LEFT

-o&"^1'

;___.|-1 **1. ,I

coierou cot,croz

ABS CONTROLUNIT26P CONNECTOR 1O numb€r) 1 2 3 4 14t5 1 6 1 7

6

/

8

1 9 , / 21

I

CHECK SERVICE (2P} CONNECTOR

l 0 . / t t 1 2 r3

lrl2f

23

UNIT22PCONNECTOR ABSCONTROL 1! numb€r)

OATALINK CONNECTORO 6P)

WHEELSENSOR 2PCONNECTOB FRONT

/.[Ttl\ REAR tc-T-l z I

r[B'

l

12 13

/

Wire side of female terminals

Terminalsideof maleterminals

19-51

ABS ControlUnit TerminalArrangement ABSCONTROL UNIT26PCONNECTOR

Wire sideof temaleterminals

Terminal numo0r

Wire Terminalsign color Terminalnamo

Voltage Conditions (lgnitionSwitch ON flt))

Dgscription teminals

PCOM (Primary common)

Power sourcefor the solenoid valve and pump motor.

scoM

Powersourcefor the solenoid

6

GRY

8

GRN

sensorsignal.

RLO Detectsleft-rearwheelsensor (Rear-left 0) s r g n a l . FRO D€tectsright-frontwheel (Front-right0) sgnsorsrgnal, STOP hects brakeswitchsignal. (Stop) (Prevents unnecess€ry ABSoperation)

2.GND

12

14

15

r6 17 19

FLO BRN^/vHT (Front-left 0)

YEL

RLOUT (Rearjeftoutlet)

RR]N REDMHT (Rear-right inlet) B1 (Battery1) 82 WHT/GRN (Baftery 2) GND2 BLK {Ground2) RR1 GRN/'/EL (Rear-right 1) R L l LT BLU (Rea.-left 1)

53mVor aboveon

4-17

(AC digitaltester Whenthe wheelis nce) turned at 1 turn/second. range){Fefera

6-19

150mvp-por above on oscilloscope

a-21

Stops Brakepedaldepressed. 9-GND Brakepedalreleased. Whenthe wheelis turnedat 1 turn/ secono.

12.GND

Powersourcefor the solenoid vatveandpumpmotor. Powersourcefor the solenoid varveanopumpmotor. Ground for the ABS control unit. Detects right-rear wheel sensorsignal.

13-GND

19-52

GND3 (Ground 3)

AC:3^6V Approx.3 V

Batteryvoltage 15.GND 16-GND 17-4

19-6 21-8

Below0.3V 53 mV or above on digitaltester Whenthe wheelis turned (ACrange) at 1 turn/second. (Referance) 150 mVp-por above on oscilloscope

23-10

Stops

Approx.2.5V '6

25.GND

Ground for the ABS cgntrol unit.

OFF

14.GND

ON

RL-IN (Rear-lett inletl

-9

53mVor aboveon (AC digitaltester range)(Referance) 150mVFporabove on oscilloscope

Approx.2.5V OV

OFF theSCSservice] lconnect connector I i

ut

BLK

ON

Approx.2.5V Batteryvoltage OV

ON

9!ops

Drivesleft-rear outletsolenoid

Drivesright-rearinlet solenoid valve.

Approx.3 V Batt€ryvoltage

10-23

Detectsleft-rearwheelsensor sagnal. FRl Detectsright-frontwheel GRN/BLK(Front-right 1) sensorsignal. FL1 Detectsleft-frontwheelsensor (Front-left1) s i g n a l . Drivesleft-r€ar inletsolenoid RED

OV

OFF theSCS service\ lConnect conneclor l \

3-GND

Detectsleft-frontwheelsensor signal. 10

ON

ON

AC:3-6 V

BLK/WHT (Secondary common) tG2 Detectsignitionswitch2 ELVBLU (lgnition 2) !9nal. (systemactivatesignal) RRO Detects right-rear wheel BLU/YEL (Rear-right 0)

= 1-GND

Output voltago

26.GND

-9

ON

OV

OFF

AC:3-6 V

OFF theSCS service] lconnect connector l \

Approx.3 V Below0.3V

\

e

UNIT22PCONNECTOR ABSCONTROL

Wiresideof femaleterminals

Volt.ge Terminal numbel

Wiro coror

Terminalsign

De3cription

lTqrminalnamsl

FR-IN

terminils

Drivesright-frontinlet solenoidvalve.

ON I-GND

RED/BLU {Front-right inlet)

riJ

Detectsservicechecksignal troublecode (Servicecheck {Diagnostic indication) signal)

scs

BRN

t

(Warning ramp)

7

BLU/RED

8

BLU/YEL

10

YEUBLK

11

FLIN RED/BLK inlet) {Front-l€ft

l4

FL.OUT {Front-left outlet)

ConditionE (lgnition Switch ON (ll)l

DrivesABSindicatorlight(The indicatorlightgo€soff when ABScontrolunitoutputsbattery volta9e), Not used. Drivesleft-frontoutlet solenoidvalve.

MCK srgnal. lMotorcheck)

22

BLK

RR-OUT (Rear-right outletl GND2 (Ground2)

AC:3-6 V

OV Appro)(.5 V Approx,2 V

Indicatorlight ON

Batteryvoltage

lightOFF Indicator

10-GNO

Approx.3 V

ON

OV

OFF

A C : 3 - 6V

ON

11-GND

PMR YELRED (Pumpmotor reray,

BLU

OFF

7-GND

OFF the lconnect SCSservicq connector I \

12-GNO

Pump 1 7 . G N D motor

reray ON 19-GND

Batteryvoltage

OFF

OV ON

OV

OFF

AC:3-6 V

Pump ON motor relay OFF OFF servicq theSCS lconnect connedor ) \ ON

21-GND uJ

22-GND

ON

OFF sewicq ponnect theSCS connedor l \

Drivesright-rearoutlel solenoidvalve.

Ground for the ABS control untt.

Approx.3 V

Approx. 5 V

14.GND

Drivespumpmotorrelay. 19

OV

OFF theSCSservicq /Connect connector I \

Drives left-front inlet solenoid

Drivesright-frontoutlet FR.OUT YEUBLU (Front-right solenoidvalve. outlet) with Honda Communicates DLC PGMTester. (Datalink LT BLU connector) BRNA/EL

ON

SCSserviceconnector connected. 4-GND SCSserviceconnector disconneded.

Detects pump motor drive

17

-9

Output voltago

Approx.3 V OV AC:3-6 V Approx.3 V Below0.3v

19-53

TroubleshootingPrecautions

ABS Indicator Light I The ABS indicatorlight comeson when the ABS controlunit detectsa problemin the system.However,even though the system is normal,the ABs indicatorlight can come on, too, under the following conditions.To determine the actualcauseof the problem,questionthe customeraboutthe problem,takingthe followingconditionsinto consideration. . Signaldisturbance . Wheelsoin . Only drivewheelsrotate . Batteryvoltage fluctuates 2. When a problemis detectedand the ABS indicatorlight comes on, the indicatorlight can stay on untatthe ignition switchis turnedoff, or it can automatically go off, dependingon the mode. . Lightstaysonuntil the ignitionswitchisturned off;Whenthe systemis inthesvstemdown mode. o Lightautomaticallygoesoff: Whenthe systemis in the controlinhibitionmode. (refer to symptom-to-systemchart) 3 The ABS indicator light stays on when the system is reactivatedwithout erasing the DTC,but it goes off after starting the car. when the wheel sensorsystem is faulty and the ABS indicatorlight comeson, the algorithm of the system automatically turns off the ABS indicatorlight after the wheel speedsignal returnsto the normal speed.while, when the DTCis erased, the CPUis resetand the ABS indicatorlight goes off when the systemcheck€dout normal by the initial diagnosis. Therefore,test-drivethe car after servicingthe wheel sensor system, and be sure that the ABS indicator light does not come on. 4. When the ABS control unit outputs battery voltage to the gauge assembty,the ABS indicator light goes off. DiagnosticTrouble Code (DTC) 1. The diagnostictroublecode (DTC)is memorizedwhen a problemis detectedand the ABS indicatorlight does not go off, or when the ABS indicatorlight comeson. The DTCis not memorizedwhen the ABs indicatorrightcomeson unressthe cpU is activated. 2. The memory can hold any number of DTCs.However,when the same DTc is detectedtwice or more, the later one is writtenover the old one. Therefore.when the same problem is detectedrepeatedly,it is recordedas one DTC. 3. The DTCSare indicatedin the orderof ascendingnumber,not in the orderthev occur. 4. The DTCSare memorizedin the EEpROM{non-volatilememorv}. Therefore,the memorizedDTCScannot be canceledby disconnectingthe battery. perform the specifiedoroceduresto erase. Solf-diagnosis 1. The self-diagnosis can be classifieldintothesefour categories: ' Initialdiagnosis; Performedright afterthe enginestarts and untiltheABs indicatorlight goes off. o ExceptABS control: Performedwhen the ABS is not functioning, . DuringABS control:Performedwhen the ABS is functioning. . Duringwarning: Performedwhen the ABS indicatorlight is ON. 2 The system performs the following controls when a problem is detectedby the self-diagnosis: . ABS indicatorlight ON . Memory of DTC . Modechangeto the "systemdown mode,,or the "controlinhibitionmode,,. ABS INDICATOR LIGHT

MAIN RELAY

SYSTEM DOWN

ON

No operal|on

Drive inhibition

Operation+r

CONTROL INHIBITION

ON

No operat|on

Orive inhibition

Operation

MODE

SOLENOID VALVE

CPU

Restartcondition lgnition switch

OFF- ON

Automatic

DTC

Memory Memory

*1: ExceptCPUfailure

19-54

t

J Kickback 1. The motor operateswhen the ABS is functioning,and the fluid in the reservoiris forcedout to the mastercylinder causingkickbackat the brakepedal. 2.

TheABScontrolunit operatesthe solenoidvalvewhen the brakepedalis releasedafterthe initialdiagnosisYoumay hearthe faint solenoidvalveoperationsoundat this time. but it is normal.

Pump Motor 1. The pump motor operateswhen the ABS is functioning 2.

You may hearthe faint operationsound The ABS control unit checksthe pump motor operationduring acceleration. at this time. but it is normal.

Brake Fluid Replacament/AirBlsading and air bleedingproceduresare the same as for conventionalbrakes 1. Brakefluid replacement Troubleshooting pre1. The troubleshootingflowchartsexplainthe procedureson the assumptionthat the causeof the problemis still sentand the ABS indicatorlight is still on. followingthe flowchartwhen the ABS indicatorlight does not come on can resultin incorNotethat troubleshooting judgment. rect 2.

\

t

Ouestionthe customerabout the conditionswhen the problemoccurred,and try to reproducethe same conditions for troubleshooting. self,diagnosisis made at varioustimes such as the initialdiagnosis,exceptABS control.during ABS control,during acceleraiion,during the specifiedvehiclespeed,etc. Therefore,the symptom cannot be checkedunlessthe check conditionsmatchwith the problemconditions

3.

When the ABS indicatorlight does not come on duringthe test drive,but the troubleshootingis performedbasedon the DTC,checkfor the looseconnectors.poor contactof the terminals,etc,beforetroubleshooting.

4.

erasethe DTCand test-drivethe car.Be surethat the ABS indicatorlight does not come on. Aftertroubleshooting,

5.

The connectorillustrationsshow the femaleconnectorswith a singleoutlineand the male connectorswith a double ouflrne.

6.

The connectorterminalcavitiescontainingfemaleterminalsare alwaysnumberedby lookingat the connectorfrom the wire side.and the cavitiescontainingmale terminalsare alwaysnumberedby lookingat the connectorfrom the terminalside.

r' 19-55

DiagnosticTrouble Code (DTCI DiagnosticTroubleCode{DTC)Indication NOTE:This operationcan also be carriedout with the HondapGM Tesrer. l

connectthe scs serviceconnectorto the servicecheckconnectorinside the passenger,s side kickpanel.

2.

Turn the ignitionswitchON (||).but do not startthe engine. NOTE:Do not depressthe brakepedalwhen turningthe ignitionswitch.

3

Recordthe brinkingfrequencyof the ABS indicatorright.The brinkingfrequency indicatesthe DTc.

4,

Turn the ignitionswitchOFF,and removethe SCSserviceconnector. NorE: The MslfunctionIndicatorLamp (MlL)will stay on after the engine is startedif the scs serviceconnectoris connected.

5.

Erasethe DTC.

Condhionsfor DTCindication . The vehicleis stoDDed. . The SCSserviceconnector is connectedbefore the ignition switch is turned ON fll). . The brakepedalis released. . Th€ SCSservice connectorremains connectedduring this procedure The DTGindication stops 8nd the ABs conltol unit executesthe softwaro tunqtion if at least one of the following conditions b satisfied: o The vehicleis not stoDoed. ' The ABS control unit receivesthe normat signal (which is for the ABS controt unit) from a Honda pGM Tester. . The SCSserviceconnector is disconnectedduring this procedu.e,

u.s.A.

@ CANADA

@

SERVICECHECK CONNECTOR {2PI

SCSSERVICECONNECTOR 07PAZ- 0010100

ABS INDICATORLIGHT

DTC: 3 3 A8S INDICAIORLIGHT

swirch Snilion

' when the ignitionswitchis turnedoN (ll),the ABs indicator light comeson to checkthe bulb. Do not count it as a DTc. o The ABS controlunit can memorizeany numberof DTCs. . The new DTCis not memorizedwhen the ABS controlunit has alreadymemorizedthe same . l f t h e D T C i s n o t m e m o r i z e d , t h e A B S i n d i c a t o r l i g h t s t a y s O N a f t e r i t g o e s o f f f o r 3 . 6 s e cDTC, onds.

19-56

L

J

DTGErasure side kickpanel. 1 . Connectthe SCSserviceconnectorto the servicecheckconnectorinsidethe passenger's 2.

Depressthe brakepedal. indicatorlight Turn the ignition switch oN (ll) while holdingthe brakepedal,but do not start the engine.The ABS goes off after two seconds.

4.

Afterthe indicatorlight goes off, releasethe brakepedal The indicatorlightcomeson afterfour seconds

5.

goes off again after four secAfter the indicatorlight comeson, depressthe brakepedal again.The indicatorlight pedal is still depressed. The brake onds.

6.

Afterthe jndicatorlight goesoff, releasethe brakepedalagain'

7.

Afterfour seconds,the indicatorlight blinkstwice for 0 3 secondand the DTCis erased

8.

Confirmthe DTCindication,and checkthat the DTCwas erased

the brakepedal NOTE:Always maintainthese steps.lf you disconnectthe scs serviceconnectorand/orfail to operate not be erased DTC will the indication, accordingto the indicatorlight

\

t

Conditions for DTCerasure o The vehicleis stopped. . The SCSserviceconnectoris connectedbeforethe ignitionswitchis turnedON {ll) . The brakepedalis depressedbeforethe ignitionswitchis turnedON (ll)' . The SCSserviceconnectorremainsconnectedduringthis procedure following conditions is The DTC erasurestops and ABS control unit executesthe software lunction it at least one ot the satisfied: o The vehicleis not stopped. duringthis servace' . The SCSserviceconnectoris disconnected .TheABscontro|unitreceivesthenormaIsigna|(whichisfortheAEscontro|unit)fromaHondaPGMTester' . The brakepedalis not operatedaccordingto the indicatorlight indication . The DTCerasureis finished 0.3sec

LIGHT ABSINDICATOR OFF DEPRESS BRAKEPEDAL RELEASE lqnitionswitch

oN (I)

J

19-57

DiagnosticTrouble Code (DTCI Symptom-to-System Chart DTC

DETECTIONTIMING

o H1=

DIAGNOSIS/ SYMPTOM

i.'s EV9

z r =t \9=

8 € E6 < _ 6

>= PNOBABLECAUSE

6tz , . ' . .

ABS indicator iighr does not com€ on when ignirion swrt.h is lu.ned on (ll)

NO DTC ON

A B S i n d i c a t o rl i g h td o e s nol90 oft 6frer engine is

t1

13

oN.

Wheel sensor (op€n/short

o

O

o

Open in the pow€. source circ!ir ror the ABS -.ndicato;lisht Elown ABS indicalo.lighr butb Open in rhe ABS indicaror tight drive cncuit. Shori ro pow€r in theWALpcircuit F a u l t y A B Sc o n t r c t ! n i t Open in the lG2 circuit Opon in the +B circuir Op€n andlor short ro body ground jn the WALP circuit Faultv AAS coni.ol unn upen, snofiro bodyground and/or shodro power in rhe wh€61

o

ll

Faulty ABS co.lrctunit

BL

12

Shortto wh6sls€n6or(O)circuir in t'e.h;;Go-nso, trtcircuti Faultywhsels€nsorinsra|ation

oN.

o

(chipp€d pulser gea/noise)

a

o

FaultyABScont.olunir

I8

31 32

Op.ni shonto bodygroundand/o.shorrtopowsrin rhe F8-OUT FL.IN

Solenoid (open/shon ro

3'l

a

ON

op€n in lh6 coM circuit

o

FT.OUT

a

FaultyABSconlrclunit

RF.IN

88 OUT 8t rN RLOUT

31 38

ON

o

op€n in tho motor pow€..ourco circlia O p € ni n i h € m o r o . c N O c i r c u i t

o

Faulty ABS conrrol unit

52

ON

o

Open in rh€ COM, PMR 6nd/o. MCKcircuir Op€n.n.Vor blown lus€ in the under hood AgS rusdretry box

o

Faufty pump moto. rotay faulv ABS conlrolunit

53

ON

54

ON

ON

. . . ,

o

lgnition voltage (low vott-

o

o

c

o

o

o

Sho.tto bodygrou.d in the pMR circuit Shon to powsr in tha puhp moror pow6rsource circu r.urty pump motor.etay FalltyABS contolunit Open, rhorr ro bodygrcund and/or blown fus€ in the B1 or 82 Shonto body ground.n.Vor short to powor in rhe COM circuit Faulty modul.tor unn Faulty ABS controt unit

o

. . . .

Connection ot the24 V bariorv tor enqins starr Faurtycharoins system Op€n in th6lG2 circuit Fa!lly ABS contrcl unil E{€rml facior{sl en bs rhe ouse{sl ot |he probtem F.ulty ABS conrrot unit

81

ON

CPU

o

o

o

o

r: It DTcs 1 1 18 {wheel sensor codes) wore del*ted the lasr time the v6h cls wEs d riv€n, rhe a8s indicator tight wi stay on u ntit lh6 ignition swirch is rurn6d oN connorunit contnms rhat rhe wheet sensoB . rc OK,

19-58

t), and the

L

e MANAGEI\,4ENT CONDITIONFOR DETECTION

DUNING ABS CONTFOL

EXCEPT ABSCONTAOL

FEFER TO PAGE

19-60

19-62

The ABS indicator lighl cones on when vehicle is stopp€d and wheel sensor a given vohaqe does nol 1 96 4

The ABS indicaror comes on under th€lollowing conditions t h e e l r e a c h e sa . W h e n m o r e t h a n o n e o t w h e e l sa r e a s t a n d s t i l a n dt h e l e l o c i r v o t t h e f a s t e s w ' fohen th. velocityof the faslesl wheel reachesor exceds a given sped, and it there ar€ somewh@ls whose velocityis slowe.lhan a cenain percenlageoi lh€ fast6t wheelsped for 3 given period . when rhere are lemporary open or short ctcuits ol rhe wheel sonsor' chipp€d pulser gear, orsrgnal orslJrbaaLe The main relay repeatsON/OFFswitching atalltimes . W h e n t h e m a i n r e l a y i s O N , a s h o r t t $ t p u l s e i s s e n t l o e a c h v a l v e l f t h e r e s s o m e d i s ' r e p an c v ,l h e A B S i n d i c a l o rl i g h t c o m e so n . . When rhe main relay is OFF,a shonl€sl pulse is s€nlto each valve lfth6 solenoid drive voltage rs out ol a qiven range, the ABS ndicalor lighl comes on

\

.t

'The pump nolot s activaled orc€ o' Mrce sfier every gn't'on sw'lch ON (ll) operarion whrle lte -^ v c h i c l ea c L e l e r a l e sl r e n t h e m o l o r o t i v e v o ' t a S e r s r h e c l e d W h e n l h e v o l l a 9 6r s a b n o r m a r , l r eA b s indicaror llghl comes on. . Afte. ABS ;onl rol com pletion, the moror isswitched ofi 6nd the main CPU checksthe molor dnve voltase. when rhe vortase is abnormsl, the ABS indicato49!!!99!:l!:_D!rino an active motor lesl or AAS control,lhe main CPU checksihe supplv voltage to the motor' whe;lhe vohage s abnofmal, the ABS indicator lightcomes on

lirhe moror drvevoltage indicates molot operalion when the main cPU does notswilch the motor oN, rhe ABs indicaro. comes on . Wh"" " ".1"".1d ""1r. f"llure is detecred,the CPU checksth€ voltage ofthe main rel6v output lllhe vohaqe is lowerthan 6 given vohage, theABS indicator light comes on . The ;ain r€lay repeatsON/OFFswitching ar a!ltimss when the main rel.v is ofi, a shorl l6st pulse is sent ro €ach valve. The CPU mon tors the reJer€ncevohage ll the vohage is out ot a g iven range' the ABS indic.tor lightcomes on wt'",, rt'e lgnitlon rottag" is ower or higherthan a given voltage,lhe CPU inhibils ABSlonlroland swirches oli the ma in relaY,6nd the ABS indicaror light com€s on When the ig n ilion vohage recove's t o n o r m a lf 6 n g 6 ,A B S i n h i b i t i o ni s c a n c e l e d .

1 96 4

19-66

19-68

19,68

19-64

1 97 1

19.73

CpU anO suU CeU ch€ck each other undercertain condnions. Whon rhe CPUSdstectthe fol' rimln lowing discrepanaies,rhe ABS indicator light comss on . whe; rh€re is discGpancv n lhacarculated wheelspeed velocirv thar continuosJor more than a given .i^/hen rhere is discrcoancvin the ehase informalion lhat continuesfor morerhan a given period ' When rhere is discrepancYin thecalculared conlfol pa.amerer' . When thewatch dog conrrolp!lsetailslof a given penod . W h e nt h 6 c h e c k o t t h €R O Mt a i 1 s . . when there is disrepancy inrhe data roading.nd wriung prcledurc ot RAM

19 7'l

t r 19-59

Troubleshooting ABS IndicatorLight DoesNot ComeOn The A8S indicator light does not come on when ignition switch is turned ON ll. Tho ABS indicator light does not come on wh€n ignition switch is tu.ned ON {lll.

check the METEB(7.5A) fuse in the under-dash fuse/relay box.

NOTE:All indicatortightsexceptthe charg, ing systemlight will not come on when the METER17.5A) ft se is btown. NO Beplacethe tu3e and recheck.

YES NOTE: Reinstallthe fuseif it is OK. Checkfor an open in th6 lcl circuii: 1, Disconnect the gaugeassem bly 5Pconnector. 2. Turn the ignitjonswitch ON l). 3. Measurethe voltage between the gauge assembly5P conn e c t o rt e r m i n a lN o . 5 a n d body ground.

ls there bafteryvoltage?

GAUGEASSEMBI"Y5P CONNECTOR

Wiresideof femaleterminals . Ropair opan in tho wiro botwe€n thc METER t7.5 At tuso and gauge .$cmbly. . Roplacc th. und.r-dash tus./ r.l.y box. lop.r cirouit in3ido the box.l

C h e c kt h e A B S i n d i c a t o rl i g h t bulb in the gaugeassembly.

ls the bulb OK?

Ch€cktor a short to power in the WALPcircuit: Measurethe voltage betweenthe g a u g e a s s e m b l y5 P c o n n e c t o r terminalNo. I and bodyground.

ls there batteryvoltage?

lTo page19-61)

19-60

Replir short to power in tho wiiG b.tweon the gruge rs3embly .nd ABS control unh.

t

J {Frompage19.60)

Checkthe geuge a$embly: 1. Turn the ignitionswitchOFF. 2. Connectthe gauge assembly 5Pconnector. 3. Connectthe terminalNo. 3 to b o d y g r o u n dw i t h a i u m p e r

GAUGEASSEMBLY5P CONNECTOR

,c? "

| l1t/'.lt/t5 JUMPER I GNDIBLK}

wrRE I

4. Turnthe ignitionswitchON (ll).

Doesthe ABS indicator lightcomeon?

-L

Replaceth€ ABS indicato. light drive circuit in the gauge ai3omblY.

.Repair open in the wire beiween the gauge assemblY and body ground. . Repair poor ground {G401, G402t.

t

19-61

Troubleshooting ABS IndicatorLight DoesNot Go Off The ABS indicator light does not go off after the engine is started. -

With enginerunning,ABS indicator light is ON. With tho SCS sewice connecto. connected l3oe page 19-561, no DTCis indicated,

ChecktheRRDEFRLY{7.5A)tuse in the under-dashfuse/relaybox.

Raphco tha furo and rochack. YES

NOTE:Feinstattthe luse it it is OK.

Checkthe ABS +B (20 A) fuse in the under hood tuse/relaybox.

R6pl.ce tho tu3c lnd r.ch.ck. YES

NOTE:Reinsta the fuse if it is OK.

ABS CONTROLUNIT 26PCONNECTOR IG2IELK/BLUI

Chockfor an open in the lG2 cirGUrt: 1. Turnthe ignitionswitchON (lt). 2. Measurethe voltage between the ABS controlunh 26Pconn e c t o rt e r m i n a lN o . 3 a n d body ground.

Wire sideof femaleterminals

Bopair opcn in tha wir. botw.cn th. RR DEFRLY 17.5Al tus. .nd ABS control unit. Checktor an opon in thG Bl end 82 circuit: M e a s u r et h e v o l t a g e b e t w e e n bodygroundand terminalsNo. 14 and No. 15individually.

ls there banery voltage?

1Topage19-63)

19-62

ABS CONTBOLUN]T 26PCONNECTOR

8T IWHT/GRNI

Rrpair opsn in tha wiro t atwa,an the ABS +B (20 Al fu.r .nd ABS control unh.

Wiresideof temaleterminals

t

v lFrompage19-621

ABS CONTROLUNIT 22PCONNECTOR

Ch6ck lor . short to body ground in ihe WALPGircuit: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e A B S c o n t r o l unit 22Pand gaugeassembly 5P connectors. 3. Checkfor continuitybetween the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d body ground.

WALP{BLU/REDI

Wire sideol femaleterminals

Ropair short to body g.ound in tho wire betweon the ABS con_ trol unit and gaugeaasembly.

ABS CONTROLUNIT 22PCONNECTOR WALP {BLU/REDI

Checkthe AgS cortrol unit: 1. Connectthe ABS control unit 22Pconnector. 2. Turnlhe ignitionswitchON (ll). 3. Measurethe voltagebetween the ABS controlunit 22Pcon' n e c t o rt e r m i n a lN o , 7 a n d body ground.

rt ls there bafteryvoltage?

Wire sideol femaleterminals Check tor rn open in lho GND2 circuit: 1. Connectthe ABS controlunit 26PconnectorterminalNo. 16 to body groundwith a iumper 2. Measurethe voltagebetween the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d body ground.

ls there batteryvoltage?

ABS CONTROLUNIT 26PCONNECTOR

wire sideol femaleterminals

' Repairop€n in the wit€ between the ABS control unit and body ground. . Rep.ir poor ground lG40'1, G1(}2t.

Checktor loo3€ ABS control unit connector!. lf necesaary,substi_ tute a known-qood ABS control unit and r€check, Check lor an open in the WALP circuit: Measurethe voltagebetweenthe g a u g e a s s e m b l y5 P c o n n e c t o r terminalNo. 1 and body ground.

GAUGEASSEMBLY5P CONNECTOR

.D ls therebatteryvoltage?

J

Ropai. opon in the wiro botween the ABS control unit end gauge assemblv.

Y

Wire sideof femaleterminals

Replacethe ABS indicrtor light driv6 ci.cuit in the gtuge assembly.

19-63

Troubleshooting WheelSensor DiagnosticTrouble Gode {DTC)ll-18: Wheol S€n3ol Diagnosis NoTE: The ABS indicatorlight comeson when only the drive wheelsare turning,signaldisturbanceis detected,etc.Therefore, test-drivethe car at a speedof 12 mph (20 krn/h)or more after turning the ignition:witch from OFF to ON fll), and if the ABS indicatorlight does not come on, the svstemis OK. A8S CONTROLUNIT 26PCONNECTOR -

-

With the ignition switch ON {ll), ABS indicator tighr doe. noi go off, Aftsr driving, ABS indicatot light comeson. With the SCS so.vice connactor conn€c,ted{soepege 19-561, DTCs11-18a.e indicrted.

Chocklhe wheol sensorci.cuit: 1 . D i s c o n n e ctth e A B S c o n t r o l unit 26Pconnector. 2. lleasure the resistance betweenthe appropriatewheel sensor(0)and (1)circuittermi,

ls the resistance OK? /Frontr750 1050o/20"C,68.F\ 68"F/ \Rear: 850- 1150O/20.C,

RRO IBLU/YELI Appropriate Terminal (0)srDE 11)SrD€ r 1, 12 (Right-front) No.8: FRo N o . 2 1 :F R I 13, 14 (Left-front) No.10:FLo N o . 2 3 :F L 1 15, 16 {Right-rear) No.{: RRo N o . 1 7 :R R l 17,18(Left-rear) No.6: RLo No.19:RLI

0Tc

. Reprir op€n in the l0l or {0 circuit wiro, or shon to thc {01circuit wi.o in thc {11circuit wirc bctween ths ABS control unit and approprietowheel a6nsor. . R.pl.ce th€ epp.opri.te wheal 3€nloa.

Checktoru short to body ground in the wheel senso. circuit: Checkfor continuity betweenthe ABS control unit 26P connector appropriatewheel sensor(0) cir cuit terminaliand body ground. . Rapair short to body ground in th6 (0) or lll cilcuit wi.. bctwa.n th6 ABS control unit and appropdaie whoel lonsor. . Rep|'c6 tho appropriatc whcel sanlor. Chock tor a sho.t to powe. in tho wheel3en3or circuit: 1. Reconnect the ABScontrolunit 26Pconnector, 2. Startthe engine. 3. Measurethe voltage between the ABS controlunit 26Pconnectorappropriate wheelsens o r ( 0 ) c i r c u i tt e r m i n a l a n d body ground. ls there4 V or more? NO

Ropair rhon to powo. in the l0l or lll circuit wire batw.en th€ ABS cont.ol unit and .pplopriata whccl !€naoa,

NOTE: . Normalvoltage:Approx.2V ' 0 V: Replace the ABScontrotunit. . 4 V or more indicatesa short to power. fio page 19-65)

19-64

RR1IGRN/YELI RLl (LT BLU}

FL1IGRN/ORN} FRl (GRN/BLKI

Wire sideol femaleterminals

t (Frompage19-64)

Checktor chippedpulsergear.

Replacethe drivesh.tt or hub unil. (Chippedpulser g€ar)

\

e

DTC 11, 13, 15. 17: Roplacethe ABS control unil. OfC 12, 11.16,18:The ABS control unit may have detected signaldisturbance.

l r 19-65

Troubleshooting Solenoid DiagnosticTrouble Code {DTC}31-38: Solenoid Diagnosis -

-

ABS CONTROLUNIT 22PCONNECTOR FL.OUT(YEL/ALK)

With the ignition switch ON (lll, ABS indicator light does nol go oft. or ABS indic.to. light comes on while ABS i3 functioning. With the SCS servicoconnector connected ls€. pag€ 19-561, DTCa31-38 are indicstod.

DTC 3 1 :F R J N

32:FR-OUT 33i FL'IN

Checkfor a short lo powor in tho sol6noid circuitl 1 . D i s c o n n e ctth e A B S c o n t r o l unit 22Pand 26Pconnectors. 2. Start the engine. 3. Measurethe voltage between the ABScontrolunitconnector a p p r o p r i a t es o l e n o i dc i r c u i t terminal*and bodyground.

ls there batteryvoltage?

34:FLOUT 3s:RRIN 36:RR-OUT 37: RLIN

38:RL-OUT

Appropriate Appropriate Connector Terminal 22P No.1 22P No.12 22P No. 11 22P No.10 26P No.13 22P No. 21 26P No.25 26P

No.12

Wiresideof femaleterminals ABS CONTROLUNIT 26PCONNECTOR

RL.OUTIYEL}

Ropri. short to powor in thc appropriate solanoid ci.cuit wiro botw6.n ths ABS cont.ol unit and modulrtor unit.

Checkfor a short to body ground in the 3olenoidcircuit: Checktor continuity betweenthe appropriate solenoidcircuitterminal*and bodyground.

Wiresideof femaleterminals

. Repairshort to body ground in lhe .ppropriato solonoid circuit wire betwoan th6 ABS control unit and modllato. unit. . Replacothe modul.tor unit.

31:FR-lN

Appropriate Terminal No.2:SCOM

32:FR-OUT

No. 2: SCOM

33i FLIN

No.1:rcOM

34:FL-OUT

No. l: PCOM

DTC Checkth€ ABS control unit: '1. Turnthe ignitionswitch OFF. 2. Connectthe ABS control unit 22Pand 26Pconnectors. 3. Connectthe SCS service con4. Turnthe ignitionswitchON {ll}. 5. Measurethe voltage between the ABS control unit 26P connectorappropriateCONIcircuit terminal++ and bodyground.

ls thereapprox.3 V? YES (Topage19-671

19-66

35: RR{N

No.1:PCOM

36:RR-OUT 37rRL'lN 38:RL-OUT

No.1:rcOM No.2:SCOM No. 2: SCOM

Checkfor loos€ ABS control unh connectora. It naceslrry, aub3titutc . known-good ABS control unit tnd recheck.

RL.OUT(YEL}

t

e (Frompage19 66)

ABS CONTROLUNIT 22PCONNECTOR

DTC

No. 1

36:RR-OUT 3 7 :B L - l N

26P

No.25

38:8I-OUT

26P

No. 12

32:FR'OUT 33: FL IN

34:FL-OUT 35: BR-lN

ls thereapprox.3V?

\

J

Terminal

22P 22P 22P 22P 26P 22P

31:FB-lN

Checktor an op€n in th€ solenoid circuit: Measurethe voltage betweenthe ABS control unit connectorappropriatesolenoidcircuitterminal* and bodyground.

FL.OUT{YEL/BLK} Conn€clor

No. 12 No.1l No. 10 No. 13 No.2l

' Repsir opon in the appropriate COM circuit wiro botwoon the ABS control unit and modulatol unit. ' Repair open in ihe appropriate sol€noid ci.cuit wiro between tho ABS control unit and modulator unit. . Roplacothe modulator unil.

Wiresideof femaleterminals

ABS CONTROLUNIT 25PCONNECTOR BL.OUT(YELI

Checkloi loGe ABS control unit connoctors. It necessarv,substitute a known-good ABS control unit and recheck. Wire sideof femaleterminals

19-67

Troubleshooting ABS PumpMotor DiagnosticTrouble Codo {DTC}51-53r ABS pump Motor Diagnosis -

With the ignition switch ON (ll), ABS indicator lighr doos not go otf. With tho SCS s€rvico connee tor conn€cted lsee page 19661, OTCa51-53 aro indicated.

Checkthe MTRCHECK(7.5A) fuse.

NO Repl.ce the fuse .nd recheck. YES NOTE:Reinstall the fuse if it is OK

N O T E : S h o r t t h e P M R t e r m i n a tt o b o d y groundfor a moment,and recheckthe fuse. lf the fuse is blown,checkfor a shortto body groundin the MCKcircuit.

AAS CONTNOLUNIT 22PCONNECTOR 7 12

11

A

t0 t l

19

2 l 22

PMRIYEL/RED} I JUMPER I WIRE

Wiresideof femaleterminals

NO Replacotho tuse and rocheck.

YES NOTE:Reinstall thefuseif it is OK.

N O T E :S h o r t t h e P M F t e r m i n a lt o b o o y groundfor a moment,and recheckthe fuse. lf the fuse is blown,checkfor a shortto body ground in the wire between the under-hood ABSluse/relaV box and pumDmotor.

Rcphce th€ pump motor rol6y.

Check the pump motor power sourcecircuit: Turnthe ignitionswitchON (ll).

Doesthe pump motoroperate?

Ch€ck for a short to !'ows. in tho pumP motor power 3ource ciacrrit: Removeth6 purnpmotor relay,

Doesthe pump motoroperate?

Checktor loGe ABS control unit connoctors. lf nocessary,substitute a known-good ABS control unit and roch€ck,

(To page19-69)

19-68

Bopairsho.t to powsr in the wir€ botwoen the under-hood A8S tuse/.elay box and ABS pump motor.

t

t (Frompage19-68)

UNDER.HOOD ABS FUSE/RELAY8()X JUMPERWIRE

Checkthe pump motor circuit: 1. Removethe pump motor relay. 2. Turnthe ignitionswitchON (ll). 3. Connectthe pump motor relay connector+8 and MOTORter minalswith a iumperwire tor a momenr,

Doesthe pump motor operate?

Ch€ckfor an open in the pump moior +B circuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe pump motor 2P connector, 3. Turnthe ignitionswitchON (ll). 4. Connectthe pump motorrelay connector+B and MOTORterminalswith a jumperwire. 5. Measurethe voltage between the pump motor 2P connector terminal No. l and body ground.

TERMINAL

TERMINAL

PUMPMOTOR2P CONNECTOR MOTOR+8 lWHTl,$

rv) Y

Wiresideot femaleterminals ls therebatteryvoltage?

\

Check the pump motor opgration: Connectthe battery{+}terminalto the pump motor 2P connectorterminalNo. 1.andthe (-)terminalto the terminalNo. 2 for a moment.

lt

Doesthe pump motoroperate?

Chockfor a short to body ground in the PMRcircuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe ABS control unit 22Pconnector. 3. Checkfor continuitybetween t e r m i n a lN o . 1 9 a n d b o d y grouno,

Repail opon in ths wirg botwgen tho pump motor and bodv ground, or poor ground (G,!09).

Ropair 3hort to body g?ound in tha wire between the underhood ABS fuse/rclay box and ABS cortrol unit.

Repaiaopen in the wire botween tho under-hoodABS fuse/relay box and pump motor.

MOTOR+B {RED}

MOTORGND (BLK)

ReDlacolho modulator unit. (Feultypump motor)

ABS CONTROLUNIT 22PCONNECTOR

WiresideoI femaleterminals

(cont'dl (Topage19-70)

19-69

Troubleshooting ABS PumpMotor (cont'dl (Frompage19-69)

Check tor an opon in the PCOM circuit: 1. Turnthe ignitionswitchOFF. 2 . R e c o n n e ctth e A B S c o n t r o l unit 22Pconnector. 3. Connectthe SCSserviceconnector, 4. Turnthe ignitionswitchON (ll). 5. Measurethe voltage between t h e p u m p m o t o r r e l a yc o n n e c t o r P C O I , tI e r m i n a l a n d body ground.

ls thereapprox.3 V?

--l

Repair opon in tha wiro bEtwoon th. und€r-hood ABS fu3./rclsy box and ABS control unit.

n

ABS CONTROLUNIT 22PCONNECTOR

Chockfor rn op6n in tho PMRcircuit: Measurethe voltage beNveenthe ABS control unit 22P connector terminalNo. 19and body ground.

ls thereapprox.3 V?

Ropair opon in tho wira b€twoon tho undor-hood ABS fu.e/rel.y box and ABS control unit.

Chock for an opon in ths MCK circuh: 1. Turnthe ignitionswitchOFF. 2- Disconnectthe SCS service connector. 3. Turn the ignitionswitchON lll). 4. Measurethe voltage between the ABS controlunit 22Pconn e c t o rt e r m i n a l N o . 1 7 a n d body ground while connecting the pump motor relay connector+8 and MOTORter' minal with a jumper wire for moment.

Repeirop.n in th. wire batween tho undor-hood ABS fu.o/rol.V box rnd ABS control unh.

Ch6cklor loose ABS contlol unit connoctors. lf ngc63ary, sub3titute d known-good ABS control unit and recheck.

19-70

wire sideoI temaleterminals

t

f

MainRelay DiagnosticTrouble Code {DTC}54: Msin Relay Diagnosis -

-

With the ignition switch ON {ll), ABS indic.tor light does not go off. With the SCS 3ervicaconnoctor connected (s€epag€ 19-561, DTC54 is indicated. checktheABS+B (20Alfuse. Replaceth6 fuso and rechock. ABS CONTROLUNIT 26PCONNECTOR

YES NOTER : einstall thefuseif it is OK. Ch€ck for an op€n in the 81, 82 circuit: M e a s u r et h e v o l t a g e b e t w e e n body ground and the ABS control '14 terminalNo. unit26Pconnector andNo. 15individually.

B1 {WHT/GRNI

Wire sideof femaleterminals Repairopen in the wire betweon the ABS control unit and underhood ABS tuse/relav box.

\

e

Checkfor a short lo body ground in the PMRcircuit: 1- Turnthe ignitionswitchOFF. 2. Removethe pump motor relay. 3 . D i s c o n n e ctth e A B S c o n t r o l unit 22Pconnector. 4. Checkfor continuitybetween t e r m i n a lN o . 1 9 a n d b o d y grouno.

ls therecontinuity?

Checktor a short to body ground in the PCOM,SCOMcircuit: 1 . D i s c o n n e ctth e A B S c o n t r o l unit 26Pconnector. 2. Checkfor continuitybetween bodygroundandthe ABScont r o l u n i t 2 6 Pt e r m i n a l sN o . 1 andNo.2 individually. ls therecontinuity?

l r

ABS CONTROLUNIT 22PCONNECTOR

Repairshort to body ground in the wire betweenthe undorhood ABS fuse/relay box and ABS control unit.

Wiresideof femaleterminals

PCOM scoM IGRN/WHT} {BLK/WHTI

. Bepai. short to body ground in tho PCOMcircuit wire betwoen the ABS control unit and underhood ABS fu3e/.olaybox. . Repair3hort to body ground in the PCOMor SCOMcircuit wire between the ABS control unit and moduletor unit. . R c p l a c et h 6 m o d u l a t o r u n i t . (Short circuit insidotho unit)

{ T op a g e1 97 2 )

(cont'd)

19-71

Troubleshooting MainRelay(cont'd) (Frompage19'71) PCOM (GRN/WHTI

Checktor a short to powor in the PCOM,SCOMcircuit: 1. Turn the ignition switch ON

(BLK/WHT}

r).

2. Measurethe voltage between body groundand ABS control unit 26P connectorterminals N o . l a n dN o . 2 i n d i v i d u a l l y .

Replacethe ABS control unit.

. Repair 3hoit to power in ihe rcOM circuil wire bgtween the ABS control unit end unde.hood ABS fuse/relaybox. . Repair sho to powor in tha PCOM oJ SCOM circuit wiro betwoen the ABS control unit and modulator unit. ' Repl.co the modul.tor unit. lshort to Dowcr iGido the unit) V o l t ag e

19-72

scoM

lgnitionVoltage DiagnosticTrouble Code (DTC)61: lgnhion Voltage Diagno3is -

With tha engin€ running, ABS indicator lighl is ON. With the SCS s€rviceconnecto. conn€ctod ls€€ page 19-561, DTC61 is indicated.

Problemv€rification: 1. Erasethe DTC. 2. Startthe engine. 3. Make sure that the ABS ind; catorlight comeson and DTC 61 is indicated.

ls DTC61 indicated?

The system b OK .t this time.

A8S CONTROLUNIT 26PCONNECTOR Checkthe lG2 cilcuii: Measurethe voltagebetweenthe ABS control unit 26P connector terminalNo.3 and body ground.

]

ls there18V or above?

IG2IBLK/BLU}

Wiresideof lemaleterminals

lf the vohage is 0 V, checklor an opon in the lG2 circuit. It there is 12 - 17 V. substitute a known-goodABS colrtrolunit and Jecheck.

I t 19-73

Troubleshooting CentralProcessingUnit (CPUI DiagnosticTroublo Code IDTC)81: CPU Disgnosis -

-

With the ignition switch ON {lll. ABS indicator light does not go oft. With tho SCS servi@ connector conn€cted lsee page 19{6}, DTC81 is indicated.

P.oblemvedfication: 1. Erasethe DTC. 2. Test-drive the vehicle. 3. Make sure that the ABS indi, catorlight comeson and DTC 81 is indicated.

ls DTC81 indicated?

The system k OK rt this time.

19-74

R€pllc6 th. ABS control unh.

Modulator Unit \

i

RemovaUlnstallation

l

CAUTION: . Do not spill brake tluid on the car; it may damage the paint; it brako lluid does contact the paint, wash it off immediately with wator. a Take care not to damage or delorm the brake lin€s during removal and installation. . To prevent the brake tluid from tlowing, plug and cover the hose €nds and ioints with a shop tow6l or equivalent mat€rial. N O T E |T i g h t e n t h e f l a rneu t s t o 1 5 N . m( 1 . 5k g n m .l 1 l b f . f t ) . Removal '1. Disconnect the modulatorunit 10Pand Dumpmotor 2P connectors. 2.

Disconnect the brakelines,then removethe modulatorunit.

Installaiion 1.

Installthe modulatorunit.then connectthe brakelines.

2.

Connectthe modulatorunit 10Pand oumDmotor 2P connectors.

3.

Bleedthe brakesystem.

4.

Startthe engine,and checkthat the ABS indicatorlight goesoff. Fom right-1461

J PUMP MOTOR 2P CONNECTOR

-R

/2e' t'

TOR UNIT

t t 19-75

ABS Control Unit

Pulsers/Wheel Sensors

Replacement

Inspection

1.

Removethe right side kickpanel.

1 . Checkthe front and rear pulserfor chippedor damaged teeth.

2.

Disconnect the ABS controlunit connecrors.

3.

Removethe ABS controlunit,

Measurethe air gap betweenthe wheel sensorand pulserall the way aroundwhile rotatingthe pulser.

4.

lnstallthe ABS control unit in the reverseorder of removal,

Slandard: 0.4 - 1.0 mm (0.02- 0.04 in, N O T E ; l f t h e g a p e x c e e d s1 . 0 m m ( 0 . 0 4i n ) , t h e p r o b a b i l i t yi s a d i s t o r t e ds u s p e n s i o na r m w h i c h shouldbe replaced.

Dbc brake typo

0.{ - 1.0mm (0.02- 0.04 in)

CONNECTORS

19-76

Drum brake typ6

t

l}

WheelSensorReplacement NOTE: . Becarefulwhen installingthesensorsto avoidtwistingthe wires. . The torquevalueof the boltsis 9.8 N.m (1.0kgf.m,7 lbf.ft). Front

\

WHEEL SENSOR FRONT

J Rear 1. 2. 3,

Removethe hub bearingunit (seesection18). Removethe four backingplatebolts. to disconnectthe Pullthe backingplateawayfrom the trailingarm, then removethe wheelsensor.lt is not necessary brakeline.

NOTE:This illustrationis drum braketype.The torquevalueof the disktype is same as drum type.

REARWHEELSENSOR

I t 19-77

l}

Body ('96 modell

\

I t

e

Doors FrontDoorIndex(4D) ...20-2 RearDoorIndex{4Dl .....20-8 DoorfndexlzDl3Dl .......20-14 Emblems fnstallation 20-118 Exterior 20-93 ComponentLocationIndex............... *FrameRepairChart .......... 20-120 * Interior 20-58 ComponentLocationIndex............... Mirrors MirrorRep|acement .................. ......... 20-24 Mirror Holder/GoverReplacement... 20-25 .......... 20-25 RearviewMirrorReolacement Moonroof .....................20-50 lndex.......... and Latch/ OpenerCable/Opener Wiperand Washer ...,.20-107 ComponentLocationIndex.......... Seatsand Seat Belts .....20-73 GomponentLocationIndex.......... ....20-119 Sub-frame Windshield,RearWindow and OuarterGlass Index.......... .....................20-26

Body {'97 modell Body ('98 modell Body ('99 modell Body ('00 model)

20-123 20-131 20-135 20-141

Doors FrontDoor lndex ,ID:

WEATHERSTRIP

I

\ t

I

r^r f\ \ )

t \ '

ffitr6-

i'

\ - !

fud -@a,

\tEf

POWERWINDOW

swtTcH Adjustment,page 20-23 DOOR PROTECTOR

OOORPOCKET

J$--"**^ 20-2

l}

GLASS Replacement, page20 6 Adiustment, page 20-20

GLASSRUN CHANNEL

t

.

t

\

' \

\

CENTERLOWER CHANNEL

e LOCKROD PROTECTOR

STRIKER Adjustment, page20-23

\

CYLINDER PBOTECTOR

\

/ h )

cYLTNoER ROD

Y

<

,/

,/

LATCH Replacement, 20-6

I t

^o ?'2'

' ll

\ ttt[ #-l|r& /

REGULATOR Replacement, page20-6

ourERHANoLE

\necuLaron HANOLE

page20-5 Replacement, LOCK CYLINOER

RETAINER CLIP INNENHANDLEROD

- ) LATCH PROIECTOR

POWERDOOR LOCKSwlTCH (driver'sonly)

//

s

*Nqd' /

-"-/

INNER HANDLE

20-3

Doors DoorPanelReplacement NOTE;Takecarenot to scratchthe door paneland other pans. 1.

Remove: . Innerhandle(seepage20-3) . Mirror mount coverpanel(seepage20-24)

2.

lf applicable, removethe regulatorhandleby pulling the clip out with a wire hook. HANOLE

4.

Releasethe clips that hold the door panel.Remove the door panelby pullingit upward. NOTE:Removethe door panelwith as littlebending as possibleto avoidcreasingor breakingit. 95 mm {3.74in.)

12mm

.L

TRIM PAD (0.47 in.) f REMOVER (Commercially availablel Snap-on r_ #A'177,o. lmm equivalenl (0.04in.l

rr-l 45 mm (1.77in.l

>i Clip loc.tions, 5

3.

l u - i

Removethe door grip coverand speakercover,then removethe screws. POWER WTNOOW >: Screwlocations, 5 swtTct{

J$- I

:fe i cL,P /\

REMovERil

_ _t/

I I

Dasconnect the ;peakerconnector, 5.

20-4

lnstallation is the reverse of the removal procedure.

\

:

OuterHandleReplacement 4.

NOTE:Raisethe glassfully. '1. Remove: . Door panel . Plasticcover(seepage2o-21 2.

Pull out the outer handle.Pry the outer handle rod out of its joint usingdiagonalcutters NOTE: note location@ of the outer a To easereassembly, joint it. beforedisconnecting rod on the handle . Takecarenot to bendthe outer handlerod. o Use a shop towel to protectthe opening in the ooor.

Pullout the retainercliP. CYLINDERPROTECTOR

OUTERHANDLE ROD i4'

BUSHING Replace.

DIAGONAL CUTTERS

,w. \

LOCKCYLINDEB

RETAINER CLIP

C

3.

Removethe bolts,then removethe cylinderprotector, lockcylinderand outer handle. >: Boltlocaiions,2

6x1.omm

I

i.eN.. tr.orgf.-, 7.2rbr.fi)

I ,2

CYLINDER

SHOP TOWEL

5.

lnstallationis the reverseof the removalprocedure NOTE:Makesurethe door locksand opensproperly.

LOCKCYLINDER ROD CYLINDER

20-5

Doors Latch Replacement

Glass/Regulator Replacement

NOTE:Baisethe glassfully.

' 1 . Removel o Door panel(seepage20-4) . Plasticcover (see page 20-2l,

1.

Remove: . Door panel(seepage20-4) . Plasticcover(seepage20-2) . Outerhandle(seepage20-5) Removethe bolt, then move the center lower channel forwa rd. Disconnectthe connector,and detachthe harness clip from the door. Bemovethe latch through the hole in the door. NOTE:Takecare not to bend the inner handlerod, outer handlerod, cylinderrod and lockrod.

Carefullymove the glassuntil you can seethe bolts, t h e n r e m o v e t h e m . C a r e f u l l yp u l l t h e g l a s s o u t throughthe window slot. NOTE:Takecarenot to drop the glassinsidethe door. >i Boltloc.tions,2

fi s'r.o-.

i

kstm,l Clb9.8 N.m11.0

_-l't!!t

,/

>: Screwlocations, 3 GLASS

LOCKROO

REGULATOR

6 x 't.0mm 8 N.m(0.8kgtm, 6 tbf.ftl 4.

Installationis the reverseof the removalprocedure. NOTE: . Make sure the inner handle rod and connector are connectedproperly. . Makesurethe door locksand opensproperly.

20-6

\

L 3.

Disconnectthe connector,and detachthe harness clip, then removethe regulatorthrough the hole in the door,

4.

Greaseall the slidingsurfacesof the regulatorwhere snown.

>: Bolt locations

B>,3

a>,4 6x1.0mm 8 N.m {0.8kgl m,

ttt*, )

REGULATOR

REGULATOR

MOTOR

lnstallationis the reverseof the removalprocedure.

I

NOTE:Rollthe glassup and down to seeif it moves freelywithout binding.Also make sure that there is no clearancebetweenthe glassand glassrun channel when the glassis closed.Adjusrthe positionof (seepage20-20). the glassas necessary

t

ar Nul locations,3 6x1.0mm 8 N.m 10.8kgf m, 6 rbt.ftl Loosen. REGULATOR {Manualtype)

20-7

Doors RearDoor Index ,[D: OUTER WEATHERSTRIP

INNER WEATHERSTRIP

PLASTIC COVER DOOR Adjustment, page 20-23

t\ \\

INNERMOLDING

POWER WTNDOW \asw[cH \ \ \ € \ \ ; \ € -*r'

:-?

(=__:\

*e€ \

/ /

/

/ DOOn GRIP COVER

20-8

\

\

\ DooR GRIP

fu4 ffir",

M

R* /

HINGE

-

o(x)R PROTECTOR

\

L

CHANNEL\ REAR \

\fl N\ \,\

\ \r\

\ iI\l l

ld 1l

6P c"AN"..: REo" coLLAR \

lll | 1l J I

)\3€)\IJ

:& fr\ \tr \ lll

6/ \

REGULATOR HANOLE

lJ

'All l'A\

OUTERHANDLE Replacement, Page20-11

W-*d a)" u\ t

POWERWINDOW MOTOR

STRIKER Adjustment, page 20'23

I I % grc

*)u*ro* LOCKROD PROTECTOR

Replacement, page 20-12

criss lLl sroeeen lll

pase20,tt Repracement,

\ l5[1tf CHANNEL

LATCH PROTECTOR

POWEROOOR LOCKACTUATOE

t 20-9

Doors Door PanelReplacement NOTE:Takecarenot to scratchthe door paneland other parts.

3.

1. Remove: . Innerhandle(seepage20-9) . Regulatorhandle(seepage20-4) 2.

Releasethe clips that hold the door panel.Remove t h e d o o r p a n e lb y p u l l i n gi t u p w a r d . NOTE:Removethe door panel with as little bendangas possibleto avoidcreasingor breakingit.

Removethe door grip cover,then removethe screws.

,L 12mm (0.47in.) T-

TRIM PAD REMOVER (Commercially available) Snap-on #4177,or lmm l---4 (o.o1in.l1 fequival€nt

>: Screwlocation3.2

rt{,nu"

-l 45mm ' 11.77in.l

> r C l i pl o c a t i o n sT,

4l N l

rRrMPAD---_Jl REMOVER

4.

20-10

.I+

F/

i

]

Installationis the reverseof the removalDrocedure.

t

Outer HandleReplacement NOTE:Raisethe glassfullY. 1.

Remove: . D o o rp a n e l . Plasticcover(seepage20-8)

2.

Removethe screws.

4.

Pull out the outer handle.Pry the outer handlerod out of its joint usingdiagonalcutters. NOTE: . To easereassembly,note locationO of the outer it. handlerod on the joint beforedisconnecting . Takecarenot to bendthe outer handlerod. . Use a shop towel to protectthe opening in the door.

3 >: Screwlocations, 6x1.0mm 6 N.m {0.6kgf m, 4 tbf.ftl

BUSHING Replace.

o

:"'*,w, DIAGONAL

\

\

a

OUTER HANDLE ROD

3.

Move the latchdown, and removethe bolts. >: Bolt locations,2 6x1.0mm 9.8 N,m ) kst.n,7.2lbiftl // 11.O SHOPTOWEL

5.

lnstallationis the reverseof the removalprocedure surethe door locksand opensproperly. NOTE:N4ake

20-11

Doors Latch Replacement

Glass/RegulatorReplacement

NOTE:Raisethe glassfutty.

L

Remove: . Door panel{seepage20-10) . Plasticcover (seepage20,8)

2.

Carefullymove the glassuntil you can seethe bolts, then removethem.

1.

2.

Remove: . Door panel(seepage20-10) . Plasticcover(seepage20-8) . Outerhandle(seepage2O-1,l Removethe lockcrankand clip. >: Screwlocation,I

NOTE:Takecarenotto dropthe glassinsidethe door.

>: Cliplocation,I

qn@l # _

__)

>: Eoltlocations, 2

|

p @ .-

_-__)

o'r.o-,n

I

9.8N.m{t.okof.m. I :'zulnt /

LOCK ROO LATCH

Removethe rearchannelcollar. NOTE:Takecare not to bendthe lock rod and inner handlerod.

3.

C a r e f u l l yl o w e r t h e g l a s s .R e m o v et h e b o l t s a n d screwfrom the rearchannel,then removethe glass from the rearchannel. NOTE:Takecarenotto dropthe glassinsidethe door. >: Bolt.screwlocations A, 1 , c, 1 I

q)h:iT(--n,,".i m 6x1.0mm 8 N.m (0.8 kgt m, 6 tbtttl

- - illt)

Disconnect the connector.

Removethe latchthroughthe hole in lne door. 5.

lnstallationis the reverseof the removatproceoure. NOTE:Makesurethe door locksand opensproperly.

20-12

B, 1 ,,<\

'/

-

)

6x1.0mm 8 N.m to.8 ksf.m, 6 tbt.ftt

IDF-IIID

I -__,/

.)

t} 4.

Carefullyremovethe glassfrom the window slot.

c

\

7.

NOTE: a lf necessary,remove the power window motor from the regulator. . Beforeremovingthe powerwindow motor,scrloe a lineacrossthe sectorgearand regulator.

REAR CHANNEL COLLAR

5.

CLIP Grease all the sliding surfaces of the regulator where shown.

SECTORGEAR

REGULATOR

Removethe outer molding,then removethe quarIer grass. OUARTER

\

POWERWINDOW MOTOR >: Bolt locations,3

POWER wTNDOW MOTOR

6.

Disconnectthe connector,and detachthe harness clip, then removethe regulatorthrough the hole in the door.

-... er l' A nicuuron 8.

lnstallationis the reverseof the removalprocedure.

>: Bolt locataons

A>,2

\ t

6x1.0mm

[l o t't.-to.arsl -. fr- - - . e- -ttt- .ttt -,/

] L

j )

I

B> , 2 6 x 'l.0 mm I N.m {0.8 ksl'm, 6 tbf.ft)

)

NOTE:Rollthe glassup and down to see if it moves freelywithout binding.Also make sure that there is no clearancebetweenthe glassand glassrun channel when the glassis closed.Adjust the positionof the glassas necessary(seepage20-20).

20-13

Doors Door Index 2DI3D:

GLASSGUIDE CLIP

sAsH

I €

*

/

.u\\

\ \

Y

OU?ER WEATHERSIRIP

\

I

et'

PLASTIC COVER

ii\ <]<--

-it v

@

$=-!xtruce

\rre

,",

INNERHANDLE

(sqjR5f"'

S

\ \

h-P

eowenooon rocKswrrcH dD

\b

\

BRACKET

INNEFHANOLE TRIM {without power door locks)

h

W/ ;ril;"i-"-\

J E powen____-.-@.*\L'l

swrrcH t

-Qa, (l+,

- p

Q*-BsfL-,"

9

wtNDow

\

DOOR Adjustment, page 20-23

dl

ARMREST POCKET ARMREST POCKET lwith power

\s-l

@."

TRIM (withpowerdoorlocks)

20-14

MTRROR MOUNT COVERPANEL

dnJ.*-{

r-1*{

SPEAKER

,P

SPEAKERCOVER

?

GLASS Replacement, page20-19 Adjustment, page 20-20 GLASSRUN CHANNEL

3ill,'^lri"*'"tt--.-.qq \, \I\ \\II REGULATOR

pagezo rs \\\\ neptacement,

\\'l\

\

trq\\\\ v.

6

tr POWER MOTOR CYLINDER PROTECTOR

LATCH Replacement, page20-18 STRIKER Adjustment, page20-23

\

RETAINEB LOCK CLIP CYLINDER

fitn

\a \.vqE

BOD PROTECTOR INNERHANDLEROD

LATCH PROTECTOR

20-15

Doors Door PanelReplacement N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d other parts. '1.

2.

5.

Remove: . I n n e rh a n d l et r i m ( s e ep a g e2 0 - 1 4 ) . Mirror mount cover panel(seepage20-24)

Releasethe clips that hold the door panel.Remove the door panel by pulling it upward.Disconnectthe speakerconnector. NOTE:Removethe door panelwith as littlebending as possibleto avoidcreasingor breakingit.

l f a p p l i c a b l e r, e m o v et h e r e g u l a t o rh a n d l e b y p u l l i n gt h e c l i po u t w i t h a w i r e h o o k . .L

REGULATOR HANDLE

12

fim TRIM PAD (0.47 in.) TREMOVER (Commercially available) Snap-on #A'177,or 1mm equivalent {0.04in.)

WIREHOOK

11.77in.l >: Clip locations,

l^

3.

J[ =l$ ll,\*

R e m o v et h e a r m r e s tp o c k e t ,t h e n d i s c o n n e ctth e powerwindow switchconnector.

,,) atrREMoVER tl -)

DOORPANEL ARMREST POCKET

4.

Removethe speakercover,then removelhe screws. >: Screwlocations, 3 I

| 6b:a,'

L"_

O) 6. COVER

20-16

CONNECTOR

lnstallation is the reverse of the removat oroceoure.

b

Outer Handle Replacement 4.

NOTE:Raisethe glassfully. 1.

2.

Remove: . Door panel . Plasticcover(seepage20-14)

Pull out the outer handle.Pry the outer handlerod out of its joint usingdiagonalcutters. NOTE: . To easereassembly, note location@ ot the outer it. handlerod on the joint beforedisconnecting . Takecarenot to bendthe outer handlerod. . Use a shop towel to protectthe opening in the door.

Pullout the retainerclip. CYLINOER PROTECTOR

EUSHING Replace. LOCKCYLINDER

DIAGONAL CUTTERS

,pr, \

RETAINER CLIP

\

e

3.

Removethe bolts,then removethe cylinderprotector, lockcylinderand outer handle. >: Boltlocations,2 6x1.omm

]

9.8N.m {1.0kgf.m, 1.2tbl,ttl )

_,

_-_-,/

CYLINDER PROTECTOR

SHOP TOWEL

5.

Installationis the reverseof the removalprocedure. NOTE:Makesurethe door locksand opensproperly.

LOCKCYLINOER CYLINOER ROD

20-17

Doors Latch Replacement NOTE:Raisethe glassfully.

3.

Removethe boltsand movethe centerlowerchannel.

1.

Remove: . Door panel(seepage20-16) . Plasticcover(seepage20-14) . Outerhandle{seepage20-17}

NOTE:Takecare not to bend the inner handle rod and lock rods.

2.

Removethe rod protector.

>: Screw locations A>,3

8>,3 6x1.0mm

ffu

LATCH

_"

l

6 N.m{0.6kef.m,

11111

)

q )

CENTERLOWEB CHANNEI CBANK HOLDER

PROTECTOR Disconnect the connector,

6x1.0mm 8 N.m 10.8kgt.m, 6 tbtft)

Remove the inner handle, then remove the latch throughthe hole in the door. 5.

lnstallationis the reverseof the removalprocedure. NOTE:Makesurethe door locksand opensproperly.

20-18

L

Glass/RegulatorReplacement 1.

Remove: . Door panel(seepage20-'16) . Plasticcover(seepage20-14)

2.

Carefullymove the glassuntil you can seethe bolts, then loosenthem. Slidethe guide rearward,remove t h e g l a s s t r o m t h e g u i d e , a n d c a r e f u l l yp u l l t h e glassout throughthe window slot.

3.

Disconnectthe connector,and detach the harness clip, then removethe regulatorthrough the hole in the door. NOTE:Scribea line aroundthe rearrollerguidebolt to showthe originaladjustment.

>: Boltlocations NOTE:Takecarenot to dropthe glassinsidethe door. a >,4 6xL0mm 8 N.m (0.8 kgt m, i

'-1

>: Bolt localions,2 6x1.0mm

E l* \3

B> , 2

9.8N.m{1.0kgtm,I 7.2tbrfil I Loosen ,/ ROLLER

t

)

6x1.omm I N.m {0.8 kgt.m, 6lbrft Loosen. ,/

I I ]

REGULATOR

J

BOLTS

GUIDE

(cont'd)

20-19

Doors (cont'dl Glass/Regulator Replacement Greaseall the slidingsurfacesof the regulatorwhere shown. NOTE: . lf necessary,remove the power window motor from the regulator. . Beforeremovingthe powerwindow motor,scribe a line acrossthe sectorgearand regulator.

GlassAdjustment NOTE: . Placethe vehicleon a firm, levelsurfacewhen adjusting the glass. . Checkthe weatherstrips and glassrun channelfor damage or deterioration,and replacethem if necessary. 1.

Remove: . Door panel(seepages20-4,10, 16) . Plasticcover(seepages20-2,8,14)

2.

Adjustthe glass.

SECTORGEAR

REGULATOR

4D: a.

Raisethe glassfully.

b.

Loosenthe glass mounting bolts (front door) and regulatormountingbolts. Push the glass rearward (front door glass)or iorward (reardoor glass).

d.

Tighten the glass mounting bolts (front door) and regulatormountingbolts.

A >: Gl.3s mountingbolt locations. B >: Regulrtor mouting bolt loc.tions. Front:

5.

Installationis the reverseof the removalorocedure. NOTE:Rollthe glassup and down to seeif it moves freely without binding.Also make sure that there is no clearancebetweenthe glassand glassrun channel when the glass is closed.Adjustthe positionof the glassas necessary.

20-20

REGULATOR

b Rear: GLASS

+"

+

REGULATOR

e.

\

J

Loosenthe front channelmountingbolts (front d o o r ) o r r e a r c h a n n e lm o u n t i n g b o l t l r e a r ooor,,

f.

Lowerthe glass.

g.

P u s h t h e f r o n t o r r e a r c h a n n e l sa g a i n s tt h e glass,then tightenthe mountingbolts.

2DI3D: Raisethe glassas far up as possible,and hold it againstthe glassrun channel. b.

>: Frontandrear

L o o s e nt h e r o l l e rg u i d e b o l t s ,a n d a d j u s tt h e glassso it is parallelwith the glassrun channel. GLASSRUN CHANNEL

channel mounting bolt locations

Front:

ROLLER GUIDEBOLTS

\

(cont'd)

20-21

Doors GlassAdjustment {cont'd) c.

Tightenthe rollerguide bolts.

d.

Loosenthe front channelbolts.

e.

Lowerthe glass.

f.

Pushthe front channelagainstthe glass,then tightenthe mountingbolts.

6.

Checkfor water leaks. Spray water over the roof and on the sealingarea as shown. NOTE: . Adjustthe water pressureas shown. . Do not squeezethe tip of the hose.

GLASS

0.5 m {1.6ft)

HOSE HOSE

U - \ ,

300 mm {11.8in)

MOUNTING BOLT 3.

Checkthat the glassmovessmoothly.

4.

Raisethe glassfully and checkfor gaps.

5.

Checkthe glassoperation.

1.

NOTE:Checkthat the glass contactsthe glass run channelevenly.

Attachthe plasticcover,then installthe door panel (seepages20 4, 10, 16). Installthe regulatorhandleso it pointsforwardand up at a 45 degreeanglewith the glassclosed.

WEATHERSTRIP

Forward -

20-22

b

PositionAdjustment

StrikerAdjustment

NOTE: Placethe vehicleon a firm, level surfacewhen adjustingthe doors.

lvlakesurethe door latchessecurelywithout slamming. lf it needsadjustment:

After installingthe door, checkfor a flush fit with the body,then checkfor equalgaps betweenthe front, rear, a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d body edgesshouldalso be parallel.Adjust at the hinges as shown,

NOTE;The strikernuts are fixed, but the strikercan be adjustedslightlyup or down,and in or out. 'L

Loosenthe screws,then insert a shop towel between the body and striker.

CAUTION:Placea shop towel on the iack to prevent damage to the door when looseningthe door and hinge mounting bohs for adiustment. BOLTS DOOR MOUNTING 8 x 1.25mm 28 N.m{2.9kgf.m.21lbt'ft} boltsslightly Loosen thedoormounting to movethedoorlN or OUTuntil it'sflushwiththebody.lf necessary, voucaninstallashimbehindone hingeto makethedooredges

Inserta shoptowel betweenthe body and

PLASTIC

P A R A L L E Lw i t h t h e b o d y .

HINGEMOUNTINGBOLTS I x 1.25mm 28 N.m (2.9kgf.m,21lbtft) Removethe innerfender, loosenthe hingemounting bolts,and movethe door BACKWARD or FORWARD, UP or DOWNas necessary to equalizethe gaps. Lowerthe glass.

J

sc8Ews 8 x 1.25mm 18 N.m (1.8kgf.m, 13 tbtftl

ifF t 2.

Lightlytightenthe screws.

3.

Wrap the strikerwith a shop towel, then adjustthe strikerby tappingit with a plastichammer. CAUTION: Do not tap the striker too hard.

The door and body edges should be parallel-

4.

Loosenthe screws.and removethe shoptowel.

5.

Lightlytightenthe screws. H o l d t h e o u t e r h a n d l eo u t , a n d p u s h t h e d o o r againstthe body to be surethe strikerallowsa flush fit. lf the door latchesproperly,tighten the screwsand recheck.

\ NOTE:Checkfor water leaks.

20-23

Mirrors Mirror Replacement NOTE:Take care not to scratchthe mirror. mirror base coverand door. l

L o w e rt h e d o o rg l a s s .

2.

Carelullypry out the mirror mount cover panel by nano.

3.

Removethe mirror mountingnuts while supporting the mirror.

a: Nutlocations,3

Power mirro.:

€)CONNECTOR (Nrirrorside) MIRROR

(Doorharness side)

CONNECTOR MIRROR MOUNT COVEB PANEL Manual mirror:

Installationis the reverseof the removalprocedure.

Removethe cap, screw and knob,then removethe mirror mount cover panel.

NOTE:Make sure the connectoris connectedproperly.

MIRRORMOUNT

KNOB

20-24

|}

Mirror Holder/CoverReplacement

RearviewMirror Replacement

CAUTION: Put on gloves to protecl your hands.

1.

Removethe rubberdamper.

2.

Pry the cover off using the end of a flat tip screwdrivef.

L

C a r e f u l l yp r y o u t t h e m i r r o r h o l d e rw i t h a f l a t t i p screwdriveras shown. PIVOT

CAUTION: When prying with a flat-tip screwdriver, wrap it with a shop towel to prgvant damage.

-6r

JOINT PIN

-G{

3.

Removethe screws,then removethe rearviewmirror,

4.

Installationis the reverseof the removalprocedure.

SCREW 5x0.8mm il N.m lo.a kgf.m, 3 lbf.ftl

SHOPTOWEL

J

Installationis the reverseof the removalprocedure. NOTE:Apply greaseto the locationsindicatedby the arrows. >: Sc.ewlocations A> ,3

ry

s>,2

I

6)drD ) To remove the screws, pull the sealaway.

SHOPTOWEL

I 20-25

Windshield,RearWindow and OuarterGlass Index NOTE:The numbersafterthe part namesshow the quantitiesof the partsused. Windshieldl2Dl3D/4D): RUBBER UPPER DAM

FASTENER, 2 (Sell-adhesive type,glassside)

FASTENER, 2 body side) lClip-type,

WINDSHIELD Removal,page20 28 page20-29 Installation,

RearWindow (2Dl4Dl:

FASTENER, 4 (Self-adhesive-type, glassside) FASTENER,4 lSelf adhesive-type, body sidel

/ /

* , /

M SPACER,

w /> @

20-26

b RearWindow l3Dl: FASTENER,4 (Self-adhesive-type, glassside) SPACER,

|

I

,o"r.".". o

bod'side)

{ff*'*'YPe DAM,2 RUBBER

tI

=

@

I

SEALA, 1

SEALB,2

e OuarterGlass: 3D:

2D: OUARTERGLASS Removal,page20-40 page20 4l Installation,

OUARTER GLASSTRIM FASTENER (Self-adhesave type, body side)

$(

\ \

\)f\

\il]

n,

FASTENER (Self-adhesive-type, glassside)

LOWERCLIP lSelf adhesive'type) LOWERRUBBER DAM

LOWERCLIP (Selfadhesive-type)

J

20-27

Windshield Removal CAUTION: . Put on gloves to plotest your h8nds. . Use seat covers to avoid damaging any surfaces. 1.

4.

To removethe windshield,first removethe: . Rearviewmirror (seepage20-25) . Sunvisorsand holders(seepage20-64) . Frontpillartrim (seepages20-59,60, 61) ! Windshieldwiper arms and cowl cover (seepage 20-1131

Apply protectivetape along the edge of the dash b o a r da n d b o d y a s s h o w n .U s i n ga n a w l , m a k e a h o l e t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ef r o m i n s i d et h e c a r . P u s ht h e p i a n ow i r e t h r o u g ht h e hole,and wrap eachend arounda pieceof woodPROTECTIVE '1" |

PIANOWIRE UPPER RUBBER DAM WINDSHIELO

Peel off the molding, and removethe glass brackers.

AOHESIVE

NOTE:When molding removal is difficult,cut the moldingwith a knife.

MOLDING

WINDSHIELO

RUBBER DAM W i t h a h e l p e ro n t h e o u t s i d e ,p u l l t h e p i a n o w i r e backand forth in a sawingmotion,and carefullycut t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ea r o u n dt h e entirewindshield. CAUTION: Hold the piano wile as closeto ihe windshield as possible to prevent damage to the body and dashboard.

3.

Pull down the front of the headliner(see page 2064). CAUTION: Take care not to bend the headlinet excsssively.

WINDSHIELD

6.

20-24

Carefullyremovethe windshield.

t

Installation '1.

G l u e t h e r u b b e rd a m a n d f a s t e n e r st o t h e i n s i d e face of the windshieldas shown.

Using a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entirewindshieldopeningflange.

NOTE:Be carefulnot to touch the windshieldwhere adhesivewill be applied.

NOTE: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper bonding. . Removethe rubberdams and tastenersfrom the body. . Maskoff surroundingsurfacesbeforepainting. 2.

>: Faslener localions, 2

FASTENER ALTGNMENT, \ -o MARK

Cleanthe body bondingsurfacewith a spongedampenedin alcohol. NOTE: After cleaning,keep oil, grease and water from gettingon the surface.

ALIGNMENT MABK

3 . lf the old windshieldis to be reinstalled,use a putty knife to scrapeoff all traces of old adhesive,then c l e a nt h e w i n d s h i e l ds u r f a c ew i t h a l c o h o lw h e r e new adhesiveis to be applied. 13.5mm (0.53in.)

NOTE:Make sure the bonding surfaceis kept free of water,oil and grease.

t

C

LOWERRUBBER DAM

CAUTION:Avoid setting the windshield on its edges; small chips may later deyelopinto cracks. NOTE: . Cleanthe shadowedarea. o Cleanarea@ as shown.

WINOSHI€LD 5.

lnside

Align and glue the molding to the edge of the windshield. NOTE: Be caretul not to touch the windshield where

& a4) WINDSHIELD MOLOING

WINDSHIELO

100mm {3.94in.l

)

J

WINDSHIELD

Apply primer(3M N'200,or equivalent) to edSe (cont'd) of the windshield.

20-29

Windshield Installation (cont'd) Installtheglassbracketsand fastenersas shown. NOTE:The numbersafterthe part namesshow the quantitiesof the oartsused.

9. With a sponge, apply a light coat of glass primer around the edge of the windshieldas shown. then lightlywipe it off with gauzeor cheesecloth.

>: Fastonerlocations,2 FASTENER^ I I

t/////, '/////l

NOTE: . Do not apply body primerto the windshield.and do not get body and glassprimerspongesmixed up. . Nevertouch the primed surfaceswith your hands. lf you do. the adhesivemay not bondto the windshieldproperly,causinga leakafterthe windshield is installed. . Keepwater. dust, and abrasrvemateraalsaway from the primedsurface. Applyglassprimer I Apply glass p.imer here.

to the molding.

GLASSBRACKETS, 2 MOLDING

7.

Set the windshieldon the glassbrackets,then center it in the opening.Make alignmentmarksacross the windshieldand body with a greasepencilat the four pointsshown. NOTE:Be carefulnot to touch the windshieldwhere adhesivewill be aDolied.

WINDSHIELD 10. With a sponge.apply a light coat of body primerto the original adhesiveremainingaround the windshield openingflange. Let the body primer dry for at least10 minutes. NOTE: . Do not apply glassprimer to the body, and be careful not to mix up glassand body primer sponges. . Nevertouch the primed surfaceswith your hands. . Maskoff the dashboardbeforepaintingthe flange. 7////l /////l

I Apply body p mer hcre.

6mm

/ SCREW

8.

Removethe windshield.

20- 3 0

16mm (0.6:|in.)

5mm (0.2 in.l

16 mm {0,63in.}

3 1 1 . Thoroughlymix the adhesiveand hardenertogether

on a glassor metal plate with a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mixing. . Followthe instructionsthat come with the adhestve.

1 4 . U s e s u c t i o nc u p s t o h o l d t h e w i n d s h i e l do v e r t h e opening,align it with the alignmentmarksmade in step7, and set it down on the adhesiveL . ightly push on the windshielduntil its edge is fully seated on the adhesiveall the way around. NOTE:Do not openor closethe doorsuntiladhesive ri vI Y

A L T G N M E N TM A R K

Beforefilling a cartridge.cut the end of the nozzle as shown.

Cut nozzleend 10 mm 10.39 in.)

7 mm (0.27in.l

tu

13. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d the edgeof the windshieldas shown. NOTE:Apply the adhesivewithin 30 minutesafter applyingthe glassprimer. 12mm (0.47in.)

l_Z oo*.t,ut

Make a slightly thicker bead at each corner.

8 mm 10.31in.l

5mm (0.2in )

='+

MOLDING

A\uloto^o -.\\ . UPPER RUBBER DAM FASTENER

/

w

WINDSHIELD LOWEB RUBBER DAM

LOWER RUBBER DAM lmm 10.04in.l

)

WINDSHIELD

1 5 . Scrape or wipe the excessadhesiveoff with a putty knifeor towel. NOTE: To removeadhesivefrom a paintedsurfaceor the windshield,wipe with a soft shop towel dampened with alcohol. 1 6 . Let the adhesivedry for at leastone hour, then spray water over the windshieldand checkfor leaks.Mark the leakingareas,let the windshielddry, then seal with sealant. NOTE: . Let the car stand for at leastfour hours after windlf the car hasto be usedwithin shieldinstallation. the firstfour hours,it must be drivenslowly. . Keepthe windshielddry for the first hour after installation. . Checkthat the ends of the side molding are set underthe cowl cover.

't7. Reinstallall remainingremovedparts. NOTE: . Installthe rearviewmirror rubber damper after the adhesivehasdriedthoroughl',. . Advisethe customernot to do the followingthings for two to three days: - Slam the doors with all the windows rolled up. - T w i s t t h e b o d y e x c e s s i v e l y( s u c h a s w h e n going in and out of drivewaysat an angle or drivingover rough,unevenroads).

20-31

RearWindow Removal 2DllDl

4.

CAUTION: . Put on gloves to protect your hands. . Uso ssat coversto avoid damaging any surlaces, . Do not damage thg roar window dofogggr grid linss, window antenna grid lines, and tsrminalg. 1.

2,

3.

Apply protectivetape along the edge of the body as shown. Using an awl, makea hole through the adhesivefrom insidethe car. Pushthe piano wire through the hole,and wrap eachend around a pieceof wood. PIANOWIRE ADHESIVE

To removethe rearwindow,first removethe: . T r u n kl i d . Rearseatcushion(seepages20-79,81) . Rearseat side bolsters{4D,see page 20-79) . Rearseat-back(2D,seepage20-81) . Rearshelf{seepages20-59,61} . Rearpillartrim {4D,see page20-59) . Sidetrim panel(2D,seepage20-61) . Ouartertrim panel(2D,see page20-61) . Rear roof trim (see page 20-65)

REARWINDOW PROTECTIVE TAPE

TAPE REARWNDOW

Disconnectthe rear window defogger connector from eachside.

PIANOWIRE

Peeloff the molding. PROTECTIVE TAPE

NOTE:When molding removal is difficult,cut the moldingwith a knile. ADHESIVE MOLDING

With a helper on the outside, pull the piano wire backand forth in a sawingmotion,and carefullycut through the adhesivearound the entire rear window.

F"*t, ID_HESI.VE ---, ,/,/

CAUTION: Hold the piano wiro as close to the rear window as possiblsto prcyent damageto the body.

REARWINDOW

S MOLDING

6.

20-32

Carefullvremovethe rearwindow.

I

lnstallation 1 . Using a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g flange.

4.

N O T E : B e c a r e f u ln o t t o t o u c h t h e r e a r w i n d o w whereadhesivewill be applied.

NOTE: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper bonding o Maskoff surroundingsurfacesbeforepainting. . R e m o v e t h e f a s t e n e r sa n d s p a c e r sf r o m t h e oooy. 2.

Apply the double-facedadhesivetape (NITTO501, or equivalent)to the edge of the rear window, then installthe moldingaroundthe edge of the rearwindow as shown.

ALIGNMENTMARK

ADHESIVE TAPE I in.) 867mm 134. 5mm {0.2in.}

C l e a nt h e b o d y b o n d i n g s u r f a c ew i t h a s p o n g e dampenedin alcohol.

ADHESIVE TAPE Thickness: 0.16mm (0.006in.l

NOTE: After cleaning,keep oil. greaseand water from gettingon the surface.

MOLDING ALIGNMENT MARK GLASS

usea putty lf the old rearwindow is to be reinstalled, knifeto scrapeoff all tracesof old adhesiveand the rubberdam,then cleanthe rearwindow surfacewith alcoholwherenew adhesiveis to be applied. NOTE:Make sure the bonding surfaceis kept free of water,oil and grease.

)

MOLDING

wtNoow

CAUTION:Avoid setting the rear window on its edges;small chips may later develop into cracks. NOTE:Cleanthe shadowedarea.

5.

Glue the fastenersand spacersto the insidefaceof the rearwindow as shown. N O T E ; B e c a r e f u ln o t t o t o u c h t h e f e a r w i n d o w where adhesivewill be applied. >:Fa3l€ner, spacer locations A >, 4 FASTENER

MOLOING

(:r:^#T

ry

ALIGNMENT

!\raRKs a>,2 Outside

I REARWINDOW

)

REARWINOOW

SPACER

liGrtrrrrertrr

\..!44llc-'''

-

-

(cont'd)

20-33

RearWindow Installation (cont'dl 6.

Gluethe fastenersto the body as shown. Fastenerlocations,4

9 . W i t h a s p o n g e ,a p p l y a l i g h t c o a t o { g l a s sp r i m e r aroundthe edgeoI the rearwindow as shown,then lightlywipe it off with gauzeor cheesecloth.

FASTENER

NOTE: . D o n o l a p p l y b o d y p r i m e rt o t h e r e a rw i n d o w . and do not get body and glass primer sponges mixed up. . Nevertouchthe primedsurfaceswith your hands. lf you do, the adhesivemay not bond to the rear w i n d o w p r o p e r l y c, a u s i n ga l e a ka t t e rt h e . e a r window is installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface. '/fur1 : lppty gtassprimerhere.

\ - . * l -E4,7-7

,.-)

,

/

l

4 Y l

F-LNGENY:,//

MOI-DING

7.

Set the rear window, then centerit in the opening. Make alignmentmarksacrossthe rear window and body with a greasepencllat the four points shown.

ALIGNMENTMARK

FASTENER REARWINDOW

10. With a sponge,apply a light coat of body primer to t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n d t h e r e a r window openingflange.Letthe body primerdry for at least10 minutes. NOTE: . Do not applyglassprimerto the body.and be care, ful not to mix up glassand bodyprimersponges. . Nevertouchthe primedsurfaceswith your hands.

-\

-.._s

/fu/

: Applyboay primerhere.

1 6m m (0.(I, in.l

16 mm (0.63in.l

l

6mm r {O.24in.}

8.

Remove the rear window.

20-34

7mm {0.28in.}

' 1 1 . Thoroughlymix the adhesiveand hardenertogether

on a glassor metalplatewilh a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mixing. . Followthe instructionsthat came with the adhesive.

14. Use suctioncups to hold the rear window over the t a r k sm a d ei n o p e n i n ga, l i g ni t w i t h t h e a l i g n m e nm a d h esiveL . ightly o n t h e s e t i t d o w n step7, and p u s h o n t h e r e a rw i n d o w u n t i l i t s e d g e sa r e { u l l y seatedon the adhesiveall the way around. NOTE:Do not openor closethe doorsuntilthe adhesiveis dry.

1 2 . Beforefilling a cartridge,cut the end of the nozzle

SUCTION CUPS

a ss h o w n .

ALIGNMENT MARK

1 0m m { 0 . 3 9i n . )

7 mm (0.27in.l

J

1 3 . Packadhesiveinto the cartridgewithout air pockets to ensurecontinousdelivery.Put the canridgein a c a u l k i n gg u n , a n d r u n a b e a do l a d h e s i v ea r o u n d the edge of the rearwindow as shown. NOTE|Apply the adhesivewithin 30 minutesafter applyingthe glassprimer. Makea slightlythicker beadat eachcorner.

12 mm 10.,Uin.)

[/

GLASS

oo*r.,u.

Scrapeor wipe the excessadhesiveoff with a putty knifeor towel. NOTE:To removeadhesivefrom a paintedsurface or the rear window, use a soft shop towel dampenedwith alcohol. 1 6 . L e t t h e a d h e s i v ed r y f o r a t l e a s to n e h o u r , t h e n s p r a y w a t e r o v e r t h e r e a r w i n d o w a n d c h e c kf o r leaks.Mark the leakingareas,let the rear window dry,then sealwith sealant.

8 mm (0.31in.)

MOLDING FASTENER

NOTE:Let the car standfor at leastfour hoursafter rear window installation.lf the car has to be used within the Iirst tour hours,it must be drivenslowly 1-7. Reinstallall remainingremovedparts

SPACER MOLDING

NOTE:Advisethe customernot to do the following thingsfor two to threedays: . .

Slamthe doorswith all the windows rolledup. Twist the body excessively(suchas when going i n a n d o u t o f d r i v e w a y sa t a n a n g l e o r d r i v i n g over rough.unevenroads).

FASTENER

) REARWINDOW

20-35

RearWindow Removal 3D:

Upper portioni

CAUTION: . Put on gloves to ptotect your hands. . Us€ seat cove6 to avoid damaging any surfaces. . Do not damage the rear window defogger grid lines. . Take carg nol scratchthe terr window molding. '1.

2.

To removethe rearwindow,firsr removethe: . Rearcentershelf(seepage20-60) . H a t c hu p p e r t r i m , h a t c ht r i m p a n e la n d h a t c h sidetrim (seepage20-63) . Rearwindow wiper arm (seepage2O-115) . Hatchspoiler(seepage20 101)

TAPE Side portion:

D i s c o n n e ctth e r e a r w i n d o w d e f o g g e rc o n n e c t o r from eachside.

GLASS

Apply protectivetape to the inner edge of the tail_ gate. From insidethe hatch,usea knifeto cut throughthe rearwindow adhesiveall the way around. NOTE: . lf the rear window is to be reinstalled,take care not to damagethe molding. . lf the molding is damaged,replacethe rear win_ dow and moldingas an assembly.

Lower portion;

HATCH

ffi#

ADHESIVE

Carefullyremovethe rearwindow. NOTE;Checkthe moldingfor damage,and replace the rearwindow if necessary.

REARWINOOW

20-36

t

lnstallation '1.

Using a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g flange. NOTE: . Do not scrapedown to the paintedsurfaceol the body; damaged paint will interferewith proper bonding. a Removethe rubberdams,spacersand fasteners from the hatch. . M a s k o f f s u r r o u n d i n gs u r f a c e sb e f o r ea p p l y i n g primer.

2.

C l e a nt h e h a t c h b o n d i n g s u r f a c ew i t h a s p o n g e d a m p e n e di n a l c o h o l . N O T E :A f t e r c l e a n i n g ,k e e p o i l , g r e a s eo r w a t e r from gettingon the surface.

3.

O

l f t h e o l d r e a r w i n d o w i s t o b e r e i n s t a l l e du, s e a putty knife to scrapeoff all tracesof old adhesive, t h e n c l e a nt h e r e a r w i n d o w s u r f a c ew i t h a l c o h o l where new adhesiveis to be applied.

4.

Glue the rubberdams to the insideface of the rear window, as shown, to containthe adhesiveduring and gluethe fasteners,spacerand seals installation, as shown. NOTE: . Gluethe rubberdams usingthe printeddots as a g ui d e . . Be careful not to touch the rear window where adhesivewill be aPPlied >r Fastener, spacorandseal locations A>,4

B > ,1 SPACER

FASTENER

/

"-*^1

w

A L.IGNMENT IIARKS __,/ C>,2 S E AA L

l

s i

'W

o.\6fif,", j

]

ryt48rq __ ,,/

D> '2

'EAL B

- \ l

NOTE;Makesurethe bondingsurfaceis keptfree of water,oil and grease.

19Pry/

CAUTION:Avoid setting the rear window on its edges;the moldingcan be permanentlydeformed. NOTE:Cleanthe shadowedarea

REARWINDOW

FASTENER

PRINTEDDOTS

REARWINDOW

MOLOING

)

(cont'd)

20-37

RearWindow Installation(cont'd) Installthe fastenersto the hatchas snown. >: Fastener locations, 4

8.

W i t h a s p o n g e .a p p l y a l i g h t c o a t o f g l a s sp r i m e r a r o u n dt h e e d g e o f t h e r e a r w i n d o w ,t h e n l i g h t l y wipe it off with gauzeor cheesecloth. NOTE: . Do nol apply body primer to the rear window, and do not get body and glass primer sponges maxedup. . Nevertouchthe primedsurfaceswith your hands. lf you do, the adhesivemay not bond to the rear w i n d o w p r o p e r l y c, a u s i n ga l e a k a f t e rt h e r e a r window is installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface.

V/////f , apety st,." o.imer here.

Inside

----

tUt

| @NJ-l

rll \

,zN \ GLASS

I

- -t-

RUBBER1 5m m DAM {0.59in.l MOLDING

I 15mm

L 10.59in.l t \ SPACER

GLASS

REARWINOOW

Set the rearwindow uprighton the hatch,then center it in the opening.Make alignmentmarks across the rear window and body with a greasepencil at the four pointsshown. NOTE: Be carefulnot to touch the rearwindow where adhesive will be applied.

FASTENER

7.

Remove the rear window.

20-38

3 9. With a sponge,apply a light coat of body primerto t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n dt h e r e a r window openingflange.Let the body primerdry for at least10 minutes.

12. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuosdelivery.Put the cartridgein a c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d the edgeof the rearwindow as shown.

NOTE: . Do not applyglassprimerto the body,and be careful not to mix up glassand bodyprimersponges. . Nevertouchthe primedsurfaceswith your hands.

NOTE:Apply the adhesivewithin 30 minutesafter applyingthe glassprimer.

////////

' acoV boay primerhere.

ffi;fr'L/:ADHEs' vE 8mm { 0 . 3 1i n . l

GLASS

t

1 0 . Thoroughlymix the adhesiveand hardenertogether on a glassor metalplatewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mlxlng. . Follow the instructionsthat came with the adhesive. 1 1 . Beforefilling a cartridge,cut the end oJ the nozzle

MOLDING

as shown.

---$ ,R1

GLASS

Cut nozzle

f\+,,"," in.t to.oa

10 mm {0.39in.)

ffi-f

MoLD|NG/

I

-.17 \

7 mm (0.27in.)

(cont'd)

20-39

RearWindow

OuarterGlass

Installation {cont'd)

Removal

13. Use suctioncups to hold the rear window over the opening.align it with the alignmentmarks made in slep 6. and set it down on the adhesive.Lightlypush on the rea. window until its edges are fully seated on the adhesiveallthe way around.

3D:

NOTE:Do not openor closethe doorsuntilthe adhe_ sive is drv.

sucTtoN CUPS

CAUTION: a Pul on gloves to protect your hands. . Use seat covers to avoid damaging any surfaces, 1. To removethe quarterglass,first removethe: . Rearseat-backand rear seat cushion (see page 20_80) . Rear center shelf and rear side shelf lsee page 20_60) . R e a rt r i m p a n e la n d s i d e t r i m p a n e l ( s e ep a g e 20_60) . Upper anchorbolts from the front and rear seat belts{seepages20-86.89) . Ouartertrim panel(seepage20-60) 2,

From insidethe car, use a knifeto cut through the quarterglassadhesiveall the way around. NOTE: . lf the clip on the rearedge is broken,the quarter glasscan be reinstalled usingbutyltape(seepage 20-421. . Apply protectivetape alongthe edgeof the entire quarterglassopeningflange.

1 4 . Scrapeor wipe the excessadhesiveoff with a putty knifeor towel. NOTE:To removeadhesivefrom a paintedsurface or the rear window. use a soft shop towel dampenedwith alcohol. 1 5 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r . t h e n spray water over the rear window and check for leaks,Mark the leakingareas,let the rear window dry, then sealwith sealant. NOTE: Letthe car standfor at leastfour hoursafter rear window installation.lf the car has to be used within the first four hours,it must be drivenslowly. Reinstallall remainingremovedparts. NOTE:Advisethe customernot to do the following thingsfor two to threedays: . Slamthe doorswith all the windows rolledup. . Tr,vistthe body excessivelylsuch as when going in and out of drivewaysat an angle or driving over rough,unevenroads).

20-40

OUARTER GLASS

lnstallation 1 . Using a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding s u r t a c ea r o u n d t h e e n t i r eq u a r t e rg l a s s o p e n i n g flange.

Uppcr portion:

AOHESIVE TAPE

Lower oortion:

NOTE: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper bonding. r Removethe rubberdams from the body. . lf any of the clips are broken,removethem from the body. . Mask off surroundingsurfacesbefore applying pnmer. Cleanthe body bondingsurfacewith a spongedampenedin alcohol.

PROTECTIVE TAPE

ADHESIVE

NOTE: Afier cleaning,keep oil, greaseand water from gettingon the surface. lf the quarterglass is to be reinstalled,use a putty knife to scrapeoff all traces of old adhesive.then cleanthe quaner glass surfacewith alcoholwhere adhesiveis to be apPlied. NOTE:Make sure the bonding surfaceis kept free of water,oil and grease.

l Pillar portion:

CAUTION: Avoid setting the quarter glass on its edges;small chips may later devglop into cracks. NOTE:Cleanrhe shadowedarea.

CLIP

3.

Carefullyremovethe quarterglass N O T E :C h e c kt h e q u a r t e rg l a s st r i m a n d c l i p s f o r damage,and replacethem if necessary'

)

(cont'd)

20-41

QuarterGlass Installation (cont'd) 4.

Gluethe upperand lower rubberdams to the inside Iace of the quaner glass,as shown, to containthe adhesivd e u r i n gi n s t a l l a t i o n . N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s whereadhesivewill be applied. >: Alignment mark locations

GLASS

UPPER RUBBER DAM

6.

lf the old quarterglassis to be reinstalled(and the c l i p o n t h e r e a r e d g e i s b r o k e no f f ) , a p p l y a l i g h t coat of primer (3I/ C-100,or equivalent), then apply butyl tape to the quarterglass,as shown. and seal the body holewith pieceof urethanetape. NOTE: . Be carefulnot to touch the quaner glasswhere adhesivewill be applied, . Do not peelthe separatoroffthe butyltape.

//////// '.8u'Jt tape tocarionst3M8628,or equivetenrl ' Thickness:3.2 mm lo.t3in.l Width:6.4mm {0.25in.) UPPER RUEBER DAM

13 mm (0.5in.l

BUTYL TAPE

\

\

l

*--T,7r--/r4--; ..

LOWER RUBEER DAM Installthe quarter glasstrim on the quarter glass, then glue the upperand lowerclipsas shown. N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s where adhesivewill be applied.

UPPER

OUARTER GLASSTRIM

OUARTER GLASS

GLASSTRIM

NOTE: Contactthe cljps againstthe quarter glass trim at the areas I n d i c a t e db y t h e a r r o w s .

20-42

GLASS

t 7.

With a sponge,apply a light coat of glassprimerto the insideface of the quarterglass,as shown,then lightlywipe it off with gauzeor cheesecloth. NOTE: . Do not apply body primer to the quarter glass, and do not get body and glass primer sponges m i x e du p . . Nevertouchthe primedsurfaceswith your hands. lf you do, the adhesivemay not bond to the quar ter glassproperly,causinga leak after the quarter glassis installed. . Keep water, dust, and abrasivematerialsaway from the primedsurface.

8. With a sponge,apply a light coat of body primerto the originaladhesiveremainingaroundthe quarter glassopeningflange.Let the body primerdry for at least10 minutes. NOTE: . Do not apply glass primer lo the body, and be c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r sponges. . Nevertouchthe primedsurfaceswilh your hands. . Maskoff the rearside trim panelbeforepainting t h ef l a n g e . /////////

| apetl body erimer he,e.

16 mm {0.63in.l

////////l : ^pptv stassprimerhe.e. 2 1m m 1 5m m {0.83in.) (0.59in.)

l

UPPER RUBBER DAM

9 . Thoroughlymix the adhesiveand hardenertogether on a glassor metalplatewith a pufty knife.

OUARTER GLASS

BUBBEB DAM

30 mm 1 5m m in.l (r.2 in.) 10.59

NOTE: . Cleanthe platewith a spongeand alcoholbefore mr x l n g . . Followthe instructionsthat came with the adhesive. 1 0 . Before filling a cartridge, cut the end of the nozzle as shown. C u t n o z z l ee n d

10 mm (0.39in.l

7 mm (0.27in.)

) (cont'd)

20-43

OuarterGlass Installation(cont'd) 11. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.put the canridgein a c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d the edgeof the quarterglassas shown.

12. Use suctioncups to hold the quarterglassover the opening,alignthe clips,and set it down on the adhesive.Lightlypush on the quanerglassuntil its edges are fully seatedon the adhesiveall the way around.

NOTE: . lf the old quarterglass is to be reinstalled,peel the separatoroff the butyl tape afterapplyingthe adhesive. . Apply the adhesivewithin 30 minutesafterapply_ ing the glassprimer.

N O T E : D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e adhesiveis drv.

i:.8i".,1/:ADHES,'E 8 rnm (0.31in.l OUARIER GLASSTRIM

OUARTER GLASSTFIM

CLIP

BUTYI. TAPE

Scrapeor wipe the excessadhesiveoff with a putty knifeor towel. NOTE:To removeadhesivefrom a paintedsurface or the quarter glass,wipe with a soft shop towel dampenedwith alcohol. 1 4 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n

spray water over the quarter glass and check for leaks.Mark the leakingareas,let the quarterglass dry, then sealwith sealant. OUARTERGLASS

32 mm { 1 . 3i n . )

''='I

[-4m,^, '"r"\

GLASS

\

/

GLASS

20-44

drt".

TAPE

NOTE: Letthe car standfor at leastfour hoursafter quarterglass installation.lf the car has to be used within the first four hours,it must be drivenslowly. 1 5 . Reinstallall remainingremovedparts. NOTE:Advisethe customernot to do the following thingsfor two to three days: . .

Slam the doorswith all the windows rolledup. Twist the body excessively(suchas when going a na n d o u t o f d r i v e w a y sa t a n a n g l e o r d r i v i n g over rough,unevenroads).

Removal Upper portion:

2Oi CAUTION: . Put on gloves to protect your hands. . Use seat covers to avoid damaging any surfaces. 1. To removethe quarterglass,first removethe: . Rear seat-backand rear seat cushion (see page 20_81) o Sldetrim panel(seepage20-611 . Rearshelf(seepage20-61) o Upper anchor bolt from the front seat belt (see page20-86) . Ouartertrim panel(seepage20-6'l) 2.

From insidethe car. use a knife to cut through the quarterglassadhesiveallthe way around.

ADHESIVE

PROTECTIVE TAPE

Rear edge portion:

NOTE: take care . lf the quarterglassis to be reinstalled, not to damagethe molding. . Apply protectivetape alongthe edgeofthe entire q u a n e rg l a s so P e n i n g flange

D

Pillar portion:

TAPE GLASS

3 . Carefullyremovethe quarterglass. NOTE:Checkthe moldingfor damage,and replace it if necessary.

I 20-45

OuarterGlass Installation 1 . Using a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding s u r f a c ea r o u n d t h e e n t i r e q u a r t e rg l a s so p e n i n g flange. NOTE: . Do not scrapedown to the paintedsurfaceof the body; damaged paint will interferewith proper bonding. a Removethe fastenerfrom the body. a lf any of the clips are broken,removelhem from the body. Mask off surroundingsurfacesbefore applying pnmer. Cleanthe body bonding surfacewith a spongedamp enedin alcohol. NOTE: After cleaning,keep oil, greaseand water from gettingon the surface. lf the quarterglassis to be reinstalled,use a putty knife to scrapeoff all traces of old adhesive.then cleanthe quarterglass surfacewith alcoholwhere adhesiveis to be applied. NOTE:Make sure the bonding surfaceis kept free of water.oil and grease.

4.

Installthe molding around the edge of the quarter glassas shown. NOTE: . lf the old molding is to be reinstalled, scrapeoff t h e o l d a d h e s i v et a p e f r o m t h e m o l d i n g ,a n d c l e a nt h e m o l d i n gs u r f a c ew i t h a l c o h o lw h e r e new adhesivetape is to be applied.Apply the double-facedadhesivetape to the molding and quarterglassas shown. . Be carefulnot to touch the quarterglasswhere adhesivewill be aoDlied. Adhesiv€tspe A (3M 4215,or equivalent) Thicknsss:o.il mm (0.02in.l Widih: 5 mm {0.2 in.} Length: /140mm {17.3in.) Adhesivetap6 I (NITTO501, or equivatontl Thickness:0.16 mm {0.006in.) Width: I mm {0.3 in.} Longlh: 4it0 mm (17.3in.) Adhosiv€tape C (3M /P13. or equivalentl Thickness:0.8 mm (0.03in.l Width: 5 mm (0.2in.) Length:30 mm (1.2in.) ADHESIVE

CAUTION: Avoid setting the quarter glass on its odges;small chips may later develop into cracks, NOTE:Cleanthe shadowedarea.

20-46

t 5.

lf the old quarterglassis to be reinstalled,glue the upperand lowerclips and fasteneras shown N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s where adhesivewill be applied. >: Clip,fastenerlocations A>,2 ALIGNMENT

B > ,1 2.5mm (0.m in.)

7.

With a sponge,apply a light coat of glassprimer to the insideface of the quaner glass,as shown,then lightlywipe it off with gauzeor cheesecloth NOTE: . Do not apply body primer to the quarter glass, and do not get body and glass primer sponges mixed up. . Nevertouchthe primedsurfaceswith your hands. lf you do, the adhesivemay not bondto the quar ter glass properly,causinga leak after the quarter glassis installed. . Keep water, dust, and abrasivematerialsaway from the Primedsurface t///////7, , aootva"av crimerhere'

MOLDING

\

15.5mm 10 mm 10.61in.l {0.39in.l

b

6.

Gluethe fastenerto the body as shown. location,1 >: Fastener

)

(cont'dl

20-47

OuarterGlass Installation(cont'dl 8. With a sponge,apply a light coat of body primer to the originaladhesiveremainingaroundthe quarter glassopeningflange.Let the body primer dry for at least l0 minutes. NOTE: . Do not apply glass primer to the body, and be c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r sponges. . Neverlouchthe primedsurfaceswith your hands. . Maskoff the rear side trim panel beforepainting the flange. ///ffi

l'1. Packadhesiveinto the canridgewithout air pockets to ensurecontinuousdelivery.Put the cartrigein a c a u l k i n gg u n , a n d r u n a b e a d o f a d h e s i v ea r o u n d the edgeof the quarterglassas shown. NOTE: . lf the old quarter glass is to be reinstalled,peel the separatoroff the butyl tape afterapplyingthe adhesive. . Peel the separator off the adhesive tape after applyingthe adhesive. . Applythe adhesivewithin 30 minutesafterapply ing the glassprimer.

: Appty aoay primer here.

1 6m m 10.63in.l

12mm 11

lo.tttn.lI l:ADHESIVE 8mm {0.31in.)

CLIP

9 . Thoroughlymix the adhesiveand hardenertogether on a glassor metal platewith a putty knife. NOTE: . Cleanthe platewith a spongeand alcoholbefore mixing. . Followthe instructionsthat came with the adhesive. 1 0 . Beforefilling a cartridge,cut the end of the nozzle as shown. Cul nozzleend 10 mrn (0.39in.)

7 mm 10.27in.)

20-4A

MOLDING

12. Use suctioncups to hold the quarterglassover the o p e n i n g ,a l i g n t h e c l i p s , a n d s e t i t d o w n o n t h e adhesive.Lightlypush on the quarterglassuntil its edges are fully seatedon the adhesiveall the way around. N O T E :D o n o t o p e n o r c l o s et h e d o o . s u n t i l t h e adhesiveis dry.

}

CLIP

1 3 . Scrapeor wipe the excessadhesiveoff with a putty knifeor towel, NOTE:To removeadhesivefrom a paintedsurface or the quaner glass,wipe with a soft shop towel dampenedwith alcohol. 1 4 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n

spray water over the quarter glass and check for leaks.Mark the leakingareas,let the quarterglass dry, then sealwith sealant. NOTE:Letthe car standfor at leastfour hoursafter quarterglass installation.lf the car has to be used within the first four hours,it must be drivenslowly Reinstallall remainingremovedpartsNOTE:Advisethe customernot to do the following thingsfor two to threedays:

)

a

. .

Slamthe doorswith all the windows rolledup. Twist the body excessively(suchas when going i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g over rough,unevenroadsl.

20-49

Moonroof Index

SWITCHPLATE Adjustment,page20 56

--:=:: CABLEASSEMBLY Replacement, page2O-55

SUNSHADE page20-52 Replacement,

0

\

g

TNNERCAELE

RAIL HOLDERB

RAIL HOLDERA

REAR DRAIN TUBE

Y< / \ u8E LfP

ll ll

I

/

U 6

./w REARDRAIN VALVE

FRONTORAINTUBE

20-50

?'''

Troubleshooting Symptom

ProbableCause 1 . C l o g g e d r a i nt u b e . 2. Gap betweenglassweatherstrjpand roof panel. 3. Defectiveor improperlyinstalledglassweatherstrip. 4. Gap betweendrainsealand roof panel. '1. Excessive clearancebetweenglassweatherstripand roof panel.

Waterleaks

Wind noise Motor noise

Glassdoes not move,but motor turns

Glassdoes not move and motor does not turn {glasscan be movedwith moonroofwrench)

1. Loosemotor. 2. Worn gearor bearing. 3. Cableassemblydeformed. '1. Clutchout of adjustment. 2. Foreignmatterstuckbetweenguide rail and slider. 3. lnnercableloose. 4. Cableassemblynot attachedproperly. 1. 2. 3. 4. 5.

Blownfuse, Faultyswitch. Batteryrun down. Defectivemotor. Faultyrelay.

GlassHeightAdjustment D

The roof panel should be even with the glassweathers t r i p , t o w i t h i n 1 . 7 : l r 3m m ( 0 . 0 7: 3 : 3i1n . ) a l l t h e w a y around.lf not, openthe giassfully,and: 1.7tl.8mm {0.07:33iin.}

1.

GLASSWEATHERSTRIP

Removethe bracketcover. Loosenthe nuts, and installthe shims betweenthe glassframe and glassbracketas shown. Shim thickness:Frontmax.3 mm 10,12in.l Rear max. 2 mm 10.08in.) Repeaton oppositesidei{ necessary.

5x1.0mm 9.8N.m 11.0kgf m, 7.2rbtft)

SRACKET COVEB

6x1.0mm 9.8 N.m {1.0kgtm, 7.2 tbf.ft)

----------1>

)

20-51

Moonroof Glass,GlassBracketand SunshadeReplacement l.

Closethe glassfully.

2.

Slidethe sunshadeall the way back.

3.

Removeboth bracketcovers.

6.

Removethe drainchannel. DRAINCHANNEL

ERACKETCOVER

Forward _--____-> 4.

Remove the nuts from both glass brackets.

7.

GLASSEBACKET

R e m o v et h e h o l d e r c o v e r . t h e n r e m o v e t h e h o l d e rB .

NUT 6x1.0mm 9 N.m {0.9 kgf.m. ? tbtftl

{i;t'm

6x1.0mm 9.8N.m(1.0kgf.m,7.2lbt.ftl

Removethe glass by lifting up and pulling forward as shown. NOTE:Do not damagethe roof panet. GLASS

20-52

RAILHOLDERB

Usingthe moonroofwrench,move the glassbracket to the positionwhere the moonroofnormallypivots down, and removethe screws.

scREws

b 9. Removethe rail holderA. NUT 6x1.0mm I N.m(0.9kgf.m,

12. Slidethe sunshadeforward,then removeit.

SUNSHAOE

\

GLASS BRACKET

Installationis the reverseof the removalprocedure. NOTE:Checkthe glassheight(seepage20-51). '14. Checkfor water leaks,

D

water. NOTE:Do not use high-pressure DRAIN CHANNEL ROD

DRAINCHANNELROOSTOP Rotateas shownto removeit from the guiderail. 10. Remove the drain channel rod slider by moving the cable slider forward using the moonroof wrench.

I

'11. Detach the drain channel rod stop from the cutout of the guide rail as shown.

20-53

Moonroof Motor,DrainTubeand FrameReplacement CAUTION: . Put on gloves to protecl your hands. . Be careful not to damagethe seats,dashboardand other interior trim. '1. Removethe headliner {seepage20-64). 2.

the motor connectorand glasspositionswitchconnector. Disconnect NOTE:When removingthe motor,detachthe connectorfrom the frame,removethe bolts and nuts,then removethe motor.

3.

Removethe glass{seepage20-52).

4.

Disconnect the draintubes,and detachthe ceilinglight harness.

5.

Removethe frame mountingbolts. NOTE; . An assistantis helpfulwhen removingthe bolts. . Removethe front boltslast.

6.

Detachthe rearhooksby movingthe frameforward,then removethe frame.

BOLT 6x1.0mm 9.8 N.m {1.0kgt m, 7.2 tht.hl 6x1.0mm 9.8 N m (1.0kgl.m,7.2lbtft)

20-54

Assembly GuideRails/Cable

L

Replacement 7.

Pullthe draintubesout the front and rearpillars. CAUTION: Put on gloves to protect your hands, NOTE:Beforepullingout the draintube,tie a string to the end of it so it can be reinstalled.

1.

Removethe frame. Removethe motor and glassbracket(seepage20-52). Removethe nuts, and lift off each guide rail, then removethe cableassemblywith slidersattached. NOTE:Take care not to bend the cable tubes and guide rails.

L Installationis the reverseof the removalprocedure. NOTE: . Beforeinstalljngthe frame,clearthe drain tubes and drainvalvesby usingcompressedair. . Checkthe frameseal. . Cleanthe surfaceof the frame. . When installingthe frame, first attach the rear hooksinto the body holes. . When connectingthe draintube, slide it over the frame nozzleat least10 mm (0.39in.). . Installthe tube clip as shown.

Upward I

I I

GROMMET

Installationis the reverseof the removalprocedure. NOTE: . Oamagedpartsshouldbe replaced. . Greasethe slidingportionwith SuperHighTemp UreaGrease,P/N08758- 9002. . Fillthe groovein eachgrommetwith sealant.

TUBECLIP

DRAINTUBE

Checkfor water leaks. NOTE:Do not use high-pressure water.

a Installthe frame sealsecurely. a Beforeinstallingthe motor. make sure both slid-

ers are parallel. Beforeinstallingthe motor. installthe frame and glass,then checkthe openingdrag (seepage20-

Ity 20-55

Moonroof Switch Plate Adjustment (Fully Closed Positionl 1.

Removethe headliner{seepage20-64).

2.

Usingthe moonroofwrench,closethe glassfully. NOTE:Checkthe glassfit to the rool panel.

3.

Usingan open-endwrench,loosenthe switchplatemountingbolts.

4.

Adjustpositionof the switchplate(switchcam)as shown.

5.

Checkthe operationof the glass(from tilt-up positionto fully closedposition,from the fully open positionto the fully closedposition)by operatingthe moonroofswitch. NOTE:Checkthe glassheight(seepage20-51).

SWITCHPLATE

GUIDE PLATE

CAELEBRACKET

SWITCH CAM

INNER CABLE END

While moving the switch plate little bv little, secure the switch plate at the position where the switch cam contactsthe switch a (a faint click is heard).

Close the glass fully, and check for water leaks. NOTE: Do not use high-pressurewater.

2 0- 5 6

OpeningDrag Check {Motor Removed)

Closing ForceCheck (Motor Installedl

Beforeinstallingthe motor, measurelhe effort required to openthe glassusinga springscaleas shown.

' 1 . A f t e r i n s t a l l i n ga l l r e m o v e dp a r t s ,h a v e a h e l p e r hold the switch to closethe glasswhile you measure the force requiredto stop it. Attach a spring scaleas shown. Readthe forceas soon as the glass stops moving,then immediatelyreleasethe switch and springscale.

CAUTION: When using a spring scale, pfotest the leading edge ol the glass with a shop towel. lf load is over 40 N (4 kgf,9 lbf),checkthe side clearance a n dg l a s sh e i g h t( s e ep a g e2 0 - 5 1 ) .

SHOPTOWEL

CAUTION: When using a spring scale, protect the lerding edge ol the glasswith a shop towel. Closing Force:200 - 290 N (20 - 30 kst, 44 - 66 lbfl

SCALE

installa new lf the torce in not within specification, lockwasher,adjustthe tensionby turnangthe motor c l u t c h a d j u s t i n gn u t , a n d b e n d t h e l o c k w a s h e r againstthe motor clutchadjustingnut. LOCK WASHER Replace.

COUNTER.

cLocKwrsE

l,e

To decrease

20-57

Interior Component Location Index SRScomDonentsare locatedjn the partsareasmarkedwith an asterisk(*). Reviewthe SRScomponentlocations,precau tions,and proceduresin the SRSsection{24)beforeperformingrepairsor service. 2Dl3Dl4Dl CENTERPILLAR UPPERTRIM {seepage20 591

CENTERPILLAR LOWERTRIM PANEL (seepage20-59)

FRONTPILLAR TRIM { s e ep a g e s2 0 5 9 , 6 0 , 6 1 ) REARROOFTRIM (seepage20-65) HEADLINER Replacement, Page20'64

REARPILLAR TRIM {seepage20 59}

:

REAR lseepage20 59) TRUNK TRIM (seepage 20-62)

*OASHBOARO ComponentRemoval/lnstallation, page 20 68 Removal,page20-70

SEAT SIDETRIM {seepage20-59)

*CARPET page20 66 Replacement,

REARTRIM PANEL lseepage20-62)

PANEL page20-67 Replacement,

3D: REARSIDE SHEI-F (seepage 20-60)

2Dl

OUARTER TRIM PANEL (see page20-60)

HATCH SIDETRIM (seepase 20 63)

OUARTER TRIM PANEL {seepage20'61)

REARROOFTRIM (seepage 20 65)

SIDETRIM PANEL (seepage20-6'l) REARROOF TFIM (seepage20'65)

HATCH UPPER TRIM lseepage20 63) CENTER SHELF lseepage20 60)

REAR PANEL lseepage20 60) HATCH TRIM PANEL (see page 20-63)

20-54

SIDETRIM {seepage20 60)

SIDETRIM PANEL (seepage20-60)

REAR PANEL (seepage20 62)

1

InteriorTrim t

Replacement CAUTION: . Put on gloves to protect your hands. o When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage. NOTE:Takecarenot to bendor scratchthe trim and panels. 4D: >: Clip locations a>,2

B>,6

r*'" nt-lt't

\wi, i '\tl l

o>,2

c >,2'l

l /

E> , 2

_tr* @, CENTERPILLAR TRIM UPPER

REARPILLAR TRIM REARSHELF

LOCKCYLINDERTRIM

tl' I

E'

v BELTUPPER ANCHOR (seepage20-85)

Disconnect the high mountbrake lrghtconnector.

T SIDE TRIM Removethe rearseatcushionand rear seatsidebolsterlseepage20-19]'.

k"si fEFT KICK PANEL

)

lnstallationis the reverseof the removalprocedure. NOTE: . lf necessary, replaceany damagedclips. . Beforeinstallingthe front seat belt upperanchor and rear shelf.make sure there are no twists or kinksin the seatbelts. (cont'd)

20-59

lnteriorTrim Replacement(cont'dl 3D: >: Clip locations A>,2 CLIP

nt-.l '"'\R\

I

I

")!

F >, lil

c >,8 ^

B>,3

N;

o>,3 l

E> , 8 l l

#, A@

s,4, ffi;T "xe

F

Y *"0 \

I

"4"

\

s

o>,2

l@@ \---

REARSIDE SHELF

B

FRONTPILLAR TRIM

E

c>,1

H>,2

G>,2

>: Screw, bolt locations 8>,6 A>,3

V

t

SIDETRIM PANEL and Removethe rearseat-back rearseatcushion(seePage20_80) the rearspeaker Disconnect connector(bothsides, for somemodels).

FRONTSEAT BELTUPPEB ANCHOR lseepage20 86)

REARTRIM PANEL SIDETRIM PANEL PROTECTOR

PIVOT BRACKET {seepage20-80)

q

lnstallationis the reverseof the removalprocedure

RIGHTKICK PANEL LEFTKICK PANEL

20-6 0

NOTE: replaceany damagedclips' . lf necessary, . Beforeinstallingthe anchorbolts,makesurethere are no tlvistsor kinksin the seatbelts'

I l 2Di >: Clip locations a>,2

>i Screw location3.4

c>,14

8>,3

D> , 3

E>,2

CLIP

nJ '.'rI\ZI

1\f-

F>,8

G>,4

TRIM

H>,2

N 4'dr FRONTPILLAR SIOETRIM PANEL Removethe rearseat-back and (seepage rearseatcushaon 20-a1l. REARSHELF

\t, FRONTSEAT BELTUPPER ANCHOR

Disconnect the high mountbrakelight SIDETRIM

SEATBELT LOWERANCHOR (seepage20-86)

€'

/>" RIGHTKICK )

v

PANEL

Installationis the reverseof the removalprocedure.

.h, 't6d

\ r \ LEFTKICK PANEL

NOTE: . lf necessary, replaceany damagedclips. . Beforeinstallingthe anchorbolts and rear shelf, makesurethere are no twists or kinksin the seat belts.

20-61

TrunkTrim Replacement CAUTION: . Put on gloves to proteci your hands. . When prying with a flat-tip screwdriver,wrap it with protestive tap€ lo prevent damage. NOTE: . Takecarenot to bend or scratchthe trim and panels. . When removingthe trunk sidetrim or trunktrim panel,fold the seat-back forward. Japan-produced: 4D:

REARTRIM PANEL

RIGHT TRUNK SIDETRIM

>: Cliplocations a>,6 NOTE:Do not push the innerclip in too far.

I

|

/

|NNER

crLP B> , 6

I J

-\--

'

\\-

B

/'/

^

l#srq-'

1 ,-

g cLlP

LTro

--

i ) :Hook locations

TRUNKMAT

A i--), r

' 2D:

a : - ), 2

TRUNK TRIM

(

Installationis the reverseof the removalprocedure. NOTE: . lf necessary. replaceany damagedclips. . To installthe A clips.pull the innerclip up. install the clip,then pushthe innerclip until it's flush.

20-62

HatchTrim Replacement CAUTION: . Put on gloves to protect your hands. . When prying with a flat-tip screwdrivel, wrap it with protestive tape to prevent damage. NOTE:Takecarenot to bendor scratchthe trim and panel.

>:Clip locations

a>,2 NOTE:Donotpushth l n n e rc l i p i n t o o f a r .

& ct-tp.

54d-

g + - \ 2.

INNF

"

Ijy.\\

\-s .V ft - k-"i-t-;-a-

a LEFTHATCH SIDETRIM

HATCH TRIM UPPER

Installationis the reverseof the removalprocedure. NOTE: . lf necessary, replaceany damagedclips. f luuns thi l . T o i n s t a l l t h e A c l i p s , p u l l t h e i n n e r c l i p u p . i n s t a l l t h e c l i p , t h e n p u s h t h e i n n e ri ct 'lsi p

I 20-63

Headliner Replacement CAUTION: When prying with a flat-tip screwdriver, wrap it with proioctiva tap€ to prevsnt damage.

2.

Removethe sunvisorand holderfrom eachside. >: Screwlocations,4

-A-,-

NOTE: . Takecarenot to bend and scratchthe headliner. . B e c a r e f u ln o t t o d a m a g et h e d a s h b o a r da n d o t h e r i n t e r i otrr i m .

1

'1. Remove: 4D: . Frontpillartrim (bothsides.seepage20-59) . Centerpillarlowertrim panel(bothsides,seepage 20 59) Upper anchorbolt from the front seat belt (both sides,seepage20-85) Centerpillaroutertrim and centerpillaruppertrim (bothsides,see page20-59) a Ceilinglight (seesection23) a Rearviewmirror (seepage20-25)

3.

Remove the grab handles and coat hanger.

ACCESS Lto

3D: . Frontpillartrim (bothsides,see page20-60) . Right rear seat-backand rear seat cushion (see page20-80) . Rearcentershelf(seepage20-60) . R e a rs i d e s h e l fa n d s i d e t r i m p a n e l( r i g h ts i d e , see page20-60) . Upper anchorbolts from the front and rear seat belts(rightside.see pages20-86,89) . Ouartertrim panel(rightside,seepage20-60) . C e i l i n gl i g h t( s e es e c t i o n2 3 ) . Rearviewmirror (seepage20-25) 2Dl . Frontpillartrim (bothsides,see page20-51) . Right rear seat-backand rear seat cushion (see p a g e2 0 - 8 1 ) Sidetrim panel(rightside,seepage20-61) a Upper anchorbolt from the front seat belt (right side,seepage20-86) a Ouartertrim panel(rightside,see page20-6'l) a Ceilinglight (seesection23) Rearviewmirror (seepage20-25)

20-64

^

scREws

COATHANGER BRACKET

COATHANGER t2D/3Dl

ACCESS LID

SCBEW

4.

Remove the rear roof trim and clips, and remove the roof trim and socket plug (moonroof model).

2D:

>: Clip locations 'l A> 2DllD,7 B > With moonroof, Without moonroof,3 3D.5

[ i l ' , f E l

':: t%

.l €E

=,/

_._-

,/

.l

2D l3D l4Dl REARROOF OUARTER IRIM PANEL

TRIM

3D: REARROOF TRIM

5.

4D: Lowerthe rearpillartrim on both sides 3D: Removethe upper anchor bolts from the front and rearseatbelts(seepages20-86,89),then lower the quartertrim panelon left side. 2 D : R e m o v et h e u p p e r a n c h o rb o l t f r o m t h e f r o n t seat belt (see page 20-86),then lower the quaner trim panelon left side.

6.

Lowerthe headliner.

7.

Carefullyremovethe headlinerthroughthe passenger'sdoor opening(2Dl4D)or hatchopening(3D).

8.

Installationis the reverseof the removalprocedure. NOTE: . When insertingthe headlinerthrough the opening, be carefulnot to fold or bendit. Also,be careful not to scratchthe bodY. . C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e securelyattachedto the trim. . W h e n i n s t a l l i n gt h e r o o f t r i m , i n s t a l lt h e j o i n t towardthe right side (moonrootmodel)

t 20-65

Carpet Replacement SRScomponentsare locatedin this area.Reviewthe SRS componentlocations,precautions, and proceduresin the SRSsection{24}beforeperformingrepairsor service. 1.

2.

4.

Removethe tootrestand parkingbrakelevermounting bolts,and detachthe clips,then removethe car pet. >:Clip localions,3

Remove: . Frontseat(seepage2O-7 4l . Rearseatcushion(seepages20 79,80, 81) o Kickpanel(seepages20-59,60,61) o Centerpillarlowertrim paneli4D,seepage20-59) . Frontseatbelt iower anchor(2Dl3D,seepage2086) . Sidetrim (seepages20-59,60,61) o Frontand rearconsoles . C o n s o l ep a n e l

:ft \

/

l

>: Bolt locations A>.2 A>,2 l6x10mm 3

e2 H ::a

) /

9.8N.mr1.okgr'm, Y E / 7.2tbtrtl

2Dl3Dl4D: FOOTREST

Removethe SRSunit covers.

3 . Cut areas@ and @ in the carpet,then pull it backas snown. >: Clip locations,2

-lM- Il

lMt

ry-l

LEFTSRS UNITCOVER

2D I3D: SIOETBIM

5.

Installationis the reverseof the removalprocedure. NOTE: . Takecarenot to damage.wrinkleor twist the carpet. . Makesurethe wire harnesses are routedcorrectly. . lf necessary, replaceany damagedclips. . Slip the carpet under the seat side trim (4D) or sidetrim panel(2Dl3D)on eachside properly. . Reattachthe cut areas@ and @ in the carpet with wire ties.

20-66

Panel Consoles/Console Replacement NoTE:Takecarenottoscratchthefrontandrealconso|es,frontseatandre|atedparts. in numberedsequence Disassemble >: Screw locations B>,4 a>,8

>: Clip locations B>.2 A>,2

'

nnffir

"=) :)

:__)

€] FRONTCONSOLE

Remove the shift lever knob (M/T)

REABCONSoLE ::r_l (witharmrest)

lnstallationis the reverseof the removalprocedure NOTE: replaceany damagedclips. . lf necessary, are not pinched. . Makesurethe wire harnesses . Makesurethe connectoris connectedproperly.

{

.

I

I

20-67

Dashboard ComponentRemovaUlnstallation CAUTION: When prying with a flat-tip screwdriver, wrap it with protoctivo tape, and apply protective tape around tho r6lat6d parts, to prevent damag6. NOTE:Takecare not to scratchthe dashboardand related pans. Instrument Danelremoval: 1.

Lowerthe steeringcolumn. Removethe screws,and detachthe clips,then carefully removethe instrumentpanel.

>: Screwlocations,2

>: Clip locations,2

.il

^ l

@sl

Pt)_ i_ ,/

:)

|

Driver'sdashboardlower cover and knee bolster removal: SRScomponentsare locatedin this area.Reviewthe SRS componentlocations,precautions. and proceduresin the SRSsection(24)beforeperformingrepairsor service. '1.

R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n r e m o v e t h e d r i v e r ' s d a s h b o a r dl o w e r c o v e r . l f equippedwith power mirrorsand moonroof,disconnectthe connectors.

>: Screw,boh loc.tions A>.3 B>,2

_ -rri *\Y _-_- J

I

/a_6x1.0mm @{[) s 8 N'mtt o rst'm, \J- 7 2_rbtftl _ -_

>: Clip locations A>.2 B>, 1

tu

PANEL

3.

Installationis the reverseof the removalprocedure.

DRIVER'S DASHBOARD LOWER COVER

Removethe bolts,then removethe kneebolster. Installationis the reverseof the removalprocedure.

2 0-6 8

Glove box removal:

Center dashboard lower covel:

Removethe bolts,then removethe glove box.

1.

Remove: . Driver'sdashboardlower cover . Glovebox

2.

Removethe screwsand bolt, then removethe center dashboardlower cover.Disconnectthe accessory socketconnector'

>: Bolt locations,2

>i Boh,screwlocations a>,1

B>'5

A s*o.e-- I

A

@;*;ry'-1'-.J _e) Installationis the reverseof the removalproceoure

Side air vent/Side defogger trim removal: SHOP TOWET_

TRIM SIOEDEFOGGER C a r e f u l l yP r Y r t a t t h e s i d e e d g e , then remove it,

HOOKS

SIDEAIR VENT Removethe driver'sdashboardlower cover,or oPenthe gloveDox, then push the cliPsfrom each opening by hand, and Pull it o u t . D i s c o n n e c tt h e c o n n e d o r s

LOWERCOVER

HOOKS

3.

Installationis the reverseof the removalproceoure'

(driver'sside).

DASHLIGHTS BRIGHTNESS CONTROLLER CONNECTOR {forsomemodels)

CFUISECONTROL MASTERSWITCH CONNECTOR (forsomemodels)

(cont'd)

20-69

Dashboard GomponentRemoval/lnstallation (cont'd) Center panel removal: 1.

2.

Remove: . Centerdashboardlowercover(seepage20-69) . Radio{seesection23) Removethe rear window defoggerswitch and hazard warningswitch,then disconnectthe connectors. 5 >: Screwlocations,

fii*

-

>: Cliplocations B>,3 A>,4

Removal S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e SRScomponentlocations,precautions,and procedures in the SRSsection(24)beforepreformingrepairsor service. NOTE: . An assistantis helpfulwhen removingand installing the dashboard. . T a k ec a r e n o t t o s c r a t c ht h e d a s h b o a r db, o d y a n d relatedparts. 1.

Remove: o Frontand rearconsoles(seepage20-67) . Consolepanel(seepage2O67), . Driver'sdashboardlower coverand kneebolster (seepage20-68) . Glovebox (seepage20-69) . Centerdashboardlowercover(seepage20-69i

2.

Lowerthe steeringcolumn (seesection17).

)

CENTER PANEI.

To avoid accidentaldeplovmentand @ possible injury, always disconnect the driver's airbag connector belore lowering the steering column lsee section 241.

rt-xR.

W

I

HAZARD WARNING

swlTcH

r44

NOTE:To preventdamageto the steeringcolumn, wrap it with a shoptowel.

"

F.IZ v l

I I

Disconnect the dashboardwire harnessconnectors, remove the nuts, then move the under-dashfuse/ relay box. Disconnectthe antennalead and moonroof relayconnectors. SRSMAIN MOONROOF DASHBOARDcltPs

3.

Mtx CONTNOL CABLE

REAR

wtNoow OEFOGGER

swtrcH

3.

Disconnect the air mix controlcable,and removethe screws,then pull out the centerpanel.

4.

Disconnectthe connectorsfrom the heatercontrol un i t .

5.

Installationis the reverseof the removalprocedure.

RELAY CONNECTORS

FRAME

HARNESS

(for some models)

NOTE: . Makesurethe connectorsare connectedproperly. . Adjustthe air mix controlcable(seesection21). ANTENNA LEAO

DATA CONNECTOR WIREHARNESS CONNECTORS Detach.

20-70

9.8 N.m (1.0 kgf m, 7.2lbt.ltl

Removethe followingpartsIrom the dashboard' . Driver'sdashboardside cover dashboardlower cover o Passenger's . Dashboardcenterlid the connectorsand air mix controlcable' Disconnect

passeneer's airbas rhefront disconnect M,::;:"lx3T:iJnif:3lilH:fl"*:1::f"*'il;ili"'" >: Bolt, screw locaiions A>,7

8xl.25mm I ,i(\ 22 N.m12.2kgt'm,I (!,@ -v,

'"tt:___J

>: Clip locations B>,1 A>, 1

,{nil Lll

ft#5 L //Hl lj%u|5 i//Wt

D > ,1

c > ,1

B > ,1 8x125mm 22 N.mt2.2kstm, 16tbf.ftl

@

6x1.0mm 9.8 N.m 11.0kgl.m,

7 2'orftl

- ---//

@

_._J

c>,6

,

,"o

W qT

W72-t11 7'::--J

I DASHBOARD AIR MIX CONTROL

Loosen the bolt.

CONNECTORS

FRONTPASSENGER'S AIRBAGCONNECTOR

Remove the bolts, then lift and remove the dashboard' pillar trim' CAUTION: Use proteqtive plates on the bottom ot the front

(cont'd)

20-71

Dashboard Removal (cont'd) 7.

lf necessary, removethe dashboardframefrom the dashboard.

>: Screw localions a>,21 B>,4 l

^

1

.

It Shl:' v Y

/

' /

\

Olb' l

\-]1

a: Nut locations,3

ra

6 x '1.0mm

Yi.!i[11"-"'". >: Clip locations

FRONTPASSENGER'S

OASHBOARD

DASHBOARD SIDECOVER

BRACKET

Installationis the reverseof the removalorocedure. NOTE: . Beforetighteningthe bolts,makesurethe dashboardwire harnessesare not pinched. a Makesurethe connectors,antennaleadand air mix controlcableare connectedproperly.

20-72

Seatsand Seat Belts Component Location Index 2Dl3Dl1Dl ANCHOR SHOULDER (4D) ADJUSTER (seePage20-85i

REABSEATBELT(2DI4DI page20-88 Replacement, page20-91 lnspection,

REARSEATEELTBUCKLE/ BELTTONGUE(2DI4DI CENTER (seep6ge 20'90)

FRONTSEATBELT Replacement, Pages20 85,86 Inspection, Page20-91

FRONTSEA Removal,Page20'74 Replacement, Page20 75 HarnessWiringand Recline CableLocations, Page20-77 Page2O'77 SeatCoverRePlacemenl,

REARSEATt2Dl4Dl Removal,pages20-79,8'l page20-82 LatchReplacement, Seat-back SeatCover RePlacement,Page20-83

SEAT FRONT BELTBUCKLES {seepage20-87)

3D: REARSEATBELTBUCKLE/ BELTTONGUE CENTER (seePage20'90)

BEARSEATBELT Replacement, Page20'89 page20-91 Inspection, REARSEAT Removal,page20 80 page20-8? SeatbackLatchReplacement, Page20_83 SeatCoverRePlacement,

20-73

FrontSeat Removal CAUTION: When prying with a flat-tip screwdriver,wrap it with protectivetape lo prevent damage.

2.

Lift the driver'sfront seat,then disconnectthe seat beltswitchconnector.

NOTE:Takecarenot to scratchthe seatcoversand body. 1.

Removethe seat track end cover,then removethe bolts.

SEAT BELT swtTcH CONNECTOR SEATTRACK COVER

) Removethe headrest.

FRONTSEAT

4.

C a r e f u l l yr e m o v et h e f r o n t s e a tt h r o u g ht h e d o o r opening.

5.

Installationis the reverseol the removalprocedure. NOTE:Make sure the connectoris connectedproperry.

SEATTRACK ENDCOVER

BOLT 8 x'1.25mft 22 N..n 12.2kgl.m, 16 rbf.ft) 8 x 1.25mm 22 N.rn 12,2kgl.m, 16 tbtft)

20-74

Replacement to prevent damage' CAUTION: When prying with a flat-tip screwdrivet,wrap it with protective tape NOTE: . Takecarenot to scratchthe seatcoversand body . Removethe front seatthroughthe door openlng' Driver's: NOTE:Referto page2O-77for the seatbelt switchharnesswiring location'

PIVOTNUT 8 x 1.25mm 22 N.m l.2.2 16 tbf.ft)

SEATCUSHION

v l

CENTERCOVER 1 0x 1 . 2 5m m 47 N.m {4.8kgf m, 35 tbt.ft)

10 x 1.25mm 47 N.m {i1.8kgl m, 35 tbr.ft)

INNERSEAT

TBACK

RECLINEADJUSTER

LOWERCAP

d

10 x 1.25mm 47 N.m {4.8 kgf'm, 35 tbtftl

l RECLINE

WIRE CONNECTING To connect,twist 180' OUTERSEAT TRACK

Installationis the reverseof the removalprocedure'

8 x 1.25mm 20 N.m 12.0kgf.m, 14 tbt.ft)

NOTE: . M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e r a r e installedProPerly. . T o p r e v e n tw r i n k l e sw h e n i n s t a l l i n gt h e s e a t back cover, make sure the materialis stretched evenlyoverthe Pad. . Greasethe slidingPortion

RECLINE KNOB

(cont'd)

20-75

FrontSeat Replacement(cont'd) Passenger's(with reclino cablel: NOTE;Referto page20-77for the reclinecablelocation. HEADREST SEAT-BACK

PIVOTNUT 8 x 1.25mm 22 N.m 12,2kgl.m, tbt.ftt SEATCUSHION

CENTERCOVER

PIVOT WASHER

10 x 1.25mm 47 N.m {4.8kgf.m, 3s tbt.ft)

LOWER CAP 10 x 1,25mm 47 N.m (4.8 kgf.m, 35 tbf.ftl

INNERSEAT TRACK

RECLINEADJUSTEB

i RECLINE COVER

LowER CAP

b

RECLINE CABLE x 1.25mm 47 N'm (4.7 kgf.m, 35 tbtftl SEAT

ruf,

To connect,twist 180'.

lnstallationis the reverseof the removalprocedure. 8 x 1.25mm 20 N.m {2.0kgf.m, 14 rbf.ft)

20-76

NOTE: . M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e r a r e installedproperly. . To preventwrinkleswhen installingthe seat-back cover, make sure the material is stretchedevenly overthe pad. . Adjustthe reclinecable. . G.easethe slidingponion.

HarnessWiring and Recline Cable Locations

Seat Cover RePlacement

NOTE:When installingthe seat cushion,make sure the seatbelt switchharness,connectorand reclinecableare fastenedcorrectlyon the seatcushionframe'

NOTE:Take care not to tear the seamsor damagethe seatcovers.

>: Cliplocations

Driver's:

CAUTION: Put on gloves to protest yout hands'

Seat-backcover removal: 1.

cover' the hook,and fold backthe seat-back Release HEADREST

Releaseall insidesprings,then fold back the seatbackcover. Passenger's(with lecline cablel:

3. Removethe headrest. Removethe headrestguide,then removethe seatbackcover.

TRACK

lnst;llationis the reverseof the removalprocedure' NOTE:To preventwrinkleswhen installinga seatevenly backcover,makesurethe materialis stretched and springs inside the pad securing before over the hook. (cont'd)

20-77

FrontSeat Seat Cover Replacement(cont'd) Seat cushion cover removal:

4.

1.

Removethe seatcushion{seepages20,75,76).

2.

Removethe clipsfrom underthe seatcushion,then loosenthe seatcushioncover. >: Cliplocataons

1 - .v

v

vl

Installationis the reverseof the removalprocedure. NOTE: . To preventwrinkleswhen installinga seatcushion cover, make sure the material is stretched evenlyoverthe pad beforesecuringthe clips. . Replacethe releasedclipswith new ones.

UPHOLSTERY RINGPLIERS

NEW CLIP

SEATFRAME CUSHION COVER

3.

Pull backlhe edge of the seat cushioncover all the way around,then releasethe clips,and remove the seatcushaoncover. >: Cliplocations

SEAT CUSHION COVER

20- 7 A

RearSeat Removal theseatcoversandbody. NOTE:Takecarenotto scratch 4D: >: Bolt locations

D>'

c>,1

l_):Hooklocations,2

] >mr b,,***-,,.1*;iffiP-"*'piii::#r-,'-, @t, 6x1.omm

l1Q-

s.aru.-tr.orer-. I 7.2lbf.ft)

)

E :-

e"r.o--

s.i N.- ir.olgr.,i 7.2'tJrftl

'/

V

.

se-ri-cusxo"[-6*

>: Cliplocations,14

"@rz, _

\

EE E S / _ot

/

v -

RIGHTSEAT SIDEEOLSTER

2u

2u

CENTEB PIVOT BRACKET

SEATCUSHION SEAT-BACK Pivot boll conslruction:

SLITS

lnstallationis the reverseof the removalprocedure

ERACKET PIVOTBOLT 8 x 1 . 2 5m m 22 N m (2.2kgf m, 16lbtftl Apply liquidthreadlock

NOTE: belts and . Beforeattachingthe seat-backand seatcushion,make sure there are no twists or kinksin the rear seat centerbelt. . When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seatcushron' . Makesurethe seat-backlockssecurely. (cont'd) . lf necessary, adiusrthe seat-backlatch(seepage20-82)and seat-back

20-79

RearSeat Removal(cont'dl 3D: ,.:): Hooklocations,2

>: Bolt locations A>,6

6xr.omm I (1.0

':^2

9.8 N.m

ksf.h,i

e

I

>: Clip locations,14

c>,1

B>,1

6x1ommI

@, E E ) qr

6x1.0mm

22 N.m {2.2kgf.m,l

tr ,"rrr,n2

,/

SEATCUSHION STRIKER Removethe sidet.im panel(seepage20-60). 6x1.0mm 9.8 N.m (1.0kgI.m, 7.2 tbf.ft)

STRIKER

STBIKER

V tt

A CENTER PIVOT BRACKET

RIGHT SEAT-BACK

\---.---

PIVOT BRACKET

LEFT SEAT.BACK Pivot bolt constiuction:

-l:/*- -"

HOOK

TOOTHEO LOCK WASHER BUSHING

Installationis the reverseof the removalprocedure.

PIVOT Ptvor BoLT BRACKET I x 1.25mm 22 N.m {2.2kgl.m. 16 lbf.ft) Apply liquidthreadlock.

NOTE: . Beioreanachingthe seat-backand seat cushion,make sure there are no twists or kinksin the rear seat beltsand centerbelt. . When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seatcushion. . Makesurethe seat-backlockssecurely. . lf necessary, adjustthe strikerand seat-back.

20-ao

2Dt

>: Bolt locations a>,6

O : Hooklocations.2

6xr.omm ] 9.8N.ml1.Okgf.m,i

,:r:2

ffi

I

g It

>: Cliplocation3,14

c>,1

B>,1

,r@.' '----EF-| 6xr.omm I 8 r.'r.o-\ffz

E w

7.2rbf.ftl

,r:r",

_)

r

s.eN.mtr.o*gf.m,'

22N.m{2.2kgtm,'

E

)

,

H/

)

SEATCUSHION SEAT.BACKMAT

vv PIVOTBRACKET

PIVOTBRACKET PIVOT BRACKET

RIGHTSEAT.BACK

,^

Pivot bolt constauctaon:

TOOTHED LOCK WASHER BUSXING

PIVOT BRACKET PIVOT BOLT I x 1.25 mm 22 N.m (2.2 kgt m. 16lblft) Apply liquidthreadlock.

lnstallationis the reverseof the removalprocedure'

NOTE; .Beforeattachingtheseat-backandseatcushion,makesuretherearenotwistsorkinksintherearseatbe centerbelt. .wheninsta||ingtheseatcushion,sliptheseatbe|tbucklesthroughthes|itsintheseatcushion. . Makesurethe seat-backlockssecurely adjustthe seat-backlatch(seepage20-82)and seat-back' . lf necessary,

20-41

RearSeat Seat-backLatch Replacement 2Dl4Dl

3D:

R e m o v et h e l o c k c y l i n d e rt r i m , t h e n r e m o v et h e r e a r s h e l f( s e ep a g e s2 0 5 9 ,6 1 ) .

Pullthe trunk mat awayfrom the seat'back(seepage2080).

NOTE:Takecarenot to bendeachlockrod. >: Boll, screw locations

a>,2 >: Boh, screw locations A>,4 6x1.0mm 9.8N.m (1.0kgt.m, 7.2 rbf.ftl

B > ,1 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbl.ft)

B> , 2 /+j

@

V SEAT"BACK

LOCKCYLINOER TRIM

LOCK CYLINDER

.i.-::

LATCHCOVEB

LOCK RODS

LEFTSEATEACKI-ATCH Installationis the reverseof the removalprocedure. NOTE: . Makesureeachlock rod is connectedsecurely. . [ / a k e s u r e e a c h s e a t - b a c kl o c k s s e c u r e l ya n d opensproperly. . lf necessary, adjustthe seat-backlatch.

20-82

Installationis the reverseofthe removalprocedure. NOTE: . Replacethe releasedclipswith new ones. . lvlakesurethe seat-backlockssecurelyand opens properly.

Seat Cover Replacement CAUTION: Put on glovesto protact your hands,

is the reverseof the removalprocedure. Installation

4.

NOTE: . To preventwrinkleswhen installlnga seatcushion cover. make sure the material is stretched evenlyoverthe pad beforesecuringthe clips. . Replacethe releasedclipswith new ones

NOTE|Takecarenotto tearthe seamsor damagethe seat covers. Seat-backcover removal: 2D l4Dl 3D: 1.

Removethe seat-back(seepages20-79,8'1).

2.

L o o s e nt h e s e a t - b a c kc o v e r b y r e l e a s i n ga l l t h e clrps.

1 . Removethe seat-back(seepage20-80). coverby releasingall the clips. Loosenthe seat-back

2.

>: Cliplocations

NOTE:Removethe lock knob, lock collar and latch cover. >: Cliplocations

3.

o

o

o

o

o

o

o

SEAT-BACK COVER

RIGHTSEAT.EACK LEFTSEAT-BACK COVER COVER Pull back the edge of the seat-backcover all the way around. then releasethe clios. >: Clip locations

o

3.

coverall the way Pull backthe edgeof the seat-back around,then releasethe cliPs. >: Cliplocations

SEAT.BACK COVER RIGHTSEAT.BACK

Installationis the reverseof the removalprocedure. NOTE: . To preventwrinkleswhen installinga seat-back cover,makesurethe materialis stretchedevenly overthe pad beforesecuringthe clips. . Replacethe releasedclipswith new ones. (cont'd)

20-a3

RearSeat SeatCoverReplacement(cont'dl 2DI3D:.

Seat side bolstor cover removal {,lDl 1.

Removethe seatside bolster(seepage20-79).

2.

Loosenthe seat side bolstercover by releasingall the clios,then removeit.

t" I FEF4+#€ a \ 'J) R-U ------) ,.oflU m

r_rolJr

>: Clip locations

SEATCUSXION COVER

SEATSIDE BOLSTER COVER

3.

Pull backthe edge of the seat cushioncover all the way around,releasethe clips,and removethe seat cusntoncover. >: Cliplocation3 /tD:

Installationis the reverseof the removalprocedure. NOTE: . To preventwrinkleswhen installinga seat side bolstercover,makesurethe materialis stretched evenlyoverthe pad beforesecuringthe clips. . Reolacethe releasedcliDswith new ones,

2Dl3Dl

S€at cushion covgr r6moval: 1.

Removethe seatcushion(seepages20-79,80, 81).

2.

Loosenthe seat cushioncover by releasingall the clips. COVER

>: Cliplocrtion3 4D:

4.

Installationis the reverseofthe removalprocedure. NOTE: . To preventwrinkleswhen installinga seat cushion cover. make sure the material is stretched evenlyoverthe pad beforesecuringthe clips. a Replacethe releasedclipswith new ones.

-I ./a l--lt___)l ) ( .) Ll!!l^t!!l 1",

RINGPLIERS UPHOLSTERY available) {Commerciallv NEWCLIP

COVER SEATFRAME

20-a4

Front Seat Belt Replacement CAUTION: Check the front seat belts for damage, and replacethem it necessary.Be carolul not to damage them during removal and installation.

Removethe centerpillaruppertrim (seepage20-59) 6.

Removethe shoulderanchoradjuster.

Front seat belt removal (4Dl: 1.

Slidethe front seatforwardfully.

2.

Removethe centerpillar lowertrim panel (seepage 20-59).

3.

Removethe upper anchorcover and lower anchor cap.

SHOULDER ANCHOR

8 x 1.25mm 23 N.m {2.3 kgt'm, 17 tbf.ft)

UPPERANCHORBOLT 7/16-20UNF 32 N.m (3.3kgitm, 24 lbf.ft) Apply liquidthreadlock.

ANCHOR ADJUSTER

7.

FRONTSEAT

BELT RETRACTOR MOUNTINGBOLT 6x1.0mm 9.8Nm(1.0kgf.m. 7.2 tbf.ftl

Installationis the reverseof the removalprocedure NOTE: . Checkthat the retractorlockingmechanismfunctions as describedon page20-91. . Makesureyou assemblethe washersand collars on the uDDerand lower anchorbolts as shown. . Beforeinstallingthe anchorbolts,makesurethere are no twists or kinksin the front seat belt.

Upper anchorboh construciion: UPPER

RETRACTOR COLLAR

UPPERANCHOR BOLT Apply liquidthread

7/1&20UNF 32 N.m (3.3kgl.m. 24 rbl.ftl

1 I

7/16-20UNF 32 N.m {3.3 kgf.m,24lbf.ft}

I

SUSHING

LOWER ANCHOR CAP

Remove all the anchor bolts and the retractor bolt, remove the retractor mounting bolt, then remove the front seat belt and retractor.

(cont'd)

20-85

Front Seat Belt Replacement(cont'dl Front seat belt removal (2Dl3Dl:

Lower anchor bolt construction: SPRING WASHER

1.

Sljdethe front seatforwardfully.

2.

Removel . Rearseat-backand rear seatcushion(seepages 20-80,81) . R e a rc e n t e rs h e l f a n d r e a r s i d e s h e l f ( 3 D . s e e page20'60) . Reartrim panel(3D,seepage20-60) . Sidetrim panel(seepages20'60,61)

3.

Removethe upperanchorcoverand loweranchorcap.

LOWERANCHOR

COLLARS

WASHEBS

LOWER ANCHOB

BUSHING

UPPERANCHORBOLT 7/16-20UNF 32 N.m (3.3kgI.m, 24 tbf.ftl

Retractorbolt construqtion: @<-'-.-.-.- ,PPERaNcHoR

RETRACTOR BOLT

TOOTHED LocK W\HER

I )r llo1r",ffi)

RETRACTOR MOUNTINGBOLT 6x1.0mm 9.8 N.m (1.0kgt m, 7.2 tbtft)

tv-\y -"\s\,/ tnl

I

LOWEB ANCHOR CAP

RETBACTOF

I

I

t

o RETRACTOR BOLT 7/16-20UNF 32 N m 13.3kgf m, 24 tbf.ftl

4.

20- 8 6

LOWERANCHORBOLT 7/16-20UNF 32 N.m (3.3kgl m, 24lbtft)

Removeall the anchorbolts and the retractorbolt, removethe retractormountingbolt,then removethe front seatbeltand retractor.

5.

Installationis the reverseof the removalprocedure.

Seat belt buckle removal:

NOTE: . Checkthat the retractorlockingmechanismfunctions as describedon page20-91. . Makesureyou assemblethe washersand collars on the uoDerand lower anchorboltsas shown. . Beforeinstallingthe anchorbolts,makesurethere are no twistsor kinksin the front seatbelt.

1.

R e m o v et h e f r o n t s e a tt h r o u g ht h e d o o r o p e n i n g {seepage20-74).

2.

Removethe centercover(seepages20-75,76).

3.

Removethe centeranchorbolt,then removethe seat beltbuckle. SEATBELT BUCKLE

SPRING WASHER

INNERSEAT TRACK

BUSHING

Lower anchor bolt construction: SPRING WASHER

4. BUSHING

COLLARS

ANCHORBOLT HARNESS 7/16.20 UNF 32 N m (3.3 kgt m, 24 lbf'ft) CLIP

Driver's:Detachthe seat belt switch connectorand harnessclip from the seatcushion(seepage20 77). Removethe seat cushion mounting bolts from the innerseattrack{seepage20-75),and movethe inner seattrack,then pull the seatbeltswitchharnessout. NOTE:Takecarenot to damagethe hingebracket.

Centsr anchor bolt construction: CENTER ANCHOR BOLT

TOOTHEO LOCKWASHER

WASHERS LowER LOCKWASHER

LOWERANCHOR ANCHOR BOLT

Reiractor bolt construction: TOOTHEO LOCKWASHER

RETRACTOB

SPRING WASHER

WASHER

Installationis the reverseof the removal procedure. NOTE: Make sure you assemblethe washers and bearingon the centeranchorbolt as shown.

20-47

RearSeat Belt Replacement CAUTION:Chack the rear seat belts for damage,and replacethem if necessary,8e carolul not to damage lhem during removal and installation. Rearseat belt removal {2Dl4D}: 1.

2.

Remove: . Rearseatcushion(seepages20-79,81) . Rearseat-back(2D,seepage20-81) . Sidetrim panel(2D,seepage20-61) . Rearshelf(seepages20-59,61) . Reartrim panel{seepage20-62} (seepage20-62) . Trunksidetrim, Japan-produced (seepage20-62) . Trunktrim panel,USA-produced

3.

Installationis the reverseof the removalprocedure. NOTE: . Checkthat the retractorlockingmechanismfunctions as describedon page20-91. . lvlakesure you assemblethe washersand collar on the upperanchorbolt as shown. . Beforeinstallingthe anchorbolt.make surethere are no twistsor kinksin the rearseatbelt.

Upper anchorboh condruqtion:

Remove all the anchor bolts and retractor bolt, then remove the rear seat belt and retractor.

UPPERANCHORBOLT 7/16-20UNF 32 N.m (3.3kgf.m,2,1lbtft)

SPRING WASHER RETNACTOR BOLT 7/1F20 UNF 32 N.m {3.3kgf.m, 24 tbt.ft)

Lower anchor bolt construction: LOWERANCXOR EOLT

LOWERANCHOR

Retractorbolt construction: 7/16-20UNF 32 N.m {3.3 kgf.m,24lbt.ft)

t7\ l/rn\

.----. A

-nrfi|lH

/7--^,

tr\7-\ /

TOOTHED LOCKWASHER

20-88

\ R€TRACTOB

\

\

RETRACTOR BOLT

Rearseal belt removal (3Dl:

4.

1.

Remove: . Rear seat-backand rear seat cushion (see page 20_80) . Rear center shelf and rear side shelf (see page 20_60) . Reartrim paneland sidetrim panel(seepage20 60)

2.

Removethe upperanchorcover

UPPERANCHORBOLT 7/16-20UNF 32 N.m {3.3 kgf.m,2it lblft)

Installationis the reverseof the removalprocedure. NOTE: . Checkthat the retractorlockingmechanismfunc tions as describedon page20-91. . Makesureyou assemblethe washersand collars on the upperanchorbolt as shown. . Betoreinstallingthe anchorbolt, makesurethere are no twistsor kinksin the rearseatbelt.

Upper snchor boh construction:

COLLARS

UPPER ANCHOR RETRACTOR

RETRACTOR BOLT 7/16-20UNF 32 N.m 13.3kgl.m. 24 tbf.ft)

Lower anchorbolt construction: REARSEAT BELT

LOWERANCHOR

LOWEF 7/r6-20UNF 32 N.m {3.3kgl.m. 24 lbf.ftl

3.

Removeall the anchorboltsand retractorbolt.then removethe rearseatbelt and retractor. TOOTHED LOCKWASHER (cont'd)

20-89

RearSeat Belt Replacement(cont'dl Soai belt buckle/Centerbolt tongue removal: 1.

Center anchor bolt construction:

Removethe rear seat cushion(seepages20-79'80, 81). Removethe center anchor bolts, then remove the seatbelt bucklesand centerbelttongue.

2Dl4Dl BELT CENTER BUCKLE TOOTHED LOCKWASHES

Installationis the reverseof the removalprocedure NOTE: Beforeattachingthe seat-backand seat cushion,makesurethereare no twistsor kinksin the cen ter belts.

CENTERBELTTONGUE

3D: CENTERANCHORBOLTS 7/1$20 UNF 32 N.m (3.3kgt.m, 2/r bl.ftl

CENTENEELT

20-90

Seat Belts Inspection 3D:

Retractor InsDection t.

Beforeinstallingthe retractor,checkthat the seatbelt can be pulledout freely.

ao" Makesurethat the seat belt does not lockwhen the retractoris leanedslowlyup to 15'from the mounted position.The seatbeltshouldlockwhen the retractor is leanedover40'.

40'- -+ -40. ..'' 15' 15'

(.

\

CAUTION:Do not attempt to disassemblethe retractor.

.-j,

,)

RETRACTOR

*: Mounted Position

Front: 4D: * 10-

3. 15

15'

i-Tl I ],f

Forward

Replacethe seat belt with a new one if there is any abnormality.

On-lhe-CarSeat Belt Inspeqtion 1.

Checkthat the seat belt is not twisted or caughton anyrnIng.

2.

A f t e r i n s t a l l i n gt h e a n c h o r s c, h e c kf o r f r e e m o v e ment on the anchorbolts. lf necessary,removethe anchorbolts and checkthat the washersand other partsare not damagedor improperlyinstalled

3.

Checkthe seatbeltsfor damageor discoloration. C l e a nw i t h a s h o pt o w e li l n e c e s s a r y

Inside

2D l3D.

CAUTION: Use only soap and water to clean. NOTE:Dirt build-upin the metal loops of the upper anchorscan causethe seat belts to retractslowly. Wipe the insideot the loopswith a cleanclothdamF enedin isopropylalcohol. ForwaJd

lnside

4.

Checkthat the seat belt does not lock when pulled o u t s l o w l y .T h e s e a t b e l t i s d e s i g n e dt o l o c k o n l y during a suddenstop or impact.

5.

Makesurethat the seatbeltwill retractautomatically when released.

6.

For each passenger'sseat belt, make sure that the l o c k i n gm e c h a n i s mi n t h e s e a t b e l t r e t r a c t o rw i l l engagewhen the seatbelt is pulledall the way out.

7.

Replacethe seat belt with a new one il there is any abnormality.

Rear: 2Dl4Di

20-91

Seat Belts Child Seat Anchor Plate Attachment points are provided for a rear seat mounted child restraintsystemwhich usesa top tether.The attachment points are locatedon the rear shelf or rear trim When usinga child panel,just behindthe rearseat-back. seatwith a top tether,installthe child seatanchorplates securely. 2Dl4Di NOTE; Remove the plug covers from the attachment pointsof the rearshelf.

TOOTHEDWASHEB

PLUGCOVERS

NOTE: Do not removethe toothedwasherfrom the childseat anchorplate.Usethe child seatanchorplatewith the toothed washer attachedto it. When installinga child seat on the rear seat,follow of the childseat the instructionsof the manufacturer Additionalanchorolatesare available.

@ r Do not us6 the child seat anchor plate for any othel . REARSHELF

3D: NOTE: The reartrim panel has perforationsat eachattachment point. Cut the rear trim panel along the perforations to makea hole. REARTRIM PANEL

POINTS

20-92

purposs; it is designedexclusivelytor installation of a child 3eat. Make suro the rear seat-back is locked firmly when installing8 child seat.

Exterior ComponentLocationIndex '1996Model Series,P/N.6150330,forthehood,trunk lid and hatchremoval. NOTE:Referto the CivicBodVRepairManual, 2Dl30llDl

ROOFMOLOING Replacement, page 20-102

SIDEWINDOW MOLDINGS

LICENSEPLATE TRIM

Replacement, page 20-102

Replacement, page 20-100

HOOD Adiustment, page 20 96 Hood Edge protector page20 99 Replacement,

TRUNKLID Adjustment,page20-97 TolsionBarRemoval, 20 99

TRUNKLID WEATHERSTRIP Replacement, page20-100 REARBUMPER Replacement, page2O-95 REARAIR OUTLET Replacement, page20-106 FUELPIPE PROTEfiOR Replacement, page20-106 TRIM FENDERWELL page20-106 Replacement,

SILLPANEL R e p l a c e m e n t ,p a g e 2 0 1 0 5 Replacement, page 20-106

3D: HATCH WEATHERSTRIP

HATCH Adjustment, page20-98

20-93

Front Bumper Replacement CAUTION:Puton glov$ to protectyour hands. NOTE: . An assistant is helpfulwhenremoving thefrontbumper. . Takecarenotto scratch thefrontbumDer andbodv.

>: golt, screw locations a>,2

B>,2

>: Clip locations, 7

i A e r r : o'n' o r-'e .A l m L.'* fl'T;Ll' \€5>_JI c>,4 ,D>,4

| -.6a l(Dl[m t'KJ)

8 x 't.25mm o x 1.0mm l,Rt j(Qll@ s.eN.mrr.orsf.m, 22N.n'.t2.2kstnf'. -ll 16 tbf.ft,

|.

7.2 tbf.hJ

FRONTBUMPERBEAM

FRONTBUMPER SIDESNFFENER

:l I ir

ABSORBER

FRONTEUMPER BEAM

lnstallationis the reverseof the removalorocedure. NOTE: . Make sure the front bumper engagesthe front bumperside stiffeneron eachside securely. . lf necessary,adjustthe front bumper side stiffener to obtainthe propergap.

20-94

FRONTBUMPER SIDESTIFFENER

RearBumper Replacement CAUTION: Put on gloveslo protect your hands. NOTE: . An assistant is helpfulwhen removingthe rearbumper. . Takecarenot to scratchthe rearbumperand body. . 2D and 4D shown here;3Dremovalproceduresare the sameas 4D. >: Screw, boll locations

A>,2

B>,4

rtn

,/_-\

>: Clip locations,7

E

. -*E]s-

.A IVilIdfIT*ff \r*,r/

\

\7

REARBUMPERBEAM

REARBUMPER

Installation is the reverse of the removalDrocedure. NOTE: . lf necessary, replace anydamaged clips. . Makesuretherearbumperengages thesideclipon eachsidesecurely.

20-95

Hood Adjustment NOTE:Beforeadjustingthe hood,looseneachbolt slightly. 1. Adjustthe hood hingesright and left,as well as fore and aft, by usingthe elongatedholes. 2.

Turn the hood edgecushions,as necessary. to makethe hood fit flush with the body at front and side edges.

3,

Adjustthe hood latchto obtainthe properheightat the forwardedge.

4.

After adjustment,tighteneachbolt securely.

) 6x1.0mm 9.8 N.m {1.0 kgt.m, 7.2 tbt.tll

NOTE: Move the hood latch right or left until the striker is centeredin the hood latchas shown.

6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbf.ftl

20-9 6

TrunkLid Adjustment NOTE;Beforeadjustingthe trunk lid, looseneachbolt slightly. 1.

Adjustthe trunk lid hingesright and left,as well as fore and aft, by usingthe elongatedholes'

2.

to makethe trunk lid fit flush with the body at the rearand side edges. Turn the trunk lid edgecushions,as necessary,

3.

Adiustthe fit betweenthe trunk lid and the trunk lid openingby movingthe striker'

4.

After adjustment,tighteneachbolt securely TRUNKLIOEDGE CUSHION TRUNK LID TRUNKLIO NOTE:Takecarenot to hit the rearwindow when looseningthe bolts.

NOTE:Move the strikerright or left until it's centeredin the trunk lid latchas shown. 9.8 N.m {1.0kgf.m, 7.2lbl.ltl

STRIKER

20-97

Hatch Adjustment NOTE: . Beforeadjustingthe hatch,looseneachbolt and nut slightly. a The suDportstrutsshouldbe removed. . To adjust,removeboth hatchsidetrim (seepage20-63)and the rearroof trim (seepage20-65). 1.

Adjustthe hatchhingesright and left,as well as fore and aft. by usingthe elongatedholes

2.

to makethe hatchfit flush with the body at eachside. Turn the hatchedgecushions,as necessary,

3.

Adjustthe hatchfit to the hatchopeningby movingthe striker.

4.

After adiustment,tighteneachbolt and nut securely. HATCH EDGECUSHION

6x1.0mm 9 . 8 N . m ( 1 . 0k g f . m ,

HATCH HINGE Rearward

HA

EDGE CUSHION j

...

\ \ l0x1 38Nm(3.9kgfm, 2.8 rbf.ft)

22 N.m (2.2 kgf.m,

\,_1q tbf.ftl HATCH HINGE

STRIKER

coVER HATCH EDGE CUSHION

NOTE:Move the strikerright or left until it's centeredin the hatchlatch.as shown.

6x1.0mm

HATCH LATCH

20-98

9.8 N.m 11.0kst.m, 7.2 tbf.ft)

Front Grille/HoodEdge

Protector

TrunkLid Torsion

Bars

Replacement

Removal

Front grille:

CAUTION:Pui on gloves to protect your hands.

NOTE:Takecarenot to scratchthe front bumper'

NOTE:Takecarenot to damagethe body

Removethe front bumper(seepage20-94)Bemovethe clips and screws,then slide the front grille forward by detachingthe hooks.

Removethe torsion barswith the torsion bar assembly t o o l w h i l eh o l d i n gt h e t r u n kl i d a s s h o w n .

4 >: Screwlocations,

" q L

A \t+lt

/

FRONTBUMPER

CENTERCLIP

E

Hood edge Ploteetor: NOTE: . When removingthe clips,usea cllp remover. replaceany damagedclips. . lf necessary, 18 >:Cliplocations,

lnstallationis the reverseof the removalprocedure' NOTE: . Adjust the torsion bars fore or aft with the torsion bar assemblYtool as shown

HOODEDGE

ll = NormalPosrtlon a = Highertensron

'-l o[_] /A.-

-----,_ ,,, \-

.

Make sure the trunk lid opens properly.

20-99

TrunkLid/Hatch Weatherstrip

LicensePlateTrim

Replacement

Replacement

When installingthe trunk lid/hatchweatherstrip.align it with the alignmentmarkon the trunk lid/hatchopening.

CAUTION: Put on glov€s to plotest your hands. NOTE:Takecarenot to scratchthe trunk lid/hatch.

NOTE: . Makesurethereare no wrinklesin the weatherstrip. . Checkfor water leaks.

1.

Removethe licenseplate.

2,

3D: Removethe hatchtrim panel(seepage20-63).

3.

Removethe nuts and clips,and detachthe clip,then removethe licenseplatetrim.

2DllDi ALIGNMENTMARK

NOTE:Takecarenot to drop the nutsinsidethe trunk lid/hatch. a: Nut locations,2

6fi\5x0.8mm I rvr?//1,8N.m{0.18 kst.m,l j llrftl ,/

>: Cliplocations,

nA

I

aa# ) - , /

WEATHERSTRIP

3D: ALIGNMENTMARK

Installation is the reverseof the removalorocedure. STEEI. CORE

NOTE:lf necessary, replaceany damagedclips.

ALIGNMENT

MARK (2Dl4D) BODY

20-100

HatchSpoiler Removal NOTE:Takecarenot to scratchthe hatchand body 1.

Removethe hatchuppertrim (seepage20-63)

2.

Removethe nuts, and detachthe clip, then lift the hatchspoileruP.

4.

removethe spoilertrim from the spoiler lf necessary. frame. NOTE:The hatchspoilertrim for Canadaproduced carscannotbe disassembled. >: Cliplocations A>,4

a: Nut locations,4

1 2lbt.ftl

_

j/

>: Scr€w

GROMMET HIGHMOUNTBRAKE LIGHTCONNECTOR

------,*;)

5.

Installationis the reverseof the removalprocedure' NOTEi replaceany damagedclips. . lf necessary, a M a k e s u r e t h e c o n n e c t o ra n d w a s h e rt u b e a r e connectedProPerlY.

Disconnectthe high mount brake light connector and rear window washer tube, then remove the hatch spoiler.

20-101

SideWindow Moldings

RoofMolding

Replacement

Replacement

CAUTION:Put on glovos to protect your hands.

CAUTION: When prying with a flat-tip screwdriver, wrap it with protestive taps to prevent damage, and use protoctiv€ tape on the body.

NOTE: . Takecare not to scratchthe body . Removethe screw,and pull th€ sidewindow molding by hand.

NOTE: Take care not to scratchthe bodv.

>: Cliplocations A>,13

K

WINDSHIELO MOLDING

>: Screw locations,

PIN lBody side)

I )

1 l

*@

) A

Installationis the reverseof the removalprocedure.

MOLOING

Installationis the reverseof the removalprocedure. NOTE:lf necessary, replaceany damagedclips.

20-102

NOTE: . Takecarenot to damagethe windshieldmolding. . Makesurethe roof moldingis installedsecurely.

Doorand SideMoldings Replacement prevent damags' CAUTION: When prying with a flat-tip scr6wdrivgr,wrap it with protective tape to NOTE; . To removethe front side molding,removethe innerfender(seepage20-106)' . To removethe door moiding,removethe door panel(seepages20-4,10,16)and plasticcover. . To removetherearsidemolding,removethe sidetrim panel(seepages20-60,611' . Takecarenot to bendthe door moldings. cleanthe door bondingsurfacewith a spongedampenedin alcohol' . Beforereassembling, . After cleaning,keepoil, greaseand water from gettingon the surface' . lf necessary, replaceany damagedclips. 4D:

FRONTDOOR MOLDING

Adhesiveareas.

2Dl3Dl

REARSIDE MOLOING

>: Cliplocations A >: 4D,11 2')13D,7

a: Plasticnut loc€tion. 1

B>,3

c>,2

@)

(cont'dl

20-103

Doorand SideMoldings Replacement(cont'dl Door molding removal:

Door molding installation:

The following materialsand tools are requiredto repair the door moldings.

1.

NOTE:Followthemanufacturer's instructions. Materials:(Reference) . Striperemover 3M 08907 Stripeadhesiveremover 3M 08908 Adhesivetape 3M SuperAutomotiveAttachmentTape Tools; a Protective tape . Knifeor Cutter . Spongeor Shoptowel . Infrareddryer

. . .

Film Putty knife Alcohol

G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g sa s snown. [\\\\\\l

: Adhesive tape tocations 60 mm t2 t i^l

4D:

40 mm 1 1 . 6i n )

Forward

L

REARDOOR

CLIP HOLDER

2Dl3Dl

CAUTION: Put on gloves to protect your hands,

100mm (3.94inl

1,050mm 141.34 inl

1 . Removethe door panel, and pull back the plastic cover, Forward

Apply protectivetape on and aroundthe molding.

!

DOORMOLDING

DOORMOLDING 5 mm {0.2inl

ADHESIVETAPE Thickness:1.2 mm 10.05in)

3.

Releasethe clips from insideof the door. Carefullv cut the adhesivetape with a knife or cutter while pullingthe edgeof the moldingaway trom the door as shown. NOTE:Take care not to scratchor bend the mold-

Installthe c l i p so n t h e m o l d i n g . H e a t t h e b o n d i n g s u r f a c eo f t h e d o o r a n d d o o r moldingwith an infrareddryer. Door: 104- 140"F(40- 60.C) Molding:68 - 86"F(20- 30.C)

Ing.

NOTE:Use carewhen heatingto preventdeformation of the molding.

KNIFE

Align the molding with the clip locations,and set the molding. Lightly push on the molding until its edgeis fully seatedon the adhesivetape. NOTE: Do not spray water on the motding within the first 24 hoursafterinstallation. DOORMOLDING

20-104

Reassemble all removedpans.

SideSill Panel Replacement NOTE: . Takecarenot to scratchthe body . 4D shown here;2Dand 3D removalprocedureis the sameas 4D'

>: Screw locations,4

W_1 NOTE:Loosenthe screw, then removethe lowercliP usinga clip remover.

SIDECLIP Removethe sidecliPsfrom the body by turningthem 45"

\

NOTErWhen removingthe side sill panel,the sideclipswill stayin the body.

SIOESILLPANEL Removethe lowercliPs, then removethe sidesill Panel by sliding it forward.

To installthe side sill panel,removethe sideclipsfrom the body. installthem on the sidesill panelon the car.

panel,then installthe sidesill

NOTE: . Takecarenot to twist the sidesill panel. replaceany damagedsideand lowerclips' . lf necessary,

20-105

Inner Fender,Fenderwellrrim, FuelPipeprotectorand Rear Air Outlet Replacement NOTE:lf necessary, replaceany damagedclips. Innertender: >: Screwlocations,4

r\

tllpo" l : , / >: Cliplocations,7

Fenderwelltrim/Fuel pipe protector/Rea. air outlet: NOTE: . Takecarenot to bendthe fenderwelltrim. . Beforelnstallingthe fenderwelltrim, cleanthe body b o n d i n gs u r f a c e w i t h a s p o n g ed a m p e n e di n a l c o h o l . . Aftercleaning,keepoil, greaseor waterfrom gettingon the surface. . To removethe fuel pipe protector,first removethe rear wheel(seesection18). . To remove the rear air outlet, first remove the rear bumper(seepage20 95). STEEL

20-106

FENDERWELL

>: Clip locations A>,4

c>,2

B>,4

I

t'frv Ah l;1A !--l1!

+

\:

and Latch/Wiperand Washer OpenerCable/Opener ComponentLocationIndex 2Dt3DItD'

o*t" y"Tl,"nll,ib?*'r.*

LOCKCYLINDER TRUNKLIOLATCH { s e ep a g e2 0 1 1 2 )

13 Replacement, Page20_1 Adiustment,Page20'117 WINDSHIELD WASHERNOZZLES A d j u s t m e n t , P a g e 2 0 _ 11 7

HOODLATCH {seepage20-110)

FUELLIDOPENER CABLE (seepage20-108i

LID OPENER CABLE (seepage20 108) LID/FUEL LIDOPENER ( s e ep a g e2 0 1 1 1 ) RELEASEHANDLE (seepage20-110)

3D: REARWINDOWWIPER ARM and MOTOR Replacement, Page20-115 Adjustment,page20 117

REARWINDOW NOZZLE WASHER page20-1 17 Adiustment,

REARWINDOW WASHERTUBE (seepage20-116) WASHERRESERVOIR Replacement, Page20-115

HATCH/ FUELLIDOPENER (seepage20 1'11)

FUELLIDOPENER CABLE (seepage20 110)

HATCHOPENER CABLE (seepage20 110)

( s e ep a g e 2 0 1 1 1 )

LOCKCYLINDER (seepage20 113)

20-107

OpenerCables Replacement NOTE: t When removingthe clips.use a clip remover. . Takecarenot to bendthe openercables. Hood op€ne. cable: NOTE;Removethe front bumper (see page 20-94)and innerfender(seepage20-106).

g ry)

>: Clip loc.tions A>,5

B >, 1

HOODREI.TASE HANDI.I (seepage20-110)

Tlunk lid/Fuel lid opener cabte (2Dl4D): NOTE:Removethe following partsfrom rhe Ieft side of the vehicle,then pull the carpetback,as necessary{see page20-66). . . . . o . . . . . . .

Rearseatcushion(seepages20-79,81) Rearseatside bolster(4D,seepage20,79) Rearseat-back(2D,seepage20-81) Centerpillarlowertrim panel(4D,seepage20-59) Lower anchor bolt from the front seat belt {2D. see page20-86) Sidetrim (seepages20-59,61) Seatsidetrim (4D,see page20-59) Sidetrim panel(2D,seepage20-61) Trunk mat and sparetire lid Reartrim panel(seepage20-62) (seepage20-62) Trunksidetrim, Japan-produced Trunktrim panel,USA-produced (seepage20-62)

>r Clip, cable cushion locations A >,4 B > , 4 D _1

2D,2

_

#lB

D>,3

:

_/

_-___)

E > , 4 D ,1 2D,2

@ i _ cablethroughthe hotein th6body.

Installationis the reverseof the removalprocedure. NOTE: a Make sure the hood openercable is routed and connectedproperly. . Makesurethe hood opensproperly.

20-10a

_,,

-/

c >, 1 l4D)

t@

TRUNK LID LATCH (seepage20'112)

?e-=....-

4D: To trunklid latch.

TRUNKLID/FUEL LID OPENER ( s e ep a g e2 0 1 1 1 )

latch.

a A

\-

'--!

-

-l

TRUNKLID OPENERCABLE

N"La FUEL

FUELLID OPEN€RCAELE

TRUNKLID/FUEL LID OPENER (seepage20-111)

LATCH (seepage 20'112)

(cont'd)

20-109

OpenerCables

Openerand Latch

Replacement(cont'dl

Replacement

Hatch/Fuellid opener cable l3Dl:

NOTE:Takecarenot to bendthe openercables.

NOTE:Removethe following parts,then pull the carpet backas necessary(seepage20-66).

Hood releasehandle:

. . . . . . .

Rearseatcushionand rearseat back(seepage20-80) Lower anchorbolt from the front seat belt (seepage 20 86) Sidetrim {seepage20-60) Sparetire lid Rearcentershelfand rearsideshelf{seepage20-60) Reartrim panel(seepage20-60) Sidetrim panel(seepage20,60)

>: Clip,cablecushionlocations a>.9 B > ,1 c>,1

#,

NOTE:Removethe kickpanel(seepages20-59,60.61). >: Bolt locations, 2

] I

6 x 1 . 0 m mj 9.8Nm {1.0kgf.m, i

HOOOOPENER CABLE (seepage20-108)

D> , 5

W#) Hood latch:

Routethe opener cablethroughthe hole in the body.

FUEL LID LATCH page20-112)

NOTE:Removethe front bumper(seepage20-94). >: Eoltlocations, 3 6 x '1.0mm

I

9.8N.m 11.0kgf.m,

HATCH/FUEL LIO OPENER

Installationis the reverseof the removalprocedure. NOTE: . Make sure each openercable is routed and connectedproperly. . Makesurethe hatchand fuel lid open properly.

20-110

Installationis the reverseof the removalprocedure. NOTE: . Makesurethe openercableis connectedproperly. . M a k e s u r e t h e h o o d o p e n s p r o p e r l ya n d l o c k s securely.

Trunk lid or Hatch/Fuellid opener:

Striker(3Dl:

N O T E :R e m o v et h e s i d et r i m ( s e ep a g e s2 0 5 9 , 6 0 . 6 1 )

NOTE: Removethe reartrim panel(seepage20-60)

>: Boll locations,2

a@-\ 6xl.0mm 9.8Nm 11.0kgf.m, 7.2 tbl.ttl

OPENERLOCK CYLINDER

>: Bolt locations, 2

Ya//t2't4Dl

ti

6xl.0mm

HATCH CAELE OPENER (seepage20-110)

l:'.j

TBUNK LID/HATCH OPENERCABLE (see 2 0 - 1 0 81,1 0 ) To trunklid latch or striker. To fuel lid latch.

\ lnstallation is the reverse of the removal procedure.

FUELLID OPENERCABLE (seepages20-108,'110)

NOTE:

. .

sure each openercableis connectedProPN4ake erlY. M a k e s u r e t h e hatch opens properly and locks securelY.

Installationis the reverseof the removalprocedure NOTE: . lvakesurethe openercableis connectedproperly. . M a k es u r et h e t r u n kl i d o r h a t c ha n df u e l l i d o p e n properly.

(cont'd)

20-111

Openerand Latch Replacement(cont'd) Fuel lid latch:

Trunk lid latch/Lock cylinder:

NOTE:Removethe followingpa(s. 2Dl4Dl . .

>: Bolt locations A>,3

Reartrim panel(seepage20-62J Rear edge of the trunk side trim or trunk trim panel (leftside,see page20-62)

6x1.omm 9.8 N.m (1.0kgf.m,

:::^

3D:

8>, 1

i

_=)

m f f er t . o m (1.0

ZS .ty

9.8N.ln

7.2-tbr.ftt

kgt m,

I

,/

CYLINOER

.

Accesspanelon the sidetrim panel

>: Eolt locations,2 | r'-\ 6x10mm (1.0 9.8 N.m kgf.m, I

FUEL I-IO LATCH

TRUNK LID OPENER

TRUNKLID LATCH CYLINDER ROD

FUELLID After installingcheckfor a flushfit with the body. CONNECTOR Disconnect.

-\

I I

TRUNK LID OPENER CABLE FUELLID OPENER CABLE (seepages20,108,1'10) FUELLID LATCH Removethe fuel lid latch by turningit 90o

Installation is the reverse of the removalprocedure. NOTE; o Makesureeachopenercableis connected prop.

elty Make sure the fuel lid opens properlyand locks securely.

20- 1 1 2

Installationis the reverseof the removalprocedure. NOTE: . Greasethe trunk lid latch. . Makesurethe trunk lid opensproperlyand locks securely. a M a k e s u r e t h e c o n n e c t o ra n d c y l i n d e rr o d a r e connectedproperty.

WindshieldWiperArms and Linkage Replacement Hatch latch/Lock cylinder:

CAUTION: Pul on gloves to protect your hands

NOTE:Removethe hatchtrim panel(seepage20-63).

NOTE:Takecarenot to scratchthe hood and body. 1.

>: Bolt locations A>,3

Removethe windshield wiper arms, then remove the hood sealand cowl cover.

B>,1

6x1.0mm

I

E ksfm,l 6 'cr 9.8N.mi1.0

6;:il;l,lr'.",

1.2lbl.trl

/

>: Clip locations B>,9 A>,9 WINOSHIELD WIPERABMS 10 x 1.25mm 18 N.m ll.8 kgf m,

CYLINDER

Hw u

\j:_

.r\

cowl covER -

r€\ L^\

!

rAs<.L ,/

LOCK cYLTNDER

./

\faa"El

rl

Disconnectthe connector,then remove the windshieldwiper linkageassemblY. Japan/Canada-produced:

lnstallationis the reverseof the removalprocedure. NOTE: . Greasethe hatchlatch. . Make sure the hatch opens properly and locks securely. . Makesurethe cylinderrod is connectedproperly.

(cont'd)

20-113

WindshieldWiperArms and Linkage Replacement(cont'dl USA-produced:

USA-produced: NOTE:Scribea line acrossthe link and windshield wiper motor to show the originaladjustment.

>r Bolt locations,3

>: Bolt locations,2 R Y

6 J (1 . 0m m 8 N.m to.skgtm, I

.E-7Y.nt

3.

)

NUT 1 0x 1 . 2 5m m '18N.m {1.8kgf.m. 13 tbtft)

S e p a r a t et h e w i n d s h i e l dw i p e r l i n k a g ea n d w i n d shieldwiper motor. Japan/Canada-produced: N O T E :S c r i b ea l i n e a c r o s st h e l i n k a n d w i n d s h i e l d wiper linkageto show the originaladjustment.

>: Bolt locations,3 O 6r1.0mm EF 8 N.m {0.8kstm,i g 5.8 tbf.ft) )

WINDSHIELD WIPERMOTOR

NUT 10 x 1.25mm l8 N rn (1.8kgtm, 13 tbtftl

4.

Installationis the reverseof the removalprocedure. NOTE: . Makesurethe connectoris connectedproperly. . lf necessary, replaceany damagedclips. . l n s t a l lt h e w i n d s h i e l dw i p e r a r m s a s d e s c r i b e d o n p a g e2 0 - 1 ' 1 7 . . Checkthe windshieldwiper motor operation. . Greasethe moving parts.

WIPERLINKAG€

20-114

RearWindow Wiper Arm and Motor

WasherReservoir

Replacement

Replacement

' t . Removethe hatchtrim panel(seepage20 63).

L

Removethe front bumper(seepage20-94).

2.

Disconnectthe connectorsand washer tubes from the washermotors.

2.

R e m o v et h e r e a r w i n d o w w i p e r a r m a n d w i p e r motor as shown.

>: Bolt locations,3

/)^

Ql(S) \./

6xt.omm

s.eru.-tt.oret'". 7.2 tbf.ft)

/

Routethe washer tubes 10the washe. reservoir

NUT 6x1.0mm 9.8 N.m 11.0kgf.m, 7.2 tbf.ft)

WIPERMOTOR

wtNDow 3.

WASHERMOTOR (3D,for somemodels)

Installationis the reverseof the removalprocedure NOTE: . Makesurethe connectoris connectedproperly .Install the rearwindowwiper arm as describedon p a g e2 0 - 1 1 7 . . Checkthe rearwindow wiper motor operation. . Greasethe moving parts.

3.

Removethe bolts, then remove the washer reservoir.

4.

Installationis the reverseof the removalprocedure. NOTE: a M a k e s u r e t h e w a s h e r m o t o r c o n n e c t o r sa n d washertubesare connectedproperly. . Checkthe washermotor operation.

20-1 1 5

WasherTube Replacement NOTE: . To removethe windshieldwashertube, removethe left innerfender(seepage20-106), . To removethe rearwindow washertube {3D),remove the followingpartsfrom the leftsideof the vehicle. -

-

Innerfender(seepage20-106) Kickpaneland sidetrim (seepage20-60) Rearseat-backand rearseatcushion(seepage2080) Sparetire lid Rearcentershelf and rearside shelf (seepage2060) Reartrim panel and side trim panel (seepage 20 60) Ouartertrim panel(seepage20-60) Rearrooftrim {seepage20-65) Hatchspoiler(seepage20-101)

>: W.sher nozzle,clip and cushion locations a>,2 c > ,1 B>,3

wttrtosnteLo6}

usxea =-d lNozzrE cv

"J>)

i !$e

q

D>,1

E > ,1

@"[q F>, 11

NtW)€ WINDSHIELD

TUBE A

REARWINDOW WASHERTUBE

washernozzle.

WIRE HARNESS

Rootethe washertube underthe wire harness. Routethe washertubes to the washer reservoir

washernozzle (seepage20-101).

REABWINDOW WASHER TUBE oo\

Installationis the reverseof the removalprocedure. NOTE: . Takecarenot to pinchthe washertubes. . lf necessary, replaceany damagedclips. . After installing,adjustthe aim of the washernozzles(seepage20-117).

20-116

(Ior some models)

Wiper Arms/WasherNozzles Adjustment Windshieldwiper/Washer:

RearWindow wiper/Washer (3Dl:

1. Adjust the wiper arms so that their park positions matchthe illustration.

1.

View trom tront to rear

View trom raar to front

-.4

.//

,'l x i

A

x

Adjust the rear window wiper arm so that its park positionmatchesthe illustration.

\

r-

---..J_.__11,:l

A'

x . .

REARWINOOW WIPERARM

WINDSHIELD WIPER ARMS

2.

B y i n s e r t i n ga t a c k a n d m o v i n g i t a s n e c e s s a r y , adjustthe washer nozzlesso that they aim at positions A, A', B, and B'shown in the illustration.

CERAMIC EDGE

B y i n s e r t i n ga t a c k a n d m o v i n g i t a s n e c e s s a r y , adjustthe washer nozzleso that it aims at position C as shown in the illustration. NOTE:The fluid jet should hit within a 50 mm (2.0 in,) radiusaroundpoint C.

NOTE:The fiuid jets shouldhit within a 50 mm (2 0 in.) radiusaroundeachof pointsA, A', B, and B'. \

Distance from center

M;r.";-lll

lrne

from black ceramrceoge

A and A'

400mm (15.7in.) 255mm (10.0in.)

B and B'

1 1 5m m ( 4 . 5i n . ) 322mm \12.7in.)

20-117

Emblems Installation Apply the emblemswhere shown. NOTE: . Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol. . After cleaning,keepoil, greaseand water from gettingon the surface. U n i t :m m ( i n . )

Aftachment Points (Reterence):

CIVICEMBLEM

CIVICemblem

CIVICemblem

TRUNKLID

TFUNK LID Vorsion emblem

20-114

Version emblem

Versionemblsm

Sub-frame

Sub-frameTorque Sequence: CAUTION: After loos€ningthe sub-frame mounting bolts, be sure to replacethem with new ones.

1 0x 1 . 2 5m m 38Nm{3.9kg{.m: 28 tbf.ft)

BOLTS 1 4x 1 . 5m m 90 N m (9.1ks{ m, 66 rbf.ft) Replace.

20-119

FrameRepairChart U n i t :m m ( i n . ) o: Innerdiameter

DETAILAREA.Y

CVT:

(5.121 177{6.971

20-120

I t:3D

SECTIONAA

012 {0.47)UpperArm

@20{0.8)Locat. Hole LowerArm Center Damoer Lower Bush Center

20-121

Body ('97 model) FrontSeat Belt Removal/lnstallatlon RearSeat RemovaUlnstallation WasherTube Windshield fndex ..........

Outline of

....20-128 ....20-126

20-124

'97 Model Changes

The molding side seal was added. The method of installing the rear seat cushion was changed (2Dl3D). A middle floor gusset was added and the method of detaching the seat belt retractor was changed (2Dl3D) The installation position of the washer tube was changed.

Windshield lndex NOTE:The numbersafterthe part namesshow the quantitiesof the partsused.

wlNDSHIELD

UPPERRUBBER DAM

MOLDING

2 FASTENER, glass side) (Self-adhesive-type,

FASTENER,2 {Clip-type,body sido)

WINDSHIELD

20-124 L-

Molding Side Seal lnstallation Glue the molding side seal to the windshield molding on each side.

20-125

RearSeat RemovaUlnstallation 3D: i_): Hook locations 4i.,,2

Bt-;,1

>: Bolt locations

a>,6

c > ,1

B>,'t I

iI

6x1.Omm -@e ' t.o.| 9.8N.m {1.0*nt.] S=222 N.m12.2kg{.m,I 7.2 tbt.trl j j g 16tbf.ft)

: STRIKER Removethe side trim panel (seepage 20 60).

,

T=ttJX,.)

MIOOLEFLOOR CENTERGUSSET

/

I

I

STNIKER

I

6x1.0mm 9.8 N.m {1.0fgf..,i .2 tb,f.ft)

l ) --::.........

VV ;*...

PIVOT

BRACKET

1

>: Clip locations,14 SEATCUSHION

l@n

HOOK

I

F

( E \ q t

A c

F

E

Pivot boft con3truction:

TOOTXED LOCK WASHER

SEAT.BACK A

Instailationis the reverseof the removalprocedure.

PIVOTBOLT BRACKET 8 x 1.25mm 22 N.m 12,2kgf,m, 16 lbl.ftl Apply liquidthreadlock.

NOTE: . Beforeattachingthe seat-backand seatcushion,make sure there are no twists or kinks in the rear seat belts and centerbelt. . When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seat cushion. . Makesurethe seat-backlockssecurely. . lf necessary, adjustthe strikerand seat-back.

20-126

,-.): Hooklocations

^(:).z

2D:

>: Bolt locations A>,6

c>,1

B>.1

6

l

e

9rJ*'Ll-",-, iV H

B() ' t

16rbr'frl

,

)

/

g v

6x1.omm i 9.8N.m11.0 ksf.m,l 7.2rbf.ft) i

>: Cliolocations,14

SEAT-AACKMAT

V

V

PIVOTBRACKET

V CENTER RIGHTSEAT-BACK

PIVOTBRACKET

LEFT SEAT-BACK

TOOIHED LOCK WASHER BUSHING

SEATCUSHION

PIVOTBOLT BRACKET 8 x 1.25mm 22 N.m {2.2kgf.m, 16 lbIft) Apply liquidthreadlock.

lnstallationis the reverseof the removalprocedure. NOTE: . Beforeattachingthe seat-backand seatcushion,make surethere are no twists or kinksin the rear seat belts and centerbelt. . When installingthe seatcushion,slip the seatbelt bucklesthroughthe slitsin the seatcushion. . Makesurethe seat-backlockssecurely . lf necessary, adjustthe seat-backlatchand seat-back

20-127

FrontSeat Belt RemovaUlnstallation 2D l3Dl

4.

1.

Slidethe front seatforwardfully.

2.

Remove: . Rearseat-backand rear seatcushion(seepages 20-126,127l. . R e a rc e n t e rs h e l f a n d r e a r s i d e s h e l f ( 3 D ,s e e page20-60) . Resrtrim panel(3D,seepage2G60) . Sidetrim panel(seepages20-60,61)

3.

Removethe upper anchorcover and lower anchor cap. UPPERANCHOREOLT 7/16-20UNF 32 N.m {3.3 kgf.m, 24 tbf.ftt

UPPERANCHOR COVER

RETRACTOR MOUNTINGBOLT 6x1.0mm 9.8 N.m (1.0kgf.m. 7.2 tbl.hl

Pull back the carpet as necessary,and removethe bolts,then removethe middlefloor gusset.

>: Boh locations,8 LOWER ANCHOB CAP

10x 1.25mm 38 N.m (3.9kgf'm, 28 rbtftl

I I i

o RETRACTORAOLT 7/16-20UNF 32 N.m 13.3kgf.m, 24 tbttrl

LOWERANCHORBOLT 7/16-20UNF 32 N.m (3.3kgt.m, 24 lbf.ft)

Removeall the anchorbolts and the retractorbolt. removethe retractormounting bolt, then removethe Iront seat belt and retractor. 6.

Installationis the reverseof the removalorocedure. NOTE: . Checkthat the retractorlockingmechanismfunctions as describedon page 20-91 o Makesuri vou assemblethe washersand collars on the upperand lower anchorboltsas shown. . Beforeinstallingthe anchor bolts, make sure there are no twists or kinksin the front seat belt.

20-124

WasherTube Replacement NOTE:To removethe windshieldwashertube, removethe left innerfender(seepage20-106). >: Washarnozzle,clipandcushionlocations c>,1 B>,1 a>,2

D>,'t

n,i#,T
G>,1

F > ,1

E > ,1

lw)*) W ) e 9) ) l_N.j

I

ECM/PCM BRACKET

c-------.WIRE HARNESS

Routethe washertube underthe wire harness

Routethe washertube behindthe EcM/PcMbracket.

WINOSHIELD

TUBE A

REARWINDOW TUBE WASHER

\/

RESERVOIR

Routethe washertubes to the washer reservolr

Routethe washertubes underthe wire harness.

is the reverseof the removalprocedure. Installation NOTE: . Takecarenot to Dinchthe washertubes. . lf necessary,replaceany damagedclips. . After installing,adjustthe aim of the washer nozzles(seepage20-117l' (cont'd)

20-129

WasherTube Replacement(cont'dl NOTE:To removethe rearwindowwashertube (3D),removethe followingpartsfrom the leftsideof the vehicle. -

Innerfender(seepage20-'106) Kickpaneland sidetrim (seepage20-60) and rearseatcushion(seepage20-80) Rearseat-back Sparetire lid Rearcentershelfand rearsideshelf(seepage20-60) Reartrim paneland sidetrim panel(seepage20-60) Ouartertrim panel(seepage20-60) Rearroof trim (seepage20-65) Hatchspoiler(seepage20-1011

>: Washer nozzle, clip and cushion locations

A> . 9

C > ,1

B>,2

I

sl

- . . . _1,

a j \ < j Q i

_ ____/ _>_t _ _/

(seepage20 101).

REARWINDOW TUBE WASHER (forsomemodels)

Installationis the reverseofthe removalprocedure. NOTE: . Takecarenot to pinchthe washertubes. . lf necessary,replaceany damagedclips. . Afterinstalling, adjusttheaim ofthe washernozzles(seepage2O-1111.

20-130

motor.

Body ('98 model) Openerand Latch HoodLatchCoverReplacement""'.' 20-132 20-132 ..'.'....'...' HatchHandleReplacement HatchLatch/LockCYlinder 20-133 "...'.."..'.'... Replacement

Outline of . .

'98 Model Changes

The hood latch cover was added The hatch handle was added (3D)

Openerand Latch Hood Latch Cover Replacement

HatchHandleReplacement

NOTE:Takeca.e not to the hood latchcoverand body.

'1.

Removethe hatchtrim panel{seepage20-63). Removethe hatchhandlebolts, >: Boltlocations,2

HOOOLATCHCOVER HOOD LATCH

I 20-132

6x1,0mm

|

9.8N.mtl.Okgf.m,I 7'2tbt':---J)

Hatch Latch/LockCYlinder Replacement 4.

Note the positionof the ioint on the handlerod (A)' Prv the handlerod ol the joint using diagonalcutt e r s ; t a k e c a r e n o t t o b e n d t h e r o d R e m o v et h e hatchhandle.

1.

Removethe hatchtrim panel(seepage20-63)'

2.

Removethe hatchlatchscrews

>: Screw locations,3 6x1,0mm 9.8 N.m 11.0kgf'm, 7.2 tbt f0

HATCH LATCH

@

BUSHING Replace.

l n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e theseitems:

Disconnectthe lock rod, the handle rod, the lock cylinder rod. and the connector,then remove the hatchlatch.

Makesure the handlerod is connectedproperly Beforeinstallingthe hatchtrim panel,makesure the hatchopensProPerlY.

LOCKCYLINDER ROD

''---t

CONNECTOR

HANDLE ROD (cont'd)

20-133

Openerand Latch Hatch Latch/Lock Cylinder Replacement(cont'd) 4.

P u l l t h el o c kr o d o u t .

lf necessary, removethe lockcylinder. >: Boltlocelion.1

6xr.omm

I

9.8 N.m (1.0kq .m, I

,:!!_J

ry*)*,, \""<,/ .z ,/\

6.

I n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e theseatems: . . .

Apply greaseto the hatchlatch. Makesurethe connectoris connectedproperly. Beforeinstallingthe hatchtrim panel,makesure the hatchopensproperlyand lockssecurely.

20-134

Body ('99 model) Dashboard CenterPanelRemovaland 20-136 lnstallation Bumpers FrontGrilleRemovaland 20-136 lnstallation ."'.....20-137 FrontAir SpoilerReplacement Seats and FrontSeatDisassemblY 20-138 ReassemblY FrontSeatTorsionBar 20-139 '.'...".'....'... Replacement Emblems tnstallation

Outline of

'99 Model Changes

The centerDanelremovaland installationproceduresare different' The front grille removaland installationproceduresare different' The front air spoilerhas beenaddedfor some modelsof 2D' driver'sseatwas addedto some models' A height-adjustable Emblemswere addedfor some modelsot 2D'

20-140

Dashboard

Bumpers

CenterPanelRemovaland Installation

FrontGrilleRemovaland Installation

1.

Removethe dashboardcenterlowercover.

NOTE:Takecarenot to scratchthe front bumper.

2.

Removethe screws,then pull out the centerpanel.

Remove the front bumper. Remove the screws. then slidethe front grilleforwardby detachingthe hooks.

>: Sc.ewlocationi,4

>: Cliplocations A> , 3 B>,4 r

l

@Y,

>: Scrowlocltion3,6

I

dbp i

UPPER VENTI(NOB

FRONTBUMPER

Disconnectthe connectorsfrom the heatercontrol unit and hazardwarningswitch. Installationis the reverseof the removalprocedure. NOTE: Make sure the connectorsare connected propefly.

a&

I Installationis the reverseof the removalprocedure.

20-136

FrontAir SPoilerRePlacement CAUTION: Put on glovesto protect your hands' NOTE: . An assistantis helpfulwhen removingthe front bumper' . Takecarenot to scratchthe front bumperand body' >: Bolt, screw localions A>,9

@l

B>,4

s*i BUMPER

lnstallationis the reverseof the removalprocedure' FRONTAIR SPOILER

NOTE: . Make sure the front bumper engagesthe front bumpersidestiffeneron eachsidesecurely' adjustthefront bumpersidestiffener o lf necessary. to obtainthe Propergap.

20-137

Seats FrontSeat Disassembly and Reassembly CAUTION: When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage. NOTE: . Takecarenot to scratchthe seatcoversand body. . Removethe front seatthroughthe door openlng.

SEAT-BACK HEADREST

Driver's:

SEATCUSHION

PIVOTNUT I x 1.25mm 22 N.m 12.2kgf,m, 16 tbf.ft)

CENTERCOVER

RECLINEADJUSTER

8 x 1.25mm 20 N.m 12.0kgf.m, lil lbtftl

EUSHING LOWERCAP 10x 1.25mm 47 N.m (4.8kgf.m, 3s rbl.ft)

WASHERS INNERSEAT TRACK

RECLINE COVER WASHER

WASHER LOWERCAP

I

8 x 1.25mm 20 N.m (2.0kg,f.m, 14 tbf.fit

8 x 1.25mm 20 N.m {2.0 kgI.rn, l4 tbf.ft)

i\",-," HEIGHTHANDLE

20-13A

FrontSeatTorsionBar Replacement in the reverseorderof disassembly'and Reassemble notetheseitems: . . . .

.

Makesurethe bushingand pivot washerare installed properly. To connectthe connectingwire,twist it 90'. Replacethe backcoverclipswith new ones To preventwrinkleswhen installingthe seat-back cover,makesurethe materialis stretchedevenly overthe pad. Apply multipurposegreaseto the moving portionof the seattrack.

NOTE|Takecarenot to tear the seamsor damagethe seatcovers. 1.

Removethe seatcushlon

2.

Removethe torsionbar from the hookwith a flat tip then pull out the torsionbar from the screwdriver, seatcushionframe Put on glovesto protectyour h an d s . TORSION SAR

SEATCUSHIONFNAME

TORSIONBAR

SEATCUSHION

FLATTIP SCREWDRIVER 3.

lnstall in the reverse order of removal'

20-139

Emblems Installation Align the applicationtape with the taillightand body,as shown,then pressthe emblem into place. Removethe apptication tape. NOTE: o Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol. . After cleaning,keepoil, greaseand waterfrom gettingon the surface. . Whenapplying,makesurethereare no wrinklesin the emblem. Attschment Point:

VERSIONEMBLEM

DOHCVTECaid€ omblom:

20-140

Vsrsion emblem:

Body {'00 model} SeatBelts ChildSeatAnchorPlateRemoval/ 20-142 fnstallation Emblem 20-144 fnstallation

Outline of '00 Model Changes The childseatanchorplateremovaland installationproceduresare different' An emblemwas addedfor some model of 3D.

Seat Belts ChildSeatAnchorPlateRemoval/lnstallation 2DllDl Attachmentpoints are providedfor a rear-seal-mounted child restraintsystem that uses a top tether.The attachment pointsare locatedon the rearshelf,tust behindthe rearseat-back. The child seatanchorplatesare installedin the middle and on both sidesof the rearshelf.Eachchild seatanchorplate is coveredwith the child seatanchorolatecover. NOTE: ' Do not removethe toothedwasherfrom the child seat anchor plate, Use the anchor plate with the toothedwasher attachedto it. . When installinga child seaton the rearseat,follow the instructionsof the manufacturer of the child seat. . When installingthe anchorplates,the one with the shonerspacergoes in the middle. . Makesurethe rearseat-backs are lockedfirmly when installinga childseat. U n i t :m m ( i n . ) ATTACHMENTPOINTS REARSHELF

CHILOSEAT ANCHOR PLATECOVER

CIIILDSEATANCHOR PLATECOVER MIDOLECHILD SEATANCHOR PLA

I x 1.25mm 22 N.m 12.2kgl.m, 16 tbt.ftt

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

17 {0.67) torward

.

15{0.s9) WASHER

CHILDSEAT ANCHOR PLATECOVER

TOOTHEO

ll ff*,".rd,',i"'"o*

I x 1,25mm N.m {2.2 kgf.m.

16tbtftl

12lO.47l

SIDE

SEAT ANCHORPLATE

TOOTHED

20-142

rl) .t

SIDE SEATANCHOR PLATE

8 x 1.25mm 22 N.m 12.2kgl m, 16 tbf ftl

19 (0.75)

3D: a top tether' The attachment Attachmentpoints are providedfor a rear-seatmounted child restraintsystem that uses pointsare locatedon the reartrim panel. panel Eachchild seat anchor The child seat anchorplatesare rnstalledin the middle and on both sidesof the rear trim p l a t e c o v e r ' s e a t a n c h o r c h i l d p l a l ei s c o v e r e dw i t ht h e NOTE: plate with the toothedwasher . Do not removethe toothedwasherfrom the child seat anchorplate. use the anchor attachedto it. child seat' . when installinga child seaton the rearseat,follow the instructionsol the manufacturerof the are lockedfirmly when installinga childseat' . Makesurethe rearseat-backs gn;16rn (in.)

ATTACHMENTPOINTS

CHILOSEAT ANCHORPLATE

;x?',rff{-*.

CHILDSEAT ANCHOBPLATE COVER 8 x 1.25mm 22 N..n (2.2 kgl'm. 16 tbfft)

20-143

Emblem Installation Applythe emblemwhere shown. NOTE: . Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol. . Aftercleaning,keepoil, greaseand water from gettingon the surface. Attachment Point (ReferencG):

U n i t :m m ( i n , )

CIVICEMBLEM

SpecialEMBLEM

3D: Specialemblem {for CanadaSoscielEditionl

20-144

Heaterand Air Conditioning Heater Air Conditioning......."'..

'.'..""" 21'1 "' 22-1

SYSTEM(SRS} RESTRAINT SUPPLEMENTAL models (exceptsome The civic sRs includesa driver'sairbag locatedin the steeringwheel hub ln addition,all glove box' the above airbaglocatedin the dashboard modelsfor canada)havea passenger's (*) to safelyservicethe sRS is includedin this serviceManual ltemsmarkedwith an asterisk Informationnecessary or replacingthese on the contentspage include,or are locatednear, sRs components.servicing,disassembling dealer' Honda authorized by an be done should therefore and precautions and tools, special will require items

@

sev€re rendsring the SRS inoperative, which could lead to personal iniury or deaih in the svent of a -";;il d€aler' Honda pertormed an authorized by be must work service frontal collision. all SRS personal . lmploper service procedures, including incorrest removal and instsllation of the sRs, could lead to iniury causedby unintentional deployment of the airbags' deploy o Do not bump the SRS unit. Otherwise. the system may fait in case of a collision. or the airbags may is ON {ll}' when the ignition switch in lhe . sRs electrical wiring harncssesare id€ntified by yellow colol coding. Related components ale located glove box' the above dashboard panel, in the and steering column, front console, dashboard,dashboald lowet Do not use electricaltest equipment on these circuits.

Heater * HeaterUnit lllustratedIndex '96 - 98 Models ................................ ....'....21-39 Replacement 21'2 '99 - 00 Models ................................ """' 21-4'l """" overhaul 21'3 HeaterControl Panel CircuitDiagram '96 - 98 Models .........21'42 Repfacement .....21-4 '99 - 00 Models ................................ 21-43 Overhaul-'96 - 98 Models ........... 21-5 '96 - 98 Models Temperature Control Troubleshooting'96 - 98 Models """" 21-44 Adjustment 21-6 SymptomChart ............................... '99 - 00 Models .......21-45 AdiustmentHeaterControl PanelInput/ 21-7 OutputSignals..............,.............. Air Mix Control Motor .......21'46 Flowcharts Test- '99 - 00 Models ...........' '99 21-8 BlowerMotor Speed ................... 00 Models ....21'46 Replacement ,...21'10 Bfower Motor Mode Control Motol ,.'.'21-13 Mode ControlMotor ............... .,...'.21'47 Test ................, Recirculationcontrol Motor .......21-16 '.'."...21-47 Replacement -14 ... 21 HeaterControl Panel ................ RecirculationControl Motor '99 - 00 Models Troubleshooting .......21-48 Test ................. 21-19 SymptomChart ............................... ......." 21-48 Repfacement 21-20 Relays Seff-diagnosisFunction............,,,.... Flowcharts .......2'l-49 Test ................. 21-21 Motor ......,.......... Air Mix Control Heater Fan Switch .....21-25 Mode ControlMotor ............... .......21-49 Test- '96 - 98 Models............. RecirculationControl Motor .......21-27 Mode Control Switch .....21'29 Bfower Motor Speed .............. 21-50 Test-'96 - 98 Models..........."....... ....21-31 Bfower Motor Power Transistor 21-35 HeaterControlPanel................,.. ....".21-50 Test - '99 - 00 Models ....'........ HeaterControl PanelInput/ beforeworkingin this area. 21-36 *: ReadSRSDrecautions OutputSignals............................. Blower Unit .........21-37 Repfacement 21-38 ................ Overhaul

lllustratedIndex '96 - 98 Models SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section{24)beforeperformingrepairsor service.

BLOWERUNIT page21-37 Replacement, Overhaul,page21-38

HEATER UNIT page21-39 Beplacement, page21-41 Overhaul,

BLOWER RESISTOB Test,

CONTROLMOTOR Test,page21-48 page21'48 Replacement,

a/c swtTcH {wirhA/c)

MOO€ MOTOR Test, page21 47 page21'47 Replacement,

HEATERFAN

swtTcH AIR MIX CONTROLCABLE Adjustment,page2'1-44 page21'43 Replacement,

Test,page2l'49

MODE

HEATERCONTBOL PANEL

Test,page 21 50

R g p l a c e m e n t ,p a g e 2 ' l - 4 2 Overhaul,page 21-43

swrTcHEs

TEMPERATURE CONTROL LEVER Adiustment,page21 44

Detroster-aqtivatedA/C System Turningthe defrosteron activatesthe A,/Cand sets the air flow mode to FRESH.lt is possibleto turn the A,/Coff or to changethe air flow to RECIRCULATE by pressingthe A/C bunon or the FRESH/RECIRCULATE button.

21-2

'99 - 00 Models and proceduresin the SRS SRScomponentsare locatedin this area,Reviewthe SRScomponentlocations,precautions, section(24)betoreperfomingrepairsor service.

BLOWEBUNIT page21-37 Replacement, Overhaul,page21 38 UNIT HEATER page21'39 Replacement, O v e r h a upl ,a g e2 1 - 4 1

RECIRCULATION CONTROLMOTOR Test,page21-48 page21-48 Beplacement,

POWERTRANSISTOR Test,page21 50

AIR MIX CONTROLMOTOB Test,page21-46 page21 46 Replacement,

BLOWER

HIGH RELAY

Test, page 21-49

MODECONTROL DIAL

HEATERVALVECABLE Adjustment,page21 45

CONTROL TEMPERATURE DIAL Adjustment,page21-45 REARWINDOW DEFOGGER

swtrcH See section 23

MODE MOTOR Test, page 21 47 R e p l a c e m e n t ,p a g e 2 l - 4 7

A/C SWTTCH lwith A/cl HEATERFAN

swtTcH CONTROLSWITCH

21-3

CircuitDiagram '96 - 98 Models LINDEF NoODFUSETFELAY 30x No1l lS0Al

Ni42 (40A) WNTTBLK +WFT

8L|(YEi

LIGHT

Y

I

crca(.-A-o\

S;rt'| | lieti{,**i'-t _ ? ' ?_[:] ! 9 [ 1 ' ? _ ? _L-:} t _ _ ?|_ _h t

21-4

\1

\-r.\

\-r-1

\'\

'99 - 00 Models

UNDEFDASH FUSElRELAY BOX

IGNTIONSWTCH

FUSE/RELAY 8OX UNDER,HOOO

**",@ **,',,*

",.@f

u,n,",,

ELUAVHT

I

Y

BLOWER MOTOR

PUSN SWITCH

BLUi BtK

BLUiBLK 1

ELOWER MOTOR HIGH RELAY

tic

GRY

PNK/BLK FED''WHT RED,YEL BRN

lHce nvosrar F)(WirhIVC)

YEL/FEO

neo aLu

6RNiYEL 8LU/!VHT YEL YEL/BLU

DASH LIGHTS-/1 BBTGNTNESS < -! lCONTROLLER

VENT MOOE HEAT CONTFOL MOTOF M.COM DEF

BRNfiHT

FEo

GFNM/HT GRNiFED

[[f&H,,4*,",, PANEL HEATERCONTROL

BLK

O :8PCONNECTOR ! :20PCONNECTOF E : 12PCONNECToR

Troubleshooting-'96

- 98 Models

SymptomChart NOTE; . Checkthe enginecoolantlevel.and allow the engineto warm up beforetroubleshooting. . Any abnormalitymust be correctedbeforecontinuingthe test. . Becauseof the precisemeasurements needed.use a multimeterwhen testing. procedurescheck: o Beforeperformingany troubleshooting - FusesNo. 41 11.5Al, No. 55 (40A) in the under-hoodfuse/relaybox. and No. 17 (7.5A) in the under-dashfuse/relay box - GroundsNo. G401,G402 - Cleanliness and tightnessof all connectors Symptom Hot air flow is low.

No hot air flow.

Romedy

Blowermotor runs.but one or more speedsare inoperative.

Performthe proceduresin the flowchart (seepage 21-8).

Blowerruns properly.

Checkfor the following: . Cloggedheaterduct . Cloggedheateroutlet . Incorrectdoor position

Blowermotor does not run at all,

Performthe proceduresin the flowchart(seepage21-10).

Blowermotor runs.

Checkfor the following: . Clogged heater duct . Clogged blower outlet . Cloggedheatervalve . Faultvair mix door . Heatervalvecableadjustment(seepage21-44) . Air mix control cable adiustment (see page 2'l-441 . Faultycoolingsystemthermostat(seesection10) . Cloggedevaporator(with air conditioning) . Frozenevaporator{with air conditioning)

Mode controlmotor does not run, or one or more modes are inooerative.

Performthe proceduresin the flowchart (seepage 21-13).

Recirculation controldoor does not chanqebetween FRESHand RECIRCULATE.

Performthe procedu.esin the flowchan(seepage21-16).

Both heaterand A,/Cdo not work.

Performthe proceduresin the flowchart(seepage21-18),

21-6

HeaterControlPanelInput/OutputSignals

HEATERCONTROLPANELlilP CONNECToR

Wiresideof lemaleterminals

Terminal No.

Wire color

1

YEL

Terminal No.

Wire color

INPUT

8

YEVRED

VENT

INPUT

INPUT

9

GRNI/EL

HEATIr'ENT

INPUT

'10

BLK

GROUND

OUTPUT

11*

BLU/RED

A./CTHERMOSTAT

INPUT

12

GRN/WHT

FRESH

INPUT

Signal

HEAT/DEF

BLfiEL WHT/BLU

+B

INPUT

4

YEUBLU

DEF

INPUT

5

RED

6

RED/8LK

LIGHT COMBINATION SWITCH

INPUT

13

GRN/RED

1

BLUMHT

HEAT

INPUT

14

GRN

DASHLIGHTS OUTPUT CONTROLLER BRIGHTNESS

Signal

RECIRCULATE HEATERFAN SWITCH

INPUT

OUTPUT

21-7

-'96 - 98 Models Troubleshooting Blower Motor Speed Blower motor runs. but one or rnore speedsare inoperative,

Chsck for a short or an open in the wire{s}: Turn the ignitionswitch ON {ll), and the heaterfan switchOFF.

Doesthe blowermotor run?

To page21 9

HEATERFAN SWITCH6P CONNECTOR Checkfor a shon in th6 wirels): 1. Turnthe ignitionswitchOFF. 2. Disconnectthe blower motor 2P connector, 3. Removethe center dashboard lower cover (see section20), the heaterlan and disconnect switch6Pconnector, 4. Disconnectthe blower resis tor 4Pconnector, 5. Checkfor continuitybetween t h e N o .2 , 3 , 4 a n d 5 l e r m i n a l s o f t h e h e a t e rf a n s w i t c h 6 P connectoa r nd bodyground individually.

ls there continuity?

Repair short in the wire(s) beiween the blower resistor,the heatertan switch and the blower motor,

21-a

Wire sideof femaleterminals

Reolace the heater fan switch,

Check the blower resislor: 1. Turn the ignitjon switch OFF. 2. Disconnect the blower resis tor 4P connector. 3, N4easure the resistance between the No. 2 and No. 4 terminals of the blower resistor,

BLOWERRESISTOR

ls thereapprox.2 - 3 ohms?

HEATERFAN SWITCH6P CONNECTOR

Checkfor an openin the wire(s): 1. Reconnect the blowerresistor 4Pconnector, 2. Removethe centerdashboard lower cover (seesection20), the heaterfan and disconnect switch6P connector. 3. Turnthe ignitionswitchON (ll). 4 . G r o u n de a c ho f t h e s et e r m i nalsindividuallyin the tollow_ ing order:No.4, 2, 5 and 3.

BLU/WHT BLU/BLK

2 1

BLU

6

JUMPER WIRE

BLU/YEL

Wiresideof femaleterminals

Does the blower motor run at p r o g r e s s i v e l yh i g h e r s p e e d s ?

Reolace the hoater fan switch.

Repairopen or causeol excessive r e s i s t a n c ei n t h e a p p r o p r i a t e wire{sl between the blower resistor and the heater{an switch.

21-9

-'96 - 98 Models Troubleshooting BlowerMotor glower motor does not run at all.

Checkthe No.55(40A)lusein the under hood fuse/relaybox, and t h e N o . 1 7 ( 7 . 5A ) l u s e i n t h e undeFdashluse/relaybox.

Repl.ce th. fuse{rl, .nd rochack.

BLOWERMOTOR2P CONNECTOR Checkthe blower motor: 1. Connectthe No. 2 terminalof the blower motor 2P connoc tor to body ground with a lumperwrre. 2. Turnthe ignitionswitchON (ll).

Doesthe blowermotor run?

f=

l 1 l

r,l **'I

ruumifalulau T o p a g e2 1 - 1 1

Wi.e sideof fernaleterminals

Chockfor an opsn in the wire: 1 . D i s c o n n e ctth e , u m p e rw i r e and the blowermotor 2P connector, 2. Measurethe voltagebetween the No. 1 terminal and body ground.

Fl

l1|_-_-l

t4 ,t

I

ls there batteryvoltage?

Ch6cktha blower motor relay: 1. Turnthe ignitionswitchOFF. 2 . R e m o v et h e b l o w e r m o t o r relayfrom the under-hood fuse/relaybox, and test it (see page21-49).

Replace tha blower moior reley.

fo page21'12

2 1-1 0

gr-urwnr

Frompage2l 10

HEATERFAN SWITCH5P CONNECTOR

Checkfor an open in the wire: 1. Turn the ignitionswitch OFF, and disconnecthe iLrmPer 2. Removethe center dashboard lower cover (see section20), the heaterfan and disconnect switch6P connector. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween the No. 3 terminal and body ground.

WiresideoI femaleterminals Repairop.n in th6 wiro betw€en the blower motor and tho heater fan switch.

Checkfor an open in the wire: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuitybetween the No. 1 terminalof the heater tan switch 6P connectorand bodyground.

Reolacotho heaterfan iwitch

Check tor an op€n in the wire betw.en the heater tan switch and body ground. ll th€ wilo b OK, check tor poor ground at G401and G102.

(cont'd)

21-11

-'96 - 98 Models Troubleshooting BlowerMotor (cont'dl F r o mp a g e2 1 - 1 0 BLOWERMOTORRELAY'P SOCKET

Checkthe under-hoodfuse/relay

1 2 1 1

t_T t-l

DOX:

N/leasure the voltagebetweenthe N o . 3 t e r m i n a lo f t h e b l o w e r motor relay 4P socketand body ground,

t

rv)

i

ls therebafteryvoltage?

Checklor an open in th€ wire: 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltage between the No. 4 terminalof the blower motor relay 4P socketand body ground. Repairopen in tho wire between the No. 17 fuss and tho blowel motor rclay, Checkfor en opon in the wire: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuitybetween the No. 2 terminalof the blower motor relay 4P socketand bodyground.

ls therecontinuity?

R e p a i ro p e n i n t h e B L U / W H T wire b€tween the blower motor relav and the blower motor.

21-12

Check foi an open in the wire betwe€n the blower motor relav and body glound. lf the wiro is OK, check fo. poor ground at G{01 and G4O2.

ModeControlMotor Mode control motor does not run, or one of more modes are inoPela-

'17(7.5A) fuse in Checkthe No. fuse/relaY box. the under-dash

Reolacethe fuse, and recheck.

MODECONTROLMOTOR7P CONNECTOR '1

Checklor an open in the wire: 1. Disconnectthe mode control motor7P connector. 2. Turnthe ignitionswitchON (ll). 3. Measurethe voltagebetween l nd body the No. l terminaa ground.

ls therebatterYvoltage?

I

I

7

5

BLK/YEL

Repairopen in the wire between the No. 17 tuse and the mode control motor.

Check {or an open in the wire: 1. Turn the ignition switch OFF. 2. Check for continuity between the No. 7 terminal of the mode conlrol motor 7P connector and body ground.

ls therecontinuity?

2

Wire sideof femaleterminals

I

3

4

5

6

1

BLK

[] Check for an open in the wire batwe€n the mode contrcl motol and body ground.lf the wir€ is OK, checkfor poor gtound at G/U)land G402.

Testthe modecontrolmotor (see page21-471.

ls the mode control motor OK?

Check the mod€ control linkage and doors: 1. Bemove the mode control motor (seepage 21-47). 2 . C h e c kt h e m o d e c o n t r o l l i n k a g e and doors for smooth move

T o p a g e2 1 - 1 4 Dothe modecontrollinkage anddoorsmovesmoothlY?

Reolace the mode control motor,

(cont'd)

-'96 - 98 Models Troubleshooting Mode ControlMotor lcont'dl F r o mp a g e2 l - 1 3 HEATERCONTROLPANELlilP CONNECTOR

Checktor a short in the wi.e(s): 1. Removethe centerdashboard lower cover (seesection20), and disconnectthe heatercontrol panel14Pconnector. 2. Checkfor continuitybetween the No. 1, 4, 7, 8 and 9 terminalsand body groundindividWiresideof lemaieterminals Raprir.ny short in the wire(s) betw€en the mode control motor and the heatercontrol panel.

Checkfor a shon to power: Checkthe samewires {or voltage.

ls thereany voltage?

T o p a g e2 1 1 5

2 1- 1 4

Repair short to pow6r in the wiro(3) betwoen the mode conlrol motor .nd tha heate. control prnel, This short also damag.s tho heater cont.ol prnel. Repail the short to power b€{ore replacing the heeterconlrol pan6l.

F r o mp a g e2 1 - 1 4 HEATERCONTROLPANEL14PCONNECTOR Checktor an open in the wire{s}: Checkfor continuitybetweenthe followingterminalsof the mode control motor 7P connectorand the heatercontrolPanel14Pconnector14P: 7P: N o . 2- N o . 4 N o . 3- N o .1 N o . 4- N o . 7 N o . 5- N o . 9 No.6- No.8

Wire sideof {emaleterminals

MODECONTROLMOTOR7P CONNECTOR Wire sideof femaleterminals

ls therecontinuitY?

Repair any opsn in the wirels) bctwoan the mode control motor and the hoator conlrol Panol

Check Io. loo3. wires or Poor connoctionsat lhe hoat€r control Danel 14P connactor, and 3t the mod6 conilol motot 7P connector. It tho connoctionsara good. rsDlacothe heat€r coilttol panel.

2 1-1 5

-'96 - 98 Models Troubleshooting RecirculationControlMotor Becirculationcontrol door does not change between FRESHand RECIBCULATE.

c h e c kt h e N o - 1 7 ( 7 . 5A ) f u s e i n the under-dash fuse/relay box.

Reolacethe tuse. and recheck. RECIRCULATION CONTROLMOTOR 4P CONNECTOR Checkfor an open in the wire: 1 . 0 i s c o n n e ctth e r e c i r c u l a t i o n controlmotor4P connector. 2. Tu.nthe ignitionswitchON (ll). 3. Measurethe voltagebetween the No. l terminal and body ground.

ls there batteryvoltage?

BLK/YEI-

Repairopen in the wir6 between the No. 17Iuseand the recirculalion conlrol motor.

Wiresideof temaleterminals

Check lhe recirculation control 1. Turn the ignition switch OFF. 2. Test the recirculation control motor {see page 21 48).

Checkthe recirculationcontrol linkageand door: 1. Removethe recirculation con' trol motor {seepage21 48}. 2. Checkthe recirculation control linkageand door for smooth

I o p a g e2 1 1 7 Do the recirculation controllink age and door move smoothly?

2 1-1 6

Reoairthe r€circulationcontrol linkageor door.

HEATERCONTROLPANEL14PCONNECTOR

F r o mp a g e2 1 - 1 6

;-?

I 7

Check{or a short in the wire(s): 1. Removethe centerdashboard lower cover (see section20), the heatercon_ and disconnect trol panel14Pconnector' 2. Checkfor continuitybetween t h e N o . 1 2 a n d N o . 1 3t e r m i nalsand body groundindivid-

8

9

'olx

5

4 11

1 2 13 14 GRN/BED

GRN/WHT

0) (0

Wire side of female terminals

Repair5hort in the wire{sl between the recirculationcontrolmotor and the heatercontrolPanel

CheckIor a short to Power: Checkthe samewiresfor voltage

I

2

3

7

8

I

1

i--?

5

6

'olx

11 12 13 14 GRN/RED

GRN/WHT

V)(v

ls there any voltage?

Repair short to Power in the wire {s) between the recirculation control motor and the heater control panel. This short also damages the heater control panel. Repair the short to Power betore replacing the heater control panel.

Check lor an open in the wire(s): Checkfor continuity between the following terminals of the recircu lation control motor 4P connector and the heater control Panel 14P 4P. N o . 2No.4

4

1 7

I

rol\l rr

I

5

12 1 3 GRN/RED

14P: N o .1 2 N o .1 3

GRN/WHT

ls there continuitY?

Repair open in the wirelsl between the recirculation control motor and the heater control panel.

r

zl/lt

CONTROLMOTOR RECIRCULATION 4P CONNECTOR Wire sideof femaletetminals

Check for loose wires or Poor connections at the heater control Danel 14P connector, and at the recirculation control motor 4P connector. lf the connections are good, replace the heater control Danel,

21-17

-'96 - 98 Models Troubleshooting HeaterControlPanel Both heater and A/C do not work.

Checkthe No. 17{7.5A) fusein the underdashfuse/relaybox, and the No. 47 (7.5A) fuse in the under hoodfuse/relaybox.

R.phce the fuso{s),.nd rccheck.

HEATER CONTROL PANEL1,lPCONNECTOR Chacktor an open in the wi.e: 1. Removethe centerdashboard lower cover (see section20), a n d d i s c o n n e c tt h e h e a t e r controlpanel14Pconnector. 2. Torn the ignitionswitchON {ll). 3. Measurethe voltage between the No. 2 terminal of the heatercontrolpanel 14Pconnectorand bodyground.

ls there bafteryvoltage?

Wiresideof femaleterminals

Rcpair opGnin th€ wiro betwoon the No. 17 tuse and the hoatcl control panel.

Checkfor an opon in the wiro: 1. Turnthe ignitionswitchOFF. 2. Measurethe voitage between t h e N o . 3 t e r m i n a lo f t h e heatercontrolpanel 14Pconnectorand body ground.

ls there batteryvoltage?

Rgprii open in th6 wira b€twacn the No. il7 tui. and the heat.t cont.ol p.nal.

Checkfoi an open in the wi.e: Checkfor continuitybetweenthe No. 10terminalot the heatercont r o l p a n e l 1 4 Pc o n n e c t o a r nd body ground. Check lor an opon in tho wire b€{w6on the hoator control oanel and body ground. lI the wirc is OK, check tor poor ground at G401.nd G4O2. Check for looae wiaos or oool connectionsat the hoater control panol 14P connector. lf the connactions dre good. 3ubstitute t known-9ood heater control panel, and rech6ck.It tho symptom/indication 9oe3 .wry, replacethe original heatel control oanol.

21- 1 8

Troubleshooting-'99 - 00 Models Symptom Chart function (see next system,refer to self-diagnosis For electricalmalfunctionswhich are indicatedby the self-diagnostic page).

a symptom' Notetheseitemsbeforetroubleshooting . Checkthe enginecoolantlevel,and allow the engineto warm up beforetroubleshooting' . Any abnormalitymust be correctedbeforecontinuingthe test .Becauseoftheprec|semeasurementsneeded,UseadigitaImu|timeterwithanoutputoflmAor|essatthe20k rangewhen testing procedurescheck: . Beforeperformingany troubleshooting fuse/relav (40 A)]n the under-hoodfuse/relaybox' and No 17 (7 5 A) in the under-dash - FusesNo. 41 115 Al,No 55 -

box GroundsNo. G401,G402 and tightnessof all connectors Cleanliness See pags

Symptom Mode controlmotor does not run, or one or more modesare inoperat've' controldoor doesnot changebetweenFreshand Recirculate' Recirculation any other Blowermotor only runson high speedposition;it does not run in Blowermotor does not run at all. Both heaterand Ay'Cdo not work

speedpositions

a1_tq

21-21 21-29 21-31 2 13 5

21-19

Troubleshooting-'99 - 00 Models Self-diagnosis Function The heatercontrolpanelhasa self-diagnosis function. Runningthe Self-diagnosis Funqtion Set the mode controldial to the Vent position,and turn the ignitionswitchON fll).Withinsix seconds afterturnangthe igni_ tion switchon. pressthe recirculation controlswitchthe requirednumberof times dependingon the recirculation indicator lightstatus: .lftheindicatorlightisON,presstherecirculationcontrolswitchfivetrmes. . l f t h e i n d i c a t o r l i g h t i s O F F , p r e s s t h e r e c i r c u l a t i o n c osnwt irtoclhs i xr r m e s . The recirculation indicatorlight will come on for two seconds.then blinkthe DiagnosticTroublecode {DTc}to indicatea faultycomponent.lf no DTc'sarefound,the indicatorlightwill not blinkafterthe initialtwo second liqht. DTCIndicationPattern(S6eDTC2l: Recirculation indicato. light on Recirculation indicator light off

' 0,3sec 2 sec W i t h i n s i x s e c o n d sa t t e r t h e ,/ t 0.3 sec ignition switch is turned ON (lll, 1.5soc pross the recirculationcontrol VENTPOSITION switch the required number ot MODECONTROLDIAL times dependingon the rocirculation indicetor light status

@ At

RECIRCULATION CONTROLSWTCH

V' DTCTroubleshootingIndex Diagnostic trouble code (DTCI

2

Rgcirculation indicator light

Component with problem

Possible cause

See page

O n eb l i n k

Air mix control motor

Obstructeddoor, laulty motor

21-21

Two blinks

Air mix control motor

Openor shortcircuit

21-23

ln caseof multipleproblems,the recirculation indicatorlight will indicateonly one DTc with the leastnumberof blinks. Resettingthe Self-diagnosisFunction Turningthe ignitionswitchOFFwill cancelthe self-diagnosis function,Aftercompletingrepairwork, run the setfdiagnosis functionagainto makesurethat thereare no other malfunctions.

21-20

Air Mix GontrolMotor door and indicatorlight indicatesDiagnosticTroublecode (DTC)1l A problemin the air mix controllinkage, Recirculation motor. heatercontrolpanel' The air mix controlmotor regulatesthe mixtureof cool/hotair accordingto outputsfrom the Self-diagnosiscircuit check indi' cates a Problem in the air mix conlrol motor circuit,

Checkth6 aii mix conirol motor: the air mix control 1. Disconnect motor 5Pconnector. 2. Testthe air mix controlmotor (seepage21-46).

ls the air mix controlmotorOK?

check the air mix control linkage and doors: 1 . R e m o v et h e a i r m i x c o n t r o l motor (seePage21-46) 2. Checkthe air mix controllinkage and doors lor smooth movement.

Do the air mix control linkageand doors move smoolhlY?

R€olacethe air mix control motor'

HEATERCONTROLPANEL2OPCONNECTOR

RED/YEL

RED/WHT

Check tor a short in the wiles: 1. Disconnectthe heater control panel 20Pconnector2. Check for continuitY between body ground and the heater control panel 20P connector t e r m i n a l sN o . 3 a n d 4 i n d i v i d ' uaIY.

Wire sideot femaleterminals

Ropairany short in th€ wire{s} betweon the heatercontrol Panel and the air mix control motor'

(cont'd) fo page21-22

21-21

Troubleshooting-'gg - 00 Models Air Mix ControlMotor (cont'dl F r c mp a g e 2 1 - 2 1

Checkfo..n open in the wires: Checkfor continuity betweenloll o w i n g t e r m i n a l so f t h e h e a t e r controlpanel20P connectorand the air mix controlmotor 5P con20P: No3 _ No.4 -

5P: N o .1 No.5

AIRMIX CONTROL MOTOR 5PCONNECTOR Wiresideot femaleterminals

Repairany open in the wiro(s) bdtwoon tha hoator control panal and air mix control motor. Check for loo3e wires or poor conneclionsat the heater control panol 20P connoctor and at the air mix control motor 5P connocto.. It the connections.rc good, substitute a known-good hoaier control panel, and rech6ck.lf the symptom/indicrtion goes away, replac6 the original heater control panel.

21-22

RecirculationindicatorIightindicatesDiagnosticTroublecode(DTc)2:AprobIemintheairmixcontro|motorcircuit from the heatercontrolpanel' The air mix controlmotor regutatesthe mi)dureof cool/hotair accordingto outputs Self-diagnosiscircuit check indicrl6s a problgm in tho air mix contiol motor circuit.

Checkth6 rir mix control motor: the air mix control 1. Disconnect motor5P connector' 2. Testthe air mix controlmotor (seepage21-46).

ls the air mix controlmotor OK?

Checkthe air mix control linkage and doors: 1 . R e m o v et h e a i r m i x c o n t r o l motor(seepage21'46). 2. Checkthe air mix controllinkage and doors for smooth

Do the air mix controllinkageand doorsmovesmoothlY?

Roglacethe air mix conlrol motor.

HEATERCONTROLPANEL2OPCONNECTOR REO/YEL Checkfor r short in the wiresl the heatercontrol 1. Disconnect panel20Pconnector. 2. Checkfor continuitybetween body ground and the heater control panel 20P connector t e r m i n a fN s o . 3 , 4 . 1 2 , 1 5a ^ d 20 individually

BEO/WHT

PNK/BLK

Wire sideof femaleterminals

ls therecontinuity?

Bep.ir any short in the wire{s) between the h€rter control panel and th6 air mix control motor.

(cont'd) Io page 21-24

21-23

-'99 - 00 Models Troubleshooting Air Mix ControlMotor (cont'dl Frompage21-23

HEATERCONTROLPANEL2OPCONNECTOR

Checktor a short to power: C h e c kt h e s a m et e r m i n a l sf o r voltage.

Wire side of female terminals

ls there any voltage?

Rapair short to pow6r in the wirelsl botween the heater control panel and the ai. mix control molor. This short also damag.s the heater control panel. Ropair the short to power betoro replacing the heater control panel.

Checkfor an open in the wire3: Checkfor continuitybetweenfol l o w i n g t e r m i n a l so f t h e h e a t e r controlpanel20Pconnectorand the air maxcontrolmotor 5P con nector. 20Pt 5P: No3 _ N o .1 No 4 _ N o .5 N o _1 2 N o .2 N o .1 5 No.4 No 20 No.3

Bepair any open in the wire(s) between the heator control panel and air mix control motor, Check tor loose wires or poor connectionsat the heator control oanel 20P connector and at th. air mix control motor 5P connector, ll the connectionsrre good, substitute a known-good heater control oanel. and recheck.lf the symptom/indication goes awry, replacethe original heater control oanel,

21-24

AIR MIX CONTROLMOTOR 5P CONNECTOR Wire sideof lemaleterminals

Mode control motor does not run. or one or more modesarc inope]ative.

C h e c kt h e N o . 1 7 ( 7 . 5A ) f u s e i n fuse/relay box. the under-dash

Replace the Iuse. and recheck.

MODECONTROLMOTOR7P CONNECTOR Checkfor an open in the wire: 1. Disconnectthe mode control motor7P connector, 2. Turnthe ignitionswitchON (ll)the voltagebetween 3. MeasLrre t h e N o . 1 t e r m i n a lo f t h e mode control motor 7P con nectorand body ground

t

2

3

1

5

BLK/YEL

Wiresideof femaleterminals ls therebatteryvoltage?

Repairopen in the wire between the No. 17 luse and lhe mode control motor.

Check the mode control motor: 1- Turn the ignition switch OFF 2, Test the mode control motor (see page 21 47).

ls the modecontrolmotor OK?

Checklhe mode control linkage and doors: 1 . R e m o v et h e m o d e c o n t r o l motor (seepage21 47). 2. Checkthe modecontrollinkage and doors for smooth move

Do the mode control linkage and doors move smoothlY?

ReDlace the mode control motor'

Check for a short to Power in the wires: 1. Iurn the,gnitjon switch ON (ll). 2, Disconnectthe heater control panel20P connector. 3. Check for voltage between the No. 2, 5, 6, 7, I and 9 ter' minals of the heatercontrol panel 20P connector and body ground individuallY.

ls lhere any voltage?

NO Io page 21 26

HEATERCONIROLPANEL2OPCONNECTOR

Wire side of female terminals Repair shorl to power in the wire{sl between the heater control oanel and the mode control motor. This short also damages the heater control Pan6l. RePair the short to power before replac' ing the heater control Panel

(cont'd)

21-25

Troubleshooting-'gg - 00 Models ModeGontrolMotor (cont'dl Frompage21-25

HEATERCONTROLPANEL2OPCONNECTOR

Chocktor a short to ground: 1. Turnthe ignitionswitchOFF. 2. Checkthe sameterminalsfor continuityto bodyground. Wire sideof femaleterminals

ls therecontinuity?

Repairany 3hort in the wirelsl between the heater control panel and ihe mode control motor.

Checklor.n open in tho wires: 1, Disconnectthe mode control motor7P connector. 2. Checkfor continuitybetween the followingterminalsof the heatercontrolpanel20Pcon nectorand the mode control motor 7Pconnector. 2OP: lPi N o . 2- N o . 7 No.5- No.2 No.6- No.6 N o . 7- N o . 5 No.8- No.4 No.I- No.3

MODECONTROLMOTOR?P CONNECTOR Wiresadeof lemaleterminals ls therecontinuity?

Check for loose wiaes or ooor connectionsat the heater control panel 20P connector rnd at the mode control motor 7P connectoa, lf the connoctionsere good, substitute a known-good heater control panol, and recheck.lf the syfiptom/indication goes away, replac€the original hoatercontrol panel.

21-26

Repair any opon in the wire(s) t€tween the h€ater control panel and tha modc contol motor.

Recirculation control door does not chango betwe€n Fresh and Recirculate.

Checkthe No. l7 (7.5A) fuseanthe underdashfuse/relaybox.

Replace the fuse, and recheck.

CONTROLMOTOR CONTRC RECIRCULATION ,lP CONNECTOR

q-?

Checklor an oPenin the wite: 1 . D i s c o n n e ct th e r e c i r c u l a t i o n controlmotor 4Pconnector. 2. Turnthe ignitionswitchON (ll) 3. Measurethe voltagebetween the No. 1 terminalof the recir culation control motor 4P connectorand body ground.

--T--T--T-|

1l2l/l1l f( v )BLK/YEt

! sideof temaleterminals

ls there batteryvoltage?

Repairopen in the wire between the No. 17 luse and lhe recirculation control motor.

Check the rccirculationcontrol motorr '] Turn the ignitionswitchOFF. 2. Test the recirculationcontrol motor (seePage21 48i Check the recirculationcontrol linkageand door: con_ 1. Removethe recirculation trol motorlseePage2l 48). control 2. Checkthe recirculation linkageand door for smooth movement. page controllink_ Do the recirculation age and door movesmoothlY?

Reoairthe recirculationconlrol linkag€ or door.

(cont'd)

Troubleshooting-'99 - 00 Models Recirculation ControlMotor (cont'd) Frcm page21-27 HEATERCONTROLPANEL8P CONNECTOR Checkfor a short to power in the 1. Turnthe ignitionswitchON {ll). 2. Disconnect the heatercontrol panel8P connector. 3. Checkfor voltagebetweenthe No.2 andNo.3 terminals ofthe heatercontrol panel 8P con, nectorand body ground indi vidually.

ls thereany voltage?

R e p a i r3 h o r t t o p o w e . i n t h e wire{a) b.tween tho haetor control paneland the recirculation Gontrol moto.. This short also damagosthe heate. control panel. Repairthe short to power b€tore .eplecing the h€ater control panel.

Checkto. a short to ground: 1. Turnthe ignitionswitchOFF. 2- Checkthe sameterminalsfor continuityto ground.

Roprir lhon in tho wir.{s) b€tweo the horter control panel and the racircr alion conhol motoa.

Checkfor an open in the wires: 1 . D i s c o n n e ct th e r e c i r c u l a t i o n control motor 4P connector. 2. Checkfor continuitybetween the followingterminalsof the recirculation controlmotor 4P connectorand the heatercon, trol panel8P connector. 8P: 4Pi N o . 2- N o . 2 N o . 3- N o . 4

GRN/WHT GRN/RED

Repairopen in ths wirolsl betw€€n the heate. co.rkol panol and the recirculationcontrol motor .

Check lor loo3a wires or poot conn€ctionsat the hoatercontrol panel 8P connector and at the aecirculationcontrol motor ilP connector,It tho connectionsare good. substitut€ e known-good heateicontrol panel,and aecheck. lf th€ symptom/indication goes away, replacethe original hedter contrclDanel.

21-28

I

1

RECIRCULATION CONTROLMOTOR 4P CONNECTOR Wiresideof femaleterminals

BIowerMotor Speed Blower motor only runs on high speed position; it does not run in any other speedPositions

N O T E :l f t h e b l o w e rm o t o r d o e s n o t run at all, referto page21-31. 3P CONNECTOR POWEBTRANSISTOR

Checkfor an open in lhe wire: the powertransis 1. Disconnect tor 3P connector, 2. Checkfor continuitybetween t h e N o . 3 t e r m i n a lo f t h e powertransistor3P connector and body ground.

l s t h e r ec o n t i n u i t y ?

3 BLK

o Check tor an open in the wire between the Power ttansistor and body gtound. lf the wire is O K , c h e c kf o r p o o r g r o u n d a t G401and G402.

Wire sideol femaleterminals

JUMPER WIRE

Check tor an open in the wire: 1 . C o n n e c tt h e N o . 1 a n d N o 3 terminals of the Power tran_ s i s t o r 3 P c o n n e c t o rw l t h a jumperwire. 2 . T u r n t h e i g n i t i o ns w i t c h O N { l l )

Repair open in the wire belween the blower motor and the Powet tranststor.

HEATERCONTROLPANEL2OPCONNECTOR Wiresideof femaleterminals Check tor an open in the wire: 1. Turn the ignition switch OFF 2 . D i s c o n n e c tt h e i u m P e r w i r e . 3. Disconnectthe heater control panel 20Pconnector. 4. Check for continuity between the No. 1 terminal of the heater control panel 20P connector and the No. 2 terminal of the Power transistor 3P

ls there continurty)

LT GRN/8LK

Repair open in the wire between the heater control Panel and tho oower transistor,

To page 21 30

(cont'd)

21-29

Troubleshooting-'99

- 00 Models

BlowerMotor Speed(cont'dl Frcm page21.29

Checktor a short in the wi.a: Checkfor continuity between the No. 1 terminalof the heatercon trol panel20Pconnector and body ground.

HEATERCONTROLPANEL2OPCONNECTOR LT GRN/BLK

Wire sideoJfemaleterminals

Repairshort in ths wire betwsen the hoater control panel and the oower transastoa. Checkfor an open in the wire: 1. Disconnect the heatercontrol panel8P connector, 2. Turnthe ignjtionswitchON 1ll). 3. Measurethe voltagebetween t h e N o . ' l t e r m i n a lo f t h e heatercontrol panel 8P con nectorand body ground.

HEATERCONTNOLPANEL8P CONNECTOR

Wire sideot femaleterminals Repeiropen in the wiio between the heater control panel and the blower motoa. Checkthe power transistor: 1. Turn the ignitionswitchOFF. 2. Reconnectthe heatercontrol panel8P and 20Pconnectors. 3. Test the power transistor {see page21 50).

ls the powertransistorOK?

Checkfor loos€ wiras or poor connections at the h€at€r control panel 8P and 20P connectolsand at th6 power transistor 3P conn€ctor. lf the connectionsare good, substituto a known-good hoater control panel, and recheck.It the symptom/indication goes away, replacethe originalheater control oanel,

21-30

BlowerMotor Blower motor does not run at all.

Checkthe No. 55 (40 A) Iuse in the under-hoodfuse/relaybox, and the No. 17 (7.5A){use in the box. fuse/relay undeFdash

Boplaceth€ fuse(3),and rechock.

MOTOR2PCONNECTOR BLOWER Check th€ blow€r motor Powel supply circuit: 1. Disconnectthe blower motor 2P connector. 2. Turnthe ignitionswitchON {ll). 3, Measurethe voltage between the No. 1 terminaloI the blow e r m o t o r 2 P c o n n e c t o ra n d bodyground.

ls there batteryvoltage?

Checktha blower motor: 1. Turnthe ignitionswitchOFF 2. Reconnectthe blower motor 2P connector. 3. Connectthe No.2 terminalo{ the blower motor 2P connec t o r t o b o d v g r o u n dw i t h a tumperwire. 4. Turnthe ignitionswitchON {ll}

Wire sideof lemaleterminals fo page 21-32

JUMPER WIRE

Doesthe blowermotor run?

To page21-33

(cont'd)

21-31

Troubleshooting-'99 - 00 Models

Frompage21-31

Checkthe blower motor relay: 1. Turnthe ignitionswitchOFF. 2 . R e m o v et h e b l o w e r m o t o r relayfrom the under hood fuse/relaybox, and test it- (see page21'49).

Replace the blower motor relay.

BLOWERMOTORRELAY4P SOCKET Check the under-hoodtuse/relay box: Measurethe voltagebetweenthe N o . 3 t e r m i n a lo f t h e b l o w e r motor relay 4P socketand body ground.

Checktor an open in the wire: 1. Turnthe ignitionswitchON (ll). 2. Measurethe voltagebetween t h e N o . 4 t e r m i n a lo f t h e blower motor relay 4P socket and bodyground.

ls therebatteryvoltage?

Repairopon in lhe wire between the No. 17 fuse and the blowet

Checkfor an open in the wire: 1. Turnthe ignitionswitchOFF. 2. Checkfor continuitybetween t h e N o . 2 t e r m i n a lo f t h e blower motor relay 4P socket and body ground.

ls there continuityl

R e p a i ro p e n i n t h e B L U / W H T wiae between the blower motor relay and the blower motor,

21-32

Check lor an ooen in the wire between the blowor motor relay and body ground. It the wiie is O K , c h e c kf o r p o o r g r o u n d a t G401and G402.

Frompage21 31

C h e c kt h e b l o w e r m o t o r h i g h relay: 1. Turn the ignitionswitchOFF, and disconnecthe iumPer 2 . R e m o v et h e b l o w e r m o t o r h i g h r e l a y ,a n d t e s t i t . { s e e page21 49).

BLOWERMOTORHIGHRELAY4P CONNECTOR Check lor an open in the wire: 1. Connect the No. 1 terminal of the blower motor high relay 4P connector to body ground with a jumPer wire. 2 . T u r n t h e i g n i t i o ns w i t c h O N ( l l ) .

JUMPER WIRE

Wire sideof femaleterminals Doesthe blowermotor run?

Repairopen in the wire belween the blower motor and the blower motor high rolay.

Checkfor an op6n in the wir6: 1. Turn the ignitionswitch OFF, a n d d i s c o n n e ct th e i u m P e r 2. Turnthe ignitionswitchON (ll). 3, Measurethe voltagebetween t h e N o . 2 t e r m i n a lo f t h e b l o w e r m o t o r h i g h r e l a y4 P connectorand body ground.

ls there batteryvoltage?

Repairopen in the wire between the No. 17 fuse and the blowor motor high relay.

Checkfor an open in the wire: switchOFF. 1. Turnthe ignitaon 2. Checkfor continuitybetween t h e N o . 3 t e r m i n a ol f t h e b l o w e r m o t o r h i g h r e l a y4 P connectorand body ground.

ls there continuity?

YES

Ch6ck lor an op.n in the wire botween the blower motor high relay and body ground. ll the wire is OK, ch6ck for poot ground at G401 end G402.

(cont'd) To page 21 34

21-33

-'99 - 00 Models Troubleshooting BlowerMotor {cont'dl Frompage21-33 BLOWERMOTORHIGHRELAY4P CONNECTOR Wire sideof femaleterminals

Checktor an opgn in the wiro: 1. Disconnect the heatercontrol panel8P connector. 2. Checklor continuitybetween t h e N o . 1 t e r m i n a lo f t h e heatercontrol panel 8P connectorand the No. 1 terminal ot the blower motor high relay4P connector.

BLU/BLK

2 3

4

o BLU/ALK t

2

a Repsi. op€n in the wir. betw.en the h..t.r contrcl p.ncl .nd tho blowar motor high rahy.

Ch€ckfor an opon in the wir6: 1. Disconnect the heatercontrol panel20Pconnector. 2. Checkfor continuity between t h e N o . 1 3 t e r m i n a lo f t h e heatercontrolpanel20Pconnectorand the No. 4 terminal of the blower motor high relay4P connector.

8

5 6

HEATEROONTROLPANEL8P CONNECTOR wir€ sido ot f€male torminals

HEATERCONTROLPANCL2OPCONNECTOR Wire sideof femaleterminals

a

I

2

3

11

12 13

5

0

7

8

I

,/1,/1,/m

15

ORN/WHT

o Ropairopon in tho wiro botwoon tha hartor cor rol pangl rnd tha blower motor high .elay.

1

2

3

4

OBN/WHT Ch.ck for looso wiros or poor conn€dions at th6 heato. control panel 8P and 20PconnectoB and at the blowol motor high relty 4P connoctor. It tho connoctions are good, substitute a knowngood heatcr control panel, and recheck. It the symptom/indication goos away, rgplacothe oiiginal heatercontrol oanol.

21-34

10

Both heater and A/C do nol work.

checktheNo.47(7.5A)fusein the under-hoodfuse/relaybox, and the N o . 1 7 { 7 . 5A ) f u s ei n t h e u n d e r dashfuse/relaybox.

ReDlacethe tuse{s),and recheck.

Check lor an open in the wire: 1. Disconnectthe heater control panel 8P connector, 2 . T u r n t h e i g n i t i o ns w i t c h O N ( l l ) . 3. Measure the voltage between the No. I terminal of the heatercontrol panel 8P connector and body ground.

ls there batteryvoltage?

HEATERCONTROLPANEL8P CONNECTOR

1 I

4

BLK/YEL

v Repairopen in the wire between the No. '17luse and th6 heater control oanel,

Wire side of female terminals

HEATER CONTROL PANEL 2OP CONNECTOR

Checkfor an open in the wire: 1. Turnthe ignitionswitchOFF. the heatercontrol 2. Disconnect panel20Pconnector. 3. Measurethe voltagelletween t h e N o . 1 0 t e r m i n a lo f t h e heatercontrolPanel20Pconnectorand body ground.

ls therebatteryvoltage?

Repairop6n in the wir€ between the No. il7 tuse and the heater controloanel,

Check for an open in the wite: Check for continuity between the No. 6 terminal of the heater con trol panel 8P connector and body ground.

ls there continuity?

Check for looso wires or Pool conneciions at the heater control oanel 8P and 20P connectors. lf the connections are good, substi' tute a known-good heat€r control Danel, and recheck. lI the goes awaY, symptom/indication r6place the original h€ater controloanel.

Wire sideof temaleterminals

I

2

1

7

5

BLK Ch6ck tor an open in lhe wire betwoen the heator control Panel and bodv ground. lf the wire is O K , c h e c kf o r p o o r g r o u n d a t G401and G402.

o

8

-'99 - 00 Models Troubleshooting HeaterControlPanelInput/OutputSignals

HEATERCONTROLPANELCONNECTORS 8P CONNECTOR

2OPCONNECTOR

12PCONNECTOR

Wire sideof femaleterminals

8P CONNECTOR(O qn Circuit Diagram) Cavity

2

Wire color

Cavily

Signal

Whe color

BLU/8LK

BLOWER FEEDBACK

INPUT

5

RED

GRN/lVHT

FRESH

INPUT

6

BLK

3

GRN/RED

4

RED/BLK

INPUT

7

BLU/YEL

COMBINATION LIGHTSWITCH INPUT (ViaNo.30 (7.5A) fuse)

8

8LfiEL

Cavity

Wirecolor

RECIRCULATE

Signal DASHLIGHTSBRIGHTNESS OUTPUT CONTROLLER

GBOUND

OUTPUT

REARWINDOWDEFOGGER OUTPUT RELAY lG2{Power)

INPUT

20PCONNECTOR{D on circuit Diagram} Cavity

Wire color LT GRN/BLK

Signal POWERTRANSISTOR EASE

OUTPUT

't1

2

BRNMHT

MODECONTROL MOTOR GROUND

INPUT

12

3

RED/YEL

AIR MIX HOT

OUTPUT

13

RED,ryvHI YEUBLU YEURED

AIR MIX COOL

OUTPUT

14

5

MODEDEF MODEVENT MODEHEAT/r'ENT MODEHEAT

INPUT

6 7 I

9 10

GRNI/EL BLUAVHT YEL

WHT/BLU

MODEHEAT/DEF +B (Power)

BLU/RED BRN ORNAA/HT

PNK,/BLK

INPUT INPUT INPUT INPUT

16 11 18 19

INPUT

20

GRY

Signal Ay'CTHERMOSTAT MOTOR AIR MIX CONTROL ND GROU BLOWER MOTORHIGH RELAY

INPUT INPUT INPUT

AIR MIX POTENTIAL

OUTPUT

AIRMIX POTENTIAL +5 V

OUTPUT

*: with Ay'c (tr on CircuitDiagraml 12PCONNECTOR Cavity l

Wilecolor

Cavity

Signal

SWITCHLEDCOMMON

9

SWITCHCOMMON

OUTPUT INPUT INPUT

INPUT

10

A,/CSWITCH

OUTPUT

INPUT

11

REARWINDOWDEFOGGER INPUT SWITCHLED

12

3

5 6

21-36

Signal

I

2

4

Wi.e colol

SWITCHLIGHTS+ SWITCHLIGHTS-

OUTPUT

RECIRCULATION CONTROL SWITCHLED A./CSWITCHLED

1

RECIRCULATION CONTROL OUTPUT SWITCH REARWINDOWDEFOGGEB OUTPUT SWITCH

Blower Unit Replacement controlmotor NOTE:The blowermotor,recirculation and blower resistorcan bs replacsdwithout rsmoving th€ blowerunit (seeneldPage). 1.

controlto "HOT." Movethetemperature '96-98:Slidethetemperature controllever. '99-00:Turnthe ignitionswitchON (ll),thenturn contolknob. Turnthe ignition the temperature switchoff,

Wrth Air Conditioning 4-b. Removoth6 ev8porator(sss pago 22-28). 6x1.0m|n 9.8 N'm

Removethe glovs box (ses ssction 20), R€moveths s6lf-tappingscrew and ths passsng6r's dashboardlow€r cover. Removothe bolt, the nut and the kn€ebolst€r,then removethe fiv€ boltsand the glove box trame,

KNEE

6x1.0mm 9.8 N'm lt'o tgf'm, t.2 lb{'ttl

Disconnoctthe connectorstrom th€ blower motor, blowor r6sistor {'96 - 98 models), power transiator ('99 - 0Omodsls), blowor motor high telay ('99 - 00 models) and recirculationcontrol motor. R€mov€ths wiro harnossclip from tho recirculation control motor, and releasethe wir6 harnsssfrom ths clamo on the blowor unit. Remove the two mounting bolts,tho mounting nut and ths blowor unit' GLOVEBOXFRAME

6x1.0mm 9,t N'm 11.0lgi.m, 7.2 tbf.fil

Without Air Condhioning 4-a. Removethe wiro harnessfrom the h68t€rduct, then remove the two self-tapping scrsws and the heatsr duct.

9.8 .m 11.0tgfm, 1.2tblfrl HEATERDUCT

lnstall in ths reverso order of removal. Mako surs that thsre is no air leaka96.

21-37

BlowerUnit Overhaul NOTE: a Beforereassembly. makesurethat the recirculation controldoor and linkagemove smoothlywithout binding.

controldoor controlmotor, make sure its positioningwill not allow the recirculation When attachingthe recirculation to be pulledtoo far. control motor,connectpower and ground,and watch the movementof the recirculaAfter aftachingthe recirculation tion controldoor.

RECIRCULATION CONTROLMOTOR Test,page21-48

m {'96 - 98 modebl BLOWER Test,page 2'l 9 POWERTRANSISTOR l'99 - 00 modebl Test,page21-50

MOTOR Test,page21'10('96 98 models)or page21'31('99 00 models)

2134

HeaterUnit Replacement SRS componentsare located in this area. Reviewthe SRScomponentlocations,precautions,and procedures in the SRSsection{24}beforeperformingrepairsor ser-

L 2.

4.

Disconnect the heaterhosesfrom the heaterunit. CAUTION:Enginecoolant will damagep8int. Ouickly rinse any spilledengins coolant from painted su aces,

Disconnect the negativecablefrom the battery. NOTE:Enginecoolantwill run out when the hoses drain it into a cleandrip pan. are disconnected;

Frcm underthe hood,open the clamp,then disconnect the heatervalve cable from the heater valve arm. Turn the heatervalve arm to the fully opened positionas shown. CLAMP

HEATERVALVCCABLE

When the engine is cool. drain the engine coolant from the radiator(seesection10). Do not remove the radiator cap when !@ the engine is hot; the ongine coolant is under pres' surg and could severelyscald you.

5.

Removethe mountingnut from the heaterunit. NOTE:When removingthe mountingnut, takecare n o t t o d a m a g eo r b e n d t h e f u e l l i n e s ,t h e b r a k e lines,etc.

I x 1.25 mm 22 N.m {2.2kgl.m, 16lblftl

21-39

HeaterUnit (cont'dl Replacement 6.

Removethe dashboard(seesection20).

7.

Removethe heaterduct (seepage 21-37)or evaporator (seepage 22-28).

8.

Disconnectthe connectorsfrom the mode control motor and air mix control motor ('99 - 00 models), then remove the wire harnessclips and wire harnessfrom the heaterunit. Removethe clip from the heater duct, then remove the two mounting nuts and the heaterunit. 6x1.0mm 9.8N.m11.0kgl.m,7.2lbf.ftl

HEATER UNIT

9.

lnstallin the reverseorderof removal.Makenote of the followingitems. Apply sealantto the grommets. Do not interchangethe inlet and outlet heater hoses.Makesurethat the clampsare secure. R e f i l lt h e c o o l i n g s y s t e mw i t h e n g i n ec o o l a n t (seesection10). Connectall cables,and makesure they are properly adjusted(see page 21-44(96 - 98 models) or page21-45('99- 00 models)). Makesurethat there is no air leakage.

21-40

Overhaul '1. Removethe two self-tappingscrewsand the heater corecover.

Pullout the heatercorefrom the heaterunit.

2.

Pullout the grommetfrom the heatercore pipes.

NOTE: Be careful not to bend the inlet and outlet pipesduring heatercore removal.

3.

Removethe self-tappingscrewand the clamp.

Assemblein the reverseorderof disassembly.

HEATERCORECOVER

GROMMET

21-41

HeaterControlPanel Replacement '95 - 98 modolsi

'9!,- 00 modols:

1 . Remove the driver's dashboard lower cover, the glove box and the center dashboardlower cover (seesection 20). Disconnect the air mix controlcablsfrom the heater unit {seepage21-44). Removethe rearwindow defoggerswitch,the hazard warning switch and the audio unit (seesection23). Disconnectthe connectorsfrom the heatercontrol panel.Removethe five self-tappingscrewsand the centerpaneltogetherwith the heatercontrolpanel.

1 . Removethe center panel together with the heater control panel (seesection 20). Removethe self-tappingscrews and the heatercontrol panelfromthe centerDanel.

NOTE: The lockingtabs are on the bottom of the connecrors.

Removethe four self-tappingscrews and the heater

Install in the reverseorder of removal.After installation, operatethe heatercontrol panel to see whether it works properly.

Install in the .everseorder of removal.Adjust the air mix control cable and the heatervalve cable {see page 21-44)..

21-42

Overhaul-'96 - 98 Models

HEATERFAN SWITCH Test,page21-49

Air Mix Control CableReplacomenl 1. Cutthe innercableon the leversideof the cableholder,then removeboth piecesof the innercable.

2. Usinga sharpknife,cut completelythroughthe end of the cablehousingat the two locations. 3. Slidethelargesectionofthecable housingoutofthe cableholder,beingcarefulnot to damagethe cablestops. 4. Carefullyremovethe cut piecesof the cablehousingwith a smallflat tip screwdriver. 5. Hookthe tip of the new air mix control cableto the temperaturecontrol lever,then push the cable housinginto the cableholderuntil it locksinto place. controlleverslidessmoothlythroughthe full strokelrom rightto left. checkthatthe temperature NOTE:Afterassembly,

21-43

TemperatureControl Adjustment-'96 - 98 Models 1.

From under the hood, disconnectthe heatervalve cablefrom the heatervalve.

6.

From underthe hood.move the heatervalvearm to t h e f u l l y c l o s e d p o s i t i o n .t h e n a t t a c ht h e h e a t e r valvecableto the heatervalvearm.

TER HEATERVALVE ARM

2.

VALVE CABLE

AIR MIX CONTROL ARM

3.

HEATERVALVE ARM

From underthe dash,disconnectthe air mix control cablehousingfrom the cableclamp,

Set the temperaturecontrolleverto MAX. COOL. With the air mix control cable attachedto the air m i x c o n t r o la r m , g e n t l y p u l l o n t h e o u t e r c a b l e housingto fully closethe door and to removeany s l a c ki n t h e c a b l e D . o n ' tp u l l t o h a r d ,o r t h e t e m p e r aturecontrolleverwill move. Hold the air mix control arm againstthe stop. then s n a p t h e a i r m i x c o n t r o l c a b l e h o u s i n gi n t o t h e c a b l ec l a m p .

21-44

7.

Hold the heatervalve arm in the closed position, and gentlypull on the heatercableouter housingto take up any slack.then installthe heatervalvecable housinginto the cableclamp.

Adjustment-'99 - 00 Models 1.

From under the hood, open the cable clamp, then disconnectthe heatervalve cable from the heater valvearm.

5.

From under the hood.turn the heatervalve arm to t h e f u l l v c l o s e d o o s i t i o na s s h o w n , a n d h o l d i t , Attach the heater valve cable to the heater valve arm, and gently pull on the heatervalvecablehousing to take up any slack,then installthe heatervalve cablehousinginto the cableclamp.

HEATERVALVEARM

From under the dash. disconnectthe heatervalve cablehousingfrom the cableclamp,and disconnect the heatervalvecablefrom the air mix controlarm.

HEATERVALVE ARM

VALVECABLE HEATER

Setthe temperaturecontroldial on MAX COOLwith the ignitionswitchON {ll). Attachthe heatervalve cableto the air mix control arm as shown above. Hold the end of the heater valvecable housingagainstthe stop, then snap the heatervalvecablehousinginto the cableclamp.

21-45

Air Mix GontrolMotor Test-'99 - 00 Models

-'99 - 00 Models Replacement

't. Disconnectthe 5P connectorfrom the air mix con-

1,

trol motor. Connectbatterypower to the No. 1 terminalof the air mix control motor, and ground the No. 5 termi, nal; the air mix control motor should run, and stop at MAX HOT.lf it doesn't,reversethe connections; the air mix control motor should run, and stop at MAX COOL.

Disconnectthe 5P connectorfrom the air mix control motor. Removethe self-tappingscrews,the air mix controlmotor and the flangecollar. 5P OONNECYOB

lf the air mix controlmotor does not run, remove i t , t h e n c h e c kt h e a i r m i x c o n t r o l l i n k a g ea n d doorsfor smooth movement. lf they move smoothly,replacethe air mix control motor. AIR MIX CONTROLMOTOR

CONTROL MOTOR Measurethe resistance betweenthe No.2 and No.3 terminals.lt shouldbe approximately4.8to 7.2 kO. Measurethe resistancebetweenthe No. 2 and No. 4 terminals.lt shouldbe approximately 3.84to 5.76kO at MAX HOT and approximately0.96to 1.44kO at MAX COOL.

21-46

Install in the reverseorder of removal.After installation, makesure the air mix control motor runs smoothly.

Mode Control Motor Test

Replacement

the 7P connectorfrom the mode control 1 . Disconnect motor.

1.

2. Connectbattery power to the No, 1 terminal, and g r o u n dt h e N o . 7 t e r m i n a l ,

Disconnect the 7P connectorfrom the mode control motor, 7P CONNECTOR

CAUTION: Never connecl the battery in iho opposite direction. U s i n ga j u m p e r w i r e , c o n n e c t h e N o . 7 t e r m i n a l i n d i v i d u a l ltyo t h e N o . 2 , 3 , 4 , 5 a n d 6 t e r m i n a l si n that order. Eachtime the connectionis made, the mode controlmotor shouldrun smoothlyand stop. NOTE:lf the modecontrolmotor doesnot run when jumpingthe first terminal,jump that terminalagain afterjumpingthe otherterminals.The mode control motor is OK if it runs when jumping the first termin a la g a i n .

MODECONTROLMOTOR

Removethe rod from the arm of the mode control motor. Remove the tyvo self-tapping screws and the mode control motor. lnstallin the reverseorderof removal.After installa' t i o n , m a k e s u r e t h e m o d e c o n t r o lm o t o r r u n s smoothly.

4.

lf the mode control motor does not run in step 3, removeit. then checkthe mode control linkageand doorsfor smoothmovement.lf they move smoothly, reolacethe modecontrolmotor,

21-47

RecirculationControl Motor Test L

Replacement

Disconnectthe 4P connectorfrom the recirculation controlmotor. Connectbattery power to the No. I terminal, and groundthe No.2 and No. 4 terminals;the recirculation controlmotor shouldrun smoothly.

L

Disconnectthe 4P connectorfrom the recirculation c o n t r o l m o t o r , a n d r e m o v et h e w i r e h a r n e s sc l i p from it.

4P CONNECTOR

CAUTION: Never connest ths battery in the opposite direction. Disconnect the No. 2 or No. 4 terminalsfrom ground; the recirculation controlmotor shouldstop at FRESH or RECIRCULATE. NOTE: Don't cycle the recirculationcontrol motor for a long time.

RECIRCULATION CONTROLMOTOR

CONTROLMOTOR

Remove the two self-tapping screws and the recirculationcontrolmotor. Install in the reverseorder of removal.After installa, tion, make sure the recirculation controlmotor runs smoothly.

4.

lf the recirculationcontrol motor does not run in step 2, removeit, then checkthe recirculation controllinkage and door for smooth movement.lf they move smoothly,replacethe recirculation controlmotor.

21-48

Heater Fan Switch

Relays

Test-'96 - 98 Models

Test Thereshouldbe continuitybetweenthe No 1 and No. 3 terminalswhen power and ground are connectedto the No.2 and No. 4 terminals,and thereshouldbe no contanuitywhen poweris disconnected.

Checkfor continuitybetweenthe terminalsaccordingto the table below. lerminal Position

1

4

2

3

5

OFF

,I

t ; 'Y

I

€ )

1

I

2

o oc)-

3 4

rJ

-o a {

Blowermotor relaY

.

Blowermotor high relay('99 00 models)

21-49

Mode Control Switch

PowerTransistor

Test-'96 - 98 Models

Test-'99 - 00 Models

Checkfor continuitybetweenthe terminalsaccordinqto the table below.

1.

Disconnsctthe 3P connectorfrom the oower transtsror.

2,

Carefullyreleasethe locktab on the No. 2 terminalin the 3P connector,then removethe terminal and insulate it from body glound.

Terminal

't0

7

1

--o

Def

o -o oo-

Vent

G

HeaVVent

o-

Position Heat HeaVDef

1 7 8

9

;l t

-o

12V1.2-3,1W

-o -o

4

No.1 laLU/aLK)

Connecta 1.2- 3.4 W bulb betweenthe No. 1 and the No. 2 cavityon the 3P connector. Reconnect the 3P connectorto the powertranslstor. Turn the ignitionswitch ON fll), and checkthat the blowermotor runs.

21-50

Air Conditioning Evaporator .....",'22'24 Replacement .....-.....""'22'29 Overhauf Compressor{SANDEN} Description ......'.'22-30 Repfacement .......22-s Outfine ............ 22'32 fndex ......"..................'.... fffustrated Circuit Diagram ......22-33 '96 - 98 Models ......"..........".......'.... "............ Cfutch Inspection......... 22-6 .......22-34 '99 Modef I ........................ ClutchOverhau """""""' 22-7 Thermal Protector Replacement .... 22-36 Troubleshooting ReliefValve Replacement......'..."".22-36 22-8 SymptomChart ".'......""................. Compressor(DENSO) Flowcharts ..""',' 22-37 Repfacement 22-9 Fan .........".................,..'. Condenser 22-39 lflustratedIndex ............................... .....""" 22-12 Compressor "'....22-40 Clutchlnspection............."'...... .........'.22'17 A/C System 22-41 Cfutch Overhaul.....................'......... A/C Thermostat 22-42 Refief Valve Replacement'..'......"'.. """'22'21 Test ........'.......' A/C Compressor Belt Relays ............22'43 Adiustment ..""'22-21 Test ....."'......... A/C ServiceTips and Precautions......22-22 Condenser .......,,22'44 Repfacement A/C System Torque Specifications'...22-23 A/C System Service A/C System Service ...,,,.......22-45 Evacuation "........'..22-24 Test ...'."......... Performance '..........--'..22'46 Charging ...."' 22-26 PressureTest Chart .................. """""""'22-46 Leakrest 22-27 ...".........," Recovery

22-2 ......'.....' SpeciafTools ".......' fffustratedfndex ......................... 22-3 22'4 Locations'.........'.... Wiring/Connector

SpecialTools

Bef. No.

Tool Number

o

* 0 7 J G G- 0 0 l 0 l 0 A 07sAz - 0010004 07947- 6340300 07965- 6920500

@

Description

Qty

BeltTensionGauge BackprobeSet DriverAttachment Hub AssemblyGuldeAttachment

1 '1 1

' Includedin the BeltTensioncauge Set,07TGG-0010004.

a

6r

L

3r

2 2-2

I

PageReference 22-43 22-14,16 22-34 22-35

lllustrated Index

EVAPORATOR page22-28 Replacement, Overhaul,page22 29

SWITCH A/C PRESSURE pressureis below200kPa{2 0 kg7cm' , Whenthe refrigerant (32kgf/cm' ' 28 psi)due to ;frigerant leakageor above3200kPa pressure swrtch lVC the blockage, psi) to refrigerant due 455 openslhe circuitto ihe AVCswitchand stopsthe air condilioning to protectthe comPressor'

SERVICEVALVE SIDE) {LOW.PRESSURE

A/C THERMOSTAT Test,page22 21

RECEIVER/DRYER B e p l a c e m e n t ,P a g e 2 2 ' 4 4

COMPRESSOR SANDENI Replacement, Page22 30 CIutchInspection, Page22 33 page22 33 ThermalProtectorInspection, ClutchOverhaul,Page22'34 page22 36 ThermalProtectorReplacement, RefiefVafveReplacemenl,page 22'36 DENSO: Replacement, Page22-37 ClutchInspection, Page22-40 ClutchOverhaul,Page22_41 page22-42 ReliefValveReplacement,

22-3

Wiring/GonnectorLocations

A/C DIODE. CONDENSER FAN RELAY, COMPRESSOR CLUTCHRELAY (Locatedin the under,hoodfuse/relaybox)

COND€NSERFAN CONNECTOR COMPARTMENT WIREHARNESS

CONNECTOR

22-4

Description Outline refrigerantthroughthe system The air conditionersystemremovesheatfrom the passengercompartmentby circulating as shown below. EVAPORATOR (Absorption of heati

BLOWERFAN

EXPANSIONVALVE (Metersthe required amountof refrigerant intothe evaporator)

THERMOSTAT

\

/

EOUALIZINGTUBE (Meterspressureand improvesthe expansion valvereactiontime) CAPILLATYTUBESENSINGBULB of the lControlsthe temPerature refrigerantleavingthe evaporator by meteringthe expansionvalve) THERMALPROTECTOR {Opensthe comPressor clutchcircuitwhen the temPerature compressor becomestoo high)

SWITCH A/C PRESSURE is below Whenthe refrigerant 200kPa(2.0kgtcm' ,28Psi) or above 3,200kPa132kgflcm', 455 psi),the Ay'Cpressure switchopensthe circuitto the A,/Cswitch and stops the to Protectthe airconditioning compressor.

RELIEFVALVE pressureat the (Relieves compressorwhenthe pressureis too high)

S] (Suctionand comPression,

I

RECEIVER/DRYER (Trapsdebris,and removesmorsturel

f-r--; (Radiation of heat)

VAPOR HIGHPRESSURE

I

LIOUID HtGHPRESSUBE LIOUID LOW PRESSURE

(R-134a)refrigerantwhich does not containchlorofluorocarbonsPay attentionto the following This car uses HFC-134a serviceitems: (R-134a)' They are not compatible' CFC-12(R-12)and HFC-134a Do not mix refrigerants (PAG)refrigerantoil designedfortheR-134acompressor(SANDEN:SPUseonlythe recommendedpolyalkyieneglycol (pAG)refrigerantoil with any other refrigerantoil will resultin Intermixingihe re-commended 10; DENSO:ND_OIL8). compressorfailure. expansionvalve' dischargeline,suctionline,evaporator,condenser,receiver/dryer, . All A,,icsystemparts{compressor, parts' R-l2 with O-ringsfor joints)haveto be properfor refrigerantR-134a Do not confuse . Usea halogengas leakdetectordesignedfor refrigerantR-134a station . R-12and R-134arefrigerantservacingequipment are not interchangeable.Use only a recovery/recycling/charging systems' air conditioning R-134a to service J2210 of sAE requirements meet the to is certified that is u,L.-listedand station before disconnectingany . Always recover the refrigerant R-134awith an approved recovery/recycling/charging A,/Cfitting.

. .

22-5

CircuitDiagram '96 -

98 Models UNDER.HOOD FUSEi BELAYBOX N0.41(8rA)

GNITON SWITCH

N0.42(40A)

UNDED RASH FUSE/RELAY 8OX N 0 . 1 (77 . 5 4 )

COMPBESSOR CLUTCH BELAY

BLUMHT

,l ,T'

( E i) BLUiBED

A/c I THERMOSTAI BLU/REO CONDENSEF FANMOTOR

WHT/SLU BLKYEL 3

*F,.X, 2

HEATER F A Nr l

+ BLK

G751

22-6

swrlcH

BLK

{ G401 G402

3

'o I 8LK

I

G40l G402

'99 - 00 Models 8OX UNDERHOODFUSE/RELAY N0.41(P,0A)

G N I T OSNW T C H

UNDERDASH BOX FUSE/BELAY N o . l 7( 7 . 5 4 )

N0.42(404)

COMPRESSOR CLUTCH FELAY

$*"

BLK

I

G751

O :8PcoNNEcToF n :20PCONNECToF coNNEcroR E 12P

PANEL CONTROL HEATER

BLK d G401 G402

22-7

Troubleshooting SymptomChart NOTE: . Any abnormalitymust be correctedbeforecontinuingthe test. . Becauseof the precisemeasurements needed.usea multimeterwhen testinq. . Beforeperformingany troubleshooting procedurescheck: - FusesNo. 47 l7-5 Al, No. 56 (20 A) in the under-hoodfuse/relay box, and No. 17 (7.5A) in the under_dash fuse/relav box - GroundsNo. c401, c402, G751 - Cleanliness and tightnessof alt connectors Symptom

Remedy

Condenserfan does not run at all.

Performthe proceduresin the flowchart {see page 22-9).

Compressorclutchdoes not engage.

Performthe proceduresin the flowchart lsee page 22-12).

Ay'Csystem does not come on (compressorand fan),

Performthe proceduresin the flowchan (seepage 22-17). . '96 - 98 models-Performthe proceduresin the flowchart {seepage21-18). . '99 - 00 models-Performthe proceduresin the flowchart (seepage21-35).

Both heaterand A,/Cdo not work.

22-8

CondenserFan Conden3erfan does not run at all.

Checkthe No. 56 (20A) fuse in the box, and the unde.hood frJse/relaY No. 17 (7.5A) fuse in the underdashfuse/relaybox.

Reolacethe fuse{s),and techeck

Removethe condenserlan rclaY' andtest it (seepage22 21i

Replacethe condenseifan relav.

FAN RELAY4P SOCKET CONDENSER

Checkthe under-hoodtus6/relaY Measurethe vohagebetweenthe fan No.2 terminalofthecondenser relav4Psocketand bodv ground.

ls there batteryvoltage?

JUMPER wlRE

Check the condenser lan Power supply circuit: Connectthe No. 1 and No. 2 teF fan relay minalsof the condenser 4Psocketwith a jumperwire

Doesthe condenserfan run?

T o p a g e2 2 - 1 0

Io page 22 11

(cont'd)

22-9

Troubleshooting CondenserFan(cont'd)

CONDENSER FAN RELAY4P SOCKET

Checktor an opon in the wi.o: 1. Disconnect the jumperwire. 2. oisconnectthe condensertan 2P connector. 3. Checkfor continuitybetween the No. 1 terminalof the condenserfan relay4Psocketand the No. 1 terminalof the condenserfan 2P connector.

ls therecontinuity?

Rapairop6n in the wirs bgtwcon the condcnsor tan rclay and the condgnlar fan.

-=F_

Checkto. en open in the wire: Checkfor continuitybetweenthe No. 2 terminalot the condenser fan 2P connector and body ground.

ls there continuity?

Replacothe condense.fan motor.

22-10

CONDENSEB FAN 2P CONNECTOR Wire side of female terminals

l ! . Ilslx @ I

Check Ior rn opon in th6 wire bctwoen the condcnser tan and body ground, lf iho wirc ii OK, chcck for poor ground at G751.

Checkthe diode: the iumPerwire 1. Disconnect 2 . R e m o v et h e A / C d i o d ef r o m box the underhoodfuse/relaY 3. Checkfor currentflow in both directionsbetweenthe A and B terminals.

B()-=iFA ls therecurrentflow in onlY one direction? A/C DIOOE2P SOCKET Chockfor an open in the wire: 1 . T u r n t h e i g n i t i o ns w i t c hO N (ll). 2. Measurethe voltagebetween the No. 2 terminalof the AJC d i o d e 2 P s o c k e ta n d b o d y ground.

ls there battery voltage?

Repairopon in the wire betwe€n the No. 17 luse and the A/c diode.

Troubleshooting Compressor

checkthe No. 56 (20A) fuse in the under'hoodfuse/relaybox, and the No. 17 (7.5A) fuse in the under, dashfuse/relaybox.

Replacethe fussls),and .echeck.

Removethe compressorclutch relay,and test it {seepage22 21).

COMPRESSOR CLUTCHRELAY .P SOCKET

Checkth6 und€r-hoodtu3e/reby Measurethe voltagebetweenthe No. 2 terminalof the compressor clutch relay 4P socketand body ground.

JUMPER WIRE

C h e c k t h e c o m p r e s s o rc l u t c h pow€r supply circuit: Connectthe No. 1 and No. 2 terminalsof the compressorclutchrelay 4Psocketwith a jumperwire.

Doesthe compressor clutchclick?

To page 22 14

22-12

fo page 22-13

Ftom page22 12

RELAY CLUTCH COMPRESSOR iaPSOCKET r--------t RED

Checkto. an opon in tho wire: the jumperwire 1. Disconnect 2 . D i s c o n n e ctth e c o m P r e s s o r clutch1Pconnector. 3. Checklor continuitybetween the No. 1 terminalo{ the com_ pressorclutchrelaY4P socket and the terminalof the compressorclutch1Pconnector'

L-r-]-_l l 2 l I --r-

l 1 l 3 l

| I

@

I

H

I

1___J-RED CLUTCH1P CONNECTOR COMPRESSOR Wire sideof femaleterminals

ls there continuity?

Repeiropen in the wiro between the compressoaclutch relaY and the comDres3orclulch.

Inspect the comPre3sorclutch clo.rance, lhe tharmal Protgdor ISANDENI,and tha compr6ssor clutch field coil {SANDEN:Soe pag. 22-33; DENSO: See Pag. 22-10t.

(cont'd)

22-13

Troubleshooting Compressor lcont'dl Frcm page22-12

COMPRESSOR CLUTCHRELAY 4P SOCKET

CheckIor an open in the wire; 1. Disconnecl the jumperwire. 2. Turnthe ignitionswatch ON (ll). 3. l\4easure the voltagebetween the No. 4 terminalof the compressorclutchrelay4P socket and body ground.

l--;l 1

2 |

---r--]

l . l 3| L-J--J Repairopen in the wire betw€en the No. 17 fuso and the compressor clutch relav.

Checkfor an open in the wira: 1. Turn the ignitionswitch OFF, then reinstallthe compressor clutchrelay. 2 . M a k es u r e t h e A / C s w i t c hi s O F F ,t h e n t u r n t h e i g n i t i o n switchON (ll). 3. Using a *BackprobeSet (T/N 0 7 S A Z 0 0 1 0 0 0 4 )m , easure the voltage betweenthe No. 1 7t e r m i n ao l I the ECM/PCM connectorA (32P)and body ground with the ECM/PCM connectors connected.

ls there batteryvoltage?

] A

BLK/YEL

(v)

!

ECM/PCMCONNECTOR A I32P}

Repairopen in the wirc betweon the compressor clutch relay and the ECM/PCtvt.

Wire side of female terminats

To page22-15 *Howto use the backprobe sets C o n n e c t t h e b a c k p r o b e a d a p t e r s t o t h e s t a c k a n gp a t c h c o r d s , a n d connect the cords to a multimeter. Using the wire insulation as a g u i d e f o r t h e c o n t o u r e d t i p o f t h e b a c k p r o b ea d a p t e r , g e n t l y s l i d e the tip into the connector from the wire side until it comes in cont a c t w i t h t h e t e r m i n a l e n d o f t h e w i r e ( s e es e c t i o n 1 1 ) .

Frcm page22-14 SWITCH2P CONNECTOR A/C PRESSURE Checklor an open in the wire: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe A/C pressure switch2Pconnector. 3. Turnth ignitionswitchON lll). 4. Measurethe voltagebetween the No. 1 terminalof the AJC pressureswitch2P conneclor and body ground. wire sideof {emaleterminals

ls therebatteryvoltage?

Repairopen in the wire between the condenserfan relay tnd the A/C oressureswitch.

A/C PRESSURE SWITCH

Check the A/C pressure switch: 1. Turn the ignition switch OFF. 2. Check for continuity between the No. 1 and No. 2 terminals of the Ay'Cpressure switch.

ls there continuity?

1o page22-16

Checkfor A/Csystemptessure.

l s t h e p r e s s u r ew i t h i n s P e c i _ f cations?

Repair the A/C pressure Problem

(cont'd)

22-15

Troubleshooting Gompressor(cont'dl Frompage22-15 '96 -98 models: Checkfor an open in thg wire: '1. Reconnectthe A"/Cpressure switch2P connector. 2. Make sure the A/C switch is O F F ,t h e n t u r n t h e i g n i t i o n switchON (ll). 3. Using a *BackprobeSet {T/N 07SAZ- 001000A),measure the voltagebetweenthe No. 5 terminalof the ECM/PCM conn e c t o r C ( 3 1 P )a n d b o d y ground with the EcM/PcM connectorsconnected('96 98 models), or between the No. 27 terminal of the ECM/PCMconnectorA (32P) and body ground with the E C M / P C Mc o n n e c t o r sc o n nected('99- 00 models).

ECM/PCMCONNECTOR C 13lPI

Wire sideot femaleterminals

'9!t - 00 mod.bi ECM/PCMCONNECTOR A I32P)

3 1 ta t6

5 0 1 l 1 1E 19

E 9 21 22

10

11

23

21

BLU/RED Rapdiropen in tho wi?e botwaon the A/C pr..-ruro lwitch rnd th. ECM/PCM. Wire sideot femaleterminals Check lor loo3e wires or oool connections at the ECM/PCM connectoBA l32P)and at the A/C pressure switch 2P connector, lf the connectionsare good, substitute a known-good ECM/PCM, and recheck. lf the svmptom/ indicationgoos away, repbce the originalECM/PCM. *How to use the backprobesets Connectthe backprobeadaptersto the stackingpatch cords, and connectthe cordsto a multimeter.Usingthe wire insulationas a guidefor the contouredtip of the backprobe adapter,gentlyslide the tip intothe connectorfrom the wire sideuntil it comesin contactwith the terminalend ofthe wire {seesection11}.

22-16

A/C System A/C system does not come on {comDressorand fan).

C h e c kt h e N o . 5 6 f u s e i n t h e u n d e r ' h o o df u s e / r e l a yb o x a n d the No. 17fuse in the under-dash box. fuse/relay

ReDlacethe fus6{s},and recheck. CONDENSER FAN RELAY4P SOCKET

Checkfor tn open in the wire: 1 . R e m o v et h e c o n d e n s e rl a n relayfrom the underhood luse/relaybox. 2. Turnthe ignitionswitchON {lli. 3- Measurethe voltagebetween the No. 4 terminalof the con d e n s e rf a n r e l a v 4 P s o c k e t and body ground.

Repairopen in the wire between the No. 17 fuse and the condenserfan r6lay,

Checkthe under-hoodfus€/r6lay box: Measurethe voltagebetweenthe No. 2 terminal of the condenser f a n r e l a y 4 P s o c k e ta n d b o d y ground,

YES Io page 22-18

(cont'd)

Troubleshooting A/C System(cont'd) Frompage22-11

A/C THERMOSTAT 3PCONNECTOR Checktor an open in the wire: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe A/C thermo stat 3P connector. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween the No. 3 terminalof the Ay'C thermostat3P connectorand body ground. Wire side oI femaleterminals

Repai. open in the wire between tho No. 17 tuso and the A/C the.mostat.

Checkloi an open in the wi.e: Measurethe voltagebetweenthe No. 1 terminalof the A,/Cthermo stat 3P connector and body ground,

ls there batteryvoltage?

Ropairopen in the wire betwoen the condedlo. lan rolay and the A/C thormostat.

Checkthe A/C th6rmostat: 1. Turnthe ignitionswitchOFF. 2. Reconnectthe A,/Cthermostat 3Pconnector. 3. Connectthe No. 2 terminalto groundwitha iumperwire. 4. Startthe engine.

. _Ff,, __ I 1 1 2 1 3 [

,r,il*"-T",-.r-'..o wrRE I

Do the fan run and the compressorclutchengage? To page22-191'96- 98 models) To page22-20('99- 00 models)

22-18

r'oA - qe m^.lalal

Ftom page22 18

HEATERCONTROLPANELlilP CONNECTOR

Checktor an open in the wire: 1. Turn the ignitionswitch OFF, t h e n d i s c o n n e ctth e i u m p e r

t

7

I

I

'olx

a

r

6

't1 12 1 3 1 4

BLU/RED

2. Removethe centerdashboard lower cover lsee section20), the heatercon' and disconnect trol panel14Pconnector. 3. Turnthe ignitionswitchON (ll). 4. Measurethe voltagebetween the No. 11 terminaland body ground.

Wire sideof femaleterminals

Repairop6n in the wire bstween the A/C th€rmostat and th6 hoater controlpanel. HEATERCONTROLPANEL1'P CONNECTOR Checklor an open in the wire: 1. Turnthe ignitionswitchOFF. 2 . D i s c o n n e ctth e h e a t e rI a n switch6P connector, 3. Checkfor continuitybetween t h e N o . 1 4 t e r m i n a lo f t h e heatercontrolpanel14Pcon_ nectorand the No.6 terminal of the heaterfan switch6P connector.

Wiresideof femaleterrninals

Check for loose wiaes or poor connections at the heater control oanel 14P connoctor and hoeter tan 3witch 5P conn€clor and at the A/C thermostet 3P connector. ll the connections are good, raplace the heator control Panel.

7

I

;--? 10

X

4 'll

5

12 13 1 4

1

2

3

a

5

6

GRN

HEATERFAN SW]TCH6P CONNECTOR

Checkfor an open in thGwire: Checkfor continuitybetweenthe No. 1 terminalof the heaterlan s w a t c h6 P c o n n e c t o ra n d b o d Y ground.

ls the heaterfan switchOK?

2

GRN

Repairopen in the wiro betweGn the heal.r control Panel and the heaterfan switch.

ls therecontinu;ty?

1

Wire sideof femaleterminals

Chock tor an open in tho wir€ between the heater lan switch and body ground. lf the wire is OK, checkfor poor groundat G401snd G402.

ReDlacethe heater tan switch.

(cont'd)

22-19

Troubleshooting

('99 00 models) Frompage22 18

Checklor an open in the wire: 1. Turn the ignitionswitch OFF, t h e n d i s c o n n e ctth e j u m p e r

HEATERCONTROLPANELanPCONNECTOR

2. Disconnect the heatercontrol panel20Pconnector. 3. Turn the ;gnition switch ON { i. 4. Measurethe voltagebetween t h e N o . 1 1 t e r m i n a lo f t h e heatercontrolpanel20Pconnectorand body ground. Wire sideof temaleterminals ls there batteryvoltage?

Checkthe push switch: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe push switch 12Pconnector. 3. Checkfor continuitybetween the No. I and No. 10terminals of the push switch 12Pconnectorwith the A/C switch ON.

Ropai. opan in tho wira batwaon the A/C thermostat and the hoater control oanol. PUSHSW]TCH12PCONNECTOR

,/1,/ 7

1

5

6

8 1 9 t 0 1 1 12

II

I

Wiresideof femaleterminals Check for loose wi.es or poor connectionsel the hgater control panel 20P connector and push switch 12Pconnector and at the A/C thermostat 3P connector. It tha connectionsare good, substitute a known-good heatea control pan€|, and recheck. lf the symptom/indication goe3 away, replacelhe original healer control oan€|,

A/C Thermostat

Test

Test 1.

Relays

thermostat(seepage22-29). Removethe Ay'C Connectbafterypowerto the No. 3 terminal,ground the No. 2 terminal,and connecta test light between the No. 1 and No.3 terminals.

Thereshouldbe continuitybetweenthe No, 1 and No.2 terminalswhen power and ground are connectedto the No.3 and No. 4 terminals,and thereshouldbe no continuitvwhen Doweris disconnected.

N O T E rU s ea 1 2V , 3 W - l 8 W t e s tl i g h t . Dip the IVCthermostatinto a cup filled with ice water, andcheckthe testlight. Serp6ntine-typeevaporator The light shouldgo off at 36 - 39'F{2 - 4"C}or less,and shouldcome on at 39 - 41"F(4 - 5"C)or more Laminale-typeevaporator The light shouldgo off at 39 - 43'F (4 - 6'C) or less,and shouldcome on at 43 - 45"F(6 - 7'C) or more

,I

'r In

I

b Io

I

2

a Condenser fan relay a Compressor clutchrelay

l f t h e l i g h t d o e s n ' tc o m e o n a n d g o o f f a s s p e c i f i e d , replacethe PVCthermostat.

12V,3W-18W

t\----,'

t:n

,,l[4..-.

22-21

A/C ServiceTips and Precautions

(R-134a) (PAG)refrigerantoil*, which are not refrigerantand polyalkyleneglycol The air conditionersystemusesHFC-134a compatiblewith CFC-12(R-12)refrigerantand mineraloil. Do not use R-12refrigerantor mineraloil in this system,and do not attemptto useR-12servicingequipmenUdamageto the air conditionersystemor your servicingequipmentwill result. *DENSOND-OlL8l *SandenSP-10: . P/N38897- PR7- A01AH:120ml (4 fl.oz) . P/N38897- P13- A0lAH: 120ml 14ll.oz,4.2lmp.oz) . P / N3 8 8 9 9 P R 7 - A 0 1 : 4 0 m f ( 1 1 / 3 f l ' o z ) . P/N38899- P13- A0l | 40 mf 111/3ll.oz,1.4lmp'oz) Use only serviceequipmentthat is U.L. listedand is certifiedto meet the requirementsof SAE J2210to removeR 134a from the air conditionersystem. CAUTION:Exposureto air conditioner ref;ige;ant and lubricant vapol or mist can irritate syes, nose and throat, Avoid breathing the air conditioner refrigerant and lubricant vapor or misl. lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice. R-'134a serviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed ai. some mixtures of air and R-t3ila have been shown to be combustible at elevated pressuresand can result !@@ in tire or explosion causing iniury or property damage. Never use compressedair lo pressuretesl R-134aservice equipment or vehicle 8ir conditioner systoms. Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand Iubricantmanufacturers. L 2. 3. 4, 5. 6.

Alwaysdisconnectthe negativecablefrom the batterywheneverreplacingair conditioningpans. any lines,plug or cap the fittingsimmediately;don't Keepmoistureand dust out of the system.When disconnecting removethe capsor plugsuntiljust beforeyou reconnecteachline. Beforeconnectingany hoseor line,applya few dropsof refrigerantoilto the O-ring. Whentighteningo. looseninga fitting,usea secondwrenchto supportthe matchingfitting. station;don't releaserefrigerant When dischargingthe system,use a R-134arefrigerantrecovery/recycling/charging into the atmosphere, Add refrigerantoil after replacingthe followingparts: NOTE: . To avoidcontamination, do not returnthe oil to the containeroncedispensed,and nevermix it with other refrigerant oils. . lmmediatelyafter usingthe oil, replacethe cap on the container,and sealit to avoid moistureabsorption. . Do not spill the refrigerantoil on the vehicle;it may damagethe paint;if the refrigerantoil contactsthe paint,wash it off immediately. .......2oml (2/3fl.oz,0.7 lmp.ozl Condenser .,.,.,.i[5 m{ 11213tl.oz,1,6lmp.ozl Evaporator .....10 mf (1/3fl.oz,0.4 lmp.ozl Lineor hose 10 m{ (1/3fl.oz,0.'llmp.ozl Receiver/Dryer 25 m{ (5/6 fl.oz, 0.9 lmp.ozl Leakagerepair ... For compressor replacement. subtract the volume of oil drained trom the Comptessor removed compressorfrom A, and drain the calculatedvolume of oilfrom the new compressor:A - Volume of removed compressor: Volume to drain from new comoressor. A: SANDEN 130 mf l/t 113ll.oz, 4.6 lmp'ozl; DENSO140 mf {4 213 ll'oz, 1.9 lmp.oz), NOTE:Even if no oil is drainedfrom the removedcompressor,don't drain more t h a nS 0m { 1 1 2 E l l . o z , 1 .l8m p . o zf)r o m t h e n e wc o m p r e s s o r . NEW REMOVED

rere COMPRESSOR

W

0 0

-0_!Tol | |

22- 2 2

COMPRESSOR

W

0 0

-0_a l00l lffi 1onrrrutrcI

LEvEr...+jEf,voLUME ^ fi+-sAME J

A/C SystemTorqueSpecifications

9.8 N'm {1.0kgf'm,7.2lbf'ftl .. ...................' O Dischargehoseto the compressor(6 x 1.0mml ............... 9.8 N'm 11.0kgf'm,7.2 lbf'ft} '... ....... ......... @ Dischargehoseto the condenser{6 x 1.0mm1................... 9.8 N'm (1.0kgl'm, 7.2 lbt'ft) . . ...........'..... . O Condenserpipeto the condenser16x 1,0mm)...............'. (5 9.8 N'm (1.0kgl'm, 7.2 lbt'ft) ..... . ... . '.......... pipe to the receivel/dryer x 1.0mml......... @ Condensel ... .......... .. . . .... 9.8 N'm 11.0kgf'm.7.2 lbl'ft) pipe x 1.0 mm)......... A to the leceiver/dryer Receiver {6 O 13 N m (1.3 kgf'm, 9.'l lbf'ft) @ Receiverpipe B to the receiverpipe A 13 N m (1.3 kgf'm, 9.4 lbnftl O Receiverpipe C to the receiverpipe B ....... 9.8 N'm (1.0kgf'm,7.2 lbtftl pipe x 1.0 mm) C to the evaporator{6 @ Receiver (6 .........'......'....... 9.8 N'm (1.0kgf m, 7.2 lbf'ftl . pipe x 1.0 mml................ B the evaporator to O Suction 31 N'm (3.2kgt'm,23 lbf'ftl ...'. . ...... . ... ...... pipe pipe B A to the suction Suction e0 ............ . . '......... 31 N'm (3.2kgl'm, 23 lbf'ft| O Suctionhoseto the suctionpipe A... .. . ... .. ............ 9.8 N'm (1.0kgf'm' 7.2 lbf'ft| @ Suctionhoseto the compressor(6 x 1.0mm)................... (8 N'm (2 'l kgf'm, 17 lbf ftl ..-........'.'......-.......24 x 1.25 mm)... bracket to the compressor Compressor @@ 44 N'm l'1.5kgf'm, 33 lbf ftl @ Compressorbracket to the cytinder block (10 x 1.25mml ... ... 59 N'm (6.0kgf'm,'|i} lbf ftl @ Compressorbracketto the left front enginemounl {12x 1.25mm}...... . . . .. .................

22-23

A/C System Service Test Performance The performancetest will help determineif the air conditionersystemis operatingwithin specifications. and is cerUseonly serviceequipmentthat is U.L.-listed tified to meet the reouirementsof SAEJ2210to remove (R-134a) from the air conditionersystem. HFC-134a CAUTION: Exposure to air conditionor rofrigerant and lubricant vapor or mist can irrilalo €yes, nose and throat. Avoid breathing tho air conditioner rstrigerrnt and lubricant vapor or mist, lf accidentalsystem dischargeoccurs, ventilate work areabeforeresumingservice. R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak tested with compressedair. some mixtur$ of air and R-134ahave been @ shown lo b9 combustible rt glgvatadpr€ssur63and can resull in tire 01 oxplosion causing inlury ot property damage. Never uao compre33edair to pressure t99t R134a ssrvico 6quipmsnt or vohicla air conditioner systems. Additional health and safety information may be obtained from the refrigerantand lubricantmanufacturers. '1. Connect a R-134a refrigerant recover/recycling/ chargingstationto the vehicle,as shown,following instructions. the equipmentmanufacturer's 2.

l n s e r t a t h e r m o m e t e ri n t h e c e n t e r v e n t o u t l e t . Determinethe relative humidity and air temperature, Testconditions: . Avoid directsunlight. . Openhood. . Open front doors. . Set the temDerature controlleveror dial to MAX, COOL,the mode control switch or dial on VENT and the recirculation controlswitchon RECIRCULATE. . Turn the A,/Cswitch on. and the heaterfan switch on MAX. . Runthe engineat 1,500rpm. . No driveror passengers in vehicle After running the air conditioningfor 10 minutes under the above test conditions,read the delivery temperaturefrom the thermometerin the dash vent and the high and low system pressurefrom the A,/C gauges.

22-24

Recovery/Rocycling/Charging Station

5.

To completethe charts: . Markthe deliverytemperaturealongthe venicalline. . Markthe intaketemperature (ambientair temperature) alongthe bottomline. . Drawa line straightup from the air temperatureto the humidity. . Marka point 10%aboveand 10%belowthe humiditylevel. . Fromeachpoint.draw a horizontalline acrossthe deliverytemperature. . The delivervtemperatureshouldfall betweenthe two lines. . Completethe low side pressuretest and high side pressuretest in the sameway. . Any measurements outsidethe line may indicatethe needfor furtherinspection.

kPa lkgf/cm'l lpsil 2900 (30) I€OI

aoy.

2500 (25) 13601 2000 t20l t280t 1500{151 12101 DELIVERY PRESSURE

30io

DELIVERY PRESSURE 80% kPa {kgf/cm') lpsil rct 400 86 -l {4) t571

980 (101 lr40l

INTAKE PRESSURE

r3ol I

300 {3} I€I

A,-]

200 l2l t28l

6 8 -

100 tll 1141 0

DELIVERY TEMPERATURE

I "'l

INTAXE PRESSURE

{20r I

,r-]

uo --]

''o' I

nt 68 (2ot

77 t2sl

86 t3o)

95 135)

10il l4ol

'F {"c)

INTAKETEMPERATURE

22-25

A/C System Service PressureTestChart Test is on page22-24, NOTE:Performance Test results

Relatedsymptoms

D i s c h a r g(eh i g h ) After stoppingcompressor.prespressureaDnor- suredropsto about200 kPa m a l l yh i g h {2.0kgflcm,,28psi)quickly,and then fallsgradually.

Dischargepressureabnormally

Air in system

Reducedor no air flow through condenser

. Cloggedcondenserfins . Condenserfan not working properly

Lineto condenseris excessively hot.

Restrictedflow of refrigerant in system . Faultycompressordischargevalve . Faultycompressorseal . Faultyexpansionvalve . Moisture in system

Highand low pressuresare balancedsoon afterstoppingcompressor,Lowsideis higherthannormal. Outletof expansionvalveis not frosted,low pressuregaugeindicalesvacuum.

Suction(low) pressureabnormally low

Probabl€cause

Expansionvalve is not frosted,and low oressureline is not cold. Low pressuregaugeindicates vacuum.

. Frozenexpansionvalve . Faultyexpansionvalve

Frozenevaporator Dischargetemperatureis low. and the air flow from vents is restricted.

Suctionpressureabnormally h i gh

Refrigerant leaks

22-26

Recover,evacuate,and rechargewith specifiedamount. Evacuation:see page 22-45 Charging:see page 22-46 Clean. Checkvoltageand fan rpm. Checkfan direction. Restricted lines Replacethe compressor.

. Replace, . Recover,evacuate,and rechargewith specified amount. ReDlace the exoansionvalve.

Runthe fan with compressor off. then checkA,/Cthermostat.

Exoansionvalveis frosted.

Cloggedexpansionvalve

Cleanor replace.

Receiver/dryer outletis cool,and inlet is warm (shouldbe warm duringoperation).

Clogged receiver/dryer

Replace.

Low pressurehoseand check joint are coolerthan the temperature aroundevaporator.

. Expansionvalveopentoo long . Looseexpansioncapillary tube

Repairor replace.

Suctionoressureis loweredwhen condenseris cooledbv water.

Excessiverefrigerantin system

Recover.evacuate,and rechargewith specifiedamount.

High and low pressureare equalizedas soon as the compressoris stopped,and both gaugesfluctuatewhile running.

Faultygasket Faultyhigh pressurevalve Foreignparticlestuckin high pressurevalve

Suctionand dis- Reducedair flow throughcondenser. chargepressuresabnormally hi g h Suctionand dischargepressure a b n o r m a l llyo w

Remedy

. Cloggedcondenserfins . Condenserfan not working properly

Replacethe compressor.

Cleancondenser. Checkvoltageand fan rpm. Checkfan direction.

Low pressurehoseand metalend areasare coolerthan evaporator.

Cloggedor kinkedlow pressure hose parts

Repairor replace.

Temperaturearoundexpansion valveis too low comparedwith that aroundreceiver/dryer.

Cloggedhigh pressureline

Repairor replace.

Compressorclutchis diny,

Compressorshaftsealleaking Replacethe compressor.

Compressorbolt{s)are diny.

Leaking around bolt(s)

Tightenbolt(s)or replacecompressor.

gasketis wet with oil. Compressor

Gasketleaking

Replacethe compressor.

Recovery and is cerUseonly serviceequipmentthat is U.L.-listed of SAEJ2210to remove tifiedto meetthe requirements (R-134a) from the air conditionersystem HFC-134a

g/Cha19ingStation R€covery/Recyclin

CAUTION: Exposure to air conditioner relrigerant and lubricant vapor or mist can illitate eyes, noss and throat. Avoid breathing the ail conditioner refrigerant and lubricant vapor or mist. lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice. R-134aserviceequipmentor vehicleair conditionersystems shouldnot be pressuretestedor leaktestedwith compressedair. some mixtures ot air and R'13'[ahavo been !@@ strown to be combustiblg at elevated pressuresand Gan resuh in fire or explosioncausinginiury or property damage, Never use compressed air to pressuretest R-134a serviceequipment or vehicleair conditionersystems. Additionalhealthand safetvinformationmay be obtained and lubricantmanufacturers. from the refrigerant 1,

Connect a R-'134arefrigerant recoverylrecycling/ chargingstationto the vehicle,as shown.tollowing instluctions. the equipmentmanufacturer's

2.

Measurethe amountof refrigerantoil removedfrom the A/C svstem after the recoveryprocessis completed. NOTE: Be sure to installthe same amount of new refrigerantoil backinto the Iy'Csystem beforechargtno.

22-27

Evaporator Replacement 1.

Movethe temperaturecontrolto "HOl" '96-98: Slidethe temoeraturecontrollever. '99-00: Turnthe ignitionswitch ON (ll),then turn the temperaturecontol knob. Turn the ignition switch off.

7.

Disconnectthe connector from th€ Ay'Cthermostat, and r€movs the wire harnessfrom the ovaporator. Remov6tho four self-tappingscrews,tho mounting bolt and ths mounting nut. Disconnectth€ drain hose,then remov€th6 avagorator.

Removethe battsry. Rgcover the refrigerant with a rocovery/recycling/ charging station (see page 22-271. 4.

Remove the bolts, then disconnectth6 suction 8nd receiverlines from th6 evaoorator. NOTE: Plug or cap the lines imm€diatoly after disconnectingthem to avoid moisture and dust contamination.

srrcrrc u E 6xl.0mm 9.8 n*ln ll.0 tg6m.

7.2lbtfrl

6 x l.0.nm 9.8l$m lt.o ldm, 7.2bl.tt) RECEiVER UNE Removethe glov6 box (seesection 20). 6.

Removothe self-tappingscr€w and the passeng€r's dashboardlower cover. Removsthe bolt. the nut 8nd the kn€e bolst6r,th6n r6mov6 th6 fiv6 bolts and the glove box frame.

22-28

Install in the reverseorder of removal. Make note of th€ following items. o lf you'r6 installinga new evaporator,add rofrigerANtOiI {SANDEN,SP-10Or DENSO,ND-OIL8) lsas page 22-221. . Replacethe O-ringswith now ones 8t 68ch titting, and apply 8 thin coat of r€frlgersd oil before installingthem. NOTE: Be sure to use the right O-rings for HFC134a(R-134a)to avoid loakago. . Apply s€alantto tha grommets. . Mske sure that ther€ is no air leakage. . Chargs ths system {s€€ page 22-161,and tost its performance(see pags 22-211.

Overhaul 1 . Pull out the A,/Cthermostatsensorfrom the evaporatorfins. Removethe self-tappingscrews and clamps from the housings.

5.

Assemblein the reverseorderof disassemblyMake noteof followingitems. .

3. Carefullyseparatethe housings,then remove the evaporator.

.

removethe expansionvalve. lf necessary, valvenuts,use the expansion NOTE:Whenloosening a secondwrench to hold the expansionvalve or the evaporatorpipe.Otherwise,they can be damaged

6th tin lrom inld side

.

HOUSING

Replacethe O-ringswith new onesat eachfitting, and apply a thin coat of refrigerantoil before installingthem. NOTE:Be sure to use the right O-ringsfor HFCto avoid leakage. 134a(R-134a) Installthe expansionvalvecapillarytube so that it is in direct contactwith the suctionline. Then wrap wathtaPe. Reinstallthe Ay'Cthermostatsensorto its original location.

TAPE Replace. lvakesurethereis no foreignmatterstuckbetween

Serpentinetype:

% Laminatetypo:

EVAPORATOR blow din out of lins air, with compressed

60t5mm l'2.1! O.2inl

6th fin lrom outle'tside

TUAE CAPILLARY

N

u' ll

6\

8 N.m 10.8kgt m, 6 tbf.ftl

VALVE

1l

N.m (2.itkgt.m, 17 tbtftl

A/C THERMOST fesr page22 21

EVAPORA LOWER

22-29

Compressor(SANDENI Replacement 1.

lf the compressoris marginallyoperable,run the e n g i n e a t i d l e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r work for a few minutes.then shut the engineoff.

7.

Disconnectthe negativecable from the battery. Recoverthe refrigerantwith a recovery/recycling/ charging station (see page 22-27l..

Loosenthe center nut of the idler pulley and the adjusting bolt. then remove the A,/Ccompressorbelt from the pulleys.Removethe two mounting bolts from the left front mount, then remove the ly'C compressor belt by passing it through the gap befiiveen the bodv and the left front mount. ADJUSTINGBOLT CENTERNUT

Removethe bolts,then disconnectthe suctionand dischargelinesfrom the compressor. NOTE:Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust contamination.

6xl.0mm

1.0x 1.25mm aa N.m 14.5kgf,m, 33 bnft)

8.

Remove the four mounting bolts and the compressor.

COMPRESSOR

Removethe condenser(seepage22-44). NOTE:Do not disconnectthe dischargehose from the condenser. Removethe power steeringpump belt (seesection 1 7t .

24 N.m l2.iakgt.m, 17 lbf.ftl

22-30

9.

removethe compressorbracketas follf necessary, lows. .

10. lnstallin the reverseorderof removal.Makenote of the followingitems. .

Removethe nut and the washer. NOTE:When tighteningthe nut of the left front mount, make sure the washeris set properlyon the left front enginemount as shown.

.

Removethe four mounting bolts and the compressorbracket.

12 x 1.25rrirn 59 N.m 16.0kgt'm, 43 tbf.ft)

COMPRESSOR BRACKET

.

. o

.

lf you're installinga new compressor,drain all the refrigerantoil from the removedcompressor, and measureits volume.Subtractthe volume of '130m? 1/3 tl'o2,4 6 lmp'oz); 14 drainedoil from the result is the amount of oil you should drain from the new compressor(through the suction fifting). Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l beforeinstallingthem NOTE: Be sure to use the right O-ringsfor HFCto avoid leakage 134a(R-134a) for R-134aSandenand Use refrigerantoil (SP-10) Hadsysspiraltype compressorsonly' To avoid contamination,do not returnthe oil to the containeronce dispensed,and never mix it with other refrigerantoils. lmmediatelYafter using the oil, replacethe cap on the container,and seal it to avoid moisture

absorption. Do not spill the refrigerantoil on the vehicle;it may damagethe painu if the refrigerantoil contactsthe paint,wash it off immediately . Adjust the Ay'Ccompressor belt (see page 22-43) and the power steeringpump belt (seesection17)' . Chargethe system(seepage 22-46),and test its oerformance(see Page22-241

.

WASHER

LEFTFRONT 1.0x 1.25mm MOUNT 44 N.m (i1.5kg{.m,33 lbl.ft)

22-31

Gompressor(SANDEN) lllustratedIndex

CENTER NUT Replace.

<--

ARMATUREPLATE lnspection,page22-33

sHrM(s) Replace. SNAPRINGB Replace.

ROTORPULLEY Inspection, page22-33

SNAPRINGA Replace.

FIELDCOIL lnspection,page 22-33

Replacement. page22,36

COMPRESSoR ] (Donot disassembte) ---------------->l

THERMALPROTECTOR Replace. page22-33 Inspection, page22-36 Replacement,

t v

i -

22-32

ClutchInsPection Checkthe platedpartsof the armatureplatefor color changes,peelingor other damage lf there is damage.replacethe clutchset.

Releasethe field coil connectorfrom the holder'then disconnectit. Checkthe thermal protectorfor continuity. lf there is no continuity.replacethe thermal protecror,

.

Checkthe rotor pulleybearingplay and drag by rotating the rotor pulley by hand Replacethe clutch set with a new one if it is noisy or has excessiveplay/drag

Measurethe clearancebetweenthe rotor pulleyand the armature plate all the way around lf the clearance is not within specifiedlimits,the armatureplate must be removed and shims added or removedas required,followingthe procedureon page22-34 Cl€arance:0.5 ! 0.15 mm {0.020t 0.006in)

NOTE:The thermal protectorwill have no continuity 1122lo128'C).When the temabove251.6to 262.4oF peraturedrops below 2408 to 219.8"F(116to 104"C), the thermalprotectorwill havecontinuity .

of the field coil Checkresistance Field Coil Resistance:3.05to 3.35 O at 68"F (20"C) replacethe lf resistanceis not within specifications, field coil.

NOTE:The shims are availablein four thicknesses: 0 . 1m m , 0 . 2m m , 0 . 4m m a n d0 . 5m m

22-33

Compressor{SANDEN) Clutch Overhaul 1.

Removethe center nut while holding the armature platewith the tool. CENTERNUT 17.6N.m {1.8kg{.m,'t3tbnft} A/C CLUTCHHOLDER {Commerciallvaveilable) Robinair:P/N 10204 Kent-Moore:P/N J37872

3.

Removesnap ring B with snap ring pliers. NOTE: . Be careful not to damage the rotor pulley and compressorduring removal/installation. . Once snap ring B is removed,replaceit with a new one.

A

\ / G::.

r\t \\:g2rl

. .

2.

-

!

L

;

j

'

-/

/

/

Removethe armatureplateby pullingit up by hand.

ARMATURE PLATE

Removethe rotor pulleyfrom the shaftwith a puller and the specialtool. NOTE:Placethe claws of the puller on the back of the rotor pulley,not on the belt area;otherwisethe rotor pulleycan be damaged.

TWOJAW PULLER {Commercially

22-34

5.

Removethe screwfrom the field coil groundterminal,then disconnecthe field coil connector. R e m o v es n a p r i n g A w i t h s n a p r i n g p l i e r s ,t h e n removethe field coil NOTE: . Be carefulnot to damagethe field coil and compressorduringremove/installation. . Once snap ring A is removed,replaceit with a new one. . When installingthe field coil, align the boss on the field coil with the hole in the compressor.

7.

A s s e m b l ei n t h e r e v e r s eo r d e r o f d i s a s s e m b l y Makenote of the followingitems. lnstallthe fieldcoilwith the wire sidefacingdown. C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o sr l i d i n g solvent. surfaceswith non-petroleum . Make sure the snap rings are fully seatedin the groove. . Make sure that the rotor pulley turns smoothly after it's reassembled . Routeand clamp the wires properlyor they can be damagedbYthe rotor Pulley.

. .

SNAP RINGA Replace.

Positionthe rotor pulleysquarelyover the field coil. Pressthe rotor pulley onto the compressor boss with the specialtool. lf the rotor pulley does not press on straight, remove it, and check the rotor pulleyand compressorbossfor burrsor damage. CAUTION: Maximum press load: 39,200 kPa (,[00kgf/cm', 5,590Psi) Press

T

HUB ASSEMBLY GUIDEATTACHMENT 07965 - 6920500 ROTOR PULLEY

t'l

i,' 22-35

Compressor(SANDENI ThermalProtestorReplacement

ReliefValveReplacement

1.

'1.

Removethe bolt,the groundterminaland the holder. Disconnectthe field coil connector.then remove the thermal Drotector. 7.{ N.m 10.75ksf.m,5lbtfr)

/

GROUND IERMINAL

Removethe reliefvalveand the O-ring. NOTE: . Do not let the compressoroil runout. . Make sure that no foreign matter enters the system,

HOI.I'ER

PNOTECTOR

o o

RELIEF VALVE 9.8 N.m {1.0kgl.m, 7.2 tbl.lrl

O.RING Replace. Cleanthe matingsurfaces. Replacethe thermal protectorwith a new one. and apply siliconesealantto the top of the thermalprotector.

Replace the O-ringwith a new one at the reliefvalve. a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l b e f o r e installingit. NOTE: . To avoid contamination.do not returnthe oil to the containeronce dispensed,and never mix it with other refrigerantoils. o lmmediatelyafter using the oil, replacethe cap on the container,and seal it to avoid moisture absorption. . Do not spill the refrigerantoil on the vehicle;it may damagethe paint; if the refrigerantoil contactsthe paint,wash it off immediately. Installand tightenthe reliefvalve.

SILICONESEALANT

3.

Install in the reverse order of removal.

22-36

Charge the system {see page 22-461,and test its performance1se6page 22-241.

Compressor(DENSO) Replacement 1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er, u n t h e work engineat idlespeed,and let the air conditioning off engine for a few minutes,then shutthe the negativecablefrom the battery' Disconnect

7.

Loosenthe pivot bolt of the idler pulleybracketand the adjusting bolt. then remove the A,/Ccompressor beltfrom the pulleys.lf necessary,removethe mounting bolts from the left front mount. then remove the fuC compressorbelt through the gap betweenthe bodv and the left front mount.

Recoverthe refrigerantwith a recovery/recycling/ charging station lsee page 22-271

PIVOTBOLT 10x 1.25mm 4,1N.m(4.5kgt'm,33lbfft)

Removethe each bolt, then disconnectthe suction and dischargelines from the compressor'Plug or them cap the lines immediatelyafter disconnecting to avoid moistureand dust contaminatlon.

6 x '1.0mm 9.8 N.m (1.0kgf m,7.2 lbfft)

'10x 1,25mm 4,0N.m (,1.5kgf'm. 33 lbt ftl

Disconnectthe compressorclutch connector,then removethe mountingboltsandthe compressor'

COMPRESSOR

the disbut do not disconnect Removethe condenser, chargehosefrom the condenser(seepage22-441' Removethe power steeringpump belt (seesectron 17]-.

24 N.m (2.4 kgf m, 17 lbf ftl

(cont'd)

22-37

Compressor(DENSOI (cont'd) Replacement 9. Removethe bolts,the suctionservicevalveand the O-ringfrom the compressor, 2s.5N.m{2.6kgf.m.18.8tbtttl

1 0 . lf necessary,remove the compressor bracket as follows. .

Removethe nut and the washerfrom the leftfront mount.When tighteningthe nut to the left front mount, make sure the washeris set p.operlyon the leftfront mountas shown. a Removethe mountingbolts and the compressor bracket. LEFTFRONT MOUNT

12 x 1,25rnm 59 N.m 16.0kgfrm, € rbf.fi) Roplace.

WASHEB

x 1.25mm 4/r N.m {4.5 kgf.m, 33 lbt ft}

22-3A

11. Installin the reverseorder of removal,and note these rtems: lf you'reinstallinga new compressor. drainall the refrigerantoil from the removedcompressor.and m e a s u r ei t s v o l u m e . S u b t r a c tt h e v o l u m e o f drainedoil from '140ml (4 28 fl{,z, 4.9 lmpoz); the resultis the amountof oil you shoulddrainfrom the new compressor(throughthe suctionfifting). Replacethe O-ringswith new onesat eachfining, and apply a thin coat of refrigerantoil before installingthem. Be sure to use the right O,rings (R-134a) for HFC-134a to avoidleakage. Use refrigerantoil {DENSO,ND-OtL8)for HFC-134a DENSOpistontype compressorsonly. To avoid contamination,do not returnthe oil to the containeronce dispensed,and never mix it with other refrigerantoils. lmmediatelyafter using the oil, replacethe cap on the container,and seal it to avoid moisture absorption. Do not spill the refrigerantoil on the vehicle;it may damagethe paint;if the refrigerantoil contactsthe paint,wash it off immediatelv. Adjust the ly'C compressor belt (see page 22-43) and the power steeringpump belt (seesection 17). Charge the system (see page 22-46),and test its performance(see page 22-24!..

lllustratedIndex BOLT CENTER

PLATE PBESSURE Inspection, Page2240

).-

sHrM(s) SNAPRINGB Replace.

PULLEY Inspection, Page22'40

SNAPRINGA Replace.

FIELDCOIL page22 40 Inspection,

RELIEFVALVE page22'42 Replacement, SUCTIONSERVICEVALVE

22-39

Compressor(DENSOI ClutchInspection Checkthe platedpartsof the pressureplatefor colo. changes,peelingor other damage.lf there is damage,replacethe clutchset. Checkthe pulley bearing play and drag by rotating the pulleyby hand,Replacethe clutchset with a new one if it is noisyor hasexcessiveplay/drag.

Measurethe clearancebetweenthe pullev and the pressureplate all the way around.lf the clearanceis not within specifiedlimits,the pressureplatemust be removedand shim(s)addedor removedas required, followingthe procedureon page22-41. Clearanca:0.5 t 0.15mm {0.020r 0.006in} NOTE:The shims are availabtein three thicknesses: 0 . 1m m , 0 . 3m m a n d 0 . 5m m .

22-40

.

Checkresistanceof the field coil. lf resistanceis not within specifications, replacethe field coil. Fiald Coil Resistanc€:3.it to 3.8 O at 20.C l68.Fl

ClutchOverhaul 1.

Removethe centerbolt while holdingthe pressure olatewith the sPecialtool.

3.

Removethe snap ring B with snap ring pliers,then remove the pulley Be careful not to damage the pulleyand comPressor'

CENTERBOLT 13.2N.m (1.35ksl m, 9.?6 lbf'ft) SNAPRINGB Replace.

A/C CLUTCH HOLOER (Commercially available) Robinair: P/N 10204 P/NJ37872 Kent-Moore:

'.L-) .'l

5$ f-t

1 / - -l l- (l ,

vll/

Removethe pressureplate and shim(s).takingcare not to losethe shim{sl. PAESSURE PLATE

(cont'd)

22-41

Compressor(DENSO) ClutchOverhaul(cont'd) Removethe screwfrom the field coil ground terminal. Removethe snap ring A with snap ring pliers. then removethe field coil. Be carefulnot to damaoe the field coil and compressor.

ReliefValveReplacement L

Recoverthe refrigerantwith a recovery/recycling/ charging station {see page 22-27), Removethe relief valve and the O-ring. plug the opening to keep foreign matter from enteringthe systemand the compressoroilfrom runningout.

SNAPNINGA Replace.

FIELO

corL

13.2N.m 11.35kgt m,9.76lbtttl

Reassemblethe compressorclutch in the reverse orderof disassembly, and notetheserrems: o I n s t a l lt h e f i e l d c o i l w i t h t h e w i r e s i d e f a c i n g down. a Cleanthe pulleyand compressorslidingsurfaces with non-petroleum solvent. . Installnew snap rings, and make sure thev are fully seatedin the groove. . Make sure that the pulley turns smoothly after it's reassembled. . Routeand clamp the wires p.operlyor they can be damagedby pulley.

22-42

Cleanthe matingsurfaces. 4.

Replace the O-ringwith a new one at the reliefvalve. and applya thin coatof refrigerantoil beforeinstalling it. Removethe plug, and installand tighten the relief vatve. Chargethe system (see page 22-46),and test its performance (seepage 22-24),

A/G GomPressorBelt Adjustment DetlectionMethod

Tension Gauge Method

'1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflectionbetweenthe A,/Ccompressorand the crankshaftPulleY

1.

A/C CompressorBelt Used Belt: 816A2 engine 390 - 540 N (40 - 55 kgf, 88 - 120 lbll Except 816A2 engine 340 - 490 N (35 - 50 ksf, 77 - 110 lbfl engine B16A2 New Belt: ?40 - 880 N {75 - 90 ksf' 170- 200 lbf) Except Bl642 engine 690 - 830 N (70 - 85 ksf, 150- 190 lbf)

A/C ComPressorBelt Used Belt: 816A2 engine 6.0- 9.5 mm 102'l - 0.37inl Except 816A2 engine 7.5- 9.5 mm (0.30- 0.37in) engine 816A2 Belt: New 4 . 5 - 6 5 m m ( 0 . 1 8 - 0 . 2 6i n ) Except 815A2 engine 5 . 0 - 5 5 m m ( 0 . 2 0 - 0 . 2 6i n l

Notetheseitemswhen adjustingbelttension: . F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n fso r t h e belttensiongauge. . lf there are cracksor any damageevidenton the belt,rePlaceit with a new one. . "Used belt" means a belt which has been used for five minutesor more. . "New belt" means a belt which has been used for lessthan five minutes

Notetheseitemswhen adjustingbelttens'on: . 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 tor lessthan five minutes. 2.

or Loosen,the centernut ofthe idlerpulley(SANDEN), lock the and pulley bracket idler the pivot bolt of the nut ofthe adjustingbolt(DENSO).

3.

Turn the adjustingbolt to get properbelttension'

4.

5.

the centernut of the idlerpulley(SANDEN), Retighten pivot boltof the idlerpulleybracketandthe lock or the nut of the adjustingbolt(DENSO). Recheckthe deflectionof the A,/Ccompressorbelt'

Attachthe specialtool to the IVCcompressorbelt as shown below,and measurethe tensionof the belt

2

or Loosenthe centernut of the idlerpulley(SANDEN)' the pivot bolt of the idler pulleybracketand the lock nut of the adjustingbolt(DENSO).

3.

Turn the adjustingbolt to get properbelttension

4.

5.

the centernut of the idlerpulley(SANDEN), Retighten or the pivot bolt of the idler pulleybracketand the lock nut of the adjustingbolt(DENSO) Recheckthe tensionof the A/Ccompressorbelt'

22-43

Condenser Replacement 1 . Recoverthe refrigerantwith a recovery/recycling/ charging station lsee page 22-271.

4.

Removethe bolt from the suctionhose bracket,and removethe two bolts and the upper mount bracket. Removethe condenserassemblyby liftingit up.

Disconnectthe condenserfan connectorfrom the Ay'Cwire harness,then remove the A,/Cwire harness from the condenserfan shroud.

NOTE:Be carefulnot to damagethe condenserfins when removingthe condenserassembly. UPPER MOUNTBRACKET 6x1.0mm 9,8 N.m 11.0kg{.m,7.2lbtft} 6x1.0mm 9.8 N.m 11.0kst m, 7.2 lbf.ftl

Remove the bolts, then disconnectthe discharge and condenserlinesfrom the condenser. 5. NOTE:Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust contamination, 6x1.0mm

olscHARGE L|NE 9.8N.m11.0

6r1.0 9.8 N.m 11.0kgl.m, 7.2 lbf.ftl

22-44

Install in the reverseorder of removal. Make note of the followingitems. .

lf you're installinga new condenser, add refriger, P - 1 0o r D E N S O ,N D - O | L8 ) a n t o i l ( S A N D E NS \see page 22-22l.. Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l befo.einstallingthem. NOTE;Be sure to use the right O-ringsfor HFC, 134a(R-134a) to avoid leakage. o B e c a r e f u l n o t t o d a m a g et h e c o n d e n s e rf i n s when installingthe condenserassembly. . Charge the system (see page 22-46),and test its performance(see page22-24i.

A/C System Service Evacuation Useonly serviceequipmentthat is U L.-listedand is certified to meet the requirementsoJ SAEJ2210to remove (R-134a) from the air conditionersystem' HFC-134a

g/Chal9ing Station R6covory/Recyclin

CAUTION: Exposure to air conditioner reftig€lant and lubricantvapor or misi can irrhaie eyes. noso and throat' Avoid breathing the ail condhioner lefrigelant and lubri cant vapor or mist. lf accidentalsystem dischargeoccurs,ventilate work areabeforeresumingservace. R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak tested with air. comDressed some mixtures of air and R-13'[8haYoboon !!@@ ffiiE-n to be "ombustible at elovatodpressurcsand can result in fire or explosion causing iniury or propsrtY damag€. Never uso complsssod air to pre3surs tost R1344 ssrvico equipment or vehicle air conditioner sy3tems, Additional health and safety information may be obtained from the refrigerantand lubricantmanuJacturers' 1 . When an A,/CSystemhas beenopenedto the atmosphere,such as during installationor repair,it must be evacuatedusing a R-134arefrigerantrecovery/ station.(lf the system has been recycling/charging should be open for severaldays,the receiver/dryer for evacuated be should system replaced,and the severalhours.) Connect a R-134a refrigerant recovery/ stationto the vehicle,as shown' recycling/charging e q u i p m e n tm a n u f a c t u r e r 'isn s t r u c t h e following trons. NOTE: lf low pressuredoes not reachmore than 93 3 kPa (7OOmmHg,27.6 in.Hgl in 15 minutes,there is probablya leak in the system Partiallychargethe system,and checkfor leaks(seeLeakTest)

22-45'

A/C System Service Charging

LeakTest

Use only serviceequipmentthat is U.L.-listed and is certified to meet the requirementsof SAE J2210to remove (R-134a) HFC-134a from the air conditionersystem.

Use only serviceequipmentthat is U.L,-listed and is certified to meet the requirementsof SAEJ2210to remove (R-134a) HFC-134a from the air conditionersystem.

CAUTION: Exposure to air conditioner refrigerant and lubricant vapor or mist can irritale eyes, nose and throat. Avoid breathing the air conditioner retrigerant and lubricant vaoor or mist,

CAUTION: Exposure io air conditioner refrigerant and lubricant vapot or mist can itritats eyes,no36and thtoat. Avoid breathing the air conditioner refrigeranl and lubricant vapor or mist,

lf accidentalsystem dischargeoccurs,ventilate work a r e a b e f o r er e s u m i n gs e r v i c e ,A d d i t i o n a lh e a l t ha n d safetyinformationmay be obtainedfrom the refrigerant and lubricantmanufacturers.

lf accidentalsystem dischargeoccurs,ventilate work areabetoreresumingservice.

Refrigerantcapacityt 600- 650 g 121.1- 22.9 ozl CAUnON: Do not overcharg€ the system; the comprcssor will be damaged.

R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretestedor leaktestedwith comoressedair.

Connect a R-134arefrigerant recovery/recycling/charging stationto the vehicle,as shown,followingthe equipment manufacturer'sinstructions.

some mixtures of air and R-134a have @ been shown to be combugtibls at elevatgd prossures and can result in tire or explosion causing iniuly or plopgrty damage.Nev€r usc compre33odair to pressure test R-13'laservica oquipment or yohiclo air conditionor systems.

Recovery/Recycling/Charging Station

Additional health and safetyinformation may be obtained from the refrigerantand lubricantmanufacturers. 1.

Connect a R-134arefrigerant recoverylrecycling/ chargingstationto the vehicle,as shown in the previous column,followingthe equipmentmanufacturer's instructions. NOTE;Be sure to installthe same amount of new refrigerantoil back into the A,/Csystem before chargIn9. Open the high-pressure valveto chargethe system t o t h e s p e c i f i e dc a p a c i t y ,t h e n c l o s e t h e s u p p l y valve,and removethe chargingsystemcouplers. Rofrigerantcapacity:600 - 650 g (21.1- 22.9 oz) Checkthe system for leaks using a R-134arefrigerant leak detectorwith an accuracyof 14 9 10.5ozl per yea. or better. lf you find leaksthat requirethe systemto be opened (to repair or replacehoses.fittings. etc.),recoverthe system accordingto the RecoveryProcedureon page 22-27. After checkingand repairing leaks.the system must be evacuated(seeSystemEvacuationon page22-451.

22-46

l'f . Electrical ....................23-89 . , . . . . . . . . . . . . . . . . . . . . , 2 3 - *2t g n i t i o nS w i t c h S p e c i aTl o o f s .......,.... 23-102 l g n i t i o n S y s t e m Troubleshooting * l n t e g r a t e d . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3 . .-.1. .5. .6. . . . U n i t C o n t r o l . 2 3 3 . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . P r e c a u t i o n s T i p sa n d . . , ,23-144 ,........ fnterlockSystem . . 23-5 ......... Five-stepTroubleshooting.............. 23-161 . . . .. ......... LightingSystem ..........,23-5 w i r e c o l o rc o d e s Lights, Exterior . 3-6 S c h e m a t iS c y m b o l s. . . . . . . . , . . . . . . . . . . . ..............2 ..'............23'171 Back-upLights Relayand ControlUnit Locations 23'174 .................. Lights Brake .. . 23'7 ... ...,..................... EngineCompartment 23'166 . . . . . . . . . . . . . . . . . . . . . . 2 3 - 8 DaytimeBunningLights(Canadal............... Dashboard F r o n tP a r k i n gL i g h t s. . . . . . , . . . . . . . . . . '... . . . . . . . .2. 3. - 1 6 7 . . . . . . . . .2 3 - 1 2 Dashboard/Door *Airbags................. l i g h t s. . . . . . . . ... . . . . . . . . .....,.. 2 3 - 1 6 7 F r o n tT u r nS i g n a L .......Section24 .....23'167 ....".'....-... Headtights 21 ......... Section Air Conditioning . . . . . . . . . . . . . . . . . . . ...23'179 B r a k e L i g h t M o u n t H i g h " " " 2 3 1 1 2 . . . . . . . . . . . " " " Aftelnator ......23'176 LicensePlateLights Section19 Anti-lockBrakeSystem{ABS) .......23'171 *A/T GearPositionIndicator.....................,. T a i t f i g h t .s. . . . . . . . . . . . . . . .......23-149 . 23-142 ..-.......,, lnterior Lights Svstem ..... .......Section14 AutomaticTransmission . . , . . . . . . . . . . . . . . . . .2, .3. -. .2. 3. .5. M o o n r o o f . . . . . . . . . . . . . 2 3 9 1 . . . . . . B a t t e r v. . . . . . . . ........ . .23-61 PowerDistribution .. . ... Section2l Blowercontrols .......,,,..23'251 ....'...........23'112 PowerDoor Locks ChargingSystem ,..............,.,...23'206 Mirrors Power Connectorldentilicationand Wire Harness ......23'13 ........ ....... . .. 23-86 R o u t i n g. . . . . . . . . . . . . . . . . . PowerRelays ............,........23-240PowerWindows ............,,....23-220 CruiseControl .......23-180 . . ... . . 23-2OO DashLightsBrightnessController............. RearWindow Defogger.......................... 23'126 "" . . . . . .. . . . . . . . . . . . 2 3 - 1 1 1 Fan controfs S p a r kP l u g s . . . . . . . . . . . . . s. .e c t i o n1 1 ................23-93 F u e lP u m D S l a r t i n gS y s t e m *stereo SoundSvstem ,................. ...............,.2 . ,3, .' .6 2 ........ . ... ,.,.,,23'147 Fuses/Refay 'Supplemental Restraint System (SRS)... . Section 24 Section11 PGM-FIControlSystem......................,....... *Gauges 23-173 FlasherSystem .......'.'....-... Turn Signal/Hazard . . . . , . , . . . . . . . 2 3 - 1 3*Undel-dash 1 23-85 Box ............,.................. C i r c u iD t iagram Fuse/Relay . . . . . . . . . . . ' . ' . . . . . . . 2 3 - 1 4vehicfe 2 """" ""' 23-140 F u e fG a u g e soeed sensor (VSSI .. . .. 23-129 +Wipers/Washers .........,.,.,...23-214 Gauge/lndicator .. . 23-75 GroundDistribution .. . .....Section21 Heateicontrols *Horn................. . . . . . . . . . . . . . . . 2 3 - 1 9NOTE: 6 Unlessotherwisespecified,referencesto auto(Mf) in this sectionincludethe CVT. matictransmission

SpecialTools

Tool Number

Ref. No.

Description

Oty

V a c u u mP u m pG a u g e0, - 3 0 i n . H g . B e l tT e n s i o nG a u g e @Test Harness FuelSenderWrench @ SCSServiceConnector KeylessEntryChecker tol ': Included i n B e l tT e n s i o nG a u g eS e t0 7 T 6 6- 0 0 1 0 0 0 4

O)

o o

A 9 7 3 X _ 0 4 1_ X X X X X 07JGG 00l0l0A OTLAJ- PT3O2OA 07NAC- SR20100 07PM - 0010r00 07MAJ- SP00300

or

(!

23- 2

1 1 'I 1 1 1

/4,

PageReference 23-245 23-140,141 23-142 23-105 23-264

Troubleshooting

ll.

Tips and Precautions N e v e rt r y t o d i s c o n n e c ct o n n e c t o r sb y p u l l i n g o n their wires;pull on the connectorhalvesinstead Alwavs reinstallplasticcovers.

Before Troubleshooting . Checkapplicablefuses in the appropriatefuse/relay box. . Checkthe batteryfor damage,state of charge,and cleanand tight connections. . Checkthe alternatorbelttension. CAUTION: . Do not quick-chargea battery unless the battery ground cable has been disconneqted,otherwise you will damage the alternator diodes. . Do not attempt to crank the engine with the battery ground cable loosely connecled or you will severely damagethe wiling,

Beforeconnectangconnectors,make sure the termlnalsare in placeand not bent.

Handling Connectois . Makesurethe connectorsare cleanand haveno loose wire terminals. . Makesure multiplecavityconnectorsare packedwith grease(exceptwatertightconnectors) . All connectorshavepush-downreleasetype locks.

LOCKINGTAB

. Some connectorshave a clip on their side used to attach them to a mount bracketon the body or on anothercomponent.This clip has a pulltype lock. Some mounted connectorscannot be disconnected unlessyou first releasethe lock and removethe connectorfrom its mount bracket.

Checkfor looseretainerand rubberseals.

RETAINER

T h e b a c k s o f s o m e c o n n e c t o r sa r e p a c k e d w i t h lf the greaseis congrease.Add greaseif necessary. taminated,replaceit.

LOCKING PAWL ON OTHER Pullto HALF OF drsengage CONNECTOR

BRACKET

(cont'd)

23-3

Troubleshooting Tips and Precautions(cont'dl Insertthe connectorall the way and make sure it is securelvlocked. Positionwires so that the open end of the coverfaces down.

V

.

NOT GOOO

F6c6 op€n end

Handling Wires and Harnosscs . Securewires and wire harnessesto the frame with their respectivewire ties at the designatedlocations, . Removeclipscarefully;don't damagetheir locks.

Slip pliers under the clip base and through the hole at an angle,then squeezethe expansiontabs to releasethe clrp.

Seatgrommetsin their groovesproperly.

l l

i l , /

il

,,

_ s*' Y - - _ Y 5-.1}8."/ \

Testing and Repairs o Do not usewires or harnesseswith brokeninsulation. Replacethem or repairthem by wrspping the break with electricaltaoe. . After installing parts, make sure that no wires are pinchedunderthem. . W h e n u s i n g e l e c t r i c a tl e s t e q u i p m e n t ,f o l l o w t h e manufacturer'sinstructionsand those describedin t h i sm a n u a l . . lf possible,insert the probe of the tester from the wire side (exceptwaterproof connector).

.

Use a probewith a taperedtip.

SNAP-BINGPLIERS

After installingharnessclips, make sure the harness doesn'tinterferewith any moving pans. Keep wire harnessesaway from exhaust pipes and other hot parts. from sharp edges of bracketsand holes,and from exDosedscrewsand bolts.

23-4

Referto the instructionsin the HondaTerminalKit for identificationand replacementof connectorterminats.

t

Five-stepTroubleshooting 1.

V e r i f yT h e C o m p l a i n t Turn on all the componentsin the problemcircuitto verifythe customercomplaint.Note the symptoms. Do not begin disassemblyor testinguntil you have narroweddown the problemarea.

2.

AnalyzeThe Schematic L o o k u p t h e s c h e m a t i cf o r t h e p r o b l e mc i r c u i t . Determinehow the circuit is supposedto work by tracing the current pathsfrom the power feed throughthe circuitcomponentsto ground.lf several circuitsfail at the sametime, the fuse or ground is a likelycause. Basedon the symptomsand your understandingof the circultoperation,identifyone or more possible causesof the problem.

3.

lsolateThe ProblemBy TestingThe Circuit Makecircuitteststo checkthe diagnosisyou made in step 2. Keepin mind that a logical,simple proceTestfor dure is the key to efficienttroubleshooting. make first. Try to the most likely cause of failure points accessible. that are easily at tests

Wire ColorCodes T h e f o l l o w i n ga b b r e v i a t i o nasr e u s e dt o i d e n t i f yw i r e colorsin the circuitschematics: w H T . . . . . . . . . . . . . . . . . . . .W . . .h. i.t.e. . . Y E L. . . . . . . . . . . . . . . . . . . . . Y . .e . .l.l.o. w ... BLK............,.,...............81ack B L U . . . . . . . . . . . . . . . . . . . . .B. .l.u. e ..... GRN.............................Green R E D. . . . . . . . . . . . . . . . . . . . .R. .e, .d. . . . . . . r. .a. n. .g. .e O R N . . . . . . . . . . . . . . . . . . . .O P N K. . . . . . . . . . . . . . . . . . . . .P. .i.n. k. . . . . B R N. . . . . . . . . . . . . . . . . . . . .B. .r.o. .w. .n. . . .r.a. .y. . . . 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 . reen T h e w i r e i n s u l a t i o nh a s o n e c o l o r o r o n e c o l o r w i t h anothercolor stripe.The secondcolor is the stripe.

WHT/BLK

FixThe Problem , a k et h e O n c et h e s p e c i f i cp r o b l e mi s i d e n t i f i e dm proceproper and safe use tools Be sure to repair. dures. MakeSureThe CircuitWorks Turn on all componentsin the repairedcircuitin all modes to make sure you've fixed the entire probl e m . l f t h e p r o b l e mw a s a b l o w n f u s e , b e s u r e t o test all of the circuitson the fuse,Makesure no new problemsturn up and the originalproblemdoes not recur.

23-5

Troubleshooting SchematicSymbols BATTERY

E @ RESISTOR

I

f

II

II

_d :

_.. '-

ilHc

VARIAELE RESISTOR

MOTOR

PUMP

THERMISTOR

CIRCUIT BREAKER

I

0 H Y II rYr

T

ANTt:f\,NA

TRANSISTORlTrl

Mast

RELAY lln no fmal poaitionl Normallyopon relay Normally closed relay

| ....--1 'rl*r

t

t"t^fi l

FUSE

GROU N D GroLrndterminal Componentground

ffl - + - |

l r l l r l

fff

CONDENSER

I T

--cn-.e

COIL,SOLENOID CIGARETTELIGHTER

r{r

tql '|

BULB

IGNITIONSWITCH

-fo

+ + + o.t-

HORN

DIODE

SWITCH (ln nirrdal positionl Normally open Normally closed

I

/F\ ttL I

\Y/ I

:CTION CONNT Input Output

V

J I

'*i."n

@ I CONNECTOR

A

lrl

P

HEATEB

A t-l

F SPEAKER,BUZZER

D

LIGHTEMITTING DIODEILEDI

A+, T T REEDSWITCH

A

*>'l!

tftl

Y

Relayand Control Unit Locations EngineCompartment

ELDUNIT UNDER.HOOD BOX FUSE/RELAY

t:

tr tr

I

I l

I

t l

u

I

FAN CONDENSER RELAY ABS UNDER.HOOD BOX FUSE/RELAY

MOTOR RELAY

RADIATOR A/C COMPRESSOR FAN RELAY CLUTCHRELAY

23-7

Relayand ControlUnit Locations '96- 97 models Dashboard:

CRUISECONINOLUNIT DAYTIME RUNNINGLIG}ITS CONTROLUNIT lCan!dal

DASHLIGHTSBRIGHTNESS CONTROLLER {Hasbuilt-incontrolunit)

GRN/RED,l IWirecolo.s:GRN/ORN, IWHT,YEL,andBLK I . MOONROOF CLOSE RELAY Cnru/VeLl fwir. colorc:GRN/ORru, andALK I IWHT.GRN/RED,

23-8

D

UNDER.OASH FUSE/RELAYBOX

INTEGRATED CONTROLUNIT

HORNRELAY

WXf/Cnru,l I Wirecolors:WHT/GRttt, ,J [GRY,andBLU/RED

tP"tat{}r)

(}t

F;;snHn-nnn"nf-H-n !r rr rr rr r,r Lr Ll u u l,r F Fnnnnnnnrrrr-1 F rr rr rJ LJ rJ r-r t-r L-rLJLr ||J

' g / tt - - - - - - , )

o

POWERWINDOWRELAY

u_::;_:_:_:_:_l_;I::

INTERLOCK CONTROLUNIT

*TCM (CVT)

*: Coupe

23-9

Relayand Control Unit Locations Dashboard:'98 - 00 models

CRUISECONTROLUNIT DAYTIME RUNNINGLIGIfiS CONTROLUNIT lCrnrda)

DASHLIGHTSBRIGHTNESS CONTROLLER {Hasbuilt-incontrolunit}

CUI RELAY STARTEB

exnfxf, I [wi]ecolor.:BLX/WHT, j |nd BLK/RED IBLU/BLK,

coloE: WHT/GRN,BLU/REO,I andWHT/GRN I

MOONROOFCLOSERELAY

CnrulYel,l fwiro colors:GRN/O8ru. endBLK I IWHT,GBN/RED,

23-10

O

REARWINDOW

DEFOGGEB

UNDER.OASH BOX FUSE/NELAY

WINDOWRELAY POWER

oF-

-=----rr

Jl

r

c

CONTROLUNIT INTERLOCK

. TCM (CVT):Coupe '99 model {USAI . KEYLESSDOORLOCKCONTROLUNIT:

23-11

Relayand Gontrol Unit Locations Dashboard/Door

AUOIOUNIT (Hasbuilt-inkeylessreceivercircuit) POWERDOORLOCI( CONTROLUNIT

ABS CONTROLUNIT

23-12

Connectorldentificationand Wire HarnessRouting D How to ldentify Connectors: "C" for connectors, ldentificationnumbershave been assignedto all connectors.The number is precededby the letter "G" for groundterminalsor "T" for non-groundterminals. Location Harness

EngineCompartment

Startercables

T 1 ,T 2 a n d@

Batterygroundcable

G 1 a n dO

EnginegroundcableA

T3 G2

E n g i n eg r o u n dc a b l eB

T4

Under-hoodABS fuse/relaybox wire harness(WithABS)

t5 ano (9

Enginewire harness

C l 0 1t h r u C 1 4 7 T 1 0 1a n dT 1 0 2 G101

Enginecompartmenlwareharness

C201thru C215 G201and G202

Main wire harness

C301thru C310 C351thru C361

Dashboard

Others {Floor,Door, Trunk/Hatch, and Rootl

C401thru C452 G401and G402

Dashboardwire harness

C501thru C520 G501

FIoorwire harness

C551thru C573 G551and G552

Rearwire harness

C601thru C62l G601and G602

Driver'sdoor wire harness

C631thru C640

door wire harness Passenger's Left reardoor wire harness(Sedan)

C651thru C657

Rightreardoor wire harness(Sedan) Roofwire harness(Withoutmoonroof)

C671thru C674

Moonroofwire harness{Withmoonroof)

C 7 l ' lt h r uC 7 1 9

C661thru C664 C701thru C719

A Heatersub-harness

C721thru C729

B Heatersub-harness

C741 thtu C744

Ay'Cwire harness

C751thru C754 G751

Hatchwire harness(Hatchback)

C761thru C768

Rearwindow defoggergrgundwire

c771 G171

Secondaryheatedorygen sensorsubnarness

C781and C782

Fueltankpressuresensorsub-harness

C791thru C793

SRSmain harness

C801thru C807 G801

Rear window defogger wire

C831thru C833

Connectorldentificationand Wire HarnessRouting

Starter Cables Connectoror Terminal

Number of Cavities

T,I

r2

Localion

Connec{sto

Rightsideof enginecompartment Rightsideof enginecompartment

Under-hoodfuse/relaybox Startermotor

Battery

Batterypositiveterminal

Notes

Battery Ground Cable Connectoror Terminal

Number of Cavities

o

Location

Conn€ctsto

Rightfront shocktower

Bodyground,via batteryground caDte

Baftery

Batterynegativeterminal

Notos

EngineGroundCableA Conn€qtoror Terminal

Number ot Cavitios

Location

Connectsto

T3

Leftside of engine

Powersteeringpump bracket

G2

Leftsideof enginecompartment

Body ground,via engineground cableA

Noles

EngineGroundCableB Connectoror Terminal

Number of Cavities

T4

Location

Conneclsto

Rightside of enginecompartment

Transmission

Rightsideof front frame

Bodyground,via engineground cableB

Noles

Under-hoodABS Fusa/RelayBox Wire Harness Connectoror Tgrminal

Number oI Cavities

Location

Conneqtsto

T5

Rightside of enginecompartment

Under-hoodfuse/relaybox

@

Banery

Batterypositiveterminal

Notes

A/C Wire Harness Connectoror Terminal

c753 c754

23-14

Number of Cavities

1 2

Location

Connectsto

Rightsideof enginecompartment Rightside of enginecompartment Rightside of enginecompartment Rightside of enginecompartment

Enginecompartmentwire harness (c209) Compressorclutch Condenserfan motor A,/Cpressureswitch

Leftsideof enginecompartment

Bodyground,via A,/Cwire harness

Notes

d

STARTER CABLES

BATTERY GROUND CABLE UNDER-HOOO ABS FUSE,/RELAY BOXWIRE HARNESS

GROUND CABLEB A/C WIRE HARNESS

23-15

Connectorldentificationand Wire HarnessRouting EngineWire HarnesslD16Y5,D16Y8enginss):'96 - 98 models Connectoror Torminal

Numbsr of Cavitiss

c1 0 1 c102 c103 c104 c104 c105 c106 c107 c108 c 109 c110 c111 c112 c113 c114 c115 c116 cl17 c118 c119 c120 cl21

10

c122 c123 cl23 c124 c125 c127 c12A c129 c130 c131 c132 c 133 c134 c135 c136

c138 c139 c140 c141 c142 c1 4 3 c144 cl44 c145 c'146 cl47

Left side of engine compartment Middle of engine Middle of engine Left side of enginecompanment Left side of enginecompartment Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine fvliddleof engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Left side of engine compartment Middle of engine Middle of engine Middle of engine Middle of engine

Connectsto

14

Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Middle of engine Right side of engine companment Behind right kick panel Under right side of dash Under riOhtside of dash Under right side of dash Under right side of dash Under right side of dash Under right side of dash

Mainwire harness(C303) Crankshaft speedfluctuation(CKF)sensor Engineoil pressure switch Alternator Alternator No. 'l fuel injector No. 2 fuel injector No.3 fuelinjector No.4 fuel injector IACvalve Throttleposition(TP)sensor l\4anifold absolutepressure(MAP)sensor Intakeair temperature(lAT)sensor Powersteeringpressure{PSPIswitch EVAPpurgecontrolsolenoidvalve Junctionconnector Junctionconn€ctor Vehiclespeedsensor{VSS} Countershaftspeedsensor Enginecoolanttemp€rature(ECT)switchA Distributor Enginecoolanttemperature(ECT)sending unrt (ECT)sensor Enginecoolanttemperature PrimaryHO2S(sensor'l) PrimaryHO2S(sensor1) Back-up lightswitch Lock-up controlsolenoidvalve Secondary HO2S(sensor2) Mainshaftspeedsensor Linearsolgnoidvalve Shift controlsolsnoidvalve Startersolenoid Junctionconnector (C446) Mainwire harnesE ECM/PCM PCM ECMiPCM ECM/PCM Mainwire harness(C305)

14

Under right side of dash

Mainwire harness(C305)

Under right side of dash

Mainwire harness(C305)

Middle of engine Middle ot engine l iddle of engine Middle of engine Middle of ongine Middle of engine Left side of enginecompartment Middle of engine Middle of engine Rightside of enginecompartment Rightside of enginecompartment Right side of engine compartment Left side of engine companment Rightside of enginecompanment Middle of engine

Knocksensor(KS) IACvalve VTECsolenoidvalve VTECpressureswitch EVAPcontrolcanister ventshutvalve EGRcontrolsolenoidvalve gearshaftspeedsensor Secondary EGRvalve EGRvalve Drivepulleyspeedsensor Solenoidconnector {CVT) Drivenpulleyspeedsensor Alternator Under-hoodfuse/relaybox

1 2 2

14 l4 3 2 2 l0 I 2

2 2 2 1 20

3l

2 2 1 2 2 2

2 2

T101 r102 G1 0 1 *1: Dl6Y5 engine *2: D16Y8engine *3: D16Y5(Ay'T), D16Y8engines

23 - 1 6

Location

Engineground, via engine wire harness

Not€s

USA Canada

Afi

USA

-' (A/r)

*, (M/T) M/T *" INT\

*, tAtf) NT: '96model *,(A,/T): '97- 98 mooets moqets M/T

-1 (l,/T)

*, (A,/T) -,(4,/T) *1{M/T) *, (A,/T) *1 (CW)

*, (A,T)

t '96 - 98 models:

c138 c109 c110

c113 T101

c141 r102 c1 c'I43 cl17 c144 c110 c118 c139 c120 c129 c146

ENGINEWIRE HARNESS

cll5 c116 c13? cr02

c145 c105 c106

23-17

Gonnectorldentificationand Wire HarnessRouting EngineWire Harness(D16Y5,Dl6Yg engines):,99- 00 models Connectot or Terminal c'101 cl02 c103 c104 c 104 c10s c107 c 108 c'r09 c110 c111 cl12 c113 cl14 cl15 c116 cl17 c118 c119 c120 cl20 c121 c122 c123 c123 cl23 cl24 c124 c125 c127 c12A c129 c 130 c131 cl32 c133 c 134 c135 c137 c138 c 139 c 140 c142 c143 c144 cl44 c145 c146 c147 T101 T102

Number ot Cavities 10 3 ,] 3 2 2 2 2 3 3 3 2 2 2 14 14 3 2 2 '10 8 ,l 2 4 8 4 2 2 4 2 2 2 1 20 32

2 2 1 2 2 2 3 2 8 2

G1 0 1

* 1 :0 1 6 Y 5engine *2: D16Y8engine * 3 :D l 6 Y 5(CW), D16Y8engines

23-14

Location Left side ot engine compartment lvliddleof engine M i d d l eo f e n g i n e Left side ot engine compartment Left side of enginecompartment Middle of engine Middle ot engine Middle of engine M i d d l eo f e n g i n e Middle oI engine Middle of engine M i d d l eo f e n g i n e M i d d l eo f e n g i n e Middle of engine Nliddleof engine Middle of engine Middle of engine Middle of engine Right side of enginecompartment Middle of engine Middle of engine N4iddleof engine Middle of engine Middle of engine Middle ot engine Middle ot engine Middlo of engine Middle of engine Middle ot engine lrliddleof engine Middle of engine Middle oI engine Middle ot engine Rightsideof enginecompartmenl Behind right kick panel Under right side of dash Behind right kick panel Behind right kick panel Behind righr kick panel Behind right kick panel Middle ot engine [,liddleof engine N4iddleof engine Middle of engine Middle oI engine Left side of engine compartment Middle of engine Middle of engine Rightside ol enginecompartment Rightsideof enginecompanment Rightsideof enginecompartment Left side of enginecompanment Rightside ot enginecompanment

Middleof englne

Conn€ctsto

Notes

Main wire harness1C303) Crankshaftspeed fluctuation (CKF)sensor Engineoil pressureswitch Alternator Alternator

No. 1 luel injector No.2 fuelinjector N o . 3f u e li n j e c t o r No.4 fuelinjector IACvalve ThrottlepositionlTP)sensor Manifoldabsolutepressure{MAP)sensor (lAT)sensor Intakeair temperature Powersteeringpressure(PSP)switch EVAPpurgecontrolsolenoidvalve Junctionconnector JUnct|OnCOnnector VehiclespeedsensorlVSS) Countershaftspeedsensor Engine coolant temperature {ECT}switch A Distributor Distributor Enginecoolanttemperature(ECT)sending unit Enginecoolant temperature(ECT)sensor PrimaryH02S (sensor1) PrimaryHO2S(sensor1) PrimaryHO2Slsensor 1) Back-uplight switch Lock'!p control solenoidvalve Secondary HO2S (sensor 2) Mainshaft speed sensor Linearsolenoidvalve Shift control solenoidvalve Starter solenoid Junctionconnector Main wire harness(C446) ECM/PCM ECM/PCM ECM/PCM

USA Canada I ] i I an I I

USA

]

*' (A/TI

*1 (CVT) *, (M/T) Mfi a (A/Tl " (A,/T)

., (4,/r) -' {AlrJ *1 (M/T)

PCtvt (KS) Knock sensor IAC valve VTECsolenoidvalve VTEC pressure switch EGRcontrol solenoidvalve Secondarygear shaft speedsensor EGRvalve EGRvalve Drive pulley speedsensor Solenoidconnector(CVT) Driven pulley speedsensor Alternator Under'hoodfuse/relaybox I Engineground,via engine wire harness

tvliT *1 (CVT)

*, (cvT) *' (cw) *1 (MiT) *1 {CVT) *1 {CVT)

*, (cvr)

D '99 - 00 models:

c132 c133 c134 c135

c130

c123 c119 cl' l1 c112

c138

c113

c117 T102 Cli(l

c117 WIRE HARNESS

c1+l c1{{)

ct15 ct18

cl16

c139

c137

c120

c102

c129 Clir6 c1a5

c126

C121 c125 C123 c122 C121

23-19

Gonnectorldentificationand Wire HarnessRouting EngineWire Harness{D16Y7engine}:'96 model Conneclor or Terminal

Number ot Cavhies

c101 c102

10

Leftsideof enginecompartment Middleof engine

c 103 c104 c104 c105 c'r06 c107 c 108 c 109 c110 c111 c112 cl13 c't14

1 4

Middleof engine Leftside of enginecompartment Leftside of enginecompartment Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Leftside of enginecompartment Middleof engine Middleof engine

L t t S

5

'14

cl16 cl17 c118 cl19

14

c120 c121

10 1 ,,

c123 c124 c124 c125 c126 c't27 c12a c129 c130 c131 c132 c133 c134 c135 T101 T102 G101

23-20

2

2

1 22

31 16

Location

Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Rightsideof enginecompartment Behindright kickpanel Underright sideof dash Underright side of dash Underright sideof dash Underright sideof dash Underright side of dash

Connectsto

Notes

Main wire harness(C303) Crankshaft speedfluctuation(CKF) sensor Engineoil pressureswitch Alternator USA Alternator Canada No. 1 fuel injector I No. 2 fuel injector No. 3 fuel injector I No,4 fuel injector IACvalve l Throttleposition(TP)sensor I Manifoldabsolutepressure(MAP)sensor Intakeai. temperature(lAT)sensor ] Powersteeringpressure(PSP)switch I USA EVAPpurgecontrolsolenoidvalve I Junctionconnector Junctionconnector I Vehiclespeed sensor (VSS) | Countershaftspeed sensor AlT Enginecoolanttemperature(ECT) I switch A Distributor Enginecoolanttemperature(ECT) sendingunit EnginecoolanttemperaturelECT)sensor PrimaryH02S (sensor1) Back-uplight switch M/T Lock-upcontrolsolenoidvalve AtJ SecondaryHO2S(sensor2) Mainshaftspeedsensor Linearsolenoidvalve Shiftcontrolsolenoidvalve Afi Stanersolenoid JunctionConnector Main wire harness{C446) ECM/PCM PCM ECM/PCM ECM/PCM

Leftside of enginecompartment Alternator Rightside of enginecompartment Under-hoodfuse/relaybox Middleof engine Engineground,via enginewire harness

! '96 model:

ENGINEWIREHARNESS C135

C13,1

T102

c r1 7 cl19 c120 cl18 c129

c105 c106 c'107 c103

i',zzct2'

c108

23-21

Connectorldentificationand Wire HarnessRouting EngineWire Harness{Dt6Y7enginel:'97 - 9g models Connectot or Terminal

Number of Csvities

c101 c102

10

c103 c104 c104 c105 c106 c107 c 108 c109 cl10 clll c112 cl13 cl14 c115 c 1l 6 c117 c118 cl 19

1

Location

Connectsto

Notes

T101 r102

Leftsideof enginecompartment Main wire harness(C303) M i d d l eo f e n g i n e Crankshaft speedfluctuation(CKF) sensor Middleof engine Engineoil pressureswitch Leftside of enginecompartment Alte|'nator USA Leftsideof enginecompartment Alternator Canada Middleof engine No. l fuel injector Middleof engine No.2 fuel injector Middleof engine No. 3 fuel injector I M i d d l eo f e n g i n e No. 4 fuel injector Middleof engine IACvalve ] Middleof engine Throttleposition(TP)sensor I Middleof engine Manifoldabsolutepressure(MAP)sensor Middleof engine Intakeair temperature(lAT)sensor ] Middleof engine Powersteeringpressure(PSp)switch I USA Middleof engine EVAPpurgecontrolsolenoidvalve Middleof engine Junctionconnector I Middleof engine Junctionconnector I Leftside of enginecompartment Vehiclespeedsensor(VSS) Middleof engine Countershaftspeed sensor I en Middleof engine Enginecoolanttemperature(ECTI switch A Middleof engine Distributor Middleof engine Enginecoolanttemperature(ECT) sendingunit Middleof engine Enginecoolanttemperature(ECT)sensor Middleof engine PrimaryHO2S(sensor1) Middleof engine Back-uplight switch Mtr Middleof engine Lock-upcontrolsolenoidvalve Middleof engine SecondaryH02S (sensor2) Middleof engine Mainshaftspeedsensor Middleof engine Linearsolenoidvalve Middleof engine Shiftcontrolsolenoidvalve AIT Rightsideof enginecompartment Stanersolenoid Behindright kickpanel Junctionconnector Underright sideof dash Main wire harness(C446) Underright sideof dash ECM/PCM Underright side of dash PcM I Arr Underright sideof dash ECM/PCM Underright sideof dash ECM/PCM Leftsideof enginecompartment Main wire harness{C305) | Aft Middleof engine EVAPcontrolcanistervent shutvalve Leftsideof enginecompartment Alternator Rightsideof enginecompanment Under-hoodfuse/relaybox

G1 0 1

Middle of engine

2

cl20 c121

10

c122 c123 cl24 c124 c125 c126 c127 c128 c129 c 130 c131 c132

2

I

2

'>

4

t

20

c134 c135

3r

cl41

2

2 3- 22

Engine ground, via engine wire harness

D '97 - 98 models:

WIREHARNESS

23-23

Connectorldentificationand Wire HarnessRouting EngineWire Harness(D15Y?engine):,99- OOmodels

c101 c102

10 3

cl03 c't04 c 104 c105 cr06

'I 3

0107

?

c108 c109 c ' t1 0 c 1 1r c112 c113 c114 c115 c116 c117 cl18 c119

2

c120 c121 c122 c123 c124 c124 c125 c127 c128 c129 c 130 c131 c134 c135

3 ?

2

14 14 3

2 8 1

Leftsideof enginecompartment Main wire harness(C303) Middleof engine Crankshaft speedfluctuation(CKF) sensor fvliddleof engine Engineoil pressureswitch Leftsideof enginecompartment Alternator Leftside of enginecompanment AlternatOr Middleof engine No. l fuel injector M i d d l eo f e n g i n e No.2 fuel injector

Middlr olsngins

M i d d l eo f e n g i n e Middleof engine Middleof engine M i d d l eo f e n g i n e M i d d l eo f e n g i n e M i d d l eo f e n g i n e Middleof engine Middleof engine Middleof engine Middleof engine Rightsideof enginecompartment Middleof engine

No.I fualitjecto,

No.4 fuel injector IACvalve Throttleposition(TP)sensor Manifoldabsolutepressure{MAp)sensor Intakeair temperature0AT)sensor Powersteeringpressure(PSp)switch EVAPpurgecontrolsolenoidvalve Junctionconnector Junctionconnector Vehiclespeedsensor(VSS) Countershaft speedsensor Enginecoolanttemperature{ECT) switch A Middleof engine Distributor M i d d l eo f e n g i n e Enginecoolanttemperature(ECT) sendingunit Middleof engine Enginecoolanttemperature(ECT)sensor Middleof engine PrimaryHO2S(sensor1) Middleof engine Back-uplight switch M/T Middleof engine Lock-upcontrolsolenoidvalve Atr Middleof engine SecondaryHO2S(sensor2) Middleof engine Mainshaftspeedsensor Atr Middleof engine Linearsolenoidvalve Alr Middleof engine Shiftcontrolsolenoidvalve Al-|. Rightsideot enginecompartment Startersolenoid Behindright kickpanel JunctionConnector Underright sideof dash Main wire harness(C446) Behindright kickpanel ECM/PCM Behindright kickpanel ECM/PCM Behindright kickpanel PCM Leftside of enginecompartment Rightsideof enginecompartment M i d d l eo f e n g i n e

23-24

USA Canada

Engineground,via enginewire harness

1O

'99 - 00 models:

c110 c114

cl11 cl13

c117

c1

c108 ct07

23-25

Connectorldentificationand Wire HarnessRouting EngineWire Harness{81642engine}:.99- 00 models

c101 c102

10 2

cl03 c104 c 104 c'105 c106 cl01 c108 c110 cl11 cl12 c1'13 c114 c115

,]

c117 cl19

4 3 2 2 2 2 3 3 2 2 2 14 14 3 2

c120 c121

'10 'I

c122 c123 c124 c129 c130 c l31 c133 c134 c137 c 138 c139 c140

2 4 2 1 20 22 25 31 2 2 I

Leftside of enginecompanment M i d d l eo f e n g i n e

Main wire harness(C303) Crankshaft speedfluctuation(CKF) sensor M i d d l eo f e n g i n e Engineoil pressureswitch Leftside of enginecompartment Alternator Leftsideof enginecompartment Alternator lvliddleof engine No. 1 fuel injector M i d d l eo t e n g i n e No. 2 tuel injector M i d d l eo f e n g i n e No. 3 fuel injector M i d d l eo f e n g i n e No. 4 fuel injector M i d d l eo f e n g i n e Throttleposition(TP)sensor Middleof engine Manifoldabsolutepressure(MAP)sensor M i d d l eo t e n g i n e Intakeair temperature(lAT)sensor Middleof engine Powersteeringpressure(PSP)swjtch M i d d l eo f e n g i n e EVAPpurgecontrolsolenoidvalve Middleof engine Junctionconnector M i d d l eo f e n g i n e Junctionconnector Middleof enginecompartment Vehiclespeedsensor(VSS) Middleof engine Enginecoolanttemperature(ECT) switch A Middleof engine Distributor M i d d l eo f e n g i n e Enginecoolanttemperature(ECT) sendingunit lMiddleof engine Enginecoolanttemperature{ECT)sensor M i d d l eo f e n g i n e PrimaryHO2S(sensor1) Middleof engine Back-uplight switch Rightsideof enginecompartment Startersolenoid Behindright kickpanel Junctionconnector Underright side of dash Main wire harness(C446) Behindright kickpanel ECM Behindright kickpanel ECtvl M i d d l eo f e n g i n e KnockSensor{KS) M i d d l eo t e n g i n e IACvalve lMiddleof engine VTECsolenoidvalve M i d d l eo f e n g i n e VTECpressureswitch Leftside of enginecompanment Rightsideof enginecompartment Engineground,via enginewire harness

USA Canada

'99 - 00 models:

c112 cl17 T102 c119 c140

c104 T101

c13t) clt5 c116 c137 c102

23-27

Connectorldentificationand Wire HarnessRouting

EngineCompartment Wire Harness conneqtor of Terminal

Number of Cavities

c201 c202 c202 c203 c204 c205 c206 c207 c208 c209 c210

10 6 2

Location

Connectsto

2

Leftsideof enginecompanment Leftside of enginecompanment Leftside of enginecompanment Leftside of enginecompartment Behindfront bumper Behindfront bumper Leftside of enginecompartment Behindfront bumper Leftside of enginecompartment Leftsideof enginecompanment Behindfront bumper

Main wire harness(C308) Main wire harness(C309) Main wire harness{C309) Cruiseactuator Windshieldwashermotor Rearwindow washermotor Leftfront turn signal/parking light Frontfog light Left headlight Ay'Cwire harness1C751) Horn

c210

1

Behindfront bumper

HOrn

c211 c212 c213 c214 c215

2

Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Behindfront bumper

Radiatorfan motor Rightheadlight Rightfront turn signal/parking light Main wire harness(C355) Washer level switch

2 2 1 3

8

G201 G202 *1r With cruisecontrol *2: Withoutcruisecontrol

2 3- 2A

Rightsideof enginecompartment Bodyground,via enginecompartment wire harness Leftsideof enginecompartment Bodyground,via enginecompartment wrre harness

Notes

Optional '96 -

97 models '98 99 models

Canada '99 model

c20l

c202

ENGINECOMPARTMENT WIREHARNESS

23-29

Connectorldentificationand Wire HarnessRouting

Main Wire HarnesslLeft side ot engine compartment branchl Connectoror Terminal

Numberof Cavities

c301 c302 c303 c304 c305 c305 c306 c307 c308 c309 c309 c310

5 2 10 3 14 8 1 I 10 2 2

* l r D ' 1 6 Ye5n g i n e * 2 : D 1 6 Y 8e n g i n e *3: With cruisecontrol *4r Withoutcruisecontrol

Location

Leftside of enginecompartment Leftside of enginecompartment Leftside of enginecompanment Leftside of enginecompartment Leftsideof enginecompartment Leftside of enginecompartment Leftsideot enginecompanment Leftside of enginecompanment Leftsideof enginecompartment Leftside of enginecompanment Leftside of enginecompanment Leftside of enginecompanment *5:'96 9gmodels

Connectsto

Notes

Windshieldwiper motor Testtachometerconnector E n g i n ew i r e h a r n e s (sC 1 0 1 ) Daytimerunninglightsresistor Canada Enginewire harness(C136) ;|.' E n g i n ew i r e h a r n e s (sC 1 3 6 ) Brakefluid levelswitch(+) Brakefluid levelswitch(-) Enginecompartment wire harness(C201) Enginecompanmentwire harness(C202) Enginecompartment wire harness(C202) Leftfront ABS wheelsensor ABS

Main Wire Harness(Rightside of enginecompartmentbranch) Connectoror Terminal

Numberof Cavities 11

c353 c354 c355 c356 c357 c359 c360 G403 ' 9 9 *1: - 00models

23- 3 0

3 I 3 2 2 '10 2 2

Location Rightsideof enginecompartment Rightsideof enginecompanment Rightsideof enginecompanment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompanment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment Rightsideof enginecompartment

Connectsto Under-hoodfuse/relaybox (CgoB) Under-hoodfuse/relaybox (C906) Underhoodfuse/retaybox (C905) Under-hoodtuse/relaybox (C907) Enginecompanmentwire harness{C214) Under-hoodABS fuse/relaybox {C927) Under-hoodABS fuse/retaybox (C926) Rightfront ABS wheelsensor ABS solenoid ABS pump motor EVAPcontrolcanistervent shut valve

Rightsideof enginecompartment Bodyground,via main wire harness

Notes

USA ABS ABS ABS ABS ABS

D

UNDER-HOOO FUSE/RELAYBOX

MAIN WIREHARNESS (leftb.anch)

c301

23-31

Connectorldentificationand Wire HarnessRouting Main Wir€ Harness(Loft side of da3h and floor branch):'96 - 97 models Connectoror Terminal

c401 c402 c403 c404 c405 c406 c407 c407 c408 c409 c410 c411 c412 c413 c414 c415 c416 c417 c418 c4l9 c420 c42'l c423 c424 c425 c426 c427 c42A c429 c430 c431 c432 c433 c434 c435 c431 c438 c439

Number of Cavhios '14

't4 I

I 10 't2 24 16 7 o

18 20 18 7 6

I o 4 7 8

14

1

Location Above under-dashfuss/relaybox Underleft side ot dash Underleft sid€ of dash Underleft side of dash Underleft side of dash Und€rleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Behindunder-dashfuse/relaybox Underleft side of dash Underleft side of dash Above under-dashfuse/relaybox Underleft sideof dash Under left side of dash Above under-dashfuse/r€laybox Underleft sideof dash Underleft side of dash Underleftside of dash Behind under-dashfuse/relaybox Eehind under-dashfuse/relaybox Behindunder-dashfuse/relaybox Behindunder-dashfuse/relaybox Behindunder-dashfuse/relaybox Under left side of dash Under left side of dash In the steeringcolumncover In the steering column cover In the steeringcolumncover In the steeringcolumncovEr Underleft side of dash Underleft side of dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Underleft sideof dash Underleft side of dash Eehind under-dashfus€/relaybox

G401 Left kick panel *2:Without moonroof *4: With moonroof *5: M/T (with cruisecontrolor for D16Y5engine) *6: With secondaryheatedoxygensensor(H02S)

23-32

Connoctsio Floo.wire harness(C555) Floorwire harness(C554) Securitysystem Cruisecontrolunit Daytimerunninglightscontrolunit Daytimerunninglightscontrolunit Roofwire harness(C701) Moonroofwire harness(C7l1) Frontfog light connector Integratedcontrolunit Dashboardwire harness(C504) Dashboardwire harness(C502) SRSmain harness(C802) Datalink connector Starter cut relay lgnitionswitch Securitysystem Clutch switch Clutch interlockswitch Under-dashfuss/relay box (C9191 Undor-dashfuse/r€laybox {C920) Under-dashtuse/relaybox (C922) Under-dashluse/relay box (C914) Under-dashfuse/rBlaybox (C915) Horn relay Brakeswilch Windshield wiper/washerswitch Rearwindow wiper/washerswitch Turn signal switch Combinationlighvturnsignalswitch Cablereel lnterlockcontrolunit Secondaryheatedoxygen sensorsubharn€ss(C781) Ay'Tgear position switch Shift locksolenoid Parkpin switch and Ay'Tgear position consolelight Transmission controlmodule(TCM) Transmission controlmodule{TCM) Under-dashfuse/relaybox {C925) Bodyground,via main wire harness

Notes

ABS Optional Canada Canada

Optional

Atr

MTT Optional Mlf

NT AN Atr Atf CVT CVT Optional

t '96 - 97 models:

MAIN WIRE HARNESS

c412 C411 c410

o

-n---nnn-

c421

-nr

n-n--n---n-nn!!!!!!uu!u!u+u

UNDER.DASH BOX FUSE,/RELAY

23-33

Connectorldentificationand Wire HarnessRouting Main Wire Harn€ss{Left side ot dash and floor branchl: '98 model Connoctoror Tgrminal

c401 c402 c403 c404 c405 c406 c407 c407 c408 c409 c410 c411 c4't2 c413 c414 c415 c416 c417 c418 c419 c420 c421 c422 c423 c424 c425 c426 c427 c428 c429 c430 c431 c432 c433 c434 c435 c437 c438

Number of Cavities 't4

l4 8 , 1 10 12 24

7 6

18 20 18 7 6

8

7 8

14 2

Location Aboveunder-dash fuse/relaybox Underleft sideof dash Underleft side of dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft sideof dash Underleft side of dash Behindunder-dashfuss/relaybox Underleft sideof dash Underleft sideof dash Above under-dashfuse/relaybox Underleft sideof dash Under-dashrelaybox Above under-dashfuse/relaybox Underleft side of dash Underleft sideof dash Underleft sideof dash Eehind under-dashfuse/relaybox Behind under-dashfuse/relaybox Behind under-dashfuse/relaybox Behindunder-dashfuse/rslaybox Behindunder-dashfuse/relaybox Under-dashrelaybox Underleft sideof dash In the steeringcolumncover In the steeringcolumncover In the steeringcolumncover In the steeringcolumncover Underleft sideof dash Underleft sideof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Underleft sideof dash Underleft sideof dash

G401 Left kick panel *2: Withoutmoonroof *4:With moonroof *5: M/T (with cruisecontrolor for D16Y5engine) *6: With secondaryheatedoxygen sensor (H02S)

23-34

Conneqtsto Floorwire harness(C555) Floorwire harness(C554) Securitysystem Cruisecontrolunit Daytimerunninglightscontrolunit Daytimerunninglightscontrolunit Roofwiro harness(C7011 Moonroofwire harness(C711) Frontfog light connector Integratedcontrol unit Dashboardwire harness(C504) Dashboardwire harness(C502) SRSmain harness(C802) Datalink connector Starter cut relay lgnitionswitch Securitysystem Clutch switch Clutchinlerlockswitch Under-dash fuse/relaybox (C919) Under-dashfuse/relaybox (C920) Under-dashfuse/relaybox (C922) Under-dashfuse/relaybox (C914) Under-dash fuse/relaybox (C915) Horn relay Brakeswitch Windshieldwiper/washerswitch Rearwindow wiper/washerswitch Turn signalswitch Combinationlight/,turn signalswitch Cablereel lnterlockcontrolunit Secondaryheatedorygen sensorsubharness(C781) Ay'Tgear position switch Shift locksolenoid Parkpin switch and Aff gear position consolelight Transmission controlmodule(TCMI Transmission controlmodule(TCM) Body ground,via main wire harness

Not€s

ABS Optional Canada Canada

Optional

M

MIT Optionsl MlT

Alr NT NT

CVT CVT

t D €8 model:

c€0 cQa I c129

"n,

ctza j81

WIRE HARNESS

c,(},l

c112 c111 c110

c121

::::::::::: r ll: UNDER-DASH BOX FUSE/RELAY

23-35

Connectorldentificationand Wire HarnessRouting

Main Wire HalnesslLoft side of dash 8nd lloor branchl: '99 - 00 mod€ls Connosto! ol Tsrminal

c401 c402 c403 c404 c405 c406 c407 c407 c408 c409 c410 c411 c412 c4' I3 c4't4 c415 c416 c417 c418 c419 c420 c42l c422 c423 c424 c425 c426 c427 c428 c429 c430 c431 c432

Number of Cavities 20 4 14 I 6 1 10 12 24 16 4 7 6 2 18 20 18 7

4 8 o

7 8

Location Above under-dashfuse/relaybox Underleft side of dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft side of dash Underleft sideof dash Behindunder-dashfuse/relaybox Under left side of dash Under left side of dash Above under-dashfuse/relaybox Underleft sideof dash Under-dashrelay box Above under-dashfuse/relaybox Underleft side of dash Underleft sideof dash Underleft side of dash Behind under-dashfuse/relaybox Behindunder-dashfuse/relaybox Behindunder-dashfuse/relaybox Behindunder-dashfuse/relaybox Behindunder-dashfuse/relaybox Under-dashrelaybox Underleft sideof dash In the steeringcolumncover In the steeringcolumncover In the steeringcolumncover In the steeringcolumncover Underlett sideof dash Underleft sideof dash Undermiddleof dash

c433 c434 c435

14

Undermiddleof dash Undermiddleof dash Undermiddleof dash

c447 c448 c449 c450 c451

22

Underleft side of dash Underleft side of dash Undermiddleof dash Underleft side of dash Underleft side of dash

18

G401 Left kick panel *2: Withoutmoonroof *4: With moonroof *5: M/T (with cruisecontrolor for Dl6Y5 engine) *6: With secondaryheatedoxygensensor(H02S)

23-36

Connoqtg to

Floorwire harness(C555) Floorwire harness(C554) Securitysystem Cruisecontrolunit Daytimerunninglightscontrolunit Daytimerunninglightscontrolunit Roofwire harness(C701) Moonroofwire harness{C711) Frontfog light connector Intagratedcontrol unit Dashboardwire harness(C504) Dashboardwire harness(C502) SRSmain ha.ness(C802) Data link connector Starter cut relay lgnitionswitch Securitysystem Clutch switch Clutch interlockswitch Under-dashfus€/relaybox (C919) Under-dashfuse/relaybox (C920) Under-dashfuse/relaybox (C922) Under-dashfuse/relaybox (C914) Under-dashfuse/relaybox (C915) Horn relay Brakeswitch Windshield wiper/washerswitch Rearwindow wiper/Washerswitch Turn signalswitch Combination light/turn signal switch Cablereel lnterlockcontrolunit Secondaryheaiedoxygensensorsubharness(C781) A/T gear position switch Shift locksolenoid Parkpin switch and A,/Tg€ar position consolelight Securitysystem Securitysystem IVT gear positionindicatortrim light Securitysystem Keylessdoor lockcontrolunit Bodyground,via main wire harness

Notes

ABS Optional Canada Canada

Optional At-|.

M/T Optional M/T

Atr AIT AJ-|.

Atr Optional Optional Optional

D '99 - 00 models: c418 c425

MAIN WIRE HARNESS

c{33 Ca34

c412 C411 C410

o

c121

-r----------

UNDER.OASH BOX FUSE/RELAY

23-37

Gonnectorldentificationand Wire HarnessRouting

Msin Wire Harness(Right side oI dash branch) Connectoror Terminal

Number of Cavities

c440 c441 c442 c443 c4M c445 c446 c452

16 2 20 7 22

G402

23-38

22

Location

Connectsto

Notes

Undermiddleof dash Underrightside of dash Underrightside of dash Underright side of dash Behindright side of kickpanel Behindright side of kickpanel Underright sideof dash Underright sideof dash

Heatersub-harness A (C721) Servicecheckconnector Junctionconnector PGM-Flmain relay ABS controlunit ABS controlunit E n g i n ew i r e h a r n e s (sC 1 3 1 ) ECM/PCM

Rightkickpanel

Bodyground,via main wire harness *'l: '99 - 00 models

D DashboardWire Harness Connector ol Terminal

c501 c502 c503 c504 c505 c507 c508 c509 c510 c513 c514 c515

Numbel of Cavities

B e h i n dd a s h b o a r ldo w e rp a n e l luse/relaybox Aboveunder-dash Above underdashIuse/relaybox Aboveunderdashtuse/relaybox Leftside of steeringwheel Leftside of steeringwheel B e l o wg a u g e s B e h i n dg a u g e s B e h i n dg a u g e s B e h i n dg a u g e s B e h i n dg a u g e s B e h i n dg a u g e s R i g h ts i d eo t g a u g e s R i g h ts i d eo I g a u g e s B e hi n d m i d d l eo f d a s h B e h i n dm i d d l eo f d a s h B e h i n dm i d d l eo f d a s h B e h i n dm i d d l eo f d a s h B e h i n dm i d d l eo f d a s h B e h i n dm i d d l eo f d a s h B e h i n dg a u g e s

20 24 to

12 5 3 20 5 5 14

r0 5

c516

20 22

c518 c519 c520

5 2 5

Connects to

Location

U n d e r - d a s{hu s e / r e l abyo x ( C 9 1 2 ) s C411) M a i nw i r e h a r n e s 1 Floorwire harness(C553) M a i nw i r e h a r n e s s( C 4 1 0 ) Cruisemain switch D a s hl i g h t sb r i g h t n e scso n t r o l l e r Junctionconnector G a u g ea s s e m b l y G a u g ea s s e m b l y G a u g ea s s e m b l y G a u g ea s s e m b l y Gaugeassembly Hazardwarningswitch Rearwindow defoggerswitch Audio unit (Keylessreceivercircuit) A u d i ou n i t l nit S e c u r i t cy o n t r o u A u d i ou n i t Securitysystem Accessorypower outlet G a u g ea s s e m b l y

Notes

A"r

SRS

A,/r

Optional*' Optional*' ABS

Body ground,via dashboardwire harness * 1 : W i t h s h i i t - u pi n d i c a t oor r c r u i s ec o n t r osl y s t e m( ' 9 6- 9 7 m o d e l s ) *2: '96 98 models *3: '99 - 00 models Undermiddle ol dash

G501

With cruisecontrolsystem('98model) c508

c509C511 c510 c515 13 lc5l7

DASHSOARDWIRE HARNESS

c520 c501 c502 c504

23-39

Gonnectorldentificationand Wire HarnessRouting

Floor Wire HarnesslCoupe/Haichbackl Connsclor or Terminal

Numberof Cavities

c551 c552 c553 c554

16 8 '16 14 20

c556 c556 c557 c558 c560 c561 c562 c564 c56s

2 25 ,) ,I 2 1 14 20 2 2 ?

1 10 G551 G552 *1r With power windows *2: Withoutpowerwindows *3: D16Y8engine{Coupe)

23-40

Location Behindunderdashfuse/relaybox Behindunder-dash fuse/relaybox Aboveunder-dash fuse/relaybox Underleft side of dash Aboveunder-dash fuse/relaybox Aboveunder-dash fuse/relaybox Driver'sdoor Driver'sdoor Passenger's door Passenger's door Middleof floor Leftsideoffloor Left B-pillar lnsideof left rearwheel Leftc-pillar LeftC-pillar LeftC-pillar Fueltank Fueltank Insideof right rearwheel RightB-pillar Fueltank Left side ot dash Leftkickpanel Leftside of floor *4: '96 - 98 models *5: '99 - 00 models

Connectsto

Notes

Under-dash fuse/relaybox {C923) fuse/relaybox (C921) Under-dash Dashboardwire harness{C503) Main wire harness(C402) ABS Main wire harness(C401) Main wire harness{C401) Driver'sdoor wire harness(C631) Driver'sdoor wire harness(C631) Passenger's door wire harness(C651) Passenger's door wire harness(C651) Parkingbrakeswitch Driver'sseatbelt switch Driver'sdoor switch Left rearABS wheelsensor ABS Rearwire harness(C601) Rearwire harness(C601) Rearwire harness{C602} Fuelgaugesendingunit Fuelpump RightrearABS wheelsensor ABS Passenger's door switch Fueltank pressuresensorsub-harness (c791) Powermirrorswitch Bodyground,via floor wire harness Bodyground.via floor wire harness

l,-

FLOORWIREHARNESS

23-41

Gonnectorldentificationand Wire HarnessRouting

Floor Wire HarnesslSedanl: Connectorol Terminal

Number of Cavities 6

c553 c554 c556 c557 c557 c558 c559 c560 c561 c562 c563 c564 c565 c566 c567 L5bY

c570 c511 c572 c513

14 25 2 25 '| 1 2 't4

1 '10 6 6 I 1

G552 *l:With powerwindows *2; Withoutpowerwindows

23-42

'96 model Location

Connectsto

Notes

Behindunderdashfuse/relaybox Behindunder-dash fuse/relaybox Above under-dashfuse/relaybox Underleft sideof dash Aboveunder-dash fuse/relaybox Drlver'sdoor Driver'sdoor Passenger's door Passenger's door Middleof floor Leftside of floor RightB-pillar lnsideof left rearwheel LeftC-pillar LeftC-pillar Fueltank Fueltank Insideof right rearwheel Left B-pillar Left side of steeringwheel R i g h tB - p i l l a r LeftB-pillar Leftquarterpanel Rightquarterpanel

Under-dash fuse/relaybox {C923) fuse/relaybox (C921) Under-dash Dashboardwire harness(C503) Main wire harness(C402) ABS Main wire harness(C401) Driver'sdoor wire harness(C631) Driver'sdoor wire harness(C631) Frontpassenger's doorwireharness(C651) Frontpassenge/sdoorwireharness(C651) Parkingbrakeswitch Driver'sseat belt switch Frontpassenger's door switch ABS Left rearABS wheelsensor Rearwire harness(C601) Rearwire harness(C602) Fuelgaugesendingunit F u e lp u m p{ F P ) ABS RightrearABS wheelsensor Driver'sdoor switch Power mirror switch Rightreardoor wire harness(C671) Leftreardoor wire harness(C661) Left rear door switch Rightreardoor switch

Leftkickpanel Left side of floor

Body ground,via floor wire harness Body ground,via floor wire harness

D '96 model:

c573

FLOORWIREHARNESS

C556

C564

c570 c560

23-43

Gonnectorldentificationand Wire HarnessRouting FloorWire Harness(Sedanl:'97 - 00 models Connectoror Terminal

c552 c553 c554 c555 c556 c557 c557 c558 c559 c560 c56'l c562 c563 c564 c566

Numberof Cavities 16 8

14 20 25 2 2 1 2 1

20 2 2 2 1

c568 c569 c570 c571 c572

l0

1 1

G551 "1r With powerwindows *2: Withoutpowerwindows

23-44

Location Behindunder-dash fuse/relaybox Behindunderdashfuse/relaybox Above under-dash fuse/relaybox Underleft side of dash Aboveunder-dash fuse/relaybox Aboveunder-dash fuse/relaybox Driver'sdoor Driver'sdoor Passenger's door Passenger's door Middleof floor Leftside of floor R i g h tB - p i l l a r Insideof left rearwheel LeftC-pillar LeftC-pillar LeftC-pillar F u e tl a n k F u e tl a n k Insideof righr rearwheel Left B-pillar F u e tl a n k Leftsideof steeringwheel R i g h rB , p i l l a r Left B pillar I ofr ^,,.riar

^.^al

Rightquarterpanel Leftkickpanel Leftside of floor * 3 : ' 9 7- ' 9 8 m o d e l s *4: '99 - 00 models

Connectsto

Notes

Under-dash fuse/relaybox (C923) Under-dash fuse/relaybox (C921) Dashboardwire harness(C503) Main wire harness(C402) ABS Main wire harness(C401) Main wire harness(C401) Driver'sdoor wire harness(C631) Driver'sdoor wire harness{C631} (C651) Frontpassenger's doorwireharness (C651) Frontpassenger's doorwireharness Parkingbrakeswitch Driver'sseatbeltswitch Frontpassenger's door switch Left rearABS wheelsensor ABS Rearwire harness(C601) Rearwire harness(C601) Rearwire harness(C602) F u e lg a u g es e n d i n gu n i t F u e lp u m p( F P ) RightrearABS wheelsensor ABS Driver'sdoor switch Fueltank pressuresensorsub-harness (c791) Powermirror switch Rightreardoor wire harness(C671) Leftreardoor wire harness(C661) Leftreardoor switch Rightreardoor switch Bodyground,via floor wire harness Body ground,via floor wire harness

D '97 - 00 models:

HARNESS

23-45

Connectorldentificationand Wire HarnessRouting

RearWire Harness(Halchbackl Connectoror Terminal

Number of Cavitiss

c601 c601 c602 c603 c604 c605 c606 c607 c608 G601

14

20 2 2 6

Location

Connectsto

Leftquarterpanel Leftquarterpanel Leftquaner panel Leftquarterpanel Left side of cargo area Rightsideof cargoarea Rightquarterpanel Rightquarterpanel Rightquaner panel

Floorwire harness{C562} Floorwire harness(C562) Floofwire harness(C563) Leftrearspeaker Leftoutertaillight Rightoutertaillight Rightrearspeaker Hatchwire harness(C761) Hatchwire harness(C762)

Middleof cargoarea

Bodyground,via rearwire harness

* 1 : ' 9 6- 9 8 m o d e l s *2: '99 - 00 models

REARWIRE

23-46

s\

Notes

Optional

Optional

D '96 '96 RearWire Harness{Coupe: - 99 models/Sedan; - 98 modelsl Connectoror Torminal

c601 c601 c602 c603 c604 c605 c606 c609 c610

Numbsr of Caviiies to

20

1

)

L O t l

c612 c613 c6'14 c616 c617 G601

1 4 2 2 2 4

Location

Connectsto

Leftquarterpanel Leftquarterpanel Leftquarterpanel Leftquarterpanel Leftsideof trunk Rightside of trunk RightquarterPanel Left side of rear window Middleof rearshelf Middleof rearshelf Rightsideof rearwindow Leftsideof trunk Middleof trunk Middleof trunk Middleof trunk Rightside of trunk

Floorwire harness(C562) Floorwire harness(C562) Floorwire harness(C563) Left rear speaker Leftoutertaillight Rightoutertaillight Rightrearspeaker Rearwindow defogger(+) High mount brakelight T r u n kl i g h t Rearwindow defogger(-l Leftinnertaillight LeftIicenseplatelight Trunklatchswitch RightlicensePlatelight R i g h ti n n e rt a i l l i g h t

Middleof trunk

Body ground,via rearwire harness

Notes

REARWIREHARNESS

23-47

Connectorldentificationand Wire HarnessRouting RearWir€ Harnsss(Sedan):'99 - O0models Connactoror Torminal

Numb€r ot Cavhios

c501 c603 c604 c605 c606 c610 c611 c6r3 c614

20 4

3 2

c617 c618 c619 c620 c621 c622 c623

a

1

G601 G602

Location

Connects to

Left quarter panel Left quarter pan€l Left side of trunk Rightsideof trunk Rightquarterpanel Middleof rearshelf Middleof rearshelf Left side of trunk Middleof trunk Middleof trunk Middleof trunk Rightside oftrunk Left side of trunk Rightside of trunk Left side of trunk Rightside oftrunk Middleof rearshelf Middleof rearshelf

Floor wir€ harness(C562) Left rear speaker Left outer taillight Rightoutertaillight Right rear speaker High mount brakelight Trunklight Leftinn6rtaillight Left licensoplate light Trunk latch switch Rightlicenseplatelight Rightinnertai ight Left outer taillight Rightoutertaillight Left innertaillight Rightinnertsillight Window antennacoil Window ant€nnacoil

Middleof trunk Middleof rsar shelf

Body ground, via rear wire harness Body ground, via rear wire harness

Notog

RoarWindow DetoggerWire Connectot or Terminal

c831 u65Z

c833

Numbor of Cavitios

2 1 1

Loc!tion Middleof rearshelf Left side of rear window Rightsideof rearwindow

REARWIREHABNESS

c603

23-48

c&tl

c62

Connrct3 to Window antennacoil Rearwindow defogger O Rearwindow defoggerO

Note!

ID Driver'sDoor Wire Harness{Coupe/Hatchback} Connector ot Terminal

Numbei of Cavities

c631 UOJ I

c632 c633 c634 c635 c636 c638 c639 c640

2 2 4 4 2 12 3 8 12

Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Insideof left power mirror Driver'sdoor

Notes

Connectsto

Location

Floorwire harness(C556) Floorwire harness(C556) Leftfront door speaker Driver'spowerwindow motor Driver'sdoor lockactuator Tweeter Powerwindow masterswltch Driver'sdoor lockswitch Leftpower mirror Powerdoor lockcontrolunlt

Coupe Coupe Coupe Coupe Coupe Coupe Coupe*3

* 1 : W i t hp o w e rw i n d o w s *2: WithoutPowerwlndows "3: Withoutkeyless

c639

DRIVER'SDOORWIREHARNESS

23-49

Connectorldentificationand Wire HarnessRouting

Passenger'sDoor Wire Harness{Coupe/Hatchbackl Connectoror Terminal

Numberof Cavities

c651

25 2 2 2 2 5 8 2

c652 c653 c654 LO55

Location

Conneststo

Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Insideof right power mirror Passenger's door

Floorwire harness(C557) Floorwire harness{C557) Rightfront door speaker Frontpassenger'spower window moror Front passenger'sdoor lockactuator Frontpassenger'spower window switch Rightpower mirror Tweeter

*1: With powerwindows *2; Withoutpowerwindows

PASSENGER'S DOORWIREHANNESS

2 3- 50

Notgs

Coupe Coupe Coupe Coupe Coupe

' Driver'sDoor Wire Harness(Sedan) Connectoror Terminal

c63r c632 c633 c634 c636 c637 c638 c639 c640

Number ol Cavities

25 2 2 4 4 16 1 3 8 12

Location

Driver'sdoor Driver'sdoor I Driver'sdoor Driver'sdoor Driver'd s oor Driver'sdoor Driver'sdoor D r i v e r ' sd o o r Insideof left Powermirror I Driver'sdoor

Connectsto

Notes

Floorwire harness(C556) s C556) F l o o rw i r e h a r n e s 1 Leftfront door sPeaker Driver'spowerwindow motor Driver'sdoor lockactuator Powerwindow masterswitch Powerwindow masterswitch Driver'sdoor lockswitch Leftpower mirror Powerdoor lockcontrolunlt

* 1 : W i t h p o w e rw l n d o w s *2: Withoutpowerwlndows

DRIVER'SDOOR WIREHARNESS

Connectorldentificationand Wire HarnessRouting Front Passenget'sDoor Wire Harness{Sedanl Connectoror Terminal

Numberof Cavities

c651

25 2

c653 c654

2 2

c656 8 *1: With powerwindows *2: Withoutpowerwindows

23-52

Location Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door lnsideof right power mirror

Connectsto Floorwire harness(C557) Floorwire harness(C557) Rightfront door speaker Frontpassenge/spowerwindowmoror Frontpassenger'sdoor lockactuator Front passenger'spower window switch Rightpower mirror

Notes

D Left Rear Door Wire HarnesslSedan) Conngctoror Terminal

Number of Cavities

c661 c662 c663 c664

2 5 t

Conneststo

Loc.tion Left8-piller Leftreardoor Left rear door Left rear door

Notes

Floorwire harness{C571) Left rear power window motor Left rear power window switch Leftreardoor lockactuator

Right Rear Door Wire Harness{Sedan) Connectoror T€rminal

Numbsr of Cavities

c671 c672

6 2 5 2

c674

Conn€ststo

Location RightB-piller Rightreardoor Rightreardoor Rightreardoor

Notes

Floorwire harness(C570) Rightrearpowerwindow motor Rightrearpowerwindow switch Rightreardoor lockactuator

Left Rear Door:

t LEFTREARDOOR WIREHARNESS

Right Rear Door:

RIGHTREARDOOR WIREHABNESS

23-53

Connectorldentificationand Wire HarnessRouting

Roof Wire Harness(Coupe/Hatchback) Connector ol Terminal

Numberof Cavities

c701 c701 c702 c719

2 6 2 1

Location

Underleft sideof dash Underleft sideof dash Middleof roof Frontof roof

Connectsto

Notes

Main wire harness(C407) Main wire harness(C407) C e i l i n gl i g h t Spotlight

* 1 : ' 9 6- 9 8 m o d e l s *2: '99 - 00 models RoofWire Harness(Sedanl Connectoror Terminal

Numberof Cavities

c701 c701 c702 c703 c719

2 1 1 1

Location Underleft sideof dash Underleft sideof dash Middleof roof Middleof roof Frontof roof

Connectsto

Notes

Main wire harness(C407) Main wire harness(C407) C e i l i n gl i g h t( P o w e r ) C e i l i n gl i g h t( G r o u n d ) Spotlighr

* l : '96 - 98 models + 2 : '99 - 00 models

MoonroofWire Harness{Coupe/Sedan} Connector or Terminal

Numberot Cavities

c711 c711 c1't2

2 6

c713 c713 c714 c714 c715

6 5

c117 c718 c719 * 1 : ' 9 6- 9 7 m o d e l s "2: '98 model *3: '99 00 models

23-54

5 4 3 2 4 1

Location

Connectsto

U nder left sideof dash Underleft sideof dash Behinddashboardlower panel

Main wire harness(C407) Main wire harness(C407) Under-dash tuse/relaybox (C910)

Leftside of dashboardbracket Leftside of dashboardbracket Leftsideof dashboardbracket Leftside of dashboardbracket Leftsideof steeringwheel Middleof roof Rearof roof Rearof roof Frontof roof

Moonroofopen relay Moonroofopen relay Moonroofcloserelay Moonroofcloserelay Moonroofswitch C e i l i n gl i g h t Moonroofmotor Moonroofmotor (Tiltswitch) Sporlight

Notes

Optional

ROOFWIREHARNESS

\,-d',

/::

23-55

Connectorldentificationand Wire HarnessRouting Hatch Wiro Harness(Hatchbackl Connectoror T€rminal

Number of Cavities

c761 c762

6

c764

2 '| 2

c768

2

Location

Connectsto

Rightquaner panel R i g h tq u a n e rp a n e l Rearof roof Rightsideof hatch Middleof hatch Middleot hatch lViddleof hatch Middleof hatch

Rearwire harness(C607) Rearwire harness(C608) High mount brakelight Rea.window defogger(+) Rightlicenselight Left licenselight Rearwindow wiper motor Hatchlatchswitch

Middle of tailgate

Bodyground,via tailgatewire harness

Notes

RearWindow D€fogg€rcround Wir€ (Hatchbackl Connoctoror Terminal

G171

23- 5 6

Number oI Cavities

Location

Connectsto

Leftsideot hatch

Rearwindow defogger(-)

Left side of hatch

Bodyground,via rearwindow defogger groundwire

Notes

l'36 - 97 models:

REARWINDOWDEFOGGER GROUNDWIRE

TCHWIREHARNESS

'98 - 00 models:

REARWINDOWDEFOGGER GROUNDWIRE

WIREHARNESS

23-57

Gonnectorldentificationand Wire HarnessRouting Heater Sub-harnessA: '96 - 98 models Connectoror Terminal

Number ot Cavities

c 72 1 c722 c723 c724

7 20 2

c727

Location

Conneqtsto

Underleft side of dash Behindglove box Behindglovebox Behindglove box Behindglovebox Behindglove box Behindglove box

Notes

Main wire harness(C440) Mode controlmotor Heatersub-harness B 1C741) Ay'Cthermostat Blowermotor Blowerresister Recirculation controlmotor

HeaterSub-harnessB: '96 - 98 mod€ls Connoctor01 Terminal

Number of Cavities

c741 c142 c743

20 14

Location

Conngctslo

Behindglove box Behindmiddleof dash Behindmiddleof dash

Heatersub-harness A (C723) Heaterfan switch Heatercontrolpanel

HEATERSUB.HARNESS A

HEATERSUB-HARNESS B

23-58

Notes

' '99 - 00 models HeaterSub-harnessA: Connectoror Terminal

Numberof Cavities

c721 c722 c723 c724 c725 c726 c727 c728 c729 c730

7 24 3 2 4 1 5 4

Heater Sub-harnessB: Connectoror Terminal

c741 c'742 c143 c744

Connectsto

Location

Underleft side of dash Behindglove box B e h i n dg l o v eb o x Behindglove box B e h i n dg l o v eb o x B e h i n dg l o v eb o x B e h i n dg l o v eb o x Behindglove box Behindglove box Behindglove box

Notes

Main wire harness(C440) Mode controlmotor B (C741) Heatersub-harness lilc thermostat Blowermotor Powertransistor controlmotor Recircuiation B (C744) Heatersub-harness Air mix controlmotor Blowermotor high relaY

'99 - 00 models

Numberof Cavities 20 8 20 1

Connectsto

Location

B e h i n dg l o v eb o x B e h i n dm i d d i eo f d a s h B e h i n dm i d d l eo f d a s h B e h i n dg l o v eb o x

A (C723) Heatersub-harness HeatercontrolPanel HeatercontrolPanel A (C728) Heatersub-harness

A HEATERSUB.HARNESS

Notes

Connectorldentificationand Wire HarnessRouting

Rear HeatodOxygen Sensor Sub-harness Connectoror Terminal

Number of Cavhies

c7a1 c782

Location Undermiddleof dash Undermiddleof dash

Connectsto

Notes

Main wire harness(C432) Secondaryheatedoxygensensor (SecondarvHO2S)

FuelTank PressureSensor Sub-harness Connectoror Terminal

Number of Cavities

c791

6

c192 c793

Location Middleof floor Leftside of fuel tank Leftside of fuel tank

Cono€ctsto Floorwire harness(C568:Coupe/ Hatchback, C574;Sedan) Fueltank pressuresensor EVAPtwo way valve

FUELTANK PRESSURE SENSOR

23-6 0

Notes

rt SRSMain Harness Conneclor or Terminal

Number of Cavities

c801 c802

2

c803

2

c804 c805 c806 c807

2 2

?

Location

Connectsto

Notes

fuse/relaybox (C911) Under-dash Underleft sideof dash A b o v e u n d e r - d a s hf u s e / r e l a Y N4ainwire harness(C412) DOX

G801

18

Memoryerasesignal{MES)connector

R i g h t s i d e o f u n d e r - d a s hf u s e / relayDox Underleft side of dash Underrightsideof dash Middleof floor Middleof floor

Cablereel airbagassemblY Passenger's connector Dummy resastor S R Su n i t

Middleof floor

Body ground,via SRSmain harness

USA Canada

SRS MAIN HARNESS

23-61

Fuses Under-hood Fuse/Relay Box

DEr-1

tr tr tr

IJ

r"l 17

LI

n5 1 IJ

r"l 56 LI

r"l 57 IJ

cgo1 lTo condensorfan relayl *: Not usod

lTo blower motor r€layl

Gr02

c903

fto l/c comprdssor] lclutchrelay I

[To radi.lor tan rolayl

NOTE;View from the backsideof the under-hoodfuse/relavbox.

cto5 [To main wir6 harne$ (C3521]

c905 lTo mainwire ha.ness(C353ll

ITo main w;re ha.ness(C351ll

23-62

(l'Component(s)or Circuitlsl Protect€d

FuseNumber

Amps

wire Color

41

80A

42

40A

WHT/BLK

To ignitionswitch(BAT)

43

7 . 5A

WHT/RED

Ceilinglight,data linkconnector,trunk light

44

1 5A

WHT/BLK

PGM-Flmain relay

Powerdistribution

Not used 46

40A

WHT/BLU

47

7 . 5A

WHT/BLU

48

30A

WHT

Powerwindow motors(via powerwindow relay) Audio unit,clock,TCM (CVT),ECM/PCM(VBU) No.33 (7.5A) fuse,To combinationlight switch(headlight) Not used

49 50

30A

WHT/GRN

Rearwindow defogger(via rearwindow defoggerrelay)

c l

20A

WHT/GRN

Powerdoor lockcontrolunit, moonroofmotor

1 5A

WHT/GRN

Horn system,brakelights,brakesignal

1 0A

WHT/BLK

Hazardwarning light, turn signal/hazardrclay

54

404

WHT/RED

O p t i o n{ + B )

55

40A

BLU,A/VHT WHT

Blowermotor (viablowermotor relay) Condenserfan motor (viacondenserfan relay)

RED

l'lc compressorclutch(viaIVCcompressorclutchrelay)

204 204

BLVBED

Radiatorfan motor (viaradiatorfan relay)

23-6

Fuses Under-dashFuse/RelayBox c912 lTo d.rhborrd wire harnes lC50'l)l c913 [To ignition 3witchl

c€l1 lTo SRSm.in

lTo m.in wir. ha]n.3s {Cra2iIll

c9l0 lTo moonroofwiroh.tn6s 1C712)l

a-)

clr15 lTo m.in wiro h.Jna3r lca23)l

r"r r"t r-r n rl 11r'l |;l r-r r-'l r-'l r-l 23

2a

25 26

21 2A A

aO3t

32

33

LI IJ IJ IJ IJ IJ IJ LJ LJ LJ tJ tJ

r-rr-r Fr r-rr-r n n ra r-1ratn r-1 1A 1a 20 21 t2 t3 ra 15 16 17

22

lTo powor window rcl.yl

LI IJ IJ IJ IJ IJ LI IJ IJ LI I"J tJ

- rfl |?t - n n rn r-'l n rat T1 T1 T"l T"l t

2

3

a

5

6

r

3

9

t

o

l

l

LI I.J LI LI I.J LI I.J LI LI IJ IJ IJ LJ LI .: Canadt *: Not usod O: C326loption @: C927loption O: C!r28loption @: c!t29 loption

(+B)l ld.3h light!)l tAOCll (lc2ll

c!17 lTo tu]n .ign.l/h.z.rd r.byl

: Not u3od l'96 -97 modelll

d.fogg.r rol.yl

NOTE:View from the backsideof the under-dashfuse/relaybox.

Clt25 (96, 97 mod.bl lTo m.in wiro ha]n.!. (C439ll

lTo m.in wiro h!rn..s 1C419)l

23-64

lrFuseNumber

Amps

Component{slor Circuit(sl Protected

wire Color

,l

Not used

2

Not used GRN

Rear window wioer motor, rear window washer motor

3

1 0A

4

1 0A

RED/BLU

R i g h th e a d l i g htrh i g hb e a m )

5

1 0A

RED/GRN

Leftheadlight(highbeam),high beam indicatorlight Not used

6 7

204

RED/VVHT

Left rearpowerwindow motor

8

20A.

YEUBLK

Right rear power window motor

Not used('96- 97 models) 9

't5

10

204

GRN/BLK

powerwindow motor Frontpassenger's

11

20A

BLU/BLK

Driver'spowerwindow motor

12

7 . 5A

YEUBLK

Turn signal/hazardrelay (via turn signal/hazardswitch)

YEL/GRN

PGM-Fl main relay

t5

1 5A

14

1.54

A

t6 17

7 . 5A

18

RED

Distributor(ignitioncontrolmodule)('98- 99 models)

GRYor BLK,^/ELSRSu nit (VA)

BLK/YEL

Cruisecontrolsystem,audio unit*1,keylessdoor lockcontrolunit*3

BLK/lr'r'HT

Alternator,VSS,ELDunit (USA),EVAPpurgevent shut valve,oxygen sensors,TCM (CVT)*'

BLI(,/BLU

ABS pump motor, rear window defogger.power mirror*3,mirror delogger*3

BLK,/YE L

A,/Csystem,power mirror*r.option (lG2)

YEUBTK

Daytime running lights relay (Canada)

19

7 . 5A

YEURED

B a c k ' u pl i g h t s

20

10A

BLK/VVHT

Daytimerunninglightscontrolunit (Canada)

21

1 0A

REDA/VHT

R i g h t h e a d l i g h t( l o w b e a m )

22

1 0A

REDI/E L

Left headlight (low beam)

1 0A

G R Yo r P N K

24

7 . 5A

GRN/ORN

25

7 . 5A

2a

YEL

204

GRN/BLK

1 5A

YEL/GRN

10 A,/' ]5A''

YEL/RED

M o o n r o o rf e l a y s Gaugeand indicatorlights.interlockcontrolunit Windshieldwiper motor,windshieldwashermotor, integratedcontrolunit {Canada) Accessorysocket(ACC) Audio unit,option (ACC) Not used

29 30

S R S U N i t( V B )

7 . 5A

RED/BLK

D a s hl i g h t so, p t i o n( d a s hl i g h t s )

1 . 5A

BLUA/VHT

PGM-Flmajn relay,integratedcontrolunit ECM/PCl\4,

RED/BLK

Front parking lights, taillights, license plate lights

7 . 5A 33 ' 9 6 *1r - 98models *2r '98 model *3: '99 - 00 models

WHT/GRN

lnterlockcontrolunit.key interlocksolenoid

23-65

Fuses ABSFuse/Relay Under-hood Box

lTo under-hoodABS tus€/relay box wire harnossl

c926

c92E

lTo main wire harness(C357)l

[To ABS pump motor relayl @27 ITo main wir6 harno$ {C356}l

FusgNumber 61

Wire Colol 40A

BRN/YEL

63

204

23-66

WHT WHT/GRN

Componont(s)or Circuit(sl Protscted ABS pump motor (viaABS pump motor relay) ABS controlunit (motorcheck) ABS controlunit (+Bl)

Power Distribution t

Circuitldentification '96-98models

UNDER-HOODABS BOX FUSEi RELAY

* 2 : 99-00models

WHT'GBN -

CONTROL

l ABsconlrorun

V

I

ABSAimpmolor

GRNMHT BRN,ryEL YEURED

I

t ABSconltolun

molor Slaner

HOOD UNDER FUSEi RELAY BOX ..........WHT/BLK ALTERNATOR No15(7sA)FUSE page (From 2370)

f7

V Y |

r_1

waming ligl Hazard reay Tunsignal/hazard {Viaswlch)

_WHT/GRN

HOTN

WHTiGBN

HOnreay

I_ .,.-., ABscontrollnil ECMiPCM T C M( C W ) r l Cruiseconlrolunil Erakelrghls

I-"-

GRN/RED

EC}?VPCM

('^') lg|[|];gil.'

*,,,,,*_$

lighl Ceiling Trunkllghr *' Spollighl Dalalinkconnecor(DLc) Integraledcontrolunil

G401 G402

WHT/8LK

w_TBLU-13

PGMFl mainrelay

I... > t-

UNOER.DASH F-SE?ELAY BCx Fa Nge23:t)

Audiounil T C M( C W ) ' , ECM/PCM Healerconlrolpanel

(cont'd)

23-67

PowerDistribution Circuitldentification(confdl UNDER HOOD FUSE/BELAY BOX

UNDEN.DASH FUSE/REIAY BOX flo page23-72) COMBINATION LIGHTSWITCH [Io page23 73, 74) UNDER,DASH FUSgRELAY BOX Oo page23'74)

wnc'N---}> wHT/GnN-

Hlgl;%,s,1 lsu'r"'

*,

Po#srdoorlockcontrol unil Moonrool molor

*HT/RED + BLUMHT-

*t Hoo5f;oA'.j1fu,uttto" Blowor fiolor

"*-f_ G()1 G402

BLu/rrit{t

(ViaA/C Fsssureswitch) ECI4/PCM

BLU/lf {I -

,VCth€modA

v{HT-

Con(,ensef lan molor

A/CcomFessor dulci

23-6 8

BLI(/RED

ECWPCM

BLI(RED

Radiator tanmolor

t

r 96'9€models * 2 : 99modol * 3 : GRY(96-97 models : GRN(9&00models

(40A)FUSE N0.42 page23.67) (Frofir FUSE/RELAY BOX UNDER.DASH

IGNTIONSWITCH

N0.16(7.5A)

WHTi BLK

t

BLI(BLU-

ABScontrolunit RELAY REAR WINDOW DEFOGGER deloggot swch) {ViaGarwndow fro page23-71 )

BA1;.' 1

l€ht Rearwindow d8loloerswilchindicalo.

'.._ ACC

r? ::: ) mirroa d€loQor Hrgn,Ma mirori;loggersYritch) lighl'2 Mirordolog06r $ tdr indicalor ri,,o,"qraor', 191 hEn,) oo*e, ivrapow mircrsMdr borsocl(el) lFusdrelay

WHT/BLK

I

conna.ior odional 1lG2)

I

. BLOWER MOTOR FELAY . CONDETISER FANRETAY . ,VCCOMPRESSOR RELAY CLWCH . NAONTOR FANRELAY pag€ 2368) 0o Heal€r conlrolPan6l ,ryCher|lDshl Modeconlrolmolor Reorolalion conlolmolor Aow€rmoloriEh aelay

V

fro page23'70)

0o pag623-12)

q, (/vrr

-

I

|.fi

::: F\

-113> vELrtsLK

t'-

I

I mrcr mircraqua|ol'r FUNNING LIGHIS DAY'IME (Ceneda) CONTFOL UN|T (f o We 23-71)

,n*,"',

,F1J'96-97mod6ls

""j '98-99 models

No.l2(7.5A)

N 0 . 1 (31 5 A )

GRNGRN_

Rearwindowwashermolof Rearwindow wipermolor

YEUBLK

relay Turnsrgnal/hazard (Viaswilch)

YEUGRN

PGM-Flmain relay

:rl l^r A k/YF l -

SRSunii(VA)

(7.54) N0.14 B./"|YEL lL

BLKryEL-

Ctr|s€conlrclJn (Viamainswildr) lEhl C'uEema'4swildr'ndicalot Audiounil(K€yossrece'ver drol4)

Kevless doortockconlroiunit

(Topage 23'70)

(cont'd)

23-69

PowerDistribution Circuitldentification(cont'd)

i.1 :'96,98 modes r.2 : 99mode *3 :GRY('96-97 models) :GRN(98'00models)

FUSE/REtAY BOX UNDEF.DASH

No1s(7sA) Anernal0r VSS HO2S EVAP conlrol canister ventshr,,l vafoe EVAP valve Flrgeconrolsoenord ECM/PCM"

sLrwHT+

Ft"t:itJY;i

BLI{WHT -}rcutcwt., BLKr'r{HT

Chargir!syslemtrghl

Back-!plighls

*3 (orPNn -

SRSunri(VB)

GBN/OF\--

Moolroolopelrelay relav MOOlrOOldOSe

POWERWINDOW RELAY (Topage23-71 ) N0.25(7.5A)

(Fusoirelay boxsockel)

InteEalei conLolunft

YEL-

Shinlocksoenod I r!/r\ lnleiockmnlrolunI J '- ' Galgeass€mbly lighl SRSindicalor ABSindicrtor lghl A/Igearposilionnd€lorl d,mmino - qrcu,l uru6e notcaoa )

(Fuse/relay boxsocl€l)

Inlegraledconlrclunt Windshield wipermolor

(ACo) IGN|T 0N SWTTCH page 23-69) lFrom

Y_ *,n,,*

........GRN,B-< | -

ImeEaleo cortolull (viawndshieLd wi9elswllci) .nolor wrrdsierdwasher (Viaswrn) power Accessory sockel(ACC) (Acc) oplioialconneclor Audio unil

23-70

l'N o5 4 1 4 0 AF)U S E (Frompage23 68)

FUSERELAYBOX UNDER.DASH

(Fuse/reay borsockel)

(+8) conneclor opliona

(7.s4) FUSE page 2370)

7 POWER WINDOW RELAY

N0.46 {40A)FUSE (From paqe23'67)

vI

"*-l_ ooo, c402

WHTiBLU BLUts-^ -

L

towetwiroowmasle's,r;.h Powerwtndow COn[Ol Jnil

(Viapower window master swilch) GRN/BLK -_J GRN/BLK GRN/BLK

power I Fronlpass€nger's moor wtnoow window masler masler sv \ swilch sr window /Viapower passengerb power I power I passengers I andfronl

-:: -.::::

I Lell'eatPowe'wndow-olot '/v'a powerwiroowmasle'swch \ \and lefl lear Powerwindowswilch./

':_:_:

I Rohlrearoolverwitow molol 'rv a @werwlfoowmaslerswrlcl l \end gh1re powerwndowswilch/

BL|(BLU -

Rearwindow delogger

No 50 (3OA)FUSE (Frcmpage 2368)

vI

N 0 . 1 (67 . 5 A ) F U S EWHT/GRN (Viaswlch) (Frompaqe23'69)

v I

BLU/YEL

"*-f,_ oit

G402

(cont'd)

23-71

PowerDistribution Circuitldentification(confdl IM/T)

(sT) rGNrTtoN swrTcH pag€ (From 23{9)

Y t-

STAFTER CUTRELAY

BLK,VHT

I

CLUTCH SWITCH

r**"'.fffr,u,r.*@**-_ -|:1jlBLT(-^,I'/HT

l

BLT(RED T

i

BLK^/HT-

l

$anersol€ndd

.

G401

BLIVREO

L-

(sT) rGNrTroN swtTcH paoe 23{9) {From

f'7 II BLK/WHT

NEUTFAL POSITION

swtTcH

/ln lL/Tgeat \ \posnionswldr/

BLT(RED

-

srarrer sotsnoid

-BLK4rrHr

(Fus€felay lox sockol) ELUVHT-

PGM-F| main retay

BLUMHT_

ECI\T/PCM

lH#|1'#i,'f,5>-**

l e ockconnol unit (viaintedocf switdr) Keyints ocl solenoid

wHr +

23-72

lrflagGt€dconlrolunit

&3T:$111.9|'ij""'n'"

!t

USA: UNDER,DASH FUSEiRELAYBOX COMEINATON LIGHTSWITCH

No.48(304) FUSE /Frcmpage\ \23{8 /

l 'o to"'to I

_ RED/BLU

(Highbeam) Figltlh6adlighl

_ BED/GRN

Highbeamindi€torlight

FEO/GRN

(Highbeam) Leflheadlighl

REDMHT

(Lowbeam) Rightheadlighl

REo/{EL-

Letl headlighl(Lowbeam)

No.a8G0A) FUSE /Frcmpage \ \23-72 )

(Fuse/relay boxsocl(el) (Fuss/relay boxsockel)

optioml @nn6clorloash hghls) InEgraledcontrolunil

HazardwamingsMch ligld Gaugelighls Audiounil nearwndowdelog0erswild lighl Cruisomainswitdrlighl ctuis€ndrcalot .. ]crmminocircu,t A/ | qsarposrrcnnor@IorJ Dashlighlsbrighhessmnlroller

FEo/BLK t

l'/T gea.pGilion consolelighl Heald conlrolpanelligtn

RED/BLK t

::: I lronloarkino liohl Hqm,

n-'i6J

*t"' t"itt'9t'6

inn"tu'll'gl't' n-,shj :: 1 | hcense Dlaleliohts Hgnri

(cont'd)

23-73

Power Distribution Circuit ldentification (cont'd) Canada: UNDER,DASH FUSE/RELAY 8OX COMBINATION LIGHTSWITCH

RED/BLU-

(Highboam) Rightheadlighl

----< FEDiBLU

N0.48{30A) /Ffornpage\ \a-68 l

l |oPASSTNG |

to

REstsTOR

REo/GRN

HiJhbeamindicator lighl

BEo/GRN -

Leftheadlighl iH,ghbeam)

L
N0.48{304) FUSE /Frompage\ \23-72 )

FEo/YEL-

(Lowbeam) L€llheadlight

(Fuse/lelay boxsockel)

(oashlighs) Optional conneclor Inleg6led conlrclunil

illtl-

Hazard wanirEswilch lighl Gauge lEhts Audio unil Re&window Yrindow Refi delogg8r delog$r swili light swildr Ctuisemainswrdrligh indEator Ctuise C/uiseindicalor l dimming 1 ,T gealposilion indicator J circu( Dasnlghlsbrignmess co oller

-

l/T ged positionconsolelqhl Hqalorcodrotpaneltighl

l-

Lefi ) . g;n1J lron 9arrn! qm

(7.54) N0.18 FUSE /Frompage \ \?3-69 J

N0.48(40A) FUSE /Frompaqe - \ \23-68 ,/

vY

E g"ffiry:'l,:1':::1

I YEUBLK

REo/BLK REO/BLK-F-

BRAKE SYSTEM LIGHT

FEDiBLK+

V

Letl I

{-

RqnJ ouerlarrqns I Al, I raittiotts i'-;*; inne'

E

fifi]t'"nt"o't't'sn"

F -

I

GFf

l-

,,4,,0*,

lf tIFLUD II ,j I LEVEL

*ro,rru -$

(Hrgh RcHTHEADLIGHT beam)

Y

-+ BEDiGRN

LEFIHEADLIGHT (High beam)

SWTCH

I 8LK I

I I

I :

G401 G402

23-74

RED6RN I

BLK

I

I PARKING I EFAKE I

swrrcH

I

I:

G401 G402

Ground Distribution Circuitldentification

Baaery

-* BLK L

o;l?f lso",ilE ;"., bqiu"trl'ff "*'n", ur,u" "ou.,,r,oo,

Trlnsmission ho!gng

(M/I) I Primary HO2S (,tffT) | {Ot6y5engtne) EGR valve EGBconrol I vave(vT) l sllenoid (Bl6A2engine) wEc flessure switdr BLK BLK

vss

BLK

PSPswtch

'96-98 '99-00models 816A2, D16Y7 engines models BRN/BLK

I

I

V

D16Y8engines D16Y5, 99-00modors

(Top?oe23-76,77)

s,-(-i-t;lBL(' E

pcMFrman reray tc" 't*' tn''n''*t''' ) wEC pressurc sMch (016Y5, : 98-00 models) D16Y8 engines

E

I 8an6ry ground cable

fal : Engine ground caueA

@ i EnginegrcundcableB

E

El , M"inttirehatn"."

: Engrne wirehamess

(cont'd)

23-75

Ground Distribution Circuitldentification(confdl '9&98 models:

(t[oileas6)>{

BRN/BLK

LGl I I EcM/PcM

lcz J

[..........{ j CKFsensor L.-!l (KS)r'::{ Knocts€rlsor PimaryH02S*?-

BFNaLK 8LU/FED REDtsLU wHT

ECIVPCM

Matnsnafi g]€eo sdnsoa -'1

Counlersiall speed sensor--={Fl

----Tal Ecr#PcM

t I HEL)

)*"

BIU

Dl6YBengine

44:lil

WHT/BED

Dl6Y5,D16Y7 sngine

vtl 8BM/BLK _ I BBi1/BLK I Divetrjileyspeed seftsor-1ll pulley 0 ven speedsensor.-lJ Seconftrygearshaltspeed sansor.-!.1

I rcurcwr

**'-i I WHT/RED + ]

WHT WHT/RED

*lr" h"rn""" El , Engln" : Main *re harness E

23-76

^l^1ll'.

FED,ALU

- - - - - - : Shietorns

* 1: D 1 6 Y 5 , 0 1 6e Yn8g i n o * 2 : ExceplDl 6Y5engine(i//T) +3: D16Y5engine(Mfi)

rt '99-00models:

(5i%ease)E>4 BRNiBLK

ERNi BtK

i.,.,].

BRIVBLK BFN/BLK

BRN/BLK BRN]BLK BRIl/8LK

BFN/BLK

r*s CKFs€nsor 1 t

r;l ao^r,qtr -1ll

'-l Knoq(sonsor(r15J

P maryHo2s*?H

ELU/FEU

!l r{EUl6LU

wHT

Mainshaflspeeossnsor -1ll

fiEU

Coutershall sp€edsensor -+F

] BLU

Ly"::::::::

)

..",r.u,.0n

Dl6Y5(CW)ongines 016Y7,

;;=-"r,i,-l

sngine 015Y5(LVT)

41-.1

;'4:v-..1 816A2,Dl6Ygengiftes

I

Ho2s:{ Secondary

Dfiv6prirEyspeeosonsot-1l

gr leysp€edsensor-Driven gea Secondary siansp€edsensor.-ll

WHT/RED-

l hEL,bLU

F I WHT WHT/RED

RED/BLU I

wHT f rau,rru(an) pgTpse- J

Bl6AzerEines Dl6Y8engines *4:016Y7, sLlbharness *1i016Y5, orygensensor wreharness E : Rearh€al6d E : Engine D16Y8Bngines ([VT) *5: D16Y5, D16Y7, *2: Excepl DI6YSengino (CW)engines *6:B16M, shielding D16Y8,016Y5 * 3:Dl6Y5 ([VT) wireharnsss -----sngine IIJ : Main

lcont'd)

23-77

GroundDistribution Circuitldentification(cont'dl

-

Erghrheadlighr

-

F r g rr: c l l p a ' h r rr3g r r Srgnlronl rufnsqfal qhi

;,.-

"'-fflri#*l:;:r.,, Wrdshield washer molor Rear window washer molor Cruise confolactualor lvasher level swch(Canada)

E

Enqine compenme wrre harness

23-78

t '96-98models: EL^ -

-

Y Y ' i i s n E o' F € " ' v ' u ' Bfale llJ d levetswlci

E

'D-cl I DahInl col"eclot

q q . - _

wperhvasher swildr Windshield

--l ,o,?'.da.

BLK-..1

BLIJ/REo

|-|d

Horn

wip€r^vasher swtch Rearwindow

l_ l-

'''"_-, rA/Tl p a ap i r s w i l c F t - , Clulcfnlelockswlcr rVT) Cruise conlrolunil

8LK

lrghtsconltolunil(CanaJa) Da,'lm€runnrng -

UNOEB,DASH FUSE/RELAY BOX

(M/Twilhcruise erEine) conlfolorlorD16Y5 (Fuserelay boxsockel)

relay Bearwindow delogger

(Flserelay borsockel)

Lnlegrated conlrol unil

(Fuse/relay boxsocke0 (Fuse/relay boxsockel)

Turnsignal/hazad @lay

8LK

J

6L^

G402 / Topage \ 23,81

--...........--

Munn'un'

+

oot

l-

Dashhghlsbfrqrllessco 'oel ftyess doorto* mnlrorLnil Seorriry @rl'olJn: Cnrisemainswilchlighl dirnming orcuil Cruiseindicalor swilchlighl Red window deloggel indicalor dimming cilo./il A/Tgearposilion

JUndon connedor

wireharness companmenl El : Engine , M"in*it" h"n".. E

retay Moofrootooen MOOnTOOI doserelay

B-(-llerX

5.nLi

?_ L

E

BLK-

Accessorypowersockel lighlcirclil SRSindicalor

BLK

endindicatols Cauges

BLK

ABSindicalor lighlcirq)rl

BLK

Gaugelights

: oashboatd w€ haness

wreharness @ : Moonrool

(cont'd)

23-79

GroundDistribution Circuitldentification(confd) '99-00models:

E

Wir'rdshield wipe.nolor BGkelluidlevelswildl

a-) l-

€y sv lo €nrnon oala hnk conn€clol lDlcl i

6L^ --

8LK

Windshigld dper^vash€r switdt

BLK

Re windo wiperlflasher ssitch

-r^ -..-l-

t m e n o o@( r o t u n nl . _ . p a * o i ns w h r h l \ 4 t l

inlerlodswildr(M,T) ClLrldr Cruis€ confolunit BL(---_

Oaymerunning tights (Canadal controtund Ctuldtsfich (l,t/Tvrithruis€corrol) Key'ess doorlockcontrol unit

UNOEN.DASH FUSgRELAYSOX (Fuserelay boxsockst) nearwindoYr delogger rclay (Fus€/relay boxsod(8t) htograted co.Irdunil (Fusdrelay borsockel) (Fuserelay boxsock€l) BLK

Tumsignal/hazard lelay

J

oh --t-

9aqe ( To 23.A2-

Moonroot swnm iroonrool openrelay Moonroot dosereiay

t -J fil BLK

G401

,JUncll0n @nfreclol

wirehamess tr : Engine@mparlrnenl

E

: Main wirehaness

23-80

: Dashboard wireharness El , Mo*tool*ite har".. E

8LK

SRSindicalor lighlcirqtil ,y'Tgoerposition indicator dimming cirdlit

BLK

poxersod@l Accessory

BLK

Gaug€s andindicators

BLK

ABSindicalor lightciro.lil

8LK

Gauge lighb Cruis€ mainswil$lEhl indicator Cruiso dimming cirorit oashlohlsbrighlness confolbt Hazard s$tdl indicator liohl

'96-98models:

(wirhABs)

8LK

A/Tjear Posilionswilch

-

seNic€check@nneclor

ABSFlmp motor

Audiounil

oit

-r-r:='

t

O

/

r

,!r'-,

BLK-

l

il-

B" t

-1:r'-

Powetdootlock@nlrolunil D vet s dootlockaclualor P yg15666110c1 swlgh

manswch ] po*ersindow E'0,'""a. *., *noo, ro,o, Fuelunil

BLK-liJ#1!ll3n"** G552

@ : fi-']

wrrehaness Dashboard

wireharness U : Floor hamess doorwire Drrve/s E

E E

A Healer sub'harness : Healer B subharness

(cont'd)

23-A1

Ground Distribution Circuitldentification(cont'dl '99-00 models: (WilhollABS)

r'1 6 | c40.tFroroaoe23-BC. I

BL( -<

I

L

E

_::I A,/Igefi posilion swilch ELDunil Servi@ checkconnector

UNDEF.H@D FUSF]RELAY BOX

rl--{ry--Browe,mororreray

BL-_14BL-

tL4

-11-51 ,r^ -.;--a-r,* n"*-fi-+aLx-lfuBLK-

-iff eLx

BLK

panel Hearer Hearer conrror conrror o6n

BLK -

"n' ff;?,m",:[:'

ABSglmpmotor

or*

_tr l G501

-

|t ,l - " * T - " ^

v

Pos€rdoorlockcortaolunit Divers doorlockaclualor Driver'sdoorlockswitch Lefl miror delogger

I

l

-L"."

BLK--.+t

G551

_ Power wndosmanswdch J Dive/sFo*grwindow motor

F-.

T F--{

BLK-.1

BLK-

Fighr.nirordetogger

ort, *it" hanes El ' Main : Dashboafd wircharness E

23-82

tr : Floorwirehamess haness tr : Drve/sdoorwife

E

: Healer sub-haness A

sub'harress B El : Healer

@

Passenger's doofw're hamess

Highmolnlbrakelighl wpermolor R€arwindow

G601

Bighmounlbrakelighl wipermolor Rearwindow TrLrnk laldlswilch

l"fn,) o*"'''*'nnt" '"t'n"' l",$')'nnt' lt$|n')''"nt"o'"'t,'nn" Tronklalci switch lighl brake Highmounl

ouo,

: 96-98models) (coupe/sedan

li|n')o*".'tt'nn'' 't*'n*" l[., ] 'nn"' .,"'jn,"""n"o'"t"''nnt" ) G601

BLK

Trunklaldr swlcll

*'lli.,ilJ:"f_'$l

{Sedan: 99 00 models)

E

:Fearwrehaness

E

, H"t"hnit"h"tnes"

(cont'd)

23-83

Ground Distribution Circuitldentification{confd}

Condens€r lanoDlor

-AGi51

F,'o."

Re wrndow d€,ogger (Ftald|bac*)

I

_a_

E] , ,,vc*itenatness ground window deloggs wile 0 : Rear E] , snst"in h.rn*

23-84

t GFY : '9&97ftod.ts GRN| 98-00models

Box Fuse/RelaY Under-dash Removal/lnstallation S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wl h e SRScomponentlocations,precautions,and procedures in the SRSsection(24)beforeperformingrepairsor ser-

lnstallation: 1.

C o n n e c t h e c o n n e c t o r st o t h e u n d e r - d a s ht u s e / relaybox,then installthe underdashfuse/relaybox in the reverseorderof removal(seesection24)'

2.

Installthe driver'sdashboardlower cover (seesec t i o n2 0 ) .

3.

Connectthe airbagconnectors{seesection24)

4.

Connectthe batterypositivecable,then connectthe negativecable.

5.

Enterthe anti-theftcodelor the radio,then enterthe customer'sradiostationpresets('99 00 models)'

6.

Confirmthat all sYstemswork properly'

vice. Removal: 1.

2.

Makesure you havethe anti-lheftcode for the radio then write down the frequencieslor the radio'spreset buttons('99- 00 modelsl. Disconnectthe batterynegativecable.then discon nectthe positivecable,and wait at leastthree min utes,

3.

the airbagconnectors(seesection24)' Disconnect

4.

R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d kneebolster(seesection20)

5.

Removethe two mountingnuts,and pull the under dashfuse/relaybox out from underthe dash'

6.

D i s c o n n e ctth e c o n n e c t o r sf r o m t h e u n d e r - d a s h fuse/relaybox, and take out the under-dashfuse/ relaybox (seesection24).

23-45

Power Relays RelayTest Turn Signal/Hazard Relay:

.

Rearwindow defoggerrelay

Seepage23-172 Normally-opentype: 1.

Checkfor continuitybetweenthe terminals. . Thereshouldbe continujtybetweenthe No. 1 and No.3 terminalswhen powerand groundare connectedto the No. 2 and No.4 terminals. . Thereshouldbe no continuitybetweenthe No. 1 and No. 3 terminalswhen power is disconnected. Terminal

\

1

-i*rt"r-*or\

3

Disconnected

o

Connected

,I YI

I

F>

, ? I rr

€

3

.

Blower motor relay

.

ABS pump motor relay

23-86

Startercut relayt'96 - 97 models Horn relayi'96 97 models a Blowermotor high relay:'99 - 0Omooers

Five-ierminaltype:

Normally-opsntYPe:

1.

Checkfor continuitybetweenthe terminals

1.

There should be continuity betlveenthe No. 1 and No. 2 terminalswhen power and groundare connectedto the No. 3 and No 5terminals. . Thereshouldbe continuitybetweenthe No 2 and No. 4 terminalswhen power is disconnected'

.

. Thereshouldbe continuitybetweenthe No. 1 and No. 2 terminalswhen powerand groundare connectedto the No. 3 and No 4terminals. o Thereshouldbe no continuitybetweenthe No 1 and No.2 terminalswhen poweris disconnected' \

Terminal Power iNo.3- No,4)

\ I

2

\

Terminal 4

Power(No.3 - No. 5)\

o- o

Disconnected

Disconnected

Connected

Checkfor continuitvbetweenthe terminals.

o

o

o-

Connected

--1 I Power window relaY Radiator fan relaY Condenser fan relaY a A/C compressor clutch relaY '98 - 00 models a Starter cut relay: '98 - 00 models a Horn relay:

-o

I I

t

'96 Moonroofopen relay: - 97 models '96 Moonroofcloserelay: - 97 models

(cont'd)

23-87

PowerRelays RelayTest (cont'd) Five-terminsltype: l.

Checkfor continuitybetweenthe terminals. .

There should be continuity betweenthe No. 1 and No, 2 terminalswhen power and ground are connectedto the No. 5 and No. 3 terminals. o There should be continuity between the No. 1 and No. 4 terminalswhen power is disconnected. Terminal

\

P"*"r{ltl"5-N".3)-\ Disconnected Connected

. .

1

oo-

4

---o ----o

Moonroofopen relay:'98-00models Moonroofcloserelay:'98 - 00 mooets

23-88

lgnition Switch Test

ElectricalSwitch RePlacement

SRS componentsare located in this area Reviewthe SRScomponentlocations.precautions.and procedures in the SRSsection{24}beforeperformingrepairsor ser-

SRS componentsare located in this area. Reviewthe SRScomponentlocations,precautions,and procedures in the SRSsection\24) beloreperformingrepairsor servtce.

1.

i / a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons('99- 00 models).

1.

M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons{'99- 00 modelsl.

2.

the batterynegativecable. Disconnect

2.

the batterynegatlvecable. Disconnect

3.

Remove the driver's dashboard lower cover and kneebolster(seesection20).

3.

R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r { s e e section20).

4.

Disconnectthe 5P connectorfrom the under dash fuse/relaybox and the 7P connectorfrom the main wire harness.

Disconnectthe 5P connectorfrom the under-dash fuse/relaybox and the 7P connectorfrom the main wire harness(seeleft column).

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.

Removethe steering column covers {see section 11t.

Terminal \

Position

1 (ACC)

(3) 5 (BAT) { t G 1 )

lnsertthe ignitionkey,and turn it to

(1)

G2)

(sr) 1.

o (LocK) | (ACC)

o- - o

l (oN)

o-

{LOCK)".

Removethe two screws and the electricalswitch from the steeringlock.

o

-o

o-

III (START)

"0

ELECTRICAL

swtTcH I I :7Pconnector Wire sideot femaleterminals WHT IBAT}

BLK/WHT{STI

7P CONNECTOR

WHT/BLK YEL(IG2}

BLK/YEL{IG1)

Wiresideof femaleterminals 6.

8.

Installin the reverseorderof removal.

lf the continuitychecksdo not agreewith the table, replacethe electricalswitch.

23-a9

lgnition Switch SteeringLockReplacement S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e SRScomponentlocations.precautions,and procedures in the SRSsection(24)beforeperformingrepairsor servtce. Remove:

Installation: l.

Installthe new steeringlock assemblywithout the key insened. Looselytightenthe new shearbolts-

L

M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w i r e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons('99- 00 models).

Insertthe ignition key, and checkfor proper operation of the steeringwheel lock and that the ignition keyturnsfreely.

2.

Disconnect the batterynegativecable.

Tightenthe shearboltsuntilthe hex headstwist off.

R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d kneebolster(seesection20).

sr{€aRSroLT Disconnectthe 5P connectorfrom the under-dash fuse/relaybox and the 7P connectorfrom the main wire harness(seepreviouspage). Removethe steeringcolumn covers,then remove the mounting bolts and nuts from the steeringcolumn (seesectionl7). Lowerthe steeringcolumnassembly, 1.

TWIST.OFFFORTION

Center-punch each of the two shearbolts,then drill their headsoff with a 5 mm (3/16in) dritt bit. CAUTION: Do not damagothe steering lock body.

Installin the reverseorderof removar. Enterthe anti-theftcode for the radio,then enterthe customer's radio station presets.

Removethe shearboltsand the steeringlockassem, oty.

23-90

Battery Test

@l your skin ol in your eyes Wear . Battery lluid lelectrolytel contalns sulfuric acid. lt may causesevere burns it it gets on protective clothing and a face shield. - It eleqtlolyte gets on your skin or clothes, rinse it off with watel immediately physician - lf electrolyte gets in your eyes,flush it out by splashing water in your eyes for at least 15 minutes; call a immediately. battery case and splatter . A battery gives off hydrogen gas. lf ignited, the hydrogen will explode and could crack the acid on you. Keepsparks,flames, and Gigarettesaway from the battery' spray out ot ths battery vents' o Overchaigingwill raise the temperature oI the electrolyte.This may force electrolyte to propcr rate. at a the battery Follow the charger manufacturel's instrustions, and chalge procedures.lf you don't have one of thesecomputUse eithera JCI or BearARBSTtester.and follow the manufacturer's erizedtesters,follow this conventionaltest procedure: ToqetaccurateresuIts,thetemperatureoftheeIectro|ytemustbebetweenT0"F(21.c)and100"F(38.c}'

lf the caseis crackedor the postsare loose,replace the battery.

lf rhe indicatorshows low electrolyte,add distilled water if Possible.

EYElndicatesOK

(#l ) Test LoadCaPacitY . A p p l y 3 0 0 a m p l o a d f o r 1 5 s e c o n d st o r e m o v e surfacecharge. . Allow 15 secondsrecoveryPerloo. . Apply test load {seeTestLoadChan). . Recordvoltageat the end of l5 seconds.

Staysabove9.6 volts; battery is OK.

Dropsbelow9.6volts.

(cont'd)

23-91

Battery Test (cont'd)

Chargeon High Sefting(40amps) Chargeuntil EYEshows chargeis OK; plus an additional30 minutesto assurefull charge. NOTE: lf the battery charge is very tow, it may be necessaryto bypassthe charger,spolarity protection circuitry. lf the EYEdoes not show chargeis OK within three hours,the batteryis no-good;replaceit. Write down how long the battery was charged.

Test Load Capacity(#2) Apply 300amp load for 15 secondsto removesurfacecharoe. Allow 15 secondsrecoveryperiod. Apply test load {seeTest LoadChan). Recordvoltageat the end of 15 seconos.

Stays above 9.6 volts; battery is OK.

,

]

Drops below 9.6 volts; baftery is no-good.

TESTLOAD CHART Usethe test loador 1/2the cold crankingamps {CCA)printedon the labelon the top of the banery.lf neitheris indicated.usethe informationbelow:

tu,

BArrERy coDE

* : 5 5 8 2 4 1( S )- M F

23-92

I

coLb@ AMps(ccAl 4 0 5( * 4 1 0 )

|

{amps) 200

StartingSystem ComponentLocationIndex

STARTERCUT RELAY(M/T} Test, page 23-86,87 A/T GEARPOSITIONSW|TCH Test,page23'154 page23-155 Replacement, CLUTCHINTERLOCK

swlTcH

o

o

ool

BATTERY Test,page23-91

STARTER Test, page 23'95 SolenoidTest,Page23 96 Replacement, Page23-100 PerformanceTest,Page23-101

23-93

Starting System ComponentLocationlndex G N I TO N S WT C H

UNDEF.HOO FU OS E i F E LB AO YX N04l (80A)

N042 (40A)

t,U,-*€,-l

ELKMHT

I t

&T GEAR POSITION SWITCH (CosednposilioN n or E)

81X,4{HT

l

BLKIWHT

STARTER CUTFELAY

-

STAPTER (Permaneit nragnel type)

23-94

__l

-

Starter Test Checkthe battery.battery positive cable, ground, startercut relay,and the wire connectionsfor loosenessand corrosion,Testagain. lf the starterstill does not crankthe engine,go to step 4,

NOTE; The air temoeraturemust be between 59 and 100'F(15 and 38"C)beforetesting. RecommendedProcedure: . .

Usea stanersystemtester. C o n n e c ta n d o p e r a t et h e e q u i p m e n ti n a c c o r d a n c e instructions. with the manufacturer's . Testand troubleshootas described,

wire and solenoid Unplug the connector(BLK,/WHT terminal)from the starter, Connecta jumper wire from the batterypositive(+) terminalto the solenoidterminal. The startershouldcrankthe engine.

Alternate Procedurg: .

Usethe followingequipment: - Ammeter,0 - 400A - Voltmeter,0 - 20 V (accuratewithin 0.1volt) - Tachometer,0 - 1,200rpm . Hookup a voltmeterand ammeteras shown.

NEGATIVE TERMINAL

.

NOTE:After this test, or any subsequentrepair. reset to clearany codes(seesectionl1) the ECM/PCM

.

Checkthe Start€r Engagemont: 1.

2.

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

Checkthe ignitionswitch(seepage23-891. 7.

Turn the ignition switch to START(llll with the shift lever in E or E position (rVT)or with the clutchpedal depressed{M/T).The startershouldcrankthe engine.

.

lf the starter does not crank the engine, go to step 3. y, l f i t c r a n k s t h ee n g i n e e r r a t i c a l l y o r t o o s l o wgl o to "Checkfor Wear and Damage" on the next page.

Checkthe startercut relay and clutch interlockswitch (seepage23-86,87). Checkthe A/f gear positionswitch(seepage23-154).

9. .

l f t h e s t a r t e rs t i l l d o e s n o t c r a n k t h e e n g i n e , removeit, and diagnoseits internalproblem lf the startercrankstheengine,goto step6.

Checkfor an open in the wire betweenthe ignition switch and starter.

(cont'd)

23-95

Starting System StarterTest lcont'dl

StarterSolenoidTest

Ch€cktor Wear and Damage The startershould crankthe engine smoothly and steadily,lf the starter engages.but cranksthe engine erratically,removeit, and inspectthe starterdrive gear and torqueconverteror flywheelring gearfor damage.

1.

.

Checkthe drive gear overrunningclutchfor binding o r s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e drive gear held, - lf damaged.replacethe gears.

Checkthe hold-incoil for continuitvbetweenthe S t e r m i n a la n d t h e a r m a t u r eh o u s i n g( g r o u n d )T. h e coil is OK if thereis continuitv,

ARMATURE HOUSING (GROUND) S TERMINAL

CheckCranking Voltsge and Curr€nt Draw Crankingvoltageshouldbe no lessthan 8.5volts. Currentdraw shouldbe no more than 350amperes. lf crankingvoltageis too low, or currentdraw too high, checkfor; . dead or low batterv. . o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g ments, . starterarmaturedragging. . shortedarmaturewinding. o excessivedrag in engine. CheckCranking rpm Enginespeedduringcrankingshouldbe above 100rpm, lf speedis too low, checkfor: . loosebatteryor stanerterminals. . excessively worn starterbrushes, . open circuitin commutatorsegments. o dirty or damagedhelicalsplineor drive gear. . defectivedrive gearoverrunningclutch. CheckSiarter Disengag€ment With the shift lever in El or @ position(A/T)or with the clutchpedaldepressed(M/T),turn the ignitionswitchto START(lll),and releaseto ON (ll). The starterdrive gear shoulddisengagefrom the torque converteror flywheel ring gear when you releasethe Key. lf the drive gear hangsup on the torqueconverteror flywheel ring gear,checkfor: . solenoidplungerand switchmalfunction, . dirty drive gear assemblyor damaged overrunning clutch.

M TERMINAL

B TERMINAL STARTER CAELE

B TERMINAL MOUNTINGNUT I N.m {0.9kgf.m, 7 tbf.ft)

Check the pull-in coil for continuity between the S and M terminals. The coil is OK if there is continuity.

J

ArmatureInspectionand Test 1 . Inspectthe armaturefor wear or damagedue to contactwith the permanentmagnetor fieldwinding. VERNIER CALIPEB

.

lf there is wear or damage.replacethe armature. I n s p e c tf o r d a m a g e .

2.

Checkcommutatorsurfaceand diameter. lf the surfaceis dirty or burnt. resurfacewith emery cloth or a lathewithin the followingspecifications, or reconditionwith #500or #600sandpaper. . lf commutatordiameteris belowthe servicelimit, replacethe armature.

.

3.

Measurethe commutatorrunout. .

. Commutator Diameter Standard{NEW) 2 8 . 0- 2 8 . 1m m ( 1 . 1 0-2 1 . 1 0 6 in)

ServiceLimit 2 7 . 5m m (1.083 in)

l f t h e c o m m u t a t o r u n o u ti s w i t h i n t h e s e r v i c e limit, checkthe commutatorfor carbon dust or brasschipsbetlveenthe segments. lf the commutatorrunout is not within the service limit, replacethe armature.

Commutator Runout Standard(NEW) 0 - 0 . 0 2m m (0 - 0.0008in)

ServiceLimit u-u!rmm (0.002in)

COMMUTATOR

(cont'd)

23-97

Starting System ArmatureInspectionand Test (cont'dl 4.

Checktor mica depth. lf necessary,undercutmica with a hacksawblade to achieveproper depth. l{ servicelimitcannotbe maintained, replacethe armature.

6.

Placethe armature on an armaturetester. Hold a hacksawbladeon the armaturecore. ARMATURE TESTER

NOTGOOD

MICA D€PTH

Commutator Mica D€pth Standard(NEW) 0 . 4- 0 . 5m m - 0 . 0 2i n ) (0.016

ServiceLimit ARMATURE

0 . 1 5m m (0.006in) .

5.

Checkfor continuitybetweenthe segmentsof the commutator.lf an open circuit exists betweenany segments,replacethe armature. 7.

lf the blade is attractedto the core or vibrates while the core is turned,the armatureis shorted. Replacethe armature.

Checkwith an ohmmeterthat no continuityexists betweenthe commutator and armature coil core, and betweenthe commutatorand armatureshaft.lf there is continuity,replacethe armature.

corLcoFE

23-98

COMMUTATOR

J

BrushInspection

BrushHolderTest 1.

Checkthat there is no continuitybetweenthe O and o brushholders. l f t h e r e i s c o n t i n u i t y , r e p l a c et h e b r u s h h o l d e r assemoly.

Measurethe brush length.lf not within the servicelimit, replacethe brush(or brushholderassembly). Brush Length Standard(NEW) 1 5 . 8- 1 6 . 2m m (0.62- 0.64in)

O BRUSHHOLDER

@ BRUSHHOLDER

2.

€) BRUSHHOLDER

Insertthe brushinto the brushholder,and b.ing the brushinto contactwith the commutator,then attach a springscaleto the spring.Measurethe springtension at the momentthe springliftsoff the brush.

SPRINGSCALE

ServiceLimit 11 . 0m m { 0 . 4 3i n )

NOTE:To seatnew brushesafterinstallingthem in their holders,slip a strip ot #500or #600sandpaper.with the grit side up, over the commutatorand smoothly rotate the armature.The contactsurfaceof the brusheswill be sandedto the samecontouras the commutator.

OverrunningClutchlnspection L

Slidethe overrunningclutchalongthe shaft.Doesit movefreely?lf not, replaceit.

2.

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

ERUSH

SpringTension 15.7- 17.7N (1.60- 1.80kgf.3.5- 4.0 lbf)

DRIVEGEAR

Starting System Starter Replacement

StarterReassembly

1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons('99- 00 models).

'1.

Pry backeachbrushspringwith a screwdriver, then positionthe brush about halfwayout of its holder. and releasethe springto hold it there.

Disconnect the batterynegativecable. Disconnectthe startercablefrom the B terminalon t h e s o l e n o i d t, h e n d i s c o n n e ctth e B L K t r H T w i r e from the S terminal. MOUNTINGBOLT 44 N.m l/t.s kgf.m.32 lbf.ft)

S TERMINAL

Installthe armaturein the housing.Next, pry back each brush spring again,and push the brush down until it seatsagainstthe commutator,then release the springagainstthe end of the brush.

aw

MOUNTINGBOLT 6,1N.m {4.5kstm.32lbtftl B TERMINAL

4.

MOUNTINGNUT 9 N,m {0.9 kgl.m, 6.s lbtftl

R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r ,t h e n remove the starter. lnstallin the reverseorderof removal. 3.

Installthe end coveron the brushholder.

NOTE:When installingthe staner cable,make sure thatthe crimpedsideofthe ringterminalis facingout. ERUSHHOLDER Crimped side of ring

TERMINAL

Connectthe batterypositivecable and negativecable to the battery. 7.

Enterthe anti-theftcodefor the radio,then enterthe customer'sradiostationpresets('99- 00 models).

23-100

-

Test Performance NOTE:Beforestaning the following checks.disconnect t h e w i r e f r o m t e r m i n a lM . a n d m a k e a c o n n e c t i o na s describedbelow using as heavya wire as possible(preferto the wire usedfor the car). ablyequivalent

RetractingTosi:

Pull-inCoilTest:

GAUTION: Do not loave the baftery conn€ctodtor more than 10 seconds.

Disconnectthe batteryalso from the body. lf the pinion retractsimmediately,it is workingproperly.

Connectthe batteryas shown, lf the staner pinion pops out. it is working proPerly. CAUTION: Do not leavo tho batterv connost€dfor more than 10 seconds.

Startor No-loadTost: 1 . Clampthe starterfirmly in a vise. Connectthe starterto the batteryas describedin t h e d i a g r a mb e l o w , a n d c o n f i r mt h a t t h e m o t o r starts and keepsrotating. Hold-in Coil Test: the batteryfrom the M terminal'lf the pinion Disconnect does not retract,the hold-incoil is working properly. CAUTION: Do not loavc lhe battsry connectedfor mot6 than 10 ssconds.

3,

lf the electric current and motor speed meet the when the batteryvoltageis a t 1 1 . 5V , specifications the starteris workingProPerly.

Specifications: 8 0 A o r l e s s ( E l e c t r i cc u r r e n t ) , 2 , 6 0 0r p m o r m o r e (Motor-speed)

23-101

lgnition System ComponentLocationIndex IGNITIONTIMING CONTROLSYSTEM . Troubleshooting, section11 . ldle speedInspection/Adjustment. section11 . Inspectionand Setting,page23-105

SERVICECHECKCONNECTOR {2P} Iwiie colors:8RN and BLKI

CONNECTOB TESTTACI{OMETER

IGNITIONWIRES lnspectionand Test,page23-110

PLUGS I n s p e c t i o n ,p a g e 2 3 1 1 1

R e p l a c e m e n t ,p a g e 2 3 ' 1 0 6 Overhaul, page 23-107 lgnition Coil Test, page 23'110 lgnition Control Module llCM) Input Test, page 23-109

23-102

lgnition System -

CircuitDiagram:'96 - 97 models UNDERHOODFUSE/RELAY8OX

r U S EF E - A VB O }

*u r-. .-*---{<9ot #

\j/

u,,."r.

|

El

|

t

v

l

B L hT E L Y E LG B N

BLKlYEL

I A l

T D C r T odpe a dc e n l e r postion CKP:Crankshall C Y PC y l n d epro s l o n

.i-

B L K / Y E LY E L I G F N IGN]TION COL

"

*]BLU' * 2 W H IB L U

I G N I T I OCNO N I R O L M O D U L(EC M ) / Hasb'rll n\ I iorse I

T D C ] C K P ] CSYEPN S o R

' J-) t I {sh,eldinsr

tf +++ $t+ l YEL

BBN/BLK

8LU

I

n

B L U B L UI

t l lI TEST n

I \-7

TACHOMETEF CONNECTOR

TACHOMETER TCM(CW)

I :

G101

23-103

lgnition System CircuitDiagram:'98-00models UNDER HOOD FUSUFELAY BOX

'x'E;;;;-;;;;l

UNDER,DASH FUSE/BELAY BOX

IGN]TION

swtTcH

/;\

Ecw.cM

l-*;-

ffiwFnBLK<-wHr\9-

t

Y

l

BTKTYELYEUGRN

9

+ FED

*IBLU'

YEt

BLK

J

J * 1 : HT A C H I *2 :TEC

23-104

-

lgnitionTiming Inspectionand Setting 1 . Checkthe idle speed,and adjustit it necessary(see '1 section 'l ).

6.

Pullout the servicecheckconnector2P (BRNand BLK wires)from the connectorholder locatedunderthe dash on the front passengerside,then connectthe to it. SCSserviceconnector(T/N07PAZ- 0010'100)

Adjust the ignition timing if necessary,as follows. Loosenthe distributormountingbolts.and turn the to distributorignition(Dl)housingcounterclockwise advancethe timing, or clockwiseto retardthe timing. ro ADVANCE -<;,

Startthe engine.Holdthe engineat 3.000rpm with no load {A,/Tin E or E. M/T in neutral)until the radiatorfan comeson, then let it idle. Connectthe timing light to the No. 1 ignitionwire, then pointthe light towardthe pointeron the timing belt cover. C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s : headlights.blower fan, rear window defogger,and air conditionerare not operating. lgnhionTiming: BOLTS MOUNTING 18N'm(1.8kgfm,13lblftl

D15Y5.D16Y7,Dl6Yg engines M/T

1 2 ' t 2 " B T D C( R E Dd) u r i n gi d l i n gi n neutral l 2 ' r 2 " B T D C{ R E Dd) u r i n gi d l i n gi n S orE

7.

Tightenthe distributormountingbolts,and recheck the ignitiontiming. the SCSserviceconnectorfrom the serDisconnect check connector. vice

816A2engine MIT

1 6 "1 2 ' B T D C( R E Dd) u r i n gi d l i n gi n neutral

POINTEB

REDMARK

23-105

lgnition System DistributorReplacement 4,

Removal: 1.

Disconnect the connectorfrom the distributor.

2.

Disconnectthe ignition wires from the distributor i g n i t i o n{ D l )c a p .

3.

Connectthe ignitionwires to the distributorignition (Dl)cap as shown.

rracfit' No. 1 CYLINDER MARK

Removethe mounting bolts from the distributor, then removethe distributorfrom the cylinderhead.

DISTRIBUTOR END

CAMSHAFTEND

TEG:

No. 1 CYLINDER

MOUNTING BOLT 18N.m11.8 kgtm,13lbf.ltl

No. 2

lnstallation: NOTE:Beforeyou installthe distributor.bring the No. 1 piston to compressionstroke TDC. 1.

Coata new O-ringwith engineoil, then installit.

2.

Slip the distributorinto position NOTE:The lug on the end of the distributorand its mating grooves in the camshaft end are both offset to eliminatethe possibilityof installingthe distributor 180"out of time.

3.

Installthemountingbolts,and tightenthem lightly.

23-106

No.a

5.

Connectthe connectorto the distributor.

6.

Setthe ignitiontiming (seepreviouspage).

7.

After settingthe ignitiontiming, tightenthe mounting bolts.

el -

DistributorOverhaul HITACHI: IGNITION DISTRIBUTOR {DI}HOUSING Checkfor cracksand damage.

Test,page23_110

TOC/CKP/CYP T r o u b l e s h o o t i n g ,s e c t i o n 11 Do not disassemble.

IGNITIONCONTROLMODULE(ICMI InputTest,page23'109

CAPSEAL Checkfor damage.

I G N I T I O N{ D I ) C A P C h e c k f o r c r a c k s ,w e a r , damage, and fouling. Clean or replace,

{cont'd)

23-107

lgnition System DistributorOverhaul(cont'dl TEC: COVER DISTRIBUTOR IGNITIONIDI) ROTOB CAPSEAL Checkfor damage. DISTRIBUTOR IGNITION{DII CAP Checkfor cracks,wear, damage,and fouling. Cleanor replace,

IGNITIONCONTROL MODULEIICM' InputTest,page23-1

WHT/BLU

IGNITIONCOIL Test,page23-110

O-RING Replace

\

I

@

DISTRIBUTOR IGNITION{DI}HOUSING C h e c k f o r c r a c k sa n d d a m a g e .

23-104

TDC/CKP/CYP S€NSOR Troubleshooting, section11 Do not disassemble.

J

lgnitionControlModule(lCMlInputTest Turn the ignition switch ON (ll). Checkfor voltage wire and body ground. betweenthe BLK/YEL Thereshouldbe batteryvoltage.

NOTE: . See section 1'l when the malfunctionindicatorlamp ( M l L )t u r n e do n . . Performan input test for the ignitioncontrol module ( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atle s t sf o r t h e ignitionsystemand the fuel and emissionssystems 1.

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

2.

the wiresfrom the lCM. Disconnect

lf there is no batteryvoltage,checkthe BLK/YEL wire betweenthe under-dashfuse/relaybox and r h el c M . . lf there is batteryvoltage,go to step4.

.

Turn the ignition switch ON (ll). Checkfor voltage betweenthe wire*r and body ground Thereshouldbe batteryvoltage.

HITACHI:

lfthere is no batteryvoltage,check: - the ignitioncoil. - the wire*1 betweenthe ignition coil and the tcM. . lf there is battery voltage, go to step 5

.

* 1 : B L U ' w i r e( H I T A C H I ) WHT/BLUwire (TEC) Disconnectthe EcM/PCMconnectorA (32P).Check for continuity on the YEUGRNwire between the and the lCM. ECM/PCM Thereshouldbe continuity. Checkfor continuityon the YEUGRNwire to body ground. Thereshouldbe no continuity.

BLK/YEL

7. TEC:

Checkfor continuityon the BLUl wire betweenthe testtachometerconnectorand the ICM Thereshouldbe continuitY. Checkfor continuityon the BLUl wire to body ground. Thereshouldbe no continuity. lf all the testsare normal,replacethe ICM

23-109

lgnition System lgnitionCoilTest

lgnition Wire lnspectionand Test

Using an ohmmeter, measureresistancebetweenthe terminals.lf the resistanceis not within soecifications. replacethe ignitioncoil.

C A U T I O N :C a r e l u l l y r e m o v e t h e i g n i t i o n w i r e s b y pulling on the rubber boots, Do not bend the wires; you might breakthem inside.

NOTE: Resistancewill vary with the coil temperature; specifications are at 68'F (20'C).

'1. Checkthe condition of the ignitionwire terminals.lf any terminalis corroded,cleanit, and if it is broken or distorted,replacethe ignitionwire.

HITACHI: Primary Winding Resistance {Betwesn the A and B lerminalsl; 0.45- 0.550 SecondaryWinding Resistanc€ (Betweenthe A and secondarywinding terminals): 22.1- 33.6 kA TERMINALB {-) TERMINALA

Checkfor broken, corroded,and bent lermrnals.

IGNITION WIRE

Connectohmmeterprobesand measureresistance. TEC: Primary Winding Resistsnce {Betweenthe A and B terminalsl: 0.63- 0.770 SecondaryWinding Resistance (Betweenthe A and secondarywinding terminals): 12.8- 19.2kO

lgnition Wire Resistance: 25 k0 max. at 68"F (20"C)

SECONDARY WINDING TERMINAL

IGNITIONWIRE

TERMINALA

23-110

TERMINALB (-)

3.

lf resistanceexceeds 25 kO, replacethe ignition wire.

Spark Plug lnspection 1.

Inspectthe electrodesand ceramicinsulatorfor: Worn or detormed

[ | i | I

. . . .

3.

t.p,op", grp Oil-fouling Carbondeposits Crackedcenter electrodeinsulator

8 1 6 A 2e n g i n e : . D o n o t a d j u s t h e g a p o f a p l a t i n u mt i p p l u g ; replacethe spark plug il the centerelectrodeis roundedor it the gap is not within the specifica t r on s . ElectlodeGap: 1 . 3 1 8 1 m m( 0 . 0 5 1! 3 o o i"n )

Standard

Cracked insulator

Platinumtip

flOUNDEDELECTROOE

',/

@_ :

Burnedor worn electrodesmay be causeclby: . Advanced i g n i t i o nt i m i n g . Loosesparkplug . Plug heatrangetoo low . Insufficient cooling F o u l e dp l u g sm a y b e c a u s e db Y : . R e t a r d e idg n i t i o nt i m a n g . O i l i n c o m b u s t i o cnh a m b e r . I n c o r r e cstp a r kp l u gg a p . P l u gh e a tr a n g e t o oh i g h . E x c e s s i vi ed l i n g / l o w s p e e dr u n n i n g . C l o g g e da i rc l e a n eer l e m e n t . Deteriorated ignitioncoil or ignitionwares 2.

D 1 6 Y 5D, 1 6 Y 7D, ' 1 6 Ye8n g i n e l . Adjustthe gap with a suitablegappingtool, and replacethe plug il the centerelectrodeis rounded as shown below.

NOTE:Useonly the sparkplugslistedbelow EngineTypes

SparkPlugs

D16Y5

Z F R 4 F1 1 ( N G K ) K J 1 4 C R - 1 (1D1 E N S O i

D16Y7, D,I6Y8

Z F R S F - 1 (1N G K ) KJ16CR-111(DENSO)

81642

P F R 6 L . 1( 3N G K ) P K 2 O P R . L(1D3E N S O }

4.

Apply a small quantity of anti seizecompound to the plug threads, and screw the plugs into the cylin der head finger-tight. Then torque them to 18 N m 1 1 . 8k g f . m ,1 3 l b n f t ) .

ElectrodeGap: Standard

1 . 1 r 8' m m ( 0 . 0 4 3 i 8 0 0 o i n )

1 . 1m m {o.{X:lin)

1

ROUNDED ELECTRODE

T

23-111

ChargingSystem ComponentLocationIndex

CHARGINGSYSTEMLIGHT (ln the gaugeassembly) Test,page23-l14

UNDER.HOOD FUSE/RELAY BOX ELECTRICAL LOADI /*Hasreplaceable (ELD)UNIT I DETECTOR '

Troubleshooting, page23-114 Replacement, page23-120 BectifierRemoval,page23,121 Rectifier Test,page23-122 RearBearingReplacement, page23-j24

*ELDunit: USA

23-112

BATTERY Test, page 23-91

[]

ALTERNATOR BELT Inspection andAdjustment, page23-t25

-

CircuitDiagram BOX RELAY HOODFUSEi IJNDER BATTERY

N0.41(80A)

,-a\

No42(40A)

I

,'-F\ BAT

I LGNlTION Gl / SWITCH

I \

\l_/ I

GRN/RED

I

I

CHARGING SYSTEM LIGHT

T

WHTiBLU

ECM/PCM

f7

I

WHT/RED

ALTERNATOF

23-1 1 3

ChargingSystem Troubleshooting lf the chargingsystemlight does not come on or does not go off, or the batteryis deador low, test the followingitems in the order listedbelow: 1. 2. 3. 4. 5.

Baftery(seepage23-91) Chargingsystemlight Voltage Alternatorcontrolsystem(USA) Alternator/regulator

ChargingSystom Light Test Charging Svstem Light Check-l : lvlakesure the chargingsystem lightcomeson.

Doesthe chargingsystem lightcomeon?

Check for a blown No. 15 t7.5A) fuso .nd a blown charging systom light bulb. ll the fuse .nd bulb .re OK, ropair the open in th6 WHT/BLUwi16.

Charging System Light Chec*-2: Startthe enoine.

Doesthe chargingsystem light go off?

ALTERNATOR 4PCONNECTOR IUSA) Wire side of femaleterminals

Volta96 Checkl Measlrethe voltageat the No. 1 lNo.2l terminalof the 4P [3Plconnectorwith the ignition switch ON flr).

ls there batteryvoltage?

IG (8LK/YEL}

R6p.ir the op6n in the BLK/YEL wire b€twsen tho altornator and und€r-dashtuso/.glay box.

ALTERNATOR 3P CONNECTOR lC.nadal Wre sideof temaleterminals

[ ]: Canada

23-114

ALTERNATOR4P CONNECTOR (USAI

{Frompreviouspage)

r?-r l 1 l 2 lWiresideof

FFI

Check tor an open in tho L cir' cuit-1: 1. Turnthe ignitionswitchOFF 2 . D i s c o n n e ctth e 4 P [ 3 P l c o n nectorfrom the alternator. 3. Groundthe No. 3 terminalof the 4Pl3Plconnector. 4. Turn the ignitionswitchON (ll)

Doesthe chargingsystem lightcome on?

femaleterminals

L ]-twHT/8LUl

I

Turn the ignition swhch OFF,and rep.ir tho open in tho wHT/ BLU wire.

3PCONNECTOR ALTERNATOR lCanada) Wire side of temaleterminals L IWHT/BLUI

.+1

l rl 2 l

-l-

l3T.l Checkfor an open in the L circuit-2: the No 3 terminalo{ Disconnect the 4P [3PI connectorfrom the ground.

L {W}IT/BLU)

ir/

Doesthe chargingsystem light go off.r (WHT/BLUI

Turn lhe ignition 3whch OFF,and .epair the 3hort to gtound in the wHT/Bl-U wire.

I l: canada

(cont'd)

23-115

ChargingSystem Troubleshooting (cont'd) Alternator Control System Test (USA):,96 - 98 modets, ,99 _ 00 Dl6y5 (M/Tl engine NorE: Beforetesting.checkproperoperationof the ELDby confirmingwith the MrL {seesectionr 1). Check for a 3hort in the circuit IALTClinel: 1. Reconnectthe 4P connector to the alternator, 2. Stan the engine,and turn the headlights{highbeam)ON. 3. Measurevoltage between the 4P connectorterminal No. 2 and the positive terminal of the battery.

BATTERY CAUTION: Be 3ure to use a voltmot€. with its plus terminal connectedto b.ttery plus and its minus terminal to the {P connectoi tgmrinal No. 2.

c {WHT/GRNt ALTERNATOR .P CONNECTOB

Wire sideoI femaleterminals

A I32PI ECM/PCMCONNECTOR 'I

a

ls there1V or less?

12 1 3 14 1 5

1

I

10 1 1

1 7 1 8 t 9 20 2'l 22

7

26 27 Check for rn opon in tha wire (ALTClinol: 1 . T u r n t h e h e a d l i g h at n d i g n i tion switch OFF. 2. Disconnect the 32Pconnector trom the ECM/PCN4. 3. Checktor continuity between the ECM/PCM32P connector terminalNo. 19 and alternator 4PconnectorterminalNo.2.

8

Wire sideof femaleterminals

21

30 ALTC (WHT/GRNI

([l

Tc

{WHT/GRNI

1 Wire side oI femaleterminals

2

ALTERNATOR

1

Bspair open in thg wire lrstween the rhern.tor .nd ECM/PCM.

ECM/PCMCONNECTOB A (32PI

Check for short in the wire (ALTC linel: 1 . T u r n t h e h e a d l i g h at n d i g n i tion switch OFF. 2. Disconnect the 32Pconnector trom the ECM/PCM. 3. Checktor continuity between the ECM/PCM32P connector t e r m i n a lN o . 1 9 a n d b o d y ground.

I

23-116

3

4

7

1 2 13 14 15 16 17 1 8

8

9

10 t 1

20 21 22 23 21

26 27

30

Wire side of femateterminats

I A

Subslitute a known-good ECM/ PCM,.nd .och6ck. It p.escribodvohago i! now available, replacethe original ECM/ PCM. Ropair3hort in the wiro betweon the ahe.nator and ECM/PCM.

2

AITC (WHT/GRN|

'99 - 0Omodels, except Dl6Y5 {M/T} engine Alternator Control System Test {USA}: MIL (seesection11)' NOTE:Beforetesting,checkproperoperationofthe ELDby confirmingwith the

BATTERY

Checklor a sho.t in the circuit {ALTCline): 1, Beconnectthe 4P connector to the alternator. 2. Startthe engine,and turn the headlights(highbeam)ON. 3. Measurevoltagebetweenthe 4P connectorterminal No. 2 a n d t h e P o s i t i v et e r m i n a lo f the battery.

CAUTION: Be sura lo use a voltmeter with its plus te.minal conneqtedio battery plus and it3 minus tgrminal to ths 4P connoctottomrinal No. 2.

c

(WHT/GRNI

Wire sideof femaleterminals

ALTERNATOR .P CONNECTOR

C 13lPI ECM/PCMCONNECTOR

ls there 1 V or less?

Chcck for rn opon in the wire (ALTClin6l: 1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF the 31Pconnector 2. Disconnect trom the ECM/PCM. 3. Checkfor continuitybetlveen the ECM/PCM31P connector terminalNo. 2 and alternator 4PconnectorterminalNo. 2

wire sideof femaleterminals Repairopcn in the wire botweon the alternstoi.nd ECM/PCM.

ls therecontinuity?

C (31PI ECM/PCMCONNECTOR Checktor short in the wire IALTC line): 1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF the 31Pconnector 2. Disconnect from the ECM/PCM. 3. Checkfor continuitybetween the ECM/PCM31P connector terminalNo. 2 and body ground.

1

2 3 23

8 I 10 5 6 1 zo 2122 /116 1 1 l o 191 25 26 21 ?8 2930 J I

ALTC (WHT/GRN)

Wire side of female terminals

o Substitute a known'good ECM/ PCM,and recheck. It prscribed voltagg is now avail' abl€, replacetho original ECM/ PCM.

Raoairshort in the wite between the alle.nator and ECM/PCM,

(cont'd)

23-117

ChargingSystem Troubleshooting(cont'd) Alt6rnator/RegulatorTest NOTE:Makesurethe bafteryis sufficientlycharged(seepage23-9j). Alte.nator/RegulatorTest'1: L C o n n e c ta S u n V A T 4 0 ( o r e q u i v a l e n t e s t e r ) ,a n d t u r n the selectorsw;tchto position 1(staning). 2. Shift to neutral(A/T in E or , n d s t a r tt h e E) positiona e n g i n e .H o l d t h e e n g i n ea t 3,000rpm with no load until t h e r a d i a t o rf a n c o m e s o n , then let it idle. 3 . R a i s et h e e n g i n es p e e dt o 2,000rpm,and hold it there.

l s t h e v o l t a g e o v e r 1 5 . 1V ?

LOADAOJUSTER {CARAONPILEI

tffil rCI 'aHrl

[ @lBt* . ,*n

Alternator/RegulatorTest-3: Apply a load with a VAT-40 until the battery voltage drops to between12- 13.5V.

To next page

23-11A

VOLTMETER POStTtVE LEAD(REDI

FIELD SELECTOR

swrTcH

ls the voltagelessthan 13.5V?

VOLTMETER NEGATIVE LEADIBLKI

L-;-;l rs-

TESTSELECTOR

Alternalor/RegulatorTe3t-2: 1. Release pedal, the accelerator and letthe engineidle. 2. Makesure all accessories are turned ofi. Turn the selector switchto position2 (charging). 3. Bemovethe inductivepick-up, and zerothe ammeter, 4 . P l a c et h e i n d u c t i v ep i c k - u p over the battery ground cable so that the arrowpointsto the batterynegatlveterminal. 5 . R a i s et h e e n g i n e s p e e d t o 2,000rpm,and hold it there.

FULLFIELO TESTER LEADIBLUI

INDUCTIVE PICK-UP IGRNI

NEGATIVETESTER CABLEIBLKI

POSITIVE TESTER CABLEIREDI

INDUCNVE PICK.UP

TIVE TEBMINAL

J Frompreviouspage

ls the amperage50 A or more?

Alternator/RegulatorTest-4: W i t h t h e e n g i n e s P e e ds t i l l a t 2,000rpm,fulltieidthe alternator.

The charging system is OK. Do not ellow CAUTION:The voltage will rise quickly when the allGrnatoris flll-fielded syslem electrical the the vollage to exceed18 V; il may damage probeintothe full field NOTE:Attacha probeto a VAT 40 full fieldtest lead,and insertthe "A (GroLrnd)" posi Switchthe fieldselectorto the accessholeat the backof the alternator' readlng the amperage check and tion momentarilV,

23-119

ChargingSystem AlternatorReplacement NOTE:Removethe alternator from belowthe vehicle. '1.

2.

3.

5.

M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons('99- 00 models). Removethe batterynegativecable,then disconnect the positivecable.

R e m o v et h e a d j u s t i n gb o l t a n d t h r o u g h b o l t n u t , then removethe alternatorbeltfrom the Dullev.

ALTERNATOR AD.'USTING BOLT 24 N.rhl2.akgf.m,17lbtft)

Disconnectthe 4P (or 3P) connectorfrom the alternaIor.

UPPERMOUNT BRACKETBOLT 44 N.m 14.5kgt.m, 33 lbl.ftl

ALTERNATOR

TERMINALNUT 7.85N.m (0.8kgf.m, 5.79lbf.ftl

BOLT

a4 N.m 14.5kstm.33lbf'ftl

LOWER MOUNT BRACKET BOLTS a4N.ml{.5 kgf.m,33lbfft) { }:Cansd.

4.

P u l l o u t t h e a l t e r n a t otrh r o u g hb o l t , t h e n r e m o v e the alternator.

R e m o v et h e t e r m i n a lnut and the WHT wire from t h eB t e r m i n a l . 7.

lf necessary,removethe mount bracketbolts. and the upperand lower mount brackets Adjust the alternatorbelt tension after installation (seepage23-125). Enterthe anti-theftcodefor the radio,then enterthe customer'sradiostationpresets('99- 00 models).

23-120

J

RectifierRemoval 1.

Removethe four through bolts.

3.

Separatethe rear housingfrom the drive-endhousing by insertinga flst tip screwdriverinto the openings and prying them a part. Be carefulnot to damage the stator with the tip of the screwdraver.

REARHOUSING

Seoaratethe rear housing and drive-end housing with the statorattachedto the rearhousing. Heatthe rear bearingseat with a 1,000W hair drier tor aboutfive minutes(120- 140'F,50 - 60"C).

DEIVE-ENDHOUSING

STATOR

{cont'd)

23-121

ChargingSystem RectifierRemoval (cont'd)

RectifierTest

Separatethe rear housingfrom the stator/rectifier assemblyby removingthe four screwsand the terminal nut. TERMINAL NUT

NOTE:The diodesare designedto allow currentto pass in one directionwhile blockingit in the oppositedirection. Since the alternator rectifier is made up of nine diodes,eachdiode must be testedfor continuityin both directionswith an ohmmeter that has diode checkino capability;a total of 18checks. 1.

6.

Checkfor continuityin eachdirectionbetween - the B and P terminals. - t h eB ' a n dPt e r m i n a l s . - E {ground)and the P terminals. All diodesshouldhave continuityin only one direcUOn.

Unsolderthe rectifierfrom the statorleads, . To avoid damagingthe diodes with heat, pinch the stator leads between pliers to carry heat off, and applythe solderingiron only long enoughto separatethe leadsfrom the rectifier. . Usea 100W solderingiron. STATOR

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

7.

Installthe new rectifierin the reverseorderof removal. . A p p l y t h e s o l d e r i n gi r o n o n l y l o n g e n o u g ht o ensure a good connectionso the heat will not damagethe diodes. a Use only a rosin coretype solderor solderjoints will corrode.

23-122

J

AlternatorBrushInsPection

RotorSlip RingTest 1.

betlveenthe slip rings Checkthe resistance 1 3 0 ohms be 8 should There . lf resistancemeetsthe specification,go to step 2. . l f r e s i s t a n c ed o e s n o t m e e t t h e s p e c i f i c a t i o n , reolacethe alternator'

1.

Separatethe drive-endhousingfrom the rear housing as describedon page23-121 Separatethe rear housingfrom the stator/rectifier assemblyby removingthe four screwsand the terminal nutfrom the rearhousing{seepage23-121} l v l e a s u r et h e l e n g t h o f t h e b r u s h e sw i t h v e r n r e r calrpers.

ROTORSHAFT

Alternator Brush Length: O Standard{NEW} 1 9 . 0m m ( 0 . 7 5i n )

1

@ ServiceLimit 5 . 0m m ( 0 2 0 i n )

SLIPBINGS

2.

Checkthat there is no continuitybetweenthe slip ringsand the rotor or rotor shaft.

3.

lf the rotor fails eithercontinuitycheck,replacethe alternator.

Stator Test '1. Checkthat there is continuitybetweeneach pair of leads. LEADS lf the brushesare lessthan the servicelimit, replace them.

CORE Checkthat there is no continuitybetweeneach lead and the coil core. lf the coil fails either continuitycheck,replacethe alternator.

23-123

GhargingSystem RearBearingReplacement

AlternatorReassembly

1.

1.

Pulloffthe rearbearing, .

.

Makesure the tips of the bearingpullerjaws are thin enough to fit betweenthe bearingand the slip rings. Do not reusethe bearing.

SLIPRINGS

P u s ht h e b r u s h e si n , t h e n i n s e r ta p i n o r d r i l l b i t (about1.8mm diameter)to hold them there.

BEARINGPULLER

BRUSHES

REABBEARING

Heat the rear bearing seat in the rear housing as describedon page 23-121.After heating,continue immediatelywith assemblingbeforethe rear bearing seatcoolscompletely, Use a hand pressto installthe new bearing.Apply pressureonly on the inner raceto avoid damaging the bearino.

Put the rear housing/stator assemblyand drive-end housing/rotorassemblytogether.tighten the four throughboltsand pull out the pin.

BRUSHAOCESSHOI."E THROUGHBOLT

I q

%*z

REAR STATOR ASSEMBLY

After assemblingthe alternator,turn the pulley by hand to make sure the rotor rotatessmoothlv and without noise.

23-124

It -

AlternatorBelt Inspectionand Adiustment DeflectionMethod: Apply a force of 98 N (10 kgl,22lbll, and measurethe deflectionbetweenthe alternatorand the crankshaftpulley. Detlection

Belt T€nsion Gauge Method: instructions.attach Followingthe gauge manufacturer's the tension. measure belt, and to the soecial tool the Tension

340- 490N (35- 50 kgf,77- 110lbf)

| 8.0- 10.5mm (0.31- 0.41in)

NOTE: On a brand-newbelt {onethat has beenrun for less than five minutes).the deflectionshouldbe 6.0 - 8.5 mm (0.26- 0.33in) when first measured.If the belt is worn or damaged,replaceit.

NOTE: On a brand-newbelt {onethat has beenrun for less than five minutes),the tension should be 540 -740 N (55- 75 kgf, 121- 165lbf)when first measured.lf the belt is worn or damaged,replaceit.

24 N.m (2.4kgl m,

CRANKSHAFT PULLEY

PULLEY

GAUGE BELTTENSION 07JGG- 0010104

lf adiustm€nt is necossary: 1.

Loosenthe lowermountingnut and the uppermounting bolt.

2,

Movethe alternatorto obtainthe properbelttension, then retightenthe uppermountingbolt and the lower torques. mountingnut to the specified

3.

It adiustment is necossary: 1,

Loosenthe lowermountingnut andthe uppermounting bolt.

2.

Move the alternatorto obtain the proper belt tension. then retightenthe uppermountingbolt and the lower mounting nut to the specifiedtorques

3.

the tensionof the belt Recheck

deflectionofthe belt. Recheckthe

23-125

Fan Controls ComponentLocationIndex

t lt lt lt tt l

tlTtlnr-l m U ! L - J f l _ l'1 - f-t t-_l

RADIATORFAN RELAY Test, page 23 87

I L--J L__JLJ f-----"1 CONDENSER FAN RELAY Test,page 23-87

UNDER.HOOO

^o

o

o"l

CONDENSER FAN MOTOR

TOR FAN MOTOR Removal,section10

ENGINE COOLANT (ECTI TEMPERATURE swtTcH Removal, section10 Test, section l0

23-126

I J

CircuitDiagram

IGNIT O NS W I T C H

FUSElRELAY BOX UNDER.HOOD No41 (8041

DASH UNDER F U S E I R E L8AOYX

|-;;;;l ii6\ "ir"'t*Tl

No42 (40A)

-l

BLKyEL -J

BLKTRED

II

1,,*"_ T-' I GRN

II I

I

\.7 V

ECM/PCM

E N GN E COOLANT l E M P E R A T U (REEC T ) SWTCH 'l fclosed : Above ( 9 3 " C ) r 9 9 " F L _l

B tK

II

G201

GaugeAssembly ComponentLocationIndex SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section(24)beforeperformingrepairsor service. 6x1.0mm 9.8 N.m 11.0kgf.m, 22lbt.lrl

VEHICLESPEEDSENSOR{VSS) page23-140 Troubleshooting,

GAUGEASSEMBLY Gauge/lndicator/Terminal LocationIndex,page23-129 Removal,page23-135 BulbLocation,page23-136 page23 138 Disassembly,

PARKINGBRAKESWITCH

FLUIOLEVELSW]TCH ENGINEOIL PR€SSURESWITCH

23-128

J

Locationlndex Gauge/lndicator/Terminal With tachometer; "C" CONNECTOB (GAUGEend INDICATORI

"8" CONNECTOR {GAUGEand INOICATOR)

"A" CONNECTOR INDICATOR} {A/TGEARPOSITION

c 1- - - - - - - - - > c 1 3

A1-----------+816

1ililil{ilrL JlltlllulllllrL o

oooo ') lo g | .

@

0006^ @ o^o @ o

E1_ _ -->E5

D1---+05

)

Fl- - -> F5

"D" CONNECTOR {ABS INDICATORI SPEEDOMETER: 60 km/hat 637 rpm or Indicates 60 mph at 1,025rpm o{the vehiclespeedsensor(VSS).

oo/

A/T GEARPOSITION INDICATOR Seepage23 149

\oo

TACHOMETER: I n d i c a t e s1 0 0 r p m a t 200 pulses per minute ol the ignition control module (lCMi.

FUELGAUGE UnitTest,page23-142 Gauge/Sending

(ECT)GAUGE ENGINECOOLANTTEMPERATURE

(cont'd)

23-129

GaugeAssembly Gauge/lndicator/Terminal LocationIndex (cont'd) Without tachometer: "A" CONNECTOR IA/T GEARPOSITIONINDICATORI A1 ------> 46

----> al4

"8" CONNECTOR {GAUGEand INDICATOR}

"C" CONNECTOR (GAUGEand INDICAIORI

B 1 .- - - - - - - - - - - - - - - - > B 1 6

C 1 - -- - - - - - - - - . . + C 1 3

JilililHililil1 JililHililL Oo_o-o

lus 0

O

0006

0 Bu-. )

"F" CONNECTOR {SRSINDICATOR)

"D" CONNECTOR {ABS INDICATORI SPEEDOMETER: Indicates 60 km/hat 637rpm or 60 mph at 1,025rpm ofthe vehiclespeedsensor(VSS).

oo/

(ECT)GAUGE ENGINECOOLANTTEMPERATUFE

23-130

\oo

A/T GEARPOSITION INDICATOF Seepage23 149

FUEL G a u g e / S e n d i n gU n i t T e s t , p a g e 2 3 1 4 2

I J

GircuitDiagram FUSE/RELAY BOX UNDEN HOOD

IJNOER,DASH FUSE/RELAY BOX

(7.54) N0.30 FUSE

f7 I t

RED/BLK

GAUGE LIGHTS

CHARGING SYSTEM LIGHT

l3wx4 l

0.4w)

l"'

WHT/BLU

v

ALTERNATOR

l

BEO/BLK

I c12

I

FFD

V

DASHLIGHTS BRIGHTNESS CONTROLLEF

fl ,,1:

tH

(Withshifi-up indicatdlighl)

tE2

I

FED/BLU

l"l"

8LK

BLU

IJ __l

CRUISE CONTROT UNIT

(wi1hcruiseconlrclsystem)

l'"^*

It -

G401 G402

Gauge Assembly CircuitDiagram{cont'd)

Fh"lurous @)-

+ BLrcwHT

BLKryEL

-rl fi'Sfvrous 16r.PAGE

eLui'rvrr

veL (Wnhlachomolgr) TURN SIGNAU HAZAROWARNING swtTcH

No.s(104) FUSE

LEFT

V I BEO/GRN

V I

I I I

RIGHT

I

:

i .-i;,l l | i

8LU4RE0

ABS CONTROL UNIT

23-132

0cM)

t v l

V I GR&ryE

lru

G401 G442

cNfldt--] CONTRoL I MODULE

G401 G402

BRAKE SYSTEM LIGHI (1.4w)

GRN/REO

I

TCM

RED/GRN

T

G552

A

Yimi+" Yo ;i:l"la',.ll,,1!:,iT "*,, l[3&1"

;i#il;-"1 lrb'ff"

I

8LK

I

GFN/RED

I ' J- i

_,L :

-

l G401 G()2

(cont'd)

23-133

Gauge Assembly CircuitDiagram(cont'dl

MATFUNCTION INOICATOR (Mr)

RED/BLU

BLU/BLK

YEURED

| ffitt'*' I V

tt

l

l

R E DBi L U

I o,u,,,

/h,,SEii

HI 'f''#lu""',.'f ENGINE orL PRESSURE SWITCH fcbsed Enqine

BLK

T G552

I

PNK

ECM/PCM

Y rtt'J"T,r.0,.*"0 topen Buchred I

GRN/ORN

WASHER LEVEL SWITCH :Floatdownl Tclosed topen Floalup .l

BLK

-

-

T G401 G402

J

Removal 1.

Removethe two screwsfrom the instrumentpanel.

2.

R e m o v et h e i n s t r u m e npt a n e l . CAUTION:Carefullyremovethe instrumentpanelwithout damagingthe clips.

3.

Tilt the steeringwheeldown with the tilt adjustmentlever.

4.

Spreada protectivecloth overthe steeringcolumn.

5.

Removethe four mountingscrewsfrom the gaugeassembly.

6.

Prythe gaugeassemblyout, and disconnectall connectorsfrom it

7-

Takeout the gaugeassembly.

GAUGEASSEMBLY

INSTRUMENT PANEL

23-135

GaugeAssembly Bulb Locations(WithTachometer)

CI{ARGINGSYSTEMLIGHT(1.,1W) GAUGELIGHTII.' WI

GAUGEI-IGHT{1,4WI LOW ENGINEOIL PRESSURE INDICATORLIGHT(1,' W}

SEATBELT REMINDER LIGHTI1.4WI HIGHEEAM INDICATORLIGHT (1.4W) LOW FUEL LIGHT 13W)

MALFUNCTION INDICATOR LAMP{MIL} BULE(1.{ Wl WASHERI.'CVEL INDICATORLIGHT {1.4Wl (Canada)

RIGHTTURNSIGNAL INDICATORLIGHTI1.4 WI

LEFTTURNSIGNAL INDICATORLIGHT{1.4WI

A/T GEAR (1.12x 6l INDICATOR (Onthe printed circuitboard)

ABS |ND|CATOR(1.. Wl {On the printed circuit board)

23-136

sRs

TOB(1.4Wl {Onthe printedcircuitboard)

GAUGELIGHTS13W) GAUGELIGHTl3.il Wl

CRUISEor SHIFT-UP INDICATOR 11. 11.12 {Onthe orintedcircuitboard)

J

Bulb Locations{WithoutTachometer)

TRUNKINDICATOR LIGHT {1.i1W}

CHARGINGSYSTEMLIGHT11,4W} (1.4W) LTGHT

GAUGELIGHT .4 Wl

LOW ENGINEOIL PRESSUBE INDICATOBLIGHT(1.4WI

SEATBELT REMINDER LIGHT(1.4WI HIGHBEAM INDICATORLIGHT

LOWFUELINDICATOR LrGl{T(3W)

MALFUNCTION INDICATOR LAMP (MIL) BULB{1.4WI

(1.1Wt

WASHERLEVEL INDICATORLIGHT {1.4W} lcanad.l

RIGHTTURN SIGNAL INOICATORLIGHT {1.ilW)

LEFTTURNSIGNAL INDICATORLIGHT{1.4WI

o /

A/T GEARPOSITION INDICATOR(1.12x 6) (Onthe printed circuitboard)

o

\ 7

GAUGELIGHTS{3 WI

aBs tNDtcAToR t1.4W) (Ontheprintedcircuitboard)

o

sRs TND|CATOR 11.4W) circuitboard} {OntheDrinted (3.{Wt

23-137

GaugeAssembly Disassembly(WithTachometerl NOTE: Handlethe terminalsand Drintedcircuit boards carefullyto avoid damagingthem.

booo .--:o'-..oooo.A

:-F.-sr';"€?;"')

A/T GEARPOSITIONINDICA MOUNNNG SCREWS tx 2)

aFl

FUELand ENGINECOOLANTTEMPEMTURE GAUGEMOUNTINGSCREWS{x 6,

l!

MOUNTING TACHOMETEB SCREWSlx 3l

PRINTEOCIRCUIT

ao

,-o ok+r .,- ll $

t'{"{q.' El I ..il \:r

q, 6\ CRUISEor SHIFT-UPINDICATOR PRINTEDCIRCUTT EOARD

ABS INDICATOR PRINTEDCIRCUITBOARD @

TACHOMETER S p e c i l i c a t i o n ,p a g e 2 3 1 2 9

METERPANEL

23-134

A/T GEARPOSITIONINOICA PRINTEDCIRCUITBOARD

(ECTI FUELend ENGINECOOLANTTEMPERATURE GAUGE

J

Disassembly{WithoutTachometerl NOTE:Handlethe terminalsand printedcircuit boards carefullyto avoiddamagingthem.

MOUNTING SPEEDOMETER (x 4) SCREWS

oOo ,.-'€'-., oOOo -/\

€3,'" ' "$?'----"')

)a.' '.,,'+':j

A/T GEARPOSITIONINDICA MOUNTINGSCREWS{x 2l

\

l

l

L

t

o

ENGINECOOLANTTEMPERATUR€ GAUGEMOUNTINGSCREWS{x 3l

FUELGAUGE MOUNTINGSCREWS{x 3)

PRINTEDCIRCUIT BOARD SRSINOICATOR PRINTEDCIRCUITBOARD

'

a

@

-

-

.-@

o o"i^>

\

Er t\t

lmw p\

A/T GEARPOSITIONINDICATOR PRINTEDCIRCUITBOARD ABS INDICATOR PRINTEDCIRCUITBOARD {ECT} ENGINECOOLANTTEMPERATURE GAUGE

d*re

\*P \ FUELGAUGE Test, page23-142

METERPANEL

METERLENS

METERVISOR

23-139

Vehicle Speed Sensor (VSSI Troubleshooting Beforetesting,inspectthe No. 15 (7.5A) fuse in the under-dashfuse/relaybox. Test the BLK wire: 1. Disconnect the 3P connector from the vehicle speed sensor

TESTHARNESS OTLAJ_ PT3O2OA

REOTESTHARNESS CLIP

(vss).

2 . C o n n e c tt h e t e s t h a r n e s s (07LAJ PT30200)only to the enginewire harness, 3. Connectthe REDtest harness clip to the positiveprobeof a PROTECTIVE TAPE

4. Checkfor continuitybetween the REDtest harnessclip and body ground.

ls therecontinuity?

Repairopon in the BLK wire b€twe€n the VSS and G101.

vss

GRNTESTHARNESS Te3tthe BLK/YELwire: 1. Connectthe WHT test harness clip to the positiveprobeof a voltmeter,and connecttheRED test harnessclip to the negative probe. 2. Turnthe ignitionswitchON {ll).

TESTHARNESS OTLA' . PT3O2OA

REDTESTHARNESS

Repairopen in iho BLK/YELwire between the VSS and the underd6sh tuse/relav box.

(To next page)

WHT TESTHARNESSCLIP

23-140

J (Fromprevaous page) WHT TESTHARNESS CLIP

Tost the BLU/WHTwirei C o n n e c tl h e G R Nt e s t h a r n e s s c l i p t o t h e p o s i t i v ep r o b e o f a voltmeter,and connectthe RED test harnessclip to the negative probe.

ls thereabout5 V or more ?

TESTHABNESS 07LAJ - Plil020a

REDTESTHARNESS CLIP

PROTECTIVE APE

Repair open in the BLU/WHT wiro b€twoon the VSS and ECM/PCM, TCM (CVT),and cruise control untt.

Test the vss: 1. Turnthe ignitionswitchOFF. 2. Connect he othertest har nessconnectorto the VSS. 3. Raisethe front ot the vehicle, and support it with safety stands, 4. Putthe vehiclein neutralwith the ignitionswitchON (ll). 5. Slowly rotateone wheel with the otherwheelblocked.

GRNTESTHARNESSCLIP

Doesvoltagepulsefrom 0 to approx.5V or more ? "8" GAUGEASSEMBLY16PCONNECTOR SpeedometerTosii '1. Disconnect the 16Pconnector " B " f r o m t h e g a u g ea s s e m blv. 2. Toucha probeto the BLUMHT wire, and connectit to body groundthrougha voltmeter. 3. Slowly rotateone wheel with the otherwheelblocked.

Doesthe meterindicatepulsing voltage?

femaleterminals

BLU

Repairopen in the BLU/WHTwi.e belween th€ VSS and the 3pe€d-

23-14 1

FuelGauge Gauge/Sending Unit Test Do not smoke while working on tho fuel !@ system. Keepopen tlame away trom your wotk atea. NOTE:Referto page 23-133for the fuel gauge system circuit. '1.

Checkthe No. 25 (7.5A) fuse in the under-dash fuse/ relay box before testing. Removethe accesspanelfrom the floor.

2.

1.

Checkthat the pointerof the fuel gaugestartsmoving toward the "F" mark. CAUTION: Turn the ignition switch OFF before the poinier reaches"F" on ihe gauge dial. Failureto do so may damagethe fuel gauge. NOTE:The fuel gaugeis a bobbin (cross-coil) type, hencethe fuel level is continuouslyindicatedeven w h e n t h e i g n i t i o ns w i t c h i s O F F ,a n d t h e p o i n t e r movesmore slowly than that of a bimetaltype.

ACCESSPANEL

. .

lf the pointerof the fuel gaugedoes not move at all, replacethe gauge. lf the gauge is OK. inspectthe fuel gaugesending unit.

Removethe fuel gaugesendingunit as shown.

\

)

Disconnectthe 3P connectorfrom the fuel gauge sendingunit. Connectthe voltmeter positiveprobe to the No. 2 terminaland the negativeprobeto the No. I terminal,then turn the ignitionswitchON (ll). Thereshouldbe between5 and 8 V. . .

lf the voltageis as specified,go to step5. lf the voltageis not as specified.checkfor: - an open in the YEUBLKor BLKwire. - poor ground (G552).

Turn the ignitionswitchOFF. Attach a jumper wire betweenthe No. 1 and No. 2 terminals,then turn the ignitionswitchON (ll).

23-142

Japan-produced

USA, Canada-produced

Low FuelIndicatorLight Test

J 9.

betweenthe No 1 and No. 2 the resistance lMeasure t e r m i n a l sa t E { E M P T Y ) ,1 1 2\ H A L FF U L L )a n d F (FULL)by movingthe lloat.

{Ceramicboardtype): USA,Canada-produced FloatPosition

E

1t2

F

(0) Resistance

1 0 5- 1 0 8

29.5- 35.5

3.5-5

NOTE:For the low fuel indicatorcircuitdiagram,referto circuitdiagram(seepage23'2311. the gaugeassembly 1 . C h e c kt h e N o . 2 5 ( 7 5 A ) l u s e i n t h e d r i v e r ' su n d e r dashfuse/relaybox beforetesting 2.

P a r kt h e v e h i c l eo n l e v e lg r o u n d .

3.

Drainthe luel into an approvedcontainer.Reinstall the fueltank drain bolt with a new washer.

4.

A d d l e s st h a n4 L ( 1 1 U . S G a l ,0 . 9 l m p G a l )o f f u e l , a n d t u r n t h e i g n i t i o ns w i t c hO N ( l l ) .T h e l o w f u e l i n d i c a t olri g h ts h o u l dc o m eo n w i t h i nf o u r m i n u t e s ' . lf the light comes on within four minutes,go to

(Wire-woundtypel: Jaoan-Ploduced FloatPosition

E

(O) Resistance

1 0 5- 1 1 0

1/2 2 5 . 5- 3 9 . 5

F

.

step8. lf the lightdoesnot come on withinfour minutes,go to step5.

Removethe accesspanellrom the Iloor' 6.

T u r n t h e i g n i t i o ns w i t c hO F F ,t h e n d i s c o n n e ctth e fuel tank sendingunit 3P connector.

1.

C o n n e ctth e f u e lt a n ks e n d i n gu n i t 3 Pt e r m i n a l sN o ' 1 a n d N o .3 w i t h a j u m P e rw i r e . l f t h e l i g h t c o m e s o n , r e p l a c et h e f u e l g a u g e sendingunit (seePage23 1421 . lf the light does not come on, checkfor: - A n o p e n i n t h e G R N / Y E Lw i r e b e t w e e nt h e f u e lg a u g es e n d i n gu n i ta n dt h e f u e lg a u g e - A b l o w nb u l b . - A poor ground(G552)

Too ot lhe workbench (Bottom of the fuel tank)

ll the resistancereadingsare beyondthe range.replace t h e f u e lg a u g es e n d i n gu n i t

female terminals

8.

A d d 4 L { 1 . 1U . S .G a l ,0 9 l m p G a l )o f f u e l T h e l i g h t shouldgo off within four minutes.

23-143

InterlockSystem ComponentLocationIndex

INTERI.OCK UNIT InputTest,page23-'146

KEYINTEBLOCKSOLENOID rnd KEYINTERLOCK SWITCH (ln the steeringlockassemblyl Test,page23-147

PARKPIN SWITCH Test,page23-148 SHIFTLOCKSOLENOID Test,page23-147

23-144

J BOX FUSARELAY HOOD UNDER

No41(80A) N0.42(404)

WHT/GFN

UNOEF,DASH FUSE/RELAY 80x GFNWHT

YEL KEY ll TNTEnLOCK || swrTcH I I

I

lr

rEt

till

SHIFTLOCK

soLENO|0 (O,l: UNLoCK)

l'

5

GRNAVI{I

r J

GR}.//WHT

I

V

l

I

LIGHIS BRAI(E I UNITI coNTROL cRUrsE UNIT I ABSCONTROT, rcM (cw) I

YEUBLK 3

5

IJNIT CONTFOL INTERLOCK

CIRCUIT KEYINTERLOCK

M GEAR POStT|ON INDICATOF

f7

WHT/BLK

I

II

t,

/P1 ennr Inposon B

)

I

RED/BLK GFNWHT

BLK

I:

I

G401 G402

G401 G402

II

f7

POSTTTON swlTcH (Clos€d : Inposilioa lll )

e,."or Vl$"ilT?l*r bdon frsn€oI lr I PUsh | \ BLK

] SENSOR

23-145

Interlock System ControlUnit Input Test 1.

Disconnect the 8P connectorfrom the interlockcontrol unit. 2 . I n s p e c t h e c o n n e c t o ra n d s o c k e tt e r m i n a l st o b e surethey are all makinggood contact. . lf the terminalsare bent,looseor corroded,repair them as necessary, and recheckthe system. . l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g inputtestsat the connector. - lf a test indicatesa problem,find and correct the cause,then recheckthe system. - l f a l l t h e i n p u t t e s t s p r o v e O K , s u b s t i t u t ea known-goodcontrolunit, and recheckthe system. lf the checkis OK, the control unit must be faulty;replaceit. N O T E : l f t h e s h i f t l o c k s o l e n o i dc l i c k sw h e n t h e ignitionswitchis turnedON {ll) and you stepon the brakepedal(with the shift lever in E), the shift lock system is electronicallynormal; if the shift leve. cannot be shifted from E], test the Aff gear position switch,park pin switch,and seesection14.

INTERLOCK CONTROLUNIT

Wire side of femaleterminals

Key Interlock System: Cavity

5

Wire

Test condition

WHT/BLU

lgnitionswitchturnedto ACC(lland key pushedin

C h e c kf o r v o l t a g e t o g r o u n d i There should be baftery voltage.

Underall conditions

Checkfor continuityto ground: Thereshouldbe continuity. Checkfor continu;tyto ground: Thereshouldbe continuity.

WHT

BLK

Shiftleverin El 6

Test: Desiredresult

BLK./BLU

Possible cause if result is not obtained BlownNo. 48 (30A) fuse in the under hood fuse/relaybox BlownNo.33 (7.5A) fuse in the under dash fuse/relaybox Faultysteeringlockassembly lkey interlocksolenoid) An openin the wire ' Poorground(G401,G402) . An openin the wire Poorground(G401,G402) FaultyAy'Tgearpositionswitch An openin the wire

Reconnect the 8P connectorto the interlockcontrolunit. Shift Lock System: Cavity 2

Wifs

YEUBLK

6

BLI(BLU

C h e c kf o r v o l t a g e t o g r o u n d : There should be banery voltage.

lgnitionswirchON (ll)

Checkfor voltageto ground: Thereshouldbe bafteryvoltage.

Shiftleverin I

Checkfor voltageto ground: Thereshouldbe 1 V or less.

lgnition switch ON lll) Brakepedaldepressed

Checkfor voltageto ground: Thereshouldbe 1 V or less. Checkfor voltageto ground: There sho(Jldbe battery voltage.

lgnitionswitchON (ll)

WHT/RED B r a k ep e d a l a n d

acceleratordepressedat the sametime

23-146

Test: Dgsiredresult

lgnition switch ON lll)

YEL

3

7

Test condition

Possiblecause if result is not obtained . BlownNo.25 (7.5A) fuse in the under, dash fuse/relaybox . An openin the wire BlownNo. 25 (7.5A) fuse in the underdash fuse/relaybox Faultyshift locksolenoid An openin the wire Poorground(G401,G402) FaultyA,/Tgear position switch An openin the wire BlownNo. 52 (15A) Iuse in the under hoodfuse/relay box FaultyPCM Faultybrakeswitch(seesection1l) Faultythrottleposition{TP)sensor (seesection1'l) An openin the wire

Shift LockSolenoidTest

KeyInterlockSolenoidTest R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d kneebolster(seesection20)

1.

D i s c o n n e ctth e 7 P c o n n e c t o rf r o m t h e m a i n w ' r e harness.

' t . Removeths front console(seesection20)' the shift locksolenoid2Pconnector' Disconnect Connect battery power to the No. 1 terminal and groundto the No. 2 terminalof the solenoidmomenIarrry. NOTE:Do not connectpowerto the No 2(-) terminal (reversepolarity)or you will damagethe diode insidethe solenoid

3.

CheckIor continuitybetweenthe terminalsin each kev oositionaccordingto the table' minal - - T e r--\

\

i*i,r" lgnition switch ACC fl) 4.

7

Key pushedin

o-

Key released

o-

-o -o

Checkthat the key cannot be removedwith power and ground connectedto the No. 7 and No 6 terminals . .

Checkthat the shift lock releaseswhen the release lever is pushed,and checkthat it locks when the releaseleveris released lf the solenoiddoes not work, replacethe solenoid'

lf the key cannot be removed.the key interlock solenoidis OK. lf the key can be removed,replacethe steering lockassembly(the interlocksolenoidis not available seParatelY).

23-147

InterlockSystem ParkPin Switch Test 1,

Removethe front console(seesection2Ol. Disconnectthe 4P connector from the park pin switch. Checkfor continuity betweenthe No. 3 and No. 4 terminalswith: - the shift leverany positionotherthan E, or - the push buttonpushedin E. Thereshouldbe continuity. Checkfor continuitybetweenthe No. 3 and No. 4 terminalswith the shift leverin E and the push button released.Thereshould be no continuiw.lf necessary,replacethe park pin switch.

NOTE:Parkpin switch4p connectorNo. 1 and No.2 terminalsare lor Ay'Tgear position console light. referto the circuitdiagramon page23-1S0.

23-14A

A/T Gear Position Indicator ComponentLocationlndex precautions, and proceduresin the sRS sRS componentsare locatedin this area.Reviewthe sRS componentlocations, or service' performing repairs section(241before

A/T GEARPOSITIONINDICATOR InputTest,page23-152

E N E E

t

r

(cw)

E

N E E

E (A/TI

A/T GEARPOSITIONSWITCH Test,page23 154 page23-155 Replacement,

23-149

A/T Gear Position Indicator CircuitDiagram CW: UNDER HOOD FUSE/RELAY BOX

IGNITION

UNDER.DASH FI.JSE/FELAY BOX

swrrcH 6;\ rr,/-TPLK+r,,'rirac

|-;,,'r&l coJ-aL("E1.<\c-t]

. PCM"

:i3M)''

V

\o3o'75A ---

I

Y

l./TGEAR POSITION INDICAToR (h lhegauge assembty) A'/TGEABPOSITIONNDICATOR OIMMING C]RCUIT

I

L TG R N

TqM'l

YYYY

No30{7.5A)

f7v t l YEL

GFN

V I

RED/BLK

t,

|

|

l

sfi0f,| |I t ,k g)coNsotEl

I Y i1?riI

t l l t'

RED

v

23-150

PostTtoN swrTcH

8LK

II

DASI|L GHTS ERIGHTNESS CONTNOLLER

A/TGEAR

*1 : 96'98modeis +2 i '99t0 models G401 G442

J

CircuitDiagram A/T

-l

'^a"

fr-.-r^ """-* -t

U__t-

T J N D EOFA S H

GNITON S WT C H

BOX BELAY H C C DF U S E UNDER

6l\ ir_i;_P_+irh\:f

f333{'*)

; h,:_

f7

I

RED,ELK

YEL PCi\4

PCM

V

A r TG E A RP O ST I O NI N DC A T O (Fn l h e g a u gaes s e m b y l

V

II

CIRCUT MD M]NG A I TG E A RP O S T O NN D L C A 1 O R

I

GRNlBLK

I

.T Gq

A13

l-

412

6LK8LU

f7

f7

I

f7

fl

t

l

I

W H T Y E L G F N SLU \. -Ti:5A FL]SE

I

II

DASHL GHTS BRIGHTNESS CONTFOLLER

VI

F:I BLK

I

l ' ,

5

2 (Nolused)

l l ^ , . , ^ , 1{'}'}'1, I A._. L,-N

posr oN I

I(d].ONSCLEI

lYi:il

I--f'- l I I I

RED

L GHTS DASH B BG H T N E S S CONTFOLLER

12

rl

\ 4

l 7

L r l

|

t.--itA'T GEAR

6

--An i

9 _ P N K -

BLK BLK

I

oio, G402

23-151

A/T Gear Position Indicator IndicatorInput Test 1 . Removethe gaugeassemblyfrom the dashboard(seepage23 135),and disconnect the 14pconnectorfrom rne gauge assemblv. Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. . .

lf the terminalsare bent.looseor corroded,repair them as necessary, and recheckthe system. lf the terminalslook OK,makethe followinginput testsat the 14pconnector. - lf a test indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input testsproveOK, but the indicator is faulty,replacethe printedcircuitboard.

"A" l{P CONNECTOR

REO

AI

BLK

M

A3

A8

A9

BLU

A4 A10

GRN

All

8RN

A6

412 A 1 3 4 1 4

LT

GAUGEASSEMBLY

+1:Not used '2: AIT '3i CVT

23-152

Test condition

Cavity

lgnition switch ON (ll) AI

A2

A3

YEL Combinationlight RED/BLK switchON and dash lightsbrightness controldial on full bright RED BLU

Shift leverin P or I

A10

GRN

Shift leverin E or E

A11

RED

Shift leverin E

412

WHT

Shift leverin E

Test: Desiredresult Check for voltage to ground: There should be banerY voltage.

Possiblecause it result is not obtained . Blown No.25 (7.5 A) fuse in the under dash fuse/relay box . An open in the wire

Checkfor voltagebetween and REDterminals: RED/BLK Thereshouldbe batterYvoltage.

Blown No. 30 {7.5A) fusein the tuse/relaybox under-dash Faultycombinationlight switch Faultydashlightsbrightness controller A n o p e ni n t h e w i r e

Checkfor continuityto ground: Thereshouldbe continuitY NOTE:Thereshouldbe no continuityin anYother Position.

. FaultyA/T gear Positionswitch . An open in the wire

Shift leverin E A 1 3 BLK/BLU NOTE:Don'tdepress the brakepedal. YEL+] A9

lgnitionswitchON (ll) and shift leverin any positionexceptPi lgnitionswitchON {ll)

GRN/err*'and shift leverin anY

Checkfor voltageto ground: Thereshouldbe batteryvoltagefor two secondsafterthe ignition switchis turnedON (ll),and then 'l lessthan V.

FaultyTCM*' ,PCM*3 FaultyPCM*r An open in the wire

positionexceptE A8

414

BLK

U n d e ra l l c o n d i t i o n s

Checkfor continuitvto ground: Thereshouldbe continuitY.

l g n i t i o ns w i t c h O N ( l l )

Checkfor voltageto ground: . Thereshouldbe bafteryvoltage*' . Thereshouldbe about5 V*r

LT GRN

. Poorground(G401,G402) . An open in the wire FaultyTCM*' ,ECM/PCM*' FaultyPCM*1 An open in the wire

*2: CVT('96- 98 models) *3r CVT('99- 00 modelsl

23-153

A/T Gear Position Indicator A/T GearPositionSwitch Test 1.

Removethe front console(seesection2O).

2.

Disconnect the 14Pconnectorfrom the A/T gearpositionswitch.

3.

Checkfor continuitybetweenthe terminalsin eachswitchpositionaccordingto the table. ' '

Move the shift leverbackand forth without pushingthe shift leverat eachswitchposition,and checkfor continuity within the rangeof free play of the shift lever. lf there is no continuitywithin the range of free play, adjustthe positionof the switch as described on the next page.

Terminalsideof maleterminals

A/T Gear Position Switch

+ 1 : Withcruisecontrolsystem

23-154

Eack - up Light Switch

Neutral Position Switch

A/T GearPositionSwitch Adjustment

A/T GearPositionSwitch Replacement 1 . Removethe front console,then disconnectthe 14P connectorfrom the A/f gear positionswltch 2.

1 . Shiftto the E position,and loosenthe nuts. slide the switchin the directionof El or E position lwithin 2.0 mm (0.079in.)l so that there is continuity betweenthe No. 1 and No 7 terminalsin the range of free play of the shift lever'

Removethe two mountingnuts swrTcH SLIDEB 3.

Recheckfor continuitybetweeneach of the terminats. NOTE: . lf adjustmentis not possible,checkfor damage t o t h e s h i f t l e v e r d e t e n t a n d / o rt h e b r a c k e t l f there is no damage.replacethe consoleswitch . The engineshouldstartwhen the shift lever is in positionN in the rangeof free play

E position A/T GEAR POSITIONSWITCH

NUTS MOUNT'NG 6 x 10 m m 98Nm(10kgtm'7lblftl " N e u t r a l "a s s h o w n P o s i t i o nt h e s w i t c h s l i d e rt o above. "Neutral",then slipthe switch Movethe shift leverto into position.

D j r e c t i o n o f - o n ,o r D l P o s i t i o n lwithin 2.0 mm (0.079 in)1

Freeplay

-lfr-

Aftachthe swjtchwith the two mountingnuts. Testthe switchin the E and E positionofthe shift lever.The engineshould start when the shift lever is in positionfl anywherein the rangeof free play 7.

Connectthe 14Pconnector,clampthe harness,and installthe front console LOCKPIN

23-155

IntegratedControl Unit CircuitDiagram UNDES H@OFUSE/RELAY BOX

IGNITION SWITCH

UNDER,DASH FUS€/RELAY 8OX WINOSHIELD WIPER/ WASHER S-W|iCI.] , OFF/INT INT

f7 Il

Y7 I l

t

t

t

l

6

,8

BLU/BLKYEUELU

-q

INTEGRATED CONTROL UNIT

" JC O M B I N E O WIPER.WASHEN

INTEEMITTENT WIPER RELAY CIRCUIT

ctncutT

I wNDSHTELD I I wrPEtuwAsHEF I I swrTcH I ELUMHT

I

I WINDSHIELD WIPEB MOTOH (As)

iI Yt_+ **i,,* J I

wHT,tsLK

8LK

I

V

WINOSHIELD WASHER MOTOR

* 1 : Wilhmmbrnedwiperwasheroperalion *2 : 96-98models

G40t G402

23-156

(A,4)

A,TGEAR PosrfloN swlrcH_ _ (Closed h posilon l?l ot [!l )

STARTER CUTFELAY

-> [h'#fBLU/BLK |

COMEINATION LIGHTSWITCH

V I REO/GRN

BOX FUSEi RELAY UNDEF.DASH

GFNiRED

YEL

I

I

a E

A iEi,I,B"'T vll".i,l

a -

. BRAKE FLUID LEVELSWITCH . PARKINGERAKE

(usA) swrTcH

,rr.nrorro .orrro,,*,, | t t -

t(

rffi |

BEMI\DEB crqcurl

\

l| / m t

tffi

nEoTsru REDTBLU -

I clnculr BLIJ/RED

neoieru

"ulTo /Itr\

YI onrveqs VI or rtor

l3fifl&''' l5frl'.' (3'&T' (3&Y ) lBLK fiti'fJ"fl lBLK 8iytr")

T c552

Y ..aorr,rro

,,-,r.0 J

|

l, /fP\

' CEILING LIGHT . KEYLESS RECE VERCIRCUIT (lnlheaudio unil")

T

A

Iu$ut,""'

DRIVER'S DOOF swtTcH open) folosed: Door (Open :Doordosed/

I3fif'3#3trr,) -::

G401

23-157

IntegratedControl Unit Input Test SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section{24)beforeperformingrepairsor service. 1.

Removethe driver'sdashboardlowercoverand kneebolster(seesection20),

2.

Disconnect the 10Pconnectorfrom the integratedcontrolunit.

3.

Removethe integratedcontrolunit from the under,dashfuse/relaybox.

4.

lnspectthe connectorand socketterminalsto be surethey are all makjnggood contact. . lf the terminalsare bent,looseor corroded,repairthem as necessary, and recheckthe system. .lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket. - lf any test indicatesa problem,find and correctthe cause,then recheck the system. - lf all the input testsproveOK,the controlunit must be faulty;replaceit.

INTEGRATED CONTROL UNIT

lOPCONNECTOR

Wire sideot femaleterminals

23-158

All Systems: Cavity

Wire

Al4

BLK

Test condilion

Test: Desiredresult

U n d e ra l l c o n d i t i o n s

Checkfor continuityto ground: Thereshouldbe continuity.

Underall conditions

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

lgnitionswitchON (ll)

Checkfor voltageto ground: Thereshouldbe bafteryvoltage.

A9

A6

Possiblecauseil rgsull is not obtained . Poorground(G401,G402) . An open in the wire . Blown No. 43 (7.5A) fuse in the under-hoodfuse/relaybox . An open in the wire . Blown No. 25 (7.5A) fuse in the under-dashfuse/relaybox . An open in the wire

Intelmittent Wiper System: Cavity B1 82

B3

Wire

Test condition

Test: Desiredresult

Possiblecauseif result is not obtained

l g n i t i o ns w i t c hO N ( l l ) , BLU/BLK and windshieldwiper and switchat OFFor INT BLU,^/VHT

Checkfor continuitybetweenthe BLU/BLKand BLU/WHTterminals: Thereshouldbe continujty.

Blown No. 26 {20A) fuse in the under-dashfuse/relaybox Faultywindshieldwiper switch Faultywindshieldwiper motor An open in the wire

l g n i t i o ns w i t c hO N ( l l ) , and windshieldwiper YEUBLU switchat INT

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

Blown No.26 (20A) fuse in the under-dashfuse/relaybox Faultywindshieldwiper switch An open in the wire

Checktor voltageto ground: Thereshouldbe batteryvoltage.

. Blown No.26 (20A) fuse in the under-dashfuse/relaybox . An open in the wire

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

. Faultywindshieldwasherswitch . An open in the wire

lgnitionswitchON (ll) *A5 lgnitionswitchON {ll), and windshieldwasher WHT/BLK switch ON *: With combined wiper'washer operatlon

{-

(cont'd)

IntegratedGontrolUnit Input Test (cont'dl

A8--------.--all

Key-in/SeatBelt R€mind€r,Lights-on ReminderSystom: Cavity

Wire

A8

B7

Test condhion

Tost: D€sirodr€guh

Combinationlight switchON

Checkfor voltageto ground; Thereshouldbe batteryvoltage.

B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e under-dashfuse/relaybox Faultycombinationlight switch An open in the wire

lgnitionswitchON (ll),

Checkfor voltageto ground: Thereshouldbe 1 V or less.

Poorground (G552) Faulty seat belt switch An open in the wire

RED/BLU and driver'sseatbelt switchunbuckled

B9

GRN

Possiblecause if result is not obtained

Driver'sdoor open

Checkfor voltageto ground: Thereshouldbe 1 V or less.

. Faultydriver'sdoor switch . An open in the wire

lgnitionkey inserted

Checkfor voltageto ground: Thereshouldbe 1 V or less.

Poorground(G401.G402) Faultyignitionkey switch An open in the wire

B l 0 BLU/RED into the ignitionkey switch Bulb CheckSystem (BrakoSystem Light): Cavity

A4

Test condilion

Wire

lgnitionswitchON {ll), brakefluid reservoir GRN/RED full, and parkingbrake teveroown lgnitionswitchat START(III)

A 1 3 BLUA/1r'HT

23-160

T6st: Dosiradresult

Possiblscauseif rasuft b not obtainod

Connectto ground:Brakesystem light shouldcome on.

B l o w nN o . 2 5( 7 . 5A l f u s e i n t h e under-dashfuse/relaybox Blown brakesystemlight bulb An open in the wire

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

Blown No.31 (7.5A) fuse in the under-dashfuse/relaybox Faultystartercut relay An open in the wire

Lighting System ComponentLocationIndex

DAYTIMERUNNINGLIGHTS RESISTOR{Canada) Test,page 23 167

DAYTIMERUNNINGLIGHTS CONTROLUNIT (Canadal InputTest,Page23 166

*HEADLIGHT Adiustment,page23-168 page23-167 Replacement,

SIGNALLIGHT page23 167 Replacement,

HIGHMOUNT BRAKELIGHT page23-177 Replacement,

LICENSEPLATELIGHTS Replacement, Page23'174

INNERTAILLIGHT R e p l a c e m e n t ,p a g e 2 3 - 1 6 9

OUTERTAILLIGHT page23 I69 Replacement,

*: Headlight and front parking/front turn signal light cannot be separated.

(cont'd)

23-161

Lighting System GomponentLocationIndex(cont'dl

HIGHBEAMINOICATOR LIGHT T U R N S I G N A L I N D I C A T O RL I G H T

DASHLIGHTSBRIGHTNESS CONTROLLER ControllerInputTest, page23-119

L

COMBINATIONLIGHTSWITCH Test,page23'165

ILI

LILI

LT

rr Lr rJ|r LJLr Lr rr !.r rr Lr rr -nnr1nr1r1r1r1|-1nn

I l L JJ

r1 n11t'1n Ttr1 r1 - 11t-1Tt-l T1 r-t L.lLt r-t r-t LJ ! ! LJ LJ ! LJ!J r-l

23-162

TURNSIGNAL/HAZARDRELAY InputTest,page23-'172

CircuitDiagram(USA) FUSEi NELAY 8OX UNDER,HOOD

'------

\

-TI" T,,: i..

--.-r\ ----.'r

To

8OX DASHFUSE/RELAY UNDER

l|-

No5 (104)

No22 (r0A)

A

T No.4

lilffl ( 0 0 4 )

I

I

I

II I

I r'

HIGHBEAM INDCATOR LIGHT

DASHLIGHTS DASHLIGHTS ERIGHTNESS CONTROLLER

(r4w)

I

G401 G4A2

8LK

I : G202

I

)N0.32

A {7.5A)

I

RED/ELK

REDiGRN

BLK

No30 (7.5A)

RED/BLK

II

I \? PABKNGLIGHTS T AL LG H T S L CENSEPLATEL GHTS

BLK

I

G201

23-163

Lighting System CircuitDiagram(Canada) FUSEi RELAY UNDER.HOOD BOX BATTERY

l\------tr\

d,$,E" T RED/BLU

-1

d

RED/

REDiGEN

UNDEFDASHFUSE/RELAY BOX

I l l , ll-l llltti /i[ii i Illri, zll",ll iu"x , I T T

No.5 0 0A)

t l ! -tl--l FEDiGRN

R € DYEL

tI

t I

+ V

REDTWHT FED/BLU

RED/GRN RED/GBN

FED/8LK

| I

|

|

I

l-,ro,u,rffl,

t I

il]liiqff'|

A l r Y,o"r.o" I BLK

t

d

G401 G402

BLK

T--

l

G202

YEL/BLK

+ V

RED/ BLK

I

qUNNING DAYT'ME LIGHTS FESSTOF

RED/GHN

I

G201

REDiGFN

I IT 5 o

I

I

I

BLK

I FED/GRN

DAYTIME RUNNING LIGHTS CONTROL UNIT

lt*"','

I

BFAKE SYSTEM LIGHT NTEGRATED CONTROL UNIT

f-7

L.ENSEoLATELTG'TS 33''9+il4[','o

l qsnlq,rr

\---J-------J

No.1g (7.5A)

)'

^-^^-.*^,{*"'"0-

t t

-rGHr

) N0.20 tl0Al

. D A S FL . G H T S. o A B ( ^ r G- T G H T S .DAS-LGH'S.TALL'GCTS

| I

|t .+_ t L nd--f) I || |ttuLj las*,irt*| | Trt*Iorr \_i-f ---J

)

,,r'o Yro*, LEVELSWTCH

[i.mi:-",,, I

t

BLK

n: G40l G402

lclosed: Floaldownl | BLK

I

.:

-L ..

G401 G402

CombinationLight Switch Test 1 . Removethe driver'sdashboardlowercoverand steeringcolumncovers(seesection20) 2.

the 4P and 7P connectorsfrom the switch. Disconnect Inspectthe connectorand socketterminalsto be surethey are all makinggood contact . .

and recheckthe system. lf the terminalsare bent,loose.or corroded,repairthem as necessary, lf theterminalslook OK,checkfor continuitybetweenthem ineach switchpositionaccordingtothetables lfthere is no continuitybetweenany of them.checkfor continuityin the switchharness - lf there is continuityin the switchharness.replacethe combinationlight switch - lf there is no continuityin the switchharness,replaceit. 4P CONNECTOR

rrr r-l

l(rr mf I

tffiT A 3A 1 1 l I

COMBINATIONLIGHTSWITCH

7P CONNECTOR

HsadlighUDimmer/PassingSwitch : Terminal

82

B1

B3

*84

B5

86

Position OFF

o- --o o- --o o- ----o

Headlight switch

LOW HIGH OFF

switch Passing

o-o-

---o --o o- ----o

ON

* : Canada

Turn Signal Switch : Teminal

\

A1

A2

A4

;',*;----__\ RIGHT

o

o

NEUTRAL LEFT

o

o 23-165

Lighting System DaytimeRunningLightsControlUnit InputTest(Canadal L

R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d kneebolster(seesection20).

2.

D i s c o n n e ct th e c o n n e c t o r sf r o m t h e d a y t i m er u n ning lightscontrolunit.

3. Inspectthe connectorand socketterminals to be surethey are all makinggood contact. lf the terminalsare bent,looseor corroded.repair them as necessary, and recheckthe system. l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g input testsat the connector, - lf anytest indicatesa problem,find and correct the cause,then recheckthe system. - lf all the input testsproveOK, the controlunit must be faulty;replaceit.

Cavity

Wire

BLK A2

et

A4

A1

TGst condition

U n d e ra l l c o n d i t i o n s

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

B l o w nN o . 2 0( 1 0A ) f u s ei n t h e under-dashfuse/relaybox An open in the wire

lgnitionswitchON (ll)

Checkfor voitageto ground: Thereshouldbe batteryvoltage.

B l o w nN o . 1 8{ 7 . 5A ) f u s ei n t h e under-dashluse/relaybox Faultyignitionswitch An open in the wire

Combinationlight switchin " =D " posi-

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

Blown No. 48 (30A) tuse in the under-hoodfuse/relaybox Faultycombinationlight switch An open in the wire

UOn

Combinationlight switchOFF;connecta jumperwire between WHT/RED the YEUBLKand WHT/RED terminals, then turn the ignition switchON (ll)

H e a d l i g h t s( h i g h b e a m ) s h o u l d come on, (andhigh beam indicator should come on).

l g n i t i o ns w i t c h O N ( l l ) , brake fluid reservoir GRN/RED full, and parking brake lever down

Connect to ground: The brake system light should come on.

23-166

. Poorground (G401,G402) . An open in the wire

Checkfor continuityto g.ound: Thereshouldbe continuity.

YEUBLK

REDiGRN

Possiblecauseit result is not obtained

Un d e ra l l c o n d i t i o n s

BLK /VHT

RED

Test: Desiredresult

Parking brake lever Lrp

Check for continuity to groundl There should be continuity.

. Poorground(G201,G202,G40'1, G402) . B l o w nb u l b s . Faultydaytimerunninglights resrstor . An open in the wire B l o w nN o . 2 5( 7 . 5A ) f u s ei n t h e under-dashf use/relaybox Blown brakesystemlight An open in the wire . Faultyparkingbrakeswitch . A n o p e ni n t h e w i r e

Turn Headlights/Front Signal/ParkingLights DaytimeRunningLightsResistor Test(Canada) CAUTION: The daytime running lights resistor becomes very hot when the daytime running lights are on; do not touch il or the attaching hardware immediatelyafter the lights have been iurned off. 1.

the 3Pconnectorfrom the resistor. Disconnect

Replacement CAUTION: Halogen headlights b€come very hot in use; do not touch them or the attaching hardware immediately after they have been turned off. 1.

Removethe front bumper(seesection20).

2.

Removethe mountingbolts,

3.

Disconnecteach connector,then removethe headlight assembly. lighVfrontturn signal/parking MOUNTING EOLT

ItTUFNSIGNAL/ HEADLIGHT/FRONT LIGHTASSEMBLY PARKING

Terminal side of male terminals

HEADLIGHT:60/55 W FRONTTURN SIGNAL/PARKINGLIGHT:21l5 w

N4easure the resistancebetweenthe resistortermi nals(No. 1 and No. 2) and the powerterminalNo. 3. Resistance:1.6 O t 0.08 O Replacethe resistorwith a new one if any of the are beyondspecification. resistances

23-167

Headlights Adjustment Headlightbecomevery hot in use;do not touch them or any attachinghardwareimmediatelyafterthey have been turnsd off. Eoforo adiu3tingth€ h.adlights: . Parkthe vehicleon levelsurface. . Makesurethe tire prgssuresare correct. a The driveror someonewho weighsthe same should sit in the driver's seat.

Adjustthe headlightsto localrequirementsby turning the adjusters. After headlight replacement,it may bs necessaryto readjustthe horizontalindicatorgear. .

.

96 - 98 modols 1.

Openthe hood.

2.

Checkthe horizontaladjustmentindicator. T h e " 0 " m a r k o n t h e h o r i z o n t a li n d i c a t o r g e a r should be alignedwith the mark on the horizontal indicator. INDICATOR HORIZONTAL

MARK

Checkthe verticaladjustmentindicator.The bubble should be centeredunderneaththe longestscribe markon the gauge. VERTICALINDICATOR:

(Bubblol

23-164

"0"mark as lf eitherindicatoris not alignedwith its describedleft column,an adjustmentcan be made by usinga Phillipsscrewdriver.

Firstinstallthe headlioht,and adjustits horizontal and vertical aimings accordingto local requirements. Then checkthat the arrow on the horizontalindicator gear is alignedwith the mark on the horizontalindicator. - l f t h e y a r e n o t a l i g n e d ,r e m o v et h e s c r e w , adiust the indicator gear, and retightenthe screw.

NOTE:As the outer lensesare made ot an acrylicoated,polycarbonatedmaterial,do not cover the headlightswhen they are turnedon.

'99 - 00 models 1.

2.

Cleanthe outer lens so that you can see the center of the headlights(A).

Parkthe vehiclein front of a wall or a screen(A). A 7.5 m (25ft)

Openthe hood. 4.

l,-

Turn the horizontaladjusterso that the arrow on the horizontalindicatorgear (A) is pointingup.

Headlights Adjustment(cont'dl Turnthe low beamson. Determineif the headlightsare aimed properly.

7.

lf necessary,adjustthe headlightsto local requirementsby turningthe horizontaladjuster(A) and the verticaladjuster(B).

Vsrtical adiustmsnt: Measurethe heightof the headlights(A).The lights should reflect52 mm \2.1 in.) below (B) headlight height. Horizontal adi$tment: The width of the refractingpoints(C)should be the same as the width of the headlightcentralpoints(D,

After headlight replacement,it may be necessaryto readjustthe horizontalindicatorgear. .

Firstinstalltheheadlight,and adjustits horizontal and verticalaimings accordingto local requirements. . Then checkthat the arrow on the horizontalindicator gear is alignedwith the mark on the horizontalindicator, - lf they are not aligned,removethe screw,adjust the indicatorgear,and retightenthe screw. NOTE:As the outer lensesare made of an acrylicoated,polycarbonatedmaterial,do not cover the headlightswhen they are turnedon.

23-170

Taillights Replacement(Except'99- 00 Sedanl NOTE: . Inspectthe gasket;replaceit il it is distortedor stays compressed. . After installingthe taillights,run water over them to makesurethey do not leak.

Inner Taillights(Coupe'96- 00 models/Sedan'96- 98 models): 1.

Openthe trunk lid, then removethe accesspanel.

2.

Disconnect the 4P connectorfrom the innertaillight.

3.

R e m o v et h e f o u r [ t h r e e ]m o u n t i n gn u t s ,t h e n p u l l o u t t h e i n n e rt a i l l i g h t . I l: Sedan

OuterTaillights('96- 00 models,except'99- 00 Sedan): 1 . O p e nt h e t r u n kl i d / h a t c h . 2.

D i s c o n n e ct h t e 4 P o r 6 P c o n n e c t otrr o m t h e o u t e r taillight.

Coupei TAILLIGHT INNER

3.

R e m o v et h e f o u r m o u n t i n gn u t s ,t h e n p u l l o u t t h e o u t e rt a i l l i g h t . 4P or 6P CONNECTOR

lSedan: INNERTAILLIGHT

Hatchback: BRAKE/TAILLIGHT:2115W TURNSIGNALLIGHT:21 W 21 W BACK-UPLIGHT:

BRAKE/TAILLIGHT:2115W TURNSIGNALLIGHT:21 W

4P CONNECTOB

2115W BRAKEiTAILLIGHT: BACK-UPLIGHT: 21 W

Taillights Replacement('99- 00 Sedanl NOTE: . Inspectthe gasket;replaceit if it is distortedor stays compressed. . After installingthe taillights,run water over them to makesurethey do not leak.

Inner Taillights: '1.

Openthe trunk lid, then removethe accesspanel.

2.

Disconnectthe 3P and 2P connectorfrom the inner taillight.

3.

Removethe three mounting nuts,then pull out the i n n e rt a i l l i g h t . [ ]: Sedan

Outer Taillights: 1.

Openthe trunk lid/hatch.

2.

Disconnectthe 4P and 2P connectortrom the outer taillight.

3.

Removethe four mounting nuts, then pull out the outertaillight.

TAILLIG}fi

r * i /

e

t

.

/

3P CONNECTOR

4PCONNECTOR BRAKE/TAILLIGHT:2115W TURNSIGNALLIGHT:21 W

23-172

BRAKE/TAILLIGHT: 2r15 W BACK.UP LIGHT: 21 W

Turn SignallHazardFlasherSystem

I J

GircuitDiagram UNOER.DASH FUSE/RELAY 80X

FUSE/RELAY 8OX UNDER.HOOD

N o . 1 2 l 57 A )

l*v GRN/YEL

t,

(NOt

,'|,."J I'

RED

II

q

I

II

J DASHLJGIlTS BRIGHTNESS CONTROLLER

BLK

Turn SignallHazardFlasherSystem Turn Signal/HazardRelayInput Test S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e SRScomponentlocations,precautions, and procedures in the SRSsection{24}beforeperformingrepairsor service. Removethe turn signal/hazard relayfrom the underdashfuse/relaybox.

1.

Inspectthe relayand fuse/relaybox socketterminals to be surethey are all makinggood contact. .

l f t h e t e r m i n a l sa r e b e n t ,l o o s eo r c o r r o d e d , repairthem as necessary, and recheckthe system. . l f t h e t e r m i n a l sl o o k O K , m a k et h e f o l l o w i n g input testsat the fuse/relaybox socket. - lf any test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the input testsprove OK,the turn signal/ hazardrelaymust be faulty;replaceit.

8Bffii \_ t-E | l\n

rl.]l l l n'rl

,.ff T-' t:

FUSE/RELAYBOX SOCKET

Cavity

2

3

Testcondition

Test: Desiredresults

Possible cause it result is not obtained

Poorground\G201,G202,G401, G 4 0 2G , s 5 1G , 5 5 2G , 6 0 1G , 761) Faultyhazardwarningswitch A n o p e ni n t h e w i r e

Hazard warning switch ON; connect the No. 1 t e r m i n a lt o t h e N o . 3 rermtnat.

H a z a r dl i g h t ss h o u l dc o m eo n .

l g n i t i o ns w i t c hO N ( l l )a n d turn signalswitchin right or left;connectthe No. 1 t e r m i n atlo t h e N o .3 terminal.

R i g h to r l e f tt u r n s i g n a l i g h t ss h o u l d c o m eo n .

. Faulty turn signal switch

U n d e ra l l c o n d i t i o n s

Checkfor continuityto ground: Thereshouldbe continuity.

. Poorground (G401,G402) . An open in the wire

lgnition switch ON (ll)

Connectfor voltageto ground: Thereshouldbe batteryvoltage.

'12(7.5 Blown No. A) fuse in the under-dash fuse/relay box Faulty hazard warning switch An open in the wire

Hazard warning switch ON

Connectfor voltageto ground: Thereshouldbe batteryvoltage.

B l o w n N o . 5 3 ( 1 0A ) f u s e i n t h e u n d e r hood fuse/relay box Faulty hazard warning switch An open in the wire

23-174

HazardWarningSwitchTest CAUTION:Be carefulnot to damagethe hazardwarning switch or the center outlet panel when prying the switch out. '96 - 98 models: '1. Prythe hazardwarningswitchout of the centeroutl e tp a n e l . 2.

'l0Pconnectorfrom the hazardwarnthe Disconnect ing switch.

3.

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table

HAZARD WARNING

'99 - 00 models: 1.

Removethe centerpanellseesection20).

2.

Removethe two screws,then remove the switch from the centerPanel PANEL CENTER

scREws .

HAZARD WARNING

swlTcH

lOPCONNECTOR

qCheckfor continuitybetweenthe terminalsin switchpositionaccordingto the table. \

Terminal

t**

1

2

3

5

6

9

I

\

ON

o

o

OFF

o -o o o

T e r m i n aN l o , 4 i s n o tu s e d .

l0

o

t !.1

o

@

o

o o

.o

LicensePlate Lights Replacement '96 - 98 Sedan/Coupe: L

Removethe two screwsfrom the licenseplate light, and pull the light out pan ot the way.

2.

Disconnect the 2Pconnectortrom the light.

3.

Takethe lensoff, then replacethe bulb. 2P CONNECTOR

Hatchback/'gg- 00 Sedan: 1.

Carefullypry the licenceplatelight out of the license platetnm.

2.

Disconnect the 2Pconnectorfrom the light.

2PCONNECTOR

23-176

Back-upLights CircuitDiagram BOX UNOERHOODFUSE/RELAY

]GNTION SWITCH

-"--""\-zI

+*HT*;L *HT/BLK

BLKTYEI

fTil"liUiEEs,x',

fr q-,

YEURED

l$*,'l

YEL

,, l^.0.,.

rb\ !'fi+l'

Y(ifi'frr-') nrosrron El tcroseo'

I

GRNiBLK

23-177

Brake Lights CircuitDiagram UNDEH HOOD FUSEiRELAYBOX BATTERY /-l I

Nos2(1sA) |

u/T'\--]-wHrGFNTwfciN_l

t

WNT/GRN

v

HORNSYSTEM

INNER TAILL]GHT

ffi; I

GRNMHT

I

A

b'rt^t-,

Yllf,ll

I

BLK

i r i I II''i Li*''] I Li; I P } BRAKE

Y ilT'

II

23-178

ffi; I

GRNMHT

I l**,,,, I l,"l i$*i BLK

+ 21W:Coup€/Sedan 18W:Halchback control J I : Wilhcruise

GRN,4fiHT

I

II

I I

gLK

II :

G601: Haldbackiooup€/Sedan G761: flatchback G601: Coupe/Sedan G602: Sedan99 mode

BLK

II

I

G601r Halchback/Coupe/Sedan

AE-'ii,t

Yut#l I BLK

HighMountBrakeLightReplacement Coupe/sedan:

Hatchback: 1.

2.

L o o s e nt h e t w o s c r e w s ,t h e n r e m o v et h e h i g h m o u n t b r a k el i g h t . B e c a r e f u ln o t t o d a m a g et h e hatchspoiler.

1.

Removethe rearshelf(seesection20).

2

R e m o v et h e t w o s c r e w s ,t h e n r e m o v e t h e h i g h mount brakelight from the rearshelf.

Removethe bulb socketfrom the light.

HIGHMOUNT BRAKELIGHT

BULBSOCKET

SCREWS

l23-179

DashLights BrightnessController CircuitDiagram

UNDEFHOODFUSE/RELAY BOX

cotvBiNATloN LIGHT SW]TCH

wHT-tlf-

,4.

UNDEF.DASH FUSEi RELAY 8OX

|-;il;I -l-*-Tl

RED/GBN

I

I

REDi 8LK

G401 G402

23-180

ControllerInputtest NOTErThe controlunit is built intothe dashlightsbrightnesscontroller. '1. Carefullypry the controllerout of the dashboard. 2.

the 3P connectorfrom the controller' Disconnect

3.

Inspectthe connectorterminalsto be sure they are a l l m a k i n gg o o dc o n t a c t . . .

lf the terminalsare bent,loose,or corroded,repair and recheckthe system. them as necessary, lf the terminalslookOK, makethe followinginput testsat the connector. - lf any test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the input tests prove OK, the controller must be faulty;replaceit

Wire sideof lemaletermlnals

Test condition

Cavity

1

RED/BLK

2

BLK

RED

Test Desited results

Combination light switch ON

Check for voltage to ground: There should be battery voltage.

U n d e ra l l c o n d i t i o n s

Checkfor continuityto ground: Thereshouldbe continuity.

C o m b i n a t i o nl i g h t switch ON

Connectto ground: DashIightsshouldcome on full bright.

Possiblecause if rgsult is not obtainGd BlownNo.30 (7.5A) fusein the Iuse/relaybox under-dash Faultycombinationlight switch An open in the wire . P o o rg r o u n d( G 4 0 1G , 402) . An open in the wire . An open in the wire

23-181

lnteriorLights Component Location Index

CEILING LIGHT Test,page23-183 SPOTLIGHTS Test,page23'184

FRONTPASSENGER'S DOORSWITCH RIGHTREARDOORSWITCH

TRUNKLIGHTlcoupe/Sedan) Test,page23-184

DRIVER'SDOOR

LEFTREARDOORSWITCH

TRUNK LATCH {Coupe/Sedan) HATCHBACKLATCHSWTTCH lHatch bec(l

23-1A2

CircuitDiagram(WithoutSpotlightsl BOX UNDEFHOODFUSE]FELAY

ON

\

OFF

BLUiBLK

q-

I I

lI ,l3g" ** |ll ,J., I

SLUlBLK

A Jiuir, Iflri:B::, ] l[3Fff'

BLK

I

| -r-l:'iil:

|l Fr+

LTGFN/REO

GRNiRED

FRONT PASSENGERS

DOOR SWTCH open ) folosed:' Door (Open Door cosed-l

L TG R NR/ E D

A

L TG R N / R E D

A

Y;'.'; Y,"^t'

13fi?s" 13fi?'1" 3;::" B::::r". 8::':tl"l | 1,3,;;:' . L l

G601.G76l Halchback G601 CoupeiSedan

3.4W. USA. Canada ProdLrced 5W W lhouimoonrool

23-18 3

InteriorLights CircuitDiagram(WithSpotlights) UNDEB HOOD FUSEi RELAY BOX

WHT/RED

WHT/RED

r*r

I' T F1,,'-1 !

SPOT. LGHTS

I

I

2 LTGRNlRED

t_:kr

t-t

, LTGRN/BLK

KEYLESS RECEIVER CIBCUIT (lntheaLid o unil)

8LU/8LK

II

| *ttt-

| ,Y. I

BLUlBLK

A

Yiri'n It3f.r'+m:r:r,l

BLK

{ G601G761rHalchbac( G601 Coupe/Sedan

xI *2

3 . 4 W: t i S A ,C a n a dpar o d u c e d 5W Japanproduced 8w W lh moofroot 5W Wlho!lmoonroof

23-144

-

(Wilhkeyessenlrysyslem)

LTGRN/RED

GBN

L LTGRN/RED

A Ttp;:' Itsl";g;" I

FFONT PASSENGERS DOOR SWITCH 'l ictoseo : I Dooropen I Open: L Doorclosed_J

I3331."..,J :

A Y"" t;:x:: | | 333i" I REAR I DooF

CeilingLight Test Without moonroot:

1.

Turn the light switchOFF

2.

Pryoff the lens.

3.

Removethe two mountingnuts (or a bolt)from the housing,then removethe housing.

Coupe/Hatchback:

4.

from the housing. the connector{s) Disconnect

5.

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.

\

rermrnal

Position

2 or 2'

1

\

OFF

MIDDLE ON

ooo-

/a\ \7

,.\ \:/ \:/

/

3 or 3'

-o --o

--o BULB(5 WI

With moonroof:

3P CONNECTOR

2' 4 1 3

q, 23-185

Interior Lights SpotlightsTest

Trunk Light Test

1. Turn the spotlightswitchOFF.

1.

Openthe trunk light coverfrom the housing.

2.

Pry off the lens.

2.

Pryout the light assembly.

3.

Removethe two screwsand the housing.

3.

Disconnect the 2Pconnectorfrom the housing,

4.

Disconnect the 1Pconnectorfrom the housing.

4.

5.

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.

Make sure that the bulb is OK. Checkfor continuity betweenthe No. 1 (+)and No.2 (-) terminals.

EULB{.')

\

Terminal

2

3

t*'*-__\

o-{

OFF

ON

23-186

o-

-*i

e, //:\ \:,/

@ /a\

\:.,/

4

--o --o -_o --o

*1 3.4 W: USA, Canada-oroduced 5 W: Japan-produced

Stereo Sound System ComponentLocationIndex and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions. section(24)beforeperformingrepairsor service. '96 - 98 models

AUDIOUNIT (STEFEORADIOTUNERI page23 189 Beplacement, Terminals,page23-190 ANTENNAMAST page23 193 Replacement,

LEFTTWEETER Replacement, Page23 191

RIGHTTWEETER Replacement, Page23 191 RIGHTFRONTSPEAKER page23'191 Replacement,

ANTENNALEAD

LEFTFRONTSPEAKER Replacement, Page23'191 SUB ANTENNA LEAD

PLAYER CASSETTE Replacement, Page23-189

q-

REARSPEAKERS page23-19'l Replacement,

(cont'd)

23-147

Stereo Sound System Component Location Index {cont'd) SRScomponentsare locatedln this area.Reviewthe SRScomponentlocations,precautions, and oroceduresin the sRS section(24)beforeperlormingrepairsor service. '99 - 00 models

AUDIOUNIT page23-189 Feplacement, Terminals,page23-190 ANTENNAMAST (Coupe/Hatchbeck) Replacement, page23,193

LEFTTWEETER page23-191 Replacement,

RIGHTTWEETER Replacement, p6ge23-191 RIGHTFRONTSPEAKER page23-191 Replacernent, WINDOWANTENNA{Sedanl Wire Test,page23 192 Wire Repair,page23-192

ANTENNALEAD

LEFTFRONT R e p l a c e m e n t ,p a g e 2 3 - 1 9 1

SUB I.TAO REARSPEAKERS page23-191 Replacemont,

23-1AA

CircuitDiagram('96- 98 modelsl UNDERDASH FUSE/RELAY 80X

IGNTIONSWITCH

BOX FUSE/FELAY UNDER.HOOD

r*.i,,";l

I

I II II

ANTENNA LEAD

WHTiELU

I

NoJ0(7sA)

v I

YEUFED R E D ] B L K

AUDIO U NT (STEREORAOLO TUNER)

@ A16

A15

BRN/WHT

I

I

t

I

SPEAKER

I

I

BLK

RED,^/Er

I

BLU/YEL

I

l

L

RIGHTREAR SPEAKER

GRY]BLK LEFTFHONT D O O FS P E A K E R

LEFT

q-

RED

I I I

J

DASHLIGHTS BRIGHTNESS CONTROLLER

RIGHT TWEETER

G501

23-189

Stereo Sound System CircuitDiagram('99- 00 models) UNDER-DASI.] FUSEi RELAY 8OX

FUSE/RELAY UNDER.HOOD BOX

l-'-r,*;l

I

II

--l

(Sedan)

I II

(Coupe/Horchbach)

F;*";

I

No30(7.54) FUSE

V I

YEUFED RED/BLK

a*[rrl

,,,[.J:,

BLK

I

I LEFTREAR SPEAKEF

_-\ / ;diFnoNi

RIGHTREAF SPEAKEB

| |

D o o RS P E A K E F |

LEFT TWEETER

neolcn |

I

v

|

HlGHT TWEETER

DASH LGHTS BHIGHTNESS CONTROLLER

G501

23-190

Removal StereoRadioTuner('96- 98 modelsl: 1.

Removethe centerdashboardlower cover (seesect i o n2 0 ) .

2.

Removethe two mountingbolts,and pullthe stereo radaotuner out.

3.

CassettePlayer('96 - 98 modelsl: 1.

Removethe front consolepanel(seesection20).

2.

Removethe DIN cord from the stereoradiotuner. Removethe four mounting bolts,then removethe cassetteplayer.

D i s c o n n e ct th e 1 6 Pc o n n e c t o r ss,u b a n t e n n al e a d and DIN cord (with cassetteplayerl,then remove the stereoradiotuner.

MOUNTINGBOLTS

16PCONNECTORS

Stereo Radio/Cassette Player ('99 - 00 modelsl: 1.

Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's oreset buttons.

2. Removethe centerpanel(seesection20). 3.

Removethe four mountingscrews,and disconnect the 20P connectorand antennalead,then remove player. the stereoradio/cassette

scREws

Enterthe anti-theftcodefor the radio,then enterthe customer'sradiostationPresets.

23-191

Stereo Sound System StereoRadioTunerTerminals '99 - 00 models:

'96 - 98 models: Forkeylessentry.

(andsecurrty) syslem

t6p coNNEcroR To DIN CORD

To DIN CORD

Csvity (forsecurity system)

A1

RED/GRN

Rightfront door speakero, righttweeter@

BLU

Leftfront door speaker@, left tweeter @

Conncctsto

2

YEL/RED

ACC(mainstereopower suppry)

5

REDI/EL

Rightrearspeaker@

Wire

Cavity

Wire

BLUI/EL

Leftrearspeaker@

7

RED/GRN

Rightfront door speaker@, righttweeter@

8

BLU

Leftfront door speaker@, left tweeter @

9

RED/BLK

Lights-onsignal Constantpower (tuning memory)

A3

RED/BLK

A4

WHT/BLU

Constantpower (tuning memoryl

10

WHT/BLU

A5

YEL/RED

ACC(mainstereopower suppry)

15

BRN,ryVHT RightrearspeakerO

A7

BLUI/EL

LeftrearspeakerO

A8

REDI/E L

RightrearspeakerO

A9

BRN/BLK

A10

GRY/BLK

412

Lights-on signal

GRYMHT

Left rearspeakerO

17

BRN/BLK

Rightfront door speakerO, righttweetero

Rightfront door speakerO, righttweeterO

18

GRY/BLK

Leftfront door speakerO, left tweeter O

Lefttront door speakerO, left tweeter O

'19

RED

RED

Dashlightsbrightness controller

Dashlightsbrightness controller

20

BLK

u r o u n o t ( l 5 ut ,

A14

BLK

G r o u n d( G 5 0 1 )

415

GRYMHT

LeftrearspeakerO

Al6

BRN/VVHT

RightrearspeakerO

T e r m i n a lA s 6 ,A 1 1a n dA 1 3 :N o t u s e d

23-192

T e r m i n a l sN o . 1 , 3 , 4 , 1 1 , 1 2 , 1 3 , a n d 1 4 : N o t u s e d

SpeakerReplacement Rearspeaker:

Front speaker: 1.

Removethe speakercover.

2.

Removethe threescrewsfrom the speaker.

3.

Disconnectthe 2P connector,and removethe door speaker.

1.

Removethe rearside shelfor rearshelf (seesection 20t.

2.

Disconnect the 2P connectorfrom the speaker.

3.

Removethe four screws,then removethe speaker.

Hatchback:

FRONTSPEAKER

Tweeter:

(}-

2P CONNECTOF

1.

Removethe door panel(seesection20).

2.

the 2Pconnectorfrom the tweeter. Disconnect

3.

Removethe mirrorgarnish.

4,

Removethe two screws,then removethe wveeter.

TWEETER

Coupe/Sedan: REAR

2P CONNECTOR

23-193

Stereo Sound System Window AntennaWire Test

WindowAntennaWireRepair

1 . W r a p a l u m i n u mf o i l a r o u n d t h e t i p o f t h e t e s t e r probeas shown.

NOTE:To make an effectiverepair,the brokensection must be no longerthan one inch. 1.

Lightlyrub the areaaroundthe brokensectionwith fine steelwool, then cleanit with alcohol.

2.

Carefullymaskaboveand belowthe brokenportion of the window antennawire with cellophanetape. OPEN

CELLOPHANE TAPE Using a small brush, apply a heavy coat of silver c o n d u c t i v ep a i n t e x t e n d i n ga b o u t 1 / 8 " o n b o t h sidesof the break,Allow 30 minutesto dry. NOTE|Thoroughlymix the paintbetoreuse. Touch one testerorobe to the window antennaterminal near,and move the other tester probe along the antennawiresto checkthat continuityexists.

WINDOWANTENNA

Checkfor continuityin the repairedwire. Apply a secondcoat of paint in the sameway. Let it dry three hoursbeforeremovingthe tape.

23-194

Window AntennaCoil Test

MastAntennaReplacement

1.

Remove the rear shelf (see section 20).

1.

Disconnect the connectorbetweenthe antennalead a n ds u b a n t e n n al e a d .

2.

D i s c o n n e ctth e 2 P a n d l P c o n n e c t o r sf r o m t h e w i n d o w a n t e n n ac o i l .

2.

Removethe two mountingscrews,then removethe m a s ta n t e n n a .

MOUNTINGSCREWS

l q 8 11 l tf--l lLB2ll lL-,--rl 1P CONNECTOB

-l 2P CONNECTOR

MAST ANTENNA

wtNoow ANTENNA

cotL

3.

Checkfor continuitybetweenterminalA1 and body g r o u n da n d b e t w e e nt e r m i n a l 4 s 1 a n d8 1 . lf there is no continuityat eithercheck,replacethe w i n d o wa n t e n n ac o i l .

23-195

Horn ComponentLocationIndex SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section(24)beforeperformingrepairsor service.

(:-,

. ,,/ \t

(6\' \K2

HORNRELAY:'98 - 00 modelslWirecolorsrWHT/GRN,cBY,l IWHT/GRN,BLU/RED ] Test,page 23 87

CABLEREEL Replacement, section24

HORNRELAY:'96 -97 modelslwire colors:WHT/GRN.GBY,I I IWHT/GRN,BLU/RED Test, page23-86

UNDER-DASH FUSE/RELAY BOX

23-196

'96 CircuitDiagram: - 97 models BATTERY

HornTest:'96 - 97 models 1.

Removethe front bumper(seesection20).

2.

Disconnect the 2P connectorfrom the horn.

HORN RELAY

LOW HORN

3.

WHT/GRN

I

Removethe horn. Test the horn by connectingbattery power to one terminaland groundingthe other,lf the horn failsto sound,replaceit.

(H)HoRN

Y I

BLU/REO

II I

BtK

I

t -l

l-

G40l G1A2

23-197

Hor n CircuitDiagram:'98 - 00 models

Horn Test:'98 - 00 models '1. Remove f.ont the bumper(seesection20).

BATTEFY

2.

D i s c o n n e tcht e 1 Pc o n n e c t of r o m t h e h o r n .

HCRI] tEtA'a

TERMINAL

T e s tt h e h o r n b y c o n n e c t i n gbattery power to the t e r m i n aI a n d g r o u n d i n gt h e m o u n t i n g b o l t . l f t h e h o r nf a i l st o s o u n d r, e p l a c ei t .

1 '98 model: WHT/GRN '99 - 00 modelsrBLU/RED

23494

Switch Test 1 . l M a k es u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o ,t h e n w r i t e d o w n t h e f r e q u e n c i e fso r t h e radio'spresetbuttons('99- 00 models). 2.

Disconnectthe batterynegativecable,then disconnect the positivecable,andwait at leastthreeminutes.

1 . Removethe driver's airbag assembly(see section 24), then disconnectthe horn connectorfrom the steeringwheel. 8 . Checkfor continuitybetweenthe No. 2 terminalof the cable reel sub-harness3P connectorand horn positiveterminal.

3 . Disconnectthe driver's airbag connector(see sect i o n2 4 ) . 4.

R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r ( s e e section20).

5.

3P connector the cablereel sub-harness Disconnect main wire harness. from the

-\

MAIN WIRE HARNESS 3P CONNECTOR

lf there is no continuity,replacethe cable reel (seesection24). lf there is continuity,repair or replacethe horn swtlcn,

Terminalsideol maleterminals

6.

HORNCONNECTOR

REEL SUB-HABNESS 3P CONNECTOR

Checkfor continuitybetweenthe No. 2 terminalof the cable reel sub-harnessand body ground with the horn switchpressed.

9 . l f a l l t e s t s p r o v e O K , r e i n s t a l tl h e d r i v e r ' sa i r b a g assembly(seesection24), and reconnectthe cable connector. reelsub-harness 1 0 . Reconnectthe driver'sairbag connector,and reinstallthe accesspanelon the steeringwheel. ' I1 . Reconnectthe batterypositivecable,then the negative termtnar.

12. After installingthe airbagassembly,confirm proper systemoperation: Turn the ignition switch ON (ll); the SRS indicator light should come on for about six seconds and then go off. Make sure both horn buttons work.

l-

a lf thereis continuity,the horn switchis OK.

lf there is no continuity,go to step6

13. Enterthe anti-theftcodefor the radio,then enterthe customer'sradiostationpresets('99- 00 models).

23-199

RearWindow Defogger GomponentLocationIndex 36 - 98 modols:

UNDER.DASHFUSE/RELAYBOX

REARWINDOWDEFOGGER SWITCH InputTest,page23-203

REARWINOOWDEFOGGER RELAY Test,page 23-86

REARWINOOWOEFOGGER FunctionTest,page23'202 DefoggerWire Repair.page23 202

23-200

'99 - 00 models:

REARWINDOWDEFOGGER

FUSE/RELAYBOX UNDER.OASH

Test,page 23-86

f

L'

' ' r olf_i af = t r F . - l j

REARWINDOWDEFOGGER (Builtinto climatecontrolunit)

REARWINDOWDEFOGGER ANTENNACOIL(Sedsn)

l-

I est, page lr- lv.t

23-201

RearWindow Defogger CircuitDiagram 36 - 98 models:

IGNITION UNOEF,HOOD FUSE/RELAY BOX

(e,oA) N0.41

swtTcH

Noa2(aoA) +WHT WHT/BLK

+

/ BAT \

\:7

ots't

| I

II

YE

BLKBLU

I T t-l t-l

wtNDow

BLK

G601 : Coupe/Sedan G77t :Nalchback

23-202

G40l G402

'99 - 00 models IGNITON SWTCH

FUSEi RELAY BOX HOOD UNDER No4r (80A)

No42 (40A)

+WHT WHT/BLK

-fO

Ctsr

\j7

|

II

BLK

8

CONTROL CLIMATE UNIT delogg€t / R€arwindow \ blill nlo J I I merorcLril \climaleconlrounil /

{/\A-4<-I

1 6

HEATER PUSH swtTcH

NDICATOS (LE0)


I II

REAF WINDOW DEFOGGEB swtTcH

,ll BLK

l-

G401 G402

G40l G402

23-203

RearWindow Defogger FunctionTest

DefoggerWireRepair

CAUTION:Bs carefulnol to scralchor damagethe defogger wires with the tester probe,

NOTE:To make an effectiverepair,the brokensection must be no longerthan one inch.

'1. Checkfor voltagebetweenthe positive terminaland body ground with the ignitionswitch and defogger switchON. Thereshouldbe baneryvoltage. .

.

1,

Lightlyrub the areaaroundthe brokensectionwith fine steelwool, then cleanit with alcohol.

2.

Carefullymaskaboveand belowthe brokenportion of the defoggerwire with cellophanetape.

lf there is no voltage,checkfor: - faulty defoggerrelay. - faultydefoggerswitch. an ooen in the BLK,/BLU wire. lf thereis batteryvoltage,go to step 2.

OPEN

POSITIVETERMINAL

CELLOPHANE TAPE ?

Using a small brush, apply a heavy coat of silver c o n d u c t i v ep a i n t e x t e n d i n ga b o u t 1 / 8 " o n b o t h sidesof the break.Allow 30 minutesto dry. NOTE:Thoroughlymix the paintbeforeuse.

2.

Checkfor continuitybetweenthe negativeterminal and body ground. lf there is no continuity,checkfor an open in the defoggergroundwire. Touch the voltmeterpositiveprobe to the halfway point of eachdefoggerwire, and the negativeprobe to the negativeterminal. Thereshouldbe approximately6 V with the ignition switchand the defoggerswitchON. .

lf the voltageis as specified.the defoggerwire is

oK. .

lf thevoltageis not as specified,repairthedefogger wrre. - lf it is more than 6 V, there is a breakin the negativehalfof the wire. - l f i t i s l e s st h a n 6 V , t h e r e i s a b r e a ki n t h e positivehalf of the wire. Checkfor continuityin the repairedwire. Apply a secondcoat of paint in the sameway. Let it dry threehoursbeforeremovingthe tape.

23-204

Switch Input Test CAUTION: Be careful not to damagc the rear window defogger switch or the center panel when prying the switch out. NOTE: Beforetesting, checkfor blown No. 16 (7.5 A) fuse/relaybox, fuse in the under-dash 1.

Prythe switch out of the centerpanel(seesection20).

2.

the 5Pconnectorfrom the switch. Disconnect

3.

Turnthe jgnitionswitchON (ll),and checkthe voltage betweenthe BLVBLU{+)andthe BLK(-)terminals. Thereshouldbe batteryvoltage . .

lf there is no voltage,checkfor an open in the BLVBLUwire. lfthere is bafteryvoltage,go to step4.

RED

terminals Wiresideof famale

4.

l-

connect a jumper wire betweenthe BLK/BLUand terminals. the BLU/YEL Turn the ignition switch ON (ll), and checkthat the rearwindow defoggerworks; if it does. replacethe defoggerswitch.

23-205

Power Mirrors ComponentLocationIndex Powel Mirror Function Test, page 23-2Oj Power Mirror Test, page 23-210 Replacement,section 20 Actuator Replacement,page 23-2'10

POWEBMIERORSwlTCH Test,page 23-209

23-206

CircuitDiagram(WithoutDefogger) BOX FUSE]FELAY UNDER.HOOD

eo;T f-*---;',;r

OF+-*'.v-f

j-_l

GNTION SWITCH

6\ r'--;.'-"j-'a,_cy'

DASH UNDER FUSEIRELAY BOX

BLK]YEL

) I d R G H T L E F T dI d F l G H r

'f- -- ---\,

T

I

T

I

.t. o l o

(}G551

23-207

PowerMirrors CircuitDiagram{With Defogger) UNDER.OASH FUSE/FELAY BOX

UNDER-HOOD FUSE/RELAY BOX

/lr,---------6 ORN/WHT

I'

l'

YEUBEO

BLUELK

---zlr

BLK

YEURED BLUMHT 8LK

I I

-f, :

G551

23-208

8LK

I

G551

G551

FunctionTest CAUTION: Be careful not to damage the mirror switch or the dashboard drivel's lower covel when prying the swhch out. Withoui defogger: 1. 2.

Pry the switch out of the driver'sdashboardlower cover. the 10Pconnectorfrom the switch. Disconnect

Left mirror inoporalive: terminalof the 10Pconnecconnectthe No. 2 {BLK/YEL) (YEURED) and the No 5 (or No terminal tor to the No. 3 6) terminalto body ground with jumper wires The left mirror shouldtilt down (or swing left)when the ignition switchis turnedON (ll) lf the mirrordoesnot tilt down (or doesnot swing left), removethe left door panel.and checkfor an open in ) i r e b e t w e e nt h e l e f t t h e B L U / W H T( o r B L U / B L K w powermirrorand the switch - lf the wire is OK.checkthe left power mirroractuator. lf the mirror neithertilts down nor swings left. repair the YEUREDwire. lf the mirroroperatesproperly,checkthe mirrorswitch'

.

Right mirror inoperative: Connectthe No. 2 (BLK/EL)terminalof the 10Pconnector terminaland the No. 9 (or No 8) to the No. 3 (YEURED) ground with jumperwires The rightmirterminalto body ( o r s w i n g l e f t )w h e n t h e i g n i t i o n d o w n t i l t ror should switchis turnedON (ll).

lOP CONNECTOR YEL/RED BLK BLK/YEL 4

5

6

POWERMIRROR

swtTcH

8

BLU/WHT YEL/BLK

\:/"*jgil*-( Wire side of female termanals

lf the mirror does not tilt down (or does not swlng left), removethe right door panel.and checkfor an open in the GRN/WHT(or YEUBLK)wire betweenthe right power mirrorand the switch. - lf the wire is OK,checkthe right power marroractuator. . lf the mirror neithertilts down nor swings left. repair the YEUREDwire . l f t h e m i r r o r o p e r a t e sp r o p e r l y ,c h e c kt h e m i r r o r switch.

.

Mirror Test Both inoperative: 1.

check for voltagebetweenthe No. 2 (BLVYEL)ter minal and body groundwith the ignitionswitchON

0r). Thereshouldbe batterYvoltage . If there is no voltage,checkfor: - blown No. 17 (7 5 A) fuse in the under-dash tuse/relaybox - an open in the BLK'/YEL wire. o lf there is batteryvoltage,go to step2. 2. Checkfor continuitybetweenthe No 4 (BLK)terminal and body ground. Thereshouldbe continuity. . lf there is no continuity,checkfor: - an open in the BLKwire. - p o o rg r o u n d( G 5 5 1 ) .

(cont'd)

23-209

PowerMirrors FunstionTest (cont'dl With dcfoggcr:

Laft mirror inopcrativ!:

1.

Connectthe No. 1 terminalto the No. 7 terminal.and the No. 4 (or Nb.9) terminalto body groundwith jumper wires.The left mirror shouldtilt down (or swing left) with the ignitionswitchON (ll). . lf the mirror does not tilt down (o. does not swing lett),checkfor an open in the YEURED(or BLUMHT) wire betweenthe left mirror and the 10pconnector.lf the wire is OK,checkthe left mirror actuator. a lf the mirror neithertilts down nor swingsleft,repair the BLU/BLKwire. t lf the mirror works properly,checkthe mirror switch.

Prythe switchout ot the driver'sdashboardlower cover.

Right mi.ror inopcrativc: Connectthe No. 1 terminalto the No. 8 terminal,and the No.4 (or No. 10)terminalto body groundwith l'umper wi.es.The right mirror shouldtilt down (or swing lett) with the ignitionswitchON (ll). . lf the mirror does not tilt down {or does not swing left),checkfor an open in the YEURED{or YEUBLK) wire betweenthe right mirror and the l0P connector. lf the wire is OK,checkthe right mirroractuator, . lf the mirror neithertilts down nor swingsleft,repair the GRN/WHTwire. o lf the mirror works properly.checkthe mirro. switch, Dafoggcr inoperEtivo:

2.

1.

Checkfor voltage betweenthe No. 3 terminal and body groundwith the ignitionswitchON (||). There should be battery voltage. a lf there is no battery voltage, checkfor; - blown No. 16 (7.5 A) luse in the under-dash fuse/rel8ybox, - An open in the BLK,iBLU wire. . It there is battery voltage, go to step 2.

2.

Connsctthe No. 3 tsrminal to the No. 6 terminal with a iumpsr wire. Both mirrors should gradually warm up when the ignitionswitchON flt). a lf neithermirror warms up, checkfor an open in the ORN/WHTwire. . It only on€ lails to warm up, check its mirror dsfogger elem6nt. . lf both mirrors warm up, checkths switch.

Disconnectthe 10Pcoonectorfrom the oower mirror switch.

Mirror Test Bolh inoparrtiv.: 1.

Checkfor voltagebetweenthe No. 1 terminaland body groundwith the ignitionswitchON flt). Thereshouldbe batteryvoltage. . lf there is no battery voltage,checkto.: - blown No. 16 (7.5A) fuse in the under-dash tuse/relaybox. - an open in the BLVBLUwrre. ! lf thero is banery voltage, go to step 2.

2.

Checkfor continuityb€tweenthe No. 2 terminaland body ground. Thereshouldbe continuitv. . ll there is no continuity,checktor: - an open in the BLKwire. - poor ground (G5511. . lJthereis continuity.checkboth mirrorsindividually 8s describedin the next column,

23-210

Switch Test

r

With defogger:

Without detogg€r: 1.

Removethe switch as dsscribedin FunctionTest (seepage23-207).

2.

Checkfor continuitybetw€enthe terminalsin each switchpositionaccordingto the table.

1.

Prv the switch out of the dashboard driver's lower

Mirror Switch: Terminal

\

rL*"--_\ UP DOWN L LEFT RIGHT

UP

I

DOWN LEFI RIGHT

2

3

4

o-

5

6

n

9

-o POWERMIRROR swtTcH

o- -o o- -o ooo- o- -o o- o- -o o- -o oo- -o oo- -o

-o -o -o Disconnectthe 1OPconnectorfrom the switch'

-o -o -o

Checkfor continuitybetweenthe terminalsin each switch position accordingto the table Mirror Switch: \

Terminal \ Position

UP DOWN L

l

7

2

-o

o-

-o

--o

oPOWERMIRROB swlTcH

UP DOWN

LEFT

-o

o-

oG

-O

-o -o -o

ooG-

-o -o

o-

-o -o

o-

RIGHT

't0

-a

o- -o

oRIGHT

9

-o

oo-

8

-o

o-

DofoggerSwhch: \

l-

Terminal Posilion ON OFF

2

\

oo-

-o

/l>\

sv

--o 23-211

PowerMirrors PowerMirror Test 1.

Mirror ActuatorReplacement (Donnelly Typel

Pryout the cover panel(seesection20).

'1. Remove the power mirror from the door {seesection 20).and disconnectthe 8P connector.

COVER

2.

R e m o v et h e m i r r o r b a s e c o v e r f r o m t h e m i r r o r housing. MIRRORHOUSING

MIRROR HOLDER Removethe mirror holderfrom the mirror housing. Gentlypull it out by hand. 4.

Terminalside of maleterminals

Removethe three screwsfrom the actuatorand the two screws from the bracket at the base of the assemory.

'99- 00models *: Canada

Disconnect the 8P connectorfrom the power mirror. Checkactuatoroperationby connectingpower and groundaccordingto the tables.

L___r"'ry1

7

I

TILTUP

o

@

TILTDOWN

@

Position

6

SWINGLEFT

o

SWINGRIGHT

@

@

DofoggerTest: 4.

Checkfor continuitybetweenthe No. 3 and No. 4 terminalsof the 8P connector. Thereshouldbe continuity.

23-212

BRACKET 5.

Removethe bracketfrom the housinq.

6.

Removethe two screws,cut the wire harness,and removethe actuator.

10, lnsertthe terminalsinto the connectorin the origin a l a r r a n g e m e n (t r e c o r d e di n s t e p 7 ) , a s s h o w n Detow. Right:

Left:

SLK/WHT*

BLK/WHTi BLU/REO'

o

,t

L, I

LT GRN

7.

Recordthe terminallocationsand wire colors'

8.

Routethe wire harnessof the new actuatorthrough t h e h o l e i n t h e b r a c k e t .B e s u r et o p a s st h e w l r e underthe bracketcliP.

.;{

a

GRY I PNK

PNK

'99- 00models ": Canada 1 1 . Apply tape to sealthe intersectionof the connector boot and the wire harness. in the reverseorderof disassemblyBe 12. Reassemble

BRACKET

carefulnot to breakthe mirror when reinstallingit to the actuator.

1 3 . Reinstallthe mirrorassemblyto the door. 't4. Operatethe power mirror to checkthat the actuator workssmoothlY.

9.

Passthe connectorboot overthe wire harness

23-213

Wipers/Washers ComponentLocationIndex SBScomponentsare locatedin this area,Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section(241betoreperformingrepairsor service.

WIPER/WASHER SWITCH Test,page23-215

REARWINDOW WIPER MOTORlHatchback) Test,page23'216

WINDSHIELD WIPERARMS/BLADES

WINDSHIELD WIPERMOTOR Test,page23-215

WASHERFLUID RESERVOIR

t_l

iTIilr WASHERMOTOR{Hatchback) Test,page23'216 INTERMITTENT WIPERRELAY (ln the integrated CIRCUIT controlunit)

23-214

I J

CircuitDiagram(Windshield) DAS'I UNDER F U S EF ' - A Y B 3 X

BOX FUSElFELAY UNDER,HOOD

G R NB t (

o ooo?, I t Y",i

NTEGRATED CONTROL IINIT / Hasb! ll.Ln \ 1 nlernrltent I perreray \w l

a/

W PEF MOTOR WLNDSHIELD

.r^_",,,*: { M } WASHEF

r,roroR

Y

I

BLK

8LK

BLK

I

l-'

II -

GzO2

G401 G402

G40l G402

ONWIPEF/WASHER NEDOPERAT COMB

23-215

Wipers/Washers

"l-

CircuitDiagram(RearWindow) UNDEN HOOD FUSE/RELAY BOX WHTi BLK+WI]T

REAFWINDOW WIPERMASHER SWITCH

,'/-t:<--

-----,-l

GRN/BLK

A I

B !K

t -

ooo, G402

23-216

ouo,

G761

Wiper/WasherSwitch Test

WindshieldWiperMotor Test

1 . Removethe driver's dashboardlower cover {see section20). Removethe steeringcolumncovers. D i s c o n n e c t h e 8 P a n d 6 P c o n n e c t o r sf r o m t h e switch, remove the two screws,and pull out the switch.

1.

Openthe hood, and removethe cap nuts.Carefully remove the wiper arms so that they do not touch the hood. Removethe cowl cover by prying out the trim clips (seesection20). D i s c o n n e ct th e 5 P c o n n e c t o lrr o m t h e w i n d s h i e l d wiper motor.

SWITCH WIPER/WASHER

Windshield: l 1 2 3 1 4|

li.l7a,lil

RearWindow:

1 1z 3 l

lT-,rtl

4.

Checktor continuitybetweenthe terminalsin each switchpositionaccordingto the table

Windshield Wiper/WasherSwitch: Terminal

\

1

2

7

5

3

I

\

Position OFF INT

LO

o -o

o o

oo

o

HI l\4ist switch"0N" " switch"0N Washer

o o

Test the motor by connectingbattery power groundaccordingto the table.

o o o

\

o

o

i**l*-

Terminal -_\

o

LOWSPEED HIGHSPEED

4

1

o

@ @

RearWindow WiPer/WasherSwitch: I

'i"*

--JTerminal

"0N" switch Washer "OFF"l (Wiper switch OFF

ON "0N" switch Washer "0N") switch {Wiper

2

3

4

lf the motor does not run or fails to run smoothiy, replaceit.

6

o- -o o- -o o- -o o- -o o- -o o- -o

5.

Connectan analogvoltmeterbetweenthe No. 5 {+) and No.3 {-) terminals.and run the motor at low or high speed. The voltmetershould indicate0 V and 4 V or less alternately.

23-217

Wipers/Washers RearWiperMotor Test (Hatchback)

WasherMotor Test

1 . Removethe hatch lower trim panel (seesection20).

1 . Removethe front bumper (seesection20).

Disconnectthe 4P connectorfrom the wiper motor assemDry,

Disconnect the 2P connectorsfrom the washer,

REARWINDOW WASHERMOTOR (Hatchbackl WASHERFLUIO RESERVOIR

Test the motor by connecting battery power to the No. 1 terminaland groundto the No.3 terminal. 3. lf the motor does not run or fails to run smoothly, reptacerI. Reconnectthe 4Pconnectorto the wiper motor. Connectan analog voltmeter between the No. 4 (+) and No.2 (-)terminals, Runthe motor by turning the wiper switch ON. The voltmetershould indicate0 V and 4 V or less alternately.

23-218

L

Test the washer motor by connecting battery power and groundaccordingto the table.

f:,ry1

Battery

1

Disconnected Connected

@

a lf the motor failsto run smoothly,replaceit. a lf the motor runssmoothly.but littleor no wasner

f l u i d i s p u m p e d .c h e c kf o r a d i s c o n n e c r € o r blockedwasher hose,or a clogged pump outlet in the motor.

WasherLevelSwitchTest (Canadal 1.

Removethe front bumper{seesection20)

2.

the 2Pconnectorsfrom the washer. Disconnect

WASHERFLUIO RESERVOIR

3.

\

WASHERLEVELSWITCH

Checkfor continuitybetweenthe terminalsin each float positionaccordingto the table. Terminal

1

2

o

o

;r"l,'t"--l FLOATUP FLOATDOWN

23-219

Power Windows GomponentLocationIndex

POWERWINDOWRELAY Test, paqe 23 87

O

-.---,---;-;n -rr----r----

_

-n--n-nn--r-

! l

fl]l

O

FRONTPASSENGER'S WINDOWSWITCH Test.page 23-230 UNDER-DASH BOX FUSE/RELAY POWERWINDOW MASTERSWITCH (Hasbuilt in controlunit) InputTest,page23-226 f e$, page23 224

FRONTPASSENGER'S WINDOWMOTOR Test,page 23-232 RIGHTREARWINOOWSWITCH{Sedanl Test, page23-230 BIGHTREARWINDOWMOTOR lSedanl Test,page 23-232

DRIVER'SWINOOWMOTOR Test,page23-231 LEFTREARWINDOWSWITCH(Sedan) Test,page 23-230 LEFTBEARWINDOWMOTOR{Sedanl f e$, page23-232

I J

CircuitDiagram('96-98Coupe/Hatchbackl BOX FUSE/RELAY UNDER.HOOD +WHT WHT]BLK WHTtsLU

l /

BLK

l,

G551 PASSENGEB'S WNDOWMOIOR

G401 G()2

23-221

Power Windows CircuitDiagram('96-98Sedan) UNDER HOOD FUSE/RELAY BOX

UNDER.DASH FUSUBELAYEOX

BLU/ELK

I.iASTER SWITCH

3 I BIGHT BEAR

l$',]ilP3,y

FBONT PASSENGER'S WINDOW

swtTcH

BLK

t LEFT HEAF WINDOW MOTOR

23- 2 2 2

R GNTREARWINDOW MOTOR

B3

FRONT PASSENGER'S WINOOW MOTOR

G551

BLK

I

G551

c401 G402

CircuitDiagram('99-00Coupe/Hatchback) FUS€/RELAY BOX UNDER.DASH

PASSENGER'S

a/ BLU'YEL BLU/ORN

BLU/RED

t,

#* lul PASSENGERS MOTOR WINDOW

DRIVERS W NDOWMOTOR

BLK

l

G401 G402

23-223

Power Windows GircuitDiagram('99-00Sedanl UNDEF.HOOO FUSE/RELAY BOX

BLK

I -.=

G551

23-224

G401 G402

FRONT PASSENGER'S

l*

''o BLU,YEL BLU/OFN

| GRN,ryEL

YEL

810 YEUGRN

8LK

l l "UB^YEUGRN

YEL

l s

4I

3IFFONT PASSENGER'S

l z

3 I RIGHTREAB

4

wINDOW SWTCH

wrNDow

.I+

FEDI{EL REDiBLU

PASSENGER'S FRONT MOTOF WINDOW

LEFTREARW]NOOW MOTOR

BLdRED lSwlTCH

El.l

2

1

RED/BLU !

G55l RIGHTREAFWINOOW MOTOR

23-225

Power Windows MasterSwitch Test (Coupe/Hatchbackl 1.

Removethe master switch from the driver's door panel (see page 23-2281.

Passenger'sSwitch: \

D i s c o n n e c t h e 1 2 P c o n n e c t o rf r o m t h e m a s t e r switch.

Terminal

P""*;l-m;\ ON OFF

OFF

MAIN SWITCH

UP

ON OFF

DOWN

ON OFF

I

A1

A1

A8

A3 A4 A5

,/l/

412

Terminal side of male terminals

3.

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.

Driver's Switch: The driver'sswitch is combinedwith the control unit so you cannot isolatethe switchto test it. Instead.run the masterswitch input test proceduresat terminals41. A3, 44. A8 and Al2 on page 23-226.lf the tests are normal, the driver'sswitchmust be faulty.

23-226

A2

A5

ooc'- --o

A6

A7

--o --o o- --o

o- --o --o o--o o--o o-

MasterSwitch Test (Sedan) 1.

Removethe armrest from the driver's door panel (seepage23-228).

Front Passenger'sSwitch: Terminal

\

B1

P*,j--f$t,l"\

D i s c o n n e ctth e 1 6 P a n d 1 P c o n n e c t o r sf r o m t h e masterswitch.

ON OFF OFF

MAIN SWITCH

UP

ON OFF

ON DOWN OFF

82

811

cl

--o

CF

o o- --o c\- --o o o o

oo o- --o o

-o

o

Left RearSwhch: \

Terminal

P".r,-'-f-mn\ ON OFF OFF

rFl

lt.:::::::l l"'ll

UP

ON OFF

Terminalsideof maleterminals

ON DOWN OFF

B1

814

815

816

c1

--o

G

o o o- -oo o- --o o- o o --o o o-_o o-

B4 B5 B6 B7

B3

/l/leu

B8 89 8 1 08 1 1

Bl5 816

Right Rear Switch: \

Terminal

'**-T-*m ON OFF OFF

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the tables

ON

UP OFF

Driv€r's Switch: The driver'sswitch is combinedwith the control unit so you cannot isolatethe switchto test it. Instead,run the masterswitch input test proceduresat terminals83, 84, 85. BOand 87 on page 23-22A.lt the tests are normal, the driver'sswitchmust be faulty.

ON DOWN OFF

B8

89

B' t0

c1

o- o 'o o- --o o- --o CF --o Cr- --o --.o o--o o--o o-

23-227

Power Windows Master Switch Input Test {Coupe/Hatchback) NOTE:The controlunit is built into the powerwindow masterswitch,and only controlsdriver'sdoor window operatlons. l

Removethe driver'sdoor panel,and disconnectthe 12Pconnectorfrom the masterswitch.

2.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. . .

lf the terminalsare bent,looseor corroded,repairthemas necessary, and recheckthe system. lf the terminalslook OK,makethe followinginput testsat the connector. - lf a test indicatesa problem,find and correctthe cause.then recheckthe system. - lf all the inputtestsproveOK,the powerwindow masterswitchmust be faulty;replaceit.

Waresideof femaleterminals

23-228

Cavity

Wire

Test condition

Test: Desiredresult

Un d e ra l l c o n d i t i o n s

Checkfor continuityto ground: Thereshouldbe continuity.

lgnitlon switch ON (ll)

Checkfor voltageto ground: Thereshouldbe batterYvoltage.

Possiblecaus€if result is not obtainsd . P o o rg r o u n d( G 5 5 1 ) . An open in the wire

BLK A8 A']

BLU/BLK

A6

GRN/BLK

RED/BLU

A3

A7

A2

RED/YEL

Checkthe driver'swindow motor: Connectthe BLU/BLK terminalto the RED/YEL It shouldrun (thewindow moves t e r m i n a la, n dt h e R E D / o o w n , . BLUterminalto the B L Kt e r m i n a lt,h e nt u r n the ignitionswilchON ( ).

connectthe GRN/BLK Check the passenger'swindow (the window BLUI/EL terminalto the BLUryEL motor: lt should run qown,. moves B L U / t e r m i n a la, n dt h e O R Nt e r m i n atlo t h e B L Kt e r m i n a lt,h e nt u r n BLU/ORN the ignitionswitchON 1 i.

412

BLU

A8

BLK

Connectthe BLU/BLK terminalto the REDI/EL t e r m i n a la, n dt h e B L K t e r m i n atlo t h e R E D / B L Ut e r m i n a lt,h e n turn the ignitionswitch

Check for voltage between the BLU and BLK terminals: APProx. 6 V should be indicated as the driver's window motor runs.

'11(20A) fuse in Blown No. 10 or the under-dashfuse/relaybox Faultypowerwindow relay A n o p e ni n t h e w i r e F a u l t yd r i v e r ' sw i n d o w m o t o r An open in the wire

window motor Faultypassenger's window switch Faultypassenger's An open in the ware

F a u l t yp u l s e r FaLiltydriver'swindow motor An open in the wire

oN (||).

23-229

Power Windows MasterSwitch Input Test (Sedan) NOTE:Thecontrolunit is built intothe powerwindow masterswitch,and only controlsdriver'sdoor window operations. 1.

Removethe driver'sarmrest,and disconnectthe 16Pand 1Pconnectorsfrom the masterswitch.

2.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. a lf the terminalsa re bent,looseorcorroded,repairthemas necessary, and recheckthe system. . lf the terminalslook OK, makethe followinginputtestsat the connector. - lf a test indicatesa problem,find and correctthe cause,then recheckthe system. - lf all the inputtestsproveOK.the powerwindow maserswitchmust be faulty;replaceit.

POWEBWINDOWMASTERSWITCH

23-230

Cavity

Test condition

Wire

U n d e ra l l c o n d i t i o n s

to:

Test: Desiredresult C h e c kf o r c o n t i n u i ttyo g r o u n d l Thereshouldbe continuity.

Possible caus! d r"suh rs nol obtrincd , An ope^

^ :he tt .e

BLK

c1 B3

BLU/BLK

B2

GRN/BLK

l g n i t i o ns w i t c hO N ( l l )

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

. B l o w nN o . 7 . 6 1 0r ' " 2 0 A f u s ei n t h e u n d e .o a s t f . s e ' e a , box . Faultypowerwindo$ 'e a, . An open in the wire

Checkthe driver'swindow motorl I t s h o u l dr u n ( t h ew i n d o wm o v e s oown).

. Faultydriver'swindow motor . A n o p e ni n t h e w i r e

YEL/BLK 8 1 5 REDA/VHT

81

C o n n e c tt h e B L U / B L K to the RED/YEL terminal RED/BLU t e r m i n a l ,a n d t h e R E D / B L U t e r m i n a lt o t h e B L K t e r m i n a l ,t h e n t u r n RED/YEL t h e i g n i t i o ns w i t c h O N 1 Ii .

B1

C o n n e ctth e G R N / B L K Checkthe front passenger's BLUIVEL terminalto the BLU|YEL wrnoowmotor: t e r m i n a la, n dt h e B L U / It shouldrun (thewindow moves

Faulty front passenger'swindow motor Faulty front passenger'swindow An open in the wire

B L Kt e r m i n a lt,h e nt u r n 8 1 1 BLU/ORN the ignitionswitchON

0r ) . connect the YEL/BLK terminal to the YEL terYEL B9 m i n a l ,a n d t h e Y E U G R N t e r m i n a lt o t h e B L K t e r m i n a l ,t h e n t u r n B t 0 Y E U G R N the ignition switch ON

Checkthe right rearmotor: I t s h o u l dr u n ( t h ew i n d o wm o v e s down).

Fauityright rearwindow motor Faulty rightwindow switch A n o p e ni n t h e w i r e

0r ) . 8 1 4 GRNI/EL

816

GRN

connect the RED,ryVHT Checkthe left rearmotor: It shouldrun (thewindow moves terminal to the GRN/ Y E Lt e r m i n a l ,a n d t h e G R N t e r m i n a lt o t h e B L K t e r m i n a l ,t h e n t u r n t h e i g n i t i o ns w i t c h O N

Faultyleft rearwindow motor Faultyleft rearwindow switch A n o p e ni n t h e w i r e

0r ) . B6

BLU

B4

BLK

Connectthe BLU/BLK terminalto the RED/ Y E Lt e r m i n a la, n dt h e B L Kt e r m i n atlo t h e R E D / B LtUe r m i n a l , t h e nt u r nt h e i g n i t i o n s w i t c hO N ( l l ) .

Checkfor voltagebetweenthe B L Ua n d B L Kt e r m i n a l s l Approx.6 V shouldbe indicatedas the driver'swindow motor runs.

Faultypulser Faultydriver'swindow motor An open in the wire

23-231

PowerWindows Passenger'sWindow Switch Test Switch sids of 5P t.rminal:

Coupo/H8tchback: 1.

Remove the armrest pocket from the door panel {seesection20}.

2

1

5

a

WINDOWSWITCH PASSENGER'S

Terminal sideol maleterminals

Checkfor continuitybetweenthe terminalsin each switch position accordingto the table. \

Terminal

il;--l UP

Disconnectthe 5P connector from th€ passenger's window switch.

Sodan: 1.

Removethe armrest(seesection20). 5P CONNECTOR

Disconnectthe 5P connector,then .emove the mounting screwfrom the passenge/sswitch.

23-232

5

2

-o -o -o

OFF

o- -o

DOWN

o- -o

5PCONNECTOR 2.

I

Driver'sWindow Motor Test Puls€rTest:

Motor Test: l.

Removethe driver'sdoor panel(seesection20).

5.

Connectthe test leadsof an analogohmmeterto the No. 3 and No. 4 terminals.

6.

Run the motor by connectingpower and ground to the No. 1 and No.2 terminals.The ohmmeterneedle shouldmove backand forth alternately.

Terminalsideof maleterminals

Disconnectthe 4Pconnectorfrom the motor. 3.

Testthe motor in each directionby connectingbattery power and groundaccordingto the table. Terminal -_l\

1

UP

o

@

DOWN

o

o

\ ;."t1."

CAUTION: When th€ molor stops running, disconn€ct one lead immediat€ly. 4.

lf the motor does not run or fails to run smoothlv. reDlaceit.

l.,, 23-233

Power Windows Window Motor Test Passenger's Re!r:

Front: 1.

Removethe passenger'sdoor panel (see section

1.

Remove the passenger'sdoor panel {see section 20).

2.

D i s c o n n e c t h e 2 P c o n n e c t o ff r o m t h e w i n d o w motor.

20t. 2.

D i s c o n n e c t h e 2 P c o n n s c t o rf r o m t h e w i n d o w moIor.

NOTE:The illustrationshowsthe right rearwindow motor;the left rearwindow motor is symmetrical.

2P CONNECTOR

\ 2P CONNECTOR

Terminalsideot msle terminals

3.

\

Checkwindow motor operationby connectingpower and groundaccordingto the table. Terminal

;;,r";--l UP DOWN

I @

3.

Terminal

\

o

DI;t;;---l

UP DOWN

@

CAUTION: When the motor stops running. dbconnest ono load immadiatoly. 4.

lf the motor doas not run or fails to run smoothly. replaceit.

23-234

Checkwindow motor operationby connectingpower and ground accordingto the table.

o

@

@

GAUTION:Whon the motor ctops running, disconnact one lead immodiatoly. 4.

lJ the moto. does not run or fails to run smoothly. rcDlaceit,

Moonroof ComponentLocationIndex

MOONBOOFSWITCH Test,page23-236

a-/ . MOONROOFCLOSERELAY lwire colors:WHT.GRN/YEL, l IGRN/oBN,BLK,and GRN/REDI Test,page23 87,88 . MOONROOFOPENRELAY f wire colors:WHT,cRN/RED,l IGBN/ORN,BLKand YEL l Test,page 23'87,88

MOONROOFMOTOR Test,page 23-236

l-, 23-235

Moonroof CircuitDiagram qELAY FUSE JNDEB.FOOD BOX

*1 9697modes :+2r'98-00 models IGNITIONSWTCH

MOONFOOF SWITCH

BLK

I

_lr

--

G40t G402

23-236

OPEN/CLOSE SWITCHI .ourrElhelifinoooglalron F! ycto6ed) {T[!b AandClerminals areconnecled. . ournolhesldnoo$ralron *: Futly (Fully?osed op€n) A andBlermrnals areconnecled. TILT/CLOSE SWITCHI . Durinq lhelihina oDeralion Fillycosed) [Ir]tuir DandFterninaliare conned€d. . Durino lheslidrno oDoraton --: lFulvdossd Fllv ooenl 0 anilElemnalsare(inhecied.

FunstionTest CAUTION: Bo careful not to damago the moonroof switch or ths driv6r's dashboard lowsr cover when prying the 3witch out.

Connectthe No. 1 (YELIterminal to body ground with a jumperwire,then turn the ignitionswitchON (ll).The moonroofshouldopen.

NOTE:Checkthe No. 51 (20 Al fuse in the under-hood tuse/relaybox and No.24 (7.5A) fuse in the under-dash fuse/relaybox, before testing.

. .

1.

Prv the switch out of the driver'sdashboardlower cover.

lf the moonrootopens,checkthe switch. lf the moonrootdoes not open,checkfor: - an open in the YELwire. - faulty moonroofopen relay. - faulty moonroofcloserelay, - poor ground(G401,G402). - fa ulty open/closeswitch.

terminalto body ground Connectthe No. 3 (YELnED) jumper wire. then turn the ignitionswitchON with a (ll).The moonroofshouldclose.

4P CONNECTOR

. .

lf the moonroofcloses.checkthe switch. lf the moonrooldoesnot close,checkfor: - an open in the YEUREDor GRN/RED wire' - faulty moonroofcloserelaY. - faulty moonrootoPenrelaY. - faultytilvcloseswitch.

Connectthe No. 2 (BLU)terminalto bodygroundwith a jumper wire, then turn the ignitionswitchoN (ll). The moonroofshouldtilt up. . .

swtTcH

lf the moonrooftilts up, checktheswitch. lf the moonroofdoesnottilt up, checkfor: - an open in the BLUwire. - taultytilvcloseswitch

terminal to bodYground 6 . Connectthe No. 3 (YEURED) with a jumperwire,then turn the ignitionswitchON (ll),The moonroofshouldtilt down. lf the moonroofdoes not tilt down, the open/close relay must be taulty. Wire sideof femaleterminals

2.

7.

Checkfor continuityto body ground on the No. 4 {BLK}terminal. Thereshouldbe continuity.

Disconnectthe 4P connector from the switch

. .

lf there is continuity,checkthe switch lf thereis no continuity,checkfor: - an open in the BLKwire - poor ground (G401,G402).

l-t 23-237

Moonroof Switch Test

Motor Test

1 . Carefullyremovethe switchfrom the driver'sdashboardlowercover{seepage23-205}.

'1.

D i s c o n n e ctth e 2 P c o n n e c t o rf r o m t h e m o o n r o o f motor.

Checkfor continuitvbetweenthe terminalsin each switchpositionaccordingto the table.

Terminal

\

Removethe headliner(seesection20).

Terminalsideof maleterminals

I

2

3

o

-o o- --o --o

4

t*',*-----__\ ut-t-

OPEN

o-

CLOSE

TILT

Checkthe motor by connectingpower and ground accordingto the table.

\_____lTr1

,l

Position

4.

OPEN

o

CLOSE

@

@

lf the motor does not run, replaceit (seesection20). NOTE: See Closing Force Checkin section 20 for motor clutchtest.

23-234

Switch Test Open/Close-Tilt/Close 1.

Removethe headliner(seesection20).

2.

from the moonthe 2P and 4Pconnectors Disconnect roof motor andthe switch.

3.

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.

\

-\

Terminal

*r*"-

.* CLOSE

TILT

..--. OPEN CLOSE 4.

1

2

3

o- - o o- --o -o o-

lf thereis no continuity,adiustor replacethe switch'

Terminalsideof maleterminals

l-t 23-239

GruiseControl ComponentLocationIndex MAIN SWITCH TesVReplacement, page 23-242

CABLEREEL Replacement,section24

BRAKE SWITCH , fest, page23-244 CRUISECONTROI.UNIT InputTest,page23-240

. PedalHeightAdjustment, section19

swrTcH{M/T)

atf SWTTCH

. Test.page 23-244 . Clutch PedalAdjustment, section12

. Test,page 23-154 ' Replac€ment,page 23-'155

ACTUATORCABLE Adjustment,page23-246

VACUUMTANK

. . . '

23-240

TORASSEMBLY Test,pag€ 23-245 Replacement,page23-246 SolenoidTest,page23-247 Disassembly,page 23-248

CircuitDiagram swlrcH tGNlTtoN

FUSEiRELAY8OX UNDER.HOOD N0.41(80A)

N0.42{40A)

BOX FUSARELAY UNDEB.OASH

N0.30(7.5A)

f/

+WNT WNT/BLK

I REO/BtX

INOICATOR LIGHT (0.84rY)

GRY+

BLUiGRN

BLU/RED

V

HORN

lP

IO SET

I J ,

lo I Q suue

GAUGE ASSEMBLY

JRN,/WH

V

gRAKE LGHTS

l-t

CBUISE CONTROL ACTUATOR

* : 9900models wlli A/T

23-241

CruiseControl GontrolUnit Input Test SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions, and proceduresin the SRS section(24)beforeperformingrepairsor service. 1.

Removethe driver'sdashboardlowercoverand kneebolster(seesection20).

2.

Disconnect the l4P connectorfrom the controlunit.

3.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact. lf the terminalsare bent,loose,or corroded,repairthem as necessary, and recheckthe system. lf the terminalslook OK, makethe followinginpul testsat the connecror. - lf any test indicatesa problem,find and correctthe cause,then recheckthe system, - lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.

14PCONNECTOR

Wiresideof femaleterminals CRUISECONTROLUNIT GRN/WHT LT GRN/RED LT GRN/BI-K

8LU/GRN*

*i '99

00 models with A/T

23-242

) Cavity

BRNA/VHT 1

BRN

11

BRN/BLK

2

GRY

3

BLK

5

Test condition

Wire

GRNA,A/HT

U n d e ra l l c o n d i t i o n s U n d e ra l l c o n d i t i o n s

lgnjtion switchON (ll), main switchON and brakepedalpushed, then released

Checkfor voltageto ground: Thereshouldbe 0 V with the Pedal pushedand batteryvoltagewith the pedalreleased.

' F a u l t yb r a k es w i t c h . A n o p e nI n t h e w l r e

Un d e rall conditions

Checkfor continuitYto groundl Thereshouldbe continuity

Brakepedalpushed, then released

Checkfor voltageto groundl Thereshouldbe batterYvoltage with the PedalPushed.and 0 V with the pedalreleased

' P o o rg r o u n d( G 4 0 1G , 402) . A n o p e ni n t h e w i r e . B l o w nN o .5 2 ( 1 5A ) f u s ei n t h e box under-hoodfuse/relaY . Faultybrakeswitch . An open in the wire

Set button pushed

Check for voltage to ground: There should be batterYvoltage.

B l o w nN o .5 2 ( 1 5A ) f u s ei n t h e box under-hoodfuse/relaY Faultyhorn relay Faultysevresumeswitch Faultycablereel An open in the wire

Attach to ground: C r u i s ei n d i c a t o rl i g h t i n t h e g a u g e assembly should come on.

B l o w nb u l b Blown No. 25 (7.5A) fuse in the underdashfuse/relaybox F a u l t yd i m m i n gc i r c u i it n t h e gaugeassemDly An open in the wire

LT GRN/ BLK

ResumebuttonPushed

RED/BLU

lgnitionswitchON (ll) and main swilch ON; raisethe front of the BLU,A/VHT car,and rotateone wheelslowlywith the otherwheel blocked.

LT GRN

14

PNK

Checkfor voltagebetweenthe BLUMHT@ and BLKO terminals: T h e r es h o u l db e 0 - 5 V o r m o r e -0- 5 V or more repeatedlY

. Faultyvehiclespeedsensor{VSS) . An open in the wire

lgnitionswitchON (ll) and main switchON

Checkfor voltageto ground: Thereshouldbe batterYvoltage.

B l o w nN o . 1 4( 7 . 5A ) f u s ei n t h e under-dashluse/relaYbox Faultymain switch An open in the wire

A,T: Shift lever in E, ojorE M/T:Clutchpedal released

Checkfor continuityto ground: Thereshouldbe continuity. NOTE:Thereshouldbe no continuitywhen the clutchPedalis depressedor when the shift lever is in other positions. Checkfor continuitybetweenNo. I terminaland No. 5 terminalof the PCMconnectorA. Thereshouldbe continuity

FaultyA/f gear positionswitch Faultyor misadjustedclutch switch(M/T) Poorground(G401,G402) An open in the wire

Underall conditions

BLU/GRN

l-,

Faulty actuatorsolenoid P o o rg r o u n d( G 2 0 2 ) A n o p e ni n t h e w i r e

to ground: Checkfor resistance 7 0 1 1 00 . b e T h e r es h o u l d

lgnition switch ON (ll)

10

to ground: Checkfor resistance Thereshouldbe 80 - 120O. to ground: Checkfor resistance Thereshouldbe 40 - 60 0.

Possiblecauseif result is not obtained

U n d e ra l l c o n d i t i o n s

LT GRN/ RED

7

Test: Desiredresult

. An open in the wire

*: '99 - 00 modelswith A,/T

23-243

CruiseGontrol Main Switch Test/Replacement 1.

Removethe driver'sdashboardlowercover(seesection 20).

2.

Carefullypush out the switchfrom behindthe dash board.

3.

Disconnect the connectorfrom the swtrcn.

Set/ResumeSwitch Test/Replacement M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e radio'spresetbuttons.('99- 00 models). 2 . Disconnectthe batterynegativecable,then disconnectthe positivecable,and wait at leastthree minutes. Disconnectthe driver's airbag connector(see section 24). Removethe dashboarddriver'slowercover(seesec, tion 20). 5. Disconnectthe cablereel sub harness3p connector from the main wire harness. 1.

MAIN SWITCH

BULBS{0.84Wt

CABLEBEEL SUB-HARNESS 3P CONNECTOS

MAIN WIRE HARNESS 3P CONNECTOR

Terminalsideof maleterminals

4.

\

Check for continuity between the terminals in each switch position according to the table.

Terminal

--\

2

r** OFF

ON

oo-

\:./ /a

\:/

-o

3

5

G

-o o-

lf there is no continuity.reDlacethe switch.

23-244

a\

\a/

\:/

-o -o

Checkfor continuitybetweenthe terminalsof the cable reel sub-harness 3P connectorin each switch positionaccordingto the table. Terminal L Position SET(ON} BESUi,|E IONI

1

2

3

o- ---o o-- ---o

l f t h e r e i s c o n t i n u i t ya, n d i t m a t c h e st h e t a b l e , the switchis OK. lf there is no continuityin one or both positions, go to step7.

7.

Removeth€ two screws,then remove the switch'

SET/NESUME

q

lf all tests prove OK, reconnectthe cable reel and connector,then reinstallthe cable reel sub-harness steeringcolumncovers

1 0 . Reconnectthe driver'sairbag connector.and reinstallthe accesspanelon the steeringwheel. the batterypositivecable,then the nega1 1 . Reconnect tive cable. 1 2 . A f t e r c o n n e c t i n gt h e a i r b a gc o n n e c t o r sc, o n f i r m propersystemoperation;Turnthe ignitionswitchON (ll);the SRSindicatorlight shouldcome on for about six secondsand thengo off. Enterthe anti-theftcode for the radio,then enterthe -00 models)' customer'sradiostationpresels{'99

8.

Checkfor continuity betweenthe terminals in switch positionaccordingto the table. Terminal -\

\ t"-"t*

SET(ON) RESUI\4E {ON}

2

3

-o oo- ---o

lf there is continuity,and it matchesthe table, replacethe cablereel. lf there is no continuityin one or both positions, reDlacethe switch.

l-l 23-245

CruiseControl BrakeSwitch Test

clutch switch Test (M/Tl

1.

1.

Disconnect the 4Pconnectorfrom the switch.

Disconnect the 2P connectorfrom the switch.

4P CONNECTOR

swtTcH

BRAKE PEDAL Checkfor continuitybetweenthe terminalsaccording to the table. 2. Terminal

\

t"r. **

\

RELEASED DEPRESSED

1

2

Checkfor continuitybetweenthe terminalsaccording to the table.

3

o- --o

Terminal -\

\

o

o

2

RELEASED DEPRESSED

3.

I

.***aal

o--

o

l f n e c e s s a r yr. e p l a c et h e s w i t c h o r a d j u s t p e d a l height(seesectionl9). 3.

23-246

l f n e c e s s a r yr, e p l a c et h e s w i t c h o r a d i u s t p e d a l height(seesection'12).

)

Actuator Test ' t . Disconnectthe actuatorcablefrom the actuatorrod

5.

and the 4Pconnector. 2.

With voltageand vacuumstill applied,try to pull the actuatorrod out by hand.You shouldnot be ableto oull it out. ll you can,it is defective

Connect battery power to the No 4 terminal and g r o u n dt o t h e N o . 1 , N o .2 a n d N o .3 t e r m i n a l s . Connecta vacuumpump to the vacuumhose Then applyvacuumto the actuator. VACUUMPUMP GAUGE,0- 30 in.Hg. {A973X- 041 -

xxxxxl

ACTUATOR

groundfrom the No.3 terminal.The actuDisconnect ator rod should return lf it does not return, but the vent hose and filter are not plugged,the solenoid valveassemblyis defective. ,lP CONNEcToR

1.

Repeatsteps 2 through 5, and disconnectground . he actuator od should f r o m t h e N o . 1 t e r m i n a lT but the vent hose and return, not lI it does return. filter are not plugged.the solenoidvalve assembly is defective.

8.

It you replacethe solenoidvalve assembly,be sure to usenew O-ringson eachsolenoid.

Terminalsideo{ maletermrnals

4.

The actuatorrod shouldpull in completely.lf the rod pulls in only pan-wayor not at all' checkfor a leaking vacuumlineor defectivesolenoid.

Disconnectpower and ground from the 4Pconnector. Disconnectthe vent hose from the actuator.Connect a vacuumpump to the actuatorvent hose port, and applyvacuum.The actuatorrod shouldpull in comp l e t e l y .l f n o t , t h e v a c u u m v a l v e i s s t u c k o p e n . Replacethe actuator'

ACTUATOFROD

l-t 23-247

CruiseControl AstuatorReplacement

ActuatorCableAdjustment

1 . Pull backthe boot,and loosenthe locknut.Then disconnectthe cablefrom the bracket.

1 . Checkthat the actuator cable operatessmoothly with no bindingor sticking.

Disconnect the cableend from the actuatorrod.

t t D

=

Stan the engine.Hold the engineat 3,000rpm with no load (Afl'in N or E, M/T in neutral)untit the radiatorfan comeson, then let it idle. Measurethe amount of movementof the actuato. rod until the cable pulls on the acceleratorlever (enginespeedstartsto increase).Free Dlayshould be 11t 1.0mm (0.43I 0.04in). ACTUATORROD

Disconnectthe 4P connectorfrom the actuator. Disconnect the vacuumhosafrom the vacuumtank. Pullout the vent hose. Removethe three mounting bolts and the actuator with the bracket. VACUUMHOSE

LOCKNUTFREEPLAY:11 1 1.0 mm {o.i|:lr 0.oit in}

lf free play is not within specs,loosenthe locknut, and turn the adjustingnut as required. NOTE: lf necessary.check the throttle cable free play (seesection11).then recheckthe actuatorrod free play. Retightenthe locknut,and recheckthe free play.

CABTI

aPCONNECTOR

lf necessary, disconnectthe cableend from the linkage over the acceleratorpedal,then turn the grommet 90' in the bulkhead,and removethe cable, 7.

Installin the revers€order of removal,and adjust free play at the actuator rod after connectingthe cable(seene)dcolumn).

23-244

ActuatorSolenoidTest

)

the 4Pconnectorfrom the actuator' Disconnect

1.

ACTUATOR

Terminalsideot maleterminals

2.

\

J

Checkfor resistancebetweenthe terminalsaccording to the table. Terminal (O) Resistance

4

3

2

\

o- --o

VENTSOLENOID 40 600 VACUUMSOLENOID 30- 500 SOLENOID SAFETY 40- 600

--o

G-

--o

o-

NOTE: Resistancewill vary slightly with temperais at 70"F(20'C). ture;sDecifiedresistance

SAFETYVALVE VACUUM VALVE

l )

From VENT HOSE

+

To VACUUM TANK

23-249

GruiseControl ActuatorDisassembly

ACTUAYORCABLE

ACTUATORBRACKET

WIRESUPPORTBRACKET

ACTUATOR Test,page23 245

SOLENOIDVAI-VES Test, page 23 247

0

o I

SOLENOID SEAL

+*R lAC E

23-250

Power Door Locks ComponentLocationIndex NOTE(With keylessentry systeml: is faulty; . It the doors unlockor lock with the transmitter,but the LEDon the transmitterdoes not come on, the LED replacethe transmitter' (However, . when vou unlockthe doorswith the transmitter,the ceilinglight (middleposition)comeson for 30 seconds. if the audio unit is not installed,the light does not come on ) . lf any door is open,you cannotlockor unlockthedoorswith the transmitter' the horn . The horn soundsonly the first time you pressa transmitterbutton. (Pressingrepeatedlydoes not activate again.) the doors relock o lf vou unlockedthe doors with the transmitter,but do not open any of the doors within 30 seconds, automatically. . The doorsdo not lockor unlockwith the transmitterif the ignitionkey is insertedin the ignitionswitch and the transm'fer . lf you pressthe PANICbutton for more than two seconds,the horn soundsfor about 30 seconds, The panic mode is switch ) ignition is in the key ignition iJ the (The be activated panic will not mode LEDcomes on. cancelledby pressingany of the transmitterbuttons' activatethe transmitter' o After replacingthe transmitterbattery,pressthe lockand unlockbuttonsfive or six timesto

RIGHTREARDOORLOCKACTUATOR Test, page 23-263 Replacement,section20

I.IFT REARDOORLOCKACTUATOR Test,page 23 263 Replacement,section20

DOORLOCKACTUATOR FRONTPASSENGER'S Test,page 23-263 section20 Replacement, AUDIOUNIT (STER€ORADIOTUNER) {'96- 98 models) lHasbuilt-inkeylessl circuit I \receiver page23-189 Replacement, Input Test,page 23-260 Terminals,page23-262 KEYLESSDOORLOCK CONTROLUNIT l'99 - 00 modelsl InputTest, Page23-257 LOCKACTUATOR Test, page 23-263 Replacement,section20

ORIVER'SDOORLOCKSWITCH Test, page23'262

Qi ,,a/

/'-'6

/----

L(ru

l-l

i'.-8,-'l

TRANSMITTER 99 - 0Otransmittershown;'96-98 transmifter alsohasan OPTIONbutton Test,page 23-264 page23_265 TransmitterProgramming,

DOORL@X CONTROLUN]T InputTest,page23 255

23-251

Power Door Locks CircuitDiagram(With KeylessEntrySystem:'96 - 98 modelsl UNDER.HOOD FUSEiRELAYBOX No.4l180A)

N0.42(40A) WHTiBLK

WHT/BED

WHT/BLU

WHT/GRN

POWER OOOR LOCKCONTROL UNT

uNLocK@ rocK @

t'

I'

8 L K YELTRED

8LU/RED

WHT/RED

LOCK KNOB

n Y |

WHT/FED

l,l,

GRNiORN

KEY -----.f--;-)

i-q__!J

GRN/]/VHT

tA-r rA] r. qJ_*:[:,,,: L ll,o"., I PASSENGER'S I DoOFLOCK I ACTUATOR

I liqi*"""r llqi*'€tr

YELIRED

G551

23-252

Y E LRi E D

I YEUREO

BLK

I

BLK

G55l

)

1

w l

r,*1.,. ,,Tr, ,

I

'r-1-| I

llltii irl:rx l5|i;e''lv

TRUNK LIGHT

I

I

@

BLU/YEL

RECEIVER CIRCUIT KEYLESS (lnlheaudio unrl)

l"'l"l''

o'*i*" | |

-"'i:"j^,"

l'*tectotro

UNIT I coNTROL

TGFIVRED

I *r.oro,ro

uNrr I coNTRor

fF7 I Y

I ,Y, | L < r ) I A A A A A Y6su-' YFHrLo,," Ii,llh* T#, -,..".l:!llT ',"**, r e*,**, r I T

BLU/RED

\

\

GRNiRED

GRN

LTGRN/NED

Y.r'ro,u

l-ope1 (eytemoved

I

BLK

I

)

;

liili.} liHi:

l -

l ;

: Door open) I lctoseo dosed J Looen Doot I

t

l

-:

l

. ooo,open | (ctoseo Loner :oootcloset I

l

-l

G402

23-253

Power Door Locks CircuitDiagram(With KeylessEntrySystem: '99-00models) UNDEF.HOOO FUSE/RELAY BOX N0.411804)

N0.51(20 )

KEYLESS DOOFLOCK COIJTROL UNIT

DRIVEF'S DOOFLOCK SWITCH

BL(

I

G551

23-254

)

1

CircuitDiagram(WithoutKeylessEntrySystem) BOX UNDERHOODFUSE/RELAY

ORIVER'S DOORLOCK S WT C H

I r

l -,t

POWER DOOR LOCK CONTROT UNT

l'

BLK

8LK

G55l

G551

23-255

PowerDoor Locks Troubleshooting sequence. NOTE:The numbersin the tableshow the troubleshooting Itemto be inspected

I

E ;

s { o

€ 5 5

O q)

o : E ,

3 .9

x 6 t n 6

o o o o > > t

l 5

: ': o

E

c

6 <

o

Symptom

o :

o F

<5 ucc I

WHT/GRN

Powerdoor locksvstemdoes not work at all.

1

Doorsdon't lockwith driver's door lockknob switch.

All doors

I

One or more doors

YEUREDor WHT/RED

Doorsdon't lockor unlock with driver'sdoor lockswitch.

All doors

GRN/WHT, GRN/ORN, YEUREDor WHT/RED

BLU,ryVHT

2

1

YEUREDor WHT/RED

One or more ooors *The powerdoor locksystemworksproperlybut the keylessentry system doesn't.

1

G401 G402

or GRNAVHT GRNiORN

*: With keylessentrysystem NOTE: . When the remotetransmitterbutton is pressedthe first time, only the driver'sdoor will unlock.When the button is pressedthe secondtime, all the doorswill unlock. lly after30 secondsif a door is not opened,or the key is out ot the ignition switch. . Thedoorswill relockautomatica will not lockor unlockthe doorswhen the key is in the ignitionswitch. . The keylessentrysystem

23-256

ControlUnit InputTest('96- 98 modelsand'99- 00 modelswithout KeylessEntrySystem) 1.

Removethe driver'sdoor panel(seesection20).

2.

D i s c o n n e tcht e 1 2 Pc o n n e c t ofr o m t h e c o n t r o ul n i t .

3.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact and recheckthe svstea lf the terminalsare bent,looseor corroded,repairthem as necessary, at the connector. . lf the terminalslook OK, makethe followinginput tests - lf any test indicatesa problem,find and correctthe cause,then recheckthe syslem lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.

.I2PCONN€CTOR

YEL/RED BLU/RED

5

1

1

8

12

BLU/WHT

Wire side o{ femele terminals

*: With keylessentry system

l-l

lcontd)

23-257

Power Door Locks Control Unit lnput Test ('96- 98 modelsand'99 - 00 modelswithout

KeylessEntrySysteml(cont'dl

Disconnect the 12Pconnectorfrom the powerdoor lockcontrolunit. CAUTION: To prevsnt damageto the actuator, apply battery voltage only momentarily. Cavity

Wire

4

BLK

Test condition

Test: Desiredresult

U n d e ra l l c o n d i t i o n s

Checkfor continuityto ground: Thereshouldbe continuity.

U n d e ra l l c o n d i t i o n s

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

WHT/GRN

2

Connectthe YEURED terminal to the WHT/ GRNterminal,andthe YEURED WHT/RED terminalto the BLKterminal momenraflty.

Checkdoor lockoperation: All passenger's doorsshould untocK.

Checkdoor lockoperation: Driver'sdoor shouldunlock.

3

Connectthe BLU/RED terminalto the WHT/ G R Nt e r m i n a la. n dt h e BLU/RED WHT/RED terminalto the BLKterminal momenraflry.

Checkdoor lockoperation: All passengerdoorsshouldlock.

5

connectthe WHT/RED terminalto the WHT/ G R Nt e r m i n a la, n dt h e WHT/RED YEL/RED terminalto t h e B L Kt e r m i n a l momenraflty. U n d e ra l l c o n d i t i o n s . BLU/YEL

Checkfor continuitybetweenthe power door lockcontrolunit l2P connectorNo. 6 terminaland audio unit 16PconnectorNo. 3 terminal:The.eshouldbe continuity.

Possiblecause if result is nol obtained . Poorground (G55'l) . An open in the wire . Blown No. 51 (20A)fuse in the under-hoodfuse/relaybox . An open in the wire Blown No. 51 {20A) fuse in the under-hoodfuse/relaybox Faultyactuator An open in the wire

An open in the wire

*: With keylessentrysystem Reconnect the 12Pconnectorto the power door lockcontrolunit. Cavity

Wire

Test condition Driver's door lock switch in LOCK

GRN,ryVHT

Tssl: Desirsd losull Checkfor voltageto ground: Thereshouldbe 1 V or less.

Faultydriver'sdoor lockswitch P o o rg r o u n d{ G 5 5 1 ) An open in the wire

Checkfor voltageto ground: Thereshouldbe 1 V or less.

Faultydriver'sdoor lockactuator P o o rg r o u n d{ G 5 5 1 ) An open in the wire

Driver'sdoor lock switchin UNLOCK

8

GRN/ORN

7

Driver'sdoor lockknob BLUA/VHT in LOCK

Possiblecauseit resull b not obtained

ControlUnit Input Test ('99- 00 modelswith KeylessEntrySystem)

)

1 . Removethe driver'skickpanel. Disconnect the 18Pconnectorfrom the controlunit. Inspectthe connectorand socketterminalsto be surethey are all makinggood contacl. and recheckthe system . lf the terminalsare bent,looseor corroded,repairthem as necessary, . lf the terminalslook OK,makerhe followinginput testsat the connector. - lf anv test indicatesa problem,find and correctthe cause,then recheckihe system - lf all the input testsproveOK,the controlunit must be faulty;replaceit

RED/SLK

BLK/YEL

5 6 '15

2 9 1 0/,'2

,/

1

8

17 18 WHT

LT

WiresideoI femaleterminals

the 18Pconnectorfrom the power door lockcontrolunit. Disconnect CAUTION: To provent damageto the actuator, apply battery Yoltageonly momentarily. Cavity

Wir€

17

BLK

t8

WHT/GRN

4

l-r

BLK/YEL

Test condition

Test: Desiredresult

Underall conditions

Checkfor contlnuityto ground: Thereshouldbe continuity.

Underall conditions

Checktor voltageto ground: Thereshouldbe batteryvoltage.

lgnitionswitchON (ll)

checkfor voltageto ground: Thereshouldbe batteryvoltage.

Possiblecause if result is not obtained . P o o rg r o u n d( G 5 5 1 ) . A n o p e ni n t h e w i r e . Blown No. 5'1(20A) luse in the under-hoodtuse/relaybox . An open in the wire Blown No. l4 (7.5A) fuse in the fuse/relaybox under-dash An open in the wire

(cont'd)

23-259

Power Door Locks ControlUnit Input Test ('99- 00 modelswith KeylessEntrySystem)(cont'd)

BLU/RED

2 3 4 9 10

12

WHT/RED

BLU/RED

8LK/YEL

8LU/WHT

YEL/RED

RED/BLK

5 6 1 8

/t/

17 td

t5

WHT/GRN

LT GRN,/RED BLK

GRN/WHT

Wiresideof femaleterminals

Disconnect the 18Pconnectorfrom the oower door lockcontrolunit. CAUTION:To prevent damageto the actuator, apply baftery voltage only momentarily. Cavity

Wile

Test condition

Test: Desiredresult

I

Connectthe YEURED terminalto the WHT/ GRNterminal,and the YEURED WHT/RED terminalto t h e B L Kt e r m i n a l momenraflty,

5

Connectrhe BLU/RED1 Checkdoor lockoperation: Driver'sdoor shouldunlock. terminalto the WHT/ G R Nt e r m i n a la, n dt h e BLU/RED WHT/RED terminalto the BLKterminal momenlaflry_

7

Connectthe WHT/RED terminalto the WHT/ G R Nt e r m i n a la, n dt h e WHT/RED YEUREDterminalto the BLKterminal momenlaflry.

23-260

Checkdoor lockoperation: All passenger's doorsshould untocK.

Check door lock operation: All passenger doors should lock.

Possiblecause if result is not obtained Blown No. 51 (20A) fuse in the under-hoodfuse/relaybox Faultyactuator An open in the wire

I the 18Pconnectorto the power door lockcontrolunit Reconnect Cavitv

Wire

Test condition

'10 GRNA/VHT Driver'sdoor lock switchin LOCK GRN/ORN

2

Driver'sdoor lockknob BLU,ryVHTi n L O C K

BLU/RED

GRY

Possiblecauseit r€sult is not obisinod . Faultydriver'sdoor lockswitch . P o o rg r o un d ( G 5 5 1 ) . A n o p e ni n t h e w i r e

Checkfor voltageto ground: Thereshouldbe 1 V or less.

Faultydriver'sdoor lockactuator P o o rg r o u n d{ G 5 5 1 ) An open in the wire

lgnitionkey inserted into the ignitionkey swttcn

Checkfor voltageto groundl Thereshouldbe 1 V or less

lgnitionkey removed from the ignitionkey swtrcn

Checkfor voltageto ground: Thereshouldbe 4 V or more

Poor ground (G401,G402) Faulty ignition key switch An open in the wire Shon in the wire

Ch."k f"r ".lt"r" t. g|'"r^d Thereshouldbe baneryvollage

A o*n tto gO ,i5 A' fr." in tf'" Lrnderhood fuse/relay box Faulty combination light switch An open in the wire

Eachdoor open,one at a trme

Checktor voltageto ground: Thereshouldbe 1 V or less.

Faultydoor swilch An open in the wire

Un d e ra l l c o n d i t i o n s

Connectto ground: H o r ns h o u l ds o u n d .

B l o w n N o . 5 2 ( 1 5A l f u s e i n t h e under hood fuse/relay box Faulty horn Faulty horn relay An open in the wire

C o m b i n a t i olni g h t switchin " :m:" RED/BLK position LT GRN/ RED

Check for voltage to groundl There should be 1 V or less.

Driver'sdoor lock swirchin UNLOCK

9

3

Tost: Desiredresult

l-l 23-261

Power Door Locks Audio Unit {KeylessReceiverCircuitl Input Test ('96- 98 models} L

R e m o v et h e a u d i o u n i t , t h e n d i s c o n n e c t h e A a n d B c o n n e c t o r s( s e e p a g e 2 3 - 1 8 9 ) .

2.

Inspectthe connector and socket terminals to be sure they are all making good contact . .

lf the terminals are bent, loose or corroded, repair them as necessary,and recheckthe system lf the terminals look OK, make the following input tests at the connector. - lf anv test indicates a problem, find and correct the cause, then recheckthe system lf all the inout tests prove OK, the control unit must be faulty; replace it.

B CONNECTOR

A CONNECTOB WHT/BLU

YEL/RED

16PCONNECTORS AUDIOUNIT RECEIVER CIRCUIT} {KEYLESS

23-262

) Disconnect the A and B connectorsfrom the audio unit. Wire

Cavity A4

Test: Desiredresult

Test condition

Check{or voltage to ground: There should be battery voltage.

lgnitionswirchACC(l)

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

0l)

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

U n d e ra l l c o n d i t i o n s

C h e c kf o r c o n t i n u i ttyo g r o u n d r T h e r es h o u l db e c o n t i n u i t y .

P c . ' E ' o - - d r G 4 0 1 ,G 4 0 2 ) A- ooen n lhe wire

lgnition key inserted i n t o t h e i g n i t i o nk e y swrtch

Check for voltage to ground: There should be 1 V or less

lgnition key removed from the ig nition key swtlcn

C h e c kf o r v o l t a g et o g r o u n d : T h e r es h o u l db e 4 V o r m o r e

P o o r g r o u n d ( G 4 0 1 ,G 4 0 2 ) Faulty ignition key switch An open in the wire Shortin the wire

Un d e ra l l c o n d i t i o n s

C h e c kf o r c o n t i n u i t yb e r w e e . l F e a u d i o u n i t 1 6 Pc o n n e c t o rl - o 3 l e r m i n a l a n d p o w e r d o o r l o c kc o n t r o l u n i t 1 2 Pc o n n e c t o rN o . 6 l e r m r n a l : T h e r e s h o u l d b e c o n t i n ut y

An open in the wire

C e i l i n gl i g h t s w i t c h i n "middle position"

C o n n e c tt o g r o u n d : T h e c e i l i n gl i g h r s h o u l dc o m e o n .

B l o w nN o . 4 3( 7 . 5A ) f u s ei n t h e under-hoodIuse/relaybox B l o w nc e i l i n gl i g h tb u l b F a ul t y c e i l i n gl i g h t A n o p e ni n t h e w i r e

Each door open, one at a time

C h e c kt o r v o l t a g et o g r o u n d : T h e r es h o u l db e ' l V o r l e s s .

. Faulty door switch . An open in the wire

Un d e ra l l c o n d i t i o n s

Connectto groundl H o r ns h o u l ds o u n d .

. Blown No. 52 ('15A) fuse in the under-hoodfuse/relaybox . Faulty horn . F a u l t yh o r n r e l a y . A n o p e ni n t h e w i r e

YEL/RED lgnition switch ON

B6

815

B1

B3

BLK,/YE L

8LK

BLU/RED

BLUlt/EL

B8

LT GRN/ BLK

814

LT GRN/ RED

Br6

. B l o w n N o . 4 7 ( 7 . 5A ) t u s e i n t h e u n d e r h o o d f u s e ,r ie l a y b o x . An open n the w re

LJndea r llconditions

WHT/BLU

A5

Possible cause if result is not obtained

GRY

Blown No. 28 , I0 A) fuse in the underdashfuse.elaybox An open " :ne n re '.1 - 5 A' iuse n the B o$. \. , , ^ o e ' a a s _ ' - s e r e l a yb o x A_ ooe^ ' :ne wrre

the B connectoronly to the audio unit. Reconnect Cavity

B9

l-l

Wire

GRN/ORN

8 1 0 GRNAr'r'HT

Test condition

Test: Desiredresult

Driver'sdoor lock s w i t c hi n U N L O C K

Checkfor voltageto ground: T h e r es h o u l db e 1 V o r l e s s .

Driver's door lock switch in LOCK

Check for voltage to grou nd: There should be 4 V or more.

Driver'sdoor lock switchin UNLOCK

Check for voltage to ground: There should be 4 V or more.

Driver's door lock switch in LOCK

Check lor voltage to ground: There should be I V or less.

PossiblecauseiI result is not obtained . . . .

P o o rg r o u n d1 G 5 5 1 ) Faultydriver'sdoor lockswitch An open in the wire S h o r ti n t h e w i r e

. . . .

P o o rg r o u n d ( G 5 5 1 ) Faulty driver's door lock switch An open in the wire Shon in the wire

23-263

Power Door Locks Audio Unit lKeylessReceiver CircuitlTerminals('96- 98 modelsl 16PCONNECTOR

Wire

Cavity

BLU/RED LT GRN

Trunklatchswitch

Ft2

BLU/YEL

Unlock(Driver'sdoor)

B4

BLU LT BLU

B6

L BLK/YE

*81

B8 B9

ORN

Removethe inner handle(seesection20).

2.

D i s c o n n e ctth e 3 P c o n n e c t o rf r o m t h e d o o r l o c k switch.

lgnition key switch

Checkfor continuitybetweenthe terminalsin each switchpositionaccordingto the table.

Valetswitch Security{lN) No. 14 (7.5A) fuse Security(D2)

LT GRN/BLK C e i l i n gl i g h t GRN/ORN Unlock(All doors)

810 *811

GRNA/VHT Lock(OutPutl

*812

WHT/BLK Security(D0) YEL/BLU Security(D'l)

+B13

1.

Destination

B1 *82

*85

Driver'sDoor LockSwitch Test

\

Terminal 1 Position LOCK

UNLOCK

8 1 4 LT GRN/RED Door switch Ground (G401,G402) B15 BLK GRY

norn

*: For securitysystem(option)

23-264

DRIVER'S DOOR LOCK swtTcH

3

o- ----o

OFF

BLU/WHT LEDO

o to

2

o

----o

Driver'sDoor LockActuatorTest

l

1.

Removethe driver'sdoor panel(seesection20).

2.

the 4Pconnectorfrom the actuator. Disconnect

DoorLodr ActuatorTest Passenger's 1.

Removethe passenger'sdoo. pa^e see sect o' 201.

2.

the 2P connectorfrom lhq aclualor Disconnect NOTE:The front passenger'sdoor lock actualor,s shown;the left rear and right rear door lock act{,a tors are similar.

J of Terminalside maleterminals Terminalsideol maleterminals

3.

Checkfor continuitybetweenthe terminalsin each knobswitchpositionaccordingto the table. Terminal

\

F""lti*

- lll

3.

o

LOCK UNLOCK 4.

\

Checkactuatoroperationby connectlngpower ano ground accordinglo the table. To preventdamage to the actuator,apply batteryvoltageonly momentarilY.

Terminal -ll Fo"JJ'-lrlon';"

1

LOCK

@

Checkactuatoroperationby conneclrngpower and ground accordingto the table To preventdamage to the actuator,apply baneryvoltageonly momentarily. Terminal

\

,

2

LOCK

O

@

UNLOCK

O

o

Position

4.

lf the actuatorIailsto work properly,replaceit.

o

UNLOCK

l-l

5.

lf the actuatorfailsto work properly.replaceit

23-265

Power Door Locks TransmitterTest NOTE: . lf the doors unlockor lock with the transmitter,but r oesnot comeon, the t h e L E Do n t h e t r a n s m i t t e d LEDis faulty;replacethe transmitter. . lf any door is open, you cannot lock or unlock the door with the transmitter. . lf you unlockedthe doorswith thetransmitter,but do n o t o p e n a n y o f t h e d o o r s w i t h i n 3 0 s e c o n d s t, h e doors relockautomatically. . The doors do not lock or unlockwith the transmitter if the ignitionkey is insertedin the ignitionswitch. 1.

Usinga keylessentrychecker(07MAJ- SP003001: . Placethe transmitteron the keylessentry checker, and pressthe transmitterbutton. - lf the indicatorlight does not come on, check for: - a dead or low batterv - Faultytransmitter - lf the ray indicatorlight comes on, the transmitteris OK. ENTRY CHECKER KEYLESS

INDICATORLIGHT TRANSMITTER

NOTE: After a transmitter battery has been replaced,aim the transmitterat the receiver,and pressthe transmitterbuttonsix times, Confirm you can hear the sound of the door lock actuatorswhen vou pressthe si)dhtime.

23-266

TransmitterProgramming('96- 98 models) )

Storing TransmitterCodes . . .

The codes of up to four transmitterscan be stored in the control unit. {lf a {ifth code is stored,the code which was storedtirst will be erased.) Whenthe systementersthe registrationmode,all previouslysloredcodeswill be erased. The systemleavesthe registrationmode and returnsto the normalmode if you - turn the valetswirchOFF,or - t u r nt h e i g n i t i o ns w i t c hO F F o ,r - do not pressthe transmitterbuttonfor more than 10 seconds

Procedure: NOTE:lt is importantto maintainthe time limits betweensteps Insertthe ignitionkey into the ignitionswatch. T u r n t h e i g n i t ; o ns w i t c hO N flr).

VALETSWITCH

Within 10seconds,go to steP3.

3. Press and hold the valet switch for at least tive seconds. (You will hearthe sound of the a c t u a t o r st u r n a n gt o U N L O C K . )

NOTE:lf the tuner is turned ON, it will go off and comeon againwhen the registrationprocedureis completed-

go to step4. Within10seconds. AUDIOUNIT 4. Pressone of the transmitter buttons, (Youwill hearthe soundof the actuators turningto UNLOCK.i

N O T E : l f y o u w a n t t o r e g i s t e rt h e c o d e s of more than one transmitter, repeat step 4 within 10 secondswith the next trans' mitter.

TRANSMTITTER

l-l

NOTE:After storingits code,makesure t h e t r a n s m i t t e rw o r k s p r o p e r l yb Y repeatedlypressingone ot its buttons. (The system starts to work when You pressany transmitterbuttonsix times-)

23-267

Power Door Locks ('99- 00 modelsl TransmitterProgramming Storing transmitter codes; The codes of up to three transmitterscan be read into t h e k e y l e s sr e c e i v e ru n i t m e m o r y .( l f a f o u r t h c o d e i s stored,the codewhich was inputfirst will be erased.) N O T E : l t i s i m p o r t a n tt o m a i n t a i nt h e t i m e l i m i t s betweenthe steps. '1. Turn the ignitionswitchON (ll). 2. Within1 to 4 sec.,pushthe transmitterlockor unlock buttonwith the transmitter aimedat the vehicle. 3. Within I to 4 sec.,turn the ignitionswitchOFF. 4. Within 1 to 4 sec.,turn the ignitionswitchON 1ll). 5 . W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle. 6. Within 1 to 4 sec.,turn the ignitionswitchOFF. 7. Within4 sec.,turn the ignitionswitchON (ll). 8 . W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r u n l o c kb u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle. 9 . Within 1 to 4 sec.,turn the ignitionswitchOFF. '10.

W i t h i n4 s e c . t, u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

1 1 . W i t h i n ' 1t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e vehicle. 1 2 . Confirm you can hear the sound of the door lock acIuarors. W i t h i n 8 s e c . ,a i m t h e t r a n s m i t t e r s( u p t o t h r e e ) whose codesyou want to storeat the receiver,and pressthe transmitterlockor unlockbuttons. C o n t i r mt h a t y o u c a n h e a rt h e s o u n d o f t h e d o o r lockactuatorsaftereachtransmittercode is stored. 1 4 . Turn the ignitionswitchOFF,and pull out the key.

Confirmproperoperationwith the new code(s).

23-268

)

SupplementalRestraintSystem(SRSI ...........24'2 SpeciafTools... Component/Wiring Locations ......24-3 fndex ................ 24-5 ................ Description ......." 24'6 Circuit Diagram Precautions/Procedures 24-7 GenerafPrecautions...............,,,,,,,.. Airbag Handlingand Storage .........24-7 24-8 SRSUnit Precautions...................... InspectionAfter Deployment ........'24-8 .......24'9 WiringPrecautions................... BackprobingSpring-loadedLock .......,24-9 Connectors Spring-loadedLock Connectol ....,,.24-10 Spring-loadedLockConnectorwith 24-10 Built-inShortContact................. Disconnectingthe Airbag .....'24'11 Connector(sl Steering-relatedPrecautions...,.,.,,.24'12

Troubleshooting 2+13 Seff -diagnostic Proctdurcs ............. 2+13 Readingthe DTC .............................. 24-15 Erasingthe DTCMcnrory ................ Troubleshooting h.ttnitt.nt ..............24-15 Failures 24-16 .................... SRSU n it ldcntificrtion Diagnostic Troublc Code (DTC) 24-17 Chart- '96 - 97 Models..."'."....... Diagnostic Trouble Code (DTCI '$ - 00 Models '.........""'24'19 ChartSRS lndicaror Light Wire ...'.,24-25 connections ........,,,,.24-26 Ffowcharts Airbag ...'.'...24-67 Repfacemant .................24'70 Disposaf Cable Reel Repfacement SRSUnh Repfacement

.........24'72 ..'......24'76

l-l -

+ sRs

SpecialTools

Ref,No,

o-, an*r @

o /a*,

I

Tool Number

07HAz- SG00500 0 7 P A Z0 0 1 0 1 0 0 0 7 s A z- T B 4 0 1 1 A 0ITAZ- SZ5011A 07TAZ- 001020A

Description DeploymentTool SCSServiceConnector SRSInflatorSimulator SRSSimulatorLeadC Backprobe Adapter,17 mm

* 1r Includedin SRSTool Set 07N4M- SM5000B *2: Usewith the stackingpatchcordsfrom T/N 07SM

o

4-2

1 1 I 1 2

001000A,BackprobeSet.

6\

o

t,

Oty

I

PageReterence 2 41 0 24-14 24-42 24-42 24-30

Component/WiringLocations Airbag Index:With FrontPassenger's

)

LIGHT(ln the gaugeassemblvl SRSINDICATOR Troubleshooting, Page24 13 Gaugeassembly,section23

To HORNSWITCH CABLEREEL Replacemenl page2!-t 2

To DRIVER'SAIRBAG

t

DASHBOARDWIREHARNESS to SRSINDICATOBLIGHTin GAUGEASSEMBLY 5P CONNECTOB

DBIVER'SAIRBAG Beplacement, page24-61 page24 70 Disposal,

AIBBAG FRONTPASSENGER'S Replacement, Page24_67 Disposal, Page24 70

SRSMAIN HARNESS to CABI-ERE€L 2P CONNECTOR

SERVICECHECK {2PI CONNECTOR IBRN,BLK]

SRSMAIN HARNESS to FRONTPASSENGER'S AIRBAG 2P CONNECTOB

SRSMAIN to UNOER-OASH BOX FUSE/RELAY 2P CONNECTOR

t,

SRSMAIN HARNESS to SRSUNIT r8P CONNECTOR

SBSMAIN HARNESS to MAIN WIREHARNESS 3P CONNECTOR

MEMORYERASESIGNAL (MES)CONNECTOR I2P) [GRY,GRYIor IGRN.GRNI

MAIN WIREHARNESS to DASHBOARDWIREHARNESS 24PCONNECTOR

SRSUNIT (lncludingsafingsensor and imPactsensorl ReplacementPage24 76

2+3

Gomponent/WiringLocations Index:Without FrontPassenger's Airbag(someCanadaModelsl

SRSINDICATOR LIGHT(ln the gaugeassembly) Troubleshooting, page24-13 Gaugeassembly,section23

To HORNSWITCH

To CRUISECONTROL SET/RESUMESWITCH

oo/

\oo

To DRIVER,SAIRBAG DASHBOARDWIREHARNESS to SRSINDICATORLIGHTin GAUGEASSEMBLY 5P CONNECTOR

DRIVER'SAIRSAG Replacement, page 24-67 page24-70 Disposal,

SERVICECHECK CONNECTOR {2P} IB8N,BLKI SRSMAIN HARNESS

SRSMAIN to UNDER-DASH FUSE/RELAYBOX 2P CONNECTOR

SRSUNIT {lncludingsafingsensor and impactsensor) Replacement. page24,76 SRSMAIN HARNESS to SRSUNIT 18PCONNECTOR DUMMY RESISTOB

SRSMAIN HARNESS MEMORYERASESIGNAL (MES)CONNECTON (2P' to MAIN WIRE IGRY,GRYIo. IGRN,GRNI HARNESS 3P CONNECTOR MAIN WIREHARNESS to DASHBOARDWIREHARNESS 24PCONNECTOR

24-4

SRSUNIT GROUNO

Description ) help protectthe driverland The sRS is a safetydevicewhich,when used in coniunctionwith the seatbelt, is designedto of the sRS unit {includingsafing consists limit. The system set a certain exceeding impact in a frontal passenger) front (and passenger's airbag) front sensorand impactsensor),the cablereel,the driver'sairbag FRONTPASSENGEB'S AIRAAG DRIVER'SAIRBAG

CABLEREEL

SRSUNtT

Operation ignitesthe inflatorcharge(s)lf necessary, The main circuitin the SRSunit sensesand judgesthe force of impactand, if and the back-uppower clrcult regulator voltage the impact, due to the batteryvoltageis too low or power is disconnected will keepvoltageat a constantlevel. resoectivelv

t

For the SRSto operate: (1) The impactsensormust activate.and sendelectricsignalsto the mlcroprocessor' must computethe signals'and must sendsignalsto the airbaginflator(s)' (2) The microprocessor and deploythe airbag(s)' ignite must {3) The inflator(s)

_"-_-l

r3B!#h

!..

I i

I

ffi,*

Self-diagnosisSystem (ll),the SRSindicatorlight comes circuitis built into the SRSunit;when the ignitionswitchis turned ON A self-diagnosis normally is operating on and goesoff afteraboutsix secondsif the system driving,it indicatesan abnormallf the liglt does not come on, or does not go off aftersix seconds,or if it comeson while ity in the system.The systemmust be inspectedand repairedas soon as possible

l,

passeson the inforthe memorywill storethe causeof the malfunctlon,and the data link circuit For betterserviceability, PGM TeslerconHonda with the read (DLC). can be intormation This link connector mationfrom the memoryto the data nectedto the DLC(16P).

24-5

Circuit Diagram IGNITION SWITCH

UNDER-HOOD FUSE/RELAY 8OX WHT/8LI( +WHT

SBSINDICATOR CIRCUIT {lnthe gaugeassembly)

Brake systsm light

passenger's airbag

DRIVER'S AIRBAG INFLATOR

lt - - - - l l II

PGM_FI

DUMMY I I BESISTOR

tll 10 16 GRY (GRN)

14 17

r

13 t5

I

t'7

:

24-6

18

3{VBl

8

GRY {GRN)

LT8LU

V

7(VAl 9

GRY IGNN)

I

G40t G402

6 SRSUNIT

I

BRN

t

.-l\./

BRN

l

.-r\./

DATALINK ECM/PCM SERVICE CONNECTOR CHECK {DLC) CONNECTOR {r6P)

t

l

la rl MEMORY ERASE SIGNAT IMES) CONNECTOR I2P)

SRSUNITTERMINALS

G801

Teminalsideoi thal€terminals

4''

Procedures Precautions/ GeneralPrecautions

)

r Carefullyinspectany SRS part beforeyou install it Do not install any part that shows signs of being dropped or improperlyhandled'suchas dents,cracksor deformation: - Airbags - Cablereel - S R Su n i t

Airbag Handlingand Storage Do not try to disassemblethe airbag assembly. lt has no s e r v i c e a b l ep a r t s O n c e a n a i r b a g h a s b e e n o p e r a t e d (deployed). it cannot be repaired or reused' For temporary storage of the airbag assembly during service. oleaseobserve the following precauttons: store the .emoved airbag assemblv with the pad sur) irbag face uo The driver's(and front passenger'sa (see c o n n e c t o ' ' s ' - a s { h a v e )a b u i l t . i n s h o r t c o n t a c t page 2a-l 1

.

: -""dd.r6t

| ..r

dtatltt-,tl force lo c.usa 3a.ix!

r-+r-a k imninncrlv slorcd lace down, could propel the unit whh enough intury

Use only a digital multimeterto checkthe system lf it's not a Honda multimeter,make sure its output ls 1OmA (0.01A) or lesswhen switchedto the smallest value in the ohmmeterrange.A testerwith a higher outputcould damagethe airbagcircuitor causeaccidentaldeploymentand possibleinjury'

-

I Do not install used SRS parts from anothervehicle When makingSRSrepairs,useonly new pans' AIRBAGCONNECTORS (Withbuilt in shon contact)

) 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 ailn s p e c t i o n s ' poslalwaysdisconnectboth the negativecableand three least at wait and battery, the tive cable from minutesbeforebeginningwork r R e p l a c e m e not f t h e c o m b i n a t i o nl i g h t a n d w i p e r / w a s h e rs w i t c h e sa n d c r u i s ec o n t r o l s w i t c hc a n b e donewithout removingthe steeringwheel: switchreplace Combinalionlightand wiper/washer ment,seesection23 - Cruisecontrolsevresumeswitch replacement'see section23.

-

l,

.

Wheneverthe ignition switch is ON {ll), or has been turnedOFFfor lessthan three minutes'be carefulnot to bump the SRSunit; the airbag(s)could accidentall y d e p l o ya n dc a u s ed a m a g eo r i n j u r y '

.

) eenactivated' W h e n e v e rt h e a i r b a g { s )h a s ( h a v e b unit. replacethe SRS

.

Store the removedairbagassemblyon a secureflat surfaceaway from any high heat source{exceeding and free of any oil' grease,detergentor 212"FI1OO"CJ water.

CAUTION: lmproper handling or storage can intern'lJy damagethe airbag assembly,making it inoperativo lf you suspect the airbag assembly has been dam€cd' inslall a new unit. and relsr lo the Deployment/DisPG'l olocedulesfor disposingol the damaged airbag

2+7

Precautions/Procedu res SRSUnit Precautions Takeextracarewhen paintingor doing body work in the areabelow the dashboard.Avoid directexDosure o f t h e S R S u n i t o r w i r i n gt o h e a tg u n s ,w e l d i n g .o r sprayang equipment. D i s c o n n e ctth e a i r b a gc o n n e c t o r ( sb) e f o r ed i s c o n nectingSRSharnessconnectors(seepage24-1|1J. After any degreeof frontal body damage,or after a collisionwithout airbagdeployment,inspectthe SRS unit for physicaldamage.lf it is dented.cracked,or deformed,replaceit.

Be surethe SRSunit is installedsecurely. Do not disassemble the SRSunit. Store the SRS unit in a cool (lessthan about 104.F/ 40"C)and dry (lessthan 80% humidity,no moisture) place.Do not spill water or oil on the SRS unit, and keepit awayfrom dust. During installationor replacement,be carefulnot to bump (impactwrench,hammer,etc.)the areaaround the SRSunit. The airbag(s)could accidentally deptoy and causedamageor injury.

24-8

InspectionAfter Deployment A f t e r a c o l l i s i o n l n w h i c h t h e a i r b a g ( s )w a s ( w e r e ) deployed,replacethe SRSunit,and inspectthe following: 1.

Inspectall the SRSwire harnesses.Replace.don,t repair,any damagedharnesses.

2.

Inspectthe cablereelfor heatdamage.lf thereis any damage,replacethe cablereel.

3.

A f t e r t h e v e h i c l ei s c o m p l e t e l yr e p a i r e dt,u r n t h e ignitionswitch on. lf the SRS indicatorlight comes on for aboutsix secondsand then goes off. the SRS systemis OK. lf the indicatorlight does not function properly,go to SRSTroubleshooting.

Wiring Precautions ) .

Neverattemptto modify,spliceor repairSRSwiring' NOTE:SRSwiring can be identifiedby specialyellow outer Protectivecovering.

BackprobingSpring'loaded Lock

Gonnectors .

When checkingvoltageor resistanceon this type of to removelne connectorthe flrst time, it is necessary wire side. probes from the insert tester to retainer NOTE: lt is not necessaryto reinstallthe removed retainer;the terminalswi I stay lockedin the connector housrng.

8e sureto installthe harnesswiresso that they are not with otherparts. oinchedor interfering RETAINER * Discardafterremoval.

t To removethe retainer,insert a flat tip screwdriver betweenconnectorbody and retainer,and carefully pry out the retainer. NOTE:Takecarenot to breakthe connector. FLATTIP SCBEWDRIVER

M a k e s u r e a l l S R Sg r o u n d l o c a t i o n sa r e c l e a na n d groundsare securelyfastenedfor optimum metal-tometalcontact.Poorgroundingcan causeintermittent problemsthat are difficultto diagnose.

a,

RETAINER

24-9

Precautions/Procedures Spring-loadedLockConnector Some SRS system connectors have a spring-loaded lock.

Spring-loadedLockConnectorwith Built-inShort Contact

Disconnecting To releasethe lock, pull the spring-loaded sleeve toward the stop while holding the opposite half of the connecror. Then pull the connector halves apart.

T h e d r i v e r ' sa j r b a g( a n df r o n t p a s s e n g e r , a s )i r b a gh a s ( h a v e )a s p r i n g - l o a d e dl o c k c o n n e c t o rw i t h a b u i l r - i n short contact.When this connectoris disconnected, the p o w e rt e r m i n a la n d t h e g r o u n dt e r m i n a li n t h e a i r b a a connectorare automatically shoned.

N O T E :B e s u r e t o p u l l o n t h e s l e e v e a n d n o t o n t h e connectorhalf.

Connectorhalves disconnected:

SPRING-LOADEO SLEEVE

GROUNDTERMINAL

Do not pull on this half of the connector.

Connecting 1.

Hold the pawl-sideconnectorhalf, and presson the backof the sleeve-side connectorhalf in the direction s h o w n .A s t h e t w o c o n n e c t o rh a l v e sa r e p r e s s e d together,the sleeveis pushedbackby the pawl.

SHORTCONTACT

NOTE:Do not touch the sleeve.

CABLEREELCONNECTOR

Conneqtorhalves connected: GROUNDTERMINAL

Whenthe connectorhalvesarecompletelyconnected, the pawl is released,and the spring-loadedsleeve locksthe connector. SPRING.LOADED SLEEVE

24-10

the AirbagConnector(sl Disconnecting

)

th€ negative battery To prevent sccidental 8irbag deployment, turn th€ ignition switch oFF. disconncct !@@ "nd *"it thr"e minutes b€fore disconnoctingany sRS conn'ctors' ffi, (C' D)' the SRSmain harness(A)from the SRSunit' disconnectboth airbags . Beforedisconnecting .Beforedisconnectingthecab|ereel2Pconnector(B),disconnectthedriver,sairbag2Pconnector(c).

'1. Disconnectthe negativebatterycable,and wait at leastthree minutes.

t

2.

the airbagconnector(sl. Disconnect

F ont PasEanga/3Side: .

Removethe glove box.then disconnectthe front passenger'sairbag2P connectorand SRS main harness 2P connector.

Driver's Side: .

Removethe accesspanel from the steeringwheel' then disconnectthe driver'sairbag2P connectorand cablereel2Pconnector.

FRONTPASSENGER'S AIRBAG 2P CONNECTOR

CABTTREEL 2? CONNECTOR

AOCESSPANEL

a, 24-11

res Precautions/Procedu Precautions Steering-related Stesring Wheel and CableReolAlignment

St€€rin9 Column Removal

NOTE:To avoid misalignmentof the steeringwheel on reassembly,make sure the wheels are turned straight aheadbeforeremovingthe steeringwheel.

CAUTION: . Eefore removing thg stggring column. disconnectthe connsstor bqtween the cable r€el and th€ SRS msin harness. . lf the stoering column is going to be romoved without dismounting th6 stoering wheel, lock the steering by turning the ignition key to o-LOCKposition, or remove the key trom the ignition switch so that the steering wheel will not turn. NOTE: W h e n t h e a i r b a ga n d c a b l e r e e l a r e d i s c o n n e c t e d , don't reconnectthe battery cable. lf the battery is reconnected and the ignitionswitch is turned ON (ll), the SRSunit will storethis as an open in the driver's airbaginflator,and the SRS indicatorlight will come on. For disconnectingthe spring-loadedlock type connector, refer to page24-'10.

Rotatethe cablereelclockwiseuntil it stops. Then rotate it counterclockwise{approximatelytwo and a half turns) until the arrow mark on the cablereel label pointsstraightup.

SRSMAINHARNESS 2PCONNECTOR Do not replacethe originalsteeringwheelwith any other design becauseit will make it impossibleto properly installthe airbag(only use genuineHondareplacement parts). After reassembly,confirm the wheels are still turned straightaheadand that the steeringwheel spokeangle is correct.lf minor spokeangleadjustmentis necessary, do so only by adjustingthe tie-rods,not by removing and repositioning the steeringwheel.

24-12 :l

r

Troubleshooting Procedures Self-diagnostic functionof the SRSsystemallowsit to locatethe causesof systemproblemsand to storethis informa' The self-diagnostic this datacan be retrievedvia a data link circuit tion in memory.For easiertroubleshooting,

I l

. When you turn the ignitionswitchON (ll),the SRSindicatorwill come on. ll it goes off aftersix seconds.the systemis n o r m al . turns . lf there is an abnormality,the systemlocatesand definesthe problem,storesthis informationin memory,and or if the batoff is turned switch ignition when the memory even in the remain will The data the sRS indicatorlight on. tery is disconnected. (2P),and turn the ignitionswitchoN (ll), o when you connectthe scs serviceconnectorto the servicecheckconnector thesRsindicator|ightwi||indicatethediagnostictroub|ecode(DTC)bythenumberofb|inks. for this code' . After readingand recordingthe DTC.proceedwith the troubleshooting

Precauiions .Useon|yadigita|mU|timetertocheckthesystem'|fit,snotaHondamu|timeter,makesureitsoutputisl0mA(0. or|esswhenSwitchedtothesma||estva|ueintheohmmeterrange,AtesterwithahigheroUtpUtcouldd airbagcircuitor causeaccidentalairbagdeploymentand possibleinjury' be carefulnottobumpthe r when-everthe ignitionswitchis oN (ll).or has beenturnedoFF for lessthanthree minutes, injuries or damage cause and deploy accidentally could airbags SRSunit;the airbag (and the front passenger's . Beforeyou ,"n1ou"th" SRS main harness,disconnectthe driver'sairbagconnector . .

)

t

connector). low, measuringvalLleswon t be Makesure the batteryis sufficientlycharged{seesection23}.lf the batteryis dead or correct. and do not connectthe terminals Do not touch a testerprobeto the terminalsin the sRS unit or harnessconnectors, with a jumperwire. Useonly the backprobeset or the specialtools' locktype connectors,referto page24-9' For backprobingspring-loaded

Readingthe DTC when the SRSindicatorlight is on, readthe DTCusingone of thesemethods: A.

follow the tester'sprompts lf the tester Connectthe HondaPGM Testerto the 16PData Link Connector{DLC),and indicatesnoDTc,DTcg-1orDTc9-2,doub|e-checkbyjumpingtheservicecheckconnectorandwatchingt indicatorlight (seenext Page) HONDAPGMTESTER

l,

Il6PI DATA LINKCONNECTOR

24-13

Troubleshooting

B. The SRSindicatorlight can also indicatethe DTCby the numberof blinkswhen the SCSserviceconnectoris connected to the servicecheckconnector(2P).

rl

J

1. Turn the ignitionswitchOFF,and wait for ten seconds.Then connectthe SCSserviceconnectorto the servicecheck connector(2P).lf you do not wait ten seconds,the SRSunit will not be completelyresetand will not outputDTCS.

SERVICECHECK CONNECTOR {2PI IGRY,GRYIor IGRN,cRN] SCSSERVICECONNECTOR 07PAZ- (m10100

Turn the ignitionswitchON (ll).The SRSindicatorlight comeson for aboutsix secondsand goesoff. Then it will indi, cate the DTC: - The DTCconsistsof a main code and a sub-code. - Includingthe most recentproblem,up to threedifferentmalfunctionscan be indicated. - In caseof a continuousfailure,the DTCwill be indicatedrepeatedly(seeexample1 below). - In caseof an intermittent failure,the SRSindicatorlightwill indicatethe DTCone time,then it will stayon (seeexample2 below). lf both a continuousand an intermittentfailureoccur,both DTCSwill be indicatedas continuousfailures. - In casethe systemis normal(no DTC),the SRSindicatorlightwill stayon (seeexample3). Readthe DTC. Turn the ignitionswitch OFF,and wait for ten seconds.Then disconnectthe SCSserviceconnectorfrom the service checkconnector(2P).

2.

3. 4.

Examplesof DTCIndications: 1.

Continuousfallure,SRSIndicatorLightisl

l.-zs

-

Main @de

r

- -

DTC21 Mosrraenr probtsm

2.

- l F M.in code ir)

r

Sub.code (2)

DTCI2

-'l

F

M a r nc o d e ( 1 1

--l

F

S u b c o d et 1 t

DTCl1 Thnd.most recenl

Intermittentfailure,SRSlndicatorLight is:

Lrghr srays on rn ca* ol DTC5l

N ormal (no failure),SRSIndicator Light is:

3. ON

No OTC,system is norhal, rhe sutb chek __.1 penod

24-14

J

Erasingthe DTCMemory

)

T o e r a s et h e D T C ( s f)r o m t h e S R S u n i t , u s e a H o n d a P G M T e s t e r( s e et h e H o n d a P G M T e s t e rS R Sv e h i c l e SystemSupplement)or the followingprocedure 1. 2.

Makesurethe ignitionswitchis OFF Connectthe SCSserviceconnectorto the MES connector(2P).Do not usea jumperwlre.

TroubleshootingIntermittent Failures lf therewas a malfunction,but it doesn'trecur,it will be storedin the memory as an intermittentfailure,and the S R Si n d i c a t olri g h tc o m e so n . Afte. checkingthe DTC,troubleshoot as lollows: 1.

.!--J

MEMORYERASE I2PI SIGNAL(MESICONNECTOR IGRY,GRYIor [GRN,GRNI

t

]P,

&

SCSSERVICECONNECTOR o?PAZ- 0010100

Turnthe ignitionswitchON (ll). The SRSindicatorlight comeson for about six seconds and goes off. Removethe SCSserviceconnector from the MESconnector(2P)within four seconds afterthe SRSindicatorlightwent off. The SRSindicatorlight comeson again.Reconnect the SCS service connectorto the lvlESconnector (2P)within the four secondsafterthe SRSindicator l i g h tc o m e so n . The SRS indicatorlight goes off. Removethe SCS s e r v i c ec o n n e c t o rf r o m t h e M E S c o n n e c t o r( 2 P ) within four seconds. 7 . The SRSindicatorlight indicatesthat the memoryis erasedby blinkingtwo times. 8. Turn the ignition switch OFF,and wait for ten seconos.

"Readingthe DTC"}. Readrhe DTC{see E r a s et h e D T C m e m o r y ( s e e Memory").

" E r a s i n gt h e D T C

3 . With the shifi leverin neutral,turn the ignitionswitch O N ( l l ) ,a n d l e i t h e e n g i n ei d l e . 4.

The SRSindicatorlight comeson for about six seconds and goesoff.

l * F

ON

--

t

-l

l

takea test Shakethe wire harnessand the connector, quick braking,cornering), drive (quickacceleration, and turn the steeringwheel fully left and right,and hold it there for five lo ten secondsto find the cause failure. of the intermittent l f t h e p r o b l e mr e c u r s t, h e S R Si n d i c a t o rl i g h t w i l l stayon.

-q

6a.c f'-

:q

Problemrecurs,light stayson

SRSindictlor lighi

MES conncclot tcaminals

6. CONNECTED

failure,the syslf vou can't duplicatethe intermittent tem is OK at thistime.

DISCONI{ECTED

O, 24-15

Troubleshooting SRSUnit ldentification +: On '98 - 00 models,the troubleshootingproceduresare differentfor eachtype of SRSunit. ldentifvthe SRSunit in the vehicleusingthe chartbelow,then follow the properflowchanin the followingpages. '98 - 00 Model SRS units MAKER NEC KEIHIN SIEMENS

IDENTIFICATION MARK*

Remark

M1

Driver'sairbagonly

M1

Driver's& Passenger's airbags

M2

Driver's& Passenger's airbags

M3

Driver's& Passenger's airbags

'96 - 97 Model SRSunits MAKER NEC

PARTSNUMBER 77960-S04-C81

Remark Driver'sairbagonly

77960-S04-N81

Driver's& Passenger's airbags

TAKATA

77960-S04-N82

Driver's& Passenger's airbags

SIEMENS

77960-S02-A81

Driver's & Passenger'sairbags, '97 Model only

LABELIIDENTIFICATION MARK)

lr 24-16

DiagnosticTroubleCode(DTG)Chart-'96 - 97 Models

l

SRSindicator light doesn'tcome on

DTC none (doesn't c o m eo n ) none *4 (doesn't go off) 1-1

Possiblecause FaultySRSindicatorlightcircuit

Sae page

Troubleshooting

24-26

FaultySRSindicatorlight circuit,internal failureof SRSunit,faultySRSpowersupply.

24-29

Openin the driver'sairbaginflator

24-42

in the driver'saarbag lncreasedresistance inflator

Troubleshooting

24-42

l-3

Shortto anotherwire in the driver'sairbag inflatoror decreasedresistance

24-44

1-4

Shortto Dowerin the driver'sairbaginflator

24-46

1-5

Shortto ground in the driver'sairbaginflator

24-48

2-1

airbag: With front passenger's airbaginflator Open in the passenger's airbag: Withoutfront Passenger's ODenin the dummy resistor

24-50 24-54

airbag: With front passenger's airbag in the passenger's Increasedresistance inflator airbag: Withoutfront Passenger's in the dummy resistor lncreasedresistance

24,50 24-54

comeson

t

a,

Correctiv6action

2-3

airbag: With front passenger's Shon to anotherwire in the passenger's airbaginflatoror decreasedresistance airbag: Withouttront passenger's Shortto anotherwire in the dummy resistor or decreasedresistance

2-4

airbag: With front passenger's airbag Shortto power in the passenger's inJlator airbag: Withoutfront Passenger's Shortto power in the dummy resistor

24-54 24-60

airbag: With front passenger's aarbag Shortto groundin the passenger's inflator without front passenger'sairbag: Shortto ground in the dummy resistor

24-56 24-61

Troubleshooting

24-52 24-59

(cont'd)

24-17

Troubleshooting Diagnostic TroubleCode(DTCIGhart-'96 - 97 Models(cont'd) Possiblgcause

53

Cortestiveaction

I Internalfailureof the SRSunit

S R Su n i t replacement

lnternalfailureof the SRSunit

SRSunit replacement

Internalfailureof the SRSunit

Internalfailureof the SRSunit

S R Su n i t replacement

Internalfailure of the SRSunitortwo failuresat a time 8-6*3

J

Internalfailure ofthe SRSunit Internalfailureof the SRSunit FaultySRSpowersupply(VBline) SRSunit replacement code (SRSunit must not be usedany longe.)

NOTE: * l: In caseof an intermittentfailureDTCg-1,it meanstherewas an internal failureof the SRSunit or a faultv SRSindica tor light circuit.Do the troubleshooting for intermittentfailures(seepage24-15). *2: lt both DTC9-2and DTC5-1are indicated,do the troubleshooting for DTCg-2. *3: Apply to the '97 modelcoupeHX and DX. *4: DTCcannotbe readwith a HondaPGMTester;checkby jumping the SCSserviceconnector.

24-18 .

)

TroubleCode(DTC)Chart-'98 - 00 Models Diagnostic NECSRSUnit SRS indicator light doesn'tcome on

DTC none (doesn't c o m eo n ) none*3 (doesn't go off)

Possiblecause

Troubleshooting

24-26

FaultySRSindicatorlight circuit,internal fallureof SRSunit,faultySRSpowersupply ( V Bl i n e )

Troubleshooting

24-34

Troubleshooting

24-39

Open in the driver'sairbaginflator

24 42

in the driver'sairbag Increasedresistance inflator

24-42

Shortto anotherwire in the driver'sairbag inflator or decreasedresistance

Troubleshooting

24-44

't-4

Shortto power in the driver'sairbaginflator

24-46

t-5

Shortto groundin the driver'sairbaginflator

24-48

With front passenger's airbag: Open in the passenger's airbaginflator Withoutfront passenger's airbag: Open in the dummv resistor airbag: With front passenger's airbag in the passenger's Increasedresistance inflator airbag: Withoutfront passenger's in the dummy resistor Increasedresistance

I r comes on

with front passenger's airbag: Shortto anotherwire in the passenger's airbaginflatoror decreasedresistance Withoutfront passenger's airbag: Shortto anotherwire in the dummy resistor or decreasedresistance

2-4

l,

Seepage

F a u l t yS R Si n d i c a t olri g h tc i r c u i t

No DTC*3 ( l i sh t comeson FaultySRSpower supply(VA linel afterselfdiagnosis) l-1

Correstiveaction

24-50 24-54

24-50 24-58

Troubleshooting

24-52 24,59

airbag: With front passenger's airbag Shortto power in the passenger's inflator Withoutfront passenger's airbag: Shon to power in the dummy resistor

24-54 24-60

With front passenger's airbag: airbag Shortto groundin the passenger's inflator airbag: Withoutfront passenger's Shortto groundin the dummy resistor

24-56 24-61

(cont'd)

24-19

Troubleshooting DiagnosticTroubleCode(DTC)Chart-'98 - 00 Models{cont'dl SRSindicator light

DTC 5-1

Possiblecause

CorrectiYeaction

See page

lnternalfailureof the SRSunit

SRSunit replacemenl

24-76

lnternalfailureof the SRSunit

SRSunit replacement

24-76

lnternalfailureof the SRSunit

SRSunit replacement

24-76

lnternalfailureof the SRSunit

SRSunit reptacement

24-76

Internalfailureof the SRSunit or two failures at a trme

Troubleshooting

24-62

g _ 1 * r* 3

lnternalfailureof the SRSunit

SRSunit replacement

24-76

9-2+2 *3

lnternalfailureof the SRSunit

5-4 6-1 6-2 o-5

6-4 7-1

comeson

7-3 8-1 8-2 8-6

10-1

SRSairbagsdeployed(SRSunit must be reDlaced)

5l|5 Untr

replacement SRSunit replacement

24-76 24-76

NOTE: * 1: In caseof an intermittentfailureDTC9-1,it meanstherewas an internalfailureof the SRSunit or a faulty SRSindicafor intermittentfailures(page24-'15). tor light circuit.Do the troubleshooting *2: In caseof an intermittentfailureDTC9-2,it meanstherewas an internalfailureof the power supply{VB line).Do the troubleshooting for intermiftentfailures. *3: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector.

\

24-20

) r KEIHINSRS Unit SRSindicator light doesn'tcome on

DTC none (doesn't come on) none*3 (doesn't go offl

comeson

Correctiveastion

See page

FaultySRSindicatorlight circuit

Troubleshooting

24-26

FaultysRs indicatorlight circuit,internal failureof SRSunit,faultySRSpower supply {VB line)

Troubleshooting

24-34

Possiblecau3e

Open in the driver'sairbaginflator

24-42

1-2

in the driver'sairbag Increasedresistance inflator

24-42

1-3

Shortto anotherwire in the driver'sairbag inflatoror decreasedresistance

1-4

Shortto power in the driver'sairbaginflator

24-46

1-5

Shortto ground in the driver'sairbaginflator

24-44

2-1

Open in the passenger's airbag inflator

24-50

airbag Increasedresistancein the passenger's inflator

24-50

Shortto anotherwire in the passenger's airbaginflatoror decreasedresistance

l , . l

I

2-4

Troubleshooting

Troubleshooting

24-44

24-52

airbag Shortto power in the passenger's inflator

24-54

airbag Shortto ground in the passenger's inflator

24-56

(cont'd)

24-21

Troubleshooting DiagnosticTroubleCode(DTCIGhart-'98 - 00 Models(cont'd) SRS indicator light

DTC 5-2 5 3

Possiblecause

Corective action

Seo page

lnternalfailureof the SRSunit

SRSunit replacement

24-76

Internalfailureof the SRSunit

SRSunit replacement

24-16

Internalfailureof the SRSunit

SRSunit reptacement

24-76

Internalfailureof the SRSunit

S R Su n i t replacement

24-76

Internalfailureof the SRSunit

SRSunit replacement

24-76

Internalfailureof the SBS unit

SRSunit reptacemenr

24-76

SRSairbagsdeployed(SRSunit must be reDlaced)

SRSunit replacement

24-76

5 4 6-1 6-2 _ 64

comeson

n 8l 8S 9 _ 1 * *r 3

10-1

NOTE: *l: In caseof an intermittentfailureDTC9-1.it meansthere was an internalfailureof the SRSunit or a faultv SRSindicator light circuit.Do the troubleshooting for intermiftentfailures(pa9e24-15). *2: In caseof an intermittentfailureDTC9-2, it meansthere was an internalfailureof the power supply(VB line).Do the troubleshooting for intermittentfailures. *3: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector.

24-22

) r

SIEMENSSRSUnit SRSindicator light doesn'tcome on

DTC none (doesn't c o m eo n )

T r o ub l e s h o o t i n g

24-26

none*3 (doesn't go ofl)

FaultySRSindicatorlight circuit,internal failureof SRSunit,faultySRSpowersupply {VB line)

Troubleshooting

24-34

1-1

in the driver's Openor increasedresistance airbaginflator

1-3

Shortto anotherwire in the driver'sairbag inflatoror decreasedresistance

1-4

Shortto power in the driver'sairbaginflator

24-46

Shon to ground in the driver'sairbaginflator Openor increasedresistancein the passengers airbaginflator

24 48

2-1

2-3

,-.

l)

See page

FaulWSRSindicatorlight circuit

comeson

l - J

Corregtiveastion

Possiblecause

24,42 Troubleshooting

24-50

Shortto anotherwire in the passenger's airbaginflatoror decreasedresistance

2-4

airbag Shortto power in the passenger's inflator

2-5

airbag Shortto ground in the passenger's inflator

24-44

24-52 Troubleshooting 24-54 24-56

^

t

(cont,d)

24-23 d

Troubleshooting TroubleCode(DTG)Chart-'98 - 00 Models(cont'dl Diagnostic SRSindicator light

DTC 5-4

6-3 6-4

comeson

Possiblecause

Corective action

See page

lnternalfailureof the SRSunit

SRSunit repracemenl

24-76

lnternalfailureof the SRSunit

SRSunit reptacemenr

24-76

Internalfailureof the SRSunit

SRSunit replacement

24-76

lnternalfailureot the SRSunit

S R Su n i t replacement

24-76

Internalfailureof the SRSunit

S R Su n i t replacement

24-16

lnternalfailureof the SRSunit

SRSunit repracemenl

24-76

SRSairbagsdeployed(SRSunit must be .eplaced)

SRSunit reptacemenl

24-76

8-1

8-2 8-6 g _ 1 **rr

10-1

NOTE: *'l: In caseof an intermittentfailureDTC9-1.it meansthere was an internalfailureof the SRSunit or a faulty SRSindicator light circuit.Do the troubleshooting for intermiftentfailu.es(page24-15). *2: In caseot an intermittentfailureDTC9-2. it meansthere was an internalfailureof the power supply(VB line).Do the troubleshooting for intermiftent failures. *3: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector.

24-24

a,

SRSIndicatorLightWireConnections SRSIndicatorLight Power Circuit

DASHBOARDWIRE HARNESS

C508 -+

To UNDER-DASH BOX FUSE/RELAY 20PCONNECTOR

To GAUGEASSEMBLY

C41 1, C412 : Terminalsido of mdlo t6rminals C501, C5O2,C508, C801. C802, C807 : Wi.6 sidcof fomalot.rminals

SRS Indicato. Light Control Circuit To SRSUNIT

a t

t I

MAIN WIBE HARNESS

SRSMAIN HARNESS GRY

BLU c411

To GAUGEASSEMBLY

O I

C501 C508 C801 C807

2oP CONNECTOR : DASHBOARDWIRE HARNESS : DASHBOARDwlRE HARNESS5P CONNECTOR 2P CONNECTOR : SRSMAIN HARNESS : SRSMAIN HARNESS18P CONNECTOR

C802 C412 C41 1 C502

: SRSMAIN HARNESS3P CONNECTOR 3P CONNECTOR : MAINWIREHARNESS : MAIN WIREHARNESS24P CONNECTOR : DASHBOARDWIRE HARNESS24P CONNECTOR

24-25

Troubleshooting TheSRSIndicatorLight Doesn'tComeOn CAUTION: Whonever ths ignition switch is ON {ll}, or has been turned OFF tor less than three minutes. be careful not to bump the SRS unit; the airbagls)could accidentallydeploy .nd caus6damage or iniuri€s. Checktho pow€r supply (fuse): Turnthe ignitionswitchON (ll),and checkwhetherthe other indicatorlightscomeon (brakesystem,etc.). Oo the other indicator liohts como on?

YES

NO

Check th6 fuso: C h e c k t h e N o . 2 5 { 7 . 5 A ) f u s e i n t h e u n d e r - d a s ht u s e / r e l a y b"t ls th6 tu36 OK?

YES

NO

))

Checkthe bulb: Replacethe No. 25 (7.5A) fuse, and checkthat the SRSindicatorlightcomeson. Doosthe SRSindicator liqhl come on7 No

I YES END

Checktho wire harns b€twecn fus6 and gauge aasambly: Checkfor an open in the wire harnessbetweenluse No. 25 {7.5A) and the gaugeassembly,and repair.Check thatthe SRSindicatorlightcomeson. Doo. tho SRSindic.tor light como on?

I I

yEs

No

END Checktho SRSindicator light bulb: 1. Turnthe ignitionswitchOFF. 2. Removethe gaugeassembly. 3. Checkfor blownSRSindicatorlight butb. ls the SRSindicator light bulb OK? YES

NO

Ch.ck the SnS indicator liglrt circuit: Replacethe bulb, and reconnectthe gauge assembly connectors. Thenturn the ignitionswitchON {ll}. Ooesth6 SRSindicato. llght come on?

I YEs

No

:ND

lAl To page 24-27

24-26

lB'Jfo page24-27

No. 25 (7.5Al FUSE

) Frompage24-26 (A)

Frompage24-26 (B)

DASHBOARDWIREHARNESS 5P CONNECTOR

check the sRs indicator light circuit: 1. Disconnectthe dashboardwire harness5P connector from the gaugeassembly. 2. Connecta voltmeterbetweenthe No. 1 terminal(+) of the 5Pconnectorand ground. 3. T!rn the ignitionswitchON 1ll),and meas!revoltage. ls there 8.5 V or loss lor six seconds atter the ignition swilch has beenturned ON {lll?

YES

NO

Faulty SRS indicator light circuit in the gauge e$embly; replace the SRS printed circuit boa.d in tho gauge ass€mblY.

I t

Checkthe wire harnessotthe SRSindicator light circuil {1): '1. Turnthe ignitionswitchOFF. 2. Disconnectthe main wire harness24P connectorfrom the dashboardwire harness. 3. Connecta voltmeterbetweenthe No. 5 terminal {+) of the mainwire harness24Pconnectorand 9round 4. Turnthe ignitionON (ll),and measurevoltage. ls thore 8.5 V or lcss tor tix second3.Itor the ignition switch has b6en turned ON lll)? YES

MAIN WIREHARNESS 2,rPCONNECTOR

NO

Short to oower in the BLU wire ol the dashboald wiro harness;rgpaii the ham€ss. WIRE DASHAOARD HARNESS2irP CONNECTOR

To page 24-28

ar

c411

(cont'd)

24-27

Troubleshooting TheSRSIndicatorLight Doesn'tComeOn (cont'dl Frcm page24.21

MAIN WIREI{ARNESS 3P CONNECTOR

Ch6cktho wire h6rn6s of tho SRSindicator light circuir (21: 1. Turnthe ignitionswitchOFF. 2. Disconnect the SRSmain harness3P connectorfrom the mainwire harness, 3. Connecta voltmeterbetweenthe No. 1 terminal(+) of the SRSmain harness3P connectorand ground. 4. Turnthe ignitionswitchON (ll),and measur€voltage. 13thore 8.5 V or less for 3ir sacond3aftgr tho ignition switch h.3 b.en turned ON llllT

YES

NO

Short to power in tho BLU wi.e of lhe m.in wiro hrnroas; r€orir tho ham6as.

SRSMAIN I{ARNESS 3P CONNECTOR

c802

SRSUNIT

Chockthe wi.e harnessotthe SRSindicatorci.cuit l3l: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe banery negativecable. th6n the positive cable,and wait three minutes. 3. Disconnectthe driver's(and front passenger's)airbagconnector{s}(seopage24-11). 4. Disconnectthe SRS main harness18Pconnectortrom 5. Connecta voltmeterbetwo€nthe No. 6lerminal {+} of the SRSmain harness18Pconnectorand ground. 6. Turn the ignitionswitchON (ll),and measurevollagg.There shouldbe 0.5V or less.

SRSMAIN HARNESS 18PCONNECTOR

ls voltago as specified?

SRS MAIN HARNESS1APCONNECTOR YES

NO

Faultv SRSunh; roplic. the unit l!€e paqo 2+76).

Shoft to Dowar in tha BLU wire ot tho SRS mein h.rn.r3: reobce the hrlne3s,

24-2a

)

TheSRSlndicatorLightDoesn'tGo Off -'96 - 97 Models CAUTION: Wheneverthe ignition switch is ON (ll), or has been turned OFFfor less than three minutes, be careful not to deployand causedamageor iniuries bump the SRSunit;the airbag{slcould accidentally Try to reproducelhe SRSindicator light: 1. Erasethe DTCmemory(seepage24'15). 2. Turnthe ignitionswitchOFF,and waitfor ten seconds. 3- Turnthe ignitionswitchON {ll),andcheckthatthe SRSindi catorlight comeson for aboutsix secondsand goesoff Doesthe SRSindicEtorlight stay on? NO

[*

Intermittent lailure, system is OK at this time. See TroubloshootingInt6rmittent Failureson page 24'15

Ch€ckthe No. 13 {15A} and No. 23 (10A) fuses: 1. Turnthe ignitionswitchOFF. 2 . C h e c kf o r b l o w nN o . 1 3 ( 1 5A ) a n d N o . 2 3( 1 0A ) f u s e si n box. the underdashfuse/relay Are the fuses OK?

vEs

No

Replacethe luses, and erasethe memory 1. Replace the fuses. 2. Connectthe SCSserviceconnectorto the MES con nector. 3. Erasethe DTCmemory(seepage24 15). the SCS switchOFF,then disconnect 4. Turn the ignitaon serviceconnectorfrom the MESconnector. 5. Turnthe ignitionswitchON (ll). Doesthe sRS indicato, tigt t go or "ne. "ii--JJl

l.J -

I YEs 1

No. 't3 {15Al FUSE

SRS UNIT

NO

END

i

Conlirm the DTC,and continue troubl6shootilg.

Checkfor an open in the SRSmain harness{VA linell '1. Tu.nthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe driver's (and front passenger's)airbag (seepage24 11). connectorls) '18Pconnectorfrom 4. Disconnectthe SBS main harness the sRS unir. the batterypositivecable,then reconnectthe 5, Reconnect negativecable. 6. Connecta voltmeterbetweenthe No. 7 tetminal (+) of the SRSmain harness18Pconnectorand ground. 7. Turnthe ignitionswitchon.

SBSMAIN HARNESS18PCONNECTOR

b there battery voltageT YES

NO

(A) To page24 30

I I

Open in the SRS main harnessIVA line); replacethe SRS main harness. (cont'd)

24-29

Troubleshooting The SRSIndicatorLight Doesn'tGo Off -'96 - 97 Models(cont'd) Frcm page 24-29 (A)

SRSUNIT SRSMAIN HARNESS 18PCONNECTOR

Checkthe SRSunit: Connectthe SRSmain harness18PconnectorterminalsNo. 6 and No.7 with a iumDerwire and

FeultySRSunit or poor cont.ct !tth. SRSftain hsmeis 18Pconnector;ch6ckthe conncctor, lf the connectoris OK, rcpl.c. tho SRSunh.

To page24-31

07TAZ- 001020A JUMPERWIRE

Wiresideot femaleterminals

24-30

DASHBOARDWINEHARNESS

) Frompage24'30 (B)

Checkth. SBSindicatot circuit: 1. Turnthe ignitionswitchOFF. 2. Removothe gaugeassembly. NoTE: Do n;t disconnectthe dashboardwire harness5P connsctorlrom the gaugeassembly 3. Turnthe ignitionswitchON (ll). 4. Connectth€ dashboardwire harness5P connectorterminalsNo. 1 and No.5with a jumperwiro. Doo3th. SRSindicstor light go offf

Fautty SRS indicltot light citouit in th. grugc a$cmbly; rcpl.ce the SRS ptint.d cilcuit boaJd in thc gtugs

mcsog A# I Btu lYEt lUUpeA Wtng

Wire side of fomale terminals

WIREHARNESS OASHBOARD 5P CONNECTOF

I t

Ch.ck tor a ihort to glound in th. SRS IndioltoJ light cir' cuit: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe dashboardwire harness5P connector from the gaugeassemblY 3. Checkresistancebetweenthe No. 1 terminal of the dash boardwire harness5P connectorand ground.Thereshould b€ 1 MOor more.

Ch.ck to. an opon in tho SnS indic.tor light circuh: of the SRS 1. Ch6ck resistanc€between the No 6 terminal 'l msin harness18Pconnectorand No. terminalot the dashboardwire harness5P connector;there should be

Wiresideol female tetmtnals SRS MAIN HARNESS lAP CONNECTOR

Wire sideot femaleterminals

(D) To page 24'33

or

To page 24-33 DASHBOARDWIREHARNESS 5P CONNECTOR

(cont'd)

24-31

Troubleshooting TheSRSIndicatorLightDoesn'tGo Off -'96 - 97 Models(cont'dl Frompage24-31 MAIN WIREHARNESS Ch6ckfor a shon lo ground in tho m.in wire harness: 1. Disconnectthe dashboardwire harness24P connector from the mainwire harness, 2. Checkresistance betweenthe No. 5 terminalof the main wire harness24Pconnectorand ground.Thereshouldbe 1 M0 or more.

Short to ground in the dashboard wire harness; repair the dashbo..d wire harnoss.

HARNESS

Checkfor a short to ground in the SRSmain h..ness: 1. Disconnect the SRSmain harness3P connectorfrom the mainwire harness, 2. Checkresistance betweenthe No. 1 terminalof the SRS main harness3P connectorand ground.Thereshorrldbe 1 fu,|0or more. ls the resistanceas specifisd?

Short to ground in the main wire harnoas;r€pair the main wire harness.

SRSMAIN HARNESS 3P CONNECTOR

Wire side oI female terminals

\

24-32

) DASHBOARDWIBEHARNESS 5P CONNECTOR

Frompage24-31 (Dl

Checklho SRSindicator Gircuitinput voliage: 1. Reconnectthe SRS main harness18Pconnectorlo the SRSunit. (+) of 2. Connecta voltmeterbetweenthe No. 1 terminal ground and connector 5P the dashboard 3. Turnthe ignitionswitchON (ll),and measure ls there 8.5 V or more six secondsafter lhe ignilion switch has beenturned ON (lll?

The Droblem h.s disappe.red due to disconnectingantl connecting the connectors. Be sure all lerminals mako oood contact, and recheck the syslem lsoe iroubleshooting Intermittent Failure3on page 2{-151' Poor contact at the SRSmain h.rn6s 18Pconnector;ch'ck

lI the problem k still present, replacethe SRS main har'

Wiresideof temale termtnars

Frompage24-31 (El

l r

SRS MAIN HARNESS 18P CONNECTOR

Checkfor an open in the dashboatdwir€ harness: 1. Disconnectthe dashboardwire harness24P connector from the mainwire harness. betweenthe No. 6 terminalof the SRS 2. Checkresistance main harness18Pconnectorand No 5 terminalof the m a i n w i r e h a r n e s s2 4 P c o n n e c t o r ;t h e r e s h o u l d b e 0 - 1 . 00 .

MAINWIREHARNESS Terminalsideot maletermlnals 24P CONNECTOR Ooen in tha BLU wire ot the dashboard wire harness; the dashboardwiie harness.

SRS MAII{ HARI{ESS laP CONI{ECTOR

Checkfor an open in the main wire harness: the SRSmain harness3P connectorfrom the 1. Disconnect mainwire harness. betweenthe No 6 terminalof the SRS 2. Checkresistance main harness18Pconnectorand No 1 terminalof the thereshouldbe 0 - 1 0 o SRSmainharness3P connector; ls the resistanceas sp€cilied? SRS MAIN HARNESS 3P CONNECTOR

. L

ODen in the BLU wire of the main wire hamess; tepair the main wire harness. Ooen in the SRS main harness;replacelhe SRS main har

24-33

Troubleshooting TheSRSIndicatorLight Doesn'tGo Off -'98 - 00 Models CAUTION: Whenever the ignition switch is ON {ll}, or has b66n turned OFF for less than three minutes, be careful not to bump the SRS unit; the airbags coutd accidentallydeploy and causedamage or iniuries. Try to reproducethe SRSindic.tor light: 1. Erasethe DTCmemory(seepage24-15). 2. Turn the ignitionswitchON (lt),and checkthat the SRS indicatorlight comeson for aboutsix secondsand ooes ol1.

Intormittentlailulo, systomis OK atthistime. SooTrouble l. o.mittgnl Failuroson paqe24-15.

Checkthe No. 23 (10 Alfuse: 1. Turnthe ignitionswitchOFF. 2. Checkfor blown No. 23 (10 A) tuse in the under,dash fuse/relaybox.

Replaceihe fus€, and 6.asethe momory 1. Replace the No. 23 110A) fuse. 2. Erasethe DTCmemory(seepage24,15). 3. Turnthe ignitionswitchON (ll).

No. 23 {10 Al FUSE FUSE/RELAY BOX

Doos the SRS indicator light go off after 3ix second3?

Checktor an open in the SRSmsin harness{VB lincl: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait tor threeminutes. 2. Disconnectthe driver's (and front passenger,s) airbag (seepage24-11). connector(s) 3. Disconnectthe SRS main harness18p connectorIrom the sRs unit. 4. Reconnectthe battery positive cable, then reconnectthe negativecable. 5. Connecta voltmeterbetweenthe No. 3 terminal (+) of the SRSmain harness18Pconnectorano qrouno. 6. Turnthe ignitionswitchON {ll). SRSMAIN HARNESS18P CONNECTOR

(A)

To page 24-35

24-34

) From page 24-34 (A) SRSMAIN HARNESS Chockiho SRSunit: Connectthe SRSmain harness18PconnectorterminalsNo' 6 and No.3 with a jumperwire and backprobe Doostho SRSindicator light go off?

Faulw SRSunit or poot co tact at the SRSftain htmes! 18Pconnoctor;chackthe connagtot. ll tha connoctorb OK roplacalho SRSunit'

SRSMAIN HARNESSI8P CONNECTOR oid tu3e No. 23 t10 A) blow? JUMPEBWIRE

(B) To page24-36

1 )

Chcck for e short to ground in th. SRS indicator lighi circuh: 1. Turnthe ignitionswitchOFF 2. Disconneitthe dashboardwire harness5P connector from the gaugeassembly. 3. Checkres-ista;cebetweenthe No l terminai ofth€dashboard wire harness5P connectorand ground There '1 shouldbe M0 or more.

Wiresidgof lemaleterminals DASHBOARDWIREHARNESS 5P CONNECTOR

ic) To page 21'31 gtug' Short to glound in th. gaugs aslomblY; .6plac' th'

DASHBOARDWIREHARNESS 5P CONNECTOR

c508

t of lemale

o!

(cont'd)

24-35

Troubleshooting The SRS Indicator Light Doesn't Go Off - '98 - 00 Models (cont,dl Frompage24 35 DASHBOAEDWIREHARNESS 1B)

Check the SRS indicetor circuit: 1. Turn the ignition switch OFF. 2. Bemove the gauge assembly, Do not dlsconnectthe dashboard wire harness 5P connector from the gauge assemoly. 3. Turn the ignition switch ON (ll) 4. Connect the dashboard wire harness5P connector terminals No. 1 and No. 5 with a jumper wire.

Doesthe SRSindicator light go om YES

NO

Faulty SRS indicator light circuit in the 9au96 assembly; replace the SRS printed circuit board in the gauge essembly.

Checkfor an open in the SRSindicator light circuit: r. rurn rne rqnrtonswrtchut-t-. 2 . D i s c o n n e ct h t e d a s h b o a r dw i r e h a r n e s s5 p c o n n e c t o r from the gaugeassembly. 3. Checkresistance betweenthe No. 6 terminalof the SBS main harness18Pconnectorand No. I terminalof the dashboardwire harness5P connector;there should be 0 1 . 00 . ls the resistanceas soecified?

YES

OASHBOARDWIRE HAR'{ESS 5P CONNECTOR

llTf;rv;1c508 .1# I Bru lYEr JUMpERWIRE

Wire sideof female rerminats

SRSMAIN HARi{ESS I8P CONNECTOR

c807

NO Wire sideof femaleterminals

(D) To page24 38

24-36

(E) To page24-38

DASHBOARDWIREHARNESS 5P CONNECTOR

) From page 24-35

(c)

MAIN WIREHARNESS24PCONNECTOR

Checklor a 3hort to glound in tho main wira harno$: 1. Disconnectthe dashboardwire harness24P connector from the mainwire harness. betweenthe No 5 terminalofthedash2, Checkresistance board wire harness24P connectorsnd ground There shouldbe 1 M0 or more

Short to giound in tha dalhbo!]d wir! ha]n'$; t'plil lho darhborrd wira hrrnos!.

WIRE DASHBOARD HARNESS24PCONNECTOR

DASHEOARDWIREHARNESS 24P CONNECTOR

BLU

Wke side oI female terminals

l )

MAIN WIBEHARNESS 3P CONNECTOR

Chockfor ! shon to ground in tho SRSmain herness: the SRSmain harness3P connectorfrom the 1. Disconnect mainwire harness. 2. Checkresistancobotween the No. 1 terminal of the SRS main harness3P connectorand ground, There shor,lldbe

3P CONNECTOR Short to ground in tha main wir6 hainoss; r'Prir the

SRSMAIN HARNESS 3P CONNECTOR

Short to ground in thc SRS main harn6s; leplac' th' SRS

l1'

(cont'd)

24-37

Troubleshooting The SRS Indicator Light Doesn't Go Off -'98

- 00 Models (cont'dl

Frompage24 36 (D) DASHBOARDWIREHARNESS Checkthe SRSindicetor circuit input voltage: 1. Reconnect the SRS main harnessl8P connectorto the SRSunit. 2. Connecta voltmeterbetweenthe No. 1 terminal(+) of the dashboard5Pconnectorand ground. 3 . T u r n t h e i g n i t i o ns w i t c hO N ( l l ) ,w a i t f o r s i x s e c o n d s , then measurevoltage, ls th€re 8.5 V or more? YES

NO

The problem has disapp€areddue to di3connectingand conneding the connectors. Be su.e all te.minals make good contact, and recheckthe system {see T.oubleshooting Inte.miftent Failureson page 24-15).

Poor contact et the SRS main harnass18p connactoricheck the connector, . ll the connector is OK, substitute a known-good SRSunit, and recheck. ' It the problem is still present, replacethe SRS main haF ness.

DASHBOARDWIRE HARNESS 5P CONNECTOR

c508

Frompage24-36

Checkfor an open in the dashboardwir6 harness: 1. Disconnectthe main wire harness24P connectorfrom the dashboardwire harness. 2. Checkresistance betweenthe No. 6 terminalof the SRS mainharness18Pconnector and No.5 terminalof the main wireharness 24Pconnector; thereshouldbe 0 - 1.00. ls the resistanceas 3pecitied? YES

SRSMAIN HARNESS 18PCONNECTOR

c807

NO

c41 l

Open in the BLU wire ot the dashboardwire harness; repair the dashboardwire harness.

Checktor an open in the main wire haanoss: 1. Disconnect the SRSmain harness3P connectorfrom the main wire harness. 2. Checkresistance betweenthe No. 6 termanalof the SRS mainharness18Pconnector and No. 1 terminalof the SRS main harness 3Pconnector; theresho!ld be O- l.O0. ls the resistancea! specified? YES

Open in the SFS main hrrness; replacethe SRS main harness.

\

SRSMAIN HARNESS 18PCONNECTOR

NO

Open in the BLU wire of the m.in wire ha.ness: .eoair the main wire harness.

24-38

Terminalsideof malelerminals

cao2 SRS MAIN HARNESS 3P CONNECTOR

No DTC-'98 - 00 Models CAUTION:Wheneverthe ignition switch is ON (ll), or has been turned OFF for less than three minuies. be careful not to bump the SRS unil; the airbags could accidentallydeploy and causedamageor iniuries Checkthe tuse: CheckIor blown No 13 {15 A) fuse in the underdash fuse/

(A)To page24'40 Beplacethe fuse.Turnthe ignitionswitchON (lll, and check that lhe tusedoesn'tblow

The oroblem has disappeared.Test'drivethc vehicleand s6e Troubleahoodng lntermittent Failureson pago 2&15

No. 13 {15A) FUSE

. J Check for short to ground betweon the under-dash fuse/ relav box end the SRS unil 1 . T L r r nt h e i g n i t i o n s w i t c h O F F 2, Disconnect the battery negative cable, then drsconnect the positivecable,and wait for three minutes' 3. Disconnect the driver's {and front passenger's airbag) c o n n e c t o r { s ){ s e e P a g e 2 4 _ 1 1 ) 4. Disconnect the SRS main harness 18P connector irom 5 . C h e c k r e s i s t a n c eb e t w e e n t h e N o 7 t e r m i n a l o f t h e S R S m a i n h a r n e s s 1 8 Pc o n n e c t o r a n d g r o u n d There should be 1 M0 or more

sRs MAIN HARNESS

FauftySRSuniu replacethe SRSunii (seepage 21-761'

O1'

(8) To page24 40

(cont'd)

24-39

Troubleshooting No DTG-'98 - 00 Models(cont'dl trom page24 39

(Bi

Checkfor short to ground in iho SRSmain ha.no$: 1. Disconnect the SRSmain harness2P connectorfrom the fuse/relay under-dash box. 2. Checkresistance betweenthe No. 7 terminalof the SFS main harness18Pconnectorand ground.Thereshould be 1.0MO or more. ls lha r6i3tlnce

as sp.cilied?

YES

NO

Short to ground in the und..-d.sh tu3a/r.lay box; roplacethe undsr-dlrh tu!6/rahy box. Short to ground in fho SRS main harness;rsplecc the SRS main htrnors. SRSMAIN HARNESS 2P CONNECTOB

FUSE/RELAY BOX

SRSMAIN HARTESS 18PCONNECTOR

c807 (A)Frompage24 39 Wir€ side ot fsmale terminals Checklor an open in the SRSmain harn€ls: 1- Turntho ignitionswitchOFF. 2. Disconnectthe bafterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe driver's (and front passenger's) airbag (seepage24-11). connector(sl 4. Disconnectthe SBS main harness18Pconnectortrom the sRs unit. 5. Reconnect the batterypositivecable,then reconnectthe negativecable. 6. Connecta voltmeterbetweenthe No. 7 terminalol the SFS main harness18Pconnectorand qro!nd. 7. Turnthe ignitionswitchON (ll),and measure

Poor contact rt the SRS main harness 18P conn.ctor: chockth€ connectoi. . ll th. connector is OK, iubstitute a known-good SRS unit, and recheck. . lf tho pioblem is still pres6nt. replace the SRS mlin haanos3.

To page24.41

24-40

SRS MAIN HAR ESS lAP CONNECTOR

c807

) Frompage24-40

Checkfor an open in the SRSmain harn6s: 1. Turnthe ignitionswitchOFF. the SRSmain harness2P connectorfrom the 2. Disconnect under-dashfuse/relaybox betweenthe No. 1 terminalol the SRS 3. Checkresistance main harness2P connectorand No. 7 terminal of the SRSmain harness18Pconnector. T h e r e s h o u l d b e0 5 O ls the resistancees specitied?

YES

NO

Poor contact at the SRS main hatness2P connector; checkthe connector. It the connector i3 OK, substitute a known-good und€rdash fuse/relav box, and recheck. .ll the Droblemi5 still pres€nt,replacelhe SRS main harness.

BOX FUSE/RELAY

SRSMAIN HARNESS 18PCONNECTOR

c807 Open in the SRS main hsrness; leplaco the SRS main harness.

)

Wire side of female terminals

SRSMAIN HARNESS 2P CONNECTOR

lrt 24-41

Troubleshooting DTC1-1and DTG1-2 CAUTION:Wheneverthe ignition switch is ON 0l), or has been turned OFF for le33 than three minutes, be careful not to bump the SRS unit; the airbagls) could accidentallydeploy and causedamage or inluries.

DRIVER'SAIRBAG

Try to reproduc€the SRSindicator light: 1. Erasethe DTCmemorylseepage24,'15). 2. Turnthe ignitionswitchON {ll),andcheckthatthe SRSindicatorlight comeson lor aboutsix secondsand goesoff. Doesthe SRSindicator liqht 3tav on?

REEL

Intermittent lailure. system is OK at this time. So€Tlouble Intermittent Failur6 on Deqe24-15.

2P CONNECTOR

AZ - SZ5011A Checkfor en open in th€ driver's airbag inllator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnectthe positivecable,and wait for three minutes. 3. Disconnectthe driver'sairbag2P connectorfrom the cable reel 2P connector. CAUTION:Do not disconnectthe pa9,!eng6.,s ailbag connector. 4. Connectthe specialtool {2 0)to the cablereel2P connec, tor. 5. Reconnectthe battery positive cable, then reconnectthe negativecable, 6. Erasethe DTCmemory{seepage24 15}. 7. Readthe DTC{seepaqe24-13). ls OTC1-1 or DTC1-2 indicatod?

07sAz-TB{0t1A t2 0 JACKT

-

Open or incroas€dresistanc€in the driver's ai.bag inoator; r€place the d ve/s airbag lse6 pege 24€?).

SRSMAIN HARNESS Checkfor an opgn in the cabl6 reel: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnect the specialtool {2 O) from the cable reel 2p connector, 3. Removethe dashboardlower cover,and disconnectthe cablereel2P connectorfrom the SRSmain harness. 4. Connectthe specialtool {2 0} to the SRS main harness 2P connector, {cont,

CABLE REEL 2PCONNECTOR

07TAz- SZ5011A

To page 24-43

(2 0 JACK)

24-42

l !

) From page 24-42

Checkfor an opgn in the cabl6 reel (cont'd): 5. Reconnectthe battery positive cable,then roconnectthe negativecable. 6. ErasetheDTCmemory(seepage24 15i 7. Readthe DTC(seepage24-13). l. DTC1-l or DTC1-2 indicrt.d?

Opan or incraGad rcsbtanca in tha crbla raal; rapllca

1 J

Chccklor .n oDcn in th. SBS mtin harne$i 1. Disconn€ctthe battery negative cabl€, then disconnect the positivecable,and wait tor threeminutes 2, Disconnectthe lront passgnger'sairbag connoctorfrom the SRSmain harness(with front pssseng€r'sairbag). 3. Disconnectthe SRS main harn€ss18Pconnectorfrom the SRS unit. Do not disconnectthe specialtool {2 0) from the SRSmain harness2P connector. 4. Checkresistancebetlveonterminals No. 1 and No 13 ot the SRSmain harness18Pconnector. Thereshouldbe approx.2.0- 3.0O.

Poor contact rt tha SRS main harna*t 18P connactor; chack tho clnnactot, . It th. conn.ctol b OK. tubttitut. a known-good SRS unit. end rcchock. .lf the problem is still prcsent, replace tho SRS main harnoss.

Ooen or incr6asadr.si3tlnca in tha SRS mlin hatnaar;

lfr 24-43

Troubleshooting DTC1-3 CAUTION:Wheneverthe ignition switch is ON {lll, or has been turned OFF lor less than thrEe minutes, be caroful not to bump the SRS unit; the airbag(s)could accidenlallydeploy and causedamage 01 iniuries.

DRIVER'SAIRBAG ASSEMALY

TrVto reproducethe SRSindicator light: 1. Erasethe DTCmemory(seepage24-15). 2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindi catorlight comeson for aboutsix secondsand goesoff. Doesthe SRSindicalor light stav on?

YES

NO

Intermittent lailure. system is OK ai this tim€. Se€Troubl€shooting Intermittent Failureson page 24-15.

REEL 2P CONNECTOR

AZ - SZ5011A

Checktor a short lo another wire in the drivo.'s eirbrg in{la1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe driver's airbag 2P connectorfrom the cablereel2P connector, CAUTION:Do not disconnectthe passenger'sairb.g connector, 4. Connectthe specialtool (2 0)to the cablereel2P connec tor, 5. Reconnectthe baftery positive cable, then reconnectthe negativecable, 6. Erasethe DTCmemory(seepage24 15). 7. Readthe DTC(seepage24-13). ls DTC1-3 indicated? YES

07saz- TB4011A {20 JACK)

NO Shon in the driver's airbag intlator; replacethe driver's airbag {seepage 24-67}. SRSMAIN HARNESS

CABLE REEL 2P CONNECTOR

Check lor a short in the ceble reel: 1. Disconnect the battery negative cable, then disconnect the positivecable,and wait for three minutes. 2. Disconnectthe special tool (2 O) from the cable reel 2p

07TAZ- SZ5011A

3. Remove the dashboard lower cover, and disconnect the cable reel 2P connector from the SRS marn naroess. 4. Connect the special tool (2 O) to the SRS main harness 2P coonector. {cont,di

fo page24-45

07sAz- TBr011A t2 0 JACKI

24-44

) Ftom page 24-44

Check for a shon in the cable reel lcont'dl: 5 , R e c o n n e c tt h e b a t t e r v D o s i t i v e c a b l e , t h e n r e c o n n e c t t h e n e g a t i v ec a b l e . 6 . E r a s et h e D T C m e m o r y ( s e e p a g e 2 4 - 1 5 ) .

7. Readthe DTClseepage24'13).

Short in the cable reel; replacethe cable reel (see page 21-721.

SRSUNIT

I J Ch€cktor a shon in the SRSmain harness: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe front passenger'sairbag connectorfrom airbag). the SRSmain harness(withfront passenger's 3. Disconnectthe SRS main harness18Pconnectortrom the SRS unit. Do not disconnectthe specialtool (2 0) from the SRSmain harness2Pconnector. 4. Checkresistance betweenterminalsNo. 1 and No. 13 of '18P the SRSmain harness connector. Thereshouldbe aDorox.2.0- 3.00.

SRSunit; replacelhe SRSunit lsee ptge 21-

Short in the SRS m.in ha.ness; roplace the SRS mein hal-

o1| 24-45

Troubleshooting DTC1-4

!

CAUTION:Wheneverths ignition 3wiich is ON {lll, or has boen turned OFF tor loss than three minutes, bs caroful not to bump the SRS unit; the airbagls) could accidoDtallydeploy and causedamage or iniulies.

DRIVER'SAIRBAG

Try to roproduc. the SRSindic.lor lightr 1. Erasethe DTCmemory(seepage24-15). 2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindicatorlightcomeson tor aboutsix secondsand goesoff. Ooes th6 SRS indicltor liqht stey on?

YES

NO

Intermitid{ failure, 3y3tem b OK at this time. S€e Troubloshooting Intormittont Failursson pago24.15.

CABLEREEL 2P CONNECTOR

Checkfor a 3hort to powo. in the d.iver's .irbag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe bafterynegativecable,then disconnect the positivecable,and wait for three minut6s. 3. Disconnectthe driver's airbag 2P connectorfrom the cablereel2P connector. CAUTION: Do not disconnoct the parsengcr'r airbag connactoa. 4. Connectthe SRSserviceconnector(2 O)to the cablereel 2P connector. 5. Reconnect the batterypositivecable,then reconnectthe negativecable. 6. ErasetheDTCmemory(seepage24-15). 7. Readth6 DTC{seopage24-13}, ls OTC1-4 indic.tedT

YES

07SAZ- TB,()11A (2 0 JACKI

NO Short to pow.r in the driver'i rirbrg inilrtor; r€pl.co the driver'! airbag l!e. paga 24-67). SRSMAIN HABNESS

CABLE REEL 2PCONNECTOR

Checkfor a ahort to Dow€r in tha crblo.eet: 1. Disconnectthe batterynegativecabl€,then disconnect the positivecable,and wait for threemrnur€s. 2. Disconnect the specialtool (2 O) trom the cable reel 2P cononector. 3. Bemovethe dashboardlower cover,and disconnectthe cablereel2P connectortrom th€ SRSmain harness. 4. Connectthe specialtool 120) to the SRSmain harness (cont'd) 2P connector.

07TAZ- Szsol'lA

fo page 24-47

t2 0 JACK)

24-46

) Frompage24-46

Chockfor a short to power in the cabls roel lcont'dl: 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erasethe DTCmemorylseepage24-15). 7. Readthe DTC(seepa1e24-131. b DTC1-4 indicat€d?

YES

NO

Short to power in tho cable reel; roplac. tho cable reel lsee Dase24-721.

SRSUNIT

I J

Chockfor e short to powot in the SRSmain hornoas: 1.Disconnectthe batterynogativecable,then disconnect the positivecable,and wait for threeminutes. airbagconnectorlrom the front passenger's 2- Disconnect the SRSmain harness(with front passenger'sairbag). 3. Removethe specialtool (2 0) trom the SRSmain harn€ss 2P connector. /t.Disconnectthe SRS main harness18Pconnectorfrom the sRs unit. 5. Reconn6ctthe battery positive cable,then reconnectthe negativecable. 6. Connecta voltmeterbetweenthe No. 1 {+i terminalof the SRSmain harness18Pconnectorand body ground. 7. Turn the ignilion switch ON lll), and measurevoltage Thereshouldbe 0.5V or less. 8.Turnthe ignitionswitchOFF. 9. Connecta voltmeter between the No. 13 (+) torminal ol the SRSmain harness18Pconnector8nd body ground. lO.Turn the ignition switch ON (ll), and measurevoltage Thereshouldbe 0.5V or less. Aro voltrges a3 specified?

YES

NO

FauftvSRSunh; roplacctho SRSunh {soepago 2+761'

Short to power in the SRS main h.rness; .eplace rhe SRS main harness.

a0 24-47

Troubleshooting DTC1-5

J

CAUTION:Wheneverthe ignition switch is ON {ll). or has been turned OFF for less than three minutes, be caretul not to bump ths SRS unit; the airbag(slcould accidentallydeploy and causedamage or iniuries.

DRIVER'SAIRBAG 2P CONNECTOR

DRIVER'SAIRBAG ASSEMBLY

Try to rep.oducethe SRSindicator light: 1. ErasetheDTCmemorv(Seepage24'15). 2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindi catorlight comeson tor aboutsix secondsand goesoff. Ooes the SRS indicator light stay onl

YES

NO

REEL

Intermittentlailure,systemis OK at this time. SeeTroubleshooting lntormittent Failure3on page 24-15.

2P CONNECTOR

AZ - SZ5011A Check for a short to ground in lh€ driver's airbag inllator: 1. Turn the ignition switch OFF. 2. Disconnect the battery negative cable, then disconnect the positivecable,and wait for three rninutes. 3. Disconnect the driver's airbag 2P connector from the cable reel 2P connector. CAUTION: Do not disconnect tho p.ssenger's airbag connectoa. 4. Connectthe specialtool (2 0)to the cable reel 2P connec tor. 5 . R e c o n n e c tt h e b a t l e r y p o s i t i v e c a b l e , t h e n r e c o n n e c t t h e negativecable6 . E r a s et h e D T C m e m o r y ( s e e p a g e 2 4 - 1 5 ) . 7 . R e a dt h e D T C ( s e e p a g e 2 4 - 1 3 1 .

I

07sAz- TB40't1A (2 0 JACK)

ls OTC1-5 indicatedT YES

NO

Short to ground in the drive/s airbeg inflator; r€pl.ce the driver's.iib.g (see page 24d1.

SRSMAIN HARNESS 2P CONNECTOR

CABLE REEL 2PCONNECTOR

Checklor a short to ground in the csble reer: l. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnect the specialtool {2 (}) from the cable reel 2P 3. Removethe dashboardlower cover,and disconnectthe cablereel2P connectorfrom the SRSmain harness. 4. Connectthe Specialtool {2 0} to the SRS main harness 2P connector(cont'd).

07TAZ- SZ5011A

To page 24-49

{2 0 JACK)

24-44

. I

) Frompage24-48 Checkfor a ahort to ground in th. cabl. r.el (cont'd): 5. Reconnectthe battery positive cable, then reconnectthe nagativ€cable. 6. Erasethe DTCmemory(seepage24-15). 7. Readthe DTC(seepage24-13). b DTC1-5 indicli.d?

YES

NO

Short to ground in tho crblc rocl; rophce the crble roel k c orsa 2+721.

T J

Chockfor e short to ground in tha SRSmain harneas: 1. Disconnectthe batterynegativecable,then disconnoct the positivecable,and wait lor three minutes. 2. Disconnectthe tront passenger'sairbag 2P connector from the SRS main harnsss {with front passeng€r's airbag). 3 Romovethe specialtool(2 0)trom th6 SRSmain harness 2P connoctor, 4. Ch€ckresistancebetween the No. 1 terminal of the SRS main harness18Pconnectorand ground.and betwgen connecthe No. 13terminalofthe SRSmain harness'l8P tor and grouncl. Thereshouldbo I Mo or more, la tha raidrnc! .3 rDccified?

YES

SRSUN]T

NO

Flulv SRSunit rcpl.c. th. SRSunit {r€e prg.2+161,

Shon to ground in th. SRS m.in h.rno$; r.pl.ce tho SRS main harnaas.

Ir, 24-49

Troubleshooting DTC2-1and DTC2-2- With FrontPassenger's Airbag

I

CAUTION: Whenever the ignition switch is ON (ll), or has been turned OFF for less than thr€e minutes, be careful not to bump th€ SRS unit; the airbags could accid€ntallydeploy and causedamage 01 iniuries. Try to reproducethe SRSindicator light: 1. Erasethe DTCmemory(seepage24-15). 2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindicatorlight comeson for aboutsix secondsand goesoff. Doesthe SRSindicator liqht stay on?

YES

NO

FRONTPASSENGER'S AIRBAG2P CONNECTOB

Int€rmitl€nl failure, sFtem is OK at thb time. Soe Troubleshooting Intermittent Failureson page 24-15.

Checktor an open in the pmi€nger's airbag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then discohnect the positivecable,and wait tor threemanutes3, Disconnect the front passenger's airbagconnectorlrom the SRSmain harness{seepage24.1... 4. Connectthe specialtool (2 0) to the SRS main harness 2P connector, CAUTION: Do not disconnectthe driver's airbag connectot, 5. Reconnectthe battery positive cable, then reconnectthe negativecable. 6. Erasethe DTCmemory(seepage24-'!5). 7. Readthe DTC(seepage24-13). ls DTC2-l or DTC2-2 indicated?

YES

MAIN HARNESS

- sz50r1A

NO

07sAz- TB4011A {2 0 JACK} Opon or increasedrosistancein the pa$enger's airbag inflator; replacetho pass€nqor'sairbaq lsee paEJe2a$71.

Io page24-51

o1 24-50

Frompage21 50 Checkfor an open in the SRSmain ha.ness: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threemrnrrtes 2. Disconnectthe driver's airbag 2P connectorfrom the cablereel2Pconnector(seepage24 11) 3. Disconnectthe SRS main harness18Pconnectorfrom the SRS unit. Do not disconnectthe specialtool (2 0) fromthe SRSmainharness2P connector' betweenthe No. 10terminaland No. 14 4- Checkresistance terminalof the SRSmain harness18Pconnector'There shouldbe apProx2 0 3.00 ls the resislanceas specified?

YES

SRSUNIT NO

Poor contact at the SRS m.in harness 18P connector; checkthe connector' . ll the connector is OK, substituto a known_goodSRS unh. and rccheck, .lf the probl€m is still present, replace th€ SRS main narness,

SRSMAIN 18PCONNECTOR

. J Ooen or incretsed resistancein the SRS m.in harness; replac6the harness.

l 0 24-51

Troubleshooting DTC2-3- With FrontPassenger's Airbag Whaneverihe ignhion switch is ON lll), or CAUTIONT has been turnod OFF lor le33 than threo minutes. be careful not to bump lhe SRS unit; ths airbags could accidontallydeploy lnd causedamage or inluries. Try to reproducetho SRSindicator light: 1. Erasethe DTCmemory (seepage24 15). 2. Turnthe ignitionswitchON 1ll),andcheckthatthe SRSindi, catorlight comeson for aboutsix secondsand goesoff. Doe3the SnS indicator light 3t.y on?

YES

NO

Intermittort tailura, 3y3tem b OK at this time. S€e Troubleshooting Intormittent Failuroson page 24-15. FRONTPASSENGER'S AIRBAG2P CONNECTOR

Checktor a 3hort io another wire or dec.oasodrelirtanct in th6 passonger'sairbag inflato.: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the Dositivecable,and wait for threeminutes. 3. Disconnectthe tront passenger'sairbag 2P connector from the SFS main harness(seepage24-11). 4. Connectthe specialtool (2 O) to the SRS main harness 2P connector. CAUTION:Do not disconn€ctth6 driver's airbag connector. 5. Reconnectthe baftery positive cable, then .econnecttho negativecable. 6. Erasethe DTCmemory{seepage24-15). 7. Readthe DTC(seepage24 13). l. DTC2.3 indicated?

YES

- szsorla

NO

Short io another wiao or d€creasedrcsi3tanc6in the prs3enger's airbag intlator; repl.ce the passong.r's .irbag lsee page 2467). {2 0 JACK) To page 24-53

24-52

l

) Frcm page 24-52

Checktor a short to another wira or docroasedtesistancoin th€ SRSmain hamess: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait tor threemanutes. 2. Disconnectthe driver's airbag 2P connectorfrom the cable reel 2P connector. 3. Disconnectthe SRS main harness18Pconnectorfrom the SRSunit. Do not disconnectthe specialtool (2 0) Irom the SRSmain harness2P connector. betweenthe No. 10terminaland No. 14 4. Checkrosistance terminalof the SRSmain harness18Pconnoctor.There shouldbe approx.2.0- 3.0f).

SRSMAIN HARNESS 18PCONNECTOR

) J

Itt 24-53

Troubleshooting DTC2-4- With FrontPassenger's Airbag

J

CAUTION:Wheneverthe ignition switch is ON lll), or has been turnod OFF for less than throa minutes, be car.Iul not to bump the SRS unit; the airbags could accidentally deployand causedamageor iniuries. Try to r€producethe SRSindicalor light: 1. Erasethe DTCmemory(seepage24 15). 2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindi catorlightcomeson Ior aboutsix secondsand goesoff. Doesthe SRSindicator light stay on? YES

NO

lDtermittenl failure, syltom b OK at this tima. S€eTrouble. shooting Int€rmittent Failuroson page 24-15.

Checklor a short to pow6r in the passenger'sairbag intlator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 3. Disconnectthe front passenger'sairbag 2P connector from the SRSmain harnesslseepage2/t 11). 4. Connectthe specialtool (2 O) to the SRS main harness 2P connector. CAUTION: Do not disconnectthe driver's airbag connector. 5, Reconnect the batteryposit;vecable,then reconnectthe negativecable. 6. Erasethe DTCmemory(seepage24-15). 7. Beadthe DTC(seepage24-13). ls OTC2-4 indicatod?

YES

NO MAIN HARNESS

AZ - SZ5011A Short to power in the passenger'sairbag inflator; replace tho passenger'sairbag lsee page 24-67)

To page24 55

24-54

07sAz- TB4011A 120 JACKI

) Ftom page 24-54 Checklor e short to power in lhe SRSmain harness: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait Ior threeminutes. 2. Disconnectthe driver's airbag 2P connectorlrom the cablereel2P connector. 3. Disconnectthe SRS main harness18Pconnectortrom the sRs unit. 4. Removethe specialtool (2 o) from the SRSmain harness 2P connector, 5. Reconnectthe baftery positive cable,then reconnectthe negativecable. 6. Connecta voltmeterbetweenthe No. 10 (+) terminalof SRSmain harness18Pconnectorand ground. 7. Turn the ignitionswitch ON lll), and measurevoltage Thereshouldbe 0.5V or less. L Connecta voltmeterbetweenthe No. 14 (+) terminalof the SRS main harness18Pconnectorand ground,and measurevoltage.Thereshouldbe 0.5V or less.

SRS UNIT

A16 voltages as specified?

YES

NO

FauftvSRSunit; repl.ce the SRSunil (seeptge 24-761

1 J Shon to power in th. SRS main harness;roplace the SRS main hanes3,

Itt 24-55

Troubleshooting DTC2-5- With FrontPassenger's Airbag CAUTION: Whenever the ignition switch is ON 0l). or has b€6n turned OFF tor loss than three minutes. be careful not to bump tho SRS unit; th€ airbags could accidentallydeploy and causedamage or injuriss. T.y lo reproducethe SRSindicator light: 1. Erasethe DTCmemory(seepage24,15). 2. Turnthe ignitionswitchON l), and checkthatthe SRSindicatorlight comeson for aboutsix secondsand ooesoff.

Intermiftem f.ilure, ty3tom ir OK at this timo. See TroubleIniermittent Failuro3on paqe24-15.

FRONTPASSENGER'S AIRBAG2P CONNECTOR

Check to. a short to g.ound in the passenger,sai.bag inflator: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe batterynegativecable,then disconnect the poshivecable,and wail for threeminutes. 3. Disconnectthe fronl passenger,sairbag 2p conneclor lrom the SRSmain harness{seepage24 l t ). 4. Conneclthe specialtool (2 0) to the SRS main harness 2P connector, CAUTION: Do not disconnectthe drivor,sairbag connec_ tor. 5. Reconnect the batterypositivecable,then reconnectthe negativecable. 6. Erasethe DTCmemory(seepage24 15). 7. Readthe DTC {seepage 24-13).

tl

MAIN HARNESS AZ - SZ50114

Short to ground in the p8,s€nger,sai.bag infleto.; replaoe rhe passenger'sairbag ls€opage24{7).

To page 24-57

07sM - TB4011A {2 0 JACK)

o! 24-56 I

)

From page 24-56

Checklor a short to ground in tha SRSmain haino$: 1. Disconnectth€ batterynegativecable.then disconnect the positivecable,and wait for threeminutes 2. Disconnectthe driver's airbag 2P connectorfrom the cable reel 2P connector' 3. Disconnectthe SRS main harness18Pconnectorfrom the sRS unit. 4. Removethe specialtool (2 0) from the SRSmain harness 2P connector, 5. Checkresistanceb€tweenthe No. 10 terminal ol the SRS main harness18Pconnectorand ground,and between the No. 14terminalot the SRSmain harnoss18Pconnec or more' tor and ground.Thereshouldbe 1 N/10 k tho rod.tanco .3 3pocified?

YES

SRSUNlT SRSMAIN HARNESS 18PCONNECTOR

NO

FaultySRSunit; topl.co the SRSunit (seopage 24-761'

Short to giound in the SRS msin hamets; replaccth€ SBS main harno33.

O l,t 24-57

Troubleshooting DTC2-1and DTC2-2- WathoutFrontPassenger's Airbag

I

CAUTION:Wheneverthe ignition switch is ON {lll. or has been turned OFF tor less than three minutes, be caretul not to bump the SRS unit; the aidag could accidentallydeployand caussdamageor iniuries. Try to reproduc€the SRSindicator light: 1. Erasethe DTCmemory{seepage24-15r. 2. Turnthe ignitionswitchON (ll),andcheckthattheSRSindi catorlight comeson lor aboutsix secondsand ooesoff. Ooesthe SRSindicalor light stay on?

SRSUNIT

Intermittent failu.e, system is OK at this time. Se€ TroubleIntermifient Failuieson paqe24-15. OUMMY RESISTOR

Check for an open oa increased resistance in the dummv teslstot: 1. Turnthe ignitionswitchOFF. 2. Removethe dummy resistorfrom the SRSmain harness 2P connector, 3. Checkthe resistance betweenthe A and B terminalsof the dummy resistor.Thereshouldbe 1.5- 2.50.

resistoa.

Checklor an open or incre.sed resisiancein the SRS main harness: '1. Disconnect the batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe driver's airbag 2P connectorfrom the cablereel2Pconnectorlseepage24 t t). 3. Disconnectthe SRS main harnesst8p connectorfrom the SBSunit. 4. Connectthe dummy resistorto the SRSmain harness2p connector. 5. Checkresistance betweenthe No- 1Oterminaland No. 14 terminalof the SRSmain harness18p connector.There shouldbe aDorox.1.5- 2.50.

SRSMAIN HARNESS 18PCONNECTOR

ls the resistance es speciti€d?

YES

Poor contact ar the SRS main hahess 18p connector; checkthe connector. . lf the connector is OK. substitute a known-good SRS unit, and recheck. . lf the problem is still present. repbce the SRS main narness.

Open or increasedresi3tanc6in tho SRS main harness;

24-5A \

O U

)

Airbag DTC2-3- Without FrontPassenger's CAUTION:Wheneverthe ignition switch is ON (lll, ot has been turned OFF for less than three minutes, be careful not to bump thc SRS unit; the ailbag could accidentallydeployand causedamageor iniuries. Try to reproducethe SRSindicator light: 1. Erasethe DTCmemorytseepage24 15). 2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindicatorlight comeson for aboutsix secondsand goesoff Doesthe SRSindicator light staYon? SRSUNIT lntermittent failure, system is OK ai this time See Int€rmittont Failureson page 2/a'15

Ch6ckfor a Short to another wile or decreasedresistancein the dummy resistor: switchOFF. 1. Turnthe ignitaon 2. Removethe dummy resistorfrom the SRSmain harness 2Pconnector. betweenthe A and B terminalsof 3. Checkthe resistance the dummy resistor.Thereshouldbe 1-5- 2.5O.

DUMMY RESISTOR

ls the resistanceas specifiod?

I J

SRSMAIN HARNESS 2P CONNECTOR

A

B

ifti Checkfor a short to another wile or decrea36dr6istance in the SRSmain harness: 1. Disconnectthe batterynegativecable,then d'sconnect the positivecable, and wait for threem inutes 2 . D i s c o n n e ct th e d r i v e r ' sa i r b a g2 P c o n n e c t o frr o m t h e cablereel2Pconnector(seepage24-l l) 3. Disconnectthe SRS main harness18Pconnectorfrom the sRs unit. NOTE:Do not connectthe dummy resistorto the SRS main harness2Pconnector. betweenthe No lO terrninalandNo lil 4. Checkresistance terminalof the SRSmain harness18Pconnector'There shouldbe 1 M0 or more.

|T' ti^i

DUMMY RESISTOR SRSUNIT

ls the resistanceas YES

SRSMAIN HARNESS 18PCONNECTOR

FauflySRSunit; replacetho SRSunit l3ee page2+761'

att

Short to another wiro or decreasedresistancein the SFS main harness;replacethe SRSmain harne3s.

24-59

Troubleshooting DTC2-4- Without FrontPassenger's Airbag CAUTION: Whenever the ignition switch is ON 0l). or has been turned OFF for lsss lhan three minutes. be caretul not bump the SRS unit; the airbag could accidentally doploy and causodamageor iniuries. Try to r€produc€tho SRSindic.to. light: 1. Erasethe DTCmemory (seepage24,15). 2. Turnthe ignitionswitchON (ll),and checkthat the SRSindicatorlight comeson for aboutsix secondsand go€soff. Do€rthe SRS indicrtor light stay on?

rEs

NO

lntormitteit t ilur., iyst m b OK at thb tim6. Sle Trouble shooling Intdmitt.nt Frilu.os on pag6 2+lS.

Checkfor a short to power in the SRSmain h.rna3s: 1. Disconnectthe bafterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Dlsconnectthe driver's airbag 2p connectorfrom the cablereel2P connector(seepage24,11). 3. Dlsconnectthe SRS main harnessl8p connectortrom the SRSunit. 4. Beconnectthe battory positiv€ cable, then reconnectthe negativecable. 5. Connecta voltmeter between the No. lO (+) terminal of the SFS main hsrness18Pconnectorand qround. 6. Turn the ignition switch ON {ll), and me-asure voltage. Thereshouldbe 0.5V or less. 7. Connecta voltmeterbetweenthe No. 14 (+) terminalof the SRS main harness18Pconnoctorand ground,and measurevoltage.Thereshouldbe 0.5V or less. A.e voltage. .3 spocifi.d? YES

NO

F.ulty SRSuniC .epla"" tl,. SnS unn l""" p"g" 2+7O:_l

Short to pow.r in tha SRS mlin harnc$ or tho dummy r*istor; chocklor contact bctwcen th. dummy r6ai3to. rnd rnother wiro. lf there is no contrct, rcphcc the SRS msin hame3s.

24-60 I

SBS UNIT

SRSMAIN 18PCONNECTOR

)

Airbag DTC2-5- Without FrontPassenger's ol CAUTTON:Wheneverthe ignition switch is ON lll)' be minutes' three than for less has been turnsd OFF acci' careful not to bump the SBS unit; the airbag could iniuries' or damage Gause and deploY dentally Tru to .oproducethe SRSindic'tor light: 1 ErasetheDTCmemory{seepage24 15)' SRSindiz. irin tfie ignitions.itch ON (ll),and checkthat the goes otf and seconOs six for about on iatoi ligiricomes on7 stay light Doesthe SRSindic.tor | NO

YES

Troubl'tn---t",-in"m l"itrt", "v"tem is oK at thb lim' seo 3hooling Intormitt6nt Failureson pago 2+15' SRSUNIT

ffih",n"""'

I J

disconnect i. oi""onn""t ttte u"tt"ry negativecable'then the Dositivedable, and wait lor th ree mrnutes' {from the z. 6i"J-"""a tt'" driver's airbag 2P connector (see page 24_11)' 2P connector reel cable from s. b]""onn""t,f'" SFS main harness18Pconnector the SRSunit. betweenNo lo terminal of the sRS L di"lfi""i"on." connectorand ground and between 18P main harness iie t'lo.t a terminatof the SRSmain harn€ss18Pconnector and ground Thereshouldbe 1 Mo or more'

SRSMAIN HARNESS 18PCONNECTOR

I I btheresistanceasso444g14._ ._

YES

NO

-Faulty sRs unit;,epltcethe sRs unit (seepage2+761'

dummY 6lort to sround in tho sRS main harness or the i""i"toi; "-ft""* fot "ont.ct bdtwo€n the dumTI Iesbt9r.and h6i'

li"r"J.

n irt"t" is no contact.r6pl'co the sRs mtin

ness,

ott 24-61

Troubleshooting DTC8-6 CAUTION: Whonover the ignition switch is ON lll), or has been turned OFF for less than thro€ minutes, be careful not to bump th6 SRS unit; the airbags could accidentallydeploy and causedamage or iniuries. Besidesindicatingan abnormalityin the SRS unit, DTC 8-6 may also indicatethat two problemsequivalentto DTC1-l and 2-4, 1-4 and 2-1,ot 1-4and 2-4 occurredat the sametime. Proceedin the ordershown below. Checkth. SRSmain harn6$: 1. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes. 2. Disconnectthe driver's airbag (and front passenger,s airbag)connector(s){see page21-111. 3. Disconnectthe SRS main harness18Pconnectorfrom rhe sRS unit. 4. Reconnectthe battery positive cable, then reconnectthe negativecable. 5. Turnthe ignitionswitchON (ll). 6, Connecta voltmeterand measurevoltagebotweenthe No. 10 terminalof the SRSmain harness1BPconnector and ground,and betlveenthe No. l{ terminaland qround. Th6reshould be aoDrox.0 - 0.5 V. Aro voltages as spacified?

YES

SRS MAIN HARNESS 18PCONNECTOR

NO

Sho.t to power in tho SRS mrin hamoss; rsplace th6 SRS main haanac3.

\

Chacl the SRSmain hrrne*s and the cabl. reel: Connect a voltmeter and measure voltage between the No. 1 terminalof the SRS main harness18p connector a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d ground.Thereshouldbe approx.0 - 0.5V. Are voltageso3 specilied?

YES

NO

SRSunit; replacethe SRSunit lse6 page 2+76).

To page24-63(A)

o1 24-62

)

, Frompage24'62(A)

Checkthe cable reel: 1. Turnthe ignitionswitchOFF 2. Disconneitthe cable reel 2P connectorfrom the SRS maln harness, 3. Turnthe ignitionswitchON {ll} 4. Connecta voltmeterand measurevoltagebetweenthe No. 1 terminalof the SRS main harness18Pconnector a n d g r o u n d , a n d b e t w e e nt h e N o 1 3 t e r m i n a l a n d ground.Thereshouldbe approx.0 - 0.5V' Are vohtg6 as specifi"dT-

YES

NO

Short to powor in the cabto reel; replace thg cable rool (seepage 24'721. Short to powet in the SRS main h.rness; replace the SRS main harness.

I J

t, 24-63

Troubleshooting DTC9-2 CAUTION: Whenever the ignition switch is ON 0l), of has been turned OFF lor lass than three minutes, be carefulnot to bump the SRS unit; the airbag(s)could accidentallydeploy lnd caqsedamageor iniuries. Checkthe tu.c: 1. Turnthe ignitionswitchOFF. 2. Checkfor blown No. 23 (10 A) fuse in the under,dash fuse/relaybox.

(A)To page24-65 Replace the tuse.Turnthe ignitionswitchON lll) , and check that the fusedoesn'tblow.

Th6 problem hs3 disappe.rod,TGt-dJiv€ the vehicloand 3eeTroublerhootingIntermiftcnt Failuro3on paqo2l-15.

No. 23 lr0 Al FUSE

FUSE/RELAY BOX

! SRSMAIN HARNESS 18PCONNECTOR

SRS UN'T

Check tol short to ground betwe.n tho unde.-da3h fus./ r.ley box and the SRSunit. 1. Turnthe ignitionswitchOFF. 2. Disconnectthe bafterynegativecable,then disconnect the positivecable, and waittorthreeminutes. 3. Disconnectthe driver's (and front passenger,s) airbag (seepage24-11). connector(s) 4. Disconnectthe SRS main harness1gp connectorfrom the sRs unit. 5. Checkresistancebetweenthe No. 3 terminal of the SRS marnharness18Pconnectorand ground, Thereshouldbe 1 MO or more.

SRSMAIN HARNESS18PCONNECTOR FeuftySRSunh; rcphce the SRSunit lsee pag.2+761.

Otf To page24-65

24-64 I

) (B) from page 24-64

Checktor ahort to ground in the SRSmain harn$s: the SRSmain harness2P connectorfrom the 1. Disconnect box. fuse/relaY under-dash betweenthe No. 3 terminalof the SRS 2. Checkresistance main harness18Pconnectorand ground Thereshould be 1.0M0 or more. ls the re3istancea3 specified? -

YES Short to giound in tho undot-drlh lut'/rol'y replace the undel-da3h fusgtgEl!9l--------.-

NO

box;

Short to ground in tho SRS m.in harn$s; roplecothe SRS main harness.

BOX FUSE/BELAY

(AlFrom page24'64 Chcckfor an op€n in th6 SRSmain harness: 1. Turnthe ignitionswitchOFF. 2. Disconne;tthe batterynegativecable,then disconnect the positivecable,and wait for threeminutes' 3. Disconnecttho driver's (and front passenger's)airbag connector(seePage24'11). 4. Disconnectthe SRS main harness18Pconnectorfrom the SRSunit 5. Reconnectthe battery positive cable, then reconnectthe neoativecable. 6. Co-nnecta voltmeter betlveen the No 3 terminal ol the SFS main harness18Pconnectorand ground' switchON (ll),and m€asure 7. Turnthe

SRSMAIN HARNESS 18PCONNECTOR

Poor contact at the SRS main harnoss 18P connoctor; checklho connoctor. . ll the connector k OK, sub3titute r known'good SRS unh. and recheck . lf the problom is slill present, lepl.ce the SRS main

o0

To page 24-66

(cont'd)

24-65

Troubleshooting DTC9-2 (cont'dl Frompage24-65

Chocktor an open in th€ SRSmain hern€ss: 1. Turnthe ignitionswitchOFF. 2- Disconnect the SRSrnainharness2p connectorlrom the under-dash fuse/relay box. 3- Checkresistance betweenthe No. 2 terminalof the SRS main harness2P conneciorand No. 3 terminal of the SFS main harness18Pconnector_ Thereshouldbe 0 0.50

Poor contact at the SRS main ha.ness2p connector; checkthe connecto.. . lf the connectoris Ol(, sub3titute a known-good underdash tuse/r€laybox, and recheck. 'lt tho problem is still present,replecethe SRS main

SRSMAIN

Open in the SBS main harness;replacethe SRS main har_ ness,

SRSMAIN HARNESS 18PCONNECTOR

\

SRS MAIN HARNESS 2P CONNECTOR

o! 24-66 I

Airbag )

Replacement After a collisionin which the airbagswere deployed'the airbagassembliesand the SRSunit must be replaced'

Front Passengel'sSide: Disconnectthe 2P connectorbetweenthe front passenger'sairbagand SRSmain harness'

.

Store a removed airbag with the pad sur' !!!@ airbag is improperly stored face down' rr trt" iFup. with a c c i d e n t a ld e p l o y m e n t c o u l d p r o p e l t h e u n i t enough force to causeserious iniury'

NOTE:When disconnected,the airbagconnectoris shorted. FRONTPASSENGER'S automaticallY AIRBAG 2P CONNECTOR

CAUTION: . Always disconnsct lhe airbag conn€ctor(s)when the harnessis disconnected. . Do not disassembleor tamper with the ailbag' NOTE: . Do not installusedSRSpartsfrom anothervehicle' When repairing,useonly new SRSparts' Do o Carefullyinspectthe airbag beforeyou install it b e i ng o I s i g n s n o t i n s i a l la n a i r b a gt h a t s h o w s cracks dents' as such handled, droppedor improperly or deformation. 1.

Disconnectthe batterynegativecable'then disconnectthe positivecablefrom the battery'and wait at leastthree minutes

2.

the airbagconnector(s): Disconnect SRSMAIN HARNESS

Driver's Side: .

3.

Removethe accesspanel from the steeringwheel' drivthen disconneclthe 2P connectorbetlveenthe er's airbagand cablereel ls NOTE:When disconnected,the airbag connector shorted automaticallY

Bemovethe airbag(s):

Driver's Side: .

bit' then Removethe two Torx bolts usinga Torx T30 removethe driver'sairbag

ORIVER'S AIRBAG

oo

TORXBOLTS Use a Torx T30 bit DRIVEE'SAIRBAG 2P CONNECTOR

(cont'd)

24-67

Airbag (cont'd) Replacement Front Passenger'sSide:

CAUTION: B€ sure to inslall the SRSwiring so that it is not pinched or interforirg with other parts.

.

Removethe three mounting nuts from the bracket, then removethe harngssclip. . Liftthe front passenger's airbagout of the dashboard by coveringthe lid and dashboardwith a cloth, and prying carefullywith a flat-tip screwdflver.

4.

Installthenew airbag(s):

Driver's Side: Placethe driver,s airbag into the steering wheel,and secureit with new Torx botrs. TORXBOLTS 9.EN.m(1,0kgf.m,7.2tbtftl Replace.

NOTE: The lid of the airbag has pawls on its side which attachit to the dashboard.

DRIVER'SAIRBAG

Front Pass€ngar'sSide: . .

P l a c et h e f r o n t p a s s e n g e r , a s i r b a gi n t o t h e d a s h board. Tightenthe front passenger,s airbagmountingnuts.

ANAAG MOUNTINGNUTS 9.8 N.m 11.0kgf.m, 7.2lbf.frl Replace.

24-6a

) 5,

the airbagconnector(s)' Reconnect

Front Passengor'sSide: a Attachthe airbagconnectorto the connectorholder' then reinstalltheglovebox.

Driver's Side: a Connectthe driver'sairbag2P connectorto the cable reel2Pconnector,then installthe acc€sspanelon the steeringwheel

AIRBAG FRONTPASSENGER'S

DRIVER'SAIRBAG 2P CONNECTOR

6.

the Connect the battery positive cable, then connect

negativecable. 7.

After installingthe airbag,confirm Proper sYstem operatlon: . Turn the ignition switch ON (ll);the SRS indicat o r l i g h t s h o u l dcome on for about six seconds and then go off a Makesure both horn buttonswork

oo 24-69

Airbag Disposal Beforescrappingany airbags(includingthose in a whole vehicleto be scrapped), the airbagsmust be deployed.lf the vehicleis still within the warrantyperiod,beforeyou deploythe airbags,the HondaDistrictServiceManager must give approvaland/orspecialinstructions. Onlvafter the airbagshave beendeployed(as the resultof vehicle collision,for example),canthey be scrapped. lf the airbagsappear intact (not deployed).treat them with extremecaution. Followthis p.ocedure:

Front Passenger'sAirbag: 4.

Removethe glove box, then disconnectthe 2p connector between the lront passenger,sairbag and SRSmain harness. FRONT PASSENGER'S AIREAG 2PCONNECTOB

Deployingthe Airbags: In.vehiclo NOTE:lf an SRS vehicleis to be entirelyscrapped,its airbagsshouldbe deployedwhile still in the vehicle.The airbagsshould not be consideredas salvageableparts and shouldneverbe installedin anotherveh;cle. c o n f i r m t h s t o a c h a i r b a g a s s e m b t yi s !@ securelymounted; otharwiso. sev€re personal iniury could result lrom deployment. 1.

Disconnectthe bafterynegativecable,then discon_ nectthe positivecable.

2.

Confirmthat the specialtool is functioningproperly by followingthe checkprocedureon the tool label or on page 24-'l'l.

SRSMAINHARNESS Cut off the airbag connector,strip the ends of the airbagwires,and connectthe deploymenttool alli_ gator clips to the airbag.placethe deploymenttool at leastthirty feet (10 meters)awayfrom the airbag.

Driver's Airbag: 3.

DRIVER'S AIRBAG

a !

FRONTPASSENGER'S AIRBAG

Removethe accesspanel,then disconnectthe 2p connectorbetweenthe driver,sairbagand the cable reet. DRIVER'S AIRBAG 2P CONNECTOR

ALLIGA CLIPS (Yellow) ALLIGATOR CLIPS {Yellowl

At loast thiny toet (10 metorsl

BATTERY

24-70

. U

E)

I Doployingth6 Airbag: Out-of-vehicle

Connecta 12 volt batteryto the tool: .

.

7.

lf the green light on the tool comes on, the aarbag ignitercircuitis defectiveand cannotdeploy t h e a i r b a g .G o t o D a m a g e dA i r b a g S p e c i a l Procedure. lf the red light on the tool comeson, the airbagis readyto be deployed.

N O T E :l f a n i n t a c t a i r b a g h a s b e e n r e m o v e df r o m a scrappedvehicle.or has been found defectiveor dama g e d d u r i n g t r a n s i t ,s t o r a g eo r s e r v i c e ,i t s h o u l d b e deployedas follows: Po3ition the airbag laca up, outdoors on @ flat ground at lsast thirty f€€t (t0 ml from any obstacles or people.

P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h e a i r b a g should deploY(deploymentis both highly audible and visible;a loud noise and rapid inflationof the bag,followedby slow deflation). lf the airbagsdeploy and the green light on the tool comeson. continuewith this procedure. . l{ an airbag doesn't deploy,yet the green light comes ON, its igniter is defective.Go to DamagedAirbagSpecialProcedure.

.

During doployment, the airbag sssom' !!@ bly can become hot enough to buln you. Wait thir' ty minutes aftsr deployment belore touching tho assembly. Disposeof the completeairbag assembly.No part of it can be reused.Placeit in a sturdy plasticbag, and sealit securelY,

1.

Confirmthat the specialtool is tunctioningproperly by followingthe checkprocedureon this pageor on the tool label.

2.

Follow steps5, 6, 7, and I of the in-vehicledeploymenl Drocequre.

DamagedAirbag SpacialProcedure CAUTION: . Wear a fsce shield and gloves when handling a deployed airbag. . Wash your handsand rinse them well with wat6r after handling. deployedairbag.

r an airb.g cannot be deployed, it should !@ iiiTi-treatcd as normal scrap; il should still be considsrsd a potontially oxplosive device that can cau3o sstious iniury. 1.

lf installedin a vehicle,lollow the removal procedure on page24-67.

2.

In all cases.makea shortcircuitby twistingtogether the two airbaginflatorwires.

AIRAAG

Packagethe airbag in exactlythe same packaging part camein. that the new replacement " D A M A G E DA I R B A G 4 . M a r k t h e o u t s i d eo f t h e b o x get confusedwith not it does so NOT DEPLOYED" your Partsstock. 5. Contactyour Honda District ServiceManager for how and whereto returnit for disposal.

3.

DeploymentTool: CheckProcedur€

t('

1.

Connectthe yellow clips to both switch protector handleson the tool; connectthe tool to a battery.

2.

Pushthe operationswitch:green meansthe tool is OK: red meansthe tool is faulty

3.

the batteryand the yellowclips. Disconnect

24-71

GableReel Replacement store a .emove airbag assambly with the !@@ pad surtace up. lf the airbag is improperly stored face down, accidentaldeploymont could propel the unit with enough force to causesorious iniury.

Makesurethe wheelsare alignedstraightahead. 4.

Removethe driver'sdashboardlowercover. TORXEOLTS Use a Torx T30 bit.

CAUTION: . Alwsys disconnectthe airbag connoctor(s)when ih€ harnessis disconngcted. . Do not disassembleor tamper with the airbag. N O T E :C a r e f u l l yi n s p e c tt h e a i r b a ga s s e m b l yb e f o r e installingit. Do not installan airbagthat shows signsof being dropped or improperly handled.such as dents, cracksor deformation. l.

Disconnectthe batterynegativecable.then disconnectthe positivecablefrom the battery,and wait at leastthree minutes. Removethe accesspanelfrom the steeringwheel, then disconnectthe 2P connectorbetweenthe driver's airbagand cablereel. NOTE:When disconnected, the airbagconnectoris automaticallyshorted. DRIVER'S AIRBAG

DRIVEB'S DASHBOARD LOWERCOVER

5.

Removethe two Torx bolts from the steering wheel, and disconnectthe horn connector.Then remove the driver'sairbag.

\

or 24-72 )

\

the connectorsfrom the horn and cruise Disconnect controlsevresumeswitches,then removethe steering wheel nut.

6.

8. Removethe columncovers.

CONTROL CRUISE SET/RESUME SWITCHCONNECTOR

STEERING NUT

HORNCONNECTOR

CABLEREEL 2P CONNECYOR

) 7.

Remove the steerlng wheel using a steering wheel pulrer.

Disconnectthe 3P connector betweenthe main wire 8nd the 2P conharnessand cablereelsub-harness, nectorbetweenthe cablereel and SRSmain harness' CABLEREEL

CONNECTOR HOLOER

WHEELPULLEF STEERING {Commerciallv_available)

) U

SRSMAIN HARNESS 2P CONNECTON

CABLEREELSUB HARNESS 3P CONNECTOR

10. Removethe cablereelfrom the column

{cont'd}

24,73 --/

CableReel Replacement(cont'd) NOTE: . B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,t h e f r o n t wheelsshouldbe alignedstraightahead. . Be sure to installthe harnesswires so that they are not pinchedor interferingwith other parts. . A f t e r r e a s s e m b l yc.o n f i r mt h a t t h e w h e e l sa r e still turned straightaheadand that the steering wheel spokeangle is correct(roadtest).lf minor spokeangleadjustmentis necessary, do so only by adjustingthe tie-rods,not by removing and repositioning the steeringwheel. 1 1 . S e t t h e c a n c e ls l e e v es o t h a t t h e p r o j e c t i o n sa r e a l i g n e dv e n i c a l l y .

Installthe steeringcolumncovers. 1 4 . lf necessary,centerthe cable reel. {New replacement

cablereelscome centered.)Do this by first rotatingthe cable reel clockwiseuntil it stops.Then rotatett coun (approximately terclockwise two and a halfturns)until the arrow markon the cablereellabelpointsstraight up.

ARROWMARK

PROJECTIONS

12. Carefullyinstallthe cable reel on the steeringcol umn shaft. Then connectthe 3p connectorto the cablereel sub-harness, and connectthe 2p connector to the SRSmain harness.

. 24-74

15. lnstall the sleering wheel, then connect the horn conneclor and cruise control sevresume switch con neclor. CRUISECONTROL STEERING WHEEL SET/RESUM€

16. Installthe steeringwheel nut, and connectthe horn c o n n e c t o tr o t h e s t e e r i n gw h e e l .T h e n i n s t a l lt h e driver'sairbag. TORXSOLTS 9.8N m 11.0kgf m, 7.2lbtftl Replace. Use a Torx T30 bit.

18. Reconnectthe driver's airbag 2P connectorto the c a b l e r e e l 2 P c o n n e c t o ra. n d r e i n s t a l tl h e a c c e s s panelon the steeringwheel. 19. Reconnect the batterypositivecable,then the negative cable.

DRIVEB'S AIRBAG

20. After installingthe cable reel,confirm propersystem operation: Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds and then go off. a Makesureboth horn buttonswork. 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 , n d m a k es u r et h ec r u i s ec o n G o f o r a t e s td r i v e a trol switcheswork.

WHEELNUT STEERING 50 N.m 15.0kgf.m,36lblft) Replace.

I

DRIVER'S 2P CONNECTOB

HORNCONNECTOB

1 7 . Attachthe cablereel2Pand 3P connectorto the conn e c t o rh o l d e r .T h e n i n s t a l lt h e d r i v e r ' sd a s h b o a r d lowercover.

)U

DRIVER'SDASHBOARDLOWERCOVER

24-75

SRSUnit Replacement CAUTION: . Betore disconnoqtinglny pErt of the SRS wire halness,disconnectth9 airbag conn"ctorlsl. . During installltion or teplacemsnt. do not bump (impact w.cnch, hamm€r stc.l the area noar tho SRS unit.

3.

Removethe right sidecoverfrom the SRSunit.

SRS UNTT

NOTE: o Do not damagethe SRSunit terminalsor connectors. . Do not disassemblethe SRS unit; it has no serviceableparts, . Storethe SRSunit in a clean,dry a.ea, . Do not use any SRSunit which has be€nsubjectedto water or showssignsof beingdroppedor improperly handled.such8s dents,cracksor deformation. 1.

Disconnectthe bstterynegativecable.then disconnectthe positivecablefrom the battery,and wait at leastthree minutes.

2.

Disconnect the airbagconnector{s}:

TOBX BOLTS Ugea Torx T30bit.

NOTE:When disconnected, the airbagconnectoris automatically shorted,

RIGHTSIOE

COVER

Driver's Side: . Removethe accesspanel from the steeringwheel. then disconnectthe 2P connectorbetweenthe driv_ er's airbagand cablereel(seepage24-11).

Removethe left side cover from the SRSunit, then d i s c o n n e ctth e S R S m a i n h a r n e s sl g p c o n n e c t o r from the SBS unit.

Front Passenge/sSide: . Disconnectthe 2P connectorbetweenthe tront oas_ senger'sairbagand SRSmain harness(seepage 2411).

SRSUNIT

5.

24-76

Removethe four Torx boltsfrom the SRSunit,then pull out the SRSunit from the driver,sside,

o\

6.

Installthe new SRSunit. N O T E : D o n o t r e u s ea t o r x b o l t t h a t h a s r e d threads.Replacethe bolt with a new one.

9 . Reconnectthe driver's aibag 2P connectorto the c a b l e r e e l 2 P c o n n e c t o rt,h e n r e i n s t a ltl h e a c c e s s panelon the steeringwheel. 1 0 . Reconnectthe tront passenger'sairbag connector to the SRSmain harness. 1 1 . Reconnect the batterypositivecable,then the nega tive cable.

' t 2 . After installingthe SRSunit,confirmpropersystem operation:Turn the ignitionswitchON (ll);the SRS indicatorlight shouldcome on for aboutsix seconds andthen go oif.

TORXBOLTS 9.8 N.m 11.0kgf.m, 7.2 lbf.ft) U3e . Torx T30 bit. SRSMAIN HARNESS

)

TORXBOLTS 9.8N.ml'1.0kg{.m,7.2lbf.ft} Usea TorxT30bit. 7.

Connectthe SRSmain harnessl8P connectorto the SRSuniu push it into posjtionuntil it clicks.

8.

I n s t a l lt h e S R S u n i t c o v e r s( r i 9 h t a n d l e f t ) .M a k e surethe coverssnaptogetherin the middle.

)(l 24-77 .-

Contents Howto UseThisManual I (seeCircuitIndex) CircuitSchematics Fuse/Relaylnformation 6 Ground-to-Componentslndex 6-6 ComponentLocationPhotooraohs 201 Conriector Views 202

CircuitIndex Accessorypowersocket 155 Airconditioner Air delivery '96198 61 '99-'00models models 61-2 Blower controls '96198 60 '99100models models 60-1 Compressor controls 62 Fans 63 Anti-lockbrakesystem(ABS) 44 A/Tgearpositionindicator CVT 89 All exceptCVT 89-1 Automatic transmission controls All '96-'98modelsexceptCVTandGX 39 '99100 All modelsexceptCVT 39-8 All GX models 39-8 '96-'98CVT 39-4 '99100cw 39-12 Back-uplights CoupeandSedan 110 Hatchbackl'10-1 Brakelights All Coupesand'96-'98 Sedans 110-15 '99-'00 Sedans 110-16 Hatchback110-17 Brake systemindicatorlight '96198 7'1 '99100models models 71-1 Ceilinglight 114-3 Chargingsystem 22 fan 63 Condenser Console lights 114 Cruisecontrol 34 Dashlights 114 Daytime running lights 110-13 gauge 81-1 Enginecoolant temperature Foglights 110-10 Frontparkinglights 110-2 Fuelgauge 81-1 Fuse/relay box Under-dash 6 Under-hood 6-4 Underhood ABS 6-3 Gauges 81 Grounddistribution14 Ground-to-Componentslndex 6-6 Hazardwarning lights '99100 All except Sedans 110-6 '99100 Sedans 110-8 Headlights110-12 Headlightswitch 100 Heater- SeeAirConditioner Horn '96197models 40 '98model 40-1 '99100models 40-2 lgnition keyreminder 73 lgnition system '96198 All'99100modelsexceptDl685 20 All modelsexceptD16Y5withMn 2O-2 All D1685engines 20-2 '99-'00 D 16Y5withM/T 20

lndicators 80 Integrated controlunit 70 lnterlocksystem All CVT 138 ' 9 6except'96J98 1 9 8 C V T1 3 8 -1 platelights License '96-'98 All Coupesand Sedans I l0-3 '99100 Sedans 110-4 Hatchback110-5 Lowfuelindicator light 74 Moonrool '96197models |22 '98-'00models 122-1 Odometer 81 indicator light 80-3 Oilpressure Powerdistribution Batteryto ignitionswitch,fuses,andrelays 1 0 Fusesto relaysandcomponents10-2 Powerdoorlocks modelswithoutkeyless All entry 130 '96-'98 modelswithkeyless entry 130-2 '99100modelswithkeyless entry 130-12 Powermirrors Without detogger 141 Withdefogger '141-2 Powerwindows 120 Programmed fuelinjection system(PGNr-Fl) All'96-98 models except D1685 23 All'99-'00modelsexceptD16Y5 withM/TandD1685 24 All D1685engines 25 '99100 D16Y5withM/T 23 Radiatorfan 63 Rear windowdefogger '96-,98 64 '99100models models 64-1 Seatbeltreminder 73 system Security '96.'98 USAHX,LX,EX 133 '96-'98Canada EX,Si 133 '99TOO HX,LX,EX,DX.VSi 133-4 '99100USA CanadaEX,Si 133-4 AllCX andDX models 133-8 Speedometer81 Startingsystem A./T(AllexceptDl685) 21 A"/r(D16Bs) 21-1 Manualtransmission 21-2 Slereosoundsystem 150 rastraintsystem(SRS) 47 Supplemental Tachometer 81 Tailliqhts Sedans 110-3 Allboupes and'96-'98 '99100Sedans 110-4 Hatchback110-5 Trunklight 114-3 Turnsignallights All except'99100 Sedans 110-6 '99-'00 Sedans 110-8 Vehiclespeedsensor(VSS) 33 Wiper/washer Front 91 Rear 92

HowToUseThisManual The nextfew pagesdescribehowthismanualis organized. Theyalso explainwhatkindof information the manualcontains, whatthat problems. informalion means,andhowto useit to troubleshoot electrical Circuitschematics breakthe entireelectrical systemintoindividual systems,likethe LowFuellndicator Lighton the nelitpage. Onlyelectrical components thatworktogetherareshowntogether, so you won'tbe distractedby unrelatedwires. Explanations of the abbreviations and svmbolsusedin the schematics beginon page[Fl. You'llneedto knowwhattheymeanbeforeyou canuse a schematiceffectively.

HowToUseThisManual

oa

CircuitSchematics Eachschematic represents onecircult.A circuit'swiresandcomponents arearranged to showcurrentflow,frompowerat the top of the page,to ground,at the bottom. SharedCircuits Othercircuitsmaysharepoweror ground terminals or wiringwiththe circuitshown.A wirethatconnectsonecircuitto another,for example,is cut shortand hasan arrowhead at the endof it pointingin the directionof currentflow.Nelitto the anowheadis the nameo{ thecircuilor comoonent which sharesthatwiring.Toquicklycheckshared wiring,checkthe operation of a component it works,you know serves.lf thatcomponent the sharedwiringis OK.

"HOT"labeltells you when the ignitionswitchsupplies powerto the fuse. \

UNDER. DASH FUSE/ SeePowerDistribution, . RELAY i t I BOX I t----t oaqetO-3. L*--:--------J 2 Y C723 Junctionconnectorhasone ol morebus bars in it; eachconnactg YELI Pao'o'8 - "" to two or morewire terminala. I

i t

. a

l l u " :^: , { l

,

c725 vlEUt/75

-> ? t SeePower Distribution, page10-3.

SoeIndicators I ASSEMBLY LOWFUEL INDICATOF LIGHT r-l :-------J

Symbols A completedescription of schematic symbolsbeginson page| 8

Brokenwiremeans

EI

A

"'"'I L?*?l?,-

Splice ---------)

i

/

Artowheadmeans wire connectsto anothercircuit; it ooints in direction of currentflow.

Connectors All in-lineandfuseboxconnectors are (C725,C416,etc.). numbered t _ connectors arenotnumbered Component I by the nameof the butareidentiJied component. lf a componenl hasmorethan eachconnector is assigned oneconnector, a letter(A,B, C, etc.).Belowmostconnector L --Cavity number; -----> numbers namesare ' andcomDonent Jiili'iJi!--' PHOTOandVIEWnumbers. ThePHOTO shoin on pageS . numberrefersto a Dhotoin the backof the bookthatshowslhe conneclor'slocationon thecar.TheVIEWnumberrefersto an 7 Male illustration in the backof the bookthat GBN/FEO terminal showstheconnector face,wirecolors, cavitynumbers, andotherdetails. connector Theconnector cavitynumbering sequence TheImletor beginsat the top leftcorneroJthe connector as seenfromeitherof theviewooints shown on pageffl . Disregard anynumbers moldedintotheconnector housino. Wires Wiresare identilied by the abbreviated namesof theircolors;the secondcolorrsthe colorof the stripe.Wiresarealsoidentified by theirlocationin a connector. The number'2" nextto the maleandfemalewireterminalsat meansthoseterminals C416,for example, join in cavity2 of connector C416.

Arrowwith note rErng othercircuilsconnccth€re.

Connectornumber; indexbeginson page203.

"o'r"/

PHOTO 52 <-

\ FUEL TANK UNIT

O rr
Numberot photo in backol book showingcomponent locationon cat. Numberof conneclorview in backof book

SeeGround Distribution, Page14'4'

--^ -----i iar";J.'It,;,rJ;ii;Bffi,Bili*l 0a0etn-a elsewhere.

cround --->lL

I I BrK I :

c301

ptioro 21

PowerDistributionSchematics PowerDistribution schematics showhowpoweris suppliedfromthe positivebatteryterminalto variouscircuitsin thecar.Referto the PowerDistribution sectionto geta moredetailedpicture of howpoweris suppliedto thecircuityou'reworkingon.

FromBatteryto lgnitionSwitch,Fuses,andRelays Individual circuitschematics beginwitha fuse.Thefirsthalfof PowerDistribution, however, "upstream" showsthewiring betweenthe batteryandthefuses. i BATTERY CYLINDER BLOCK

t t

I

II

L.lt

I -

J

l l

",-*f ]fo,o

i.Jr;-t

I| t ! -

STARTER Pase21

!

t FUSE31

I

f

iL_i***'" i

*

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I

ilr------

L-------J

!

r ----------------Y-?-

l

r

qrI' FUSE rusesoI ruseasI rusega| ' ,s. ,aI =u.- srl ruse FUSE/I4 aai ruse47 ruse5{' soI' ruse FUSE51' sri ruse FUSE52 ' FUSE ia powEF \ powrn

Bc, \F,.n .;,cren \ ooon \coounc \ cor,r. \sun noor\ \tcsw \ FUsE w'NDowf50a t3f*f5# {* .i1-;.*"1liT""fi3f* fffi'*"f'* fS?'* f5# fffi*" f'* fs?'* OOOB

T101

4

34 GAN

ALK

f102

l l

l l

ALTERNATOR Page22

\COOLING

"";%,, Y rtr,'.9l' -%,t",, vtEw47 I w-

\SUN

BOOF \ FOWER

SeePowerDastribution, pages10'10 10,10and and10-11.

! vH-,alr.lt -

' I ---il 9,1?t.urr, 'rrr., i I l--4F--?-

a

I

r(op-B)

FUSE5

t i!?'.,,?"" t::=. A/C CLUICH (FNHEATED SEAD 204

.{Noru3€d) J$ifl#ii

FUSE6

ECU

204 Jtocl

-I l ty::.1----.- Ii FUSE8

DF POWEF SEAT

204 }3fo**."".o'

t-L- - -L- - -:rJ:e'-- -Ei s+s-r -.Fl-J-Jrr.-. C901 C921 {Not PHorozz OPTION Used) v/EW22 CONNECTOB

page10-2. SeePowerDistnbution,

YEL

c330

7

c901 vlEw22

't PowER

I uon-I Wlt{DOW i. racrsit RELAY P^da 1t L-J P;dr1ii-

a

CON.

- - -L - - -. ... Ji - -.J.- - -e-- -l. - - -La - J- - - I - - -

1

i-f, r--

\

FUSE4 FADIO 104

FUSE3

FUSE12

CONOENSEFFAN RELAY COOLING FAN RELAY

FUSE19

(BUltNrrG LIGHT)

R/C MIRROF

I I I \ \

ToFuses17,18,21, and24,for details, seePowerWindows page120.

I I I

See Power Distribution,pages 10-4and 10-5.

HowToUseThisManual

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PowerDistributionSchematics(cont'd) FromFusesto Relaysand Components showsthewiring"FromFusesto Relaysand Thesecondhalfof PowerDistribution by showingwhichcircuitsshareluses.lf Thiscanspeedyourtroubleshooting Components." circuitandanothercircuitsharea fuse,checka showsthalan inoperative PowerDistribution to you knowthefuseis goodandpoweris available lf it works, the other circuit. in component circuit. the inoDerative

I

i *. to

i ru..'.'

l *

\

){nuo$rouc}rr)

}g*"""'

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I

UNDER. DASH FUSE/ RELAY BOX

I tusttt

tt

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I ,

'f,"c;93,.:

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lv'Ew6o !

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l--J POWER SEAT CONTROL UNIT Paoe143-2 PHdro t2. wEw110

t t

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ALTENNATOR Paoe22 PHdro 29

l t

l l

L------J STEREOAMPLIFIER Paoe150-3 PHdfo 1s3 vtEw 106

(cont'd)

GroundDistribution Schematics ThissampleGroundDistribution schematic showsall of the components thatsharetwo groundpoints.

TCS FRONT RIGHT CONTROL PASSENGER'SREARDOOR FRONT UNIT PASSENGER'SSEATBELT ASHTRAY Page35 SEATHEATER SWITCH LIGHT Page145 Page147 P a g e1 1 4

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HowToUseThisManual ComponentLocations or connector is locatedon thecar,lookup itsphotonumberin the To seewherea component Location sectionin the backof the book.The photowillalsotellyouthecolorof Component the connector, andhowmanycavitiesit has.

I I 3

r -

|

1 GAUGE

r - 1 cRUtsE

! !fi':* a

| I_S-9_EIBLY

l t ' ' " " '

r I

To see where connectorsand parts are located,look up their photos in the Component Locationsection. 1 POWERTRAIN UNrr I CONTROL

i[i9#r,

ground,or nameor a connector, lf thereis no photonumberbelowor besidea component Indexthatbegins terminalnumber,lookup thatnameor numberin the Connector-to-Harness has,whereit'slocated, andwhat on page203.Thechartlistshowmanycavitiesa connector harness, andthe the location on the to. The related illustration shows connector's it connects harnessrouting. and Wke HarnessRouling Connactorldontlticallon Drlvors Sea!wne Harn€ss

Lefts'd.Hrc hatu$ 1c2611 Lofts'd. src hamass1c262) F6ar up.dow^n.morykisor

l DFIVEF'S POWER SEATWIAE HAFNESS

It a connectoron a schematichas no photonumber,look it up in the Connector ldentilicationchart and relatedillustration.

203

E

c712 c7t6 \ c702 c701

203.1

oo

ConnectorViews cavities,lookup itsviewnumberin the Connector of a connector's Toseethe configuration whereit Viewsectionin the backof the book.Eachviewincludesthecolorof the connector, to. is located,andwhatit connects Viewsto helplocatethe propercavitywhenyou needto probea Usethe Connector hasmorethanonewireof the same helpfulif theconnector lt canbe especially connector. cotor. circuits in separate viewscanalsobe usedto helpdiagnosemultiplesymptoms Connector sharedby thosecircuits.Here's whichcouldbe causedby a singleproblemin a connector how: for thatcircuit. and lookup the schematic 1. Pickoneof the multiplesymptoms (includepage in thatschematic 2. Makea listof allthe in-lineandfuseboxconnectors numbers). on yourlistto seeil circuits Viewsection,lookup eachconnector 3. Then,in the Connector lf they do, inspectthatconnector runthroughoneof them. relatedto the othersymptoms for the oroblem. wiperdon'twork.Listall andthewindshield Theblower,rearwindowdefogger, Example: in the blowercontrolscircuitandthencheckthe Connector in-lineandfuseboxconnectors (sample findthatC324is commonto the rearwindowdefogger below). You Viewsection circuit,so you inspectC324andfindthe problem,bentterminals. circuitandwiper/washer

ConnectorViews (cont'd) 21. C324 Brown Behindleftkickpanel - Connectsleftenginecompartry'ent wireharnessto mainwireharness

ll,ll, 5 1 . WHT(Blowercontrols) 2 . YEUBLU(Rearwindow

defogger) (Starting) BLK,ryVHT BLU/YEL (Wiper/washe0

6

7 5 . 8LU (Wiper/washed 6 . BLfiEL (lgnition) (ABS) 7 . WHT/BLU

HowToUseThisManual Symbols Wire Color Abbreviations The followingabbreviationsare used to identifywire colorsin the circuitschematics: BLK.... BLU.... BRN.... GRN.... GRY.... L T B L U. LTGRN. ORN.... P N K. . . . P U R. . . . R E D. . . . WHT... Y E L. . . .

.........b|ack . . . . . . . . b. l u e ,......b . rown . . . . . . . .g r e e n . . . . . . , . .g r a y .....lightbtue ....lightgreen . . . . . . .o r a n g e . . . . . . . , .p. i n k . . . . . . . .p u r p l e . . . . . . . . . .r e d .........white . . . . . . . .y e l l o w

A brokenlinemeansthispartof thecircuit is notshown;referto the circuitlistedfor the complete schematic.

oo

"ral

-.1

SeeGround Distribution, page141.

o

I

Whereseparatewires join,onlythespliceis shown;for detailson theadditional wiring, referto thecircuits listed.

G101

UNDEROASH FUSE/ RELAY BOX

ili::i

Wires A wavylineat the endof a wiremeanslhe wireis brokenby the bindingof the bookor by a "choice" bracketbutcontinues on the nextpage.

8LK

Cruise Control, € aaa Indrcalors Gauges,

a.

! YEUsLK T

tl

Wirechoicesfor optionsor different modelsarelabeled andshownwitha "choice" bracketlikethis.

Wireinsulation can be onecolor,or onecolor withanothercolorstripe. (Thesecondcoloris thestripe.) Thiscircuitcontinues on page. (The another arrow showsdirection o{ current flow.)Totollowthe RED/ BLKwirein thisexample, youwouldturnto page23-5 andlookfor the "2"anow.

{[

+##l:i""l

Manual lransmission

ryil;::,

Thismeansthe branchof the wireconnects to another circuit.ThearrowDointsto the nameof the circuitbranch wherethewirecontinues.

""^l Nameof Circuit

""' .""1"""1".'0 Thisbrokenlinemeans bothterminals arein connector C134.

I

:-l

- "C" Connectors The cavities(and wire terminals)in each connectorare numberedstarting from the trom upperleft,lookingat the maleterminals the terminalside (or lookingat the female f romthewireside.Bothviewsarein lerminals the same directionso the numbersare the even same.)All actualcavitiesarenumbered, in them. if theyhaveno wireterminals WlreSlde ot

TerminalSlde ol MaleTsrminals

Femalg Trrmlnala

Thissymbolrepresents onebusinsidethecaoof a A \ iunctionconnector. connectorcap lr"ctb. \ containsseveralbuses,but \

that onlytheoneaffecting The ciriuitwillbeshown.

| A

c103

--f f

!!*!"*F"#fi5';,H I wiresto Remaining the samebusare represented by a brokenline.

SeeGauges

t t

l l

Splices

The connectorcavitynumberis listednextto The eachterminalon the circuitschematic. shownbelowis #6. cavity/terminal Cavlty/ Termlnsl6

Solicesareshownas a dot.Theirlocation andthe numberof wiresmayvary on the harnessmanufacturer. depending

*-I I ",.-"* *"1 *-l*-l*-l*"1 *-l a---a---a--- a--- o

-a

Components A solidborderlinemeansthe is shown. entirecomponent

t_J

Terminal

Thismeanstheconnector connectsdirectlyto the componenr.

{

T

_A

Thismeanstheconnector to a lead(pigtail) connects wireddirectlyto the component.

A brokenborderlineindicales l thatonlypartof the component l is shown. Thenameof the componentappearsnext to its upperrightcorner followedby notesabout itsfunction.

l l

BRAXE

swtTcH

Closed wilh pedaldepressed.

HowToUseThisManual

oo

Symbols "G" Ground -

Switches

Thissymbolmeansthe endol the wireis attached(grounded) to thecarframeor to a metal \ partconnected to theframe. \i

Theseswitchesmove together; the brokenstraight linebetweenthemmeansthe, are mechanically connected.

ffi

Othertypesof switches are controlled by a coilor a solid statecircuit.Unlessotherwise noted.all switches areshown (rest) position, in theirnormal with poweroff.

ffi

I I oro,|

-t'

Eachwireground(G)it --/ for reference. numbered Thisgroundsymbol(dot the and3 lines)overlapping meansthe housing component is grounded of the component to the carframeor to a metal partconnected to theframe. Thissymbolrepresents the bus insidea ground connector. Thedots I

Solid-state

;"r"LI I I i:l*,':1,'^:*,:"

connectto. terminals Thegroundsymbol(largedot) is theconnection betweenthe part busandmetal(grounded) of the car.

- "T" Terminals Each"T"lerminal(ringtype) for reference is numbered and location. A "T"terminalis securedwitha screwor bolt. Shielding

Thisrepresents RFI (RadioFrequency Interference) shielding arounda wire.The is always shielding to ground. connected

Fuses Thismeanspoweris supplied whentheignition switchis in ON (ll).

\t,,,, T

Currentrating

Diodes A rectifier diodeworkslikea one wayvalve.lt allowscurrentto llowonlyin thedirection of the arrow.

f--l;j-i",.. I

A Zenerdiodeblocksreverse justlike currentat normalvoltages a rectifier diode.At highvoltages. however, a Zenerdiodeallows currentto flowin reverse

oo

Troubleshooting Five-Step L VerifyThe Complaint in the problem Turnon allthecomponents circuillo checktheaccuracyof the customer Do notbegin Notethe symptoms. complaint. or testinguntilyou have disassembly narrowed downthe problemarea. 2. AnalyzeThe Schematic for the problem Lookup theschematic howthecircuitis circuit.Determine to workby tracingthe current supposed pathslromthe powersourcethroughthe to ground.Also,trace circuitcomponents circuitsthatsharewiringwiththe problem circuit.The namesof circuitsthatsharethe samefuse,ground,or switch,andso on,are referredto in eachcircuitschematic.Try to operateanysharedcircuitsyou didn'tcheck in step1. lt the sharedcircuitswork,the sharedwiringis OK,andthe causemustbe in thewiringusedonlyby the problem circuit.lf severalcircuitsfailat the same time,thefuseor groundis a likelycause. andyour Basedon thesymptoms of the circuit'soperation, understanding identifyoneor morepossiblecauses. 3. lsolateThe ProblemBy TestingThe Circuit Makecircuitteststo checkthe diagnosis you madein step2. Keepin mindthata is the keyto logical,simpleprocedure Test efficient troubleshooting. for the most likelycauseof failurefirst.Tryto maketests at pointsthatareeasilyaccessible.

TestEquipment devices. Mostcircuitsincludesolid-state Testthevoltagesin thesecircuitsonlywith or higherimpedance digital a 1o-megaohm mUltimeter. Neverusea test lightor analog meteron circuitsthatcontainsolid-state to the devicesmayresult. devices.Damage Test Light and DVOM devices,usea On circuitswithoutsolid-state A testlightto checkfor voltage. testlightis madeup of a 12voltbulbwitha pairof leads one lead,touchthe Aftergrounding attached. otherleadto variouspointsalongthecircuit wherevoltageshouldbe present.The bulb willgo on if thereis voltageat the pointbeing tested.lf you needto knowhowmuch voltageis present,usea digital (DVOM). volVohmmeter Self-PoweredTest Light and DVOM testlightto checkfor Usea self-powered is Thistool madeup of a lightbulb, continuity. battery,and tlvo leads.To test it, touchthe the lightshouldgo on. leadstogether: testlightonlyon an Usea self-powered the circuit.First,disconnect unoowered battery,or removethe fusethat feedsthe circuityou areworkingon. Selecttwo points in the circuitbelweenwhichyouwantto Conneclone leadof the checkcontinuity. testlightto eachpoint.lf there self-powered the testlight'scircuitwillbe is continuity, andthe lightwillgo on. completed,

4. Fix The Problem Oncethe specificproblemis identified, makethe repair.Be sureto usepropertools andsafeprocedures. 5. MakeSureThe CircuitWorks in the repaired Turnon all components circuitin all modesto makesureyou've fixedthe entireproblem.ll the problemwas a blownfuse,be sureto testall of the circuitson thatfuse.Makesureno new problems turnup andtheoriginalproblem not recur. does

TESTLIGHT SELF-POWERED

lf, in addition,you need lo know exacW hc'. much resistancethere is betweentwo oo'^= (DVOM) use a digitalvolUohmmeter

acdrt'Cn

t1

HowToUseThisManual TestEquipment(cont'd) In the"OHMS"range,the DVOMwillmeasure resistancebetweentwo pointsalonga circuit. Lowresistancemeansgoodcontinuity. Diodesand solid-statedevicesin a circuitcan makea DVOMgivea falsereading. Tocheck a reading,reversethe leads,andtakea secondreading.lf the readingsdiffer,the componentis affectinglhe measurement. JumperWire Usea jumperwireto bypassan opencircuit. A iumperwireis madeup ot an in-linefuse holderconnectedto a set of test leads.lt shouldhavea five amoerefuse.Never connecta jumperwireacrossa shortcircuit. Thedirectbatteryshortwillblowthefuse.

Troubleshooting Precautions BeforeTroubleshooting

oa

1. Checkthe mainfuseandthefusebox. 2. Checkthe batteryfor damage,stateof charge,andcleanandtightconnections. CAUTION: . Donot quick-charge a batteryunlers the batterygroundcablehasbeen disconnected, or you will damagethe alternatordiodes. . Do not attemptto cranktheenginewlth the groundcabledisconnected or you will severelydamagethewiring. WhileYou'reWorking 1. Makesureconnectors areclean,andhave no looseterminals or receptacles. 2. Makesurelhatconnectors withoutwire (silicone) sealsarepackedwithdielectric grease.PartNumber:08798-9001 . Packwllh dlelectrlc(sillcons)greass

Short Finder (Short Circuit Locater) Shortfindersare availableto localeshortsto ground.Theshorttindercreatesa pulsing magnetic fieldin the shortedcircuitwhlchyou can followto the locationof the short.lts use is explained on page15. pushit untilit Whenconnecting a connector, "clicks"intoplace. Do not pull on the wires when disconnectinga connector.Pull only on the connectorhouslngs.

SHORT FINDER

To ordei any test equipmentshownabove, contactyour localtool supplier.Fora list of suppliers andtoolnumbers,referto Honda Required SpecialToolsand Equipment ServiceBulletin.

Most circuits Includesolid-state devlces.Testthe voltagesIn these circuits only with a lo-megaohmor higher impedancedigital multlm6ter. Neveruse a test light or analogmeter on chcuits that contain solld-state devices.Damageto the devices may result.

oo

Tests Troubleshooting Testingfor Voltage

Testingfor Continuity

Whentestingfor voltageat a connector withoutwireseals,youdo nothaveto seoarate thetwo halvesof the connector. fromthe back. Instead,probethe connector Alwayscheckbothsidesof the connector andbentterminals becausedirty,corroded, (noelectrical contact= cancauseproblems an open).

at a connector Whentestingfor continuity you withoutwireseals, do nothaveto thetwo halvesof the connector. separate Jromthe back. lnstead.Drobethe connector Alwayscheckbothsidesof the connector becausedirty,conoded,andbentterminals contacl= cancauseproblems(noelectrical an open).

1. Connectoneleadof thetestlightto a knowngoodground,or,if you'reusinga (DVOM),placeit in digitalvoltohmmeter DCvoltsrange,and the appropriate connectits negativeleadto ground.

the negativecablefromthecar 1. Disconnect you're usinga DVOM,placeit in battery.lf "OHMS" range. the lowest test 2. Connectone leadof a self-powered part of the lightor DVOMto oneendof the circuitvouwantlo test.

connecthere [fl5tst-t and light should

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swrrcH

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6m""*soLENo,D here I { lll connect I

I

3#Ji8iL,* lj!!J

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Connecttheotherleadof the testlightor DVOMto the pointyouwantto check. lf thetestlightglows,thereis voltage present.lf you'reusinga DVOM,notethe voltagereading.lt shouldbe withinone batteryvoltage. voltof measured A lossof morethanonevoltindicates a problem.

A

Connectthe otherleadto the otherend. testlightglows,thereis lf the self-powered lf you'reusinga DVOM,a low continuity. readingor no reading(zero),means goodcontinuity.

NOTE:Alwaysusea DVOMon high A testlightmaynot circuits. impedance glow(evenwithbafteryvoltagepresent).

r3

HowToUseThisManual Troubleshooting Tests Testingfor VoltageDrop

Testinglor a Shortwith a TestLight or DVOM

Wires,connectors, andswitchesaredesigned to conductcurrentwilha minimumlossof voltage.A voltagedropof morethanonevolt indicates a Droblem.

1. Removethe blownfuseanddisconnect the load.

'1.Placethe digitalvolVohmmeter (DVOM)in the appropriate DCvoltsrange.Connect the positiveleadto the endof the wire (orto theconnector or switch)closestto the bafterv.

2. Connecta test lightor digital\roltr'ohmmeter (DVOM),switchedto the appropnareDC voltsrange,acrossthe tuselerminalsto makesurevoltageis present.Youmight haveto turnthe ignitionswitchto ON: checkthe schematic to see.

TESTLIGHT ol DVOM

<-

s80RT TO GFOUNO

Disconnecl lhe load here.

3''

Connectthe negativeleadto the other endof the wire(orthe othersideof the connector or switch). Turnon the components in the circuit. The DVOMwillshowthedifference in voltagebetweenthetwo points.A difference, or drop,of morethanone voltindicates a oroblem. Checkthe circuitfor loose,dirty,or bentterminals.

ffito.'"o'o .t.

Beginning nearthelusebox,wigglethe harness. Continue thisat convenient ooints aboutsix inchesapartwhilewatchingthe testlightor DVOM. Wherethetestlightgoesoff,or the DVOM voltagedropsto zero,thereis a shortto groundin thewiringnearthatpoint. NOTE:Alwaysusea DVOMon high impedance circuits. A testlightmaynot glow(evenwith batteryvoltagepresent).

co

Testingfor a Short with a Sell-Powered Test Light or DVOM

Testingtor a Short with a Short Circuit Locator (Short Finder)

1. Removethe blownfuseanddisconnect the batteryand load.

1. Removethe blownfuse.Leavethe batteryconnected.

test 2. Connectone leadof a self-powered (DVOM) lightor digitalvolUohmmeter (switchedto the lowest"OHMS"range)to thefuseterminalon the loadside.

2. Connectthe shortfinderacrossthe battery sideof andthe load(component) terminals thefuseterminal. SATTERY

Dlsconnectthe batlery. FUSE BOX Removethe fuse.

<-

ssoRrro ciouNo

FUSE BOX

SHORT FINOER

SELF. POWERED TESTLIGHT o1 DVOM

Dlsconnectthe load here.

.)"' r| SOLENOID

I swtrcH

Kl"

Connectthe otherleadto a known goodground. nearthefusebox,wigglethe 4. Beginning thisat convenient harness.Continue pointsaboutsix inchesapartwhile watchingthetestlightor DVOM. testlightgoeson or 5 . lf the self-powered a lowreadingor no displays DVOM the (zero), is a shortto ground there reading in thewiringnearthatPoint.

-.T.1

"'at

PULSING MAGNETIC FIELD \

I-

I

\8

\


...unillthe needleslops moving.

.r. r l l l < <'llt

No NO PULS|NG PUISING z

,l

--t

MAGNETTC FIELD

SHOFTT stl GFOUNO

m I I

3. Closeallswitchesin thecircuil you'retesting.

SoLENOTO

(co,f,O

r5

HowToUseThisManual Troubleshooting Tests(cont'd) 4. Turnon the shortfinder.Thiscreatesa pulsingmagnetic fieldaroundthe wiring betweenthefuseboxandtheshort. 5. Beginning at thefusebox,slowlymove theshortfinderalongthecircuitwiring. ThemeterwillshowcurrentDulses throughsheetmetalandbodytrim.As longas the meteris betweenthefuseand lhe short,the needlewillmovewitheach currentpulse.Onceyou movethe meter pastthe pointof the short,the needlewill stopmoving.Checkthewiringand connectors in thisareato locatethecause of the short.

co

Fuse/Relay Information

co

- Under-dash Fuse/Relay Box FrontView

c501 (Todashboard wireharness)

c801 SRSmainharness) CI-o

c422 (Tomainwireharness)

c913

(To ignitionswitch)

c712 (Tomoonroofwireharness)

c423 (Tomainwireharness)

T1 T-t T"l T"t r-r r-'l T1 F n r-l r-l r'1

23 24 25 26 27 28 29 30 31 32 33 I-J I.J I.J IJ IJ IJ LJ IJ IJ I.J I.J I-I

r"1r-t r-t T-l r"l r-r Fl r:1 n rJ n 12 13 14

t5

16 17

t8

19 2A 2t

POWER wtNDow RELAY

22

LI I.J L! LI tJ LJ (J LI IJ IJ T-I I.J

n r:l rj.l |-l T"l Tl r:t n r-l |;.l r-r r-l 1

2

3

4

5

6

7

I

9

10 11

LI LI IJ LJ LJ I,J T-I I.J TJ IJ I.-I tJ

. : Canada i : Not Used O : C926loprion(+B)l @ : C927loption (dashlights)] O : C928[Option(ACC]I @ : C929loption (lc2)l

^ : Not used ('96-'97models)

TURN SIGNAUHAZARD RELAY

REARWINDOW DEFOGGER RELAY

RearView c551 flo lloorwireharness) c421 (Tomainwireharness)

css2

INTEGRATED CONTROL UNIT CONNECTOR A

c419 Oo mainwireharness)

(Tofloor wire harness)

c420

(To main wire harness)

6

c439 f96.'97 MODELS and ALL GX MOOELS) (Tomainwireharness)

Fuse Number

Amps Page

FuseName

Componentor Circuit Protected Not used

Notused '10 r 1 n - 2

(RRWIPER RRWASHER)

I

i R HiLHIGHBEAM | L H/L HIGHBEAM

DRLcontrolunit(Canada) 10 | 11 0 - 1 2i Rightheadlight, DRLcontrolunit(Canada) Lettheadlight,

I ro-rs i (P/vvRR-R)

Rightrearwindowmotor lgnitioncoil('98-'00modelsexceptGX)

(rGNCO|L)

windowmotor | 120-1 | Frontpassenger's

AS) I (P,^/V

i (PiWDH)

system(option) Security

| 120-2 | Leftrearwindowmotor

RR-L) | (PAIV

10

Rearwiper,Securitysystem(option) pre-wiredfor accessorysecuritysystem) (Vehicles

|

20

TURNLIGHTS

windowmotor 1 12O I Driver's Hazardwarningswitch

FUELPUMP (SRSUNIT)

mainrelav,SRSunit PGM-FI

(cRUrsE CoNTROL)

Stereoradiotuner('96-'98USA:LX,EX,and HX), doorlock Cruisecontrolmainswitch,Keyless entry) ('99-'00 with keyless models controlunit

/KtrVt trSS\

15

ALTERNATOR SPSENSOR

16

I RRDEFRELAY

l-a

TCM(96-'98CW, PGM-FI 1 0 - 4 I ELDunit,Gaugeassembly,

7.5

1 0 - 8 I Rearwindowdefogger('96-'98models),ABS control

I unit.Powermirrorswitch('99-'00modelsexceptGX) Powermirrors('96-98modelsandallGXmodels), Air delivery,Blowercontrols,AilCcompressor Fans controls,

r/C i-HEATER I RELAY

LIGHT 1 7.5 1 I (RUNNING RELAY) t l I

I DRLcontrolunit(Canada)

i BACK-UPLTGHTS (RUNNING LIGHT)

i Back-uplights DRLcontrolunit(Canada)

I R H/L LOWBEAM

' 1 0 l 1 1 o - 1 2 Rightheadlight

I L H/LLOWBEAM |

10 1 1 1 0 - 1 2| L e f th e a d l i g h t SRSunit

(SRS)

(cont'd)

6-1

Fuse/Relay Information - Under-dash Fuse/Relay Box (cont'd) Fuse Number

FuseName

Amps Page

(P/WRELAY) (S/RRELAY)

LO Componentor Clrcuit Protected

i Powerwindowrelay,Moonrool

FRWIPER FRWASHER

10-7 | Frontwioer/washer

CIGARETTE LIGHTER ACCSOCKET

10-7

I RAD|OCLOCK

I

I

powersocket Accessory

1 1 01 1 5 ) l 1O-7 | Stereoradiotuner('96198models),Audiounit ('99100

t

l

I model)

Not used

i 7.5 i 1 1 4 i

I

srnnrensrorunl7.s lzl , zt -t , ! | I ot 21-2 t

eCU-nmainretay, PCM/ECM, Integrated controt unit

I LICENSE LIGHTS I

7.5 | 1oo-1| Parkinglights,Licenseplatelights,Taillights

UNIT)| | (fNTERLOCK

7.5 | 10-12 I Interlock system

I rerruesls

* = '98models

6-2

Dash& consolelights

I

t

l

- Under-hood Box ABSFuse/Relay

(To underhood ABS fuse/relaybox w re harness)

ABSPUMP MOTORRELAY

(To main wire harness)

(Tornainwlreharness)

Fuse Number

FuseName PUMPMOTOR

I ABS+B I!,ITRCHECK

componentor circuit Proiected ABSpumpmotor | 10-14 I ABScontrolunit unit i ABScontrol

6.3

Fuse/Relay Informationlcont'd)

- Under-hoodFuse/Relay Box

LO

FrontView T'102 (Toenginewireharness)

T1 Oostartercables)

DEn t-l

tr tr tr

IJ

tJ t-l

51

IJ

n IJ

n

5T

IJ

*: NotUsed

RearView [[o mainwireharness)

c353 Tomainwireharness

ffo mainwireharness)

6-4

fto mainwireharness)

Fuse Number

FuseName

Componentor Circult Protected

Amps Page

Powerdistribution

BATTERY

lgnitionswitch INTERIOR LIGHT | FI E/M

7.5 | 10-10 | DLC,Ceilinglight,Trunklight 15 i PGM-FImainrelay,Fuelinjectionrelay(GX)

i (20GX)i

Notused POWERWINDOW

| 10-10 | Powerwindowrelay Stereoradioiuner('9G'98mod€ls),Audiounit('99100 TCM (9e'98 models),Heatercontrolpanel,PCM/ECM,

BACKUP

cvr) HEADLIGHT

i 1 0 - 1 2i Headlights Notused

REARDEFROSTERI

Rearwindowdefoggerrelay

DOORLOCKUNIT, ROOF

'99-'00models Powerdoor lockcontrolunit (allexcept withkeyless),Keylessdoor lockcontrolunit ('99-'00 Moonroof modelswithkeyless),

SrOPLr i HORN,

i 1 0 - 1 3i Hornrelay,Brakeswitch Hazardwarningswitch

HAZARD OPTION

MOTOR I i HEATER

system(option) I 1 0 - 1 3I Security motorrelay i 10-1 i Blower CondenserJanrelay,A'lCcompressorclutchrelay

(CONDENSER FAN) COOLINGFAN

l1o-1

Radiatortan relay

&5

Ground-to-Components Index NOTE:All groundwiresareBLKunlessotherwise noted. Ground

Page

Components or CircuitGrounded

Battery(BLKYEL)

\rl

pumpbracket Steering

t + - r gI Transmission housing G101 (-1)

ano 14-1

Powertrain or enginecontrolmodule(PG1and pG2areBLK:LG1and LG2are BRN/BLK), EGRcontrolsolenoid valve(CW, EGRvalveandliftsensor(Dt6ySengine withM,/T), Enginecoolanttemperature switch,pGM-Flmainrelay,powersteering pressure (USA), switch PrimaryHO2S(D16Y5 enginewithl\/,/T), Vehiclespeedsensor, VTECpressure switch(D16Y5/D16Y8 engines), CKFsensor(BRN/BLK), Transmission controlmodule(CYf)(Pc1 is BLK:LG1is BRN/BLK) Shielding betvveen (allhaveBRN/BLK the PCMor ECMandthesecomponents wires): CKFsensor, TDC/CKP/CYP sensor.Primary andsecondary heatedoxygensensors. Knocksensor(CWDl6YBengine),Mainshaft speedsensor(AiTexceptCVT), Countershaft (A/T speed sensor except CVf) I Shielding between theTCMandthesecomponents (CVT)(allhaveBRN/BLK wires): Drivepulleyspeedsensor,Drivenpulleyspeedsensor,Secondary gearshaft speedsensor

G101 (-2)

14-2 and 14-3

Powertrain or enginecontrolmodule(PG1and pG2areBLK;LG1and LGzare BRN/BLK), EGRcontrolsolenoidvalve(D16Y5 engine),EGRvalve(Dt685),Engine coolanttemperature switch,Fuelpressure regulator shut-off solenoidvalve(D1685), PGM-FI mainrelay,Powersteeringpressure (USA), switch Vehicle speedsensor, VTEC pressure switch(AllexceptD16Y7engine), CKFsensor(A except81642)(BRN/BLK) Shielding between the PCMor ECMandthesecomponents (allhaveBRN/BLK wires): CKFsensor,TDC/CKP/CYP sensor,Primaryand secondaryheatedoxygensensors, Knocksensor(AllexceptD16Y7engine),i/ainshaftspeedsensor(Arf exceptCW), Countershaft speedsensor(A,/T exceptCVf),Drivepulleyspeedsensor(CW),Driven pulleyspeedsensor(CVT),Secondarygearshaftspeedsensor(CVf)

G202 G401

6-6

fan motor,Rightfrontparking/turn signattight,Rightheadtight I Badiator 14-4 I Cruisecontrolactuator, Leftfrontparking/turn signallights,Leftheadlight, Rearwindow washer motor, Windshield washermotor,Washerfluidlevelswitch(,99-'00 Canada) I | +-o powersocket,Brakefluidlevelswitch,Clutchinterlock Accessory switch(M/T),Clutch and switch(lillTwithcruise/D16Y5 enginewithMfD,Combination wiperswitch(Zwires), 14-7 Cruisecontrolmainswitch,Cruisecontrolunit,Dashlightsbrightness controller, Data linkconnector, Daytimerunninglightscontrolunit(Canada), Gaugeassembly, Horn ('96-'97models),Integrated controlunit,Interlock controlunit(ArI),Keyless doorlock controlunit('99-'00modelswithkeyless), Moonroof closeandopenrelays,Moonroof switch,Parkpin switch(A/r), Powerwindowrelay,Rearwindowdefoggerrelay,Rear windowdefoggerswitch('96-'98models),Steering lock,Stereoradiotuner(,96-,98 USA:LX,EX,and HX),Turnsignal/hazard relay,Windshield wipermotor.....plus grounded everything throughG402

f.,lO

Componentsor Clrcult Grounded

Ground

Arr gearpositionswitch,ABScontrolunit (3wires),Blowermotorhigh relay('99-'00 models),Blowermotorrelay,ELDunit,HeaterJanswitch('96-'98models),Heater controlpanel,Modecontrolmotor('96.98models),Powertransistor('99-'00models), groundedthroughG401 everything Servicecheck connector....plus

G402

| 14-13| ABSpumpmotor Audiounit('99-'00models) 1l-9 i Stereoradiotuner('96-'98models), Drivsr'sdoor lockactuator,Driver'sdoor lockswitch,Drivefswindowmotor'Leftmirror defogger,Pow€rwindowmasterswitch(2 wires),Powerdoor lockcontrolunit (all except'99-'00withkeyless),Powermirrorswitch

G552 G601 (Hatchback)

s€atbeltswitch,Fuelpump,Fueltankunit,Rightmkrordefogger 14-9 i Driver's 14-12i Leftand rightback-uplights,Leftand rightbrakelighvtaillights,Lefland rightrear groundedthroughG761 eveMhing turnsignallights,Leftand righttaillights....plus

G601 I 14-10 Highmountbrakelight,Leftand rightback-uplights,Leftand rightinnerbrakelighv taiilights,Lettand rightlicenseplalelights,Lettand rightouterbrak€lighvtaillights' (AllCoupesl Trunklatchswitch Leftand rightrearturn signallights,RearwindowdeJogger, ano (96198 S6dans) 14-11 Highmountbrakelight,Leftand rightback-uplights,Leftand rightbrakelighvouter G601 taillights,Leftand rightinnertaillight,Leftand rightrearturn signallight'Rearwindow (99-'oo deJogger(GX),Trunklatchswitch Sedans) G602

Windowantennacoil

('ss-'00 Sedans)

G761 (Hatchback) G771 (Hatchback)

14-12 Hatchlatchswitch('98-'00models),Highmountbrakelight'Leftand rightlicenseplate i lights,Rearwindowwipermotor...plus groundedthroughG601 everything Rearwindowdefogger

14-13i SRSunit(2wires)

*1 = All '96-98models€xceptDl685, '99100D16Y5withM/T *2 = '98 D1685,all '99-'00modelsexceptDl6Y5with M/T

e7

PowerDistribution

- FromBatteryto lgnitionSwitch,Fuses,and Relays T1

ToUndeF hoodABS Fuse/Relay Boxon BATTERY p a g e1 0 - 1 4 .

STARTER P a g e2 1 , 2 1 - 1o, t 2 1 - 2

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c415

1

c913

Vehicles pre-wired for accessory security system

PHOTO 6A

FUSE16 FUSE17 AR DEF FEIAY

HEATEA !'/C FEIAY

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FUSE27

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SeePowerDistribution, pages10-8and 10-9.

l

L--------J

To Fuse3'|, for delails,seeStartrnq page21,21-1 System, , ot 21-2.

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T101

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PHOTO 10

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STEERING LOCK

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SeePower Distribution, page10-6.

SeePower Distribdion, pagos10€ and 10-7.

gLXTYEI

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SeaPower Distribuiion, page10-4.

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(cont'd)

10-7

PowerDistribution - FromFusesto Relaysand Components(cont'd) I I I

3 \

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10-9

PowerDistribution - FromFusesto Relaysand Components (cont'd) I I FUSE'3

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PowerDistribution - FromFuseto Relaysand Components(cont'd) I I I I 9 l

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RIGHT BACK.UP LIGHT Page110-l

/-.t

)

\_,,

I I l

l-y-

r-t

\_,, I

(98-'00 mooets 2)

l

c605 vlEwa

'98-'00 ' models : HIGH MOUNT : HATCH BRAKE ; LATCH LIGHT , swrTcH ' Page80-2 Page ' PHO|O 11A 110-t7

: l ; l . BLU/ I BLK

i 2

I I

: ; . , '

REAR wlNDow WIPER MOTOR Page92

:t

I

i L-J

c z s ai z l c z s z

PHO|O 126

G761

G601

14-12

'.!

PHOTO 109 PHO|O 132 (98i00

- Gl, G2,G3,and G403

BATTERY

STEERING PUMP BRACKET

TRANS-

t t

I I

I I

l l

I I T3

PHOTO20

G1

ABS PUMP MOTOR Page44-

MtsstoN

PHOTO 5

I I

I I

L

r4

J

BFI{

Ptlofo 13

c360

1

G3 PHO|O 20

I I

!.

PHOTO 13

c403

- G751,G771,and G801 CONDENSER FAN i,OTOR

SRSUNIT Page47

Page

,l

I

PHO|OT0 vtEw 51

I I

I

t

l

L------J 17

c753

GFY(20) OTGFN

G751

GFY(r9) or GFN

!.

G801

14-13

lgnitionSystem -

All '96-'98ModelsexceptDl685; '99-'00Dl6Y5 with M/T NOTE:ForServiceCheckConnector details,seepage23-3. @ rDc

CKP sensor input

sensor Inpur (IDCP)

POWERTRAIN or ENGINE CONTROL MODULE (PCMor ECM)

CYP sensor input

(CKPP)

(CYPP)

L-----------J

<..-/4 i

ti

t

iLi:"_gl_i i L-----1!-----r

:L_1__I,X,*., 96-97 models

98-00 modets

I

"a*,telfi

BLKI/EL

I I

I H

:T- I ,rrrr.iFiFx".-,''ril'fi pagelo-1. I

SeePower DASH ll Distribution,I F U S E / I ( I

J__99'"'_

! iii:?ifq"l **:' PHO|O 33 PHOTO123ICW)

10 BLK,YEL

10

c101 vlEW28

c'120 vlEW29

Secondary

c120 BLK

vlEW29

SparkPlugs

c14 rIDcM) Sensor ground L--

20

-

IGKPM) Sensor ground -

--

-----J

(CYPM) Sensol ground

POWERTRAIN or ENGINE CONTROL MODULE (PCMor ECM) P H o r a3 6

F U S E9

Lq::--F.itl,

I xr*" *-"*,t";' BLK/ YEL

=

uI """%t'3.

".:l

o63

I I

UNOEROASH FUSE/ RELAY BOX

lgoition outElt

ofl-

POWERTRAIN or ENGINE MODULE CONTROL (PCMor ECM) PHO|O 86

c'l20 YEUGFN

DISTRIBUTOR

BIU

9

c120

ALU

vtEw29

c101 BLU

vtEw28

'. YF,fl}l. BLU I

,

r -.--

cel

.l TBANSMTSS|ON

I:. igF"![E#' lr-ri";l:';9""

viEw60

TEST TACHOMETEB CONNECTOR

i i:*bi

irlg:l L-----

.I GAUGE I ASSEMBLY

rA*oxErEn iw,tr?,' ----

I I

J

20-1

lgnitionSystem -

All Dl685 engines;All '99-'00Modelsexcept Dl6Y5 with M/T NOTE:ForServiceCheckConnector details, seepage24-4(exceptD1685)or 25-4(D1685). STEERING LOCK

POWERTRAIN

sii.s*- | (Pcn'orEcM) lm'3#n '3#n iffffiEgr I '8f",

',L_I__J, L------

-----J

Wro

86

D1685

All exceptD1685

fi

!l---+--l 'i---

"*1,[ F,*';.,

!

gLK.Yert

ul9f#'

UNDER-iF--Hs-,mT-l !'T-f*-'i"i pase lGi. DASH ll I I Distdbution, .I

j----i'fl '","?siii,xl 9'x*" i*n"'."i.x,r -.t !

{F+

LJ_gg'n'_

a FUSE/ RELAY - ! BOX

I "-l I '-l I *"-^lr";J -"1 I

I

='i.{i31i",,-

I

.t0 BLKI/EL

c101 PHO|O 142 lA1685)

vtEw29

Sec!l|dary

WHT/BLU

BLU,^VEL ELK

c120

7 ALK

FED

c21

c9

;;--;;---o;;;l Sensor ground

L ------

20-2

vtEw29

SparhPlugs

c30

Sonsor ground -----J

POWERTRAIN Sensor I or ENGINE CONTROL gtound MODULE (PCMor ECM) P H o r o3 6

I

!Lig::___J

1 Y C419

UNDER-

^,ol',lill,l?"u'rlir? IA) BOX

vlEw2a 10 (D16Y7/D16Y8 s)

LTBLUor ALU/GRN

FUsEe

RELAY

c120

OFN/ALU

l(

lgnition oulput signat flcM)

I YEUGBN

POWEBTRAIN or ENGINE CONTROLMODULE (PCMor ECM) vtEw 70

c'120 vtEw29

DISTRIBUTOR

lgniiion

Primary outPut contsol

nrpur

signal Ground

Fh^ih-

"p_il; output

BLU _9BLU

8 9LU

:'!'\?-- -

D 1 6 8 5- - - - - - - ,

c101 vtEw2a ----------<- c442 I a|-ua I 19 g a aru I l

frerminals 1-4] olo'25 vlEw54 C411 PHOTA 60 vtrwoo ,

cBA TEST TACHOMETER

cor.rNEcToR

PHO|O2l

|

-

-.t

GAUGF

i f#f rAcHoirErER ift?i,?""i i liitr" !I I L--J L ----

- ---

-J

20-3

StartingSystem - AutomaticTransmission (All exceptDl685) .133-7, or 133-12 NOTE:Forcarsequippedwithoptionalsecuritysystem,seeSecuritySystem,page133-3, for startingsystemcircuitschomatic. WHT/BLK

c3s2 PHO|O I vlEw 27

--l =-mF,Uf. 9,lLTi ld;f,,"pag€10.

I

ftxiE "2

c415

lta":

E1 404

slan? (ll)

I

J

I I .I ELECTRICAL I I roAo I I I DETECTOR Gtol ulr I I Ia Ptfifo I II I It J I

BLKAIVHT

i

c415

1 ELK./YEL

c416 PHOTO 53

au(|vEL

for Vehiclsspre-wired system accessory securaty

BL'(4I/HT

c 4 t6

4

PHO|O56 f98 'oo) vtEwt2

R'SE 4I lA??tNY ,ol

(NotUsed)

PHO|O 53

ALXAVHY

Allsxcsptow

SoePow6r I Distibution, ! page10. a

'10 c433 aLKlvHr

cw

BLKAVHT

- ----J

7

T1

PHOTO 9

13:;-1ifl;ft?R tg 'lPHoto

)2

!L-----L---J BLKFED

BLI(RED

c433

1I ELIVBED

SoePowr Dslributbn, Pa€o10. BATTERY

PHOTO 76

a ALKNED

c4rI

9 a c101 er.xiwxr I ffo,rtfl't

PHO|O 63

4

r'

STARTER PHO|O 34

Ft gg 3r 5? F En 3E ^r 7.94

A13

t

l

II{TEGRATED

co|{TnoL UT{IT

PHOfOU

, - -vtEw = =67 --J l G l

21

Sso PGM-FI,page &1 ot 24-1.

UNDER. DASH FUSE/ RELAY BOX

- Automatic (D1685) Transmission

WHT/BLK

. J 9,1'3.

c352

r=-----L-_-_-_-_-_-=_-_-Tl.*1"","1 WHt a V|EW14

vtEw27

UNDER.HOOO FUSE/RELAY BOX

FUSE42 tGt

ao

li F 3,"j,[',ul Page10' tcx,^ ) "'{----1iLi.' | ll

|

Li-gl{l======i---i

.I ELECTRICAL I LOAD r DETECIOn | (ELD)uNtr

"i*-iIr-m'

I PHOTO 9

I

BLKAVHT N

PHOTO 76 V/EWa t

1--*---''! "tN

7

\o3

bz

A"/TGEAR POStTtON

swrTcH

BLKREO

"'-";;tr 11

SeePower Distribution, page10.

c433

ALKRED 4 STARTER CUT FELAY PHO|O 129 (99100)

".u,"if---'

c419

FUSE31 STAffER Src{AI 7.54

UNDERDASH FUSE/ NELAY BOX

A't3

-,*!s#;:{" r-^==.1 Stador control

POWERTRAIN CONTROL (PCM) MODULE

:il

c101 vtEw28

SeePower Distribdion, Page'10.

SeePGlr-Fl, page25. STARTER

BATTERY

21-1

StartingSystem - ManualTransmission NOTE:Forcarsequippedwithoptionalsecuritysystem,seeSecurity System,page133-3,or 133-7,or 133-12 for startingsystemcircuitschematic. WHT/BLK

c3s2

PHOTA 8 vtEw 27

r.------T-------------=;-*^:-lsrEERtNG

UNDER-HOOD I FUSE/RELAY BOX

FUSE42 to! a0a

ELECTBICAL IOAD DETECTOR (ELO)UN|T

c415

Ii

I I _l I

1j;cx y'

1'----> R*.|?xf:iiiliffi' t"t%?I,, Distribulion. I page10.

it-jtr'tl i j (0)

r---_-_€rx^,:jF;f r,+lo t'tii:,J?""" A ;-;:.==:

Ptloro I

;--;*;.-f

SaePo'/Y€r Dislibution, pag€10. ------J T1

-. - - - 1 - -

.o0"," 3,rffiEj, ,'rr-'OO 4 ('98100models3)

^.:---

STARTER CUT RELAY

---;;;;i[

PHO|A 129198) PllO|O r35 f99 00)

ALU/BLK

Se6Ground Dislribution, page14-6.

cLUrcHTNTERLOCK t

Closedwrlhclutchpedal I fullydepressed. ll PHoro1ra I

"**" ! a

BLK/FED

Se€ Power Distibution, page10. BATTERY

9

ct01

BLKAVHT

vlEW2A

c4't9 4

STARTER

f2

E--r.---?q_l l

vtEw49

srAFrEn

FUSE31 STAATER SICIIAL 7.5A

UNDERDASH FUSE/ RELAY BOX

At3

t t

l l

INTEGRATED col{tRoL ut{ll

PHO|OU

I-

21-2

G1

SsePGM-FI, page231 ot 2+1.

ChargingSystem UNDERHOOD FUSE/ See Power RELAY Distribution, BOX pag610.

FUSE15 ALT€IIIAION sP SEII|SOF 7.5A - ) l

t ,

FUSE41 SeePower Diskibution, page10.

I

------J

BATTEFY 804

vtEw50

USA BATTERY BLKI"VI/HT

BLKAVHT

'

L-----

l9nition rnput LOaO

ourpur

Ground

!

'l ELECTFICAL; l LOAD :l DETECTOR (ELO)UNIT : l ;l :l

tl, l

G1

:l :l GFN/FED

WHT/REO

r i6

*Fi

A30 f D16)

i:1E15_'_ - -I

I i !

ALTERNATOR

22

T101

* = 96-98rAllmodels except '99'00:01685 D16Y5 with i.4/T ** = '96' 98:Allmodels '99r00:D16Y5 with t\4/T, D1685

POWER-

"'.1 -. ^ unit input ELD '

, I rnlrn or i ietCrHe ! coNrRoL I MODULE (PCM

I I Art€rnator

: lllerlato.r I or t",fl?il"' controrsrsnar a:"^y] i i 3' Pq_oro

T

L]

' ""-

SeePower Distribution, page10-5.

GFN/RED

SeeGround I Distribution,I page14-5. I

Y

:.i *. B,'"',1; _. i

L-

-

----,1-

,zscnrl

PHA|O

,L

-

-

J

'(' C17)

(,.^;?f, .A1e)Y c2[ I I'HT/ ll

:('c;3)T : cs i 'r",".oI ' U oi : (c'r9ill-_:-'

BLXYEL .l

'c11"2)

u

\

t t8

c501 PHOTO 60 vlEw 55

Bl5

i-Hffi--ryj[#'ff"'" B,I6Y

WiIT/BLU

3

I I

cso1

PHOTO @ vtEw 55

A1

'&zT---------1

Puoro63 WIIT/BLU vtEW50 6 WHI/BIU

t |

u3ti

c10'r

PHO|O21 PHO|O 142(O16e5) vlEw 2a

I

a I

UNIT

Prafo 61 vtEtl$T

l.---------J

22-'1

'99100Dl6Y5with M/T) PGM-FI(All '96-'98ModelsexceptDl685;

- -r,-sfr.H$S..,E.Jgg" | f I

't FUE€rt4 flEfl rta

c3st 7 ll ia"o"to u vlEwu

Se6PotYea Distribution, pagot0".11.

aa4

J

I ?PJ., I

i I ffi**l ! I

|

H

se€Pow€{

Oistribution,

l_l_iYi1_ ' r F,x?', v'E!53 I "a,-ro"n i

I _______u.

BLU

"lf i orrl

SeeA,/T Controls

"lt---

fl ;x

c101 VEW 2A

10

cl31 vtEW59

BIK

23

NOT-E: Fu^se.31 is HO-f-with lgnitionSwitchin START(tDandclutchpedatdepressed or A"iTGearSelector in PARK(P)or NEUTRAL (N),seeSiartingSysteni,page2i or 21-2.

UNDEROASH FUSE/ RELAY BOX

SeeInt€orated ControlJnit. page70.

PHOTO58

---l-lf

-----=-------------=--:

c420

i

vtEw53

"au*",I zI PGM-FI MAIN RELAY vtEW18

""-"'l |flrn*', ""^"*l *L I --- I H;[h;-ensnewrh",r-t :--*f 3l3yi:131ffi,-'' 016Y5/D16Y8

i

D16,

jt

ii

ffifi:iil:"'"" il

N

l i l T : { x sI l -UTtl

iryffi$il: iiffifrffi,,1_,_:____

, :i

,A124 , ,^lAcy) I, rAurr'arve

nt;*Y:l"" lr 'uv"nv' \I t'-----

I L------

, , A14A, A13A (iAcvP) (rAcv N) r--.-, , ii r--r : ,

IACvalvecontrot

' | :I ' ,

416A crnt pumpconkol Fuelpump Fuel control

C6A $rs)

POWERTRAIN

input!| :rNGtNF Staninput Start ;'NG|NE ICONTROL I MODULE

':------------i

l(PcMorEcM) ---J

t';[?,i?"*

(cont'd)

23-1

PGM-FI(All '9G'98ModelsexceptD16B5;'99-'00D16Y5with MiT)

I bnilbn out$rt sionel @r)

lDC CKP CYP a€nsor aanaor s€nEor ing'lt input input fiDCP)

(O(PE

t

CKF s9nsor inpul &$n

(CYP4

I

A20

tI

)

(

:.

I

"H,,,*,"^. ;{-r*:-:'${##*i I i * u.* m:#f: ruigffi?lFl-"44ffiil'i*-1 luffi::r|[ 1

J

Z

"

C12O

s A ctoz

lll9!9^vlEW29

'ry-li15fi,ffiYi"++#" "l*r 1|-l l-'"-L::___U-__-i.", "*l *l

,n*,,o.o I v{'{r/REDI

l

l

| "''ol

tr*dffiiffi iL-------

!-=-n*-r=d*--,=-,.r-------t?il-1

! ",r1,

PowEBTRAIN

[:fl:*

r

l """'"'* |

![ ruW* ;aee:+-:'

ff*:ifltBtr. I I -----Jffi-:cu1 lr-J wEwlo

G10l PHO|O 33 PHOfO 123 lCVn

23-2

i i

,r.^

\,

see,ence 3!13o,

oft,lo n[%!t?ooi8",,loGlitid "oll,??9, ilffs,

i &------

sensor

n,&l]o

POWERTRAIN ot ENGINE CONTROL ruMODULE (PCMor ECM)

I sewiceIili

*ii!o*

'no$., IIa:; vlE --J

85

vlEw59

See eeABS ABS, RS,M A/T SRS, rontrots (cw) Controls

Y

I

-rJ

Se€Ground Dis ibution, page14-5.

Y

LF

PHO|O 123 (C\.t)

SeeGround Distribution, page14.

I l t L___l -

:

G402

(cont'd)

23-3

PGM-FI(All '9G'98 Modelsexcept D16B5;'99100D16Y5with MfI)

1@

i-l-,;;*--

UNDERHOOD FUSE/ RELAY BOX

L--LT-: 'f 9;u;,

wHT'REo rrEt3' I aaa4 wnineo I r I DATALINK CONI€CTOR(DLC)

'11,c,i"',3, vrF 2/

wHr/cFNI ll wxTcnr art ,r"ro"" !

see Powar Distdbution, page1S10.

, I (WithCruiseControti) | rrF.t

Seepower Distibution, Page10-13

BRAKESWtTCh

Fi3:{i'r'rs35 **".,*.-,lf,1i ffif{"s1 oauwxr

vtEw 48

"""f":T-C-l*

*-l l ,""oL.rr. I I ffi;"i;ii" I t------j F=Ln&1?i,inars'.rqr -----=ffi, ;,?fl:&'" o"n,n", I H i u+ --------=J lfii?iif. ,, L----1z I ",., irlot,bas . -

21 F-----

TTELU II

cRNu/Hr I

cel

18KSW)

Data inpW

B.ake switch input

ortsut WEG orgssure h,vitchinput

v/EW )e

ouJl

(K"UNB

, I :

L'gitr! ^o

wEc

valve conkol

inout rPbPs

Ag GRN/YEL

wEc

PRESSURE swtTcH

POWERSTEERING (PSP) PRESSURE SWITCH

Sg€Ground Distribltion, page14, I

ALK

iu,**," L_jFiF,""*l *.u_-ig:-l d'Gr01 PHO|O 123 IClr|)

23-4

r--F-------'l I t FUSE2s

i

UNDERI DASH

Poweri 5Eii" ) rg'" see

gT:1*l3l l""gT",, Ir---*----i]1--]"-.t t-------) Y-I

- --

- - --

I

--YyEL I

aEnT

- - -

I

.--+---r--.r----

Ii

1?'20) yELI fierminals I iuoros,

'

EsA

'

C4A

T

' I

I

vtw 56

: i

.1cAucE

t----,r:----.1--

I I Fff'"*'" @ i iafll-i i !ftTr:**' SlHi'#" ! Vl}8f{fiil E i AruE*f*mi \+/il3ifii'"'[9i \y' ucnr Iu: lffi, :i rc"""c"r !! II I -i----J,-------;-J L-J.---.

:A A ! /tl\

Sse Power SaePowe.

t,.\_--..^t : ' MALFUNCTIOI{(USA)

',L

,t I ,r I

'

I ; | ' I '.

'

A3OA

'

shin-uir th$-"n-'

: , I

Ks inout {xs)

,

i---

:

i outr

: :

irg) ikti-

ii ;i

't'f

i

,l

*""*l

fr.,,!+Jf

' -----

",_:I

"uArO86

, I v)twzo :I ,:

i*frw ii HFI*i.*'* "tl:"eererd

i I ii I----.[:*s*'"! ii Fn=--lrilnarsl' i .-rH1

"""".*l |n!?,*I : i : f915i3."5" ! rlsl .

- - -"

Ctutch switchinPut (clsw)

l-IlFi!

il--Uilli II ii |I

;l oTEN(iTNE ;l9t^Eltg[F ' lcoNTRoL ' r MODULE

. indicator control

i I ^:lt*,,. T1'"""

i*'*n!

i

:

:

A18 A ----,uE-ritlt-tontrot lalL'ioitrot

|

:

i "."K1( tA"o,'

""-:;'-f,

------

lctrcun ! L-?-J

l1t---J

c_ : gr"9l,, PHoro

33 PHoTaln lcw) C W D i 6 y 8e n g i n e - -

:

: -----

!Bii!'#s;

l-*; "'*l

!

L__-f *-erco--ol -

G4ul PHQra57 D 1 6 y 5 e n g r n e wM i t /hT - - - - j

(COnt,d)

23-5

PGM-FI(All '9G'98ModelsexceptDl685; '99r0OD16y5with M/T)

ECM control data

Reference vollage NREF)

inDut OMA}

(VREF)

Reference voltag€

EGR control ' I solenoid sofenoid vave ; I vave controt i| i| control , ! (EsOLr :L------

OMA)

ECM control data output

TRANSMISSION ECM CONTROL control MODULE(TCM) data llEv/ 69

:q{.J

OMB)

I

ECM control data jnput

shift lock circuit Circult

Pa(kl neutral neutr

{

i;;;;';; ' '

circuit control

."

neutralReverseD4 input input input

D3 input

ta

*

'i\,

2 indtcator, ; input control | -, |

"""'"x "lL :i1",' [J=:ITTIT'{t -l il1l :1,. "'J;:;;,.,"^, i ".f:;;,.,"^, !1.,."n, control {sru,

inPut (A}FNP)

|

' :

(sLU)

Interlock Svstem

: I lt ti.."stEBkTJBi ""il*l"* : i

| /" \J

VALVE I SOLENOTD PHaro12a

I

'; i t'i!",,, pase ;;;a',, Bi"ifit**1 14 i l *-1. i ---f ' |

4- cror

23-6

PHAfO 123

!'#$tl ii{"Ff*,

!.gg1mr..

rAlPNPr TATPFI {ATpO4i dlPD3)

tAfPzr

See Automatrc TransmissionControls

rDarNDl

/

I

: , '

, ' :

See Fans

'

:

l

i i, * " 1r

Y

i

ii. *, I l

i

/i**fffi'* I ; cornrd

I'

'.--..--r-

.-,---;---l

|

\\ \

t !

' : ;

Seely'C Compressor Controls

l

i

YI

: l

l:

"*"."1 |

l

:

:

Y

See Charging Charorno System Systein

[

i ot. I I.!, i ; o,.

I

rrz.l,

r,rcffi"oro,

i'

clulcfi rday COntrOl

"''I

/, &rrr:rr

',n,-I

I

SeeVehicle SpeedSensor

ryss)

Nc

roqrsrrnpd * [

".,^." ! I

:

:

! i l : - ^u".o " "*,Il" . o 1i : o i :

:

e.St* l*.]["n nput

Altemator

FRfrgd

:

;

.r_l

POWERTRAIN

i: 13'"',1+?3.' I MODULE ; | (PcMor EcM)

r ' ;'

u.1;lf*

Y

Altornstor Altsrnqtor conrol

tSJ",

i; lw,t?'" I i

I

$:--lJ

t See

NC Compressor Controls

See Charging Sysetm

(cont'd)

23-7

PGM-FI(All '9e'98 Modelsexcept D16B5;'99-'00D16y5with M/T)

- D16Y7Engine

'I 'i ,| r!

pressure sensorinput praNKi (Pr^Nn,

, '

Ret€rencesensor voltag€ input OCc2) \wtz) irpsr {rPs)

:

D i sy

j

o r oy o r y

ECT sensorrnput (Ecr)' iEcr}

IAT sensorinDut ' (AT) ,tAr)

primary HO2Sinout l"no)si{PHozs)

',[ i . - - 1 * . " . f f i , " [] i l B L K r y E lL-------J-----

D 2y

D8y

II I

--_-__J

D7y

.l I ul,I l='i$d""-""---ffi][.[

IffiryI IH; iw|

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I

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l

lt

r !

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r

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lY

nals

I,E, J8

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I

\

\ I,

POWERTRAIN T

t

!I

'i,l,llouu

ri

AtTEii|AtOf, ^ aPsE|{aon see Fower t5a Distribution, ^

MODULE I (PCMoTECM) :

99coldary HO2SinBt

I

E*o,*. CONTROL

FUSE15

UNDER. DASH FUSE/ RELAY BOX PHOTA 58

---]-l-"jt='-.i

\T,T]K

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DT4 WHT/NED

BLKAVHT

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1

c101

1I'j

vtEw2a

. c115 , Oermlnals ,'t-71

T

t

c401

I vtEw38 ALKAVHT

SeePow€r Distribution, page10.5.

c568 BLKAVHT

VIEW4

,l

WHI/FED

_

{ Evaponn- 2 TIVE EMtSStON (EVAP) CONTROL CANISTER VENTSHUT VALVE

rn+5-m EVAPORATIVE EMtSStON (EVAP)PURGE CONTROL SOLENOID VALVE

IT GFN

EVAPORA.' TIVE ' EMtSStON (EVAP) : BYPASS i , SOLENOID VALVE

PHATO 39

c125 c130 Oermlnals 1n0) BFN/BLK

Ses Grourd DisMbdion, pag€14-1.

BLU 1

c568

vtEw52

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BLKNVHT

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c131 vlEw59

G101 PHO|Q 33

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A15

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i .

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canistqvent sotenoid l":iiEt$'[i, varvaclntror,llg'r+

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23-9

PGM-FI(All '9e'98 ModelsexceptD1685;'99-'00D16YSwith M/T)

- D16Y8Engine -, tt - - - " "

I I

;

ii hffi- i ffis*#""r, i"[ ' | (PTAN6 'L-------4-----

i -:l

,

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t

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c123

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I

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PHOTO 15

LTGA

2

PRIMARY HEATED OXYGEN SENSOR (H02S)

ALK

-i

cr23

PHOTO 42

,{

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c 5

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GRN/BIK

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a

'

I

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23-10

-------

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t t

f

)or ENGINE

\

-

I ! , -------

FUSE15 AL1EA|{A]OA

sPsExsoa

CONTROL MODULE (PCMor ECM)

Secondary HO2Sinput (sf,o2sl

7.54

UNDER. DASH FUSE/ SeePower RELAY Distribution, BOX page10-5.

- ,.-".,-^,o"::.f=_ BLKryVHT

-l-rtl : $ i """,".--*'i-"fj*"

c401

ll er-x'wnr g A crer

BLKAA/HT

see Power

Distribution, ' page10-5. :

FED 1

BLKAVHT

, BLK ' YEL

c432

c568

1

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SECOND-F rl ARY I I

' f-tl-l EVAPORATIVE I EMISSION 'I I

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97 model a coupes,

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I

A 1 5A

{Pcs) EVAPpurge controisolenoid

valve control

:, | ' :

, ,

A2gA

{vs!,) EVAPcontrol canistervent shut valve conkgl

4 2 8| ' -=-7(2wBs) EVAPbypass solenoid

valve control

tb------

23-11

PGM-FI(All '9G'98ModelsexceptD16B5;'99 D16Y5with MiT)

- D16Y5Engine

23-12

'I r :i : ,

. fruzs HOzS VScelt Label Dumo red$snce voltag€ vohagsBeftrence Befe{encebell c€ll . l"dqanc6 insJt input voltage control (rABELt Ms+) tlP-.vs-) (rp+)

Fflmary Primary ' HOzS' ' heater i control ; (Po2sHrc);

, : ; ,

*l -l "* i I'*l*'l i ----i---

I ORENGINE a CONTROL i c(JNIHo | MOOULE (p-Q!/|OB | (PCM I ECM) r;!J?.* j

primary HOzS !-1029 inpul l"Y_

irlr iill :L+.1

I

l----,

. (_l_.o-l annar-x : I | I seeGrourd : I

FED/ YEL

:

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"""r"a^ I tl

+9,1:1o,,,

F I

INTAKE ' AIR ; TEMPER.. ATURE (rAr) SENSOR'

H

PHO|O4s

i

t

i !

From nextpage.

aa BRN/BLK

4

c123

c123

PHO|O 40 vlEw 19

PRIMARY HEATED OXYGEN SENSOR (H02S)

PRIMARY HEATED OXYGEN SENSOR (HO2S)

-- -.-g c123 ,7 ,t1":.," I :: ' t---o} "",'"?", vtEw19

ErKl

lDistribution. e g g t q eI " d !

f f i 3 1 !i 1 ' 1

i::

ll

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Ill

|ll

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l i ii ioty iI

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I

;

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,

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v t a ea l

(cont'd)

23-13

PGM-FI(All '96-'98ModelsexceptD1685;'g$.'00D16y5with M/T)

- D16Y5engine(cont'd)

r- - - - - - - 1 Secondary H02S anput (sH02s)

---------1 FUSE15

POWERTRAIN OJ

ENGINE CONTROL MODULE (PCMor ECM)

UNDERDASH FUSE/ RELAY BOX

$t"t!ilS8" seePower t.5A

-

Distribution,

page10-5.

I

D14 I' ,n"r,"aoI

rtr i,tj l

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EVAPORATIVE : EM|SSTON ; (EVAP)PUBGE. CONTROL SOLENOID VALVE

BLK,/li!/HT

c568 BLK,\II/HT 1

EVAPORATIVE EMtSStON (EVAP) BYPASS SOLENOID VALVE

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PHOfO 38

c125

(SeeS/M page| 1-9 for'99-'00 models)

c568 '98-'00 mooets

c4o1

:

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Yanver.x I b9^

23-14

,.ul

3A-3uA---g'A--i--**----f'I (sro2sc) (so2sHrc)

;:m

AA8r"yhearer control

(pcs)

,

i rvffi's" sorenoid : valv6control I

-"-*"i

- ''

-

:

:

l! 39Y.E!: euo8S:noo' E\"L'Yssl'iH;in';' :ill*',":* ;:fl'".t"* iiF!ii"te'ryse

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FUSE/RELAY BOX

I I

i !

I I

UNDER.DASH IFUSE/RELAY \ FUELPUMP I BOX PHarc 58 { {"rl"t* i seePower I | ro t FUSE

H I

Distribution.I page1o-2. I

L-Y,------J 8 Y C420

BLU

:1,sLu

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input

inpd

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\

t

a L------

24

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t

NOTE:Fuse3l is HOTwithlgnitionSwitchin START(lll)andclutchpedaldepressed or (N),seeStarting A'/TGearSelector in PARK(P)or NEUTRAL System,page21 or 21-2.

UNDER. DASH FUSE/ RELAY BOX

FUSE31 SIAilEfi SIGT{AL 7.fi

See ldeoratod ControlUnit, page 70.

PHOTO 58

11

10

c420 vtEv,/53

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lcql

.I

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s"liii'p", ! EHc,le

! CONTROL

(cont'd)

24-1

PGM-FI(All '9$'00 ModelsexceptD16Y5with M/T and D1685)(cont'd)

'iffi ]L

l r lgnition

! I output I signal ! ncut L-------

TDC sensor inpt$ dDcB

CKP CYP sensor ssnsor input input (CKpPr tdveel

CKF sensor input tCxepl

t l \

------J

I I

,Tf;=44ff=''fiffi;^.,"^ ffiP ilffi:*'" Lqsry:ffi_ tt-i ffilJ N N ; ", -;ffi'

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|

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24-2

"'

il;ffi6 ifttEtrh", L-J ___J

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r-Gtor = ,*ZiZ1\r,"

POWERTRAIN ol ENGINE CONTROL MODULE (PCMor ECM)

I

t ! ,

c,orna (LG1)

Ground 1LG2)

Ground (PG1)

Ground (PG2)

Reference voltage (vcc1)

Map sensor input

Service cnecK conn€ctor Input (scs)

Sensor ground (sGl)

PHOfO 86

A10

MANIFOLD ABSOLUTE PRESSURE (MAP} SENSOR PHO|A 49 p16v7l

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Y

--J

I

SERVICE CHECK CONNECTOR

SeeGround Distribution, page14-5.

vtEw39

SeeGround Distribution, page14-2.

II

Se€Ground

___J :

c402

(cont'd)

24-3

PGM-FI(All '9$"q) ModelsexceptD16Y5with M/Tand D1685)(cont'd)

@----1-:::=*"---l

@

i-l;;-|

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lc_.ltg+I9i

Drsribution,

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pag€ 142. ff&G{lfd

f Fi"frW """,*f,f,',11,r,",.*, !

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PHO|O58

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;ll

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i

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: Fa;;;iror

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,

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(cont'd)

24-5

PGM-FI(All '99-'00ModelsexceptD16Y5with M/T and D16B5)(cont,d)

- D16Y5Engine

I Rererence iecnuaruerirt voltaqe i sensorInput I TEGFL' L-------

rvca?r

- . . iiftii*

rp

sensorinput Opsl

inpul rFirir.rxt

l"*o,

$'n"o.

input rECn

inp"r i,ari _______.J

t t

.I t

c130 18-20) Oerminals vtEW52

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YEU BLU

YEUALU

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EXHAUST GAS RECIRCULATION (EGR)VALVE LIFTSENSOR

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PHO|O 36

1

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lr;: H

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H#*iiff''I tllfrtr'l TEMPER.

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vtEw38

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lu'"t!H"3fii:' L __

24-6

7a J V|EW

POWERTRAIN CONTFOL MODULE (PCM)

r

FUSE15 AI'EiIIATOR 3F S€txsoe ?.5A

PHOTO 86

SeePow€r Disltbution, page10"5.

UNDERDASH FUSE/ RELAY BOX

PhoTo 58

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heator

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conlrol

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varv€ controt

conaor

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shutvalve

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24-7

PGM-FI(All '99-'q) Modelsexcept D16Y5with M/T and D1685)(cont'd)

- Dl6Y7Engine

a I

lFueltan* lpr€asura F€nsorinpJt | (rt^xn L-------

TP ssnsor input Crpsr

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t ECT sensorinput lscn

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\

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t II ,

ct6 BLKT^YEL

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I

k FUEL TANK PRESSURE SENSOR (SeeS/M

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vtEw40

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ct31

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PHOTO 103

c401

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c123

GRN/ALK

{ clt5 (Ierminals 8-14) vlEw38

contaol

24-8

PRIMARY HEATED OXYGEN SENSOR (HO2S)

--.t

I ,-

\

POWERTRAIN

lo, ,tOU*._. I CONTROL

1il6'dirtE-

r

--1 FUSF15

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PGM-FI(All '9S"00Modelsexcept D16Y5with M/T and D1685)(cont'd) - Dl6Y8/816A2 Engines I I I Rrol tank ipressure : ssnsotinDul | (Pr^No L----

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INTAKE AIR TEMPER. ATURE

PRIMARY HEATED OXYGEN SENSOR (H02S)

SENSOR

PHOTO 13i

(rAr)

*'.,9s,g';,, f

PHO|O 15 LT GFII

2

o"",".,. -I$"";*", I "rnLi':______I

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24-10

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ir. tt !

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(PCS)

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(vSV)

EVAPcontrol canistervenl shutvalve control

Yi',,,u,

----

L2WBS)

POWER.

EVAPbypass ! TRAINor solenoid I ENGINE valvecontrol I CONTROL MODULE ----J

| (PCMor ECM)

vtEW70

24-11

(D1685) FuelInjectionSystem(PGM-F|) Programmed (N), in PARK(P)or NEUTRAL NOTE:Fuse31 is HOTwithlgnitionSwitchin START(lll)andA'/TGearSelector seeStarting System,page21-1.

@

ii6iir-

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HI FED ll I

&l?3.,"","'o-,rr ,o"on oBon ! Tlaclng

onr

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arsl

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page

canver|

rrsl

er-u onn

t

- - - - - - -- - -;s,nl- -ffi'J-.'"-;t--7;,i----&;----i-,"ffifi input input Oac*rjp I I I

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t T /IlU GFNYEI

r vv 'rT# #""?,* ! I *"ll 'fi-----n {F;H:{" h,T5$B.II J J lvA!::, ! [--iI I I ! t l -"1

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| Phoro58

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,,..!.

a24 '-^-*'!

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f,mihHin. {

I (PCM)

lif''?;"

FromB FromA on facingpage.

v I

WHT/REO

c401

WHT/BED WHT/FED

WIIT/BED

a

*"rr"a^ |

,L-:l'il

mm1:2

FUEL INJECTOR RELAY

FUELPRESSURE REGULATOR SHUT.OFF SOLENOID VALVE

PHOTO 135

r-

vlEw73

W}ITIRED

r arr<

S€sGround Dietribution.

LJ* IT ;.;.il, *'"J'. | ' m ' mm,t ,iJ,-, m'ill"'"-"' c150

:

c4o'l

PHO|O147

a

vtEW72

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PorYgr

Ground Grouft

v' a -

i{

fl[J2)

(rNJ3]

it.;:;t"'-

INJECTOR CONTROL MODULE

0NJ4]

Ground

I-J

Ground

;:[ BFN/BLK

I I I

SeeGround oistribtnbn,

I 8LXI

""'7lw;8"'"

;.;..{

:il

c.t 16 (Terminals'l-7)

SeeG.ound Dislribution, pag€14-3.

Distribr;tion, pags r{-6.

ti :

BFN/ BLK

!

y'o,J

PHOIO 86

clot

Y

!-'

G101

2s-1

PGM-FI(D1685)(cont'd)

I t

I

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I I

h. I (

ct20 vtEw29

DISTRIBUTOR PHO|O 44

IGNITION CONTBOL MOOULE

TDC/

Se3Ground Distrilutbn, page14-3.

I I :nl I

c|(P/ CYP

0cM)

Y

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I I

-,'il"i -*-*i -.?'ii - - - - - -ri**i -''! Sensor Saflsor ground ground

L------

25-2

C30

S€nsor ground

Sansor ground

| 3l"J:uel POWERTRAIN CONTROL ! MODULE (PCM) !

l t

b;,.i,,

I I

) ur"lro

Ground (tcz)

Ground Grornd (PG1j

(PO2)

Rsier€nce voltaoe Ncto

Map ssnBor input (MAP}

S€nsor ground (SGr)

POWERTRAIN CONTROL MODULE (ECM)

Sewica chock cottn6ct0r fioul ' (scs)

PHO|O 86 vtEw 70

ic------

a20Y

B22

82

(Ierminals8.14) vtEv\/39

S€€Ground Dlsr.ihJtion, pags14-5.

S€eGround Distribution, p8g€14-2.

II

Ses Grolnd

F

PHOTO 33

3rr;rs'

-F

___l :

G4/l2 PHQTO 125

(cont'd)

25-3

PGM-FI(D1685) (cont'd) ( UNDERHOOD FUSE/ RELAY BOX

uYt%%, WHT/REO vr6wJ, I

aaz 4

wxlnro I

8 Y C352 ll Proro8

S€EPowsr Bistribution, pag€10-10.

,""'o"n I u'* " ll wwcnr

Se3Powet Distribution, pags 1&13-

.4

*"r,o"., ll

sI

I

DATA LINK coNNECTOR (DLC)

qA l'?!-1 BRAKESWTTCH | Closedwithbrake | /

!-l-ij 9;'3,1ff'**""

'T

"*'-.1, See ABS,

i

ll

ci t 3 11

tlofo t 'EW5! vtEw 59 F------

(x.irie oata inpuv output

: I

-----gl-

VIEC vafue contol

812I'

GFN,^YEL i

I

! I

I

F':t;" o"n,,,.f, r{r *."

Il-i-JJlll!,[.fi"'"

25-4

\ : (

Pt9q Brako switch input WEC prossure switchinpllt

PSP switch inpui

;ry---T (wU)

\

lPSPSvv)

flffiii':Y-2E

"l

t --l

I I \

a

"*|

---J

I I

POWERSTEERING (PSP) PRESSURE

swtTcH

SeeGround Distribution, pag€ 1+2.

t__________L

@

----t

UNDER.

2s t FUSE I p.4:! ) Iff" sesPower| ;"Eiii

I |

IL--*----il--l-J tF,%., l------+ 3l'i:?'J:" 'oY F;%. YELI v/Ew 55

---

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f I Y

c+ lv'rwto r--'1r-:-----'l

seePower

!

pass10'6 Disiribution,

See Fans

I

G U N|

see

I

I

I

ComDressor Conliols

| BLKnEo

I

*o I

o,.1.

I

o',,l

GAUGE

l"?i*,"..

f* ,\

! f,s";"ty"tt vtEwTl |

i @$eFH,t*i

see!y'c

B L U V H|T

I

I

see

Startrnq System

'-iminatstz'zo1

Charorno Syste-m

! T16r I "".11-lro,.. I

I

-ruil

|

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o"no"n!f[?iSuo

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GRNFED f

sVC131

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,r---U,a"i---strF-*-*"r"tr8*i-#%,.----;w;,---lne [it^'" \

tan control

\

r i

i

rL------

control

'[g3l

I

l27Y BLU,FEo I

Y See Vehicle SpeedSensor

(vss)

Atternaror FR

i"R8!,

c23 ll,

t

Input

-._ AJc rsquest

VSS

BtUw}rI I

ciutchreiaycontrol

l I

Y See A,/C Compressor

contiot

",gl,1o "ur

l

w8rRED I

I

Y

Atternator controt

"'11'%, --------J

| (pCM) |l. puoroea iir*. I

I

"rX

wxronr

l

I

I

Y -'-d

3i:,""I"'n'"n

(cont'd)

25-5 I

PGM-FI(D1685) (cont'd)

EGR vdvo EGR In valvs s€mor nd*6nc6 voltac€ ol inDut : cont control inDln volt|ce I G.€GF} GGf,q N@a L------87 c28

Fueria ( pres$uro i.snsor inout inbut .(PFoJ

lP inDul s€{tlor input s8fi8of fiPg'

t h.tsllank tenF,

ingJl sonsolifix, ssnsof fiFO) ------J

\ II ; ,

c150

PHOTO112

j

C'ro1 PHO|O sl

c575 vtEw7i

EXHAUST GASRECIR. CULATION (EGR)VALVE and LIFT SENSOR

THROTTLE POSrT|0N CIP) SENSOR

PHOfO 36

FUELTANK PRESSURE SENSOn

FUEL TA}IK TEMPEB. ATURE SENSOR

H """r":x PHOTO116

(

1 Y

o GRI{/BLK

4

c575

GNN/BLK

c401 GNN/gLK

2

PHOfO 57 vtEw 40

cls0

GRN/BL(

n"*r"a^[

'r cai/BLXll

creA r--?

POWERTBAIN

lsJiH,I CONTROL MOOULE I groundI (PCM)

I

25-6

I

J

PHOfO 86

a

-.t

POWERTRAIN

lcoNTRoL \.

. -,.^-I llglllTP-. . sensor_rnpul ; nFa

I rL------

I MODULE

Fuel p{sssure sansor input

sensor input

(PF2)

.s€nsor i;ir*,o input :

GcD

i|An

I

--------J

c13I'

c14Y

c26

From facing page.

v !

FUEL TEMPERATURE SENSOR

_l

ENGINE COOLANT TEMPERATURE

INTAKE AIR TEMPERATURE

SENSOR

SENSOR

flltur'ffi (Ecr)

(rAr)

From nen page.

v i

GFN/BLKlI i EG-f

,{J

c't 15 (ferminals&14) vtEw38

(cont'd)

25-7

PGM-FI(Dl685) (cont'd) \ ' (

i

Primary HO2S

Secondary

Input (PHO25) (PHozst

(sHo?sr

input

L-------

J,

POWERTRAIN T CONTROL MODULE (PcM)

I I

S€s Power Distribution, p6gs1&5.

PHO|O A6 vlEW 70

UNDERDASH FUSE/ RELAY BOX PHOTO 58

J, i'tj I

Lti-'!

! !

SeeGround Distuibution, pago14-2.

t "l

G101

PHOfO 33

c't23

:li 1

SeaPower Dislibution, pag€'1G5.

c125

(

BLK

PRIMARY HEATED OXYGEN SENSOR (HO2S)

SECONDARY HEATED OXYGEN SENSOR (HO2S)

BLK

c123

2

c125

GFN/ ALK

HOzS' n€ater conlrol

25-8

HO2S hgater control

POWERTRAIN CONTROLMODULE (PcM)

I

VehicleSpeedSensor(VSS) \ . (

il';;---l

I

\

ALTENNATOA

UNDER-DASH FUSE/RELAY BOX

I PHO|O 5a

I I""::,",,", !

Lr_f1l_i 9#":1" ".*,1,[

CRUISE

vtEw69

12

EtuwHr|

! so""oo!iio',6T""f iffii !

!

!;i#:*! l;i"i;'!

L---J B11 Y

TRANS.

MtsstoN I v"ni"t" CONTROL I v"ni"pI CONTROL UNIT l:g9qd l:p"gd I MODULE iineilt i vtEw43 I'T$, I FCM)

[il

iiTs'l,D . ^ . . 1 * l'ffi,

[il

I [

!y:ll*!Bb'^i1?'J.' lr*J l;6';irtE iipEr',r" liib-r,ro,ecu1

L ( - C 1 8 )Y

I [

J

vtLNTo

SeePowerDistribution, page10-5.

(

"""-' Y'

Oerminats1.t-13) vlEw52

lgnitjon

Vohiele speeo ouptn

VEHICLE SPEED SENSOR (VSS) PHATA 35

Ground

= '96-98: AllmodelsexceptD1685 '99 00: D 16Y5 w th Lr/T = '96-'98:All models '99-'00:D16Y5 with M/I D1685

33

.i a

- Howthe GircuitWorks Withthe ignitionswitchin ON (ll) or START(lll), batteryvoltageis suppliedthroughfuse15 and the BLI(WHTand BLK/YELwireto the vehicle speedsensor(VSS).Thesensoris groundedby the BLKwireto G101. Thespeedometer and othercontrolunitsin the circuitsupplyabout5 wire.Thevehiclesoeed voltsto the BLU/WHT groundsthe (VSS) intermittently sensor generates BLUMHTwirewhich a pulsedsignal in it. Thenumberof pulsesperminute increases/decreasos withthe soeedof the car. Reterto th€ ServiceManual(Section23, Electrical) procedures. tor specifictostsor troubleshooting

33-1

CruiseControl (

FUSE i4

I

t

i

P*", f tlfl*t.,s"" DistribulDn,

|

(CBUISECO{TAOL)

\

a

UNDER.DASH FUSE/RELAY BOX

H

L--g----r9101_

".,."11[ftT:{.

See Dash and Console Lights

"-T[_

! i,*f+*l f:L[

CRUISE CONTROL MAIN swtTcH

"oN" It{otcAToR

\fa See Dashand Console Lights

Openwith brakepedal depressed.f--

I

LrcRNI

I

Ir

,.L-----

r#e i--l L-------

34

'r

"""I *"1 I

t

---3-l -ffi$r------( l --------J

* = '96-'97models *' = GXmodels

;iil;------'l onl|, ATO9IT l5a

506 Po\r€r Dislrhulbn, pagelot3.

UNDER-HOOD FUSE/RELAY BOX

----li----J

i

c352

8

PHOTO8

WHT/GFN

,r:ill

ilifl'?H]"*,--

,rllI g**. ---!

",f,*,,":l CABLE

S€s llorns -----J

I REEL I I I

STEERING WHEEL

?

I I

l r I

BRAKE

.

Closedwith brak€pedal deprcssed,

Rlroma/ Accel Sultch

swtTcH PHOTO 68

3 ItK

2 gu{

r-r------

1 CABLE IREEL

I

3ll'

CNU|sE CONTNOL SETngSUtE swlTcH

| \

I

"+f--a=={ --.'*""*-[ \rnfig*,',,"1o,, ","*" *-'*:'! |s.triL!fl8;lp,*,;,,LT.FN,FEDI

o"n.t""t I

L-

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..^at

J

,,^"1,

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(s6-'s7moders i)J[ Br?kp swilch

fr^

intut

\ I

- -

(sl g -o9"95]I-( e6-e7moders lll Sevdecel signalinput

cRUlsE ---:--l Resuma/ t Ctitrf-nlOr_ acc€lsignal i uNif

inp,n

| p#ib * 13 lvtEw

(cont'd)

34-1

CruiseControl(conrd)

\ta - --

;lG;r-usEz5

J,T"r"r,E;oAit tusEiRELAY

IiF" 3g;g;; f,%,,

-------' page.tG6. I L:4---:---J

SeeDash and Console

;I

Ss€ po$/er Distribution, page10-6.

wEw56 -r+

GAUGE I ASSEMBLY

CRUI6E CONTROL

rNrxcaTon UGHT

\1

E3 BL|(

I

----*-

I

I J

E2Y

""t===j I

t-ffiI c0f 0r

I

Se€GroundDistribution, pag61+7.

c411 PHOTO 60

RED/BLU

= G401

I I

10 ('96197models9) 'Cruigecontrol' indlcatorlight codrol

Cruisecontrol actuatorqontol

I

Gro{nd ('96198 models 8) o

11 ENN/ELX

aFt/Bu( 2 aLu

6nNAVST

c202

4 BBT{ 4

BRt{lv}tT

3

PHOfO23 VIEW1

c203

PHOTO18

CRUISE CONTROL ACTUATOR

Se€GroundOistribution, page1+4.

l'

34-2

G202

""r1

i -

'99100

016Y7/D16Y8with A"/T -

POWERTRAIN Cruise CONTROL conrol MODULE sgnal (PcM)

i8s)i

| \

-

-

iil

-

;

-

i

-

-

*

-

-

-

' '

Cruise control signaloutput

.

l

c

= '96-'98:All models '99100: D16Y5with M/T,01685

R

U

|

s

E I CONTROL |oNir I PHATO55

I .--------;----

13 ' vtEw

vehiclespeedinput

oisengageinput

---J

SeeVehicle Sensor rySS) "{ CLUTCH

swtTcH

Open with clutch pedal oepresseo.

,--r-s=-. A/T GEAR POSITION

swtTcH

L- ----

SeeGrolnd Dlslribution, page14-6.

I

Y

l

l

L__l #

:

x

ALU,ryVHT

O-a

See Gfound Digtribution, page 14-5.

I

3

ct30 Cferminals 11.13)

PHATO E3 vlEw 52

VEHICLE

lI:::1"I SPEED SENSOR I output I

(vss)

J

G401

34-3

GruiseControl(cont'd) - Howthe CircuitWorks Thecruisecontrolsystemusesmechanical and electrical devicesto maintain thecar'ssDeedat a settingselectedby the driver. SystemDescription Thecruisecontrolunitreceives command signals fromthecrursecontrolmainswitchandthecruise controlSeVResume switch.Withthe ignition switch provided (ll) (lll), in ON or START voltageis to the cruisecontrolmainswitchthroughfuse14.When youpushtheswitchto ON,poweris provided to the cruisecontrolunitandthe brakeswitch. The cruisecontrolunitreceivesinformation about operating conditions fromthebrakeswitch,the vehiclespeedsensor(VSS),andtheclutchswitch (manual transmission) or theA,/Tgearposition transmission). Thecruisecontrol switch(automatic unitthensendssignalsto thecruisecontrolactuator whichregulates thethrottleposition to maintain the selected speed.Theconlrolunitcompares the actualspeedof thecarto theselected speed.The controlunitthenusesthe resultof thatcomoarison to openor closethethrottle.

(

Youcan cancelthe cruisecontrolsystemby turningthe mainswitchoff. Thisremovespowerto thecontrolunitanderasesthesetspeedfrom memory.lf the systemis disengaged temporarily by the brakeswitch,or clutchswitch,andthe car's speedis stillabove25 mph,pressthe resume switch:thecarwillautomatically returnto the previously setspeed. For gradualacceleration withoutpressingthe pedal,pushthe RESUME accelerator switchand holdit there.Thiswillsendan "acceleration" signal to the controlunit.Whenyou releasethe switch,the systemwill be reprogrammed for the newspeed.To slowthe car down.oushthe SETswitchin and hold it there.Thissendsa "deceleration" signalto the controlunit,causingthe car to coast.Whenthe desiredspeedis reached,releasethe SETswitch. This reprograms the systemtor the newspeed. Referto the ServiceManual(Section23, Electrical) procedures. tor specifictestsor troubleshooting

(

The brakeswitchreleasesthe system'scontrolof the throttleat the instantyou presson the brake pedal.Theswitchsendsa signalto thecontrolunit by removingpowerfromthe normallyclosedbrake powerat the input(GRYwire),andproviding (GRN/vVHT normally openbrakeinput wire).The controlunitresponds by allowing thethrottle to close.The clutchswitchor the A,/Tgearposition switchsendsa "disengage" signalto thecontrolunit that alsoallowsthe throttleto close. The cruisecontrolsystemwillset and automatically maintain anyspeedabove25 mph(40km/h).Toset it, makesurethemainswitchis on andtheswitch indicator is on.Then,afterreaching thedesired speed,presstheSETswitch.Thissendsa "set" signalto thecruisecontrolunitwhich,in turn, controlsthe cruisecontrolactuatorto maintainthe setspeed. Whenyoupushthe SETswitchandthecruise controlsystemis on,the"cruisecontrol" ON indicator lightsup.

a 34-4

A/T Controls(All '96-'98ModelsexceptCW and GX)

r.( UNDER"HOOD

r5A

see power

I FUSE/RELAY I BOX I

--li$"i':,--i

L-.At----8 Y 93^s_1'"'".u

__*____..,,53-j"i__ 8Y C352

I iii'i"'

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see power

t"*tr*t1,'.':,:;i , i

ll

oisirioution,

la---

.

[--*

!

-t

SeePower

6iri,iortion, page 10-13.

wHrGFNlt

(withcrurse 4) A l"'rl(-1 BRAKEswrrcH brake | \ lClosed.with

Ir-I Il,?,|fll,"P'"""o

L*--J

-----.#ku" ::::: ,. L *" -:;tr *";.!, 'o ---------tty"c;11,, f

c 1 0, | !

I

(SKSV,

Batteryinput service ;;;;iVehrcte connector speed

Brakelwitch nPUt Linearsotenoid input

(scs)

{Ls})

:

l;?t?:if,

Ds^'

Lvou,

I

l;-,f

(vss)

c18lr "ar-"tI

rLs )

Shiftcontrotsol€noid valveconhol {sHA'

ehin Lock-upconkol iJ'[ solenoidvatvecontrot tliiJ"it

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(cont'd)

39-9

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!d

c433

A/T GEAR POStTtON SWITCH

--*

BLK 1

c433

6LK BLK

a-<

"'*l |

SeeGaound

Disaibdion, *o" to-t

Y

t_ _ _ _-gcji____l '--PHOIO 125

39-15

Horn - '96-'97 Models UNDER. HOOD FUSE/ RELAY BOX

c353

PHOTOs

SeePower Oistribution, pag610-13.

""^T.!,HORN RELAY PHA|O 58

6 g c411 | _vtEw

60

a,

BLU/FEO

---l i cnv I

:i :i-I:::--l i ! !'-'! fevtess ,,lr--J

! a;fi."*I

::.-------J . , STEREO TUNER RAOIO

18 A C516

sEcuRtw

SYSTEM CONNECTOR

c214

1

(oPTroN)

vtEw21

PHO|O 73 VEW 5A

| | vtEw68

WHT/qRN VHT/qRN

pre-wired--Vehicles lor accessory securitysystem

c430 BLU

I

1 Sse Cruise Control -------

J

GBY

-

-.!

HORN

l

STEERING

WHEEL

h :

40

c4o1

PHQ|A 57

- '98 Model FUSE52

I I I

floFft,

sroPtT 154

I Y C3s2

S€oPowsl Disfibdion, page1013.

""',o"nI il?lo,'

wHT/cFN

U

@.

THI

UNDER. HOOD FUSE/ RELAY BOX

:t c353

HORN RELAY

o GFY

87 :

; :'

l c.oMBrNAroN !'Gi-'! Il UIio| swrrcH !!9f1I i l l

GBY

2 ELU

I I

I

iq!ffi" a * L--

--

- --

40-1

Horn - '99-'00 Models UNDER. HOOD FUSE/ RELAY BOX

FUSE52 HORI, SfOP LT t5a

HORN RELAY

---------^1

GRY

i

:'

o.--------; cnvl ri-'--.|

',

l--J

T

:

: coMBtNATtoN

:' lrft ! puotozz !',f,11" | | i---

BIU/FED

o r J---a-----r---O

i " l i

I

2

i I : ;

vttwu

E r " " pe tx . o o e -r - - - j

i ;l i ;,1..., '

r--1

:

SECUR|TY

, I

i!,o!o 73 vlEw58

: l l : s Y s r E M , i a , c o N N E c r o R '

, ,

: i , I I

!

!

L--J KEYLESS

DooRLocK coNTRoL UNIT

(oPrloN)

c214 v|EW21

with Kevless Entry

PHOIO 134 vtEw 75

Vehiclespre-wiredfor accessorysecuritysystem

GRY

c430 ELU

PHOTO 65

.l I

a \ I

SeeCruise Control

I I I I

CABLE REEL

GRY

STEERING WHEEL HORN

a!m" niffil" 40-2

.,1 ,

Anti-LockBrakeSystem(ABS) UNDER.HOOD

H'.'"" ii[*:'*" 1

c357 PHOTO 4

GFN

10 BEO

c359

PHO|O 6

Grqlnd 2 {GX!2)

l"l Fi* :l :l

!Ji I-J .-L----i il T

44

PHOIO 125

UNDER-HOOD r------1 ABSFUSE/ FUSE61 RELAYBOX PUIiP

olon

c356

Right Rear ABS Solenold (Out)

night Reer ABS Soloroid (ln)

i-.t_____l

Lett Front ABS Solenoid (od)

FUSE63 MTN CHECK 7.54

3

*fitr c357 2

YEURED

c356

A19

\

RightrearABS solenoidcontrol

\

i

/ &------

comm6n

LeftftontABS solenoidcontrot

(PMR)

(MCK)

Pump

Motor

motdr ;i; loni of

^

Service.check connectorinput

11.I BRN

"Tl

'Tl

I trrt

sRS.ATcontrols

SERVICE CHECK CONNECTOR

I t-!

---_____J

See GrOUnd

vttt 63

LTBLU vccvnv

DATALINK CONNECTOR (DLC)

PHA|A 125

': 1

c360 ABS PUMP MOTOR

pHOrOso

Pll'lo.,jpn. p y:l:!:1

'--=-Ea;

I i

aBscoNrRor_lrNr

*L_T'=Llj:t

PHoIo 83

I

I! !

l

DLC inpuvoltput

A14 r rr eru

check

I

See Ground

*---==4oi PHOfO,/

44-1

Anti-LockBrakeSystem(ABS)(cont'd) ( .I UNDER-

!'-r;us?;---l H5BE"FUSE16 iA DEF

ilrryilrfi#ftilHri 'tr

lEtsY SeePower :ar Distribution, page10-8.

L-g------J

wHr/GRN

c421

F,1%' v/El.V 2Z

I

I t"r,o""

O--t 'n"r,o^n I

10

vlEW50

page 1G6.

I

pHoro5d

c501 vlEW55

SeePowerDistribution, page1S6.

se€Power

Distribution, 10-13' Page

YEL

D5

GAUGE ASSEMBLY

.tr

.I BRAKE

r -N-

|

| swrrcH

\

igr:*

AAS INDICATOR LIG}IT

usA a'KBLU

o"ntr"r

Carsda

!

It

I

'96-97 mooels

D3

Dl

ftff^"n"o''''ot ', \ ',i:,tr?""" ""*[:-l ! P"g"t+-z I ".., ".-l i"., I I ;nl m;r""#,usi:", L------J I *

".r',

".1

",I

mI

T1*l

{FLo)

i

seecroundDistributiofl,

iffit ' n

:

iot

{FL1)

B23Y

i

(FBo)

B8Y

I

{FF1)

B21lf

i

(Rr"o)

B6Y

^*ry*l:-------l

8Bi"o.

ir .UH|T

iicib et vlEw63

Sg____gT]-__g,l-j

BlsY

(

G401

1lo2) lgnition2 ' used) ; 4ts5lnolcalor l i g hct o n l r o l Speedsensoranputs r - - - - j .

t,"LTfflo", Input Blolf

!

B4X

B17f

o"",'.. o""l .,",-ul u.,"..1 I

r| | r | t I t , l l , l "on" 't---'+----"[. I --fo f!'?'%,' ll ll I *"*-l ti *"1 ""n*",lo"no""l "**.I *"1.'"."1*,*.[

I r L___t"" " t__t"." 1___!"."" "lf-*i":'' ;FJ,;::;":f3:::1'' "4::3' "r.f_ t'l ,.,Jtri"?r. ll;l]flffi lFli.ft. lU]flqtfl lt;Tt?f lt"F"Ti?l I lt5T8?lI l"#tgl I

44-2

(

- Howthe CircuitWorks The anti-lockbrakesystem(ABS)preventslocking of thewheelsas a resultof heavybrakingand/or poorlraction.A vehiclewithlockedwheelscannot be steered.The anti-lockbrakesystemcontrolsthe thedriverto application of thebrakes,allowing maintain controlof thesteering. theantilockbrake Underanti-lock conditions, system(ABS)modulatesthe pressureof the brake tluidto eachbrakecaliper.Thissystemis a four at eachcaliperis channelsystem:thepressure of the pressureal any controlledindependently othercaliper.Whenevera wheelis likelyto lock theanti-lock brakesystem dunngbraking, at thatwheel.When modulates thebrakeoressure is reduced to the pointwhere the brakepressure of wheellocking, thereis no longeranypossibility braking thesystemreturnsto theconventional systemmodeof operation. Batteryvoltageis appliedat all timesthroughfuse switch 63 to theABScontrolunit.Whenthe ignition to the is in ON (ll),batteryvoltageis supplied controlunitthroughfuse16.Thecontrolunitis case grounded.Inputsare receivedfromthe brakeswitch andthe individualwheelsensorslocatedat each wheel.TheABScontrolunitusestheseinputsto unit.Thesolenoids solenoid controlthe modulator pressure appliedto each adjustthehydraulic calioer. function. TheABScontrolunithasa self-diagnosis fault, it turns on the unit detects a Whenthecontrol "ABS"indicator brake theanti-lock anddisables braking system.lf thefaultis notin theconventional to operatenormally system,the brakeswillcontinue feature. butwithouttheanti-lock '19, Referto the ServiceManual(Section testsor for specific Anti-Lock BrakeSystem) procedures. troubleshooting

44-3

Supplemental Restraint System(SRS) (

UNDER-DASH FUSE/RELAY FUSE23 BOX (sRs)

FUSE13

FUELPUUP FBA UMT) 15A

SeePower Distibution, page10-2. c801 PHOTO 58

PHO|O 111

G F Y0 7 ) or GFN

{18)

. To avoid accidentaldeploymentand possible iniury alwaysdisconnectthe driver'sairbagand f rontpassenger's airbagconnectors(automatically shorted)beforeworkingnearany SRSwiring. . CAUTION: Wheneverthe ignitionswitchis ON (tt), or hasbeenturnedOFFfor lessthanthreeminutes, be caretulnot to bump the SRS unit; the airbags could accidentallydeploy and cause damageor SRSMEMORY ERASE (MES)CONNECTOR iniuries. STGNAL G A Y ( 2 1 )o r G R N

GFN

GFY O4) or GRN

lgnition Input (VA)

lgnition input (VB)

Driver's cont.ol

SRS UNIT

SRSindicator lighlcontrol

MESconnectorinput

rffi{{_ilil ;

Passenger's ai|bagconlrol

t ,

prc..

rnpuv Ourpul

Service check connector Inpu

t-----Passengefs : airbagcontrol ; , /+rr

; , Ground I pir-r

14

GRY (5)or GFN

GRY

GFY

0)

t2l

GFN

GFN

i ffi

ir:r*::"." ffirtu!-T:l

2 ALK

J(ii t\

i lffil i""'"1*"o,"'.1''

'"'Jl ilstEl'{s6.e8' , oATAL|NK I

"Tl

-ffiffi,*l-{

SERVTCE (DLC) CHECK CoNNECTOR piarasa CONNECTOR

,J:

vtEw48

H!=";=_J Hiffii'r:fi:*"i t shortcontact)

L_________J

47

|

-

FCqOt

PHO|A 57

PHOIO 125

a

UNDER.DASH FUSE/RELAY BOX

FUSE25

PHO|O5E

IIEIEB 754

S88 Fowor

I

L-L-iri:---

"l*no

c412

J

rur"'"""., GAUGE ASSEMBLY PHOfO 67

c41t PHOTO @ VIEWN

I I I I I I

I

J

i Btr.BR""Xi

I l

I

l

L__l €

= G4ol PHOfO 57

47-1

BlowerControls '96-'98Models

@ UNDER.DASH FUSE/RELAY BOX

UNDER. HOOD FUSE/ RELAY BOX

PHOTO 5A

BLOWEF

noToR BELAY PEOfO I

(

BLU/ YEL 1 l BLU/

HEATER FAN SWITCH

SeeGror Ground Dbtribution, Dbtributi page 14-5. oaqg14.

ar<

L -

60

II

_l

c402

6 1 BLK

BLK

BLK

calr

See L/c Compressor Controls

- '99-'00Models

i-F;;t

iGi'i'-----'l

UNDER.HOOD FUSE/RELAY BOX

BEATEA ,'/C RE|AY 7.5A

L-t'::-i "d[ft?"l'

L-*----::--J

FUSE55 HEAIER t/toToR

UNDER. HOOO FUSE/ RELAY BOX

".*1.[F*ft"

n BLU

UNDERDASH FUSE/ Power See RELAY Dist.ibution, BOX page10"9. PHOTO 58

I I

-".. i c.u, --';-lP;!o;i:

$

---------J

Se€Powsr Dl8tdbution, pago1O11.

l

3ffJ?il3'o'"o'o*'on

,f

ALOWEF moToR REIAY

-f-***;;Iru PHOTOI

l1

:::::: - ---r-- -- J L__f_---_-_ BLIV YEI

BIU

g€ePowsr Dlslribution, pag€lGg,

t!.-

---:-----.l ------------a--E

za

'r BLowER l-'n I A lm-o-roC'

Ir

eaoz PHoro12s

I( MrlProraE3 I Y I -

=----GG-a

".","i-l' Ea

JI

1 lgnition Blower I t Battory input molor i i (brckup) t ,,o*", ffJtt' ' 'Jback I I _ Power motor i highrelay transislor !

Ls::s1gl-tt:---J A6

813

alK

OFN/ WHT

HEATER I"-'FI CONTROLI | pAHel I I PHorotr7 | tt wr'vzo I ;_\

vtEvl57

POWER | rAlHStStOn pHoro 13e I I

6

BLOWER MOTOR TIIGH RELAY PHO|O 83

|

lJ J I

BLK

2

c440

BIK

SeeGround Oistribution, page'14-5.

"l

G402

Se€Ground

Si:lf:::'>-1 G402

60-1

Air Delivery

a

- '96-'98Models

I :

\

I FUSEiRELAY

H€AITN

! f I9"",'

i

UNOER-DASH

17 t FUSE f

:

seePowsr !

BOX

PHOTA 58

otsaibution, i

LJ----':g':'--.i 9 C420

BLx,yEL

Y ELK/'(EL PHora363 I

a

er.x,ter-[ SgEPorvst DistrtbLditr, pags I S9.

".*..";:.it#?.9.,, RECIRCULATION CONTROL MOTOR PHO|O A2

SeeDashand ConsoleUghts

c723 GBN/IVHT

12

r I I I I

GBN/NED

PHOTO138 vtEw 57

13

S6€IVC ComprsssofControls

€ \

\'a 61

I

MODE CONTROL MOTOR

;T 1[

:",;[---___l:il t 1___"rt YEUBEO

_:o_

c723

YEUBED

138

HEATER CONTROL PANEL

8

I I I

.l

\rt

t

\

it

Venl Swltch

lleat Swltch

\

I I I I c723

,rlK

S9eGround Distribution, page14-5.

h

-_l

G402

61-1

Air Delivery

a

- '99-'00Models

- -{-;;;

-

r--T----.I

i|

,ry:i.l?

i

- - - - - UNDEB-DASH UNDER-HOOD ; PJ,'.',8.J390 IIFUSE/RELAY iI T;; Il:usE/RELAy H$3,',8 t::u:E^tt ];FPJ",

1;:t"*

i

i m'.u" se€power i "t8L,,

a a l'"0 r3l",lli"i:" L-J..----5::---:-J

i

iL--{..-----J t

'[r;T:1"

"",":"rfi?ll,

*-*..l -",*"1-J l r ! ,n",".uI

lt

I

SeePower Distribution,

I I

I SeePowerDistnbution. U page1o-9.

,,L::':l-------*Y=l "*o"."",,t

[I r e l -

*,:.'.Y%

l t

MODE CONTROL MOTOR

RECIRCULATION CONTROL MOTOR PHOTO139

:'l-4riffi ;L:L{;I{,tt't{{f 'il

:tr*,tr Htr Ttr =tr ;l*tr *tr T Ti Ttr lgnition Mod€ Mode Battery (backup) input detrost h€av delrost Air

Sensor mix grgund cool

Ground

Mode L4ode heat heav venl

Air mix hot

Mode vent

Air mix 5Y poientia, reTgrano9rnrrul

l\tod€ motor gIouno

13 BFN

SeeGround Distribution, page14-5.

I

61-2

R€circulato Fresh

ft++il

c4 t,

cl

WHT I

ONN

c723 F ash/ Roclre Swftch

AIR MIXTURE CONTROL MOTOR

I

So€Roar I Windolv : Delogger

Reclrc.

SeeRear Window Oetogger

Y

t t L__l --tGo3,

vtEw76

I

AFN SLK

CONTROL PANEL

Recirc Recirc S$,itch Swilcfi switch tED LED common mput control common - J ;;-; J'J - - - J-JL i5:- -

c9 Y cl1

812

a

L-------

oatLEo ---J HEATER PUSH

swtTcHEs

(

- Howthe CircuitWorks '96198Models

'99J00 Models

The air deliverysystemdirectsthe flowof air used systems. by the heaterandair conditioner

The heatercontrolpanelreceivesbatteryvoltageat all timesthroughfuse47. Withthe ignitionswitchin ON (ll), voltageis suppliedto the heatercontrol panelthroughfuse17.Thecontrolpanelis groundedat G402. The heatercontrolpanelcontrolsthe air delivery motors,and suppliesa 5 VDC reterencevoltageto the air mixturecontrolmotor. The air mixtureand modecontrolmotorseach receiveinputstromthe heatercontrolpanel.The air mix motorregulatesthe mixtureof coldand hot air doot by varyingthe positionof the heater-evaporator

ModeSelection Modeselectionis controlledby the modeswitches in the heatercontrolpanelandthe modecontrol motor.Whenyouselecta specificmode,voltageis appliedthroughthedimmingcircuitto the LED, whichcomeson, indicatingthe modeselected. Groundis orovidedto the modecontrolmotor thoughthat modeswitch.The motorthen runsuntil the air controldoorreachesthe properposition. Fresh/Recirculation 56lection button,a Whenyou pressthe freshor recirculation groundsignalis sentfromthe heatercontrolpanel controlmotor.The motorthen to the recirculation doorreachesthe proper runsuntilthe recirculation position.Batteryvoltageis alsoappliedthroughthe LED,andthe dimmingcircuitto thecorresponding LEDcomeson. Referto the ServiceManual(Section21, Heater)for proc€dures. specitictestsor troubleshooting

The modecontrolmotorcontrolsthe directionand volumeof outletair.The air flowcan be directedto the dashboardventsor the cornervents. Boththe air mixturecontrolmolorand modecontrol motorare groundedby the h€alercontrolpanel. The recirculation controlmotorreceivesbattery swilchis voltagethroughfuso17whentheignition of thefresh/recirc theposition in ON (ll).lt regulates door,and is controlledby two positioninputsfrom "Fresh"). the heatercontrolpanel("Recirc"and Referto the ServiceManual(Section21, Heater)tor procedures. specifictestsor troubleshooting

61-3

A/CCompressor Controls

\ a

- AllModels

@ f-T-*-'.T'---lH53.',EPA?' i-l-------

i iflH* !F,?r",, | tsBi":J;"#il ! | | oaoe1o-9. ! L_J1_j:_-_j

***

e Y c42o ifi"l' f

seepower

^

UNDER-HOOD FUSE/RELAY BOX

ia f6F"'.i:.",", T I !

I H

i !

I |

SeePower Distriburion.

pase 1o-1.

&c

COMPRESSOR CLUTCH RELAY

-

Y

PHOfO 10

l

-t---------J

c353

: POWERTRATN I or ENGINE

! ,acc, ! arn.^-^,o..^,

i.,ii.r| fi3$18. ! iii"i-iiii"v A/Crequest (pCMor ECM) II

!

a pHOrOa6 v t E w7 0

(ACSJ

L------J

cc5) M7

a

REO

c2'14 BEO 1

vtEW21

c209

RED

c752 ct31 BLU/RED ? BLU/FEO

2 BLU/FEO

:"1'!i'------;

COMPRESSOR THERMAL PROTECTOR

a='e6-'s8: except D1685 '99100:A||moders

Fi:rz, vtEw21

ir'iio ,"

D16Y5with l\illT '* = 96-'98:All models 99. 00: Dt6y5 wth t\4/t Dl6Bb

atc

c1

PRESSURE

swtTcH

".,n""t 1( " ".r-".rf,"tA%

A,/C COMPRESSOR CLUTCH

"."-:,fi tfr,]4.

v

To facing page ('96''98 models) or page62'2 ( 99-'00models).

62

!

(on bracket)

- '96-'98Models FromC214on facingpage.

UNDER. HOOD FUSE/ RELAY BOX

v "**il'ifr"e;

S€eFwvof Distrih$on, pags10'11.

INDICATOR

----1

HEATER co TROL PANEL D i m m i n- o I Clrcult

L------J SeeAit Delivery

'l ctte

I

lrc

I I I 10 HEATER FAN

swtTcH

62-1

AiC CompressorGontrols(cont'd)

- '99-'00Models

(

Frompage62.

vI

.I

UNDER. I HOOD i FUSE/ I RELAY

*"-ilii.,"r,

ihtli

I Box I J

UNDER.HOOD FUSE/RELAY BOX SegPow6r Distrlbutiofl, pag€'lGl1-

c353

4

PHO|O 8

BLUAVHT 15 6LUAVHT

a,/c

THERMOSTAT Olt below 3 " C( 3 7 " F ) .

l[,,* "'"" ".j:[ru*,,ry ';.!, "..;X

(

THERMISTOR

B11A

A8A

r - - : = -A/C -II

Switch common

l'lC switch LgD codrol

,c,/c

switch itput

cl

GBN

ORN

t/c

Swltch S€eAir Delivefy, Rear Window Dslogg6f

B€ttery (backup)

Switch IED cormon

c5

{;[ B ' I O| '

lgnition input

request

vtEW57

Grouod

BIK

SeeAir D€livery, Rgar Window D€foggar

r,/c

HEATER PUSH

swrTcHEs SeeGround Dist.ibdion, page1,1-5.

Ot'l lndicatof

Y

I

=ffi; PHOfO 125

62-2

HEATER I CONTROL : PANEL

(

- Howthe CircuitWorks Batteryvoltageis suppliedthroughtuse56 to the A,/Ccompressor clutchr€laycontactsat all times. Withthe ignition switchin ON (ll),vollageis applied to the coilof the A,/Ccompressor clutchrelay throughfuse 17.Whenyou pushthe A,/Cswitch ON,andthe heaterfan switchis in position| , 2, 3, or 4, a "ground" inputis provided to the engine controlmodule(ECM)or powertrain controlmodule (PCM)throughthe l'lC thermostatandthe l'lC pressureswitch. TheA,/Ccompressor clutchrelayis groundedby the enginecontrolmodule(ECM)or powertraincontrol module(PCM).Whenenergized, theA'lC compressor clutchrelayallowsbatteryvoltageto turnon the A,/CcomDressor clutch. TheA,/CON indicatorlightcomeson whenthe A,/C systemis requested. A,/CThermostat The A'lCthermostatis locatedon the evaoorator housing.The A,/Cthermostatturnsoff the A,/C at the compressor clutchif the temperature goesbelow3'C (37'F).Thisprevents evaporator fromfreezingon the evaporatorfins condensation theairdeliveryintothepassenger andblocking compartment. Theblowermotorwillkeeprunning whenthe sensorturnsoff the comDressor. A,/CPressureSwitch The fuC oressureswitchis locatedin the condenser is in a high outletlinewhererefrigerant pressureliquidstate.The switch temperature/high willsenseabnormally highor lowpressure, and ground, This removes openthecircuit. andthe compressor willstoprunning. ThermalProtectot Thethermalprotector,locatedon the A,/C compressor, opensandturnsthe compressor off if it senseshightemperature. Oncethecompressor will cools,theswitchwillcloseandthecompressor beginrunningagain. Referto the ServiceManual(Section22, AirConditioning) for specific testsor procedures. troubleshooting

62-3

Fans - AllModels

\,1

|

cof{oENs€R

FAN RELAY Prtofo10 Se€I'i C Compre€sor Cont ols

c352

1 ALKAED

f

uY 9,;%,. cFN vIEw5e

"'

;

Y:.

\ra

BLKaEo

";::-:.."-!

I

T ---::Y

""'I h!ii'in"," 'is.2o) : :

I :

spliced together insteadof in thejunction connectoron Dl6Y5models

l;l:'l?'* i I i,o''ur,ff;,

II r---,; |JBEI :; I control | I

I du.

,I

c753

1 BLU/BLK

CONDENSER FAN MOTOR ALK 2

c753

BLK

:L--J ' ' '

: I I

H :I

:

PoWERTRAIN or E N G I NC E O N T R O L' MODULE (PCMoTECM) :

PHAfO 86 wEw 7a

ENGINE COOLANT TEMPERATURE swtrcH

l l q A- - - - .

c211 BLL

PHO|O 33

?

RADIATOR FAN MOTOR

I

BLK

t1 - '96.f98: models '99-'00:All 016Y5withM/I 01685 '99-'00: "2 = Allmodelsexcept D16Y5 withM/Tand01685

Ses Gro!nd Grolnd Diskibution, page 14. oaqe14.

i:

"'*1F J T _l I I

Se€Ground Ostribution, Pago14.4"

PHOTO11

BLK 1

c211

ELK

'Glot

*

63

czsr

33 123lCVIl

*

czor

a

- '96-'98Models

i-ITy::.;--l il-;;.;l il;; UiB!'* i-T ig;Eili--l Liff" tS^*

Fromunder,hood Fuse/Relay Boxon From Under-hood

;

(

I

H

HEATEB

liEF; i$f" i| llH**"", 1"1 seepower i ?r*' ' IiL8ry-s:d-J i-r-g-.'I.-

rac,nspaee

U l S I r l O U I r O nI , e l l o ' O 5 8 L l v - - - -

L-I----q,ryli"--Jr'i L-L---q'i.'g;-.1wxreru 9

V

".,*"'l |

I vr'wi."

X ,cgr,g ""

SeoPow€r Disaibution, page10n1.

::::ll6iirf{ffi.","., --- --'''lB;,zfz "f

"$r*,,,, Jl[1__::.fif-o

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-1-'

Gll".-11yorror"-:'L

r------,F-

UNDER. HOOD FUSE/ RELAY ! BOX

[

A/C ON INOICATOR

L -----

HEATER CONTROL PANEL

-J

SeeAk Delivery Gate

tc

I

L---rr--

---

- -J

IF-F;Ia,ic

Swltch

,!r---*l h ...

,----------J

-:{l-lit't;; L€:_jftH+z "*f

,""n,ouno

___-i*-] 63-1

Fans (cont'd)

rla

- '99-'00Models

iTm,il-l5;i;T iln"lgg1 *-"' L_t]stE"_i*-o* !-J-___i

"W"u'

".*L[F*f,l"' -*,".'"[ftT,;.'

I

I

SsePower

.-.. ',-.',

?+

3s;iT:3:'

S€€Pow€r

I

?'4

3ff:?f?l:

::--

;+ OEE I

I

{***,Pase*11

Dbfibution, pacp10.9.

It

a,/c

THERMOSTAT Offbelow 3'C (37"F).

2 Y ^..._-_I *-*"! 2oV c723

l t

tI

L - -_-\Tgr?;u

'l I I rHERMrsroR lt | q/

t

r l

I

I 2 39 - - - - - - - - - - - - - - 2 , f,

l ar-x,ver|

t

l

I

t

I c723 ,2tr prtoroz!3a

t

n tn*t,".u I I

orl ---riliii"--

---rF------

"tol (backup)

inplt

requ€si

i

HEATER CONTROL PANEL

I vlEw76 Switch" common

L-----

N

r,/c

svritcn LED control

switch input

c

Swikh LED cofrrnon

l I Ground

_ _.i

A6 BLK

A/C Swlbh S€eAlt Deliv€ry, Baar Window D€loggpr

63-2

SeeAir Dslivery, n6ar Window Delogoor

a/c

ON lrdlcalqr

HEATER PUSH

swtTcHEs SeeGround Distribution, pag€1+5.

I

;-a; J

rfa

- Howthe CircuitWorks RadiatorFan Voltageis providedat all timesto the radiatorfan relay(contacts)throughfuse57. Withthe ignition swilchin ON (ll),voltageis provided to thecoilof therelaythroughluse 17. The radiatortan relaycan be groundedthrough switchor the eitherthe enginecoolanttemperature enginecontrolmodule(ECM)or powertraincontrol module(PCM). The enginecoolanttemperature switchgrounds (coil) radiator fan relay when the engine the coolanttemperature exceeds199'F (83'C).The switchopenswhencoolanltemperature decreases 3'- 8'C. CondenserFan Voltageis providedat all timesto the condenserfan relay(contacts)throughfuse56. Withthe ignition switchin ON (ll), voltageis providedto the coilof the relaythroughfuse17.WhenyoupushtheA'lC switchandputtheheaterfanswitchin 1, 2,3, o( 4 position,the ly'C thermostatcomeson, the condenserfan relayenergizes,andthe condenser fanmotorruns. A,/CThermostat is locatedon the evaporator TheA,/Cthermostat housing.TheA,/Cthermostat tumsoff the A/C clutchif the temperature at the compressor goesbelow3'C (37'F).Thisprevents evaporator fromfreezingon the evaporator fins condensation andblockingthe air deliveryintothe passenger goesbelow3'C lf the temperature compartment. groundwillbe (37"F)tumingoff the Ay'Cthermostat, fan relay.Thiswill removedfromthe condenser deenergize the relayand removevoltagefromthe fan motorcausingthefan to stoprunning. condenser Reterto the ServiceManual(Section23, Eleckical) procedures. for specifictestsor troubleshooting

63-3

RearWindowDefogger - '96-'98Models

il l1c

SeeDashand ConsoleLights

UNDER-DASH r - F - - - - 1 I FUSE/RELAY

FR DEF R€LAY 7_54

c501

@

.I

FUSE16

FEO/ BL|<

\rl

ff":;;1il,l"'3|""

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c351

vtEw55

vtEw34

REAR

wtNDow

DEFOGGER SWITCH

rf

ll-,--:L::

See Dash and Console Lights

S€eGround Distribution, page14-7.

NEAH wtNDow DEFOGGER RELAY

UNOERDASH FUSE/ RELAY BOX

P|1oTO59

L--------

-------J

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Y

I I

a rr(

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I

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:

g"x%,0, ".^,"i'uI ' * 9,g%,,, eu,eul

G401

|.Tl

IiIDEFoGGER

II "

*-l

seecround Distnbutron, Pase14-10

"r- |

I

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PHA|O 1A2

nean

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I

I

^--.

PHOra1AA

- '99-'00Models

t@

r

I I

HEJT'EFAIC RETAY See Power 7JA

0istribution, pag€1&9.

".*:.f L

PHOfO 58

I

t sl*t-' '"o'o'

L-*----J 3 Y C3s1

J

c420

UNDER-HOOD IFUsE/RELAY

r-r---1 | ( #tt*

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FUSE'7

vtEw53

!

Ss6 Pows Dist bution, pag€10-9.

HEATER CONTROL PANEL

"T.I lgnitioninpd

I I I

LED gontrol

Swiich Slitoh Groulld co{Y}rnon inM A6

c9

ALX

BLK

c12 YEL

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c1

A7

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ORN

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r' R€aI Wlndow Dcrogger Sultch

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RearwinoowI dofogger I

Snitch LED common

-

21

Se€Air ; D6livory

BLU/ YEL BLU/ YEL

Deliv€ry ---J HEATERPUSHSWITCHES

L-------

c723

PHO|O 138

c440

ON Indlcitor

56€ Air

I. G,rc2

wlIT/GFI{

4 (GX10) BLU/ YEL

PHO|O81 vtEw45

c411 PHOTO 60

vtEw60

PHOTO63 vtEw53

vtEwss 5

8

SeeGound Distdbltion, page14-7.

I I I I

UNDEN.DASH FUSE/RELAY BOX

c420

c501

PHO|O 5e

I I I I I

NEAB wlNooly DEFOGGEN F€I.AY

Prrolo 59

cssl vtEw47

Halchback

"*1[ftTi.:-wtNDow cotL ANTENNA

{cx'l) T 9,*%,,

[93ff''n'*' ",-"",-, 1 t o REAR

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lll

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H

DEFOGGER

:

eY

G401 PHOIO 57

DEFoGGER

-.1

wtNDow

t_

I wrNDow

arr<

BEAR

I

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*-r" *"r' I J

Sre Ground DFtrtbditm, pago1+7.

".-i."tr ftTi",,' t

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S€9Grolnd Distribtdion, pag€1+ 10

ffiff$Ee I

I

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cttr

PHOfO 10A

64-1

RearWindowDefogger - Howthe CircuitWorks '96198Models

I

Voltageis appliedat alllimesthroughtuse50 to the rearwindowdetoggerrelay(contacts). Withthe ignition switchin ON (ll),voltageis appliedthrough tuse16to the rearwindowdefogger switch. Whenyou turnthe switchON,voltageis appliedto thedefogger timercircuit.Thetimercircuitsupplies voltageto the rearwindowdefoggerrelay(coil).The relayenergizesand suppliesvoltageto the rear windowdefogger.The defoggergridthenheatsthe rearwindowto removeany condensation fromthe glass. The defoggertimercircuitwillautomatically turn off the rearwindowdefoggerafterabout25 minutes. Referto the ServiceManual(Section23, Electrical) procedures. for specifictestsor troubleshooting '99100Models Voltageis appliedat all timesthroughfuse50 to the rearwindowdeloggerrelay(contacts). Withlhe ignition switchin ON (ll),voltageis appliedthrough fuse16to the heatercontroloanel. Whenyouturnthe rearwindowdefoggerswitch ON,a signalis sentto lhe defoggertimercircuit built-into the heatercontroloanel.Thetimercircuit suppliesvoltageto the rearwindowdefoggerrelay (coil).The relayenergizesand suppliesvoltageto the rearwindowdefogger.The defoggergridthen heatsthe rearwindowto removeanv condensation fromthe glass.

a

Thedefoggertimercircuitwill automatically turnotf the rearwindowdefoggerafterabout25 minutes. Referto the SeryiceManual(Section23, Electrical) procedures. for specificteslsor troubleshooting

a 64-2

Integrated ControlUnit NOTE:Fuse31 is hotwithlgnitionSwitchin START(lll)andclutchpedaldepressed or A,/TGearSelector in (N),seeStarting PARK(P)or NEUTRAL System,page21,21-1,ot 21-2.

t@ i'l-;;,-lH8B'r* | \ rrmn1gn I FUSEI i f t*" LJr____J

u'lftf,%, vtEw3a

SeeBrake System lndicator

ig8f" PHOT7 O

S wHr/FED |

li^hl

3fl3,n'"n sYsteh

wHr,FED I

!t

<--=-

,r"r,".0 |

| FUSE 3I staaTEa SIGI{AT 7AA

S€s Siarling Syslsm,pago21, 21-1.or 21'2.

SEsBrake System lndicetor Light

,n"r,".u I

.l B*?r:"" ,.!,.*, Ssa ClharSrrE I Systom I

I

I I I

A6

\ \ \ \ \ \

EogGound Distlbution, page l,l-7.

I

L------

--r-r..r'

3

c420 PHO|O 63 vtEw 53

FED/BLU

See Ceiling Light

SeeSeatBelt andlgnition KeyRemind€rs

/

I I I I I

SeeWiper,ryVasher

@ I

.1 -

t

t

I SeaPower Distfibution,

I I 1

pag€10-5. iz

FUSE15

FUSE30

ALTEi}IATOR sP 8S$80n

l|lslFl,|tEl{l uotfT3

?.54

FR \I/IP€g Fi WASTIEF 204

7'5A soe Headtight sss Power Distibution, Switch, -

A8

UNDERDASH FUSE/ RELAY BOX

FUSE26

page100-t. pags1G7. fo INTEGRATED CONTNOL UNIT

\

vEw af

\ \

Ught8.ON nemhder Circrti

\

Combin€d l,Ylper/ Warhot Cireuit

lfllsnl|liter Wip6r Relay Circuit

\ \

t

I

,

I

I I

a-------

*I "'r I

I

I

I

-----[---t----""r,".*I ".u-"rl t t \--

See WiperMasher

70-1

BrakeSystemIndicatorLight

- '96-'98Models

NOTE:Fuse31 is hotwith lgnitionSwitchin START(lll) and clutchpedaldepressedor A,/Tgearselectorin (N),seeStarting PARK(P)or NEUTRAL System,page21, 21-1,or 21-2.

FUS€ 31 atAirEn 8Gl{tt 7.all

UNDERDASH FUSE/ RELAY BOX

FUSE25 s." Ponr"t ffR S€oStarlingSysl6m, pag621,2l-1,or el-2,

Distribulion, page10-6.

rry

r I I I I I I I

a

c501

PHOTO60 vtEw55

I

Ss€ Pow6r Dlstribution, page1G6.

;?l

---.I

GAUGE I ASSEMBLY

$os Indicators

i',i!i,I2'

(slt--95.:l-_i l:

8

s 3A cso3 "lir%?u'

r--- CW ----.

GRN/FED

i! !

ll virw 'i'jriro

|!

s I iiiiir^ "lw;t,

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i o"^r"'o |

99€grqn'd

- 31i3*:'. |

b---4---

I I

CONTROL ;

i moouleficlrt) i' I

PHO|O 121

, vtLw 6s --l:ffiffi--i i

| i: :! 3113'"0* "o* 31ffi --.L- -TFr,lifu:i-|l -trfr; ----9tF":--T-tY-E;"41i'", -----.1J- -tlb$Lsr'{.i------:g,tgLesr.l----- .Tf"*;',r;,f'.F?f;l', J--:J--i lsrss9l;-;?--q1Al" :L:W-J :: i: i i LTS-: -""'"L--i:t--i3trFlr*n

i: ! I ': t

lll

:

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ii: i ti

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ffitre"ninas; :---.

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i e r i :- - - - - ' : : : - - - :

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,

anlxe rLUto

Ffl

illJff*ttt** i*l [JFHi:"'l*iTfit* u.-u.*il ii "."""J[ft*,,tl3"ilj*il I

Y

U i

71

Cior F6r6sz

i frpanxrxc

ii :'

i r#"Al[';u3*'""i

lilt:','x;l I

il4.lFfffff'UJ:"" ii EJi,fii,i,"-" i r-j I r-

tE^- usA.

phoroTs

: ,l - - - - . t - - - - - canada

pHoro7s

*

I C+6t Froiit sz

- '99-'00Models NOTE:Fuse31 isJtotwith lgnitionSwitchin START(lll) and clutchpedaldepressedor A,,/T gearselectorin PARK(P)or NEUTRAL (N),seeStarting System,page21,2i-1, ot 21-2.

--Iil;--------l

Fr,lrs 3i

s""po*"r ) 9ff" "-

3m" -\,

I

SeeStartingsystem.

pasezr.zi-t.'or'ztlz.

cot{TRoL UNIT ftoa 64 vEwa7

I I I I

Bulb chek outp$

Brake Bulb Chsck Cheuh

erouna

l3.fftT:4"" I Bi?[lT':i, o"n"tot'

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--ffi ;iI rt^F-;amre II [i;"s"'"." vir:ii, c+l

uGHr (R ' rNprcAroR

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I

rcll6T6tl I Y lBn | (usA! (canrda)

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L----------

. Distribution.

._____=Fl}_*t0"_____.1

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I

UNDER" DASH I FUSEi RELAY l BOX

|

L--*-:J8 55 YY

-:--' --

J

o""'"T| "";%u,

"""'"';i"a#;", S€6Ground Distribution, pago14-7.

I I

c420

c551

PHO|O 6i vtEw 53

PHOfA 63

(r;'

c419

15

PHO|O 63

Used)

14

|

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DAYnME

|RUNN|NG

*

i Llt:i-ib'f#Iu'"'' ---Y -- """* i

GBN/FED II PHOIO 22

5fi

FED/GFN I c419

:

18Jl iE?'8'

:'

f ?-'! uloen-oasx I I I I

Sss Gfound Distribution. pag€147.

T

Y

t t L_l .'-4o.'

I

I FUSE/RELAY

| | lP9l_-

:

1 Y Cs51

".o'o""! iffl1oru" l l-rlrl I '

:

PARKTNG , I BRAKESWITCH

I

'

ennxerluro

I LEVELSWITCH

| /_,?lfJ",ii"."gl'.-

w::::" "'-1":::: ! 3:"'lll"*l

".-l I

lIdft"f[]r'"r'" i L__l +

c"n"o":-

"igt-ol'-

----j

:

G40l

PHOIO 57

71-1

BrakeSystemIndicatorLight(cont'd) - Howthe CircuitWorks The brakesystemindicatorlightcomeson to alert the driverthatthe parkingbrakeis applied,or that the brakefluidlevelis low.lt alsocomeson as a bulbtestwhentheengineis cranked.

a

ParkingBrake Withtheignition switchin ON (ll)or START(lll), voltageis appliedthroughfuse25 to the brake systemlight.Whenyou applythe parkingbrake,the switchclosesand providesa groundfor the light. Thelightthencomeson to remindyouthatthe parkingbrakeis applied. Brake Fluid Level switchin ON (ll) or START(lll), Withthe ignition voltageis appliedthroughfuse25 to the brake systemlight.lf the brakefluidlevelis low,the brake fluidlevelswitchcloses,providinggroundto the circuit.The brakesystemlightthencomeson, thed verto a lowbrakefluidlevelin the alerting brakemastercylinder.(Checkbrakepadwear beforeyou addfluid). Bulb Check Withtheignition switchin START(lll)andclutch pedaldepressedor A'lTgearselectorin PARK(P) (N),voltageis appliedthroughfuse31 or NEUTRAL to the brakebulbcheckcircuit.The brakebulb currentto flowthrough checkcircuitcloses,allowing the brakesystemlightand bulbcheckcircuitto ground.The brakesystemlightthencomeson to testthe bulb. Referto the ServiceManual(Section23, Electrical) procedures. for specifictestsor troubleshooting

71-2

\fa

SeatBeltand lgnitionKeyReminders --f*.?*-j

UNDEF-HOOD FUSE/RELAY BOX

--LryJ ',J,trni:

UFIEN ?,irA

S6s Pow€f

Distribrtion, pe961&10.

.4

UNDER.DASH FUSE/RELAY BOX

FUS€ 25

PHOfO 58

Ss€Power Distribution, Fag61G6.

r:f ftir +

(Termlnals17-20)

t

vlEw 56

YEI

S€€Pow€t Distibliion, pag€10"6.

r--xr------

----rer,'-----l$Fffi *' r"il-ffi3#-.-T-lii*"f

R T Y Tf

*;-'-1,rffi{ru+" iFn- ffi.sL,'#* lBffir'i iiw-Q!"" iL_@__J_i .I

Beepero0tpul

Ssar Door f€y b6h swiich sr'/itch switcfl Inpu inpul input Inpur inpd Inpr',t

il-----*=f,f-----J -ni=of'"

|

|

|

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86 l'

"'o'""I

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Y:___L__ --[--:p----j 'lftf'*

'"'"'"1 I f--. Erid*'i,ll*, "',,"."1 ^i:,:l"tt"#" I | '"''"[ . ,*'*., ,*,, tx,,:., ,.*, I t *Fgt I it:- _ _ _, .r..*;ff'"* o",ur*,. -^l ',

I

Lqffi^j'-. 'lt'-h* t""ff*;--- hl.u.1f '=es'oomode,sexcep,cx ilT,.+ry, ".-l ttr,'g$t i I "'*tj t t AgBBBBB$"l',il* L:i I cFNI

seecround I

il",jli'.91' I *r

:

c4oj

PHO|O 57

73

PHoros6

:

G4ol

Howthe CircuitWorks Seat Belt Warning Withthe ignitionswitchin ON (ll) or START(lll), batteryvoltageis appliedto the seatbeltreminder light.Whentheseatbeltis notbuckled, the seat beltreminder/key-on beepercircuitin the integrated controlunitsensesgroundthroughthe closedseatbeltswitch.Theseatbeltreminderlight comeson andstayson,andthe beeperbeepsfor 6 seconds. The reminder lightandbeeperwillstop whentheseatbeltis buckledor thetimercircuit deactivatesthem. lgnitionKeyWarning Batteryvoltageis suppliedat all timesto the seat beltreminder/key-on beepercircuitin the integrated controlunit.Whenyouturnon the ignitionkeyswitchthe integrated controlunit sensesground.lf youopenthedriver'sdoor,the doorswitchcloses,causingthebeeperto sound untilthe dooris closed. Referto the ServiceManual(Section23, Electrical) procedures. for specitic testsor troubleshootrng

73-1

LowFuelIndicatorLight

\rl 't UNDER.DASH

I FUSE/RELAY BOX I I I PHOTO 58

J

pag6 106.

,

-ls,T,*-*:lligff*, l',;l:'l?,'

or*+*i

I

T F Ii

"I

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!ra

A oxc€ptGX

AFN/GFI{

c410 c503

9FN/GBN

PHO|O 61

15

vlEw3s c'131 PHO|O A5

BLU/FEO vtEw59

I TANK : UNIT Than|tlrlor So€ qauges L-----J

PowERTRAtN I i$grtor I MoD]LE(pcM) I

i

- ----J SaeGround Distribution, pa$ 14-9.

74

A3A !'-{ilril}-1

Lowtuel

I CONTROL

S'

i18l7"*

Howthe GircuitWorks All ExceptGX

Do not smoke while working on the fuel system. Keepopen flame awaytrom the work area.Drain fuel only into an approvedcontainer. A thermistor is mounted in thefueltankunit.When thethermistor is cool,itsresistance is veryhigh. Whenthethermistor's temperature increases, its resistancedecreases.Fuelin the fueltanktransters heatawaylromthe thermistorfastenoughto keepit coolso the thermistor'sresistancestayshighand lhe lowfuelindicator lightdoesnotcomeon.When thefuelleveldropsbelowthethermistor, the thermistor's temoerature increases. Withoutthefuel to coolit, the thermistor'sresislancedecreases, allowing currentto llowthroughthelowfuel indicator lightandthethermistor to ground,andthe lowfuelindicator lightcomeson. Referto theServiceManual(Section 23, Electrical) procedures. for specifictestsor troubleshooting GX ThePCMturnson the lowfuelindicator lightwhen thefuellevelis low.ThePCMwillalsoblinkthe indicatorlightwhena problemis detectedby the fueltankpressure sensoror thefueltank temperature sensor. Referto the ServiceManualGXSupplement (Section 11, FuelandEmissions) for specific tests procedures. or troubleshooting

74-1

Indicators

! a UNDER-DASH FUSE/RELAY BOX

PlloTO 58

Dim input Grolnd

lgnition lndicatof contlol

'1

3in""li"?''"" ,

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canada

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N|GHT TURI'l slclrlAl INOICATOR LIGIIT

see Gauges ----J GAUGE ASSEMBLY

BLU/NED =[

SeeABS S€

SeesRs ==:

PHOIO 67 vlEw 71

=

I

1

c507 (Termlnals1.6) vlEw56

S€e(Ground Grouft Distribtltion, page 4-7. e, 114-7.

l____l -

G4o1

PHOIO 57

(cont'd)

80-1

Indicators(cont'd) .I

UNDER-DASH IFUSE/RELAY

FUSE2s

I I I I

! F,gI".,

UETER 7.54

SeePower Distribution,I page10€. I J

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B3Y

"*,*" i SeeBrake System Inbicator

'., t

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pre_w reo so. savenricres ror (oPrroN) F"EIi,6HiJttr" accessory """"";:"J; securrtv !H;fi;"";Jt"' svstem rc;1rg ii|ot$,,

"Lu,"r" i: ".u,"r" !

ll _- _- _- _ - _- i_l ll__-_-_---v-' _- E" r\ sl !' -; _-r -_' -_ -_ -_ -_ -_-_-_-_-- -_ ii o Zl 6 csoe A C503 Paoro PsOrOo' 6t I]l

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accessorysecuritysystem

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Coupeand Sedan

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seecround

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80-2

BLU/BLK v/Er,! e Jf

"arr"a*l

TRUNKLATCH SWITCH Closedwith trunkopen.

3rr<

'96197 models

'98-'00models

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Gauges(cont'd) - Howthe GircuitWorks Whenthe ignition switchis in ON (ll)or START(lll), batteryvoltageis suppliedthroughfuse25 to the gaugesin thegaugeassembly. Speedometerand Odometer Theodometerand soeedometer drivecircuits receivepulsesfromthe vehiclespeedsensor (VSS).Thepulserateincreases as thecar accelerates. The frequencyand durationof these inputpulsesare measuredand displayedby the speedometer, odometerandtripmeter. Tachometer Thetachometerdrivecircuitreceivespulsesfrom theignition controlmodule(lCM)in thedistributor assemblyor the ECM/PCM.The solid-state lachometer thendisplays thesepulsesas engine speed.Foreach200pulsesperminutefromthe ignition controlmodul€(lCM)or the ECM/PCM, the tachometer displays100RPM. EngineCoolantTemperatureGauge gaugehastwo The enginecoolanttemperature intersecting coilswoundarounda permanent magnetrotor.Voltageappliedto the coils,through fuse25, generatesa magneticlield.The magnetic field,controlledby the coolanttemperature sending unit,causesthe rotorto rotateand the gauge needleto move.As the resistancein the sending unitvaries,currentthroughthe gaugecoils changes.The gaugeneedlemovestowardthe coil withthe strongestmagneticfield. The6nginecoolanttemperature sendingunit's resistancevariesfromabout137ohmsat low enginetemperature to between3H6 ohmsat high (radiatorfan running). temperature Referto the ServiceManual(Section23, Electrical) procedures. for specific testsor troubleshooting

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Fuel Gauge(All except cX) Thefuelgaugehastwointersecting coilswound arounda permanentmagnetrotor.Voltageapplied to thecoils,throughtuse25,generates a magnetic field.Themagnetic field,controlled by thefuel gaugesendingunit,causesthe rotorto rotateand thegaugeneedleto move.As the resislance in the sendingunitvaries,currentthroughthegaugecoils changes. Thegaugeneedlemovestowardthecoil withthestrongest magnetic field. Thefuelgaugesendingunit'sresistance varies fromabout2-5ohmsat full,to about110ohmsat empty.Whenyou turnthe ignitionswitchoff,the gaugeremainsat the lastreadinguntilyou turnthe ignition switchto ON (ll)or START(lll)again, Referto theServiceManual(Section 23, Electrical) procedures. forspecific testsor troubleshooting FuelGauge(GX) Thefuelgaugehastwointersecting coilswound arounda permanentmagnetrotor.Voltageapplied to the coils,throughfuse25, generatesa magnetic field.Themagnetic field,controlled by the PCM, causesthe rotorto rotateandthe gaugeneedleto move.The PCMcalculatesthe gasquantityin the fueltankby usingthefuelpressure valuedetected by thetueltankpressure sensorandthefuel temperature valuedetectedby the fueltank temperaluresensor,andoutputsthe signalto the gaugeassembly. The gaugeneedlemovestoward thecoilwiththestrongest magnetic field. Whenyouturnthe ignitionswitchoff, the gauge remains at the lastreadinguntilyouturnthe ignition switchto ON (ll)or START(lll)again.Whenthe PCMdetectsa malfunction withthe fuelpressureor gas temperature, or detectsa leak,the PCM reduces thefuelmeterto 0. Referto theServiceManualGX Supplement (Section 11, FuelandEmissions) forspecific tests procedures. or troubleshooting

a

a 81-2

A/T GearPositionIndicator

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A/T GearPositionIndicator(conrd) - Howthe CircuitWorks Withtheignition switchin ON (ll) or START(lll), voltageis appliedto the A,/Tgearpositionindicator. The A,/Tgearpositionswitchprovidesa groundfor eachposition. As an inputis grounded, itsindicator lightcomeson. lf youselectR,for example, ground willbe provided to the inputof theA,/Tgearposition indicato(andthe R indicator willcomeon. Withtheheadlight switchin PARKor HEAD,voltage is appliedto the RED/BLK wireterminal. This panelillumination changes the indicator fromfixed to controlled by thedashlightsdimmerinput throughthe REDwire. Whenthe powertrain(allexcept'96-'98CVT)or ('96198CVT)controlmodule(PCMor transmission TCM)detectsan abnormalityin the automatic transmission controlsystem,or whenyou request diagnostic troublecodesthroughtheservicecheck connector, the PCMor TCMwill makethe D4 (D for lightblink. CVT)indicator Referto theServiceManual(Section14, AutomaticTransmission) for specifictestsor procedures. troubleshooting

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91-1

FrontWiperMasher(cont'd) - Howthe CircuitWorks Whenthe ignition switchis in ON (ll)or START(lll), batteryvoltageis appliedto lhe combination wiper switch.andthe windshieldwiDermotor. Low Speed Whenyou turnthe wiperswitchto LO,the wiper motor'slowspeedwindingis groundedthroughthe BLUwireandthe LO speedcontactsof the wip€r switchat G401,and the wipersrunat low speed. ParUOfl Whenyouturnthe wiperswitchOFF,the integrated controlunit(PARKinput)grounds thewipermotor throughthe BLUMHTwire.Thecamswitchon the motorsignalsthe integratedcontrolunitthatthe wipersarein the PARKposition; thecontrolunit ground from thenremoves the motor,and the wipersstopin the PARKposition. High Speed Whenthewiperswitchis in Hl,thehighspeed windings wipermotorare of thewindshield grounded throughthe BLUIrELwireandthe Hl contactsof the wiperswitchat G401,and the wipersrunat highspeed. Intermittent Whenthe wiperswitchis in lNT,batteryvoltageis appliedthroughthe YEUBLUwireto the integrated controlunit(lntermittent wiperON input).The integratedcontrolunit(lnt€rmittenvPark Wiper Control)groundsthe low speedwindingsof the wipermotorand the wipersmakea singlesweep everyfew seconds(SeeLowSpeedabove).When thewiperretumsto the PARKposition, thepark switchappliesbatteryvoltagethroughthe BLUMHTwireto the integratedcontrolunit(PARK input),andthewipersstopin the PARKposition. Mist Whenyoupullthewiperswitchdownto MIST position, the highspeedwindings ot thewipermotor throughthe BLU^/ELwireandthe aregrounded closedcontactsot the mistswitchat G401,and the wipersmakeonepassacrossthewindshield at high speed.The ParUOfffunctionthentakesoverand the wipersstopin the PARKposition.

91-2

Washel Whenyou pullthe wiperswitchtowardyouto turn on the washerswitch,batteryvollageis appliedto the washermotor.The motorpumpsfluidontothe windshield untilyoureleasethe lever;on '98r99 models,the integratedcontrolunit(windshield washerON input)s€nsespowerat the WHT/BLK wireterminaland runsthe wiperswheneverthe washermotorruns. Referlo the ServiceManual(Seclion23, Electrical) procedures. for specifictestsor troubleshooting

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L.-r

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*=Male-Female terminalsreversed for'99-'00 models

s"o"n" "*cept 491!] 1'so'sa ('99-'00 modelsexceptGX l8)

RED/BLK

c605

2 ^

2 ^ LEFT LICENSE PLATE LIGHT

SeeGround Oistribution, page14-10.

RIGHT LICENSE PLATE LIGHT

@ @

RIGHT OUTER BRAKE LIGHT/ TAILLIGHT

".,,*-fJr

c613

PHOTO115

See Brake

SeeBrake Lights

:rd

r:d

ALK

Y

BLK

ryI

V

l-

erxI

AlK

c613

LEFT OUTER BRAKE LIGHT/ TAIL. LIGHT

SeoGround Distribution, page14-10.

erx I

o -l

*.-*L=t

RIGHT INNER BRAKE LIGHT/ TAILLIGHT

INNER BRAKE LIGHT/ TAILLIGHT

SeeGround Di6tribution, page1410.

c604

c517

1 BLK

C60s

4 BLK

4

c604

BLK

Se€Ground Distribution, page14-10.

I .-

G60l

110-3

LicenseLights,ParkingLights,and Taillights(cont'd) - '99-'00Sedans Frompage110-2.

FEO/BLK

18 (GX5)

c562 vtEw42

REO/BLK

SeeBrake Lights

CBtl^lvl{t

1 l

1 l LEFT LICENSE PLATE LIGHT

3 RIGHT LICENSE PLATE LIGHT

RIGHT BRAKE LIGHT/ OUTER TAILLIGHT

@ @ zY zY

2 ^

2A

@

LEFT INNER TAILLIGHT

rY

110-4

@ rY

RIGHT INNEB TAILLIGHT

LEFT BRAKE LIGHT/ OUTER TAIL. LIGHT

- Hatchback \

*=l\4ale-Female terminalsreversed lor'99-'00 models

('99r00

FEO/ALK

REO/BLI(

c604 RED/BI-K

See Brake Lights

FED/BLK

c607

2

5

PHO|O 112

RED/BLX

RED/BLK

".","*[ ""-.*":"::*l :!"-_[ __[1-.EbkN,*_."0" lx r'il'''"' @ **"3 fl.flthf -. "".fl .t#:." T "* | "*u,.,,,1 RIGHT LICENSE PLATE

itI

-i*-T:l-J

S€eCround Dislribution, pags 14-12,

c605 PHOTO118

vlEwa

Y

I

2 c608

I

G601

"-- l

I F"al,,,

PHoro132 -1 :

(98100 modets)

110-5

TurnSignaland HazardWarningLights

- All except'99-'00 Sedans

TUHII SIGNAU HAZARD REI-AV ?nofog

UNDER. OASH FUSE/ BELAY BOX

c411

15

PHOTO 60 vlEw 60

:n-

c501

See Ground D$tribution, page l4-7.

vtEw5! 55

u Isee Dash L Lights

T

*x ll FED/B FED/BLX tBl

GAN/OFN PHOfO 57

I _1

HAZARD WARNING l{azAio U'AN G swtTcH vtEw32 SW|TCH UGHT

-";;r";;;------"-.";:l[-;.:r

l:r---

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5iiil3"J:Ui*

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I

i

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., L I

LEFTTURI{

I

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@iJ8l$,o" @tSS'* i 3""",n",, IH TH

Indicators L-------i

82

II ffi"ufi:I'oo

ALK

SeeGroundDistribution, wge 14-7.

I

t

t

l

L___l #

:

G401 PHOfO 5/

110-6

-l

?EEi *,.:ffi

----J

\ *=l\4ale-Female terminalsreversed for'99-'00 models

COMBINATION LIGHT

Tum Signal Switch

l

From Splice or facing page.

vi

cnrineo csor I

c423

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\

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|

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"

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l

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c201

l

vtEw30

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i

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See Parking Lights

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l

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uorr

./A

I b

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ar-< and 1+12 "'iI 3:"":ix'5: I ."oo I

s e eG r o u n o

c2o2 !t- PHOTO 19

"I

I ."n.

2

aLK

4- c6ol PHA|A 1A2

PHOIO 173 (Halchback)

110-7

TurnSignaland HazardWarningLights

- '99-'00Sedans

@

i-f;.;l iL J)Li- -r- J-

3 Y c352

H33'""

i Bl oEx t F f PHoro 7

vlEw27

tun

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c411

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PHOfO @ vlEw 60

S€€Ground Distih.dion, pag€ 14-7.

I UNDER. I DASH : FUSE/ I RELAY

I BOX

i PHO|O 58

--------J c501 vtEw55

PHO|O 57

HAZARD WARNING

swtTcH vtEw32

'--{

ToUnderdash Box Fuse/Relay on thispage. GAUGE ASSEMBLY

See Gauggs, lndicato.s L-----

s2 ALK

II ff;f#looo

S€eg.ound Dist$bution, pag€t4-7,

lL___ll +

:

G401 PHOfO 57

110-8

\

COMBINATION LIGHT

Tum Signal

swrTcH

Swltctl

ytEW64

A2

From Splice on facing page.

v

GRN/FED

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I

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t

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110-9

Fog Lights

_ Vehiclespre'wired for accessory securitysystem SECURITY SYSTEM CONNECTOR (oPT|ON)

c403

a "!'19*13* u,.*,"

li[?i,i'*' i t-' BsJ:?'tr! LJ------J

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----.t

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: PswrrcH HOIOT2 I

\ ot' tttr(

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BEo,naHT I

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aeomnr

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FUSF

I I

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FOGLIGHT IN-LINEFUSE l-l

u lvtEw

!7

gee Ground Distribution, pag€144.

- - - - . OptionalFogLightSwitchHarness LIGHT SWITCH ' oFF a-a

oN

FOGLIGHTON INDICATOR

c408 PHOTO66

- - _ _ - - t

c201 VEW 3A

::-*frt*, ii c207

BLU/REO

\

BLU/REO

li @r'ali "Ttrr*, ".-.:jlr*., i ar-xI ---+ narness

110-11

Headlights - CoupeandSedan |

/

FUSE48

UNDER-HOOD | FUSE/RELAY

: \ HEADLTGHT :BOX I I 3oa I pHoroT LJ----J I Y C3s2 ulEY:?-- - wHrl PYo-rg8-

Vehiclespre-wired - - - for accessory securitysystem 5 f|

SECURIrySYSTEM CONNECTOR (oPTloN)

- - canada WHT

C419

P H Q | O 6 3v t E W 4 s

i t-'d*ltr! lF"{il'.]'*' COMBINATION LIGHT

Headligtrt Swlich n e r o 'pinx t

".;L

swrTcH

t - +pl66 * . o o * j cmx HEAo I J ---J4B1 Y -.^^-- I#

----J

SeeHeadlioht Swirch, oao6100.

- Canada -

FUSE21 F i/t IOW AEAM

FUSE4 B H/L HIGll BEAM

UNDER. DASH FUSE/ RELAY BOX

L--{..--1 Y Cs01

".o,o"ni[?,lo,uo ^..?fiurti I *i;[fl?i ve /a ce.l, V|EWz1

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] j : : : - :

T_l Eqr I

RIGHT HEADLIGHT

--g------J

1IIGH

lLr -

:

G401

PHOTO57

110-12

See Ground Distdbution, page 14-4.

SoeGround Distribution, page14-4.

\

- Canada

--

f 3 A

r' I I I

16

Pdoto\i vttw.rs

F r

FUSE sE 20 2!

ra FUSE

(EUXMtIG xM G Uclfr) 7.5A

$r,rlxlxs ucl|l R€laY) 7.ta

-il*'*

c420

vtEw53

BIKWHT

A4

UNDER.DASH FUSE/RELAY BOX

SeeBrake System IndicatorLight

l

cnvneo I

asl

Brakesysiem indicatorlight control

lgnition

Ughis-on Sattery npur Hoadl8hicornrol

b'rak8input

Ground

vtEw66

B1

\

DAYTIME RUNNING LIGHTS CONTROL UNIT

BED/GRN

OAYTIME RUNNING LIGHTS RESISTOR

H

PARKING BRAKE swtTcH Closedwith parkingbrake applied.

\

S€eGround Dlstribution, page 1,1-6.

I

Y

L _-J + :

G401 PHOTO57

110-13

Headlights (cont'd) - Howthe CircuitWorks Low Beams Withthe headlight switchin HEADandthedimmer switchin LO,currenttlowsthroughthe headlight switch.fuse21. fuse22.andthelowbeam tilaments to ground,andthelowbeamscomeon. HighBeams Withtheheadlight switchin HEADandthedimmer switchin Hl,currentflowsthroughthe headlight switch,dimmerswitch,fuses4, 5, andthehigh beamfilaments to ground,andthehighbeams comeon. Currentalsollowsthroughthe highbeamindicator lightto ground.The highbeamindicator comeson to remindthedriverthatthe highbeamsareon. Flash-to-Pass Theflashfeatureworkswiththe headlight switchin youmove (low PARK, or HEAD When OFF, beams). theflash-to-pass switchto ON,currentflows throughthe switch,fuses4 and5, andthehigh to ground,andthehighbeams beamfilaments flash.Thehighbeamindicator alsoflashesduring theflashoperation. Theflashfunctionhasno effect if thehighbeamsarealreadyon DaytimeRunningLights(Canada) Whenyouturnthe ignition to ON (ll) withthe parkingbrakereleased, thedaytimerunninglights controlunitsupplies batteryvoltageat the WHT/RED wire.Thisvoltageis appliedto thehigh throughthedaytimerunninglights beamheadlights resistor. Eachhighbeamheadlight receives less thanbatteryvoltagecausingthemto comeon at reducedbrightness. lf theparkingbrakeis set,a groundsignalis applied to thedaytimerunninglightscontrolunitat the RED/GRN wire.lf theparkingbrakeis setwhenyou firstturnthe ignition switchto ON (ll),thehighbeam headlights willremainoff untilyoureleasethe parkingbrake.Oncethe highbeamheadlights are on,settingtheparkingbrakewillnotturnthemofi. Whenlowor highbeamoperation is requested, batteryvoltagefromthe headlight switchis applied to thedaytimerunninglightcontrolunitviathe RED wire.Thedaytimerunninglightscontrolunitthen turnsofftheheadlights.

110-14

Referto theServiceManual(Section 23,Electrical) procedures. forspecific testsor lroubleshootrng

tl

BrakeLights - All Coupesand'96-'98Sedans ?-------

i iI

t t!::o )t SrTIr 154

UNDER-HOOD

geePower Distribution,

i FUSE/RELAY BOX i

L--E-]-p3n:"'1--.:

8 Y C3s2 *nrlo." i[o"'r?, I *"r,o"n

SeePower Distribution, page1013.

o----a

wHr/GFN i WithCruiseControl t

WithoutCruiseControl

,r"r,o*[

*"r,n*[

1 BRAKE SWTTCH

r t

BNAKESWITCH Closedwithbrake pedaldepressed.

l-'rt

l4J LQlt'*'*t'**" o""*,1, n""n",.tr

PHOTO 68

!

I

rt

\

PGM.FI

o"*n"", I

c442 fferminals'l! -14)

*=Male-Female reversed terminals for '99-'00models

PHO|O 125 GFN/II/HT

13 ('99100modelsexceptGX 17) GFN^^/HT

2 ('99-'00models except GX 10) GFNMHT

vtEw 54 c401

c563 (C562'99100modelsexceptGX)* V|EW42

GFN,ryVHT

Without optionalspoiler

GAN/

with optionalspoilar

GFN/

BLK

\ a + 9,6,91o,",

110-15

BrakeLights - '99100Sedans '_-._-_:---t-u!E az

xonn,

UNDER.HOOD I ErreE/oEr Av I FUSE/RELAY I

oaoe tG13.

s Y c3s2

wHT/cBN Ploroz' I

wHrrGRN

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a?,oJ.,

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aToPrr t6a | ?--'-----------t L--:t------------J

Se€ Power Oigtribution, pags1G13.

WithoutCruis€Contd

BRAKESWITCH Closedwithbrake pedaldepressed. PHOTO 8

o"na", I --f

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II I

o !

110-16

G601

vfith oplional spoiter

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SBePower Dbtribution, page1G13.

UNDER.HOOD I FUSE/RELAY BOX

S€ePowor

**TT rr.l

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BRAKESWITCH

. l I Closedw{h brake

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c607

HIGH MOUNT BRAKE LIGHT

@ ".i.I >-ra BLK

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c608

vtEwI

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|

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G401 P4ofo57

114-1

CeilingLight,TrunkLight,and Spotlights

LT GRN/ALK

'96.98USA:CX,DX '96.[98Canada:All

'96-'98USA: LX,EX,and HX

'98:GX '99100:All exceptDX

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114-2

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n

RIGHT ; REAR DOOR SWITCH : Closed with ; door open. ,

\,f

r=Male-Female terminalsaeversed for'99-'00 models

DASH FUSE/ RELAY BOX

Se€Pow€r Disfibution, pag61o-t0.

ftTll,' -",,".'"f Hatchback I

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c407 (vtEw2

I

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c407 LT GAN/EIK or lT GRN/RED

"il

(v/Fw2 98r0o mod€rs)

SeoGround Distdbution, pagst+10 ot 1+1'l.

\

P H o t o5 8

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_J_____

20

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PHOTO 102

114-3

PowerWindows

- Driver'sDoorand FrontPassengerDoor

--

l'l-'G'-.i**oo* I i',I3.',8J39"

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'ry'

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PHOfO 6S

I I I

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\ \

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D ver'5 Switch

POWER wtNDow

Contrsl Unlt

MASTER

swtTcrl

PHATO 88 vlEw 36

I I I (SedanA4) 8

(SedanA5) REO/^YEL

1 FEDor aEO/BLU

(SedanA7) 4

(SedanA6) 12 ALU

RED/BLU

c633 YELo. REo/YEL

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DRIVER'S wlNDow MOTOR

BLK

4

c633

ALK

SeeGround Distribution, page14-7.

I

.---+< -

I

G401 PHOIA 57

1 20

I SeeGroundDistibution, page14€.

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120-1

Power Windows (cont'd) - RearDoors

BEDAV}IT

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f', 120-3

PowerWindows (contd) - Howthe CircuitWorks CAUTION: Youcould iniureyour arms,hands,or you fingersif unintentionally switchthe driver's window to "automaticdown" while working in that door with the power on. Disconnectthe window switch conneclot or the batterywhen working in the driver's door. SystemDescription Theoperation of the powerwindowsis controlled by the mainswitchin the powerwindowmasterswitch. Whenthe mainswitchis in OFF,onlythe driver'sdoor windowcanbe openedor closed.Withthe main switchON,all windowscanbe ooenedor closed eitherby swtchesin the masterpanel,or swttchesin thedoors.Thedriver'swindowswitchalsohasan automatic downmodewhichis tumedon by pushing theswitchdownto its secondoosition. The powerwindowsare drivenby reversiblemotors. Eachmotoris protect€dby a built-incircuitbreaker. lf thewindowswitchis heldon too long(withthe windowobstructed, or afterthewindowis fullyup or down),thecircuitbreakeropensthecircuit.The circuitbreakerresetsautomaticallv as it cools. Driver'sWindow Withthe ignitionswitchin ON,voltageis providedto the coilof the powerwindowrelaythroughfus€24. Thecontactsof the powerwindowrelayclose,and voltageis appliedto the driver'sswitch.Whenyou pushthe powerwindowmasterswitchto UP,voltage is appliedto the driver'swindowmotor.(Themotor's groundpathis backthroughthe masterpower windowswitch.)The driver'swindowmotorthen drivesthe windowup.Whenyoupushthe switchto DOWN,voltageis appliedin the oppositedirection andthe motordrivesthe windowdown. Automatic Down(Driver'sWindow) Withthe ignitionswitchin ON or START,voltageis appliedto the coil of the powerwindowrelay.The contactsof the powerwindowrelaycloseand voltageis appliedlo the powerwindowmaster switch.Whenyoupushthedriveasswitchto the AUTODOWNposition, voltageis appliedthrough thedriver'sswitchto thedriver'swindowmotor.The pulsesat thepulserinputwhile controlunitreceives the motoris running. Whenthewindowis fully down,themotorstops,andpulsesareno longer generated by thepulser.Thisis sensedby the controlunitat thepulserinput,andvoltageis no longerappliedto the driver'swindowmotor.

120-4

PassengerWindows Withthe ignitionswitchin ON,voltageis appliedto the coilof the powerwindowrelaythroughfuse24. The contactsof the powerwindowrelaythenclose, applyingvoltageto the individualwindowswitches and the powerwindowmasterswitch.Withthe masterpanelmainswitchON,thepassenger windowscan be ooeratedfromthe individual windowswitchesor fromtho masterpanelswitches. Whenyou pushthe frontpassengsr's window switchto UP,voltageis appliedto the f ront passenger's windowmotor.(Themotoris grounded throughthe contactsin the frontpassenger's windowswitchandthe oowerwindowmaster switch.)The windowmovesup as longas you hold the switchin the UP position.lf you pushthe switch to DOWN,voltageis appliedin th€ opposite directionto the frontpassenger's windowmotor,and the windowmovssdownas longas you holdthe switchin the DOWNDosition. Thewindowswitches in the otherdoorsoperatesimilarly. Whenyou pushthe frontpassenger's switchin the masterpanelto UP,voltageis appliedthroughthe frontpassenger's windowswitchcontactsto the frontpassengefswindowmotor.(Themotoris groundedthroughthe contactsin the front passenger's windowswitchandthe powerwindow masterswitch.)The windowmovesup as longas youholdtheswitchin the UP position. lf youpush the switchto DOWN,voltageis appliedin the oppositedirectionto lhe frontpassenger's window motor,and the windowmovesdownas longas you holdthe switchin the DOWNposition.The other passenger windowswitches in themasterpanel operatesimilarly. Referto the ServiceManual(Section23, Electrical) procedures. for specifictestsor troubleshooting

Moonroof

'96-'97Models

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---1

UNDER.DASH IFUSE/RELAY

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122-1

Moonroof (cont'd) - Howthe CircuitWorks MoonroofOpen

MoonrootClosefrom the Tilt Position

Whenyou pushthe moonroofswitchto the OPEN position, the moonroof openswitchappliesground "open"relaythroughtheYELwire. to the moonroof The moonroof"open"relayappliesbatteryvoltage motorthroughthe GRN/RED wire. to themoonroof "close"relaysupplies groundto the Themoonroof moonroofmotorthroughits normallyclosedrelay conlacls.Whenthe moonroofmovesout of the fully thetilvclose switchmovesto the closedoosition. theopen/close switchmovesto the OPENposition; OPENoosition.

Whenyou pushthe moonroofswitchto the CLOSE posilion,the moonroof"open"switchappliesground to the moonroof"close"relaythroughthe YEURED wire,open/close switchand moonroof"open"relay. "open" The moonroof relayappliesbatteryvoltageto the moonroofmotorthroughthe GRN/REDwire.The moonroof"close"relaysuppliesgroundto the moonroofmotorthroughits normallyclosedrelay contacts.Whenthe moonroofis fullyclosed,the tilvcloseswitchmovesto the closedoositionandthe open/close switchmovesto the CLOSEDposition. Referto the ServiceManual(Section23, Electrical) procedures. for specifictestsor troubleshooting

MoonroolTilt Whenyoupushthe moonroof switchto theTILT position, the moonroot tiltswitchappliesgroundto "close" relaythroughthe BLUwire, themoonroof tilvclose switchand REDwire.Themoonroof "close"relayappliesbatteryvoltageto the GRNffEL wireto the moonroofmotor.The "open"relaysupplies groundto the moonroof moonroofmotorthroughits normallyclosedrelay is in thetiltoosition, Whenthe moonroof contacts. the trlvcloseswitchmovesto the TILTEDposition; the open/closeswitchmovesto the TILTED Dosition. MoonroofClosetrom the Open Position Whenyou pushthe moonroofswitchto the CLOSE "close"switchappliesground position, the moonroof "close" relaythroughtheYEURED to themoonroof The wire,tilvclose switchandGRN/RED.wire. moonroof"close"relayappliesbatteryvoltageto the motor.The GRNI/ELwireto the moonroof "open" ground relaysuppfies to the moonroof closedrelay moonroof motorthroughits normally is fullyclosed,the Whenthe moonroof contacts. the tilvclose switchmovesto theclosedposition; switchmovesto theCLOSEDposition. open/close

122-2

PowerDoorLocks - All ModelsWithoutKeylessEntry FUSE/RELAY i--r?Grs;-'iUNDER.HOOD BOX r

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130-1

PowerDoorLocks

- '96-'98ModelsWithKeylessEntry I

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130-3

Power Door Locks (cont'd) - Howthe CircuitWorks KeylessEntrySystem the powerdoor Thekeylessdoorlockscombine keyJob transmitter. The keyless lockswitha remote part The keyless of the radio. receiverunitis directinputsf romthe ignition receiver unitreceives passenger doorswitches,and an keyswitch,the inputtromthe driver'sdoorswitchthrough indirect the integratedcontrolunit. PowerDoor Locks (With or Wlthout Keyless) The powerdoorlocksystemis madeup of the oowerdoorlockcontrolunit.driver'sdoorlock switch,and individualdoorlockactuators.The powerdoorlocksare controlledby the driver'sdoor lockswitchand the driver'sdoorlockactuator switch. Transmitter(With KeylessEntry) Thetransmittersendscodedradiowavesignalsto the keylessreceiverunitwhenone ot its buttonsis pressed.Eachtransmitterhasa uniquecodethat mustbe 'laught"to the keylessreceiverunitbefore it can operatethe doorlocksor any otherlunction. to operate can be programmed Up to 4 transmitters locks. the keylessdoor Door Locking (With or without KeylessEntry) Whenyou pushthe driver'sdoorlockswitchto the groundis appliedto the GBN/IVHT lockposition, wireto the oowerdoorlockcontrolunit.The control unitthenappliesbatteryvoltageto the WHT/RED wireandgroundto theYEUREDwire.The passengerdoorlockactuatorsthenactivateto lock doorlocks. thecorresponding Whenyou lockthe driver'sdoorwiththe keyor door locked,andthedriver's lockknob,it is mechanically doorlockactuatorswitchappliesgroundto the oowerdoorlockcontrolunit.The controlunitthen appliesbatteryvoltageto the WHT/REDwireand groundto the YEUREDwire,activatingthe passengerdoorlockactuatorswhichlockthe doors. Dool Locking with Transmitter Whenyoupressthe LOCKbuttonon the remote transmitter, the powerdoorlockcontrolunitapplies batteryvoltageto the WHT/REDwireandgroundto doorlock the YEUREDwire.The passenger thenactivateandlockthe doors.A ground actuators slgnalis alsoappliedto the BLU/REDwireto lock the driver'sdoor.lf anydooris open,youcannotlock it usingthe remotetransmitter.

130-4

Door Unlocking(With or Without KeylessEntry) Whenyoupushthedriver'spowerdoorlockswitch groundis appliedto the to the unlockposition, GRN/ORNwireto the powerdoorlockcontrolunit. The controlunitthenappliesbatteryvoltageto the wiresandgroundto the YEUREDandBLU/RED The WHT/REDwire. doorlockactuatorsthen activateto unlockthe doors. Whenyouunlockthedriver'sdoorwiththekeyor the unlocked; thedoorlockknob,it is mechanically otherdoorsdo not unlock. Door Unlocking(WithTransmltter) Whenyou pressthe UNLOCKbuttonon lhe remote transmitteronce.the powerdoorlockcontrolunit appliesbatteryvoltageto the WHT/REDwireand groundto the BLU/REDwireto unlockthe driver's door.Whenyou pressthe UNLOCKbuttontwice, the controlunitthenappliesgroundto the YEURED wiresto activatethe passengerdoorlocks.lf youdo notopena doorwithin30 secondsafterunlocking the doors the doorswiththe transmitter, relock. automatically TransmltterProgramming switchON (ll). 1. Turntheignition the Valet-Disarm buttonon the Press and hold 2. (between andthe the AM/FM button radio programming CD/TAPEbutton)to enterthe mode.(Continueto holdthe buttonduringthe procedure, willbe cancelled.) or programming Checkthatthe powerdoorlockscycleto confirm mode. thatyou'rein the programming "UNLOCK' "LOCK' buttonon the or 3. Pressthe power doorlocks transmitter. Checkthatthe cycleto confirmthatthe codewasaccepted. 4. Pressthe"LOCK"or "UNLOCK"buttonon each (Youcan program of the remainingtransmitters. per vehicle.) up to fourtransmitters havebeen 5. Afterall the transmitters programmed, buttonto releaselhe Valet-Disarm mode. exitthe programming BeepOn/OftFeature 'I. Pressand holdthe LOCKandOPTIONbuttons on the transmitter. LED: 2. Watchthe transmitter's Oneflash:Beeoactivated. Twotlashes:Beeodeactivated.

KeylessReceiverUnit Troubleshooting lf a faultykeylessreceiverunithasone of the symptomsbelow,turnto the pagelistedand followthe procedure.lf the symptomseemsrelatedto an inputproblem,or is notcovered appropriate troubleshooting procedures, by the troubleshooting do the InputTestson page130-6. Referto the circuitschematicon pages 130-2and 130-3as needed. SymptomIndex KeylessEntryDoesNotWorkIn Any Mode

Page130-8

CeilingLightDoesNotComeOn WhenTheDoorsAre Unlocked WithTheTransmitter ....

Page130-9

DoorsDo Not UnlockOr LockWithThe Transmitter. . . . "Beeo"FeatureOn HornDoesNotSoundWithThe Transmitter

Page130-1 0 Page130-11 Page130-11

.1,

H o r nD o e sN o tS t o pS o u n d i n.g. . . . . .

Page130-11

Input Tests

Page130-6

Power Door Locks (cont'd) KeylessReceiverUnitInputTest fromtheaudiounit. disconnected withA (Main)andB (Keyless) testsarepertormed Thefollowing

Wire Color

Terminal No.

TestConditlon

Test: DesiredRasult Checkfor vollageto ground: Thereshouldbs battery voltage.

4

WHT/BLU Underallconditions

5

YEURED lgnitionswitchACC(l) Th€reshouldbe battery

Checklor voltageto ground:

Terminal No.

voltage.

Wire Color

TestCondiiion

lgnitionkeyinserted intothe ignitionkey switch BLU/RED lgnitionkey r€moved key tromtheignition switch

3

BLUI/EL Underallconditions

6

BLK/YEL lgnition switchON (ll)

8

LTGRN/ BLK

Ceiljnglightswitchin "middleposition"

14

LT GRN/ RED

Eachdooroponed, oneat a time

tc

BLK

Underallconditions

16

GRY

Underallconditions

130-6

Test:DesiredResult Checkfor voltageto ground: Thereshouldbs 1 V or less. Checklor voltageto ground: Thereshouldbe 4 V or more.

PossibleCauseit resull is not obtained BlownNo.47 (7.5A)tusein the under-hood fuss/relaybox o An openin the wire a BlownNo.28 (10A)fuseinthe box underdashfusg/relay a An openin the wire a

PossibleCauseif rssult i3 not obtalned a a a a

Checkfor continuitybetween the audiounit16Pconnector No-3 terminalandpowerdoor I lockcontrolunit12Pconnsctor No.6 terminal:Thereshould be continuity. . Checkfor voltageto ground: Thersshouldbe battery vollage. .

Poorground(G401,G402) Faultyignitionkeyswitch An openin the wire Shortin the wire

An openin thewire

BlownNo.14 (7.5A)fusein the fuse/relay box under-dash An openin thewire a BlownNo.43 (7.5A)fusein the undsr-hood fuse/relaybox to ground:Theceiling a Blownceilinglightbulb Connect lightshouldcomeon. a Faulty ceilinglight o An openin thewire to ground: a Faultydoorswitch Checkfor continuity Thereshouldbe continuity. a An openin lhe wire to ground: a Poorground(G401,G402) Checkfor continuity Thereshouldb€ continuity. a An openin thewire . BlownNo.52(15A)fusein the under-hood tuse/relaybox Conn€ctto ground: . Faultyhorn Hornshouldsound. . Faultyhornrelay . An openin thewire

\

Thefollowing testsareperformed withA (Main)reconnected to theaudiounit. B

Terminal No. 9

10

Wire Color GRN/ORN

GRN/vvHT

TestCondilion

Test:DesiredResult

Driver's doorlock switchin UNLOCK

Check tor voltage to ground: Thereshouldbe l V or less.

Driverdoorlock switchin LOCK

Checkfor voltageto ground: Thereshouldbe 4 V or more.

Driver's doorlock switchin UNLOCK

Checkforvoltage to ground: Thereshouldbe 4 V or more.

Driver'sdoorlock switchin LOCK

Checkfor voltageto ground: Thereshouldbe 1 V or less.

PossibleCauseit result is not obtained o . . .

Poorground(G551) Faultydriver'sdoorlockswitch An openin thewire Shortinthewire

r . o o

Poorground(G551) Faultydriver'sdoorlockswitch An openinthewire Shortin the wire

\

\

130-7

Power Door Locks (cont'd) KeylessEntryDoesNotWorkIn Any Mode verifythatallthe NOTE:Beforebeginning, programmed to the vehicle. transmitters are 1. Doesthe radioworkproperly? Yes- Go to step9. No - Go to the neldstep. NOTE:Forsteos2 - 8. referto the schematicdiagramforthe StereoSoundSystemon page150. fusebox)and 2. Arefuses28 (inthe under-dash fusebox)OK? fuse47 (intheunder-hood Yes- Go to step4. No - Replacethe blownfuse,thengo to the nen steo. 3. Doesthefuseblowagain? Yes- Locateand repairthe short. No- Retestthesystem. withtheoptional security 4. ls thevehicleequipped system? Yes- Go to the nextsteP. No - Go to steD6. 5. Doesthe keylessentryworkcorrectlywhenthe securitycontrolunitconnectoris disconnected? Yes- Faultysecuritysystem,go to security systemforfurthertroubleshooting. No - Go to thenextstep. 6. ls therebatteryvoltageat terminal4 of the radio (A)? mainharnessconnector

=

A

Yes- Go to the nen step. No - Locatethe openin the wiringbetween tuse47 andthe radio. 7 . ls therebatteryvoltageat terminal5 of the radio (A),whenthe ignition mainharness connector (l) switchis in theACC or ON (ll) position?

Yes- Go to the nextstep. No - Locatethe openin the wiringbetween fuse28 andthe radio.

130-8

fromterminal14of theradio 8. ls therecontinuity mainharnessconnector(A) to ground?

Yes- Replacethe radio. No - Repairthe openin the wiringbetweenthe radioandtheground(G501). 9. Doesthe transmitterLEDcomeon whenanyot the buttonsare oressed? Yes- Go to steo 12. No - Go to the nextsteo. '10.lsthetransmitterbatteryinstalledwiththe positivesidefacingup?

Yes- Ensurethatthe batterycontacttabsare repositioned, then replacethe battery. Removethe keyfromthe ignition,then closethe doorsand trunk.Pressthe six times, LOCKbuttonon the transmitter thengo to the nextstep. No - Ensurethatthe bafterycontacttabsare thenreinstallthe batlery repositioned, correctly.Thenreprogramthe transmitter and retestit. Usethe procedureon page programming. 130-4for transmitter LEDcomeon whenanyof 11. Doesthetransmitter the buttonsare oressed? Yes- Go to the nextstep. and programit by No - Replacethe transmitter on page130-4. usingtheprocedure in all modes? 12.Does thesystemworkproperly Yes Finished. Thesystemis OK. No - Go to the nextsteD.

\,1

\lr

13. Recheck witha knowngoodtransmitler reprogrammed to thevehicle.Doesthesystem workproperly in all modes? Yes- Replacethe transmitter and programit by usingthe procedure on page130-4. No - ReDlace the radio.

CeilingLightDoesNotComeOnWhen TheDoorsAre UnlockedWithThe Transmitter NOTE:Thevehiclemusthavea tactoryradioinstalled. 1. ls theceilinglightswitchin thecenterposition? Yes- Go to the nexl steo. No - Reposition theceilinglightswitchand retest. 2. Doestheceilinglightcomeon withtheceiling lightswitchin theON position? Yes- Go to the nextstep. No - Repairtheceilinglightcircuit. 3. Doesthetransmitter LEDcomeon whenanvof the buttonsare oressed? Yes- Go to the nextstep. No - Checkthe transmitterbattery,then retest. lf theceilinglightstilldoesnotwork,go to the nextsteD. 4. Recheckwitha knowngoodtransmitter reprogrammed to thevehicle.Doesthesystem workproperly in all modes? Yes- Replacethe transmitter and programit by procedure page usingthe on 130-4. No - Goto the ne)dsteo. (B) 5. Withthekeylessentryharnessconnector jumper wire disconnected fromthe radio.runa f romterminal 8 to ground. Doestheceilinglightcomeon?

Yes- Replacethe radio. No - Repairtheopenin the keylessentry 8 harnessconnector {B)terminal (LTGRN/BLK) wire.

\

130-9

Power Door Locks (contd) DoorsDo Not UnlockOr LockWith TheTransmitter 1. Do thedoor'sunlockandlockwhenusinqthe driver'sdoorlockswitch? Yes- Go to the nextstep. No - Repairthepowerdoorlocksystem. LEDcomeon whenanvof 2. Doesthetransmitter are the buttons oressed? Yes- Go to the nextsteo. No - Checkthe transmitterbattery,thenretest. It lhe doorsstilldo notunlockor lockwith the transmitte(go to the nextstep. Recheckwitha knowngoodtransmitter to the vehicle.Doesthe system reprogrammed in all modes. workproperly Yes- Replaceand programthe transmitter, thenretest.Usethe procedureon page programming. 130-4for transmitter No- Gotothenextstep. I of the keyless Runa jumperwirefromterminal (B) ground. to entryharnessconnector

5. Runa jumperwirefromterminal10ol the (B)to ground. keylessentryharness connector Do the doorslock?

ves - Go to ttie nextsteo. No - Repairtheopenin theterminal10 (GRN/vVHT) wire. Doesthe voltageat terminal1 of the keyless entryharnessconnector(B) changefrombattery voltagewhenthe key is not in the ignition,to lessthan1 voltwhenthekeyis in the ignition?

Dothedoorsunlock?

Yes- Go to the nextsteD. No - Repairtheopenin theterminal9 (GRN/ORN) wire.

Yes- Go to the nextstep. switchor repairthe No - Replace theignition wire. terminal1 (BLU/RED) damaged keyless 7. Doesthe voltageat terminal14 of the entryharnessconnector(B) changefrombattery voltagewhenallthedoorsareclosed,to less than 1 voltwhenany dooris opened?

Yes- Replacethe radio. No - Repairtheopenin theterminal14 (LTGRN/RED) wire.

130-10

HornDoesNotSoundIn ThePanic "Beep" ModeOr WithTheTransmitter FeatureOn

a

NOTE:The transmitterhasa BeepOn/Offfeature. Referto page130-4for howto tumthe beepon or off. 1. Doesthehornsoundwhenthe HORNbuttonis oressed? Yes- Go to the nextsteD. No - Repairthehorncircuit. 2. Doesthe transmittorLEDcomeon whenanyof the buttonsare pressed? Yes- Go to the nextstep. No - Checkthe transmitterbatterythenretest. ll the beepfeaturestilldoesnotwork,go to the nextsteo. 3. Recheckwitha knowngoodtransmitter to the vehicle.Doesthe system reprogrammed workproperlyin all modes? Yes- Replaceand programthe transmitter, then retest.Usethe procedureon page programming. 130-4for transmitter No Go to thenextstep. 4. Withthe keylessentryharnessconnector(B) wire fromthe radio,runa.iumper disconnected f romterminal16to ground.

HornDoesNotStopSounding security withtheoptional 1. ls thevehicleequipped system? Yes- Go to the nextstep. No - Go to step3. Do€sthe hornstopsoundingwhenthe security controlunitconnectoris disconnected? Yes- Replacethe securitycontrolunit. No- Go to thenextstep. Doesthe hornstopsoundingwhenthe keyless entryharnessconnector(B) is disconnected? Yes- Reolacethe radio. No - Reoairthe homcircuit.

Doesthehornsound?

Yes- Reglacethe radio. No - Repairtheopenin theterminal16 (GRY) wire.

\

130-11

PowerDoorLocks

- '99-'00Modelswith KeylessEntry

@ i-f?G;.-----l

UNDERDASH FUSE/ RELAY BOX

i ?f*""t:::",i L-,H-i{*q-J 8 Y C419

vtEW49

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Door open input

Grgund

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'14 GRN

130-12

t5

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See Headlight Switch

c447

vlEw58

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UNDERDASH FUSE/ RELAY BOX

GFN

I

ALU/f,EO

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a9

Lighls tlash control

3

LT GFN/RED

SeeGround Distribution, pageI +6,

lgnltion input

C415 PHora 6a ALU/IVITT

VlEtt\/ 14

STEERING LOCK PHO|O 71

lgntlion Kay SYrftch Closedwith key in ignition.

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f*-.l'il

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,

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FRONT PASSENGER'S DOORLOCK ACTUATOR

aaa

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KEYLESS DOOR LOCK CONTROL UNIT

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.

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130-13

Power Door Locks (conrd) - Howthe CircuitWorks KeylessEntrySystem Thekeylessdoorlockscombine the powerdoor lockswitha remotekey-fobtransmitter. The keyless doorlockcontrolunitreceives directinputsfromthe ignition keyswitch,the passenger doorswitches, inDutfromthedriver'sdoorswitch andan indirect throughthe integrated controlunit. PowerDoor Locks The powerdoorlocksystemrs madeup ot the keylessdoorlockcontrolunit,driver'sdoorlock switch,andindividual doorlockactuators. The powerdoorlocksarecontrolled by thedriver'sdoor lockswitchand the driver'sdoorlockactuator switch. Transmittel The transmitter sendscodedradiowavesignalsto the keylessdoorlockconlrolunitwhenoneof its Eachtransmitter buttonsis pressed. hasa unique codethat mustbe 'laught"to the conlrolunitbefore it canoperatethedoorlocksor anyotherfunction. Up to 4 transmitters can be programmed to operate thekeylessdoorlocks. DoorLocking Whenyoupushthedriveasdoorlockswitchto the groundis appliedto theGRNMHT lockposition, wireto the keylessdoorlockcontrolunit.The controlunitthenappliesbatteryvoltageto the WHT/RED wireandgroundto theYEUREDwire. The passengerdoorlockactuatorsthenactivateto lockthecorresponding doorlocks. Whenyoulockthednver'sdoorwiththekeyor door lockknob,it is mechanically locked,andthedriver's doorlockactuator switchappliesgroundto the oowerdoorlockcontrolunit.Thecontrolunitthen appliesbatteryvoltageto theWHT/RED wireand groundto theYEUREDwire,activating the passenger doorlockactuators whichlockthedoors. Door Lockingwith Transmitter Whenyou pressthe LOCKbuttonon the remote transmitter, the keylessdoorlockcontrolunilapplies batteryvoltageto the WHT/REDwireand groundto the YEUREDwire.The passenger doorlock actuatorsthenactivateand lockthe doors.A ground signalis alsoapplied to the BLU/RED wireto lock the driver'sdoor.lf anydooris open,youcannotlock it usingthe remotetransmitter. DoorUnlocking Whenyoupushthedriver'spowerdoorlockswitch groundis appliedto the to the unlockposition, wireto the keylessdoorlockcontrolunil. GRN/ORN Thecontrolunitthenappliesbatteryvoltageto the YEUREOandBLU/RED wiresandoroundto the

130-14

WHT/REDwire.Thedoorlockactuatorsthen activate to unlockthedoors. Whenyouunlockthedriver'sdoorwiththe keyor thedoorlockknob,it is mechanically the unlocked; otherdoorsdo notunlock. DoorUnlockingwith Transmitter WhenyoupresstheUNLOCKbuttonon the remote transmitter once,thekeylessdoorlockcontrolunit appliesbatteryvoltageto the WHT/REDwireand groundto the BLU/RED wireto unlockthedriver's door.Whenyou pressthe UNLOCKbuttontwice, thecontrolunitthenappliesgroundto theYEURED wireslo activatethe passengerdoorlocks.lf youdo notopena doorwithin30 seconds afterunlocking the doorswiththe transmitter, the doors automatically relock. TransmitterProgramming . Entering theprogramming modecancelsall learnedtransmitter codes,so noneof the previouslyprogrammed transmitters willwork. Youmustreprogramall the transmitters once you'rein theprogramming mode. . To keepthe systemfromexitingthe programming mode,complete eachstepwithin5 seconds of theprevious step,andprogram the transmitters within10 secondsof eachother. '1. Turnthe ignition switchON (ll). "LOCK" 2. Pressthe or "UNLOCK" buttonon one (A non-programmed of thetransmitters. transmitter canbe usedforthisstep.) 3. Turnthe ignition switchOFF(0). 4. Repeatsteps1, 2, and3 twomoretimeswith thetransmitter usedin step2. 5. Turntheignition switchON (ll). "LOCK" 6. Pressthe or "UNLOCK" buttonon the sametransmitter. Checkthatthe powerdoor lockscycleto confirmthatyou'rein the programmrng mooe. "LOCK" 7. Pressthe or "UNLOCK" buttonon each (Youcanprogramup to four lransmitter. pervehicle.) lransmitters Checkthatthepower doorlockscycleafteryou pusheachtransmitter button,contirmingthatthe systemhasaccepted thetransmitter's code. BeepOn/OffFeature 1. Pressandholdthe LOCKandOPTIONbuttons on thetransmitter. 2. Watchthetransmitter's LED: Oneflash:BeeDactivated. Twoflashes:Beepdeactivated.

KeylessReceiverUnit Troubleshooting lf a faultykeylessdoorlockcontrolunithasone of the symptomsbelow,turnto the pagelistedandtollowthe procedure.lf the symptomseemsrelatodto an inputproblem,or is not covered troubleshooting appropriate procedures, on by thetroubleshooting do the InputTestson page130-16.Referto thecircuitschematic pages130-12and130-13as needed. SymptomIndex KeylessEntryDoesNotWorkIn Any Mode CeilingLightDoesNotComeOn WhenTheDoorsAreUnlocked .... WithTheTransmitter

Page130-17 Page130-18

Page130-1 I DoorsDo Not UnlockOr LockWithThe Transmitter. . 'Beep" Feature On ......... Page130-19 HornDoesNotSoundWithTheTransmitter

\

HornDoesNotSoundInThe PanicMode .. . .i.n. .g. . . . . . . . . . HornDoN e so t S t o p S o u n d

Page130-19 Page130-19

Input Tests

Page130-16

.

130-15

Power Door Locks (cont'd) KeylessDoor Lock Control Unit Input Test Thefollowingtestsare performedwiththe keylessdoorlockcontrolunitconnectordisconnected.

Wire Color

Terminal No.

Test Condition

Test: Desir€dResult

PossibleCauseif result ls not obtain€d

BlownNo.43 (7.5A)luse in the under-hood tuse/relaybox Connectto ground:Theceiling o Blownceilinglightbulb lightshouldcomeon. a Faulty ceilinglight a An openin the wire a

1

LT GRN/ BLK

3

lgnitionkeyinserted intothe ignitionkey switch BLU/RED lgnitionkeyremoved lromthe ignitionkey switch

BLfiEt

b

Ceilinglightswitchin "middleposition"

lgnition switchON (ll)

switchin REO/BLK Headlight PARK OTHEAD

LT GRN/ RED

Eachdooropened, oneat a time

GRY

Underall conditions

BLK

Underallconditions

15

130-16

Ch€cklor voltageto ground: Thereshouldbe I V or less. Checkfor voltageto ground: Thereshouldbe 4 V or more. Checklor voltageto ground: Thereshouldbe battery voltage. Checkfor voltageto ground: Thereshouldbe battery voltage.

Poorground(G401,G402) Faultyignitionkeyswitch An openin the wire o Shortin the wire a a a

. . a a

o

BlownNo.14 (7.54)fusein the under-dash fuse/relaybox An openin thewire Blown No. 32 (7.5A)luse in the under-dashfuse/relaybox A faulty headlightswitch An open in the wire

Checklor continuity to ground: o Faultydoorswitch Thereshouldbe continuitv. o An openin the wire . BlownNo.52 (154)fusein the under-hood fuse/relaybox Connectto ground: . Faultyhorn Hornshouldsound. . Faultyhornrelay o An openin the wire Checklor continuity to ground: a Poorground(G401, G402) Thereshouldbe continuity. a An openin the wire

rl,

KeylessEntryDoesNot Workln Any Mode verifythatallthe NOTE:Beforebeginning, transmitters are programmed to the vehicle. withtheoptional 1. ls thevehicleequipped security system? Yes- Go to the nextsteD. No - Go to step3. 2. Doeslhe keylessentryworkcorrectlywhenthe is disconnected? security controlunitconnector Yes Faultysecuritysystem,go to security systemfor f urtherlroubleshooting. No - Go to the nextsteo. 3. Doesthe transmitterLEDcomeon whenanvof the buttonsare pressed? Yes- Go to step6. No - Go to the nextstep. 4. ls the transmitter batteryinstalledwiththe positive sidefacingup?

Doesthe transmitterLEDcomeon whenanvof the buttonsare oressed? Yes- Go to the nextsteo. No - Replacethe transmitter and programit by on page130-14. usingthe procedure Doesthe systemworkproperlyin all modes? Thesystemis OK. Yes- Finished. No - Go to the nextstep. 7. Recheckwitha knowngoodtransmitter to thevehicle.Doesthesystem reprogrammed workproperly in all modes? Yes- Replacethe transmitterand programit by on page130-14. usingthe procedure Replacethe keylessdoorlockcontrolunit. No

\r;

Yes- Ensurethatthe batterycontacttabsare repositioned, then replacethe battery. Removethe keytromthe ignition,then closethe doorsandtrunk.Pressthe LOCKbuttonon the transmittersix times, thengo to the nextstep. No - Ensurethatthe batterycontacttabsare repositioned, then reinstallthe battery correctly.Thenreprogramthe transmitter and retestit. Usethe procedureon page programming. 130-14 fortransmitter

\ r 130-17

Power Door Locks (cont'd) CeilingLightDoesNotComeOnWhen TheDoorsAre UnlockedWithThe Transmitter 1. ls theceilinglightswitchin thecenterposition? Yes- Go to the nextsteD. No - Reposition theceilinglightswitchand relesI. 2. Doestheceilinglightcomeon withtheceiling lightswitchin theON position? Yes- Go to the nextsteo. No - Repautheceilinglightcircuit. LEDcomeon whenanvof 3. Doesthetransmitter the buttonsare oressed? Yes- Go to the nextstep. No - Checkthe transmitterbattery,then retest. lf theceilinglightstilldoesnotwork,go to the nextstep. 4. Recheckwitha knowngoodtransmitter reprogrammed to the vehicle.Doesthe system in all modes? workproperly Yes- Replacethe transmitterand programit by on page130-14. usingthe procedure No - Go to the nextstep. 5. Withthe keylessdoorlockcontrolunitconnector runa jumperwirefromterminal1 disconnected, to ground.

DoorsDo NotUnlockOr LockWith TheTransmitter 1. Dothedoor'sunlockandlockwhenusingthe drivefsdoorlockswitch? Yes- Go to the nextsteo. No - Repairthepowerdoorlocksystem. LEDcomeon whenanvof 2. Doesthetransmitter the buttonsare oressed? Yes- Go to the nextsteo. No - Checkthe transmitterbatlery,thenretest. lf thedoorsstilldo notunlockor lockwith go to the nextstep. the transmitter, 3. Recheckwitha knowngoodtransmitter reprogrammed to the vehicle.Doesthe system properly work in all modes. Yes- Replaceand programthe transmitter, then retest.Usethe procedureon page programming. 130-14 fortransmitter No - Go to the nextsteo. 4. Doesthe voltageat terminal3 of the keyless doorlockcontrolunitconnectorchangefrom batteryvoltagewhenthe keyis not in the ignition, to lessthan1 voltwhenthekeyis in the ignition?

Doestheceilinglightcomeon?

Yes- Replacethe keylessdoorlockcontrol un[. No - Repairtheopenin theterminalI (LTGRN/BLK) wire.

Yes- Go to the nextstep. No - Replacethe ignitionswitchor repairthe wire. terminal 3 (BLU/RED) damaged 5. Doesthe voltageat terminal12 of the keyless doorlockcontrolunitconnectorchangefrom batteryvoltagewhenall the doorsareclosed,to lessthan I voltwhenanydooris opened?

Replacethe keylessdoorlockcontrolunit. Reoairtheooenin theterminal12 (LTGRN/RED) wire.

130-18

HornDoesNotSoundIn ThePanic ModeOr WithTheTransmitter"Beep" FeatureOn NOTE:The transmitterhasa BeepOn/Otttoature. Referto page130-14for howlo turnthe be€pon or off. 1. Doesthehornsoundwhonthe HORNbuttonis oressed? Yes- Go to the nextstep. No - Repairthehorncircuit. 2. Doesthe transmitterLEDcomeon whenany of the buttonsare Dressed? Yes- Go to the nextsteP. battery,thenretest. No - Checkthe transmitter lf the beepfeaturestilldoesnotwork,go to the nextsteo. 3. Recheckwitha knowngoodtransmitter to the vehicle.Doesthe system reprogrammed properly in all modes? work Yes- Replaceand programthe transmitter, thenretest.Usethe procadureon pag€ programming. 130-14 fortransmitter the neLt siep. Go to No 4. Withthe keylessdoorlockcontrolunitconnector runa iumperwirefromterminal disconnected, 15to ground.

HornDoesNotStopSounding 1. ls the vehicleequippedwiththe optionalsecurity system? Yes- Go to the nextstep. No - Go to steD3. Doesthe hornstopsoundingwhenthe security controlunitconnoctoris disconnected? Yes- Replacethe sEcuritycontrolunit. No - Go to the nsxtstep. Doesthe hornstopsoundingwhenthe keyless doorlockcontrolunitconnectoris disconnected? Yes- Replacethe keylessdoorlockcontrolunit. No - ReDairthe horncircuit.

Doesthe hornsound?

Yes- Replacethe keylessdoorlockcontrolunit. No - Repairtheopenin th€terminal15 (GRY) wire.

\lr 130.19

SecuritySystem

- '96-'98USA:HX, LX, EX;'96-'98Canada: EX.Si UNDERHOOD FUSE/ RELAY BOX

@ @ UNDER. DASH FUSE/ RELAY I I C5s1 ! BOX

FUSE3

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t"'1,",*

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wnr I

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|

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{'96-97models3)

I : '98model

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il il

Horn control

Baitery

tgnition

I

'96-97models

\ I

lgnition key

I i*iiirr inilt

8LU/ FED

eround

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, Ag::l^.

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aLuneo Ill v,rwoo-'gr-u.neo v,rw DU BLU/BEo O -( eruneoll ' + c4is

sersarr R, See Seat Belt

and tgnitionKey Reminders

.,u*i,l( il,?l?.uo

r-{---;:E[t-:--.rsrEERrNG sTEERTNG lgnltionKsy

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Swftch

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c201 vlEw30

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133

---'------l POWERDOORLOCK ; CONTROL UNIT ,

---- Canada

';;;1;

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Driver

door unlock inpd

'F":;!-_--",*tIi input

| :

juj_.r, lpr,_j

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,i,Hfil_[l!,ffisH

i ,of.--sL--d,---t--------cl-+-'dl , t i *t : LED control

door ooor Drivgr'sdoor uavgrs Drtusr's unloc* outpul

Unlock untocx untock

: :; , '

'r Va a rrEs t \\I vvatst ; $vitch s,vitch f iinqrt narr

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UNIT Nlr '. i; u

Bus Remote Securiiy Bus Securiiv o rnout d 'de2 LED L E Dccontrol o n t r o ld data a t a0 d€,.az outDut --.;Y---^;Y---:Y

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input

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datalI iunrr

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!:""'"^l 7-1 e4re4lon

(cont'd)

133-1

SecuritySystem

- '96-'98USA:HX, LX, EX;'96-'98Canada:EX,Si (cont'd) -----l

I

ooor

sEcuRlrY I CoNTROL ! UNIT I PHora73 sB JvtEw

trllnx

switch Inpur

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BLU/ALK

c503

6

LT GFN/RED

BLU/ALK

c562

12 (Sedan'15)

vtEvl 42

BLU/BLK

-{

BLU/BLK

EAA

i,i-"i

Light

c411

H ":-f

PHOIO 60

TRUNKLATCH

vtEw60

swrTcH

Closedwith vunKopen.

SeeGround DislrihJtion, pag€1*10.

Or--<

".^

LTGBN/REO

| l- G601

LTGRN/FED

a " *

[ LT.FN,BED i

.l:T,lT_t

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,

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ll

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I

,

H

F

: i

i

FRONT PASSENGER'S' DOOR SWICH: Closed with : door open.

PHOTO96

c401 ------Sedan

i

H

LEFT REAR DOOR SWITCH Closedwith dooropen.

rflf5ii'

lCJEfii:t*,,,'i -

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133-2

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SECURITY STARTER CUTRELAY

PHOTO53 PTOIO56 ( 98 modsls) vlEW12

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TNTERLoCK

pedalfully oepresseo.

Se€G.ound Distribution, pagel4$.

T

rl r

Y

I

I

L____l +. :

G401

t A/T GEAR I POSTTTON

8LK/FED

c433

11

aswrTcH

o t - r \

BLKRED

L!

I

cLUrcH

c433

10

L---J---

I I I

J

ALI(RED

",#"It#f;,.+,"

I

".o"ro! .@

BLvFEo

"'o"'r"f, "'ot

See Starting System

ro'ffzr----,

BLKAVHT

STARTER

r::1

I

t

uo'r STARIER I soLE orD

l

PHOTO57

L--------J

133-3

SecuritySystem

- '99-'00USA: HX, LX, EX, DX-VSi; '99-'00Canada:EX, Si

@@ - ---- -----t@ -- --F; I i"t]:.:*' i | ffii:- I i['"",llae' i 1 F,... L-i:i--:::.J

@

L-t----------i::=t s:i F#r"" ;Tto" t*x;,3'' u:; ;ntn" "..f ",-^:"\P;!i?," ...'*lii:i',," I lft:i:3''.I::, wHr'cuN --^*[ftFi" --f *nr "..

2 lf c353

7 t'

8 Y C352

C4l9

1 v C423

-"'"""[q **l -"r,"""Iq I

l

SeePowsr Disti brrtion,

i !

I

C4il8

Batiery

!,"1{}"'

{Not

--t----

rsnidon

IEBP*'

tgnitionkey

f \.

vabr

L-----t:gg-____ --;;----.T _gs___ggg___-,r ---C214

;iP,li:

r:[3o-.o<

BLU/FEo I

ffi8i?;g"'fu,

I ".u,"?!..,uR8fr.,!3"Iii, ".^l lgdIon Kry Swhch Gbssd with key in ignition. -----J

'l?,ii;'?,ffi8lli"?,1 Pag€14-6. ".*

fl 133-4

I

. 1"*.

.+i"ili"" swtTcH

STEERING LOCK

BLUAAIHT

HORN

--i BLU

I

!---J r

1

-^l o

I

SeeGround Distribrtion, pag€l+7.

:':l

ELK

c450

a

\

i

----'canada ;;;;-gr"Srrif,fI

"

:

-

-=l

*i'[?'29

i r-----

: | 3;::, I

unlock

I

unlock

: L-j5----j!g-------':g:-j ' 6l-----r-T--------

i e""e'I o"no"n! _

i

t

,

lock

I

qNPEE-llqgo

i I l[+'ffi!l[?::'*' :

;

1T

@

r1----1

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or

ii I I i - , d I i " " r l - - - ] r l i'uf---rilf-----".u.".,.1 o"no""i

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I

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zl-----8l---------qf------rJ -l:'.:=il

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i

3-----

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i *"I *'*'.! I .."1 *..*"! i | i ,,[-----[-----,J iI

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rlr

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-;

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i

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7 ^

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[ib,!".p."i I;yJ;l*,"'""t1'ffi"'r3o

!33lY"o

----i*o i

I 13tr8"?*1 I

+

(cont'd)

133-5 )

SecuritySystem

- '99-'00USA: HX, LX, EX, DX-VSi; '99-'00Canada:EX,Si (cont'd)

LT ONN/BED

LTGFN/REO

13

LTGBN/RED

PHOTO113

?-a@ c41r

i

"i:,1'**

LT GFN/REO

I Lr cRNiBED

I

c401 LT GFN/BED

I

------Sedan

T

'll------'l

I

Bsl

I

a

UNDER.DASH FUSE/RELAY BOX

' *l;;

!l :i-------T-'lsFs6l'" t !u x r ll:nJffeffii*4'aw"o'" ! L------J-J

RIGHT REAR DOOR SWITCH : Closedwith; dooropen.,

L_____":r----__ I-'r|

DRIVER'S

I q IDooR

Ir-\l3l3ll3T* H-

133-6

door open.

PHO\O 96

IT GBN/FED

E

FRONT PASSENGER'S DOOR SWITCH Closed with door open.

STEEBING LOCK

ii-=1;-i*r*iTfifil Ir il.^-.. ./ _r.n:'o ! !!r3"'.rhil.1ilri ! --ii-;;;I'-----==---**,^r..!i'i"i'

SECURITY SIARTEF CUTRELAY

"-dI iryissu'Y I

PHO|O 56 vtEw 12

Mrt

BLKAIIIfIT

o

STARTER

cur

RELAY

------;r

PHO|O 135

cw

A/f sxceptCW

"'li'l t**," BLK,^,HI ll

I I I I I

V/Ew4 r

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Ia

,It

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c433

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't0 BLK/IIT/HT

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i

"."JJ"!F;?',?,-

$fri*'fl:J I clutch pedalfully oepresseo.

c433 PHOIO 76

I

",-o"ao I T cLUrcH

BLKr{VHT

-

".o"ro!

o@

PHO|O 130

BLKFED

See Starting System

SeoGfound Distribution, page 14-6.

il

c101

)21

vtEw2l 2A I

\

.

STARTER START 34

r::-1 STAHTER uo" I lsoLENotD

t

l

L--------J

133-7

Security System (cont'd)

- '96-'97CX and DX Models(cont'don page 133-10) NOTE:Wiresthat look likethis e:=---{ betweenfactorvharnessconnectors.

arepan of the optionalSecuritySystemharnessinstalled STEERING LOCK

@

r-------

FUSE 52 toRr{, sTorlrotir t5a

!'"*'i! iltr? _ili* !i*.1-/*.,i I L---*--J

"",,""i"1---"-",-,""rf &f,.f,,,

t--"-.*-*t------J

I

uAcgt

Ho'nReray ll Connector

t A-----1.:A ll

'l lonltion I

ar-x,ver"erorooo ll

"""o"n *""T ll ll 1A-------/{

HORN RELAY

".,,".:J[-'I .--.tf rvll

a:

"ll

sEcuRrw

GAY

IN.LINE FUSE HOLDER

H( Relay 114 Horn a l Connecto. c( .-t GRY

"""'

+

ALK,YEL 11

)e florns

Horn

""''"h [*u c214

vtEw21

/1H?#,

SECURITY CONTROL UNIT vtEw58

O ___________1F_( c415 ".u "eo ll

" U c+ts

'i!,1fl0

See Seat Belt

ano ronrl|on KeYReminder

gd!ryi--],.,,.*,"o

eLu,,,viiYll9,'9.60

!"*" ilnffi"* L+ kevInignition.I I L--ll------J

"'utTf, "o',u PHofo46a

BLU/FED

c20'l

oLK ll

PHO|O 23 vtEw 3a

BLK

G401

133-8

lgnition

Batiary

V

- '98-'00CX and DX Models(cont'don page 133-10) NOTE:Wiresthat look likethis e=-* betweenlactoryharnessconnectors.

arepartof the optionalSecuritySystemharnessinstalled STEERING LOCK UNOER-HOOD FUSE/RELAY BOX

-1[::_5J*nt ,trft?;"," s Y c3s1 ,n"r,".oI i[o"to,'

liuF;lt"ls'rs?

i iL:"::Ifui '--T'Il,].----r

HORN RELAY

PHOIO t35 ( 99 0o models)

;.;l

i-t-fii;r,'im:";

c926 OPTION PHO|O 62

sEcuRrw

t

IN.LINE FUSE HOLDER

cnvllConnector 9"" Horns ll

;.'".*"' TBriE:,, Lii+ ,"" l-l--';] ll 'Jl '' lL--l[JL---:-----------C - - - tt* --, - . :- ;_: i.rl::t;;;[.?jsor+3r 't--J'''*uo i lff], ;,:"1. I ii}"*:* iw,E"

lc,o,na i Y#,iln,"o* i - 9JlflB'],iff, -J--------- . l .-- - L:;; - ' -i'. - -- --s-J[-J rsy]sf l-' ll

; '

i

'fi

BLU REo| | ".r,".o ' ---

"

ll *ll

ll

fl

-

i ".,".oii----iiiu

see seat Bettand

[tJ.li'fll5"t

:

'

: -BLU^YHr z!9X;2""|"i!'}?."" r{i y*sr.. SWITCH' ' ; r { i fs si;;;i; "l{

-l-'-

ll

BLK ll

'

i iQffi*"it*" "'u*TI L--IF-----J

i,-

. - - - -.

Itr

2 gLuneo --;'

"i-jttz---'rsrEER STEERTNG l/rlu'-'u"i i ,# ll ;i'".'J^ i

Fii;i,"

eLull 11

J

"o,u

r atv r lt PHofo 60 v / E w' 4 _8!Kll

HOBN

:

G401

133-9

SecuritySystem

- AIICX and DX Models(cont'd) NOTE:Wiresthat look likethis -:= betweenfactorvharnessconnactors.

arepartof the optionalSecuritySystemharnessinstalled

SECURITY

LT GFN/BLK Lf GRN/REO

2

c407 PHO|O 52 Y/El4 ? ( 98' 00 mod€rs)

LT GFN/BLK ('99' 00 modsls LT GBN/RED)

14

c41t PHO|O 6A vtEw 60

'99-'00models

LT GFN/REO

(Not useo) c411

13

vtFw20

LI GFN/BEO

a,o^n,"ao I

r-----{asl I - - -l.l' il-

LTGFN/FED

-----1

UNDER.OASH FUSE/RELAY 11 BOX 1 INTEGRAT€D PHoro 5a (,99_,00 models15)

ififlLliF"#t::-

LTGAN/BED

Sedan - - -

LTGBN/RED

H

fTl33'J"*''

FRONT PASSENGER'S DOOR

lldi$"",""',:;llswtTcH PHO|O96

Closed with door open.

IT rui=ifl H

RIGHT REAB DOOR

:

dooropen.

Closedwith dooropen.

;

PHO|OqT

PHO|A9T

R EAR

=-

I

133-10

c40'r

SWITCH Closed with

swtTcH

l t FUsE4s ! \ xamucnr I I.A LJ,----J

UNDER.HOOD I FUSEiRELAY ! BoX 7 I PHoro

c352

vtEw27

SoePow€rDistdbulion, page1&12, E2

CombinationLight SwitchConnector

See lndicators

LIGHT FLASHER RELAY

COMBINATION I LIGHTSWITCH | v;iw;

I |

4 aLUor ALU/YEI

c503

iTFffiliBi+B,il :"'s#Ji""I coNrRoL iI #input$ iI

vtEw58

L ----J

3Y

BLU/BLK ll

:a

Brui 8rK ll

ftT-f."," *,rlfr

Combination Light Switqh Connector

,^ftslllflli^ir,, Ha,chback

Coupatnd Sedan

"'u'"t*X ".u,"." See Trunk aE,<

aau,"a" fi

-*;"1

' * 9 # 1 " ,,,

'9+ 97 models

SeeHeadlight Swiich, peg61(n.

vEwe g8-,oomodets BLU/BLKrf

Light

TRUNK LATCH

swrTcH

";-f"^' l qi*$qlilljij::,:}#x I-I-t

I swtrcx

I I

se€Ground

5--r< !#itl8 or14-11 ".* I o"o'

PHOIO ro2lorcoDr'99 oo sedan) PHofo 113

FE

HATCH LATCH

""'*if

":^f

.|:

r = l\,lale- Female reversed termrnals lor'99-'00models

"tut

o tr
seecround

EXTERIOR LIGHTS

SeoGround Distribution

Distribution, Page14-12'

+ 9131",,, 133-11

SecuritySystem - All CX and DX Models (cont'd)

@

NOTE:Wiresthat look likethis S--------S are partol the optionalSecuritySystem harnessinstalledbetweenlactory harnessconnectors. From

"===-F=F*F,Ff Tfo?"

STEERING LOCK

page j33_9.

It

v ""'ll

10 Pase

-,/

l

!ltb3'-fi:-#-1iln i aLI(AVHI

'99198models (l or

1T

I

'99100models

c415

AIKWHT

vlEw14

Jl.

sEcuRrw

SECURITY STARTER CUTRELAY

LEO

PHO|O 53 vtEw 12

l-

ll ll

.",;T; "":JI------;;lt *"ll

ELKBEDII

ll

,JL----- 'dl*------

t{

'll

c4r5 PHOTO N

AubrnatbTransmission

".**"rI

[ :,i

AU(WHT

't0

2 ('98-'00mod€ls5)

('98100models3) 4

? STARTER CUT RELAY

PHO|O54 PHO|O 129 ( 9€ model)

paso14€.

I

*-l " y

L_______l .------+;_ PHO|OST

133-12

swtTcH

BLI(FEO

( 9+ 00 models)

't1

c433

au(/FEo

".o""0! CLUTCH INTERLOCK SWITCH Closedwithclutch pedaltullydepressed.

A"ITGEAR POStTTON

I I I I I

".*"9tr

rnJ"lsz1'[ 1-sel-oo

c433

BLXAVI{T

BLKT'!VHT

".o".0

aE4 ar-rvneo ll

'f, "";%,,

see

Starting System

BLKTTBT vrEw28 I r-11------.|STABTER

34 I PHoro ! r3r smnren coit | 1 ; SoLENOID I

i !.__J L--------J

i

Howthe CircuitWorks Arming the SecuritySystem Thesecurity systemcanbe armed: r By pressing theremotecontrolLOCKbutton (ifequipped) . 20 secondsatterclosingall doors(C)UDXonly)

Disarmingthe Systemwithout the Remote Transmitter(HX,LX, and EX) Youcandisarmthesystemby turningthe ignition thedisarm/valet switchto ON (ll) andpressing switchon the rightsideol thestereotunerface.The disarmswitchwillalsodisarmthesvstemafterthe systemhasbeentriggered.

Arming with the Transmitter The securitysystemcan be armedby removingthe ignitionkeyfromtheignition switch,closingall doorsandthetrunk,andpressing the LOCKbutton you the transmitter. When arm the systemin this on LED on, way,the remotecontrol comes the status per LEDflashesonce second,theparkinglights flashonce.thedoorslock.andthe hornsounds onceif the beeosoundmodeis on. PassiveArming(CXand Dx only) to OFF,removethe Whenyouturntheignition keyfromtheignition switch,andcloseall ignition thedoorsandthetrunk;thesystemwill armitself20 secondsafterthetrunk automatically or lastdooris closed.Whenyouarmthesystem thisway,the statusLEDtlashes4 timespersecond duringtheexitdelaytime,andoncepersecond afterthe systemis armed;the parkinglightswill flashonceto confirmthatthesystemis armed. Triggeringthe Alarm Atteryou'vearmedthe system,it willtriggerthe is opened.lf the alarmif anydooror the trunldhatch whenthe systemis armedor batteryis disconnected it will immediately in the alarmmode,reconnecting the triggerthealarm.Whenthealarmis triggered, followingwilloccurfor 30 seconds: . thehornsounds o theparkinglightsflashoncepersecond .

thestatusLEDflasheshviceoersecond

.

thestarteris disabled

Disarmingthe Systemwith the Remote Transmitter(Hx, Lx, Ex, DX-V,and Si) UNLOCKbuttonwilldisarm Pressing thetransmitter the system.The parkinglightsllasht\iviceif the Theparkinglights alarmhasnotbeentnggered. has times if the alarm beentriggered. flashthree you pressthe unlock lf Thedriver'sdoorwillunlock. buttontwice,it willunlockalldoors.lf a dooris not thesystemwilllockall openedwithin30 seconds, doorsandrearm. Disarmingthe System(CXand DXonly) lf thesystemarmsitself,thereis a 20 seconddelay afteryouopena doorbeforethealarmwilltrigger. Todisarmthesystemin thismode,simplyturnthe ignition switchto the ON position ldentityingTrippedSensors whichsensortripsthealarm Thesystemidentifies thestatusLED.Todisplaythetrip by flashing switch3 sensorflashcode,pressthe disarm/valet timeswithin5 secondsafterthe systemhasbeen to Thestatussensorwillblinkaccording disarmed. thefollowino codes:

Sensors Door TrunldHatch SystemSwitches

Numberof Flashes 1 blink,pause,repeat 2 blinks,pause,repeat 3 blinks,pause,repeat

instructions, seethesecurity Forfurtheroperating syslemowner'smanual.

After30 seconds, thealarmwillstopandthe thetransmitter systemwillrearm.Pressing UNLOCK buttonwilldisarmthesvstem.

tlr (cont'd)

133-13

Security System (cont'd) SecurityControl Unit Troubleshootlng lf a faultysecuritysystemhasone of the symptomsbelow,turnto the pagelistedandfollowthe appropriate procedure.lf the symplomseemsrelatedto an inputproblem,or is not coveredby the troubleshooting procedures, troubleshooting do the InputTestson page133-15.Referto the circuitschematicon pages133 through133-12as needed. Symptomlndex SecuritySysiemDoesNotWorkIn Any Mode(HX,LX, EX) SecuritySystemDoesNotWorkIn Any Mode(CX,DX) SecuritySystemDoesNotArm (CX,DX)

Page133-18

SecuritySystemDoesNotArm (HX,LX, EX,DX-V,SD

Page133-19

SecuritySystemDoesNot DisarmWithThe Transmitler (HX,LX,EX,DX-V,Si) SecuritySystemDoesNot Disarm(CX,DX) . . . .

Page133-20

Page133-17 Page133-18

Page133-20

SecuritySystemDoesNot DisarmWithThe ValetSwitch Page133-21 c96-' 98HX,LX,EX) . SecuritySystemDoesNot DisarmWithThe ValetSwitch('99 models) . . . Page 133-22 SecuritySystemDo€sNotWorkIn The ValetMode ('96.,98HX,LX,EX) . Page133-21 ('99models)........ Page 133-22 DoesNotWorkInTheValetMode Security System SecuritySystemAlaim DoesNotTriggerWhenThe Systemls Armed AndTheTrunkOr A Doorls Ooened SecuritySystemDoesNot'Beep"3 TimesWhenThe Systemls Armed WithThe TrunkOr A DoorOpen(HX,LX, EX,DX-V Si) ParkingLightsDo Not Flash(CX,DX)

133 -1 4

Page133-23 Page133-23 Page133-24

ParkingLightsDo NotFlash(HX,LX,EX,DX-VSi) SecuritySystemStatusLEDStaysOn (HX,LX, EX,DX-V Si) SecuritySystemStatusLEDDoesNotCom€On (HX,LX, EX, DX-V,Si) . StarterCut DoesNotWorkProperly('96198HX, LX, EX,DX-V,SD . . . . . .

Page133-25 Page133-26

StarterCut DoesNotWorkProperly(CX,DX) . . . . .

Page133-28

HomDoesNotSoundWhenAlarmls Triggered Input Tests

Page133-29

Page133-26 Page133-27

Page133-l5

Ir

SecurityControlUnit InputTest Thefollowing testsareperformed withtheelectrical conneclor disconnected fromthesecurity controlunit.

1

2 3 4

X

5

1 1 12 1314 15

Terminal No.

rol

6 7

I

9 10

1 7 1 8 1 9 20 21 22

Wire Color

Test Condition

Test:DesiredResult

2

LT GRN/ RED

Eachdoor opened, one at a time

Checkfor conlinuityto ground: Thereshouldbe continuity.

a

3

BLU/BLK TrunUHatchopen

Checkforcontinuity to ground: Thereshouldbe continuity.

a a

Possible Cause il result is not obtained

.

10

WHT

Underall conditions

Checktor voltageto ground: Thereshouldbe battery voltage.

. . . .

\ ;

11

YEL (BLK/YEL lgnitionswitchON (ll)

cx, DX) BLK

t5

18

Underallconditions

lgnition keyinserted intotheignition key switch BLU/RED lgnition keyremoved fromtheignition key switch

GRY

Underall conditions

Checkfor voltageto ground: Thereshouldbe battery voltage. to ground: Checkforcontinuity Thereshouldbe continuity. Check for voltageto ground: Thereshouldbe 1 V or less. Check for voltageto ground: Thereshouldbe 4 V or more.

Connect to ground: Hornshouldsound.

Faulty door switch An open in the wire

Faultytrunldhatch latchswitch An openin thewire BlownNo.6 (3A)fusein the under-hood fuse/relay box (HX,LX,EX,DX-VSi) BlownNo.54 (40A)fusein the under-hood fuse/relay box(CX,DX) Blown(3A)fusein security in-line fuseholder(CX,DX) An openin thewire

.

BlownNo 3 (10A)fuse in the under-dashtuse/relaybox (HX, LX, EX, DX.V,Si) Blown(3A)fuse in the securityin-line fuse holder(CX, DX) An open in the wire

a a

Poorground(G401,G402) An openin thewire

a a a a

Poorground(G401,G402) Faulty ignitionkey switch An open in the wire Shortin the wire

.

BlownNo.52 (15A)luse in the under-hoodluse/relay box Faultyhorn Faultyhorn relay An open in the wire

.

. . .

133-15

Security System (cont'd) Thefollowingtestsare performedwiththe electricalconnectorconnectedto the securitycontrolunit.

Terminal No. 1

Wire Color

YEUBLU Underallconditions

BLU

5

12

14

ORN

Valetswitchpressed

Underall conditions

BLU/WHT (BED Underallconditions CX,DX) RED/ WHT

17

19

TestCondition

Securitysystemin PANICmode

REDI/EL Securitysystem (GRN DX) alarmtriggered

cx,

BLUA/EL

22

/'oa-'oq mooels WHT/BLK)

133-16

Underallconditions

Test:DesiredResult Check tor voltage to ground: There should be approximately 5 volts.

Checktor voltageto ground: Shouldchangefrom 5 voltsto less approximately than 1 voltwhenvaletswitchis prsssed.

PossibleCauseil result is not obtained a a a a

a Checkfor voltageto ground: Thereshouldbe approximately 5 volts. o . Checkfor voltageto ground: Thereshouldbe approximately . 4 volts.

Checkfor voltageto ground: Shouldchangefrombattery voltageto lessthen1 voltwhen in the PANICmode. Checktor voltagsto ground: Shouldchangefrombattery voltageto lessthen 1 voltwhen securitysystemalarmis triggsred.

a a a a a I

a

BlownNo.6 (3A)fusein the box under-dash fuse/relay Faultysecuritycontrolunit Faultyradio('96-98models) or valetswitch('99models) An openinthewire BlownNo 6 (3A)tusein tho tuse/relaybox under-dash Faultysecuritycontrolunit An openin thewire Faultyradio('96198models) or securityLED('99models) BlownNo.48 (30A)luse in the fuse/relay box under-hood Faultylightflasherrelay Faultysecurityconlrolunit An openin the wire Faultysecuritystarlercut relay Faultysecuritycontrolunit An openin the wire

a BlownNo.6 (3A)fusein the Checktor voltageto ground: fuse/relaybox under-dash Thereshouldbe approximately a Faultysecuritycontrolunit 5 volts.

\

.

SecuritySystemDoesNot WorkIn Any Mode(HX,LX,EX,DX-V,Si) 1. ls fuse6 (intheunder-dash box)OK? Yes- Go to the nextsteo. No - Replace the blowntuse,thengo to the nextsleD. 2. Doesthefuseblowagain? Yes- Go to the nextstep. No - Retestthe system. 3. Disconnect the securitycontrolunitconnector. 4. ls therecontinuity fromterminals 1, 10,12,ot 22 to oround?

\iu

6. ls therecontinuity f romterminal13 ot the security controlunitconnector to ground?

Yes- '96-'98models:Go to the nextsteD. '99 models:Replace thesecurity control unit. No - Locatethe openin the wiringbetweenthe securitycontrolunitandground(G401). 7 . Withthe securitycontrolunilconnector reconnected, is therebatteryvoltageat terminal 21 ot thesecuritvcontrolunitconnector?

Yes- Locatethe shortin the wiringbetweenthe security controlunitandthe radio('96-'98 models) or keylessdoorlockcontrolunit ('99model). No - Go to thenextstep. 5. ls therebatteryvoltageat terminal10 of the securitv controlunilconnector? Yes- Go to the nextstep. No- Beplacethesecurity controlunit. 8 . ls therebatteryvoltageat terminal5 of the keylessentryharnessconnector(B)?

Yes- Go to the nextsteo. No - Locatetheopenin thewiringbetween fuse6 andthesecuritv controlunit.

Yes- Replacethe radio. No- Repairthedamaged LTBLUwire betweenthe securitycontrolunitand the radio.

rfe 133-17

Security System (cont'd) SecuritySystemDoesNotWorkln Any Mode(CX,DX) 1. ls luse54 (inthe under-hood fusebox)OK? Yes Go to the nextstep. No - Repiace theblownfuse,thengo to the nextstep. 2. ls thefusein thesecuriiyin-linefuseholderOK? Yes- Go to the nextstep. No - Replace theblownfuse,thengo to next srep. 3. Doeseitherfuseblowagain? Yes- Locateand repairthe short. No - Retestthe system. 4. ls therebatteryvoltageat terminal10 of the securitycontrolunitconnector?

Yes- Go to the nextstep. No - Locatethe openin the wiringbetween fuse54 andthesecurity controlunit. 13ol the ls there from terminal 5. continuity ground? control unit connector to security

SecuritySystemDoesNotArm (CX,DX) 1. Placetheceilinglightin thecenterposition. Doestheceilinglightcomeon,evenwithallthe doorsclosed? Yes- Faultydoorswitchor shortin wiringto doorswitches. No - Go to the nextsteo. 2. Withthe ignition switchin theON (ll) position, in thegauge doesthetrunkopenindicator assembly comeon,evenwiththetrunkclosed? Yes- Faultytrunklatchswitchor shortin the BLU/BLK wire. No - Go to the nextstep. 3. Doesvoltageat terminal2 of the securitycontrol unitconnectorchangefrombatteryvoltagewith all doorsclosed,to lessthan1 voltwhenany dooris ooened?

Yes- Go to the nextstep. 2 No - Repairtheopenin theterminal (LTGRN/BLK wire. or LTGRN/RED) Doesvoltageat terminal3 of the securitycontrol unitconnectorchangefrombatteryvoltagewith thetrunkclosed,to lessthan1 voltwhenthe trunkis oDened?

thesecurity controlunit. Yes- Replace the No Locatetheopenin thewiringbetween controlunitandG401. securitv v]" - R"pt"." tne securitycontrolunit. No - Bepairtheopenin theterminal 3 (BLU/BLK) wire.

133-18

SecuritySystemDoesNot Arm (HX,LX,EX,DX-V,Si) 1. Withall thedoorsclosed,do thedoorslock whenyoupressthetransmitter LOCKbutton? Yes Go to the nextsteo. No - Go to DoorsDo NotLockWithThe Transmitter, on page130-11('96-98 models)or 130-18('99models). Checkthetrunkopenindicator in thegauge assembly. Withthe ignition switchin theON (ll) position, doesthetrunkopenindicator comeon evenwiththe trunkclosed? Yes- Faultytrunklatchswitchor shodin BLU/BLK wire. No - Go to thenextsteo. Doesthe voltageat terminal2 of the security controlunitconnector changefrom approximately 5 voltswithalldoorsclosed,to lessthan1 voltwhenanydooris opened?

Yes- Go to the nextstep. No - Repairthedamaged terminal2 (LTGRN/RED) wire. Doesthevoltageat terminal 3 of thesecurity controlunitconnectorchangefrombattery voltagewiththetrunkclosed,to lessthan1 volt whenthetrunkis ooened?

Yes- Go to the nextsteo. No - Repairthedamaged terminal 3 wire. {BLU/BLK) 5 . Doesthevoltageat terminal15 of thesecurity controlunitconnector changefrombattery voltagethe keyis notin theignition, to lessthan 1 voltwhenthekeyis in the ignition?

o.

Yes- Go to the-nextstep. No - Repairthe damaged terminal15 (BLU/RED) wire. ls ihereapproximately 5 voltsat terminal 22 of thesecuritycontrolunitconnector?

Yes- Go to the nextstep. thesecurity No - Replace controlunit. 7. ls thereapproximately 5 voltsat terminal12 ('96-'98models)or 14 ('99models)of the keylessreceiver unit('96- 98models)or the keylessdoorlockcontrolunit('99models)? '96198modelsi

Yes- Replace the radio('96-'98models)or the keylessdoorlockcontrolunit('99 models). ('96-'98 WHT/BLK No - Repairthedamaged ('99models)wire models) or BLU/YEL between thesecurity controlunitandthe radio('96- 98models)or the keylessdoor lockcontrolunit('99models).

133-19

SecuritySystem(cont'd) SecuritySystemDoesNotDisarmWith (HX,LX,EX,DX-V,Si) TheTransmitter 1. Withallthedoorsclosedandlocked,do the doorsunlockwhenthetransmitter UNLOCK buttonis pressed? Yes- Go to thenextstep. No - Go to "DoorsDo NotUnlockWithThe ('96-98 Transmitte/' on page130-11 models)or 130-18('99models). 2. ls thereapproximately 5 voltsat terminal1 of the securitv controlunitconnector?

Yes- Go to the nextstep. No - Security controlunit. voltage at terminal13 ofthe 3. ls therebattery ('9698models)or the unit keylessreceiver keylessdoorlockcontrolunit('99models)? 96. 98models:

'99 models:

Yes- Beplacethe radio('96-'98models)or the keylessdoorlockcontrolunit('99 models). YEUBLUwire No - Repairthedamaged thesecurity between controlunitand the radio.

133-20

SecuritySystemDoesNot Disarm

(cx,Dx)

1. ls thetusein thesecurityin-lineluseholderOK? Yes- Go to the nextstep. the blownfuse,thengo to the No - Replace nexlsreD. 2. Doesthefuseblowagain? Yes- Locateand repairlhe short. No- Retestthesystem. 3. ls therebatteryvoltageat terminal11of the whentheignition security controlunitconnector, switchis in theON (ll) position?

Yes - Replacethe securitycontrol unil. No - Locatethe open in the wiringbetween the ignitionswitchand lhe securilycontrol unit.

rl,

SecuritySystemDoesNot DisarmWith The ValetSwitch SecuritySystemDoesNot Work ln The ValetMode('96-'98HX,LX, EX) fusebox)OK? 1. ls luse3 (inthe under-dash to the next steD. Yes Go theblownfuse,thengo to the No - Replace nextstep. 2. Doesthefuseblowagain? Yes- Locateand reoairthe short. No - Retestthesystem. 3. ls therebatteryvoltageat terminal11of the security controlunitconnecto(whentheignition switchis in theON (ll) position?

Yes- Go to thenextstep. No - Locatetheopenin thewiringbetween controlunit. luse3 andthesecurity 4 of the ls lhereapproximately 5 voltsat terminal (B)? connector keylessentryharness

5 of the 5 voltsat terminal 5. ls thereapproximately controlunitconnector? security

Yes- Goto the nextstep. No - Locatetheopenin the BLUwirebetween controlunitandthe radio. thesecurity control 5 oJthesecurity 6 . ls thevoltageat terminal 5 fromapproximately changed unitconnector voltsto 0 voltswhenthevaletswitchis pressed?

thesecurity controlunit. Yes- Replace the radio. No - ReDlace

Yes- Goto thenextstep. the radio. No - Replace

rl e 133-21

SecuritySystem(cont'd) SecuritySystemDoesNot DisarmWith TheValetSwitch SecuritySystemDoesNotWorkIn The ValetMode('99-'00models) 1. ls fuse3 (inthe under-dash fusebox)(HX,LX, EX,DX-V,Si)or thefusein thesecurilyin-line luseholder(CX,DX)OK? Yes- Go to the nextstep. No - Replace theblownfuse,thengo to the nextstep. Doesthefuseblowagain? Yes- Locateand reoairthe short. No- Retestthesystem. 3. ls therebatteryvoltageal terminal11of the security controlunitconnector, whenthe ignition switchis in theON (ll) position?

Yes- Go to the nextsteo. No - Locatethe openin the wiringbetween fuse3 (HX,LX,EX,DX-V,Si)or theluse in thesecurityinlinefuseholder(CX, DX)andthesecurivcontrolunit.

133-22

4. ls thereapproximately 5 voltsat terminal 5 of the securitycontrolunitconnector?

Yes- Go to the nextsteo. No - Replacethe securitycontrolunit. ls the voltageat terminal5 of the securitycontrol unil connectorchangedfromapproximately 5 voltsto 0 voltswhenthe valetswitchis pressed?

Yes- Replace thesecurity controlunit. No - Checkthatthevaletswitchis working properly, thencheckforan openin the wiringbetweenthe valetswitchandthe security controlunit.

SecuritySystemAlarmDoesNot Trigger WhenTheSystemls ArmedAndThe TrunkOr A Doorls Opened SecuritySystemDoesNot"Be€p"3 Times WhenTheSystemis ArmedWithTheTrunk Or A DoorOpen(HX,LX,EX,Dx-V SD then 1. Placetheceilinglightin thecenterposition, openandclosethedoorsoneat a time.Do all thedoorsoperatetheceilinglightproperly? Yes- Go to the nextsteo. No - Repairtheceilinglightcircuit. Withthe ignition switchin theON (ll) position, in thegauge doesthetrunkopenindicator assembly comeon withthetrunkopen? Yes- Go to the nextstep. No - Faultytrunklatchswitchor an openin the wire. BLU/BLK Doesthe voltageat terminal2 of the security controlunitconnectorchangetrombattery voltagewithall doorsclosed,to lessthan I volt whenanydooris opened?

4. Doesthe voltageat terminal3 of the security controlunitconnectorchangefrombattery voltagewiththetrunkclosed,to lessthan1 volt whenthetrunkis opened?

Yes- Replacethe securitycontrolunit. 3 theoDenin theterminal No - ReDair (BLU/BLK) wire.

Yes- Go to the nextstep. 2 No - Repairtheopenin theterminal (LTGRN/RED) wire.

133-23

Security System (conrd) ParkingLights Do Not Flash(CX,DX) 1. Do theparkinglights,headlights, andtaillights comeon withthe headlight switchin the HEAD position? Yes- Go to the nextstep. No - Repairthe parkinglights,headlights, or taillights circuit. 2. ls therebatteryvoltageat terminals1 and 2 of the lightflasherrelayconnector?

4 of the lightflasher 5. Doesthevoltageat terminal relayconnectorchangefrombatteryvoltageto 0 voltsrepeatedly whenthesystemis in thealarm triggered mode?

q I =

dHl .t.

Yes- Go to the nextstep. No - Repairtheopenin theWHTwire fuse48 andthe lightflasher between relay. ls therebatteryvoltageat terminal4 of the light flasherrelayconnector?

Yes- Replacethe lightflasherrelay. No - Go to the nextstep. Withthe securitycontrolunitconnector disconnected, runa jumperwirefromtermrnal 17to ground. Do theparkinglightscomeon?

-F-,

tlllJ t 3 l 4 n

l

I

t v l r = Yes- Go to the nextstep. No - Replace thelightflasherrelay. Withthe lightflasherrelayconnector runa jumperwirefromterminal1 disconnected, to terminal3. Dothe parkinglightsandtaillights comeon?

Yes- Go to the nextstep. No - Repairtheopenin the RED/GRN wire.

133-24

Yes- Replacethe securitycontrolunit. No - Repairtheopenin theterminal17 (REDAIVHT) wire.

ParkingLightsDo Not FlashIn Any Mode (HX,LX,EX,DX-VSi) andtaillights 1. Dothe parkinglights,headlights, switchin the HEAD comeon withtheheadlight oosition? Yes- Go to the nextsteo. or No - Repairthe parkinglight,headlight, taillight circuit. 2. Doesthehornsoundwhenthetransmitter PANICbuttonis oressed? Yes- Go to the nextstep. No - Goto the"HornDoesNotSoundInthe PanicMode"teston page130-11('96-98 models)or 130-18('99models). 3. ls therebatteryvoltageat terminals1 and2 of the lightflasherrelayconnector?

5. Withthe lightflasherrelayconnector .l runa jumperwirefromterminal disconnected, to terminal3. comeon? Dotheparkinglightsandtaillights

o.

Yes- Go to the nextstep. wire. No - Repairtheopenin the RED/GRN 4 of the lightflasher Doesthevoltageat terminal relayconnector(C403)changefrombattery whenthe security voltageto 0 voltsrepeatedly svstemis in the PANICmode?

q

Yes- Go to the nextstep. No - Reoairtheopenin theWHTwire fuse48 andthe liqhtflasher behveen reray. ls therebatteryvoltageat terminal4 ol the light flasherrelayconnector? Yes- Go to the nextsteD. the lightflasherrelay. No - Replace

I =

the lightflasherrelay. Yes- Replace No Go to the nextsteP. controlunitconnector With thesecurity 7. runa jumperwirefromterminal disconnected, 17 to ground. comeon? Dothe parkinglightsandtaillights

Yes- Replacethe securityconlrolunit. No - Repairtheopenin theterminal17 (REDMHT)wire.

\t 133-25

SecuritySystem(cont'd) SecuritySystemStatusLEDStaysOn (HX,LX,EX,DX-V,Si)

SecuritySystemStatusLED DoesNot ComeOn ('96-'98HX,LX, EX)

1. DoesthesecuritysystemstatusLEDgo out whenthesecurity controlunitconnector is disconnected? Yes- Replace thesecurity controlunit. No - '96-'98models:Go to the nextsteD. '99 models:Locateandrepairthe shortin the BLUMHTwirebetween thesecurity LEDandthesecurity controlunit connector. 2. DoesthesecuritysystemstatusLEDgo out whenthekeylessentryconnector (B)is disconnected? Yes- Locateand repairthe shortin the BLU,ryVHT wire behveenthe keylessentry (B)andthesecurity harnessconnector controlunilconnector. No - Beplacethe radio,

1. ls therevoltageat terminal11of the keyless (B)? entryharness connector

Yes- Go to the nextsteo. No - Replace the radio. ls therevoltageat terminal14of thesecurity controlunitconnector?

Yes- Go to the nextsteo, No- Locateandrepairtheopenin the BLUMHTwire. Withthe keylessentryharness (B) connector jumper connected, runa fromterminal14 of the security controlunitconnector to ground. Doesthesecuritv statusLEDcomeon?

Yes- Replace thesecurity controlunit. No - Reolace the radio.

133-26

StarterCut DoesNot Work Properly (HX,LX, EX,DX-V,Si) systemconnector 1. Withthesecurity runa jumperwirefromterminal disconnected, ground. 19to

startercut relayconnector 4. Withthesecurity 2 runa jumperwirefromterminal disconnected, 4. to terminal Doestheslartermotoroperatewhenthe ignition switchis turnedto START(lll)?

Doesthestartermotoroperatewhenthe ignition switchis turnedto START(lll)?

thesecurity controlunit. Yes- Replace No Go to thenextsteD. 2 and3 of 2 . ls therebalteryvoltageat terminals whenthe thesecurity startercut relayconnector, ignition switchis in theSTART(lll)position?

Yes- Go to the nextstep, system. No - Repairthestarting startercut relayconnector 5 . Withthesecurity doesthevoltageat terminal6 reconnected, changefrombatteryvoltageto 0 voltswhenthe Mode? systemis in theAlarmTriggered

4

I =

Yes- Go to thenextstep, wire No - Reoairtheooenin the BLK/YEL the ignition switchandthe between security startercut relay. 6 of the 3 . ls therebatteryvoltageat terminal securitv startercut relav?

Yes- Replacethe securitystartercut relay. No - Repairtheopenin terminal19 (BED/YEL) wire.

@

I =

Yes - Go to the next steo. No - Replacethe securitystartercut relay.

\rr 133-27

Security System (cont'd) StarterCut DoesNot Work Properly

(cx,Dx)

1. Withthesecuritysystemconnector runa jumperwiref romterminal disconnected, ground, 19to

4. Withthe securitystartercut relayconnector disconnected, runa jumperwirefromterminal 2 to terminal 4. Doesthe startermotoroperatewhenthe ignition switchis turnedto START(lll)?

Doesthestartermotoroperatewhentheignition switchis turnedto START(lll)?

Yes- Replace thesecuritycontrolunit. No - Go to the nextsteo. ls therebatteryvoltageat terminals2 and 3 of the securitystartercut relayconnector, whenthe ignition switchis in theSTART(lll)position?

Yes- Go to the nextsteo. No - Repairlhe startingsystem. Doesthe voltageat terminal6 of the security startercut relaychangetrombatteryvoltageto 0 voltswhenthe systemis in the AlarmTriggered Mode?

q

I =

Yes- Go to the nextstep. No - Repairtheopenin the BLKMHTwire the ignition between switchandthe securitystartercut relay. ls therebatteryvoltageat terminal6 of the securitvstartercut relav?

4o t_ =

Yes- Go to the nextstep. No - Beplacethesecurity startercut relay.

133-28

Yes- Replacethe securitystartercut relay. No - Repairtheopenin theterminal19 (GRN) wtre.

Horn DoesNot SoundWhenAlarm ls Triggered 1. Doesthehornsoundwhenthe hornbuttonis pressed? Yes- Go to the nextstep. No- Repairthehorncircuit. 2. Withthe securitycontrolconnector runa jumperwiref romterminal disconnected, '18to ground. Doesthe hornsound?

.1,

thesecurity controlunit. Yes- Replace No - Repairtheopenin thelerminal18 (GRY)wire.

lr I 133-29

lnterlockSystem

- Allexcept'96-'98CVT UNDEROASH

T-----1 FUSE25

page10-12. FUSE33

glD^:R-

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'""'o*-'' x?! o,"*",! i-l =-CF'!,n:E!-l | -$-.",., .^AX-----.,'dtA--"^",." eowen. i lfl.iilF]iH*,"'i''t#'---.r=23[11 Hfl*gff*

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t:l*ii** ffi 'trii'df,' """'" ,",'3,fii;1,1,''tr ! fit:'/:,:iffJff nearlne snrnrever

I ll

-

TNTERLOCK CONTROL UNIT

wxrneot

--4-------------Lt,

*?,1fl92

Key Intedock Clrcuit Allowskey int€rlock solenoidto be energized unlessshift leveris in "P"

";t-,".f";,

Shltt Lock Chcuil Preventsshifibck solenoidtrom energizingunless brakep€dalis d€pfessedard pedalis acc€le{ator not depr€ssed.

;.-9,[

aL(BLU

SeeA/TGear PositionIndicator A/T GEAR POSITION

.----<

BLK/BLU

c433

swtTcH

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i-*t'

f,

9e€ urutse

I

'-i_:{ ilt:tfi'F1 #

:

O-<( BLK IG401 PHO|O 57

138

Control BLK 1 BLK

BLK

I I I I

*1 = 96 D16Y8engine:Allexcept uoupes '97 D16Y7 engine:All except CaliforniaCoupe and California Sedan LX '97 D16Y8 engine:All except Coupesand Calilornia Sedan D1685engine:All *2 = '96 D16Y8engine:AllCoupes '97 D16Y7 engine:California Coupe, CaliforniaSedan LX '97 D16Y8 englne:AllCoupes, Calilornia Sedan '98 model: All *3 = '99 model:All

SeeGround Distribution, page14-5. )rq

-l

- '96-'98CVT

THROTTLE BRAKE SWTTCH r--'l I ..-. -, I PoslrloN l c l o s e dw r l h

l-l-'l | |

i.:1r1'jflI$s l&l!fii{+f "o'ouloo,

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=ffan+' Shltt Lock Clrcuil Preventsshiftlock solenoidlrom €nergizingunlees brakep€dalis depressedand pedalis accelerator not depressed.

Key ldedock Clrcult Allowsk€y interlock solenoidto be energized unl6ssshitt leveris in'P"

;;.r";;

;-;5[

BLKBIU BLKBTU I ar< i

I

vtEw26

NOTE: ln case of system the malfunction, shift lever can be releasedby pushing the ignitionkey into the releaseslot near the shitt lever.

SeeA/f Gear Position lndicator

-------r

I NTERLOCK CONTROL UNIT

A / TG E A R

il{t-\-"i ' -iffi'dqF" l;#i;",; !

l,'-

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138-1

PowerMirrors - Without Defogger

r,-;;---j \

/

I

HEAIEF A/C FEIAY

t uo

f-----f

UNDERDASH 1

s"" Po*", !

RELAY BOX

Distribution, I

L_i:i:_J

I I I I I

f,-G;--I lF---t

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L_i:i'i_ rt;%,"

-l

UNDER-

I OASH FUSE/ I RELAY I BOX I I

J

BLK/BLU

vlEw22

*'ii%.,

10

BLK/BLU

vtEW46

L

'96-'98models andall GXmodels

'99r00models exceptGX

POWER MIRBOR swtTcH vtEw33

a-

G-t BLU/BLK

('98 00 mooets 2't) 15

BLU/ALK

c639 LT GRN

c656

vlEW23

LEFT MIRROR

RIGHT MIRROR SeeGround Distribution, page14-8.

G551

141

How the CircuitWorks Thetwooutsidemirrorsarecontrolled by thepower mirrorswitch.Eachmirrorhastwo reversible motors:onemotormovesthemirrorup anddown andtheothermotormovesthe mirrorlettandright. Thepowermirrorswitchcontains fourswitches to controlmirroradjustment, andtwoswitches to selecttheleftor rightmirrorWiththeignitionin ON (ll),batteryvoltageis supplied to the powermirror swrtch. Themirrorselector switchdirectsvoltage fromtwoof thedirection switches to eitherthe left or the rightmirror. MirrorUp

MirrorRight Whenyou pressthe "right"edgeof the mirror adjustment button,groundis supplied fromoneof the lefvrightswitchcontactsto bothmirrors;battery voltageis suppliedfromthe oppositeleft/rightswitch contact through themirrorselectswitch.lf themirror selectswitchis in the leftor rightposition,battery voltageis supplied to thecorresponding mirror lefuright motorwhichthentiltstheselected mirrorto theright. Referto theServiceManual(Section 23,Electrical) procedures for speclfictestsof troubleshooting

Whenyoupressthe"up"edgeof themirror adjustment button,groundis supplied fromoneof the up/downswitchcontactsto bothmirrors;battery voltageis supplied fromtheopposite up/down switchcontactthroughthe mirrorselectswitch.lf themirrorselectswitchis in theleftor rightposition, batteryvoltageis supplied to thecorresponding mirroruo/downmotorwhichthentiltstheselected mtrroruD. MirrorDown Whenyoupressthe"down"edgeof the mirror Irom adjustment button,batteryvoltageis supplied swilchcontacts to bothmirrors; oneof the up/down a groundis supplied fromtheopposite up/down switchcontactthroughthe mirrorselectswitch.lf the mirrorselectswitchis in the leftor rightposition, batteryvoltageis supplied to thecorresponding mirrorup/downmotorwhichthentiltsthe selected mrrroroown. Mirror Left Whenyoupressthe"|eft"edgeof the mirror adjustment button,batteryvoltageis supplied from one of the lefurightswitchcontactsto bothmirrors; fromtheopposite lefuright a groundis supplied switchcontactthroughthemirrorselectswitch.lf the mirrorselectswitchis in the leftor rightposition, batteryvoltageis supplied to thecorresponding mirrorlefvright motorwhichthentiltstheselected mirrorto the lett.

141-1

PowerMirrors - With Defogger

i I ;;;

------

I HJ.o.',8.3.f;,"

geePower if,g}"",

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V'EW55

'ol9,;%,, V/EW 46 I

BL(/B!U

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a

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Minor Selecto. Switch O = Neutral 1 = Lelt 2 = Rlght

ORN/

aaa --

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OFN/

20

24

BLUA!/HT

21

c557

cs56

vlEw62 ORN/

OBN/WHf

BLU/ RED

BLK/

vlEw2i

SeeGroundDistribution, page14-8.

".^ | ...

4

vtEw23

FEO

LEFT

c639 BLK

c639

G551

',41-2

POWER MTRROR

c656 ORN

BLKryVHT

3

c656

BLK

vlEw24

SeeGroundDislribution, page14-9.

".* | ..- Gs52

How the CircuitWorks Thetwooutsidemirrorsarecontrolled bythe power mirrorswitch.Eachmirrorhastworeversible motors:onemotormoveslhe mirroruo anddown andtheothermotormovesthemirrorleftandright. Thepowermirrorswitchcontains fourswitches to controlmirroradjustment, anda switchlo select the leftor rightmirror.Withthe ignitionON (ll), batteryvoltageis supplied to the powermirror switch.Themirrorselectorswitchdirectsvoltage Iromthedirection switches to eitherthe leftor rioht mtrror. MirrorUp Whenyoupressthe"up"edgeof the mirror adjustment button,voltageis supplied fromoneof the UPswitchcontacts to bothmirrors. Withthe mirrorselectswitchin theLEFTor RIGHTDosition. groundis provjded forthecorresponding up/down motorthroughtheopposite UPswitchcontact. Batteryvoltageis supplied to the mirrorup/down motorwhichthentiltstheselected mirroruo. MirrorDown

MirrorRight Whenthemirrorselectswitchis in theLEFTor RIGHTposition, andyoupressthe'?ight"edgeof the mirroradjustment button,groundis provided to bothcorresponding mirrormotorsthroughoneof the RIGHTswitchcontacts. Voltageis supplied to thecorresponding leruright motorthroughthe oppositeRIGHTswitchcontact.Batteryvoltageis supplied to the mirrorleft/rightmotorwhichthen tiltstheselected mirrorright. Mirror Detoggers Withthe ignitionswitchin ON (ll),batteryvoltageis to the mirrordefoggerswitch.Whenyou supplied pressthe mirrordefoggerswitchON,voltageis suppliedto bothmirrordefoggers, causingthemto heatup and removeanyfogfromthe mirrors.The oppositesideof eachdefoggergridis connected to grouno. Referto theServiceManual(Section 23, for specific BodyElectrical) testsand procedures. troubleshooting

Whenyoupressthe"down"edgeof the mirror adjustment button,groundis provided throughone of the DOWNswitchcontactsto bothmirrors. Withthe mirrorselectswitchin the LEFTor RIGHT position, voltageis suppliedto the corresponding up/downmotorthroughtheoppositeDOWNswitch contact.Batteryvoltageis supplied to the mirror up/downmotorwhichthentiltsthe selected mtrrordown. Mirror Left Whenthemirrorselectswitchis in theLEFTor RIGHTposition, andyoupressthe"lett"edgeof the mirroradjustment button,voltageis supplied to both mirrormotorsthroughoneof the corresponding LEFTswitchcontacts. Groundis provided forthe lefvright corresponding motorthroughtheopposite LEFTswitchcontact, 8atteryvoltageis supplied to the mirrorleft/rightmotorwhichthentiltsthe mirrorleft. selected

I,J 141-3

StereoSoundSystem

;;-;l P,)r'=.,8-Jl3g"FUSE28 BA.K.IJP

i.l

| ?pJ" ,

I

(15A 9A no{br.)

I 't9

c351

-"r,"atrf

c501 vlEw55

c928 OPTION CONNECTOR

* = '96. 98models

SeePower Distribution, p a g e1 0 - 1 1 .

aa4,

18

UNDER-DASH FUSE/RELAY BOX

RAOIO CLOCK

c411

See Dash and ConsoleLights

vlEw60

.^fi;l ;,tr rA2)

ra10)

BLU

GRY/BLK

8

14

ra1) ?

18

REO/GFN

REO/GFN or BLU I '

RED/GRN (96 s7 moders BLU)

' RED

.'I LEFT I I TWEETER

, BLU

,

I r

c503

(withpowermirror617) BRN/BLK or GRYIBIK

RED/GRN

BRN/BLK

1 (with oower milors 6) C556 PHA|O93 vtEw61 aLU or RED/GRN

(withpowermirrors7)

, '

E L U , ( s 6 9 7m o d e sF E O / G F N )

. 1 RIGHT TWEETER.

c6s7

1

GFY/BLK BFN/BLK)

Tweeters

150

17

BFN/ALK

13

BLU

1 (withpowermirrors16)

rAe)

c557

GFY/BLK vtEw62 or BRN/ALK

* = 96-98 models

-

'96-'98 f'4odels

SeePowerDoorLocks (withKeylessEntry)

' I

LT ELU

BLU/ FEO

LI GRN/ atK

' 8 1

ilil':[:I::l"l (.A14) 20

rA8)

fA7)

BLK

REO/YEL

BLU/ryEL

c503 BLU/YEL

2 (A '99-'007) ('96-98Sedans12)

GFYA!/HT

7 (AI'99-'006) ('96-'98Sedansl3)

STEREO RADIOIUNER ('96.98models) vtEw6a

or AUDIO UNIT '00 (99 models)

BED/YEL

(Alt'99-'009) ('96-'98Sedans10)

c562 *

**=

Male- Female terminals reversed for'99-'00

BLU/YEL

REAR SPEAKER

I

J

RIGHT REAR SPEAKER

G501

150-1

AccessoryPowerSocket -.t

|

) rusezr

|

)33$ifl*

UNDER-DASH

| [N1e'ne*" lPHoroia

t__tglll__J " [ffi']'' i

"..""" I II

,I

l'-l-l

AccEssoRY

lQli{y#lfr

SeeGround Distribution, page14-7.

l

l

t

v

l

t

L__l #

: c4o1

PHAfa 57

155

ComponentLocation 1 . B e h i n dF r o n t G r i l l e

4. Right Rear Cornerof EngineCompartment

2. Behind Left Side of Front Bumper

5. Right Side of EngineCompartment

\

\b

3. Behind Left Side of Front Bumper

6. Right Side of EngineCompartment

\

201

b

7. Right Rear Corner of Engine Compartment

10. Right RearCorner of EngineCompartment

8. Right Rear Corner of Engine Compartment

11. Right Front Corner of EngineCompartment

9. RightRearCornerof EngineCompartment

12.RightFrontGornerof EngineCompartment

\

L

201-1

ComponentLocation 13. Lower Right Front of EngineCompartment

16. Left Front Corner of EngineCompartment

14. Front of EngineCompartment

17. Left Front Corner of Engine Compartment

\

\

15.!-owerLeft Frontof EngineCompartment

18.LeftFrontCornerof EngineCompartment

\

201-2

\

19.Left FrontCornerof EngineCompartment

22.Letl RearCornerof EngineCompartment

20. Left Front of Engine Compartment

23. Left Rear Corner of Engine Compartment

21. Left RearCornerof EngineCompartment

24. LowerLeft Rearof EngineCompartment

\

POWERSTEERINGI

\

201-3

ComponentLocation 25. Lower Left Rear of Engine

28. Lower Right Side of Engine Compartment

26. Left Side of Engine (All Except 816A2)

29. Lower Right Front of Engine

\

\

27. Right Frontof Engine

30. LowerFrontof Transmission

\

201-4

\

31. Right Side of Engine Compartment(Mff)

34. Lower Right Side of Engine

32. Right Front of Engine Compartment

35. Lower Right Rear of Engine

SPEED SENSOR

(vss)

\

33. Right Side of Engine

36. Right Side of D16Y5Engine(D1685Similar)

201-5

ComponentLocation 37. Top Right Side of D16Y7Engine

40. Front of D16Y5Engine(D1685/D16Y7 Similar)

38. Top Center of Engine (except Dl685)

4 1 . F r o n to f D l 6 Y 5 E n g i n e( D I 6 8 5 / D 1 6 Y 7S i m i l a r )

\,

J

\

39.RightRearof EngineCompartment

42.Frontof Dl6Y8 Engine('96-'98)

t

201-6

43. Undersideof Vehicle('96-'98D16Y8)

46. Lower Rear of D16YBEngine (Others Similar)

44. Right Side of D16Y8Engine (Others Similar)

47.Rearof D16Y8Engine(D16Y5and D1685Similar)

45. Rear of D16Y8Engine (All except D16Y7)

48.Top LeftSideof D16Y7Engine

\

201-7

ComponentLocation 49. Top of D16Y7Engine

52. Behind Left Side of Dash Panel

50. Left Side of Dash Panel

53. Behind Left Side of Dash Panel ('96-'97)

\

\

51. Behind Left Side of Dash Panel

54. Behind Left Side of Dash Panel('96-'97Models)

\

201-g

55. Behind Left Side of Dash Panel

58. Behind Left Side of Dash Panel

c712 (3-BRN)('96Model) (3-GRN)('97-'00Models)

56. Upper Left Kick Panel

59. Behind Left Side of Dash Panel

57. Left Kick PanelArea

60. Behind Left Side of Dash Panel

201-9

Location Cornponent 61. Behind Left Side of Dash Panel

64. Rear of Under-dashFuse/RelayBox

62. Behind Left Side of Dash Panel

65. Undersideof SteeringColumn

\

\

63. Rear of Under-dashFuse/RelayBox

66. Behind Left Side of Dash Panel

\

201-'l 0

\

67. Rear of Gauge Assembly

70. Behind Left Side of Front Console

68. Behind Left Side of Dash Panel

71. Right Side of SteeringColumn

69. Behind Left Side of Dash Panel

72. LettSideof SteeringColumn

\

\

201-1 1 :FFF :

l::

:

aalrlffiiilffi::-E--:

Locatlon Gomponent 73. Rear of Radio ('96-'98)

76. Below Front Console

74. Undersideof HeaterControl Panel ('96-'98)

77. Lett Side of Center Console

75.BehindFrontConsole

78. Right Side of Center Console

2Q1-12

\

79. Below Center Console

82. Behind Glove Box ('96-'98)

80. Below Front Console ('96-'98)

83. Below Right Side of Dash Panel

8'1.Behind Right Side of Dash Panel

84. Behind Glove Box

\

\

201-'l 3

Location Cornponent 8 5 . B e h i n dR i g h t K i c k P a n e l

88. Driver's Door

\

CONNECTORB ii

86. Behind Right Kick Panel

89. Top Front of Driver's Door (Frt. Pass. Similar)

\

87. Undersideof Driver's Seat

90. Frontof Driver'sDoor(Frt.Pass.Similar)

\

201-14

\

91. Front of Driver'sDoor (Frt. Pass.Similar)

94" Front of Left Rear Door (Right Similar)

92. Rearof Driver'sDoor (Frt. Pass.Similar)

95. Rear of l-eft Rear Door (Right Similar)

93.Driver'sDoor(Frt"Pass.Similar)

96.At Driver'sDoorStrikerArea(Frt.Pass.Similar)

\

201-15

ComponentLocation 97. Left Rear Door Striker Area (Right Similar)

100. Below Left Side of Rear Seat (Right Similar)

98. Driver'sDoor Sill

101. Left of Rear Seat (Sedan Shown, Others Similar)

\

\

99. Left CenterPillar(Right Similar)

102.Genterof RearShelf(Coupe/Sedan)

\

201-16

103. Below Center of Rear Seat

106.Insideof Left RearWheel(Right Similar)

104. Left Front Corner of Fuel Tank ('96-'98)

107.Undersideof Roof

105.lnside of Left Front Wheel (Right Similar)

108.Left Undersideof Hatch Lid

\

201-17

ComponentLocation 109.Undersideof Hatch Lid ('96-'97Models)

112.Right Side of Cargo Area (Hatchback)

110.Undersideof Hatch Lid

113.Centerof End Panel

\

\,

1 1 1 . B e h i n dL e f t S i d e o f D a s h P a n e l

1'14.LettSideof TrunkLid (withOptionalTrunkSpoiler)

\,

201-18

b

'99-'00Sedan) 115.Left Side of Trunk Lid (except

'99-'00Sed.) 118. Left Rear of Trunk/CargoArea (except

116.Centerof Trunk Lid

119.Top of Transmission(CVT)

117.RearSpoileron TrunkLid

(CVT) 120.RightSideRearof EngineCompartment

\

L

201-19 ffi=

Location Gomponent 121.Behind Left Kick Panel('96-'98CVT)

124. Rear of Engine Compartment(CVT)

\

TRANSMISSION C O N T R O LM O D U L E

(rcM)

122.Right Side Lower EngineCompartment(CVT)

125.Behind Right Side of Dash Panel

\

123.RightFrontof Engine(CVT)

126.Undersideof Hatch Lid

\

2A1-20

\

127.Letl Rear of Trunk ('98)

130.Behind Left Side of Dash

Similar) 131.Undersideof Vehicle,Rearof Engine 128.Rearof Dl6Y8 Enginewith n/VT(B16AZD16Y5

129. Behind Left Side of Dash ('98)

132.Undersideof Hatch Lid ('98-'00)

b

201-21

ComponentLocation 133.Below Rear of D16Y8Eng. (816A2 Similar)('99-'00) 136. Behind Left Side of Front Console ('99-'00)

134.Behind Kick Panel('99-'00)

137. Behind Center Panel ('99-'00)

I \

135"Behind Left Side of Dash Panel ('99-'00)

138.BehindFrontConsole

c723 (20-GRY) ('96-'98Models) (24-BLU)('99-'00Models)

\

201-22

t,![!!til**}t$]Sl1Ht€:!i!ifj

139.BehindGloveBox ('99-'00)

(GX) 142.Lett RearCornerEngineGompartment

140. Undersideof Rear Shelf ('99-'00Sedans)

143. Right Rear of Engine Compartment(GX)

141.TopCenterof Engine(GX)

144. Behind Left Kick Panel (GX)

201-23

GomponentLocation 145. Left Side of Trunk (GX)

148. Below Right Side of Center Console

146. Behind Back Seat (GX)

149. Undersideof Vehicle,Left Rear of Engine (Si)

F U E LT A N K P R E S S U R E SENSORAND FUELTANK TEMPERATURE SENSOR

(rNSrDE)

l47.Behind Left Side of Back Seat (GX)

201-24

150.RightFrontof Engine(Si)

\

I O

(Si) 151.LowerFrontof Transmission

152. Left Center of End Panel ('99-'00Sedan)

201-25

ConnectorViews u System CavityNumbering

WIRESIDE of FEMALETERMINALS

TERMINAL SIDE ot MALETERMINALS

LOCKINGDEVICE Must be at top.

In-LineConnectorView Index (viewsbegi

202-2)

Connector

View

c s 1 6 . . . . . . . . . . . . . . . 5. .8. c 5 5 1. . . . .. . . . . . . . . . . . .4 7 c 5 5 2. . . . .. . . . . . . . . . . . .2 2 c 5 5 6 . . . . . . . . . . . . . . . 6. .1. c 5 5 7 . . . . . . . . . . . . . . . 6. .2. c 5 6 2. . . . .. . . . . . . . . . . . .4 2 c 5 6 8 . . . . . . . . . . . . . . . .4. . . . c s 7 0 . . . . . . . . . . . . . . . . 5. . . . c571 . . . . . . . . . . . . . . . . . . . . 5 c 5 7 5 . . . . . . . . . . . . . . . 7. .3. C 6 0 4( H a t c h b a c.k. .). . . . . 7 C 6 0 5( H a t c h b a c.k. .). . . . . I C 6 0 7( H a t c h b a c. .k.). . . . . 9 c 6 3 9 . . . . . . . . . . . . . . . . .2 3 c 6 5 6. . . . . . . . . . . . . . . . . .2 4 c 7 2 3 . . . . . . . . . . . . . . . 5. .7.

202

-

Component Connector View Index (Viewsbeginon page202-21 Connector

View

A B SC o n t r oUln i t . . . . . . . . ......63 A u d i oU n i t( ' 9 9 - ' 0m0o d e l s ) ......74 CombinationLightSwitch . . . . . . . . . . . . . . . 64 WiperSwitch . . . . . . . . . . . . . . 65 Combination C r u i sC e o n t r oUl n i t . . . . .....43 C \ T T T r a n s m i s sSioolne n o i d. . . . . . . . . . . . . 2 5 (DLC) DataLinkConnector ..... 48 DaytimeRunnlngLightsControlUnit ..... 66 E n g i nceo n t r oM l o d u l (eE C M .) . . . . . . . . . . 7 0 ExhaustGas Recirculation(EGR)Valve and Lift Sensor(D16Y5 Mfl, D1685). . . . 10 G a u gAe s s e m b l y .............71 H a z a r d W a r n l n g S w i t .c, h, ,,.,... , , , , . . . 3 2 HeaterControlPanel('96-'98 models) .....44 HeaterControlPanel('99-'00 ...., 76 models) HeaterFanSwitch('96-'98 models),,,.... 11 f n i e c t oCr o n t r oM l o d u l e( G X ). . . . . . . . . . . . 7 7

Connector

View

I n t e g r a t eCdo n t r oUl n i t .......,. 67 fn t e r f o cCk o n t r oUl n i t . . . . ...... 26 KeyfessDoor Lock Control Unit . . . . , . . . . . 75 M o d eC o n t r oMl o t o r. . . ........'17 Moonroo .......13 Cfl o s eR e l a y. . Moonroo Ofp e nR e l a y. . . .......15 P G M - FMI a i nR e l a y. . .......... 18 P o w eD r o o rL o c kC o n l r oUl n i l . . . . . . . . . . . 3 7 P o w eM r i r r oS r w i t c h. , . . . ...... 33 P o w eW r i n d o wM a s t eSr w i t c h. , . . . . . . . . . 3 6 P o w e r t r aC i no n t r oM l o d u l e( P C M ). . . . . . . 7 0 S e c u r i tCy o n t r oUl n i t. . . , ..,,... 58 SecuriS t yt a r t eCr u tB e l a y. . . . . . , , , . . . . , , 1 2 . . . . . . . . . . . . .5 1 S R SU n i t models)...... 68 StereoRadioTuner('96-'98 Transmission ControlModuleCICM).....69

I / 202-1

ConnectorViews (cont'd) 1.

C202(withCruiseControl)

4.

gRN/BLK (Cruise control) BRN,ryVHT (Cruisecontrol) RED/BLK (Headlight switch)

2.

BLU(PGi.4-Fr) LTGRN(PGM-FI) BLl(WHT(PGI\4-FD

BRN{Cruise conkol) 5 WHT/BLK

(Frontwipetwashel)

C407 ('98-'00Models)

5.

3.

6.

- Green - On Jrontof under-dashtuse/relaybox - On main wire harness

*1: YEL (Fuse3) *2: GRN (Rearwiper/washe4

2 3 GRN/YEL

GRN/ORN{Tu.nsignals) GRN/BLK (Frontwiper/washer) 6 GRN/RED (Turnsignals)

5

(Turnsignals)

*1= USA:tX, EX,HX,DX-VSi EX,Si Canada: *2= Hatchback

202-2

c570

YEL (Powerwindows) 2 WHT/RED (Power doorlocks) 3 YEUGRN (Powerwrndows)

5

c423

4 5 YEUBLU(PGM,FI) GRN/BLK(PGI\,4.FD

- Blue - In rightdoorpillar - Connectsfloorwireharnessto rightreardoor wlrehafness

- Gray - Behindleftsideol dash,abovekickpanel - Connectsmainwireharnessto roofor moonroo{ wtreharness

WHT/RED (Ceilinglight) l\4ale- LT GRN/RED Female - LT GRN/BLK or LT GRN/RED (Ceilinglight)

c568 - Gray - BelowJueltankunitconnector - Connects to tueltank floorwireharness pressure suo-narness

- Gray - Leftsideol enginecompartment - Connects to engine mainwireharness wre harness compartment

YEL/BLK (Powerwindows) 5 6 YEURED

(Powerdoorlocks)

c571 - Blue - In lettdoorpillar - Connectsfloorwireharnessto lettreardoor wlreharness

MaIe_ YEL Female- GBN/YEL (Powerwindows) WHT/RED (Powerdoor locks) Male - YEUGRN Female- GBN (Powerwindows)

N4ale YEUBLK Female- RED,ryVHT (Powerwindows) 5 6 YEURED

(Powerdoorlocks)

7.

\

C604 (Hatchback) - Gray - Leftrearol cargoarea - Connectsrearwireharnessto leftouter taillight assembly

1 GRN/BLK (Back-uplights) 2 l\4ale GRNIYEL Female- GRN/RED (Turnsignalandhazard warninglights) BLK (G601)

8.

4 GRNAVHT (Brakelights) 5 FED/BLK (Headllght switch) 6

C605 (Hatchback) - Gray - Rightrearof cargoarea - Connects rearwireharness to rightouter taillight assembly

n-

I

a t |

-n _

10. ExhaustGasRecirculation (EGR)Valveand Lift Sensor (D16Y5MfI D1685) - Gray - Toprightsideof engine - On enginewireharness

(EGRinput) 1 WHT/BLK 2 GRN/BLK (Sensorground) 3 YEUBLU (Reference voltage)

4 BLK (Ground) 5 6 PNK (EGRcontrol)

11. HeaterFanSwitch ('96-'98Models) - Brown Centerof dash - On heater-sub B wireharness

a 2 a

l 3 I 4 t 5 t t t l IJ

1 GRN/BLK

(Back-up lights) 2 GRNTYEL (Turn hazard signaland warning lights)

9.

3 BLK(G601) (Brakelights) 4 GFNAVHT 5 RED/BLK

(Headlight switch) 6

C607 (Hatchback) - Blue - Rightsideo{ cargoarea - On rearwireharness

1 BLK(Ground) (L4edium 2 BLUAVHT LOspeedinput) 3 BLU/BLK (Hlspeedinput)

12. SecurityStarterCut Relay/C416 - Natural * Upperleftkick panel - On mainwireharness

t l

1 BLU/BLK(lndicators) 2 RED/BLK (Licenselights)

)

/

(8rake lights) 3 GBN,ryVHT 4 LTGBN (Rearwiper/washe0

BLU(LOspeedinput) (Medium BLU/YEL Hlspeedinput) 6 GFIN(Blower switchON input) 4 5

5 GRN (Rearwiper/washer) 6 LTGRN/BLK (Rear\/iperwasher)

1 2 AllexceptCX and DXI [,4ale:BLK,^r'r'HT Female:BLKI/EL CX and DXi BLI(WHT (Batteryinput) All except CX and DX: BLK^/EL CX and DX:BLK/WHT (Bafteryinput)

3 '

[.4ale- BLK/WHT Female- BLKAVHT or BLKRED (Starteroutput) 5 6 All excepiCX and DX: RED/YEL CX and DX:GRN (Securitystarterc!1 relaycontrolinpul)

202-3

ConnectorViews (cont'd) 13. MoonroofCloseRelay - Brown('96-'97 models)or Gray('98-'00 models) - Upperleftkickpanel - On moonroof wireharness '96- 97 Models:

15. MoonroofOpenRelay - Brown('96-'97 models) models)or Gray('98-'00 - Upperleftkickpanel - On moonroolwireharness '96. 97 Models: , 1

^ t

6 1 WHT (Batteryinput) 2 GRN//EL {Motor conirol) 3 GRN/ORN (lgnitionlnput)

BLK (Ground) 5 6

GBN/RED(Coilconkol)

'98r00 Models:

GRN/YEL (Motorcontrol) 2 WHT(Batteryinput) 3 GRN/RED (Coilcontrol)

4 BLK (G401) 5 GRN/ORN (lgnitioninput)

1 WHT(Batteryinput) 2 GRN/FED (lvlotorcontrol) 3 GRN/ORN (lgnition input) '98r00 Modelsi

GBN/RED (lvlotorcontrol) input) 2 WHT(Battery 3 YEL(Coilcontrol)

BLK (Ground) 5 6 YEL (Coilconkol)

4 BLK (G401) 5 GRN/ORN (lgnitioninput)

16. C422

14. C415 - Brown - Aboveunderdashfuse/relaybox - Connects to steering lockpigtail mainwireharness

- Green - On trontol under-dash tuse/relaybox - On mainwireharness

7

* 1:[,4ale BLKryEL - BLKMHT Female *2: BLK,/WHT (Startoulput) - BLU/RED l\.4ale Female- BLUruVHT (lgnilion keyswitch outpur) - WHT/BLK N4ale Female- WHT (Battery input)

l\,4ale BLK Female- BLU^VHT (Ground) Ani Male - WHT Female- WHT /EL (Key interlockswitch ourpur) A/T:WHT/BLU (Keyinterlock solenold control) A"rT:WHT/GRN (Batteryinpul)

*1= Vehiclespre-wired for accessory securitysystem *2= Vehiclesnot prewiredfor accessory securitysystem

202-4

l FED/BLU(Headlights) 2 3 (Headlights) 4 REDAVHT

5 WHT(Fuse48) 6 7 BED/GRN

(Headlight switch)

-

17. ModeControlMotor

20. c136

- Green - Behinddash,rightof steering column - On heatersub-harness-A

- Gray - Leftrearof enginecompartment

- Connects engine wire harnessto main wire harness '96198 D't6Y5:

1 2 3 4 5

(lgnitioninput) BLK,TYEL YEUBLU(Detrostinput) YEL(H/DEF input) (Heatinput) BLUA/VHT (BI-LEV GRN/YEL input)

(Ventinput) 6 YEURED 7 '96. 98:BLK(G402) '99-'00r BRNAVHT {Motorgroundinput)

18. PGM-FIMain Relay - Brown - Behindrightsideo{ dash - On mainwireharness

1 Male- BLUAVHT Female- BLU|/EL (A"/T controls) (A,/T 2 GRN,^WHT controls) 3 YEL(A/Tcontrols) (A/Tcontrols) 4 GRN/YEL 5 PN(BLK (fff gs6lrq;s; 6 PNI(BLU(A/Tcontrols) (Ar/T 7 GRN/BLK controls) (A/Tcontrols) 8 RED/BLU 9 WHT(A/Tcontrols)

(A"/T 10 WHT/RED controls) 11 '98models: GRN/BLK (PGr,4-Fr) 12 GRN(A/Tcontrols) 13 l\4ale- REDMHT - RED/BLU Female (4,/Tcontrols) - BLIVWHT 14 N4ale Female- ORN/BLU (A/Tcontrols)

'96198D16Y7/D16Y8:

'l 4

1 GRN/YEL (Fuelpumpcontrol) (Fuse31) 2 BLUAVHT 3 B L K( G 1 0 1 )

* 1 :Y E U G R N (Fuelpumpoutput) *2:WHT/RED (Fuelsupplycontrol) (Fuse13) YEUGRN 6 YEUBLK(Poweroutput) (Fuse44) 7 WHT/BLK

(A/Tcontrols) GRN/BLK WHT/RED (lnterlock system)

5 WHT(A/Tcontrols) 6 BLU(Antfse11re;s; 7

3

*1= All exceptDl685 *2= D16Bs A 01685:

19. Cl23 (D16Y5M/T) - cray - Righttronto{ engine - Connectsenginewireharnessto primary HO2Spigtail

BLI(WHT {Heatercontrol) ground) 2 BLK(Heater 3 GRN/BLK (Sensor ground)

WHT(Hgatercontrol) 5 6 WHT(Sensorinput) 7 BLK(Sensor input) ground) 8 RED(Sensor

1 2 3 4 5

BRN(PGM-FD RED(PGIV-FD BLU(PGI\4-FD YEL(PGI,4,F|) l\4ale- GFN Female- WHT/RED (PGM-FD

(A'tlgs6trels; 6 GRN/BLK 7 BLU(A/Tcontrols) 8 wHT (A/I controls)

202-5

23. C639

21. C214

- Black,ryVhite - Topfrontot driver'sdoor - Connects to driver's doorwireharness driver's powermirrorpigtail

- Gray - Rightsideof enginecompartment - Connects enginewireharness to mainwireharness

Without Defogger: '96- 97 models: Male - WHT/GRN Female - BLU/FED (Horn) '98-'00models: BLU/RED(Horn) 2 BLKRED(Fans) 3 WHT (Fans)

4 5 6

1 2

*io t0,,"

controls) compressor

4

(A,/C 7 BLU/RED compressor controls) (I'/C BLU,ryVHT controls) compressor

6 Male - LT GRN Fema|e - BLU/BLK (Left/rightcontrol)

lvlale PNK Female- YEURED (Common) MaIe_ GRY Female BLUA/VHT (Up/downcontrol)

With Oelogger: 1 2 3 l\,lale- BLKAVHT Female- BLK (Ground) 4 lvlale- BLU/RED Female ORNAVHT (Delogge4

lvlale- LT GRN Female BLU/BLK (Corrmon) i.4ale- PNK Female- YEURED (Up/downconkol) Male - GRY Female- BLU,ryVHT (Lett/rightcontrol)

24. C556

22. C552

- Black,ryVhite - Topfrontof frontpassenger's door - Connectstrontpassengefsdoorwireharness powermirrorpigtail to passenger's

- Green - On rearof under-dash fuse/relaybox - On tloorwireharness

WithoutDefogger: 1 *1: FEDA/VHT (Powerwindows) 2 *1: YEL/BLK (Powerwindows) 3 *1:YEL/BLK (Powerwindows) 4 *1 | RED/WHT (Powerwindows)

GRN/BLK (Powerwindows) 6 GRN/BLK (Powerwindows) 7 *2: BLK/YEL (Powermifiors) BLU/BLK {Powerwindows)

l

2 3

4

l\4aleFemale BLK (Not Used) l\4aleFemale- ORN/WHT (Not Used)

Male OBN Female - YEUBLK (LefVrightcontrol) l\4ale- PNK Female - YEL/RED (Common) Male BRN Female- GRNA/VHT (Up/downconkol)

With Delogger: *1= Sedanonly *2='96''98:All '99-'00rGX

202-6

1 2 3 Male - BLK^VHT Female - BLK (Ground) 4 l\.4ale- BLU/RED Female - ORNAVHT (Defogger)

[.4ale- ORN Female - YEL/BLK (Left/rightcontrol) lrale - PNK Female- YEURED (Up/down conkol) l\,lale- BFN Female'GFiN (Common)

-

25. CW Transmission Solenoid - Gray - Lowerfrontof transmission - On enginewireharness

5 GRN/BLK(SOLIN H) 6 PNK/BLK(HLCLS _) 7 GRN|VEL(SH LS -) 8 PNK/BLU(SC LS _)

1 2 GRNAVHT(H LC LS +) 3 BLUAVHT(SH LS +) 4 YEL (SC LS +)

26. InterlockControlUnit - Gray - BehindleftsideoJdash,rightof steering column - On mainwireharness

28. C101 - Gtay - Left rear of engine compartment - Conneclsenginewire harnessto main wire harness

- BLK/YEL 1 l\,4ale Female- BLK,ryVHT (Fuse15) 2 B L K( G 1 0 1 ) (Oil 3 YEURED pressure indicator light) : R N / B L( K G101) 4 * 1 / * 4B 5 YEUBLK(PGI\4,FD 6 WHT/BLU (Charging system)

(Gauges) 7 YEL/GRN I *1: BLU(lgnition sYstem) 9 Male- BLK VHT Female- BLKRED (Slartingsystem) 10 *2: BLKryEL (lgnition system) *3: Male- BLK/YEL Female- RED (lgnition system)

1 7

WHT(Key interlockswitchinput) 6 BLKBLU(Parklnput) (Shin 7 WHT/RED lockcircuitcontrol) WHI/BLK (Parkplnswitchinput)

(Keyinterlock WHT/BLU solenoid control) input) 2 YEL(lgnition (Shiftlock 3 YEUBLK solenoid control) 4 BLK(G401)

*1= 96-'98models:All '99: D16Y5with M,iT *2= '96-'97models:All '98-'99modelsrGX *3= '96-'98 models: All except GX *4=: '98''00Models:GX

27. C352 - Gray - On bottomof under-hood {use/relay box - On mainwireharness

1 7

I

1 GRN (Fans) 2 BLUAVHT(fuC compressorcontrolS) 3 WHT/BLK (Hazardwarning lights) 4 WHT/BLK(Fuse42)

8

9

BLKRED(A/C compressor clutch relaycontrol) (Fuse17) 6 BLK,/YEL 7 (Fuse52) 8 WHT/GRN I WHT(Fuse48)

202-7

ConnectorViews (cont'd) 30. c201

29. C120 - Gray - Topcenterof engine

- Connects engine wire harnessto distributor assemblypigtail

- Blue - Leftsideof enginecompartment - Connects to engine mainwireharness wireharness compartment

All except'99-'00016Y7/D16Y8:

l YEUGRN (lgnition inputsignal) - LTBLU 2 l\.4ale Female- BLU (CKPsensoroutput) 3 Male- ORN/BLU Female- GRN [tDC sensoroutput) - ORN 4 l\.4ale Female- YEL (CYPsensoroutput) -= '96j98: All '99100: D1685

l\4ale- BLU/YEL Female- WHT (CKPsensorground) - WHT/BLU l\.4ale FCMAIE _ HtsL'

(TDCsensorground) l\4ale- WHT Female- BLK (CYPsensorground) Male- BLU - .Female *: BLU (Engine speedoutput) (lgnitioninput) 1 0BLK/YEL

'99-'00016Y7/D16Y8:

l GRNA/EL (Turnsignal and hazard warninglights) 2 RED/BLK (Headlight switch) 3 REDAVHT (Headlight switch) 4 D16Y5: Male - GRN/BLK Female HatchbackiGRN/BLK {Bearwipetwashe0

9b- 9/ mooets:

lvlale- BLU/RED Female BLK (Horns) '99-'00: Canada PNK (lndicators) RED/BLU (Headlight switch) 7 BLU/RED(Fog lights) I GRN/RED Cturnsignal and hazardwarning lights) BED/GRN (Headlightswitch) 1 0 RED/YEL (Headlightswitch)

31. C359 - Orange - Rightsideot enginecompartment - Connectsmainwireharnessto ABSmodulatorunit

l YEUGRN (lgnition inputsignal) 2 Male- LTBLU - BLU Female (CKPsensoroutput) 3 Male- ORN/BLU - GRN Female CIDCsensoroutput) 4 Male- ORN - YEL Female {CYPsensoroutput)

202-8

(lgnitioninput) BLK/YEL WHT (CKPsensorground) Male- WHT/BLU - RED Female ffDC sensorground) BLK (CYPsensorground)

l\4ale- REDAVHT Female- GRNA/VHT (Power) - BLK l\,4ale - YEVBLK Female (FL-OUr) Male- 8RN Female BLIJ {RR-OLrr) l\4ale BLU Female- RED/BLK (FL-rN) Male- PUR Female- RED&VHT (RR-rN)

6 Male- WHT Female- YEUBLU (FR-OUr) 7 YEL(RL-OUr) I Male- ORN Female- RED/BLU (FRrN) I Male GRN Female- RED(RL-|N) 10 Male RED Female- BLK,ryVHT

(scol\,1)

-

32. HazardWarningSwitch - Gray - Centerol dash - On dashboardwireharness

34. C351 - Gray - On bottomof under-hood fuse/relaybox - On mainwireharness

4

1 6

l GRN/RED (Leftturn signal indicatorlight output) 2 GRN/YEL (Rightturn signal indicatorlight output) 3 GRN/ORN Ourn signal/hazard relay control) 4

5 YEL/BLK(lgnitioninput) 6 WHT/BLK(Batteryinpul) 7 8 RED/BLK(Dash and console lights) g RED(Dashand consolelights) 1OGRNAVHT (Turnsignal/hazard relay power)

33, PowerMirror Switch

7

I I9

2 WHT/BLU (Powerwindows) 3 WHT/GRN (Rearwindow defogger) 4 BLK (G402) 5 WHT/FED (Fuse54)

I10

11

(Fuse43) 6 WHT/RED (PGM-Fl) 7 WHT/BLK (Fuse47) 8 WHT/BLU (Fuse51) I WHT/GRN 1 0_ 11 BLUAVHT (Blowercontrols)

35. C41o(A/T) - Gray - lilountedto top of underdash{use/relay box - Connectsmainwireharnessanddashboard wtrenarness

- Greenor Whiteor Gray - Leftof steeringcolumn - Onfloorwireharness

WithoutOelogger: 1

2 *1: BLK,|YEL *2r BLKBLU (lgnitioninput) 3 YEURED(Common) 4 BLK (G551) 5 8LU,ryVHT (Leftup/down control) With Delogger: 1 BLIVBLU(lgnitioninput) 2 BLK (G551) 3 BLIVBLU(lgnitioninPut) 4 YEURED (Common)

-

6 ORNMHT (Detoggercontrol) '96198 models, '98-'00 GX '99 00 models except GX

I

6 BLU/BLK (Leftleft/rightcontrol) 8 YEUBLK (Rightleft/rightcontrol) 9 GRNAVHT (Rightup/downcontrol) 10 7 BLU/BLK (Lettleft/rightcontrol) 8 GRNMHT (Rightup/downcontrol) 9 BLU/WHT (Lettup/downcontrol) 1OYEL/BLK (Rightleft/rightconnol)

2 3 GX: BLU/GRN {Low fuel indicator) 4 GX:ORN/BLU (Fuelgauge) 5 WHT (A/T gear positionindicator) 6 RED (A,/Tcontrols) 7 BLI(BLU (A,rTcontrols) 8 All except CVT: BRN (AiT gear position indicator)

I BLU (Aft gear position indicator) 10 GRN (A/I gear positionindicator) 11 D16Y7/D16Y8: Male - GRN/BLK Female YEL (A/T conkols) D1685/D16Y5: GRN/BLK (M controls) 12 LT GRN (A/T controls)

202-9

ConnectorViews (cont'd) 36. PowerWindowMasterSwitch Coupe/Hatchback: - Gray - Driver'sdoorarmrest - On driver's doorwireharness

(lgnition BLU/BLK input) BLU/ORN (RFmotorcontrol) 3 RED/YEL (LFmotorcontrol) FED/BLU (LFmotorcontrol) 5 BLK(G551)

6 GRN/BLK (lgnition input) 7 BLU/YEL (RFmotorcontrol) 8 BLK(G551) 10 12 BLU(Autocontrol)

37. PowerDoorLockControlUnit (All except'99-'00modelswith

keyless) - Gray - In driver'sdoor - On driversdoor wire harness

1 GRNMHT(Lockinput) 2 YEURED (Unlock/lock output) 3 BLU/RED (unlock/lock control) 4 BLK{Ground) (Lockoutput) 5 WHT/RED (Drivefs 6 BLU/YEL doorunlockinput)

7 BLU/WHT(Lock input) B GRN/ORN (Unlockinput) 10 11 12 WHT/GRN (Batteryinput)

Sedan: - In driver'sdoorarmrest

ConnectorA - Gray - On driver'sdoorwireharness

l BLU/YEL (RFmotorcontrol) (lgnitioninput) 2 GRN/BLK (lgnition input) 3 BLU/BLK 4 BLK(G551) 5 RED/YEL (LFmotorcontrol) 6 8LU (Autocontrol) 7 RED/BLU (LFmotorcontrol) 8 YEUBLK(lgnitioninput)

I YEL (RRmotor control) 1OYEUGRN (RRmotor control) 11 BLU/ORN (RF motor control)

14 GRN/YEL (LR motor control) 15 REDMHT (lgnitioninput) 16 GRN (LRmotorcontrol)

ConnectorB

202-10

- Blue - Rearof engine,belowintakemanifold - Enginewireharness junctionconnector

r----------l (Fuse15) 1 8LK?ryEL (Fuse15) 2 BLK/YEL 3 BLKTEL(Fuse15) (Fuse15) 4 BLK/YEL (Fuse15) 5 BLK,/YEL (Fuse15) 6 BLK/YEL (Fuse15) 7 BLK,TYEL L_______-J

- Brown - On driver's doorwireharness 1 BLK(Gss1)

38. Cl15

E

r---------"1 (PGMFD 8 GRN/8LK (PGM.FD 9 GRN/BLK (PGr\,4-Fr) 10 GRN/BLK (PGM-Fr) 11 GBN/BLK (PGM-FD 12 GRN/BLK (PGM-FD 13 GRN/BLK (PGM-Fr) 14 GRN/BLK L______--_J

Terminalsgrouped together are connectedby the same bus bar

-

41. C433

39. Cl16 - Gray - Rearol engine,belowintakemanifold - Enginewireharness junctionconnector

8 BLK s B L K( G 1 0 1 ) 1 0 B L K( G 1 0 1 ) 1 1 B L K( G 1 0 1 ) 1 2 B L K( G 1 0 1 ) 1 3 U S A :B L K( G 1 0 1 ) 1 4 B L K( G 1 0 1 )

2 *1:YEL/BLK *2iYEURED (PGM-Fr) 3 * 1 :Y E U B L K

\ t

L_i9yj'L____i

switch pigtail

r-:-_-::::^-_---'1 (G101)

i-'-j-----l

(PGl\4-Fr) 4 *l:YEUBLK *2TYEURED (PGr\4-F|) 5 *1i YEL/BLK *2:YEURED (PGM-Fr) 6 * 1 :Y E U B L K *2:YEURED (PGMFr) 7 *1:YEUBLK *2:YEURED

- Gray - Below console center - Connects to A'/Tgearposition mainwireharness

L___-----J

' 1 : A l l e x c e pG t X '2: GX Terminalsgrouped togetherare connected by the same bus bar.

40. c401 - Gray - Behindleftkickpanel - Connectsmainwireharnessto floorwireharness

1 BLK (Cruiseconlrol) 2 l\,1ale- LT GRN Female (Notused) 3 Male - YEL Female- YEURED (Back-uplights) 4 GRN/BLK (Back-uplights) 5 f,rale- GRN/YEL Female - BLU (A,/Tcontrols) 6 l\.4ale- GRN/BLU Female GRN (A,/Tcontrols) 7 Male - GRN/ORN Female - YEL (A/T conkols)

9 PNK(Cruisecontrol) 1OBLI(WHT (Starting system) 11 BLI(RED (Startingsystem) 12 Male- GRNIVHT Female- BLK/BLU (A,/Tcontrols) 13 Male- GRN/RED Female- WHT (A,/T controls) 14 Male- GRN Female- RED (A,/Tcontrols)

'99-'00ModelsexceptGx:

'99100 GX Models: All '96-'98 Models and

1 *1: BLKWHT(PGM-F|) *2:YEL/BLU(PGl\4'Fl) 2 Hatchbacki LTGRN/BLK (Rearwiper/washer) .2: BLU/YEL {PGM-Fl) 3 Hatchback:LT GRN (Rearwiper) .2: GRN/BLK(PGM'Fl) 4 * 1 : Y E U B L U( P G MF l ) *2: GRN/VEL(PGl,I-Fl) 5 *1: GRN/BLK(PGM-FI) *2: WHT/RED(PGl\4-Fl)

-

6 BED/BLU (Seat belt reminder) 7 WHT/GRN(Fuse51) 8 1.: LTGRN (PGM'F|) I 1.i BLU (PGl\.4-Fl) 10 GRN (lgnitionkey remrnoer) 11 LT GRN/RED (Ceilinglight) 12 GRN/BLK (Back-uplights) 13 GFN,TVHT(Brakelights) 14 ExceptGX:YEUGBN {PGM-Fr) ' 9 8 *1= D16Y5iAll models '98 models '97 Coupeand SedanLX,all D16Y7r California '98 models '96-97 Coupes,'97 Calilornia Sedans,all D16Y8:All *2= GX models

1 GRN/ORN (Powerdoorlocks) (PGM-Fl) 2 BLK,ryVHT 3 Coupe/Sedani GRNA/VHT (Powerdoor locks) Hatchback: (Rear LTGRN/BLK wiper) BLU/BLK 4 Coupe/Sedan: (Security system) Hatchback: LTGRN(Rearwipeo 5 YEUBLU(PGl\4-Fl) (PGM,FD 6 GRN/BLK 7 RED/BLU (Seatbeltreminder) 8 *3:WHT/RED (Powerdoorlocks) 9 *3: BLU/RED (Powerdoor locks)

10 '3: BLU^VHT (Powerdoor locks) 11 l\.4aleFemale - WHT/GRN (Fuse51) 12 LTGRN (PGM-FD 13 BLU (PGr\4Fr) 14 GRN (lgnitionkey reminder) 15 LTGRN/RED (Ceilinglight) 16 GRN/BLK (Back-uplights) 17 GRN,ryVHT (Brakelights) 18 YEUGRN(PGI\4.FD 19 *3: YEURED (Powerdoor locks) 20 Canada: BLU/YEL (Powerdoor locks)

*3= USA HX, LX,EX OX-VSi

202-11

ConnectorViews (conrd) 42. C562 - Gray - Behindleftsideol rearseatback

- Connectsfloor wire harnessand rear wire harness '99-'00ModelsexceDlGX:

'96-'98 CouDe/Hatchbaqk:

'I

2 't1 1 2

1 LTGRN (Powerdoorlocks) 2 BLU/YEL (Stereosoundsystem) 3 RED/YEL (Stereosoundsystem) 4 GRN/BLK (Back-uplights) (Fuse43) 5 *WHT/BED GRN 6 Hatchback: (Rearwiper/washer) 7 GRYAVHT (Stereosoundsystem) *=

8 BRNMHT (Stereosound system) 9 RED/BLK(Headlight switch) 1OGFN/YEL (Turnsignal lights) l1GRN/RED Ournsignallights) 12 BLU/BLK(lndicators) 13 Hatchback:LT GBN (Rearwiper/washer) 14 Hatchback: LT GRN/BLK (Rearwiper/washer)

Male terminal not used on Hatchbackmodels

'96-'98SedanexceptGX:

l GRN/RED (Turnsignallights) 2 _ 3 l,4ale- YEUBLK Female- (Notused) 4 ftrale- WHT/BLU Female- {Notused) 5 LTGRN (Powerdoorlocks)

8 WHT/RED (Trunklight) 9 GRN/BLK (Back-up lights)

202-12

4 t 5 14

6 I 7 15

1 2 11:LTGRN/BLK (Rearwiper/washe0 3 * 1 :L TG R N (Rearwiper/washe0 4 a 1 rc R N (Rearwiper/washe0 6 GRYMHT (Stereosoundsystem) 7 BLU/YEL (Stereosoundsystem) 8 BRN,^/VHT (Stereosoundsystem) 9 REDA/EL (Stereosoundsystern) 10 GRN,^/VHT (Brakelights)

16 17

9 10 I 't8 1 9 20

11 GRN/RED (Turnsignallights) 12 GRN/YEL Ournsignallights) (lndicators) 13 BLU/BLK 14 16 17 BLI(BLU (Reafwindow defogger) 18 RED/BLK (Headlightswitch) 19 GRN/BLK (Back-uplights) 20 *2: WHT/FED(Fuse43) * 1= Hatchback * 2= Femaleterminal not used on Hatchback mooers

All GXModels:

1ORED/YEL (Stereosoundsystem) 11 BRNA,ryHT (Stereosoundsystem) 12 BLU/YEL {Stereosoundsystem) 13 GRYA/VHT {Stereosoundsystem) 14 RED/8LK (Headlight switch) (lndicators) 15 BLU/BLK 16 GRN/TEL (Turnsignallights)

GRN/RED (Turnsignallights) 2 3 4 5 GBN/BLK (Back-uplights)

RED/BLK (Headlight switch) (lndicators) 7 BLU/BLK I GRN/YEL (Turnsignallights) 6

-

44. HeaterControl Panel('96-'98)

43. CruiseControlUnit - Gray ('96-'97models)or Blue ('98-'00models) - Behind lett side ol dash - On mainwire harness '96-'97Models:

1 BRN(Cruise control actuatorcontrol) 2 GBY (Brakeswitchinput) 3 BLK(Ground) 4 GRN,ryVHT (BrakeswitchInput) 5 LTGRN/RED (Set/decel signalinPUt) 6 LTGRN/BLK (Resume/accel inPut) 7

8 BRN,AiVHT (Ventsolenoidcontrol) 9 RED/BLU ("Cruise Control" indicator lightconkol) (Vacuum 10 BRN/BLK solenoid controi)

12 BLUMHT (Vehicle speedinput) input) 13 LTGRN(Power input) 14 PNK(Dlsengage

- Green - Centerol dash - On heater-sub-B wireharness

control) 1 YEL(H/DEF (lgnition input) 2 BLKTYEL 3 WHT/BLU (Batteryinput) 4 YEUBLU (Defrost control) -) 5 RED(lllumination (lllumination +) RED/BLK 6 (Heatconkol) 7 ELUruVHT (Ventcontrol) 8 YEL/RED

9 GRN/YEL (Bl'LEV control) 10 BLK(Ground) 11BLU/FED (lVCthermostat input) 12 GRNMHT (Freshcontrol) 13 GRN/FED (Recirc.control) 14 GRN (A/CON input)

45. c440 - Blue - Belowrightsideof dash - Connectsmainwireharnessto heater-sub-A wrrenarness

'98-'00Models:

7

1 I

I

10 11

'I BBN(Actuator control) 2 GRY (Brakeswitchinput) 3 BLK(G401) 4 5 GRN,^/VHT (8rakeswitchrnput) 6 LTGRN/RED (Set/decelsignal inPut) 7 LTGRN/BLK (Resume/accel signalinput)

'12 1 3 1 4

8 *1: BLU/GRN (Cruisesignal) 9 BFN/WHT {Actuatorcontrol) 1O RED/ALU (lndicatorlightconkol) 11 BRN/BLK (Actuatorcontrol) 12 BLU,ryVHT (Vehiclespeed input) 13 LTGRN (Powerinput) input) 14 PNK (Dlsengage

2 BLK (G402) 3 BLU/WHT (Blowercontrols) 4 '99-'00:BLU/YEL (Rearwindow defoggeo

7

10 (Fuse47) 11 WHT/BLU 12 BLK(G402) 13 RED(Dashand Iights) console (Dashand 14 RED/BLK consolelights) (FVC 15 BLUAVHT conkols) compressor (Airdelivery) 16 BLK/YEL

9

\ *1=

99-'00w(h A/T

202-13

GonnectorViews (conrd) 46. C503

48. DataLinkConnector(DLC)

- Blue - lvlounted to sideof under-dash fuse/relaybox - Connectsfloorwireharnessto dashboard wtrenarness

1 * 1 :G B N / O R N (Powerdoorlocks) 2 *1rBLU|/EL (Powerdoorlocks) (Brake 3 GRN/RED systemindicatorlight) * 1 rL TG R N (Power doorlocks) (Low 5 *3:GRN/YEL fuelindicator light) (lndicators) 6 BLU/BLK 7 *3: BLU/YEL (Stereosoundsystem) (Gauges) B *3:YEUBLK 9 *3: GRY/WHT (Stereosoundsystem)

10 *1: GRNAVHT (Powerdoorlocks) *2:BL(BLU (Powermirfors) 11 *3: BRNMHT (Stereosoundsystem) 12 *3: RED/YEL (Stereosoundsystem) 13 GRY/BLK (Stereosoundsystem) 14 BLU (Stereosoundsystem) 15 BRN/BLK (Stereosoundsystem) 16 RED/GBN (Stereosoundsystem)

- Gray - Belowleftsideof dash,abovekick panel - On mainwireharness

9 10

4 6 LTBLU(SRS) 7 8 WHT/BED (Batteryinput)

12 BLK (G401) 13 BLK (G401) 14 15 BLU/YEL (DLCinpuVoutput)

*1= '96-'98models *2: '99-'00models *3= All except GX models

47. C551

49. C419

- Green - On rearof under-dash tuse/relaybox - On floorwire harness

1 BED/GRN(Brake system indicatorlight) 2 4 BLI(BLU (Rearwindow defogger) 5 GBN/RED(Brake system indicatorllght) 6 * 1 :W H T / R E D (Trunklight) 7 8 Hatchback:GBN (Rearwiper/washer)

9 10 11 GRN/YEL (Turnsignal and hazard warning lights) 13 RED/BLK (Headlightswitch) 14 15 GRN/RED (Turnsignal and hazard warning lights)

*1= AllexceptGX models

202-14

- Green - On rearof under-dash fuse/relaybox - On mainwireharness

1 '98''00models:RED (lgnitionsystem) 2 WHT/RED(Fuses4) 3 Canada: WHT (Fuse48) 4 BLI(RED (Startingsystem) 5 WHT (Fuse48) 6 WHT/RED(Fuse43) 7 1 * :W H T (Securitysystem) I *2: BLK,TYEL {Powerdoor locks) I Canada:YEL/BLK (Headlights)

1 OY E U R E D (Backup lights) 11 (Fuse51) 13 WHT/GRN 14 '96-'98CVT:BLKWHT (A/Tcontrols) 15 Canada: GRN/RED (Headlights) 16 A/TiYEL(lnterlock system) 17 RED/BLK (Headlight switch) 18 Canada: RED/GRN (Headlights)

"1 = USA:LX,EX,HX,DX-VSi EX,Si Canada: 12 = '99100USA:LX,EX,HX,DX-VSi

-

52. C130

50. c421 - Green - On rearof under-dash fuse/relaybox - On mainwireharness

- Brown - Belowrightsideot dashpanel - Enginewireharness junctionconnector

T---------"1

10 GRN/YEL(Turnsignal and hazard lights) 11 12 USA:BLKAVHT (Chargingsystem) (Fuse15) 13 BLKryVHT 14 GRN/RED(Brake indicatorsystemlight)

l RED/YEL (Headlight switch) (ABS) 2 BLIVBLU 3 RED/GRN (Headlight switch) 4 GFIN/BLK (Frontwiper/washer) 5 FED/BLU (Headlight swrtch) 6 WHT/BLU (Charging systern) 7

I

16 GRN/RED(Turnsignal and hazard lights) 17 BED/BLK (Headlight switch) 18 RED/BLK (Headlight switch)

9 REDAVHT (Headlight switch)

10

I l

6

12 13 14 15

1 G F Y( 1 )o r G R N (Drivefs nflator) 2 3 GRY(17)or GRN (lgntion input)

6 GRY (21)or GRN (SRSindicalorcontrol) 7 GRY (18)or GRN (lgnitionnput) 8 GBY (14)or GRN(MES) 9 G B Y( 1 3 )o f G R N (Servicecheck connectorinput)

groupedtogetherare Terminals connectedby thesarre busbar. *1= 96-98 models: AllexceptD16Y5 '99-'00models: D1685 *2= 96-98models: D16Y5/D1685 '99-00rAllexcept D1685

L_-_____--J

r---------'1 (PGl\4-Fl) 14 YEL/BLK 15 YEL/BLK(PGr\4'Fr) (PGI\4,FI) 16 YEUBLK (PGr\4,Fr) 17 YEUBLK L______---J

T----------1

1 8 * 1 :G R N( F a n s ) *2:YEUBLU (PGM-Fl) 1 9 * 1 :G R N( F a n s ) .2: YEUBLU (PGM-Fl) 20 *1: GRN(Fans) .2: YEUBLU (PGM-Fl) _______--J

- Green - On rearof under-dash fuse/relaybox - On mainwireharness

- Yellow - BelowcenteroJdash - On SRSmarnwireharness

3

L---------J

11 BLUMHT(VSS) (VSS) 12 BLU,ryVHT (VSS) 13 BLU,^/VHT

53. C420

51. SRSUnit

1

1 8 R N / B L K( G 1 0 1 ) (G101) 2 BRN/BLK 3 BRN/BLK(G101) 4 BRN/BLK(G101) 5 BRN/BLK(G101) 6 BRN/BLK(G101) 7 BRN/BLK(G101) (G101) I BRN/BLK (G101) 9 BRN/BLK (G101) 10 BBN/BLK

7

8

't7 't8

10 GRY (4) or GRN (Frt.pass. inflato4 11 13 GBY (2) or GRN (Drivefs nflator) 1 4 G B Y( 5 )o r G R N (Frt.pass. inflator) 15 GRY(3) or GRN (DLC input/output) 1 6 G R Y( 1 9 )o r G R N (G801) 17 GRY (20)or GRN (G801) 1B GRY (6) or GRN (MES)

1 CanadarRED/BLU (Headlights) 2 3 8LK (G401) 5 WHT/GRN (Rearwindow defogger) 6 WHT/BLU (Powerwindows) 7 8 YEL/GRN(PGM-FD I BLK//EL(Fuse17) 1O BLUAVHT(PGM,FI)

11 BLUMHT (PGI,4-FI)

14 16 Canada:BLKAVHT (Headlights) 18 A/TrWHT/GRN (lnterlocksystem) 19 20 WHT/RED (Ceilinglight)

202-15

ConnectorViews (cont'd) s6. c507

54. c442

- Whiteor Blue - BehindleftsideoJdash - Dashboard junctionconnector wireharness

- Whiteor Orange - Behindrightkickpanel - l\,lain junctionconnector wireharness

r---------T 1 BLU (lgnitionsystem or Gauges) 2 BLU (lgnitionsyslem or Gauges) 3 BLU (lgnitionsystem or Gauges) 4 BLU (lgnitionsystem

orcauses)

L_-:-:::'-' ____J L_ t-----------1

5 6 7

(PGM-FD 11 GRN/WHT 12 GRN/WHT (A/T controls) 13 GRNMHT (ABS) 14 GRNMHT

L_ lc,r'.".oIr"D__ _.j r----------_l

| 15 BLUMHT(vSS) I 16 BLUMHT(VSS)

L

T----------l

(Brake 8 GRN/RED systemindicatorlight) (Brake 9 GRN/RED systemindicatorlight) (Brake 10 GRN/RED systemindicatorligh0 -..1 _

| I

T?_BLUSTrySS)--..] -

-l

| 1 8 B F N / B L(KG 1 0 1 ) G101) | 1 9 B B N / B L(K (c101) | 20 BRN/BLK

I | |

l---------

L---------J

r --------'l

r---------"1

L---------J

grouped Terminals together areconnected by the samebus bar.

- Green - On trontof under-dash tuse/relaybox - On dashboard wireharness

202-16

BLK (G401) BLK (G401) 8LK {G401) 8LK (G401) BLK (G401) 8LK (G401)

L________J

T--------"1 7 BED (Dashand consolelights) B BED (Dashand consolelights) I RED(Dashand consolelights) 10 RFD (Dashand consolelights) L---_---_J

T---------l 11 RED/BLK(Dash and consolelights) 12 RED/8LK(Dash and consolelights) 13 RED/BLK{Dash and consolelights) 14 RED/BLK(Dash and consolelights) 15 RED/BLK(Dash and consolelights) 16 RED/BLK(Dash and consolelights) L--------J

T--------T

17 YEL(Fuse25) 18 YEL(Fuse25) 19 YEL(Fuse25) 20 YEL(Fuse25) L--------J

Term nals grouped together are connected by the same bus bat

55. C501

l RED/GFN (Headlight switch) 2 *1 : BLKBLU (Fuse16) 3 WHT/BLU (Chargingsystern) 4 BLK (G401) 5 GRNMHT (Turnsignallights) 6 GRN/RED (Turnsignallights) 7 GRN/ORN (Turnsignallights) 8 8LU/YEL (Rearw ndow delogger) 9 GFN/YEL (Turnsignallights) -1 =All e),ceptGX

1 2 3 4 5 6

'10YEL(Fuse25) 11 YEL/BLK (Turnsignallights) (Fuse14) 12 BLKTYEL 13 YEUGRN(Accessory powersocket) 15 RED/BLK (Headlight switch)

1BBLK/WHT (Charglng system) 19 YEL/RED (Stereo soundsystem) 20

-

57. c723

58. SecurityControlUnitiC447lC516

- Connects heater-sub-A wireharness to heater-sub-B wireharness

- Green - Aboveradio('96-98)or rightof steeringcolumn (99-'00)

'96-'98 Models:

- Gray - Belowrightsideof dash

4 1 5

1 1 l

12 13

14

6 1 7 16

l BLUAVHT (Blowercontrols) 2 BLU(Blowercontrols) 3 YEL(Airdelivery) (A/C 4 WHT/BLU compressor controls) 5 RED(Dashlights) (Airdelivery) 6 GRN^VHT (Ar delivery) 7 GRN/RED (Airdelivery) I BLUAVHT (Airdelivery) 9 BLK,ryEL (Airdelivery) 10 YEUBLU

17

I

9

10

1 8 1 9 20

11 BLU/YEL (Blowercontrols) (Dashlights) 12 BED/BLK 13 BLK(G402) t4 15 BLK (Blowerconlrols) 16 BLU/BLK (Blowercontrols) 18 BLU/RED(A/C compressorcontrols) 19 GRN/YEL(Airdelivery) 20 YEURED(Airdelivery)

'99-'00Models: - Blue - Behindcenterot dash

><

1 11 12

13 14 15

7

6

rGlxllT 1 8

8

9

10

1 9 20 21 22

USA:HX,LX,EX,DX-VSi;Canada:EX,Si: 1 USA:YEUBLU (Set) 2 LTGRN/RED (Door swiich input) 3 BLU/BLK (Trunkswitch rnput) 4 5 BLU (valet switch inpu0 6 CanadaiGFNAVHT (Lock output) 7 Canada: BLU/YEL (Driver'sdoor lock oulpurJ I Canada:GRN/OBN (Unlockoutput) 9 10 WHT (Battery) 11 YEL (lgnition) 12 USA:OHN (Alarmin)

13 BLK (G401) 14 BLUMHT (SecurityLED conkol) 15 BLU/RED(lgnition key switchinput) 17 REDAVHI (Lightflashcontrol) 18 GRY (Hornconkol) 19 RED/YEL (Startercut output) 20 Canada:LTGRN (Nolused) 21 ,96-,98USA:LT BLU (Securityoutput) 22 '96 98 USA: WHT/BLK (Bus data 0) '99-'00 USA:BLU/YEL (Unset)

CX and DX: 1 RED/BLK(Dashlights) 2 BRNMHT (Audelivery) (Airdelvery) 4 GRNA/VHT 5 GBN/BED(Airdelivery) 6 GRN/YEL(Alrdelivery) 7 YEURED(Airdelivery) (Au delivery) 8 BLU,ryVHT 9 YEL (Andelivery) 10 YEUBLU(Arrdelivery) 11 LTGRN/BLK (Blowercontrols) 12 ORN,AiVHT (Blowercontrols)

I

13 BBN (Airdelivery) 14 RED(Dashlights) 15 GRY (Airdelrvery) (Air delivery) 16 RED,ryVHT 17 RED/YEL(Airdelivery) 18 PNK/BLK(Airdelivery) 19 20 BLU/RED(A/C compressorcontrols) 21 BLUI/EL (Bearwindowdefogger) 22 WHT/BLU(Fuse47) 23 BLKryEL(Fuse17) 24 BLK \G402)

1 2 LTGRN/BLK (Dooropen input) 3 BLU/BLK (Trunk/hatchopen input) 5

'96 '98: BLU (Security ndicatorcontrol) 99- 00: BLU (Valelswitchinput)

6 7 B I 10 WHT (Batteryinput)

11 BLK/YEL(lgnitioninput) 13 BLK (Ground) 14 RED (Securityindicator control) 15 BLU/RED (Keyin ignitioninput) 16 17 BLUor BLU/YEL (Lighttlash control) 18 GRY(Horncontrol) 19GRN (Slartercut control) 20 22

202-17

ConnectorViews (cont'd) 59. Cl31 - Green - Behindrightkick panel - Connectsmainwire harnessto enginewire harness

'96.'98D16Y5,'99-'00D16Y5with M/T: 1 '98-'00models:LTGRN (PGl\4-Fl) 2'991001 M a l e ' L TG R N M H T Female (Notused) A/TrRED/BLK (A/Tcontrols) '98r00 models: 3 YEL/BLU

(PGrV-Fr) 4 A/T: LT GRN (PGl\.4-Fl) lVl/T:RED (PGi.4-Fl) 5 '97 models with l\4/T: Male - RED/GRN Female - WHT/BED (PGl\,4-Fl) A/T:WHT/RED (lnterlock) 6 GRN (Fans) 7 BLU/RED(A/T compressorcontrols) I GFN/OnN(PGl\4-Fl) I BRN (PGr\,4-Fr) 10 WHT/BLU(PGM-Fl) '98-'00models:BLU 11 (PGir-Fr)

12 A,/T:WHT/RED(PG|VI-FD 13 A/T:RED/GRN (A/Tcontrols) M/T:GRN/BLK (PGr\,1-Fr) 14 A/T:PNK(PGM-FD M/T;GRN/BLK (Back-uplights) 15 A/T:GRY(PGl\,l-Fl) l\,4,rT: Male- YEURED Female YEL (Back-up lights) 16 USA GRN/RED (Charging) (PGMFD 17 GRN,ryVHT (Vehicle 18 BLUAVHT speeosenso4 (A,IT 19 BLK/RED controls) compressor (PGM-FD 20 GRN/YEL - BLU/YEL 21 N,4ale Female- LTBLU (PGM-Fr) 22 Male- BLU/WHT Female BLU/ORN (PGt4,Ft)

'96.'98016Y7: 1 *1: LTGRN (PGM-F|) 2 *2: GRN/BLK (A/T controls) 3 *2: WHT (A/T controls) '98 models: [rale - WHT/RED Female- (Notused) 4 A/Ti LT GRN (A/T controls) 5 *1i YEL/BLU(PGM-Fl) *2: WHT/RED (lnterlock) 6 GRN (Fans) 7 BLU/RED(A/C compressorcontrols) I GRN/ORN(PGlvl-Fl) 9 BRN (PGT,I-FD 10 WHT/BLU(PGM-Fl) 1 1 * 1 r B L U( P G L 4 - F | )

13 *1i GFN/BLK(PGl\4'Fl) *2: BLU (A/T controls) 14 A/TiYEL (A/Tconlrols) M/T:GRN/BLK (Back-uplights) 15 A/TiMale - GRN Female- PNK (A/Tconkols) lvl/tT:Male - YEL/RED Female- YEL (Backup lights) 16 USA:GRN/BED (Charging) (PGIVI.FD 17 GRN,^/VHT 18 BLU,ryVHT (Vehicle speedsensor) 19 BLI(RED(A/C compressorcontrols) 20 GRN/YEL(PGM-Fr) 21 ftIale BLUffEL Female - LT BLU (PGM,Fl) 22 Male - ELUMHT Female - BLU/ORN

(PGrvl,Fr) '96-'98016Y8: 1 *3: LTGRN (PGlvl'Fl) 2 lvlale- GRNIVHT Female- GRN/BLK (PGr\.4,F1) 3 WHT/RED(PGl\,4-F0 4 A"rT:LT GHN (A/T controls) 5 *3: YEUBLU(PGM-Fl) 6 GRN (Fans) 7 BLU/RED(A/T compressorcontrols) 8 GRN/ORN(PGr\4'F|) 9 BRN (PG|\4-F|) 10 WHT/BLU(PG[,4-Fr) 11 *3: BLU (PG[.4-F|) (PGl\4-Fl) 12 BLK,ryVHT 13 *3r GBN/BLK(PGM-Fl) 14 A/T:YEL (A,rTcontrols) M/T:GRN/BLK (Back-uplights)

- GRN 15 A/Tr l\,4ale Female- PNK (A/T controls) lVl/T:[/ale YEUBED Female- YEL (Back'up lights) 16 USA:GRN/RED (Charglng) (PG[r-Fl) 17 GRN,ryVHT 18 BLUAVHT (Vehiclespeed senso4 19 BLK/RED(A/T compressorcontrols) 20 GRN/YEL(PG[' Fl) 21 Male - BLU//EL Female- LT BLU (PGr,1-FD 22 l\,4ale- BLUMHT Fernale BLU/ORN (PGt\r-Ft)

*1 = '97 models:California sedanLX coupes,Californla '98 modelsiall models *2 = '96 models: all A,rT '97 modelsrall A"lTexcept Coupe DX *3 = '96 models:allcoupes '97 models:all coupes,California Sedans '98 models:all models

202-18

'99-'00 Models exceot D16Y5 with M/T and D1685:

Dt685: 1 RED(PG[,1-F0 2 BRN(PGM,F|) 3 Male BLU/BLK - BLUMHT Female (Starting system) 4 lrale ORN/8LU Female ORN (Fuelgauge) 5 LTGRN(PGM-FD 6 GRN(Fans) (r,/C 7 BLU/RED compressor controls) (PGM-Fr) 8 GRN/ORN 9 BRN(PGM-FD (PGM.FO 1OWHT/BLU 11 BLU(PGM-F|) 12 YEL(PGM-FI) 13 WHT/BED (lnterlocksystem)

\

14 15 l\.4ale- BLU/GRN Female- BLU/RED (Low fuel indicator) 16 GRN/RED (Chargingsystem) 17 GRNA/VHT(PGl\.4 FD 18 BLUAVHT (Vehiclespeed sensor) 19 BLTVRED(r,/C compressorcontrols) 20 GBN/YEL(PGr\.4-FD 21 N4ale- BLU/YEL Female - LT BLU

(PGr\,,rFr) 22 l\4ale BLU&VHT Female - BLU/ORN (PGr,4-Fr)

1 D16Y5/D16Y7: BLI(WHT(PGM.FI) 2 D16Ys/D16Y7: wHr/RED(PGt\4-Ft) WHT(4,/Tcontrols) 3 A,rT: 4 *1: LTGRN (A/Tcontrols) 6 M/T:Male- YEURED Female- YEL (Backup lights) 7 GRN(Fans) (PG[,4-Fr) 8 GRN/8LK Fl) 9 USA:GRN(PGf.4 (PGM-FD 1OWHT/BLU 13 *1: BLU(A/Tconkols)

1 4 * 1 :Y E L *2: GRN/BLK (A/T controls) 15 *1:Male GRN Female- PNK (A/T controls) *2: Male - GRN Female- LTGRN/RED (A,fTconkols)

18 M/T:GRN/BLK (Backup lights) 19 BLUMHT (Vehiclespeed sensor) 20 YEUBLU(PGI\4-FD 21 RED/YEL(PGt\,'l,FD 22 BRN/BLK(G101)

*1 = A/T except CVT

)

202-19

ConnectorViews (cont'd) 60. c411 - Blue - Mountedto top ol under-dash fuse/relaybox - Connectsmainwireharnessto dashboardharness

'98 GX and All '99-'00Models:

'95198 Models excepl GXI 1 *1: RED/GRN

(PGrvr-FD

2 A2:WHT (Security system) (Security system) 4 5 BLU(SRS) 6 *2rGRY (Cruisecontrol) 7 *2: BLU/RED (Security system) 8 RED/BLU (Cruise control) 9 LTGRN(Cruisecontrol) 10 '96- 97models: (ABS) BLU/YEL (Gauges) 11 YEUGRN 12 RED(Dashand consolelights) '13LTGRN/RED (Ceiling light)

*1 = Withshitt-upindicator

202-20

14 USALX,EX,andHX: LTGRN/BLK light) {Ceiling ExceptUSALX, EXand HX: ftrale- LTGRN/RED Female- LTGRN/BLK (Ceiling light) 15 WHT/BLK (Hazardwarninglights) 16 *2: RED|YEL (Security system) 17 *2: REDA/VHT (Security system) (Stereo 18 WHT/BLU soundsystem) system) 19 BLU(lgnition 20 RED/BLU (Seatbettreminder) (PGN4 21 GRN/OBN FD (VSS) 22 BLUAVHT (Oilpressure 23 YEURED indicatorsystem) (ABS) 24 BLU/RED USA:LX:EX,HX CanadarEX,Si

14

1 2

15 WHT/BLK (Hazardwarninglights)

4 All except GX: BLU/YEL (Rearwindow defogger) 5 BLU (SRS) 7 B RED/BLU (Cruisecontrol) 9 LT GRN {Cruisecontrol) 10 *1: PNK (lndcators) GX: BLU/YEL(Bear window defo9ger) 1l YEL/GBN(Gauges) 12 RED (Dashand console lights) 13 *2: Male- LT GRN/RED Female- Not used (Ceilinglight)

18 WHT/BLU (Stereosoundsystem) 19 BLU(lgnition system anogaugesl 20 RED/BLU (Seatbellreminder) (PG[,4-Fl) 21 GRN/ORN 22 BLU,ryVHT O/SS) 23 YEURED (Oilpressureindicator) (ABS) 24 BLU/RED

*1 = Allexcept CW andGX *2= AllexceptGX

\

61. C556(withPowerDoorLocks) - Gray - In driver's doorjamb - Connectstloorwireharnessto driver'sdoor wtrenarn€ss

'I

2 7

)

- Gray - In frontpassenger's doorjamb - Connectsfloorwireharnessto passenger's doorwireharness

4

8

9

10

7

8

4

5

9

10

13 14 15

1 1 12 t3 14 15

1 6 1 7 1 8 1 9 20

1 6 1 7 1 8 1 9 20

21 22 23 24

2'l 22

11

\

62. C557(withPowerDoorLocks)

1 '9: GRN/BLK (Powerwindows) 2 *9: BLU/BLK (Powerwindows) 3 *7: YEUBLK (Powerwindows) 4 *7: REDMHT (Powerwindows) 5 .3: WHT/GRN 14rBLU,TWHT (Powerdoorlocks) 6 i9: BLU//EL (Powerwindows) 7 '9: BLU/ORN (Powerwindows) I *7:YEL (Powerwindows) 9 *7:YEUGRN (Powerwindows) 10 *7: GRN/VEL (Powerwindows) 1 1 * 7 iG R N (Powerwindows) 12 WHT/RED (Powerdoorlocks) 13 "3: YEUBED (Powerdoorlocks) 14 *1:YEURED *2: BLU/BLK (Powermirrors) 15 '96-'97models: BLU/BLK (Powermirrors) 13:BLU/YEL (Powerdoorlocks *4: BLU/BED (Powerdoorlocks) Powermirrorswithout Powermirrorswith deloggers '98 model:All '99-'00models:Without Keyress '99r00models:With Keyress '98modelr All '99-'00models: Power

16 '96. 97models: BLU '98-'00models: Male- RED/GRN Female- BLU (Stereosoundsystem) 17 '96197modelsl GRY/BLK '98r00modelsl Male- BRN/BLK Female- GRY/BLK (Stereosoundsystem) 18 *8:GRN/WHT (Powerdoorlocks) 19 *8rGRN/ORN (Powerdoorlocks) 20 t1 | BLU,TWHT r2:YEURED (Powermirrors) 21 '96-'97 models: BLU/TEL (Powerdoorlocks) *5: BLU/BLK (Powermirrors) *6: BLU,TWHT (Powermir.ors) 22 BLK(Gssl) 23 BLK(G551) 24 *2: ORNMHT (Powermirrors)

mirrorswithout deloggers 99100 mod6ls: Power mirrorswith deloggers *7= Sedan *8= '96- 98USA:LX,HX, EX '99-'00 USA:All *9= All except '00 Canada DX-V:With Power Door Locks Only

l GRN/BLK {Powerwindows) 2 BLU/YEL (Powerwindows) 3 BLU/ORN (Powerwindows) 4 WHT/RED (Powerdoorlocks) 5 YEURED (Powerdoorlocks) 6 '96197models: RED/GRN '98-'00modelsl l\4ale- BLU - RED/GRN Female (Stereosoundsystem) 7 '96-'97 models: BRN/BLK '98-'00 models: Male- GRY/BLK Female- BRN/BLK (Stereosoundsystem)

24 25

9 YEUBLK (Pow€rmirrors) 10 *1:GRNA/VHT *2rYEURED (Powermirrors) 12 13 12:ORNMHT (Powermirrors) 14 *2: BLK (Powermirrors)

18 20-

23

*2: GRN,TWHT (Powermirrors)

'6=

r1= Withoutmirrordefoggers *2= With mirrordefoggers

202-21

ConnectorViews (cont'd) 64. CombinationLightSwitch

63. ABSControlUnit

- Lettsideof steeringcolumn

- AboverightkickPanel

A Connector

A Connector

- Natural - On main wire harness

- Orange - On mainwireharness

1 RED/BLU(FR-|N)

12 YEUBLU(FR.OUT)

3 4 BRN (SCS)

14 LTBLU(DLC)

7 BLU/BED(WALP) '96197 models: 8 BLU|YEL(Not used) 9 _ 10 YEUBLK (FL-OUT) 11 RED/BLK(FL-|N)

ConnectorB - Natural - On mainwireharness

(+81) 14 WHT/GRN (+82) 15 WHT/GRN 16 BLK{GND2) (FRl) 17 GRN/yEL 1 819 LTBLU(RL1)

8 GRN(FRo) (STOP) 9 GRNAVHT (FLo) 10 BRNAVHT

(FRl) 21 GRN/BLK 22_ (FL1) 23 GRN/ORN

12 YEL(RL-OUT) (RR"IN) 13 REDAVHT

25 RED(RL-IN) 26 BLK{GND3)

202-22

(Rightturn GRN/YEL signalpoweroutput)

21 BLU(RR-OUI) 22 BLK(GND1)

- Orange - On mainwireharness

6 GRY(RLo)

3

1 6(MCK) 17 BRN/YEL 1 819 YEURED(PlVlR)

ConnectorB

(PCOM) 1 GRN^VHT 2 BLr(wHT{SCOM) (lG2) 3 BLIVBLU 4 BLU/fEL(RRo)

GRN/ORN Ournsignal switchpowerinput) (Lettturn GRN/RED signalpoweroutqut)

(Headlight RED/GRN switchoutpUt) WHT(Fuse48) (Dimmer REDAvHT switchLOoutpu0 CanadarRED (DRLoutput)

(Dimmer FED/BLU switchHl output) 6 WHT(Fuse48) '98100models:GRY 7 {Horns)

65. Combination WiperSwitch - Rightsideot steering column

66. DaytimeRunningLightsControl Unit - Behind left side ol dash

ConnectorA - Natural - On mainwire harness

ConnectorA - Natural - On mainwirenarness

ffi

3

I

6

1 BLU(Windshield wiper

motorLOWconkol) BLU/YEL (Windshield wiper motorHIGHcontrol) YEUBLU(lntermittent wiperONinput)

8

4 GnN/BLK(Fuse26) 5 BLK(G401)

1 WHT/RED

3

(H€adlight control) (Battery) 2 BLKAVHT

RED(Lights-on input)

7 BLU/BLK(lntermittenv parkwipercontrol) (Windshield 8 WHT/BLK washermotor)

\

ConnectorB (C4271(withRearWiper)

ConnectorB

- White - On mainwire harness

- Gray - On mainwireharness

1

3

4

lilale - GRN Female - LT GRN (Rearwindow wiper motor conkol) lrale - LT GRN Fema|e_ LT GRN/BLK (Rearwindowwiper motor control)

3

5 6

BLK (G401) Male - WHT Female- GRN (Fuse3) Male - BLU F€male _ GRN/BLK (Rearwindow washer motor control)

1 BLK(Ground) (lgnition) 2 YEUBLK 3 GRN/RED (Brakesystem indicatorlightconkol)

4 5 6

RED/GRN (Parkingbrakeinput)

7 8

)

202-23

GonnectorViews (cont'd) 67. IntegratedControlUnit

68. StereoRadioTuner('96-'98)

- On underdashfuse/relaybox

- Centerot dash

A Connector

ConnectorA

- Connectscontrolunitto under-dash fuse/relaybox

- Gray - On dashboardwireharness

1 Notused

4 5 6 7

Erakebulbcheckoutput input lgnition input lgnition lgnjtioninput

8 Lights ONinput input 9 Battery 1 1_ 13 Startinput 14 Ground

- Natural - On mainwireharness

202-24

9 BRN/BLK -) (RFspeaker 1OGRY/BLK (LFspeaker-) 12RED (lllumination control) 14 BLK(Ground) 15 GFY,4/VHT (LRspeaker-) 16 BRNAVHT (RRspeaker-)

ConnectorB (USAHX,UX,and EX; CanadaEXandSi)

Connectol B

l BLU/BLK {Frontwiper/washer) 2 BLUA/VHT (Frontwiper/washe0 3 YEUBLU (Frontwiper/washer) 4 '98-'00models: WHT/BLK (Frontwiper/washer)

1 RED/GRN (RFspeaker+) 2 BLU(LFspeaker+) 3 RED/BLK (lllumination control) 4 WHT/BLU (Batteryinput) (lgnition input) 5 YEURED 6 7 BLU/YEL (LRspeaker+) 8 RED/TEL (RRspeaker+)

- Green - Ondashboard wireharness

(Driver's 7 RED/BLU seatb€ltswitchinput) 8 LTGRN/RED (Dooropeninput) I GRN(Oriver's doorswitchinput) 't0 BLU/RED (Keyin ignitioninput)

l BLU/RED (Keyswitchinput) 2 LTGRN(Notused) 3 BLU/'EL(Drivels doorunlockoutput) 4 BLU(Security system) 5 LTBLU system) {Security (lgnitioninput) 6 BLIVYEL 7 ORN(Security system) 8 LTGRN/BLK (Dooropenoutput) 9 GRN/ORN (Unlock/lock output)

1OGRNAVHT (Unlock/lock output) 11 BLU/WHT (Security system) '2 WHT/BLK (Security system) 13 YEUBLU (Security system) 14 LTGRN/RED (Dooropeninput) 15 BLK(Ground) 16 GRY(Hornconkol)

-

69. Transmission ControlModule(TCM)('96-'98CVT) - Behindleftkickpanel

\

ConnectorA

ConnectorB

- Gray - On mainwireharness

- Gray - On mainwireharness

1 PNI(BLU (SC LS -) 2 PN|(BLK (H LS -) 3 GRN/YEL(SH LS _) 4 BRN/BrK(LG1) 5 BLU (NE) 6 7 BLU (ATP-L) I GRN (ATP-S) 9 YEL (ATPD) 1O LT GRN (ATPPN) 11 WHT (ATPR) 12 BL(WHr (rG1) 13 BLK (PG1)

14 YEL(SCLS +) 15 GRNMHI(HLCLS +) (SHLS+) 16 BLU/YEL (LG1) 17 BRN/BLK 18 1 9_ (DIND) 20 GRN/BLK

23 WHT/BLU ryBU) 24 2s BLI(WHT(rG1) 26 BLK(PG1)

(SOLrNH) 1 GRN/BLK (MAP) 2 RED/GRN 4 RED/BLK |rPS) 5 BLUMHT(VSS) 6 PNK[rMB) 7 GRYrrMA) (NDNSG) 8 RED/BLU 9 WHT(NDN) (NDR) 1ORED/BLU

(STOPSVV) 12 GRNAVHT 13 LTBLU(DIAG-H) 14 BRN(SCS) (VEL) 15 WHT/RED (vErSG) 16 ORN/BLU 17 GRN(NDRSG) (HBRKSW) 18 GRN/RED 19 (VREF) 20 WHT/RED

)

202-25

ConnectorViews (cont'd) 70. PCMor ECM(All '96-'98ModelsexceptD1685;'99-'00D16Y5MfO Note:Forall othermodels,seepage202-28. - Belowrighttrontfootrest

ConnectorB (A/Tonly - exceptCW)

- Gray - On enginewireharness

- Gray - Onenginewireharness

6 't6 '18 12 13 14 15 17 1

2

ConnectorA

3

25 26 2?

10

11

20 21 22

23

24

3'r

32

28 29 30

1 YEL(rNJ4) 2 BLU(rNJ3) 3 RED(rNJ2) 4 B R N( N J 1 ) 5 BLI(WHT(SO2SHTC) 6 BL(WHT (PO2SHTC) 7 D16YswithM/Tl PNK(E-EGR) CWi RED(ESOL) 8 D16Y5/016Y8: GRN/rEL(wS) (LG1) 9 BRNiBLK 10 BLK(PGl) (lGPl) 11 YEUBLK 12 D16Y5/016Y8 BLI(BLU0ACV) 13 11:ORN{IACVN) 14 11rBLKBLU(IACVP) (PCS) 15 RED/yEL

*1 = D16Y5/D16Y8:A"/T D16Y7:All

202-26

9

I

4

16 GRNffEL(FLB) 17 BLI(FED(ACC) (MrL) 18 GRN/ORN (ALTC) 19 USA:WHT/GRN 20 YEUGnN(CM) (LG2) 22 BRN/BLK 23 BLK(PG2) 24 YEUBLK(tGP2) (VBEF) 2s CW: WHT/REO 27 USA|GRN(FANC) 28 .2r BLU(2WBS) (VSV) 29 .2r LTGRNAVHT 30 with shift-upindicator: (Shift-up WHT/RED indjcatorcontrol) CW; WHTiRED(SLU)

I 2 3 4 s

wHT (LS-) RED(LS+) (SHA) BLU/YEL GRNiBLK(LCB) YEL(LCA)

8 PNK(ATPD3) 9_ 1 0_ 11 GRN,4HT(SHB) (SLU) 12 WHT/RED (D4rND) 13 GRN/BLK

14 WHT(NMSG) 1s RED(NM) 16 WHT(ATPR) 17 BLU(ATP2) 1 81 9-

22 GRN(NCSG) 23 BLU(NC) 24 YEL(ATPD4) 25 LTGRN(ATPNP)

\

ConnectorC

ConnectorD

- Blue - On enginewireharness

- Gray - On enginewireharness

'I

4

8

9

10

1 1 1 2 1 3 1 4 't5 't6 1 7 1 8 1 9 20 21 22

23 24 25

\

26 27 2a

(CKFP) 1 BLU/RED 2 BLU(CKPP) 3 GRN[rDCP) 4 YEL(CYPP) (ACS) 5 BLU/REO (STS) 6 BLU/ORN 7 BRN(SCS) 8 LTBLU(K.LINE) I CVT:GRY[rMA) (VBU) 10 WHT/BLU (CKFM) 11 WHT/RED 12 WHT(CKPM) 13 RED[rDCM) 14 BLK(CYPM) 1s Dl6Ys/D16Y8i (VTM) BLU/BLK 16 USA:GRN(PSPSW) 17 WHT/RED {ALTF)

29 30 3 1

(VSS) 18 BLUA/VHT 19 -,. 20 21 22 23 016Y5withl\.4/T: BLK(lP+) 24 D16Y5withM/T: RED(rP-, VS-) 25 D16Y5withM/T: wHT (VS+) 26_ 27_ 28 29 CW: LTGRN(ATPNP) D16Y5withl\4/T: RED(CLSW 30 CW: PNKOMB)

L 2

1 7

8

4 9

13 14 15

1 RED/BLK [TPS) 2 REDMHT(ECI) (MAP) 3 RED/GRN (vCC1) 4 YEURED (BKSW) 5 GRN,A/VHT 6 CWD16Y8: (KS) RED/BLU 7 WHT(AllexceptD16Y5 M/'T- PHO2S) (D16Y5M/T- LABEL) (IAT) 8 RED/YEL

10 1 1

12

16

I D16Y5iWHT/BLK

(EGRr) 10 YEUBLU(VCC2) (SG2) 11 GRN/BLK (SG1) 12 GRN,ryVHT 13 016Y5/D16Y8: GRN/BLK RED//EL D16Y7:

(sHo2sG)

(SHO2S) 14 WHT/REO 15 '2: LTGRN(PTANI9 (EL) 16 USA:GRN/RED

*2 = '96D16Y8 AllCoupes enoine: 97 D16Y7 enoine. Calitornia CouoeandCalifornia Sedan LX '97 D16Ygengine:All CoupesandCalifornia Sedan '98- 99:All

t 202-27

ConnectorViews (conrd) 70. PCM or ECM (D1685,All '99-'00Modelsexcept Dl6Y5 Mff) Note:Forall othermodels,see page202-26. - Belowrighttrontfootrest

ConnectorA

ConnectorB

- Gray - On mainwireharness('99100except01685) - On enginewireharness (D1685)

- Gray - On enginewireharness

2 4 6 7 8 9 't2 1 3 1 4 t 5 1 6 '17 '18 1 9 20 21 22 25 26 27

2a 29 30 31

1 *1: BLUAVHT

(srscHrL)

2 *1:GRNffEL[rFO) (FWARN) 3 -1I BLU/RED 14:BLU{2WBS) 4 * 1 : O R N( FM E T E R ) .ar LTGRN/WHT (VSV) 5 *2: BLU/GFN(CRS) (PCS) 6 .4r RED/YEL 7 CVT:YELiATPD) I BLI(WHT(SO2SHTC) 9 CW: LTGRN(ATPDN) 10 BRN(SCS)

t0

11

23

24

32

17 BU(RED(ACC) (Mrr) 18 GRN/ORN 19 .4: BLU(NEP) 20 GRN(FANC) 21 *1: LTBLU(K-LINE) .4: BLU/YEL (K-LINE) (PFO) 22 *1: BLU/YEL CVT:ALU(ATPL) (SHO2S) 23 WHT/RED (STS) 24 *1: BLU/ORN *4: BLU/^,iVHT (STS)

(D4|ND) 14 13:GRN/BLK

26 GRN(PSPSW) (ACS) 27 BLU/BED WHT/RED 28 A"/T: 29 *4: LTGRN(PTANK) (EL) 30 GRNiRED

(FLR) 16 GRN/yEL

(BKSW) 32 GRNAVHT

'1 = "2 = a3 = *4 =

D16B5 D16Y7/D16Y8 with A"/T A,/Texcept CW ExceptD1685

202-28

(IGP1) I YEUBLK 2 BLK(PG1) 3 RED(rNJ2) 4 BLU(rNJ3) 5 YEL(NJ4) 6 i4: BL(BLU (IACVP) 7 D1685:PNK(E-EGR) CW: RED(ESOL) 8 'l: WHT(LS-) CVT:PNIVBLK (HLCLSI\,!) 9 YEUBLK(IGP2) 1o BLK(PG2) 1 1 B R N( N J 1 ) (VTS) 12 '2: GRN/YEL (CM) 13 YEUGRN

a1 = a2 = '3 = 14 =

A"fTexcept CVT Except 016Y7 M,/Texcept D16Y7 A/T,All D16Y7

14 01685:LTGRN (NJ MOD) 15 .4r ORN(IACV N) 1 6_ 1 7 . 1 r R E D( L S + ) CW: GRN/WHT (HLCLSP) 18 CW:PNKBLK

(scLsM)

19 (LGl) 20 BRN/BLK (VBU) 21 WHT/BLU (LG2) 22 BRN/BLK 23 r3: BL(BLU (IACV) 25 CW: YEL(SCLSP)

ConnectorC

ConnectorD

- Blue - On enginewireharness

- Gray - On enginewireharness

1

2

3

6

4

7

8

26 27 2A

(PO2SHTC) 1 BLK/WHT (ALTC) 2 WHT/GRN (KS) 3 al: RED/BLU

\ I

(ALTP) 5 WHT/RED (EGR2) 6 12WHT/BLK (SGl) 7 GRNAVHT 8 BLU(CKPP) 9 WHT(CKPM) (VTM) 10 *3: BLU/BLK

13 D1685:GRN/RED OF2) (PF2) 14 01685:BLU/RED 16 WHT(PHO2S)

cw D16Y8,816A2 cw D1685 Dl6Y7 Except

6

29 30 31

(MAP) 17 RED/GRN (SG2) 18 GRN/BLK (VCC1) 1s YEURED 20 GRN(TDCP) 21 REDfiDcl\4) (CKFP) 22 BLU/RED (VSS) 23 BLU,ryVHT 24 25 RED/yEL(lAT) (ECT) 26 REDAVHT (TPS) 27 RED/BLK 28 YEUBLU(VCC2) 29 YEL(CYPP) 30 BLK(CYPr,,t) 31 WHTiRED(CKFrVr)

4

1

1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22

23 24 25

J

I

s l 't0

o

13 14 15

10

r r l lr z

16

D1685,'99100exceptCW: 1 YEL(LCA) (SHB) 2 GRN,ryVHT (LCB) 3 GRN/BLK 5 6 7 8

.1 : BLIVYEL (VBSOL) WHT(ATPR) BLU/YEL {SHA) PNK(ATPD3)

9 YEL (ATPD4) 10 BLU (NC) 11 RED (Ntvl) 12 WHT (NMSG) 13 LT GRN (ATPNP) 14 8LU {ATPP2) 16 GRN (NCSG)

*1= ExceptD1685

'99100cw: (VEL) 1 WHT/RED (rNHSOL) 2 GRN/BLK 3 GRN/vEL(SHLSl\4) (SHLSP) 4 BLUAVHT 5 BLK^fEL(VBSOL) 6 WHT(ATPR) 7 BLKWHT(VELSG) 8

I 1OWHT(NDN) (NDR) 11 RED/BLU 12 GRN(NDRSG) (ATPS) 13 LTGRN/RED (DIND) 14 GRN/BLK 16 REDMHT(NDNSG)

t 202-29

Connector Views (conrd) 71. GaugeAssembly - Left side of dash

ConnectorA (A/Tonly)

ConnectorC

- Green - On dashboardwireharness

1 YEL(lgnition input) (Headlight 2 RED/BLK switchON input) 3 RED (Dashlightbrightness controllerinput) 4 BLU(L or 2 indicatorcontrol) 6 D16Y7/D16Y8: BRN(Notused) 8 BLK(G401)

- Blue - On dashboardwireharness

1 *: YEL(lgnition input) 2 *: PNK(Washer lluid levelinput) 3 YEUBED (Lowoil pressure indicatorlightcontrol) 4 YEL(lgnition input) (Malfunction 5 GRN/ORN indicatorlightcontrol) 6 RED/GRN {Lightson Hl input) (Hazard 7 GBN/RED warningswitchinput)

9 D16Y7/D16Y8: YEL 01685/016Y5: GRN/BLK (D4or D indicator control) 10 GRN(03or S indicatorcontrol) 1 1R E D (N indicatorcontrol) 1 2W H T (F indicatorcontrol) 13 BLI(BLU (P indicatorcontrol) 14 LTGBN (Park/neutral output)

8 BLU (Enginespeedinput) 10 1 2F E D (Dashlightbrightness controllerinput) 13 RED/BLK (Headlight switchONinput)

*= '99-'00:All except CVT

ConnectorB

ConnectorD

- Blue - On dashboardwireharness

- Orange - On dashboardwireharness

2 BLK (G401) 3 BLU/BLK(Trunkopen indicatorlight control) 4 GRN/YEL(Hazard warning switch input) 5 GRN/RED (Brakesystem indicator lightcontrol) 6 RED/BLU(Seat belt indicatorlight control) 7 '96-'97 model: BLU,ryEL (not used) 8 ExceptGX: GRN/YEL GX: 8LU/GRN (Lowfuel indicatorlight control)

202-30

10 ExceptGX:YEUBLK cX: ORN/BLU (Fuelgaugecontrol input) 11 BLUAVHT (Vehicle speedsensor (VSS)input) (Engine 12 YEUGRN coolanttemperature sending unitinput) 14 15 BLI(IVHT (lgnitioninput) 16 WHT/BLU (Chargingsystem indicatorlight control)

I

2

(ABS BLU/RED indicator lightcontrol)

3 BLK (G401) 4 5 YEL (lgnitioninput)

\

ConnectorE - Groen - On dashboardwireharness

Wllh Crulss: 1 (Cruise 2 RED/BLU conkol indicator control) 3 BLK(G401)

(Headlight 4 RED/BLK switchON input) 5 YEL(lgnitioninput)

WlthShtft-upIndlcator:

T

1 RED (Dashlightsbrightn€ss controllerinPut) (Shift-up 2 RED/BLU indicatorcontrol)

3 BLK(G401) (Headlight RED/BLK switchONinput) YEL(lgnitioninput)

ConnectorF - Yellow - On dashboardwir€harness

1 BLU(SRSindicator

BLK(G401)

lightcontrol) 2

)

5 YEL(lgnitioninput)

-

202-31

Connector Views (cont'd) 72. C1s0 (GXModel)

74. Audio Unit ('99-'00Models)

- Lightgreen - Leftrearof enginecompartment - Connectsenginewireharnessto mainwireharness

1 2 3 4 5

(PGM-FI) YEUBLU (PGM.FD GRN/BLK LTGRN(A/t controls) (PGM-FD YEURED GRN/rEL(PG|\,1-FD

6 BLU/IEL(PGM-FD 7 Male- PNK

Female- GRN (4,/Tconvols) YEL(A,/Tcontrols)

73. C575 (GXModel) - Gray - Behindleftsideof rearseatback - Connectsfloorwireharnessto subluel cord

1 BLK(PGM.FD 2 WHT/RED(PGI\4-FD (PGM.FI) 3 GRN/YEL

202-32

5

(PGr\4-Fr) GRN/BLK (PGI\'-FD BLU/YEL YEUBLU(PGI\,4,FD

- LightBlue - Centerol dash - On dashbaord wireharness

']]](lgnition 2 YEURED input)

12* 14

5 RED/YEL (RFspeakerf) 6 BLU/YEL (LRspeaker+) 7 RED/GRN (BFspeaker +) I BLU(LFspeaker+) 9 RED/BLK (lllumination control) 10 WHT/BLU (Batteryinput)

15 BRN,^/VHT -) {RRspeaker 16 GRYAVHT (LRspeaker-) 17 BRN/BLK (RFspeaker-) 18 GRY/BLK -) {LFspeaker 19RED (lllumination control) 20 BLK(G501)

75. KeylessDoorLockControlUnit (USAOnly) - Gray - At lettkickpanel - On mainwireharness

l LTGRN/BLK (Dooropenoutput) 2 BLU,ryVHT (Lockinput) 3 BLU/RED (Keyswitchinput) 4 BLK/YEL (lgnition input) 5 BLU/RED (Unlock/lock control) 6 FED/BLK (Lightflashcontrol) 7 WHT/RED (Unlock/lock output) 8 YEURED (Unlock/lock output)

9 GRN/ORN (Unlock input) '10GRNA/VHT (Lockinput) 11 ORN{Securiiy system) 12 LTGRN/RED {Dooropeninput) 13 YEUBLU (Security system) 14 BLU/YEL (Security system) 15 GRY(Horncontrol) 17 BLK(G401) 18 WHT/GRN (Batteryinput)

76. HeaterControlPanel ('99100Models) - Centerof dash

ConnectorC

ConneclorA

- Black - Toheaterpushswitches

- Gray - On heatersub-harness A

1 BLUiBLK

(Blowercontrols) (Airdelivery) GRNAVHT (Airdelivery) GRN/RED (Dashlights) 4 RED/BLK

RED(Dashlights) BLK(G402) 7 BLUfYEL (Rearwindowdefogg€0 (Fuse17) 8 BLK,TYEL

1 ORN(Airdelivery) 2 4 WHT(Airdelivery) 5 GRN(ry'Ccompressor control) 6 PUR(Roarwindow delogge4

7 RED(Dashlights) 8 BLU(Dashlights) I BLK(Airdelivery) compressor 10 GRY(Ay'C controls) 1'1BRN(Airdelivery) 12 YEL(Rearwindow defogge0

\

ConnectorB

77. Injectorcontrol Module (GXModel)

- Black - On heatersub-harness A

- Gray - Behindleftkickpanel - Onmainwireharness

1 LTGRN/BLK (Blowercontrols) 2 BRN,A/VHT (Airdelivery)

)

(Airdelivery) 4 REDA/VHT (Airdelivery) 5 YEUBLU (Airdelivery) 6 YEURED (Airdelivery) 7 GRN/YEL (Airdelivery) 8 BLU,ryVHT (Airdelivery) 9 YEL {Airdelivery)

1OWHT/BLU (Fuse47) 11 BLU/RED WC controls) compressor 1 2B R N (Airdelivery) 13 ORNAVHT (Blowercontrols) 1 415 PN(BLK (Airdelivery) 1 6_ 1 9_ 20 GRY (Airdelivery)

1 2 3 4

RED(rNJ2) BRN(rNJl) BLK(G401) _

8 YEL(TNJCNTL4) 9 BLU(TNJCNTL3) 1o RED(tNJCNTL2) 11 BRN0NJCNTL1) (G101) 12 BRN/BLK 13 YEURED(Switched ignition input)

14 YEL (tNJ4) 15 BLU (rNJ3) 16 BLK (G401)

1 92021

24 LI GRN (INJMODE) 25 BRN/BLK(Gr01) 26 YEURED (Switched ignition input)

202-33

Connectorldentificationand Wire HarnessRouting Connector Numberof or Cavities/ Terminal Color

Location

Connectsto

Starter Cables T1

r2

Rightside of enginecompartment Under-hood luse/relay box Rightside of engine Stanermotor

t+l

Battery

Batterypositiveterminal

Rightfrontshocktower

Bodyground,via batteryground cable

Battery

Batterynegativeterminal

Leftend of engine

Powersteeringpumpbracket

Tooleftsideot bulkhead

Bodyground,via engineground cableA

BatteryGroundCable

o EngineGroundCableA t!t

EngineGroundCableB T4

Bightsideof enginecompartmentTransmission

(rit

Rightsideof frontframe

Bodyground,via engineground

Under-hood ABSFuse/Relay BoxWireHarness Rightsideof enginecompartment Under-hood ABSfuse/relaybox

tc

o

Battery

Batterypositiveterminal

Leflfrontof enginecompartment Leftfrontof enginecompartment Leflfrontof enginecompartment Lefttrontof enginecompartment

Enginecompartment wireharness A,/Ccompressor clutch Condenser fan motor A,/Cpressureswitch

A,/CWireHarness c209 wtJl /,\-7Ee

c754 G751

4-GRY 1.GRY 2-GRY 2-GRY

Leftfrontof enginecompartment Bodyground,via A,/Cwire harness

Notes

\ . .

STARTER CABLES

BATTERY GROUND cAELE

\ . .

UNDER.HOOD ABS FUSE/RELAY

BOXWIRE HARNESS

ENGINE GROUND CAELEB

)

A/C WIRE HARNESS

-

203-1

Connectorldentificationand Wire HarnessRouting Connector Numberot or Cavities/ Terminal Golor

Location

Connectsto

Notes

EngineWire Harness(Dl6Y5,D16Y8engines):'96-98modelsand '99;00 D16Y5dM/T c101 c102 c 103 c104 Q104 c105 c106 c107 cl 08 cl09 cl10 c1l1 cl'12 c113 c114 c'115 c116 c'117 c 118 c119 c120 c121 c122 c123 c123 c124 Q124

c125 c 126 c127 c128 c129 c130 c131 cl32 c 134 c135 c136 c137 c138 c139 c'140 c141 c142 c143 c144 c'|44 c145 c146 c147

203-2

1O-GRY 3.GRY 1-CLR 4-GRN 3-N/A 2-BLK 2-BLK 2-BLK 2-BLK 3-GRY 3-GRY 3-GRY 2.BLK 2.GRY 2-BLK 14-BLU 14-GRY 3.GRY 2-BLK 2-GRY 1O-GRY 1.BLK 2.GRY 4-GRY 8-GRY 2-GRY 2.GRY 4-GRY 2.BLK 2.BLK 2-GRY 1.BLK 2O.BRN 22.GRN 32.GRY 25.GRY 31-BLU 16.GRY 14-GRY 8.GRY 2-GFIY 2.GRY 1-GRY 2-GRY 2-BLK 2-GRY 2.BLK 3-GRY 6-GRY 2.BLK 8-GRY 2-BLK

Left side of engine compartment Left side of engine Middleof engine I att .i.la

^f an^i^6

Left side ot engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine [,liddleof engine Middleot engine Middleot engine Middleof engine Middleof engine Middleof engine l\,liddleof engine Rightside of enginecompartment Rightsideof enginecompartment Middleot engine Middleof engine Middleof engine Middleof engine l\,liddleof engine Nliddleof engine Middleot engine Middleof engine Middleot engine Middleof engine Middleof engine Nliddleof engine Rightside of engine Underrightside of dash Behindrightkickpanel Below right front footrest Below right front footrest Below right front footrest Below right front tootrest Left side ot engine compartment Left side of engine compartment Middleof engine liliddleot engine Middleof engine Nriddleol engine Right side of engine compartment Middleol engine Rightside of enginecompartment Middleof engine N,liddle of engine Rightside of enginecompartment Rightside of enginecompartment Bightsideof enginecompartment

Mainwireharness CKFsensor Engineoil pressure switch Alternator Alternator No.1 fuelinjector No.2 fuelinjector No.3 fuelinjector No.4fuelinjector IACvalve TP sensor MAPsensor IATsensor Powersteeringpressureswitch EVAPpurgecontrolsol€noidvalve Junctionconnector Junctionconnector Vehiclespeedsensor(VSS) Countershatt speedsensor Enginecoolanttemperature switch Distributor Enginecoolant temp.sending unit ECTsensor Primary HO2S(sensor'1) Primary HO2S(sensor'1) Back-uplightswitch Lock-upcontrolsolenoidvalves SecondaryHO2S(sensor2) lvlainshafl speedsensor Lanear solenoid Shiftcontrolsolenoidvalves Startersolenoid Junction connector Mainwireharness ECM/PCMconnector A PCMconnectorB ECM/PCNI connectorC ECM/PCl\,,| connectorD Mainwireharness Malnwireharness Knocksensor(KS) IACvalve VTECsolenoidvalve VTECpressureswitch EVAPcontrolcanisterventshutvalv€ EGRcontrolsolenoid valve gearshattspeedsensor Secondary EGRvalve EGRvalve Drivepulleyspeedsensor CVTtransmission solenoid Drivenpulleyspeedsensor

USA Canada

AlT

USA

'2( tr\

'3

-1(M/r) t\4/T

'2 (Anl '1

'2 (An) '2 (Nr) '2 (AtT)

'2 (Atr) -1 (An) -2( fi| M/T

.1 (Arr) .1 (A,T) "1 (A/r) -1 (M/r) .1 (CVT) ,1 (cw) '1 (CVT)

Connector Numberof Cavitiesl or Color Terminal

Notes

Connects to

Location

'9&98 modelsand'9$'fl) D16Y5dIWT (cont'd) EngineWire Harness(D16Y5,D16Y8engines): Lett side of engine Rightside of enginecompartment

T101 r102

Alternator fuse/relaybox Under-hood

Engineground.viaenginewirehamess Rightof engine G101 '1:D16Y5 engine .2: D16Ygengine '3: D16Y5(A,/T). D16Y8enoines '4: '96model:dtlcoupes,'97 model:all Sedan,'98-'00 California model:allcoupes,

'96-'98modelsand '99-'00D16Y5dM/T:

I

clll cr19 I

c138 c110

c109

cl13

Tlor

c141. T102. c147cl4:t' cl17' clal c1|{) cl18 c139 cl20 c129 c1a6 c1a5

€NGINEwlRE HARNESS

cl l5 c116 c137

cr02 c105 c106

) - f

203-3

Connectorldentificationand Wire HarnessRouting Connector Numberof or Cavities/ Terminal Color

Location

Connectsto

Notes

Enginewire Harness(Dl6Y5, Dl6Y8 engines):'99-'00modelsexceptD16y5w/M/T c 101 c102 c103 cl04 c104 c105 c106 c107 c108 c109 c110 c111 cl12 c 11 3 c115 c117 c118 c119 c120 c120 c12'l cl22 c123 c124 c124 c125 c126 c127 c128 c129 c130 c'131 c133 ct34 c 135 c137 c138 c139 c 140 c142 c143 c144 c'|45 c147

203-4

1O-GRY 3.GRY 1-CLR 4-GRN 3-N/A 2.BLK 2.BLK 2-BLK 2.BLK 3-GRY 3-GRY 3.GRY 2-BLK 2.GRY 2-BLK 14-BLU 14-GRY 3-GRY 2-BLK 2-GRY 1O-GRY 8.GRY ,1-BLK 2.GRY 4.GRY 4.GRY 2.GRY 2.GRY 4.GRY 2.BLK 2-BLK 2-GRY 1-BLK 2O-BRN 22-GRN 25-GRY 31-BLU 16-GRY 2-GRY 2.GRY 1-GRY 2-GRY 2-GRY 2-BLK 3.GRY 2.BLK 8-GRY 2.BLK

Left side of engine compartment Leftside of engine Middleof engine Leftsideof engine Leftside of engine Middleot engine Middleof engine N,liddle of engine l\4iddle of engine Middleof engine Niliddle of engine N,,liddle of engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Rjghtside of enginecompartment Rightside of enginecompartment Middleof engine Mlddleof engine l\4iddle of engine Middleof engine Middleof engine [iliddleof engine lvliddleof engine Middleof engine Middleof engine l\4iddle of engine Middleol engine Middleof engine N,liddle of engine Rightside of engine Under right side of dash Behindrightkick panel Below right front tootrest Below right front footrest Below right lront footrest [iliddleof engine l\,liddleof engine Middleof engine Middleof engine L4iddle of engine Rightside of enginecompartment Middleof engine Rightside of enginecompartment Rightside of enginecompartment Rightside ot enginecompartment

Mainwireharness CKFsensor Engineoilpressure switch Alternator Alternator No.1 fuelinjector No.2luel injector No.3 fuel injector No.4fuelinjeclor IACvalve TP sensor MAPsensor IATsensor Powersteeringpressureswitch EVAPpurgecontrolsolenoidvalve Junctionconnector Junction connector Vehiclespeedsensor(VSS) Countershaft speedsensor Enginecoolanttemperature switch Distributor Distributor Enginecoolant temp.sending unit ECTsensor Primary HO2S(sensor1) Primary HO2S(sensor1) Back-uplightswitch Lock-upcontrolsolenoidvalves SecondaryHO2S(sensor2) Mainshaitspeedsensor Linearsolenoid Shiftcontrolsolenoid valves Startersolenoid Junction Connector Mainwireharness ECN4/PCM connectorB ECM/PCMconnectorC PCMconnectorD Knocksensor(KS) IACvalve VTECsolenoid valve VTECpressureswitch EGRcontrolsolenoidvalve Secondary gearshaftspeedsensor EGRvalve Drivepulleyspeedsensor CVTtransmission solenoid Drivenpulleyspeedsensor

USA Canada

ATT

USA

'2 (An\ '1

-1(cw) '2

Mft lNr) '1

'2 (Afil '2 (An)

'2 (Anl

Atf

t\4/T -1 (CVr) '1 (CVT)

.1 (CW) -1 (CVT) '1 (CVT)

.1(cw

\

-

Connector ol Terminal

Numberof Cavities/ Color

Connectsto

Location

Notos

EngineWireHarness(Dl6Y5,D16Y8engines):'99-'00modelsexceptD16Y5dM/T (cont'd) T101 T102

Leftsideof engine Right side oI engin€ compartment

Alternator tuse/relaybox Under-hood

G101

Rightsideot engine

Engineground.viaenginewirehamess

.1: D16Y5engine -2:D16Y8engine

'99;00 models except Dl6Y5 w/M/T:

I .

C134

-\-

\ c133 ctrg

c130

c112

cr0g l.tto

c123 ('21 ct13 cr38

Clilt

T102 Ctit3 cl17 G1a4

cltt c139 ct20 c1?9 cr$ C1'15

) . . c1l5 C124 cl25

c1z2 c121

203-5

Connectorldentificationand Wire HarnessRouting Connector Numberof or Cavities/ Terminal Color

Location

Connectsto

Notes

EngineWire Harness(Dl6Y7):'96 model c101 c102 c103 cl04 c104 c 105 c106 c107 c108 c109 c110 c111 c112 c 1 13 c114 c115 c116 c117 c118 c119 c120 c121 c122 c123 c124 cl24 c125 c126 c127 cl28 c129 c130 c131 cl32 nl2?

c134 al eR

T101 T102 G101

203-6

1O.GRY Leftsideof enginecompartment Mainwireharness 3-GRY Leftsideof engine CKFsensor Middleof engine Engineoil pressure switch 4.GRN Leftsideof engine Alternator 3-N/A Leflsideof engine Altemator 2.BLK Middleof engine No. 1 fuel injector 2-BLK Middleof engine No.2 fuelinjector 2-BLK Middleof engine No.3 fuelinjector 2-BLK Middleof engine No.4 fuelinjector 3.GRY Middleof engine IACvalve 3-GRY Middleof engine TP sensor 3.GRY Middleof engine MAPsensor 2-BLK Middleof engine IATsensor 2.GRY Middleof engine Powersteeringpressureswitch 2-BLK Middleof engine EVAPpurgecontrolsolenoidvalve 14-BLU Middleof engine Junction connector 14-GRY Middleof engine Junction connector 3.GRY Rightsideof enginecompartment Vehiclespeedsensor(VSS) 2.BLK Rightsideof enginecompartment Countershaft speedsensor 2-GRY Middleof engine Enginecoolanttemperature switch 1O-GRY Middleof engine Distributor 1-BLK Middleof engine Enginecoolanttemperature sendingunit 2-GRY Middleof engine ECTsensor 4.GRY Middleof engine PrimaryHO2S(sensor1) 2.GRY Middleof engine Back-uplightswitch 2-GRY Middleof engine Lock-upcontrolsolenoidvalves 4-GRY Middleof engine SecondaryHO2S(sensor2) 2.BLK Middleof engine Mainshaft speedsensor 2-BLK Middleof engine Linearsolenoid 2-GRY Middleof engine Shiftcontrolsolenoidvalves 1-BLK Rightsideof engine Startersolenoid 2O-BRN Underrightsideof dash JunctionConnector 22-GRN Behindrightkickpanel Mainwireharness 32.GRY Belowrightfrontfootrest ECM/PCM connector A 25-GRY Belowrightfrontfootrest PCMconnectorB 31-BLU Belowrightfrontfootrest ECM/PCM connector C 16.GRY Belowrightfrontfootrest ECM/PCM connector D Leftsideof enginecompartment Alternator Rightsideof enginecompartment Under-hood fuse/relaybox Rightside of englne

Engineground,viaenginewire narness

USA Canada

A/T

USA

Atf

M/T

Arl AtT A/T Afi

Aff

a

'96 model:

ENGINEWIREHAFNESS

c135 cl3a

c133 cl32

I

c106

cr07

c12Eci2s

c103

c121bros ."r. "irt cltr "\r,

) . .

203-7

Connectorldentificationand Wire HarnessRouting Connector Numberof or Cavities/ Terminal Color

Location

Connectsto

Noles

EngineWire Harness(Dl6Y7 engine):'97-'98models c101 c102 c103 c104 c104 c105 c106 c107 c108 c109 c110 c111 c113 c114 c115 c116 c118 c119 c'120 c121 c122 c124 c124 c125 c126 c127 c128 c129 cl30 c131 c132 c133 c134 c135 \, | 'tO

c141

1O-GRY 3-GRY 1.CLR 4.GRN 3.N/A 2-BLK 2-BLK 2-BLK 2-BLK 3.GRY 3-GRY 3-GRY 2-BLK 2.GRY 2-BLK 14.BLU 14.GRY 3.GRY 2-BLK 2-GRY lO.GRY 1-BLK 2-GRY 4.GRY 2.GRY 2-GRY 4.GRY 2.BLK 2.BLK 2-GRY 1-BLK 2O-BRN 22-GRN 32-GRY 25.GRY 31-BLU 16.GRY 8-GRY 2-BLK

Leflsideof enginecompartment Mainwirehamess Lettsideof engine CKFsensor Middleof engine Engineoil pressure switch Leftsideof engine Alternator Leflsideof engine Altemator Middleof engine No. 1 fuel injector Middleof engine No.2 fuel iniector Middleof engine No.3 fuel iniector Middleof engine No.4 fuelinjector Middleof engine IACvalve Middleof engine TP sensor Middleof engine MAPsensor Middleof engine IATsensor Middleof engine Powersteeringpressur€switch Middleof engine EVAPpurgecontrolsolenoidvalve Middleof engine Junctionconnector Middleof engine Junctionconnector Rightsideof enginecompartment Vehiclespeedsensor(VSS) Rightsideof onginecompartmont Countershaft speedsensor Middleof engine Enginecoolanttemperature switch Middleof engine Distributor Middleof engine Enginecoolanttemperatu re senorng unI Middleof engine ECTsensor Middleof engine PrimaryHO2S(sensor1) Middleof engine Back-uplightswitch Middleof engine Lock-upcontrolsolenoidvalves Middl€of engine SecondaryHO2S(sensor2) Middleof engine Mainshaftspeedsensor Middleof engine Linearsolenoid Middleof engine Shiftconirolsolenoidvalves Rightsideof engine Startersolenoid Underrightsidoof dash Junclionconnector Behindrightkickpanel Mainwireharness Belowrightfrontfootrest ECM/PCMconnectorA Belowrightfrontfootrest PCMconnector B Belowrightfrontfootrest ECM/PCMconnectorC Belowrightfrontfootrest ECM/PCMconnsctorD Leftsideof enginecompartment Mainwireharness Rightsideof enginecompartmsnt EVAPcontrolcanisterventshut VAIVE

T101 T102

Leftsideof engine Altemator Rightsideof enginecompartment Under-hood fuse/relaybox

G101

Rightsideof engine

203-8

Engineground,viaengine wtrenarness

USA Canada

USA

Nf

M/T A/T Atl

An AIT

NT

A/T

'97-'98models:

ENGINEWIREHARNESS cl30 cl3l T1

l'qii c101

c117

\ t

T10l

c119 c104

c120

cl09 c11s clt6 c102

22

cl21

203-9

Connectorldentificationand Wire HarnessRoutino Conneclor Numberof or Cavities/ Terminal Color

Location

Connectsto

Notes

EngineWire Harness(Dl6Y7 engine):'99100models c101 Q102

c103 c104 c104 c105 UIUO

c107 c108 c109 c110 c111 c112 c113 c114 c11s c116 c117 c118 c119 c120 c121 c122 c123 c124 cl24 c126 c\27 cl28 cl29 c 130 c131 c'133 c134 v tJc

1O-GRY 3.GRY 1-CLR 4-GRN 3.N/A 2-BLK 2.BTK 2.BLK 2-BLK 3-GRY 3-GRY 3-GRY 2.BLK 2-GRY 2-BLK 14-BLU 14.GRY 3-GRY 2.BLK 2-GRY 8-GRY 1.BLK

Leftsideof enginecompartment Leftsideof engine Middleof engine Leftsideof engine Leftsideof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleol engine Middleof engine Middleof engine Middleof engine Rightsideof enginecompartment Rightsideof enginecompartment Middleof engine Middleof engine Middleof engine

2-GRY 4-GRY 2-GRY 2-GRY 4.GRY 2-BLK 2-BLK 2-GRY 1-BLK 2O.BRN 22-GRN 25-GRY 31-BLU 16-GRY

Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Middleof engine Rightsideof engine Underrightsideof dash Behindrightkickpanel Belowrightfrontfootrest Belowrightfrontfootrest Belowrightfrontfootrest

Mainwireharness CKFsensor Engineoil pressure switch Alternator Altemator No.1 fuelinjector No.2 fuelinjector No.3 fuelinjector No.4 fuel injector IACvalve TP sensor MAPsensor IATsensor Powersteeringpressureswitch EVAPpurgecontrolsolenoidvalve Junction connector Junction connector Vehiclespeedsensor(VSS) Countershaft speedsensor Enginocoolanttemperature switch Distributor Enginecoolanttemperature sendingunit ECTsensor PrimaryHO2S(sensor1) Back-uplightswitch Lock-upcontrolsolenoidvalves H02S(sensor2) Secondary Mainshatt speedsensor Linearsolenoid Shificontrolsolenoidvalves Startersolenoid Junction connector Mainwireharness ECM/PCM connector B ECM/PCM connector C PCMconnector D

T101 r'l02

Leftsideof engine Alternator Rightsideof enginecompartment Under-hood fuse/relaybox

G101

Rightside of engine

203-10

Engineground,via enginewire narness

USA Canada

USA

AIT

Mrl Atf AN A/T AlT

Afi

I

'99-'00models:

WIREHARNCSS

cr10 ct 14

I I

c111

c112

c113

cl17

cr

1101

c10a 15

c102

ciz, cizs cizs cizz c121 c1o8 c1o7

203-11

Connectorldentificationand Wire HarnessRoutinq Connector Numberot oa Cavities/ Terminal Color

Location

Connectsto

Notes

EngineWire Harness(816A2engine):'99;00 models c101 c102 c103 c104 c104 cl05 c106 c107 c108 c110 c111 c112 c113

1O-GRY 2-GRY 1.CLR 4-GRN 3.N/A 2-BLK 2-BLK 2-BLK 2-BLK 3.GRY 3.GRY 2-BLK 2-GRY

Leftsideof enginecompartmenl Lettsideof engine Middleof engine Leftsideof engine Leftsideof engine Middleof engine Middleof engine Middleof engine Middleol engine Middleof engine Middleof engine Middleof engine Middleot engine

c114 c115 c116 cl17 c119 c120 c121

2-BLK 14-BLU 14-GRY 3-GRY 2-GRY 1O-GRY 1-BLK

c't22 c123 c124 c129 c130 c131 c133 c134 c137 c138

2-GRY 4-GRY 2-GRY 1-BLK 2O.BRN 22-GRN 25-GRY 31-BLU 2-GRY 2-GRY 1-GRY 2-GRY

Middleof engine EVAPpurgecontrolsolenoidvalve Middleof engine Junction connector Middleof engine Junction connector Rightsideof enginecompanment Vehiclespeedsensor(VSS) Middleot engine Enginecoolanttemperature switch Middleof engine Distributor Middleof engine Enginecoolanttemperature sendingunit Middleot engine ECTsensor Middleot engine PrimaryHO2S(sensor1) Middleof engine Back-uplightswitch Rightsideof engine Startersolenoid Underrightsideof dash Junction connector Behindrightkickpanel Mainwireharness Belowrighttrontfootrest ECMconnector B Belowrightfrontfootrest ECMconnector C Middleof engine KnockSensor(KS) Middleof engine IACvalve Middleof engine VTECsolenoid valve Middleof engine VTECpressureswitch

c140

Mainwireharness CKFsensor Engineoil pressure switch Alternator Altemator No.1 fuelinjector No.2 fuelinjector No.3 fuel injector No.4 fuelinjector TP sensor MAPsensor IATsensor pressure Powersteering switch

T101 T102

Lettsideof engine Alternator Rightsideof enginecompartment Under-hood fuse/relaybox

G101

Rightsideof engine

203-12

Engineground,via enginewire narness

USA Canada

USA

a

\

-

'99-'00models:

cl12 c117 T102

) . -

ClO,l

cti9

Tl0t c1:19 c115

c120

ct16

c129

cr37 c12l

c102

c1a2 cloE

)

<

l

203-13

Connectorldentificationand Wire HarnessRoutino Connector Number ot or Cavities Terminal

Location

Connectsto

EngineWireHarness(D1685) c101 cl02 c103 c104 c105 c106 c107 c108 c109 c110 c111 cl12 c113 cl15 cl16 c117 c118 c119 c120 c121 c122 c123 c124

1O-GRY 3-GRY 1-CLR 4-GRN 2.BLK 2-BLK 2-BLK 2-BLK 3-GRY 3-GRY 3.GRY 2-BLK 2.GRY 14-BLU 14-GRY 3-GRY z.BLK 2.GRY ,1O.GRY 1-BLK

c139 c140 c144 c150 c151 c152

2-GRY 4.GRY 2.GRY 4-GRY 2-BLK 2.BLK 2-GRY 1.BLK 2O-BRN 22-GRN 32-GRY 25-GRY 31-BLU 16-GRY 8-GRY .I-GBY 2-GRY 6.GRY 8-LTGRN 2-GRY 2.BLK

c153

3.N/A

wtlc u tzo

c127 c128 c129 c130 c131 c132 t/ IJO

c134 UIJC lJt.to

T101 7102 G101

203-14

Leftsideof enginecompartmenl Mainwireharness Leftsideot engine CKFsensor Middleof engine Engineoil pressure switch Leftsideof engine Alternator Middleof engine No.1 tuelinjector Middleof engine No.2 fuelinjector Middleof engine No.3 fuelinjector Middleof engine No.4 fuel injector Middleof engine IACvalve Middleof engine TP sensor Middleof engine MAPsensor Middleof engine IATsensor Middleof engine Powersteeringpressureswilch Middleof engine Junction connector Middleof engine Junction connector Rightsideof enginecompartment Vehiclespeedsensor(VSS) Rightsideof enginecompartment Countershaft speedsensor Middleof engine Enginecoolanttemperature switch Middleot engine Distributor Middleof engine Enginecoolanttemperature sendingunit Middleof engine EU I SenSOr Middleof engine PrimaryHO2S(sensor1) Middleof engine Lock-upcontrolsolenoidvalves Middleof engine SecondaryHO2S(sensor2) Middleof engine Mainshaft speedsensor Middleof engine Linearsolenoid Middleol engine Shiftcontrolsolenoidvalves Rightsideof engine Startersolenoid Underrightsideof dash Junction connector Behindrightkickpanel Mainwireharness Belowrightfrontfootrest PCMconnector A Belowrightfrontfootrest PCMconnector B Belowrightfrontfootrest PCMconnector C Belowrightfrontfootrest PCMconnector D Leftsideof enginecompartment Mainwireharness Middleof engine WEC solenoid valve Middleof engine VTECpressureswitch Middleof engine EGRvalve Leftsideof enginecompartment Mainwire harness Middleof engine Fueltemperature sensor Rightsideof enginecompartment Fuelpressure regulator shut-oft solenoid valve Rightsideof enginecompartment Fuelpressure sensor Leftsideof engine Alternator Rightsideof enginecompartment Under-hood fuse/relaybox Rightside of engine Engineground,via enginewire narness

Notes

-

c1lt clt1

cr

clts ftog ctto c113 T10t 16

12

I I EMIINEIVIRE HAFT{ESS

203-15

Connectorldentificationand Wire HarnessRoutino Connector Numberof or Cavities/ Terminal Color

Locatlon

Connectsto

Notes

EngineCompartment WireHarness c201 c202 c202 UZUJ

c204 c205 c206 c207 c208 c209 c210 c210 c212 c213 c214 c215

1O-BLU Leflsideof enginecompartment 6.GRY Leftsideof enginecompartment 2.GRY Leftsideol enginecompartment 4-GRY Leftsideof enginecompartment 2-GRN Behrnd frontbumper 2-BRN/VVHT Behindfrontbumper 3-GRY Leftsideof enginecompartment 1.BRN Behindfrontbumper Leftsideof enginecompartment q-u11 r Leftfrontof enginecompartment 2.GRY Behindfrontbumoer 1-BLU or BLK 2-GRY 3-BLK 3-GRY 8.GRY 2-GRY

G201 G202

'1 cruise control '2:: With Without cruisecontrol

203- 1 6

Behindfrontbumoer

Mainwire harness Mainwireharness Mainwire harness Cruisecontrolactuator Windshield washermotor Rearwindowwashermotor Leftfrontturnsignal/parking light Fronttog light Leftheadlight A,/Cwire harness Horn Horn

Rightfrontof enginecompartment Radiatorfan motor Rightsideot enginecompartment Rightheadlight Rightsideof enginecompartmont Righttrontturnsignal/parking light Rightsideof enginecompartment Mainwire harness Behindfrontbumoer Washerlevelswitch Rightsideof enginecompartment Bodyground,via engine compartment wire harness Leftsideot enginecompartment Bodyground,via engine wire harness comDartment

'1 "1

Optional '96-'97 models '98-'00 models

Canada '99r00 models

qroo

c207

ENGINEOOMPA WIREHARNESS ) < >

203-17

Connectorldentificationand Wire HarnessRoutino Connector Numberot or Cavities/ Terminal Color

Location

Connectsto

Notes

MainWire Harness(Left side of enginecompartmentbranch) c101 cI36 c136 c150 c201 c202 c202 c301 c302 c304 UOUO

c307 c310

1O.GRY 14-GRY 8.GRY 8.LTGRN 1O-BLU 6.GRY 2-GRY 5.GRY 2.NAT 3-N/A 1.BLK 1-BLK 2.ORN

Leftsideot enginecompartment Leftsideof enginecompartment Letlsideof enginecompartment Lettsideof enginecompaftment Leftsideof enginecompartment Leftsideof enginecompartment Leftsideof enginecompartment Leftsideof enginecompartment Leftsideof enginecompartment Leftsideof enginecompartment Leftsideof enginecompartment Leftsideof enginecompartment Leftsideof enginecompartment

Enginewireharness .1 Enginewirehamess 'r.q Enginewirehamess r5 Enginecompartment wireharness Enginecompartment wireharness Enginecompartment wireharness .4 Enginecompartment wireharness Windshield wipermotor Testtachomeierconnector Daytimerunninglightsresistor Canada Brakefluidlevelswitch(+) Brakefluidlevelswitch(-) LeftfrontABSwheelsensor ABS

.1: '96-98A/TwithD16Y5enoine '2: '96-98A,/TwithD16Y7/D16Y8 enoines .3: Withcruisecontrol *4:Withoutcruisecontrol .5: GX model

MainWireHarness(Rightsideof enginecompartment branch) c214 c351 wacl UJCJ

c356 c357 c358 UOCY

c360 c361

8-GRY 11.GRY 9.GRY 5-BRN 3-GRY 3-ORN 2.ORN 2-ORN 10-oRN 2.ORN 2-8RN

Rightsideof enginecompartment Enginecompartment wirehamess Rightsideof enginecompartment Under-hood fuse/relaybox Rightsideof enginecompartment Undef-hood tuse/relaybox Rightsideof enginecompartment Under-hood fuse/relaybox Rightsideof enginecompartment ELDunit Rightsideof enginecomparlment Under-hood ABSfuse/relaybox Rightsideot enginecompartment UnderhoodABSfuse/relaybox Rightsideot enginecompanment RightfrontABSwheelsensor Rightsideof enginecompartment ABSmodulator unit Rightsideof enginecompartment ABSpumpmotor Rightsideof enginecompartment EVAPcontrolcanistervent shutvalve

Bightsideof enginecompartment Bodyground,via main wtrenarness .1: '99-'00modelsexceptGX model G403

203-18

USA ABS ABS Al'D AE5

ABS -1 ABS

-

I

)

203-19

Connectorldentificationand Wire HarnessRouting Connector Numberol or Cavities/ Color Terminal

Location

Connectsto

Notes

MainWire Harness(Left side of dash and floor branch):'96-'97models Behindleftkickpanel Behindleftkickpanel Underleftsideot dash

Floorwire harness ABS Floorwire harness Lightflasherrelayconnector Optional (Security) 14-GRY Underleftsideof dash Cruisecontrolunit c404 A Canada 4-NAT DRLcontrolunitconnector Underleftsideof dash c405 B Canada DRLcontrolunitconnector 8-GRY Underleftsideof dash c406 -2 Roofwireharness 2-GRY Underlettsideot dash c407 '4 Moonroofwireharness 2-GRY Underleftsideof dash c407 Optional Frontfog lightconnector 1-BRN Underleftsideof dash c408 fuse/relay controlunit 1O-WHT Behindunder-dash box Integrated c409 AtT wire harness 12-GRY Aboveunder-dash fuse/relaybox Dashboard c410 wire harness 24-BLU Aboveunder-dash fuse/relaybox Dashboard c411 Aboveunder-dash fuse/relaybox SRSmainharness 3-YEL c412 16-GRY left Datalinkconnector Under sideof dash c413 M/T 4.BLU Underleftsideof dash Startercut relay c414 fuse/relaybox lgnition 7-BRN Aboveunder-dash switch c415 Securitystartercut relayconneclor Optional 6.NAT Underleft sideof dash c416 '5 Clutchswitch 2-N/A Underleft sideof dash c417 M/T 2-YEL Underleftsideof dash Clutchinterlockswitch c418 fuse/relay Under-dash fuse/relay box 18-GRN Behindunder-dash box c419 fuse/relay box Underdashfuse/relaybox 2O.GRN Behindunder-dash c420 fuse/relaybox Under-dash fuse/relaybox 18-GRN Behindunder-dash c421 fuse/relaybox iuse/relaybox Under-dash 7-GRN Frontof under-dash c422 Frontof under-dash fuse/relaybox Underdashfuse/relaybox w+4J 6-GRN Hornrelay 4-NAT Underleftsideof dash c424 Brakeswitch 4-WHT Underleftsideof dash c425 wiperswitch Combination 8.WHT Behindsteering columncover connector A wiperswitch Combination 6-WHT Behindsteering columncover c427 connectorB lightswilch 4-NAT Behindsteering Combination columncover c428 A connector lightswitch 7-NAT Behindsteering columncover Combination c429 connectorB Underleftsideof dash Cablereel c430 3-GRY Atl lnterlockcontrolunit c431 8-GRY Underlettsideot dash heatedoxygensensor 4.GRY Belowfrontconsole Secondary c432 '6 sub-narness AN A,/Tgearpositionswitch 14-GRY Belowfrontconsole c433 AN 2-GRY Belowfrontconsole Shiftlocksolenoid c434 4-GRY Belowfrontconsole Parkpin switchand A,/Tgear lJ+OC position Atf consolelight panel CVT 26-GRY Behindlettkick TCMconnectorA c437 CVT TCMconnectorB v+.to 22-GRY Behindleftkickpanel luse/relaybox 1-GRN Behindunder-dash fuse/relay box Under-dash c439 Leftkickpanel Bodyground,via mainwire G401 harness .2: Withoutmoonroof .5: M/T(withcruisecontrolor for D16Y5engine) .6: Withsecondaryheatedoxygensensor(HO2S) "4: Withmoonroof

c401 c402 c403

203-20

14-GRY 4-ORN 4-NAT

-

'96-'97models:

8

C

0

C428 C426

c425 C429 I C4271 C431

i,lAlN WIRE HARNESS

t

c421

UNDER.OASH FUSE/RELAY BOX c424

c420

203-21

Connectorldentificationand Wire HarnessRouting Connector Numberof or Cavities/ Terminal Color

Location

Connectsto

Notes

MainWire Harness(Left side of dash and tloor branch):'98 modeland all GX models c401 c402 c403 c404 c405 c406 Q407 c407 c407 c408 c409 c410 c411 c412 c413 c414 c415 c416 c417 c418 c419 c420 c421 c422 c423 c424 c425 c426 c427 c428 c429 c430 c431 c432

14-GRY 4.ORN 4-NAT 14-BLU 4-NAT 8.GRY 2.GRY 2-GRY 6.GRY 1-BRN 1O-WHT 12-GRY 24-BLU 3-YEL 16-GRY 5-BLK 7-BRN 6-NAT 2.N/A 2.YEL 18.GRN 2O.GRN 18-GRN 7.GRN 6.GRN 5-BLK 4.WHT 8-WHT 6-WHT 4-NAT 7-NAT 3.GRY 8-GRY 4-GRY

Behindlettkickpanel Behindlettkickpanel Underlettsideof dash Underlettsideol dash Underlettsideof dash Underleftsideof dash Underlettsideof dash Underlettsideot dash Underleftsideof dash Underl€ftsideof dash Behindundsr-dash tuse/rBlay box Aboveunder-dash tuse/relaybox Aboveunder-dash tuse/relaybox Aboveunder-dash fuse/relaybox Underlettsideof dash relaybox Under-dash Aboveunder-dash tuse/relaybox Underleftsideof dash Underlettsideof dash Underleftsideof dash Behindunder-dash tuse/relaybox Behindunder-dash tuse/relaybox Behindunder-dash tuse/relaybox Frontof under-dash tuse/relaybox Frontol under-dash fuss/relaybox Under-dash relaybox Underlettsideot dash Behindsteering columncover Behindsteering columncover Behindsteering columncover Behindsteeringcolumncover Und€rleftsideof dash Underlettsideof dash Belowfrontconsole

c433 c434 c435

14-GRY 2.GRY 4.GRY

Belowfrontconsole Belowfrontconsole Belowfrontconsole

c437 c438 c439 c447 c448

26.GRY 22-GRY 1.GRN 4-N/A 26-GRY

Behindleftkickpanel Behindleftkickpanel Behindunder-dash fuse/relaybox Underlettsideof dash Behindleftkickpanel

Floorwireharness ABS Floorwireharness (Security) Optional Lighttlasherrelayconnector Cruisecontrolunit DRLcontrolunitconnectorA Canada DRLcontrolunitconnectorB Canada ,2 Bootwireharnsss ,4 Moonroofwireharness '7 Boofwireharness Frontfog lightconnector Optional Integrated controlunit AIf Dashboard wireharness wireharness Dashboard SRSmainharness Datalinkconnector Mtf Starlercut rslay lgnitionswitch cut relayconnector Oplional Securitystrarter '5 Clutchswitch M/T Clutchinterlockswitch Under-dash fuse/relaybox Under-dash fuse/relaybox fuso/rolaybox Under-dash UndeFdash fuse/relaybox Under-dash fuse/relaybox Hornrelay Brakeswitch wiperswitchconnectorA Combination wipersrvitchconnectorB Combinalion lightswitchconnectorA Combinalion Combinalion lighiswilchconnectorB Cablereel AN lnterlockcontrolunil '6 heatedoxygensensor Secondary suD-narness An A,/Tgearpositionswitch A,/T Shiftlocksolenoid Alf Parkpin switchandA/T gear position consolelight CW TCMconnectorA CVT TCMconnectorB '7 Underdashlus€/relaybox '7 Fuelinjectorrelay '7 Injectorcontrolmodule

Left kick panel

Bodyground,via mainwireharness

G401

-2: Withoutmoonroof (exceptGX) -4: Withmoonroof '5: M/T(withcruisecontrolor for D16Y5engine) '6: Withsecondary heatedoxygensensor(H02S) t7: GX model

203-22

s

t

'98 modelsand all GX models: c417 c425 c408 c418

MAINWIRE HARNESS

c413 c401

) e c438 OT

c448

c439(Gx) C412

o

C411 C4l0

c421

-----nn-----

) - j UNOER-DASH FUSE/BELAY BOX

203-23

Connectorldentificationand Wire HarnessRouting Connector Numberot ol Terminal

Cavlties/ Color

Location

Connectsto

Notes

MainWire Harness(Leftside of dash and floor branch):'9$00 modelsexceptGX model

c42A c429 c430 c431 c432

2O.GRY 4.ORN 4.NAT 14.BLU 4-NAT 8-GRY 6.GRY 6.GRY 1-BRN 1o-wHT 12-GRY 24-BLU 3.YEL 16-GRY 5.BLK 7-BRN 6.NAT 2-N/A 2-YEL 18.GRN 2O.GRN 18.GRN 7.GRN 6.GRN 5-BLK 4.WHT 8.WHT 6-WHT 4-NAT 7.NAT 3.GRY 8.GRY 4-GRY

Behindleftkickpanel Behindleftkickpanel Underleftsideof dash UnderlettsideoI dash Underlettsideof dash Underletl sideol dash UnderlettsideoI dash UnderletlsideoI dash Underleflsidsol dash Behindunder-dash fuse/relaybox Aboveunder-dash fuse/relaybox fuse/relaybox Aboveunder-dash Aboveunder-dash fuse/relaybox Underlettsideot dash Under-dash relaybox Aboveunder-dash fuse/relaybox Underleftsideof dash Underleftsideot dash Underlettsideof dash Behindunder-dash fuse/relay box Behindunder-dash fuss/relaybox Behindunder-dash fuse/relaybox Frontof under-dash fuse/relaybox Frontof under-dash fuse/relaybox relaybox Under-dash Underloftsideot dash Bohindsteeringcolumncov6r B6hindstesringcolumncover Behindsteering columncover Behindsteeringcolumncover Underlettsideot dash Underlettsideot dash Belowfronlconsole

c433 c434 c435

14-GRY 2-GFY 4-GRY

Belowfrontconsole Belowfrontconsole Belowfrontconsole

c447 c448 c450 c451

22.GRN 2-GRY 3-GRY 18-GRY

Underlettsideot dash Underlettsideof dash Underleftsideof dash Behindlettkickpanel

c401 c402 c403 c404 c405 c406 c407 c407 c408 c409 c4t0 Q411 c412 c413 c414 c415 c416 c417 c418 c419 c420 c42'l c423 c424 c425 c426

G401

Leftkickpanel

'2: Withoutmoonroof "4: Withmoonroof '5: M/T(withcruisecontrolor for D16Y5engine) '6: Withsecondary heatedoxygensensor(HO2S)

203-24

Floorwireharness Floorwireharness (Sscurity) Lightflasherrelayconnector Cruisecontrolunil DRLcontrolunitconnectorA DRLcontrolunitconn€ctor B Roofwireharness Moonroofwireharnsss Fronttog lightconnector Intsgratgd controlunit Dashboard wireharn€ss Dashboard wireharness SRSmainharness Datalinkconnector Startercut relay lgnitionswitch S€curitystartercut relayconnector Clutchswitch Clulchinterlockswitch Under-dash fuse/relaybox Under-dash tuse/ralaybox Under-dash tuse/ralaybox Under-dash fuse/relaybox fuse/relaybox Under-dash Hornrelay Brakeswitch A wiperswitchconnector Combination Combination wiperswitchconn€ctorB A Combination lightswitchconnector lightswitchconn€ctorB Combination Cablereel lnterlockcontrolunit heatedoxygensensor Secondary sub-narnsss A/T gsarpositionswitch Shittlocksolenoid Parkpin switchandA/T gear positionconsololight Securitycontrolunitconnactor SecurityLEDconnector Valetswitchconnector(Security) Keylessdoorlockcontrolunit Bodyground,via mainwire narness

ABS Optional Canada Canada

Optional AN

Mrl Optional '5 M/T

AN '6

An Atf Atf Optional Optional Optional MKoyloss

\

5'

'99-'00modelsexceptGXmodel:

MAINWIRE HARNESS

c435

) t

c432

c433 C434

c421

-rr3OOO

FUSE/RELAY BOX

) - :

203-25

Connectorldentificationand Wire HarnessRouting Connector Numberol Cavities,/ or Terminal Color

Connectsto

Location

MainWire Harness(Rightside of dash branch) c131 c440 c441 c442 c443 c444 c445 c452 G402

22.GRN 16-BLU 2.BLU 2O-WHT or GRN 7-BRN 22-ORN 26-ORN 32.GRY

Behindrightkickpanel Undermiddleof dash Underrightsideof dash Underrightsideof dash

Enginewireharness A Heatersub-harness Servicecheckconnector Junctionconnector

Underrightsideof dash Behindrightkickpanel Behindrightkickpanel Belowrightfrontfootrest

PGM-Flmainrelay A ABScontrolunitconnector ABScontrolunitconnectorB A ECM/PCM connector

Rightkickpanel

Bodyground,via mainwire namess

.1: '99100modelsexceotD l6Y5withM/TandD1685 MAINWIREHARNESS

203-26

Notes

)

Connector Numberof Cavities/ or Color Terminal

\

Location

Connectsto

Notes

12-GRY 24-BLU 2O.GRN 16-BLU 5-GRY 3-GRY 2O-WHT or BLU 5-YEL 5-GRN 14.GRN 16.8LU 13-BLU 1O-GRY 5-N/A 16-GRN

fuse/relaybox Aboveunder-dash fuse/relaybox Aboveunder-dash fuse/relaybox Frontof under-dash fuse/relaybox Belowunder-dash Leftof steeringwheel Leftof steeringwheel Belowgauges

Mainwireharness Mainwireharness Underdashfuse/relaybox Floorwireharness Cruisemainswitch controller Dashlightsbrightness connector Junction

Afi

Leftsideof dash Lettsideof dash Leftsideof dash Leflsideof dash Leftsideof dash Centerot dash Csnterof dash Behindmiddleof dash

SRS .1

c515 c516

20-N/A 22.GRN

Behindmiddleol dash Behindmiddleof dash

F connector Gaugeassembly E connector Gaugeassembly GaugeassemblyconnectorA GaugeassemblyconnectorB GaugeassemblyconnectorC Hazardwarningswitch Rearwindowdefoggerswitch B (Keyless Audiounitconnector receivercircuit) Audiounil Securitycontrolunit

c518

16-GRY 5.N/A

Behindmiddleof dash Behindmiddleof dash

AudiounitconnectorA SecurityLEDconnector

c520

2-BLK 5-ORN

Behindmiddleof dash Leftsideof dash

Accessorypoweroutlet GaugeassemblyconnectorD

Undermiddleof dash

wire Bodyground,via dashboard narness

WireHarness Dashboard c410 c411 c501 c503 TJJUC UCUO (Jcu/

c508 cs09 c510 tJctl

c512 uc t.t

c514

.'

G501

AN

.2 -2 Optional -2 .2 Optional ("2 Canada) ABS

'1: Withshift-upindicatoror cruisecontrolsystem('96-'97models) .2: '96198models .3: '99-'00models Withcruisecontrolsystem('98-'00models) c5o9csrr c510 c515 13 1c517

DISHAOABDw|RE IIARNESS

)

- ,

203-27

Connectorldentificationand Wire HarnessRouting Connector Numberot or Cavities/ Terminal Color

Location

Connectsto

Notes

Floor Wire Harness (Coupe/Hatchback) c401 c401 c402 c503

Behindleftkickpanel Behindleftkickpanel Behindleftkickpanel Belowunder-dash fuse/relaybox Behindunder-dash fuse/relaybox Behindunder-dash fuse/relay box Driveasdoor Driver's door Passenger's door Passenger's door Belowcenterconsole Lettsideof floor LeftB-pillar Belowleftsideof rearseat Leftquarterpanel Leftquarterpanel Leftquarterpanel Topof fueltank Topof fueltank Belowrightsideof rearseat RightB-pillar Topot fueltank

trco.'

14.GRY 2O-GRY 4-ORN 16-BLU 16.GRN 8-GRN 25-GRY 2-NAT 25-GRY 2-NAT 1-WHT 2-GRY 1-WHT 2.ORN 14-GRY 2O-GRY 2-BRN 3.BRN 2.BRN 2-ORN 1-WHT 6-GRY

vcov

1O-GRY Leftsideof dash

v)az ucco ucc/ trcc/ u556 uccv UCOU

c561 u30z UCOZ UCOJ

c564 u5b5 ucoo uco/

Leftkickpanel G552 Leftsideof tloor -1: Withpowerwindows "4: '96-98models .2: Withoutoowerwindows .5: '99-'00models .3: Withfueltankoressure sensor

203-28

Mainwireharness Mainwireharness Mainwireharness Dashboard wireharness Underdashfuse/relaybox fuse/relaybox Under-dash Driver's doorwireharness Drivefsdoorwireharness Passenger's doorwire harness Passenger's doorwire harness Parkingbrakeswitch Driver'sseatbeltswitch Driver'sdoorswitch LeftrearABSwheelsensor Rearwire harness Rearwireharness Rearwireharness Fueltankunit Fuelpump RightrearABSwheelsensor Passenger's doorswitch pressure Fueltank sensor sub-harness Powermirrorswitch Bodyground.via floorwire hamess Bodyground,via floorwire hamess

"5 ABS

"1 '1 '2

AEIJ

'4 '5

'tI'D

-3

ll-

)

\

c558

C555

FLOORWIREHARNESS

) t

c402

)

qo1

-tt

203-29

Connectorldentificationand Wire HarnessRouting Connector ol

Terminal

Numberof Cavities/ Color

Location

Connectsto

Notes

FloorWire Harness(Sedan) c401 c401 c402 c503 c551 trccz vcco ucc/ \,CC/

u55b UCDY UCOU

c561 lJcoz

ucoz UCOZ 1'-coJ lJ50.t

ucoc ucoo uco/ ucoo

c569 c570 c571 wJt z TJC/J

v3/c

14-GRY 2O-GRY 4.ORN 16-GRN 16-GRN 8-GRN 25-GRY 2-NAT 25-GRY 2-NAT

Behindleftkickpanel Behindleftkickpanel Behindleftkickpanel Belowunder-dash fuse/relay box Behindunder-dash fuse/relay box Behindunder-dash fuse/relay box Driver's door Driver's door Passenger's door Passengels door

1-WHT 2.GRY 1-WHT 2-ORN 8-GRY 16.GRY 20-GRY 2-BRN 3.BRN 2-BRN 2-OBN 1-WHT 6-GRY

Belowcenterconsole Leftsideof floor RightB-pillar Belowleftsideof rearseat LeftC-pillar LeftC-pillar LeftC-pillar LeftC-pillar Topof fueltank Topol fueltank Belowrightsideof rearseat LeftB-pillar Topof tueltank

1O-GRY 6-BLU 6.BLU '1-WHT

Leftsideof dash RightB-pillar LeftB-pillar Leftquarterpanel Rightquarterpanel Behindleftsideof rearseat

1.WHT 6-GRN

Leftkickpanel Leftsideof floor .1: Withpowerwindows -3: '96-'98 exceptGX .2: Withoutpowerwindows .4: '99-'00models modelsexceptGX G551 tftcz

203-30

Mainwireharness Mainwireharness Mainwireharness Dashboard wireharness Under-dash fuse/relay box Under-dash fuse/relay box Driver's doorwireharness Driver's doorwireharness Frontpassengeas doorwire harness Frontpassenger's doorwire harness Parkingbrakeswitch Driver's seatbeltswitch Frontpassenger's doorswitch LeftrearABSwheelsensor Rearwireharness Rearwireharness Rearwireharness Bearwireharness Fueltankunit Fuelpump RightrearABSwheelsensor Driver's doorswitch Fueltankpressure sensorsubharness Powermirrorswitch Rightreardoorwireharness Lettreardoorwireharness Leftreardoorswitch Rightreardoorswitch Fuelsub-harness Bodyground,viafloorwirehamess Bodyground,viafloorwirehamess

-3, GX "4

ABS

"1 '1

ABS GX o

-3, GX exceptGX exceptGX ABS exceptGX

GX

\

I.r Sedan:

FLq)N w|REHARNESS cs64

)

)

-

c565

l

,

203-31

Connectorldentificationand Wire HarnessRouting Connectol Numberof or Cavlties/ Terminal Color

Location

Connectsto

Notes

RearWire Harness(Hatchback) lJ50z

ucoz LJco.t

c603 c604 UOUC TJOUO

c607 c608

14.GRY 2O-GRY 2.BRN 2-GRY 6.GRY 6.GRY 2-GRY 6-BLU 2-BRN

G601 .1: '96-'98models .l: '99-'00models

203-32

Lettquarterpanel Leftquarterpanel Leftquarterpanel Lettquarlerpanel Leftsideof cargoarea Rightsideof cargoarea Rightquarterpanel Rightquarterpanel Rightquarterpanel

Floorwire harness Floorwireharness Floorwireharness Leftrearspeaker Leftoutertaillight Rightoutertaillight Rightrearspeaker Hatchwiroharness Hatchwire harness

Middleof cargoarea

Bodyground,via rearwireharness

"1

,2 Optional

Optional

I \

)

Connector Numberot or Cavities/ Color Terminal

\

Locatlon

Connectsto

Notes

RearWire Harness(Coupe:'96-'00models/Sedan:'96-'98models) UCOZ

w?oz

c562 tJJO.t

c603 c604 TJOUC TJOUO

c609 c610 c611 c612 c613 c614 c615 c616 uot/

G601

) r l

8.GRY 14-GRY 2O-GRY 2-BRN 2-GRY 4-GRY 4-GRY 2-GRY 1-BLK 2.BRN 2.GRY 1-BLK 4.GRY 2.BRN 2.BTK 2-BRN 4.GRY

Leftquarterpanel Leftquarterpanel Leftquarterpanel Leftquarterpanel Leftquarterpanel Leftsideof trunk Rightsideof trunk Rightquarterpanel Leftsideof rearwindow Middleof rearshelf Middleof rearshelf Rightsideof rearwindow Leftsideof trunklid Middleof trunklid Middleot trunklid Middleof trunklid Rightsideof trunklid

Floorwireharness Floorwireharness Floorwireharness Floorwireharness Leftrearspeaker Leftoutertaillight Righloutertaillight Rightrearspeaker Rearwindowdefogger(+) Highmountbrakelight Trunklight Rearwindowdefogger(-) Leftinnertaillight Leftlicenseplatelight Trunklatchswitch Rightlicenseplatelighl Rightinnertaillight

Middleof trunk

Bodyground,via rearwirehamess

GX "1

'96r98 Optional Optional

.1: CouDe:'96198models,Sedan:'96-98 modelsexceptGX '2: CouDe:'99r00 models EEARWIREHARNESS

)

-:'

203-33

Connectorldentificationand Wire HarnessRoutinq Connector ol Terminal

Numberof Cavities/ Color

Location

Connectsto

Notes

RearWireHarness(Sedan):'99-'00models c562

cs62 c563 c603 c604 UOUS

c609 c610 c611 c612 c613 c614 c615 c618 c619 c620 c621 c622 c623

2O.GRY 8.GRY 2-BRN 2.GRY 4-GRY 4-GRY 2-GRY 'I-BLK 2.BRN 2.GRY 1-BLK 3-GRY 2.GRY 2.BLK 2-GRY 3.GRY 2-GRY 2.GRY 2-GRY 2-GRY 1-BRN 1.BRN

G601 G602

Leftquarterpanel Leftquarterpanel Leftquarterpanel Leftquarterpanel Leftsideof trunk Rightsideot trunk Bightquarterpanel Lettsideof rearwindow Middleof rearshelf Middleof rearshelf Rightsideol rearwindow Lettsideot trunklid Middleot trunklid Middleot trunklid Middleof trunklid RightsideoI trunklid Leftsideof trunk Rightsideof trunk LettsidsoI lrunklid Rightsideof trunklid Mlddleol rearshell Mlddleol rearshelf Middleof trunk Mlddle ot rear shelf

Floorwireharn€ss Floorwir€harness Floorwireharness Leftr€arspgaker Lettbrakelighvouter taillight Rightbrakelighuouter taillight Rightrsarspeaker Rearwindowdetogger(+) Highmountbrakelight Trunklight Rearwindowdefogger(-) Lettback-uplighl Lettlicenseplatelight Trunklatchswitch Rightlicenseplatelight Rightback-uplight Lettrearturnsignallight Bightrearturnsignallight Leflinnertaillight Rightinnertaillight Windowantsnnacoilconnector C Windowantennacoilconnector A Bodyground,via rearwirehamess Bodyground,via rearwirehamess

exceptGX GX GX Optional

Optional GX

GX

exceptGX excsptGX exceptGX

RearWindowDefoggerWire(exceptGX) c831 c832 c883

2-BRN '1-BLK '1-BLK

Middleof r€arshelt Leltsideot rearwindow Rightsideof rearwindow

WindowantennacoilconnectorB Rearwindowdefogger(+) Rearwindowdefogger(-)

c610 c619 c605 c617 ca21 c616 c615 G601(GX)or G602(excepiGX)

c614

c562 Cs63 C609 c603 REARWIRE HAFNESS

203-34

canl c62,.

c6t3 c6m

G6O1(excrpt GX)

ll..

)

\

Connector Numberot Cavities/ or Color Terminal

Connectsto

Location

Noteg

Driver'sDoorWireHarness(Coupe/Hatchback) .E
ucco

c632 c633 c634 c635 c636 c638 c639 c640

25.GRY 2-NAT 2-GRY 4.GRY 4-GRY 2-GRY 12-GRY 3.GRY 8.BLI(WHT 12-GRY

Driver'sdoor Driver's door Driver'sdoor Driver'sdoor door Driver's Drivefsdoor Driver'sdoor Driver'sdoor Insideof leftpowermirror door Driver's

Floorwire harness Floorwire harness Leftfrontdoorspeaker Driver'soow€rwindowmotor Driver'sdoorlockactuator Tweeter Powerwindowmasterswitch Driver'sdoorlockswitch Leftoowermirror Powerdoorlockcontrolunit

"1

'2 Coupe Coupe Coupe Coupe Coupe Coupe Coupo(-3)

.1: Withoowerwindows *2: Withoutpowerwindows .5' nii;gO:Sl'emodelswithpowerdoorlocks,'99-'OO modelswithpowerdoorlocksbut withoutkeylessentry

)

OOORWIREHARNESS DRTVER'S

203.3s

Connectorldentificationand Wire HarnessRoutinq Connector Numberof or CavitieV Terminal Color

Location

Connectsto

Notes

Floorwireharness Floorwire harness Rightfrontdoorspeaker powsrwindow Frontpassenger's molor Frontpass€nger's doorlock actualor powerwindow Frontpassenger's switch Rightpowerminor Tweeter

.1

Passenger'sDoor Wire Harness(Coupe/Hatchback) 25-GRY 2-NAT 2-GRY 2-GRY

Passenger's door Passenger's door Passenger's door Passenger's door

c654

2.GRY

Passenger's door

uocc

5-NAT

Passenger's door

ucc/ ucc/ lJOCZ r,ro3J

c656

8.BLKMHT Insideof rightpowermirror uoc/ Z-(lHY Passenger's door .1: Withpowerwindows .2: Withoutoowerwindows

PASSENGER'S DOORWIREHARNESS

203-36

Coupe Coupe Coupe Coupe Coupe

)

\ :

Connector Numberof Cavltles/ or Terminal Color

Location

Connectsto

Notes

Driver'sDoorWireHarness(Sedan) c632 c633 c634 c636

25-GRY 2.NAT 2-GRY 4.GRY 4-GRY 16-GRY

Driver's door Driver's door Driver'sdoor Driver'sdoor Driveisdoor Driveisdoor

c637

l.BRN

Driver'sdoor

t cco ucco

c638 c639 c640

Driver'sdoor 3.GRY S.BLKAVHT Insideol leftpowermirror 12.GRY Driver'sdoor

Floorwirehamess Floorwireharness Lefttrontdoorspeaker Driver'spowerwindowmotor Driver'sdoorlockactuator Powerwindowmasterswitch connectorA Powerwindowmasterswitch connectorB Driver'sdoorlockswitch Leftpowermirror Powerdoorlockcontrolunit

'1 ",1 .,1

'1

'3

'1 : WithDowerwindows '2: Withoutoowerwindows '3: All '96198modelswithpowerdoorlocks,'99-00 modelswithpowerdoorlocksbutwithoutkeylessentry

c638 )

-',

) t 203-37

Gonnectorldentificationand Wire HarnessRoutino Connector Numberot or Cavities/ Terminal Color

Location

Connectsto

Notes

Floorwireharness Floorwireharness Rightfrontdoorspeaker powerwindow Frontpassenger's motor Frontpassenger's doorlock actuator power Frontpassenger's windowswitch Rightpowermirror

'1 '2

FrontPassenger's DoorWireHarness(Sedan)

UOCJ

25-GRY 2-NAT 2-GRY 2-GRY

Passenger's door Passenger's door Passengeis door Passenger's door

t/OC+

2-GRY

Passenger's door

L,occ

5-NAT

Passenger's door

uoco

8.BLKMHT

t-J5/

c652

*1: Withoowerwindows '2: Withoutpowerwindows

FRONTPASSENGER'S

DOORWIREHARNESS

203-38

Insideof rightpowermirror

'1 '1 '1 "1

)

\

Connector Numberof or Cavities,/ Color Terminal

Location

Connectsto

Notes

Left RearDoorWire Harness(Sedan) c571 UOOZ uoo.t

c664

6-BLU 2.GRY 5-NAT 2-GRY

LeftB-pillar Leftreardoor Leftreardoor Leftreardoor

Floorwireharness Left rearDowerwindowmotor Lett rearoowerwindowswitch Leftreardoorlockactuator

Right RearDoorWire Harness(Sedan) c570 wotl uo/.t

c674

6-BLU 2.GRY 5.NAT 2.GRY

RightB-pillar Rightreardoor Rightreardoor Rightreardoor

Floorwireharness Rightrearpowerwindowmotor Rightrearpowerwindowswitch Riohtreardoorlockactuator

Left Rear Door:

) 0 LEFT REARDOOR WIREHARNESS

RightRearDoor:

RIGHTREAR DOOR WIRE HARNESS

)

203-39

Connectorldentificationand Wire HarnessRouting Connector Numberof or Cavities/ Terminal Color

Location

Connectsto

Notes

Roof Wire Harness(Coupe/Hatchback) c407 c407 c702 c719

2-GRY 6-GRY 2-WHT 1-WHT

Underlettsideof dash Underleftsideof dash Middleof roof Frontof roof

Mainwire harness Mainwireharness Ceilinglight Spotlight

.2

'l : '96-'98models '2: '99-'00models

RoolWireHarness(Sedan) c407 c407 c702 c703 c719

2-GRY 6-GRY 1-WHT 1-WHT 1-WHT

Underleftsideof dash Underleftsideof dash Middleof roof Middleof roof Frontof roof

Mainwireharn€ss Mainwirehamess Ceilinglight(Power) Ceilinglight(Ground) Spotlight

"1

-2, GX .2

.1: '96-'98models .2: '99100models

MoonroofWireHarness(Coupe/Sedanl c407 c407 c712 c713 c713 c715 u/ to

c717 c718 c719

2.GRY 6-GRY 3-BRN or GRN 6-BRN 5-GRY 6.8RN 5-GRY 4-GRY 3-WHT 2-BRN 4-GRY 1-WHT

*1:'96'97 models '2: '98models "3: '99r00models

203-40

Underleftsideof dash Mainwire harness Underleftsideof dash Mainwire harness Frontof under-dash fuse/relaybox Undsr-dash fuse/relaybox Leftsideof dashboardbracket Leftsideof dashboardbracket Leftsideof dashboardbracket Lettsideof dashboardbracket Leftof steeringwheel Middleof roof Rearof roof R€arof root Frontof roof

Moonroofopenrelay Moonrootopenrelay Moonroolclosarelay Moonroofcloserelay Moonrootswitch Ceilinglight Moonroofmotor Open/close andtilucloseswitches Spotlight

.3 '1 '2,.3 -1 '2,'3

'2,.3

I \.,

,-i'

)

)

-

203-41

Gonnectorldentificationand Wire HarnessRoutinq Connector Numberof ot Terminal

Cavities/ Color

Location

Connectsto

HatchWire Harness(Hatchback) c607 c608 c763 c764 c765 u/oo u /oo

6-BLU 2-BRN 2.N/A 1-BLK 2.GRY 2.GRY 4-NAT 2.GRY

\r/ol

Rightquarterpanel Rightquarterpanel Rearof roof Rightsideof hatchlid Middleof hatchlid Middleof hatchlid Middleof hatchlid Middleof hatchlid

Rearwireharness Rearwireharness Highmountbrakelight Rearwindowdefogger(+) Rightlicenselight Lettlicenselight Rearwindowwipermotor Hatchlatchswitch

Middleof hatchlid

Bodyground,via tailgatewire namess

RearWindowDeloggerGroundWire (Hatchback) c771 G771

203-42

'1-BLK

Leftsideof hatchlid

Rearwindowdefogger(-)

Lettsideof hatchlid

BodygrouM,via rearwindow defoggerwire

Notes

\

\

)

\

'96-'97models:

REARWINDOWDEFOGGER WIRE GROUND

WIREHARNESS

) . t l

TCH WIRE HARNESS

)

203-43

Connectorldentificationand Wire HarnessRouting Connectol Numberof Cavities/ or Color Terminal

Connectsto

Location

Notes

'96-'98models HeaterSub-harnessA: c440 c722 c723 c724 c725 c726 c727

16-BLU 7.GRN 2O.GRY 3-GRY 2.NAT 4-BRN 4.GRN

Undermiddleof dash Behindmiddleot dash Behindfrontconsole Behindglovebox Belowrightsideof dash Behindglovebox Behindglovebox

Mainwireharness Modecontrolmotor B Heatersub-harness A,/Cthermostat Blowermotor Blowermotorresistor controlmotor Recirculation

'96;98 models HeaterSub-harnessBt

c743

2O-GRY 6-BRN 14-GRN

Behindfrontconsole Behindmiddleof dash Behindmiddleof dash

A Heatersub-harness Heaterfan switch Heatercontrolpanel

A HEATER SUB.HARNESS

1"t-

u. B SUB.HARNESS HEATER

203-44 l\-

)

._'

Connectol o1 Terminal

Numberot Cavltles/ Color

Connectsto

Location

Notes

A: '99-'00models HeaterSub-harness c440 c722 c723 c724 wlzc

c726 c727 c728 c729 c730

16.8LU 7-GRN 24-BLU 3-GRY 2-NAT 3-NAT 4.GRN 1-BRN 5-GRN 4-BRN

Undermiddleof dash Behindmiddleof dash Behindfrontconsole Behindglovebox Belowrightsideof dash Behindglovebox Behindglovebox Behindfrontconsole Behindglovebox Behindglovebox

Mainwire harness Modecontrolmotor B Heatersub-harness A'lCthermostat Blowermotor Powertransistor controlmotor Recirculation B Heatersub-harness Air mixcontrolmotor Blowermotorhighrelay

B: '99-'00models HeaterSub-harness c723 c728 c742 c743

24.BLU 1-BRN 8-GRY 2O.BLK

Behindfrontconsole Behindfrontconsole Behindmiddleof dash Behindmiddleof dash

A Heatersub-harness A Heatersub-harness panel conn€ctorA Heatercontrol HeatercontroloanelconnectorB

A HEATER SUB.HARNESS

HEATERSUB-HARNESSB

203-45

Connectorldentificationand Wire HarnessRouting Connector Numberot or Cavities/ Terminal Color

Location

Connectsto

Notes

lrrr-

Rear HeatedOxygen Sensor Sub-harness c782

4-GRY 4-GRY

Belowfrontconsole Belowfrontconsole

Mainwireharness Secondary heatedoxvoen -- sensor (Secondaiy HO2S)

FuelTankPressureSensorSensorSub-harness ucot'

c792 c793

6.GRY 3-BRN 2.BRN

Topof fueltank Leftsideof fueltank Leftsideof fueltank

Floorwire harness Fueltankpressure sensor EVAPtwo wayvalve

\y,.-

FUELTANKPRESSURE SENSOR SUB-TiARNESS

203-46

!'t

l--i

Connector ol Terminal

Numberot Cavities/ Color

Location

Connectsto

Notes

SRSMainHarness c412 c801 c803

3-YEL 2.YEL 2.YEL

c804 c805 c806 c807

2-YEL 2-YEL 2.YEL 18-YEL

G801

fuse/relaybox Aboveunder-dash Underleftsideof dash fuse/ Rightsideof under-dash relaybox Underleftsideof dash Undercenterof dash Middleof floor Middleof floor

Mainwireharness fuse/relaybox Under-dash Memoryerasesignal(MES) connector Cablereel Passenger's airbagassembly Dummyresistor connector SRSunit

Middleof floor

Bodyground,via SRS mainhamess

USA Canada

SRS MAIN HARNESS

Lg

203-47

Connectorldentificationand Wire HarnessRouting Connector ot Terminal

Numborot Cavities

Location

Connectsto

Notes

t

(GX) FuelSub-Harness uc/c

c682 c683 c684

6-GRN 2-GRY 3-N/A 2-GRY

Behindleft sideof rearseal Leftsideof trunk Middleot trunk Middleof trunk

Floorwire harness Fuellank internalsolenoidvalve Fuellank oressuresensor Fueltanktemoerature sensor

FUELSUB.HARNESS

t

203-48