Civic EJ6, EJ7, EJ8 (96-00) Service Manual

I NTRODUCTI ON
How to Use Thi s Manual

Thi s manual cont ai ns i nf ormat i on f or t he 1996
-
2000 Cl Vl C. l t i s
di vi ded i nt o 24 sect i ons. The f i rst page of each sect i on i s marked
wi t h a bl ack t ab t hat l i nes up wi t h i t s correspondi ng t humb i ndex
t ab on t hi s page and t he back cover. You can qui ckl Y f i nd t he f i rst
page of each sect i on wi t hout l ooki ng t hrough a t ul l t abl e ol con_
t ent s. The symbol s
pri nt ed at t he t op corner of each
page can al so
be used as a qui ck ref erence syst em.
Each sect i on i ncl udesl
1. A t abl e of cont ent s, or an expl oded vi ew i ndex showi ng:
. Part s di sassembl Y sequence.
. Bol t t orques and t hread si zes.
. Page ref erences t o descri pt aons i n t ext
2. Di sassembl y/ assembl y
procedures and t ool s.
3. I nspect i on.
4. Test i ng/ t roubl eshoot i ng.
5. Repai r .
6. Adj ust ment s.
Special Information
!@
Indicates a sttong possibility of sover.
perconal iniurY
or loss ol lite if in3tructions are not followd.
GAUTION: Indicaiqs a
possibility ot plsonal 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.
NOTE: Gi ves hel pf ul i nf ormat i on.
CAUTfON: Detaifed descriptions ol standard workshop
p.oceduro3.
safoty
principles and servico operations are not included. Pleaso
not e t hat t hi s manual cont ai n3 wet ni ngs and caut i ons agai nst
some sp6ci f i c sGrvi c met hods whi ch coul d 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 evaY conceivablg
way, nor could HONDA invqstigato all 3uch way3. AnYono using
sgrvi ce
procedures or l ool s, whet hei or nol rGcommendod bY
HONDA, must srtisty hifisetf thoroughlylhat nohher
pefsonal sefety
nor vehiclc satsty will be
reopardi2ed.
Al l i nt ormat i on cont ai ned i n t hi s manual i s based on t he l at est prod
uct i nf ormat i on avai l abl e at t he t i me oI pri nt i ng We reserve t he
ri ght t o make changes at any t i me wi t hout not i ce No
part of t hi s
publ i cat i on may be reproduced, st ored i n ret ri eval syst em, or t rans'
mi t t ed, i n any f orm by any means, el ect roni c, mechani cal ,
phot o
copyi ng, recordi ng, or ot herwi se, wi t hout t he
pri or wri t t en
permi s-
si on of t he
publ i sher. Thi s i ncl udes t ext , f i gures and t abl es.
*Transaxl e
ds
Fi rst Edi t i on 8/ 99 1848
Pages
Al l Ri ght Reserved
HONOA MOTOR CO., LTD.
Sorvico Publication Offico
As sect i ons wi t h
*
i ncl ude SRS component s;
sDeci al
precaut i ons are l equi red when servl cl ng
*El ect r i cal
't
*SRS
SRS
l l
General Informati on
Ghassi s and Pai nt Codes . . . . . . . . . . . . . . . . . . . . . . . 1-2
l denti fi cati on Number Locati ons ......... 1-32
Warni ng/Cauti on Label Locati ons ....... 1-33
Under-hood Emi ssi ons
Control Label .......... ....... 1-37
Lift and Support Points
Li f t and Saf et y St ands . . . . . . . . . . . . . . . . . . . . . . . 1-41
Fl oor Jack . . . . . . . . . . . . . . . . . . . . . . . 1-42
Towi ng . . . . . . . . . 1-43
U.S. 1996 Model
(2-door
Hatchback)
Vehicle ldentif ication Number
2HG EJ 6 32* TH I 00001
Manufacturel, Make and
Type of Vehicle
2HG: HONDA OF CANADA
MFG. , I NC.
HONDA Passenger
vehi cl e
Li ne, Body and Engi ne Type
EJ6: CIVIC 3-door/D16Y7
Body Type and Transmission Type
3: Hatchbacl ds-speed
Ma nua I
4: Hatchbacl (4' speed
Automati c
Chassi s and Pai nt Godes
Vehicle Grade
2i CX
4i DX
6: DX
o a
Chck Digit
Model Year
T: 1996
Factory Code
H: Al l i st on Pl ant , Ont ari o, Canada
Destinations
Serial Numbel
Vehicle ldentification Number
and Federal Motor Vehicle
Safety Standard Certif ication
O '
Paint Code
COLOR
GY. l 6P
D16Y7 1500001
Engi ne Type
D 16Y7: 1600 SOHC 16-vatves
Sequenti al Mul ti port
Fuel -i nj ected Engi ne
Seri al Number
44RA: 4-speed Automati c Transmi ssi on
S40 : s-speed Manual Transmi ssi on
GY, 16P
NH-503P
NH.583M
R-97
Mi dori Green Pearl
Granada Bl ack Pearl
New Vogue S
j l ver
l vl etal l i c
Roma Red
1- 2
o e
1HG EJ652
*
T L 000001
1HG: HONDA OF AMERI CA
t\4FG., l NC.
HONDA Passenger vehi cl e
MFG. , I NC.
HONDA Passenger vehi cl e
Line, Body and Engins Type
EJ6: CIVIC 4' door/D' 16Y7
EJ8: CIVIC 4-door/D16Yo
Body Type and Transmission TyPe
5: Sedan/5-speed Manual
7: LX with IVC
Check Di gi t
Model Year
T: 1996
L: East Li berty, Ohi o Pl ant, U.S.A.
H: Al l i ston Pl ant, Ontari o, Canada
O O
U.S. 1996 Model
(4-door
Sedanl
Safety Standard Gertification
O O
Paint Code
COLOR
8.73M
D16Y7
-
' ]500001
D16Y7: 1600 SOHC 16-val ves Sequenti al
Mul ti port Fuel -i nj ected Engi ne
Dl 6Y8: 1600 SOHC VTEC 16-val ves Sequenti al
U. S. A : D16Y7, Dl 6Yg 1500001-
I ransmlssron
Transmission Type
A4RA: 4 speed Automati c Transmi ssi on
S40 : s-soeed Manual Transmi ssi on
A4RA
(U.S.A.):
5000001-
S40 {JAPAN)
: 1000001-
Cycl one Bl ue Metal l i c
Cypress Green Pearl
Frost Whi te
New Vogue Si l ver Metal l i c
l sl and Coral Pearl
B-73M
G-82P
NH-538
NH-503P
NH-583M
R,95P
l a
1 - 3
Chassis and Paint Codes
U.S. 1996 Model
(2-door
Coupe)
Safety Standard Certification
I HG EJ 6 12* T L 000001
Line. Body and Engine Type
EJ6: CIVIC 2-doorD16Y7
EJ7: Cl Vl C 2-doorD l 6Y5
EJ8: Cl Vl C2-door/D16Y8
Check Digit
Model Year
T: 1996
L: East Li berty, Ohi o Ptant, U.S.A.
1:Coupe/s-speed
Ma nua I
2: Coupe/4-speed Automati c, CVT
4: DX with A'lC, HX with A,,/C, EX
5: DX wi th ABS and A,/C, EX wi th ABS
o f
Engi ne Number
Engi ne Type
D16Y5: 1600 SOHC WEC E 16-vatves
D 16Y7: 1600 SOHC 16-vatves
D16Y8: 1600 SOHC WEC 16-vatves
Seri al Number
JAPAN: Dl 6Y5
-
130000' 1-
U.S.A. : D16Y7, D16YB
-
150000' 1-
Paint Code
o a
COLOR
G.82P
1300001
A4RA | 4-speed Automati c Transmi ssi on
S40 : s- speed Manual Tr ansmi ssi on
M4VA I Conti nuousl y Vari abte
Transmi ssi on (CVT)
A4RA : 5000001-
S40 : 1000001-
M4VA: 1000001-
NH-503P
NH-538
NH 583M
R-81
R-95P
Cypress Green Pearl
Frost Whi te
Mi l ano Red
1- 4
O O
O O
CANADA 1996 Model
(2-door
Hatchback)
2HG EJ 632* TH 000001
Manulacturer, Make and
Type of Vehicle
2HGr HONDA OF CANADA
HONDA Passenger
vehi cl e
Li ne, Body and Engi no Type
EJ6: Cl vl C3-door/D16Y7
3: Hatchbacl d5-speed
Manua I
4: Hatchbacl d4-speed
Automati c
Vehicle Grade
2, Cx
3: CX-G
O O
Check Digit
Model Yeal
T: 1996
Factory Code
sel i al Number
and Canadian Motor Vehicle
Paint Code
COLOR
GY.l 6P
D 16Y7
-
D16Y7: 1600 SOHC' 16-val ves
Sequenti al Mul ti Port
A4RA: 4-sDeed Automati c Transmi ssi on
S40 : 5-sDeed Manual Transmi ssi on
Mi dori Green Pearl
Roma Red
GY-16P
NH-503P
NH-583M
R-97
0 0
1 - 5
CANADA 1996 Model
(4-door
Sedanl
Chassi s and Pai nt Codes
l H G
r-'
Manufacturer, Make and
Tvpe oI Vehicle
I HG: HONDA OF AMERTCA
MFG, , I NC.
HONDA Passenger
vehi cl e
Line, Body and Engine Type
EJ6: CIVIC 4-door/D t 6y7
6: Sedan/4-speed
Automatl c
Engi ne Number
Engi ne Type
D16Y7r 1600 SOHC
' 16-vatves
Sequenti al N4ul ti port
Seri al Number
Transmission
Number
Paint Code
!)
3 * T 5 800001
D16Y7
-[
170000' l
I
Vehicle Grade
3: LX
4: LX wi th ABS
5: LX with ABS and A,/C
6: EX
7: EX wi th ABS
Check Digit
Model Year
Tr 1996
Factory Code
Seri al Number
COLOR
8.73M
O '
5000001
t
A4RA
T
Transmi ssi on
Type
Seri al Number
A4RA: 5000001-
S40 : 1000001-
B 73M
G-82P
NH-503P
NH,538
NH.583M
Cycl one Bl ue Met al l i c
Cypress Green Pearl
Frost Whi te
New Vogue Si l ver Met al l i c
1- 6
)
1HG EJ 6 12. TL 000001
Line, Body and Engine TYPe
EJ8: Cl Vl C2' door/D16Y8
Body Type and Transmission TYPe
Vehicle Glade
2: DX, Si
3: Si wi th ABS
5: DX wi th ABS
Check Digit
Model Yeal
T: 1996
L: East Li berty, Ohi o Pl ant, U S.A.
O O
CANADA
1996 Model
(2-door
CouPe)
and Ganadian Motor Vehicle
Saf ety Standard Certif ication
D16Y7: 1600 SOHC l 6-val ves
Sequenti al
Mul ti Port
D16Y8: 1600 SOHC Vl EC 16-val ves
Seri al Number
Paint Code
Engine Number
O '
COLOR
NH-538
A4RA
-
5000001
S40 : 5-speed Manual Transmi ssi on
Cypress Green Pearl
Frost Whi te
Mi l ano Red
G-82P
NH-503P
NH-538
NH 583M
R-81
R 95P
O O
1-7
Chassis
and Paint
Codes
Vehicl Grade
2: CX
4: DX
Check Digit
Model Year
V: 1997
Factory Code
Destinations
Seri al Numbel
Vehicle ldentification
Number
Salety Standard Certification
U.S. 1997 Model
(2-door
Hatchback)
Number
2HG EJ6 32* VH 1 00001
Manufac-turer,
Make and
Type of Vehicle
MFG. , I NC.
HONDA Passenger
vehi cl e
Lins, Eody and Engine Type
EJ6: Cl vtC3-door/D16y7
Body Typo and Transmission
Type
Manual
4: Hatchbacl v4-speed
Automati c
O O
O O
Paint Code
COLOR
NH-583M
D16Y7: 1600 SOHC 16-vatves
Sequenti al
Mul ti port
Fuel -i ni ected
Engi ne
A4RA: 4-speed Automati c Transmi ssi on
B4RAt 4-speed Automati c Transmi sston
44RA: 6000001-
B4RA: 6000001-
S40 : 1000001-
NH,5O3P
N H-583N4
PB-7 4P
R-97
Dark Amethyst Pearl
Roma Red
1- 8
O O
0 0
U.S. 1997 Model
(4-door
Sedanl
JHM EJ6 52* VS 000001
Manulaqturer.
Make and
-t
Type of Vehicle
HONDA MOTOR CO.,
LTD.
HONDA Passenger
vehi cl e
HONDA OF AMERICA
MFG. , I NC,
HONDA Passenger
vehi cl e
HONDA OF CANADA
MFG. , I NC,
HONDA Passenger
vehi cl e
Li ne, Body and Engi ne TYPe
EJ8: Cl Vl C 4-door/D 16Y8
Eody Type and Transmission TYPe
5: Sedan/S-sPeed
Manual
6: Sedan/4-speed
Automattc
7: LX wi th A/C
Check Digit
Model Yeal
V: 1997
Factory Code
L: East Li beny, Ohi o Pl ant, U S.A
S: Suzuka Pl ant, Mi e Prefecture, Japan
Seri al Numbel
Transmission
Number
Transmission TYpe
A4RA: 4-speed Automati cTransmi ssi on
B4RA : 4-speed Automati c Transmi ssi on
M4RA: 4-speed Automati c Transmi ssron
S4O : s-speed Manual Transmi ssi on
Seri al Number
A4RA
(U.S.A.) : 6000001^
B4RA
(U.S.A.) : 6000001"
M4RA
(JAPAN): 2000001-
S40 {JAPAN)
: 1000001-
Paint Code
COLOR
8.73M
t o
Vehicle Grade
2i DX
4: EX
D16Y7 2300001
Mul ti port Fuel -i ni ected
Engi ne
D16Y8: 1600 SOHC WEC 16-val ves Sequentral
Mul ti Port Fuel -i nj ected Engi ne
JAPAN: D16Y7, D16Y8
-
2300001-
U.S.A. : D16Y7, D16Y8
-
2500001-
A4RA
-
6000001
Cypress Green Pearl
Frost Whi te
l nza Red
B 73M
G-82P
NH,538
NH-503P
NH.583M
R-96P
O O
1- 9
U.S. 1997 Model
(2-door
Coupe)
Number
O O
Engine Number
Engi ne Typ6
D16Y5: 1600 SOHC VTEC-E 16 vatves
D16Y7: 1600 SOHC 16-val ves
Dl 6Y8r 1600 SOHC VTEC 16 vatves
Seri al Number
JAPAN: D16Y5 2300001-
U.S.A. : Dl 6Y7, Dl 6Y8
-
2500001-
Paint Code
D16Y5
-
2300001
e o
COLOR
Li no. Eody and Engi ne Typ6
EJ6: Cl Vl C2-door/D16y7
EJ7: Cl Vl C2-door/Dl 6Yb
Check Digit
Model Yeal
V: 1997
84RA : 4-speed Automati c Transmi ssron
S40 :s-speed Manual Transmi ssi on
M4VA: Conti nuousl y Vari abl e
A4RA : 6000001-
B4RA: 6000001-
S40 : 1000001-
M4VA: 2000001-
G.82P
NH-503P
NH,538
NH-583M
R-8r
Cypress Green Pearl
Frost Whi te
Mi l ano Red
1 - 1 0
G.82P
l o
2HG EJ6 32* VH 000001
e o
CANADA
1997 Model
(2-door Hatchbackl
Number
-[
Manufacturer,
Make and
]
Type oI Vehicle
MFG. , I NC.
HONDA Passenger
vehi cl e
Body Type and Transmission
TYPe
3: Hatchbacl d5-sPeed
l vl an ual
4: Hatchbacl V4-speed
Automati c
Vehi cl e Grade
2i CX
3: CX-G
a o
Check Digit
Model Yeal
V: 1997
Factory Code
Sel i al Number
Numbel
and Canadian
Motor Vehicle
Paint Code
COLOR
NH.5O3P
D16Y7:
' 1600
SOHC 16-val ves
Sequenti al Mul ti Pon
Fuel -i ni ected Engi ne
A4RA: 4-speed Automati c Transmi ssi on
B4RA: 4-speed Automati c
Transmi ssi on
S4O : s- speed Manual Tr ansmi ssi on
A4RA: 6000001-
84RA; 6000001-
S40 : 1000001'
Dark Amethyst Pearl
Roma Red
NH-503P
NH.583M
PB.1 4P
R-97
e o
1- 11
Chassis
and Paint
Godes
CANADA 1997 Modet
(4-door
Sedan)
Number
1- 12
]l
0 0
Paint Code
COLOR
B.73M
e a
l HG EJ6 53
* V
L 800ool
EJ6: Cl vtC4-door/D16y7
Body Typ and Transmission Type
5; Sedan/5-speed
Manual
4: LX wi th ABS
5; LX with ABS and A,/C
7: EX wi th ABS
8: EX with ABS and Ay'C
Ch.ck Digit
Model Year
V:
'1997
D16Y7 2750001
1600 SOHC 16-vatves
,A4RA: 4-speed Automati c Transmi ssi on
B4RA: 4 speed Automati c Transmi ssi on
44RA: 6000001-
B4RA: 6000001-
S40 : 1000001-
B-73M
NH-503P
NH-538
NH-583M
Cypress Green Pearl
Frost Whi te
E-
1HG EJ 6 12* VL 800001
EJ6: Cl vl C2-door/D16Y7
Body Type and Tr8nsmission
TYP8
Vehicle Grado
2: DX, Si
3: Si wi th ABS
5: DX wi th ABS
6: DX with ABS and l'lc
7: Si wi th ABS and A,/C
Check Digit
Model Ysar
V: 1997
a o
CANADA
1997 Model
(2-door
CouPel
Number
Safety Standard
Certification
Engine Number
Engins Typs
D16Y8: l 600 SOHC VTEC 16-val ves
Fuel -i ni ected
Engi ne
Seri al Number
Paint Code
COLOR
NH-538
D16Y7 2750001
0 0
A4RA
-
6000001
A4RA: 4-speed Automati c
Transmi ssi on
B4RA: 4-speed Automati c
Transmi ssi on
S4O : s-speed Manual Transmi ssi on
A4RA: 6000001-
B4RA: 6000001*
S40 : 1000001-
Cypress Green Pearl
Frost Whi te
Mi l ano Red
G-82P
NH-503P
NH-538
NH-583M
R- 81
a o
1 - 1 3
Ghassi s and Pai nt
Godes
Vehicle Grade
2i CX
4: DX
Check Digit
Model Year
W: 1998
Factory Code
Hr Al l i ston Pl ant, Ontari o, Canada
Deslinations
Serial Numbet
U.S. 1998 Model
(2-door
Hatchback)
Vehicle ldenti{ication
Number
2HG EJ6 3 2. WH 1 00001
Manufactursr, Mak and
Type of Vehicle
MFG., INC.
HONDA Passenger
vehi cl e
Lin, Body and Engine Type
EJ6: Cl vl C3-door/D16y7
Manual
4: Hatchbacl/4-speed
Automati c
0 a
0 0
Paint Code
COLOR
NH.583M
D16Y7:
' 1600
SOHC l 6-val ves
B4RA: 4-speed Automati c Transmi ssi on
NH-592P
NH-583M
PB,74P
R-97
Fl amenco Bl ack Pearl
Dark Amethyst Pearl
Roma Red
1- 14
a o
JHM EJ6 52* WS OOOOO1
e o
U.S. 1998 Model
(4' door
Sedan)
Type of Vehicle
JHM: HONDA MOTOR CO.
LTD.
HONDA Passenger
vehi cl e
HONDA OF AMERICA
MFG. , I NC.
HONDA Passenger
vehi cl e
HONDA OF CANADA
MFG, , I NC,
HONDA Passenger
vehi cl e
TYPe
5: Sedan/5-sPeed
Manual
6r Sedan/4-speed
Automati c
Engine Number
Engine Type
D 16Y7:
D l 6Y8:
Serial Number
JAPAN: D16Y7. D16Y8
-
3300001-
U.S.A : D16Y7, D16Y8
-
3500001^
Paint Code
COLOR
B-73M
3300001
1600 SOHC 16-val ves Sequenti al
Mul ti port Fuel ' i nj ected Engi ne
1600 SOHC VTEC 16-val ves Sequenti al
r o
vehicle Grade
2i DX
4: EX
7: LX wi th IVC
Check Digit
Model Yeal
W: 1998
Factory Code
L: East Li berty, Ohi o Pl ant, U S.A
H: Al l i ston Pl ant. Ontari o, Canada
Seri al Number
000001: JAPAN, U.S.A.
500001:CANADA
Sa{ety Standard Certif ication
D16Y7
B4RA 700000' I
84RA : 4-speed Automati c Transmi ssi on
M4RA: 4-speed Automati c Transmi ssi on
S4O :s-speed Manual Transmi ssi on
B4RA
(U.S.A.) : 7000001-
M4RA
(JAPAN): 3000001"
S40
(JAPAN) : 1000001-
Cypress Green Pearl
Taffeta Whi te
l nza Red Pearl
B-73M
G 82P
NH-578
NH-592P
NH-583M
R-96P
e o
1 - 1 5
Ghassis and Paint
Codes
U.S. 1998 Model
(2,door
Coupel
Safety Standard
Certification
l HG EJ 6 12* WL 000001
Line, Body and Enginc Type
EJ7: Cl VtC2-door/D16ys
Type
5: EX wi th ABS and IVC
Chock Digir
Model Year
W: 1998
L: East Li berty, Ohi o
ptant.
U.S.A.
e a
Engine
Number
Engine Type
D16Y5: 1600 SOHC WEC-E l 6,vatves
Sequenti al
Mul ti port
Fuel -i nj ected
Engi ne
Fuel -i n.i ected
Engi ne
Dl 6Y8: 1600 SOHC WEC 16-vatves
Sequenti al
Mul ti port
Fuel -i nj ected
Engi ne
Serial Number
JAPAN: D16Y5
-
3300OOt-
U.S.A. : D16Y7, D' 16y8
-
3500001-
Paint Code
D16Y5
3300001
0 a
COLOR
G.82P
S40 : s- speedManual Tr ansmi ssi on
M4VA: Conti nuousl y
Vari abl e
B4RA: 7000001-
S40 : 1000001-
M4VA: 4000001-
NH-592P
NH-578
NH-583M
R-81
Cypress Green Pearl
Taffeta White
New Vogue Si l ver Metal ti c
Mi l ano Red
1 - 1 6
a a
2HG EJ6 32+WH 000001
t r O
CANADA
1998 Model
(2-door Hatchback)
Number
Manulacturet,
Make and
Type of Vehicle
HONDA Passenger
vehi cl e
TYPe
Man ual
Automati c
Vehicle Grade
2t CX
3 : C X G
Check Digit
Model Year
W: 1998
Factory Code
Seri al Number
Vehicle
ldentification
Number
and Canadian
Motor Vehicle
Saf ety Standard
Certif ication
Paint Code
COLOR
NH.592P
1600 SOHC 16-val ves
Sequenti al
l vl ul ti Port
Fuel - i nj ect ed Engi ne
84RA: 7000001-
S40 : 1000001'
Dark Amethyst Pearl
Boma Red
NH-592P
NH-583M
PB-7 4P
R-97
1- 17
CANADA
1998 Model (4-door
Sedanl
Number
Chassis
and Paint
Codes
2HG
.I
Manufacturer,
Make and
Type of Vehicte
I
]
MFG, , I NC.
HONDA
passenger
l
vehi cl e
JHM: HONDA | \4OTOR
CO.,
I
r_rD
]
HONDA
passenger
I
vehi ct e
I
Type
5: Sedan/5 speed Manual
Pl ant, Ontari o, Canada
Pl ant, N4i e Prefecture,
Japan
900001
A O
H
6: Sedan/4-speed
Automati c
Vehicle Grade
0: EX
3: LX
4: LX Wi th ABS
5: LX with ABS and A"/C
7: EX wi th ABS
8: EX with ABS and A"/C
Check Di gi t
Model Year
W: 1998
Fastory Code
H: Al l i st on
S: Suzuka
Seri al Number
0 0
800001^: JAPAN
900001-: CANADA
Number
PaintCode
COLOR
8.73M
Fuel -i nj ected
Engi ne
3750001- : U. S. A.
370000' l -:
JAPAN
B4RA
{U.S.A,) : 700000.1-
M4RA (JAPAN):
3000001-
S40 (JAPAN)
:
' tOO0OO1-
B-73M
NH-592P
NH-578
NH-583M
Cycl one Bl ue f\4etal l i c
Cypress Green Pearl
Fl amenco
Bl ack
pearl
Taffeta White
1 - 1 8
a o
Vehicle ldentif ication Numbel
1 HG EJ 6 1 2 * W
MFG, , I NC,
HONDA Passenger
vehi cl e
EJ6: CIVIC 2 door/D16Y7
EJ8: CIVIC 2 dootD16Y8
Vehi cl e Grade
2: DX, Si
3: Si wi th ABS
5: DX wi th ABS
6: DX wi th ABS and A,/C
7: Si wi th ABS and A,/C
Check Digit
Model Year
W: 1998
L: Easr Li berty, Ohi o Pl ant, U.S A.
a a
CANADA
1998 Model
(2-door
CouPe)
safety Standard Certification
Engi ne Number
Engi ne Type
D' 16Y7: 1600 SOHC 16-val ves
Sequenti al l vl ul ti Port
Fuel i ni ected Engi ne
D16Y8: 1600 SOHC VTEC 16-val ves
Sequenti al Mul ti Pon
Fuel -i ni ected Engi ne
Serial Numbel
D16Y7: 375000' l '
D16Y8: 3780001-
t i o
Paint Code
COLOR
NH-578
D16Y7
B4RA: 4-speed Automati c Transmi ssron
84RA: 7000001-
S40 : 1000001-
Cypress Green Pearl
Taffeta White
Mi l ano Red
G-82P
NH-592P
NH-578
NH-583M
R,81
1 - 1 9
l i l l l l *l l
t a
U.S. 1999
Model
(2-door
Hatchbackl
Vehicle ldentif ication
Number
2 H G E J 6 3 2 * X H 1 0 0 0 0 1
Manufacturer,
Make and
T
Type of Vehicte
MFG. . t NC.
I
HONDA
passenger
I
vehi cl e
- _ r
EJ6: CI VI C3- door / Dt 6y7
Type
3: Hatchback/b-speed
Ma nua I
4: Hatchbacl /4-speed
Automati c
Chassis
and Paint
Codes
Vehicle Grade
2: CX
4: DX
a a
Check Digit
Model Year
X: 1999
Factory Code
Destinations
Seri al Numbel
Vehicle
ldentification
Number
and Federal
Motor Vehicle
Safety Standard
Certification
1 a
Paint Code
COLOR
NH-583M
D' 16Y7: 1600 SOHC l 6-vatves
Sequenti al Mul ti pon
Fuel -i nj ected
Engi ne
B4RA: 8000001-
S40 | 1000001-
NH.592P
NH.583M
PB-14P
R-97
Fl amenco BIack Pearl
Dark Amethyst Pearl
Roma Red
1-20
a a
r o
U.S. 1999 Model
(4' door
Sedan)
J HM EJ 652* XS
000001
-f
Manufacturel ,
Make and
Type ol vehicle
Vehicle Grade
' l :
DX-V
2t DX
4: EX
7: LX
HONDA Passenger
vehi cl e
HONDA OF CANADA
MFG. , I NC.
HONDA Passenger
vehi cl e
HONDA MOTOR CO.,
LTD.
HONDA Passenger
vehi cl e
Line. Body and Engine TYPe
EJ6: CIVIC 4 door/D16Y7
EJ8: Cl Vl C4- door / D16Y8
5: Sedan/S-speed
Manual
6: Sedan/4-speed
Automati c
r o
Check Digit
Model Year
X: 1999
Factory Code
L: East Li berty, Ohi o Pl ant, U S.A
Serial Numbel
000001:JAPAN. U.S.A.
500001:CANADA
Paint Code
COLOR
NH-s78
Engine Type
D,]6Y7:
D16Y8:
1600 SOHC 16-val ves Sequenti al
U.S.A : D16Y7. D16Y8- 4500001-
B4RA
(U.S.A.) : 8000001-
M4RA {JAPAN):4000001-
S40
(JAPAN) :
' 1000001-
l ced Teal Pearl
Cl over Green Pearl
Taffeta White
l nza Red Pearl
BG. 41P
NH-578
NH-592P
NH.583M
R-96P
t a
1-21
Chassis
and Paint
Codes
Vehi cl e Grade
2: DX, HX
4: EX
5: EX Wi th ABS, Si
Check Digit
Model Year
X: 1999
Factory Code
Seri al Number
Number
U.S. 1999 Model
(2-door
Coupe)
Number
1HG EJ 6 12* XL 000001
Manutacturer,
Make and
Type of Vehicle
' 1HG:
HONDA OF AMERTCA
MFG. , I NC.
HONDA Passenger
vehi cl e
EJ7: Cl Vl C2- door / D16y5
EM1: CIVIC 2-doorl B' 1642
1: Coupe/s-speed
Manual
Engine Number
Engine Type
81642:' 1600
DOHC VTEC 16 vatves
Fuel -i nj ected
Engi ne
Dl 6Y5: 1600 SOHC WEC-E 16 vatves
Fuel i nj ected Engi ne
D16Y7: 1600 SOHC t6-vatves
Fuel ,i nj ected
Engi ne
D16Y8: 1600 SOHC VTEC 16-vatves
Serial Numbel
JAPAN: 816A2, Dl 6Y5
-
4300001-
U.S.A. : D16Y7, D16Y8
-
4SO000t -
Paint Code
a a
t a
COLOR
S40, S4C: 5-speed Manuat Transmi ssi on
M4VA : Conti nuousl y Vari abl e
B4RA : 8000001-
S40, S4C: 1000001-
M4VA : 5000001-
B-95P
G-95P
NH-592P
NH-578
NH-583M
R-97
El ectron Bl ue Pearl
Cl over Green Pearl
Taffeta White
Roma Red
1-22
I
NH.592P
e a
CANADA 1999 Model
(2-door
Hatchback)
2HG EJ 632* XH 000001
-rl
Type of Vehicl
l \4FG., l NC.
HONDA Passenger
vehi cl e
3r Hatchbacl ds speed
Ma nua I
4r Hatchbacl d4-speed
Automati c
Vehi cl e Grade
2: CX
3: DX
r o
Check Di gi t
Model Year
X: 1999
Factory Code
Serial Number
Paint Code
COLOR
NH.592P
Engr ne Nu
Engi ne Type
B4RA 8000001
T t
Transmission Type
Seri al Number
84RA: 800000' l -
S40 : 1000001-
Dark Amethyst Pearl
Roma Red
NH-592P
NH-583M
PB.74P
R,97
t a
1-23
Ghassis and Paint Codes
Vehicle Grade
0: EX
3: LX
4: LX wi th ABS
5: LX wi th ABS and l VC
7: EX wi th ABS
8: EX with ABS and Ay'C
Ch6ck Digit
Model Year
X: 1999
Factory Code
CANADA 1999 Model
(4-door
Sedanl
J HM EJ 653* XS 8OOOO1
Manufaclurer, Make and
Type ot Vehicle
JHM: HONDA MOTOR CO.,
LTD.
HONDA Passenger
vehi cl e
MFG. , I NC.
HONDA Passenger
vehi cl e
5: Sedan/s-speed Manual
6: Sedan/4-speed
Automati c
e o
r o
S: Suzuka
H: Al l i ston
Seri al Number
Pl ant, Mi e Prefecture, Japan
Pl ant, Ontari o, Canada
800001: JAPAN
900001: CANADA
Paint Gode
COLOR
BG. 41P
D16Y7 4700001
Engi ne Type
D 16Y7: 1600 SOHC 16-val ves Sequenti al
JAPAN: D16Y7
-
4700001-
U.S.A : D' 16Y7
-
4750001-
M4RA: 4-speed Automati c Transmi ssi on
S40 rs-speed Manual Transmi ssi on
B4RA
(U.S.A.)
: 8000001-
M4RA
(JAPAN);
400000' l -
S40
(JAPAN)
: 1000001-
BG. 41P
G-95P
NH-578
NH-592P
NH-583M
R-97
l ced Teal Pearl
Cl over Green Pearl
Taffeta White
Roma Red
1-24
t a
CANADA 1999 Model
(2-door
CouPel
1HG EJ 6 12* XL 800001
Type of Vehicle
l HGr HONDA OF AMERI CA
I
MFG, , I NC.
HONDA Passenger
vehi cl e
Line. Body and Engine TyPe
- i
EMl r CIVIC 2' doorl B' 16,42
1:Coupe/s-speed
M an ual
2: Coupe/4-speed
Automati c
Vehicle Grade
2: DX, Si
4: Si R
5: Si R wi th ABS
6: DX with ABS and IVC
7: Si wi th ABS and A,,/C
Check Digit
Model Year
X: 1999
Factory Code
Seri al Numbel
Engine Number
D16Y7
Engine Type
816,42: 1600 DOHC VTEC 16-val ves
Fuel i nj ected Engi ne
D16Y7: 1600 SOHC 16' val ves
D16Y8: 1600 SOHC VTEC l 6-val ves
Fuel ' i nj ected Engi ne
Seri al Number
81642: 1700001-
D16Y7: 4750001-
D16Y8: 4780001'
Transmission Number
Paint Code
Co l or
Cl over Green Pearl
Fl amenco Bl ack Pear l
Taffeta White
Roma Red
COLOR
NH-592P
4750001
B4RA
T
Transmi ssi on Type
B4RA : 4-soeed Automati c Transmi ssi on
S40. S4C: 5-sgeed Manual Transmi ssi on
Seri al Number
B4RA : 8000001-
S40, S4C: 1000001-
B.95P
G-95P
NH-592P
NH 578
NH-583M
R 9 7
t o
Nfl
1-25
Chassi s and Pai nt Codes
Vohicle Grade
2: CX
4: DX
Check Di gi t
Model Yeal
Y: 2000
Fastory Code
H: Al l i ston Pl ant, Ontari o. Canada
Seri al Number
Vehicle ldentification NumbeI
U.S.2000 Model
(2-door
Hatchback)
2 HGEJ 6 3 2 *
H 100001
Type of Vehicle
MFG, , I NC.
HONDA Passenger
Vehi cl e
Body Type and T.ansmission Type
Manual
4: Hatchbacl d4-speed Automati c
Paint Code
Dl 6Y7: 1600 SOHC I6-val ves Sequenl al
Mu l ti port Fuel -i nj ected Engi ne
5500001
-[
D 16Y7
0 0
t o
COLOR
NH.583M
84RA: 4 speed Automati c Transmi ssron
S40 :s-speed Manual Transmi ssi orr
84RA: 900000' l -
S40 | 100000' l -
NH-578
NH.583M
NH-592P
R-97
Taffeta White
New Vogue Si l ver l r4etal l i c
Roma Red
1-26
r o
t
U.S.2000 Model {4-door
Sedan)
J HM EJ 652* YS000001
Manufacturer, Makg and
Type of Vehicle
LTD.
HONDA Passenger
Vehi cl e
HONDA OF AMERICA
MFG., INC.
HONDA Passenger
Vehi cl e
HONDA OF CANADA
IVIFG., INC,
HONDA Passenger
Vehi cl e
6: Sedan/4-speed Automati c
Engine Type
Mul ti port Fuel -i ni ected Engi ne
D16Y8: 1600 SOHC VTEC 16-val ves
Sequenti al Mul ti port Fuel -i ni ected
Engi ne
Sorial Numbsr
Japan: 5300001-
U.S.A.r 5500001-
Paint Code
Engine Number
2HG:
Dl 6Y7, 5300001
Vshicle Grade
2: DX
4: EX
7: LX
Check Digit
Model Year
Y: 2000
Factory Code
S: Suzuka Pl ant, Mi e Pretecture, Japan
Serial Number
Japan, U. S. A. : 000001-
Canada: 500001-
COLOR
NH-578
S4RA : 4-sDeed Automati c Transmi ssi on
S40, S4C : s-speed Manual Transmi ssi on
S4RA {Japan)
B4RA
(U.S.A.)
S40, S4C
(Japan)
l ced Teal Pearl
Cl over Green Pearl
Taffeta White
Ti tani um Metal l i c
Vi ntage Pl um Pearl
BG- 41P
G.95P
NH-578
NH-592P
YR.525M
RP.32P
t o
1- 27
U.S.2000 Model
(2-door
Coupe)
Number
l HG EJ 6 12
* Y1000001
Manufacturer. Make and
Type ol Vehicle
' 1HG:
HONDA OF AMERICA
t\4FG., tNC.
HONDA Passenger
Vehi cl e
EJ6: Cl vl C2-door/Dt6Y7
EJ7: Cl Vl C2,door/D16y5
EM1: CIVIC 2-doorl B1642
Type
1 : Coupe/s-speed Manual
Vehicle Grade
2: DX, HX
4: EX
5: EX wi th ABS, Si
Check Digit
Model Year
Y: 2000
Factory Code
Serial Number
Number
Engine Number
81642, D16Y5: 5300001-
Dl 6Y7, Dl 6Y8: 5500001-
Engi no Type
Bl 642; 1600 DOHC WEC
' 16-vatves
Sequenti al Mul ti port Fuel -i nj ected
Engi ne
D' I6Y5: 1600 SOHC WEC-E 16.vatves
Sequenti al Mul ti port Fuel -i nj ected
Engi ne
D16Y7: 1600 SOHC 16-val ves Sequenl al
D16Y8: 1600 SOHC WEC 16-vatves
Sequenti al Mul ti pon Fuel -i nj ected
Engi ne
Serial Number
COLOR
D16Y5
-
5300001
t a
t o
Paint Code
S40, S4C: 5-speed Manual Transmi ssron
M4VA :Conti nuousl yVari abl e
Transmi ssi on
(CVT)
B4RA : 9000001*
S40. S4C: 1000001-
M4VA :6000001-
B-95P
NH-578
NH.583M
NH-592P
R-81
Cl over Green Pearl
Taffeta White
Mi l ano Red
1-28
NH.592P
t o
2HG EJ 632* YH 000001
r o
CANADA 2000 Model
(2-door
Hatchbackl
Manufaqturor, Make and
Type of Vehicle
HONDA Passenger
Vehi cl e
EJ6: Cl Vl C 3-door/Dl 6Yt
3: HatchbacUs-sDeed Manual
4; Hatchbacld4-speed Automatic
Vehicle Glade
2t CX
3: OX
5r SE
Check Digit
Model Yoal
Y: 2000
Factory Code
H: Al l i ston Pl ant. Ontari o, Canada
Serial Numbr
Saf ety Standard Certif ication
Paint Code
COLOR
NH.592P
D 16Y7
-
Se1i 8l Number
84RA: 9000001-
S40 : 1000001-
Roma Red
NH.583M
NH.592P
R-97
RP-32P
1-29
Vehicle Grade
0: EX
1: LX-V
2: LX-V wi th ABS
3: LX
4: LX wi th ABS
5: LX with ABS and ly'C
7: EX wi th ABS
8; EX with ABS and A,,/C
Check Digit
Model Yar
Y: 2000
Fac'tory Code
CANADA 2000 Model
(4-door
Sedanl
Manufaqturer, Makg and
Number
J HM EJ 6 52* YS800001
Type ot Vehicle
LTD.
HONDA Passenger
Vehi cl e
MFG. , I NC.
HONDA Passenger
Vehi cl e
Body Type and Transmission Typ
5: Sedan/s-speed Manual
6: Sedan/4-speed Automati c
Transmission Number
Code
Pai nt Code
Paint Code
Cl over Green Pearl
Ti tani um Metal l i c
r o
Paint
r o
Serial Number
Japan : 800001-
Canada: 900001-
COLOR
NH.583M
D16Y7
Engine Type
D' t6Y7 | 1600 SOHC 16-val ves Sequenti al
Japan: 5700001-
U.S.A.: 5750001-
5000001
--t
Transmission Type
B4RA : 4-speed Automati c Transmi ssron
Seri al Number
54RA
l Japan) : 500000' 1-
B4RA
(U.S.A,);
900000 1-
S40
(Japan)
:
' 1000001,
S4RA
-
G-95P
NH,583M
NH.592P
YR-525M
RP.32P
1- 30
r o
CANADA 2000 Model
(2-door
Coupel
l HG EJ6' l 2
*
Y 1800001
Type of Vehicle
MFG, , I NC.
HONDA Passenger
Vehi cl e
EJ6r Cl Vl C2-door/D16Y7
EJ8: Cl Vl C2-door/D' 16Y8
EM1: CIVIC 2-door/B1642
1 : Coupe/s-speed Manual
2: Coupe/4-speed Automati c
Vehicle Grade
2: DX, Si
4: Si R
5: Si R wi th ABS
6: DX with ABS and A,/C
L
7: DXG
Check Digit
Model Year
Y: 2000
Factory Code
L: East Li bertv, Ohi o Pl ant. U.S.A.
Seri al Number
Paint Code
COLOR
NH-592P
81642 5700001
816A2: 1600 DOHC VTEC 16-val ves
Sequenti al Mul ti port Fuel -i ni ected
Engi ne
Dl 6Y7:
' 1600
SOHC 16-val ves Sequenti al
D16Y8: 1600 SOHC WEC 16-val ves
Sequenti al Mul ti pon Fuel -i nj ected
E ng i ne
81642: 5700001-
D16Y7: 575000' l -
D16Y8: 578000' l -
B4RA :4-speedAutomati cTransmi ssi on
S40, S4C: s-speed Manual Transmi ssron
B4RA : 9000001-
S40, S4C: 1000001-
Cl over Green Pearl
Mi l ano Red
8.95P
G.95P
NH-583M
NH.592P
R-81
r a
1- 31
ldentification Number Locations
Vehicle ld6ntification
Numbsr
(Vl N)
t ,
t a
Number
1-32
t a
Warni ng/Cauti on Label Locati ons
A: CABLE REEL CAUTION A:
'96
-99
model
TO SERVI CE MANUAL FOR DETAI LED I NSTRUC.
TtoNs.
'00
model
ALLATION OF THE SRS CAELE REEL IS CRITICAL TO
THE PROPER OPERATION OF THE SRS SYSTEM. REFER TO
THE SERVI CE MANUAL DETAI LED I NSTALLATI ON
INSTRUCTIONS.
(cont ' d)
1- 33
C: DRIVER MODULE OANGER
DANGER
EXPLOSIVE/FLAMMABLE
CONTACT WITH ACIO. WATER OR HEAVY METALS SUCH
AS COPPER. I.EAD OR MERCURY MAY PRODUCE HARMFUL
AND I RRI TATI NG GASES OR EXPLOSI VE COMPOUNDS,
STOBAGE TEMPERATURES MUST NOT EXCEED 2OO' F
I1(x}"CI.
FOR PROPER HANDLING. STORAGE AND DISPOS.
AL PROCEDURES REFER TO SERVICE MANUAL. SRS SUP.
PLEMENT.
POTSON
CONTAINS POISONOUS SODIUM AZIOE AND POTASSIUM
NITRATE.
FIRST AID:
IF CONTENTS ARE SWALLOWED, INDUCE VOMITING, FOB
EYE CONTACT. FLUSH EYES WTTH WATER FOR 15 MINUTES.
IF GASES {FNOM ACIO OR WATEB CONTACTI ARE INHALED,
SEEK FRESH AIR. IN EVERY CASE, GET PBOMPT MEDICAL
ATTET,ITION.
KEEP OUT OF REACH OF CHILDREN.
Br oRIVER MODULE WARNING
WARNING
THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIOEN-
TALLY DEPLOYEO, CAN SERIOUSLY HURT OR KILL YOU.
. DO NOT USE ELECTRICAL TEST EoUIPMENT oR PROB-
ING OEVICES.
THEY CAN CAUSE ACCIDENTAL DEPLOYMENT.
o NO SERVI CEABLE PARTS l NSl DE. DO NOT
DISASSEMBLE.
. PLACE AIRBAG UPRIGHT WHEN REMOVED.
. FOLLOW SERVICE MANUAL NSTBUCTIONS CAFEFULLY.
Warni n g/Gauti on
Label Locati ons
(cont'dl
t o
-==-J
_)
F
v7777m7na
r o
*
Except CANADA CX
E: SBS INFORMATION: U.S. model
('96.
'97
model)
CAUTION
TO AVOID SERIOUS INJURY:
. FOR MAXIMUM SAFEW PROTECTION IN ALL TYPES OF
CBASHES, YOU MUST ALWAYS WEAR YOUR SAFETY
BELT.
. DO NOT INSTALL REARWARD-FACING CHILD SEATS lN
ANY FRONT PASSENGER SEAT POSITION.
. DO NOT SIT OR LEAN UNNECESSARILY CLOSE TO THE
AIRBAG.
. DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OR
BETWEEN THE AIRSAG AND YOURSELF.
o SEE THE OWNER, S MANUAL FOB FURTHER
INFORMATION AND EXPLANATIONS.
. THE SRS MUST BE INSPECTED TEN YEASS AFTER IT IS
INSTALLED,
. THE DATE OF I NSTALI - ATI ON I S SHOWN OF THE
DRIVER'S DOORJAMB.
U.S. model
('00
modelI
WARNING
DEATH OR SERIOUS INJURY CAN OCCUR,
. CHI LDREN 12 AND UNDER CAN BE KI LLED BY THE
AIRBAG.
. THE BACK SEAT IS THE SAFEST PLACE FOR CHILOREN.
. NEVER PUT A REAR- FACI NG CHI LD SEAT l N THE
FRONT.
o SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG.
o ALWAYS USE SEAT BELTS AND CHILD RESTRAINTS.
D: DRIVER INFORMATION: CANADA mod6l l'96
- gtt
modell
ALWAYS WEAR YOUR SEAT BELT
. THIS CAR IS EOUIPPED WITH A DRIVER AIRBAG AND A
FRONT SEAT PASSENGER AIRBAG' AS A SUPPLEMEN-
TAL RESTRAINT SYSTEM ISRSI.
. IT IS OESIGNED TO SUPPLEMENT THE SEAT BELT,
U.S. model l'98, 39 model)
WARNING
OEATH OR SERIOUS INJURY CAN OCCUR.
. CHI LDREN 12 AND UNOER CAN BE KI LLED BY THE
AIREAG.
. THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN.
o NEVER PUT A BEAR. FACI NG CHI LD SEAT I N THE
FRONT.
. SIT AS FAR BACK AS POSSIBLE FROM THE AIRBAG.
. ALWAYS USE SEAT BELTS AND CHILD RESTRAINTS.
. THE SRS MUST BE INSPECTED TEN YEARS AFTER IT IS
INSTALLED,
. THE DATE OF I NSTALLATI ON I S SHOWN ON THE
DRIVER'S DOORJAMB.
1-34
r o
Llo
CANADA model
('00 model)
CAUTION
TO AVOID SERIOUS INJURYT
. FOR MAXIMUM SAFETY PROTECTION lN ALL TYPES OF
CRASHES, YOU MUST ALWAYS WEAR YOUR SAFETY
BELT.
. DO NOT INSTALL REARWARD-FACING CHILD SEATS lN
ANY FRONI PASSENGER SEAT POSITION.
. DO NOT PLACE ANY OBJECTS OVER THE AIRBAG OR
BETWEEN THE AIRBAG AND YOURSELF.
. SEE THE OWNER' S MANUAL FOR FURTHER
I NFORMATI ON AND EXPLANATI ONS.
Except Cx tor passenger side
F: ASSISTANT INFoRMATION: US MODEL
('96.
'97
modl)
AIRBAG SEE OTHER SIDE,
U.S. model l'98
-
00 modell
AIRBAG WARNING
FLIP VISOR OVER
Ll o
G: STEERING COLUMN NOTICE
NOTICE
TO PBEVENT SRS DAMAGE, REMOVE STEERING WHEEL
BEFORE REMOVI NG STEERI NG SHAFT CONNECTI NG
BOLT.
ll: MONITOR CAUTION
NOTICE
. NO SERVICEABIf PABTS lNSlDE.
. REFER TO SERVICE MANUAL FOR DETAILED INSTRUC'
TtoNs.
DANGER
EXPLOSIVE/FLAMMABLE
CONTACT WITH ACID, WATER OR HEAVY METALS SUCH
AS COPPER, LEAD OR MERCURY MAY PRODUCE HARM.
FUL AND I RRI TATI NG GASES OR EXPLOSI VE COM-
POUNDS, STORAGE TEMPERATURES MUST NOT EXCEED
2OO' F I 1OO"C}. FOR PROPER HANOLI NG, STORAGE AND
DI SPOSAL PNOCEDURES REFER TO SERVI CE MANUAL'
SRS SUPPLEMENT.
POISON
CONTAINS POISONOUS SODIUM AZIDE AND POTASSIUM
NITRATE.
FIRST AID
IF CONTENTS ARE SWALLOWEO, INDUCE VOMITING. FOR
EYE CONTACT, FLUSH EYES WITH WATEB FOR 15 MIN-
UTES. IF GASES IFROM
ACID OB WATER CONTACT) ABE
INHALED. SEEK FRESH AIR. IN EVERY CASE, GET PROMPT
MEDICAL ATTENTION.
KEEP OUT OF REACH OF CHILDREN,
WARNING
THE AIRBAG INFLATOR IS EXPLOSIVE AND, IF ACCIDEN-
TALLY OEPLOYED, CAN SERIOUSLY HUBT OR KILL YOU.
. DO NOT USE ELECTRI CAL TEST EOUI PMENT OR
PROBING DEVICES.
THY CAN CAUSE ACCIDENTAL DEPLOYMENT'
. NO SERVI CEABLE
PABTS l NSl DE. oO NoT
DISASSEMBLE.
. PLACE AIRBAG UPRIGHT WHEN REMOVED
. FOLTOW SERVICE MANUAL INSTRUCTIONS CAREFULLY
I: FRONT SEAT PASSENGER MOOULE DANGER
Jr SRS WARNING IHOOD)
'
Exceot CANADA CX
K: PASSENGER AIRBAG CAUTION
u.S. model l'98
-
00 model)
WARNING
CHI LDREN CAN 8E KI LLED OR I NJUREO BY PASSENGER
AIRBAG,
THE BACK SEAT IS THE SAFEST PLACE FOR CHILDREN 12
AND UNDER. MAKE SURE ALLCHI LDREN USE SEAT BELTS
OR CHILD SEATS.
(cont ' d)
1- 35
SUPPLEMENTAL RESTRAINT SYSTEM ISRS}
THI S VEHI CLE I S EOUI PPED WI TH DBI VER AND FRONT
SEAT PASSENGER AIRBAGS'.
ALL SRS ELECTRI CAL WI RI NG AND CONNECTORS ABE
COLORED YELLOW.
TAMPERI NG WI TH, DI SCONNECTI NG OR USI NG
ELECTRICAL TEST EOUIPMENT ON THE SRS WIRING CAN
MAKE THE SYSTEM INOPERATIVE OR CAUSE ACCIDENTAL
FIRING OF THE INFLATOR.
WARNING
THE AI RBAG I NFLATOR I S EXPLOSI VE AND, I F ACCI DEN.
TALLY DEPLOYED, CAN SERIOUSLY HURT YOU. FOLLOW
SERVICE MANUAL INSTRUCTIONS CAFEFULLY'
Warni ng/Cauti on Label Locati ons
(cont'd)
191t7 CANADA Mod6l
t ,
t ,
1- 36
t ,
Under-hood
Emissions Control Label
(1996,
1997 model)
Emi ssi on
Example:
Group ldentification
VACUUM HOSE ROUTING DIAGRAM
50ST {50
States):
THIS VEHICLE CONFORMS TO U.S, EPA AND STATE OF
CALIFORNIA REGULATIONS APPLICABLE TO 1996 AND
1997 MODEL YEAR NEW MOTOR VEHICLES.
/$ST (49
States/Federall:
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLI CABLE TO
' 1996
AND 1997 MODEL YEAR NEW
MOTOB VEHICLES,
CAL
(Calitornis):
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF
CALIFORNIA REGULATIONS APPLICABLE TO 1996 AND
,1997
MODEL YEAR NEW PASSENGER CARS PROVIDED
THAT THIS VEHICLE IS ONLY INTROOUCED INTO COM-
MERCE FOR SALE IN THE STATE OF CALIFORNIA.
-VEHICLE
Ei / ISSION CONTROL INFORMATION
E\ G\ . r r Mr r vt sNr s\ JLK6\ Dsp- A( . MFN 590( - - , . O CI VI C
f a: n
!APOF!]V4
-AV.t'
!-rirorrSrMAc
\Y:/
CATALYST
IwcN02S{2)sFr
Fl . t ar ost q! t MA\ uAt t oaaooTo\ a- \ ' oFM^
r o\
r t Tl
r . \ F Jo( O\ D
'
O\ S E\ Gr \ l AI NOnMA- Ool ql l NCTMoEqA Uql
l H i
a-LACCESSoT rS
r-F\Eo0F C00ll\G
-A\
0( \-!-lJ
TRANSM1SSION N NEUTFAI
NO OTHERAOJUSIMENTS NEEDEO. O8D IICERTIFIED
IDLESPEEO
ATDC
NDr(Jl6CR.L1l
r.r
-i ,
"
TH SVEH CLE CONfOFMSTO U S. EPA AND STATE
OF CALfORNIA RECULAI ONSAPPLICA8IElO 1997
MOOET YEAR NEW MOTOR VEH CL' S ilil]]lrl
Er!4#_"E!!ifl 4q!sq+HT-q4E!rL
N US TIEB l FULL
11211
.?2E
AO2 HONDA MoTOR C0 , tTD
Engi ne and EvaPorati ve
Fami l i es
Engine Family: V H N l . 6 V J G K G K
Model Year
T: 1996
V: 1997
T I
T| I
Manufacturer
HN: Honda
Displacemnt
V: Li ght Duty Vehi cl e/Passenger Car
Fuel Systsm and Number of valves
J: El ectroni c Sequenti al Mul ti port Inj ecti on
(three
or more val ves
per cyl i nder)
Fuel Type
G: Gasol i ne
Standard
F: 49 or 50 States Ti er 1
K: 49 or 50 States Tier 1
1: Cal i f or ni a Ti er 1
2: Cal i forni a TLEV
3: Cal i forni a LEV
4; Cal i forni a ULEV
Catalyst
E, F, G. H: Three Way Catal yst
OBD
K
-
T: OBD Equi pped
Evaporat i ve Fami l y: v HN 1077 BYMAc
' | T
Model Year
T: 1996
|
V: 1997
l
Manufacturel
HN: Honda
Storage System
1: Cani st er
Canister Working Capacity
(grams)
Canister Configulation
A: Pl asti c Housi ng
(Cl osed Bottom)
B: Pl asti c Housi ng
(oPen
Bottom)
Fuel Systsm
Y: Fuel Inj ecti on
Fuel Tank
M: Metal
Standard
A: Current Evap
E: Enhanced Evap
Wi l d Card
1-37
Under-hood Emi ssi ons
Control Label
(l ggg
model )
Emission Group ldentification
Example:
50ST
(50
Statosl:
THIS VEHICLE CONFORMS TO U,S. EPA AND STATE OF
CALI FORNI A REGULATI ONS APPLI CABLE TO 1998
MODEL YEAR NEW MOTOR VEHICLES,
ilgsT
149 States/Federal):
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS
APPLICABLE TO 1998 MODEL YEAR NEW MOTOR VEHI.
CLES.
CAL
(California):
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE OF
CALI FORNI A REGULATI ONS APPLI CABLE TO 1998
MODEL YEAR NEW PASSENGER CARS PROVI DED
THAT THIS VEHICLE IS ONLY INTRODUCED INTO COM.
MERCE FOR SALE IN THE STATE OF CALIFORNIA.
oR3. ' @M| LES| 3, @| f r l w! cs
VEHICLE EI\4ISSION CONTROL INFORIVATION
rH SVEH CLE CONFOFMS IO U S EPA AND
STA1E OF CALIFORNIA RE6ULAIIONS APPLICABLE
IO 199A MODEL YEAR NEWTIEV PASSENGER
CA8S PFOV OEO TI]AI ' HIS VEI CLE S OILY
INIBODUCEDINTOCOMMEfi CE FOR SALE N TNC
CATALYST
IWCINO?S]2)EGR6F
/OBO ] CEFT]F ED
VALVE LASH
1C0L0l EX 0 r51002mm
NO OTHTR AO.]USIMI\IS NI' TOEO
I]ONDA MOTOB CO.,ITD
OE
1- 38
r o
Engi ne and Evaporati ve Fami l i es
r f
Engi ne Fami l y:
v 0' t . 6 JL2
Model Year
W: 1998
Manufacturer
HNX
HNX: Honda
Type
V: Li ght Duty Vehi cl e/Passenger
Car
Displacement
Sequence Characters
Evaporative Family:
W HNX E 0065
HNX: Honda
Type
E:
Model Year
AAD
T
W: 1998
Manufacturel
Canister Work C.pacity (glamsl
Sequence Characters
EVAP
L O
(1999
model l
Emi ssi on Group l denti fi cati on
Example:
VEHICLE EMISSION CONTROL INFOEMATION
13 S VEH CLE CONFORMS IO U S E
APPL CABLETO I999 MOOELYEAR NEW PASSENCER
CATALYST
IAIV L{SH
COLD
SPARTPLU6CAP
E v
@o
HONDA MOTOECO LTD
FEDERAL TIER 1:
THIS VEHICLE CONFORMS TO U.S, EPA REGULATIONS
APPLICABLE TO
' 1999
MODEL YEAR NEW PASSENGER
CARS.
CALIFORNIA
+ NLEV {RESTRICTEDI
TLEV:
THIS VEHICLE CONFORIVIS TO CALIFORNIA
REGULA-
TIONS APPLICABLE TO 1999 MODEL YEAR NEW TLEV
PASSENGER CARS AND TO U.S. EPA NLEV PROGRAM
REGULATIONS APPLICABLE TO 1999 NEW TLEV PAS-
SENGER CARS.
THIS VEHICLE MAY ONLY BE INTRODUCED
INTO COM-
MERCE FOR SALE IN CALIFORNIA, A STATE THAT HAS
THE CALIFORNIA STANDARDS
IN EFFECT TO WHICH
THI S VEHI CLE HAS BEEN CERTI FI ED,
A STATE THAT
HAS OPTED INTO THE NLEV PROGRAM, OR A STATE
CONTIGUOUS
THERETO.
50 STATE LEV + CFFV + NLEV {UNRESTRICTED}:
THI S VEHI CLE CONFORMS TO U. S. EPA NLEV AND
CLEAN- FUEL
VEHI CLE AND CALI FORNI A
REGULA'
TI ONS APPLI CABLE TO GASOLI NE
FUELED 1999
MODEL YEAR NEW LEV I PASSENGER
CARS/ LI GHT
DUW TRUCKS].
50 STATE TLEV + NLEV
(UNRESTRICTED):
THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULA'
TIONS APPLICABLE TO 1999 MODEL YEAR NEW TLEV
PASSENGER CARS AND CALI FORNI A REGULATI ONS
APPLICABLE TO 1999 MODEL YEAR NEW TLEV IPAS'
SENGER CARS/LIGHT DUW TRUCKS].
Engi ne and Evaporati ve
Fami l i es
Engine Family:
Model Yeal
X: 1 9 9 9
X
T
J F1
T
AAD
_T
Manutacturer
HNX: Honda
Tvpe
V: Li ght Duty Vehi cl e/Passenger
Car
Disolacement
Sequence Characters
Type
R: ORVR
Canister Work CaPacitY
(gramsl
Sequence Characters
Evaporative FamilY:
+ +
Model Year
I
X: 1999
l
Manufacturer
HNX: Honda
0090
T_
R
HNX V
rT
r l
0 t . 6
1- 39
Under-hood
Emission
Control
Label
(2000
model)
Emi ssi on
Group l denti fi cati on
Example:
oRs' MM|LESt4,0oorml ,wtscN
VEHICLE EMISSION CONTROL INFOBI\4ATION
T8ISVEH CLE CONFOfi MS TO U,S EPA RECIJLATIONS
APPLICABLE IO ' OOO MODEL YEAS NEW PASSENGER
CATALYST
vAtw LcsH rN 0.20:0 0? nn
lcorDr EX 0 25:0 0? mh
SPAAKPIIJGCAP
NO OTNER AD.IUSIMENIS NEOTO
t0N0a M0T08
(0.
Lro
FEDERAL TIER 1:
THIS VEHICLE CONFORMS TO U,S. EPA REGULATIONS
APPLICABLE TO 2OOO MODEL YEAR NEW PASSENGER
CARS.
CALIFORNIA + NLEV
(RESTR|CTEDt
TLEV:
THI S VEHI CLE CONFORMS TO CALI FORNI A
REGULA-
TIONS APPLICABLE TO 2OOO MODEL YEAR NEW TLEV
PASSENGER CARS AND TO U,S. EPA NLEV PROGRAM
REGULATIONS APPLICABLE
TO 2OOO NEW TLEV PAS-
SENGER CARS.
THIS VEHICLE MAY ONLY BE INTRODUCED
INTO COM.
MERCE FOR SALE IN CALIFORNIA. A STATE THAT HAS
THE CALIFORNIA STANDARDS IN EFFECT TO WHICH
THIS VEHICLE HAS BEEN CERTIFIED,
A STATE THAT
HAS OPTED INTO THE NLEV PROGRAM,
OR A STATE
CONTIGUOUS THERETO.
50 STATE LEV + CFFV + NLEV
{UNRESTRTCTED):
THI S VEHI CLE CONFORMS TO U. S, EPA NLEV AND
CLEAN. FUEL VEHI CLE AND CALI FORNI A REGULA,
TI ONS APPLI CABLE TO GASOLI NE FUELED 2OOO
MODEL YEAR NEW LEV PASSENGER
CARS.
EPA CERTI FI CATI ON
TEST FUEL: EPA UNLEADED
GASOLINE
50 STATE TLEV + NLEV (UNRESTRICTED}:
THIS VEHICLE CONFORMS TO U.S. EPA NLEV REGULA.
TIONS APPLICABLE TO 2OOO MODEL YEAR NEW TLEV
PASSENGER CARS AND CALI FORNI A REGULATI ONS
APPLICABLE TO 2OOO MODEL YEAR NEW TLEV PAS-
SENGER CARS.
n
1-40
L ,
Engi ne
and Evaporati ve
Fami l i es
r o
Engine Family:
Y HNX V 01, 6 JF1
Model Yeal
Y; 2000
Manufaqturer
HNX: Honda
Type
V: Li ght Duty Vehi cl e/passenger
Car
Displacoment
Sequence Charaqtgrs
Evaporative Family:
Y HNX R OO99 AAD
Model Year
Y: 2000
Manufaeturer
HNX: Honda
Type
R: ORVR
Canister Work Capacity (grams)
Ssquence Characters
L O
Lift and SupPort
Points
L,O
Lift and SafetY Stands
t!ffi when heavv rear components
such as suspensi on'
fuel tank' spare ti re' hatch' and trunk l i d are to be
-aE
removed,
place additional wetght Inihe luggage arga before hoisting. when substantial weight is lemoved from the rear
of the vehicls. the center of
gravity may change and can cause the vehicle to tip tolward on the hoisi
NOTE:
. Si nce each ti re/wheel assembl y wei ghs approxi matel y
30 l bs
(14
kg)' pl aci ng the front wheel s i n the l uggage area can
assi st wi th the wei ght di stri buti on
. Use the same support
poi nts to suppon the vehi cl e on safety stands'
Pl ace the l i ft bl ocks as shown.
Rai se the hoi st a l ew i nches
(centrmeters) and rock the vehi cl e to be sure i t i s fi rml y supported'
Rai se the hoi st to ful l hei ght, and i nspect l i ft
poi nts for sol i d support
1 .
2.
3.
REAR SUPPORT POINT
1-41
Lift and Support Points
Fl oor Jack
Appl y the parki ng
brake and bl ock the wheets that
are not bei ng l i fted.
When l i fti ng the rear of the vehi cl e, put
the gearshi ft
l ever i n reverse
(Automati c
transmi ssi on/Cw
i n
E
posi ti on).
Rai se the vehi cl e hi gh enough to i nsert the safety
stands.
Adj ust and pl ace
the safety stands so the vehi cl e
wi l l be approxl matel y l evel , then l ower the vehi cl e
onto them.
FRONT:
Always use safety stands whon working on or undel
any vehicle that is supported by only a
iack.
Never attempt to use a bumper j ack
for l i fti ng or
supporting the vehicle.
t ,
1 .
REAR:
1-42
LIFT PLA
4.
Cent er t he
j acki ng
bracket i n t he mi ddl e
of t he
i ack
l i f t pl at f orm.
Cent er t he
i ack
bracket i n t he mi ddl e
of t he j ack
l i f t pt at f orm.
-,-_
LIFT PLATFORM
L ,
Towi ng
l f the vehi cl e needs to be towed, cal l a
professi onal tow-
i ng servi ce. Never tow the vehi cl e behi nd another vehi
cl e wi th i ust
a rope or chai n l t i s very dangerous'
Emergency Towing
There are three
popul ar methods of towi ng a vehi cl e:
Flat-bed Equipment
-
The operator loads the vehicle on
the back of a truck. Thi s i s the best way of transporti ng the
vehi cl e.
Wheel Lift Equipment
-
The tow truck uses t\ivo
pivoting
arms that
go under the ti res {front
or rear} and l i fts them
of f t he
gr ound. The ot her t wo wheel s r emai n on t he
ground.
Sling-type Equipment
-
The tow truck uses metal cables
wi th hooks on the ends. These hooks
go around
parts of
the frame or suspensi on,
and the cabl es l i ft that end of
the vehi cl e off the ground The vehi cl e' s suspensi on
and
body can be seri ousl y damaged i f thi s method of towi ng
is attemDted.
l f the vehi cl e cannot be transported by fl at-bed. i t shoul d
be towed wi th the front wheel s off the ground l f due to
damage, t he vehi cl e must be t owed wi t h t he f r ont
wheel s on the
ground, do the fol l owi ng:
l vl anual Transmi ssi on and CW
. Rel ease the parki ng brake
. Shi ft the transmi ssi on to neutral
(CW
to
E
posi ti on)'
Automati c Transmi ssi on
. Rel ease the
Parki ng
brake.
. Sta rt the engi ne.
. Shi ft to LDl l
posi ti on, then E
posi ti on.
. Turn oi f the engi ne
CAUTION;
o lmploper towing
preparation will damage ihe tfans-
mission. Follow the above
procedute exaqtly lf you
cannot shi ft the tl ansmi ssi on
or start the engi no
laulomatic
transmissionl,
yout vehicle must be trans-
ported
on a flat-bed.
. lt is best to tow the vehicle no farther than 50 mils
(80
km), and ksop thE speed below 35 mph
(55
km/hl
. Trying to lift 01 tow
your vehicle by tho bumpF will
caus setious damagg. Ths bumpers are not dEigned
to supportthe vshicle's weigh.
tJO
1-43
Front:
Rear:
TI E DOWN HOOKS
TOWI NG HOOK
Specifications
Standards
and Servi ce
Li mi ts "' .".' .""'
3-2
Desi gn Speci f i cat i ons, . . ' . . . . , . ' . . ' . . . .
". . . ""' 3-20
Body Speci fi cati ons
"' ."' ." 3-23
( ur bY5,
ul 6Y7, Dl 6Yg enl
MEASUREMENT
Si nes)
-Sect i on6 -
STANDARD I NFWT
Compressi on
250 rpm and wi de open t hrof t l e
kPa {kgf / cm, , psi )
Nomi nal
Mi ni mum
Maxi mum vari at i on
Warpage
Hei ght
End pl ay
Camshaf t t o-hol der oi l cl earance
Tot al runout
Cam l obe hei ght D16y7
D16Y5
D16Y8
I N
EX
I N
EX
I N
EX
Secondary
Pri mary
Mi d
Secondary
930 {9. 5, 135)
200 12 0 ?R\
Cyl i nder head
92. 95
-
93. 05 {3. 659 3. 663)
0. 05 {0. 002)
Camshaft
0. 05, 0. 15 ( 0. 002
0. 006)
0.050
-
0.089 (0.002 _
o.oo4)
0. 03 ( 0. 001) max.
35. 299
(1. 38971
31.241 /.1.4678)
38. 427 (1. 5129)
32.193
11 .267 4l
38. 784 (1. 5269)
36. 778 (1. 4479)
38. 274 (1. 5068)
37. 065 . 4592)
38. 008 (1. 4964)
0.5
(0.02)
0.15 (0.006)
0.04 (0.002)
=
Val ve cl earanca
{Col d)
Val ve st em O. D.
St em-t o gui de
cl earance
wi dt h
St em i nst a ed hei ght
Free l engrh
Dt 6y7
D16Y5
I N
EX
I N
EX
I N
EX
I N
EX
I N
EX
I N
EX
I N
EX
I N
EX
I N
EX
D16Y8
t . D.
I nst al l ed hei ght
0. 18
-
0. 22 10. 007
-
0. 009)
0. 23 0. 27
(0. 009
0. 011)
5. 48
-
5. 49 (0. 2157
0. 2161)
5. 45
-
5. 46 {0. 2146
_
0. 2150}
0. 02
-
0. 05 (0. 001 _
o. oo2)
0 . 0 5 - 0 0 8 l o n o 2 - n n n ? l
5. 45 (0. 2146)
5.42 tO.21341
0. 08 (0. 003)
0. 11
( 0. 004)
1. 6
(0. 063)
2. 0
(0. 079)
53.a9
\2.122|j
$. a9
Q. 122)
Val ve seat
0. 85
-
1. 15 (0. 033 -
0. 045)
1. 25
-
1. 55
10. 049
-
0. 061i
53. 17
-
53. 64 { 2. 093
_
2. 112)
53. 17
-
53. 64
(2. 093 _
2. 112)
Val ve spri ng
57 . 9 (2. 2a)
56.5 \2.221
57 .9 t2.29l
58.0
(2.2a)
58. 7 {2. 31i
Val ve gui de
5. 51
-
5. 53 ( 0. 217 -
0. 218)
5. 51
-
5. 53
(0. 217 _
0. 218)
17.85
-
18.35
\0.103
-
0.722)
18. 65 19. t 5
(0. 734 _
0. 754)
5. 55 t 0. 219)
5. 5s {0. 219)
Rocker arm Arm-t o shaf t cl earance
I N
EX
0. 017
-
0. 050 (0. 0007
0. 0020)
0. 018
-
0. 054
(0. 0007 -
0. 0021)
0. 08
(0. 003)
0. 08 (0. 003)
Standards
and Service
Limits
Cylinder Head/Valve
Train
(Dt6y5,
Dt6y7, D
L ,
r a
3-2
L O
Uni t of i engt h: mm
( ! n)
930
(9. 5, 135)
20012. 0, zal
0. 05
-
0. 15
(0. 002 -
0. 006)
0. 050
-
0. 089
(0. 002 -
0. 004)
0. 0310. 001) max.
33. 088
(1. 3027i
36. 261 {1. 4278)
34. 978
( 1. 3771)
32. 785 {1. 2907)
35. 720
(1. 4063)
34. 691
(1. 3658)
u*u l o. r , ool
5. 420
(0. 2134)
0. 08
(0. 003)
0. 11
( 0. 004)
2. 0
(0. 08)
2. 0
(0. 08)
38. 185
( 1. 5033)
37. 885
( 1. 4915)
250 r pm
( mi n
r i and
Nomi nal
wi de open t hrot t l e
Mi ni mum
kPa
(kqf / cm' , psi ) Maxi mum vari at i on
End pl ay
Camshaf t -t o hol der oi l cl eance
Tot al runout
Cam l obe hei ght
l N Pri mary
Mi d
Secondary
EX Pri mary
Mi d
Secondary
0. 15
-
0. 19
(0. 006
-
0. 007)*
0. 17
-
0. 21
(0. 007
-
0. 008)*
5. 475
-
5. 485 10. 2156
-
0. 2159)
5. 450
-
5. 460
(0. 2146
-
0. 2150)
0. 025
-
0. 055
(0. 0010
0. 0022)
0. 050-0. 080
(0. 0020
-
0. 0031)
Val ve cl earance
Val ve st em O. D.
Stem-to-guide clearance
I N
EX
I N
EX
I N
EX
1. 25
-
1. 55 {0. 049
-
0. 061)
r. 25
-
1. 55
(0. 049
-
0. 061)
37. 465
-
37. 935
(1. 4750
-
1. 4935)
37. 165
-
37. 635
(1. 4632 -
1. 4817)
I N
EX
I N
EX
wi dt h
St em i nst al l ed hei ght
40. 92
( 1. 611) * '
40. 91
( 1. 6111"
36. 71
(1. 415)
41. 96
( 1. 652) * r
4 r. 94
(1. 651)*'
f ree t *gt h
l N OUTER
5. 51
-
5. 53
(0. 217
-
0. 218)
5. 51
-
5. 53
(0. 217 -
0. 218i
12. 55
-
13. 05
(0. 494 0. 5' j 4)
12. 55
-
13. 05
(0. 494 -
0. 514)
LD.
l N
EX
I nst al l ed hei ght
l N
EX
0.025
-
0.052
(0.0010 0.0020)
o.o2s
-
0.052 {0.0010
0.0020)
Cylinder Head/Valve
Train
(816A2
engine)
-
Section
MEASUREMENT
STANDARD INEW)
SERVICE LIMIT
*:
Measuri ng
poi nt bet ween camshaf t and rocker arm'
*1:
NTHON H; TSUJO manuf act ured vat ve spri ng.
*2:
CHUO HATSUJO manut act ured val ve spnng.
3- 3
MEASUREMENT
, n7
_--
STANDAFO
INEW}
0. 07 10. 003) max.
75. 00 75. 02
(2. 953 -
2. 954)
7 4.9A0 7 4.990 t2.9520 2.95241
0. 010
-
0. 040 (0. 0004
0. 0016)
1. 020
-
1. 030
10. 0402
_
0. 0406)
1. 220 1. 230 (0. 0480 -
0. 0484)
2. 805
-
2. 820
{ 0. 1 104
_
0. 11 t 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. 30
-
0. 45 ( 0. 012 -
0. 018)
0. 20
-
0. 70
10. 008 0. 028)
18. 994
-
19. 000 (0. 7478 _
0. 7480)
0. 010
-
0 0?2 l o oona -n dnôl
SERVI CE LI MI T
0. 10
(0. 004)
75. 07 (2. 956)
0. 05 (0. 002)
0. 5
(0. 02)
74. 970 (2. 9516)
0. 05
(0. 002)
1. 05 ( 0. 041)
1. 2510. 049)
2. 85
(0. 112)
0. 13 { 0. 005)
0. 13
(0. 005)
0. 60
(0. 024)
0. 70 (0. 028)
ljqql)
_
oro
to.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)
Cyl i nder bl ock
Warpage of deck surf ace
Bore di amet er
Bore t aper
Rebori ng l i mi t
Ski rt O. D. at 5 mm
(0. 2
i n)
f rom bot t om of ski n
Cl earance i n cyl i nder
Groove wi dt h
{f or ri ng) Top
Second
oi l
Ri ng t o-groove cl earance Top
Second
Ri ng end gap
Top
Second
oi l
o. D.
Pi n-t o pi st on
cl earance
Pi n-t o rod i nt erf erence
Smal l end bore di amet er
Large end bore di amet er Nomi nal
End pl ay i nst al l ed on crankshaf t
Pi st on
Pi st on ri ng
Pi st on pi n
Connect i ng
rod
0. 014
-
0. 040 (0. 0006 _
0. ool 6)
18. 96
-
18. 98 (0. 746
0. 747)
48. 011. 89)
0. 15
-
0. 30
(0. 006 -
0. 012)
Cr ankshaf t
Mai n
j our nal di amet er
Rod
i our nal di amet er
Taper
Out of -round
End pl ay
Tot al runout
Mai n beari ng t o-l ournal o' t cl earance-
No_ l and 5j our nal s
_
No. 2, 3 and 4
j our nat s
Bod beari ng t o, j ournat oi l ct earance
54. 976
-
s5. 000 (2. 1644 -
2. 1654)
44. 91 6
-
45. 000
1' 1. 17 01
_
1. 71 11
1
0. 002510. 0001)
max.
0. 0025 (0. 0001)max.
0. 10
-
0. 35
(0. 004
0. 014)
0. 03 (0. 001)
max.
Bea. i ngs
0. 018
-
0. 036 (0. 0007
0. 0014)
0. 024 0. 042
(0. 0009 -
0. 0017)
0. 020
-
0. 038 (0. 0008 _
o. oo. t 5)
Standards
and Service
Limits
Engine Block
{Dl6Y5, D16Y7, Dt6y8 enginesl
-
Section
L,
LO
3-4
L O
Section 7
Unl t of l engt h: r nm
(
n)
Engine Block
(816A2
engine)
-
MEASUREMENT
Warpage of deck surf ace
Bore di amet er
Bore t aper
Rebori ng l i mi t
STANOARD {NEW)
0. 05
(0. 002)
8L00 81. 02
( 3. 189 3. 190)
SERVI CE LI MI T
0. 08 {0. 03)
81. 07
( 3. 192)
0. 05
(0. 002)
0. 25
( 0. 01)
Cyl i nder bl ock
Pi st on Ski n O D. At 15 mm
(0. 6 i n)
{rom bot t om of ski rt
Cl earance i n cyl i nder
Groove wi dt h
(f or ri ng)
ToP
Second
oi l
80. 980
-
80. 990
(3. l UUz 3. rUubl du Y/ u l J. ro/ o,
I
0. 010 0. 040
(o. ooo4 -
0. 0016' 0 05 r0 002)
I
I O3O 1. 040
10. 0406
-
0. 04091
1 060
{0 0417)
|
1. 230
-
1. ?40 {0. 0484
.
0. 04881
1. 260
10. 04961
1
' *:
?:::i ?l :91' ::l l :l I::::::= l
Pi st on r i ng
Ri ng- t o- gr oove cl ear ance
Ri ng end
gap
o. D.
Pi n t o-pi st on cl earance
Pi n' t o rod i nt erf erence
Smal l end bore di amet er
Large end bore di amet er
End pl ay i nst al l ed on crankshaf t
Mai n
j ournal di amet er
No. 1, 2, 4 and 5
i ournal s
No. 3
j ournal
Rod
j ournal di amet er
Taper
Out of round
End
pl ay
Tot al runout
Mai n beari ng t o_j ournal oi l cl earance
No. 1, 2, 4 and 5
j our nal s
No. 3
j our nal
Bod beari ng' t o i ournal
oi l cl earance
Second
Top
Second
oi l
Nomi nal
0. 13
(0. 005)
0. 1310. 005)
0. 60
(0. 024)
0. 60 t 0. 024)
0. 7010. 028)
0. 70
(0. 028)
,rr]q!4l
-
l
u. u45
-
u. u/ u l u. uu
r o
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)"
20. 994
-
21. 000 {0. 8265
-
0. 8268)
0. 010
-
0. 022
(0. 0004 0. 0009)
0. 013
-
0. 032
(0. 0005
-
0. 0013)
20. 968 20. 981
(0. 8255
-
0. 8260)
lliSlto?,o.oou
o.o''r,
o.rotoo'ut
Pi st on
pi n
Connect i ng r od
54. 976 55. 000
(2. 1644
-
2. 1654)
54. 970
-
54. 994
(2. 1642 2. 1651)
44. 976
-
45. 00011. ' 1707
-
1. 1711|
0. 005
(0. 0002) max.
0. 004
(0. 0002) max.
0. 10 0. 35
(0. 004
-
0. 014)
0. 020
(0. 0008i max.
0. 010
(0. 0004)
0. 006
(0. 0002)
0. 45
( 0. 018)
0. 030
(0. 0012)
Crankshaf t
Eeari ng
0.024
-
0.042
(0.0009 0.0017)
o.o3o
-
0.048 {0.0012
0.0019)
0.032
-
0.050
(0.0013
-
0.0020)
0.06
(0.002)
0.06
(0.002)
0.06
(0.002)
*1:
RI KEN manut act ured
prst on rrng
*2: TEI KOKU
PI STON RI NG manuf act ured
pi st on ri ng
ginesl Section 8
( cont ' d)
Engine Lubri, cation
(Dl6Y5,
Dl5Y7' Dl6Y8 enginesl
-
MEASUREMENT
STANOARD
(NEW) SRVICE LIMIT
4. 3
(4. 5, 3. 8)I or engi ne overhaul
3. 6
(3. 8,
3. 2) f or oi l change, i ncl udi ng f i l t er
3. 3
(3. 5, 2. 9) f or oi l change, wi t hout f i l t er
3. 7
( 3. 9, 3. 3) f or engi ne over haul
3. 3
(3. 5, 2. 9) f or oi l change, i ncl udi ng f i l t er
3. 0 {3. 2,
2. 6} f or oi l change, wi t hout f i l t er
0. 02
-
0. 14
(O. OO1 -
0. 006)
0. 20 {0
008)
0. 10 0. 18
(o. oo4
-
0. 007)
i
0. 20
(0
008)
o 03 !.08
(qool!.oo3l
_
(0
006)
-
70
( 0. 7,
10) mi n.
340
( 3. 5, 50) mi n
Engi ne oi l
Capaci t y |
(US qt , l mp qt ) D16Y7
D16Y5 D16Y8
l nner-t o-out er
rot or radi al cl earance
Pump housi ng t o_out er rot or radi al cl earance
Pumo housrnq_t o rot or a)ri al cl earance
Pressure set t i ng wi t h oi l t emperat ure
176' F
(80' Ci
kPa
(kgf / cm' ,
Psi I
at i dl e
at 3,000 rpm
Oi l
pump
Rel i ef val ve
3- 5
MEASUREMENT
STANDARD INFWI
Engi ne oi l
Capaci t y f
(uS qt , l mp qt )
I nner-t o out er rot or radi al cl earance
Pump body-t o out er rot or radi al cl earance
Pump body t o-rot or axi al cl earance
4. 8 (5. 1,
4. 2) f or eng; ne overhaul
4. 0 (4. 2,
3. 5) f or oi l change, ; ncl udi n
3 . 7
( 3 . 9 . 3
3 ) f o r d i l . h , n d e ' ^ , i r h ^ , , r
g oi l f i l t er
Oi l pump
0. 04
-
0. 16 {0. 002
-
0. 006)
0. 10
-
0. 19 ( 0. 004- 0. 007)
0. 02 0. 07 10. 001
, 0. 003)
0. 20
(0. 008)
0. 20 {0. 008)
0 15 {O OO6i
Rel i ef val ve
Pressure set t i ng 176"F (80. C)
kPa (kgf l cm, ,
psi )
at ; dt e
at 3, 000 rpm
70 (0. 7,
10) mi n.
340
(3. 5, 50)
mi n.
Standards
and Service
Limits
Engine Lubrication
(B16A2
engine)
(cont,d) -
Section 8
Cooling
-
Section 10
L,
L .
MEASUREMENT
STANOARO {NEW)
Radr at or
Cool ant capaci t y t 1US
qt , t mp qt )
i ncl udi ng engi ne, heat er, cool i ng l i ne and
reservot r
Beservoi r capaci t y:
0. 4 f {0. 42 US qt ,
0. 35 l mp qt )
81642 engi ne
5. 0 {5. 3, 4. 4) f or overhaul
4. 5 (4. 8,
4. 0) f or coot ant change
D16Y5, D16Y7, D16Y8 engi nes:
M/ T: 4. 2 (4. 4,
3. 7)f or overhaul
3. 1
(3. 3,
2. 7) f or cool ant change
A"/T: 016Y7
4. 1 (4. 3,
3. 6) f or overhaul
3. 0 (3. 2,
Dl 6Y8
4. 3 {4. 5, 3. 8)f or overhaul
3. 2
(3. 3,
CW: 4. 3 (4. 5, 3. 8)f or
overhaul
3. 2
(3. 3,
2. 8)f or coot ant chanqe
Radi at or cap Openi ngpr essur e
kPa( kgl / cm, , psi )
St ar t t o open
. F
( . C)
Ful l y open
"F
( ' C)
Val ve l i f t at f ul t y open
93 123 ( 0. 95-
1. 25, 14 18)
169
-
176 ( 76
80)
194
(90)
8. 0
( 0. 31) mi n.
196
-
203 191 95)
Subt ract 5
-
15 {3
-
8) f rom act ual
, , ON, ,
t emperat ure
Ther most at
Cool i ng f an
Ther moswi l ch
' ON"
t emper at ur e F r . C,
Ther moswi t ch
"OFF'
l emper at ur e
. F
(
C)
L
3- 6
L ,
Uni t of l engt h: mm
( i n)
Fuel and Emission
-
Section
MEASUREMENT
STANOARO
(NEW)
260 310
(2. 7 -
3. 2, 38
-
46)
260
-
310
(2. 7
-
3. 2, 38
-
46i
260
-
310
(2. 7
-
3. 2, 38
-
46)
210
-
320 Q.A
-
3.3, 40
-
47 1
45 { 11. 9, 9. 9)
M/T
(neutral)
I
A/T or C\.T
(lE or
fd
positioni
Fuel
paessure
regul at or
Pressure wi l h f uel pressure regul at or vacuum hose
di sconnect ed
kPa
(kgvcm' ,
Psi )
D16Y5
D 16Y7
D16Y8
81642
Fuel t ank
Capaci t y I
(US gal , l mp gal )
E ngi ne
l dl e speed rpm
016Y5
D16Y7
D16Y8
816A2
u.s.A.
Canada U, S, A.
Canada
670 1 50
6701 50
6 7 0 1 5 0
700 t 50
7501 50
7501 50
7501 50
700 t 50
700 I 50
7001 50
7 5 0 1 5 0
750 r 50
l dl e CO %
0. 1 max.
Clutch
-
Serrtion 12
MEASUREMENT
STANDARD {NEWI I
SERVICE LIMIT
Cl ut ch
pedal Pedal hei ght
t o f l oor
St r oke
Pedal
pl ay
Di sengagement hei ght
t o f l oor
to carpet
16s
(6
1/ 2)
130 140
(5
1/ 8 5 1/ 2)
12
-21
t 1l 2
-
13/ 161
83
(3 1/ 4)
44
(1
3/ 4) mi n. Ref erence
Fl ywheel
Cl ut ch surf ace ruoout
Ri vet head dept h
Thi ckness
0.05
(0.002) max.
0.15
(0.006)
Cl ut ch di sc
1. 3- 1. 9
( 0. 05
-
0. 07)
8.5
-
9.1
(0.33 -
0.36)
0. 2 { 0. 01)
5.5
(0.22)
Pressure
pl at e Warpage
Di aphragm spri ng f i ngers al i gnment
0. 03
(0. 001) max
0. 6
(0. 02) max
0. 15
(0. 006)
1. 0
(0. 04)
Lro
3-7
lfllHlllllllllrltllli[
Standards
and Service
Limits
Manual Transmission
S40
-
Section 13
MEASUREMENT
Capaci t y |
(US
qt , t mp qt )
End pl ay
Di amet er of bal l bear i ng cont act ar ea A
( Tr ansmi ssi on
housi ng si de)
Di amet er of 4t h, 5t h gear
cont act ar ea B
Di amet er of 3r d gear cont act ar ea C
Di amet er of bal l bear i ng cont act ar ea D
( Cl ut ch
housi ng si de)
Bunout
STANDARD INEW}
' 1. 9
( 2. 0,
1. 7) f or over haul
1. 8
( 1. 9,
1. 6) f or oi t change
0. 11 0. 18
( 0. 004 _
0. 007)
21. 987
-
22. 000 (0. 8656
0. 8661)
26. 980 26. 993 (1. 0622 _
1. 0627)
33. 984 34. 000
(1. 3380
1. 3386)
25. 917
-
25. 99011. 0227
1. 0232)
0. 02 ( 0. 001)
max.
SEBVI CE LI MI T
r o
Mai nshaf t
Adj ust
21. 930
( 0. 8634)
26. 930 (' 1. 0602i
33. 930 (1. 3358)
25. 92011. 0205)
0. 05
(0. 002)
39. 07
(' r. 538)
0. 33
{ 0. 013)
0. 31
( 0. 012)
30. 15
( 1. 187)
30. 05
( 1. 183)
37. 07 { 1. 459)
0. 31
( 0. 0' 12)
28. 35 ( 1. 116)
LrO
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)
30. 12
-
30. 17 ( 1. 186
1. 188)
37.009 37.025
(1.4570 _
1.4577)
0.06
-
0.19
(0.002 -
0.007)
28.42
-
2a.47
11.119,1.1211
Count ershaf t Di amet er of needl e beari ng cont act area A
Dj amet er of l st gear
cont act ar ea
g
Di amet er of bal l bear i ng cont act ar ea C
Runout
30. 000- 30. 015
{ 1. 181 1
-
1. 1817)
35. 984
-
36. 000
( 1. 4167
1. 4173)
24. 980 24. 993
(0. 9835 -
0. 9840)
0. 02
( 0. 001) max.
29. 950 ( 1. 1791)
3s. 930 r . 4146)
24. 930 (0. 9815)
0. 0s
(0. 002)
End pl ay ( When
t i ght ened by t he speci f i ed t or que)
Thi ckness
41. 009
-
41. 025 ( ' t . 6145
1. 6152)
0. 03 0. 10
(0. 001 _
0. 004)
30. 41 30. 44 ( 1. 197 -
1 198)
41 . 01
11. 617J
0. 22
(0. 009)
30. 36
( 1. 195)
gear
End pt ay (When
t i ght ened by t he speci f i ed t orque)
44.009
-
44.025 (1.7326
1.7333)
0.04
-
0.12 (0.002 -
0 005)
31. 91 31. 96
( 1. 256
1. 258)
44.01 11.t35)
0. 24
(0. 009)
31. 85
( 1. 2s4)
33. 04 { 1. 301)
38. 93
(1. 533)
32. 01 ( 1. 260)
27. 06 ( 1. 065)
33.93
(1.336)
3r . 93 { 1. 257)
22.81 (0.898)
23. 51 ( 0. 926)
15. 08
(0. 594)
0. 14
( 0. 006)
0. 4
( 0. 016)
0. 16 (0. 006)
o. 6210. 02441
12. 78 ( 0. 5031)
t . D.
o. D.
Lengt h
33. 000
-
33. 010
(1. 2992
1. 2996)
38. 989 39. 000 11. 53s0_ 1. 53s4)
32.03
-
32.06 tl.261
-
1.2621
Spacer col l ar
( Mai nshaf t
4t h
and 5t h gear )
Beverse rdl er gear
LD.
Gear t o r ever se gear
shaf t cj ear ance
27. 002 27. 012 ( 1. 0631 _
1. 0635)
33.989
-
34.000 (1.3381 -
1.3386)
3r.989
-
32.000 (1.2594
1.2598)
22.83
-
22.86
(0.899
0.900)
23.53 23.56
(0.926 -
0.928)
r s. 016 15. 043 ( 0. 5912 _
0. 5922)
0. 032 0. 077
(0. 0013 _
0. 0030)
Ri ng- t o gear cl ear ance
{ Ri ng pushed
agai nst gear )
0. 73
-
1. l 8
( 0
029
-
0. 046)
For k f i nger t hi ckness
For k t o- synchr o sl eeve cl ear ance
l sv2nd/ st h
I 6. 2
-
6. 410. 244
-
O. ZS2)
3rdl 4t h 7. 4 i . 6l O 2g1 O 2ggt
0. 35
-
0. 65 (0. 014 -
0. 026)
Beverse shi t t f ork Fork pawl groove wi dt h
Fork t o-reverse i dl er gear
cl earance
L groove
wi dt h
Fork' t o-5t h/ reverse
shi f t pi ece pi n cl earance
12. 7
-
13. 0 ( 0. 50 _
0. 51)
0. 5 1. t
(0. 020
0. 043)
7 . 05
-
7 . 25 t O. 21A
-
0. 2851
0. 05 0. 35
(0. 002
0. 014)
Sh i f t a rm A t nner di amet er of sh i f t arm C cont act
f f i
Shi f t ar r 14- go "L; L ". m C cl ear ance
13. 05 13. 13 ( 0. 514
0. 517)
0. 05
-
0. 23
(0. 002 _
0. 009)
I nner di amet er of shi f t arm B shaf t cont act poi nt
Shi f t arm 8-t o shaf t cl earance
Shi f t arm B t o-shi f t pi ece
cl earance
Di amet er of shi f t pi ece
cont act poi nt
13. 973
-
14. 000 (0. 5501
0. 5512)
0. 013 0. 070
(0. 0005 _
0. 0028)
0. 2
-
0. 5 {0. 008 0. 020)
12. 9 13. 0
( 0. 508 -
0. 512)
MBS Shi f t prece
Di amet er of pi n
6. 9 7 . 1 \ O. 27 0 2A)
0. 095
(0. 004)
0. 14
( 0. 006)
Adj ust wi t h shi m
Di f f er enl i al car r i er Pi ni on shaf t bor e di amet er
Car r i er - t o pi ni on
shaf t cl ear ance
Dr i veshaf t bor e di amet er
Car r i er t o, dr i veshaf t cl ear ance
18. 010 18. 028 (0. 7091 _
0. 7098)
0. 023 0. 057
(0. 0009 -
0. 0022)
26. 025 26. 04s
{1. 0246_ 1. 0254)
0. 045
-
0. 086 (0. 0018
0. 0034)
Backl ash
Pi ni on gear
bore di amet er
Pi ni on gear-t o pi ni on
shaf t cl earance
0. 05 0. 15
(0. 002
0. 006)
18. 042
-
18. 066 ( 0. 7103 _
0. 7113)
0. 055
-
0. 095 {0. 0021
_
o. oo37)
0 0. 1 10
-
0. 004)
3- 8
L O
Uni t of l engt h: mm
( i n)
Tr ansmi ssi on oi l
43.009 43.025
(1.6933 -
1.6939)
0.06 0.21
(0.002 -
0.008)
31.42
-
31.41 \1.231
1.2391
t . D.
End
pl ay
Thi ckness
Di amet er of bal l beari ng cont act area A
Di amet er of l st gear cont act area I
Di amet er of needl e beari ng cont act area C
Runout
LD.
End
pl ay
{When t i ght ened by t he speci f i ed t orque)
Thi ckness
LD.
o. D.
Lengt h
Spacer col l ar
(CoLrnt ershaf t 2nd
gear )
Spacer col l ar
( Mai nshaf t 4t h
and 5t h
gear )
LD.
o. D.
Lengt n
Manual TransmissionS4C
-
Section 13
MASUREMENT
Mai nshaf t Fnd pl aV
Di amet er of bal l beari ng cont act area C
(Cl ut ch
housi ng si de)
Di amet er of 3rd gear cont act area B
Di amet er of bal l beari ng cont act area ' q
( Tr ansmi ssi on housi ng si de)
Runout
Capaci t y |
(US qt , l mp qt )
LD.
End pl ay
Thi ckness
2. 3
( 2. 4, 2. 0) f or over haul
2. 2
( 2. 3,
1. 9) f or oi l change
0. 11
-
0. 18
( 0. 004 -
0. 007)
21 .917
-
21 .990 11.1015
-
1 .10201
37. 984 38. 000
(1. 4954 1. 4960)
27. 987
-
28. 000
( 1. 1018 1. 1024)
STANDARD {NEW)
0. 02
( 0. 001) max.
SERVI CE LI MI T
Adt ust
27. 930
( 1. 0996)
37 930
(1. 4933)
27. 940
( 1. 1000)
0.05
(0.002)
Mai nshaf t 3r d and
4t h gear s
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)
24. 980 24. 993
(0. 9835
0. 9840)
36. 984 37. 000
(1. 4561 -
1. 4567)
33. 000
-
33. 015
(1. 2992 -
1. 2998)
0. 02
(0. 0008) max.
3rd
4t h
43. 08
( 1. 696)
0. 3
( 0. 01)
34. 3
(' t . 350)
31.3 11.232)
43. 08
( 1. 696)
0. 3
( 0. 01)
31. 311. 232)
24. 940
(0. 9818)
36. 930
(1. 4539)
32. 950
( 1. 2970)
0. 05
(0. 002)
41. 07
( 1. 617)
0. 25
( 0. 01)
41. 009
-
41. 025
( 1. 6145 -
1. 6152)
0. 045
-
0. 205
(0. 0018 0. 0081)
44.009 44.025 {1.7326
-
1.7333)
0.07 0.14
(0.003 -
0.006)
28.92
-
28.97
(1.1386
-' j .1405)
36. 521
-
36. 531
(1. 4378 1. 4382)
41. 989- 42. 000
( 1. 6531
-
1. 6535)
29. 07
-
29. 09 11. 1444
-
1. 1453)
44. 07
( 1. 735)
0. 24
(0. 009)
28. 8
( 1. 134)
36. 54
( 1. 439)
41. 93
( 1. 651)
31 .0O2
-
31 .012 11 .2205
-
1 .2209'l
36. 989
-
37. 000 {1. 4563
-
1. 4570)
56.45
-
56.55 1'2.2224
-
2.22641
26.03
-
26.0A 11 .025
-
1 .021 |
31. 06
( 1. 223)
36. 94
( 1. 454)
( cont ' d)
3- 9
MEASUREMENT
STANDARD
(NEW)
SERVICE LIMIT
Reverse i dl er gear
t.D.
Gear-to reverse gear
shaft clearance
20. 016
-
20. 043 (0. 7880 -0. 7891)
0. 036
-
0. 084 {0. 0014
-
0. 0033)
20. 09
(0. 7909)
0. 16
(0. 006)
Synchro ri ng Ri ng t o-gear cl earance
(Ri ng pushed
agai nst gear)
0. 73
-
1. 18 (0. 029
0. 046) 0. 4
( 0. 016)
Doubl e cone
Cl earance
(Ri ng pushed
agai nst gead
Out er synchro ri ng t o gear
I n ner synchro ri ng t o-gear
Out er synchro ri ng-t o-synchro cone
0. 9s
-
1. 68 10. 037
-
0. 066)
0. 5
-
1. 0
(0. 02 -
0. 04)
0. 5 1. 0 (0. 02 -
0. 04)
0. 6
(0. 024)
0. 3 { 0. 01)
0. 3
( 0. 01)
Shi f t f ork
Fork {i nger t hi ckness
Fork-t o synchro sl eeve cl earance
7. 4
-
7. 6 ( 0. 291-
0. 299i
0. 35
-
0. 65
(0. 015
0. 026) 1.0
(0.04)
Beverse shi f t f ork
Fork pawl groove wi dt h
Fork-t o-reverse i dl er gear
cl earance
L-groove wi dt h
At 5t h gear
si de
At reverse side
Fork'to-5th/reverse shift piece pin
clearance
At 5t h gear
si de
At reverse si de
13. 0
-
13. 3 10. 512
-
0. 524)
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. 4 0. 9
(0. 02
0. 04)
0. 05 0. 45
(0. 002 -
0. 018)
1 { 0. 07)
Shi f t pi ece
Shi f t pi ece-t o-shi f t
arm cl earance
Groove wi dt h of shi f t arm cont act area
Shilt'piece-to-shift fork shaft clearance
Width of shift lork contact area
0. 1
-
0. 3
(0. 004 -
0. 012)
8. 1- 8. 2
( 0. 319 -
0. 323i
0. 2
-
0. 5
(0. 008
0. 020)
1 1. 9
-
12. 0 10. 469
-
0. 472)
0.6
(0.02)
0.8
(0.03)
Sel ect ar m
Sel ect arm-t o-i nt erl ock cl earance
Sel ect arm t o-shi m cl earance
0. 05
-
0. 20
(0. 002 -
0. 008)
0. 01
-
0. 2 10. 0004
-
0. 008)
0. 45
(0. 018)
I nt erl ock Wi dt h of sel ect arm cont act area 9. 9
-
10. 0 (0. 390
0. 394)
Change pi ece
Change pi ece-t o-shi l t
arm hol der cl earance
Groove wi dt h ot shi t t arm hol der cont act area
Change pi ece-t o
sel ect arm cl earance
Groove width of select arm contact area
0.05
-
0.35
(0.002 -
0.014)
12. 05
-
12. 15 \ 0. 474
- 0. 47a1
0.05
-
0.25
(0.002 -
0.010)
12.05
-
12. t5
(0.474 -
0.478)
0. 8 {0. 03)
0. 5
(0. 02)
Fi nal dr i ven gear Backl ash
0. 090
-
0. 149
(0. 0035 -
0. 0059) 0. 200
(0. 008)
Di f f erent i al carri er
Pi ni on shat t bore di amet er
Carri er t o-pi ni on shaf t cl earance
Dri veshaf t bore di amet er
Carri er-t o dri veshaf t cl earance
Carri er-t o-i nt 6rmedi at e shat t cl earance
18. 000
-
18. 016 10. 7087
-
0. 7093)
0. 013
-
0. 045 {0. 001 0. 002)
24.000
-
28.021
11.1024 1.1032)
0. 020, 0. 062 (0. 0008 -
0. 0024)
0. 05
-
0. 087 {0. 0020
-
0. 0034)
0. 10 {0. 004)
0. 12
(0. 005)
0. 14
(0. 006)
Di f f erent i al pi ni on
gear
Backl ash
Pi ni on gear
bore di amet er
Pi ni on gear-t o-pi ni on
shaf t cl earance
0.05
-0.15
(0.002 -
0.006)
18. 042 18. 066 ( 0. 710 -
0. 711)
0.055
-
0.095
(0.002 -
0.004) 0. 15
( 0. 006)
Set ri ng t o beari ng out er race
0
-
0. 10
(0 -
0. 004) Adj ust wi t h shi m
Standards and
Manual Transmission
Service
S4C
(cont' d)
Limits
-
Section 13
ua
.'1'
3- 10
L,O
Automatic T tssron Section 14
Uni t of l engt hi mm
( i n)
f ansmtssron
-
MEASUREMENT
STANOARD {NEWI
SERVI CE LI MI T
Transmi ssi on
f l ui d
Capaci t y f
(US qt , l mp qt i 5. 9
(6. 2,
5. 2)I or overhaul
2. 7
(2. 9,
2. 4) f or f l ui d chanse
sgO
g8ol 85
SO, r zO r SO,
r Ao, e' 0 I 0,
Hydraul i c
kPa
(kgf/cm', psa)
Li ne pressure at 2, 000 rpm i n E or E
posi t i on
1s t c l ul c h
pr es s ur e al 2, O0Or pmi n D. pos i t i on
2nd cl ut ch
pressure at 2, 000 rpm i n
El
posi t i on 800
-
850
(8. 2 -8. 7,
120
-
124) 760
( 7. 7, 110)
3rd and 4t h cl ut ch
pressure at 2, 000 rpm i n
l Fl
posi -
t i on
810- 860
( 8. 3
-
8. 8, 118
-
125) 7 6 0
( 7 . 8 , 1 l 1 )
St al l speed rpm
(Check
wi t h vehi cl e on l evel ground) 2,100
28
1_
ffi9
30. 0
( 1. 18)
28. 5 \ 1. 12)
2 9 . 1
( 1 . 1 5 )
28. 511. 121
Unt i l grooves worn out
Di scol orat i on
Cl ut ch
Cl ut ch i ni t i al cl earance
Cl ut ch ret urn spri ng f ree l engt h
(A4RA,
B4RA Transmi ssi on)
l M4RA
Transmi ssi on)
Cl ut ch di sc t hi ckness
Cl ut ch
pl at e t hi ckness
Ctr t"h ""d
pl"t" thl"t**
(A4RA, B4RA Transmi ssi on)
1st , 2nd
3r d, 4t h
1st
2nd, 3r d, 4t h
l st
2nd, 3r d, 4t h
1st
2nd, 3r d, 4t h
Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
Mar k I
Mark I
M"*l
Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
Mark 8
Mark 9
Mark 10
Mar k 11
Mar k 12
Mar k l 3
Mar k 14
Mar k 15
Mar k 16
Mark 17
Mark 18
Cl ut ch end pl at e t hi ckness
( M4RA Tr ansmassi oni
0. 65
,
0. 85
(0. 026 -
0. 033)
0. 40
-
0. 60
(0. 016 -
0. 024)
32. 0
( 1. 26)
30. s
(1. 20i
31 . 1 11. 221
30. 5
( 1. 20)
1. 88
-
2. 00 {0. 074
-
0. 079)
1. 55
-
1. 6510. 061
- 0. 065)
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. 75
-
2. 80
( 0. 108 0. 110)
2. 85 2. 90
( 0. 112 -
0. 114)
Di scol or at i on
1
I
I
Di scol or at i on
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. 106
-
0. 110)
2. 8
-
2. 9 10. 110
0. 114)
2. 9
-
3. 0
( 0. 114- 0. 118)
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. 126
-
0. 130}
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. 130 0. 134)
3. 4
-
3. 5
(0. 134 -
0. 138)
3. 5
-
3. 6
(0. 138 0. 142)
3. 6 3. 7 { 0. 142-
0. 146)
3. 7
, 3. 8
10. 146
-
0. 150i
Di scol or at i on
1
I
I
L
I
Di scol orat i on
( cont ' d)
3 - 1 1
Standards
and Service Limits
Automatic Transmission
(cont' d) -
Section l4
MEASUREMENT
STANOARD
{NEW) SERVI CE LI MI T
Di amet er of needl e beari ng cont act area
On mai nshaf t st at or shaf t beari ng
On mai nshaf t 2nd gear
On mai nshaf t 4t h gear
col l ar
On mai nshaf t 1st gear
col l ar
On count ershaf t (l ef t
si de)
On count ershaf t 3rd gear col l ar
On count ershaf t 4t h gear
On count ershaf t reverse gear col l ar
On count ershaf t 1st gear
col l ar
On reverse i dl er gear
shaf t
I nsi de di amet er of needl e beari ng cont act area
On mai nshaf t 1st gear
On mai nshaf t 2nd gear
On mai nshaf t 4t h gear
On count ershaf t 1st gear
On count ershaf t 3rd gear
On count ershaf t 4t h gear
On count ershaf t reverse gear
On reverse i dl er gear
On st at or shaf t
(ATF pump
si dei
On st at or shal t
(st at or
si de)
shaf t hol der l . D.
End pl ay
Mai nshaf t l st gear
Mai nshaf t 2nd gear
Mai nshaf t 4t h gear
Count ershaf t l st gear
Count ershaf t 3rd gear
Count ershaf t 4t h gear
Count ershaf t reverse gear
Sel ect o. hub O. D.
Mai nshaf t 4t h gear
col l ar l engt h
Marnshaf t 4t h gear
col l ar I l ange t hi ckness
col l ar l engt h
22.980 22.993
10.9047 0.9052|j
35. 975 35. 991
( 1. 4163 -
1. 4169)
31. 975 31. 991 ( 1. 2589_, 1. 2595)
30. 975
-
30. 991 t 1. 2195 1. 22011
36. 004 36. 017
( 1. 4175 -
1. 4180)
35. 980 35. 996
( 1. 4165 -
1. 4172)
27. 980
-
27. 993 ( 1. 1016 -
1. 1021)
31. 975 31. 991
( 1. 2589 -
1. 2595)
31. 97s 31. 991
( 1. 2589 -
1. 2595)
13. 990
-
14. 000 {0. 5508
-
0. 5512)
35. 000, 3s. 016 ( 1. 3780 -
1. 3786)
41. 000
-
41. 016
11. 6142
-
1. 6148)
38. 000
-
38. 0' 16 {1. 4961
-
1. 4967)
38. 000 38. 016
(1. 4961 -
1. 4967)
41. 000 41. 016 ( 1. 6142 -
1. 6148)
33. 000
-
33. 016
(1. 2992
1. 2998)
38. 000
-
38. 016
(1. 4961 -
1. 4967)
18. 007
-
18. 020 (0. 7089 -
0. 7094)
29. OO0
-29. O1311. 1417 -
1. 14221
27. O00 27. 02111. 0630
-
1. 0638)
' 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)
4. 435
-
4. 525
(0. 1746 -
0. 1781)
27. 00- 27. 15 ( 1. 063 -
1. 069)
Count ershaf t di st ance col l ar l engt h
38. 87
-
38. 90 {1. 530
-
1. 531)
38. 92 38. 95 {1. 532
-
1. 533)
38. 97
-
39. 00
( 1. 534, 1. 535i
39. 02
-
39. 05
(1. 536 -
1. 537)
39. 07
-
39. 10 {1. 538
-
1. 539)
39. r 2
-
39. 15
( 1. 540 -
1. 541)
39. 17
-
39. 20
( 1. 542 -
1. 543)
39. 22
-
39. 25
(1. 544 -
' t . 545)
39. 27 39. 30
(1. 546 -
1. 547)
Count ershaf t 3rd gear col l ar l engt h
, 96
97 model s
'98
-
00 modets
col l ar l engt h
col l ar f l ange
t hackness
Count ershaf t 1st gear col l ar l engt h
Count ershaf t l st gear col l ar f l ange t hi ckness
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. 6 10. 094 0. 102)
14. s
-
14. 6 (0. 571 -
0. 575)
2. 4 2. 6
(0. 094 -
0. 102)
Wear or damage
t a . \
L
Automatic T nsmtsston Section 14
Un; t of l engt h: mm { i n)
r
MEASUREMENT
a
STANDARD INEW)
SEBVI CE LI MI T
Transmi ssi on
Mai nshaf t 2nd gear t hr ust washer t hi ckness
Thrust washer t hi ckness
Mai nshaf t bal l beari ng l ef t si de
Countershaft 3rd
gear splined washer
'96
97 models
' 98
-
00 model s
One-way cl ut ch cont act area
Count ershaf t 1st gear LD.
Park gear O. D.
Mai nshaf t f eed
pi pe A, O. D.
(at
15 mm
(0. 59 i nl f rom
Mai nshaf t f eed
pi pe B, O. D.
(at
30 mm {1. 2 i n) f rom end)
Count ershaf t f eed
pi pe O. D. l at 15 mm
(0
59 i n) f rom
eno)
Mai nshaf t seal i ng ri ng t hi ckness
129 mm 11. 1 i ni and 35 mm { 1. 4 i n) )
Mai nshaf t bushi ng l . D.
Mai nshaf t bushi ng LD.
Count ershaf t bushi ng LD.
Mai nshaf t seal i ng ri ng
goove wi dt h
3. 97 4. 00 10. 156
-
0. 157)
4. 02
-
4. 05
(0. 158 0. 159)
4. 07
-
4. 10
( 0. 160 -
0. 161)
4. 12
-
4. 15
( 0. 162 0. 163)
4. 17
-
4. 20 10. 164
-
0. 165)
4. 22
-
4. 25
(0. 166 -
0. 167)
4. 27
-
4. 30
( 0. 168- 0. 169)
4. 32
-
4. 35
( 0. 170 0. 171)
4. 37
-
4. 40 10. 172
-
0. 173)
4. 42
-
4. 45 10. 114
-
0. 175l
1
I
+
Wear or damage
2. 95
-
3. 05 { 0. 116
-
0. 120)
2. 43 2. 50
(0. 096 -
0. 098)
4. 45
-
4. 50
( 0. 175 -
0. 177i
4. 95
-
5. 00
(0. 195
0. 197)
Wear or damage
+
I
83. 339
-
83. 365
(3. 2810 3. 2821)
66. 685
-
66. 698
(2. 6254
-
2. 6259)
8. 97
-
8. 98
(0. 353
-
0. 354)
5. 97 5. 9810. 2350
-
0. 2354i
7. 97
-
7. 98
(0. 3138
-
0. 3142)
1. 87
-
1. 97 {0. 074
0. 078)
6. 0 r8
-
6. 030 {0. 2369
-
0. 2374)
9. 000
-
9. 01s 10. 3543-0. 3549)
8. 000-8. 022
(0. 3150
-
0. 3158)
2.025
-
2.015 l0.0197
-0.0417)
Wear or damage
Wear or darn age
8. 95
(0. 352J
5. 95
( 0. 234)
7. 95
( 0. 313)
1. 80
( 0. 071)
6. 045
(0. 2380)
9. 03
(0. 356)
8. 03 {0. 316)
2. 08
(0. 082)
Regul at or
val ve body
Seat i ng r i ng conl act ar ea l . D.
35. 000 35. 02511. 3780 1. 3782) 35. 050
(1. 3799)
Shi f t i ng devi ce and
par k br ake cont r ol
Reverse shi f t f ork I i nger t hi ckness
Park brake pawl
Park gear
5. 90
-
6. 00
(0. 232 -
0. 236) 5. 40
(0. 213)
l Wear
or ot her def ect
Servo body Shift fork shaft bore LD.
Shi f t f ork shaf t val ve bore l . D.
14. 000
-
14. 010
(0. 5512
-
0. 5516)
37. 000
-
37. 039
(1. 4567
-
1. 4582) 37. 045
( 1. 4585)
ATF
pump ATF pump gear si de cl earance
ATF pump gear-t o-body cl earance
Dri ve
Dai ven
ATF pump dri ven
gear LD.
ATF pump dri ven gear shaf t O. D
0. 03
-0. 05
{0. 001
-
0. 002)
0. 1050
-
0. 1325
(0. 0041
-
0. 0052)
0. 0350
-
0. 0625
(0. 0014
-
0. 0025)
14. 0' | 6
-
14. 034 {0. 5518
-
0. 5525i
13. 980 13. 990
(0. 5504 0. 5508)
0. 07
(0. 003)
Di f f er ent i al
car r i er
Pi ni on shaf t cont act area LD.
Carri er t o' pi ni on cl earance
Dri veshaf t cont act are LD.
Carri er t o-dri veshaf t cl earance
18. 010 18. 028 {0. 7091
0. 7098)
0. 023
-
0. 057
(0. 0009
-0. 0022)
26. 025
*
26. 045 11. 0246
1. 0254)
0. 045
-
0. 086
(0. 0018
-
0. 0034)
0. 1 {0. 004)
0. 12 { 0. 005)
Di f f erent i al
prnron gear
Backl ash
t . D.
Pi ni on gear t o- pi ni on shaf t cl ear ance
0. 05
-
0. 15 {0. 002
-
0. 006)
18. 042
-
18. 066
(0. 7103 -
0. 7113i
0. 055
-
0. 095
(0. 0022 -
0. 0037) ffi.oour
Set r i ng- t o bear i ng out er r ace cl ear ance
0
-
0. 15
(0
0. 006)
Adj ust
(cont ' d)
3- 13
Standards and ServiceLi mi ts
Section
' 14
Automatic Transmission (cont' d)
UO
MEASUREMENT
STANDARD {NEW}
Wi re Di a.
o.D. Free Longth No. ol Coils
Hegul at or val ve spri ng A
Regul at o. val ve spri ng B
St at or react i on spri ng
Modul at or val ve spri ng
Torque convener check val ve spri ng
Cool er rel i ef val ve spri ng
Rel i ef val ve spri ng
2nd ori t i ce cont rol val ve spri ng
1-2 shi f t val ve spri ng
2-3 sh i f t val ve spri ng
3 4 shi f t val ve spri ng
' l
st accumul at or spri ng
4t h accumul at or spri ng B
4t h accumul at or spri ng A
2nd accumul at or spri ng A
3rd accumul at or spri ng A
2nd accumul at or spri ng B
3rd acc! mul at or spri ng B
2nd accumul at or spri ng C
Lock up shi f t val ve spri ng
Lock up t i mi ng val ve spri ng
Lock-up cont rol val ve spri ng
3 4 of i f i ce cont rol val ve spri ng
Servo cont rol val ve spri ng
CPC val ve spri ng
CPB val ve spri ng
4t h exhaust val ve spri ng
Spri ngs
1. 8 { 0. 071)
1. 8 { 0. 071)
4. 5 \ O. 117)
1. 4
( 0. 055)
1. 0 10. 039)
1. 0
(0. 039)
1. 1
( 0. 043)
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. ' 110)
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)
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. 2l o. 402l
17. 0 {0. 676)
29. 0
( 1. 152)
17. 5 ( 0. 6951
9. 0
(0. 358)
31. 0 ( 1. 220)
14. 5 {0. 576)
7. 6
(0. 302)
8. 1
( 0. 319)
6. 610. 262)
6. 6
(0. 262)
8. 1
(0. 322)
5.6
(0.2231
8. 1 10. 322)
6.1 10.242)
87. 8
(3. 457)
44.0 i.732l'
30. 3
( 1. 193)
35. 0 {1. 378)
33. 8
( 1. 331)
33. 8
( 1. 331)
37. 1
( 1. 461)
34. 8
(1. 370)
41. 3 ( 1. 626)
57.0
(2.2441
51 . 0
\ 2. 2441
89. 1 {3. 508)
51. 6
( 2. 031)
87. 0
(3. 425)
39. 011. 535)
89. 3
(3. 516)
20. 7 ( 0. 815)
35. 1 11. 382)
68. 012. 6711
73.7
12.902)
80. 7
(3. 177)
38. 0 {1. 496)
37. 5 f i . 476)
52. 1
(2. 051)
12. 2
(0. 480)
47. 2 {1. 858}
36. 4 {1. 433)
16. 5
1 1 . 0
1 . 9
10. 9
4. 2
4. 2
1 3 . 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
1 4 . 1
24. 6
20.4
18. 3
19. 5
CVT Section 14
3-14
MEASUREMENT
STANDARD INEWI SERVICE LIMIT
Transmi ssi on
f l ui d
Capaci t y f {US
qt , l mp. qt )
6. 4 {6. 8, 5. 6) f or overhaul
3. 9
(4. 1,
3. 4) f or f l ui d change
Hydraul i c
pressure
1kgflcm,,
psi)
Forward cl ut ch pressure
at 1, 500 rpm i n
E
posi t i on
1. 4
-
1. 15
114. 3
-
11. A, 203
-
2531
Reverse brake pressure
at 1, 500 rpm i n
E
posi t i on
1. 4
-
1. 75 (14. 3
11. 8, 203 2531
Dr; ve pul l ey pressure
at 1, 500 rpm i n
E
posrt ron
o. 2
- 0. 7
12. 0
- 7. 1, 28-
1011
Dri ven pul l ey pressure at 1, 500 rpm i n
N
posi t i on
r . 5
-
2. 3 115. 3
-
23. 5, 218
-
334)
Lubri cat i on pressure
at 3, 000 rpm i n
E
posrt ron
Above 0. 212, 30)
St al l speed f pm (Check
wi t h vehi cl e on l evel ground)
E
posi t i on
E, E, El
posi t i ons
2,500
3,000
2,350
-
2,650
2,800
-
3, r00
Cl ut ch
Cl ut ch i ni t i al cl earance Forward cl ut ch
Start clutch
Reverse brake
Cl ut ch ret urn spri ng f ree l engt h Forward cl ut ch
Start clutch
Reverse brake
Cl ut ch di sc t hi ckness Forward cl ut ch
St art cl ut ch
Reverse brake
Cl ut ch pl at e
t hi ckness Forward cl ut ch
St a rt cl ut ch
Reverse brake
0. 6
-
0. 8
(0. 024 -
0. 031)
0. 5
-
0. 7
(0. 020
0. 028)
0. 45
-
0. 75
(0. 018 -
0. 030)
30. 5 { 1. 201)
40. 9
( 1. 610)
29. 4
( 1. 157)
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)
, *x. ar}
38. 9
( 1. 531)
27. 411. 019l '
Unt i l grooves worn out
Unt i l grooves
worn out
Di scol orat i on
Di scol orat i on
Di scol orat i on
L.
cw Section 14
[ Jni t of l engt h: mm
( i n)
MEASUBEMENT
STANDARD {NEW}
SERVICE LIMIT
Forward cl ut ch end
pl at e t hi ckness Mark 1 or 15
Mar k 2 or 16
Mar k 3 or 17
Mar k 4 or 18
Mar k 5 or 19
Mark 6 or 20
Mark 7 or 21
Mark 8 or 22
Mark I or 23
Mark 10 or 24
Mark 11 or 25
Mark 12 or 26
Matk 13 ot 21
3. 4
-
3. 5 10. 134
-
0. 138)
3. 5
-
3. 6
( 0. 138 -
0. 142)
3. 6
-
3. 7
( 0. 142 -
0. 146)
3. 7 3. 8
(0. 146 0. 150)
3. 8
-
3. 9
( 0. 150 -
0. 154)
3. 9
-
4. 0
( 0. 154 -
0. 157i
4. 0
-
4. 1
( 0. 157 -
0. 161)
4. 1
-
4. 2
(0. 161
-
0. 165)
4. 2
-
4. 3
(0. 165 -
0. 169)
4. 3
-
4. 4
(0. 169
-
0. 173)
4. 4
-
4. 5 10. 173
-
0. 177i
4. 5 4. 6
( 0. 177 0. 181)
4. 6
-
4. 7
(0. 181 -
0. 185)
Di scol orat i on
Di scol or at i on
Reverse brake end
pl at e t hi ckness Mark 1
Mark 2
Mark 3
Mark 4
\44 rk 5
Mark 6
Mark 7
Mark 8
3. 55
-
3. 65
(0. 140
0. 144)
3. 75
-
3. 85 10. 148
-
0. 152)
3. 95
-
4. 05
(0. 156 -
0. 159i
4. 15
-
4. 25
( 0. 163
0. 167)
4. 35
-
4. 45
(0. 171 -
0. 175)
4. 55
-
4. 65
(0. 179
-
0. 183)
4. 75
-
4. 85
(0. 187 -
0. 191)
4. 95
-
5. 05
(0. 195 -
0. 199)
Di scol or at i on
1
I
Di scol or at i on
ATF
pump
ATF pump dri ve
gear shaf t O. D.
ATF pump dri ven gear shaf t O. D.
ATF pump body bushi ng l . D. Dri ve gear shaf t
Dri ven gear shaf t
ATF pump gear si de cl earance
ATF pump gear-to-body clearance Drive gear
Dri ven
gear
9. 98
-
9. 99
(0. 3929 0. 3933)
9. 98
-
9. 99 {0. 3929
-
0. 3933)
10. 000
-
10. 015
(0. 3937 0. 3943)
10. 000
-
10. 015
(0. 3937 0. 3943)
0. 01s
-
0. 035
(0. 0006 0. 0014)
0. 035
-
0. 0505
(0. 0014-
0. 0020)
0.035
-
0.0505
(0.0014
-
0.0020)
Wear or damaged
Wear or damaged
Wear or damaged
Wear or damaged
Transmi ssi on Di amet er of needl e beari ng cont act area
I nput shaf t
-
f l ywheel si de
I nput shaf t f orward cl ut ch si de
Dri ve pul l ey shaf t
-
st art cl ut ch si de
Dri ve pul l ey shaf t
-
f l ywheel si de
Dri ve
pul l ey shaf t
-
f orward cl ut ch si de
Thrust cl earance
Carri er and ri ng gear
Dri ven
pul l ey shaf t and st art cl ut ch hub
I nput shaf t and ATF
pump dri ven sprocket
Secondary
gear shaf t and f l ywheel bal l beari ng
19. 987
-
20. 000
(0. 7869 -
0. 7874)
19. 987
-
20. 000
(0. 7869 -
0. 7874)
43. 981
-
43. 991
(1. 7315 -
1. 7319)
24. 007
-
24. 020
(0. 945 -
0. 946)
24. 007
-
24. 020
(0. 945 -
0. 946)
0. 050
-
0. 110
(0. 0020
-
0. 0043)
0. 000
-
0. 130 10. 000
-
0. 005)
0. 370
-
0. 650
(0. 015 -
0. 026)
0. 00 0. 15
(0. 00
0. 006)
Wear or damaged
Wear or damaged
Wear or damaged
Wear or damaged
Wear or damaged
(cont ' d)
3- 15
Transmi ssi on
(cont ' d)
MEASUREMENT
Thr ust shi m, 25 x 31 mm t hi ckness
STANDARD
{NEW}
rl z-r-osr-o. o+o
ool rr
1. 09
-
1. 12
( 0. 043
0. 044)
1. 16 1. 19
( 0. 046 -
0. 047)
1. 23 1. 26
(0. 048
0. 050)
1. 30
-
1. 33
( 0. 051
0. 052)
1. 37
-
1. 40
(0. 054
0. 055)
1. 44
-
1. 47
(0. 057
0. 058)
1. 51 1. 54
( 0. 059
0. 061)
1. 58 1. 61
( 0. 062 -
0. 063)
1. 65
-
1. 68 (0. 065
0. 066)
1. 72 1. 75
{0. 068 0. 069)
1. 79 1 . a2 t 0. O10
-
0. 012] }
1. 055 1. 085 ( 0. 0415
0. 0427)
1. 125
-
1. 155
( 0. 0443
0. 0454)
1. 195
-
' I . 225
(0. 0470
0. 0482)
1. 265
-
1. 29s
( 0. 0498
0. 0510)
1. 335 1. 365 (0. 0526 -
0. 0537)
1. 40s
-
1. 435 (0. 0553 -
0. 0565)
r. 475 1. 505 {0. 0580 0. 0593)
1. 545 1. 575
(0. 0608
0. 0620)
1. 615 1. 645 (0. 0636 -
0. 0648)
1. 685 1. 71510. 0663
-
0. 0675)
1. 755
-
1. 785 {0. 0691 0. 0703)
SERVICE LIMIT
I
Wr"r - d-"-"g"d
i i
1 1
i r
Cot t ers t hi ckness
2. 87
-
2. 90
( 0. 1
13
-
0. 114)
2. 97
-
3. 00
( 0. 117
0. 118)
3. 07
-3. 10
\ 0. 121 0. 122)
3. 17
-
3. 20
( 0. 125
0. 126)
Wear , or damaged
I
Wear or damaoed
ATF pump
dri ve sprocket t hrust shi m, 22 x 28 mm
t hi ckness
1. 12 1. 1510. 044
-
0. 045)
1. 37 1. 40
(0. 054 -
0. 055)
1. 62
-
1. 65
(0. 064
0. 065)
1. 87
-
1. 90
( 0. 074, 0. 075)
2. 12 2. 15 (0. 083 -
0. 08s)
2. 37 2. 40
(0. 093
0. 094)
Wear or damaged
t
{
Wear or damaged
Secondary gear
shaf t t hrust shi m, 25 x 35 rnm
t hi ckness
2. 80
-
2. 85
( 0. 1' t 0 -
0. 112)
2. 90 2. 95
( 0. 114 -
0. 116)
3. 00 3. 05
( 0. 118 -
0. 120)
3. 10
- 3. 15
10. 122 0. 124)
3. 20
-
3. 25
( 0. 126,
0. 128i
3. 30
-
3. 35
(0. 130
0. 132)
3. 40
-
3. 4s 10. 134 0. 136)
3. 50 3. 55
( 0. 138 -
0. 140)
3. 60, 3. 65
( 0. 142
0. 144)
3. 70
-
3. 75 ( 0. 146
0. 148)
3. 80
-
3. 8510. 150 0. 152)
Wear or damaged
Wear or damaqed
I nput shaf t f eed pi pe
O. D.
Dr i ve pul l ey
l eed pi pe
For war d cl ut ch f eed pi pe
I nput shaf t bushi ng t . D.
Dr i ve pul l ey f eed pi pe bushi ng
For war d cl ut ch f eed pi pe
bushi ng
Dr i ven shaf t f eed pi pe
O. D.
St ar t cl ut ch f eed pi pe ( r i ght
si de cover si de)
Dr i ven pul l ey f eed pi pe
St an cl ut ch f eed pi pe ( f t ywheet
housi ng si de)
Dr i ven pul l ey
shaf t bushi ng LD.
St an cl ut ch f eed pi pe ( r i ght
si de cover sr oer
Dr i ve pul l ey f eed pi pe
St ar t cl ut ch f eed pi pe ( f l ywheel
housi ng si de)
Secondar y dr i ven gear
seal i ng r i ng gr oove
wi dt h
St ar t cl ut ch end pl at e l . D.
I nput shaf t seal i ng r i ng gr oove
wi dt h
Dnve pul l ev
shaf t LD. at seal i ng r i ng
Par k br ake cone
Par k br ake pawl
Par k gear
6. 97
-
6. 98
(0. 274 -
0. 27s)
11. 47
-
1' 1. 48
( 0. 4516
0. 4520)
7. O0O 7. 0t 510. 2156
-
0. 2762] l
11. 500 11. 518 ( 0. 4528
0. 4535)
6. 97
-
6. 9A \ 0. 214 0. 275: l
11. 47
-
11. 48 ( 0. 4516 _
0. 4520)
8. 97 8. 98 10. 353
-
0. 354)
7. 000 7. 015 (0. 2756 -
0. 2762)
1 1. 500
-
' 11. 518
(0. 4528 -
0. 4535)
9. 000 9. 015 10. 354
-
0. 355)
2. 50 2. 65
(0. 098
0. 104)
88. 900, 88. 935 (3. 500 -
3. 501)
2. 00 2. 10
10. 079
-
0. 083)
5*
6. 95
(0. 274)
11. 45
( 0. 451)
7. 030
(0. 277)
11. 533 ( 0. 4s4)
6. 95
(0. 274)
11. 45 ( 0. 451)
8 95
(0. 352)
t . 030l 0. 2t 7l
1r . 533
( 0. 454)
9. 03
(0. 356)
2. 655 (0.
r05)
Wear or damaged
2. 105
( 0. 083)
Wear or damaqed
Shi f t i ng devi ce
ano par K
br ake cont r ol
Wear or ot her def ect
Standardsand Servi ce Li mi ts
CW {cont' d) Section 14
r l
w
3- 16
ro
Uni t of l engt h: mm l i n)
STANDARD {NEW)
SERVICE LIMIT
MEASUREMENT
Di f f erent i al
Dt ri "*"t "| p' . b"
gear
S"t rrg-t " b""i l "s
Pi ni on shaf t cont act ar ea LD.
Car r i er - t o
pi ni on cl ear ance
Dr i ve shaf t cont act ar ea l . D.
Car r i er t o dr i veshaf t cl ear ance
Backl ash
LD.
Pi ni on
gear t o- pi ni on shaf l cl ear ance
) ut er r ace cl ear ance
18. 010 18. 028' 0. 7091
-
0. 7098)
0. 023 0. 057
(0. 0009 -
0. 0022) 0. 1
(0
004)
26.025
-
26.045
(.0246
1 0254\
0. 045 0. 086
(0. 0018 -
0. 0034) 0. 12(0. 005)
0 05
-
0. 15 i 0 002 0. 006)
18 042 18. 066 { 0. 7103 0. 7" l 3)
0. 055
-
0. 095
(0. 0022 -
0. 0037) 0. 15 {0. 006)
0 0. 15
(0 -
0. 006)
Adj l rst
MEASUBEMENT
Wi re Di a O. D. Free Lengt h
I
No. of Coi l s
Spr i ngs PH regul at or val ve spri ng
1 2
(0
047)
PH cont rol val ve spri ng
1 7 {0. 067)
PL regul at or val ve spri ng 0 9
(0. 035)
PH' PL cont rol val ve spri ng 1 0
(0
039)
cr ut l h r educ' ns vdr ve spnns
] : 19 9] : l
LLbri cat i on val ve spri ng
I b
(u ubJr
Shi t t val ve spri ng
1 4
(0. 055)
Shi f t cont rol val ve spri ng
1 0
(0. 039)
St an cl ut ch cont rol val ve spri ng 0. 4
(0
016)
Pi t ot regul at or val ve spri ng 0. 6
(0
024)
St art cl ut ch val ve accumul at or spri ng 1 2 \ 0 O47)
Reverse cont rol val ve spri ng 1 2
(0. 047)
Shi f t i nhi bi t or val ve spri ng 1 3
(0
051)
9. 0 {0. 354)
13. 4
(0. 528)
1. 2l O. 2A3\
10. 0
(0. 394)
16. 8
( 0. 661)
13. 4
(0. 528)
8. 2
(0. 323)
1 .4 t0.2911
4. 1
( 0. 161)
5.7 t0.224)
8. 3 {0. 327)
9. 4
(0. 370)
13. 2
( 0. 520)
26. 7
( 1. 051)
39. 4
( 1. 551)
14. 6
( 0. 575)
31. 4
( 1. 236)
44. 4 \ 1. 14al
51. 6
( 2. 031)
34. 1
( 1. 343)
19. 3
( 0. 760)
12. 1
( 0. 476)
9. 5
( 0. 374)
29. 8
( 1. 173)
31. 4
( 1. 236)
48. 3
( 1. 902)
r 0. 0
8. 1
1. 2
8. 6
8. 0
13. 0
1. 5
6. 8
5. 0
12.3
1 1 . 0
10. 6
Section 14
Steering Section 17
M/ S: [ , 4anual st eer i ng, P/ Sl Power st eer i ng
*:
When usi ng a ne; bet t , adj ust del l ect i on or t ensi on t o new val ues. Run t he engi ne f or 5 mi nut es t hen t ur n i t of f -
Readj ust t he def l ect i on or t ensi on t o used bel t val ues.
cw
MEASUREMENT
STANDARD {NEWI
St eer i ng wheel Pl ay at st eer i ng wheel ci r cumf er ence
St ar t i ng l oad at st eer i ng wheel ci r cumf er ence
N
( ksf ,
l bf )
Manual st eer i ng
Power st eer i ng
Engi ne r unni ng
0
-
10
( 0
0. 4)
1 5
( 1 . 5 , 3 . 3 )
29
( 3. 0, 6. 6)
Gearbox Angl e of rack gui de screw l oosened M/ S
f rom l ocked
posi t i on P/ S
Prel oad at pi ni on gear shaf t N m
(kgl cm, l bf i n) M/ S
20! 5"
20' Max
0. 5
-
1. 7
( 5 -
17, 4. 3
-
14. 8i
0. 6 1. 2
( 6 -
12, 5. 20
-
10. 42)
Pump
pr essur e wi t h val ve cl osed
( oi l
t emp. / speed: 40' C
( 105"F) mi n. / i dl e
Do not r un f or mor e t han 5 seconds) .
kPa
( kgt cm?, psi )
6, 400
-
7, 400 {65
-
75, 920
-
1, 070)
Power st eer i ng
f l ui d
Recommended
power st eeri ng f l ui d
Fl ui d capaci t y | {US
qt , l mp
q0
Reservoi r
HONDA Power St eeri ng Fl ui d
0. 85
(0. 90, 0. 75)
at di sassembl y
0. 4 { 0. 42. 0. 35}
7. 5 11. 0 {0. 30
-
0. 43)wi t h used bel t
5. 0 7. 0
(0. 20
0. 28) wi t h new bel t
10. 5
-
14. 0 10. 41
-
0. 55) wi t h used bel t
7. 5 10. 010. 30 0. 39) wi t h new bel t
390 540 {40 55, 88
' 120)
wrt h used bek
340
-
490
(35 -
50, 77
-
110) wi t h used bel t
740 880
(75 -
90, 170
-
200) wi t h new bel t
640 780
( 65 -
80, 143- 176) wi t h newbel t
Power st eeri ng
bel t *
Def l ect i on wi t h 98 N
(10
kgf , 22 l bf )
bet ween pul l eys
' 99
model l 81642 Engi ne Type onl y
' 96 ' 99
model s: Ot her Engi ne TYPes
r on. i onf f i
N
(kgf ,
l bf )
' 99
model : 81642 Engi ne Tvpe onl y
' 96
-' 99
' 99
model r 81642 Engi ne TYPe onl Y
' 96 ' 99
3-17
MEASUREMENT
STANOARO INEW} SERVICE LIMIT
al gnmenl
Camber
Front
Rear
Cast er Front
Tot al t oe
Front
Bear
Front wheel t urni ng angl e I nward wheel
Out ward wheel
0" 00' 1 1"
- 1 . 1
1 '
1' 40' I 1"
I n' 1. 01 2. 0 { 1/ 16 t 1/ ' 16)
I n 2. 0 l j B ( 1/ 161
1/ 16)
39.50'
33' 10' ( Ref er ence)
Bi m r unout Al umi num wheel Axi al
Badi al
St eel wheel Axi al
Radl a I
0 0.7
(0 -
0.03)
0- 0. 7
( 0 -
0. 03)
0
-
1. 0
( 0
0. 04)
0
-
1. 0
( 0
0. 04)
2. 0
(0. 08)
1. 5 10. 06)
2. 0 {0. 0B)
1. 5
(0. 06)
Wheel bear i ng
End pl ay
Front
Rear
0 0. 0s (0 -
0. 002)
0 0. 05
(0
0. 002)
Standards and Service Limits
Suspension
-
Section 18
Brakes
-
Section 19
*1.
5410 St amped on t he cal i per body.
*2.
2056 St amped on t he cal i per body.
Air Conditioning
-
Section 22
*:
When usi ng a new bel t , adj ust def l ect i on or t ensi on t o new val ues. Run t he engi ne f or 5 mi nut es t hen t ur n i t of { .
Readj ust def l ect i on or t ensi on t o used bel t val ues.
3- 18
MEASUREMENT
STANDARO INEWI SERVICE LIMIT
Parkl ng brake
Pl ay i n st roke at 196 N
(20
kgf , 44 l bf i l ever f orce
To be l ocked when pul l ed
6
-
I not ches
Foot brake
peoal
Pedal hei ght
(wi t h
f l oor mat removed) M/ T
A/'T, CVT
Free pl ay
156. 5
{ 6. 16)
161
(6
5/ 16)
1 5 ( 1 / 1 6 - 3 / 1 6 )
Mast er cvl i nder Pi st on t o pushrod
cl earance
0
-
0. 4
(0
0. 02)
Di sc brake Di sc t hi ckness Front
Rear
Di sc runout Front
Rear
Di sc paral l el i sm
Front and rear
Pad t hackness Front
Rear
20. 9
-
21. 8 (0. 82 -
0. 86)
8. 9
-
9. 1
(0. 350 -
0. 358)
9. 5 10. 5* '
8. 5
-
9. 5*'
7. 0 8. 0
( 0. 28- 0. 3r )
19. 0 (0. 75)
8. 0
( 0. 31)
0. 10
( 0. 004)
0. 10
(0. 004)
0. 015
(0. 0006)
1. 6
(0. 06)
1. 6
( 0. 06)
' r. 6
(0. 06)
Rear brake
drum
LD.
Li ni ng t hi ckness
200 17.a7l
4. 0
( 0. 16)
201 \7 .911
2. 0 {0. 08}
MEASUREMENT
STANDARD INEWI
Condi t i oni ng
SANDEN
Lubri cant t ype: SP 10 (P/ N
38897
-
Pl 3
-
A01AH or 3889
Lubri cant capaci t y Condenser
mf (f l oz,
l mp oz) Evaporat or
Li ne or hose
Recei ver
I
-
P13 A0l i l For refri gerant: HFC-134a (R,134a))
|
20 \2t3 0.11
I
45
(1
2/3, 1.6)
10
( 1/ 3, 0. 4)
10 t 1/ 3, 0. 4)
NI PPONDENSO Lubri cant t ype: ND' O| L8
(P/ N
38899
-
PR7
-
003)
(For
Re
Lubri cant capaci t y Condenser
mf
(f l oz,
l mp oz) Evaporat or
Li ne or hose
Recei ver
f . i gerant : HFC, 134a
(R-134a))
25
(s/ 6
0. 9)
60
( 2, 2. 11
10 ( 1/ 3, 0. 4)
10
( 1/ 3. 0. 4)
Compressor
SANDEN
Lubri cant t ype: SP-10
Lubri cant capaci t y ml
l f l oz, l mp oz)
Fi el d coi l resi st ance at 68' F
(20"C)
O
Pul l ey-t o-pressure pl at e
cl earance
130 150 (4
1/ 3 4. 6, 5. 0
-
5. 3)
0. 5 r 0. 15 10. 020 t 0. 006)
NI PPONDENSO Lubri cant t ype: ND-Ol L8 {P/ N 38899
-
PR7
, 003
or P/ N 38899
pR7 -
AO1)
(For
Ref ri gerant : HFC 134a {R, 134a))
Lubr i cant capaci t y m{ ( f l oz, l r npoz)
| 14O( 4. 7, 4. 9J
- 15S{ 5. 2. 5. 4)
St at or coi l r esi st ance at 20' C
( 68. F)
0
Pul l ey- t o- pr essur e pl at e cl ear ance
3. 4
-
3. 8
0. 510. 15
( 0. 0210. 006)
Compressor
bel t *
Def f ect i on wi t h 98 N
(1Okgl . 22l bl l
bet ween pul l eys
7. 5
-
9. 5
(0. 30
0. 37) wi t h used bel t
5. 0
-
6. 5
(0. 20 -
0. 26)wi t h new bel t
Bel t t ensi on N
(kgf ,
l bf )
Measured wi t h bel t t ensi on gauge
340 490 i 35 50, 77
-
110) wi t h used bel l
690
-
830
(70 -
85, 150 190) wi t h new bel t
Electrical Section 23
*:
When usi ng a new bel t , adj ust def l ect i on or t ensi on t o new val ues. Run t he engi ne f or 5 mi nut es t hen t urn i t of f
Readi ust def l ect i on or t ensi on t o used bel t val ues
Uni t of engl h: mm { n)
MEASUREMENT
STANDARD {NEW}
l gni t i on coi l Rat ed vol t age V
Pri mary wi ndi ng resi st ance at 68' F
(20' C) o
HI TACHI
TEC
Secondary wi ndi ng resast ance at 68' F 120"C)
kO
HI TACHI
TEC
1 2
0. 45 0. 55
0. 63 0. 11
22. 4
-
33. 6
12. A
-
19. 2
l gni t i on wi re Resi st ance at 68' F
(20' C)
kf )
Fi r i ng or der
25 max.
1 - 3 - 4 2
Spark
pl ug
Type
Gap
See sect i on 23
1.1 3,
(o.o -3*.)
l gni t i on t i mi ng At i dl e
'
BTDC l Red)
Al t er nat or bel t + Def l ect i on wi t h 98 N
( 10
kgf , 22l bf )
bet ween
pul l eys
8. 0
-
10. 5 {0. 31
-
0. 41} wi t h used bel t
6. 0
-
8. 5 {0. 26- 0. 33)wi t h new bel t
Bel t t ensi on N
(kgf , l bf )
Measured wi t h bel t t ensi on gauge
340
-
490
(35 -
50, 77 110) wi t h used bel t
540
-
740 ( 55
-
75, 121. 165) whh newber t
( MI TSUBI SHI )
Out put l 3. 5 V at hot A
Coal resi st ance
(rot or)
at 68' F
(20"C) kO
Sl i p r i ns O. D.
Brush l engt h
Brush spri ng t ensi on
g (oz)
STANDARD INEWI
SERVICE LIMIT
75
3. 4- 3. 8
I
-
Z2. j \ 0. A9)
22. 2 \ 0. 47)
19. 0
(0. 75) 5. 0
(0. 20)
340 420
( 12. 0
14. 8)
Al t ernat or
( DENSOi
Out put
' 13. 5
V at hot A
Coi l resi st ance
(rot or)
at 68' F
(20' C) k0
Sl i p r i ng O. D.
Erush l engt h
g (oz)
80
2.2
-
3.0
14.4
(0.57)
|
14.0
(0.55)
10.5
(0.41) 1.5
(0.06)
330 { 11. 6)
Starter
(MITSUEA
1. 0 kw
1.2 kW)
Tvpe
Commut at or mi ca dept h
Commut at or runout
Commut at or O. D.
Brush l engt h
(new)
N
(ksf , l bf )
Gear reduct i on
0. 4
-
0. 5
(0. 016 -
0. 020) 0. 15(0. 006)
o o. o2
(o -
0. 000e) |
o. o5
(o. oo2)
28. 0- 28. 1
( 1. 102 1. 106)
|
27. 5( 1. 083)
15. 8
-
16. 2 10. 62
-
0. 64) 11. 0
( 0. 43)
15. 7
-
11 . 1
{1. 60
-
1. 80, 3. 5
-
4. 0i
3- 19
Design Specifications
ITEM
METRIC ENGLI SH NOTE
DI I / I ENSI ONS Overal l Lengt h
2 door Coupe/ 4 door Sedan (, 96
98)
(' 99, ' 00)
2 door Hat chback (, 96,
, 97)
(' 98 -
00)
Over al l wi dt h
Overal l hei ght 2 door Coupe/ 2 door Hat chback
4-door Sedan
Wheel base
I
Track FronvRear
Ground Cl earance
Seat i og Capaci t y
4, 445 mm
4, 450 mm
4, 170 mm
4, 180 mm
1, 705 mm
1, 375 mm
1, 390 mm
2, 620 mm
1, 475/ 1, 415 mm
150 mm
175. 0 i n
115. 2 i n
164. 2 i n
164. 6 i n
67. 1 i n
54. 1 i n
54. 7 i n
103. 1 i n
58. 1/ 58. 1
5. 9 i n
WEI GHT (USA)
Gross Vehi cl e Wei ght Rari ng (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 Hat chbacl CX. DX r' 96, 97,
cx, DX
(' 98)
cx
(,99,
,00)
DXM/ Ti ' 9 9 , 0 0 i
DX A/T
(
99, 00,
4 door Sedan DX, LX, DX-V
EX
3, 290 t bs
3, 320 t bs
3, 330 t bs
3, 360 rbs
3, 290 rbs
3, 310 t bs
3, 440 t bs
3, 480 t bs
3, 285 t bs
3, 290 t bs
3, 290 t bs
3, 290 t bs
3, 330l bs
3, 330 t bs
3, 460 t bs
WEI GHT (CANADA)
Gross Vehi cl e Wei ght Bat i ng
(GVWR)
2-door Coupe DX
(' 96)
DX
(' 97
00)
DX-G
si 1, 96)
si
(' 97 -
00)
si R
2 door Hat chback CX, CX, G
(' 96)
cx, cx,G 1,97)
cx-G
(,98)
cx
(' 98
00)
DX M/T, SE M/I
DX A,/T, SE A,/T
4 door Sedan LX, LX V
EX M/I
EX A/T
1, 500 ks
1, 510 kg
1, 510 kg
1, 560 kg
1, 570 kg
1, 590 ks
1, 495 kg
1, 505 kg
1, 510 ks
1, 510 ks
1, 510 kg
1, 530 kg
1, 510 kg
1, 510 ks
1, 540 ks
ENGI NE Type
Cyl i nder Arrangement
Bore and St roke D16Y5, D16Y7, Dt 6y8
B 1642
Di spl acement D16Y5, D16Y7, Dl 6Y8
81642
Compressi on Rat i o D16Y5, D16y7
D16Y8
816A2
Val ve Trai n
Lubri cat i on Syst em
Oi l Pump Di spl acement at 6, 800 engi ne rprn
D16Y5, D, l 6Y7, D16Y8
81642
Wat er Pump Di spl acement
at 6, 000 engi ne rpm 016Y5, D16Y7, D16y8
816A2
Fuel Requi red D16Y5, D16Y7, D16y8
816A2
Wat er-cool ed, 4-st roke SOHC*1, SOHC
VTEC"', SOHC WEC.E'3, DOHC VTEC{
gasol i ne
engi ne
I nl i ne 4 cyl i nder, t ransverse
2. 95 x 3. 54 i n
3. 19 x 3. 05 i n
97. 0 cu-i n
97. 3 cu i n
9. 4
9. 6
10.2
Bel t dri ven, 4 val ve per
cyl i nder
Forced and wet sump, t rochoi d pump
33. 4 f
(35. 3
US
qt ,
29. 4 l mp qt )/ mi nut e
43. 8 |
(46. 3
US qt , 38. 6 l mp qt )/ mi nut e
125 { {132 US qt , 110 l mp qt }/ mi nut e
140 f {148 US qt , 123 l mp qt }/ mi nut e
UNLEADED gasol i ne wi t h 86 Pump
Oct ane Number or hi gher
Premi um UNLEADED gasol i ne
91 Pump
Oct ane Number or hi gher
75. 0 x 90. 0 mm
81. 0 x 77. 4 mm
1, 590 cm3
1, 595 cm3
* 1:
D16Y7
*' :
D16Y8
*3:
D16Y5
*' :
816A2
STARTEB Type/ Make
Normal Out put
Nomi nal Vohage
Hour Rat i ng
Di rect i on of Rot at i on
Gear reduct i on/ MI TSUBA
1. 0 kw, 1. 2 kw
12V
30 seconds
Cl ockwi se as vi ewed f rom gear
end
5- Z. V
-
trEM
I
merntc ENGLISH
NorEs
SfAnff n i *nt-i - W"' gf,t Ml l SUBA r.u, l .z kw r' 4 rg
CLUTCH Cl ut ch Type
Cl ut ch Faci ng Area
M/T
CVT
M/T
Si ngl e pl at e dry, di aphragm spri ng
Torque convert er
Mul t i pl at es wet sanP, hYdraul i c
160 cm, 25 sq i n
Synchroni zed 5-speed f orward, 1 reverse
4 speed aut omat i c, 1 reverse
Non st age speed f orward, 1 reverse
Di rect 1 : 1
TRANSMI SSI ON Transmi ssi on Type
Pri mary Reduct i on
M/T
Arr
CW
Manual t r ansmi ssi on
Gear Rat i o 1st
2nd
3rd
4t h
5th
Reverse
Fi nal Reduct i on Gear rat i o
Gear t YPe
Engi ne t ype
D16Y5 | D16Y7 D16Y8 I
81642
3. 250
1. 182
1. 112
0. 909
0. 702
3. 153
3.250
1. 182
1 . 1 1 2
0.909
0. 702
3. 153
3.250
1. 909
1. 250
0. 909
0. 102
3. 153
3. 230
2. 105
1. 458
1. 107
0. 875
3. 000
* 1 : 2
d o o r
Hat ch back
+2r
2- door Coupe,
and 4 door
Sedan
3.122
13.122"11.053" 1
4.250
|
4.266
Si ngl e hel i cal gear
Engi ne t ype
D16Y7 | D16Y8
Aut omat i c t ransmi ssi on
Gear Rat i o
' l st
2nd
3rd
4th
Reverse
Fi nal Reduct i on Gear rat i o
Gear t YPe
2. 600
1. 468
0. 926
0. 638
1. 954
2. 122
0. 975
0. 638
1. 954
1.351 4.357
cw
Gear Rat i o Low
-
O. D.
Reverse
Secondary Reduct i on Gear Rat i o
Fi nal Reduct i on Gear Rat i o
2. 466 0. 449
2. 466
1. 333
4. 357
AI R
CONDI TI ONI NG
Cool i ng Capaci t y
3,530 Kcal/h 14, 000 BTU/ h
Compressor Type/ Make
No. of CYl i nders
CaPaci t Y
Max. Speed
Lubricant CaPacitY
Scrol l / SANDEN
85.7 m//rev 5.22 cu inkev
10,000 rpm
130 mf 41l 3t l oz.
|
4. 6 i mp oz
sP, 10
Compressor Type/ Manuf act urer
No. of Cyl i nder
Capacity
Max. Speed
Lubri cant CaPaci t Y
Lubri cant TYPe
Swash-pl at e/ DENso
1 0
155. 3 mf / rev
9. 4 cu_i n/ rev
76, 000 rpm
140 mf
|
4 2l 3f l oz,
I 4 9 l mp o z
ND' OI L8
Condenser Type
Cor r ugat ed
f i n
Evaporat or
TyPe
Corrugat ed f i n
El ower TyPe
Mot or I nput
SPeed Cont rol
Max. CaPaci t y
Si rocco fan
200w112v
4 speed var i abl e
460 m3/h 16,200 cu ft/h
Temper at ur e Cont r ol
Compressor Cl ut ch TyPe
Power ConsumPt i on
Dry, si ngl e
pl at e,
Pol Y-V' bel t
dri ve
40 W max. / 12 V at 68' F
(20' C)
Ref ri gerant TyPe
ouant i t y
HFC 134a
(R' 134a)
650
gos
|
22. 9 i soz
( cont ' d
)
4
. \ t
J - Z I
ITEM
METRIC ENGLI SH NOTE
STEERI NG
SYSTEM
Tvpe
P/s
M/S
Overal l Rat i o
p/ S
M/S
Turns, Lock-t o Lock
p/ S
M/S
St eeri ng Wheel Di a.
Power assi st ed, rack and pi ni on
Rack and pi ni on
1l . 1
20.3
3. 6
4. . 1
380 mm 15. 0 i n
SUSPENSI ON TYPe
Front and Rear
Front and Rear
I ndependent doubl e wi shbone, coi l spri ng
Telescopic, hydraulic nitrogen gas-filled
WHEEL
ALI GN| \ t 4ENT
Camber
Front
Rear
Cast er
F. ont
Tot al Toe
Front
Rear
0.00,
-
' t'
1.40'
l n 1 mm l n 1/ 16
I n 2 mm I n 1/ 16
EBAKE SYSTEM Type
Front
Rea r
Pad Surf ace Area Front
Rea r
Parki ng Brake
Type
Power assi st ed sel f adj ust i ng vent i l at ed di sc
Power assi st ed sel f adi ust j ng sol i d di sc
Power assi st ed sel l adj ust i ng dr! m
37. 5 cm' x 4 5. 8 sq i n x 4
44. 1ct n, x4
]
6. 84sq- i nxa
67. 2 cmz x 4
|
t o. + sq i n ' I
21.2 cm, x 4 3.3 sq in x 4
Mechani cal act uat i ng, rear t wo wheel
brakes
5410 st amped on
t he cal i per body
2056 st amped on
t he cal i per body
Drum
Disc
TIRE Si ze and Pressure
See l i re i nt ormat i on l abel
WASHER Capaci t y 2door Coupe/ 4, door Sedan
2, door Hat chback
2. 5 f
(2. 6
LJS qt , 2. 2 l mp qt )
4. 5 |
( 4. 8
US qt , 4. 0l mp qt )
2. 51
(2. 6
US qt , 2. 2 l mp qt )
4. 5 f
(4. 8
US qt , 4. 0 l mp qt )
USA model
Canada model
DX
Except DX
ELECTRI CAL Baftery
Starter
Al t ernat or
Fuses I n Under dash Fuse/ Fel ay Box
I n Under-hood Fuse/ Bel ay 8ox
I n Under hood ABS FLrse/ Rel ay Box
Headl i ght s
Front Turn Si gnal / Parki ng Li ght s
Rear Turn Si gnal Laght s
Brake/ Tai l l i ght s
I nner Tai l l i ght s*,
Hi gh Mount Brake Li ght
Back up Li ght s
Li cense Pl at e Li ght s
Cei l i ng Li ght
Trunk Li ght s
Gauge Li ght s
I ndi cat or Li ght s
l l l umi nat i on and Pi l ot Li ght s
Heat er Cont rol Panel Li ght s
12 V 38 AH/ 5 HR
12 V 1. 0 kW, 1. 2 kW
1 2 V 7 5 A, 8 0 A
7. 5 A, t 0 A, 15 A, 20 A
7. 5 A, 10 A, 15 A, 20 A, 30 A, 40 A, 80 A
7. 5 4. 20 A, 40 A
1 2 V_ 6 0 / 5 5 W
12V
- 2115W
12V
-
21W
12V
-
21/ 5W
1 2 V - 5 W
12 V 18 W* " 21 W+"
* 3
12V 21W
1 2 v - 5 w
l 2 V- 8 W( Wi t h mo o n r o o f l
12 V
-
5W
(Wi t hout
moonroof )
1 2 V - 1 . 4 W, 3 W
' t 2
v 1. 12W. 1. 4 W
1 2 v - 0 . 8 4 w, 1 . 4 W
1 2 V 1 . 4 W
Design Specifications
(cont' d)
P/ S: Power St eeri ng M/ S: Manual St eeri ng
*l :
2-door Coupe
*2:
2door Hat chback
*3:
4-door Sedan
*4:
USA
(HAM),
Canada
(HCM) produced
*5:
Japan produced
3-22
L '
Body Specifications
Uni t : mm
( i n)
2-door Coupe:
l t t9)
gtt' t
Body Specifications
(cont' d)
2-door Hatchback:
Li f
Uni t : mm ( i n)
3-24
(t
t9]
gre' r
I.
(r' tsl
06' l
U ni t : mm
( i n)
4-door Sedan:
3-25
Mai ntenance
Lubri cati on
Poi nts
.""."".'
4' 2
Mai ntenance
Schedul e
for 1996 Model
Normal Gondi ti ons
' .""" 4-4
Severe Condi ti ons
."""" 4-6
Mai ntenance
Schedul e
for 1997 Model
Normal Condi ti ons
."""'
4-8
Severe
Condi ti ons
....""' 4-10
Maintenance
Schedule
for 1998 Model
Normal Condi ti ons
"""" 4' 12
Severe
Condi ti ons
.""""
4-14
Mai ntenance
Schedul e
for 1999 Model
Normal Condi ti ons
."""' 4' 16
Severe Condi ti ons
."""" 4' 18
Mai ntenance
Schedul e
for 2000 Model
Normal Condi ti ons
."""' 4-2O
Severe Conditions
"'.""' 4-22
I
Lubrication
Points
For the detai l s of l ubri cati on poi nts
and types of l ubri cants to be appl i ed, refer to the l l l ustrated Index and vari ous work
procedures (such
as Assembl y/Reassembl y,
Repl acement,
Overhaul . Instal l ati on, etc.) contai ned i n each secti on.
No.
LUBRICATION POINTS
Engi ne
LUBRICANT
"Energy
Conservi ng" grade
oi l ,
The oil container may also display the Apl Certification mark
shown bel ow. Make sure i t says
,,For
Gasol i ne Engi nes.,,
SAE Viscosity: See chart below,
I
Transmi ssi on
Manual
Genui ne Honda MTF*1
Genui ne Honda Premi um Formul a
Automati c Transmi ssi on Fl ui d (ATF)*,
Genui ne Honda CVT Fl ui d*3
Genui ne Honda DOT3 Brake Fl ui d*a
Automati c
CVT
3 Brake Li ne
ClL,tci t""e 4
I
Genui ne Honda DOT3 Brake Fl ui d*a
Power steeri ng gearbox
Steering grease
P/N 08733
-
BO70E
Shi ft l ever pi vots (manual
transmi ssi on)
Grease wi th mol ybdenum
di sul fi de
7
-:
ti
9
1 0
' l ' l
l 3
1 4
' t7
1 8
19
20
21
22
Rel ease fork
(manual
trancmi <si ^nl
Steeri ng boots
Tai l gate hi nges and l atches (2-door
Hatchbackl
Steeri ng bal l
j oi nts
Shi ft l ever
(automati c
transmi ssi on)
Pedal l i nkage
Brake master cyl i nder pushrod
Super Hi gh Temp Urea crease (p/N
08798
-
9OO2)
i
Mul ti -purpose grease
I
I
Honda Whi te Li thi um Grease
Mul ti -purpose grease
Si l i cone grease
@
Trunk hi nges and l atch (4-door
Sedan and 2-door
Coupe)
Door hi nges upper and l ower
Door openi ng detents
Hood hi nge and hood l atch
-
FUet T t er t t d
Cl utch master cyl i nder pushrod
Throttl e cabl e end and throttl e l i nkage
Rear brake shoe l i nkages
Steeri ng wheel (back
si de)
23
E
-
Cal i per pi ston
seal , dust seal ,
cal i per pi n. pi ston
Throttl e cabl e end
(dashboard
l ower panel )
Power steering system
(for
cars with
p/S)
Ai r condi ti oni ng compressor
ComDressor oi l :
SANDEN: SPlo P/N 38897
- p13 -A01AH
or 38899
- p13_
A01
{For Refri gerant: HFC-134a (R-134a))
CERTIFICATION
SEAL
ffi
NorE: The i tems m arked
*
1,
*2, +3, *4
and
+5
on above chan are descri bed as fol ows:
*1:
Al ways use Genui ne Honda Manual Transmi ssi on Fl ui d (MTF).
Usi ng motor oi l can cause sti ffer shi fti ng because i t
does not contai n the proper
addi ti ves.
*2:
Al ways use Genui ne Honda
premi um
Formul a Automati c Transmi ssi on
Fl ui d
(ATF).
Usi ng a non-Honda ATF can affect
shi ft qual i ty.
+3:
Use Genui ne Honda cVTfl ui d onl y usi ngotherfl ui d
can affect tra nsmi ssi on operati on and may reduce transmi ssi on l i fe. *4:
Al ways use Genui ne Honda DoT3 Brake Fl ui d. Usi ng a non-Honda brake fl ui d can cause corrosi on and dec.ease the l i fe
of the svstem.
*5:
Al ways use Genui ne Honda Power steeri ng Fl ui d. usi ng any other type of power
steeri ng fl ui d or automatrc transmi ssi on
fl ui d can cause i ncreased wear and poor
steeri ng i n col d weather.
4-2
Recommended Engi ne Oi l
Engi ne oi l vi scosi t y f or
ambrent t emperat ure ranges
API SERVICE LABEL
NOTE: Lubri cate al l hi nges, l atches and l ocks once a year'
l n corrosi ve areas, more frequent l ubri cati on i s necessary'
We recommend
Honda Whi te Li thi um Grease'
4-3
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Engi ne
Engi ne Removal /l nstal l ati on
................ 5-1
Gyl i nder Head/Val ve Trai n ................... 6-1
Engi ne Bf ock . . . . . . . . . . . . . . . . . . . . . 7-1
Engi ne Lubri cati on
........... 8-1
Intake Mani fol d/Exhaust System ........ 9' 1
Cool i ng
. . . . . . . . . 10-1
En
g
i ne Removal /l nstal l ati on
Removal
". . ' . ' 5' 2
lnstaf lation
'.' 5-12 lgr"
Engi ne RemovaUl nstal l ati on
Removal
@@
1 .
. Make sure
iacks
and salety stands are placed ploperly
and hoist brackets are attached to the correct posi-
tions on the engine.
. Make sure the vehicle will not roll off stands and fall
whi l e you are worki ng under i t.
CAUTION:
. Use fender covers to avoi d damagi ng pai nted sur-
face.
. Unplug the wilin9 connectors caretully while holding
the conngstor portion to avoid damage,
. Mark all wiring and hosos to avoid misconnoction.
Also, be sure that they do not contact other wiring or
hoses or interfere with other parts,
Secure the hood as open as possi bl e.
Di sconnect the battery negati ve termi nal fi rst. then
the posi ti ve termi nal . Remove the battery.
Remove the strut brace
(B' 16A2
engi ne).
8 x 1 .25 mm
24 N.m {2.4 kgl.m, 17 lbf.ft}
Di sconnect the battery cabl es from the under-hood
fuse/rel ay box and battery
posi ti ve
termi nal .
STRUT BRACE
UNDER. HOOD
FUSE/ RELAY
BOX
BATTERY CABLES
5-2
ECM/ PCM
(
5. Remove the battery and battery base.
8 x 1. 25 mm
24 N.m (2.4
kgf.m, 17 lbf ftl
7.
Di sconnect the connectors from the ECM/pCM.
Di sconnect the mai n wi re harness connector.
MAI N WI RE HARNESS
CONNECTOR
8. Remove the i ntake ai r duct and ai r cl eaner housi ng.
D16Y, ongino:
a. Remove the resonator and i ntake ai r duct.
6 x 1 . 0 mm
9.8 N.m
(1.0
kgt m, 7.2 lbf.tt)
INTAKE AIR
Disconnect the intake air tempsrature
(lAT)
sen-
sor connector, then rmove thg air cleaner hous-
I ng.
6 x 1 . 0 mm
9.E N.m
(1.0
kgtm, t.2lbtft,
AIR CI."EANER
HOUSING
IAT SENSOR
CONNECTOR
016Y5, Dl6Y& 815A2 enginsl
a. Di sconnect t he I AT sensor connect or , t hen
remove the i ntake 8i r duct and ai r cl eaner hous-
Ing.
6 x 1 . 0 mm
9.8 N m {1.0 kgtm, 7.2 lbl'ft)
AIR CITANER
HOUSING
INTAKE AIR
DUCT
IAT SENSOR
CONNECTOR
9. Di sconnect the engi ne wi re harness connector on
the l eft si de of the engi ne compartment.
(cont' d)
5-3
Removal
(cont' dl
10. Rel i eve fuel pressure (see
secti on l 1).
!@
Do not smoke while working on the fuel
system, Keep open flame or spark away from the
wolk area. Drain fuel only inlo an approved container.
11. Remove t he evapor at i ve emi ssi on ( EVAP)
cont r ol
cani ster hose and fuel feed hose.
D16Y7 engi ne:
BANJO BOLT
33 N m (
3.it lgt m, 25 lbt.ft)
FUEI- FEED HOSE
D16Y5, D16Y8, Bt642 engines:
5-4
I
12. Remove the brake
hose and vacuum
D16Y7 engi ne:
booster vacuum hose, fuel return
hose.
VACUUM HOSE
Dl6Y5, D16Y8, Bl642 enginos:
BRAKE BOOSTER
VACUUM HOSE
13. Remove the throftl e cabl e by l ooseni ng the l ocknut,
then sl i p the cabl e end out of the accel erator l i nk-
age.
NOTE;
. Take care not to bend the cabl e when removi ng
i t. Al ways repl ace any ki nked cabl e wi th a new
one.
. Adj ust the throttl e cabl e when i nstal l i ng
(see
sec-
t i on 1 1) .
D16Y7 engi ne:
D16Y5, D16Y8, B16A2 engines:
LOCKNUT
LOCKNUT
14, Di sconnect the connectors from the PCM.
Remove t he
gr ommet and wi r e har ness cl amps,
then pul l out the ECM/PCM connectors
6 x 1 . 0 mm
16. Remove the mounti ng bol t and l ock bol t, then remove
the
power steering
(P/S) pump belt and
pump
NOTE: Do not di sconnect the P/S hoses.
816A2 engi ne:
Remove the adj usti ng bol t and mounti ng boi ts,
then remove the P/S
pump bel t and
pump
(cont ' d)
5- 5
AOJUSTING
Engine Removal/lnstailation
Removal
(cont'dl
Dl6Y5. DrGYr, D16Y8 enginas:
-1.
Remove the mounti ng bol t and l ock bol t, then
remove the P/S pump
bel t and pump.
MOUNTING BOLT
8 x 1.25 mm
24 N.m {2.4 kgl.m, 17 tbf.ftl
LOCK BOLT
8 x 1. 25 mm
24 N.m 12.4 kgf.m, 17 lbf.ftl
17. Loosen the i dl er pul l ey
center nut and adj usti ng
bol t, then remove the ai r condi ti oni ng (A[/C)
compressor belt.
IDI.IR PULLEY CENTER
NUT
10 x 1. 25 mm
a,l N.m
{,1.5 kgt.m, 33 lbf.ft)
5- 6
(
' 18.
Remove the ransmi ssi on ground
cabl e and hose
ct8mo.
HOSE CLAMP
6 x
'1.0
mm
19. Remove t he cl ut ch sl ave cyl i nder and l i ne/ hose
assembty (M/T).
NOTE:
.
Do not di sconnectthe pi pe/hose
assembl y.
. Do not operate the cl utch pedal
once the sl ave
cylindr has been removed.
o Take care not to bend the l i ne.
6x 1, 0mm
8x 1. 2Smm
11 N.m {1.1 kgt.m,
2a N.m t2.4 kgf.m,
I tbf.ftl
17 tbf.ftl
8 x 1. 25 mm
2a N'm {2,4 kgt m,
17 tbt.ftl
20. Remove the shi ft cabl e
(CVT)
WASHER
Pt-Aslc
21. Di sconnect t he
Power
swi tch connector, and
cramp.
LOCKNUT
29 N.m {3.0 kgf m,22lbf'ft}
st eer i ng
pr essur e
( PSP)
r emove t he wi r e har ness
CLIP
l l
I
Remove the radi ator caP.
!!!@
usa care when lmoving the tadiator
Ap to avoid scalding by hot coolant or steam'
Rai se t he hoi st t o f ul l hei ght .
SHIFT CABLE
(cont' d)
25.
26.
27.
24. Remove the front ti res/wheel s and spl ash shi el d.
u x l .u mm
SHIELD
9.8Nm(1 0 kqt' m,
7.2lbf.ftl
Drai n the engi ne cool ant
(see page 10-7). Loosen
the drai n
pl ug i n the radi ator.
Drai n the transmi ssi on
fl ui d Rei nstal l thedrai npl ug
usi ng a new washer
(see
secti on 13, 14).
Drai n the engi ne oi l . Rei nstal l the drai n bol t usi ng a
new washer
(see page 8-6).
28. Remove the shift rod and extension rod
(M/T)
SHIFT ROD
EXTENSI ON
ROD
8 x 1. 25 mm
22 N.m t2.2
kgf'm,
't6lbtft)
ER
6 x 1 . 0 mm
Removal (cont' dl
29. Remove the Ay' C compressor.
NOTE: Do not di sconnect the Ay' C hoses.
30.
8x 1.25 mm A/C COMPRESSOR
24 N.m (2.{
kgf.m, t7 tbtft}
Remove the shi ft cabl e (IVT).
NOTE:
.
Take care not to bend the cabl e when removi ng
i t. Al ways repl ace any ki nked cabl e wi th a new
one.
. Adj ust the shi ft cabl e when i nstal l i ng (see
sec_
t i on 14) .
8 x 1. 25 mm
22 N.m (2.2
kgf.m, 16 lbf.frl
LOCK WASHER
Bepl ace.
6 x 1 . 0 mm
14 N.m (1.4
kgf.m, tO tbtft)
5- 8
A/C COMPRESSOR
t
{
31. Remove exhaust pi pe
A.
Dl6Y5. D16Y7 engines:
8 x 1.25 mm
22 N.m 12.2 ksl.m. 16 tbI.fr)
Repl ace.
SELF.LOCKING
8 x 1. 25 mm
16 N. m (1. 6
kgt m,
12 tbt.ftl
Repl ace.
D16Y8 ongi n6;
8 x 1. 25 mm
22 N.m
(2.2
kgf.m. 16 tbf.ftl
Repl ace.
GASKET
Repl ace.
SELF.LOCKING
NUT
10 x 1. 25 mm
33 N.m {3.4 kgt.m,
25 lbr'frl
Repl ace.
SELF. LOCKI NG NUT
8 x 1. 25 mm
16 N. m
11. 6 kgf . m, 12 l bt f t )
Repl ace.
SELF-LOCKING NUT
l 0 x 1. 25 mm
54 N.m (5.5
kgf.m, 40 lbf.ft)
Repl ace.
81642 engi ne:
8 x 1. 25 mm
22N,n 12
2 kdl'rn,
Repl ace.
,&
16 rbt.ftl
Repl ace.
SELF.LOCKING
8 x 1. 25 mm
16 N.m t1.6
kg{ m, 12 lbl'ft)
Repl ace.
GASKETS
Repl ace.
10 x 1 .25 mm
s4 N.m {5.5
kgf m, 40 lbf'ftl
32.
PIPE A
RePl ace'
Remove the damper forks
(see
secti on 18).
Di sconnect t he suspensi on l ower ar m bal l
j oi nt s
(see
secti on 18).
Remove the dri veshafts.
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.
NoTE: Coat al l
pr eci si on- f i ni shed sur f aces wi t h
cl ean engi ne oi l . Ti e
pl asti c bags over the dri veshaft
enos.
34.
HO2S CONNECTOR
!^.
35.
36.
Lower the hoi st.
Remove the upper and l ower radi ator hoses and
heater hoses,
37. Removs the ATF cool er hoses, then
pl ug the ATF
cooler hoses and
PiPes
(A,/T)
UPPER
RADIATOR
HOSE
HOSES
(cont' d)
Engi ne RemovaUl nstal l ati on
Removal (cont' d)
38. Attach the chai n hoi st to the engi ne.
HOISTING BRACKET
I nst al l on t he cyl i nder head
wi t h a 8 x 1 . 2 5 mmb o l t .
5- 10
39. Remove the l eft and ri ght front mount and bracket'
MOUNT/BRACKET
40. Remove the rear mount bracket.
41. Remove the uPPsr bracket.
42. Remove t he t r ansmi ssi on
mount br acket , t hen
remove the transmi ssi on
mount.
44.
Check that the engi ne/transmi ssi on
i s compl etel y
free of vacuum hoses, fuel and cool ant hoses and
el ectri cal wi ri ng.
Sl owl y rai se the engi ne approxi matel y
150 mm
(6
i n)'
Check once agai n that al l hoses and wi res are di scon-
nected from the engine^ransmission
Rai se the engi ne al l the way, and remove i t from the
car.
UPPER
TRANSMISSION
45.
5 - 1 1
Engine RemovaUlnstallation
Installation
Brackei Bolts Torque Specifications:
Dl 5Y5, Dl 6Y7, Dl 6Y8 ngi nss
D16Y5, D16Y8 engi nes
(M/Tl :
REAR STIFFENER
8 x 1. 25 mm
2/t N.m 12.4 kgf.m, 17 tbf.ftl
EXCEPT D16Y5, Dl 6Yg engi nes
l M/ T)j
STIFFENER
Ti ght en t he bol t s on t he st i f f ener
i n t he numbered sequence as shown
10 x 1. 25 mm
44 N.m
14.5 kgf.m,
33 tbf.frt
O8 x 1 . 2 5 mm
24 N.m
{2.4 kg{.m,
17 tbr.ftt
10 x 1. 25 mm
14 N.m
14.5 kgt m,
33 tbf.ft)
10 x 1. 25 mm
44 N.m
{4.5 kgt m,
33 tbr.ftl
10 x 1. 25 mm
54 N.m
{5.5 kgf.m,
40 rbf.ftl
10 x 1. 25 mm
44 N.m {4.5 kg'f.m,
33 t bt f t l
ALTERNATOF
BRACKET
li) o).
l 3l 10 x 1. 25 mm
44 N.m
{1.5 kgt.m,
33 tbt.ft)
8 x 1. 25 mm
24 N.m (2.4
kgf.m,
17 tbf.ft)
o16Ys, D16Y8
engi nosl M/ T):
FRONT
STIFFENER
10 x 1. 25 mm
4,4 N.m
{4.5 kg{.m.
33 tbf.ftl 8 x 1. 25 mm
2{ N.m (2.t
kgtm,
17 rbtft)
10 x 1. 25 mm
14 N.m (4.5
kgf.m,
33 lbf.ftl
5-12
816A2 engi ne
P/S PUMP
BRACKET
REAR
STIFFENER
SIDE ENGINE
MOUNT BRACKET
t 0 x 1. 25 mm
ia{ N.m
(i1.5 kgt rn,
33 lbt.tr)
t
12 x 1. 25 nm
57 N.m {5.8 kgf,m,
12 tbl.ttl
8 x 1. 25 mm
24 N.m
(2.4
kgl.m,
17l bf . f t )
FRONT
STIFFENER
A/C COMPBESSOR
BRACKET
10 x 1. 25 mm
54 N m {5.5 kgf m, a0 lbl ft}
10 x 1. 25 mm
4a N,m
(4.5
kgf.m,
33 tbf.ftt
ALTERNATOR
BRACKET
' 12
x 1. 25 mm
57 N.m {5.8
kgt'm,
42 tbt.ft)
8 x 1. 25 mm
24 N.m {2.4 kgf.m,
17 t bt f t )
' 10
x 1. 25 mm
,14 N.m {,1.5 kgt.m,
33 rbf.ft)
(cont' d)
5- 13
Engine Removal/lnstallation
Installation
(cont'd)
Engino Inst!llation:
Install the engine in the reverse order of removal.
Bei nstal l the mount bol ts/nuts i n the fol l owi ng
sequence.
Failure to follow these procedures
may cause excessive
noi s and vi brati on, and reduce bushi ng l i fe.
l , Instal l the transmi ssi on mount and bracket, then
ti ghten the bol ts on the frame si de,
NOTE; Do not ti ghten the bol ts/nuts on the trans_
mi ssi on si de.
CW;
10 x 1. 25 mm
38 N.m
{3.9 kgt m. 28 lbt.ftl
5-14
I
I
2, Instal l the upper bracket, then ti ghten the nuts i n
the numbered ssquence shown
(O _
@).
l '
a
O
t2 x 1.25 mm
74 N.m 17.5 kgf.m,
O
t2 x t.2s mm
74 N.m 17.5 kgtm,
rbrft)
3. Instal l the rear mount bracket, then ti ghten the bol ts
i n the numbered sequence shown
(O -
@).
CVT:
O
12 x 1. 25 mm
59 N.m
(6.0 kgl'm,
ilil
lbf ftl
Repl ace.
12 x 1. 25 mm
59 N.m 16.0
kgf'm,
|:r tbf.tt)
Repl ace.
O
12 x 1. 25 mm
59 N'm {6.0 kgf'm,
/
lbf.ftl
Replace.
Except CVT:
, @
14 x' 1. 5 mm
/
8:t N.m {8.5 kgf.m,
/
61 rbr.fr)
\ Replace.
O
12 r 1. 25 mm
59 N m 16.0
kgt m,
(}
tbf.ftt
Repl ace.
Ol a x 1 . 5 mm
83 N.m 18.5 kgf.m,
61 tbf.ftl
Replace.
L
4. Ti ghten the bol vnuts on the transmi ssi on mount
bracket i n the numbe.ed sequence shown
(O -
O).
@
t2 x t.2s mm
7,1N.m
(7.5 kg{ m, 54 lbf ftl
Ti ghten the bol ts on the ri ght front mounvbracket i n
the numbered sequence shown
(O -
@).
GW:
O
to x 1.25 mm
54 N.m {5.5 kgl.m.
/|{}
lbf.ftl
10 x 1. 25 mm
4,1 N.m {4.5 kgf.m. 33 lbf.ftl
(cont' d)
5- 15
12 x 1,25 mm
fl N.m 16.5 kgt.m,
47 tbf.ftl
Installation
(cont'd)
Except CVT:
12 x 1. 25 mm
64 N.m
(6.5
kgd.m,
Ti ghten the bol ts/nut on the l eft front mount i n the
numbered sequence shown
{O
-
@).
( t
12 x 1. 25 mm
83 N' m ( 8. 5
kgf . m, 61 t bt . t r l
/+4
N.m 14.5 kgf.m,
33 lbt.trl
O
12 r 1. 25 mm
59 N.m 16.0 kgt.m,
43 tbt.rtl
Sepl ace.
5- 16
\
7. Perform the fol l owi ng:
.
Cl ean the areas where the dri veshaft(s) and the
i ntermedi ate
shaft contact the transmi ssi on (di f_
ferenti al ) thoroughl y wi th sol vent or carburetor
cteaner, and dry wi th compressed ai r.
. Check that the set ri ngs on the ends of the dri ve_
shaft and i ntermedi ate shaft cl i ck i nto pl ace.
CAUTION: Use new set rings,
. Adj ust the shi ft cabl e
(see
secti on 14).
. Adj ust the throttl e cabl e
(see
secti on 11).
.
Adj ust the crui se control cabl e
(see
secti on 23).
.
Refi l l the engi ne wi th engi ne oi l
(see
page
8-6).
. Refi l l the transmi ssi on wi th fl ui d
(see
secti on 13,
14) .
. Refi l l the radi ator wi th engi ne cool ant (see
page
10-7).
. Bl eed ai r from the cool i ng system wi th the heater
val ve open
(see page
j 0-7).
.
Cl ean the battery posts
and cabl e termi nal s wi th
sandpaper, assembl e them, then appl y grease
to
prevent
corrosaon.
. Inspect for fuel l eakage (see
secti on
j
l ).
After assembl i ng the fuel l i ne, turn on l ) the i gni _
ti on swi tch (do
not operate the starter) so that the
fuel pump
runs for approxi matel y two seconds
and the fuel l i ne pressuri zes.
Repeat thi s opera_
taon two or three ti mes, then check for fuel l eak_
age at any poi nt
i n the fuel l i ne,
Mount and Brackst Bohs/Nuts Torque Value Spocitications:
A:
' 10
x 1. 25 mm
64 N.m {6.5 kgl'm, 47 lbf'ft}
B: 10 i 1. 25 mm
44 N. m {4. 5
kgi m, 33 l bt f t )
C: 12 x 1. 25 mm
83 N.m 18.5
kgt'm, 61 lbf'ft)
D: 12 x 1. 25 mm
59 N.m
(6.0 ks{ m, 43 lb{ft)
Replace.
REAR MOUNT
SIDE ENGINE
MOUNT
Cylinder Head/Valve Train
Dl 6Y5, D16Y7, Dl 6Y8 engi nes
Special Tools ............. G2
VTEC Control System
Troubleshooting Flowchart .........." 6-3
VTEG Solenoid Valve
Inspection
............" 6-6
VTEC Rocker Arms
Manual lnspection
(D16Y5
engi ne) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Manual Inspection
(D16Yg
engi nel . . . . . . . . . . . . . . . . ' . . . . . . . . . . . . 6-7
Inspection Using Special Tools
{D16Y5
engi ne} . . . . . . . . . . . . . . . . . . . . . ""' . . . 6-8
(D16Y8
engi ne) . . . . . . . . . . . . . . . . . . . . . . . . . ' . ' . 6-10
Valve Clearance
Adi ust ment
. . . "". . . . . 6-12
Valve Seals
Replacement
(Cylinder
head removal
not requi redl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1t l
Crankshaft Pulley and PulleY Bolt
Replacement
."...... &16
Timing Selt
l l l ust rat ed I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Inspection
.............. 6-18
Tension Adjustment ........................ 6- 1 I
Removal
. . . . . . , , . . . . . . . . . 6-19
lnstallation
............. 6-20
Crankshaft Speed Fluctuation
(CKF)
Sensor
Repf acement
.........6' 22
Cylinder Head
l l l ust rat ed I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Removal . . . . . . . . . . . . . . . . . 6-27
Warpage . . . . . . . . . . . . . . . . 6-40
lnstallation
............. 6-45
Rocker Arms
Removal ................. 6-30
Disassembly/Reassambly
............... 6-31
Rocker Arms and Lost Motion Assemblies
Inspection
(D16Y5,
D16Yg
enginesl
"..........' 5-34
Rocker Arms and Shafts
Glearance Inspection ....................... 6-35
Camshaft
Inspection
.............. 6-36
Valves, Valve Springs and Valve Seals
Removal
. . . . . . . . "". . . . . 6-38
Valve Guides
Valve Movement .............................. 6-39
Replacement
.........6-41
Reami ng
. . . . . . . ' . . . . . . ' . ' 6-43
Valve Seats
Reconditioning
.' ....6' 40
Valves
lnstallation
............. 6-tt3
Camshaft/Rocker
Arms and
Camshaft Seal/Pulley
lnstallation
............. 6-44
Speci al Tool s
\ (
Ref. No. I Tool Number
o
o
@
@
o
o r @- 1
a n d O - 2
@
o
OTHAH
_
PJTOl OB
07JAA
-
001010A
07JAB
-
0010204
OTLAJ
_
PR3O2OB
07NAB
-
0010404
07NAJ
-
P07010A
01406
-
0020201
OTMAJ
-
PY4O' 114
07MAJ
-
PY40120
07406
-
0070300
07742
-
0010100
Val ve Gui de Reamer, 5.5 mm
Socket, 17 mm
Hol der Handl e
Ai r Stopper
Hol der Attachment. 50 mm
Pressure Gauge Adapter
A/f Pressure Hose
A/T Pressure Hose,2,210 mm
Ay'T Pressure Adapter
A,/T Low Pressure Gauge
WPanel
Val ve Gui de Dri ver,
5.5
mm
6-43
6- 16
o- t o
6-8, 10
6- 16
6-4
6-4
6-4
6-4
6-4
6-4't, 42
-rE=-!fT----F
o
@
@
@
o
O- r
-A\
g
@
El
ril
6l
A - 2
a
6-2
VTEC Control System
Troubl eshooti ng Fl owchart
tFtrsrl
#ilH:::lj1t:"J:T,?ffnostic
rrouble code
(Drc)
Pr25e: A probrem in the vrEc Pressure switch circuit or
Reter to page 1 l -38 th roug h 1 1-55 before trou bl eshooti ng.
*
Road Test:
Accel er at e i n 1st gear t o an engi ne speed over 3, 000 r pm
(D16Y5
engi ne) or 6, 000 rpm
(D' 16Y8
engi ne).
Hol d t hat engi ne speed f or at l east t wo seconds.
I t DTC P1259 i s not repeat ed duri ng t he f i rst road t est , repeat
t hi s t est t wo more t ames.
VTEC PRESSURE SWITCH 2P
CONNECTOR
Termi nal si de of
mal e t ermi nal s
Wi r e si d6 ol f emal e
r er mt nat s
VTM
l1
(BLu/BLK)
f;-) |
I
I
Y
I
The MIL has been reoorted on.
DTC P1259 is sto.ed.
Check the VTEC Cont.ol Syst6m:
1. Do t he engi ne cont rol modul e
(ECM)/powertrain
control mod
ule lPCM) Reset Procedure
(see
sect i on 11).
2. St an t he engi ne.
3. Warm up t he engi ne t o normal
operat i ng t emperat ure
(cool -
i ng f an comes on).
4. Do t he Boad Test . *
Intermittont tailura, 3y3t.m is OK
at thia time.
Check f or ooor connoct i onr o.
l oose wi rea at VTEC oi assurc
lwitch, VTEC solonoid valvo .nd
ECM/PCM,
l s OTC P1259 i ndi cat ed?
Test rhe VTEC Prensure Switch:
1. Turn t he i gni t i on swi t ch OFF.
2. Disconnect the VTEC Pressure
switch 2P connector.
3. Check f or cont i nui t y bet ween
VTEC pressure swi t ch 2P con-
nect or t ermi nal No. 1 and No.
2.
Replace the VTEC preasure 3witch. l s t her e cont i nui t y?
Te3t the VTEC Pressure Switch
Wire:
1. Turn t he i gni t i on swi t ch ON l l l ).
2. Measure t he vol t age bet ween
VTEC pr ess u r e swi t ch 2P
connect or No. l and body
ground.
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.
l f t ha wi ro i 3 OK, 3ubrt i t ut e a
known- good ECM/ PCM and
recheck.
l s t her e bat t er y vol t age?
{To
page 6' 4i
I
VTEC Control System
Troubleshooting
Flowchart
(cont'd)
VTEC PRESSURE SwlTCH 2P
CONNECTOR
Wire side of female
(rmrnat s
VTEC SOLENOID VALVE lP
CONNECTOR
I r----'t I
ll
'
ff---r
' - ' 1
I
I
-L
Termi nal si de of
mal e t ermi nal
A/T LOW PRESSURE
w/PAt{EL
07406-0070300
NOTE: Keep measur i ng t i me as shor t as
possi bl e
because engi ne i s runni ng wi t h no
l oad (l ess
t han one mi nut e).
PRESSURE GAUGE
ADAPTER
07NAJ
-
P07010A
A/T PRESSURE I{OSE
07406
-
0020201
ot
A/T PRESSURE HOSE.
2,210 mm
07MAJ
-
PY&llA
and
A/T PRESSURE ADAPTER
07MAJ
-
PY,()120
6-4
(From page
6-3)
(To page 6-5)
Test the VTEC Pr6suro Switch
Wiro:
Nleasure voltage across the VTEC
pressure
swi t ch 2P connect or.
.
Rcpai . opon i n t ho wi re
brtw.en VTEC pr6.urc
switch
and G101.
.
lf th. wir6 b OK, sub.thuto a
lnown-good ECM/PCM !nd
racheck.
ls there baftery voltage?
Te3t the VTEC Solonoid V.lve:
2. Di sconnect t he VTEC sol enoi d
val ve 1P connect or.
3. Check for continuity between
t he VTEC sol enoi d val ve 1P
connect or t ermi nal No. 1 and
body ground.
l s t here 14
-
30 0?
Te3t tho WEC Solonoid Vatvo:
' 1.
Remove t he VTEC pressure
swat ch and i nst al l t he speci al
t ool as shown, t hen rei nst al l
the VTEC pressure
switch.
2. Reconnoct the VTEC solenoid
val ve 1P connect or and VTEC
pressure
3, Connect t he t achomet er
(see
sect i on 11).
5, War m up engi ne t o nor mal
operat i ng t emperat ure (cool ,
6. Check oi l pressure
at engi ne
speeds D16Y5 engi ne: 1, 000
and 3. 000 rpm, D16Y8 engi ne:
1, 000, 3, 000 and 5, 000 rpm.
ls pressure
below 49 kPa
(0.5
kgflcm,, 7 psi)?
In.poct the VTEC aolonoid vllvo
ls.c
p.g.
&6).
: (
t
I
t
:
t
I
I
(From page 6' 4)
Test the VTEC Solenoid Valve:
2. Di sconnect t he wEC sol enoi d
valve 1P connector.
3. At t ach t he bat t er y
posi t ave
t ermi nal t o t he VTEC sol enoi d
val ve t ermi nal .
4. St ar t t he engi ne and check
t h e o i l p r e s s u r e a t e n g i n e
speed of 5, 000 rpm.
Inspect lhe VTEC solonoid valve
lsee
p6ge m).
l s t he
pressure above 390 kPa
(4. 0
kgt cm' , 57 psi )?
Test the VTEC Pressure Switch:
With the battery
positive terminal
connect ed t o t he VTEC sol enoi d
val ve, measure vol t age bet ween
t he ECM/ PCM connect or t ermi nal
' 96
-
98: Cl 5, ' 99
-
00: C10 and
body ground.
l s t her e bat t er y vol t age above
5, 000 r pm?
T6st t he VTEC Sol enoi d Val ve
wire:
connect or t er mi nal and t he
ECM/ PCM connect or t ermi nal
'96
-
98: A8,
'99
00r B'12.
Repair open in the wire between
the ECM/PCM
('96 -
98: A8,
'99
-
0o: 8l2l and VTEC solenoid v.lv6
connoc{or.
Test t he VTEC Sol enoi d Val ve
Check for continuity between the
VTEC sol enoi d val ve 1P connect or
t er mi nal nd body gr ound.
ReDair 3hort in the wire between
the ECM/FCM
('96 -
98: A.8,
'99
-
0O: Bl2l and VTEC aolenoid valve
connectot,
l s t here cont i nui t y?
Substitute a known-good ECM/
PCM and r echeck. l f sympt om/
i ndi cat i on goes away, r epl ace
the original ECM/PCM.
VTEC SOLENOID VALVE
1P CONNECTOR
Termi nal si de of
mal e t ermi nal
ECM/PCM CONNECTOR C {31P}
'99
-
00:
'96
-
98:
CONNECTOR
'99
-
00:
VTEC SOLENOID
VALVE
ECM/PCM CONNECTOR
B {25Pt
1P CONNECTOR
'96
-
98:
VTEC SOLENOID
VALVE
ECM/PCM CONNECTOR
A {32P1
VTS
{GRN/ YEL)
wi re si de o{ f emal e
t ermi nal s
wi re si de oI t emal e
t ermi nal s
VTM
VTEC Sol enoi d Val ve
Inspecti on
1.
6 x 1 . 0 mm
12 N. m 11. 2 kgf . m, 8. 7 l bt f t )
Di sconnect t he 1P connect or f r om t he VTEC sol e-
noi d val ve.
Measure resi stance between the termi nal and body
gr ound.
Resi stance: l 4
-
30 O
l f the resi stance i s wi thi n speci fi cati ons, remove the
VTEC sol enoi d val ve assembl y f r om t he cyl i nder
head, and check the VTEC sol enoi d val ve fi l ter for
cl oggr ng.
. l f there i s cl oggi ng, repl ace the engi ne oi l fi l ter
and t he engi ne oi l .
VTEC SOLENOID VAI-VE ASSEMBLY
6- 6
(
4. l f the fi l ter i s not cl ogged, push the VTEC sol enoi d
val ve wi th your fi nger and check i ts movement.
. l f the VTEC sol enoi d val ve i s normal . check the
engane oi l pressure.
6 x 1 . 0 mm
12 N. m {1. 2 kgt . m, 8. 7l bf . f t )
I
. (
I
\
;
. . l '
VTEC Rocker Arms
2.
Manual Inspecti on
(D16Y5
engi ne)
3.
1 .
4.
Set the No. 1 pi ston at TDC.
Remove the cyl i nder head cover.
NOTE: Refer to page 6-46 when i nstal l i ng the cyl i n-
der head cover.
Move the i ntake secondary rocker arm on the No.
' l
cyl i nder manual l y.
Check that the i ntake secondary rocker arm moves
i ndependentl y of the pri mary i ntake rocker arm,
SECoNDARY Pt
ROCKER ARM
.
Push and pul l .
Check t he i nt ake secondar y
cyl i nder at TDC.
r ocker ar m of each
a l f the i ntake secondary rocker arm does not move,
remove the pri mary and secondary i ntake rocker
arms as an assembl y and check that the pi stons i n
t he secondar y and
pr i mar y r ocker ar ms move
smoothl y.
a l f any rocker arm needs repl aci ng, repl ace the pri -
mary and secondary rocker arms as an assembl y.
PRIMARY ROCKER ARM
4.
Manual Inspecti on
(D16YB
engi ne)
1 . Set the No. 1 pi ston at TDC.
NOTE: Reter to page 6-46 when i nstal l i ng the cyl i n-
der head cover.
Push the i ntake mi d rocker arm on the No. 1 cyl i n-
der manual l y.
Check that the i ntake mi d rocker arm moves i ndepen-
dentl y of the pri mary and secondary i ntake rocker
arms.
MID ROCKER
ARM
Check the i ntake mi d rocker arm of each cyl i nder at
TDC,
l f t he i nt ake mi d r ocker ar m does not move.
remove the mi d, pri mary and secondary i ntake
rocker arms as an assembl y and check that the pi s-
t ons i n t he mi d and pr i mar y r ocker ar ms move
smoothl y.
l f any r ocker ar m needs r epl aci ng, r epl ace t he
pri mary, mi d, and secondary rocker arms as an
assemory.
5,
6-7
VTEC Rocker Arms
Inspecti on Usi ng Speci al Tool s
(Dl 6Y5
engi nel
CAUTION:
. Before using th6 Valve Inspection Tool, make 3ure
that ths ai r pressure gaugo
on the ai r comptsssor
indicates over
iloo
kPa
14 kgf/cmr, 57 psi).
. Inspecl th6 valv clearance beforo rocker atm insDec"
ti on,
' 1.
Cover the timing belt with a shop towel to protect tho
belt.
Check ths intakg primaty rocker arm of each cylindqr at
TDC.
NOTE: Refer to
page
6-46 when i nstal l i ng the cyl i n-
der head cover.
Pl ug the rel i ef hol e wi th the speci al tool .
YY
OTLAJ
-
PR3O2OB
(
3, Remove the seal i ng bol t from the i nspecti on hol e
and connect the an ai r pressure regul ator wi th a 0
-
100 psi gauge.
10 x 1.0 mm
SEALING BOLT
20 N.m {2.0 kgj'm. 14lblft}
l
I
' 10
x 1. 0 mm
ADAPTER
; NSpCTTONHOLE
(Commerci al l y
avai l abl e)
l '
Pul l t he di al and
turn to adl ust,
Loosen the regul ator val ve on the val ve i nspecti on
tool and appl y the speci fi ed ai r pressure.
Spocified Air Pressurei
250 kPa
{2.5 kg,t/cm,,36 psi}
o-at
5. Wi th the speci fi ed ai r
pressure appl i d, push up the
ti mi ng
pl ate; the synchroni zi ng
pi ston wi l l pop out
and engage the i ntake secondary rocker arm.
Vi sual l y check the engagement of the synchroni zi ng
prston.
NOTE;
The synchroni zi ng
pi ston can be seen i n the
gap
between the secondary and pri mary rocker arms,
Wi th the ti mi ng pl ate engaged i n the groove on
t he t i mi ng
pi st on,
t he
pi st on i s l ocked i n t he
oushed out Dosi ti on.
TIMIiIG
PLATE
SPRIT{C
PRIMARY ROCKER ARM
AIR PRESSURE
GROOVE
SECO DARY
ROCKER ARM
TIMIT{G PLATE
TIMING SPRING
6- 9
6. Stop appl yi ng ai r
pressure and push up the ti mi ng
pl ate; the synchroni zi ng
pi ston wi l l snap back to i ts
ori gi nal
posi ti on.
Vi sual l y check the di sengagement of the synchro-
ni zi ng
pi stons.
NOTE:
. When the ti mi ng pl ate i s pushed up, i t rel eases
the ti mi ng pi ston, l etti ng the return spri ng move
the synchroni zi ng pi ston to i ts ori gi nal posi ti on.
7. Repl ace the i ntake rocker arms as an assembl y i f
either does not work correctly,
TIMING PLATE
oll PASSAGE --!
PRIMARY ROCKER
ARM
SECOI{DARY
ROCKER ARM
TIMII{G SPRII{G
RETURI{ SPRING
Remove the spsci al tool s.
After inspection, check that the malfunction indicator
l amp
(Ml Ll
does not come on.
TIMI G PISTOI{
VTEC Rocker Arms
(D16Y8
enginel
CAUTION:
o Before using the Valve Inspection Tool. mak6 sure
that the ai r pressure gauge
on the ai r comprsssor
indicates ovor 400 kPa {4 kgf/cm,, 57
psil.
. Inspect th6 valve clearanco before rockar arm inspec-
ti on.
. Covr th timing belt with a shop towel to
protect
the bolt.
.
Check tho intake prima.y rockff arm of each cylindel
at TDC.
1 . Remove the cyl i nder head cover.
NOTE: Refer to page
6-46 when installing the cylinder
neao cover,
Pl ug the rel i ef hol e wi th the speci al tool .
OTLAJ
-
PR3O2OB
I,^ A IA
o - t u
3. Remove the seal i ng bol t from the i nspecti on hol e
ancl connect an ai r pressure
regul ator wi th a 0
-
100
psi gauge.
l 0 x 1. 0 mm
SEALI NG EOLT
20 N.m (2.0
kgf.m, 14 lbf.ft)
(
AIR PRESSURE
REGULATOR
{Commerci al l y
avai l abl e)
.
Pul l t he di al and
t urn t o adj ust ,
4. Loosen the regul ator val ve on the val ve i nspecti on
tool and appl y the speci fi ed ai r pressure.
Specified Air Pressure:
250 kPa {2.5 kgf/cm', 36 psil
PRI MARY ROCKER
ARM
SYNCHRONIZING SYNCHRONIZING
PISTON A PISTON B
Make sure that the i ntake
pri mary
and secondary
rocker arms are mechani cal l y connected by the pi ston
and that the mi d rocker arm does not move when
oushed manual l Y.
5.
MID ROCKER SECONDARY
ARM ROCKER ARM
SECONDARY
ROCKER ARM
lf any intake mid rocker arm moves independently of
the
primary
and secondary rocker arms, replace the
rocker arms as a set.
t
1.
8.
9.
Remove the speci al tool s.
Use a 10 mm di amet er r od t o depr ess each l ost
moti on assembl y through i ts ful l movement.
Repl ace any l ost moti on assembl y that does move
smoothl y.
After i nspecti on, check that the MIL does not come
on.
ASSEMBLY
6 - 1 1
Valve Clearance
Adjustment
NOTE:
. Val ves shoul d be adj usted onl y when the cyl i ndsr
head temperature i s l ess than 100"F
(38"C).
. After adj usti ng, retorque the crankshaft pul l ey
bol t
(see page
6-16).
1, Remove the cyl i nder head cover.
NOTE; Refer to
page
e46 when installing the cytinder
head cover.
2. Remove the upper cover
(see page
6-19).
3. Set the No. 1 pi ston
at TDC. The
"UP"
mark on the
camshaf t pul l ey
shoul d be at t op, and t he TDC
marks shoul d al i gn wi th the cyl i nder head surface.
TDC MARKS
4. Adj ust val ves on No, 1 cyl i nder.
Intako: 0.18
-
0.22 mm
{0.007
-
0.009 in}
Exhaust: 0.23
-
0.27 mm
(0.009 -
0.011 i nl
"UP"
MARK
6- 12
No. 4
5. Loosen the l ocknut, and turn the adj ustment screw
unti l the feel er gauge sl i des back and forth wi th a
sl i Oht amount of drag,
D16Y7 engi n.:
CAUTION: Do not oyerti ghl en the l ocknuts; tho
rockor arms are made of aluminum.
INTAKE end EXHAUST VALVE
LOCKNUTS
Dl6Y5, Dl6Y8 engin3:
INTAKE .nd EXHAUST VALVE
LOCKNUTS
20 N. m
12. 0 kst m, 14l bt f t )
Adiusting screw locations:
IMTAKE
o.4 1{o. 3 No. 2
t r '
(
nb. 3 No. 2 No. 1
EXHAUST
18 N.m (1.8
kgI.m, 13 tbl.ftl
6. Ti ghten the l ocknut, and check the cl earance agai n.
Repeat the adj ustment i f necessary.
GAUGE
7 . Rotate the crankshaft 180' countercl ockwi se
(cam-
shaft oul l ev turns 90' 1. The
"UP"
mark shoul d be on
the exhaust si de. Adj ust val ves on No. 3 cyl i nder.
"UP-
MARK
t
8. Rot at e t he cr ankshaf t
' 180'
count er cl ockwi se t o
br i ng No. 4 pi st on t o TDC. Bot h TDC gr ooves ar e
once agai n vi si bl e. Adj ust val ves on No. 4 cyl i nder .
Rotate the crankshaft 180' countercl ockwi se to bri ng
No. 2 pi ston to TDC. The
"UP"
mark shoul d be on
the i ntake si de. Adj ust val ves on No. 2 cyl i nder.
-UP' MARK
6- 13
Valve Seals
Repl acement
(Cyl i nder
head removal not requi redl
NOTE: Cyl i nder head r emoval i s not r equi r ed i n t hi s
procedure.
The procedure
shown bel ow appl i es when usi ng the i n-
car val ve spr i ng compr essor
( Snap- on
YA884S wi t h
Y48845
-
2 A7/8" attachment).
!@@
Alway wear approved eye protection
when
using ihe in-cai valve spring compressor.
1. Turn the crankshaft so that the No. I and the No. 4
pi stons
are at top dead center
(TDC).
2. Remove the cyl i nder head cover and the rocker arm
assembl y.
NOTE:
. Ref er t o page 6- 30 f or r ocker ar m assembl y
removat.
. When r emovi ng or i nst al l i ng t he r ocker ar m
assembl y, do not remove the camshaft hol der
bol t s. The bol t s wi l l keep t he hol der s, spr i ngs
and rocker arms on the shaft.
. Refer to page 6-46 when i nstal l i ng the cyl i nder
head cover.
Remove the fuel i nj ectors and the wi re harness.
Usi ng the 8 mm bol ts suppl i ed wi th the tool . mount
t he t wo upr i ght s t o t he cyl i nder head at t he end
camshaf t hol der s. The upr i ght s f i t over t he cam-
shaft as shown.
l nsert the cross shaft through the top hol e of the
two upri ghts.
3.
4.
6- 14
Intake Valve Seals:
6. Sel ect the 7/8 i n di ameter short compressor attach-
ment, and fasten the attachment to the No. 4 hol e of
the l eve. arm wi th the speed pi n suppl i ed.
8.
7. l nsert an ai r adapto. i nto the spark pl ug hol e.
pump
ai r i nto the cyl i nder to keep the val ve cl osed whi l e
compressi ng spri ngs and removi ng the val ve keep
ers.
Put shop towel s over the oi l passages
to prevent
t he val ve keeper s f r om f al l i ng i nt o t he cyl i nder
neao.
OIL PASSAGES
Posi ti on the l ever arm under the cross shaft so the
l ever i s perpendi cul ar
to the shaft and the compres-
sor attachment rests on top of the retai ner for the
spri ng bei ng compressed. Use the front posi ti on
sl ot on the l ever as shown.
,
I
i '
OIL PASSAGES
IN-CAR SPRING COMPRESSOR
SLOT
10. Usi ng a downward moti on on the l ever arm, com-
.press
the val ve spri ng and remove the keepers from
t he val ve st em. Sl owl y r el ease
pr essur e on t he
spri ng.
11. Remove the val ve seal s
(see page 6-38).
12. Instal l the val ve seal s {see
page 6-43).
13. Instal l the spri ngs, the retai ners and the keepers i n
reverse order of removal .
Exhaust Valvs Sesls:
Sel ect the 7/8 i n. di ameter short compressor attach-
ment, and fasten the attachment to the No. 2 hol e of
the l ever arm wi th the speed
pi n suppl i ed.
Posi ti on the l ever arm under the cross shaft so the
l ever i s
perpendi cul ar to the shaft and the compres-
sor attachment rests on top of the retai ner for the
spr i ng bei ng compr essed. Use t he f r ont posi t i on
sl ot on the l ever as shown.
' 14.
IN-CAR SPRING COMPRESSOR
7/8 in SHORT ATTACHMENT
L
16. Usi ng a downward moti on on the l ever arm, com-
press the val ve spri ng and remove the keepers from
t he val ve st em. Sl owl y r el ease
pr essur e on t he
spnng.
Remove the val ve seal s {see
page 6-38),
Instal l the val ve seal s
(see page 6-43).
Instal l the spri ngs, the retai ners and the keepers i n
Repeat steps 6 to 19 on the other cyl i nders.
' t7.
' 18.
19.
20.
6- 15
Crankshaft Pulley and Pulley Bolt
Replacement
When i nst al l i ng and t i ght eni ng t he pul l ey. f ol l ow t he
procedure
bel ow,
Cl ean, r emove any oi l , and l ubr i cat e poi nt s
shown
bel ow.
O: Cl ean
x: Bemove any oi l
a: Lubri cate
TIMING BELT
GUIOE PLATE
Crankhaft pulley bolt size and torque value:
14 x 1.25 mm
20 N.m
{2.0 kgl.m, 14 lbf.ft) + 90'
NOTE: Do not use an i mpact wrench when i nstal l i ng.
HOI.I'ER HANDTI
07JAB
-
001020A
HOLDER ATTACHMENT. 50 mm
07NAB
-
ootoilllA
S(rc(ET, 17 mm
07JAA-lxtl010A or
{Co.nm.rci.lly .v.il.bl.}
CRANKSHAFT
6- 16
' 1.
Ti ghten the pul l ey
bol t to the speci fi ed torque.
Torque: 20 N.m
{2.0 kgf.m, 14 lbf'ft}
Use I fel t ti p pen
to mark the pul l ey
bol t head and
washer.
EMBOSSING MARKS
3. Ti ghten the pul l ey
bol t an addi ti onal 90".
EMBOSSING MABK MARKING
\
MARKING
MARKING
I
Ti mi ng Bel t
Illustrated lndex
NOTE:
. Refer to page 6-20 for how to posi ti on the crankshaft and
pul l ey before i nstal l i ng the bel t.
. Mark the di recti on of rotati on on the bel t before removi ng.
a Do not use the upper cover and l ower cover for stori ng removed i tems,
. Cl ean the upper cover and l ower cover before i nstal l i ng.
. Repl ace the ca mshaft seal s and cra n kshaft sea l s i f there i s oi l l eakage.
. Refer to page 6-16 before i nstal l i ng the ti mi ng bel t.
CYLINDER HEAD
COVER
Reler to
page 6-46
when i nstal l i ng.
HEAD COVEB GASKET
Replaco when l6akin9,
domaged or deteriorated.
Apply liquid gasket at
th lour corners of the
tecessos.
d
@
TIMING BELT
I nspect i on,
page 6-18
Adj ust ment ,
page 6-18
Removal ,
page 6-19
Installation. page 6-20
I x 1.25 mm
3t N.m {3.8 kgf'm, 27 lbfftl
Appl y engi ne oi l t o t he bol t
thleads.
CRANKSHAFT SPEED FI.UCTUATION
lcr(Fl sENsoR
Repl acement ,
Page
6-22
UPPER COVEB
l nst al l wi t h
surf ace f aci ng i n.
TIMING BELT
DRIVE PULLEY
Repl acement ,
page 6_16
6 x 1 . 0 mm
9.8 N'm 11.0 kgt m,
7.2 tbf.ft)
NUBBER SEALS
Replace when damaged
or deledorated.
LOWER COVER
FUBBER
PLUG
CRANKSHAFT PULLEY
Repl acement ,
page 6' 16
PULLEY BOLT
lil x 1.25 mm
20 N.m 12.0 kgt.m,
14 lbt'ft) + 90"
Repl acement ,
page
6' 16
Do not us6 an impact
wrench when i nst al l i ng.
x 1. 0 mm
BOLT
o-RING
10 x 1, 25 mm
Reol ace.
14 N.m {,1.5 kgt m, 33 lbt ftl
6 x 1 . 0 mm
t2 N.m 11.2 kgf'm,
8.7 tbt f0
9.E N'm
(1.0
kgt.m,
?.2 tbf.ftl
\ . - , o
6-17
Ti mi ng Bel t
Inspecti on
1 .
2.
3.
. Ref er t o page 6 46 when i nst al l i ng.
Remove the upper cover
(see
page 6 19).
I nspect t he t i mi ng bel t f or cr acks and oi l or cool ant
soakr ng.
NOTE:
. Repl ace the bel t i f oi l or cool ant soaKeo.
. Remove any oi l or sol vent that gets on the bel t.
Rot at e pul l ey
and i nspect bel t .
After i nspecti ng, retorque the crankshaft
pul l ev
bol t
{see
page
6- 16).
o - I 6
Tensi on Adj ustment
CAUTION: l t*ays aa;j "t the ti mi ng bett rensi on wi th
the engi ne col d.
NOTE:
. The tensi oner i s spri ng l oaded to appl y tensi on to the
bel t automati cal l y after maki ng the fol l owi ng adj ust
ment .
. Al ways rotate the crankshaft countercl ockwi se when
vi ewed f r om t he pul l ey
si de. Rot at i ng i t cl ockwi se
may r esul t i n i mpr oper adj ust ment of t he bel t t en-
si on.
. l nspect the ti mi ng bel t before adj usti ng the bel t ten-
st on.
1 . Remove the cyl i nder head cover.
.
Refer to page 6,46 when i nstal l i ng.
Remove the upper cover
(see page 6,' 19).
Rotate the crankshaft fi ve or si x revol uti ons to set
the bel t.
Set the No.
' l
pi ston
at TDC
(see page
6-21).
Loosen the adj usti ng bol t 180' .
2.
3.
4.
5.
\ I
ADJUSTING BOLT
44 N.m {4.5 kgt m,
33 rbf.ft)
7.
8.
Rotate the crankshaft countercl ockwi se three teeth
on the camshaft pul l ey.
Ti ghten the adj usti ng bol t.
After i nspecti ng, retorque the crankshaft pul l ey bol t
(see page
6-16).
Removal
NOTE:
. Repl ace the ti mi ng bel t at 105,000 mi l es
(168.000 km)
accordi ng to the mai ntenance schedul e
(normal con-
di ti ons/severe
condi ti ons).
l f the vehi cl e i s regul arl y dri ven i n one or more of the
fol l owl ng condi ti ons,
repl ace the ti mi ng bel t at 60.000
mi l es
(U.S.A.)
100,000 km {Canada).
. I n
ver y hi gh t emper at ur es
( over 110' F. 43' C)
.
In very l ow temperatures
(under
-20' F, -29"C)'
! Turn the crankshaft
pul l ey so the No. 1 pi ston i s at
top dead center
(TDC)
before removi ng the bel t
(see
page 6' 21).
. Inspect the water
pump before i nstal l i ng the ti mi ng
bel t {see Page
10-14).
1. Remove the spl ash shi el d
(see page 5-7).
2. Loosen the mounti ng bol t and l ock bol t. then remove
the
power
steeri ng
(P/S) pump bel t and
pump
MOUNTING
BOLT
8 x 1. 25 mm
2il N m 12.4
kgl m, 17 lbf'ft)
P/ S PUMP
BELT
I x 1.25 mm
24 N m
(2.4 kgf m, 17 lbt ft)
Loosen t he i dl er
pul l ey cent er nut and adj ust i ng
bol t, then remove the ai r condi ti oni ng
(AVC) com-
pressor bel t
(see
Page
5-6).
Loosen the mounti ng nut and l ock bol t, then remove
the al ternator bel t.
ALTERNATOR
BELT
LOCK BOLT
I x 1. 25 mm
24 N.m 12.4
kgf.m,
r? tbI.ft)
3.
MOUNTING
NUT
10 x 1. 25 mm
44 N.m 14.5
kgl m,
33 rb{ ft)
5. Remove the di psti ck, then remove the upper cover
and i dl er
Pul l eY
bracket
NOTE: Do not use the upper cover to store removed
i tems.
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgf . m,
7. 2
IDLER
I x 1. 25 mm
24 N.m
(2.4 kgl.m, 17 lbf'ft)
BRACKET
6. Remove the upper bracket {see
page 6-29)
NOTE:
. Use a
j ack to support the engi ne before the upper
bracket is removed
. Make sure to
pl ace a cushi on between the oi l
pan and the
j ack.
Remove the crankshaft
pul l ey
(see page 6-16).
Remove the l ower cover and di psti ck tube
NOTE; Do not use the lower cover to store removed
i tems.
1.
.'.
DIPSTICK TUBE
LOWER
6 x 1 . 0 mm
9. 8 N. m
(1. 0 kgf m,
7.2 rbt.ft)
(cont' d)
6- 19
Repl ace.
Ti mi ng Bel t
Removal
(cont'd)
9. Remove the CKF sensor from the oI pump.
10. Loosen the adj usti ng bott l gO..
t o r emov e t ens i on f r om t he
reti ghten the adj usti ng bol t.
12 N.m
11.2 kgt.m,
8.7 rbf.ftl
Push the tensi oner
t i mi ng be l t . t hen
AD.'USNNG BOLT
4{ N.m 14.5 kgt m,
33 tbtftl
1 1. Remove t he t i mi ng bel t .
6-20
l nstal l ati on
Instal l the ti mi ng bel t i n the reverse order of removal ;
Onl y key poi nts
are descri bed here.
l . set rhe ti mi ng bel t dri ve pul l ey
so that the No. 1 pi s-
ton as at top dead center
(TDC),
Al i gn the groove
on
the ti mi ng bel t dri ve pul l ey
to the poi nter
on the oi l
pump.
TDC MARK
POINTER
I
t
I
TIMING BELT
DBIVE PULLEY
Cl ean.
I
2. Set t he camshaf t pul l ey
t o TDC. Al i gn t he TDC
marks on the camshaft pul l ey
to the cyl i nder head
surface.
3. Instal l the ti mi ng bel t ti ghtl y i n the sequence shown'
OTi mi ng
bel t dri ve
pul l ev (crankshaft) )@Adj usti ng
pul l ey
-towater pump pul l ey J@Camshatt
pul l ey'
NOTE: Make sure the ti mi ng bel t dri ve
pul l ey and
camshaft Pul l eY
are at TDC
7.
Loosen and reti ghten the adi usti ng bol t to tensi on
the ti mi ng bel t.
l nstal l the l ower cover and upper cover.
NOTE: Cl ean t he upper and l ower cover s bef or e
i nstal l ati on.
l nstal l the crankshaft
pul l ey, then ti ghten the
pul l ey
bol t
(see page &16)
Rotate the crankshaft
pul l ey about fi ve or si x turns
countercl ockwi se
so that the ti mi ng bel t
posi ti ons
on the
Pul l eys.
Adj ust the ti mi ng bel t tensi on
(see page 6-18).
8.
L
9. Check that the crankshaft
pul l ey and camshaft
pul -
l ey are both at TDC.
CRANKSHAFT PULLEY:
CAMSHAFT PULLEY:
l f the camshaft and crankshaft
pul l eys are not posi -
ti oned at TDC, remove the ti mi ng bel t and adj ust
the
posi ti on fol l owi ng the
procedure on
page 6-20'
Then rei nstal l the ti mi ng bel t.
After i nstal l ati on, adj ust the tensi on of each bel t
. See secti on 23 for al ternator bel t tensi on adj ust-
ment.
a See secti on 22 tot NC
compressor bel t tensi on
adj ustment.
. See secti on 17 for P/S pump bel t tensi on adj ust
ment,
(wHrTE)
"UP"
MARK
TDC MARK
1 1 .
6-21
Crankshaft
Speed Fluctuation (CKF)
Sensor
2.
3.
5.
Repl acement
4.
1 .
6 x 1 . 0 mm
' 12
N. m
{1. 2 kgt . m,
8.7 tbf.ft)
6. Instal l the CKF sensor i n reverse order of removal .
NOTE: Refer to page
6-46 when i nstal l i ng.
Remove the crankshaft pul l ey (see page
6_16),
Remove t he upper cover and di pst i ck/ t ube
{ see
page
6- 19) .
Remove the l ower cover and i dl er pul l ey
bracket
(see page
6-19).
Di sconnect the CKF sensor connector,
then remove
the CKF sensor.
CKF SENSOR
CONNECTOR
6-22
: (
I
Gyl i nder
Head
l l l ustrated
Index
CAUTION:
. To avoi d damage, wai t unti l the engi ne cool ant temperatul e drops bel ow 100"F
(38' C)
before removi ng the cyl i nder
head.
. When handl i ng a metal
gasket, take care not to fol d i t or damage the contact surface'
NOTEr Use new O-ri ngs and
gaskets when reassembl i ng'
CYLI NDER HEAD
COVER
Refer to
page 6 46, when
i nst al l i ng cyl i nder head cover.
WASHER
Repl ace when damaged
or deteriorated.
O.RING
Replace.
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgf . m, 7. 2 l bf f t )
Appl y soapsuds t o t hreads and cyl i nder head
cont act surf ace when repl aci ng t he rubber
seal , t hen t emove any soapsuds af t er i nst al l
i ng rubber seal .
RUBBER SEAL
or deteriorated.
CYLINDER HEAD BOI-T
10 x 1. 25 mm
67 N.m 16.8
kgf m, a9 lbt'ft)
Ti ght eni ng,
Page
6-46
Appl y engi ne oi l t o t he t hreads.
HEAD COVEB GASKET
Repl ace when l eaki ng,
damaged or det eri orat ed.
Appl y l i qui d gasket at
t he f our corners ol t he
recesses,
DISTRIBUTOR
See sect i on 23.
8 x 1 .25 mm
24 N.m
(2.4 kgf.m,
17 tbt.ft)
CYLINDER HEAD
GASKET
Replace.
8 x 1. 25 mm
24 N.m {2.4
kgf m, 17 lbf ftl
t (cont ' d)
6-23
PINS
Cyl i nder
Head
lllustrated
Index
(cont'dl
(
- / )
_.
-
E
"or to reassembri ng,
crean at the parts i n sorvent, dry them and appry rubri cant to anv contact oarts.
D16Y7 engi ne:
ROCKR ARM
ASSEMBLY
Removal , page
6 30
I nspect i on, page
6-35
8 x 1. 25 mm
20 N.m (2.0
kgt.m, 14 tbt.ftl
Appl y engi ne oi l t o t he
H
B
O-RING
Repl ace.
INTAKE VALVE SEAL
Repl ace.
VALVE SPRING
SEAT
INTAKE VALVE
GUI DE
: a
t
i
VALVE
SPRI NG RETAI NER
EXHAUST VALVE
SEAL
VALVE SPRING
SEAT
EXHAUST VALVE
GUI DE
rnspect ron, page
6, 39
Bepl acement , page
6 4l
Aeami ng, page
6-43
8 x 1. 25 mm
37 N m
(3. 8
kgt m,
27 tbtftl
Appl y engi ne oi l t o
t he t hreads.
INTAKE VALVE
Removal , page
6-38
l nst al l at i on, page
6-43
Removal , page
6, 27
Warpage, page
6 40
Val ve seat recondi t i oni ng,
page
6-40
I nst al l at i on, page
6-45
VALVE
t
t
t
CAMSHAFT
nspect ron, page
6-36
OI L CONTROL
ORI FI CE
Cl ean.
KEEPERS
\
EXHAUST VAL
SPRI NG
c - A
9- 2. +
L
6 x 1 . 0 mm
12 N.m (1.2
kst.m, 8.7 tbf.ft)
Appl y engi ne oi t t o t he
t hreads.
VALVE KEEPERS
SPRING RETAINER
INTAKE VALVE
SPRI NG
D16Y5 engi ne:
I x 1. 25 mm
20 N.m
(2,0 kgf m, 14 lbf ft)
threads.
ROCKEB ARM
ASSEMBLY
Femoval ,
page 6-30
I nspect i on, Page
6-34
6 x 1 . 0 mm
12 N.m 11.2
kgf m, 8.7 lbf'ftl
t hreads.
VALVE KCEPERS
SPRING RETAINER
CAMSHAFT
I nspect i on,
page 6-36
6 x 1 . 0 mm
12 N, m 11. 2
8.7 tbf.ft)
WEC SOLENOID
VALVE
B
INTAKE VALVE
SPRING
INTAKE VALVE SEAL
Replace.
VALVE SPRING
SEAT
INTAKE VALVE
GUI DE
CAMSHAFT
PUL|'IY
VTEC SOLENOID
VALVE FILTER
Repl ace.
OIL CONTROL
ORIFICE
Cl ean.
VALVE
SPRING RETAINEB
EXHAUST
V
SPRING
VE
EXHAUST
VALVE
SEAL
t "o' """. uoau,
SEAT
Repl ace.
GUI DE
I nspect i on,
page 6-39
Repl acement , Page
6-41
Reami ng,
page 6-43
EXHAUST
VALVE
OIL SEAL
Repl ace.
HEAD
8 x 1. 25 mm
37 N.m 13.8
kgf.m,
27 tbf.frl
t he l hreads.
(cont ' d)
6-25
INTAKE VALVE
Removal ,
page 6 38
I nst al l al i on, Page
6 43
Removal ,
page 6-27
Warpage, Page
6 40
Val ve seat recondi t i oni ng'
page 6-40
l nst al l at i on,
page 6_45
Cyl i nder
Head
lllustrated
Index
(cont'dl
VALVE KEEPERS
SPRING RETAINER
INTAKE VALVE
VTEC SOLENOID
VALVE FILTEB
Repl ace.
OI L CONTROL
ORIFICE
Cl ean.
INTAKE VALVE SEAL
Repl ace.
VALVE SPRING
SEAT
INTAKE VAI.VE
GUI OE
CAMSHAFT
PULLEY
I
I
VALVE KEEPERS
SPRI NG RET
EXHAUST VALVE
SPRING
@
EXHAUST VALVE
SEAL
Repl ace.
8 x 1. 25 mm
37 N. m 13. 8 kgt m,
27 tbfitl
t he t hreads.
EXHAUST
VALVE
-vp
e,.i o"o reassembri ng,
crean at the parts
i n sorvent, dry them and appry rubri cant to any contact parts.
D16Y8 engi ne:
LOST MOTION
ASSEMgLY
ROCKER ARM
ASSEMBLY
Removal , page
6 30
I nspect i on, page
6-34
5 x l . 0 mm
12 N. m
{1. 2
8.7 tbf.ft)
VALVE SPRING
SEAT
EXHAUSTVALVE O. RI NG
GUI DE Repl ace.
I nspect i on, page
6 39
Repl acement , page
6 41
Reami ng, page
6 43
LOST MOTION
ASSEMBLY
HOLDER
INTAKE
VALVE
Bemoval , page
6 38
6 43
20 N.m
12.0 kgl.m, 14 tbf.ft)
Appl y engi ne oi t t o t he
t hreads.
\
\
s 9
i l l l
CAMSHAFT
I nspect i on,
page
6-36
OI L SEAL
Bepl ace.
CYLINDER HEAD
Removal , page
6 27
Warpage, page
6-40
Val ve seat recondi t i oni ng,
page
6 40
6-45
6 x 1 . 0 mm
12 N. m (1. 2
kgt . m, 8. 7 l bf . f t l
t hreads,
Removal
Engi ne removal i s not requi red for thi s procedure
!!!s@
Make sure
i acks
and sal ety stands are
f
ta"eata"ea propetty and hoist brackets are attached to the
correct
positions on the engine.
CAUTION:
. Use tender covel s to avoi d damagi ng
pai nted sul -
faces.
o To avoi d damage, unpl ug t he wi l i ng connect or s
careful l y whi l e hol di ng the connector
porti on to
avoi d damage.
. To avoi d damagi ng the cyl i nder head, wai t unti l the
engi ne cool ant t emper at ur e
dr ops bel ow 100" F
{38"C}
before loossning the tetaining bolts.
NOTE:
o Mar k al l wi r i ng and hoses t o avoi d mi sconnect l on
Al so, be sure that they do not contact other wi ri ng or
hoses, or i nterfere wi th other
parts.
. Inspect the ti mi ng bel t before removi ng the cyl i nder
h ead.
. Tur nt he cr ankshaf t
pu l l ey so t hat t he No. l pi st oni sat
top dead center
(see
Page
6-21)
' 1.
Di sconnect the negati ve termi nal from the battery'
Dr ai n t he engi ne cool ant
( see page' 10- 7) .
a Remove the radi ator cap to speed drai ni ng.
Remove the i ntake ai r duct and ai r cl eaner housi ng
(see page 5 3).
Remove t he mount i ng bol t and l ock bol t . t hen
r emove t he power st eer i ng
( P/ S) pump bel t and
pump
(see page 5' 5).
Loosen t he i dl er pul l ey cent er nut and adj ust i ng
bol t' then remove the ai r condi ti oni ng
(A' l c) com-
pressor bel t
(see
Page
5-6).
Loos en t he mount i ng nut and l oc k bol t . t hen
remove the al ternator bel t
(see page 6-19).
Remove the P/S pump bracket
(see page 5-12).
3.
4.
2.
6.
1.
8. Remove the throttl e cabl e by l ooseni ng the l ocknut,
then sl i p the cabl e end out of the throttl e l i nkage
NOTE:
. Take care not to bend the cabl e when removi ng i t
Al ways repl ace any ki nked cabl e wi th a new one
(see
sec-
t i on 1 1) .
D16Y7 engi ne:
Dl6Y5, Dl6Y8 engines:
THFOTTLE
CABLE
(cont' d)
6-27
LOCKNUT
CABLE
Cyl i nder
Head
Removal (cont'd)
9. Rel i eve fuel pressure (see
secti on 11),
E@E
Do not smoke while working
on tho fuel
system. Ke6p opgn flame or
gpark
away from lhe
work area, Drain fuel only into an app.oved containgr.
10. Remove the evaporati ve
emi ssi on (EVAP)
control
cani ster hose, fuel feed hose and breather hose.
D16Y7 engi ne:
BANJO BOLT
33 N.m
{3.4 kgt m,
25 tbf.ftt
BREATHER HOSE
D15Y5, Dl 6YB engi nes:
BANJO AOLT
33 N.m (3.4
kgf.rn,
25 tbf.ftt
EVAP CONTROL
CANISTER HOSE
6- 28
(
1 1. Remove the brake booster vacuum hose. fuel return
hose and vacuum hose (see page
S_4).
12. Remove the water bypass hose and posi ti ve
crank_
case venti l ati on (pCV)
hose.
016V7 engi ne:
PCV HOSE
D16Y5, D16Y8 engi nes:
\ a
I
WATER EYPASS
PCV HOSE
13. Remove t he upper radi at or hose' heat er hose and
wat er bYPass hose
WATER
EYPASS
HOSE
UPPER
RADIATOR
HOSE
1 4 .
HEATER
HOSE
Remove t he engi ne wi r e har ness connect or s
and
wi re harness cl amps f rom t he cyl i nder head and t he
i nt ake mani f ol d.
o Four fuel i nj ector connectors
. Engi ne cool ant temperature
(ECT)
sensor con-
nector
a
a
a
ECT switch connector
ECT gauge sendi ng uni t connector
Throttl e
posi ti on sensor connector
Mani tol d absol ute
pressure
(MAP) sensor con-
nector
Pri mary heated oxygen sensor
(pri mary HO2S)
connector
Secondar y
heat ed oxygen sensor
( secondar y
HO2S) connector
(D16Y7 engi ne)
Exhaust
gas reci rcul ati on
(EGR) val ve l i ft sensor
connector
(D16Y5 engi ne)
. VTEC sol enoi d val ve connector
(Dl 6Y5, D16Y8
engr nes)
. VTEC
pressure swi tch connector
(D16Y5. D16Y8
engr nes,
. l dl e ai r control
(l AC) val ve connector
15. Remove the spark
pl ug caps and di stri butor from
the cyl i nder head.
Remove the uPPer bracket.
NOTE:
. Use a
j ack t o suppor t t he engi ne bef or e t he
upper bracket i s removed.
. Make sure to pl ace a cushi on between the oi l
pan and the
j ack.
12 x 1. 25 mm
74 N.m {7.5
kgf m.
sil lbl.ftl
UPPER
BRACKET
' 17.
Remove the cyl i nder head cover'
CYLINDER
HEAD COVER
(cont ' d)
6-29
Cylinder Head
Rocker
Arms
18.
19.
2 1 .
22.
Removal
(cont'd)
Remove the ti mi ng bel t {see
page
6-19).
Remove the camshaft pul l ey
and back cover,
CAMSHAFT
PULLEY
Cl ean when i nst al l i ng.
6 x 1 . 0 mm
8 x 1. 25 mm
37 N.m (3.8
kgf.m,
21 tbtlrl
bol t t hreads.
Remove the exhaust manifold
{see
pages
9-6 and 9_7).
Remove the i ntake mani fol d (see pages
9-2 thru 4).
Remove the cyl i nder head bol ts, then remove the
cyl i nder head.
CAUTION: To prvent
warpage, unsclew lhe bohs
in sequonce 1/3 turn at a time; rgpeat tho sequence
until all bolts are loosened.
CYLINDER HEAD BOLTS LOOSENING
SEOUENGE:
6- 30
Removal
1. Loosen the adj usti ng screws.
2. Unscrew the camshaft hol der bol ts, then,remove
the rocker arm assembl y.
NOTE:
a Unscrew the camshaft hol der bol ts two turns at a
t,me, i n a cri sscross pattern,
to
prevent
damao_
i ng the val ves or rocker arm assembl y.
.
When removi ng the rocker arm assembl y, do not
remove the camshaft hol der bol ts. The bol ts wi l l
keep the camshaft hol ders, the spri ngs and the
rocker arms on the shaft.
CAMSHAFT
HOLDER BOLTS LOOSENING
SEOUENCE:
\
(
ADJUSTING SCREWS
Di sassembl y/Reassembl y
NOTE:
. l denti fy
parts as they are removed to ensure rei nstal l ati on i n ori gi nal l ocati ons'
. l nsDect rocker shafts and rocker arms
(see page 6-35).
. Rocker arms must be i nstal l ed i n the same
posi ti on i f reused.
. when r emovi ng or i nst al l i ngt he r ocker ar m assembl y, donot r emove t he camshaf t hol der bol t s. The bol t swi l l keept he
hol ders, spri ngs and rocker arms on the shaft.
-Zl
pri o,
,o reassembl i nq, cl ean al l the pans i n sol vent, dry them and appl y l ubri cant to any contact
poi nts.
|
-
TNTAKE RocKER
TNTAKE RocKER
D16Y7 engi ne:
Lefter
"8"
is stamped
on rocker arm.
ARM A
(4 placesl
ARM B
14
places)
INTAXE
ROCKER SHAFT
SPRING
{4
places)
ROCKER SHAFT
COLLAR
14
plac.3l
ROCKER
I
I
I
I
B A \ ' A
f i f t L$\ f t
: oo) [ *o:
l l l l .
I Jol----t
No.3 CAMSHAFT
| |
ruo. z cltusxerr
1i
T-* l=Bl-* d
,", 'l
l=^
^l
qJ?[l'-qJ'Ll
' I ^
B A
EI
[ilH
l"\
9
t (cont ' d)
6- 31
Rocker Arms
Disassembly/Reassembly (cont'dl
NOTE:
. l denti fy pans as they are removed to ensure rei nstal l ati on i n ori gi nal l ocati ons.
. Inspect rocker shafts and rocker arms (see page
6-34).
. Rocker arms must be i nstal l ed i n the same posi ti on
i f reused.
t when removi ng or i nstal l i ng the rockerarm
assembl y, do not remove the camshaft hol der bol ts. The bol tswi l l keepthe
hol ders, spri ngs and rocker arms on the shaft.
I
eri or to reassembri ng, crean a

the parts
i n sorvent, dry them and appry rubri cant to any contact poi nts.
D16Y5 engi ne:
ROCKER ARMS
TIMING PLATE
RUBBER BANO
(
\
-]-
-P'g,rp
t +. t ' t l l
\--,?|,
-
\2i
l
No. 5 CAMSHAFT
_
l
HOLDER
l
No. 4 CAMSHAFT
HOLDER
No. 3 CAMSHAFI
HOLDER
No . 2
HOLDER
\ r a
I
EXHAUST ROCKER
ARM B
{,1
placs)
EXHAUST ROCKEE SHAFT
Letter
"A"
is slamped
II{TAKE ROCKER SHAFT
! -r I
?h'ffi*ffi'
/ ^
- - -
IOCKER SHAFT
Letter
"8"
is stamped
6-32
D16Y8 engi ne:
No. 5 CAMSHAFT
HOLDER
ARM B
ROCKER ARMS
No. 4 CAMSHAFT
HOLOER
No. 3 CAMSHAFT
HOLDER
No. 2 CAMSHAFT
HOLDER
No.
'l
CAMSHAFT
HOLDER
R(rcKER SHAFT
SPRING
Let t er
"B"
i s st amped
Let t er
"A"
i s st amped
L
INTAKE SOCKER SHAFT
ROCKER SI{AFT
COLLAR NUBBER BAND
COLLAR
EXHAUST ROCKER SHAFT
6-33
Rocker Arms and Lost Motion
Assemblies
Inspecti on (D16Y5,
Dt6Y8 engi nesl
NOTEr When r eassembl i ng t he pr i mar y
r ocker ar m,
car ef ul l y appl y ai r pr essur e
t o t he oi l passage
of t he
rocker arm.
1. Inspect the rocker arm pi ston.
push
i t manual l y.
-
l f i t does not move smoothl y, repl ace the rocker
ar m assembt y.
Dl 6Y5 engi ne:
ROCKER ARM
TIMING PISTON
TIMING SPRING
SYNCHRONTZING
PISTON
SECONDARY
ROCKER ARM
MI D ROCKER ARM
PRI MARY ROCKER
SYNCHRONI ZI NG
PISTON A
NOTE:
.
Appl y oi l to the pi stons
when reassembl i ng.
o Bundl e the rocker arms wi th a rubber band to prevent
them from separati ng.
6- 34
(
\
DI6YS engi ne:
NOTE: Set the ti mi ng pl ate
and return spri ng as shown
oerow.
RETURN
CAMSHAFT HOLDER
Dl 6Yg engi ne:
2. Remove the l ost moti on assembl y from the hol der
and i nspect i t. Test i t by pushi ng
the pl unger
wi th
your
fi nger.
-
l f t he l ost mot i on assembl y pl unger
does not
move smoothl y, repl ace i t.
LOST MOTION ASSEMBLY
\ a
Pu3h
I
Cl earance
Inspecti on
Measure both the i ntake rocker shaft and exhaust rocker
shaft.
1. Measure the di ameter of the shaft at the fi rst rocker
l ocatron.
2. Zero the gauge to the shaft di ameter'
I
3. Measur e t he i nsi de di amet er of t he r ocker ar m and
check for an out of-round condi ti on.
Rockel Arm-to-Shaft Cl earance
Standard
(Newl :
l ntake: 0.017
-
0.050 mm
{0.0007
-
0.0020 i nl
Exhaust: 0.018
-
0.054 mm
(0
0007
-
0 0021 in)
Servi ce Li mi t:0.08 mm {0.003
i nl
Repeat these measurements on al l the rockers.
-
l f the cl earance i s over the servi ce l i mi t, repl ace the
rocker shaft and al l over tol erance rocker arms.
6- 35
Gamshaft
Inspection
NOTE:
. Do not rotate the camshaft duri ng i nspecti on.
. Remove the rocker arms and rocker shafts.
1. Put the camshaft and the camshaft hol ders on the
cyl i nder head. then ti ghten the bol ts to the speci fi ed
toroue.
Spocified torqu:
8 mm bolts; 20 N.m
(2.0
kgf.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:
@, @ @, @
6- 36
E
\
(
2. Seat the camshaft by pushi ng
i t toward the rear of
3, Zero the di al i ndi cator agai nst the end ofthe camshaft.
Push the camshaft back and fonh, and read the end
ptav.
Camshaft End Play:
Standard {New):0.05
-
0.15 mm
10.002
-
0.006 inl
Sorvice Limit 0.5 mm
(0.02
in,
I
5.
Remove the bol ts, then remove the camshaft hol d-
ers from the cyl i nder head.
-
Li ft the camshaft out of the cyl i nder head, wi pe i t
cl ean, then i nspect the l i i t ramps, Repl ace the
camshaf t i f any l obes ar e pi t t ed.
scor ed, or
excessi vel y worn,
-
Cl ean the camshaft beari ng surfaces i n the cyl i n-
der head, then set the camshaft back i n pl ace.
-
Pl ace a pl asti gage
stri p across each
Iournal .
Instal l the camshaft hol ders, and ti ghten the bol ts to
the soeci fi ed toroue.
\ , l
6, Remove the camshaft hol ders. then measure the
wi dest
poni on of the pl asti gage on each
j ournal .
Camshaft-to-Holder Oil Clearance:
Standard lNew):0.050
-
0.08!t mm
{0.002
-
0.004 in}
Service Limit : 0.15 mm {0.006
in)
l f the camshaft-to-hol der oi l cl earance i s out ot tol -
erance:
-
And t he camshaf t has al r eady been r epl aced,
you must repl ace the cyl i nder head.
-
l f the camshaft has not been repl aced, fi rst check
the total runout wi th the camshaft supported on
V-bl ocks.
Camshaft Total Runout:
Standard
(New):
0.03 mm
(0.001
inl max.
Service Limit: 0.04 mm {0.(X)2
in)
-7.
Rot at e camshat t
whi l e measuri ng.
L
-
l f the total runout of the camshaft i s wi thi n tol er-
ance, repl ace the cyl i nder head.
-
l f the total runout i s out of tol erance, repl ace the
camshaft and recheck the camshaft-to-hol der oi l
cl earance. l f the oi l cl earance i s sti l l out of tol er-
ance. repl ace the cyl i nder head.
INTAKE EXHAUST
O16Y/ engi ne 35.299
(1.3897)
37.281
(1.4678)
D16Y5
engrne
PRI 38.427 11.51291
38.784
(1.5269)
SEC 32. 193
( 1. 2674)
D l 6Y8
engr ne
PRI 36.77811.44791
38.008
(1.4964)
MI D 38.274
(1.5068)
sEu 37.065
(1.4592)
8. Check the cam l obe hei ght wear.
Cam l obe hei ght standard
(New)
t/g
a* rN Ex
- D16Y5 engine
PRI; Pri mary cam l obe, SEC: Secondary cam l obe
MtD: Mi d cam l obe. T/B: Ti mi ng bel t
l N: Intake, EX: Exhaust
PRI sEc MI DSEC
rts
- Dl6YE ongine
Uni t mm
( i n)
Check t hi s area {or wear.
6-37
Removal
NOTE: l dent i f y val ves and val ve spr i ngs as t hey ar e
removed so that each i tem can be rei nstal l ed i n i ts ori oi -
nal oosi ti on.
' 1.
Usi ng an appropri ate-si zed socket and
pl asti c
mal -
l et. l i ghtl y tap the val ve retai ner to l oosen the val ve
keepers before i nstal l i ng the val ve spri ng compres-
sor.
Instal l the spri ng compressor. Compress the spri ng
and remove the val ve keeper.
PLASTIC MALLET
SOCKET
VALVE SPRII{G COMPRESSOR
Snl p-on CF711 or KD-383
whh #32 JAWS
6- 38
L
(
3. I nst al l t he val ve gui de seal remover.
SEAL REMOVER vat vF GI nF !
4. Remove the val ve seal .
I
VALVE GUIDE SEAL REMOVER
LISLE P/N 57900 or KD3350
Val ve Gui des
lntake Valve Dimensions
A Standsrd l Newl : 29.9
-
30.1 mm
B Standard
(New):
C Standal d {Newl :
C Service Limit:
D Standard
(New):
D Service Limit:
11. 18
-
1. 19 i nl
117.42
-
117.72 mm
(4.523 -
4.635 inl
5.'18
-
5.49 mm
{0.2r57
-
0.2r61 i n)
5.,[5 mm
(0.21,16
in]
0.85
-
1.15 mm
(0.033
-
0.0'15 in)
0.65 mm
(0.026
i n)
Exhaust Valve Dimensions
A Standard l New): 25.9
-
26.1 mm
B Standard {Newl:
C Standard {New):
C Service Limit:
D Standard {New):
D Service Limit:
(1.02 -
1.03 i n)
114.60
-
114.90 mm
11.512
-
4.521in1
5.i[5
-
5.46 mm
10.21l t6
-
0.2150 i nl
5.,12 mm 10.213'l
in)
1.05
-
1.35 mm
{0.041
-
0.053 in)
0.95 mm {0.037 i n}
Valve Movement
Measure the gui de-to-stem cl earance wi th a di al i ndi -
cator whi l e rocki ng the stem i n the di recti on of normal
thrust
(wobbl e
method).
lniake Valve Stem-to-Guide Clearance:
St8ndard l New):
0.04
-
0.10 mm
10.002
-
0.004 i n)
Service Limit: 0.16 mm 10.006
in)
Exhaust Valvs Stem-to-Guide Glearance:
Standard {New}: 0.10
-
0.16 mm
10.004
-
0.006 in)
(0.009
in)
O
/'-_)
. l f t he measur ement exceeds t he ser vi ce l i mi t ,
recheck usi ng a new val ve.
. l f the measurement i s now wi thi n the servi ce
l i mi t, reassembl e usi ng a new val ve.
. l f t he meas ur ement s t i l l ex c eeds t he l i mi t ,
recheck usi ng the al ternate method bel ow, then
repl ace the val ve and gui de, i f necessary.
NOTE: An al ternate method of checki ng
gui de to
stem cl earance i s to subtract the O.D. of the val ve
stem, measured wi th a mi crometer, from the l .D. of
t he v al v e gui de, meas ur ed wi t h an i ns i de
mi crometer or bal l gauge. Take the measurements
i n t hr ee
pl aces al ong t he val ve st em and t hr ee
pl aces i nsi de the val ve gui de. The di fference be-
t ween t he l ar gest
gui de measur ement and t he
smal l est stem measurement shoul d not exceed the
servi ce l i mi t.
lntake Valve Stgm-to-Guidg clearance:
Standard {Newl: 0.02
-
0.05 mm
{0.001
-
0.002 in)
Ssrvico Limit 0.08 mm
(0.003
in)
Exhaust Valvo Stem-to-Guide Clearance:
Standard {New): 0.05
-
0.OB mm
{0.002
-
0.003 in)
Srvice Limit 0.11 mm
(o'Ooil
in)
Val ve ext ended 10 mm out f rom seat .
6- 39
Cylinder Head
Valve Seats
Warpage
NOTE: l f t he camshaf t - t o- hol der oi l cl ear ances
( see
page 6-36) are not wi thi n speci fi cati on, the cyl i nder head
cannot be resurfaced.
l f the camshaft-to-hol der oi l cl earances are wi thi n sDeci ,
fi cati ons, check the cyl i nder head l or warpage.
l f warpage i s l ess than 0.05 mm
(0.002
i n), cyl i n-
der head resurfaci ng i s not requi red.
l f warpage i s between 0.05 mm
(0.002
i n) and
0.2 mm
{0.008 i n), resurface the cyl i nder head.
Maxi mum r esur f ace l i mi t i s 0, 2 mm
( 0. 008
i n)
based on a hei ght of 93 mm
(3.66
i n).
Measure al ong edges, and three ways across center.
Cylinder Head Height:
Standard {Newl : 92.95
-
93.05 mm
{3.659
-
3.66:} in)
6-40
\
Recondi ti oni ng
' 1.
Renew the val ve seats i n the cyl i nder head usi ng a
val ve seat cutter.
NOTE: l f t he gui des
ar e wor n
( see page
6- 39) .
r epl ace t hem
( see page 6- 41) bel or e cut t i ng t he
val ve seats.
VALVE SEAT
CUTTER
(Commerci al l y
avai l abl e)
2.
?
4.
Car ef ul l y cut a 45' seat , r emovi ng onl y enough
materi al to ensure a smooth and concentri c seat.
Bevel the upper edge of the seat wi th the 30. cutter
and the l ower edge of the seat wi th the 60' cutter.
Check the wi dth of the seat and adj ust accordi ngl y.
Make one more very l i ght pass wi th the 45" cutter to
remove any possi bl e burrs caused by the other cut-
Iers.
Valve Seat Width:
Standard
(Nw):
Intake: 0.85
-
1.15 mm 10.033
-
0.045 i n)
Exhaust: 1.25
-
1.55 mm {0.049
-
0.061 in}
Sorvice Limit:
Intake: 1.6 mm
(0.063
i nl
Exhausl: 2.0 mm
(0.079
in)
Seat Wi dt h
5. Af t er resurf aci ng t he seat , i nspect f or even val ve
s e a t i n g r Ap p l y Pr u s s i a n Bl u e c o mp o u n d t o t h e
val ve f ace, and i nsert t he val ve i n i t s ori gi nal l oca-
t i on i n t he head, t hen l i i t and snap i t cl osed agai nst
t he seat several t i mes.
Val ve Gui des
7.
VALVE
SEAT
PFUSSIAN BTUE COMPOUNO
The actual val ve seati ng surface. as shown by the
bl ue comDound, shoul d be centered on the seat.
. l f i t i s too hi gh
(cl oser
to the val ve stem), you
must make a second cut wi th the 60' cutter to
move i t down, then one more cut wi th the 45'
cutter to restore seat width,
. l f i t i s too l ow
(cl oser
to the vsl ve edge),
you
must make a second cut wi th the 30" cutter to
move i t uD, then one more cut wi th the 45' cutter
to restore seat width.
NOTE: The fi nal cut shoul d al ways be made wi th
the 45" cutter.
l nsert the i ntake and exhaust val ves i n the head and
measure the val ve stem i nstal l ed hei ght.
Intake. Exhau3t Siem Installsd Height:
Standard
(New):
53.17
-
53.6,4 mm
12.093
-
2.112 i n)
Sorvice Limit: 53.89 mm
(2.122
in)
lf the valve stem installed height is over the service
l i mi t. reDl ace the val ve and recheck. l f i ts sti l l over
t he ser vi ce l i mi t , r epl ace t he cyl i nder head; t he
val ve seat i n the head i s too deep.
VALVE STEM
INSTALLED HEIGHT
8.
\-
Replacement
1 . As i l l ustrated bel ow, use a commerci al l y-avai l abl e
ai r-i mpact val ve
gui de dri ver attachment modi fi ed
to fi t the di ameter of the val ve gui des. In most cases.
the same
procedure can be done usi ng the speci al
tool and a conventi onal hammer.
VALVE GUIDE DRIVER
l Commerci al l v avai l abl e)
5. 3 mm
87 mm
+-
57 mft
t3.43 i n)
|
12 24 i nl
tr-r
' 10. 8
mm
(0. 42
i nl
or
VALVE GUIDE DRIVER, 5.5 mm
07742
-
0010100
Sel ect the
proper repl acement
gui des. and chi l l them
i n the freezer secti on of a refri gerator for about an
nour.
Use a hot pl ate or oven to evenl y heat the cyl i nder
head to 300"F
(150' C).
Moni tor the temperature wi th
a cooki ng thermometer.
CAUTION:
. Do not use a torch; it may warp the head.
Do not got the head hottel than 300"F
(150"C1;
excessive heat may loosen thg valve seats.
To avoid burns. use heayy gloves whon handling
the heated cylinder had.
{cont ' d)
6-41
Val ve Gui des
Replacement
(cont'd)
Worki ng from the camshaft si de, use the dri ver and
an ai r hammer t o dr i ve t he gui de about 2 mm
( 0. 1
i n)
towards the combusti on chamber. Thi s wi l l knock off
some of the carbon and make removal easi er.
CAUTION:
. Always wear satety goggles
or a face shield when
driving valve guides.
. Hol d the ai r hammer di rectl y i n l i ne wi th the
valve guide to prevent damaging the driver.
Turn the head over, and dri ve the gui de out toward
the camshaft si de of the head.
VALVE GUIOE ORIVER,
5.5 mm
07742
-
001 01 00
It a val ve gui de sti l l won' t move, dri l l i t out wi th a
8 mm {5/16 i n) bi t, then try agai n.
CAUTION: Drill guides
only in extreme cases; you
could damage the cylinder head it the guide breaks.
6. Remove the new gui des from the freezer, one at a
ti me, as you need them.
6-42
I
7. Appl y a thi n coat of cl ean engi ne oi l to the outsi de
of the new val ve gui de. Instal l the gui de from the
camshaft si de of the head; use the speci al tool to
dri ve the gui de i n to the speci fi ed i nsral l ed hei ght. l f
you have al l 16 gui des
to do, you may have to reheat
t he head.
VALVE GUIOE
DRI VER, 5. 5 mm
07742
-
0010100
l l
Valve Guide lnstalled Height:
Intake: 17.85
-
18.35 mm
(0.703 -
0.722 i nl
Exhausi : 18.65
-
19.15 mm
(0.734 -
0.754 i n)
VALVE GUI DE
Valves
Reami ng
NOTE: For new val ve gui des onl y.
1. Coat both the reamer and val ve gui de wi th cufti ng
or l .
2. Rotate the reamer cl ockwi se the ful l l ength of the
val ve gui de bore.
3. Cont i nue t o r ot at e t he r eamer cl ockwi se whi l e
removi ng i t from the bore.
4. Thoroughl y wash the gui de i n detergent and water
to remove any cutti ng resi due.
5. Check the cl earance wi th a val ve
(see page 6-391.
Veri fy that the val ve sl i des i n the val ve gui de wi th-
out exerti ng
Pressure.
Tur n r eamer i n
cl ockwi se di recl i on
on l y.
REAMER, 5.5 mm
O7HAH. PJ' O' I OB
I
REAMER
o
a)
o ,
o
o
1 .
l nstal l ati on
Coat val ve stems wi th engi ne oi l . Insert the val ves
i n the val ve gui des.
NOTE: Make sure l he val ves move up and cl own
smoothl y.
l nstal l the spri ng seats on the cyl i nder head.
I nst al l t he val ve seal s usi ng t he val ve gui de seal
i nst al l er .
NOTE: Exhaust and i ntake val ve seal s are not i nter-
changeabl e.
2.
3.
WHITE
SPRING
BLACK
SPRING
INTAKE VALVE SEAL EXHAUST VALVE SEAL
VALVE GUIDE SEAL
INSTALLER
KD2899
( Commer ci al l y
avai l abl e)
NOTE: Use smal l l D end of
P
(cont ' d)
6-43
Valves
Camshaft/Rocker Arms and
Camshaft Seal /Pul l ey
Installation
(cont'd)
4. I nst al l t he val ve spr i ng and val ve r et ai ner . t hen
i nstal l the val ve spri ng compressor. Compress the
spri ng and i nstal l the val ve keepers.
NOTE: Pl ace the end of the val ve spri ng wi th cl ose-
l y wound coi l s toward the cyl i nder head.
l Cornmerci al l y avai l abl e)
Snap-on CFrll or KD
-
3tX'
with #32 JAWS
Li ghtl y tap the end of each val ve stem two or three
ti mes wi th a pl asti c mal l et to ensure proper
seati ng
of the val ve and val ve keepers.
NOTE: Tap the val ve stem onl y al ong i ts axi s so you
do not bend the stem.
'
6-44
Instal l ati on
CAUTION:
. Make sure that all tockers are in alignment with their
valvgs when torquing the rocket assembly bolts,
. Val ve l ocknul s shoul d be l oosened and adi usti ng
screws backed off bofore installation.
. To prevont
tho rocker arm a$smbl y from comi ng
apad, l6av the camshaft holder bohs in the holdeB.
1. After wi pi ng down the camshaft, camshaft seal and
j our nal s
i n t he cyl i nder head, l ubr i cat e bot h sur -
faces and i nstal l the camshaft.
2. Cl ean and i nstal l the oi l control ori fi ce wi th a new
O-ri ng.
CAMSHAFT SEAL
Seal housi ng surf ace shoul d be dry.
Appl y a l i ght coat of oi l t o camshaf t
and i nner l i p of seal .
3. Turn the camshaft until its keyway is facing up
(No.
pi st on
TDC).
OIL CONTROL ORIFICE
Cyl i nder
Head
4. Appl y l i qui d gasket (Part
No. 08718
-
0001 or 08718
-
0003) to the head mati ng surfaces of the No. 1 and
No.5 camshaft hol ders.
-
Appl y l i qui d gasket to the shaded areas
Set the rocker arm assembl Y i n
pl ace and l oosel y
i nstal l the bol ts.
-
Make sure that the rocker arms are
properl y posi -
ti oned on the val ve stems.
Ti ghten each bol t two turns at a ti me i n the sequence
shown bel ow to ensure that the rockers do not bi nd
on the val ves.
Specitied torquo:
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 bol ts: O, @. @, @
7. Instal l the back cover. then i nstal l the camshaft pul -
!
6-45
l nstal l ati on
l nstal l the cyl i nder head i n the reverse order of removal :
NOTE:
. Al ways use a new head gasket.
. Cyl i nder head and cyl i nder bl ock sur f ace must be
cl ean.
.
"UP"
mark on the camshaft
pul l ey shoul d be at the top
. Turn the crankshaft so the No. 1 pi ston i s at TDC
(see
page 6-20).
. Cl ean the oi l control ori fi ce before i nstal l i ng.
a Do not use the upper cover and l ower cover to store
removeo rl ems.
Cl ean the upper cover and l ower cover before i nstal -
taUon.
Cyl i nder head dowel pi ns must be al i gned.
1 .
CYUNOER HEAD
PINS
(cont' d)
Cylinder Head
Installation
(cont'dl
Posi ti on the camshaft correctl y
(see page 6-20).
Ti ghten the cyl i nder head bol ts sequenti al l y i n four
steps.
rsr st.p:
O
-
@
20 N.m
(2.0
kgf.m, 14 lbf'ft|
2nd srep:
O
-
@
49 N.m
(5.0
kgf.m, 36 tbtft)
3rd stop;
O
-
@
67 N.m {6.8 kgf.m,
/r9
lbl'ft}
4th st6p:
O, O 67 N.m
16.8 kgf.m, 49 tbf.ftl
NOTE:
. We r ec ommend us i ng a beam- t y pe t or que
wrench, When using a preset-type
torque wrench.
be sure to tighten slowly and not to overtighten.
. If a bol t makesany noi sewhi l eyou aretorqui ng i t,
loosen the bolt, and retighten it from the 1st step,
CYLINDER HEAD BOLTS TOROUE SEOUENCE:
Instal l the i ntake mani fol d and ti ghten the nuts i n a
cri sscross
pattern
i n two or three steps, begi nni ng
wi th the i nner nuts
(see pages
9-2 thru 9-4).
. Al ways use a new i ntake mani fol d gasket.
Instal l the exhaust mani fol d and ti ghten the nuts i n
a cri sscross pattern i n two or three steps, begi nni ng
wi th the i nner nut {see
pages 9-6 and
g-7).
. Al ways use a new exhaust mani fol d gasket.
I nst al l t he exhaust mani f ol d br acket . l nst al l t he
exhaust
pipe
A and the bracket, then install the cover.
4.
6-46
\-
(
7. Instal l the ti mi ng bel t
(see page 6-20).
Adj ust the val ve cl earance
(see page
el 2),
Instal l the head cover gasket i n the groove of the
cyl i nder head cover , Seat t he r ecesses f or t he
camshaft fi rst, then work i t i nto the groove
around
the outsi de edges.
NOTE:
. Bef or e i nst al l i ng t he head cover gasket , t hor -
oughl y cl ean the seal and the groove.
. When i nstal l i ng, make sure the head cover gas-
ket i s seat ed secur el y i n t he cor ner s of t he
recesses wath no gap.
COBNERS OF
THE RECESS
CORNERS OF
THE REcEss
covEB
Appl y l i qui d gasket to the head cover gasket at the
four corners of the recesses.
NOTE:
.
Use l i qui d gasket, Pan No. 08718
-
0001 or 08718
-
0003.
. Check that the mati ng surfaces are cl ean and dry
before appl yi ng l i qui d gasket.
. Do not i nstal l the parts i f fi ve mi nutes or more
hav e el aps ed s i nc e appl y i ng l i qui d gas k et .
Instead, reappl y l i qui d gasket
after removi ng ol d
resi due.
. After assembl y, wai t at l east 30 mi nutes before
fi l l i ng the engi ne wi th oi l .
8.
9.
I
10.
11. When i nst al l i ng t he cyl i nder head cover , hol d t he
head cover gasket i n the groove by pl aci ng your fi n-
gers on the camshaft hol der contacti ng surfaces
(top
of the semi ci rcl es)
Set the spark
pl ug seal on the spark
pl ug tube.
Once t he cyl i nder head cover i s on t he cyl i nder
head, sl i de the cover sl i ghtl y back and forth to seat
the head cover
gasket.
NOTE:
. Before i nstal l i ng the cyl i nder head cover, cl ean
t he cyl i nder head cont act i ng sur f aces wi t h a
shop towel .
. Do not touch the
parts where l i qui d gasket was
aDol i ed.
. Take car e not t o damage t he spar k
pl ug seal s
when i nstal l i ng the cyl i nder head cover,
. Vi sual l y check the spark pl ug seal s for damage.
. Repl ace any washer that i s damaged or deteri o-
rated.
6 x 1 . 0 mm
9. 8 N. m 11. 0 ksf . m, 7. 2l bf f t l
\g-----*o""t'
P t l
v e
E E
\_
6-47
12. Ti ghten the nuts i n two or thre steps. In the fi nal
step, ti ghten al l bol ts, i n sequence, to 9 8 N' m
(1.0
kgf.m, 7.2 lbf.ft).
NOTE: After assembl v, wai t at l east 30 mi nutes
before fi l l i ng the engi ne wi th oi l
After i nstal l ati on, check that al l tubes, hosss and
connectors are installed correctlY
1 ?
Gylinder
Head/Valve Train
816A2 engine
Special Tools
............. 6' 50 Rocker Arms
VTEC Contlol System
Troubfeshooting Flowchart ............ 6-51 Disassembly/Reassembly
...............6' 72
VTEC Solenoid Valve
Inspection
...""' ...... 5-54 Inspection
.........""' 6-73
VTEC Rocker Arms
Manual I nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54 Cl earance I nspect i on . . ' . . . "' . . . . . . . . . . . . . . 6-74
Inspection Using Special Tools .....' 6-55 Camshafts
Valve Clearance
.^ Adiustment
.........." 6-57 Valves' Valve Springs and Valve Seals
. t Crankshaft Pulley and Pulley Bolt Removal
""""""""' 6-77
Replacement
..".....6-59 Valve Seats
Timing Belt
Reconditioning
......6' 78
Cylinder Head
lnstallation ' ............ 6-82
Speci al Tool s
(
\
Description
Oty Page Relerence
q oTHAH PJ7010B
g
I
07JAA- 001020A
g
I
07JAB- 0010204
I
07JAB
-
0010404
g 07LAJ
-
PR3020A
|6) 07MAA
-
PR70100
g
I
ozvu,r
-
enu orzo
g 07MAF
-
PR9010A
g 07742
-
0010100
( ! D
I
07757- PJ10104
Val ve Gui de Reamer , 5. 5 mm
Socket, 19 mm
Hol der Handl e
Pul l ey Hol der Attachment. 50 mm
Ai r Stopper
Tappet Adj uster
Tappet Locknut Wrench
Val ve Spri ng Compressor Attachment Extensi on
Val ve Gui de Dri ver, 5.5 mm
Val ve Spri ng Compressor Attachment
1
I
6-81
1 6 5 9
1 6-59
1
]
6-5s
1
I
6-55
1 6-57
1 6-57
1
J
6-77
1 6-80, 81
1 6-71
t
a;
aL)
' n
-=<-,,LE;;
(D
a
6- 50
\-
VTEC Control
SYstem
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC)
Pl 259:
VTEC Sol enoi d
Val ve ci rcui t
Refer to
page 1' l -38 through 11 55 before troubl eshooti ng
Troubleshooting
Flowchart
YES
A probl em i n the WEC Pressure Swi tch ci rcui t or
*
Road Test :
Accel erat e i n 1st
gear t o an engi ne speed over 6, 000 rp '
Hol d t hat engi ne speed f or at l east t wo seconos'
l f t he DTC P1259 i s not repeat ed duri ng t he f i rst road t est '
repeat t hi s t est t wo more t i mes
CONNECTOR
Ter mi nal s i de of
mal e t er mt nal s
WM
/1
IBLU/BLKI
/
1
Y------r
t--------- l I
\1-/
|
I
I
I
1
Wi re si de of f emal e
t ermi nal s
(cont' d)
6- 51
The MIL has been teported on.
DTC P1259 is siored.
Check the VTEC Control SYsiem:
1. Do t he engi ne cont rol modul e
( ECM
) Reset Pr ocedur e
( see
sect i on 11).
2. St art t he engi ne
3. Warm uP t he engi ne t o normal
operat i ng t emPerat ure
(cool
4. Do t he Road Test . *
lntermittent
failure, sYstem is OK
at this time.
Check f or Poor connect l ons
or
l oose wi res at VTEC
Pressure
swilch. VTEC aolenoid valvo and
ECM.
l s DTC P1259 i ndi cat ed?
2. Di sconnect t he VTEC Pressure
VTEC pressure swi t ch 2P con
n e c t o r t e l mi n a l
No 1 a n d
No . 2 .
Reolace the VTEC Pre3sure
switch.
Test the VTEC Pressure Switch
Wire:
1. Turn t he i gni t i on swi t ch ON
(l l ).
2. N4easure t he vol t age bet ween
VTEC
pr ess u r e swi t ch 2P
c o n n e c t o r No . 1 a n d b o d y
gr ound,
I nspect l or an open or short t o
ground in the wire between the
VTEC orassure swilch and ECM
{c101.
l f t he wi re i 3 OK, subst i t ut e a
known-good ECM and recheck.
{To
page 6 52)
VTEC Control System
Troubleshooting
Flowchart (cont,d)
CONNECTOR
Wi re si de of t emal e
t ermi nal s
OIL PRESSURE
GAUGE
(Comm.rcially
avail.bte)
GAUGE JOINT ADAPTER
SNAP.ON MT26.17
10 x 1. 0 f t m
.
Use new washer when
i nst al l i ng t he seal i ng bot t .
NOTE: Keep measur i ng t i me as shor r as
possi bl e
because engi ne i s runni ng wi t n no
l oad l l ess t han one mi nut e).
6-52
(
VTEC SOLENOID VALVE lP
CONNECTOF
Ir------r I
lLl.ll-r
I
I
I
t
Termi nal si de of
mal e t ermi nal
I
(From
page
6-5l l
(To page
6-53)
Test tha VTEC P.es3uro Switch
Wi.e:
Measure voltage across the VTEC
pressure
Ropair opon in the wiro batwoen
VIEC pr...urc
switch and G lot .
l f t he wi ro i s OK, 3ubl t i t ut r a
known-good ECM and rochack.
ls there battery voltage?
Test the VTEC Solenoid V.tve:
val ve 1P connect or.
connect or t ermi nal No, I and
body ground.
l s t here 14
-
30 O?
Te3t the VTEC Sotonoid Vatve:
' 1.
Remove t he VTEC pressure
swi t ch and i nst al l t he speci al
t ool as shown. t hen rei nst al l
the VTEC pressure
switch.
2. Reconnect the VTEC solenoid
val ve 1P connect or and VTEC
pressure
swi t ch 2P connect or,
3. Connect t he t achomet er (see
sect i on 1l ) .
4. St art t he engi ne.
5. War m up engi ne t o nor mal
operat rng t emperat ure (cool -
6. Check oi l pressure
at engi ne
s p e e d o f 1 , 0 0 0 , 3 , 0 0 0 a n d
5,000 rpm.
ls pressure
below 49 kPa
(0. 5
kgf l cm, , 7 psi )?
Inipoct thg VTEC aolenoid valve
l3ee
P8go
6-54).
I
(From page 6-52)
Test the VTEC Solenoid Valve:
1. Turn t he i gni t i on swi t ch OFF
valve 1P connector,
3. At t ach t he bat t er Y Posr t r ve
t ermi nal t o t he VTEC sol enoi d
val ve t ermi nal .
4. St ar t t he engi ne and check
t h e o i l
Pr e s s u r e
a t e n g i n e
speed ol 5, 000 rPm
lrcoect the VTEC solenoid valve
(see page S54)
ls the
pressure above 390 kPa
(4.0
kgt/cm?, 57
Psi)?
With the battery Positive
terminal
connect ed t o t he VTEC sol enoi d
val ve, measure vol t age bet ween
t he ECM connect or t ermi nal C10
and body
ground.
ls there battery voltage above
5, 000 r pm?
Test t he VTEC Sol enoi d Val ve
Wi re:
2. Check f or cont i nui t v bet ween
con nect or t er mi nal and t he
ECM connect or t ermi nal 812
the ECM lB12| and VTEC aolenoid
Test l he VTEC Sol enoi d Val ve
Wi re:
Check f or cont i nui t y bet ween t he
VTEC sol enoi d val ve' l P connect or
t ermi nal and body
ground.
Repair short in the wiro b'tween
the ECM
(
812) and VTEC aolenoid
Subst i t ut e a known' good ECM
and recheck. lI sYmptom/indica'
tion goes away. repleca the origi-
nal ECM.
VTEC SOLENOID VALVE
1P CONNECTOR
Ter mi nal si de of
mal e t er mi nal
VIEC SOLENOID
VALVE
1P CONNECIOR
ECM CONNECTOR
B l2sP)
ECM CONNECTOR C
(31PI
WM
Wi re si de ot f emal e
t ermrnal s
VTEC SOLENOID
VALVE
1P CONNECTOR
I ' f t
I
I
t ermanal
6-53
VTEC Solenoid Valve
VTEC
Rocker Arms
a
I
(
Inspection
1. Remove t he VTEC sol enoi d val ve assembl y f r om
t he cyl i nder head. and check t he VTEC sol enoi d
val ve fi l ter for cl oggi ng.
. l f there i s cl oggi ng, repl ace the engi ne oi l fi l ter and
engi ne oi l .
6x 1. 0mm
12 N.m (1.2
kgf.m, B,7 tbf.ftl
l f the fi l ter i s not cl ogged. push
the VTEC sol enoi d
val ve wi th your fi nger and check i ts movemenr.
. l f the VTEC sol enoi d val ve i s normal , check the
engi ne oi l pressure.
6 x 1 . 0 mm
12 N. m
(1. 2
kgt m, 8. 7 l bt . f t )
6- 54
L-
SOLENOID
Manual Inspecti on
1. Set the No. 1 pi ston
at TDC.
2. Remove the i gni ti on wi re cover and the wi res.
3. Remove the i gni ti on cl amps whi l e pul l i ng
up on the
Iock.
6 x l . 0 mm
9. 8 N. m (1. 0
kgl . m, 7. 2 t bt f t l
I GNI TI ON
WIRE COVER
IGNITION
WI RE
\
LOCK
NOTE: Refer to
page 6-88 when i nstal l i ng the cyl i n-
der head cover.
Push the mi d rocker arm on the No. 1 cyl i nder man-
ual l y.
Check that the mi d rocker arm moves i ndependentl y
of the
primary and secondary rocker arms.
Check the mi d rocker arm ot each cyl i nder at TDC'
. lf the mid rocker arm does not move, removs the
mi d,
pri mary and secondary rocker arms as an
assembl y and check that the
pi stons i n the mi d
and
pri mary rocker arms move smoothl y.
. l f any rocker arm needs repl aci ng, repl ace the
pri mary. mi d, and secondary rocker arms as an
assembl y.
7.
2. Pl ug the
per).
Inspection
Using SPecial
Tools
CAUTION:
. Bfore using tho Yalvo inspeciion tool, mako suro
that ths air
pre3sure gauge on the air comprossor
indicatos ovor
/rco
kPa
(,1
kgf/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. Remove the cYlinder head cover.
NOTE: Rsfer to
page 6-86 when installing the cylin-
der head cover.
relief hole with the special tool
(Air
Stop-
OTLA'
-
PRSO2OA
3. Remove the bol t and washer from the i nspecti on
hole and connoct the an air
pressure regulator with
a 0
-
100
psi gauge.
AIF STOPPEB
TNSPECTION
HOIE
OTLA'
-
PR3O2OA
t0 x 1.0 mrn
20 N.m {2.0 kgf m,
14 tbt'fr)
AIR PRESSURE
REGULATOR
{Cornm.rcirlly avril.bl.l
BEGULATOR VALVE
.
Pul l t he l ever and
turn to adjust.
{cont'd}
6- 55
VTEC Rocker
Arms
4.
Inspection
Using Special Tools
(cont,dl
Loosen t he val ve on t he r egul at or and appl y t he
speci fi ed ai r pressure.
Specified Air Pressuro:
250 kPa
{2.5 kgtlcm,, 36 psil
-
490 kPa {5.0 kgtcm,, 7t psil
Make sure that the pri mary
and secondary rocker
ar ms ar e mechani cal l y connect ed by t he pi st ons
and that the mi d rocker arms do no. move wnen
pushed
manual l y.
SECONDARY
ROCKER ARM
. l f any mi d rocker arm moves i ndependentl y
of
the pri mary
and secondary rocker arms, repl ace
the rocker arms as a set.
Remove the tool s.
Check the operati on of the l ost moti on assembl y by
pushi ng
on t he mi d r ocker ar m. The l ost mot i on
as s embl y s houl d c ompr es s f ul l y and oper at e
smoothl y through i ts ful l stroke. Repl ace the assem_
bl y i f i t does not work smoothl y.
After i nspecti on. check that the Mal functi on Indi _
cator Lamp {Ml L) does not come on.
7.
6- 56
I
l l
; l
Valve Glearance
Adjustment
NOTE:
. Val ves shoul d be adj usted onl y when the cyl i nder
head temperaturs
is less than 100'F
(38'C)'
. After adj usti ng,
retorque the crankshaft
pul l ey bol t to
177 N.m
(18.0
kgf' m, 130 l bt' ft)
1. Remove the cyl i nder head cover'
NOTE: Refer to
page G86 when i nstal l i ng the cyl i n-
der head cover.
2. Set No. 1
pi$on at TDC. The
"UP"
mark on the
pullsy
should be at the top, and TDC
grooves on the
pulley
should align with the
pointer on the back cover' TDC
grooves {white
paint) on the crankshaft
pulley should
align with the
pointer on the timing belt lower cover'
Number I
Piston
at TDC:
4.
Adj ust val ves on No. 1 cyl i nder.
lntako: 0.15
-
0.19 mm {0'006
-
0.007 in)
ExhaGt 0.17
-
0.21 mm {0'007
-
0 008 inl
Loosen the l ocknut, and turn the adj usti ng screw
unti l the feel er
gauge sl i des back and forth wi th a
sl i ght amount of drag.
TAPPET ADJUSTER
WFENCH SET
07MM
-
PR70110
TAPPET LOCKNUT
WRENCH
07MAA
-
PR70120
Adiusting sclaw location:
LOCKNUT
20 N.m {2.0 kgf'm, lil lbt'ftl
(cont' d)
6-57
Valve Clearance
I
I
I
Adjustment
{cont'd)
5. Ti ghten the l ocknut and recheck cl earance.
Repeat adj ustment i f necessary.
Rot at e t he c r ank s haf t 180. c ount er c l oc k wi s e
(camshaft
pul l ey
turns 90' ). The
"Up"
mark shoul d
be on the exhaust si de. Adj ust val ves on No. 3 cyl i n-
der.
Number 3 piston at TDC:
FELER GAUGE
"UP-
MARKS
6- 58
7. Rot at e t he cr ankshaf t
' 180.
count er cl ockwi se
t o
bri ng No. 4 pi ston
to TDC. The
,,Up,.
mark shoul d
be poi nti ng
strai ght down. Adj ust val ves on No. 4
cyl i nder.
Number 4 piston
at TDC:
8, Rot at e t he cr ankshaf t 180. count er cl ockwi se t o
bri ng No. 2 pi ston
to TDC. The
"Up.,
marks shoul d
be on the i ntake si de. Adj ust val ves on No. 2 cyl i n_
der.
Number 2 piston
at TDC:
L
Crankshaft
PulleY and PulleY Bolt
Repl acement
When i nstal l i ng and ti ghteni ng the pul l ey, fol l ow the
procedure bel ow'
Cl ean, remove any oi l , and l ubri cate
poi nts shown bel ow
a: Cl ean
x : Bemove anY ol l
a: Lubri cat e
PULLEY BOLT
WASHER
TIMII
GUID
Crankshaft
pulley bolt size and torque value:
14 x 1. 25 mm
177 N.m t18.0
kgtm, 130 lbf'ftl
NOTE: Do not use an i mpact wrench when i nstal l i ng'
X X
X X
x x
I i
x
X
X
X X
X
X
BELT
GUIOE PLATE
PULLEY HOLOR ATTACHMENT,
50 mm
07JAB
-
0O10,OA
CRANKSHAFT
X X X X X
6- 59
Ti mi ng Bel t
lllustrated Index
NOTE:
. Refer to page 6-59 for posi ti oni ng
crankshaft and pul l ey
before i nstal l i ng bel t.
. Mark the di recti on of rotati on on the bel t before removi no.
a Do not use the mi ddl e cover and l ower cover for stori ng r' emoved i tems.
. Cl ean the mi ddl e cover and l ower cover before i nstal l ati on.
WASHER
I
or det eri orat ed.
CAP NUT
x 1, 0 mm
9. 8 N. m l r. 0 kgf . m, 7. 2l bt f t l
CYLINDER
HEAD COVER
Ref er t o page
6-86
when i nst al l i ng.
HEAD COVER GASKET
Repl ace when l eaki ng,
damaged or deteriorated.
Appl y l i qui d gasket
at
t he f our corners ol t he
recesses,
TIMING BELT
I nspect i on, page
6-61
Adj ust ment , page
6-61
Replacement, page
6-62
I
6 x
' 1. 0
mm
9.8 N.m {1.0 kgf.m, 7.2 lbt.ftl
l 0 x 1. 25 mm
5a N.m
{5.5 kgl.m,
40 tbt ftt
MIDDTE COVER
6 x 1. 0 mrn
9.8 N.m {1.0 kgf.m,
7.2 tbt-ltl
8 x 1. 25 mm
N.m
{5.7 kgt.m,
41 tbt fr)
6 x 1 . 0 mm
N.m 11.0 kgf.m,
7.2 tbt.ft'l
PULLEY BOLT
14 x 1. 25 mm
177 N.m
{18.0 kgf.m. 130 tbt.ft}
Bepl acement , page
6-59
Do not use an i mpact
wrench when i nst al l i ng.
TIMING BELT
DRIVE PULLEY
I nst al l wi t h concave
surtace facing out.
Remove any oi l and cl ean.
LOWER
COVER
CRANKSHAFT PULLEY
Repl acement , page
6-59
-
- o
6- 60
Repl acement , page
6-59
Inspection
NOTE: Refer to page 6-86 when i nstal l i ng the cyl i n-
der head cover.
Inspect the ti mi ng bel t for cracks and oi l or cool ant
soakrng.
NOTE:
. Repl ace the bel t i f oi l or cool a nt soaked.
. Remove any oi l or sol vent that
gets on the bel t'
I
Rot at e PUl l eY
and i nspect bel t -
After i nspecti ng, retorque the crankshaft
pul
to 177 N.m
(18.0
kgf' m, 130 l bf' ft)
'L
l nspect t hrs area
Tension Adiustment
CAUTION: Always adiust timing belt tension with the
engine cold.
NOTE:
. The tensi oner i s spri ng-l oaded to appl y
proper ten
si on to the bel t automati cal l y after maki ng the fol l ow-
i ng adj ustment.
. Al ways rotate the crankshaft countercl ockwi se
when
vi ewed from the pul l ey si de. Rotati ng i t cl ockw' se
may resul t i n i mproper adj ustment of the bel t ten-
si on.
1, Remove the cyl i nder head cover.
NOTE; Refer to
der head cover.
2. Set the No. 1 pi ston at TDC
(see page 6-64)
3. Rotate the crankshaft l i ve or si x revol uti ons to set
the bel t.
4. Set the No. 1
Pi ston
at TDC
ADJUSTING BOLT
54 N.m
(5.5
kgt.m, a0 lbtftl
5.
7.
8.
Loosen the adj usti ng bol t 180' .
Rotate the crankshaft countercl ockwi se
three teeth
on the camshaft
Pul l eY.
Ti ghten the adj usti ng bol t.
After adj usti ng, retorque the crankshaft
pul l ey bol t
to 177 N.m
(18.0 kgf' m, 130 l bnft)
l ey bol t
6- 61
Ti mi ng Bel t
Removal
NOTE:
. Repl ace the ti mi ng bel t at 105,000 mi tes
(168,000
km)
accordi ng to the mai ntenance schedul e
(normal
con-
di ti ons/severe condi ti ons).
l f the vehi cl e i s regul arl y dri ven i n one or more of the
fol l owi ng condi ti ons, repl ace the ti mi ng bel t at 60,OOO
mi l es
(U.S.A.)
100,000 km {Canada).
.
In very hi gh temperatures (over
110"F, 43"C).
.
In very l ow temperatures (under -20.F,
29.C).
. Turn the crankshaft pul l ey
so the No. 1 pi ston i s at
top dead center
(TDC)
before removi ng the bel t
(see
page
6-57).
. Inspect the water pump
before i nstal l i ng the ti mi ng
bel t {see
page
10-14).
1 .
IOLER PULLEY BRACKET
EOLT
10 x 1. 25 mm
44 N.m 14.5 kgf.m, 33 bnft)
6-62
Remove the spl ash shi el d
(see
page
5-9).
Remove the adj usti ng bol t and mounti ng bol ts, then
r emove t he power st eer i ng ( P/ S) pump
bel t and
pump.
8 x L 2 5 mm
24 N m {2.{ kgf.m, 17 lbf.ft)
Loosen the idler pulley
bracket bolt and adjusting bolt,
then remove the ai r condi ti oni ng (A,/C)
compressor
belt
aDJUsnNG
44 N.m
14.5 kgt.m, 33 lbf.ft)
P/S PUMP LOWER ARACKET
a \
4. Loosen the mounti ng nut and l ock bol t, then remove
LOCK BOLT
8 x 1. 25 mm
24 N.m {2.4 kgt.m.
17 rb{.ftl
5. Remove the upper bracket
(see page
6-69).
NOTE:
. Use a
jack
to support the engine before removing
the upper bracket.
o Pl ace a cushi on between the oi l pan and the
j ack.
Remove the P/S pump l ower bracket
8 x 1. 25 mm
24 N.m 12.,1 kgf.m,
17 tbf.ftl
l 0 x 1. 25 mm
' - f '
MOUNTING
10 x 1. 25 mm
44 N.m (4.5
kgf.m.
33 rbf.ftt
BELT
HEAT SHIELD
7.
8.
pul l ey (see page 6-59).
Remove the cyl i nder head cover'
NOTE: Refer to
der head cover.
Remove the mi ddl e cover and l ower cover.
NOTE: Do not use the mi ddl e and l ower covers for
stori ng removed i tems.
MIDDLE COVER
LOWER COVER
9.
10. Loosen the adj usti ng bol t 180' .
t o r emov e t ens i on f r om t he
reti ghten the adj usti ng bol t.
9.8 N.m lt.o
kgf m,
7.2lw'ftl
Push the tensi oner
t i mi ng bel t , t hen
N.m
(5.5 kgt'm,
1 1. Remove t he t i mi ng bel t .
TDC
l nstal l ati on
Instal l the ti mi ng bel t i n the reverse order of removal ;
Onl y key
poi nts are descri bed here.
1. Set the ti mi ng bel t dri ve
pul l ey so that the No. 1 pi s'
ton i s at top dead center
(TDC). Al i gn the
groove on
the ti mi ng bel t dri ve
pul l ey to the V poi nter on the
oi l
pumP.
set the camshaft
pulleys so that the No. 1 piston is at
TDC.
Align the TDC marks on the intake and exhaust cam-
shaft
pulleys.
MARK
(cont' d)
6- 63
POINTER
Ti mi ng Bel t
lnstallation
(cont'dl
3. Instal l the ti mi ng bel t ti ghtl y i n the sequence shown.
@
Ti mi ng bel t dr i ve pul l ey ( cr ankshaf t ) +
@
Adjusting pulley
*
@
Water pump pu
ey
+
@
Intake
camshaft pulley
+
@ Exhaust camshaft pulley,
NOTE: Make sure the ti mi ng bel t dri ve pul l ey
and
camshaft
pullevs
are at TDC,
Loosen and reti ghten the adj usti ng bol t to tensi on
the ti mi ng bel t.
Instal l the l ower cover and mi ddl e cover.
NOTE: Cl ean the mi ddl e and l ower covers before
i nstal l i ng.
Instal l the crankshaft pul l ey,
then ti ghten the pul l ey
bol t
(see page 459).
Rotate the crankshaft pulley
about five or six turns
counterclockwise so that the timing belt positions
on
the pul l eys.
Adj ust the ti mi ng bel t tensi on (see page
A611.
7.
6-64
a
9. Check that the crankshaft pul l ey
and camshaft pul -
leys are both at TDC.
CRANKSHAFT PULLEY
CAMSHAFT PULLEY:
l f the camshaft and crankshaft pul l eys
are not posi -
ti oned at TDC, remove the ti mi ng bel t, adj ust the
posi ti on
fol l owi ng the procedure
on page
&63, then
rei nstal l the ti mi ng bel t.
After i nstal l ati on, adj ust the tensi on of each bel t.
. See section 23 for alternator belt tension adjust-
ment.
.
See secti on 22l or
NC compressor bel t tensi on
adiustment,
. See section 17 for P/S pump
belt tension adjust-
ment.
' l
10.
1 1 .
I
"UP"
MARKS
Cyl i nder
Head
lllustrated
Index
CAUTION:
. To avoid damaging the cylinder head, wait until the engine coolant tempsraturo drops below 100"F
(38"C1
bofote
removing it,
. when handling a metal
gasket, take caro not to fold the
gaskot or damage the contact surface of the gasket.
NOTE: Use new O-ri ngs and
gaskets when reassembl i ng.
CYLINDER HEAO
PLUG
Repl ace.
)@
DISTRIBUTOR
8 x 1 ,25 mm
27 N.m P.E
kgl m.
20 tbf.fo
t he t hreads.
cr.rMp.S
CAMSHAFT
\ A
"o''*t*';
wes@
OIL SEAL
Replace.
6 x l ,omm
9.8 N' m tl .0 kgt' m,7.2l bf ft)
RUBBER SEAL
Replace when damaged
or detedorated.
6 x 1 . 0 mm
9.8 N.m
(1.0 kgf'm,
7.2 rbnftl
fi
%
IGNMON
WIRE COVER
CYLINOER
HEAD
COVER
Refer to
page 6-86
when i nst al l i ng
HEAD COVER GASKET
Repl ace when l eaki ng, damaged
or det eri orat ed.
Appl y l i qui d
gasket at t he
corners of the recesses,
Page
6-86
8 x 1, 25 mm
24 N.m {2.4
kgf'm,
1? tbf.ftl
EXHAUST
10 x 1. 25 mm
56 N.m
(5.7
kgf m,
,r1 lbl.ft)
(cont' d)
6-65
Cyl i nder Head
lllustrated Index
(cont'dl
CYLINDER HEAD
BOLTS
11 x 1. 5 mm
83 N.m {8.5 kg{.m, 61
Appl y engi ne oi l
t o t hreads.
INTAKE VALVE SPRING INNER
VALVE KEEPERS
SPRI NG RETAI NER
INTAKE VAI.VE SPRING OUTER
valvEKEEPEBS\:""j"*'
SPRING RETAINER
EXHAUST VALVE
SPRING
VALVE SEAL
Repl ace.
VALVE
LOST MOTION
ASSEMBLY
EXHAUST VAL
VALVE SEAL
Repl ace.
SPRING SEAT
VALVE GUI DE
INTAKE VALVE
ROCKER SHAFT
SEALI NG AOLTS. 20 mm
64 N.m (6.5
kgt.m, 47 tbf.ft)
t
i l
HEAO OIL CONTROL
ORI FI CE
Cl ea n.
a
6- 66
Removal
Engi ne removal i s not requi red for thi s procedure.
!@@
Make sure
jacks
and safety stands are placed
properly and hoist brackels are attached to correst
posi-
tion on the engine,
CAUTION:
o Use fender covers to avoi d damagi ng pai nted sur-
faces.
To avoi d damage, unpl ug t he wi l i ng connect or 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 loosening the retaining bolt.
NOTE:
. Unspeci fi ed i tems are common.
. Mark al l wi ri ng and hoses to avoi d mi sconnecti on.
AIso, be sure that they do not contact other wi ri ng or
hoses or i nterfere wi th other parts.
o Inspect the ti mi ng bel t before removi ng the cyl i nder
n eao.
. Turn the crankshaft
pul l ey so that the No. 1 pi ston i s
at top dead center
(see page 6-64).
1. Di sconnect the negati ve termi nal from the battery.
Drai n the engi ne cool ant {see
page 10-7).
. Remove the radi ator cap to speed drai ni ng.
Remove the strut brace
(see page 5-2).
Remove t he i nt ake ai r duct and ai r cl eaner housi ng
(see page 5-3).
Remove the adj usti ng bol t and mounti ng bol t, then
remove the power steeri ng
(P/S) pump bel t and pump
(see page 5 5).
2.
3.
4.
\
ADJUSTING
6. Loosen the i dl er pul l ey bracket bol t and adj usti ng
bol t , t hen r emove t he ai r condi t i oni ng
( A/ C)
com-
pressor bel t.
IDLER PULLEY BRACKET
BOLT
10 x 1.25 mm
44 N.m {4.5 kg,l.m, 33 lbt.ft}
7. Loosen the mounti ng nut and l ock bol t, then remove
LOCK BOLT
8 x 1. 25 mm
24 N.m {2.4 kgf.m,
17 t bt f t l
ALTERNATOR
BELT
10 x 1. 25 mm
,l,l
N.m {4.5 kgf.m,
33 tbf.ft,
(cont ' d)
6-67
Cylinder Head
Removal
(cont'd)
8. Remove the P/S pump
l ower bracket.
8 x 1. 25 mm
24 N.m 12.4 kgf.m,
17 t bt f t l
9.
T SHI ELD
10.
P/S PUMP LOWER
BRACKET
10 x 1.25 mm
44 N.m {4.5 kgf.m,
33 tbf.frl
Rel i eve fuel pressure (see
secti on l 1).
@
Do not smok6 whi l e worki ng on fuel
system, keep open flam or spark away lrom work
ara, Drain fuelonly into an approved cortainr.
Remove the evaporati ve emi ssi on
(EVAP)
control
cani ster hose, fuel feed hose and breather hose.
BANJO BOLT
33 N.m
(3.4
kgl.m.25 lbf.ftl
BREATHER
HOSE
WASHERS
6- 68
\.
11. Remove the brake booster vacuum hose, fuel return
hose and vacuum hose
(see page 5 4).
12. Remove the water bypass hose and positive crankcase
ventilation
(PCV)
hose.
WATER BYPASS
HOSE
WATER EYPASS
HOSE
Remove the throttl e cabl e and throttl e control cabl e
by l ooseni ng the l ocknut, then sl i p the cabl e end out
of the throftl e l i nkage.
NOTE;
. Take care not to bend the cabl es when removi ng
them. Al ways repl ace any ki nked cabl e wi th a new
one.
(see
sec-
t i on I I
) ,
. Adj ust the throttl e control cabl e when i nstal l i ng
(see
secti on 14).
CONTROL
CABLE
1 a
PCV HOSE
WATER BYPASS
HOSE
14. Remove the upper radi ator hose, heater hose and
water bvpass hose.
HEATER
Remove the engi ne wi re harness connectors and wl re
harness cl amps from the cyl i nder head and the i ntake
mani fol d.
Four fuel i nj ector connector
Engi ne cool ant temperature
(ECT)
sensor connec-
tor
ECT gauge sendi ng uni t connector
ECT swi tch connector
l dl e ai r control
(l AC)
val ve connector
Manifold absolute
pressure (MAP)
sensor connec-
tor
Throttl e
posi ti on sensor connector
Pri mary Heated oxygen sensor
(Pri mary
HO2S)
connecror
VTEC sol enoi d val ve connector
15.
a
a
a
a
a
\
16.
17.
Remove the spark pl ug caps and di stri butor form
Remove the upper bracket.
NOTE:
. Use a
jack
to support the engine before removing
the uppr bracket is removed.
. Pl ace a cushi on between the oi l
panandthej ack.
12 x 1.25 fi n
74 N.m 17.5 kgtm,
UPPER BRACKET
18. Remove the cyl i nder head cover.
{cont ' d)
6- 69
Cyl i nder Head
19.
20.
Removal
(cont'dl
Remove the ti mi ng bel t {see
page
6-62).
Remove the back cover and camshaft pul l eys.
BACK COVER
56 N.m
(5.7
kgf m,
41 tbt.f0
6 x l . 0 mm
9.8 N,m
(1.0
kgf.m, 7.2 lbf.ft)
21, Remove the exhaust mani fol d
(see
page 9-8).
22. Remove the i ntake mani fol d
(see page
g-5).
23. Loosen the adj usti ng screws.
INTAKE
No. 4 No. 3 No. 2 No. 1
6-70
24. Remove the camshaft hol der pl ates,
camshaft hol d-
ers and camshafts.
CAMSHAFT
HOLDER PLATE
Remove the cyl i nder head bol ts, then remove the
cyl i nder head.
CAUTION: To prevsnt
warpage. unscrew the bolts
in sequonc 1/3 turn at a tim; lepeat lh6 sequence
until all bolts aro loosened.
CYLINDER HEAD BOLTS LOOSENING SEOUENCE:
CYLINDER HEAD
PLUG
Repl ace.
t
\ 1
\
\ i
b4
CAMSIIAFTS -
Rocker Arms
Removal
' 1.
Hol d the rocker arms together wi th a rubber band to
prevent them from separati ng.
Remove the i ntake and exhaust rocker shaft oi l con-
trol ori fi ces, then remove the VTEC sol enoi d val ve
and the seal i ng bol ts.
NOTE: The shapes ofthe i ntake and exhaust oi l con-
trol ori fi ces are di fferent, l denti fy the
parts as they
are removed to ensure rei nstal l ati on i n the ori gi nal
l ocauons.
2.
EXHAUST ROCKER
SHAFT ORIFICE
INTAKE ROCKER
ORIFIGE
Cl ean.
Cl ean.
O. RI NG
O. RI NG
Repl ace.
RUEBER BAND
Repl ace.
_
( l X
- dJ' v- l - <
r -Y^\ / /. I
\
6-71
3. Scr ew 12 mm bol t s i nt o t he r ocker ar m shaf t s.
Remove each rocker arm set whi l e sl owl y
pul l i ng
out the i ntake and exhaust rocker arm shafts.
12 mm BOLTS
ROCKER ARM SHAFTS
Rocker Arms
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:
. l denti fy parts
as they are removed to ensure rei nstal l ati on i n ori gi nal l ocati ons.
. Inspect rockershafts and rockerarms (see page6-73).
o Rocker arms must be i nstal l ed i n the same posi ti on i f reused.
. Cl ean the rocker shaft ori fi ces when i nstal l i no.
a
I
eri or. to ,"i nstal l i ng, cl ean arr the parts
i n sorvent, dry them, and appry rubri cant to any contact surfaces.
y'///
CYLTNDER NUMBER
SEALING BOLTS 20 mm
64 N m {6.5 kg{.m,
/t7
lbf.ftl
k
r ROCKEN
I NTAKE ROCKER ARM ASSEMBLI ES
Inspection
NOTE: When reassembl i ng the pri mary rocker arm, care-
ful l y appl y ai r
pressure to the oi l passage of the rocker
ar m.
PRI MARY ROCKER ARM
MI D ROCKER ARM
Inspect each rocker arm
pi ston. Push i t manual l y
-
lf it does not move smoothly. replace the rocker
arm assemDl y.
1 .
SECONDARY
Check prst on movement
NOTE:
. Appl y oi l to the pi stons when reassembl i ng.
. Bundl e the rocker arms wi th a rubber band to
keep them together as a set.
PI STONS
PRI MARY
\
6-73
2. Remove the l ost moti on assembl y from the cyl i nder
head and i nspect i t. Test i t by pushi ng the pl unger
wi th your fi nger,
-
l f t he l ost mot i on assembl y does not move
smoothl y, repl ace i t.
LOST MOTION ASSEMBLY
Push
I
Clearance Inspection
Measure both the i ntake rocker shaft and exhaust rocker
shaft.
1. Measure di ameter of shaft at the fi rst rocker l oca-
t r on.
2. Zero gauge
to shaft di ameter.
Surl ace shor/ l d be smoot h.
MI CROMETER
6-74
3. Measure the i nsi de di ameter of each rocker arm and
check for out-of-round condi ti on
Rocker Arm-to-Shaft Clearance:
Intake and Exhaust
Standard {Newl : 0.025
-
0.052 mm
{0.0010
-
0.0020 i n)
Service Limit: 0.08 mm {0.003 in)
Inspect rocker arm
face for wear.
Repeat for al l rockers.
-
l f over l i mi t, repl ace rocker shaft and al l overtol -
erance rocker arms.
NOTE: l f any rocker arm needs repl acement, repl ace
al l three rocker arms i n that set {pri mary, mi d, and
seconoary).
Camshafts
Inspecti on
NOTE:
. Do not rotate the camshaft duri ng i nspecti on.
. Removg the rocker arms and rocker shafts.
' L
Put the camshafts and camshaft hol ders on the cyl i n-
der head. and then ti ghten the bol ts to the speci fi ed
torque.
Specified Torque:
O
-@:
8 mm botts 27 N.m {2.8
kgf.m,20 l bt' ft)
Appl y engi ne oi l to the threads,
O
-
@:
6 mm bolts 9.8 N.m
(1.0
kgf m, 7.2 lbf'ft)
Seat the camshaft by
pushi ng i t toward the di stri bu-
tor end of the cyl i nder head.
Zero the di al i ndi cator agai nst the end of the di stri b-
utor dri ve. then push the camshaft back and fonh
and read the end
pl ay.
Camshaft End Play:
Standard {New}: 0.05
-
0.15 mm
{0.002
-
0.006 i nl
Servi ce l i mi l : 0.5 mm
(0.02 i n)
o o o o o o o
o o o o o
\-
4. Remove the bol ts. then remove the camshaft hol d-
ers from the cyl i nder head.
-
Li ft the camshaft out of the cyl i nder head, wi pe
cl ean, t hen i nspect t he l i f t r amps. Repl ace t he
camshaft if lobes are pitted, scored, or excessively
-
Cl ean the camshaft beari ng surfaces i n the cyl i n
der head, then set the camshaft back i n pl ace,
-
Insert a pl asti gage stri p across each
i ournal .
Put the camshaft on the cyl i nder head. then i nstal l
the camshaft hol ders, and then ti ghten the bol ts to
the speci fi ed torque as shown i n the l eft col umn on
thi s
page.
Remove t he camshaf t hol der s, t hen measur e t he
wi dest
porti on of the pl asti gage on each
j ournal .
Camshaft
-to-Hold1
Oil Clearsnce:
Standard {Newl: 0.050
-
0.089 mm
{0.002
-
0.004 inl
S6rvice Limit: 0.15 mm 10,006 inl
(cont ' d)
6- 75
PLASTI GAGE STRI P
Gamshafts
Inspection
(cont'dl
7. l f the camshaft-to-hol der oi l cl earance i s out of tol -
erance:
-
And the camshaft has al ready been repl aced, you
must repl ace the cyl i nder head.
-
l f the camshaft has not been repl aced, fi rst check
the total runout wi th the camshaft supported on
V-bl ocks.
Camshaft Total Runout:
Standard
(New):
0.03 mm {0.001 i n} max.
Service Limit: 0.04 mm
(0.002
inl
-
l f the total runout of the camshaft i s wi thi n tol er,
-
l f the total runout i s out of tol erance. repl ace the
camshaft and recheck the camshaft to,hol der oi l
cl earance. l f the oi l cl earance i s sti l l out of tol er-
INTAKE EXHAUST
PRIMARY
33.088 mm
{1.3027 i n)
32.785 mm
(1.2907
i nl
MI D
36.267 mm
(1.4278
i n)
35.720 mm
{1.4063 i n)
SECONDARY
34.978 mm
( 1. 3771
i nl
3i 1. 691 mm
(1. 3658
i n)
8. Check the cam l obe hei ght.
Cam lobe height standard
(New):
Cam Position
I
INTAKE
MI D
EXHAUST
SEC MI D PRI
TI B
T/ B: TI MI NG BELT
PRI : PRI MARY
MI D: MI D
Check t hrs area l or wear.
Removal
NOTE: l denti fy val ves and val ve spri ngs as they are
removed so that each i tem can be rei nstal l ed i n i ts ori gi -
nal Dosi ti on.
l . Usi ng an appropri ate-si zed socket and
pl asti c mal -
l et, l i ghtl y tap the val ve retai ner to l oosen the val ve
keeoers.
PLASTIC
Instal l the val ve spri ng compressor. Compress the
spring and remove the vSlve keepers.
VALVE SPRING
COMPRESSOR
ATTACHMENT
07757
-
PJ1010A
VALVE SPRING
COMPRESSOR ATTACHMENT
EXTENSION
OTMAF
-
PRgOIOA
I
Sn. p-on CFr1l
COMPRESSOR
6-77
3. I nst al l t he val ve gui de seal remover.
VALVE GUIDE SEAL REMOVER
COMMERCIALLY AVAILABLE
Ltst-E P/N 571100
()R
KD3350
4. Remove the val ve gui de seal .
Valve Dimensions
lntake Valvo
A Standsrd {Newl; 32.90
-
33.10 mm
(1.295 -
1.303 in}
B St ndard {New}: 101.00
-
101.30 mm
(3.976 -
3'988 in}
C Stsndard
(Nowl:
5./t5
-
5.,185 mm
(0.2156 -
0.2159 in)
C Servico Limit 5.445 {0.21/l| in)
D Siandard
(N!w):
1.05
-
1.35 mm
(0.041 -
O.05il inl
D S.vice Limit: 0.85 mm {0.033
inl
Exhaust Valve
A Standard l Newl i 27.90
-
28.10 mm
(1.098 -
1.106 i n)
B Stlndard {Nowl:
100.m
-
1qr,90 mm {3.961
-
3.972 in)
C Stsndard {Now}:
5.450
-
5.,[60 mm {0.21,16
-
0.2150 in)
C Service Limit 5.420 10.213,0 inl
D Standard {New): 1.65
-
1.95 mm
(0.065 -
0.077 in)
D Sorvico Limit: l.ils mm 10.057
inl
Valve Seats
Reconditioning
1. Renew the val ve seats i n the cyl i nder
val ve seat cutter.
NOTE: l f any gui des
ar e wor n
( see
r epl ace t hem
( see page
6- 80) bef or e
val ve seats,
head wi th a
page 6- 79) ,
cut t i ng t he
Carefully cut a 45o seat, removing only enough mate-
rial to ensure a smooth and concentric seat.
Bevel the upper edge of the seat with the 30" cutter
and the l ower edge of the seat wi th the 60. cutter.
Check width of seat and adjust accordingly,
Make one more very l i ght pass wi th the 45" cutter to
remove any possi bl e
burrs caused bv the other cut-
ters.
Valve Seat Width:
Standard
(Newl :
1.25
-
1.55 mm {0.0' t9
-
0.061 i n)
Service Limii: 2.0 mm 10,08 inl
Sear Wi drh
6-78
5. After resufaci ng the seat. i nspect for even val ve
seat i ng: Appl y Pr ussi an Bl ue Compound t o t he
val ve face, and i nsert the val ve i n i ts ori gi nal l oca-
t i on i n t he head. t hen l i f t i t and snap i t cl osed
agai nst the seat several ti mes.
PRUSSI AN BLUE COMPOUND
The actual val ve seati ng surface, as shown by the
bl ue compound, shoul d be centered on the seat.
. lf it is too high
(closer
to the valve stem), you must
make a second cut with the 60. cutter to move it
down, then one more cut wi th the 45. cutter to
restore seat width.
. lf it is too low
(closer
to the valve edge), you
must
make a second cut with the 30. cutter to move it
up. then one more cut with the 45. cutter to restore
seat width.
NOTE: The fi nal cut shoul d al ways be made wi th
the 45" cutter,
7. Insen the i ntake and exhaust val ves i n the head and
measure val ve stem i nstal l ed hei oht.
Intaka Valve Stem Installed Height:
Standsrd lNaw): 37.465
-
37.935 mm
(1./P50 -
r.4935 i nl
0.5033 in)
Exhau3t Valv Stem Installed Height:
Standard
(New):
37.165
-
37.6i|5 mm
(1.46:t2 -
1.i 1817 i nl
Servico Limit 37.885
(1.4915
inl
lf valve stem installed height is over the service limit,
replace the valve and recheck. lf it is still over the ser-
vi ce l i mi t, repl ace the cyl i nder head; the val ve seat i n
the h6ad is too deep.
(
Cyl i nder
Head
Val ve Gui des
Warpage
NOTE: lf camshaft-to-holder oil clearances
(see page 475)
are not within specification, the head cannot be resurfaced.
l f camshaft-to-hol der
oi l cl earances are wi thi n speci fi ca-
ti ons, check the head for warPage.
. l f warpage i s l ess than 0.05 mm
(0.002
i n) cyl i nder
head resurfaci ng i s not requi red.
. l f warpage i s between 0.05 mm
(0.002
i n) and 0 2 mm
(0.008
i n), resurface cyl i nder head
. Maxi mum resurface l i mi t i s 0.2 mm
(0.008
i n) based
on a hei ght of 142 mm
( 5. 59
i n) .
PRECISION STRAIGHT EDGE
Measure al ong edges, and three ways across center'
Cylinder Head Height:
Standard l Newl : 1i 11.95
-
142.05 mm
15.589
-
5.593 in)
Valve Movement
Measure the
gui de-to-stem cl earance wi th a di al i ndi ca-
t or whi l e r ocki ng t he st em i n t he di r ect i on of nor mal
thrust
(wobbl e
method).
lntake Valve Stem-to-Guide Cl6arance:
Standard
(Newl :
0.05
-
0.11 mm
(0.0020 -
0.0043 inl
Service Limit: 0.15 mm {0.0059
inl
Exhaust Valve Stem-to-Guide Clealance:
Standard l Newl : 0.10
-
0.16 mm
(0.0039 -
0.0063 inl
Service Limit: 0.24 {0.0094
in)
Val ve extended 10 mm out from seat.
lf the measurement exceeds the service limit, recheck
using a new valve.
l f the measurement i s now wi thi n the servi ce l i mi t.
reassemble using the new valve
lf the measurement still exceeds the limit. recheck using
the alternate method below. then replace the valve and
guide, if necessary.
NOTE: An al ternate method of checki ng
gui de to stem
clearance is to subtract the o.D. of the valve stem, mea-
sured with a micrometer, from the l.D. of the valve
guide,
measured with an inside micrometer or ball gauge.
Take the measurements i n three
pl aces al ong the val ve
stem and three
pl aces i nsi de the val ve gui de.
The di fference between the l argest gui de measurement
and the smal l est stem measurement shoul d not exceed
the servi ce l i mi t.
lntake Valv Stem-to-Guide Clsarance:
Standard lNswl: 0.025
-
0.055 mm
10.0010
-
0.0022 i nl
service Limit: 0.08 mm
(0.003 in)
Exhaust Valve Stem-to Guide Clarance:
Standard {Newl:
0.050
-
0.080 mm
{0.0020
-
0.0031 inl
Service Limit 0.ll mm
(0.004
in)
6- 79
t
Val ve Gui des
Replacement
1. As i l l ustrated bel ow, use a commerci al l v avai l abl e
ai r-i mpact val ve gui de
dri ver attachment modi fi ed
t o f i t t he di amet er of t he val ve gui des. l n most
cases, the same procedure
can be done usi ng the
sDeci al tool and a conventi onal hammer.
COMMERCIALLY AVAILABLE
VALVE GUIDE DRIVER
87 mm -L-
sz mm
(3.43
inl
I
tz.zr int
r E-
t t
10. 8 mm
10.42 inl
ol
VALVE GUIOE DRIVER,
5.5 mm
077,P
-
0010100
Sel ect t he pr oper r epl acement gui des
and chi l l
t hem i n t he f r eezer sect i on of a r ef r i ger at or f or
about an hour.
Use a hot pl ate or oven to evenl y heat the cyl i nder
head to 300"F
(150"C).
Moni tor the temperature wi th
a cooki ng thermometer.
CAUTION:
. Do not use a torch; it may warp tho head.
. Do not get tho head hotter than 300"F {150"C};
excesgive heat may loosen thg valve seats.
. To avoid burns. use haaw gloves
whon handling
the heatod cylinder head.
6-80
Worki ng from the camshaft si de, use the dri ver and
an ai r hammer to dri ve the gui de about 2 mm
(0.1
i n)
towards the combusti on chamber. Thi s wi l l knock off
some ofthe carbon and make removal easi er.
CAUTION:
. Always wsar safety goggles
or a face shield whsn
driving valve guides.
. Hol d the ai r hammer di rctl y i n l i ne wi th the
valve guide to prevont damaging thg dtiver.
Turn the head over and dri ve the gui de
out toward
the camshaft si de of the head.
VALVE GUIOE DRIVER,
5.5 mm
077{2
-
0010100
l f a val ve gui de sti l l won' t move. dri l l i t out wi th a
8.0 mm
(5/16
i n) bi t, then try agai n.
CAUTION: Drill guides only in extreme cases; you
could damago the cylinder head if ths guide br6aks.
Remove the new gui de(s)
from the freezer, one at a
ti me, as vou need them.
-:^-,65i^q
NNSp-<
7. Appl y a thi n coat of cl ean engi ne oi l to the outsi de
of the new val ve gui de. Instal l the gui de from the
camshaft si de of the head; use the speci al tool to
dri ve the
gui de i n to the speci fi ed i nstal l ed hei ght. l f
you have al l l 6 gui des to do, you may have to reheat
t he head,
VALVE GUIDE DRIVER,
5.5 mm
077i12
- (x)l01(x)
tr
A\
Valve Guide Installed Hoight:
lntake: 12.55
-
13.05 mm {0.,194
-
0.514 in)
Exhaust: 12.55
-
13.05 mm 10.494
-
0.51' l i n)
VALVE GUIDE
\
Reami ng
NOTE: For new val ve gui des onl Y.
1. Coat both reamer and val ve
gui de wi th cufti ng oi l .
2. Rotate the reamer cl ockwi se the ful l l ength of the
val ve gui de bore.
Cont i nue t o r ot at e t he r eamer cl ockwi se whi l e
removi ng i t from the bore
Thoroughl y wash the gui de i n detergent and water
to remove any cutti ng resi due.
Check cl earance wi th a val ve l see
page 6-73)
. Ver i f y t hat t he val ve sl i des i n t he i nt ake and
exhaust val ve gui des wi thout exertl ng
pressure.
REAMER HANDLE
Turn r6amer i n
clockwise direction
a
VALVE GUIOE REAMER. 5.5 mm
OTHAH
-
PJTO1IIB
6- 81
Valves
1 .
Instal l ati on
Coat the val ve stems wi th oi l . l nsert the val ves i nto
the val ve gui des.
NOTE: Check that the val ves move up and down
smoothl y.
Instal l the spri ng seats on the cyl i nder head.
Instal l the val ve seal s usi ng the speci al tool .
NOTE: Exhaust and i ntake val ve seal s are not i nter-
changeabl e.
WHITE
SPRING
VALVE GUIDE SEAL INSTALLER
KD-28)g (Commerci al l y
avai l abl e)
NOTE: Use smal l l D
end of t ool ,
2.
BRACK
SPRING
VALVE SEAL
Repl ace.
tNsTALLER VALVE GUIDE SEAL
KD-2899
NOTE: Use smal l l D
end of t ool
(
4. l nst al l t he val ve spr i ng and val ve r et ai ner , t hen
i nstal l the val ve spri ng compressor. Compress the
spri ng, and i nstal l the val ve keepers.
NOTE: Pl ace the end of the val ve spri ng wi th cl osel y
wound coi l s toward the cyl i nder head.
VALVE SpRtNG
VALVE SPRTNG
COMpRESSOR
COMPRESSORATTACHMENT
ATTACHMENT
EXTENSTON
0775?
_ pJlOl0A o?MAF
-
PR9010A
VALVE SPRING COMPRESSOR
l Commerci al l y avai l abl e)
Snap-on CF711 or KD-3tXl
with #32JAWS
Li ght l y t ap t he end of each val ve st em t wo or t hree
t i mes wi t h t he wooden handl e of a hammer t o ensure
proper
seating of the valve and valve keepers.
NOTE: Tap t he val ve st em onl y al ong i t s axi s so
you do not bend t he st em.
I
5.
Rocker
Arms
l nstal l ati on
1 .
2.
3.
l nst al l t he r ocker ar ms i n t he r ever se or der of
removal :
. Val ve adj usti ng l ocknuts shoul d be l oosened and
the adi usti ng screw, backed off before i nstal l a-
t r on.
. The component
parts must be rei nstal l ed i n the
ori gi nal l ocati ons.
l nstal l the l ost moti on assembl i es.
l nst al l t he r ocker ar ms whi l e i nser t i ng t he r ocker
arm shaft i nto the cyl i nder head
NOTE: Remove the rubber band after i nstal l i ng the
rocker arms.
12 mm BOLT
\
6-83
4. Cl ean and i nstal l the rocker shaft ori fi ces wi th new
O- r i ngs. l f t he hol es i n t he r ocker ar m shaf t and
cyl i nder head are not i n l i ne wi th each other, screw
a 12 mm bol t i nto the rocker arm shaft and rotate
the shaft.
NOTE: The shapes of the rocker shaft ori fi ces tor
the i ntake and exhaust are di fferent. The ori fi c'
must be i nstal l ed i n the
proper l ocati ons.
INTAKE ROCKER
SHAFT ORIFICE
EXHAUST ROCKER Clean
SHAFT ORIFICE
O.RING
O
I
Cylinder Head
Instal l ati on
l nstal l the cyl i nder head i n the reverse order of removal :
NOTE:
. Al ways use a new head and mani fol d gasket.
. The cyl i nder head gasket
i s a metal gasket,
Take care
not to bend i t.
. Rotate the crankshaft, set the No. 1 pi ston
at TDC
(see
page
6-63).
. Do not use t he mi ddl e cover and l ower cover f or
storang removed i tems.
.
Cl ean the mi ddl e cover and l ower cover before i nstal _
l ati on.
o
Replace any washers that are damaged or deteriorated.
1. Instal l the cyl i nder head gasket,
dowel pi ns
and the
head oi l control ori fi ce on the cyl i nder head.
NOTE: Cl ean the oi l control ori fi ce when i nstal l i ng.
DOWEL PIN
6-84
2, Ti ghten the cyl i nder head bol ts i n two steps. In the
fi rst step, ti ghten al l bol ts i n sequence to about 29
N.m
(3.0
kgf.m, 22 tbf.ftl. ln the final step, tighten in
the same sequence to 83 N.m
(8.S
kgf.m,6t l bf.ft).
NOTE:
. Appl y cl ean engi ne oi l to the bol t threads and
under the bol t head.
.
We r ecommend usi ng a beam- t ype t or que
wrench. When using a preset-type
torque wrench,
be sure to tighten slowly and not to overtighten.
. lf a bolt makes any noise while you
are torquing it,
loosen the bolt, and retighten it from the 1st step.
CYLINDER HEAD BOLT TOROUE SEOUENCE
11x 1. 5 mm
83 N.m 18.5 kgf.m, 61 tbf.ftl
Instal l the i ntake mani fol d and ti ghten the nuts i n a
cfl sscross pattern
i n two or three steps, begi nni ng
wi th the i nner nuts.
.
Al ways use a new i ntake mani fol d gasket.
Instal l the exhaust mani fol d and ti ghten the new
sel f-l ocki ng nuts i n a cri sscross pattern
i n two or
three steps. begi nni ng wi th the i nner nuts.
. Al ways use a new exhaust mani fol d gasket.
4.
5. l nstal l the camshafts and camshaft oi l seal s.
NOTE:
. l nstal l the camshafts wi th the keyway faci ng up.
. l nstal l the oi l seal wi ththespri ng si de faci ng i n.
. The oi l seal housi ng surface shoul d be dry'
. Set the O-ri ng and dowel
pi n i n the oi l
passage
of the No, 3 camshaft hol der'
CAMSHAFT
OIL SEAL
Repl ace.
Appl y l i qui d
gasket
(P/N
08718
-
0001 or 08718
-
0OO3) to the head mati ng surfaces of the No. 1 and
No. 5 camshaf t hol der s on bot h t he i nt ake and
exhaust si de.
NOTE: Cl ean and dry the cyl i nder head mati ng sur-
faces before appl yi ng l i qui d
gasket.
-
Appl y l i qui d
gasket to the shaded areas'
7- l nstal l the camshaft hol ders and camshaft hol der
pl aIe.
NOTE: The arrows marked on the camshaft hol ders
shoul d
poi nt to the ti mi ng bel t.
Tighten each bolt two turns at a time in the sequence
shown below.
NOTE: Wipe off the excess liquid
gasket from the No.
1 and No. 5 camshaft holders with a shop towel
(D -
@:
8 x 1.25 mm 27 N.|n
(2.8
ksf'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
( D
o o o o o o
EXHAUST
l nstal l the back cover and camshaft
pul l eys.
{cont' d)
o o o o 0 o
@
CAMSHAFT
6-85
Cyl i nder Head
Installation
(cont'dl
10. Al i gn t he mar ks on t he cyl i nder head pl ug t o t he
cyl i nder head upper surface, then i nstal l the cyl i n,
der head pl ug i n the cyl i nder head.
PLUG
Repl ace.
Instal l the ti mi ng bel t
(see page 6-63).
Adj ust the val ve cl earance
(see page 6-61).
Instal l the head cover gasket
i n the groove of the
cyl i nder head cover . Seat t he r ecesses f or t he
camshaft fi rst, then work i t i nto the groove
around
the outsi de edges,
NOTE:
. Before i nstal l i ng the head cover gasket,
thorough-
ly clean the head cover gasket and the groove.
. When i nstal l i ng, make sure the head cover gasket
i s seated securel y i n the corners of the recesses
wrrn no gap.
1 1 .
13.
1 '
CYLI NDEB HEAD
HEAD COVEB
6-86
(
\
14. Appl y l i qui d gasket
to the head cover gasket
at the
ei ght corners of the recesses.
NOTE:
.
Use l i qui d gasket, Part No. 08718
-
0001 or 08718
-
0003.
before appl yi ng l i qui d gasket
. Do not i nstal l the parts i f fi ve mi nutes or more
hav e el aps ed s i nc e appl y i ng t i qui d gas k et .
Instead, reappl y l i qui d gasket after removi ng ol d
restdue.
. After assembl y. wai t at l east 30 mi nutes before
f i l l i ng t he engi ne wi t h oi l .
15. When i nstal l i ng the cyl i nder head cover, hol d the
head cover
gasket i n the groove by
pl aci ng your fi n-
gers on the camshaft hol der contacti ng surfaces
(toD
of the semi ci rcl es).
Once t he cyl i nder head cover i s on t he cyl i nder
head, sl i de the cover sl i ghtl y back and forth to seat
the head cover
gasket.
NOTE:
. Be{ore i nstal l i ng the cyl i nder head cover, cl ean
the cvl i nder head contacti ng surfaces usi ng a
shoP towel .
. Oo not touch the
parts where liquid
gasket was
appl i ed.
. Repl ace any washer taht i s damaged or deter' o-
rated.
t
\
6-A7
16. Ti ghten the nuts i n two or three steps. In the fi nal
step, ti ghten al l nuts, i n sequence, to 9 8 N' m {1 0
kgf.m, 7.2 lbf.ft).
NOTE: After assembl y,
wai t at l east 30 mi nutes
before fi l l i ng the engi ne wi th oi l .
After i nstal l i ng, check that al l tubes' hoses and con-
nectors are installed correctly.
17.
Engi ne Bl ock
Speci af Tool s . . . . . . . . . . . " 7-2
l l l ust l at ed I ndex . . . . . . . . . . . . . . . . . . . . ". . ' . . . . . . . . . . 7-3
Flywheel and Drive Plate
Repf acement
"""' .' 7-7
Connecting Rod and Crankshaft
End Pl ay
. . . . . . . . . . . ". . . . 7-8
Main Bearings
Cl earance
. . . . . . . . . . . . . . . 7-9
Sel ect i on
. . . . . . . . . . . . . . . . 7-10
Connecting Rod Bearings
cl earance
. . . . ' . . . . . . . . . . 7-11
Sel ect i on
. . . . . . . . . . . . . . . . 7-11
Pistons and Crankshaft
Removaf
. . . . . . . . . . . . . . . . . 7
-12
Crankshaft
I nspect i on
. "". . . . . . . . . 7-14
Pistons
I nspect i on
. . . . . . "' . . . . . 7-15
f nst af f at i on
. . . . . . . . . . . . . 7-23
Cylinder Block
l nspec' t i on
. . . . . . . . . . . . . . 7-16
Bore Honi ng
. . . . . . . . . . 7-17
Piston Pins
Removal
. . . , . . . . . . . . . . . ' . 7-17
l nst al l at i on
. . . . . . . . . . . . . 7-18
I nspect i on
. ' . . . . . . . . . . . . 7-19
Connecting Rods
Sel ect i on
. . . . . . . . . . . . . . . . 7-18
Piston Rings
End Gap
. . . . . . . . . . ". . "' 7' 2O
Repfacement
.........7-2O
Ring-to-Groove Clearance ...........' .' . 7
-21
Af i gnment
. . . . . . . ""' . . 7' 21
Crankshaft Oil Seal
f nst af f at i on
. . . . . . . . . . . . . 7-22
Crankshaft
fnstaffation
..-.-..' .".' 7' 23
Oil Pan
l nst al l at i on
. . . . . . . . . . . . . 7-26
Oil Seals
fnstaffation
....""""' 7-29
r - f
Speci al Tool s
Ref. No.
I Tool Numbel
o
aal
@
o
@
6'
@
o
07LAB
-
PV00100
07749
-
0010000
07947
-
SB00200
07948
-
SB00' 101
07973
-
PE00200
07973
-
PE00310
07973
-
PE00320
07973
-
PE00400
07973
-
S800100
07973
-
6s70500
07973
-
6570600
Ri ng Gear Hol der
Dri ver
Seal Dri ver
Dri ver Attachment
Pi l ot Col l ar
Pi ston Pi n Dri ver Shaft
Pi ston Pi n Dri ver Head
Pi ston Pi n Base Insert
Pi ston Base Head
Pi ston Base
Pi ston Base Spri ng
1-7
7- 22, 29
7.29
7- 22, 29
7 - 1 7 , 1 8
' 7
- 17,
1a
7- 11, 1A
7
- 17,
18
1- 17, 18
7- 17, 18
7 - 1 7 , 1 8
Y(\!
a.:
ai
C
a
Eg
o t0
arll
a
7-2
\
lllustrated
Index
I
runri cate att i nternal
parts wi th engi ne oi l duri ng reassembl y'
NOTE:
o Appl y l i qui d
gaskettothe mati ng surfaces ofthe ri ght si de cover and oi l
pumpcase before i nstal l i ngthem'
. Use l i qui d
gasket , par t No 08718- 0001
or 08718- 0003'
. Cl ean the oi l
pan gasket mati ng surfaces betore i nstal l i ng the oi l
pan
81642 engi ne:
DRAIN BOLT
44 N, m {4. 5
kgf ' m, 33
l bt ' f t )
6 x 1. 0 mm
' 11
N. m
( 1. 1 kgI ' m,
I tbl.ft)
OI L PAN
Ret er t o page 7 27
6 r 1. O mm
12 N. m t 1. 2
kgl ' m, 8 7 l bf ' l t )
OIL PAN GASKET
BUFFLE PLA
1 2 x 1 . 0 mm
103 N. m { 10. 5
kgf ' m,
76 t br. f t )
6 x 1. 0 mm
11 N. m
( 1 . 1 kgf . m,
8 tbI.fr)
GASKET
Repl ace.
FLYWHEEL
(M/ TI
1 2 x 1 . 0 mm
74 N. m
( 7. 5
kof . m, 54 l bf ' f t )
1^
c{Eb
\%^
t*^
*o"rr^--(Wffi
oa*,trto2,.w
FLYWHEEL COVER
I M/ T)
DRIVE PLATE
COVER
(Ai T)
1 1 x 1 . 5 mm
76 N. m
(7. 9 kgf ' m, 56 l bf ' f t )
t hreads.
NOTE: Af t er t orqurng
each cap, t urn crankshaf t
t o check f or bi ndi ng.
MAI N EEARI NG CAP
MAIN BEARINGS
Sel ect i on,
page 7_10
NOTE: New mai n beari ngs musl
be sel ect ed bY mat chi ng crank
and bl ock i dent i f i cat i on
markrngs
CRANKSHAFT
I nst al l at i on, Page
7' 23
OIL JET BOLT
16 N. m 11. 6 kgf ' m, 12 l bl ' f t )
OIL JET
I nspect i on, Page
8_10
Check
f or cracks
6 x 1 . 0 m m
11 N. m { 1. 1
kgf ' m, I l bf ' f t }
CRANKSHAFT OIL SEAL
I nst al l at i on,
pagesl 22 andl 29
Repl ace-
DOWEL
PIN
OI L PUMP
Overhaul ,
page 8-' l 1
Removal / l nspect i on,
page 8-13.
t o mat i ng surl ace.
RI GHT SI DE COVER
t o mat i ng surf ace.
THRUST WASHERS
8 x 1. 25 mm
24 N. m {2. 4 kgf . m, 17 l bf ' f t )
Grooved si des f ace out ward
NOTE: Thrusr washer t hi ckness
i s t i xed and must not be changed
by gri ndi ng or shi mmi ng
O-RI NG
Repl ace
CRANKSHAFT SEAL
11 N. m { 1. 1
kgf ' m, l nst al l at i on,
pages 7' 29 and I 14
a l bt . l t l Hepl ace.
( cont ' d)
d#*
lllustrated Index
(cont' dl
I
Luori cate att i nternal parts
wi th engi ne oi l duri ng reassembl y.
NOTE:
' Appl y l i qui d gasket
to the mati ng surfaces ofthe ri ghtsi de
coverand oi l pumpcase
before i nstal l i ngthem.
.
Use l i qui d gasket, part
No. 08718
-
0001 or 087,18
_
OOO3.
. Cl ean the oi l pan gasket
mati ng surfaces before i nstal l i ng i t.
D16Y7 engi ne:
6 x 1 . 0 mm
12 N. m
( 1. 2
kgt . m.
8. 7 t bf . t r)
DRAIN BOLT
44 N. m
{4. 5 kgt . m. 33 t bt . t t l
, (
I
I
OIL PAN GASKET
FLYWHEEL COVER
I M/ T)
6 x 1 . 0 mm
12 N. m (' l
. 2 kgt . m, 8. 7 t bt . t rl
OIL PAN
Ref er t o page
7-27
Appl y l i qui d gasker
t o
t hese poi nt s.
Repl ace.
WASHER
Repl ace.
12 x
' 1. 0
mm
1 1 8 N. m
{12. 0 kgt . m,
87 t bf . t r}
11 x 1. 5 mm
51 N. m
15. 2 kgl . m, 38l bt f t l
t hreads.
NOTE: Af t er t orqui ng
each cap, turn the crankshaft
MAIN BEARINGS
Sel ect i on, page
7-10
MAI N BEARI NG CAP
CRANKSHAFT
7 23
NOTE: New mai n beari ngs must
be sel ect ed by mat chi ng crank
and bl ock i dent i f i cat i on marki ngs.
6 r 1 . 0 mm
1 1 N. m
{ 1 . 1
6 x 1. 0 mm
1 1 N. m 1 1 . 1
ksI.m, 8 lbt.ft)
OIL SCREEN
kgt.m, 8 lbf.trl
Check f or cracks.
CRANKSHAFT
OIL SEAL
I nst al l at i on,
pages
1 22 a^d 7-29
\:eprace'
GASKET
Repl ace.
6 x 1 . O mm
11 N. m { 1. 1 kgt . m,
8 rbt . f rl
RI GHT SI DE COVER
1o mat rng surf ace,
OI L PUMP
Overhaul , page
8-12
Bemoval / l nspect i on,
page
8-13
DOWEL PIN
WASHERS
Gr ooved si des f ace out war d.
NOTE: Thr ust washer t hi ckness
i s f i xed and must not be changed
by gr i ndi ng
or shi mmi ng.
CRANKSHAFT
SEAL
l.j"Ji:l"^
pages z.2e --.S)
Repl ace.
6 x 1. 0 mm
1 1 N. m
{ 1 . 1
8 t bt . f r)
7-4
BREATHI NG PORT COVER
MOUNT BOLTS
6 x 1 . 0 mm
11 N. m
{ 1. 1 kgt . m, 8 t bf . f r }
t o
t he boh t hreads.
DOWEL PI N
D16Y5, D16Y8 engines:
DRAIN BOLT
39 N. m 14. 0
kgt ' m,
Appl y l i qui d
gasket t o
t hese
poi nt s.
OIL PAN
Ref er t o
page 7-25
WASHER
Repl ace.
29 lbl.tt)
\
\^
6 x 1. 0 mm
q%
P
I
FLYWHEEL COVER
(M/ T}
1 2 x 1 . 0 mm
1 1 8 N. m
(12. 0 kgt . m, 87 l bt ' f t )
FLYWHEEL
(M/TI
t 2 N. m 11. 2
kgf ' m,
8.7 lbl.ftl
11 x 1. 5 mm
51 N. m
(5.2 kgf'm, 38 lbf ftl
Appl y engi ne oi l t ot he bol t
t hreads.
NOTE: Af t ert orqui ng
each cap, t urn crankshaf t
MAI N
BEARING
MAIN BEARINGS
Sel ect i on,
page 7-10
NOTE: New mai n beari ngs must
be sel ect ed by mat chi ng crank
"nJ lr."i io"irriti"",ion-markings.
--------*-i6{\
CRANKSHAFT
I nst al l at i on,
page 7-23
6 r 1 . 0 mm
11 N. m
(1
1 kgf ' m, I l bf ' t t l
OI I PAN GASKET
Repl ace.
DRIVE PLATE COVER
{A/T or CVT)
1 2 r 1 . 0 mm
74 N. m
17. 5
kgl . m, 54 l bf ' f t )
DBIVE PLATE {A/T or CVTI
Check for cracks
6 x 1. O mm
11 N. m { 1. 1
kgl ' m,
8 tbl.ftl
CRANKSHAFT
OIL SEAL
l nst al l at i on,
pages 7'?1 and
'1
'28
Repl ace.
RI GHT SI DE COVER
Appl y l i qui d
gasket
OIL SCREEN
GASKET
Repl ace.
OIL PUMP
Overhaul ,
page 8_12
page 8-13
Appl y l i qui d
gasket
to mating surface.
DOWEL PIN
WASHEFS
Grooved si des t ace out ward
NOTE: Thrust washer t hi ckness
i s f i xed and must not be changed
bV
gri ndi ng or shi mmi ng.
CRANKSHAFT SEAL
I nst al l at i on,
pages 7 29
and 8-14
Repl ace.
BREATHING
PORT COVER
MOUNT BOLTS
6 x 1. O mm
11 f {. . n
(1. 1 kgf ' m, 8 l bf ' f l )
Appl y l i qui d
gasket t o
t he bol t t hreads.
O. RI NG
Repl ace.
6 x 1. 0 mm
11 N. m
( 1
1 kgl ' m,
8 tbr.ftl
(cont' d)
7-5
\
OOWEL PIN
lllustrated Index
(cont'd)
NOTE: New rod beari ngs must be sel ected by matchi ng connecti ng rod assembl y and crankshaft
( see page
7, 11) .
i denti fi cati on
marki ngs
Lubri cate al l i nternal parts
wi th engi ne oi l duri ng
reassembtv.
PI STON I NSTALLATI ON
DI RECTI ON:
EXHAUST
4\/=\6\z\
\e/!rqrf/
I NTAKE
PISTON RINGS
Repl acement . page
7-20
Measurement , pages
7 20 andj -21
Al i gnment , page
7-21
PISTON PIN
Removal , page 7, 17
I nst al l at i on, page 7-18
I nspect i on, page 7, 19
CONNECTING ROD
End pl ay, page
7-8
Sel ect i on, page 7, 18
CONNECTING ROD
BEARINGS
Cl ear ance, page 7 11
Sel ect i on, page 7- 11
CONNECTING ROD BEARING CAP
7-23
NOTE: l nst al l caps so t he
bearing recess is on the
same si de as t he recess
i n t he rod.
PISTON
I nspect ron, page
7-15
NOTE: Bet ore removi ng t he pi st on,
i nspect t he
t op of t he cyl i nder bore f or carbon bui l d-up or
ri dge. Bemove ri dge i f necessary, page
7-13
ENGINE BLOCK
Cyl i nder bore i nspect i on, page 7-16
Warpage i nspect i on, page
7, ' 16
Cyl i nder bore honi ng, page 7, 17
I nspect t op of each cyl i nder bore
f or carbon bui l d-up or ri dge
before removing piston.
Remove ri dge i f necessary, page
7-13
CONNECTING
ROD CAP NUT
816A2 ngin6:
9 x 0. 75 mm
{0 N.m (4.1
kgt m, 30 tbf.ftl
D16Y5, Dl6Y7. D16Y8 engines:
8 x 0. 75 mm
3l N.m {3.2 kg{.m,
23 tbt.fr)
t he bol t t hreads.
NOTE: Af t er t orqui ng each beari ng
cap, rotate crankshaft to
check f or bi ndi ng.
7-6
Flywheel
and Drive Plate
Repl acement
Manual Transmi ssi on:
816A2 engi ne:
Remove the ei ght fl ywheel bol ts, then separate the fl y-
wheel f r om t he cr ankshaf t f l ange. Af t er i nst al l at i on'
ti ohten the bol ts i n the sequence shown
RI NG GEAR HOLDER
"-i
OTLAB PVOOl OO
Remove the six flywheel bolts, then separate the flywheel
from the crankshaft fl ange. After i nstal l ati on, ti ghten the
bolts in a crisscross Pattern.
RI NG GEAB
I nspect ri ng gear
t eet h l or wear or
damage.
RI NG GEAR
I nspect ri ng
gear
t eet h l or wear or
teetn lor wea( or
/
danase.
\ ,///.'
1 2 x 1 . 0 mm
103 N. m
(10. 5 kgf . m, 76 l bf . t t )
12 x 1. o mm
1 18 N, m
(12.0 kgI.m, 87 l bf.ftl
L
rurS;u'.\
$..3s'
Automatic Transmission:
Remove the si x dri ve
pl ate bol ts, then separate the dri ve
ol ate from the crankshaft fl ange. Atter i nstal l ati on, ti ghten
the bolts in a crisscross Pattern.
t 7. 5
kgl . m, 54 l bl ' l t l
1 2 x 1 . 0 mm
74 N. m
7-7
Connecting Rod and Crankshaft
End Pl ay
Connecling Bod End Play:
Standard (Newl :
0.15
-
0.30 mm
10.006
-
0.012 i nl
Servi ce Li mi t: 0.40 mm
(0.016
i nl
l f out-of-tol erance. i nstal l a new connecti ng rod.
l f sti l l out-of-tol erance, repl ace the crankshaft (see
pages 7-12 and 7-23).
a
a
7- 8
\
Push the crankshaft fi rml y away from the di al i ndi cator,
and zero the di al agai nst the end of the crankshaft. Then
pul l
the crankshaft fi rml y back toward the i ndi cator; di al
readi ng shoul d not exceed servi ce l i mtr.
Grankshaft End Play:
Standard (Newl:
0.10
-
0.35 mm
(0.00,f -
0.01,t inl
Servic Limit 0.it5 mm
(0.018
in)
. l f end pl ay i s excessi ve, i nspect the thrust washers
and thrust surface on the crankshaft. Repl ace
Darts as
necessary.
NOTE: Thrust washer thi ckness i s fi xed and must not be
changed ei ther by gri ndi ng
or shi mmrng.
Thrust washers are i nstal l ed wi th grooved
si des faci ng
outward.
Mai n Beari ngs
4.
Gl earance
1 . To check mai n bear i ng- t o- j our nal oi l cl ear ance.
remove the mai n caps and beari ng hal ves.
Cl ean each mai n
j our nal
and bear i ng hal f wi t h a
cl ean shop towel .
Pl ace one stri p of
pl asti gage across each mai n
j our-
na l .
NOTE: l f the engi ne i s sti l l i n the car when you bol t
the mai n cap down to check cl earance, the wei ght
of the crankshaft and fl vwheel wi l l fl aften the
pl asti -
gage further than
j ust
the torque on the cap bol t.
and
gi ve you an i ncorrect readi ng. For an accurate
r eadi ng, suppor t t he cr ank wi t h a
j ack
under t he
count er wei ght s
and check onl y one bear i ng at a
t i me,
Rei nst al l t he bear i ngs and caps, t hen t or que t he
bol ts.
lst step: 25 N'm
(2.5
kgl'm. 18 lbf'ft)
Fi nal steD:
B16A2 engine:
76 N.m
(7.8
kgf.m, 56 lbf'ft)
D16Y5, Dl6Y7, D16Y8 engines:
51 N.m
(5.2
kgf'm, 38 lbf'ft)
NOTE: Do not rotate the crankshaft duri ng i nspec-
t r on.
Remove the cap and beari ng agai n, and measure the
wi dest
part ot the pl asti gage.
Main Boaring-toJournal
Oil Clearance:
816A2 engine:
Standald {New}:
No. l, 2, 4, 5 Journals:
O.O2,l
-
0.042 mm 10'00(B
-
0.0017 in)
No. 3 Journal s:
0.030
-
0.048 mm {0' 0012
-
0' 0019 i n)
Servico Limit: 0.06 mm {0.002
in,
Dl6Y5, Dl6\rr, Dl6Y8 engines:
Standard
(Nsw):
No. 1,5 Journal s:
0.018
-
0.035 mm {0.0007
-
0'001'[ in)
No. 2. 3, 4 Journal s:
0.02,1
-
0.0,(2 mm {0'0009
-
0.0017 in}
(0.002 in)
\
7-9
7.
l f the
pl asti gage measures too wi de or too narrow,
(remove
the engi ne i f i t' s sti l l i n the car), remove the
crankshaft, and remove the upper hal f of the bear-
i ng. Instal l a new. compl ete beari ng wi th the same
col or code {sel ect
the col or as shown on the next
page), and rechsck the cl earance.
CAUTION: Do nol fil, shim, or scrape the bearings
or tho cap3 to adiust cleatanc.
l f the
pl asti gage shows the cl earance i s sti l l i ncor-
rect, try the next l arger or smal l er beari ng
(the
col or
l i sted above or bel ow that one), and check agai n
NOTE: l f the
proper cl earance cannot be obtai ned
by usi ng the appropri ate l arger or smal l er beari ngs,
replace the crankshaft and start over.
Mai n Beari ng
Selection
CAUTION: lf the codes are indecipherable because of an
accumulation of dirt and dust, do not scrub them with a
wire brush or scraper. Clean them only with solvent ol
deiergent.
Crankshaft Bore Code Location
81642 engi ne:
Letters have been stamped on the end of the bl ock as a
code for the si ze of each of the 5 mai n
j ournal
bores.
Use t hem, and t he number s or bar s st amped on t he
crank {codes for mai n
j ournal
si ze), to choose the correct
beafl ngs.
Mai n Jour nal Code Locat i ons { Nomber s or Bar c)
Eearing ldentification
Col or c ode r s
on l he edge of
t he bear ng.
Lar ger cr ank bor e
a c D
- - - - - - - - - - - ""'
Smal l er beanngt l hr cker )
9""1
B' : ""
Al ack
Bl ack
Al ue
7- 10
\
Letters have been stamped on the end of the bl ock as a
code for the si ze of each of the 5 mai n
j ournal
bores.
Use them, and the numbers stamped on the crankshaft
(codes
for mai n
j ournal
si ze), to choose the correct bear-
I ngs.
Mai n Journal Code Locati on
(Numbers)
\
Col or code
on t he
edge of
t he bear i ng-
Ldr ger cr ank bor e
Smal l er bea ng
{ t h' cker )
l r - l
t # l
t + , t l
f l 4 t l
f
' - ' t
Smal l er Smal l er
maan beari ng
j ournal
{t hi cker)
Red Pi nk
Gr een
Pi nk
Gr een Brown
Green Brown Bl ack
Green Brown Bl ac k El ue
I
Beari ng l dent i f i cat i on
B c D
Connecti ng
Rod Beari ngs
Cl earance
Remove the connecti ng rod cap and beari ng hal f
Cl ean t he cr ankshaf t r od
i our nal
and bear i ng hal f
wi th a cl ean shop towel .
Pl ace pl asti gage across the rod
j ournal .
Rei nstal l the beari ng hal f and cap, and torque the nuts.
Torque
Bl 6A2 engi ne:
40 N.m
(4.1
kgl.m, 30 lbf'ft)
Dr6Y5, D16Y7, D16Y8 engi nss:
31 N'm
(3.2
kgf.m, 23 lbf ftl
NOTE| Do not rotate the crankshaft during inspection.
Remove the rod cap and beari ng hal f and measure
the wi dest part of the pl asti gage.
Connecting Rod Bearing-to.Journal Oil Glearance:
816A2 engi ne:
Standard lNewl: 0.032
-
0.050 mm
10.0013
-
0.0020 i n)
Servi ce Li mi t: 0.06 mm 10.002 i nl
Standard lNew): 0.020
-
0.038 mm
(0.0008
-
0.0015 i n)
Service Limit 0.05 mm 10.002
inl
' 1.
4.
l f the
pl asti gage measures too wi de or too narrow'
remove the upper hal f of the beari ng, i nstal l a new,
compl ete beari ng wi th the same col or code
(sel ect
t he c ol or as s hown i n t he r i ght c ol umn) , and
recheck the cl earance.
CAUTION: Do not lile, shim, or scrape the bearings
or the caps to adiust clgarance.
lf the
plastigage shows the clearance is still incorrect.
try the next l arger or smal l er beari ng
(the
col or l i sted
above or bel ow that one), and check cl earance agai n.
NOTE: l f the Droper cl earance cannot be obtai ned
by usi ng the appropri ate l arger or smal l er beari ngs,
repl ace the crankshaft and start over.
PLASTIGAGE STRIP
\
7.
7- 11
Selection
CAUTION: lf the codes are indecipherable because of
an accumul ati on of di rt and dust, do not scl ub them
with a wile brush or scraper. Clean them only with sol-
vent or detergent,
Connecting Rod Code Location
Numbers have been stamped on the si de of each con
necti ng rod as a code for the si ze of the bi g end Use
them, and the l etters stamped on the crankshaft
(codes
for rod
j ournal
si ze), to choose the correct bearl ngs
Hal f of number l s
st amped on beari ng
cap and t he ot her
hal f i s st amped on
r od.
Bearing ldentilication
Col or code i s on t he
edge of
t he beari ng.
lfA--;T] |
l l e " ' t t l ;
l l c o r l l l l l
I lD;;ilril |
l - l
Larger brg end bore
Smal l er
Smal l er
r od bear l ng
j our nal
( t hi cker )
- - - - - - - - - - - - - - - -
Smal l er bear i ng{ t hr cker )
Red Pi nk Gr een
Pi nk Green
Green Erown Bl ack
Green Brown Bl ack Bl ue
1 2 3 4
Connecti ng Rod Journal Code Locati ons
(Lettel s)
Pistons and Crankshaft
Removal
1. Remove the oi l pan
assembl y.
2. Remove the ri ght si de cover.
816A2 engine
D16Y5, Dl 6Y7, D16Y8 ongi nes
RIGHT SIDE
7- 12
\
3. Remove the oi l screen.
4. Rmove the oi l pump.
816A2 engi n
OIL SCREEN
D16Y5, D1oyr, D16Y8 engin.s
O-RI NG
Repl ace.
5, Remove t he baf f l e pl at e (816A2
engi ne).
OIL PUMP
6. Remove the bol ts and the beari ng caps.
CAUTION: To prevenl warpago unscrow lhe bolts
in squence 1/3 turn at a tims, rpaat the soquence
until all bolts ar loo3ened.
MAIN BEARING CAP BOLTS LOOSENING SEOUENCE
Remove the rod caps/beari ngs and mai n capvbear-
i ngs. Keep al l caps/beari ng i n order.
Li ft the crankshaft out of the engi ne, bei ng careful
not to damage
j ournal s.
7.
S:_]ILOJLOAO
CRANKSHAFT
14.
7- 13
q
Remove the upper beari ng hal ves from the connect-
i ng rods and set them asi de wi th thei r respecti ve
caos.
Rei nstal l the mai n caps and beari ngs on the engi ne
in
proper
order,
l f you can feel ri dge of metal or hard carbon around
t he t op of each cyl i nder , r emove i t wi t h a r i dge
reamer. Fol l ow the reamer manufacturer' s i nstruc-
I| ons.
CAUTION; lf the ridge is not removed, it may dam-
age tho
pistons
as they are pushod out.
RI OGE REAMER
10.
1 1 .
12. Use the wooden handl e of a hammer to dri ve the
pastons out.
13. Rei nstal l the connecti ng rod beari ngs and caps after
removi ng each pi ston/connecti ng rod assembl y.
Mark each
pi ston/connecti ng rod assembl y wi th i ts
cyl i nder number to avoi d mi xup on reassembl y.
NOTE: The exi sti ng number on the connecti ng rod
does not i ndi cate i ts posi ti on i n the engi ne, i t i ndi -
cates the rod bore size.
Crankshaft
Inspection
. Cl ean the crankshaft oi l passages wi th pi pe cl eaners
or a sui tabl e brush.
. Check the keyway and threads.
Al i gnment
. Measur e r unout on al l mai n
j our nal s
t o make
sure the crank i s not bent.
. The di fference between measurements on each
j ournal
must not be more than the servi ce l i mi t.
Crankshaft Total Indicated Runout:
Bl 6A2 engi ne:
Standard
(Newl:
0.020 mm {0.0008 in} max.
Service Limit: 0.030 mm {0.0012 inl
Standsrd {New): 0.03 mm
(0.001
i n} max.
Service Limit; 0.0i1 mm 10.002 in)
Suppor t wi t h l at he
t ype t ool or V bl ocks.
7- 14
Out-of-Round and Tapet
. Measure out-of-round at the mi ddl e of each rod
and mai n
j ournal
i n two
pl aces.
a The di fference between measurements on each
j ournal
Joulnal Out-of-Round:
81642 engi ne:
Standard
(New):
0.0004 mm
{0.0002 in) max.
{0.0002 in)
Dr6Y5, Dl6Y7, D16Y8 engines:
Standard
(Newl:
0.0025 mm
(0.0001
inl max.
Service Limh: 0.005 mm
(0.0002
inl
r ound at mi ddl e.
. Measure taper at the edges of each rod and mai n
j our nal .
. The di fference between measurements on each
j ournal
Journal TaDer:
B16A2 ongi ne:
Standard lNewl: 0.005 mm
(0.0002
inl max.
(0.00i1
inl
D16Y5, D16Y7, Dl 6YB engi nes:
Standard
(New):
0.0025 mm {0.0001 in) max.
(0.0002
in)
\
Pistons
Inspection
1 . Check the
pi ston for di storti on or cracks,
NOTE: l f a cyl i nder i s bor ed. an over si zed
pi st on
must be used.
Measure the
pi ston di ameter at a di stance A from
bottom of the skirt.
816A2 engi no:
A: 15 mm 10.6 i n)
A: 5 mm
(0.2
i nl
Piston Diameter:
816A2 engi ne:
-
80.990 mm
13.1882
-
3.1886 i n)
(3.1878
in)
Standard {New):
7,f.980
-
7i1.990 mm
|.2.9520
-
2.9521in!
Servi ce Li mi t: 74.970 mm {2.9516
i nl
SKI RT DI AMETER
5 7- 1
3. Cal cul ate the di fference between the cyl i nder bore
di ameter
(see page 7-16) and the pi ston di ameter.
Piston-to-Cylinder Clsarance
Standard l Newl :
0.010
-
0.0,10 mm
(0.0004 -
0.0016 i nl
Servico Limit: 0.05 mm {0.002 in}
l f the cl earance i s near or exceeds the servi ce l i mi t,
i nspect the pi ston and cyl i nder bl ock for excessi ve
wear.
Oversizo Piston Diametor
816A2 ongi ne:
0.25t 81.23
-
81.21 mm
(3.1980 -
3.1984 inl
D16Y5. D16Y7, D16Y8 engines:
O.25t 75.23
-
75.21 mm
(2.9618 -
2.9622 in)
0.50: 75.i18
-
75.49 mm {2.9716
-
2.9720 in}
Cylinder Block
Inspection
'L
Measure wear and taper i n di recti ons X and
y
at three
l evel s i n each cvl i nder as shown.
Cylinder Boro Size
816A2 engi ne:
Standard
(Newl :
81.00
-
81.02 mm
{3.1t| :l
-
3.190 i nt
{3.192 i n)
Standard
lNew): 75.00
-
75.02 mm
(2.9s3 -
2.954 in)
Sarvice Limit: 75.07 mm
(2.956
in)
Oversize
816A2 engiDe:
0.25t 41.25
-
A1.27 mm
{3.199
-
3.200 in)
D16Y5, D16Y7, D16Y8 Engi nes:
0.25t 75.25
-15.27
mm
(2.9626 -
2.963,0 in)
0.50: 75.50
-
75.52 mm
12.9721- 2.9i32 inl
Bore TaDet
Limit:
(Difference
between first and third measure"
ment) 0.05 mm
(0.002
inl
7- 16
l f the measurements i n any cyl i nder are beyond
the Oversize Bore Service Limit, replace the block.
lf the block is to be rebored. refer to
piston
Clear-
ance Inspection
(see page
7-15) after reboring.
NOTE: Scored or scratched cyl i nder bores must be
honed.
Reboring Limit:
Bl 642 engi nc:
0.25 mm
(0.01
i n)
Dl 6Y5, D16Y7, D16Y8 engi ns:
0.50 mm
(0.02
in)
Check the top of the bl ock for warpage,
Measure al ong the edges and across the center as
shown.
SURFACES TO BE MEASUREO
Engi ne Bl ock Warpage:
Bl6A2 engine:
Standard (Now):
0.05 mm {0.002 inl max.
Service Limh: 0.08 mm
(0.003
in)
DtOYs, D16Y7, D16Y8 nginas:
Standard
(Nw):
0.07 mm l0.OO3 inl max.
Servica Limit; 0.10 mm {0.00it in)
PRECI SI ON STRAI GHT EDGE
Cylinder
Block
Piston Pins
Bore Honi ng
1 . Measure cyl i nder bores as shown on
page 7-16. l f the
block is to be reused, hone the cylinders and remea-
sure the bores.
Hone cyl i nder bores wi th honi ng oi l 8nd a fi ne
(400
grit) stone in a 60 degree cross-hatch
pattern.
NOTE:
. Use onl y a ri gi d hone wi th 400
gri t or fi ner stone
such as Sunnen, Ammco, or equi val ent.
. Do not use stones l hat are worn or broken.
When honi ng i s compl et e, t hor oughl y cl ean t he
engi ne bl ock of al l metal
parti cl es. Wash the cyl i n-
der bores wi th hot soapY water, then dry and oi l
i mmedi atel y to
prevent rusti ng.
NOTE: Never use solvent. it will only redistribute the
gri t on the cyl i nder wal l s.
l f scori ng or scratches are sti l l
present i n cyl i nder
bores after honi ng to the servi ce l i mi t, rebore the
cyl i nder bl ock.
NOTE: Some l i ght verti cal scori ng and scratchi ng i s
acceptable if it is not deep enough to catch
your fin-
gernai l and does not run the ful l l ength of the bore.
CYLI NOES BLOCK
CYLI NDER
NOTE:
. After honi ng, cl ean the cyl i nder thoroughl y wi th
soapy warer.
. Onl v a scored or scratched cyl i nder bore must be
noneo.
Removal
l . Assembl e t he speci al t ool as shown.
PISTON BASE HEAD
07973
-
SBtx)too
f t
PISTON PIN BASE
INSERT
01973
-
PE00'0)
pt n
NOTEi Us6 a hydraulic press.
When pressi ng t he pi n i n or out .
make sure that the recesssd
portion of the piston aligns
wi t h t he l i ps on t he col l ar.
r g
g\
lj*N*,""
2. Assembl e and adj ust the l ength of the
pi ston
dri ver and shaft to 53 mm
(2.1
i nl as shown.
PISTON PIN DRIVER HEAD
07973
-
PE00320
Proat
0
PISTON PIN
DRIVER SHAFT
0t973
-
PEqr310
PILOT COLLAR
07973
-
PE00200
3. Pl ace the pi ston on the spci al tool and
press the
pi n
out wi th the speci al tool s and a hydraul i c
press.
Emboss6d mark facing up
7- 17
Connecting Rods Pi ston Pi ns
Selection
Each rod fal l s i nto one of four tol erance ranges
{from O to
+ 0.024 mm
(0
to + 0.0009 i n), i n 0.006 mm (0.0002
i n)
i ncrements) dependi ng on the si ze of i ts bi g end bore. l t,s
then stamped wi th a number {1, 2,3, or 4) i ndi cati ng the
range.
You may f i nd any combi nat i on ot l , 2, 3, or 4 i n any
engrne.
Normal Eore Si ze: 48.0 mm
(1.89
i n)
NOTE:
o Reference numbers are for bi g end bore si ze and do
NOT i ndi cate the posi ti on
of the rod i n the engi ne.
. Inspect connecti ng rod for cracks and heat damage.
CONNECTI NG ROD AORE
REFERENCE NUMBER
Hal f of number i s st amped on
beari ng cap, t he ot her hal f on
connect rng rod.
7- 18
Instal l ati on
1. Use a hydraul i c press for i nstal l ati on.
. When pressi ng the pi n i n or out, be sure you posi
ti on the recessed fl at on the pi ston agai nst the l ugs
on the base attachment.
816A2 engi ne
The ar r ow must f ace t he
t i mi ng bel t si de of t he
eng I ne.
The mark must f ace
t he t i mi ng bel t si de
of t he engi ne.
D16Y5, D16Y7, O16Y8 engi nes
The arrow must f ace t he
t i mi ng bel t si de o{ t he
engi ne and t he connect i ng
rod oi l hol e must f ace t he
rear of t he engi ne.
Adj ust t he l engt h of t he
pi st on pi n dri ver t o
53 mm
(2. 09
4n)
PISTON PIN DRIVER SHAFT
07973-PEOo3r0
PISTON PIN DRIVER HEAD
il--Z
P,"roNPrN
PILOT COLLAR
07973-PE00200
PISTON PIN BASE INSERT
07973 PEO0400
PISTON EASE HEAO
07973
-5800100
, (
a
lnspection
1 .
Oversize:
Oversize:
NOTE; Al l repl acement
pi ston pi ns are oversl ze.
2. Zero the di al i ndi cator to the pi ston pi n di ameter'
Measure the di ameter of the
pi ston pi n.
Piston Pin Diametel:
B16A2 engi ne:
Standard {New): 20.994
-
21.000 mm
(0.8265 -
0.8268 in)
20.997
-
21.003
10.8267
-
0.8269 inl
D16Y5, Dl 6Y7, Dl 6YB engi nes:
Standard l Newl :
18.99,1- 19.000 mm
(0.7478 -
0.7480 i nl
18.997
-
19.003
{0.7479
-
0.7481 i n)
3. Measure the pi ston pi n-to-pi ston cl earance.
NOTE: Check the pi ston for di storti on or cracks.
l f the pi ston pi n cl earance i s greater than 0.024 mm
( 0. 0009
j n) ,
r emeasur e usi ng an over si zed
pi st on
pi n.
Piston Pin-to-Piston Clearance:
Standard
(New):
0.010
-
0.022 mm
(0.0004
-
0.0009 in)
Check the di fference between the pi ston pi n di ame-
ter and the connecti ng rod smal l end di ameter'
Piston Pin-to-Connesting Rod Interterence:
816A2 engi ne:
Standard
(New):
0.013
-
0.032 mm
(0.0005 -
0.0013 i n)
D16Y5, D16Y7, Dl 6YB engi nes:
Si andard l Newl ; 0.014
-
0.040 mm
4 .
10.0006
-
0.0016 i nl
7- 19
Piston Rings
End Gap
1 . Usi ng a pi ston, push
a new ri ng i nto the cyl i nder
bore 15
-
20 mm
(0.6 -
0.8 i n) from the bottom.
Measure the pi ston ri ng end-gap wi th a feel er gauge:
. l f the gap i s too smal l , check to see i f you have
the proper ri ngs for your
engi ne.
. l f the
gap
i s too l arge. recheck the cyl i nder bore
di ameter agai nst the wear l i mi ts on page 7-16,
l f the bore i s over the servi ce l i mi t, the cvl i nder
bl ock must be rebored.
Pkton Ring End-cap:
Top Ring
81642 engino
Siandtrd
(New):
0.20
-
0.35 mm
{0.008
-
0.01,1 in)
Service Limit: 0.60 mm l0-02i1 inl
D16Y5. Dl6Y7, D16Y8 enginos
-
0.30 mm
{0.006
-
0.012 i n)
Ssrvic Limit 0.60 mm {0.024 inl
Socond Ring
816A2 ongina
Standard
(Nowl:
0.40
-
0.55 mm
10.016
-
0.022 i nl
(0.028
inl
D16Y5, D16Y7, Dt6Y8 engines
Standard
(New):
0.30
-
0.ia5 mm
{0.012
-
0.018 i n)
10.028 inl
Oi l Ri ng
81642 ongine
Standard
{Now): 0.20
-
0.50 mm
(0.008 -
0.020 inl
Sorvico Limit: 0.70 mm
(0.028
in)
Dl6Y5. Dl6Y7, D16Y8 nginos
Standard
(Nowli
0.20
-
0.70 mm
(0.008 -
0.028 inl
Servica Limit: 0.80 mm 10.031 in)
7-20
Replacement
1 . Usi ng a ri ng expander. remove the ol d pi ston
ri ngs.
Cl ean al l ri ng grooves
thoroughl y.
NOTE:
. Use a squar ed- of f br oken r i ng or r i ng gr oove
cl eaner wi th bl ade to fi t pi ston grooves.
o Top ri ng groove
i s 1.0 mm
(0.039
i n)wi de.
.
Second ri ng groove i s 1.2 mm
(0.047
i n) wi de.
. Oi l ri ng groove i s 2,8 mm
(0.11
i n) wi de.
.
Fi l e down the bl ade i f necessary.
CAUTION: Do noi use a wire blush to clean ring
lands. or cut ring lands deepol with cleaning tool.
NOTE: l fthe pi ston
i s to be separated from the con-
necti ng rod, do not i nstal l new ri ngs yet.
3. Instal l new ri ngs i n the proper
sequence and posi -
taon
(see page 7-22).
NOTE: Do not reuse ol d pi ston
ri ngs.
(Commerci al l y
avai l abl e)
Ring-to-Groove Clearance
After i nstal l i ng a new set of ri ngs, measure ri ng-to-
groove cl earances:
Top Ring Clearance
Standard
(New):
B16A2 angine:
0.045
-
0.070 mm
(0.0018 -
0.(X128 in)
Dl6Y5, Dt6Y7, Dl6Y8 engins:
0.035
-
0.060 mm {0.0014
-
0.002'l in)
service Limit: 0.13 mm
(o.fixi
in)
Second Ring Clearance
Standard lNow):
B16A2 engine:
0.0/t0
-
0.065 mm
(0.0016 -
0.0026 in)
Dl6Y5, D16Y7, D16Y8 onginos:
0.030
-
0.055 mm
(0.(X)12 -
0.0022 in)
Sewica Limh: 0.13 mm
(0.005
io)
. , o
Al i gnment
1. Instal l the ri ngs as shown.
NOTE: The manufacturi ng marks must be faci ng
upward.
SECOND RING
(Darkl
Piston Ring Dimsnsions:
Uni t mm
( i n)
Uni t mm
( i n)
TOP RING
(Chrome)
t----T f
l B
t---f_-L
A
Top Ri ng
(St andard)
Second Ri ng
(Standard)
B
Bl 642 engi ne 3. 1
( 0. 12) 1.0
(0.04)
D16Y5, D16Y7,
D16Y8 engi nes
2. 6
( 0. 10)
1.0
(0.04)
B
816A2 engi ne 3. 3
( 0. 13)
1.2
(0.05)
D16Y5, D16Y/.
D16Y8 engi nes
3. 0
( 0. 12)
1.2 {0.05t
(cont' d)
7- 21
Pi ston Ri ngs
Crankshaft Oil Seal
Al i gnment
(cont' dl
TOP RING
---.>
SECOND RING >
MARK
,a-)
/\_4
o,.rô(
qffi<--sPACER
\Z-.
v
Rotate the ri ngs i n thei r grooves to make sure they
do not bi nd.
Posi ti on the ri ng end gaps
as shown:
DO NOT posi t i on any ri ng gap
at pi st on t hrust surf aces.
DO NOT posi t i on any ri ng gap
i n l i ne wi t h t he pi st on pi n hol e.
OI L RI NG GAP
SECOND RING GAP
Approx. 90
TOP RING GAP
7-22
Installation
The seal surface on the bl ock shoul d be dry.
Appl y a l i ght coat of oi l to the c.ankshaft and to
t he l i p of t he seal .
1. Dri ve the crankshaft oi l seal squarel y i nto the ri ght
si de cover usi ng the speci al tool s.
HANDLE DRI VER
07749 0010000
seal wi t h t he
pan number si de
f aci ng out .
Conf i r m t hat t he cl ear ance i s equal al l t he way
around wi th a feel er gauge.
Cl earance:0.5
-
0.8 mm
(0.02 -
0.03 i nl
NOTE: Refer to page 8-14 for i nstal l ati on of the oi l
pumo
si de crankshaft oi l seal .
, (
\
Pistons
Grankshaft
l nstal l ati on
Bef or e i nst al l i ng t he pi st ons, appl y a coat of
engi ne oi l t o t he r i ng gr oov es and c y l i nder
bores.
l f the crankshaft i s al ready i nstal l ed:
. Set the crankshaft to BDC for each cyl i nder.
. Remove the connecti ng rod caps, and sl i p short
secti ons of rubber hose over the threaded ends
of the connecti ng rod bol ts.
. l nstal l the ri ng compressor. check that the bear-
i ng i s securel y i n pl ace, then posi ti on the pi ston
i n the cyl i nder, and tap i t i n usi ng the wooden
handl e of a hammer .
o Stop after the ri ng compressor
pops free, and
check the connecti ng rod-to-crank
j ournal
al i gn-
ment before
pushi ng the
pi ston i nto
pl ace
. Appl y engi ne oi l to the bol t threads. Instal l the
rod caps wi th beari ngs, and torque the nuts to:
815A2 engi ne:
40 N.m {,1.1 kgf.m, 30 lbf'ft|
31 N.m
(3.2
kgf' m,23 l bf' ft)
l f the crankshaft i s not i nstal l ed:
. Remove the rod caps and beari ngs, i nstal l the ri ng
compressor, then posi ti on the pi ston i n the cyl i n-
der, and tap i t i n usi ng the wooden handl e of a
hammer.
. Posi ti on al l Di stons at top dead center.
1 .
2.
The arrcw must f ace
t he t ami ng bel t si de
of t he engi ne.
CONNECTING ROO
OI L HOLE l D16Y5, D16Y7, D16YB ongi nes)
NOTE: Mai ntai n downward force on the ri ng com-
pressor to prevent the ri ngs from expandi ng before
enteri ng the cyl i nder bore.
RUBBER
,lll
l nstal l ati on
Before i nstal l i ng the crankshaft, appl y a coat of
engi ne oi l to the mai n beari ngs and rod beari ngs.
Insert the beari ng hal ves i nto the cyl i nder bl ock and
connecti ng rods.
Hol d the crankshaft so the rod
j ournal s
for cyl i nders
No.2 and No. 3 are strai ght down.
Lower the crankshaft i nto the bl ock, seati ng the rod
j ournal s
i nto connecti ng rods No. 2 and No. 3, and
i nstal l the rod caps and nuts fi nger-ti ght.
1 .
2.
3.
5.
Grooved si des face
oul ward.
Botate the crankshaft cl ockwi se, seat
j ournal s i nto
connecti ng rods No, 1 and No.4, and i nstal l the rod
caps and nuts fi nger-ti ght.
NOTE: Instal l caps so the beari ng recess i s on the
same si de as the recess i n the rod.
Check rod beari ng cl earance wi th
pl asti gage (see
page 7- 11) , t hen t or que t he capnut s. Appl y engi ne
oi l to the bol t 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|
NOTE: Reference numbers on connecti ng rod are
for bi g-end bore tol erance and do not i ndi cate the
posi ti on of pi ston i n the engi ne.
Li ne up t he marks when
i nst al l i ng t he connect r ng r od
cap.
6. Instal l the thrust washers on the No. 4
j ournal .
Oi l
(cont ' d)
7-23
the thrust washer surfaces,
Crankshaft
Installation
(cont'd)
7. I nst al l t he mai n bear i ng caps.
Check cl earance wi th pl asti gage (see page
7-9), then
ti ghten the beari ng cap bol ts i n 2 steps.
First step: 25 N.m {2.5 kgf.m, 18 lbf.ft)
Second stop:
B1642 engi ne:
76 N.m
{7.8 kgf.m, 56 lbf.ft)
51 N.m
(5.2
kgf.m, 38 lbf.ft)
NOTE: Coat the thrust washer surfaces and bol t
threads wi th oi l .
MAIN BEARING CAP BOLTS TIGHTENING SEOUENCE
o o c o o
CAUTION: Whenever any crankshaft or connecting
rod bearing is replaced, it is necGssary after reassom-
bly to run the engine at idling spe6d until it reaches
normal operating temperature, than continue to run
it for approximately 15 minutos.
:V fr\-/.---\-/.-
7-24
NOTE:
.
Use l i qui d gasket, part No. 08718
-
0001 or08718-
0003.
.
Check that the mati ng surfaces are cl ean and dry
before apptyi ng l i qui d gasket.
. Appl y l i qui d gasket
evenl y, bei ng careful to cover
al l the mati ng surface.
.
To prevent
oi l l eakage, appl y l i qui d gasket
to the
i nner threads of the bol t hol es.
.
Do not i nstal l the parts i f fi ve mi nutes or more
have el apsed si nce appl yi ng the l i qui d gasket.
Instead reappl y l i qui d gasket
after removi ng the
ol d resi due.
.
After assembl y, wai t at l east 30 mi nutes before
L Appl y l i qui d gasket
to the bl ock mati ng surface of
the ri ght si de cover, then i nstal l i t on the cyl i nder
bl ock.
Bl 6A2 engi ne;
Appl y t i qui d gasl et
al ong
t he br oken l i ne.
RI GHT SI DE COVER
81642 ongi n:
D16Y5, Dl6fr, Dl6Y8 engines:
k9l . m,
RIGHT SIDE
DOWEL PINS
6 x 1. 0 mm
1 1 N. m { 1 . 1
a rbf.ft)
OOWEL PIN
9. Appl y l i qui d
gasket to the oi l
pump mati ng surtace
of the bl ock, then i nstal l the oi l
pump on the cyl i n-
der bl ock.
Appl y
grease to the l i ps of the oi l seal s.
Thgn, al i gn the i nner rotor wi th the crankshaft and
i nst al l t he oi l
pump. When t he
pump i s i n
pl ace,
cl ean any excess
grease off the crankshaft. Check
that the oi l seal l i ps are not di storted.
B16A2 ongino:
Appl y l i qui d gasket al ong
t he broken l i ne,
Dl6Y5, Dl6Y7, Dt6Y8 ongino3:
al ong t he broken
OIL PUMP }{OUSING
{cont' d)
7-25
Crankshaft
Oi l Pan
Instal l ati on
(cont' d)
NOTE:
. Appl y a l i ght coat of oi l to the crankshaft and i o
t he l i p of seal .
.
Use new O- r i ngs and appl y oi l when i nst al l i ng
t hem.
10. l nst al l t he oi l scr een.
816A2 engi ne:
6 x 1 . O mm
l l N' m ( 1
. 1 kgl . m,
8 tbt.Irl
,.//
{ /
cor*rt
(. . ao Repl ace.
t(^^
11 N. m
11 . 1 kgf . m,
a lbl'ltl ,/
.rB
tbt4tl
/
* P /
& ^/ t
O. RI NG
Repl ace.
Ot L Put i t P
24 N. m
( 2. 4
kgf . m,
' 17
l bl . f r)
kgf . m,
OI L SCREEN
6 x 1 . 0 mm
1 1 N. m { 1 . 1 kgf . m,
6 x 1 . 0 m m
1 1 N . m
{ 1 . 1
8 tbt.rr)
I
I
a l bf . f r)
DOWEL PI N
r T
l l e
/ OI L PUMP
6 x 1 . 0 mm
1 1 N. m
l l . 1 kgf ' m, a l bf . f rl
7-26
Instal l ati on
D16Y5, Dl 6Yg engi nes:
1. I nst al l t he oi l pan gasket on t he oi l pan.
OI L PAN
GASKET
Repl ace.
OI L PAN
I
2. Appl y l i qui d gasket to the bl ock mati ng surfaces of
the oi l pan, then i nstal l i t. Appl y l i qui d gasket to the
shaded areas.
NOTEI
. Us e l i qui d
gas k et par t No. 087 18
-
0001 or
08718
-
0003.
before apPl yi ng l i qui d gasket.
. Appl y l i qui d
gasket as an even bead, centered
between the edges ol the mati ng surface'
. To prevent l eakage of oi l , appl y l i qui d
gasket to
the i nner threads of the bol t hol es
. Do not i nstal l the
parts i f fi ve mi nutes or more
have el apsed si nce appl yi ng the l i qui d
gasket
l nstead, reappl y l i qui d
gasket after removi ng the
ol d resi due
. After assembl y,
wai t at l east 30 mi nutes before
Ti ght en nut s f i nger - t i ght
bel ow.
OIL PAN
at si x poi nt s as shown
I
3.
4. Tighten all bolts and nuts, starting from nut
@,
clock-
wi se i n three steps.
NOTE: Excessi ve ti ghteni ng can cause di storti on of
the oi l pan gasket and oi l l eakage.
Torque: 12 N' m {1.2
kgt' m,8.7 l bf' ft|
816A2, D16Y7 engines:
1. Appl y l i qui d
gasket on t he oi l
pump and r i ght si de
cover mati ng areas as shown bel ow.
NOTE:
. Us e l i qui d
gas k et , par t No. 08718
-
0001 or
08718
-
0003.
before appl yi ng l i qui d gasket
. Appl y l i qui d
gasket as an even bead, centered
between the edges ol the mati ng surface'
. To prevent oi l l eakage, appl y l i qui d
gasket to the
i nner threads of the bol t hol es
. Do not i nstal l the
parts i f fi ve mi nutes or more
have el apsed si nce appl yi ng the l i qui d
gasket
Instead, reappl y l i qui d
gasket after removi ng the
ol d resi due.
. Aftel assembl y, wai t at l east 30 mi nutes before
CYLI NDER
ELOCK
Appl y l i qui d
gasket
t o t hese
pornt s-
Appl y l i qui d
gasket
t o t hese
pornt s.
(cont ' d)
7
-27
Oi l Pan
lnstallation (cont'dl
Instal l the oi l pan gasket
and oi l pan
NOTE:
a Use a new oi l pan gasket.
.
I nst al l t he oi l pan
no mor e t han f i ve mi nut es
after appl yi ng l i qui d gasket.
816A2 engine:
OIL PAN
GASKET
Rpl ace.
Appl y l i qui d
gasKet
to
t hese poi nt s.
t o t hese poi nt s.
OIL PAN
GASKET
Bepl ace.
7-28
\
3, Ti ghten the bol ts and nuts fi nger ti ght at si x poi nts
as shown bel ow.
Ti ght en al l bol t s and nut s, st ar t i ng f r om nut
O.
cl ock wi se i n three steps.
NOTE: Excessi ve ti ghteni ng can cause di storti on of
the oi l pan gasket
and oi l l eakage.
Torque: 12 N.m
{1.2 kgf.m, 8.7 lbf.ft)
4.
Oi l Seal s
l nstal l ati on
NOTE:
. Engi ne removal i s not requi red.
. The crankshaft oi l seal housi ng shoul d be dry.
Appl y a l i ght coat of
grease to the crankshaft and to
the l i ps of the seal s.
1. Usi ng t he speci al t ool , dr i ve i n t he t i mi ng
pul l ey-
end seal unt i l t he dr i ver bot t oms agai nst t he oi l
pump.
When the seal i s i n
pl ace, cl ean any excess
grease
off the crankshaft and check that the oi l seal l i p i s
not distorted.
07947
-S800200
l nst al l seal wi t h t he
part number sade
f aci ng out .
I
2. Measure the fl vwheel -end seal thi ckness and the oi l
seal housi ng depth. Usi ng the speci al tool . dri ve the
fl ywheel -end seal i nto the rear cover to the poi nt
where the cl earance between the bottom of the oi l
seal and the ri ght si de cover i s 0.5
-
0.8 mm
(0.02
-
0.03 i n)
(see page 7-23).
NOTE: Al i gn the hol e i n the dri ver attachment wi th
the Di n on the crankshaft.
DRIVER ATTACHMENT
0794a-s800101
lnslall seal with the
part number side
f aci ng out .
DRIVER
07749-0010000
7
-29
Engi ne
Lubri cati on
Speci al Tool s
. . . . . . . . . .
"' . """. 8' 2
l l l ustrated Index ...........
.' ..' 8-3
Engi ne Oi l
I nspect i on
. . . . . ' . . . . . . ". . . . . "' .
8-6
Repl acement . . . . . . . . ' . . . . . . ". ' . ' . . . ". . . . ". . . . . . "
8-7
Oi l Fi l t er
Rep1acement . . . . . . . . . . . . . . . ". ' . . . ' . . ' . . . . . ' . ' . . . ".
8-8
Oil Pressure
Testi ng
' .....' 8-9
Oi l Jet
(B16A2
engi ne)
I nspect i on
. . . ' . ' . . . . . . ". . . . "' . . 8-10
Oi l Pump
overhaul . ' . . .
. . . . . ' . . . ' . . ' . """' 8-11
Removal /l nspecti on/l nstal l ati on
..' .... 8-1 3
Special Tools
Ref. No.
I Toot Number
07746
-
0010400
07749
-
0010000
07912
-
6110001
Attachment, 52 x 55 mm
Dri ver
Oi l Fi l ter Wrench
o 6\
,6
\
\
l l
a
8-2
\
lllustrated
Index
NOTE:
. Use new O-ri ngs when reassembl i ng
. Appl y oi l to O-ri ngs before i nstal l ati on
. Use l i qui d
gasket, Part No 08718
-
0001 or 08718
-
0003.
CAUTION: Do not overiighten the drain bolt.
6 x 1 . 0 mm
12 N. m
(1. 2
kqt m, 8. 7 l bl . f t l
. Cl ean the oi l
I ng.
B1642 engine:
pan gasket mating surlaces before install-
WASHER
RePl ace'
DRAIN BOLT
44 N.m
(4.5
kgl'm,33 lbt'ft)
Do not overt rght en.
6 x 1 . 0 mm
11 N. m
(1. 1
kgt m,
OIL PAN
Reler to page 7'27
OI L PAN
GASKET
Repl ace-
6 x 1 . 0 mm
11 N'm
(1.1
kgl.m,8 lbf.ft)
OIL BREATHER
CHAMEER
8
otL
SCREEN
GASKET
Repl ace.
!
fl
[50
BAFFLE PLATE
OIL JET BOLT
16 N'm 11.6 kgf.m, 12lbt'ttl
OIL JET
I nspect i on,
page 8-10
8x 1+5mm
24 N.d\l2.il kgf.ft,
t7 tbtft)
OIL FILTER
Repl ace.
ENGINE OIL PRESSURE SWITCH
Pipe Taper) 28 Threads/inch
Clean
Use
proper l i qui d seal ant .
6 x 1 . 0 mm
11 N. m 11. 1 kgt m,
8 tbt.frl
Overhaul .
page 8' 11
Removal / l nspect i on, Page
8-13
Appl y l i qui d gasket t o (cont , d)
mat i ng surf ace of engi ne bl ock
Repl acemenl ,
page 8- 8
Repl ace.
8-3
lllustrated
Index
(cont' dl
NOTE:
.
Use new O-ri ngs when reassembl i ng.
. Appl y oi l to O-ri ngs before i nstal tal | on.
.
Use l i qui d gasket, Part No. 08718 0001 or 0e719
0003.
.
Cl ean the oi l pan gasket
mati ng surfaces before i nstal l _
i ng.
. Appl y l i qui d gasket
to the recesses of the oi l pan gas
ket
(see page 7-27).
D16Y7 ngi ne:
OI L PUMP
Overhaul , page
8-12
I nspect i on, page
8 13
t o t he mat i ng surf ace
of t he bl ock.
DOWEL PIN
CAUTION: Do not overtighten the drain bolt.
ENGI NE OI L PBESSURE SWI TCH
18 N. m
(1. 8
kgt m, 13 t bt . t rl
1/ 8 i n. BSPT
(Bri t i sh
St andard Pi pe Taper)
28 t hreads/ i nch.
Use
proper
l i qui d seal ant .
O-BI NG
Repl ace.
OI L BREATHER
CHAMBER
6 x 1 . 0 mm
' 11
N. m { 1. 1 ksnm,
8 t bt f t )
6 x 1 . 0 mm
1l N. m
{1. 1 kgf -m,
8 tbf.ftl
l l
OIL PAN
GASKET
Bepi ace.
OIL PAN
Ref er t o page 7- 27
6 x 1 . 0 mm
11 N m
( 1. 1
kgt . m,
8 tbl.ftl
t o
6 x 1. 0 mm
l 2 N. m
{1. 2 kgt m, 8. 7 t bf . f t )
DRAIN BOLT
44 N.m
{4.5 kgtm, 33 tbf.ft}
Do not oveni ght en.
a
8-4
NOTE:
. Use new O-ri ngs when reassembl i ng.
. Appl y oi l to O-ri ngs before i nstal l ati on.
. Use l i qui d
gasket, Part No 08718
-
0001 or 08718
-
0003.
. Cl ean the oi l
pan gasket mati ng surfaces before i nstal l -
I ng.
O.RING
Repl ace.
OI L PUMP
Overhaul , Page
8 12
I nspect i on, Page
8 13
OOWEL PI N
Appl y l i qui d
gasket
t o t he mat i ng surf ace
of t he bl ock.
CAUTION:
Do not overtightsn the drain bolt.
ENGINE OIL PRESSURE SWITCH
18 N,m l'1.8
kgf.m, 13 lbf.ftl
1/ 8 i n. ESPT
(Bri t i sh
St andard Pi pe Taper)
28 Threads/ i nch. use
proper l i qui d seal ant .
O-RING
OIL BREATHER
CHAMBER
6 x 1 . 0 mm
11 N. m {1. 1 kgf . m,
I tbt'ftl
6 x' 1. 0 mm
11 N. m
(' 1. 1 |
8 tbf.ft)
GASKET
Repl ace.
FILTER
Repl acement ,
page 8_8
BAFFL PLATE
6 x 1 . 0 mm
11N. m 11. 1
kgl . m,
8 tbf.ftl
6 x 1 . 0 mm
11 N. m 11. 1
kg{' m,
8 rbf.ftl
OIL PAN
GASKET
Fepl ace.
OIL PAN
Reler to page 7 26
\3
6 x 1 . 0 mm
12 N. m {1. 2 kg{. m, 8. 7 l bf f t l
BOLT
39 N. m
(4. 0 kgf . m. 29l bt f t l
Do not overtighten.
\
8- 5
Engi ne
Oi l
Inspection
1 . Park the vehi cl e on l evel ground,
and turn off the
engi ne. Al l ow the oi l a few mi nutes to drai n back
i nto the oi l pan
so the di psti ck wi l l show the actual
l evel .
Make certai n that the oi l l evel i ndi cated
on the di p_
stick is between the upper and lower marks.
l f the l evel has dropped
cl ose to the l ower mark.
add oi l unti l i t reaches the upper mark.
CAUTION: lmert thc dipstick carfully to avoid bnd_
ing it.
Bl6A2 angin.:
,,7.fp--)*,".
rowrn-u
l
D16Y5, D16Y7, Dt6y8 ongines:
8-6
Replacement
CAUTION:
Removo
the drai n bol i careful l y
whi l e l ho
engine is hot; the hot oil may causo scalding.
:1.
Warm up the engi ne.
2. Drai n the engi ne oi l .
81642, D16Y7 engi ns:
{rl N.m (4.5
kgf.m,33 tbt ft}
Do not overtighten.
D16Y5, Dl6Y8 6ngin93:
WASHER
DRAIN BOLT
39 N.m 14.0 kgfm, 29 tbf,f0
uo not overt i ght en.
DRAIN BOLT
Requirement
API Service Grade: Use an
"Energy
Conservi ng"
SJ grade oi l or an
"Energy
Conservi ng l l " SH
grade oi l ,
SAE 5W
-
30
preferred
You can al so use an oi l that bears the
API CERTIFICATION
mark.
Capaci ty
[atol z
engi ne:
3.7 f
(3.9
US
qt,3.3 l mp
qtl
I
at oi l change.
J
4.0 r 9.2 US
qt, 3.5 l mp
qtl
I
at oi l change, i ncl udi ng fi l ter'
|
4. 8 f
( 5. 1
Us
qt , 4. 2 l mp
qt )
I
after engi ne overhaul
I
Dl 6Y7 engi ne:
3.6 f
(3.8 US qt, 3.2 l mP qt)
I
at change. i ncl udi ng fi l ter.
I
3.3 f
(3.5
US
qt,2.9 l mP
qtl
I
at change, wi thout fi l ter.
I
4. 3 f
( 4. 5
us
qt , 3. 8 l mp
qt l
I
after engi ne overhaul .
J
L
3.3 { {3.5 US
qt,2.9 l mp
qt}
I
at change, i ncl udi ng fi l ter.
3. 01
( 3. 2
US
qt , 2. 6l mp qt )
I
at change, wi thoutfi l ter.
3.7 {
(3.9
US
qt,3.3 l mp
qt}
-
' 1.fter
engi ne overhaul .
Change
Every 7,500 miles
(12,000 km) or
12 months
(Normal Condi ti ons).
Every 3,750 miles
(6,000 kml or
6 months
(Severe
Conditions).
3. Rei nstal l the drai n bol t wi th a new washer. and rbfi l l
the engi ne wi th the recommended oi l .
NOTE: Under normal condi ti ons, the oi l fi l ter shoul d be
repl aced at every other oi l change Under severe condi -
ti ons, the oi l fi l ter shoul d be repl aced at each oi l change'
The numbers i n the mi ddl e of the API Servi ce l abel tel l
you the oi l ' s SAE vi scosi ty or wei ght Sel ect the oi l for
vour car accordi ng to thi s chart:
30 20
- 10
0 10 20 30
4OoC
An oi l wi t h a vi scosi t y of 5W
-
30 i s pr ef er r ed f or
i mproved tuel economy and year-round
protecti on i n the
car. You may use a 10W
-
30 oi l i f the cl i mate i n your area
i s l i mi ted to the temperature
range shown on the chart'
Ambient Temoerature
API CERTIFICATION
MARK
API SERVICE LABEL
Run the engi ne tor more than three mi nutes, then
check for oi i l eakage
8-7
Oil Filter
Repl acement
After the engine has been run, the exhaust pipe
will
be hot; be careful when working around ihe exhaust
pi pe.
Be careful when loosening
the drain bolt whils the
engine is hot. Burns can resuh because the oil tem-
peratu16
is very high.
Remove the oi l fi l ter wi th the oi l fi l ter wrencn.
Inspect the threads and rubber seal on the new fi l ter.
Wi pe off the seat on the engi ne bl ock, then appl y a
l i ght coat of oi l to the new fi l ter,s rubber seal .
NOTE: Use onty fi tters wi th a bui l t-i n bypass sys,
t em.
Appl y oi l t o rubber seal
bef ore i nst al l i ng.
l .
I nspect t hr eads and
r ubber seal sur f ace.
8-8
Instal l the oi l fi l ter by hand.
After the rubber seal seats, ti ghten the oi l fi l ter cl ock_
wi se wi th the oi l fi l ter wrench.
Tighten: 7/8 tu.n clockwise.
Tightening
tolque: 22 N.m
(2.2
kgt.m, 16lbf.ft)
OIL FILTER WRENCH
07912
-
6110001
Oil Pressure
Use thi s
procedure to ti ghten the fi l ter i f ei ght num-
bers
(1
to 8) are
pri nted
on the surface of the fi l ter.
1) Make a mark on the oi l fi l ter base under the num-
ber that shows at the bottom of the filter when
the rubber seal i s seated.
2l Ti ghten the fi l ter by turni ng i t cl ockwi se seven
numbers from the marked
point. For example, if a
mark i s made under the number 2 when the rub
ber seal is seated, the filter should be tightened
unti l the number 1 comes up to the marked
poi nt'
7/8 turn
Number when rubDer
seal i s seat ed
Number af t er t i ght eni ng.
CAUTION:
Usi ng any procedure other than those
shown could rosult in serious engins damage due
to oil leakage
5. After i nstal l ati on. fi l l the engi ne wi th oi l up to the spec-
ified level, run the engine for more than three minutes,
then check for oi l l eakage
MARK
Number when rubber
seal i s seated
5 7 8
Number after ti ghteni ng 8 1
5 1
Testing
l f the oi l
pressure warni ng Ii ght stays on wi th the engi ne
runni ng, check the engi ne oi l l evel . It the oi l l evel i s cor-
rect:
1. Connect a tachometer'
2. Remove the engi ne oi l
pressure swi tch, and i nstal l an
oal pressure gauge.
ENGINE OtL PRESSURE SWITCH
MOUNTING HOLE
ADAPTER
(1/8\28. BSPTI
{Commerci al l Y
avai l abl ei
Start the engi ne. Shut i t off i mmedi atel y
i f the gauge
regi sters no oi l
prssure. Repai r the
probl em before
conti nui ng.
Al l ow the engi ne to reach operati ng temperature
(tan
comes on at l east tl i vi ce). The
pressure shoul d be;
Engine Oil Temperature:
176"F
(80"C1
Engine Oil Pressulo:
At ldle: 69 kPa
(0.7
kgf/Gm'. 10
Psi)
mi ni mum
At 3.000 rpm: 3/Ut kPa
(3.5
kgt/cm', 50
psi)
mi ni mum
. l f the oi l Dressure
i s wi thi n speci fi cati ons, repl ace
the oi l pressure swi tch and recheck.
. l f the oi l pressure i s NOT wi thi n speci fi cati ons,
i nspect the oi l pump (see page 8-10).
OIL PRESSURE GAUGE
(Commerci al l v avai l abl e)
8-9
Oi l Jet
(B1642
engi ne)
Inspection
1 . Remove the oi l
j et (see page
8-3) and i nspect i t as
fol l ows.
Make sur e t hat a 1. 1 mm
( 0. 04
i n) di amet er dr i l l
wi l l go through the nozzte hol e
(j .2
mm
(0.05
i n)
di ameter).
Insert the other end of the same 1.1 mm
(0.04
i n)
dr i l l i nt o r he oi l i nt ake ( i . 2
mm
( 0. 05
i n) di ame_
ter).
Make sur e t he check bal l moves smoot hl y and
has a stroke of approxi matel y 4.0 mm
(0.16
i n).
Check the oi l
j et
operati on wi th an ai r nozzl e. l t
shoul d take at l east 200 kPa
(2.0
kgf/cm,, 28 psi )
to unseat the check bal l .
NOTE: Repl ace the oi l
j et
assembl y i f the nozzl e
rs damaged or bent.
CHECK BALL
SPRI NG
16 N. m
11. 6 kgf , m, t 2 t bf . f i l
Mounti ng torque i s cri ti cal . Be very preci se
when
i nst al l i ng.
Torque: 16 N.m
(1.6
kgt.m, 12 tbt.ft)
1. 2 mm
( 0. 05
i nl
8- 10
Oi l Pump
Overhaul
NOTE:
. Use new O ri ngs when reassembl l ng.
. Appl y oi l to O-ri ngs before i nstal l ati on.
. Use l i qui d
gasket, Part No. 08718
-
0001 or 08718
-
0003
. The rotors must be i nstal l ed to the same di recti on i n order'
o After reassembl y,
check that the rol ors move wi thout bi ndi ng'
B15A2 engi ne:
6 x 1 . 0 mm
7 N.m
(0.7 kgf m, 5 lbf ft)
OUTER ROTOR
Inspecti on,
page 8-13
INNER ROTOR
page 8-13
OOWEL
PIN
O-RING
Repl ace.
6 x 1 . 0 mm
11 N. m
( 1. 1
8 tbtfrl
kgf.m,
PUMP HOUSI NG
I nspect i on,
page 8-13
Appl y l i qui d
gasket
t o t he mat i ng surf ace of
t he cyl i nder bl ock
8 x 1. 25 mm
24 N,m {2.i1
kgl.m.
17 tbf.ft) RELIEF VALVE
Valve mlst slide freeiy
i n housi ng bore.
Repl ace i f scored. OIL SEAL
Repl ace.
l nst al l at i on,
page 8- 14
SEALING BOLT
39 N.m l4O
kgt'm,
29 tbt frl
\
(cont' d)
SPRING
8- 11
Oi l Pump
Overhaul
(cont' dl
NOIE:
.
Use new O r i ngs when r eassembl i ng.
. Appl y oi l to O ri ngs before i nstal raUon.
. Use l i qui d gasket , Par r No. 08718
-
0001 or 08718_0003.
. The rotors must be i nstal l ed to the same di recti on.
.
After reassembl y, check that the rotors move wi thout bi ndi ng.
(
6 x 1 . 0 mm
7 N.m
(0.7
kgI.m, 5 lbf ftl
PUMP HOUSI NG
I nspect i on, page
8 13
t o mat i ng sur f ace of
t he cyl i nder bi ock
I NNER ROTOR
I nspect ron, page
8 13
DOWEL PI N
PUMP COVEB
O-RI NG
_.feor,""
\
6 x 1 . 0 mm
11 N. m {1. 1 kgf . m, 8l bl . f t )
RELI EF VALVE
Val ve must sl i de f r eel y
i n hous i ng bor e.
Repl ace i f scor ed
OIL SEAL
[".?li;:;"".
*,",
,.rg
""rc
@.-*or"."
9''ggttt*
8- 12
4.
Removal /l nspecti on/l nstal l ati on
2.
3.
1 .
5.
6.
1.
8.
Dr ai n t he engi ne oi l .
Turn the crankshaft and al i gn the whi te groove on
the crankshaft
pul l ey wi th the
poi nter on the l ower
cover.
Remove the cyl i nder head cover and upper cover'
Remove the power steeri ng
pump bel t, ai r condi -
ti oner bei t and the al ternator bel t
pul l ey and remove the l ower
cover.
Remove the ti mi ng bel t.
Remove the dri ve pul l ey.
Remove the oi l
pan and oi l screen.
O.RING
Repl ace OOWEL PI N
OI L SCREEN
9. Remove the oi l
PumP.
! ' a
10. Remove t he scr ews f r om t he
pump housi ng, t hen
separate the housi ng and cover'
Check the i nner-to-outer rotor radi al cl earance on
the pump rotor. l f the i nner-to outer rotor cl earance
exceeds t he ser vi ce l i mi t , r epl ace t he i nner and
outer rotors.
lnner Rotor-to-Outer Rotor Radial Clearance
Standard {New}:
815A2 engi ne 0.04
-
0.16 mm
(0
002
-
0'006 in)
D16Y5, D16Y7, D16Y8 engi nes
0.02
-
0.14 mm 10.001
-
0.006 i n)
(0
008 inl
OUTER ROTOR
INNER ROTOR
Check the housi ng-to-rotor axi al cl earance on the
pump rotor. l f the housi ng-to rotor axi al cl earance
exceeds the servi ce l i mi t, repl ace the set of i nner
and outer rotors and/or the
pump housi ng
Housing-to-Rotor
Axial Clearance
Standard
(Nw):
816A2 engine 0.02
-
0.07 mm
(0.001 -
0.003 i nl
0.03
-
0.08 mm
(0.001 -
0.003 i nl
Srvi ce Li mi t: 0.15 mm 10.006
i n)
1 1 .
' t 2.
(cont ' d)
8- 13
Oi l Pump
RemovaUlnspection/lnstallation
(cont'dl
13. Check the housi ng-to-outer rotor radi al cl earance.
l f t he hous i ng- t o- out er
r ot or r adi al c l ear anc e
exceeds the servi ce l i mi t, repl ace the set of i nner
and outer rotors and/or the pump
housi ng.
Housing-to-Outer
Rotor Badial Clearanco:
Standard
{Newl : 816A2 sngi ne 0.10
-
0.19 mm
(0.004 -
0.007 in)
D16y5, Di 6y7, Dt6y8 engi nes
0.10
-
0.18 mm
{0.00i t
_
0.007 i n)
(0.008
in)
l nspect both rotors and pump
housi ng for scori ng
or other damage. Repl ace parts
i f necessary.
Remove the ol d oi l seal from the oi l pump.
Usi ng the speci al tool , gentl y
tap i n the new oi l seal
unti l the dri ver bottoms agai nst the pump.
NOTE: The oi l seal al one can be repl aced wi thout
removi ng the oi l pump.
DRIVER ATT
5 2 x 5 5 mm
077a6
-
0010ao0
14.
15.
16.
8-14
PUMP HOUSING
17. Reassembl e
the oi l pump,
appl yi ng thread l ock to
the pump
housi ng screws.
18. Check that the oi l pump
turns freel y.
19. Appl y a l i ght coat of oi l to the seal l i p.
20. Instal l the two dowel pi ns and new O-ri ng on the oi l
pump.
21. Appl y l i qui d gasket
to the cyl i nder bl ock mati ng sur_
face of the oi l pump.
NOTE:
.
Use l i qui d gasket,
Part No.08718
-
oOOj or 08718
-
0003.
.
Check that the mati ng surfaces are cl ean and dry
before appl yi ng l i qui d gaskel
.
evenl y, i n a narrow bead cen-
tered on the mati ng surface.
o To prevent
l eakage of oi l , appl y l i qui d gasket
to
the i nner threads of the bol t hol es.
.
Do not i nstal l the parts
i f fi ve mtnures or more
hav e el aps ed s i nc e appl y i ng l i qui d gas k et .
Instead. reappl y l i qui d gasket
after removi ng the
ol d resi due.
. After assembl y, wai t at l east 30 mi nutes before
81642 engi ne:
\
al ong t he broken l i ne.
22. Instal l the oi l pump on the cyl i nder bl ock.
Appl y grease to the l i p ot the oi l
pump seal .
Then. i nstal l the oi l pump onto the crankshaft.
When the
pump i s i n pl ace, cl ean any excess
grease
off the crankshaft and check that the oi l seal l i p i s
not di storted.
81642 engi ne:
8 x 1. 25 mm
6 x 1 . Omm
24 N.m
(2.i4
kg[.m,
17 tbl.trl
11 N.m {1.1
kg{.m,
8 rbt ft)
O.RI G
Repl ace.
DOWEL PINS
GASKET
Replace.
OIL SCREEN
6 x 1 . 0 mm
rl N. m {1. 1 kgf ' m,
I tbf.ftl
D16Y5, D16Y7. D16Y8 engi nos:
OOWEL PIN
6 x 1 . 0 mm
11N' m
( 1. 1 kgf m'
O.RING
Repl ace.
DOWL PIN
GASKET
Repl ace.
6 x 1 . 0 mm
6 x 1.0 mm
'11
N'm {1 1 kgf'm,
11 N. m
(1. 1
kgf . m,
I l bf f t l
8 lbf.ft)
! o
8- 15
l nstal l the oi l screen.
Instal l the oi l pan (see pages 7-26 or 7-27).
NOTE: Cl ean the oi l pan gasket mati ng surfaces.
lntake Manifold/Exhaust System
l ntake Mani fol d
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
Exhaust Mani fol d
Rep| acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ".
9-6
Exhaust Pipe and Muffler
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' . ' . ". . 9-9
Three Way Catalytic Converter {TWCI
I nspect i on
. . . . . . . . . . . . . . . . . . "' . 9-12
Heated Oxygen Sensor
(HO2SI
Rep| acement . . . . . . . . . . . . . . . . . . . . . . . . . . . ' . . ". . . . . "
9-12
L_s
r f o
Intake Mani fol d
Repl acement
NOTE: Use new O-ri ngs and gaskets
when reassembl i nq.
CAUTION:
.
Check tor folds or scratchos on the surface of tbe gasket.
. Replace with a now gasket
if damaged.
D16Y7 engi ne:
8 x 1. 25 mm
22 N.m 12.2 kgtm, 16 tbtftl
INTAKE MANIFOLD
Repl ace i f cracked or
if mating surfaces are
damaged.
8 x 1. 25 mm
23 N.m {2,3 kgt m.
17 rbf.ftl
INTAKE MANIFOLD
BRACKET
8 x 1. 25 mm
24 N.m {2.4 kgf.m, 17 tbf.ftl
9-2
D16Y5 engi ne:
6 x 1 . 0 mm
12 N'm
(1.2
kgl.m,8.? lbf'ft)
EGR CHAMBER
INIAKE MANIFOLD
Replace if cracked or
if mating surfaces are
8 x 1. 25 mm
21 N m
(2.1
kgf.m,
15 tbtft)
damageo,
INTAKE AIB CONTROL
(IAC) VALVE
(M/TI
8 x' 1, 25 mm
22 N. m
(2. 2 kst m, 16l bl f t l
8 r 1. 25 mm
2a N.m
(2.4
kgt m,
17 rbt.ft)
EXHAUST GAS
RECIRCULATION
(EGRIVALVE
8 x 1,25 mm
22 N.n 12.2 kol'm,
16 tbftr)
INTAKE MANIFOLD
BRACKET
8 x 1. 25 mm
23 N.m 12.3
kgf'm,
17 tbt fr)
(cont ' d) I
9-3
l ntake Mani fol d
Repl acement
(cont' dl
NOTE: Use new O,ri ngs and gaskets when reassembl i ng.
CAUTION:
. Check lor folds or scratches on the surface of the gasket.
. Replace with a new gasket il damaged.
D16Y8 engi ne:
INTAKE MANIFOLD
i f mat i ng surf aces are
oamageo,
INTAKE AIR CONTROL
{ract vAt_vE
{M/Tl
GASKET
Repl ace.
8 x 1. 25 mm
24 N. m {2. { kgt m.
17 t bt f t t
THROTTLE
BODY
8 x 1. 25 mm
22 N.rn |.2.2 kgl.rn,
16 tbtft)
INTAKE MANIFOLD
BRACKET
9-4
816A2 engi ne:
INTAKE MANIFOLD
i f mat i ng surf aces are
oamageo,
8 x 1. 25 mm
22 N.rA 12.2 kgl.trr,
16 tbtftt
o
t_-l
U H
E
INTAKE AIR CONTROL
IIACI VALVE
8 x 1. 25 mm
24 N.m 12.4 kgf.m,
17 tbtftl
8 x 1. 25 mm
23 N.m {2.3 kg{.m,
17 tbt.ftl
Al N-m 12.2
kgt.m,
16 tbt.ftl
MANIFOLD
BRACKET
n
""\--
VlCd>-^
M\G
y o
9- 5
Exhaust Manifold
Repl acement
NOTE: Use new gaskets
and sel f-l ocki ng nuts when reassembl i ng.
CAUTION:
. Check for folds or scratchs on the surface of the gasket.
. Replace with a new gasket it damaged.
D16Y5. D16Y7 engi nes:
I x 1. 25 mm
24 N.m
{2.4 kgt.m, 17 tbtft}
MANI FOLD
BRACKET
PRIMARY HEATED
OXYGEN SENSOR
IPRIMAFY HO2SI
44 N.m {4.5 kgf m, 33 lbtft)
Repl acement , page 9-12
GASKET
Repl ace.
I x 1. 25 mm
31 N. m
(3. 2
kgf . m,
23 tbf.ft)
Bepl ace.
WAY CATALYTIC
CONVERTER {TWCI
l nspect i on, page
9' 12
6 x 1 . 0 mm
11 N. m {1. 1 kgt m, 8 l bf . f t )
SECONDARY HEATED
OXYGEN SENSOR
(SECONDARY HO2S}
44 N.m 14.5
kgf.m,33 lbf.ft)
9- 6
D15Y8 engi ne:
8 x 1. 25 mm
2,1 N.m
(2.a kgf'm,
17 tbf.ftl
GASKET
Repl ace.
8 x 1.25 mm
31 N.m 13.2 kgf'm,
23 lbf.ftl
Replace.
PRIMARY HO2S
44 N.m
(4.5
kgf.m, 33 lbtft)
EXHAUST MANIFOLD
BRACKET
10 x 1. 25 rnm
(cont' d)
9-7
/r4
N.m {4.5 kgf.m, 33 lbf.ft)
v
Exhaust Mani fol d
Replacement
(cont'dl
NOTE: Use new gaskets
and sel f-l ocki ng nuts when reassembl j ng.
CAUTION:
. Check for folds or scratches on the surface ot the gaskt.
. Rplace with a new gaskot if damagod,
B16A2 engi ne:
GASKET
Repl ace.
10 x 1. 25 mm
44 N.m {4.4 kgt.m,
33 tbl.ft)
SELF.LOCKING NUT
8 x 1 .25 mm
31 N.m
(3.2
kg{.m, 23 lbf.ft)
Replace-
EXHAUST MANIFOLD
BRACKET
10 x 1. 25 mm
4{ N.m
(4.5
kgf.m. 33 tbt.fil
9- 8
\
Repl acement
NOTE: Use new gaskets and sel f-l ocki ng nuts when reassembl i ng
HEAT SHIELO
6 x 1 . 0 mm
9.8 N.m tl.0
kgf'm,7.2lbf'ft)
EXHAUST PIPE B
EXHAUST PIPE TIP
/
O
6 x 1 . 0 mm
9.8 N.m 11.0 kgt m, 7.2 lbf'ftl
oP----------------
8 x 1. 25 mm
22 N.m 12.2 kg
.m,
16 tbf.f
Replace.
Ti ghl en t he bol t s i n
st eps, al t ernat i ng
si de t o-si de.
8 x 1. 25 mm
22 N.m 12.2
kgl'm, 16lbl'ttl
Replace.
Tighten the bolts in steps,
alternating side-to-side
GASKET
Repl ace.
SELF-LOCKING
NUT
8 x 1. 25 mm
16 N.m 11.6
kgt m, 12 lbt'ftl
Replace.
(cont ' d)
9- 9
MUFFLER
neOlace.
----------"+@
SELF.LOCKING NUT
10 x 1. 25 mm
33 N.m
(3.4
ksd.m,
25 lbf.frl
Repl ace.
Replacement
{cont'dl
NOTE: Use new gaskets and sel f-l ocki ng nuts when reassembl i ng.
D16Y8 engi ne:
MUFFLER
HEAT SHI ELD
6 x 1 . 0 mm
9.8 N.m
(1.0
kgl m, 7.2 lbf.ft)
EXHAUST PI PE
SECONDARY HO25
44 N.m {4.5 kgl.m, 33 lbtftl
GASKETS
Repl ace.
EXHAUST PI PE A
SELF-LOCKING NUT
10 x 1. 25 mm
54 N.m {5.5 kgl.m, 40 lbtft}
Repl ace.
16 N. m { 1. 6 kgl . m, 12l bf . f t }
Repl ace-
d'*'ou"'"'""'
6 x 1 . 0 mm
9. 8 N. m
(1. 0 ksf m, 7. 2l bf f t )
8 x 1. 25 mm
22 N.rn 12.2 kgl.m,
16 tbt.ft)
Repl ace.
Ti ght en t he bol t s i n
st eps, al t ernat rng
si de-t o-si de.
SELF.LOCKING NUT
10 x 1. 25 mm
33 N.m {3.4
kgf.m,
25 tbtftl
Repl ace.
TWC
i nspecti on,
page 9-12
I x 1- 25 mm
22 N m
(2.2 kgf.m. 16 lbfft)
Ti ght en t he bol t s i n st eps,
al t er nat i ng si de' t o sade.
e) GASKET
Hepl ace.
9- 10
816A2 engino:
MUFFLER
_.,.
EXHAUST PIPE
-/-
tlP
g
\ 6 r 1 . o mm
9.8 N m 11.0 kgf'm, 7.2 lbl'ttl
GASKET
Repl ace.
8 x 1. 25 mm
2. N'm 12.2 kgl-m,
t6 tbtf0
Replace.
Tighten the bolts in
steps, alternatrng
side-to-side.
6 x 1 , 0 mm
9, 8 N. m 11. 0
7.2lbl4rl
SELF-LOCKING NUT
l 0 x 1. 25 mm
3:t N.m {3.4 kgf m,24lbf'ftl
ReDlace.
PRIMARY IIEATED
OXYGEN SENSOR
{PRIMARY HO2S)
ll N.m
(4.5
kgl.m,
33 tbt f0
Replacement,
SECONDARY HEATED
OXYGEN SENSOR
{SECONDARY HO2SI
lrt N.m 14.5 kgf.m,
33 rbl.ft)
GASKET
Rplace.
twc
I nspect i on,
page 9-12 GASKEIS
Replace.
SELF.L(rcKNG NUT
10 x 1.25 mm
5,r N.m 15.5 kgf.m,
,|{}
lbf.ft)
ReDlace.
8 x 1 . 2 5 mm
22 N.m {2.2 kgt m, 16 lbf.ftl
Replsce.
Tight6n the bolts in st6ps,
alternating side-to-side.
8 x 1.25 mm
16 N.m 11.6 kgt.m,
12 rbf.ft)
Fpl 8ce.
I
Replaca.
9- 11
TWC
HO2S
Inspection
l . Usi ng a fl ashl i ght, make a vi sual check for pl uggi ng,
mel ti ng and cracki ng of the catal yst.
816A2, D16Y8 engi nes:
-\
6{
- ) \
lT
a
A
FLASHLIGI{T
9- 12
Repl acement
Pri mary HO2S:
1. Remove the pri mary
HO2S.
a. Di sconnect t he pr i mar y
HO2S connect or , t hen
remove the cover.
8 x' 1. 25 mm
24 N.m {2.4 kgl.m,
PRIMARY H02S
CONNECTOR
b. Remove the pri mary
HO2S.
| \l ,l(
I bK/l
l llw.
/ \ \
(
PBI MARY
HO2S
44 N m (4.5
kgf.m, 33 tbI.ft)
Bt6A2, Dl6Y8 engines:
a. Di sconnect the
pri mary HO2S connector then
remove the
pri mary HO2S.
816A2 engi ne
D16Y8 engi ne
PRIMARY
H02S CONNECTOR
PRIMARY HO2S
44 N.m {4.5 kgt'm.33 lbf'ft)
L
2. Install the
primary HO2S in reverse order of removal'
Secondsry H02S:
1. Remove the secondary HO2S
Dl6Y5, Dt6Y7 engines:
a. Di sconnect t he secondar y
HO2S connect or .
then remove the secondary HO2S'
02 SENSOR
816A2, Dt6Y8 ongin6s:
a. Remove the
grommet, and
pull out the secondary
HO2S connector, then disconnect the secondary
HO25 connector'
SECONOARY
H()2S
CONNECTOR
{cont' d)
9- 13
HO2S
Replacement (cont'd)
b, Remove the secondarv HO2S.
02 SENSOR WRENCH
SECONOARY HO2S
4,r N.m (4.5
kgf.m, 33 tbf.ft)
I nst al l t he secondar y HO2S i n r ever se or der of
removat.
9- 14
w a
Cool i ng
fl l ustrated
Index ."..."...
""' 10-2
Radiator
Repl acement
. ' . . . . ' . . . . ". . . "
Engi ne Cool ant
Refi l l i ng
and
Bl eedi ng
Cap Testing
Testing
Thermostat
Repl acement
. . . . . . . . . . . . . ' . . . .
Testing
10-6
10-7
10-9
10-9
10- 10
10- 10
Engine Goolant
TemPerature
(ECT)
Switch
Testi ng
""" 10-11
Water PumP
fffustrated
Index ......' ...
" 10-12
Inspecti on
' 10' 14
Repl acement
. . ' . . ' . . . . ". . . ' . ' . . . . ' . . ' . . . . . ' . """
10-14
!
lllustrated Index
@@
system is under high pressure
when the
engi ne i s hot. To avoi d dangsr of rsl easi ng scal di ng
engine coolant, removo the cap only when the engine is
coot.
Total Cool i ng System Capaci ty
fl ncl udi ng heater and
foservoir
(0.4
f
(0.42
US qt,
0.35 tmp qt)ll:
*2:
81642 engi ne
*3:
D16Y7 engi ne
* 4:
D16Y8 engi ne
CAUTION: l f any engi ne cool ant spi l l s on pai nted por-
tions of the body, rinse it off immediately.
NOTE:
.
Check al l cool i ng system hoses for damage, l eaks or
deteri orati on
and repl ace i f necessary.
. Check al l hose cl amps and reti ghten i f necessary.
.
Use new O-ri ngs when reassembl i ng.
RADIATOR CAP
Pressure t est , page
' 10
8
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgt m,
7.2 tbt.ltl
UPPER
RADIATOR
HOSE
UPPER BRACKET
AND CUSHI ON
COOLANT
RAOIATOR
Engi ne cool ant ref i l l i ng and bl eedi ng,
page 10 7
Leak t est , page
10-9
I nspect sol dered
j oi nt s
and
seams f or l eaks,
Bl ow out di rt I rom bet ween
cor e f i ns wi t h compr essed ai r .
l f i nsect s, et c, , ar e cl oggi ng
r adi at or , wash t hem of f wi t h
r ow pr essur e wat er .
RESERVOIR
5 x 0 . 8 mm
A:
,1.4
N.m {0.45 kgf.m, 3.3 tbtftl
g:
5. 4 N. m (0. 55
kgt m. 4. 0 t bf . f t )
6 x 1 . 0 mm
7.2 N.m
(0.73
kgt.m,
5.3 tbtftl
LOWER
CUSHI ON
RADIATOR FAN
BADIATOR
FAN
DRAI N
PLUG
O- RI NG
Repl ace.
LOWEB
RADIATOR
HOSE
FAN MOTOR
SHROUD
Ar TOYO RADIATOR manufactured radi ator
B: NIPPONDENSO manufacfared raoraror
10-2
Ref er t o sect i on 14
Mt-|-
4. 2 f ( 4. 4
US qt , 3. 7
t mp qt ) * j
5. 0 / (5. 3
U$ q1, 4. 4 16p q11*z
4. 1 f
( 4. 3
US qt ,
3. 6 l mp q0* 3
4.31
(4.5
US qt,
3.8 tmp qt)*a
CVT 4. 3 f
( 4. 5
US qt , 3. 8
I mp qt )
*1i
i i l
lv
Engine Hose Connections:
D15Y7 engi ne:
CONNECTING
PIPE
HEATER
HOSES
{cont' d)
IAC VALVE
WATEF BYPASS
THERMOSTAT
HOUSING
VALVE
10- 3
lllustrated
Index
(cont'd)
Engi ne Hose Connecti ons:
Repl ace.
IAC VALVE
(M/TI
IAC VALVE
{A/T)
WATER BYPASS
HOSE
THERMOSTAT
HOUSI NG
O.RING
Repl ace.
\
\
\
\
h
CONNECTING
PIPE
HEATER
VALVE
HEATER
HOSS
10- 4
CONNECTING
PIPE
Engine Hose Conneqtions:
81642 engi ne:
O-RING
Repl ace.
b
WATER BYPASS
HOSE
HEATER
VALVE
HEATER
HOSES
THERMOSTAT
HOUSING
ENGI NE OI L COOLER
10- 5
Radiator
Replacement
Drai n the engi ne cool ant.
Remove t he upper and l ower r adi at or hoses, and
ATF cool er hoses.
Di sconnect the fan motor connector.
Remove the radi ator upper bracket, then pul l
up the
raotator,
RADIA
ATF COOLER
HOSES (A/T)
Ref er t o sect i on
UPPER RAOIATOR HOSE
6 x 1 . 0 mm
7.2 N.m (0.73
kgf.m.
5.3 tbf.ft)
1 .
2.
3.
5. Remove the fan shroud assembl i es and other parts
from the radi ator.
Instal l the radi ator i n the reverse order of removal :
NOTE:
.
Set the upper and l ower cushi ons securel y.
. Fi l l t he r adi at or wi t h engi ne cool ant and bl eed
the ai r.
6 x 1 . 0 mm
CAP
Y|lT,PS:|"
i.i ru- ii b rgr.-,
AND CUSHION
7.2 tbr.ftl
1 4
(
I
RESEBVOI R TANK
RADIATOR
LOWER
CUSHION
RAOIATOR FAN/SHROUD
ASSEMBLY
DRAIN PLUG
O- RI NG
Repl ace.
LOWER RAOIATOR HOSE
ATF COOLER
PIPES
{A/T)
,iiiiii
10- 6
tl
Engi ne Cool ant Refi l l i ng and Bl eedi ng
CAUTION:
when
pouri ng engi ne cool ant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtrical
parts or the
paint. lf any coolant spills, rinse it
off immediately.
1. Sl i de the heater temperature control l ever to maxl -
mum heat. Make sure the engi ne and radi ator are
cool to the touch.
Remove the radi ator caP.
Loosen the drai n
pl ug, and drai n the cool ant'
Remove the drai n bol t from the cyl i nder bl ock'
D16Y5. D16Y7, Dl 6Yg sngi nes:
DRAIN PLUG
0d
I
r o
78 N. m {8. 0
kgl m. 58l bt ' f t )
6.
1.
B1642 engi n:
WASHER
Repl ace.
DRAIN BOLT
78 N m
(8
0 kgf m' 58l bfft)
Appl y l i qui d
gasket to the drai n bol t threads, then
rei nstal l the bol t wi th a new washer and ti ghten ' t
securel y.
Ti ghten the radi ator drai n
pl ug securel y
Remove, drai n and rei nstal l the reservoi r' Fi l l the
tank hal fway to the MAX mark wi th water, then up
to the MAX mark with antitreeze.
(cont ' d)
10-7
MAX MARK
Radiator
Engine Coolant Refilting
and Bleeding
(cont,dl
8. Mi x t he r ecommended
ant i f r eeze wi t h an eoual
amount of water i n a cl ean contai ner.
NOTE:
o
Use onl y genui ne
Honda anti freeze/cool ant.
.
For best corrosi on protecti on.
the cool ant con_
cent r at i on must be mai nt ai ned year _r ound
at
50% mi ni mum. Cool ant concentrati ons
l ess than
50% may not pr ovi de
suf f i ci ent pr ot ect i on
agai nst corrosi on or freezi ng.
. Cool ant concent r at i ons gr eat er
t han 60010 wi l l
i mpai r cool i ng ef f i ci ency and ar e not r ecom_
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
{0.4 f
10.42 US qr,
0.35 lmp qt),I;
*1:
D16Y5, D16Y/, O16Y8 engi nes
*2:
81642 engi ne
*3;
Dl 6Y7 engi ne
*4:
Dl 6Y8 engi ne
M/r
3.8 f {4.0 US qt, 3.3 l mp qt)*1
4.5 /
(4.8
US qt.
4.0 tmp qt)*,
Att
3. 7,
( 3. 9
US qr , 3. 3
t mp qt ) . 3
3. 9 /
( 4. 1
US qt , 3. 4l mp qt ) * .
CW
3. 9 /
( 4. 1
US qt , 3. 4
t mp qt l
10- 8
\.- I
9. Pour cool ant i nto the radi ator up to the base of the
fi l l er neck. and i nstal l the radi ator cap l oosel v.
Start the engi ne and l et i t run unti l i t warms up
(the
radi ator fan comes on at l east twi cer.
Turn off the engi ne. Check the l evel i n the radi ator.
add cool ant i f needed.
Put the radi ator cap on ti ghtl y, then run the engi ne
agai n and check for l eaks.
10.
1 1 .
Cap Testing
1. Remove the radi ator cap, wet i ts seal wi th engi ne
cool ant, then i nstal l i t on the
pressure tester'
RADIATOR PRSSURE TESTER
(Commerci al l Y avai l abl e)
RAOIATOR
(for
32 mm neck' l ow
Pro{i l e)
Apply a
pressure of 93
-
123 kPa
(0.95
-
'l
25 kgflcm''
14
-
18 psi ) .
Check for a drop i n
Pressure.
l f the
pressure drops, repl ace the cap
I
t
ADAPTOR
Testing
L Wai t unti l the engi ne i s cool , then careful l y remove
t he r adi at or cap and f i l l t he r adi at or wi t h engi ne
cool ant to the top of the ti l l er neck
Attach the
pressure tester to the radi ator and appl y
a
pressure of 93
-
' 123
kPa
(0.95
-
1.25 kgfl cm' , 14
-
18
psi l .
RADIATOR
PRESSURE
TESTER
l Commerci al l Y
avai l abl e)
ADAPTOR
(f or
32 mm neck, l ow
Prof i l e)
Inspect for engi ne cool ant l eaks and a drop In pres-
sure.
Remove the tester and rei nstal l the radi ator cap
NOTE: Check for engi ne oi l i n the cool ant and/or
cool ant i n the engi ne oi l .
10- 9
Thermostat
Repl acement
THERMOSTAT
HOUSI NG
NOTE: Use a new O-ri ng when reassembl i nq.
THERMOSTAT
Instal l wi th pi n
up.
ENGI NE COOLANT
TEMPERATURE
{ECT)
swtTcH
24 N.m {2.4 kgf.m, t7 tbf.ft)
THERMOSTAT
6 x 1 . 0 mm
12 N. m
{1. 2 kgf . m, 8. 7
t bf . f rl
1 0 - 1 0
EGT Switch
-f
Testing
Repl ace the thermostat i f i t i s open at room temperature'
To test a closed thermostat:
1, Suspend the thermostat i n a contai ner of water as
shown.
THEBMOMETER
THERMOSTAT
Heat the water, and check the temperature
wi th a
thermometer.
Check the temperature
at whi ch the
thermostat fi rst opens, and at whi ch i t i s ful l y open
CAUTION: Do not let the thermometer
touch the
bottom of the hot Gonlainel.
Measure l i ft hei ght of the thermostat
when ful l y
open.
STANDARD
THERMOSTAT
Lift height
above 8.0 mm
(0.31 inl
Starts opsning: 169'
-
176'F
(76' -
80'Cl
Fully open:
194'F {90"C1
! ' o
10- 1
1
Testing
!!@
Romoving the EcT swhch while lhs engine
i!-ot can cause the coolant to sPray out, seriously scald-
ing you. Always lst th ongine and rediator cool down
before removing ihe ECT switch.
NOTE: Bl eed ai r from the cool i ng system after i nstal l i ng
the ECT switch
(see
Page
10-7)
1. Remove the ECT swi tch from the thermostat hous-
i ng
(see
Page' 10-10).
2. Suspend the ECT swi tch i n a contai ner of water as
shown.
Heat the water, and check the temperature
wi th a
thermometer.
CAUTION:
Do not let the thermomoter
touch tho
bottom of the hot container'
Measure the resi stance between the A and B termi -
nal s accordi ng to the tabl e.
4.
Terminal
Oo"rffi
swlTcH
ON
196'
-
203"F
(91"
-
95' C)
o-
-o
OFF
5"
-
15'F {3"
-
8'C)
lower than the temPera-
ture when t goes on
Water Pump
lllustrated
Index
NOTE:
.
Use new O-ri ngs when reassembrrng.
. Use l i qui d gasket,
Part No. 08718
-
0OOl or 087 t8
_
0003.
O16Y5, D16Y7, D16Y8 engi nes:
ECT GAUGE
SENDING UNIT
9 N.m
{0.9 kgI.m,
7 tbnftl
t o t he t hreads.
ENGINE
COOLANT
TEMPERA
TURE (ECT)
SENSOR
1E N.m (1,8
kgf.m,
13 rbttt)
6 x 1 . 0 mm
9. 8 N. m
{1. 0 kgf . m,
7.2 tbt.ft'|
O.RING
Repl ace.
WATER OUTLET
COVER
ECT SW1TCH
24 N.m
12.4 kgf.m,
17 rbf.ftl
6 x l . 0 mm
12 N. m
{1. 2 kgf . m,
8.7 tbf.ft)
6 x 1 . 0 mm
'12
N.m {1.2 kgt m,
8.7 lbt fr)
10 x 1. 25 mm
itl
N.m 14.5 kgt m,
33 rbf.ftl
O.RING
Replace.
10- 12
815A2 engine:
WATER OUTLET
COVER
6 x 1 . 0 mm
9.8 N.m {1.0 kgl'm,
7,2 tbl.ftt
ECT GAUGE
SENDING UNIT
9 N.m
(0,9 kgf.m,
7 rbf.ft)
Appl y l i qui d
gasket
t o t he t hreads.
r
ENGINE COOLANT
TEMPERATURE
(ECT)
SENSOR
18 N.m {1.8 kgf.m,
13 tbtftl
6 x 1 . 0 mm
12 N. m
(1, 2
kgd m,
8.7 tbf.ftl
16@
aY@
t"
S X 1.0 Mrf
WATEN PUMP
iiil:i'iij rnr..,
Inspection,
pase 10'1'r
8.7 tbf.ftl
\ l o
1 0 - 1 3
Water Pump
Inspection
' t.
2.
Remove the ti mi ng bel t
(see
secti on 6).
Tur n t he wat er pump pul l ey
c ount er c l oc k wi s e.
Check that i t tarns freel y.
Check for si gns of seal l eakage.
NOTE: A smal l amount of
"weepi ng,,from
the bl eed
hol e i s nor mal .
Dl 6Y5, Dl 6Y7, D16Y8 engi nes:
BLEED
HOLE
B16A2 engi ne:
BLEED HOLE
BLEED HOLE
BLEED HOLE
10- 14
Repl acement
6 x 1 . 0 mm
1 . Remove the ti mi ng bel t
(see
secti on 6).
Remove the water pump
by removi ng fi ve bol ts.
NOTE: Inspect, repai r and cl ean the O-ri ng groove
and mati ng surface wi th the cyl i nder bl ock.
12 N.m
{1.2 kgf.m, l 0 x 1.25 mm
8.7 lbt.ft) {4 N.m
14.5 kg{.m.
33 tbt.ft)
Bl 642 engi ne:
WATER
PUMP
@;2
6 x 1 . 0 mm
12 N. m 11. 2 kg{. m,
8.7 tbf.ft)
O. RI NG
Repl ace.
3. Install the water pump
in the reverse order of removal.
NOTE:
o Keep the O-ri ng i n posi ti on
when i nstal l i ng.
.
Cl ean t he spi l l ed engi ne cool ant .
d
orp,
I
!
Fuel and Emrssl ons
Soeci al Toof s
. . . . . , . . . . " . . , . 11- 2
Component Locations
l ndex . . . . . . . . . . . . . . . . . . . . . ,
. . . . . . . . . 11- 3
Svstem Description
Vacuum Connecti ons ................,,..,.. ......... 11-12
El ectri cal Connecti ons ...............,.,.,... ....... 11-29
Syst em Connect or s . . . . . . . . , . , . , . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 51
Troubl eshooti ng
Tr oubl eshoot i ng Pr ocedur es . . . . . . . . . . . . . . . . . . . 11- 81
Engi ne Control Modul e/Powertrai n
Control Modul e Termi nal
Afi angement ....,.,..... 11-88
Di agnosti c Troubl e Code Chart .................,., 11.97
How to Read Fl owcharts .,.......................... . 11-103
PGM-Fl System
System Descri pti on ...... 11-10,1
Troubleshooting Flowcharts
Contl ol Modul e ........ 11-107
Mani tol d Absol ute Pressure Sensor .....' . . ... 11-115
fntake Ai r Temperatui e Sensor ..... . . ., . 11' 121
Engi ne Cool ant Temperatuae Sensol ........., 11-128
Throttl e Posi ti on Sensor ...................,........... 11-132
Primary Heated Orygen Sensor
(Sensor
1l ... 11-139
Secondary Heated Oxygen Sensor
( Sensor
21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 153
Heated Oxygen Sensor Heater ...................,. 11-157
Fuel Suppl y System ...... 11-164
Random Mi sl i r e . . . . . . . , . . 11- 166
Mi sfi re Detected i n One Cyl i ndsr ................. 11-167
Knock Sensor . , . , . . . . . . . . . . . . 11- 170
CKP/TDC/CYP Sensor ................................... 11' 172
Vehi cl e Speed Sensor ...........,......,...,.,........... 1t-176
Barometri c Pressure Sensor ...............,......... I 1-178
El ect r i cal Load Det ect or , . , , . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1- 179
CKF Sensor . . . . . . . . . . . . . . . . . . . . 11- 183
ECM/PCM Internal Ci rcui t ............................. I 1-188
A/T Si gnal {TMA/TMBI
.................................. I 1-189
ldle Control System
System Doscri pl i on ............ 11-190
l dl e Control System ...... 11-192
l dl e Ai r Control Va1ve .................................... I 1-19i 1
Starter Swi tch Si gnal .................................... 1 1' 202
Ai r Condi ti oni ng Si gnal ................................. 11' 201
Ahernator FR Si gnal .................................... . 1 1-208
Br akeSwi t ch Si gnal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . f 1" 210
Power Sleering Prossure Switch Signal ......11-212
A/T Gear Posi ti on Si gnal ............................... 11-216
Cl utch Swi i ch Si gnal ................................-.... 11-214
l dte Speed Setti ng . .............11-220
Fuel Supply System
Fuel Li nes .,...................,.,.,.,11-221
Fuef Tube/Oui ck-Connect Fi tti ngs ..........,.,........ 11
-227
System Descri pti on ....' .... 11-230
Fuel Pressure .......,.,,........... 11-230
Fuef fni ectors ......................11-232
Fuf Pressure Regul ator .....,.......................' ...,. 11-231
Fuef Fi fter ............................11-235
Fuel Pump . . . . . . . . . . . . . ' . . . . . . . ' . . . . 11- 236
PGM-FI Mai n Rel ay .............11' 237
Fuel Tank ................ ....,...' .' .' 11' 211
Intake Air System
System Descri pti on
....-.-.....11-243
Ai r Cfeaner ...........,......."". .11-211
Throttl e Cabl e .....................11-211
Throttfe Body ........ ..' ... . . .,.11-211
Fuel Ini esti on Ai r Control System ,.,.,....-........... 11-250
Emission Control System
System Descri pti on .-..........11-252
Tai fpi p Emi ssi on ...............11-252
Three Way Catafyti c Convertr ............,.,,.,.,.,.... 11
-252
Exhaust Gas Raci rcul ai i on System ...,.,,,,.,.,.,.,,. 11' 254
Positive Crankcas Ventilation System .... . . .. 11-266
Evaoorati ve Emi ssi on Control s ..................,,..,.,. 11
-267
Special Tools
a \-
Special Tools
Rf. No.
I Tool Number Dsscription
Oty
I
Pagr Reference
O
@
/n
@
@
@
A973X_041
_
XXXXX
07JAZ
-
0010008
07PAZ
-
0010100
07sAz
-
001000A
07406
-
0040001
07406
-
0040304
Vacuum Pump/Gauge, 0
-
30 i n.H9
Vacuum/Pressure Gauge, 0
-
4 i n.Hg
SCS Servi ce Connector
Backprobe Set
Fuel Pressure Gauge
Fuel Pressure Adapter,6 x 15 mm
I
I
1
2
1
I
11-251,256, 257
,
273,27 4, 283,284,
286, 288, 289, 291,
294,296,297
11-294,295
11- 81
11- 83
1't-230, 231, 234
11- 230
ta
1n
\Y
11- 2
Gomponent
Locati ons
L
l ndex
D16Y5 engi ne:
{I ATI SENSOR
Troubl eshoot i ng,
ELECTRICAL LOAD
DETECTOR IELD)
(USA
mod6l)
Troubl eshoot i ng,
page 11 179
THROTTLE POSITION ITP)
SENSOR
Troubl eshoot i ng, page 1 1-132
MANIFOLD ABSOLUTE
PRESSURE IMAPI SENSOR
Troubl eshoot i ng, page 1' l -115
EXHAUST GAS RECIRCULATION
IEGRI VALVE and EXHAUST GAS
RECIRCULATION IEGRI VALVE
LIFT SENSOR
Troubl eshoot i ng,
page' l 1-254
INTAKE AIR TEMPERATUR
IDLE AIR CONTROL
(IAC) VALVE
{M/T)
Troubl eshooti ng,
page 1 1-194
{EGRI CONTROL SOLENOID
VALVE ICW)
Troubl eshoot i ng.
page 1 1-254
EVAPORATIVE EMISSION
IEVAPI PUNGE CONTROL
SOLENOID VALVE
Troubf eshooting,
Page
1 1'21 1, 243
CRANKSHAFT
POS|TTON/
TOP DEAD CENTER/
CYLINDER
POS|T|ON
POWER STEERING
PRESSURE
(PSP) SWITCH
(USAI
Troubl eshoot i ng, Page
1 1-212
KNoCK SENSoR
(Ks)
(cwl
1 1' 170
ICKP/TDC/CYP}
SENSOR
(Bui l t i nt o t he di st ri but or)
Tr oubl eshoot i ng, Page
1 1' 172
VEHICLE SPEED SENSOR
1 1-176
FLUCTUATION
(CKF} SENSOR
1 1
-183
ENGINE COOLANT
TEMPERATURE
IECT) SENSOR
11 128
IDT.E CONTROL IIACI
VALVE
{cw)
11 198
WAY CATALYTIC
CONVERTER ITWCI
Troubleshooting, Page
1 1-252
PRIMARY TIEATED
SENSOR {PNIMARY
HO2SI
tsENsoR 1t {M/Tl
Troubl eshoot i ng, Page' l
1-146
PRIMARY HEATED OXYGEN
SENSOR
(PRIMARY HO2SI
tsENsoR
1l {cw}
1 1-139
SECONDARY HEATED OXYGEN
SENSOR {SECONDARY HO2S)
{SENSOR 2)
Troubl eshoot i ng,
page 11 153
(cont' d)
1 1- 3
Component Locations
Index
(cont'd)
D16Y8 engi nc:
THROTTLE POSITION {TPI
SENSOR
ELECTRICAL LOAD
DETECTOR IELDI {USAI
INTAKE AIR TEMPERATURE
I I ATI SENSOR
Troubl eshoot i ng, page 1 1, 124
MANIFOLO ABSOLUTE
PRESSURE {MAPI SENSOR
Troubl eshoot i ng, page
1 1-1 15
IDI.E
{A/T)
IDI.E AIR CONTROL IIACI VALVE
lMtfl
IEVAPI PURGE CONTROL
SOLENOIO VALVE
Troubleshooting, page 1 1 27 1. 283
CRANKSHAFT
POSTTTON/
TOP DEAD CENTER/
CYLINDER
POStTtON
POWER STEERING PRESSURE
(PSPI
SWTTCH |USA)
{CKP/TI'C/CYPI SENSOR
(Bui l t
i nt o t he di st ri but or)
Troubl eshoot i ng. page 1 1-172
KNOCK SENSOR IKSI
Troubl eshoot i ng, page 11 170
CRANKSHAFT SPEED
FLUCTUANON
ICKFI SENSOR
1 1, 183
CONTROL {IACI VALVE
ENGINE COOLANT
TEMPERATURE
{ECTI SENSOR
Troubl eshooti ng, page 11 128
PRIMARY HEATED OXYGEN SENSOR
{PRIMARY HO2S} (SENSOR
1l {'96
-
98 modolsl
1 1-139
'9!t
-
00 modols:
'96
-
98 modols:
THREE WAY CATALYNC
CONVERTER ITWCI
Troubl 6shooti ng, page 1 1-252
THREE WAY CATALYNC
CONVERTER ITWCI
Troubleshooting. page 1 1-252
SENSOn
(SECONDARY
HO2SI
(SENSOR
2I
SENSOB
ISECONDARY HO2S} ISENSOR 2I
Troubl oshoot i ng, page
1 1-155
PRIMARY HEATEO OXYGEN SENSOR
IPRIMARY HO2SI ISENSOR 1I
1 1-141
11- 4
D16Y7 engine:
ELECTRICAL LOAO
DETECTOR
(ELD)
IUSA}
Troubl eshooti ng, Page
11' 179
THROTTLE POSITION ITPI
SENSOR
MANIFOLD ABSOLUTE
PRESSURE
(MAPI SENSOR
Troubl eshoot i ng,
Page
1 1-1 15
r1-132
CRANKSHAFT
POSTTTON/
TOP DEAD CENTER/
CYLINDER
POSITION
POWER STEERll\lG PRESSURE
{PSP' SWTTCH {USA)
11 212
IDLE AIR CONTROL
(IAC) VALVE
Troubl eshoot i ng,
page 1 1-198
Troubl eshooti ng,
(VSSI
Troubl eshooti ng, Page
1 1-176
IIATI SENSOR
Troubl eshooti ng, page 11 124
l
/ i
CRANKSHAFT SPEED
{CKP/TDC/CYPI
SENSOR
(Bui l t i nt o t he di st ri but orl
' t
1-172
FLUCTUATION ICKFI SENSOR
1 1-183
PRIMARY HEATED OXYGEN
SENSOR
(PRIMARV HO2S)
{SENSOR 1l
Troubl eshoot i ng,
page 1 1' 139
ENGINE COOLANT
TEMPERATURE
(ECTI
SENSOR
Troubl eshoot i ng,
page 11 128
EVAPOBATIVE EMISSION
(EVAPI
PURGE CONTROL
SOLENOID VALVE
THNEE WAY CATALYTIC
CONVERTER ITWCI
Troubl eshoot i ng,
page 1 1-252
Troubf eshoot i ng,
page 1 1 27 1, 283
SENSOR
(SECONDARY HO2S)
(SENSOR 2l
Troubl eshoot i ng,
Page
1 1-1 53
(cont' d)
, l . l t r
| |
-r,
Component Locations
Index
(cont'dl
Bl 6A2 engi ne:
{IAT} SENSOR
Troubl eshoot i ng, page 1' 1-125
MANIFOLO AESOLUTE
PRESSURE
IMAPI SENSOR
Troubl eshoot i ng. page
11-1 19 IOLE AIR CONTROL {IAC) VALVE
1 1, 196
ELECTRICAL LOAD
DETECTOR IELDI
(USA)
THROTTLE POSITION ITPI
SENSOR
11-134
CRANKSHAfi
POStTtON/
TOP DEAD CENTER/
CYLINDER
POStTtON
{CKP/TDC/CYPI SENSOR
(Bual t
i nt o t he di st ri but or)
Troubl eshoot i ng,
page 11-174
POWER STEERING PRESSURE
{PSPI SWTTCH
(USA)
1 1-214
VEHICLE SPEED SENSOR {VSS}
ENGINE
CRANKSHAFT SPEED
FLUCTUATION (CKFI
SENSOR
11- t 85
TEMPERATURE
IECTI SENSOR
I 1-128
THREE WAY CATALYTIC
CONVERTER ITWC)
Troubl eshoot i ng, page 1 1, 252
SCONOARY HEATED OXYGEN
sf
rlsoR
sfCoNDARY HO2SI
{SENSOR 2)
: ?shoot r ng, page
11 155
- 6
IPRIMARY HO2S)
ISENSOR 1I
1 1
I
CLUTCH SWITCH lDl6Y5 ongino
M,/TI
Troubl eshoot i ng,
page 1 1-218
'96
-
98 modsls:
Sell-diagnostic Procedures.
page 11 81
ENGINC CONTROL MOOUI.T
(FCMI/POWERTRATN
CONTROL MODULE IPCMI
'9!,
-
0o modol3:
PGM.FI MAIN RELAY
Rsl ay Test i ng,
page 11-237
Troubl eshoot i ng,
page 1 1-238
PGM.FI MAIN RELAY
Rel ay Test i ng, page l 1 237
Troubl eshoot i ng, pago 1' ! 238
SERVICE
l2Pl
CONNECTOR
ENGINE CONTROL MODU1T
(ECM}/POWERTRAIN
CONTROL MODULE IPCMI
Troubl eshoot i ng,
page 11 111
SERVICE CHECK CONNECTOR
tzPl
Self-diagnostic Procedures,
page 11- 81
Self-diagnostic Procedures,
page 11-81
{cont' d)
11- 7
Component Locati ons
Index
(cont' dl
' 96
D16Y8 engi ne
(coupel ,
' 97
D16Y7 engi ne
(coupe:
KL model , sedan: KL
(LXl
model ),
' 97
D16Y8 engi ne
(coupe:
al l model s, sedan: KL model l ,' 98-al l model s:
FUEI- VAPOR PIPE
FUEL FEED PIPE
FUEL GAUGE SENDI NG UNI T
Test i ng, see sect i on 23
FUEL PUMP
Test i ng, page 11 236
Repl acement ,
page 11 236
FUEL FILTER
Repl acement ,
VAPOFATIVE EMISSION
(EVAPI
CONTROL CANISTER
VENT SHUT VALVE
Troubl eshoot i ng, page l 1' 283
FUEL FILL
CAP
FUEL TANK
Repl acement, page
I l -241
IEVAPI CONTROLCANISTER
IEVAP) BYPASS SOLENOID
VALVE
-283
FUEL INJECTORS
Repl acement , page 1 1-232
(EVAPI
TWO WAY VALVE
Testi ng, page 11 294
FUEL
REGULATOR
Test i ng, page 11- 234
TANK PRESSURE
SENSOR
Tr oubl eshoot i ng, page 11- 275
Repl acement , page
1 1- 234
' 96
Dt6Y5 engi ne,' 96 D16Y7 engi n,
' 96
D16Y8 engi ne
(sedanl ,
'97
D16Y5 engine,'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 FEED PIPE
FUEL
FITTINGS
Precaut i ons, page 1 1-227
Di sconnect i on, page 11 227
Connect i on, page 11-228
FUEL VAPOR PIPE
FITTINGS
IEVAPI CONTROL CANISTER
Troubl eshoot i og, page 1 1-271
FUEL FILTER
Repl acement , page 1 1-235
FUEL PUMP
Test i ng, page 11-236
FUEL TANK
Bepl acement , page 11 241
TI VE EMI SSI ON
{EVAP)
TWO WAY VALVE
Test i ng, page 11-294
TUBE/OUICK.CONNECT
FUEL PRESSURE
REGULATOR
Test i ng, page 11' 234
Precaut i ons, page 1 1-227
Di sconnect i on, page 11' 227
Connect i on, page 1 1-228
1 1 - 8
FUEL RETURN PIPE
'99
-
00 models:
IEVAP} PURGE CONTROL
SOLENOID VALVE
Troubl eshoot i ng,
page 1 1' 288
FUEL GAUGE SENDI NG UNI T
Test i ng, see sect i on 23
FUEL VAPOR PIPE
ONBOARD REFUELING VAPOR
RCOVERY IORVRI
VENT SHUT VALVE
Test , page 11 296
{EVAP)
CONTROL CANISTER
VENT SHUT VALVE
Tr oubl eshoot i ng, Page
1 1_288
FUEL FILTER
Bepl acement, page 11-235
FUEL FEED PIPE
FUEL RETURN PIPE
FUEI- PUMP
Testi ng,
page 11 236
Repl acement,
page 11-236
FUEL FILL
CAP
{EVAPI CONTROL
Troubl eshoot i ng,
page 1 1_288
FUEL
PULSATION DAMPEB
FUEL INJECTORS
Repl acement ,
page 1 1' 232
FUEL PRESSURE
REGULATOR
{EVAP)
BYPASS SOLENOID
VALVE
Troubl eshoot i ng,
page 1 1-288
FUEL
RAI L
FUEL TANK PRESSURE
SENSOB
1 1' 274
IEVAPI TWO WAY VALVE
Test i ng, page 11 295
Test i ng,
page 11-234
Repl acement ,
page 11 234
FUEL TUBE/OUICK.CONNECT
FITTINGS
Precaut i ons, page 1 l -227
Di sconnect i on, page 11 227
Connect i on, page 1 1-228
Repl acement ,
page 1 1- 241
I (cont ' d)
1 1- 9
Component Locations
Index
(cont'd)
D16Y5, D16Y8 ongi ne:
RESONATOR
D16Y7 6ngi n:
AIR CLEANER IACLI
Repl acement , page
11-244
THROTTLE BODY (TBI
I nspect i on, page
1 1-247
Removal , page
11-248
Di sassembl y, page 11 249
THROTTLE CABLE
lnspection/Adjustment. page
1 1
-244
I nst al l at i on, page 11 245
AIR {FIA} CONTROL
VAIVE
{'99 modeli
D16Y8 6ngin6)
Test i ng, page 11, 250
POSITIVE CRANKCASE
VENTILATION IPCV) VALVE
I nspect i on, page
11-266
AIR CLEANER IACLI
Repl acement , page
11, 244
THROTTLE CABIT
f nspect i on/ Adj ust ment . page
1 1, 244
1 1-245
.iBoov
ffet
I nspect i on, page 11 247
Removal , page 11, 248
Di sassembl y, page 1 1-249
POSITIVE CRANKCASE
VENTILATION IPCVI VALVE
I nspect i on, page 1 1-266
1 1 - 1 0
RESONATOR
\-
816A2 engine:
AIR CLEANER
(ACLI
Repl acement ,
Page
11-244
THROTTLE BODY {T8)
I nspect i on. page 11-247
Removal , page 1
' 1-248
Di sassembl y,
page 1 1-249
THROTTLE CABLE
lnspection/Adiustment,
page 1 1
-244
l nst al l at i on,
page 1 1-245
POSITIVE CRANKCASE
VENTILATION IPCVI VALVE
I nspect i on,
page 1 1-266
11- 11
System Description
Vacuum Connections
D16Y5 engi n6
(' 96 -
97 model sl :
To EVAPORATIVE EMISSION
(EVAPI
TWO WAY VALVE
MANIFOLD
ABSOLUTE
PRESSURE
IMAPI
SENSOR
VAPORATIVE
EMISSION IEVAPI
PURGE CONTROL SOLENOID
VALVE
EXHAUST GAS BECIRCULATION
(EGR)
VALVE end EXHAUST GAS
RECIRCULATION IEGR) VALVE
LIFT SENSOR
Qo
FRONT OF VEHICLE
To CRUISE
CONTROL
DIAPHRAGM
(wat h
crui se cont rol )
Qo
O: Vacuum hose No.
11- 12
(EGR)
CONTROL SOLENOID
\
VALVE {CVT}
\
.' .-'
\
I
I
\ )
FUEL PRESSURE REGULATOR
D16Y5 engi ne l ' 98
-
00 model s):
tEVAPI THREE WAY VALVE {98 model)
IEVAP' CONTBOLCANISTER
FILTER 1'99
-
00 modelsl
EVAPORATIVE EMISSION {EVAPI
CONTROL CANISTER
VENT SHUT VALVE
l'99
-
00 modelsl {EVAP)
TWO WAY VALVE
(EGRI
VALVE and EXHAUST GAS
RECIRCULATION IEGRI VALVE
LIFT SENSOR
tcwl
. . , . - - - - - . - ( CWo n t y l
IEGR}
CONTROL SOLENOIO
VALVE ICVTI
,t'ffi,
ig
EVAPORATIVE
EMISSION {EVAP)
PURGE CONTROL
CANISTER
MANIFOLD
ABSOLUTE
PRESSURE {MAPI
SENSOR
EVAPORATIVE
EMISSION {EVAP) Qo
To CRUISE
CONTROL
DIAPHRAGM
(wi t h
crui se cont rol )
VALVE
FRONT OF VEHICLE
o: Vacuum hose No.
(cont' d)
1 1 - 1 3
L
System Description
Vacuum Connecti ons
{cont' d}
Dl 6Y8 engi ne l ' 96
-
98 model s):
To EVAPOBATIVE EMISSION
IEVAPI THREE WAY VALVE
{'96 coupe,
'97
coupe: all models.
'97
sedan: KL model.
'g8-models)
(EVAPI
CONTROL CANISTER
VENT SHUT VALVE
{' 96 coupe, ' 97 coupe: al l model s,
'97
sedan: KL model.
'g8-modelsl
{EVAP)
TWO WAY VALVE
{' 96 coupe, ' 97 coupe: al l model s,
sed6n: KL model)
EVAPORATIVE
EMISSION {EVAPI
PUBGE CONTROL
CANISTER
{EVAPI PUBGE
CONTROL CANISIER
l'96 sadan,
'97
sodan: XA,
FUEL PRESSURE
REGULATOR
MANIFOLD ABSOLUTE
PRESSURE
(MAP)
SENSOR
I
KC mod6l3l
EVAPORATIVE
EMISSION {EVAPI
To CRUISE
CONTROL
DIAPHRAGM
{wi t h crui se cont rol )
VALVE
FRONT OF VEHICLE
11- 14
Dl6Y8 ongino
('99 -
00 modols):
VAPORATIVE EMISSION
(EVAP}
CONTROL CANISTER
VENT SHUT VALVE
{EVAPI
CONTROL CANISTER
FILTER
To EVAPORATIVE
EMISSION
(EVAPI
TWO WAY VALVE
FRONT OF VEHICI-E
To CRUISE
CONTROL
DIAPHRAGM
(with
cruise control)
EVAPORATIVE
EMISSION IEVAPI
PURGE CONTNOL
CANISTER
REGULATOR
{cont' d)
1 1 - 1 5
System Description
Vacuum Connecti ons
(cont' dl
D16Y7 engi ne
(' 96
model s,' 97 coupe: KA. Kc model s,
' 97
sedan: KA, Kc, KL l Dx) model s,' 97 hatchback: al l model sl :
EVAPORATIVE
EMISSION (EVAPI
PURGE CONTROL
FUEL
PRESSURE
REGULATOR
To EVAPORATIVE
EMI SSI ON {EVAP}
TWO WAY VALVE
MANIFOLD ABSOTUTE
PRESSURE (MAP)
To CRUI SE
CONTROL
DIAPHRAGM
l wi t h crui se
EVAPORATIVE
EMI SSI ON
(EVAPI
PURGE CONTROL
CANISTER
FRONT OF
VEHICLE
11- 16
Dl 6YT engi ne
(' 97
coupe: KL model ,' 97 sedan: KL ILX)
model ,' 98 model "gg model "oo model ):
{EVAP} THREE WAY VALVE
l'97 coupe: KL model,
'97
sedan: KL
(LX)
model,
'98
modell
{EVAP) CONTROL CANISTER
FILTER
('99 -
0O models)
EVAPORATIVE EMISSION {EVAP)
CONTROL CANISTER
VENT SHUT VALVE
(EVAP)
CONTROL CANISTER
VENT SHUT VALVE
I EVAPI
TWO WAY VALVE
PURGE JOINT
EVAPORATIVE
EMISSION {EVAP}
PURGE CONTROL
CANISTER
FUEL PRESSURE
REGULATOR
_.\,,..,_..-.
{'97
coupe: KL model,
'97
sedan: KL
(LX)
model.
'98
model)
MANIFOLD ABSOLUTE
PRESSURE {MAP) SENSOR
To CRUISE
CONTROL
DIAPHRAGM
l wi t h
crui se cont rol )
EVAPORATIVE
EMI SSI ON
(EVAP}
gtt
FRONT OF VEHICLE
VALVE
(cont' d)
11- 17
System Description
Vacuum Gonnections
(cont'd)
B16A2 engine:
EVAPORATIVE EMISSION (EVAPI
CONTROL CANISTER
VENT SHUT VALVE
(EVAPI
CONTROL CANISTER
FILTER
EVAPORATIVE
EMISSION {EVAPI
PURGE CONTROL
CANISTER
To EVAPOBATTVE EM|SS|ON
(EVAPI
TWO WAY VALVE
EVAPORATIVE
EMISSION IEVAPI
PUBGE CONTROL SOLENOID
VALVE
2
VEHICLE
MANIFOI.D ABSOLUIE
PRESSURE (MAPI
SENSOR
FUEL PRESSURE
REGULATOR
To CRUISE
CONTROL
DIAPHRAGM
(wi t h
crui se cont rol )
1 1 - 1 8
Dl6Y5 engine
('96
-
97 modelsl:
o
,6i
@
o
@
)
@
o
@
(il
(i'
PRIMARY HEATED OXYGEN SENSOR {PRIMARY
HO2S,
SENSOR 1'
SECONDARY
HEATED OXYGEN SENSOR
(SECONDARY
HO2S. SENSOR 2l
MANIFOLD ABSOLUTE PRESSURE {MAP) SENSOR
ENGINE COOLANT TEMPERATURE
(ECTI SENSOR
INTAKE AIR TEMPERATURE IIAT) SENSOR
KNOCK SENSOR
(KS)
CRANKSHAFT SPEED FLUCTUATTON
(CKF}
SENSOR
IOLE AIR CONTROL
(IAC} VALVE
THROTTLE BODY
(TBI
FUEL INJECTOR
FUEL PULSATION DAMPER
FUEL FILTER
FUEL PUMP I FPI
FUEL TANK
:li Vacuum hose No
*:
CVT only
FUEL TANK EVAPORATIVE EMISSTON {EVAP)
VALVE
AIR CLEANER
RESONATOR
POSITIVE CRANKCASE VENTIL/ATION IPCVI
VALVE
EXHAUST GAS RECIRCULATION IEGR)
CONTROL
SOLENOID VALVE
(EGRI VALVE
EXHAUST GAS RECTRCULATION IEGRI
VALVE LIFT
SENSOR
EVAPORATIVE
EMISSION IEVAPI
PURGE CONTROL
SOLENOID VALVE
EVAPORATIVE EMISSION {EVAP}
CONTROL CANISTER
EVAPORATIVE
EMISSION {EVAP}
TWO WAY VALVE
THREE WAY CATALYTIC CONVERTER
(TWCI
{D
o
(D
@
@
@
@
@
@
@
@
(cont ' d)
1 1 - 1 9
! ' a
System Description
Vacuum
Connecti ons (cont' d)
D16Y5 engi ne (' 98
modet):
-: Vacuum hose No,
*:
CW onl y
(9
POSITIVE CRANKCASE VENTILATION
{PCV} VALVE
?!J EXHAUST GAS BECIRCULATION (EGR}CONTROL
SOLENOI O VALVE
'1 ExHAUST GAs RECIRCULATIoN
IEGRI VALVE
22 EXHAUST GAS RECIRCULATION
{EGR} VALVE LIFI
SENSOR
J EvApoRATtvE EMtsstoN
{EvAp}
puRGE
coNTRoL
SOLENOID VALVE
q4
PURGE JOINT
@
EVAPoRATIVE
EMIssIoN
{EVAP) coNTRoL CANISTER
@
IEVAP} BYPASS SOLENOID
VALVE
?? EVAPORATIVE
EMISSION
{EVAP) THREE WAY VALVE
ITII
EVAPORATIVE
EMISSION
IEVAP} CONTROL CANISTER
VENT SHUT VALVE
O
FUEL TANK PRESSURE
sENsoR
QlI EVAPORATIVE EMISSION
{EVAP}TWO WAY VALVE
8' THREE WAY CATALYTIC CONVERTER
{TWCI
il) PRIMAFY HEATED OXYGEN SENSOR
IPRIMARY HO2S.
SENSOR 1)
O SECoNDARY HEATEo oxYGEN sENsoR
{sEcoNDARY
HO2S. SENSOB 2)
iq] MANIFOLD ABSOLUTE PRESSURE (MAPI
SENSOR
O
IECT) SENSOR
5 INTAKE AIR TEMPERATURE
{IATI SENSOR
!
KNOCK SENSOR t KSl
O CRANKSHAFT SPEED FLUCTUATIoN
{cKF) sENsoF
O
IDLE AIR coNTRoL
{IAc) vALvE
99
THROTTLE BODY ITBI
@
FUEL INJECToR
O FUEL PULSATION DAMPER
@ FUEL F -TER
@ FUEL PRESSURE REGULAToR
[ 4 FUEL PUMP I FPI
(9
FUEL TANK
(D
FUEL TANK EVAPoRATIVE
EMIssIoN
IEVAPI VALVE
O' AIR CLEANER
(D
RESoNAToR
11-20
D16Y5 engi ne
(' 99 -
00 model sl :
O)
(PBIMARY HO2S,
SENSOR 1)
O
SECONDARY
HEATEO OXYGEN SENSOR {SECONDARY
HO2S. SENSOR 2)
6] MANIFOLD ABSOLUTE PRESSURE IMAPI
SENSOR
rO CruCIruC COOUruT
TEMPERATURE IECTI
SENSOR
o
rrurlxe ln ETUpERATURE 0AT)
SENSOR
.d KNOCK SENSOR
(KS}
O CN,NruXSXITT
SP:ED FLUCTUATION
(CKFI SENSOR
@
rou an corurnoL 0Ac)
valvE
O
THROTTLE BODY
(TB)
@
FUEL INJECTOR
E)
FUEL PULSATION OAMPER
t? FUEL FILTER
G)
OI
FUEL PUMP
(FP)
Gi
FUEL TANK
G)
AIR CLEANER
fi? RESONATOR
Gl
posmvr
cnglrcAsE VENTILATION
(PCV) VALVE
@
EXHAUST GAS RECIRCULATION IEGR}
CONTROL
SOLENOID
VALVE
6 EXHAUST GAS RECTRCULATION
(EGR) VAI-VE
rf exxlust cls nectRcuLATloN IEGR) vALvE LIFT
SENSOR
@
EVAPORATIVE
EMISSION
(EVAPI PURGE CONTNOL
SOLENOID VALVE
O} PURGE JOINT
io :vaponanve eutssloN
(EVAP) coNTRoL cANlsrER
d rvlponlrtve EmtsstoN tEvAPl
BYPASS soL-eNolD
VALVE
6
EVAPORATIVE EMISSION {EVAP)
CONIROL CANISTER
FILTER
@
EVAPORATIVE
EMISSION
(EVAPI CONTROL CANISTER
VENT SHUT VALVE
OA FUEL TANK PRESSURE SENSOR
6 :vlponlnvg er,/tlssloN tEvAPl
TWO WAY VALVE
6 oNgoano nerueltNc vAPoR REcovERY {onvRl
VENT
SHUT VALVE
!)
ONBOARD REFUELING VAPOR RECOVERY
(ORVRI VAPOR
RECIBCULATION
VALVE
@
(TWCI
(cont ' d)
11-21
L
System Description
Vacuum
Connecti ons (cont' d)
D16Y8 engine ('96
sedan,
'97
sedan: KA, KC modelsl:
(PRIMARY
HO2S.
SENSOR
SECONOARY HEATED OXYGEN SENSOR
{SECONDARY
HO2S, SENSOR 2l
MANIFOLD ABSOLUTE PRESSUBE
{MAPI SENSOR
{ECTI SENSOR
INTAKE AIR TEMPERATUFE
IIATI SENSOR
KNOCK SENSOR IKSI
CRANKSHAFT SPEED FLUCTUATION
{CKFI SENSOR
IDLE AIR CONTROL
IIACI VALVE
THROTTLE EODY
(T8)
FUEL INJECTOR
FUEL FILTER
FUEL PUMP {FPI
FUEL TANK
FUEL TANK EVAPORATIVE EMISSION
IEVAP} VALVE
AIR CLEANER
RESONATOR
{PCV} VALVE
EVAPORATIVE
EMISSION
IEVAP) PURGE CONTROL
SOLENOID VALVE
EVAPORATIVE
EMISSION
EVAFORATIVE EMISSION
IEVAP} TWO WAY VALVE
THREE WAY CATALYTIC CONVERTER (TWC'
{M/ T}
i @ l
: F @ i
Hi i Fl
(A/T)
I ENGINE I
I
coor-rruri
i @ i + i
l/A. nfi
|
( Or ) l
/ U [ |
\)l#t,/ ,6
0)
t;
-l
@
!o,
(t
@
@
@
@
@
@
(9
@
@
@
(D
@
A)
@
11- 22
D16Y8 engine l'96 coupe.'97 coup6: all models.'97 sodan: KL modol.'98 modell:
?
3-
a
6
7.
a
9
,!
1?
!
1 {
r 5
PRIMARY HEATEO OXYGEN SENSOR IPRIMARY
HO2S,
SENSOR 1)
SECONDARY HEATED OXYGEN SENSOR ISECONDARY
HO2S. SENSOR 2l
MANIFOLD ABSOLUTE PRESSURE IMAPI SENSOR
ENGINE COOLANT TEMPERATURE IECTI SENSOR
(IATI SENSOR
KNOCK SENSOR {KS)
CRANKSHAFT SPEED FLUCTUATION ICKFI SENSOR
IOLE AIR CONTROL {IAC) VALVE
THROTTLE BODY ITBI
FUEL INJECTOR
FUEL FILTER
FUELPRESSURE
REGULATOR
FUEL PUMP I FPI
FUEL TANK
FUEL TANK EVAPORATIVE EMISSION IEVAP)VALVE
AIR CLEANER
RESONATOR
(PCV) VALVE
EVAPORATIVE EMISSION IEVAPI PURGE CONTROL
SOLENOID VALVE
CONTROL CANISIER
EVAPORATIVE EMISSION IEVAPI
BYPASS SOLENOIO
VALVE
THREE WAY VALVE
EVAPORATIVE EMISSION IEVAPI
CONTROL CANISTER
VENT SHUT VALVE
FUEL TANK PRESSUFE SENSOR
EVAPORATIVE EMISSION IEVAP)
TWO WAY VALVE
THREE WAY CATALYTIC CONVERTER ITWCI
@
o
@
@
@
@
@
@
@
@
@
(cont' d)
11-23
System Description
Vacuum Connecti ons (cont' dl
D16Y8 engi ne
l ' 99
-
00 modetsl :
(]-i
PAIMARY HEATEO OXYGEN SENSOR
{PRIMARY HO2S,
SENSOR 1)
..2r SECONOARY HEATEO OXycEN SENSOB
ISECONDARY
HO2S, SENSOR 2l
i3) MANIFOLD ABSOLUTE PBESSURE
{MAPI SENSOR
O
ENGINE cooLANT TEMPERATURE (ECTI
sENsoR
(5)
{IAT} sENsoR
G] KNOCK SENSOR IKSI
?r CRANKSHAFT SPEEo FLUCTUATTON
{CKF) SENSOR
.O IDLE AIR coNTRoL
{IAc)vALvE
i-9] THROTTLE BOOY {TB)
(O
FUEL INJECToR
I]'i FUEL FILTER
.O
FUEL PRESSURE REGULAToR
[ t FUEL PUMP {FPl
.D FUEL TANK
il' AIR CLEANER
TD RESONATOR
O FUEL TNJEC oN AtR tFtA) coNTRoL vAt_vE
.19 POSITIVE CRANKCASE VENTILATION
{PCVI VALVE
.19) EVAPORATIVE
EMIssIoN
{EVAP) PURGE coNTBoL
SOLENOID VALVE
g PURGE JorNT
tj EVApoRATtvE EMtsstoN
{Evap} coNTRoL cANtsTER
C4 EVAPONANVE EMISSION (EVAP)
BYPASS SOLENOID
VALVE
?3 EVAPORATIVE
EMISSION
{EVAP} CONTROL CANISTER
FI LTER
A4 EVAPoBATIVE EMIssIoN (EVAP)
coNTRoL CANISTER
VENT SHUT VALVE
C! FUEL TANK PRESSURE sENsoR
EO EVAPOBATIVE EMISSION (EVAP)
TWO WAY VALVE
e? oNBoARD REFUELtiIG vApoR REcovERy
{oRvR} VENT
SHUT VALVE
@ oNBoARD REFUELTNG vapoR REcovERy (oRvR)
vapoR
RECIRCULATION VALVE
iP THREE WAY CATAI.YTIC CONVEBTER
{TWCI
' -
* o ' * -
-
COOLANT
]L
n
r l
L
ii8'x'",
*
--j
I
IM TTI ^
n 14
[l (2i )
- f r l -
1ry|
11- 24
|-
DI 6YTengi ne( ' 96mode| . , 97coupe: KA, Kcmode| s, , 97sedan: KA, KC, KL{ Dx} modet s, ' gThat chback: a| | model s} :
COOLANT
o
l)
r.-.
.t)
a:!)
o
-o
aro
a1t
(PRIMARY HOzS,
SENSOR 1)
SECONDARY HEATED OXYGEN SENSOR {SECONDARY
HOzS, SENSOR 2)
MANIFOLD AESOI-UTE PRESSURE IMAP) SENSOR
ENGINE COOLANT TEMPERATURE IECT) SENSOR
(IAT} SENSOR
CRANKSHAFT SPEED FLUCTUATION
(CKF) SENSOR
IDLE AIR CONTROL
(IACI VALVE
THROTTLE BOOY
(TB)
FUEL INJECTOR
FUEL FI LTER
FUEL PUMP IFPI
FUEL TANK
FUEL TANK EVAPORATIVE
EMISSION
(EVAPI VALVE
AIR CLEANER
RESONATOR
POSITIVE CRANKCASE
VENTILTATION IPCVI
VALVE
EVAPORATIVE
EMISSION
(EVAP} PURGE CONTROL
SOLENOID VALVE
EVAPORATIVE
EMISSION
(EVAP)
CONTROL CANISTER
EVAPORATIVE
EMISSION IEVAPI
TWO WAY VALVE
(TWCI
[3)
@
ao
(o
a
@
(0
@)
(cont ' d)
11-25
System
Description
Vacuum
Connections (cont'd)
Dl6Y7 angin6
('97
coup.: KL modl, sedan: KL
(LX)
model,,9g modet):
i1] PRIMARY HEATED OXYGEN SENSOR (PRIMARY
HO2S,
SENSOR 1)
E) SECONDARY HEATED OXYGEN SENSOR
{SECONDARY
HO2S, SENSOR 2l
l
MANTFOLD ABSOT_UTE PRESSUnE
tMAp) SENSOR
r ENGINE COOLANT TEMPERATURE
|ECT) SENSOR
]
IIAT} SENSOR
6 CRANKSHAFT SPEED FLUCTUATION
ICKFI SENSOR
17
IOLE AIR CONTROL
IIACI VALVE
@ THRoTTLE BoDY {TBI
O
FUEL INJEGToR
(9
FUE|- FTLTEF
O FUEL PRESSURE REGULAToR
@ FUEL PUMP {FPI
(D
FUEL TANK
@
FIFL TANK EVAPoRATIVE EMIssIoN
{EVAPIVALVE
(,
AIR CLEANER
(tO
RESONATOR
l?
PoSITIVE cRANKcAsE VENTILATIoN
IPcv}VALVE
IA
EVAPORANVE
EMISSION
TEVAPI PURGE CONTROL
SOLENOID VALVE
19 EVAPORATIVE
EMISSION
E EVAPORATIVE
EMISSION (EVAPIBYPASS
SOLENOID
VALVE
' EVAPoRATIVE
EMIssIoN
IEVAPI THREE wAY vALvE
Q' EVAPORATIVE
EMISSION
VENT SHUT VALVE
@ FUEL TANK PRESSURE sENsoR
{?1! EVAPORANVE
EMISSION
IEVAPI TWO WAY VALVE
?5 THREE WAY CATALYTIC CONVERTER
ITWC'
11-26
Dl6Y7 engins
('99
-
00 modelsl:
PRIMARY HEATED OXYGEN SENSOR {PRIMARY
HO2S,
SENSOR 1)
iiconoanv
neareo oxYGEN sENsoR ISECoNDARY
HO2S, 9ENSOR 2)
MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR
ENGINE COOLANT
TEMPERATURE
(ECT} SENSOR
(IATI SENSOR
CRANKSHAFT
SPEED FLUCTUATION ICKFI
SENSOR
IOLE AIR CONTROL
(IAC} VALVE
THROTTLE BODY
(TBl
FUEL INJECTOR
FUEL FILTER
FUEL PUMP
(FP)
FUEL TANK
AIR CLEANER
RESONATOR
6d POSITIVE CRANKCASE
VENTILATION
(PCV) VALVE
6 rvapoamve eutssloN tEvAP)
PURGE coNTRoL
SOLENOID VALVE
CO PURGE JOINT
6 evlponnnve eutssloN
(EvAPl coNTRoL cANlsrER
i evlponnnve eussloN {EVAP}
BYPASS solrNolD
VALVE
6)
EVAPORATIVE
EMISSION
(EVAPI CONTROL CANISTEN
FILTER
@
EVAPORATIVE
EMISSTON
(EVAP) CONTROL CANISTER
VENT SHUI VALVE
A FUEL TANK PRESSURE SENSON
d rvlpoamve emtsstoN tEvAPl
rwo wAY vALvE
6 orueonno nerueLING vAPoR REcovERY loRvnl
vENT
SHUT VALVE
)
ongolno neruellNc
VAPOR RECOVERY {ORVR)
VAPOR
RECIRCULATION
VALVE
)
THREE WAY CATALYTIC
CONVERTER
(TWC)
a
6t
@
!.,
o
@
ao
@
@
(}
@
@
(cont' d)
11-27
I
a
System Description
Vacuum Connections (cont'd)
816A2 engi ne:
@ EvApoRATtvE
EMtsstoN
tEvAp)
puRGE
coNTRoL
SOLENOID VALVE
@
PURGE JoINT
t EvApoRATtvE
EMtsstoN (EVApt
coNTRoL caNtsTER
QA EVAPORATIVE EMISSION (EVAP)
BYPASS SOLENOID
VALVE
@ EVApoRATtvE EMtsstoN
lEvApl coNTRoL caNtsrER
FILTER
@ EvApoRATtvE
EMtsstoN
{EvApt coNrRoL cANtsrER
VENT SHUT VALVE
@ FUEL TANK PRESSURE sENsoR
GI EVAPORATIVE EMISSION (EVAP}
TWO WAY VALVE
@ ONBOARD REFUETING VAPOR RECOVERY
{ORVR} VENT
SHUT VALVE
@ oNBoAnD REFUELING vApoR REcovERy (oRvRl
vApoR
.
RECIRCULATION
VALVE
(c}
{TWCI
('
IPRIMARY HO2S.
SENSOR 1l
.?) SECONDARY HEATED OXYGEN SENSOR
{SECONDARY
HO2S, SENSOR 2)
13] MANIFOLD ABSoLUTE PRESSURE (MAP)
sENsoB
i' ENGINE COOLANT TEMPERATURE
IECT) SENSOR
O INTAKE AIR TEMPERATURE
ITATI SENSOR
i6l KNOCK SENSOR {KS}
O oRANKSHAFT SPEED FLUCTUATIoN
{cKF} sENsoR
@
IDLE AIR coNTRoL (IAc}
VALVE
) THRoTTLE BoDy trB|
(D
FUEL INJECToR
O FUEL PULSATIoN DAMPER
[D FUEL FILTER
@ FUEL PRESSURE REGULAToR
! I FUEL PUMP I FP)
f,' FUEL TANK
(iD
ArR CLEANER
t' RESONAToR
'.1]i
POSITIVE cRANKcAsE VENTILATIoN
{Pcv} VALVE
11-28
Electrical
Gonnections
('96
-
98 Models,'99
-
00 Dl6Y5 engine with M/T)
(
I
.a:
arr .nd Drar, .nsrF
=.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.
{cou9.; .ll Dod.b..r!.t: lG nod.ll, sa Or6Y5 mdn',
' 10:
MfI lD1aV5 .ncir.l
rrt.
Exc.or M/I
(D15Y5.ntin.l
r12:
O16Y5. Ol6Ya.ncln.
rt5.
i9?
Ot0\., ssid l6up.;
(L
mod.l,..d..:
Kl ttxl mod.ll, 9a Dl6rr.ndn.
To A/C PlEStUnC 6wrctt
No, 13 l{ Et tU[9 ll5 Al
No. ri Al'ltElATOll
gt
lNtol lt,5 Al
t{o. 3l EtAatEn
gc
at lt.5 al
clEc{
.2.
Arr
pt6rt,
DraYt .nlh.t
.a:
AfI .nd Drart .ndn
o [rnEnoR UGtlT lt.s Ar
o
HoRx tr5 AF
o rcr l|o Ar
(cont ' d)
11-29
r:
h tL o.d..{ood io/t l.v bor
System Description
Electrical Connections ('96 -
98 Models,
,99
-
00
(cont'd)
PRESSURE
SENSOE
EGR
UFT
sENsoR
* 3
EGR
uF
D16Y5 engi ne wi th M/Tl (
SENSOF
solENoto vALvE
*3
wec soLeton vltve'!2
SENSOR
SPEED sENsoR' 2
COUNTEFSHAFI
sPEED sENsoR* 2
soeeloto vltve l*2
ToI|{TEFLOCK
CONTBOLUNIT
*l : t SA model
*2: A/T(DI6W, oi6y8 engine)
*3: CVT(DI 6Y5
6ngi ne)
1.4 : A"/T and Dl6Y7 engine
*5; Except A/T and Dl6Y7 engine
*6: A/T(O16YO engin6)
*7:CW(DI6y5
ongine) and D16y8 engino
*8;'96 Ol6Y8 sngine (coupe),
,97
D16y5
ongine
(coup:
all modol!, sedan: KL
modoD,
'98
Dl6Y5 engine,
'98
ot6Y8
en9ne
*9: D16Y5
engi n.
*10 : |!UT(D16Y5 engine)
*ll : Except iUT(Dl6Y5engine)
*12: D16y5, 016yo engino
*13: DI 6YO engi ne
*14: Dl 6Y7
engi ne
*15: ' 97
D16Y7 engi ne [ coupe: KL modet ,
ssdan: KL(LX) modetl,
'9gDt6y7
engine
c-rrusren vem srur vtvrlf;
ECM/ PCMA( 32P)
ECM/ PCi / l BEsP)
ECM/ PCMD( 16P)
1 1- 30
TERMINAL LOCATIONS
l-
[ *-
I
l-.i-*.,*,.
SEiV|qE CHECK
@NI\IECIOR
r-Bu(
f-*
@NI\ECIOR
(cont ' d)
ceor
1 1 - 3 1
System Description
Electrical Connections
('96 -
98 Models,
,99
-
00 Dl6y5 engine with M/T)
(cont'd)
ptozs'"
pozslttc*rr
WHT,'RED'l
s02sHTc
-BLK/WHT
aLKlyeL!
LraeL*ro
pozsntc*lu
: soL*3
BLU/ALK
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. ngi ne)
i7:
CVI {D l6Y5 Gosin.) .nd D16yo snqine
r8:' 96
DI6YB .ngi..
lcoup.),
,97
Dt6yl
ensio. (coups:
lll mod6ts, s.d6n. KL
dod6ll,' 98 D16y5 6ngine.,9a D16y8
ongi ne, ' 99 -
00 Ot 6Y5 ( M/ Tl onoi ne
' 9:
Dl6Y5 ongine
' 10:
M/T lO16Y5 engine)
' l
r: Ex@pt M/T (Dt6y5
engine)
r' 12:
Ot6Y5, Ol6Y8.ngine
' 15r' 97
D16Y7.ngine
{coupe: Kt- model, sedan:
(L (l-Ximod.l),
' 98
Dl6y7 angins
*12
Ho2s
(sENsoF
l)
c125
Ho2s
(sENsoR
2)
cr l s*' u
HO2S ( SENSOR'
c142
ecR cortnoL*3
SOLENOID VALVE
c14o
wrlaeo!{-L wrzneo.=r.:
GFN/ BLr-I
FcFN, wHr J
alvwrr'Ll ar-x,rvnr,
-ff
f--fi"-r".^'--] I
;lcnr-caz
fi
\
VTC PRESSURE
11- 32
PSP SWITCHI
c1t 7
atu/wHT
=..'-_
/ YEL J l r . ^ r ' \ - r I
wHr---]
FaMrr=ll

L_id-ll
8r-x,--L- |
CAI\IISTER VENT
tr--+r
-*'
I
=
calT
_
66s' fr:-l
l - BL! ( - - -
-
l f . a
-
I
CLUTCH SWTCH'X
_-o_
I
(cont ' d)
1 1- 33
IT GRN/WI{T
ctor
System Description
Electrical Connestions
{'96
- gB
Models,
,99
-
00 Dl6yS engine with M/T)
(cont'dl
rDic M
ct(P P
CXP M
RET'
YEUGifl
CIG M
\
lhx/
ALJ(I
&
l ' l
A
L: ]
12:
A/t tD16Yt, Dt0Y8.ncin.t
13:
C1/t lDtOYS ssin.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.
sN90fi
I
I
rDc
sEt\tsoi
I
I
cxP
FI F']E E
T T i T
8At{/ aR / !R|{/ AAX/
11- 34
LC B'
(cont ' d)
1 1- 35
NCSC'
L
System Description
('96
-
98 Models,'99
-
00 Dl6Y5 engine with M/Tl
(cont'dl
GA|l/OfiN
Cl3i C,ta6
cart c5o2
t--l
c5t2
o",.uonr.
l FSIX' {
|
| FYEI l
g
. l
c5t0
GRN/aaX: r
dYEr .
I
LrGiN'
-
8rK/8ru
-
BEo
- -J
I
GRN-_' -
8ru'--1
Orl0 C50il
LT
IYTENLOC|(
CO TROT UMI
FronIAD|AtOh FAx
T'
-
RElAv EqtswIrEH
BLu/REo,-
l f
B!u/FEo,-----l ro a/c swrrcH
t_.1
,10:
M/T {D16Y5..sin.l
.11:
Erc.pt M/l lOr5Y5.nginel
' 12:
Ol6Y5, DlSYa.ngin.
' 15:
97 Dl5Y7.ngin. {coup.: Klmod.l, $d.n:
(l
lLXlmod.ll, 9A DIOYT.nsin.
GRN/BIXI.
-
LT GRflr-
T
8r"K/8ru
f"*
f r
ct3t c&t6
12:
A/l (Dr5Y7,
Dl6Y8.nglnel
r3:
CyI lOl5Y5..sinel
' .:
A/T.nd Dr6Y7.nsin.
15:
Erc.pt A/T .nd D16Y7.ngin6
' 5r
A/i {Dl6Ya.nginl
17:
CVT (D16Y5
.noin.) rnd O16Ya .ngine
' 8r' 96
015Y3 .ngin. lcoup.), 9t O16Ya sngin.
( coop. r . l l nod. l . , . . d. n: KLmod. l ) ,
98ol 6Y5o. gi ns,
' 94
Di6YA .ngin.,
' 99
-
0O D15Y5 lM/Tl 6ngin.
".*,".u---f
REo--__-
YEri
-
Gur{
-------
Brur-
-
l
L
-
Etur
ArGEAR ?O6frO Swlrcs
1 1- 36
UGIfI &AMRY
o5A) 60a)
A//C CIUICH
-wHT/gtU
c354
-BLVRED
-
GRN/REO
f "*
F*n*
-*r
-l
I lsrc
Aros^
|
f*-__l I
| i i l ?-\ . p--l I
I
n c B
l l l
I FI JEL PI I / | P I I I
l n * l l l
t l
n l
l5-,- i I
I
Na15
| |
l arlnrl Ton l L l
I
sPsE*soa oia
l l
l <\ - , o l i l
I
NczsMErER
I
I
05$
|
F- l
*t*'fi
8ru/wHr
-.1
YEUGRN
a
".-;"{
BtK,$rtf
t
'*+
u oR.HOOD
FUSE/REIAY BOX
uN0n-oAsH
FTJSE/FEIAY BOX
(cont' d)
11-37
ct31
WH' /ALU
System Description
('96
-
98 Models,
'99
-
(cont'dl
atu
EVA? EVPASS
I " l
f
AED
F]
T
RD/
GRII
c13r c4a6
o.3a
r- r---------------
_ l t
I
-
t | |
l l
r c r r
I
-
1 |
{
|
J t I
t t I
]-t
r
ol25
Srli$},
'AAXE SWIICH
GRt{n'Y}rP-___-.l
)
caQ
Lll
lrl
I l J/c
--
. t l
i - l
'2:
A/T {Dl6Y7, 016Y8.ngin.)
,3:
CW {Dl6Y5.nsin.l
14:
A/T rnd DIGYT lnginc
'5:
Ex6pt A/T.nd O'l6Y7.ngin
'6r
A/T (Ol6Yg
cnsin.)
rtrCvI
lol6Y5 .ngin) .nd Ol6Y8ngin.
18:'96
O 16Y8 .ngin. lcoup.l,
'97
Dl6Y8.nein.
{coop.: .ll mod.l., t d.nr KL mod.t,,'98 Dr6Y5.ngin6,
'98
Dr 6YE .nein.,
'!Xl
-
0O O16Y5 {M/T).ngin.
19:
Dl6Y5.ngin6
r l 0:
M/ T { Dl 6Y5. ngi n! )
il1:
Exc.pt M/r {Dr6Y5 anginl
' 12:
Dl6Y5, 016Y8.ngin.
' 13:
O l6Y8 angin.
' 1a:
Ol 6Y?. ngi n.
' 15:' 97
Dl6Y7..qin. (coup:
Kl dod.t, sd.n:
Kl (Lx)
mod.l), 98 D16Y7 6ngin.
1 1 - 3 8
Electrical Connestions
('99
-
00 Models except Dl6Y5 engine with M/Tl
L ChUISE COXTnOI UNII
lo CO|IPi33OR CUrrcH BEI Y
lo A/c PRESSUiE alYrc|l
To FAoIAIOR FAI REL Y EcT3wllcll
SENSOF
FIJSES:
(D
IN1ERIOR UGHT O5A)
'
@ BACK UP O5A*
@HonN
(15A).
(DSATTERY
OOA*
@ rcl
(104*
@FrvM
(r5A*
@No. I3FUELPLMP
(lEA)
@ No. 25 MEIER CrsA)
@ ib. 15 ALTERNATOR SP SEI{SOR OJA)
O ib. 3l STARTER SIGML
(75A)
':
h lhc ud.rhood lu..//rcbY box
(cont' d)
1 1 - 3 9
-:
T
)
I
FUEI II{JECIOBS
System Description
('99
-
(cont'd)
T:I
1
0
EVAP PURGE CONTROL
SoLENOtOVAIVE
c26 ECT
ECTSENSOR
D
EVAP COI{TROL CANISIE R
I ATSENSOR
ta-t
c25 tAT
HO2S
( sENSoFt
EVAP BYPASS SOI.ENOID VALVE
cl Po2s{tc
"Eso!
87
)w
EGF coNTRoL solENoro vaLvE'"
c16PHO2S
vl sBr 2
VTEC SOLEr{O|D VATVE
H02S
iSENSOR 2) ,w
A23 SHO2S
VTECPFESSUFESWITCH
sEt{soR
-t
,.1 f
I
BRAKE SWITCH
c7 sG1
SENSOB
(Buln
l o F
@E
lfil
*
_r
/V\
|
GAUGE
* l assEMBL
I
I
l-
SPEEOSENSOR
tr
D5VBSOL o4tND A14
N DTI
NC DTO
SPEEDSENSOR
LS+ Bl 7
UNEAR SOLENOID VALVE
T'I AT?04 LS- a3
LOCI
P r .
l
03alP03
LCA 01
P CONTBOISOIENOiDVALVE B
LCB 03
IOI{IROL SOLENOID VAIV A
SHIFI COTITROL SOLENOID VALVE B
SHE D2
POStTtON
t - - - -
I
To IIIT!FLOCK CONTROL UNIT
- - t
L
l -
I
I
11-40
- . . _. . _. . _. . _l
, ' -J
- '
GAUGE
ASSEMALY
DRIVE PULLEY
SPEED SENSOR
ORIVEN PULLEY
SPEED SENSOR
SECONOARY
GEAB SHAFT
SPEED SENSOR
SOLENOID
To INTERLOCK CONIBOL UNIT
*l : USA model
*2: a/T(D16Y/, D16Y8 engine)
,.3: CW(016Y5 engine)
*4: A/T and D16W engine
*5: Except A/T and Dl5Y7 engine
*6: Cw(Dl6Y5 engine), Dl5Y8 engine and 816A2 engine
(cont ' d)
11- 41
EcM/ PcMA( 32P)
EcM/ PcMB( 25P)
7 I I 1 0 1 1
t 4 16 171 81 92012122 23 24
ECM/ PCMC( 31P)
ECM/ PCMD( I 6P)
I
TERMINAL LOCATIONS
System Description
('99
-
00 Models except D16Y5 engine with M/Tl
(cont'dl
UFTSENSOR
L
ABS CONTROL UNIT
CONI{ECTOR
-
BLX
_r
"*
\
sEnucE cSEcK
CONNEC'OR
11- 42
aLul-
_--r
".*
"to'
f
*31ou..."
I
t "on"t"to"
I
lll*,
llo2s (sENsoR
t
SECONOARY
HO2S (SENSOR 2)
I-
wrrzneo'f15151
FCA
,a[HT
-]
f- I
FELWWHI.- FFi/v\^- I
F ETJVWrfT'--I l+ |
HO2S (gENSOR 2)
\-
11-43
System Description
Electrical Gonnections
('99 -
00 Models except Dl6yS engine with M/T)
(cont'd)
cad__J
neozvef-
-l
q30
1""
h/wFDl
t + l
-l
vss
EVAP CONTROL
CANISTEF VENT
SHUI VALVE
l,,"
I
Fl
T
I
|
"u,
LB|.X'--Jf-ll
PsP swrcH'
VTEC
soLEt{oto
VALVE
cl i a
BLTC.YEL
----J----]
neo,"yrr.'--{l-
---5
|
EVAP PUBGE
CONTROL
SOLENOIDVALVE
clat
11- 44
-E--l
| ^
qYP
I
I Y $rsoi I
- l
I
I / . Jr Dc I
I Y
SEr$Oi
I
I
t l
f--A
o'
I
I
v)
sEr,rsoi I
I
|f-------l I
l l
' cM
| |
_L:_---J
DIgIRIBUTOR
CKFSENSOR
FI
--
I
AFN/
ar-xl
til
|-
EiN/
ELxl
BRN/
B!K'
,l
o l
EFN/
aLKl
;q
L P I
BFN/
ar-xl
J-
I * l
I
(cont ' d)
tr:-l
t E l
T
I
I
BRN/
ELxt
11-45,
System Description
('99
-
(cont'd)
cl09
racvP*{
-
BLK/eLu
-l
q t
p l
MAINSHAFT SPEEO SENSOR
cl l a
COUN' IERSHAFTSPEED SENSOR
c121
t t I I
UNEAR
SOLNOIDVALVE
SOLENOID VALVE
--
11- 46
" f
I
' - L
' ORN
YEL
iFx/
I
Lll
c!o4 crro
qF
/ELKT
lrcnf
RED
GiN
aLuT
wnnrd#"Si "*f i [ *
BLU GR +
"
35111'o,- u",,
CnXr#
F 'h MDIA'OR FAr{ FELAY'
I
(cont' dl
At cAR PO3tllOl{ SWlrCH
BLI,IREO +
To A/C SwlICH
11-47
System Description
('99 -
(cont'dl
DRIVE PULIEY SPEEO SENSOF
SECONDAFY GEAF
SHAFT SPEEO SENSOR
SCLSM
INHSOL
PNK/BLK
YE!'
PNK/BIU
cnvauC
c131 CrKa
GFN/Brf I f cnvsuC
L_
,T GEAF POSII|ON SWITCH
11-48
A/CO-UfAl
ELD' '
;:l
T
BLK
YEVGRI{
UNDER-HOOD
FUSE/RELAY BOX
UNDER-DASH
FUg/FELAY AOX
(cont' d)
BLtCWlfi
-
*tT
sLrc\t/trt
1
BLvwHr
1
c501
r..
-{
11-49
System Description
Electrical Connections ('gg -
00 Models except Dl6y5 engine with M/Tl
(cont'd)
CsO5 -r-\
-
YELI6RN
f/ \
I t P I
'-
BLK
__1\
/
I
\'----l
Ft,EL PUMP
EVAP BYPASS
SOLENOID
VALVE
ft ti-l
I l J/ c T
T__l I
t.] I
c425
__
I
LwHr
GRN
{-l
_cnnzwm'_{h\_,
I
aBAKE StlflTCB
*l : USA mod6l
*2: A/T(Di6W, Dt6Y8 engine)
*3: CW(DI6Y5 engino)
*4: A,rT e16 915y7 "nn,n"
*5: ExceB AfT and Dl6Y7 engine
,16:
Cyr(DI6Y5 n9ine), D16y8 engine and B,tOA2 engins
*7: Dl 5Y8, 816A2 engi ne
Elt^-l
'tF'tF
q23
r_
c446
I
L
vever-u
-
l l--
,.,- ,.u
t | l
L--
cnrzer-rc-{f
cnnzar-x,
YEL/GRN
YEVELU
-
YEL/GRN
-
YEVBLU
lr cat'
_
LT GRN2
qar/auC - qaN/eud
BLVWHf
-
BLK/WiT
BLIII
-
BLul
1 1- 50
System Connectors [Fuel
Pumpl
'95
-
98 models,
'99
-
00 Dl6Y5 engine with M/T:
ffi
c565
E
c792*r,.'5 c793|.,.s
*1r
USA modl
'2:
A/T {O16Y7,
D16Y8 ensine}
13:
CVT {O16Y5
ensinl
*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, sd.nr KL modell,
' 98
Dl 5Y5. ngi ne, ' 98
D16Y7 engi ne,
'99
-
OO Dl6Y5
(M/Tl engine
r9:
D16Y5 ongine
t 10:
M/ T { D15Y5 ensi nel
r 1t :
ExceDt M/ T
( D16Y5 engi ne)
t l 2:
D16Y5, Dl 6Yg engi ne
*13:
Dl 6Y8 engi ne
r14:
D16Y7 engine
*15:'97
Dl6Y7 ensine {coupe:
KL model, sodan:
KL
(LX) modeu,'98 Dt6Y7 engine
NOTE: . Di fferent wi res wi th the same col or have been
gi ven a number suffi x to di sti ngui sh them
(for
exampl e' YEUBLK1
and YEVBLK' are not the samel .
. O: Rel ated to Fuel and Emi ssi ons System'
.
-
Connector wi th mal e termi nal s
(dou
bl e outl i ne): Vi ew f rom term i nal si de
-
Connector wi th femal e termi nal s
(si ngl e outl i ne): Vi ew from wi re si de
c7931...15
ffi
1 1- 51
System Description
System Connectors
IEngine Compartment]
'96
-
'98
Dl6Y5, Dl6Y8 engin,
'99
-
O0 Dt6y5 engine wirh M/f:
I
:
i r
I
11-52
\
Cl0,r
{C.nadal
r'fr]
l6mrrrnru I
ElilrwA----l
lTltHtBtu__l
:lo.
l ' l r l
l r l . l
c109..
r'frtr
16lonl
-l
l @LYEUBLK' I
bfgl-rcgtu'---l
c102
r'Trtt
l6lwtr,eED'
_-l
E|BFIvBLK
-l
l6lga-tnEcl--l
c105
Etr
c106
ffi
c114
fr
c108
ffi
c107
ffi
Bf f i f f i
c113* 1
ffi ffi
,DGRN/BLK'
(9
LT GRN?
BLU]
3
8
NOTE:
. Di fferent wi res wi th the same col or have been
(for
6xampl e, YEUBLK1
and YEUBLK' are not the same).
. O: Rel ated to Fuel and Emi ssi ons Systm'
.
-
(doubl e
outl i ne): Vi ew from termi nal si de
-
(si ngl e outl i ne): Vi ew trom wi re si de
(cont ' d)
1 1 - 5 3
c1a2.r
fr
System Description
System Gonnectors
[Engine Compartmentl (cont,d)
36
-
98 Dl6Y5, Dl6Y8 engine,
,99
-
O0 Dt6y5 engine with M/T:
t (
I
I
I
I
C1,&r.3
c139r"
c120
c122
c354r1
G101
11-54
c1t 7
r'ffi]
f'TBLir-l
lO
BLX,YEI
I
l6lEtu^tHr__-l
c125
ffi
16lwrrin+o' t
liSlcFN/BLK I
16T8LK^'Er-- l
-.,IBaK,r
/Hr.
I
c141*'
___l:t_
l - l r l
I ' LT GRNA/VHT I
f,]-BLK,rEf-__l
cl 16
c1t 5
c l 11
c128.'
ffi
1618r-uf/EL-_]
161-cfl,avHr
-l
cl45rrc
Ft _
l-,T,ITd
t_-Ttli I
c127*'
fr
IFFEc'--__l
ftlwHn-'_l
-c,1*
t-El-r
l 1 I
2 l 3 l
l . l
' u l
16lvvrrr/BtK---.l
l gl cnN/ Br K,
I
l O
YEvBru
I
16r l srK' I
ET-
--
f+plr-,
-_l
c118"
ffi
trl-clrl---]
l atl IBLU, I
c126*'
ffi
fOTwHn-_-l
l Ol REo.
I
:.trn
.EL
[ t T, l . l
v
I i wHl/8tK I
lETc RNi BLF--l
ET-YtrrrruBiu-__-l
q]54't
r,f,"|
I i IBLK4/VHT I
l Ol s L K I
I O LGRN/ RED
I
c112
fr
c120
tdl
cnN/YEt--l
NOTE:
. Di fferent wi res wi th the same col or have been
(for
exampl e, YEUBLK'
and YEUBLIC are not the same).
. O: Bel ated to Fuel and Emi ssi ons System'
.
-
(doubl e
-
(si ngl e outl i ns): Vi ew from wi re si de
{cont' d}
c121*'
ffi
c123
ffi
c1a0rt
fr
l6lgrf,---_-l
I OI REB
I
c13!,.f
E
c122
i
YEUGFN o
BLU5 REO!
8L(,
YEL'
9 8t u
5 10 BLK/YEL
c351
1 1- 55
System Description
System Connectors
lEngine Compartmentl
{cont,dl
36
-
98 D15Y7 ngine:
\
' l '
1 1- 56
\,
c101
c102
f,ftl
I . WHT/ FED. I
| ? l EFN/ 8LK' I
f3TBr--/BEo-l
c107
EE
c1o4
c104
' 1 l canadal
ffi
r'ftl
l 3 l . l
c105
ffi
c106
ffi
c113* !
r=1
, ' l \
\2
l i GRN. I
ftELiJ
- -l
c108
ffi
c112
ffi
o GRNELKI
o
ELUT
3
1
I
Di fferent wi res wi th the same coror nave been
gi ven a number suffi x to di sti ngui sh
them {for
exampl e. YEUBLKl
NOTE:
o
a
O: Rel ated to Fuel and Emi ssi ons System
-
(doubl e outl i ne): Vi ew from termi nal si de
-
(cont' d)
11-57
f BLI(YEL
6 WHT/BLU
BLK'
YEVGflN
3 YEVBED I BLU
'4.
BRN/ 8LK'
BLK,A/VHT
.alYEUBLKi
l 0 BLKYEL
System Description
System Connectors
IEngine Compartment] (cont,d)
'96
-
98 Dl6Y7 .ngin.:
\
\
1 1- 58
I
c114
ffi
c109
r'ff;t
Flo-'u
I
l ! veugLx' I
ftFwatu;'--l
c123
ffi
cl 18 {A/T}
F l r l
I OI GFN' I
16l
Barr--
-
l
cl 17
r'ftr
fdl'.,c---_l
l ? BLKt Et I
b]-Br.-^^,Hr-_-l
cl24
(A/Tl
fr
lTlzRN,tsril I
l6l-YtL,
---l
l ol FED/wHr I
fd-cRN/8tK'_]l
cl 28l A/T)
F l , l
I C I SLU/ YEL I
161-Grr.,*1/Hl
I
Gt54*,
F1Eh
l ' l 3Ll J
l6ElKl,,/Hr-l
I6TBLK
-_l
I O LGRN/
RED
I
Di fferent wi res wi th the same col or have been
(for
exampl e, YEUBLK1
O: Rel ated to Fuel and Emi ssi ons System.
-
(doubl e
-
c141r 16
ffi
lO LT GBN,.VVHT I
161-BIK/YEL-_--l
c121 |AFI
ffi
16lwHr--l
l Ol REp
I
cl26
(A/Tl
fr
fol;nrr-_-l
l Ol REo.
I
c125
ffi
l 3 l . l
lTltHr/R$'
-l
loiiED/vEr--l
bfBaK/vEL- l
f!]BLX,1,,i HT' -l
NOTE:
o
a
L
t
YEUGNN
8LU5 o BEF
@ CRN: BIK3
YELl
9 BLU
5 10 8LX]"/E!
1 1- 59
System Description I
System Gonnectors
lDash and Floor]
'96
-
98 modols,
'gtl
-
00 Dl6yS engine with M/T:
1 1 - 6 0
crlo tA/Tl
v
6 t 7 8 l s l r o
' t l
12
tffii
ffi
lEr.r.r,ll
l 1 l sl x, ^/ t l ' I l l l r l nEo'
I
l l l sl ' ( ^, ! Hr
I
l ?I BLX I
13 wHT,aLK I
FF*
-]l
l-r-lw'r/cFNl'l
'
sdurnyAlrm sFr.m
c125
a:2'
w
l--r;-l
l! LcFN,.,vH? |
L]-]llg!N
,-l
l al wHr r esN I
l l l cRY I
l r l - | l ( J c RN^ nHP I
hl- - - l6ltHrGFN
--.1
csto |ArIl
BLK
Different wires with the same color have been
given a number suffix to distinguish them
(Jor
example,
YEUBLKT
NOTE:
o
a
a
and YEUBLK' are not the same)
o: Rel ated to Fuel and Emi ssi ons System'
-
-
(cont' d)
1 1 - 6 1
!t
BLX
5
BLU
22
YEL
System Description
System Connectors
lDash and Floorl
(contd)
'96
-
98 models,'99
-
00 Dl6Y5 engine with M/T:
(
c432*13
11- 62
(O16Y5, Dl6Y8.nlin.3l
lOl6Y?.ngir.l
ct33.r tFcM-B)
C134 {EC[r,l/FCMal
cr35lEcM/PCM-D)
NOTE:
e
f'Tfl'n
I-IBLffiHJ-I
ltlcRr'r/wlr
l]l
l-''lwHtREcp
-l
liELx/wNr'
--l
ca3l
ffi
Tttr-Ei
---
FltEtstK
ll
FfwNr/RED''_l
lTltHr/BL( l
ffi
@
F I r t
Irli I
tilwHT,"Ed-l
|
. lcFMMr
I
11 BLX^VHT' I
11
B!x.^rHr I
Di fferent wi res wi th the same col or have been
(for
exampl e, YEUBLKT
O: Rel ated to Fuel and Emi ssi ons System
-
(doubl e
-
(si ngl e
outl i ne): Vi ew from wi re si de
c t32 {ECt/r/pcM-a)
2 6 E 9 l 0 t l
12 t 3 l/a
'ts
t 6 17 1E l 9 20
24
25 21 2a 29 30
c{t3
l .
7
9 r o l r t 12 t 3
I 2 a l 5 8 9 t 0
l ! 12 13 1 7 t 8 l 9
11- 63
System Description
System Connectors
IEngine Compaftment]
'99
-
00 D16Y5
ICVT), D16Y8 engine:
cl 14 C142' 3
*1:
USA model
' 2:
A/ T {D16Y7, O16Y8 engi ne)
*3:
CVT l D16Y5 engi ne)
*4: A/ T
and D16Y7 engi ne
*5:
Except A/T and D16Y7 engine
*6:
CVT {D16Y5 engine).
O16YB engi n and
816A2 engine
*7:
D'|6Y8, 81642 engine
11- 64
f f i f f i
c108
NOTE:
. Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLK1
and YEUBLK' are not the same)
. O: Rel ated to Fuel and Emi ssi ons System.
.
-
(doubl e
-
(si ngl e
C11, t
r-E--r
1 1
2 l
cl 13* ,
A
\^y
|6IcFN;--l
FIBLr l
c109*.
'-l-t_,
l 1 l 2
3 l
lglE*
---l
I I YEVBLKI I
|5lBwBuJ-u--l
c137r'
c
c112"
ffi
c302
ffi
(cont ' d)
1 1- 65
c'r04
{Canada)
l r l 2
3 l
lSltHr/REo"
_-l
Fl
xrvef
ll
F]-wHrr+r/BLU I
_"1on
ffi
l 3
{ l
c101 c'r02
r'fil--dl
lElwHr/FED"-
lttl-R^r/BLr-
lSfBruritnEp -
c138' 5
e
System Description
System Conneetors
IEngine Compartment]
(cont'd)
'9!l
-
00 Dl6Y5
{CvT}, Dl6Y8 onginol
v
C14,0*3
c139
cl20
c1{{}
c122
1 1- 66
cl 17
l 1
2 l 3 l
|6l;LKr-----l
l Ol ELK, ^/ EL I
I
tlsLU^/vHl
ll
c112
t 1 l 2 l
121+'
F-i
l 1
2 l
c120r3
l 1 l 2 l 3 l 1 l
ffil
l 5 l 6 l 7 l E l
l6TE"^r"". 1
ItT"Eu I
Cl i t l
fr
l6lir
cFlr/wnT
I
ITIBL/./YEL
I]l
c147r3
fr
l6FEDl.ryxF_l
fdvi
Hr.
-
l
l6EnNta,
--.l
Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLKT
o: Rel ated to Fuel and Emi ssi ons System
-
-
c351
(cont' d)
11-67
1 8 BLK
o YEUELKI BLK'
YEVBLK] BLKI
YEUBLKI ELKI
o YEUELKI 0, ALKI
o YEVBLK'
(9
BLK'
YEVBLKI BLKJ
c123
l 1
2 l
m
FiiTwHr.
--l
l
cnN,,srr,
I
lt|sLKrElll
lolTlx,wH-r'
ll
c140
A
w
16lBLLliBLa--l
I6ELK'
--_l
c122
a
v
IoFED
//Hr--l
1olcnlriBirc I
c145.3
t . / t 2 t s a l
lffi
l 5 l c l 7 l 8 l
C35/a'1
f,ftf
16l
BLK/wHr
I
16lgl(
I-l
16lGBNinEo l
J. YEUGFN o
BLU' a REDl
.11 ALKI
o YEL'
5 t 0 8LK/YEL
c118*'
l 1
2 l
c125
rffil
trtr
Iij wHri FEDi_l
I a I GFN/ BLK, I
I 9
BLK, r yEL
I
l6ELK,wHr I
c143*3
ffi
ldElK
î Hrr_l
trlwirmEp, I
c126r' C.127.'
c128r'
f f i f f i f f i
ffi;F---- FlREo,-___l
El;*lvr.l
l , I RFD' I l r l wHr ' I l er l cRN/ wHr r I
c144*3
c145'3
_,q. ,---t
/-----f
11
2l
l r
t 2
3 J
\-/
I J I WHr/ BLK I l (1-] l 68N, I
|-|cFN,RLr<, I l6tFtj--reDtsLu ]
FIYEUR.I
--1
c352
1l5l
Lr/H-1-_r
t o l t r l l 5 l 0
/ i t
E l
it]
GRN/BLK]
o @ PNI(BLK
GRN/YEL3
(,
(9
PNVBLU
2
GRN 6 BLX'EL
1
3 WHT/BLK o
i, 9
o aL&aD
System Description
a
System Connectors
lEngine
Compartmentl
(cont'dl
'99
-
00 D16Y7 engine:
\
I
1 1- 68
I
c102
f'tr]
c101
c104*,
rftr
EE
C1oia
{Canade)
r'ffi-a
c10s
ffi
c106
ffi
c10B
ffi
c107
ffi
c112
ffi
c3o2
tu
NOTE:
. Different wires with the same color have been
given a number suftix to distinguish them
(for
example, YEUBLK'
and YEUBLK' are not the samel.
O: Rel ated to Ful and Emi ssi ons System.
-
-
(si ngl e
outl i ne): Vi ew from wi r si de
(cont' d)
c113r '
a
a
a
11- 69
System Description
System Connectors
[En
gine
Compartmentl
(cont,d]
'99
-
0O D16Y7 ngin:
11- 70
c l 16
cl 10
c115
Di fferent wi res wi th the same col or have b6en gi ven a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLKl
c123
ffi
c11a
@
cl20
. . + , 1
l+'.1'+:l
c109
r'ft]
flofr-N
_-l
I t I YEUBLK, I
IEIBLvBLU'
I
c141
ffi
16T
Lr cRN^/v-H;l
161-BrxtEL-__l
c11E tA/Tl
l - l , l
l Ol GBN, I
f6lBr-r,--l
cl r 7
F1ftr
@fBLK-_-l
I a BLKTYEL I
|ol-Balro/Hl
-l
c121lAtfl
l - l r l
McnN/ BLK' I
f4tEr--
__-l
c125
rfrr
Etr
I t l wHri REo' I
ItrIRED/YEL,
_-l
bl BLK
Ea
-l
ftl
BLK^tHi'l
-
(doubl e
outl i nel : Vi ew from termi nal si de
-
(si ngl e
outl i n): Vi ew from wi re si de
NOTE: .
a
a
(cont' d)
11- 71
o 8TK?YEL .!l GBN/8TKI
2 BLICYEL o GffN/8TK1
BLK/YEL @GNN/aLK?
(t
BLfiEL o GRN/BLK
BLK/YEI 12
BLKJ^/EL !3 GRN/BLX'
8LK/YEL GRN/BLK'
c128
(A/Tl
_El-
I ' l
, l
I OI BLUryEI ' I
161-crNalrHr'
-l
(xlsarr
Ftr.T
l6ELffiHr-]
tr18!(
-___-l
l gl c RN/ REp I
c12t l[lTl
ffi
EIWHF
_l
l ( ?l REp, I
c126 lA/Tl
fr
EIwHI-__-l
l ) l FEp5 I
c352
c351
System Description
System Connectors
[Engine
Compartment]
(cont'dl
816A2 engi ns:
11- 72
c105
ffi
C10, 1
(Canadal
I r l z 3 l
16lwHrsEo.
-l
I 2
BLK/ YEL
I
ftlwHri
BLUIl'l
cl t 3
D
c123
ffi
l 3
4 l
c104
l 1
2 l
l-f.l
c102
F1+..r
l 1
2 3 l
ffl'wHnrD"
--.l
ItrERlxBLa__l
lo."llBurntotl-l
c101
C11i l
ffi
c137
a
c108
ffi
c107
ffi
c106
ffi
c302
tu
c138
A
v
FTBtKiBLtr__l
lZTYEuBLKi l
NOTE: o Di fferent wi res wi th the same col or have been
(for
exampl e, YEUBLKl
O: Rel ated to Fuel and Emi ssi ons Svstem. a
(cont' d)
11- 73
-
(doubl e
-
(si ngl e
.1' BLKYEL 6 WHT/BLU
e BLKI
1 YEUGRN
3 YEUREO 8
9 BLKryVFT
5l YEUBLKI
10 BLK,ryEL
BLK^/EL :d) GBN/BLK'
2 BLK/YEL GRN/8LK'
3 BLK,YEL GRN/ BLK'
rlj
GRN/BLK'
ELKTYEL 12
BLI(YEL rt GFN/BLK'
!l
System Description
System Connectors
[Engine
Gompartmentl
(cont'd]
81642 enginoi
v
11- 74
c122
A
,g
l-iln'eo*r,vHr__-l
l[lcRNiBLitl]l
cl 17
r'trTl
16lBLK,-__-l
lO BLX,\,E[ |
16l
Btu/wil-
c112
ffi
Cliro
o
C1'11
ffi
l6l-ciN/YEL'
_-l
NOTE:
. Di fferent wi res wi th the same col or have been gi ven a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLK1
O: Rel ated to Fuel and Emi ssi ons System,
-
(doubl e
-
c'54*1
f r l
z l s l
fflErKwH---l
l Ol BLr I
f6lGrrunEp
-l
11- 75
System Description
a
a
a
System Connectors
[Dash
and Floor]
('99 -
fil models except D16Y5 engine with M/Tl
L
11- 76
L
v1 s
8 l 7 l 6 l e t 0r
l ! 2 1
'
Scui tAr.h Sysi .m
cL5
lwithod
cruir. cort?oll
c510 ta/T)
;--F--
t r t 2 l
w
l-T
-
--l
l .
-
I
elz5
{with crui* codrol)
r'ffitr
1 3
r l
lElwHT"cRN I
YEL
f,ED/BLK .!
-
-
(si ngl e
Different wires with the same cotor have been
given a number suffix to distinguish them
(for
example, YEUBLKl
O; Rel ated to Fuel and Emi ssi ons System
D
t!
t-
NOTE:
o
a
a
(cont' d)
11- 77
t 2 13
t 5
5
14
i! aL(
LTATU
1
E t 0 t 1 ,/ ./ie /
1Al , / 20
2 a
9 t 0 l 2 13111 /
l 6 17 18
!t
t1t
2 3 I 7 a 9
10 1 1 12 t3 / l r 5l /
18 t 9
12
YEL
YEL 3LK
2
System Description
System Connectors
lDash
and Floor]
(cont'dl
('99 -
00 modls oxcpt Dl6Y5 ongine with M/T)
11- 78
c130
I 10
l 1 12 13 1,4t 5 t a 11 t 8 t 9
ct 3r
1 l z 3 l t / X 6 1 7 8 9 t o
cr34 tEcM/PCM-C)
cr35 lPCM-Dr: cr35lPcl|.D,
ca32
l r
2 3 . 1
IiGTNiBN
Ill
l5l-wxr,nol]l
l:a BLX vHI I
NOTE; . Di fferent wi res wi th the same col or have been
(for
exampl e, YEUBLK1
and YEUBLK, are not the samel .
O: Rel ated to Fuel and Emi ssi ons Svstem.
-
(doubl e
-
(si ngl e
l r l 2 l
lll*
-_-l
t n
B s I
c1a
l r
2 l
f.fil
,bl onrrwlrl.l
ftlBLrwHri-
Flirx,lvHJ
l]-l
c,|52 tEcM/PCM-Al
\-
a
' t /
3 l - 1 . 5 1
/ t g
to
'lt
12 l 3
2 a t 6 I E e t | 0
111'12I t I t I t [ l
11- 79
System Descriptions
System Connectors
lFuel
Pump]
('9!, -
00 models 6xcept Dl6Y5 ongino with M/T)
\
(
I
c568
ffi
c565
E
c792
Di fferent wi res wi th the same col or have been gi ven
a number suffi x to di sti ngui sh them
(for
exampl e, YEUBLKI
and YEVBLK, are not the same).
-
(doubl e
-
Connector wi th femal e termi nal s (si ngl e
c793
fr
NOTE: o
a
a
1 1- 80
Troubleshooting
Troubleshooting
Procedures
How To Begi n Troubl eshooti ng
When the Mal functi on Indi cator Lamp
(Ml L)
has been reported on, or there i s a dri veabi l i ty
probl em, use the appropr' -
ate orocedure bel ow to di agnose and repai r the
probl em'
A. When the MIL has come on:
,1.
connect the Honda PGM Tester or an oBD l l scan tool to the 16P Data Li nk connector
(DLC)
l ocated near the l eft
ki ck
panel .
2. Turn the i gni ti on swi tch ON
(l l )
3. Check the DTC and note i t. Al so check and note
the freeze trame data
Refer to the Di agnosti c Troubl e Code Chart and
begi n troubl eshooti ng.
NOTE:
. Seet heoBD| | scant ool or HondaPGMTest er user , smanua| sf or speci f i coper at i ngi nst r uct i ons. .
. Thescant oo| ol t est er canr eadt heDi agnost i cTr oub| ecodes( DTc} , f r eezef r amedat a, cur r ent dat a, andot her
Engi ne Control Modul e
(ECM)/Powertrai n Control Modul e
(PCM)
data'
oFr eezef r amedat ai ndi cat est heengi necondi t i onswhent hef i r st ma| f unct i on, mi sf i r eor f ue| t r i mma| f unct i on
was detected. l t can be useful i nformati on
when troubl eshooti ng'
B. When the MIL has not come on ,
out there i s a d ri veabi l i ty
probl em, refer to the Symptom Chart on
page 1 1-84'
c. DTcswi | l bei ndi cat edbyt heb| i nki ngof t heMa| f unct i on| ndi cat or Lamp( M| L) wi t ht hescsser vi ceconnect or con.
nected.
Connect the SCS servi ce connector to Servi ce Check Connector as shown
(The
2P Servi ce Check Connector i s
| ocat edunder t hedashont hepassenger , ssi deof t hevehi c| e' ) Tur nt hei gni t i onswi t choN{ | | ) '
OBO ll SCAN TOOL ol
HONOA PGM TESTER
SERVICE CHECK
CONNECTOR I2P)
scs sERvlcE
(cont'd)
MALFUNCTION
I NDI CATOR
LAMP
DATA LINK CONNECTOR Il6PI
07PAZ
- (x)l0100
1 1 - 8 1
Troubleshooting
Troubleshooting
Procedures (cont,dl
l l , Engi ne Control Modul e (ECM)/powertrai n
Control Modul e
(pCM)
Reset
procedure
NoTE: Resetting the EcM/PcM will erase any stored DTcs and any freeze data. lt will also restart all readiness code
moni tors.
Ei ther of the fol l owi ng
acti ons wi l l reset the ECM/PCM.
.
Use the OBD l l scan tool or Honda
pGM
Tester to cl ear the ECl M,s/pCM,s
memory.
NorE: see the oBD l l scan tool or Honda PGM Tester user' s manual s for speci fi c operati ng i nstructi ons.
' Turn the i gni ti on swi tch oFF. Remove the BACK uP
(7.5
A) fuse from the under-hood fuse/rel ay box for 10 sec-
onds.
NorE: Bemovi ng the BACK uP
(7
5 A) fuse cancel s the cl ock and the radi o presets.
Make note of the customer,s
presets
so you
can reset then
l l l . Fi nal Procedure (thi s procedure
must be done after any troubl eshoottng)
1. Remove the SCS Servi ce Connector i f i t i s connected.
NoTE: If the Scs servi ce connector i s connected and there are no DTcs stored i n the EcMi pcM, the MtL wi l l stay
on when the i gni ti on swi tch i s turned ON 0l ).
2. Do the ECM/PCM Reset
procedure.
3. Turn the i gni ti on swi tch OFF.
1-82
l f the i nspecti on for a
parti cul ar code requi res vol tage or resi stance checks at the ECM/PCM connectors, remove the ri ght
ki ck
panel . Pul l the carpet back to expose the ECM/PCM. Remove the ABS control uni t i f so equi pped. unbol t the EcM/
PCM bol t. Turn the i gni ti on swi tch oFF, and connect the backprobe sets and a di gi tal mul ti meter as descri bed bel ow
check the system accordi ng to the
procedure descri bed for the appropri ate code(s) l i sted on the fol l owi ng
pages'
The i l l ust rat i on
shows
'96
-
'98
models.
How to Use lhe Backprobe Sets
connect the backprobe adapters to the stacki ng
patch cords, and connect the cords to a mul ti meter. usi ng the wi re i nsul a-
ti on as a gui de for the contoured trp of the backprobe adapter.
gentl y sl i de the ti p i nto the connector from the wi re si de
unti l i t comes i n contact wi th termi nal end of the wi re'
BackProbe
BACKPROEE SET
07SAZ
-
001000A lTwo
DIGITAL MULTIMETER
(Commercially
avail.bleI or
Ks
-
AHM
-
32
-
oo3
(cont'd)
KICK PANEL
1 1- 83
Troubleshooting
Troubleshooting
Procedures (cont,dl
CAUTION:
. Punqturing ihe insulation on a wirs can cause poor
or intermiftent electricar connections.
I Bring the testr probe
into contacl with the terminatlrom
the terminal side of wire harnesg conncctors in the
gngin
compartment. For temale connectors,
iust
touch lightly with the tester probe
and do not inse.t the probe.
\ I
RUBBER SEAL
Other Probabl e Causes for an engi ne that wi l l not start:
-
Compressi on
-
Starti ng system
-
l ntake ai r l eakage
-
Overheati ng
-
Engi ne l ocked up
-
Battery
-
Ti mi ng bel t
TESTER PROBE
Symptom Chart
Li sted bel ow are symptoms and probabl e
causes for probl ems
that Do NoT cause the Mal functi on i ndi cator Lamp (Ml L)
to
come on. l f t he MI L was r epor t ed on, go
t o page
11_81.
Troubl eshoot each probabre
cause i n the order ri sted
(from
reft to ri ght) unti r the symptom i s eri mi nated.
The probabl e
cause and troubl eshooti ng page reference can be found berow.
L
*:
' 99
-
00 model s
TERMI NAL
SYMPTOM
PROBABLE CAUSE
4, 2, 3, 5, 20, 14, 1
2, 4, 11, 16, 13,
' t9
?, s^6. 16
1 , 8 , 1 0 . 9
Engi ne wi l l not sta rt
Hard starti ng
Col d fast i dl e too l ow
Col d f ast i dl e t oo hi gh
l dl e speed fl uctuates
7, 8, 10. 9
Troubl eshoot for mi sfi re on pages
l 1-166, 167
Mi sfi re or rough runni ng
LOW power
E"g| * "t "l b
2,9, 10, 12, 11, 16,
' t8,20
2 , 4 , 1 1 , 7 , 2 0 , 8 , 5 , 1 5
' t9,
21
1r, , 1
Di ffi cul t to refuel *
Fuel overfl ows duri ng refuel i ng*
11- 84
Probable Cause List lFor
th DTC Chart, see
page 11-971
*:
' 99
-
00 model s
Probable Gause
Page
System
1
1 1- 107 Engi ne Control Modul e
(ECM)/Powertrai n Control Modul e
(l ' uM)
PGM-Fl mai n rel ay
l ^ ^ i t i ^ n cwet am
2
11-230,231
3
' t' t-237
Secti on 23
5
1' 1- 172, 183
Crankshaft Posi ti on/fop Dead Center/Cyl i nder
Fosl tl on sensor cl rcul r' Lr\F sel rsor
ci rcui t
Intake Ai r Temperature
(l AT)
sensor ci rcui t
l dl e Ai r Control
(l AC)
Val ve
l dl e speed adj ustment
Throttl e bodY
Throftl e cabl e
Mani fol d Absol ute Pressure
(MAP) sensor
Throftl e Posi ti on
(TP)
sensor
Barometri c
pressure
(BARO)
senso'
Mf
g"a, po"i ti on si gnal
(see page 11-216) or cl utch swi tch si gnal
Brake swi tch si gnal
Ai r Cl eaner
l ntake ai r
pi pe
Three Way Catalytic Converter
(TWC)
Evaporati ve emi ssi on
(EVAP)
control
Contami nated fuel
ORVR vent shut val vs
' t 1- 124
7
1 1- 194
I 11-220
-
223
11-241
' 10
11-244
1 1
1 1 - 1 1 5
12
11-132
1 3
' t 1- 178
1 4 Secti on 14. 11-218
1 5
11-210
16
' t 1- 244
18
11-252
1 9
11-261
20
21*
11- 296
(cont ' d)
11- 85
Troubleshooting
Troubleshooting
Procedures
(cont,dl
ECM/PCM Data
By connecti ng the OBD l l scan tool or the Honda
pGM
Tester to the l 6p data l i nk connector (DLC),
vari ous data can be
retri eved from the EcM/PcM. The i tems Ii sted i n the tabl e bel ow conform to the sAE recommended practi ce.
The Honda PGM Tester al so reads data beyond that recommended bv SAE.
understandi ng thi s data wi l hel p to fi nd the causes of i ntermi ttent fai rures or engi ne probrems,
NOTE:
'
The
"operati ng
val ues" gi ven
bel ow are approxi mate val ues and may be di fferent dependi ng on the envi ronment and
t he i ndi vi dual vehi cl e.
. Unl ess noted otherwi se,
"at
i dl e speed,, means i dl i ng wi th the engi ne compl etel y warmed up, Ay' T i n posi ti on
@
or
E],
M/T i n neutral , and the Ay' C and al l accessori es turned off.
(
Data
Description
Operating Value Freeze Data
Di agnosti c
Troubl e Code
(DTC)
l f the ECM
/PCM detects a probl em,
i t wi l l store i t as a
code consi sti ng of one l etter and four numbers.
Dependi ng on the probl em,
an SAE-defi ned code
(poxxx)
or a Honda-defi ned code (Pl xxx)
wi l l be outDut to the
rester.
l f no probl em
i s detected,
there i s no output.
YES
Engi ne Speed The ECM/PCM computes engi ne speed from the si gnal s
sent from the Crankshaft Posi ti on sensor.
Thi s data i s used for determi ni ng the ti me and amount of
fuel i nj ecti on,
Nearl y the same as
tachometer i ndi cati on.
YES
Vehi cl e Speed The ECM/PCM converts pul se
si gnal s from the Vehi cl e
Speed Sensor
(VSS)
i nto speed data.
Nearl y the same as
speedometer i ndi cati on
YES
Mani fol d
Absol ute
Pressure
{MAP)
The absol ute pressure
caused i n the i ntake mani fol d bv
engi ne l oad and speed.
Wi th engi ne stopped:
Nearl y the same as atmo-
sphefl c pressure
At i dl e speed:
24
-
31 kPa
(180 -
280
mmHg, 7. 1
-
11. 0 i nHg)
YES
Engi ne Cool ant
Temperature
(ECT)
The ECT sensor converts cool ant temperature i nto vol t_
age and si gnal s the ECM/PCM. The sensor i s a thermi stor
whose i nternal resi stance changes wi th cool ant temDera_
ture. The ECM/PCM uses the vol tage si gnal s from the
ECT sensor to determi ne the amount of i ni ected fuel .
Wi th col d engi ne:
Same as ambi ent temper,
ature and IAT
Wi th engi ne warmed up:
176
-
194.F
(80 -
90.C)
YES
Heated Oxygen
Sensor
{HO2S)
(Pri mary,
Sensor 1)
(Secondary
Sensor 2)
The Heated Oxygen Sensor detects the oxygen content
i n the exhaust gas
and sends vol tage si gnal s to the
ECI\4/PCM. Based on these si gnats, the ECM/pCM con_
trol s the ai rl fuel rati o. When the oxygen content i s hi gh
(that
i s, when the rati o i s l eaner than the stoi chi ometri c
rati o), the vol tage si gnal i s l ower.
When the oxygen content i s l ow
(that
i s, when the rati o
i s ri cher than the stoi chi ometri c rati o), the vol tage si gnal
i s hi gher.
0. 0
-
1. 25 V
At i dl e speed:
about 0.1
-
0.9 V
NO
( Sensor
1)
1 1- 86
Data
Descriotion
Loop status i s i ndi cated as
"open"
or
"cl osed"'
Cl osed: Based on the HO2S output, the ECM/PCM deter-
mi nes the ai rl fuel rati o and control s the amount of i nj ect-
ed fuel .
Open: l gnori ng HO2S output, the ECM/PCM refers to si g-
nal s from the TP, MAP, and ECT sensors to control the
amount of i nj ected fuel .
The air/fuel ratio correction coefficient for correcting the
amount ot i nj ected fuel when H02S feedback i s i n the
cl osed l oop status When the si gnal from the HO2S i s
weak, short term fuel tri m
gets hi gher, and the ECM/PCM
i ncreases the amount of i nj ected fuel The ai rl fuel rati o
gradual l y gets ri cher, causi ng a hi gher HO2S output
Consequentl y,
the short term fuel tri m i s l owered, and
the ECMi PCM reduces the amount of i nj ected fuel
Thi s cvcl e keeps the ai rl fuel rati o cl ose to the stoi chi o-
metri c rati o when i n cl osed l oop status'
Operating
Value F eeza Data
HO2S
Feedback
Loop Status
At i dl e speed: cl osed
YES
Short Term
Fuel Tri m
! 20%
YES
Long Term
Fuel Tri m
Long term fuel tri m i s computed from shon term fuel
tri m and i ndi cates changes occurri ng i n the fuel suppl y
svstem over a l ong
Peri od
l f l ong term fuel tri m i s hi gher than 1.00, the amount of
injecGd fuel must be increased. lf it is lower than 1 00'
the amount of i nj ected fuel must be reduced'
! 20%
YES
l ntake Ai r
Temperature
{IAT)
The IAT sensor converts i ntake ai r temperature
i nto vol t-
age and si gnal s the ECM/PCM. When i ntake ai r tempera-
ture i s l ow, the i nternal resi stance of the sensor
i ncreases. and the vol taqe si gnal i s hi gher'
Wi th col d engi ne:
Same as ambi ent temPer'
ature and ECT
YES
At i dl e speed:
approx. 10 %
YES
Throttle
Posi ti on
Based on the accel erator
pedal posi ti on, the open' ng
angl e of the throttl e val ve i s i ndi cated
l gni t i on
Ti mi ng
l gni ti on ti mi ng i s the i gni ti on advance angl e set by the
gCV/eCV.
tn"
gCU/PCM
matches i gni ti on ti mi ng to the
dri vi ng condi ti ons.
CLV i s the engi ne l oad cal cul ated from the MAP data'
At i dl e speed: 12' i 2'
(81642
engi ne: 16" t 2")
BTDC with the SCS ser-
vice connector connected.
NO
Cal cul ated
Load Val ue
{CLV)
At i dl e speed:
1 5 - 3 5 %
At 2.500 rpm with no load:
12
-
30%
YES
r o
11-87
Troubleshooting
E n gine/P_o,weft
ra in Control Module Term inal Arra n gement
(' 96 -
98 Model s,
' 99
-
00 Dl 6yS
engi ne wi th M/T)
-
ECM/PCM CONNECTOR A I32PI
1
I NJ6
2
INJ3 INJ2
1
I NJl
5 6 7 I
LG1
1 0
PGl
l 1
I GPl
1 2
ACV
13 1 1 1 5
PCS
1 6
FLR
17
acc
18
MI L
19
ALTC
20
tcM
22
PG2
21
I GP2
27 2A 25
VSV
30
SLU
ECM/PCM CONNECTOR A
(32P)
' 2:
A./T
(D16Y7,
016Y8 engine)
13:
CvT (D16Y5
enoin)
' ,4:
A/T and D16y7 engine
*5:
Except A/T and D16Y7 nsine
' 6r
A/T
(D16Y8
ensine)
' 7
Cw 1D16Y5 eng, nel and D16y8 ensr ne
'"'3:Bi..I?'Jt;".'e'.!ti.?i?l'""."T8"_";btfr
"fl
1- 88
Wi r e si de of f emal e t er mi nal s
NOTE:Standard battery vol tage 1 2 t s
' 10i
i,4/T
(D16V5
engine)
r 11
Ex. ept M/ l ( D16V5
enqi nel
r 12:
016Y5, D16YB enqi ne
r 15: ' 97
016Y7 engi ne l coupe: KL modet , sedan: KL ( LXl
modet ) ,
' 98
D16Y7 engi ne
1
1
Sign.l
YEL l NJ4 ( No. 4
FUEL I NJECI OB) D ves No 4 ruel injector.
Wi l h engi ne r unni nq: ddl y coni r ot ed
2 BLU l NJ3 l No. 3 FUEL TNJECTOBJ Dr i ves No. 3 l ue I nt ecl or .
3 8ED I NJ2 ( NO,
2 FUEI I NJECTON)
Drives No. 2 iuel njector.
88N l NJl ( No.
1 FUEL I NJECTOB) Di ves No. 1 r uel i nj ect or .
5
SO2SIITC (SECONDAFY
HEATED
OXYGEN SENSOF HEATEF CON
TFOL)
Orives secondary heated oxyqen sensor With ignilion switch ON
(lll:
batery vo lage
Wi t h f ! l l ywar med up engi ne r unni nq: dLt v cont r ol ed
6 BLXAVHT
PO2SHTC (PRIMAFY
HEATEO
OXYGEN SENSOR HEATER
CONTROL)
Drives prihary
healed oxygen sensor Wi t h i gni t i on swi t ch ON l t t ) : baner yvot t ase
wl h r d l l y wd r me d u p c n g n e , L n n r r q
d u r y , o r l . o t r e d
FED{
ESOL (EGF
CONTRO!
SOIENOIO VALVE)
Dr i ves EGF conl r ol sol eno d vat ve. Wilh EGR operating during drving wiih fu|y warmed
up engrne: duty controtted
Wi l h EGF nol opef at i ng: O V
E.EGR Wi t h EGF oper at i ng du. i ng dr i v og wi l h i ut y war med
up en9i ne: dut ycont . ol t ed.
With EGR not ooeralino; o V
8* r / GFN/YEL
WS
(VTEC
SOLENOTD VALVE) Drives VTEC solenoid va ve
Wi l h eng ne at ow engi ne speed: O V
Wirh engine at h gh enqine speedr banery vohaae
9 Bf l N/ BLK LG1
( LOGI C
GROUND)
Gr o! nd l or t he CM/ PCM conl r ot c r cui t . Lessl han 1. 0 V at a t t i mes
t 0 ALK PG1 I POWEF GFOUND) Gr ound i or r he ECM/ PCM power . t cuf .
1 1
YEVBLK
IGPT iPOWEF SOUFCE) Power source forthe Ec[,l/PcM conlro Wilh ignition swirch ON
(tt):
battery voltage
With gntron switch OFF: 0 V
BLVBLU IACV (IDLE
AIN CONTROL VALVE)
Wi l h engi ne r ! nn ng: dl t y cont r o ed
13, . o8N
I ACV N l I DLE AI 8 CONTFOL
VALVE NEGATIVE SIOE)
Drivesthe IAC valve {negalive side).
BLVBLU
IACV P
(IDLE
AI8 CQNTROL
VALVE POSITIVE SIDE)
Orives IAC vaive (posilive
side).
FEO/YEL
PCS (EVAP
PURGE CONTFOT
SOI ENOI OVALVE)
Drives EVAP pu.ge controtsolenoid vatve. Wi l h engi oe r unni ng, engi n coot ani bet ow 154, F
' 68' Cr
bancry vohaSe w' ln ens nc runn,.o. eng,rc
GRN/YEL
FL8 (FUEL
PU[4P FELAY) Or i ves f uel pump r el ay.
0 V {or
two secor os ahe' tJ n ng ' onir or \wnch ON ,,,,,
I 7 BLI(REO
ACC
(A,/C
CLUTCH RELAY)
Drives A/C clutch relay.
Wi r h compr essor ONr 0 V
Wilh compressof OFF:banery votrage
1 8 GFN/ ONN
MIL (I\,lALFUNCTION
INDICATOF
Wi t h MI L l Lr ned ON: 0 V
With illl turned OFF: banery volaqe
1 9 ' ,
AITC {AITERNAIOR CONIROL) se.ds ahernator controt signat. Wirh fully warmed.up engine ru.ntng: battery votlas
During drivins wnh smatl eteclricat toad: O V
20 YEVGRN
I CM
( I GNI ' TI ON
CONTROL
MOOU!E)
wi t h i gnl t l on swi l ch ON ( t l ) : b6nr y
vohage
Wi l h ensi ne r unni ns: aboul t 0 V ( dependi ng
on
22 BRN/BLK LG2 ( LOGI C
GAOUND) Ground for the ECM,/PCM conrrot ci' cu L Less than 1.0 V at a tt mes
23 BLK PG2 i POWEA GROUND)
Gr o! nd l or t he ECM/ PCM power
ci r cui r .
24 YEUBLK
lGP2 (POWR
SOUSCE)
Power sou.ce lor the ECM/PCl, conrrol Wnh ignilion swilch ON {it):battery vohage
Wi l h i gni l i on swi t ch OFF: 0 V
25* 6 WHT/FED
VSEF IREFEfl ENCE VOLTAGE) Provrdes reference voIaOe to TCM.
Wi t h i gni t i on swi t ch ON
( t t ) : abour
5 V
Wt h gni t i on swl t ch OFF: O V
21' 1 GFN
FANC {RAOIATOR FAN
CONTFOL)
Drives radialof fan ielay.
Wi th radi al or fan f!nn nqr O V
Wi l h radi ato.tan stopped: battery
BL!
2WBS
(EVAP
BYPASS
SOLENOIO VALVE]
Orives EVAP bypass sotenotd va !e. Wi t h i gni r i on swr r ch ON
( t t ) : bar er y
vo r ase
LT GRNA/VHT
VSV
(EVAP
CONTFOTCANISTEF
VENT SHUT VAIVE)
Drives EVAP conlfot canisrer venl shul wnh i gni r i on sw' t ch ON l r | l bar er y vol aqe
WHT/NED
SLU ( I NTEFLOCK
CONTFOL
UNI T)
Detects intenock conlrotLn t signal Whh i gni t i on swi t ch ON
( t t ) and
br ake peda
depf essed: battery vollage
PCM CONNECTOR B {25P)
Wi re si de of {emal e t ermi nal s
CONNECTOR
B
(25P)',
* 1i
USA model
*2:
A/ T
(D16Y7, Dl 6Yg engi ne)
*3:
CVT
(D16Y5 engi ne)
*4:
M
and Dl 6Y7 engane
*5:
Except A. rT and 016Y7 engi ne
*6:
A, / T
(D16Y8
engi ne)
*7r
CVT
(D16Y5 engi ne) and D16Y8 engi ne
* 8:
' 96
D16Y8 engi ne
( coupe) , ' 97 D16Y8
model s, sedan: KL model ) , ' 98 Dt 6Y5
engi ne, ' 99 00 Dl 6Y5 1M/ Ti engi ne
*9:
D16Y5 engi ne
*10:
M/ T
(D16Y5 engi ne)
*11:
Except M/ T {D16YS
engi ne}
*12i
D16Y5, D16Y8 engi ne
*
13: D16Y8 engi ne
*14:
D16Y7 engi ne
*15:
' 97
Dl 6YTengi ne
(coupe: KL model , sedan: KL
(LX) model )'
' 98D16Y7
engi ne
(cont , d)
engi ne
( c oupe:
al l
engi ne, ' 98 D16Y8
FCM
NOTE: Standard battery vol tage i s 12 v'
erminal T
numoer
Wire
cot ol
Terminal
name
Description
Signal
1
LS_
(LI NEAR SOLENOI D
VALVE
-
SI DE)
Ground f or l i near sol enoi d val ve
Wii-ignnion switctr oN {ll}:
pulses
2 RED
LS+
(LINEAR
SOLENOID
VALVE + SIDE)
-Drii6l
linear solenoid valve
Wi t h i gni l i on swi t ch uN
(l l l : pul ses
3 BLU/YEL
SHA {SHIFT CONTROL
SOLENOID VALVE A)
-Drives
shift control solenoid
valve A Wi t h engi ne runni ng i n 2nd, 3rd
gears:
battery voltage
Wi t h engi ne runni ng i n 1st , 4t h
gears:
about 0 V
4 GRN/ BLK
LC B
(LOCK' UP CONTROL
SOLENOI D
VALVE B}
Dri ves l ock up cont rol sol enoi d
val ve B.
With lock-up ONI battery voltage
Wi t h l ock-up OFF: 0 v
5 YEL
LC A
(LOCK. UP CONTROL
SOLENOI D VALVE A)
Dri ves l ock up cont rol sol enoi d
With lock-uP ON: baftery voltage
Wi t h l ock-up OFFi 0 V
8 PNK
ATPD3
(NT GEAR POSI.
TI ON SWI TCHi
Detects Py'T
gear
Position
switch
si gnal .
In [D31
position: 0 V
ln ;y other
position: battery voltage
1 l GRN^lr'HT
SHB
(SHI FT CONTROL
SOLENOI D VALVE B)
DnGs shift conttol solenoid valve B
Wi t h engi ne runni ng i n 1st , 2nd: bat t ery
vo|taqe
Wi t h; ngi ne runni ng i n 3rd, 4t h: about 0 V
12 WHT/RED
SLU
(I NTERLOCK CON
TBOL UNI T)
-DlivEilite'lock
control,rnit. With ignition switch ON
(ll) and brake
pedal depressed: 0 V
1 3 GRN/ BLK
D4 I ND
(D4
I NDI CATOR
LI GHT)
Dri ves D4 i ndi cat or l i ght . Wi t h
Pl l
i ndi cat or l r ght t ur neo ur r : oar t er v
vol t aoe
Wi t h
l d
i ndi cat or l i ght t ur ned OFF: 0 v
1 4 WHT
NMSG {MAINSHAFT
SPEED SENSOR GROUND)
GZiiI'for
mainshaft speed sensol
Wi th engi ne runni ng: Pul ses
In E
posi ti on: 0V
I n any ot her
posi t i on: bat t er y vol t age
RED
NM {MAI NSHAFT
SPEED
SENSOR)
Detects mainshaft speed sensor
srgnal .
ATPR {M
GEAR POSI
TI ON SWI TCH)
Detects M
gear
Position
switch
si gnal
' t 1
BLU
ATP2 {A/T GEAR POSI
TI ON SWI TCH)
Detects A/T
gear
Position
switch
si gnal .
I n
E
posi t i on: 0V
In any other
22 GRN
NCSG
(COUNTERSHAFT
SPEED SENSOR GROUND)
Ground for countershaft speed
sensor.
23 BLU
NC
(COUNTERSHAFT
SPEED SENSOR)
Detects countershaft speed sensor
si gnal .
Vvith ignition switch ON
(ll),
and front
wheels rotating:
Pulses
24 YEL
ATPD4 {M GEAF POSI-
TI ON SWI TCH)
Det ect s M
gear
Posi t i on
swi t ch
si gnal .
l n
E
posi t i on: 0 V
I n any ot her
posi t i on: 5 V
25 LT GRN
ATPNP
(A"/T
GEAR POSI
TI ON SWI TCH)
Detects A/T gear
Position
switch
s r gnal ,
I n
E
or E
posi t i on: 0 V
In any other
! a
11- 89
Troubleshooting
Engine/P_o_wgrtrain
Control Module Terminal
Arrangement
('96 -
98 Models
'99
-
00 Dt6y5 engine with M/T)
tc'oniOi
ECM/PCM CONNECTOR
C {31PI
1
CKFP
2
CXPP TDCP
a
ACS
5
sTs
7
scs
I I
rMA
10
v8u
12 13 14 t 5 15 17
ALTF
TE
vss
23
lP+
21
25 29 30
TMA
Wi re si de of f emal e t ermi nal s
ECM/PCM CONNECTOR C
(31PI
NOTE: Standard baftery voltage is 12 V
' 1:
USA model
r 2r A, . T
( D16Y7,
O16Y8 ensane)
*3:
CVT
( O16Y5
engi ne)
*4:
Ay'T and O16Y7 engine
'5:
Excepl A./T snd Dl6Y7 engine
16:
Ay'T
(D16Y8
ensine)
{ 7:
CVT ( Dl 6Y5
eosi ne) and O16Y8 enoi ne
"8:
96 Dl 6Y8 engi ne ( coupe) , ' 97
D16y8 engi ne
( coupe:
at l
: ed- 9I t ! ! r nodel r , ' 98
D16y5 ensi ne, , 98 D16y8 e; si ne.
D16Y5 l M/ T) ensi ne
1- 90
19:
D16Y5 engi ne
' 10:
M/ T
( Dl 6Y5
engi ne)
*11r
Except M/ T 116Y5 engi ne)
*12:
*13:
Dl 6Y8 enqi ne
*14:
O16Y7 engi ne
i 15: ' - 97
O16Y7 engj ne
( coupe:
KL modet , sedan: KL ( LX)
modet ) ,
' 98D16Y7
enqi ne
'99
-
00
1
To.min!l
number
Wira
coloa
Torminal
name
Do6criptlon
Signal
1 BLU/RED CKFP
(CKF
SENSOR P SIDE) Detects CKF sensor.
Wi t h engi ne runni ng: pul ses
2 BLU CKPP
(CKP
SENSOF PSIDE) Detects CKP sensor.
Wi t h engi ne r unni ng: pul ses
3 GRN TDCP {TDC SENSOR PSIDE} Detects TDC sensor,
Wi t h engi ne r unni ng: put ses
4 YEL CYPP (CYP
SENSOR P SIDE) Detects CYP sensor.
Wi t h engi ne r unni ng: pul ses
5 BLU/ FED
ACS {Tr'C SWITCH SIGNAL) Detects ,ay'C sw;tch signat. With Iy'C switch ONr 0 V
With Ay'C switch OFF: batrery vottage
6 BLU/ORN
STS
(STARTER
SWITCH
SI GNAL)
Detects staner swilch signal, Wi t h st aner swi t ch ON l t l t ) : bat er y vohage
With staner switch OFF: 0 V
8RN
SCS
(SERVICE
CHECK
SI GNAL)
Detects service check connector signal
{the signalcausing a OTC indicationl
With the connector connected: O V
with the connector disconnected: about 5 v
or battery voltage
LT 8LU K, LI NE
( DLC)
Sends and r ecei ves scan i ool si gnal , Wirh ignition switch ON { ): about 5 V
9+3 GRY
Dat 6 communi cat i on wi t h TCM: ECM
control ctat6 output
( t t ) : put ses
10 WHT/BLU
VBU
(VOLTAGE
BACK UP) Power source forthe ECM/PCM
control circuit. Power sourc lorthe
DTC memory
Battery voltage at all times
1 1 WHT/RED
CKFM {CKF SENSOR M
SI DE)
Ground t or CKF sensor si gnal .
12
CKPM
(CKP
SENSOR M
SIDE)
Ground f or CKP sensor s; gnat .
RED
TDCI\4
(TDC
SENSOR M
SI DE)
Ground for TDC sensor signal.
1 4 BLK
CYPM
(CKP
SENSOB M
SI DE}
Groond for CYP sensor signal.
15. " BLU/BLK
VTM
(VTEC
PRESSURE
swtTcH)
Oetscts VTEC pressure switch signal. Wrth engine at low enginespeed:0 V
Wth engineathigh engine speed: tatteryvoltase
1 6
GRN
PSPSW (P/S
OIL PRESSURE
swtTcH)
Detects PSP switch signal. At idle with steering wheel in straight ahead
posi t i on: 0 V
At idle with stsering wheet at fult tock battery
voltage
'17
WHT/RED
ALTF
(ALTERNATOR
FR
SI GNAL)
Detects ahernator FR signal. With fullyw6rmed up engine running:0 V- bat-
teryvohage (depending
on electricat toad)
18 BLUI/VHT
VSS { VEHI CLE SPEED SEN-
SOR}
Oetects VSS signal.
Whh i gni t j on swi t ch ON { t t ) and f r ont wheet s
rotating: cycles 0 V- 5 V
23+14 BLK l P+ {HO2S PUt r4P CELL +} Controls HO2S pump
ce . Wi t h i gni t i on swi t ch ON
( l l ) :
abour 0. 5
-
5. 3 V
24.10 RED
rP-, vs- {Ho2s coMt oN) Reference voltage supply. Wi t h f ul l ywar med up engi ne et i dl e:
about 2. 6- 2. 8 V
25*r o VS+ (VS
CELL VOLTAGE) Det ect s VS cel l vol t age.
Wi t h i gni t i on swi t ch ON t ) : abour 7 V
29
LT GRN*'
ATPNP (Ar'T
GEAR POSI,
TroN swrTcH)
Deteds Ay'T g6srposhion
switch signat. I n
E
orE posi t i on:
O V
ln any other position:
battery vottage
RED{ r o
CLSW
(CLUTCH
SWITCH} Detects clutch switch signal, Wilh clutch pedal
released: about 5 V
With clutch
pedal
deDressed: O V
30
PNK4
TMB
Data communication with TCM:
ECM cont r ol dat a i nput
Wi t h i gni t ; on swi t ch ON
( l t ) : put ses
ECM/PCM CONNECTOR D I16P)
Wi re si de ot f emal e t ermi nal s
ECM/PCM CONNECTOR D l16P)
NOTE: Standard battery voltage is 12 V
Te.minal
numbr
Wire
color
Terminal
n! me
Dor.ription
Signal
RED/BLK
TPS
(THROTTLE POSITION
SENSOR}
Detects TP sensor signal.
With throttle fully open: about 4.8 V
Wi t h t hrot t l e f ul l y cl osedl about 0. 5 V
REDA/VHT
ECT {ENGI NE COOLANT
TEMPERATURE SENSOR
Detects ECT sensor signal
Wi t h i gni t i on swi t ch ON{l l ): about 0. 1
-
4 8 v
(depending on engine coolant lempe ratu re)
3 RED/G RN
MAP {MANI FOLD
ABSO'
LUTE PRESSURE SENSOR}
Det ect s MAP sensor si gnal . Wi t h i gni t i on swi t ch ON(l l ): about 3 V
At i dl e: about 1. 0 V
{dependi ng
on engi ne speed)
YEURED
VCCl
(SENSOR VOLTAGE) Power source lor MAP sensor. Wi t h i gni t i on swi t ch ON
(l l ):
about 5 v
Wi t h i gni t i on swi t ch OFF: 0 V
5 GRNMHT
BKSW {BRAKE SWITCHI Detects brake switch signal
With brake
pedal
released: 0 v
With brake
pedal depressed: baftery voltage
6* ?
RED/BLU KS {KNOCK SENSOR}
Detects KS signal.
Wi t h engi ne knocki ng:
Pul ses
1
PHO2S
(PRIMARY HEAT-
ED OXYGEN SENSOR,
SENSOR 1)
Detects
Primary
heated oxygen
sensor
(sensor 1l si gnal
With throttle fullv opened from idle with
I ul l y warmod up engi ne: above 0. 6 V
With throttle
quickly closed: below 0.4 v
LABEL
Detects LABEL resistance
Wi t h engi ne r! nni ng: about 0. 3
-
4. 9 V
8 RED//EL
I AT
(I NTAKE AI R TEM-
PERATURE SENSOR)
Detects IAT sensor signal. With ignition switch ON
(ll):
about 0 1
-
4.8 V {depending
on intake air temperature)
9 * l
WHT/ BLK
EGRL i EGR VALVE LI FT
SENSOR)
Detects EGR valve lift sensor signal At i dl e wi t hout vacuum: about ' 1 2 V
Wi t h 27 kPa
(2OO mmHg, 8 i n. Hg): about 4 3 V
10 YEUBLU
VCC2
(SENSOR VOLTAGE) Provides sensor voltage,
Wi t h i gni t i on swi t ch ON(l l ): about 5 V
1 1 GRN/ BLK SG2
(SENSOR
GROUND} Sensor
ground.
Less t han 1. 0 V at al l t i mes
12 G RN,4/1r'HT SG1
(SENSOR
GROUND) Ground for MAP sensor.
Less t han 1. 0 V at al l t i mes
GRN/ BLK*1?
SHO25G
(SECONDARY
HEATED OXYGEN SEN'
SOR, SENSOR 2 GROUND)
Ground for secondary heated oxy-
gen sensor
(sensor 2).
1 4 WHT/RED
SH02S
(SECONDARY
HEATED OXYGEN SEN'
soR, sENsoR 2)
Detects secondary heated oxygen
sensor
(sensor 2) si gnal .
With throftle fully opened lrom idle with
f ul l y warmed up engi ne: above 0. 6 V
Wi t h t hrot t l e
qui ckl y cl osed: bel ow 0. 4 V
15| 3.
* 15
LT GRN
PTANK {FUEL TANK PRES.
SURE SENSOR)
Detects fueltank
prgssure sensor' Wi t h f uel f i l l caD opened: about 2. 5 V
16* 1
GRN/ RED
EL
(ELD) Detects ELD signal.
Wi t h
parki ng l i ght s t urned on at i dl e: about
2. 5
-
3. 5 V
Wi t h l ow beam headl i ght s t urned on at
i dl e: about 1. 5
-
2. 5 V
*1:
USA model
*2r
A/ T
(D16Y7, D16Y8 engi ne)
*3:
CVT
(D16Y5
engane)
*4:
A, / T and Dl 6Y7 engi ne
*5:
Except A/T and D16Y7 engine
*6:
A"/ T
(D16Y8 engi ne)
i 7:
CVT
(Dl 6Y5
engi ne) and Dl 6Y8 engi ne
* 8:
. 96
D16Y8 engi ne
( coupei , ' 97 D16Y8 engi ne
model s, sedanr KL model ) , ' 98 016Y5 engi ne,
engi ne,
' 99
-
00 D16Y5
(M/ T)
engi ne
*9:
D16Y5 engi ne
*10:
M/ T
(D16Y5
engi ne)
*11:
Except M/ T
(Dl 6Y5 engi ne)
*
12r D16Y5. D16YB engi ne
*13:
D16Y8 engi ne
*14:
Dl 6W engi ne
*15:
' 97
D16Y7 engi ne
(coupe: KL model , sedan: KL l LX) model ),
' 98D16Y7
engi ne: (coupe:
al l
' 98
D16Y8
(cont' d)
1 1- 91
Troubleshooting
Engine/P_o,wertrain
Control Module Terminal Arrangement
('99 -
ECM/PCM CONNECTOR A
(32P)
Wi re si de ot t emal e t ermi nal s
NOTE:Standard battery vol tage i s l 2 V
Sign!l
3 BLU
2WSS (EVAP
8YPAsS SOLENOID Drives EVAP bypass solenoid vatve, With gn' tion swnch ON (lll
banery votlage
LT GRN/I/VIIT
VSV {EVAP CONTNOL CANISTER
VENTSHUTVALVE]
Drives EVAP controt ca n isrer vnt shut Wilh ignilion switch ON {tl): bttery vottage
8LU/GNN
C8S (CRUISE
CONTSOL SIG Oown shift signal inpot lrom c.uise conrrol When crurss control is used:purses
6 8ED/YEL
PCS {EVAP PURGE CONTROL
SOTENOI OVALVE)
Drives EVAP purge conrrol sotenoid vatve. With engine running, engine cootant, betow r54.F (6a,C):
With engine.unning, ngine coolant, abov 154.F
(68' C):
duty conlrolled
YEL
ATPD {AT GEAR POSITION
SWITCH)
ootects A/T gear posnion
swilch s,gnar.
In otherthan
@
posilion: Apprcx. 5 V
8 BLK,IflHT
SO2SHTC (SECONDARY
HEAT
ED OXYGEN SENSOS HEATEF
CONTFOL)
Drives sscondary hared oxygen senso. Wilh isn,rion swirch ON
(ll):banery
votrase
Wi t h l ul l y war m6d dpngi r e r unn' ng: dur y cont r ol ed
LT GRN
ATPNP (AT
GEAF POSITION
SWITCH)
oereds A/T
9a
r position
switch signat. I n
Par r or neul r sl : 0 V
I n anyot her posi t i on
appr ox. 5 v
t 0 88N
SCS
( SERVI CE
CHECK SI GNAL) Oetects ssruice check connecror signal
(the
signalcausing a OTC indication)
with rh t6rminal connected: 0 v
With the rerm ina I disconneded: abour 5 V of banry
GNN/BIK
D4I ND ( D4I NDI CATON]
Drives Oa indicaio. lighr.
Wi t h D4 i ndi cat or l i ght t ur ned ON: O V
With D4 indicator lightturned OFF: battery vo ttage
G8N/YET
FTF (FUEL PUI\,4P SELAY) Orivos tuel pump relay,
0V for two sconds lfrer turnrng rgnilior swtcn ON
(ll),
then battry voltage
1 1 BTI(RED
ACC (Al/C
CTUTCH SELAY) Drives A./C clutch reray.
With compressor ON:O V
Wilh comp.ssor OFF; battery vottage
1 8 GFN/OFN
MI! (A,IAIFUNCTION
INDICA.
TOF LIGHT)
Wi t h Ml Lt ur ned ON: 0 V
With l\,llL tornod OFF|batrery votrsge
1 9 8t u NEP ( ENGI NE
SPEED PUTSEI Oulputs6ngine speed pulse,
Wi l h engi n6. unni ng: put ses
20 GFN
FANC {SADIATOR FAN CON
TnoL)
Orives radiarortan relay.
Wi r h r . di st or t 6n r unni ng: OV
With radiatortan stopped: banery vottage
21 ELUA/EL K LINE
Sends and rceives s.an lool signal. With ignition switch ON
(ll):p!tss
22' l BLU
ATP L {AT GEAS POSITION
swtTcH)
Oelocis A"/T gear posirion
switch siSnat.
In othfflhan
E
position:
Apprcx. 5 V
23
SHO25 (SECONOARY
HEATED
OXYCEN SENSOR, SENSOF 2)
Detects secondsry hoard oxygen sensor 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
24
STS ISTAFTEN SWITCH SIG Debcrs staner switch signat. Wirh srarterswitch ON
(tttJ:
batteryvottoge
With sraftsr cwirch OFF:0 V
26 GFN
PSPSW iPlS PNESSURE
SWITCII SIGNAL)
Derecrs PSP switch signat. Atidle with steoring wheolin srraightahead position:
O V
At idl6with steering wheetal fult lock: barery vo ttags
27 BLU/REO
ACS
(AJC
SWITCH SIGNALJ Oer*ts ,ay'C swirch signat. Wiih ty' C switch ON;0V
Wilh Ay' C switch OFF|aboor 5V
WHT/RED
SLU i I NTERLOCK CONTROI
UNIT)
Drivos interloct control unit. With ignltion switch ON (ll)and
brake pedal
depresed: batlory volrage
29 LT GRN
PTANK (FUEL
TANK PFESSUEE
SENSOR)
Oer6ds lul tank prssura
sonsor signat. Wi l h i g. r r r d swi r ch ON r t t r and f uet t i

cap ooen6d.
30 GRN/ FEO
Er ( ELOI
Wi t h par ki ng
l i ghl sr ur ned on ar i dt ei aboui 2. 5- 3. S V
Wirh low beam hedlig hts turnqd on ai idts: aboul 1.5
2. 5 V
32 GRN/' WHT
AKSW (BFAKE
SWITCH) Detets brak swrtch signEt, With brake pedal r6lased:0 V
Whh brake pedaldepres*d:
battery voltEse
' 1: A. / T
( D16Y7,
D16Y8 engi ne)
*2:
rvt/T
13:
CVT
(D16Y5
engine)
11- 92
ECM/PCM CONNECTOR B
(25PI
FCM CONNECTOR B {25P)
NOTE: Standard battery voltage is 12 V
Sign.l
YELtsLK
IGP1 IPOWER SOUflCE) Powor sou rca for the ECM/PCM conlrolcir whh ignilion swilch ON
(ll)ibatteryvoltage
With ignition switch OFF:0 V
BLK PGl { POWEB GNOUND)
Ground fo. the ECM,/PCM contrclcncuit'
Less than 1.0 V at slltimes
FED l NJ2
( No
2 FUEL I NJECI OR) Drives No. 2 ful inieclor'
Wirh enqine runnin9: dulv conlroll6d
BLU l NJ3
( No. 3 FUEL I NJECTOB) Orives No.3 fuel inieclor'
YEL l NJ, r l No. 4 FUEL I NJECTOF) Drives No. 4 luel injector'
6 BLI(BIU
IACV P
(IDLE AIR CONTROL
VAIVE POSITIVE SIDE)
O.ivs IAC valve {Posirivo side)
Wilh engine running: duty conrrollod
BED
ESOL {EG8 CONTROL
SOLENOID VALVE)
Drives EGF controlsolonoid valve With EGR operaiing during driving wirh follv warmed
up onginsl dutY controlled
Wi l h EGR nol opr . r i ng: 0 V
PNKSLK
HlC tstvr
(PH-PL CONTnOL
LINEAfl SOLENOID NEGATIVE
st0E)
G rcund for PH-PL control linsar solsnoid
8. ,
LS
- (A/T CLUTCH PFESSURE
CONTROL SOTENOIDVALVE'
sroE)
A/Tclutch
prsssure conrrol solnod valv
pow6r slpply negative elecrode
With ignilion swirch ON
(ll):dutv controlld
9 YEUBLK
rGP2 {POWE8 SOUFCE)
Powor $urce for lhe ECI{,' PCM controlc' rcuit wnh ignirion swirch ON
(ll): banry voltag
with ignirion swnch oFF:0 v
10 BLK PG2I POWER GSOUNDI Ground lor ths ECM/PCM controlctrcuil
1 1 8RN I NJl { No, 1 FUEL I NJEqI OR) orives No. r ru6l Iniocror.
With onsino at low lpm:0V
with ens,n. ar hish tpm:bsneryl9!9gl-
12"
GRN,.YEL
WS
(WEC SOLENOID VALVE) Orivos WEC solanoid v.lvs.
13 YEUGRN
ICM {I6NITION CONTROL MOD
ULE}
With ignition switch ON
(ll)r b5n6ry voltgs
Wilh engino running: Puls6
1 5 ORN
IACV N
(IDLE AIN CONTSOI
VALVE NEGATIVE SIOE)
Drivos the IAC valve lnogativ 3idel
With ngin ru nningi dr]tv controlled
RED
LS +
(A,/T
CIUICH PRESSURE
CONTFOT SOIENOIOVALVE
+
SIDE}
A/T clutch
prso.6 controlsolenoid
valve
pow6r slpply
posiliv oroclrode
Wirh ignition swatch ON
(lll: dutYcontrorled
HLC LSP
(PH-PI
CONTROI LIN.
EA8 SOLENOID POSITIVE SIDE)
Orives PH-PL control liner solenoid
With
qnition switch ON
(lll: Pulsing srgnal
PNK/BTU
SC LSM
(STAfiT CLUTCH
LINEAR SOLENOIO NGATIVE
SI DE)
Groundforstartclutchcontrol
line6r
20 BnN/AtK LGI
(LOGIC GEOUNO)
Ground for lh EcM/PcM controlcircuit'
L6se r han 1. 0 v. i al l t i mes
21
VBU IVOLTAGE 8AC( UP) Powet source torlhe ECM/PCM control circuit
Power sourco tor th6 DTC mmory'
Battaryvoltage aitnEtrmes
22 BFN/8IK LG2
(LOGIC GSOUND)
Ground iorths ECMnCM conrrol circuir' tsss thah 1.0 v al all times
23 8LI(BLU
IACV
(IOTE AIR CONTROL
Witn ongine funning: dutv conrol!6d
25'3
YEL
SC LSP {STANT CLUTCH LINEAR
sotENorD PoSlrlvE slDE)
Orives sran clutch control linesr solonoid. With ignilion swilch ON
(ll): Pulsing sign3r
r1:
A/r
(D16\t, D16Y8 ensins)
' 3: CVT
{ O16Y5ensi no)
' 4:
Ol6Y5, Dl6Y8, B164? onsina
(cont' d)
1 1- 93
Troubleshooting
Eng ine/P_owertrain Control Module Term inal Arrangement
('99
-
(cont,d)
ECM/PCM CONNECTOR C {31P)
NOTE;Standard
* 1; 4" / T
l D16Y7, D16Y8 ensi nel
43:
CVI ( 016Y5 engi ne)
' 4:
D16Y5, D16Y8, 81642 engin
ECM/FCM CONNECTOR C 13lPI
i s 12 V.
Sig.al
l BLK4/VHT
PO2SHTC (PNIMARY
HEATEO
OXYGEN SENSOB HEATES CON
TROL)
Drivss primary hoated orygen sensof With ignition switch ON (lr)rbanery
volage
Wr h f Jl y war ned up ngi r . r u. . i 19: dut y. oar o ed
2 WHT/GFN
ALTC (ALTESNATOB
CONTSOL) Sends aliernalo. control sig nal, With fullywa.med upengine ronning; banery vohase
Dur i ng d. i vi ng wi t h smal l el ect . i cat i oad; O V
3 8ED/ BLU K5 (KNOCK
SENSOR)
with sngine knocking: pulses
5 WHT/RED
ATTF {AITEFNATOR FR SIGNAL' Detects slternaror FR si9n.l. Wi t h t ul l ywar med up engi ne r unni ng: O V- bat t er y
vor t age( dependi ngon er ect f i cat t oad)
WHT/8LK
EGRL ( EGN
VAI VE LI FTSEN
SOR)
Dete.ts EGR valve lrft sensorsignat.
GRN,4r'l/flT SGl I SENSOE GBOUND) Groond fo. MAP snsor. Lss r han 1. 0 v at al l t i mes
8 8l u CKPP (CKP
SENSOR P SIOE'
With engine running: pulses
9
CKPM {CKP SENSOR M SIDEI Ground for CKP sensor.
BLU/BLK
wlvl
(wEc
PREssuSE swtTcll
SIGNAI)
Dtocts VTEC pfessure
switch signat, Wi t h ngi ne at l ow engi nospeed: 0V
With engin at high engino speed : banery vo ttaae
1 6
PHO25 (PRII\,1AFY
HEATED
OXYGEN SENSOR, SENSOR 1)
Oetects primary
heated oxygen s6nsor lsen- With lhrottle f!l1y opend from idtewith tuly,
wa.med !p engin: Ebove 0.6 V
Wilh thronl quickly closed: btow 0.4 V
FED/GRN
MAP (I\,4ANIFOLD
ASSOLUIE
PFESSUSE SENSOB}
Dotocrs i,4AP sensor signsl. With ignitioh switch ON (ll):about
3 V
At i dl ei 6boul 1. 0 V ( dependi ng
on engi ne speed)
1 8 GBN/8LK SG2 ( SENSOR
GSOUND)
Less t han 1. 0 V ar al t t i mes
'19
YEUNED
VCCl (SENSOR
VOLTAGEI Powersourcero MAPsenso.. Wi t h i gni t i on swi l ch ON { l l ) : about 5 V
Wi r h i qni t i on swi t ch OFF] 0 V
20 GNN IDCP (TDC
SENSOB P SIDEI
With ongine running: pulses
21 8ED TDCI\,I (TDC
SENSOR M SIOE) Ground lor TOC aensor.
22 BTU/NED CKFP
( CKF
SENSOR P SI DE)
With engine running: p!lses
23
VSS {VEHIClE SPEED SENSOR)
Wi l h i gnr t | on swi ch ON r l l r snd l r ont wl - ee' r ot at i ng.
cycles 0 V about 5V or baneryvottage
25 BED/YEL
IAT ONTAKE AIF TEi,4PEBA.
TUEE SENSOR)
Detects IAT senso. signat. With ignition switch ON (ll):
about 0.1 4.8 V
ldepending on i.take air ternpe.atu re)
26 8ED,ryVHT
ECT
(ENGINE
COOLANTTEI\,I.
PESATUBE SENSOR)
Oelects ECT sensor signal. Wi t h i gni r i on swi r ch ON { l l ) : about 0. 1
- 4. 8
V
(depending
on engine coolant temperatu re)
21 NED/BLK
TPS (THROTTLE
POSITION SEN,
SOF)
Detects TP sensor signal. Wilh th.onle fully opn: about 4.a V
With rhronle f!lly closed: about 0.5 V
2a YEVBLU
VCC2 (SENSOR
VOLTAGE) Provides s6nsor voltag. Wi t h i gni r i on swi r ch ON
( t t ) : about
5V
With ignilion swiich OFF:0 V
29 YEL CYPP
(CYP
SENSOR P SIDE)
Wi l h ngr ne r unni ng: pr uses
3o BLK CYPM (CYP
SENSOR M SIDE] G,ound for CYP sonsor.
J 1 WHT/FED CKFM
(CKF
SENSOB M SIDE) Ground fo. CKF sonsorsign6i.
11- 94
ECM/PCM CONNECTOR
O {16P)
Wi re si de ol t emal e t ermi nal s
ECM/PCM CONNECTOR D {16P)
(D16Y7, D16Y8 engi nel
NOTE: Standard battery voltage is 12 V.
L
.1
A/J
(Dl6Y7, Dr6Y8 engine)
(cont'd)
1 1- 95
5i!ml
YEL
LCA
(LOCK.UPCON]ROL
SOLENOID VALVE A)
Orivos look-up controlsolnoid wlv a. With lock-up ON: httery vollage
With lock-up OFFi 0 V
GRN,M/HT
SHB {SHIFT CONTFOL
SOLENOIO VALVE B)
Drivos sh ift cont.ol solanoid valv6 B ln E
posnion, in 1st lnd 2nd
eoat
,n
E E
pos'
tion:Battsry voltago
I nEl posi r i on. i n 3r d
seat
i n pd,
El
i n. t h
sear
i n
l_d
polition: o v
3' '
GRN/BLK
LC8
(IOCK UP CONTBOL
SOLENOID VALVE B)
Drivs locl up conttol solnoid v6lv B when fulllock-up: Banory vollaga
Wnh naf locl-uP: Pulsing si9n6l
5' ,
BLK/YEL
VSSOI
(BATTEsYVOLTAGE
FOB SOLENOID VALVE)
Powe. sourc ol solGnoid valve
wirh ignirion sitch ON
(ll): battory voltaoe
Wirh ignnion switch OFF:0 v
ATPR
(AT
GEAR POSITION
swrTcH)
Detecrs Ay' T g6a. position switch signal.
In any olhr
position: APProx. 10 V
8LU/YEL
SHA iSHIFI CONTROL
SOLENOIDVALVE A)
Oriv6 sh ift conirol solnoid valve A. ln
tr,tr
position, in 2nd nd 3rd sear
in
lpd, &l
posirion: Battry vollsgo
;n 1d soar
in
E, E
position, in.ih se6r
in
E
PNK
ATPO3
(AT GEAR POSITION
SWITCH)
Oot6cts Ay' T S6.r
poeirioo switch siSnal
In Enyoth.r
position: APPror, t0 v
9' '
YEL
ATPD4 {AT GEAE POSITION
swrTcH)
Oorocts A/I gs8r position switch signal.
In any oth6t
position:APProx 5 V
BIU
NC
(COUNTE RSHAFT SPEED
SENSOB)
DetocB counr.shaft sp66d $osr sig.als Dpnding on v6hicls 8ped;Pul.ins signal
Wh6n vhicls i5 ltoPPsd:0 v
REO
NM
(MAINSHAFTSPEED SEN.
soR)
Olcts mainshalt spd 3.nsor 3ign.ls Wi$ engino rLrnningl
PUls6s
NMSG {MAINSHAFT SPEEO
SENSOR GFOUNO)
Groundfo, mainshaft sp@d sensor.
13' ' !T GFN
ATPNP {AT GEAF POSITION
swrrcH)
oetscts A/T
96ar
pGitaon swhch signal In par* or n6ulral:0 V
In sny olhd
po3ition: APProx l0V
BLU
ATPz {AT GEAE POSITION
swrTcHl
Dorcis !y' T gos. posilion swilch signal.
In any oth6r Position:
APProx, 10 V
16' '
GAN
NCSG {COUNTEBSHAFT
SPEED
SENSOE GROUND)
Ground lor countershaii sp3d s6nsor.
r
l o
Troubleshooting
En gine/P_oweft
ra in Control Module Termina I Arran gement
('99 -
00 Models except Dl6YS engine with M/Tl
(cont,dl
ECM/PCM Connectol D
(16P1
Wi r e si de of f emal e t er mi nat s
ECM/PCM CONNECTOR D {16P)
(Dl6YS
engine: CVTI
*3:
CVT
(Dl 6Y5
engi ne)
NOTE: Standard battery vol tage i s 12 V
ECM/PCM CONNECTON D
(r6P)
frminal
numDea
Wire color Termi nal name
Description
Si gnal
1+3 WHT/RED
VEL (SECONDARY
GEAR
SHAFT SPEED SENSOR)
Secondary gear shaft speed
sensor,
Dependi ng on vehi cl e speed: pul ses
When vehi cl e i s st opped: 0 V
2*3 GRN/BLK
I NHSOL
{I NHI BI TOR
SOLENOI D CONTROL)
I nhi bi t or sol enoi d cont rol .
Wi t h i nhi bi t or sol enoi d ON: baf t ery
vol t age
Wi t h i nhi bi t or sol enoi d OFF: 0 V
3+3 GRN/YEL
SHLSM (SHIFT
CONTROL
LINEAR SOLENOID
NEGATIVE SIDE)
Ground for shi ft control l i near
sol enoi d.
BLU^/vHT
SHLSP (SHIFT
CONTROL
LINEAR SOLENOID
POSITIVE SIDE}
Dri ves shi f t cont rol l i near
sol enoi d power.
(t l ): pul ses
5*3 BLK,/YE L
VBSOL
l BATTERY
VOLTAGE FOR
SOLENOID VALVE)
Power source of sol enoi d val ve.
(l l ):
banery
vol t age
6*3 WHT
ATPR
(AT
GEAR
POSITION SWITCH)
Detects A,/T gear position
switch
sr gnal .
I nRpos i t i on: 0V
In any other posi ti on:
Approx. 10 V
BLKA/VHI
VELSG (SECONDARY
GEAR SHAFT SPEED
SENSOR GROUND)
Ground for secondary gear
shaft
speed sensor.
10* . WHT
NDN
(DRIVEN
PULLEY
SPEED SENSOR)
Detects dri ven pul l ey speed
sensor srgnal .
In other than Park or neutral : pul ses
1 1 * 3 RED/BLU
NDR
(DRIVE
PULLEY
SPEED SENSOR)
Detects dri ve pul l ey
speed
sensor srgnal .
In other than Park or neutral t pul ses
12*3 GRN
NDRSG
(DRIVE
PULLEY
SPEED SENSOR
GROUND)
Ground f or dri ve pul l ey
speed
sensor.
13*3 LT GRN/RED
ATPS (AT
GEAR
POSITION SWITCH)
Detects Ay'T gear position
switch
srgnal .
I n S posi t i on: 0
V
In any other posi ti oni
Approx, 10 V
14*3 GRN/BLK
DIND 1D INDICATOR
LIGHT)
Dri ves D i ndi cator.
Wi th D i ndi cator turned ON: 5 V
Wi th D i ndi cator turned OFF: O V
16* r RED^/VHT
NDNSG (DRIVEN
PULLEY SPEED
SENSOR GROUND)
Ground f or dri ven pul l ey
speed
sensor.
1 1- 96
Diagnostic Trouble Code
(DTCI
Chart
connector i s connected
a1:
Dl 6Y5 engi ne
(CVT)
*2:
Except D16Y5 engi ne
(M/T)
* 14: ' 97
model
* 15: ' 96
model
* 16:
' 98
model
(cont' d)
11- 97
DTC
{Ml L
i ndi cati on*l
Delection liem Probable Cause Page
Mani fol d Absol ute
Pressure Ci rcui t
Range/Performance Probl em
.
Vacuu m connecti on
.
MAP sensor 11 1 1 5
P0107
(3)
Pressure Ci rcui t
Low Input
Open or short i n MAP sensor ci rcui t
MAP sensor
ECMiPCM
TCM* 1
11
't1'l
P0108
( 3)
Pressure Ci rcui t
Hi gh I nput
Open i n MAP sensor ci rcui t
MAP sensor
ECtvt/PCM
't
1 121
P0. 111* 14.
* 15
( 10)
l ntake Ai r Temperature
Ci rcui t
.
IAT sensor
11-124
PO112 {10}
Intake Ai r
Temperature Ci rcui t
Low Input
Short i n IAT sensor ci rcui t
IAT sensor
ECMiPCM
11-125
P0113
( 10)
l ntake Ai r
Hi gh I nput
Open i n IAT sensor ci rcui t
IAT sensor
ECM/PCM
't1-126
P0116
( 86)
Engi ne Cool ant
.
ECT sensor
.
Cool i ng system 11-124
PO't't7 {6)
Engi ne Cool ant
Low Input
Short i n ECT sensor ci rcui t
ECT sensor
ECM/PCM
11-129
P0118
( 6)
Engi ne Cool ant
Hi gh l nput
Open i n ECT sensor ci rcui t
ECT sensor
ECM/PCM
11- 130
?0122 t1l
Throttl e Posi ti on
Ci rcui t
Low Input
Open or short i n TP sensor ci rcui t
TP sensor
ECM/PCM
TCM*1
11-132
P0123
( 7)
Throttl e Posi ti on
Ci rcui t
Hi gh I nput
Open i n TP sensor ci rcui t
TP sensor
ECM/PClvl
11- 136
P0131* '
( 1)
Pri mary Heated Oxygen Sensor
Ci rcui t Low Vol tage
( Sensor
1)
Short i n Pri mary HO2S
(Sensorl
) ci rcui t
Pri mary HO2S {Sensor
1)
Fuel suppl y system
ECM/PCM
1 1- 139
P0132*'
('r)
Ci rcui t Hi gh Vol tage
( Sensor
1)
Open i n Pri mary HO2S {Sensor
1} ci rcui t
Pri mary HO2S
(Sensor
1)
ECM/PCM
1 1- 143
P0133* '
( 61)
Sl ow Response
( Sensor 1)
.
Pri mary HO2S
(Sensorl )
.
Exhaust system 11- 145
P0135* ?
( 41)
Pri mary Heated Oxygen
Sensor Heater
Ci rcui t Mal functi on
(Sensor
1)
.
Open or short i n Pri mary HO2S
(Sensor
1) heater ci rcui t
.
ECM
11-151
*:
The DTCS i n parenthesi s wi l l be i ndi cated by the bl i nki ng of the Mal functi on Indi cator Lamp
(Ml L)
when the SCS servi ce
! t a
Troubleshooting
DTC
lMlL indicationl
Datection hsm Probablo Cause Page
P0137
(63)
Ci rcui t Low Vol tage
(Sensor
2)
Short i n Secondary HO2S
l Sensor 2) ci rcui t
Secondary H02S {Sensor 2)
ECM/PCI\4
1 1- 153
P0r38 {63)
Ci rcui t Hi gh Vol tage
(Sensor
2)
Open i n Secondary HO2S (Sensor
2) ci rcui t
Secondary HO2S
(Sensor
2)
EC[I/PCM
1 1 - 1 5 4
P0' 139 (63)
Secondary Heated Orygen Sensor
Sl ow Response
(Sensor
2)
Secondary H02S l Sensor 2)
1l - 156
P0141 ( 65)
Heater
Ci rcui t Mal functi on
(Sensor
2)
.
Open or short i n Secondary HO2S
(Sensor
2) heater ci rcui t
.
ECM/PCM
11-157
P0171
( 45)
System Too Lean Fuel suppl y syst em
Pri mary HO2S
(Sensor
1)
MAP sensor
Cont ami nat ed f uel
Val ve cl earance
Exhaust l eakage
1 1 , 1 6 4
P0172
(45)
System Too Rich Fuel suppl y system
Pri mary HO2S (sensor
l )
MAP sensor
Contami nated fuel
Val ve cl earance
11- 164
P0300*16'
}l ?
and
some of
Po3o1
/r'' \
P0302
l 72l
P0303
l 73l
P0304
\7
4l
Random Mi sf i re l gni ti on system
Fuel suppl y system
MAP sensor
EGR system
IAC val ve
Contami nated fuel
Lack of fuel
r1-r66
P0301
P0302
P0303
P0304
/ r t \
172l
l 73l
\7
4l
-
Cyl i nder 1
-
Cyl i nder 2
-
Cyl i nder 3
-
Cyl i nder 4
Misfire Detected
Fuel Inj ector
Fuel Inj ector ci rcui t
l gni ti on system
Low compressi on
Val ve cl earance
11 167
P0325*3
(23)
Knock Sensor
(KS)
Ci rcui t
Mal functi on
Open or short i n Knock Sensor
(KS)
ci rcui t
Knock Sensor
{KS)
ECM/FCtvl
1 1 - 1 7 0
P0335
(4)
Crankshaft Position
Sensor Ci rcui t
Mal functi on
Crankshaft Posi ti on Sensor
Crankshaft Posi ti on Sensor ci rcui t
ECM/PCM
11-172
P0336
( 4)
Crankshaft Posi ti on
Sensor
Range/Performance
.
Crankshaf t Posi t i on Sensor
.
Ti mi ng bel t ski pped t eet h 11- 172
P040' r*r (80)
Exhaust Gas
Reci rcul ati on
Insufficient Flow Detected
'
EGR val ve
.
EGR l i ne
P0420
(67)
Catalyst System
Effi ci ency Bel ow
Threshol d
.
Th.ee Way Catalytic converter
.
Secondary HO2S 11 253
(DTCI
Chat
(cont'dl
*3:
D16Y5 engi ne
(CVT),
D16Y8 engi ne and B1642 engi ne
*4:
D' 16Y5 engi ne
*16:
' 98
model
+17:
' 99
-
00 model s
,Jla
1 1- 98
, ' o
L
*: The
E
i ndi cat or l i ght and t he Mal t unct i on I ndi cat or Lamp
(Ml L)
may come on si mul t aneousl y.
*1:
D16Y5 engi ne
(CVT)
"5:
' 96
D16Y5 engi ne, D16Y7 engi ne, D16Y8 engi ne
(sedan). ' 97 D16Y5 engi ne, Dl 6Y7 engi ne
(coupe:
KA, KC model s, sedan: KA.
KC, KL
(DX)
model s, hat chback: al l model s), D16Yg engj ne
(sedan:
KA, KC model s)
*6:
' 96
D16Y8 engi ne
(coupe), ' 97 Dl 6Y7 engi ne
(coupe:
(LX)
model ), ' 97 D' 16Y8 engi ne
(coupe:
al l model s,
sedan: KL model ), ' 98-al l model s, ' 99-al l model s, ' 00-al l model s
*12:
Except A, , / T
(D16Y7,
D16Y8 engi nei
*13:
A"/ T
(D16Y7,
D16Y8 engi ne)
! l
* 14: ' 97
model
* 16: ' 98
model
"
17:
' 99
-
00 model s
(cont ' d)
1 1- 99
DTC
{MlL indication}
Detoction ltm Probable C.use Page
P0441*5
(92)
Evaporati ve Emi ssi on Control
System Insufficient
Purge Fl ow
EVAP Purge Control Sol enoi d Vai ve
Open or short i n EVAP Purge Control
Sol enoi d Val ve ci rcui t
EVAP Control Canister
Vacuum l i nes
ECM/PCM
11-271
P0451' 11
( 91)
Fuel Tank Pressure Sonsor Ci rcui t
Range/Parformance
.
Fuel Tank Pressure Sensor
'
ECM/PCM
11 274
P0452{6
(9r
)
Fuel Tank Pressure Sensor Ci rcui t
Low Input
Short i n Fuel Tank Pressure Sensor ci rcuat
Fuel Tank Pres$ure Sensor
ECM/PCM
11-275
P0453*6 {91)
Fuel Tank Pressure Sensor Ci rcui t
Hi gh Input
ODen i n Fuel Tank Pressure Sensor ci rcui t
Fuel Tank Pressure Sensor
ECM/PCM
11-219
P0500*1,
(17)
Vehi cl e Speed
Sensor Ci rcui t
Mal functi on
Vhi cl e Speed Sensor
Vehi cl e Speed Sensor ci rcui t
ECM
1 1 - 1 7 6
P0501*' 3 l 17l
Vehi cl e Speed
Sensor Ci rcui t
Range/Performance
Vhi cl e Sped Sensor
Vehi cl e Speed Sensor ci rcui t
PCM
r 1- 176
P0505
(14)
ldle Control System
lvl a lfu n ctio n
.
IAC valve
.
Throttle Body
1 1 - 1 9 2
P0700*r3
and some of
P0715
P0720
P0730
(70)*
P0740
P0753
P0758
Automatic
Transaxl e
Sect i on 14
P0700*1
and
(70)*
P0725
Automati c Transaxl e
Secti on 14
( 13)
Barometri c Pressure
Ci rcui t
Range/Performance Problem
.
ECM/PCM
(Baro
sensor)
1 1- 178
P1107
( 13)
Barometri c
Pressure Ci rcui t
Low Input
.
ECM/?CM
(Baro
snsor)
11- 178
P1108
( 13)
Barometri c
Pressure Ci rcui t
Hi gh I nput
.
ECM/PCM l Baro sensor)
1 1- 178
P1121* ' .
* 16. * ' ?
\ 71
Throt t l e Posi t i on Lower Than
Expected
.
I r sensor
11- 138
P1122' 14. *16. *n 17l
Throt t l e Posi t i on Hi gher Than
Expected
.
TP sensor
11-' 138
15)
Lower Than Expected
.
MAP sensor
1 1' 123
P 1 1 2 9 * 1 r . * 1 6 . * " ( 5 )
Hi gher Than Expected
.
MAP sensor ' t 1- 123
Troubleshooting
(DTGI
Chart
(cont'dl
*7:
D16YS engi ne
(M/T)
*8:
D16Y5, D' 16Y8 engi ne
*9:
USA model
* 14r ' 97
model
*15r
' 96
model
DTC
(MlL
indicationl
Detection lt6m Probablc Cause Page
P1162+1
(48)
(Sensor
1) Ci rcui t
Mal functi on
Open or short i n Pri marv HO2S
(Sensor
1
Pri mary H02S
(Sensor
1)
1 1- 146
P] 163'
( 61)
(Sensor
' 1)
Ci rcui t
Sl ow Response
.
Pri mary HO2S
(Sensor
1)
11- 145
Pl 164* r
( 61)
Pri mary Heat ed Oxygen Sensor
(Sensor l ) Cj rcui t Range/
Performance Problem
.
Pri mary HO2S
(Sensor
1)
1 1- 150
P1165* ?
( 61)
(Sensor
1) Ci rcui t Range/
Performance Probl em
.
Pri mary HO2S
(Sensor
1)
11- 150
P1166'
( 41i
(Sensor
' 1)
Heater System El ectri cal
Probl em
Open or short i n Pri mary HO2S
(Sensor
1)
heater ci rcui t
Pri mary HO2S
(Sensor
1)
ECM/PCM
1 1- ' 161
P1167* '
( 41)
l Sensor 1) Heater System
Mal functi on
Open in Primary HO2S
(Sensor
1) VS+ circuit
Pri mary HO2S
(Sensor
1) Heater
Pri marv HO2S {Sensor 1)
1 1- 163
P1168*'
(48)
(Sensor
1) LABEL Low Input
.
Short i n Pri mary HO2S
(Sensor
1) LABEL
ci rcui t
1 1 - 1 5 1
Pl 169* ?
( 48)
(Sensor
1)IABEL Hi gh Input
.
Open i n Pri mary HO2S
(Sensor
1)IABEL
ci rcui t
.
Short i n ground
ci rcui t
1 1 . 1 5 2
P1259*3
(221
WEC Syst em Mal f unct i on
WEC Sol enoi d Val ve
Open or short i n WEC Sol enoi d
Valve circu it
VTEC Pressure Switch
Open or short in VTEC Pressure Switch
ci rcui t
ECM,FCM
Secti on 6
P1297*s
(20)
El ect ri cal Load
Det ect or Ci rcui t
Low I nput
Electrical Load Detector
Electrical Load Detector circuit
ECM/PCM
11- 179
Pr298+' l 20l
El ectri cal Load
Detector Ci rcui t
Hi gh I nput
Electrical Load Detector
Electrical Load Detector circuit
ECM/PCM
1 1- 181
ano
some of
P0301
P0302
P0303
P0304
l 71l
l72l
l 73l
l 7 4l
Bandom Mi sfi re
l gni ti on system
Fuel supply system
MAP sensor
EGR system
IAC val ve
Contami nated fuel
Lack ol fuel
1 1 - 1 6 6
1 1 - 1 0 0
DTC
(Ml L i ndi cati onl
Detection ltem Probable Cause Page
P1336
(54i
Crankshaf t Speed
Fl uct uat i on Sensor
I nt ermi t t ent I nt errupt i on
.
CKF sensor
1 1 1 8 3
P1337
(54)
Crankshaft Speed
Fl uctuati on Sensor
No Si gnal
CKF sensor
CKF sensor ci rcui t
ECM,PCM
11- ' 183
P13s9
(8)
Crankshaft Position/Top
Dead Center Sensor
Di sconnected
'
CKP/TDC sensor ci rcui t
11-187
P1361
(8)
Top Dead Center
Sensor Intermi ttent
Interruptron
.
t uL s ens or
11-172
P1362
(8)
Top Dead Center
Sensor No Si gnal
TDC sensor
TDC sensor ci rcui t
ECIV/PCM
11-172
P1381 { 9)
Cyl i nder Posi t i on Sensor
I nt ermi t t ent I nt errupt i on
.
CYP sensor
11-172
P1382
(9)
Cyl i nder Posi t i on Sensor
No Si gnal
CYP sensor
CYP sensor ci rcui t
ECM/PCM
11-112
P1456*5
(90)
System Leak Detected {Fuel Tank
Area)
Fuel f i l l cap
Vacuum connect i on
Ful t ank
Fuel t ank pressure sensor
EVAP bypass sol enoi d val ve
EVAP two way valve
EVAP cont rol cani st er vent shut val ve
EVAP cont rol cani st er
EVAP
purge cont rol sol enoi d val ve
11-283
P1457*6
(90)
System Leak Detected
(EVAP
Control Cani ster Area)
Vacuum connect i on
EVAP cont rol cani st er
Fuel t ank pressure sensor
EVAP two way valve
EVAP cont rol cani st er vent shut val ve
Fuel Tank
EVAP
purge
cont rol sol enoi d val ve
11-283
L
*6:
' 96
D16Y8 engi ne
(coupe),' 97
Dl 6Y7 engi ne
(coupe:
(LXl
model ),' 97 D16Y8 engi ne
(coupe:
al l model s,
sedan: KL model ),' 98-al l model s,' 99-al l model s,' 00-al l model s.
(cont' d)
1 1 - 1 0 1
I t a
Troubleshooting
(DTCI
Ghart
(cont'd)
DTC
lMlL indicationl
Detegtion hom Probablo Csuss Page
P1491* !
\ 12J
EGR Val ve
Lift Insufficient
Detected
EGR val ve (wi th
l i ft sensor)
EGR val ve l i ft sensor ci rcui t
EGR control sol enoi d val ve
(A,/I)
EGR control sol enoi d val ve ci rcui t
EGR l i ne
EGR val ve ci rcui t
(M/T)
ECM
' t1-256
P1498*. 112)
EGR Val ve
Li f t Sensor
Hi gh Vol t age
EGR val ve
(wi t h
l i f t sensor)
EGR val ve l i f t sensor ci rcui t
ECM
11- 265
Pl 508* 10
( 14)
l dl e Ai r Control Val ve
Ci rcui t Fai l ure
IAC val ve
IAC val ve ci rcui t
ECM
' 11- 194
{ 14)
l dl e Ai r Control Val ve
Ci rcui t Fai l ure
Open or short i n IAC val ve ci rcui t
IAC val ve
ECM/PCM
1 l - 1 9 8
P1607 1-)
Engi ne Cont rol
Modul e/ Powert rai n Cont rol l vl odul e
l nt ernal
Ci rcui t Fai l ure A
.
ECM/PCM
11- 188
P1655*1
(30) TMA,/TMB Si gnal Li ne Fai l ure ODen or sho.t in TMA,/TMB circuit 11- 189
P1705
P1706
P 1753
P1758
P1768
P1785
P1790
P1791
P1793
(70)*
P1870
P1873
P1879
P1885
P1886
P1888
P1890
P1891
Automati c Transaxl e
Secti on 14
*:
The
E
i ndi cator l i ght and the Mal functi on Indi cator Lamp {Ml L) may come on si mul taneousl y.
*4:
D16Y5 engi ne
(M/T)
+10:
Except A/T and Dl 6Y7 engi ne
*11:
A,/T and D16Y7 engi ne
*18:
D16Y5 engi ne
(CW) (except
' 99
-
00 model s)
11- 102
How to Read Flowcharts
A fl owchart i s desi gned to be used from start to fi nal repai r. l t' s l i ke a map showi ng you the shortest di stance. But beware:
l f you go off the
"map"
anywhere but a
"stop"
symbol , you can easi l y
get l ost.
tSrARTl
(bol d
type)
FanoNl
@
tsroP I
{bol d type)
Descri bes the condi ti ons or si tuati on to start a troubl eshooti ng fl owchart.
Asks you to do somethi ng;
perform a test, set up a condi ti on etc.
Asks you about the resul t of an acti on, then sends
you i n the appropri ate troubl eshooti ng di recti on.
The end of a seri es of acti ons and deci si ons. descri bes a fi nal repai r acti on and someti mes di rects you to
an earl i er part of the fl owchart to confi rm
your repai r,
NOTE:
. The term
"l ntermi ttent
Fai l ure" i s used i n these charts, l t si mpl y means a system may have had a fai l ure. but i t checks
out OK at thi s ti me. l f the Mal functi on Indi cator Lamp
(Ml L)
on the dash does not come on, check for
poor connecti ons
or l oose wi res at al l connectors rel ated to the ci rcui t that you are troubl eshooti ng
(see
i l l ustrati on bel ow)'
. Most of the troubl eshooti ng fl owcharts have you reset the Engi ne Control Modul s
(ECM)/Powertrai n
Control Modul e
(pCM)
and try to dupl i cate the Di agnosti c Troubl e Code
(DTC).
l f the probl em i s i ntermi ttent and
you can' t dupl i cate the
code, do not conti nue though the fl owchart. To do so wi l l onl y resul t i n confusi on and, possi bl y, a needl essl y repl aced
ECM/PCM.
.
,,Open"
and
"Short"
are common el ectri cal terms. An open i s a break i n a wi re or at a connecti on. A short i s an acci -
dental connecti on of a wi re to ground or to another wi re. In si mpl e el ectroni cs, thi s usual l y means somethi ng won' t
work at al l . In compl ex el ectroni cs
(l i ke
ECM' s/PCM' sl . thi s can someti ms mean somethi ng works, but not the way i t' s
suDDosed to.
toosE
1 1 - 1 0 3
PGM-FI System
System Description
CKP/TDC/CYP Sensor
MAP Sensor
I AT Sensor
TP Sensor
EGR Val ve Li f t Sensor*'
Pri mary H02S
Secondary HO2S
VSS
BARO Sensor
ELD*'
KS
St art er Si gnal
ALT FR Si gnal
Ai r Condi t i oni ng Si gnal
A/ T Gear Posi t i on Si gnal
Bat t ery Vol t age {l GN. 1}
Erake Swi t ch Si gnal
PSP Swi t ch Si gnal
Fuel Tank Pressure Sensor*i
VTEC Pressure Swi t ch*5
Cl ut ch Swi t ch Si gnal *6
Count ershaf t Speed SensornB
Mai nshaf t Speed Sensorrs
- \
----t
/
F; i l r r
j " - - - - - f i - t r i - ' r . ; l
Fb"t."'i"
d" c;;il
F,h"' c;;tr*".io";-l
@. "r. l "sc; ; l l
EaM/PcM
B""k-p F"""till
r \
-:/
Fuel I ni ect ors
PGM-Fl Mai n Bel ay {Fuel Pump)
MI L
I AC Val ve
! y' C Compressor Cl ut ch Rel ay
Radi at or Fan Rel ay*,
Condenser Fan Rel ay
ALT*'
l cM
EVAP Purge Cont rol Sol enoi d
Pri mary HO2S Heat er
Secondary H02S Heat er
EGR Cont rol Sol enoi d Val ve*r
EGR val ve*6
EVAP Bypass Sol enoi d Val ve*'
EVAP Cont rol Cani st er Vent Shut
VTEC Sol enoi d Val ve*5
DLC
Lock-up Cont rol Sol enoi d Val ve*a
Shi f t Cont rol Sol enoi d Val ve*3
Li near Sol enoi d Val ve*3
*1:
Dl 6Y5 engi ne
*2:
USA model
*3:
CW
(D16Y5
ensi ne), D16Y8 engi ne and 81642 ensi ne
*4:
' 96
D16Y8 engi ne l coupe), ' 97 Dl 6Y7 engi ne
(coupe:
(LX)
model ), ' 97 D16Y8 engi ne {coupe: al l model s, sedan: KL
model ), ' 98-al l model s, ' 99' al l model s, ' 00-al l model s
+5:
D16Y5, D16Y8, 816A2 engi ne
*6:
M/ T
(D16Y5
engi nei
*7:
CVT 1D' l 6Y5 engi ne)
+8:
A/ T
(D16Y7,
D16Y8 engi ne)
*9:
' 96
D16Y5 engi ne, ' 96 D16Y7 engi ne, ' 96 Dl 6Y8 engi ne
(sedan), ' 97
D16Y5 engi ne, ' 97 Dl 6Y7 engi ne
(coupe:
KA, KC model s, sedan:
KA, KC, KL
(LX)
model s, hat chback: al l model s), ' 97 D16Y8 engi ne
(sedan:
KA, KC model si
PGM-FI Sy3lem
The PGM-Fl syst em on t hi s model i s a sequent i al mul t i pon f uel i nj ect i on syst em.
Fuel iniector Timing and Duration
The ECM/ PCM cont ai ns memori es f or t he basi c di scharge durat i ons at vari ous engi ne speeds and mani f ol d ai r f l ow rat es.
The basi c di scharge durat i on, af t er bei ng read out f rom t he memory. i s f urt her modi f i ed by si gnal s sent f rom vari ous sen-
sors t o obt ai n t he f i nal di scharge durat i on.
ldle Air Control
l dl e Ai r Cont rol Val ve l l AC Val ve)
When t he engi ne i s col d. t he A, / C compressor i s on, t he t ransmi ssi on i s i n gear, t he brake pedal i s depressed, t he P/ S l oad
i s hi gh, or t he al t ernat or i s chargi ng, t he ECM/ PCM cont rol s current t o t he I AC Val ve t o mai nt ai n t he correct i dl e speed.
lgnition Timing Control
. The ECM/ PCM cont ai ns memori es f or basi c i gni t i on t i mi ng at vari ous engi ne speeds and mani f ol d ai r f l ow rat es.
l gni t i on t i mi ng i s al so adj ust ed f or engi ne cool ant t emperat ure.
. Aknockcont rol syst em was adopt ed whi ch set s t he i deal i gni t i on t i mi ng f or t he oct ane rat i ng of t hegasol i ne used. *3
Othgr Control Funqtions
1. St art i ng Cont rol
When t he engi ne i s st art ed, t he ECM/ PCM provi des a ri ch mi xt ure by i ncreasi ng f uel i nj ect or durat i on.
2. Fuel Pump Cont rol
. When t he i gni t i on swi t ch i s i ni t i al l y t urned on, t he ECM/ PCM suppl i es ground t o t he PGM-Fl mai n rel ay t hat sup-
pl i es current t o t he f uel pump f or t wo seconds t o pressuri ze t he f uel syst em.
. When the engine is running, the ECI\4PCM supplies ground to the PGM-FI majn relay that supplies current to the fuel
oumo.
. When t he engi ne i s not runni ng and t he i gni t i on i s on, t he ECM/ PCM cut s ground t o t he PGM-FI mai n rel ay whi ch
cut s current t o t he f uel pump.
11- 104
INPUTS
ENGI NE CONTROL MODULE
( ECMY
POWERTRAIN CONTROL MODULE
(PCM)
OUTPUTS
3.
5.
6.
1.
Fuel Cut-off Control
. Duri ng decel erati on wi th the throttl e val ve cl osed, current to the fuel i nj ectors i s cut off to i mprove fuel economy at
speeds over the fol l owi ng rpm:
.
D16Y5 engi ne
( M/ T) : 850
r pm
.
D]6Y5 engi ne
(CVT),
D' 16Y8 engi ne
(USA
M/T): 920 rpm
.
Dl 6Y8 engi ne
(USA
A,/I), D16Y7 engi ne
(USA
A,/T);910 rpm
.
D16Y8 engi ne
(Canada
M/T), D16Y7 engi ne
(canada):
990 rpm
'
D16Y8 engi ne
(Canada
M/T): 1,000 rpm
.
816A2 engi ne: 970 r pm
. Fuel cut-off acti on al so takes
pl ace when engi ne speed exceeds 6,900 rpm
(D16Y5,
D16Y7 engi ne; D' 16Y8 engi ne:
7,000 rpm. 816A2 engi ne: 8.100 rpm), regardl ess of the posi ti on of the throttl e val ve, to
protect the engi ne from
over-rewi ng. Wi th
' 99
Dl 6Y7 engi ne
(A,/T)
and
' 99
D16Y8 engi ne
(A./T),
the PCM cuts the fuel at engi ne speeds over
5,000 rpm when the vehi cl e i s not movi ng.
IVC Compressor Cl utch Rel ay
When the ECM/PCM recei ves a demand for cool i ng from the ai r condi ti oni ng system, i t del ays the compressor from
bei ng energi zed, and enri ches the mi xture to assure smooth transi ti on to the A,/C mode
Evaporati ve Emi ssi on
(EVAP)
Purge Control Sol enoi d Val ve*'
When the engi ne cool ant temperature i s above 154' F
(68' C).
the ECM/PCM control s the EVAP purge control sol enoi d
val ve whi ch control s vacuum to the EVAP purge control cani ster.
(EVAP)
Purge Control Sol enoi d Val ve*a
When the engi ne cool ant temperature above 154"F
(68"C),
i ntake ai r temperature above 32"F
(0' C)
and vehi cl e speed
above 0 mi l e
(0
km/h) or [Ay' C compressor cl utch on and i ntake ai r temperature above 160"F
(41' C)],
the ECM/PCM
control s the EVAP purge control sol enoi d val ve whi ch control s vacuum to the EVAP
purge control cani ster.
Exhaust Gas Reci rcul ati on
(EGR)
Control Sol enoi d Val ve*?
When EGR i s requi red for control of oxi des of ni trogen
(NOx)
emi ssi ons. the ECM control s the EGR control sol enoi d
val ve whi ch suppl i es regul ated vacuum to the EGR val ve
Al ternator Control
The system control s the vol tage generated at the al ternator i n accordance wi th the el ectri cal l oad and dri vi ng mode,
whi ch reduces the engi ne l oad to i mprove the fuel economy.
ECM/PCM Fail-safe/Back-up Functions
1. Fai l safe Functi on
When an abnormal i ty occurs i n a si gnal from a sensor, the ECM/PCM i gnores that si gnal and assumes a pre-pro-
grammed val ue for that sensor that al l ows the engi ne to conti nue to run.
2. Back-uD Functi on
When an abnormal i ty occurs i n the ECM/PCM i tsel f, the fuel i nj ectors are control l ed by a back-up ci rcui t i ndependent
of the system i n order to permi t mi ni mal dri vi ng.
3. Sel f di agnosi s Functi on l Mal functi on
Indi cator Lamp
(Ml L)l
When an abnormal i ty occurs i n a si gnal from a sensor, the ECM/PCM suppl i es
ground for the l vl l L and stores the DTC
i n erasabl e memory. When the i gni ti on i s i ni ti al l y turned on, the ECM/PCM suppl i es ground for the MIL for two sec-
onds to check the MIL bul b condi ti on.
4. Two Tri p Detecti on Method
To prevent fal se i ndi cati ons, the Two Tri p Detecti on Method i s used for the HO2S, fuel meteri ng-rel ated. i dl e control
system, ECT sensor, EGR system and EVAP control system sel f-di agnosti c functi ons. When an abnormal i ty occurs,
the ECM/PCM stores i t i n i ts memory. When the same abnormal i ty recurs after the i gni ti on swi tch i s turned OFF and
ON 0l ) agai n, the ECM/PCM i nforms the dri ver by l i ghti ng the Ml L. However, to ease troubl eshooti ng, thi s functi on i s
cancel l ed when
you j ump
the servi ce check connector. The MIL wi l l then bl i nk i mmedi atel y when an abnormal i ty
occurs,
5. Two
(or Three) Dri vi ng Cycl e Detecti on Method
A
"Dri vi ng
Cycl e" consi sts ot starti ng the engi ne. begi nni ng cl osed l oop operati on, and stoppi ng the engi ne. l f mi sfi r-
i ng that i ncreases emi ssi ons i s detected duri ng two consecuti ve dri vi ng cycl es, or TWC deteri orati on i s detected dur-
i ng three consecuti ve dri vi ng cycl es, the ECM/PCM turns the MIL on. However, to ease troubl eshooti ng, thi s functi on
i s cancel l ed when you j ump
the servi ce check connector. The MIL wi l l then bl i nk i mmedi atel y when an abnormal i ty
occurs.
(cont ' d)
1 1- 1 05
. 1 .
PGM-FI System
System Description
(cont'dl
Lean Burn Control {D16Y5 engine: CvT)
The l ean burn control system i s based on the characteri sti c i ncrease i n crankshaft angul ar accel erati on whi ch occurs i n
when the ai r-fuel rati o gets l eaner.
The CKF sensor, whi ch i s mounted on the crankshaft, moni tors sngi ne speed, l f crankshaft angul ar accel erati on fal l s bel ow
a certai n l evel
(target
ai r-fuel rati o l evel ), the amount of i nj ected fuel i s reouceo.
l f crankshaft angul ar accel erati on exceeds thi s l evel . the amount of fuel i s i ncreased.
Thi s system i mproves fuel economy and dri veabi l i ty by control l i ng the amount of i nj ected fuel i n the l ean burn range
i mmedi atel v before combusti on starts to deteri orate.
1 1- 1 06
TOC/CKP/CYP SENSOR
MAP SENSOR
CKF SENSOR
ECM
Compari son oI current ai r
fuel ratio to target ratio
I
Engine Control Module/Powertrain
Control Module
(ECM/PCM)
t' 96
-
98 Model s,' 99
-
00 Dl 6Y5 engi ne wi th M/Tl
L
NOTE: l f t h i s svmpt om i s i nt ermi t t ent , check f or a l oose f use No. 25 {METER 7. 5 A) i n t he
underdash {use/ rel ay box, a poor connect i on at ECM/ PCM t ermi nal A18, or an i nt ermi t
t ent ooen i n t he GRN/ ORN wi re bet ween t he ECM/ PCM
(A18)
and t he
gauge assembl v.
PGl {BLKI
ECM/PCM CONNECTOR A
(32P}
(cont' d)
11- 107
The Malfunc{ion Indicator Lamp
{Ml Ll never comes on
(even l or
t wo secondsl at t er i gni t i on i s
turned on.
Turn t he i gni t i on swi t ch ON
(l l ).
-
Repai r short or open i n t he
wile botwoen No. 25 {MTERI
17,5
Altus and gau99 assem'
bt y.
-
Repl aco No. 25 I METERI
(7, 5
A)tuse.
l s t he l ow oi l pressure l i ght on?
Try to start the engine.
Does t he engi ne st an?
Check lor an open in the wiles
{PG
linosl:
(l l ).
2. l deasur e vo l t age bet ween
body
gr ound and ECM/ PCM
connect or t ermi nal s A10 and
A23 i ndi vi dual l y.
Check tor an open in the wire ot
bul b
(Ml L l i ne):
2. Connect t he ECM/ PCM con-
nect or t ermi nal A' 18 t o body
ground wi t h a
j umper
wi re.
3. Turn the ignition switch ON
(ll).
Repai r open i n t he wi r e( s)
bet ween ECM/ PCM and G101
(localod at the thetmostat hous_
i ngl t hat had more t han 1. 0 V.
l s t hore l ess t han 1. 0 V?
Substituto . known-good ECM/
PCM and recheck. I t sympt om/
i ndi cat i on
go6s away, roPl ace
the origin.l ECM/PCM.
-
Repai r open i n t h wi r es
betwoen ECM/PCM lAl8l and
gaug6 a$embly.
-
Replace the MIL bulb,
l s t he MI L on?
PCM and . echeck. l f sympt om/
i ndi cat i on
goes away, repl aco
2 6 8 l 0 1 1
12 l 3 t 5 t 6 1 t I t 19 20 22 23 2a
25 27 xt 30
MrL
I luanpen wrnr
I GRN/ ORN) I
! 1 ,
PGM-FI System
Engine Control Module/Powertrain Control Module
(ECM/PCMI
(' 96
-
98 Model s,' 99
-
(cont' d)
NOTE:
.
When t here i s oo Di agnost i c Troubl e Code
(DTC)
st ored, t he Mt L wi

st ay on i f t he SCS
servace connect or i s connect ed and t he i gni t i on swi t ch i s on,
.
l f t hi s sympt om i s i nt ermi t t ent , checkl or:
-
A l oose Fl E/ M 115 A) f use i n t he under hood l use/ rel ay box
-
A l oose No. 13 FUEL PUMP f use (15
A) i n t he underdash f use/ rel ay box
-
An i nt ermi t t ent shon i n t he wi re bet ween t he ECM/ PCM
(C7)
and t he servi ce cnecK
connector
-
An i nt er mi t t ent shor t i n t he wi r e bet ween t he ECM/ PCM
( A18)
and t he gauge
assembl y
-
An intermittent shon in the wire between the ECM/PCM {D4) and the MAp sensor
An i nt ermi t t ent short i n t he wi re bet ween t he ECM/ PCM
(D10),
t he Tp sensor, t he
EGR val ve l : f t sensor
(D16Y5
engi ne) and/ or t he Fuel t ank pressure
sensor
(, 96
Dl 6Y8 engi ne
(coupe),
' 97
016Y7 engi ne
(coupe:
(LX)
model i ,
' 97
016Y8 engi ne {coupe: al l model s, sedan: KL modet i , ' 98, al l model s}
-
PGM-FI mai n rel ay
.
See t he OBD l l scan t ool or Honda PGM Test er user' s manual s l or speci t i c operat i ng
i nst ruct i ons.
ECM/PCM CONNECTOR C 13lPI
(To page 11 109)
(To page 11, 109)
1 1 - 1 0 8
The Maltunction Indicator Lamp
(MlLl
stays on o. comes on eftar
two sconds,
Check t he Oi agnosl i c Troubl e
Code {DTC}I
1. Connect a scan t ool or Honda
PGM Test er.
(l l ).
3. Read t he DTC wi t h t he scan
t ool or Honda PGM Test er.
Go to troubleshooting p.ocdurs
(se pago 11{11.
Are any DTC{s) i ndi cat ed?
Check the DTC by MIL indication:
2. Connect t he SCS servi ce con,
nect or t o t he ser vi ce check
connector.
(l l i .
Repair opon ol short in wire
botwoen the ECM/PCM
(C8)
and Data Link Connector.
Go to troublelhooting proce-
dure l s6e
page 11-811.
Does t he MI L i ndi cat e any DTC?
Try t o st art t he engi ne.
Does the engine start?
Check f or a short i n t he wi re
(SCS
linl:
1. Di sconnect t he SCS ser vi ce
connect or.
2. St op t he engi ne and t urn t he
i gni t i on swi t ch ON {l l i .
3. Measure vol t age bet ween t he
C7 and body ground.
Ropair short to body
Iround
in
the wire betweon ECM/PCM lCTl
and sorvice check connector.
l s t here approx. 5 V?
scs tBRNI
l Fr om
page 11 108)
Check for a short in the wire {MlL
l i nel l
2. Disconnect the Eclvl/PCM con-
nect or A
(32P).
3. Turn t he i gni t i on swi t ch ON {l l ).
Ropair short to body gtound in
the wir. between the ECM/PCM
l A18) and Ml L.
l s t he MI L ON?
PCM and recheck. l t 3ympt om/
i ndi cai i on
goes away, rePl ace
ihe original ECM/PCM.
( Fr om page 11 108)
I nspect Fl E/ M
(10 A) f use i n t he
undeFhood Iuse/relay box.
-
Repai r shor t i n t he wi r g
bt weon Fl E/ M
(15
A) l use
and PGM-FI main rolay.
-
Replace Fl E/M
(15
Alfuse.
I nspect No. 13 FUEL PUMP
(15
A)
f use i n t he under-dash f use/ rel aY
-
Repai t l hor t i n t he wi r e
botween No. 13 FUEL PUMP
115
Al fuse and PGM-FI main
reray.
-
Ropl ace No. 13 FUEL PUMP
115 Al tu3o.
Check for a short in a 3nsor:
(l l i .
2. Di sconnecl t he 3P connect or
f rom each sensor one at t i me:
.
TP sensor
.
EGR val ve l i f t sensor
(D16Y5
engrne)
.
Fuel t ank pr essur e sensor
( ' 96
D16Y8 engi ne
( coupe) ,
' 97
D16Y7 engi ne
( couPe:
( LX)
mo d e l ) , ' 9 7 D1 6 Y8 e n g i n e
l coupe:
al l model s, sedan:
KL model , ' 98-al l model s)
{ To
page 11 110)
(cont' d)
1 1 - 1 0 9
!
PGM-FI System
( Fr om page 11- 109)
Replace the sensor that caused
the light to go
out.
Does t he N4l L go OFF?
Check f o. a short i n t he wi . os
(VCC
lines):
' : .
Turn t he i gni t i on swi t ch OFF.
2. Di sco n n ect t he ECM/ PCM
connect or D
(16P).
body gr ound and ECM/ PCM
connect or t er mi nal s D4 and
D10 i ndi vi dual l y.
Ropair short to body ground
i n t he wi re bet weon ECM/
PCM
{O4) and MAP s6n3or.
Repair short to body ground
i n t he wi re bet ween ECM/
PCM
l D10l , t he TP sensor, t he
EGR val ve l i f t sensor {D16Y5
engine) and/or the Fuel tank
pressure
sensor {' 96 Dl 6Yg
engi ne l coupe) , ' 97 D16Y7
engi ne
( coupe:
KL model ,
sedan: KL
( LXl
model ) ,
' 97
D16Y8 engi ne
( coupe:
al l
models, sedan: KL model. 8-
al l model sl .
Check t or rn open i n t he wi res
(l GP
l i nes):
1. Di sconnect t he f uel i nj ect ors
and I AC val ve connect ors,
(l l ).
3. Meas u r e vol t age bet ween
connect or t er mi nal s A11 and
424 i ndi vj dual l y.
-
Repai r open i n t he wi rel s)
bet ween ECM/ PCM ( A11,
A24l and PGM-Fl mai n rel ay.
-
Check f or poor connect i ons
or loose wiras at the PGM-FI
mai n rel ay,
-
Test t he PGM-FI mdi n rel av
l see
pag6 11-237).
l s t here bat t ery vohage?
Check f or an open i n t he wi res
(LG
l i ne3):
1. Reconnect al l sensor connec
t ors.
2. Reconnect t he ECM/ PCM con-
nect or D
(16P).
(l l ).
4. Measur e vo l t age bet ween
connect or t er mi nal s Ag and
A22 i ndi vi dual l y.
Repai r open i n t he wi r ol gl
btwen ECM/PCM
{A9, A22} and
G101 that had more than 1.0 V.
l s t here l ess t han 1. 0 V?
Substitute 6 known-good ECM/
PCM and rcheck. l f sympt om/
i ndi cat i on
9os
away, repl ace
Control Modul e
(ECM/pCMl
('96 -
98 Models,
'99
-
00 D16Y5 engine with M/Tl
(cont,dl
ECM/PCM CONNECTOR D {16P}
ECM/PCM CONNECTOR A
(32P}
11- 110
LG1
VCCl {YEL/ RED}
IGP 1
{YEL/BLKI
2 I 1 1
12 1 3 l 5 t 6 I t t 8 t 9 20 23 21
25 27 2a 29 30
IGP 2
(YEL/ BLKI
v) ( l
{8RN/
BLK)
I 2 5 8 t o l 1
'12
t t 11 t 5 l 6 1 7 t 8 t 9 20 23 2a
2A 23 30
LG2
{8RN/
8LK}
Engi ne Control Modul e/Powertrai n Control Modul e
(ECM/PCM)
('95
-
00 Models except Dl6Y5 engine with M/T)
NOTE:
.
When t here i s no Di agnost i c Troubl e Code l DTC) st ored, t he MI L wi l l st aY on i f t he SCS
serui ce connect or i s connect ed and t he i gni t i on swi t ch i s on.
.
l f t hi s sympt om i s i nt ermi t t ent , check f or:
-
A l oose No. 25
(METER)
{7. 5 A) f use i n t he underdash f use/ rel ay box
-
A l oose Fl E/ M
(15
Al l use i n t he undeFhood f use/ rel ay box
-
A l oose No. 13 FUEL PUMPf use
(15
A) i n t he under-dash f use/ rel ay box
-
An i nt ermi t t ent shon i n t he wi re bet ween t he ECM/ PCM
(A18)
and t he
gauge assem'
-
an intermittent short in the wire between the ECM/PCM
(C19)
and the MAP sensor
-
An i nt ermi t t ent short i n t he wi re bet ween t he ECM/ PCM {C28), t he TP sensor, t he
EGR val ve l i f t sensor
(D16Y5
engi ne) and/ or t he Fuel t ank
pressure sensor
(' 96 D16Y8
engi ne
(coupe), ' 97 D16Y7 engi ne l coupe:
KL model , sodan: KL
(LX)
model )"g7
Dt 6Y8 engi ne
(coupe:
al l mod; l s, sedanl KL model ), ' 98-al l model s, ' 99-al ' model s'
' 00-al l
model s.
-
PGM' FI mai n rel ay
.
See t he oBD l l scan t ool or Honda PGM Test er user' s manual s f or speci f i c operat i ng
i nst ruct rons,
ECM,/PCM CONNECTOR A I32PI
The Mrlfunction Indicator LamP
{MlL) never comes on {even tor
t wo seconds) af t er i gni t i on i s
t urned ON l l l ).
Turn t he i gni t i on swi t ch ON l l l ).
-
Repai r shot t or open i n t ho
wire bstwoon No. 25 IMETER)
l ?. 5 A)t use and
gauga t som_
blv.
-
Reol ace No. 25
(METERI (7. 5
Al l use.
l s t he l ow oi l pressure l i ght on?
Try to start the engine.
Check for an opon in the wire or
bul b
(Ml L l i ne):
1. Turn the ignition switch OFF.
2. Connect t he ECM/ PCM con'
nect or t ermi nal A18 t o body
ground wi t h a
i umper
wi re.
(l l )
Does the engine start?
-
Repai r open i n t ho wi r e3
betwoon ECM/PCM
(A18) and
gaugo .*tembly.
-
Rool.ce the MIL bulb.
PCM and rochoc&. lf sYmptom/
i ndi cat i on
goes sw6y, repl . ce
tho original ECM/PCM.
Inspect Fl E/M
(15
A)fuse in the
underhood Iuse/relay box.
Rop. i r shor t i n t he wi r c
bet won Fl E/ M
(15
A) l uso
and PGM-Fl mrin rGl.y.
Reol.ce Fl E/M
(15 A)tusa.
l nspect No. 13 FUEL PUMP {15 A}
luse in the under-dash fuse/relay
-
Reoai r shor t i n t he wi r o
between No. 13 FUEL PUMP
115 Al luse sod PGM-FI main
relay.
-
Reol ace No. 13 FUEL PUMP
115 A) tuse.
( To page 11 112)
(cont ' d)
11- 111
. f ,
PGM-FI System
( Fr om page' 11- 111)
Check l oi an open i n t he wi res
(lGP
linesl:
1. Di sconnect t he l uel i ni ect or and
IAC valve connectors.
(l l ).
3, Measu r e vol t age bet ween
connect or t er mi nal s 81 and
Bg i ndi vi dual l y.
-
Repai r open i n t he wi r o( 3)
bet ween ECM/ PCM l Bl , B9l
and PGM-Fl main relay.
-
Check t or poor connect i ons
or loose wires al the PGM-FI
main relav.
-
Test t ho PGM-FI mai n rehy
(3.e page 11-237).
Check t or an open i n t he wi res
(PG,
LG lines):
1. Reconnect t he f uel i ni ect or
and I AC val ve connect ors.
2. Measur e vol t age bet ween
body
ground
and ECM/ PCM
connect or t ermi nal s 82, 810,
820 and 822 i ndi vi dual l y.
Repai r open i n t he wi r el s)
bet ween ECM/ PCM and G 101
llocated ai the l6ft side of tho
i nt aks m. ni f ol dl t hrt h. d more
t han 1. 0 V.
l s t here l esst han 1. 0 V?
Check f or a short i n t he wi res
{VCCI, VCC2 lin6s}:
Measure vol t age bet ween body
ground and ECM/ PCM connect or
t ermi nal s C19 and C28 i ndi vi dual l y. Check toa a 3hort in s 3ensor:
Wh i l e me a s u r i n g v o l t a g e
bet ween body ground and ECM/
PC[ / t connect or t er mi nal s C19
and C28 i ndi vi dual l y, di sconnect
t he 3P connect or of each sensor
one at t i me:
.
MAP sensor
.
TP sensor
.
EGR val ve
.
Fuel t ank pressure
sensor
Reoair short in lhe wire betwe.en
MAP 3ansor , TP sensor , EGR
valve, Fuel tank pres3ure
3ensor
and ECM/PCM {Cl9, C28).
Substiiute a known-good ECM/
PCM and racheck. ll symptom/
i ndi cet i on goes eway, repl ace
th6 original ECM/PCM. Repl ac e t ho s ans or t hat had
.pprox. 5 V.
('99 -
00 Model except Dl6Y5
(M/Tl
Modul e
(ECM/PCM)
(cont'd)
Control
engi ne)
ECM/PCM CONNECTOR B {25P)
LG1
(BRN/ BLKI
ECM/PCM CONNECTOR C
(31P)
f emal e t er mi nal s
vcc2
IYEL/BLUI
vccl
{YEL/RED)
11- 112
NOTE:
"in-"n
tf'"r" is no Diagnostic Trouble Code
(DTCi
stored, the MIL will stav on ;{ the scs
servi ce connect or i s connect ed and t he i gni t i on swi t ch i s ON
(l l )
.
l f t hi s sympt om i s i nt ermi t t ent , check f or:
-
An i nt ermi t t ent short i n t he wi re bet ween t he ECM/ PCM
(A10) and t he servi ce check
connect or
-
An i nt er mi t t ent shor t i n t he wi r e bet ween t he ECM/ PCM
( A181
and t he gauge
.
s"" i t ' " Oab l l scan t ool or Honda PGM Test er user' s manual s f or speci f i c operat i ng
i nst ruct i ons.
' l
ECM/PCM CONNECTOR
A I32P)
The Malfunction Indicator LamP
lMlL) staYs on or comes on after
Check t he Di agnost i c
Tr oubl e
Code
(DTC):
1. Connect a scan t ool or Honcl a
PGM Test er.
(l l )
3. Read t he DTC wi t h t he scan
t ool or Honda PGM Test er.
Go to troubloshooting Procdures
(see page 1141).
Are any DTC(S) i ndi cat ed?
check the DTC by MIL indic.tion:
2. Connect t he SCS servi ce con_
nect or t o t he ser vi ce check
(l l )
Repair open or 3hort in wiro
between ihe ECM/PCM
(A21)
and Data Link Connector.
Go to troubleshooting Ploce_
du.es
(see page 11-811.
Does t he MI L i ndi cat e anY DTC?
Tr y t o st ar t t he engi ne
Substitute . known-good
ECM/
PCM and recheck l t sYmpt om/
i ndi cat i on
goes awaY, rePl aca
th. original ECM,/PCM.
Check f or a shor t i n t he wi . e
(Scs line):
and t urn t he i gni t i on swi t ch
oN 1 ) .
2- Meas u r e vol t age bet ween
body
gr ound and t he ECM/
PCM connect or t ermi nal A10
Reoair short to body
ground in
the wiro bstwaen ECM/PCM
(A101
and service chck connoctot.
( To page 11- ' 114)
(cont' d)
1 1 - 1 1 3
PGM-FI System
Engine Gontrol Module/Powertrain
Control
('99
-
00 Models except Dl6Y5 engine with
Modul e
(ECM/PCMI
M/T)
(cont'dl
{ Fr om page 11 1 l 3)
Check for a short in the wi.e lMlL
l i nel r
2. Disconnect the ECM/PCM con
nect or A
(32P).
(l l ).
Repai r shorl t o body ground
i n
the wire between the ECM/PCM
{A18}and Ml L.
l s t he MI L ON?
Substituto a known-good ECM/
PCM and rcheck. l f sympt om/
i ndi cat i on goes
away, ropl ace
the o.iginal ECM/PCM.
11- 114
Manifold Absolute
Pressure
(MAP)
Sensor
('96
Models)
The scan tool i ndi cates Di agnosti c Troubl e Code
(DTC) P0106: A mechani cal
probl em
(vacuum l eak) i n the
(MAP)
Sensor system'
TheMAPsensor conver t smani f oI dabsoI ut epr essur ei nt oei ect r i caI si gna| sandi npUt st heEcM/ PcM'
OUTPUT
VOLTAGE
( v13. 5
3.0
2.5
2.0
1. 5
1. 0
0.5
0
l i n. Hgl GAUGE
-
The MIL has been reported on
-
OTC P0106 is storod.
-
Or from Ptobable Cause Lisl.
Problom verificetion:
1. Do t he ECM/ PCM Reset Pro-
cedure.
2. St ar t t he engi ne and keep
engi ne speed at 1, 000 rpm f or
one mi nut e wi t h t he t ransmi s'
si on i n
@
or
I Posi t i on
{Mf f
i n neut ral ).
Check t or vacuum l eakage or
bl ockage bet ween t he MAP sen'
sor and t hrof t l e body Check the MAP sensor outPut:
(l l ).
3. Check t he MAP wi t h t he scan
t ool .
l s t here l eakage or bl ockage?
Chock the MAP snsol output:
1. St op t he engane.
(l l ).
t ool .
READING
300
(mm
Hgl
( To page 11 116)
{cont' d)
l l ,
( To page 11- 116)
1 1 - 1 1 5
PGM-FI System
( Fr om page
11- 115i
{ Fr om
page 11- 115)
Chock to. poor response:
1. St ar t t he engi ne. Hol d t he
engine at 3,000 rpm with M in
E
or
E
position,
M/T in neu
t ral unt i l t he radi at or t an comes
on, t hen t ur n t he i gni t i on
switch OFF.
t ool .
ls a N4AP ot 40.0 kPa {300 mmHg,
12. 0 i n. Hg) or l ess i ndi cat ed wi t hi n
one second after staning the
engi ne?
The MAP sensor is OK st this time.
Check lor poor
response:
engine at 3,000 rpm with M in
E
or
E
posi t i on,
M/ T i n neu-
tral until the radiator fan comes
on, t hen t ur n t he i gni t i on
switch OFF.
t ool .
ls a MAP of 40.0 kPa (300
mmHg,
12. 0 i n. Hg) or l ess i ndi cat ed wi t hi n
one second after starting the
engi ne?
PCM and rechock. lt symptom/
i ndi cat i on go6s . way. . 6pl rce
th original ECM/PCM.
Manifold Absolute Pressure
(MAP)
Sensor
('96
Modelsl
(cont'dl
11- 116
Manifold
Absolute Pressure {MAP}
Sensor
('96
-
98 Models,'99
-
00 D16Y5 engine with M/T)
I
(DTC) PO107: A l ow vol tage
(hi gh
vacuum)
probl em i n the
(MAP) sensor.
MAP SENSOR 3P CONNECTOR
(C111)
vccr
(YEL/BEDI
(D16Y5 engi ne
(wi t h
cw))
T
YES
(cont' d)
11- 117
Tho MIL has been roportd on.
DTC P0107 is storod.
Problam verification:
(l l ).
l ool .
lntormittont failuro, sYatgm ia OK
al thb timo. Chock lor
Pool
con_
noqtiona or looso wirca at C111
{MAP !6nsor) ond ECM/PCM.
l s approx. 101 kPa
(760
mmHg,
30 in.Hg) indicated?
Chock for an opon in wiJe
(VCCI
l i no):
2. Di sconnect t he MAP sensor
(ll).
MAP sensor connect or No l
t ermi nal and No 2 t ermi nal
Ropair open in tho wit btwocn
ECM/PCM
(Dill
tnd MAP !enso].
Check for .n open or ahort in the
MAP 3naor:
Check t he MAP wi t h t he scan
t ool .
l s approx. 2 kPa
(15
mmHg,
0. 6 i n. Hg) or l ess i ndi cat ed?
Chsck to. a short in the TCM:
2. Di sconnect t he 22P connect or
f rom t he TCM.
3. Tur n t he i gni t i on swi t ch ON
0r).
4. check t he MAP wi t h t he scan
t ool .
( To page 11- 118)
PGM-FI System
( Fr om page
11- 117)
l s approx. 2 kPa
(' 15
mmHg, 0. 6
i n. Hg) or l ess i ndi cat ed?
Check f or a short i n i he wi re
{MAP line)l
2. Di sco n nect t he ECM/ pCM
connect or D
(16P).
the MAP sensor connector No.3
t ermi nal and body ground.
R6pair lhort in tha wire btwaen
ECM/PCM
{D3l .nd MAP !6ru0r.
PCM..nd recheck. normal MAP
is indiceted, .eplsce lhe original
ECM/PCM,
(MAp)
Sensor
('96 -
98 Models,'99
-
(cont,d)
MAP SENSOR 3P CONNECTOR IC1l1I
MAP
(RED/GRNI
Wi re si de of f emat e; rmi nat s
11- 118
|'
Manifold
Absolute Pressure
(MAP)
Sensor
(;gg
-
OO Models except
Dl6Y5 engine
with M/T)
The scan tool i ndi cates Di agnostrc Troubl e Code
(DTC) PO1O7: A l ow i nput
(hi gh vacuuml
probl em i n the
(MAP) sensor'
The MAp sensor converts mani fol d absol ute
pressure i nto el ectri cal si gnal s and i nputs the ECM/PCM'
OUTPUT
VOLTAGE
l vl 3. 5
3.0
2.5
2.0
1. 5
1. 0
0.5
0
(in.Hgl GAUGE
REAOING
(mmHgl
lq, 2oo 3q,
(x,
5q) 6q) 700
MAP SENSOR 3P CONNECTOR IC114)
vccl
tYEL/RED)
Wire sido of fomalg tormin6ls
.-l
-
The MIL h'3 been reported on
-
OTC P0107 b stord.
Problem verilication:
1. Turn t he i gni t i on swi t ch ON {l l )
2. check t he N4AP wi t h t he scan
t ool .
lntermittent
failuro, 3Ystom is OK
at this time. Chck for
Poor
con'
nection3 or loose wiros at C111
IMAP sonsorl and ECM/PCM.
ls approx. 101 kPa
(760 mmHg,
30 i n. Hg)i ndi cat ed?
Ch.ck for an opcn in wit. {vCC1
l i nel :
1. Turn the ignition switch OFF
connect or.
(ll).
MAP sensor connect or No. 1
t ermi nal and No 2 t ermi nal
Repair opsn in the wirg botween
ECM/PCM
(C19)
rnd MAP seGor.
( To page 11- 120)
{cont' d)
1 1 - 1 1 9
PGM-FI
System
Manifold
Absolute Pressure (MApl
Sensor
('99 -
00 Models except Dl6yS
engine with M/T)
(cont,dl
MAP SENSOn 3P CONNECTOB
tcllilt
MAP
(RED/GRNI
Wire side of female terminals
( Fr om page
11 119)
Check for an open or shon in the
MAP snsor:
Check t he MAP wi t h t he scan
t ool .
l s approx. 2 kPa
(15
mmHg,
0. 6 i n. Hg) or l ess i ndi cat ed?
Check t or a sho. t i n l he wi re
{MAP l i ne):
2. Di scon n ect t he ECN4/ pCN4
connect or C
(31P).
the MAP sensor connector No. 3
Repair short in the wire between
ECM/ PCM
{Cl 7} and MAp sn-
sor.
PCM and rech6ck. lf no.mal MAp
is indicated, replace the o.iginal
ECM/rcM.
11- 120
!
Manifold
Absolute
Pressure
(MAPI
Sensor
-
i ;i dl ga
l i l ;del s,' 99
-
00 Dl 6Y5 ensi ne wi th M/T)
l l
The scan tool i ndi cates Di agnostrc Troubl e code
(DTC) Po108: A hi gh vol tage
(l ow
vacuum)
probl em i n the
(MAP) sensor.
MAP SENSOR 3P CONNECTOR ICl11}
MAP
IRED/GRNI
JUMPER WIRE
Wi re si de ol f emal e t ermi nal s
vccl
IYEL/RED)
ECM/PCM CONNECTOR D
(16PI
MAP
(RED/GRN)
sG1
(GRN/WHT)
(cont' d)
11- 121
OTC m108 is stolod.
Problem vetitication:
1 . St a r t t h e e n g i n e . Ho l d t h e
engi ne at 3, 000 rPm wi t h no
l oad
(i n Park or neut ral ) unt i l
the radiator fan comes on, then
let it idle.
t ool .
lntormittent
lailure, sFtom k OK
.t thb time. Chock lor
Poor
con'
nections or loorg wires at Cll'l
|MAP sensorl snd ECM/PCM.
l s 101 kPa
(760 mmHg, 30 0 i n. Hg)
or hi gher i ndi cat ed?
Check t or an open i n t he MAP
36nSOt:
2. Di sconnect
t he MAP sensor
3P connect or.
3. I nst al l a
j umper wi re bet l veen
t he MAP sensor 3P connect or
t ermi nal s No 3and No 2.
(l l ).
t ool .
l s 101 kPa
(760 mmHg, 30 0 i n. Hg)
Check f or an open i n wi re
(SG1
l i ne):
1. Remove t he
i umper
wi re.
MAP sensor 3P connect or t e.
mi nal s No. 1 and No 2
Rapai. open in the wito batwoen
ECM/PCM
(D12) .nd MAP !en.or. l s t here approx. 5 V?
Check f or an oPon i n t he wi i e
(MAP linel:
2. Connect t he ECM/ PCM con-
nect or t ermi nal s D3 and D12
with a
iumPer
wire.
(l l ).
t ool .
Repair opon in the wiles bstlt oon
ECM/PCM
(D3l
and MAP 3oGor.
l s 101 kPa
(760
mmHg, 30 0 i n. Hg)
Substituto a known'good ECM/
PCM and rochock. ll normal MAP
is indicated, replace tho original
ECM/PCM.
JUMPER WIRE
l r ,
PGM-FI System
(MAPI
Sensor
11- 122
('99 -
00 Models except D16YS engine with M/T)
(contd)
(DTC)
P0108: A hi gh vol tage
fl ow vacuum) probl em
i n the
Mani fol d Absol ute Pfessure
(MAp)
sensor,
MAP SENSOR 3P CONNECTOR
(C111I
MAP
IRED/GRNI
vccl
IYEL/RED)
ECM/PCM CONNECTOR C
(31PI
JUMPER WIRE
Tho MIL has boon rcDortod on.
DTC ml 08 b stolod.
Problem verification:
' 1.
St ar t t he engi ne. Hol d t he
engi ne at 3, 000 rpm wi t h no
l oad (i n
Park or neut ral ) unt i l
let it idle.
t oot ,
Intormittent f.ilu.e, rystom is OX
at thi! time. Chock tor poor
con-
n6ction3 or looso wirea at C111
(MAP
3en. or) and t ho ECM/
PC-M.
l s 101 kPa
(760
mmHg. 30
i n. Hg) or hi gher i ndi cat ed?
Check f or an open i n t he MAP
aon5('r:
1. Turn t he i gnal i on swi t ch OFF.
3P connect or.
3. Install a
jumper
wire betwesn
t he MAP sensor 3P conn6ct or
t ermi nal s No. 3 and No. 2.
4. Turn the ignition switch ON {ll).
t ool .
l s 101 kPa
(760
mmHg, 30
Check fo. an opcn in wiro
(SGl
l i ne):
1. Removo t he
j umper
wi re.
2. Measure voltage between the
MAP sonsor 3P connect or t er
mi nal s No. 1 and No. 2.
Roprir opon in tha wiJo bctwoen
thc ECM/FCM (C7l
rnd the MAp
sonln t.
ls there approx. 5 V?
Chsck f or an open i n t ho wi . e
{MAP lino}:
2. I nst al l a
j umper
wi re on t he
ECM/PCM connectors between
C7 and C17.
(ll).
t ool ,
Repair opn in the wir6a bstwoon
tho ECM/FCM (C171
and rh6 MAp
scnltoa.
l s 101 kPa (760
mmHg, 30
PCM and rechcck, It normal MAP
is indiceted. r.place tho original
ECM/PCM.
JUMPER WIRE
--
L
Manifold
Absolute Pressure
(MAP)
Sensor
(cont'dl
The scan tool i ndi cates Di agnosti c Troubl e code
(DTc)
P1128: Mani fol d Absol ute Pressure
(MAP)
l ower than
exoected.
(DTC)
P1129: Mani fol d Absol ute Pressure {MAP)
hi gher than
exoected,
-
Tho MIL has been tPorted on.
-
DTC P1128 is stored.
(l l ).
t ool .
lntermitteni failu.e, sYstom i! OK
at thb time.
l s 54. 1 kPa
(406
mm Hg, 16. 0
-
The MIL has been roported on.
-
DTC P1129 is slorod
Problem v6rilicaiion:
l oad
t he r adi at or f an comes on,
t hen l et i t i dl e.
t ool .
Int6rmittent failuto, sy3tem i3 OK
at thi3 time.
l s 43. 3 kPa
(325 mm Hg, 12 8
i n. Hg)or l ess i ndi cat ed?
11- 123
PGM-FI
System
Intake Air Temperature (lAT)
Sensor
('96 -
97 Models)
(DTC)
P0111: A range/performance probl em
i n the l ntake Aar
Temperature (l AT)
Sensor ci rcui t.
The IAT sensor i s a temperature dependant resi stor (thermi stor).
The resi stance of the thermi stor decreases as the i ntake
ai r temperature i ncreases as shown bel ow.
RES|STAI{CE
{tol
. 32 .. ro. tr. 2r, zaa r..l
-20
o 20 /|o
ao ao 100 rrotlcl
INTAIG AIR TEMPEMTURE
-
The MIL hss beon reported on.
-
-
Or from Probable C.use List.
2. Di sconnect t he I AT sensor 2P
connect or,
3. Remove t he I AT sensor.
4. Reconnect t he I AT sensor 2p
5. Leave the IAT sensor exposed
t o ambaent t emperat ure,
6. Turn the ignition switch oN fll).
7. Check t he I AT wi t h t he scan
t ool .
Rsplscg the IAT sensor.
Check tho IAT sensor output:
1. Warm t he I AT sensor wi t h a
hai r dryer-
t ool .
Di d t he I AT ri se 2"F (1. C)
or more
f rom t he ambi ent t emperat ure?
Intrmittont failu.e, system is OK
at this time.
Replsce the IAT sensor.
11- 124
I
Intake Air Temperature
(lATl
Sensor
P0112: A l ow vol tage
(hi gh
temperature)
probl em i n the
l ntake Ai r Temperature
(l AT)
sensor ci rcui t.
RESISTANCE IKOI
.-l
* 2:
l f t he engi ne i s war m, i t wi l l be
hi gher t han ambi ent t emPerat ure.
IAT SENSOR 2P CONNECTOR {C112)
. a2 .. toa rra rrl l:rt t.al
20 0 20 ro ao ao too t2ot.cl
INTAXIE AIR TEMPEFATURE
IAT
{RED/YEL)
t er mr nar s
-+-r
I ' l ' l
-_T-
I
=
The MIL has been Teported on.
1. Turnt he i gni t i on swi t ch ON 1l l )
t ool -
l s 302' F
(150"C)
or hagher
(or
H Li mi t i n Honda mode ot
PGM Test er) or 0 V i ndi cat ed?
l s t he correct ambrent t emper
at ure i ndi cat edi ' ?
Roolac tho IAT 3ensor.
lntermittent failure, svstom is OK
6t this tim. Check for
Poor
Gon-
nections or loos wires st C112
{lAT.en3orl
and ECM/PCM.
Check tor a shon in the IAT sen-
sor:
1. Disconnect the IAT sensor con
nect or.
t ool .
l s 302" F
( 150' C) or hi gher
( or
H' Li mi t i n Honda mode of
PGM Test er) or 0 V i ndi cat ed?
Ch6ck for s short in the wira
(lAT
l i n):
2. Disconnect the ECM/PCM con-
nect or D
(16P) (C (31P))*' .
the IAT sensor 2P connector ler-
mi nal No. 2 and body
ground.
Reoair short in the wire bstween
ECM/ PCM t D8
(c25)' 1) and I AT
PCM and recheck. It normel IAT
is indicated, replace the original
ECM/PCM.
*
l :
' 99
-
0O model s except Dl 6Y5 engi ne wi t h M/ T- r f ,
11- 125
PGM-FI System
Intake Air Temperature (lAT)
Sensor
('96 -
98 Models,'99
-
11- 126
(DTC)
POl 13: A hi gh vol tage
fl ow temperature) probl em
i n the
Intake Ai r Temperature (l AT)
sensor ci rcui t,
taT sENsoR 2P CONNECTOn (Cl12l
I '
j r l
SG2
'---.]__+
tAT
(GRN/ BLKI
I I I RED/ YEL}
JUMPER
WIRE
ECM/PCM CONNECTOR D
(16PI
IAT IRED/YEL)
sG2
(GRN/BLK)
JUMPER WIRE
The MIL has been reported on.
DTC P0113 b sto.6d.
Problem veritication:
(l l ).
t ool .
Intermittent tailuJe, systom is OK
at this time, Check to. poor
con-
nections or loose wir.s at C112
{lAT senso.l .nd ECM/PCM,
l s
-4' F
1-20"C) or l ess (or
L Li mi t
i n Honda mode of PGNI Test er) or
5 V i ndi cat ed?
Check for an open in the IAT sen-
sol:
1. Di sconnect t he I AT sensor 2p
connector,
2. Connect the IAT sensor 2P con-
nect or t er mi nal s No, 1 and
No. 2 wi t h a
j umper
wj re.
3. Check t he i nt ake ai r t empera,
t ure wi t h t he scan t ool .
l s
-4"F (
20' C) or l ess (or
L-Li mi t
i n Honda mode of PGM Test er) or
5 V i ndi cat ed?
Repbce the IAT sensor.
Check tor an open in th6 wires
{l AT. SGzl i ne! ):
2. Connect ECM/ PCM connect or
t ermi nal s D8 and D11 wi t h a
(ll).
t ool .
l s
-4"F (
20' C) or l ess
(or
L-Li mi t
i o Honda mode ol PGM Test er) or
5 V i ndi cat ed?
Rp6ir opan in the wiro! hween
EC-M/PCM
lD8. 011l and IAT sen-
PCM end recheck. lf normal IAT
is indic.ted, replace the original
ECM/ PCM.
L
I
Intake Air Temperature
(lAT)
Sensor
('99
-
00 Modeis except D16Y5 engine
with M/Tl
(DTC)
(l ow
temperature)
probl em i n the
Intake Ai r Temperature
(l AT)
sensor ci rcui t.
IAT SENSOR 2P CONNECTOB IC112'
r-+-r
I t l , l
sG2
L1__f
lAr
IGRN/BLK} I I
(RED/YELI
JUMPER
WIRE
Wi re si de of l emal e t ermi nal s
The MIL has ben rePorted on.
DTC P0113 i3 stored.
Problm vetification:
(l l ).
t ool .
Intormittont f.iluro, tyrtom i. OK
.t thi! tim.. Chocl for Poor
con'
nactions or looso wit6 !t C112
tlAT ..n!or) rnd ECM/PCftl,
l s
-4"F (-20"C) or l ess
(or L-Li mi t
5 V i ndi cat ed?
Check tor an open in tho IAT son'
304:
1. Di sconnect t he I AT sensor 2P
connector,
2. Connect the IAT sensor 2P con_
nect or t er mi nal s No. 1 and
No. 2 wi t h a
j umPerwi re.
3. Check t he i nt ake ai r t empera-
t ure wi t h t he scan t ool .
l s
-4"F
{-20"C) or l ess
(or
L-Li mi t
5 V i ndi cat ed?
Check lor an open in iho wirg3
{lAT,
SG2 linesl;
t ermi nal s C18 and C25 wi t h a
i umper
wi re.
(ll)
4. check t he I AT wi t h t he scan
t ool .
Roprir opan in tho wilaa brlwocn
ECM/ PCM
(C18, C25l . nd I AT
!on30r.
l s
-4"F (-20"C) or l ess
(or L-Li mi t
i n Honda mode oI PGM Test erl or
5V i ndi cat ed?
substituts a known'good ECM/
PCM and recheck. ll normal IAT
is indicated, replace the otiginal
ECM/PCM.
ECM/PCM CONNECTOR C
(31PI
JUMPER WIRE
11-127
PGM-FI System
Engine Coolant Temperature
(ECTI
Sensor
(DTC)
P0116; A range/performance probl em
i n the Engrne
Cool ant Temperature (ECT)
Sensor ci rcui t.
The ECT Sensor i s a temperature dependant resi stor (thermi stor).
The resi stance of the thermi stor decreases as the engi ne
cool ant temperature i ncreases as shown oetow.
RESISTANCE
(ko)
NOTE: l f DTC P0117 and/or P01' 18 are stored at the same ti me as DTC
for DTC P0116.
Possible Cause
. ECT sensor deteri orati on
. Mal functi on i n the thermostat and cool i ng system
Troubleshooting Flowchart
- a
32 68 r 0a l a0l ?6 2t 2 2481' r r
-20
o 20 ao o D r@ Il, r'c)
ENGINE COOLANT IEMPERATURE
P0116, troubl eshoot those DTCS fi rst. then recheck
11- 128
THERMISTOR
-
The MIL has bogn reported on.
-
1. St ar t t he engi ne. Hot d t he
l oad (i n
2. Wi t h t he scan t ool , check t he
Intermiftent lailure. system is OK
ai thi. time. Ch.ck the thc.mo-
stat 6nd thc cooling system.
i s 176 200' F {80
-
93' C)or
0. 0- 0. TVi ndi cat ed?
Check t he t hermost at and t he
cool i ng syst em. l l t hey al s OK,
raplace the ECT sensor.
|.
' f
fD;r.tt
(DTC)
(hi gh
temperature) probl em i n the
| j g
Engi ne Cool ant Temperature
(ECTI
sensor ci rcui t.
ECT SENSOR 2P CONNECTOR
(C122I
Substitute . lnown-good ECM/
PCM .nd rocheck. It normrl ECT
is indic.ted, replaco the original
ECM/PCM,
*: ' 99 -Oo
model s except D16Y5 engi newi t h M/ T
(cont' d)
11- 129
The MIL has been ,eported on.
DTC ml 1 7 is storod.
Problom vorification:
(ll).
2. Check t he ECT wi t h t he scan
t ool .
Intermittont failulo, sy3tom it OK
at thk tim., Chock for
Poor
oon-
n.ctions or loo!. wiraa at C122
IECT 3en orl and ECM/FCM.
l s 302"F
(150"C) or hi gher {or
H-Li mi t i n Honda mode of
PGM Tester) or 0 V indicated?
Check toJ a short in the ECT s.n-
5(' t:
1. Di sconnect t he ECT sensor 2P
connect or.
rool .
l s 302"F
(150"C)
or hi gher {or
H-Li mi t i n Hond6 mode of
PGM Testerl or 0 V indicated?
Check f or a 3hort i n t ho wi ro
IECT linel:
nect or D
(16P) (C
{31P))*.
the ECT sensor 2P conneclor ter-
mi nal No, 1 and bodyground.
B.gair short in the wiro bltween
ECM/ PCM
(D2 (C261' l
. nd ECT
. 1,
PGM-FI System
(ECT)
Sensor
('96
-
98 Models,'99
-
00 D16YS engane with M/T)
(cont'd)
The scn tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0118; A hi gh vol tage
(l ow
temperature) probl em i n the
Engi ne Cool ant Temperature (ECT)
sensor ci rcui t.
ECt SENSOR 2P CONNECTOR {C1221
ECT
IRED/WHTI
JUMPER WIRE
sG2
(GRN/BLK)
ECM/PCM CONNECTOR D Il6PI
sG2 tGRN/81r0
Wi r e si de of I emal e t er mi nal s
-
Tho MIL ha3 bcen roorted on.
-
OTC m118 b stored.
Problom vorificttion:
(l l ).
t ool .
Intcrmitt.nt failui.. rydom is OK
at thir timc. Chack for Door con-
naction! or loor! wiaar at C122
IECT ..n.orl .nd ECM/rcM,
ls
-4"F (-20'C)
or less
(or
L-Limit
in Honda mode ol PGM Tester) or
5 V indicated?
Chsck lor sn open in thc ECT 3an-
soa:
1. Di sconnect t he ECT sensor
2P connector.
z. Lonnecr r ne ELt sensor zF
connect or t ermi nal s No. 1 and
No. 2 wi t h a
j umper
wi re.
tool.
ls
-4'F (-20'C)
or loss (or
L-Limit
in Honda mode ol PGM Testerlor
5 V indicated?
Chack for an opon in the wire.
{ECT, SG2lin..l:
2. Connect ECM/PCM connector
j umprwi re.
(ll).
t ool .
l s
-4' F
1-20' Cl or l ess
(o.
L-Li mi t
in Honda mode ol PGM Tester)or
5 V indicated?
Reprir oprn in tha wirar bstwoon
CCM/PCM
IDZ Dl1) .nd EGT rcn-
aor.
Sub3titut. s known-good ECM/
FCM and r.chcck, It normel ECT
i! indicatod, roplaco tho origin.l
ECM/PCM.
JUMPER WIRE
1 1 - 1 3 0
PGM-FI System
t
I
(ECT)
Sensor
('99
-
(DTC)
(l ow
temperature)
probl em i n the
Engi ne Cool ant Temperature
(ECT)
sensor ci rcui t.
ECT SENSOR 2P CONNECTOR {C122)
ECT
(RED/Wr{T)
JUMPER IVIRE
sG2
{GRN/BLK)
wire side of female terminals
ECM/PCM CONNECTOB C 131PI
The MIL has been reported on,
oTC P0118 is stored.
(l l ).
t ool .
lntormittent failuro, systom is OK
at thb timo. Check lor
poor con'
nections or 10036 wiraa at C122
{ECT ssnsorl and ECM/rcM.
l s
-4' F (-20"C) or l ess l or L-Li mi t
i n Honda mode o{ PGM Test er) or
5 V i ndi cat ed?
Check for an open in the Efi sen'
sori
1. Di sconnect t he ECT sensor 2P
connector,
2. Connect t he ECT sensor 2P
connect or t ermi nal s No, 1 and
No. 2 wi t h a
j umper wi re.
t ool .
l s
-4"F
1-20"C)
or l ess
(or L-Li mi t
in Honda mode of PGM Tester) or
5 V i ndi cat ed?
Check for sn open in the wires
IECT. SG2 linesl:
j umper
wi re.
(ll).
4. Check t he ECT wi t h l he scan
t ooi .
Rspair opon in th6 wiros bstwoon
ECM/ PCM
(Cl 8,
C26l and ECT
3ensot.
l s
-4' F
{-20"C) or l ess
(or
L-Li mi t
i n Honda mode of PGN4 Test er) or
5 V i ndi cat ed?
Substitute 6 known-good ECM/
PCM and recheck. l{ no.mal EcT
is indicatod, .eplace the original
ECM/PCM.
JUMPER WI RE
1 1 - 1 3 1
PGM-FI System
Throttle Position
ITP)
Sensor
('96 -
98 Models,'99
-
(DTC)
P0122: A l ow vol tage probl em i n the Throttl e Posi ti on
(TP)
sensor ci rcui t.
The TP Sensor is a potentiometer. lt is connected to the throttle valve shaft. As the throttle
position
changes, the throttle
posi ti on
sensor vari es the vol tage si gnal to the ECM/PCM.
OUTPUT VOLTAGE IVI
1
2
1
0
s{i2
(GRN/BLKI
THROTTLE
OPENING
FULL
THROTTLE
TP SENSOR 3P CONNECTOR ICllOI
vocz
(YEL/BLUI
Wi re si de ot f emal 6 t ermi nal s
ECM/PCM CONNECTOR D IT6PI
SG2 IGRN/ALKI
{ To
page l 1- 133)
Termi nal si de of mal e t ermi nal s
11- 132
-
Tho MIL h63 boon roportod on.
-
DTC m122 i. storcd.
Probl6m voritiction:
(ll).
2. Check t he t hr ot t l e posi t i on
wi t h t he scan t ool .
ls there approx. .49 V when
the throttle is fully closed and
approx. 4.5 V when the throttle
is lully op6ned?
Int..mittent tailura, rFiem ir OK
at thit tima. Chock tor Door con-
nections or loorc wires !t C110
ITP lonrorl .nd ECM/FCM.
Ch6ck l or rn opon i n t he wi re
(VCC2l i nel :
2. Di sconnect t hs TP sensor 3P
connector.
3. Turn the ignition switch ON lll).
4, Measure vol t age bet ween
the TP sensor 3P connctor ter-
mi nal s No. l and No. 3.
Check for rn opcn in wire IVCC2
line):
Measure vol t age bet ween ECM/
PCM conneclor terminals D10 and
0 1 1 .
Chock for rn open or 3hort in TP
lon30t:
2. At t he snsor si de, measure
resistance between the TP sen-
sor terminals No. 1 and No. 2
with the throttle fully closed.
Roplir opn 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.
t
'P SENSOR 3P CONNECTOR
ECi'/PCM CONNECTOR
D {16PI
TPS IRED/
Btx)
IGRN/BLK)
t-
h m
sG2
6 I t t o t l 12
t l t 5 t a
Wire side ol lemale terminals
lDl6Y5
engine
f
TPS IRO/
BLKI
SG2 IGRN/BLKI
{From
page l 1' 132}
l s t here approx. 0. 5
-
0. 9 k0?
Check for an opsn or 3hort in tho
TP sensor:
Measure resi sl ance bet ween t he
TP sensor t er mi nal No. 2 and
No. 3 with the throttle fully closod.
l s t here approx. 3. 6
-
5. 4 k0?
Chock lor an open in the ECM/
PCM ITPS
lin6l:
1. Reconnect t he TP sensor 3P
connector.
2. Turn the ignition switch ON {ll}.
ECM/PCM connector terminals
Dl and D11.
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.
ls there approx. 0.5 Vwhen the
throttle is fully closed and
approx. 4.5 Vwhen the throttle
is fully opened?
Check tor . short in tha TCM:
2. Disconnect the 22P connector
from the TCM.
(ll).
/t.
Measure voltage between ECM
connect or t er mi nal s D1 and
D1 1 .
l s t here approx. 0. 5 V when t he
throftle is tully closed and
approx. 4.5 V whon the throttle
is fully opened?
Ropair rhort in the wir bdtwcon
ECM/PCM
(D11,
TCM and TP i.n.
30r,
1 1- 133
PGM-FI System
Throttle Position
(TPl
Sensor
('99
-
00 Models except D16Y5 engine with M/T)
l TO12Z _TI
scan tool i ndi cates Di aqnosttc Troubl e Code
(DTC)
P0122: A l ow vol tage probl em
i n the Throttl e
posi ti on
-
{ | r, sensoa crrcurl .
The TP Sensor is a potantiometer.
lt is connected to the throttle valve shaft. As the throttle position
changes, the throttle
position
sensor varies the voltage signal to the ECM/PCM.
ERUSH
HOI.DEN
OUTPUT VOLTAGE
(VI
BRUSH
BESIS?OF
TERi'I AL
5
4
3
2
1
o
INNER
BUS}IING
THROTTLE
OPE II{G
FULL
THROTTLE
TP SENSOR 3P CONNECTOR
{Cl1OI
sG2
IGRN/8LKI
vcc2
(YEUBLUI
Wi re si de of t emal e t ermi nal s
ECM/PCM OONNECTOR C 131P)
Ch.Gk for rn opan or 3hort in TP
36nlot:
2, At t he sensor si de, moasure
r esi st ance bet ween t he TP
sensor 3P connector terminals
No. 1 and No. 2 with th throt,
t l e f ul l y cl osed.
(To page 11-135)
-
Th. MIL har boon.6portcd on.
-
DTC P0122 b siored.
1. St ar t t he engi ne, Hol d t he
l oad
(i n
t he r adi at or f an comes on.
t hen t urn t he i gni t i on swi t ch
OFF,
(ll).
ls there approx. .49 V when
the throttle is fully closd and
approx, 4.5 V when the throttle
i s f ul l y opened?
l||t rmittont failura, lyrtom b OK
at thi! tima. Chock tor poor
con-
nactionr o. looao wires rt C110
{TP 3.n!or} rnd ECM/PCM.
Check for an opan or 3hort in tho
wi.c
(VCC2
linc):
2. Di sconnect t he TP sensor 3P
connector,
(ll).
4. Measure vol t ago bet ween
the TP sensor 3P connector ter
mi nal s No. 1 and No. 3.
l s t hero approx. 5 V?
Chccl tor .n opln in wiro IVCC2
linl:
Mgasure vol t ago bet ween ECM/
PCM connector terminals C18 and
R.prir opcn in the wiro bctw.en
ECM/PCM (C281
and TP 3nror.
Subrtituto r known-good ECM/
PCM .nd rochcck. lf pro.c.ibed
voltaga i! now available, roplaco
tho origin.l ECM/PCM.
Wi re si de ol f emal e t ermi nrl s
Ter mi nal si de of mal e t er mi nal s
1 1 - 1 3 4
L
L
I
(From page 11-134)
l srhere approx. 0. 5
-
0. 9 ko?
Chock for an open or 3hort in the
TP 3en30r:
Measure resistance between the
TP sensor 3P connect or t ermi nal s
No. 2 and No. 3 wi t h t he t hrot t l e
tully closed.
l s t here approx. 4. 5 k0?
Check for .n opon in th ECM/
PCM
(TPS
lino):
1. Reconnect the TP sensor con-
nector.
3. Measure voltago between Cl8
t ermi nal and C27 t ermi nal on
the ECM/PCM conneclor.
Sub.lltut. . known-good ECM/
PcM lnd r.chock. ll
pr6cribod
vohago b now lvallabla, aeplrca
tho originrl ECM/PCM,
ls there approx. 0.5 V when the
approx. 4.5 V when the throttle
is fully opend?
Ropair ahort in th. wiro b{ween
ECM/FCM lC18l .nd TP ..n.o].
TP SENSOR 3P CONNECTOR
Termi nal si de ol mal e t ermi nal s
ECM/PCM OONNCCTOR C
(31PI
Wi re si de oI f emal e t ermi nal s
. 1,
1 1 - 1 3 5
PGM-FI System
Throttle Position
(TP)
Sensor
(6 -
98 Models, 39
-
(DTC)
P0123: A hi gh vol tage probl em i n the Throttl e Posi ti on
(TP)
sensor ci rcui t.
TP SENSOR 3P CONNECTOR IC1lOI
sG2
IGRN/BLKI
vcc2
{YEL/BLUI
ECM/PCM CONNECTOR D
(16P)
SG2
(GRN/BLKI
1 1 - 1 3 6
The MIL has been reportod on.
DTC P0123 is sto.ed.
Problom veritication:
l s t here approx. 10% when t he
approx. 90o/o when the throttle
is lully opened?
Intermittont tailuro, system is OK
at thb timo, Check for ooor con-
nociion3 or loos6 wiros at C110
ffP snsor) and ECM/PCM.
Chgck to. an opan in the TP son-
sot:
connect or.
(ll).
4. At t he harness si de, measure
voltage between tho TP sensor
3P connect er t ermi nal s No, 1
and No. 3.
Ch. ck t or . n open i n t he wi ra
(SG2
linel:
PCM connect or t ermi nal s D10 and
D1 1 .
Repair op6n in the wire betwoen
ECM/PCM
(D11)
rnd TP s6nsor.
PCM snd rech.ck. lf pra3cribed
voltago is now available, replsce
tho original ECM/PCM,
I
Throttle Position
(TP)
Sensor
('99
-
00 Models except D16Y5 engine with M/Tl
probl em i n the Throftl e Posi ti on
{TP) sensor ci rcui t.
TP SENSOR 3P CONNECTOR {C11OI
sG2
{GRN/BLKI
voc2
{YEUBLU}
' l '
Wi re si de of f emal e t erm; nal s
ECM/PCM CONNECTOR C
(31PI
Wi re si de of f emal t ermi nal s
(cont' d)
11- 137
DTC P0123 is slored.
l oad
(i n
t he r adi at or f an comes on
t hen t urn t he i gni t i on swat ch
OFF,
2. Turn t he; gni t i on swi t ch ON
(l l ).
3. Check t he t hr ot t l e Posi t i on
lntormittenl tailure, 3ystom is OK
at this time. Check tor
Poor
con'
neqtions or loo3 wires at C'110
(TP
sensorl tnd ECM/PCM.
l s t here approx. 10% when t he
t hrot t l e i s f ul l y cl osed and
approx. 90% when the throttle
i s f ul l y opened?
Chck for an open in the TP s6n-
soJ:
(l l ).
4. At the wire harness side, mea-
sure vol t age bet ween t he TP
sensor 3P connector terminals
No. 1 and No. 3.
Check t or an open i n t he wi re
(SG2l i no):
PCM connect or C
(31Pi t ermi nal s
C18 and C28.
Repair open in the wite betwen
ECM/PCM
(Cl81and TP son.or.
PCM and recheck. lf Pr$cribed
voltage is now aveilabl6. replace
PGM-FI System
Throttle Position
(TP)
Sensor
(cont'd)
-
The MIL hss been.eported on.
-
DIC P1121 i. stored.
Problem vedficatiod:
(l l ).
l s TP
*%
or hi gher i ndi cat ed
when the throftle is tully
openod?
Intermittent tailure, ryttem i! OK
rt t hi st i mo.
I
Pl 121
|
The sca n tool i ndi cates Di ag nosti c Troubl e Code
(DTC)
Pl 121: Throttl e Posi ti on
(TP)
l ower than expected.
* :
11. 8 { D16Y5 engi nei
12. 9 {016Y7 engi ne)
12. 2
(D16Y8
engi ne)
13. 7
(816A2
engi ne)
I P1122 I
(DTC)
P1122: Throttl e Posi ti on
(TP)
hi gherthan expected.
*:
16. 5 {Dl 6Y5, Dl 6Y8 engi ne}
16. 9
(D16Y7
engi ne)
16. 5
(81642
engi ne)
-
The MIL ha3 be6n repoJted on.
-
DTC Pl122 i. llorod.
P.oblom v6dfication:
(l l ).
l s TP' 70 or l ss i ndi cat ed when
t he t hrot t l e i s f ul l y cl osed?
Intormitt6ot frilu.o, aFtom b OK
at thb timo.
1 1 - 1 3 8
Primary Heated Oxygen Sensor {Primary
HO2SI
(Sensor
1)
t
('96
-
The Heated Oxygen Sensor
(HO2S)
detects the oxygen content i n the exhaust gas and si gnal s the ECM/PCM. In operati on,
the ECM/PCM recei ves the sj gnal s from the sensor and vari es the durati on duri ng whi ch fuel i s i nj ected To stabi l i ze the
sensor,s output, the sensor has an i nternal heater. The Pri mary HO2S
(Sensor
1) i s i nstal l ed i n the exhaust mani fol d.
HO2S:
VOLTAGE {VI
(DTC)
P0131; A l ow vol tage
Oxygen Sensor
(H02S) (Sensor
1) ci rcui t.
R| cH-AI R-
-
LEAN
FUEL
RANO
probl em i n t he Pri mary Heat ed
SENSOR
ztRcoNlA
The MIL has ben teported on.
DTC P0131 is siorcd.
Problom verificalion:
1. Do t he ECM/ PCM Reset Pro'
cedure.
l oad
(i n
t he radi at or f an comes on,
3. Test -dri ve wi t h t he A/ T i n
E
position (M/T in 4th gear)
4. Check t he Pr i mar y HO2S
(Sensor
1) output voltage with
t he scan t ool duri ng accel era-
tion using wide open throttle.
lntcrmiftnt failura, 3Y3tem is OK
at this tims. Check for Poor
con-
nections or loo3e wi.o3 at C123
(Pri ml ry HO2S, 3sn3or 1) and
ECM/PCM,
(To page 1I -140)
{cont' d)
1 1 - 1 3 9
PGM-FI System
( Fr om page 11- 139)
Check for a shon in the HO2S:
2. Di sconnect t he Pri mary HO2S
(Sensor
1) 4P connect or.
3. St art t he engi ne and l et i t i dl e.
(Sensor
1)out put vol t age wi t h
t he scan t ool ,
Does i t st ay at 0. 1 V or l ess?
Check f or a short i n l he wi re
(PHO2S
linel:
nect or D
(' l 6P).
t he Pri mary HO2S l sensor 1)
4P connect or t er mi nal No. 1
and body ground.
Repair short in lhe wire b6tw6en
ECM/rcM
(D7)
and Primary llO2S
{Sensor 1}.
PCM and recheck. l l sympt om/
indication goes
awry, replaco the
original ECM/PCM.
Primary Heated Oxygen Sensor
(Primary
HO2S)
(sensor
1l
('96
-
(cont'dl
PRIMARY HO2S lsonsor 1l
,tP
CONNECTOR lC123l
11- 140
(Primary-
Fjq?S)
(Sensor
1l
('99
-
0b Models exiept D16Y5 engine with M/T)
TheHeat edoxygensensor s( Ho2S) det ect t heoxygencont ent i nt heexhaust gasandsi gna| st heEcM/ PcM' | noper at i on,
the EcM/pcM recei ves the si gnars from the sensor and vari es the durati on duri ng whi ch fuel i s i nj ected. To stabi l i ze the
s ens or , s out put , t hes ens or nas ani nt er naI heat er . ThePr i mar y Ho2S( s ens or l ) i s i ns t a| l edi nex haus t mani f o| d( D16Y8.
81642 engi ne: exhaust Pi Pe
A)
SENSOR
TERMINALS
VOLTAG
(VI
HEATER
TERMINALS
The scan tool i ndi cates Di agnosti c
Troubl e Code
(DTC)
Oxygen Sensor
(HO2S) (Sensor 1) ci rcui t
RI CH+ AI R-
-
LEAN
FUEL
RATIO
probl em i n t he Pri mary Heat ed
HEATER
-
The MIL has been tPorted on.
-
DTC P013'l is stored.
engi ne at 3, 000 rpm wrt h no
l oad
(i n
t he radi at or f an comes on
3. Check t he Pr i mar Y HO2S
lSensor
1) output voltage wath
t he scan t ool duri ng accel era
tion using wide open throttle
lntermittont f.ilure, 3ystem i3 OK
at thi3 time. Check tor
Poor
con'
nections or loose wires el C123
{Pri mary
HO2S, Sensor 1) and
ECM/PCM.
Does the voltage stay at 0 5 v
or l ess?
Check t he f uel pr essLl r e ( see
Page
11, 109) .
( To page 11 142)
(cont ' d)
11- 141
PGM-FI System
(Primary
HO2SI
(Sensor
1)
('99
-
(cont'd)
PRIMARY HO2S {Soror 1} 4P CONNECTOR lc123l
PHO2S
f----l
,wHl_l:-f;-l
0ffi
_L
Chock fo. a shori in the HO2S:
(Sensor
1i 4P connect or.
3. St an t he engi ne and l et i t i dl e.
(Sensor
1) out put vol t age wi t h
t he scan t ool .
Does i t stay at 0.5 V or l ess? Roplaco the HO2S
(Sensor
1).
Check t or a short i n t he wi re
{PHO2S linel:
2. Disconnect the EcltI/PcM con-
nect or C {31P).
t he Pri mary HO2S l sensor 1)
4P connect or t ermi nal No. 1
and body ground.
ReDair shorl in the wi.e between
ECM/ PCM ( Cl 61
and Pr i mar y
HO2S
(Sercor
11.
indication goes away, replace the
original ECM/PCM.
11- 142
(Primary
HO2SI
(Sensor
1)
('96
-
9b Models except Dl6Y5 engine with M/Tl
PHO29
IWHT}
(DTC)
probl em i n the Pri mary Heated
Oxygen Sensor
(Pri mary H02S)
(Sensor' l )
ci rcui t.
PRIMARY HO2S
(Sonso.
'll
4P CONNECToR
tc123t
sG2
IGRN/
BLKI
ECM/PCM CONNECTOR D I16PI
JUMPER WIRE
PHO2S
(WHT}
SG2 IGRN/BLKI
Wi re si de of t em6l e t ermi nal s
Problm verification:
cedure.
l oad
(i n
3. Test -dri ve wi t h t he A/ T i n
E
posi t i on (M/ T i n 4t h gear)
(Sensor 1) oLl t Put vol t age wi t h
t he scan t ool duri ng decel era'
t i on usi ng compl et el y cl osed
throttle.
Int.rmittont fiilur., system it OK
at thb timo. Chock for Poot
con-
nections or loo3a wir63 at Cl23
l Pri marY HO2S, SensoJ 1l . nd
ECM/PCM.
Does t he vol t age st ay at 1. 0 V
or more?
Check for an open in the Primary
HO2S:
(Sensor 1) 4P connect or'
3. Connect t he Pr i mar Y HO25
lSensor
l) 4P connector termi-
nal s No. 1 and No. 2 wi t h a
(l l ).
5. Check t he Pr i mar Y H02S
(Sensor 1i outPut voltage with
the scan tool.
l st here 1. 0 V or more?
Check f or an open i n t he wi ro
{PHO2S
l i ne):
2. Connect EcM/ PcM connect or
t er mi nal s D7 and D11 wi t h a
j umper wrre,
3. Turn the ignition switch ON lll)
(Sensor 1) output voltage with
the scan tool,
Replir open in tho wirc btwccn
ECM/ PCM l o?)
and Pr i m! . Y
HO2S lsonsor 1).
l s t here 1. 0 V or more?
PCM and recheck. lf 3ymptom/
i ndi cet i on
goos awey, r opl ace
the oliginal ECM/PCM.
11-143
PGM-FI System
(Primary
HO2SI
(Sensor
1)
('99 -
(DTC)
P0132: A hi gh vol tage probl em i n the
pri mary
Heated
Oxygen Sensor
(Pri mary
HO2S)
{Sensor I ) ci rcui t.
PRIMARY HO2S lsn3or 1' 4P
CONNECTOR
(c123t
PHO2S
IWHTI
ECM/PCM CONNECTOR C 131PI
sG2
(GRN/
BLK)
SG2 IGRN/8LK}
Ware si de of f emal e t ermi nal s
OTCP0132 is stored.
Problem vorificalion:
1. Do t he ECM/ PCM Reset Pro
cedure,
St a r t t h e e n g i n e . Ho l d t h e
engane at 3, 000 rpm wi t h no
l oad (i n
t he radi at or f an comes on.
Ch e c k t h e Pr i ma r y HO2 5
{Sensor l i out put vol t age wi t h
t he scan t ool duri ng decel era-
t aon usi ng compl et el y cl osed
t hrot t l e.
Intermittent tailure, systom k OK
at this time. Chock tor poor
con-
nections or looso wir* at Cl23
(Pri mal y
HO2S, Sonsor 1) and
ECM/PCM.
Check lor an open in the Primary
H02S:
l Sensor 1)connect or.
3. Connect t he Pr i mar y H02S
(Sensor
1)4P connect or t ermi
(l l ).
5. Check t he Pr i mar y H02S
{Sensor l) output voltage with
the scan tool.
Check l or an open i n t h wi re
(PHO25
linl:
j umper wi re.
3. Turn t he i gni t i on swi t ch ON {l l i .
(Sensor
1i output voltage with
the scan tool,
Roptir op.n in tho wire betweon
ECM/ PCM
l Cl 6l and Pr i m. r y
HO2S lsensor 11.
Subsiitute a known-good ECM/
PCM and r. check. l f sympt om/
i ndi cat i on goos
away, repl ece
11- 144
(Pri mary
HO2S)
(Sensor
1l
(DTC)
P0133: A sl ow response probl em i n the Pri mary Heated
Oxygen Sensor {Pri mary
H02S)
(Sensor 1) ci rcui t.
(DTC)
Pl 163: A sl ow response
Oxygen Sensor
(Pri mary
HO2S)
(Sensor 1)ci rcui t
Description
By control l i ng the ai rl fuel rati o wi th a Pri mary Ho2S {Sensor
1) and a secondary HO2S {Sensor
2), the deteri orati on of the
pri mary
HO2S
(Sensor 1) can be eval uated by i ts feedback
peri od. when the feedback
peri od of the Ho2s exceeds a cer-
tai n val ue duri ng stabl e dri vi ng condi ti ons, the sensor wi l l be
j udged
as deteri orated
when deterioration has been detected during two consecutive trips. the MIL comes on and DTC P0133 or P1163*
will be stored'
NOTE: tf DTC P0131, P0132 and/or P0135 are stored at the same ti me as DTC P0133, troubl eshoot those DTCS fi rst' then
troubl eshoot DTC P0133. l f DTC Pl 162, P1168 and/or P1169 are stored at the same ti me as DTC P1163, troubl eshoot those
DTCS fi rst, then recheck for DTC Pl 163.
Possible Cause
o Pri mary HO2S
(Sensor
' l )
Deteri orati on
o Pri mary HO2S Heater
(Sensor 1)Deteri orati on
. Exhaust system l eakage
Troublsshooting
Flowchart
tFol3al
I
P1163
-
-
DTC P0133 and/ or Pl 163* i s
stored,
Problem Verilication:
cedure-
2. Connect t he scan t ool
l oad
(i n
4. Connect t he SCS servi ce con-
nect or.
5. Test - dr i ve u nder I ol l owi ng
condi t i ons.
-
55 mph
(88 km/ h) st eady
speed
-
A/f in
D
position {M/T in
5t h
gear)
Unt i l readi ness code comes
lntermittent failure, 3Y3tem i3 OK
at thi3 time. Ch.ck lol
Poor
con-
ncctions or loosc wiros at C123
{C145)! lPrimary
HO2S, Sensor 1l
and ECM/PCM.
Replace th6 Prim.ry HO2S
(Sen'
sor 11.
*:
P' l 163
(D16Y5 engi ne wi t h M/ T)
11- 145
PGM-FI
System
Itil-"w
(primary
HO2S)
(sensor
1l
(Dl 6Y5
engi ne wi th M/Tl
(DTC) p1162:
A mal functi on i n the
pri mary
Heated Oxygen
Sensor
(Pri mary
HO2S) (Sensor
1) ci rcutt.
Doscription
The Pri mary Heated orygen sensor
(Pri mary
Ho2s)
{sensor 1) operates over a wi de ai rl fuel range. The
pri mary
Ho2S
(Sensor
1) i s i nstal l ed i n the exhaust mani fol d.
SEI{SOR
ELEMENT
SENSOR
TERMI NALS
ECM CONNECTOR C
(31PI
PRIMARY HO2S
(SENSOR
1)8P
CONNECTOR {Clir5)
f emal e t ermi nal s
of f emal e
t er mi nal s
NOTE: l f DTC Pl 162 i s stored at the same ti me as DTC Pl 167, troubteshoot DTC
p1162
fi rst, then recheck for DTC
p1167.
( To page 11- 147)
-
lh6 MIL hes b6on reDorted on.
-
DTCPl162 ir 3tored.
Problom v6rificationi
1. Do t he ECM Reset Procedure.
3. Wait at least tlvo minutes.
Test dri ve t or several mi l es wi t h
t he t ransmi ssi on i n 3rd gear.
Hol d
the engine speed at 1,500 rpm.
l s DTC P1162 i ndi cat od?
Intermittent tailuro, systom is OK
at this timo. Check tor
poor
con-
nections or loose wires at C145
(Pl i mr. y
HO2S, Senso. t ) and
ECM,
Chock f or an open i n t he wi re
(lP+
lins):
2. Di sconnect ECM connect or C
{31P) f rom t he ECM.
f rom t he Pri mary HO2S
{Sen-
sor 1) .
t he Pri mary HO2S (Sensor
1)
and ECM connect or t ermi nal
c23.
Repair open in the wire betwaon
ECM
(C231
end Pri m. ry HO2S
l sen3or l ).
Inspect lor poor
terminal to termi-
nal contact at the Primary HO2S
lsensor
'l
I connoctor and ECM.
It terminal contect is OK, roplace
lh6 Primrry HO2S {Sensor 1}.
11- 146
Check the ECM input vottage {lP-/
VS- lino):
2 Turn t he i gni t i on swi t ch ON
(l l )
ECM connect or t ermi nal s C24
Ch.ck the ECM:
2. Di sconndct ECM connect or C
{31P){rom
t he ECM.
3. Check lor continuity between
body
gr ound and ECM con
nect or t ermi nal C24
l s t here more t han 0. 5 V?
-
Repai r open i n t he wi re
betwen ECM {C2{l
and Pri-
ma.y HO2S {Snsor
1 l.
-
Substitute a known-good ECM
and recheck. It symptom/indi
cation
goes away. replace the
odginal ECM.
Check to. r short in the wi.e {lP-/
VS- lin6l:
f rom t he Pri mary HO2S l sen-
sor 1) .
2. Check tor continuity between
body
ground and ECM connec-
t or t ermi nal C24
Ropair short in the wire bstween
the Primary HO2S lsensor
1) and
ECM
(C24).
Check t he ECM out put vol t age
{VS+
linel:
N4easure vol t age bet ween ECM
connect ort ermi nal s
C25 and D11.
Check for a short in the wire
(VS+
line):
{31P)
I rom t he ECM.
3. Check {or cont i nui t y bet ween
body
gr ound and ECM con
nect or t ermi nal C25.
l s t here mot e t han 0. 5 V?
ECM CONNECTORS
l Fr om
page' 11- 146)
c
(31Pl
D {15P)
tP-/vs- tREol
f emal e t ermrnal s
sG2
(GRN/BLKI
(cont ' d)
11- 147
I 2 3 a 6 8 9 10
1 1 12 13 l a 1 5 t 6
'17
16
22
23 2a 25
27 2a
29 30
O\ rP-/vs-
:Z
taeot
,l
2 3 a 5 5 I 9 10
1 1 12 13 1a 15 16 1 7 t 8
22
23 21 25
21 2A
E 30
0)
{REDr
2 3 a 5
1 8 9 1 0
l 1 12 13 t a
' 15 't6
17 18
22
23 21 E
27 2A 29 30
[]) vs*
I rwsrt
( To page 11- 148)
( To page 11 148)
PGM-FI System
(Pri mary
HO2SI
(sensor
l )
(Dl6Y5
engine with M/T)
(cont'd)
( Fr om page 1l - 147) ( Fr om
page 11 147)
( To
page 11 149)
{GRN/ BLK}
(GRN/ 8I -K}
( To page 11- 149)
11- 148
Subst i t ut e a known-good ECM
and rechock. tf symptom/indicr-
tion goes away, replace the origi-
nal ECM.
llP+
l i n6):
I rom t he Pri mary HO2S
(Sen-
sor 1) .
2. Check t or cont i nui t y bet ween
body ground
and ECM connec-
t or t ermi nal C25.
Repair short in the wiro botween
the Primarv HO2S
{Sensor 1} and
ECM {C25}.
Replace th Primary HOzS {Sen-
sor 11.
| 2 3 r a 1 a 9 t o
t l 12 t 5 16 1 1 1a
p
ffi;r,
w''.""i0"or.
I l emat e l er ml
check the EcM:
(Sen-
sor 1).
(l l ).
4. Measure voltage between ECN4
connect or C25 and D11.
Check the ECM input voltage
llP-/
vS-linel:
l oad
(t ransmi ssi on
i n neut ral )
unt i l t he radi at or f an comes on,
2. Measure voltage between ECM
connect or t ermi nal s C24 and
Dt 1 .
Subsl i t ut e a known-good ECM
and rgcheck. It symptom/indica-
tion goes
away, repl.ce the origi-
nal ECM.
l s t here 2. 6 2. 8 V?
Check t h6 ECM out put vol t age
(VS+
linel:
Measure vol t age bet ween ECM
connect or t ermi nal s C25 and D11.
7 a 9 t 0
I t 1 2 t 3 t 6
'11
t a
VS+
{WHT}
sG2
2 3 5
, 9
, 1 0
1 l 12
l 3
'ta
t 5 15
1 2 i 3 5 a 9 t 0
't2 ' tt
t 5 t t r l 22
VS+
{WHT)
sG2
2 3
6 l t 9 l l
13 15
( Fr om page 11' 148)
Roplac th Primary HOzS
(Sen'
sor 11.
Subst i t ut e a known-good
ECM
and recheck. lf symptom/indica'
tion
goes awav, replace th odgi'
nal ECM.
Check t he ECM oul put vol t age
(l P+ l i nel :
connect or
t ermi nal s C23 and D11
ECM
and recheck f symptom/indica-
tion
goes awaY, replace the origi_
nal ECM.
Check the ECM:
( 31Pl f r om t he ECM.
3. Check f or cont i nui t y
bet ween
body
gr ound and ECM con-
nect or t ermi nal C23
Check f ot an oPen i n t ha wi re
llP+
linel:
2. Di sconnect t he 8P connoct or
(Sen-
sor ' l ) .
t he Pri marY HO2S
(Sensor 1)
and ECM connect or t ermrnal
c23.
Repair open in the wire belween
ECM { C231 and Pr i mar y HO2S
{Sensor
11.
Subst i t ut e a known_good ECM
and r6check. lf symPlom/indica'
tion
goos away, replace the odgi-
nal ECM.
Check for a short in the wire llP+
l i ne):
f rom t he Pri mary HO2S {Sen'
sor 1) ,
body
gr ound and ECM con-
Repair short in lhe wire belween
the Primary HO2S
(Sensor
'l)
dnd
ECM {C23).
Replace the Primary HO2S
(Sen'
sor 1) .
sG2
(GRN/BLKI
Wi re si de of
f emal e t ermanal s
PRIMARY HO2S
(SENSOR
1l 8P
coNNECTOR lC1a5l
l P+
( BLK)
Wi re si de of
f emal e t ermrnal s
of f emal e
t ermi nal s
NO
(cont ' d)
1 2 3 a 6 8 9 1 0
1 1 12 13 14 1 5 16 17 18 22
21 25
a 30
I
l P+
6)
tBrK)
ECM CONNECTOR C {31P}
2 3 a 6 7 I I 10
1 1 1 2 1 3 1 l 1 5 16 1 1 18
,4
22
23 2a 25
A 30
A\
lP+
Ij/ IBLK)
11- 149
PGM-FI
System
l:in1.".fy
(primary
HO2SI
(sensor
1l
(D16Y5
engine with M/D
(cont'd)
The scan toor i ndi cates Di agnosti "
-Tl :y| *
code
(DTC) pl 164:
A range/performance probrem
i n the
pri mary
Heated Oxygen Sensor (pri mary
HO2S) (Sensor
1)ci rcui t.
(DTC) p1165:
A
(pri mary
HO2S)
(sensor
1) ci rcui t.
range/performance probl em
the
pnmarv
The MIL has beon reponed on.
Problem Verilication:
1. Do t he ECM Beset Procedure.
l oad
(t ransmi ssi on
i n neut ral )
unt i l t he radi at orf an comes on.
nector.
4. Test-drive in 4th gear.
Starting
at 1, 600 rpm, accel erat e usi ng
wide open throttle for at least 5
seconds. Then decelerate tor at
least 5 seconds with the throt
tle completely closed.
Intgrmittent failure, syrtem b OK
at this time. Check tor Door con-
noctions or loose wires at C1a5
(Pri mary
HO2S. Senso.

and
ECM.
l s DTC Pl 164 i ndi cat edT
-
-
Intermittent l.iluro, system b OK
at lhis time. Chck tor poor
con-
noctions or loose wir6 at Ci45
(Pri oary
HO2S, Sen3or 1l . nd
ECM.
Replace the P.imary HO2S
(S6n-
sor 11.
Problem Vo.ification:
1. Do t he ECM Reset Procedl re.
2. St ar t t he engi ne. Hot d t he
l oad
(t ransmi ssi on
i n neut ral )
unt i l t he r adi at or f an comes
3. Connect t he SCS servi ce con,
nector.
4. Test - dr i ve u nder f ol l owi ng
condi t i ons.
-
55 mph st eady speed
Transmi ssi on i n 5t h gear
Until readiness code comes
1 1 - 1 5 0
t
Troubl e Code
(DTC) P1168; A l ow vol tage
Oxygen Sensor
(Pri marv Ho2S)
(Sensor 1) LABEL ci rcui t'
-
The MIL has b6n reponed on'
-
DTC P1168 is storcd
Problem vedfication:
1. Do t he ECM Reset Procedure
3. Wait at least two minutes
lntalmittent
failure' aYstom b OK
at thi3 time. Chock lor
Poor
con-
nection3 or loo3o wiro3 at C145
(Pri mary HO2S, S. n. or
1l and
ECM.
Chock th. ECM:
2. Di sconnect t he ECM connec'
t or D 116P) .
3. Check for continuity
between
ECM connect or t ermi nal
D7
and body
ground
Sub3titut.
e known-good
ECM
6nd r.chock. lf rymptom/indica-
tion
gocr away, r.Placs the origi_
nal ECM.
Check f or t shot t i n l hg wi re3
ILABEL
line):
1. Di sconnect
t he Pri mary HO2S
(Sensor 1) 8P connect or'
2. Check for continuitv
between
ECM connect or
t ermi nal D7
and body
ground
Reoair short in the wir63 botlvoon
lhe Primary HO2S {Sensor
1} end
ECM
(O71.
ECM CONNECTOR
D {16PI
LABEL {WHTI
wire side of female terminals
LABEL
(WHTI
(cont ' d)
PGM-FI System
IiT-"-w
Heated
9{ygglSensor
(primary
HO2SI
(Sensor
1)
(Dl 6Y5
engi ne wi th M/Tl
l conr' d)
1T1163 Ih"
scan tool i ndi cates Di agnosti c Troubl e code
(DTc)
P1169: A hi gh vol rage probtem
i n the
pnmary
Heated
-
Uxygen Sensor {pri mary HO2S) (Sensor
.l )
LABEL ci rcui t.
PSTMARY HO2S (SENSOR
1l 8p CONNECTOR
(145)
LABEL
IWHTI
ECM CONNECTOR O {16P}
(GRN/BLK)
f emal e
IGRN/BLKI
-
The MIL hrs been reported on.
-
DTC Pl169 i3 stored.
L Do t he ECM Reset Procedure.
3. Wait at least two minutes.
Intormittent f.ilure, sv*em b OK
at this time. Check for poor
con-
n.ctions or loose wires at C145
(Pri m. ry
HO2S, Sensor 1l and
ECM.
Chck I or an op6n i n t h wi re
(LABEL
line):
(Sensor
1) 8P connector.
(ll).
Pri mary HO2S
l sensor 1) 8P
connect or No, 4 t ermi nal and
body ground.
Check l or an open i n t he wi re
{SG2l i nel :
1. Turn t he i gni t i on swi l ch OFF.
2. Di sconnect ECM connect or D
(16P)t rom
t he ECM.
3. Check for continuity betlveen
ECM connect or t ermi nal D1l
and Pri mary HO2S
(Sensor
1)
8P connect or t ermi nal No. 3.
Ropair opon in the wires betweon
lhe P.imary HO2S
{Sensor
't}
and
ECM tD7l.
Rpair open in th6 wire between
the Primary HO2S lsensor 1) and
ECM
(011).
Roplace the Primary HO2S (Sen-
sor 1).
1 2 3 a 5
6 8 9 10 1 t 1 2
t 3 1 4 15 16 sG2
si de of
e t ermi nal s
t l l
I
I
--
rl
;G2
I 2
6
3 4
8
11- 152
Secondary
Heated Oxygen Sensor {secondary
HO2S)
(Sensor
2l
*' t
: D16Y8 engi ne
*2:'99 -
O0 m;dels except D16Y5 engine with M//T
(DTC)
probl em i n the Secondary Heated
Oxygen Sensor
(Secondary HO2S)
(Sensor 2) ci rcui t'
SECONDARY
HO2S ls.n.ot
2)
,rP
CONNECTOR
(C125, C782')
Wire side oI temale terminals
(cont'd)
1 1 - 1 5 3
-
Tho MIL has been reported on
-
cedure.
engi ne at 3, 000 rpm wl t h no
l oad
Secondar y
HO2S
( Sensor 2)
out put vol t age at 3, 000 rPm
lntermittent frilure, sYdem is OK
at this tim6. Check for
Poor
con'
nections or loolo wir.3 at C131t
(locatod undor right.ido of desh)'
C432. {located
under middle of
dashl, cl25 lc782lr {Secondary
HO2S) tsensor 2l .nd ECM/PCM.
Does the voltage staY at 0.3 V
or l ess?
Ch6ck tot a sho.t in the Scondery
HO23:
' 1.
2, Di sconnect t he Secondar Y
HO2S l Sensor
2)4P connect or.
4. Check t he Secondar Y HO2S
lsensor
2) output with the scan
tool,
Check t or a shor t i n t he wi r e
{SHO2S
linel:
2. Di scon n ect t ho EcM/ PCM
connect or D {16P) {A
(32P))*'
t he SecondarY H02S
(Sensor
2) 4P connect or t ermi nal No 1
and body
ground.
Rpair short in tho wire bstwoen
ECM/ PCM l D14
( A231* ' | and
Secondarv HOzS
(Sensor 2).
PCM and recheck lf 3ymptom/
i ndi cal i on
gos awaY, t ePl t co
the oiigin.l ECM/PCM.
PGM-FI System
I
a
a
9ggoqOfry
(Secondary
HO2S)
{sensor
2l
('96
-
98 Models;
'99
-
00 D16YS engine with M/Tl
(DTC)
PO' 138: A hi gh vol tag probl em
i n the Secondary Heated
Oxygen Sensor
(Secondary
HO2SI
(sensor
2) ci rcui t.
SECONDARY HO2S ls.nsor 2l
4P CONNECTOR C125 tc782t*
JUMPER WIRE
sHo2s
IWHT/RED}
sHo2sG
(RED/YEL)
(GRN/WHT)*
(GRN/BLK)*'
ECM/FCM CONNCTOR D Il6PI
sH()2sG
{YEL/RED)
{GRN/BLK}'
JUMPER WINE
' i
D16Yg engi ne
*1i
Dl 6Y5 engi ne
-
Ths MIL ha3 bcen r6port.d on.
-
DTC m138 i. 3tored.
Problem vorilication:
cedure.
engi ne at 3. 000 rpm wi t h no
l oad
(i n
the radiatorfan comes on.
3. Wi t h t he scan t ool , chckt he
Secondar y HO2S { Sensor 2)
outputvoltageat 3,000rpm.
Into.mittant failurc, sy3tem b OK
rt thi3 tims. Ch6ck tor poor
con-
n6clionr or loo3 wiroa at C13'l*
(locat
d und6r right lido of dr'h),
C/2r (loc.tod
undr middle ol
d.rhl, C125 {C782lr
(Socond.ry
HO2S S6n3or 2) .nd ECM/PCM.
Chcd( for rn open in the Socond!ry
f|o2s:
2. Di sconnect t he Secondar y
HO2S
(Sensor
2) 4P connector.
3. Connect the Secondary HO2S
(Sensor
2) 4P connect or t er-
mi nal s No. 1 and No. 2 wi t h a
JUmper
wi re.
4. Tu.n the ignition switch ON
(ll).
5. Chock t he Secondar y HO2S
(Sensor
2) output vollage with
the scan tool.
Check t or an open i n t he wi ro
(SHO2S
lin6l:
1. Turn t h6 i gni t i on swi t ch OFF.
j umper
wi re.
3. Turn the ignition switch ON {ll}.
4. Check t he Secondar y HO2S
( Sensor
2) ol t put vol t age
Rapair op.n in the wiio botw.on
ECM/PCM
lD13 and/or Dlal and
S.cond.ry HO2S lsnsor 21.
l s t hore 0. 6 V or more?
Subslituto a known-good ECM/
PCM .nd rccheck. lt symptom/
i ndi cat i on goe!
rway, repl ace
11- 154
Secondary
(SecondarytlO2S)
(Sensor
2l
('99
-
00 lilodels except DtGYS engine
with M/T)
(DTC)
probl em i n the secondary Heated
Oxygen Sensor
(Secondary H02S)
(Sensor 2) ci rcui t.
SECONDARY HO2S {Snsot
2}
4P CONNECTOR Cl25 lc782l'
JUMPER WIRE
I r
sH02s
(WHT/RED)
sG2
{GRN/BLKI
Wi re si de of f emal e t ermanal s
ECM/PCM CONNECTORS
A
(32P1
Wi re si de ot f emal e t erml nal s
gs92g
111yp17p5py |
.lutuPea wtne
-
The MIL has beon reportod on.
-
DTC m138 is.tored.
Ploblem vorification:
1. Do t he ECM/ PCN4 Reset Pro-
cedure.
2. St ar t t he engi ne Hol d t he
l oad
(i n
the radiator{an comes on
3. Check t he Secondar Y H02S
(Sensor 2) out put vol t age at
3, 000 rpm wi t h t he scan t ool
lntormittont failuio, sYstom b OK
st thir timo. Check for
Poor
con_
nections ot loo39 wiJo3 af Cl3lr
(located under right ride ot desh),
C432'
(locatod undot middle of
dashl, Cl25 {C782lr
(Secondaiy
HO2S Son3or 2l and ECM/PCM.
Does the voltage stay at 0 6 V
or more?
Ctd( tor an opan in the Secondary
l|o2s:
2. Di sconnect t he Secondar Y
HO2S
(Sensor 2) 4P connector.
3. Connect t he Secondary HO2S
(Sensor 2) 4P connecl or t er_
i umper
wi re.
(l l )
5. Check t he SecondarY HO2S
l Sensor
2) out pt l t vol t age wi t h
t he scan t ool ,
l st here 0. 6 V or more?
Check l or an open i n t he wi ro
(SHO2S line):
t ermi nal s A23 and C18 wi t h a
j umper wrre,
(ll).
4. Check t he Secondar Y HO2S
{ Se n s o r
2 ) o u t Pu t v o l t a g e
with the scan tool.
Repair opon in tho wire betwecn
ECM/PCM
(A23)
and SocondarY
HO2S {Sansor 2).
Substitut a known'good ECM/
PCM and recheck. It symptom/
i ndi cat i on
goes awey, JePl aco
the otiginel ECM/PCM
*i
016Y8 engi ne
1 1 - 1 5 5
PGM-FI System
(Secondary
HO2S)
{sensor
2l
[FO13a]l
The scan tool i ndi ctes Di agnosti c Troubl e Code {DTC) P0139: A sl ow response probtem
i n the Secondary Heated
-
Uxygen Sensor
(HOzS) (Sensor
2) ci rcui t.
1 1 - 1 5 6
-
-
l oad {i n Park or neut ral ) unt i l
Secondar y HO2S
( Sensor
2)
output at 3,000 rpm.
Intermiftent failure, system i! OK
at this tims. Check for
pool
con-
nections or loos6 wiles at C131.
{located undor ght lide of dash),
C432'
(locrted
under middle ot
d. shl Cl 25
(C782l r (Socondary
HO2S) (Sonsor
2) and ECM/FCM.
Does t he vol t age st ay wi t hi n
0. 3
-
0. 6 V f or t wo mi nut es?
* :
D16Y8 engi ne
tFo135l
iPol4tl
(HO2SI
Heater
(' 96
-
98 Mbdel s,' 99
-
*: p0141 (To page 11-158)
**:
D' 16Y8 engane
The scan tool i ndi cates Di agnostrc Troubl e code
(DTC)
P0135: An el ectri cal
probl m i n the Pri mary Heated
Oxygen Sensor
(Pri mary
HOi S)
(Sensor 1) Heater system
(Except
D16Y5 engi ne wi th M/T)'
The;can tool indicates Diagnostic Trouble code
(DTC)
P0141: A problem in the secondary Heated oxygen sensor
(secondarv
HO2S)
(Sensor
2) Heater ci rcui t.
PRIMARY HO2S
(Son.or 1l aP CONNECTOR
SECoNDARY HO2S tsensor
2l
ilP
CONNECTORT
PRIMARY HOzS
(SENSOR 1) 4P CONNECTOR ICl23I
SECONDARY HO2S ISENSOR
2) 4P CONNECTOR {C125I*
PO2SHIC, SO2SHTC
IBLK/WHT)
SECONDARY HO2S ISENSOR
2)
,tP
CONNECTOR 1C782)'*
so2sHTC
{BLK/WHT)
I (cont' d)
11-157
-
The MIL h.s boen Jeponed on.
-
DTC P0135, and/or Polal .re
stoled.
Problem verificationl
ceduae,
lniermittent tailura, sYttam i! OK
at thi3 time, Chsck for
Poor
con'
neci i on3 or l oose wi l G3 at
C131**
(locat.d undo. right sido
ot dashl, C{32**
(loc.ted under
mi ddl e ol dashl , C123
(Pri marY
HO2S. Sansor 1) C125 l c782l *r
{Socondery
H02S, Sonsor 2l '
and EcM/PcM.
Check for an open or 3hort in tho
HO25:
2. Disconnect the HO2S
(Primary
or Secondary*)
(Sensor 1 or
Sensor 2) 4P connector'
3. At t he Ho2s si de, measur e
resistance between the HO2S
4P connect or t ermi nal s No. 3
and No. 4.
l s t here 10
-
40 0?
Check f or cont i nui t y bet ween
body
gr ound and t he HO2S 4P
connect or t er mi nal s No. 3 and
No. 4 i ndi vi dual l y
Chock for an oPen ot short in tho
wire |PO2SHTC,
SO2SHTC* linol:
(l l ).
HO2S 4P connect or t ermi nal s
No. 3 and No. 4.
( To page 11' 158)
PGM-FI System
a
a
(HO2S)
Heater
('96 -
98 Models,'99
-
(cont'dl
PRIMARY HO2S
{SENSOR 1I 4P CONNECTOR
{c1231
SECONDARY HO2S
{SENSOR 2} 4P
coNNECTOR
1C125)r
r-l
--'1
l l i 2 l
f;T;t
tcl
|BLK/
&)
YELI
Y
Wi re si de of fomal e l ermi nal s
SECONDARY HO2S
ISENSOR 2) 4P CONNECTOR
{c78ilf
IBLK/WHT)
(From page
11-157)
Wire sid ot temale terminals
SO2HTC(BLK/WHTI* PO2SHTC{BLK/WHTI
*:
P0141
*+:
Dl 6Y8 engi ne
1 1 - 1 5 8
( Fr om page 11- 157)
Check tor an op6n or 3hoft in the
wire
{lGl lin6):
Measur e vol t age bet ween t he
HO2S 4P connect or t ermi nal s No. 3
(D16Y8
engi ne: No. 4) and body
ground.
-
Repai r open or shon i n t he
wire between Primary HO2S
lson.or 1), {No. 15 ALTERNA-
TOR SP SENSORI (7.5
Al fuse
and Secondary HO2S, Sonsol
2t,.
-
Replace the No. 15 ALTERNA-
TOR SP SENSOR 17.5 A) tuse.
Check f or an open i n t he wi re
IPO2SHTC, SO2SHTC' linel:
2. Reconnect t he HO2S 4P con-
nector.
nector A
(32P).
(l l ).
ECM,/PCM connector terminals
46 and 410 {A5 and A10)*.
Ropail opan in the wire btwoen
ECM/ PCM
l A6, A5l * and HO2S
{Primary, Secondary+1.
l s t here 0. 1 V or l ess?
PCM and recheck. ll symptom/
i ndi cat i on goes
awry, repbce
ECM/PCM CONNECTOR A I32P)
so2sHrc
I
tBLK/WH0.J
pozsxtc E/
IBI-K/WHTI
^
,-----{v}-
| . = , |
I
PG1
IBLK}
3 u
I JsTgT
ro l l
12 r3 t 5 t 6 I t t a r9 20 z2l 23 21
25 27 2A 2i 3o
{PO2SHTC. SO2SHTC* line):
' 1.
nector A
(32P1.
the ECM/PCM connector termi-
nal 46 (A5)*
and body ground.
Repair short in thg wire betwen
ECM/ PCM l A6, A5*l . nd HO2S
(P.im.ry,
Socondary*).
PCM and recheck. It symptom/
i ndi cet i on goes
away, rophce
I
Heated
Oxygen Sensor
(HO2S)
Heater
i'ss
-
oo Mb-dels except D16Y5 engine with M/Tl
The scan toot i ndi cates Di agnosti c Troubl e Code
(DTC)
P0135: An el ectri cal
Oxygen Sensor
(Pri mary
ttOi S)
(Sensor 1) Heater system {Except
D15Y5 engi ne wi th M/T)'
The
-scan
tool i ndi cates Di agnosti c Troubl e Code
(DTC) P0141; A
probl em i n the Secondary Heated Oi gen Sensor
(Secondarv
HO2S) {Sensor
2) Heater ci rcui t
Fo13sl
Fol 11l
lntermiftent failuro, sYstom b OK
at thit limo. Ch6ck lor
Poor
oon'
nect i ont or l ooso wi t a! at
C131'* {loc.tod
und.t right ido
ol drshl, C432'*
(located undel
mi ddl o of dashl , C123
(Pri marY
HOzS, Sensor 1) C125
(Ct 82l r'
(socondary HO2S, Sensor 2)t
.nd ECM/PCM.
PRIMAFY HO2S ls.n.or
ll
rrP CONNECTOR
SECOITIDARY
HO2S
(Srn.ol21 4P CONNECTOR'
PRIMARY HO2S {SENSOR
1}
ilP
@NI{ECTOR lc123l
sEcoNDARY HO2S ISENSOR
2) aP @NNECTOR
(C125)'
3l-, l-tl-t
Fo2sHrc. so2sHrc
ver.t
l ^-1 .'l
{BLK/wHrl
1 1
' ! ' l - l
|
--=-
I
u----{v)'---..-'
Wire side of {emale terminals
SECO'TIDARY Ho2S
(SENSOR 2,
4P CONNESTOR {C7&llt'
so2sHTc
(BLKnflHTl IBLK/WHT)
(cont' d)
1 1 - 1 5 9
r : p0141
{ To
page 11- 160}
**:
D16Yg engi ne
-
The MIL has been reponed on.
-
DTC P0135. and/or P0141 are
storod.
Problem vorification:
cedut e.
2. St an t he engl ne.
Chock foi an open or short in the
HO25:
2. Disconnect the HO2S
(Primary
or Secondary*) l Sensor
1 or
Sensor 2) 4P connector'
3. At t he H02S si de, measur e
resistance between the HO2S
4P connect or t ermi nal s No. 3
and No. 4.
l s t here 10
-
40 n?
body
gr ound and t he HO2S 4P
connect or t er mi nal s
No. 3 and
No. 4 i ndi vi dual l Y.
Check for an opon or short in lho
wire
(PO2SHTC, SO2SHTC+ line):
' 1.
(l l ).
H02S 4P connect or t erml nal s
No. 3 and No. 4.
{To
page 11-160}
PGM-FI System
(HO2S)
Heater
('99
-
( Fr om page 11- 159)
PCM and recheck. l f sympt om/
i ndi cat i on goes
away, repl ace
(cont'dl
PRIMARY HO2S ISENSOR 1I 4P CONNECTOB
{c123)
SECONDANY HO2S ISENSOR 2} 4P
coNNECTOR (C125)*
-r--r ,
l r
z l
- f -
1 3
4 l
lc'l
L--r-J-r
relxr
p1
YELI
Y
SECONDARY HO2S
(SENSOR
21 4P CONNECTOR
{c782}rr
IG1 IBLK/WHT)
NO
Wi re si de of f emal e t el mi nal s
ECM/PCM CONNECTORS
ECM/FCM CONNECTORS
* :
P0141
**:
Dl 6Y8 engi ne
1 1- 1 60
{l Gl * l i ne}i
Measure vol t age bet ween t he pri
mary HO2S 4P connector terminal
No. 3
(D16Y8
engi ne: No. 4) and
body ground.
-
Repei r open or shon i n t he
wire between Primary HO2S
lsensor 1), {No. 15 ALTERNA-
TOR SP SENSOR)
(7.5
A) fus
and Secondary HO2S, Sensor
2t,.
-
ReDlace the No. 15 ALTERNA-
TOR SP SENSOR {7.5 A tuse.
Check , or an open i n t he wi res
(PO2SHTC,
SO2SHTC' linel:
2. Reconnect t he HO2S 4P con-
nector,
3. Disconnect the ECN4/PCM con
nect or C
(31Pi (ECM/ PCM
con-
nect or A
(32P))i .
(l l i .
ECM/ PCM connect or t ermi nal s
82 and Cl 182 and AB)*.
Reprir open in the wirc betwon
ECM/ PCM
(Cl ,
A8i ) and HO2S
(Primary,
Secondary+).
(From page 11 l 59i
Check t or a short i n t he wi res
IPO2SHTC, SO2SHTC* linel:
2. Di sconnect t he ECM/ PCM con-
nect or C
(31Pi (ECM/ PCM
con
nect or A
(32P)i *.
the ECM/PCM connector termi
nal C1 {A8)* and body ground.
Repai. short in the wire btween
ECM/ PCM
l cl , A8. l and HO2S
(Pdmery,
Secondary*1.
PCM end recheck. l f sympt om/
i ndi cat i on goes away, repl ace
(HO2SI
Heater
(Dl 6Y5
engi ne wi th M/Tl
(DTC) P1166: An el ectri cal
Oxygen Sensor
(Pri mary H02S) Heater system.
PRIMABY HO2S ISENSOR 1I 8P CONNECTOR
Termi nal si de of
mal e t ermi nal s
I (cont' d)
1 1 - 1 6 1
-
The MI L has been l ePort ed
-
DTC Pl166 b stored.
Intermitlent failura, sYstem b OK
at t hi s t i me
(t e3t
dri ve maY be
ngcessary). Check for poor con-
nections or loose wires between
C145
(Pri mary HO2S, Sen3or 1l
end ECM.
l s DTC P' l 166 i ndi cat ed?
Check the Primary HO2S
(Sensot
1l resistence:
(Sensor 1) 8P connect or.
3. At t he Pr i mar y HO2S
( Sen
s o r 1 ) , me a s u r e r e s i s t a n c e
bet ween No. 1 and No. 2 t er_
Replace lhe Primery HO2S
(Sen-
sor 11.
l s t here 2 13 O?
Check f or a shor t ed Pr i mar Y
HO2S lsensor
1):
body
ground and each t ermi nal .
Check f or a shor t ed Pr i mar Y
HO2S {Snsor
1l:
Check for continuity between ter'
mi nal No. 1 and t er mi nal s No. 3,
4, 6, 7 and 8 i ndi vi dual l y.
l s t her e conl r nui l y?
( To page 11' 162)
PGM-FI System
I
a
a
Ch6ck the PO2SHTC circuit:
1. St art engi ne and keep engi ne
rpm at i dl e.
2. At t he engi ne wi re harness,
measur e vol t age bet ween
Pri mary HO2S
(Sensor
1) 8P
connect or t ermi nal No. 1 t er
mi nal and body ground.
(PG
linell
Measurc voltage between Primary
HO2S
(Sensor
1) 8P connector ter-
mi nal s No. l and No. 2.
l s t here moret han 5 V?
Repair opon in the wi.o bEtwoon
t he HO2S. nd G101
(l ocat ed
at
th.rmonat housingl.
l s t here more t han 5 V?
Subst i t ul e a known-good ECM
.nd .echeck. lt 3ymptom/indica-
tion
906!
rwry, roplace the origi-
nal ECM,
Check l or a shor t i n t he wi r e
{PO2SHTC line):
2. Di sconnect ECM connect or A
(32P)t rom
t he ECM.
ECM connect or t er mi nal 46
and body
ground.
Ropair 3hort in tho wire betwoen
t he ECM {46} and t he Pri m. ry
HO2S lson3or 11.
(PO2SHTC linel:
ECM connect or t ermi nal 46 and
t he Pri mary HO2S
(Sensor
1)8P
connect or t ermi nal No. 1.
Repair opsn in the wir6 botween
ECM {A6} .nd the Primary HO2S
l sonror 1).
Subst i t ut o a known- 9ood ECM
and rech6ck. lf symptom/indica-
tion goes away, replace the origi-
nal ECM.
(HO2S)
Heater
(Dl6Y5
engine with M/Tl
(cont'd)
( Fr om page 11- 161) PRIMARY HO2S
(SENSOR
1} 8P CONNECTOR {Cl45I
PO2SHTC
{BtK/WHT)
PO2SHTC
IALK/WHTI
ECM CONNECTOR
11- 162
\.
!
\
A {32P}
o
6 I 9 l r o I t
1 2 t 3 l 5 t6 1 ' t 8 t 9 a 221 23 2a
25 2' 2a E ito
,1 | ---
(DTC)
Pl 167: A system mal functi on i n the Pri mary Heated
Orygen Sensor {Pri mary
HO2S)
(Sensor
1) Heater ci rcui t
PRIMABY HO2S ISENSOR
1} 8P CONNECTOR
t c145l
ECM CONNECTOR C
(31P)
-
The MIL has ben reported on.
-
DTC Pl167 i3 3tored.
Problem Veritication:
engi ne at 3, 000 mm
wi t h no
l oad
(t ransmi ssi on i n neut ral )
unt i l t he radi at or f an comes
on.
Intormittont failure, system i3 OK
at thia time. Chock for
Poor
con_
noction3 or looso wilgt ai Cl45
(Pri mary HO2S, Son3or 1l and
ECM.
l s DTC1167 i ndi cat ed?
Check l or sn open i n t he wi re
(VS+ linel:
{Sensor 1) 8P connect or.
(l l ).
4. Measure voltage betwen the
Pri mary HO2S
(Sensor
' 1)
8P
connect or t ermi nal No 6 and
body ground.
Ch.ck the ECM:
ECM connector terminsl C25 and
body
ground.
Repair opon in the wite ECM
(C25)
and P m.ry HO2S
(Sn3or 11.
Replaco the Primary HO2S
(Son-
sor 11.
Substitute ! known-good ECM
and r6check. lf symptom/indica-
tion
gos6 away, r.place tho origi'
nd ECM,
,l
2 3 4 5 8 9 10
1 1 12 13 t 4 15 16 17 18
a 21 25 a 30
VS+
{WHTI
t ermi nal s
1 1- 163
PGM-FI System
Fuel Supply System
D017-i l
Th""""ntool i ndi cates Di agnosti c Troubte Code {DTC)
p0171;Thefuet
system i stoo l ean.
1P0172 |
fne scan tool i ndi cates Dl agnosti c Troubl e Code
(DTC)
P0172:Thefuel system i stoo ri ch.
Description
By moni tori ng the Long Term Fuel Tri m, l ong term mal functi ons i n the fuel system wi l l be detected.
l f a mal functi on has been detected duri ng two consecuti ve tri ps, the MIL wi l l come on and DTC P0171 and/or P0172 wi l l be
stored.
NOTE: l f some of the DTCS l i sted bel ow are stored at the same ti me as DTC P0171 andl ot P0172, l touhl eshoot those DTCS
fi rst. then recheck for DTC P0l 7l andl ot P0172.
P0106- 8, P1128* 3.
* 5,
P1129* 3
* 5
MAP Sensor
P0135; Pri mary HO2S Heater
P0137. P0138: Secondary HO2S
P0' 141: Secondary HO2S Heater
P0401: EGR Fl ow Insuffi ci ent*1
P0441: EVAP System Insuffi ci ent Purge Fl ow*6
P1259: VTEC System*,
P1491:EGR Val ve Li ft Insuffi ci ent*r
P1498: EGR Val ve Li ft Sensor Hj gh Vol tage*r
*r:
D16Y5 engi nes
*' :
Dl 6Y5, D16Y8, 81642 engi ne
*3:
' 97
model s
* a: ' 96
model s
f 5:
' 98
-
00 model s
*6:
' 96
D16Y5 engi ne,' 96 D16Y7 engi ne,' 96 D16Y8 engi ne
(sedan),' 97
D16y5 engi ne,,97 D16y7 engi ne
(coupe:
KA, KC mo+
el s, sedan KA. KC, KL
(DX)
model s. hatchback; al l model s),' 97 D16Y8 engi ne
(sedan:
KA, KC model s)
Possible Cause
DTC P0' 171
l oo l ean
DTC P0172
too rach
Fuel Pump i nsuff i ci ent f l ovpressure
Fuel Feed Li ne cl ogged, l eaki ng
Fuel Pressure Regul ator stuck open
Fuel Fi l ter cl ogged
Fuel Inj ector cl ogged, ai r i ncl usi on
Gasol i ne doesn' t meet Owner' s Manual spec.
Pri mary HO2S
(Sensor
1) deteri orated
MAP Sensor range/performance*.
EGR System mal functi on
(too
much fl ow)*1
Val ve Cl earance
Exhaust l eak
Fuel Pressure Regul ator cl ogged, stuck cl osed
Fuel Return Pi pe cl ogged
Fuel Inj ector l eaki ng
Gasol i ne doesn' t meet Owner' s Manual spec.
Pri mary HO2S
(Sensor
1) deteri orated
MAP Sensor range/performance*a
EGR System i nsuffi ci ent fl ow*1
EVAP Purge Control Sol enoi d Val ve l eaki ng, stuck opened
Val ve Cl earance
11- 164
t
' l
NO
a-,-:-
-
YES
-
The MIL ha3 bon rePorled on.
-
DTC P0171 a^dl ot P0172 arc
stored,
i s t he f uel
pressure OK?
Check the fuel
ptssure regulator
and fusl re{urn
pipe.
l s t he f uel pressure t oo hi gh
ort oo l ow?
Check the Primary HO2S:
I oad
(i n
t he radi at or I an comes on
2 . Ch e c k t h e Pr i ma r y HO2 S
( Sensor 1) out put wi t h t he
scan t ool ,
Check t he t u6l pump. f uel l eed
pipe, ful fiher, and Iuel
Pressure
regulator.
Does i t st ay at l ess t han 0. 3 V
or more t han 0. 6 V?
Check l or a st i cki ng or l eaki ng
EVAP
pur ge cont r ol sol enoi d
Wi t h a vacuum
PumP,
aPPI Y vacu-
um t o t he EVAP
pur ge cont r ol
sol enoi d val ve f r om t he i nt ake
mani f ol d si de.
Does i t hol d vacuum?
Check the MAP sensor outputr
(l l )
t ool .
Check th6 response of the MAP
sensoa:
t ool .
l s a MAP of 40. 0 kPa 1300
mmHg,
12. 0 i nHg) or l ess i ndi cat ed wi t hi n
one second after starting the
engi ne?
-
Check th valve cloarance.
-
Check the EGR
rystem
lD16Y5
enginel.
-
lf they are OK, rplace the tuel
iniocto]3.
1 1 - 1 6 5
PGM-FI System
Random Misfire
lFoioo l*u o, [FTioo l*'
*'
and
(DTC)
P0300* 5 or P1300* 3
* 1
and s ome of P0301
-
P0304:
Random mi sfi re.
Description
Mi sfi re detecti on i s accompl i shed by moni tori ng the crankshaft speed wi th the crankshaft speed fl uctuati on
(CKF)
sensor
whi ch i s attached to the crankshaft.
l f mi sfi ri ng strong enough to damage the catal yst i s detected. the MIL wi l l bl i nk duri ng the ti me of i ts occurrence, and DTC
P0300*5 or P1300*3' *' and some of DTCs P0301 through P0304 wi l l be stored. Then, after mi sfi re has ceased, the MIL wi l l
come on.
l f mi sfi ri ng that i ncreases emi ssi ons i s detected duri ng two consecuti ve dri vi ng cycl es, the MIL wi l l come on, and DTC
P0300*5 or P1300*3
*a
and some of DTCS P0301 through P0304 wi l l be stored.
NOTE: l f some of the DTCS l i sted bel ow are stored at the same ti me as a mi sfi re DTC. troubl eshoot those DTCS fi rst, then
recheck for the mi sfi re DTC.
P0106*4. P0107. P0108, P1128*3
*5,
Pl 129*3
*5;
MAP sensor
P0131. P0132: HO2S
P0171, P0112i Fuel meteri ng
P0401, P 1491, P1498: EGR svstem*1
P0505: l dl e Control System
P1253: VTEC System*,
P1361, P1362: TDC sensor
P1381, Pl 382: CYP sensor
P1508: IAC val ve
Possible Cause
. Fuel pump i nsuffi ci ent fuel pressure,
amount of fl ow
. Fuel l i ne cl oggi ng, bl ockage, l eakage
. Fuel fi l ter cl oggi ng
. Fuel pressure regul ator stuck open
. EGR system mal functi on*1
. Di stri butormal functi on
. l gni ti on coi l wi re open. l eakage
*l :
D16Y5 engi ne
. l gni ti on control modul e mal functi on
*2:
D16Y5, D16Y8, Bt6A2 engi ne
. MAP sensor range/performance, poor
response*r
*3:
' 97
model s
. Val ves carbon deposi t
*4;' 96
model s
. Compressi on l ow
*5:
' 98
-
00 model s
. IAC val ve mal functi onr.
. VTEC system mal functi on*,
. Fuel does not meet Owner' s Manual spec., l ackoffuel
. HO2S
. HO2S ci rcui t
Troubleshooting
By test-dri vi ng, determi ne the condi ti ons duri ng whi ch mi sfi re occurs, Dependi ng on these condi ti ons, test i n the order
descri bed i n the tabl e bel ow.
\
Possi bl e
\
- - - ^ - - -
\
rage
cause
EGR* 1
system
Crankshaft
position (CKP)
sensor
Fuel
pressure
Distributor and
lgnition wires
t cM
Cl earance
tAc
Val ve
MAP
sensor
secti on 6
11-230,
231
section 23 section 23 section 6 11- 194 11
Onl y l ow rpm and
l oad
o @ @ o o
Onl y accel erat i ng
@ o @ @
Onl y hi gh rpm and
t oao
o o @
Not speci fi c
o o @
NOTE: l f mi sfi re doesn' t recur, some
possi bl e
causes are fuel that doesn' t meet owne/s manual
spec, l ack of fuel , carbon deposi ts on spark pl ug, etc.
1 1- 1 66
I
P0304
I
Misfire Detected in One Cylinder
P0301 |
(DTC)
P0301: Cyl i nder 1 mi sfi re detected.
[F03O2l 16"""untool i ndi cates Di agnosti c Troubl e code
(DTc)
P0302: Cyl i nder2 mi sfi re detected.
[FO3Ofl 16" ".un toot indicates Diagnostic Troubte Code
(DTC)
P0303; Cylinder 3 misfire detected.
I
P0304 I
ths..rr tool i ndi cates Di agnosti c Troubl e Code
(DTC)
PO3O4: Cyl i nder 4 mi sfi re detected.
Dscription
l Mi sfi re detecti on i s accompl i shed by moni tori ng the crankshaft speed wi th the crankshaft speed fl uctuati on
(CKF)
sensor
whi ch i s attached to the crankshaft,
l f mi sfi ri ng strong enough to damage the catal yst i s detected, the MIL wi l l bl i nk duri ng the ti me of i ts occurrence, and DTC
PO3O1, P0302, PO3O3 or P0304 wi l l be stored. Then, after the mi sfi re has ceased, the MIL wi l l come on.
l f mi sfi ri ng that i ncreases emi ssi ons i s detected duri ng two consecuti ve dri vi ng cycl ss, the MIL wi l l come on, and DTC
P0301, P0302, P0303 or P0304 wi l l be stored.
NOTE: l f some of the DTCS l i sted bel ow are stored at the same ti me as a mi sfi re DTC, troubl eshoot those DTCS fi rst, then
recheck for the mi sfi re DTC.
PO106*1, P0107, P0108. P1128*3' *5, P1129*3' *5: MAP sensor
P0131, P0132: HO2S
P0171, P0172iFuel suppiy system
P0335, P0336: CKF sensor
P0401. P1491, P1498: EGR system
P0441: EVAP system Insuffi ci ent purge fl ow*6
Pl 359. P1361. Pl 362: TDC sensor
P1381. Pl 382: CYP sensor
*o:
' 96
model s
*6:
' 96
D16Y5 engi ne,' 96 D16Y/ engi ne,' 96 D16Y8 engi ne {sedan),' 97
D16Y5 engi ne,' 97 D16\4, engi ne
(coupe:
KA,
KC model s, sedan KA. KC, KL
(DX)
model s, hatchback:al l model s),' 97 D16Y8 engi ne
(sedan:
KA, KC model s)
Possible Cause
. Fuel i nj ector cl oggi ng, fuel l eakage, ai r l eakage
. Fuel i nj ector ci rcui t open or shorted
. Spark
pl ug carbon deposi ts, foul i ng, mal functi on
. l gni ti on wi res open. l eaki ng
. Di stri butor mal functi on
. ComDressi on l ow
. Val ve cl earance out of spec
. VTEC system mal functi on
(D16Y5,
D16Y8. 81642 engi ne)
. HO2S
. HO2S ci rcui t
(cont' d)
11- 167
r ' a
PGM-FI System
Misfire in Detected One Gylinder
(cont'dl
Troubleshootin g Flowchart
NOTE:
.
l f t here i s no t reeze dat a of mi sf i ri ng,
j ust
cl ear t he DTC.
.
I t t here i s no f reeze dat a of mi sf i ri ng,
t est dr i ves under var i ous condi t i ons
-
-
DTC P0301. P0302. P0303, or
P030il is indicated.
Check the fuel iniecto. lunction:
St an t he engi ne, and l i st en f or a
cl i cki ng sound at t he f uel i nj ect or
i n t he
probl em
cyl i nder.
Check f or an open or short i n t he
harness bet ween ECM/ PCM and
t he f uel i ni ect or.
Repair open or short in the wir.
Replace the fuel iniector.
Sub3t i t ut e a known- good
ECM/ PCM and r echeck. I t
sympt om/ i ndi cat i on goes
away, replace the original ECM/
PCM.
1. Af t er checki ng and recordi ng
t he f reeze dat a, do t he ECM/
PCM Reset Procedure.
2. Exchange t he spark pl ug f rom
t he
probl em cyl i nder wi t h one
f rom anot her cyl i nder,
3. Connect t he SCS servi ce con'
nect or,
4. Test -dri ve t he vehi cl e several
t i mes i n t he range of t he f ree2e
data.
( To page 11- 169)
1 1- 1 68
I
l l
t
NOTE: l f t here i s no f reeze dat a of mi s_
f i ri ng, t est dri ves under vari ous condi
t i ons are necessary.
( Fr om page 11' 168)
Intermittent misfire due to spark
plug fouling, etc.
(firing
is OK ar
t hi s t i me).
ls DTC P0301, P0302, P0303,
or P0304 i ndi cat ed?
Does t he mi sf i re occur i n t he
ot her cyl i nder?
Replace the faulty spark plug.
Check for fuel iniector mallunc-
l | on:
1. Ex c hange t he f Lr el i nj ec t or
f r om t he pr obl em c y l i nder
wi t h one f r om anot her cyl i n
der .
2. Let t he engi ne i dl e f or t r r vo mi n-
utes.
3. Test - dr i ve t he vehi cl e sever al
times in the range ot the freeze
dat a.
l nt ermi t t nt mi st i re due t o bad
contact in the fuel iniector con-
nector
(firing is OK at this time).
l s DTC P0301, P0302, P0303,
or P0304 i ndi cat ed?
Does t he mi st i re occur i n t he
ot her cyl i nder?
Replace the taulty fuel injector.
Check lhe following items:
.
Cylinder leak-down
.
Compression
.
Crankshat t speod t l uct uat i on
{CKF) sensoi
1 1- 1 69
PGM-FI System
Knock Sensor
(KSl (' 96
-
98 D16Y5 engi ne wi th CW and' 96
-
98 D16Y8
engi ne)
Forr-l
I,3,.""""
tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P0325: A mal functi on i n the ci rcui t of the Knock sensor
DIAPHRAGM
ECM/PCM CONNECTOR D {16PI
KS 2P CONNECTOR
(Cl371
KS
(RED/BLUI
KS
I RED/
BLU)
The MIL has bgen roportsd on.
DTC PO:t25 is stored.
Problom veiilication:
1. Do t he ECM/ PCM Reset Proce-
oure,
l oad
(i n
t he r adi at or t an comes on,
3. Hol d t he engi ne at 3, 000
-
4,000 rpm tor at least 60 sec-
onds.
Intermittenl fsilu16, 3y3l6m b OK
at thi3 timg lteat drivo mav ba
noc63saryl.
Chock t or
poor
connecl i oni or
loose wire3 btwccn C137 {knock
len3or
(KS)l
and ECM/PCM.
Check for a short in tho wire {KS
linel:
2. Di sconnect t he knock sensor
2P connect or,
3. Di scon n ect t he ECM/ PCM
connect or O
(16P).
ECM/ PCM connect or t er mi -
nal s D6 and body ground.
Reo.ir 3hort in the wire between
ECM/ PCM {DG) . nd knock 3. n-
(KS
l i nel :
ECM/ PCM connect or t ormi nal D6
and knock sensor 2P connect or
t ermi nal No. l .
Ropair open in the wire bgtweon
ECM/ PCM l D6l and knock sen-
3(' t.
Subst i t ut e a known-good knock
sensor and recheck.
Rsplace th. o.igin.l knock snsor.
PCM end recheck. lf 3ymptom/
i ndi cat i on goes rway, repl ace
rhe original ECM/PCM.
1 \
I
t ert
,_-
e s l
ni ni
,--tl
le oI tem
rl s
al
1 2 1
1 8 9
' t0
1 t 12
13 l 4 t 5 t 6
11- 170
Knock sensor
(Ks)
r99
-
00 D16Y5 engine with cw,
'99
-
00 D16Y8 engine and
816A2 engine
(DTC)
P0325: A mal functi on i n the ci rcui t of the Knock Sensor
{ KS} .
OIAPHRAGM
ECM/PCM CONNECTOR C
(31P)
KS 2P CONNECTOR
(C1371
KS
t
DTC m325 is stored
cedure,
2 . St a r t t h e e n g i n e Ho l d t h e
l oad
(i n
3. Hol d t he engi ne at 3. 000
-
4,000 rpm for at least 60 sec'
onds.
lntermittent failure, system is OK
at thi3 time lt3t drive maY b
nocessaryl.
Chsck t or
poor
connect i ons or
loose wiros at C137 {knock
sen'
sor {KSll and ECM/PCM.
ls DTC P0325 indicated?
Chck for a short in tho wire
(KS
linel:
2, Di sconnect t he knock sensor
1P connect or.
ECM/ PCM connect or t er mi _
nal s C3 and body ground.
Repri. short in the wiro bqtwecn
ECM/PCM lc3l and knock 3ensor.
Check f or an open i n l he wi re
{KS linc):
ECM/ PCM connect or t ermi nal C3
and knock sensor connect or t er-
mi nal No. 1.
Replir open in the wire bdtweon
ECM/PCM {Ctl and knock sensor'
Subst i t Lr t e a known' good knock
sensor and r echeck,
Replace tho otiginal knock sensor.
substitute a known-good ECM/
PCM and r echeck. l l sympt om/
i ndi cat i on
goes awaY, r ePl 6co
tha o.iginal ECM/PCM.
ECM/PCM CONNECTOR
11- 171
PGM-FI System
tFos3sl
tFffi6l
tPr361 I
fPfi62l
fFr38il
tF13s2-l
Crankshaft Position/Top Dead Genter/Gylinder Position
(CKP/TDC/CYP)
Sensor
('96
-
98 Models,
'!n
-
(DTC)
P0335: A mal functi on i n the Crankshaft
posi ti on
(CKp)
sensor ci rcui t.
(DTC)
P0336: A range/performance probl em i n the Crankshaft
Posi ti on
(CKP)
sensor ci rcui t.
(DTC)
P1361: Intermi ttent i nterruoti on i n the Too Dead Center
(TDC)
sensor ci rcui t.
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P1362: No si gnal i n the Top Dead Center
(TDC}
sensor
circuit.
(DTC)
P1381: Intermi ttent i nterrupti on i n the Cvl i nder Posi ti on
{CYP) sensor ci rcui t.
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) Pl 382: No si gnal i n the Cyl i nder Posi ti on
(CYP}
sensor
ci rcui t.
Description
The CKP Sensor determi nes ti mi ng for fuel i nj ecti on and i gni ti on of each cyl i nder and al so detects engi ne speed. The TDC
Sensor determi nes i gni ti on ti mi ng at start-up
(cranki ng)
and when crank angl e i s abnormal . The Cyp Sensor detects the
posi ti on of No. 1 cyl i nder for sequenti al fuel i nj ecti on to each cyl i nder. The CKP/TDC/CYP Sensor i s bui l t i nto the di stri bu-
ror.
NOTE: l f DTC P1359 i s stored atthesameti me as DTC P0335. P0336, P1361, Pl 362, P1381 and/or P1382, troubteshoor DTC
P1359 fi rst, then recheck for those DTCS.
Ot6y5 6ngi ne: Dt6y7, ot6y8 enqi n6s:
SENSOR
BOTOR
TDC
SENSOR
CKP
SENSOR SENSOR
ROTOR
SENSOR
ROTOR
SENSOR
ROTOR ROTOR ROTOR
DISTRIBUTOR 1OP
coNNECTOR tC120t TDC P
-
The MIL hrs been reported on.
-
DTC P0335, P0336, P1361,
P1362, P1381 and/or Pl382 6re
stored,
dure.
Intermittent hilu.e, system b OK
at this time. Check tor poor con-
nctions or 10036 wiros at C120
{distributor} and ECM/PCM.
ls DTC P0335, P0336, P1361, P1362,
P1381 and/or P'l382 indicated?
Check f or an open i n t he CKP/
TDC/CYP sensor:
2. Di sconnect t he di st ri but or 10P
3. Measure resi st ance bet ween
t he t ermi nal s of t he i ndi cat ed
sensor
(*see
t abl e).
Replace the distributor ignition
housing (soe
section 23).
l s t here 350
-
700 0?
CYP M {BLK}
SENSOR DTC
SENSOR
IERMINAT
ECMfCM
TERMINAT COLOR
CKP P033s
m336
2 c2 BLU
6 c12
TDC P1361
P1362
3
GRN
7 c l 3 RED
CYP P! 381
P' t382
c4 YEL
8 c14 8LK
11- 172
(From page | 1-172)
Check f o. a sho. t i n t he CKP/
TDC/CYP sensor:
Ch e c k f o r c o n t i n u i t y t o b o d Y
ground on bot h t ermi nal s of t he
i n d i c a t e d s e n s o r i n d i v i d u a l l y
1*see t abl e).
Repl aco t he di 3t ri but or i gni t i on
hoGing lsee section 23).
ICKP/TOC/CYP
line3):
1. Reconnect t he di st ri but or 10P
connecaor.
2. Di sconnect t he EcM/ PCM con-
nect or C {31P}.
3. N4easure resi st ance bet ween
sensor on t he ECI M/ PCM con-
nect or {*see t abi e}.
Repair open in the indicated sen-
sor wires lrsee tablel.
ls there 350
-
700 o?
Chock l or. short i n t he wi res
ICKP/TDC/CYP
lines):
body ground and ECM/ PCM con-
nector terminals C2, C3 and/or C4
i ndi vi dual l y.
Repai. short in the indic.ted sen_
sor wire3
('soe
tablol,
Substitute e known-good ECM/
PCM, and iecheck. ll sYmptom/
indication
goes awev, rPlace the
original ECM/PCM.
DISTRIBUTOR
10P CoNNECTOR {C1201
Termi nal si de of
mal e t ermi nal s
ECM/PCM CONNECTORS C 131P)
CI(P P TDC P CYP P
(YEL)
M
CKP M
(WHT)
M
IBLKI
Wi re si de of
CYP P
I YELI
(REDI
TDC P
(GRN)
CKP P
(BLU}
t
TDC P
(GRNI
11- 173
PGM-FI System
l-Fos3sl
tFos36l
tF1361 l
Fr362-1
tF13sil
Crankshaft Position/Top Dead Center/Cylinder Position
(CKP/TDC/CYPI
Sensor
f99
-
(DTC)
P0335: A mal functi on i n the Crankshaft Posi ti on
(CKP)
sensor ci rcui t.
(DTC)
P0336: A range/performance probl em i n the Crankshaft
Posi ti on
(CKP)
sensor ci rcui t.
(DTC)
P1361: Intermi ttent i nterrupti on i n the Top Dead Center
{TDC) sensor ci rcui t.
The scan tool i ndi cates Di agnosti c Troubl e Code {DTC) P1362: No si gnal i n the Top Dead Center
(TDC)
sensor
ci rcui t.
(DTC)
P1381: Intermi ttent i nterrupti on i n the Cyl i nder Posi ti on
(CYP)
sensor ci rcui t.
l Ti aSt
(DTC)
P1382; No si gnal i n the Cyl i nder Posi ti on
(CYP)
sensor
:
ci rcui l .
DoscriDtion
The CKP Sensor determi nes ti mi ng for fuel i nj ecti on and i gni ti on of each cyl i nder and al so detects engi ne speed. The TDC
Sensor determi nes i gni ti on ti mi ng at start-up
(cranki ng)
and when crank angl e i s abnormal . The CYP Sensor detects the
posi ti on
of No. 1 cyl i nder for sequenti al fuel i nj ecti on to each cyl i nder. The CKP/TDC/CYP Sensor i s bui l t i nto the di stri bu-
tor.
NOTE; l f DTC P1359 i s stored at the same ti me as DTC P0335, P0336, P1361. P1362, P1381 and/or P1382, troubl eshoot DTC
P1359 fi rst, then recheck for those DTCS. D16Y5 engi no:
SENSOR
ROTOR
TDG
SENSOR
CKP
SENSOB
TDC
SENSOB
CKP
SENSOB
CYP
sNson
BOTOR ROTOR BOTON ROTOR ROTOR
D16Y7, D16Y8 ongine:
(To page 11-175)
1- 174
-
-
DTC P0335, P0336. P1361,
P1362, P1381 rnd/or P1382.re
stored.
Problem verific{tion:
1. Do the ECM/PCM Reset Proce-
dure.
Intormittcnt failure, systom b OK
at thb time. Check to. poor con-
nections or loose wires at C120
(dktributorl
and ECM/PCM.
ls DTC P0335, P0336, P1361, P1362,
P1381 and/or Pl382 indicated?
Check t or an open i n t he CKP/
TDC/CYP 3enior:
2. Di sconnect t he di st ri but or 10P
connector,
sensor
(*see
t abl e).
Replrce the distributor ignition
hou3ing
(!ee
section 231.
ls there 350 700 0?
SENSOR DTC
SENSOR
TEBMI NAI
ECM/PCM
TERI\,4INAI COLOR
CKP P0335
P0336
2 c8 8LU
6 c9
TDC P1361
P1362
3 c20 GRN
7 c21 BED
CYP P1381
P1342
c29 YEL
I c30 BLK
Dl 6Y5. 816A2 engi ne:
DISTRIEUTOR
Termi nal si de ol
mal e t ermi nal s
016Y7, Dt6Y8 engine:
DISTRIBUTOR
8P CONNECTOR
(Cl201
Termi nal si de ol
mal e t ermi nal s
CKP M
IWHT}
lDC M
(REDI
ECM/PCM CONNECTOR
c l31P)
wi re si de of f emal e t ermi nal s
t
l 0P coNNECTOR {C120)
(From page 11-174)
Chock f or . 3hor t i n l ho CKP/
Tlrc s6n3o.:
Check { or cont i nui t y t o body
ground on bot h t srmi nal s of t he
i ndi cat ed sensor i ndi vi dual l Y.
Chsck for an open in the wile3
ICKP/TIrc
line6l:
1. Rconnect t he CKP/ TDC son-
sor 4P connector.
nect or C 131P).
t he t ermi nal s ol t he i ndi cat ed
sensor on t he ECM/ PCM con-
nect or 1*see t abl el .
Ropsir opon in tho indiclted son-
ior wiro3 l*!sa tabla).
ls there 350
-
700 o?
Chack f or a . ho i n t h6 wi ros
{CKP/TDC
lino3l:
body
ground and ECM/PCM con-
nect or t ermi nal s C8, C20 and/ or
C29 individually.
Rcpair rhort in th. indicat.d 36n_
lor wirar {'3ac trblol.
Substituto . known-good ECM/
PCM lnd rechock. lf 3ymptom/
i ndi cat l on
go6s aw. y, ropl l c.
ECM/PCM CONNECTOR C
(31P)
Wi re si de of f emsl e t ermi nal s
CKP P
11- 175
PGM-FI System
Vehicle Speed Sensor
(VSSI ('96 -
98 Models,'99
-
@
(DTC)
P0500: A mal functi on
probl em
i n the Vehi cl e Speed
Sensor
(VSS)
ci rcui t Iexcept A!/T
(D16Y7,
D16Y8 engi ne)1.
(DTC)
P0501: A range/performance probl em i n the Vehi cl e
Speed Sensor
(VSS)
circuit [A,rT {D16Y7, D16Y8 engine)].
ECM/PCM CONNECTORS
A {32P}
LG.t
VSS IBLU/WHT}
Wi re si de ot t emal e t ermi nal s
LGI
( BRN/ 8LK}
The MIL has been reDorted on.
DTC P0500 or P0501 is stored.
1- Test dri ve t he vehi cl e.
2. Check t he vehi cl e speed wi t h
t he scan t ool .
Intermittent tailure, system is OK
at this time. Check tor Door con-
nect i ons or l oose wi res at C117
{VSSl and ECM/ PCM.
l s t he correct speed i ndi cat ed?
Check f or an open i n t he ECM/
PCM:
2. El ock t he rear wheel s and set
t he parki ng brake.
3. Jack up t he f ront of t he vehi cl e
and suppor t i t wi t h saf et y
stands.
(l l ).
5. Bl ock t he ri ght t ront wheel and
sl owl y r ot at e t he l ef t f r ont
6, Measure vol t age bet ween t he
nal s C18 and A9.
Subslitute a known-good ECM/
indic.tion goes away, replace the
orisinal ECM/PCM.
Does t he vol t age pul se 0 V
and 5 V?
Check t or a short i n i he ECM/
PCM:
2. Di sco n n ect t he ECM/ PCM
connect or C
(31P).
4. Bl ock t he r i ght f r ont wheel
and sl owl y rot at e t he l ef t f ront
C18 and A9.
PCM and r echeck. l I sympt om/
i ndi cat i on goes away. r epl ace
Does t he vol t age pul se 0 V
and s V?
-
Repai r shor t i n t he wi r e
betwGen ECM/PCM {C18} end
vss, TcM.
-
Repai r open i n t he wi r e
between ECM/PCM {Cl8} and
vss.
-
l f wi r e i s OK, t est t he VSS
lsee section 23).
{BRN/ BLK}
2 3 9 l 0 l t
12 1 6 1 1 t 8 t 9 20 23 21
2A 29 30
c {31P}
I 3 8 1 9 1o
t l 12 i a l r 5 i 6 l 10
./
I 2 3 5 6 a 9 l 0 1 1
12 l 3 l 5 t 6 1t l 8 t 9 20 22 2a
27 20 29 30
1 2 9 10
t 2 l 13l . l 7 I
l ,
/
1,/
231r . l s l
t.
,
) ,rl L
VSS {BLU/ WHT}
11- 176
fFosoo-l
lFosoil
(VSS) ('99
-
00 Models except
Dl6Y5 engine
with M/T)
Thes c ant oo| i ndi c at es Di agnos t i c Tr oub| ec ode( DTc ) Po5o0: Ama| f unc t i onpr obl emi nt heVehi c | es peed
Sensor
(VSS) ci rcui t l except
A//T
(D16Y/, D16Y8 engi ne)l '
Thes c ant oo| i ndi c at es Di agnos t | c Tr oub| eCode( DTC) Po5o1: Ar ange/ per f or manc epr ob| emi nt heVehi c l e
SDeed Sensor {VSS)
ci rcui t tA,/T
(D16Y7,
D16Y8 engi ne)1.
ECM/PCM CONNECTORS
B {25P)
I
t
Wi re si de ol l emal e t ermi nal s
ECM/PCM CONNECTORS
B E5PI
OTC P0500 or P0501 is stored.
1. Test -dri ve t he vehi cl e.
2. Check t he vehi cl e speed wi t h
t he scan t ool
lntermitt6nt
failure, sYstem is OK
at thb time. Check tor
Poor
con-
nections or loose wir6 at C117
{vss} .nd ECM/PCM
l s t he correct sPeed i ndi cat ed?
Check for an open in the ECM/
PCM:
2. Bl ock t he rear wheel s and set
t he
parki ng brake
3. Jack uP the front ofthe vehicle
stands.
(l l ).
5. Block the right front wheel and
sl owl y r ot at e t he l ef t f r ont
6, Measure vol t age bet ween t he
ECM/ PCM connect or t er mi _
nal s C23 and 820.
Substituto a known'good ECM/
PcM and rechck. ll sYmptom/
indiction
goes awaY, lsplace the
original ECM/PCM.
Does t he vol t age
Pul se
0 V
and 5 V or bat t er y vol t age?
Check f or a short i n t he ECM/
PCM:
2. Di sco n n ect t he EcM/ PcM
connect or C
(31P).
(l l )
4. Bl ock t he r i ght f r ont wheel
and sl owl y rot at e t he l ef t f ront
C23 and 820.
Substiiute . known-good ECM/
PCM and r6check. lf symptom/
i ndi cat i on
goes awaY, rePl ace
Does t he vol t age
Pul se
0 V
and 5 V or battery voltage?
-
Reoai r shor t i n t he wi r e
between ECM/PCM {C23} and
vss. TcM.
-
Repai . open i n t he wi r e
between ECM/PCM {C231 and
vss.
-
l f wi re i s OK, t esr t he VSS
{see sestion 23).
11- 177
PGM-FI System
Barometric Pressure
(BAROI
Sensor
(DTC)
Pi 106: A range/performance probl em
i n the Baromerrrc
Pressure
(BARO)
Sensor ci rcui t.
(DTc)
P1107: A l ow vol tage probtem
i n the Baro sensor ci rcurr.
The scan tool i ndi cates Di agnosti c Troubre code {DTC)
p1108:
A hi gh vortage probrem
i n the Baro sensor
ci rcui t.
fF1l ot
tPlloal
The MIL ha3 been rDortsd on.
DTC Pl106 is stored.
1. Do t he ECM/ PCM r eset pr o-
cedure,
l oad
(i n
let it idle.
3. Connect the SCS service con
nector.
4. Test dri ve wi t h t he A/ T i n
E
position,
M/T in 4th gear.
5. Accel er at e f or f i ve seconds
using wide open throttle.
Intormittont tailure, system is OK
at this time.
Substitut e known-good ECM/
indication goes .way, .oplsce the
o.iginal ECM/PCM.
The MIL has been .oported on.
DTC P'l107 o. Pl108 is stored.
P.oblem veritication:
1. Do t he ECM/ PCl vl Reset
pro
cedure,
(l l ).
Intormittent frilure, syitem i3 OK
at this time.
l s DTC P1 107 or Pl 108 i ndi cat ed?
PCM and rechock. It symptom/
i ndi cat i on goes away, . 6pl ace
11- 178
Electrical
Load Detector
(ELDI
{'96
-
98 Models,'tn
-
00 D16Y5 engine
with M/T}
Troubl e code
(DTC) P1297: A l ow vol tage
probl em i n the El ectri cal Load
Detector
(ELD) ci rcui t.
ELD 3P CONNECTOR
(c35'rl
l-- ,
l l l 2 l 3 l
--f
..
ao
(GRN/REDI
Y
ECM/PCM
CONNECTOR
O I16PI
Problem
verification:
' ! .
Do t he ECM/ PCM Reset Pro-
cedure.
2. St a rt t he engi ne
3. Turn on headl i ght s
lntermittent tailure, sYstem is OK
at this time. Check for
Poor
con-
nection3 or loose wires at C131
tlocated
under righl side of da3h).
C354
(ELDIand ECM/PCM.
Ch.ck lor short in the ELD:
Measure
vol t age bet ween body
ground and t he ELD 3P connect or
t er mi nal No. 3.
l s t here approx. 4 5 V?
Check for a short in tho wile
(EL
l i nel :
1. Turn t he i gni t i on swi t ch OFF'
2. Di sconnect
t he ECM/ PCM con
nect or D
(16P)
body
connect or t ermi nal D16
R6pair short in the wire between
ECM/ PCM
(D161and ELD.
Substitute a known-good
ECM/
PCM and recheck l f sympl om/
i ndi cat i on
goes awaY, rePl ace
the original ECM/PCM
r a
11- 179
PGM-Fl System
Elestrical Load Detector
|ELD) t'glf
-
00 Models except D16y5 engine with M/Tl
(DTC)
P' 1297; A l ow vol tage probtem
i n the El ectri cal Load
Detector
(ELD)
ci rcui t.
ELD 3P CONNECTOR
tC354)
EL
{GRN/REOI
ECM/PCM CONNECTOB A I32PI
Wi r e si de of l emal e t er mi nal s
cedure.
2. St a rt t he engi ne.
3. Turn on headl i ght s.
Inlermittont failur6. systom i3 OK
at this time, Chock tor ooor con-
nestions or loose wires at C131
(locrted
undor ight side ot d.shl,
C354
(ELDI
and ECM/PCM.
Check for short in th6 ELD:
ground
and t he ELD 3P connect or
t er mi nal No. 3.
l s t here approx. 4. 5 V?
Check to. a short in the wne (EL
l i nel :
' L
nect or A
(32P).
3. Check tor continuity betlveen
body gr ound
and ECM/ PCM
connect or t ermi nal A30.
Repair short in the wile between
ECM/PCM
lA30) and ELD.
Sub3titute a known-good ECM/
PCM and rechck. It symptom/
i ndi cat i on goes
away. repl ace
1 1 - 1 8 0
Elestrical
Load Detector
(ELD)
f96
-
98 Models''99
-
00 D16Y5
engine
with M/T)
Thes c ant ool i ndi c at es Di agnos t i c Tr oubl eCode( DTC) P1298: Ahi ghv ol t agepr obl emi nt heEl ec t r i c al Load
Detector
(ELD) ci rcui t
ELD 3P CONNECTOR
{G's'I
Wi r e si de ol f emal e t er mi nal s
EL I GFN/ REDI
Problom
vcrificttion:
1. Do t he EcM/ PCl Vl
Reset Pro-
cedure,
3. Turn on headl i ght s. lntarmitt..rt
l.ilur., ryttcm
b OK
.t thia tim. Ch.ck lor
Poo'
con-
nections or looaa wir.3 at C131
lbcd.d
und.r right ide ol dalhl'
Gl5a {EU)} .nd ECM/PCIYI
l s DTC P1298 i ndi cat ed)
Ch. ck
l or t n oPan i n t ho wi r'
(lGl linol:
1. Tur n t he i gni t i on and head'
l i oht s OFF
2. D] ""onn""t
t he ELD 3P con_
nector-
3. Turn the ignition switch ON {ll)'
4. Measure voltage between body
ground and the ELD 3P connec
tor terminal No.
'1.
R.oair ogan in tha wira Mw"n
ru". rs ltTEnrlton
SP SelSOn
t ?. 5 A, f u! . i n t h. undcr-dr3h
tu3e/r.l!Y
box .nd ELD.
Chcck
l or t n oP. h i n t hc wi r e
{GND
lincl:
1. Tur n t he i gni t i on swi t ch and
headl i ght s
OFF.
2. Di sconnect
t he ELD 3P con_
nect or '
3. Check f or cont i nui t y
bet ween
body
gr ound and t he ELD 3P
connect o.
t er mi nal
No 2
Raprir opcn in the wira bstwtn
ELD conncctor
lnd G/O2.
Ch.ck lor !n oplo in tha wirc IEL
lin.l:
Check for continuity
between the
ELD 3P connect or
t er mi nal No 3
and ECM/ PCM
connect or
t er mi
nal D' 16.
Rapaii opcn in the wira btw"n
ECM/FCM
(I)161 .nd th. ELD'
Ch.d( fo. r m.llunction
in thc ELD:
1. Rec onnec t
t he ELD 3P c on'
2. St ar t t h engi ne and al l ow i t
t o i dl e.
3. Wh i l e meas ur i ng
v ol t age
beNveen
ECM/PCM connector
t er mi nal s
D16 and A9, t ur n
t he headl i ght s on { l ow) .
Does t he vol t age dr oP?
Sub3titut.
. known_good
ECM/
PCM .nd rcch.ct. lt sYmptom/
i ndi cat i on
goas away/ i apl l c'
thc origin.l
ECM/PCM
wi r e si de of l emal e t er mr nal s
Wi r e si de of I emal e t er mi nal s
t ' a
)
1 1 - 1 8 1
PGM-FI System
Elestrical Load Detector
(ELDI ('99 -
00 Models except D16y5 engine with M/Tl
(DTCI
Pl 298: A hi gh vottage probl em
i n the Etectri cal Load
Detector
(ELD)
ci rcui t.
ELD 3P CONNECTOR (65/0
EL {GRN/REOI
Wi re si de of f ernal e t ermi nal s
ELD 3P CONNECTOR (CA54I
TI
r l 2 l 3 l
I
crvo
(o)
(BrKr
Y
ECM/PCM CONNECTORS
A
(32P1
Wi re si de of l emal e
EI-
IGRN/RED)
t ermi nal s
ECM/PCM CONNECTORS
A {32P)
Problem ve.itication:
1. Do t he ECN4/ PCM Reset
pro
cedure.
3- Turn on headi i ght s.
Inte.mittent teilu.e, svstem is OK
at this lime. Chock for Door con-
nections or loose wires at Ci31
{ l ocat ed under Ji ght si de ot
daihl, C354 (ELD)
and ECM/PCM.
{l G1 l i ne}:
1. Tur n t he i gni t i on and head-
l i ght s OFF.
2. Di sconnect t he ELD 3P con
3. Turn t he i gni t i on swi t ch ON (l l ).
ground
and the ELD 3P connec-
t ort ermi nal No. 1.
Repair opon in tho wiro batwen
No. 15 ALTERNATOR
Sp SENSOR
{7. 5 A} f use i n t h6 undor-dash
Iuse/reley box and ELD.
Check f or an open i n t he wi ro
{GND l i nel :
1. Turn t he i gni t i on swi t ch and
headl i ght s OFF.
2. Di sconnect t he ELD 3P con
nector.
body ground
and t he ELD 3P
connect or t ermi nal No. 2,
Repair open in the wire bstwoen
ELD connsctor and Gia02.
Check ,or an open in the wire
IEL
linel:
nector A
(32P).
t he ELD 3P connect or t ermi nal
No. 3 and ECM/ PCM connec-
t or t ermi nal A30.
Chock fo. a malfunction in the ELD:
'1.
Reconnect the ELD connector
and ECM/ PCM connect or
A
(32P).
2. St an t he engi ne and al l ow i t
t o i dl e.
3 . Wh i l e me a s u r i n g v o l t a g e
between ECM/PCM connector
t ermi nal s A30 and B2O, t urn
t he headl i ghrs on ow).
Repsir opn in the wire between
ELD connector and ECM/PCM.
i ndi cat i on goes
away. repl ace
lh6 original ECM/PCM.
Does t he vokage drop?
Wi r e si de of f mal e t er mi nal s
11- 182
\
Crankshaft
Speed Fluctuation
(GKFI
Sensor
.
firC-
48 Models,
'99
-
(DTC)
P1336; Intermi ftent i nterrupti on i n the Crankshaft Speed
Fl uctuati on
(CKF)
sensor ci rcui t.
Thescant ooI i ndi cat esDi agnost i cTr oub| ecode{ DTC) P1337: Nosi gnaI i nt hecr ankshaf t speedF| uct uat i on( cKF}
sensor circuit.
D6scription
Thedi agnost i csyst emhasapu| ser r ot or ont hecr ankshaf t andapu| sepi ck- upsensor ont heengi nebl ock. TheEcM/ PcM
moni tors the crankshaft speed ftuctuati on based on the cKF sensor si gnal , and
j udges
that 8n engi ne mi sfi re occurred i f
the fl uctuati on
goes beyond a
predetermi ned l i mi t'
I
fPrk6l
lFr3g7-l
CKF SENSOR 3P CONNECTOR
L:l
. ) l l . ' -
Ir-T--T---.]
l 1 l 2 l 3 l l
L -
''---r
CKFM I I
CKFP
twrfi t 1,.^\ |
l sLul
\.7
CKF M
IWHT}
CKF P
IBLUI
I
(cont' d)
-
The MtL hds been reported on.
-
DTC P1336 and/ or P1337 a. e
stored.
P.oblem vrific.tion:
dure.
2. St an t he engi ne
lntormittont lailur6, tY3tom b OK
at thit tima. Chock tor
Poor
con'
nactions or loota wito! at C102
IC-KF
son$rl .nd ECt /PCM,
and
mrka suro CKF tonaor mounting
boh ittigM.
Chock for .n open in tho CKF aen-
30t:
2. Disconnect the CKF sensor 3P
connector,
3. Measur e
t he r esi st a nce
bet ween t he CKF sensor 3P
No . 3 .
l s t here 1. 6- 3. 2 kO?
Chck tor a short in the CKF son'
30ti
Check { or cont i nui t Y
bet ween
body
ground and t he CKF sensor
3P connect or t ermi n6l s
No. 1 and
No. 3 i ndi vi dual l Y.
( To page 11 184)
1 1 - 1 8 3
PGM-FI
System
(From page
11 183)
Check l or an open i n t he wi res
I CKF l i nes):
1. Reconnect t he CKF sensor 3p
2. Dl sconnect t he ECM/ PCM con-
nect or C
(31P).
3, Measure resi st ance bet ween
ECM/ PCM connect or t er mi
nal s Cl and Cl 1.
ECM/ PCM
{C1, C11} and t he CKF
l s t here 1. 6 3. 2 kO?
Check f or a shor t i n t he wi r e
{CKF l i ne}:
body ground
and ECM/ PCM con,
Repair short in the wiro bstwoen
ECM/PCM
{Cl) and the CKF son-
PCM, and recheck. l f sympt om/
indication goes awry, replace the
original ECM/PCM.
Crankshaft Speed Fluctuation (GKFI
Sensor
(' 96 -
98 Model s,' 99
-
00 D16V5
engi ne wi th M/Tl
(cont,d)
a \
ECM/PCM CONNCTOR C
(31P}
CKF P
(8LU/ REO)
CKF M
(WHT/REO)
Wi r e si de of f emal e
t er mt nat s
CKF P
(BLU/ RED)
6r l-i
r F
t l
a 6 7
8 9 10
1 2 13 11 1 5 t 6 1 7 1 8
21 27 2A 29 30
11- 184
t
Crankshaft
Speed Fluctuation
(CKF)
Sensor
-
('99
-
00 Mociels except D16Y5 engine with M/T)
(DTC) P1336: Intermi ttent i nterrupti on i n the crankshaft speed
Fl uctuati on
(CKF)
sensor ci rcui t
The scan tool indicates Diagnostic Trouble Code
(DTC)
P1337: No signal in the Crankshaft Speed Fluctuation
(CKF)
sensor circuat,
Description
Thedi agnost i csyst emhasapul ser r ot or ont hecr ankshaf t andapu| sepi ck- upsensor ont heengi neb| ock. TheEcM/ PcM
moni tors the crankshaft speed fl uctuati on based on the cKF sensor si gnal . and
j udges
that an engi ne mi sfi re occurred i f
the fl uctuati on
goes beyond a
predetermi ned l i mi t'
I
Ftu6l
tF13g7l
CKF SENSOR 3P CONNECTOR
r--r t
|-.r-r'--]l
l l l l 2 l 3 l l
. l - - - ' . - T_
CKFM
I I
CKFP
t wHTl | / Ai i
l Bl ul
--\9-
Ter mi nal si de oI mal e t er mi nal s
CKF M
(WHT)
CKF P
(BLU)
t (cont' d)
1 1 - 1 8 5
-
The MIL has bon reportad on.
-
DTC P1336 and/ or P1337 are
stored.
1. Do the ECM/PCM Reset Proce'
dure.
lntermittcnt failuro, sydcm is OK
ai this time. Check lot
Poor
con_
noctions or loo3e wiros at C102
ICKF snsor) and ECM/FCM, and
make suro CKF sansor mounting
bolt b tight.
Check tor an open in the CKF sen_
2. Di sconnect t he CKF sensor 3P
3. Measur e t he r esi st ance
bet ween t he CKF sensor 3P
No . 3 .
l s t here 1. 6 3. 2 kO?
Check for a short in ihe CKF sen_
sot:
Chec k f or c ont i nui t y bet ween
body gr ound and t he CKF sensor
3P connect or t er mi nal s No 1 and
No. 3 i ndi v i dual l Y.
( To page 11- 186)
PGM-FI System
Crankshaft Speed Fluctuation (GKFI
Sensor
('99 -
00 Models except D16YS engine with M/Tl
(cont,d)
I \
t ermi nal s
a I
(Frorn page l 1-185)
Check Ior an opsn in the wires
(CKF
lines):
1. Reconnect t he CKF sensor 3p
connect or.
nect or C {31P}.
3. Measure resi st ance bet wen
nal s C22 and C31.
Repair opqn in th. wire bo{ween
ECM/PCM (CZ,
Ctll and th. CKF
lon30r.
l s t her e 1. 6- 3. 2 k0?
ICKF line):
Check f or cont i n! i t y bet ween
body ground
and ECM/ PCM con-
Roplir thort in tho wirg b.iwoon
ECM/FC'ftl
lc22l and tho CKF 3n-
PCM, and r.ch.ck. It symptom/
indication
90o.
aw!y, 6pbco the
original ECM/PCM.
1 1 - 1 8 6
l , a
Crankshaft
Position/Top
Dead Center/Cylinder
Position
(CKP/TDC/CYPI Sensor
Thescant oo| i ndi cat esDi agnost i cTr oub| ecode( DTc) P1359: Apr ob| emi nt hecr ankshaf t Posj t i on/ TopDead
Center/Cvl i nder
Posi ti on
(CKP/TDC/CYP) sensor ci rcui t'
-
-
DTC P1359 is stored
1. Do t he ECM Reset Procedure
2. St an t he engi ne l f t heengi ne
won't start, crank it for at least
10 seconds-
lntermittent failure, sYstem is OK
Check f or
poor connecl l on3
or
loose wires at C120 {distributor}
and ECM,/PCM.
Check f or
poor connect i ons or
loose wires between the distribu
tor and the ECM/PCM
Substitute a known'good ECM/
PCM, and rccheck. lt 3ymPtom/
i ndi cat i on
goes awt Y, rePl ace
r
t a
11- 1A7
PGM-FI
System
ECM/PCM
lnternal
Circuit
[Fi 6oi l th" """n tool i ndi cates Di agnosti c Troubl e
code
(DTc) p1607:
An EcM/pcM l nternal ci rcui t
probtem.
-
-
Problern verif ication:
1. Do t he ECN4/ PCM Reset
pro-
cedure.
2. Turn t he i gni t i on swi t ch ON t ).
3. Wai t 10 seconds.
l s DTC P 1607 i ndi cat ed?
Substitule a known-good ECM/
indication goes
away, .epl.ce the
origin.l ECM/PCM.
1 1 - 1 8 8
[F16551l
Th" ""un toot i ndi cates Di agnosti c Troubl e Code
(DTC) P1681: TIVA,/TMB si gnal l i ne fai l ure
2. Dri ve t he vehi cl e I or several
mi l es at varyi ng speeds
lnt.rmittent failure, system is OK
at ihis time. Check tor
Poor
con-
nections or loos wires at C131
llocated under right side of dash),
C438 ITCM) and ECM.
Check l or an oPen i n t he wi re
(TMA l i ne):
( 31P) f r om t he ECM
(l l ).
4- Measur e vo l t ag e bet ween
ECM connect or t er mi nal Cg
and body
ground.
ITMA
line,:
Measure vol t age bet ween TCM
22P connect or t ermi nal No 7 and
body
ground.
l s t here bat t ery vohage?
Ropair shod in the wire bstwen
the EcM
(C!l) and the TcM.
{TMB
l i ne}:
2. Reconnect ECM connect or c
( 31P) .
f rom TCM.
(l l ).
TCM 22P connect or t erml nal
No. 6 and body
ground.
th EcM {Ca) and the TcM.
Check f or a 3ho. t i n t he wi re
{TMB
lin6,:
connect or t ermi nal C30 and body
ground,
Subst i t ut e a known' good ECM
and recheck. It symPtom/indica'
tion
goes away, teplace the origi-
nal ECM.
Reoair short in the wile b6tween
the ECM {C30} and the TCM.
f,epair open in the wire between
the EcM
(C30)
and the TcM.
I J
A/T Si gnal
(TMA/TMBI
(' 96
-
98 Dl 6Y5 engi ne
wi th GW)
ECM CONNECTOR C 131P}
TMA I GRYI
fcu22P
CONNECTOR
l l
TMB*
{PNK}
2 3 1 6 7 8 9 10
1 t
'12
13 14 15 16 17 1 8
23 2a 25
29 30
Wire side oI temale
t ermi nal s
t l ,
1 1 - 1 8 9
ldle Control System
System Description
The i dl e speed ot the engi ne i s control l ed by the l dl e Ai r Control
(l AC)
Val ve.
The val ve changes the amount of ai r bypassi ng i nto the i ntake mani fol d i n response to el ectri c current control l ed bv the
ECM/PCM. When the IAC Val ve i s acti vated, the val ve opens l o mai ntai n the proper i dl e speed.
D16Y5, D16Y8, Br6A2 engi ne
(M/T):
(ROTARYI
tac vat-vE
EI{GINE
cooLAI{T
VARIOUS
sEI{SORS
VARIOUS
SENSORS
INTAKE MANIFOTD
Dl 6Ys {CVTl , D16Y8 engi ne l A/T):
D16Y7 engi ne:
{ROTABY)
;iy--,
- ---<fltitf.trj
INTAKE
MANIFOLD
11- 190
1 . After the engi ne starts, the l Ac val ve opens for a certai n ti me. The amount of ai r i s i ncreased to rai se the i dl e speed
about 150
-
300 rpm.
When the cool ant temperature i s tow, the IAC val ve i s opened to obtai n the
proper fast i dl e speed. The amount of
bypassed ai r i s thus control l ed i n rel ati on to the engi ne cool ant temperature'
IOLE SPEED
l rpml
176
80
ENGI E
COOLANI
TEMPERATURE
t " Fl
t oc)
l l
' t.
Whent hei d| espeedi sout of speci i i cat i onandt hescant oo| doesnot i ndi cat eDi agnost i cTr oub| ecode( DTc) P0505
or P1508. check the fol l owi ng i tems:
.
Adi ust the i dl e speed {see
page 11-220}
.
Starter swi tch si gnal
(see page 11-202)
.
Ai r condi ti oni ng si gnal
(see page l 1-204)
.
ALT FR si gnal
(see
Page
11-2081
'
Brake swi tch si gnal
(see page 11-210)
.
PSP swi tch si gnal
(excapt
Canada model )
(see page 11-212)
.
A,/T gear position signal {see section 14, Dl6Y5 engine
(CVT):
page 11- 216)
.
Cl utch swi tch si gnal
(D16Y5
engi ne wi th M/T)
(see page 11-218)
.
Hoses and connecti ons
'
IAC val ve and i ts mounti ng O-ri ngs
l f the above i tems are normal , substi tute a known-good IAC val ve and readj ust the i dl e speed
(see page 11-220)
| f t hei d| es peeds t i | | c annot beadj us t edt os pec i f i c at i on( andt hes c ant oo| does not i ndi c at eDTc P0505or P] 50S)
after IAC val ve repl acement. substi tute a known-good ECM/PCM and recheck. l f symptom
goes away, repl ace the
ori gi nal ECM/PCM.
ldle Control System
l dl e Control System
l F0505 l
Th" """n tool i ndi cates Di agnosti c Troubl e Code
(DTC)
PO5O5: tdte controt system mal functi on.
NOTE: l f DTC P1508 or P1509 i s stored at the same ti me as DTC P0505, troubl eshoot DTC
p1508
or
p1bog
fi rst. then
recheck for DTC P0505.
Possible Cause
. IAC val ve mechani cal mal functi on
. Throttl e body cl ogged pon, i mproper adj ustment
. Intake mani fol d gasket l eakage
. Intake ai r hose l oose l eakage
. Vacu um l eak
. ECT sensor i ncorrect output
. Throttl e Posi ti on sensor i ncorrect output*r
1 . S t a r t t h e e n g i n e . Ho l d t h e
eng; ne at 3, 000 r pm wi t h no
l oad
( j n
Par k or neut r al ) unt i l
t he r adi at or f an comes on, t hen
*r l et i t i dl e.
t 2. wi t h rhe scan t oot , ct ' ei t Ge l
Thr ot t l e posi t i on
shoul d be
appr ox. 10% wi t h t he t hr ot
t l e f ul l y cl osed.
E ngi ne c ool ant t emper a-
t ur e shoul d be 194 205' F
( 90
96. Ci .
l f t hey ar e not wi t hi n t he
spec. , r epai r t he f aul t y sen
L. _ _9oI 9[ cr ] 41 l
3. Chec & t he engi ne s peed at
i dl e wi t h no- l oad c ond; t i ons i
headl i ght s , bl ower f an, r ear
def ogger , r adi at or f an, and ai r
condi t i oner ar e not oper at i ng
\see
page l1-22O
-
223).
at this time.
l s t he i dl e speed OK?
l s i t 550 r pm or l ess?
( To page 11, 193)
* 1r ' 96
model s onl y
11- 192
( To page l l - 193)
I
L
1D16Y5,
D16Y8 engi ne wi t h M/ T 81642 engi ne)
I
D16Y7 engi ne:
{ Fr om
page 11- 192)
Check the IAC valve:
Di sconnect t he 3P connect or f rom
t he I AC val ve.
Check the IAC valve:
Di sconnect t he 2P connect or
f rom t he I AC val ve.
Does t he engi ne speed drop or
t he engi ne st al l ?
Adiust the {base} idle speod
(see
page 11-220
-
2231.It it's impos-
aible, clean the
ports in lhe throt'
tle bodv,
( Fr om page 11- 192i
Check Ior vacuum leaks:
2. Remove t he i nt ake ai r duct
from the throttle body.
4. Put
your f i nger on t he l ower
pon i n t he t h. ot t l e body.
Chck t or vecuum l oaks, m. ke
sure t he t hrot t l e val ve i s com_
pletaly closed, end repair as nec-
Does t he engi ne speed dr oP?
Adiust the idle speed
(see page
11-220
-
2231. lf it's impossible,
reolace the IAC velve.
UPPER
PORT
1 1- 1 93
ldle Control System
ldle Air Control
(lACl
Vatve
('96
-
98 Dl6ys, Dl6yB engine with M/Tl
(DTC)
P1508: A probl em i n the l dl e Ai r Controt fl AC) varve
ci rcui t.
The IAC Val ve changes the amount of ai r bypassi ng the throttl e body i n response to a current si gnal from the ECM i n
order to mai ntai n the proper i dl e speed.
IAC VALVE 2P CONNECTOR ICl3A)
,flrcer
h-:J
iYEL/BLKI
!.__-,/ -lt
(v)
-T
-=
tAcv
(BLK/
ELUI
ECM CONNECTOR A I32PI
Wi re si de oI l emal t ermi nal s
VALVE
6 a 10 l l
12 t 3 r5 t 6 l 7 t 8 t 9 20 23 2a
t*
25
&
a 2A 3o
The MIL hss bon repo.ted on.
DTC P'l508 i. itorod.
Problem vorification:
cedure,
St art t he engi ne, and warm i t
uP t o normal operat i ng t em-
perature.
Intormittont t!llur., sy.tcm b OK
at thb tim6. Chsck fol poor
con-
ncctionr or loo3e wirot at C138
(lAC
valv.l.nd ECM.
Check f or an opcn i n t he wi ro
(l GPl
l i ne):
2. Di sconnect t he I AC val ve 2P
connector.
(l l ).
4. Measure vohage between body
ground
and t he I AC val ve 2P
connectorterminal No. 2.
R.prir opan in the wiro botwa.n
IAC valv..nd PGM-FI main r.l.y.
Chock for an opon or sho in the
wire
(IACV
linal:
and reconnect t he I AC val ve
connect or.
2. Disconnect the ECM connector
A (32P).
3. Turn t he i gni t ; on swi t ch ON
(l l ).
body gr ound and ECM con-
nect or t ermi nal A12.
(To page 1l -195)
11- 194
I
I
( Fr om page 11- 194)
Repair open or short in the wire
bet ween ECM l Al 2l and I AC
Check the IAC valve Iunction:
Moment ari l y connect ECM con-
n e c t o r t e r mi n a l s A1 2 a n d A1 0
wi t h a
j umPer wi re several t i mes.
Does t he I AC val ve cl i ck?
and recheck. It symPtom/indica-
tion
goes away, replace the origi-
nal ECM.
ldle Gontrol System
ldle Air Control
(lAG)
Valve
('99
-
00 Dl6Y8 engine with M/T, Bt6A2 enginel
[Fl 50g l ]h"
scan tool i ndi cates Di agnosti c Troubl e Code
(DTC)
P1508: A probl em i n the l dl e Ai r Controt AC) vatve
-
Ct r CUt t .
The IAC Val ve changes the amount of ai r bypassi ng the throttl e body i n response to a current si gnal from the ECM i n
order to mai ntai n the proper i dl e speed.
IAC VALVE 2P CONNECTOR IC138'
la
rcpr
I - {YEL/8LKI
\ 2 t -
- d ,
Y
-=
Wi r e si de ot f emal e t er mi nal s
Wi r e si de of l emal e t er mi nal s
VALVE
The MIL has boon roorted on.
DTC P1508 is srored.
Probl6m verification:
cedure.
2. St art t he engi ne, and warm i t
up t o normal operat i ng l em-
perature.
at this timg. Check to.
poor
con-
noctions or loose wires at C138
{lAC valvel and ECM.
Ch6ck f or an open i n t he wi r
{l GPl l i no}:
connect or.
(l l ).
ground and t he I AC val ve 2P
connecl or t ermi na I No. 2,
Repair opon in the wire bgtwoen
IAC valve and PGM-Fl main relay.
Check tof an open or short in the
wire {IACV line}l
and reconnect t he I AC val ve
2. Disconnect the ECM connector
B {25P).
(l l ).
body gr ound and ECM con
nct or t ermi nal 823.
( To page 11- 197)
1 1- 1 96
t
I
{ Fr om
page 11- 196)
Repair opon or short in lhe wire
between EcM lBzl) and lAc valve.
l s t here bat t ery vol t age?
Check the IAC valve fundion:
Moment ari l y connect ECM con-
nect or t ermi nal s 823 and 82 wi t h
a
i umpe.
wi re several t ames.
Does t he I AC val ve cl i ck?
and rocheck. ll symptom/indicd-
tion
gos away, rePlace tho origi_
nal ECM.
11- 197
ldle Control System
ldle Air Control
(lAC)
Valve
('96
-
98 A/T and Dl6Y7 enginel
The
(Rotary)
IAC Val ve changes the amount of ai r bypassi ng the throttl e body i n response to a current si gnal from the
ECM/PCM i n order to mai ntai n the proper i dl e speed,
BIMETAL
VALVE STOPPER
1P1509
Thescantool i ndi cates Di agnosti c Troubl e Code
(DTC)
P1509: A probl em i n the i dl e Ai r Control
(tAC)val ve
ci rcui t.
PGl IBLKI
IAC VALVE 3P CONNECIOR
IACV N IACV P
I GP
Termi nal si de of mal e
t ermi nal s
*:
I ACV N l i ne
1 1 - 1 9 8
The MIL has bn roported on.
oure.
(l l ).
Intermittent failura, systom ia OK
at this time. Check tor
poo.
con-
noctions or loose wires at C109
llAC valve) and ECM/PCM.
Check f or an opon i n t he wi rer
{PG lines):
Measure vol t age bet ween bodv
ground
and ECM/ PCI I connect or
t ermi nal s A10 and A23 i ndi vi du
Repair opn in the wires betwoen
ECM/ PCM and G101 l l ocat ed at
tho thermostat housing).
Chock th ECM/PCM inpui volt-
agel
2. Disconnect ECM/PCM connec-
t or A
(32P)f rom
t he ECM/ PCM.
(l l ).
4. Measu r e vol t age bet ween
connect or t ermi nal s A14 and
A13* i ndi vi dual l y.
Ch6ck th6 IAC valve:
connect or,
3, Measure resi st ance bet ween
I AC val ve 3P connect or t ermi -
nal No. 2 and t er mi nal s No. 1
and 3 i ndi vi dual l y.
l s t here 16
-
28
g?
i ndi cat i on goos away, r epl ace
th origin.l ECM/PCM.
SHAFT
rAcv N loRNl*
( To page 11- 199)
1 2 3 a 5 6 E l 0 1 1
12 13 14 r 5 16 1 7 18 t9 20 2:2 23 21
27 2A A 30
IACV P {BLK/BLUI
t
l From
page 11-198)
Chock f or an opon i n t ho wi l o
(l GP
l i ns):
' 1.
connector,
(ll),
4. At the wire hamess, measure
voltage between IAC valve 3P
body
ground.
Raprir opn in th wirc botw.n
th. IAC vrlv6 and PGM.FI mtin
rehy.
Check for rn open in tho wil.s
(IACV
P,IACV Nr linesl:
2. Disconnect the ECM/rcM con-
necror A
(32P).
IAC valve 3P connecto. terma_
nal No. 3 and ECM/ PCM con-
nect or t er mi nal A14
( a
nd
between IAC valve 3P connec-
t or t ermi nal No. 1 and ECM/
rcM connector terminal A13l*.
Ropair opan in tha wito bgtwoon
ths IAC vrlv! rnd ECM or PCM
{A14, 413. 1.
Check f or e l hort i n t ho wi ros
(IACV
e
nCV Nr linc):
body
ground and ECM/ PCM con-
nect or t er mi nal s A14 and A13*
i ndi vi dual l y.
Rapair rhort in thr wi]. batwaon
th. IAC v.lvc .nd ECM/PCfvl {A14,
Ar3.t.
Check the IAC V.lvo:
1. Di sconnect t he I AC Val ve 3P
IAC Valve 3P connector termi-
nai No. 2 and t ermi nal s No. 1
and No. 3 i ndi vi dual l Y.
l s t here 16
-
28 O?
Subrtituto a known-good ECM/
PCM and rchd( lt .vmptom/indi
calioo
gp. .way, ruplace tho odgi
ml Eqvt/FCM.
IAC VALVE 3P CONNECTOR IClG'}
IGP IYEL/BIX)
tAcv N
(oRNt*
IACV N
Wi rc si de of l emal e t eami nal s
IAC VALVE 3P CONNECTOR
IACV P
Termi nal si de of mal 6
t et mt nat s
(32P)
l l
toRNt*
t I
IACV P
(BLK/8LU}
ECM/PCM
CONNECIOR A
IACV P
(BLK/BLU}
I o , t l 0
' t 1
1Z 13 t a 15 l 6 17 t a l 9 m x2 23 21
25 21 i6 a 3o
,|
3 1 .
5 7 a I l 0 t l
12 t 3 r .
l r s
t 5 11 r8 t 9 20 22 23 2a
27 2a A 30
IACV P
(BLK/SLU}
r l a
-:
I ACV N l i ne
1 1 - 1 9 9
ldle Gontrol System
The
(Rotary)
IAC Val ve changes the amount of ai r bypassi ng the throttl e body i n response to a current si gnal from the
ECM/PCM i n order to mai ntai n the
proper
i dl e speed.
BIMETAL
HOLDER
BIMETAL
SHAFT VALVE STOPPER
ECM/PCM CONNECTOR B {25P}
(To page 11-201)
IACV N IACV P
ldle Air Control
{lACl
Valve
('99
-
00 A/T and Dl6Y7 enginel
YES
1P1509 l Thescantool
i ndi cates Di agnosti c Troubl e Code
(DTC)
P1509:A probl em i nthe i dl eAi rControl
(l AC)val ve
ci rcui t.
IGP
Ter mi nal si de of mal e
t er mi nal s
Sub3titute e known-good ECM/
PCM .nd recheck. lf 3vmptom/
i ndi cal i on goos away, repl ac6
thc original ECM/PCM.
*:
I ACV N l i ne
11-200
Tho MIL has ben reported on.
OTC P1509 is sto.ed.
Problem verilicationr
dure.
(l l ).
Intermittont tailure, sy3tem i3 OK
at thb time. Check for
poor
con'
noctions or loose wiros at C109
(lAC
velvel and ECM/PCM.
Check f or an oDen i n t he wi l os
IPG linesl:
ground and ECM/ PCM connect or
t ermi nal s 82 and 810 i ndi vi dual l y.
Ropail open in the wires be'twen
ECM/PCM .nd G101 llocated .t
the the.mostat housingl.
Check tho ECM/PCM input volt-
age:
2. Disconnect ECM/PCM connec-
t or A
(32P)t rom
t he ECM/ PCM.
(ll).
4, Measur e vol t age bet ween
body ground and ECM/ PCM
connect or t er mi nal s 86 and
815* i ndi vi dual l y.
Chock the IAC v.lve:
1. Turn t he i gni t i on sw; t ch OFF.
connoctor.
I AC val ve 3P connect or t ermi '
nal No. 2 and t ermi nal s No. 1
and 3 i ndi vi dual l y.
l s t here 16
-
28 O?
I
I
L
IACV N
(oRN)*
IACV P
{BLK/BLU'
ECM/PCM
CONNECTON B
(25PI
IACV N
(oRNt .
IACV N IACV P
IACV P
IBLK/BLUI
I GP
(From page 11 200)
IAC VALVE 3P CONNECTOR {C1O9I
IGP
(YEL/BLK)
Check t oi an open i n t hg wi re
{l GP
l i ne):
connector.
(l l )
4, At t he wi re harness, measure
voltage between IAC valve 3P
body gro!nd.
the IAC valve and PGM-FI main
reraY.
IIACV
P. IACV N' lines):
nect or A
(32P).
3. Check l or cont i nui t y bet ween
IAC valve 3P connector termi'
nal No. 3 and ECM/ PCM con-
nect o r t er mi nal B6
( and
beNveen IAC valve 3P connec
t or t er mi nal No. 1 and ECM/
PCM connect or t ermi nal 815)*.
Repair open in the wiro ltstwcen
the IAC valvo and CM/PCM
(86,
815' 1.
Check f or a shon i n t he wi res
(IACV P, lACv N* linesl:
body
ground and ECM/ PCM con-
nect or t er mi nal s 86 and 815*
i ndi vi dual l y.
Reoair short in the wiro Mweon
the lac valve end ECM/FCM
(86,
815*).
Check the IAC valv:
l . Di sconnect t he I AC Val ve 3P
connector,
2. Measure resi sl ance bet ween
IAC Valve 3P connector termi
nal No. 2 and t ermi nal s No 1
and No. 3 i ndi vi dual l y
l s t here 16
-
28 O?
Substituta . known-good ECM/
PCM and rochcdc f 3ymptom/indi
cation
goa away, rdace the origi
nal ECM/Pqvl.
"r
I ACV N l i ne
N
11-201
ldle Control System
Starter Switch Signal
('96
-
98 Models,'99
-
Thj s si gnal s the ECM/PCM when the engi ne i s cranki ng.
NOTE:
. A/T: Transmi ssi on i n
E or E
posi ti on
. M/T: i n neutral
a l32Pl LGl
Wi re si de ot f emal e l ermi nal s
Check tor an open or short in the
wire ISTS linel:
PCM connect or t ermi nal s A9 and
C6 wi t h t he i gni t i on swi t ch i n t he
st art l l l l i
posi t i on.
Inspect the No. 31 STARTER SIG-
NAL
(7.5
A) fuse in the underdash
fuse/relay box.
-
Repai r . hor t i n t he wi r e
bot woen t ha ECM {C6l and
tho No, 31 STARTER SIGNAL
{ 7. 5 Al t uss or t he PGM- FI
main relay,
-
Roolac. the No. 3'l STARTER
SIGNAL l?.5 Al tu3.
Staner 3witch signal is OK.
Repair opon in th6 wiro botwean
ih. ECII4/PCM
(C6)
and the No.31
STARTER SIGNAL {7.5 Al tulo.
ECM/PCM CONNECTORS
{BRN/BLKI STS IBLU/ORNI
2 1 6 9 10 I t 3 5 6 7 a 9 l 0
l 2 l 3 l a 15 ! 6 17 1a 19 20 22 2a t t 12 t3 l 4 t 5 t 6 17 1E
25 2l 2A 7t 30 23 2a 29 30
11-202
\
Starter Switch Signal
('99
-
NOTE:
.
M/ f : Cl ut ch pedal must be depressed.
.
A, / T: Transmi ssi on i n
E or E
posi t i on
ECM,/PCM CONNECTORS
I
Thi s si gnal s the ECM/PCM when the engi ne i s cranki ng
Chck for an open or short in the
wire {STS linel:
PC[ / | connect or t er mi nal s A24
and 820 wi t h t he i gni t i on swi t ch
i n t he st art posi t i on (l l l ).
I nspect t he No. 31 STARTER SI G-
NAL
(7. 5
Al l use i n t he under-dash
-
Repai r 3hort i n t ho wi re be'
t ween t ho ECM/ PCM l A24)
and tho No. 31 STARTER SIG-
NAL 17.5 Al fuse or the PGM-FI
mein relay.
-
ReDlaco the No. 31 STARTER
SIGNAL 17.5 Al fuse.
Staner 3witch signal is OK.
Repair open in the wirc betwean
the ECM/PCM lA24) and the No.
31 STARTER SIGNAL {7.5 Alfuse.
W; re si de of f emal e t ermi nal s
ldle Gontrol System
Air Gonditioning Signal
('96
-
98 Models,
'99
-
a {32P1
ECM/PCM CONNECTORS
c l 3l Pl
Thi s sj gnal s the ECM/PCM when there i s a demand for cool i ng from the ai r condi ti oni ng system.
(To page 11-205)
{ACS l i ne):
2. Di sconnect t he A/ C pressure
switch 2P connector {see sec
tion 22).
(l l ).
4. Measur e vo l t a ge
bet ween
nal s C5 and A9.
Check for a .hort in the wi.e {ACS
l i ne):
nect or C
(3l Pi .
body
gr ound
and ECM/ PCM
connect or t ermi nal C5,
Reotir short in the wi.e between
t he ECM/ PCM l c5l and rhe A/ C
pressure switch.
l s t her e cont i nui t y?
-
ECM/rcM .nd re.fieck. f Dre-
scribed voltage is now avail
tble, replace the original ECft4/
PCM,
-
See the air conditioner inspe-
tion lse sction 221.
Check t or an opn i n t he wi re
IACC lin6l:
2. Reconnect t he A/ C pressure
(l l ).
4. Moment ar i l y connect ECM/
PCM connect or t ermi nal s A9
and A17 wi t h a
j umper
wi r e
LGl I BRN/ 8LKI ACS {BLU/RED)
2 3 6 1 I 9
't0
I t t 3 a 8 9 t 0
12
't3
1a l 5 l 6 17 t 8 t 9 20 23 2a l l 12 l 3 l !a i 5 ! 6 1 7
'tE
25 2l 2A 29 30 23 2a 25 29 30
ACS
(BLU/BEDI
LGl IBRN/BLKI
1 2 3 a s l s l r l
l o l g l
r o
l r r I
1 2 1 3 1 4 l 5 16 y) nl t sl nl / @)
zr
I
zr
I
25 27
1!M1 1-/r
ACC
11-204
IBLK/RED)
JUMPER WIRE
(From page 11-204)
Check f or an open i n t he wi r
(ACC linel:
Moment ari l y connect underhood
f use/ rel ay box 9P connect or t eF
mi nal No. 5 t o body ground wi t h
a
i umper
wi re several t i mes.
l s t here a cl i cki ng noi se f rom
t he I VC compressor cl ut ch?
See ai r condi t i onor i nspect i on
(see
3oction 221.
the Py'C compressor clutch?
r he ECM/ PCM l Al 7l
and t h6
under-hood f u3e/ rol aY box 9P
connector lC352l.
Check f or t he oPerat i on of t he
Alcl
2. Turn t he bl ower swi t ch ON
3. Turn t he AJC swi t ch ON.
Chock t or an open i n t he wi re
IACS linel:
PCM connect or t ermi nal s A9 and
c5.
Does the Ay'C operate?
Air conditioning signal is OK.
Repair open in the wire btween
the EcM/PcM lC5) and the A/c
3witch.
l s t her e l ess t han 1. 0 V?
-
Subst i i ut e a known- good
ECM/ PCM and recheck l l
sympt om/ i ndi cat i on 9oes
away, . opl ace t he or i gi nal
ECM/PCM.
-
See the air condhioner insPc_
tion {see sc{ion 22).
UNDER.HOOD FUSE/BELAY
BOX 9P CONNECTOR 1C352)
1 2
I
a
5 8 9
ACC
(BLK/RI
Wi re si de of
ACC
(BLK/REDI
t ermi nal s
JUMPER
WIRE
ECM/PCM CONNECTORS
r f
A t32P)
LGl
c {31Pl
t
(BRN/BLK) ACS IBLU/RED)
I 2 3
a 9 10 1 t 3 I 8 9 t 0
12 13 15 l 6 11 l a 19 20
23 2a t t 12
't3
l a
' t5
t 6 1 7 t a
25 27 2A 29 30
23 2a 29 30
ldle Control System
Air Conditioning Signal
('99 -
Thi s si gnal s the ECM/PCM when there i s a demand for cool i ng from the ai r condi ti oni ng system.
ECM/PCM CONNECTORS
a l32P)
ECM/PCM CONNECTOR A {32P)
ECM/PCM CONNECTORS
A
(32P1
Chock t or a shor t i n i he wi . e
(ACS
lin6):
(ll).
nal s A27 and 820.
(ACS
linel:
' 1.
nect or A
(32P).
Reoair short in lhe wi.e botweon
the ECM/PCM
(A271
and rhe A/C
pressure swilch.
Srr66tituto a known{ood ECM/
PCt4 tnd rechock. It prascribd
voltage is now available, re-
plac the original ECM/rcM.
Soo the air conditioner insoec-
tion {see sction 22}.
Check t o. an opon i n t ho wi . e
(ACC
linel:
2. Reconnect t he A/ C pressure
switch 2P conneclor.
(l l ).
4. Moment ar i l y connect ECN4/
and 820 wi t h a
j umper
wi r e
(To page
'!
1-207)
11-206
LGl { BRN/ BLK)
I
JUMPR
WIRE
UNDER-HOOO FUSE/RELAY
sox 9P coNNEcroR lca52l
1 2 3 a
5 6 8 9
ACC
(8LK/REDI
Wi re si de of
t ermi nal s
ECM/PCM CONNECTORS
A
(32P1
f emal e
(From page 11-206)
Check f or an open i n t he wi t e
I ACC l i no):
Moment ari l y connect under_hood
l use/ rel ay box 9P connect or t eF
mi nal No. 5 t o body
ground wi t h
a
j umper wi re several t i mes.
the Iy'C compressor clutch?
S6e ai r condi t i oner i nsPoct i on
l3oa section 221
l s t here a cl i cki ng noi se l rom
the ly'C compressor clutch?
Ropair open in tho wilo betwgn
the ECM/PCM lA17) and the A/C
clutch rolay.
Chock f or t he oporat i on of l ho
AIC:
1, St art t he engi ne.
2. Turn t he bl ower swi t ch ON
3. Turn the ray'C switch ON.
Check l or an open i n t he wi ro
(ACS
lino):
PCM connect or t er mi nal s A27
and 820.
Does the Iy'C operate?
Air conditioning signal is OK.
Repair op6n in the wiro bctwoon
lhe ECM/PCM lA27l and tho A/C
3witch.
l s vol t age l esst han 1. 0 V?
-
Sub6iitut r knownood ECtt /
PCM and rccheck. l l sYmP-
t om/ i ndi cat i on 9oe3. waY,
replaca the original ECM/PCM
-
See the ai. condhionGr in3pc-
tion lsee soc{ion 221.
11-207
ldle Control System
Alternator
(ALTI
FR Signal
{'96
-
98 Models,'99
-
00 Dl6y5 engine with M/Tl
ECM/PCM CONNECTORS
a {32P)
LGl
(BRN/BLK)
ALT CONNECTORS IC1O4I
JUMPER
JUMPER
WI RE
WI RE
ALT F
{WHT/REO)
Thi s si gnal s the ECM/PCM when the Al ternator
(ALT)
i s chargi ng.
Inspoction of ALT FR Signal.
Check tor a short in tfte wire (ALT
F linel:
1. oi sconnect t he 4P
(3P)*
con-
nect or f rom t he ALT.
(l l ).
3. M easu r e vol t age bet ween
nal s C17 and A9.
Check lor a sho.t in the wire
{ALT
F line):
r. I urn rne t gn| l t on swt l ch ul -f ,
2. Di sconnect t he negat i ve bat -
tery cable from the baftery.
nect or C {31P).
body gr ound
and ECM/ PCM
connect or t ermi nal C17.
Check th operation of the ALT:
2. Reconnect t he ALT 4P
(3P)*
connect or t o t he ALT.
l oad
(i n
Park or neut ral ) unt j l
t he radi at or f an comes on, t hen
l et i t i dl e.
4. [ , 4easu re vol t age bet ween
C17 and A9.
Repair short in the wire betwen
the ECM/PCM {Cl71and th ALT.
PCM and recheck. It prescribed
voltage is now available, roplace
the originrl ECM/PCM.
Does the voltage decrease when
headl i ght s and r ear def ogger ar e
t ur ned on?
ALT FR signal is OK.
Check tor an open in the wire
(AlT
F linel:
tery cable from the battery.
3. Di sco n nect t he ECM/ PCM
connect or C
(31P).
4. Di sconnect t he 4P
(3P)*
con,
nector from the ALT.
5. Connect t he ALT 4P
13P)l con
nect or t ermi nal No. 4
(No.
1)'
t o body ground
wi t h a
i umper
connect or t ermi nal C17,
Repai r op6n wi re bot ween t h
ECM/ PCM (C171rnd
t h ALT.
c {31P)
1 1 7 8 I 10
1 1 12 13 14 15 16 17 18
23 21 25 a 30
o
ALT F IWHT/REDI
4P
3P*
1 2 l
Flr
rr-ri-f
rwHr/
(V)
neor
Y
*:
Canada model
11-208
3 I 7 8 9 10
1 l 12 13 l 4 15 16 17 18
/l
23 21 25 E 30
o
ALT F IWHT/REDI
t
Alternator
(ALT)
FR Signal
('99
-
00 Models except
Dl6Y5 engine
with
M/T)
Thi s si gnal s the ECM/PCM
when the Al ternator {ALT)
i s chargi ng
ECM/PCM CONNECTORS
ECM/PCM
CONNECTOR
C
(31P}
l t
l P
ALT CONNECTORS IClO4I
JUMPER
JUMpER
WlnE
WIRE
Wi re si de of f emal e t erml nal s
ECM/PCM CONNECTOR C
(31PI
3P*
NO
Check lor an opn in the wire
(ALT
F l i ne, :
1. Turn t he agni t i on swi t ch OFF
tery cable {rom the battery.
3. Di sconnect t he ECM/ PCM con'
nect or C
(31P).
(3P)* con'
nect or f rom t he ALT.
5. Connect t he ALT 4P
(3P)*
con-
nect or t ermi nal
No 4
(No. 1)*
t o bodY
ground wi t h a
i umper
body
connect or t ermi nal C5
--?--
1 l 2 l
|#
i 3 l . l
otriJ
rwxrr
(V)
neor
Y
lnsoeclion oI ALT FB Signal.
Check {or a short in the wire {ALT
F line):
(3P)+ con
nector from the ALT
(l l )
3. Measurc voltage between EcM/
PCM connect or t ermi nal s C5
and 820.
Check tor a short in the wirc
(ALt
F line):
2. Di sconnect t he negat i ve bat _
tery cable from the baRery'
3. Disconnect the ECM/PCM con'
nect or C
(31P).
body
connect or t ermi nal C5
l s t here aPProx. 5 V?
Check the operation
otthe ALT:
2- Reconnect t he ALT 4P
( 3P) *
connector to the ALT
engi ne at 3, 000 rpm wrt h no
l oad {i n Park or neut ral i unt i l
4- Measure voltage between ECM/
PCM connect or
t ermi nal s C5
and 820.
the EcM/PCM {C5l
and the ALT.
Substitute a known-good
ECM/
PCM and rechock. l f
P. esc. i bed
voltage is now availabl, ieplace
tho original ECM/PCM
Does t he vol t age decr ease when
headl i ght s and r ear del ogger ar e
t ur ned on?
ALT FF signal is OK.
Repai r oPen wi re bet woen t | l o
ECM,/PCM {C5) and the ALT.
ALT F
(WHT/RED)
*:
Canada model
Wi re si de of f emal e t ermrnal s
ldle Control System
Brake Switch Signal
('96 -
98 Models,
'99
-
00 Dl6YS engine with M/Tl
Thi s si gnal s the ECM/PCM when the brake
pedal
i s deoressed.
LGl
BKSW
(GRN/
WHTI
D {16P)
Wi re si de of f emal e t rmi nal s
Inspection of Brake Switch Signal.
Are t he brake l i ght s on wi t hout
depressi ng t he brake pedal ?
Depress t he brake pedal .
I nspect t he HORN (15
A) f use i n
the under-hood fuse/ relay box.
Do t he brake l i ght s come on?
-
Repai r shor t i n t he wi r e
between the brake 3whch and
rhe HORN 115 At lu3e.
-
Replace the I|oRN 17.5 A) tus.
between the brake switch and
t he HORN 115 Al f use.
Inspect th6 br.ke switch {s6
section l9l.
I BKSW l i ne):
1. Oepress t he brake pedal .
ECM/ PCNI connect or t ermi nal s
Ag and D5 with the brake pedal
oepresseo.
Repair open in the wire btween
the ECM/PCM {Dsl and the brake
switch.
Brakc switch sign.l is OK.
ECM/PCM CONNECTOFS
A
(32Pt IBRI\ v
,l
a 6 7 8 10 11 1 2 I
12 1 3 1 1 15 1 6 1 7 t 8 19 20 22 23 2a
I 9 10 1 1 12
25 21 2A a 30 13 14 1 5 16
11- 210
I J
Brake Switch Signal
('99
-
00 Models
except
Dl6Y5 engine
with M/Tl
Thi s si gnal s the ECM/PCM when the brake
pedal i s depressed
I
lnsoection ot Brake Switch signal.
Are t he brake l i ght s on wi t hout
depressi ng
t he brake Pedal ?
Depress t he brake
Pedal
I nspect t he HoRN {15 A} f use i n
the underhood fuse/ relay box'
Do t he brake l i ght s come on?
-
R. pai r short i n t he wi ro be'
tween the brake switch and
t he HORN
(15
Al f use.
-
Replac the HORN
(15 A) tuse.
-
Repai r open i n t he wi t e be'
t ween t he brako swi t ch and
t he HORN
(15
Al f use.
-
lnsoect the brake switch
(3ec
section tgl.
Check f ot an oPen i n t he wi re
{BKsw
linel:
1. Depress t he brake Pedal .
2. Measure vohage beween ECM/
and 820 wi t h t he brake Pedal
depressed.
Bepair open in the wire between
t he ECM/ PCM
( A32) and t he
brake switch.
Brake switch signal i5 OK
ECM/PCM CONNECTORS
BKSW
(GRN/WHTI
LG1 {BRN/BLK)
Wi r e si de o{ f emal e t er mi nal s
ldle Control System
lgy"t9!"_"ring
Pressure
(PSPI
Switch Signal
('96
-
98 Models,
'99
-
00 DlGy5 engine witn fU/f)
(USAI
Thi s si gnal s the ECM/ PCN4 when the power
steeri ng l oad i s hi gh.
ECM/PCM CONNECTORS
PSP SWITCH 2P CONNECTOR
PSP SW IGRNI
JUMPER
l--L
I
I
w f R E
- 2 /
GND
(BLKI
Wi re si de ol femal e termi nai s
Inspection o{ PSP switch signal.
Check for an opon in the wire {PSP
SW linelr
(l l ).
ECM/ PCM connecr or t er mi -
nal s A9 and C16.
Check lor an open in the wire
(PSP
SW line):
2. Di sconnecl t he PSP swi t ch 2p
(l l ).
4. At t he harness si de, connect
t he PSP swi t ch 2P connect or
t e r mi n a l s N o . l a n d N o . 2
wi t h a
j umper
wi re.
Ag and C16.
-
Repai r open i n t he wi r o
between the ECM/PCM lc16l
and the PSP switch.
-
Repai r open i n BLK wi r e
betwoen the PSP switch and
G101.
Check the operation of the PSP
switch:
' 1.
St art t he engi ne
2. Tur n st eer i ng wheel t o f ul l
3- Measu r e vol t age bet ween
A9 and C16.
PSP switch signel is OK.
Wi re si de oI t emal e t ermi nal s
11- 212
( To page 11' 2' 13)
t
Check l or a 3hor t i n t he PSP
switch:
f rom t he PSP swi t ch.
(l l )
nal s Ag and C16.
Check tor a short in the wiro {PSP
SW linel:
' 1.
nect or C
(31P).
body
connector terminal C16.
ls there battery vohage?
Repair ahort 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
ECM/PCM CONNECTORS
' l
1 2 a 6 1 8 9 t 0
t l 12 1 3 1 4 1 5 16 17 18
23 21 25 a 30
o
PSP SW
(GRNI
1
-213
ldle Control System
Power Steering Pressure
(PSP)
Switch Signal
('99
-
00 Models except Dl6y5 engine with M/T)
(USAI
Thi s si gnal s the ECM/PCM when the power
steeri ng l oad i s hi gh.
PSP SWTTCH 2P CONNECTOR
(qts6)
PSP SW
(GRN)
JUMPER T---7
1
\
wlRE LJ-
2-l
GND I BLK)
Wi16 sid6 of temale terminals
ECM/PCM CONNEgTORS
Inspoction ot PSP switch signal.
Check for an opn in the wire
(PSP
SW linel:
(l l ).
2. Measure voltage between ECN4/
PCM connect or t ermi nal s 426
and 820.
Check for .n open in tho wire IPSP
SW line):
2. Di sconnoct t he PSP swi t ch 2P
connect or.
(ll).
4. At t he wi re si de, connect t he
PSP switch 2P connector ter-
j umper
wi re.
5. Measure voltage between ECM/
PCNI connoctor terminals 426
and 820.
-
Ropai. opgn in ths wire be-
t w. n t he ECM/ PCM {A261
rnd th6 PSP switch.
-
Ropsir opon in BLK wi.o bo-
t woen t ho PSP swi t ch and
G101.
Check the operation ot the PSP
sw;tch:
' 1.
St art t he engi ne
2. Turn st eeri ng wheel sl owl y.
3. Measure voltage between ECM/
PCM connector terminals 426
and 820.
PSP switch sign8l i3 OX.
11- 214
( To page 11- 215)
\
(From page 11' 2141
Check l or a shor t i n t ho PSP
swhch:
from the PSP switch
3. Turn the ignition switch ON {ll)
4. Measure vohage between ECW
and 820.
Ch6ck for a short in tho wiro IPSP
SW lino,:
nector A
(32P).
3. Check for continuity betweon
body
ground and ECM/ PCM
connector terminal A26
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
ECM/PCM CONNECTORS
' l '
5
-21
ldle Control System
Automatic Transaxle
(CVTI
Gear Position Signal
('96 -98
D16Y5 engine with CW)
ATP NP
{LT GRNI
I NP
GBN)
Thi s si gnal s the ECM when the transmi ssi on i s i n
@
or
@
posi ti on.
Check t he operat i on oI t he A/ T
gear position
switch:
1. Turn t he i gni t i on swi t ch ON f l t ).
2. Observe t he A/ T shi f t posi t i on
i ndi cat or and sel ect each posi
t i on separat el y.
See lhe A/T gear position
indica-
tor inspction
{see sec{ion l/tl.
Check tor a short in the wir6 (ATp
NP l i ne):
I rom t he gauge
assembl y.
f rom t he TCM.
4. Turn t he i gni t i on swi t ch ON f l l ).
5. Measure voltage between ECM
connect or t er mi nal s A9 and
c29.
Check for a short in the wire lATp
NP l i nel l
2. Di sconnect t he ECM connec
t or C
(31P).
body gr ound
and ECM con
Check for an open in the wire lATp
NP lina):
1. Tur n t he i gni t i on swi t ch OFF_
2. Beconnect t he 14P connect or
t o t he gauge
assembl y.
3. Reconnect t he 26P connect or
t o t he TCM.
4. St a r t t he engi ne.
5 . Me a s u r e v o l t a g e b e t we e n
ECM connect or t er mi nal s A9
and C29 wi t h t he t r ans mi s
si on i n
E and
E
posat i ont
t he ECM { C291 and t he gauge
assemblv,
Subst i t ut e a known- good ECM
and r echeck. l f pr escr i bed
vol t -
age is now avrilable, replace the
o. i gi nal ECM.
Wire side ot female terminals
2 4 5 7
I 9 1 0
t 1 12 13 1a 15 1 5 1 7 1 8
23 21 25
29 30
ATP
(LT i o
( To page 11' 217)
11- 216
t
L
( Fr om page 11- 216)
-
bet ween t he ECM {C291 and
lhe
Ituge
assomblv.
-
betwoen the
gauge assembly
and t he A/ T gea.
Posi t i on
switch.
Chock for a short in the wite
(ATP
NP l i ne):
connect or t ermi nal s Ag and C29
wi t h t he t ransmi ssi on
i n gear.
ReDair short in the wire be'tween
ECM
(C291
and
gauge a3somblY.
A/T
gar position signal is OK
LG1 IEBN/BLK)
ECM CONNECTORS
ATP NP
Wi re si de of f emal e t ermi nal s (LT
GRN)
ldle Control System
{
(
a
Clutch Switch Signal
(Dl6YS
engine with M/Tl
Thi s si gnal s the ECM when the cl utch i s engaged.
A {32P}
ECM CONNECTORS
LGl
(BRN/BLK)
\-
cLsw
(RED}
Inrpaction ot dutch rwitch signal.
Check f or on opon i n t he wi ro
(CLSW
linel:
' ! .
(l l ).
2. Measure voltage betweon ECt!4
A9.
Ch.ck tho clutch switch:
from the clutch switch.
(ll).
4. Measure voltage btween ECM
ls thare approx. 5 V?
Check f or a short i n t h6 wi re
(CLSW
line)l
1. Turn t he i gni t i on swi rch OFF.
2. Di sconnect t he ECM connec
t or C
(31P)t rom
t he ECM.
ECM connect or t ermi nal C29
and body ground.
Chcck f or an open i n t hg wi re
{CLSW linel:
1. Depress t he cl ut ch pedal .
2. Moasure voltage between ECM
connect or t ormi nal s C29 and
A9.
Repair short in the wirc between
t ho ECM { C291 and t ho cl ur ch
switch.
Sub3t i t ut g a known-good ECM
and rechock, It p.e3cribed
vohago
i! now available, roplace the orig-
inal ECM.
2 6 1 8 9 10
1 l
12 t 3
'ta
t 5 l 6 17 l 8 22
o
(To page
11-219)
11- 218
!
{ Fr om
page 11- 218)
Check lho clutch switch:
from the clutch switch.
t he cl ut ch swi t ch connect or
t ermi nal s No. 1 and No. 2 wi t h
t he cl ut ch
pedal depressed
l s vol t age l ess t han 1. 0 V?
-
Adiu3t the clutch swiich.
-
Reolace lhe clutch switch.
Check for an open in tha wiie:
1. Turn t he i gni t i on swi t ch ON l l l )
clutch switch connector terml'
nal No. 1 and body
ground with
t he cl ut ch
pedal depressed.
Repair opn in the wire betwoen
t he EcM
(C291 and t hc cl ut ch
swilch.
Repair open in BLK wire between
the clutch switch and Gircl.
Clutch switch signal is OK.
CLUTCH SWITCH 2P CONNECTOR
j - t
-
t ermrnal s
CLUTCH SWITCH 2P CONNECTOR {C41',
-f--r
I ' l ' l
-l_-
clsw
1;1
tREDr
Y
Wire 6ide of lemale
t er mi nal s
I
l r ,
11-219
ldle Control System
ldle Speed Setting
Inspection/Adiustmenl
'96, '97
Dl6Y5.
'96
-
00 Dl5Y8 sngine with M/T
NOTE:
. Bef or e set t i ng t he i dl e speed, check t he f ol l owi ng
i tems:
-
The MIL has not been reported on.
-
l gni t i on t i mi ng
-
Spark pl ugs
-
Ai r cl eaner
-
PCV system
o ( Canada)
Pul l t he par ki ng
br ake l ever up. St ar t t he
engi ne, then check that the headl i ghts are off.
1. Start the engi ne. Hol d the engi ne at 3.000 rpm wi th
no l oad
(taansmi ssi on
i n neutral ) unti l the radi ator
fan comes on, then l et i t i dl e.
2. Connect a tachometer.
3. Di sconnect the IAC val ve connector.
4. l f the engi ne stal l s, restart the engi ne wi th the accel -
erator pedal sl i ghtl y depressed. Stabi l i ze the rpm at
1,000, then sl owl y rel ease the pedal unti l the engi ne
i dl es.
Check i dl i ng i n no-l oad condi ti onsr headl i ghts. bl ower
fan. rear defogger, radi ator fan, and ai r condi ti oner
are not operati ng.
l dl e spsed shoul d be:
450 1 50 rpm
11-220
Adj ust the i dl e speed, i f necessary, by removi ng the
cap and turni ng the i dl e adj usti ng screw.
NOTE; After adj usti ng the i dl e speed i n thi s step,
recheck the i gni ti on ti mi ng
(see
secti on 23).
l f i t i s out of spec, go
back to step 4.
IDLE
7. Reconnect the 2P connector on the IAC val ve, then
do the ECM reset procedure.
8. Restart and i dl e the engi ne wi th no-l oad condi ti ons
for one mi nute, then check the i dl e speed.
NOTE: ( Canada)
Pul l t he par ki ng br ake l ever up.
Start the engi ne, then check that the headl i ghts are
off.
ldle spsd should b:
670 i 50 rpm
IUSA)
750 t 50 rpm {Canada}
9. l dl e the engi ne tor one mi nute wi th headl i ghts
{Low)
ON. and check the i dl e speed.
ldle speed should be:
750 :r 50 rpm
10. Tur n t he headl i ght s of f . l dl e t he engi ne f or one
mi nute wi th heater fan swi tch at Hl and ai r condi ti oner
on, then check the i dl e speed.
810150 r pm
NOTE: l f the i dl e speed i s not wi thi n speci fi cati on,
see Symptom Chan on page 11-84.
t
t
I
' 96.' 97
D16Y5 engi ne wi th CVT,' 96
-
00 D16Y8 ongi ns
wi th A/T and' 96
-
00 Dl 6Y7 ngi ne
Adi ust the i dl e speed usi ng a Honda PGM Tester i f
pos-
si bl e. l f not, use the fol l owi ng
procedure:
NOTEI
. Leave the IAC valve connected
. Betore setti ng the i dl e speed. check the fol l owi ng
items:
-
The MIL has not been reported on'
-
l gni ti on ti mi ng
-
Spark
Pl ugs
-
Ai r cl eaner
-
PCV system
2. Start the engi ne. Hol d the engi ne at 3,000 rpm wi rh
no l oad
( i n
Par k or neut r al ) unt i l t he r adi at or f an
comes on, then l et i t i dl e.
3. Check the i dl e speed wi th no-l oad condi ti ons: head-
i i ghts, bl ower fan, rear defogger, radi ator fan, and
ai r condi ti oner
are not operatl ng
ldl spoed should be:
USA:
D16Y5 engi ne wi th CVT, D16Y7 engi ne wi th A/T'
Dl6YB engine with A/T:
700 :r 50 rpm
(in
E
or El Positionl
D16Y7 engine with M/T:
670 i 50 rpm
Canada:
Dl6Y8 sngin, Dl6Y7 engins:
M/T 750 t 50 rpm
NT
750 1 50 rpm
(i n
E
or El Posi ti on)
Adj ust the i dl e speed, i f necessary, by removi ng the
cap and turni ng the i dl e adi usti ng screw 1/2-turn
cl ockwi se
or countercl ockwi se
D16Y5, D16Y8 engine:
IDLE
ADJUSTING
Dl6f, ongine:
NOTE: When
you remove the ACL housi ng, do not
di sconnect the IAT sensor connector
Af t er t ur ni ng t he i dl e adj ust i ng scr ow 1/ 2- t ur n'
check the i dl e speed agai n. l f i t i s out of spec, turn
the i dl e adj usti ng screw 1/2-turn agaan'
NOTE: Do not turn the i dl e adj usti ng screw more
than 1/2-turn wi thout checki ng the i dl e speed'
l dl e t he engi ne f or one mi nut e wi t h heat er f an
swi tch at Hl and ai r condi ti oner on, then check the
i dl e speed.
M/T 810150 r pm
A/T. CvT 810 t 50 rpm
(i n
El
or E Posi ti on)
NOTE:
. Do not turn the i dl e adj usti ng screw when the ai r
condi ti oner i s on.
. l f the i dl e speed i s not wi thi n speci fi cati on.
see
Symptom Chart on
page 11-84
(cont' d)
11-221
ldle Control System
ldle Speed Setting
(cont'dl
Inspeqtion/Adiustment
38 D16Y5 engine whh M/T,'99
-
00 81642 engine
NOTE: Before setti ng the i dl e speed, check the fol l ow-
i ng i tems;
-
-
-
Spark pl ugs
-
Ai r cl eaner
-
PCV system
' 1.
Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(transmi ssi on
i n neutral ) unti l the radi ator
fan comes on, then l et i t i dl e.
Connect a tachometer.
Di sconnect the IAC val ve 2P connector and the EVAP
purge control sol enoi d val ve 2P connector.
EVAP PURGE
CONTROL
SOLENOID VALVE
l f the engi ne stal l s, restart the engi ne wi th the accel -
erator pedal
sl i ghtl y depressed. Stabi l i ze the rpm at
1.000, then sl owl y rel ease the pedal
unti l the engi ne
i dl es.
Check i dl i ng i n no-l oad condi ti ons: headl i ghts, bl ower
fan, rear defogger, radi ator fan, and ai r condi ti oner
are not operati ng.
ldl speed should be:
450 i 50 rpm
11-222
l f necessary, adj ust the i dl e speed, by removrng l ne
cap and turni ng the i dl e adj usti ng screw.
After adj usti ng the i dl e speed recheck the i gni tl on
ti mi ng
(see
secti on 23). l f i t i s out of spec, go
back
to step 4.
| DLE
7. Reconnect the 2P connectors to the IAC val ve and
the EVAP purge
control sol enoi d val ve, then do the
ECM reset procedure.
8. Restart and i dl e the engi ne wi th no-l oad condi ti ons
for one mi nute, then check the i dl e sDeed.
ldle speed should bo:
USA:
D16Y5 engine: 670 i 50 rpm
81642 engine: 700 i 50 rpm
Canada:
81642 engine: 750 t 50 rpm
NOTE: l f the i dl e speed i ncreases to 8l O t 50 rpm,
thi s means the EVAP system i s purgi ng
the cani ster.
To stop the purgi ng
temporari l y, rai se the engi ne
speed above 1,000 rpm wi th the accel erator pedal ,
then sl owl y rel ease the pedal .
9. l dl e t he engi ne f or one mi nut e wi t h headl i ght s
(Low)
ON. and check the i dl e speed.
750 i 50 rpm
10. Tur n t he headl i ght s of f . l dl e t he engi ne f or one
mi nute wi th heater fan swi tch at Hl and ai r condi -
ti oner on, then check the i dl e soeed.
ldls speed should be:
810 t 50 rpm
l f t he i dl e speed i s not wi t hi n speci f i cat i on, see
Symptom Chart on page 11-84.
\
I
'98
-
0O D16Y5 ongine with CvT
Adj ust the i dl e speed usi ng a Honda PGM Tester i f pos-
si bl e. l f not, use the fol l owi ng
procedure:
NOTE:
. Leave the IAC val ve connected.
. Before stti ng the i dl e speed, check the fol l owi ng
rtems:
-
-
-
Spark
Pl ugs
-
Ai r cl eanr
-
PCV svstem
'1.
Connect a tachometer.
2. Stan the engi ne. Hol d the engi ne at 3,000 rpm w' th
no l oad
(transmi ssi on i n
E
or E]
posi ti on) unti l the
radi ator Jan comes on, then l et i t i dl e.
3. Check t he i dl e speed under no- l oad condi t i ons:
head lights, blower fan, rear defogger, radiator fan,
and ai r condi ti oner are not operatl ng.
ldlo spaod ehould bo: 700 t 50 rpm
. l f the i dl e speed i s wi thi n the speci fi cati on, the
procedure is comPlete.
. lf the idle sDeed is out of specitication,
9o
to step 4'
4. tf the i dl e speed i s 810 1 50 rpm, thi s means the
EVAP system i s purgi ng the cani ster. To stop the
purgi ng temporari l y, rai se the engi ne speed above
l,OO0 rgm with the accelsrator
pedal. Slowly release
the
pedal . and rscheck the i dl speed.
. tf the i dl e speed i s wi thi n the speci fi csti on, the
Drocedure i s comPl ete.
. lf the idle sped is out of spocification,
go to step 5.
5. Di sconnect th EVAP
purgs control sol enoi d val ve
2P connector.
EVAP PURGE
CONTROL
6. Remove the cap and turn the i dl e adi usti ng screw
1/2-turn clockwise or counterclockwlse
IDLE
7. After turning the idle adjusting screw 1/2-turn, check
the i dl speed agai n. l f i t i s out of spec, turn the i dl e
adjusting screw 1/2-turn again.
NOTE: Do not turn the i dl e adj usti ng screw more
than 1/2-turn wi thout checki ng the i dl e speed.
Turn the i gni ti on swi tch OFF. Reconnect the EVAP
purge control sol enoi d val ve 2P connector' then do
the ECM reset
Procedure.
Start the engi ne. l dl e the engi ne for one mi nute wi th
heater fan swi tch at Hl and ai r condi ti oner on, then
check the i dl e speed.
ldle spaed should be:
810 t 50 rpm
(in
El
or E Posiiion)
l f the i dl e speed i s not wi thi n speci fi cati on, see
Svmptom Chart on
Page
11-84.
9.
SOLENOID VALVE
11-223
Fuel Supply System
Fuel Li nes
NoTE: Check fuel system l i nes, hoses, fuel fi l ter, and other components l or damage, l eaks and deteri orati on, and repl ace
i f necessary.
(2. 2
kgt . m, 16l bf . f t )
(D16Y5
engi ne: 28 N. m
2.8 kgtm, 21 lbf ft)
The i l l ust rat i on
shows' 99
00 model s.
t/
,ee.- ;
4/
/.,/
Tl
...,.'
..4,/
i,/
I
22 N. m
11-224
I
'96
-
98 models:
NOTE: Check al l hose cl amps and reti ghten i f necessarY.
M
/v
FUEL
FILTER
PRESSURE
REGULATOR
I
FUEL
TANK
FUEL
GAUGE
SENDING
UNI T
BASE GASKET
Repl ace.
Cl amp I n r he mi ddl e
@
Cl amp i n t he mi ddl e
1 0 - 1 4 mm
(0. 39 -
0. 55 i nl
(cont ' d)
11-225
Fuel Supply System
Fuel Lines
(cont'dl
.99
-
00 models:
NOTE: Check al l hose cl amps and reti ghten i f necessary.
: Do not di sconnect the hose from the pi pe.
ONBOARD REFUELING VAPOR
BECOVERY IORVRI
VENT SHUT VALVE
B
FUEL
GAUGE
lt N.rn l1.a
kgt.m,
r0 lbt ftl
ftr, n'fo'
PRESSURE
REGULATOR
11-226
I
Fuel Tube/Oui ck-Gonnect Fi tti ngs
Precautions
!@
Do not smoke whi l e worki ng on the fuel
system, Keep open flames away from your work a.ea'
The fuel tube/qui ck-connect fi tti ngs assembl y connects
the i n tank fuel
pump
wi th the fuel feed pi pe. For remov-
i ng or i nst al l i ng t he f uel pump and f uel t ank, i t i s neces-
sary to di sconnect or connect the
qui ck-connect fi tti ngs.
Pay attenti on to l ol l owi ng:
. The fuel tube/qui ck-connect fi tti ngs assembl y i s not
heat - r esi st ant ; be car ef ul not t o damage i t dur i ng
wel di ng or other heat-generati ng
procedures
. The fuel tube/qui ck-connect fi tti ngs assembl y i s not
aci d-proof; do not touch i t wi th a shop towel whi ch
was used for wi pi ng battery el ectrol yte. Repl ace the
fuel tube/qui ck-connect fi tl i ngs assembl y i f i t came
i nto contact wi th el ectrol yte or somethi ng si mi l ar.
. When connect i ng or di sconnect i ng t he f uel t ube/
qui ck connect l i l t i ngs assembl y, be car ef ul not t o
bend or twi st i t excessi vel y. Repl ace i t i f damaged
A di sconnected
qui ck-connect fi tti ng can be reconnecl ed,
but t he r et ai ner on t he mat i ng pi pe cannot be r eused
once i t has been removed from the
pi pe. Repl ace the
retatner wnen
. Repl aci ng t he f uel pump.
. Repl aci ng the fuel l eed pi pe.
. l t has been removed l rom the
Pi Pe.
. l t i s damaged.
ACCESS PANEL
I
Disconnestion
!@
Do not smoke whi l e worki ng on the l uel
system. Keep open llames away lrom youl work area.
1. Rel i eve fuel pressure
(see pages 11' 230,2311.
2. Check t he t uel qui ck- connect t i t t i ngs f or di r t , and
cl ean i f necessary.
3. Hol d the connector wi th one hand and
press down
the retai ner tabs wi th the other hand, then pul l the
connector off.
NOTE:
o Be carel ul not to damage the pi pe or other
pans
Do not use tool s.
. l f the connector does not move, keep the retai ner
tabs
pressed down, and al ternatel y
pul l and
push
the connector unti l i t comes off easi l y.
. Do not remove the retai ner from the pape; once
removed, the retai ner must be repl aced wi th a
new one.
LOCKING PAWL
BETAINER TAB
CONNECTOR
Check the contact area o{ the
pi pe for di rt and dam-
age.
. l f the surface l s di rty, cl ean i t.
. l f the surface i s rusty or damaged, repl ace the
fuel pump or fuel feed pi Pe.
4.
(cont ' d)
11-227
PIPE
Fuel Supply System
Fuel Tube/Ouick-Connect Fittings
(cont'd)
5. To prevent damage and keep out torei gn matter,
cover t he di sconnect ed connect or and oi oe end
wi th pl asti c bags.
PI.ASIIC BAGS
11-228
Connecti on
!s@
Do not smoke whi l e worki ng on the fuel
system. Keep open llames away from your work area.
1. Check the pi pe contact area for dj rt and damage,
and cl ean i f necessary,
I nsert a new ret ai ner i nt o t he connect or i f t he ret ai ner
i s damaged, or af t er
. repl aci ng t he f uel pump.
. repl aci ng t he f uel f eed pi pe.
. removi ng t he ret ai ner f rom t he pi pe.
N.w RETAINER
(l nsert
i nt o
t he connect or. )
CONTACT AREA
t
Bel ore connecti ng a new fuel tube/qui ck-connect fi ni ng
assembl y, remove the ol d retai ner from the mati ng pi pe
wi t h t he
t abs pul l ed
apan, remove
and di scard t he
I
ret arner
New FUEL TUBE/
OUICK.CONNECT
FITTING ASSEMELY
3. Al i gn the
qui ck-connect fi fti ngs wi th the pi pe, and
al i gn the retai ner l ocki ng pawl s wi th the connector
grooves. Then press the qui ck-connect fi tti ngs onto
the pi pe unti l both retai ner pawl s l ock wi th a cl i ck-
i ng sound.
NOTE: l f i t i s hard to connect,
put a smal l amount
of new engi ne oi l on the pi pe end.
Connection with new retainer:
4. Make sure the connecti on i s secure and the pawl s
are fi rml y l ocked i nto pl ace; check vi sual l y and by
pul l i ng the connector.
RCTAINER
Reconnect the battery negati ve cabl e, and turn the
i gni t i on swi t ch ON
( l l ) .
The f uel pump wi l l r un f or
about t wo seconds, and f uel
pr essur e wi l l r i se.
Repeat two or three ti mes, and check that there i s
no l eakage i n the fuel suppl v system
11-229
Fuel Supply System
System Description
The fuel suppl y system consi sts of a fuel tank, i n-tank
hi gh pressure fuel pump, PGM-FI mai n rel ay, fuel fi l ter,
fuel pressure regul ator, fuel i nj ectors. and fuel del i very
and return l i nes. Thi s system del i vers pressure-regu-
l ated fuel to the fuel i nj ectors and cuts the fuel del i very
when the engi ne i s not runni ng.
Fuel Pressure
l'96 Modelsl
Relieving
Before di sconnecti ng fuel pi pes
or hoses, rel ease pres-
sure from the system by l ooseni ng the 6 mm servi ce
bol t on top of the fuel fi l ter.
. Do not smoke whil6 working on the fuel system.
Kgsp opon flames or sparks away from youl
work
area.
. Be sure to rel i eve fuel pressure
whi l e the i gni ti on
switch is off.
1. Wri te down the frequenci es for the radi o' s preset
buttons.
2. Di sconnect the battery negati ve cabl e from the bat-
tery negati ve termi nal .
3. Remove the fuel fi l l cap,
4. Use a box end wrench on the 6 mm servi ce bol t at
the fuel fi l ter whi l e hol di ng the speci al banj o bol t
wi th another wrench,
5. Place a rag or shop towel over the 6 mm service bolt.
6, Sl owl y l oosen the 6 mm servi ce bol t one compl ete
rurn.
. A fuel pressure gauge can be attached at the 6 mm
servi ce bol t hol e.
. Al ways reDl ace the washer between the servi ce
bol t and the speci al banj o bol t whenever the ser-
vi ce bol t i s l oosened.
. Repl ace al l washer s whenever t he bol t s ar e
removeo.
11-230
Inspoction
1. Rel i eve fuel pressure.
2. Remove the service bolt on the fuel filter while hold-
i ng the banj o bol t wi th another wrench. Attach the
speci al tool .
FUEL
PRESSURE
GAUGE
07406
-
00ir0(x)1
Start the engi ne. Measure the fuel pressure wi th the
engi ne i dl i ng and the vacuum hose of the fuel pres-
sure regul ator di sconnected from the fuel pressure
regul ator and pi nched. l f the engi ne wi l l not start,
turn the i gni ti on swi tch ON
(l l ),
wai t for two sec-
onds, turn i t off, then back on agai n and read the
fuel pressure.
Pr3sure should bo:
260
-
310 kPa
(2.7 -
3.2 kgt/cmr, 38
-
46 psi)
Reconnect vacuum hose to the fuel pressure
regulator,
Pressure should bo:
200
-
25O kPa l2.O
-
2.5 kgf/cm', 28
-
36 psil
lf the fuel pressure
is not as specified, first check the
fuel pump
{see
page 11-2361. l f the fuel pump i s OK,
check the fol l owi ng:
. l f t he f uel pr essur e i s hi gher t han speci f i ed,
inspect for;
-
Pi nched or cl ogged fuel return hose or l i ne.
-
Faulty fuel pressure regulator
(see page 11-234).
. lf the fuel pressure is lower than specified, inspect
for:
-
Cl ogged fuel fi l ter.
-
Faulty fuel pressure regulator
{see
page 11-234).
-
Fuel l i ne l eakage.
REGULATOB
t J
Fuel Pressure {'97
and later Models)
ReliGving
Before di sconnecti ng tuel pi pes or hoses, rel ease pres-
sure from the system by l ooseni ng the 12 mm banj o
bol t on top of the fuel fi l ter.
@
o Do not smoke whilo working on the fuel sy3lom.
Ksgp opn flames or sparks away tlom
Your
work
arga.
. Be sure to rel i eve fuel pressul e whi l e the i gni ti on
swhch is off.
1. Wri te down the frequenci es for the radi o' s
preset
buttons,
2. Di sconnect the battery negati ve cabl e from the bat-
tery negati ve termi nal .
3. Remove the fuel fi l l cap.
Use a box end wrench on the 12 mm banj o bol t at
the fuel fi l ter whi l e hol di ng the fuel fi l ter wi th anoth-
er wrench.
Pl ace a rag or shop towel over the 12 mm bani o bol t.
Sl owl y l oosen the 12 mm banj o bol t one compl ete
t ur n.
4.
I
12 mm BAtt O
BOLT
33 N.m
(3.i1 kgf m,
25 tbf.f0
NOTE: Repl ace al l t he washer s whenever t he 12
mm bani o bol t i s l oosened or removed.
Inspaqtion
1. Rel i eve fuel pressure.
2. Remove the 12 mm banj o bol t from the fuel fi l ter
whi l e hol di ng the fuel Ji l ter wi th another wrench
Attach the speci al tool s.
3. Start the engine the fuel
Pressure
with the
engine idling and the vacuum hose of the fuel pres-
sure regulator disconnected from the fuel pressure
regulator and
pinched lfthe 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$3uro ehould be:
excepi 816A2 sngine:
260
-
310 kPa {2'7
-
3.2 kgf/cm" 38
-
{6
Fi}
B16A2 engine:
27O
-32O
kPa P.8
-
3'3 kgf/cm',
'10 -
47
psi)
4. Reconnect vacuum hoso to the fuel
pressure regulator'
Pre33ure 3hould be:
except B16A2 engin:
2OO
-
250 kPa {2.0
-
2'5 kgf/cm', 28
-
36
psi)
B16A2 engino:
210
-
260 kPa 121
-
2.6 ksf/cm', 30
-
37 psi)
lf the fuel
pressure is not as specified, first check the
f uel
pump ( see page 11- 236) l f t het uel
pumpi soK,
check tho fol l owi ng:
. l f t he f uel
pr essur e i s hi gher t han speci f i ed,
inspect for:
-
Pi nched or cl ogged fuel return hose or l i ne.
-
Faul ty fuel pressure regul ator
(see page 11-
2341.
. lf the fuel pressure is lower than specified, inspect
for:
-
Cl ogged fuel fi l ter.
-
Faul ty fuel
pressure regul ator
(see page l 1-
2341.
-
Fuel l i ne l eakage.
FUEL PRESSURE
ADAPTER BOLT, 12 mm
tguxt8-PD6-0101
CLAMP
REGULATOR
11-231
Fuel Supply System
Fuel Injectors
Replacement
@
Do not smoke when working on the tuel systgm, Keep
gp6n
flames away from your work area
' f.
Rel i eve the fuel pressure (see pages 11-230,231J.
2. Di sconnect the connectors from thefuel i nj ectors
(D16Y7
engi ne: Remove the ai r cl eaner).
3. Di sconnect the vacuum hoses from thefuel pressure regul ator. Pl aceashoptowel overthefuel return hose, then di s-
connect i t from the fuel pressure
regul ator. Di sconnect the vacuum hoses and 2P connector from the EVAp purge
control sol enoi d val ve.
4. Remove the retai ner nuts on the fuel rai l .
5. Di sconnect the fuel rai l .
6. Removethefuel i nj ectors from the i ntake mani fol d.
D16Y5, D16Y8 engi ne:
NOTE: l l l ustrati on shows D16Y8 engi ne.
D16Y5 engi ne i s si mi l ar .
12 N. m
11.2 kgl.m,
8.7 rbt.ft)
12 N. m
11. 2 l gl . m,
8.7 rbt.ftl
.q
w
E4
Y
V
e
ffi
}Y
g
E
O.RING
Replace.
CUSHION
RING
Repl ace.
O.RING
Repl ace.
cusl{toN
RING
Repl ace.
SEAL
RING
Repl ace.
ffi
E
E
V
R
w
t
Y
EVAP
PURGE CONTNOL
SOLENOID VALVE
FUEL
11-232
\ J
81642 engi ne:
EVAP
12 N. m
{1. 2 kgl m;
8.? lbt.ft)
FUEL
PRESSURE
REGULATOR
O.RING
Repl ace.
cusHloN
RING
Replace.
PURGE CONTROL
SOLENOID VALVE
\
SEAL
RING
Repl ace.
7. Sl i de new cushi on ri ngs onto the fuel i nj ectors.
8. Coat newO-ri ngswi th cl ean engi neoi l , and
putthem onthefuel i nj ectors.
9. Insert the fuel i nj ectors i nto the fuel rai l fi rst.
10. Coatnewseal ri ngs wi th cl ean engi ne oi l ,and
press them i ntothe i ntake mani fol d.
11. To prevent damage to the O-ri ngs, i nstal l the fuel i nj ectors i nthefuel rai l fi rst, then i nstal l them i nthe i ntake mani fol d.
' 12.
Instal l and ti ghten the retai ner nuts.
13. Connect the vacuum hoses and fuel return hose to the fuel pressure regul ator, Connect the vacuum hoses and 2P
connector to the EVAP
purge control sol enoi d val ve.
14. Instal l the connectors on the fuel i nl ' ectors
(D16YI
engi ne; Instal l the ai r cl eaner).
(l l ),
butdo not operate the starter. After the tuel pump runs for approxi matel y two seconds,
the fuel
pressure i n the fuel l i ne ri ses. Repeat thi s two or three ti mes, then check whether there i s any fuel l eakage.
11-233
Fuel Supply System
Fuel Pressure Regulator
Te3ting
@
Do not smoke during the tast. Keep open
flamcs away from your work arsa.
1. Attach the speci al tool (s) to the servi ce port
on the
fuel fi l ter
(see pages 1 1-230, 231).
Pressure should bo:
except 81642 engine
260
-
310 kPa |'2.7
-
3.2 kgllcrn2,38
- /t6 psil
816A2 engi ne:
27O
-
320 kPa 12.8
-
3.3 kgf/cm,, 40
-
47 psi)
{with the tuel pressure regulator vacuum hose
disconnested and pinched)
Reconnect the vacuum hose to the fuel pressure
regul ator.
Check that the fuel pressure ri ses when the vacuum
hose from the fuel pressure regulator is disconnected
agai n.
l f t he f uel pr essur e di d not r i se, r epl ace t he f uel
pressure regutal or.
CLAMP
REGULATOR
11-234
Reolacement
@@
Do not smoke while working on luel sys-
tem. Keep open flame away from your work area,
1. Pl ace a shop towel under the fuel pressure
regul ator,
then relieve fuel
pressure (see pages 11-230,231l..
2. Di sconnect the vacuum hose and fuel return hose.
3. Remove the two 6 mm retai ner bol ts and the fuel
pressure regurator.
Appl y cl ean engi ne oi l to a new O-ri ng. and careful l y
i nstal l i t i nto i ts proper posi ti on.
I nst al l t he f uel pr essur e r egul at or i n t he r ever se
order of removal .
I
Fuel Fi l t er
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
sal e di stance betwoen battery tormi nal s and any
tools.
The f uel f i l t er shoul d be r epl aced whenever t he f uel
pressure drops bel ow the speci fi ed val ue [260
-
310 kPa
12.7
-
3.2 ksl/cm',38
-
46
psi),
|270
-
320 kPa
(2.8 -
3 3
kgf/cm,, 40
-
47 psi ))* wi th the fuel
pressure regul ator
vacuum hose di sconnected and
pi nchedl after maki ng
sure that the fuel pump and the fuel
pressure regul ator
are OK.
*:
81642 engi ne
1. Pl ace a shop towel under and around the fuel fi l ter.
2. Relieve fuel
pressure (see pages 11-230,231]-
Remove t he 12 mm banj o bol t and t he f uel f eed
pi pe from the fuel fi l ter, whi l e supporti ng i t wi th the
another wrench, as shown.
Remove the fuel fi l ter ci amp and fuel fi l ter'
l nst al l t he new f uel f i l t er i n t he r ever se or der
removal , and note these i tems:
a When assembl i ng, use new washers as shown
. Cl ean t he f l ar ed
j oi nt
of hi gh
pr essur e hoses
thoroughl y before reconnecti ng them.
I
,96
MODELS:
(3.4
kgl.m,
25 rbf.ftl
,97
AND LATER MODELS:
12 mm
BANJO
BOLT
33 N. m
12 mm
BANJO
BOLT
33 N.m
t3.4 kgf m,
25 lbf.fr)
\\i(o-r
\)
11-235
Fuel Supply System
Fuel Pump
Testing
!@
Do not smoke during the test, Keep open
fl ame away from your work atea,
l f you suspect a probl em wi th the fuel pump,
check that the
fuel pump actual l y runs; when i t i s ON
(l l ),
you wi l l hear
some noi se i f you hol d your ear to the fuel fi l l port wi th the
fuel fi l l cap removed. The fuel pump shoul d run for two
seconds when i gni ti on swi tch i s fi rst turned ON
(l l ).
l f the
fuel pump does not make noi se, check i t as fol l ows:
L Remove the seat cushi on
{see secti on 20).
2. Remove the access panel from the fl oor.
3. Make sure the i gni ti on swi tch i s OFF, then di scon-
nect the Iuel tank 2P connector.
4. Connect the PGM-FI mai n rel ay 7P connector termi -
nal No. 4 and No. 5 wi t h a
j umper
wi r e.
PGM-R MAIN RELAY 7P CONNECTOR lC4,(|l
FUEL PUMP
IYEL/
GRN}
IGN 1
(YEL/GRNI
tcs6s)
FUEL PUMP
(YEL/ GRNI
Wire side of
t emal e t ormi nal s
JUMPER WIRE
Wi re si de of temal e termi nal s
Check that battery vol tage i s avai l abl e between the
fuel pump connector termi nal No. 1 and body ground
when the i gni ti on swi tch i s turned ON
(l l ).
CONNECTOR
=
[t
L3l
.i)
T
lf battery voltage is available, check the fuel pump
ground. l f the ground i s OK, repl ace the fuel pump.
l f there i s no vol tage, check the wi re harness (see
page 11- 238) .
11-236
Replacement
@E
Do not smoke whi l e worki ng on tuel svs-
tem. Keep open llames away from your work area.
1. Remove the seat cushi on
(see
secti on 20).
2. Remove the access panel trom the fl oor.
3. Di sconnect the 2P connector from the fuel pump.
4. Remove the fuel pump mounti ng nuts.
5. Remove the fuel pump from the fuel tank.
6. Instal l pans i n the reverse order of removal .
ACCESS PANEL
i
I
PGM-Fl Mai n Rel ay
Descri pti on
The PGM- Fl mai n r el av act ual l v cont ai ns t wo i ndi vi dual
rel ays. Thi s rel ay i s l ocated at the ri ght si de of the cowl .
One rel ay i s energi zed whenever the i gni ti on i s on whi ch
suppl i es the battery vol tage to the ECM/PCM, power to
the l uel i ni ectors, and
power for the second rel ay. The
second rel ay i s energi zed l or two seconds when the i gni -
t i on i s swi t ched ON
( l l l ,
and when t he engi ne i s r unni ng,
to suppl y power to the l uel pump.
PGM-FI
MAIN RELAY
J
I
t
FUEL PUMP
Rel ay Testi ng
NOTE:
. It the engi ne starts and conti nues l o run. the PGM Fl
mai n r el ay i s OK.
. Use t he t er mi nal number s bel ow;
i gnore the termi nal numbers mol ded i nto the rel ay,
1. Remove t he PGM Fl mai n r el ay.
2. Attach the battery posi ti ve termi nal to the No. 2 ter-
mi nal and the battery negati ve termi nal to the No 1
termi nal of the PGM-Fl mai n rel ay. Then check for
cont i nui t y bet ween t he No. 5 t er mi nal and No 4t er -
mi nal of t he PGM Fl mai n r el ay.
. l f there i s conti nui ty,
go on to step 3.
. l f t her e i s nocont i nui t y, r epl acet he PGM- Fl mai n
rel ay and ret est .
No. 3
No. 1
To l GN. 1
To GROUND
To ST. SWITCH
To ECM/PCM {A161
To 8AT O
To ECM/PCM
{(a11,
A241,
(81. B9l *l
To FUEL PUMP
.r
'99
model
3. Al tach the batterv
posi ti ve
termi nal to the No.5 ter-
mi nal and the battery negati ve termi nal to the No. 3
termi nal of the PGM-Fl mai n rel ay. Then check that
there i s conti nui ty between the No. 7 termi nal and
No. 6 termi nal of the PGM-Fl mai n rel ay.
. l f there i s conti nui ty,
go on to step 4
. l f t her e i s nocont i nui t y, r epl acet hePGM- Fl mai n
rel ay and retest.
Attach the battery
posi ti ve
termi nal to the No. 6 ter-
mi nal and the battery negati ve termi nal to the No. 1
termi nal of the PGM Fl mai n rel ay. Then check that
there i s conti nui ty between the No. 5 termi nal and
No. 4 termi nal of the PGM-Fi mai n rel ay.
. l f there i s conti nui ty, the PGM-Fl mai n rel ay i s OK.
l f the fuel
pump
sti l l does not work, go to Harness
Testi ng on the next page.
. l f there i s no conti nui ty, repl ace the PGM Fl mai n
4.
(cont ' d)
11-237
rel ay and ret est .
Fuel Supply System
PGM-FI Mai n Rel ay
(cont' dl
Circuit Troubleshootin g
PGM.FI MAIN RELAY 7P CONNECTOR {C443)
GND
{8LK)
/BLK}
-
Engine will not start.
-
l nsoect i on of PGM-FI mai n
relay and relay harne$.
{GNO l i ne}:
l . Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he PGM-Fl mai n
rel ay 7P connect or.
t he PGM Fl mai n rel ay 7P con-
nect or t ermi nal No. 3 and body
ground.
Ropai. open in the wir between
t he PGM-FI mai n . el av and G101.
Check for an open or short in the
wire {BAT lin}:
N4easur e vol t age bet ween t he
PGM-FI mai n rel ay 7P connect or
terminal No. 7 and body ground.
-
Repai r open or sho. t i n t he
wire between the PGM-FI main
r el ay and t he Fl E/ M { 15 A}
fus.
-
Repl ace t he Fl E/ M
(15
Al l u3e
i n t he under-hood f use/ rel ay
oox.
ls lhere battery voltage?
Check tor an open or short in the
wi re {l Gl l i ne):
(l l ).
2. Measure the voltage between
t he PGM-Fl mai n rel ay 7P con'
ground.
-
Repai r open or short i n t he
wire betwoen the PGM-FI main
r el av and t he No. 13 FUEL
PUMP (15 A)tuse.
-
Rpl ace t he No. 13 FUEL
PUMP {15 A} tus in the under-
d.sh fus/relay box.
Ch.ck for an open or short in the
wire {STS lino}r
1. Turn t he i gni t i on swi t ch t o t he
START
(l l l ) posi t i on.
NOTE:
.
M/ T: Cl ut ch pedal must be
oepresseo.
.
A/ T: Transmi ssi on i n
E
or
E
posi t i on.
2, Measure t he vol t age bet ween
t h e PGM- Fl ma i n r e l a y 7 P
connect or t ermi nal No, 2 and
body ground.
1 2
[,
a 5 6 7
1 2 3
BAT
{WHT
a 5 6 ,
' 96
98 model s:
(To page 1l 239)
' 99
-
00 model s:
(To page I l -240)
11-238,
J I
I
-
Repai r open or 3hort i n t he
wire bstwer the lGM-Fl main
rolsy .nd the No. 31 STARTER
SGNAL 17.5 A) tuse.
-
Reolace the No. 31 STARTER
SI GNAL
(7. 5 Al f u3o i n t he
unde.-dash tusg/rolav box.
Chock l or ! n open i n t he wi t .
lFLn
line)l
nect or A
(32P).
the PGM-FI main relay 7P con-
nectorterminal No. 1 and ECM/
PCM connector terminal A16.
Ropair op6n in th. walo betwoan
t he ECM/ PCM l A16) and t hc
PGM-FI main rolaY.
Ch6ck f or an opon i n t h. wi . e3
l l cPl , l GP2l i nesl :
1. Reconnect the ECM/PCN4 con-
nector A
(32P).
2. Reconnoct t he PGM-Fl mai n
relay connector,
(ll)
ECM/PCM connector termanals
A11 and A10, and bet ween
A24 6nd A10.
Repeir opon in th6 wire bet-
ween ttre ECiA /PCM
(A11, A24)
and tho PGM-FI msin r.lty.
Rplac. tho FGM-FI main rc|.Y.
Check t or an open i n t he ECM/
PCM:
2, Measur e vol t age bet ween
A16 and A10 when t he i gni t i on
switch is lirst turned ON
(ll) for
two seconds.
Substituta a known-good ECM/
PCM and rechcck. lf
proacribod
voltege is now availablc, r.Place
the originll ECM/PCM.
l s t hero 1. 0 V or l ess?
Ch6ck t h. PGM- FI m. i n l ol ay
(.ee pagc 11-2371.
(' 96 -
98 model s)
t32Pt
IGP2
{YEL/BLKI
FLR
IGRN/YELI
PGl
3
l 5
6 7 l
l s l e l
t l 1 l
12 13
'ta
l 5 t 6
't7
t 8 t 9 20 221 23 2a
25 27 28 4t
(cont' d)
1 1- 239
IBLK)
{GRN/YELI
FLR
(GRN/YELI
2 3
( )
a 6 t
ECM/PCM CONNECTOR A
2 1 I l 0 t1
12 r3 1'al 5
't6
1' t t i 9 ml ,/ x2 23 2a
25 21 2e 29 3ol./
PGl
(BLK)
1 I
12
't/t
15 t 6 17 t 8 t 9 zi
25 27 2A 4t 30
4 l
Fuel Supply System
-
Repai r opn or short i n t he
wir betlveen the PGM-FI main
relay and the No. 31 STARTER
SIGNAL 17.5 A) fuse.
-
RoDlace the No. 31 STARTER
SI GNAL { 7, 5 Al t use i n t he
under-dash luse/rolay box.
(FLR
l i nel :
nect or A
(32P).
the PGM-FI main relay 7P con-
nector terminal No. 1 and ECM/
PCM connector terminal A16.
Repair open in the wir6 botween
t he ECM/ PCM
( A161
and r he
PGM-FI main relay.
{lGPl, lGP2 line3):
1. Reconnect t he ECM/ PCM con-
nector A {32P).
2. Reconnect t he PGM- Fl mai n
relay connector.
(ll).
ECN4/PCM connector terminals
81 and 820, and bet ween
Bg and 820.
-
Repair open in the wire bet-
ween t h. ECM/ PCM (81,
Bg)
snd the PGM-F main rolay.
-
Roplace th PGM-FI main relav.
Chock t or an open i n t h6 ECM/
PCM:
A16 and 82 when t he i gni t i on
switch is first turned ON lll) for
Sub3titute . known-good ECM/
PCM and rochock. lf prescribed
vohege is now available, replace
Choc k t he PGM- Fl m. i n r 6l ay
{see
p.ge 11-2371.
PGM-FI Main Relay
(cont'd)
_._(9x .
qq -gqerll
_
PGM.FI MAIN FELAY 7P CONNECTOR
{C4}
FLR
ECM/PCM CONNECTORS
A (32P1
Wi r e si de of f em6l e t er mi nal s
ECM/PCM CONNECTOR B {25PI
IGP2 {YEL/BLKI
I GRN/ YEL}
I GP2
(YEL/BLKI
11-240
I J
' l '
I
Fuel Tank
'96
-
98 models:
Replacement
I
1. Rel i eve the fuel
pressure (see pages \1-230' 23' l l '
(see
secti on 20).
3. Remove the access
panel from the fl oor'
4. Di sconnect the 2P
(C565) and 3P
(C564) connectors
(' 96
D]6Y8 engi ne
(coupe)
' 97
D16Y/ engi ne(coupe:
KL model '
sedanKL( LX) model ) . ' 97D' l 6YSengi ne( coupe: al l model s' sedan: KLmodel ' 98- al l model s) : and6P( C568) connec-
tor),
5. Disconnect
the hose and
quick-connect fittings
(see pag es'l'l-225' 2271
6. Jack up the vehi cl e, and support i t wi th
j ackstands'
7. Removethefuel
tank cover
(' 96,' 97
model ) orthefuel hose
j oi nt protector'
8. Bemovethedrai n
bol t,and drai nthefuel
i nto an approved contai ner'
9. Di sconnect
the hoses {see
page r i -i zst. Sri a" nu"i i he cl amps, then twi st hoses as you pul l , to avoi d damagi ng them'
10. Pl ace a
j ack.
or other support, under the tank'
11. Remove the strap nuts, and l et the straps fal l free'
12. Removethefuel
tank l f i t sti cks on the undercoat appl i ed to i ts mount' caref u l l y pry i t off the mount'
13. | nst a| | t hedr ai nbo| t wi t hanewwasher . t hencoat t hedr ai nbo| t wi t hNoxr ust l 24B, A| | owt heNoxr ust dr yf or 20mi n-
ules.
14. Instal l the remai ni ng
pans i n the reverse order of removal '
SASE GASKET
Repl ace.
BASE GASKET
Repl ace.
!@@
Do not smoke while working on fuel system' Keep open flame away from
your work ar'a'
TANK
STRAPS
DRAIN BOLT
,19
N.m {5.0 kgt m, 36 lbf.ftl
(cont' d)
11-241
Fuel Supply System
Fuel Tank
{cont'dl
39
- (xt
models:
Replac6ment
o
@
Do not smoke whire working on fuer system. Kep open frama away trom your
work area.
1. Rel i evethefuel pressure (see pages
11-230,23' l l .
2. Remove the seat cushi on l see secti on 2O).
3, Remove the access panel
fromthefl oor.
4. Di sconnectthe2P
(C565)
and3P(CS64) connectors and 6p
(C569)
connecror.
5. Di sconnect the hose and qui ck-connect
fi fti ngs
(see pages
1l -226,22j ),
6. Jack up the vehi cl e, and support i t wi th
j ackstands.
7. Removethefuel hose
j oi nt protector
and heat shi el d.
8. Removethedrai n bol t. and drai nthefuel i ntoan aporoved contai ner.
9 Di sconnect the hoses
(see page
11-226). Sl i de back the cl amps. then twi st hoses as you pul l ,
to avoi d damagtng rnem.
10. Pl ace a
j ack,
or other support, under the tank,
11. Remove the strap nuts, and l et the straps fal l free,
' 12.
Removethefuel tank. l f i tsti cks onthe undercoat appl i ed to i ts mount, careful l y pry i toffthe mount.
13. Instal l thedfai n bol twi th a new washer. then coat the d rai n bol t wi th Noxrust 124B,Al l owthe Nox.ust drv for 20 mi n-
utes.
14. Instal l the remai ni ng parts
i n the reverse order of removal ,
Repl ace.
DRAIN BOLT
,19
N.m
(5.0
kgf.m, 36lbf.ft)
11-242
Intake
Air System
\ J
System DescriPtion
The system supp| i es ai r for a| | engi ne needs' | t consi sts of the i ntake ai r pi pe' Ai r C| eaner
(ACL}, i ntake ai r duct, Thrott| e
Body
(TB), l dl e Ai r control
(l Ac) val ve and i ntake mani fol d. A resonator i n the i ntake ai r
pi pe provi des addi ti onal si l enci ng
as ai r i s drawn i nto the system.
D16Y5, D16Y8, 816A2 engine {M/Tl
YEL/ -
From PGM-FI
aLK
-
MA|N RELAY
BLK/
BLU
-- ORN
INTAKE
AIR
DUCT
IROTARYI
IAC VALVE
I aru
ENGINE
COOLANT
BLK/
INTAKE
AIR DUCT
I
D16Y5 engine
(CVT), D16Y8 engine
(A/T)'
f'ttlxr ,tla"tpoto
D16Y7 engi ne:
{ROTARY)
IAC VALVE
VARIOUS
SENSORS
INTAKE
AIR
PIPE
tr
RESONATOR
! r ,
IAC VALVE
BLK
11-243
lntake Air System
Ai r Cl eaner
(ACLI
NOTE: Do not cl ean t he ACL el ement i t wi t h com-
pressed
air {except dry type).
D16Y5, D16Y8, 816A2 engi ne:
ACL ELEMENT
Normal conditions:
Repl ace ai r cl eaner el ement every
30, 000 mi l es (48, 000
km) or 24
mont hs whi chever comes f i rst .
Svoae conditions:
(Use
normal schedul e
except in dusty conditions)
Replace every 15,OOO
mi l es (24, 000
km)or 12 mont hs
whichever comes first.
D16Y7 engi ne:
ACL ELEMENT
Normal conditions:
Repl ace ai r cl eaner el ement every
30, 000 mi l es (48, 000
km) or 24
mont hs whi chever comes f i rst ,
Seve.s conditions:
(Use
normal schedul e except
i n dust y condi t i ons)
Repl ace every l 5, 000
whi chever comes f i r st .
11-244
Throttle
Cable
Inspection/Adiustment
1. Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad ( i n
2. Check that the throftl e cabl e operates smoothl y wi th
no bi ndi ng or sti cki ng. Repai r as necessary.
3. Check cabl e free pl ay at the throttl e l i nkage. Cabl e
defl ecti on shoutd be 10- l 2 mm
(3/B -
112 i n.l .
D16Y5, D16Y8 engi ne:
CABLE
BRACKET
LOCKNUT
DEFLECTION
1 0 - 1 2 mm
BI A- 112 i nl
D16Y7 engi ne:
LOCKNUT
DEFLECTION
10- 12 mm
l3lA
-
lninl
\ J
816A2 engine:
DEFLECTION
1 0 - 1 2 mm
Bl a- 112i nl
CABLE ADJUSTING
BRACKET NUT
t
l f defl ecti on i s not wi thi n specs' l oosen the l ocknut'
turn the adj usti ng nut unti l the defl ecti on i s as speci -
fi ed, then reti ghten the l ocknut.
Wi th the cabl e
properl y adi usted, check the thronl e
val ve to be sure i t opens ful l y when
you push the
accel erator
pedal to the fl oor. Al so check the throt-
tl e val ve to be sure i t returns to the i dl e
posi ti on
whenever
you rel ease the accel erator
pedal '
LOCKNUT
lnstallation
Dl 6Y5, Dr6Y8, D16Y, ngi ne:
1. Open the throttl e val ve ful l y, then i nstal l the throttl e
cabl e i n the throttl e l i nkage, and i nstal l the cabl e
housi ng i n the cabl e bracket.
D16Y5, D16Y8 engins:
LOCKNUT
Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
( i n
Hol d the cabl e sheath. removi ng al l sl ack from the
caDl e
(cont' dl
11-245
Intake Air System
Throttle Cable
(cont'dl
4. Set t he l ocknut on t he cabl e br acket . Adj ust t he
adj usti ng nut so that i ts free pl ay i s O mm.
5. Bemove the cabl e sheath from the throttl e bracket,
reset the adj usti ng nut and ti ghten the l ocknut.
O16Y5, D16Y8 engi no:
ADJUSTING NUT
9. 8 N. m
{1.0 kgl.m,
1.2 tbt.ttl
DtGYT 6ngi ne:
11-246
816A2 engine:
1. Open the throttl e val ve ful l y, then i nstal l the throttl e
cabl e i n t he t hr ot t l e l i nkage. and i nst al l t he cabl e
housi ng i n the cabl e bracket,
THROTTLE LINK
LOCKNUT
ADJUSTING
NUT
Start the engi ne. Hol d the engi ne at 3.000 rpm wi th
no l oad
( i n
Hol d t he t hr ot t l e l i nk t o t he t hr ot t l e l ever ; t her e
should be no clearance.
Hol d the cabl e sheath, removi ng al l sl ack from the
cabl e.
Turn the adj usti ng nut unti t i t i s 3 mm
{1/8 i n.) away
from the cable bracket,
LOCKNUT
9. 8 N. m
(1. 0
kgt m,
7.2 tM.ttl
ADJUSTING NUT
Ti ght en t he l ocknut . The cabl e def l ect i on shoul d
now be 10
-
12 mm l 3/ B
-
1/ 2 i n. ) . l f nor . s ee
Inspecti on/Adj ustment.
3 mm 11/ 8 i n. )
I
Throttle
BodY
Description
The throttl e bodY i s ei ther a si ngl e-barrel
si de-draft type
(D16Y5, D16Y8, 816A2 engi ne) or a down-draft type
(D16Y/
engi ne). The l ower
porti on ot the throttl e val ve i s
heated by engi ne cool ant from the cyl i nder head' The
i dl e adj usti ng
screw whi ch regul ates the bypass ai r i s
l ocated on the top of the throttl e body
THROTTLE
POS|T|ON lTPl
SENSOR
IDLE AD.'USTING
SCREW
t
In3pection
1. Check t hat t he t hr ot t l e cabl e oper at es smoot hl y
wi thout bi ndi ng or sti cki ng.
l f there are any abnormal i ti es, check for:
. Excessive
wear or
play in the throttle valve shaft'
. StickY or binding throttle lever at the fully closed
Posi ti on.
. Clearance between throttle stop screw and throt-
tl e l ever at the ful l y cl osed
posi ti on'
D16Y5, Dl6Y8 engine:
THROTTLE
STOP SCREW
{Do not adjust.)
Dl6Y7 ongine:
816A2 engins:
THROTTLE LINK
STOP SCREW
THROTTTE STOP SCREW
(Do not adj ust . )
Replace the throftle body if thsre is excessive
play in the
throttl e val ve shaft or i J the shaft i s bi ndi ng or sti cki ng'
(cont' d)
11-247
{Do
not adjust.)
Intake Air System
\ r J
Throttle Body
(cont'dl
Removal
D16Y5, Dl 6Y8, 81642 engi ne:
D15Y7 engi ne:
AIR CLEANER
{ACLI
22 N.m
12.2 kgl.m,
16 rbf.ftl
NOTE:
. Do not adj ust the throttl e stop screw.
. After reassembl y, adj ust the throttl e cabl e
{see
page
l l -244).
. The TP sensor i s not removabl e.
IAT SENSOR
MAP SENSOR
GASKET
Repl ace.
11-248
THROTTLE CABLE
\
Disasssmbly
Dl 6Y5, Dl 6Y8 engi ne:
2. 1 N. m
(0. 21 ksf . m, 1. 5 l bl f t l \
b Y
TP SENSOR
MAP
SENSOR
11 115
3. 5 N. m t 0. 35 kgl m, 2. 5 l bl f t l
B16A2 sngine:
MAP SENSOR
Troubl eshoot i ng,
page 1 1' 1 15
IDLE AOJUSTING
MAP
SENSOR
1 1-1 19
z.'t N.m
10.21 kgf'm,
1.5 tbf.frl
TP SENSOR
11-249
Intake Air System
Fuel Injection Air
(FlA)
Controt System
I'99
-
00 Dl6yg enginel
Dsscription
When the engi ne runni ng
l engi ne cool ant bel ow 149oF
(6S"C)],
the fuel Inj ecti on Ai r
(FtA)
Control Val ve sends i ntake ai r to
the fuel i ni ectors.
E> : INTAKE
AIR
FUEL
INJECTOB
11-250
\ J
Fuol Iniection Air {FlA)
Contlol Valve T$ting
1. Start the engi ne.
2. Remove the vacuum hose from the fi tti ng on the
i ntake ai r duct, and connect a vacuum
gauge to the
nose.
NOTE: Engi ne cool ant temperature
must be bel ow
149"F
(65"C).
VACUUM PUMP/GAUGE,
0- 30 i n. Hg.
A973X
-
041
-XXXXX
Rai se and l ower the engi ne speed, and make sure
the vacuum
gauge readi ng changes as the engi ne
speed changes.
l f vacuum readi ng does not change check these
rtems:
. The vacuum l i nes of FIA system for mi srouti ng,
l eakage, breakage and cl oggi ng.
. The FIA controt valve for cracks or damage
. The cooling system
(see
section 10).
Hol d the engi ne at 3,OOO rpm wi th no l oad
(i n
Park
or neutral ) unti l the radi ator fan comes on, thn l et
i t i dl e and recheck.
l f vacuum readi ng changes check these i tems:
a The FIA control val ve for cracks or damage.
. The cool i ng system
(see
secti on 10).
11-251
Emission Gontrol System
System Description
The emission control system includes a Three Way Cata-
l yti c Convener
(TWC),
Exhaust Gas Reci rcul ati on (EGR)
system,. Positive Crankcase Ventilation (pCV)
system and
(EVAP)
Control system. The emi s-
sion control system is designed to meet federal and state
emission standards.
*:
D16Y5 engi ne
Tai l pi pe Emi ssi on
Inspestion
@@
Do not smoke during ihis procedure.
Keep
any open flame away from your work area.
1. Start the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
( i n
comes on. then l et i t i dl e.
Check and, i f necessary, adj ust the i dl e speed
(see
page 11-220
-
223).
Warm up and cal i brate the CO meter accordi ng to the
meter manufacturer' s i nstructi ons.
Check i dl e CO wi th the headl i ghts, heater bl ower,
rear wi ndow defogger, cool i ng fan, and ai r condi ti on-
er off.
NOTE:
( Canada)
Pul l t he par ki ng
br ake l ever up.
Start the engi ne, then check that the headl i ghts are
off.
CO mete. shoul d i ndi cate 0.1% maxi mum.
NOTE:
' 98
Dl 6Y5 engi ne
-
l f the i dl e speed i ncress-
es to 8101 50 rpm, thi s means the EVAp system i s
purgi ng
the cani ster. To stop the purgi ng
temporari -
l y. rai se the engi ne speed above 1,000 rpm wi th the
accel erator pedal , then sl owl y rel ease the pedal .
11-252
e
FORWARD
-
Three Way Catalytic Converter
(TWCI
Doscription
The Three Way Catal yti c Converter
(TWC)
i s used to
conven hydrocarbons (HC),
carbon monoxi de (CO),
and
oxi des of ni trogen
(NOx)
i n the exhaust gas
to carbon
di oxi de
(COr),
di ni trogen
(N,)
and water vapor.
D15Y5, D16\r, engine:
'99
-
00 D16Y8, 81642 engine:
ENGINE SIDE
t
\
l To420l
Th" """n toot i ndi cates Di agnosti c Troubte code
(DTc)
p0420:
catatyst sysrem effi ci ency bel ow threshol d.
Description
Thi s system eval uates the catal yst' s capaci ty by means of the Ho2s {Pri mary
and secondary) output duri ng stabl e dri vi ng
condi ti ons. l l deteri orati on has been detected duri ng two consecuti ve dri vi ng cycl es. the MIL comes on and DTC P0420 wi l l
be stored.
NOTE: l f some of the DTCS ti sted bel ow are stored at the same ti me as DTC P0420, troubl eshoot those DTCS fi rst. then
recheck for DTC P0420
P0137, P0138: Secondary HO2S
(Sensor 2)
Po14' 1:Secondary
H02S {Sensor
2) Heater
Possibl Cause
. TWC Deteri orati on
. Exhaust system l eakage
Troubleshooting
Flowchart
I
DTC P0420 is stored
1. Do t he ECM/ PCM Reset Proce
dure.
2 . St a r t t h e e n g i n e Ho l d t h e
engi ne at 3, 000 rpm wat h no
l oad {i n
3. Connect t he SCS servi ce con
4. Test dr i ve 40
-
55 mph f or
appr ox, t wo mi nut es Then
decel erat e f or at l east 3 sec_
onds wi t h t he t hr ot t l e com'
pl et el y cl osed- Then reduce
t he vehi cl e speed t o 35 mph,
a n d t r y t o h o l d i t u n t i l t h e
readi ness code comes on
Intermittent Iailure, system is OK
at t hi s t i me.
Check the TWC {see section 9l
lf necessary, replace the TwC
Exhaust Gas Reci rcul ati on
(EGR)
System
(D16yS
engi ne)
Doscription
The EGR system i s desi gned to reduce oxi des of ni trogen emi ssi ons
(NOx)
by reci rcul ati ng exhaust gas
through the EGR
val ve and the i ntake mani fol d i nto the combusti on chambers. l t i s composed of the EGR val ve. EGR vacuum conrrot vatve.
EGR control sol enoi d val ve. ECM and vari ous sensors.
The EcM contai ns memori es for i deal EGR val ve l i fts for varyi ng operati ng condi ti ons, The EGR val ve l i ft sensor detects
the amount of EGR val ve l i ft and sends the i nformati on to the ECM. The ECM then compares i t wi th the i deat EGR val ve l i ft
whi ch i s determi ned by si gnal s sent from the other sensors. l f there i s any di fference between the two. the EcM cuts cur-
rent to the EGR control sol enoi d val ve to reduce vacuum appl i ed to the EGR val ve.
EGR CONTROL
CVT: SOLENoID vALvE
EGN VALVE LIFT SENSOR
BLK
I
I
11-254
4
The scan tool i ndi cates Dl agnosti c Troubl e cod {DTc}
Po4ol : l nsuffi ci ent fl ow i n the Exhaust Gas Reci rcul ati on
(EGR)
svstem.
Doscription
Deteri orati on
(cl oggi ng, l eakage, etc.) i n the EGR l i ne or EGR val ve i s detected by means of the changes i n MAP before
and after the operati on of the EGR val ve.
l f deteri orati on has been detected duri ng two conscuti ve dri vi ng cycl es, the MIL wi l l come on and DTC P0401 wi l l be
stored.
Po$ible Causeg
. Cl oggi ng. l eakage i n the EGR l i ne
. Faul ty EGR val ve
\
-
Tho MIL ht! bacn rgportod on.
-
DTC m40l is 3torod.
Problom vorification:
dure.
2. Connect the SCS service con-
nector,
3. Tost -dri ve under t he f ol l owi ng
condi t i ons.
-
Without any electrical load
-
Decel erat e l rom 55 mPh
(88
km/ h)l or at l east 5 sec-
onos
lntormiftam f!ilu.a, ayltam ia OK
.t thb time,
-
Clo.n tho inttkc mlnifold EGR
port wittr carbursto. clotner.
-
Cl.an the
pa$lgo insido tho
EGR val vo wi t h crrburat or
cloanol or aoglaca tha vllvo.
Exhaust Gas Recirculation
(EGR)
System
(D16Y5
engine with GWI
(cont'dl
l Tl 49i l
T_he scan tool i ndi cates Di agnosti c Troubl e Code
(OTC)
P1491: A mal functi on i n the Exhaust Gas Reci rcul ati on
-
l Egh) svst em.
CvT l M/T see page 1l -2611:
J
EGR VALVE
LIFT SENSOR #16 HOSE
PUMP/ GAUGE, 0- 30 i n. Hs
A973X- 041- XXXXX
EGR
VALVE
DTC P1491 is stoled.
du re.
2. Connect t he SCS servi ce con'
l oad {i n Park or neut ral ) unt i l
t he radi at or f an comes on,
4. Dri ve t he vehi cl e on t he road
f or approx. 10 mi nut es. Try t o
keep t he engi ne speed i n t he
1, 700
-
2, 500 rpm range.
Intermittonl failure, system is OK
at this time. Check for Door con-
nections or loose wires at, C144
{EGR velve} and ECM/PCM.
l s DTC P l 49l i ndi cat ed?
Chec k f o. v ac uum t o i he EGR
1. Disconnect the No. 16 hose from
t he EGR val ve.
2 . Co n n e c t a v a c u u m p u mp /
gauge t o t he hose.
3. St ar t t he engi ne and l et i t i dl e.
l s t here any vacuum?
Check t or a mal f unct i on i n t he
EGR control solenoid valve:
' 1.
Di s c onnec t t he EGR c ont r ol
solenoid valve 2P connector,
2. Bec hec k t he No. 16 hos e f or
Check vacuum hose rout i ng o,
t he ent i re EGR svst em. l f hose
rout i ng i s OK, repl ac t he EGR
control solenoidvalv6.
l s t her e any vacuum?
PCM and r echeck. I t sympt om/
i ndi cal i on goes away, r epl ace
(To page 11 257)
11-256
\
EGR VALVE
LIFT SENSOR #16 HOSE
I
(From page 11-256)
EGR VALVE LIFT SENSOR
3P CONNECTOR lC14.l)
zF\
vccz
I- . ] IYEL/BLU)
l l
2 l 3 l - - - l
- r _ 7 |
v-,, I
SG2I GRN/ BLK) I ^ I
I{Vts
ECM CONNECTOR D {16P)
PUMP/ GAUGE, 0
-
30 i n. Hs
4973X- 041- XXXXX
sG2
(GRN/BLKI
vcc2
IYEL/BLU}
PCM CONNECTORS C
(31P}'
YES
1
(cont' d)
1-257
Check f o. a mal l unct i on i n t he
EGF valv:
1. ldove the vacuum
pump/gauge
t o t he EGR val ve.
2. Wi t h t he engi ne at i dl e, appl y
26. 7 kPa
(200
mmHg, 8. 0 i n. Hg)
of vacuum t o t he EGR val ve.
Does t he engi ne st al l or run
rough and does t he EGR val ve
hol d vacuum?
I VCC2l i nel :
2. Di sconnect t he EGR val ve l i f t
sensor 3P connect or.
(l l ).
EGR val ve l i f t sensor 3P con'
nect or t er mi nal s No. 3 and
No . 2 .
l s l her e appr ox. 5 V?
Check f or an oDen i n t he wi re
{VCC2 line}:
ECM/ PCM connect or t er mi nal s
D10 and Dl 1
(C18
and C28)*.
Rep.ir open in the wire between
r he EGR val ve snd ECM/ PCM
{Dl0 {C28)*).
l st her e appr ox. 5 V?
Sub3titute t known-good ECM/
PCM end recheck. lt 3ymptom/
i ndi cat i on
goos eway, repl ace
th6 original ECM/PCM. ( To page 1l - 258)
*:
' 99
-
00 model s
(EGRI
System
(Dl6Y5
engine with CW)
(cont'dl
EGR VALVE LIFT SENSOR
3P CONNECTOR {Cl251
./
EGR L
(WHT/BLKI
EGR L
IWHT/BLKI
EGR L
{WHT/BLKI
sG2
{GRN/BLK}
sG2
{GRN/BLK}
Termi nal si de ol mal e t ermi nal
ECIT'I CONNECTOR D II6PI
Wir side of fmale terminals
PCM CONNECTORS C
(31PI*
{To
page 11-259)
11-258
{From
page 11-257}
Chock lor an opcn or short in th.
EGR v.lve lift .nsor
' 1.
2. At t he sensor si d, measur
resi st ance bet ween t he EGR
valve lift sensor 3P connector
t ermi nal s No. 1 and No. 2.
ls there continuity or resis'
t ance ot 100 k0 or hi gher?
Chock tor sn opn or lhort in the
EGR valve lift lonror:
Measure resi st ancg bet ween t he
EGR val ve l i f t snsor 3P connec-
t or t ermi nal s No. 1 and No. 3.
l s t here 100 k0 or hi gher?
Ch.ck tor an ooon or rhon in thc
wiro IEGRL linc):
1. Beconnect t ho EGR v6l ve l i f t
sensor 3P connect or.
2. Turn tho ignition switch ON
(ll).
D9 and Dl 1
(C6
and C18l *.
(To page 11-259)
I
I
PCM CONNECTORS C
(31P)*
ECM CONNECTOR O {I5PI
t
(From page 11-258)
Check f or a 3hort i n t he wi re
{EGRL
l i nel :
ECM/ PCM connect or t ermi nal Dg
Repair opn in the wire between
th6 EGR valve and the ECM/PCM
(D9
tc6trt.
ReDair short in the wirc batweon
the EGR valve and ECM/PCM {Og
(c5t*).
( Fr om page 11- 258)
11, 260)
Check ths vacuum routing:
' 1.
Recon nect t he vacuum
pump/ gauge t o t he No. 16
hose.
3. At t he EGR cont rol sol enoi d
val ve si de, connect t he bat -
t ery posi t i ve t ermi nal t o t he
EGR cont r ol sol enoi d val ve
connect ot t ermi nal No. 1.
4. Whi l e wat chi ng t he vacuum
gauge, connect t he bat t er y
negat i ve t ermi nal t o t he EGR
cont rol sol enoi d val ve 2P con-
nect or t ermi nal No. 2,
l s t here approx. 26. 7 kPa
1200
mmHg, 8. 0 i n. Hg) of
vacuum wi t hi n
' l
second?
Chock the vlcuum hos6s:
2. I nspect t he No. 16 and No. 10
hoses for leaks, restrictions or
mt srouUng.
EGR CONTROL SOLENOID VALVE
2P CONNECTOR
Terminal side oI
mal e l ermi nal s
(cont' d)
11-259
(EGR)
System
(Dl6Y5
engine with CW)
(cont'dl
t J
(From page 11-259)
EGR CONTROL SOLENOID
VALVE 2P CONNECTOR {C142}
Wi re si de
of lemale
t ermi nal s
ECM
CONNECTOR
a t32Pl
Chock lor an open in the wire
(E
SOL linsl:
I rom t he EGR cont rol sol enoi d
3. Disconnect the ECN4/PCM con-
nect or A
(32P) (B (25P))*
f rom
the EcM/PCM.
ECM/ PCl , connect or t ermi nal
47
(86)*
and t he EGR cont rol
sol enoi d val ve 2P connect or
t er mi nal No. 2.
Repair opon in th. wir. bstwocn
tha EGR control 3olnoid valvo
and tho ECM/PCM
(A7
186l'1.
Check f or . rhort i n t he wi re
(ESOL
linel:
EGR controlsolenoid valve 2P con-
ground,
R.p.ir ahort in tha wi.c b.twecn
the EGR control iolonoid vllye
and th. ECM/FCM
{A7
(46}rl.
Check f or an opon i n t he wi ro
I GND l i nel :
EGR cont rol sol enoi d vai ve 2P con-
nect or t ermi nal No. I and body
ground,
Rcpai. opn in the wir6 b6'twoen
the EGR control rol.noid valve
and G101.
Sub3titule a known-good ECM/
PCM and rechock. lf symptom/
i ndi cat i on goes away, r epl ac
ESOL
IRED)
ESOL
I RED)
Wi re si de
of f emal e
t ermi nal s
-
-_-]
I
EGR CONTROL SOLENOID
VALVE 2P CONNECTOR ICl'2}
Wi re si de
of f emal e
i l
t ermi nal s
ECM
CONNECTOR
B l25P)
ESOL
(REDI
Wi re si de
of f emal e
rermt nat s
*:
' 99
-
00 model s
11-260
\ J
Exhaust Gas Recirculation System
(D16Y5
engine with M/T)
M/T:
EGR VALVE 6P CONNECTOB
(C14'rl
G10l
IBLK}
1
a
PNK
IE.EGRI
Wi 16 si de of mal e t ermi nal s
I
sG2
{GRN/
BLK}
vcc2
{YEL/
BLU)
-
Th6 MIL ha3 bon reponed on.
-
DTC Pl,{tl is 3tored.
Prcblem verification:
2. Connect t he SCS servi ce con_
nect or.
l oad
(t ransmi ssi on i n neut ral )
unt i l t he radi at or f an comes on.
4. Dri ve t he vehi cl e on t he road
for approx. 10 minutes. Try to
keep t he engi ne speed i n t he
1,700
-
2,500 rpm range.
lnlermittont tailure, svalem is OK
at thi3 tim6. Check foi Poor
con'
nections or looso wiro3 at Cl/K
IEGR valvsl and ECM.
Check t or a mal f unct i on i n t he
EGR valv6:
2. Di sconnect t he EGR val ve 6P
connector.
3. St ant he engi ne and l et i t i dl e
EGR val ve 6P connect or t ermi '
nal s No. 4and No. 6.
Check the EGR valve:
EGR valve 6P connector termi
nal s No. 2 and No. 3.
and recheck. It symptom/indica_
tion
goes away, replace th origi-
nal ECM.
l s t here approx. 5V?
(To page 11-262)
( Fr om page 11- 261)
Check tor open in the wire (SG2
l i nel :
ECM c o n n e c t o r t e r mi n a l s D1 0
a n d D1 1 .
Repsir open in lhe wire beiween
ECM l Ol l l and EGR val ve.
2, At t he sensor si de, measur e
resi st ance bet ween t he EGR
val ve 6P connect or t ermi nal s
No. 1 and No. 2.
l s t her e cont i nui t y or r esi s-
t ance of 100 k0 or hi gher?
Measure resi st ance bet ween t he
EGR val ve 6P connect or t er mi
nal s No. 1 and No. 3.
l s t here 100 k0 or hi gher?
(D16Y5
engine with M/T)
(cont'dl
ECM CONNECTOR D {16P)
vcc2
(YEL/BLU)
\ v
sG2
IGRN/BLK)
Wi re si de of f emal e t erm; nal s
EGR VALVE 6P CONNECTOR
EGR L
(WHT/
BLK}
SG2
(GRN/BLK)
Termanal si de of mal e t ermi nal s ' l '
EGR L
{WHT/
BLK}
vcc2
{YEL/BLU}
(To pase 11 263)
1
-262
T
t
l From
page 11-262)
Chock f or rn opon i n t he wi re
{EGR L l i nel :
1. Reconnect t he EGR val ve con
nector.
2. Tu. n t he i gni t i on swi t ch ON
(l l ).
3. Measure voltage betweon the
PCM connect or t ermi nal s Dg
and Dl 1.
Check tor th wirc
(EGR
L line):
ECM connect or t ermi nal Dg and
body ground.
Roprir op6n in the wirs botwean
the EGR valvo.nd th. ECM lD9).
Rooair ahort in tho wiro baftr,otn
tho EGR v.lv..nd the ECM lDgl.
Chck the EGR valve:
2. Di sconnect t he EGR val ve 6P
connector.
3. Connect t he bat t ery
posi t i ve
terminal to EGR valve 6P con-
nectorterminal No. 6.
4. Stan the engine and let it id'e,
then connect the battery nega_
t i ve t ermi nal t o EGR val ve 6P
con nector term inal No, 4,
ECM CONNECTOR D I16P'
EGR VALVE 6P CONNECTOR
wire sid6 of lemale te.minals
(cont' d)
(Dl6Y5
engine with M/Tl
(cont'dl
l From
page 11 263)
EGR VALVE
6P CONNECTOR {C144}
J
Wi re si de
of f emal e
t ermt nal s
J
Check lor an opn in the wire
(E-
EGR l i ne):
2. Disconnect the ECM connector,
A
(32P)t rom
t he ECM.
ECM connect or t er mi nal A7
and t he EGR val ve 6P connec-
t ort ermi nal No. 6.
Repair open in the wiro botween
t he EGR val v6. nd t h ECM {A71.
Check tor a short in the wire {E-
EGR l i n6l :
ECM connect or t ermi nal A7 and
body ground.
Reoair shorl in tho wiro belwen
the EGn vake rnd the ECM lA7l.
Check f o. an open i n t ho wi ro
I GND l i ne):
EGR val ve 6P connect or t ermi nal
No. 4 and body gr ound.
R6pai. open in th wir. between
t h6 EGF cont rol sol enoi d v6l ve
and G101.
Subst i t ut e 8 known-good ECM
and recheck. It symptom/indica-
tion goes away, roplace the origi-
nal ECM.
CONNECTOR
A
l 32P)
2
a
I G101
Q)
raur
-264
J \
The scan tool i ndi cates Di agnosti c Troubl e
Reci rcul ati on
(EGRl val ve
l i ft sensor ci rcui t.
(D16Y5
engi nel
Code {DTC) P1498: A hi gh vol tage probl em i n the Exhaust Gas
EGR VALVE LlFf SENSOR 3P {M/T: 6Pl CONNECTOR
(C1441
cvT:
vcc2
{YEL/BLUI
SG2 IGRN/BLK)
I
M/T:
sG2
{GRN/
BLKI
Wir side ol lemale terminals
ECM CONNECTOR D
(16P)
vcc2
(YEL/BLUI
sG2
(GRN/BLK)
Wi r si de of f emal e t ermi nal s
PCM CONNECTORS C 131P)'
11-265
-
-
DTC P1498 is storod.
Problm verification:
dur e.
Intermittent tailure, sy3lem is OK
at lhis time. Check tor
poor con'
nections or loose wire3 at C144
|EGR valvel and ECM/PCM.
Check f or an open i n t ho EGR
valv6 lift sen3or:
2. Di sconnect t he EGR val ve l i f t
sensor 3P
(M/ T:
6Pl connect or.
(l l ).
EGR valve litt sensor 3P lM/T:
6P) connect or t ermi nal s No. 3
and No. 2.
Check lor opn in th wire
(SG2
l i ne):
PCM connect or t ermi nal s 010 and
D1l
(C18
and C28)*.
Repair open in tho wiro betwoen
ECM/ PCM l Dl 1
(Cl 8)r)
and EGR
valvo lift sensor.
Substitute . known-good ECM/
i ndi crt i on
goes away, repl aco
the original ECM/rcM.
*: ' 99 -
00 D16Y5 engi ne wi t h CVT
Positive Crankcase Ventilation
IPCVI
System
Descripiion
The Posi t i ve Cr ankcase Vent i l at i on
( PCV)
syst em i s
desi gned to prevent bl ow-by gas from escapi ng to the
atmosphere. The PCV val ve contai ns a spri ng-l oaded
pl unger. When the engi ne starts, the pl unger
i n the PCV
val ve i s l i fted i n proporti on to i ntake mani fol d vacuum
and the bl ow-by
gas i s drawn di rectl y i nto the i ntake
mani fol d.
D15Y5, D16Y8, 816A2 ongins:
BREATHER
HOSE
Dl6'|11 6ngin6:
-: aLOW-BY VAPOR
-: FnESH AIF
11-266
tJ
lrcpection
1. Check the PCV hoses and connecti ons for l eaks and
cl oggi ng.
2. At i dl e, make sure there i s a cl i cki ng sound from the
PCV val ve when the hose between the PCV val ve
and the i ntake mani fol d i s l i ghtl y pi nched wi th your
fi ngers or pl i ers,
D16Y5, D16Y8 ongins:
BREATHER
HOSE
PCV VALVE
Gent l y
pi nch here.
Bl6A2 engins: VALVE
l f there i s no cl i cki ng sound, check the PCV val ve
grommet for cracks and damage. If the grommet i s
OK, repl ace the PCV val ve and recheck.
PCV
1 \
Evaporative Emission
(EVAPI
Controls
Description
The evaporati ve emi ssi on control s are desi gned to mi ni mi ze the amount of fuel vapor escapi ng to the atmosphere. The
system consi sts of the fol i owi ng components:
A. Evaporative Emission
(EVAP)
Control Canisto]
An EVAP control cani ster i s used for the temporary storage of fuel vapor unti l the fuel vapor can be
purged from the
EVAP control cani ster i nto the engi ne and burned.
B. Vapor Purge Control System
EVAP control cani ster
purgi ng i s accompl i shed by drawi ng fresh ai r through the EVAP control cani ster and i nto a port
on the i ntake mani fol d. The purgi ng vacuum i s control l ed by the EVAP purge control sol enoi d val ve.
I ' 96
D16Y5 engi ne, ' 96 Dl 6Y7 engi ne, ' 96 D16Y8
engi ne
( s edan) , ' 97 D16Y5 engi ne, ' 97 D16Y7
engi ne
( couper KA, KC model s, sedan: KA, Kc'
KL i DX)
model s , hat c hbac k : al l model s ) ,
' 97
D 16Y8 engi ne
(sedan:
KA, KC model s)l
I ' 96 D16Y8 engi ne
( c oupe) , ' 97 D16Y7 engi ne
( c oupe:
KL model , s edan: KL
( LX) model ) " 97
D16Y8 engi ne
(coupe:
al l model s, sedan: KL model )
' 98-al l
model s,' 99-al l model s,' 00-al l model sl
I
c.
D.
or
l ' l c COMPRESSOR CLUTCH ON
and
INTAKE AIR TEMPERATURE ABOVE 160"F
(41' C)
Fuel Tank Vapor Control System
When fuel vapor
pressure
i n the fuel tank i s hi gher than the set val ue of the EVAP two way val ve, the val ve opens and
regul ates the fl ow of fuel vapor to the EVAP control cani ster.
Onboard Refueling Vapor Recovery
(ORVRI
System {'99
-
00 models}
Duri ng refuel i ng. the oRVR {onboard
Refuel i ng Vapor Recovery) vent shut val ve opens wi th the
pressure i n the fuel
tank. and feeds the fuel vapor to the EVAP control cani ster.
t (cont ' d)
11-267
EVAP PURGE CONTROL SOLENOID VALVE DUTY CON-
TROLLED AFTER STARTING ENGINE
ENGINE COOLANT TEMPERATURE ABOVE 154' F {68"C)
INTAKE AIR TEMPERATURE ABOVE 32' F
(O' C)
and
VEHICLE SPEED ABOVE O MILE
(O
KM/h}
ENGINE COOLANT TEMPERATURE ABOVE 154' F
(68' C)
IEVAPI
Controls
(cont'd)
' 96
D16Y8 ongi ns
(coupol .' 97
D16Y8 ngi no
(coups:
al l modl s, sedan: KL model ),' 98 D16Y5 engi ne
(al l
mod6l sl ,' 98
Dl5YB engine {all modols):
{
BLK/
YEL
From
<
No. 15
FUEL
TANK
PRESSURE
SENSOR
EVAP PURG
CONTROL
SOLENOID VALVE
.
LT GRN
GRN/
BLK
ALTERNATOR
SP SENSOR
(7. 5
A)
VARIOUS
SENSORS
YEL/
BLU
VNT SHUT
EVAP
BYPASS
SOLENOID
VALVE
L
BLU
WHT
RED/
YEL
L __
LT GRN/
EVAP
TWO WAY
VALVE
INTAKE
MANIFOI.I'
'97
D16Y7 engin.
(coupa:
KL model, sedan: KL {LX) model},38 Dl6\r/ engine:
?:y-
-<
From
No. 15
ALTERNATOR
SP SENSOR
17. 5 A)
FUEL
TANK
PRESSURE
SENSOR
YEL/
BLU
LT G]
GRN/
BLK
LT GRN/
WHT
BLU
YEL
EVAP
BYPASS
RED/
VALVE
EVAP
TWO WA
VALVE
EVAP CONTROL
CANISTER
FUEL FILL
CAP
BLK
11-268
FUEL TANK
J
'96
Dl6Y5 engine,'96 D16Y8 engine
(sodanl,'97
Dl6Y5 sngino,'97 Dl6Y8 sngine
(sedan:
KA, KC modols):
EVAP
TWO WAY
EVAP
PURGE
CONYROL
SOLENOID
VALVE VAL
From
No. 15
BLK/YEL__
_
<
ALTERNATOR
-
SP SENSOR
FUEL
FILL
CAP
VARIOUS
SENSORS
(cont' d)
11-269
I
'96
D16Y' engin.,.9? D16Y7 engine {coupe:
KA, KC models, sedan: KA. KC, Kl- IDX)
modols, hatchback: all models}:
From
No. 15
3lI/-
- - -{
ALTERNAT'R
SP SENSOR
RED/
YEL
EVAP
PUBGE
CONTROL
SOLENOID
VALVE
FUEL
FILL
CAP
8LK
+
t \,"ro*,
MANIFOLD
(EVAPI
Controls
(cont'd)
' 99
-
00 Dl 6Yg engi ne,' 99
-
00 Dl 6Y5 ngi ne,' 99
-
00 81642 engi ne:
FUEL
TANK
PRESSURE
SENSOR
EVAP
BYPASS
SOLENOID
VALVE
From
BLK/ -
No. 15
YEL
_ ALTERNATOR
SP SENSOR
{7. 5 A)
- GRN/
BLK
BLU
*=ol
LT GRN/
WHT
ONBOARD REFUELING
FUEL TANK
EVAP PURGE
CONTROL
SOLENOID VALVE
EVAPORATIVE
EMISSION {EVAP)
CONTROL
CANISTER
FILTER
YEL
LT GRN
VAPOR RECOVERY IONVR) VENT
SHUT VALVE
ONBOARD REFUELING
VAPOR RECOVERY IORVN} VAPOR
RECIRCULATION VALVE
'99
-
00 D16Y7 engine:
EVAP CONTROL
CANISTER
BLK/
YEL
From
No. 15
< ALTERNATOR
SP SENSOR
{7. 5 A}
FUEL
TANK
PRESSURE
SENSOR
EVAP
EYPASS
SOLENOID
VALVE
-
BLU
LT GNN/
WHT
EVAP PURGE
CONTROL
SOLENOIO VALVE
INTAKE
MANIFOLD
EVAP
TWO WAY
VALVE
FUEL TANK
ONBOARD REFUELING
VAPOR RECOVERY
{ORVRI VENT
SHUT VALVE
EVAPORATIVE
EMISSION {EVAPI
CONTROL
EVAP CONTROL
ONBOARD REFUELING
VAPOR RECOVERY IORVRI VAPOR
RECIRCULATION VALVE
CANISTER
FILTER
YELI
8LK
11- 270
CANISTER
\ J
\
,96
D16Y5 engine,,96 D16r,gngino,,96
Dt6Y8 engine {3edan)'
37 D16Y5 engino..97 D16r, engine {coupe:
KA, Kc mod-
els. sedan: KA, KC, KL {DX}
models. hatchback: all modols}''97 Dl6Y8 ongine
(sdan: KA' KC modlsl:
(DTC)
P0441: Evaporati ve Emi ssi on
(EVAP)
control system
i nsuffi ci ent
purge fl ow.
Description
By moni tori ng the
purge l i ne vacuum wi th the MAP sensor, the ECM/PCM can detect i nsuffi ci ent EVAP control system
purge fl ow.
Possible Cau3e
. EVAP Purge Control Sol enoi d Val ve
. EVAP Purge Control Sol enoi d Val ve Ci rcui t
. EVAP Control Canister
. Vacuum Li nes
. ECM/PCM
Troubl93hooting
Flowchart
Wire side of female
t ermi nal s
EVAP PURGE CONTROI-
sottNotD vALvE 2P
CoNNECTOR
(Cl1al
r-+-r
I ' l ' l
lG-ro.*l'rr"r
O)
Y
(cont'd)
11-271
-
The MIL has bsGn.eportad on.
-
DTC milal k rtored.
Pioblem vsrificJtion:
engi ne at 3, 000 rPm wi t h no
l oad {i n Park or nout ral ) unt i l
the radiator fan comes on.
2. Do the ECM/PCM Reset Proce'
dure,
nector.
4. Test-drive under following con-
ditions on the road
-
Without any electrical load
-
A/ T i n
E
or
E
Posi t i on
(M/T in 3rd-sth
gear)
-
Engi ne sPeed bet weon
1,200
-
2.400 rpm.
-
Decelerate {rom 50 mph
(80
knl/h)to 15 mph
(24
km/h)
lntormittont lailuro, sFtorn b OK
at thi. timo. Chck tor
Poor
con'
ncction3 or looac wir.3 at C144
{EVAP
purgo cont rol t ol onoi d
vrtv.l .nd ECir/FCttl.
ls DTC P0441 indicatod?
Ch.ck fo. !n opn in the wiro l|(il
linel:
2. Di sconnect t he EVAP
Purge
cont rol sol enoi d val ve 2P con_
necl or,
(ll)
4. Measur voltage between body
ground and t he EVAP
Purge
control solenoid valve 2P con-
nector terminal No 1.
Rop.ir opor in tho wir6 btwon
the EVAP
purgo codtiol tolonoid
v.lvo rnd tho No 15 ALIERNA'
TOR SP SENSOR 17.5
A)lu.o.
{To
page 11-272)
(EVAPI
Controls
(cont'dl
(From page
11-271)
I
ECM/PCM CONNECTOR D I32P}
PGl IBLKI
Check t he EVAP purge
cont rol
solenoid valvei
1. Reconnect t he EVAP pur ge
cont rol sol enoi d val ve 2P con-
nect or.
t ermi nal s A15 and 410 wi t h a
Check for an open or short in the
wire (PCS
line):
PCM connect or t ermi nal A15 and
body gro! nd.
Does t he sol enoi d val ve cl i ck
when t he
j umper
i s connect ed?
Che'ck for a short in the wir6 {PCS
line):
nect or A (32P).
3. Di sconnect t he EVAP purge
cont rol sol enoi d val ve 2P con
nector.
Repai. short in the wir6s betwoon
the EVAP purge
control solanoid
valve and ECM/rcM lA15l.
Rpair opn in the wir$ betwon
tho EVAP purge
control solenoid
valve and ECM/rcM lA15l.
Check the vacuum lin3:
Check t he vacuum l i nes ol EVAP
syst em f or mi srout i ng, l eakage,
breakage and cl oggi ng.
Are t he vacuum l i nes OK?
PCS {REO/YEL)
t 3 8 9 t 0
' t t
12 l 3
'I't
t 5 t 5
'11
I E 19 20 23 2a
?5 21 2A 29 30
PCS {RED/YEL)
2 3 a 6 7 E 9 t 0 I t
12 t 3
'ta 't5
l 6 17 t a 19 20 22 23 21
2a 27 28 A 30
0)
Pcs
{REo/YELI
- 272
J \
(From page 11-272)
D16Y5 engi ne:
JUMPER WIRE
VACUUM
PUMP/
GAUGE,
VACUUM
PUMP/
GAUGE,
0
-
30 in.Hg
As73x
-
0il1
-
xxxxx
0
-
30 in.Hg
A973X
-
otl
-
xxxxx
I
EVAP CONTROL
CANISTER
ECM/PCM CONNECTOH D I32PI
VACUUM/
PBESSURE
GAUGE0- 4i n. Hg
07JAZ
-
0010008
D16Y7, Dl 6Y8 engi ne:
t
VACUUM/PRESSURE
GAUGE
0- 4 i n. Hg
o?JAZ
-
001fl)OB
(cont' d)
11-273
PGl IBLKI
Check l he EVAP
Purge
cont rol
solsnoid valve:
1. Di sconnect t he vacuum hose
from the EVAP controlcanister'
2. Connect t he vacuum
PumP
t o
t he hose and aPPI Y vacuum
Does i t hol d vacuum?
Check the EVAP control canister:
1. Reconnect the vacuum hose to
the EVAP control canlster.
2. Connect t he vacuum/ Pressure
gauget o t he
Purge
aar hose
t ermi nal s A15 and A10 wi t h a
i umper
wi re.
5. Check t he vacuum
Check t he EVAP t wo way val ve
(see page 11-193)
Does the EVAP two waY valve
Replace the EVAP two wsY valve.
PCM . nd recheck. l t symPt om/
indicrtion
go6s away, rePlace the
original ECM/PCM.
D16Y5 sngi n:
(EVAP)
Gontrols
(cont'd)
'99
-
0O models only:
(DTC)
P0451: The Fuel Tank Pressure sensor ci rcui t range/
oerformance Drobl em.
ECM/PCM CONNECTORS
wi re si de ot f emare t ermi nars
sG2 I GRN/ BLK)
FUEL TANK
PRESSURE
SENSOR
VACUUM
PUMP/ GAUGE, 0
-
30 i n. Hg
FUEL TANK
PRESSURE
SENSOR
ASSEMBLY
EVAP TWO
WAY VALVE
I J
t l '
Ths MIL has been reDortgd on.
DTC m/$1 i3 stored.
Check the tuel tank pros3ure
ser|-
sor:
dure.
2. Remove t he t uel l i l l cap.
(ll).
4. N4oni t or t he FTP Sensor vol t -
a g e wi t h t h e Ho n d a PGM
Test er , or measur e vol t age
bet ween body gr ound
and
ECN4/PCM connector terminals
A29 and C18.
l s t here approx. 2. 5 V7
Check tho tuel tank pressure
!on-
soa:
1. Remove t he f uel t ank
( see
page 11 2421.
2. Remove t he f uel t ank pr es-
sur e sensor assembl y f r om
t he f uel t ank.
3. Connect t he f uel t ank Pressure
Sensor sub- har ness 6P con-
nect or t o t he access panel
si de connect or,
4. Disconnect the hose between
t he EVAP t wo way val vg and
the fuel tank pressure
sensor at
the EVAP two way valve end.
5. Connect a vacuum pump
t o
t he open end of t hat hose.
(ll).
7. Moni t or t he FTP Sensor vol t ,
age wi t h t he Honda PGM
between ECM/PCM connector
t er mi nal s A29 and C18, and
carefully pump vacuum on the
hose one stroke at a time.
8. The vol t age sho! l d smoot hl y
drop from the stading approx.
2. 5 V down t o approx.
' 1. 5
V.
STOP appl yi ng vacuum when
the voltage drops to approx. 1.5
V or damage t o t he f uel t ank
pressure
sensor may occur.
Does t he vol t age drop t o
approx. 1. 5 V and hol d?
PCM and r6check. I t sympt om/
indicltion
90e3
aw.y, replac\. th
original ECM/PCM.
A
(32P)
A973X
-
041
-
xxxxx
11- 274
\ J
Fuel Tank Pro3sure sensor 196 D16Y8 engi ne
(coupe).' 97 D15Y7 engi ne {coupe:
(LX)
modeu,' 97
D16Y8 engine
(coupe: all models, sedan: KL model,
'98-all
models)
'99
-
00 D16Y5 engine with M/Tl:
\
PTANK
{LT GRNI
vcc2
(YEL/BLU}
FUEL TANK
PRESSURE SENSOR
3P CONNECTOR
(C7921
sG2
I GRN/ 8LK)
Foc2l : : i l " : " t ool i ndi cat esDi agnost i cTr oubl ecode( DTc) P0452: A| owvo| t agepr ob| emi nt heFue| TankPr essur e
The fuel tank
pressure sensor converts fuel tank absol ute
pressure i nto el ectri cal si gnal s and i nputs the EcM/PCM.
OUTPUT
VOLTAGE
tvt
4.5
-?
kPa
(-50 mmHg,
-2
i n. Hg)
ECM/PCM CONNECTOR O I16P)
+7 kPs
150 mmHg,
2 i n. Hg)
PRESSURE
(cont' d)
11-275
-
-
Check the vacuum lines:
Check t he vacuum l i nes of t he
f uel t ank
pressure sensor f or mi s-
r out i ng, l eakage, br eakage and
cl oggrng.
Problem vritication:
dure.
2. Remove t he l uel f i l l caP.
3. Turn t he i gni t i on swi t ch ON l l l )
4. Moni t or t he FTP Sensor vol t _
bet ween bodY
gr ound and
ECM/ PCM t ermi nal Dl 5.
lntermittent tailuro, sYstem i5 OK
dt this timo. Chock for
Poot
con-
neciion3 or loose wir* at C131
llocatod
under right side ot dashl,
C4O1
(located
.bove under'da3h
t uso/ i el ay box), C574 1C568)*
{l ocat ed
under accss Panel l .
C792 lfuel tank
pressule sen3or)
and EcM/PCM.
Check tol an opn in wite
(VCC2
l i ne):
2. Rei nst al l t he f uel f i l l caP.
3. Di sconnect t he f uel t ank
Pres'
sure sensor 3P connect or-
(ll)
5, Measure voltage between the
f uel t ank pressure sensor 3P
connect or No. l t ermi nal and
No. 2 t ermi nal .
Repair open in the wite between
the fuel tank Prs3ure
an3or and
th6 EcM/PcM
(D1ol.
(To page 11' 276)
(EVAP)
Controls
(cont'dl
!
FUEL TANK
PRESSURE SENSOR
3P CONNECTOR
{C7921
PTANK
{LT GRN)
sG2
{GRN/BLK)
Wire side of fmal terminals
{From
page
11-275)
Check t o. ! short i n t he wi ro
IPTANK linol:
firel tank pressure
sensor 3P con-
nect or No. 3 t ermi nal and No. 2
t ermi nal ,
Check f o. a Short i n t he wi re
IPTANK IinoI:
2. Disconnect the ECM/PCM con,
nect or D 116P).
t he f uel t ank pressure
sensor
3P connect or No. 3 t ermi nal s
and body ground.
Repair thort in thc wire betwean
tho fuel iank
pre$uro
3naor and
ECM/FCM tDl5t.
ls there continuity?
Substitute ! known-good ECM/
PCM and recheck. lf .ymptom/
indication go6s
awry, repleco th6
origin.l ECM/PCM.
PTANK
{LT GRNI
-276
\
' 99
-
00 model s excepi Dl 6Y5 engi ne wi th M/T:
(DTC)
probl em i n the Fuel Tank Pressure
sensor.
The fuel tank
pressure sensor converts fuel tank absol ute
pressure i nto el ectri cal si gnal s and i nputs the ECM/PCM
OUTPUT
VOLTAGE
(vl
t.5
0.5
-7
kP.
(-g)
mmHg,
-2
i n. Hgl
+7 kP.
150 mmHg,
2 i n. Hgl
PRESSURE
I
FUEL TANK
PRESSURE SENSOR
SUB.HARNESS
6P CONNECTOR
(C574 (C568)rl
vcc2
(YEL/BLUI
sG2
{GRN/BLK}
Wi re si de o{ t emal e t ermi nal s
The MIL has been .eported on.
DTC P0452 is stored
Check t he vacuum l i nes of t he
f uel t ank
pressure sensor l or mi s-
cl oggrng.
Are t he vacuum hnes OK?
du re,
2. Bemove t he f uel f i l l caP.
3. Turn t he i gni t i on swi t ch ON {l l )
4. Monitorthe FTP Sensor voltage
with the Honda PGM Tester' or
measure voltage between body
groLrnd and ECM/PCM connec_
t or t ermi nal A29.
lntermitlent tailure, 3Ystem b OK
at this time. Check for
Poor
con'
nections or loose wire3 at C131
{located
under right side of dash},
C401 {located
above under'dash
t use/ rel ay box), C574
(C568)*
l l ocdt ed
under access Panel ) ,
C792
(tuel
rank Prcssure
sensorl
and ECM/PCM.
Check for an open in wire {VCC2
l i ne):
2. Rei nst al l t he l t rel f i l l caP
3, Remove the access
Panel
from
the floor.
Pres'
sur e sensor sub- har ness
6P
(l l ).
6. At the access Panel
side, mea_
sure voltage between the fuel
t ank Pressure
sensor sub-nar-
ness 6P connect or No 5t ermi
nal and No. 6 t erml nal .
Repair open in tho wire between
th6 ful tank
Prossuro
sen3oa and
the ECM/PCM lc28).
l s t her e appr ox 5 V?
ECM/PCM CONNECTOR
A
(32P)
PTANK {LT BLUI
I
l l
(To page
' 11-278)
(cont' d)
Emission Control
System
Evaporative
Emission
(EVAPI
Controls
{cont,dl
J
FUEL TANK
PRESSURE SENSOR
SU8-HABNESS
6P CONNECTOR
1C574 tC568)rt
PTANK
{LT GRN}
PTANK
I LT GRN}
( Fr om page 11- 277)
{PTANK line):
At t he access panel
si de, mea
sur e vol t age bet ween t he f uel
t ank pressure
sensor sub-harness
6P connect or No. 2 t ermi nal and
No. 6 t er mi nal .
Chock l or a Shor t i n t he wi . e
(PTANK
l i ne):
nector A (32P).
t he f uel t ank pressure
sensor
sub-harness 6P connect or No.
2 t ermi nal s and body ground.
Repair short in the wi.e betwsen
the luel tank pressure
sensor and
ECM/PCM
{A291.
Subsiitute a known-good ECM/
PCM and rechock. l f sympt om/
indication goes away, replac the
original ECM/PCM.
11- 278
\
Fue| Tank Prssure sensor 196
Dr6Y8 engine
(coupe},,97 D16Y7 angino
(coupo:
KL mode|' 3edan: KL
(Lxl
modg||',97
Dl6Y8 engine
(coupe:
all modeb, sedan: Ki model.'98'all modols) 39
-
0O Dl6Y5 ongins with M/Tl:
r FoG' l : : ; Jl " t oo| i ndi cat esDi agnost i cTr oub| ecode( oTc) P0453; Ahi ghvo| t agepr ob| emi nt heFue| TankPr essur e
ECM/PCM CONNECTOR D Il6PI
PTANK
ILT GRNI
\
Wire side of tgmale torminals
FUEL TANK
PRESSURE SENSOR
3P CONNECTOR
(C792)
vcc2
(YEL/BLU}
sG2
(GRN/BLKI
Wire sid of female terminals
I
sG2
IGRN/BLKI
PTANK
IGBN/RED}
(cont'd)
11-279
The MIL has beon reponed on
DTC P0453 b stored.
Check t he vacuum l i nes oI t he
f uel t ank
cl oggi ng.
dure.
2. Femove t he f uel f i l l cap
3. Turn t he i gni t i on swi t ch oN
(l l ).
4. Moni t or t he FTP Sensor vol t -
bet ween bodY
gr ound and
ECM/ PCM connect or t ermrnal
D15.
lntormittont t iluro, 3Ystem is OK
at this time. Check lot
Poor
con_
noctiona or loo3e wirat at C131
{loc.ted
undor right 3id6 of d8hl,
CaOl llocatod
rbov. under-dalh
f us6/ rel ay boxl , C574
(C568l r
l l ocat od
und6l accoss Pan6l l ,
C792 lfuel tank Preasulo
aonlorl
end ECM/PCM.
Check f or an oPen i n t he wi re
(SG2l i ne):
2. Rei nst al l t he f uel l i l l cap
Pres-
sure sensor 3P connect or.
(ll)
f uel t ank
Pressure
sensor 3P
connector terminals No. 1 and
No . 2 .
Ropair opon in the wira btwsn
the fuel tank
prasure sonlor and
ECM/ PCM
(Dl 1).
l s t here aPProx. 5 V?
(PTANK line):
f uel t ank Pressure
sensor 3P con-
nect or No. 3 t ermi nal and No. 2
t ermrnal ,
*:
coupe
{ To
page 11- 280)
(EVAPI
Controls
(cont'dl
\ v
ECM/PCM CONNECTOR D {16PI
PTANK
{LT GRN)
SG2
(GRN/BLK}
l Fr om page 11- 2791
{PTANK l i ne):
PCM c o n n e c t o r t e r mi n a l s D1 5
and D] 1.
ECM/ PCM
l D15) and l uel t ank
pressuae
sensor.
PCM end recheck. l t sympt om/
indication goes awav, replace the
original ECM/PCM.
-2AO
\
'99
-
0O modols except Dl5Y5 engine with M/T:
r Fo45' : : n" : " t ooI i ndi cat esDi agnost i cTr oub| ecode( DTc) P0453: Ahi ghvo| t agepr ob| emi nt heFUel TankPr essur e
FUEL TANK
PRESSUNE SENSOR
SUB.HARNESS
6P CONNECTOR {C574
(C568)}}
vcc2
{YEL/BLUI
sG2
IGRN/BLK)
PTANK
{LT GRNI
(cont ' d)
11-281
PTANK {LT GRN)
Check t he vacuum l i nes ot t he
f uel t ank
cl oggi ng.
du re,
2. Remove t he f uel f i l l caP
(l l ).
4. Moni t or t he FTP Sensor vol t '
bet ween body
gr ound and
A.29.
lntermittent failuro. svstem b OK
at this time. Check for Poor
con_
noct i ons or l oo3 wi re3 at C131
{located under tight side of dash),
C4Ol {located above underdash
f use/ rel ay boxl , C57{
(C5681'
l l ocal ed unde. access Panel l ,
C792 {fuel
tank
Pressure
sensorl
aod ECM/PCM.
Chck f or an open i n t he wi r a
{ SG2l i ne) :
1. Tur n t he i gni t i on swi t ch OFF.
2. Rei nst al l t he f uel f i l l caP
3 . Re mo v e t h e a c c e s s
P a n e l
l r om t he f l oor .
Pr es-
s ur e s ens or s ub- har nes s 6P
(ll)
6, At t he access Panel si de,
mea-
t ank
pr essur e sensor sub_har -
ness 6P connect or t er ml nal s
No . 5 a n d No . 6 .
the fueliank Pres3ure
3ensor and
ECM/PCM {Cl8).
Check l or an oPen i n t he wi re
{PTANK
l i nel :
At t he access
Panel
si de, mea
t ank
pressure sensor suo_harness
6P connect or No. 2 t ermi nal and
No. 6 t ermi nal .
l s t her e appr ox. 5 V?
( To page 11. 282)
(From page 11-281)
Check t or an open i n t h wi re
(PTANK
line):
PCi / l connect or t er mi nal s A29
and C18.
Repsir open in tho wire between
ECM/ PCM {A29} . nd f uol t ank
oao!3uro tensor.
PCM and rscheck. It symptom/
indication goes aw.y, ..plsc. the
original ECM/FCM.
(EVAP)
Controls
(cont'd)
I J
ECM/PCM CONNEfiORS
a {32P)
SG2 IGRN/BLK)
Wi re sade of f emal e t ermi nal s
t I
a
PTANK ILT GRNI
11-282
\"
\
t,96
D16Y8 engine
(coup6l,'9? Dl6Y7 engine
(coupe: KL model, sedan: KL
(LX)
model)"g7 Dl6Y8 ongine
(coupe: all mod-
els, sedan: KL model,'98-8ll modelsl 39
-
00 Dl5Y5 engine with M/Tl:
(DTc) P1456: Evaporati ve Emi ssi on
(EVAP) control system l eak
detected
(fuel
tank sYsteml
(DTC)
(EVAP)
control system l eak
detected
(EVAP
control canister system).
Fr4t6l
fF14s7
Possible Causs
. Fuel fi l l cap
. Vacuum Connecti ons
. Fuel Tank
. EVAP Control Cani ster Vent Shut Val ve
. EVAP Control Cani ster Vent Shut Val ve Ci rcui t
. EVAP Purge Control Sol enoi d Val ve Ci rcui t
. EVAP Bypass Sol enoi d Val ve
. EVAP Bypass Sol enoi d Val ve Ci rcui t
. Fuel Tank Pressure Sensor
. Fuel Tank Pressure Sensor Ci rcui t
. EVAP Control Canister
. Throttle Body
Troublsshooting
Flowchart
VACUUM
PUMP/ GAUGE, 0
-
30 i n. Hg
A973X
-
041
-
xxxxx
I
EVAP
CONTROL
.4,
cANrsrER
re ./
VALVE
{S----r*::n
\ (cont' d)
-
The MI L ha3 been rePof t ed
on.
-
DTC P1456 or P1457 is stored.
Check the EVAP control canbtol
vent shut valve:
I r om t he EVAP t hr ee waY
val ve and connect a vacuurn
pump t o t he hose.
2. Remove t he EVAP cont r ol
cani st er vent shut val ve I rof i
t he canrst er.
(l l i
4. Appl y vacuum t o t he hose.
Chock f or . shon i n t he wi re
(VSv linel:
Disconnect the 2P connector {rom
t he EVAP cont rol cani st er vent
Does t he val ve hol d vacuum?
Repair short in the wir betwcen
the EVAP control canister vent
shut v. l ve and t ho ECM/ PCM
tA29|.
Check the EVAP control canister
vent shui valve:
t ermi nal A29 t o body
ground
wi t h a
i umPer
wi re.
(ll).
4. Appl yvacuum t o t he hose
Reohce the EVAP control canis-
ter vent shttt valve.
3 7 I 9 t 0 1 t
't2
t 3 t 5 t 6 I t I t t 9 20 2a 2a
25 a A
ILT GRN/W{T) I
JUMPER WIRE
Wi re si de of f eml l t ermi nal s
(To page 11-284i
( To page 11 284)
11-283
(EVAPI
Controls
(cont'dl
1
EVAP CONTROL
CANISTER VENT SHUT
VALVE 2P CONNECTOR IC141}
l l t r t
+
rcl
o)
(8LK/YErl
I
t emal e t ermi nal s Wi re si de ot
ECM/PCM CONNECTOR A
(32PI
VSV ILT GRN/WHT}
' l'
Wiro side of lemale
t grmi nal s
VACUUM
PUMP/
GAUGE, 0
-
30 i n. Hg
4973X
-
041
-
XXXXX
(From page 1l -283)
{To
page 1l -285}
Check the vacuum whon cold:
shown from the EVAP control
canrster and connect a vacuum
gauge t o t he hose,
2. St art t he engi ne and al l ow i t
t o i dl e.
NOTE: Engi ne cool ant t em-
perat ure must be bel ow 154oF
(68'C)
or lVC switch OFF.
3. Oui ckl y rai se t he engi ne speed
to 3,000 rpm.
(From page l 1-283)
Check f or an open i n t ho wi re
(l Gl
l i ne):
l rom t he EVAP cont rol cani s-
t er vent shut val ve.
(l l ).
EVAP controlcanister vent shut
val ve 2P connect or t er mi nal
No. 2 and body ground.
Repair open in the wire betwen
the EVAP control c.ni3tei vent
shut valve and th6 No. 15 ALTER-
NATOR SP SENSOR 17.5 Al fuse.
Cfisck tor an opon in the wire
(VSV
line):
2. Beconnect t he 2P connect or
t o t he EVAP cont rol cani st er
vent shut val ve.
(l l ).
nal s A29 and Al 0.
Rep.ir open in the wire betwoon
shut val ve and t h ECM/ PCM
tA29t.
Replace th6 EVAP control canis-
ter vent 3hut valve.
PGT
(BLKI
: l
I 2 3
l ' l t l ' l l e l s l
r o
I r I
12 13 t 6 lnltlr@/lzzl zs
f
il
25
11-284
\
\
(From page 11-284)
\
(cont ' d)
11-285
EVAP PURGE CONTROL SOI.INOID
VALVE 2P CONNECTOR IC114I
Wi re si de ot
f emal e
t ermi nal s
? ,
I , l , l i l ? " " , , , u
EL,TW
YEL)
Check t he EVAP
pi rrge cont rol
solenoid valvei
l rom t he EVAP purge cont rol
sol enoi d val ve.
t o 3, 000 rpm.
l s t here vacuum?
InsDect vacuum ho56 routing.
l l OK, repl ace t he EVAP
Purge
control solenoid valve.
Chock f or a short i n t he wi re
(PCS
linel:
2. Di sconnect ECM/ PCM connec'
t or A
(32Pi .
t he EVAP
PUrge
cont rol sol e
noid valve 2P connector termi
nal No. 2 and body
ground.
Check the vacuum when hot:
t he
parki ng brake.
3. Jack up t he f ront o{ t he vehi -
cl e and support i t wi t h saf et y
st ands,
engi ne al 3, 000 rpm wl t h no
l oad
l et i t i dl e.
5, Check f or vacuum at t he vac-
uum hose wi t h t ransmi ssaon
i n gear ( A/ T i n
B Posi t i on,
M/T in lst gear) after starting
t he engrne.
6. Ouickly raise the engine speed
to 3,000 rpm.
Reoair short in the wire botween
the EVAP
purg cor|t]ol solenoid
valve and the ECM/pcM lA15l.
PCM and r echeck. l f sYmPt om/
indication
goes eway. repl.c the
original ECM/PCM.
Check t he EVAP
Purg
cont rol
solenoid valve:
from the EVAP
Purge
control
sol enoi d val ve and war m l t
up t o normal operat i ng t em_
perature again if necessary
4. At t he harness si de, measure
vol t age bet ween t he EVAP
Purge
cont rol sol enoi d val ve
and No. 2 wi t h t he t ransmi s
si on i n gear (A, / T
i n E Posi -
t i on, M/ T i n 1st gear).
In3pect vacuum ho3 touting.
ll OK, replace EVAP
Purge
con-
lrol aolenoid vtlv.
Check l o. an open i n t he wi re
l l Gl l i nel :
At the harness side, measure volt
age between the EVAP
Purge
con-
t rol sol enoi d val ve 2P connect or
t ermi nal No. 1 and body ground
Repeir open in tho wire between
EVAP
purge conttol solenoid valv
and the No. 15 ALTERNATOR SP
SENSOR
(7.5
A fu3e
IBLK/YELI
l To
page 11 286i
(To page 11-286)
(From page 11 285)
Check l or an opn i n t he wi re
{PCS line}:
2, Reconnect the 2P connector lo
t he EVAP purge cont rol sol e-
noi d val ve.
(l l l .
415 and A] 0.
Repai. opn in the wire bGtween
the EVAP purge
control solenoid
val ve and t he ECM/ PCM {A151.
PCM and retest. tf sympiom/indi-
cat i on goes
away, repl ac6 t he
original ECM/PCM.
(EVAPI
Controls
(cont'd)
(From page 11' 285)
(To page
' l 1
287)
\ .
ECM/PCM CONNECTOR A {32P}
PCS
{RED/YEL)
PGl
{BLK)
Wire side of
temale
t ermi nal s
EVAP BYPASS
SOLENOID VALVE
O.RING
Bepl ace.
PUMP/
GAUGE, 0
-
30 i n. Hg
A973X
-
041
-
xxxxx
EVAP TWO WAY VALVE
EVAP IWO WAY
Check the EVAP two way valvo:
See EVAP two way valve test
(see
page 11' 294) .
Replace tho EVAP two way valve.
Check the EVAP bypr$ 3olenoid
from the EVAP two way valve
and connect a vacuum pump
t o t he hose.
2. Tur n t he i gni t i on swi t ch ON l l l ) .
3. Appl y vacuum t o t he hose. Check t or a shor t i n t he wi r e
{2WBS linel:
Di sconnect t he 2P connect or f rom
t he EVAP bypass sol enoi d val ve.
Repair short in the wire betwen
EVAP bypass solnoid valve and
rhe ECM/PCM lA28).
11-286
I
ECM/PCM CONNECTOR A
(32P)
2WBS
(BLUI
Wi ro si de ol
Iemale
t ermi nal s
JUMPER
_
WIRE
EVAP BYPASS SOLENOID
VALVE 2P CONNECTOR {C793I
Wire side of
femal
t ermi nal s
\
ECM/P,CM CONNECTOR a l32Pl
Wir side of female
t ermi nal s
(cont' dl
11-2A7
(From page 11-286)
Check the EVAP bypa3s 3olenoid
t ermi nal A28 and body
ground
wi t h a
j umper wi re.
(ll).
ChGck t or an opon i n l ho wi t e
(lGl lin6l:
t rom t he EVAP bypass sol e-
noid valve.
(ll).
2P connect or t ermi nal No- 1
and body
ground.
R.pair open in tha wil botwoon
EVAP
purg. cor|trol 3olenoid valve
.nd tho No. 15 ALTERNATOR SP
SENSOR 17.5 Al tu3e.
Check l or an open i n t he wi re
{2WBS
line):
l . Turn t he i gni t i on swi t ch OFF.
2. Reconnsct t he 2P connect or
t o t he EVAP bypass sol enoi d
(l l )
4. Measure vol t age bet ween
ECM/rcM connector terminals
A28 and Al 0.
Ch6ck t he f ol l owi ng
P. . t s
f or
l 6akage t o at mosPher e, and
roplir or rephco if neca3aary:
'
fuel fill c.D
.
tu6l t.nk
.
tuel vapor
pipe
.
EVAP two way v3lvo
.
EVAP bypa3! solanoid vtlY.
,
fuel tlnk
pra63uro
3on3or
.
EVAP control canBte.
.
EVAP cont rol crni st or vent
shut vtlvo
.
EVAP
purgo cont rol l ol onoi d
.
vscuum hoseS and connoction3
Roprir opon in tho wiro betwoen
th. EVAP byp.$ 3ol6noid valve
rnd tho EcM/PcM lA28l.
I 2 5 7 8 t 0 1 1
'12
t t 1 5 t 6 t 8 t 9 20 23 21
27 26 29 3o
PGl
(BLKI
I
I
I 7 l l s l e l
r o
l r ' I
't2
r3 ,"l!j'"EBUP)._3)_!J
E nt
ll 4al*l 4 l,-'l
2WaS {BLUI
\
{EVAP)
Controls
(cont'dl
\ J
tF1456-l
tP14sz-l
EVAP
CONTROL
CANISTER
VENT
SHUT
VALVE
O.RING
Replace.
EVAP
CONTROL
CANISTER
( To page 11' 289)
'99
-
00 modols except Dl6Y5 engine with M/T:
(DTC)
(EVAP)
detected
(fuel
tank svstem).
(DTC)
(EVAP)
detected
(EVAP
control cani ster system).
Possible Cause
. Fuel fi l l cap
. Vacuum Connecti ons
. Fuel Tank
. EVAP Control Cani ster Vent Shut Val ve
. EVAP Control Cani ster Vent Shut Val ve Ci rcui t
o EVAP Purge Control Sol enoi d Val ve Ci rcui t
. EVAP Bypass Sol enoi d Val ve
0
- 30
i n, Hg
. EVAP Bypass Sol enoi d Val ve Ci rcui t
. Fuel Tank Pressure Sensor
. Fuel Tank Pressure Sensor Ci rcui r
. EVAP Control Cani ster
. ORVR vent shut val ve
. ORVR vapor reci rcul ati on val ve
. Throttl e Body
VACUUM
PUMP/GAUGE,
A973X
-
oal
-
xxxxx
T-t
t \
DTC P1456 o. P1457 is stored.
Check the EVAP cont.ol canister
vent shul valve:
f r om t he EVAP t hr ee way
val ve and connect a vacuum
pump t o t he hose.
2 . Re mo v e t h e EVAP c o n t r o l
cani st er vent shut val ve f rom
t ne canrst er.
(l l ).
Check f or a short i n t he wi ro
(VSV
linel:
Disconnect the 2P connector from
t he EVAP cont r ol cani st er vent
Does t he vai ve hol d vacuum?
RoDair 3hort in the wire botwen
the EVAP control canilter vent
shut val ve and t he ECM/ PCM
{A4t.
Check the EVAP cont.ol canister
vnl shut valve:
t er mi nal A4 t o body gr ound
wi t h a
j umper
wi re.
(l l ).
Reolace the EVAP control canis-
ter veni shut valve.
11-288
l To
page 11-289)
\
EVAP CONTROL
CANISTER VENT SHUT
ECM,/PCM CONNECTORS
t G1
IBLK/WHT}
A973X
-
0/r1
-
XXXXX
t ermrnat s
\
?,
T-t
f l
VACUUM
PUMP/
GAUGE, 0
-30
i n. Hg
\
(cont' d)
11-289
{From
page l 1 288}
{To
page 11-290)
Chck the vac[um when cold:
1, Di sconnect t he vacuum hose
shown from the EVAP control
canister and connect a vacuum
gauge to the hose.
2. St art t he engi ne and al l ow i t
t o i dl e.
NOTEi Engi ne cool ant t em
perat ure must be bel ow 154"F
(68'C)
or Ay'C switch OFF.
to 3,000 rpm.
(From page 11-288)
Check f or an open i n t ha wi re
(lGt linol:
f rom t he EVAP cont rol cani s-
t er vent shut val ve.
EVAP control canister vent shut
val ve 2P connect or t ermi nal
No. 2 and bodyground.
shut valve .nd the No. 15 ALTER-
NATOR SP SENSOR {7.5 A)fu3e.
Chd( for an opn in the wiie IVSV
linel:
2. Rconnect t he 2P connect or
t o t he EVAP cont rol cani st er
vent shut val ve,
(l l ).
nal s A4 and 82.
Repair open in the wire bctween
t he EVAP cont rol cani st or vent
shut val ve and l he ECM/ PCM
{44t.
Rcolaco tho EVAP control canis.
t6r vent shut valvo.
a t32P)
-
Chck t he EVAP purge cont rol
solenoid valv6:
f rom t he EVAP purge cont rol
sol enoi d val ve.
to 3,000 rpm.
Insped vacuum hose routing.
l f OK. ropl ace t he EVAP
purge
control solonoid valve.
Chock t or r short i n t he wi r
{PCS l i ne):
2. Di sconnect ECM/ PCM connec-
t or A
(32P).
3- Check t or cont i nui t y bet ween
t he EVAP purge cont rol sol e-
noid valve 2P connector termi-
nal No. 2 and body
ground.
Check the vacuum when hot:
t he parki ng brake.
3. Jack up t he l ront of t he vehi -
cl e and support i t wi t h saf et y
st ands.
l oad
(i n
Park or neut ral i unt i l
let it idle.
5. Check f or vacuum at t he vac-
uum hose wi t h t ransmi ssi on
i n gear ( A/ T
i n
E
posi t i on,
lvl/T in 1st gear) after starting
t he engi ne.
6. Ouickly raise the engine speed
to 3,000 rpm.
Rooair shoft in the wire belwegn
the EVAP pulg6 control solenoid
valvs and tho ECM/PCM {A61.
PCM and rech6ck. lt 3ymptom/
indicrtion
90e3
rway, r6plac6 th
o.iginal ECM/FCM.
Check t h EVAP purge cont rol
solenoid valve:
1. Turn t he; gni t i on swi t ch OFF.
f rom t he EVAP purge cont rol
sol enoi d val ve and warm i t
up t o normal operat i ng t em-
perature again if necessary.
4- At t he harness si de, measure
vol t age bet ween t he EVAP
purge cont rol sol enoi d val ve
2P connect or t er mi nal No. 1
and No. 2 wi t h t he t r ansmi s-
si on i n gear
{A/ T
i n
E
posi -
t i on, M/ T i n l st geari .
In3pect vacuum hoae routing.
lf OK, repl.ce EVAP purge con-
trol solonoid valve.
(l G1
l i na):
At the harnoss side, measure volt-
age beNveen the EVAP purge con-
t rol sol enoi d val ve 2P connect or
t ermi nal No. 1 and body ground.
Repair open in the wire blwen
EVAP purge contrl 3olenoid valv6
and lhe No. 15 ALTERNATOR SP
SENSOR 17.5 A, fu3e.
(EVAPI
Controls
(cont'dl
(From page 11-289)
( To page 11- 291)
11-290
I J
EVAP PURGE CONTROL SOLENOID
PCS
IRED/YEL)
t emal e
t ermrnars
of
PCS
(RED/YEL)
t Gl
IBLK/
YEL)
{ To
page 11 291)
I
ECM/PCM CONNECTOR
I
EVAP TWO WAY
VALVE
Wi re si de of
t emal e
t ermi nal s
FUEL
TANK
(cont' d)
11-291
tn
VACUUM
PUMP/ GAUGE, 0
-
30 i n Hs
A973X
-
041
-
xxxxx
(From page l 1 290)
Check the EVAP two way valve:
See EVAP two way valve test
(see
page 11- 295) .
Roplace the EVAP two way valve
Check the EVAP bypa$ solenoid
1 . Re mo v e t h e f u e l t a n k
( s e e
page 11-242J.
2. Li I t up t he f uel t ank wi t h a
transmission iack,
and connect
t he f uel t ank
pressure sensor
sub harness 6P connect or t o
t he access
panel si de connec_
t or,
from the EVAP two way valve
and connect a vacuum
PumP
t o t he hose,
(l l )
( To page 11 292)
(From page 11-290)
{PCS
l i n6):
2. Reconnect t he 2P connect or t o
t he EVAP
purge cont rol sol e-
4. Measu r e vol t age bet ween
EClr/PCM connector terminals
A6 and 82.
Ropair open in the wire between
the EVAP
purge Gontrol solenoid
vrlve and th6 ECM/PCM lA6l
PCM rnd re{61. lf symptom/indi'
cat i on
goes away, rePl ace t he
oiiginal ECM/PCM.
(EVAPI
Gontrols
(cont'd)
EVAP BYPASS
SOLENOID VALVE
Y
( Fr om page l 1' 291)
{2WBS linel:
Disconnect the 2P connector {rom
t he EVAP bypass sol enoi d val ve.
EVAP bypass solenoid velve and
rhe ECM/PCM {A3).
Ooes t he val ve hol d vacuum?
Check the EVAP bvpr$ 3olenoid
t ermi nal A3 and body ground
with a
jumper
wire.
(l l ).
Chck l or an op. n i n t he wi re
l l cl l i nol :
f rom t he EVAP bypass sol e-
noi d val ve.
(l l l .
4, Measure voltage between the
and body ground.
Repair open in the wir6 btwn
EVAP purg6 control 3olanoid valve
and the No. 15 ALTERNATOR SP
SENSOR {7.5 A) Iuse.
EVAP SYPASS SOLENOIO
VALVE 2P CONNECTOR IC793}
tG1
{BLK/WHT)
Wi re si de of
f emal e
t ermi nal s
{ To
page 11 293)
11-292
(To page 11 293i
I
\
\ l
(From page 11-292i
Chock t he t ol l owi ng
part s t ol
l eakage t o ai mospher o, and
ropaii or replaco if necess6.y:
.
fuel fill cap
.
fuel tank
.
fuel v.por pipe
.
EVAP two way valve
.
EVAP bypas solonoid valve
.
tuel tank
pre3suae sen3or
.
EVAP control cankter
.
EVAP cont r ol cani si er veni
3hut valve
.
EVAP
purge cont t ol sol enoi d
.
ORVR vent 3hut valve
.
ORVB vaoor recirculation valve
.
vacuum hoses tnd connactions
(From page 11 292)
Check t oi an opon i n t he wi ro
(2wBS
linol:
t o t he EVAP bypass sol enoi d
(ll).
43 and 82.
Reprir opan in tho wire be(wean
th. EVAP byp.is solonoid valve
rnd rhe EcM/PcM
(A31.
(cont' d)
11-293
(EVAPI
Controls
(cont'd)
(EVAPI
Two Way Valve Testing
l ' 96
DIGYS engi ne l coupel ,' 97 Dl 6Y7 engi ne
(coupe:
KL
model , sedan: KL
(LX)
modol l ,' 97 Dl 6Y8 engi ne {coup:
alt models, sedan: KL model,
'98-all
modelsll:
2. Remove t he vapor l i ne f r om t he EVAP t wo way
val ve. and connect i t to a T-fi tti ng from a vacuum
gauge and a vacuum pump as shown.
VACUUM/ PRESSURE
I J
f96 D16Y5 engi ne,' 96 D16Y7 engi ne,' 96 D16Y8 ongi ne
(sedanl ,' 97
D16Y5 engi ne,' 97 Dl 6Y7 engi ne {coupe: KA,
KC models, sedan: KA, KC, KL {DX} models, hatchback:
al l modsl s),' 97 D16Y8 engi ne {sedan:
KA, KC model s}l :
1. Remove the fuel fi l l cap,
2. Remove t he vapor l i ne f r om t he EVAP t wo way
val ve on the fuel tank, and connect i t to a T-fi tti ng
f r om a v ac uum gauge and a v ac uum pump as
snown.
VACUUM/
PRESSURE GAUGE,
0
-
4 i n. Hg
07JAZ
-
0010008
VACUUM
PUMP/ GAUGE.
0
-30
i n. Hg
A973X- 041
- XXXXX
Appl y vacuum sl owl y and conti nuousl y whi l e watch-
i ng the gauge. The vacuum shoul d stabi l i ze momen-
tari l y at 0.8
-
2.1 kPa
(6 -
16 mmHg, 0.2
-
0.6 i n.Hg).
l f t he v ac uum s t abi l i z es
( v al v e
opens ) bel ow
0. 8 k Pa { 6 mmHg, 0. 2 i n. Hg) or abov e 2. 1 k Pa
(16
mmHg, 0.6 i n.Hg), i nstal l a new val ve and retest.
Move the vacuum
pump
hose from the vacuum fi t-
ti ng to the pressure fi tti ng, and move the vacuum
gauge hose from the vacuum si de to the pressure
si de as shown.
Sl owl v
pressuri ze
the vapor l i ne whi l e watchi ng the
gauge. The pressure shoul d be stabi l i ze momentari
l y above 1. 0 kPa
( 8
mmHg. 0. 3 i n. Hg) .
. l f t he pr essur e moment ar i l y st abi l i zes
( val ve
opens) above
' 1. 0
kPa
( 8
mmHg, 0. 3 i n. Hg) , t he
val ve i s OK.
. l f the pressure stabi l i zes bel ow 1.0 kPa
(8
mmHg,
0.3 i n.Hg), i nstal l a new val ve and retest.
Appl y v ac uum s l owl y and c ont i nuous l y whi l e
watchi ng the gauge. The vacuum shoul d stabi l i ze
momentari l y at 0.7
-
2.0 kPa
(5 -
15 mmHg, 0.2
-
0.6
i n. Hg ) .
( v al v e
opens ) bel ow
0. 7 k Pa
( 5
mmHg, 0. 2 i n. Hg) or abov e 2. 0 k Pa
(15
mmHg, 0.6 i n.Hg), i nstal l a new val ve and retest.
Move the vacuum
pump
hose from the vacuum fi t-
' l '
4.
5.
ti ng to the pressure fi tti ng, and move the
gauge hose from the vacuum si de to the
si de as shown.
PRESSURE
SIDE
Sl owl y
pressuri ze
the vapor l i ne whi l e watchi ng the
gauge. The pressure shoul d stabi l i ze at 1.3
-
4.7 kPa
( 0 -
35 mmHg, 0. 4
-
1. 4 i n. Hg) .
. I t t he pr essur e moment ar i l y st abi l i zes
( val ve
opens) at 1. 3
-
4. 7 kPa
( 10
-
35 mmHg, 0. 4
-
1. 4
i n. Hg), the val ve i s OK.
. l f the pressure stabi l i zes bel ow 1.3 kPa
(10
mmHg,
0.4 i n.Hg) or above 4.7 kPa
(35
mmHg. 1.4 i n.Hg),
install a new valve and retest.
vacuum
pressure
GAUGE
0- 4 i n. Hg
T-FITTING
T-FITTING
11-294
\,
\
(EvAPl
Two Way Valve T6ting
'99
-
00 modols:
' L
Remove the fuel tank
(see page 11-242).
2. Remove the vapor l i ne {rom the EVAP two way
val ve
(l ocated
above the EVAP control cani ster), and
connect i t to a T-fi tti ng from vacuum
gauge and
vacuum
pumo
as snown,
VACUUM/PRESSURE
GAUGE
0
- i l i n. Hg
07JAZ
-
001(x)08
r y ( L
"*'"""_,";f1
T.FITTING
Appl y vacuum sl owl y and conti nuousl y whi l e watch-
i ng the
gauge.
The vacuum shoul d stabi l i ze momentari l y at 0.8
-
2.1 kPa {6
-
16 mmHg, 0.2
-
0.6 i n.Hg).
( v al v e
opens ) bel ow
0. 8 k Pa
( 6
mmHg, 0. 2 i n. Hg) or abov e 2. 1 k Pa
(16
mmHg, 0.6 i n.Hg), i nstal l a nsw val ve and retest.
Move the vacuum pump hose from the vacuum fi t-
ti ng to the
pressure fi tti ng, and move the vacuum
gauge hose from the vacuum si de to the
pressure
si de as shown.
GAUGE, 0
-
30 i n. Hg
4973X
- (Xl -
xxxxx
J.
5. Sl owl y
pressuri ze
the vapor l i n whi l e watchi ng the
gauge.
The
pr essur e
shoul d be st abi l i ze moment ar i l y
above 1.0 kPa
(8
mmHg, 0.3 i n.Hg).
. l f t he
pr essur e moment ar i l y st abi l i zes
( val ve
opens) above 1.0 kPa
(8
mmHg, 0.3 i n.Hg), the
val ve i s OK.
. l l the pressure stabi l i zes bel ow 1.0 kPa
(8
mmH9,
0,3 i n,Hg), i nstal l a new val ve and retsst.
(cont' d)
11-295
(EVAP)
Controls
(cont'dl
ORVR Vent Shut Valve Test
Float Test
1. Make sure the fuel tank i s l ess than hal f ful l .
2. Remove the fuel fi l l cap to rel i eve the fuel tank pres-
sure, then rei nstal l the cap.
3. Remove the fuel hose
j oi nt
protector. Di sconnect
the ORVR vapor reci rcul ati on hose, and connect a
vacuum pump to the vapor reci rcul ati on hose.
ORVR VAPOE
RECIRCULATION
VACUUM PUMP/
GAUGE, 0
-
30 i n. H9
A973X
-
041
-
xxxxx
Pl ug the hose port.
Appl y vacuum t o t he ORVR vapor r eci r cul at i on
nose.
. l f the vacuum hol ds, repl ace the ORVR vent shut
val ve {see
page 11-297).
. l f the vacuum does not hol d, the fl oat i s OK.
4.
11-296
Vatve Tcst
1. Make sure the fuel tank i s l essthan hal fful l .
3. Remove the fuel hose
joint protector.
Disconnect the
ORVR si gnal hose.
ORVR
SI GNAL
HOSE
Disconnect the vacuum hose from the EVAP control
cani ster. and then pl ug the port wi th a pl ug.
VACUUM
PUMP/ GAUGE,
0
-
30 i n, Hg
A973X-041-XXXXX
CONTROL
CANISTER
VENT SHUT
VALVE
Disconnect the vacuum hose from the EVAP control
canister vent shut valve, and connect a vacuum pump
to the vacuum hose,
Pump the vacuum pump 80 ti mes.
. l f the vacuum hol ds, go to step 7,
. l f thevacuum does not hol d, goto step9.
\
\
7. Connect a second vacuum pump to the OBVR si gnal
nose.
VACUUM PUMP/
GAUGE. 0
-
30 i n. Hg
A973X
-
041
-
xxxxx
Appl y vacuum
(1 pump) to the ORVR si gnal hose,
then check the vacuum on the
pump i n step 6.
. l f the vacuum hol ds, repl ace the ORVR vent shut
val ve.
. l f the vacuum i s rel eased, the ORVR vent shut
valve is OK.
Disconnect the ORVR
quick
disconnect from the EVAP
canister, then
plug the
port
on the canister.
Reappl y vacuum
(80 pumps).
. l f the vacuum hol ds, reDl ace the ORVR vent shut
val ve,
. lf the vacuum does not hold, inspect the EVAP can-
i ster vent shut val ve O-ri ng. l f the O-ri ng i s OK,
replace the EVAP canister and repeat step 4.
\
I
11-297
ORVR Vent Shut Valve Replacement
1. Remove the fuel tank
(see page 1 1-242).
2. Remove the ORVR vent shut val ve from the fuel tank.
3. lnstall oarts in the reverse order of removal.
J
Transaxle
cf utch
.""""" 12' 1
Manual Transmi ssi on . . . . . . . . . . . . "' . ' . . ". ' . . . ' .
13-1
Automati c Transmi ssi on ........ "........ " ". 1 4-1
Di fferenti al
... 15-1
Dri veshafts
." 16-1
J
t
Cl utch
Speci af Tool s . . . . . . . . . . . . . . . . . . . . . 12-2
f l f ust rat ed I ndex . . . . . . . . . . . . . . . . 12-3
clutch Pedal
Adj ustment .................... 12' 4
Clutch Master Cylinder
Removal /l nstal l ati on
..... 12-5
Slave Cylinder
Removal /l nstal l ati on .....12' 6
Pressure Plate
Removal /l nspecti on ...... 12-7
Clutch Disc
Removal /l nspecti on ...... 12-8
Flywheel
I nspect i on . . . . . . . . . . . . . . . . . . . . . . . 12-9
Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Clutch Disc, Pressure Plate
l nst al l at i on . . . . . . . . . . . . . . . . . . . . . 12-10
Release Bearing
Removal /l nspecti on ......12-11
f nst al f at i on . . . . . . . . . . . . . . . . . , . . . 12-12
\
Speci al Tool s
I t J
Ref. No. Tool Number Description Oty Page Reterence
o
\31
(
@
!o/
OTJAF
_
PM7O11A
OTJAF
_
PM70124
07LAB
-
PV00100 or
07924, PD20003
07746
-
0010100
07749
-
00' ]0000
07936
-
3710100
Cl utch Al i gnment Di sc
Cl utch Al i gnment Shaft
Ri ng Gear Hol der
Dri ver
Hand l e
12-7
12- 7
, 8,
10, 11
' t 2- 7, 9, 10, 11
12 10
12- ' t O
12- 1
, 8,
10, 11
(r\
a U
2-2
lllustrated
Index
\
NOTE:
. Whenever the transmi ssi on i s removed, cl ean and
grease the rel ease beari ng sl i di ng surface
. l f the parts marked wi th an asteri sk
(*)
are removed, the cl utch hydraul i c system mustbe bl ed
(seepage 12-6)
. Inspect the hoses for damage, l eaks, i nterference, and twi sti ng
'RESERVOIF
TANK
ASSIST SPRING
LOCK PIN
5 x 1 , 0 mm
9.8 N.m
(1.0 kgf.m,
7.2 tbtftl
*CLUTCH
LINE
15 N. m {1. 5
kgJ m,
11 tbt.ft)
RELEASE BEARING
page 12-1 1
I nst al l at i on,
page 12-' 12
*CLUTCH
MASTER CYLINDER
Removal / l nst al l at i on,
page 12 5
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbf.ft)
FLYWHEEL
I nspect aon, page 12I
Repl acement ,
Page
12-9
CLUTCH DISC
page 1 2-8
l nst al l at i on,
page 12-' 10
' 12
x 1. 0 mm
118 N. m {12. 0 kgt ' m, 86. 8l bf f t )
PBESSURE PLATE
Bemoval / l nspect i on,
page 12 7
I nst al l at i on,
page 12' ' 10
8 x 1. 25 mm
22 N m
(2.2
kgf.m, 16lbf ft)
ISLAVE
CYLINDER
page 12_6
12-3
Glutch Pedal
Adjustment
NOTE:
. To c hec k t he c l ut c h i nt er l oc k s wi t c h and c l ut c h
swi tch, see secti on 23.
. The cl utch i s sel f-adj usti ng to compensate for wear.
CAUTION: lf there is no clearance between the mas-
ter cylinder pislon and push rod, the release bearing
i s hel d agai nst the di aphragm spri ng, whi ch can
result in clutch slippage 01 other clutch problems.
1. Loosen l ocknut A, and back off the cl utch swi tch
(or
adj usti ng bol t) unti l i t no l onger touches the cl utch
peoar.
2. Loosen l ocknut C, and turn the
push rod i n or out to
get the speci fi ed stroke {@} and hei ght
(@)
at tne
cl ut ch pedal .
3. Ti ghten l ocknut C.
4. Thread i n the cl utch swi tch {or adi usti ng bol t) unti l
i t contacts the cl utch
pedal .
9002)
Tur n t he cl ut ch swi t ch
( or
adj ust i ng bol t ) i n an addi -
ti onal 3/4 to 1 ful l turn.
Ti ghten l ocknut A.
Loosen l ocknut B on the cl utch i nterl ock swi tch.
Measure the cl earance between the fl oor board and
cl utch pedal wi th the cl utch pedal ful l y depressed.
Rel ease the cl utch pedal 15
-
20 mm {0.59
-
0.79 i n)
from the ful l y depressed posi ti on and hol d i t there.
Adj ust the posi ti on of the cl utch i nterl ock swi tch so
t hat t he engi ne wi l l st ar t wi t h t he cl ut ch pedal i n
t hi s posi t i on.
Thread the cl utch i nterl ock swi tch an addi ti onal i n
3/4 to 1 ful l turn.
Ti ghten l ocknut B.
LOCKNUT B
9. 8 N. m ( 1. 0
k91. m, 7. 2 l bt . t t )
INTERLOCK SWITCI{
J
' l L
5.
7.
8.
9.
10.
ASSIST SPRING
-Atl
CLUTCH SWITCH
lo. ADJUSTING BOLTI
LOCKNUT A
9. 8 N' m
(1. 0
kgI . m, 7. 2 l bf , f t )
LOCKNUT C
18 N. m { 1. 8 kql . m, 13l bf . f t }
@
( STROKE
at PEDAL) : 130
-
140 mm
( 5. 12 -
5. 51 i n)
@
(TOTAL
CLUTCH PEDAL FREE PTAYI: 12
-
21 mm
(0.47
-
0.83 i n) i ncl udethepedal pl ay 1 10 mm
(0.04 -
0.39 i n)
@
(CLUTCH PEDAL HEIGHT):
' ]65
mm {6.50 i n) to the fl oor
@
( CLUTCH PEDAL DI SENGAGEMENT HEI GHT) : 83 mm
( 3. 27
i n) mi ni mum t o t he f l oor
12-4
Glutch
Master Gylinder
I
RemovaUl nstal l ati on
CAU'NON:
. Do not sDi l l brake l l ui d onthevehi cl e;i t
may damage
the
paint; if brake fluid does contact the
paint, wash
it off immediatelY with water.
. Plug the end ofthe clutch line and reservoir hos with
a shop towelto
prevent brake tluid from coming out
1. The br ake t l ui d can be r emoved f r om t he cl ut ch
master cyl i nder reservoi r wi th a syri nge
2. Di sconnect the cl utch l i ne and reservoi r hose from
the cl utch master cyl i nder.
19N. m 11. 9
kgf . m,
14 t bf . t t l
[.
3. Pry out the l ock pi n, and pul l the
pedal pi n out
the yoke. Remove the nuts
NUTS
8 x 1 .25 mm
13 N. m {' 1. 3 kgt . m, 9. 4l bf f t )
)
of
CLUTCH LI NE
iffi,
4. Remove the cl utch master cyl i nder.
CLUTCH
MASTER CYLINDER
l nst al l t he cl ut ch mast er cyl i nder i n t he r ever se
order of removal .
NOTE: Bl eed the cl utch hydraul i c system {see
page
12-61,
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 brake fluid from coming oul.
- 61' sr p" , Hi gh Temp Ur ea cr ease
( p/ N
08798
-
90021.
: Brake Assembl y Lube or equi val ent rubber
grease.
1. Di sconnect the cl utch l i ne from the sl ave cvl i nder.
2. Remove the sl ave cyl i nder from the cl utch housi ng.
12-6
3. I nst al l t he sl ave cyl i nder i n t he r ever se or der of
removal .
NOTE: Make sure the boot i s i nstal l ed on the sl ave
cvl i nder.
.
CLUTCH LINE
15 N.m
(1
.5 kgf.m, 1 1 l bf.It)
SLAVE CYLI NDER
-G4
(P/N
08798- 90021
8 x 1. 25 mm
22 N. m 12. 2 kgl . n,
16 l bl . l t )
:^.
.:i!!!!!
:l
(Brak
Assembly
Lubol
Bl eed the cl utch hydraul i c system.
a Attach a hose to the bl eeder screw, and suspend
the hose i n a contai ner of brake fl ui d.
. Make sure there i s an adequate suppl y of fl ui d at
the cl utch master cyl i nder, then sl owl y pump the
cl utch pedal unti l no more bubbl es appear at the
bl eeder hose.
.
Refi l l the cl utch master cyl i nder wi th fl ui d when
done.
. Al ways use Genui ne Honda DOT 3 Brake Fl ui d.
Usi ng a non-Honda brake fl ui d can cause corro-
si on and decrease the l i fe of the system.
. Confi rm cl utch operati on, and check for l eaki ng
fl u i d.
Pressure
Plate
\
Removal /l nsPecti on
1 . Inspect the fi ngers of the di aphragm spri ng for wear
at the rel ease beari ng contact area.
Check the di aphragm spri ng fi ngers for hei ght usi ng
the speci al tool s and a feel er
gauge.
Standard {New}: 0.6 mm
(0.02
i nl max.
Seruice Limit: 1.0 mm {0.04
in}
FEELER GAUGE
CLUTCH ALIGNMENT DISC
OTJAF_PM7O1 1A
CLUTCH ALIGNMENT SHAFT
OTJAF-PM7012A
HANDLE
07936-37tOtOO
l f the hei ght exceeds the servi ce l i mi t, repl ace the
pressure
Pl ate.
3. Instal l the speci al tool s
PRESSURE PLATE
MOUNTING
BOLT
ALI GNMENT SHAFT
OTJAF-PM7012A
HANDLE
07936- 371010O
o7924-PD20003
GEAR HOLDER
07LA8-PVOOI OO
ot
ENGINE
BLOCK
ADJUSTER BOLT
BOLT
4. To prevent warpi ng, unscrew the pressure pl ate
mount i ng bol t s i n a cr i sscr oss
pat t er n i n sever al
steps, then remove the
pressure pl ate.
\ r f
12- 7
l nspect the
pressure pl ate surface for wear' cracks,
and bur ni ng.
Inspect for warpage usi ng a strai ght edge and l eel er
ga uge.
NOTEr Measure across the
pressure pl ate at three
pornrs.
Standard
(Newl:
0.03 mm
(0.001 inl max.
(0.006
inl
l f the warpage exceeds the servi ce l i mi t, repl ace the
pressure pl ate.
STBAIGHT EDGE
Clutch Disc
RemovaUlnspection
2.
' 1.
Remove the cl utch di sc and speci al tool s.
CLUTCH
oTJAF-pM7012A
xl tori
07936- 3710100
Inspect l i ni ng of the cl utch di sc for si gns of sl i ppi ng
or oi l . l f i t i s burned bl ack or oi l soaked, repl ace i t.
Measure the cl utch di sc thi ckness.
Clulch Disc Thickness:
Standard
(Now):
8.5
-
9.1 mm
(0.33 -
0.36 i n)
Servi c Li mi t: 5.5 mm
(0.22
i nl
CLUTCH
l f t he t hi ckness i s l ess t han t he servi ce l i mi t . . eol ace
t he cl ut ch di sc.
12-8
U
4. Measur e t he dept h f r om t he l i ni ng sur f ace t o t he
ri vets, on both si des.
Rivet Depth:
Standard
l Newl : 1.3
-
1.9 mm {0.05
-
0.07 i n} mi n.
(0.01
in)
l f the depth i s l ess than the servi ce l i mi t, repl ace the
cl utch di sc.
CLUTCH DISC
Flywheel
\
Inspection
1 .
2.
3.
Inspect the ri ng gear teeth for wear and damage
I ns pec t t he c l ut c h di s c mat i ng s ur f ac e on t he
fl ywheel for wear, cracks, and burni ng.
Measure the fl ywheel runout usi ng a di al i ndi cator
t hr ough at l east t wo f ul l t ur ns Push agai nst t he
f l y wheel eac h t i me y ou t ur n i t t o t ak e up t he
crankshaft thrust washer cl earance.
NOTE: The r unout can be measur ed wi t h engi ne
i nstal l ed.
Standard
(New): 0.05 mm
(0.002 inl max.
Servi ce Li mi t: 0.15 mm {0.006
i n)
FLYWHEEL
OIAL INOICATOR
FLYWHEEL
l f the runout exceeds the servi ce l i mi t. repl ace the
fl ywheel .
Turn the i nner race o{ the bal l beari ng wi th
your ti n-
ger. The bal l beari ng shoul d turn smoothl y and qui
etl y. l f the i nner race does not turn smoothl y and
qui et l y, r epl ace t he bear i ng. Check t hat t he bal l
beari ng outer race fi ts ti ghtl y i n the fl ywheel . l f i t i s
l oose. repl ace the bal l beari ng
I J
4.
BALL BEARI NG
\
t O
Replacement
1. Instal l the speci al tool .
MOUNTING
BOLTS
RITIG GEAR HOLDER
oTLAB-PV00100
ot
o7924-PD20003
2. Remove the fl ywheel mounti ng bol ts i n a cri sscross
pattern i n several steps as shown,
and remove the
fl ywheel ,
Remove the bal l beari ng from the fl ywheel
(cont' dl
12-9
FLYWHEEL
t\
m\J
Flywheel
Clutch Disc, Pressure Plate
Repl acement
(cont' dl
4. Dri ve the new bal l beari ng i nto the fl ywheel usi ng
the speci al tool s as shown.
DRI VER
07749-0010000
ATTACHMENT,
3 2 x 3 5 mm
07746-OOIOTOO
FLYWHEEL
BEARI NG
Al i gn the hol e i n the fl ywheel wi th the crankshaft
dowel pi n and i ns t al l t he f l y wheel . I ns t al l t he
mounti ng bol ts fi nger-ti 9ht.
Instal l speci al tool , then torque the fl ywheel mount-
i ng bol ts i n a cri sscross pattern
i n several steps as
snown.
5.
6.
MOUNTING BOLTS
118 N. m
( 12. 0
kgl . m,
87 tbf.ft)
RING GEAR HOLDER
07LAB-PV00100
ol
07924
-PO20003
WV
a// ,
12-10
Instal l ati on
1. I nst al l t he speci al t ool .
Y
07936-3710r00
{P/N 08798-90021
RI NG GEAR HOLDER
07LAB-PVOO100
ot
07924-PD20003
OTJAF_PM7012A
2.
3.
Instal l the cl utch di sc usi ng the speci al tool s.
Instal l the pressure pl ate.
RING GEAR HOLDER
oTLAB PV00'l OO
07924 PD20003
OTJAF_PM70124
HANOLE
07936- 3710100
CLUTCH DISC
Release
Bearing
)
4. Torque the mounti ng bol ts i n a cri sscross
pattern as
shown. Ti ght en t hem i n sever al st eps t o
pr event
warpi ng the di aPhragm
sPri ng.
19 rbf . f t )
\
RING GEAR HOLDER
oTLAB-PV00100
ot
07924-PD20003
CLUTCH ALIGNMENT
SHAFT
OTJAF_PM7O12A
HANOLE
07936- 3710100
MOUNTING
BOLTS
8 x 1. 25 mm
25 N. m
(2. 6
kgl ' m.
Removal/lnspection
1. Remove the rel ease fork boot from the cl utch hous-
I ng.
2. Remove the rel ease fork from the cl utch housi ng by
squeezi ng the rel ease fork set spri ng wi th
pl i ers
Remove the rel ease beari ng.
Check the rel ease beari ng for
pl ay by spi nni ng i t by
hand.
CAUTION:
The rel eass beari ng i s
packed wi th
grease. Do not wash it in solvent.
l f there i s excessi ve
pl ay, repl ace the rel ease bear-
i ng wi th a new one.
RELEASE FORK
12-11
Rel ease Beari ng
Instal l ati on
NOTE: Us e onl y Super Hi gh Temp Ur ea Gr eas e
(P/N
08798
-
9002).
1. Wi th the rel ease fork sl i d between the rel ease bear-
i ng pawl s, i nstal l the rel ease beari ng on the mai n-
shaf t whi l e i nser t i ng t he r el ease f or k t hr ough t he
hol e i n t he cl ut ch housi ng.
RELEASE FORK BOLT
12 x
' l
. 25 mm
tP/N 0a79a-90021
O. 3- 0. 9
s 10. 01
- O. 03
ozl
Al i gn the detent of the rel ease fork wi th the rel ease
f or k bol t , t hen pr ess t he r el ease f or k over t he
rel ease fork bol t sequarel y.
-Gr
08798-9002)
2.
12-12
I J
3. Move the rel ease fork ri ght and l eft to make sure
that i t fi ts properl y agai nst the rel ease beari ng, and
that the rel ease beari ng sl i des smoothl y.
4. Instal l the rel ease fork boot; make sure the boot
seal s around the rel ease fork and cl utch housi no.
J
Manual Transmi ssi on
S40 Model
(Al l
except' 99
-
00 2-door Si ' Si R)
Manual Tr ansmi ssi on
. . . . . ". . . . . . ' . ' . . ". . . . . ".
13- 1
S4C Model
('99
-
00 2-door Si, SiRl
Manual Tr ansmi ssi on
. . . . . . . . . . . . . . . . . . . . . . . . . . . '
13- 45
\
\ t a
\
S40 Model
(All
except'99
-
00 2-door Si' SiR)
Manual
Transmi ssi on
Speci al Tool s
. . ' . . . . . . . . . . 13-2
Maintenance
Transmi ssi on
Oi l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3
Back-up Light Switch
Repl acement
. . . . . . . . . 13-3
Troubleshooting
' ....... 13-4
Transmission
AssemblY
Removal
. . . . . . . . . . . . . . . . . 13-5
l nst al l at i on
. . . . . . . . . . . . . 13-8
l l l ust rat ed
I ndex . . . . . . . . . . . . . . . ' . . . . . . . . . ". . . . . . . .
13-10
Transmission Housing
I Removaf
.."""""""' 13-12
J
R"rr"r"" Shift Holder
Cl earance l nspect i on . . . . . . . . . . . . . . . . . . . . . . .
13-13
Reverse ldler Gear
Removal
. . . . ' . . . . . . . . . . " 13-14
Mainshaft,
Countershaft, Shift Fork
Di sassembl y
. . . . . . ' . . . 13-14
Mainshaft AcsemblY
I ndex . . . . . . . . . . . . . . .
. . . . . . . 13-15
Cl earance
I nspect i on . . ' . . . . . . . . . . . . . . . . . . . . 13-16
Di sassembl y
. . . . . . . . . . 13-17
I nspect i on
. . . . ' . . . . . . . . . 13-18
Reassembl y
. . . . . . . . . . . 13-19
Countershaft
AssemblY
l ndex . . . . . . . . . . . . . . . .
. . . . . . 13-20
Cl earance l nspect i on . ". . . . . . . . . . ' . . . . . . . " 13-21
Disassembly
..."""' 13-22
I nspect i on
. . . . . . . . . . . . . . 13-23
Reassembl y
. . ' . "". . . 13-23
Shift Fork AssemblY
l ndex . . . . . . . . . . . . . . .
. "' . . . 13-25
Cl earance l nspect i on . ". . . . . . . ". . . . . . . . ' . .
13' 26
MBS Shift Piece Inspection ....-.....' .. 13' 27
Synchro Sleeve, Synchro Hub
f nspection/lnstallation
.......' ...... ".... 13' 27
Synchro Ring, Gear
I nspect i on
' . . . . ' . . ". . . . 13' 28
Shift Rod
Removal
. ' . . . . . . ". """ 13' 29
Differential
l ndex . . . . . . . "' . . . . . .
. ' . "' 13-30
Backl ash I nspect i on . . . . . . . . . . . ". . . . . . . ". . .
13-30
Beari ng Bepl acement ' . . . . . . . . . . . . . ' . ". . . .
13' 31
Final Driven Gear Replacement
' ..... 13-31
Thrust Shim Adiustment
..."........... 13-32
Clutch Housing Bearing
Replacement
.......' . 13-34
Mainshaft Thrust Shim
Adiustment
' ....' ..".. 13-36
Transmission
Reassembly
........... 13-39
Oil Seals
Replacement
......... 13-43
Gearshift Mechanism
Overhaul
. . . . . . . . . . . . . . . . 13-44
\
Speci al Tool s
Ref. No. I Tool Numbet
Description (Xy
I
Page Reference
o
@
o
.@
!'5,
@
o
@
6
@
@
@
(3
OTGAJ PG2O11O
OTGAJ PG2012O
07GAJ
-
PG20130
07736
-
A010004
07746
-
0010300
07746
-
0010400
07746
-
0030100
07746
-
0030300
07746
-
0030400
07749
-
0010000
07JAD
-
PH80101
07JAD
-
PH80200
07947
-
6110501 or
07947
-
6110500
Mai nshaft Hol der
Co l l a r
Mai nshaft Base
Adj ustabl e Beari ng Pul l er, 25
-
40 mm
Attachment. 42 x 47 mm
Attachment,52 x 55 mm
Dri ver, 40 mm LD.
Attachment, 30 mm I.D.
Attachment, 3S mm LD.
Dri ver
Dri ver Attachment
Pi l ot. 26 x 30 mm
Seal Dri ver Attachment
1 13-38
1 13-37
1
I
13-37
1 13- 34, 35
1 13- 34. 35
1 13- 34, 35
1
|
13-19,24
31, 32
1 13-19,24
1 13-19,24
r
I
t 3-34, 35, 43
1 13-43
1 13,43
1 I 13-43
*
Must be used wi th commerci al l y-avai l abl e
3/8"-j 6 Sl i de Hammer.
o aa
al
\91
o
ai
f!
o
l y tr
I v
I
Mai ntenance
Transmi ssi on Oi l
NOTE: Check the transmi ssi on oi l wi th the engi ne OFF
and t he vehi cl e on l evel gr ound.
1. Remove the oi l fi l l er pl ug, then check the l evel and
condi ti on of the oi l .
OIL FILLER PLUG
/14
N.m
(4.5
kgl .m,33 l bl .ft)
Proper Level
4.
WASHER
Repl ace.
The oi l l evel must be up t o t he f i l l er hol e. l f i t i s
bel ow the hol e, add oi l unti l i t runs out. then rei n-
stal l the oi l fi l l er pl ug wi th a new washer.
l f the transmi ssi on oi l i s di rty, remove the drai n
pl ug
and dr ai n t he oi l .
Rei nstal l the drai n
pl ug wi th a new washer, and refi l l
the transmi ssi on wi th the recommended oi l to the
proper l ever.
NOTE: The drai n pl ug washer shoul d be repl aced at
every oi l change.
Rei nstal l the oi l fi l l er pl ug wi th a new washer.
Oi l Capaci ty
1.8 f
(1.9
US qt. 1.6 l mp qtl at oi l change
1.9 {
(2.0
US
$,
1.7 l mp qt) at overhaul
Al ways use Genui ne Honda Manual Tr ansmi ssi on
Fl ui d {MTF).
Usi ng motor oi l can cause sti ffer shi ft-
i ng because i t does not cont ai n t he
pr oper addi -
t| ves.
\
\
Replacement
NOTE: To test the back-up l i ght swi tch, see secti on 23
1. Di sconnect the connector, then remove the back-up
l i ght swi rch connector from the connector cl amp.
2. Remove the back-up l i ght swi tch.
25 N. m
(2. 5 kgf ' m, 18l bf ' l t l
Instal l the new washer and back-up l i ght swi tch
Connect the back-up l i ght swi tch connector.
ASHER
13- 3
Troubleshooting
Reverse Gear Noise Reduction System
Whenever the cl utch
pedal
i s depressed to shi ft i nto reverse, the mai nshaft conti nues to rotate because of i ts i nerti a.
The resul ti ng speed di fference between mai nshaft and reverse i dl er gear produces gear noi se.
The reverse gear noi se reducti on system empl oys a cam pl ate whi ch was added to the reverse shi ft hol der. When shi fti ng
i nto reverse, the sth/reverse shj ft pi ece, connected to the shi ft l ever, rotates the cam pl ate. Thi s causes the sth synchro set
to stop the rotati ng mai nshaft. As there i s no speed di fference between mai nshaft and reverse i dl er gear, there wi l l be l ess
gear norse.
NOTE: Thi s system i s not a ful l y-synchroni zed gear noi se reducti on system.
Therefore,
you may hear gear noi se when
O
you shi ft i nto reverse wi th the vehi cl e not yet compl etel y stopped.
@
you
shi ft
qui ckl y i nto reverse duri ng fast i dl i ng.
-
Gear noise is oresent when shift-
ing into reverce after the engine
is started.
Test - dr i ve t he vehi cl e.
l s t he gear noi se present when
shi f t i ng i nt o 5t h gear?
Beplace the 5th synchro hub and
3leeve e3 a set,
Measure t he cl earance bet ween
5t h shi f t f or k and 5t h synchr o
sl eeve {see
page 13' 26).
l s t he cl earance 1. 0 mm
(0. 04
i n) or l ess?
Measure t he MBS shi f t pi ece pi n
(see page 13-27).
l s
(
6. 8 mm
(0. 27
i n) or more? Replace the MBS shift piece.
ReDlace the reve6e ahift hold.r.
13-4
Transmission
Assembly
I
Removal
@
. Make sure
iacks
and safety stands are
placed propdy,
and hoist brackets are atlachd 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.
CAUTION: Use fender covers to svoid damaging
painted
surfaces.
1. Di sconnect the negati ve {-)
cabl e fi rst, then the
pos-
itive
(+)
cable from the battery'
Drai n transmi ssi on oi l {see
page 13-3).
Remove the i ntake ai r tube. i ntake ai r duct and ai r
cl eaner housi ng assembl y
(see
secti on 5).
Di sconnect the starter motor cabl es, transmi ssi on
ground wi re and back-up l i ght swi tch connector.
6x1.0 mm BACK-UP LIGHT
9.8 N.m
(1.0 ksf.m, 7.2 l bI.ft) swl TcH CoNNECTOR
8x 1 . 25 mm
8. 8 N. m { 0. 9 kgt . m, 6. 5 l bf . f t l
\
ARTER
5. Remove the wi re harness cl amps.
vss
CONNECTOR
6. Di sconnect the vehi cl e speed sensor
(VSS)
connec-
ror.
Remove the cl utch l i ne bracket, cl utch l i ne cl amp,
and sl ave cvl i nder.
CAUTION:
. Do not opsr.te tho clutdh
pedal once the 3lavc
cylindor has b6on romoved.
. Tske care not to bend tha clutch lin6.
7.
(cont' d)
13- 5
Transmission Assembly
Removal
(cont' dl
8. Remove the dri veshafts
(see
secti on 161.
NOTE: Coat al l the preci si on fi ni shed surfaces wi th
cl ean engi ne oi l or grease. Ti e pl asti c bags over the
dri veshaft ends,
DRI VESHAFT
10 x 1. 25 mr n
43 N. m 14. 4 kgt . m,
32 rbf.frl
COTTER PI N
Repl ace.
SELF
1 2 x 1 . 2 5 mm
49- 59 N. m
( 5. 0 - 6. 0
kgt . m,
36-43 l bf . f t )
9. Remove exhaust pi pe A.
Repl ace.
1 2 x 1 . 2 5 mm
64 N. m {6. 5 kgt . m, 47 l bf . t r)
GASKETS
Repl ace.
IF\
sELF-LocKt NG NUT. ' ' 1/
Repl ace.
8 x 1. 25 mm
16 N. m { 1. 6 kgf ' m,
12 t bf . f t )
EXHAUST
PI PE A
SELF-LOCKI NG NUT
Repl ace.
I x 1. 25 mm
22 N. m
(2. 2
kgf . m,
16 t bt ' f r)
SELF-LOCKI NG NUT
Repl ace.
33 N. m {3. 4 kgf . m, 25 l bt . f t )
D16YB engi ne:
1 0 x 1 . 2 5 mm
54 N. m 15. 5 kgl ' m, 40 l bf . t t l
SET RI NG
13- 6
v
' 10.
Remove the shi ft rod and extensi on rod.
SI' IIFT BOD
8 x 2 2 m m
SPRING PIN
Repl ace.
EXTENSI ON ROD
PI N PUNCH, 8. O mm
(Commerci al l y
avai l abl e)
f-
' 1' 1.
Remove the engi ne sti ffeners and cl utch cover.
D16Y5, D16Y8 engines:
10 x 1. 25 mm
44 N. m
(4. 5
kgt . m,
33 tbf.tr)
I x 1. 25 mm
24 N. m
(2. 4
kgf . m
17 l bt . f rl
COVER
8 x 1. 25 mm
24 N.m 12.4 kgf'tn,
17 t bt . t r)
12.
D16Y7 engi ne:
ENGI NE
STI FFENER
10 X 1. 25 mm
It4
N' m
(4.5
kqf' m,33 l bf' l tl
Instal l the bol ts i n the cyl i nder head and attach a
chai n hoi st to the bol ts, then l i ft the engi ne sl i ghtl y
to unl oad the engi ne and transmi ssi on mounts.
CHAIN HOIST
13. Remove the sDl ash shi el d,
\
8 x 1. 25 mm
24 N. m
{2. 4 kgl . m,
SPLASH SHIELD
14. Remove the ri ght front mounvbracket.
' l O
x
' l . 25
mm
44 N' m
(4. 5
kgl . m,
33 rbf . f rl
Repl ace.
1 2 x 1 . 2 5 mm
64 N. m t 6. 5 kgf . m, 47 l bf ' f t )
Pl ace a
j ack
under the transmi ssi on.
Remove the transmi ssi on mount bracket and mount.
16.
TRANSMI SSI ON
MOUNT
TRANSMI SSI ON
BRACKET
(cont ' d)
13-7
Removal (cont' d)
17. Remove t he t hr ee upper t r ansmi ssi on mount i ng
bol ts and the l ower starter mounti ng bol t,
STARTER
MOUNTI NG
BOLT
1 0 x 1 . 2 5 mm
44 N. m
(4. 5
kgf . m,
33 rbnftl
TRANSMISSION
MOUI{TING EOLTS
1 2 x 1 . 2 5 mm
& N. m
(6. 5
kgt ' m, 47 l bl . f t l
18. Remove the rear mount bracket bol ts and transmi s-
si on mounti ng bol ts.
12 x 1. 25 mm
64 N. f t 16. 5 kgl . m, 47 l bl . f t l
SPECIAL BOLT
Repl ace.
' l l
x 1. 5 mm
84 N.m
(8.5
kgf.m, 61 lbf.ftl
SPECIAL BOLT
Repl ace.
14 x 1, 5 ml n
84 N. m
(8. 5
kgl . m, 61
WASI{ER
REAR
MOUNT
BRACKET
rbl.ftt
Pul l the transmi ssi on away from the engi ne unti l i t
cl ears the mai nshaft. then l ower i t on the transmi s-
si on
j ack.
CAUTION: Take caro not to b6nd tho clutch lin.
1( |
Installation
Instal l the transmi ssi on assembl y i n the reverse order of
removal .
Before i nstal l i ng, check that the two dowel
pi ns are
i nstal l ed i n the cl utch housi ng.
When i nstal l i ng the starter cabl e, make sure that the
cri mped si de of the ri ng termi nal i s faci ng out
(see
secti on 23).
Appl y grease to the parts as shown, then i nstal l the
rel ease fork and rel ease beari ng,
NOTE: Use onl y Super Hi gh Temp Ur ea Gr ease
(P/N
08798
-
9002).
RELEASE FORK BOLT
1 2 x 1 . 2 5 mm
29 N' m 13. 0 kgt , m,
(P/N
08798-90021
22 tbl.ttl
RLEASE
BEARI NG
J
RELEASE
FORK
8()07
r a
{Pi N 08798-9002)
tP/N 08798-90021
0. 3- 0. 9 g
10. 01- 0. 03 ozl
. Torque the mounti ng bol t and nuts i n the sequence
shown.
O
12 x 1. 25 mm
64 N. m {6. 5 kgt . m,
47 l bf . f r)
@
1 2 x 1 . 2 5 mm
74 N. m
(7. 5 kgl ' m,
54 tbt.fr)
Check that the bushings are not twisted or offset.
I nst al l t he cl i p as shown.
SHI FT ROD
Turn the boot so the hol e i s faci ng down.
Make sure the boot i s i nstal l ed on the shi ft rod.
O)
12 x
' l .25
mm
64 N.m 16.5 kgl .m,
47 tbt.ft)
I
a
a
a
a
8 x 1. 25 mm
N. m t 2. 2
kgt . m, l 6 l bl ' t t )
6 x 1 . 0 mm
9. 8 N. m
( 1. 0
kgl . m.
7. 2 t bf . t r)
. Appl y grease to the sl ave cyl i nder
push rod.
NOTE: Use onl y Super Hi gh Temp Ur ea Gr ease
{P/N 08798
-
9002}.
CLUTCH
UNE
a
a
(P/ N
-6tl
08798-9002)
8 x 1. 25 mm
22 N. m 12. 2 kgl . n.
16 t bf . f rl
. Turn the breather cap so that the
"F"
mark
poi nts at
the front of the car as shown.
Refi l l the transmi ssi on wi th the recommended oi l
(see page 13-3).
Connect the positive (+)
cable first, then the negative
(-)
cable to the battery.
Check the cl utch oDerati on,
Shi ft the transmi ssi on and check for smooth opera-
ti on.
Check the front wheel al i gnment
(see
secti on 18).
FRONT
13- 9
lllustrated lndex
!
Refer to the drawi ng bel ow for transmi ssi on di sassembl y/reassembl y,
Cl ean al l the
parts thoroughl y i n sol vent and dry wi th compressed ai r.
I
l uuri cate attthe parts wi th oi l before reassembty.
NOTE:
. Thi s transmi ssi on uses no
gaskets
betvveen the maj or housi ngs; use l i qui d gasket (Pi N
08718-0001 or08718-0003)
(see page 13-41).
. Al ways cl ean the magnet
@
whenever the transmi ssi on housi ng i s di sassembl ed.
. Inspect al l the beari ngs for wear and operati on.
a6_
' %/t' *.
k+-o
-{-g}.-_a
13- 10
Torque Val ue
A
-
15 N.m
(1.5
kgf.m, 1' 1 l bf.ft)
B
-
27 N.m
(2.8
kgf.m. 20 l bi ft)
C
-
31 N.m {3.2
kgnm, 23 l bi ft)
\
O
BALL BEARING
(*T)
ANGULAR
BALL BEARING {*2I
O
5TH SYNCHRO HUB
O
5TH SYNCHRO SLEEVE
)
SYNCHRO SPRING
o
SYNCHRO B| NG
@
5TH GEAR
@
gz
xgt x 23.5 mm
NEEDLE BEARING
@ SPACER COLLAR
@3 4 x 3 9 x 2 3 mm
NEEDLE BEARING
(D
4TH GEAR
O
SYNCHRO RING
C)
SYNCHRO SPRING
CO
3RD/4TH SYNCHRO SLEEVE
@
3RD/4TH SYNCHRO HUB
(}
3RD GEAR
@3 4 x 3 9 x 2 7 . 5 mm
NEEDLE BEARING
G)
MAINSHAFT
G)
WASHER
@
SPRING WASHER
@
BALL BEARING
Check for wear and
operati on.
(E
26x42x7 mm OIL SEAL
Repl ace.
@
28 mm PLUG BOLT
5,1 N.m {5.5
kgf'm,
/t0
lbt'ft)
@
l sT/zND SELECT SPRING
L. 36.26 mm
(1./P8
i n)
@
SHIFT ARM SHAFT
@
CLUTCH HOUSING
@
INTEELOCK GUIDE BOLT
39 N.m
(4.0
kgf.m, 29 lbf.ftl
@
REVERSE SHIFT HOLDER
@
REVERSE IDLER GEAR
@
REVERSE IDLER GEAR SHAFT
@
5 x 22 mm SPRING PIN
Repl ace.
@
3RD/4TH SHIFT PIECE
@
5TH/REVERSE SHIFT PIECE
@
MBS SHIFT PIECE
@
1ST/2ND SHIFI FORK
* 1: D16Y7
engi ne
*2:
@
3RD//|TH SHIFT FORK
@
5TH/REVERSE SHIFT FORK
@
52 mm SNAP RING
@
65 mm THRUST SHIM
(*11
70 mm THRUST SHIM
(*21
Sel ecti on,
page 13-36
@
OIL GUIDE PLATE
@
wASHER Repl ace.
@
BACK.UP LIGHT SWITCH
25 N.m
(2.5
kgf'm, 18 lbf'ft)
@
sET SCREW
22 N.m {2.2 kgf.m, 16 lbl.ft}
@
WASHER Repl ace.
@D
SPRI NG 1. 31. 6 mm
( 1. 2, 1i nl
@
STEEL BALL 15/16 i n)
@
BACK-UP LIGHT
SWITCH HARNESS BRACKET
@
TRANSMISSION HANGER
@ 32 MM SEALING BOLT
25 N.m
(2.5
kgf.m, 18 lbt'ft)
@ OIL SEAL
Repl ace.
@ OIL DRAIN PLUG
39 N.m
(4.0
kgf.m, 29 lbf.ft)
@
WASHER Repl ace.
@}
OIL FILLER PLUG
44 N.m
(4.5
kgf.m, 33 lbf'ftl
@
WASHER Repl ace.
@)
TRANSMISSION HOUSING
)
CLUTCH LINE BRACKET
@
OIL GUTTER PLATE
@
REVERSE LOCK CAM
@
REVEBSE SELECT SPRING
L. 63.4 mm {2.,196 in)
@
REVERSE SELECT RETAINER
@
SHIFT ARM C
@
SHIFT ARM B
@
INTERLoCK
@
COLLAR
@
SHIFT ARM A
@
SPRING WASHER
@
MAGNET
@ sET BALL SPRING BOLT
22 N.m
(2.2
kgf.m, 16 lbf.ftl
@
14 x 20 mm DOWEL PIN
@
72 mm THRUST SHIM l *11
80 mm THRUST SHIM
(*21
Sel ecti on,
page
' 13-33
@
DIFFERENTIAL ASSEMBLY
See
page 13-30
@
14 x 25 x 17.5 mm OIL SEAL
Repl ace.
@
35 x 56 x 8 mm OIL SEAL
Repl ace.
@ SHIFT ROD
@
BOOr
@
OIL GUIDE PLATE
@3 0 x 4 7 x 2 1
mm
NEEDLE BEARING
(*
1}
3 0 x 5 5 x 2 1 mm
NEEDLE BEARING {' 2)
@
COUNTERSHAFT
@36x 41
x 25. 5 mm
NEEDLE BEARING
Check for wear and
operatron.
@
l sT GEAR
@
FRICTION DAMPER
@
SYNCHRO RING
@
SYNCHRO SPRTNG
@
l ST/2ND SYNCHRO HUB
@
REVERSE GEAR
@
SYNCHRO SPRING
@
SYNCHRO RING
@
FRICTION DAMPER
@
SPACER
@3 9 x 4 l x 2 7 mm
NEEDLE BEARING
@ 2ND GEAR
@
3RD GEAR
@
4TH GEAR
@
sTH GEAR
@)
BALL BEARING {*
1}
NEEDLE BEARING
(*2}
@
BALL BEARING
@)
SPRING WASHER
@
LoCKNUT Repl ace.
108
-
0- 108 N. m
f t t . o*
o- 1r. o kst . m, l
179.6-
0- 79.6 rbtft
I
\ t
13- 1 1
Transmi ssi on Housi ng
Removal
NOTE: Pl ace the cl utch housi ng on two pi eces of wood
t hi ck enough t o keep t he mai nshaf t f r om hi t t i ng t he
workbench.
1. Remove the back-up l i ght swi tch.
2. Remove transmi ssi on hanger.
TRANSMISSION
HANGER
BACK-UP LIGHT SWITCH
Remove the setti ng screws. washers. spri ngs, and
steel bal l s.
STEEL BALLS
O. 5/ 16 i n
SPRING
L. 31. 6 mm I 1. 24 i nl
13- 12
SETTING SCREW
6.
4. Loosen the transmi ssi on housi ng attachi ng bol ts i n
a cri sscross pattern i n several steps, then remove
t hem.
Remove the 32 mm seal i ng bol t.
Expand the snap ri ng on the countershaft bal l bear-
i ng, and remove i t from the groove usi ng a pai r of
snap ri ng pl i ers.
32 mm SEALING EOLT
Separate the transmi ssi on housi ng from the cl utch
housi ng, and wi pe i t cl ean of the seal ant.
Remove the thrust shi m, oi l gui de pl ate. and oi l gut-
ter pl ate from the transmi ssi on housi ng.
(o
7.
otLGUTTER
TE
SNAP RING
Reverse Shift Holder
)
Glearance Inspection
1 . Measure the cl earance between the reverse shi ft
fork and sth/reverse shi ft
pi ece pi n.
Standard: 0.05
-
0.35 mm 10.002
-
0.01,1 inl
Service Limit 0.5 mm
(0.02
in)
l f the cl earances are more than the servi ce l i mi t.
measure the wi dths of the groove i n the reverse
shifi fork.
Standard: 7.05
-
7.25 mm
(0.278 -
0.285 inl
l f the wi dths of the grooves are not wi thi n the
standard, repl ace the reverse shi ft hol der wi th a
new one.
l f the wi dth of the
grooves are wi thi n the stan-
dard, repl ace the sth/reverse shi ft
pi ece wi th a
new one,
\
t
REVERSE
3. Measure the cl earance between the reverse i dl er
gear and the reverse shi ft fork.
Standard: 0.5- 1.1 mm {0.02
-
0.0,1i n)
Service Limii: 1.8 mm 10.07 inl
REVERSE IDLER GEAR
l f the cl garances i s more than thg servi ce l i mi t, mea-
sure the width of the reverse shift fork.
Standlrd: 12.7
-
13.0 mm {0.5110
-
0.512 in}
l f the wi dth i s not wi thi n the standard, repl ace
the reverse shi ft hol der wi th a new one.
l f the wi dth i s wi thi n the standard, repl ace the
revsrse i dl er gear wi th a new one.
REVRSE SHI FT FORK
REVERSE SHI FT FORK
REVERSE SHIFT HOLOER
1 3 - 1 3
Reverse ldler Gear
Mainshaft, Cou ntershaft,
Shift Fork
Removal
1. Remove the reverse shi ft hol der.
REVERSE SHIFT
HOLOER
Remove the reverse i d l er
i dl er
gear.
gear
shaft and reverse
REVERSE I DLER
GEAR SHAFT
13- 14
Di sassembl y
1. Remove t he i nt er l ock gui de bol t f r om under t he
cl utch housi ng.
SHIFT ARM 8
ATTACHING BOLT
CLUTCH
HOUSING
INTERLOCK GUIDE BOLT
Remove the shi ft arm B attachi ng bol t.
Remove the mai nshaft and countershaft assembl i es
wi th the shi ft fork from the cl utch housi nq.
NOTE: Before removi ng the mai nshaft and counter-
shaft assembl i es, tape the mai nshaft spl i nes to
pro-
tect the seal .
Tape t he mai nshaf t
spl i nes.
WASHER
SPRING
WASHER
Mainshaft
Assembly
I
l ndex
Note the fol l owi ng duri ng reassembl y:
. The 3rd/4th and sth svnchro hubs are i nstal l ed wi th a
press
. Instal l the angul ar bal l beari ng wi th the thi n-edge outer race faci ng the sth synchro hub
. Instal l the bal l beari ng wi th the bal l cage faci ng up
pri or
to reassembl i ng, cl ean al l the
parts i n sol vent, dry them and appl y l ubri cant to al l contact surfaces the 3rd/4th
and sth svnchro hubs.
Bal l cage f aces uP.
Thi n edge of out er
race laces down.
3RD/4TH SYNCHRO SLEEVE
page 13' 27
SYNCHRO SPRI NG
SYNCHRO RI NG
I nspect i on,
page 13- 28
BALL BEARING {*1)
ANGULAR BALL BEARING
('2)
Check for wear and operataon.
Note the direction ot installation
5TH SYNCHRO
SLEEVE
l nspect i on, page 13-27
SYNCHRO HUB
SYNCHRO RI NG
I nspect i on,
pase 13 28
sTH GEAR
I nspect i on,
page 13- 17
3RD GEAR
l nspect i on,
page 1 3-1 6
34 x 39 x 27. 5 mm
NEEDLE BEARI NG
Check f or wear
ano opet af l on,
MAI NSHAFT
I nspect i on, page 13- 18
CHAMFEB
32 x 37 x 23. 5 mm
NEEDLE BEARI NG
Check f or wear and
operat i on.
SPACER COLLAB
I nspect i on,
page 1316
3 4 x 3 9 x 2 3 m m
NEEDLE EEARI NG
Check f or wear
and operat i on,
4TH GEAR
rnspecl ron,
*1:
D16Y7 engi ne
*2:
p a g e 1 3 ' 1 6
RI NG
I nspect aon, page 13 28
SPRI NG
1 3 - 1 5
Mainshaft Assembly
NOTE: l f repl acement i s requi red, al ways repl ace the
synchro sl eeve and hub as a set.
1. Measure the cl earance between 2nd and 3rd gears,
Standard: 0.06
-
0.21 mm
10.002
-
0.008 in)
(0.013
i nl
2ND GEAR
3RO GEAR
l f the cl earance i s more than the servi ce l i mi t. mea-
sure the thi ckness of 3rd
gear,
Standard: 3O.22
-
3O.27 mm
{1.190
-
1.192 i n}
Servi ca Li mi t: 30.15 mm
(1.187
i nl
l f the thi ckness of 3rd gear i s l ess than the ser-
vi ce l i mi t, repl ace 3rd gear wi th a new one.
l f the thi ckness of 3rd gear i s wi thi n the servi ce
l i mi t, repl ace the 3rdl 4th synchro hub wi th a new
one.
/
-J-
i l - )
f r l " -
TI
Hl I
3RD GEAR
1 3 - 1 6
3. Measure the cl earance between 4th gear and the
spacer col l ar.
Standard: 0.06
-
0.19 mm
10.002
-
0.007 in)
10.012 in)
+
4TH GEAR
INDICATOR
I
f
-r
''==f{'
5TH GEAR
l f the cl earance i s more than the servi ce l i mi t, mea-
sure di stance
@
on the spacer col l ar.
Standard: ?2.V.
-
22.86 mm
10.8!t8
-
0.900 in)
Sorvica Limii: 22.81 mm {0.8t8 inl
4TH GEAR
SIDE
SPACER
COLLAR
l f di stanc
@
i s l ess than the servi ce l i mi t, repl ace
the spacer col l ar wi th a new one,
l f di stance
@
i s wi thi n the servi ce l i mi t, measure
the thi ckness of 4th gear.
Standard: 30.12
-
30.17 mm
(1.186 -
1.188 i nl
Servi c6 Li mh: 30.05 mm
(1.1&l
i nl
4TH GEAR
l f the thi ckness of 4th gear i s l ess than the ser-
vi ce l i mi t, repl ace 4th gear wi th a new one.
l f the thi ckness of 4th gear i s wi thi n the servi ce
l i mi t, repl ace the 3rdl 4th svnchro hub wi th a new
one,
di
T
6. Measure the cl earance between the spacer col l ar
and sth
gear.
Standard: 0.06
-
0.19 mm 10.002
-
0.007 inl
(0.012
i nl
4TH GEAR
DIAL
INDICATOR
I
-<=q,
7.
5TH GEAR
sure di stance @
on the spacer coi l ar
Standard: 23.53
-
23.56 mm
10.926
-
0.928 in)
Sowice Limit 23.51 mm {0.926 in}
SPACER
COLLAR
sTH GEAR
SIDE
l f di stance @
i s l ess than the servi ce l i mi t, repl ace
the spacer col l ar wi th a new one,
l f di stance @
i s wi thi n the servi ce l i mi t, measure
thickness of 5th
gear.
Siandatd: 28.1:2
-
28.17 mm
11. 119
-
1. 121 i n)
Servi ca Li mi t: 28.35 mm
(1.116
i nl
sTH GEAR
vi ce l i mi t, repl ace sth
Oear
wi th a new one.
l f the thi ckness of sth gear i s wi thi n the servi ce
l i mi t , r epl ace t he 5t h synchr o hub wi t h a new
one.
Di sassembl y
1. Remove the bal l beari ng usi ng a beari ng pul l er as
shown.
BEARI NG PULLER
(Commerci al l y
avai l abl el
CAUTION: Remov ths synchro hubs using a
press
and steel blocks as shown. Us of a
iaw-type
pullel
can caus damage lo the gear teeih.
Suppor t 4t h gear on st eel bl ocks. and pr ess t he
mai nshaft out of the sth svnchro hub as shown.
{cont' d)
13-17
Mainshaft Assembly
Disassembly
(cont'd)
3. Support the 3rd gear
on steel bl ocks, and press
the
mai nshaft out of the 3rd/4th synchro hub as shown.
1 3 - 1 8
Inspection
' 1.
I nspect t he gear sur f ace and bear i ng sur f ace f or
wear and damage. then measure the mai nshaft at
poi nts A, B, C, and D.
Siandard: A: 21.987
-
22.000 mm
10.8656
-
0.8661 i nl
B: 26.980
-
26.993 mm
11.0622
-
1.0627 inl
C: 33.98,1- 34.000 mm
(1.3380 -
1.3385 i n)
D: 25.977
-
25.990 mm
|.1.0227
-
1.0232 inl
Service Limit: A: 21.930 mm 10.8634 inl
B: 26.930 mm {1.0602 in}
C: 33.930 mm
(1.3358
i n)
D: 25.920 mm
(1.0205
i n)
Check for wear and damage
l f any part of the mai nshaft i s l ess than the servi ce
l i mi t, repl ace i t wi th a new one.
2. Inspect for runout.
Standardi 0.02 mm
(o.(Xtl
in) max.
Srvice Limii: 0.05 mm
(0.002
in)
NOTE: Suppor t t he mai nshaf t at bot h ends as
snown.
l f the runout i s more than the servi ce l i rni t, reol ace
the mai nshaft wi th a new one.
Y
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.
NOTE: Refer to
page 13-15 for reassembl y sequence.
1. Support 2nd
gear on steel bl ocks' then i nstal l the
3rd/4th synchro hub usi ng the speci al tool s and a
oress.
ATTACHMENT,
35 mm LO.
07746-OO3O/+OO
\r' ,
2I{D GEAR
Instal l the 3rd/4th synchro sl eeve by al i gni ng the
stops of the 3rdl4th synchro sleeve and hub.
NOTE; After i nstal l i ng, check the operati on of the
3rd/4th svnchro hub set
SYf{CHRO SLEEVE
3. Instal l the sth
ano a press.
synchro hub usi ng the speci al tool s
DRI VR, 40 mm I O.
07746
-0030' 100
ATTACHMENT,
30 mm l .D.
07746
-O030300
sTH SYNCHRO
HU8
Instal l the bal l beari ng i n the di recti on shown usi ng
the speci al tool s and a
Press.
DRIVER,
iO
mm l.D.
07746
-
lxxlollx'
ATTAGHMENT, 30 mm l.D.
077i16
-
00303qt
BAI-L BEARING
Bal l cage f aces uP
*1:
D16Yt engane
*2:
Dl 6Y5, D16Y8 6ngi nes
1 3 - 1 9
Countershaft Assembly
Index
I . r
NOTE:
-re
The 3rd, 4th, and sth gears
are i nstal l ed wi th a press.
Pri or_to reassembl i ng, cl ean al l the parts i n sol vent, dry them and appl y l ubri cant to al l contact surfaces except the
3rd, 4th, and 5th gears.
Snap ri ng groove f aces up.
LOCKNUT Repl ace.
108- O- 108 N. m
I
1 1 . 0 - O- 1 1 . 0 k s t . ml
I
79. 6-0- 79. 6 l bt . f t
I
SYNCHRO SPRI NG
SYNCHRO RI NG
I nspect aon, page 13- 28
FRI CTI ON DAMPER
Thi n edge ol out er
race f aces down.
Check f or wear and
operat ron,
/
BALL EEAR| NG
t *1)
t
NEEDLE BEARTNG (. 2)
Check f or wear
and operat ron,
WASHER
BEARI NG
GEAR
4TH GEAR
3RD GEAR
2ND GEAR
FRICTION DAMPER
SYNCHRO SPRI NG
SYNCHRO RI NG
I nspect i on, page 13-28
36 x 41 x 25. 5 mm
NEEDLE BEARI NG
Check f or wear and operat aon.
1ST GEAR
l nspect i on, page
13 21, 28
l nspect i on, page 13-21, 28
3 9 x 4 4 x 2 7 mm
NEEDLE BEARIfI'G
Check f or wear and
operat i on.
SPACER COLLAR
REVERSE GEAR
l nspect i on, page 13 27
1ST/ 2ND SYNCHRO HUB
*1:
D' 16Y7 engi ne
*2:
13-20
I ) t
Clearance
Inspection
NOTE: l f repl acement i s requi red, al ways repl ace the
synchro sleeve and hub as a set.
1. Measure the cl earance between the countershaft
and l st
gear.
Standard: 0.03
-
0.10 mm
(0'(X)l -
0'qt4 in)
Sorvic. Limit: 0.22 mm
(0.009
inl
2. l f the cl earance i s more than the servi ce l i mi t, mea-
sure the thi ckness of 1st
gear.
Standard: 30./tl
-
30.'l'l mm
11.197
-
1.198 i n)
Servics Limit 30.36 mm
(1.195 in)
l f the thi ckness of 1st
gear i s l ess than the servi ce
l i mi t, repl ace l st gear wi th a new one.
l f the thi ckness of 1st gear i s wi thi n the servi ce
l i mi t, repl ace the l sv2nd synchro hub wi th a new
one.
GAUGE
1ST GEAB
3. Measure the clearance between 2nd and 3rd
gears.
Standard: 0.04
-
0.12 mm
(0.002 -
0.005 in)
Servico Limit: 0.2,1 mm 10.009
in)
sure th thi ckness of the spacer col l ar'
stlndard: 32.G1
-
32'06 mm
{1.261
-
1.262 i n}
S6rvica Limh: 32'01 mm
(1'260
in)
SPACER
COLLAR
l f the thi ckness i s l ess than l he servi ce l i mi t, repl ace
the sDacer col l ar wi th a new one.
l f ths thi ckness i s wi thi n the servi ce l i mi t, measure
the thi ckness of 2nd
gear.
Standard: 31.91
-
31.96 mm
11.256
-
1.258 i nl
Soryi ce Li mi t 31.85 mm
(1.25,1i nl
z4:_-
2I{D GEAF
/ l \ \ \ /
j'T
-
"b/
P-
1^' .-1r.--l
- - f
l f the thi ckness of 2nd
gear i s l ess than the ser-
vi ce l i mi t, repl ace 2nd
gear wi th a new one.
l f the thi ckness of 2nd
gear i s wi thi n the servace
l i mi t, repl ace the l sv2nd synchro hub wi th a new
one,
13-21
Di sassembl y
CAUTION: Remove the gears usi ng a press and steel
blocks as shown. Use of a
iaw-type
puller can damage
the gear teeth.
1. Sec ur el y c l amp t he c ount er s haf t as s embl y i n a
bench vi se wi th wood bl ocks.
2. Rai se the l ocknut tab from the groove
of the coun-
t er shaf t , t hen r emove t he l ocknut and t he spr i ng
washer.
3. Remov e t he bear i ngs us i ng a bear i ng pul l er
as
shown.
EEARING PULLER
\
4. Support 4th gear on steel bl ocks, and press
the coun-
tershaft out of 5th and 4th gears as shown.
Support 1st gear
on steel bl ocks, and press the coun-
tershaft out of 3rd gear
as shown.
5.
I . /
3RD GEAR
1ST GEAR
Inspection
1 .
surfaces l or
countershaft
Inspect the
gear surfaces and bearang
wear and damage, t hen measur e t ne
at poi nts A, B, and C.
Standard:
A: 30.000
-
30.015 mm
( 1. 1811- 1. 1817 i nl
B: 35.984
-
36.000 mm
( 1. i 1167
-
1. 4173 i nl
C: 24.980
-
2i1.993 mm
{0.9835
-
0.9840 in)
Seryi ce Li mi t: A: 29.950 mm
(1.1791 i nl
B: 35.930 mm
(1 ' 1146
i n)
C: 24.930 mm 10.9815
i n)
Check oi l passages
f or cl oggr ng-
I
Check f or wear
ano oamage.
. l f any
part of the countershaft
i s l ess than
servi ce l i mi t, repl ace i t wi th a new one.
Inspect for runout.
Standard:
0.02 mm
(0.001
i nl max.
Seryice Limit: 0.05 mm {0'002
in)
. l f the runout i s more than the servi ce l i mi t. repl ace
the countershaft
wi th a new one.
t he
2.
t ,
3. Instal l the
parts on the countershai t
Reassembl y
CAUTION:
. Press the 3rd,4th, and sth gears on the countershaft
without lubrication.
. When installing the 3rd. 4th, and 5th
geals, support
the shaft on steel bl ocks and i nstal l the
gears usi ng a
pless.
NOTE: Rel er to
page 13-20 for reassembl y sequence'
1. l nstal l the needl e beari ng on the countershaft'
, 3 6 x 4 1 x 2 5 . 5 mm
NEEDLE BEARI NG
COUNTERSHAFT
2. Assembl e the pans bel ow as shown.
NOTE: Check that the fi ngers of the fri cti on damper
are securel y set i n the
grooves of the 1sv2nd syn-
chro hub.
2ND GEAR
3 9 x / + 4 x 2 7 mm
NEEDLE BEARING
SPACER COLLAR
FRICTION DAMPER
SYNCHRO RING
SYNCHRO SPRING
REVERSE GEAR
l ST/ 2NO
SYNCHRO
HUB
SYNCHRO SPRING
SYNCHRO RING
FRICTION DAMPER
1ST GEAR
(cont ' d)
13-23
Reassembly
(cont'd)
4. Suppon the countershaft on a steel bl ock as shown
and i nstal l 3rd gear usi ng the speci al tool s and a
press.
PRESS
35 mm l . o.
07746-0030400
5. Instal l 4th gear usi ng the speci al tool s and a
press.
DRl vER. 40 mm
DRI VER, 40 mm LO.
07746
-0030100
ATTACHMENT,
07746- 0030100
ATTACHMENT,
DRI VER, 40 mm l . D.
07746-0030100
ATTACHMENT,
30 mm l . D.
35 mm LO.
07746-0030400
6. Instal l 5th gear usi ng the speci al tool s and a Dress.
07746-0030300
5TI{ GEAR
.g
7. Instal l the beari ngs i n the di recti on shown usi ng the
sDeci al tool s and a oress.
CAUTION: Instal l ths beari ngs wi th a maxi mum
pressure
ot 7.8 kN {800 kgt, 5,786 lbfl.
ATTACHMENT,
30 mm l . D.
07745
- q'303tl)
*1:
016Y7 engi ne
*2:
Thi n edge of out er
race faces down,
8. Secur el y cl amp t he count er shaf t assembl v i n
bench vise with wood blocks.
LOCKNUT
108+0r 108N. m
(11.0 *
0
-
11.0 kgt m. 79.6
-
0
*
79.6 tbf.ft)
Instal l the spri ng washer, ti ghten the l ocknut, then
stake the l ocknut tab i nto groove.
/rt-\
sry
Snap ri ng
\
lacss up.
\ J
Shift Fork AssemblY
l ndex
I
I
eri o, ,o reassembl i ng,
cl ean al l the
parts i n sol vent, dry them, and appl y l ubri cant to any contact
parts'
3RD/ 4TH SHI FT FORK
5THi REVERSE
SHI FT FORK
5TH/REVERSE
SHIFT PIECE
M8S SHI FT
PI ECE
3RD/ 4TH
SHI FT PI ECE
1ST/ 2ND SHI FT FORK
\ a
13-25
Shift Fork Assembly
NOTE: The synchro sl eeve and the synchro hub shoul d
be replaced as a set.
l . Measure the cl earance between each shi ft fork and
i ts matchi ng synchro sl eeve.
Standard: 0.35
-
0.65 mm {0.014
-
0.026 int
Service Limit 1.0 mm
(0.04
in)
sure the thi ckness of the shi ft fork fi ngers.
Standard:
3rd/ilth: 7.il
-
7.6 mm
{0.291
-
0.299 in}
lst/2nd, 5th: 6.2
-
6.il mm
(O.2,tt -
0.252 in)
l f the thi ckness of the shi ft fork fi nge.s i s not
wi thi n the standard, repl ace the shi ft fork wi th a
new one.
l f the thi ckness of the shi ft fork fi ngers i s wi thi n
the standard. repl ace the synchro sl eeve wi th a
SHI FT FORK
13-26
J
3. Measure the cl earance between the shi ft pi ece
or
shi ft fork and the shi ft arm B.
Standard: 0.2
-
0.5 mm {0.008
-
0.02 in}
Sarvice Limit: 0.62 mm 10.0244 inl
sure the groove
of the shi ft pi ece
or shi ft fork,
Standard: 13.2
-
13.4 mm
(0.520 -
0.b28 inl
l f the groove
of the shi ft pi ece
or shi ft fork i s not
wi thi n the standard, repl ace the shi ft pi ece
or
shi ft fork wi th a new one.
l f the groove of the shi ft pi ece or shi ft fork i s
wi thi n the standard, repl ace the shi ft arm B wi th
a new one.
\ J
Synchro
Sleeve,
Synchro
Hub
MBS Shift Piece InsPection
1. Measure the wi dth of the MBS shi ft
pi ece.
Standard; 6.9
-
7.1 mm 10
272
-
0.280 inl
Service Limit: 6.8 mm {0.268
inl
l f the wi dth of the MBS shi ft
pi ece i s l ess than
servi ce l i mi t, repl ace the MBS shi ft
pi ece'
t
I nspection/l
nstallati on
' 1.
l nspect
gear teeth on al l synchro hubs and synchro
sl eeves t or r ounded of f cor ner s, whi ch i ndi cat e
I nst al l each synchr o hub i n i t s mat i ng synchr o
sl eeve, and check for freedom of movement.
NOTE: l f repl acement i s requi red, al ways repl ace
the synchro sl eeve and synchro hub as a set.
SYNCHRO
SLEEVE
When assembl i ng
the synchro sl eeve and synchro
hub, be sure to match the three sets of l onger teeth
(120
degrees apart) on the synchro sl eeve wi th the
three sets of deeper
grooves i n the synchro Hub
CAUTION: Do not install th sYnchro sleeve with
its longsr tsth in the synchro hub slots bocause ii
will damage ths spring ring.
LONGER TEETH
13-27
Synchro Ri ng, Gear
Inspection
1. Inspect the synchro ri ng and gear.
A: Inspect the i nsi de of the synchro ri ng for wear.
B: Inspect the synchro sl eeve teeth and matchi ng
teeth on the synchro ri ng for wear
(rounded
off).
r-\ /-\
oioi *-o*
C: Inspect the synchro sl eeve teeth and matchi ng
teeth on the gear for wear
(rounded
off).
, \ n
U t J
GOOO WORN
D: Inspect the
gear
hub thrust surface for wear.
E: Inspect the cone surface for wear and roughness.
Fr Inspect the teeth on al l gears for uneven wear,
scori ng, gal l i ng, and cracks.
2. Coat the cone surface of the gear wi th oi l . and pl ace
the synchro ri ng on the matchi ng gear.
Rotate the
synchro ri ng. maki ng sure that i t does not sl i p.
Measure the cl earance between the synchro ri ng
and gear al l t he way ar ound.
NOTE: Hol d the synchro ri ng agai nst the gear evenl y
whi l e measuri ng the cl earance.
Synchro Ring-to-Gear Clearance
Standard: 0.73
-
1.18 mm {0.029
-
0.046 i n}
Service Limit 0.4 mm {0.02 in)
l f the cl earance i s l ess than the servi ce l i mi t, repl ace
the synchro ri ng and synchro cone.
SYNCHRO
SYNCHRO
\a
r /
13-28
Shift
Rod
Removal
NOTE: The steel batl sareal l
of the same si ze
(5/16 i n)'
1. Remove the di fferenti al assembl y'
2. Remove t he 28 mm
pl ug bol t and l st / 2nd sel ect
spr i ng.
3. Remove the shi ft arm C attachi ng
bol t'
4. Remove the shift arm shaft'
NOTE: Be careful notto l ose the steel bal l '
5. Remove the steel bal l , spri ng, and col l ar'
SHI FT ARM C
SHI FT ARM B
INTERLOCK
6. Remove shi ft arms C and B, and the i nterl ock, then
remove the reverse sel ect spri ng and retai ner'
7. Remove the shi ft arm A attachi ng bol t, the set bal l
spri ng bol t, set spri ng, and steel bal l '
8. Remove the shi ft rod' then remove the shi ft arm A'
9. Remove the reverse l ock cam'
10. Remove the magnet.
CAM
REVERSE
SELECT RETAINER
REVERSE SELECT SPRING
L. 63. 4 mm {2. 50
i nl
REVERSE LOCK
l
I
V /
' l J
\s
SPRI NG L. 21. 4 mm
(0. 843 i n)
SI{IFT ARM A
1 4 x 2 0
OOWEL PIN
COLLAR
,*(S* \
6S* \
srtrr ran,t srarr
\ \
\
',)r,r"o
r..."r "rr,*n
\
t . 36. 26 mm {1. 428
i n,
28 mm PI-UG BOLT
OI L SEAL
Repl ace.
&-"onn"
BALL
SPRI NG EOLT
SPRING
L. 25. 6 mm 11. 01
i nl
DI FFERENTI AL
ASSEMBLY
SHI FT ROD
Differential
Check l or cr acks.
BALL BEARI NG
Check f or wear and damage.
DI FFERENTI AL
THRUST SHI M
Sel ect i ve part
SPEEDOMETER
DRI VE GEAR
1 0 x 1 . 0 mm
101 N. m
(10. 3
ksf . m. 74. 5 l bt . f t l
Lef t -hand t hreads
ffi
FrNAL DRTvEN o*^r' @
c' ec' owea' - Zl
BALL BEARI NG
Check f or wear and damage.
13- 30
Backlash Inspection
' 1.
Pl ace di fferenti al assembl y on V-bl ocks, and i nstal l
both dri veshafts.
OI AL
Measure backl ash of both pi ni on gears.
Standard
{New); 0.05
-
0.15 mm
{0.002
-
0.006 in)
l f the backl ash i s not wi thi n the standard, reDl ace
the di fferenti al carri er.
S I
I
Beari ng
RePl acement
NOTE: Check beari ngs for wear and rough rotati on l f
the beari ngs are OK, removal i s not necessary'
' 1.
Remove the bal l beari ngs usi ng a beari ng
pul l er as
shown.
EALL BARI NG
l nstal l new bal l beari ngs usi ng the speci al tool as
shown.
NOTE: Dri ve the beari ngs squarel y unti l they bot-
tom agai nst the carrl er.
DRI VER, 40 mm LD.
?746
-0030100
\ 1 ,
Fi nal Dri ven Gear RePl acement
1, Remove the bol ts i n a cri sscross
pattern i n several
steps, then remove the fi nal dri ven
gear from the
di tferenti al carri er'
NOTE: The fi nal dri ven
gear bol ts have l eft-hand
threads.
10 x 1. 0 mm BOLT
1o1 N. m l l O. 3
kgf ' m, 74
5l bf ' f t )
Lel t' hand
threads
l nstal l the fi nal dri ven
gear by ti ghteni ng the bol ts
in a crisscross
pattern in several steps'
Differential
Thrust Shim Adjustment
1. Instal l the di fferenti al assembl y, maki ng sure i t bot-
toms i n the cl utch housi ng, usi ng the speci al tool as
shown.
DRIVER, 40 mm LD.
07746 0030100
Instal l the thrust shi m.
NOTE: Instal l the same si ze thrust shi m that was
removed.
Y
Instal l the transmi ssi on housi ng (see page l 3-41).
NOTE: Do not appl y l i qui d gasket
to the mati ng sur-
face of the cl utch housi ng.
Ti ght en t he t r ansmi ssi on housi ng at t achi ng bol t s
(see page
13-42).
I x 1,25 mm
27 N.m
(2.8
kgt'm, 20 lbf'ft}
Use the special tool to bottom the differential assem-
bl y i n the cl utch housi ng.
t J
6. Measure cl earance between thrust shi m
i ng outer race i n transmi ssi on housi ng.
and bear-
13-32
7. l f the cl earance i s more than the standard, sel ect a
new thrust shi m from the fol l owi ng tabl e
NOTE: It the cl earance measured i n step 6 i s wi thi n
the standard.
go to step 10.
Standard: 0
-
0.10 mm l0
-
0.00/t inl
72 mm THRUST SHIM: D16Y7 engi n
\
Part Number
Thickness
41441
-
PL3
-
A00 1.0 mm
(0.0394
i n)
41442- PL3- A00
' 1
.1 mm {0.0433
i n)
41443- PL3- A00
1.2 mm {0.0472
i n)
41444- PL3- A00
1. 3 mm
( 0. 0512
i n)
41445- PL3- A00
1. 4 mm
( 0. 0551 i n)
41446- PL3- A00
1. 5 mm
( 0. 0591 i n)
41447- PL3- A00
1. 6 mm
( 0. 0630 i n)
41448- PL3- A00
1.7 mm
(0.0669
i n)
4r 449- PL3- A00
1.8 mm
(0.0709
i n)
41450- PL3- A00
1. 05 mm { 0. 0413
i n)
41451- PL3- A00
1. 15 mm
( 0. 0453 i n)
41452- PL3- A00
1.25 mm
(0.0492 i n)
41453- PL3- A00
1.35 mm
(0.0532
i n)
41454- PL3- A00
' 1.45
mm
(0.057' l
i n)
41455- PL3- A00
1. 55 mm
( 0. 0610
i n)
41456- PL3- A00
1.65 mm
(0.0650
i n)
41457- PL3- A00
1. 75 mm
( 0. 0689 i n)
80 mm THBUST SHIM: D16Y5. D16Y8 engi nes
Remove the bol ts and transmi ssi on housi ng.
Repl ace t he t hr ust shi m sel ect ed i n st ep 7, t hen
Remove the bol ts and transmi ssi on
housi ng. Appl y
l i qui d gasket t o t he sur f ace of t he t r ansmi ssi on
housi ng and reassembl e
8.
9.
10.
Part Numbel
Thickness
41441
-
PL3
-
B00 1. 0 mm
( 0. 0394 i n)
41442- PL3- 800
1. 1 mm
( 0. 0433 i n)
41443- PL3- 800
1. 2 mm
( 0. 0472
i n)
41444- PL3- 800
1. 3 mm
( 0. 0512 i nl
41445- PL3- 800
1. 4 mm
( 0. 0551
i n)
41446- PL3- 800
1. 5 mm
( 0. 0591 I n )
41447- PL3- 800
1.6 mm
(0.0630
i n)
4r 448
-
PL3
-
800 1.7 mm
(0.0669 i n)
4 t449
-
PL3
-
800 1.8 mm
(0.0709
i n)
41450- PL3- 800
' 1. 05
mm
( 0. 0413 i n)
41451
-
PL3
-
800
' 1.15
mm
(0.0453 i n)
41452- PL3- 800
1.25 mm
(0.0492
i n)
41453- PL3- B00
1. 35 mm
( 0. 0532
i n)
41454- PL3- B00
1. 45 mm
( 0. 0571
i n)
41455- PL3- B00
1. 55 mm
( 0. 0610
i n)
41456- PL3- 800
1.65 mm
(0.0650 i n)
4 1 4 5 7 - PL 3 - 8 0 0
1.75 mm {0.0689
i n)
Cl utch Housi ng Beari ng
Repl acement
Mainshaft
1. Remove the bal l
shown.
beari ng usi ng t he speci al t ool as
3i 8
"
-16
SLI DE HAMMER
(Commerci al l y
avai l abl e)
ADJUSTAELE BEARI NG
PULLER, 25-40 mm
07736-AO10004
2, Remove t he oi l seal f rom t he cl ut ch housi ng,
CLUTCH
Repl ac e.
13-34
l.
3, Dri ve the new oi l seal i nto the cl utch housi ng usi ng
ATTACI{MENT, 42 x 47 mm
07746
-0010300
CLUTCH
HOUSI NG
Dri ve the bal l beari ng i nto the cl utch housi ng usi ng
ATTACHMENT, 52 x 55 mm
DRI VER
07746 0010400 07749-0010000
t . /
07749
-0010000
Cou ntershaft
1. Remove the needl e beari ng usi ng the speci al tool as
shown. then remove the oi l
gui de pl ate
3/ g
"
-16
SLI DE HAMMER
{Commerci al l y
avai l abl e)
PULLER, 25-40 mm
07736-AO1000A
\
2. I nst al l t he oi l
gui de
Pl at e,
t hen
bear i ng i nt o t he cl ut ch housi ng
tool s as shown.
d r i ve t he needl e
usi ng t he speci al
' 1:
ATTACHMENT,
42 x 47 mm
07746-0010300
*2:
ATTACHMENT,
52 x 55 mm
07746
-0010400
ORIVER
07749
-0010000
CLUTCH
HOUSI NG
NEEOLE BEAFI NG
GUIDE PLATE
NEEOLE BEARI NG
* 1:
D16Y7 enqi ne
*2:
OI L GUI DE PTATE
13- 35
Mai nshaft Thrust Shi m
Adjustment
Remove t he t hr ust shi m and oi l
the transmi ssi on housi ng.
1 . gu i de pl at e
f r om
THRUST SHI M
OI L GUI DE
PLATE
TBANSMI SSI ON
HOUSI NG
Instal l the 3rd/4th synchro hub, spacer col l ar, 5th
synchro hub, bal l beari ng, and thrust washer on the
mai nshaft. Instal l the assembl y i n the transmi ssi on
h ousi ng.
@
gnol +l x
syNcHRo HUB
THRUST WASHER
SPACER COLLAR
4.
Measur e t he di st ance
@ bet ween t he end of t he
transmi ssi on housi ng and thrust washer.
NOTE:
.
Use a strai ght edge and verni er cal i per.
. Measure at three l ocati ons and average the read-
Ings.
Measure the di stance
@ between the surfaces of
the cl utch housi ng and beari ng i nner race.
NOTE:
. Use a strai ght edge and depth gauge.
. Measure at three l ocati ons and average the read-
Ings.
sTH SYNCHRO I I UB
BALL EEARING
CLUTCH
L
HOUSI NG ENO OF
13- 36
I NNER RACE OF BALL AEARI NG
\
5. Sel ect the proper
shi m on the basi s of the fol l owi ng
cal cul ati ons:
NOTE: Use onl y one thrust shi m.
(Basi c
Formul a)
( B)
+
{ C) . 0. 95
=
shi m t hi ckness
Example of calculation:
Di st ance
@
( 2. 00
mm) + Di st ance
@
=
2.09 mm
subtract the spri ng washer hei ght
(0.95
r equi r ed t hr ust shi m
( 1. 14
mm)
65 mm THRUST SHIM: D16Y7 engi ne:
( 0. 09
mm)
mm)
=
t ne
r 1
Part Numbor Thickness
23931
-
PL3 A10 0. 60 mm
(0. 0236
i n)
23932
-
PL3 A10 0. 63 mm 10. 0284 i n)
c 23933
-
PL3 A10 0. 66 mm {0. 0260 i ni
D 23934 PL3
-
A10 0. 69 mm
(0. 0272
i n)
E 23935- PL3- 410 0.72 mm 10.0283 i n)
F 23936- PL3- 410 0. 75 mm 10. 0295 i n)
G 2 3 9 3 7 - PL 3 - A1 0 0. 78 mm {0. 0307 i n}
23938 PL3
-
A10 0. 81 mm
(0. 0319
i n)
I 23939
-
PL3 At 0 0. 84 mm
(0. 0331
i n)
J 23940- PL3- Ar 0 0. 87 mm (0. 0343
i n)
23941
-
PL3
-
A10 0. 90 mm
(0. 0354
i n)
L 23942
-
PL3 A10 0. 93 mm
(0. 0366
i n)
23943- PL3- A10
0. 96 mm
(0. 0378
i n)
N 23944 PL3
-
A10 0. 99 mm 10. 0390 i n)
o 23945- PL3- A10 1. 02 mm {0. 0402 i n}
23946
-
PL3 A10 1. 05 mm ( 0. 0413
i n)
o 23947 PL3
-
410 1. 08 mm
(0. 0425
i n)
R 23948- PL3- A10 1. 11mm ( 0. 0437
i n)
s 23949 PL3
-
A10 1. 14 mm { 0. 0449 i n}
T 2 3 9 5 0 - PL 3 - A1 0 1. 17 mm
( 0. 0461
i n)
U 23951 PL3
-
A10 1. 20 mm
(0. 0472
i n)
23952- PL3- Ar 0 1. 23 mm {0. 0484 i n)
23953- PL3- A10 1. 26 mm {0. 0496 i n}
X 23954
-
P13, A10 1. 29 mm
(0. 0508
i n)
23955
-
PL3 A10 1. 32 mm
(0. 0520
i n)
z 23956- PL3- Ar 0 1. 35 mm
{0. 0531 i n)
23957- PL3- A10 1. 38 mm
(0. 0543
i n)
AB 239s8
-
PL3 A10 1. 41 mm
(0. 0555
i n)
AC 23959 PL3
-
A10 1. 44 mm
(0. 0567
i n)
AD 23960
-
PL3 A10 1. 47 mm
(0. 0579
i n)
23961
-
PL3 410 1. 50 mm
(0. 0591
i n)
23962 PL3
-
A10 1. 53 mm
(0. 0602
i n)
AG 23963- PL3- 410 1. 56 mm (0. 0614
i n)
AH 23964
-
PL3 A10 1. 59 mm (0. 0626
i n)
AI 2 3 9 6 5 - PL 3 - A1 0 1. 62 mm
{0. 0638 i n)
23966 PL3
-
A10 1. 65 mm
(0. 0650
i n)
AK 23967- PL3- A10 1. 68 mm
{0. 0661 i n)
23968 PL3
-
A10 1. 71 mm {0. 0673 i n)
23969- PL3- A10 1. 74 mm
(0. 06a5
i ni
AN 23970- PL3
- A10
1. 77 mm ( 0. 0697
i n)
AO 23971
-
PL3
-
A10 1. 80 mm
10. 0709 i n)
70 mm THRUST SHIM: Dl6Y5, Dl6Y8 engins
Part Number
Thickness
23931
-
PL3
-
800 0. 60 mm 10. 0236
i n)
23932- PL3- 800
0.63 mm
(0.0284 in)
c 23933- PL3- 800
0. 66 mm
(0. 0260 i n)
D 23334- PL3- 800
0. 69 mm 10. 0272
i n)
E 23935- PL3- 800 0. 72 mm
(0. 0283 i n)
F 23936
-
PL3 800 0. 75 mm
(0. 0295 i n)
23937- PL3- B00
0. 78 mm
(0. 0307 i n)
23938- PL3- 800
0. 81 mm
(0. 0319 i nl
23939- PL3- 800
0. 84 mm
(0. 0331 i n)
23940- PL3- 800
0. 87 mm {0. 0343 i n)
23941
-
PL3
-
800 0. 90 mm
(0. 0354 i n)
L 23942- PL3- 800
0.93 mm
(0.0366
i n)
23943- PL3- 800
0. 96 mm
(0. 0378 i n)
N 23944- PL3- 800
0. 99 mm i 0. 0390 i n)
o 2394s- PL3- 800
1. 02 mm
(0. 0102 i n)
P 23946- PL3- 800
1. 05 mm {0. 0413
i n}
o 23947- PL3- 800
1. 08 mm
(0. 0{25 i n)
23948
-
PL3 800
' 1. 1' 1
mm
(0. 0437 4n)
23949- PL3- 800
1. 14 mm
(0. 0449 i nl
T 23950- PL3- 800
1. 17 mm
(0. 0461 i n)
23951
-
PL3
-
800 1. 20 mm
(0. 0472 i n)
23952- PL3- 800
1. 23 mm
(0. 0444 i n)
239s3- PL3- 800
1. 26 mm {0. 0496
i n)
X 23954- PL3- 800
1. 29 mm
(0. 0508 i n)
2395s- PL3- 800
1. 32 mm
(0. 0520 i n)
z 23956- PL3- 800
1. 35 mm
(0. 0531 i n)
23957- PL3- 800
1. 38 mm
(0. 0543 i n)
A8 23958- PL3- 800
1. 41 mm
(0. 0555 i n)
AC 23959- PL3- 800
1. 44 mm {0. 0567
i n)
AD 23960- PL3- 800
1. 47 mm
(0. 0579 i n)
2396' t - PL3- 800
1. 50 mm
(0. 0591 i n)
23962- PL3- 800
1. 53 mm
(0. 0602 i n)
AG 23963- PL3- 800
1. 56 mm
(0. 0614
i n)
AH 23964- PL3- 800
1. 59 mm
(0. 0626 i n)
23965- PL3- 800
1, 62 mm
(0. 0638 i n)
23966- PL3- 800
1. 65 mm
(0. 0650 i n)
AK 23967- PL3- 800
1. 68 mm
(0. 0661 i n)
23968- PL3- 800
1. 71 mm
(0. 0673 i n)
23969- PL3- 800
1. 74 mm
(0. 0685 i n)
AN 23970- PL3- 800
1. 77 mm
(0. 0697 i n)
AO 23971- PL3 800 1. 80 mm
(0. 0709
i nl
6. Instal l the oi l
gui de pl ate and sel ected thrust shi m i n
ths transmi ssi on housi ng
NOTE:
. Cl ean t he t hr ust washer , spr i ng washel and
thrust shi m thoroughl y bel ore i nstal l ati on.
. l nst al l t he t hr ust washer , spr i ng washer and
thrust shi m
proPerl Y.
THRUST SHI M
I
OI L GUI DE
PLATE
TRANSMI SSI ON
HOUSI NG
8.
o
10.
7, Instal l the thrust washer and spri ng washer i n the
mai nshaft.
l nstal l the mai nshaft i n the cl utch housi ng
Pl ace the transmi ssi on housi ng over the mai nshaft
and onto the cl utch housi ng.
Ti ghten the cl utch and transmi ssi on housi ngs wi th
several 8 mm bolts.
NOTE: l t i s not necessar y t o use seal i ng agent
between the housings'
8 x 1.25 mm
27 N'm t2.8 kgf.m. 20 lbf'ft)
Tap the mai nshaft wi th a pl asti c hammer.
Check the thrust clearance in the manner doscribsd
bel ow.
CAUnON: Mc.suromont 3hould bo mlde !t room
tomp9laturs.
a. Sl i de the mai nshaft base and the col l ar over the
mai nshaft.
CLUTCH
HOUSI NG
1 1 .
l z .
MAITISHAFT BASE
07GAJ-PG20130
COLLAF
07GAJ
-PG20120
{cont' d}
13-37
THRUST WASHER
SPRING WASI{ER
Mai nshaft Thrust Shi m
I
I
Adj ustment
(cont' dl
b. At t ach t he mai nshaf t hol der t o t he mai nshaf t as
fol l ows:
NOTEI
. Back- out t he mai nshaf t hol der bol t and l oosen
the two hex bol ts.
. Fi t t he hol der over t he mai nshaf t so i t s l i p i s
toward the transmi ssi on.
. Al i gn t he mai ns haf t hol der ' s l i p ar ound t he
gr oove at t he i nsi de of t he mai nshaf t spl i nes,
then ti ghten the hex bol ts.
MAI NSHAFT HOLOER
BOLT
MAINSIIAFT
HOLDER
07GAJ- PG20110
d .
Seat the mai nshaft ful l y by tappi ng on the end wi th
a pl asti c hammer.
Thr ead t he mai nshaf t hol der bol t i n unt i l i t
j ust
contacts the wi de surface of the mai nshaft base.
u
e. Zero a di al gauge
on the end ofthe mai nshaft.
MAINSHAFT HOLDER
07cAJ_PG20110
Turn the mai nshaft hol der bol t cl ockwi se: stop turn,
i ng when the di al gange
has reached i ts maxi mum
movement . The r eadi ng on t he di al gauge
i s t he
amount of mai nshaft end ol av.
CAUTION: Turning the mainshaft holder bolt more
than 60 degres after the needle ot the dial gauge
stops moving may damage the iransmission.
l f the readi ng i s wi thi n the standard. the cl earance i s
correcl.
l f the readi ng i s not wi thi n the standard, recheck the
shi m thi ckness.
Standard: 0.11
-
0.18 mm
{0.00i t
-
0.007 i n}
t.
\ , J
Transmission
Reassembly
NOTE: The steel bal l s are al l ofthe same si ze
(5/16
i n).
1. Instal l the magnet and reverse l ock cam.
2. Set shi ft arm A on the cl utch housi ng, then i nstal l
the shi ft rod.
3. Instal l the spri ng washer and shi ft arm A attachi ng
bol t.
Instal l the steel bal l , spri ng, and set bal l spri ng bol t.
Instal l shi ft arm B i n the i nterl ock, then set i t on the
cl utch housi ng.
1.
Insert shi ft arm shaft i n the cl utch housi ng.
Instal l the col l ar, spri ng. and steel bal l i nto the case.
Compress the bal l and i nsert the shi ft arm shaft,
Instal l shi ft arm C i n shi ft arm A, then i nsert the shi ft
arm shaft.
Install the reverse select retainer and reverse select
spri ng onto shi ft arm shaft.
Instal l the di fferenti al assembl y.
5.
8.
9.
10.
A : 8 x 1 . 0 m m
3' l N, m
(3. 2
kgt . m, 23 l bf . f t )
6 x 1. 0 mm
15 N. m 11. 5 kgt . m, 11 l bt ' f t l
OI L SEAL
Repl ace.
SI{IFT ARM C
COLLAR
REVERSE SELECT SPRING
L. 63. 4 mm 12. 50 i n)
REVERSE LOCK CAM
REVERSE SELECT RETAINER
sHtFT ARM '
___\.*^
rNrERLocK
p
|Jiiill---=l@
MAGNET
SET BALL SPRING BOLT
22 N.m 12.2 kgl.m, 16 lbf'ftl
SPRING
L. 25. 6 mm
( 1. O1
i n)
SHI FT AFM A
CLUTCH
HOUSI NG
SHI FT ARM SHAFT
(cont ' d)
13- 39
SHI FT ROD
\ r l
BOOT
Transmission
Reassembly
lcont'dl
11. Posi ti on the 36 mm spri ng washer and washer onto
the mai nshaft beari ng.
MAI NSHAFT/ COUNTERSHAFT
SHI FT FORK ASSEMELI ES
Tape t he mai nshaf t
spl i nes.
12.
13.
Instal l the mai nshaft, countershaft, and shi ft fork
assembl i es.
NOTE; Al i gn t he f i nger of t he i nt er l ock wi t h t he
groove in the shift fork shaft,
l nstal l the spri ng washer and shi ft arm B attachi ng
bol t.
I x 1. 0 mm
31 N.m
(3.2
kgl .m, 23 l bt.ft)
I ST/ 2ND SELECT SPRI NG
L. 36. 26 mm 11. 428 i n)
54 N. m 15. 5 kgf . m,
40 tbt.ftl
SPf,ING
WASHER
GUIDE BOLT
14.
39 N. m 14. 0 kgf . m, 29 l bf . f rl
Instal l the 1sv2nd sel ect spri ng, 28 mm pl ug bol t.
and i nterl ock gui de
bol t,
NOTE: Appl y Ii qui d gasket (P/N
08718
-
0001 or
08718
-
0003) to the threads of the 28 mm pl ug bol t
and i nterl ock gui de bol t.
13-40
15. Instal l the reverse i dl er gear and reverse i dl er gear
shaft.
REVERSE IDLER
GEAR SHAFT
L J
16. Instal l the reverse shi ft hol der.
REVERSE SHIFT
l 5 N. m
( 1. 5
kgf . m,
11 l bt . t rl
GEAR
6 x 1 . 0 mm
17. Instal i the oi l
gutter
Pl ate.
I nst al l t he oi l
gui de pl at e and t hr ust shi m on t he
transmi ssi on housi ng.
Appl y Ii qui d
gasket to the surface of the transmi s-
si on housi ng mat i ng wi t h t he cl ut ch housi ng as
shown.
NOTE:
. Us e l i qui d
gas k et
{ P/ N
08718
-
0001 or
08718
-
0003).
. Remove the di rty oi l fromtheseal i ng surface.
. l f 5 mi nutes have passed after appl yi ng l i qui d
gasket, reappl y i t and assembl e the housi ngs.
. Al l ow i t to cure at l east 20 mi nutes after assem-
bl y before fi l l i ng the transmi ssi on wi th oi l .
18.
19.
\
OI L GUTTER PTATE
TRANSMI SSI ON HOUSI NG
Liquid gasket
20. l nstal l the dowel
pi ns and the transmi ssi on housi ng.
Lower the transmi ssi on housi ng wi th the snap ri ng
pl i ers, and set the snap ri ng i nto the groove of the
countershaft beari ng.
NOTE: Check that the snap ri ng i s securel y seated
i n the
groove of the countershaft beari ng
32 mm SEALI NG EOLT
25 N. m
(2. 5
kgf . m, 18l bf . f t l
4. 6
- 8. 3
mm
10. 14- 0. 33 i nl
Instal l the 32 mm seal i ng bol t.
NOTE: Appl y l i qui d gasket
( P/ N
08718
-
0001
08718
-
0003) to the threads.
(cont ' d)
22.
13-41
Transmi ssi on
Reassembly
(cont'd)
23, Ti ghten the transmi ssi on housi ng aftachi ng bol ts i n
t he number ed sequence i n sever al st eps shown
Del ow.
8 x 1.25 mm
Tolque: 27 N.m 12.8 kgf.m. 20 lbf.ft)
EACK.UP LIGHT SWITCH
HARNESS BRACKET
24. Instal l the steel bal l s, spri ngs, and set screws.
K)w
s
WASHER
Repl ace.
STEEL EALLS
D. 5i 16 i n
SETTI NG SCREW
22 N. m 12. 2 kgf . m, 16 l bf . f t l
//-',, o
/ I \ . - - " - 4
;'c'-9,/t-)
13-42
L. 31. 6 mm 11. 24 i n)
25. I nst al l t he back- up l i ght swi t ch and t r ansmi ssi on
hanger.
8 x 1. 25 mm
27 N. m 12. 8 kgl . m, 20 l bt . l rl
TRANSMI SSI ON
HANGER
I . /
25 N. m
(2. 5 kgt . m, 18 l bf . f t )
Oi l Seal s
Replacement
Transmission Housing:
1. Remove the oi l seal from the transmi ssi on housi ng.
l nst al l t he oi l seal i nt o t he t r ansmi ssi on housi ng
usi ng the speci al tool s as shown.
SEAL ORIVER
ATTACHMENT
07947- 6110501 or
07947- 6110500
OI L SEAL
Repl ace.
\ t ,
OTJAD PHAO2OO
13-43
Cl utch Housi ng:
1. Remove the oi l seal from the cl utch housi ng.
l nstal l the oi l seal i nto the ci utch housi ng usi ng the
speci al tool s as shown.
ORIVER ATTACHMENT
oTJAO
-PXaO101
OI L SEAL
Repl ace.
, 2 6 x 3 0 mm
Gearshift Mechanism
Overhaul
NOTE:
. I nspect r ubber par t sf or wear anddamagewhendi sassembl i ng; r epl aceanywor nor damagedpar t s.
. Instal l the cl i p as shown.
. Turn the boot so the hol e i s faci ng down as shown.
. Make sure the boot i s i nstal l ed on the shi ft rod.
SHI FT LEVER KNOE
7. 8 N. m { 0. 8 kgf . m, 5. 8 l bt . t t )
EXTENSI ON
BOLT
)
searr' p))
p
f***
\\-ii,,l?' "
SHIFT -Vvvvvvvvvvvvvvvvl
tlourur Replace.
| 1
22 N'm
12.2 ksf'm, 16 lbt.ftl
ii,".i'----....-.9
/
g-ia',rf,',,"'
\\
sELF-LocKrNG Nur
sEAr
' 6
.rrr*(,o"" o-","o, \ \
;":' i:;u --
CLI P
d
ul/
/,1:\
MOUNT
l': I
cusHroN
,
\ / \ / - s
SHI FT l / \ / -
LEVER \,
et-
ffi
PY:,' \1^l lW -"or.o*
Dusr\
.-\
\5
".o.o)@1
-o-E
"ot'o'
sHlFr
\:/
Q,gD 22 N.m
IiUei__-.....p
anecxer
,-/n I I I
?!il,
e* ^.-.-n{wl\^fr
J
"r^r"
7****r
""'%ilf
t @
t 1
t \
sHrFT LEVER
I
BALL HOLDER
\
REAR JorN*lr,""17E@
_6,
L\
EXTENSI ON
SELF-LOCKI NG NUT
Repl ace.
6 x
' 1. 0
mm
9. 8 N. m { 1. 0 kgf . m, 7. 2 l bf . l r }
t J
SPRI NG PI N
Repl ace.
-6r
16 tbf.trl
13-44
S4C Model
('99
-
00 2-door Si, SiR)
Manual Transmi ssi on
Special Tools ............' 13-46
Maintenance
Transmi ssi on Oi 1 . . . . . . . . . . . . . . . . . . . ' . . . . . . . . . . 13-47
Repfacement
...""" 13' 47
Removal
. . . . . . ' . . . . . . . . . . 13-/ t B
l nst al l at i on
. . . . . . . . . . . . . 13-52
l l l ust rat ed l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-54
Removal
. . . . . . . . . . . . . . . . . 13-55
Beverse Shift Holder, Reverse ldler Gear
Clearance lnspection ...................".. 13-57
Removal
. . . . . . . . . . . . . . . . . 13-58
Change Holder Assembly
Cl earance l nspect i on . . . . . . . . . . . . . . . . . ". . . . 13-59
Removal
. . . . , , . . . . . . . . . . . 13-61
............... 1 3-62
Mainshaft, Countershaft, Shift Fork
Removal
. . . . . . . . . . . . . . . . . 13-63
Shift Rod
Removal
. . . . . . . . . . "' . . . . 13-64
Shift Fork Assembly
l ndex . . . . . . . . . . . . . . . .
. . . . . . 13-65
Cl earance l nspect i on . . . . . . . . . . . . . ' . . . . . . . . . 13' 66
Mainshaft Assembly
l ndex . . . . . . . . . . . . ""
. . . . . . 13-67
Cl earance l nspect i on . . . . . . . . . . . . . . . . . . . . . . . 13-68
Disassembly
.......... 13-71
fnspection
' ."' .......' , 13' 72
Reassembly
.......' ... 13-73
f ndex . . . . . . . . . . . . . . . .
". . . . 13-71
Gl earance I nspect i on' . . . . . . ' . . . . . . . . . . . ' . . .
1 3' 75
Disassembly
.......... 13-76
f nspect i on
. ' . . . . . . . . . . . . 13' 77
Reassembly
"......... 13' 78
Inspection
.............. 13' 8C
Installation
............. 13-80
Synchro Ring, Gear
I nspect i on
. ' . . . . . . . . . . . . 13-81
Differential
l ndex . . . . . . . . . . . . . . . .
. . . . . . 13-82
Backlash Inspection ..."..........."' ...... 1 3-82
Final Driven Gear Replacement ...... 13-83
Beari ng Repl acement . . . . . "' . . . . . . . ""' . . 13-83
Thrust Shim Adiustment ......""' ..... 13-84
Clutch Housing Bearing
Replacement
..' ...... 13-86
Mainshaft Thrust Glearance
Adiustment
' .........' . 13-88
Transmission
Reassembly
."' ....... 13-91
Oil Seals
Replacement
..' ...... 13-96
Gearshift Mechanism
Overhaul
. . . . . . . . . . . . . . . . 13-97
\
Special Tools
Speci al Tool s
I
I
I
./
Ref. No. Tool Number
Dscription
Oty
I
Remark
o
@
o
-@
@
o
@
@
@
o
@
07GAJ
-
PG20110
07GAJ
-
PG20l 30
07JAD
-
PH80l 0' 1
07736
-
A010004
07746
-
0010300
07746
-
0010400
07746
-
0030100
07746
-
0030300
07746
-
0030400
07746
-
0041100
07749
-
0010000
07947
-
SD90200
Mai nshaft Hol der
Mai nshaft Base
Dri ver Attachment
Adj ustabl e Beari ng Pul l er,25
-
40 mm
Dri ver, 40 mm LD.
Attachment, 30 mm LD.
Attachment, 35 mm LD.
Pi l ot, 28 mm
Hand l e
Dri ver Attachment
I
1
1
1
I
1
'l
I
1
1
1
'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 used wi th commerci al l y-avai l abl e 3/8,,-16 Sl i de Hammer.
o
aol
@ (t 4^
Mai ntenance
\
Transmi ssi on Oi l
NOTE: Check the oi l wi th the engi ne OFF. and the vehi -
cl e on l evel ground.
1. Remove the oi l fi l l er pl ug, then check the l evel and
condi t i on of t he oi l .
OI L FI LLER PLUG
ia4 N.m {{.5 kgf'm,
Proper Level
33 tbtfrl
The oi l l evel must be up t o t he f i l l er hol e. l f i t i s
bel ow the hol e, add oi l unti l i t runs out, then rei n-
stal l the oi l fi l l er pl ug.
l f the transmi ssi on oi l i s di rty, remove the drai n
pl ug
and drai n the oi l .
pl ug wi th a new washer. and refi l l
the transmi ssi on oi l to the proper l evel .
NOTE: The drai n
pl ug washer shoul d be repl aced at
every oi l change.
Rei nstal l the oi l fi l l er
pl ug wi th a new washer.
Oil Capacity
2.2 f {2.3 US. qt, 1.9 lmp. qtl at oil change.
2.3 f {2./f
US. qt. 2.0 lmp. qt} at overhaul.
Al ways use Genui ne Honda Manual Tr ansmi ssi on
Fl ui d
(MTF).
Usi ng motor oi l can cause sti ffer shi ft-
i ng because i t does not contai n the
proper addi -
ti ves.
OIL FILLER PLUG
ila N.m {4.5 kgf.m, 33 lbt'ftl
Repl ace.
\ 1 ,
Replacement
NOTE: To check the back-up l i ght swi tch, see secti on 23.
1. Di sconnect the connector, then remove the back-up
l i ght swi tch connector from the connector cl amp.
2. Remove the back-up l i ghr swi tch.
AACK.UP
25 N.m 12.5
kgf.m, 18 lbf'tt) Repl ace.
l nstal l the new washer and the back-up l i ght swi tch.
Check the transmi ssi on oi l l evel .
4.
l
,
{
Removal
@
Make sure
iacks
and safoty stands are placad plop-
erly
(3ee
section l).
Appl y
parki ng braks and bl ock rear wheel s so car
will not roll off stands and fall on
you while working
under il.
CAUTION: Us6 fonder cove6 to avoid damaging painted
sudaces.
Di sconnect the negati ve
(-)
cabl e from the battery,
then the posi ti ve (+l
cabl e.
Drai n the transmi ssi on oi l . then rei nstal l the drai n
pl ug wi th a new washer
(see page 13-47).
Remove the i ntake ai r duct and the ai r cl eaner hous-
i ng assembl y
(see
scti on 5).
Di sconnect the back-up l i ght swi tch connector and
the transmi ssi on
ground wi re.
Remove the l ower radi ator hose cl amp from the
transmi ssi on hanger B.
L
8 x 1 .25 mm
22Nm12.2kgl'm,
LOWER RADIATOR
HOSE CLAMP
16 rbtft)
13-48
7.
Bemove the wi re harness cl amps.
Di sconnect the starter motor cabl es and the vehi cl e
speed sensor
(VSS)
connector.
8 x 1. 25 mm
8.8 N.m
(0.9
kgf.m,
6.5 tbtftl
STARTER
MOTOR
CABLES
8. Remove the cl utch l i ne bracket and the sl av6 cyl i n-
oer.
NOTE: Do not operate the cl utch pedal once the
sl ave cyl i nder has been removed.
\ J
9. Remove t he t hr ee upper t r ansmi ssi on mount i ng
bol ts and l ower starter motor mounti ng bol t.
' 10.
Remove the engi ne spl ash shi ei d.
TRANSMISSION
MOUNTING
BOLTS
12 x 1. 25 mm
6,1 N.m
(6.5
kgd m, 47 lbf'ft|
STARTER
MOTOR
MOUNTING
BOLT
10 x 1.25 mm
a,t N.m 14.5
kgl.m.
33 tbf.trl
CONNECTOE
11. Di sconnect the heated oxygen sensor
(HO2S)
con-
nector, then remove exhaust pi p A.
H02S
SELF.LOCKING NUT
Replace.
8 r 1. 25 mm
16 N.m
(1.6
kgf.m, 12lbf'ft)
Replace.
10 x 1, 25 mm
54 N.m {5.5 kgf.m,
'lll lbf.ft)
12. Remove the cotter pi ns and l oosen the castl e nuts,
then separate the bal l
j oi nts
from the l ower arm
(see
secti on 18).
13. Remove the ri ght damPer fork.
10 x 1.25 mm
a3 N.m lil.a kgf.m, 32 lbf'ft| ,
SELF.LOCKING NUT
R6place.
12 x 1. 25 mm
6a N.m
(6.5 kgl.m,
47 rbf ft)
RIGHT
DAMPER
FORK
CASTI.T NUT
12 x 1, 25 mm
a9
-
59 N.m
(5.0 -
6.0 kgtm,
36
- i(t lbf.ftl
(cont ' d)
! -
r i a - 11
: \/-/
' t ' '
'-a
SPLASH SHIELD
13-49
Removal (cont' d)
14. Remove the driveshafts and the intermediate shaft
(see
secti on 16).
NOTE: Coat al l preci si on
the fi ni shed surfaces wi th
cl ean engi ne oi l or
grease.
Ti e pl asti c
bags over the
driveshaft ends,
Remove the bolt, then disconnect the change elden-
si on.
Remove the cl i p and the spri ng pi n, then di sconnect
the change rod.
8x 22mm
SPRING PIN
CLIP Replace.
15.
13- 50
17. Remove the front and the rear engi ne sti ffensrs.
18. Remove the cl utch cover.
CLUTCH COVER
6 x 1 . 0 mm
12 N.m
(1.2
kg{.m,
9 tbf.ftl
x
'l
.25 mm
t J
24 N.m {2.4 kgt m,
17 rbt ftl
)
19. Remove the ri ght front mounvbracket.
10 x 1 . 25 mm
,14
N.m {4,5
kgf.m,
WASHERS
20. Pl ace a transmi ssi on
j ack
under the transmi ssi on
and a
j ack
stand under the engi ne.
21. Remove the transmi ssi on mount
SPECIAL BOLT
Repl ace.
12 x 1 . 25 mm
64 N.m 16.5
kgl'm, 47 lbf ftl
TRANSMISSION
3- 51
22. Remove the rear mount bracket bol ts and the trans-
mi ssi on mounti ng bol ts
12 x 1. 25 mm
5{ N.m 16.5 kgf.m, 47 lbl.ft)
61
WASHER
23. Pul l the transmi ssi on away from the engi ne unti l i t
cl ears the mai nshaft, then l ower i t on the transmi s-
si on
j ack.
SPECIAL BOLT
Repl ace.
14 x 1. 5 mm
8il N.m
(8.5
kgtm,
l nstal l ati on
Instal l the transmi ssi on assembl y i n the reverse order of
removal .
. Before i nstal l i ng, check that the two dowel
pi ns
are
i nstal l ed i n the cl utch housi ng.
. When i nstal l i ng the starter cabl e. make sure that the
cri mped si de of the ri ng termi nal i s faci ng out
(see
secti on 23).
. Appl y grease
to the parts as shown, then i nstal l the
rel ease fork and rel ease beari ng.
NOTE; Use onl y Super Hi gh Temp Ur ea Gr ease
(P/N
08798
-9002).
RELEASE FORK BOLT
29 N.m 13.0 kgf.m,
22 tbllrl
(P/N
08798
-
9rD2l
-R1
tP/N 08798
-
13-52
CLIP
L
f
;
Torque the mounti ng bol t and nuts i n the sequence
shown.
Check that the busi ngs are not twi sted or offset.
@
t2 x 1.25 mm
6,t N.m 16.5 kgtm,
47 lbf.ft) O
t2 x 1.25 mm
6,r N.m
(6.s
kg{.m,
17 tbf.ft)
O
12 x 1. 25 mm
7i l Nm17. 5kgf . m,
5it lbt ft)
I
Instal l the al i p and the spri ng pi n
on the change
j oi nt
as snown.
Turn the shi ft rod boot so the hol e i s faci ng down as
snown.
Make sure the shift rod boot is installed on the change
rod.
CHANGE ROO
FL.-
SPRING PIN
l l hept ace,
8 mm PIN
PUNCH
/ "*,*
lo,iD(
CHANGE
./
EXTENSfoN
(
^
st
l?rffi
l \ K
. Appl y
grease to the sl ave cyl i nder
push rod.
NOTE: Us e onl y Super Hi gh Temp Ur ea Gr eas e
(P/N
08798
-
9002).
6 x 1 . 0 mm
9.8 N' m
(1.0 kgl m,
7.2 tbl.ft)
-6,4
-
9m2)
Refi l l the transmi ssi on wi th oi l
(see page 13-47).
Connect the
posi ti ve (+)
cabl e fi rst, then the negati ve
( -
) cable to the battery.
Check the cl utch oPerati on.
Shi ft the transmi ssi on, and check for smooth opera-
t i on.
(see
secti on 181.
(P/N
08798
8 x 1 .25 mm
22N.n 12.2
kgl'm,
16 tbf.ftl
a
a
a
a
lllustrated Index
t
Refer to the drawi ng bel ow for transmi ssi on di sassembl y/reassembl y.
Cl ean al l the
parts thoroughl y i n sol vent and dry wi th compressed ai r.
I
Luori cate att the pans wi th oi l before reassembl y.
NOTE:
. Thi s transmi ssi on uses no gaskets between the maj orhousi ngs; use l i qui d gasket (P/N
08718-0001 or08718-0003)
(see page
' 13-93).
. Al ways cl ean the magnet @
whenever the transmi ssi on housi ng i s di sassembl ed.
. Inspect al l the beari ngs for wear and operati on.
?-c
\ I
ir 6d
a
h P
l t t
i a . f l
)
K1T\A
l , l 1r
@r t ?
u
L6q
i " \ ^
Br
'u
t @ )
E,M
A
# & f
o-*ffiX,
@
I
R
h
" i i
' F@
,
D
13- 54
Bol t Si ze
Torque Val ue
c
n
E
F
6 x 1 . 0 mm
6 x 1 . 0 mm
8 x 1. 0 mm
8 x
' 1. 25
mm
8 x 1. 25 mm
8 x 1, 0 mm
12 N.m
(1.2
kgnm, 8 l bf' ft)
15 N. m
( 1. 5 kgf ' m, 11 l bf f t )
15 N. m
( l . 5
kgf . m, 11 l bi f t )
24 N' m
(2.4
kgi m, 17 l bi ft)
27 N.m
(2.8
kgf.m,20 l bf' ft)
30 N.m
(3.1
ksf m. 22 l bi ft)
5i WASHER Replace.
6
TRANSMrssioN HouslNG
!9 80 mm SHIM
@
SHIFT PIECE SHAFT
(6'
INTERLOCK
@
sHrFr PECE
6} SHIFT ARM HOLDER
@ seucr nnrvt
I9 SELECT RETURN SPRING
@
10 mm SHI M
6,
10 mm WASHER
@
LOCK COLLAR
i6sl 3 x l5 mm SPRING PIN Replace.
t0 8 mm SPRING WASHER
A)
CHANGE PIECE
l l SPRI NG L. 25. 6 mm
(1. 01
i n)
'' MAGNET
?4) CLUTCH HOUSING
t a. 14 x 25 x 16 mm OI L SEAL Repl ace.
A sHrFT Boo
O
D|FFERENT|aL ASSEMBLY
See sect i on 15
iIO SHIFT ROD BOOT
6 OIL GUIDE PLATE
@ 33 x 60 x 20 mm NEEDLE BEASING
O BEARING RETAINER PLATE
lD LocK WASHER Replace.
.0
couNTERSHAFI
A DISTANCE COLLAR
6 & x 4I x 22 mm NEEDLE BEARING
6. 1sr GEAR
@
FRICTION DAMPER
O SYNCHRO RING
.d SYNCHRO SPRING
@
1ST/2ND SYNCHRO HUB
..9i. REVERSE GEAR
C)
DOUBLE CONE SYNCHRO
O
FRICTION DAMPER
S SPACER
6
T2 x TI x 24 mm NEEDLE BEARING
(!'
2ND GEAR
61 3RD GEAR
iD 4TH GEAR
@
5TH GEAR
(O
NEEDLE BEARING
(10
BALL BEARING
@ SPRING WASHER
f,o
LoCKNUT Replace.
108
-
0- 108 N' m
111. 0-
0* 11. 0 kgf m,
80* 0- 80l bI . f t )
IO CLUTCH LINE BRACKET
.d BACK.UP LTGHT SWITCH HARNESS BRACKET
:!, ANGULAR BALL BEABING
:2,
STOP RING
:3] TAPER RING
..-I NEEOLE BEARING
l!--
SPACER
O
SYNCHRO RING
? SYNCHRO SPRING
E 5TH/REVERSE SYNCHRO SLEEVE
...] sTH/REVERSE SYNCHRO HUB
O
SYNCHBO EING
.11-r sTH GEAR
1A 38 x 43 x 26 mm NEEDLE BEARING
I13) SPACER COLLAR
[!]
/ITH GEAR
.T5) SYNCHRO RING
O
SYNCHRO SPRING
17 3RD/4TH SYNCHRO HUB
O
3RD/4TH sYNcHRo SLEEVE
ii9 38D GEAR
8I
MAINSHAFT
2i WASHER
A
SPRING WASHR
?I
BALL BEARING
.a4,
28 x 41 x 7 mm OIL SEAL Replace.
.2i 35 x 56 x 8 mm OIL SEAL Replace.
t-t 14 x 20 mm DowEL PIN
.'] OIL CHAMBER PLATE
O
REVERSE I DLER GEAR SHAFT
.iI.., REVERSE IDLER GEAR
'd REVERSE SHIFI HOLDER
ait srH/REVERSE sHIFT PIECE
'34
5 x 22 mm SPRING PIN Replace.
3' 1ST/2ND SHIFT FORK
,34'
3RD/4TH SHIFT FORK
i9t) srH/nevense sstrr ronx
33 OIL GUTTER PLATE
!'
SNAP RING
3d 72 mm THRUST SHIM
@
OIL GUIDE PLATE
4t 10 mm WASHER Repl ace
ti REVERSE TDLER GEAR SHAFT BoLT
54 N. m {5. 5
kgf m, 40l bI f t )
4N TBANSMISSION HANGER B
43] BREATHER CAP
A,J TRANSMISSION HANGER A
IT' BACK-UP LIGHT SWITCH
I
25 N. m {2. 5 kgl . m, 18l bl f t l
14 mm WASHER RePl ace
aO 14 mm
tt
16 mm 16 mm SEALING BOLT
29 N.m
(3.0 kgf m,22 lbf ft)
:4s) 32 mm SEALING BoLT
25 N m 12.5 kgl m, 18 lbl'ft)
40 x 62 x I mm OIL SEAL Replace
STEEL BALL D. 5/ 15 i N
SPRI NG L. 30 mm {1. 2 i n)
12 mm WASHER Repl ace.
SET SCREW
22 N.m {2.2
kg{ m, 16 lbl ftl
OI L DRAI N PLUG
39 N. m {4. 0 kgf m, 29l bt f t l
WASHER Repl ace.
OI L FI LLER PLUG
4,t N.m {4.5
kgl m, 33 lblftl
.!rl
00
@l
13- 55
Removal
NOTE: Pl ace the cl utch housi ng on two pi eces
of wood
t hi ck enough t o keep t he mai nshaf t f r om hi t t i ng t he
workbench.
' 1.
Remove the back-up l i ght swi tch.
2. Remove transmi ssi on hanger B.
3. Remove the set screws, the spri ngs, and the steel
bal l s.
BACK.UP UGHT
swrTcH
SET SCREW
4. Remove the reverse i dl er gear
shaft bol t.
WASHER
Repl ace.
REVEBSE
13- 56
5. Loosen the transmi ssi on housi ng attachi ng bol ts i n
a cri sscross pattern i n several steps, then remove
them.
TRANSMISSION
HANGER A
Rmove the 32 mm seal i ng bol t.
Expand the snap ri ng on the countershaft bal l bear-
i ng, and remove i t from the groove
usi ng a pai r of
snap ri ng pl i ers,
32 mm SEALING BOLT
o.
1.
I {
ATTACHING BOLT
SNAP RING
Reverse Shift Holder,
Reverse ldler Gear
Separate the transmi ssi on housi ng from the cl utch
housi ng, and wi pe i t cl ean of the seal ant.
Remove the 72 mm thrust shi m and the oi l gui de
pl ate from the transmi ssi on housi ng
72fifi
THRUST SHIM
TRANSMISSION
HOUSING
Remove the 16 mm seal i ng bol t and the ol l
gutter
plate.
OIL GUTTER PLATE
fi
1 .
Clearance
Inspection
Measure the cl earance between the reverse shi ft
hol der and the 5th/reverse shi ft
pi ece pi n
Standard:
Revsrs. Sids: 0.05
-
0./t5 mm {0'002
-
0.018 in}
5th Side: 0.4
-
0.9 mm
(0.02 -
0.0'l in)
sTH/REVERSE SHIFT PIECE PIN
l f the cl earance are not wi thi n the standard, mea-
sure the wi dth of the
grooves i n the reverse shi ft
hol der.
Standard:
Rsvers Side: 7.05
-
7.25 mm
(0'278
-
0.285 in)
5th Sid6: 7.,1- 7.7 mm
(0.29 -
0 30 inl
REVERSE SIDE
l f ths wi dth of the
grooves are not wi thi n the
standard, replace the reverse shift holder with a
new one.
grooves are wi thi n the stan-
dard, repl ace the sth/reverse shi ft
pi ece wi th a
new one
{cont' d)
13- 57
Reverse Shift Holder, Reverse ldler Gear
(cont'dl
3. Measure the cl earance between the reverse
gear and the reverse shi ft hol der.
Standard: 0.5
-
1.0 mm
10.02
-
0.04 i nl
(0.07
inl
i d l er
l f the cl earance i s more than the servi ce l i mi t. mea,
sure the wi dth of the reverse shi ft hol der.
Standard: 13.0
-
13.3 mm
(0.512 -
0.524 i n)
the reverse shi ft hol der wi th a new one.
reverse i dl er gear wi th a new one.
13- 58
Removal
1. Remove the reverse shi ft hol der.
Remove the reverse i dl er gear
and the reverse i dl er
gear shaft.
REVERSE
SHIFT HOLDEB
REVERSE
IDLER
Change
Hol der Assembl Y
,
Glearance
InsPection
1 . Measure the cl earance between the shi ft
pi ece and
the shi ft arm hol der.
Standard:
0.1
-
0.3 mm {0.004
-
0.012 i n)
service Limit: 0.6 mm {0.02
in)
l f the cl earance
i s more than the servi ce l i mi t, mea-
sure the wi dth of the
groove i n the shi ft
pi ece'
Standard: 8.1
-
8 2 mm {0' 319
-
0.323 i n}
l f the wi dth of the groove i s not wi thi n the stan-
dard, repl ace the shi ft
pi ece wi th a new one'
groove i s wi thi n the standard,
repl ace the shi ft arm hol der wi th a new one'
SHI FT PI ECE
SHIFT ARM HOLDER
SHIFT PIECE
4.
3. Measure the cl earance between the sel ect arm and
the i nterl ock.
Standard: 0.05
-
0.20 10 002
-
0.008 inl
Servi ce Li mi t:0.45 mm
(0.018 i nl
sure the wi dth of the i nterl ock.
Standatd: 9.9
-
10.0 mm
(0.390 -
0.39't in)
the i nterl ock wi th a new one.
sel ect arm wi th a new one.
(cont' d)
I NTERLOCK
13- 59
Change Holder Assembly
(cont'd)
t he 10 mm shi m.
Standard: 0.01
-
0.2 mm
(0.0004 -
0.008 in)
l f the cl earance i s not wi thi n the standard, sel ect
and i nstal l the appropri ate l 0 mm shi m for the cor-
rect cl earance from the chart bel ow.
mm Shi m
8.
SELECT ARM
l 0 mm SHI M
Part Number
Thickness
24435- 689- 000
0.8 mm
(0.031
i n)
B 24436- 589- 000
1.0 mm
(0.039
i n)
c 24437- 689- 000
1.2 mm
(0.047
i n)
D 24438- 689- 000
1. 4 mm ( 0. 055
i n)
E 24439- 689- 000
1. 6 mm
{ 0. 063 i n)
13- 60
I
9. Measure the cl earance between the shi ft arm hol der
and the change pi ece.
Standard;
0.05
-
0.35
(0.fi)2 -
0.014 inl
(0.03
in)
l f the cl earance i s more than the servi ce l i mi t. mea_
sure the groove
of the change pi ece.
Standard: 12.05
-
12.15 mm
{0.i[7it4
-
0.47txt inl
l f the groove
i s not wi thi n the standard, repl ace
the change pi ece
wi th a new one.
l f the groove
i s wi thi n the standard, repl ace the
shi ft arm hol der wi th a new one.
v o
SHI FT ARM HOLOER
CHANGE PIECE
U O
the change Pi ece.
Standard:
0.05
-
O'25 mm 10'002
-
0'010 in)
Servica Limii: 0.5 mm {0.02
in)
sure the wi dth of the change
Pl ece.
Standard:
12.05
-
12.15 mm {0.47'|{
-
0 47tI| inl
CHANGE PIECE
l f the wi dth i s not wi thi n the standard,
repl ace
the change Pi ece
wi th a new one'
sel ect arm wi th a new one.
' t2.
a
a
SELECT ARM
Removal
1. Bemove the shi ft
pi ece shaft. then remove the shi ft
pi ece and the i nterl ock.
SHIFT PIECE SHAFT
INTERLOCK
2. Remove t he change hol der assembl y'
13- 61
Change
Holder Assembly
I
P' i o' to ' """sembri ng,
crean aI the pans i n sorvent, dry them and appry l ubri cant to any contact surfaces.
l 0 mm SH| M
I
,o mm wAsHEF
t /
@@d.
r ] 7
|
3 x 16 mm SpRt NG
I
Repl ace.
RTURN SPRING
SELECT ARM
13- 62
Mainshaft,
Countershaft,
Shift Fork
Removal
1 . Remove the mai nshaft and the countershaft assem-
bl i es wi th the shi ft forks from the cl utch housi ng.
NOTE: Tape the mai nshaft spl i ne before removi ng
the mai nshaft and the countershaft assembl i es.
Remove the spri ng washer and the washer'
v
MAINSHAFT
COUNTERSHAFT
Remove the di fferenti al assembl y from the cl utch
housi ng.
Tape t he
spl rnes.
WASHER
DIFFRENTIAL ASSEMBLY
4. Remove the chamber Pl ate.
CLUTCH HOUSING
CHAMEEF PLATE
CLUTCH HOUSING
13- 63
Shift Rod
Removal
1. Remove the shi ft rod boots.
2. Remove t he change pi ece
at t achi ng bol t and t he
spri ng washer.
3, Bemove the set screw. then remove the spri ng and
the steel bal l .
4, Remove t he shi f t r od, t hen r emove t he change
pi ece,
5. Remove the oi l seal .
l _
CHANGE PIECE
SPRING
L. 25.6
11. 01 i nl
STEEL
(D.
s/16
SPRING WASHEN
OIL SEAL
Rpl acs.
*ry
SHIFT
noD
BOOTS
\ , , r l
ATTACHING AOLI
SET SCREW
13-64
Shift
Fork AssemblY
lndex
-A
eri or ro reassembl i nq. cl ean al l the
parts i n sol vent, dry them and appl y l ubri cant to any contact
pans
I
mm PI N PUNCH
sTH/REVERSE
SI{IFT FORK
3RD/4TH SHIFT FORK
Shift Fork Assembly
NOTE: The synchro sl eeve and the synchro hub shoul d
be repl aced as a set.
1. Measure the cl earance between each shi ft fork and
i ts matchi ng synchro sl eeve.
Standard: 0.35
-
0.65 mm {O.Ol i t
-
0.026 i nl
Servi ce Li mi t: 1.0 mm t0.04 i nl
SHIFT FOBK
l f the cl earance i s more than the servi ce l i mi t. mea_
sure the thi ckness of the shi tt fork fi noers.
Standard: 7.4
-
7.6 mm
(0.291 -
0.299 i n)
l f t he t hi ckness of t he shi f t f or k f r nger s r s not
wi thi n the standard, repl ace the shi ft fork wi th a
new one.
l f the thi ckness of the shi ft fork fi ngers i s wi thi n
the standard, repl ace the synchro sl eeve wi th a
13- 66
3. Measure the cl earance between the shi ft pi ece
and
the shi ft fork shafts.
Standard:
0.2
-
0.5 mm
(0.008 -
0.02 i nl
{0.03 in)
l f the cl earance i s more than the servi ce l i mi t. mea-
sure the wi dth of the shi ft Di ece.
Standard: 11.9
-
12.0 mm
(0.469 -
0.i t72 i n)
l f the wi dth of the shi ft pi ece
i s not wi thi n the
standard, repl ace the shi ft pi ece
wi th a new one.
l f the wi dth of the shi ft pi ece
i s wi thi n the stan_
dard, repl ace the shi ft fork wi th a new one.
t ,
SHIFT PIECE
Mainshaft
AssemblY
l ndex
Note the fol l ow
. The 3rd/4th and the 5th synchro hubs are i nstal l ed wi th a press
. Instal l the angul ar bal l beari ng wi th the thi n-edged cuter race faci ng the stop rrng'
Pri orto reassembl i ng. cl ean al l the
parts i n sol vent,drythem, and appl y l u bri ca nt to any contact su rfaces The
3rd/4th and the sth synchro hubs, however, shoul d be i nstal l ed wi th a press before l ubri cati ng them'
ANGULAR BALL BEARING
I nspect l or wear
and operat i on.
Not e t he drrect l on
oI i nst al l at t on.
v
SYNCHRO
SPRING
3RO/4TH SYNCHRO HUB
3RD GEAR
I nspect i on,
page 13-68, 81
3RO/4TH SYNCHRO SLEEVE
SYNCHRO
SPRING
STOP RING
TAPER RING
NEEOLE EEARING
I nspect f or wear
and operat i on.
SPACER
SYNCHRO RING
I nspect i on.
page 13-81
SYNCHRO
SPRING
SYNCHRO HUB
5TH/REVERSE
SYNCHRO SLEVE
SYNCHEO
SPRING
I nspect i on,
page 13-81
NEEDLE BEARING
and operat i on.
SYNCHRO RING
I nspect i on,
page 13 8' 1
GEAR
I nspecl r on,
page 13- 70, 81
NEEDLE BEARING
I nspect I or wear
and operat i on.
COLLAB
4TH GEAR
I nspect i on,
page 13' 69, 81
13-67
Mainshaft Assembly
NOTE: l f r epl acement i s r equi r ed, al ways r eDl ace t he
synchro sl eeve and the synchro hub as a set.
1. Measure the cl earance between 2nd and 3rd oears,
Standard: 0.06
-
0.21 mm
(0.002 -
0.008 i nl
(0.01
i nl
sure the thi ckness of 3rd gear.
Standard: 34.92
-
3i t.97 mm t1.375
-
1.377 i nt
Service Limit: 3,1.3 mm
(1.350
inl
l f the thi ckness of 3rd gear i s l ess than the ser-
vi ce l i mi t. repl ace 3rd gear wi th a new one.
l f the thi ckness of 3rd gear i s wi thi n the servi ce
l i mi t, repl ace the 3rd/4th synchro hub wi th a new
one.
I d
3. Measure the cl earance between 4th gear and the
spacer col l ar.
Standard: 0.06
-
0.21 mm
(0.002 -
0.008 inl
Servic Limit: 0.3 mm
(0.01
inl
It the cl earance i s more than the servi ce l i mi t, mea-
sure di stance @
on the spacer col l ar
Standard: 26.03
-
26.08 mm {1.025
-
1.027 in}
4TH GEAR
SIDE
SPACER COLLAE
5. l f di stance @
i s not wi thi n the standard. repl ace the
spacer col l ar wi th a new one. l f di stance O
i s wi thi n
the standard. measure the thi ckness of 4th
gear'
Standard: 31.12-31' 17 mm {1.237
-
1.239 i nl
Servi ce Li mh:31.3 mm
(1.232
i n)
vi ce l l mi t, repl ace 4th gear wi th a new one.
l f the thi ckness of 4th
gear i s wi thi n the servi ce
l i mi t, repl ace the 3rd/4th synchro hub wi th a new
one,
(cont' d)
13- 69
Mainshaft Assembly
(cont'dl
6. Measure the cl earance between sth gear and
spacer col l ar.
Standard: 0.05
-
0.21 mm
(0.002 -
0.008 i nl
Servi ce l i mi t: 0.3 mm 10.012
i nl
sure di stance )
on the spacer col l ar.
Standard: 26.03
-
26.08 mm {1.025
-
1.027 i nl
t he
1.
5TH GEAB
\
8. l f di stance
(E
i s not wi thi n the standard, repl ace the
spacer col l ar wi th a new one.
l f di stance @
i s wi thi n the standard, measure the
thi ckness of 5th gear.
Standard: 31.12-31.47 mm {1.237
-
1.239 i n}
Servi ce Li mi t:31.3 mm {1.232 i n)
vi ce l i mi t, repl ace sth
gear wi th a new one.
l f the thi ckness of 5th gear i s wi thi n the servace
l i mi t , r epl ace t he 5t h synchr o hub wi t h a new
one.
u , a
5TH GEAR
3-70
SPACER COLLAB
Disassembly
1. Remove the bal l beari ng usi ng a beari ng pul l er as
shown.
BEABI NG PULLER
BALL BEARING
CAUTION: Remove the synchro hubs using a ptess
and the stsl blocks as shown. Use of a
i8w'type
puller can cause damage to th
gear teeth.
Suppor t st h gear on st eel bl ocks, and pr ess t he
mai nshaft out of the sth synchro hub, as shown.
3. Suppor t 3r d
gear on st eel bl ocks, and pr ess t he
mai nshaft out of the 3rd/4th svnchro hub, as shown.
13-71
Mainshaft Assembly
Inspection
1. Inspect the gear surfaces and the beari ng surfaces
for wear and damage. then measure the mai nshaft
at poi nts A, B, and C. l f any
parts
of the mai nshaft
are l ess than the servi ce l i mi t, reDl ace mai nshaft
wi th a new one.
Standard:
A: 27.987
-
28.000 mm {1.1018
-
1.1024 i n}
B: 37.98i1
-
38.fi)0 mm
(1.,|!t5,0 -
1.4960 inl
Ci 27.977
-
27.990 mm 11.1015
-
1.1020 i nl
Service Limit:
A; 27.940 mm {1.1000 i n}
B: 37.930 mm
(1./{133
i n)
C:27.930 mm
(1.0996
i nl
(
2. Inspect for runout. l f the runout i s more than the
servi ce l i mi t, repl ace the mai nshaft wi th a new one,
Standard: 0.02 mm 10.0008 inl max.
Ssrvice Limit: 0.05 mm 10.002 inl
NOTE: Suooor t t he mai nshaf t at bot h ends as
shown.
t
I nspect f or wear
ano oamage.
I nspect oi l
passages
t or cl oggi ng.
13- 72
Reassembly
CAUTION:
. Press the 3rd/4th and the 5th synchro hubs on the
mainshaft without lubrication.
o When i nstal l i ng the 3rd/,l th and the sth synchro
hubs, support the mai nshaft on steel bl ocks, and
installthe synchro hubs using a prsss.
. Install the 3rd/4th and the sth synchro hubs with a
maxi mum pl essur of 19.6 kN
(2,000
kg, 14,466 l bl .
NOTE: Refer to page 13-67 for reassembl y sequence.
1, Support 2nd gear on steel bl ocks, then i nstal l the
3rd/4th synchro hub usi ng the speci al tool s and a
press, as snown.
NOTE:
. Af t er i ns t al l i ng. c hec k t he oper at i on of t he
3rd/4th synchro sl eeve and hub.
. Assembl e the 3rd/4th synchro hub and sl eeve
together betore i nstal l i ng them on the mai nshaft.
Cl osed end
3RD/4TH
SYNCHRO HU3
DBIVER, 10 mm l.O.
07746
-
00301U)
/ lrrlcHlileNr. ss .- t.o.
07746
-
0030,100
l.
3RD/{TH
SYNCHRO
SLEEVE
2ND GEAR
2. Instal l the sth synchro hub usi ng the speci al tool s
and a press as snown.
DRI VER, {0 mm l . O.
07746
-
0030100
ATTACHMENT,
35 mm LD.
sTH SYNCHRO HUB
07716
-
0030,100
3. I nst al l t he angul ar bal l bear i ng usi ng t he speci al
tool s and a
press as shown.
PRESS
+
DRIVER, 40 mm LD.
0?7a6
-
It030100
Gountershaft Assembly
Index
DAMPER
ST GEAR
Inspection, page 13-75
EALL EEARING
and operat i on.
NEEDLE BEARI NG
l nspect f or wear
ano operat on.
5TH GEAR
4TH GEAR
3RD GEAR
NOTE:
3
The 4th and sth gears
are i nstal l ed wi th a press.
Pri or to reassembl i ng, cl ean al l the parts i n sol vent, dry them and appl y l ubri cant to any contact surfaces. The 4th
and 5th gears. however, shoul d be i nstal l ed wi th a press before l ubri cati ng them.
REVERSE GEAR
LOCKNUT Repl ace
1 0 8 " 0 - 1 0 8 N . m
i 11. 0
-
0- l 1. 0kgt m,
1 8 0 - 0 - 8 0 l b t t r
WASHER
DISTANCE
COLLAR
COUNTERSHAFT
NEEDLE BEARING
and operat ron,
NEEDLE BEARING
ano operat ron,
SPACER
FRICTION DAMPER
DOUBLE CONE
I nspect i on, page 13 81
SYNCHRO SPRING
13-74
I
I
I
, '
I
Cl earance Inspecti on
1. Measur e t he cl ear ance bet ween t he 1st gear and
di stance col l ar.
Standard: 0,045
-
0.205 mm
10.002
-
0.008 in)
(0.01
inl
2. l f the cl earance exceeds the servi ce l i mi t. measure
the thi cknesses of 1st
gear.
lST GEAR
Standard: 29.45
-
29.50 mm {1.159
-
1.161 i n}
DISTANCE COLLAR
Standard:@ 36.5 mm
(1.4i 1i n)
@
,12.0
mm
(1.65
i n)
@
30. 0 mm
( 1. 18
i n)
l f the thi cknesses of 1st gear and di stance col l ar
are l ess than the standard, repl ace wi th a new
one.
l f the thi cknesses of 1st gear and di stance col l ar
are wi thi n the standard, repl ace the l sv2nd syn-
chro hub wi th a new one.
3. Measur e t he cl ear ance bet ween
gears.
Standard: 0.07
-
0.14 mm
(0.003 -
0.006 inl
Servico Limii: 0.24 mm
(0.009
in)
t he 2nd and 3r d
3RD GEAR
2ND GEAR
4. l f the cl earance exceeds the servi ce l i mi t, measure
the thi cknesses of znd
gear and spacer.
2ND GEAR
Standard: 28.92
-
28.97 mm
(1.139 -
1.1' t1 i nl
'-.
ll
-=Jl
71 il
SPACER COLLAR
Standard: 29.07
-
29.09 mm {1.1i t4
-
1.1,15 i nl
l f the thi cknesses of 2nd gear and spacer are l ess
than the standard, repl ace wi th a new one.
l f t he t hi cknesses of 2nd gear and spacer ar e
wi thi n the standard, repl ace the l sv2nd synchro
hub wi th a new one.
13-75
Disassembly
1. Secur el y cl amp t he count er shaf t assembl v i n a
2. Rai se the l ocknut tab from the groove
i n the coun-
tershaft, then remove the l ocknut and the spri ng
washer.
Remove the bal l beari ng usi ng a beari ng pul l e.
as
shown.
BEARING PULLER
BALL BEARI NG
13-76
4, Remove the beari ng outer race, then remove the
needl e beari ng usi ng a beari ng pul l er as shown.
BEARING PULLEF
BEARING
CAUTION: Romove the gears
using a
pr63
and the
stesl blocks as shown, Use of a
,aw-typo
puller
can
cause damage lo lhe gear
tooth.
Support 4th gear on steel bl ocks, and press the
countershaft out of sth and 4th gears,
as shown.
sTH GEAF
{TH GEAR
. (
a
I
t
I
t
Inspection
1. Inspect the gear surfaces and the bearing surfaces
for wear and damage, then measure the counter-
shaft at points A, B, and C. lf any parts of the coun-
tershaft are l ess than the servi ce l i mi t. reDl ace coun-
torshaft with a new one.
Standard:
A: 2/t.980
-
2{.993 mm
(0.9835 -
0.9&O in}
B: 35.984
-
37.000 mm {1.4561
-
1.4567 in)
G: 33.fiD
-
33.015 mm {1.2992
-
1.2998 in)
Sorvicc Limit:
Ar 2/t.9't0 mm 10.9819 inl
B: 36.930 mm {1.'l5qt in}
C: 32.950 mm {1.2972 in}
Inspct for wear
I nspect oi l
passage f or cl oggi ng.
13-77
2. Insoect for runout. l f the runout i s more than the
servi ce l i mi t, reol ace the countershaft wi th a new
one.
Strndard: 0.02 mm {0.(x)08 in) max.
Servic. Limit 0.05 mm
(0.002
in)
NOTE: SuoDort th countershaft at both ends as
shown.
Rotate lwo complele
revot ut ons.
Reassembly
CAUTION:
. Pross 4th 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 pressure
of
25.5 kN
(2,600
ksf, 18,806lbf).
NOTE; Refer to page 13-74 for reassembl y sequence.
' 1.
Instal l the di stance col l ar and the needl e beari nos
on the countershaft.
COUNTERSHAFT
Instal l the fri cti on damper, the synchro ri ng, and the
synchro spri ng on 1st gear.
Instal l the 1sv2nd synchro hub by al i gni ng the fi n-
gers on the fri cti on damper and the grooves
i n the
1sv2nd synchro hub, as shown.
lST/2NO
13-78
lSI GEAR
i n s t e p s 2 - 6 o n t h e
{
4. l nstal l the reverse gear.
I nst al l t he synchr o spr i ng. and t he doubl e cone
synchro as shown.
Assembl e the fri cti on damper, the needl e beari ng,
and 2nd gear,
then i nstal l them by al i gni ng the fi n-
gers
on the fri cti on damper and the grooves i n the
1sv2nd synchro hub wi th the fi ngers of the doubl e
cone synchr o and t he gr ooves on 2nd gear , as
snown.
Instal l the spacer.
FRICTION DAMPER
Instal l the parts
assembl ed
countershaft.
;
2ND GEAR
9. Suppor t t he count er shaf t on a st eel bl ock, and
i nstal l 4th gear usi ng the speci al tool s and a press.
as 5nown.
ATTACHMENT, 35 mm LD.
07746
-
0030400
Suppor t t he count er shaf t on a st eel bl ock, and
i nstal l 5th gear usi ng the speci al tool s and a press,
as shown.
ATTACHMENT, 30 mm I,D,
07746
-
0030300
10.
\
' 1' 1.
I nst al l t he needl e beari ng, t hen i nst al l t he bal l bear-
i ng usi ng t he speci al t ool s and a press as shown.
PRESS
DRI VER, 40 mm LD.
07746
-
0030100
ATTACHMENT, 30 mm LD.
07746
-
0030300
J.-
12. Secur el y cl amp t he count er shaf t assembl y i n a
l nstal l the spri ng washer, ti ghten the l ocknut, then
stake the l ocknut tab i nto the groove.
LOCKNUT
108- 0- 108N. m 111. 0- 0- 11. 0k gt . m,
80+ 0* 80 l bf' ftl
WOOD BLOCKS
13-79
Inspection
1 , Inspect
gear teeth on al l synchro hubs and synchro
sl eeves for rounded off corners. whi ch i ndi cates
I nst al l each synchr o hub i n i t s mat i ng synchr o
sl eeve and check for freedom of movement.
NOTE: l f repl acement i s requi red, al ways repl ace
the synchro sl eeve and synchro hub as a set.
Instal l ati on
When assembl i ng the synchro sl eeve and synchro hub,
be sur e t o mat ch t he t hr ee set s of l onger t eet h
( 120
degrees apart) on the synchro sl eeve wi th the three sets
of deeper grooves i n the synchro hub.
CAUTION: Do noi i nstal l tho synchro sl eeve wi th i ts
longer toeth in the synchro hub slots, because it will
damage the spring ring.
SYNCItRO
SLEEVC
LONGER TEETH
13- 80
Synchro Ri ng, Gear
Inspection
' 1.
Inspect the synchro ri ng and
gear.
A: Inspect the i nsi de of the synchro ri ng for wear'
B: Inspect the synchro sl eeve teeth and matchi ng
teeth on the synchro ri ng for wear
(rounded
off).
o o
GOOD WORN
C: Inspect the synchro sl eeve teeth and matchi ng
teeth on the gear for wear
(rounded
off).
n n
U U
GOOO WORN
D: Inspect the
gear hub thrust surface for wear.
E: Inspect the cone surface for wear and roughness.
F: Inspect the teeth on al l gears for uneven wear,
scori ng,
gal l i ng, and cracks'
2. Coat the cone surface of the
gear wi th oi l , and
pl ace
the synchro ri ng on the matchi ng
gear. Rotate the
ri ng, maki ng sure that i t does not sl i p
Measure the cl earance between the synchro ri ng
and gear al l t he way ar ound.
NOTE: Hol d the synchro ri ng agai nst the gear even-
l y whi l e measuri ng the cl earance.
Synchro Ring-to-Gear Clearance
Standard: 0.73
-
1.18 mm
(0.029 -
0.0'16 in)
Ssrvice Limit:0.,0 mm {0.02 in}
Double Cone Synchro-to-Geal Clearanc
Standald:
@:
(Outer
Synchro Ring to Synchro Con6l
0.5
-
1.0 mm 10.02
-
0.04 i n)
@:
(Synchro cone to Gearl
0.5
-
1.0 mm
(0.02
-
0.04 i nl
O: {Outer
Synchlo Ring to Gear)
0.95
-
1.68 mm
(0.037 -
0.066 i n)
Service Limit:
@:
0.3 mm {0.01
i n}
@:
0.3 mm {0.01 i n)
O:
0.6 mm t0' 02
i nl
l f the cl earance i s l ess than the servi ce l i mi t, repl ace
the synchro ri ng and sYnchro cone.
SYNCHRO SPRING
SYNCHRO RING
t
SYNCHRO CONE
13- 81
Differential
Index
FINAL DRIVEN GEAR
I nspect t or wear and damage.
80 mm SHIM
Sel ect i on, page' 13, 84
101 N.m
{10.3 kgtm,74.5 lbf.ft)
BALL BEAFING
I nspect f oa wear and ooerat i on.
13-82
Backlash Inspection
1. Pl ace the di fferenti al assembl y on V-bl ocks and i nstal l
both axles.
Measur e t he backl ash of bot h pi ni on gear s. l f t he
backl ash i s not wi thi n the standard, repl ace the di f,
ferenti al carri er.
Standard
(New):
0.05
-
0.15 mm
(0.002 -
0.006 i nl
DI AL I NDI CATOR
r l a
Fi nal Dri ven Gear Repl acement
' 1.
Remove the bol ts i n a cri sscross pattern i n several
steps, and remove the fi nal dri ven gear from the di f-
ferenti al carri er.
NOTE: The f i nal dr i ven gear bol t s have l ef t - hand
threads,
12 x 1. 0 mm
101 N.m {'10.3 kgf.m,74.5 lbf.ftl
Left hand
FI NAL DRI VEN GEAR
Chamf er on i nsi de daamet er of
f i nal dri ven gear f aces carri er.
2. Instal l the fi nal dri ven
gear by ti ghteni ng the bol ts
i n a cri sscross
pattern i n several steps. NOTE: Dri ve the beari ngs squarel y unti l they bot-
tom agai nst the carri er.
BALL BEARING
13- 83
Beari ng Repl acement
NOTE: Check the bal l beari ngs for wear and rough rota-
ti on. l f beari ngs are OK, removal i s not necessary.
1. Remove the bal l beari ngs usi ng a standard beari ng
pul l er
and beari ng separator as shown.
BEARI NG PULLER
BEARI NG SEPARATOR
lCommercially
availab16)
BALL BEARING
2. I nst al l new bal l bear i ngs usi ng t he speci al t ool as
shown.
Differential
Thrust Shim Adjustment
1. Instal l the di fferenti al assembl y, maki ng sure i t bot
toms i n the cl utch housi ng, usi ng the speci al tool as
shown.
ORI VER, 40 mm LO.
o7746-0030100
l nst al l t he 80 mm shi m.
NOTE: l nstal l the 80 mm shi m that was removed.
mm SHI M
13-84
(
4.
Instal l the transmi ssi on housi ng
(see page 13-94).
NOTE: Do not appl y l i qui d gasket to the mati ng sur-
face of the cl utch housi ng.
Ti ght en t he t r ansmi ssi on housi ng at t achi ng bol t s
(see page 13-94).
I x 1.25 mm
27 N'm
(2.8
kgf.m, 20 lbf.ftl
Use the speci al tool to bottom the di fferenti al assem.
bl y i n the cl utch housi ng.
Measure cl earance between the 80 mm shi m and
beari ng outer race i n the transmi ssi on housi ng.
t
7. l f the cl earance i s not wi thi n the standard, sel ect a
new 80 mm shi m from the fol l owi ng tabl e.
Standard: 0
-
0.10 mm
(0 -
0.004 i nl
80 mm Shi m
Part Number Thickn6ss
41441
-
PL3
-
800
' 1.0
mm
(0.0394
i n)
B 41442- PL3- B00 1.1 mm
(0.0433 i n)
c 41443- PL3- 800 1.2 mm
(0.0472
i n)
D 41444- PL3- 800 1. 3 mm
( 0. 0512
i n)
41445- PL3- 800
1. 4 mm
( 0. 0551
i n)
41446- PL3- 800 1. 5 mm
( 0. 0591 i n)
41447- PL3- 800 1.6 mm
(0.0630 i n)
H 41448- PL3- 800 1.7 mm
(0.0669 i n)
41449- PL3- 800
1.8 mm
(0.0709
i n)
K 41450- PL3- B00 1. 05 mm
( 0. 0413
i n)
41451
-
PL3
-
800 1.' 15 mm
(0.0453
i n)
IV 41452- PL3- 800 1.25 mm
(0.0492
i n)
N 41453- PL3- B00 1.35 mm
(0.0532 i nl
P 41454- PL3- 800 1.45 mm
(0.0571 i n)
41455- PL3- 800
1. 55 mm
( 0. 0610 i n)
R 41456- PL3- 800 1.65 mm
(0.0650
i nl
41457- PL3- 800 1.75 mm
(0.0689
i n)
NOTE; l f the cl earance measured i n step 6 i s wi thi n
the standard, it is not necessary to
9o
to step 9.
13- 85
8. Remove the bol ts and transmi ssi on housi ng.
Bepl ace the 80 mm shi m sel ected i n step 7, then
Reassembl e the transmi ssi on and i nstal l the trans-
mi ssi on housi ng.
10.
Cl utch Housi ng Beari ng
Replacement
Mainshaft:
L Remove the bal l beari ng usi ng the speci al tool s as
shown.
3/81_ 16 SLIDE HAMMER
{ c ommer c i al l y av ai l abl e)
ADJUSTAELE BEARING
PULLER, 25
-
40 mm
07736
-
A01000A
2. Remove the oi l seal from the cl utch housi no.
13- 86
CLUTCH HOUSING
BALL BEARING
(
3. Dri ve the new oi l seal i nto the cl utch housi ng usi ng
HANOLE
07749
-
0010000
07746
-
0010300
4.
OIL SAL
Repl ace.
Dri ve the bal l beari ng i nto the cl utch housi ng usi ng
HANDLE
07749
-
0010000
07746
-
0010il{)0
PILOT, 28 mm
07746
-
0041100
Countershaft:
1. Bend the tab on the l ock washer down, then remove
the bol t and beari ng retai ner
pl ate.
BEARING RETAINER PLATE
cLutcH tlouslNG
Remove the needl e beari ng usi ng the speci al tool s
as shown, then remove the oi l gui de pl ate'
3/8'
-
16 SLIOE HAMMER
(Commerci al l Y avai l abl e)
^ LOCK WASHER
g
Reol ace.
d---""-
t
ADJUSTABLE BEARING
PULLER, 25
-
{o mm
07736
-
Aolmo A
3. Posi ti on the oi l
gui de pl ate and new needl e beari ng
i n the bore of the ctutch housi ng, then dri ve i n the
needl e beari ng usi ng the speci al tool s as shown
NOTE: Posi ti on the needl e beari ng wi th the oi l hol e
faci ng up.
NEEDLE
OIL HOLE
NEEDLE
BEARING
Instal l the beari ng retai ner
pl ate and new l ock wash-
er, then bend the tab agai nst the bol t head'
8 x 1 0 mm
15 N'm
(1.5 kgt'm, rl |bt'ft)
LOCK
WASHER
Replace.
13-47
Mainshaft
Thrust
Clearance
Adjustment
1. Remove the 72 mm thrust shi m and oi l gui de pl ate
from the transmi ssi on housi ng.
4.
TFANSMISSION
HOUSING
72 mm THRUST SH|M
TRAt{SMtSStON
HOUSING
OIL GUIOE PLATE
l nstal l the 3rd/4th synchro hub. spacer col l ar,5th
synchro hub. spacer, and bal l beari ng on the mai n_
shaft, then i nstal l the above assembl y i n the trans_
mi ssi on housi ng.
l nstal l the washe[ on the mai nshaft,
Measure di stance
@ between the end of the trans-
mi ssi on housi ng and washer.
NOTE;
.
Use a strai ght edge and verni er cal i per.
. Measure at three l ocati ons and average the read_
i ng. ENO ot
lnA sMtsstoN
HOUSING
MAINSHAFT
3RD/irTH SYNCHRO HUB
SPACCR COLLAR
5TH SYNCHRO HUB
o
B
13- 88
AALL BEARING
V .
5. Measure di stance
@ between the end of the cl utch
housi ng and beari ng i nner race.
NOTE;
.
Use a strai ght edge and depth gauge.
.
Measure at three l ocati ons and average the read-
i ngs.
Sel ect the prcpet 72 mm thrust shi m from the chart
by usi ng the formul a bel ow.
NOTE: Us onl y one 72 mm thrust sntm.
Shim Selection Formula:
From the measurements you
made i n steps 4 and 5:
.
Add di stance
O l step 5) to di stance
@
(step
4).
. From thi s number, subtract 0.93
(whi ch
i s the
mi dpoi nt of the fl ex range of the cl utch housi ng
beari ng spri ng washer).
. Take thi s number and compare i t to the avai l abl e
shi m si zes i n the chart.
{For exampl e)
B; 2. 39
+ C: 0.22 -
0.93
2.61 =
1.68
Try the 1.68 mm
(0.0661
i n) shi m.
INNER RACE ot EALL BEARING
72 mm Thrust Shim
t
Part Number
Thickness
23931
-
P21 000 0. 60 mm {0. 0236
i n}
23932- P21
- 000
0. 63 mm 10. 0248
i n)
c 23933 P21
-
000 0. 66 mm
(0. 0260 i n)
D 23934
-
P21 000 0. 69 mm
(0. 0272 i n)
E 2393s - P21- 000
0. 72 mm
(0. 0283 i n)
F 23936- P21
- 000
0. 75 mm
(0. 0295 i n)
G 23937
-P21-O00 0. 78 mm
(0. 0307 i n)
23938- P21
- 000
0. 81 mm
( 0. 0319 i n)
23939- P21
- 000
0. 84 mm
(0. 0331 i n)
J 23940- P21
- 000
0. 87 mm
(0. 0343 i n)
K 23941 P21
-
000 0. 90 mm
(0. 0354 i ni
L 23942
-
P21 000 0. 93 mm
(0. 0366 i n)
23943- P21
- 000
0. 96 mm 10. 0378
i n)
N 23944
-
P21
-000
0. 99 mm
(0. 0390 i n)
o 23945
-
P21 000 1. 02 mm
(0. 0402 i n)
P 23946
-
P21 000 1. 05 mm
(0. 0413 i n)
o 23947
-
P2l 000 1. 08 mm
(0. 0425 i n)
R 23948- P21
- 000
1. ' 1
' l
mm
(0. 0437 i n)
S 23949
-
P21 000 1. 14 mm
(0. 0449 i n)
T 23950
-
P21 000 1. 17 mm
( 0. 0461 i n)
23951
-
P21
-000
1. 20 mm
(0. 0472 i n)
23952
-
P21
-000
1. 23 mm
(0. 0484 i n)
23953- P21
- 000
1. 26 mm
(0. 0496 i n)
X 23954- P21
- 000
1. 29 mm
(0. 0508 i n)
23955
-
P21
-000
1. 32 mm
(0. 0520 i n)
z 23956- P21
- 000 1. 35 mm
(0. 0531 i n)
23957- P21
- 000
1. 38 mm 10. 0543
i n)
AB 23958
-
P21
-000
1. 41 mm
(0. 0555 i n)
AC 23959 P21
-
000
1. 44 mm {0. 0567
i n)
23960
-
P21 000 1. 47 mm
(0. 0579 i n)
AE 23961
-
P21
-000 1. 50 mm {0. 0591
i n)
23962 P21
-
000 1. 53 mm {0. 0602
i n)
AG 23963- P21
- 000 1. 56 mm
( 0. 0611i n)
AH 23964- P21
- 000
1. 59 mm {0. 0626
i n)
23965- P21
- 000
' 1. 62
mm {0. 0638
i n)
23965- P21
-
000 1. 65 mm
(0. 0650 i n)
AK 23967- P21
- 000
1. 68 mm {0. 0661
i n)
23968
-
P21
-000
1. 71 mm 10. 0673
i n)
23969 P21
-
000
1. 74 mm {0. 0685
i n)
AN 23970- P21
- 000
1. 77 mm {0. 0697
i n)
AO 23971
-
P21
-000
1. 80 mm
(0. 0709 i n)
7. l nstal l the thrust shi m sel ected and oi l gui de pl ate i n
the transmi ssi on
housi ng.
72 mm THRUST
OIL GUIDE PLATE
TRANSMISSION
HOUSING
8. I nst al l t he spr i ng washer and washer on t he bal l
beafl ng.
NOTE:
. Cl ean the spri ng washer, washer and thrust shi m
throughl y before i nstal l ati on.
. I nst al l t he spr i ng washer , washer and t hr ust
shi m
properl Y.
-WASHR
-<]>-.-'
x -sPRtNG WASHER
-.-sK
( ( 9r '
l nstal l the mai nshaft i n the cl utch housi ng.
Pl ace the transmi ssi on
housi ng over the mai nshaft
and onto the cl utch housi ng.
Ti ghten the cl utch and transmi ssi on housi ngs wi th
several 8 mm bol ts.
NOTE: l t i s not necessar y t o use seal i ng agent
between the housi ngs.
8 x 1.25 mm
27 N.m
(2.8
kgf.m. 20 lbf'ft)
Tap the mai nshaft wi th a pl asti c hammer.
(cont' d)
9.
10.
' I
l .
12.
13- 89
Mainshaft
Thrust
Clearance
Adjustment (cont'd)
13. Check the thrust cl earance i n the manner descri bed
oetow.
CAUTION: Measuremenl
should be made at room
tempetature.
a. Sl i de the mai nshaft
base over the mai nshaft.
MAINSHAFT
EASE
07GAJ
-
PG20.130
b. Attach the mai nshaft hol der to the mai nshaft
as
fol l ows:
NOTE:
.
Back-out the mai nshaft hol der bol t and l oosen
the two hex bol ts.
. Fi t the hol der over the mai nshaft
so i ts l i p i s
towards the transmi ssi on.
. AI i gn t he mai nshaf t hol der . s I i p ar ound t he
groove
at the i nsi de of the mai nshaft
spl i nes,
then ti ghten the hex bol ts.
MAINSHAFT HOLOER
BOLT
MAINSHAFT
[--F-e
l6fffi l\nrx
|
-
\-/ I/
Borrs
ff
MAINSHAFT
HOLDER
07GAJ
-
PG20110
MAINSHAFT
BASE
07GAJ
-
PG20130
13- 90
c. Seat the mai nshaft ful l y by tappi ng i ts end wi th a
pl asti c
hammer.
d. Thread the mai nshaft hol der bol t i n untj l i t
j ust
contacts the wi de surface of the mai nshaft
base.
e. Zero a di al gauge
on the end ofthe mai nshaft.
f. Turn the mai nshaft hol der bol t cl ockwi se;
stoo
t ur ni ng when t he di al gauge
has r eached
i t s
maxt mum
movement . The r eadi ng
on t he di al
gauge
rs the amount of mai nshaft
end Dl av.
CAUTION:
Turni ng tho mai nshaft
hol der bol t
more than 60 degrees after the needle of the dial
guge
stops moving may damage the transmis_
ston.
07cAJ
_
PG20110
g. l f the readi ng i s wi thi n the standard, the cl ear-
ance is correct.
l f the readi ng i s not wi thi n the standard. recheck
the shi m thi ckness.
Standard: 0.11
-
O.18 mm
{0.004
-
0.007 i n}
DIAL GAUGE
Transmi ssi on
ReassemblY
1. Instal l the new oi l seal
2. Set the change
Pi ece.
3. Instal l the shi ft rod
4. Instal l the steel bal l ' the spri ng, and the set screw'
5. Instal l the spri ng washer and change
pi ece attach-
i ng bol t.
6. Instal l the shi ft rod boots.
8 x 1 . 0 mm
31 N. m 13. 1
kg-m,
22lb-ltl
CHANGE
PIECE
@:4
OIL SEAL
Repl ace.
SPRING
WASHER
7. Instal l the oi l chamber Pl ate'
6 x
' 1. 0
mm
12 N. m
(1. 2 kg-m, 9l b-f t |
SPRING
, / L. 256f i m
B( ) (
@ /
t't o'ti"l
I
{zw"y-6@
q
10.
Set the spri ng washer and the washer'
l nstal l the mai nshaft, the countershaft,
and the shi ft
fork assembl i es.
NOTE: Al i gn t he f i nger of t he i nt er l ock wi t h t he
groove in the shift fork shaft.
SHIFT FORKS
13- 91
Transmission
Reassembly
(cont'd)
11. I nst al l t he change hol der assembl y.
6 x 1 . 0 mm
15 N. m {1. 5 kgf . m,
12 N. m {1. 2 kgf . m, 9l bt f t l
CHANGE HOLDER
ASSEMBLY
Instal l the shi ft pi ece and the i nterl ock. then i nstal l
the shi ft pi ece
shaft.
12.
13-92
(
13. Measure the di stance
@ after mounti ng the shi ft
pi ece
shaft. l f i t' s i ncorrect. check the i nstal l ati on.
Di stance
@:
11.9
-
12.3 mm
{0./t7
-
0.48 i nl
14. Instal l the .everse i dl er gear
and the reverse i dl er
gear shaft.
REVERSE IDLER GEAR
REVERSE
IDLE
t l
15. Instal l the reverse change hol der.
6 x 1 . 0 mm
' 15
N. m 11. 5
kgi m, 11 l bl f t l
Instsl l the oi l
gui de pl ate and the 72 mm thrust shi m
i nto the transmi ssi on
housi ng.
17.
18.
Instal l the oi l
gutter pl ate.
Bend the hook of the oi l
gutter pl ate, then i nstal l the
16 mm seal i ng bol t.
NOTE: Appl y l i qui d
gasket
{P/N
08718
-
0001 or
08718
-
16 mm SEALING BOLT
29 N.m t3.0 kgl'm, 22 lbt'ft}
Appl y l i qui d
gasket to the surface of the transmi s-
si on housi ng as shown'
NOTE:
. Us e l i qui d
gas k et
( P/ N 087' 18
-
0001 or
08718
-
00031.
. Remove the di rty oi l from the seal i ng surface'
. l f 5 mi nuts have
passed after appl yi ng l i qui d
gasket, reappl y i t and assembl e the housi ngs'
. Allow it to cure at least 20 minutes after assem-
bl v bsfore fi tl i ng the transmi ssi on wi th oi l '
19.
(cont' d)
13- 93
--- Li qui . l
gaskt
Transmi ssi on
Reassembl y
(cont' dl
Instal l the dowel pi ns.
I nst al l t he t r ansmi ssi on housi ng
by al i gni ng t he
groove
i n the housi ng wi th the fi nger on the stop
f l ng.
GROOVE
21.
Lower the transmi ssi on housi ng wi th the snap ri ng
pl i er s,
and set t he snap r i ng i n t he gr oove
of t he
countershaft beari ng.
TRANSMISSION
HOUSING
13-94
(
23. Check that the snap ri ng i s securel y seated i n the
groove
of the countershaft beari ng.
Di mensi on
6) as i nstal t6d: 4.6
-
8.3 mm
(0.181 -
0.327 i nl
24. Instal l the cl utch l i ne bracket, transmi ssi on hanger
A and back-up l i ght swi tch ctamp, then ti ghten the
t r ansmi ssi on
housi ng at t achi ng bol t s i n t he num_
bered sequence shown bel ow.
ATTACHING
BOLTS
8 x 1.25 mm
TRANSMISSION
HANGER A
27 N m
12.8 kgtm, 20 tbt.trl
BACK.UP LIGHT
SWITCH CLAMP
lar---'o o
"W
25. Instal l the 32 mm seal i ng bol t
NOTE: Appl y l i qui d
gasket
( P/ N 08718
-
0001 or
08718
-
26. Ti ghten the reverse i dl er
gear shaft bol t'
REVERSE IDLER GAR
SHAFT BOLT
10 x 1. 25 mm
5a N.rn t5.5 kgl m, {0 lbtftl
32 mm SEALING BOLT
25 N.m {2.5 kgl'm,
l nst al l t he st eel bal l s, t he spr i ngs, and t he set
screws.
Instal l the back-up l i ght swi tch and the transmi ssi on
hanger B.
BACK.UP LIGHT SWITCH
25 N. m 12. 5 kgt m, 18 l bl t t l
TRANSMISSION
HANGER B
8 x
21
17
1. 25 mm
N.m
(2.4 kgf m,
lbf.ftt
I
I
I
I
EALL
\
\
\
\
SET SCREW
' 12
x 1. 0 mm
22 N.m
(2.2
kgf'm,
16 tbt.trl
13- 95
Oi l Seal s
Replacement
Trrn3mirdon Housing:
1. Remove the oi l seal from the transmi ssi on housi ng.
Instal l the oi l seal i nto the transmi ssi on housi ng
usi ng the spci al tool s as shown,
HANDLE
07149
-
d)l(xxto
OIL SEAL
Repl ace.
HOUSING
13- 96
OIL SEAL
Repl ace.
{
Clutch Housing:
1. Remove the oi l seal from the cl utch housi ng.
OIL SEAL
Repl ace.
Instal l the oi l seal i nto the cl utch housi ng usi ng the
speci al tool s
as shown.
HANDTI
0t?a9
-
001o(xto
Gearshift
Mechanism
Overhaul
NOTE:
. Inspect rubber
parts for wear and damage when di sassembl i ng;
. Instal l the spri ng
pi n and the cl i p on the change
j oi nt
as shown'
. Turn the shi ft rod boot so the hol e i s faci ng down as shown'
. Make sure the shi ft rod boot i s i nstal l ed on the shi ft rod'
reDl ace any worn or damaged Parts.
I x 1. 25 mm
22 N.m 12.2 kgf.m, 16 lbf.ft)
ffi-:t't:il1ii51i?"'*,
TU
/g3i'51!Exii
V
ExrENsroN
EXTENSfON
ilr'eol.T
EXTENSION END
BUSHING
h
V\
EXTENSION
WASI{ER B
MOUNT
-_.--_-_---
\ @2'
\ --1'>=2 -:liT.i'ff"
.o,-.o*&--ffi{---*,
v/,,/
BALL SEAT
8 x 1. 25 mm
22 N.m 12.2 kgf'm, 16lblftl
,
@
EXTENSION ROD
SHIFT ROD
SPRING
END
BOOT
N:
g
sHrFr LEvER
.*rr"r,o"-tf
V-oiliiSi[a
MOUNTING I --::=t SHIFT I"EVER
BRAcxEr
/
9-l--enr
xoloen
8 x 1.2s mm
:-,rro""a,
ii-ri- ri.z rsr.-,
-.Q
u
16 tbf.ft)
,,,.
,rar-aoa*,"o "u,
/
E ,",t.ruaa
Repl ace.
6 x 1 . 0 mm
9. 8 N. m
(' 1. 0
kgt ' m,
7 tbr.ftt
8 x 2 2 mm
SPRING PIN
Repl ace.
I
I
t
@
CLIP
9.a-"t' t
PIN
SHIFT ROD
/
ZW
lt#
- , \
HOLE
13-97
Automati c
Transmi ssi on
Aut omat i c
Transmi ssi on' . . . .
"' . . ' . . ". . . ' . . ' 14-1
Conti nuousl y
Vari abl e Transmi ssi on
(Cy1l
. . . . . . . . . .
14-193
t
r o
Automatic
Transmission
Speci al Tool s .........
.....' ."".' -.-.' 14' 2
Descri pti on
.,....................-...... 14-3
power
Fl ow
......,................. 14"6
El estroni c Control System .... . ................' ..' .' .. 14-13
Hvdraul i c Control
.....' ......" 1' l -19
Hydraul i c F| ow......
.' .' .".' ....11-21
Lock-up System
' ............ ... t/t' 33
Electrical System
Component Locati ons....,.............' ......' .............' .,.
14' 39
PCM Circuit Diagram
lA/T
Control Systm:
'96
-
98 Models) .........'.. 1/t-40
PCM Tarminal Volt8ge/Measuring Condhions
{'96
-
98 Modebl
A/T Control System ............
PCM Circuit Disgram
(A/T
Conlrol System:
'99
-
00 Modsls) '..........' 14-44
PCM Terminal Voltage/Measuring Conditions
('99 -
00 Models)
A/T Control System ...
Troubleshooting Proceduros ....
Symptom-to-ComPonent
Chari
Efectri caf SFi em
-
' 96
-
98 Model s ' ..-.-..."' .' ..11-52
Eloqtrical System
-'99 -
00 Modols ... .........". 1+54
EleclricatTroubl$hooting
('96 -
98 Models)
Valve Body
Repai r ....................
........' .... 14-139
Valve
Assembly
ATF Pump
1,1-1i10
I nspect i on
. . . . . . . . . . . ' . . . . . . . . . . 14- 141
Main Valvs Body
Disassmbf
y/lnspoction/R.sssembly .'.'.'.'.. -. -. 1 1-1 12
Secondsry Valve BodY
Disa$embfy/lnspoction/Rsassembly
......'.'.'.'. 11-111
Regulator Valve Body
Disa$embly/lnspoction/Rea3sembly
..........'... 14-1{5
Servo Body
Disassombly/lnspction/Reassembly
.".'........ 14-146
Lock-up Valv6 Body
Dis$s.mbf
y/ln3poction/Rea$embly .'.. -. -..'.'.' 1 1-1 17
Mainsh!ft
Dkassembly/lnepction
Reassembly ..'...'........ 14'148
Inspocti on
.............' ..........' . l
i t-149
Countsrshaft
Disa$embly/lnspeqtion/Rea3sembly
.......'...'.. 1a-l51
Dba$ombly/Re$s.mblY
11-152
til-46
I
rl-48
Electrical Troubleshooting
('9!t -
00 Models)
Troublsshooting Flowchart3
Lock-up Control Solenoid vslvo A/B AssemblY
RePlacoment
Shift Cont.ol Solenoid Valve A/B A3sembly
Inspestion
Ona-way Clutch
Disassembh/lrupoction/Rca$embly
.. "'........ l4-155
Clutch
lllustlttcd Ind.x {A48A,
B4RA Transmlssion) ..' 14-156
tustr.tod Index
(MrnA Transmi$ionl ............ til-158
...................... 14-153
L
14-56
1+81'
14-105
1+105
Repl acoment ......
Mainshaft/Countorshaft
Spod Sonsors
Repl acemsnt
......' ."' ........... l i t' 108
Hydraulic System
Symptom-to-Componeni
Chart
Hydraulic Sydem
r+109
t 4- 113
1+116
11-117
Rea$emblY
14-106 Difforrr ial
llhdraied Index
........ t4-156
B.ckhrh ln3poction
. 14-167
Boaring Roplacemont
..-..........11-167
..... 14-108 Diftrrsniial Carrior Repl8cemeni .'.-.............'...' lil-168
Oil Sall Romoval
t4-t 59
Oi l Soal l n3tal l sti on/Si dc Cl earance' ......' .....' ...
1' l ' 169
Torqua Convertcr Housing Boarings
Mlin3haft Besring/Oil Scal Roplac.ment ."..'.. lil-172
Counio6hatt Betring R.plscem.nt ..'...... ....... 14-173
Test . . . . . , . . . . . .
14-106
14-107
14-160
11-162
11-171
11-175
Replacement
Test .....,.,..........
Road Te3t
Linear Solenoid AsssmblY
Stall Speed
lllustrated Indax
Transmi ssi on/End Cover' . ....
Transmi ssi on Hou3i ng,.............' .' ......' ....""..-.-..
11-128
Torque Conve.ter Housing/Valvo Body ........... 14-130
End Cover
14-itB
Park Stop
1+119
In3pecti on/Adi ustmsnt...' ......' .' ............' ...."""' 14-175
Transmbgion
Reassombly
11-122
Torquo Convertet/Drivr Plsie ............'.'............'.. . l4-182
Transmission
11.726
Inrtallation
Tranlmission Housing Boarings
Msinsh.ft /CounteEhaft
Bearings
B!pltcomgnt
Rcvo.3s ldlor Gear
lnrtallation
Cooler Flushing ..
Shift Cabls
Test
Fluid Level
Checki n9 .........."..' .' .....
Changi ng
Pressure Testing
Transmission
Transmission
Rgmoval ..
l i l -176
.' ..........' .' .' ..... 1' l -183
. . . . l i l -187
11-132
Adiustmont
RemovaUlnttallation
1,1-190
l i t-191
Transmisgion Housing
Removal . . . ' . ' . . . . . .
. . . . . . ' . . . . . 14- l 3i l
Tolque Convgrter Housing/valvs Body
Rsmoval .........,......
............. 14-136
Valve CaDs
Descri pti on
.......' ................. t 4' 138
Shift lndicator Panel
Adi u3t mant
. . ' . . . . . . . . . . . . . . . . . . 14- 192
ATF Coolor Hoses
Connecti on
..,............,.,....... l ' l -192
Shi ft Lever .,........
Special Tools
l.-
a
Ref. No. Tool Number
o
,6'\
)
@)
@-
@
@
o
@
@
@
@. .
@
@
@
@
@
07GAB
-
PF50101
07GAE
-
PG40200 or
OTGAE
-
PG4O2OA
07HAC
-
PK4010A
07JAD
-
PH80101
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
07947
-
611501
Mai nshaft Hol der
Cl utch Spri ng Compressor Bol t Assembl y
Housi ng Pul l er
Driver Attachment
Pi l ot, 26 x 30 mm
Cl utch Spri ng Compresso. Attachmenr
Backprobe Set
IVT Oi l Pressure Hose, 2210 mm
Ay'T Oil Pressure Hose, Adapter
Ay'T Oil Pressure Gauge Set
dpanel
A,/T Low Pressure Gauge
Wpanel
Adj ustabl e Beari ng Pul ter, 25
-
40 mm
Aftachment, 62 x 68 mm
Aftachment, 72 x 75 mm
Dri ver 40 mm l .D.
Dri ver
Driver Attachment, 68 mm
I
1
1
1
I
1
,l
'l
1
I
1
1
14- 133, 180
14-160, 163
14- 135
14-171
14-' t7' l
14-160, 163
14-49
14- 50, 113
r 4- 119
14- 1 19
14- 119
' 14-1
19
14- 172, 173
14- 172, ' t 73, 114
14-172,174
14-153, 167. 169, 170
1+17 1
,
17 2, 173, 17
14-'t7'l
4
w
@ o
*07HAE
-
P150101 can be used as a substi tute.
**Must
be used wi th commerci al l y-avai l abl e
3/8,,
_
16 sl i de
E-E
@
@ @
hammer.
=k
l al
g
)
ry
o
e
@
o
----a\
\<-t-'- /
\26
@ @
@ @
@
a L
14-2
Description
The automati c transmi ssi on i s a 3-el ement torque converter and a dual -shaft el ectroni cal l y control l ed uni t whi ch
provi des
4 soeeds forward and 1 reverse.
Torque Convertel, Geats, and Clutches
The torque converter consi sts of a
pump, turbi ne and stator, assembl ed i n a si ngl e uni t. They are connected to the engi ne
crankshaft so they turn together as a uni t as the engi ne turns. Around the outsi de of the torque converter i s a ri ng gear
whi ch meshes wi th the starter
pi ni on when the engi ne i s bei ng started. The enti re torque converter assembl y seryes as a
fl ywheel whi l e transmi ui ng
power to the transmi ssi on mai nshaft.
The transmi ssi on has two paral l el shafts: the mai nshaft and the countershaft. The mai nshaft i s i n Ii ne wi th the engi ne
crankshaft. The mai nshaft i ncl udes the 1st, 2nd and 4th cl utches,
gears tor 2nd, 4th, reverse and l st
(3rd gear i s i ntegral
wi th the mai nshaft, whi l e the reverse
gear i s i ntegral wi th the 4th gear). The countershaft i ncl udes the 3rd cl utch, and
gears for 3rd,2nd, 4th, reverse. 1st and
park. The gears on the mai nshaft are i n constant mesh wi th those on the counter-
shaft. When certai n combi nati ons of gears i n transmi ssi on are engaged by cl utches.
power i s transmi tted from the mai n-
shaft to the countershaft to
provi de
E, l d, E,
and
E
posi ti ons.
Electronic Control
The el ectroni c control svstem consi sts of the Powertrai n Control Modul e {PCM), sensors, a l i near sol enoi d and four
sol enoj d val ves. Shi fti ng and l ock-up are el ectroni cal l y control l ed for comtonabl e dri vi ng under al l condi ti ons. The PCM i s
l ocated bel ow the dashboard, under the front l ower panel on the passenger' s si de
Hydraulic Control
The val ve bodi es i ncl ude the mai n vatve body, the secondary val ve body, the regul ator val ve body, the servo body and the
l ock-up val ve body through the respecti ve separator
pl ates, They are bol ted on the torque converter housang
The mai n val ve body contai ns the manual val ve, the 1-2 shi ft val ve. the 2nd ori fi ce control val ve, the CPB {Cl utch
Pressure
Back-up) val ve, the modul ator val ve. the servo control val ve, the rel i ef val ve, and ATF pump gears The secondary val ve
body contai ns the 2-3 shi ft val ve. the 3-4 shi ft val ve, the 3-4 ori fi ce control val ve, the 4th exhaust val ve and the CPC
(Cl utch
pressure
Control ) val ve. The regul ator val ve body contai ns the
pressure regul ator val ve, the torque converter check val ve,
the cool er rel i ef val ve, and the l ock-up control val ve. The servo body contai ns the servo val ve whi ch i s i ntegrated wi th the
reverse shi ft fork, and the accumul ators. The l ock-up val ve body contai ns the l ock-up shi ft val ve and the l ock-up ti mi ng
val ve. The l i near sol enoi d and the shi ft control sol enoi d val ve Ay' B are bol ted on the outsi de of the transmi ssi on housi ng,
and the l ock-up control sol enoi d val ve Ay' B i s bol ted on the outsi de of the torque converter housi ng. Fl ui d from regul ator
passes through the manual val ve to the vari ous control val ves. The cl utches recei ve fl ui d from thei r respecti ve teed pi pes
or i nternal hydraul i c ci rcui t.
Shift Control Mechanism
Input from vari ous sensors l ocated throughout the car determi nes whi ch shi ft control sol enoi d val ve the PCM wi l l acti vate
Acti vati ng a shi ft control sol enoi d val ve changes modul ator
pressure, causi ng a shi ft val ve to move. Thi s pressuri zes a l i ne
to one of the cl utches, engagi ng that cl utch and i ts correspondi ng
gear, The shi ft control sol enoi d val ves A and B are con-
trol l ed by the PCM.
Lock-up Mechanism
In ,Dt1
posi ti on, i n 3rd and 4th. and i n
E
posi ti on i n 3rd,
pressuri zed fl ui d i s drai ned from the back of the torque converter
through a fl ui d passage, causi ng the l ock-up
pi ston to be hel d agai nst the torque converter cover. As thi s takes
pl ace, the
mai nshaft rotates at the same as the engi ne crankshaft. Together wi th hydraul i c control , the PCM opti mi zes the ti mi ng of
the l ock-up mechani sm. The l ock-up val ves control the range of l ock-up accordi ng to l ock-up control sol enoi d val ves A and
B, and l i near sol enoi d. When l ock-up control sol enoi d val ves A and B acti vate, the modul ator pressure changes The l ock-
up control sol enoi d val ves A and B and the l i near sol enoi d are control l ed by the PCM.
(cont ' d)
14-3
Description
(cont' dl
Gear Selection
The shi ft l ever has si x posi ti ons:
E
PARK.
E
REVERSE,
N
NEUTRAL,
E
1st through 4th gear ranges,
E
1st through 3rd
gear ranges,
@
2nd gear.
Starti ng i s possi bl e onl y i n
E
and
E
posi ti ons
through the use of a sl i de-type, neutral -safety swi tch.
Automatic Transaxle
(A/f,
Gear Position Indicator
The Ay' T gear posi ti on i ndi cator i n the i nstrument panel
shows whi ch gear has been sel ected wi thout havi ng to l ook down
at the consol e.
Clutchs
The four-speed automati c transmi ssi on uses hydraul i cal l y-actuated cl utches to engage or di sengage the transmi ssi on gears.
When hydraul i c pressure i s i ntroduced i nto the cl utch drum, the cl utch pi ston moves. Thi s presses the fri cti on di scs and
steel pl ates together, l ocki ng them so they don' t sl i p. Power i s then transmi tted through the engaged cl utch pack to i ts
hub-mounted gear. Li kewi se, when the hydraul i c pressure i s bl ed from the cl utch
pack,
the
pi ston
rel eases the fri cti on di scs
and the steel pl ates, and they are free to sl i de past
each other. Thi s al l ows the
gear
to spi n i ndependentl y on i ts shaft,
transmi tti ng no
power.
lst Clutch
The 1st cl utch engages/di sengages 1st gear, and i s l ocated at the end of the mai nshaft,
j ust
behi nd the ri ght sroe cover.
The 1st cl utch i s suppl i ed hydraul i c pressure
by i ts ATF feed pi pe
wi thi n the mai nshaft.
2nd Clulch
The 2nd cl utch engagegdi sengages 2nd gear, and i s l ocated at the mi ddl e of the mai nshaft. The 2nd cl utch i s
j oi ned
back-to-back to the 4th cl utch. The 2nd cl utch i s suppl i ed hydraul i c pressure
through the mai nshaft by a ci rcutr connect-
ed to the i nternal hvdraul i c ci rcui t,
3rd Clutch
The 3rd cl utch engages/di sengages 3rd gear, and i s l ocated at the end of the countershaft. The 3rd cl utch i s suool i ed
hydraul i c pressure
by i ts ATF feed pi pe wi thi n the countershaft.
ilth
Clutch
The 4th cl utch engages/di sengages 4th gear,
as wel l as reverse gear,
and i s l ocated at the mi ddl e of the mai nshaft. The
4th cl utch i s
j oi ned
back-to-back to the 2nd cl utch. The 4th cl utch i s suppl i ed hydraul i c pressure by i ts ATF feed pi pe
wi th i n the mai nshaft.
\ - a
Position
De3cription
E
PARK
E
REVERSE
N
NEUTRAL
E
DRIVE
{1st through 4th)
Ei
DRtvE
(' l st
through 3rd)
B SECOND
Front wheel s l ocked; park pawl engaged wi th pa*
on countershaft. Al l cl utches rel eased.
Reverse; reverse sel ector engaged wi th countershaft reverse gear
and 4th cl utch l ocked.
Al l cl utches rel eased.
General dri vi ng; starts off i n 1st, shi fts automati cal l y to 2nd, 3rd, then 4th, dependi ng on vehi cl e
speed and throttl e posi ti on.
Downshi ft through 3rd, 2nd and 1st on decel erati on to stop. The l ock-up
mechani sm comes i nto operati on i n
@
posi ti on
i n 3rd and 4th
gear.
Use for rapi d accel erati on at hi ghway speeds and general
dri vi ng; up-hi l l and down,hi l l dfi vi ng; stans
otf in 1st, shifts automatically to 2nd, then 3rd, depending on vehicle speed and throttle position.
Downshifts through 2nd to lst on deceleration to stop. The lock-up mechanism comes into operation
i n 3rd gear,
Use for engi ne braki ng or better tracti on starti ng off on l oose or sl i ppery surfaces; stays i n 2nd
gear,
does not shi ft up and down.
14-4
One-way Clulch
The one-way clutch is positioned between the countershaft 1st gear and the
park gea., with the park gear splined to the counter-
shatt, The 1st gear provi des the outer race surface, and the park gear provi des the i nner race surface. The one-way cl utch
l ocks up when power i s transmi tted from the mai nshaft 1st gear to thetountershaft 1st gear. The l st cl utch and gears
remai n engaged i n the 1st, 2nd. 3rd, and 4th
gear ranges i n the
p!1, p!
or
L?l
posi ti on.
However, the one-way cl utch di sengages when the 2nd, 3rd, or 4th cl utches/gears are appl i ed i n the
E, E
or @
posi ti on.
Thi s i s because the i ncreased rotati onal speed of the
gears
on the countershaft overri des the l ocki ng
"speed
range" of the
one-way cl utch. Thereafter, the one-way cl utch free-wheel s wi th the 1st cl utch sti l l engaged.
zNO CLUTCH
,lTH
CLUTCH
1ST CLUTCH
MAINSHAFT
COUNTERSHAFT
ONE.WAY CLUTCH
INSIDE OF ONE.WAY
CLUTCH
Spl aned wi t h count er
shaft
di sengage out si de
and i nsi de oI t he
3RO CLUTCH
OUTSIDE OF ONE.WAY
CLUTCH
PANK GEAR
The spr ags engage/
OVER-RIDING
LOCKING SPEED CONDITION
LOCKING CONDITION
14-5
Description
Power Flow
O: Operates, x: Doesn' t operate.
*1:
Al though the 1st cl utch engages, dri vi ng power i s not transmi tted as the one-way cl utch sl i ps.
*2:
The one-way cl utch engages when accel erati ng, and sl i ps when decel erati ng.
\ART
POSMON\
TOROUE
1ST GEAR
CLUTCH
2ND GEAR
2ND
CLUTCH
3RD GEAR
3RD
CLUTCH
4TH
REVERSE
GEAR
PARK
GEAR
CONVERTER
CLUTCH
E
o
o
E
o
o o
E
o
D]
1ST o o*,
2ND o o* , o
3RD o o* 1 o
4TH o o* 1 o o
tr
o O* r
2ND o o+r o
3RD o o* 1 o
E
o o* 1 o
14-6
lXl
Position
Hydraul i c
pressure i s not appl i ed to the cl utches. Power i s not transmi fted to the countershaft.
E
Position
Hydraul i c
pressure i s not appl i ed to the cl utches. Power i s not transmi tted to the countershaft.
The countershaft i s l ocked by the park pawl i nterl ocki ng the park gear.
TOROUE CONVERTER
rST CLUTCH
COUNTERSHAFT
FI NAL DRI VE
3RD CLUTCH
14-7
Description
Power Flow
(cont'dl
lst Gesr
(E
or
@
position)
In
l E
or E posi ti on,
the opti mum gear i s automati cal l y sel ected from 1st,2nd,3rd and 4th gears,
accordi ng to condi ti ons
such as the bal ance between throttl e openi ng
(engi ne
l oad) and vehi cl e speed.
1. Hydraul i c pressure
i s appl i ed to the 1st cl utch, whi ch rotates together wi th the mai nshaft, causi ng the mai nshaft 1st
gear to rotate.
Power i s transmi tted to the countershaft 1st gear, whi ch dri ves the countershaft vi a the one-way cl utch.
Power i s transmi tted to the fi nal dri ve gear,
whi ch dri ves the fi nal dri ven gear.
TOROUE CONVERTER
MAI NSHAFT 1ST GEAR
l ST CLUTCH
MAINSHAFT
AY CLUTCH
FI NAL DRI VE GEAR
PARK GEAR
L
COUNTERSHAFT
1ST GEAR
14-8
2nd Gear {8, E or E
position)
E
Posi ti on i s
provi ded to dri ve onl y 2nd
gear.
1. Hydraul i c
pressure i s appl i ed to the 2nd cl utch on the mai nshaft, and
power i s transmi fted vi a the 2nd cl utch to the
mai nshaft 2nd gear.
2, Powet transmitted to the mainshaft 2nd
gear
is conveyed via tho countorshaft 2nd gear, which drivos the counter-
shaft.
3. Power i s transmi ned to the fi nal dri vB
gear, whi ch dri ves the fi nal dri ven ge8r.
NOTE: Hydraulic
pressure is also applied to the 1st clutch, but since the rotation speed of ths 2nd
gear
excaads that
of lst gear, power
from
'lst
gear is cut off at the one-way clutch.
TOROUE CONVERTER
2ND CLUTCH
MAII'ISHAFT
COUNTEBSHAFT 2I{D GEAR
(cont' d)
14-9
Description
Power Flow
(cont'dl
3rd Gear
(bl
or bd
positionl
1. Hydraul i c pressure i s appl i ed to the 3rd cl utch. Power from the mai nshaft 3rd gear i s transmi tted to the countershaft
3rd gear.
2. Power i s transmi tted to the fi nal dri ve gear,
whi ch dri ves the ti nal dri ven gear.
NOTE: Hydraul i c pressure
i s al so appl i ed to the 1st cl utch, but si nce the rotati on speed of 3rd gear
exceeds that of 1st
gear, power from l st gear i s cut off at the one-way cl utch.
TOROUE CONVERTER
MAI NSHAFT 3RD GEAR
MAI NSHAFT
COUNTERSHAFT
3RD GEAB
3RD CLUTCH
14-10
DRI VEN GEAR
4th cear lE
position)
1. Hydraul i c
pressure i s appl i ed to the 4th cl utch, whi ch rotates together wi th the mai nshaft, causi ng the mai nshaft 4th
gear to rotate.
2. Power i s transmi tted to the countershaft 4th
gear' whi ch dri ves the countershaft'
3. Power i s transmi tted to the fi nal dri ve
gear, whi ch dri ves the fi nal dri ven
gear'
NOTE: Hvdraul i c
pressure
i s al so appl i ed to the l st cl utch, but si nce the rotati on speed of 4th gear exceeds that of 1st
gear, power from 1st gear i s cut off at the one-way cl utch
TOROUE
MAI NSHAFT 4TH GEAR
COUNTERSHAFT
FI NAL ORI VEN GEAR
14-11
Description
Power Flow
(cont'd)
El
Po3ition
1, Hydraul i c pressure i s swi tched by the manual val ve to the servo val ve, whi ch moves the reverse shi ft fork to the
reverse position. The reverse shift fork engages with the reverse selector, reverse selector hub, and the countershaft
reverse gear.
Hydraul i c pressure i s al so appl i ed to the 4th cl utch. Power i s transmi ttd from the mai nshaft reverse gear vi a the
reverse idler gear
to the countershaft reverse gear.
The rotation direction of the countershaft reverse gear is changed via the reverse idler gear,
Power i s transmi tted to the fi nal dri ve gear, whi ch dri ves the fi nal dri ven gear.
TOROUE
MAI NSHAFT
COU TERSHAFT
REVERSE SELECTOR
HUB
REVERSE SETICTOR
REVERSE SHIFT
FORK
REVERSE IDLER
14- 12
FINAL ON|VEN GEAR
Electronic
Control SYstem
The el ectronac controt system consrsts of a Powertrai n control Modul e
(PcM),
sensors, a Ii near sol enoi d and four sol enoi d
val ves, shi fti ng and l ock-up are el ectroni cal l y control l ed for comfortabl e dri vi ng under al l condi ti ons The PCM i s l ocated
bel ow the dashboard, under the front l ower
panel on the
passenger' s si de
PGM-FI
Control Sy3tem
A/T Control SYstom
Shift Control
Lock-uD Control
14-13
Description
Electronic Control System
(cont'd)
Shift Control
The PCM i nstantaneousl y determi nes whi ch gear shoul d be sel ected by vari ous si gnal s sent from sensors, and actuates
the shi ft control sol enoi d val ves A and B to control shi fti ng. Al so. a Grade Logi c Control System has been adopted to con-
trol shi fti ng i n E posi ti on whi l e the vehi cl e i s ascendi ng or descendi ng a sl ope, or reduci ng speed.
Poshion Gear
Shift Control Solenoid
Vslve A
Shift Control Solenoid
Valve B
8, t r
1st OFF ON
2nd ON ON
3rd ON OFF
E
4th OFF OFF
tr 2nd ON ON
E- Reverse ON OFF
*See
page 14-31 for reverse i nhi bi tor control descri pti on.
Lock-up Control
From sensor i nput si gnal s, the PCM determi nes whether to turn the l ock-up ON or OFF, and acti vates l ock-up control
sol enoi d val ve A and/or B accordi ngl y. The combi nati on of dri vi ng si gnal s to l ock-up control sol enoi d val ves A and B and
the l i near sol enoi d
pressure
i s shown i n the tabl e bel ow.
Lock-up Conditions
Lock-up Control
Solenoid Valvo A
Lock-up Control
Solenoid Valve B
Linoar Solonoid
Prggguro
Lock-up OFF OFF OFF Hi gh
Lock-up, Hal f ON
Duty operation
OFF
*
ON
Low
Lock-up, Ful l ON ON Hi gh
LOCK- Up
duri ng decel erati on
ON
Duty operation
OFF
-
ON
a
14-14
GRADE LOGIC CONTROL SYSTEM
How i t works:
The
pCM
compares actual dri vi ng condi ti ons wi th dri vi ng condi ti ons memori zed i n the PCM, based on the i nput from the
vehi cl e speed sensor, the throttl e
posi ti on sensor, the barometori c
pressure sensor, the engi ne cool ant temperature sensor,
the brake swi tch si gnal , and the shi ft l ever posi ti on si gnal , to control shi fti ng whi l e a vehi cl e i s ascendi ng or descendi ng a
sl ope, or reduci ng speed.
SIGNALS OETECTED
O.iving Resi3lence
Judgemenl ot Conirolling Arca
.
Ascending mod
lFuzzy
loqicl
.
Gradual Ascending mode
'
Step Ascending mode
.
Oescending mode
.
Gr.du.l Descending mode
.
Steep D6cending mode
14-15
Description
{cont'dl
Ascending Control
When the PCM determi nes that the vehi cl e i s cl i mbi ng a hi l l i n
E
posi ti on,
the system oxtends the sngagement area of
2nd gear
and 3rd gear to prevent
ths transmission from frquently shifting between 2nd and 3rd
gears,
and between 3rd
and 4th gears,
so the vehi cl e can run smooth and have more power when needed. There are two ascendi ng modes wi th
di fferent 3rd
gear
dri vi ng areas accordi ng to the magni tude of a
gradi ent
stored i n the
pCM.
NOTE:
. The PCM memory contai ns shi ft schedul es between 2nd and 3rd gears,
and between 3rd and 4th gears
that enabl e the
PCM' s fuzzy l ogi c to automati cal l y sel ect the most sui tabl e gear accordi ng to the magni tude of a gradi ent
. Fuzzy l ogi c i s a form of arti fi ci al i ntel l i gence that l ets computers respond to changi ng condi ti ons much l i ke a human
mi nd woul d,
Dssconding Control
When the PCM determi nes that the vehi cl e i s goi ng
down a hi l t i n E posi ti on,
the shi ft-up speed from 3rd to 4th gear
when th throftle is closed becomes faster than the set speed for flat road driving to widen the 3rd gear
driving area.
Thi s, i n combi nati on wi th engi ne braki ng from the decel erati on l ock-up, achi eves smooth dri vi ng when the vehi cl e i s
descendi ng. There are two descendi ng modes wi th di fferent downshi ft (4 -
3) schedul es accordi ng to the magni tude of a
gradi ent stored i n the PCM. When the vehi cl e i s i n 4th gear, and you are decel erati ng on a gradual hi l l , or when
you
are
applying the brakes on a steep hill, the transmission will downshift to 3rd gear.
When you
accel6rate, the transmission will
then return to 4th gear.
ASCENDING MODE
DESCENDING MODE
4TH SHIFTING
L .
F
CHARACTERISIICS
CONTROL AREA
ff.1"11",
vehicr. 3ped
ff;Tlr.,
vohicre speed
GRADUAL ASCENOING
CONTROL AREA
Docel6ration Control
When the vehicle goes
around a corner. and needs to first decelerate and then accelerate. the rcM sets the data for deceleration
control to reduce the number of times the transmission shifts. When the vehicle is decelerating from speeds above 26 mph
(41
km/h), the rcM shifts the transmission from 4th to 2nd earlier than normal to cope with upcoming acceleration.
14-16
Circuit Diagram and Terminal Locations
-'96 -
98 Modols
IGNITIONSWiTCH
tc1
IOCI(
-
UP CONTBOL
SOTENOID VALVE A
LOCK-UPCONTSOT
soLtNoto valvE I
SIIIFT CONTFOL
sHrFrc0mioL
SOLENOIDVATVE B
UI{EAR SOLENOIO
IGPl
IGP2
vcc2
TPS
sG2
14-17
Description
(cont'dl
Ci rcui t Di agram and Termi nal Locati ons
-' 99 -
O0 Model s
GNTONSWI CH
,,--b. rcj
L I
LOCK.UPCONIFOL
SOLEI\Q D VALVE A
LOCK UP CON'IROL
SOLENODVALVEB
SH FI CONTROL
SHIFTCONTFOL
SOLENOIDVALVEE
L NEAF SOLEIOIO
PG2
IGP2
v3u
vcc2
sc2
6NII ON SWICH
14- 18
Hydraul i c
Control
The hydraul i c control system i s control l ed by the ATF
pump, val ves, accumul ators, and el ectroni cal l y control l ed sol enoi ds'
TheATFpUmpi s dr i v enby s p| | nes ont heendof t het or quec onv er t er Whi c hi s at t ac hedt ot heengi ne. F| ui df r omt heATF
pumpf | owst hr ought her egu| at or va| vet omaj nt ai nspeci f i edpr essur et hr ought hemai nva| vebodyt ot hemanuaI va| ve'
di r ec t i ngpr es s ur et oeac hof t hec | ut c hes . Thev a| v ebody i nc | udes t hemai nv ai v ebody , t her egu| at or v al v ebody , t he
| oc k - upv a| v ebody , t hes ec ondar y Va| v ebody , t hes er v obody , t heI i near s o| enoi d, t hes hi f t c ont r o| s o| enoi dv a| v el VB
assembl y, and the l ock up control sol enoi d val ve A/B assembl y. The shi ft control sol enoi d val ve Ay' B assembl y and the l i n-
ear sol enoi d are bol ted on the outsi de of the transmi ssi on housi ng. The l ock-up control sol enoi d val ve A,/B assembl y i s
bol ted on the outsi de of the torque converter housi ng
SHIFT CONTROL
SOLENOIO VALVE A/8
ASSEMBLY
LINEAR SOLENOID
SERVO BOOY
REGULATOR
VALVE BODY
VALVE
VALVE BOOY
(cont ' d)
CONTROL
SOLENOID VALVE A/B
ASSEMBLY
ATF PUMP GEARS
14-19
Description
Hydraulic
Control
(cont'dl
Msin Valve Body
The mai n val ve body houses the manual val ve, the 1-2 shi ft val ve, the 2nd ori fi ce control val ve, the cpB val ve, the modu-
l ator val ve' the servo control val ve, and the rel i ef val ve. The pri mary
functi ons of the mai n val ve body are to swatch fl ui d
pressure
on and off and to control the hydraul i c pressure goi ng
to the hydraul i c control svstem.
2ND ORIFICE CONTROT
VALVE
1-2 SHIFT VALVE
RELIEF VALVE
CPC VAL
3-4 SHTFT V
VALVE
Socondary Valve Body
The secondary val ve body i s l ocated on the mai n val ve body. The secondary val ve body houses the 2-3 shi ft vatve, the 3-4
shi ft val ve, the 3-4 ori fi ce control val ve, the 4th exhaust val ve, and the CpC val ve.
CONTROL
2.3 SHIFT VALVE
4TH EXHAUST VALV
VALVE
14-20
VALVE
\
Regulator Valve BodY
The regul ator val ve body i s l ocated on the mai n val ve body. The regul ator val ve body consi sts of the regul ator val ve' the
torque-converter
check val ve, the cool er rel i ef val ve, and the l ock-up control vai ve'
REGULATOR VALVE
BODY
REGULATOR
VALVE
COOLER RELIEF VALV
LOCK, UP SHI FT VALVE
CONVERIER
CHECK
VALVE
CONTROL VALVE
Lock-up Valve BodY
The l ock-up val ve body wi th the l ock-up shi ft val ve and the l ock-up ti mi ng val ve i s l ocated on the regul ator val ve bodv
LOCK-UP NMING VALVE
i c ont d
1+21
Description
Hydraulic Control
(cont'dl
Regulator Valve
The regul ator val ve mai ntai ns a constant hydraul i c pressure
from the ATF pump
to the hydraul i c control system, whi te
al so furni shi ng fl ui d to the l ubri cati ng system and torque converter. The fl ui d from the ATF pump
fl ows through B and 8,.
The regul ator val ve has a val ve ori fi ce. The fl ui d enteri ng from B fl ows through the ori fi ce to the A cavi ty. Thi s pressure
of
the A cavi ty pushes
the regul ator val ve to the ri ght si de, and thi s movement of the regul ator val ve uncovers the fl ui d port
to the torque converter and the rel i ef val ve. The fl ui d fl ows out to the torque converter, and the rel i ef val ve and regul ator
val ve moves to the l eft si de. Accordi ng to the l evel of the hydraul i c pressure
through B, the posi ti on
of the regutator vatve
changes and the amount of the fl ui d from B' through D and c al so changes. Thi s operati on i s conti nued. maantai ni ng the
l i ne pressure,
NOTE: When used.
"| eft"
or
"ri ght"
i ndi cates di recti on on the i l l ustrati on betow.
ENGI NE NOT RUNNI NG
TOROUE CONVERTER
ENGI NE RUNNI NG
To TOROUE CONVERTER Lubrication
Stator Roaction Hydraulic Prossur6 Control
Hydraul i c pressure
i ncreases accordi ng to torque, are performed
by the regul ator val ve usi ng the stator torque reacti on.
The stator shaft is splined with the stator in the torque converter, and its arm end contacts the regulator sprang cap. when
the vehi cl e i s accel erati ng or cl i mbi ng
(Torque
Convertr Range), the stator torque reacti on acts on the stator shaft, and
the stator arm pushes
the regul ator spri ng cap i n the di recti on of the arrow i n proponi on
to the reacti on. Jne stator reac-
ti on spri ng compresses, and th reoul ator val ve moves to i ncrease the l i ne pressure
whi ch i s regul ated by the regul ator
valve. The line pressure
reaches its maximum when the stator torque reaction reaches its maximum.
STATOR SHAFT ARM
REGULATOR VALVE
14-22
STATOR
ATOR SHAFT ARM
SPRING CAP
\
Servo Body
The servo body i s l ocated on the secondary val ve body. The servo body contai ns the servo val ve whi ch i s i ntegrated wi th
the reverse shi ft fork, and the accumul ators
2NO ACCUMULA
SERVO BODY
1ST ACCUMULATOR
3RD ACCUMULATOR
SERVO VALVE/SHIFT
FORK SHAFT
NoTE: The i l l ustrati on shows the' 96
-
' 98
model s; the
' 99
-
00 model s are si mi l ar'
14-23
Description
Hydraul i c Fl ow
General Chart ol Hydraulic Pressure
ATF Pump-
pegurator
varve
-_l -
Li ne
pressure -f-
Modurator
pressure
-
Li near sorenoi d
|
-Cl utch pressure
-Torque
Converter
pressure
t-Lubri cati on
Pressure
Distribution of Hydraulic Pressur
.
Regul ator Val ve
-]-
Torque Converter
pressure
F_
Lubri cati on
pressure
i -
To regul ate Li ne
pressure
.
Manual val ve
_
To sel ect Li ne
pressure
_
cl utch
pressure
'
Modul ator Val ve i /odul ator
pressure
_ ___f_
Shi ft Control Sol enoi d Val ves
F_
Lock_up Control Sol enoi d Val ves
L_
Li near Sol enoi d
.
1-2 Shi ft Val ve
-
l
.
2-3 Shi ft Val ve
-
1-
Ctutch
pressure
.
3-4 Shi ft Val ve
l r a
PORT NO. DESCRIPTION
OF PRESSURE PORT NO. DESCRIPTION
OF PRESSURE PORT NO. DESCRIPTION OF PRESSURE
1 LINE
6B
MODULATE
(SHIFT
CONTROL
SOLENOID VALVE B)
41 4TH CLUTCH
LINE
MODULATE
(LOCK-UP
CONTROL
SOLENOID VALVE A)
56 LINEAR SOLENOID
LINE
6D
MODULATE
(LOCK-UP
CONTROL
SOLENOID VALVE B)
90 TOROUE CONVEBTER
2 LINE
6D'
MODULATE
(LOCK-UP
CONTROL
SOLENOID VALVE B)
91 TOROUE CONVERTER
LINE
7 LINE
92 TOROUE CONVERTER
LINE
8 LINE/CPC
93 ATF COOLER
3" LINE
9 LINE
94 TOROUE CONVERTER
4 LIN E
' 10
1ST CLUTCH
95 LUBRICATION
LINE
20 2ND CLUTCH
YO TOROUE CONVERTER
LI NE
20A 2ND ACCUMULATOR
97 TOROUE CONVERTER
5
LINE
99 SUCTION
MODULATE
30 3RD CLUTCH
X DRAIN
6A
MODULATE
(SHIFT
CONTROL
SOLENOID VALVE A)
40 4TH CLUTCH
14-24
\
@
Position
As the engi ne turns, the ATF pump al so starts to operate, Automati c transmi ssi on fl ui d
(ATF)
i s drawn from
(99)
and di s-
charged i nto
(1).
Then, ATF fl owi ng from the ATF
pump becomes the l i ne pressure
(1).
The l i ne
pressure (1)
i s regul ated
by the regulator valve. The torque convrter inlet
pressure (92)
enters
(94)
of the torque converter through the lock-up
shift valve and discharges into
(901.
The torque converter chck valve
prevents the torque converter
pressure from rising'
Under thi s condi ti on, the hydraul i c
pressure i s not appl i ed to the cl utches'
NOTE: When used,
"1eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c
ci rcui t'
14-25
Description
Hydraulic Flow
(cont'd)
L?j
Position
The l i ne pressure (1)
fl ows to the manual val ve and the modul ator val ve. The l i ne pressure (1)
changes the trne pressure
(4)
and
(25)
at the manual val ve. and changes to the modul ator pressure
at the modul ator val ve. But the moourator pres-
sure
(6)
does not fl ow to each shi ft val ve because shi ft control sol enoi d val ves A and B are turned oN by the
pcM.
The
l i ne pressure (4) passes
through the cPB val ve and the cPc val ve. and changes to the l i ne pressure (s),
th;n fl ows to the
1-2 shi ft val ve. The l i ne pressure
{S) from the l -2 shi ft val ve changes to the 2nd cl utch pressure (20)
at the 2-3 shi ft val ve.
The 2nd cl utch pressure (20)
i s appl i ed to the 2nd cl utch. and the 2nd cl utch i s engaged. The l i ne pressure (4) passes
through the 1-2 shi ft val ve and the ori fi ce, and changes the l st cl utch pressure,
The 1st cl utch pressure (10)
atso fl ows to
the 1st cl utch. However, no power
i s transmi tted because of the one_way cl utch.
NOTE: When used,
"Ieft"
or
"ri ght"
i ndi cates di recti on on the hvdraul i c ci rcui t.
14-26
E! or l8! Position
1. l st Gear
The fl ow of fl ui d through the torque converter ci rcui t i s same as i n
E
posi ti on, The l i ne
pressure tl ows to the manual
val ve and the modul ator val ve. The l i ne pressure changes to the modul ator
prssure (6)
at the modul ator val ve and to
the l i ne
pressure
(4)
at the manual val ve. The modul ator
pressure
(61
fl ows to the l sft end of the 1-2 shi ft val ve and the
3-4 shi ft val ve because shi ft control sol enoi d val ve A i s turned OFF and B i s turned ON by the PCM. The 1-2 shi ft val ve
i s moved to the ri ght si de. The l i ne
pressure
(4)
changes to the l st cl utch
pressure (10)
at the 1-2 shi ft val ve and the
ori ti ce. The l st cl utch
pressure
(10)
i s appl i ed to the 1st cl utch and tho 1st accumul ator; consquentl y, the vehi cl e wi l l
move as the engi ne
power i s transmi tted.
NOTE: When used,
"| eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcui t'
(cont' d)
14-27
Description
Hydraulic Flow
(cont'd)
2nd G.!r
As tha speed of the vehi cl e reaches the prescri bed
val ue, shi ft control sol enoi d val ve A i s turned oN by means of the
PCM The modul ator pressure
{64} i n the l eft end of the 1-2 shi ft val ve i s rl eased by turni ng shi ft controt sotenoi d
valve A oN The 1-2 shift valve is moved to the left side and uncovers the port
to allow line pressure
{5) to the z-3
shift valve. The line pressure (5)
changes to the 2nd ctutch pfessure
l2O) at the 2-3 shift valve. The 2nd clutch pressure
(20)
i s appl i ed to the 2nd cl utch, and the 2nd cl utch i s 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 Cl utch Pressure (20) +
2nd Cl utch
The hydraulic pressure
also flows to the 1st clutch. However, no power
is transmittod because of the one-way ctutch.
NOTE: When used,
"| eft"
or
,,ri ght,,
i ndi cates di recti on on the hydraul i c ci rcui t.
\-
14-28
I
3. 3rd Gear
As the soeed of the vehi cl e reaches the
prescri bed val ue, shi ft control sol enoi d val ve B i s turned OFF by means ol the
pCM.
Shi ft control sol enoi d val ve A remai ns ON. The modul ator
pressure (6)
fl ows to the ri ght end of the 1-2 shi ft
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 shi ft val ve covers the
port to stop l i ne
pressure (5)
to the 2nd cl utch and uncovers to the 3-4 shi ft val ve
as the 2-3 shi ft val ve i s moved to the ri ght si de. The l i ne pressure
(5)
becomes the 3rd cl utch
pressure (30)
at the 3-4
shi ft val ve. The 3rd cl utch
pressure (30)
i s appl i ed to the 3rd cl utch, and the 3rd cl utch i s engaged'
Fluid flows by way of:
-
Li ne Dressure
(4)
*
CPB Val ve
-
Li ne Pressure
(5) *
1-2 Shi ft Val ve
-
Li ne Pressure
(5) *
2-3 Shi ft Val ve
-
Li ne Pressure
(5) *
3-4 Shi ft Val ve
-
3rd Cl utch Pressure
(30)
-
3rd Cl utch
The hvdraul i c
pressure al so fl ows to the 1st cl utch. However, no
power i s transmi tted because of the one-way cl utch
as i n 2nd
gear.
NOTE: When used,
"| eft"
or
"ri ght"
14-29
Description
Hydraulic Flow
lcont'dl
4th Goar {E Position}
As the speed of the vehi cl e reaches the prescri bed
val ue, shi ft control sol enoi d val ve A i s turned OFF bymeans ofthe
PCM Shi ft control sol enoi d val ve B remai ns oFF. The modul ator pressure (6)
fl ows to the l eft end of the t-2 shi ft
val ve and the l eft end of the 3-4 shi ft val ve. The modul ator pressure (64)
i n the l eft end of the 1-2 shi ft val ve equal s
the modul ator pressure
{68) i n the ri ght end of the 1-2 shi ft val ve, the 1-2 shi ft val ve remai ns at l eft si de by the ten-
si on of the val ve spri ng.
The 3-4 shi ft val ve i s moved to the ri ght si de by the modul ator pressure (64).
The 3_4 shi ft val ve covers the port
to the
3rd cl utch and uncovers the port
to the 4th cl utch as thi s val ve i s moved to the ri ght si de. The 4th cl utch pressure (4.1)
from the 3-4 shi ft val ve becomes the 4th cl utch pressure (40)
at the manual val ve. The 4th cl utch pressure (401
i s
appl i ed to the 4th cl utch, and the 4th cl utch i s engaged.
Fl ui d fl ows by way of:
-
Li ne pressure (4) *
CPB Val ve
-
Li ne Pressure
(5) +
1-2 Shi ft Val ve
-
Li ne
pressure
(5) *
2-3 Shi ft Val ve
-
Li ne Pressure
(5) -
3-4 Shi ft Val ve
-
4th Cl utch
pressure
(41) +
Manual Val ve
_
4th Cl utch
pressure
(40)
*
4th Cl utch
The hydraul i c pressure
al so fl ows to the l st cl utch. However, no power
i s transmi tted because of the one-way crutch
as i n 2nd and 3rd gear.
NOTE: When used,
"| eft"
or
"ri ght,,
\
14- 30
L
E
Position
The fl ow of fl ui d through the torque convefter ci rcui t i s the same as i n
E
posi ti on The l i ne pressure (1)
changes to the
l i ne
pressure
(3)
and fl ows to the l -2 shi ft val ve. The i i ne pressure
(3)
changes to the l i ne pressure
(3' )
at the
' l -2
shi ft val ve
and fl ows to the servo val ve. The servo val ve i s moved to the ri ght si de
(Reverse
range
posi ti on) and uncovers the
port
to
al l ow l i ne
pressure
{3") to the manual val ve, The l i ne
pressure
{3' ) from the 1-2 shi ft val ve fl ows through the servo val ve to
the manual val ve and changes the 4th cl utch
pressure
(40).
The 4th cl utch
pressure
(40)
i s appl i ed to the 4th cl utch, and
the 4th cl utch i s engaged,
Reverse Inhibitor Control
When the E
posi ti on i s sel ected whi l e the vehi cl e i s movi ng forward at speds over 6 mph
(10
km/h)' the PCM outputs the
1st speed si gnal to shi ft control sol enoi d val ves A and B; shi ft control sol enoi d val ve A i s turned oFF, shi ft control sol enoi d
val ve B i s turned ON. The 1-2 shi ft val ve i s moved to the ri ght si de and covers the
port to stop l i ne
pressure
(3' )
to the
servo val ve. The l i ne
pressure (3' )
i s not appl i ed to the servo val ve, and the 4th cl utch
pressure (40)
i s not appl i ed to the
4th clutch, as a result,
power is not transmitted to the reverse direction'
When used.
' l eft"
or
"ri ght"
i ndi cates di recti on on the hydraul i c ci rcui t'
14-31
Description
Hydraulic Flow
(cont'd)
lll
Position
The fl ow of fl ui d through the torque converter ci rcui t i s the same as i n
E
posi ti on.
The l i ne pressure (1)
changes to the
l i ne pressure (3)
and fl ows to the l -2 shi ft val ve. The l i ne pressure (3)
changes to the l i ne pressure (3,)
at the 1-2 shi ft val ve
and fl ows to the servo val ve. The servo val ve i s moved to the ri ght si de
(Reverse
range posi ti on)
and uncovers the port
to
al l ow l i ne pressure (3")
to the manual val ve as i n
@
posi ti on.
The l i ne pressure (3")
from the servo val ve i s Intercepted by
the manual val ve. However, hydraul i c pressure
i s not suppl i ed to the cl utches, and the
power
i s not transmi tted.
NOTE: When used,
"| eft"
or
"ri ght"
14-32
\
Lock-up System
Lock-up Clutch
1. Ooerati on
(cl utch
onl
with the lock-up clutch on, the fluid in the chamber between the torque converter cover and the lock-up piston is drained
off, and the converter fluid exerts
pressure through the
piston against the torque converter cover, As a result, the conven-
er turbine is locked to the convefter cover. The effect is to bypass the converter, thereby
placing the vehicle in direct drive
LOCK.UP PISTON DAMPER SPRI NG
The power flows by way ot:
Engi ne
{
Drive
plate
i
Torque converter cover
I
Lock-up
piston
Damper spri ng
I
Turbi ne
Mainshaft
ODeration {clutch
off}
With the lock-up clutch off, the fluid flows in the reverse of
"clutch
on." As a result, the lock-up
piston moves away from
the converter cover, and the torque converter lock-up is releassd.
Engi ne
t
Drive
plate
I
Torque convener cover
{
Pump
I
Turbi ne
Mai nshaft
TOROUE
COVER
(cont ' d)
COI{VERTER
\
TURBNE
MAI NSHAFT
14- 33
Description
Lock-up System
(cont'd)
TOROUE CONVERTER
In B.rl posi ti on,
i n 3rd and 4th, and l Dl _- posi ti on
i n 3rd.
pressuri zed
fl ui d i s draj ned from the back of the torque
converter through a fl ui d passage.
causi ng the l ock-up
pi ston
to be hel d agai nst the torque convener cover. As
thi s takes pl ace,
the mai nshaft rotates at the same speed
as the engi ne crankshaft, Together wi th the hydraul i c
cont r ol , t he PCM opt i mi zed t he t i mi ng of t he l ock_up
system. Under certai n condi ti ons, the l ock_up cl utch i s
appl i ed duri ng decel erati on, i n 3rd and 4th gear.
The l ock-up system control s the range of l ock_up accord_
i ng to l ock-up control sol enoi d val ves A and B. and the
l i near sol enoi d. When l ock-up control sol enoi d val ves A
and B acti vate, modul ator pressure
changes. Lock_up
control sol enoi d val ves A and B and the l i near sol enoi d
ar e mount ed on t he out si de of t he t or que conver t er
housi ng. and are control l ed by the
pcl vl .
Lock-up Condi ti ons/Lock-up
Control Sol enoi d Val ves/
Linear Solenoid Pressure
MODULATOR
PRESSURE
.--
LINEAR SOLENOID PRESSURE
LOCK.UP CONTROL
. VALVE
LOCK.UP
CONTROL
SOLENOID VALVE
Lock-up
Condi ti ons
Lock-up Control
Solenoid Valve
Lineal
Solenoid
Pressure
A B
Lock-up OFF OFF OFF Hig h
Lock-up. Hal f ON
Duty operation
OFF
-
ON
Lock-up. Ful l
ON ON Hi gh
Lock-up
duri ng
decel erati on
ON
Duty operation
OFF
*
ON
Low
TOROUE CONVERTER
CHECI( VALVE
RELIEF VAI-VE
LOCK.UP TIMING
VALVE
^
r______rr r
cooLER RELTEF VALVE
t'-
14-34
ATF PUMP
I
TOROUE CONVERTER
No Lock-up
. Lock-up Control Sol enoi d Val ve A: OFF
. Lock-up Control Sol enoi d Val ve B: OFF
. Li near Sol enoi d Pressure: Hi gh
The pressuri zed fl ui d regul ated by the modul ator works
on both ends of the l ock-up shi ft val ve. Under thi s condi -
ti on, the pressures worki ng on both ends of the l ock-up
shi ft val ve are equal , the l ock-up shi ft val ve i s moved to
the ri ght si de by the tensi on of the val ve spri ng al one.
The fl ui d from the ATF
pump
wi l l fl ow through the l eft
si de of the l ock-up cl utch to the torque convener; that i s,
the l ock-up cl utch i s i n OFF condi ti on.
NOTE: When used,
"l eft"
or
"ri ght"
i ndi cates di recti on
on the hydraul i c ci rcui t.
MOOULATOR PRESSURE
LINEAR SOLENOIO PRESSURE
(cont ' d)
LOCK.UP CONTROL
SOLENOID VALVE
RELIEF VALVE
LOCK-UP TIMING
VALVE
9 L ]
I COOLER RELIEF VALVE
ATF PUMP
14-35
Description
Lock-up System
(cont'dl
TOROUE
CONVERTER
Half Lock-up
. Lock-up Control Sol enoi d Val ve A: ON
Lock-up Control Sol enoi d Val ve 8: Duty Operati on
OFF
-
ON
Li near Sol enoi d Pressure: Low
The PCM swi tches the sol enoi d val ve A on to rel ease the
modul ator pressure
i n the l eft cavi ty of the l ock_up shi ft
val ve. The modul ator pressure
i n the ri ght cavi ty of the
l ock-up shi ft val ve overcomes the spri ng force; thus the
l ock-up shi ft val ve i s moved to the l eft si de.
The l i ne pressure
i s then separated i nto the two pas-
sages to the torque converter:
Torque Converter Inner
pressure:
enters i nto ri ght
sade to engage l ock-up cl utch
Torque Converter Back
pressure:
enters i nto l eft si de
to di seogage l ock-up cl utch
The back pressure (F2)
i s regul ated by the l ock-up con-
trol val ve, whereas the posi ti on
of the l ock-up ti mi ng
val ve i s determi ned by the l i near sol enoi d Dressure and
tensi on of the val ve spri ng. Al so the posi ti on
of the l ock_
up control valve is determined by the back pressure
of
the lock-up control valve, torque converter pressure
reg_
ul ated by the torque converter check val ve, and modul a_
tor pressure
determi ned by the l ock-up control sol enoi d
val ve B. The PCM swi tches the l ock-up control sol enoi d
val ve B on and off rapi dl y
{duty operati on} under certai n
conditions to regulate the back pressure (F2)
to lock the
torque convener properly.
NOTE: When used,
"l eft"
or
"ri ght"
on the hvdraul i c ci rcui t.
MODULATOR PRESSURE
LINEAR SOLENOTD PRESSURE
LOCK.UP CONTROL
VALVE
LOCK.UP CONTROL
SOI.TNOID VALVE
A 8
TOROUE CONVERTER
CHECK VAI-VE
RELIEF VALVE
LOCK-UP TIMING
VALVE
^
L____J'r
cooLER RELTEF valvE
14-36
ATF PUMP
TOROUE CONVERTER
Full Lock-up
. Lock-up Control Sol enoi d Val ve B: ON
o Li near Sol enoi d Pressure: Hi gh
When t he vehi cl e speed f ur t her i ncr eases. t he l i near
sol enoi d
pr essur e i s i ncr eased t o hi gh i n accor dance
wi th the l i near sol enoi d control l ed bv the PCM.
The l ock- up t i mi ng val ve over comes t he spr i ng f or ce
and moves to the l eft si de. Al so, thi s val ve cl oses the
fl ui d port l eadi ng to the l eft si de of the l ock-up control
Under thi s condi ti on. the modul ator
pressure
i n the l eft
si de of t he l ock- up cont r ol val ve had al r eady been
rel eased by the l ock-up control sol enoi d val ve B; the
l ock-up control val ve
j s
moved to the l eft si de. As thi s
t akes
pl ace,
t he t or que conver t er back pr essur e i s
rel eased ful l y. causi ng the l ock-up cl utch to be engaged
f ul l y.
NOTE: When used,
"| eft"
or
"ri ght"
on the hvdraul i c ci rcui t.
MODULATOR PRESSURE
LINEAR SOLENOIO PRESSURE
{cont ' d)
LOCK.UP CONTROL
SOLENOID VALVE
RELIEF VALVE
LOCK.UP TIMING
VALVE
'r
,-.r'
cooLER RELTEF vALvE
ATF PUMP
14-37
Description
Lock-up System
(cont'dl
TOROUE CONVERTER
Deceleration Lock-up
. Lock-up Control Sol enoi d Val ve B: Duty Operati on
OFF
-
ON
a Li near Sol enoi d Pressure: Low
The PCM swi tches sol enoi d val ve B on and off rapi dl y
under cer t ai n condi t i ons. The sl i ght l ock- up and hal f
l ock-up regi ons are mai ntai ned so as to l ock the torque
converter properl y.
NOTE: When used,
"l eft"
or
"ri ght"
on the hydraul i c ci rcui t,
MOOULATOR PRESSURE
LINEAR SOLENOID PRESSURE
LOCK-UP CONTROL
SOLENOID VALVE
RELIEF VALVE
LOCK. UP TI MI NG
VALVE
COOLER RELIEF VALVE
ATF STRAINER
1434
ATF PUMP
Component
Locations
POWERTRAIN CONTROL
MODULE
(PCM)
TRANSAXLE {A/TI
COUNIRSHAFT
SPEED SENSOR
SOI,TNOID VALVE
ASSEMBLY
SOLENOID VALVE
ASSEMBLY
GEAR POSITION SWITCH
SPEED SENSOR
1+39
PGM Gircuit Diagram
(A/T
Control System:
'96
-
98 Modelsl
UNDEfl
-HOOD
FUSE/RELAY BOX
No. 41
(80A1
N0. 42 l 40A)
No. 47 {7. 5 A)
No. l 3
( 15A)
Arp Np
l on,ô l
r,,
l otrr l 6l t l 3]t l ot*
UNDER DASH
FUSE/REIAY 8OX
/8LU
c 1 0
YEUBLK BtK
424
Btx
At 0 423
' 96: BLU/ BED
'97, '98r
GFN/BLK
T T T
YEL GRN BLU
LT GRN
BLK/BTU
RED
GRNiELK
F-
BTK/BI.U
F_wHr
F-
GRN
f-
GRN
F-
Bru
GRN
BLU
NorE:
t
:ro5v
T
: r o 12v
GAUGE ASSEMBTY
A,T GEAR POSITION
I NDI CATOR
8 2 4 t 8 8 t B 1 7
'96:
GRN 8LU
'96:
BLU/RED
al
' 97, ' 98:
GRN/ 8LK
--
SERVICE CHECK CONNECTOR
LOCK
-UP
CONTROL
SOLENOIO VALVE
ASSEMELY
RED WHT
t l
l l '
I T
t l
l l
Lo-l
MAINSHAFT
SPEED SENSOR
T
BRNiBLK
I
I
I
-
G 101
NCSG ILS
-
ILS
+
ISH
A
ISH
B
l tc
A
l tc
B
SHIF'CONTROL
SOTENOID VALVE
ASSEMEI-Y
PCM Terminel Locations
14-41
PCM Terminal Voltage/Measuring
Gonditions
('96
-
9g Models)
A/T Control System
The PCM termi nal vol tage and measuri ng condi ti ons are shown for the connector termi nal s that rel ate to the A"/T control
system. The other PCM termi nal vol tage and measuri ng condi ti ons are descri bed i n secti on I l .
A l32P) Connctot B I25P) Connector C
( 31P) Conngct or
D
( 16P) Connect or
PCM CONNECTOR A I32P}
Terminal Numbor Signal Dcacription
Moasuring Conditions/Te.minal Voltage
A1 to A8 -
see section 1 I
-
A9 LG1 Ground
A10 PG1 Grou nd
A11 I GPl Power supply system Wi th i gni ti on swi tch ON
(l l ):
8attery vol tage
With ignition switch OFF: 0 V
412 to A2l -
see section I I
-
Ground
423 PG2 Ground
A'24 IG P2 Power supply system Wi th i gni ti on swi tch ON
(l l ):
Battery vol tage
A25 to A32 -
see secti on l 1
-
PCM CONNECTOR B
(25P}
Terminal Number Signal Description Measuring Conditions/T6rminal Voltage
B1 LS- Li near sol enoi d power
suppl y
negative electrode
l gni ti on swi tch ON
(l l ):
Pul si ng si gna.
82 Li near sol enoi d power
suppl y
positive
electrode
(l l ):
Pul si ng si gnal
SHA Shi tt control sol enoi d val ve A
control
In 2nd gear
and 3rd gear i n E, E posi ti on,
and i n
@, @
posi ti on: Battery vol tage
In l st gear
and 4th gear
i n E. E posi ti on:
0 V
B4 LCB Lock-up control solenoid valve B
control
When ful l l ock-up: Battery vol tage
When hal f l ock-up: Pul si ng si gnal
B5 LCA Lock-up control sol noi d val ve A
control
When l ock-up i s ON: Battery vol tage
Wi th no l ock-up: 0 V
86 to 87 Not used
B8 ATP D3 IVT g6ar posi ti on
swi tch @ posi -
ti on si gnal i nput
l nEpos i t i on; OV
In other than E posi ti on:
Battery vol tage
Bg t o 810 Not used
\-
14-42
I
PCM CONNECTOR B {25P1 {cont'dl
Termi nal Number Si gnal Description Measuring Conditions/Terminal Vohage
8 1 1 SHB Shi ft control sol enoi d val ve B
control
In 1st gear and 2nd gear i n -q1,
q11
posi ti on,
and i n
E]
In 3rd
gear and 4th
gear i n l D.J, [Dr- posi ti on: 0 V
B't2 SLU Interl ock control When i gni ti on swi tch i s ON
(l l ),
brake
pedal
deoressed and accel erator Dedal rel eased: 0 V
8 1 3 D4 IND D4 Indi cator l i ght control When i gni ti on swi tch i s fi rst turned ON
(l l ):
Battery voltage for two seconds
In E
posi ti on: Baftery vol tage
B't 4 NMSG Mai nshaft speed sensor ground Al ways: 0 V
E t c NM Mai nshaft speed sensor si gnal
i nput
Dependi ng on engi ne speed: Pul si ng si gnal
When engi ne i s stopped: 0 V
816 ATP R Ay'T gear position switch
E
posi ti on si gnal i nput
I nE posi t i on: 0V
In other than E
817 ATP 2 A/T gear position switch
E
posi-
I nE posi t i on: 0V
In orher than
E
818 t o 821 Not used
s22 NCSG Countershatt speed sensor ground Al waysr 0 V
B23 NC Countershaft speed sensor si gnal
i nput
Dependi ng on vehi cl e speed: Pul si ng si gnal
When vehi cl e i s stopped: 0 V
B24 ATP D4 Ay'T gear position switch lor posi-
I nEpos i t i on: 0V
In other than 6 posi ti on: 5 V
ATP NP A,/T gear position switch E
and
N
posi ti on si gnal s i nput
I nE and
E
posi t i ons: 0V
In otherthan E
and
N]
positions: Battery voltage
PCM CONNECTOR C {31P)
Termi nal Number Si gnal Description Measuring Conditions/Terminal Voltage
Cl to C6
-
see secti on 11
-
c1 Servi ce check si gnal Wi th i gni ti on swi tch ON
(l l )
and servi ce check
connector oDen; 5 V
Wi th i gni ti on swi tch ON
(l l )
and servi ce check
connector connected wi th sDeci al tool : 0 V
C8 to Cg
-
see secti on 11
-
c10 VBU Back-up power system Always battery voltage
C11 t o C31
-
see secti on
' 11
-
PCM CONNECTOR D
(16P}
Termi nal Number Si gnal Description Measuring Conditions/Terminal Voltage
Dl to D4
-
see secti on 11
-
D5 STOP SW Brake swi tch si gnal i nput Brake
pedal depressed: Battery vol tage
Brake pedal rel eased: 0 V
D6 t o D16
-
see secti on 1 l
-
14-43
PCM Gircuit Diagram
(A/T
Gontrol System:'99
-
00 Models)
UNOEF DASI
FL]SE/FELAY BOX
t a T06 T Dr.
INTRLOCK
CCNTFOL
uN|l
ert*rll
I STARTEF
r-->l
I
l__
sL!
I
UISEF,DASH
FISSIEL YmX
r,Jo 25 (7 5A) GAUGE ISSEMBLY
Lr GRN
-----l
l"--
LTGRll
L
eultru
----iF
erkLu
14-44
SPEEO
SENSOF
f7
I
I
I
I
CONNECTOF
1r 6P)
Y
I
I
I
ttt*'"
"*ttot **" 1*u)
,5-,
I
I
I
fl**',*"
I
BLK
I
G401
ECI
SHIFI CONTFOL
solEtto vALvE
ASSEMSLY
PCM Terminal Voltage/Measuring Conditions
('99
-
00 Models)
A/T Control System
The PCM termi nal vol tage and measuri ng condj ti ons are shown for the connector termi nal s that are rel ated to the A//T con-
trol system, The other PCM termi nal vol tage and measuri ng condi ti ons are descri bed i n secti on
,11.
PCM Connoctor Tgrminrl Locations
PCM CONNECTOR A {32PI
PCM CONNECTOR 8
(25P}
Terminal Numbel Si gnal Description Masuring Conditions/Terminal Voltage
A10 5L5 Servi ce check si gnal Wi th i gni ti on swi tch ON
(l l )
and servi ce check
connector open: Approx, 5 V
(l l )
and servi ce check
connector connected with sDecial tool: 0 V
A14 D4 IND E i ndi cator l i ght control When i gni ti on swi tch i s fi rst turned ON
(l l ):
ApDrox. 10 V for two seconds
In E posi ti on: Approx. 1O V
428 ILU Interl ock Control When i gni ti on swi tch ON
(l l ),
brake pedal
depressed, and accel erator
pedal
rereaseo:
Battery voltage
A.32 STOP SW Brake swi tch si gnal i nput Brake pedal
depressed: battery voltage
Brake oedal rel eased:0 V
Terminal Number Si gnal Descdption Measuring Condhions/Torminal Voltag6
B1 ! GP1 Power supply system Wi th i gni ti on swi tch ON
(l l ):
Battery vol tage
PGl Ground
B8 LS AM Li near sol enoi d power
suppl y
negati ve el ectrode
(l l ):
Pul si ng si gnal
B9 IG P2 Power supply system With ignition switch ON
(ll):
Baftery voltage
810 PG2 G rou nd
917 LS AP Li near sol enoi d power suppl y
posi ti ve
el ectrode
(l l ):
Pul si ng si gnal
B20 Gr ound
VBU Back-up power
suppl y Always battery voltage
822 Gr ound
\
14-46
FCM CONNECTOR D {16P)
\ o
14-47
Terminal Number Si gnal Do3cription Measuring Conditions/Torminal Vohage
D1 LCA Lock-up control sol enoi d val ve A
control
When l ock-up i s ON: Battery vol tage
Wi th no l ock-up: 0 V
SHB Shi ft control sol enoi d val ve B
control
In
E
posi ti on, i n 1st and 2nd gear i n E, E
position: Battery voltage
l n 3rd gear i n E, E, i n 4th gear i n E posi -
t i on; 0 V
D3 LCB Lock-up control sol enoi d val ve B
control
When ful l l ock-up: Battery vol tage
Wi th hal f l ock-up: Pul si ng si gnal
D4 Not used
D5 VB SOL Lock-up control sol enoi ds, shi ft
control sol enoi ds and l i near
sol enoi d
power suppl y el ectrode
wi th i gni ti on swi tch oN
(l l ):
Battery vol tage
Wi th i gni ti on swi tch OFF: 0 V
D6 ATP R Ay'T gear position switch
E
posi ti on i nput
t nEposi t i on: 0V
In other than
E
posi ti on: Approx. 10 V
SHA Shi ft control sol enoi d val ve A
control
In
E]
posi ti on, i n 2nd and 3rd
gear i n
p!,
[Q]
position: Battery voltage
In 1st gear i n E, @
posi ti on, i n 4th gear i n El
Dosi ti on: 0 V
D8 ATP D3 A/T gear position switch
E posi ti on i nput
I n E posi t i on: 0V
In otherthan @
D9 ATP D4 Ay'T gear position switch
E
position switch
In El posi ti on: 0 V
In other than E posi ti on: Approx. 5 V
D10 NC Countershaft speed sensor signal
i nput
When vehi cl e i s stooped: 0 V
D1 1 NM Mainshaft speed sensor signal
Inpur
Dependi ng on engi ne speed: Pul si ng si gnal
When engi ne i s stopped: 0 V
D't2 NMSG Mai nshaft speed sensor
ground
D13 ATP NP
Ay'T gear position switch E
and
E
posi ti on i nput
I nE and E
posi t i ons: 0V
In other than E
and
E
positions: Approx. 10 V
D14 AfP 2 Ay'T gear position switch
E
posi ti on i nput
t nEposi t i on; 0V
In other than
E
position: Approx. 10 V
D16 NCSG Countershaft speed sensor
ground
Troubleshootin g
Procedures
Chccking the Diagnostic Trouble Code IDTC)
with an OBD ll Scan tool or Honda PGM Tester
when the PCM senses an abnormal i ty i n the i nput or output systems, the
pl
i ndi cator l i ght i n the gauge
assembl y wi l l
bl i nk. When the 16P Data Li nk Connector
(DLC) (l ocated
under the dash on the dri ver,s si de) i s connected to the OBD l l
Scan Tool or Honda PGM Tester as shown, the scan tool or tester wi l l i ndi cate the Di agnosti c Troubl e Code
(DTC)
when
the i gni ti on swi tch i s turned ON{l l ).
l f the El i ndi cator l i ght or the MIL has been reported on, or l f a dri veabi l i ty probl em i s suspected, fol l ow thi s procedure:
1. Connect the OBD l l Scan Tool
(conformi ng
to SAE J19781 or Honda PGM Tester to rhe 16p DLC.
(See
the OBD l l Scan
Tool or Honda PGM Tester user' s manual for speci fi c i nstructi ons. l f you
are usi ng the Honda PGM Tester, make sure i t
is set to the SAE DTC type.)
(l l l ,
and observe the DTC on the screen,
3, Record al l fuel and emi ssi on DTCS, A/T DTCS, and freeze data.
4 l f there i s a fuel and emi ssi ons DTC, fi rst checkthe fuel and emi ssi ons system as i ndi cated bythe DTC
(except
for DTC
P0700). DTC P0700 means there i s one or more A,/T DTC, and no probl ems
were detected i n the fuel and emi ssi ons ci r-
cui t of the PCM.
5. Wri te down the radi o stati on oresets.
6. Reset the memory wi th the PGM Tester or by removi ng the BACK UP fuse i n the passenger' s
under-dash fuse/rel ay box
for more than 10 seconds.
7. Dri ve the vehi cl e for several mi nutes at speeds over 30 mph
(50
km/hr), and then recheck for DTCS. l f the A"/T DTC
returns, go to the Symptom-to Component Chart on pages
14-52 and 14-53 for' 96
-
98 model s, and pages 14-54 and
14-55 for the' 99
-
00 model s, l f the DTC does not return, there was an i ntermi ttent probl em
wi thi n the ci rcui t. Make
sure al l pi ns and termi nal s i n the ci rcui t are ti ght, and then go to step
g.
8. Reset the radi o
preset
stati ons, and set the cl ock.
OBD ll SCAN TOOL or
HONDA PGM TESTER
DAYA LINK CONNECTOR {16P}
14-44
Chocking th Diagnostic Trouble Code
(DTCI
with the Servico Check Conneqtor and SpcialTool
When the PCM senses an abnormal i ty i n the i nput or output systems, the @
i ndi cator l i ght i n the
gauge
assembl y wi l l bl i nk
When the Service Check Connector
(locatd
under the dash on the
passengsr side) is connected with the special tool as
shown, the E
i ndi cator l i ght wi l l bl i nk the Di agnosti c Troubl e Code
(DTC)
when the i gni ti on swi tch i s turned ON
(l l ).
When the
E
indicator light has been reported on, connect the Service Check Connector with the special too'.
Then turn ON
(l l )
the i gni ti on swi tch and obssrve the E
i ndi cator ti ght.
CONNECTOB
SERVICE CHECK
CONNECTOR I2PI
07PAZ
-0010100
Codes 1 through 9 are indicated by individual short blinks, Codes 10 and above are indicatd by a sories of long and short
bl i nks. One l ong bl i nk equal s 1O short bl i nks. Add the l ong and short bl i nks together to determi ne th code. After deter-
mining the code, refer to the electrical system Symptom-to Component Chart on
pages 1+52 and 1+53 for'96
-
98 mod-
el s, and 14-54 and 14-55 for the
' 99
-
00 model s.
Sr DTC 1
s.. DTC 2
Long blink Short blink lfiYa tim.!,
Sc DTC 15
(cont' d)
GAUGE ASSEMBLY
Short blink loncel
14-49
Troubleshooting Procedures
1 .
2.
(cont'dl
Remove the ki ck panel on the passenger' s
si de {see secti on 20}.
Remove the PCM. and turn the PCM over.
Inspect the circuit on the PCM according to the troubleshooting flowchart with the spocial tools and a digital multime-
ter as shown.
How lo Use tha Backprobe Set
Connect the backprobe adapters to the stacki ng patch
cords, and connect the cords to a mul ti meter. Usi ng the wi re
i nsul ati on as a gui de
for the contoured ti p of the backprobe adapter, gentl y
sl i de the ti p i nto the connector from the
wi re si de unti l i t comes i n contact wi th the termi nal end ofthe wi re.
BACKPROSE
BACKPROBE SET
07saz
- (xtl(xtoA
{two required)
DIGITAL MULNMEIER
(Commrcially
6vailabll
- aHM- 32- 003
t..
14- 50
or equivalnt
PCM Reset Procedure
1. Turn the i gni ti on swi tch off.
2. Remove the BACK UP fuse
(7.5
A) from the under-hood fuse/rel ay box for
' 10
seconds to reset the PCM'
NOTE:
. Di sconnecti ng the BACK UP fuse al so cancel s the radi o
preset stati ons and cl ock setti ng Make note of the radi o
presets before removi ng the l use so
you can reset them
. i n"
gCfU
memory can al so be cl eared by usi ng the OBD l l Scan Tool or Honda PGM Tester'
Final Procedure
NOTE: This
procedure must be done after any troubleshooting.
2. Reset the PcM.
3. Di sconnect the oBD l l scan Tool or Honda PGM Tester from the Data Li nk connector, or remove the speci al tool from
the Servi ce Check Connector.
(l l ),
and set the radi o presets and cl ock setti ng'
5' ToVer i f yt hepr ob| emi sr epai r ed, t est . dr i vet heVehi c| ef or sever al mi nut esat speedsover 30mph( 48km/ h) .
14-51
Symptom-to-Component
Ghart
Electrical System
-'gG -
98 Models
*1:
The DTC i n the parentheses
i s the code E i ndi cator l i ght i ndi cates when the Data Li nk connector i s connected to the
Honda PGM Tester.
*2:
Whenever the Honda PGM Tester or Scan Tool detects an automati c transmi ssi on control system DTC,
p07OO
wi l l be
set in the PGM-FI control svstem.
DTCII
E Indicaior
Light
MI L
Dotection ltem
Page
P1753
f l )
Bl i nks ON
Lock-up control sol enoi d val ve A
14-56
P1758
\ 21
Bl i nks
ON
Lock-up control sol enoi d val ve B
14-58
P1705
( 51
Bl i nks ON
Ay'T gear position
switch
(short
to groundl
14-60
P1706
( 6)
OFF ON
A,/T gear position
switch
(open)
14-62
P0753
l 7l
Bl i nks ON
Shi ft control sol enoi d val ve A
14-64
P0758
{ 8)
El i nks ON
Shi ft control sol enoi d val ve B
14-66
POl 20
( 9)
Bl i nks ON
Countershaft speed sensor
14-68
P0715
{ 15)
' 96
-
97
model s:
OFF
' 98
model :
Bl i nks
ON
Mai nshaft speed sensor
14-70
P1768
{ 16)
Bl i nks ON
Li near sol enoi d
't
4-72
P0740
(40)
OFF ON
Lock-up control system
14-7 4
P0730
( 41)
OFF ON
Shift control system
14-75
P0700*,
(none)
Automati c transmi ssi on control svstem i n the
pGM-Fl
control svstem
14-52
SYmPtom
E
i ndi cator l i ght does not come on tor two seconds after i gni ti on
swi tch i s fi rst turned ON {l l }.
E
i ndi cator l i ght i s on constantl y
(not
bl i nki ng) whenever the i gni ti on
swi tch i s ON
(l l ).
Shi ft l ever cannot be moved from
@
posi ti on wi th the brake pedal
depressed.
Inspecti on Ref.
Page
11-16
14- 78
Inspecti on
' t4-79
l f the sel f-di agnosti c l -d
i ndi cator l i ght does not bl i nk,
perform an i nspecti on accordi ng to the tabl e bel ow.
NOTE: l f a customer descri bes the symptom for code Pl 706 {6),
i t wi l l be necessary to recreate the symptom by test-dri v-
i ng, then recheck the DTC.
14- 53
Chart
Electrical System
-'99 -
00 Models
*1:
The DTc in the parentheses
is the code
E indicator tight indicates when 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,
p07oo
will be
set in the PGM-FI control svstem
DTC*I
E Indicator
Light
MIL
Dotostion ltem
Page
P1753
f i )
Bl i nks ON
Lock-up control sol enoi d val ve A
' 14-80
P1758
t2l
Bl i nks
ON
Lock-up control sol enoi d val ve B
14-82
P1705
{ 5}
Bl i nks
ON
Ay'T gear position
switch
{short to ground)
14-84
P1706
( 6)
OFF ON
y'VT
gear position
switch
{open)
14-81
P0753
\ 71
Bl i nks
ON
Shi ft control sol enoi d val ve A
14-89
P0758
( 8)
Bl i nks ON
Shift control solenoid valve B
14-9r
P0720
( 9)
Bl i nks ON
r4-93
P0715
( 15)
B l i nks
ON
14-95
P1768
( 16)
Bl i nks
ON
Li near sol enoi d
't
4-97
PO7 40
(40)
OFF ON
Lock-up control system
14-99
P0730
( 41)
OFF ON
Shift control svstem
14- 100
P0700*,
(none)
OFF
Automatic transmission control system in the
pGM_Fl
controt svstem
14-54
E
i "dl .r." fi Sh, 1."""".
y{*fu
Reference
page
14- 101
l E
i ndi cator l i ght does not come on for two seconds after i gni ti on swi tch i s fi rst turned oN
(l l ). 14-102
Shi ft l ever cannot be moved from E
posi ti on wi th the brake
pedal deprsssed'
14- 104
l f the sel f-di agnosti c E i ndi cator l i ght does not bl i nk and fol l owi ng symptoms appear,
perform an i nspecti on accordi ng to
the tabl e bel ow.
14- 55
Electrical Troubleshooting (,96 - gg
Models)
Troubleshooting
Flowchart
-
Lock-up
contror sorenoid
Varve A
Po$ible Cau3e
.
Di sconnecl ed l ock-up cont rol
solenoid valvo A connector
.
Short or open in lock-uD control
solenoid valv A wire
.
Fauliy lock-up contlol solonoid
valve A
PCM CONNECTORS
.
OBD ll Scrn Toot indicates Code
P1753.
.
Sel f - di agnosi s
@
i ndi cat or
light blinks once.
Check for a Short to Powo.:
2. Di sconnect t he A
(32p)
and B
( 25P)
connsgl 6ps 1r q- t ha
PCM.
3. Turn t he i gni t i on swj t ch ON 0t ).
t he 85 and Ag or A22 t ermi
nal s.
Repair shoit to power
in the wire
betwen the 85 terminal and thg
lock-up coDtrol tolenoid valve A.
Mea3ure Lock-up Cont rol Sol e-
noid Valve A RGislance:
' 1.
between the 85 and A9 or A22
t ermi nal s.
Check lor looso PCM connctoB.
lf nece$.ry, substituto a known-
good
aolonoid valve ass.nblv ol
PCM end rech6ck.
l s t he resi st ance 12
-
25 O?
NOTE: Record al l freeze data before you
troubl eshoot.
A l32P)
To page' 14- 57
From page 14-56
Ch6ck Lock-up Control Solenoid
Valve A tor a Short Cilcuiti
lrom the lock-up control sole-
noi d val ve assembl Y.
t he 85 and Ag or A22 t ermi -
nat s.
Ropair 3hort to
giound in iha wila
b.twoqn th6 85 terminrl rnd tho
locl-up control 3olanoid valvo A.
Mo..ura Lock-up Control Sole'
noid Velve A Reri3tanc. at tho
Solenoid Conn6cto.:
Measure the resistance between
t he No. 2 t ermi nal of t he l ock-up
cont rol sol enoi d connect or and
body
ground.
Chock f or opan i n t ha wi t .
ba(w.an tha 85 torminll lnd the
lock-uo control lolanoid vtlYa A.
ls the resistance 12
_
25 O?
Roplsce tho lock"up cont.ol 3ol_
noid vllvo arsembly.
PCM CONNECIOBS
Wi re si de of l em6l et ermi nal s
LOCK.UP CONTROL
SOrINOID
CONNECTOR
YEL
Teami nal si de of mal o t ermi nal s
lml
- , f
( o)
I
14-57
Electrical Troubleshooting (' 96 -
9g Modelsl
Troubleshooting
Ftowchart
-
Lock-up
control sorenoid Varve B
Possible Cause
.
Di sconnect ed l ock-up cont rol
solenoid valve B connector
'
Short or open in lock-up control
solonoid valve B whe
.
Faulty lock-up control solenoid
valve B
PCM CONNECTORS
.
OBD ll Scan Tool indicrtes Code
P1758.
.
Self-diagnosis
E
indicrtor light
blinkstwice.
Check for a Shon to Power:
(32p)
and B
( 25P)
connect or s f r om t he
PCM,
3. Turn t he i gni t i on swi t ch ON t ).
t he 84 and A9 or A22 t ermi -
nal s.
Repeir short to
power
in the wire
between the 84 teiminal and the
lock-up control solenoid valve B.
Moasure Lock-up Cont rol Sol e-
noid Valve B Resistance:
bet ween t he 84 and Ag or
A22 t ermi nal s.
Check for loose FCM connectors,
lf necessary, substitute a known-
good
solenoid valve assembly ol
P1CM and rech6ck.
-
25 O?
troubl eshoot.
A {32P)
To page 14- 59
t-
From page 14 58
Check Lock-up Control Solenoid
Valve B for a Short Circuh:
f rom t he l ock-uP cont rol sol e'
noi d val ve assef i bl y.
t he 84 and A9 or A22 t erma-
nal s,
Rgprir 3hort to
ground in tho wite
Hwoon the 84 torminal and the
lock-uo contlol solonoid valvs B.
Measu.o Lock-uP Control Sole'
noid Valve I Resistance at tho
Solenoid Connector:
Measure t he resi st ance bet ween
t he No. 1 t ermi nal o{ t he l ock-up
cont rol sol enoi d connect or and
body
ground.
Chcck t or opcn i n t he wi rs
btlve.n the 84 ierminal and tho
lock-up conttol solonoid vllvc B.
-
25 O?
Reolace the lock'up control sole-
noid valve assemblY.
PCM CONNECTORS
Wi re si de oI l emal e t ermi nal s
LOCK.UP CONTROL
SOLENOID
CONNECTOR
IFl;II
-r:-]
6nn/eLKfi
I
Termi nal
si do ot mal e t ermi nal s
14- 59
Electrical
Troubleshooting (' 96 -
9g Models)
Troubleshooting
Flowchart
-
A/T Gear
position
Switch
(Shortl
NOTE: Record al l freeze data before you troubl eshoot.
Poiriblo Caus6
.
Short i n A/ T go. . posi t i on
awhch wira
.
Fauhy A/T goa. position
swhch
NOTE: Code P1705 (5)
t he PCM recei ves t wo
i nput s at t he same t i me.
i s caused when
gear posi t i on
'
OBD ll Scln Toot indic.tes
Cod6
P1705.
.
Sofidi.gno3b
E indicato] tighr
blinksfivatim...
Observo th. A/T Go.r
po3ition
Indicator:
1. Turn t he i gni t i on swi t ch ON l ).
2. Observe the A"/T gear position
i ndi cat or , and shi t t t o each
post t ron,
Do any indicatoG stay on
when the shift lever is not in
those positions?
Tho sy3tem b OK.t this timo.
Check th6 wilc harnari for dam-
rga.
M.r.ur. ATP R Vohlge:
1. Shi f t t o al l posi t i ons
ot hert han
E.
2. Nileasure the voltage between
t he 816 and Ag or A22 t ormi -
nat s,
Check f or short i n t ha wi ro
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 connoc-
to13. lf nacetaary, subrtitute a
knownood Pcllt and roa|rsck.
Meesur. ATP NP Vohage:
1. Shi f t t o al l posi t i ons ot hr t han
Eor E.
2. Moasure the voltage between
the 825 and A9 or A22 termi
nat s.
Check f or short i n t he wi re
b.tw..n th6 B:I5 torminrt 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
wi r. 3 r. o OK, chack t or l ooso
PCM conn. ct orr. I t n. cosarry.
sub.tituto a known-good
pCM
.nd r.chock.
M.Gur. ATP D4 Voltago:
1. Shi f t t o al l posi t i ons ot hert han
l D. l .
2. Measure the voltage betwen
rhe 824 and Ag or A22 t ermi -
nal s.
Check t or 3hort i n t ho wi ro
bc{wocn the 824 terminrl and tho
A/T ge.r poiition
switch. lI wile
ia OK, chock tor loo3o
plCM
con-
ncctoaa. It nacossarv, sublthute a
known-good PCM and rechck.
PCM CONNECTORS
YES
To page
14-6' :
14- 60
From
page 1 4-60
PCM CONNECTORS
Measuro ATP D3 Voltage:
1. Shi f t t o al l
posi t i ons ot her t han
tr.
nal s.
Ch. ck t or shor t i n t he wi r e
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 connec-
tor3. lf nece3rary, substituta a
known-good PCM lnd rochck
Morsuro ATP2 Voltage:
1. Shi f t t o al l
6t
2. Measurc the voltage between
t he 817 and Ag or A22 t erml -
n6l s.
Check f or short i n t he wi l e
btwesn 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-good PICM and recheck.
check for loose PCM connectors.
lf noc*sarY. sub3titute a known_
good PCM and r.chock.
' 96:
GRN' 97
-
98: PNX
B
(25P1
14-61
Electrical
Troubleshooting ('96 - gg
Modelsl
Troubleshooting
Flowchart
-
A/T Gear
position
Switch
(Open)
.
OBD ll Scan Tool indicates Code
P1706.
.
Self-di.gnosk
E indicator tight
blinks six timos.
Measure ATP 04 Voltege:
1. Shi f t t o
E
posi t i on.
t he 824 and A9 or A22 t ermi
nal s,
l s t her e vol t age?
Possible Causo
.
Disconnected A/T gear position
switch connctor
.
Open i n A/ T gear posi t i on
switch wire
.
Faulty A/T gear position
switch
troubl eshoot.
Moasure ATP I Voltage:
1. Turn t he i gni t i on swi t ch ON 1 ).
2. Shi f t t o
E
posi t i on.
the B'f6 and Ag ot A22 tetmi-
nat s.
Ropai. opn in the wire betwen
the Bl6 terminal.nd the A/T gear
position
swhch.
Measur ATP NP Voltage:
1. Shi f t t o
E or
E
posi t i on.
t he 825 and A9 or A22 t ermi ,
nal s,
Repeir open in the wir between
tho B25 terminal and th6 A/T geer
position
indicator or tho A/T
96.r
position
3witch.
Rcpair open in the wire between
tto 82{ to.minal and th6 A/T geat
lrosition
3witch.
To page 14 63
PCM CONNECTORS
NO
1
L
+62
From
page 14-62
Measure ATP 03 Voltagei
1. Shi f t t o
E Posi t i on.
2. l vt easure t he vol t age bet ween
nal s.
Ropair open in tho wils between
the 88 terminal .nd tho A/T
goar
oosition switch
Mea3ur. ATP2 Vohage:
1. Shi f t t o E Posi t i on.
t he 817 and Ag or A22 t ermi '
nal s,
Repair open in the wirc botweon
t he B17 t er mi nal r nd t he A/ T
geer poaition 3witch.
Chock for loose PCM connctoB.
lf nec*sary, sub3titute e known'
good PCM and rocheck.
PCM CONNECTORS
'95:
GRN 37
-'98:
PNK
14- 63
Electrical Troubleshooting (' 96
-
98 Modelsl
Troubleshooting
Flowchart
-
Shift Gontrol Solenoid Valve A
Po$ible Cau3e
.
Di sconnect ed shi f t cont r ol
solenoid valve A connector
.
Short oi open in shift control
solenoid valve A wire
.
Faul t y shi rt cont rol sol enoi d
PCM CONNECTORS
'
P0753.
.
Sett{iagnosis
E
indicator light
blinks seven tim6.
Check tor a Short to Power:
(32P)
and B
{ 25 Pi connect or s t r om t he
PCM.
the 83 and A9 orA22 terminals.
Repair short to powe.
in the wir6
between the 83 terminal .nd the
shift control solonoid valvo A.
Moa3ure Shift Control Solenoid
Valve A Resistanc:
2, Measur e t he r esi st ance
between the 83 and A9 or A22
t ermi nal s.
Chck for loose PCM connectors.
lf nc6srry, subatitute a known-
good
solenoid valve a3,sembly or
PCM end rocheck.
-
25 0?
NOTE: Record al l freeze data before
you
troubl eshoot.
A t32Pl
To page 14-65
From page 14-64
Check Shi f t Cont rol Sol . noi d
v.lve A loi a Short Circuh:
' 1.
from the shift control solenoid
val ve assembl Y.
the 83 and Ag or A22 terminals.
Roprir shon to
ground in th. wil.
b.twon th. B:t t.rmin.l rnd tho
ihift conLol aolonoid valvc A
Mea3ur. Shift Control Solonoid
v.lvo A Rgistance !t tho solendd
Connoc'tor:
t he No. l t ermi nal of t h shi f t con_
trol solenoid connector and body
ground.
Chack t o. open i n t h. rt i r.
b.t^raan tha 8:l Lrtnlnll tnd tho
thift conlrol 3olanoid valva A.
-
25 O?
PCM CONNECTORS
Wi re si de o{ f emal e t ermi nal s
SHIFT CONTROL SOLENOID
CONNECTOR
----!=--
FI-I1
=r==--
alurvEL5f
I
I
14- 65
Electrical Troubleshooting (' 96
- g8
Modelsl
-
Shift Control Solenoid Valve B
Possible Cause
'
Di sconnect ed shi f t cont rol
solenoid valve I connectol
.
Short or open in shift control
solenoid valve B wire
.
Faul t y shi f t cont rol 30l enoi d
valve B
PCM CONNECTORS
.
OBD ll Scan Tool indic.tes Code
P0758.
.
Solt-diagnosis
E
indicator light
blinks eight times.
Chock for a Short to Power:
1. Turn t he i gni t i on swat ch OFF.
2. Di sconnect t he A (32P)
and B
(25P)connectors
from the PCM.
(ll).
nal s,
Repair short to powar
in the wire
bot wcen t he 811 t ormi nal and
the shift control solenoid valve 8.
Measure Shift Cont.ol Solenoid
Valve B Resktance:
2, Meas u r e t he r esi st ance
bet ween t he Bl l and A9 or
A22 t ermi nal s.
Checl for loose PiCM connector3.
lf necssary, sub3titute a known-
good
solenoid v.lve assembly ol
PCM and recheck.
-
25 O?
troubl eshoot,
A t32P)
To page 14 67
\
From page 14-66
Check Shi f t Conl r ol Sol noi d
valve B tor a Short Circuit:
trom the shift control solenoid
val ve assembl y.
nal s,
Replir shon to ground in th wire
betwe.n the 811 terminal and the
3hift control solenord valvo B.
Measure Shift Control Solenoid
vrlve B Resistance at the Sole-
noid Connector:
t he No. 2 t ermi nal of t he shi f t con
trol solenoid connector and body
ground.
Check t or ooen i n t he wi re
betw..n thc 81 1 ttminal ard tha
shift control solonoid vrlv6 B.
l s t he resi st ance 12 25 O?
, 2
l l
r . 5
PCM CONNECTORS
SHIFT CONTROL SOLENOID
CONNECTOR
GRN/WHT
14-67
(' gO
-
98 Modelsl
Troubleshooting
Flowchart
-
Countershaft
Speed Sensor
Po$iblo Causa
'
Loosg or l aul t y conncct i on
botwocn tho PCM and c.i hrr-
n1't!
'
Di sconnoct ad count orahot t
lpo{ san3or oonnoctot
.
Short or opon in countorshaft
speed lonsor wire
.
F ulty counte.lhalt spe6d s6n-
sol
COUNTERSHAFT SPEED SENSOR
CONNECTOR
lFI,]1
-F=r
9 l
L_l
PCM CONNECTOR B I25P}
1
l'
NOTE; Record al l freeze data before
you
troubl eshoot.
.
OBO ll Scln Tool indicat6 Code
m7z).
.
S6l t -di rgnosi s
E
i ndi c. t ol
light blink! nin. tim6,
ls the countershaft spoed sensor
i nst al l ed properl y?
Moa3ure CountoEhaft Sped S6n-
sor Reaktanc at tho Son3or Con-
noctor
t rom t he count ershaf t spged
sensor connector,
2. Measure the resistance of the
countershaft sDeed sensor,
-
600 0?
Chock Countersh.ft Spood Scr|3ol
for a Shoft Circuit:
1. Di sconnect t he B {25P) con
nector from the PCM.
t he body ground
and t he 823
t e r mi n a l a n d 8 2 2 t e r mi n a l
i ndi vi dual l y.
Repai. .hort in th. wiroa b.t$ren
tho 823 lnd 822 torminals .nd
lho counteBhaft lpocd aenro..
To page 14- 69
4-68
Measure CounteFhaft Spd S6n-
sor Resistance:
1. Connect t he count er shaf t
speed sensor 2P connect or,
2 , Me a s u r e t h e r e s i s t a n c e
between the B23 and 822 tel
mt nal s.
Repair looso terminal ol opon in
the wiro3 between th6 823 and
822 terminal3 and the counter-
shaft soeed aen3or.
-
600 0?
Check tor loosc rcM connestors.
ll nocessary, sub3titute a known-
good PCM and recheck.
PCM CONNECTOR 8 I25PI
14- 69
(' 96
-
98 Modelsl
-
Mainshaft Speed Sensor
you
troubl eshoot.
Po$ible Cause
.
Disconnectd mainshaft sDed
Sensor @nnoctot
.
Shor t or open i n mai nshat t
sJted s6nsoa wire
.
Faulty mainshaft lpeed s6nso.
NOTE: Co d e P0 7 1 5
( 1 5 )
o n t h e PCM
doesn' t al ways mean t here' s an el ect ri cal
probl em
i n t he mai nshaf t or count ershaf t
speed sensor ci r cui t ; code P0715 ( 15)
may al so i ndi cat e a mechani cal probl em
i n t he t ransmi ssi on.
MAINSHAFT SPEEO
SENSOR CONNECTOR
PCM CONNECTOR B I25PI
.
m715.
.
Sel f - di r gnosi 3
E
i ndi cat or
light indicstes Code 15.
Check t he mai nshaf t and count er-
shaf t speed sensor i nst al l at i on.
Are the mainshaft and countershaft
speed sensor installed properly?
Moasure Mainshaft Spoed Sgnsol
Rosi st ance at t he Sensor Con-
nctor:
from the mainshaft speed sen-
sor connect or.
2. Measure t he resi st ance ot t he
mai nshaf t speed sensor.
ls the resistance 400 600 O?
Check Mainshaft Sp6ed Sensor
for a Short Circuil:
1. Di sconnect t he B {25P) connec'
tor lrom the PCM.
body
ground
and 815 t ermi nal
and t he 814 t ermi nal i ndi vi du,
Repai. shon in the wi.os bstwoen
t he 815 and 814 t e. mi nal s and
the mainshatt .Dood 3ensor.
To page 14- 71
14-70
From page 14-70
Mea3uro Main3haft speed sensor
Resistance:
1. Connect t he ma; nshaf t sPeed
sensol 2P connect or,
2. [ / l easu r e t he r esi st ance
bet ween t he 815 and 814 t er_
mi nal s.
Run the Electical TrouH.hooting
Flowcirrt for cod. P0720 l9l.
Check for loose P1CM connoctors.
ll ncesslrY, 3ubstitute a known'
good PCM and racheck.
-
600 O?
Check NM wire Continuityl
from the mainshaft speed sen'
sor connector.
t he 815 t ermi nal and t he No. 1
t er mi nal of t he mai nshaf t
speed sensor connector.
Rgpsi. opon in thc wira bctwgn
t he 815 t ormi nrl and t h6. t ai n_
shatt soeod lensoa,
Check NMSG Wire ContinuitYr
814 t ermi nal and t he No. 2 t ermi
nal of the mainshaft sped sensor
connector,
Repair open in the wira botwGon
t he 814 t ermi nal and l he mai n'
shsft spod 3en3or.
Check for loo3o PCM connoctoB.
ll neca$8ry, subditute a known-
good PCM and rgchock.
Wi re si de oI f emal e t erml nal s
MAINSHAFT SPEED SENSOR
CONNECTOR
14-71
(' 96
-
98 Modelsl
-
Linear Solenoid
NOTE: Record al l freeze data before vou troubl eshoot,
Po$ible Caus6
.
Di sconnoct od l i neaJ sol onoi d
connectot
.
Short or open in linoar solenoid
'
Faulty linoar solonoid
LINEAR
SOLENOID CONNECTOR
l;r]l
TT
Y I
L I
RED WHT
OBO ll Scan Tool indicates Code
P176a.
Sel f - di agnosi 3
E
i ndi cat or
light indicates Code 16,
Measure Linear Solenoid Resist-
ance at the Solenoid Connecto.:
l rom t he l i near sol enoi d con
nect or,
3. Measure t he resi st ance of t he
l i near sol enoi d.
l s t he resi st ance approx. 5. 0 O?
Check Linear Solenoid for a Shon
Circuit:
1. Di sconnect t he B 125P) connec-
tor from the PCM.
t he body ground and t he B1
t ermi nal and 82 t ermi nal i nda-
vi dual l y.
Repair short in the wires bgtwoen
the Bl and 82 terminab and the
lineti solsnoid.
Meaaure Linoar Solenoid RGi3t-
anc:
1. Connect t he l i near sol enoi d
connector.
bet ween t he 81 and 82 t ermi -
nal s,
Ropair looso terminal or open in
the wires botwen the 81 and 82
telminals end the linear solenoid.
To page 14-73
14- 72
Check the G.ound Circuit:
A9 and A10 t ermi nal s.
.
Rapai r opan i n t he wi r o
botweon th6 tormin.b Ag rnd
A10 and G101.
.
Raprir looc
iunction
connrc{or.
.
R.p.ir poor ground
{G101}.
Chock tor 100!6 PCM connectors.
ll nocessary, substituto a known-
good PCM and r6ch6ck.
Ftom page 14-72
PCM CONNECTOR A I32P}
Wi ro si de of t 6mal e t ermi nal s
14-73
(' 96
-
98 Models)
-
Lock-up Control System
NOTE: Record al l freeze data before vou troubl eshoot.
Possible Cause
Faulty Lock-up cont.ol system
NOTE: Do not cont i nue wi t h t hi s t roubl esnoonno
ot her DTCS have been correct ed.
unt i l t he causes of any
.
OBD ll Sc6n Tool indicatG Code
m7{0.
.
Self-diagnosis E indicator light
indicates Code 40.
Check tor Another Code:
Check whet her t he OBD l l scan
t ool or t he E i ndi cat o, l i ght
i ndi cat es anot her code.
Perf orm l he Troubl o3hooi i ng
Fl owchar t t or t he i ndi cat ed
Code(s). Recheck for cod. P07il0
lilol aftor iroubl3hooting.
Does t he OBD l l scan t ool or
t he E i ndi cat or l i ght i ndi cat e
anot her code?
Tast Line Pressure:
Measur e t he l i ne pr essur e ( see
page 14-119 and 14-120).
Repai r t ho hydreul i c ayst em a3
necessary
{3ee
page
14-119).
Repl ace t he Lock- up Cont r ol
Sol enoi d Val ve Assembl y and
R6check;
1. Bepl ace t he l ock up cont r ol
sol enoi d val ve Ay' B assembl y
(see page 14-105).
2. Turn t he i gni t aon swi t ch OFF
and reset the PCM by remov
i ng t he BACK UP
(7. 5
A) f use
i n t he underhood f use/ rel ay
box f or more t han 10 seconds,
3. Usi ng t he scan t ool , check t o
be sure t hat t he engi ne cool
ant t emper at ur e i s i n 176' F
(80'C)
and above.
4. Dr i ve t he vehi cl e at 55 mph
(88
km/ h) const ant l y f or more
t han one mi nut e.
5. Recheck f or code P0740
(40).
Does t he OBD l l scan t ool
i ndi cat e code P0740 {40)?
The systom k OK at this time.
l'.
14-74
-
Shift Control System
Possible Cause
Faulty shift control system
.
P0730.
.
Sel l - di agnosi s E i ndi cat or
light indicates Code
ill.
Check tor Another Coder
t o o l o r t h e E, i n d i c a t o r l i g h t
i ndi cat e anot her code.
Perl orm t hs Troubl eshool i ng
Fl owch. r t f or t he i ndi c. t . d
Code(sl. Recheck tor code m730
l4'l I atter troubleshooting.
Does t he oBD l l scan t ool or
t he E i ndi cat o' . t i ght i ndi
cat e anot her code?
Test lst, 2nd, 3rd and 4th Clutch
Pressure:
Measure t he 1st , 2nd, 3rd and 4t h
cl ut ch
pressure (see page 14119
t hr u 14- 121) .
Ropair the hydrlulic systom !s
necessary {see
page 14-1 19 and
11-1211.
l s each cl ut ch
pressure wi t hi n
t he servi ce l i mi t ?
Repl ace Shi f t Cont rol Sol enoi d
valve Assembly, Linear Solenoid
Assambly and Rechock:
1 . Re p l a c e t h e s h i f t c o n t r o l
sol enoi d val ve A' / B assembl y
(see page 14-106).
2. Repl ace t he l i near sol enoi d
assembl y l see
page 14 108).
and reset the PCM memory by
removi ng t he EACK UP
(7. 5
A)
t use i n t he under hood f use/
r el ay box f or mor e t han l 0
seconds,
4. Dr i ve t he vehi cl e at over 12
mph
(20
km/ h) i n 1st , 2nd, 3rd
and 4t h gear f or more t han 30
seconds at P1
position.
5. Recheck t or code P0730
(41).
Does t he OBD l l scan t ool or
t he Ed i ndi cat or t i ght i ndi
cat e code P0730 {41)?
The swt6m is OK et this time.
NOTE: Do not cont i nue wi t h t hi s t roubl eshoot i ng unt i l t he causes ot any
other DTCS have been corrected.
(' 96
-
98 Models)
-
E
Indicator Light Does Not Gome On
PCM CONNECTOR A I32PI
Tha
E
indicator light does nol
come on when the ignition swhch
is first turned ON
(lll.
{lt should
come on tol about two sconds.l
Chock the SeJvico Check Connec-
tor:
Make sure t he speci al t ool
(SCS
Seryice Conneclor) is not connect-
ed to the service check connector.
l s t he speci al t ool
(SCS
Servi ce
Connector) connected to the ser
vice check connector?
Disconnect the special tool trom
thc sarvice check connoctor and
rocheck.
Check th6
E
indicator Light:
Shift to lD.l oosition.
Check tor loose PCM connecto6.
ll nece3sary, sub.titute a known-
good
FCM and r.chock.
Check the Ground Circuit:
' 1.
2. Disconnecr the A {32P}connec-
tor lrom the PCM.
t he A9 t er mi nal and body
ground
and t he A22 t ermi nal
and body ground.
Repai r op6n i n t ho wi r gs
between tho A9 ot M2 tormi-
nal s and G101.
Rcpair poor glound
{G101).
To page 14-77
l.
14-76
From
page 14-76
BRN/BLK
BRN/BLK
'96:
BLU/RED
,97, '98:
GRN/BLK
Measure Powor Suppl y Ci l cui t
Voltage:
(l l ).
t e r mi n a l s A9 a n d A1 1 a n d
bet ween t er mi nal s A22 and
424.
RGpair opon or short in the wire
boiween the A11 andlot Ml lor'
mi nal s, t he PGM-Fl m. i n rel . Y,
end the tu36 box.
Mo.sure D4 IND Voltago:
2. Connect the A {32P} connector
to the PCM.
3. Connecl a di gi t al mul t i t est er
t o t he B13 and Ag or A22 t er-
mi nal s,
(ll)
and make sure that the voltage
is available for two seconds.
Chack t or opan i n t hc wi t a
bct woon t ha 813 l armi nal and
t h. gauge ar! . mbl y. l f wi . c i !
OK, chock for . frulty
E
indica-
tor light bulb or a l.uhy g.ug.
a.!.mbly printod circuit bolrd.
Chock for loose PCM connoctort.
Chock t ho A/ T gGat pol i t i on
switch. lI n6ca$sry, substitute a
known-good PCM and rochock.
PCM CONNECTOR A I32PI
14- 77
(' 96
-
98 Models)
Th6
E
indicstor light is on con-
st . nt l y {not bl i nki ngl whenevei
the ignition switch is ON lll).
Measure 04 IND Voltage:
2. Di sconnect t he B 125P) connec-
tor from the PCM.
(l l ).
t he 813 t er mi nal and body
ground,
Repair 3hort to pow. in the wiro
bet ween t he 813 t ermi nal end
thc gauge asiombly.
Meaiure ATP Dil Voltage:
2. Connect t he I
(25P)
connect or
t o t he PCM.
(ll).
4. Shi f t t o any
posi t i on
ot hert han
grou nd.
Check for a short to ground
on tho
wir6. It wire i3 OK, .eplac6 the A/T
goar po3ition indbator,
-
E
Indicator Light On Constantly
a
!
PCM CONNECTOR B
(25P)
l.
14- 7A
Troubleshooting
Flowchart
-
Brake Switch Signal
Symptom
Shift lever cannol b moved f.om
B
pGition with the brako
podrl
depr8sed.
PCM CONNECTORS
Check Brako Light Operation:
Deoress t he brake
pedal .
Rop.ir faulty braks switch cilcuit
lsos soction 231.
Are the brake lights ON?
Measure SToP SW Vohag:
2. Di sconnect t he A l 32P) and D
{ l 6P) connect or s f r om t ho
PCM.
3. Measure the voltage belween
t he D5 and A9 or A22 t ermi -
nal s wi t h t he br ake
Pedal
depressod.
Rap.i. opon in the wira bctn oen
t ha 05 t ermi nal and t ho bt rkc
lwitdr.
.
Brake switch 3ign.l is OK.
.
Ch6ck lor looao PCM oonnoctors.
It nocassary, aubctilute a known-
good PCM and rcheck.
.
Inspoct the brake switch circuit
{s6e section 231.
(' 99
-
00 Models)
-
Lock-up Control Solenoid Valve A
NOTE: Record all freeze data before vou troubleshoot.
Possible Cause
.
Di sconnoct ed l ock-uD cont rol
sol enoi d val ve A/ B al sembl y
connector
.
Short or opon in lock-up conkol
solenoid valv6 A wire
.
valva A
'
Open in VB SOL wire
FCM CONNECTORS
LGl IBRN/BLXI
LG2
(BRN/BLK)
LGl
(BRN/BLKI
LG2 IBRN/8LK)
To page 1+81
a \
.
OBD ll Scan Tool indic.t6 Code
P1753.
.
Sel f - di agnosi s
@
i ndi cat or
light blink3 once.
Check lor a Short to Power:
L Turn t he i gni t i on swi t ch OFF.
2. Di sconnect t he B
(25P)
and D
( 16P)
connect or s l r om t he
PCt\4.
(l l ).
t he Dl and 820 or 822 t ermi -
nat s.
Ropair short to
powcr
in the wire
bstwoon tho Dl tolminal and the
lock-up cor|lrol lolonoid valvo A.
Measu.e Lock-up Cont.ol Sole-
noid V.lvo A R63btanc6:
bet ween t he Dl and 820 or
822 t ermi nal s.
-
25 O?
Measure VB SOL Vohage:
(l l ).
t he D5 and 820 or 822 t ermi -
nal s.
Check f or bl own No. 15 17. 5 Al
fu3 in the undordash fuse/raby
box. l{ th tusa ii OK, r.pair opon
in the wira btwoen th 05 torfti-
nal and thc undr{ash fuso/rlay
box.
Check to.loose tarminalfit in the
PCM connecl oa3. l l necessary,
subst i l ut e a known-good PCM
and rocheck.
B
(25Pt
l l
D {16P1
B
(2sPt
l l
D {16P1
I t25Pt D
(16P1
l..
14-80
From page 14-80
Check lor continuity between the
820 t er mi nal and body gr ound,
and bet ween t he B22 t er mi nal
and body
ground.
Ropair opon in thc wircs betwe6n
the 820 lnd 822 tolminals .nd
ground
{G10l l , and t epai r
Pool
ground (G10'l).
Check Lock-up Cont.ol Solonoid
valve A for a Shon Cilcuit:
trom the lock-up control sole-
noid valve ry'B assembly.
2. Check for continuity betlven
t h6 D1 and 820 or 822 t ermi -
nal s.
R6p. i r 3hort t o gl ound i n t hc
wir. b.two.n the Dl torn|in.l
ard th. lock-up conttol iol.noid
valva A.
Maasuro Lock-up Control Sol.-
noid Vllve A Ro.istance at tho
Solanoid Conn6ctor:
the No. 2 terminal of the lock-up
control solenoid valve
y'y'B
assem-
bly connector and body
ground.
R6placo tho lock-up control solo_
noid valve A/B.$6mblY.
ls the resistance
'12
-
25 O?
Chack f or opon i n t ho wi r o
botweon the Dl t..minal and tho
lock-up control solenoid Yalva A.
PCM CONNECTOR B {25P}
I.G1
(BRN/BLKI
Wi re si de of l 6mal e t ermi nal s
PCM OONI{ECTORS
LOCK.UP CO TROL SOTINOID VALVE
A/B ASSEMBLY CON]TECTOR I2P}
]F]AL
r-f-
I
LC A {YEu
(o)
Y
I
B
(25p)
l l
o l 16P)
IBRN/BLK} LG2IBRN/BLK}
14-A1
(' 99
-
00 Models)
-
Lock-up Control Solenoid Valve B
NOTE| Record al l freeze data before
you
troubl eshoot.
Possibla Cause
.
Oi sconnect ed l ock-uD cont rol
sol enoi d vel ve A/ B assembl y
connector
.
Short or open in lock-up control
solenoid valv B wire
.
valve B
'
Open in VB SOL wire
rcM CONNECTORS
To page 14- 83
'
OBD ll Scan Tool indic.tes Code
P1758.
.
Sel f - di agnosi s
E
i ndi cat or
light blinks twice.
Chack for a Short to Power:
2. Di sconnect t he I
(25P)
and D
( 16P)
PCM.
3. l urn t he i gni t i on swi t ch ON
(l l ).
the D3 and 820 ot 822 tetmi-
nal s,
Repair short to power in the wire
between the D3 terminal and the
lock-up contlol solenoid valve B.
Measure Lock-up Cont rol Sol e-
noid Vdlve I R8i3tance:
bet ween t he D3 and 820 or
822 t ermi nal s.
-
25 O?
Measure VB SOL Voltago:
nal s.
Check f or bl own No. 15 {7. 5 Al
fus in the under-dash luse/reley
box. It the fuse is OK, repair open
in the wir6 between th6 DS termi
nal and the under-dash fuse/reby
oox,
Chock for loose te.minal fit in the
PCM connect ors. I t necessary,
subst i t ut e a known-good PCM
end recheck.
B t2sP) l l
D t15P)
I {2sPt l l
D
(16Pt
B
(25P1
D t16Pt
\
14-82
From
page 14-82
Check f or cont i nui t Y bet ween t he
820 t er mi nal and body
gr ound,
and bet ween t he 822 t er mi nal
and body
ground
Repair open in the wires between
t he 820 and 822 t ermi nal s and
ground
| G101),
and repai r
Pool
ground (G1011.
Check Lock-up Control Solenoid
Valve B lor a Short Cilcuit:
f rom t he l ock_uP cont rol sol e-
noi d vai ve A/ B assembl Y.
t he D3 and 820 or 822 t ermi
nal s.
Rep. i r short t o
ground i n l ho
wi re bet ween l he D3 t ermi nal
and the lock-up contlol solenoid
valve B.
Measure Lock-up Cont rol Sol 6'
noi d Val ve B Resi st ance at t he
Sol6noid Connctor:
t he No. 1 t ermi nal of t he l ock uP
control solenoid valve A'lB assem_
bl y connect or and body
ground-
Repl.ce the lock-up control 3olc
noid valve A/B a$emblY.
-
25 0?
Ch6ck { or open i n t he wi r e
between the D3 terminal dnd ihe
lock-up control solnoid valve B.
PCM CONNECTOR B
(25PI
LG1
(BRN/BLK)
2 3 5 1 6 I
l 0 1 1 / 1 5
LG2
o o
(BRN/BLKI
LOCK.UP CONTROL SOLENOID VALVE
A/B ASSEMBLY CONNECTOR
(2PI
t;TJ
l l t
z
! ] 4
LC B
(GRN/BLKI
I
t
(o)
Y
I
Termi nal si de of mal e t ermrnal s
B
(25P1
-
l l o
t16Pt
14-83
Electrical Troubleshooting (' gg -
00 Models)
Troubleshooting
Flowchart
-
A/T Gear
position
Switch
(Short)
troubl eshoot.
Po$ible Cause
'
Shor t i n A/ T go. r posi t i on
swhch wire
.
Faulty A/T goar position
switch
NOTE: Code P1705 (5)
t he PCM r ecei ved t wo
i s caused when
gear posi t i on
PCM CONNECTORS
LGl
(BRN/BLK)
LG2
(BRN/BLKI
Wi re si de of f emal et ermi nal s
B
{25P1 l l D
(16P1
.
OBD ll Scan Tool indicrtB Code
P1?05.
.
Sol t - di agno3i 3
E
i ndi cat or
light blink. tive times.
Observo t he A/ T Gear Posi t i on
Indicetori
1. Turn t he i gni t i on swi t ch ON f i t ).
2. Observe the lVT gear position
i ndi cat or, and shi f t each posi ,
! on separat el y.
Does any i ndi cat or st ay on
when t he shi f t l ever i s not i n
t hat posi t i on?
The sFtom is OK at thi3 time.
Check the wi.e harness for dam-
aga.
Do al l gear posi t i on
i ndi cat ors
go out?
Moasure ATP R Voltage:
ot hert han
E.
the DG and 82O o( 822 terfii-
nat s.
Check t or short i n t he wi re
batwoen tha DB terminal and the
A/T go.r porhion
switch or A/T
g6ar po3i t i on
i ndi cat or, and
chock f or opon i n t he wi res
between the B20 and B22 trmi-
n.ls and body ground (G10
. tf
wirc rro OK, chsck fo. loo3e tel-
ftinal fit in the FCM connectors. ll
noceisary, substiiute e known-
good
FCM and rcheck.
To page
14-85
\
14-84
From
page 14-84
Measule ATP NP Voltage:
1. Shi f t t o al l
pl
or E.
nal s.
Check f or ahot t i n l he wi re
bet ween t hs D13 t ormi nal 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 connoct or3. l f nocet 3. rY,
substitute . known-good PCM
and r6check.
Measure ATP D4 voh.g:
1. Shi ftto al l posi ti ons otherthan
E
the Dg and 820 or 822 termi-
nal s.
Ch. ck l or 3hor t i n t hs wi l o
betweon tho lxl termin.l and tho
A/T
ge.r pGhion switch. It wites
are OK. chock fo. looao trminal
fit in the PCM conn.ctoB. lf noc_
.*sary, sulFtitute a known-good
PCM .nd rechock.
Moa3ure ATP D3 Vohsge:
1. Shi f t t o al l
tr.
nal s.
Check t or 3hort i n t he wi t s
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 connctoG. lf nec_
a3$ry, 3ubatitute e known'good
PCM and r.check.
To page l 4' 86
PCM CONNECTORS
o t 16Pl B {25P)
LGl
(BRN/BLK)
g
t25P)
LGl
(BRN/8IJ()
LGl IBRN/BLK)
GRN)
D t16P)
IYEL)
2 3 1 1 1 5
l 6
8
1 1
2
t V- s -
10n\/ t7 / \
1 6
7 I 9 1 0 t 1 2
I
o zlzz
/l/1,/ 113
TI
L---{O--l
\=/
LG2{BRN/BLKI
,/t\_
\a t9
ATP NP
(LT
Wi rc si de o{ f emal e t erml nal s
3 115 8 l
l2
5
9 10 111/ t6l / 17
l s l t l a
1 12
20
)
W
Wl/l
'3111/ll
+
LG2
(BBN/BLKI
- < _
ATP D4
LG2
(BRN/BLK}
14-85
ElectricalTroubleshooting (' gg -
00 Models)
Troubleshooting
Flowchart
-
A/T Gear
position
Switch
(Short) (cont,dl
LGl (BRN/ BLK}
FCM CONNECTORS
B {25P)
D l 16Pl
1 2
[Ll
8 1 2 3 5
9 1 0 1/ 113/ 151/)11
7 8 9 t 0 1 12
,/ 20
ATP 2 {BLUI
Measule ATP 2 Vohage:
ot her t han
l
nal s,
Check f or short i n t he wi re
bet ween t he D14 t ermi nal and
the A/T gear position
switch or
A/ T ge. r posi t i on
i ndi cat or. I t
wires aae OK, check loa loose ter-
minal th in ths PCM connectors. ll
necessary, substitute a known-
good
FCM and recheck.
Ch6ck for loose terminal fit in the
PCM connoct ors. l f necessary,
and recheck.
\
14-86
Troubleshooting
Flowchart
-
A/T Gear Position Switch
(Open)
Po$ible Cause
.
Disconnectod A/T goar position
switch conngdor
.
Open i n A/ T gear posi t i on
switch wire
.
Fautty Aft
gear poshion switch
PCM CONNECTORS
Wi re si de of l emal et ermi nal s
D
(16P1
GRNI
B
( 25Pt
l l Dt l 6Pl
IARN/BLK)
LG2IBRN/BLKI
2 { 6
,|
2 3 5
I
't0
1 1 / t5l / 1 8 9 12
ATP NP
(LT
.
OBO ll Scan Tool indicatd Codc
P1706.
'
Ssl f - di agnosi s E
i ndi cat or
light blink3 six tim6.
Test the Ay'T gear position switch
(see section 23).
Moasure ATP R Volt.ge:
' 1.
(' l ).
2. Shift to E
position.
the D6 and 820 ot 822 termi'
nal s.
Repoir opon in the wire bitween
the D6 torminll and the A/T go.r
position switch.
Measuro ATP NP Volt ge:
1. Shi f t t o
E
or E
posi t i on.
2. Measlre the voltage between
nal s,
Ropair opn in thc wire betwoon
t he D13 t er mi nr l and t he A/ T
ge.r position switch.
LG1 {BBN/BLKI
I o page 14-88
(cont' d)
Electrical
Troubleshooting (' gg -
00 Models)
Troubleshooting
Flowchart
-
A/T Gear
position
Switch Open
{cont,d)
PCM CONNECTORS
B l2sPl D {16P)
1 2 4 1 5 6 I
9 10 11)./ t5l / 11 1 8 9 1 12
zo ztzzl
l//l hsr),41
f
]_c;l
j
r-cz tgaNlelxr
-
ATP D4
(YEL} LGl {BRN/BI.KI
I.G1
IERN/BLKI
B
(25P1
LGl IBRN/BLKI
D {16P}
From page 14-87
Moalure ATP 04 Vohago:
1. Shi f t t o
pl l posi t i on.
t he Dg and 820 or 822 t ermi
nal s.
Repair opon in the wire betweon
the lrg terminal and the A/T goat
poshion
switch.
Measure ATP D3 Vohage:
1. Shi f t t o
l &
posi t i on.
nat s.
Reprir opcn in the wirc b?twoen
the D8 terminrl and tho A/T goar
Dosition twitch.
Mersurc ATP 2 Voltage:
1. Shi f t t o
E
posi t i on.
t he Dl 4 and 820 or 822 t ermi -
nal s,
Reprir opon in the wire betweon
t ho Dl 4 t e. mi nal rnd t he A/ T
go.r position
switch.
Ch6ck tor loose terminal tit in the
PCM connect ors. l l necossery,
subsl i t ut e . known-good
pCM
and recheck.
LG2I BRN/ BLKI
I 2
5 l
l 6 l /
8
9 10 11)/
Itsln
7 8 9 12
ATP 2 IBLUI
t..
14- 88
Troubleshooting
Flowchart
-
Shift Control Solenoid Valve A
NOTE: Record al l Jreeze data before you troubl eshoot.
Possible Cru3.
'
Di sconnect od 3hi f t cont rol
sol onoi d val va A/ B a33embl Y
connactot
.
Short or opon in shift cont.ol
solonoid valvo A wits
.
Faul t y shi f t cont rol . ol enoi d
.
op.n in vB SOL wi.e
To page 14-90
PCM CONNECTOBS
LG1{BRN/ BLK}
LG2I BRN/ BLKI
LGl IBRN/BI-K)
LG2IBBN/BLK)
.
OBD ll Scan Tool indic.ts6 Code
Pot53.
.
Solt-diagno.is E
indicrtot light
blinks seven time6.
Chock tor a Short to Power:
2. Di sconnect t he
g
(25P)
and D
( 16P)
connecl or s f r om t he
PCM,
3. Turn the ignirion switch ON
(ll)
,1.
Measure the voltage between
nal s,
Rcpair short to
powet in the wile
bt^reen tho D7 termin.l .nd the
shift control aolonoid valve A.
Mee3ur. Shift Control Solonoid
Valve A Roaisttnce:
822 t ermi nal s.
-
25 O?
Me.3uro vB SOL Voh.ge:
(l l ).
nal s.
Check tor blown No. 15 17.5
A)
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.
Check for loose t6tminalfit in th
PCM connoct ors. I t necessary,
subst i t ut e e known-good PCM
and rechock.
I t25Pt l l
D {16P)
B rzsPt
o trQil
(cont ' d)
14- 89
Electrical Troubleshooting (' gg -
00 Models)
Troubleshooting
Flowchart
-
Shift Control
Solenoid Valve A
(cont,O)
LGl
(BRN/BLKI
rcM CONNECTORS
LGl {BBN/BLKI LG2 (BRN/BLKI
SHIFT CONTROL SO|'INOID VALVE
A/B ASSEMBLY CONNECTOR
I2PI
SH A {BLU/YELI
From page
14-89
Check l or cont i nui t y bet ween t he
820 t ermi nal and body ground,
and body ground.
Repai r open i n i he wi r es
between th 820 and 822 termi-
n a l s e n d g r o u n d
{ G1 0 l l . a n d
repa, r poor ground
{G101}.
Check Shi t t Cont rol Sol enoi d
Valve B for a Short Circuit:
f rom t he shi l t cont rol sol enoi d
valve A,/B assembly.
t he D7 and 820 or 822 t ermi ,
nal s.
Rpair short to ground
in the wiie
bartwen the D7 te.minal and the
shift control solonoid valve A.
Meesuro Shift Control Solenoid
Valve A RGistance at the Solenoid
Connector:
t he No. 1 t er mi nal of t he shi f t
cont r o I sol enoi d val ve A/ B
assembt y connect or and body
grounct ,
Repl.ce tho shift control solenoid
valve A/B rssmblv.
Check f or open i n t he wi r e
between the D7 termindl and the
shift control 3olonoid valve A.
B t 25Pt
l l D t 16Pt
\
14-90
Troubleshooting
Flowchart
-
Shift ControtSolenoid
Valve B
Possiblg Cause
.
Di sconnect gd i hi l t cont rol
solenoid valve A/B conneciot
r
Short or oDen in shift conlrol
3olgnoid vrlve B wito
.
Faul t y 3hi f t cont rol sol enoi d
velve B
.
Opn in VB SOL wire
rcM CONNECTORS
LGl IBRN/BLKI
LG2IBRN/BLK)
Wire side of {emale terminals
LGi
(BRi|/BLKI LG2 IBRN/8LK)
To page 14-92
(cont ' d)
14- 91
.
OBD ll Scan Tool indic.l6 Code
P0758.
'
Self-diagnosb El
indicator light
blinks eighl tim6.
Check tor a Shortto Power:
(25P)
and D
( 1 6 P) c o n n e c t o r s f r o m t h e
PCM.
(l l i .
nal s,
Repaft 3hon to
Powor
in the wir
btirvoon the D2 termin.l and the
3hift control solenoid valve B.
Masure Shift Control Solenoid
Valve B R6isttnce:
822 t ermi nal s.
-
25 O?
Me.sure VB SOL Vohage:
(l l ).
t he D5 and 820 or 822 t ermi '
nars.
Check l ol bl own 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 ter-
minal and the under'dash fus/
relav box.
Check for loo3e terminal fit in the
PCM connect ol s. l f necossarY,
subst i t ut e a known_good PCM
and rocheck,
B
(25Pt
-
I l D
{16P)
B {25P1
D
(t6Pl
Electrical Troubleshoot:ng (' gg -
00 Models)
Troubleshooting
Flowchart
-
Shift Control Solenoid Valve B
(cont,dl
LGl
(BRN/BLK)
IBRN/BLKI LG2IBRN/BLK)
Wi re si d ot f emal e t ermi nal s
FCM CONNECTORS
SHIFT @NTROL SOENOID VALVE
A/A ASSEMBLY CONNECTOR (2PI
. - _
1 ) 2
- . T -
I
sn e tcanlwxrt
(o
Y
I
Termi nal si de oI mal e termi nal s
820 t er mi nal and body gr ound,
and body ground.
Ropai r opan i n t he wi r gs
b.twocn the 820 rnd 822 te.mi,
n. l s and gr ound
l G10t ) , and
..p.ir poor ground
lG10t).
Check Shi f t Cont rol Sol . noi d
Vrlve B tor a Short Ci.cuit:
from the shift control solenoid
valve A/B assembly.
nal s.
Repair 3hort 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
Connc,toa:
Messure the rsistance belween
t he No. 2 t er mi nal of t he 6hi f t
cont r ol sol enoi d val ve A/ B
assembl y connect or and body
ground.
R.pl.co th. 3hift control lolenoid
v!lv. A/8.lsombly.
-
25 O?
Chack f or open i n t he wi . e
betwoon th D2 termin.l and the
3hift control lolanoid valv6 8.
B
( 25P1
-
l l Dt
From page' 14-91
SH B
(GRN/WHTI
\
14-92
Troubleshooting
Flowchart
-
Countershaft
Speed Sensor
NOTE: Record all freeze data before
you troubleshoot
Po$iblo Cause
.
Loos or f sul t y connecl i on
between the PCM and vehicle
hainoss
'
Di sconnect od count ersh. f t
spoed senaof connoctor
.
Short or opgn in counteBhaft
3Deed aensor wire
.
Faulty counloEhaft 3ped sen'
soa
COUNTERSHAFf
SPEED
SENSOR
CONNESTOR
Termi nal si de oI mal e t ermi nal s
FCM CONNECTOR
D I16PI
rconl c
1+93
NC IBLUI
.
OBD ll Scan Tool indicat6 Code
PO720.
.
Self-diagnosis E
indicator light
blinks nin6times.
Check t he count er shaf t sPeed
sensor i nst al l at i on, and check i t
l or damage.
ls the countershaft speed sensor
i nst al l ed
properl y, and not dam-
aged?
Reinstall or replace and rechock.
Measurg Counl ershat t SPeed
Sgn3ol R6istance at tho Son3ol
Connector:
f rom t he count ershaf t sPeed
sensor.
2, Measuro count ershaf t sPeed
sensor resistanca at the sensor
connector.
-
600 O?
Chcck CounteEh.tt SPeed Sen'
sor lor a Short Circuit:
1. Di sconnect t he D { 16P) con
nector trom the PCM.
body
ground and t he D10 t er_
mi nal and D16 t ermi nal i ndi -
vi d! al l y.
R6oai. short in tl| wi.6a bstwan
t he D10 and D16 t . rmi nal i end
tho countdthatt rPod senaor.
To page 14 94
Electrical Troubleshooting (' gg
-
00 Modelsl
From page
14-93
Measure Count eJahaf t Speed
Sensor Circuit tor an Open:
1. Connect t he count er shal t
speed sensor connect or,
bet ween t he Dl 0 and D16 t er
mt nat s.
Roptir loo. t6.minal or opan in
th6 wir! betwon lho D10 lnd
D16 t . rmi na13 and t he count . r-
shatt apaad aaNor.
-
600 O?
Check for loose t.rminal frt in the
PCM connect ors. I t necal sary,
3ubst i t ut e a known-good PCM
and recheck.
-
Countershaft Speed Sensor
(cont,d)
PCM CONNECTOR D I16PI
\
14-94
Troubleshooting
Flowchart
-
you troubl eshoot.
Possible Causg
.
Diaconncted mainshaft spoed
sen3or connector
' Shor t
or open i n mai nshaf t
sDeed sen3or wile
.
Faulty main3halt speed sensor
NOTE: Code P0715
(15)
on t he PCM doesn' t
al ways mean t here' s an el ect rrcal
probl em i n
t he mai nshaf t or count ershaf t speed sensor
ci rcui t ; code P0715 {15) may al so i ndi cat e a
mechani cal
probl em i n t he t ransmi ssj on Any
pr obl em causi ng i r r egul ar count er shaf t t o
mai nshal t speed di f f erence can cause t hl s
code.
l l l
, .
.TT
( o l
- i - l
t l
si de oI mal e termi nal s
MAINSI{AFT SPEED
SENSOR CONNECTOR
Termi nal
PCM CONNECTOR D
(16P)
NMSG
(WHT)
(cont' d)
14- 95
.
m715.
.
Sell-diagno3is E
indicator indi-
cates Code 15.
Check t he mai nshaf t and count er-
shat t speed sensors i nst al l at i on,
and check t hem f or damage.
Are the mainshaft and countershaft
speed sensor installed
properly,
and not damaged?
Rsinalall or replace and rocheck.
Mea3u. e Mei nshal t SPeod
Sensor Residance al the Sen3or
Connector:
f r om t he mai nshaf t sPeed
sensor.
2, Nreasure mainshaft speed sen_
sor resi st ance at t he sensor
connector.
-
600 O?
Check Mainshaft Sp.ed Sen3o.
for a Short Circult:
1. Di sconnect t he D
(16P)
con-
nect or t rom t he PCM.
body
ground and t he D11 t er'
mi nal and D12 t er mi nal i ndi
vi dual l y.
Bopair 3hort in the wiros btwen
t he 011 and D12 t ermi n. l s rnd
th main3hett spd aensoa.
To page 14 96
(' gg
-
00 Models)
-
(cont,dl
PCM CONNECTOR D {16PI
2 3 /)
6 1 8
rghrll
[e]
NM IREDI
(
I
NMSG {WHTI
(REDI
MAINSHAFT SPEED
SENSOR OONNECTOR RED
NMSG IWHTI
From page l 4-95
Measur e Mai nshat t Speed
Sensor Resistance:
1. Connect t he mai nshaf t speed
sensor connect or.
2. Measure t he resi st ance bet -
ween t he Dl 1 and D12 t ermi -
nat s.
Run the Electricel Troublshooting
Flowchart lor cod6 m?m l9).
Chck lor loo.o te.minol fit in th6
PCM connect ors. l f necossary,
subst i t ut e r known-good PCM
end .echeck.
-
600 0?
Check NM Wire Continuity:
from the mainshaft speed sen-
sor.
t he D11 t ermi nal and t he No. 2
t er mi nal ot t he mai nshaf t
speed sensor connect or,
Ropair opon in the wiro lratwoen
t ho Dl l t srmi nal and t ha mai n-
3hatt sped sensor.
Check NMSG Wire Continuity:
Dl 2 t ermi nal and t he No. 1 t ermi -
nal of t he mai nshaf t spoed sen-
Repai. open in the wire betwoen
t he D12 t ermi nal and t he mei n-
shaft 3peod sansor.
Check Ior loose terminal fit in the
PCM connect ors. l f necesaary.
and recheck.
1 2 3 5
6 7 8
t 1v
NM
o
6 1 7 8 9 l l 12
I
o
t1v
WHT
1
\
14-96
-
Linear Solenoid
you
troubleshoot.
Poitibl. Cau3.
.
Di sconnact ed l i noaJ t ol anoi d
connaclol
.
Shorl or opon in linolr solonoid
.
Flulty linoar 3olenoid
.
ODon in VB SOL wit.
.
ODen in PG lino
PCftI @NNECTORS
Wire side ol female terminals
PCM OONNECTOR B I25PI
LGT
(BNN/BLKI
LG2 {BBN/BLKI
Wir6 side of Iemale terminals
LINEAF SOITNOID OONNECTOR
Flr-11
=T=T
o l
Y I
L_l
Termi nal si de of mal t ermanal s
(cont' d)
B t25Pl D {16P1
.
OBD ll Scln Tool indic.t.t Codo
P1768.
.
Self-diagnosis E
indicltol indi-
cat6 Cods 16.
Moasur. VB SOL Voltago:
2. Di sconnect t he B {25P) and D
( 16P) connect or s f r om t he
PCM.
(lll.
nal s.
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.
Ch.ck th. Ground Circuit:
2. Check lor continuity betwoen
t he t ermi nal s 82 and 822 and
bet ween t er mi nal s 810 and
820.
Rapair opal| in tfr wi|! batlwao
th. tcrrnln.l. 82, B10, B:20. .nd
BZI .id Gt01. R.p.ir
poor ground
t G10rl .
M. ! sure Li nea. Sol enoi d
Rcai 3t ancc rt t ha Sol anoi d
Conn6ctor:
1. Di sconnect t he l i nearsol enoi d
connectol,
2. Measure the resistance of the
l i near sol enoi d.
ls the resistance approx. 5 O?
To page 14-98
1+97
(' 99
-
00 Modelsl
-
Linear Solenoid
(cont'dl
Check Li nea. Sol enoi d t or a
Short Ci.cuit:
body ground and t he 88 t ermi nal
and B17 t ermi nal i ndi vi dual l y.
From page 14 97
Repair shon in the wir6 between
th 88 and 817 terminals and the
linar solenoid,
Measur e Li near Sol enoi d
Resistance:
1. Connect t he l i near sol enoi d
connect or,
2. Meas u r e t he r esi st ance
bet ween t he Bg and 817 t er
mt nal s,
Repair loose te.minal or open in
the wire botwoen the 88 .nd Bl7
t.rmin.b end the linoar 3olenoid.
Check for loose terminal tit in the
PCM connct ors, l f necessary,
subst i t ut 6 a known-good PCM
and recheck.
LSAM (WHTI
14- 98
-
Lock-up Control System
Possibl Cause
Faulty Lock-up control sy3tem
NOTE: Do not cont i nue wi t h t hi s t roubl eshoot i ng
other DTCS have been corrected.
unt i l t he causes of any
m14/J.
Slf-diagnosis .D4l indicalor light
indicates Code 40.
Check for Another Code:
t o o l o r t h e : E i n d i c a t o r l i g h t
i ndi cat es anot her code,
Per f or m t he Tr oubl eshoot i ng
Fl owchar t t or t he i ndi cat ed
Codels|. Rocheck to. code P0740
(40)
.fter troublBhooting.
ooes t he OBD l l scan t ool or
rhe E i ndi cat or l i ght i ndi cat e
anot her code?
Test Line Pressure:
Measur e t he l i ne pr essur e ( see
page 14 119 and 14- 120) .
Repai r t he hydrrul i c sy3t em as
n6c6ssary
(see page 14-1191.
l s t he l ane pressure wi t hi n t he
servi ce l i mi t ?
Repl ace t he Lock- up Cont r ol
Sol enoi d Val ve Assembl y and
Recheck:
1. Repl ace t he l ock- up cont r ol
sol enoi d val ve A/ B assembl y
(see page 14-105).
and reset the PCM by remov
i ng t he EACK UP
(7. 5
A) f use
i n t he underhood {use/ rel ay
box f or more t han 10 seconds.
3. Usi ng t he scan t ool , check t o
be sure t hat t he engi ne cool -
ant t emper at ur e i s i n 176' F
(80'C)
and above.
4. Dr i ve t he vehi cl e at 55 mph
(88
km/ h) const ant l y f or more
t han one mi nut e,
5. Recheck f or code P0740 {40).
Does t he OBD l l scan t ool
i ndi cat e code P0740
(40)?
The svstem i3 OK .t this time.
14- 99
(' 99
-
00 Modelsl
-
you
troubl eshoot.
Po33ibl. Crus6
Frulty 3hift control ryrtom
.
OBD ll Scan Tool indicrtd Code
m730.
.
Sel f - di r gnosi s E i ndi cat or
light indicst. Codo 41.
Check for Anoth. Code:
t ool or t he E i ndi cat or l i ght
i ndi cat e anot her code.
Prrf orm t ho Troubl c! hoot i ng
Fl owch. rt f or t h. i ndi crt . d
Cod.l3l. R.ch.ck tor cod. m730
141| .tt r troubldhootlng.
Doest he OBD l l scan t ool or
t he E i ndi cat or l i ght i ndi -
cate another code?
Test 13t, 2nd, 3rd .nd 4th Clutch
Prglture:
Measure t he 1st , 2nd, 3rd and 4t h
cl ut ch pressure (see page 14-119
t hr u 14 121) .
R.prir tho hydrlulic ayrtam aa
n.c.3t..y lr.o
p!9. lil-119 rnd
1+1211.
ls each clutch pressure
within
t he servi ce l i mi t ?
Roplace Shift Control Solenoid
Valve Asembly. Linoar Sol.noid
Assembly .nd Recheck:
1. Repl ace t he shi f t cont r ol
sol enoi d val ve A/ B assembl y
(see page 14-106).
2. Repl ace t he l i near sol enoi d
assembl y {see
page
14-108}.
and reset the PCM memory by
removing the BACK UP
(7.5
A)
f use i n t he under-hood f use/
r el ay box f or mor e t han 10
seconds,
4. Dr i ve t he vehi cl e at over 12
mph
(20
kn/h) in 1st, 2nd, 3rd
and 4th gear lo. more than 30
seconds at lPll position.
5. Recheck f or code P0730 (41).
Doest he OBD I l scan t ool or
t he E ; ndi cat or l i ght i ndi -
cat e code P0730
(41)?
Th. sFtcm b OK .t this time.
NOTE: Do not cont i nue wi t h t hi s l roubl eshoot i ng unt i l t he causes ot any
other OTCS have beon corrected.
I
14- 100
-
El
PCM CONNECTOR A I32P)
Wi re si de of l emal e t errnanal s
PCM CONNECTOR D {16P)
ATP D'
2 5
6 1 e
11(
12
t {
I r o
(YELI
The Dll indicator lighi is on con-
st ant l y {not bl i nki ng) whenever
the ignition switch is ON
(lll.
Moasure D4 IND Voltage:
2. Di sconnect t he A { 32P} con-
nect or f rom t he PCM.
(l l ).
t h e A1 4 t e r mi n a l a n d b o d y
ground.
Repsir short to
power in the wire
bet ween t he A14 t ormi nal and
the gauge assembly.
Measure ATP D4 Voltagel
2. Connect t he A
(32P)
connec
t or t o t he PCM.
(l l ).
4. Shi t t t o any
posi t i on ot her
tha n
[ql.
t h e D9 t e r mi n a l a n d b o d y
ground.
Test the A/T gear position switch
( see
sect i on 23) .
Check I or a short t o ground i n
the wire betweon the D9 termi-
nal and A/T gear position switch.
It wire is OK, substitute a known-
(' 99
-
00 Models)
-
E
Indicator Light Does Not Come On
FCM CONNECTOR B
(25P}
LGl {8RN/ALKI
{BRN/ 8LK}
LGl IBNN/BLK} LG2 {BRN/BLK)
i 2 t 5 6 q
9 10 t7
LG2
o) (o
The
Pll
indicator light does not
come on when t he i gni t i on
switch is fi.st turned ON
(ll).
llt
shoul d come on f or about t wo
seconda.l
Check t he Servi ce Check Con-
nector:
(SCS
Service Connector) is not connect-
ed to the service check connector?
l s t he speci al t ool {SCS Servi ce
Connect or) i s not connect ed t o
t he seNi ce check connect or.
Disconnect the special tool from
the service check connector and
r6check.
Check the Dll lndicator Lighti
Shi f t t o
d
posi t i on.
Check for loose terminal fit in the
PCM connect o13. I t necessary.
sub3t i t ut e a known-good PCM
and recheck.
Does t he
@
i ndi cat or l i ght
come on?
( 25P)
con-
nector from the PCM.
ground, and bet ween t he 822
Repai r open i n t he wi r es
between the B20 rnd 822 termi-
n a l s a n d g r o u n d ( G1 0 1 ) ,
a n d
rep.ir poor ground (G1011.
Measure Power Suppl y Ci rcui t
Voltage:
1. Turn t he i gni t i on swi t ch ON {l l }.
t er mi nal s B1 and 822 and
bet ween t er mi nal s Bg and
820.
Repair open or short in the wi.o
between th6 81 and/or 89 termi-
nal s and t he PGM-FI mai n rel av,
and bet ween t h PGM-FI mai n
rl ey rnd t he under-hood t us/
relay box.
To page
14' ' 103
14-102
From page 14-102
Measu.e D4 IND Voltago:
2. Connect t he B
(2SPi connect or
t o t he PCM.
3. Connect a di gi t al mul t i met er
t o t he A14 and 820 or 822 t er-
(l l ),
and make sure t hat vol t age i s
avai l abl e f or t wo seconds.
Chock f or ooon i n t ho wi t e
bet ween t he A' t 4 t srmi nal . nd
t he gauge. 3s. mbl y. l l wi t e i 3
OK, chock to. a t.ulty indicator
l i g h t b u l b o r . f e u l t y g a u g c
e336mbly
p.inted
circuit board.
Check D4 IND lor a Short Citcuit:
Check lor continuity between the
A14 t ermi nal and body ground.
Rop.ir short in thc wirg btwoen
th. Al4 tormin.l .nd tho gaugo
a$ombl y. l l wi ro i s OK. chock
tho
gsugo a3rambly.
Check fo. loose terminal tit in thc
PCM connectoB. Chock the A/T
gear posi t i on swi t ch. I t ncce3-
sary, subst i t ut e a known-good
PCM and rechock.
PCM CONNECTORS
14- 103
El ectri cal Troubl eshooti ng
(' 99
-
00 Model sl
-
Brake Switch Signal
PCM CONNECTORS
Shift lever cannot be moved trom
E
position with tho b.ake pedal
depressod.
Check Brake Light Operation:
Depress t he brake
pedal .
Repair t ulty brake switch circuit
{see sction 23}.
Are t he brake l l ght s ON?
Mea3ure STOP SW Vohage:
(32P)
and B
{ 25P} connect or s f r om t he
PCM,
t he A32 and 820 or 822 t ermi -
n a l s wi t h t h e b r a k e p e d a l
depressed.
Repair open in the wire betwsen
t he A32 t ermi nal rnd t ho brrk6
switch.
.
Brak switch sign.l is OK.
.
Check for loose terminal fil in
lhe PCM connctors. lf neces-
sary. substitute a known-good
PICM and recheck.
.
InsDect the breke 3witch circuit
lsee section 231.
B {25P)
\
14-104
Lock-up Gontrol Solenoid Valve A/B Assembly
Test
' 1,
Di sconnect the 2P connector from the
trol sol enoi d val ve 1y' 8 assembl y.
TERMINAL SIOE OF
MALE TERMINALS
tocK-up con-
LOCK.UP CONTROL
SOLENOID VALVE A/B
ASSEMBLY
Measure the resistance between the No. 2 terminal
(sol enoi d
val ve A) of the l ock-up control sol enoi d
val ve connector and body
ground, and between the
No. 1 termi nal
(sol enoi d
val ve Bl and body
ground.
STANDARD: 12
-
25 O
Repl ace the l ock-up control sol enoi d val ve assem-
bly if the resistance is out of specification.
l f the resi stance i s wi thi n the standard, connect the
No. 1 termi nal of the l ock-up control sol enoi d val ve
connector to the battery
positive terminal. A clicking
sound shoul d be heard. Connsct the No. 2 termi nal to
the battery
positive
terminal. A clicking sound should
be heard. Replace the lock-up control solenoid valve
assembl y i f no cl i cki ng sound i s heard.
Replacement
NOTE: Lock-up control sol enoi d val ves A and I must bs
removed/replaced as an assembly.
1. Remove t he mount i ng bol t s and l ock- up cont r ol
sol enoi d val ve Ay' B assembl v.
6 r 1. 0 mm
12 N. m
( 1. 2
kgf . m, 8. 7 l bl . f t l
/:'-
Cl ean t he mount i ng surf ace
and fluid psssages.
Cl ean the mounti ng surface and fl ui d
passages of
th6 l ock-up control sol enoi d val ve assembl y, and
instsll a new lock-up control solnoid valve Ay'B with
a new filtsr/gaskt.
Check the connector for rust, dirt or oil, and racon-
nect it securely.
1+105
Shift Control Solenoid Valve A/B Assembly
Test
1. Di sconnect the 2P connector from the shi ft control
sol enoi d val ve A,/B assembl v.
SHIFT CONTROL
SOLENOID VALVE A/B
ASSEMBLY
N4easure the resi stance between the No. 1 termi nal
(sol enoi d
val ve A) of the shi ft control sol enoi d val ve
connector and body ground, and between the No. 2
termi nal
(sol enoi d
val ve B) and body ground.
STANDARD: 12
-
25 O
Repl ace the shi ft control sol enoi d val ve assembl y i f
the resi stance i s out of speci fi cati on,
l f the resi stance i s wi thi n the standard, connect the
No. 1 te.mi nal of the shi ft control sol enoi d val ve
connector to the battery posi ti ve termi nal . A cl i cki ng
sound shoul d be heard. Connect the No. 2 termi nal
to the battery posi ti ve termi nal . A cl i cki ng sound
shoul d be heard. Repl ace the shi ft control sol enoi d
val ve assembl y i f no cl i cki ng sound i s heard.
14-106
Repl acement
NOTE: Shi ft control sol enoi d val ves A and B must be
removed/repl aced as an assembl y.
1. Remove the mounti ng bol ts and shi ft control sol enoi d
valve A,/B assembly.
5 x L 0 mm
12 N. m
(1. 2
kgf . m, 8. 7 l bf . f t )
CONNECTOR BRACKET
FILTER/GASKET
Bepl ace.
Cl ean t he mount i ng surf ace
and f l ui d passages.
Cl ean the mounti ng surface and fl ui d passages of
t he shi f t cont r ol sol enoi d val ve assembl y, and
i nstal l a new shi ft control sol enoi d val ve Ay' B wi th a
new fi l ter/gasket and the cl amp bracket.
Check the connector for rust. di rt or oi l . and recon-
nect it securelv,
Linear Solenoid Assembly
Test
1. Di sconnect the l i near sol enoi d connector.
LI NEAR SOLENOI D
4.
Measure the resi stance between the No. 1 and the
No. 2 termi nal s of the l i near sol enoi d connector.
STANDARD: applox. 5 O
l f the resi stance i s out of speci fi cati on, repl ace the
l i near sol enoi d assembl y.
Connect the No. 2 termi nal of the l i nsar sol enoi d con-
nector to the batterv
positive
terminal and connect
the No. 1 termi nal to the battery negati ve termi nal A
cl i cki ng sound shoul d be heard.
l f not, remove the l i near sol enoi d assembl y.
Check that the l i near sol enoi d fl ui d passage Ior dust
or di rt.
Connect t he No. 2 t er mi nal of t he l i near sol enoi d
connector to the battery posi ti ve termi nal and con-
nect the No, 1 termi nal to the battery negati ve terma-
nal . Check that the val ve moves.
Di sconnect one of the battery termi nal s and check
that the val ve rel eases.
NOTE: You can see the val ve movement through
the fl ui d
passage i n the mounti ng surface of the l i n-
ear sol enoi d assembl y.
LINEAR SOLENOID
VALVE
l f the val ve bi nds, or moves sl uggi shl y, or the l i near
sol enoi d does not operate, repl ace the l i near sol enoi d
assembly.
1.
14-107
Mai nshaft/Cou ntershaft
Li near Sol enoi d Assembl y Speed Sensors
Repl acement
1. Remove the mounti ng bol ts and the l i near sol enoi d
assemory.
Cl ean the mounti ng surface
and fl u i d passages.
6 x 1 . 0 mm
12 N. m 11. 2 kgl m,
8.7 tbf.ftl
@
@
GASKET
Cl ean the mounti ng surface and fl ui d passage
of the
l i near sol enoi d assembl y and transmi ssi on housi ng.
Instal l a new l i near sol enoi d assembl y wi th a new
gasl(et.
NOTE; Do not pi nch the gasket when i nstal l i ng the
l i near sol enoi d; make sure that the gasket
i s i nstal l ed
properl y i n the mounti ng groove of the l i near sol e-
noi d.
Check the l i near sol enoi d connector for rust, di rt or
oi l , and connect i t securel y,
LINEAR
SOLENOID
ASSEMELY
I
14-108
Replacement
' t.
6 x
12
8.7
Remove the 6 mm bol t and the countershaft speed
sensor from the ri ght si de cover.
COUNTERSI{AFT
SPEED SENSOR
O. RI NG
Repl ace.
MAINSHAFT
SPEED
SENSOR
MAINSHAFT SPEED
SENSOB WAS}IER
(D16Y7
engi nel
6 x 1 . 0 mm
12 N. m
(1. 2
kgf m,
8.7 tbf.ft)
1. 0 mm
N. m
(1. 2
kgf . m,
rbf ft)
\
\
\ / ,
%/ E: )
Remove the 6 mm bol t and the mai nshaft sDeed
sensor from the transmi ssi on housi no.
Repl ace the O-ri ng wi th a new one before i nstal l i ng
the countershaft speed sensor or th mainshaft speed
sensor.
NOTE: Instal l the mai nshaft speed sensor washer on
the mai nshaft speed sensor. The mai nshaft speed
sensor washer i s used on model s wi th the D' | 6Y7
engi ne.
Chart
Hydraulic System
SYMPTOM
Check t hese i t ems on t he Check l hese l ems on
PROBABLE CAUSE Li st t he NOTES LI st
Engi ne runs, but vehi cl e does not move i n any gear. 1 . 2 , 3 , 5 , 6 , 7 . 3 6 , 3 8 K, L , R, S
Vehi cl e moves i n
E, E,
but not i n
l rl ,
pr-,
posi t i on. 6, 8, 9, 10, 30, 54 c , M, o
Vehi cl e moves i n
Dl , E, El ,l ut
not i n
E
posi ti on. 6 , 1 1 , 1 2 . 2 4
C , L
Vehi cl e moves i n
-o1] , @, @,
Uut not i n
E
posi t i on. 4, 6, 14, 15 c , L , o
Vehi cl e moves i n E
posi t i on. 10, 12, 13, 14, 16, 29, 33, 34, 35 C, D
Excessi ve i dl e vi brat i on.
1. 2, 19, 32, 36, 45, 41, 4a
Poor accel erat i on; f l ares on st art i ng ot f i n
E, [ Dl ]
posi t i on
St al l rpm hi qh i n ! ! 1,
p! 1,
E
posi t i on. 1 , 2 , 3 , 6 , 3 4 , 4 1 K , L , R
st al l rom hi oh i n D. r, l D, l oosi t i on.
6. 8. 10 C , D
5t "[ rprn rsn ^ a"t "t -at 6 , 1 2
C, D
1 4
N
11 , 32. 45, 41 , 48
No shi f t
19, 20, 40, 48, 49 G , L
Fai l s t o shi f t i n
81,
pl l posi t i on; f rom l st t o 3rd
gear 22, 49
Fai l s t o shi f t i n 03, D.
oosi t i on; f r om l st t o4t h
qear 22. 23, 48
Errat i c upshi f t i ng.
1' 2 upshi f t , 2-3 upshi f t , 3-4 upshi f t
1-2 upshi f t
3' 4 upshi f t
58
21, 48
22, t 9
23, l a
Harsh upshi f t {1 2).
12, 19, 20, 29. 50, 51, 57. 54
Harsh upshi f t
(2' 3). 13, 19, 20, 24, 27
,
29, 50. 51 , 51 , 58 C , D , E , H , L
Har sh upshi f t
( 3' 4) . 14, 19, 20, 25, 28, 29. 50, 51 , 51 , I C, D, E, I , L
Harsh downshi f t
(2-1) 19, 20. 24, 43, 54, 57 , 58 o
Harsh downshi f t
(3-2). 12, 19, 20, 25, 43, 55, 57, 5A C , D , E , H
Harsh downshi f t
(4-3). 13, 19, 20, 26, 43, 56, 57, 58 C, D, E, I
Fl ares on 2-3 upshi f t .
13, 19, 20, 24. 21, 51
F I
Fl ares on 3-4 upshi f t .
14, 19 . 20, 25. 24, 51 E , L , N
Excessi ve shock on 2-3 uPshi f t .
13. 19, 20, 24, 27 .
43. 50. 51 , 58 E , L , N
Excessi ve shock on 3-4 uPshi f t .
14, 19, 20, 25. 2A, 8, 50, 51 , 58 E , L , N
Lat e shi f t f rom El
posi t i on t o Lq! or &l
posi t i on. 10, 30
Lat e shi f t f rom E
posi t i on t o E
posi t i on. 4, 14, 21, 53 o
Noi se f rom t ransmi ssi on i n al l shi f t l ever
posi t i ons 2 , 3 1
K, L , O
Vehi cl e does not accel et at e mor e t han 31 mph { 50 km/ h) 1 7
shi f t l ever does not oper at e smoot hl y.
6, 39
P
Fai l s t o shi f t ; st uck i n 4t h gear . 19, 48, 49
Transmi ssi on wi l l not shi f t i nt o park i n
[ a]
posi t i on 6, 18, 39
St al l r pm hi gh; al l cl ut ch pr essur es ar e i n speci f i cat i on. 41
D , K , O
Lock up cl ut ch does not di sengage.
19, 44, 45, 46. 41, 50, 51. 54
Lock up cl ut ch does not operat e smoot hl y.
19, 41, 44, 45, 46, 47, 50, 51, 58 L
Lock-up cl ut ch does not engage.
19, 41, 4t , 15, 46, 41
, 50,
51, 57, 58
F I
Vi brat i on i n al l posi t i ons
(cont ' d)
The fol l owi ng symptoms can be caused
by i mproper repai r or assembl y
Check these i tems,on th^
l tems on the
PROBABLE CAUSE DUE TO
NOTES Li st
IMPROPER REPAIR Li st
Vehi cl e creeps i n
N
posi ti on. R1, R2
Vehi cl e does not move i n
&l
or Pl l
posi ti on.
R4
Transmi ssi on l ocks up i n
E
posi ti on. R3, R11
Excessi ve drag i n transmi ssi on.
R6
K, R
Excessi ve vi brati on, rpm rel ated.
R7
Noi se wi th wheel s movi ng onl Y.
R5
Mai n seal pops out.
R8
Vari ous shi fti ng
probl ems.
R9, Rl O
PROBABLE CAUSE DUE TO IMPROPER REPAIR
l mproper cl utch cl earance.
l mproper
gear cl earance.
Park l ever i nstal l ed upsi de down.
one-way {sprag) cl utch i nstal l ed upsi de down.
Reverse sel ector hub i nstal l ed upsi de down.
ATF pump bi ndi ng.
Torque converter not ful l y seated i n ATF
pump.
Mai n seal i mproperl y i nstal l ed.
Spri ngs i mproperl y i nstal l ed.
Val ves i mproperl y i nstal l ed.
Shi ft fork bol t not i nstal l ed.
14- 11
Chart
Hydraulic System
(cont'dl
G.
n,
set i dl e rpm i n gear to speci fi ed i dl e speed. l f sti l l no good,
adj ust motor mounts as outl i ned i n engi ne
secti on of thi s manual .
l f the cl utch pack i s sei zed or i s excessi vel y worn. i nspect the other cl utches for wear, and check the ori fi ce
control val ves, CPC val ve and l i near sol enoi d for free movement.
l f the l i near sol enoi d i s stuck, i nspect the cl utches for wear.
l mproper al i gnment or mai n val ve body and torque converter housi ng may cause ATF pump
sei zure. The
symptoms are mostl y an rpm-rel ated ti cki ng noi se or a hi gh-pi tched squeak.
l f the l st cl utch feed pi pe gui de
i n the end cover i s scored by the mai nshaft, i nspect the bal l beari ng for
excessi ve movement i n the transmi ssi on housi ng. l f oK, repl ace the end cover as i t i s dented. The o-ri no
under the gui de i s probabl y
worn.
Repl ace the mai nshaft i f the bushi ng for the 4th feed pi pe i s l oose or damaged. l f the 4th feed pi pe
i s danF
aged or out of round, replace the right side cover.
Repl ace the mai nshaft i f the bushi ng for the 1st feed pi pe i s l oose or damaged. l f the 1st feed pi pe
i s darn-
aged or out of round, repl ace i t.
A worn or damaged sprag cl utch i s mostl y a resul t of shi fti ng the transmi ssi on i n
the wheel s rotate i n reverse, such as rocki ng the vehi cl e i n snow.
or E posi ti on
whi l e
Inspect for damage and wear:
1. Reverse sel ector gear teeth chamfers.
2. Engagement teeth chamfers of countershaft 4th and reverse gear.
3. Shi ft fork for scuff marks i n center.
4. Di fferenti al pi ni on
shaft for wear u nder pi n i on gears.
5. Bottom of 3rd cl utch for swi rl marks.
Repl ace i tems 1,2,3 and 4 i f worn or damaged. l f transmi ssi on makes a cl i cki ng, gri ndi ng
orwhi rri ng noi se,
al so repl ace mai nshaft 4th gear, reverse i dl er gear. and countershaft 4th gear i n addi ti on to 1, 2, 3 or 4.
lf differential pinion
shaft is worn, overhaul differential assembly, and replace ATF strainer, and thoroughly
cl ean transmi ssi on, fl ush torque converter, cool er and l i nes.
lf bottom of 3rd clutch is swirled and transmission makes gear
noise, replace the countershaft and final driven
gear.
Be very careful not to damage the torque converter housi ng when repl aci ng the mai n bal l beari ng,
you
may al so damage the ATF pump
when you torque down the mai n val ve body. Thi s wi l l resul t i n ATF
pump
sei zure i f not detected. Use the oroper roors.
Instal l the mai n seal fl ush wi th the torque converter housi ng. l f you push i t i nto the torque converter
housi ng unti l i t bottoms out, i t wi l l bl ock the fl ui d return passage
and resul t i n damage.
See fl ushi ng procedure, page 14-187 and 188.
l f the l arge cl utch pi ston
O-ri ng i s broken, i nspect the pi ston groove
for rough machi ni ng.
l f the l -2 shi ft val ve i s stuck cl osed, the transmi ssi on wi l l not upshi ft. l f stuck open, the transmi ssi on has
no 1st gear.
l f the znd ori fi ce control val ve i s stuck. i nspect the 2nd and 3rd cl utch oacks for wear.
l f the 3-4 ori fi ce control val ve i s stuck, i nspect the 3rd and 4th cl utch oacks for wear.
l f the cl utch pressure
control val ve i s stuck cl osed, the transmi ssi on wi l l not shi ft out of 1st gear.
l f the ATF strai ner i s cl ogged wi th parti cl es
of steel or al umi num, i nspect the ATF pump
and di fferenti al
pi ni on shaft. l f both are OK and no cause for the contami nati on i s found, repl ace the torque converter.
Inspect the frame for col l i si on damage.
14- 112
Road Test
NOTE: Warm up the engi ne to normal operati ng tem
peratu re
(the
rad i ator fan comes on )'
1. Appl y
parki ng brake and bl ock the wheel s. Start the engi ne, then shi ft to E
posi ti on whi l e depressi ng the brake
Dedal , Depress the accel erator
pedal and rel ease i t suddenl y. The engi ne shoul d not stal l '
2. Repeat same test i n E Posi ti on.
3. Test-dri ve the vehi cl e on a fl at road i n the
E
posi ti on. Check that the shi ft
poi nts occur at approxi mate speeds shown
i n the tabl e. Al so check for abnormal noi se and cl utch sl i ppage.
NOTE: Throttl e
posi ti on sensor vol tage represents the throttl e openi ng
a. Unbol t the PCM for road testi ng; refer to
page 14-50.
b. Setthedi gi tal mul ti meter to check the th rottl e
posi ti on sensor vol tage between PCM termi nal s;
.
' 96
-
98 model s: D1 {+) and A9
(-)
or 422
(-}.
.
' 99
-
00 model s: C27
( +)
andB20t - ) or B22{ - } .
BACKPROBE ADAPTER
BACKPROBE SET
07sAz
-
001oq)A
{two requiredl
DIGIIAL MULTIMETER
lCommercially
available)
KS- AHM- 32- 003,
or equivalenl
'96
-
98 Modelsr
PCM CONNECTORS
B t 25Pl
c
(31P)
LG1 I BRN/ BLK)
I
(25P1 c
(31P}
A t32Pt
D
(16P)
'9!t
-
00 Models:
1 +1 1 3
Road Test
(cont' dl
.91 Posi ti on: Dl 6Y7 engi ne
. Upshift
Throttle Opening Unit of speed l st
+
znd 2nd
*
3rd 3rd
t
4th Lock-up ON
Throttl e posi ti on sensor
vol tage: 0.75 V
mph 9 - 1 2 20- 23 28- 32 21
- 24
km/h 1 5 - 1 9 32- 37 45- 52 34- 39
Throttl e posi ti on
sensor
vol t age: 2. 25 V
mph
40- 45 62- 67
km/h 34- 40
95
-
104 99
-
't08
Ful l y-opened throttl e
sensor
vol tage: 4.5 V
mph 33- 38 101
-
' t 12
99
-
109
km/h 5 3 - 6 1 1 0 2 - 1 1 5 163
-
180
' 159
-
176
Downshift
Throftle Opening Unit of speed Lock-up OFF 'lth +
3rd 3rd
+
2nd 2nd
t
l st
Ful l y cl osed throttl e
sensor
vol tage: 0.5 V
mph
't9
-
22 17
- 20
6 - 9 ( 3 r d + l s t )
km/h 30- 35 27
-32
10
-
15
(3rd +
1st)
sensor
vol tage: 4.5 V
mpn 95
-
105 85- 95 5 4 - 6 1 2 5 - 3 0
km/h 153
-
169 137
-
153 87- 98 4 0 - 4 8
-q1 Position: DI6YB engine
. Upshift
Downshift
NOTE:
. Lock-up ON: The l ock-up control sol enoi d val ve A turns ON.
. Lock-up OFF: The l ock-up control sol enoi d val ve A turns OFF.
Throttle Opening Unit of speed lst
+
2nd 2nd
-
3rd 3rd
+
4th Lock-up ON
Throftl e posi ti on sensor
vol tage: 0.75 V
mph 9 - 1 2 20- 23 2 A- 3 2 21
- 24
km/h 1 5 - 1 9 32- 37 45- 52 34- 39
sensor
vol t age: 2. 25 V
mpn 21
- 25
40- 45 59- 65
km/h 34- 40
95
-
104 99
-
108
sensor
vol tage: 4.5 V
mph 32- 37 62
- 70
96
-
107 95
-
106
km/h 5 2 - 6 0 100
-
113
't55
-
112
't53
-
'170
Throttle Opening Unit ot speed Lock-up OFF 'lth +
3rd 3 r d + 2 n d I 2 n d + l s t
Ful l y-cl osed throttl e
sensor
vol tage: 0.5 V
mph 19- 22 17
- 20
6- 9( 3r d+ 1s t )
km/h 30- 35 27
-32
l 0
-
15
(3rd +
l st)
Ful l y opened throttl e
sensor
vol tage: 4.5 V
mpn 91
-
101 5 4 - 6 1 2 5 - 3 0
km/ h
' 147
-
163 137
-
153 87- 98 I 40- 48
l.
14- 114
Accel erate to about 35 mph
(57
km/h) so the transml ssi on i s i n 4th, then shi ft from
Dl posi ti on to
Z
posi ti on The
vehi cl e shoul d i mmedi atel y begi n sl owi ng down from engi ne braki ng'
CAUTION: Do not shift from -91 or
-Dd
position to E
position at speeds ov6r 63 mph {100
km/hl;
You
mav damage
the transmission.
Check for abnormal
noi se and cl utch sl i ppage
i n the fol l owi ng
posi ti ons'
E
(2nd Gear) Posi ti on
l l Accel erate from a stop at ful l throttl e. check that there i s no abnormal noi se or cl utch sl i ppage.
b. Upshi fts and downshi fts shoul d not occur wi th the sel ector i n thi s
posi ri on'
E
(Reverse) Posi ti on
i "ccel erate from a stop at ful l throttl e, and check for abnormal noi se and cl utch sl i ppage'
Test i n B
(Park) Posi ti on
Park the vehi cl e on sl ope
(approx. l 6' ), appl y the
parki ng brake' and shi ft i nto E
posi ti on Bel ease the brake; the veh'
cl e shou,d nol move
1 + 1 1 5
Stall Speed
Test
CAUTION:
.
To prevnt
transmission damage, do not t6st stall speed for more than ro sgconds at a time.
. Do not shift the levor while raising the engine speed.
. Bo sule lo remove the pressure gauge
betoro testing stall speed.
' 1.
Engage the parki ng
brake, and bl ock the front wheel s.
2. Connect a tachometer to the engi ne, and start the engi ne.
3. Make sure the Ay' C swi tch i s OFF.
4. After the engi ne has warmed up to normal operati ng temperature (the
radi ator fan comes on). shi ft i nto
E
posi ti on.
5. Ful l y depress the brake pedal
and accel erator for 6 to
g
seconds, and note engi ne speed.
6. Al l ow two mi nutes for cool i ng, then repeat the test i n
@ and
@
posi ti ons.
NOTE:
. Stal l speed tests shoul d be used for di agnosti c purposes
onl y,
. Stal l speed shoul d be the same i n o.,
E and
E
posi ti ons.
Stall Spsed RPM:
Specification: 2.700 rpm
Service Limit: 2,550
-
2,850 rDm
TROUBLE
PROBABLE CAUSE
.
Low fl ui d l evel or ATF pump
outDur
.
Cl ogged ATF strai ner
.
Pressure regul ator val ve sl uck cl oseo
.
Sl i ppi ng cl utch
.
Sl i ppage of 4th ctutch
.
Sl i ppage of 2nd cl utch
.
Slippage of lst clut"tr or. t"t g""io*-*"y
"lut"h
Stal l rpm hi gh i n D.,
E
and
E
posi ti ons
Stal l rpm hi gh i n
El
posi ti on
E
posi ri on
Stal l rpm hi gh i n E
posi ti on
Stal l rpm l ow i n LDa . El
and
E
posi trons .
Engi ne output l ow
.
Torque converter one-way cl utch sl i ppi ng
14- 116
Fluid Level
Ghecki ng
NOTE: Keep al l forei gn
parti cl es out of the transmi s-
sron.
1 . Warm up the engi ne to normal operati ng tempera-
ture
(the
radi ator fan comes on)
Park the vehi cl e on the l evel
ground, then turn off
the engrne.
Remove the di psti ck
(yel l ow l oop) from the trans-
mi ssi on. and wi pe i t wi th a cl ean cl oth.
Insert the di psti ck i nto the transmrssron
Remove t he di pst i ck and check t he f l ui d l evel l t
shoul d be bet ween t he upper mar k and l ower
marks.
UPPER MABK
LOWER MARK
l f the l evel i s bel ow the l ower mark,
pour the recom-
mended f l ui d i nt o t he t i l l er hol e t o br i ng i t t o t he
upper mark. Al ways use Genui ne Honda Premi um
Formul a Automati c Transmi ssi on Fl ui d
(ATF). Usi ng
a non-Honda ATF can affect shi ft
qual i ty
K
L
DIPSTICK IYELLOW
LOOPI
7. Insert the di psti ck back i nto the transmi ssi on i n the
di recti on shown.
FRONT
I nst al l t he di pst i ck i n t he ext ent
of the direction shown.
14-117
Fluid Level
Changi ng
NOT: Keep al l forei gn parti cl es
out of the transmi s-
si on.
' 1.
Bri ng the transmi ssi on up to operati ng temperature
(the
radi ator fan comes on) by dri vi ng the vehi cl e.
Park the vehi cl e on the l evel ground,
and turn the
engine off.
Remove t he dr ai n pl ug.
and dr ai n t he aut omat i c
transmi ssi on fl ui d
(ATF).
NOTE: l f a cool er fl usher i s to be used, see
page
14-
187 and 14-188.
TRANSMISgION END OOVER
DNAIN PLUG
18 x 1. 5 mm
49 N.m
(5.0
kgtm, 36lbf.ftl
SEALING WASHER
Replace.
Rei nstal l the drai n pl ug
wi th a new seal i ng washer,
then refi l l the transmi ssi on wi th the recommended
fl ui d i nto the fi l l er hol e to the upper mark on the
di pst i ck. Al ways use Genui ne Honda
pr emi um
Formul a Automati c Transmi ssi on Fl ui d
(ATF).
Usi ng
a non-Honda ATF can aftect shi ft qual i ty.
Automatic Transmission Fluid Capacity:
2.7 | |'2.9 US ql,2.a lmp qtl at Ghlnging
5.9 f 16.2 US qt. 5.2 lmp qt) at overhaul
I
14- 11A
Pressure
Testing
@
I While testing, be caroful of th rotating front wheels.
. Make sure lifts,
iacks,
and satoty stands are
placod properly (see
section 1)'
CAUTION:
. Beforo iesting, be sure the transmission fluid is tilled to tho
proper level'
. Warm up tho engine before testing'
1. Rai se the vehi cl e
(see
secti on 1).
2. Warm up the engi ne, then stop the engi ne and connect a tachometer'
3. Connect the oi l
pressure gauges to each i nspecti on hol e.
TOROUE: 18 N.m
(1.8
kgf'm, 13 lbnft)
cAUTloN: connact the oil
pressuro gauges securely; be suro not to allow dust and other foreign
Parlicles
to entel
the inspestion holos'
A/T OIL PRESSURE GAUGE
SET w/PANEL
07t06
-
0020400
A/T LOW PRESSURE GAUGE
SET WPANEL
07406
-
0070300
A/T OIL PRESSURE HOSE
ADAPTER
07Mru
-
PY0120
(4
requiJedl
A/T OIL PBESSURE HOSE
2210 mm
OTMAJ
-
PY4{)llA
14 roquircdl
Start the engi ne, and measure the respecti ve
ptessure as fol l ows'
a Li ne Pressure
. 1st Clutch Pressure
. 2nd,3rd and 4th Cl utch Pressure
Instal l a new washer and the seal i ng bol t i n the i nspecti on hol e. and ti ghten to the speci fi ed torque'
TOROUE: l8 N.m
(1.8
kgf'm,13lbf'ft)
NOTE: Do not reuse ol d seal i ng washers; al ways repl ace washers'
(cont' d)
14-119
Pressure Testing
(cont'd)
Line Pressure/1st Clutch Pressurc Measurement
1. Set the parki ng
brake, and btock both rear wheel s securel y.
2. Start the engi ne, and run i t at 2,OOO rpm.
3. Shi ft to
N
or
E
posi ti on,
then measure l i ne pressure.
NoTE: Hi gher pressure
may be i ndi cated i f measurements are made i n shi ft l ever posi ti ons
other than
@
or
@
posi
tron.
4. Shi ft to
tq;l
posi ti on, hol d the engi ne at 2,000 rpm, and measure 1st crutch pressure.
1ST CLUTCH PRESSURE
INSPECTION HOLE
(Marked
wi t h
"1")
LOCK.UP CONTROL
SOLENOID VALVE A/8
ASSEMBLY
VALVE A/B ASSEMBLY
PRESSURE
SHIFT LEVER
POS|TtON
SYMPTOM PROBABLE CAUSE
FLUID PRESSURE
Standard
Service Limit
Li ne
N
o r E No
(or
l ow)
l rne pressure
Torque converter,
ATF pump, pres-
sure regutator.
torque converter
check val ve
830
-
880 kPa
{8.5
-
9.0 kgf/cm?,
120
-
130 psi )
780 kPa
(8.0
kgf/cm' , 110 psi )
1st Cl utch
D;l
No or l ow 1st
pressure
1st Cl ut ch
\
14-120
2nd, 3rd and 4th Clutch Pressure Measurement
1. Set the
parki ng brake, and bl ock both rear wheel s securel y'
2. Start the engi ne, and run i t the engi ne at 2,000 rpm'
3. Shi ft to E
posi ti on, then measure 2nd cl utch
pressure
4. Shi ftto El
posi ti on, then measure3rd cl utch
pressure
5. Shi ft to E
posi ti on, then measure 4th cl utch
pressure'
6. Shi ft to E
posi ti on, then measure 4th cl utch
pressure'
INSPECTION
HOI'E
(Marked wi t h
"3")
2ND CLUTCH
PRSSURE
INSPECTION
HOLE
FLUID PRESSURE
standard I
sorviqe Limit PRESSURE
SHIFT LEVER
POStT|()N
SYMPTOM
PROBABLE CAUSE
2nd Cl utch tr
No or l ow 2nd
pressure
2nd Cl utch
800
-
850 kPa
(8.2 -
8.7 kgflcm',
120
-
120
psi )
760 kPa
(7.7
kgf/cm' , 110
Psi l
3rd Cl utch tr
No or l ow 3rd
pressure
3rd Cl utch
8'10
-
860 kPa
(8.3
-
8.8 kgt/cm',
120
-
130
psi )
760 kPa
(7.8 kgt/cm' , 110
Psi )
4th clutch
p.l
No or l ow 4th
presSure
4th cl urch
E
Servo Valve or 4th
Cl utch
1+121
Transmission
Removal
@
Maks sure lifts,
iacks
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.
CAUTION: Use tender covers to avoid damaging paint-
ed surfaces.
1, Di sconnect the battery negati ve (_)
termi nal from
the battery, then remove the posi ti ve (+)
termi nal .
2. Remove the i ntake ai r duct.
D16Y7 engi ns:
Remove the i ntake ai r duct and resonator.
D16Y8 engi ne:
Remove the i ntake ai r duct and the ai r cl eaner hous-
i ng assembl y,
3. Remove the starter cabl es and cabl e hol der from
the starter motor.
MOTOR CABLE
MOTOR CABLE
14-122
4. Remove the transmi ssi on ground
cabl e, and di scon_
nect the l ock-up control sol enoi d connector.
LOCK.UP CONTROL
SOLENOID CONNECTOR
5, Di sconnect
the vehi cl e speed sensor (VSS)
connec_
tor and the countershaft speed sensor connector.
VEHICLE
SPEED
6. Remove the transmi ssi on housi ng mounti ng bol ts
and the rear engi ne mounti ng bol t.
Di sconnect the shi ft control sol enoi d, the l i near sol e-
noi d, and the mai nshaft speed sensor connectors'
7.
SHIFT CONTROL
SOLENOID CONNECTOR
LINEAR SOLENOID
CONNECTOR
MOUNTING BOLTS
BRACKET
8. Remove t he dr ai n pl ug, and dr ai n t he aut omat i c
t r ansmi ssi on f l ui d
( ATF) .
Rei nst al l t he dr ai n
pl ug
wi th a new seal i ng washer.
DRAIN PLUG
18 x 1. 5 mm
'9 N m t5 o kgf'm' 36 lbf'ft|
9. Remove t he spl ash shi el d.
Repl ace.
SPLASH SHIELD
{cont ' d)
14-123
Transmission
Removal (cont' d)
'10.
Remove the cotter pins
and castle nuts, thn separate
the balljoints from the lower arms
(see
section 1gl.
DAMPER PINCH BOLT
NUT
FORI(
FORK
BOLT
11. Remove the ri ght damper fork bol t. thn
ri ght damper fork and dampor.
COTTER PIN
Repl ace.
separate
12.
1 a
14.
Pry the right and left driveshafts out ofthe differential.
Pul l on the i nboard
j oi nt
to remove the ri ght and l eft
drivsshafts
(see
section 16).
Tie plastic
bags over the driveshaft onds.
NOTE: Coat all precision
finished surfaces with clean
engi ne oi l .
Remove the exhaust pi pe
A,
NOTE: Dl 6YB engi ne i s shown; D16y7 engi ne i s
si mi l ar.
t 9 .
SELF-LOCKING NUT
Repl ace.
L
14-124
EXHAUST PIPE A
MOUNT/BRACKET
17.
18.
16. Remove the shi ft cabl e cover. then remove the shi ft
cabl e by removi ng the control l ever,
CAUTION: Take car6 not to bond the shift cable.
Remove the right front mounvbracket.
Remove the ATF cool er hoses at the ATF cool er
l i nes. Tufn the ends of the ATF cool er hoses uo to
prevent
ATF from fl owi ng out, then pl ug
the ATF
cooler hosgs and lines.
NOTE: Check for any si gn of l eakage at the hose
i oi nts.
WASHER
19. Remove the engi ne sti ffener and the torque con-
verter cover.
Remove the ei ght dri ve
pl ate bol ts one at a tl me
whi l e rotati ng the crankshaft
pul l ey.
Remove the di stri butor.
Attach a hoi sti ng bracket to the engi ne, then l i ft the
engi ne sl i ghtl y.
HOIST
BRACKET
20.
21.
COVER
23. Pl ace a
j ack
under the transmi ssi on. and ra6a :' .
transmi ssi on i ust
enough to take wei ght otf ol tF.
mounts. then remove the transmi ssi on mounl
TRANSMISSION
MOUNT BRACKET
Remove the transmi ssi on housi ng mounti ng bol ts
and the rear engi ne mounti ng bol ts.
Pul l the transmi ssi on away from the engi ne unti l i t
cl ears the 14 mm dowel
pi ns, then l ower i t on the
transmi ssi on
j ack.
l f necessary, remove the torque converter anc:"
starter motor.
24.
25.
1+16
lllustrated Index
Transmi ssi on/End
Cover
a-'tEO
\
14-126
O
ROLLER
O
COLLAR
O
o-RING Repl ace.
@
FEED PIPE FLANGE
@
O-RING Repl ace.
@
SNAP RING
)
3RD CLUTCH FEED PIPE
)
COUNTERSHAFT
LOCKNUT
(FLANGE NUT)
23 x 1.25 mm Repl ace.
o
coNlcAL SPRING WASHER Replace.
@
PARK GEAR
@
ONE.WAY CLUTCH
@
COUNTERSHAFT lST GEAR
@
NEEDLE BEARING
@
COUNTERSHAFT
lST GEAR COLLAR
@
o-Rl NGs Repl ace.
@
END covER GASKET Repl ace.
E)
DOWEL PINS
@
PARK PAWL STOP
@
LocK WASHER Replace.
@
PARK STOP Selective
part
D
PARK LEVER
@
PARK LEVER SPRING
D
DRAIN PLUG
)
SEALING WASHER Replace
@
o-RING Repl ace.
@
COUNTERSHAFT SPEED SENSOR
@)
PARK PAWL
@
PARK PAWL SPRING
@
PARK PAWL SHAFT
@
LINEAR SOLENOID ASSEMBLY
@
LINEAR SOLENOID GASKET REPIACE.
@)
END COVER
@
lsT CLUTCH FEED PIPE
@
O-RINGS Repl ace.
@
FEED PIPE FLANGE
C)
SNAP BING
@
MAINSHAFT LOCKNUT
(FLANGE
NUTI 21 x 1 25 mm
Repl ace.
@
CONICAL SPRING WASHER RePlace
@)
lST CLUTCH ASSEMBLY
@
o-Rl NGs Repl ace.
)
THRUST WASHER
@)
THRUST NEEDLE BEARING
@
NEEDLE BEARING
@
MAINSHAFT lST GEAR
@
MAINSHAFT lST GEAR COLLAR
@)
ATF COOLER LINE
@
SEAUNG WASHERS Replace.
@
LINE BOLT
@
ATF DIFSTICK
@
ATF COOLER LINE
@
UNE BOLT
@
SEALING WASHERS Replace.
@
VEHICTT SPEED SENSOR
@
O-RING Replace.
TOROUE SPECIFICATIONS
Bolt/Nut No. Torque Value
Size
Remarks
6B
8F
12A.
' l 8D
2'tM
23C
' 12
N' m
(1.2
kgi m,8.7 l bi ft)
14 N.m
(1.4
kgf.m, 10 l bf' 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)
103 N.m {10.5
kgf' m,75.9 l bi ft)
6 x 1 . 0 mm
6 x 1 . 0 mm
8 x 1, 25 mm
12 x 1. 25 mm
18 x 1. 5 mm
21 x 1. 25 mm
23 x 1. 25 mm
Li ne bol t
Drai n
pl ug
Mai nshatt l ocknut: Left-hand threads
Countershaft l ocknut:
Left-hand threads
14-127
lllustrated Index
6A
I
e
:!_..
I
14-128
O
LocK WASHER Repl ace,
O
REVERSE SHIFT FORK
O
COUNTERSHAFT REVERSE GEAR COLLAR
G)
COUNTERSHAFT REVERSE GEAR
@
NEEDLE BEARING
@
REVERSE SELECTOR
O
REVERSE SELECTOR HUB
@
COUNTERSHAFT 4TH GEAR
O
NEEDLE BEARING
@
DISTANCE GOLLAR, 28 mm Selective
part
O
COUNTERSHAFT 2ND GEAR
@
THRUST NEEDIE BEARING
@
COUNTERSHAFT 3RD GEAR
@
NEEDLE BEARING
@
COUNTEBSHAFT 3RD GEAR COLLAR
@
THRUST NEEDLE BEAFING
O
SPLINED WASHER
@
3RD CLUTCH ASSEMBLY
@
O-RtNGs Repl ace.
@
COUNTERSHAFT
@ SNAP RING
@
THRUST WASHER
)
THRUST NEEDTE BEARING
@}
MATNSHAFT 4TH GEAR/REVERSE GEAR
@i
NEEDLE BEARINGS
@
THRUST NEEDLE EEARING
@)
MAINSHAFT 4TH GEAR COLLAR
@
2ND/4TH CLUTCH ASSEMBLY
@
o-RlNGs Replace.
@
THRUST WASHER,36.5 x 55 mm Selctive
part
@
@
MAINSHAFT zND GEAR
@
NEEDLE BEARING
@
@
MAINSHAFI
@
SALING RINGS, 35 mm
@
SEALING RING,29 mm
@}
NEEDIE BEARING
@
SET RING
@
sHrFT CONTROL SOLENOID VALVE A/B ASSEMSLY
@
HARNESS CLAMP BRACKET
@
SHIFT COI,ITROL SOI"ENOID FILTER/GASKET Replace.
@ CONNECTOR BFACKET
@D
TNANSMISSION HANGER
@
BREATHER CAP
@
MAINSHAFT SPEED SENSOR
@
MATNSHAFT SPEED SENSOR WASHER {Dl6Y' ongine}
@
O-RING Repl ace.
@
SNAP RING
@
MAINSHAFT TRANSMISSION HOUSING BEARING
@
OOUNIERSHAFT TRANSMISSION HOUSING BEARING
@
REVERSE IDLER GEAR SHAFT HOLDER ASSEMBLY
@
NEEDI.E BEARING
@
olL SEAL Replace.
@
SET RING, fll mm Selective
part
@
rnANsMrssloN HouslNG
@
REVERSE IDI."ER GEAR
@
DowEL PINS
@
TRANSMISSION HOUSING GASKET Replace.
@
DIFFERENfIAL ASSEMBLY
@
OIL SEAL Replace.
@
TOROUE CONVERTER HOUSING
TOROUE SPECIFICANONS
Boh/Nut No. Torquo value Size
Romarks
6B
10A
12 N.m {1.2 kgf.m,8.7 l bf.ft)
14 N.m
(1.4
kgf' m, 10l bf' ft)
44 N.m
(4.5
kgf.m, 33 lbf'ft)
6 x 1 . 0 mm
6 x 1 . 0 mm
10 x 1. 25 mm
14-129
lllustrated lndex
Torque Converter Housing/Valve Body
to\
\*
L
14-130
O
ATF FEED PIPE
O
ATF STRAINER
O
SERVO BODY
' 99
-
00 model s servo body has i ntegral l y mol ded
servo detent.
@
SERVO SEPARATOR PLATE
('
SECONDARY VALVE BODY
@
DOWEL P|NS
O
SECONDARY SEPARATOR PLATE
@
SERVO DETENT BASE
('96 -'98
models)
O
ATF FEED PIPES
(D
ATF FEED PIPES
O
SHAFT STOP
@
CONTROL SHAFT
D
DETENT ARM SPRING
@
DETENT ARM
(9
DETENT ARM SHAFT
@
FILTER Repl ace.
(?
CHECK BALLS
@
TOROUE CONVERTER CHECK VALVE
@
TOROUE CONVERTER CHECK VALVE SPRING
@
DOWEL PINS
@
LOCK.UP VALVE BODY
@
LOCK-UP SEPARATOR PLATE
@
REGULATOR VALVE BODY
@}
DOWEL PINS
@
COOLER RELIEF VALVE SPRING
@
COOLER RELIEF VALVE
@
O-RING Repl ace.
@
STATOR SHAFT
@
STOP SHAFT
@
ATF FEED PIPE
@
MAIN VALVE BODY
@
ATF PUMP DRIVEN GEAR SHAFT
@
ATF PUMP DRIVEN GEAR
@
DOWEL PINS
65) ATF PUMP DRIVE GEAR
@
MAIN SEPARATOR PLATE
@
SUCTION PIPE COLLAR
@
ATF MAGNET
@
COUNTERSHAFT TOROUE CONVERTER HOUSING
BEARING
@
ATF GUIDE PLATE
@
ToRoUE CONVERTER HOUSING
@
OIL SEAL Repl ace.
@
MAINSHAFT TOROUE CONVERTER HOUSING
BEARING
@)
olL SEAL Replace.
@
LOCK-UP CONTROL SOLENOID FILTER/GASKET
Reol ace.
@
LOCK-UP CONIROL SOLENOID VALVE A/B ASSEMELY
@
CONNECTOR BRACKET
TOROUE SPECIFICANONS
Bolt/Nut No. Torque Valug
Siz
Remarkg
12 N.m
(1.2
kgf.m,8.7 l bnft) 6 x 1 , 0 mm
14- 131
End Cover
Removal
NOTE:
. Cl eanal l parts thoroughl y i n sol vent or carburetor cl eaner, and drywi th compressed ai r,
. Bl ow out al l passages,
. When removi ng the ri ght si de cover, repl ace the fol l owi ng:
-
O-ri ngs
-
Mai nshaft and countershaft l ocknuts
-
Coni cal spri ng washgrs
-
End cover
gasket
-
Lock washer
-
Seal i ng washers
END COVER
6 x 1. 0 mm BOLT
13 Bol t s
PARK PAWL
PARK ITVER
LOCK WASHER
COUI{TERSI{AFT
LINE AOLT
tST GEAF COLLAR
I
14-132
SEALING WASHERS
1 . Remove the 13 bol ts securi ng the end cover, then
remove the cover.
Sl i p the speci al tool onto the mai nshaft as shown.
MAINSHAFT HOLOER
07GAB
-
PFs0101
Engage the park pawl wi th the park gear.
Cut the l ock tabs of the mai nshaft and countershaft
l ocknuts usi ng a chi sel as shown. then remove the
l ocknuts and coni cal spri ng washers
CAUTION: Keep all of lhe chiseled
particles out of
the transmission.
NOTE:
. Mai nshaft and countershaft l ocknuts have l eft-
hand threads.
. Al ways wear safety
gl asses.
4.
cHrsL
LOCKNUT
LOCK TA8
5.
6.
1 1 .
Remove the speci al tool from the mai nshaft after
removi ng the l ocknuts.
Remove the 1st cl utch and mai nshaft 1st gear assem
bl y and mai nshaft 1st gear col l ar from the mai nshaft.
7. Remove the park pawl . spri ng and shaft.
8. Remove the park l ever from the control shaft.
9. Usi ng a uni versal two-j aw pul l er, remove the park
gear , one way cl ut ch and count er shaf t 1st gear
assemory.
PULLER
(CommerciallY available)
PARK GEAR
10. Remove the needl e beari ng and the countershaft
1st gear col l ar from the countershaft
Remove the ATF cool er l i nes and ATF di psti ck.
14-133
Removal
MAINSHAFT
MOUNTING BOLTS
18 Bol t s
TRANSMISSION
HANGER
MAINSHAFT
SUB.ASSEMBLY
SENSOR WASHER
l D16Y7 engi ne)
MAINSHAFT
SPEED SENSOR
TRANSMISSION
HOUSING GASKET
DIFFEBENTIAL
ASSEMBLY
TOROUE CONVERTER
HOUSING
SUB.ASSEMBLY
L,
14-134
Torque Converter Housing/Valve
Body
Removal
ATF FEEO PIP
LOCK-UP VALVE
BODY
PI N
6 x 1 . 0 mm
LOCK-UP SEPARATOR
PLATE
REGULATOR
VALVE SODY
DOWEL PIN
COOLER RELIEF VAL
SERVO DETENT STRAINER
SERVO EODY
SEPARATON
BASE
ATF FEED
PIPES
CONTROL
SHAFT
DETENT
ARM SHAFT
DETENT
ARM
ATF FEED PIPE
6 x 1 . 0 mm
5 Eol t s
6 x 1 . 0 mm
3 Eol t s
MAIN VAL
BODY
ATF PUMP
DRIVEN
VALVE BODY
PIN
GEAR SHAFT
ATF PUMP
MAIN SEPARA
PLATE
SECONDARY
SEPARATOR PLATE
NOTE: The i l l ustrati on shows the
' 96
-
98 model s, the
' 99
-
00 model s do not have the servo detent base; the servo detent
i s i ntegral wi th the servo body.
L
14-136
NOTE;
. Cl ean al l parts thoroughl y i n sol vent or carburetor
cl eaner, and dry wi th compressed ai r.
. Bl ow out al l passages.
. When removi ng the val ve body, repl ace the O-ri ng.
l , Remove the ATF feed pi pes from the servo body,
secondary val ve body and mai n val ve body.
For' 96
-
98 model s: Remove the ATF strai ner and
servo detent base
(two
bolts).
For' 99
-
00 model s: Remove the ATF strai ner
(one
bol t).
Remove the servo body and servo separator
pl ate
{' 96
-
98 model s: seven bol ts,' 99
-
00 model s: ei ght
bol ts).
Remove the secondary val ve body, shaft stop and
secondary separator pl ate (three
bol ts).
Remove the l ock-up val ve body and separator pl ate
{seven bol ts).
Remove the regul ator val ve body
(one
bol tl .
Remove the stator shaft and stop shaft.
Remove the detent spri ng from the detent arm. then
remove the control shaft from the to.que converter
housi ng.
Remove the detent arm and detent arm shaft from
the mai n val ve body.
Remove the mai n val ve body
(fi ve
bol ts).
NOTE: Do not l et the ei ght check bal l s fal l outofthe
mai n val ve body when r emovi ng t he mai n val ve
body.
Remove the ATF pump driven gear shaft, then remove
the ATF pump gears.
Remove the mai n separator pl ate and two dowel
pi ns.
7.
' t' 1.
10.
12.
14.
13. CI ean t he i nl et openi ng of t he ATF st r ai ner t hor -
oughl y wi th compressed ai r. then check that i t i s i n
good condi ti on, and the i nl et openi ng i s not cl ogged.
I NLET OPENI NG
Test the fi l ter by pouri ng cl ean ATF fl ui d through
the i nl et openi ng. Bepl ace the ATF strai ner i f i t i s
cl ogged or damaged.
NOTE: The ATF str8i ner can be reused i f i t i s not
cl ogged.
14-137
Valve Caps
Description
Caps wi t h one pr oj ect ed
t i p and one f l at end ar e
i nstal l ed wi th the fl at end toward the i nsi de of the
valve body.
Caps wi th a proj ected ti p on each end are i nstal l ed
wi t h t he smal l er t i p t owar d t he i nsi de of t he val ve
body. The smal l ti p i s a spri ng gui de.
Toward outside of valvo body.
Toward insido ot valvo body.
Caps wi t h one
pr oj ect ed
t i p and hol l ow end ar e
i nstal l ed wi th the ti p toward the i nsi de of the val ve
body. The ti p i s a spri ng
gui de.
Towa.d outside o, valv6 bodv.
I
14-138
Toward insid of valv6 bodv.
Caps wi th hol l ow ends are i nstal l ed wi th the hol l ow
end away from the i nsi de ofthe val ve body.
Caps wi th notched ends are i nstal l ed wi th the notch
toward the i nsi de of the val ve body.
Caps wi th fl at ends and a hol e through the center are
i nstal l ed wi th the smal l er hol e toward the i nsi de of
the val ve bodv.
Toward outsido of valve bodv.
Ef l a
Toward inlido ot valve bodv,
Caps wi th fl at ends and a groove
around the cap are
i nstal l ed wi th the grooved
si de toward the outsi de of
the val ve body.
Toward oulsido of valv6 body.
"-\"h
,A
\za9
Sectional view.
Toward insido ol valvo body.
Valve Body
2.
Repai r
NOTE: Thi s repai r i s onl y necessary i f one or more of
the val ves i n a val ve body do not sl i de smoothl y i n thei r
bores. You may use thi s procedure to free the val ves i n
the val ve bodi es.
1. Soak a sheet of #600 abr asi ve
paper i n ATF f or
about 30 mi nutes.
Careful l y tap the val ve body so the sti cki ng val ve
drops out of i ts bore.
CAUTI ON: l t may b necessar y t o use a smal l
screwdriver to pry the valve free. Be careful not to
scratch the bore whh the screwdriver.
Inspect the val ve for any scuff marks. Use the ATF-
soaked #600 paper to pol i sh off any burrs that are
on the val ve, then wash the val ve i n sol vent and dry
i t wi th compressed a i r.
Rol l up hal f a sheet of ATF-soaked
paper, and i nsert
i t i n the val ve bore of the sti cki ng val ve.
Twi st the
paper sl i ghtl y, so that i t unrol l s and fi ts the
bor e t i ght l y, t hen
pol i sh t he bor e by t wi st i ng t he
paper as you push i t i n and out.
CAUTION: The valve body is aluminum and doesn't
require much polishing to remove any burrs,
3.
4.
ATF-soaked
#600 abrasive Paper
5.
7 .
Remove the #600 paper and thoroughl y wash the
enti re val ve body i n sol vent. then dry i t wi th com-
pressed ai r.
Coat the val ve wi th ATF, then drop i r i nto i ts bore.
It shoul d drop to the bonom of the bore under i ts
own wei ght. l f not, repeat step 4, then retest.
VALVE BODY
Remove the val ve. then thoroughl y cl ean i t and the
val ve body wi th sol vent. Dry al l parts wi th com-
pressed
ai r. then reassembl e usi ng ATF as a l ubri
cant.
W
-M
14- 139
Valve
Assembly
NOTE:
Coat all parts with ATF before assembly.
. Instal l the val ve, val ve spri ng and cap i n the val ve
body and secure wi th the rol l er.
5-'--------P/ -_^?=w_
=/
/-\
(
,. )
l_/1
-,.1\)
VALVE BODY
VALVE AODY
VALVE
h
14-140
SPRI NG
. Set the spri ng i n the val ve and i nstal l i t i n the val ve
body. Push the spri ng i n wi th a screwdri ver, then
i nstal l the spri ng seat.
SPRIITG SEAT
VALVE BODY
Instal l the val ve, spri ng and cap i n the val ve body.
Push the cap, then i nstal l the cl i p.
ATF Pump
Inspection
1. Instal l the ATF pump gears and ATF pump dri ven
gear shaft i n the mai n val ve body
NOTE:
. Lubri cate al l
parts wi th ATF duri ng i nspecti on.
. Instal l the ATF pump dri ven
gear wi th i ts grooved
and chamfered si de faci ng up as shown.
MAIN VALVE BODY
ATF PUMP ORI VEN GEAR
Grooved and chamf e. ed si de
2. Measure the si de cl earance of the ATF pump drave
and dri ven
gears.
ATF Pump Gears Side {Radial)
Clearance:
Standard
(New):
ATF Pump Drive Gear
0.105
-
0.1325 mm {0.004
-
0.q)5 i n}
ATF Pump Drivsn Gear
0.035
-
0.0625 mm
(0.0014
-
0.0025 i nl
MAIN VALVE SOOY
YZ]
o?
ATF PUMP
DRIVE GEAR
ATF PUMP
DRIVEN GEAR
I nspect t eet h f or wear and damage
l nspect teeth for wear and damage.
3. Remove the ATF
pump dri ven
gear shaft. Measure
the thrust cl earance of the ATF pump dri ven
gear-
to-valve bodY.
ATF Pump Drive/Drivon Gear Thrust {Axial}
Cloarance:
Standard
(Now):
0.03
-
0.05 mm 10'001
-
0.002 inl
(0.003
in)
1+141
Main Valve Body
Disassembly/lnspection/Reassembly
NOTE:
. Cl eanal l parts thoroughl y i n sol vent or carburetor cl eaner, and drywi th compressed ai r. Bl owoutal l passages.
. Repl ace the val ve body as an assembl y i f any pans
are worn or damaged.
.
Check al l val ves for free movement. l f anyfai l tosl i defreel y, see Val ve Body Repai ron page,l 4-139.
. Coat al l parts wi th ATF duri ng assembl y.
CAUTION: Do not use a magnet to removs tha check balls; it may magnetizo the balls.
CPB VALVE
VALVE CAP CLIP
ORIFICE CONTROL VALVE
BALLS, 8
lST ACCUMULATOR CHOKE
MODULATOR
VALVE
RELIEF VALVE
VALVE
MAIN VALVE EODY
I nspect f or wear, scrat ches
and scori ng.
SEBVO CONTROL VAL
I.2 SHIFT VALVE
14-142
VALVE CAP
CHECK BALL
w
MAIN VALVE BODY
(Sectional viewl
SPRING SPECIFICATIONS
CHECK BALLS
CHECK BALLS
Uni t : mm
( i n)
No. Springs
Standard
(New)
Wire Dia. o.D. Free Length No. ot Coils
o
@
@
@
@
@
Rel i ef val ve spri ng
Modul ator val ve spri ng
CPB val ve spri ng
1-2 shi ft val ve spri ng
2nd ori fi ce control val ve spri ng
Servo control val ve spri ng
1. 1
( 0. 043)
' 1.4
(0.055)
0.9
(0.035)
0.9
(0.035)
0.7
(0.028)
1.0
(0.039)
8.6
(0.342)
9.4
(0.374)
8.1 t0.3221
7.6 {0.302)
6.6
(0.262)
8.'t to.322l
37. 1
( 1. 461)
35.0
(1.378)
47.2
(1.8s8)
41. 3
( 1. 6261
34.8
(1.370)
52.1 t2.O51l
13. 4
10. 9
1 C ?
' 15.3
22.0
20.8
1+143
Secondary Valve Body
NOTE:
. Cl eanal l
parts thoroughl y i n sol vent or carburetor cl eaner. and drywi th compressed ai r, Bl owoutal l passages.
. Repl ace the secondary val ve body ki t. P/N 27700
-
P4R
-
315
(The
secondary val ve body ki t i ncl udes the l i near sol enoi d
assembl y) i f any parts are worn or damaged.
. Checkal l val ves for free movement. l f anyfai l to sl i de freel y, seeVal veBody Repai ron page 14-139,
. The CPC val ve i s i nstal l ed i n the secondary val ve body, hel d i n pl ace by the l ock bol t.
2.3 SHIFT
VALVE
3.4 SHIFT VAL
.TH EXHAUST VALVE
LOCK BOLT
CAUTION: Do not move.
SECONDARY VALVE BODY
I nspect f or wear, scrat ches 6nd
scori ng.
3-'l ORIFICE CONTROL VAL
VALVE
Uni t : mm
( i n)
No. Spri ngs
Standard {New)
Wire Dia. o.D. Free Longth No. of Coils
o
ra,
.n
3-4 shi ft val ve spri ng
2-3 sh i ft val ve spri ng
4th exhaust val ve spri ng
3-4 ori fi ce control val ve spri ng
0. 910. 035)
0.9 {0.035)
0.9 {0.035)
0.7 {0.028)
7.6
(0.302)
7.6
(0.302)
6.1 10.2421
6.6
(0.262)
57 .O 12.2441
57 .O 12.2441
36.4
(1.433)
37.5
(1.476)
26.8
26.8
24.6
14-144
Regulator
Valve Body
NOTE:
. cl eanal l
parts thoroughl y i n sol vent or carburetor cl eaner, and drywi th compressed ai r. Bl owoutal l
passages
. Repl ace the val ve body as an assembl y i f any parts are worn or damaged.
. check al l val ves for free movement. l f anyfai l tosl i detreel y, see val ve Body Repai ron
page 1+139.
1. Hol d the regul ator spri ng cap i n pl ace whi l e removi ng the stop bol t. once the stop bol t i s removed. rel ease the spri ng
cap sl owl y.
CAUTION: The regulator 3pring cap can
pop out when the stop boh is removod'
2. Reassembl y i s the reverse order ofths di sassembl y
procedure.
NOTE:
o Coat al l
parts wi th ATF duri ng assembl y.
. Al i gn the hol e i n the regul ator spri ng cap wi th the hol e i n the val ve body, then
press the spri ng cap i nto the val ve
body, and ti ghten the stop bol t.
STOP BOLT
6 x 1 . 0 mm
12 N. m 11. 2
8.7 tbf.lrl
\ ^/^' ou*' oRsPRrNGcAP
*N@
REGULATOR VALVE
\=f
-.-*
*fi
/F { a-tLocK.uPcoNrRoLvALVE
cooLERRELl EFvALVr"r?
ry
roRouE coNvERrER cHEcKv ^LvE//
v ^r* "r**::f\
vi{LvE cAp
SPRING SPECIFICANONS
REGULATOR
VALVE BODY
Inspect lor wear, scratches
and scorl ng.
Uni t: mm
(i n)
No, Springe
Standard
(Now)
Wire Dia. o.D. Free Lengrth No. of Coils
o
o
@
@
@
Regul ator val ve sPri ng A
Regul ator val ve spri ng B
Stator reacti on spri ng
Cool er rel i ef val ve spri ng
Torque converter check val ve spri ng
Lock-up control val ve sPri ng
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)
' r4.7
(0.584)
9.6
(0.381)
35.4
(1.407)
8.4 {0.334)
8.4 {0.334}
6.6 {0.262}
87.8
(3.457)
44.0
(1.732)
30.3
(1.193)
33. 8
( 1. 331)
33. 811. 3311
38.0 {1.4961
11. 0
1. 9
8.2
a.2
' t
4.1
14-145
Servo Body
NOTEI
. cl ean al l parts thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r. Bl ow out al l passages.
. Repl ace the val ve body as an assembl y i f any parts
are worn or damaged.
. Repl ace the O-ri ngs.
. The servo body shows the
' 96
-
98 model s: the
' 99
-
00 model s have an i ntegral l y mol ded servo detent.
SERVO BODY
I nspect f or wear , scr at ches and scor i ng.
,______.-
g
1 l
v
"-------'g
ZruO lCCUr,irUr-nrOn
---rrr___-p
n\='l
3,ii11---------*5
^rrr4
I
O. RI NG
Repl ace.
3RO ACCUMULATOR PI STON
4TH ACCUMULATOR PISTON
SNAP RI NGS
1ST ACCUMULATOR PISTON
Uni t : mm
( i n)
No. Spri ngs
Standard {New)
Wire Dia. o.D. Free Length No. of Coi l s
o
(a
@)
o
@
' I
st accumul ator spri ng
4th accumul ator spri ng A
4th accumul ator spri ng B
3rd accumul ator spri ng A
3rd accumul ator spri ng B
2nd accumul ator spri ng C
2nd accumul ator spri ng A
2nd accumul ator spri ng B
2.1
(0.083)
2. 6
( 0. 102)
2. 3
( 0. 091)
2. 8
( 0. 110)
2.210.0871
2.2 t0.0a7l
2.4
(0.094)
' 1.6
(0.063)
16.0
(0.636)
17.0
(0.676)
10.2l o.402J
17. 5
( 0. 695)
31.0
11.220)
14.5
(0.576)
29. 0
( 1. 152)
9.0
(0.358)
89.1
(3.s08)
87.0
(3.425)
51. 6
( 2. 031)
89.3
(3.516)
35. 1
( 1. 382)
68.012.677)
39.0
(1.535)
20.7
(0.815)
14.2
13. 8
' 13.9
L
14-146
Lock-up
Valve BodY
NOTE:
. Cl ean al l
pans thoroughl y i n sol vent or carburetor cl eaner' and dry wi th compressed
ai r' Bl ow out al l
passages'
a Repl ace the val ve body as an assembl y
i f any
parts are worn or dmaged'
. Checkal l val ves for free movement
ttanytai ti o stl ae freel y' see Val ve Body Repai ron
page 14-' 139'
. Coat al l
parts wi th ATF duri ng assembl y
LOCK.UP VALVE BODY
I nspect f or wear, scrat ches
and sconng.
VALVE CAP
LOCK-UP TIMING VAL
SPRING SPECIFICATIONS Uni t : mm
( i n)
73.1 t2.902J
ao.7 13.'1771
7.6
(0.302)
8. 1
( 0. 319)
Lock-up shi ft val ve sPrang
Lock-up ti mi ng val ve sPrl ng
14-147
Mainshaft
Disassembly/lnspestion/Reassembly
NOTE:
. Lubri cate al l parts wi th ATF duri ng reassembl y.
. I nspect t het hr ust needl ebear i ngsandt heneedl ebear i ngsf or gal l i ngandr oughmovement ,
. Before i nstal l i ng the O-ri ngs, wrap the shaft spl i nes wi th tape to prevent
damagi ng the O_ri ngs.
. Locknut has l eft-hand threads.
LOCKNUT
{FLANGE NUTI
21 x 1. 25 mm
78 N. m (8. 0
kgl . m, 58 l bt . f t t
Repl ace.
SNAP RI NG
CONI CAL SPRI NG WASHER
Reol ace.
l ST CLUTCH
ASSEMBLY
THRUST WASHER
THRUST NEEOI.E
BEARING
4TH GEAN
O-RI NGS
Repl ace.
THRUST WASHER
THRUST NEEDLE
BEARING
MAI NSHAFT
Check spl i nes f or excessi ve
wear and oamage.
Check beari ng surt ace f or scori ng,
scrat ches and excessi ve wear.
BEARI NG
BEARINGS
THRUST NEEDLE
BEABING
4TH GEAR COLLAR
2ND/4TH CLUTCH
ASSEMBLY
THRUST NEEDLE
EEARING
2NO GEAB
NEEDLE BEABI NG
THRUST NEEDLE
BEARING
1ST GEAR
1ST GEAR
COLLAR
TRANSMISSION
HOUSI NG BEARI NG
O-RINGS
Repl ace.
THRUST WASHER, 36. 5 x 55 mm
Sel ect i ve part .
SEALI NG RI NGS,
35 mm
I nst al l t he seal i ng r i ng
mat i ng f aces as shown,
RI NG,
29 mm
NEEDLE BEARING
SET RING
14-148
Inspection
a Cl earance Measurement
NOTE: Lubricate all
parts with ATF during assembly.
1, Remove the mai nshaft beari ng from the transmi s-
si on housi ng
(see
Page
14-1741.
2. Assemble ths
parts below on the mainshaft.
NOTE: Do not assembl e the O-ri ngs duri ng i nspec-
tl on.
LOCKNUT
CONICAL SPRIIIG WASHER
SNAP RING
lST CLUTCH ASSEMBLY
TXRUST WASHER
1ST GEAR COLLAR
TRA SMISSION
HOUSII{G BEARING
THRUST WASHER
4TI{ GEAR COLLAR
2ND/4TH CLUTCH
ASSEMBLY
THRUST WASHER
36.5 x 55 mm
Selective
part.
THBUST NEEDLE
BEARING
2ND GEAR
AEABII{G
IHRUST NEEDLE
BEARING
MAINSHAFT
3. Torque the mai nshaft l ocknut to 29 N' m
(3.0
kgf' m,
22 tbt,ftl.
NOTE: Mai nshaft l ocknut has l eft-hand threads.
29 N' m t3.0
kgl ' m, 22 l bt' ft)
Hol d 2nd
gear agai nst the 2nd cl utch' then measure
the clearance between 2nd
gear and 3rd
gear with a
feel er
gauge.
NOTE: Take measurements in at least three
places,
and use the avrage as the actual clearance'
STANDARD: 0.05
-
0.13 mm 10.002
-
0.005 in)
THRUST WASHER,
36. 5 x 55 mm
(cont ' d)
1+149
Mainshaft
Inspection
(cont'd)
5. l f t he cl ear ance i s out of t ol er ance, r emove t he
thrust washer and measure the thi ckness.
THRUST WASHER
6. Sel ect and i nstal l a new washer, then recheck.
THRUST WASHER 36.5 x 55 mm
After repl aci ng the thrust washer, make sure the
cl earance i s wi thi n tol erance.
7.
No. Part Number
Thickness
1 90441
-
P4P
-
010 4.00 mm (0.157
i n)
90442- P4P- 010
4. 05 mm
( 0. 159
i n)
90443- P4P- 010
4. 10 mm
( 0. ' 161
i n)
4 90444- P4P- 010 4. 15 mm
( 0. 163
i n)
90445- P4P- 010 4.20 mm
(0.165
i n)
90446- P4P- 010
4.25 mm
(0.167
i n)
7 90447- P4P- 010
4.30 mm
(0.169
i n)
8 90448- P4P- 010
4. 35 mm
( 0. 171
i n)
90449- P4P- 010 4. 40 mm
( 0. 173
i n)
10 90450- P4P- 000 4. 45 mm
( 0. 175
i n)
b
14- 150
Countershaft
NOTE:
. Lubri cate al l parts wi th ATF before reassembl y'
. tnrp"",,n",t
-"t needl e beari ngs and the needl e beari ngs for gal l i ng and rough movement'
. Before i nstal l i ng the O-ri ngs. wrap the shaft spl i nes wi th tape to
prevent damagi ng the O-ri ngs
. Locknut has l eft-hand threads
LOCKNUT
(FLANGE NUT}
23 x 1. 25 mm
103 N. m
{10. 5
kgf ' m, 75. 9 l bf ' t t )
Repl ace.
Lef t ' hand l hreads
CONTCAL
SPRI NG
WASHER
Repl ace.
GEAR
CLUTCH
1ST GEAR
BEARING
lST GEAR COLLAR
TRANSMISSION
HOUSING
BEARING
REVERSE
GEAR
NEEDLE
BEARING
SELECTOR
SELECTOR
4TH GEAR
NEEDLE BEARING
DISTANCE COLLAS,
28 mm
Selective
pa .
COUNYERSHAFT
Check spl i nes
l or excessl ve
wear and damage
2'{D GEAR
THRUST NEEDLE
BEARING
3RD GEAB
NEEDLE
BEARING
3RD GEAR COLLAR
THRUST
NEEDLE EEARING
SPLI NEO
WASHER
3RD CLUTCH
ASSEMBLY
Check beari ng
surf ace
f or scori ng'
scrat ches
and excessi ve
wear'
Repl ace.
1 +1 5 1
Countershaft
1. Usi ng a hydraul i c press, press
out the countershaft
whi l e supporti ng 4th gear.
NOTE: Pl ace an attachment between the press
and
the countershaft to prevent
damage to the shaft.
CAUTION: Do not allow the countershaft to fall and
hit the g.ound
when pressed
clear.
14-152
2. Assembl e the parts
on the countershaft
as shown
oetow.
NOTE;
. Lubri cate al l parts
wi th ATF duri ng assembl y.
.
Before installing the O-rings, wrap the shaft splines
with tape to prevent
damaging the O_rings.
4TH GEAR
NEEDLE EEARI NG
DISTANCE COLLAR, 28 mm
Selective part.
2ND GEAR
THRUST NEEOLE BEARI NG
3RD GEAR
NEEDI.E EEARING
3RO GEAR COLLAR
THRUST NEOLE BEARING
SPLI NED WASHER
3RD CLUTCH ASSEMBLY
O. RI NGS
Repl ace.
COUNTERSHAFT
3. Instal l the reverse sel ector hub on the countershaft
sub-assembl y,
and then
press the reverse sel ector
hub usi ng the speci al tool and a press as shown'
Inspection
r Cl earance Measurement
NOTE; Lubri cate al l
parts wi th ATF duri ng assembl y
1. Remove the countershaft beari ng from the trans-
mi ssi on housi ng
(see page l 4-174)
2. Instal l the
parts bel ow on the countershaft usi ng l he
speci al tool and a
press as descri bed on thi s
page
NOTE: Do not assembl e the O-ri ngs duri ng i nspec-
ti on.
REVERSE
SELECTOR
HUB
4TH GEAR
NEEDLE BEARING
DISTANCE
COLLAR,
28 mm
Selectave Part.
2ND GEAR
THRUST
NEEDLE BEARING
3RD GEAR
BEARING
3RD GEAR COLLAR
THBUST NEEDLE
BEARING
SPLINEO
WASHER
3RD CLUTCH
ASSEMBLY
(conl ' d)
14- 153
Gountershaft
Inspecti on
(cont' dl
3. I nst al l t he par t s
bel ow on t he count er shaf t sub-
assembt y, t hen t or que t he l ocknut t o 29 N. m ( 3. 0
kql.m
, 22 blf.ftt .
NOTE: Countershaft l ocknut has l eft hand threads.
(=)-----'
v
LOCKNUT
Lef t hand t hreads
CONI CAL SPRI NG
WASHER
PARK GEAR/ONE.WAY
CLUTCH/ 1ST GEAR
ASSEMBLY
NEEOLE BEARI NG
.I
ST GEAR COLLAR
BEARI NG
REVERSE GEAR
COLLAR
\
14-154
4. Measure the cl earance between the 2nd gear
and
the 28 mm di stance col l ar wi th a feel er gauge.
NOTE: Take measurements
i n at l east three pl aces.
and use the average as the actuar ctearance.
STANDAFD:
0.10
-
0.18 mm
{0.004
-
0.002 i nl
l f the cl earance i s out of tol erance. remove the 2g
mm di stance col l ar and measure the wi dth.
Sel ec t and i ns t al l a new di s t anc e c ol l ar , t hen
recheck.
DISTANCE COLLAR, 28 mm
7. Afret sel ecti ng a new di stance col l ar, recheck the
cl earance and make sure i t i s wi thi n tol erance.
OI STANCE COLLAR, 28 mm
No. Part Numbr
widrh
1 90503- PCg- 000
39. 00 mm ( 1. 535
i n)
2 90504- PCg- 000
39. 10 mm
{
1. 539 i n)
90505- PCg- 000
39. 20 mm ( 1. 543
i n)
90507- PCg- 000
39. 30 mm
{ 1. 547 i n)
90508- PC9- 000
39. 05 mm
( 1. 537
i n)
90509- PCg- 000
39. 15 mm
( 1. 541
i n)
7 90510- PCg- 000
39. 25 mm (
1. 545 i n)
I 90511- PCg- 000
38. 90 mm ( 1. 531
i n)
90512- PCg- 000
38. 95 mm
( 1. 533
i n)
One-way
Clutch
Di sassembl y/l nspecti on/Reassembl y
1. Separate countershaft 1st gear from the park gear
by turni ng the park gear i n the di recti on shown
2. Remove the one-way cl utch by pryi ng i t up wi th the
end of a screwdri ver.
COUNTERSHAFT
1ST GEAR
ONE-WAY CLUTCH
NOTE: l nst al l i n t hi s di rect i on.
ONE'WAY
CLUTCH
COUNTERSHAFT
lST GEAR
COUNTERSHAFT l ST GEAR
SCREWORIVER
14- 155
3. Inspect the parts as fol l owsl
PARK GEAR
I nspecl t he
park gear
f or wear and scorrng.
ONE-WAY CLUTCH
I nspect t he one-way
cl ut ch f or damage and
l aul t y movement .
l ST GEAB
Inspect countershalt lst gear
for wear ancl scorl ng.
After the
parts are assembl ed, hol d countershaft 1st
gear and turn the park gear i n the di recti on shown
to be sure i t turns freel y. Al so make sure the park
gear does not turn i n the opposi te di recti on.
Clutch
lllustrated Index
(A4RA,
B4RA Transmission)
3RD CLUTCH
O-RINGS
Beplace.
CLUTCH
ptSTON
lST CLUTCH
CLUTCH
DRUM
CLUTCH END
PLATE
SPRING RETAINER
RETUNN SPRING
CLUTCH DRUM
SNAP RING
CLUTCH END
CLUTCH PLATES
St andard t hi ckness:
1. 6 mm (0. 063
i n)
SNAP RING
CHECK VALV
\
14-156
SNAP RING
2NDi4TH CLUTCH
SNAP RING
SPRING
RETAINER
RETURN SPRING
DISC SPRING
CHECK VALVE
O.RINGS
Replace.
4TH CLUTCH DRUM
CLUTCH PISTON
CLUTCH PLATES
St andardt hi ckness:
O-RI NGS
2. 0 mm {0. 079 i n)
Repl ace.
SNAP RING
14-157
Clutch
lllustrated Index
(M4RA
Transmission)
3RD CLUTCH
CLUTCH
DRUM
CLUTCH PISTON
DISC SPRING
CLUTCII END
rST CLUTCH
CLUTCH E D
SI{AP RIiIG
CLUTCH PLATES
St andard t hi ckness:
1. 6 mm (0. 063
i n)
CHECK VALVE
L
14- 158
SNAP RING
2ND/4TH CLUTCH
VALVE
2. 0 mm
(0. 079 i n)
2ND CLUTCH
DRUM
CLUTCH PISTON
RETURN SPRING
\ l - .
CLUTCH
PISTON
RETURN SPRING
SNAP RING
14- 159
Clutch
Disassembly
1 . Remove the snap ri ng. then remove the cl utch end
pl ate, cl utch di scs and pl ates.
SCREWDRI VER
SNAP RI NG
2. Remove the di sc spri ng.
NOTE: Except 2nd cl utch.
1
CLUTCI{ DRUM
DI SC SPRI NG
L
14-160
3. Instal l the speci al tool s as shown.
CLUTCH
COMPRESSOR
AOLT ASSEMBLY
07GAE
-
PG4tt200
ol
O'GAE
-
FG4O2OA
CLUTCH SPRI NG
COMPRESSOR
ATTACHMENT
07LAE
-PX40, t
00
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
PX()100
o1
07HAE
-
P150100
CLUTCH SPRING
COMPRESSOR
ATTACIIMENT
oTLAE-PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
Px/Ol00
ot
07HAE
-
PLs0100
CLUTCH
COMPRESSOR
BOLT ASSEMBLY
07GAE
-
PG/O200
OTGAE
-
PG4O2OA
CAUTION: lf eithd end of the 3pocial tool issotoveran
area ot the spring rstainer which is unsupportd by tho
return spring, tho rtainl may be damagod. Bo eure the
special tool is adiusted to have full contact with tha
spring retainor.
SPRING RETAINER
4. Compfess the return sprang.
Do not sat horo.
5. Remove the snap ring. Then remove the special tools,
spring retainer and return spring.
Wrap a shop rag around the cl utch drum, and appl y
air
pressure to the ATF
passage to remove the pis-
ron.
Pl ace a fi nger ti p on the other end whi l e appl yi ng
air
pressure.
OSHA.APPROVED
SPRING RETAIItIER
PISTON
14-161
Clutch
Reassembl y
NOTE:
. Cl ean al l par t s t hor oughl y i n sol vent or car bur et or
a
cl eaner, and dry them wi th compressed ai r.
Bl ow out al l passages.
Lubri cate al l parts
wi th ATF before reassembl y.
Inspect the check val ve; i f i t' s l oose, repl ace the pi s-
to n.
1 .
CHECK VALVE
2. Instal l new O-ri ngs on the cl utch pi ston.
O RI NGS
PI STON
-
14-162
3. Instal l the pi ston
i n the cl utch drum, Appl y pressure
and rotate to ensure proper
seati ng,
NOTE: Lubri cate the pi ston
O-ri ng wi th ATF before
i nstal l i ng.
CAUTION: Do not pinch
the O-ring by insta ing the
piston
with too much force.
CLUTCI I DRUM
I nst al l t he r et ur n spr i ng and spr i ng r et ai ner , and
posi ti on
the snap ri ng on the retai ner.
CLUTCI { DRUM
CLUTCH SPRI NG
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
or
07HAE
-
P150100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
PX4010o
07HAE
-
PL50100
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
07GAE
-
PG40200
O7GAE. PG4O2OA
SPRING
CAUTION: l f ei the. end of the sDeci al tool i s set
over an area of the spring retainer which is unsup-
ported by the rsturn spri ng, the i etai ner may be
damaged. Bs sure the speci al tool i s adj usted to
have full contact with the spring retainer.
Sot hsro.
SPECIAL TOOL
RETAINER
6. Compress the return spri ng.
(cont ' d
)
Do not sot hore.
14- 163
Glutch
Reassembly
(cont'd)
7. I nst al l t he snap r i ng.
Removs the speci al tool s.
Instal l the di sc spri ng.
NOTE: I nst al l t he di sc spr i ng i n t he di r ect i on
shown, except 2nd clutch.
SNAP RI NG
8.
o
14-164
h
10.
l l .
Soak the cl utch di scs thoroughl y i n ATF for a mi ni -
mum of 30 mi nutes.
Starti ng wi th a cl utch pl ate,
al ternatel y i nstal l the
cl utch pl ates
and di scs. Instal l the cl utch end pl ate
with flat side toward the disc.
NOTE: Before i nstal l i ng the pl ates
and di scs, make
sure the i nsi de of the cl utch drum i s free of di n or
other foreign mafter.
CLUTCH END PLATE
Instal l i n thi s di recri on.
12. Instal l the snap ri ng.
SCREWDRIVER
SNAP RING
13. Measure the cl earance between the cl utch end
pl ate
and top di sc wi th a di al i ndi cator' Zero the di al i ndi -
cator wi th the cl utch end
pl ate
l owered and l i ft i t up
to the snap ri ng. The di stance that the cl utch end
pl ate moves i s the cl earance between the cl utch end
pl ate and top di sc.
NOTE| Take measurements i n at l east three
pl aces,
and use the average as the actual cl earance.
Clutch End Plste-to-Top Disc Clearance:
OI AL I NDI CATOR
CLUTCH END
PLATE
Cl earance
14.
CLUTCH DI SC
l f t he cl ear ance i s not wi t hi n t he ser vi ce l i mi t s,
sel ect a new cl utch end
pl ate from the fol l owi ng
tabl e.
NOTE: l f the thi ckest cl utch end
pl ate i s i nstal l ed,
but the cl earance i s sti l l over the standard, repl ace
the cl utch di scs and cl utch
pl ates.
PLATE NUMBER
Thickn6ss
Cl utch
SerYice Limit
1st
2nd
3rd
4th
0.65
-
0.85 mm
(0.026 -
0.033 i n)
0.65
-
0.85 mm
(0.026
-
0.033 i n)
0.40
-
0.60 mm
(0.016 -
0.024 i n)
0.40
-
0.60 mm
(0.016
-
0.024 i n)
CLUTCH ENO PLATE
14- 165
Plate No. Part Number Thickness
,l
2
J
4
5
6
1
8
q
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
2. 1 mm
( 0. 083
i n)
2.2 mm
(0.087
i n)
2. 3 mm
( 0. 091
i n)
2.4 mm
(0.094
i n)
2.5 mm
(0.098
i n)
2. 6 mm
( 0. 102
i n)
2. 7 mm { 0. 106 i n)
2. 8 mm { 0. 110 i n)
2, 9 mm
( 0. 1
' 14
i n)
CLUTCH END PLATE
A4RA,
g4RA
Transmission:
M,IRA Transmi$ion:
15. After repl aci ng the cl utch end pl ate. make sure that
the cl earance i s wi thi n tol erance.
Plate No. Part Number Thickness
1
3
'l
.'
q
10
1 1
' t2
1 3
1 4
1 5
' 16
17
18
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
2.4 mm
(0.094 i n)
2.5 mm
(0.098
i n)
2. 6 mm { 0. 102
i n)
2. 7 mm
( 0. 106
i n)
2. 8 mm
( 0. 110
i n)
2. 9 mm
( 0. 114
i n)
3. 0 mm { 0. 118
i n)
3. 1 mm
( 0. 122
i n)
3. 2 mm
( 0. 126
i n)
3. 3 mm
( 0. 130
i n)
2. 1 mm
( 0. 082
i n)
2.2 mm {0.086
i n)
2.3 mm
(0.090
i n)
3. 4 mm
( 0. 134 i n)
3. 5 mm
( 0. 138
i n)
3. 6 mm
( 0. 142 i n)
3. 7 mm
( 0. 146 i n)
3. 8 mm
( 0. 150
i n)
Differential
l l l ustrated l ndex
BOLT
1 0 r 1 . 0 mm
' 10' l
N' m
(10. 3
k91. m, 74. 5 l bf . f t l
Left-hand threads
SET RING, 80 mrrt
FI NAL DRI VEN GEAR
I nspect t or excessi ve wear.
I nst al l i n t hi s di rect i on.
efef
BALL BEARING
I nspect f or f aul t y movement .
DIFFERENTIAL CARRIER
I nsoect f or cracks,
R OL L E R , 5 x 1 0 mm
SPEEDOMETER ORI VE
GEAR
l nst al l i n t hi s di rect i on.
SNAP RI NG
EALL BEARI NG
I nspect f or f aul t y movement -
-
14- 166
Backlash lnspection
1. Pl ace di fferenti al assembl y on V-bl ocks and i nstal l
both axles.
Check backl ash of both
pi ni on gears
Standard {Now): 0.05
-
0.15 mm {0.002
-
0.006 in)
l f backl ash i s out of tol erance, repl ace the di fferen-
ti al carri er.
Bearing Replacement
NOTE: Check beari ngs for wear and rough rotati on. l f
beari ngs are OK, removal i s not necessary.
1, Remove beari ngs usi ng a beari ng pul l er.
BEARING PULLER
(Commerci 6l l y
avai l abl e)
2. Instal l new beari ngs usi ng the speci al tool as shown.
14-167
Differential
Diff erential Carrier Replacement
L Remove the fi nal dri ven gear from the di fferenti al
carrier.
NOTE: The fi nal dri ven gear
bol ts have l eft-hand
threads.
Pry the snap ring off differential carrier, then remove
the speedometer dri ve
gear
and 5 x 10 mm rol l er.
SNAP RI NG
3. Instal l the 5 x l 0 mm rol l er i n the di fferenti al carri er,
Instal l the speedometer dri ve gear wi th i ts cham-
fered si de faci ng the carri er. Al i gn the cutout on the
bore of the speedometer dri ve gear wi th the 5 x 10
mm rol l er.
L
14-168,
5. Al i gn the hooked end of the snap ri ng wi th the pi n-
i on shaft as shown, then i nstal l the snap ri ng i n the
differential carrier groovs.
SNAP RING
Hooked end Instal l i n thi s di recti on.
SPNI G PIN
Instal l the fi nal dri ven gear, then ti ghten the bol ts to
the speci fi ed torque.
TOROUE: 101 N.m
(10.3
kgf'm, 74.5 lbf.ftl
NOTE: The fi nal dri ven
gear
bol ts have l eft-hand
threads.
BOLTS
1 0 r 1 . O mm
1Ol t {. m 11O. 3 kgf . m,
74.5 lbl.frl
Left-hand rhreads
FINAL DRIVEN
GEAR
l nstal l i n thi s
di r ect i on.
DIFFERENTIAL
CARRIER
7. I nst al l a new bal l beari ng
(se page 14-157).
I nst al l i n t hi s di recl on.
Oi l Seal Removal
1. Remov the differential assembly.
2, Remove the oi l seal from the transmi ssi on housi ng,
OIL SEAL
Ropl ace.
t he oi l seal f r om t hs t or que conver t er Remove
housi ng.
OIL SEAL
Repl ace.
TOROUE CONVERTEF
HOUSING
Oil Seal Installation/Side Glearance
1. Instal l a 2.50 mm
(0.098
i n) set ri ng,80 mm i n trans-
mi ssi on housi ng.
NOTE: Do not i nstal l the oi l seal vet.
RING, 80 mm
TRAITISMISSlON
HOUS|l{G
Instal l the di fferenti al assembl y i nto the torque con-
verter housi ng usi ng the speci al tool as shown.
I nst al l t he t r ansmi ssi on housi ng and t i ght en t he
bol ts {see
page 14-178 and 14-179).
{cont ' d)
14- 169
Differential
Oi l Seal Instal l ati on/Si de Cl earance
(cont' d)
4. Tap on the transmi ssi on housi ng si de of the di ffer-
enti al assembl y wi th the speci al tool to seat the di f-
ferenti al assembl y i n the torque converter housi ng.
DRI VER 40 mm l . D.
L
14-170
5. N4easure the cl earance between the 80 mm set ri ng
and outer race of the bal l beari no i n the transmi s-
si on housi ng.
STANDARD: 0
-
0.15 mm
(0 -
0.006 i nl
SET RI NG, 80 mm
BALL BEARI NG
l f the cl earance i s more than the standard, sel ect a
new set ri ng from the tabl e, and i nstal l :
SET RING, 80 mm
NOTE: l f the cl earance measured i n step 5 i s stan-
dard, it is not necessary to perform steps 7 and 8.
Remove the transmi ssi on housi ng.
Repl ace the 2.50 mm
(0.098
i n) 80 mm set ri ng wi th
the one of the correct thi ckness sel ected i n step 6.
7.
Part Number Thickness
90414- 689- 000
904r 5- 689- 000
90416- 689- 000
90417- 689- 000
90418- 689- 000
904r 9- PH8- 000
2.50 mm
(0.098
i n)
2. 60 mm { 0. 102 i n)
2. 70 mm { 0. 106 i n)
2. 80 mm
( 0. 110
i n)
2. 90 mm
( 0. 114
i n)
3. 00 mm
( 0. 118
i n)
9. l nstal l the new oi l seal fl ush wi th the transmi ssi on
housj ng usi ng the speci al tool s as shown
DRIVER
077i(}
-
0010000
PILOT.
2 6 x 3 0 mm
07JAO
-
PH80200
DRIVER ATTACHMENT, 68 mm
079i 17-6110501
10. l nstal l the new oi l seal fl ush wi th the torque con-
verter housi ng usi ng the speci al tool s as shown
DRIVER
07749
-
0010000
14- 171
Torque Converter Housing Bearings
Mainshaft Bearing/Oil Seal Replacement
1 . Remove the mai nshaft beari ng and oi l seal usi ng
3/8"16 SLIOE HAMMER
ADJUSTAELE BEARING
PULLER, 25
- ilo
mm
07736
-
A01000a
L
14- 172
2. Drive in the new mainshaft bearing until it bottoms
i n the housi ng usi ng the speci al tool s as shown.
DRIVER
077
-
0010000
l nstal l the new oi l seal fl ush wi th the housi ng usi ng
DBIVER
07749
-
0o l0(xt0
ATTACHMENT,
72x75 mf i
07746
-
001 0600
Countershaft Bearing Replacement
' 1.
Remove the countershaft beari ng usi ng the speci al
tool s as snown.
3,/8'.16 SLIDE HAMMER
{Commerci al l v avai l abl e)
AOJUSTABLE
BEARING
PULLER,
2 5 - { Omm
07736
-
A0'1000A
2.
5 .
Instal l the ATF
gui de pl ate.
Dri ve the new beari ng i nto the housi ng usi ng the
ATTACHMENT,
6 2 x 6 8 mm
0
-
0.03 mm
(0 -
0. 001 i nl
14-173
Transmission Housing Bearings
L
Mainshaft/Countershaft Bearings Replacement
To remove the mai nshaft and countershaft beari ngs
from the transmi ssi on housi ng, expand each snap
ri ng wi th snap ri ng pl i ers,
then push
the beari ng out
usi ng the speci al tool s and a press
as shown.
NOTE: Do not r emove t he snap r i ngs unl ess i t ' s
necessary to cl ean the grooves i n the housi ng.
DRIVER
07749
-
0010000
ATTACHMENT,
6 2 x 6 8 mm
PRESS
\
07746
-
DFI VEB
07749
-
0010000
TTACHMENT
ATTACHMENT
. Mainshaft Bearing Installation us:
ATTACHMENT. 72 x 75 mm
07746
-
0010600
. Countershaft Bearing Installation use:
077/16
-
0010500
IRN
{L{r.)n
\bZ
MAINSHAFT BEARING
L
14- 174
SNAP RING
Expand each snap ri ng wi th snap ri ng pl i ers, i nsert
t he new bear i ng par t - way i nt o t he housi ng usi ng
the speci al tool s and a press as shown, Instal l the
beari ng wi th the groove faci ng outsi de the housi ng.
NOTE: Coat al l parts wi th ATF.
Rel ease the pl i ers, then push
the beari ng down i nto
the housi ng unti l the ri ng snaps i n pl ace around i t.
07749
-
0010000
ATTACHMENT
.
Mainshaft Bearing Removal use:
077/16
-
0010600
.
Counte6haft Bsaring Removal use:
07746
-
0010500
After i nstal l i ng the beari ng veri fy the fol l owi ng:
. The snap ri ng i s seated i n the beari ng and hous-
i ng grooves.
. The ri ng end gap i s correct.
(0 -
0.28 i n)
ENDGAP: 0 - 7 mm
Reverse ldler Gear
Park Stop
l nstal l ati on
1, l nstal l the reverse i dl er gear.
Instal l the reverse i dl er gear shaft hol der and needl e
beari ng i nto the transmi ssi on housi ng, then ti ghten
the bol ts.
6 x 1. 0 mm
12 N. m l l . 2 kgf ' m,
8. 7 t bf . f t l
GEAR
' 1.
Inspection/Adiustment
Set the
park l ever i n the
E
posi ti on.
Measure the distance between the
park pawl
shaft
and the
park
l ever rol l er
pi n
as ahown.
STANDARD: 72.9
-
73.9 mm 12.87
-
2.91 inl
PARK PAWL
SHAFT
l f the measurement i s out of tol erance, sel ect and
i nst al l t he appr opr i at e
par k st op f r om t he t abl e
Del ow.
PARK STOP
PARK STOP
After repl aci ng the park stop, make sure the di s-
tance i s wi thi n tol erance.
/A\
Measuri ng
\v
Mark Part Numbr Lr 12
I 24537- PAg- 003 11. 00 mm
(0.433
i n)
11. 00 mm
( 0. 433
i n)
24538- PAg- 003 10. 80 mm
(0.425
i n)
10.65 mm
( 0. 419 i n)
24539- PAg- 003 10. 60 mm
( 0. 417
i n)
10. 30 mm
(0.406
i n)
14-175
Transmission
Reasembly
NOTE;
.
Coat all parts
with ATF.
. Bepl ace the fol l owi ng parts:
-
O-ri ngs
-
Lock washers
-
Gaskets
-
Mai nshaft and countershaft l ocknuts and coni cal spri ng washers
-
Seal i ng washers
TOROUE: l2 N.m
(1.2
ksf'm,8.7 lbf.ft)
6 x
' l . 0
mm
7 Bol t s
FEED PIPE: A
LOCK.UP VALVE
BODY
LOCK.UP SEPARATOR
PLATE
REGULATOR VALVE
BODY
DOWEL PINS. 2
6 x l . 0 mm
1 Bol t
ATF STRAINER
ATF FEED
PIPES:
a
COOIER RELIEF VALVE
TOROUE CONVENIER
CHECK VALVE
STATOR SHAFT
O.RING
STOP SHAFT
ATF FEEO PIPE: H
5 x 1 . 0 mm
5 Bol t s
DOWEL PINS.
MAIN VALVE BODY
ATF PUMP
SERVO SEPARATOR
PLAYE
6 x 1 . 0 mm
7 Bolts
SERVO BODY
SECONOARY
SEPARATOR PLATE
CONTROL
GEAR SHAFT
ATF PUMP DFIVEN
GEAR
MAIN SEPARATOR
PLATE
DOWEL PINS,
/
SHAFI
'
-
7r(
t'se
-
oo ôd"t"t
l l i
tri
TOROUE CONVERTER
HOUSING
NOTE: The i l l ustrati on shows the' 96
-
98 modsl s, the' 99
-
00 model s do not have the servo detent base; the servo
detent i s i ntegral wi th the servo bodv.
14- 176
L-
1 . Instal l the ATF magnet and sucti on
pi pe col l ar i n the
torque converter housi ng. i f necessary.
l nstal l the mai n seDarator
pl ate
and the two dowel
pi ns on the torque converter housang.
Instal l the ATF
pump dri ve gear, ATF
pump dri ven
gear and ATF
pump dri ven
gear
shaft on the torque
converter housing.
NOTE; Instal l the ATF
pump dri ven
gear wi th i ts
grooved and chamfered si de taci ng down.
ATF PUMP
ATF PUMP DRIVEN
GEAR SHAFT
ATF PUMP
DRIVEN GEAR
Grooved and chamf ered
si de t aces separal or
pl at e.
MAIN SEPARATOR
PLATE
4. Loosely install the main valve body with five bolts.
Make sure the ATF
pump drive gear rotates smoothly
in the normal operating direction and the ATF pump
dri ven
gear shaft moves smoothl y i n the axi al and
normal operati ng di recti ons.
Instal l the secondary val ve body, separator
pl ate
and two dowel
pi ns on the mai n val ve body.
NOTE: Do not i nstal l the bol ts.
6. Instal l the control shaft i n the housi ng wi th the con-
trol shaft and manual val ve together.
7. l nstal l the detent arm and arm shaft i n the mai n
val ve body, then hook the detent arm spri ng to the
detent arm,
SERVO SEPARATOR PLATE
DETENT
MANUAL VALVE
DETENT ARM SPRING
15.
14-177
a
10.
1 1 .
Instal l the servo body and separator
pl ate on the
secondary valve body
('95 -
98 models: seven bolts.
' 99
-
00 model s: ei ght bol tsl .
For
' 96
-
98 model s: Instal l the servo detent base
and the ATF strai ner
(two
bol tsl .
For' 99
-
00 model s: Instal l the ATF strai ner
(one
bol t).
Ti ghten the fi ve bol ts on the mai n val ve body to 12
N.m
(' 1.2
kgf.m,8.7 l bf.ft).
Make sure the ATF
pump dri ve
gear and ATF
pump
dri ven
gear shaft move smoothl Y'
l f the ATF
pump dri ve
gsar and ATF pump dri ven
gear shaft do not move freely, loosen ths five bolts
on the mai n val ve body, and di sassembl e the val ve
bodi es.
Realign the ATF pump driven gear shaft and reassem-
ble the valve bodies, then retighten the bolts to the
specified torque,
CAUTION: Fsi l ul e to al i gn tho ATF
pump dri ven
goar shaft corr.ctly will rscuh in a sized ATF
pump
drive
goar or ATF
pump d ven gear shaft.
Install the stator shaft and stop shaft.
Instal l the bol ts and the shaft stop on the secondary
valve body, then tighten the bolts
(three
boltsl.
Instal l the torque converter check val ve, cool er rel i ef
val ve and val ve spri ngs i n the regul ator val ve body.
then i nstal l the regul ator val ve body on the mai n
valve bodv
(one
bolt).
Instal l the l ock-up val ve body on the regul ator val ve
bodv
(seven
bolts).
Instal l the ATF feed
pi pes i n the mai n val ve bodY,
the three ATF feed
pi pes
i n the secondary val ve and
the four ATF feed
pi pes
i n the servo body.
(cont' dl
12.
't
3.
14.
PUMP
Transmi ssi on
_\,]ffi l
Reassembly
(cont'd)
TRANSMISSION
HANGER
MAINSHAFT
SUB. ASSEMBLY
*''
Ufln
$*U . /
MOUNTING BOLTS
10 x 1. 25 mm
4{ N.m {4.5 kg{.m,33 lbI.ft)
REVERSE GEAR
COLLAR
REVERSE GEAR
LOCK WASHER
SHIFT FORK
MAINSHAFT SPEED
SENSOR WASHER
(D16Y7
engi ne)
MAINSHAFT
COUNTERSHAFT
SUB.ASSEMBLY
OIFFERNTIAL
ASSEMBLY
SPEED
TRANSMISSION
HOUSING GASKET
TOROUE CONVERTER
HOUSI NG
14-178
17.
18.
19.
l nst al l t he r ever se i dl er
gear and t he
gear shaf t
hol der
( see page 14- 175) .
l nstal l the di fferenti al assembl y i n the torque con-
verter housi ng.
Assembl e t he mai nshaf t sub- assembl y
and t he
c ount er s haf t s ub- as s embl y ,
t hen i ns t al l t hem
together i n the torque converter housl ng
MAI NSHAFT
SUB-ASSEMBLY
20,
COUNTERSHAFT
SUB.ASSEMBLY
Turn the shi ft fork so the l arge chamfered hol e i s
taci ng the fork bol t hol e, then i nstal l the shi ft fork
wi th the reverse sel ector, and ti ghten the l ock bol t'
Bend the l ock tab agai nst the bol t head
SHI FT FORK
LOCK WASHER
Repl ace.
6 x 1 . 0 mm
4 N. m
(' l . 4 kgl ' m,
1O l bt ' f t )
Lar ge chamt er ed
hol e
21.
22.
l nstal l the needl e beari ng, countershaft reverse gear
and reverse
gear col l ar on the countershaft.
Al i gn the spri ng
pi n on the control shaft wi th the
transmi ssi on
housi ng
groove by turni ng the control
shaft.
CONTROL SHAFT
Instal l the two dowel
pi ns and a new
gasket on the
torque converter housi ng.
Pl ace the transmi ssi on
housi ng on the torque con-
verter housi ng.
CAUTION: Make sure that l he mai nshaft speed
sensor is not installed on the transmission
housing
before installing the transmission
housing on the
torque convrter housing.
l nst al l t he t r ansmi ssi on
housi ng mount i ng bol t s
al ong wi t h t he t r ansmi ssi on hanger , t hen t i ght en
the bol ts i n two or more steps i n the sequence as
shown.
TOROUE:
,l,t
N'm l{.5
kgf'm, 33 lbf'ft}
TRANSMISSION
HANGER
24.
o
(cont ' di
SPRING PIN
14-179
Transmission
26. Sl i p the speci al tool onto the mai nshaft as shown,
MAINSHAFT HOLDER
07GAB
-
PF50101
Instal l the park l ever on the control shaft.
Assembl e t he one- way cl ut ch and t he par k gear
wi th the countershaft l st gear (see page
l 4-1S5).
Instal l the countershaft l st gear
col l ar. needl e bear_
ing, and the countershaft 1st gearlpark gear
assembly
Reassembly
(cont'dl
on the countershaft.
l STCLUTCH PARK
ASSEMBLY GEAR
27.
28.
29.
30. Instal l the park pawl
shaft, spri ng, pawl ,
and pawl
stop on the transmi ssi on housi ng, then engage the
park pawl wi th
the park gear.
14-180
31. I nst al l t he mai nshaf t 1st gear
col l ar on t he mai n_
shaft.
32. Wrap the shaft spl i nes wi th tape to prevent
the O-
ri ngs, then i nstal l new O-ri ngs on the mai nshaft,
33. Assembl e the thrust washer, thrust needl e beari ng,
needl e beari ng, and mai nshaft ?st gear
i n the l st
cl utch assembl y, then i nstal l them on the mai nshaft.
34. Instal l new coni cal spri ng washers and l ocknuts on
each shaft.
CAUTION: Install the conical spring washers in the
direction shown.
MAINSHAFT
LOCKNUT
Lef t hand t hreads
CONICAL SPRING WASHERS
i nstal l i n thi s di recti on.
35. Ti ghten the l ocknuts to the speci fi ed torque.
NOTE:
.
Do not use an i mpact wr ench. Al wavs use a
torque w.ench to tighten the locknut.
.
Mai nshaft and countershaft l ocknuts have l eft_
hand threads.
TOROUE:
MAINSHAFT
78 N.m (8.0
kgf.m, 58 tbf.ft)
COUNTERSHAFT
t03 N.m
1r0.5 kgf.m, 75.9 tbt.ftl
36. Remove the special tool from mainshaft, then stake
each l ocknut usi ng a 3.5 mm
punch as shown'
COUNTERSHAFT
LOCKNUT
Set the
park
lever in the
El
position, then verify that
the
park
Pawl
engages the
Park
gear
l f the Dawl does not engage ful l y, check the
park
pawl stop clearance
(see page 14-175).
Tighten the lock boll and bend the lock tab'
10 tbl.ftl
a'f
38.
ao
LOCK
WASHEF
0. 7
-
1. 2 mm
(0.03
-
0.05 in)
E r l . O mm
14 t {. m
(1. 4 kgf ' m,
\.-
(o)
40. Instsl l the end cover wi th two dowel
pi nsandanew
gasket
(thirteen bolts)'
TOROUE: 12 N'm
(1.2
tgf'm. 8.7 lbf'ft}
END COVER
lnstall the ATF cooler lines with new sealing wash-
9rs.
TOROUE: 28 N.m {2.9
kgf'm. 21 lbt'ft1
Install the ATF diPstick.
41.
14-181
Torque
Converter/Drive
plate
6 x 1 . 0 m m
12 N. m
(1. 2
kgt . m, 8. 7 l bf . f t )
/
E PLATE
74 N. m 17. 5 kgl . m, 54 l bf . f t l
Torque in a ctisscaoss oattern.
@
@
L
14-182
Transmission
1 .
l nstal l ati on
Fl ush the ATF cool er as descri bed on
page l 4-187
and 14-188.
Install the torque converter assembly securely with
a new O-ri ng on the mai nshaft
STARTER MOTOR
14 mm DOWEL PI N
TOROUE
O-RING
CONVERTER
Replace
l nstal l the starter motor on
housi ng, then i nstal l the two
the torque converter housi ng.
lil mm DOWEL PIN
the torque converter
14 mm dowsl
pi ns i n
MOUNTING
BRACKET
Pl ace the transmi ssi on on a
j ack,
and rai se i t to the
engi ne assembl y l evel .
Attach the transmi ssi on to the engi ne, then i nstal l
two transmi ssi on housi ng mounti ng bol ts and two
rear engi ne mounti ng bol ts.
REAR ENGINE
MOUNNNG BOLTS
1 , 1 r 1 5 mm
&| N.m 18.5
kgf m, 61 lbf'ft]
Repl ace.
64 N.m {6.5 47 tbf frl
WASHER
ENGI NE
MOUNTING BOLTS
12 x 1. 25 mm
45 N.m {4.5 kgf.m,
JACK
6. Instal l the transmi ssi on mount bracket.
12 x 1. 25 mm
6il N.m {6.5 kgf.m, a7 lbf'ft)
12 x 1. 25 mm
74 N.m
(7.5
kgf.m,
54 tbt.fr)
TRANSMISSION MOUNT
7. Instal l the remai ni ng transmi ssi on housi ng mount-
i ng bol ts and remai ni ng rear engi ne mounti ng bol t.
REAR ENGINE
MOUNTING BOLT
14 x 1. 5 mm
el N.m
(8.5 kgt'm,
61 tbl.ft)
Replace.
HOUSING
MOUNTING BOLTS
12 x 1. 25 mm
g
N m
(6.5 kgf m,
'l? lblftl
8. Remove t he t ransmi ssi on
j ack.
(cont'd)
14- 183
Transmission
Installation
(cont'dl
9. Attach the torque converter to the drive plate
with
ei ght dri ve pl ate
bol ts and torque as fol l ows:
Rotate the crankshaft pul l ey
as necessary to ti ghten
the bolts to 1/2 of the specified torque. then to the
final torque, in a crisscross pattern.
After ti ghteni ng the l ast bol t, check that the crank-
shaft rotates freely.
TOROUE: 12 N.m {1.2 kgl.m, 8.7 tbt{r}
10 x 1.25 mm
6 x 1 . 0 mm
12 N.m
(1.2
kgt m,
8.7 rbt ft)
I \ 1.25 mm
2/t N.m {2.4 kg{.m,
17 tbt ftl
CONVERTEB
10. Instal l the torque convener cover and the ngi ne
stiffener.
'11.
Tighten the crsnkshaft pully
bolt, if necessary (see
secti on 61.
12. Connect the ATF cooler hoses to the ATF cooler lines
(see page
1,t192).
ATF COOIIR
UNE
10 x 1. 25 mm
a,l N.m {4.5 kgl.m,
33 rbt.ftt
RIGHT FRONT 12 x 1.25 mm
MOUNT/BRACKET
6.t N.m
(6.5
kg{.m,
47 tbt ftl
13. Instal l the ri ght front mounvbracket.
4,r N.m 14.5 kgf.m,33 lbtft)
COVER
L,
14-1A4
SHIFT CABLE
SHIFT CAAE COVER
14. Instal l the control l ever wi th a new l ock washer to
the control shaft, then i nstal l the shi ft cabl e cover.
CAUION: Taks care not to bend the shift cable.
L(rcK WASHER
Repl ace.
8 x 1,25 r'|m
22N-m
12.2 tgt m. 16lbnftl
x 1. 0 mm
tit N.m 11.4 kgt m,
10 tbr,ft,
15. l nstal l the exhaust pi pe
A.
NOTE: D16Y8 engine is shown; D16y/ engine is sim_
i l ar.
Repl ace.
GASKET
Repl ace.
SELF.LOCKING NUT
Repl ace.
10 x 1. 25 mm
54 N.m
(5.5
lgf.m,
40 tbt ftl
NUT
SELF.LOCKING NUT
Replace.
8 x 1. 25 mm
22 N.m {2.2 kgl.m, 16lbtfrl
Replace.
8 x 1. 25 mm
16 N. m {1. 6 kgI . m,
12 tbf.ft)
16. Instal l a new set ri ng on the end of each dri veshaft'
17. Instal l the ri ght and l eft dri veshafts
(see
sscti on 16)
CAUTION: Whil6 installing the driveshafE in the
diffarential, be surs not lo allow du3t and othor for-
eign
particls to enler into the transmission.
NOTE:
. Clean the areas where the driveshafts contact the
transmi ssi on
(di fferenti al ) thoroughl y wi th sol -
vent or carburetor cl eaner, and dry wi th com-
pressed air.
. Turn the ri ght and l eft steeri ng knuckl e ful l y out-
ward, and slide each driveshaft into the differen-
ti al unti l
you feel i ts set ri ng cl i p engage the si de
gear.
18. Instal l the damper fork, then i nstal l the ri ghtand l eft
bal l
j oi nts
to the each l ower arm wi th the castl e nuts
and new cotter
Plns.
DAMPER PINCH BOLT
10 x 1 .25 mm
a3 N.m l4.ia
kgf.m,
32 tbl.ftl
4l
COTTER
Repl ace. SELF.LOCKING
NUT
12 x 1. 25 mm
6il N.m t6.5
kgf'm,
il7 lbf ftl
Replace.
19. I nst al l t he spl ash shi el d.
{5.0
-
6.0 kgf m, 36
- iB
lbf'ft|
CASTLE NUT
12 x 1, 25 mm
49
-
59 N.m
20. Connect the mai nshaft speed sensor, the l i near sol e-
noi d and the shi ft control sol enoi d connectors.
SHIFT CONTROL SOLENOIO LINEAR SOITNO|o
CONNECTOR
CONNECTOR
6 r 1. 0 mrn
12 N. m
(1. 219f . m,
E.7 lbf.frl
CONNECTOR
21. Connect the countershaft speed sensor and the vehi-
cle speed sensor
(VSS)
connectors.
VEHICI..E SPEED
SENSOR CONNECTOR
COUNTERSHAFT
SPEED SENSOR
CONNECTOR
(cont' dl
14-185
Transmission
Installation
{cont'd)
Connect the l ock-up control sol enoi d connector. and
i nstal l the transmi ssi on ground
cabl e.
6 x
' 1.0
mm
12 N.m
{1.2 kgf.m, 8.7 lbl.ft}
LOCK.UP CONTROL
SOLENOID CONNECTOR
Connect the staner cabl es on the staner motor. and
i nstal l the cabl e hol der.
NOTE; When i nstal l i ng the starter cabl e termi nal .
make sure that the cri mped si de of the ri ng termi nal
i s faci ng out
(see
secti on 23).
6 x 1 . 0 mm
12 N. m 11. 2 kg{. m. 8. 7 t bt f t l
{0.9 kg'f.m, 7 lbf.ftl
TRANSMISSION
GROUND CABLE
b
14-186
STARTER CAELE
24. Instal l the i ntake ai r duct.
D16Y7 engi ne:
Instal l the i ntake ai r duct and the resonaror.
D16Y8 engi ne:
l nstal l the i ntake ai r duct and the ai r cl eaner hous_
ang assembl y.
25. Refi l l the transmi ssi on
wi th ATF
(see
page 14_1.18).
26. Connect the posi ti ve (+)
cabl e fi rst. then the nega-
tive
(-)
cable to the battery.
27. Check the i gni ti on ti mi ng
(see
secti on 23).
28. Start the engi ne. Set the parki ng
brake, and shi ft the
transmi ssi on through al l gears.
three ti mes. Check
the shi ft cabl e adj ustment (see
page
14_190).
29, Check the front wheel al i gnment (see
secti on 1g).
30. Let t he engi ne r each oper at i ng t emper at ur e ( t he
cool i ng fan comes on) wi th the transmi ssi on
i n
N
or
@
posi ti on,
then turn i t off and check the fl ui d
l evel (see page
14- 7).
31. Road test as descri bed on pages
14-113 thru
,14_116.
Cool er
Fl ushi ng
!!!@
To
prevent iniury to. face and eyas, always
-ea. safetv
gl asses ot a face shi el d when usi ng the
transmission flusher.
NOTE: Thi s
procedure shoul d be
performed before rei n-
stal l i ng the transmi ssi on.
1. Check the tool and hoses for wear and cracks before
usi ng. l f wear or cracks are found, repl ace the hoses
before usi ng.
Usi ng the measuri ng cup, fi l l the tank wi th 2' l ounces
(approxi matel y 2/3 ful l ) of bi odegradabl e
fl ushi ng
fl ui d
(J35944
-
20). Do not substi tute wi th any other
f l ui d. Fol l ow t he handl i ng
pr ocedur e on t he f l ui d
contarner.
Secure the fl usher fi l l er cap, and
pressuri ze the tank
with compressed
air to between 550
-
829 kpa
(5
6
-
8.45 kgfl cm' . 80
-
120Psi ).
NOTE: The ai r l i ne shoul d be equi pped wi th a water
trap to ensure a dry ai r system.
Hang the tool under the vehi cl e.
Attach the tank' s di scharge hose to the return l i ne
of the transmi ssi on cool er usi ng a cl amp.
Connect the drai n hose to the i nl et l i ne on the trans-
mi ssi on cool er usi ng a cl amP
IMPORTANT:
Securely clamp the opposite end oJ the drain hose to a
bucket or fl oor drai n.
TRA MtssroN
TRANSMISSION COOLER
FLUSHER
{Commcrci.llY
avail.blel
Kent-Moore J384O5'A
or equivelent
NS
I
{r
Water
7. With the water and air valves off, attach the water and
ai r suDol i es to the fl usher' l Hot
water i f avai l abl e.)
8, Turn on the fl usher water val ve so water wi l l fl ow
through the cool er for 10 seconds.
NOTE; l f water does not tl ow through the cool er, i t
i s compl etel y
pl ugged. cannot be fl ushed, and must
be repl aced.
9. Depress the trigger to mix the flushing fluid into the
water flow. Use the wire clip to hold the trigger down'
Whi l e fl ushi ng wi th the water and fl ushi ng fl ui d for
two mi nutes, turn the ai r val ve on for fi ve seconds
everv 15
-
20 seconds to create a surgi ng acti on'
AIR PRESSURE: MAX 845 kpa {8.45
kgf/cm' , 120 psi )
Turn the water val ve off. Rel ease the tri gger, then
reverse the hoses to the cool er so you can fl ush i n
the opposi te di recti on. Repeat steps 8 through 10'
12, Rel ease the tri gger, and ri nse the cool er wi th water
onl v for one mi nute
13. Turn the water valve off, and turn off the water supply
14. Turn the ai r val ve on to dry the system out wi th ai r
for two ful l mi nutes or unti l no moi sture i s vi si bl e
l eavi ng the drai n hose.
CAUTION: Residual mobturo in tho cooler or pipas
can damage the transmksion'
15. Remove the fl usher from the cool er l i ne. Attach the
drai n hose to a contal ner.
16. Instal l the transmi ssi on,
and l eave the drai n hose
attached to the cool er l i ne
{cont ' d)
10.
' 11.
14-187
Transmission
17.
Cool er Fl ushi ng
(cont' dl
Make sure the transmi ssi on i s i n the
E
posi ti on.
Fi l l the transmi ssi on wi th ATF, and run the engi ne
for 30 seconds or unti l approxi matel y 0.95 f
(1.0
US
qt.,0.8 l mp qt.)
i s di scharged.
Remove the drai n hose, and reconnect the cool er
return hose to the transmi ssi on
(see
page
l 4-192).
Refi l l the transmi ssi on wi th ATF to the oroDer l evel
(see page
14-118).
18.
19.
b
14-18A
TOOL MAINTENANCE
1. Empty and rinse after each use. Fill the can with water
and pressuri ze
the can. Fl ush the di scharge l i ne to
ensure that the uni t i s cl ean.
2. l f di scharge l i qui d does not foam, the ori fi ce may be
bl ocked.
3. To cl ean, di sconnect the pl umbi ng
from the tank at
the l arge coupl i ng nut.
ORIFICE
GRT{G
Remove the in-line filter from the discharge side and
clean if necessary.
The fluid orifice is tocated behind the filter.
Cl ean i t wi th the pi ck
stored i n the bottom of the
t ank handl e, or bl ow i t cl ean wi t h ai r . Secur el v
reassemble all Darts.
FILLER CAP
Shift
Cable
!@@
Make sure lifts are
placed properly
(see
seqti on 1).
1. Remove the front consol e
(see
secti on 20).
2. Shi ft to E
posi ti on, then remove the l ock
pi n Jrom
the adj uster.
SHIFT CABI.f
7 N.m
(07kst ' m, 5l bl ' f t l
3, Remove the shift cable bracket.
SHIFT CABLE
BRACKET
6 x 1 . 0 mm
9.8 N.m
{1. 0 kgf m, 7. 2
4. Remove the shi ft cabl e hol der.
5. Bemove the shi ft cabl e cover.
6. Remove the control Iever from the control shaft,
then remove the shift cable. Take care not to bend
the cabl e when removi ng/i nstal l i ng
i t
I x
' 1. 25
mm
22 N.m
12.2 kgl'm.
16 tbl.ftl
SHIFT CABLE HOLDER
SHIFT CABLE
LOCK WASHER
Repl ace.
6 x 1 . 0 mm
12 N. m
('1.2
ksf.m,
8.7 rbtftl
CONTBOL LEVER
6 x
' l . 0
mm
14 N. m
7.
(!.il kgt.m. 10lbl.ftl
lnstall the shift cable in the reverse order of removal'
Check t he cabl e adj ust ment on r eassembl y
( see
page 14-190).
14- 189
Shift Cable
Adjustment
@
Make sure l i fts are ptaced properl y (see
secti on 1).
(see
secti on Z0l .
2. Shi ft to
@
posi ti on.
then remove the l ock pi n from
the adi uster.
7 N. m
(0. 7
5 tbtftl
kgt m.
14-190
3. Check t hat t he hol e i n t he adj ust er i s per f ect l y
al i gned wi th the hol e i n the shi ft cabl e. There are
two hol es i n the adj uster. They are posi ti oned
90.
apart to al l ow cabl e adj ustment i n 1/4 turn i ncre-
ments.
Exact
Al i gnment
4. lf the hole is not perfectly
aligned, loosen the lock-
nut on the adj uster and adj ust as requi red.
5. Ti ghten the tocknut to 7 N.m
(0.7
kgf.m, 5 tbf.ft).
6. Instal l the l ock pi n
on the adj uster. l f
you
feel the
l ock pi n bi ndi ng as you rei nstal l i t, the cabl e i s sti l l
out of adj ustment and must be readj usted.
7. Make sur e t he l ock pi n
i s seat ed i n t he adj ust er
securetv.
8. Move the shift lever to each gear,
and verify that the
shi ft posi ti on i ndi cator fol l ows the automati c trans-
axl e gear posi ti on
swi tch.
9. St ar t t he engi ne, and check t he shi f t l ever i n al l
gears.
lf any gear does not work properly,
refer to
troubl eshooti ng (see
page 14-109 thru 1' 4-' 112).
10. Insert the i gni ti on key i nto the key cyl i nder on the
Ay' T gear posi ti on
i ndi cator panel ,
and veri fy that the
shi ft l ock l ever i s rel eased.
Cabl e
Too Short
Cabl e
Too Long
Shift Lever
PUSH KNOB SPRI NG
SILICONE GREASE
SCBEW
N. m {0. 3 kgt m. 2 l bf f t )
Appl y non-hardeni ng t hread l ock seal ant
SCREW
3 N. m {0. 3
kgi f m, 2 l bl f t )
GEAR POSITION INDICATOR PANEL
COVER
SHIFT LEVER ASSEMBLY
SHIFT INDICATOR
BUSHI NG
-61
SILICONE GREASE
LEVER
SHIFT LOCK
SCREW
3 N. m {0. 3
g
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgf . m,
7.2 tbt.ft)
A/T GEAR POSITION
PLATE
SHIFT LEVER BRACKET BASE
SHIFT LEVER
2/""*"
,.@
*
_.\__r.\
-Rt
\ooru.r.,
A/T GEAR POSITION SWITCH
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgf . m. 7. 2l bf . f t )
BASE COLLAA
14-191
Shift Indicator Panel
ATF Cooler Hoses
Adiustment
' 1.
Check that the i ndex mark on the i ndi cator al i ons
wi th the
N mark on the shi ft i ndi cator panel when
the transmi ssi on i s i n NEUTRAL.
3 N. m {0. 3 kgf . m, 2l bt . f t l
l f not al i gned. remove the front consol e
{see secti on
20t.
Remove the shi ft i ndi cator panel
mounti ng screws
and adj ust by movi ng the panel ,
NOTE: Whenever the shift indicator panel is removed,
reinstallthe panel
as described above,
I NDEX MARK
L
14-192
Connecti on
1. Connect the ATF cool er hoses to the ATF cool er l i nes
and ATF cool er, and secure them wi th the cl i ps as
shown.
TRANSMISSION CLIP
Continuously
Variable Transmission
(CVTI
Spec i al Tool s
. . . . . . . . . . . . . . . . 14- 194
Des c r i pt i on
. . . . . . . . . . . . . . . . . . . . 14- 195
Cl utches/Reverse
Brake/Pl anetary
Gear / Pul l eys
. . . . . . . . . . 14- 198
power
Fl ow
. . . . . . . . . . . . . . , . . . . . 14- 200
El ectroni c Control SYstem
(,96 -
98 Modets)
......14-203
(' 99 -
oo Model s)
" 14-205
Hydraul i c Control
' ....... 14-208
Hydraul i c Fl ow
.' ..-.....' ...
' 14-212
Park Mechani sm
.....-...' .' 14-222
Eleqtrical Systom
Component
Locati ons
' 96
-
98 Model s
""""""' 14-224
,99
-
00 Modets
............. 14-225
TCM Ci rcui t Di agram
(' 96 -
98 Model s) ............. 14-226
TCM Terminal Voltage/
Measuri ng Condi i i ons
(' 96 -
98 Model s) ' .... 14-228
PcM Ci rcui t Oi aqram
{A/T Control System:
' 99
-
00 Model s} ...--.... 14-230
PCM Termi nal Vol tage/Measuri ng Condi ti ons
(' 99
-
00 Model s)
A/4 Control System
.' .' ...14-232
Troubl eshooti ng Procedures ... . .... .....' ,........."'
' 14-234
Chart
El ectri cal System
-
' 96
-
98 Model s ......' .....
' 14-234
El ectri cal System
-' 99 -
00 Model s ..' ....-..-.
' 11-210
Troubl eshooti ng
Fl owcharts
(' 96
-
98 Model s)
"""' 11-242
Troubl eshooti ng
Fl owchart
(' 99
-
0O Modets)
...... 14-265
Li near Sol enoi ds/l nhi bi tor
Sol enoi d
Test . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 14- 29f
Dri ve Pul l ey/Dri ven
Pul l ey/Secondary Gear
Shaft Speed Sensors
Repl acement
.........' ...... .14-292
Start Clutch Control
Start Cl utch Cal i brati on Procedure ....... ....,. 14-293
Hydraulic SYstem
Chart
Hydraul i c System
' .' .......14-294
Road Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
14- 296
Stal l Speed
Test . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 14- 294
Fl ui d Level
Checki ng/Changi ng
....... 14-299
Pressure Testi ng
................. 14-300
Lower Val ve BodY Assembl Y
Repl acement
. . . . . . . . . . , . . . 14- 302
ATF Fi l ter
..... 14-303
Transmission
Transmi ssi on
Remov al . . . . . . . . . . .
. 14- 304
l l l ustrated Index
Transmi ssi on/Lower
Val ve BodY
Assembl y
. . . . . . . . . . . . . . . . . 14- 308
Transmi ssi on Housi ng/Fl ywheel Housi ng ... 14-310
End Cover/f ntermedi ate Housi ng ..........' .' .... 14-312
Transmi ssi on Housi ng/
Lower Valve Body Assembly
Removal . . . . . . . . . . ' . . . .
. . " 14- 314
Transmi ssi on Housi ng/Fl ywhesl Housi ng
Removal .................
........ 1+316
End Cover/l ntermedi ate
Housi ng
14-318
Removal .........,...............
Manual Val ve Body
Disassembly/lnspection/Reassemblv
.'.'.'..... 1 4-320
Forward Clutch
l l t ust r at ed I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14- 321
Di sassembl v
.................. 14-322
Reassembl v
, ,, . ' ,' ,' ......14-324
Secondary Gear Shaft
25 x 35 mm Thrust Shi m Sel ecti on ..' .' ....-... 14-324
Differential
l l l ustrated l ndex ...,.....................,.,...-.-.-...' ...
14-329
Backl ash Inspecti on
.-....14-329
Beari ng Repl acement ......' ........' ....' ... ....' ... 14-330
Di fferenti al Carri er Repl acement ........' ........ 14-330
Oi l Seal Removal
........... 14-331
Oi l Seal Instal l ati on/Si de
Cl earance ....... . . 14-331
Fl ywheel Housi ng Input Shaft Oi l Seal
Repl acement .....,....
...' .' .. 14-333
Transmi ssi on Housi ng Beari ngs
Driven Pulley Shaft Bearing
Repl aceni ent ...................' . . ...................' .. 14-334
Secondary Gear Shaft Bearing
Reol acbment ...................... . .......... . ........ 14-335
Flywheel Housing Beating
Reo1acement . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . .
14- 335
Ri ng Gear Beari ng
Repl acement . . . . . . . . .
. . . . . . . . 14- 336
Control Shaft Assembly
Removal / l nst al l at i on
. . . . . . . . . . . . . . . . . . . . ' . . . . . . . . . . .
14- 336
Transmi ssi on
Reassembl y
.................. 14-338
Fl ywheel /Dri ve Pl ate .. . ...... . ...... ... . ....-.....' .' ...14-341
Transmi ssi on
l nstal ati on
..................... 14-348
Cool er Fl ushi ng
.' ......... 14-352
shi ft cabl e
Removal / l nst al l at i on. . . . ' . . . . . . . . . "
" " " 14- 354
Adj ust ment
. . . . . . . ' . . . . . . . . 14- 355
Shi f t Lever
. . . . . . . . . . . . . . . . . . . . . . . . , .
14' 356
Shi ft Indi cator Panel
Adj ust ment
. . . . . . . . . . . . . . . . 14- 357
ATF Cooler/Hoses
l nst a l l at i on . . . . . . , , . . . . . .
. . . . 14- 357
Special Tools
o
@
alr *
@
o
@
6l
@
o
@
@- "
@
@
@
o
@
07GAE
-
PG40200
07JAD
-
PH80200
07LAE
-
PX40100
07PM
-
0010100
07sM- 0010004
07TAE
-
P4V01l 0
07TAE
-
P4V0120
07TAE
-
P4V0130
07 tvl AJ
-
PY4011A
07MAJ
-
PY40l 20
07406
-
0020400
07406
-
0070300
07736
-
A0r 0004
07746
-
0010100
07746
-
0010500
07746
-
0010600
07746
-
0030100
07749
-
0010000
07947
-
6110501
01947
-
6340201
Cl utch Spri ng Compressor Bol t Assembl y
Pi l ot. 26 x 30 mm
Cl utch Spri ng Compressor Attachment
Backprobe Set
Reverse Brake Spri ng Compressor
Stan Cl utch Remover
Stan Cl utch Instal l er
A/T Oi l Pressure Hose,2210 mm
Ay'T Oil Pressure Hose, Adapter
Ay' T Oi l Pressure cauge Set
Wpanel
Ay'T Low Pressure Gauge w/panel
Adj ustabl e Beari ng Pul l er, 25
-
40 mm
Dri ver 40 mm l .D.
Dri ver
Driver Aftachment, 68 mm
Dri ver Attachment, 58 x 72 mm
I
1
2
I
a
,l
1
1
1
,1
1
1
'1
I
1
1
' t4-322,325
14-333
14-322,325
't4-235,293
14-236, 296
r 4- 319, 339
't
4-311
14-342,343
' t4-300
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
*07HAE
-
PL5010l can be used as a substi tute.
**Must
be used wi th commerci al l y-avai l abl e
3/8.,- 16 sl i de hammer.
E*E
o
e
@
>.'.-
-t-'-
t'
\;4
e' o
1:,'Jt*
dAt:-
i o ( 3 1 3
@
@
@
@ 18l
aio
@
IR
L
14-194
Description
The Conti nuousl y Vari abl e Transmi ssi on
(CVT)
i s an el ectroni cal l y control l ed automati c transmi ssi on wi th dri ve and dri v
en Oul l evs, and a steel bel t. The CVT
provi des non stage speeds forward and one reverse. The enti re uni t i s posi ti oned i n
l i ne wi t h t he engi ne.
Transmi ssi on
Around the outsi de of the fl ywheel i s a ri ng gear whi ch meshes wi th the starter
pi ni on when the engi ne i s bei ng staned.
The transmi ssi on has four
paral l el shafts: the i nput shaft, the dri ve pul l ey shaft. the dri ven
pul l ey shaft, and the secondary
gear shaft. The i nput shaft i s i n l i ne wi th the engi ne crankshaft. The dri ve
pul l ey shaft and the dri ven pul l ey shaft consi st of
movabl e and fi xed face pul l eys. Both pul l eys are l i nked by the steel bel t.
The i nput shaft i ncl udes the sun gear. The dri ve pul l ey shaft i ncl udes the forward cl utch whi ch mounts the carri er assem-
bl y on the forward cl utch drum. The carri er assembl y i ncl udes the
pi ni on gears whi ch mesh wi th the sun gear and the ri ng
gear. The ri ng gear has a hub-mounted reverse brake di sc.
The dri ven
pul l ey
shaft i ncl udes the start cl utch and the secondary dri ve
gear whi ch i s i ntegral wi th the
park gear' The sec-
ondary
gear shaft i s posi ti oned between the secondary dri ve gear and the fi nal dri ven gear. The secondary gear shaft
i ncl udes the secondary dri ven gear whi ch serves to change the rotati on di recti on. because the dri ve
pul l ey shaft and the
dri ven oul l ev shaft rotate the same di recti on. When certai n combi nati ons of
pl anetary gears i n the transmi ssi on are
engaged by the cl utches and the reverse brake, power i s transmi tted from the dri ve pul l ey shaft to the dri ven pul l ey shaft
to provi de
E, E, E,
and El .
Electronic Control
'96
-
98 Models:
The el ectroni c control system consi sts of the Transmi ssi on Control Modul e
(TCM),
sensors, three l i near sol enoi ds, and a
i nhi bi tor sol enoi d. Shi fti ng i s el ectroni cal l y control l ed under al l condi ti ons'
The TCM i s l ocated bel ow the dashboard, behi nd the ki ck panel on the dri ver' s si de.
'99
-
00 Models:
The el ectroni c control svstem consi sts of a Powertrai n Control Modul e
(PCM),
sensors, three l i near sol enoi ds and an
i nhi bi tor sol enoi d. Shi fti ng i s el ectroni cal l y control l ed under al l condi ti ons. A Grade Logi c Control System to control shi ft-
i ng i n
E
posi ti on whi l e the vehi cl e i s ascendi ng or descendi ng a sl ope.
The PCM i s l ocated bel ow the dashboard, under the ki ck
panel
on the
passenger' s si de.
Hydraulic Control
The l ower val ve body assembl y i ncl udes the mai n val ve body, the Pressure Low
(PL)
regui ator val ve body, the shi ft val ve
body, the start cl utch control val ve body, and the secondary val ve body. They are
posi ti oned on the l ower part of the
t r ansmi ssi on housi ng.
The mai n val ve body contai ns the Pressure Hi gh
(PH)
control val ve, the l ubri cati on val ve, and the
pi tot regul ator val ve.
The secondary val ve body contai ns the PH regul ator val ve, the cl utch reduci ng val ve, the start cl utch val ve accumul ator,
and the shi ft i nhi bi tor val ve. The PL regul ator val ve body contai ns the PL regul ator val ve and the PH-PL control val ve
whi ch i s i oi ned to the PH,PL control l i near sol enoi d. The i nhi bi tor sol enoi d val ve i s bol ted on the PL regul ator val ve body.
The shi ft val ve body contai ns the shi ft val ve and the shi ft control val ve. whi ch i s
j oi ned
to the shi ft control l i near sol enoi d.
The start cl utch control val ve body contai ns the start cl utch control val ve, whi ch i s
j oi ned
to the start cl utch control l i near
sol enoi d. The l i near sol enoi ds and the i nhi bi tor sol enoi d are control l ed by the TCM or PCM. The manual val ve body whi ch
contai ns the manual val ve and the reverse i nhi bi tor val ve, i s bol ted on the i ntermedi ate housi ng.
The ATF
pump
assembl y i s l ocated on the transmi ssi on housi ng, and i s l i nked wi th the i nput shaft by the sprockets and
the sprocket chai n. The pul l eys and the cl utch recei ve fl ui d from thei r respecti ve feed pi pes, and the reverse brake recei ves
fl ui d from i nternal hydraul i c ci rcui t.
Shift Control Mechanism
Input from vari ous sensors l ocated throughout the vehi cl e determi nes whi ch l i near sol enoi d the TCM or PCM wi l l acti vate.
Acti vati ng the shi ft control l i near sol enoi d changes the shi ft control val ve pressure, causi ng the shi ft val ve to move. Thi s
pressuri zes the dri ve pul l ey pressure to the dri ve
pul l ey and the dri ven pul l ey pressure to the dri ven pul l ey and changes
thei r effecti ve
pul l ey rati o. Acti vati ng the start cl utch control l i near sol enoi d moves the start cl utch control val ve. The start
cl ut ch cont rol val ve uncovers t he
port , provi di ng pressure t o t he st art cl ut ch t o engage i t
(cont ' d)
14- 195
,!
Description
(cont'd)
Gear Selstion
The shi ft l ever has si x posi ti ons:
@
pARK,
E
REVERSE,
E
NEUTRAL,
E
DR| VE,
g
SECOND, and
El
LOW.
Staning is possible
only in
E and
E
positions
through the use of a slid6-type, neutrafsafety switch.
Automrtic Transaxle
{A/T} Gear Position Indicltor
The A-lT gear position indicator in the instrument panel
shows which gear has been selected without having to look down
at the consol e.
Poshion
De3cription
E
PARK
E
REVEBSE
E
NEUTRAL
D
DRIVE
E
SECOND
E
LOW
Front wheel s l ocked; park pawl
engaged wi th the park gear on the dri ven pul l ey
shaft. The start
clutch and the forward clutch released.
Reverse; reverse brake engaged.
Neutral; the start clutch and the forward clutch released.
General dri vi ng; the transmi ssi on automati cal l y adj usts to keep the engi ne at the best speed for
dri vi ng condi ti ons.
For rapid accelsration at highway speeds; the transmission shifts into a lower range of ratios for
better acceleration and increased engine braking.
For engi ne braki ng and power
for cl i mbi nO; the transmi ssi on shi fts i nto the l owest range of the
ralros.
l-
14-196
STEEL BELT
START CLUTCH
INPUT SHAFT
DRIVE PULLEY
ATF FILTER
14-197
Description
Clutches/Reverse Brake/Planetary Gear/Pulleys
Clulches/Reverse Brake
The CVT uses t he hydr aul i cal l y- act uat ed cl ut ches and br ake t o engage or di sengage t he t r ansmi ssi on gear s. When
hydraul i c pressure i s i ntroduced i nto the cl utch drum and the reverse brake pi ston cavi ty, the cl utch pi ston
and the reverse
brake pi ston move. Thi s presses the fri cti on dj scs and the steel pl ates
together, l ocki ng them so they don' t sl i p. Power i s
then transmi tted through the engaged cl utch pack
to i ts hub-mounted gear. and through engaged ri ng gear to pi ni on
gears.
Li kewi se, when the hydraul i c pressure
i s bl ed from the cl utch
pack
and the reverse brake
pi ston
cavi ty, the pi ston rel eases
the fri cti on di scs and the steel
pl ates,
and they are free to sl i de
past
each. Thi s al l ows the
gear
to spi n i ndependentl y on i ts
shaft, transmi tti ng no power.
Start Clutch
The start cl utch, whi ch i s l ocated at the end of the dri ven
pul l ey
shaft, engages/di sengages the secondary dri ve gear.
The start cl utch i s suppl i ed hydraul i c pressure
by i ts ATF feed pi pes wi thi n the dri ven pul l ey shaft.
Forward Clutch
The forward cl utch, whi ch i s l ocated at the end of the dri ve pul l ey
shaft, engages/di sengages the sun gear.
The forward cl utch i s suppl i ed hydraul i c pressure by i ts ATF feed pi pe
wi thi n the dri ve
pul l ey
shaft.
Reverse Brake
The reverse brake, whi ch i s l ocated i nsi de the i nte.medi ate housi ng around the ri ng gear, l ocks the ri ng gear i n
E
posi -
ti on. The reverse brake di scs are mounted to the ri ng gear and the reverse brake
pl ates
are mounted to the i ntermedi ate
housi ng. The reverse brake i s suppl i ed hydraul i c pressure
by a ci rcui t connected to the i nternal hydraul i c ci rcui t.
Planetary Gear
The pl anetary gear consi sts of a sun gear, a carri er assembl y, and a ri ng gear. The sun gear i s connected to the i nput shaft
wi th spl i nes. The pi ni on gears are mounted to the carri er whi ch i s mounted to the fo.ward cl utch drum. The sun gear
i nputs the engi ne power vi a the i nput shaft to the pl anetary gear,
and the carri er outputs the engi ne power. The ri ng gear
i s onl y used for swi tchi ng the rotati on di recti on of the
pul l ev
shafts,
In
E. E,
and E
posi ti ons (forward
range), the pi ni on gears don' t rotate and revol ve wi th the sun gear, so the carri er
rotates. In
E]
posi tj on
{reverse range), the reverse brake l ocks the ri ng gear
and the sun gear
dri ves the
pi ni on gears to
rotate. The pi ni on gears rotate and revol ve i n the opposi te di recti on from the rotati on di recti on of the sun gear,
and the
carri er rotates wi th pi ni on gear revol uti on.
Pulleys
Each pul l ey consi sts of a movabl e face and a fi xed face, and the effecti ve pul l ey .ati o changes wi th engi ne speed. The
dri ve pul l ey and the dri ven pul l ey are l i nked by the steel bel t.
To achi eve a l ow pul l ey rati o, hi gh hydraul i c pressure works on the movabl e face of the dri ven
pul l ey
and reduces the
effecti ve di ameter of the dri ve
pul l ey.
and a l ower hydraul i c pressure
works on the movabl e face of the dri ve pul l ey
to
el i mi nate the steel bel t sl i ppage. To achi eve a hi gh pul l ey rati o, hi gh hydraul i c pressure works on the movabl e face of the
dri ve pul l ey and reduces the ei fecti ve di ameter of the dri ven pul l ey,
and a l ower hydraul i c
pressure
works on the movabl e
face of the dri ven
pul l ey to el i mi nate the steel bel t sl i ppage.
b
14- 198
ATF PUMP
DRIVEN SPROCKET
RING GEAR
FLYWHEEL
DRIVE PLATE
ATF PUMP
DRIVE PULLEY
REVERSE BRAKE
PISTON
FORWARD CLUTCH
BEVERSE BRAKE
CARRIER
RING GEAR
PLANETARY
PI NI ON GEARS
INPUT SHAFT
ATF PUMP
DRI VE CHAI N
ATF PUMP
DRIVE SPROCKET
START CLUTCH
DRIVEN PULLEY
STEEL BELT
SECONDARY DRIVE GEAR
PARK GEAR
DRIVEN PULLEY
SHAFT
FINAL DRIVE GEAR
SECONDARY GEAR
SHAFT
a--
i ___
il
14-199
Description
Power Flow
E
Position
. Start Cl utch: rel eased
. Forward Cl utch: rel eased
. Reverse Brake: released
Hydraul i c pressure i s not appl i ed to the start cl utch. forward cl utch, and the reverse brake. Power i s not transmi tted to the
secondary dri ve gear.
E
Position
. Start Cl utch: rel eased
a Reverse Brake; rel eased
Hydraulic pressure is not applied to the start clutch, forward clutch, and the reverse brake. Power is not transmitted to the
secondary drive
gear. The secondary drive gear is locked by the
park pawl interlocking the
park gea..
FI-YWHEEL FORWARD
INPUT SHAFT
SUN GEAR
START CLUTCH
ORIVEN PULLEY
FINAL ORIVE
GEAR
PARK GEAR
FINAL DRIVEN GEAR
D
14-200
E, E,
and
E
Positions {Forward
Rangel
. Sta rt Cl utch: engaged
. Forward Cl utch: engaged
o Reverse Brake: rel eased
1, The hydraul i c
pressure i s appl i ed to the forward cl utch and the start cl utch, and the sun
gear dri ves the torward
cl utch.
2. The torward cl utch dri ves the dri ve
pul l eV
shaft. whi ch dri ves the dri ven pul l ey shaft l i nked by the steel bel t.
3, The dri ven
pul l ey
shaft dri ves the secondary dri ve gear, vi a the start cl utch.
4. Power i s transmi tted to the secondary dri ven
gear, whi ch dri ves the fi nal dri ven
gear.
NOTE: The worki ng hydraul i c
pressure on the movabl e face of each shaft depends on the throttl e openi ng
posi ti on.
DRIVE PULI.f Y
FLYWHEEL
STEEL AELT
CLUTCH
INPUT SHAFT
START CLUTCH
SECONDARY DRIVEN
GEAR
(cont ' d)
FINAL DRIVEN GEAR
14-201
Description
Power Flow
(cont'd)
E
Position
. Sta rt Cl utch: engaged
. Reverse Brake: engaged
1. The hydraul i c pressure i s appl i ed to the reverse brake and the start cl utch. The sun gear dri ves the pi ni on gears, and
the pi ni on gears revol ve around the sun gear. The carri er assembl y rotates i n the opposi te di recti on from the rotati on
di recti on of the sun gear.
The carri er assembl y dri ves the dri ve pul l ey shaft vi a the forward cl utch drum, and the dri ve pul l ey shaft dri ves the
dri ven pul l ey shaft l i nked by the steel bel t.
The dri ven
pul l ey shaft dri ves the secondary dri ve gear vi a the start cl utch.
Power i s transmi tted to the secondary dri ven gear, whi ch dri ves the fi nal dri ven gear.
3.
4.
2.
DRIVE PULLEY STEEL EELT
DRIVE
PULLEY
REVERSE BRAKE
CARRI ER ASSEMBLY
INPUT SHAFT
SUN GEAR
PI NI ON GEAB
RI NG GEAB
STABT CLUTCH
DRI VEN PULLEY
SECONDARY DRIVE
GEAR
FINAL
GEAB
SECONDARY ORI VEN
GEAR
FI NAL ORI VEN GEAR
14-202
('96
-
98 Modelsl
The el ectroni c control system consi sts of the Transmi ssi on control Modul e
(TcM),
sensors, three l i near sol enoi ds, and an
i nhi bi tor sol enoi d. Shi fti ng i s el ectroni cal l y control l ed under al l condi ti ons
The TCIM i s l ocated bel ow the dashboard, behi nd the ki ck panel on the dri ver' s si de'
The TcN4 control s the transmi ssi on to reduce engi ne speed and retai n the engi ne' s cool i ng effi ci ency when the vehi cl e i s
dri ven wi th Iul l throttl e accel erati on
l f t he vehi cl e i s cont i nuousl y dr i ven at f ul l t hr ot t l e accel er at i on, t he TCM r egul at es t he
pul l ey hydr aul i c
pr essur e t o
i ncrease the pul l ey rati o, whi ch, as the resul t. reduces the engi ne speed and retai ns the desi gned cool i ng effi ci ency After
the vehi cl e has been dri ven at a l ower engi ne speed for a whi l e, the TCM i ncreases the
pul l ey rati o to the ori gi nal rati o.
For smooth starti ng i n the
E
posi ti on, the TcM sends a si gnal to the EcM to cut off the rvc cl utch {i f the A!/c i s on) and
i ncreases the engi ne speed to 900 rpm when the transmi ssi on i s shi fted to the E
posi ti on'
The start cl utch functi ons to make smooth starti ng
possi bl e. To l et the start cl utch functi on
properl y. the TCM regul ates
the start cl utch hydraul i c
pressure based on the enti ne' s negati ve
pressure memori zed i n the E
posi ti on'
:
:
z
z
z
S*ond.ry G..r Sh:ft
(cont ' d)
14-203
Description
('gG -
98 Modelsl
(cont'dl
GNITIONSWITCN
Pri
-
Pt coNTnoL
LrN ns0LtN0t0
SIAiT CLUTCH CONTSOL
LINEAFSOLENOID
sHtFT CONmOI
LINIAftSOLENOID
BFAXELIGHT
PAS|(ING 8MI(E SWITCH
i\\c-...............- +B
i\--------.--_ rcr
:
MAP(PBI
g s61
E
rtDiRxo
g
TM8
scs
1 2 3 5 1 8 I 1 0 1 1
' t 2
2 5 7 8 9 1 0
1 4 1 7 20 23 26 12 1 3 t 4 t 6 1 7 1 8 20
D
14-204
Electronic Gontrol System
('99
-
00 Modelsl
The el ectroni c controt system conststs of a Powertrai n control Modul e
(PCM).
sensors, three l i near sol enoi ds and an
i nhi bi tor sol enoi d. shi fti ng i s el ectroni cal l y control l ed under al l condi ti ons A Grade Logi c control system to control shi ft-
i ng i n
E
posi ti on whi l e the vehi cl e i s ascendi ng or descendi ng a sl ope'
f n" pCVi r l ocat edbel owt hedashboar d, under t heki ckpanel ont hepassenger ' ssi de'
The
pCM
control s the transmassi on to reduce engi ne speed and retai n the engi ne' s cool i ng effi ci ency when the vehi cl e i s
dri ven wi th ful l throftl e accel erati on
l f the vehi cl e i s conti nuousl y dri ven at l ul l throttl e accel erati on, the PCM regul ates the
pul l ey hydraul i c
pressure to
i ncrease the
pul l ey rati o whi ch. as the resul t, reduces the engi ne speed and retai ns the desi gned cool i ng effi ci ency After
the vehi cl e has been dri ven at a l ower engi ne speed for a whi l e, the PCM i ncreases the
pul l ey rati o to the ori gi nal rati o'
i "i ".nl ",rr starti ng i n the E
posi ti on, the PcM cuts off the ,Vc cl utch
(i f
the A/c i s on) and i ncreases the engi ne speed to
900 rpm when the transmi ssi on i s shi fted to the
E
posi ti on'
The start cl utch functi ons to make smooth starti ng
possi bl e. To l et the start cl utch functi on
properl y, the PcM regul ates
the start cl utch hydraul i c
pressure based on the engi ne' s negati ve
pressure memori zed i n the E
posi ti on'
FCM
s*o.d.ry G..t Sh.h
(cont ' d)
14-205
Description
('99 -
00 Modelsl
(cont'dl
Grade Logic Control System
How i t works:
The PcM compares actual dri vi ng condi ti ons wi th memori zed dri vi ng condi ti ons. based on the i nput from the vehi cl e
speed sensor, the throttl e posi ti on sensor, the mani fol d absol ute pressure
sensor, the engi ne cool ant temperature sensor,
the brake swi tch si gnal , and the shi ft l ever posi ti on
si gnal , to control shi fti ng whi l e the vehi cl e i s ascendi ng or descendi ng
a sl ope.
Ascending Control
When the PCM determi nes that the vehi cl e i s cl i mbi ng a hi l l i n
E
posi ti on,
the system sel ects the most sui tabl e shi ft
schedul e
(pul l ey
rati o) accordi ng to the magni tude of a gradi ent.
so the vehi cl e can run smooth and have more power
when needed. There are three ascendi ng modes wi th di fferent shi ft schedul es accordi ng to the magni tude ot a
gradi ent
i n
the PCM.
Descending Control
when the PCM determi nes that the vehi cl e i s goi ng down a hi l l i n
E
posi ti on.
the system sel ects the most sui tabl e shi ft
schedul e
(pul l ey
rati o) accordi ng to the magni tude of a gradi ent.
Thi s, i n combi nsti on wi th engi ne braki ng, achi eves
smooth dri vi ng when the vehi cl e i s descendi ng, There are three descendi ng modes wi th di fferent shi ft schedul es accord-
i ng to the magni tude of a gradi ent
i n the PCM.
L
14-206
-'99 -
00 Models
IGN1TIONSWTCH
PH.PLCOiTSOL
LINEAF SOLEIID
SIAFT CLIJICH COTITROL
LINEiF SOLETIO
SHIFI CONTNOT
LINEAR SOLEI{OIO
INNIB TOF SOLETIOIO
IGPl
vcc2
TPS
14-207
Description
Hydraulic Control
The hydraul i c control system i s control l ed by the ATF pump.
the val ves, and the sol enoi ds. The ATF pump
i s dri ven by the
i nput shaft. The ATF pump
and the i nput shaft are l i nked by the ATF pump
dri ve chai n and the sprockets, The i nhi bi tor
sol enoi d val ve and the l i near sol enoi ds. whi ch are l ocated on thei r val ve body, are control l ed by the TCM or
pcM.
Fl ui d
from the ATF pump
fl ows through the PH regul ator val ve to mai ntai n speci fi ed pressure
to the dri ve pul l ey,
the dri ven pul -
l ey, and the manual val ve,
The l ower val ve body assembl y i ncl udes the mai n val ve body, the PL regul ator val ve body, the shi ft val ve body, the start
cl utch control val ve body, and the secondary val ve bodv.
Main Valve Eody
The mai n val ve body contai ns the
pH
control val ve, the rubri cati on val ve, and the pi tot regul ator val ve.
PH Control Valve
The PH control val ve suppl i es PH control pressure (PHCI
i n accordance wi th the
pH-pL
control pressure (HLc),
and sup-
pl i es PH control pressure
to the PH regul ator val ve, whi ch al so regul atss PH pressure.
At ki ck-down, i t i ncreases
pH
control pressure
whi ch i ncreases the hi gh
(PH) pressure.
Thi s shortens the shi ft speed by rel easi ng the reverse i nhi bi tor
pressure (Rl )from
the i nhi bi tor sol enoi d val ve.
Lubrication Valve
The l ubri cati on val ve control s the l ubri cati on pressure
to each shaft and mai ntai ns l ubri cati on pressure.
When rne pres-
sure i s too hi gh, the spri ng i s compressed. Thi s moves the l ubri cati on val ve and opens the fl ui d l eak passage.
Pitot Regulalor Valv6
The pi tot regul ator val ve control s the start cl utch pressure (SC)
i n accordance wi th the engi ne speed, when the el ectron-
i c control system i s faul w.
MAIN VAIVE
BODY
L.
14-208
Secondary Valve Body
The secondary val ve body contai ns the PH regul ator val ve. the cl utch reduci ng val ve' the start cl utch val ve accumul ator'
and the shi ft i nhi bi tor val ve
PH Regulator Valve
The
pi
regul ator val ve mai ntai ns hydraul i c
pressure suppl i ed from the ATF
pump. and suppl i es PH
pressure to the
hvdraul i c control ci rcui t and the l ubri cati on ci rcui t. PH
pressure i s regul ated at the PH regul ator val ve by the PH control
pressure
(PHC)
from the PH control val ve.
Cluteh Reducing Valvo
The clutch reducing valve receives PH pressure from the PH regulator valve and regulates the clutch reducing
pressure
(cR).
The cl utch reduci ng val ve suppl i es cl utch
pressure (cR)
to the manual val ve and the start cl utch control val ve' and
suppl i es si gnal
pressure to the PH-PL
pressure control val ve. the shi ft control val ve, and the i nhi bi tor sol enoi d val ve'
Start Clutch Valv Accumulator
The start cl utch vatve accumutator stabi l i zes the hydraul i c
pressure that i s suppl i ed to the start cl utch'
Shift Inhibitor Valve
The shift inhibitor valve switches the fluid passage to switch the start clutch control from electronic control to hydraulic
control when the electronic control system is faulty. lt also suppliss clutch reducing
pressure
(cR)
to the
pitot regulator
val ve and the
pi tot l ubri cati on
pi pe.
START CLUTCH VALVE
SECONDARY VALVE
BODY
SHIFT INHIBITOE VALVE
(cont ' d)
PH REGULATOR
VAL
REDUCING
VALVE
14-209
Description
Hydraulic Control
{cont'dl
PL Regulator Valve Body
The PL regul ator val ve body contai ns the PL regul ator val ve and the PH-PL control val ve. whi ch i s
j oi ned
wi rh the
pH-pL
control l i near sol enoi d. The i nhi bi tor sol enoi d i s bol ted on the
pL
regul ator val ve body.
. PL Regulator Valve
The PL regul ator val ve suppl i es l ow p.essure (pL)
to the pul l ey
to el i mi nate steel bel t sl i ppage.
The PL pressure
i s control l ed by the
pH-pL
control
pressure (HLC).
. PH-PL Control Valve
The PH-PL control val ve control s the PL regul ator val ve accordi ng to engi ne torque. The PH-PL control val ve suool i es
PH-PL control pressure (HLC)
to the PH control val ve to regul ate PH pressure hi gher than
pL
pressure. The
pH-pL
con-
trol val ve i s control l ed by the PH-PL control l i near sol enoi d. whi ch i s control l ed by the TcM or
pcM,
. Inhi bi tor Sol enoi d
The i nhi bi tor sol enoi d control s the reverse i nhi bi tor val ve by turni ng on and off. Al so, the i nhi bi tor sol enoad control s
pH
control pressure (PHC)
by appl yi ng reverse i nhi bi tor pressure (Rl )
to the PH control val ve. The i nhi bi tor sol enoi d i s con-
trol l ed by the TCM or Pcl vl .
Start Clutch Control Valv Body
The start cl utch control val ve body contai ns the start cl utch control val ve. Both are
j oi ned
to the stan cl utch control l i near
sol enoi d.
. Start Clutch Control Valve
The start cl utch control val ve control s start cl utch engagement accordi ng to the throttl e openi ng. The start cl utch con,
trol val ve i s control l ed by the stan cl utch control l i near sol enoi d, whi ch i s control l ed bv the TCM o.
pCM.
START CLUTCH CONTROL
vAt-vE
LOWER VALVE BODY
ASSEMBI-Y
PH.PL CONTROL
LINEAR SOLENOID
I.
14-210
Shift Valve BodY
The shi ft val ve body contai ns the shi ft val ve and the shi ft control val ve. Both are
i oi ned
to the shi ft control l i near sol enoro.
r tl' ft1il1rf"",""
is controred
by shift varve
pressure
(sV) from the shift contror varve. The shift varve distributes
pH
pi ""aur" "nO PL
pressure to dri ve
pul l ey and the dri ven
pul l ey' to shi ft the transmi ssi on'
t t*"rilf:::lr';ivarve
contrors
the shift varve in accordance
with the throttre opening and vehicle speed rhe shift
control val ve i s convorr"o
uv ti " "i i rt "ontrol
l i near sol enoi d, whi ch i s control l ed
by the TcM or PcM When the el ec-
troni c control system i s faul ty, t;; sni ft controt
uutue "wi tches the shi ft i nhi bi tor val ve to uncover the
port l eadi ng the
pi tot regul ator
pressure to the start cl utch
CONTROL VALVE
VALVE BODY
T;J:"i """1ff"t""i l ody
contai ns the manuar
varve and the reverse i nhi bi tor varve. The manuat varve bodv i s borted to the
i ntermedi ate
housl ng
. Manual Val ve
The manual val ve mechani cal l Y
uncovers/covers
the fl ui d
passage accordi ng
to the shi ft l ever
posi ti on'
'
ff:e;;;.'::'?Xftl::T",*
is contro ed by the reverse inhibitor
pressure
(Rl). lt intercepts the hvdraulic circuit to the
reverse brake whi l e the vehi cl e i s movi ng forward at speeds over approxi matel v
6 mph
(10 km/h)'
REVRSE INHIBITOR
VALVE
MANUAL VALVE
BODY
SHIFT CONTROL
MANUAL
VALVE
14-211
Description
Hydraulic Flow
General Chart of Hydraulic
prossure
' Shi f t
Val ve
.
Shi f t i nhi bi t or Vat ve
PH REGULATOR
VALVE
NO.
DESCRIPTION
OF PRESSURE
CLUTCH CONTROL
ATF COOLER
CLUTCH REDUCING
NO.
DESCRIPTION
OF PRESSURE
PITOT PIPE
cc
PP
coL
PR PITOT REGULATOR
RECIRCULATION RCC
DN DRIVEN PULLEY
RI REVERSE INHIBITOR
REVERSE BRAKE
START CLUTCH
SHIFT II"IHl BITOR
SUCTII' N
SHIFT VALVE
LEAK
DR DRIVE PULLEY
RVS
FWD FORWARD
CLUTCH
PH-PL CONTROL
sc
HLC
sl
LUB LUBBICATION
PRESSURE HIGH
SUC
PH
PHC PH CONTROL
X
PL PRESSURE
LOW
14-212
E
Position
Ast heengi net ur ns. t heATFpumpa| sost ar t st ooper at e. F| ui df r omt heATFpumpf | owst ot hePHr egu| at or va| veandt he
c| Ut chr educi ngva| ve. ThePHr egu| at or va| ver egu| at eshi ghpr essur e( PH) . andsendi t t ot heshi f t Va| veandt hePLr egU'
l at or val ve. Thehi ghpr essur e( PH) f l owst ot hemovabl ef aceof t hedr i venpul l eyvi at heshi f t val ve' andt ur nsi nt ol ow
pr essur e( PL) at t hePLr egu| at or va| ve. Thel owpr essur e( PL} f | owst ot hemovab| e' aceof t hedr i vepu| | eYvi at heshi f t
val ve. At thi s ti me, the
pul l ey rati o remarns l ow'
Thehi ghpr essur e( px) uecomest t r ect ut chr educi ngpr essur e( CR) at t hec| ut chr educi ngva| Ve. Thec| ut chr educi ngpr es.
sure
(CR) fl ows to the start cl utch cont' oi uatt". tn"l t"n' al val ve' the PH-PL control val ve' and the shi ft control val ve' and
is intercepted bY those valves
Under thi s condi ti on,
hydraul ac
pressure i s not appl i ed to the cl utches and reverse brake'
(cont' d)
14-213
Description
Hydraul i c
Fl ow
(cont' dl
lll
position,
at low spod range
The fl ow of fl ui d up to the dri ve pul l ey,
the dri ven pul l ey,
and the cl utch reduci ng val ve i s the same as i n
El
posi ti on.
The
pul l ey
rati o i s l ow because the dri ven pul l ey
recei ves hi gh pressure (PH),
and the dri ve pul l ey recei ves l ow pressure (pL),
The cl utch reduci ng pressure
{cR) fl ows through the manual val ve to the forwaro cl utch, ttren forward ci ul cn i s engaged.
The forward cl utch then dri ves the dri ve pul l ey
shaft, whi ch dri ves the d(ven pu
ey shaft.
Al so' cl utch reduci ng pressure
{cR) fl ows to the start cl utch control val ve, and becomes cl utch control pressure
{cc).
cl utch control pressure (cc)
becomes start cl utch pressure (sc)
at the shi ft i nhi bi tor val ve. stan cl utch pressure
{sc) i s
appl i ed to the start cl utch to engage the start cl utch.
14-214
E
position, at middle sPeed range
Ast hespeedof t hevehi c| er eachest hepr escr i bedVa| ue, t heshi f t cont r o| | i near sol enoi di sact i vat edbyt heTcMor PcM'
Theshi f t cont r o| | i near so| enor ocont r oI st t r esni f t cont r oI Va| vet oact i vat eshi f t Va| vepr essur e( SV) ' c| ut chr educi ngpr es-
sure
(CR) trom the cl utch reducl ng val ve becomes
shi ft val ve
pressure
(SV)
at the shi ft control val ve Shi ft val ve
pressure
( SV) f l owst ot he| ef t " noot t r ' " st ' i t t u" t ue. t heshi f t Va| Vet ot her i ght si deandposi t i oni ngi t i nt hemi dd| eof i t st r ave| . The
shi ft val ve covers th"
pon ao ",oo nLi or".i rr" ti Hl
a ,tr"
pul l eys, and uncovers
the
port l eadi ng l ow
pressure
(PL)
to the
pu eys. The dri ve
pu ey and tne ori Jen
pri Ly | ."""i u" to*
pressure
(PL).
At thi s ti me, the
pul l ey rati o i s i n the mi ddl e'
Pressure remai ns to appl y the forward cl utch and the start cl utch'
NOTE: When used,
"| eft"
or
"ri ght"
ci rcui t'
(cont ' d)
14-215
Description
Hydraulic
Flow
(cont'd)
@
position,
at high spe6d range
As the speed of the vehi cl e reaches the prescri bed
val ue, the shi ft control l i near sol noi d moves the shi ft contror vatve to
i ncrease shi ft val ve pressure (SV)
at the l eft end of the shi ft val ve. ttre srri t vatve moves to the ri ght si de compared to i ts
posi ti on
at the mi ddl e pul l ey
rati o. The shi ft val ve uncovers
the port
l eadi ng hi gh pressure (pxi to
ttre d.ve pul ey
and
uncovers the port
l eadi ng l ow pressure (PL)
to the dri ven pul l ey.
The dri ve pu| ey
recei ves hi gh pressure (pH)
and the dri v-
en pul l ey
recei ves l ow pressure (pL).
The pul l ey
rati o i s hi gh.
Pressure remai ns to appl y the forward
cl utch and the start cl utch,
NOTE: When used,
"l eft,,
or,,ri ght" i ndi cates
di recti on on the hydraul i c ci rcui t.
L
14-216
E
position
The fl ow of fl ui d up to the dri ve
pul l ey, the dri ven
pul l ey' and the cl utch reduci ng val ve i s the same as i n E
posi ti on The
pul l ey rati o i s l ow b"car"" tt " o ri u",i ' prti "vi """v""
t' i gtr
pressure.(pH) and the dri ve
pul l ey recei ves l ow
pressure {PL).
The manual val ve i s shi fted i nto the B
posi ti on, and i t uncovers the
port that l eads reverse brake
pressure
(RVS)
to the
reverse i nhi bi tor val ve. The i nhi bi toi Jenoi d turns off by means of the TcM or PcM, and reverse i nhi bi tor
pressure
(Rl )
i s
appl i edt ot her i ght endof t he, " u" , " " i nt , i ui . o, u, | ve. Ther ever sei nhi bi t or va| vemovest ot he| ef t si de, anduncover st he
pr"a"ur" ti vst,o,he
reverse brake. cl utch reduci ng
pressure
(cR)
becomes
reverse brake
pressure
(RVS)
at the manuat *r"-, "nJ tro*" to the reverse brake. The reverse brake i s engaged, and i t l ocks the ri ng
gear.
NOTE: When used,
"| eft"
or
"ri ght"
ci rcui t'
(cont ' d)
14-217
Description
Hydraul i c Fl ow
(cont' dl
E
position
Reverse Inhibitor Conirol
l f the
E
posi ti on
i s sel ected whi l e the vei i cl e i s movi ng forward at speeds over 6 mph
(10
km/h), the i nhi bi tor sol enoi d
doesn' t turn off by means of the TcM or PCM Reverse i nhi bi tor pressure (Rl )
i s not appl i ed to the reverse i nhi bi tor val ve
as the reverse i nhi bi tor sol enoi d turns on. The reverse i nhi bi tor val ve i s kept on the ri ght si de, and covers the pon
ro srop
reverse brake pressure
{RVS} to the reverse
brake from the manual val ve. Reverse bri ke pressure (RVs)
i ; not appri ed to
the reverse brake, and power
i s not transmi tted
to the reverse di recti on.
NOTE: When used,
"l eft,'
or,,ri ght,, i ndi cates di recti on on the hydraul i c
ci rcui t.
14-218
E
position
The fl ow of fl ui d up to the dri ve
pul l ey' and the cl utch reduci ng val ve i s the same as i n E
posi ti on'
Cl utch reduci ng
pressure
(CR) t' "*" i " i i " start cl ut;h control val ve, the manual val ve, and the shi ft control val ve' and i s
i ntercepted
bY those val ves.
Under i hi s condi ti on,
hydraul i c
pressure i s not appl i ed to the cl utches and reverse braKe'
fr
- --l
4t1.1 , 1
'rltll
(cont' d)
14-219
Description
Hydraulic Flow
(cont'd)
lll
position,
when th electronic control system is fauhy.
when the el ectroni c control svstem (l i near
sol enoi ds and sensors) i s faul ty, the transmi ssi on uses the pi tot pi pe pressure
(PP)
to 311o- rh" u"hi cl e to dri ve.
when al l l i near sol enoi ds and sensors are off because of a faul ty el ectronrc control system, cl utch reduci ng pressure (cR)
fl ows to the start cl utch control val ve, the manual val ve, the PH-PL control val ve, and the shi ft control val ve. cl utch reduc-
i ng pressure (cR)
becomes shi ft varve pressure (sV)
at the shi ft contror varve, and shi ft varve pressure
{sv) i s appri ed to
the l eft end of the shi ft val ve and the ri ght end of the shi ft i nhi bi tor val ve. The shi ft val ve moves to the ri ght si de. and
uncovers the pon
that l eads hi gh pressure (PH)
to the dri ve pul l ey
and uncovers the po.t
tl r"t r""1" ro,,"-pressure (pL)
to
the dri ven pul l ey
At thi s ti me, the pul l ey
rati o i s hi gh, The shi ft i nhi bi tor val ve moves to the l eft si de, and uncovers the
port
that l eads shi ft i nhi bi tor pressure (Sl l
to the pi tot
l ubri cati on pi pe
and the pi tot
regul ator val ve. tne prtot
l ubri cati on
pi pe
di scharges fl ui d i nsi de of the pi tot
fl ange, and di scharged fl ui d enters i nto the pi tot pi pe
and i t i s appl i ed to the l eft
end of the pi tot
regul ator val ve. The pi tot
regul ator val ve moves l o the ri ght si de, and uncovers the port
that l eads pi tot
regul ator pressure (PR)
to the shi ft i nhi bi tor val ve. Pi tot regul ator pressure
{pR) becomes start cl utch pressure
{sc1 at the
shi ft i nhi bi tor val ve, and i s appl i ed to the stan cl utch. The stan cl utch rs engaged. The forward cl utch pressure (FWD)
i s
appl i ed to the forward crutch, and the forward crutch i s engaged. Thi s al ows the vehi cre to dri ve.
NOTE: When used.
"| eft"
or
,,ri ght' ,
14-220
I.
E]
position, when the elestronic Gontrol system
is faulty'
The fl ow of tl ui d up to the dri ve
pul l ey' and the start cl utch i s the same as i n
El
posi ti on
The manual val ve i s shi fted i nto the l E
posi ti on' and i t uncovers the
pressure {RVS} to the
reverse i nhi bi tor
val ve. Reverse ,"nl u-i ,"i p*r""i "
(Rl )
i s appl i ed to.the ri ght end of the reverse i nhi bi tor
val ve because of
af aul t yi nhi bi t or sol enoi d. The' " t ' " , " " i nf t i Ui t o' val vemovest ot hel ef t si de' anduncover st hepor t t hat l eadsr ever se
brake
pressure {RVS)
to the ,"u"r." i r"t"- cru,ch reduci ng
pressure
(cR)
becomes
reverse brake
pressure
(RVS)
at the
manual val ve, and,l ows to the ,e\r"rs" l r"re. ttre reverse brake i s engaged and l ocks the ri ng
gear' Thi s al l ows the vehi -
cl e to dri ve i n reverse.
NOTE: When used,
"l eft"
or
"ri ght"
on the hydraul i c
ci rcui t'
14-221
Description
Park Mechani sm
The park
mechani sm l ocks the transmi ssi on
by engagi ng the park pawl
wi th the park gear
whi ch i s i ntegral wi th the sec-
ondary dri ve gear' The secondary dri ve gear engages wi th the secondary dri ven gear whi ch engages wi t-h the fi nal dri ven
gear.
shi fti ng to
E
posi ti on
causes the park
cone
(i nstal l ed
at the end of the park
rod) to press
the park pawl
onto the park gear.
Even i f the end of the park pawl
ri des on the top of the park gear
teeth, sl i ght movement of the vehi cl e wi l l cause the park
pawl
and the park gear
to mesh wi th each other compl etel y
because the park
cone recei ves the tensi on from the park rod
spri ng The park pawl
recei ves the tensi on
(whi ch
acts to separate the park pawl
from the park gear)
from the park pawl
spri ng.
PARK PAWI-
PARK CONE
START CLUTCH
PABK GEAR
PARK ROD
PARK PAWL
PARK ROO
SPRI NG
14- 222
D
Component Locations
36
-
98 Models
BRAKE SWITCH
DRIVEN PULLEY
SPEED SENSOR
INHIBITOR SOLENOID
ENGINE CONTROL
MODULE IECMI
SECONDARY GEAR SHAFT
SPEEO SENSOR
AUTOMATIC TRANSAXLE (A/T}
GEAR POSITION SWITCI{
MANIFOLD ABSOLUTE
VEHICLE SPEEO SENSOR
{vss}
IMAPI SENSOR
THROTTI.I POSITION
{TPI
SENSOR
PH.PL CONTROL
LINEAR SOLENOID
/i/
i
,'
/ ,','4
,i/:1
t"--.---.-
i,,
-_,-:-_a.--:
il
LINEAR SOLENOID
PULLEY
SHIFT CONTROL
LINEAR SOLENOTD
$r,
14-224
h
SPEED SENSOR
'99
-
00 Models
CONTROL
AUTOMATIC TRANSAXLE IA/TI
GEAR POS]TION SW]TCH
MANIFOLD ABSOLUTE
SECONDANY GEAR SHAFT
SPEED SENSOR
IMAPI SENSOR
tvss)
THROTTLE POS]TION ITP)
SENSOR
PH.PL CONTBOL
LINEAB SOLENOIO
DNVEN PUL]-EY
SPEED SENSOR
PULLEY
SHIFT CONTROL
LINEAR SOLENOIO
LINEAR SOIENOID
SPEED SENSOR
14-225
TCM Ci rcui t Di agram
(' 96 -
98 Model sl
UNDEN. HOOD FUSE] RELAY BOX
UNDER OASH
FUSE/RELAY 80X
No. 52 1l 5A)
No. 4l l 80A) No. 47 ( 7. 5A)
To t 2v
l G1
sToP sw
T
HBR( sw-
-
rur
A/ T GEAR POSI TI ON
I NDI CATOR
I GNI TI ON COI L
Y
I
i
I
I
BI-U
r s l
PARKING
BRAKE
swrTcH
V
I
I
I
I
I
GRN/ REO
, t , I
l
I
I
GnN,4,vHT
LT GRN
ELKi BI-U
RED
GRN/BLK
NoTEi i f
: ro 5V
T
: To t 2v
cRN
---l
F----- GnN
Bru
-J
F------ 61U
8LK
I
I
T
l
G401
G404
, o I
J'
^ A '
14-226
WHT/RED ELUMHT GRY PNK
B6 B7
B2O LB5
|
'i-
*l
L'
t l
- P
t -
BLK
I
I
-
G 1 0 1
Lli:"
+.
il
BRN/BLK
rNHrBl T0R
I
SOLENOI D I
I
n
-:
G 1 0 1
wHT I
wHT
qED
I
PNUSLK
I
PNK,BLU
1
G8N/YEL
J
GRN/BLK
T T T T T
T
T
T
T
T
T -.T-. T
I
cnN
I
nro,wHr BLKMHT
I
GRN{WHT-...1_... YFt
-_..1_.-.
BLUIEL^^.,1,.
nroi eru
--
wi rr
J
wxi tnro
I
eruxi al r
I
PNKi BLU
I
GBN,^vEt
J
GRNi BIK
_ L , r _ r _ r L r l l
'r-- -T'
T
-T -r
T
-T- -T-
T
I I I I | | c*Hl**t I 'i' I
sLU'i^'Hr
I
I I | | | |
pr'rxisLr
I PNK7BLU I
GBN/YEI
I
GRN/BIK
l l l l l l t l l l l
d s t g @ @ @ l e ]
SFiYbtt"','J- 3FIYE,',X!b'J SEigY#I SBniho,
8i0ft
3il[ip'
T
5PEE'sENsoR
!8[$fo,o
!'$,'Afl]:
!'8$nlo'o
l
TCM Teflnlnal Locations
X
><
2 3 5 7 1 0
' 1 1
2
5 6 7 8 1 0
1 4 1 7 20 25 26 1 4 1 7 1 8 20
,/1,/
TCM- A
( 26P) Conner t or TCM
- B
l 22P) Connedor
14- 227
TCM Termi nal Vol tage/Measuri ng
Gondi ti ons
('96
-
98 Modelsl
TCM Terminal Loc.tions
TCM-A l25P) Connecto.
TCM CONNECTOR A
(26P}
TCM-B (22P)
Connectot
2 4 1 8 9 10 1 1 12 13
11 15 16 1 7 20 23 25 26
Terminal Numbet Si gnal Dsscription Moasuring Conditions/Torminsl Vohrgo
A1 SC LS_
Stan cl utch control l i near sol enoi d
power
supply negative electrode
Engi ne i dl i ng,
E
posi t i on:
Approx. 0.4 V
HLC LS-
PH-PL cont rol l i near sol enoi d Dower
Engi ne i dl i ng,
E
posi ti on:
Approx. 0.7 V
Shi ft control l i near sol enoi d oower
Engi ne i dl i ng,
E
posi ti on:
Approx. 0.8 V
A4 LG1 Ground
NE Engi ne speed si gnal i nput Wi th engi ne runni ng: Pul si ng si gnal
A6 Not used
A7 ATP L
A/f gear position
switch
El
position
si gnal i nput
I nEpos i t i on: OV
In other than
El
posi ti on:
Approx. 1O V
A8 ATP S
ly'T gear position switch
E
position
si gnal i nput
In
lg
position:
0 V
In other than
E
A9 ATP D
A{/T gear position
switch
E
position
si gnal i nput
In
lll
position:
0 V
In other than
E
posi ti on:
Approx. 10 V
Ar 0 ATP NP
A,/T gear position
switch
E
or
E
posi ti on
si gnal s i nput
I nEor Epos i t i on: oV
In otherthan
E
orE posi ti on:
Approx. 1O V
A 1 1 ATP R
A,/T gear position
switch
E
position
si gnal i nput
In
lE
position:
0 V
In other than
E
posi ti on: Approx. 1O V
A.12 t Gl Power supply system
(l l ):
Banery vol tsge
A13 PG1 Ground
4 1 4
Start clutch control linea. solenoid
power
supply positive
electrode
Engi ne i dl i ng,
E
posi ti on:
Approx. 2.5 V
A15 HLC LS+
PH-PL control line8|. solenoid power
supply positive electrode
Engi ne i dl i ng,
El
posi ti on:
Approx. 5.0 V
A16 SH LS+
Shift control linear solonoid oower
supply positive
electrode
Engi ne i dl i ng,
E
posi ti on:
Approx. 6.0 V
417 Ground
A18 Not used
A19 Not used
420 D IND
E
i ndi cat or l i ght cont rol
When
l9l
indicator light comes on: Approx.
jO
V
When
l l l
i ndi cat or l i ghr OFF: 0 V
A2'l Not used
422 Not used
VBU Back-up power
system Always battery voltage
424 Not used
A.25 t G1 Power supply system
(l t ):
Baf t ery vol t age
PG1 Ground
L
14-228
TCM CONNECTOR
B
(22P}
Terminal Numbel Si gnal
Description
Measuring Conditions/Terminal
Voltage
B1 SOL I NH I nhi bi t or sol enoi d cont rol Wi t h i nhi bi t or sol enoi d ON: Baf t ery vol t age
Wi t h i nhi bi t or sol enoi d OFF: 0 V
82
MAP
(PB)
-M
an i f ol d Absol r-rte Pressure IMAP)
sensor si gnal i nPUt
Wi t h i qni t i on swi t ch ON
(l l ): Approx. 2. 5 V
Wi t h e; gi ne adl i ng: Approx. 1. 0 V
(dependi ng on
engi ne speed)
B3
Not used
B4
TPS
-Throttl e
Posi ti on
(TP)
sensor si gnal
i nput
(l l )
and t hrof t l e f ul l y open:
4. 14
-
4. 42 V
(l l )
and t hrot t l e f ul l y
cl osed: 0. 44
-
0. 56 V
VSS Vehi cl e Speed Sensor
(VSS)
si gnal
I npur
(l l ) and rot at i ng f ront
wheel sr 0- 5Vcycl e
TMB Dat a communi cat i on wi t h ECM:
Transmi ssi on cont rol dat a out pUt
Wi t h i gni l i on swl t ch UN l l l ): rul sl ng sl gnar
81
TMA Dat a communi cat i on
wi t h ECl vl :
PGM Fl cont rol dat a i nPut
Wi t h i gni t i on swl t ch uN { l l , : l - ul sl ng sl gnal
B8
NDN SG Dri ven
pul l ey speed sensor ground
B9
NDN Dri ven
pul l ey speed sensor si gnal
i nput
l n ot her t hTnE and E
posi t i on: Pul si ng si gnal
8 1 0 NDR Dri ve
I nput
-tn
ottrer ttran E
ana E
posi ti on: Pul si ng si gnal
8 1 1
Not used
812
STOP SW Brake swi tch si gnal i nPut With brake
pedal depressed: Battery voltage
Wi th brake
pedal rel eased: 0 V
813 DIAG-H
(TXD/RXD)
Dat a communi cat i on:
Di agnost i c t roubl e code out Put
Wi t t r i gni t i o. r s*i t ct ' ON
(l l ):
Approx 5. 0 V
8 1 4
Se-i ce ct rect si gnat Wi t h i gni t i on swi t ch ON
(l l )
and servi ce check
connect or oPen: APProx. 5 V
Wi t h i qni t i on swi t ch ON
(l l )
and servi ce check
"onn"i t ot . connect "d wi t h speci al t ool : 0 V
Secondary
gear shaft speed sensor
si gnal i nput
When vehi cl e i s stoPped: 0 V
8 1 5
VEL
8 1 6 VEL SG Secondary
gear shaf t speed sensor
grouno
8 1 7 NDR SG Dri ve
pul l ey speed sensor
ground
818 HBRK SW Parki ng brake swi t ch si gnal i nPut Wi t h
parki ng brake l ever
pul l edr 0 V
Wi t h
parki ng brake l ever rel eased: Bat t ery vol t age
819
Not used
B20 VREF +5 V relerence
(l l ):
Approx 5 V
821
Not used
Not used
PCM Circuit Diagram
(A/T
Control System:
'gg
-
00 Models)
UADEF D'SI
FUSSFEUY 8OX
r{o.2s (7 5A)
tGNtTtc{l
SWTCH
UNDER.OASN
FUSF]NEUY 8OI
iPrE:
T
ro sv
I N
l D
,:--
^1 GETB POSITIoi{
14-230
EIINE
COOLTI'II
TEUPEFATUFE
SENSOF
SPEED
SEllsoF
Y
I
I
I
GFN8U
J-
H
I NHIEITOR
I
soLEr,roro
I
:
l l l l
E E
*fl&'u''!l^"
iflfl.S$'
soLEl|0
T I
.-l-
t t t t
I
u00u
I
ilillfSIft,'
14-231
PGM Terminal Voltage/Measuring Conditions
('99
-
00 Modelsl
A/T Control System
The PCM termi nal vol tage and measuri ng condi ti ons are shown for the connector termi nal s that are rel ated to the A/T con-
trol system. The other PCM termi nal vol tage and measuri ng condi ti ons are descri bed i n secti on 11.
PICM Connoctor Terminrl Location3
Terminal Number Si gnal Descriplion Measuring Condhions/Torminal Voltage
A7 ATP D A,/T gear position switch
E
posi ti on i nput
I nEpos i t i on: OV
In other than
E]
A9 ATP NP A/T gear position switch
@
and
S
posi ti ons i nput
In
E and
El
posi ti ons: 0 V
In other than
E]
and
E
A10 Timing and adjustment service
check si gnal
Wi th i gni ti on swi tch ON {l l } and servi ce check
connector oDen: 5 V
(l l )
and servi ce check
connector connected wi th soeci al tool :0 v
ATP L A,/T gear position switch
I
posi ti on i nput
In
E
posi ti on;
OV
In other than
E
posi ti on:
Approx. 10 V
STOP SW Brake swi tch si gnal output Brake pedal
depressed: Battery voltage
Brake
pedal
rel eased: 0 V
PCM CONNECTOR B I25P}
Terminal Number Signal Description Moasuring Condhions/Terminal Vohage
B1 I GPl Power suppl y ci rcui t from mai n
relay
(l l l :
Battery vol tage
Wi th i gni ti on swi tch OFF: 0 V
82 PG1 Ground
B8 HLC LSM PH-PL control l i near sol enoi d
power
supply neqative electrode
B9 IGP2 Power suppl y ci rcui t from mai n
rel ay
(l l l :
Battery vol tage
Wi th i gni ti on swi tch OFF:0 V
810 PG2 Ground
817 HLC LSP PH-PL control l i near sol enoi d
power suppl yposi ti ve el ectrode
Wi th i gni ti on swi tch ON {l l ): Pul si ng si gnal
818 SC LSM Start cl utch control l i near
sol enoi d power
suppl y negati ve
el ectrode
s20 LGI Ground
821 VBU Back-up power
suppl y Always battery voltage
B22 Ground
825 SC LSP Stan cl utch control l i near
sol enoi d power suppl y posi ti ve
electrode
(l l ):
Pul si ng si gnal
t
14-232
\ a
PCM CONNECTOR D {16P)
14-233
Termi nal Numbs] Si gnal
Description
Measuring Conditions/Terminal Voltage
D1
VEL Secondary
gear shaft speed
sensor si gnal i nput
When vehi cl e i s stoPPed: APProx. 0 V
02 SOL I NH l nhi bi tor sol enoi d control
Wi th i nhi bi tor sol enoi d ON: Battery vol tage
Wi th i nhi bi tor sol enoi d OFF: 0 V
D3 SH LSM Shi ft control l i near sol enoi d
power suppl y negati ve el ectrode
D4 SH LSP Shi ft control l i near sol enoi d
power suppl y
posi ti ve el ectrode
(l l ):
Pul si ng si gnal
D5 VB SOL Power suppl y for sol enoi d val ves Wi th i gni ti on swi tch ON
(l l ):
Baftery vol tage
Wi th i gni ti on swi tch OFF:0 V
D6
ATP R A,/T gear position switch E
posi ti on i nput
I nEpos i t i on: 0V
In other than B
posi ti on; Approx. 10 V
D]
VEL SG Secondary
gear shaft sPeed
sensor
ground
D8
Not used
D9
Not used
D10 NDN Dri ven
anput
In other than E
and
E
D11
NDR Dri ven
i nput
l n other than
E
and
E
D12 NDR SG Dri ve
ground
D13
ATP S A,/T
gear position switch E
posi ti on i nput
I nE
posi t i on: 0V
In other than E
D14
D IND D i ndi cator l i ght control
When i gni ti on swi tch i s fi rst turned ON
(l l ):
Battery voltage for two seconds
In
E
D15
Not used
D16
NDN SG Dri ven
grou nd
Troubl eshooti ng Procedures
l . How To Begi n Troubl eshooti ng
When the
E
i ndi cator l i ght has been reported on, use the appropri ate procedure
bel ow to di agnose and repatr the
pr oDl em.
A. When t he
@
i ndi cat or l i ght has come on:
l connect the Honda PGM Tester or an oBD l l Scan Tool to the 16P Data Li nk Connector
(DLc)
l ocated near the l eft
ki ck panel .
Tur n t he i gni t i on swi t ch ON
( l l ) .
Check the DTC and note i t. Al so check and note
the freeze frame data.
Ref er t o t he Di agnost i c Tr oubl e Code Char t and
begi n t r oubl eshoot i ng.
INOICATOR
LIGHT
NOTE: SeetheOBDl l Scan Tool or Honda PGM Tester user' s manual s for speci fi c operati ng i nstructi ons.
Some PGM-FI probl ems
wi l l al so make the
E
i ndi cator l i ght come on. After repai ri ng the
pGM-Fl
system, di sconnect the
BACK UP fuse
(7.5
Al i n the under-hood fuse/rel ay box for more than l 0 seconds to reset the TCM or PCM memory, rnen
recheck.
NOTE: Di sconnecti ng the BACK UP fuse al so cancel s the radi o preset
stati ons and the cl ock setti ng. Make note of the
radi o presets before removi ng the fuse so
you
can reset them,
2.
3.
o0\e--loo
OATA LINK CONNECTOB I16P}
14-234
B. DTCS wi l l be i ndi cated by the bl i nki ng of the E
i ndi cator l i ght wi th the SCS servi ce connector connected to the
Servi ce Check Connector as shown.
(The
Servi ce Check Connector
(2P)
i s l ocated under the dash on the passen
ger' s si de of the vehi cl e.) Turn the i gni ti on swi tch ON
(l l ).
CONNECTOR
07PAZ
-
00101(x)
codes 1 through 9 are i ndi cated by i ndi vi dual shon bti nks. codes 10 and above are i ndi cated by a seri es of l ong and short
b| i nk s . one| ongbl i nk equa| s l os hor t b| i nk s . Addt he| ongands hor t b| i nk s t oget her t odet er mi net hec ode. Af t er det er
mi ni ngt hecode, r ef er t ot hee| ect r i ca| syst emsympt om- t o- component char t onpagesl 4- 238and14. 239f or t he, 96_98
model s, and on
pages 14-240 and 14' 241 for the
' 99
-
00 model s
Soc DTCI
Sor DTC2
Long blink
Short blinks |tive timsl
some
pGM-Ft
probl ems wi

atso make the E
i ndi cator l i ght come on. After repai ri ng the PGM-FI system, di sconnect the
BACKUPf us e( 7. 5A) i nt heUnder . hoodf us e/ r e| ay box f or mor et hanl 0s ec onds t or es et t heTc Mor Pc Mmemor y , t hen
recheck.
Scc DTCI5
(cont' d)
14-235
i i
i : j
,,,/
CONNECTOR {2PI
Shorl blink
(oncc)
Troubleshooting Procedures
(cont'd)
C. l f the i nspecti on for a
parti cul ar
code requi res vol tage or resi stance checks at the TCM or PCM connectors, remove
the dri ver' s si de ki ck panel ,
and unbol t the TCM, and at the PCM connectors, remove the passenger' s
si de ki ck
panel , and unbol t the PCM. Turn the i gni ti on swi tch OFF, and connect the backprobe sets and a di gi tal mul ti meter
as descri bed bel ow. Check the system accordi ng to the procedure
descri bed for the appropri ate code(s) l i sted on
the fol l owi ng pages.
6 x 1 . 0 mm
9.9 N.m
{1.0 kgt m,
How to use lhe Backprob SE{
Connect the backprobe adapters to the stacking patch cords, and connect the cords to a multimeter, Using the wire
i nsul ati on as a gui de for the contoured ti p of the backprobe adapter, gentl y
sl i de the ti p i nto the connector from the
wi re si de unti l comes i n contact wi th the termi nal end of the wi re.
BACI(PROBE SET
07saz
-
001 txtoa
Itwo requirodl
DIGITAL MULTIMETER
(Commarcially
avsibblel
KS- AHM- 32- ( x) 3,
or oquivalent
6 x
' l , 0
mm
9.E N.m
(1.0
kgf.m,
7.2 rbtftt
coRo
14-236
ADAPTER
ll. TCM Reset Plocedure
1. Turn the i gni ti on swi tch off.
2. Remove the BACK Up fuse
(7.5
A) from the under-hood fuse/rel ay box for 10 seconds to reset the TCM or PCM.
NOTE:
. Di sconnecti ng the BACK UPfuse al so cancel sthe radi o preset stati ons and the cl ock setti ng Make nol e ofthe radi o
presets before removi ng the fuse so you can reset them
BACK UP
t7.s Al FusE
. The TCM or PCM can al so be cl eared by usi ng the OBD l l Scan Tool or Honda PGM Tester'
DATA LINK CONNECTOR {16PI
lll. Final Procedut
NOTE: Thi s procedure must be done after any troubl eshooti ng
' 1.
Turn the i gni ti on swi tch off.
2. Reset the TcM or PCM.
3. Di sconnect the OBD l l Scan Tool or Honda PGM Tester from the Data Li nk Connector
(16P),
or remove the speci al tool
from the Servi ce Check Connector.
(l l ),
and set the radi o presets and cl ock setti ng.
OBD ll SCAN TOOL o.
PGM TESTER
14-237
Chart
Electrical System
-'96 -
98 Models
*:
The DTC i n parentheses
i s the code
@
i ndi cator l i ght i ndi cates when the Data Li nk Connector i s connected to the Honda
PGM Tester.
DTC*
O
Indicator
Li ght
MIL
Detection ltem
Page
P1790
( 3)
Bl i nks ON
sensor
14-242
P179'l
( 4)
Bl i nks ON
Vehi cl e speed sensor
14-243
P1705
( 5)
Bl i nks ON
Ay'T gear position
switch
(short
to groundl
't
4-244
P1706
(6)
OFF ON
A/T gear position
switch {open)
14-246
P0725
( 1 1 )
Bl i nks ON
l gni ti on coi l
14-248
P1793
112l
Bl i nks ON
Mani fol d absol ute pressure
sensor
14-249
P 1870
(30)
Bl i nks ON
Shi ft control l i near sol enoi d
14-250
P' 1873
( 311
Bl i nks ON
PH-PL control l i near sol enoi d
14-25'l
P1879
(32)
Bl i nks ON
Start cl utch control l i near sotenoi d
14-252
P1882
Bl i nks ON
Inhi bi tor sol enoi d
14-253
P1885
(34)
Bl i nks ON
Dri ve pul l ey
speed sensor
1l-Zb4
P1886
(35)
Bl i nks ON
Driven pulley
speed sensor
14-255
P1888
(36)
Bl i nks ON
Secondary gear
shaft speed sensor
14-256
T t o55
(37)
Bl i nks ON
ECM or TCM
14-257
P1890
l 42l
Bl i nks ON
Shi ft control system
14-259
P1891
(43)
Bl i nks ON
Start clutch control svstem
14-260
14-23a
l f the sel f-di agnosti c E
i ndi cator l i ght does not bl i nk,
Symptom
Inspecti on Ref.
page
E
i ndi cator l i ght does not come on for two seconds after i gni ti on swi tch
i s fi rst turn on
(l l ).
14-262
E
i ndi cator l i ght i s on constantl y
(not
swi tch i s on
(l l ).
14-264
NOTE:
. l f a customer descri bed the symptom for code P1706
(6),
i t wi l l be necessary to recreate the symptom by test dri vi ng,
then recheck the DTC.
. Someti me the E
i ndi cator l i ght and the Mal functi on Indi cator l amp
(Ml L)
may come on si mul taneousl y. l f so, repai r the
pGM-Fl
system accordi ng to the DTc, then reset the memory by removi ng the BACK uP fuse i n the under-hood
fuse/rel ay box for more than 10 seconds. Dri ve the vehi cl e for several mi nutes at a speed over 30 mph
(50
km/h)' then
recheck the DTC.
14-239
Symptom-to-Com ponent
Chart
Electrical
System
-'99 -
00 Models
r:
The DTc i n parentheses
i s the code
E
i ndi cator l i ght i ndi cates when the Data Li nk connector i s connected to the Honda
PGM Tester.
DTCT
E
Indicatot
Lighr
MIL
Detostion ltem
Page
P1705
( 5)
El i nks
ON
A,/T gear posi ti on
swi tch
(short
to grouno,
14-265
P1706
(6)
OFF ON
A"/T gear position
switch (open)
14-26
P1870
(30)
Bl i nks
ON
Shi ft control l i near sol enoi d
14-271
P1873
( 31)
Bl i nks ON
PH-PL control l i near sol enoi d
14-213
P1879
t32l
Bl i nks ON
Stan cl utch control l i near sol enoi d
Inhi bi tor sol enoi d
14-215
P1882
(33)
Bl i nks ON 't
4-277
P1885
(34)
Bl i nks ON
Dri ve pul l ey
speed sensol
't
4-279
P1886
(35)
Bl i nks
ON
Dri ven pul l ey
speed sensor
14-281
P1888
(36)
Bl i nks
ON
Secondary gear shaft speed sensor
Shift control system
14-283
P1890
\421
Bl i nks ON
14-245
P1891
(43)
Bl i nks ON
Start clutch control system
14-286
14-240
l f the sel f-di agnosti c E
i ndi cator l i ght does not bl i nk.
SYmPtom
IDI i ndi cator l i ght does not come on for two seconds after i gni ti on swi tch
i s fi rst turned ON
(l l ).
l E1 i ndi cator l i ght i s on constantl y
(not
swi tch i s ON { l l ).
Inspecti on
Ref. page
14-284
14-290
NOTE:
. l f a customer descri bed the symptom for code Pl 706
(6),
i t wi l l be necessary to recreate the symptom by test dri vi ng,
then recheck the DTC.
. i ometi mes, tfre E
i ndi cator l i ght and the Mal functi on Indi cator l amp
(Ml L) may come on si mul taneousl y
l f so, repai r
the PGM-Fl system accordrng to the DTC, then reset the memory by removi ng the BACK UP RADIO fuse i n the under-
hood fuse/rel ay box for more than 10 seconds. Dri ve the car for several mi nutes at a speed over 30 mph {50 km/h)' then
recheck the DTC.
14-241
Electrical Troubleshooting ('96
-
98 Modelsl
Troubleshooting
Flowchart
-
Throttle
position
(Tpl
Sensor
Possible Cause
.
Disconnected throftle position
(TPl
3ensor connoctol
.
Short or open in TP sensor wire
.
Fauhy TP sensol
TCM CONNECTORS
Wi re s; de of f emal e t ermi nal s
.
OBO ll Scan Tool indic.tes Code
P1790.
.
Self-diagnosis
E
indicator light
blinks three times.
Check l or Anot har Code or MI L
Bl i nki ng:
1. Turn t he i gni t i on swi t ch ON 1 ).
2. Check whether the OBD ll scan
t ool i ndi cat es anot her code or
the Malfunction Indicator Lamp
(Ml L)
bl i nks
(see
secri on 11).
Does the OBD ll scan tool indicate
anot hercode ori st he MI L bl i nk-
i ng?
Repai r t he PGM-FI syst om
(3ee
section 111.
Measure VREF Voltage:
(26P)
and B
{ 22P} connect or s l r om t he
TCM.
{f l ).
4. Measure the voltage bet\iveen
t he 820 and A13 or 426 t ermi -
nal s,
Repair open or short in thc wire
b,stween the Bao tcrminal rnd the
ECM.
l s l here approx. 5 V?
Measure TPS Voltago:
Measure t he vol t age bet ween t he
B4 and A13 or 426 t ermi nal s.
Repail open in the wire trtweon
the Erl t6.minal ind the TP sen3o..
l s t here 0. 4
-
0. 6 V?
Check for loose TCM connectors.
good
TCM and r6check.
you
troubl eshoot.
BLK
WHT/RED
A {26P1
Troubleshooting
Flowchart
-
(VSS)
you troubl eshoot'
Po$rible Ctuse
.
Di sconnect ed
vehi cl e speed
sensor
(VSS)
connectol
.
Short or open in VSS wire
'
Faulty VSS
@
.
Make sure lifts,
iacks,
and saltY stands are
placed properly 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
.
P1791.
.
Setf-diagno3is E
indicato. light
blinks tour times.
Ref er t o secl i on 23 f or vehi cl e
soeed sensor IVSSI test
Check the VSS Voltage:
1. Rai se t he vehi cl e
2. Shi f t t he t r ans mi s s i on
t o l E
posr t l on.
( 26P)
and B
( 22P) c onnec t or s f r om t he
TCM.
4. Tur n t he i gni t i on swi t ch ON { l l ) .
5. Rot at e t he f r ont wheel and
check for the voltage between
t he 85 and 413 or A26 t er mi -
nal s. Bl ock t he ot her wheel so
at does not turn
Check f or oPn i n t he wi re
between the 85 terminal and the
vehi cl e speed sensor {VSS}.
l f
wi re i s OK, check t he vSS
(see
soction 23).
Does0Vandappr ox
5 V or mor e
appear al t ernat el Y?
Check for loos TCM connedors
lI necssary, substitute a known'
good TCM and recheck.
14-243
-
9g Models)
Troubleshooting
Flowchart
-
A/T Gear
position
Switch
(Short)
troubl eshoot.
Posrible Cause
.
Shor t i n A/ T go. r posi t i on
switch wire
.
Faulty A/T gar polition
switch
NOTE: Code P1705(5) i s caused when
t he TCM r ecei ves t wo gear posi t i on
I nput s at t he same t i me.
TCM CONNECTOR A {26P}
To page 14-245
.
P1705.
.
Seif-diagnosis
@
indicator light
blinksfive times.
Obsorve t he A/ T gear posi t i on
indicetor:
1[ ) .
2. Observe tho Ay'T gear position
i ndi cat or , and shi f t t o each
posi t i on
separat el y.
Th6 lyrtcm i3 OK at thi. tima.
Check the wi.s hamels for drm.
ag9.
Do any
jndicators
stay on when the
sh;ft lever is not in that position?
Measure ATP R Vohage:
ot her t han
E.
nat s.
Check f or sho. t i n t ho wi re
btwoon the Al1 t rminaland th6
A/l ge.r polhion
switch or A/T
gear position
indicstor. lf wilo is
OK check for loos6 TCM conncc-
tora. It nocassery, subrtitute a
known-good TCM and rchsck.
Measure ATP NP Volt.ge:
ot her
t han
@
or
@.
nal s,
Ch. ck t or 3hort i n t h wi rc
bt wen t hc Al 0 t ermi n. l and
the A/T
96r.
porition
indicrtor,
or a short in the wilea b?twecn
tho A/T gerr porition
indic.to.
and t he A/ T geer posi t i on
switch. It wires ar6 OK, chsck for
loose TCM conn.clols. ll nccNe3-
sa.y, substituto a known-good
TCM rnd locheck.
Measure ATP O Vohage:
ot her t han
E,
t he Ag and A13 or 426 t ermi
nal s.
Checl t or short i n t he wi re
lrtweon tho A9 terminal and the
A/T g6a. position
3witch. lf wire
b OK. check tor loos TCM con-
nectors. lf nocelsary, substhute a
known-good TCM and rechack.
l s t her e appr ox.
' 10
V?
14-244
b
Fr om
page l 4- 244
Measure ATP S Vollage:
1. Shi f t t o al l
Posi t i ons
ot her t han
2. Measur e t he vol t age bet ween
t he A8 and A13 or A26 t er mi
nal s .
Check l or shot t i n t he wi re
between the A8 terminal and the
A/T
gea.
Position
switch or the
A/T gear position indicator. lf wire
is OK, check for loose TCM con_
nectors. lI necessary, substitute a
known-good TCM and recheck.
Measure ATP L Voltage:
' 1.
Shi f t t o al l posi t i ons ot her t han
E-
t he A7 and A13 or A26 t ermi -
nal s.
Check f or short i n t he 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 con-
nectors. ff necessary, substilute a
known-good
TCM and recheck.
Check lor loose TCM connectors.
lf necessary. substitute a known'
TCM CONNECTOR A
(26P)
14-245
Electrical
Troubleshooting (,96
-
9g Models)
Troubleshooting
Flowchart
-
A/T Gear
position
Switch
(Openf
troubl eshoot.
Pos.ribls
Cause
.
Disconnocted A/T gear position
switch connector
.
Open in A/T gear position
switch
.
Faulty A/T gear position
switch
TCM CONNECTOR A I26PI
.
OBD ll Scan Toot indicat* Code
P1706,
.
Solf-diagnosis
E indicator tight
blinb six times.
Measule ATP R Volt.gei
1. Turn the ignition switch ON l).
2. Shi f i t o
E
posi t i on.
t he A11 and 413 or , 426 t ermi -
nal s.
Repair open in tho wire betwoen
l he A11 t er mi nal and t he A/ T
goar po3ition
switch.
Measure ATP NP Volt.gei
1. Shi f rt o
E orE posi t i on.
2. Measure the voltage betlveen
t he A10 and A13 or 426 t ermi
nal s.
Repair open in the wiro between
t he A10 t er mi nal . nd t ho A/ T
gea. poshion
swhch.
Measure ATP D Vohage:
1. Shi f t t o
E
posi t i on.
t he Ag and A' 13 or 426 t ermi -
Repair open in the wire lretween
the A9 terminel and the A/T gear
position
3witch.
To page
14-Z4j
14-246
Fr om
page 14 246
Moasure ATP S Voltage:
1. Shi f t t o E Posi t i on
t he A8 and 413 or 426 t ermi
nal s,
Bepair open in the wir between
the A8 trminal and the A/T gear
position switch.
Measure ATP L Vohage:
1. Shi f t t o E Posi t i on
t he A7 and A13 or 426 t ermi -
nal s.
the A7 terminal and the A/T geal
Dosition switch
Chock tor loose TCM connectors.
lf necessary, substitute a l(nown-
good TCM and recheck,
TCM CONNECTOR A l26p)
14-247
Electrical
Troubleshooting ('96 -
9g Models)
Troubleshooting
Flowchart
-
lgnition
Coil
troubl eshoot,
Po3rible Cause
.
Dbconnected
ignition coil con-
nectol
.
Short o. op6n ignition coil wire
'
F.ulty ignition coil
.
POl25.
.
Soll-diagnosis
E indicarol light
indicates Code 11.
Measure NE Voltrge:
1. Di sconnect
t he A {26p) con
nector from the TCM.
t he A5 and 413 or A26 t ermi -
nal s,
R6p.i. open or short in the wire
blween the A5 te.minsl and tho
ignhion coil. It wir b OK, check
the ignition coil test lsoc aoction
23t.
Check for loose TCM connector.
It nec$sery. substilute a known-
good TCM and .echeck.
Troubleshooting
Flowchart
-
Manifold
you troubl eshoot
Absolute
Pressure {MAPI
Sensor
TCM CONNECTORS
PG.iblo Cau3
.
Dkconnoctod
manilold .bsoluto
ore33urc IMAP)
sensor connoc'
lor
.
Short or opcn in MAP s.nsor
MAP sen3or
.
P1793,
.
self-diagno3b E
indicato. light
indicats Code 12.
Chock tor Another Cod or MIL
Bl i nki ng:
(l l ).
2. Check whether the OBD ll scan
tool indicates another code or
the Mal{unction Indicator LamP
(Ml L) bl i nks
(sse
sect i on 11).
Does the OBD llscan tool indicate
anot her code or i st he l Vl L bl i nk-
in9?
Measure VREF voltage:
2. Disconnect the A
(26P)
and B
( 22P) connect or s
t r om t he
TCM.
(ll).
4, Measure the voltage between
t he B2O and A13 or A26 t ermr
nal s.
Rpair opon or 3hort in the wire
botwoan the 820 t.minal and
the EcM.
l st here aPprox. 5 V?
Msasure MAP IPB)
volt.ge:
Measure the voltage betlveen the
82 and A13 or 426 t ermi nal s.
Repair opon ot shorl in the wiro
betwesn the 82 torminal end th
MAP sensol.
Check for loo3e TCM connstors.
lf nec*sarY, sub3titute a known'
good TCM and rechock.
WHT/RED
14-249
Electrical
Troubleshooting (,96 -
9g Modelsl
Troubleshooting
Flowchart
-
Shift Control
Linear Solenoid
Possible Cause
'
Disconnected
3olenoid h.rnis
connoctor
.
Short or open in 3hift control
linear solenoid wire
.
Faulty shift control linear sole-
noi d
SOLENOID HARNESS
8P CONNECTOR
Ter mi nal
st de of mal e t er mi nal s
8LU/ YEL
troubl eshoot.
.
OBD ll Scan Toot indicates Code
P1870.
.
Selt-dirgnosis
[d
indic.tor tight
indicatos Code 30.
Measure Shift Control Linoar Sole-
noid Resistance
at the Solenoid
Harness Connector:
1. Di sconnect
t he 8p connect or
f rom t he sol enoi d harness con
nector.
2, Measu r e t he r esi st ance
betlveen the No. 3 and the No.
7 t ermi nal s of t he sol enoi d haF
ness connector.
l s t he resi st ance 3. 8
-
6. 8 O?
Check Shift Controt Linear Sote-
noid for a Short Circuit:
1. Di sconnect
t he A ( 26p)
con,
nector from the TCM.
body ground
and t he A3 t er
mi nal and t he A16 t er mi nal
i ndi vi dual l y.
Repair shon in tho wire6 betweon
the A3 and A16 termin.ts lnd tho
body ground.
Measur e Shi t t Cont r ol Li ne. r
Solenoid Resistance:
1. Connect t he 8P connect or t o
t he sol enoi d harness connec,
t or.
bet ween t he 43 and A16 t er-
Repair loose terminal oa open in
the wires between the 43 and
A16 t ermi nal 3 and t he sol enoi d
harness connector.
l s t he resi st ance 3. 8 6. 8 O?
Chock for loose TCM connectorc.
ll necessary, substitute a known-
good
TCM and recheck.
BLU/WHT
GRN/ YEL
TCM CONNECTOR A I26PI
GRN/ YEL
l l 1 2 l :
IriGlx
1 5 7 8 9 10 1 1 12 13
1 7 2t)
23 25 26
14-250
Troub|eshooti ngF|owchart_PH-PLControJLi nearSo|enoi d
NOTE| Record al l treeze data before
you troubl eshoot
Possible cause
'
Disconnected solenoid harness
connectof
.
Short or oPen in PH_PL control
.
Faulty PH-PL control linear sole_
noi d
SOLENOIO
HARNESS
8P CONNECTOR
GRN/WHT
Termi nal si de of mal e t erml nal s
.
OBD ll Scan Tool indicates Codo
P1873.
.
sef-diagnosis E
indicalor light
indicat6 Code 31.
Measure PH-PL Cont rol Li near
Solenoid Resistance at the Sole_
noid Hatness Connectot:
f rom t he sol enoi d harness con-
nector,
bet ween t he No 2 and t he No.
6 t ermi nal s of t he sol enoi d har
ness connector'
-
6. 8 0?
Check PH- PL Cont r ol Li neer
Solenoid for a Short Circuit:
1. Di sconnect t he A 126P)
con-
nector lrom the TCM
body
ground and t he A2 t er
mi nal and t he A15 t er mi nal
i ndi vi dual l y.
Repai r shor t i n t h wi r es
between the A2 and A15 lermi_
nals and the body
glound.
Measut e PH-PL Cont rol Li near
Solenoid Resi3tance:
t he sol enoi d harness connec-
t or,
2, Meas u r e t he r esl sl ance
bet ween t he , q2 and A15 t er_
Rep.il loose tetminal or oPen in
th6 wires betwccn the A2 and
A15 l ermi nal s and t he sol enoi d
harness connctol.
l st he resi st ance 3. 8-6 8 O?
Check for loose TCM connactors
lf neceasery, Substitute a known-
good TCM and rechock.
PNK/ BLK
TCM CONNECTOR
A
(26P)
o
PNK/BLK
I 2 3 4 5 7 8 I 10 l 1 1 2 13
11
' t5
16 1 7
20
/,,/
23 25 26
IGRN/wHr
o
*r}l
t'T,
E[
PNK/8LK
3 a 5 I 9 10 1 1 12 13
16
20 23 25 26
GRN/ WHT
14-251
Electrical
Troubleshooting ('96 - gg
Modelsl
Troubleshooting
Flowchart
-
start clutch control Linear solenoid
NOTE: Record all freeze data before you
t.oubleshoot.
Po$iblo C.u.o
'
Di3aonnoctod solanoid harncat
connactol
.
Short or opon i n st art cl ut ch
control linoar tolanoid wira
.
Faulty ttart clutch control lino.r
solanoid
SOLENOID HARNESS
8P CONNECTOR
.
OBO ll Scan Tool indicatG Code
P1879.
.
Self-dilgno.is
E indicator light
indiclt$ Code 32.
Me. suro St a. t Cl ut ch Cont rol
Linear Solenoid Rosirtrnco st th.
Solenoid Hrrn6rs Connecto.:
from the solenoid harness con-
nector.
between the No. 4 and the No.
8 t ermi nal s ot t he sol enoi d har-
ness connectot.
-
6. 8 0?
Chock Start Clutch Control Lin-
oar Solenoid tor a Short Circuit:
(26p)
con,
nector from the TcM.
body ground
and t he A1 t er-
r ni nal and l he Al
i l
t er mi nal
i ndi vi dual l y.
Rapri r 3hort i n t ha wi ra3
b.ftvcen tho A1 .nd Atil t .mi.
n.l. .nd thr body ground.
Measure St an Cl ut ch Cont . ol
Lineer Solenoid F6aist.ncei
tor.
bet ween t he 41 and Al 4 t er-
mi nal s,
Rcplir loose tcrminal or oDcn in
thG wiras b.tween the Al rnd
Ala torminal3 rnd tha 3olanoid
hamaas connactor.
l s t he resi st ance 3. 8- 6. 8 O?
Check for loose TCM connecto.s.
good
TCM and iecheck.
YEL
PNK/BLU
TCM CONNECTOR A I26P}
-{r-
E
PNK/BLU
2 3 a 5 1 I 9 10 l l 12 13
a 15 t 6 1' 20
a 25 2G
YEL
14-252
Troubleshooting
Flowchart
-
Inhibitor Solenoid
NOTE: Record al l treeze data betore
you troubl eshoot
Po$ibls Cause
.
Dbconnected solenoid hatness
connedor
'
Short or opon in inhibitor sole'
noid wire
.
Faultv inhibitor solenoid
SOLENOID HARNESS
8P CONNECTOR
.
OBD ll Scan Tool indic.td Code
P1882.
.
Selt-di.gnGis E
indicator lighl
indic.tos Code 33.
Mea3ure Inhibhor Solenoid Resid-
ance at t he sol noi d Harness
Connector:
f r om t he sol enoi d har ness
connect or.
2. Measur e t he r esl st ance
betlveen the No 5 terminal of
t or and body
ground.
-
21 0 0?
Check I nhi bi t or Sol enoi d l or a
Short Circuii:
( 22P) con-
nect or f rom t he TCM.
t h e B1 t e r mi n a l a n d b o d y
gro! no.
Repair rhort in the wire ltetwegn
the 81 dnd the bodY
ground.
Mea$rr Inhibitor Solenoid ResBt'
anoe:
t he sol enoi d harness connec_
I Or.
bet ween t he Bl and body
gr ound.
Reoair loose terminal or open in
the wire betwean the 81 and the
solenoid hame3s connector'
-
21. 0 O?
Ch6ck for loose TCM connectors.
ll necessary, substhule a known_
good TCM and techeck.
14-253
Electrical
Troubleshooting
{' 96
-
9g Models)
Troubleshooting
Flowchart
-
Drive
pulley
Speed
Sensor
'
P1885.
.
Self-diagnosis
E indicator tight
indicates Code 34.
troubl eshoot,
Check t he dr i ve pul l ey
speed sen,
sor i nst al l at i on.
l s t he dri ve pul l ey
speed sen-
sor i nst al l ed properl y?
M6a3ure Drive Pulley Sped Sn-
sor Resistance ai the Seosor Con-
nectot:
f rom t he dri ve pul l ey
speed
sensor connect or.
2. Measure t he resi st ance of t he
dri ve pul l ey
speed sensor.
-
600 O?
Check Ori ve Pul l ey Speed Sen-
sor tor a Short Circuit:
(22P)connec-
t ort rom t he TCM.
2. Check f or cont i nui t y bet veen
body ground
and t he 810 t er-
mi nal and 817 t er mi nal i ndi
vi dual l y.
Rspair shon in the wi.es botwoen
t he Bl 0 and 817 t e. mi nal s and
the driva pulloy
3peod 3eniol.
Measure Drive Pulley Spd Sen-
sor Re3istance:
1. Connect t he dri ve pul l ey
speed
sensor 2P connector.
bet ween t he 810 and 817 t er-
mt nal s.
Repair loos6 t.rmin.l or open in
th. wiros botweon tho Bl0 and
817 torminals and thg driva pul-
ley spgd sensor.
-
600 O?
Check tor looso TCM connoctor.
ll necessary, substituto a known-
Po$ible Cause
.
Oisconncted drive pulley
speed
sensor connector
.
Shon or opn i n dri ve pul l ey
spged sonsor wire
.
Faulty drive pulley
spoed s.n-
sot
ORIVE PULLEY SPEED
SENSOR 2P CONNECTOR
lT_ T---_l

1
| 2 t l
t|]--+i
- r r
l 9
t l
L_t
si de oI mal e t ermi nal s
TCM CONNECTOR 8 I22PI
REO/ BLU
Termi nal
REO/ 8LU
J ( l
2 4 5 6 8 9 10
v
12 13 t 4 15 16 17 18 20
GRN
o
1 2 1 5 iliI;W1M
12 1311 15 1 6 tdil)lil/l
GRN
14-254
b
Troubleshooting
Flowchart
-
Driven Pulley Speed Sensor
you troubl eshoot'
Po3sible Cause
.
Di sconnect ed dt i ven Pul l eY
so6ed sensor connector
.
Short or open in driven PulleY
apeed sen3or wire
.
Faulty driven
PulloY
sPeod 3en-
DRIVEN PULLEY SPEEO
SENSOR 2P CONNECTOR
l - _r -
| 1 2 l
:-
t 9
t t
L_.1
TCM CONNECTOR
I l22p)
WHT
t ermrnal s
.
P1886.
.
Sell-diagnosis E
indicator light
indicates Code 35.
l s t he dri ven Pul l ey
speed sen-
sor i nst al l ed
proPerl Y?
Masure Driven Pulley SPed Sen_
sor Resbt nce at the Sensor Con-
neclof:
f rom t he dri ven PUl l ey
speed
sensor connect ol .
2. Measure t he resi st ance ot t he
dri ven
pul l ey speed sensor.
l s t he resi st ance 350 600 0?
Check Driven Pulley Speed Sen-
sor {or a Short Circuit:
1. Disconnect the B
(22P)
connec_
tor from the TCM.
body
ground and t he BB t er
mi nal and 89 t ermi nal i ndi vi d'
Repair sho.t in the wiles between
lhe 88 and Bg lerminals tnd the
driven
pulleY 3Peed 3nsor.
Measure Driven Pulley SPeed Sn-
sor Reistance:
1 . Co n n e c t t h e d r i v e n Pu l l e Y
speed sensor 2P connect or'
2. M easu r e t he r esi st ance
bet ween t he 88 and Bg t erml _
nal s.
Repair loos terminal or oPen in
the wires between the Bg and Bg
t ormi nal s and t he dt i ven
Pul l ey
3D6eO S6n50a,
-
600 O?
Check lor loose TCM connector.
lf necessary, substitute a known_
good TCM and rechack.
^\,
REO/BLU
o
1 2 a 6 8 9 10
12 13 1 a 15
'16 '17
18 20
Wi r e si de oI f emal e t er mi nal s
RED/ BLU]
o
WHT
1 2 1 6 8 10
12 131a 15 16 1 7 18 20
14-255
(' 96
-
98 Modelsl
-
Secondary Gear Shaft Speed Sensor
Po$ible Cause
.
Di sconnect ed secondary geal
shaft speod sen3or connectol
.
Short ol open in scondary gear
shaft sped sen3or wiro
.
Faul t y secondary gear
shat t
speed snsor
SECONDARY GEAR SHAFT SPEED
SENSOR 2P CONNECIOR
l l l l ; l l
T_T
l @
t l
LJ
si de of mal e t er mi nal s Termi nal
TCM CONNECTOR B {22P}
14-256
troubl eshoot.
.
P1888.
.
Selt-diagnosis
Iq indicator light
indicates Code 36.
Check t he secondary gear
shaf t
speed sensor i nst al l at i on.
l s t he secondary gear
shaf t speed
sensor i nst al l ed properl y?
Measure Secondary Gear Shef t
Speod Sensor R8istance at the
Sensor Connector:
f rom t he secondary gear
shaf t
speed sensor connector.
2. Measure t he resi st ance ol t he
secondary gear shal t speed
-
600 0?
Check Counterchaft Speed Son-
sor for a Short Circuit:
1. Disconnect the B 122P) connec
t orf rom t he TCM.
body ground
and t he 815 t er
mi nal and 816 t er mi nal i ndi
vi dual l y.
Repair short in the wir6 bctuveen
t h. 815 and 816 t ormi nrl s. nd
the scondary ge.r
shaft speod
Measu.e Secondary Gear Shatt
Speed Sensor Resistance:
1. Connect t he secondary gear
shaf t speed sensor 2P connec-
bet ween t he 815 and 816 t e.
mr nal s.
Reprir loose terminal or opcn in
the wires between the 815 and
8'16 terminals and the secondary
gar shaft sped snsor,
Check lor loose TCM connector.
lf ncessary, substitute a known-
I 2 1 5 6 9 10
12 131a 15 16 1 7 18 20
WHT/RED
T -
ORN/BLU
D
(o.
1 a 5 6 7 8 I 10
12 13 14 15 1 5 1 7 18 20
WHT/REI
A
I
ORN/ BLU
L
Troubleshooting
Flowchart
-
TMA and TMB Signals
you troubl eshoot'
Possible Cause
.
Shor l or op. n i n TMA wi . o
botwo6n 87 terminal and ECM
.
Shor t or open i n TMB wi r o
bdtwoon BG to.min.l .nd ECM
.
F.ulty ECM
.
Faulty TCM
TCM CONNECTOR B
(22P)
GRY
o
I 2 a 5 8 9 10
12 1311 1 5 16 17 18 20
GRY
ECM CONNECTOR C 13lPI
1 2 3 a 5 6 l 8
9 r 0
1 112 t 3 l a 16 1 8
/ /
29130
/
::)
I 2 a 5 6 8 9 10
12 t 3 14 1 5 16 17 1 8 20
.
OBD ll Scsn Tool indicate3 Codo
P1655.
.
Self-diagnosb E
indicator light
indicales Cod6 37.
Check TMA Wire Continuity:
2- Di sconnect t he I
(22P)
con-
nector lrom the TCM
3. Di sconnect t he c
( 31P) con'
nector from the ECM
t he 87 t er mi nal of t he TCM
and t he Cg t er mi nal oI t he
ECM,
Ropail open in the wire betwcen
the TCM and the ECM.
Check TMA Wir for a Short Cir-
cuit:
87 t ermi nal of t he TCM or t he Cg
t er mi nal ol t he ECM and body
ground.
check rhe EcM:
1. Reconnect t he C
( 31P) con'
nector to lhe ECM, and the B
(22P)
connect or t o t he TCM
(l l ).
t he C9 t er mi nal oI t he ECM
and body
ground.
Chock tor loose ECM connectors.
lf nscossary, subdituta a known'
good ECM .nd lecheck.
To
page 14 258
(cont' d)
14-257
-
98 Models)
Troubleshooting
Flowchart
-
TMA and TMB Sigrrals
(cont,d)
TCM CONNECTOR 8 {22P}
PNK
PNK
PNK
f rom page 14 257
Check TMB Wire Continuity:
1. Turn t he i gni ri on swi t ch OFF.
2. Di sconnect t he C
(31P)
connec,
t or f rom t he ECM, and t he I
(22P)
connector from the TCM.
t he 86 t er mi nal ol t he TCM
and t he C30 t er mi nal of t he
ECM,
rhe TcM and the EcM.
Check TMB Wire tor a Short Cir-
cui t :
86 t er mi nal ot t he TCM or t he
C3 0 t e r mi n a l o t t h e ECM a n d
body ground.
Check the TCM:
1. Reconnect t he B
( 22p)
con-
nect or t o t he TCM, and t he C
(31P)
connect or t o t he ECM.
(l l ).
t he B6 t er mi nat of t he TCM
and body ground.
l s t here approx. S V?
Check for loose TCM connoctors.
lf necessary, substitute e lnown-
o
2 I 6 7 t 8 I 10
12 1314 16 17 18 20
ECM CONNECTOR C 131P}
2 a 5 6 7 8 I 10
l l 1213l a 17118
/l/l )/)/l/l )aol'ol/
PNK
o
2 4 5 6 , 8 9 10
12 1311 15 16 11 1E 20
2 1 5 7 8 10
12 13 14 15 16 1 7 1 8 20
I t
Troubleshooting
Flowchart
-
Po$ible Cause
Faulty 3hift control system
OgD ll Scan Tool indicates Code
P'1890.
Self-diagnosi3 E
indicator light
indicates Code 42.
Check for Anolhet Code:
Check whet her t he E
i ndi cat or
l i ght i ndi cat es anot her code.
Per t or m t he Tr oubl eshool i ng
Fl owchr r t t o. t h i ndi cet . d
Codel sl .
l s t he E
i ndi cat or l i ght i ndi
Check Stall Speed RPM:
Me a s u r e t h e s t a l l s p e e d RPM
(see page 14-298).
l s t he st al l speed over 3, 500 rpm?
l s t he sl al l speed bel ow 2. 0o0 r pm)
Test - dr i ve and Check E ngi ne
Speed:
1. Dr i ve t he vehi cl e at 30 mPh
(50 km/ h) const ant l Y f or sev_
eral manut es.
2. Check t he engi ne speed
l s t he engi ne speed wi t hi n t he
speci f i cat i on
( see page 14 296
and 14 297\?
14-259
(' 96
-
98 Models)
-
Start Clutch Control System
you
troubl eshoot.
Po$ible Ceuaa
Frulty start clutch cont.ol 3ys-
tem
14-260
OBO ll Scan Tool indic.le3 Cod6
P1891.
Solt-diagnosis
E
indicator light
indicates Code
(1.
Check for Another Codo:
Check whet her t he
@
i ndi cat or
Poi f orm t ho Troubl cahoot l ng
Fl owchrrt l or t he i ndi cat . d
Code(sl.
l s t he
E
i ndi cat or l i ght i ndi -
Test Strrt Clutch Oper.tion:
from the solenoid harness con,
nector.
3. St art t he engi ne, and shi f t t o
E
posi t i on.
4. Check whet her t he vehi cl e
moves.
Rcplaca th. strrt dudt r$amt ly.
Check Creeping Sped:
2. Reconnect the 8P connector to
t or,
3. St art t he engi n6, and shi f t t o
E
posi t i on.
creeps, and chock t he creep-
I ng speed.
Does t he vehi cl e move and i s
t he cr eepi ng speed appr ox. 3
mph
( 5
km/ h) ?
To page
14-261
E
Fr om page 14 260
Measure t he st al l speed RPM
(see
page 14' 298).
l s t he st al l speed over 3, 500 rpm?
Warm Up Engi ne and Recheck
Fai l ure:
1. War m uP t he engi ne t o nor '
mal oper at i ng t emPer at ur e
(t he radi at or f an comes on)
2. Check whet her t he st art cl ut ch
probl em appears agai n.
Does t he
probl em appear?
The svstem is OK at this time.
rl ,
J
14-261
('96
-
98 Modelsl
-
Pl
Indicator Light Does Not Gome On
TCM CONNECTOR A {26P)
BLI
l -
I
1 2 3 a 5 8 9 1 0 1t 12 nl
1a 15 16 17 20 23 25 rt
o
8LK
The
E
I ndi cat or l i ght does not
come on when the ignition switch
i s t i rst t urned ON {l l ). {l t shoul d
come on for aboul two sconds,)
Chock the Service Check Connec-
lot:
(SCS
Ser vi ce Connect or ) i s not con
nect ed t o t he seryi ce check con
nect or,
(SCS
Servi ce
Connect or) connect ed t o t he ser-
vi ce check connect or?
Disconnct the sDecial tool from
the seruice check connector and
recheck.
Check the E
Indicator Light:
Shift to [5] oosition.
Check fo. loose TCM connectors.
lf neceasary, substitute a known-
good TCM .nd rochock.
Does t he E
come on?
Chck th6 Ground Circuit:
2. Di sconnect t he A 126P) con-
ground
and t he 426 t ermi nal
and body
ground.
. Repai r
open i n t he wi r es
betwoon lhe A13 or A26 termi-
nel 3 and G101.
.
Repai . poor ground
{G1011.
To page 14-263
14-262
>.
Ft om page 14 262
Measure Powet SUPPI Y Ci . cui t
Voltage:
1. Turnt he i gni t i on swi t ch ON
(l l )
t e r mi n a l s A1 2 a n d A1 3 a n d
bet ween t er mi nal s A25 and
426.
between the A'12 andlor Ms ler-
mi nrl s and t he under-dash f use
DOX,
Measure D IND Voltage:
2. connect t he A
(26P)
connec
t or t o t he TcM.
3. Connect a di gkal mul t i t est er
t o t he A20 and A' 13 or A26 t er
mi nal s.
(l l ),
and make sure that the voltage
i s avai l abl e f or t wo seconds.
Check t or opon i n t he wi r e
bet ween t he A20 l 6rmi nal and
the gaug assembly. It the wite
is OK, check tor a faultY ipl
indi-
calor light bulb or a faulty
gauge
assembly
prir ed circuit boatd.
Check D INO for an Shott Circuit:
( 26P)
con-
t he A20 t ermi nal and t he No. I
t ermi nal of t he
gauge assem-
bl y connect or
(see
sect i on 23).
Bepair open in the wire between
the A20 terminal and the
gauge
assembly.
Check tor looso TCM connecto.s.
Check t he A/ T
ge. r
Posi t i on
switch. lf nec6ssary, substitute a
known-good TCM and rcheck
BLK/WHT
I
r
2 a 7 10 1 1 12 13
14 t 5 16 17 20 23 25 26
BLK/WHT
A
I
I
TCM CONNECTOR A I26P)
TCM CONNECTOR
A
(25P}
BLK
BLK
GRN/ BLK
1 2 a 5 8 9 10 1 1 12 13
1 l 15 16 1 7
20 23 25 26
o
GRN/ BLK
GAUGE ASSEMBLY
14P CONNECTOR
a 5
7 8 9 1 0 1 1 12 14
GRN/ BLK
(' 96
-
98 Modelsl
-
lq
TCM CONNECTOR A {26PI
YEL
The
E
indic.tor light is on con-
st ant l y {not bl i nki ng} whonever
the ignilion switch is ON llll.
Measure D INO Voltage:
( 26P)
con'
(l l ).
ground,
Repeir 3hort to power in thc wire
bet ween t ho A20 t ermi nal and
ihe gauge
assmbly.
Measure ATP DVohage:
2. Connect t he A
(26P)
connec-
t or t o t he TCM.
(l l ).
4. Shift to any position
other than
E,
t h e A9 t e r mi n a l a n d b o d y
grou nd.
Check tor a short to ground on
t he wi re. l l wi re i s OK, . epl . ce
the A/T gear position indic.tor.
2 3 4 7 8 10 l l 12 13
1a 15 16 1 7 20 23 25 26
GRN/ BLK
1 2 3 a 5 7 8 9 10 1t 12 13
1a t 5 16 17 20 a 25 26
14-264
-
Electrical
Troubleshooting
('99
-
00 Models)
Troubleshooting
Flowchart
-
(Short)
you troubl eshoot.
Po3sible Cause
.
Short in A/T gear po3ition 3witch
.
F.ulty A/T
ge6r
Position
switch
NOTE: Code P1705(5) i s caused when
t he PCM r ecei ved t wo gear
Posi t i on
PCM CONNECTORS
LGl
(BRN/8LKI LG2
(BRN/8LKI
(cont' d)
14-265
B t 25Pt l l O( 16P1
.
oBD ll scln lool indicats code
P't705.
.
Self-diagnosb E
indicator light
blinks fivetims.
Obseive tho A/T Gear Polition
lndicetor:
(l l ).
2. Observe the A,/T
gear positaon
i ndi cat or, and shi f t oach
Posi -
t i on separat el y.
Tho ry3t 6m i s OK at t hi s t i ms.
Check t h wi r o hsr no! ! t or
damage.
Does any indicator stay on
when t he shi f t l ever i s not an
t hat
posi t i on?
M.Furo ATP R Vohtge:
1. Shift to all
positions other than
E.
t he D6 and 820 or 822 t ermi '
nal s,
Chock f or l hor t i n t ho wi t
betwen the D6 telminal and thg
A/T ge.r position 3witch or A/T
gear po3i t i on i ndi ct t oi , ! nd
chcck f or open i n t he wi t gs
botwon the 820 lnd 822 tetmi_
n. l s and body g. ound (G1011. F
wiro3 ere OK, check tor loo3o ter'
minal fit in the PrCM connoctors.
ll n6c3sary, 3ubstitute a known-
good PCM and rochock.
To page 14 266
('99
-
00 Models)
Troubf eshooting Flowcharl
-
AIT Gear Position Switch
{Short) {cont,d}
From page 14 265
LGl
IBRN/BLK) LG2 {BRN/BLK}
A t 32Pl
j l
B {25P)
ATP D
(YEL)
LG1 {BRN/ALKI LG2 IBRN/BLK)
Measure ATP NP Voltage:
' 1.
Shi f t t o al l posi t i ons
ot her t han
E o r I
the A9 and 820 or 922 te(mi-
nal s.
Check f or shor t i n t he wi r e
betwoen ths Ag terminal and the
A/T gerr position
switch, .nd in
t he
E
. nd
E
posi t i on
3i gnal
wi r os bot ween t he A/ T gear
posi t i on
i ndi c. t or and t he A/ T
gear positaon
switch. lf wircs .re
OK, check tor loose terminal tit in
t he PCM connect ol s. l f nces-
3ary, substitute a known-good
PCM and rocheck.
Me.sure ATP D Vohago:
ot her
t han
E.
the 47 and 820 ot 822 tet-r'i-
nal s,
Check t or 3hort i n l he wi re
btwaen thc A7 terminel and the
A/T g6ar position
switch. lf wir.s
are OK, ch.rck to. loose terminal
fit in th6 PCM connectoF. lf nsc-
ossary. substhute a known-good
PCM and ..check.
a l 32Pl l l B
(25P1
To page 14-267
14-266
M6asure ATP S Voliag:
1. Shi f t t o al l
posi t i ons ot her
t han E.
nal s.
Check f or shor t i n t he wi r e
bet ween t he D13 t ermi nal and
the A/T gear position lwitch or
A/ T goar posi t i on i ndi cat or. I t
wir6s are OK, check lor loose lr-
minal fit in the PCM connectors.
ll nec*3arv, substitute a known'
good PCM and r6check.
l s t here approx.
' 10
V?
Measure ATP L Voltage:
1. Shi { t t o al l
posi t i ons ot her
t han E.
nal s.
Check l or sho. t i n i he wi r e
bet wgon t he A22 t ermi nal and
th. A/T geat position switch or
A/ T gear posi t i on i ndi cat or. I t
wires are OK, chck for 10036 ter-
minal fit in the PCM connectors.
lf n6cessery, substitute a known_
l s t here approx- 10 V?
Check tor loos terminalfit in the
PCM connect ors, I t nec6s3arY,
and rech6ck.
From page 14-266
B t2sP)
LG1{BRN/BLKI
t32Pl
PCM CONNECTORS
Wi re si de of I emal e t ermi nal s
PCM CONNECTORS
D
(16P1
ATP S {LT GRN/RED)
LG2
(BRN/BLKI
B t25Pl
{'99
-
00 Models)
Troubfeshooting Flowchaft- AIT Gear Position Switch
(Openl
Po$ible Cau3e
.
Oilconnected A/T goar position
switch
.
Opn in A/T go.r po.ition
switch
wi?o
.
Faulty A/T gear polition
switch
PCM @NNECTORS
(BRN/BI.XI
LG2IBRN/BLKI
wire side of fomale terminals
I-G1
(BRN/BLKI
LG2 {BRN/BLK)
B {25P) I tO
(16P1
ATP NP ILT GRNI
A
t:r2Pt
Il s tzspt
.
OBD ll Scan Tool indicstE Code
P1706.
.
Selt-diagnGi!
E
indicato. light
blinks six tima.
Test the IVT gear position
switch
(see
sect i on 23).
Measu.e ATP R Voltage:
(l l ).
2. Shi f t t o E
posi t i on.
nal s,
Ropair opcn in the wi.. hr.raGn
th6 DO torminrl lnd the A/t g..r
position
awitch.
Measure ATP NP Vohage:
' 1.
Shi f t t o
E
or
N
posi t i on.
the A9 and 820 ot 822 letmi-
nal s,
Ropair op6n in th wiro b{woan
the Ag t.rminal and the A/T go..
position
.witch.
To page 14 269
14-264
From page 14-268
LGl IBRN/BLK}
Moasule ATP D voltago:
1. Shi f t t o
El
posi t i on.
t he A7 and 820 or 822 t ermi
nal s.
Repair open in the wira betwo6n
the A7 torminal and the A/T
ge.r
po3ition switch.
Measure ATP S Vollag6:
' 1.
Shi f t t o E
posi t i on.
t he D13 and 820 or B22 t ermi
nal s.
Repair opn in tho wire between
i he D13 t ermi nal . nd t he A/ T
gear position switch,
A {32P} l l
B l 25Pl
LGl IBRN/BLK) LG2
(BRN/BLKI
(cont' d)
14-269
To
page 14-270
{'99
-
00 Models}
-
(Openl (cont'dl
Bepair opon in the wiro bgtwen
l ho A22 t ormi nal and t he A/ T
goar poihion
lwitch.
PCM CONNECTORS
B
(25P1
LGT (BFN/ALK}
1 2 . 1 5
/
7 I
9
't0
l 1 Br1/l/41i t8
l l
l LG2
o)
( o)
IBRN/BLKI
From page 14-8-269
Msasuro ATP L Voftage:
1. Shi f t t o E
posi t i on.
nal s,
Check LG Wiro for .n Open Cir-
cuit:
' ]
t he 820 t r mi nal and body
ground,
and bet ween t he 822
Ropai' op.n in the wira botw.n
the 820 rnd 822 toJminals .nd
body ground, and . opsi . pool
ground (Gl 01l .
Check tor loose te.minal frt in th6
PCM connctors, lf ncessary, sub-
stitut a knowo-good PCM and
a6check,
14-270
J
Troubleshooting
Flowchart
-
Shift Control Linear Solenoid
you troubl eshoot
Possiblc Cause
.
Disconncted solenoid harnos3
connectol
.
Short or oDen in shilt control
linetr solonoid wiro
.
Faulty shift control linear sole_
noi d
.
Opn in VB SOL wite
.
ODen in PG'l and PG2 wires or
poor ground
{G10'l)
f ,
wi re si de ot f emal e t ermi nal s
LG1 IBRN/BLKI
LG2I BRN/ BLK)
{cont' d)
14-271
PCM CONNECTORS
B( 25P)
-
Dl l 6P)
. OBD l l Scan Tool i ndi cat os
Code P1870.
.
Solf-diagnosis E
indic.lor light
indic.ts Code 30.
M6a3ure VB SOL voltage:
2. Di sconnect t he B 125P) and D
PCM,
(l l ).
nal s.
Repair open or shod in the wire
under-dash tuso/telay box.
Check the Ground Circuitl
the terminafs 82 and 822 and
820.
Repair open in the wi.e betwoen
t he t ermi n. l s 82, B10, B20, and
822 and G101. Repai r
Pool
ground (G101).
LG1 I BRN/ BLKI
PCM CONNECTOR
B PsPI
PG,I IBLK)
10 page 14-272
a
(' 99
-
00 Model s)
-
Shift Gontrol Linear Solenoid
(cont'dl
SOI."ENOID HARNESS 8P CONNECTOR
PCM CONNECTOR D {16P}
SH LSM IGRN/YELI SH LSP {BLU/WHTI
Wire side oI temale terminals
SH LSM {GRN/YELI SH LSP IALU/WHT}
t uom page 14 271
Measur e Shi f t Cont r ol Li near
Solenoid R6sistance at the Sole-
noid Hrrness Connector:
1. Di sconnect t he sol enoi d har
ness 8P connect or.
bet ween t he No. 3 and No- 7
t ermi nal s oI t he sol enoi d har
ness 8P connect or,
-
6. 8 o?
Check Shift Control Linar Sole-
noid tor a Short Circuit:
body
ground and t he D3 t ermi nal
and D4 t ermi nal i ndi vi dual l y.
Rep.ir short in th wir trtwlren
ihe D3 and D4 torminab .nd the
shift cont.ol line.. solenoid.
Measure Shi t t Coni rol Li neer
Solenoid Resbtance:
1. Connect t he sol enoi d harness
8P connector.
bet ween t he D3 and D4 t ermi -
nat s.
Repeir loose ierminrl or open in
the wire3 between tho D3 and D4
t ermi nal s end t he shi f t cont rol
linear solenoid.
-
6. 8 O?
Check tor loose terminal fit in the
PCM connect or3, I t necessary,
and recheck.
SH LSP
SH LSM
14- 272
-
PH-PL Control Linear Solenoid
you
troubleshoot.
Possibls c.use
.
Oisconn6dod solenoid harness
conn6ctol
.
Short or ooen in PH-PL control
.
F.ulty PH-PL cont.ol linear sole-
noid
.
ODen in VB SOL wire
.
Opn in PGl and PG2 wires or
poor ground
l G101l
PCM CONNECTORS
LGT IBRN/BLKI
LG2 IBRN/BLK)
(cont' d)
B
(25P1 D {16P}
.
OBD l l Scan Tool i ndi cat es
Codo P1873.
.
sslt-disgnosis E
indicltor light
indicates Code 31.
Mo.surevB SOL Vohagg:
2. Di sconnect t he 8
(25P)
and D
( 16P)
PCM,
3. Turn tho ignition switch ON
(ll),
nal s,
Ropair open or shod in the wiJe
bstwaon tho D5 terminal and the
under-dalh tuso/relay box.
Check the Ground Circuh:
820.
Fepair open in tho wiro btwen
tho torminds 82, 810, 820, and
822 and G101. Repai r
Poor
ground (G1011.
(BRN/ BLX)
Fo
page 14-274
PCM CONNECTOR B
(25P|
14-273
('99
-
00 Models)
-
PH-PL Gontrol Linear Solenoid
(cont'd)
From page l 4-273
SOLENOID HARNESS 8P CONNECTOR
PCM CONNECTOR B
(25PI
Mea3ure PH-PL Cont rol Li near
Solenoid Rosistance at lhe Sole-
noid Harness Connector:
1. Di sconnect t he sol enoi d har-
ness 8P connect or.
2. Measu r e t he r esi st ance
bet ween t he No. 2 and No. 6
t ermi nal s oI t he sol enoi d har
ness 8P connector.
-
6. 8 O?
Check PH-PL Control Linear Sole-
noid lor a Short Circuit:
body ground and t he 88 t ermi nal
and 817 t ermi nal i ndi vi dual l y.
Rep.i. 3hort in the wiro bsh^,een
lhc 88 and 817 terminals and the
PH-PL cont.ol linear solenoid.
Measure PH-PL Cont rol Li near
Solenoid Resistance:
8P connect or,
between the 88 and 817 termi-
nal s.
Repair loose te.minal or open in
t he wi res bet ween t he 88 rnd
817 te.minlb .nd the PH-PL con-
trol linear solenoid.
l s t he resi st ance 3. 8-6. 8 O?
Check lor loose ierminal fit in the
PCM connect oTa. l f necessary,
.nd recheck.
HLC LSP
HLC LSM
HLC I.SM (PNK/BLK)
HLC LSM {PNK/BLKI
-j-
i 8
lisl
i . ( (
3 5 / 1 1
I l 0
A/'.n
20
HLC LSP IGRN/WHT}
14- 274
Troubleshooting
Flowchart
-
Start
you troubl eshoot'
Clutch Control Linear Solenoid
PCM CONNECTORS
LGl
(BRN/BLKI
(cont' d)
14-215
Po$ible Cause
.
Disconnected solenoid harness
connedol
.
Short or open i n st a. t cl ut ch
control linear solenoid wiro
.
Faulty 3tart clutch conttol linar
solenoid
'
Ooen in VB SOL wire
.
Open in PGI and PG2 wires or
poor ground {G101)
B l25P) --
o l16P)
' OBD l l Scan Tool i ndi cat es
Code Pl879.
.
self-diagnosis E
indicstor light
indicates Code 32.
Measure VB SOL Voltag6:
2. Di sconnect t he B {25P) and D
( 16P) connect or s
{ r om t he
PCM.
(l l ).
nal s,
Reprir opon or short in the wire
undei-d.sh luse/relaY box.
Check the Ground Ciicuit:
' 1.
the terminafs 82 and 922 and
820.
Rep.ir open in the wire betwesn
the terminab 82, 810, 820. tnd
822 and G101. RePai r
Poor
ground l G101l .
LGl IBRN/BLK)
To
page 14-276
PCM CONNECTOR
B {25PI
Electrical Troubleshooting ('gg
-
00 Modelsl
Troubleshooting
Flowchart
-
start clutch control Linear solenoid
(cont,d)
Frcm page 14. 275
T6rmi nal
si de of mal e t ermi nal s
Wire side of f6male terminals
SC LSM
(PNK/BLU)
Measurs St art Cl ut ch Cont rol
Linear Solenoid Raistance at ths
Solenoid Harnes Connector:
1. Di sconnect t he sol enoi d har-
ness 8P connector.
2, M easu r e t he r esi st ance
bet ween t he No. 4 and No. I
t ermi nal s of t he sol enoi d har-
ness 8P connect or,
l s t he resi st ance 3. 8- 6. 8 0?
Check Start Clutch Control Line.r
Solenoid tor a Short Circuit:
Check for continuity between tho
body ground
and t he 818 t ermi -
nal and B2St ermi nal i ndi vi dual l y.
Rp.ir short in th. wire bctw.on
t h6 818 and 825 t ermi n. l r rnd
the 3hift cont ol linc.r solonoid.
Measure St art Cl ut ch Cont rol
Linear Solenoid R6ist.nco:
8P connclor.
betlveen the 818 and 825 ter,
mt nat s,
Raprir looa. t.minal or opan in
tha wirars lratwe.n the B18 and
825 t ermi nal 3 and t ha st ! rt
clutch control linoar 3olanoid,
l s t he resi st ance 3. 8-6. 8 O?
Check to. loose tarminal fit in tho
PCM connact ors. I t necessary,
and recheck.
SC LSP
SC LSM
14-276
Troubleshooting
Flowchart
-
lnhibitor Solenoid
you troubl eshoot'
Po3sible Cause
.
Oi3connec'ted solenoid harn6s
connectoa
.
Shorl or open in inhibitor 3ole-
noid wir
.
Faulty inhibitor solenoid
.
ODen in vB SOL wire
.
Open in PGl and PG2 wires or
poor ground
{G101}
PCM CONNECTORS
LGl I BRN/ BLKI
LG2
(BRN/BLKI
(cont' d)
14- 217
. OBD
l l Scan Tool i ndi cai es
Codo P'l882.
.
Self-diagnosis E
indicttor light
indic.tes Code 33.
Me'sure VB SOL voltagel
' 1.
(25P) and D
PCM.
(l l )
4. Measu.e the voltage between
t he D5 and 820 or B22 t ermi -
nal s.
between the D5 tolminal and the
undor-dash lu36/relay box.
Chck the Ground Circuit:
bet ween t er mi nal s B' 10 and
820.
Rpair open in the wire between
the torminal3 82, 810, B20, and
B2 2 . n d G 1 0 1 . Re Pa i r
Po o r
ground
{G101).
(BRN/BLKI
To page 14-278
('99
-
00 Models)
-
Inhibitor Solenoid
(cont'dl
SOL INH
Mersure Inhibitor Solenoid R6b-
t . nce at t he Sol enoi d Harne3s
Connctor:
1. Di sconnect t he sol enoi d har,
ness 8P connector,
bet ween t he No. 5 t ermi nal of
t he sol enoi d harness 8P con-
nect or and body ground.
-
21. 0 O?
Check I nhi bi t or Sol onoi d f o. .
Short Ci.c!it:
D2 and 820 or 822 t ermi nal s.
R.p.ir 3hort in thc wire botwaan
th 02 t.rminal and the inhibhot
solenoid.
Measur 6 I nhi bi t or Sol enoi d
Re3istance:
1, Connect t he sol enoi d harness
8P connector.
2, Measur e t he l esi st ance
822 t ermi nal s.
Rcpair loo3. tarminal or opan in
tho wha brtw.n tho D2 to.mi-
nal .nd tho inhibitor lolonoid.
-
21. 0 O?
Check fol looso torminal fit in the
PCM connect ors. l f ncessaay,
and rcheck.
Ft om page 14- 277
LGl
IBRN/BLKI
LGl {BRN/ALKI
B t25P) l l
D t16P)
B t25Pt otl 6Pt
14-274
Troubleshooting
Flowchart
-
Drive Pulley Speed Sensor
NOTE: Record al l freeze data before you troubl eshoot'
Possible Cau3
.
Di sconnect ed di i ve Pul l eY
soeed s6n3or connectol
.
Short or open i n dri ve
Pul l . Y
sooed sonsor wire
.
FaultY drive PulleY
spod sen'
301
DRIVE PULEY SPEED
SENSOR @NNEfiOR
PCM CONNECTOR D
(16PI
NDR SG IGRNI
Wi re si de o{ I emal e t ermi nal s
(cont' d)
14-279
. OBD
l l Scan Tool i ndi cat es
Code Pl885.
.
Selt-diagnosb E
indicator light
indicatos Code 34
check t he dri ve
pul l eY sPeed sen-
sor i nst al l at i on, and check i t f or
damage.
l s t he dri ve Pul l eY
speed sen-
sor i nst al l ed
properl y, and not
damaged?
Rein3tall or roplace and techeck
Measuro Drive PulleY Speed Sen_
sor Ro3i st anco at t he Sonsol
Connector:
1. Di sconnect t he 2P connecl or
f rom t he dri ve
Pul l ey
speed
sensor,
2. Measure dri ve
Pul l ey
speed
sensor resislance at the sen-
sor connecror.
-
600 O?
Check Drivo PulleY SP6d Sen3o.
lor . Short Circuit:
1. Disconnect the D {16P) connec-
torlrom the PCM.
body
ground and t he D11 t er
mi nal and D' l 2 t ermi nal i ndi
vi dual l y.
Repai . shor t i n t he wi l es
between the Dll lnd D12 termi-
nals and iho drive
Pull.Y
speed
To page 14-280
Electrical Troubleshooting ('gg
-
00 Models)
Troubleshooting
Flowchart
-
Drive
pulley
Speed Sensor
(cont,d)
PCM CONNECTOR D {16P}
From page
14-279
Measure Drivo Pulley Speed Sen-
sor Circuit tor an Open:
1 . Co n n e c t t h e d r i v e p u l l e y
speed sensor connector,
2. l vl easu r e t he r esi st ance
bet ween t he Dl 1 and Dl 2 t er-
mi nal s.
R6pair loose tgrminal or opan in
the wiros betwon tho D1,l .nd
Ol2 tarminrl! .nd th. drivs pul-
ley speed *n3or.
-
600 O?
Ch6ck for loose lerminal tit in the
PCM connect ors, l l nece3saay,
substituto a known-good PCM
6nd rcheck.
14-280
Troubleshooting
Flowchart
-
Driven Pulley Speed Sensor
NOTE: Record all freeze data betore
you troubleshoot'
Po3sible Caus
'
Oi sconnect ed dr i ven Pul l eY
speed s6nlor connoctor
.
Short or opon in d.iven Pulley
soeed sonsol wirc
.
Faulty driven Pulley
speed sen_
sor
DRIVEN PULLEY SPEED
SENSOR CONNECTOR
FCM CONNECTOR
D If6P)
NDN IWHTI
(cont' d)
' OBD l t Sc. n Tool i ndi cat es
Code Pl886.
.
Self-diagnosb E
indicator light
indicrt. Codo 35.
Check t he dr i ven
Pul l ey
speed
sensor i nst al l at i on, and check i t
I or damage.
l st he dri ven
pul l eY speed sen'
sor i nst al l ed
ProPerl y,
and not
damaged?
Boin3tall or ropl.ca and recheck.
M. . sure Dri von Pul l oY SPoed
Sonsor Rosblanco at the S6n3or
Conn6ctori
t rom t he dri ven PUl l ey
sPeed
sensor,
2. l veasure dri ven Pul l ey
speed
sensor resi st ance at t he sen_
sor connect or.
-
600 0?
Check Dtivon Pulloy SPed Sen'
sor for a Short Circuit:
1. Disconnect the D
(16P) connec-
torfrom the PCM.
body
ground and t he D10 t er'
mi nal and Dl 6 t ermi nal i ndi -
vi dual l y.
Raoai r shot t i n t ho wi . 6s
betwoon th. Dlo end D16 tormi'
nak .nd the ddven Pulley
spod
Fo
page 14'282
14-2A1
['gg
-
00 Models)
Troubleshooting
Flowchart
-
Driven
pulley
Speed Sensor
(cont,dl
NON SG IRED/WHTI
From page l 4 281
M6asure Dri ven Pul l ey Speed
Sensor Circuit Ior an Opn:
1 . Co n n e c t t h e d r i v e n p u l l e y
speed sensor connector,
bet ween t he D10 and Dl 6 t er-
mi nal s.
Rgpair loose terminal or open in
the wires botwosn the Dlo and
016 torminab rnd the drivon Dul-
ley speed 3ensoa,
-
600 O?
Check tor loose terminal tit in the
PCM connect ors, l f necessary,
sub3t i t ut e a l nown-good PCM
and rech6ck.
14-282
Troubleshooting
Flowchart
-
Secondary
Gear Shaft Speed Sensor
you troubl eshoot
Po$ible Causo
.
Oi sconnect od secondarY
gear
shaft speed sensor conn66or
'
short or open in secondary
gear
shaft sped sensor wiro
.
Faul t y secondarY
gear 3haf t
sPeed sensor
SECONDARY
GEAR SHAFT
SPEEO SENSOR CONNECTOR
PCM CONNECTOR
D I15P)
VEL
(WHT/REO) VEL SG IALK/WHTI
Wi r e si de oI f emal e t er mi nal s
(cont' d)
14-243
'
OBD l l Scan Tool i ndi cat es
Code P1888.
.
Self-diagnosis E
indicalor light
indicats Code 35.
Check t he secondarY
gear shaf t
speed sensor i nst al l at i on, and
check i t f or damage.
l s t he secondary
gear shaf t
speed sensor i nst al l ed
properl y, and not damaged?
Reinatall or replace and rocheck.
Measure SocondarY Gear Sh.ft
Speed Sen3or Resistance at the
Sensor Connector:
t rom t he secondary
gear shaf t
speed sensor.
2. Measure secondary
gear shaf t
speed sensor resistance at the
sensor connect or.
-
600 0?
Check SecondarY
Gear Shaf t
Speed Sensor lor a Short Circuit:
1. Di sconned t he D
(16P) connec-
tor from the PCM.
body
ground and t he D1 t er-
mi nal and D7 t er mi nal i ndi -
vi dual l y.
Repai r shor t i n t he wi r os
b. t ween t he Dl and D7 t ermi _
ne13 and t h secondar Y
geal
3haft lpeed sonsor.
To page 14-284
Electrical Troubleshooting (' gg
-
00 Modelsl
Troubleshooting
Flowchart
-
Secondary Gear Shaft Speed Sensor
(cont'd)
Wi16 side of female t6rminals
From page 14 283
Moasu. Secondary Gaar Shaft
Spo6d Sonsor Ci r cui t t or an
Openi
1. Connect t he secondary gear
shaf t sp6ed sensor connect or,
2. M easu r e t he r esi st ance
between the Dl and D7 termi
nal s,
Repair looao terminal or opon in
the wiraa batuvacn the Dl and D7
t . rmi nrl s snd t he second! ry
geer
rhatt 3peod 3.nior.
-
600 O?
Check for looso terminal lit in the
PCM connect ors. l f necessary,
subst i l ut e a known-good PCM
.nd recheck.
14-284
Troubleshooting
Flowchart
-
you troubl eshoot
Possible cause
Faultv shift control svstem
'
OBD ll Scan Tool indicates Codo
P1Ato.
.
Self-diagnosis E
indicator light
indicatos Code 42.
Check for Anothr Code:
Check whet her t he E
i ndi cat or
Prf orm t he Tl oubl eshoot i ng
Fl owchar t f or t he i ndi cat ed
Code(sl.
l s t he E
i ndi cat or l i ght i ndi
Measur e t he st al l sPeed RPM
(see page 14-298).
ls the stall speed over 3,500 rpm?
ls the stall speed below 2,000 rpm?
Test - dr i ve and Check Engi ne
Speed:
L Dri ve t he vehi cl e at 30 mph
150
km/ h) const ant l y f or sev-
eral ml nut es.
2. Check t he engi ne speed
l s t he engi ne speed wi t hi n t he
speci f i cat i on
(see
Page
14' 296
and 14'297)?
14-245
Electrical Troubleshootang ('gg
-
00 Models)
Troubleshooting
Flowchart
-
Start Clutch Control System
Possibl Cause
Faul t v st art cl ut ch cont rol sys-
l em
you
troubl eshoot.
f o page
14 287
.
P1891.
.
Self-diagnosis
E
indicator tight
indicates Code 43.
Check for Another Codel
Check whet her t he
E
i ndi cat or
Perf orm t he Troubl eshoot i ng
Fl owchart t or t he i ndi c. t ed
Codelsl.
l s t he
E
i ndi cat or l i ght i ndi -
Test Stsn Clutch Operation:
from the solenoid harness con
nector.
3. St art t he engi ne, and shi f t t o
E
posi t i on.
moves.
Repl.c the stan clutdt rasemHy.
Check Croeping Sp6d:
2. Reconnect t he 8P connect or t o
t he sol enoi d har ness connec
3. St r t t he engi ne, and shi f t t o
E
posat i on.
4. Chec k whet her t he v ehi c l e
cr eeps, and check t he cr eep
i ng speed.
Does t he vehi cl e move and i s
t he cr eepr ng speed appr ox, 3
mph
( 5
km/ h) ?
14-2A6
a t
a I
From page 14' 286
Check Srall Speed RPM:
Measure t he st al l speed RPM
(see
page 14-298).
l s t he st al l speed over 3, 500 rPm?
Warm Up Engi ne and Becheck
F ilure:
1. War m up t he engi ne t o nor
mal oper at ang t emPer at ur e
(t he radi at or f an comes on).
2. Check whet her t he st an cl ut ch
probl em appears agai n.
Does t he
probl em appear?
The 3v3tem ia OK at thi! iime.
14-2a7
('99
-
00 Models)
-
El
Indicator Light Does Not Come On
LGl {BRN/BLK)
LGl I ARN/ BLK) LG2I BRN/ BLKI
The
D
i ndi cat or l i ght does not
come on whon ths ignhion switch
is tirst turned ON {lll. llt should
come on tor about two sconds.)
Check the Service Check Connec-
tor:
Make sure t he speci al t ool {SCS
Ser vi ce Connect or l i s not con
nect ed t o t he servi ce check con-
nector,
( SCS
Service Connectorl connected
t o t he ser vi ce check connec-
t or ?
Disconnect the spcial tool f]om
the seruice chcck connoclor and
aecheck.
Check the
E
Indicalor Light:
Shi f t t o E
posj t i on.
Check tor loose te.minal fit in the
PCM connect ors, l f nocessary,
and aecheck.
Does t he E
( 25P)
con
ground,
and bet ween t he 822
Fepai r open i n t h. wi r os
btw.en the 820 end 822 termi-
nal s and gr ound
{ G1011, ! nd
repair poor ground
{G1011.
Measure Power Suppl y Ci rcui t
Voltage:
1. Turn t he i gni t l on swi t ch ON
(l l ).
t er mi nal s Bl and 822 and
bet ween t er mi nal s B9 and
820.
Ropair opn or short in tho wire
btween the Bl and/or B!| tarmi-
nds and the PGM-FI main .ohy,
and bet ween t ho PGM-FI mai n
relay and the under-hood fuso/
rlav box.
To page 14-289
14-2AA
From
page 14-289
Msaaure D IND Volt.ge:
2. Connect t ho B
(25Pl connect or
t o t he PCM.
3. Connect a di gi t al mul t i met er
t o t he D14 and 820 or 822 t er-
mt nal s.
i l . Turn t he i gni t i on swi t ch ON
(lll, and make sure that voltage
is available for two seconds
Check f or open i n t he wi r e
bet ween t ha D14 t ermi nal rnd
t he
gauge a33embl Y. l f wi ro i a
OK, chock for . frulty indicator
l i ght bul b or a I aul t y
gaug.
a3r6mbly
printod circuit board.
Check D IND for a Short Circuit:
Check lor continuitY between the
D14 t ermi nal and body
ground.
Rgpair 3hort in the wire b.tween
the D14 tcrminal and tho
gauge
a*somblY.
Check for loose terminsl fh in the
PCM connectors Check tho A/T
goar posi l i on swi t ch. I t neces'
saiy, iubstitute a known_good
PCM rnd rochock.
PCM CONNECTORS
D {16P1
(BRN/BI.X)
D4 IND
(GRN/BLK}
1 2 3 r s
1 / 7
I 2 1 5
9 10 nn
fT /fl
6 l 1 12
o
lzlzz ,rl/zs
1311
- -T---=4'+:l
LG2I BRN/ BLKI \ =/ |
r
l z
3 5
6 i
/ l /
t0 1112
l 0
D' IND
o
IGRN/BLKI
4-289
ElectricalTroubleshooting ('gg
-
00 Models)
-
E
FCM CONNCCTOR D tl6PI
2 3 I 5
6 1 t0 12
tsll
/
rc
I
I
D4 rND
o
(GRN/BLK)
rcM CONNECTOR A I32PI
ATP Dil {YELI
The
E
indicator light is on con-
stantly {not blinkingl whenever
the ignition switch is ON lll|.
Mersure D IND Voltage:
2. Di sconnect t he D
( 16P)
con-
(l l ).
t h e 0 1 4 t e r mi n a l a n d b o d y
ground,
Repair short to power in tho wire
bst ween t he Dl 4 t ermi n. l snd
the gaug
r3sembly.
Measure ATP DVoltage:
2. Connect t he D
( 16Pi
connec-
t or t o t he PCM.
4. Shift to any position other than
E,
5. l Measure t he vol t age bet ween
t h e 4 7 t e r mi n a l a n d b o d y
gr ound.
Test the A/T gear position
switch
{see sect i on 23).
Check f or a shorl l o ground
i n
the wire between tho A7 termi-
nal and A/T ge.r polition
switch.
l, wire is OK, substitute a known-
14-290
Li near Sol enoi ds/l nhi bi tor
Sol enoi d
)
Test
1. Di sconnect the 8P connector from the sol enoi d har-
ness connector.
SOLENOI D HARNESS
CONNECTOR
ATF OIPSTICK
Measure the resi stance of the shi ft control l i near
sol enoi d between the No. 3 and No. 7 termi nal s of
the sol enoi d harness connector.
Measure the resi stance of the PH-PL control l i near
sol enoi d between the No. 2 and No. 6 termi nal s
Measure the resi stance of the start cl utch control
l i near sol enoi d between the No 4 and No. 8 termi -
nats,
STANDARD: 38- 6. 8O
Measur e t he r esi st ance of t he i nhi bi t or sol enoi d
between the No. 5 termi nal and body
ground
STANDARD: 11. 7
-
21. 0 O
Repl ace t he l ower val ve body assembl y i f any
sol enoi d resi stance i s not wi thi n i ts standard.
7. l f al l ot the resi stances are wi thi n the standard, a
cl i cki ng sound shoul d be hear d when connect r ng
the batterv termi nal s to the sol enoi d harness con-
nector termi nal s bel ow:
Shift control linear solsnoid
No.3: Batterv Posi ti ve
termi nal
No. 7: Battery negati ve termi nal
PH-PL control linear solenoid
No.2: Batterv oosi ti ve
termi nal
No. 6: Baftery negati ve termi nal
Start clutch control linear solenoid
No. 4: Battery
Posi ti ve
termi nal
No.8: Battery negati ve termi nal
lnhibitor solsnoid
No,5: Batterv Posi ti ve
termi nal
Body ground: Battery negati ve termrnal
SOLENOID HARNESS CONNECTOR
l f no cl i cki ng sound i s hear d, r epl ace t he l ower
val ve body assembl Y,
NOTE: l f the l ower val ve body assembl y repl ace-
ment i s requi red, see Lower Val ve Body Assembl y
Repl acement
(page 14-302).
14-291
Drive Pulley/Driven Pulley/Secondary
Gear Shaft Speed
Sensors
Repl acement
CAUTION: While replacing the speed sensor, be sure not to allow dust and other foreign parliclos
to enter into the trans-
mission.
' 1.
Di sconnect the connectors for the dri ve pul l ey, the dri ven pul l ey,
and the secondary gear shaft speed sensor.
2. Remove the 6 mm bol t from the transmi ssi on housi ng, and remove the dri ve pul l ey.
the dri ven pul l ey, and the sec-
ondary gear shaft speed sensors.
3. Repl ace the O-ri ngs before rei nstal l i ng the dri ve pul l ey,
the dri ven pul l ey,
and the secondary gear
shaft sped sen-
sors.
6 x 1 . 0 mm
12 N.m
(1.2 kgf.m,8.7 lbf.ft)
6 x 1 . 0 mm
12 N. m (1. 2
kgt . m,
8.7 tbf.ft)
DRIVEN PULLEY SPEED SENSOB
14-292
Start Clutch Control
@
T
Start Clutch Calibration Procedure
NOTE: When the fol l owi ng
parts are repl aced, the TCM
must memori ze the feedback si gnal for the start cl utch
control.
. TCM
. Transmi ssi onassembl y
. Stan cl utch assembl y
. Lower val ve bodv assembl y
. Engi ne assembl y or overhaul
'96
Model Only
CAUTION: Do not uso this
procsdure on'97
- (X)
mod-
els or
you will damage the transmission. On
'97
-
00
models, the TCM or PCM memorizes ths loodback sig'
nals when
you drive the vehicle.
1. Engage t he
par ki ng br ake, and bl ock t he f r ont
wheel s securel y.
2. Connect the SCS servi ce connector to the Servi ce
Check Connect or as shown.
( The
Ser vi ce Check
connector
(2P)
i s l ocated under the dash on the
passenger' s si de of the vehi cl e.)
CONNECTOR
07PAZ
-
lDl01(xt
Start the engi ne, and warm i t up to normal operat-
i ng temperature
(the
radi ator fan comes on twi ce).
Ful l y depress the brake
pedal and accel erator for 20
seconds i n the E]
posi ti on.
rl
,
CONNECTOR I2PI
14-293
7.
Shi ft i nto
E
o| . E
posi ti on. To store the engi ne
negati ve
pressure i n memory. Iet the engi ne i dl e i n
E
or E
posi ti on for one mi nute under the fol l ow-
i ng condi ti ons:
. Wi th the brake
pedal depressed,
. with the
y'\/c
switch oFF.
. Wi th the combi nati on l i ght swi tch OFF.
. Wi th the heater fan swi tch OFF.
. Turn OFF al l other el ectri cal systems
NOTE: Start step 5 within 60 seconds after the radi-
ator fan goes off.
Shi ft i nto
E
posi ti on, and l et the engi ne i dl e for two
mi nutes to store the feedback si gnal i n memory
under the same condi ti ons as i n step 5.
Connect the Honda PGM Tester. Check that the TCM
has compl eted the start cl utch cal i brati on.
NOTE:
. The TCM wi l l not store the feedback si gnal when
the CVT fl ui d temperature i s bel ow 40"C
(104' F)
even i f the engi ne cool ant temperature reaches
the normal operati ng temperature.
. Repeat these
procedures unti l the start cl utch
cal i brati on i s compl eted-
Di sconnect t he SCS ser vi ce connect or f r om t he
Service Check Connector.
'97
-
00 Models
The TCM
('97 -
98 models) and PCM
('99 -
00 models)
memori ze the feedback si gnal when you dri ve the
vehicle as follows:
. After warmi ng up the engi ne
(the
radi ator fan
comes onl .
. Shi ft i nto
E
posi ti on.
. Turn OFF al l el ectri cal systems,
. Dri ve the vehi cl e up to the speed 37 mph
(60
km/h).
. Af t er t he speed r eaches 37 mph
( 60 km/ h) ,
release the accelerator for 5 seconds.
Symptom-to-Component Chart
Hydraulic System
*1:
Some gear noi se i s normal i n the
Ll l
posi ti on
due to pl anetary gear
acti on.
14-294
SYMPTOM Check these i tems on the PBOBABLE CAUSE Li st
Engi ne runs, but vehi cl e does not move i n any posi ti on.
' t , 2, 3, 4, 5, 6, 7, 8, 9,
10, 20, 34, 35, 36, 38, 41
@, [.
p
posi ti ons.
10,11, 12, 20, 41
E
posi ti on.
5,
' to,
11, 12, 17, 1A, 19, 20,39, 41
No shi ft to hi gher rati o, 9, 13, 14. 15, 16, 35, 37, 40
Poor accel erati on. 9, 13,' t4,' t5,16. 20, 35, 37, 38, 40
Fl ares on movi ng. 9,' t0, 20, 2' t, 35, 36, 38, 40, 42
Excessi ve shock when depressi ng and rel easi ng
. ^âl A/ . r ^r Â. 1. I
9, 10, 20, 2'1, 35, 36, 3A, 42
No engi ne br aki ng. 9, 20, 21, 35, 36, 38
Vehi cl e does not accel erate i n
l l l
posi ti on.
9, 17, 18, 19, 20. 35, 36, 38
Vehi cl e moves i n
E
posi ti on.
(Shi ft
cabl e adj ustment i s proper).
10, 22, 23
Late shi ft from
N
posi ti on to
E
posi ti on,
and from
E
posi ti on
to
E
posi ti on.
' 10,
11, 12, 22, 41
Late shi ft from
E
posi ti on to
E
posi ti on.
and from
E
posi ti on
to
N
posi ti on.
1l , ' t 2, 17, 18, 22, 41
Engi ne stops when shi fted to
E
posi ti on from
E
posi ti on.
9, 10,20,35,37,34, 42
Engi ne stops when shi fted to
E
posi ti on from
I
posi ti on.
9, 18, 19,20,25,26,35,37,38, 42
Noi se from transmi ssi on i n
@
posi ti on.rl
5, 17, 18,
' t9,25,26
Excessi ve i dl e vi brati on. 2, 3, 4, 21, 24
Noi se from transmi ssi on i n
@
and
@
posi ti ons.
2, 3, 19, 24, 25, 2A
Hunti ng engi ne speed. 16, 35, 37, 38
Vi brati on i n al l posi ti on.
8, 2a
Shi ft l ever does not operate smoothl y. 11,29, 4' l
Transmi ssi on wi l l not shi ft i nto
l l l
posi ti on
or transmi s-
si on cannot be removed from
E
posi ti on.
11
, 29, 30, 31, 32,33
Vehi cl e does not accel erate to more than a certai n speed. 9, 10, 14, 15, ' t 6, 20, 35, 37
Excessi ve shock on starti ng off. 38, 42
Fl ares on accel erati ng at l ow speed. 20, 21
,38, 42
Excessi ve vi brati on i n
E, E, tr, E
posi ti ons.
20,21,38, 42
Low engi ne speed i n
E. E. tr. E
posi ti ons.
20, 21, 38, 42
St al l speed hi gh. 10, 20, 38
Stal l speed l ow.
9, 20, 27
,37 ,
38
Judder on starti ng off. 20, 43
t .
r l ,
f l ,
PROBABLE CAUSE LIST
Low CVT fl ui d l evel
ATF pump worn. AT gears worn or damaged. Forei gn materi al i n ATF pump.
ATF
pump
chai n/ATF
pump sprocket worn or damaged.
Input shaft worn or damaged.
Sun gear wor n or damaged.
Fi nal dri ven oear worn or damaqed,
Secondary dri ve
gear/secondary dri ven
gear worn or damaged-
5
6
1
8 Fl ywheel /dri ve
pl ate worn or damaged.
Intermedi ate housi ng assembl y worn or damaged.
9
' 10
Forward cl utch defecti ve.
Shi ft cabl e broken/out of adi ustment.
M"nu"t t"uffi
ATF feed
pi pe (pul l ey pressure) worn or damaged.
Vchi cl c speed sensor defecti ve.
TCM or PCM defecti ve.
Reverse brake detective.
1'r
't2
1 3
1 4
1 6
'11
' 18
1 q
Pl anetary gear worn or damaged.
Sta rt cl utch defecti ve.
ATF feed
pi pe (start
cl utch
pressure) worn or damaged
20
t ' t
Cl utch cl earance/reverse brake cl earance i ncorrect.
23 Reverse brake return spri ng/retai ner worn or damaged
24 Needl e beari ng on i nput shaft worn or damaged.
25 Thrust needl e beari ng on carri er worn or damaged.
Thrust washer on carri er worn or damaged.
Enoine outout low.------------------------
Fl vwhcel assembl v defecti ve.
Control l ever worn or damaged.
Park
pawl /park pawl shaft worn or damaged
Detent l ever/park brake rod assembl y worn or damaged
27
29
30
32 Park gear worn or damaged.
Park pawl spri ng worn or damaged.
ATF strai ner/ATF fi l ter cl ogged.
Lower valve body assembly defective.
Lower val ve bodv assembl v defecti ve
(PL
regul ator val ve body assembl y defecti ve)'
33
34
50
Lower val ve bodv assembl y defecti ve
(shi ft
val ve body assembl y defecti ve).
Lower val ve bodv assembl v defecti ve
(start
cl utch control val ve body assembl y defecti ve)'
39 Lower val ve bodv assembl v defecti ve {i nhi bi tor sol enoi d defecti ve}
40 Sol enoi d harness worn or damaged.
Manual val ve body worn or damaged.
PB feedback system defective.
CVT fl ui d deteri orated.
4 1
43
14-295
Road Test
NOTE: Warm up the engi ne to normal operati ng temperature
(the
radi ator fan com6s on).
1. Appl y the
parki ng
brake and bl ock the wheel s. Start the engi ne, then shi ft to the
E
posi ti on whi l e depressi ng the
brake
pedal . Depress the accel erator pedal
and rel ease i t suddenl y. The engi ne shoul d not stal l .
2. Test i n
E
posi ti on
Park the vehi cl e i n a sl ope
(approx.
16' ). appl y the parki ng brake, and shi ft i nto
E
posi ti on. Rel ease the brake; the
vehi cl e shoul d not move.
3. Test-dri ve the vehi cl e on a fl at road i n the
posi ti on
shown i n the tabl e. Check that the engi ne speeds meet the approx-
i mate vehi cl e speeds shown i n the tabl e.
NOTE: Throttle position
sensor voltage represents the throttle opening. To monitor the throttle position
sensor volt-
age, use one of the fol l owi ng methods:
A. Connect the Honda PGM Tester, and
go
to the PGM-FI Data Li st.
A 1
For road testing on
'96
-
98 models, remove the drive/s side kick panel
to expose the TCM; on
'99
-
OO models,
remove the passenger's
side kick panel to expose the PCM
(see page l,[-236),
Set the digital multimeter to check throttle position
sensor voltage between terminals:
.
'96
-
98 modols: TCM 84 {+} and Aa
(-)
or A17
(-1.
.
'99
-
0O models: FCM C27 {+l and 820
(-l
ot 822 l-1.
DIGITAL MULTIMETER
(Commerci.lly
rvrilabl.l
KS- AHM- 32- 003
or oquivalant
BACKPROBE ADAPTER
BRN/ BLK
A {26P1
TPS {BED/BLK}
'96
-
98 Models:
BRN/BLK
14-296
OBD ll SCAN TOOL or
HONOA PGM TESTER
D{16Pt
Ware si de ot f emal e t ermi nal s
o
@
position: Engino Speed rPm
Throttle Opening
Vehiclo Speed
-
25 mph l/()
km/h)
|
37 mph {60
km/h)
|
62 mph {100
km/h}
Throttl e
posi ti on sensor vol tage: 0.75 V 1,250
-
1,650
Throttl e
posi ti on sensor vol tage: 2' 25 V 2,500
-
3,100 2,650
-
3,250
2,700
-
3,300
Throttl e
posi ti on sensor vol tage; 4 5 V
Ful l throttl e
posi ti on
3,950
-
4,550 4,650
-
5,250
5,200
-
5,800
o
$l
position: Engine Speed rPm
Throttle Oponing
Vehicle Spoed
2s mph
(40
km/hl
|
37 mph
(60
km/hl
|
62 mph {r00
km/h}
Throttl e
posi ti on sensor vol tage: 0.75 V 1,800
-
2,200
2,200
-
2,800 3,550
-
4,150
Throttl e Dosi ti on sensor vol tage: 2.25 V 2,950
-
3.550
3,250
-
3,850 4,050
-
4,650
Throftl e
posi ti on sensor vol tage: 4.5 v
Ful l throftl e
posi ti on
4,100
-
4,700
5,100
-
5,700 5,900
-
6,500
o
E
position: Engin Sp6ed rPm
Throttle Oponing
Vehiclo Spoed
25 mph
(40
km/hl
|
37mPh{60km/h)
J
62 mph 1100
km/h}
Throttl e Dosi ti on sensor vol tage: 0.75 V 3,100
-
3,700 3,650
-
4,250 4,450
-
5,050
Throttl e
posi ti on
sensor vol tage; 2.25 V 3,500
-
4,100
4,050
-
4,650 4,800
-
5,400
Throttl e
posi ti on sensor vol tage: 4.5 V
Ful l throttl e
posi ti on
4,100
-
4,700 5,100
-
5.700
5,900
-
6,500
14-297
Stall Speed
Test
CAUTION:
. To prevent transmission damage, do not test stall spd for mole than 10 seconds at a time.
. Do not shift the lsver whils raising the engine speod.
. Be sure lo remove the pressure gauge
before tosting stall speed.
. Stall speed tssts should be used tor diagnostic purposes only,
1. Engage the parki ng brake, and bl ock the tront wheel s.
2. Connect a tachometer to the engi ne, and stan the engi ne.
3. Make sure the A/C swi tch i s OFF.
4. After the engi ne has warmed up to normal operati ng temperature
(the
radi ator fan comes on), shi ft i nto
E
posi ti on.
5. Ful l y depress the brake pedal and accel erator for 6 to 8 seconds, and note engi ne speed,
6. Al l ow two mi nutes for cool i ng, then repeat the test i n
E, E,
and
E
posi ti ons.
Stall Speed BPM in
E
poshion:
Specification: 2,500 rpm
Servic Limit: 2,350
-
2.650 rpm
Stall Speed RPM in
E, E
and
E
positions:
Specitication: 3,000 rpm
Service Limit: 2,800
-
3,100 rpm
TROUBLE PROBABLE CAUSE
@.
p.
[,
and
@
posi ti ons
Low fl ui d l evel or ATF pump output
Clogged ATF strainr
PH regulator valve stuck closed
Sl i ppage of forward cl utch
Faul ty start cl utch
E
posi ti on
.
Slippage of reverse brake
.
Faul ty start cl utch
Stal l rpm l ow i n
E, P, [,
and
@
posi ti ons Engi ne output l ow
Faul ty stan cl utch
Stuck shi ft val ve
14-294
Fl ui d Level
l .
Checki ng/Changi ng
CAUTION: while chscking and changing, be sure not to
allow dust and other toreign particles to entl inlo the
transmission.
Checking
NOTE: Check the fl ui d l evel wi th the engi ne at normal
operati ng temperature
(the
radi ator fan comes on).
' 1.
Par k t he vehi cl e on t he l evel gr ound. Tur n of t t he
engr ne.
2. Remove the di psti ck
(yel l ow
l oop) from the trans-
mi ssi on, and wi pe l t wi th a cl ean cl oth.
NOTE: Check the transmi ssi on fl ui d 50 to 90 sec-
onds after shutti ng off the engi ne.
3. Insert the di Dsti ck i nto the transmi ssi on.
DIPSTICK
(YELLOW
LOOPI
Remove t he di pst i ck and check t he f l ui d l evel .
shoul d be between the uDDer and l ower mark.
DIPSTICK
5. l f the l evel i s bel ow the l ower mark, add fl ui d i nto
t he f i l l er hol e t o br i ng i t t o t he upper mar k. Use
Genui ne Honda CW Fl ui d onl y.
6. Insert the di psti ck i nto the transmi ssi on.
14-299
Changing
1. Bri ng the transmi ssi on up to normal operati ng tem-
perature (the
radi ator fan comes on) by dri vi ng the
vehi cl e. Park the vehi cl e on the l evel ground, and
turn off the engi ne.
2. Bemove the drai n
pl ug, and drai n the CVT fl ui d.
NOTE| l f a cool er fl usher i s to be used, see page 14-
352 and 14-353.
pl ug wi th a new seal i ng washer,
t hen r ef i l l t he t r ansmi ssi on wi t h Genui ne Honda
CVT Fl ui d to the upper mark on the di psti ck.
Automatic Transmission Fluid 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 ovlhaul
Rscommended Automatic Transmission Fluid:
Genuine Honda CVT Fluid-
Use Genui ne Honda CW fl ui d onl y. Usi ng other fl u-
i ds can af f ect t r ansmi ssi on oper at i on and may
reduce transmi ssi on l i Je.
Change Interval:
Normal Condition: 30, 000 miles 148,000
km)
Severe Condition: 30,000 miles
(48,000
km), but it
you drive at high sPeeds in high
t90"F
(32'C)
and abovol temper-
atures, the ttansmi ssi on fl ui d
should be changed evsrY 15,000
miles 124,000 km).
{-]lr
ORAIN PLUG
18 x 1. 5 mm
a9 N.7n
(5.0
kgl.m, 36 lb{'ftl
SEALING WASHER
Repl ace.
Pressure Testing
. While testing, be careful of the rot8ling front wheels.
. M8k6 suro lifts,
iacks,
and satety stands are
placed properly
lsee section 11.
CAUTION:
. Before testing, be sur. the transmb3ion fluid is fillod to the propor
lcvel.
. Warm up the engin to nolmal operating tsmperature bofore testing
. While tsting, be 3ure not to allow dust and other loreign particles
to onler into the transmi$ion.
1. Rai se the front of the vehi cl e, and support i t wi th safety stands
(see
secti on 1).
2. Set the
parki ng
brake. and bl ock both rear wheel s securel y.
3. Allow the front wheels to rotate freely.
4. Warm up the engi ne
(the
radi ator fan comes on), then stop ari d connect a tachometer.
5. Connect the speci al tool to each i nspecti on hol e.
TOROUE: 18 N.m
(1.8
kgt'm, 13 tbtfr)
GAUTION:
. Connect the oil pressuro gauge !!curoly, bs sur6 not to allow dust and other foroign particlG3
to ontar the inspsc-
tion 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.90
MPa,50.0 kS cr*,771psi) or more when molsuring driv.
pulley pressure
and driven pullcy
pre33ure.
NOTE:
. D.ive pulley pressure may be above 3,430 kPa
(3.i8
MPa,35.0 kgf/cmr, 498 psi) whn there is a transmission
prob-
lem that causes the TCM or PCM to go into the fail-safe mode,
. Use a commerci al l y avai l abl e oi l
pressure gauge
that measures 4,900 kPa {4.90 MPa, 5O.O kgf/cmr, 711 psi ) or
more, and the Ay' T Oi l Pressure Hose, 2210 mm
(07MAJ -
PY4011A).
FORWARD CLUTCH PRESSURE
INSPECTION
l Marked wi t h
"F")
REVERSE BRAKE PRESSURE
INSPECTION I.IOLE
A/T OIL PRESSURE
GAUGE
SET W/PANEL
0ta{r6
-
oO2Oi|(Xt
A/T LOW PRESSURE
GAUGE W/PANEL
0706
- qt7o:t{ro
DRIVE PULLEY PRESSURE
INSPECTION HOI.E
(Marked
wi t h
"DR")
A/T PRESSURE HOSE
ADAPTER
07MAJ
-
PYar'120
lil R.qulr.d)
A/T PRESSUBE HOSE
2210 mm
07MAJ
-
PYitollA
la R.quir.d)
(
INSPECNON HOLE
(Marked
wi t h
"SC")
CLUICH PRESSURE
INSPECTION HOLE
(Marked
wi t h
"LUB")
DRIVEN PULLEY PRESSURE
INSPECTION HOLE
l Marked wi t h
"DN")
14- 300
ATF DIPSTICK
1.
Start the engi ne.
Shi ft to the respecti ve shi ft l ever
posi ti ons i n the tabl e, and measure the fol l owi ng
pressures at 1' 500 rpm'
. Forward Cl utch Pressure
. Reverse Brake Pressure
. Dri ve Pul l ey Pressure
. Dri ven Pul l ey Pressure
8. Shi ft to E
posl ti on, and measure the l ubri cati on
pressure at 3,000 rpm'
Di sconnect the speci al tool after
pressure testl ng
Instal l the seal i ng boi ts i n the
j nspecti on
hol es wi th new seal i ng washers, and ti ghten the bol ts to the speci fi ed
toroue.
TOROUE: 18 N.m {1.8 kgf'm, 13 lbf'ft}
CAUTION: Keep all foreign
particles out of the transmission'
9.
10.
PBESSURE
SHIFT LEVER
POSmON
SYMP{OM PROBABLE CAUSE
FLUID PRESSURE
Standard/Ssrvice
Limit
Forwa rd
Cl utch
E
No or l ow for-
ward cl utch
pressure
Forward Cl utch 1. 4
-
1. 75 MPa
(14.3 -
17.8 kgtcm' , 203
-
253
Psi )
Reverse
Brake
ts
No or l ow
reverse brake
pressure
Reverse Brake 1. 4
-
1. 75 MPa
(14.3 -
' 17.8
kg7cm' , 203
-
253
Psi )
Dri ve
Pul l ey
N
No or l ow
dri ve pul l ey
pressure
ATF pump, PH reg-
ul ator val ve, PL
regul ator val ve,
Shi ft val ve
0.2
-
0.7 MPa
(2
-
7.1 kgfl cm' , 28
-
101
Psi )
Dri ve
pul l ey
pressure roo
hi gh
PH regul ator val ve,
PL regul ator val ve,
Shi ft val ve. Shi ft
control l i near
sol enoi d
Dri ven
Pul l ey
No or l ow
dri ven
pul l ey
pressure
ATF
pump, PH reg-
ul ator val ve, Shi ft
val ve, Shi ft control
l i near sol enoi d
1. 5
-
2. 3 MPa
(15.3 -
23.5 kg?cm' , 218
-
334
Psi )
Dri ven
pul l ey
pressure too
h i gh
PH regulator valve
Lubri cati on
No or l ow
l ubri cati on
pressure
ATF pump,
Lubri cati on val ve
Above 0.2 MPa
(Above
2 kgf/cm'. 30
Psi)
14- 301
Lower Valve Body Assembly
Replacement
@
Make sure lifts,
iacks,
and safty stands
are placsd proprly
{sea section 1).
CAUTION: Whi l e removi ng and i nstal l i ng th6 l ower
val ve body asssmbl y, b sul e not to al l ow dust and
other forign particles to entsr inio the transmksion.
1. Rai se the front of the vehi cl e, and support i t wi th
safetv stands
(see
secti on 1).
2. Set the
parki ng brake, and bl ock both rear wheel s
securetv.
4.
6.
Remove t he dr ai n pl ug, and dr ai n t he CVT f l ui d.
Rei nstal l the drai n pl ug wi th a new seal i ng washer
(see page 1+299).
CAUTION: Keop all of other toreign parliclos
out of
the transmission.
Di sconnect the 8P connector from the sol enoi d har-
ness connector.
l i nes. Turn the ends of the ATF cool er hoses up to
prevent ATF from fl owi ng out, then pl ug
the ATF
cool er noses.
CAUTION: Keep all of other foroign particlo3 out of
tho transmission.
Remove the right front mounvbracket.
10 x 1. 25 mm
ila N.m
(,1.5
kgf.m, 33 lbtft)
RIGHT FRONT
MOUNT/BRACKET
ATF COOLER LINE
10 x 1. 25 mm
sil N.m 15.5 kgf.m,
40 rbr.ft)
ATF COOLER HOSE
14-302
14.
7. Remove the ATF cool er outl et l i ne.
8. Remove the ATF cool er l i ne bracket bol t.
9. Remove the ATF pan (fourteen
bolts).
10. Remove the ATF strai ner
(two
bol ts).
1 l . Remove the one bol t securi ng the sol enoi d harness
connector,
12. Remove t he
bol ts).
l ower val ve body assembl y
( ei ght
LINE BOLT
28 N. m
(2. 9
kgt m, 21 l bt f t )
SEALING
Repl ace.
ATF COOI.-ER
OUTLET
OOWEL PIN
O.RING
Fepl ace.
SOLENOIO HARNESS
CONNECTOR
5 x 1 . 0 mm
12 N. m 11. 2 kgt . m,
8.7 tbt.ftl
O.RING
Repl ace. ATF
STNAINER
6 x 1 . 0 mm
12 N.m 11.2 kgt m,
E.7 tbt'ft)
OOWEL NN
BODY ASSEMBLY
6 x 1 . 0 mm
12 N. m 11. 2 kgf . m,
8.7 rbf.ft)
ATF PAN GASKET
Repl ace.
VALVE
ATF COOLER INLET
UNE BRACKET BOLT
8 x 1, 25 mm
26 N.m {2.7 kgf.m,
20 tbf.frl
13.
ATF PAN
x 1. 0 mm
12 N.m 11.2 kgf.m, E.7 lbf.ftl
Instal l the new l ower val ve bodv i n the reverse
ordgr of the removal orocedure.
CAUTION: Koep all ot other fo.oign particles out of
ths transmission.
NOTE:
. Repl ace the fol l owi ng parts:
-
O- r i ngs on t he sol enoi d har ness connect or
and the ATF strai ner
-
ATF pan gasket
-
Seal i ng washers
. l f t he ATF cool er i nl et l i ne br acket i s bent or
warped, put i t back to the ori gi nal posi ti on.
Perform the start cl utch cal i brati on orocedure on
page 14-293.
ATF Filter
l .
!@
Make sure lifts,
lEcks,
snd safoty stands
ara
pl8ced properly
{sae section 1).
CAUTION: While removing and installing the ATF tilier,
be sure not to allow dust or other for6ign
particle3 to
enter thg transmission.
1. Rai se the front of the vehi cl e, and support i t wi th
safety stands
(see
secti on 1).
2. Set the
parki ng brake, and bl ock both rear wheel s
securel y.
3. Remove t he dr ai n
pl ug, and dr ai n t he CVT f l ui d.
Rei nstal l the drai n pl ug wi th a new seal i ng washer
{see
page 14-299).
f l ,
5.
CAUTION: Keep al l torei gn
parti cl es out ot the
transmission.
l i nes. Turn the ends of the ATF cool er hoses up to
prevent ATF from fl owi ng out, then
pl ug the ATF
cool er noses.
CAUTION: Keep al l forei gn
parti cl es out of the
transmission.
Remove the ri ght front mounvbracket.
10 x 1. 25 mm
4{ N.m {i1.5 kgf.m,33 lbf ft)
ATF COOLER LINE
10 x 1. 25 mm
54 N.m {5.5
kgt'm,
40 rbl.ft)
ATF COOLER HOSE
( | ' t
14- 303
6. Remove the ATF cool er outl et l i ne.
7. Remove the ATF cool er l i ne bracket bol t.
8. Remove the ATF
pan (fourteen
bolts)
9. Remove the ATF cool er i nl et l i ne from the ATF
pan
(three
bol ts).
10. Remove the ATF fi l ter, and cl ean i t.
11. Check that the ATF fi l ter i s i n good condi ti on.
12. Repl ace the ATF fi l ter i f i t i s cl ogged.
LINE BOLT
28 N.m
{2.9
kgf.m,21 lbt.ft)
ATF COO1TR OUTIET
6 x 1 . 0 mm
ATF COOLER INI-ET
LINE ERACKET BOLT
8 x 1. 25 mm
26 N.m
(2.7
kgt.m,
20 rbtftt
O.RING
Repl ace.
ATF
ATF FILTER
ATF PAN
6 x 1 . 0 mm
12 N.m
(1.2
kgt'm,8.7 lbl'ft)
l nst al l t he ATF f i l t er i n t he r ever se or der of t he
removal procedure.
GAUTION: Keep al l forei gn parti cl es out ot the
transmission,
NOTE:
Repl ace t he O- r i ngs, t he ATF pan gasket and
seal i ng washers.
l f t he ATF cool er i nl et l i ne br acket i s bent or
warped.
put i t back to the ori gi nal posi ti on
GASKET
Repl ace.
' 13.
12 N m
(1. 2 kgf m,
Transmission
Removal
@
. Mako suro lifts.
iacks,
and satety stands are placod
properly,
and hoi3t bracket are attached to lhe cor-
rect
position
on the engine {see soction 1}.
. Appl y
parki ng
brake and bl ock rar wheel s so tha
vehicle will not roll off stands and fall on
you
while
working undor it.
CAUTION: Use tender covers to avoid damaging painted
surfaces.
Di sconnect the battery negati ve
(-)
termi nal from
the battery, then remove the
posi ti ve (+)termi nal .
Remove the i ntake ai r duct and ai r cl eaner housi ng
1.
assembl y.
3. Remove the starter cabl es and cabl e hol der from
the starter motor.
STARTER CABLE
STARTER MOTOR
14-304
4, Di sconnect the sol enoi d harness connector, the dri ve
pul l ey
speed sensor connector, and the ground
cabl e
termi nal s.
DRIVE PULI.-EY
SPEED SENSOR
CONNECTOR
SOLENOIO HARNESS
CONNECTOR
Remove the cl i p, then separate the shi ft cabl e from
the control l ever,
CAUTION: Take care not to bend the shift cable.
WASHER
WASHER
GROUND CABLE
GROUND CAELE
CONTROL LEVER
S}IIFT CABLE
I
6. Di sconnect the vehi cl e speed sensor
(VSS)
connec-
tor, the dri ven
pul l ey speed sensor connector, and
the secondary
gear shaft speed sensor connector.
SECONDARY GEAR
SHAFT SPEED
ORIVEN PULLEY
SPEED SENSOR
CONNECTOR
SENSOR
7. Remove the transmi ssi on housi ng mounti ng bol ts.
14- 305
8. Remove t he dr ai n
pl ug, and dr ai n t h CVT f l ui d
Reinstall the drain
plug with a new sealing washer.
CAUTION: While installing the drain
plug' bo 3ur.
nol i o al l ow du3l 8nd other torei gn
parti cl es to
enter into th trsnsmi$ion.
DRAIN PLUG
18 x 1. 5 rnm
(,
N.m
(5.0 kgfm, 36 lbf'ft|
9. Remove the spl ash shi el d.
SEALING WASHER
Repl aco.
Transmission
Removal
(cont'd)
10. Remove the cotte. pins and castle nuts, then separate
the bal l
j oi nts
from the l ower arm
(see
secti on 1g).
SELF-LOCKING
\
-=V,
NUT \
Replace.
oitupea rOax
Remove the ri ght damper fork bol t, then separate
ri ght damper fork and damper.
Pry the ri ght and l eft dri veshafts out of the di fferen-
t i al .
Pul l on the i nboard
j oi nt
to remove the ri ght and l eft
dri veshafts (see
secti on 16).
Ti e pl asti c
bags over the dri veshaft ends.
NOTE: Coat al l preci si on
fi ni shed surfaces wi th cl ean
engi ne oi l .
Remove the exhaust pi pe A.
/\<,\
CASTLE I{UT
COTTER
Repl ac6.
' t
1.
' t2.
t J .
14.
q.
SELF.LOCKING
NUT
Repl ace.
SELF.LOCKING NUT
Replace.
14- 306
EXHAUST PIPE A
19.
' 16,
Remove the ri ght front mounvbracket,
ATF COOLER HOSE
17. Remove the ATF cool er hoses at the ATF cool er
l i nes. Turn the ends of the ATF cool er hoses uo to
prevent
CVT fl ui d from fl owi ng out, then pl ug
the
ATF cool er hoses and l i nes,
NOTE: Check for any si gn of l eakage at the hose
j oi nts.
18. Remove the engine stiffeners and the flywheel cover.
Remove the ei ght dri ve pl ate
bol ts one at ti me whi l e
rotati ng the crankshaft pul l ev.
ENGINE STIFFENER
Remove the di stri butor'
Atach a hoi sti ng bracket to the engi ne, then l i ft the
engi ne sl i ght l y.
Pl ace a
i ack
under the transmi ssi on.
and rai se the
transmi ssi on
j ust
enough to take wei ght off of the
mounts, then remove the transmi ssi on
mount bracket
TRANSMISSION
MOUNT
22.
TRANSMISSION
MOUNT
14-307
23. Remove t he t r ansmi ssi on
housi ng mount i ng bol t
and rear engi ne mounti ng bol ts
REAR ENGINE MOUNTING
TRANSMISSION
HOUSING
MOUNTING BOLT
Pul l the transmi ssi on
away from the engi ne unti l i t
cl ears the l 4 mm dowel
pi ns, then l ower i t on the
transmi ssi on
j ack
WASI{ER
lllustrated
Index
Transmission/Lower
Valve Body Assembly
14- 308
O ATF DIPSTICK
O
o-RI NG Repl ace.
.'
SOLENOID HARNESS CONNECTOR
@
LOWER VALVE BODY ASSEMBLY
O
DOWEL PIN
O LINE BOLT
.i ATTf COOUR IruIET LINE B8ACKET BOLT
]
lrr cooua truler LINE ASSEMBLY
O
SEALING WASHER RePIACE'
G,
ATF COOLER OUTLET PIPE
6)
o-RI NG Repl ace.
@
ATF FILTER
f O
o-RI NG Repl ace.
@
ATF PAN
(3
DOWEL PIN
(D
O-RI NG Repl ace.
E)
ATF STRAINER
@
ATF MAGNET
(9
ATF PAN GASKET
RePIACE'
O
ATF MAGNET
t
oRAIN PLUG
@
SEALING wAStlER Replace.
Bolt/Nut No.
Torque Value
Size
Remarks
8F
12J
18D
12 N.m {1.2
kgf m, 8.7 l bf' ft}
26 N.m
(2.7
kgi m,20 l bf' ft)
28 N.m
(2.9
kgf' m,21 l bf' ft)
49 N.m
(5.0
kgf'm, 36 lbf'ft)
6 x 1 . 0 mm
8 x 1. 25 mm
12 x 1. 25 mm
18 x 1. 5 mm
Li ne bol t
Drai n
pl ug
14- 309
lllustrated Index
Transmi ssi on Housi ng/Fl ywheel
Housi ng
8G
I
)
H
14-310
C
O-RI NG Repl ace.
e)
OIL SEAL RePlace
.' FLYWHEEL HOUSING
O
flVWneel
}|OUSttttG GASKET Replace
6 DIFFERENTTALASSEMELY
@
lrr
plsslce
uruE ASSEMBLY
O
O-RING Repl ace
@
DOWEL PIN
)
ATF PUMP ASSEMBLY
(O
DowEL Pl N, 18 x 10 mm
O
O-RING Replace.
o DowEL PlN, 22 x 10 mm
lrr
puup
oRve cxltttt
iA SNAP RING
f3 fxaUst St|t|l, zz t 28 mm Selective
part
Gt
lrr
punp
ontve spaocxer
O PITOT FLANGE
ito nTF
purrap
ontve SPRoGKET HUB
(O
THRUST WASHERS
@
PITOT PIPE BRACKET
O
PITOT LUBRICATION
PIPE
@
PITOT PIPE
t3 OIL SEAL Replace.
Oa SEt AtitC, SO mm Selective Part
o3 lrr
passlce
ltnE HoLOER ASSEMBLY
6)
o-RING Replace.
)
START CLUTCH ATF FEED PIPE
CO
O-RI NG Repl ace.
I
FEEO PIPE FLANGE
@
SNAP RING
O'
CONNECTOR
BRACKET
@
BALL BEARING
6}
SNAP RING
64 COTTER RETAINER
6D CoTTERS,25.5
mm selective Part
6t stlnt cLutcH asseMsLv
@
secoruomv
ontvE GEAR ASSEMBLY
@
o-RINGS Replace
6) DIFFERENTIAL
COVER
rO ttaUSr SntU, zs t 35 mm Selective
part
@
SECONDARY
GEAR SHAFT
@
PARK PAWL SHAFT
@
PARK PAWL SPRING
.1i PARK PAWL
@
TONGUED WASHER REPIACE,
@
PARK ROO HOLDER
@
BALL BEARING
@
o-RI NG Repl ace.
@
@
OIL SEAL Replace.
f t ,
)
6 x 1 . 0 mm
8 x 1. 25 mm
8 x 1. 25 mm
8 x 1. 25 mm
12 N.m
(1.2
kgnm,8.7 l bf' ft)
22 N.m
(2.2
kgf' m. 16l bf' ft)
26 N.m
(2.7
kgf'm, 20 lbf'ft)
29 N.m {3.0
kgf'm, 22 lbift)
14-311
lllustrated Index
Right Side Cover/lntermediate
Housing
88
I
.Fi.
6)
TRANSMISSION
HOUSING GASKET Replace'
@
DOWEL PIN
@)
ATF FEED PIPE
@
o-RING Repl ace.
60 o-RING Replace.
@)
DRIVE PULLEY SPEED SENSOR
@
TRANSMISSION
HANGER
@ SNAP RING
@
txaust Sxtfu, zs t 31 mm selective
part
@
SALL BEARING
6J RING GEAR
6D SNAP RING
@
aevense aRlxe rND PLATE Selective
part
@
REVERSE BRAKE DISC
@
REVERSE BRAKE PLATE
@
DISC SPRING
6} THNUST WASHER
@}
finusr NeeoLr eelnNc
@
THRUST WASHER
@
GARRIER ASSEMBLY
@
THRUST WASHER
@
@}
SUN GEAR
@
SEALING RING REPIACE'
@
NEEDLE BEARING
@
INPUT SHAFT
@
NEEDLE BEARING
@
SEALING RING FEPIACE'
@
SEALING RING {RUBBERI
Replace'
@
ATF FEED PIPE
O
END COVER
O
ATF FEED PIPE
O
DOWEL PIN
@
O-RI NG Repl ace.
G) FEED PIPE FLANGE
@
reeo
ppe
ruruce
puru
O] ROLLER
O IruTENMEDNTE
XOUSING ASSEMBLY
ao corutnoL sxlrr lsseugLv
@
tnlrusmtsstottt
ttoustt'tc
@
SHIFT CABLE BRACKET
c)
BREATHER CAP
@
oll- SEAL Replace.
@
CONTROL LEVER
G LoCK WASHER Replace.
(D
secololaY
ceaR SHAFT SPEED sENsoR
o)
onvel
put-uv
sPEED SENSOR
@
O-RING Repl ace.
(O
SNAP RING
6 rnmrsutsstoru xouslNc oRlvEN PULLEY
SHAFT ROLLER BEARING
@
END COVER GASKET REPIACE'
@ o-RING
Repl ace
6o mnruulL vnLVe
goDY
LINE A
64
MANUAL VALVE BODY LINE B
@
O-RING Replace.
@
DETENT SPRING
O
ATF FEED PIPE
@
O-RING Replace.
@
MANUAL
VALVE EODY
@ DOWEL PIN
@
r'rllull valve
goDY
SEPARAToR
PLATE
6D SNAP RING
@t
roRwlno cturcx ASSEMBLY
@
o-RING Replace
@ SNAP RING
o3 spnlruc aetlrupn/RETURN
SPRING ASSEMBLY
@
nevense ennr eBtottt
@
o-RING Fepl ace.
@
SNAP RING RE'AINER
@ ATF FEED PIPE
. 1,
6 x 1 . 0 mm
6 x 1 . 0 mm
8 x 1. 25 mm
8 x 1. 25 mm
8 x 1. 25 mm
12 N.m
(1.2
kgf' m,8.7 l bf' ft)
14 N.m {1.4
kgf' m, 10 l bi ft)
37 N.m
(3.8
kgf'm, 27 lbf'ft)
26 N.m
(2.7
kgf' m,20 l bf' ft)
29 N.m
(3.0
kgf'm, 22 lbf'ft)
6B
8B
8F
8G
14-313
rl ,
Transmission
Housing/Lower
Valve Body
Assembty
Removal
NOTE:
. Cl ean al l parts
thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r.
.
When removi ng the l ower val ve body, repl ace the fol l owi ngl
-
O-ri ngs
-
ATF pan gasket
-
Seal i ng washers
DOWEL PIN
ATF STRAINER
6 x 1. 0 mm BOLT
ATF PAN GASKET
Repl ace.
ATF COOLER INLET LINE
BRACKET BOLT
8 x 1. 25 mm
ATF COOI..ER INLET LINE
O.RING
Repl ace.
SOLENOIO HARNESS CONNECTOR
6 x' 1. 0 mm BOLT
LOWER VALVE BODY ASSEMBLY
6 x 1. 0 mm BOLT
14-314
6 x 1. 0 mm EOLT
l .
' 1.
2.
5.
6.
7.
Remove the ATF cool er i nl et i i ne bracket bol t'
Remove the ATF cool er outl et l i ne
Remove the ATF
pan
(fourteen bol ts).
Remove the ATF strai ner {two bol ts)
Remove the one bol t securi ng the sol enoi d harness
connector, then
push the connector.
Remove the l ower val ve body
(ei ght
bol ts)
Cl ean the i nl et openi ng of the ATF strai ner thoroughl y
wi th compressed ai r, then check that i t i s i n
good
condi ti on, and the i nl et openi ng i s not cl ogged'
ATF STRAINER
INLET OPENING
Repl ace the ATF strai ner i f i t i s cl ogged or damaged
NOTE: The ATF strai ner can be reused i t i t i s not
cl ogged.
2 c '
c;2
ar\
14-315
Transmission
Housing/Flywheel
Housing
Removal
NOTE:
.
Cl eanal l parts
thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r.
.
. When removi ng the transmi ssi on housi ng/fl ywheel housi ng, repl ace the fol l owi ng:
-
O-ri ngs
-
Secondary dri ve gear
assembl y
-
Sta rt clutch assemblv
-
Fl ywheel housi ng gasket
ATF PASSAGE LINE
HOLDR ASSEMBLY
IX)WEL PIN
OIFFERENTIAL ASSEMBLY
SNAP RING
COTTER RETAINER
COTTERS, 25.5 mm
Selective part
8 x 125 mm BOLT
O.RING
Rsplaco.
VWHEEL HOUSING
EYWIIEEL HOUSING GASKET
Roolace.
START CLUTCH
ASSEMBLY
Repl ace.
ATF PA$gAGE
UNE ASSEMBLY
6 x 1,0 mm BOLT
O.RING
Replace.
ATF PUMP DRIVE CHAIN
SNAP RING
THRUST SHIM,
2 5 x 3 5 mm
Seloctive part
SECONDARY
GEAR SHAFT
SECONDARY DRIVE
GEAR ASSEMBLY
Repl ace.
PARK
PAWL SHAFT
THRUST SHIM, 22 r 28 mm
Seloctive part
GRII{GS
Replac.
6 x 1.0 mm BOIT
ATF PUMP DRIVE
SPROCKET
PfTOT FLANGE
ATF PUMP DRTVE
SPROC|(ET HUB
THRUST WASHERS
PARK PAWL
SPRING
INPUT SHAFT
14-316
DRIVEN PULLEY SHAFT
InANSMISS|O]{
HOUSTNG
)
1 . Remove the ATF
passage l i ne hol der assembl y'
Remove the fl ywheel housi ng
(twenty bol ts)'
Remove the ATF
passage l i ne assembl y
(one bol t)
Remove the ATF
pump drive sprocket
(three
bolts),
then remove the ATF
pump dri ve chaan.
Move the
pitot flange toward its cutout, then remove
the
pitot flange.
PITOT PIPE
Remove the snap ring securing the ATF
pump drlve
sprocket hub. then remove the 22 x 28 mm thrust
shim, the ATF
pump drive sprocket hub and the thrust
wasners,
Remove the di fferenti al
assembl Y.
Remove the park pawl shaft, the
park pawl spri ng,
and the
park
Pawl '
Remove the snap ri ng securi ng the start cl utch, then
remove the cotter retainer and the cotters.
7.
9.
J
14-317
10. Set the speci al tool on the start cl utch' and attach the
oawl of the speci al tool to the
park gear securel y as
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
par-
ticles to enter into the drivon
pull6y shaft'
START CLUTCH
REMOVER
07TAE
-
P4V0120
1 1 . Remove the start cl utch and the secondary dri ve
gear assembl y usi ng the speci al tool , then remove
the secondary
gear shaft.
START CLUTCH
REMOVER
07TAE
-
P4V0120
START CLUTCH
ASSEMBLY
Repl ace.
START CLUTCH
ASSEMBLY
PAWL
End Cover/lntermediate
Housing
Removal
NOTE:
. Cl eanal l parts
i n sol vent or carburetor cl eansr, and drywi th compressed ai r,
.
.
When removing the end cover/intermediate housing, replacs the following parts:
-
O-ri ngs
-
End cover gasket
-
Transmi ssi on housi ng gasket
-
Seal i ng ri ngs
-
Seal i ng washers
8 x 1 .25 mm BOLT
REVERSE BRAKE
{ u
END PLATE
6 x 1.0 mm BOLT
Dtsc
PLATE
DISC SPRING
SNAP
THRUST
END COVER
GASXET
Feplac.
2 5 x 3 1 mm
Selective part
RING GEAR
THRUST WASHER
THRUSI NEEDLE
BEARING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLE
BEARING
SUN GEAR
INPUT SHAFT
SNAP RING
CLUTCH END
PLATE
sNAP /
R|NG I
8 x 1.25 mm BOLT
TRANSMISSTON
HOUSING GASKET
Replace.
DOWEL PIN
INIERMEDIATE
HOUSING ASSEMSLY
FORWARD CLUTCH
ASSEMBLY
SEALING RING
(RUBBER}
Repl ace.
SNAP RING
o.BING
Replace.
SNAP RING
RETAINER
SPRING RETAINER/
RETURN SPRINGS
14-318
HOUSING
l .
1 .
2.
Remove the end cover {three
6 mm bol ts, el even 8
mm bol ts).
Remove the manual val ve body l i nes A and B
3. Remove the snap ri ng securi ng the ri ng gear, then
remove the thrust shi m and the ri ng gear'
4. Remove the snap ri ng securi ng the reverse brake
di scs and
pl ates, then remove the reverse brake end
pl ate. brake di scs, brake
pl ates, and di sc spri ng'
5. Remove the carri er wi th the thrust washers and the
thrust needl e beari ng from the forward cl utch
6. Remove the sun
gear and the i nput shaft as a sub
assembl y
bY
Pul l i ng
i t
The sun
gear i s press fi tted ti ghtl y i nto i nput shaft'
7. Remove the snap ri ng securi ng the forward cl utch,
and remove the snap ri ng securi ng the forward cl utch
end
plate, then remove the forward clutch end
plate'
8. Rei nst al l t he car r i er on t he f or war d cl ut ch, t hen
secure the carri er wi th the snap ri ng on the forward
cl utch end
Pl ate.
9. Remove the forward cl utch and carri er assembl y
together.
' 10.
l nst al l t he speci al t ool t o r emove t he snap r i ng
securi ng the reverse brake return spri ng retai ner as
snown.
REVERSE BBAKE
SPRING COMPRESSOR
07TAE
-
PaV0110
11. Compress the return spri ngs. then remove the snap
ri ng
CAUTI ON:
l f t he spr i ng r et ai ner t ab i s on t he
rsverse braks
pi ston, tho spti ng l etai ner may be
damaged. Be surs the spring letainer tab is not on
the
piston.
SPfiING FETAIiGR
TAB
Remove the speci al tool , then remove the spri ng
retai ner/return
spri ng assembl y.
Remove the seal i ng bol t securi ng the reverse brake
pressure i nsPecti on hol e.
Appl y ai r pressure to the i nspecti on
hol e to remove
the reverse brake
Pi ston
12.
13.
14.
16.
' t7
SPBING REYAINER/
RETURiI SPRIiIG
ASSEMALY
REVERSE BNAXE
PISTON
o-Rrllcs
Replace.
FCVERSE BRAKE
PRESSURE INS?ECTK)N
HOt l
SEALING
WASHER
Replace.
8 x 1. 25 mm
18 N.m 11.8 kgf.m, 13 lbf.ttl
Remove the snap ri ng retai ner from the dri ve pul l ey
shaft.
Remove the manual val ve body
(fi ve bol ts)'
Remove the rol l er and
push the control shaft assem-
bl y toward the outsi de of the transmi ssi on
housi ng,
then remove the i ntermedi ate housi ng
(four
bol ts)'
SPECIAL TOOL
14-319
Manual Val ve Body
Di sassembl y/l nspecti on/Reassembl y
NOTE:
.
Cl ean al l parts
thoroughl y i n sol vent or carburetor cl eaner, and dry wi th compressed ai r. El ow out al l passages.
. Coat al l parts wi th CVT Fl ui d duri ng assembl y.
SPRING SEAT
REVERSE INHIBITOR
VALVE SPRING
REVERSE INHIBITOR
VALVE
MANUAL VALVE
MANUAL VALVE BODY
Inspect for wear, scratches
and sconng,
14-320
Forward
Clutch
l .
lllustrated
Index
CLUTCH
PISTON
CLUTCH
ORUM
\
\
\ _
DISC SPRING
CLUTCH
END PLATE
SNAP RING
14-321
Forward Clutch
Disassembly
1. Remove the snap ri ng, then remove the cl utch end
pl ate, cl utch di scs, and pl ates.
SNAP RING
2. Remove the di sc spri ng.
t
CLUTCH DRUM
OISC SPRING
14-322
SPRING RETAINES
CLUTCH SPRING
COMPRESSOR
BOLT ASSEMBLY
o7R{E-PG402OO
CLUTCH SPRI NG
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE
-
PXa0100 or
07HAE
-
P150100
CAUTION: lf ither ond of the spcial 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 spccial tool is adiusted to hava tull con-
taqt with the sp.ing retainer.
SPECIAL TOOL
Do not Bt here.
4. Compress the return sprl ng.
Remove the snap ri ng. Then remove the speci al tool s,
spri ng retai ner, and return spri ng.
SPBING RETAIT{R
6. Wrap a shop rag around the cl utch drum, and appl y
air
pressure to the fluid
passage to remove the
piston.
Pl ace a fi nger ti p on the other end whi l e appl yi ng ai r
pressure.
OSHA-APPROVED
30
psi
NOzzLE
14-323
Forward Glutch
Reassembly
NOTE:
. Cl ean al l parts thoroughl y i n sol vent or carburetor
cl eaner, and dry them wi th compressed ai r.
. Lubri cate al l parts wi th CW Fl ui d before reassembl y.
1. Inspect the check val ve; i f i t' s l oose, repl ace the
pi s-
ton.
CHECK VALVE
Instal l new O-ri ngs on the cl utch
pi si on.
PISTON
14-324
3. Instal l the pi ston i n the cl utch drum. Appl y pressure
and rotate to ensure proper seatang,
NOTE: Lubri cate the
pi ston
O-ri ng wi th CVT Fl ui d
before i nstal l i ng.
CAUTION: Do not pinch thc O-ring by installing the
pistoo with too much torqo.
CLUTCH DRUM
Instal l the return spri ng and spri ng retai ner, and
posi ti on the snap ri ng on the retai ner.
CLUTCH DRUM
l .
5. l nstal l the sDeci al tool s as shown.
CLUTCI{ SPRING
COMPRESSOR
BOLT ASSEMBLY
oTGAE-PG40200
CAUTION: lf either end of the special tool is set ovel
an area of lhe spring retainr which is unsupported
by the return spring, tho retainsr may be damaged'
Be sure the special lool is adiusted to have full con-
tact with the spring tetainer.
Sgt h6r6.
SPECIAL TOOL
CLUTCH SPRI NG
COMPRESSOR
ATTACHMENT
07LAE
-
PX40100
CLUTCH SPNING
COMPRESSOR
ATTACI{MENT
07LAE
-
Pxil010o o.
07HAE
-
P150100
Do not sat hore.
6. Compress the return sPrl ng'
8. Remove the speci al tool s.
(cont ' d)
SIIAP RING
RETAINER
14-325
Forward Clutch
Reassembly
{cont'd)
9. Instal l the di sc spri ng.
NOTE: Instal l the di sc spri ng i n the di recti on shown.
-\
"arr"" o"u*
1 1 .
Soak the cl utch di scs thoroughl y i n CW Fl ui d for a
mi ni mum of 30 mi nutes.
Starti ng wi th a cl utch pl ate.
al ternatel y i nstal l the
cl utch
pl ates
and di scs. Instal l the cl utch end
pl ate
wi th fl at si de toward the di sc.
NOTE: Before i nstal l i ng the pl ates and di scs, make
sure the i nsi de of the cl utch drum i s free of di rt or
other toreign matter.
CLUTCH END PLATE
Instal l i n thi s di rcti on.
10.
DI SC SPRI NG
14-326
13. Verify that the snap ring end gap is correct.
SNAP RING
CLUTCH
Mi ni mum 7. 9 mm
(0. 31
i ni
14. Measure the cl earance between the cl utch end
pl ate
and toD di sc wi th a di al i ndi cator, Zero th di al i ndi ca-
tor with the clutch end
plate lowered, and lift it up to
the snap ring. The distance that the clutch end
plate
moves is the clearance between the clutch end
plate
and toD di sc.
NOTE: Take measurements i n at l east three pl aces,
Clutch End Plate-to-Top Disc Clesranc:
STANDARD: 0.6
-
0.8 mm 10.024
-
0.031 inl
15. It the clearance is out of tolerance, select a new ciutch
end
pl ate from the fol l owi ng tabl e, then recheck.
NOIE: l f i he thi ckest cl utch end
pl ate i s i nstal l ed but
the cl earance i s sti l l over the standard, repl ace the
cl utch di scs and cl utch
Pl ates.
FORWARD CLUTCH END PLATE
After repl aci ng the cl utch end pl ate, make sure thal
the cl earance i s wi thi n tol erance.
16.
PTATE I{UMBEN
Plate No. Part Number Thi cknss
1 o r 1 5 22561
-
P4V
-
003 3. 5 mm
( 0. 138
i n)
2 o r 1 6 22562
-
P4V
-OO3
3. 6 mm
( 0. 142 i n)
3 o r 1 7 22563- P4V- 0033. 7 mm
( 0. 146
i n)
4 o r 1 8 22564
-
P4V
-
003 3. 8 mm
( 0. 150
i n)
5 o r 1 9 2256s- P4V- 0033. 9 mm
( 0. 154
i n)
6 o t 2 0 22566- P4V- 0034. 0 mm
( 0. 157
i n)
7 ot 21 22567
-P4V -003
4. 1 mm
( 0. 161 i n)
8 o t 2 2 22568- P4V- 003 4. 2 mm
( 0. 165
i n)
9 o t 2 3 22569- P4V- 003 4. 3 mm { 0. 169
i n)
10 or 24 22570-P4V
-OO3
4. 4 mm
( 0. 173
i n)
' l l
or 25 22571, P4V- 0034. 5 mm
( 0. 177
i n)
12 ot 26 22572- P4V- OO34. 6 mm
( 0. 181 i n)
13 ot 27 22573-P4V
-OO3
4. 7 mm { 0. 185
i n)
14-327
Secondary Gear Shaft
25 x 35 mm Thrust Shim Selection
1. Measure the di stance between the fl ywheel housi ng
surface and the bal l beari ng as shown, then note
the measurement
(Measurement
A).
FLYWHEEL
HOUSING
>dt?'
BALL BEARING
EALL
FLYWHEEL
BEARING
HOUSTNG
Instal l the secondary gear shatt i n the transmi ssi on
housi ng.
Measure the di stance between the transmi ssi on
housi ng surface and the thrust washer mounti ng
surface of the secondary gear
shaft as shown, then
note the measurement
(Measurement
B).
O
Measuri ng Di st ance A
BALL
14-328
Cal cul ate 25 x 35 mm thrust shi m thi ckness bv fol -
l owi ng formul a.
FORMULA;
25 x 35 mm Thrust Shim Thicknoss
= Measurement A
-
Measurement B + Fl ywheel
Housing Gasket Thickness: 0.5 mm {0.020 in}
Example:
Measurement A: 32.7 mm
(1.287
in)
Moasurem.nt B: 30.! mm {1.185 in}
25 x 35 mm Thrust Shim Thickness
= 32.7 mm
(1.287
i n)
-
30.1 mm
(1.185
i n)
+ 0.5 mm
{0.020
in)
= 3.1 mm
(0.122
i nl
Select 25 x 35 mm Thrust Shim D.
Sel ect the 25 x 35 mm thrust shi m from the fol l ow-
i ng the tabl e.
THRUST SHIM, 25 x 35 mm
No. Part Number Thickne3s
90551
-
P4V
-
000 2. 8 mm
( 0. 110
i n)
B 90552- P4V- 0002. 9 mm
( 0. 114
i n)
c 90553- P4V- 0003. 0 mm
( 0. 118
i n)
D 90554- P4V- 000 3. 1 mm
( 0. 122
i n)
E 90555- P4V- 000 3. 2 mm
( 0. 126
i n)
90556- P4V- 000 3.3 mm
(0.130
i n)
G 90557- P4V- 000 3. 4 mm
( 0. 134
i n)
H 90558- P4V- 000 3. 5 mm
( 0. 138
i n)
90559- P4V- 0003. 6 mm
{ 0. 142 i n)
90560- P4V- 000 3. 7 mm
( 0. 146
i n)
K 90561
-
P4V
-
000 3.8 mm
(0.' 150
i n)
Differential
l .
lllustrated Index
BOLTS
10 x 1. 0 mm
98 N.m 110.0
kgf.m,
72 tbl.ltl
Left-hand threads
FII{AL ORIVEN GEAR
BAIT EEANIM;
SET RING. 8() tnm
Soloctivo pan
Bacl(lash Inspection
1. Place the differential assembly on V-blocks, and install
both axles.
2. Check the backl ash of both pi ni on gears.
Standard
(Newl:
0.05
-
0.15 mm 10.002
-
0.006 in)
PINION GEARS
lf the backlash is out of tolerance, replace the differ-
enti al carri er.
14-329
Differential
Bearing Replacement
NOTE: Check the beari ngs for wear and rough rotati on.
l f the beari ngs are OK, removal i s not necessary.
' 1.
Remove the bal l beari ngs usi ng a beari ng pul l er.
Instal l the new bal l beari ngs
wi th a press as shown.
BAI-L BEARING
usi ng t he speci al t ool
ORIVER 10 mm l.O.
07746
-
0030100
14- 330
BALL BEARING
Differential Carrier Replacement
1. Remove the fi nal dri ven gear from the di fferenti al
carner.
NOTE: The fi nal dri ven gear bol ts have l eft-hand
threads.
BOLTS
10 x 1, 0 mm
98 N'm
110,0 kgf.m,
72 tbl.ttl
Left-hand threads
DIFFERENTIAL
CARRIER
Instal l the fi nal dri ven gear wi th i ts chamfered si de
on the i nner bore faci ng the di fferenti al carri er.
Tighten the bolts to the specified torque in a crisscross
Paftern.
TOROUE: 98 N.m
(10.0
kgt.m, 72 lbf.ft)
l .
Oi l Seal Removal
Remove the di fferenti al assembl y.
Remove the oi l seal from the transmi ssi on housi ng.
1 .
2.
TRANSMISSON
HOUSING
OIL SEAL
Rplaca.
3. Remove the oi l seal from the fl ywheel housi ng.
Oi l Seal Instal l ati on/Si de
Cl earance
1. l nstal l a 2.50 mm
(0.098
i n) thi ck 80 mm wi de set
r i ng i n t he t r ansmi ssi on housi ng.
NOTE: Do not i nstal l the oi l seal
yet.
TRANSMISSION
HOUStl{G
l nstal l the di fferenti al assembl y i nto the transmrs-
si on housi ng usi ng the speci al tool as shown
DIFFEREI{NAL
ASSEMBLY
(cont ' d)
14-331
Differential
Oil Seal Installation/Side Clearance
(cont'dl
3. Instal l the fl ywheel housi ng, and ti ghten the bol ts.
DOWEL PIN
1 .25 mm
N m
(3.0
kgt m,22 lbf.ttl
8 x
29
u i
g E
14-332
4. Measure the cl ea.ance between the 80 mm set ri ng
and outer race of the bal l beari ng i n the transmi s-
si on housi ng.
STANDARD: 0
-
0.15 mm
(0 -
0.006 i n)
l f the cl earance i s more than the standard, sel ect a
new set ri ng from the tabl e, and i nstal l i t.
SET RING, 80 mm
NOTE: l f the cl earance measured i n steD 4 i s stan-
dard, it is not necessary to perform
steps 7 and 8.
Remove the fl ywheel housi ng.
Repl ace ttl e 2.50 mm
(0.098
i n) set ri ng, 80 mm wi th
the one ot the correct thi ckness sel ected i n steD 5.
6.
7.
Part Number Thickness
904' r 4- 689- 000
90415- 689- 000
90416- 689- 000
90417- 689- 000
90418- 689- 000
90419- PH8- 000
2.50 mm
(0.098
i n)
2. 60 mm
( 0. 102
i n)
2. 70 mm
( 0. 106
i n)
2. 80 mm
( 0. 110
i n)
2. 90 mm ( 0. 114
i n)
3. 00 mm
( 0. 118
i n)
Fl ywheel Housi ng
Input Shaft Oil Seal
l .
8. Instal l the oi l seal i n the transmi ssi on housi ng usi ng
the sDeci al tool s as shown.
DRIVER
07749
-
0010d)0
9. Instal l the oi l seal i n the fl ywheel housi ng usi ng the
soeci al tool s as shown.
PILOT,
2 6 x 3 0 mm
oTJAD
-
PH80200
DRIVER
ATIACHMENT, 58 x 72 rnin
0?947
-
d'40201
Replacement
1. Remove the i nput shaft oi l seal from the fl ywheel
housi ng.
OIL SEAL
Instal i the oi l seal i n the fl ywheel housi ng usi ng the
soeci al tool s as shown.
FLYWHEEL
lmtalled depth:
2. 5- 3. 5 mm
ro"nri':,ilii.rl
t @
14- 333
Transmi ssi on Housi ng Beari ngs
Driven Pulley Shaft Bearing Replacement
1. To remove the dri ven pul l ey
shaft b' eari ng trom the
t r ansmi ssi on housi ng, expand t he snap r i ng wi t h
snap r i ng pl i er s, t hen push t he bear i ng out usi ng
the speci al tool s and a press as shown.
NOTE: Do not remove the snap ri ng unl ess i t' s nec-
essary to cl ean the groove i n the housi ng.
07749
-
001(xDo
ATTACHMENT,
7 2 x 7 5 mm
07746
- (x'l05U)
077i()
-
001(xrco
14-334
SNAP RING
Expand the snap ri ng wi th snap ri ng pl i ers,
i nsert
the new beari ng part-way i nto the housi ng usi ng
the speci al tool s and a press as shown. Instal l the
beari ng wi th the groove faci ng outsi de the housi ng.
NOTE: Coat al l pans wi t h CW Fl ui d.
Rel ease t he pl i er s,
t hen usi ng t he speci al t ool s,
push
the beari ng down i nto the housi ng unti l the
snap ri ng snaps i n pl ace.
BEARING
ATTACHMENT,
7 2 x 7 5 mm
07746
-
OO1 0600
GROOVE
SNAP RING
After i nstal l i ng the beari ng veri fy the fol l owi ng:
o The snap ri ng i s seated i n the beari ng and hous-
ing grooves.
. The ri ng end gap i s correct.
END GAP| 0
-9
mm
l0
-
0.35 inl
Flywheel Housing
Beari ng
Repl acement
1. Remove the secondary
gear shaft beari ng usi ng the
3/ 8"
-
16 SLI DE HAMMER
{Comm6rciallY
availablel
SECONDARY GEAR
ADJUSTABI.T BEARING SHAFT BEARING
PULLER.25
-
40 mm
07736
-
A01000A
Instal l the new secondary
gear shaft beari ng unti l i t
bottoms i n the transmi ssi on housi ng. usi ng the spe-
ci al tool s as shown.
Replacement
1. Remove the secondary
gear shaft beari ng usi ng the
soeci al tool as shown.
3/8"
-
16 SLIDE HAMMER
lCommorcially aY.ilabl6l
2. l nstal l the new secondary
gear shaft beari ng unti l i t
bottoms i n the fl ywheel housi ng, usi ng the speci al
tool s as shown.
DRIVER
07749
- (x)10000
ATTACHMENT.
62xGgmm
07745
-
0010500
14- 335
Ri ng Gear Beari ng Control Shaft Assembly
Replacement
1. Remove t he ri ng gear beari ng.
RING GEAR
Instal l the new ri ng gear beari ng unti l i t bottoms i n
the ri ng gear. usi ng the speci al tool s as shown,
DRIVER
07?{9
-
001(xxxt
RING
14- 336
1. Remove the bol t and l ock washer.
CONTROL SHAFT
ASSEMBLY
6 r 1 . 0 mm
14 N.ft
11.4 kg{.m,
10 rbf.ftl
TRANSMISSION
CONTROL
LEVER
LOCK WASHER
Repl ace.
2. Remove the control lever from the control shaft.
3. Remove the control shaft assembly.
4. Instal l the control shaft assembl y i n the transmi ssi on
housi ng.
Instal l the control l ever to the control shaft.
Instal l and ti ghten the bol t wi th a new l ock washer.
Transmi ssi on
Reassembl y
CAUTION: While reassembling. be sure not to sllow dust and othor foreign particles to enter into the transmission.
NOTE:
. Coat al l parts wi th CVT Fl ui d.
. Repl ace the fol l owi ng parts:
-
O-ri ngs
-
Seal i ng r i ngs
-
Seal i ng washers
-
Gaskets
-
Start cl utch assembl y and secondary dri ve gear
assembl y
8 x 1. 25 mm
37 N.m
{3.8 kgf.m,27 lbtftl
MANUAL VALVE
6 x 1 . 0 mm
12 N m 11.2 kgf.m,8.7 lbl.ft)
LINES
REVERSE BRAKE
END PLATE
Dtsc
PLATE
DISC SPRING
THRUST WASHER
CARRIER ASSEMBLY
THRUST WASHER
THRUST NEEDLE
BEARING
END COVEB
DOWEL
PIN
END COVER GASKET
6 x 1 . 0 mm
12 N. m 11. 2 kgt m, 8. 7 l bt f t )
THRUST SHI M, 25 x 31 mm
Selective part
RING GEAR
THRUST WASHER
THRUST
BEARING
8 x 1. 25 mm
29 N.m 13.0 kgl m, 22 lbtftl
INTERMEDIATE
HOUSING ASSEMBLY
ROLI.IR
SNAP
RING
e B
H^ c
MANUAL
VALVE
BOOY
SUN GEAR
INPUT SHAFT
(RUBEERI
ATF FEED PIPE
O-RINGS TRANSMISSION
HOUSING GASKET
SNAP RING
FORWARD CLUTCH
SNAP RING
SHAFT
ASSEMALY
DOWEL PtN
SPRING RETAINER/
RETURN SPRING
ASSEMBLY
REVERSE BRAKE PISTON
O.RINGS
SNAP RING
ATF FEED PIPES
14- 338
SNAP RING RETAINER
1.
7.
l nstal l the ATF feed
pi pe i n the transmi ssi on hous-
i ng, and i nstal l the three ATF feed
pi pes wi th new
O- r i ngs i n t he t r ansmi ssi on
housi ng,
Install the two dowel
pins and new transmission
hous-
i ng
gasket on the transmi ssi on housi ng.
Push the control shaft assembl y toward the outsi de
of the transmi ssi on
housi ng, then i nstal l the i nter-
medi ate housi ng assembl y
(four
bol ts).
l nstal l the manual val ve body separator
pl ate and
t he t wo dowel
pi ns on t he i nt er medi at e housi ng,
then i nstal l the rnanual val ve body wi th the detent
spri ng
(fi ve
bol ts).
Put the control shaft assembl y back, then i nstal l the
rol l er i n the i ntermedi ate
housi ng.
l nstal l the reverse brake
pi ston i n the i ntermedi ate
housi ng.
Instal l the spri ng retai ner/return
spri ng assembl y on
the reverse brake
Pi ston.
NOTE: Instal l the return spri ngs on the spri ng
gui des
of the reverse brake
piston securely
tnstal l the speci al tool to compress the return spri ng
as shown.
REVERSE BRAKE
SPRING COMPRESSOR
07TAE
-
P4V0110
6.
L
1
CAUTION:
lf the spring retainer tab is on the reverse
brakc
piston, the spring rstainer may be damaged'
Be sure the spring retainer tab is not on the
piston'
rp
SPECI ALTOOL REVERSEBRAKE
-^
14- 339
10.
9.
14.
Compress the return spri ngs, then i nstal l the snap
ri ng i n the i ntermedi ate housi ng above the spri ng
retai ner.
Veri fy that the snap ri ng end
gap i s correct'
Mi n i
/,,-
'-t,,,,.
// \\
i/
',r
' 1 ,
.r' //
'/.
.-J?
RI NG SNAP
mum 15 mm 10. 59 i n)
Soak t he r ever se br ake di scs t hor oughl y
i n CVT
Fl ui d f or mi ni mum 30 mi nut es.
Instal l the di sc spri ng on the reverse brake
pi ston'
St ar t i ng wi t h a r ever se br ake
pl at e, al t er nat el y
i nstal l the reverse brake
pl ates and di scs l nstal l the
reverse brake end
pl ate, and the snap ri ng'
Measure the cl earance between the reverse brake
end
pl ate and the top di sc wi th a di al i ndi cator' Zero
the di al i ndi cator wi th a reverse brake end
pl ate
l owered, and l i ft i t up to the snap ri ng The di stance
that the reverse brake and
pl ate moves i s the cl ear-
ance between the reverse end
pl ate, and the top
di sc.
i n at l east three
pl aces'
and use the average as the actual cl earance'
STANDARD:
0.45
-
0.75 mm
(0.018
-
0'030 in)
{cont' d)
1 1 .
12.
13.
Transmi ssi on
16.
Reassembly
(cont'dl
21.
17.
lf the clearance is not within the standard, remove the
reverse brake end pl ate
and measure i ts thi ckness.
Sel ect and i nstal l a new reverse brake end Dl ate.
then recheck.
NOTE: l f t he t hi ckest r ever se br ake end ol at e i s
i nstal l ed, but the cl earance i s sti l l over the standard,
repl ace the reverse brake di scs and pl ates.
REVERSE BRAKE END PLATE
After repl aci ng the reverse brake end pl ate, make
sure that the cl earance i s wi thi n the standard.
Remove t he snap r i ng, r ever se br ake end pl at e,
di scs, pl ates.
and di sc spri ng.
I nst al l t he snap r i ng r et ai ner on t he dr i ve
pul l ey
shaft.
Wrap the dri ve pul l ey
shaft spl i nes wi th tape to
pre-
vent damage t o t he O- r i ngs, t hen i nst al l new O-
n ngs.
Instal l the forward cl utch assembl y on the dri ve pul -
l ey shaft, then i nstal l the snap ri ng.
SITAP
O-RINGS
18.
19.
20.
SI{AP RIM;
BETA EB
DRIVE PUI.IEY
SHAFT
Plat6 No. Part Number
Thickness
1 22551
-
P4V
-
003 3. 6 mm
( 0. 142
i n)
22552-P4V-003
3. 8 mm
( 0. 150
i n)
22553- P4V- 0034. 0 mm ( 0. 157
i n)
4 22554- P4V- 003 4. 2 mm
( 0. 165
i n)
5 22555- P4V- 003 4. 4 mm
( 0. 173
i n)
6 22556- P4V- 003
4. 6 mm
( 0. 181
i n)
7 22557
-P4V -OO3
4. 8 mm
( 0. 189
i n)
8 22558- P4V- 003
5.0 mm
(0.200
i n)
14-340
25. Instal l the carri er assembl y on the forward cl utch.
22. Veri ty that the outsi de di ameter ol the snap ri ng i s
correct.
SI{AP RIiIG
Instal l the i nput shaft and the sun gear
as a sub
assemDry.
I nst al l t he t h. ust needl e bear i ng and t he t hr ust
washer on the sun gear.
CARRIER ASSEMBLY
THFUST I'IEEDI!
EEARIT{G
Msxi mum 41.4 mm 11.63 i n)
IHruST
26. Instal l the thrust washer, the thrust needl e beari ng'
and the thrust washer on the carri er assembl y'
SNAP
RING
THRUST SHIM,
2 5 x 3 1 mm
Sel ect i ve Pan
21.
24.
RING GEAR
THRUST NEEDLE THRUST WASHERS
EEARING
CARRIER
ASSEMBLY
l nstal l the ri ng
gear and the 25 x 31 mm thrust shi m,
then i nstal l the snaP rrng.
Veri fy that the outsi de di ameter of the snap ri ng i s
correct,
Maxi mum 30. 7 mm
(1. 21 i n)
SNAP RING
Measure the cl earance between the 25 x 31 mm
thrust shi m and the snaP rl ng.
STANDARD:
O.O5
-
0.11 mm
(0.0020
-
0.00'8 in)
i n at l east three
pl aces'
and use the average as the actual cl earance
29.
,**r#*,".
'-
t
)
RING GEAR
14-341
30.
31.
l f the cl earance i s out of tol erance, remove the 25 x
31 mm thrust shi m and measure i ts thi ckness'
Sel ect and i nstal l a new 25 x 31 mm thrust shi m.
then recheck.
snap nng.
RING
After repl aci ng the 25 x 31 mm thrust shi m, make
sure that the cl earance i s wi thi n tol erance and the
snap ring outside diameter
is correct'
Instal l the di sc spri ng i n the di recti on shown'
St ar t i ng wi t h a r ever se br ake
pl at e, al t er nat el y
i nstal l the reverse brake
pl ates and di scs l nstal l
sel ected reverse brake end
pl ate, then i nstal l the
32.
33.
34.
REVERSE
END PLATE
BRAKE
Dtscs
SPRING
l nst al l i n t hi s di r ect i on.
(cont' d)
REVERSE
PI-ATES
No. Part Numb.l
Thickne*3
90451
-
P4V
-
000 1. 05 mm
(0. 041 i n)
B 90452- P4V- 000
1. 12 mm
(0. 044 i n)
c 90453-P4V-000
' 1. 19
mm
(0. 047 i n)
D 90454
-
P4V
-
000
' l . 26
mm
(0. 050 i n)
90455- P4V- 000
1. 33 mm
(0. 052 i n)
F 90456-P4V-000
1. 40 mm
(0. 055 i n)
904s7-P4V-000
1. 47 mm
(0. 058 i n)
90458-P4V-000
1. 54 mm
(0. 06' l i n)
90459-P4V-000
' 1. 61
mm
(0. 063 i n)
J 90460-P4V-000
1. 68 mm
(0. 066 i nl
K 90461- P4V- 000
1. 75 mm
(0. 069 i n)
90462-P4V-000
1. 82 mm
(0. 072 i n)
M 904a0-P4V-000
1. 085 mm
(0. 0427 i n)
N 90481- P4V- 000
1.155 mm
(0.0454 in)
o 901a2-P4V-000
1. 225 mm
(0. 0482 i n)
90483-P4V-000
1. 295 mm
(0. 0510 i n)
o 90484- P4V- 000
1.365 mm
(0.0537 in)
R 904a5-P4V-000
1.435 mm
(0.0565 in)
90486-P4V-000
1.5O5 mm
(0,0593 in)
T 90487-P4V-000
1.575 mm
(0.0620 in)
90488-P4V-00{)
1.645 mm {0.0648
in)
90489-P4V-000
1. 715 mm
(0. 0675 i n)
90490-P4V-000
1.785 mm
(0.0703 in)
Transmission
Reassembly
(cont'd)
35. Veri fy that the snap ri ng end gap
i s correct.
Mi ni mum 18 mm
( 0. 71
i n)
,/\,
."or**ol!/'
Instal l the manual val ve body l i nes A and B wkh
new O-ri ngs on the manual val ve body and the i nter-
medi ate housi ng.
6 x 1 . 0 mm
12 N..n (1.2
kgt m,
8.7 rbtft)
8 x 1. 25 mm
37 N.m 13.8 kgf.m,27 lbf.ftl
fl
g
END
COVER
37.
END
COVER GASKET
DOWEL PINS
O-RINGS
MANUAL VALVE
BODY LINE A
uaNYuAL VALVE
Install the two dowel pins and new end cover gas_
ket on the intermediate housing, then install new O_
rings on the ATF feed pipes.
Instal l the end cover
(three
6 mm bol ts, el even
g
mm bol ts).
NOTE: Instal l the ni ne 8 mm bol ts i n the end cover
( t wo
8 mm bol t s r emai n i n t he end cover ) t hen
ti ghten the el even 8 mm bol ts.
14-342
39. Instal l the park pawl ,
spri ng, and shaft on the trans-
mi ssi on housi ng, then move the control l ever to anv
gear
other than
E
posi ti on.
THBUST SHIM,
25x 35mm
SNAP RING
COTTER
RETAINER
COTTERS,
25. 5 mm
Sel ect i ve pan
START CI.UTCH
ASSEMBLY
O.RINGS
PARK
PAWL SPRING
PARK PAWL
,10,
Install the secondary gear
shaft with setected 25 x
35 mm thrust shim
(see page
,14-328).
41. Wrap the dri ven pul l ey
shaft spl i nes wi th taDe to
prevent
damage to the O-rings, then install new O_
ri ngs.
42, Assemble ths secondary drive goar
assembly in the
start clutch assembly, then installthem on the driven
pulley
shaft,
43. Pul l the handl e of the speci al tool up, then i nstal l
the tip of it into the driven pulley
shaft hole, and set
the special tool 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.
I
c,rr r,unar".
SECONDARY
GEAR SHAFT
START CLUTCH
INSTALLER
07TAE
-
P4V0r30
SECONDARY
ORIVE GEAF
ASSEMBLY
44. Push the handl e of the speci al tool , then ti ghten the
nut to seal the secondary dri ve
gear assembl y on
the dri ven
pul l eY shaft securel Y.
STAAT CLUTCH Ii'ISTALIIR
07TAE
-
PaV0130
OF
46.
SHAFT HA'{DI,-E
Pul l the handl e of the speci al tool up, and remove
the speci al tool .
lnstallthe cotters, then measure the clearance Delween
the cotters and the start cl utch
gui de
STANDARD: 0
-
0.13 mm
(0 -
0.005 i nl
and use the average as the actual cl earance
GAUGE
lil
(il
COTTERS, 25.5 mm
START
1
GAUGC
START CLUTCH
14-343
47.
48.
l f the cl earance i s not wi thi n the standard, remove
the cotters and measure thei r thi ckness
Sel ect and i nstal l new cotters, then recheck.
COTTERS, 25.5 mm
After repl aci ng the 25.5 mm cotters, make sure that
the cl earance i s the standard
l nstal l the cotter retai ner and the snap rl ng
Veri fy that the outsi de di ameter of the snap ri ng i s
correct.
Mi ni mum 33. 9 mm
(1. 33 i n)
SNAP RII{G
l nst al l t he t hr ust washer s. t he ATF
pump dr r ve
sprocket hub and the 22 x 28 mm thrust shi m on the
i nDUt shaft, then i nstal l the snap ri ng.
49.
50.
52.
THRUST WASXERS
INPUT SHAFT
(cont ' d)
No. Part Number
Thickness
90429- P4V- 000
2.9mm
( 0. 114
i n)
B 90430- P4V- 000
3.0mm
( 0. 118 i n)
c 90431
- P4V- 000
3. 1 mm
( 0. 122 l n)
D 90432- P4V- 000
3. 2 mm
( 0. 126
i n)
SNAPRI NG\
ATF PUMP DRIVE
SPROCKET HUB
THFUST SHIM, 22 x 2a mm
Selective
pan
Transmission
Reassembly
(cont'd)
53. Veri fy that the outsi de di ameter of the snap ri ng i s
correct.
Maxi mum 26. 3 mm
( 1. 04
i n)
54.
SNAP RING
Measure the cl earance between the 22 x 28 mm
thrust shi m and the snap ri ng.
STANDARD: 0.37
-
0.65 mm
(0.015 -
0.026 inl
l f the cl earance i s out of tol erance, remove the 22 x
28 mm thrust shi m and measure i ts thi ckness.
Sel ect and i nstal l a new 22 x 28 mm thrust shi m,
then recheck.
55.
co.
No. Part Numbr Thicknsss
c 90573- P4V- 0001. 15 mm
( 0. 0, { 5
i n)
D 90574- P4V- 000 1.40 mm {0.055 i n)
E 90575- P4V- 000 1.65 mm
(0.065
i n)
F 90576- P4V- 000 1.90 mm
(0.075
i n)
90577- P4V- 000 2. 15 mm
( 0. 085
i n)
90578- P4V- 000 2.40 mm
(0.095
i n)
14-344
INPUT SXAFT
After repl aci ng the 22 x 28 mm thrust shi m. make
sure that the cl earance i s wi thi n tol erance and the
snap ri ng outsi de di ameter i s correcr.
Instal l the pi tot fl ange usi ng i ts cutout as shown to
cl ear the pi tot pi pes.
Instal l the ATF pump
dri ve sprocket. and
put
the
ATF pump
dri ve chai n on the ATF
pump
dri ve and
dri ven sprockets, then i nstal l 8nd ti ghten the bol ts
(three
bolts).
TF PUMP DRIVE CHAIN
58.
59.
6 x 1 . 0 mm
12 N.m
11.2 kg{.m,8.7 lbf.ftl
ATF PUMP ORIVE
SPROCKET
PITOT FLANGE
ATF PUMP
l .
60. Instal l the di tferenti al assembl y
61. Instal l the ATF
passage l i ne assembl y wi th new O-ri ngs
(one
bol tl '
62. Instal l thethreedowel
pi nsand new fl ywheel housi ng
gasket on the transmi ssi on housi ng'
63. Instal l the fl ywheel housi ng and connector bracket
(twenty
bol ts)'
passage l i ne hol der assembl y
(two
bol ts)'
8 x 1. 25 mm
29 N.m t3.o kg['m, 22 lbf'ttl
I
ATF PASSAGE L|NE
I
"o.o.'o{
d
\n
rm
\A
o-nrnc--.-..ff
FLYWHEEL HOUSING
GASKET
6 x 1 . 0 mm
12 N.m {1.2
ksf'm,
8.7 tbf.ftl
/
g
u g
s l l
FLYWHEEL HOUSING
CONNECTOR BRACKET
DOWEL PIN
DIFFERENNAL ASSEMBLY
DOWEL PIN
ATF PASSAGE LINE
ASSEMALY
6 x 1 . 0 mm
12 N.m 11.2
kgd'm,
8.7 tbr.tr)
O.RING
DOWEL PIN
TRANSMISSION
ItousrNG
ATF PASSAGE
LINE ASSEMBLY
PASSAGE LINE
GUI OE
(cont ' d)
14-345
Transmi ssi on
Reassembly
(cont'dl
65 l nstal l the sol enoi d harness connector wi th a new O-ri ng
(one
bol t), then i nstal l the l ower val ve body assembl y wi th
three dowel pi ns (ei ght
bol ts).
66. Instal l the ATF strai ner wi th a new O-ri ng
(two
bol ts).
67. l f necessary, assembl e the ATF pan,
ATF fi l ter, and the ATF cool er i nl et l i ne
(see page
14_303).
pan
wi th the two dowel pi nsand
a new ATF pan gasket (fourteen
bol ts).
69. Instal l the ATF cool er i nl et l i ne bracket bol t.
70. Instal l the ATF cool er outl et l i ne wi th the l i ne bol t and new seal i ng washers.
6 x 1 . 0 mm
12 N. m 11. 2 kgf . m,
8.7 rbtft)
DOWEL PINS
ATF STRAINER
DOWEL PINS
ATF PAN,/ATF FILTER/
ATF COOLER INLET
LINE ASSEMELY
@
@
C4
CONNECTOE
6 x 1 . 0 mm
12 N. m {1. 2 kgf . m,
8.7 tbtftl
6 x 1 . 0 mm
1 2 Nm1 1 . 2 k g l . m,
8.? tbf.ft)
LOWER VALVE BODY
ASSEMBLY
6 x 1 . 0 mm
12 N. m 11. 2 kgf . m,
8.7 tbt.ft)
ATF COOI.ER INI.IT
LINE BRACKET BOLT
I x 1. 25 mm
26 N.m
(2.7
kgt.m, 20 lbf.ft)
ATF COOLER OUTI.IT LINE
14-346
Fl ywheel /Dri ve
Pl ate
DRIVE PLATE
/,1
vl
a
o0
a9
WASHER
FLYWHEEL
l nspect t he t eet h of t he ri ng
gear f or excessi ve wear'
. . /
.t
12 x 1. 0 mm
74 N.m
(7.5 kgf.m, 54lbfft)
Torque in a crisscross
Pattern
Transmission
Installation
Fl ush the ATF cool er as descri bed on pages
14-352
and 14-353.
Remove the used grease
i n the fl ywheel hub caD
and fl ywheel spl i nes.
Fill the inside of the flywheel hub cap, and coat the fly-
wheel hub splines with Super High Temp Urea Grease
(P/N
08798
-
9002) as shown.
L
SEALING RING
{RUEBER)
SPLINES
Apply SUPEB HlcH TEMP
UREA GREASE
lPlN 08798
-
90O2t
SUPER HIGH TEMP
UREA GREASE
(P/N
08798
-
!)0021
1. 5-2. 5 g
10. 05-0. t 9 oz)
I nst al l a new seal i ng r i ng
( r ubber )
on t he i nout
shaft, and i nstal l two
' 14
x 20 mm dowel Di ns i n the
fl ywheel housi ng.
Instal l the fl ywheel securel y on the i nput shaft, then
i nstal l the starter motor on the fl ywheel housi ng.
4, 1Nm
la.5 kgt.m, 33 tbt.ft)
INPUT SHAFT
STARTER
l4 x 20 mm DOWEL
ptN
.4;i
"lrj
,i
rr,"r.,
., a
14-348
FLYWHEEL
MOUI{T
74 N.m (7.5
tstm,5a tbtftt
6. Pl ace the transmi ssi on on s
j ack,
and rai se i t to the
engi ne assembl y l evel .
7. Anach the transmi ssi on on the engi ne, then i nstal l
the transmi ssi on housi ng mounti ng bol t and rear
engi ne mounti ng bol ts.
TRANSMISSION
HOUSING
MOUNTING BOIT
6,1 N.m
16.5 kgl.m,
47 tbtttl
59 Nrn {6.0 kgl.m.
,
lbt ftl
WASHER
l nstal l the transmi ssi on mount bracket. Ti ghten the
l ong bol t l oosel y, and ti ghten the nuts and bott on
the mount bracket to the speci fi ed torque. Then
tighten the long bolt to the specified torque.
REAR ENGINE MOUNTING
BOLT
Replace.
12 x 1. 25 mm
12x 1. 25 mn
6,r N'm
16.5 kgtm,47 tbtftl
l-".--..-,^
G \ V
TRANSMISSON
MOUNT BRACKET
12 x 1. 25 mn
l .
9. Instal l the remai ni ng transmi ssi on
housi ng mount-
i ng bol ts.
PRIMARY OXYGEN SENSOR
Remove the transmi ssi on
j ack
and the hoi st. then
remove the hoist bracket from the engine'
Attach the fl vwheel to the dri ve
pl ate wi th ei ght
bol ts and torque as fol l ows:
Rotate the crankshaft
pulley as necessary to tighten
rhe bol ts to hal f of the speci fi ed torque, then to the
fi nal torque, i n a cri sscross
pattern.
Af t er t i ght eni ng
t he l ast bol t .
check t hat t he
crankshaft rotates freelY.
10.
1 1 .
12. Instal l the fl ywheel cover and the engi ne sti ffeners
DRIVE
6 x l . 0 mm
12 N.m
-
l12
kgf'm'
rE
8.7 tbf.ftl
ENGINE
STIFfENEB
10 x 1.25 mm
art N.m la.s kgt.m,
33 tbtftt
8 x 1. 25 mm
24 N.m
(2.1 kgf'm,
17 tbt.ftt
DRIVE PI.ATE BOLT
6 x 1 . 0 x 1 4 mm
12 N. m {1. 2
kgt m.
8.7 lbf,ftl
8 x 1. 25 mm
26 N.m
12.7
kqfin,
20 rbt'ftl
FLYUTHEEL
ENGINE STIFFENER
8 x 1. 25 mm
10 x 1. 25 mm
r,a N.m {4,5
kgf m,
33 tbf.ftl
MOUNNNG BOLT
6il N.m {6.5 kgf.m, 47 lbf'ftl
24 N.m
(2.4
kgt'm,
'17
lbf'ftl
22 N.m t2.2
kgl m, 16lbf'ftl
14-349
13.
14.
Tighten the crankshaft
pulley bolt, if necessary
(see
secti on 6).
Connect the ATF cooler hoses to the ATF cooler lines
(see page 14-357).
CAUTION: Whilo connecting the ATF cooltr hGes,
b sure not lo allow dust and other loreign
parti-
cles to entg. into the transmission.
15. Instal l the ri ght front mounvbracket'
10 x 1. 25 mm
a,r N.m {4.5 kgf'm,33 lbt ftl
RIGHT FRONT
MOUNT/BRACKET
ATF COOLER LINE
10 x 1 .25 mm
54 N.m {5.5 kgt'm,
4{) tbl.ftt
ATF COOI,TR HOSE
16. I nst al l t he exhaust
Pi Pe
A.
EXHAUST PIPE A
GASKET
Repl ace.
@
\
SELF.LOCKING
NUT
Repl ace.
10 x 1. 25 mm
5/a N.m {5.5
kgt m,
irc lbf.ft)
(cont'dl
*s$o
oor*rr-@
Repl ace.
SELF.LOCKING
Repl ace.
8 x 1. 25 mm
SELF.LOCKING
NUT
Replace.
8 x 1. 25 mm
16 N.m {1.6 kgl'm,
12 tbl.ftt
Transmission
17.
Installation
(cont'd)
Instal l I new set ri ng on the end of each dri veshaft.
Instal l the ri ght and l eft dri veshafts
(see
secti on 16).
CAUTION: Whi l e i nstatl i ng the dri ve3hafts i n the
differential, be sure not to allow dust and olher for-
aign particles
to enter into tho transmission.
NOTE:
. Cl ean the areas where the dri veshafts contact the
transmi ssi on
{di fferenti al } thoroughl y wi th sol -
vent or carburetor cl eaner, and drv wi th com-
Dressed ai r.
. Turn the ri ght and l eft steeri ng knuckl e ful l y out-
wa.d, and sl i de each dri veshaft i nto the di fferen-
ti al unti l you feel i ts set ri ng cl i p engage the si de
gear.
Instal l the damper fork, then i nstal l the ri ght and l eft
bal l
j oi nts
to each l ower arm wi th the castl e outs
and new cotter pins.
19.
10 x 1. 25 mm
43 N.m
{4.4 kgf.m, 32 lbf.ftl
SELF-LOCKING NUT
Repl ace.
12 x 1. 25 mm
6l N.m
CASTI.I
' 12
x 1. 25 mm
{6.s ksr.m. 47 tbr.ftr
l!
_
ll ffiteo
-
s.o tet'.,
14- 350
20. Instal l the spl ash shi etd.
a
a
I
6
I
6 *
"a,a
s
21.
SECONOARY GEAR
SHAFT SPEED
SENSOB CONNECTOR
6 x 1. 0 mm
9.8 t{.m 11.0 kgt.m,
7.2 tbf.trl
Connect the vehi cl e speed senso. connector. the
dri ven pul l ey
speed sensor connector and the sec-
ondary gear
shaft speed sensor connector,
6 x 1 , 0 mm
12 N.m {1.2 kg{.m, 8.7 tbf,ft)
DRIVEN PULLEY
SPEED SENSOR
CONNECTOR
E.
6 x 1.0 m.rl
'12
N.m
{1.2 kg{.m,8.7 tbf.fo
22. Instal l the shi ft cabl e end on the control l ever, and
i nstal l the shi ft cabl e on the shi ft cabl e bracket'
CAUTION:
Take care not to bend the shift cable'
23. l nstal l the cl i p i n the di recti on shown.
LOCKNUT
SHIFI CABLE 29 N m {3.0 kg{ m, 22lblftl
SHIFT CABLE
ERACKET
WASHER
IPLASTIC)
CONTROL LEVER
24, Connect the sol enoi d harness connector. the dri ve
pul l ey speed sensor connect or .
and t he gr ound
cabl e termi nal s.
6 x 1 . 0 mm
12 N. m {1. 2 kgf . m.
8,7 rbtft)
GROUND CABLE
TERMI NAL
6x1. 0mm
GROUND
TERMI NAL
12 N. m {1. 2 kgf ' m,
8. 7l bt f rl
DRIVE PULLEY
SPEED SENSOR
CONNECTOR
SOLENOID HARNESS
CONNECTOR
25. Connect the starter motor cabl e on the starter motor.
and i nstal l the cabl e hol der.
NOTE: When i nstal l i ng the staner motor cabl e. make
sur e t hat t he cr i mped si de of t he r i ng t er mi nal i s
faci ng out
(see
secti on 23).
STARTEB
B MOUNTING NUT
9 N.m
(0.9 kgf m,7 lbf ft)
26. Instal l al l removed connectors and cl amps'
27. Instal l the di stri butor.
28. Instal l the i ntake ai r duct and ai r cl eaner housi ng
29.
assemDl y.
Ref i l l t he t r ansmi ssi on
wi t h t he r ecommended
Genui ne Honda CVT Fl ui d
(see page 14-2991
CAUTION: While filling the CvT Fluid, bs surs not io
allow dust and other fotoign
particles to entor into
the transmission.
Connect the battery
positive
(+)
terminal first, then
the negative
(-l
terminal to the battery'
Check the i gni ti on ti mi ng
(see secti on 23).
Start the engi ne. Set the
parki ng brake, and shi ft the
transmi ssi on
through al l gears three ti mes Check
shi ft cabl e adj ustment
(see page 14-355).
(see
secti on 18)
Let t he engi ne r each oper at i ng t emper at ur e
( t he
radi ator fan comes on) wi th the transmi ssi on
i n l Xl
or E
posi ti on, then turn i t off and check fl ui d l evel '
Perform the start cl utch cal i brati on
procedure on
page 14-293.
Road test as described on
pages 14-296 and 14-297
30.
31.
34.
36.
STARTER MOTOR
14-351
Transmi ssi on
Gool er Fl ushi ng
@
To prevent
iniury to face and eyes, always
wear safety gl asses
or a tace shi el d when usi ng the
transmission flusher.
NOTE: Thi s procedure
shoul d be performed
before rei n-
stal l i ng the transmi ssi on.
'1.
Check the tools and hoses for wear and cracks before
usi ng. l f wear or cracks are found, reDl ace the hoses
before usi ng.
4.
Usi ng the measuri ng cup. fi l l the tank wi th 2,1 ounces
(approxi matel y
2/3 ful l ) of bi odegradabl e fl ushi ng
fl ui d
(J35944 -
20). Do not substi tute wi th any other
f l ui d. Fol l ow t he handl i ng pr ocedur e
on t he f l ui d
contatner.
Secure the fl usher fi l l er cap, and pressuri ze
the tank
wi th compressed ai r to between 5S0
-
829 kpa
(5.6 -
8.45 kgf/cm' , 80
-
120 psi ).
NOTE: The ai r l i ne shoul d be equi pped wi th a water
trap to ensure a dry ai r system,
Hang the tool under the vehi cl e.
Attach the tank' s di scharge hose to the return l i ne
oi the transmi ssi on cool er usi ng a cl amp.
Connect the drai n hose to the i nl et l i ne on the trans-
mi ssi on cool er usi ng a cl amp.
IMPORTANT:
Securely clamp the opposite end ofthe drain hose to a
bucket or fl oor drai n,
t
TRANSMISSION COOLER
FLUSHER
{Commercially available)
Kent-Moore J384O5-A
or oouivalent
TRANSMISSION
14-352
7. With the water and air valves off, attach the water and
ai r suppl i es to the fl usher.
(Hot
water i f avai l abl e.)
8. Turn on the fl usher water val ve so water wi l l fl ow
through the cool er for 10 seconds.
NOTE: l f water does not fl ow through the cool er, i t
i s compl etel y pl ugged,
cannot be fl ushed, and must
be repl sced.
9. Depress the trigger to mix the flushing fluid into the
water flow. Use the wire clip to hold the trigger down.
' 10.
Whi l e fl ushi ng wi th the water and fl ushi ng fl ui d for
two mi nutes. turn the ai r val ve on for fi ve seconds
every 15
-
20 seconds to create a surgi ng acti on.
AIR PRESSURE: MAX 845 kpa
(8.45
kgflcmr, 120 psi)
11. Turn the water val ve off. Rel ease the tri gger, then
reverse the hoses to the cool er so you can fl ush i n
the opposi te di recti on. Repeat steps 8 through 10.
12. Rel ease the tri gger. and ri nse the cool er wi th water
onl y for one mi nute.
13, Turn the water valve off, and turn off the water supply.
' 14.
Turn the ai r val ve on to dry the system out wi th ai r
for two ful l mi nutes or unti l no moi sture i s vi si bl e
l eavi ng the drai n hose.
CAUTION: Rosidual mobturo in the
qooler
or lines
cln damage the transmission,
15. Remove the fl usher from the cool er l i ne. Attach the
drai n hose to a contai ner.
16. Instal l the transmi ssi on. and l eave the drai n hose
attached to the cool er l i ne.
l .
17. Make sure the transmi ssi on i s i n the E]
posi ti on.
Fi l l t he t r ansmi ssi on wi t h cvT Fl ui d, and r un t he
engi ne for 30 seconds or unti l approxi matel y 0 95 {
( 1. 0
US qt . , 0. 8 l mp qt . ) i s di schar ged.
Remove the drai n hose, and reconnect the cool er
return hose to the transmi ssi on
(see page 14-355)
Refi l l the transmi ssi on wi th CVT Fl ui d to the
proper
l evel
(see page 14-299).
18.
' 19.
.l
,
TOOL MAINTENANCE
1. Empty and ri nse after each use. Fi l l the can wi th water
and
pressuri ze the can. Fl ush the di scharge l i ne to
ensure that the uni t i s cl ean.
2, l f di scharge l i qui d does not foam, the ori fi ce may be
bl ocked.
3. To cl ean, di sconnect the
pl umbi ng from the tank at
the l arge couPl i ng nut.
FILTER
\
\
-
0--D
i
I
O.RING
Remove the i n-l i ne ti l ter from the di scharge si de and
cl ean i f necessary'
The fl ui d ori fi ce i s l ocated behi nd the fi l ter. Cl ean i t
wi th the
pi ck stored i n the bottom of the tank han-
dl e. or bl ow i t cl ean wi th ai r. Securel y reassembl e
al l parts.
COUPLING
NUT
I
I
-@q
\
ORIFICE
FILLER CAP
14- 353
Shift Cable
@
Make sure lifts,
iacks
pl aced properl y (see
seqti on 11,
(see
secti on 20).
2. Shi ft to
E
posi ti on, then remove the l ock pi n from
the adi uster.
ADJUSTER
14-354
Remove the ai r cl eaner housi ng assembl y.
Remove the cl i p from the control l ever, and l oosen
the l ocknut.
CLIP SHTFT CABLE LOCKNUT
29 N.m 13.0 kgf m,22 lbf.ft)
SHIFT CABI-E
BRACKET
7.
8.
CONTROL LEVER
Remove the shi ft cabl e from the control l ever, the
shi ft cabl e bracket, and the cl amp.
Remove the shi ft cabl e bracket bol ts and nuts, then
remove the shi ft cabl e. Take care not to bend the
shi ft cabl e when removi ng/i nstal l i ng i t.
SHIFT CABLE BRACKET
lnstall the shift cable in the reverse order of removal.
Check the cabl e adj ustment
(see page 14-355).
\ .
*o"ra" \
{1. 2 kgI m, 8. 7 l bl f t )
t
Adjustment
!@
Make sure lifts,
jacks
placed properly (see
section 1).
l . Remove the front consol e
(see
secti on 20).
2. Shi ft to
I
posi ri on, then remove the l ock pi n from
the adj uster.
SHI FT CAELE
l ,
,l
{ 0. 7
kgf . m, 5l bf ' l t l
3. Check that the hol e i n the adi uster i s perfectl y al i gned
wi th the hol e i n the shi ft cabl e. There are two hol es i n
the adj uster. They are posi ti oned 90" apart to al l ow
cabl e adj ustment i n 1/4 turn i ncrements.
l f the hol e i s not perfectl y al i gned, l oosen the l ock-
nut on the adj uster and adj ust as requi red.
Ti ghten rhe l ocknut to 7 N.m
(0.7
kgi m,5 l bf' ft).
Instal l the l ock
pi n on the adj uster' l f you feel the
l ock pi n bi ndi ng as you rei nstal l i t. the cabl e i s sti l l
out of adj ustment and must be readj usted
Make sur e t he l ock pi n i s seat ed i n t he adi ust er
securery.
l Move the shi ft l ever to each
posi ti on, and veri fy that
t he shi f t
posi t i on i ndi cat or f ol l ows t he aut omat l c
transaxl e
gear posi ti on swi tch.
St ar t t he engi ne, and check t he shi f t l ever i n al l
posi ti ons. l f any gear does not work
properl y, refer
to troubl eshooti ng
(see page 14-294 and 14-295).
Insert the i gni ti on key i nto the key cyl i nder on the
Aff gear posi ti on i ndi cator
panel , and veri fy that the
shi ft l ock l ever i s rel eased.
7.
10.
14- 355
Shift Lever
KNOB LEVER
SCREW
,l
PUSH KNOE SPRING
SHIFT
PUSH KNOB
\
\re
X
./
,/
-6r
SILICONE GREASE
SHIFT INDICATOR LAMP.
SCREW
3 N.m
10.3 kgl.m.2 lbf.ttl
/ t n r n
Jl / I
3 N.n l0.3 xgt m, 2 lbf ftl
a,-,/ /
Apply non-hardening th'
\2 I
Appl y non-hardeni ng t hread l ock seal ant .
SCREW
3 N.m {0.3 kgf'm, 2 lbl.ft)
A/T GEAR POSTTON INDICATOR PANEL
LEVER COVER
A/T GEAR POSMON SWNCH
BUSHING
-611
SII.'|CONE GREASE
SHIFT I.TVEB ASSEMBLY
dE("""--
L@KP'N
n2
SHIFT LOCK
sotENol D
6 x 1 . 0 mm
9,8 N.m 11.0
kgf.m,
7.2 tbtft)
-<tl
SILICONE GREASE
A/T GEAR POSITION
PLAYE
3 N.m
10,3 kqf.m,
2tbfitl
SHIFT LEVEN BRACKET BASE
SHIFT LEVER
6 x 1 . 0 mm
9.8 N.m {1.0 kgf.m,7.2 lbf ftl
BASE COLLAR
14- 356
Shift Indicator Panel ATF Gooler/Hoses
Adjustment
1 . Check t hat t he i ndex mar k on t he i ndi cat or al i gns
wi th the E
mark on the shi ft i ndi cator panel when
the transmi ssi on i s i n NEUTRAL.
l f not al i gned, remove the front consol e {see secti on
20).
Remove the shi ft i ndi cator panel mounti ng
and adj ust by movi ng the panel .
NOTE: Whenever the shift indicator panel is removed,
rei nstal l the Danel as descri bed above.
I t ,
14-357
lnstallation
1. Instal l the ATF cool er, ATF cool er l i ne assembl y and
the ATF cool er hoses.
6 x 1 . 0 mm
11 N.m
('l 1 kgf.m,8.0lbl'ftl
ATF COOLER LINE ASSEMBLY
ATF COOLER HOSE
RADIATOR
6 x 1 . 0 mm
9.8 N.m 11.0 kgf'm, 7 8 lbf'ft)
ATF COOLER
Connect the ATF cool er
l i nes and ATF cool er. and
as shown.
hoses to the ATF cool er
secure them wi th the cl i ps
1 l l
Tf
{ i
l.T
6 - 8 mm
10.2
-
0.3 in)
3 3 - 3 5 mm
11. 3
-
1. 4 i nl
2 - 1 mm
10. 1
-
0. 2 i n)
2 - i l mm
{ 0. 1
-
0. 2 i n)
ATF COOI..ER HOSES
I
Speci al Tool s
Ref. No. I Tool Number Description Oty
I
Remark
o
@
,a
\9'
o
@
@
07JAF
-
SH20400
07LAD
-
PW50601
07MAC
-
S100200
07746
-
0010300
07746
-
0010400
07746
-
0030400
07749
-
0010000
07965
-
SD90100
07xAc
-
0010100
Support Base Attachment
Inner Race Dri ver
Bal l Joi nt Remover, 28 mm
Driver Attachment, 42 x 47 mm
Driver Attachment, 52 x 55 mm
Dri ver Attachment, 35 mm l .D.
Handl e Dri ver
Support Base
Threaded Adapter, 22 x 1.5 mm
1
1
1
1
I
I
1
I
1
@
e
@
&
w
@
@
c
6
@
\r'
lo,
c[G)
8-)
g e
l..---,l
G)
16-2
Driveshafts
Inspecti on
Driveshaft Boot
Check the boots on the dri veshaft for cracks, damage,
l eaki ng
grease and l oose boot bands. l f any damage i s
found, repl ace the boot and boot bands,
Loose Splines
Turn the dri veshaft by hand and make sure the spl i nes
and
j oi nt
ar e not excessi vel y l oose. l f any damage i s
found, repl ace the i nboard
j oi nt.
Twisied or Cracked
Make sure the dri veshaft i s not twi sted or cracked.
Reol ace i t i f necessarv.
DRIVESHAFT
BOOT BANDS
1 .
Removal
Loosen the wheel nuts sl i ghtl y.
Rai se the front of the vehi cl e, and support i t wi th
safety stands i n the proper l ocati ons
(see
secti on
' l ).
Remove the wheel nuts and front wheel s.
Drai n the transmi ssi on fl ui d
(see
secti on 13 or 14).
Rai s e t he l oc k i ng t ab on t he s pi ndl e nut , t hen
remove the nut.
Remove the sel J-l ocki ng nut and fl ange bol ts.
FLANGE BOLT
10 x 1. 25 mm
(cont' d)
16- 3
1.
Driveshafts
Removal
(cont' d)
8. Remove t he cot t er pi n f rom t he l awer arm bal l
j oi nt
cast l e nut . and remove t he nut .
I nst al l a 12 mm hex nut on t he bal l
j oi nt .
Be sur e
that the hex nut i s fl ush wi th the bal l
j oi nt
pi n end,
or the threaded secti on of the bal l
j oi nt pi n mi ght be
damaged by the speci al tool .
Use the speci al tool as shown i n secti on 18, to sepa-
rate the bal l
j oi nt
and l ower arm. Be careful not to
damage the bal l
j oi nt
boot.
NOTE: l f necessary, appl y penetrati ng
type l ubri ,
cant to l oosen the bal l
j oi nt.
Pry the dri veshaft assembl y wi th a screwdri ver, as
shown, to force the set ri ng at the dri veshaft end
past the groove.
10.
11.
3. 5 mm
07MAC
-
SL00200
SCREWDRIVER
16-4
12. Pul l t he i nboar d
j oi nt ,
and r emove t he dr i veshaf t
from the di fferenti al case as an assembl y. Do not
pul l on the dri veshaft; the i nboard
j oi nt
may come
apart. Use care when pryi ng out the assembl y, and
pul l i t strai ght to avoi d damagi ng the di fferenti al oi l
seat .
13. Pul l the knuckl e outward, and remove the dri veshaft
out boar d
j oi nt
f r om t he f r ont wheel hub usi ng a
pl asti c
hammer.
SCREWDRIVER
DRIVESHAFT
t
Di sassembl y
lnboard Joint Side:
1. Car ef ul l y cl amp t he dr i veshaf t i n a vi se wi t h sof t
j aws,
t hen r emove t he set r i ng f r om t he i nboar d
j oi nt.
2. Remove the boot bands. Take care not to damage
the boot.
. l f the boot band i s a l ocki ng tab type, pry up the
l ocki ng t abs wi t h a scr ewdr i ver , and r ai se t he
end of the band.
. It the boot band i s a wel ded type, cut the boot
ba nd.
. l f the boot band i s a cri mpi ng type, pry up the
end of the band wi th a screwdraver.
. l f the boot band i s a doubl e l oop type, l i ft up the
band bend.
Locking Tab Typs
Welded Type
J
Repl ace.
l ,
Crimping Type
Doubl e Loop Type
Mar k each r ol l er and i nboar d
j oi nt
t o i dent i f y t he
l ocati ons of rol l ers and grooves i n the i nboard
j oi nt.
Then remove the i nboard
j oi nt
on the shop towel .
Be careful not to drop the rol l ers when separati ng
them from the i nboard
i oi nt.
INBOARD JOINT
Check spl i nes for wear or damage,
Check i nsi de bore for wear.
Inspect for cracks.
(cont ' d)
16- 5
Driveshafts
Disassembly
(cont'dl
4. Mark the rol l ers and spi der to i denti fy the l ocati ons
of the rol l ers on the sDi der, then remove the rol l ers.
BARING REMOVER
{Commerci al l v avai l abl e}
STOP RING
(Appl i cabl e
to
' 96
-
98 modol s and
Erazil-produced driveshafts)
Remove the ci rcl i p.
Mark the spi der and dri veshaft to i denti fy the
posi -
ti on ot the spi der on the shaft.
Remove the spi der usi ng a beari ng remover.
Remove the stop ring
(Applicable
to
'96
-
98 models
and Brazil-produced driveshafts).
Wrap the spl i nes on the dri vsshaft wi th vi nyl tape to
prevent damage to the boot and dynami c damper.
DRIVESHAFT
1.
VINYL TAPE
DYNAMIC DAMPER
Check for damage.
Remove t he i nboar d
dynami c damper.
INBOARO AOOT
I nspect f or cracki ng,
splitting and wear.
16- 6
boot, and i f necessary, the
Outboard Joint Side:
1. Li f t up t hc t hr ee t abs wi t h a scr ewdr i ver , t hen
remove the boot bands, Take care not to damage
the boot.
NOTE:
.
l f the boot band i s a doubl e l oop type, l i ft 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 scrwdrivr and lift uo the snd of the
band.
2. Slide the outboard boot to the inboard
ioint
side.
TAB
OUTBOABD BOOT
1
4.
Wi pe off the
grease to expose the dri veshaft and
the outboard
i oi nt
i nner race.
Mark the dri veshaft at the same posi ti on of the out-
board
j oi nt
end wi th pai nt.
5. Careful l v cl amp the dri veshaft i n a vi se.
THREADED ADAPTER, 24 x 1.5 mm
07xac
- (x)102(x)
Remove the outboard
j oi nt
usi ng a speci al tool as
snown.
7.
8.
Remove the dri veshaft from the vi se
Remove the stop ri ng from the dri veshaft.
DRIVESHAFT
Fepl ace.
16-7
Driveshafts
Reassembly
U.S. and Canada-Producad Drivshafts
Note these i tems duri ng reassembl y'
.
Cl ean the di sassembl ed parts wi th sol vent, and dry them thoroughl y wi th compressed ai r, Do not wash the rubber
pans wi th sol vent.
o ;..j l @l : Thoroughl y pack the i nboard
j oi nt
and both
j oi nt
boots wi th the
j oi nt grease i ncl uded i n the new dri veshaft
ser,
Grease quantity:
l nboard Joi nt 115
-
135 g ( 4. 0 -
4. 8 oz)
Outboard Joi nt 115
-
135 g ( 4. 0 -
4. 8 oz)
. The' 98 Canada model and al l
' 99
-
00 model s uses a TPE
(Thermopl asti c
Pol yester El astomerl outboard
j oi nt
boot. Use
the ear cl amp type boot band i n the outboard
j oi nt
boot set.
STOP RING
('96 -
98 models)
-6r
Pack cavi t y wi t h grease.
DYNAMIC DAMPER
OOUBI.S LOOP BAND
Repl ace.
INBOARD BOOT
-6l
Pack cavi t y wi t h grease.
EAB CLAMP BAND
Repl ace.
STOP RING
Replace.
EAR CLAMP BAND
Repl ace.
DRIVESHAFT
OUTBOARDBOOT
ITPE)
-6ll
,
Pack cavity with grease.
EAR CLAMP BAND
Replace.
-G.1
CIRCLIP
16- 8
OUTBOARD JOINT
l /
t t
Brazil-Produced Driveshafts
Note these i tems duri ng reassembl y
. cl ean the di sassembl ed
parts wi th sol vent, and dry them thoroughl y wi th compressed aj r. Do not wash the rubber
parts wi th sol vent.
. .fut :Thoroughl y
pack the i nboard
j oi nt
and both
j oi nt
boots wi th the
ser.
Greas
quantity:
l nboard Joi nt
115
-
135 g ( 4. 0 -
4. 8 ozl
Outboard Joi nt 115
-
135 g
{ 4. 0
-
4. 8 oz)
INSOARD JOINT
DRIVESHAFT
BOOT BANDS
Repl ace.
-6.l
Pack cavity
(cont' d)
16- 9
l , z
wr t h gr ease,
Driveshafts
Reassembly
(cont'dl
Japan-Produced Driveshafts
Note these i tems duri ng reassembl y.
.
Cl ean the di sassembl ed
pans
wi th sol vent, and dry them thoroughl y wi th compressed ai r. Do not wash the rubber
parts with solvent.
o r@l : Thoroughl y pack the i nboard
j oi nt
and both
j oi nt
boots wi th the
set.
Grease quantity:
Inboard Joi nt
1600 DOHC WEC engi ne 130
-
140
9
(4.6 -
4.9 oz)
Except 1600 DOHC VTEC engine 110
-
120 g ( 3. 9 -
4. 2 oz)
Spl i nes
(Al
0.5
-
1.0 g (0.018 -
0.035 oz)
Outboard Joi nt
' 1600
DOHC WEC engi ne Rubber boot 90
-
'l
00
g (3.2 -
3.5 oz) TPE boot; 105
-
115
9
(3.7 -
4.1 oz)
Except 1600 DOHC VTEC engine Rubber boot 70
-
80
g
|'2.5
-
2.8 ozl TPE boot 95
-
105
g (3.4 -
3.7 oz)
{1600 DOHC VTEC angi ne)
SET RING
Replace.
-6{@
INBOARD BOOT
-6;
DYNAMIC DAMPER
DYNAMIC
Repl ace.
DOUA|.I Lq)P BAND
Repl ace.
(Rubber
typc)
LOOP BAND
Replace.
Pack cavity with grease-
CLAMP BAND
],*"u,
,"^S
/
t'.t$
,'
'
,/s
-'-
OUTBOARD BOOT
IRUEBER)
1 6 - 1 0
tttt t*'
-----_.r...-
._
Repl ace.
lnboard Joint Side:
1, Wrap the spl i nes wi th vi nyl tape to
prevent damage
to the boots and dynami c damPer.
TAPE
INBOARD BOOT
DYNAMIC DAMPER
Instal l the dynami c damper and i nboard boot to the
dri veshaft, then remove the vi nyl tape. Take care
not to damage the boots.
I nst al l t he st op r i ng i nt o t he dr i veshaf t
gr oove
(Appl i csbl e to
' 96
-
98 model s and Brazi l
-
Produced
dr i veshaf t s) .
Al ways r ot at e t he st op r i ng i n i t s
groove to be sure i t i s ful l y seated.
@--c't"t't
STOP RING
(ApplicablG to'96- 98 modob and
Brrzil-Producrd drivoshaftrl
Instal l the spi i l er on the dri veshaft by al i gni ng the
marks on the sDi der and the end of the dri veshaft.
Fi t the ci rcl i p i nto the dri veshaft
groove. Al ways
rotate the ci rcl i p i n i ts
groove to be sure i t i s ful l y
seated.
VINYL
-
-\r/
-<@
l r ;
6. Fi t the rol l ers onto the spi der wi th thei r hi gh shoul -
ders faci ng outward, and note these i tems:
. Rei nstal l the rol l ers i n thei r ori gi nal
posi ti ons on
the spi der by al i gni ng the marks
. Hol d the dri veshaft
poi nted up to
prevent the
rol l ers from fal l i ng off.
Pack the i nboard
j oi nt wi th the
j oi nt grease i ncl uded
in the new driveshaft set.
Grease
quantity:
Japan-Produced:
1600 DOHC VTEC ongine:
130
-
1/t0
g
14.6
- '[.9
oz)
Except 1600 DOHC VTEC angine:
110
-
120
I
{3'9
- il'2
oz}
Left inboard ioint
splines O:
0' 5
-
1.0
s
(0.018 -
0' 035 oz)
U.S,, Canada, and Brazil'Produced:
115
-
135
g ( 40- 4. 8ozl
7.
6
-6.l
(cont' d)
16- 1 1
Hi gh shoul der f aces
Driveshafts
Reassembly
(cont'dl
8. Fi t the i nboard
j oi nt
onto the dri veshaft, and note
these i tems:
. Rei nstal l the i nboard
j oi nt
onto the dri veshaft by
al i gni ng the marks on the i nboard
j oi nt
wi th the
marks on the rol l ers.
. Hol d t he dr i veshaf t so t hat t he i nboar d
j oi nt
poi nts up to prevent i t from fal l i ng off.
Adj ust the l ength of the dri veshafts to the fi gure
bel ow, then adj ust the boots to hal fway between
ful l comDressi on and ful l extensi on. The ends of the
boots seat i n the
groove of the dri veshaft and
j oi nt.
Right driveshaft, 1600 OOHC VTEC model:
475
-
480 mm
(18. 7 -
18. 9 i n)
Left driveshaft, all othei models:
774-779 mm
(30. 5 -
30. 7 i n)
Right driveshaft, all other models:
501
-
506 mm 119. 7
-' 19. 9
i nl
Left driveshaft. 1600 DOHC WEC model:
475
-
480 mm 118. 7
-
18, 9 i nl
16- 12
OYNAMIC DAMPER OUTBOARD JOINT
10. l f necessary posi ti on the dynami c damper as shown
Detow.
. Instal l a new dynami c damper band. and bend
down both sets of l ocki ng tabs.
. Li ghtl y tap on the doubl ed-over ponj on of the
band to reduce i ts hei ght.
Loft:
1600 DOHC VTEC model : 26 i 2 mm
(1.0
t 0.1 i nl
Al l other model s: 9,1t 2 mm
(3.7
10.1 i nl
Wi th
"SR1"
mark: 7512 mm 12.9 ! 0.1 i nl
Right:
16dl DOHC VTEC model s: 2612 mm 11.0 t 0.1 i nl
All other modelii
DYNAMIC DAMPER
-SR1"
MARK
U.S. and Canada-Produced ITPE BOOTI
Left 53612 mm {21.1 10.1 i n}
Ri ght: 2txt 12 mm {10.i t 1 0.1 i n}
5512 mm
( 2. 2
t 0. 1 i nl
INBOARO JOINT
DYNAMIC DAMPER BAND
l .
11. Set the doubl e l oop band onto the boot and dynam-
i c damper wi th the band end toward the front ot the
vehi cl e.
LOOP BANO
Pul l up the sl ack i n the band bY hand
Mark a posi ti on on the band 10
-
14 mm {0
4
-
0 6
i n) f r om t he cl i P.
DOUBLE
,
1' )
13.
CLIP
I p
14.
15.
Thread the free end of the band through the nose
secti on of the boot band tool and i nto the sl ot on
t he wi ndi ng mandr el .
Pl ace a wrench on the wi ndi ng mandrel of the boot
band tool , and ti ghten the band unti l the mark
you
made on the band meets the edge of the cl i p.
Mark on band.
Li ft up the boot band tool to bend the free end
the band 90 degrees, then center-punch the cl i p'
16.
(cont' d)
1 6 - 1 3
(KD-3191 or equi val ent )
HAMMER
Driveshafts
17.
Reassembly
(cont'dl
Unwi nd the boot band tool , and cut off the excess 5
-
10 mm
(0.2 -
0.4 i n) from the cl i p.
5 - 1 0 mm
10.2
-
0.a inl
Secure the end of the boot band by tappi ng i t down
wi th a hammer,
19. Instal l the new set ri ng,
18.
Note these items after reassembly:
. Make sure the band and cl i p does not
anythi ng and the band does not move.
a Remove any grease remai ni ng on the
surfaces.
interfere with
su rrou ndi ng
16- 14
Outboard Joint Sid.:
1. Wrap the spl i nes wi th vi nyl tape to
prevent
damage
to the boot.
TPE tvDe:
-.
OUTBOARO BOOT
ITPE)
BOOT BAND
Repl ac,
Rubber typ.:
I nst al l t he boot band and out boar d boot , t hen
remove the vinyl tape. Take care not to damage the
boot,
Install the stop ring into the drivshaft groove.
DRIVESHAFT
>
VINYL TAPE
VINYL TAPE
J
)
4. lnsert the driveshaft into the outboard
joint
until the
stop ri ng i s cl ose on the
i oi nt.
DRIVESHAFT
To compl etel y seat the outboard
j oi nt, pi ck up the
dri veshaft and
j oi nt,
and drop them from about 10
cm
(4
to 5 inches) onto a hard surface. Do not use a
hammer as excessi ve force may damage the dri ve-
shaft.
16- 15
J
6. Check the al i gnment of the
pai nt mark wi th the out-
board
j oi nt
end.
Pack the outboard
joint
with the
joint grease includsd
in th new
ioint
boot set.
Gleaso
quanlity
U.S., canada, and Brazil'Ploducod:
115
-
135 g
{4.0
-
4.8 oz}
Japan-Producod:
161X, DOHC VTEC angino:
Rubbor boot: 90
-
100 g
13.2
-
3.5 oz)
TPE boot: 1tl6
-
115
I {3'7
- tl'l oz}
Excapt 1000 DOHC VTEC engine:
Rubbel boot: 70
-
80 g
l.2.5
-
2.8 ozl
TPE boot: 95
-
105
g
{3.4-
3.7 oz}
7.
DRIVESHAFT
(cont' d)
Driveshafts
Reassembly
lcont'd)
Instal l the outboard boot and the boot bands.
. lf the boot is the rubber type. go
to step 13.
. lf the boot is the TPE type, go to step 9.
Fi t the boot ends onto the dri veshaft and outboard
i oi nt.
10, Set the ear cl amp band by threadi ng the tab i nto the
hol es of the band.
EAR CLAMP BAND
Reolace.
8.
1 6 - 1 6
11. Cl ose the ear
porti on
of the band wi th a commer-
ci al l y avai l abl e boot band Di ncerc.
BOOT BAND PINCERS
KENT-MOORE J, 35910
or eoui val ent
Chsck the clearanca between the closed ear oonion
of the band. l f the cl esrance i s not wi thi n the stan-
dard, close the ear portion
of ths band further.
6.0 mm
(0.24
in) MAX
3.0 mm 10.t2 inl MAX
EAR FOFNON
I
13. Fi t t he boot ends ont o t he dr i veshaf t
and t he
outboard
j oi nt
Fi t the doubl e l oop boot bands onto the boot ends'
Pul l up the sl ack i n the band by hand'
Mark a
posi ti on on the band 10
-
14 mm {0
4
-
0 6
i n,) from the cl i P.
14.
16.
CLIP
l r z
17. Thread the free end of the band through the nose
secti on of a commerci al l y
avai i abl e boot band tool
KD-3191 or equi val ent and i nto the sl ot on the wi nd-
i ng mandrel .
BOOT BAND TOOL
l Commerci al l Y
avai l abl e)
KD-3191 or equi val ent
MANDREL
Pl ace a wrench on the wi ndi ng mandrel of the boot
band tool , and ti ghten the band unti l the marked
spot on the band meets the edge of the cl i p'
Li ft uo the boot band tool to bend the free end of
the band 90" to the cl i p Center
punch the cl i p, then
fol d over the remai ni ng tai l onto the cl i p
Mark spot.
18.
1 q
(cont' d)
16-17
Driveshafts
Reassembly
(cont'dl
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
i n.) tai l protrudi ng
from the cl i p.
21. Bend the band by tappi ng i t down wi th a hammer.
NOTE: Maks sure the band and the cl i p does not
i nterfere wi th anythi ng, and the band does not
mov6. Remove any grease
remai ni ng i n the sur-
roundi ng surtaces.
AANO END
1 6 - 1 8
INBOARD JOiIT
SET RII{G GR(X)VE
Installation
1, Instal l the new set ri ng onto the dri veshaft groove.
Always use a new set ring whenever the driveshaft
i s bei ng i nstal l ed.
2. Instal l the outboard
j oi nt
i nto the knuckte.
OUTBOARD JOINT
KNUCKI.E
3. l nsert the i nboard end of the dri veshaft i nto the di f-
t er ent i al or i nt er medi at e shaf t unt i l t he set r i ng
l ocks i n the
groove
NOTE: Clean the areas where the driveshaft contact
the transmission
(differential) thoroughly with solvent
or carburetor cleaner, and dry with compressed air'
INBOARD JOINT
INBOARD JOINT
Replace.
GROOVE
an
DIFFERENTIAL
l nstal l the knucki e on the l ower arm. then trghten
the castl e nut and i nstal l a new cotter
pi n
NOTE: wi pe off the
grease before ti ghteni ng the
nut at the bal l
i oi nt.
CAUTION:
. Be careful not to damago the ball
ioint
boot'
. Torque the castle nut to the lower torque spci-
fication, thsn tighten it only far enough to align
the slot with th pin hol6. Do not align the nut
by loosening.
CASTLE NUT
12 x 1 .25 mm
COTTER PIN
Repl ace.
On reassembl Y,
bend t he cot t er
pi n
J
i$ -
59 N.m 15.0
-
6.0 kgl m,35
-
43 lbf ftl
1 6 - 1 9
5. l nstal l the damper tork over the dri veshaft and onto
t he l ower ar m. I nst al l t he damper i n t he damper
fork so the al i gni ng tab i s al i gned wi th the sl ot i n
the damPer fork.
FLANGE BOLT
l 0 r 1.25 mm
rit N.m t4.a
kgf.m, 32 lbf.ft)
AIIGN|NG TAB
1.
SELF-LOGKING NUT
12 x 1.25 mm
6,1N.m 16.5
kgi.m, a7 lbfftl
Replace.
Loosel y i nstal l the fl ange bol ts and the new sel f-
l ocki ng nut.
Appl y oi l to the seati ng surface of the new spi ndl e
nut.
181 N m 118.5 kgt'm, 13il lbt'ftl
NOTE: Aftortightening, use a drift to
stake the spindle nut shoulder against the drivoshaft'
8. Instal l a new spi ndl e nut, then ti ghten the nut'
9. Cl ean the mati ng surfaces ot the brake di sc and the
wheel . then i nstal l the front wheel wi th the wheel
nuts.
10. Ti ghten the fl ange bol ts and the new sel f-l ocki ng
nut wi th the vehi cl e' s wei ght on the damper.
11. Refi l l the transmi ssi on
wi th recommended fl ui d
(see
secti on 13 or 14).
' t2.
Check the front wheel al i gnment and adj ust i f nec-
essary
(see secti on 18),
FRONT WHEEL
SPINDLE NUT 22 x 1.5 mm
WHEEL NUT 12 x 1.5 mm
108 N.m
(11.0
kgl'm,
g)
lbl ftl
Intermediate Shaft
Removal
Drai n the transmi ssi on oi l or fl ui d
{see secti on 13 or
r 4).
Remove the l eft dri veshaft
(see page
16-3).
Remove the three dowel bol ts.
OOWEL BOLTS
' 10
x 1. 25 mm
Remove the i ntermedi ate shaft from the di fferenti al .
CAUTION: Hold the intermsdiate shaft horizontal
until it is clear of lhe dilterential to prevent damage
to the differential oil seal.
' 1.
2.
3.
INTERMEDIATE SHAFT
16-20
Disassembly
NOTE: Be careful not to damage the metal ri ngs on the
i ntermedi ate shaft duri ng di sassembl y.
1. Remove the set ri ng.
2. Remove the i ntermedi ate shaft outer seal from the
Deafl ng suppon.
3. Remove the external ci rcl i p,
Di sassembl y
Press the i ntermedi ate shaft out of the shaft beari ng
usi ng the speci al tool s and a press as shown.
Remove the i nternal ci rcl i P
Press
I
SUPPORT BASE
ATTACHMENT
07JAF
-
SH20400
INTERNAL CIBCLIP
BEARING SUPPORT RING
Check for damage or di storti on
6. Press the i ntermedi ate shaft beari ng out ot the bear-
i ng support usi ng the speci al tool s and a
press as
shown.
HANOLE DRIVER
0?749
-
00'10000
Press
I
DRIVER ATTACHMENT,
12x47 mm
07746
-
0010300
FLOATING RUBBEB
DAMPER
Check f or det eri orat i on
and oamage.
SUPPORT BASE
ATTACHMENT
07JAF
_
SH20it00
BEARING SUPPORT
Check f or damage
I
sErR' NG
A4\
Reolace
V U
OUTER SEAL
Repl ace.
(cont ' d)
ReassemblY
NOTE:
. cl ean the di sassembted
parts wi th sol vent, and dry them thoroughl y wi th compressed ai r' Do not wash the rubber
parts wi th sol vent.
. Becareful
not to da mage the metal ri ngson the i ntermedi ate shaftduri ng
reassembl y'
BEARING SUPPORT RING
DOWEL BOLTS
10 x 1. 25 mm
39 N. m 14. 0
kgf . m, 29 l bI f t l
EXTERNAL CIRCLIP
Pack t he i nt eri or
of t he out er seal .
2 . 0 - 3 5 s 1 0 . 0 7 - 0 1 2 o z )
INTERNAL CIRCLIP
INTERMEDTATE SHAFT BEARING
Repl ace,
INTERMEDIATE
SHAFT RING
l J
16-21
lntermediate
Shaft
Reassembly
(cont'd)
1. Press the i ntermedi ate shaft beari ng i nto the bear-
i ng support usi ng the speci al tool s and a press
as
shown.
Prass
I
DRIVER ATTACHMENT,
52x 55mm
07746
-
001 0(X)
Seat the i nternal ci rcl i p i n the groove
of the beari ng
suppon.
Press the i ntermedi ate shaft i nto the shaft beari ng
usi ng the speci al tool s and a press.
Praa.r
I
@---
LJ
INTERMEDIATE
SHAFT
DRIVER ATTACHMENT,35
mm LD.
16-22
Seat the external ci rcl i p i n the groove
of the i nter-
medi ate shaft.
Instal l the outer seal i nto the beari ng support usi ng
NOTE: Instal l the seal ftush wi th the beari ng sup-
port.
Pre$
t
HANDr.r DRTVER
-
0011r(x)0
Pack the Interior
of the ouler seal.
2. 0- 3. 5 g
{0. 07
-0. 12
ozl
OUTEN SEAL
Instal l the new set ri ng
groove.
ORIVER ATTACHMENT,
52x55mm
077i16
-
0010/O0
i n the i ntermedi ate shaft
lnstallation
1. l nsert the i ntermedi ate shaft assembl y i nto the di f-
ferenti al .
CAUTION: Hol d the i ntermodi ate shaft hori zontal
to
prevent damag to the difterential oil seal'
NOTE: Cl ean the areas where the i ntermedi ate shaft
contacts the transmi ssi on
(di fferenti al ) thoroughl y
with solvent or carburetor cleaner, and dry with com-
Dressed ai r,
2. Instal l the three dowel bol ts, then ti ghten them'
DOWEL BOLTS
10 x 1. 25 mm
39 N.m {i1.0
kgf'm, 29 lbf'ftl
l z
16-23
l .
t
Steering
Speci af Tool s
. . . . . "' . . . . . 17-2
Manual Steeri ng
Component
Locations
l ndex . . . . . . . . . . . . . . . .
. . . . . . . 17-3
Inspection
and Adiustment
St eeri ng Operat i on
"' . . . . . . ". . . . . . . . . . . . . . .
17-4
Rack Gui de Adi ust ment . . . . . . . . . . . . . . . . . . .
17-5
*Steering
Wheel
(See power steering section)
*Steering
Column
(See power steering sectionl
Steering Gearbox
Removal
. . . . . . . . . . . . . . . . . 17-5
Disassembly
......."" 17-7
Reassembl Y
. . ' . . . . . . . . . 17-9
l nst al l at i on
. . . . . . . . . . . . . 17-13
Power Steering
Component
Locations
l ndex ". . . . . . . ". . . . .
"""' 17-15
System DescriPtion
Fl ui d Fl ow Di agram . . . . . . . . . "". . . . . . . . . . . . .
17' 16
St eeri ng
Pump . . . . . . . . . . . . ' . . . ". . . . . . . . "' . . . -- 17
-17
St eeri ng Gearbox . ". . . . . . . . . . . . . . . . . ' . . . ' . ' . '
17-20
Troubleshooting
Generaf Troubleshooting
..........--.... 17' 22
Noi se and Vi brat i on . . . . . . . . . . . . . . . . . . . . . . . . .
17
-26
Ff ui d Leaks
. . . . . . . . . . . . . 17-28
Inspection and Adiustment
St eeri ng Operat i on' . . . . . . . "' . . . . . . . . ' . . . . . .
1 7-30
Power Assist Check
Wi t h Vehi cl e Parked . . ". . . . . . . . . . . . . . . .
17-30
Steering Linkage and Gearbox ....." 17-31
Pump Beft
...--.""".. 17-32
Rack Guide Adiustment .' .......' .......' .
17' 33
Fl ui d Repl acement
. . . . . ' . . ". . . . . . . . . . . . . . . . .
17-33
Pump Pressure Check .............' ....-. " 17
-34
' Steering
Wheel
Removal
. . "' . . . . . . . . ' . . . 17-35
lnstallation
............. 17-35
......' .....' .' 17-36
*Steering
Column
....' ........... ---.... 17' 37
lnspection
.............. 17' 38
Power Steering Hoses, Lines
Fluid Leakage Inspeetion ............' .... 17-39
Replacement
......".. 17-39
Power Steering PumP
Removal / l nst al l at i on
. ' . ' . . ' . . ' . . . . . . . . . . . . .
17-40
Di sassembl y
". . . . . . . . . 17-41
fnspection
.......---' ." 17' 42
Reassembl y
. . ' . . . . . . . . . 17-44
Steering Gearbox
Removal
. . . . ' . . . . . . . . . "' 17' 47
DisassemblY
..........' 17-49
Reassembl y
' . . . . . . . . . . . 17-55
l nst al l at i on
. . . . . . . . . . . . . 17-65
Ball Joint Boot Replacement
.......' .. 17-68
I r /
lp
Ref. No I Tool Number
Description
Oty
I
Pag Reterence
o
@
@
@
@
fof
@
@
@
@
@
@
@
@
@
@
@
@
@
07GAF
-
PH70100
07GAG
-
SD4010A or
07GAG
-
SD40100
07GAG
-
SD4020A or
07GAG
-
S040200
*07JGG
-
00r 010A
07MAC
-
5100200
OTNAD
-
SR3O2OA
07NAG
-
SR3090A or
07NAG
-
SR30900
07RAK
-
5040110
07RAK
-
5040121 or
07RAK
-
5040t20
07406
-
0010004 or
07406
-
001000r
07725
-
0030000
07746
-
0010100
07746
-
0020100
07746
-
0030300
07749
-
0010000
07916
-
SA50001
07965
-
SA50500
07974
-
SA5020A or
07974
-
SA50200
07974
-
SA50800
Pi l ot Col l ar
Pi ston Seal Ri ng Gui de
Pi ston Seal Ri ng Si zi ng Tool
Bel t Tensi on Gauge
Bal l Joi nt Remover, 28 mm
Cyl i nder End Seal Bemover Attachment
Pi ston Seal Ri ng Si zi ng Tool
P/S Joi nt Adaptor
(Pump)
P/S Joint Adaptor
(Hose)
P/S Pressure Gauge
Uni versal Hol der
Attachment,32 x 35 mm
Driver, 22 mm l.D.
Attachment, 30 mm l.D.
Dri ver
Locknut Wrench, 40 mm
Front Hub Di VAssembl y Tool
Sl eeve Seal Ri ng Si zi ng Tool
Bsl l Joi nt Boot Cl i p Gui de
1
1
'I
1
'I
1
I
1
1
I
1
1
I
1
1
I
1
I
11-54
17-59
' 17-59
17
-32
17
-6,
47
17-51
| /-ao
17
-34
17
-31
't7
-34
't7-42,
16
17- 57, 58
17-10
17-44
't7
-57
17-5,33
17-68
17
-57
17-57, 6A
*
l ncl uded i n the Bel t Tensi on cauge Set, 07TGG
-
OO10OOA.
o
p
v
@ o
_
ts7-
dysB
aal
@
@
( o )
F=1
@
@ @
@
@
@
17- 2
Component
Locati ons
t
l ndex
Manual Steeri ng
NOTE:
. l f an i ntact ai rbag assembl y
has been removed from a scrapped vehi cl e or has been found defecti ve or damaged dur-
i ng transi t. storage or servi ce, i t shoul d be depl oyed
(see
secti on 24)'
o Before removi ng the
gearbox, remove the dri ver' s ai rbag assembl y and steeri ng wheel
. After i nsta l l i ng the gearbox, check the wheel al i gnmentand adj ust i f necessary
SRS components
are l ocated i n thi s area. Revi ew the SRS component l ocati ons,
precauti ons, and
procedures i n the SRS
secti on 124) before
performi ng repai rs or servi ce'
STEERING WHEEL
Removal / l nst al l at i on, Page
17' 35
Di sassembl y/ Feassembl Y,
page 17-36
DRIVER'S AIRBAG ASSEMBLY
Removal / l nst al l at i on, see sect i on 24
STEERING COLUMN
Removal / l nst al l at i on, Page
17-37
I nspect i on,
page 17' 38
CABLE REEL
see sect i on 24
IGNTTION SWITCH
See section 23
STEERING GEARBOX
Rack Gui de Adi ust ment , Page
17-5
Removai ,
page 17' 5
Di sassembl y, Page
17_7
Reassembl y,
page 17_9
I nst al l at i on,
page 17 13
TIE.ROD END BALL JOINT
Bal l Joi nt Boot Repl acement ,
page 17-68
J
t ,
17-3
Inspection and Adjustment
Steering Operation
Steeri ng Wheel Rotati onal Pl ay
Pl ace the front wheel s i n a strai ght ahead posi ti on
and
measure the di stance the steeri ng wheel can be turned
wi thout movi ng the front wheel s.
ROTATIONAL PLAY: 0
-
10 mm
(0 -
0.4 i n)
l f the pl ay exceeds the servi ce l i mi t, perform
rack gui de
adj ustment
(see page l T-5).
l f the pl ay i s sti l l excessi ve after rack gui de adj ustment,
i nspect the steeri ng l i nkage and gearbox
as descrj bed
Detow.
Steering Linkage and Gearbox
TIE.ROO LOCKNUT
Check f or l oose l ocknut .
BOOT
I nspect f or damage and det er i or at i on.
STEERING JOINTS
Check f or l oose j oi nt
END BALL JOI NT
I nspect f or f aul t y movement
ano oamage.
GEABBOX MOUNTI NG
I nspect f or det eri orat i on.
GEABBOX ASSEMBLY
Stering Effort Check
Rai se the front wheel s off the ground.
Turn the steeri ng wheel wi th a spri ng scal e and check i ts
reaorng,
Standard: 15 N
(1.5
kgf, 3.3 l bl l maxi mum
l f i t r eads mor e. per f or m r ack gui de
adj ust ment
( see
page 17- 5) .
COLUMN
I nspect f or l oose col umn
mount i ng bol t s and nut s.
PINION SHAFT GROMMET
f or damage and det eri orat i on.
BALL JOINT BOOT
I nspect f or damage and det eri orat i on.
See pago 17-68 tor replacement.
a o -
\ - - - - - - - - - U
17- 4
I nspect f or l oose mount i ng bol t s.
Steeri ng Gearbox
l . r
Rack Gui de Adj ustment
NOTE: Per f or m t he r ack gui de adj ust ment wi t h t he
wheel s i n the strai ght ahead posi ti on.
1. Loosen the rack gui de screw l ocknut wi th the spe-
ci al tool , then l oosen the rack gui de screw.
LOCKNUT WRENCH, 40 mm
07916
-
SA5000r
Ti ghten the rack gui de screw unti l i t compresses the
spri ng and seats agai nst the rack gui de, then l oosen
rt.
Reti ghten the rack gui de screw to 4 N' m
(0.4
kgf m,
2.9 l bf.ft), then back i t off to speci fi ed angl e.
Specilied Return Angle: 30' max.
Ti ght en t he l ocknut whi l e hol di ng t he r ack gui de
Check for ti ght or l oose steeri ng through the com-
pl ete turni ng travel .
Recheck steeri ng effort
(see page 17-4).
4.
RACK GUI DE SCREW
l , z
Removal
NOTE: Usi ng sol vent and a brush, to wash any oi l and
di rt off the gearbox. Bl ow dry wi th compressed ai r.
1. Rai se the front of vehi cl e, and support i t on satety
stands i n the proper l ocati ons
(see
secti on I ).
2. Remove the front wheel s.
3. Remove the steeri ng wheel
(see page 17-35).
4. Remove the steeri ng
l oi nt
cover
Remove the steeri ng
j oi nt l ower bol t, and di scon-
nect the steeri ng
j oi nt
by movi ng the
j oi nt
toward
t he col umn.
(cont ' d)
17-5
STEERING JOINT COVER
LOWER BOLT
STEERING JOINT
Steering Gearbox
Removal (cont' d)
Remove the cotter pin from the castle nut
('96 -
'97
models) or nut
('98 -
'00
models) and remove the nut.
Instal l the 10 mm hex nut on the bal l
j oi nt.
Be sure that the 10 mm hex nut is flush with the ball
joint pin
end, or the threaded section of the ball
joint
pi n mi ght be damaged by the bal l j oi nt remover.
NOTE: Remove the bal l
j oi nt
usi ng the speci al tool ,
Refer to secti on 18 for how to use tho bal l
j oi nt
remover.
Separate the ti e-rod bal l
j oi nt
and knuckl e usi ng the
speci al tool .
CAUTION: Avoid damaging the ball
ioint
boot.
Remove the l eft ti e-rod end, then sl i de the rack al l
the way to the ri ght.
Separate the exhaust pi pe A or TWC
(see
secti on
g).
Di sconnect the shi ft l i nkage
(see
secti on 13 or sec-
t i on 14) .
Remove the stiffener plate.
7.
' 10.
1 1 .
12.
Repl ace.
17-6
13. Remove the mounti ng bracket,
Pul l the steeri ng gearbox al l the way down to cl ear
th
pi ni on
shaft from the bul khead, then remove the
pi ni on
shaft
grommet,
Move the steering gearbox to right so the left rack
end cl ears the rear beam, then ti l t the l eft si de down
to remove it from the car.
t 5 .
STEENING GEARBOX
PINION SHAFT GROMMET
)
Disassembly
' 1.
2.
Pl ace the
gearbox i n a vi se wi th a soft
j aws,
then
cl amp t he gear box at t he mount br acket or gear
housi ng.
CAUTION: Be carcful not to distort the
gear hous-
in9 by clamping it too iight in the vise incorrectly.
Remove the ti e-rod end and l ocknut.
Remove the boot bands and ti e-rod cl i ps. Pul l the
bogts away from the ends of the gearbox.
/
TIE.ROD CLIP
4. Hol d t he s t eer i ng r ac k wi t h one wr enc h, and
unscrew the rack end wi th another wrench.
CAUTION: Be caleful not to damagc the rack sur'
facs with the wrench.
STEERING RACK ENO
l ,
17- 7
7.
Push the ri ght end of the rack back i nto the cyl i nder
housi ng so the smooth surface that ri des agai nst
the seal won' t be damaged.
Loosen t he l ocknut , and r emove t he r ack gui de
screw.
Remove t he di sc washer , spr i ng and r ack gui de
from the gear housi ng.
RACK GUIOE
SPRING
8.
9.
LOCKNUT RACK GUIDE SCREW
Remove the pi ni on dust seal and the 35 mm snap
nng.
Hol d the
pi ni on shatt wi th a vi se securel y
Remove the
pi ni on by tappi ng evenl y around the
fl anged secti on of the gearbox wi th a pl asti c ham-
met.
CAUTION: Do not tap on tho steering rack.
NOTE| Do not reuse the removed pi ni on.
9._
ViF=\_
PINION DUST SEAL
Repl ace.
SNAP RING,35 mm
STEERING PINION
Fepl ace.
DISC WASHER
Steering Gearbox
Disassembly
(cont'dl
10. Sl i de the steeri ng rack out of the cyl i nder housi ng.
CAUTION: Be carelul not to damage the bushing in
the cyl i nder housi ng.
11. Remove t he r ack end bushi ng.
GEARBOX MOUNTING CUSHION
I nspect i nner wal l t or wear or damage.
17-8
12. Repl ace the gearbox mounti ng cushi on i f necessary:
. To remove the cushi on, use a sharp kni fe and make
a cut down the l ength of the cushi on. Be careful not
to damage the pai nt on the outsi de of the cyl i nder
housi ng. Remove the ol d cushi on.
. Appl y weatherstri p adhesi ve to the i nsi de of the
new cushi on. Instal l the cushi on onto the cyl i nder
housi ng and posi ti on i t 20
-
22 mm
(0.79 -
0.87 i n)
from the end of the cyl i nder housi ng as shown.
NOTE: Af t er i nst al l i ng t he cushi on, wi pe of f any
excess adhesi ve t hat may have dr i pped i nt o t he
i nsi de of t he cyl i nder housi ng.
20
-
22 mm 10.79
-
0.87 in)
Reassembl y
NOTE:
. Cl ean the di sassembl ed
parts wi th sol vent, and dry them wi th compressed ai r. Do not di p the rubber parts i n sol vent.
. Al wavs repl ace the non reuseabl e parts wi th new ones before assembl y
. Do not al l ow dust, di rt, or other forei gn materi al s to enter the steeri ng
gearbox.
-6,1
PI NI ON OUST SEAL
Repl ace.
RACK ENO BUSHI NG
\
^lr
r@
-6i
GEARBOX MOUNTI NG CUSHI ONS
V."^pR,NG,3smm
t r
a /
^$'q0
\
")*o' ' o"' "' *
DI SC WASHER
RACK GUI DE
(cont ' d)
17- 9
t J
Steering Gearbox
Reassembl y
(cont' dl
L Appl y a thi n coat of grease
to the i nsi de surface of
t he r ack end bushi ng.
Grease quanti ty: 1
-
3
S 10.04-0.1 ozl
CAUTION: Do not ti l l the sl ots wi th greas;
thy
must remain open to serve as air
passages,
I nst al l t he r ack end bushi ng by al i gni ng t he r ound
proj ecti on on the bushi ng wi th the hol e i n the cyl i n-
der housi ng
4.
Grease the steeri ng rack teeth.
I nst al l t he st eer i ng r ack i nt o t he cyl i nder housi ng
careful l y to avoi d damagi ng the rack end bushi ng.
CYLINDER HOUSING
17- 10
11. Adj ust the rack gui de screw
(see page 17-5).
Dri ve i n the steeri ng
pi ni on i n the gear housi ng wi th
the soeci al tool s.
ORIVER.
22 mm l . D.
o7716-
qr20100
SNAP RING, 35 mm
PINION DUST
SEAL
Repl ace.
Vi nyl t ape
STEERING
PINION
7.
I nst al l t he 35 mm snap r i ng secur el y i n t he gear
housi ng groove.
Appl y vi nyl tape to the pi ni on shaft, then coat the
vi nyl tape wi th grease.
Instal l the pi ni on dust seal on the gear housi ng unti l
i t seats properl y, then remove the tape.
Gr ease t he sl i di ng sur f ace of t he r ack gui de, and
i nstal l i t on to the gear housi ng.
Instal l the spri ng, di sc washer and rack gui de screw
on the gear housi ng.
NOTE: Instal l the di sc washer wi th i ts convex si de
faci ng i n.
LOCKNUT
SPRING
RACK GUTDE
RACK GUIOE SCREW
10.
Dtsc w,
a(-\
\ l 1
*l
\ , , /
\
I t
12.
13.
l nst al l t he new l ock washer i n t he gr oove i n t he
steeri ng rack.
Instal l the steeri ng rack end i nto the rack
LOCK WASHER
RACK END 54 N m ts.s kgf'm, 40 lbtft)
Repl ace.
TAB
( l * v
14.
15.
RACK END
Hol d the steeri ng rack wi th a wrench and ti ghten
the rack end wi th another.
CAUTION: Be careful not to damage the tack sur-
fac with the wrench.
After ti ghteni ng the rack ends, stake the four sec-
ti ons of the l ock washer wi th a rol l pi n dri ft and a
mal l et.
. Pl ace the wood bl ock on the
press tabl e. then set
the l ock washer secti on of the rack end on the
wood bl ock securel Y.
. Be sure the tool i s al i gned wi th the fl at secti ons
of the steeri ng rack end before
pressi ng
. Stake the l ock washer i n the center of the fl at
section of the steering rack end.
ROLL PIN DnlFTl
(Commorci.lly .Yril.blol
Snap-On No. PPRS or oquival.nt
NOTE: This drift has a flat
tip, to
prevent puncturing
of met al washer.
srEEatruG
nlCr/
rl,
WOODEN BLOCK
TIE.ROO CLIP
16. Appl y
grease around the outsi de ot the rack end
housi ng.
Appl y a l i ght coat of si l i cone
grease to the boot
grooves on the rack ends.
l nstal l the boots i n the rack end wi th the ti e-rod
cl i ps.
NOTE: Instal l the boot band wi th the rack i n the
strai ght ahead
posi ti on
(ri ght
and l eft ti e-rods are
equal i n l ength).
=-.
.r=-q!q!!.n
SILICONE GREASE
17.
(cont' d)
17- 11
NOTE| WiPe
grease off
t he t hread sect l on
Steeri ng Gearbox
Reassembl y
(cont' d)
2 1 .
' 19.
20.
Instal l the boot band so that the l ocki ng tabs of the
band
(stake poi nts) are i n the range shown bel ow.
{ Tabs shoul d f ace up and sl i ght l y f or war o. ,
Bend both sets of l ocki ng tabs.
Li ghtl y tap on the doubl ed-over porti ons
to reduce
t hei r hei ght .
CAUTION: Stake the band l ocki ng tabs fi rml y.
22. Sl i de t he r ack r i ght and l ef t t o be cer t ai n t hat t he
boots are not detormed or twi sted.
St ake poi nt s
+
Fronr
Lett Boot Band
(Vi ewed
f rom t he l ef t si de)
Right Boot Bend
(Vi ewed
f rom t he ri ght si de)
1 7 - 1 2
)
l nstal l ati on
Sl i de the rack al l the way to the ri ghl
Instal l the pi ni on shaft grommet, and i nsert the
pi n
i on shaf t up t hr ough t he bul khead.
NOTE| Al i gn the notch i n the pi ni on shaft
grommet
wi t h t he t ab on t he gear housi ng.
1 .
2.
J
3. Instal l the mounti ng brackets wi th the two gearbox
mount i ng bol t s on t he cushi on.
NOTE: The arrow on t he bracket
poi nt t oward t he f ront .
STEEBING GEARBOX
{4.0 kgt.m,29 lbf.ftl
J
4. I nst al l t he st i f f ener
pl at e wi t h t he t wo gear box
mounti ng bol ts and sti ffener
pl ate attachi ng bol ts.
NOTEr I nst al l t he bol t s l oosel y f i r st . t hen t i ght en
them securel y.
GEARBOX MOUNTING EOLTS
43 N.m {4.4 kgf.m, 32 lbf'ftl
5. Center the steeri ng rack wi thi n i ts stroke
6. Sl i p the l ower end ot the steeri ng
j oi nt
onto the
pi n
i on shaf t
( l i ne
up t he bol t hol e wi t h t he gr oove
around the shaft), and ti ghten the l ower bol t.
NOTE:
. Connect the steeri ng shaft and
pi ni on wi th the
steeri ng wheel and steeri ng rack centered
Be s ur e t hat t he l ower s t eer i ng
j oi nt
bol t i s
secur el y i n t he gr oove i n t he st eer i ng gear box
pi n i on.
l f the steeri ng wheel and rack are not centered,
r eposi t i on t he ser r at i ons at l ower end of t he
steeri ng
i oi nt.
STEERING JOINT
STEERING JOINT
LOWER BOLT
22 N.m
{2. 2 kgf . m, 16l bf ' f t }
(cont' d)
I t - t 5
STIFFENER PLATE
ATTACHING BOLTS
38 N.m
(3.9
kgf.m.28lbf.ftl
Steering Gearbox
Installation
(cont'dl
Center the cabl e reel by fi rst rotati ng i t cl ockwi se
unt i l i t st ops. Then r ot at e i t count er cl ockwi se
(approxi matel y
two turns) unti l the arrow mark on
the l abel poi nts strai ght up. Rei nstal l the steeri ng
wheel
(see page 17-35).
Instal l the steeri ng
j oi nt
covr wi th the cl amps and
cl rps.
7.
STEERING JOINI COVER
17- 14
9. Reconnsct the ti-rod ends to the steering knuckles,
thon ti ghtsn th castl e nut
(' 96 -' 97
model s) or nut
(' 98 -' 00
model s) to the speci fi ed torque, and i nstal l
new cotter pins.
NOTE: Before connecting the tie-rod ends, wipe off
any gr eas e
c ont ami nat i on f r om t he bal l
j oi nt
tapered section and threads.
CAUTION: Torque lhe ct3tle nut to thr lowsr torque
spoci fi cati on, thn ti ghton i t onl y tar anough to
align the 3lot with tho
pin
hob. Do not align the
nut by loosening
('96 -
'97
modcls onlyl.
TIE.ROD
COTTER PINS
R6pl ac6.
On rgassombly, b6nd
'96
-
37 model3:
cotter prn as shown.
'98
-
'00
modol3:
NUT
4a N.m
(4.5
kgf.m,
33 lbr.ftl
CAST1T NUT
,O - ilt
N'm
{4,0
-
4.8 kgf.m.
29
-
35 tbtftl
10. Installthe exhaust pipe A or TWC
(see
section 9).
Connect the shift linkage
(see
section 13 or section
14) .
Instal l the front wheel s.
After installation, perform the following checks.
. Adjust the front toe
(see
section 18).
.
Check the steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE: Turn the ri ght and l eft ti e-rods equal l y.
l l .
Component
Locati ons
I
l ndex
Power Steering:
NOTE:
. l i an i ntact ai rbag assembl y has been removed trom a scrapped vehi cl e or has been found defecti ve or damaged dur-
i ng transi t. storage or servi ce, i t shoul d be depl oyed
(see
secti on 24).
. Before removi ng the gearbox, remove the dri ver' s ai rbag assembl y and steeri ng wheel .
. After i nstal l i ng the
gearbox, checkthewheel al i gnmentand adj ust i f necessary.
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons.
precauti ons, and procedures i n the SRS
secti on {24} before
performi ng repai rs or servi ce.
STEERI NG WHEEL
page 17-35
Di sassembl y/ Feassembl y,
page 17-36
DRIVER'S AIRBAG ASSEMBLY
Removal / l nst al l at i on, see sect i on 24
STEERING GEAREOX
Rack Gui de Adi ust ment , page 17' 33
/
Removal , page 17 47
Di sassembl y,
page 17-49
Reassembl y, page 17-55
I nst al l at i on,
page 17-65
VALVE EODY UNIT
Overhaul ,
page 17 52
COLUMN
Femoval / l nst al l at i on,
page 17-37
I nspect i on,
page 17-38
CASLE REEL
Removal/lnstallation, see section 24
IGNITION SWITCH
See section 23
POWEF STEERING PUMP
Pump Bel t I nspect i on, page 11-32
Pump Bel t Adi ust menl , page 11' 32
Pump Pressure Check,
page 17 34
page 17' 40
Di sassembl y/ Reassembl y,
page 17-41
TIE.ROD END BALL JOINT
Bal l Joi nt Boot Repl acement ,
page 17-68
1, ,
17- 15
System Description
Fl ui d Fl ow Di agram
The system i s a compact rotary-val ve-type power steeri ng, connected to the steeri ng gearbox. The fl ui d pressure i s pro-
vi ded by a vane-type pump whi ch i s dri ven by the engi ne crank pul l ey. The amount of fl ui d and pressure i s regul ated by
the fl ow control val ve bui l t i nto the pump. The fl ui d pressure from the pump i s del i vered to the val ve body uni t around the
pi ni on of the steeri ng gearbox. The val ve i nsi de the val ve body uni t control s the hydraul i c pressure and changes the di rec-
ti on of the fl ow. The fl ui d then fl ows to the power cyl i nder. where rack thrust i s generated. Fl ui d returni ng from the power
cyl i nder fl ows back to the reservoi r, where the fl ui d i s
"fi l tered"
and suppl i ed to the pump agai n.
RESERVOIR
VALVE BOOY UNIT
SUB.VALVE
FLOW CONTROL VALVE STEERING GEARBOX
17- 16
)
Steeri ng
Pump
Construction
The
pump i s a vane-type i ncorporati ng a fl ow control val ve
(wi th
an i ntegrated rel i ef val ve) and i s dri ven by a POLY-V-bel t
from the crank
pul l ey. The pump features 10 vanes. Each vane performs two i ntake/di scharge operati ons for every rota-
ti on of the rotor. Thi s means that the hydraul i c fl ui d pressure pul se becomes extremel y smal l duri ng di scharge.
/
ROTOR VANE CAM RING
Operation
The bel t-dri ven
pul l ey rotates the rotor through the dri ve shaft. As the rotor rotates, the hydraul i c
pressure i s appl i ed to
the vane chamber of rhe rotor and the vanes wi l l rotate whi l e bei ng
pushed onto the i nner ci rcumference of the cam ri ng.
The i nner ci rcumference of the cam ri ng has an extended
porti on wi th respect to the center of the shaft, so the vanes
move downward i n the axi al di recti on as the rotor rotates. As a resul t of thi s rol l er movement. the i nternal vol ume of the
vane chamber wi l l change, resul ti ng i n fl ui d i ntake and di scharge
START OF FLUID INTAKE: FLUID INTAKE: FLUID MOVEMENT:
FLUID DISCHARGE:
The v anes ar e pus hed ont o
t he i nner ci r cumf er ence ol t he
cam r i ng,
l he vol ume of t he vane cham- The sucked- i n f l ui d moves
ber i ncreases so t hat f l ui d i s t oward t he di scharge
port .
sucked i n.
As t he vanes r et ur n t o t he
t hei r or i gi nal Posi t i on
on t he
i nner si de, t he vol ume of t he
vane chamber decr eases so
t he f l ui d i s di schar ged f r om
t he di scharge
port .
(cont ' d)
a - t 4 -
I I - | t
FLOW CONTROL VALVE
J
System Description
Steering Pump
(cont'dl
The fl ow control val ve and sub-val ve i n the pump per-
forms the fol l owi ng steps
@
through
@
to control the
fl ow of fl ui d, that i s to i ncrease the di scharge vol ume
when engi ne speed i s l ow, and to decrease i t when the
engi ne speed i ncreases. The assi stance thrust of the
s t eer i ng gear box c hanges i n c ompl i anc e wi t h t he
change i n the di scharge vol ume.
When the engi ne starts, fl ui d di scharged from the
di scharge port starts to fl ow through oi l passage
A,
the fi xed ori fi ce and the vari abl e ori fi ce to the steer-
i ng gearbox. When the engi ne speed i s extremel y
l ow, the return port i s cl osed by the fl ow control
Fl ui d pressure
di scharged from the di scharge port
i s appl i ed to the top of the sub-val ve, and the fl ui d
pressure
that
passed
through oil
passage
A is applied
to the bottom of the sub-valve. When this happens,
the pressure difference between the ends of oil
pas-
sage A, which is caused by the resistance oil passage
A when t he f l ui d f l ows t hr ough t he passage. i s
appl i ed to the sub-val ve, However, the
pressure
di f-
ference appl i ed to the sub-val ve. that i s the force
that
pushes
the sub-val ve down, i s too smal l to
overcome the spring force, and the variable orifice is
ful l y open when the engi ne speed i s extremel y l ow.
Because the fl ui d vol ume fl owi ng through the fi xed
ori fi ce and vari abl e ori fi ce i ncreases, a pressure
di f-
terence i s created between the ends of these ori -
fi ces, and i t i ncreases i n proporti on
to the engi ne
speed. As the fl ui d pressure
that
passed
the fi xed
ori fi ce and vari abl e ori fi ce i s di rected to the bottom
of the fl ow control val ve. a pressure
di fference i s
created between the top and bottom of the valve,
whi ch
pushes
down t he f l ow cont r ol val ve and
opens the return port. As a resul t, pan of the fl ui d
di scharged from the di scharge port feturns to the
pump sucti on port, keepi ng the di scharge vol ume
constant.
In thi s condi ti on, the sub-val ve does not move. and
the vari abl e ori fi ce stays ful l y open.
l o
t r r
t r r
l o
3
J
o
PUMP R. P. M.
To STEERING GEARBOX
SUB.VALVE
To STEEnING GEARBOX
FLOW CURVE
!rs+/f/ffih\\
o,,-i^"l^tKzYt)9
1y
ul3Yl
FLOW CONTNOL VALVE
su8-vALvE
ORIFICE
ToP
17- 18
FLOW CONTROL VALVE
t
To STEERING GEARBOX
To STEERING GEAREOx
@
The fl ui d vol ume that fl ows thorough oi l passage A
and the
pressure
dj fference appl i ed to the sub-val ve
i ncr ease i n
pr opor t i on
t o t he engi ne speed. The
sub-val ve l owers overcomi ng the spri ng force, and
i t stans to cl ose the vari abl e ori fi ce to regul ate the
di scharge vol ume, When thi s happens, the fl ui d vol -
ume fl owi ng to the steeri ng
gearbox decreases as
the engi ne speed i ncreases. At the same ti me, the
fl ow control val ve conti nues to control the fl ui d vol -
ume to the return Port,
@
As the engi ne speed i ncreases funher, the
pressure
di fference at the sub-val ve i ncreases further as wel l .
The sub-val ve then cl oses the vari abl e ori fi ce com-
pl et el y, r egul at i ng t he di schar ge vol ume f ur t her .
When t hi s happens, t he f l ui d vol ume di schar ged
from the
pump to the steeri ng
gearbox i s regul ated
and mai nt ai ned at a gi ven l evel unt i l t he engi ne
speed reaches the hi gh speed range The fl ow con-
trol val ve functi ons conti nues to control the fl ui d
vol ume to the return Port.
Pressure Relief
Pr essur e at t he di schar ge si de of t he f i xed or i f i ce i s
di rected to the bottom of the fl ow control val ve. When
the
pressure
bui l ds up, the rel i ef val ve i n the fl ow con-
trol val ve opens to rel ease the pressure at the bottom of
t he val ve. Thi s al l ows t he f l ow cont r ol val ve t o be
pushed
back by the
pressure di fference, and the fl ui d
vol ume to the
pump return
port i ncreases.
As expl ai ned above. the system keeps the
pump di s-
char ge
pr essur e
( r el i ef pr essur e) f r om exceedi ng t he
gi ven l evel by control l i ng the vol ume of the fl ui d to the
pump
rel urn
pon,
1. ,
DAMPING ORIFICE
{Docreases
excessiv
vibration in the valv6.)
17- 19
)
RELIEF VALVE {Opan)
SUB.VALVE
FLOW CONTROL VALVE
/F
ft>..\
'-/K\A/A
o'.'to"5lo'#2"n
af
11\ D7
FLOW CONTROL VALVE
System Description
Steering Gearbox
The rack-and-pi ni on type steeri ng gearbox
has a val ve body uni t i ncorporated wi th the pi ni on to control the steeri ng fl ui d
pressure.
Steeri ng fl ui d from the pump i s regul ated by a rotary val ve i n the val ve body uni t and i s sent through the cyl i n,
der l i ne to the power cyl i nder, where hydraul i c pressure i s appl i ed. The steeri ng fl ui d i n the other si de of the
power
cyl i n,
der returns through the cyl i nder l i ne and val ve body uni t to the reservoi i .
VALVE EODY UNIT
CYLINDER LINE
To RESERVOm
+-
From PUMP
-;
POWER CYLINDER
Valve Body Unit
Insi de the val ve body uni t i s the val ve, whi ch i s coaxi al wi th the pi ni on
shaft, and control s the steeri ng fl ui d pressure.
The
val ve housi ng i s connected wi th the fl ui d l i ne from the
pump,
the return l i ne to the reservoi r, and the two cyl i nder l i nes
from the respecti ve power cyl i nder. The pi ni on
shaft i s doubl e
-
structured wi th the i nput shaft connected to the
pi ni on
gear, both of whi ch are i nterconnected wi th the torsi on bar.
The pi n i nserted i n the val ve and the pi ni on shaft groove engage; thi s al l ows the pi ni on shaft to rotate together wi th the
val ve. Because of thi s constructi on, the di fference i n angl e i n the ci rcumferenti al di recti on between the i nput shaft and the
val ve becomes l arger accordi ng to the torsi onal strength of the pi ni on or steeri ng resi stance. However, maxi mum torsi on
between the shafts i s regul ated by the engaged spl i nes of the shafts at the
pi n
engagement secti on to hol d the torsi on bar
wi thi n the set val ue,
Thi s al l ows the steeri ng system to functi on as an ordi nary rack-and-pi ni on type steeri ng i f the steeri ng fl ui d i s not pressur-
i zed because of a faul ty pump,
VALVE
Difforence in angle botwoon the
input shaft and pinion shsft
PINION SHAFT
l o
INPUT SHAFT
-l
a
17-20
INPUT SHAFT
Pressure Control
Low assi st at hi gher speeds:
Whens t eer i ngr es i s t anc eI s I ow, s uc has whendr i v i ngat hi ghs peeds , or whendr i v i ngs t r ai ght ahead, t hei nput s haf t i s
near or i n the neutral
posi ti on, so there i s l i ttl e or no fi ow ro any of the
power cyl i nder ori fi ces. Most oI the feed
pressure
f r omt hepumpi s by pas s edt ot her es er v oi r . Bec aus eof t hi s , t hepr es s ur es t ay s t hes amei nbot hs i des of t hepower c y | | n-
der, resul ti ng i n l ow or no assl st
VALVE From PUMP
SECTION A-A
RETURN PASSAGE
l To RESERVOI RI
POWER CYLINDER
STEERING GEARBOX
Hi gh assi st at l ower speeds:
When steeri ng
resi stance i s hi gh. such as when dri vi ng at l ow speeds' or when turni ng the wheel wi rh the vehi cl e
s t opped, t hedi f f er enc e| nang| ec r eat edbet weent hei nput s haf t andt heVa| v eopens t hef | ui dpas s ageonones i de, and
c | os es t hef l ui dpas s ageont heot her s i de, at eac hpai r of or i f i c es ' Thef | ui dpr es s ur ei nc r eas es i nt hes i deo| t hepower
cy| i nder | edbyt he| ar ger f | ui dpassage' Thi si ncr easedpr essur epushesont her ackpi st on, a| l owi ngt hest eer i ngwhee| t o
be turned wi th l i ght effort. on the other si de of the
power cyl i nder, the return
passage opens al l owi ng the steeri ng tl ui d to
r et ur nt hr oUght hei nput s haf t t ot her es er v oi r ' Thef | ui dpas s ages t ot hepower c y | i nder aut omat i c a| | y c hangei ns | z e,
i ncreasi ng as the steeri ng resrstance i ncreases. In other words, the passages become l arger and power assi st i ncreases
when the steeri ng effort woul d normal l y be hi gh,
(for exampl e' when
parki ng or maki ng l ow speed turns)' and the
pas-
sagesbecomesma| | er andpower assi st decr easeswhent hest eer i ngef f or t wou| dnor ma| | ybe| ow, ( f or examp| e, when
dri vi ng at hi gh speeds or strai ght ahead).
FLUIO PASSAGE TO
POWER CYLINDER
/t=\
\a!-4,))
=YjJ
RESERVOIR
SECTION A-A
l '
{High
fluid
Pressure}
Troubleshooting
General Troubleshooting
Check the fol l owi ng before you
begi n:
. Has the suspensi on been modi fi ed i n a way that woul d affect steeri ng?
. Are ti re si zes, ti re vari ety and ai r pressure
correct?
. l sthe steeri ng wheel ori gi nal equi pment or equi val ent?
. l sthe powersteeri ng pump
bel t properl yadi usted?
. l s steeri ngfl ui d reservoi rfi l l edto proper
l evel ?
. l s the engi ne i dl e speed correct and steady?
Hard Steering
(Check
the powor
assist. se page
17-3o. lfthe torce is over 29 N
(3.0
kgf, 6.6lbo, Procede with this troubleshootinq.)
Abnormal
lluid pressure
{fluid
pressure
i s t oo hi gh)
Faulty valve body unit
Relief pres-
sure too low
Abnormal
Faulty llow control valve
(Repl ace
t he
pump
es an
assembly)
Chck t he f eed snd r et ur n ci r cui t l i ns ano nose
bet w6n t he gearbox
and pump
f or cl oggi ng and
dlormation.
Normal l i ne and hose
Check t he pump f l ui d pressure
(soe page 17-34).
l / easure st eady-st at e t l ui d pres-
s! re whi l e i dl i ng wi t h t he bot h
val ves t ul l y open.
It should be 1.500 kPa
(15
kgf/cmr,
213 psi )
or bel ow.
Normal
Check th flow control vslve (see page
17-42).
.
Chock the valvo lor smooth movement in the hous-
i ng.
.
Check the reliefvalve for leaks.
Check t he pump
f l ui d pressure
{see
page
17-34).
Measur e pump
r el i ef pr essur e
while idling with the pressure
con-
trol valve Iully closed.
It should be 6,400
-
7,400 kPa
(65 -
75 kgflcm,,920
-
1,070 psi)
Normal rel i sf pressure
17- 22
Go to
page
17-23
Faulty pump
assembly
I
Abnormal
Def ormed
Faul t y cyl i nder l i nes
Adi ust ment OK
Faul t y val ve body uni t
Normal
I
I
Compai r t he st eeri ng t o anot her al i ke
vehi cl e.
/
Check t he f orce requi red t o t urn
t he wheel
(see
Page
17 30i
St art t he engi ne and measure t he
f orce requi red t o t urn t he wheel
t o t he ri ght and l ef t . Di f f erence of
t he l or ce r equi r ed t o t ur n t he
wheel t o t he ri ght and t o t he I ef t
shoul d be 2. 9 N 10 3 kgf , 0. 7 l bf )
or bel ow.
Check for bent rack shaft
Check rack
gui de adi ust ment
(see
page 17-33).
(cont' d)
17
-23
1, ,
Troubleshooting
General Troubleshooting (cont'd)
Assi st (excessi vel y
l i ght st eeri ng) at
hi gh speed.
Shock or vi brat i on when wheel i s
t urned t o {ul l l ock.
St eer i ng wheel wi l l not r et ur n
smoot hl y.
lf the problem
is not corrected by
adi ust i ng t he rack gui de,
adj ust
t he f r ont wheel al i gnment l see
sect i on 181.
Check t he rack gui de f or proper
adi ust ment (see page
17 33).
Check t he rack gui de f or proper
adj ust ment (see page
17-33).
Rack gui de
i s adj ust ed properl y.
l f t he probl em
i s not correct ed by
adj ust i ng t he rack gui de,
repl ace
t he gearbox.
Check t he bel t f or sl i ppage and
aol ust as necessar y
{ see
page
11 32).
A and B cyl i nder l i nes ar e nor -
mal , check wheel al i gnment (see
sect i on 18).
Wheel al i gnment i s abnor mal ,
adjust as needed.
Wheel al i gnment i s normal .
Check t he st eeri ng wheel opera-
t i on and power
assi st check {see
page l T-30).
I t t he measurement s are out of
speci f i cat i ons, adj ust t he r a ck
gui de.
l f t he probl em
i s not correct ed by
adj ust i ng t he rack gui de, repl ace
t he gearbox.
17- 24
/
Uneven or rough st eeri ng
Steering wheel kicks back
duri ng wi de t ! rns.
ll,
)
Adjust the rac* guide (see page 17-3).
l f t he
probl em i s not correct ed bY
adj ust i ng t he rack gui de, repl ace
t he
gearbox.
Adiust the belt tension. Feplace the
belt, il necessary
(see
Page
17 32).
l f t he engi ne st al l s when t he wheel
i s t urned whi l e car i s st opped or
movi ng at l ow speed, adj ust t he
i dl e sped
(see
sect i on 11)
l dl e speed l ow or errat i c.
Check
power sleering fluid level lf
the level is excessively low, check
lor leaks in the system. Add lluid
to the specified level.
Ai r i n reservoi r, or check Power
st eeri ng I l ui d l evel .
l f l t ui d l evel i s OK, check O-ri ngs
and seal s on bot h ends of t he
pump i nl et hose, and t he P/ S
pump housi ng mat i ng surf aces
and t he
pumP shaf t oi l seal f or
suct i on l eaks. RePl ace
Part s
as
nocessary.
Adjust the belt tension
(see
Page
17 32)or repl ace bel t .
Pump bel t sl i PPi ng on
PLr l l eY
(pump st ops moment ari l Y)
Check if pump press{rre is normal
and the
gauge needle travel is 500
kPa
( 5
kgl / cm?, 7l
Psi )
or l ess.
Chock the flow control valve if the
needle travel exceeds 500 kPa
(5
kgflcm', 71
Psi).
l{ the flow control
valve is normal, replace the
PumP
as an assemoly.
Install the power steering
pressure
gauge, Close the
Pressure
contrcl
valve fully and m6ssure the
PumP
pressure {se
page 17-34}.
17
-25,
Troubleshooting
Noise and Vibration
NOTE; Pump noi se i n fi rst 2
-
3 mi nutes after starti ng i n col d weather i s normal .
Hummi ng
Rat t l e or chat t eri ng
Hummi ng due t o pul sat i on
of f l ui d i s normal ,
part i cul arl v
when t he wheel i s
turned with the vehicle stooDed.
lf equipped with automatic trans-
mi ssi on, t he hum coul d be t he
torque conveater or
pump
noise.
Confirm by temporarily removing
the pump
belt.
Hi gh-pressure l i ne t ouchi ng t he
frame.
Reposition the line.
Loose st eeri ng shaf t connect or,
t i e-rod. or bal l j oi nt .
Check and t i ght en, or r epl ace
paats
as necessary.
Col umn shaf t wobbl i ng. Replace the column assembly.
Check t he rack gui de t or proper
adjustment (see page 17,33).
Adiusi, if necessry.
Rat t l i ng sound and f eel i ng when t urni ng t he st eeri ng wheel raght and l ef t wi t h t he
engi ne OFF i s normal .
Pump noi se, t hough not l oud. t rom t he val ve body uni t can be heard whon t urn-
i ng t he st eeri ng wheel ri ght or l ef t . Thi s i s normat .
CAUTION: When impsting, do not hold the steering wheet a[ the way to
the right or the left.
17-26
)
Pump noase
Grat i ng noi se
f rom
pump
Pump
gear noi s
Check t he t l ui d l evel .
l f l ow, f i l l t he r eser voi r t o t he
proper level, and check lor leaks.
Tighten or replace as nocessary.
Cavitation caused bY air bubbles
i n t he f l ui d.
Check lor a crushed suction hose
or a l oose hose cl amp al l owi ng
ai r i nt o t he suct i on si de of t he
sy$em.
Tighton or roplace as necossary.
NOTE: Pump noi se uP t o 2
-
3
mi nut es al t er st ar t i ng i n col d
weat her i s normal
Compare
pumP noise at operating
temperature to simular vehicle.
l f pump noi s i s abnormal l Y l oud,
remove and inspect the
PUmP
for
w6ar and damage
(see
Page
17-
41) .
l z /
Rattle or chattgring
17- 27
Ti ght en or repl ace t he
Pul l ey.
l f shat t i s l oose, r ePl ace t he
pump.
t r
Troubl eshooti ng
Fl ui d Leaks
Check the gearbox
assembl y for oi l l eaks careful l y. Oi l can l eak out of vari ous poi nts.
dependi ng on l ocati on of the
faul ty oi l seal s/seal ri ngs. Check the fol l owi ng before removi ng the gearbox
from the frame_
St eeri ng Gearbox
Leaki ng f rom t he oi l seal on t he
t op of t he val ve housi ng.
Repl ace t he val ve oi l seal f rom
t he val ve housi ng.
Leaki ng f rom cyl i nder end i nt o
left tie rod boot.
Repl ace t he val ve oi l seal t rom
t he pi ni on
shaf t .
Repl ace t he cyl i nder end seal on
t he gear housi ng si de.
Leaki ng l rom cyl i nder end i nt o
right tie-rod boot.
Repl ace t he cyl i nder end seal on
the cylinder end side.
Leaki ng l rom t he shaf t upper end
sect ron or pi n
engagement sec,
t i on ol t he pi ni on
shaf t .
Repl ace t he val ve body uni t .
Ti ght en t he connect or. l f i t ' s st i l l
l eaki nO, repl ace t he I i ne, cyl i nder
or val ve housi ng uni t .
Leaki ng f rom cyl i nder l i ne A or B
connections {at tlare nut}.
Leaki ng caused by a damaged
cyl i nde. l i ne A or B.
Repl ace cvl j nder l i ne A or B.
Leaki ng f rom f eed l i ne and ret urn
l i ne
i oi nt
f i t t i ng on t he val ve body
uni t
(at
f l are nut ).
Tighten the connector. ll it's still
l eaki ng, repl ace t he l i ne, , oi nt f i t ,
t i ng or val v6 housi ng.
17- 2a
Pump out l et l i ne
(hi gh pressure,
/
Pump i nl et I i ne
(l ow-pressure)
Repl ace t he housi ng O-ri ngs
l f t he housi ng st i l l l eaks, rePl ace
t he
pumP.
Reservoir is overfilled
Pul l of f t he hose and drai n t he
reservoi t t o t he
Proper
l evel .
Ai r l eak i n suct i on si de of t he sys'
t em
(reservoi r, i nl et hose, t ront
pump seal ).
Tighten the fifting. lI it's still leak-
ing, replace the O-ring or feed line. Leaki ng at t he t hr eaded f i t t i ng
Leaki ng at t he swagged
j oi nt .
Leaking because ol damage, dete_
ri orat i on, or i mProPer assembl Y.
Reolace or rePair as necessarY.
t J
17-29
Steering Operation
Pl ace the front wheel s i n the strai ght ahead posi ti on,
and measure the di stance the steeri ng wheel can be
turned wi thout movi ng the front wheel s.
ROTATIONAL PLAY: 0
-
10 mm l0
-
0.39 inl
l f the pl ay
exceeds the servi ce l i mi t. perform
rack gui de
adj ustment
(see page
17-33).
l f the
pl ay
i s sti l l excessi ve after rack gui de
adj ustment.
i nspect the steeri ng l i nkage and gearbox
as descri bed
on the nel(t pag.
ROTATIONAL PLAY
17-30
Power Assist Gheck with
Vehicle Parked
1. Check the power
steeri ng fl ui d l evel
(see page
17-
33) and pump
bel t tensi on
(see page 17-32).
2. Start the engi ne, al l ow i t to i dl e. and turn the steer-
i ng wheel from l ock-tol ock several ti mes to warm
up the fl ui d.
3. Attach a spring scale to the steering wheel. With the
engi ne i dl i ng and the vehi cl e on a cl ean, dry fl oor,
pul l
the scal e as shown and read i t as soon as the
ti res begi n to turn.
The scal e shoul d read no more than 29 N
(3.0
kgf.
6.6 l bf). l f i t reads more, check the
gearbox
and
pump,
D 0
I
Steeri ng
Li nkage and Gearbox
TIE-ROD END BALL JOINT
I nspect f or f aul t y movement
and damage.
STEERING COLUMN
I nspect f or l oose col umn
mount i ng bol t s and nut s
BOOT
Inspect damage and det eri orat aon
STEERING GEARBOX
l nspect f or l oose mount i ng bol t s.
GEARBOX MOUNTI NG CUSHI ONS
I nspect f or det eri orat i on
STEERING JOINTS
Check f or l oose
j oi nt bol t s.
l . /
TIE-ROD LOCKNUT
f or l oose l ocknut
BALL JOINT BOOT
I nspect f or damage and det eri orat aon'
See
page 17-68l or repl acement .
SHAFT GROMMET
I nspect f or damage and det er i or at aon.
l r z
17-31
Pump Bel t
NOTE: When usi ng a new bel t, fi rst adj ust the defl ecti on
or tensi on to the val ues for the new bel t, then readj ust
the defl ecti on or tensi on to the val ues for the used bel t
after runni ng engi ne for fi ve mi nutes.
Inspection
Attach the speci al tool to the bel t and measure the ten-
si on of the bel t.
Tension:
'99
-'00
modls: B1642 Engin. Type only
Used Bsh: 390
-
540 N
lao
-
55 kgt.88
-
120 tbf)
New Belt: 740
-
880 N
{75
-
90 kgf, 170
-
200 tbt}
'96
-
'00
models: Other Engine Types
Used Beh: 340
-
490 N
(35 -
50 kgf, 77
-
ilO tbfl
New Belt: 640
-
780 N
165
-
80 ksf, 1&
-
176 tbf)
NOTE:
. l f there are cracks or any damage evi dent on the bel t,
reDlace it with a new one.
. Fol l ow the manufacturer' s i nstructi ons for the tensi on
gauge.
BELT TENSION GAUGE
07JGG
_
001010A
Inspect the pump
bel t for cracks or any damage.
Replace the belt with a new one if necessary.
Measuremont without Beh Tension Gauga:
Appl y a force of 98 N
(10
kgt,22 l bfl and measure the
defl ecti on between the power
steeri ng pump
and the
crankshaft pul l eys.
Dsflectior:
'99
-'00
model3: 816A2 Engine Typ onty
Used Beh: 7.5
-
11.0 mm 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
-
14.0 mm
(0.ial -
0.59 inl
Now Beh: 7.5
-
10.0 mm
(0.30 -
0.39 i nl
POWER STEERING PULUY
CRANKSHAFT PULLEY
17-32
Adiustment
1. Loosen the power
steeri ng pump
mounti ng bol ts.
2. Adj ust the bel t tensi on.
'99
-
'00
modls: 816A2 Engin Typo only
. Turn the adj usti ng bol t by hand to
get
the proper
bel t
tensi on, then reti ghten the mounti ng bol ts,
ADJUSNNG BOLT
PUMP MOUNNNG BOLTS
24 N.m (2.4
kgf'm, 17 tbtftl
POWER STEERING
PUMP
'96
-'00
modek: Othcr Engins Typos
.
Pry power
steering pump
away from the engine with
a wrench to get
the proper
belt tension, then retight-
en the mounti ng bol ts.
PUMP MOUNTING BOLT
24 N.m (2,4
kgf.m, 17 lbl.ftl
PUMP MOUNTING BOLT
24 N.m {2.a kgt m, 17 tbtftl
Start the engi ne and turn the steeri ng wheel from
l ock-to-l ock several ti mes, then stop the engi ne and
recheck the deflection of the belt,
I
Rack Gui de Adj ustment
NOTE: Perform rack
gui de adj ustment wi th the wheel s
i n the strai ght ahead
Posi ti on.
1. Loosen the rack gui de screw l ocknut wi th the
ci al t ool .
'96
-
'97
models:
Loosen the rack
gui de screw
'98
-
'00
models:
Remove the rack gui de screw and remove the ol d
seal ant off of the threaded secti on.
Appl y new seal ant al l around the threads. Loosel y
i nstal l the rack
gui de screw
Ti ghten the rack
gui de screw to 25 N' m
(2.5
kgf' m.
18 l bf.ft), then l oosen i t.
Reti ghten the rack gui de screw to 3 9 N' m
(0.4
kgi m,
2.9 lbf.ft), then back it off to specified angle.
Specified Return Angle: 20" max.
Ti ght en t he l ocknut whi l e hol di ng t he r ack gui de
screw.
Check for ti ght or l oose steeri ng through the com-
pl ete turni ng travel .
Perform fol l owi ng i nsPecti ons:
. Steeri ng operati on
(see page 17-30).
. Power assi st wi th vehi cl e parked.
4.
LOCKNUT WRENCH, 40 mm
l r
17-33
Fl ui d Repl acement
Check the reservoi r at regul ar i nterval s, and add fl ui d as
necessary.
CAUTION: Always us Genuine Honda Power Stearing
Fl ui d-V or S. Usi ng any other type of power stori ng
t l ui d or aut omat i c t r ansmi ssi on l l ui d can cause
increased wear and
poor
steering in cold weathor.
SYSTEM CAPACITY:
0.85 l i ter 10.90 US'
qt,0.75 l mp' qt)
at disassembly
RESERVOIR CAPACITY:
0.4 liter
(0.42
US.
qt, 0.35 lmP.qt)
LEVEL LINE
LOWER LEVEL LINE
1. Rai se the reservoi r, then di sconnect the return nose.
2. Connect a hose of sui tabl e di ameter to the di scon-
nected return hose, and
put the hose end i n a sui t-
abl e contai ner.
CAUTION: Take care not to spi l l tho fl ui d on the
body and
parts. Wipe off any spilld fluid at oncs'
3. Start the engi ne, l et i t run at i dl e, and turn the steer-
i ng wheel from l ock-to-l ock several ti mes When
f l ui d st ops r unni ng out of t he hose, shut of f t he
engi ne, Di scard the fl ui d.
4. Rei nstal l the return hose on the reservoi r'
5. Fi l l the reservoi r to the upper l evel l i ne.
6. Start the engi ne and run i t at fast i dl e, then turn the
steeri ng trom l ock-to-l ock several ti mes to bl eed ai r
trom the system.
7. Recheck the fl ui d l evel and add some i t necessary.
CAUTION: Do not fi l l the reservoi r beYond the
upper lvel line.
HOSE
lnspection and Adjustment
Pump Pressure Check
Chec k t he f l ui d
pr es s ur e
as f ol l ows t o det er mi ne
whether the troubl e i s i n the pump
or
gearbox.
NOTE: Fi rst check the power
steeri ng fl ui d l evel and
pump
bel t tensi on.
CAUTION: Disconnect the high pr$sure
hos with care
so as not lo spill the power
sieering tluid on tha frame
and other
parts.
1. Di sconnect the outl et l i ne from the Dumo outl et fi t-
ti ng, then i nstal l the P/S
j oi nt
adaptor
(pump)
on the
Dumo outl et.
2. Connect the P/S
j oi nt
adaptor
(hose)
to the
power
steeri ng pressure gauge,
then connect the outl et
hose to the adaptor.
3. Instal l the power steeri ng pressure gauge to the P/S
j oi nt
adaptor
(pump)
as shown.
ourlEr HosE FnrNo ,t"ll lrilu"ott
P/S JOINT ADAPTOB IHOSEI
07RAK
-
S0i10l2r
ol
07RAK- 50{{)120
P/S PRESSURE GAUGE
07406
-
001000A
or
07406
-
0010001
4. Open the shut-off val ve ful l y.
5. Open the pressure control val ve ful l y.
17-34
(Pa.t
of tooll
11 N. m
11.1 kgt m, 8 lbf.ftl
PRESSURE
CONTROL VALVE
SHUT.OFF
VALVE
PUMP OUTLET
FITTING
6 x 1.0 mm BOLT
lPart of tool)
11 N. m
11. 1 kgf m, 8 l bt f t l
7.
Start the engi ne and l et i t i dl e.
Turn the steeri ng wheel from l ock-to-l ock several
ti mes to warm the fl ui d to operati ng temperature.
Measure steady-state fl ui d pressure
whi l e i dl i ng. If
t he pump i s i n good condi t i on, t he gauge
shoul d
read l ess than 1500 kPa
(15
kgf/cmr, 213 psi ).
l f i t reads hi gh, check the outl et l i ne or val ve body
uni t
(see
General Troubl eshooti ng 17-22).
Cl ose t he
pr essur e
cont r ol val ve, t hen cl ose t he
shut-off val ve gradual l y
unti l the pressure gauge
needl e i s stabl e. Read the oressure.
l mmedi atel y open the
pressure
control val ve ful l y.
GAUTION: Do not keep lhe prossure control valve
closd more then 5 soconds or the pump could be
damagod by over-heating.
l f the pump i s i n good
condi ti on, the gauge
shoul d
read at least 6,400
-
7,400 kPa
(65 -
75 kgflcm,, 920
-
1,070 psi ).
A l ow readi ng means pump
output i s too
l ow for ful l assi st. Repai r or repl ace the pump,
9.
P/S PBESSURE GAUGE
07{16
-@1@OA
oi
SI{UT.OFF VALVE
Steering
Wheel
l , /
Removal
SRS component s ar e l ocat ed i n t hi s ar ea Revi ew t he
SRS component l ocati ons,
precauti ons, and
procedures
i n the SRS secti on
(24)
before
performi ng repai rs or ser-
vi ce.
NOTE: Bef or e r emovi ng t he st eer i ng wheel . al i gn t he
front wheel s strai ght ahead.
1. Remove t he dr i ver ' s ai r bag assembl y f r om t he
steeri ng wheel
(see
secti on 24)
2. Di sconnect the horn connector and crui se control
swi tches connector.
CRUISE
SWITCHES CONNECTOR
3. Remove the steeri ng wheel nut
STEERING WHEEL NUT
Repl ace.
Remove the steeri ng wheel by rocki ng i t sl i ghtl y from
si de-to-si de as
you pul l steadi l y wi th both hands.
ag N.m {5.0
kgt rn, 36lbfft)
1 . ,
17-35
l nstal l ati on
CAUTION: Do not tap on the steering wheel or steering
column shaft when installing the stsering wheel.
NOTE: Bef or e i nst al l i ng t he st eer i ng wheel , al i gn t he
front wheel s strai ght ahead.
1. Bef or e i nst al l i ng t he st eer i ng wheel , cent er t he
cabl e reel , Do thi s by fi rst rotati ng the cabl e reel
cl ockwi se unti l i t stops. Then rotate i t countercl ock-
wi se approxi matel y two turns The arrow mark on
the cabl e reel l abel shoul d
poi nts strai ght up.
Instal l the steeri ng wheel wi th the steeri ng wheel
nut.
NOTE: Be sure the steeri ng wheel shaft engages
the cabl e reel and cancel i ng sl eeve.
Attach the crui se control swi tches connector i o the
steeri ng wheel cl i P,
Connect the horn connector.
I nst al l t he dr i ver ' s ai r bag assembl y, and conf i r m
proper system operati on
(see
secti on 24).
Check t he hor n and cr ui se cont r ol swi t ches f or
proper operatrons.
CAELE REEL
Steering Wheel
STEERING WHEEL
*@*&*W
@,
17-36
Steeri ng Col umn
I
SRS component s ar e l ocat ed i n t hi s ar ea. Revi ew t he
SRS component l ocati ons, precauti ons, and procecl ures
i n t he SRS sect r on
( 24)
bef or e per t or mi ng r epai r s or ser -
vi ce.
NOTE: Bef or e r emovi ng t he st eer i ng col umn f or SRS,
remove the dri ver' s ai rbag assembl y and cabl e reel l see
sect i on 24) .
1. Remove t he st eer i ng wheel
( see page 17 35) .
2. Remove t he dr i ver ' s dashboar d l ower cover and
dri ver' s knee bol ster
(see
secti on 20).
3. Remove the combi nati on swi tch assembl y from the
st eer i ng col umn sha{ t by di sconnect i ng t he connec-
tors.
4. Di sconnect the i gni ti on swi tch connectors.
5. Remove t he st eer i ng
j oi nt
cover .
6. Bemove t he st eer i ng
j oi nt
bol l s.
7. Di sconnect t he st eer i ng
i oi nt
by movi ng t he
j oi nt
toward the col umn, and remove i t from the col umn
shaft.
8. Remov e t he s t eer i ng c ol umn by r emov i ng t he
at t achi ng nut s and bol t .
UPPER
RETAINING COLLAB
NOTE: Take care not t o l et t he
ret ai ni ng col l ar f al l out of
posi t i on duri ng i nst al l at i on.
STEERI NG JOI NT BOLTS
22 N. m {2. 2 kgf . m, 16l bt f t }
9. Instal l ati on i s the reverse of the removal procedure
NOTE:
. Make sure the steeri ng
j oi nt
i s connected as fol l ows:
a. Insert the upper end of the steeri ng
i oi nt
onto the
steeri ng shaft
(l i ne
up the bol t hol e wi th the fl at on
the shai t), and l oosel y i nstal l the upper
j oi nt
bol t.
b. Sl i p t he l ower end of t he st eer i ng
j oi nt
ont o t he
pi ni on shaft
(l i ne
up the bol t hol e wi th the groove
ar ound t he shaf t ) , and l oosel y i nst al l t he l ower
j oi nt
bol t.
Be sure that the l owei
j oi nt
bol t i s securel y i n the
groove i n the pi ni on shaft.
c. Pul l on t he st eer i ng
j oi nt
t o make sur e t hat t he
steeri ng
j oi nt
j s
ful l y seated. Then ti ghten the
i oi nt
bol t s.
. 8e sure the wi res are not caught or pi nched by any
parts when i nstal l i ng the col umn
. Make sure the wi re harness i s routed and fastened
properl y.
. Make sure the connectors are
properl y connected.
STEERING COLUMN
COMBINATION SWITCH
ASSEMBLY
FLANGE NUT
13 N. m {1. 3 kgl . m. 9 l bf f t )
COLUMN COVER
FLANGE BOLTS
22Nm12. 2kgl ' m,
16 tbt.tr)
UPPER JOINT BOLT
Bol t musl l i ne up
on shaf t .
Groove.
LOWER JOINT BOLT
8oh must l i ne up wrt h
groove around on shaf t .
CLIP
J
JOINT COVER
17-37
Steeri ng Col umn
Inspection
NOTE: The ti l t steeri ng col umn type i s shown; the con-
vent i onal st eer i ng col umn i s si mi l ar except f or t he t i l t
mechant sm.
Check the steeri ng col umn bal l beari ng and the steer-
i ng
j oi nt
beari ngs for pl ay and proper
movement. l f
there i s noi se or i f there i s excessi ve pl ay,
repl ace the
steeri ng col umn as an assembl y.
Check the retai ni ng col l ar for damage. l f i t i s dam-
aged, repl ace the retai ni ng col l ar.
Check the absorbi ng pl ates,
absorbi ng pl ate
and sl i di ng capsul es for di stoni on or breakage.
Repl ace the steeri ng col umn as an assembl y
are di storted or broken.
COLUMN BALL
ABSORBING PLATE GUIDES
gui des
i f they
SLIDING
BEARINGS
TILT LOCK BOLT
Ti ght en t he l ock bol t wi t h
t he t i l t l ever rai sed.
This part is attachod
to the column bracket
wi t h t he
pl ast i c i nj ect i ons.
1 . Move the ti l t l ever from the l oose
posi ti on
to l ock
posi ti on
3 to 5 ti mes; then measure the ti l t l ever
prel oad l 0 mm {0.4 i n) from the end ofthe ti l t l ever.
Preload: 70
-
90 N
(7 -
9 kgf. 15
-
20 lbf)
l f t he measur ement i s out of t he speci f i cat i on,
adj ust the pfel oad
usi ng the fol l owi ng procedures.
a. Loosen the ti l t l ever, and set the steeri ng col umn
i n the neutral posi ti on.
b. Remove the 6 mm l ock bol t and remove the stop.
c. Adj ust the prel oad by turni ng the ti l t l ock bol t l eft
or fl gnr.
d. Pul l up the ti l t l ever to the uppermost posi ti on and
i nstal l the stop. Check the prel oad
agai n. l f the
measurement i s sti l l out of speci fi cati on, repeat
the above procedures
"a"
through
"c"
to adj ust.
CAUTION: Be caretul not to l oosen tho ti l t l ever
when i nstal l i ng the stop or ti ghteni ng the 6 mm
lock bolt.
1 7 3 a
10 mm
(0. 4
i nl
9. 8 N. m
(1. 0 kgl . m, 7 l bf . f t )
Power Steering Hoses, Lines
Fl ui d Leakage Inspecti on
HOSES and LINES
. I nspect hoses f or damage, l eaks, i nt er f er ence or
twi sti ng.
. Inspect tl ui d l i nes for damage, rusti ng and l eakage.
. Inspect for l eaks at hose and l i ne
j oi nts
and connec-
ti ons.
POWER STEERING swtTcH
12 N. m {1. 2 kgt . m, 9l bt . f t }
CYLINDER HOUSING-to.CYLINDER LINES
28 N.m
(2.7 kgf.m, 20 lbf.ft)
VALVE BODY UNIT-to-CYLINDER LINES
' 17
N. m {1. 7
12 tbl.ftl
VALVE BODY UNIT-Io-FEED/RETURN LINES
Feed l i ne: 14 x
' 1. 5
mm l l are 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. 7 kgf . m, 20 l bt f t )
HOSE CLAMP:
. Posi ti on the hose cl amps at the
poi nts i ndi cated
(b)
i n
the drawi ng above.
. Sl i de the hose over the l i ne unti l i t contacts the stop.
8()07
Check f or l eaks.
OUTLET HOSE
11 N. m
GAR8OX and VALVE BODY UNIT
Check for l eaks at the mati ng surface
and fl are nut connecti ons,
tbt
(Doubl e
Ri ng Typei
CAUTION: Check all clamps for deterioration or delor-
mation; replace with the clamps new ones il necessary.
( 1. 1
kgf . m, 8
PUMP ASSEMBLY
Check f or l eaks at t he pump
seal , i nl et and out l et f i f t i ngs.
Replacement
NOTE:
. Connect each hose to the correspondi ng
pi pe securel y
unti l i t contacts the stop on the l i ne. Instal l the cl amp
or adi ustabl e cl amp at the speci fi ed di stance from the
hose end as shown.
. Add the power steeri ng fl ui d to the speci fi ed l evel on
the reservoi r and check for l eaks.
ADJUSTABLE HOSE CLAMP:
. Posi t i on t he adi ust abl e hose cl amps at t he poi nt s
i ndi cated
(a)
i n the drawi ng above.
. Sl i de the hose over the l i ne unti l i t contacts the stop.
2. 5
-
5. 5 mm
{0. 01
-
0. 22 i n)
2.0
-
4.0 mm
(0. 08 -
0. 16 i n)
2. 5
-
5. 5 mm
(0. 01-
0. 22 i n) 1 . ,
17-39
Power Steering Pump
NOTE: Eefore di sconnecti ng the hoses from the
pump,
Dl ace a sui tabl e contai ner under the vehi cl e.
1. Remove the bel t by l ooseni ng the pump mounti ng
bol t s and adj ust i ng bol t
( ' 99 - ' 00
model s: 81642
Engi ne Type onl y).
OUTLET LINE 11 N. m {1. 1 kgf ' m,
8
L
PUMP MOUNTING BOLT
24 N.m
(2.4
kgl.m, 17 lbf ft)
2. Cover the Ay' C compressor wi th several shop towel s
to
protect i t from spi l l ed power steeri ng fl ui d.
3. Di sconnect the i nl et hose and the outl et l i ne from
the pump, and pl ug them.
NOTE: Take care not to spi l l the fl ui d on the body
or parts, Wi pe off any spi l l ed fl ui d at once.
4. Remove t he pump mount i ng bol t s and adj ust i ng
bol t
( ' 99 - ' 00
model s: 816A2 Engi ne Type onl y) ,
then remove the
pump.
NOTE:
. Do not turn the steeri ng wheel wi th the
pump
removeo.
. Wrap the openi ng of the pump wi th a pi ece of
tape to prevent forei gn materi al from enteri ng
t he pump.
17-40
1.
8.
Connect the i nl et hose and the outl et l i ne. Ti qhten
the pump fi tti ngs securel y.
Loosel y i nstal l the pump i n the
pump bracket wi th
mounti ng bol ts and adj usti ng bol t
(' 99
-' 00
model s:
81642 Engi ne Type onl y).
Instal l the pump bel t.
CAUTION:
. Make sure that the power steering belt is prop-
orly positioned on the
pulleys.
. Do not get power stoering tluid or
grease in the
power
steering bsh or pulley faces. Clean off any
fluid or grease before installrtion.
Adj ust the pump bel t
(see page 17-32).
Fi l l the reservoi r to the upper l evel l i ne
(see page
Di sassembl y
CAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly.
NOTE:
. Ctean the di sassembl ed
parts wi th a sol vent, and dry them wi th compressed ai r. Do not di p the rubber parts i n a sol -
vent.
. Al wavs repl ace the O-ri ngs and rubber seal s wi th new ones before assembl y.
. Appl y recommended
power steeri ng fl ui d to the
parts i ndi cated i n the assembl y
procedures'
. Do not al l ow dust, di rt, or other forei gn materi al s to enter the
power steeri ng system.
. Repl ace the
pump as an assembl y i fthe parts i ndi cated wi th asteri sk
(*)
are worn or damaged'
FLANGE BOLTS
20 N.m {2.0 kgf.m,
14 rbf ft)
5 mm ROLLER
4. 5 mm ROLLER
*OUTER
SIOE PLATE
*SUB-VALVE
.PUMP
NOTOR
}SIDE
PLATE
l , /
SNAP RING
13 x 1. 9 mm O-RI NG
Repl ace.
15. 2 x 2. 4 mm O-RI NG
Repl ace.
I NLET JOI NT
51 x 2. 4 mm O-RI NG
Repl ace.
FLANGE BOLTS
11 N m 11. 1 kgf . m,
8 rbf.ftl
PUMP SEAL
Repl ace.
PUMP SEAL SPACR
.PUMP
DRIVE SHAFT
BALL BEARING
l nspect i on and RePl acement ,
see page 17-43
10 mm CIRCLIP
*FLOW
CONTROI- VALVE
I nspect i on and Overhaul ,
se[
pase tt.tz g
4 --{;'rX!;'
seatuc/
$
mm O-RI NG
PULLEY NUT
6il N.m {6.5 kgf.m,
47 tbf.frl
FI-OW CONTROL VALV CAP
49 N.m {5.0 kgt m,
36 rb{.ft)
(cont' d)
17-41
J
Power Steering Pump
Disassembly
(cont'dl
2.
' t .
Drai n the fl ui d from the pump.
Hol d the steeri ng
pump i n a vi se wi th soft
j aws,
hol d the pul l ey wi th the speci al tool , and remove
the
pul l ey
nut and
pul l ey.
CAUTION: Be careful not to damage the
pump
housing with the
iaws
of the vise and extension bar.
UNIVERSAL HOLDER
Loosen the flow control valve cap with a hex wrench
and remove i t.
4. Remove the O-ri ng, fl ow control val ve and spri ng.
5. Remove the i nl et
j oi nt
and O-ri ng.
6. Remove the pump cover and pump cover seal .
7. Remove the outer si de
pl ate, pump
cam ri ng, pump
rotor, pump vanes, si de pl ate and O-ri ngs.
8. Remove the snap ri ng, then remove the sub-val ve
from the pump housi ng.
9. Remove the ci rcl i p, then remove the pump dri ve
shaft by tappi ng the shaft end wi th the pl asti c ham-
mer .
10. Remove the pump seal spacer and pump seal .
17- 42
Inspection
Flow Control Valve:
1. Check the tl ow control val ve for wear. burrs, and
other damage to the edges of the grooves i n the
vatve,
FLOW
CONTROL VALVE
Check for
damage to edges.
Inspect the bore the flow control valve for scratches
or wear.
Sl i p the val ve back i n the pump, and check that i t
moves in and out smoothly.
l f OK, go on step 4; i f not, repl ace the pump as an
assembl y. The fl ow control val ve i s not avai l abl e
separately.
Attach a hose to the end of the valve as shown.
FLOW CONTROL VALVE TIOSE
4.
I
5, Submerge the val ve i n a contai ner of
power steer-
i ng fl ui d or sol vent. and bl ow i n the hose. l f ai r bub-
bl es l eak t hr ough t he val ve at l ess t han 98 kPa
(1.0
kgf/cm' , 14.2 psi ), repai r i t as fol l ows.
, AIR PRESSURE
?
i-- POWER STEERTNG
FLUID or SOLVENT
Hol d the bottom end of the val ve wi th a open end
wrench.
Unscrew the seat i n the top end of the val ve. and
remove any shi ms, the rel i ef check bal l . rel i ef val ve
and rel i ef val ve spri ng.
7.
l . /
RELIEF CHECK BALL
1 . ,
SEAT
9 N.m
{0.9 kgf'm, 6.5 lbt'ftl
RELIEF VALVE
SPRING
Cl amp t hi s end i n
a open end wrench,
8. Cl ean al l the
parts i n sol vent, dry them off, then
reassemble and retest the valve. lf the flow control
val ve tests OK, rei nstal l i t i n the
pump. l f the fl ow
control val ve sti l l l eaks ai r, repl ace the
pump as an
assembl y. The fl ow control val ve i s not avai l abl e
separatel Y.
NOTE: 11 necessary, rel i ef pressure i s adj usted at
the factorv by addi ng shi ms under the check bal l
seat. l f you found shi ms i n your val ve, be sure you
rei nstal l as many as
You
took out.
RELIEF VALVE
{W-*"'
FLOW CONTROL VALVE
17-43
Ball Bearing:
1. Inspect the bal l beari ng by rotati ng the outer race
sl owl y. l f any
pl ay or roughness i s fel t, repl ace the
bal l beari ng.
Remove and di scard the bal l beari ng usi ng a
press
as snown.
Instal l the new bal l beari ng usi ng a press as shown.
Ball Boaring Rsplaccmont:
l nst al l wi t h t he
r ed shi el ded si de
f aci ng down.
NOTE: Support t he i nner race
wi t h t he t ool securel y.
BALL BEARING
Prcrt
Power Steering Pump
Reassembly
1 . Al i gn the
pi n of the sub-val ve wi th the oi l
passage
i n pump housi ng. and push down the sub-val ve.
Instal l the snap ri ng properl y.
OIL PASSAGE
Al i gn t he pi n of
t he oi l passage.
PUMP HOUSING
SNAP RING
Instal l the new pump seal i n the pump housi ng by
hand, then i nstal l the pump seal spacer.
NOTE: Insert the pump seal wi th i ts grooved si de
faci ng i n.
Posi ti on the pump dri ve shaft i n the pump housi ng,
then dri ve i t i n usi ng a speci al tool as shown.
Instal l the 40 mm ci rcl i p wi th i ts radi used si de fac-
i ng out,
ATTACHMENT, 30 mm
BALL BEARING
40 mm CIRCLIP
d
gf'uMP
oRrvE sHAFr
/ffi\
f.\'vj
H
PUMP SEAL SPACER
n , /
/:K
/ZA\.--
PUMP SEAL
V
Reptace.
17
-44
ROLl.ERS
Coat the
pump
cover seal and the cover bushi ng
wi th the power steeri ng fl ui d, then i nstal l the pump
cover seal i nto the groove i n the pump cover.
l nstal l the outer si de ol ate over the two rol l ers.
ROL1IR
OUTER SIDE PLATE
4.5 mm ROLLER
5 mm ROLLER
PUMP COVER
BUSHING
Set the pump cam ri ng over the two rol l ers wi th the
" o "
mark on the cam ri ng upward.
7.
ROI,IIR SET HO'"ES
PUMP CAM RING
I
8.
9.
Assembl e
pump rotor to the pump cover wi th the
" " "
marks on the rotor faci ng down.
Set the 10 vanes i n the grooves i n the rotor.
NOTE: Be sure that the round ends ot the vanes are
i n contact wi th the sl i di ng surface of the cam ri ng.
Coat t he O- r i ng wi t h power st eer i ng f l ui d, and
i nstal l i t i nto the grooves i n the si de pl ate.
Instal l the si de
pl ate
on the cam ri ng by al i gni ng the
rol l er set hol es i n the si de pl ate wi th the rol l ers.
mm O-RING
ROLIIR SET HOTT
SET HOI.Ê
0 E
g n
10.
1 1 .
r
E
15.2 x 2,1
Replace.
PUMP ROTOR
SIDE PLATE
ROI.I.ERS
l ,
' t2.
Coat the O-ri ng wi th
power steeri ng fl ui d. and
posi
ti on i t i nto the pump housi ng.
Instal l the
pump cover assembl y i n the pump hous-
t ng.
FI.ANGE EOLTS
20 N.m
(2.0
kgf.m,
14 tbf.ft)
PUMP COVER
ASSEMBLY
51 x 2. 4 mm
Repl ace.
Coat t he f l ow cont r ol val ve wi t h power st eer l ng
fl ui d.
15. l nst al l t he f l ow cont r ol val ve and spr i ng on t he
pump housi ng.
Coat t he O- r i ng wi t h
power st eer i ng f l ui d, and
i nstal l i t on the Jl ow control val ve cap.
Instal l the fl ow control val ve cap on the pump hous-
't
4.
16.
17.
i ng, and t i ght en i t .
{cont' d)
17-45
FLOW CONTROL
VALVE CAP
49 N.m
(5.0
kgj m,
36 tbf.ft)
Power Steering Pump
Reassembly
(cont'dl
Coat t he O- r i ng wi t h power
st eer i ng f l ui d, and
i nstal l i t i nto the grooves i n the i nl et
j oi nt.
Instal l the i nl et
j oi nt
on the pump housi ng.
' 11
N. m
(1. 1
kgt . m,
8 |bnft)
I nst al l t he pul l ey as shown bel ow, t hen l oosel y
i nstal l the pul l ey nut. Hol d the steeri ng pump i n a
vise with soft
jaws.
CAUTION: Be carful not io damage the
pump
hous-
ing with the
jaws
ot the vise.
15.2 x 2.4
Repl ace.
-
EI
17-46
21. Hol d the pul l ey wi th the speci al tool , and ti ghten the
pul l ey nut.
UNIVERSAL HOLDER
PULLEY NUT
64 N.m {6.5 kgf.m,
Check that the pump turns smoothl y by turni ng the
pul l ey
by hand.
Steering
Gearbox
)
Removal
NOTE: Usi ng sol vent and a brush, wash any oi l and di rt
off the val ve body uni t i ts l i nes. and the end i f the
gear-
box. Bl ow dry wi th comPressed ai r.
1. Drai n the power steeri ng fl ui d as descri bed on
page
2. Raise the front of vehicle, and support it on safety
stands in the
proper locations
(see
section 11.
3, Remove the front wheel s.
4. Remove the dri ver' s ai rbag assembl y, and steeri ng
wheel
(see page 17-35)
5. Bemove the steeri ng
j oi nt
cover.
6.
Remove the steeri ng
j oi nt
l ower bol t, and l oosen
the steeri ng
j oi nt
upper bol t. Di sconnect the steer-
i ng
j oi nt
by movi ng the
i oi nt
toward the col umn
t J
17- 47
TIE.ROD END
7. Remove the cotter
pin from the castle nut {'96
-'97
models) or nut
('98 -
'00
modslsl and remove the nut.
BALL JOINT REMOVER.
28 mm
07MAC
-
SLqI2|X)
'98
-
'00
mod.b:
NUT
8.
COTTER PINS
Repl6ce.
l nstal l the t0 mm hex nut on the bal l
j oi nt.
Be sure that the 10 mm hex nut i s fl ush wi th the bal l
j oi nt pi n end, or the threaded secti on of the bal l
j oi nt pi n mi ght be damaged by the speci al tool .
NOTE: Remove the bal l
j oi nt
usi ng the speci al tool .
Refer to secti on 18 for how to use ths bal l
j oi nt
remover.
Seoarate the ti e-rod bal l
j oi nt
and knuckl e usi ng the
speci al tool .
CAUnON: Avoid damaging tho ball
ioint
boot.
Remove the left tie-rod end, then slide the rack all the
way to the right.
Separate the exhaust
pipe A or TWC
(see
section 9).
Disconnect the shift linkage
(see
section 13 or section
14) .
(cont' d)
9.
10.
1 1 .
12.
Steering Gearbox
Removal
{cont'dl
Loosen the 14 mm fl are nut and di sconnect the feed
l i ne.
Loosen the adj ustabl e hose cl amp and di sconnect
the return hose.
Loosen the 16 mm fl are nut and remove the return
hose
j oi nt
trom the val ve body uni t.
CAUTION: After disconnecting lhe hos6 and lin6.
plug or seal the hose and line with a
pioca
ol tapa
or equi val ent to
prevenl forei gn matori al s trom
entsring the valve body unit.
NOTE: Do not l oosen t he cvl i nder l i ne A and
between the val ve body uni t and cyl i nder.
ADJUSTABLE HOSE
CLAMP
Remove the sti ffener Dl ate.
NOTE: Some stiffener plate attaching bolts are also
used as
gearbox mounti ng bol ts. The gearbox wi l l
ti l t to si de when these bol ts are removed.
13.
14.
t 9 .
16.
17-48,
17. Remove the mounti ng brackets.
Pul l the steeri ng gearbox al l the way down to cl ear
the pi ni on shaft from the bul khead. then remove the
pi ni on shaft grommet.
Move the steering
gesrbox
to right so the left rack
end cl ears the rear beam, then ti l t the l eft si de down
to remove it from the vehicle,
CAUTION: Be careful not io bend or damage the
fagd l i ng and cyl i ndsr l i n99 whgn rgmovi ng thg
ggarbox,
18.
STEERING GEANEOX
)
Disassembly
t )
Steering Rack DisassemblY
NOTE:
r Before di sassembl e the
gearbox, wash i t off wi th sol
vent and a brush.
. Do not di p seal s and O-ri ngs i n sol vent.
1. Remove the steeri ng
gearbox
(see page 17-47]..
2. Remove the ti e-rod end and l ocknut.
3. Remove ai r tube and cl i Ps.
Remove the boot bands and ti e-rod cl i ps Pul l the
boots away from the ends of the
gearbox.
BOOT
( | - , TIE.ROD CLIP
Hol d the steeri ng rack wi th a wrench
(' 98 -' 00
mod-
el s: l eft end onl y), and unscrew the rack end wi th
another wrench.
CAUTION: Be caroful not to damage the rack 3ur-
faco whh the wrench.
NOTE:
' 96
-' 97
model s i s shown.
STEERING RACK END
STEERING RACK
Loosen the l ocknut, then remove the rack
gui de
screw and O-ri ng
(' 96 -' 97
model s onl y)
Remove the spri ng and the rack gui de from the gear
housi ng.
7.
{cont' d}
17
-49
LOCK WASHER
Steering Gearbox
Disassembly
(cont'd)
8. Remove cyl i nder l i nes A and B from the gearbox.
CYLINDER LINE
g
CYLINOCR LINE A
Drai n the fl ui d from the cyl i nder fi tti ngs by sl owl y
moving the steering rack back and forth,
Remove the two flange bolts, then remove the valve
body uni t from the gearbox. (See page 17-52 for
val ve body uni t di sassembl y.)
VALVE BOOY UNIT
FLANGE
BOLT
10.
'96
-
'97
mod.ls:
32 mm SHIMS
98
-
'00
modok:
WAVE WASHER
17-50
13. Loosen and remove the cvl i nder end.
11. Dri l l a 3 mm
(0.12
i n) di ameter hol e approxi matety
2.5
-
3.0 mm
(0.10 -
0.12 i n) i n depth i n the staked
poi nt
on the cyl i nder.
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
-
0.12 in}
CYUNDER
12. Hol d t he st eer i ng
snown.
gear box
usi ng a C- cl amp as
t
t 5 .
16.
14. Assembl e a 12 x 1.25 mm fl ange nut onto a 12 x 175
mm
grade 10 fl ange bol t as shown.
NOTE: Wr ap t he t l ange por t i on of t he bol t wi t h
vi nyl tape to protect the cyl i nder.
12, mm FLANGE
BOLT
12 mm FLANGE NUT
VINYL TAPG
{p/N 90i77
-
SLo
-
000}
Instal l the fl ange bol t i nto the end of the steeri ng
r ack unt i l i t bot t oms i n t he hol e, t hen back t he
fl ange bol t out
' l l 4
turn. Hol d the fl ange bol t, and
ti ghten the fl ange nut agai nst the rack by hand.
Instal l the beari ng separator on the gearbox housi ng
a5 snown.
FLANGE BOLT
BEARING SEPARATOR
0
-
1112" I
lCommercially
availablo)
STEERING RACK
CYLINDER END SEAL
Set the
gearbox i n a
press so the gear housi ng
poi nt
upward, then
press the cyl i nder end seal and steer-
i ng rack out of the
gearbox
NOTE: Hol d the steeri ng rack to keep i t from fal l i ng
when
pressed cl ear.
CAUTION:
. Be carsful not damage to i nn6l surface ot the
cylinder housing with the flange bolt.
. Do not
pl ace your l i ngers under th steri ng
rack.
t . /
17.
12 x 175 mm Ptess
1 . ,
the spe-
srcl e.
securel y
Replace.
J__--'- ,----)t'
| ,-----'" ,-,-'-'
| fiN\\ ----'
|
.Wl'----
I
t
-'4a
| ^--.'--4
A ooY----- \
Q)
*
srerhtnc
nact
20. l nsert a 24" l ong,3E" dri ve extensi on and
ci al tool i nto the cyl i nder from the gearbox
NOTE: Make sure that the speci al tool i s
posi ti oned on the backup ri ng edges'
18, Remove the 12 mm bol t and nut from the steeri ng
rack,
19. Remove t he cyl i nder end seal f r om t he st eer i ng
racK.
CYLINDER HOUSING
CAUTION: Be caroful not damago to inner surfaco
of the cylinder housing with the specisl tool'
21. Set the
gearbox i n a press, then
press out the cYl i n-
der end seal and backup ri ng from the
gearbox,
GAUTION:
. Keep the tool sttaight to avoid damaging the cylin'
der wall. Check th tool angls, and corrst 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 brak the backup ring. and the cylinder snd
sal will lemain in tho
gearbox.
BACKUP RING
CYLINDER END SEAL
CYLINDER END SEAL
REMOVER ATTACHMENT
07NAD
-
SR3020A
(cont' d)
17-51
Pross
Steeri ng Gearbox
Di sassembl y
(cont' dl
22. Carel ul l y pry
the pi ston
seal ri ng and O-ri ng off the
prsl on
rack.
CAUTION| Be caletul not to damage the inside of
seal ring groove and piston
edges when removing
the seal ri n9,
Repl ace.
17-52
Valve Body Unii Disassembly
23. Eefore removi ng the val ve housi ng, appl y vi nyl tape
to spl i nes of the pi ni on shaft.
24. Separate the val ve housi ng from the pi ni on
shaft/
val ve usi ng a
press.
VALVE HOUSING
Vi nyl t . pe
PINION SHAFT
Check the i nner wal l of the val ve housi ng where the
seal ri ng sl i des wi th your fi nger. l f there i s a step i n
t he wal l , t he val ve housi ng i s wor n. Repl ace t he
val ve housi ng.
NOTE:
Ther e may be t he sl i di ng mar ks f r om t he seal
r i ng on t he wal l of t he val ve housi ng. Repl ace
the val ve housi ng onl y i f the wal l i s stepped.
When the val ve housi ng i s repl aced,
j nstal l
new
shi m(s) on the beari ng surface of the housi ng to
adj ust the thi ckness.
Check t he i nsi de of val ve housi ng
whether the wall is stepped.
I
l . /
26. Check f or wear . bur r s and ot her damage t o t he
edges of the
grooves i n the sl eeve'
NOTE: The pi ni on shaft and sl eeve are a
preci si on
mat ched set l f ei t her t he
pi ni on shaf t or sl eeve
must be repl aced, repl ace both
parts as a set'
SLEEVE
SEAL RINGS
Check f or
Peel
of f or
damage.
27. Remove the ci rcl i P and
Pi
pi ni on shaft.
ni on shaft sl eeve from the
1 . ,
-r
t rt .<
l r
- 9 9
28. Usi ng a cutter or an equi val ent
tool , cut and remove
the l our seal ri ngs from the sl eeve'
CAUTION:
Be careful not to damage the edges of
the slgevs
grooves and outer surface whsn lemov-
ing the seal rings.
29. Usi ng a cutter or an equi val ent
tool , cut the val ve
seal i i ng and O-ri ng at the
groove the
pi ni on shaft'
Remove the val ve seal ri ng and O-ri ng'
CAUTION:
Be careful not to damage the edges oI
the
pi ni on shaft
gl oove and outer surface when
removing the valve seal ling and O-ring'
VALVE SEAL RING
Repl ace.
(cont' d)
SLEEVE
Cut t i ng
sl ot
Posr t l on.
Steering Gearbox
Disassembly
(cont'd)
30. Bemove the val ve oi l seal and backup ri ng
{' 96
-' 97
model s) or wave washer
(' 98 -' 00
model s) from the
oi ni on shaft.
NOTE:
. Inspect the ball bearing by rotating the outer race
slowly. lf there is any excessive play,
replace the
pi ni on
shaft and sl eeve as an assembl y.
. The pinion
shaft and sleeve are a
precise
fit; do
not i nt er mi x ol d and new
pi ni on
shaf t s and
steeves.
'98
-
'(x)
mod.lr:
WAVE WASHER
Replace.
31. Press the val ve oi l seal and rol l er beari ng
{' 96
-,97
model sl or bushi ng
( ' 98 - ' 00
model sl out of t he
val ve housi ng usi ng a hydraul i c press
and speci al
tool shown below.
NOTE: Do not use a hammer; i t wi l l damage the
speci al tool .
'96
-
'97
modob:
PILOT COLLAR
07GAF
-
PH70100
VAI.VE OIL SEAL
Replace.
BOI.I"ER BEARING
Replace.
PILOT COLLAR
07GAF
-
PHtoroo
VALVE OII. SEAL
Replace.
BUSHING
Beplace.
BALL BEARING
'96
-
'00
mod.b:
17-54
)
Reassembly
NOTE:
. cl ean the di sassembl ed
parts wrth a sol vent, and dry them wi th compressed ai r. Do not di p the rubber
parts i n a sol -
vent.
. Al ways repl ace the O-ri ngs and rubber seal s wi th new ones before assembl y'
. Appl y the recommended
power steeri ng fl ui d to the
parts+ndi cated i n the assembl y
procedures'
o Do not a| | ow dust, di rt, or other forei gn materi al s to enter the
power steeri ng system.
a Use the appropri ate speci al tool s where necessary'
FLANGE BOLTS
20 N.m
(2.0 kgt'm, 14lbf ftl
CYLINDER
LINE B
VALVE HOUSING
FLARE NUTS
28 N.m
(2.7 ksf m,20 lbf ftl
VALVE OIL SEAL
Repl ace.
CYLINDER END SEAL
Repl ace.
f itllTllli".",'r'o,.n,ft
''*^'*-1$*-/s6-,,mode,3:
EUSHING
Replace
'P'\--
BEARING
SLEEVE SEAL RINGS
..-------......
SS
.----
",a"a,,
*---
--,
Replace.
lss-,
Replace.
Xll,Y5"l'.
"o.
--r...-
gY------..r.u,
,-f-..-S:
_
,96
_,9?
models:
--l--------=-
ircriip'ii.rt'-
l . /
BACKUP
Repl ace.
I
,
wAvE wAsHER
d
-.-.-r_
i"pru"".
CYLINDER HOUSING //
-\-
, AJ
-\
O.RING
/ ,S-'..- ReDtace.
_
j GEAR HouslNG l.g
--'\-
\-
t
F
\ntonsrnrr
.,_-\
\ s
-
'oo
,,iod"t., -s-'---------
vALvE SEAL R'NG
S_.<---,tj-
97 models onlY:
CYLINDER END SEAL
)@OOD
m\
n"prac".
/'\N,."._
nrNG
I
'98
-
'oo
-
RACK GUIDE
\
models:
:scREw
I
O.RING
Repl ace.
.98
-
'00
models:
CYLINDER
END
69 N.m {?.0
kgt'm,51 lbl'ft)
(cont' d)
17-55
CYLINDER LINE A
t J
Steering Gearbox
Reassembly
(cont'd)
Valve Body Unit Reassembly
1. Appl y vi nyl tape to the stepped porti on
of the pi n-
i on shaft, and coat the surface of the vi nyl taoe wi th
the power steeri ng fl ui d.
2. Instal l the backup ri ng
(' 96 -' 97
model s) or wave
washer
(' 98 -' 00
model s) wi th i ts tapered si de as
shown bel ow.
3. Coat the i nsi de surface of the new val ve oi l seal
wi th power
steeri ng fl ui d.
4. Sl i de the val ve oi l seal over the pi ni on
shaft, bei ng
careful not to damage the seal i ng l i p.
Vinyl t.po
{Stepped
ponion}
Tap6red position.
BACKUP
Groove side.
sure t he spri ng i s
seatod in the oil seal.
'98
-
'00
mod.b:
CAUTION: InstEll ihe valve oil seal whh its groov.d
3ide tacing opposite tho boaring.
Appl y vi nyl tape to the spl i nes and stepped porti on
of the shaft, and coat the surface of the vinyl tape
wi th the power
steeri ng fl ui d.
Fi t the new O-ri ng i n the groove
of the
pi ni on
shaft.
Then sl i de the new val ve seal ri ng over the shaft
and the groove i n on the
pi ni on
shaft.
Remove the vi nyl tape from the pi ni on shaft,
'96
-
'97
models:
l i p
7.
VALVE SEAL RIiIG
Repl ace.
Do not over-expand.
17-56
8. Appl y power
steeri ng fl ui d to the surface of the
val ve seal r i ng t hat was i nst al l ed on t he pi ni on
shaft.
9. Appl y power
steeri ng fl ui d to the i nsi de of the spe-
ci al tool . Set the l arger di ameter end of the speci al
tool over the val ve seal ri ng.
10. Move the speci al tool up and down several ti mes to
make the val ve seal ri ng fi t i n the pi ni on
shaft.
11, Remove the soeci al tool .
12. Turn the speci al tool over, and set the smal l er di am-
eter end of the speci al tool over the val ve seal ri ng.
Move the speci al tool up and down several ti mes to
make t he val ve seal r i ng f i t snugl y i n t he pi ni on
shaft.
PISTON SEAL BING
SIZING TOOL
07NAG
-
SR:togoA
ol
07NAG
-
SR3|X)00
(g(m
Use the larger diameter
end of the special
tool first to make
the valve seal ring
f i t i n t he
pi ni on
shaf t .
Make t he val ve seal ri ng
f i t snugl y i n t he pi ni on
shaf t usi ng t he ot her end
(smal l er
di amet er end) of
t he speci al t ool .
I
14.
Appl y
power steeri ng fl ui d to the surface of the spe-
ci al tool . Set the new seal ri ngs over the speci al tool
f r om t he smal l er di amet er end of t he t ool , and
expand the seal ri ngs. Do two ri ngs at a ti me from
each end of the sl eeve.
NOTE;
. Do not over-expand
the seal ri ng. Instal l the resi n
seal ri ngs wi th care so as not to damage them'
After i nstal l ati on, be sure to contract the seal
ri ngs usi ng the speci al tool
(si zi ng tool ).
. There are two types of sl eeve seal ri ngs: bl ack
and brown. Do not mi x the di fferent types of
sl eeve seal ri ngs as they are not compati bl e
Set the speci al tool i n the
grooves i n the sl eeve, and
set each ri ng i n each
groove securel y.
NOTE: After i nstal l ati on, compress the seal ri ngs
wi th
your fi ngers temPorari l Y
BALL JOINT BOOI CLIP GUIDE
07S7,1- SA50800
SLEEVE
15. Appl y
power steeri ng fl ui d to the seal ri ngs on the
sl eeve, and to the enti re i nsi de surface of the spe-
ci al tool .
16. l nsert the sl eeve i nto the speci al tool sl owl y'
17. Move t he sl eeve each di r ect i on sever al t i mes t o
make the seal ri ngs snugl y fi t i n the sl eeve'
NOTE: Be sure
ri ngs are not turned uP.
SITEVE SEAL RING
SIZING TOOL
0797a
-
SA5020A or
07974
-
SA50200
that the seal
fr
J
17-57
18. Appl y
power steeri ng
fl ui d to the surface o{ the
pi n-
i on shaft. Assembl e the sl eeve over the
pi ni on shaft
by al i gni ng t he l ocat i ng
pi n on t he i nsi de of t he
sl eeve wi th the cutout i n the shaft. Then i nstal l the
new ci rcl i p securel y i n the
pi ni on shaft
groove'
NOTE:
Be car ef ul not t o damage t he val ve seal r i ng
when i nserti ng the sl eeve.
Instal l the ci rcl i p wi th i ts radi used si de toward the
sl eeve.
Appl y
power steeri ng fl ui d to the seal ri ng l i p of the
val ve oi l seal . then i nstal l the seal i n the val ve hous-
i ng usi ng a hydr aul i c
pr ess and speci al t ool s as
shown.
CAUTION: Install the valve oil seal with its
grooved
side facing the tool.
' 19.
ATTACHMENT.
3 2 x 3 5 mm
0774.6
- q)101(x)
Pre3s
I
DRIVER
07749
-
0010000
VALVE OIL SEAL
Repl ace.
Make sure t he
spri ng i s i n t he
oi l seal . (cont ' d)
Steering Gearbox
Reassembly
(cont'd)
SLEEVE SEAL RINGS
Repl ace.
8e sure t hat t he
seal nngs are not
t urned up, t hen
i nst a l l .
21. Appl y vi nyl tape to the pi ni on
shaft. then coat the
vi nyl tape wi th power
steeri ng fl ui d.
Sealing lip face.
VALVE OIL SEAL
VALVE HOUSING
Press the new beari ng
(' 96 -
' 97
model s) or new
bushi ng
(' 98 -' 00
model s) i nto the val ve housi ng
usi ng a hydraul i c press
and speci al tool as shown,
NOTE: Pl ace the rol l er beari ng
(' 96 -' 97
model s) on
the val ve housi ng wi th the stamped l etter faci ng up
towards the val ve si de.
DRIVER
077itg-001tXlOO
22. Insert the pi ni on
shaft i nto the val ve housi no.
CAUTION: Be careful noi to damage th valve seal
ri ngs.
23. Remove the vi nyl tape from the
pi ni on
shaft.
20.
Pr033
+
3: I x35mm
07746
-
0010,t(x)
'96
-
'97
models:
ROLLER BEARING
Letter stamped tace
upward.
ATTACHMENT,
'98
-
'00
modob:
?/_vusHrNG
['---v-lt
\ 4)
PINION
E
17-5A
24. Pr ess t he
pi ni on
shaf t / sl eeve usi ng a hydr aul i c
press
as shown.
NOTE: Check t hat t he pi ni on
shaf vsl eeve t ur ns
smoothl y by turni ng the pi ni on
shaft.
)
Steering Rack Reassembly
25. Coat the
pi ston seal ri ng
gui de wi th
power steeri ng
fl ui d, then sl i de i t onto the rack, bi g end fi rst'
26. Posi ti on the new O-ri ng and new
pi ston seal rl ng on
the speci al tool , then sl i de them down toward the
bi g end of the tool
NOTE:
. Do not over expand the resi n seal ri ngs l nstal i
the resi n ;eal ri ngs wi th care so as not to dam-
age them. After i nstal l ati on, be sure to contract
the seal ri ng usi ng the speci al tool
(si zi ng
tool )
. Repl ace the
pi ston' s O-ri ng and seal ri ng as a set'
27. Pul l the O-ri ng off i nto the
pi ston groove, then
pul l
the
pi ston seal ri ng off i nto the pi ston groove on top
ol the O-ri ng
PISTON SEAL RING
GUI DE
07GAG
-
SD4O10A ol
07GAG
-
SD,ol(xt
Coat the
pi ston seal ri ng and the i nsi de of the spe-
ci al tool wi th
power steeri ng fl ui d.
Careful l y sl i de the tool onto the rack and over the
pi ston seal ri ng.
Move the speci al tool back and forth several ti mes
to make the
pi ston seal ri ng fi t snugl y i n the
pi ston'
PISTON
Repl ace.
E
PISTON
31. Wrap vi nyl tape around the rack teeth and rack end
edges, then coat the surface of the tape wi th the
power
steeri ng fl ui d
NOTE: Make sure that the vi nyl tape i s wrapped
careful l y so that there i s no stepped
porti on
Coat the i nsi de surface of the new cyl i nder end seal
wi th power steeri ng fl ui d.
Instal l the cyl i nder end seal onto the steeri ng rack
wi th i ts grooved si de toward the
pi ston.
CAUTION: When i nstal l i ng the cyl i nder end seal ,
be cai eful not damage the seal i ng l i p face of tho
seal with the edgss or teeth of th stering rack'
CYLINDER END SEAL
Make sur e t he
sPr i ng i s i n t he cyl i nder
end soal
Remove the vi nyl tape from the steeri ng rack
NOTE: Remove any resi due oftape adhesi ve
(cont' dl
17-59
Steering
Gearbox
Reassembly
{cont'd)
35. I nst al l t he new backup r i ng on t he st eer i ng r ack,
then pl ace
the cyl i nder end seal to pi ston.
Grease the steeri ng rack teeth, then Insen the steer-
i ng .ack i nto the gear housi ng.
CAUTION: Be careful not to damage to inner sur-
face of the cylindsr housing with the rack edges.
36.
BACKUP RING
17-60
37. Instal l the fl ange bol t i nto the end of the steeri no
r ack unt i l i t bot t oms i n t he hol e, t hen back t hl
f l ange bol t out 1/ 4 t ur n. Hol d t he f l ange bol t and
ti ghten the fl ange nut agai nst the rack by hand.
38. Instal l the cyl i nder end seal i nto the bottom of the
cyl i nder by pr essi ng
on t he bol t wi t h a pr ess
as
shown.
CAUTION: Do not push
on the boh with excessive
force as it may damage tho cylinder end seal.
12 x 175 mm FLANGE BOLT
{P/N 90177
-
SLo
-
000}
12 mm FLANGE NUT
?q
Remove t he f l ange bol t . and cent er t he st eer i ng
rack.
Wr ap vi nyl t ape ar ound t he r ack end edges. and
coat the surface of the tape wi th the power
steeri ng
fl ui d.
NOTE: Make sure that the vi nyl tape rs wrapped
carefully so that there is no stepped portion.
Preas
)
41. Coat the i nsi de surface of the new cyl i nder end seal
wi th
power
steeri ng fl ui d.
Instal l the cyl i nder end seal onto the steeri ng rack
wi th i ts
grooved si de toward the
pi ston'
Push i n the cyl i nder end seal wi th your fi nger'
CAUTION:
When i nstal l i ng the cyl i nder 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
CYLI NDES
END SEAL
Repl ace.
Make sure t he sPri ng
i s i n t he cyl i ncl er end seal
CYLINDER
END
SEAL
Remove the vi nyl tape from the steeri ng rack'
NOTE: Remove any resi due oftape adhesi ve
Hol d the steeri ng
gearbox usi ng a C-cl amp as shown'
GEARBOX
C-CLAMP:
l - ,
46.
47.
Coat t he i nsi de sur f ace of t he cyl i nder end wi t h
power steeri ng fl ui d, then i nstal l the cyl i nder end by
screwi ng i t i nto the cyl i nder housang.
Remove the C-cl amp from the steeri ng
gearbox'
After ti ghteni ng the cyl i nder end' stake the
poi nt of
t he cyl i nder
housi ng shown bel ow For ' 98
- ' 00
model s
go to step 51.
NOTE: Stake the cyl i nder i n the
posi ti on opposi te
from where the stake was removed duri ng di sas-
semol y.
Be caref ul not t o damage
t he bushi ng when i nsert i ng
t he cyl i nder end.
49. Sel ect the 32 mm shi m(s)
(' 96
-' 97
model onl y)'
NOTE: Onl y r ei nst al l t he or i gi nal 32 mm shi m( s)
when the steeri ng
gearbox i s reassembl ed
wi thout
repl aci ng the pi ni on shatt, val ve housi ng, and gear
box housi ng wi th new ones.
l f t he
pi ni on shaf t , val ve housi ng, and
gear box
housi ng are repl aced, sel ect the new shi m{s) as fol -
l ows.
Shim selection:
a. Set the four 32 mm shi ms on the beari ng surface of
t he
gear box housi ng. Tot al t hi ckness
of t he f our
shi ms shoul d equal no more than 0 70 mm'
Shi m set: four 32 mm shi ms
(Thi ckness: 010 mm'
0.15 mm, 0.20 mm, 0.25 mm respecti vel yl
CAUTION:
Th four 32 mm shi ms do not have
thickness identification
marks Measure the thick-
ness of each shim using a micrometsr,
and mark
the shim lor identification.
(cont' d)
17-61
Stake
point. Depth: 1 0 mm
(0.04 in)
Steering Gearbox
Reassembly
(cont'd)
b. I nst al l t he val ve body uni t on t he gear box,
and
tighten the flange bolts to the specified torque.
VALVE BODY UNTT FLANGE BOLT
20 N.m {2.0 ksl.m, 14lbI.ftl
Measure the cl earance between the gearbox
and
val ve body uni t usi ng a feel er gauge
as shown.
NOTE: Measure the cl earance at the poi nt
mi dway
between the two mounting bolts.
Det er mi ne t he r equi r ed t hi ckness of t he 32 mm
shi ms by subtracti ng the cl earance obtai ned i n the
step
"c"
from the total thi ckness of the four shi ms.
( Tot al
t hi ckness of t he 4 shi ms)
-
( Cl ear ance) =
Requi red thi ckness of the shi ms
NOTE: Sel ect the shi ms so that the total thi ckness
i s cl ose to. but l ess than, the requi red thi ckness,
17-62
54.
Example:
Measurement i s 0.28 mm
(0.011
i n):
0.70
-
O.28 =
0.42 mm
(0.028 -
0.011 =
O.Ot7 i nl
The sel ected shi ms shoul d be 0.28 mm l O.OtO i n) and
0.15 mm
{0.006 i n} i n thi ckness.
l f the rqui red shi m thi ckness i s 0.10 mm or l ess, no
shims are necessarv.
50. Sot the sel ected 32 mm shi ms
(,96 -
,97
model s
only) on the bearing surface ofthe gearbox
housing.
FLANGE BOLT
20 N.m
12.0 ksf.m, 1l lbtftl
VALVE BODY UNIT
'96
-
37 modsl3 only:
32 mm SHIMS
{S.loctod numb.r of
3him!l
Coat ths new O-ring with grease,
and carefully fit it
on the val ve housi ng.
Appl y grease
to the needl e beari ng i n the gearbox
housi ng.
Instal l the val ve body uni t on the gearbox
housi ng
by engagi ng the gars.
NOTE: Note the val ve body uni t i nstal l ati on posi -
ti on
(di recti on
of l i ne connecti on).
Tighten the flange bolts to the specified torque.
O-RING
Repl ace.
-A-l
NEEDLE BEARING
-R1
51.
EA
)
55. Instal l the cyl i nder l i nes A and B.
NOTE:
. Cl ean t he
j oi nt s
of t he cyl i nder
l i nes A and B
thoroughl y.
The
j oi nts must be free of forei gn
materl al .
. Instal l the cyl i nder l i nes A and B by ti ghti ng the
fl are nuts by hand fi rst, then ti ghten the fl are
nuts to the speci fi ed torque.
56.
57.
Grease the sl i di ng surface of the rack
gui de, and
i nstal l i t onto the
gear housi ng
36
-
'97
models:
Appl y a thi n coat of grease to the new O-ri ng, and
i nstal l i t on the rack
gui de screw.
38
-
'00
models:
Remove the old sealant off of the threaded section,
then appl y new seal ant al l around the threads
Instal l the spri ng, rack
gui de screw and l ocknut on
the
gear housi ng.
Adj ust the rack
gui de screw
(see page 17-33)'
NOTE: After adj usti ng, check that the rack moves
smoothl y by sl i di ng the rack ri ght and l eft'
' 1
l : .
r 1
58.
-Gl
O.BING
Replace.
17 N.m {1.7 kgt'm, 12 lbl.ft)
28 N.m
(2.7 kgf m,20 lbf ftl
CYLINDER LINE 8
CYLINDER LINE A
l /
LOCKNUTS
60, l nst al l t he new l ockwasher i n t he
gr oove i n t he
steeri ng rack.
61. Screw each rack ends i nto the rack'
62. Hol d the steeri ng rack wi th a wrench
(' 98
-' 00
mod-
el s: l eft end onl Y), and ti ghten the rack ends'
CAUTION: Bo cateful nol to damage ihe rack sur-
face with the wranch.
NOTE:
' 96
-' 97
model i s shown.
STEERING RACK END
54 N'm t5 5 kgt m' 40 lbl'ft)
STEERING RACK
After ti ghteni ng
the rack ends, stake the four sec-
ti ons of l ock washer wi th a dri ft and a mal l et.
Place the wood block on the
press table. then set
the l ock washer secti on of the rack end on the
wood block securelY.
Be sure the tool i s al i gned wi th the fl st secti ons
of the steeri ng rack end bel ore
pressi ng.
Stake the l ock washer i n the center ot the fl at
section of the steering rack end.
LOCK WASHER
NOTE: Thi s dri f t has a f l at ,
t o
prevent punct uri ng
WOODEN BLOCK
{cont' d}
17- 63
Steering Gearbox
Reassembly
(cont'dl
64. Appl y grease
to the ci rcumference of the rack end
housi ng.
RACK END GROOVE
=^.
#-q!:s!!H
SILICONE GREASE
Appl y a l i ght coat of si l i cone gr ease
t o t he boot
grooves on the rack ends.
l nstal l the boots i n the rack end wi th the ti e-rod
cl i ps.
NOTE: Instal l the boots wi th the rack i n the strai ght
ahead posi ti on (ri ght
and l eft ti e-rods are equal i n
l ength).
66.
RACK END
NOTE: Wipe the grease
off
t he t hread sect i on.
17- 64
TIE.ROD CLIP
67. Adj ust the ai r hose fi tti ng posi ti on
of the boots bv
turni ng i t as shown bel ow.
LEFT BOOT
(Vi ewed
f rom t he
left side)
RIGHT BOOT
{Viewed from the
ri ght si de)
AIR HOSE FITTING
Install new boot bands on the boot, and bend both
sets of locking tabs.
CAUTION: Stlke ths band locking tabs firmly.
Li ghtl y tap on the doubl ed-over porti ons
to reduce
thei r hei ght.
Sl i de the rack ri ght and l eft to be certai n that the
boots are not deformed or twisted.
7 1 . Connect t he ai r t ube bet ween t he r i ght and l ef t
boot.
l nstal l the cl i ps on the cyl i nder l i nes' then cl amp the
ai r tube wi th the cl i Ps.
l . /
CYLINDER LINE A
CLIP
l - ,
l nstal l ati on
CAUTION: Be carelul not to bend or damage the feed
line and cylinder lines when installing the
gearbox'
1, Before i nstal l i ng the gearbox, sl i de the rack al l the
way to ri ght.
2. Instal l the mounti ng cushi on on the steeri ng
gear-
DOX.
Instal l the
pi ni on shaft
grommet, then i nsert the
pi n-
i on shaft up through the bul khead.
NOTE: Al i gn the notch i n the
pi ni on shaft
grommet
wi th the tab on the val ve housi ng.
I nst al l t he mount i ng br acket over t he mount t ng
cushi on, then i nstal l two
gearbox mounti ng bol ts'
MOUNTING BRACKET
cusHroN
39 N.m
(4.0
kgj m, 29 lbtftl
NOTE: I nst al l t he bracket
wi t h t he arrow Pornl l ng
t oward t he f ront .
(cont' d)
17- 65
Steering Gearbox
Instal l ati on
(cont' dl
5. I nst al l t he st i f f ener pl at e
wi t h t he t wo gear box
mounti ng bol ts and sti ffener pl ate aftachi ng bol ts.
CAUTION: Be sure the ai r tube i s not caught or
pinched by stiffener plate,
NOTE: I nst al l t he bol t s l oosel y f i r st , t hen t i ght en
them securel y.
7.
8.
6. Instal l the return hose
j oi nt
by ti ghteni ng the l 6 mm
f l ar e nut .
Connect the rel urn hose securel y, and ti ghten the
adj ust abl e hose cl amp f r om t he engi ne compar t -
ment.
Connect t he f eed l i ne and t i ght en t he 14 mm f l ar e
nut .
NOTE: Make sur e t hat t her e i s no i nt er f er ence
between the fl ui d l i nes, the rear beam or any other
parts.
ADJUSTABLE HOSE
CLAMP
(see page 17-39)
16 mm FLARE NUT
28 N.m
{2.9 ksl.m. 20 lbf.ft)
RETURN
1a mm FLARE NUT
37 N.m
(3.8
kg{.m, 27 lbt.ftl
ATTACHING AOLTS
38 N.m
13.9 kgf.m, 28 lbf.ftl
MOUNTING BOLTS
(}
N.m
(4.a
kgt m, 32 lbf.ftl
17- 66
9. Center the steeri ng rack wi thi n i ts stroke.
Sl i p the l ower end of the steeri ng
j oi nt
onto the pi n-
i on shaf t
( l i ne
up t he bol t hol e wi t h t he gr oove
around the shaft), and ti ghten the upper and l ower
steeri ng
j oi nt
bol t.
NOTE:
.
Connect the steeri ng shaft and pi ni on wi th the
cabl e reel and steeri ng rack centered.
. Be sure that the lower steering
joint
bolt is securely
i n the groove i n the steeri ng gearbox pi ni on.
. l f the steeri ng wheel and rack are not centered,
r eposi t i on t he ser r at i ons at l ower end of t he
steeri ng
j oi nt.
10.
STEERING JOINT
UPPER BOLT
22 N.m
(2.2
kgf.m,
16 tbt.ftl
PINION SHAFT
Groove,
STEERING JOINT
LOWER BOLT
22 N. m
(2. 2
kgt . m, 16l bt t t l
1 1 .Center the cabl e reel by fi rst rotati ng i t cl ockwi se
unt i l i t s t ops . Then r ot at e i t c ount er c l oc k wi s e
(approxi matel y
two turns) unti l the arrow mark on
the l abel poi nts
strai ght up. Rei nstal l the steeri ng
wheel (see page 17 35).
)
1 ?
12, Instal l the steeri ng
j oi nt
cover wi th the cl amps and a
cl r p.
Reconnect the ti e-rod ends to the steeri ng knuckl es,
ti ghten the castl e nut
(' 96 -' 97
model s) or nut
(' 98
-
' OO
model s) to the speci fi ed torque, and i nstal l new
cotter
plns.
NOTE: Before connecting the tie-rod ends, wipe off
any
grease contami nati on
from the bal l
j oi nt tapered
secti on and threads.
CAUTION: Torquo the castle nut to the lower torque
spcification,
then tighten it only tar enough to align
the slot with the
pin hole. Do not align the nut by
loosening {,96
-'97
models only).
COTTER PINS
Repl ace.
On reassembly, bend
\
t he cot t er
Pi n
6s shown.
'96
-'97
models:
'98
-'00
modls:
t r
CASTLE
NUT
40
-
a8 N'm
(4.0 -
4.8 kgf'm,
29
-
35 lbf.ftl
NUT
&l N.m
{a.5
kgf'm, 33 lbl'ftl
NE-ROD END
( l - ,
17-67
14.
15.
16.
17.
18.
Instal l the exhaust
pi pe A or TWC
(see
secti on 9).
Connect the shi ft l i nkage
(see
secti on 13 or secti on
14) .
l nstal l the front wheel s
Fi l l the system wi th
power steeri ng fl ui d, and bl eed
ai r from the system
(see page 17-331
After i nstal l ati on,
perform the fol l owi ng checks
. St ar t t he engi ne, al l ow i t t o i dl e, and t ur n t he
steeri ng wheel from l ock-tol ock several ti mes to
warm up the fl ui d. Check the
gearbox for l eaks
(see page 17-39).
. Adj ust the front toe
(see
secti on 18).
. Check the steeri ng wheel spoke angl e. Adj ust by
turni ng the ri ght and l eft ti e-rods, i f necessary.
NOTE: Turn the ri ght and l eft ti e-rods equal l v
Bal l
j oi nt
Boot Repl acement
'96
-
'97
models:
1. Remove the boot set ri ng and the boot.
CAUTION: Do not contami nate the boot i nstal l a.
tion section with grsase.
2. Pack the i nteri or of the boot and l i p wi th grease.
3. Wi pe the grease
off the sl i di ng surface of the bal l
pi n,
then
pack
the l ower area wi th fresh grease.
CAUTION:
. Keep grease
off the boot installation seciion and
the tapered sction ot the ball pin.
. Do not allow dust, dirt, or oth6r foreign materi-
als to 6nt8r the boot.
LIP EALL PIN TAPERED
SECTION
Wi pe of f t he grease.
INSTALLATION
SECTION
Wi pe of f t he grease.
Instal l the boot i n the groove
of the boot i nstal l ati on
secti on securel y, then bl eed the ai r from the boot.
-6lr
BOOT
SECTION
Wi pe of f t he grease
4.
ADJUSTING BOLT
Adj ust t he dept h
by t urni ng t he bol t .
SET RING
Adj ust the speci al tool wi th the adj usti ng bol t unti l
the end of the tool al i gns wi th the groove
on the
boot. Sl i de the set ri ng over the tool and i nto
posi -
UOn.
CAUTION: After installing the boot,
qhsck
the ball
pin tapered section for grease
contamination and
wipe it it necGsary.
17-68
'98
-
'00
models:
CAUTION: Do not contaminato the boot installation sec-
tion with grease.
1. Remove the boot from the ti e-rod end, and wi De the
ol d grease
off the bal l
pi n.
2. Pack the lower area ofthe ball pin
with fresh grease.
3. Pack the i nteri or of the new boot and l i D wi th 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.
BOOT INSTALLA
SECTION
Wipe off the grase,
Instal l the new boot usi ng the speci al tool as shown
bel ow.
NOTE: The boot must not be a gap
atthe boot instal
lation sections.
LtP
.6r
J_/
ru
CAUTION: Aftor installing the boot, chock the batl
pin
tapgred section tor grgase cortamination. and
wipe it it nces3ary.
FRONT HUB
DIS/ASSEMBLY TOOL
07965
-
SA5o500
)
Suspensi on
Speci al Tool s . . . . . . . . . . . . . 18-2
Component Locations
l ndex , , . . . . . . . . . . . . . . . . . . . . f 8-3
Wheel Alignment
Cast er . . . . . . . . . . . . . . . . . . . . . 18-4
Camber . . . . . . . . . . . . . . . . . . l 8-4
Front Toe Inspection/
Adiustment ........ 18-5
Rear Toe lnspection/
Adi ust ment . . . . . . . . 18-5
Turni ng Angl e I nspect i on . . . . . . . . . . . . . . . . 18-6
Wheel/Hub Inspection
Beari ng End P| ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 8-7
Wheel Runout . . . . . . . 18-7
Front Suspension
Suspension Arms Replacement
(' 96 -
99 model sl . . . . . . . . . . . . . . . . . . . . . . . . . . 18-8
(' 99
2D Si and Si-R models) ........ 18-9
Knuckl e/ Hub Repl acement . . . . . . . . . . . . . 18-10
Lower Ball Joint Replacement ....... 18-16
Bal l Joi nt Boot Repl acement . . . . . . . . . . 18-17
Front Damper
Removal . . . . . . . . . . . . . . . . . 18-17
Di sassembl y/ 1nspect i on . . . . . . . . . . . . . . . . . . 18-18
Reassembl y . . . . . . . . . . . 18-19
l nst al l at i on . . . . . . . . . . . . . 18-19
Rear Suspension
(' 96 -
99 model s) . . . . . . . . . . . . . . . . . . . . , . . . . . 18-21
(' 99
2D Si and Si-R models) ........ 1A-22
Hub Bearing Unit Replacement ...... 18-23
Upper Arm Eushing
Replacement .....18-25
Rear Damper
Removal . . . . . . . . . . . . . . . . . 18-26
Disassembly/|nspection ............. ..... 1A-27
Reassembl y . . . . . . . . . . . 18-28
l nst al l at i on . . . . . . . . . . . . . 18-29
l r
Special Tools
Ref. No. Tool Numbor Description Oty Page Reteronc
o
)
@
\9
o
@
aa\
@
o
@
@
@
07GAF
-
SE00200
07GAF
-
SE00401
07GAG
-
SD40700
07JAF
-
SH201 l 0
07JAF
-
SH20120
07JAF
-
SH20200
07MAC
-
S100200
07746
-
0010500
07749
-
0010000
07947
-
6340201
07965
-
SB00100
07965
-
5800200
07965
-
SD90100
07974
-
SA50700
Hub Assembl y Gui de Attachment
Hub Di vAssembl y Base
Bal l Joi nt Boot Cl i p Gui de
Hub Di s/Assembl y Pi l ot, 38 mm
Hub Di s/Assembl y Shaft,22.4 x25.4 mm
Bal l Joi nt Remover Base
Bal l Joi nt Remover,2S mm
Dri ver
Driver Attachment
Eal l Joi nt Remover/l nstal l er
Bal l Joi nt Instal l er Base
Support Base
Bal l Joi nt Boot Cl i p Gui de
,|
1
1
1
1
1
1
1
1
1
1
1
I
1
t d - t c
18- 14
18- 17
18- 14
18- 14
18- 16
18- 12, 13
18- 14
18- 14
18- 15
18- 16
18- 16
18- 15
18- 16, 17
o @ @. @ @
@
o @
1a- 2
Component
Locati ons
)
l ndex
Wheel Al i gnment , page l 8 4
FBONT DAMPER
.
Removal ,
page 18-17
.
Di sassembl y/ l nspect i on,
page 18-18
.
Reassembl y,
page 18' 19
.
I nst al l at i on,
page 18-19
KNUCKLE/ HUB
.
Repl acement , page 18' 10
Front Suspension:
Rear Suspsnsion:
UPPER ARM
'
Repl scement ,
page 18-8
.
Wheel Beari ng Repl acement , page 18-14
.
Lower Eal l Joi nt Repl acement , page 18-16
STABILIZER BAR
'
Repl acement ,
page 18-8
LOWER ARM
.
Repl acement ,
Page
18-8
UPPER ARM
'
Repl acement , page 18 20
LOWER ARM
.
Replacement,
page 18-20
REAR DAMPEB
.
Removai .
page 18-26
.
Disassembly/lnspection,
page 18-27
.
Feassembl y,
page l S-28
.
I nst al l at i on,
page 18-29
ARM
TRAILING ARM
'
Repl acement ,
page 18-20
l - ,
.
Fepl acement , page 18 20
18- 3
Wheel Al i gnment
,f,
Caster
NOTE: For pr oper i nspect i on/ adj ust ment of t he wheel
al i gnment check and adj ust the fol l owi ng before check-
i ng t he al i gnment .
. Check that the suspensi on i s not modi fi ed.
. Check the ti re si ze and ti re pressure.
. Check the runout of the wheel s and ti res.
. Check the suspensi on bal l i oi nts. {Hol d a wheel wi th
your hands and move i t up and down and ri ght and
l eft to check for wobbl i ng.)
Inspection
NOTE: Use commer ci a l l y- avai l abl e comput er i zed f our
wheel al i gnment equi pment t o measur e wheel al i gn-
ment
{ cast er . camber , t oe, and t ur ni ng angl e) . Fol l ow
the equi Dment manufacturer' s i nstructi ons.
Check the caster angl e.
Caster angle: 1',10' I 1'
l f out of speci fi cati on, check for bent or damaged
suspensron components.
2.
1 .
18-4
Camber
lnspection
NOTE: Use commer ci al l y- avai l abl e comput er i zed f our
ment ( cast er ,
camber , t oe, and t ur ni ng angl e) . Fol l ow
the equi pment manufacturer' s i nstructi ons.
1. Check t he camber angl e.
Camber angl e:
Front: 0'00'
j
1"
Re a r : - 1 " 1 1 "
2. l f out ol speci fi cati on, check for bent or damaged
suspensron components.
?
Front Toe Inspection/Adiustment
NOTE: Use commer ci al l y- avai l abl e comput er i zed f our
ment
( cast er ,
1. Check the ti re pressure.
Center steeri ng wheel spokes.
Check t he t oe wi t h t he wheel s
poi nt ed st r ai ght
a head.
Front toe: l N 1 1 2 mm l l N l /16 r 1/16 i nl
-
l f adj ustment i s requi red, go on to step 4.
-
l f no adj ustment i s requi red, remove al i gnment
equrpmenr.
Loosen the ti e-rod l ocknuts, and turn both ti e-rods
i n the same di recti on unti l the front wheel s are i n
strai ght ahead
posi ti on.
TIE.ROD LOCKNUT
' 14
x 1.5 mm
4.
t J
6.
Turn both ti e-rods equal l y unti l the toe readang on
the turni ng radi us gauge i s correct.
After adj usti ng, ti ghten the ti e-rod l ocknuts.
NOTE: Reposi ti on the ti e-rod boot i f i t i s twi sted or
di spl aced.
4,1 N.m {4.5 kgf.m, 33 lb{.ft)
2.
Rear Toe Inspection/Adiustment
NOTE: Use commer ci al l y- avai l abl e
comput er j zed I our
wheel al i gnment equj pment t o measur e wheel al i gn-
ment
( cast er ,
1. Rel ease
par ki ng br ake.
NOTE:
a Measur e di f f er ence i n t oe measur ement s wl t h
the wheel s
poi nted strai ght ahead.
. i f the
parki ng brake i s engaged,
you may
get an
i ncorrect readang,
Rear toe-i n: 2 11 mm ttl tol l l l S
i nt
-
l f adj ustment i s requi red, go to step 2.
-
l f no adj ustment i s requi red, remove al i gnment
equi pment .
Before adj ustment, note the l ocati ons of adi usti ng
bol ts on the ri ght and l eft compensator arms
Loosen the adj usti ng bol ts, and sl i de the compen
sator arm i n or out. as shown, to adj ust the toe
ADJUSTING BOLT
10 x 1. 25 mm
In
CoMPENSAToR
ARM
4. Ti ghten the adi usti ng bol ts
. Exampl e:
Af t er t he r ear t oe i nspect i on, t he wheel i s 2 mm
(0.08
i n) out of the speci fi cati on.
-
Move t he ar m so t he adj usf i ng bol t moves 2 mm
(0.08 i n) i nward trom the
posi ti on recorded before the
adj ustment.
-
The di stance the adj usti ng bol t i s moved shoul d be
equal to the amount out-of-speci fi cati on.
64 N.m 16.5 ksf m, 47 lbtft)
18- 5
Wheel Al i gnment
Turni ng Angl e Inspecti on
NOTEr Use commer ci al l y- avai l abl e comput er i zed f our
ment
( cast er ,
' 1.
Tur n t he wheel r i ght and l ef t whi l e appl yi ng t he
br ak e, and meas ur e t he t ur ni ng angl e of bot h
wneets.
Turni ng angl e:
lnward wheel: 39'50'
Outwal d wheel
(ref
erencel : 33' 10'
2. l f t he t ur ni ng angl e
check f or bent or
nent s,
i s not wi thi n the speci fi cati ons,
da m aged suspensi on compo-
18- 6
Wheel /Hub Inspecti on
\
Beari ng End Pl ay
1. Rai se the vehi cl e off the ground, and suppon i t wj th
safety stands i n the
proper l ocati ons
(see
secti on 1).
2. Remove the wheel s, then rei nstal l the wheel nuts
3. Attach the di al gauge as shown.
4. N4easure the beari ng end
pl ay by movi ng the di sc i n
or outward.
Front/Rar:
Standard: 0
-
0.05 mm l 0
-
0.002 i nl
Measure end
pl ay at
hub f l ange.
t . /
Bear:
Measur e end
Pl aY
at cent er of
t he hub cap.
l f the beari ng end pl ay measurement i s
the standard, repl ace the wheel beari ng.
l J
more than
1A- 7
Wheel Runout
1. Rai se the vehi cl e off the ground, and support i t wi th
safety stands i n the
proper l ocati ons
(see
secti on I I
2. Check for bent or deformed wheel s.
3. Attach the di al gauge as shown.
4. Measure the wheel runout by turni ng the wheel .
Front and Rear Wheel Axisl Runout:
Standard:
Steel Whoel: 0
-
1.0 mm
(0 -
0.0,1 inl
Aluminum Wheel: 0
-
0.7 mm
(o -
0.03 in)
Servica Limit: 2.0 mm
(0.08
inl
Front and Rear Wheel Radill Runout:
Standard:
Steol Wheel: 0
-
1.0 mm
(0 -
0.04 in)
Al umi num Wheol : 0
-
0.7 mm
(0 -
0.03 i n)
Service Limit: 1.5 mm {0.06 i n}
l f the wheel runout i s more than the servi ce l i mi t,
repl ace the wheel .
Front Suspension
('96 -
99 models)
CAUTION:
. Replace the selt-locking nuts after removal.
. The vehicle should be on the
ground
betore any bolts or nuts connected to rubber mounts or bushings are tightened.
NOTE:
. Wi pe off any di rt, oi l or grease on the threads before ti ghteni ng the fasteners.
. The ri ght and l eft damper forks are not i nterchangeabl e. The l eft damper fork i s marked wi th
"AL"
whi l e the ri ght
damper fork i s marked wi th
"AR'
. The ri ght and l eft upper arms are not i nterchangeabl e. The l eft upper arm i s marked wi th
"SO1-L"
whi l e the ri ght upper
arm i s marked wi th
"SOl -R".
. Before ti ghteni ng the upper and l ower mounti ng nuts on the stabi l i zer l i nk, adj ust the l ocati on of the l i nk wi th the sus-
pensi on
under vehi cl e l oad.
. When i nstal l i ng the radi us arm washers, the
"FR"
mark faces the front ofthe vehi cl e.
. After i nstal l i ng the suspensi on arm, ch eck the front wheel al i gnment, and adj ust i f necessary (see page 18-4).
FLANGE BOLTS
10 x 1. 25 mm
54 N.m 15.5 kgl.m,
40 tbf.ftl
STAEILIZER END
RUBBER BUSHI NG
BALL JOINT BOOT
.
Check f or det er i or at i on and damage.
.
See
page
18- 16 f or boot r epl acement .
STABILIZER BAR
Check f or bendi ng and damage.
Check for deterioration
- ---\--
and damage,
-\
FLANGE BOLT
14 x 1. 5 mm
/)l
103 N.m {10.5 kg{.m,.
t, ,/4,
76lb{.ft)
\
t,,"-iV
v : \
FLANGE BOLT-
;iffillr-"-
ilHitffi*::,"*"
and damaoe,
o.'-----------
14 x 1. 5 mm
Repl ace.
83 N.m {8.5 kgf.m, 61 lbf.ftl
LOWER ARM
Check f or
c
Jl
TT
da
1{ x 1. 5 mm
89 N.m {9.1 kgt m. 66 lbtft)
- 6 ;
SILICONE GREASE
RUBBER BUSHING
DAMPER FORK
Check f or damage.
SELF-LOCKING NUT I x 1.25
22 N.m
(2.2
kg{.m, 16lbf.ftl
Repl ace.
FLANGE BOLT
10 x 1. 25 mm
N.m {4.6 kgt m.
32 tbf.ft)
SELF-LOCKING NUT
12x 1. 25 mm
Repl ace.
6it N m {6.5 kgf.m, 47 lbf.ftl
RUEBER BUSHING
.
Check f or det eri orat i on and damage.
.6t",.,"o".c"Ke
STAAI L| zER END RUBBER EUSHI NGS
Not e t he di rect i on
of t he bushi ngs.
18- 8
I
Suspensi on Arms Repl acement
(' 99
2D Si and Si -R model s)
CAUTION:
. The vehicle should be on the
ground belore any bolts or nuts connected to rubber mounts or bushings are tightened.
NOTE:
. Wi pe off any di rt, oi l or grease on the threads before ti ghteni ng the fasteners
. The ri ght and i eft damper forks are not i nterchangeabl e. The l eft damper fork i s marked wi th
"AL"
whi l e the ri ght
damper fork i s marked wi th
"AR"
. The ri ght and l eft upper arms are not i nterchangeabl e. The l eft upper arm i s marked wi th
"SOl -L"
whi l e the ri ght upper
arm i s marked wi th
"SO1-R".
. Before ti ghteni ng the upper and l ower mounti ng nuts on the stabi l i zer l i nk, adi ust the l ocati on of the l i nk wi th the sus-
pensi on under vehi cl e l oad.
. When i nstal l i ng the radi us arm washers, the
"FR"
mark faces the front of the vehi cl e.
. After i nstal l i ng the suspensi on arm, check the front wheel al i gnment, and adj ust i f necessary
(see page 18-4).
FLANGE BOLTS
10 x 1. 25 mm
sit N.m 15.5 kgf.m,
40 tbtftl
UPPER ARM
'
Check t he bal l
j oi nt
boot f or
det eri orat i on and damage.
.
Check t he bushi ng f or det eri orat i on
ano oamage,
.
Check t he bal l
i oi nt
f o. f aul t y
movement and cl amage.
STABILIZER BUSHING
Al i gn t he st abi l i zer mark
wi t h t he end of st abi l i zer bushi ng
FLANGE BOLT
14 x 1. 5 mm
l . /
103 N. m
(10. 5 kgf . m,
76 tbr.ftl
STABILIZER LINK
.
Check t he bal l i oi nt boot f or
deterioration and damage.
.
Checkt he bal l i oi nt t or f aul t y
movement and damage.
STABILIZER BAR
FLANGE BOLT 8 x 1.25 mm
22 N.m
(2.2 kgf.m, 16lbf.ft)
SELF-LOCKING NUT
14 x 1. 5 mm
Repl ace.
83 N.m 18.5 kgf m, 61 lbf.ft)
-.6r srr-,co",
hSHrtlrT.[*"u
6g619g
ano oamage.
SELF.LOCKING NUT
10 x 1.25 mm 29 N m 13.0
kgf m, 22 lbf ftl
Repl ace.
Hol d t he bal l
i oi nt
pi n usi ng a hex wrench,
and t aght en t he sel f ' l ocki ng nut .
LOWER ARM
Check f or
damage.
FLANGE NUT l0 x 1.25 mm
29 N.m 13.0 kgI m,2.2 lbf ft)
Bef ore t i ght eni ng t he {l ange nut ,
posi t i on t he bal l
j oi nt
Pi n
i n t he mi ddl e of i t s range of t ravel ,
wi t h t he suspensi on under vehi cl e l oad
FLANGE BOLT
14 x 1. 5 mm
89 N.m 19.1 kgf.m, 66 lbf.ft)
FLANGE BOLT
10 x
' 1. 25
mm
43 N.m {4.4 kgf.m,
32 tbtft)
DAMPR FORK
Check l or damage.
DAMPER FORK
RU88ER BUSHING
Check f or det eri orat i on and damage.
4@lsrlrcoNE GREASE
SELF.LOCKING NUT
12 x 1. 25 mm
Repl ace.
64 N m 16.5
kgl.m, 47 lblft)
J
RANGE
18- 9
Front Suspension
Knuckl e/Hub Repl acement
CAUTION:
. Replaco tho salf-locking nuts after romoval.
. The vehiclo should be on tho
ground
bsfore any bohs or nuls connected to 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 onl y genui ne Honda wheel wei ghts for al umi num wheel s. Non-genui ne wheel wei ghts may corrode and damage
the al umi num wheel s.
. On the al umi num wheel s, remove the center cap from the i nsi de of the wheel after removi ng the wheel ,
. Before i nstal l i ng the brake di sc, cl ean the mati ng surfaces of the front hub and brake di sc,
. Before i nstal l i ng the wheel , cl ean the mati ng surfaces of the brake di sc and wheel .
o Wi pe off the grease before ti ghteni ng the nut at the bal l
j oi nt.
CALIPER MOUNTING BOLT
12 x 1. 25 mm
108 N. m {11. 0 kgl . m, 80l bf . f t )
LOWER BALL JOINT
Inspect for faulty
movement and wear.
CASTLE NUT
10 r 1. 25 mm
39
- ia7
N.m
(4.0 -
4.8 kgf.m, 29
-
35 lbf,ftl
COTTER PIN
Repl ace.
WHEEL BEARING
Repl ace.
Repl acement , page
18-14
CIRCLIP
SCREW
5 x 0 . 8 mm
5 N.m {0.5 ksl.m, 4 lbf.ftl
Repl acement , page
18-16
SET RING
BALL JOINT BOOT
FRONT HUB
Check f or damage and
cracks.
Repl acement ,
page 18-10
and damage.
CASTLE NUT
12 x 1.25 mm
49
-
59 N.m l5.O
-
6.0 kg{.m. 36
- /(}
lbf,ftl
SPINDI.T ]{UT
22 r 1.5 mm
lEl N.m {18.5 kgf.rn, 13{ lbl.ttl
Replace.
NOTE:
.
Before instelling the spindle nut. apply
6n9i ne oi l t o t h6 seat i ng surf ace of t he nut .
.
Atter tightening, uso a drift to stake the
spindle nut should6r against the driveshaft.
BRAKE DISC
Check f or wear and
rust.
l nspect i on, sect i on 19.
WHEEL NUT
12 x 1. 5 mm
'108
N.m
1r1.0 kgf.m, 8lt lbf.ft)
6 mm BRAKE DISC RETAINING SCREW
9.8 N.m 11.0 kgf.m, 7 lbtft)
1 8 - 1 0
)
1 . Loosen the wheel nuts sl i ghtl Y.
Raise the front of the vehicle, and support it with safe-
ty stands in the
proper locations
(see
section 1).
Remove the wheel nuts and wheel .
3.
l )
WHEEL NUT
'108
N.m
18' l N. m 118. 5
kgf m, 134l bl f t i
Repl ace.
NOTEI Bef ore i nst al l i ng t he spandl e nut , appl y
engine oil to the seating surface of the nut After
t i ght eni ng, use a dri f t t o st ake t he spi ndl e nut
shoul der agai nsl t he dri veshaf t
Rai se t he l ocki ng t ab on t he spi ndl e nut , t hen remove
t he nut .
Remove t he brake hose mount i ng bol t s.
BRAKE HOSE MOUNTING BOLT
I x 1. 25 mm
12 N.m
(1,2 kgtm,8,7 lbf'ftl
6. Remove the cal i per mounti ng bol ts and hang the
cal i per assembi y to one si de
CAUTTON:
To prevent acci dental damage to the
caliper assembly or brake hoso' use a short
piece of
wire to hang the caliPer tlom lhe undelcarriage.
{11 kgf m, 80 lbl.ft)
CALIPER MOUNTING BOLTS
12 x 1. 25 mm
108 N.m {'11.0 kgtm, 80 lbt.ft)
7. Remove the 6 mm brake di sc retai ni ng screws.
8.
I x 1.25 mm BOLTS
Screw two 8 x 1.25 mm bol ts i nto the di sc to
push i t
away from the hub,
NOTE: Turn each bolt two turns at a tame to prevent
cocki ng the di sc excessi vel Y.
Remove the brake di sc from the knuckl e.
Check the front hub for damage and cracks.
Remove t he wheel sensor f r om t he knuckl e
( f or
vehi cl es wi th ABS).
NOTE: Do not di sconnect the wheel sensor connec-
tor.
N. m
6 mm BRAKE OISC
RETAINING SCREWS
9.8 N.m t1.0 kgf.m, 7 lbf'ft)
{' 1. 0
kgf m,
7 tbf.ft)
10.
1 1 .
MOUNTI NG
WHEEL
BOLTS
9.8 N.m
11.0 kgf,m, 7 lbf'ft)
(cont ' d)
Front Suspension
Knuckle/Hub Replacement
(cont'dl
NOTE: Use the speci al tool to separate the bal l
j oi nts
from the suspensi on or steeri ng arm,
CAUTION: 86 careful not lo damage the ballioint boot.
12. Cl ean any di n or
grease
off the bal l
j oi nt.
pi n from the steeri ng arm, and
remove the nut.
14. Apply
grease
to the special tool on the areas shown,
Thi s wi l l ease i nstal l ati on of the tool and
prevsnt
damage to the
pressure
bolt threads.
PRESSURE AOLT
Instal l a 10 mm hex nut onto the bal l
j oi nt.
Be sure
j oi nt pi n
end to
prevent
damage to the threaded end of the bal l
j oi nt.
Instal l the speci al tool as shown. Insert the
j aws
careful l y, maki ng sure you do not damage the bal l
j oi nt
boot. Adi ust the
i aw
spaci ng by turni ng th6
pressure bolt.
NOTE: l f necessary, appl y penetrati ng
type l ubri -
j oi nt.
COTTER.PIN
Repl ace.
On reassembly,
bend the cofter pin
15.
16.
CASTI.T NUT
10 x 1, 25 mm
39
-
47 N.m
14.0
-
4.8 kgf.m,
29
-
3s tbl.ftt
CASTLE NUT
10 r 1.2s mn--]*-
corrcn nn
.\
18-12
Replace-
17. Once the speci al tool i s i n pl ace,
turn ths adj usti ng
bol t as necessary to make the
j aws paral l el .
Then
hand-ti ghten the
pressure
bol t, and recheck the
j aws
to make sure they are sti l l paral l el .
AI\IUSTING BOLT
NOTE: After making the adiustment to the adiust-
ing bolt, be sure the head of the adjusting bolt is in
this
position
to the allow the
jaw
to
pivot.
Wi th a wrsnch, ti ghten the
pressure
bol t unti l the
ball
joint
shaft pops loose from the steering arm.
E@
we.r cye plotection.
Thc brtt
ioint
cln brcrk loose suddenly and sclt'tol dirt or other
d.brb inio youl .ye..
Rsmov the tool, then remove th nut from the end
of the bal l
i oi nt
and pul l
the bal l
j oi nt
out of the
stoering/suspension arm. Inspct the ball
joint
boot
and replace it if damaged.
18.
1 0
)
20, Remove the cotter
pin
from the lower arm ball
joint
castl e nut. and remove the nut.
COTTER.PIN
Repl ace.
On reassembl y,
bend the cotter
Pan
l r
CASTLE NUT
12 x 1.25 mm
49
-
59 N.m
(5.0 -
6.0 kgl m,36-,13 lbf'ft|
BALL JOINT REMOVER, 28 mm
07MAC
-
SL00200
21. l nstal l a 12 mm hex nut onto the bal l
j oi nt.
Be sure
j oi nt pi n end'
or the threaded secti on of the bal l
j oi nt pi n mi ght be
damaged by the bal l
j oi nt
remover.
22. Use the speci al tool as shown on page l 8-12 to sep-
arate the bal l
i oi nt
and l ower arm.
NOTE; l f necessary, appl y
penetrati ng type l ubri -
j oi nt.
l J
1 8 - 1 3
25.
26.
Remove the cotter
pi n
from the upper bal l
j oi nt
cas-
tl e nut, and remove the nut.
12 mm HEX NUT 07MAC
-
SL00200
l nstal l the 12 mm hex nut onto the bal l
j oi nt
Be sure that the hex nut i s fl ush wi th the bal l
j oi nt
pi n end, or the threaded secti on of the bal l
j oi nt pi n
ml ght be damaged by the bal l
j oi nt
remover'
Use the speci al tool as shown on page l 8-12 to sep-
arate the bal l
j oi nt
and knuckl e.
NOTE: l f necessary, appl y
penetrati ng type l ubri
j oi nt.
Putl the knuckte outward and remove the driveshaft
outboard
joint
from the knuckle by tapping the drive-
shaft end wi th a
pl asti c
hammer, then remove the
knuckl e.
KNUCKLE
' 12
x 1. 25 mm
39
-
47 N.m
14.0
-
4.8 kgf m,
29
-
35 tbf.ft)
Check f or damage.
Front Suspension
Knuckl e/Hub Repl acement
(cont' dl
NOTE: Replace the bearing with a new one after removal.
27. Separate the hub from the knuckl e usi ng the speci al
tool s and a hydraul i c press.
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 engaged belore
pressing.
HUB DIS/ASSEMBLY
PILOT,38 mm
07JAF
-
SH20110
HUB DIS/ASSEMALY
SHAFT. 22. { x 25. 4 mm
07JAF
-
SH20120
28. Remove the ci rcl i p and the spl ash guard from the
knuckl e.
Press
BEARTNG
t
SEPARATOR -
O
-
1112 i n.
(Commerci al l y
avai l abl e)
Check t or bendi ng and damage.
18-14
29. Press the wheel beari ng out ofthe knuckl e usi ng the
speci al tool s and a Dress as shown,
DRIVER
07749
- (X)l
0000
Pross
t
KNUCKLE
ATTACHMENT,
6 2 x 6 8 mm
07746
-
0010500
HUB DIS/ASSEMBLY BASE
07GAF
-
SEoo4Ol
Press the wheel beari ng
usi ng the speci al tool s, a
press as shown.
WHEEL BEARING
Replace.
i nner race from the hub
beari ng separator, and a
HUB DIS,/ASSSMBLY
PILOT, 38 mm
07JAF
-
SH20110
KNUCKLE
FRONT I{U8
HUB DIS/ASSEMBLY
SHAFT, 22. 4 x 25. 4 mm
07JAF
-
SH20120
I
NOTE: Wash t he knuckl e and hub t hor oughl y i n
hi gh fl ash
poi nt sol vent before reassembl y.
31. Press a new wheel beari ng i nto the knuckl e usi ng
the speci al tool s and a
press as shown
NOTE: Pl ace t he wheel bear i ng ont o t he knuckl e
wi th the
pack seal
(metal
col or) toward the i nsi de
Be careful not to damage the sl eeve of the
pack
seal .
Press
HANOI.E
07749
-
001
DRIVER
ATTACHMENT
5 8 x 7 2 mm
07947
-
6340201
DOUBLE LIP SEAL
{BLACK COLOR)
KNUCKLE
SUPPORT BASE
07965
-
SD90100
Instal l the ci rcl i p securel y i n the knuckl e
groove'
Instal l the spl ash
guard, and ti ghten the screws.
scREws
5 N.m
(0.5
kgd m, 4lbt'ft)
32.
33.
l - ,
1 8 - 1 5
34. l nstal l the hub on the knuckl e usi ng the speci al tool s
shown and a hydraul i c
press as shown.
CAUTION: Take care not to distort tho splash
gusrd'
HUB/ASSEMBLY
GUIDE ATTACHMENT
07GAF- SEflt2d)
KNUCKLE
FRONT HUB
SUPPORT BASE
07966
-
StXx)100
SPLASH GUARD
tnstall the knuckle in the reverse order of removal'
and
pay parti cul ar attenti on to the fol l owi ng i tems:
. Be careful not to damage the bal l
j oi nt
boots
when i nstal l i ng the knuckl e.
. Torque al l mounti ng hardware to the speci fi ed
torque valugs.
. Torque the castl s nuts to the l owr torque specl -
fi cati ons, then ti ghten them onl y far enough to
al i gn the sl ot wi th the
pi n hol e. Do not al i gn the
castl e nut by l ooseni ng.
. l nstal l new cotter
pi ns
i nto the castl e nuts after
torqui ng.
. Avoi d twi sti n0 the sensor wi res when i nstal l i ng
the wheel ssnsor.
. Before i nstal l i ng the brake di sc, cl ean the mati ng
surfaces of the front hub and the i nsi de of the
brake di sc.
. Before i nstal l i ng the wheel , cl ean the mati ng sur-
face ofthe brake di sc and the i nsi de of the wheel
. Check the front wheel al i gnment, and adj ust i t i f
necessary
(see page 18-4).
Front Suspension
L
Lower Ball Joint Replacement
Remove the knuckl e
(see page 18-11).
Remove the boot by pryi ng
the set ri ng off.
Check t he boot f or det er i or at i on and damage.
repl ace i f necessary.
Instal l the speci al tool s onto the bal l
j oi nt
and ti ght-
en the casfl e nut.
Posi t i on t he speci al t ool s over
shown. then set the assembl y i n
bal l
j oi nt
out of the knuckl e,
BALL JOINT REMOVER/INSTALLER
07965
-
SB00r00
CASTLE NUT
t he bal l
j oi nt
as
a vi se. Press the
l f
7.
BALL JOINT REMOVER BASE
07JAF
-
SH20200
Pl ace the bal l
j oi nt
i n posi ti on by hand.
Instal l the speci al tool s over the bal l
j oi nt
as shown,
then press the bal l
j oi nt
i n.
BALL JOINT INSTALLEB BASE
07965
-
5800200
BALL JOINT HOUSING SURFACE
1 8 - 1 6
8. Instal l the bal l
j oi nt
boot and set ri ng usi ng the spe-
ci al tool
(see page 18-16).
ADJUSTING BOLT
Adj ust rhe dept h by
t urni ng t he bol t .
Instal l the knuckl e i n the reverse order of removal ,
and pay parti cul ar attenti on to the fol l owi ng i tems:
. Be careful not to damage the bal l
j oi nt
boots
when i nstal l i ng the knuckl e,
. Torque al l mounti ng hardware to the speci fi ed
torque val ues.
. Torque the castl e nuts to the l ower torque speci -
fi cati ons. then ti ghten them onl y far enough to
al i gn the sl ot wi th the pi n hol e. Do not al i gn the
castl e nut by l ooseni ng.
. Instal l new cotter pi ns i nto the castl e nuts after
torquang.
. Avoi d twi sti ng the sensor wi res when i nstal l i ng
the wheel sensor.
. Before i nstal l i ng the brake di sc. cl ean the mati ng
surfaces of the front hub and the i nsi de of the
brake di sc.
. Before i nstal l i ng the wheel , cl ean the mati ng sur-
face of the brake di sc and the i nsi de of the wheel .
. Check the front wheel al i gnment, and adj ust i t i f
necessary {see
page 18-4).
Front Damper
!
Bal l Joi nt Boot RePl acement
1 . Remove the set ri ng and the boot.
CAUTION: Do not contami nate the boot i nstal l a-
tion section with
grease.
Pack the i nteri or of the boot and l i p wi th grease
EALL PIN TAPERED SECTION
EOOT INSTALLATION SECTION
Wi pe of f t he
grease.
BOOT INSTALLATION SECTION
Wi pe of f t he
grease.
l J
3. Wi pe the grease off the sl i di ng surface of the bal l
pi n and
pack wi th fresh grease.
CAUTION:
. Keep
grease off the boot installation section and
the tapeled section of the ball pin.
5.
. Do not allow dust, dirt, or other toreign materi-
al s to enter the boot.
Instal l the boot i nto the groove of the boot i nstal l a-
ti on secti on securel y, then bl eed the atr.
Instal l the upper and l ower bal l
j oi nt
boot set ri ngs
usi ng the speci al tool s as fol l ows:
Lower bal l
j oi nt : Adi ust t he speci al t ool wi t h t he
adj usti ng bol t unti l the end of the tool al i gns wi th
the groove on the boot. Sl i de the set ri ng over the
tool and i nto
Posi ti on.
BALL JOINT
AOJUSTING BOLT
Adjust the depth by
t urni ng t he bol t .
BOOT CLIP
GUI DE
4.
UPPER EALL
JOINT EOOT:
07GAG
-
SD40700
LOWER BALL
JOINT BOOT:
07974
-
SA50700
CAUTION: After installing the boot, check the ball
pin tapsrod section fol grease contamination and
wipe it if necessary.
l t
18-17
Removal
l . Remove the front wheel s
(see page 18-11).
2, Remove t he damper
pi nch bol t t r om t he t op of
damper fork.
DAMPER FORK
OAMPER
FORK
BOLT
OAMPER
PI NCH
AOLT
10 x 1. 25 mm
SELF-LOCKING NUT
12 x 1. 25 mm
Repl ace.
Remove the damper fork bol t and sel f-l ocki ng nut
from the bottom of the damper fork, then remove
damper fork.
Remove the damper by removi ng the two nuts
DAMPER
Front Damper
Disassembly/lnspection
Disassembly
' 1.
Compress the damper spri ng wi th the spri ng com-
pressor
accordi ng to the manufacturer,s i nstruc-
ti ons, then remove the sel f-l ocki no nut.
CAUTION: Do not compress the spring more than
ncessary to remove the nut.
10 mm SELF-
LOCKING NUT
Repl ace.
STRUT SPRING
COMPRESSOR:
(Commerci.lly
availabl.l
BRANICKO T/N MST.s8I}A, T/N 7200,
or eouivalent
Rel ease the pressure from thg spri ng compressor,
then di sassembl e the damper as shown i n the next
col umn.
Inspostion
1. Reassembl e al l parts, except the spri ng.
2. Push on th damper assembl y as shown.
Check for smooth operati on through a ful l stroke,
both compressi on and extensi on,
NOTE: The damper shoul d move smoot hl v. l f i t
does not
(no
compressi on or no extensi on), the gas
i s l eaki ng, and the damper shoul d be repl aced.
Check for oi l l eaks, abnormal noi ses, or bi ndi ng dur-
ing these tests.
18- 18
DAMPER UNIT
Repl ace.
DAMPER MOUNTING WASHER
BASE
DAMPER MOUNTING
BUBBER
and damage.
DAMPR SPf,ING
Check tor weakened compression
and damage.
SPBING MOUNTING RUBBER
and damage,
BUMP STOP
Check for
damage.
DUST COVER
PLATE
and
BUMP STOP PLATE
OUST COVER
\
Reassembly
2.
' t.
l r
Instal l the damper uni t on a spri ng compressor.
Assembl e the damper i n reverse order of removal
except the damper mounti ng washer and sel f l ock-
i ng nut .
NOTE: Al i gn the bottom of the damper spri ng and
spri ng l ower seat as shown.
STRUTSPRING
COMPRESSOR:
lcommercially
availablel
BRANICK@ T/N MST.58OA, T/N 7200,
or 6quivalnt
SPBING LOWER SEAT
Pos i t i on t he damper mount i ng bas e ont o t he
damper uni t as shown.
Compress the damPer sPri ng.
Instal l the damper mounti ng rubber, damper mount-
i ng washer, and a new 10 mm sel f-l ocki ng nut.
Hol d the damper shaft. and ti ghten the 10 mm sel f-
l ocki ng nut.
SELF-LOCKING NUT
10 x 1.25 mm
29 N.m 13.0 kgf m, 22 lbf ft)
3.
4.
Repl ace.
DAMPER
MOUNTING WASHER
( l - t
lnstallation
1. Loosel y i nstal l the damper onto the frame wi th the
al i gni ng tab faci ng i nsi de. then l oosel y i nstal l the
two fl ange nuts.
FLANGE NUTS
10 x 1 ,25 mm
49 N.m
(5.0 kgt'm, 36 lbf'ftl
DAMPER ASSEMBLY
{cont ' d)
1 8 - 1 9
Front Damper
Installation
(cont'd)
2. Instal l the damper fork over the dri veshaft and onto
t he l ower ar m. I nst al l t he f r ont damper i nt o t he
damper fork so the al i gni ng tab i s al i gned wi th the
sl ot i n the damper fork.
ALIGNING TAB
DAMPER
PI NCH
EOLT
10 x 1. 25 mm
43 N.m 14.4 kgf.m, 32 lbtftl
12 x 1. 25 mm
64 N.m 16.5 kgl.m, 47 lbtftl
Repl ace.
Loosel y i nstal l the damper pi nch
bol t i nto the top of
the damper fork.
Loosel y i nstal l the damper fork bol t and a new sel f-
l ocki ng nut i nto the bottom of the damper fork.
Rai se the knuckl e wi th a fl oor
j ack
unti l the vehi cl e
just
lifts off the safety stand.
@E
The ftoor
ilck
must be sscuroty posi-
lionsd or personal iniury may ruh.
Ti ghten the damper pi nch bol t.
Ti ghten the damper fork bol t and sel f-l ocki ng nut.
Ti ghten the fl ange nuts on top of the damper.
Instal l the brake hose mounts wi th the brake hose
mounti ng bol ts.
Instal l the front wheel .
7.
8.
9.
10.
1a-20
Rear Suspension
I
Suspension
Arms Replacement
('96
-
99 modelsl
tffi Whsn ths suspension arms ar6 to be removed.
place additionsl weight in the trunk bafore hoisting' Whn
-
substantial
weight is removed ftom th6 teal of ths vehicl6, the center of
gravity may change causing ths cat to tip tor'
ward.
CAUTION:
.Thgvehi c| eshoul dbonthggroundboforeanybohsornutsconnectodtorubbel mountso]bughi ngsareti ghton.
NOTE:
. Make sure the toe adj usti ng bol ts on the compensator
arm are i nstal l ed i n the same di recti on'
.
,,t
UP 1,, or
,,t
UP LH G,. or
,.t
UP LK,, or
"t
UP LS' . i s stamped on the | eft upper arm and
,,t
UP R" or
"t
UP RH G., or
"t
UP RK" or
"t
UP RS" on the ri ght upper arm'
. The ri ghtand l eft "ornp"n""to, ui tt rre symmetri cal l nstal l sothe
"t
UP" stamped si de faces forward'
. Af t er i nst a| | i ngt hesuspens| onar m, checkt her ear whee| al i gnment , andadj ust i f necessar y( seepagel S- 4) .
FLANGE BOLT
10 x 1. 25 mm
54 N.m
ADJUSTING BOLT
(FLANGE BOLTI
10 x 1. 25 mm
BUSHING
and oamage.
(5.5
kgf'm, 40 lbf'ftl
UPPER ARM INNER
47 tbf.ftl
t J
l0 mm FLANGE BOLT
N.m t4.0
kst m, 29l bl ftl
DAMPER MOUNTING
BOLT
(FLANGE BOLT}
10 x 1. 25 mm
5 4 N m
(5.5 kgd.m,
iro lbf'ft)
FI.ANGE BOLT
10 x 1, 25 mm
54 N.m
(5,5
ksrf.m, 4{} lbf'ft}
UPPER ARM
Check f or bendang
damage-
TRAILING ARM
COMPENSATOR ARM
Check f or bendi ng
ano oamage,
COMPENSATOR
ARM
I NNER BUSHI NG
.-
SILICONE
.@] GREASE
Check t or det eri orat aon
and damage.
FLANGE BOLT
10 x 1. 25 mm
64 N.m {6.5 kgt'm,
47 lbf.ft)
LOWER ARM
Check f or cracks
ano damage.
LOWEN ARM BUSHING
.,-
SILICONE
..i@l GREASE
and oamage,
FLANGE AOLT
12 x 1. 25 mm
64 N.m {6.5
kgf m,
47 tbf.ftt
FLANGE BOL
10 x 1. 25 mm
I
54 N.m
\
(5.5 ksrm, ao lbf'ftl
1A-21
Rear Suspension
Suspension Arms Replacement ('gg
2D Si and Si-R models)
CAUTION:
.
Roplace the self-locking nut after removal.
'
The vehicle should be on the gtound
before any bohs or nuls connected to rubber mounts or bushing are tightened.
NOTE:
'
Make sure the toe adj usti ng borts on the compensator arm are i nsta| ed i n the same di recti on.
.
"t
UP L" or
"t
UP LH G" or
"t
Up LK" or
"l
Up LS,, i s stamped on the l eft upper arm and
,,t
Up R,, or
"t
Up RH G,,
" i
UP RK" or
" t
UP RS" on t he r i ght upper ar m.
. The r i ght and l ef t compensat or ar m ar e symmet i car . I nst al l sot he" upr " mar kpoi nt st ot hef r ont .
. After i nstal l i ng the suspensi on arm, check the wheel ati gnment and adi ust i f necessary,
FLANGE BOLT
'10
x 1.25 mm
54Nm155kgl . m,
,rc
lbf.ftl
8 rhm BOLTS
22 N.m
{2.2 kgf.m, 16 tbtfrl
STABILIZER BUSHTNG
FLANGE BOLT
10 x 1. 25 rnm
54 N.m {5.5 kgt m, iro
lbf.ft)
STAEILIZER BAR
Check f or bendi ng or damage.
FLANGE BOLT
10 x 1 . 25 mm
64 N m {5.5 kgf.m,47 lbtftl
FLANGE BOLT
10 x 1. 25 mm
54 N.m 15.5 *gf.m,
and
UPPER ARM BUSHING
Al i gn t he st abi t i zer mark
wi t h t he end ot t he st abi l i zer bushi ng.
FLANGE BOLT
' 10
x 1. 25 mm
54 N.m 15.5 kgt.m, a0 lbtftl
stLrcoNE
UPPER ARM BUSHING
iO
lbf.ftl
TRAILING ARM
Check f or bendi ng and
EOLTS
10 x 1. 25 mm
39 N m ll kgf.m, 29 lbf.ft)
UPPER ARM
Check f or bndi ng or damage.
#@l
stLtcoNE
COMPENSA TOR ARM BUSHING
COMPENSATOR
ARM BUSHING
and damage.
FLANGE NUT
r
'1.25
mm
29 N.m {3.0 ksl.m,22 lbtft}
Belore tightening the flange nut,
posi t i on
t he bal l
j oi nt pi n
i n t he mi ddl e ol i t s range of
t ravel , wi t h t he suspensi on under
vehi cl e l oad.
LOWER ARM
Check f or damage-
BUSHI NG
FLANGE BOLT
l 0 x 1. 25 mm
6l N.m 16.5 kg{.m, a7 lbt.ftl
FLANGE BOLTS
10 x 1, 25 mm
64 N.m {6.5 kgf.m, 47 lbf.ftl
SELF.LOCKNG NUT
LOWER ARM
-Gr
stltcoNE
10 x 1.25 mm 29 N.m
(3.0
ksl.m, 22 tbtfrl
Repl ace.
Hol d t he bal l
i oi nl
pi n
usi ng a hex w. enct .
and t i ght en t he sel f j ocki ng nut .
STABILIZEB LINK
LOWER ARM BUSHING
.
Check for deterioration and damaoe.
'
See page
18 25 f or bushi ng repl aci ement .
'
.
Check t he bushi ng f or det er i or at i on ano oamage.
18-22
I
Hub Beari ng Uni t RePl acement
For vehi cl es wi th drum brakes.
' 99
2D Si and Si -B model s
NOTE:
o Use onl y
genui ne Honda wheel wei ghts for al umi num wheel s Non-genui ne
wheel wei ghts may corrode and damage
t he al umi num wheel s.
. ont hea| umi numwhee| s, r emovet hecent er capf r omt hei nsi deof t heWhee| af t er r emovi ngt hewhee| '
. Before i nsta| | i ng the brake di sc
(or brake drum), c| ean the mati ng surfaces of the rear hub and the brake di sc
(or
brake
or um, .
. Before i nstal l i ng the wheel , cl ean the mati ng surfaces ofthe brake di sc(or brake drum) andwheel '
* 1 :
*2' .
12
6 mm FLANGE BOLT
9.8 N.m {1.0 kgf m, 7 lbf'ft|
*2
SPLASH GUARO
Check f or cracki ng
and damage.
SPINDLE WASTIER
SPINDLE NUT
22 x 1. 5 mm
181 N, m
(18. 5 kgt ' m. 134l bf f t )
Repl ace.
NOTE:
'
Bef ore i nst al l i ng t he spi ndl e nut , appl y
engi ne oi l t o t he seat i ng surf ace of t he
nut ,
'
Af t er t i ght eni ng, use a dri f t
Punch
t o l ock t he spi ndl e nut shoul der i nt o
TRAILING ARM
and oamage,
l r
t he spi ndl e.
HUB CAP
Bepl ace.
12
BRAKE DISC
Check f or wear and
rust ,
'2
6 mm BRAKE DISC RETAINING SCREW
\ 9.8 N'm 11.0
kgt m, 7 lbf'ft|
)
*1
BACKING PLATE
/\
*1
BRAKE SHOE
r1
FLANGE BOLT
10 x 1. 25 mm
6,0 N.m
(6.5 ksl.m,47 lbl'ftl
REAB
'1
BRAKE ORUM
HUB UNIT BEARING
and damage.
WHEEL NUT
12 x 1. 5 mm
108 N.m {11.0 kgt' m.80l bt' ft)
(cont' d)
1A-23
l - t
Rear Suspensi on
Hub Beari ng Uni t Repl acement (cont' dl
NOTE: Di sc type {' 99 2D Si and Si -R modets)
1. Loosen the wheel nuts sl i ghtl y.
2. Rai se the rear of vehi cl e, and support i t wi th safety
stands i n the proper
l ocati ons
{see secti on 1).
3. Remove the wheel nuts and rear wheel .
4. Pul l the parki ng
brake l ever up.
5. Remove t he hub cap.
6. Rai s e t he l oc k i ng t ab on t he s pi ndl e nut , t hen
remove the nut. SPINDLE NUT
22 x 1.5 mrn
181 N. m (18. 5
kgf ' m, 134l bf . f i )
Repl ace.
NOT:
.
Eef ore i nst al l i ng t he spi ndl e nut ,
appl y engi ne oi l t o t he seat i ng
surf ace of t he nut .
.
Af t er t i ght eni ng, use a dri f t t o
st ake t he spi ndl e nut shoul der
agai nst t he spi ndl e.
l For
vehi ctes
\
\wi th
drum brakes;/
WHEEL NUT
12 x 1. 5 mm
108 N. m
I I 1 kgt m, 80 lbf.ftl
HUB CAP
Repl ace-
NOTE: Take care not t o damage t he hub unt t
on di sassembl y.
Remove t he 6 mm brake di sc ret ai ni ng screws.
7.
6 mm BRAKE DISC
RETAINING SCBEWS
9.8 N.m
11.0 kgl.m, 7 lbf.frl
1A- 24
8.
9.
Rel ease the parki ng
brake l ever.
Remove t he br ake dr um, hub uni t bear i ng, and
spi ndl e washer
l for vehi cl es wi th drum brakes).
BRAKE DRUM
SPINDI-E WASHER
10. Remove the 6 mm fl ange bol ts and cal i per shi el d.
CALIPER SHIELO
6 mm FLANGE BOLTS
9.8 N.m {1.0 kgf.m, 7 lbf,ft)
T
1 1 .
1 )
Remove the two brake hose mounti ng bol ts
Remove t he cal i per b. acket mount i ng bol t s, and
hang the cal i Per to one si de
CAUTION: To
prevent acci dental damage to the
caliper or brake hose, use a short
piece of wile to
hang the caliper from the undercarriage.
BRAKE HOSE MOUNTING BOLTS
22 N'm {2.2 kgf'm, 16lbt"ft}
CALIPER
10 x 1.25 mm
38 N'm
(3.9 kgf'm, 28 lbf'ftl
Screw two 8 x 1.25 mm bol ts i nto the di sc to push i t
away from the hub.
NOTE: Turn each bol t two turns at a ti me to pre-
vent cocki ng the di sc excessi vel y.
Remove the brake di sc.
Remove the hub uni t beari ng from the spi ndl e
SPINOLE WAS}IER
l r
14.
15.
l t
16. l nstal l i n the reverse order of removal .
1A-25
Upper Arm Bushi ng RePl acement
1. Remove t he upper ar m bushi ng and upper ar m
j nner
bushi ng as shown
UPPER ARM INNER BUSHING
UPPER ARM BUSHING
REAR UPPER ARM
Scri be a l i ne on the upper arm i nner bushi ng so that
i t i s i n l i ne wi th the bol t mounti ng surface
Mark to
poi nts on the upper arm so that they are In
l i ne and make a ri ght angl e wi th the arm as shown
i n the drawi ng.
BOLT MOUNTING
SURFACE
Dri ve i n the upper arm i nner bushi ng wi th the marks
al i gned.
Dri ve the upper arm bushi ng i nto the upper arm
NOTE: Dri ve i n the upper arm bushi ng and upper
ar m i nner bushi ng unt i l t hei r l eadi ng edges ar e
fl ush wi th the uPPer arm
t t
I
5.
UPPER ARM
Rear Damper
Removal
1. Bemove the rear wheel s
(see page
1g-22).
2. Remove the speaker cover and speaker
(Hatchback).
Sedan and Coupe: Remove the trunk si de panel (see
secti on 20).
3. Remove the two flange nuts.
FLANGE NUTS
10 x 1. 25 mm
4. Remove
FLANGE BOLT
10 x 1,25 mm
Remove the fl ange bol t that connects the l ower arm
to the trai l i ng arm.
the fl ange bol t from the damper.
FLANGE BOLT
'10
x 1 .25 mm
18-26
6. Lower the rear suspensi on, and remove the damper.
I
Disassembly/lnsPection
l r
Disassembly
1. Compress the damper spri ng wi th the spri ng com-
pr essor accor di ng t o t he manuf act ur er ' s i nst r uc-
ti ons, then remove the sel f-l ocki ng nut.
GAUTION: Do not compress the spring more than
necessary to remove the sell-locking nut.
STNUT SPRING COMPRESSOR:
lComm6rcially
.vailablel
ERANICKo T/N MST-580A, T/N 7200, or equivalent
Rel ease t he pressure f rom t he spri ng compressor.
t hen di sassembl e t he damper as shown on page 18-
( | - r
lnspection
1. Reassembl e al l parts, except the sprl ng.
2. Push on the damPer as shown.
WOODEN BLOCK
Check for smooth operati on through a ful l stroke,
both compressi on and extensi on.
NOTE: The damper shoul d move smoot hl y l f i t
does not
(no
compressi on or no extensi on), the gas
i s l eaki ng, and the damper shoul d be repl aced.
Check Jor oi l l eaks, abnormal
noi ses, and bi ndi ng
duri ng these tests.
{cont ' d)
18-27
Rear Damper
Disassembly/lnspection (cont'dl
SELF-LOCK|NG NUT -
el
10 x 1. 25 mm v
29 N.m {3.0 kst'm, 22 lbf.ftl
Repl ace.
DAMPEB
MOUNTING
WASHER
DAMPER MOUNTING
8U8BER
Check t or
det eri orat i on
ano oamage.
DAMPER
COLLAR
DAMPER
MOUNTING BASE
OAMPER MOUNTING
DAMPER SPRING
Check lor weakness,
compressi on, and damage.
SPRING MOUNTING
RUBBER
ano oamage.
BUMP STOP
Check for weakness
and damage,
BUBBES
Check f or
det eri orat i on
ano oamage.
OUST COVER PLATE
DUST COVER
Check l or bendi ng
DUST COVER BOOT
and damage.
18-2A
OAMPER UNIT
Repl ace.
:
Reassembly
1 . Instal l the damper uni t onto a spri ng compressor.
NOTE: Fol l owthe manufacturer' s i nstructi ons.
Assembl e the rear damper i n the reverse order of
di sassembl y except the damper mounti ng washer
and sel f-l ocki ng nut.
NOTE: Al i gn the bottom of the damper spri ng and
spri ng l ower seat as shown.
Pos i t i on t he damper mount i ng bas e ont o t he
damoer uni t as shown.
SIRUT SPRING COMPRESSOR:
DAMpERMOUNTTNG
(Commerciattyavaitabtel
BRANICKO T/N MST-580A, T/N 7200.
or cquivalont
Compress the damper spri ng wi th the spri ng com-
pressor.
Instal l the damper mounti ng washer, and l oosel y
i nstal l a new sel f-l ocki ng nut.
Hol d the damper shaft wi th a hex wrench, and ti ght-
en the sel f-l ocki ng nut.
SELF-LOCKING NUT
DAMPER
10 x 1, 25 mm
29 N m 13.0 kgt.m, 22 lbtftl
MOUNTING
WASHER
Rear Damper
I
lnstallation
' 1.
Lower t he r ear s us pens i on, and
pos i t i on t he
damper wi th the spri ng stop
poi nted toward the l eft
SPRING STOP
2. Loosel y i nstal l the two fl ange nuts
FLANGE NUTS
10 x 1. 25 mm
49 N.m
(5
kgf.m, 36 lbt'ft)
Ti ght en t hese nut s i n
st ep 7.
l r
3. Loosel y i nstal l the fl ange bol ts.
FLANGE BOLT
10 x 1. 25 mm
54 N.m {5.5 kgf m, 40 lbt'ft1
FLANGE BOLT
10 x 1 . 25 mm
54 N.m {5.5 kgf.m,
/r0 lb{.ft|
7.
Rai se the rear suspensi on wi th a fl oor
j ack
unti l the
vehicle
just
lifts off the safety stand.
!@@
Tne floor
iacx
must be securelY
Posi-
tionod or
peFonal iniury may rssull
Ti ghten the fl ange bol ts.
Ti ghten the two fl ange nuts on top of the damper to
the speci fi ed torque.
Check the rear wheel al i gnment and adj ust i f neces-
sary
(see page 18-4).
1A-29
t
Brakes
Conventi onal
Brakes
..."... 19-1
Anti -l ock Brake System
(ABS)
."......".. 19-43
I t - ,
l t
t
Conventi onal
Brake
Speci af Tool s . . . . . . . . . . . . . 19' 2
Component Locations
l ndex . . . . . . . . . . . . . . . . . . . . . . 19-3
Inspection and Adiustment
Brake System Rubber Parts
and Brake Boost er . . . . . . . . . . . , . , . . . . . . . . . . . . . 19-4
Brake Pedal . . . . . . . . . . . . 19-5
Parki ng Brake . . . . . . . . 19-6
Bl eedi ng . . . . . . . . . . . . . . . . . 19-7
Front Brake Pads
Inspection and Replacement .......... 19-8
Front Erake Disc
Di sc Runout I nspect i on . . . . . . . . . . . . . . . . . . . 19-12
Disc Thickness and Parallelism
I nspect i on . . . . . . . . . . 19-12
Front Brake Caliper
Di sassembl y . . . . . . . . . . 19' 13
Reassembl y . . . . . . . . . . . 19-16
Master Cylinder/Brake Booster
Removal / l nst al l at i on . . . . . . . . . . . . . . . . . . . . . . . 19-21
Pushrod Clearance Adiustment ...... 19-22
Brake Booster Inspection ................ 19-23
Rear Brake Pads
Inspection and Replacement ,,........ 19-24
Rear Brake Disc
Di sc Runout l nspect i on . . . . . . . . . . . . . . . . . . . 19-26
Disc Thickness and Parallelism
Inspection .......... 19-26
Rear Brake Caliper
Disassembly ...........19-27
Reassembl y
. . . . . . . . . " 19-31
Rear Drum Brake
I ndex/ l nspect i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-35
Inspection ....,.,....... 19-36
Brake Shoe Disassembly ..............." 19-37
Brake Shoe Reassembl y . . . . . . . . . . . . . . . ' . . 19-37
Brake Hoses/Lines
Inspection/Torque Specifications ..... 19-39
Hose Repl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-40
Parking Brake Cable
lnspection and Replacement ........,. 19-41
l - l
Special Tools
Ref. No. I Tool Numbo] Descriplion Oty
I
Page Reference
o
07HAE
-
SG00100
07JAG
-
SD40100
07914
-
SA50001
Brake Spri ng Compressor
Pushrod Adj ustment Gauge
Snap Ri ng Pl i ers
19-28, 33
19-22
o
@
19-2
Component
Locati ons
I
l ndex
ERAKE PEDAL
Inspectron and
Adj ustment, page 19 5
BRAKE HOSES LINES
Inspecti on/Torque speci f i cati ons, page 1 9-39
Hose Repl acement, page 19-40
MASTER CYLINDER/BRAKE BOOSTER
page 19 21
Pushrod Cl earance Adj ust ment ,
page 19_22
Brake Booster Inspection,
page 19-23
l J
PARKING BRAKE CASLE
i nspect i on and Repl acement ,
page 19 41
FRONT BRAKES
NOTE: There are two types offront brake calipers:
The cal i per t ypes can be i dent i t i ed by t he
"5410"
or
"2056"
st amped on t he cal i per body. Check t he
type ot the brake caliper betore servicing.
Front Brake Pads
5410 Type: page 19-8
2056 Typer page 19 10
Front Brake Di sc, page 19-12
Front Brake Cal i per
5410 Type: page 19-13
2056 Type:
page 19-14
BBAKE
Adi ust ment , page 19-6
REAR ORUM BRAKES
I nspect i on,
page 19-36
Brake Shoe Bepl acement ,
page 19' 37
REAR DISC BRAKES
Rear Brake Pads, page 19 24
Rear Brake Di sc, page 19 26
Rear Brake Cal i per,
page 19' 27
l J
19- 3
)
@
@
@
Brake System Rubber Parts and Brake Booster
Brake Boostet
Check brake operati on by appl yi ng the brakes.
l f the brakes do not work properl y,
check the brake
booster, Repl ace the brake booster as an assembl y
i f i t does not work properl y
or i f there are si gns of
l eakage.
Piston Cup and Pressure Cup Inspeqtion
. Check brake operati on by appl yi ng the brakes.
Vi sual l y check for damage or si gns of fl ui d l eak-
age.
Repl ace t he mast er cyl i nder as an assembl y i f
the pedal
does not work properl y
or i f there i s
damage or si gns of fl ui d l eakage.
. Check f or a di f f er ence i n br ake pedal st r oke
bet ween qui ck and sl ow br ake appl i cat i ons.
Repl ace the master cyl i nder i f there i s a di ffer-
ence i n oedal stroke.
Brake Hoses
Vi sual l y check for damage or si gns of fl ui d l eakage.
Repl ace the brake hose wi th a new one i f i t i s dam-
aged or l eaki ng.
Caliper Piston Seal and Piston Boots
Check brake ope.ati on by appl yi ng the brakes.
l f the pedal does not operate properl y, the brakes
drag. or there i s damage or si gns of fl ui d l eakage,
di sassembl e and i nspect the brake cal i per. Repl ace
the boots and seal s wi th new ones whenever the
brake cal i Der i s di sassembl ed.
Wheol Cylindor Piston Cup and Dust Cover
Check brake operati on by appl yi ng the brakes.
l f the pedal does not operate properl y, the brakes
drag, or there i s damage or si gns of fl ui d l eakage,
di sassembl e and i nspect the wheel cyl i nder. l f nec-
essary, repl ace the wheel cyl i nder as an assembl y.
19-4
)
Brake Pedal
Pedal Hei ght
1. Di sconnect the brake swi tch connector, l oosen the
brake swi tch l ocknut, and back off the brake swi tch
unti l i t i s no l onger touchi ng the brake
pedal ,
2. At the carpet cutout, measure the pedal hei ght from
the ri ght si de center of the
pedal pad.
PUSHROD
LOCKNUT
Standard Pedal Height
(with
carpet removed):
M/T: 156.5 mm 16.16 i nl
A/T, CVT: 161 mm
(5
5/16 i n)
3. Loosen the pushrod l ocknut, and screw the
pushrod
i n or out wi th pl i ers unti l the standard
pedal hei ght
from the fl oor i s reached. After adj ustment, ti ghten
the l ocknut fi rml y.
NOTE: Do not adi ust t he
pedal hei ght wi t h t he
Dushrod depressed.
I t
PUSHROO LOCKNUT
15 N. m
(1.5
kgf.m. 11 lbI.ft)
POINT ICUTOUTI
4. Screw i n the brake swi tch unti l i ts pl unger i s ful l y
depressed
(threaded
end touchi ng the pad on the
pedal arm). Then back off the swi tch 1/4 turn to
make 0. 3 mm
( 0. 01
i n) of cl ear ance bet ween t he
threaded end and pad. Ti ghten the l ocknut fi rml y.
Connect the brake swi tch connector.
CAUTION: Make sure that the brake lights go off
when the
pedal is released.
LOCKNUT
5. Check the brake
pedal free pl ay as descri bed bel ow.
Pedal Free Plsy
1. Wi th the engi ne off, i nspect the pl ay on the pedal
pad by
pushi ng the
pedal by hand.
Free Pl ay: 1
-
5 mm
(1/16 -
3/16 i nl
2. l f the pedal free pl ay i s out of speci ti cati on, adj ust
the brake swi tch.
CAUTION: lf the pedal free play is insufficient, it
may result in brake drag.
BRAKE PEDAL PAO
)
19- 5
* 0. 3 mm
(0. 01
i n)
Parki ng Brake
Inspection
1. Pul l the parki ng brake l ever wi th 196 N {20 kgf. 44 l bf)
force to ful l y appl y the parki ng brake. The parki ng
brake l ever shoul d be l ocked wi thi n the sDeci fi ed
number of cl i cks.
Lever Locked clicks: 6
-
I
Pul l ed up 96 N 120 kgf , 44l bf )
2. Adj ust the parki ng brake i f the l ever cl i cks are out of
speci fi cati on.
Adiusiment
NOTE: After servi ci ng the rear brake pads
or cal i pers, or
the rear brake shoe, l oosen the parki ng
brake adj usti ng
nut, start the engi ne, and depress the brake pedal
sever-
al ti mes to set the sel f-adj usti ng brake before adj usti ng
the parki ng brake.
1. Rai se the rear wheel s off the ground,
and support
the vehi cl e on safety stands.
l@
Elock the front wheels bofore
iacking
uD the rear ot the v6hicle.
2. On vehi cl es wi th rear di sc brakes, make sure the
parki ng brake arm on the rear brake cal i per contacts
the brake cal i oer Di n.
wi t h 1
\
19- 6
Remove the rear consol e
(see
secti on 20).
Pul l the parki ng brake l ever up one cl i ck,
Ti ghten the adj usti ng nut unti l the rear wheel s drag
sl i ghtl y when turned.
Bel ease the
parki ng
brake l ever ful l y, and check that
the rear wheel s do not drag when turned. Readj ust
if necessarv.
Make sure that the parki ng brakes are ful l y appl i ed
when the parki ng
brake l ever i s pul l ed up ful l y.
Rei nstal l the rear consol e.
7.
8.
ADJUSTING NUT
I
Bl eedi ng
CAUTION:
. Always use Genuine Honda DOT 3 Brake Fluid. Using 8
non- Honda br ak f l ui d can cause cor r osi on and
docrea3e the 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 immdiately with water.
NOTE: The reservoi r on the master cyl i nder must be at
the MAX
(upper) l evel mark at the start of the bl eedi ng
pr ocedur e and checked af t er bl eedi ng each br ake
cal i per. Add fl ui d as requi red.
1. Make sure the brake fl ui d l evel i n the reservoi r i s at
the MAX l upper)
l evel l i ne.
MAX {UPPER) LEVEL
CYLINDER
Have someone sl owl y
pump the brake
pedsl several
ti mes, then appl y steady
Pressure.
Loosen the brake bl eed screw to al l ow ai r to escape
f r om t he syst em. Then t i ght en t he bl eed scr ew
securel y.
Repeat the
procedure for each wheel i n the sequence
shown bel ow unti l ai r bubbl es no l onger appear i n
the fl ui d.
Refi l l the master cyl i nder reservoi r to the MAX
(up-
per) l evel l i ne.
ELEEDING SEOUENCE:
O Front Right
(D
Bo.r Right
O
Front Left O
Rear Left
1 , ,
19-7
FRONTT
REAR lDrum Brakel:
REAR
(Disc
Brake):
AIEED SCREW
9 N.m
(0.9
ksf m, 6.5 lbf'ft)
Front Brake Pads
Inspection and Replacement
NOTE: There are two types of front brake cal i pers:
The cal i per t ypes can be i dent i f i ed by t he
" 5410"
or
"2056"
stamped on the cal i per body as shown bel ow.
Check the type of the brake cal i per before servi ci ng.
5i110 Type:
NOTE: For 2056 type di sassembl y procedures.
see
page
19- ' 10.
Never use an air hose or dry brush lo clean brake
assgmblios.
Use an OSHA approved vacuum cl eaner to avoi d
breathing brake dust.
Loosen the front wheel nuts sl i ghtl y, then rai se the
vehi cl e, and support i t on safety stands. Remove
the front wheel s.
Remove the brake hose bracket from the knuckl e.
Remove the cal i per bol t, and pi vot the cal i per up
out of the wav.
1 .
2.
NOTE: Check the hoses and pi n boots for damage
and deteri orati on.
CALIPER BOLT
19- 8
4. Remove the pad shi m. pad retai ners, and pads.
NOTE: When the cal i per i s equi pped wi th an outer
pad shi m, repl ace the shi m together wi th the pads
5. Usi ng ver ni er cal i per s, measur e t he t hi ckness of
each brake pad l i ni ng. The measurement does not
i ncl ude the pad backi ng pl ate thi ckness.
Brake Pad Thickno$:
Standard: 9.5
-
10.5 mm 10.37
-
0.41 in)
SerYico Limit 1.6 mm {0.06 in}
l f the brake pad thi ckness i s l ess than the servi ce
l i mi t, repl ace the front Dads as a set.
)
I t
7. Cl ean the cal i per thoroughl y; remove any rust, and
check for
grooves and cracks.
8. Check the brake di sc for damage and cracks.
9. l nstal l the
pad
retai ners,
10. Appl y
grease to the
poi nts i ndi cated by the arrows
i n the fol l owi ng i l l ustrati on:
NOTE: Use the
pad grease i ncl uded i n the pad set
or Mol ykote Nl 77 grease, and appl y a thi n coat of
grease evenl y to the desi gnated poi nts.
o Pi ston end and i nner Dad contact surface
. Pad and cal i oer bracket contact surface
. Outer
pad and cal i per body contact surface
. Outer
pad
shim and outer pad contact surface
. Outer
pad
shi m and cal i per body contact surface
WEAR INDICATOB
INNER PAD
OUTER PAD
1 1. Instal l the brake
pads
and
pad
shi m correctl y.
. Whon reusi ng the pads, al ways rei nstal l the
brake pads in their original
positions to
prevont
loss of braking efticiency.
. Contaminated brake discs or pads teduce stop-
ping ability. Keep grease oft the discs and pads'
NOTE: l nstal l the Dad wi th the wear i ndi cator on
the i nsi de.
l . t
' 12.
Push i n the pi ston so that the cal i per wi l l fi toverthe
pads, Make sure that the pi ston boot i s i n posi ti on
to prevent damagi ng i t when pi voti ng the cal i per
down.
Pi vot the cal i per down i nto
posi ti on,
then i nstal l the
cal i per bol t and ti ghten i t.
CAUTION: Be caretul not damage the
pi n boot
when pivoting the caliper dowr.
l nstal l the brake hose bracket on the knuckl e
NOTE: Inspect the brake hose for i nterference or
twi sti ng.
Depress the brake pedal several ti mes to make sure
the brakes work. then test-drive.
NOTE: Engagement of t he br ake may r equi r e a
greater pedal stroke i mmedi atel y after the brake
pads have been repl aced as a set. Several appl i ca-
t i ons of t he br ake pedal wi l l r est or e t he nor mal
Dedal stroke.
After i nstal l ati on. check for l eaks at hose and l i ne
j oi nts
or connecti ons, and reti ghten i f necessary.
13.
14.
15.
16.
(cont' d)
19- 9
CALIPER BOLT
N m
(3.3
kgf m,2a lbf.ft)
Front Brake Pads
2056 Type:
@
. Never use an ai r hose or dry brush to cl gan brake
assemblies.
. Use an OsHA-approved vacuum cl eanor l o avoi d
breathing broke dust.
Inspection and Replacement
(cont'dl
1. Loosen the front wheel nuts sl i ghtl y. then rai se the
the front wheel s.
2. Remove the brake hose bracket from the knuckl e.
3. Remove the cal i per bol t B, and pi vot the cal i per up
out of the wav,
EOLT B
NOTE: Check the hoses and pi n boots for damage
and deteri orati on.
Remove the pad shi m, pad retai ners, and pads.
NOTE: When repl aci ng the
pads,
repl ac the shi m
together wi th the
pads
as a set,
OUTER
PAD SHIM
Check f or wear .
INNER PAD
PAO RETAINERS
Check f or weakness and
damage,
OUTER PAD
1 9 - 1 0
5. Usi ng ver ni er cal i per s. measur e t he t hi ckness of
each brake pad l i ni ng. The measurement does not
i ncl ude the pad backi ng pl ate thi ckness.
Brake Pad Thicknsss:
Standard; 8.5
-
9.5 mm 10.33
-
0.37 in)
Servica Limh: 1.6 mm {0.06 in}
l f the brake pad thi ckness i s l ess than the servi ce
limit, replace the front pads
as a set,
Cl ean the cal i per thoroughl y; remove any rust. and
check for grooves
and cracks.
Check the brake di sc for damage and cracks,
Instal l the pad retai ners.
7.
8.
9.
)
l O. Appl y
grease to the poi nts i ndi cated by the arrows
i n the fol l owi ng i l l ustrati on:
NOTE: Use the pad grease i ncl uded i n the pad set
or Mol ykote M77
grease, and appl y a thi n coat of
grease evenl y to the desi gnated
poi nts.
. Pi ston end and i nner pad contact surface
o Pad and cal i per bracket contact surface
. Outer
pad and cal i per body contact surface
. Outer
pad shi m and outer pad contact surface
. Outer pad shi m and cal i per body contact surface
OUTER PAD
OUIER
PAD SHI M
I 1. Instal l the brake
pads and pad shi m correctl y
@
o When reusi ng the pads, al ways rei nstal l the
brake
pads in their original positions to plevent
loss of braking etticiencY.
. Contaminated brake discs ol
pads reduce stop-
ping ability. Keep grease oft the discs and
pads.
NOTE: I nst al l t he
pad wi t h t he wear i ndi cat or on
the i nsi de.
WEAR INDICATOR
12. Push i n the
pi ston
so that the cal i per wi l l fi t over the
pads. Make sure that the pi ston boot i s i n
posi ti on
t o pr event damagi ng i t when pi vot i ng t he cal i per
CALIPER BOLT B
26 N.m {2.7 kgt m,
20 rbl.ftl
1 4 .
13. Pi vot t he cal i per down i nt o posi t i on, t hen i nst al l
cal i per bol t B and ti ghten i t.
l nstal l the brake hose bracket on the knuckl e.
NOTE: Inspect the brake hose for i nterference and
twi sti ng.
Depress the brake
pedal several ti mes to make sure
the brakes work, then test-dri ve
NOTE: Engagement of t he br ake may r equi r e a
greater pedal stroke i mmedi atel y after the brake
pads have been repl aced as a set. Several appl i ca-
t i ons ot t he br ake
pedal wi l l r est or e t he nor mal
pedal stroke.
After i nstal l ati on, check for l eaks at hose and l i ne
j oi nts
and connecti ons, and reti ghten i f necessary.
16.
PISTON
19- 1 1
Front Brake Disc
Disc Runout Inspection
L
2.
Loosen the front wheel nuts sl i ghtl y, then rai se the
the front wheel s.
Remove the brake pads (see page 19,8).
I nspect t he di sc sur f ace f or damage and cr acks.
Cl ean the di sc thoroughl y and remove al l rust.
Use wheel nuts and sui tabl e pl ai n washers to hol d
the di sc securel y agai nst the hub, then mount a di al
i ndi cat or as shown, and measur e t he r unout at
10 mm
(0.4
i n) from the outer edge of the di sc.
Brake Disc Runout:
(0.004
inl
WHEEL NUT ANO
PLAIN WASHER
'108
N.m
(11
kg{.m, 80 lbf.ft)
l f the di sc i s beyond the servi ce l i mi t, refi ni sh the
brake di sc wi th an on-car brake l athe, The Kwi k-
Lathe produced
by Kwi k-way Manufacturi ng Co.
and the
"Front
Brake Di sc Lathe" offered by Snap-
on Tool s Co. are approved for thi s operati on.
Max. Refinish Limit: 19.0 mm
(0.75
in)
NOTE: A new di sc shoul d be refi ni shed i f i ts runout
i s greater than 0.10 mm
(0.004
i n)
19- 12
Di sc Thi ckness and Paral l el i sm
Inspection
1 . Loosen the front wheel nuts sl i ghtl y, then rai se the
the front wheel s.
Remove the brake pads (see page 19-8).
Usi ng a mi cr omet er , measur e di sc t hi ckness at
ei ght poi nts,
approxi matel y 45" apart and 10 mm
(0.4
i n) i n from the outer edge of the di sc.
Brake Dbc Thickn6s:
Standlrd: 20.9
-
21.8 mm
(0.82 -
0.86 in)
Max. Refinishing Limit: 19.0 mm 10.75 inl
NOTE: Repl ace the brake di sc i f the smal l est mea-
surement i s l ess than the max. refi ni shi nq l i mi t.
Brake Disc Parallelism: 0.015 mm
(0.fit06
in) max.
NOTE: Thi s i s the maxi mum al l owabl e di fference
between the thi ckness measurements.
l f the di sc i s beyond the servi ce l i mi t for paral l el i sm,
refi ni sh the brake di sc wi th an on-car brake l athe.
The Kwi k-Lathe produced
by Kwi k-Way Manufac-
turi ng Co. and the
"Front
Brake Di sc Lathe" offered
by Snap-on Tool s Co. are approved for thi s opera-
ti on.
NOTE: See secti on 18 for brake di sc reDl acement.
Front Brake Caliper
I t
Di sassembl y
NOTE: There are two types of front brake cal i pers:
The cal i per t ypes can be i dent i f i ed by t he
" 5410"
or
"2056"
stamped on the cal i per body as shown bel ow.
Check the type of the brake cal i per before servi ci ng.
5410 Type:
NOTE: For 2056 type di sassembl y
procedures, see page
19- 14.
@
o Never use an ai r hose ot dry brush to cl ean brakg
assemblies.
. Use an OSHA approved vacuum cl ganer to avoi d
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
passages with compressed air.
L Remove the banj o bol t, and di sconnect the brake
hose from the cal i Der.
CALIPER
BANJO EOLT
SEALING
Repl ace.
BOLTS
Remove the cal i per bol ts, then remove the cal i per
from the bracket.
l J
Repl ace.
3. Remove t he cal i per
pi ns and pi n boot s f r om t he
cal i oer bracket,
CALTPER PIN B
CAL|PER BRACKET
CALIPER PIN A
4, l f necessary. appl y compressed ai r to the cal i per
fl ui d i nl et to get the
pi ston out. Pl ace a shop rag or
wooden bl ock as shown to cushi on the
pi ston when
i t i s expel l ed. Use l ow pressure ai r i n short spurts.
@
. Do not place your iingers in tront ol the
piston.
. Do not use hi gh ai r
pressure; use 8n OSHA
approved 30 PSI nozzls,
Remove the pi ston from the cal i per, and check the
pi ston for scori ng.
Remove the boot cl i p,
pi ston boot and
pi ston seal .
CAUTION: Take care not to damage the cyl i ndcr
PISTON SEAL
Repl ace.
BOOT CLIP
Repl ace.
\ ,
,t.
(
\)
PISTON BOOT
CALIPER BODY
Check f or scori ng
(cont ' d)
1 9 - 1 3
Front Brake Caliper
2056 Type:
@
Disassembly
(cont'dl
Nevor u3e an air hos or dry brush to clgan brake
assomblios.
Use an OSHA approved vacuum cl 6aner to avoi d
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.
. Clan all parts in brake fluid and air dry; blow out 8ll
passagss with compr63d air.
1. Remove the banj o bol t, and di sconnect the brake
hose from the cal i per.
SEALING WASHERS
Remove cal i per bol t B, pi vot the cal i per up out of
the way, then remove the cal i per from the bracket.
Remove the gui de pi n boot from sl eeve A on the
cal i Der bracket.
GUIDE PIN BOOT
Repl ace.
GALIPER BRACKET
Check t or cracks.
Check f or damage.
19- 14
4. Remove t he pi n
boot , sl eeve B and sl eeve boot
from the cal i per body.
CALIPER EODY
Check f or scor i ng
on cyt i nder wa .
SLEEV B
Check for damage.
l f necessary, appl y compressed ai r to the csl i per
fl ui d i nl et to get the pi ston
out. Pl ace a shop rag or
wooden bl ock as shown to cushi on the oi ston when
i t i s expel l ed. Use l ow pressure
ai r i n short spurts,
a
a
Do not placo your lingers in ftont ol tho pkton.
Do noi usa hi gh ai r prsssure; uso an OSHA
approved 30 PSI nozzle.
Remove the pi ston from the cal i per, and check the
pi ston for scori ng.
WOODEN ALOCK
7. Remove the boot cl i p,
pi ston boot and
pi ston seal .
CAUTION; Take care not to damage the cyl i nder
bore.
goor
cLtP
Repl ace.
SEAL
NSTON BOOT
Repl ace.
I
l . t
1 9- 15
Front Brake Galiper
Reassembly
5410 Type:
NOTE: For 2056 type reassembl y procedures,
see page 19-18.
o Never use an air hose or dry brush to clean brako assemblies.
.
Use an OSHA approved vacuum cleanerto avoid breathing brake dust.
. Contaminated brake discs or pads
reduce stopping abilhy.
. when reusing the pads, always reinstall the brake pads in their original positions
to prvent loss of braking fficiency.
CAUTION:
. Do not spill brake fluid on the vehicle; it may damage the paint; if brake fluid dos contaci the psint,
wash it oft imme"
diately with water.
. Clean all parts in brake fluid and air dry; blow out all passags whh comp.ssed air.
. Betore reassembling, check that all parts
are free ol dust and othor toreign particlos.
. Replace parts wilh new ones whenever specified to do so.
. Make sure no dirt or other toreign mattr 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 decresse the
life of th system.
NOTE:
. Coat the
pi ston, pi ston
seal , and cal i per bore wi th cl ean brake fl ui d.
. Repl ace al l rubber parts wi th new ones whenever di sassembl ed.
z_.
.=-.q8! .9!,H:
Use recommended rubber grease in the caliper seal set.
-.61' use recommended seal grease i n the cati per seal set.
BRAKE PADS PIN BOOTS
Repl ace.
OUTER PAD SHIM
-o
-'''---&@
CAI-IPER PIN A
-
BLEED SCREW
S N.m (0.9
kgt.m, 6.5 tbf.ftl
"k..6
*/
\ *
car-rpen
prr'r
e-....,-q\,
- W
@{
q
1
PAD RETAINERS
CALIPER BRACKET
WEAB INDICATOR
t i l f l i l t n
t w
t f i l J l
WEAB rNDrcAroR
\J I I
l nsr al l i nner pad wi t h
l AV
irs weat indicatot !pwatd/,.
CALIPER BRACKEI MOUNTING BOLT
108 N. m {11. 0 kgt m, 80l bf . f t )
PISTON BOOT
Repl ace.
-6r
/
eoor cr-re
I
neptace.
6/
vo
PISTON SEAL
Repl ace.
1 9 - 1 6
CALIPER BODY
' 1.
Cl ean the pi ston and cal i per bore wi th brake fl ui d,
and i nspect for wear and damage.
Coat t he new
pi st on seal wi t h t he r ecommended
rubber grease i n the cal i per seal set. and i nstal l the
seal i n the cyl i nder
groove.
Appl y the recommended seal
grease i n the cal i per
seal set to the seal i ng l i ps and i nsi de of a new
pi s-
ton boot, and securel y i nstal l i t i n the cal i per wi th the
new boot cl i p.
CAUTION: Be careful nol to damage the cal i per
cyl i nder wal l .
PISTON SEAL
Repl ace.
--^.
,:=-qE!!!-H
RUBBER GREASE
Lubr i cat e t he cal i per and
pi st on wi t h br ake f l ui d,
then i nstal l the pi ston i n the cyl i nder wi th the di shed
end faci ng i n.
I J
PISYON BOOT
Replace.
j@i
SILICONE GREASE
CALIPER
-6l
CALIPEB PIN B
Appl y the recommended seal grease i n the cal i per
seal set to the sl i di ng surface of the
pi ns and the
l nsi de of the new
pi n
boots.
l nstal l the pi n boots i nto the grooves i n the cal i per
bracket
properl y.
CALIPER ERACKET
7. Insert
pi n A and
pi n B i nto the cal i per bracket.
8. Instal l the
pi n boots i nto the
grooves i n the pans
propeny.
9. Instal l the brake
pads i n thei r ori gi nal
posi ti ons
(see
page 19-9).
10. Push i n the pi ston so that the cal i per wi l l fi t over the
pads,
and i nstal l the cal i Per.
11. Ti ghten the cal i per bol ts.
12. Connect the brake hose to the cal i per wi th new seal -
i ng washers, and ti ghten the banj o bol t.
-6.l
PIN BOOTS
Repl ace.
-6l
CALIPER PIN
BANJO EOLT
34 N.m
(3.5 kg{ m, 25 lbflt}
SEALING WASHERS
Repl ace.
' 13.
CALIPER BOLT
32 N.m 13.3 kgt.rn, 24lblft)
Fi l l the brake reservoi t and bl eed the brake system
{see
page 19-7).
Perform the following checks:
. Check for l eaks at hose and l i ne
j oi nts
and con-
necti ons. and reti ghten i f necessary.
. Check for brake hoses for interference and twisting.
(cont' d)
14.
19-17
Front Brake Caliper
Reassembly
(cont'd)
2056 Type:
. Never use an air hose or dry b.ush to clean brake assemblies.
. Uso an OSHA approved vacuum cleansr to avoid breathing brake dust.
. Contaminated brake discs or pads
reduce stopping 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 imme-
diately with water.
. Clean all parts in brake tluid and air dry; blow out all passages
with compr63ed air.
. Beforo reassembling, check that all parts
are fre of dust and other foreign particles,
. Replace parts with new ones whenevea specified to 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-Honda brake fluid can caus corrosior and decrease the
life ol the system.
NOTE:
. Coat the pi ston, pi ston seal , and cal i per bore wi th cl ean brake fl ui d.
. Repl aceal l rubber parts wi th new ones whenever di sassembl ed.
.' =5@:
Use recommended rubber grease
i n the cal i per seal set,
-6l ' Use recommended seal grease
In the cal i per seal set.
@6--i#i['i,?li"..;:l]l?Y]li"'"'
I
r""'"rr r"""ip"autr,
-/ffr
\ \
e"6ft
'ADRETATNERS
i t swear ndcat or u' war d
Mf f i A
pr
GUIDE PIN BOOT
\\ ) {I I II ) I I
%
caL,PER
\I\d/
tt\
'
id 6
u -es
'---r..'.*
".-,."oo*'J.l, ru,oonW
U
**=*t
WEAR,INDICAToR.
,ffi
\
OUTERIPAD
BLEED SCREW
9 N.m
(0.9
kgf.m, 6.5 lbf.ft)
\
o @
CALIPER BRACKET
PISTON EOOT
Repl ace.
-
.&l
BOOT CLIP
Repl ace.
SLEEVE A
SLEEVE 8
- " - 41
r{.i'""Jg*'
a,t/
c'f3!@
q.-
t\
20 tbf.ftl
CALIPER BOLT B
26Nm{ 2. 7kgf . m,
CALIPER BODY
PIN BOOT
Repl ace.
BRAKE PAOS
1 9 - 1 8
1 . Cl ean the
pi ston and cal i per bore wi th brake fl ui d,
and i nspect for wear and damage.
Coat a new Di ston
seal wi th the recommended rub-
ber
grease i n the cal i per seal set, and i nstal l the seal
i n the cyl i nder
groove.
Appl y the recommended seal grease i n the cal i per
seal set to the seal i ng l i ps and i nsi de ol a new
pi s-
ton boot, and securel y i nstal l i t i n the cal i per wi th a
new boot cl i p.
CAUTION: Be carel ul not to damage ths cal i por
cylinder wall.
Repl ace.
=_.
-1!!4!!n
RUBEER GREASE
I J
Repl ace.
-6,
SILICONE GREASE
t . /
4. Lubri cate the cal i per and
pi ston wi th brake fl ui d,
t hen i nst al l t he
pi st on i n t he cyl i nder wi t h t he
di shed end faci ng i n.
Appl y the recommended seal
grease i n the cal i per
seal set to the sl i di ng surface oJ sl eeve B and the
i nsi de of the new
pi n
and sl eeve boots.
l nstal l the new sl eeve and
pi n boots 8nd sl eeve B
on the cal i Der.
NOTE: Make sure to install the boots into the
grooves
in the caliper and sleeve B properly.
SI.EEVE BOOT
Y
PIN BOOT
Repl ace.
(cont' d)
1 9 - 1 9
SLEEVE B
Front Brake Caliper
Reassembly (cont'dl
7. Appl y the recommended seal grease i n the cal i per
seal set to the sl i di ng surface of sl eeve A and the
i nsi de of a new gui de pi n
boot.
I nst al l t he gui de pi n
boot i nt o t he gr oove
i n t he
sl eeve A.
Make sure that the brake pad
retai ners and brake
pads
are i n thei r ori gi nal posi ti ons (see page
19-10).
Instal l the cal i per onto sl eeve A, and pi vot i t down
i nto posi ti on.
NOTE: Instal l the gui de pi n
boot i nto the groove i n
the cal i per properl y.
BRACKET
SLEEVE A
19-20
1 1 .Connect the brake hose to the cal i per wi th new seal -
i ng washers, and ti ghten the banj o bol t.
Ti ghten the cal i per bol t B.
Fill the brake reservoir and bleed the brake svstem
(see page
19-7).
Perform the following checks.
i oi nts
and con-
nectaons, and retighten if necessary.
.
Check for brake hoses for interference and twist-
I ng.
13.
14.
BANJO BOLT
26 N.m
(2.7
kgl.m, 20 lbtftl
Master Cylinder/Brake
Booster
I
RemovaUlnstallation
CAUTION:
. Be care{ul nol to bend or damage the brake lines when
rsmoving the mastsr cYlinder.
. Do not soill brakefluid on the vehicle; it may damage
the
paint; if brake fluid does contact the paint, wssh
it off immediatelY with water'
. To prevent spill3, cover the hose
ioints
with rags or
shop towels.
9. Remove the four booster mountl ng nuts
10. Pul l the brake booster forward unti l the cl evi s i s
cl ear of the bul khead.
11. Remove t he br ake boost er f r om t he engi ne com-
panmenr.
' 12.
Instal l the brake booster and master cyl i nder i n the
CAUTION:
. When connecti ng the brake l i nes. 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.
NOTE: l f r epl aci ng t he mast er cyl i nder or br ake
boost er , check and adi ust t he pushr od cl ear ance
be{ore installing the master cylinder
(see page 19-221'
Fi l l t he mast er cyl i nder r eser voi r , and bl eed t he
brake svstem
(see
Page
19-7).
After i nstal l ati on. check the brake
pedal hei ght and
brake
pedal tree pl ay
(see page l 9-5) and adj ust i f
necessary.
BRAKE BOOSTER
(Wi th
ABS: 7" + 8" tandem brake booster)
BRAKE FLUIO LEVEL
SWITCH CONNECTORS
MASTER CYLINDER
VACUUM HOSE
1 .
2.
3,
5.
Di sconnect the brake fl ui d l evel swi tch connectors'
Remove the reservoi r cap from the master cyl i nder'
The brake fl ui d may be sucked out through the top
of the master cyl i nder reservoi r wi th a syrl nge.
Di sconnect the brake l i nes from the master cyl i nder'
Remove t he mast er cyl i nder mount i ng nut s and
washers.
\ l /
6. Remove the master cylinder from the brake booster'
7. Disconnect the vacuum hose trom the brake booster'
pi n and cl evi s
pi n from the cl evi s'
CAUTION: Do not disconnect the clevb by remov-
ing it from the operating rod of the brako booster' lf
the clevis is loosened, adiust the
pushrod length
before installing th brake booster
(see page 19-221'
COTTER PIN
Repl ace.
To Rear Wheel Cyl i nders
1 4 .
-6.4
CLEVIS PIN
To Front Cal i per
(Wi t hout ABS)
$
t ' N' t ' t t r nt ' - ' '
To Front Cal i per
l Wi t hout
ABSi
PBOPORTIONING CONTROL
VALVE
15 N. m {1. 5 kgl m,
11 tbtft)
15 N. m { 1. 5 kgi f . m, 11 l bt f t }
( Wi t h ABS: To modul at or uni t )
l r
19-21
Master Cylinder/Brake
Booster
Pushrod Glearance Adjustment
NOTEr
. The mast er cyl i nder pushr od- t o- pi st on
cl ear ance
must be checked and adj ustments made, i f neces_
sary, before i nstal l i ng the master cyl i nder.
. ABS type is shown, conventional brake type is similar.
1. Set the speci al tool on the master cyl i nde. body;
push
in the center shaft until the top of it contacts the end
ofthe secondary pi ston
by turni ng the adj usti ng nut.
Wi thout di sturbi ng the center shaft' s Dosi ti on, i nstal l
the speci al tool upsi de down on the booster.
Instal l the master cyl i nder nuts, and ti ghten to the
speci fi ed torque.
Connect the booster i n-l i ne wi th a vacuum gauge
O
_
101 kPa
(0 -
760 mmHg, 30 i n.Hg) to the booster,s
engi ne vacuum suppl y, and mai nt ai n an engi ne
speed that wi l l del i ver 66 kpa
(500
mmHg, 20 i n.Hg)
vacuum.
Wi th a feel er gauge.
measure the cl earance Detween
the gauge
body and the adj usti ng nut as shown.
Clearance: 0
-
0.4 mm
{0
-
0.02 in)
VACUUM GAUGE
(Commrcially
availeblel
0
-
101 kPa
{0
-
760 mm Hg, 30 in.Hg)
AOJUSTING NUT
FEELER GAUGE
19-22
10.
NOTE: l f t he cl ear ance bet ween t he gauge
body
and adj usti ng nut i s 0.4 mm
(0.02
i n), the pushrod-
to-pi ston cl earance i s 0 mm. However, i f the cl ear_
ance between the gauge
body and adj usti ng nut i s
0 mm, the pushrod-to-pi ston
cl earance i s 0.4 mm
(0.02
i n) or more. Therefore, i t must be adj usted and
rechecked.
6. l f cl earance i s i ncorrect, l oosen the star l ocknut, and
turn the adj uster i n or out to adj ust.
NOTE;
.
Adj ust the cl earance whi l e the speci fi ed vacuum
i s appl i ed to the booster.
.
Hol d the cl evi s whi l e adj usti ng.
Ti ghten the star l ocknut securel y.
Remove the speci al tool .
0
-
0.4 mm
(0 -
0.02 i n)
7.
ADJUSTER
PUSHROD
ADJUSTMENT GAUGE
07JAG
-
SD('1(x)
9. Adj ust the pushrod
l ength as shown i f the booster
rs removed.
STAR LOCKNUT
22 N.m
{2.2 kg,f.m, 16lbtft)
1 1 6 1 0 . 5 mm
{{. 571 0. 02 i n)
PUSHROD
LOCKNUT
15 N. m 11. 5 kgf . m, 11 t bt f t l
I nst al l t he mast er cyl i nder
{see
page l 9-21).
Brake Booster InsPection
Functi onal Test
1. Wi th the engi ne stopped, depress the brake
pedal
several ti mes to depl ete the vacuum reservoi r, then
depress the
pedal hard and hol d i t for 15 seconds l f
t he
pedal s i nk s ' ei t her t he mas t er c Yl i nder
i s
bypassi ng i nternal l y, or the brake system
(master
cyl i nder . l i nes. modul at or ,
pr opor t i oni ng cont r ol
val ve, or cal i Per) i s i eaki ng.
2. Start the engi ne wi th the
pedal depressed
l f the
pedal si nks sl i ghtl y, the vacuum booster i s operati ng
nor mal l y. l f t he
pedal hei ght does not var y, t he
booster or check valve is faultY.
3. Wi th the engi ne runni ng. depress the brake
pedal
l i ght l y. Appl y
j ust
enough
pr essur e t o hol d back
aut omat i c t r ansmi ssi on
cr eep. l f t he br ake
pedal
si nks mor e t han 25 mm
( 1. 0
i n. ) i n t hr ee mi nut es,
t he mast er cvl i nder
i s f aul t y. A sl i ght change i n
pedal hei ght when the A' l C compressor
cycl es on
and of f i f nor mal .
( The A/ C c ompr es s or
l oad
changes the vacuum avai l abl e to the booster' )
Leak Test
1. Depr ess t he br ake
pedal wi t h t he engi ne r unni ng.
then stop the engi ne. l f the pedal hei ght does not
vary whi l e depressed for 30 seconds, the vacuum
boost er i s OK. l f t he
pedal r i ses. t he boost er i s
faul ty.
2, Wi th the engi ne stopped, depress the brake
pedal
sever al t i mes usi ng nor mal
pr essur e When t he
Dedal i s fi rst depressed, i t shoul d be l ow On con-
secuti ve appl i cati ons, the
pedal hei ght shoul d
grad-
ual l v ri se. l f the
pedal posi ti on does not vary, checK
the booster check val ve.
l . /
19-23
Booster Check Valve Test
1. Di sconnect the brake booster vacuum hose at the
booster.
2. Stan the engi ne and l et i t i dl e. There shoul d be vac-
uum. l f no vacuum i s avai l abl e, the check val ve i s
not worki ng
properl y. Repl ace the brake booster
vacuum hose and check val ve, and retest.
BRAKE BOOSTER
VACUUM HOSE
( Check val ve
bui l t - i n)
Rear Brake Pads
Inspecti on
and Repl acement
Never use an ai r hose or dry brush to cl ean brake
assembl i es.
Use an OsHA-apptoved vacuum cl aner to avoi d
breathing brake dust,
Bl ock the front wheel s, l oosen the rear wneet nuts
sl i ght l y, suppor t t he r ear of t he vehi cl e on saf et y
stands, then remove the rear wheel s.
Rel ease the parki ng
brake, and remove the cal i oer
sh i el d.
CALIPER SHIELD
Remove the brake hose cl amp bol t from the trai l i ng
arm fi rst, then remove the two cal i per mounti ng
bol ts and the cal i per from the bracket.
CAUTION:
. Thoroughl y cl ean the outsi de of the cal i Der to
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.
NOTEr Check the hoses and pi n
boots for damage
or deteri orati on.
PARKING BRAKE CABLE ^.. ._-_ ---.
'L
19-24
4. Remove the outer pad shi m, pads,
and pad
retai ners.
PAO RETAINERS
OUTER PAO
SHI M
Check for
REAR BRAKE PADS
Check for wear.
Usi ng ver ni er cal i per s, measur e t he t hi ckness of
each brake pad
l i ni ng. The measurement does not
ancl ude the pad
backi ng pl ate
thi ckness.
Brake Pad Thickness:
Standard: 7.0
-
8.0 mm
{0.28
-
0.31 in}
{0.06 in}
l f the pad
thi ckness i s l ess than the servi ce l i mi t,
repl ace the pads and shi ms together as a set.
BACKING PI-ATE
I
7 .
1 1 .
Cl ean the cal i per thoroughl y; remove any rust, and
check for grooves and cracks.
Check the brake di sc for damage and cracks.
l vl ake sur e t hat t he
pad r et ai ner s ar e i nst al l ed i n
thei r correct posi ti ons.
PAD RETAINERS
Appl y grease to the
poi nts i ndi cated by the arrow i n
the fol l owi ng drawi ng:
NOTE: Use the
pad grease i ncl uded i n the pad set
or l Mol ykote M77 grease, and appl y a thi n coat of
grease evenl y to the desi gnated
poi nts.
. Pi ston end and i nner pad contact surface
. Pad and cal i per bracket contact surface
. Outer pad shi m and outer
pad contact surface
. Outer
pad shi m and cal i per body contact surface
l nst al l t he br ake
pads
and out er
pad shi m on t he
cal i per bracket. Instal l the i nner pad wi th i ts wear
i ndi cator faci ng downward.
@
i when reusi ng the pads, al ways rei nstal l the
brake
pads in iheil original
posiiions lo prevont
loss ol braking efficiency
. Contaminaled brake discs or
pads reduce stop-
ping ability. Keep grease off the discs and pads.
t . /
19-25
12. Rotate the cal i per
pi ston
cl ockwi se i nto the cyl i nder'
then al i gn the cutout i n the
pi ston wi th the tab on
the i nner pad by turni ng the
pi ston back
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.
CALIPR MOUNTING
BOLTS
23 N,m {2.3 kg{.m, 17 lbt'ft)
13.
14.
15.
CUTOUT
BRAKE CALIPER
Instal l the brake hose cl amp on the trai l i ng arm.
Instal l and ti ghten the cal i per mounti ng bol ts.
Instal l the cal i per shi el d.
After i nstal l ati on. check for l eaks at hose and l i ne
j oi nts
and connecti ons, and reti ghten i f necessary.
Depress the brake pedal several ti mes to make sure
the brakes work, then test-dri ve
NOTE: Engagement of the brake may requrre
greater
pedal travel i mmedi atel y after the brake pads have
been repl aced as a set. Several l i ght appl i cati ons of
the brake
pedal wi l l restore the normal
pedal travel .
Greater than normal pedal travel may damage the
master cyl i nder.
16.
1 7 .
Rear Brake Disc
Di sc Runout Inspecti on
1 . Loosen the front wheel nuts sl i ghtl y, then rai se the
vehi cl e, and suppon i t on safety stands. Remove
the front wheel s.
Remove the brake pads (see page
19-24).
I nspect t he di sc sur f ace f or damage and cr acks.
Cl ean the di sc thoaoughl y, and remove a

rust.
Use wheel nuts and sui tabl e pl ai n washers to hol d
the di sc securel y agai nst the hub. then mount a di al
i ndi cat or as shown. and measur e t he r unout at
10 mm
(0.4
i n) from the outer edge of the di sc.
Brake Disc Runout:
Servi ce Li mi t:0.10 mm {0.00,t i n)
5. l f the di sc i s beyond the servi ce l i mi t, refi ni sh the
brake di sc,
Max. Retinishing Limit: 8.0 mm {0.31 in)
NOTE: A new di sc shoul d be refi ni shed i f i ts runout
i s greater than 0.10 mm
(0.004
i n).
19-26
Di sc Thi ckness and Paral l el i sm
Inspection
1. Loosen the front wheel nuts sl i ghtl y, then rai se the
the front wh6el s.
2. Remove the brake pads (see page
j 9-24).
3. Usi ng a mi cr omet er . measur e di sc t hi ckness at
erght poi nts,
approxi matel y 45" apart and 1o mm
{0.4 i n) i n from the outer edge of the di sc. Repl ace
the brake di sc i f the smal l est measurement i s l ess
than the max. refi ni shi ng l i mi t.
Brake Disc Thickness:
Standard: 8.9
-
9.1 mm
(0.350 -
0.358 in)
Max. Rsfinishing Limit: 8.0 mm
{0.31 in}
Brake Disc Parallelirm: 0.015 mm
(0.0006
inl msx.
NOTE; Thi s i s the maxi mum al l owabl e di fference
between the thi ckness measurements.
4. l f the di sc i s beyond the servi ce l i mi t for Daral l el i sm.
refi ni sh the brake di sc.
NOTE; See secti on 18 for brake di sc repl acement.
Rear Brake Caliper
Di sassembl y
@
f l ' ,l ever use an ai r hose or dry brush to cl ean
assembl i es.
. Use an OsHA-approved vacuum cl eaner to
brake
avoi d
. Contaminated brake discs or
pads reduce stopping
abi l i ty.
CAUTION:
. Do not spill brake tluid on the cal; h may damage the
paint; if brake fluid does contact the
paint, wash ii
ofl immediatelY with water.
. To prevent spills, cover the hose
ioints
whh rags or
shop towls.
. Clean all
parts in brake fluid and air dry; blow out all
passagss with complessed air.
1. Remove the cal i per shi el d
(see page 19-24).
2. Remove t he l ock
pi n and cl evi s
pi n. Remove t he
cabl e cl i p, and di sconnect the cabl e from the arm
CABLE CLIP
Remove the banj o bol t and two seal i ng washers
Remove the two cal i per mounti ng bol ts and cal i per
body from the bracket.
CALIPER MOUNTNG AOLTS
CALIPER BRACKET
Check f or cracks
SEALING
WASHERS
Repl ace.
BANJO
BOLT
5, Remove t he pi ns and pi n boot s f r om t he cal i per
bracket.
6. Remove the
pad spri ng from the cal i per body
PI N A
(cont' d)
19-27
Rear Brake Gal i per
Disassembly
(cont'd)
7. Remove the pi ston
by rotati ng the pi ston
counter-
cl ockwi se wi t h t he t ool , and r emove t he pi st on
boot.
CAUTION: Avoid damaging the piston.
PISTON BOOT
Replace.
Remove the pi ston
seal .
CAUTION: Take care not to damage the cylinder
bore.
CALIPER BODY
Check for scoring on
9. Instal l the speci al tool between the cal i per bodv and
spnng cover.
CAUTION: Be caretul not to damags the inside of
the caliper cylinder during caliper disassembty.
BRAKE SPRING
COMPRESSOR
07HAE
-
SG00100
11.
LOCKNUTS
Posi ti on the l ocknuts as shown. then turn the shaft
unti l the pl ate j ust
contacts the cal i per body.
NOTE: Do not compr ess t he spr i ng under t he
spri ng cover.
Turn the shaft cl ockwi se 1/4
-' l l 2
tu.n to comoress
adj usti ng spri ng B i n the cal i per body.
CAUTION: To preyant
damage to the inner compo-
nonts. do not turn the shaft mor than 1/2 turn.
SHAFT
LOCKNUTS
PISTON SEAL
Repl ace.
ADJUSTII{G
SPRING 8
19-28
\
13.
Lower the l ocknuts ful l y, and ti ghten them securel y.
NOTE: Keep the l ocknuts i n thi s posi ti on unti l you
r ei nst al l t he ci r cl i p.
Remove the ci rcl i p wi th snap ri ng
pl i ers.
SNAP RING
PLI ERS
07914
-
SA50001
't
4. Hol d the
pl ate wi th your fi ngers, and turn the shaft
countercl ockwi se. Remove the speci al tool from the
cal i oer.
LOCKNUTS
l . /
15. Remove the adj usti ng bol t.
Remove the spri ng cover, adj usti ng spri ng B, spacer,
beari ng A, and cup from the adj usti ng bol t.
Remove the sl eeve
pi ston, and remove the pi n from
the cam i n the cal i per body.
'17
.
SLEEVE PISTON
Check l or wear and
damage,
i
I
I
6-50-a
w l
\
I
O-RIITG
Repl 6ce.
(cont' d)
19-29
Rear Brake Gal i per
Disassembly
(cont'dl
18. Remove the return spri ng.
PARKING LEVER/
CAM ASSEMBLY
Check l or damage.
Remove the parki ng
l ever and cam as an assembl v
from the cal i per body.
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 loosen the parking
nut,
Remove the cam boot.
RETURN
SPRING
19.
19- 30
I
Reassembl y
HP* "n ",, hos6 or drv brush to ctoan brake assemblies.
o Use an OSHA-approved vacuum cleanel to avoid brealhing brake dust'
. Contaminated brake discs or
pads reduce stopping 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 damage lhe
paint; if brake fluid does contacl the paint' wash it oft imme-
diately with water.
. Clan all Darts in brake fluid and air dry; blow out all passagss with comPressed air'
. Belore rsas3embling, check that all parts ars free ot du3t and othor torign
particles'
. Replace
parts with new ones whenever spscifiod to 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-Honda brake fluid can Gtuse corrosion and decrease the
lif of ths system.
NOTE:
. Coat
pi ston, pi ston seal , and cal i per bore wi th cl ean brake fl ui d
. Repl ace al l rubber
parts wi th new ones whenever di sassembl ed.
o .-' {@]: Use recommended si l i cone and
pi n greases i n the cal i per seal set.
. -ffi ,Use recommended rubber
grease i n the cal i per seal set.
RETuRN sPRTNG
-"'9
8 mm FLANGE BOLT
23 N.m
(2.3 kgt'm, 17 lbf ftl
BLEED SCREW
@
9 N. m
(0. 9
kgt m, 6. 5l bf ' f t |
CUP
=^.
PISTON BOOT
(cont' d)
19- 31
BEARING A
PAO SPNING
F
\
OUTER PAD SHIM
r---
Replace.
.ffi
PIN BOOTS
Replace.
-61
@@-t-.
"l-r,r., "or"'*o " orr"
I
@.,
23 N.m {2.3 kgtm, 17l bf.ftl
\@
PISTON SEAL
Repl ace.
CALIPEB
BRACKET
iiilji:ll;;
__X.,,..".^
BRAKE PAOS
PISTON
l /
CALIPER BMCKET
\
MOUNTINGEOLTS
----.-,o,
54 N.m
(5.5
kgf.m, 40lbl.ft)
q%
Rear Brake Caliper
Reassembly
(cont'dl
L
PARKING NUT
28 N.m
(2.8
kgt m,
20 rbr.trt
Pack al l cavi ti es of the needl e beari ng wi th the rec,
ommended rubber grease
i n the cal i per seal set,
Coat a new cam boot wi th recommended rubber
grease i n the cal i per seal set, and i nstal l i t i n the
cal i per body.
SPRII{G
WASHEN
z.
.-_e!!!9!.{
RUBBER
GREASE
Appl y recommended rubber grease i n the cal i per
seal set to the pi n contacti ng area of the cam, and
i nstal l the cam and l ever assembl y i nto the cal i per
bodv.
l nstal l the return spri ng.
CAUTION:
. When the cam and lever wgre separatod. b surg
to assemble them bofore installing the cam in
the cal i per body, Instal l the l evr and spri ng
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.
19-32
5. I nst al l t he pi n i n t he cam.
O.RING
Repl ace.
SLEEVE PISTON
Instal l a new O-ri ng on the sl eeve
pi sron.
Instal l the sl eeve pi ston
so that the hol e i n the bot-
tom of the pi ston i s al i gned wi th the
pi n
i n the cam,
and the two pi ns
on the pi ston
are al i gned wi th the
hol es i n the cal i oer.
Coat a new cup wi th recommended rubber grease
i n the cal i per seal set, and i nstal l i t wi th i ts groove
faci ng the beari ng A si de of the adj usti ng bol t.
7.
8.--:BTif
@'-.-3nfi""'i"
@--seacrn
$
eeenrne a
fi,*,*^"
GF-
Fi t the beari ng A, spacer. adj usti ng spri ng B, and
spri ng cover on the adj usti ng bol t, and i nstal l them
i n the cal i Der cvl i nder.
CUP
Replace.
=^.
#-g!!!!!Jl
RUBBER GREASE
o
10. l nst al l t he speci al t ool ont o t he spr i ng cover , and
turn the shaft unti l the l ocknut contacts the pl ate.
Check that the fl ared end of the spri ng cover i s bel ow
the ci rcl i p
groove.
Instal l the ci rcl i p i nto the groove. then remove the
speci al tool .
NOTE: Check that the ci rcl i p i s seated i n the
groove
properl y.
11.
12.
CIRCLIP
t . t
SPRING COVER
13. Coat a new pi ston seal wi th recommended si l i cone
grease i n the cal i per seal set, and i nstal l i t i n the cal i -
per.
PISTON BOOT
Repl ace.
RUBBER GREASE
Appl y recommended rubber grease i n the cal i per
seal set to the seal i ng l i ps and i nsi de of a new pi s-
ton boot, and i nstal l i t i n the cal i per.
Coat the outsi de of the pi ston wi th brake fl ui d, and
i nst al l i t ont o t he adj ust i ng bol t whi l e r ot at i ng i t
cl ockwi se wi th the tool .
CAUTION: Avoid damaging the piston and
piston
boot.
PISTON SEAL
Repl ace.
-6l
14.
PISTON
(cont' d)
19- 33
Rear Brake Caliper
Reassembly
(cont'dl
' 16.
Instal l the pad spri ng onto the cal i per.
Appl y the recommended pi n groase i n the cal i per
seal set to the sl i di ng surface of the pi ns
and i nsi de
of the new pi n boots.
Instal l the pi n
boots i nto the grooves
i n the cal i per
bracket properly.
PIN BOOTS
Repl sce.
(Bl.ck
Colorl
PI N
Repl 6ce.
19. Insert pi n A and pi n B i nto the cal i per bracket.
20. Instal l the pi n boots i nto the grooves i n the
propefl y.
PAD SPRING
11.
PIN GREASE
19- 34
pr ns
22.
21. Instal l the brake pad retai ners and brake pads (see
page
19-25).
Al i gn the cutout i n the pi ston
wi th the tab on the
i nner pad (see page
19-25).
Instal l the cal i per onto the cal i per bracket. and ti ght-
en the cal i per mounti ng bol ts.
CALIPER MOUNTING BOLTS
23 N.m {2.3 kg{.m. 17 lbf.ft)
WASHERS
Replace.
BANJO BOLT
34 N.m
13.5 kg{.m.
25 rbtft)
24. Connect the brake hose to the cal i per wi th new seal ,
i ng washers, and ti ghten the banj o bol t,
Insert ths cabl e through the arm, and connect the
cabl s to the l ever wi th the cl evi s pi n and l ock pi n.
Instal l the cabl e cl i p securel y.
CLEVIS PIN
- t
/ / t
LOCK PIN
Roplace.
26. Instal l the cal i Der shi el d.
27. Fi l l the brake reservoi r, and bl eed the brake svstem
(see page 19-71.
28. Operate the brake pedal
several ti mes, then adj ust
the parki ng
brake
(see page
19-6).
29. After i nstal l ati on, perform
the fol l owi ng checks:
j oi nts
and con-
necti ons, and reti ghten i f necessary.
.
Check the parki ng
brake l ever for operati on, and
adjust it if necessary.
. Check for brake hose for i nterference or twi sti nq.
Rear Drum Brake
Index/l nspecti on
' 1.
a
a
Never use an air hose or dly brush to clean brake assemblies,
Use an OSHA approved vacuum cleanar to avoid breathing brake dust,
Contaminated brake linings or drums reduce stopping ability.
Block the tront wheels before
iacking
up ths rar of lhe vehicle.
Bl ock the front wheel s, l oosen the rear wheel nuts sl i ghtl y, support the rear of the vehi cl e on safety stands, then
remove the rear wheel s.
2. Rel ease the parki ng brake, and remove the rear brake drum.
I N m 10.9 kgtm, 6.5 lbf.ftl
TENSION PIN
10 mm BOLT
6, 1N m 15. 5 kgf m,
47 tbf.ft)
WHEEL CYLINDER
I nspect f or l eakage.
l f necessary, repl ace as an assembl y.
u-cLrP
Repl ace.
WAVE
WASHER
PARKING BRAKE LEVER
Marked l ef t and ri ght .
Check f or weakness
ano oamage,
UPPER RETURN SPRING
I
@
J
PIVOT PIN
BACKING PLATE
Marked l el t and ri ght-
/
f-l
.^
I
I
*'t")
ct Ev' sB
/
( t
/
,.ro,".r r.*,"n
/ ,
I nst al l securel y on
| /
t ensi on pi n.
d " /
IU
ADJUSTER BOI-T
Check rat chet t eet h
f or wear and damage.
LOWER RETURN
SPRI NG
Check f or weakness
and oamage.
BRAKE SHOE
I nspect i on, see
page 19-36
l f br ake shoes ar e t o be
r eused, mar k and r eassembl e
i n same
posi t i on.
SELF.ADJUSTER
LEVEB
SELF-ADJUSTER
SPRING
Check f or weakness
ano oamage.
BRAKE DRUM
I nspect i on, see page
' 19
36
t
19- 35
Rear Drum Brake
Inspection
1 .
4.
Check the wheel cyl i nder for l eakage.
Check the brake l i ni ngs for cracki ng, gl azi ng, wear,
and contami nati on.
Measure the brake l i ni ng thi ckness.
Brake Lining Thickness:
Standard: 4.0 mm {0.157 i n}
Service Limit: 2.0 mm 10.08 in)
NOTE; Measurement does not i ncl ude brake shoe
thi ckness.
l f the brake l i ni ng thi ckness i s l ess than the servi ce
l i mi t, repl ace the brake shoes as a set.
Check the beari ngs i n the hub uni t for smooth oper-
ation. lf defective, refer to section 18
WHEEL CYLI NDER
LI NI NGS
19- 36
6. Measure the i nsi de di ameter oJ the brake drum
usi ng the i nsi de verni er cal i pers.
Drum Inside Diameter:
Standard: 199.9
-
200.0 mm {7.870
-
7.874 i n)
Servi c Li mi t: 201.0 mm
(7.913
i nl
l f t he i nsi de di amet er of t he br ake dr um i s mor e
than the servi ce l i mi t, repl ace the brake drum.
Check t he br ake dr um f or scor i ng, gr ooves,
and
cracks.
7.
8.
INSIDE VERNIER CALIPERS
BRAKE ORUM
t -
Brake Shoe Di sassembl y
1. Remove t he t ensi on
pi ns by pushi ng t he r et ai ner
spri ngs and turni ng them.
TENSI ON PI NS
RETAINER SPRINGS
Lower the brake shoe assembl y, and remove the
l ower return spri ng.
NOTEi Be careful not to damage the dust cover on
the wheel cyl i nder.
Remove the brake shoe assembl y.
Di sconnect the parki ng brake cabl e from the parki ng
brake l ever.
Remove the upper return spri ng, sel f-adj uster l ever,
and sel f - adj ust er spr i ng, and separ at e t he br ake
snoe5.
t
3.
4.
ADJUSTEB BOLT
Check rat chet t eet h f or
wear ano oamage.
UPPER RETURN SPRING
Check f or weakness
ano oamage.
ll
, ' /
N
r
//
t
6. Remove the wave washer, parki ng brake l ever, and
pi vot pi n from the brake shoe by removi ng the U-
cl r p.
PARKING ERAKE
I-EVER
WAVE WASHER
/
@@
I
I
U-CLI P
Repl ace.
Brake Shoe Reassembly
1 . Appl y brake cyl i nder grease (P/Nr
08733
-
B020E) or
equi val ent rubber
grease to the sl i di ng surface of
the
pi vot pi n,
and i nsert the pi n i nto the brake shoe.
Instal l the
parki ng brake l ever and wave washer on
the
pi vot pi n
and secure them wi th the U-cl i p,
NOTE: Pinch the U-clip securely to prevent the pivot
pi n from comi ng out of the brake shoe.
,6;::"'
(cont' d)
19-37
LEVER
Rear Drum Brake
Brake Shoe Reassembly
{cont'dl
Connect t he par ki ng br ake cabl e t o t he par ki ng
brake l ever.
Appl y grease on each sl i di ng surface.
!@
contami nated brake l i ni ngs reduce
stopping ability. Keep grease or oil off the blake lin-
ings. Wipe any excess grease off the parts,
. Appl y brake cyl i nder grease
{P/N: 08733
-
8020E)
or equi val ent r ubber gr ease
t o t he sl i di ng sur -
faces as shown.
+a
Sl i di ng surl ace
Appl y Mol ykote 44MA to the brake shoe ends and
opposi te edges ofthe shoes as shown.
_'
o Opposite edge of the shoe
+O
Br ake shoe ends
19- 38
13.
5. Cl ean the threaded porti ons of cl evi ses A and B.
Coat the threads of the cl evi ses wi th grease. To
shoften the clevises, tun the adjuster bolt.
6. Hook the sel f-adj uster spri ng to the sel f-adj uster
l ever fi rst, then to the brake shoe
7. Instal l the cl evi ses and upper return spri ng. noti ng
the i nstal l ati on di recti on.
NOTE: Be careful not to damage the wheel cyl i nder
dust covers,
8. Instal l the l ower return spri ng.
9. Instal l the tensi on pi ns and retai ni ng spri ngs.
uppER RETURT{ SpRtNG
CLEVIS B
CLEVIS A
Instal l the brake drum.
l f the wheel cyl i nder has been removed, bl eed the
brake system
(see page 19-7), and check for l eaks at
brake l i ne connecti ons, and reti ghten i f necessary.
Depress the brake pedal several ti mes to set the
sel f-adj usti ng brake.
Adj ust the parki ng brake
(see page 19-6).
' t0.
1 1 .
12.
LOWER RETURN SPRING
Brake Hoses/Lines
L J
Inspection/Torque Specifications
t. Inspect the brake hoses for damage, deteri orati on, l eaks, i nterference, and twi sti ng.
2. Check the brake l i nes for damage, rusti ng. and l eakage. Al so check for bent brake l i nes.
3. Check for i eaks at hose and l i ne
i oi nts
and connecti ons, and reti ghten i f necessary'
4. Check the master cyl i nder and ABS modul ator uni t for damage and l eakage
CAUTION: Replace tho brake hose clip whenevr the brake hose is serviced.
ABS MODULATOR UNIT-Io-BRAKE l-lNE
19 N.m
(1.9 kgf.m, 14lbl.ftl
PROPOBTIONING CONTROL VALVE.
io-BRAKE LINE
l 5 N. m
(1. 5 11 tbf.ftl
MASTER CYLINDER-Io-BMKE LINE
15 N.m
(1.5 ksrf.m, 11 lbf'ft)
REAR DISG BRAKE:
BRAKE HOSE-to4ALlPER
{BANJO BOLT}
34 N. m
(3. 5
kgt m, 25 l bf f t l
BLEEO SCREW
9 N'm
(0.9
kgf.m, 6.5 lM.ftl
BRAKE LINE-to-WHEEL CYLINDER
15 N.m
(1.5
kgl.m, 11 lbf.ftl
BLEED SCREW
7 N.m {0.7 kst m, 5 lbf,ttl
J
BRAKE LINE-io-aRAKE HOSE
15 N. m {1. 5
11 tbtft)
BRAKE LINE-Io-BRAKE HOSE
15 N.m
(1.5
kgt.m, 11 lbf'ft)
(BANJO
BOLT}
3,1 N.m 13.5 kgf.m, 25 lbf.ft)
J
19- 39
Brake Hoses/Lines
Hose Replacement
CAUTION:
. Bgfore reagsembling, chgck that all parts are free of
dust and othor foroign particles.
. Repl8ce parts 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.
1 . Replace the brake hose if the hose is twisted, cracked,
or i f i t l eaks.
Di sconnect the brake hose from the brake l i ne usi ng
a 10 mm fl are nut wrench.
FLARE NUT
WRENCH
l Commerci al l y
ava i l abl e)
BRAKE LINE
BRAKE HOSE
Remove and di scard the brake hose cl i D from the
brake hose.
Remove the banj o bol t, and di sconnect the brake
hose from the cal i per.
Remove the brake hose bracket from the knuckl e.
19- 40
10.
6. Instal l the brake hose bracket and brake hose onto
the knuckl e fi rst. then connect the brake hose to the
cal i per wi th the banj o bol t and new seal i ng washers.
BRAKE HOSE
6 mm HOSE BRACKET
BOLTS
9. 8 N. m
{1. 0 kgf m, 7 l bt f r}
BANJO BOI.T
34 N.m
{3.5 kgf.m,25 lbt.ftl
7. I nst al l t he br ake hose ont o t he uooer br ake hose
bracket with a new brake hose clip
15 N. m
(1.s
ks{.m, 11 lbl.ftl
Connect the brake l i ne to the brake hose.
After i nstal l i ng the brake hose, bl eed the brake sys-
tem
(see page 19-7).
Perform the fol l owi ng checks:
. Check the brake hose and l i ne
j oi nt
for l eaks, and
ti ghten i f necessary.
. Check the brake hoses for i nterference and twi st-
I ng.
8.
Parki ng Brake Cabl e
L
Inspecti on and Repl acement
CAUTION: The
parking blake cables must not be bent or distorted. This will lead to stiff operation and
premature cable
fai l ure.
PARKING BRAKE CABLE
Check f or f aul t y movement .
PARKING BRAKE LEVER
Check f or smoot h
operat i on.
\ i ,
EOUALIZER
PARKING BRAKE SWITCH
Disc Brake Type:
Di sconnect the parki ng brake cabl e from the l ever on the
caliper by removing the lock pin and clevis
pin, and remove
the cabl e from the arm by removi ng the cl i p
CLEVIS PIN
Drum Brake Type:
Remove the
parki ng brake cabl e from the backi ng
pl ate
usi ng a 12 mm offset wrench as shown.
12 mm
OFFSET WRENCH
(Commerci al l y
avai l abl e)
DISC BRAKE TYPE:
CLEVIS PIN
PARKING ERAKE CABLE
{tt
BACKING PLATE
/
19-41
L -
t
Anti-lock Brake System
(ABSI
Speci al Tool s . . . . . . . . . . . . . 19-44
Component Locat i ons . . . . . . . . . . . . . . . . . . . . . . . . . 19-45
(ABS)
Features/Construction ..................., 19-46
Operat i on . . . . . . . . . . . . . . . 19-47
Circuit Diagram ......... 19-50
ABS Control Unit Terminal
Arrangement ......... 19-52
Troubleshooting Precautions ............. 19-54
(DTCI
Diagnostic Trouble Gode
(DTCI
I ndi cat i on . . . . . . . . . . . 19-56
DTC Erasure . . . . . . . . . . . 19-57
Symptom-to System Chart ............. 19-58
Troubleshooting
ABS Indicator Light Does Not
Come On . . . . . . . . . . . . 19-60
ABS Indicator Light Does Not
Go Of f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-62
Wheel Sensor ........ 19-64
Sol enoi d . . . . . . . . . . . . . . . . . 19-60
ABS Pump Mot or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-68
Mai n Rel ay . . . . . . . . . . . . . 19-71
lgnition Voltage .... 19-73
Central Processing Unit
{CPU} ........ 19-74
Modulator Unit
Removal/lnstallation ....................... 19-75
ABS Control Unit
Replacement
......... 19-76
Pulsers/Wheel Sensors
I nspect i on
. . . . . . . . . . . . . . 19-76
Wheel Sensor Replacement ............ 19-77
t /
Special Tools
Ret. No.
I
Tool Number
I
Description
I
O,V
I
page
Reference
(!)
I
07PM- 0010100
I
t I 19_s6
19-44
Component Locati ons
t a
SERVICE CHECK CONNECTOR {2PI
BIGHT.REAR WHEEL
SENSOR CONNECTOR
MOOULATOR UNIT ABS CONTROL UNIT
RI GHT-REAR WHEEL SENSOR
LEFT.RAR WHEEL
SENSOR CONNECTOR
J
UNDER.DASH FUSE/RELAY 8OX
LEFT.FRONT WHEEL SENSOR
ABS +B
(20
A) FUSE
UNDER.HOOD FUSE/RELAY BOX
lcl lilo Al FUSE
ABS INDICATOR LIGHT
UNOEF.DASI{ FUSE/RELAY BOX
HORN/STOP I15 A) FUSE
UNDER.HOOO ABS FUSE/RELAY BOX
PUMP MOTOR {'O A} FUSE
PUMP MOTOR BELAY
E
o
METEB I7.5 AI FUSE
0
0
0
00000
n
00000
u
BR DEF RLY 17,5 A) FUSE
t
MTR CHECK
(7. 5
AI FUSE
19-45
(ABSI
Featu res/Construction
When the brake pedal i s depressed duri ng dri vi ng, the wheel s can l ock before the vehi cl e comes to a stop, In such a case,
the maneuverabi l i ty of the vehi cl e i s reduced i f the front wheel s are l ocked, and the stabi l i ty of the vehi cl e i s reduced i f the
rear wheel s are l ocked, creati ng an extremel y unstabl e condi ti on. The ABS preci sel y control s the sl i p rate of the wheel s to
ensure the gri p
force of the ti res. and i t thereby ensures the maneuverbi l i ty and stabi l i ty of the vehi cl e.
Judgi ng the vehi cl e speed. the ABS cal cul ates the sl i p rate of the wheel s based on the vehi cl e speed and the wheel speed,
then i t control s the brake fl ui d pressure
to attai n the target sl i p rate.
Grip Force of Tire and Road Surlace
COEFFICIENT OF
FRICTION
TARGET SLIP RATE
Slip Rate
BRAKING
START POINT
ROTATIONAL
DIRECTION
RADIAL
DIRECTION
OF THE
ROTATIONAL
OIRECTION
A: Distance without slio
8: Slippsd distance
C: Actuel distance
sr-rrmre=f= SLIP RATE
VEIIICLE SPEED
-
WHEEL SPEEO
VEHICLE SPEED
19-46
t -
Operation
t
ABS Control Unit
Main Control
The ABS control uni t detects the wheel speed based on the wheel sensor si gnal i t recei ved, then i t cal cul ates the vehi cl e
speed based on the detected wheel speed. The control uni t detects the vehi cl e speed duri ng decel erati on based on the
rate of decel erati on.
The ABS control uni t cal cul ates the sl i p rate of each wheel . and i t transmi ts the control si gnal to the modul ator uni t
sol enoi d val ve when the sl i p rate i s hi gh.
The
pressure reducti on control i s a three-mode system, that i s pressure reducti on, pressure retai ni ng and pressure i ntensi -
fyi ng modes.
Self
-diagnosis
Funqtion
The ABS control uni t i s equi pped wi th a mai n CPU and a sub CPU, and the CPUS check each other'
The CPUs check the ci rcui t of the svstem.
When the CPUS detect fai l ure, they shi ft to the
"system
down mode" or the
"control
i nhi bi ti on mode"
The sel f-di agnosi s can be cl assi fi el d i nto these four categori es:
O:
Ini ti al di agnosi s
@:
Except ABS control
@:
Duri ng ABS control
@:
Duri ng warni ng
On-board Diagnosis Funstion
The ABS control uni t i s connected to the data l i nk connector {16P).
The ABS system can be di agnosed wi th the Honda PGM Tester.
(cont ' d)
MODE ABS INDICATOR LIGHT
MAIN
RELAY
SOLENOID
VALVE
CPU Restart condi ti on DTC
SYSTE IV
DOWN
ON
No
operati on
Dri ve
i nhi bi t i on
Operat i on*r
l gni ti on
switch
OFF
+
ON Memory
CONTROL
I NHI BI TI ON
ON
No
operal ron
Dri ve
i nhi bi ti on
Operati on Automati c Memory
*1:
Except CPU fai l ure
/
19-47
{ABS)
Operation
(cont'dl
ABS Modulator
The ABS modul ator consi sts of the i nl et sol enoi d val ve, outl et sol enoi d val ve, reservoi r, pump, pump motor and the
dampi ng chamber.
The modulator reduces the caliper fluid pressure
directly, and it is also referred to as a circulating type because the brake fluid
circulates through the caliper, reservoir and the master cylinder.
The hydraul i c control has three modes: pressure
reduci ng, pressure
retai ni ng, and pressure
i ntensi fyi ng.
The hydraul i c ci rcui t i s the i ndependent four channel type, one channel for each wheel .
RF LR
Pressure i ntensi fyi ng mode: Inl et val ve open, outl et val ve cl osed
Pressure retai ni ng mode:
Pressure reduci ng mode:
Motor operati on mode:
r N: I NLETVALVE
{ NORMALt Y OpENI
OUT: OUTIET VALVE {NORMALIY CTOSED)
Master cyl i nder fl ui d i s pumped
out to the cal i Der.
Inl et val ve cl osed, outl et val ve cl osed
Cal i per fl ui d i s retai ned by the i nl et val ve and outl et val ve.
Inl et val ve cl osed, outl et val ve oDen
Cal i per fl ui d fl ows through the outl et val ve to the reservoi r.
When starti ng the pressure reduci ng mode, the pump
motor i s ON.
When stoppi ng ABS operati on, the pump
motor i s OFF.
The reservoi r fl ui d i s pumped
out by the pump,
through the dampi ng chamber, to the master
cvl i nder.
PUMP MOTOR
19-48
L
Wheel Soeed and Modul at or Cont l o
t
OUTLET
VALVE
ON
OFF
I NLET
VALVE
ON
OFF
t\,40ToR
ON
OFF
when the wheel speed drops sharpl y bel ow the vehi cl e speed, the i nl et val ve cl oses to retai n the cal i per fl ui d pressure
When the wheel speed drops further, the outl et val ve opens momentari l y to reduce the cal i per fl ui d pressure. The pump
motor starts at thi s ti me.
As the wheel speed i s restored, the i nl et val ve opens momentari l y to i ncrease the cal i per fl ui d pressure.
Wheel SensoJ
The wheel sensors are the magneti c contactl ess type
As the gear pul ser teeth rotate past the wheel sensor' s magneti c coi l , AC current i s generated The AC frequency changes
i n accordance wi th the wheel speed. The ABS control uni t detects the wheel sensor si gnal frequency and thereby detects
the wheel speed.
There are four wheel sensors, one for each wheel
The gear pul ser has 50 teeth.
EEL SPEED
at LOW SPEED
gl
=
o
GEAR PULSEB
WHEEL SENSOB at HI GH SPEED
/
19- 49
Gircuit Diagram
MOOULATOR UNIT IOP CONNECTOR
zrJrF!_
l l l
2 3 l l
14TiEltl
c@4
PIMP MOTOR 2P CONNECTOR
( Ll
number )
fFl
GTN
UNDER.HOOO A8S FUSE,/FELAY BOX
3P CONNECTOR
(O
number)
| 2 3 l
UNDER.HOOD AAS FUSE/RELAY BOX
2P CONNECTOR
(!
number)
|
- l
GAUGE ASSEMELY 5P CONNECTOR
---t--
t 1 t / 1 3 ) / l 5 l
Wi re si de ot temal e termi nal s
-
E8l{'Ytr
AA DEF BLY I7.5AI
_@f_u,
n4@f-n,
LEFT.FSONT SOLENOIO
UNDER-OASH FUSSRELAY 8OX
ZoP CONNECTOR
(O
numbe,
2 3 5 6 7 8 I
t 0 t l t3 /
i 15 /
t 8 20
UNDER.OASH FUSE,/RELAY
BOX
18P CONNECTOR
( E
numbr )
2 3 5 6
9 l l 2 13) t 4
/ 1 6 1 7
19- 50
t
ABS CONIROL UN]T
ECM / PCMISCS'
V
,,,
+-{l-, ?,,]
B6li! [,b.,,,,,
-F-
SENSOR
+B
Y
WHTNED
8U(
J-
G,Ol, Ga02
l
\EWIK
LEFT.
RIGHT,
LEFT
;___.|-1
**1.
,I
coierou
SERVICE CHECK
CONNECTOR
(2P}
l r l 2 f
OATA LINK
CONNECTOR O
6P)
WHEEL SENSOR
2P CONNECTOB
FRONT
/.[Ttl\
REAR
tc-T-l
I
z l
r [ B '
12 13
ABS CONTROL UNIT 26P CONNECTOR
1O numbr)
1 2 3 4 6 / 8 I l 0 . /
t t 12
r3
1 4 t 5 1 6 1 7 19 , / 21 23
-o&"^1'
cot, croz
Termi nal si de of
mal e t ermi nal s
1! numbr)
/
19- 51
ABS Control Unit Terminal
Arrangement
Terminal
numo0r
Wire
color
Terminal sign
Termi nal namo
Dgscription
Voltage
Conditions
(lgnition
Switch ON flt))
Output voltago
teminals
PCOM
(Pri mary
common)
Power source f or t he sol enoi d
val ve and pump
mot or.
1-GND
ON
=
ON O V
AC: 3-6 V
BLK/WHT
scoM
(Secondary
common)
Power source for the sol enoi d
2.GND
OFF
lConnect
the SCS service\
\ conneclor
l
Approx. 3 V
ELVBLU
tG2
(l gni ti on
2)
Detects ignition switch 2
!9nal.
(system
activate signal)
3-GND
Battry voltage
BLU/YEL
RRO
(Rear-ri ght
0)
Detects right-rear wheel
sensor si gnal .
4-17
When the wheel i s
turned at 1 turn/second.
53 mV or above on
digitaltester (AC
ra nge) {Fefera nce)
150 mvp-p or above
on oscilloscope
6 GRY
RLO
(Rear-l eft
0)
Detects left-rear wheel sensor
sr gnal .
6- 19
8 GRN
FRO
(Front-right
0)
Dtects right-front wheel
sgnsor srgnal ,
a-21
Stops Approx.2.5V
STOP
(Stop)
hects brake switch signal.
(Prevents
unnecessry ABS operation)
9-GND
Brake pedal
depressed. Battery voltage
Brake pedal released.
O V
10 BRN^/vHT
FLO
(Front-left
0)
Detects left-front wheel sensor
si gnal .
10-23
When the wheel is
turned at 1 turn/
secono.
53 mV or above on
digitaltester (AC
range) (Referance)
150 mVFporabove
on oscilloscope
9!ops
Approx. 2.5 V
12 YEL
RLOUT
(Rearjeft
outlet)
Dri ves l eft-rear outl et sol enoi d
12. GND
ON
-9
ON O V
OFF AC: 3^6 V
REDMHT
RR]N
(Rear-ri ght
i nl et)
Dri ves ri ght -rear i nl et sol enoi d
valve.
13-GND
OFF
lconnect
the SCS service]
i connector
I
Approx. 3 V
1 4
B1
(Battery
1)
Power source for the sol enoi d
vatve and pump
motor.
14.GND
Battery voltage
1 5 WHT/G R N
82
(Baftery
2)
Power source for the solenoid
varve ano pump
motor.
15. GND
r6 BLK
GND2
{Ground 2)
Ground f or t he ABS cont rol
uni t .
16-GND
Bel ow 0.3 V
1 7 GRN/'/EL
RR1
(Rear-ri ght
1)
Detects right-rear wheel
sensor si gnal .
17-4
When the wheel i s turned
at 1 turn/second.
53 mV or above
on di gi tal tester
(AC
range)
(Referance)
150
mVp-p or above
on osci l l oscope
1 9 LT BLU
RLl
(Rea.-l eft
1)
Detects left-rear wheel sensor
sagnal .
19-6
GRN/BLK
FRl
(Front -ri ght
1)
Detects right-front wheel
sensor si gnal .
21-8
FL1
(Front -l ef t
1)
Detects left-front wheel sensor
si gnal .
23-10
Stops
Approx. 2.5 V
RED
RL-IN
(Rear-l ett
i nl etl
Dri ves l eft-rar i nl et sol enoi d
25.GND
ut
ON
' 6
-9
ON O V
OFF AC: 3-6 V
OFF
lconnect
the SCS service]
\ connector
l
Approx. 3 V
BLK
GND3
(Ground
3)
Ground for the ABS cgntrol
uni t .
26.GND
Bel ow 0.3 V
19-52
e \
t
Terminal
numbel
Wiro
coror
Termi nal si gn
De3cription
Volt.ge
ConditionE
(lgnition Switch ON
(ll)l
Output voltago
lTqrminal namsl
terminils
RED/BLU
FR-IN
{Front-right
i nl et)
Drives right-front inlet
sol enoi d val ve.
I - GND
riJ
ON
-9
ON O V
OFF AC: 3-6 V
OFF
/Connect
the SCS servicq
\
connector I
Approx. 3 V
BRN
scs
(Service
check
si gnal )
Detects service check signal
{Di agnosti c
troubl e code
i ndi cati on)
4-GND
SCS service connector
connected.
O V
di sconneded.
Appro)(. 5 V
7 BLU/RED
(Warni ng
ramp)
Dri ves ABS i ndi cator l i ght
(The
i ndi cator l i ght gos off when
ABS control uni t outputs bat-
tery volta9e),
7-GND
I ndi cat or l i ght ON Approx, 2 V
Indi cator l i ght OFF Battery voltage
8 BLU/YEL
Not used.
10 YEUBLK
FL.OUT
{Front-left
outl et)
Drives left-front outlet
sol enoi d val ve. 10- GNO
ON
ON O V
OFF AC: 3- 6 V
11 RED/BLK
FLIN
{Front-lft inlet)
Drives left-front inlet solenoid
11- GND
OFF
lconnect
the SCS servicq
\
connector I
Approx. 3 V
YEUBLU
FR.OUT
(Front-ri ght
outl et)
Drives right-front outlet
sol enoi d val ve. 12-GNO
l 4 LT BLU
DLC
(Data l i nk
connector)
Communi cates wi th
PGM Tester.
Honda
14.GND
Approx. 5 V
17 BRNA/EL
MCK
l Motor check)
Detects
pump motor drive
srgnal . 17. GND
Pump
motor
reray
ON Battery voltage
OFF O V
1 9 YELRED
PMR
(Pump
motor
reray,
Dri ves
pump motor rel ay.
19-GND
ON
ON O V
OFF AC: 3-6 V
OFF
ponnect the SCS sewicq
\
connedor l
Approx. 3 V
BLU
RR-OUT
(Rear-ri ght
outl etl
Drives right-rear outlel
sol enoi d val ve.
21- GND
uJ
ON
Pump
motor
relay
ON O V
OFF AC: 3-6 V
OFF
lconnect
the SCS servicq
\
connedor )
Approx. 3 V
22 BLK
GND2
(Ground 2)
Ground for the ABS control
unt t .
22-GND
Bel ow 0.3 v
19- 53
Troubleshooting
Precautions
ABS Indicator Light
I The ABS i ndi cator l i ght comes on when the ABS control uni t detects a probl em
i n the system. However, even though
the system i s normal , the ABs i ndi cator l i ght can come on, too, under the fol l owi ng condi ti ons. To determi ne the
actual cause of the probl em, questi on
the customer about the probl em,
taki ng the fol l owi ng condi ti ons i nto consi der-
ati on.
. Si gnal di sturbance
. Wheel soi n
. Onl y dri ve wheel s rotate
. Battery voltage fluctuates
2. When a probl em i s detected and the ABS i ndi cator l i ght comes on, the i ndi cator l i ght can stay on untat the i gni ti on
swi tch i s turned off, or i t can automati cal l y go off, dependi ng on the mode.
. Li ghtstayson unti l the i gni ti on swi tch i sturned off;When the system i s i nthesvstem down mode.
o Li ght automati cal l y goes
off:
When the system i s i n the control i nhi bi ti on mode.
(refer
to symptom-to-system
chart)
3 The ABS indicator light stays on when the system is reactivated without erasing the DTC, but it goes
off after starting
the car.
when the wheel sensor system is faulty and the ABS indicator light comes on, the algorithm of the system automatically
turns off the ABS indicator light after the wheel speed signal returns to the normal speed. while, when the DTC is erased,
the CPU is reset and the ABS indicator light goes
off when the system checkd out normal by the initial diagnosis.
Therefore, test-drive the car after servicing the 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.
(DTC)
1. The di agnosti c troubl e code
(DTC)
i s memori zed when a probl em
i s detected and the ABS i ndi cator l i ght does not go
off, or when the ABS i ndi cator l i ght comes on.
The DTC i s not memori zed when the ABs i ndi cator ri ght comes on unress the cpU i s acti vated.
2. The memory can hold any number of DTCs. However, when the same DTc is detected twice or more, the later one is
wri tten over the ol d one.
Therefore. when the same problem
is detected repeatedly, it is recorded as one DTC.
3. The DTCS are i ndi cated i n the order of ascendi ng number, not i n the order thev occur.
4. The DTCS are memori zed i n the EEpROM
{non-vol ati l e memorv}.
Therefore, the memorized DTCS cannot be canceled by disconnecting the battery.
perform
the specified orocedures to
erase.
Solf-diagnosis
1. The sel f-di agnosi s can be cl assi fi el d i nto these four categori es:
' Ini ti al di agnosi s; Performed ri ght after the engi ne sta rts and unti l theABs i ndi cator l i ght goes
off.
o Except ABS control: Performed when the ABS is not functioning,
. Duri ng ABS control : Performed when the ABS i s functi oni ng.
. Duri ng warni ng: Performed when the ABS i ndi cator l i ght i s ON.
2 The system performs
the following controls when a problem is detected by the self-diagnosis:
. ABS i ndi cator l i ght ON
. Memory of DTC
. Mode change to the
"system
down mode,, or the
"control
i nhi bi ti on mode,,.
MODE ABS INDICATOR LIGHT
MAIN
RELAY
SOLENOID
VALVE
CPU Restart condi ti on DTC
SYSTEM
DOWN
ON
No
operal | on
Drive
i nhi bi ti on
Operati on+r
l gni ti on
switch
OFF
-
ON Memory
CONTROL
I NHI BI TI ON
ON
No
operat| on
Orive
i nhi bi ti on
Operati on Automati c Memory
*1:
Except CPU fai l ure
19- 54
t J
t \
Kickback
1. The motor operates when the ABS i s functi oni ng, and the fl ui d i n the reservoi r i s forced out to the master cyl i nder
causi ng ki ckback at the brake pedal .
2. TheABScontrol uni t operates the sol enoi d val ve when the brake pedal i s rel eased afterthe i ni ti al di agnosi s Youmay
hear the fai nt sol enoi d val ve operati on sound at thi s ti me. but i t i s normal .
Pump Motor
1. The
pump motor operates when the ABS i s functi oni ng
2. The ABS control uni t checks the pump motor operati on duri ng accel erati on. You may hear the fai nt operati on sound
at thi s ti me. but i t i s normal .
Brake Fluid Replacament/Air Blsading
1. Brake fl ui d repl acement and ai r bl eedi ng
procedures are the same as for conventi onal brakes
Troubleshooting
1. The troubl eshooti ng fl owcharts expl ai n the procedures on the assumpti on that the cause of the
probl em i s sti l l
pre-
sent and the ABS i ndi cator l i ght i s sti l l on.
Note that troubl eshooti ng fol l owi ng the fl owchart when the ABS i ndi cator l i ght does not come on can resul t i n i ncor-
rect
j udgment.
2. Ouesti on the customer about the condi ti ons when the
probl em occurred, and try to reproduce the same condi ti ons
for troubl eshooti ng.
sel f,di agnosi s i s made at vari ous ti mes such as the i ni ti al di agnosi s, except ABS control . duri ng ABS control , duri ng
accel erai i on, duri ng the speci fi ed vehi cl e speed, etc. Therefore, the symptom cannot be checked unl ess the check
condi ti ons match wi th the probl em condi ti ons
3. When the ABS i ndi cator l i ght does not come on duri ng the test dri ve, but the troubl eshooti ng i s performed based on
the DTC, check for the l oose connectors.
poor contact of the termi nal s, etc, before troubl eshooti ng.
4. After troubl eshooti ng, erase the DTC and test-dri ve the car. Be sure that the ABS i ndi cator l i ght does not come on.
5. The connector i l l ustrati ons show the femal e connectors wi th a si ngl e outl i ne and the mal e connectors wi th a doubl e
oufl rne.
6. The connector termi nal cavi ti es contai ni ng femal e termi nal s are al ways numbered by l ooki ng at the connector from
the wi re si de. and the cavi ti es contai ni ng mal e termi nal s are al ways numbered by l ooki ng at the connector from the
termi nal si de.
r'
19- 55
Diagnostic
Trouble
Code
(DTCI
Diagnostic
Trouble
Code
{DTC) Indication
NOTE: Thi s operati on can al so be carri ed out wi th the Honda
pGM
Tesrer.
l connect the scs servi ce connector to the servi ce check connector i nsi de the passenger,s
si de ki ck panel .
(| | ).
but do not start the engi ne.
NOTE: Do not depress the brake pedal
when turni ng the i gni ti on swi tch.
3 Record the bri nki ng frequency of the ABS i ndi cator ri ght. The bri nki ng frequency i ndi cates the DTc.
4, Turn the i gni ti on swi tch OFF, and remove the SCS servi ce connector.
NorE: The Msl functi on Indi cator Lamp (Ml L)
wi l l stay on after the engi ne i s started i f the scs servi ce connector i s
connected.
5. Erase the DTC.
Condhions for DTC indication
. The vehi cl e i s stoDDed.
. The SCS service connector is connected before the ignition switch is turned ON
fll).
.
The brake pedal i s rel eased.
. Th SCS service connector remains connected during this procedure
The DTG indication stops 8nd the ABs conltol unit executes the softwaro tunqtion if at least one of the following condi-
tions b satisfied:
o
The vehi cl e i s not stoDoed.
' The ABS control unit receives the normat signal
(which
is for the ABS controt unit) from a Honda
pGM
Tester.
. The SCS service connector is disconnected during this
procedu.e,
u.s.A.
@
CANADA
@
SERVICE CHECK
CONNECTOR {2PI
SCS SERVICE CONNECTOR
07PAZ
-
0010100
ABS INDICATOR LIGHT
DTC : 3 3
A8S INDICAIOR LIGHT
Snilion
swirch
' when the i gni ti on swi tch i s turned oN
(l l ),
the ABs i ndi cator l i ght comes on to check the bul b. Do not count i t as a DTc.
o The ABS control uni t can memori ze any number of DTCs.
. The new DTC i s not memori zed when the ABS control uni t has al ready memori zed the same DTC,
. l f t heDTCi snot memor i zed, t heABSi ndi cat or l i ght st aysONaf t er i t goesof f f or 3. 6seconds.
19- 56
L J
DTG Erasure
1 .
2.
Connect the SCS servi ce connector to the servi ce check connector i nsi de the passenger' s si de ki ck panel .
Depress the brake pedal .
Turn the i gni ti on swi tch oN
(l l )
whi l e hol di ng the brake
pedal , but do not start the engi ne. The ABS i ndi cator l i ght
goes off after two seconds.
After the i ndi cator l i ght
goes off, rel ease the brake
pedal The i ndi cator l i ghtcomeson after four seconds
After the i ndi cator l i ght comes on, depress the brake
pedal agai n. The i ndi cator l i ght goes off agai n after four sec-
onds. The brake
pedal i s sti l l depressed.
4.
5.
\ t
6. After the
j ndi cator
l i ght goes off, rel ease the brake pedal agai n'
7. After four seconds, the i ndi cator l i ght bl i nks twi ce for 0 3 second and the DTC i s erased
8. Confi rm the DTC i ndi cati on, and check that the DTC was erased
NOTE: Al ways mai ntai n these steps. l f you di sconnect the scs servi ce connector and/or fai l to operate the brake
pedal
accordi ng to the i ndi cator l i ght i ndi cati on, the DTC wi l l not be erased
Conditions for DTC erasure
o The vehi cl e i s stopped.
. The SCS servi ce connector i s connected before the i gni ti on swi tch i s turned ON {l l )
. The brake
pedal i s depressed before the i gni ti on swi tch i s turned ON
(l l )'
. The SCS servi ce connector remai ns connected duri ng thi s
procedure
The DTC erasure stops and ABS control unit executes the software lunction it at least one ot the following conditions is
satisfied:
o The vehi cl e i s not stopped.
. The SCS servi ce connector i s di sconnected duri ng thi s servace'
. TheABs c ont r o| uni t r ec ei v es t henor maI s i gna| ( whi c hi s f or t heAEs c ont r o| uni t ) f r omaHondaPGMTes t er '
. The brake
pedal i s not operated accordi ng to the i ndi cator l i ght i ndi cati on
. The DTC erasure i s fi ni shed
ABS INDICATOR LIGHT
OFF
DEPRESS
BRAKE PEDAL
RELEASE
0 . 3 s e c
lqnition switch
oN
( I )
J
19-57
Diagnostic Trouble
Code
(DTCI
Symptom-to-System
Chart
DTC
o
H 1 =
DIAGNOSIS/
SYMPTOM
DETECTION TIMING
> =
PNOBABLE CAUSE i . ' s
E V 9
8E
z r
\ 9 =
6 < _ 6
= t
6t z
NO
DTC
ABS indicator iighr does
not com on when ignirion
swrt.h is lu.ned on
(ll)
,
Open in the pow.
source circ!ir ror the ABS -.ndicato;l isht
.
Elown ABS indicalo.lighr butb
'
Open in rhe ABS indicaror tight drive cncuit.
.
Shori ro powr
in theWALpcircuit
.
Faul t yABS cont r ct ! ni t
ON
ABS i ndi cat or l i ght does
nol90 oft 6frer engine is
Open in the lG2 circuit
Opon in the +B circuir
Opn andlor short ro body ground
jn
the WALP circuit
Faultv AAS coni.ol unn
t 1
oN.
Wheel sensor (opn/short
O o o
o
13
upen, snofiro bodyground and/or shodro power in rhe wh61
Faulty ABS co.lrctunit
l l
BL
12
oN.
(chippd pulser gea/noise)
o a
o
Short to wh6slsn6or (O)circuir
in t'e.h;;Go-nso,
trtcircuti
Faulty whsel snsor insra|ation
Faulty ABS cont.olunir
I 8
31
ON
Solenoid (open/shon
ro
a o a
Op.ni shon to bodyground and/o. shorrto powsr
in rhe
opn in lh6 coM circuit
Faulty ABS conlrclunit
32
F8-OUT
FL. I N
3'l
FT. OUT
RF. I N
88 OUT
31
8t r N
38
RLOUT
ON
o o
opn in tho motor pow..ourco
circlia
Opn i ni h mor o. cNOci r cui t
Faulty ABS conrrol unit
52 ON
o o
Open in rh COM, PMR 6nd/o. MCKcircuir
Opn.n.Vor blown lus in the under hood AgS rusdretry box
Faufty pump
moto. rotay
faulv ABS conlrolunit
53 ON
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
54 ON
o o c
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
ON
lgnition voltage (low
vott-
o o o o
.
Connection ot the24 V bariorv tor enqins starr
.
Faurtycharoins system
.
Opn in th6lG2 circuit
.
Fa!lly ABS contrcl unil
81 ON CPU o o o o
E {rml facior{sl en bs rhe ouse{sl ot |he probtem
F.ulty ABS conrrot unit
r:
It DTcs 1 1 18 {wheel sensor codes) wore del*ted the lasr time the v6h cls wEs d rivn, rhe a8s indicator tight wi

stay on u ntit lh6 ignition swirch is rurn6d oN t), and the connorunit contnms rhat rhe wheet sensoB . rc OK,
19- 58
L e
\ .t
CONDITION FOR DETECTION
MANAGEI\,4ENT
FEFER
TO
PAGE
DUNI NG
ABS CONTFOL
EXCEPT
ABS CONTAOL
19-60
19- 62
The ABS indicator lighl cones on when vehicle is stoppd and wheel sensor a given vohaqe does nol
19 64
The ABS indicaror comes on under thlollowing conditions
. When
mor et han one ot wheel s ar e a st andst i l and t hel el oci r v ot t he f ast est wheel r eaches a
'
fohen th. velocity of the faslesl wheel reaches or exceds a given sped, and it there ar somewh@ls
whose velocity is slowe.lhan a cenain percenlage oi lh fast6t wheelsped for 3 given period
.
when rhere are lemporary open or short ctcuits ol rhe wheel sonsor' chippd
pulser gear, orsrgnal
or sl Jr baaLe
19 64
The main relay repeats ON/OFF switching atalltimes
. Whent hemai nr el ayi sON, ashor t t $t pul sei ssent l oeachval ve l f t her e s some di s' r epa ncv, l he
ABS i ndi cal or l i ght comes on.
.
When rhe main relay is OFF, a shonlsl
pulse is snlto each valve lfth6 solenoid drive voltage rs
out ol a
qiven range, the ABS ndicalor lighl comes on 19-66
' The pump nolot s activaled orc o' Mrce sfier every
gn' t' on sw' lch ON
(ll)
operarion whrle lte
-^
vchi cl e acLel er al es l r ent hemol or ot i vevo' t aSer sr hecl ed
When l hevol l a96 r s abnor mar , l r e Abs
indicaror llghl comes on.
.
Afte. ABS ;onl rol com
pletion, the moror isswitched ofi 6nd the main CPU checks the molor dnve
voltase. when rhe vortase is abnormsl, the ABS indicato49!!!99!:l!:_-
19-68
D!rino an active motor lesl or AAS control,lhe main CPU checks ihe supplv voltage to the motor'
whe;lhe vohage s abnofmal, the ABS indicator lightcomes on
19,68
lirhe moror drvevoltage indicates molot operalion when the main cPU does notswilch the motor
oN, rhe ABs indicaro. comes on 19-64
.
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 rlay repeats ON/OFF switching ar a!ltimss when the main rel.v is ofi, a shorl l6st pulse
is sent ro ach valve. The CPU mon tors the reJernce vohage ll the vohage is out ot a g iven range'
the ABS indic.tor lightcomes on
1 9 7 1
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 lig ht coms on When the ig n ilion vohage recove' s
t o nor mal f 6ng6, ABS i nhi bi t i on i s cancel ed.
19. 73
rimln CpU anO suU CeU chck each other undercertain condnions. Whon rhe CPUS dstectthe fol'
lowing discrepanaies, rhe ABS indicator light comss on
.
whe; rhre is discGpancv n lhacarculated wheelspeed velocirv thar continuosJor more than a
given
.i^/hen
rhere is discrcoancv in the ehase informalion lhat continuesfor morerhan a given period
'
When rhere is discrepancY in thecalculared conlfol
pa.amerer'
.
When thewatch dog conrrolp!lsetailslof a given penod
.
When t h6 checkot t h ROM t ai 1s.
.
when there is disrepancy inrhe data roading.nd wriung
prcledurc ot RAM
19 7' l
t r
19- 59
Troubleshooting
ABS Indicator Light Does Not Come On
YES
NOTE:
Rei nstal l the
fuse i f i t i s OK.
The A8S indicator light does not come on when ignition switch is turned ON ll.
NOTE: Al l i ndi cat or t i ght s except t he charg,
i ng syst em l i ght wi l l not come on when t he
METER
17. 5 A) f t se i s bt own.
NO
GAUGE ASSEMBI"Y 5P CONNECTOR
Tho ABS indicator light does not
come on whn ignition switch is
tu.ned ON {lll.
check t he METEB (7. 5
A) f use i n
t he under-dash f use/ rel ay box.
Beplace the tu3e and recheck.
Check for an open in th6 lcl cir-
cuii:
1, Di sconnect t he gauge
assem
bl y 5P connect or.
2. Turn the ignitjon switch ON l).
t he gauge
assembl y 5P con-
n e c t o r t e r mi n a l No . 5 a n d
body ground.
.
Ropai r opan i n t ho wi r o
bot wen t hc METER t 7. 5 At
tuso and gauge .$cmbly.
.
Roplacc th. und.r-dash tus./
r.l.y box. lop.r cirouit in3ido
the box.l
Check t he ABS i ndi cat or l i ght
bul b i n t he gauge
assembl y.
l s t he bul b OK?
Chck tor a short to power in the
WALP circuit:
Measure the voltage between the
gauge
assembl y 5P connect or
t ermi nal No. I and body ground.
Replir short to power
in tho wiiG
b. t weon t he gruge
rs3embl y
.nd ABS control unh.
l To
page 19-61)
19- 60
{From
page 19. 60)
Check the
geuge a$embly:
2. Connect t he gauge assembl y
5P connect or.
3. Connect t he t ermi nal No. 3 t o
body
gr ound wi t h a
i umper
(l l ).
Replace th ABS indicato. light
drive circuit in the
gauge ai3om-
blY.
Does t he ABS i ndi cat or
l i ght come on?
. Repai r
open i n t he wi r e
bei ween t he
gauge assembl Y
and body
ground.
.
Repai r
poor gr ound
{ G401,
G402t.
J t
GAUGE ASSEMBLY 5P CONNECTOR
,c? "
l 1 t / ' . l t / t 5 |
JUMPER I GND IBLK}
wrRE
I
-L
t
19- 61
Troubleshooting
The ABS indicator light does not go
off after the engine is started.
-
Wi t h engi ne r unni ng, ABS
indicator light is ON.
-
With tho SCS sewice connec-
to. connected l3oe
page 19-561,
no DTC is indicated,
Checkt he RR DEF RLY {7. 5 A)t use
in the under-dash fuse/relay box.
Raphco tha furo and rochack.
Check t he ABS +B (20
A) f use i n
the under hood tuse/relay box.
R6pl.ce tho tu3c lnd r.ch.ck.
Chock for an open in the lG2 cir-
GUrt:
(l t ).
t he ABS cont rol unh 26P con-
body ground.
Bopair opcn in tha wir. botw.cn
th. RR DEF RLY 17.5 Al tus. .nd
ABS control unit.
Check tor an opon in thG Bl end
82 circuit:
Measur e t he vol t age bet ween
body ground
and t ermi nal s No. 14
and No. 15 i ndi vi dual l y.
Rrpair opsn in tha wiro t atwa,an
the ABS +B (20
Al fu.r .nd ABS
control unh.
ls there banery voltage?
1To
page 19-63)
ABS Indicator Light Does Not Go Off
YES NOTE: Fei nst at t t he l use i t i t i s OK.
YES NOTE: Rei nst a

t he f use i f i t i s OK.
I G2I ELK/ BLUI
ABS CONTBOL UN]T 26P CONNECTOR
8T IWHT/GRNI
19-62
l From
page 19-621
Ch6ck lor . short to body
ground
in ihe WALP Gircuit:
2. Di sconnect t he ABS cont r ol
uni t 22P and gauge assembl y
5P connectors.
t he ABS cont rol uni t 22P con-
body ground.
Ropair short to body g.ound in
tho wire betweon the ABS con_
trol unit and
gauge aasembly.
Check the AgS cortrol unit:
1. Connect t he ABS cont rol uni t
22P connect or.
2. Turn l he i gni t i on swi t ch ON
(l l ).
t he ABS cont rol uni t 22P con'
n e c t o r t e r mi n a l No , 7 a n d
body
ground.
Check tor rn open in lho GND2
circuit:
t o body ground wi t h a
i umper
body
ground.
'
Repair opn in the wit between
the ABS control unit and body
ground.
.
Rep. i r
poor gr ound l G40' 1,
G1(}2t.
Check tor loo3 ABS control unit
connector!. lf necesaary, substi_
tute a known-qood ABS control
unit and rcheck,
Check lor an open in the WALP
circuit:
gauge assembl y 5P connect or
Ropai. opon in the wiro botween
the ABS control unit end gauge
assemblv.
Replace the ABS indicrtor light
driv6 ci.cuit in the gtuge assem-
bl y.
t v
WALP {BLU/REDI
rt
.D
Y
WALP {BLU/REDI
wi re si de ol f emal e t ermi nal s
J
19- 63
Troubleshooting
Wheel Sensor
Diagnostic Trouble Gode {DTC) ll-18: Wheol Sn3ol Diagnosis
NoTE: The ABS indicator light comes on when only the drive wheels are turning, signal disturbance is detected, etc. Therefore,
test-drive the car at a speed of 12 mph
(20
krn/h) or more after turning the ignition:witch from OFF to ON fll), and if the ABS
indicator light does not come on, the svstem is OK.
0Tc
Appropri at e Termi nal
(0)srDE
11) SrD
r 1, 12
(Right-front)
No. 8: FRo No. 21: FRI
13, 14
(Left-front)
No. 10: FLo No. 23: FL1
15, 16 {Right-rear) No. {: RRo No. 17: RRl
17, 18
(Left-rear)
No. 6: RLo No. 19: RLI
RLl
(LT
BLU} FRl (GRN/BLKI
NO
NOTE:
.
Normal vol t age: Approx. 2 V
'
0 V: Repl ace t he ABS cont rot uni t .
.
4 V or more indicates a short to power.
A8S CONTROL UNIT 26P CONNECTOR
RRO
I BLU/ YELI
RR1 IGRN/YELI
FL1
I GRN/ ORN}
-
With the ignition switch ON
{ll), ABS indicator tighr doe.
noi go
off,
-
Aftsr driving, ABS indicatot
light comes on.
-
With the SCS so.vice connac-
tor connc,ted {soe
pege
19-561,
DTCs 11-18 a.e indicrted.
Chock lhe wheol sensor ci.cuit:
uni t 26P connect or.
2. l l easur e t he r esi st ance
between the appropriate wheel
sensor
(0)
and
(1)
ci rcui t t ermi ,
.
Reprir opn in the l0l or {0 cir-
cuit wiro, or shon to thc {01 cir-
cuit wi.o in thc {11 circuit wirc
bctween ths ABS control unit
and approprieto wheel a6nsor.
.
R.pl.ce th epp.opri.te wheal
3nloa.
l s t he resi st ance OK?
/ Front r
750
-
1050 o/ 20"C, 68. F
\
\ Rear:
850- 1150 O/ 20. C, 68"F
/
Check toru short to body ground
in the wheel senso. circuit:
ABS cont rol uni t 26P connect or
appropri at e wheel sensor
(0)
ci r
cui t t ermi nal i and body ground.
.
Rapair short to body ground
in
t h6 ( 0)
or l l l ci l cui t 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 t he ABS cont rol uni t
26P connector,
nect or appropri at e wheel sen-
sor
( 0)
ci r cui t t er mi nal and
body ground.
Ropair rhon to powo.
in the l0l
or l l l ci rcui t wi re bat w. en t h
ABS cont.ol unit and .pplopriata
whccl !naoa,
l s t here 4 V or more?
fio
page
19-65)
19-64
t
\ e
(From page 19-64)
Check t or chi pped pul ser gear.
Repl ace t he dri vesh. t t or hub
unil.
(Chipped pulser gar)
DTC 11, 13, 15. 17: Ropl ace t he
ABS control unil.
Of C 12, 11. 16, 18: The ABS con-
trol unit may have detected sig-
nal di st urbance.
l r
19- 65
Troubleshooting
Sol enoi d
{DTC} 31-38: Solenoid Diagnosis
YES
FL. OUT (YEL/ ALK)
-
(lll,
ABS indicator light does
nol go
oft. or ABS indic.to.
light comes on while ABS i3
functioning.
-
With the SCS servico connec-
tor connected ls.
pag
19-561,
DTCa 31-38 are indicstod.
Check for a short lo powor
in tho
sol6noid circuitl
uni t 22P and 26P connect ors.
2. St a rt t he engi ne.
t he ABS cont rol uni t connect or
appr opr i at e sol enoi d ci r cui t
t ermi nal * and body ground.
Ropri . short t o powor
i n t hc
appropriate solanoid ci.cuit wiro
bot w6. n t hs ABS cont . ol uni t
and modulrtor unit.
Check for a short to body ground
in the 3olenoid circuit:
Check tor continuity between the
appropri at e sol enoi d ci rcui t t ermi -
nal * and body ground.
.
Repair short to body ground
in
lhe .ppropriato solonoid circuit
wire betwoan th6 ABS control
unit and modllato. unit.
.
Replaco the modul.tor unit.
Check th ABS control unit:
' 1.
22P and 26P connect ors.
4. Turn t he i gni t i on swi t ch ON {l l }.
the ABS control unit 26P con-
nector appropriate CONI circuit
t ermi nal ++ and body ground.
Check for loos ABS control unh
connectora. It naceslrry, aub3ti-
tutc . known-good ABS control
unit tnd recheck.
DTC
Appropriate
Connector
Appropriate
Termi nal
31: FRJ N 22P No. 1
32: FR-OUT 22P No. 12
33i FL'IN 22P No. 11
34: FL OUT 22P No. 10
3s: RRI N 26P No. 13
36: RR-OUT 22P No. 21
37: RLIN 26P No. 25
38: RL-OUT 26P No. 12
RL.OUT IYEL}
DTC
Appropriate
Termi nal
31: FR- l N No. 2: SCOM
32: FR-OUT No. 2: SCOM
33i FLIN No. 1: rcOM
34: FL-OUT No. l : PCOM
35: RR{N No. 1: PCOM
36: RR-OUT No. 1: rcOM
37rRL' l N No. 2: SCOM
38: RL-OUT No. 2: SCOM
RL.OUT
(YEL}
19- 66
(To page 19-671
(From page 19 66)
Check tor an opn in th solenoid
circuit:
Measure the voltage between the
ABS control unit connector appro-
pri at e sol enoi d ci rcui t t ermi nal *
and body ground.
'
Repsir opon in the appropriate
COM circuit wiro botwoon the
ABS control unit and modulatol
unit.
'
Repair open in ihe appropriate
solnoid ci.cuit wiro between
tho ABS control unit and modu-
lator unit.
.
Roplaco the modulator unil.
Check loi loGe ABS control unit
connoctors. It necessarv, substi-
tute a known-good ABS control
unit and recheck.
t e
\ J
FL.OUT {YEL/BLK}
DTC
Conncl or Ter mi nal
31: FB- l N 22P No. 1
32: FR'OUT 22P No. 12
33: FL IN 22P No . 1 l
34: FL-OUT 22P No. 10
35: BR-lN 26P No. 13
36: RR-OUT 22P No. 2l
37: BL- l N 26P No. 25
38: 8I -OUT 26P No. 12
BL. OUT
(YELI
19-67
Troubleshooting
ABS Pump Motor
Diagnostic Trouble Codo {DTC} 51-53r ABS
pump
Motor Diagnosis
YES NOTE: Shor t t he PMR t er mi nat t o body
NOTE: Rei nst al l
ground f or a moment , and recheck t he f use.
t he f use i f i t i s OK
l f t he f use i s bl own, check f or a short t o body
ground
i n t he MCK ci rcui t .
AAS CONTNOL UNIT 22P CONNECTOR
7 A t 0 t l
12 1 1 1 9 2 l 22
PMR IYEL/RED} I JUMPER
I WIRE
NO
NO
YES
NOTE: Rei nstal l
the fuse i f i t i s OK.
NOTE: Shor t t he PMF t er mi nal t o booy
ground
f or a moment , and recheck t he f use.
l f t he f use i s bl own, check f or a short t o body
ground in the wire between the under-hood
ABS l use/ rel aV box and pumD
mot or.
-
(ll),
ABS indicator lighr doos
not go
otf.
-
With tho SCS srvico connee
tor conncted lsee
page 19661,
OTCa 51-53 aro indicated.
Check the MTR CHECK
(7.5
A) fuse.
Repl.ce the fuse .nd recheck.
Replaco tho tuse and rocheck.
Rcphce th pump
motor rol6y.
Check t he pump
mot or power
source circuit:
(l l ).
Chck for a short to !'ows. in tho
pumP motor power
3ource ciacrrit:
Remove t h6 purnp
mot or rel ay,
Does t he pump mot or operat e?
Bopair sho.t to
powsr
in the wir
bot woen t he under-hood A8S
t use/ . el ay box and ABS pump
motor.
Does t he pump
mot or operat e?
Check tor loGe ABS control unit
connoctors. lf nocessary, substi-
tute a known-good ABS control
unit and rochck,
(To page 19-69)
19- 68
t t
(From page 19-68)
UNDER.HOOD ABS
FUSE/RELAY 8()X
TERMINAL
TERMINAL
PUMP MOTOR 2P CONNECTOR
MOTOR +8 lWHTl,$
rv)
-
Y
Wi re si de ot femal e termi nal s
\ lt
MOTOR +B {RED} MOTOR GND
(BLK)
(cont' dl
19- 69
JUMPER WI RE
Check the pump motor circuit:
1. Remove the
pump motor relay.
(l l ).
3. Connect the
pump motor relay
connect or +8 and MOTOR t er
mi nal s wi t h a
i umper
wi re t or
a momenr,
Chck f or an open i n t he pump
moior +B circuit:
2. Di sconnect t he pump mot or
2P connect or,
(l l ).
4. Connect t he pump mot or rel ay
connect or +B and MOTOR t er-
mi nal s wi t h a
j umper
wi re.
t he pump mot or 2P connect or
t er mi nal No. l and body
ground.
Does t he
pump mot or operat e?
Repaia open in the wire botween
t ho under-hood ABS f use/ rel ay
box and pump motor.
Check t he
pump mot or opgra-
t i on:
Connect the battery {+}terminal to
the
pump motor 2P connector ter-
mi nal No. 1. and t he
(-)t ermi nal t o
the terminal No. 2 for a moment.
ReDlaco lho modulator unit.
(Feulty pump motor)
Does t he
pump mot or operat e?
Chock for a short to body ground
in the PMR circuit:
2. Di sconnect t he ABS cont rol
t e r mi n a l No . 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
t ha wi re bet ween t he under-
hood ABS f use/ rcl ay box and
ABS cortrol unit.
(To page 19-70)
Troubleshooting
ABS Pump Motor
(cont'dl
(From page 19-69)
Check tor an opon in the PCOM
circuit:
2. Reconnect t he ABS cont r ol
nector,
(l l ).
t he
pump mot or r el ay con
nect or PCOI , I t er mi nal and
body
ground.
Repair opon in tha wiro bEtwoon
th. undr-hood ABS fu3./rclsy
box and ABS control unit.
Chock for rn op6n in tho PMR cir-
cuit:
Measure the voltage beNveen the
Ropair opon in tho wira btwoon
tho undor-hood ABS fu.e/rel.y
box and ABS control unit.
Chock f or an opon i n t hs MCK
circuh:
2- Di sconnect t he SCS servi ce
connector.
3. Turn the ignition switch ON lll).
nect or t er mi nal No. 17 and
body
ground whi l e connect -
i ng t he
pump mot or r el ay
connector +8 and MOTOR ter'
mi nal wi t h a
j umper
wi re f or
moment .
Repeir op.n in th. wire batween
tho undor-hood ABS fu.o/rol.V
box rnd ABS control unh.
Ch6ck lor loose ABS contlol unit
connoctors. lf ngc63ary, sub3ti-
tute d known-good ABS control
unit and recheck.
n
--l
wi re si de oI t emal e t ermi nal s
19-70
t f
Mai n Rel ay
Diagnostic Trouble Code {DTC} 54: Msin Relay Diagnosis
YES
NOTE: Rei ns t al l
the fuse i f i t i s OK.
B1
{WHT/GRNI
\ e
PCOM
I GRN/ WHT}
scoM
{BLK/ WHTI
(cont' d)
19-71
-
{l l ), ABS i ndi c. t or l i ght does
not go off.
-
With the SCS 3ervica connoc-
tor connected
(se pag 19-561,
DTC 54 is indicated.
checkt he ABS +B
(20
Al f use.
Replace th6 fuso and rechock.
Chck for an opn in the 81, 82
circuit:
Measur e t he vol t age bet ween
body ground and the ABS control
uni t 26P connect or t ermi nal No.
' 14
Repair open in the wire betweon
the ABS control unit and under-
hood ABS tuse/relav box.
Check for a short lo body ground
in the PMR circuit:
1- Turn t he i gni t i on swi t ch OFF.
2. Remove the
pump motor relay.
grouno.
Repai r short t o body ground i n
t he wi r e bet ween t he undor -
hood ABS f use/ rel ay box and
ABS control unit.
Check tor a short to body ground
in the PCOM, SCOM circuit:
body
ground and t he ABS con-
t r ol uni t 26P t er mi nal s No. 1
.
Bepai. short to body ground in
tho PCOM circuit wire betwoen
the ABS control unit and under-
hood ABS fu3e/.olay box.
.
Repair 3hort to body
ground in
the PCOM or SCOM circuit wire
between the ABS control unit
and moduletor unit.
.
Rcpl ace t h6 modul at or uni t .
(Short
circuit insido tho unit)
{ To
page 19 72)
l r
Troubleshooting
Mai n Rel ay
(cont' d)
(From page 19' 71)
PCOM
(GRN/WHTI
scoM
(BLK/WHT}
Check tor a short to powor in the
PCOM, SCOM circuit:
r).
body ground and ABS cont rol
uni t 26P connect or t ermi nal s
No. l and No. 2 i ndi vi dual l y.
.
Repai r 3hoi t t o power i n i he
rcOM circuil wire bgtween the
ABS cont rol uni t end unde. -
hood ABS fuse/relay box.
.
Repai r sho t o
powor
i n t ha
PCOM oJ SCOM ci rcui t wi ro
betwoen the ABS control unit
and modulator unit.
'
Repl . co t he modul . t or uni t .
lshort to Dowcr iGido the unit)
Replace the ABS control unit.
Vo l t a ge
19-72
l gni ti on Vol tage
(DTC)
61: lgnhion Voltage Diagno3is
A8S CONTROL UNIT 26P CONNECTOR
I G2I BLK/ BLU}
] Wi re si de of l emal e t ermi nal s
-
With tha engin running, ABS
indicator lighl is ON.
-
With the SCS srvice connec-
to. connctod ls
page 19-561,
Problem vrification:
1. Erase t he DTC.
3. Make sure t hat t he ABS i nd;
cat or l i ght comes on and DTC
61 i s i ndi cat ed.
l s DTC 61 i ndi cat ed? The system b OK .t this time.
Check the lG2 cilcuii:
l s t here 18 V or above?
lf the vohage is 0 V, check lor an
opon in the lG2 circuit.
It there is 12
-
17 V. substitute a
known-good ABS colrtrol unit and
Jecheck.
I t
19-73
Troubleshooting
Central Processing Unit
(CPUI
Diagnostic Troublo Code IDTC) 81: CPU Disgnosis
-
{lll. ABS indicator light does
not go
oft.
-
With tho SCS servi@ connec-
tor conncted lsee
page 19{6},
P.oblem vedfication:
1. Erase t he DTC.
2. Test -dri ve t he vehi cl e.
3. Make sure t hat t he ABS i ndi ,
cat or l i ght comes on and DTC
81 i s i ndi cat ed.
l s DTC 81 i ndi cat ed? Rpllc6 th. ABS control unh.
The system k OK rt this time.
19-74
\ i l
Modul ator Uni t
CAUTION:
. Do not spill brake tluid on the car; it may damage the paint; it brako lluid does contact the paint, wash it off immedi-
ately with wator.
a Take care not to damage or delorm the brake lins 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
matri al .
NOTE| Ti ght ent hef l ar e nut st o 15 N. m
( 1. 5
kgnm. l 1 l bf . f t ) .
Removal
' 1.
Di sconnect the modul ator uni t 10P and Dump motor 2P connectors.
2. Di sconnect the brake l i nes, then remove the modul ator uni t.
Instal l ai i on
1. Instal l the modul ator uni t. then connect the brake l i nes.
2. Connect the modul ator uni t 10P and oumD motor 2P connectors.
3. Bl eed the brake system.
4. Start the engi ne, and check that the ABS i ndi cator l i ght goes off.
F o m
right-1461
PUMP MOTOR
2P CONNECTOR
J
-R
/2e'
t '
TOR UNIT
t t
19- 75
ABS Control Unit
Pulsers/Wheel
Sensors
Repl acement
1. Remove the ri ght si de ki ck panel .
2. Di sconnect the ABS control uni t connecrors.
3. Remove the ABS control uni t,
4. l nstal l the ABS control uni t i n the reverse order of
removal ,
CONNECTORS
19-76
Inspection
Check the front and rear pul ser
for chi pped or dam-
aged teeth.
Measure the ai r gap
between the wheel sensor and
pul ser
al l the way around whi l e rotati ng the pul ser.
Slandard: 0.4
-
1.0 mm
(0.02 -
0.04 in,
NOTE; l f t he gap
exceeds 1. 0 mm
( 0. 04
i n) , t he
pr obabi l i t y i s a di st or t ed suspensi on ar m whi ch
shoul d be repl aced.
Dbc brake typo
0. {
-
1. 0 mm
(0.02 -
0.04 in)
Drum brake typ6
1 .
l}
t
Wheel Sensor Replacement
NOTE:
. Becareful when i nstal l i ngthe sensors to avoi d twi sti ng the wi res.
. The torque val ue of the bol ts i s 9.8 N.m
(1.0
kgf.m, 7 l bf.ft).
Front
FRONT WHEEL SENSOR
Rear
1. Remove the hub beari ng uni t
(see
secti on 18).
2. Remove the four backi ng
pl ate bol ts.
3, Pul l the backi ng pl ate away from the trai l i ng arm, then remove the wheel sensor. l t i s not necessary to di sconnect the
brake l i ne.
NOTE: Thi s i l l ustrati on i s drum brake type. The torque val ue of the di sk type i s same as drum type.
REAR WHEEL SENSOR
J \
I t
19-77
l}
e \
Body
(' 96
model l
Doors
Front Door Index
(4D)
...20-2
Rear Door Index
{4Dl
.....20-8
Door fndex
l zDl 3Dl
.......20-14
Embl ems
f nstallation 20-118
Exterior
Component Locati on Index ............... 20-93
*Frame
Repai r Chart .......... 20-120
*
Interior
Component Locati on Index ............... 20-58
Mirrors
Mi rror Rep|acement .................. ......... 20-24
Mirror Holder/Gover Replacement ... 20-25
Rearvi ew Mi rror Reol acement .......... 20-25
Moonroof
l ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
Opener Cable/Opener and Latch/
Wiper and Washer
Component Locati on Index .......... ...,. 20-107
Seats and Seat Belts
Gomponent Locati on Index .......... ..... 20-73
Sub-f rame . . . . 20-119
Windshield, Rear Window and Ouarter Glass
I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
Body
{' 97
modell
Body
(' 98
modell
Body
(' 99
modell
Body
(' 00
model)
20-123
20-131
20-135
20-141
I t
Doors
Front Door lndex
,ID:
WEATHERSTRIP
POWER WINDOW
swtTcH
ffitr6-
fud
-@a,
\tEf
Adjustment, page
20-23
DOOR
PROTECTOR
OOOR POCKET
r^r f\ i'
I I \ ) t \ '
\ t \ - !
20-2
J$--"**^
l}
GLASS
Repl acement ,
page 20 6
Adi ust ment ,
page 20-20
GLASS RUN
CHANNEL
CENTER LOWER
CHANNEL
e
CYLINDER
PBOTECTOR
REGULATOR
Replacement,
page 20-6
LOCK ROD
PROTECTOR
STRIKER
\ '
Adj ust ment ,
\ l l
page 20-23
\ tt t[
#-l|r&
/ h )
/ Y <
cYLTNoER
,/
ROD ,/
LATCH
Repl acement ,
20-6
LOCK
CYLINOER
RETAINER
CLIP
ô
?' 2'
ourER HANoLE
\necuLaron
HANOLE
POWER DOOR
LOCK SwlTCH
(dri ver' s
onl y)
Repl acement ,
page 20-5
INNEN HANDLE ROD
LATCH
PROIECTOR
- )
/
s /
*Nqd'
/
-"-/
t t \
. \
' \
I t
INNER
HANDLE
20-3
Doors
Door Panel Repl acement
NOTE; Take care not to scratch the door panel
and other
pans.
1. Remove:
. Inner handl e
(see page 20-3)
. Mi rror mount cover panel (see page
20-24)
2. l f appl i cabl e, remove the regul ator handl e by pul l i ng
HANOLE
3. Remove the door gri p cover and speaker cover, then
remove the screws.
>: Screw locations, 5
POWER WTNOOW
swtTct{
the cl i p out wi th a wi re hook.
20-4
4. Rel ease the cl i ps that hol d the door panel . Remove
the door panel
by pul l i ng i t upward.
NOTE: Remove the door panel
wi th as l i ttl e bendi ng
as possi bl e
to avoi d creasi ng or breaki ng i t.
95 mm {3.74 in.)
.L
12 mm
(0.47
i n.) f
TRIM PAD
REMOVER
(Commerci al l y
avai l abl el
Snap-on
#A'177, o.
equi val enl
l m m
(0.04
in.l
r_
rr-l
45 mm
(1. 77
i n. l
>i Clip loc.tions, 5
l u - i
J$- I
:fe i
cL,P
/\
I
REMovERi l
I
_ _t/
Dasconnect t he
; peaker connect or,
5. l nst al l at i on i s t he reverse of t he removal procedure.
\ :
Outer Handl e Repl acement
NOTE: Rai se the gl ass ful l y.
' 1.
Remove:
. Door panel
. Pl asti c cover
(see page 2o-21
2. Pul l out the retai ner cl i P.
6 x 1 . o mm I
i.e N.. tr.o rgf.-,
I
7.2 rbr.fi)
,2
C
3.
CYLINDER PROTECTOR
LOCK CYLINDEB
RETAINER
CLIP
Remove the bol ts, then remove the cyl i nder
protec-
tor, l ock cyl i nder and outer handl e.
>: Bol t l ocai i ons,2
CYLINDER
LOCK CYLINDER
CYLI NDER ROD
20-5
4. Pul l out the outer handl e. Pry the outer handl e rod
out of i ts
j oi nt
usi ng di agonal cutters
NOTE:
a To ease reassembl y, note l ocati on @
of the outer
handl e rod on the
j oi nt
before di sconnecti ng i t.
. Take care not to bend the outer handl e rod.
o Use a shop towel to
protect the openi ng i n the
ooor.
OUTER HANDLE
ROD
DIAGONAL
CUTTERS
SHOP
TOWEL
l nstal l ati on i s the reverse of the removal procedure
NOTE: Make sure the door l ocks and opens
properl y.
BUSHI NG
Repl ace.
\
,w.
5.
i4'
Doors
Latch Replacement
NOTE: Bai se the gl ass ful l y.
1. Remove:
. Door panel (see page
20-4)
. Pl asti c cover
(see
page 20-2)
.
Outer handl e
(see page
20-5)
Remove the bolt, then move the center lower channel
forwa rd.
Di sconnect the connector, and detach the harness
cl i p from the door. Bemove the l atch through the
hol e i n the door.
NOTE: Take care not to bend the i nner handl e rod,
outer handl e rod, cyl i nder rod and l ock rod.
6 x
' t.0
mm
8 N.m
(0.8
kgt m,
6 tbf.ftl
4. Instal l ati on i s the reverse of the removal procedure.
NOTE:
. Make sure the i nner handl e rod and connector
are connected properl y.
. Make sure the door l ocks and opens properl y.
LOCK ROO
20-6
' 1.
Glass/Regulator Replacement
Removel
o Door panel (see page 20-4)
. Plastic cover
(see page
20-2l,
Careful l y move the gl ass unti l you can see the bol ts,
t hen r emove t hem. Car ef ul l y pul l t he gl ass out
through the wi ndow sl ot.
NOTE: Take care not to drop the glass inside the door.
>i Bolt loc.tions,2
f i
s' r . o- .
i
Cl b9.8
N.m 11.0 kst m,l
_-l't!!t ,/
GLASS
REGULATOR
\ L
3. Di sconnect the connector, and detach the harness
cl i p, then remove the regul ator through the hol e i n
the door,
>: Bolt locations
a > , 4
t t t * ,
)
6 x 1 . 0 mm
8 N. m {0. 8 kgl m,
B > , 3
ar Nul locations, 3
I t
6 x 1 . 0 mm
8 N.m 10.8 kgf m,
6 rbt.ftl
Loosen.
REGULATOR
{ Manual t ype)
REGULATOR
4. Grease al l the sl i di ng surfaces of the regul ator where
snown.
REGULATOR
MOTOR
l nstal l ati on i s the reverse of the removal
procedure.
NOTE: Rol l the
gl ass up and down to see i f i t moves
freel y wi thout bi ndi ng. Al so make sure that there i s
no cl earance between the
gl ass and gl ass run chan-
nel when the
gl ass i s cl osed. Adj usr the posi ti on of
the gl ass as necessary
(see page 20-20).
20-7
Doors
Rear Door Index
,[D:
OUTER
WEATHERSTRIP
I NNER
WEATHERSTRIP
DOOR
Adjustment,
page 20-23
INNER MOLDING
fu4
ffir",
M
R*
/ -
HINGE
POWER WTNDOW
\a-
sw[cH
\ \
\ \
\ ; \

-*r'
*e
(=__:\
\
:-?
\
/ \
/ \
/
DooR
/
GRIP
DOOn
GRI P
COVER
o(x)R
PROTECTOR
t\
\ \
PLASTIC
COVER
20-8
\ L
lJ
\
\fl
REAR CHANNEL\
N\
\ \ , \
\ \ r \
\ i \
I l l
l d 1l
6P l l l
REo" c"AN"..:
| 1l
coLLAR
\ J I
) ) \ I J
6/
\3-
REGULATOR
HANOLE
:& fr\
\ t r \ l l l
' Al l
cri ss l Ll
l'A\
sroeeen
lll
W-*d
t
a)"
u\
*)u*ro*
\
Repracement,
pase 20
,tt
l5[1tf
CHANNEL
OUTER HANDLE
Repl acement , Page
20-11
STRIKER
Adjustment,
page 20'23
I
I
%
grc
POWER WINDOW
MOTOR
LOCK ROD
PROTECTOR
LATCH
PROTECTOR
Replacement,
page 20-12
POWER OOOR
LOCK ACTUATOE
t
20-9
Doors
NOTE: Take care not to scratch the door panel and other
parts.
1. Remove:
. Inner handl e (see page 20-9)
. Regul ator handl e
(see page
20-4)
2. Remove the door gri p cover, then remove the screws.
>: Screw l ocat i on3. 2
20-10
3. Rel ease the cl i ps that hol d the door panel . Remove
t he door panel by pul l i ng i t upwar d.
NOTE: Remove the door panel wi th as l i ttl e bend-
ang as possi bl e
,L
12 mm
(0.47
in.) T-
TRIM PAD
REMOVER
(Commerci al l y
avai l abl e)
Snap-on
#4177, or
equivalnt
4
l N l
rRrM PAD---_Jl
i
REMOVER .I+ ]
F /
rt{-
l mm
l - - - 4
, nu"
(o.o1i n.l 1
f- -l
45 mm
'
11. 77 i n. l
>r Cl i p l ocat i ons, T
4. Instal l ati on i s the reverse of the removal Drocedure.
t
Outer Handl e Repl acement
NOTE: Rai se the gl ass ful l Y.
1. Remove:
. Door panel
. Pl asti c cover
(see page 20-8)
2. Remove the screws.
6 x 1 . 0 mm
6 N. m {0. 6 kgf m,
4 tbf.ftl
a \
3. Move the l atch down, and remove the bol ts.
>: Bol t l ocat i ons, 2
6 x 1 . 0 mm
9.8 N,m
)
11.O
kst.n,7.2lbiftl
//
out of i ts
j oi nt
usi ng di agonal cutters.
NOTE:
. To ease reassembl y, note l ocati on
O
of the outer
handl e rod on the
j oi nt
. Use a shop towel to protect the openi ng i n the
door .
BUSHING
Repl ace.
OUTER
HANDLE
ROD
5.
o
DIAGONAL
\
:"'*
,w,
procedure
NOTE: N4ake sure the door l ocks and opens
properl y.
SHOP TOWEL
20-11
Doors
Latch Replacement
NOTE: Rai se the gl ass
futty.
1. Remove:
. Door panel (see
page
20-10)
. Pl asti c cover
(see page
20-8)
.
Outer handl e (see page
2O-1 ,l
2. Remove the l ock crank and cl i p.
>: Screw location, I >: Clip location, I
qn@l
#
|
_ __)
_- __)
LOCK
ROO
LATCH
Remove the rear channel col l ar.
NOTE: Take care not to bend the l ock rod and i nner
handl e rod.
Di sconnect
t he
connect or.
6 x 1 . 0 mm
8 N.m (0.8
kgt m,
5.
6 tbtttl
Remove the l atch through the hol e i n l ne door.
l nstal l ati on i s the reverse of the removat proceoure.
NOTE: Make sure the door l ocks and opens properl y.
20-12
,,<\
8 N.m
to.8 ksf.m, 6 tbt.ftt
IDF-IIID I
.)
- __, /
2.
L
p
o' r . o- , n
I
@
9.8 N.m {t.o kof.m. I
.-
:' zul nt
-
/
3. Car ef ul l y l ower t he gl ass.
Remove t he bol t s and
screw from the rear channel , then remove the gl ass
from the rear channel .
NOTE: Take care not to drop the gl ass
i nsi de the door.
>: Bolt. screw locations
A, 1 , c, 1
I
q)h:iT(--n,,".
i m
- - illt) '/ -
)
Glass/Regulator
Replacement
Remove:
. Door panel
{see
page
20-10)
. Pl asti c cover
(see page
20,8)
Careful l y move the gl ass unti l you
can see the bol ts,
then remove them.
NOTE: Take care notto drop the gl ass i nsi de the door.
>: Eolt locations, 2
6 x 1 . 0 mm
B, 1
t}
4. Careful l y remove the gl ass from the wi ndow sl ot.
c \
REAR
CHANNEL
COLLAR
Remove the outer mol di ng, then
Ier
grass.
remove the
quar-
5.
\
the door.
>: Bol t l ocat aons
A > , 2
]
6 x 1 . 0 mm L
[l
o t't.- to.a rsl -.
j
fr
e ttt ttt
)
- - - . - - - . - , /
B > , 2
6 x
' l . 0
mm
I N.m {0.8
ksl'm,
6 tbf.ft)
I
)
OUARTER
\ t
20-13
7.
CLIP
Grease al l t he sl i di ng surf aces of t he regul at or where
shown.
NOTE:
a l f necessary, remove the
power wi ndow motor
from the regul ator.
. Before removi ng the power wi ndow motor, scrl oe
a l i ne across the sector
gear and regul ator.
SECTOR GEAR REGULATOR
POWER WINDOW
MOTOR
POWER
wTNDOW
MOTOR
l'

-...
er
A nicuuron
8. l nstal l ati on i s the reverse of the removal
procedure.
NOTE: Rol l the
gl ass up and down to see i f i t moves
no cl earance between the
gl ass and
gl ass run chan-
nel when the
gl ass i s cl osed. Adj ust the posi ti on of
the
gl ass as necessary
(see page 20-20).
Doors
Door Index
2DI3D:
OU?ER
WEATHERSIRIP
GLASS GUIDE
CLIP
I
sAsH
* /
\
.u\\
\ Y \ I
e t '
SPEAKER COVER
INNER HANDLE
ii\
MTRROR MOUNT
<]<-- COVER PANEL
-it v
$=-!xtruce
\rre
(sqjR5f"'
@."
\s-l
h-P
\
-Qa,
\
(l+,
@
TRIM
(with power
door locks)
\
eowen ooon
\
rocK swrrcH
\b
INNEF HANOLE
TRIM
{without
power
dD
door locks)
DOOR
Adjustment,
page 20-23
BRACKET
d l
h
W/
ARMREST
POCKET
;ri l ;"i -"-\
9
J E
powen____-.-@
wtNDow
.*\L'l
swrrcH
t
- p
Q*-BsfL-,"
ARMREST
POCKET
lwith
power
PLASTIC
COVER
, " ,
S
dnJ.*-{
r-1*{
,P
SPEAKER
20-14
?
GLASS
Repl acement ,
page 20-19
Adj ust ment ,
page 20-20
GLASS RUN
CHANNEL
3ill,'^lri"*'"tt--.-.qq
\,
\I\
\\II REGULATOR
\\\\
neptacement,
page
zo rs
\\'l\
\ 6
trq\\\\ v.
CYLINDER
PROTECTOR
tr
POWER
MOTOR
LATCH
Repl acement ,
page 20-18
STRIKER
Adjustment,
page 20-23
\
fitn
\a
\.vqE
LOCK
CYLI NDER
RETAINEB
CLI P
BOD PROTECTOR
INNER HANDLE ROD
LATCH
PROTECTOR
20-15
Doors
NOTE: Take car e not t o scr at ch t he door panel and
other pa rts.
' 1.
Remove:
. I nner handl e t r i m
( see page 20- 14)
. Mi rror mount cover panel (see page
20-24)
2. l f appl i c abl e, r emov e t he r egul at or handl e by
pul l i ng t he cl i p out wi t h a wi r e hook.
REGULATOR HANDLE
WI RE HOOK
Remove t he ar mr est pocket ,
t hen di sconnect t he
power wi ndow swi tch connector.
ARMREST
POCKET
4. Remove the speaker cover, then remove l he screws.
3.
I
| 6b:a,'
L"_
COVER
20-16
TRIM PAD
REMOVER
(Commerci al l y
avai l abl e)
Snap-on
#A'177, or
equivalent
1 m m
{0. 04 i n. )
5. Rel ease the cl i ps that hol d the door panel .
Remove
the door panel by pul l i ng i t upward. Di sconnect the
speaker connector.
NOTE: Remove the door panel wi th as l i ttl e bendi ng
as possi bl e
.L
12 f i m
(0.47
in.) T-
>: Clip locations,
l ^
J[
=l$
ll,\*
atr-
,,)
REMoVER
tl
-)
11.77 in.l
O)
CONNECTOR
6. l nst al l at i on i s t he reverse of t he removat oroceoure.
DOOR PANEL
b
Outer Handle Replacement
1. Remove:
. Door panel
. Pl asti c cover
(see page 20-14)
2. Pul l out the retai ner cl i p.
3. e \
CYLI NOER PROTECTOR
LOCK CYLI NDER
RETAINER
CLIP
Remove the bol ts, then remove the cyl i nder protec-
tor, l ock cyl i nder and outer handl e.
>: Bol t l ocati ons,2
6 x 1 . o mm ]
9. 8 N. m {1. 0 kgf . m,
1.2tbl,ttl )
_, _-_-,/
CYLI NDER
PROTECTOR
LOCK CYLI NOER
CYLI NOER ROD
20-17
out of i ts
j oi nt
usi ng di agonal cutters.
NOTE:
. To ease reassembl y, note l ocati on
@
ot the outer
handl e rod on the
j oi nt
. Use a shop towel to protect the openi ng i n the
door.
DIAGONAL
CUTTERS
SHOP
TOWEL
NOTE: Make sure the door l ocks and opens
properl y.
EUSHI NG
Repl ace.
\
,pr,
Doors
Latch Replacement
1. Remove:
. Door panel (see page 20-16)
. Pl asti c cover
(see page 20-14)
.
Outer handl e {see
page 20-17}
2. Remove the rod protector.
LATCH
PROTECTOR
20-18
3. Remove the bol ts and move the center l ower channel .
NOTE: Take care not to bend the i nner handl e rod
and l ock rods.
>: Screw locations
A > , 3 8 > , 3
q )
CENTER LOWEB
CHANNEI
CBANK
HOLDER
Di sconnect
t he connect or,
6 x 1 . 0 mm
8 N.m 10.8 kgt.m,
6 tbtft)
Remove the i nner handl e, then remove the l atch
through the hol e i n the door.
l nstal l ati on i s the reverse of the removal procedure.
NOTE: Make sure the door l ocks and opens properl y.
5.
6 x 1 . 0 mm
l
ffu
6 N.m {0.6 kef.m,
_"
11111
)
L
2.
1 . Remove:
. Door panel (see page 20-' 16)
. Pl asti c cover
(see page 20-14)
Careful l y move the gl ass unti l you can see the bol ts,
then l oosen them. Sl i de the gui de rearward, remove
t he gl ass t r om t he gui de, and car ef ul l y pul l t he
gl ass out through the wi ndow sl ot.
NOTE: Take care not to drop the gl ass i nsi de the door.
>: Bol t l ocal i ons, 2
6 x 1 . 0 mm
E
9.8 N.m
{1.0 kgtm,
I
l*
7.2 tbrfil
I
\3 Loosen
,/
J t
GUIDE
the door.
NOTE: Scri be a l i ne around the rear rol l er gui de bol t
to show the ori gi nal adj ustment.
>: Bolt locations
a > , 4
6 x L 0 mm
I
6 x 1 . o mm I
I N.m {0.8 kgt.m,
6l brf t
]
Loosen.
, /
B > , 2
8 N.m
(0.8
kgt m,
i
' -1
)
ROLLER REGULATOR
BOLTS
(cont' d)
20-19
Doors
(cont'dl
Grease al l the sl i di ng surfaces of the regul ator where
shown.
NOTE:
. l f necessary, remove the power wi ndow motor
from the regul ator.
. Before removi ng the power
wi ndow motor, scri be
a l i ne across the sector gear
and regul ator.
REGULATOR
5. Instal l ati on i s the reverse of the removal orocedure.
NOTE: Rol l the gl ass up and down to see i f i t moves
no cl earance between the gl ass
and gl ass run chan-
nel when the gl ass i s cl osed. Adj ust the posi ti on
of
the gl ass as necessary.
SECTOR GEAR
20-20
Glass Adjustment
NOTE:
. Pl ace the vehi cl e on a fi rm, l evel surface when adj ust-
i ng the gl ass.
. Check the weatherstri ps and gl ass run channel for dam-
age or deterioration, and replace them if necessary.
1. Remove:
. Door panel (see pages 20-4, 10, 16)
. Pl asti c cover
(see pages 20-2,8, 14)
2. Adj ust the gl ass.
4D:
Rai se the gl ass ful l y.
Loosen the gl ass mounti ng bol ts
(front
door)
and regul ator mounti ng bol ts.
Push the gl ass rearward
(front
door gl ass)
or
i orward
(rear
door gl ass).
Ti ghten the gl ass mounti ng bol ts
(front
door)
and regul ator mounti ng bol ts.
A >: Gl . 3s mount i ng bol t
locations.
B >: Regulrtor mouting
bolt loc.tions.
Front :
a .
b.
d.
REGULATOR
b
GLASS
REGULATOR
+
" +
J \
e. Loosen the front channel mounti ng bol ts
(front
door ) or r ear c hannel mount i ng bol t l r ear
ooor , ,
f. Lower the gl ass.
g. Push t he f r ont or r ear channel s agai nst t he
gl ass, then ti ghten the mounti ng bol ts.
>: Front and rear
channel mount i ng
bolt locations
Front:
\
Rear:
2DI3D:
b.
Rai se the gl ass as far up as possi bl e, and hol d
i t agai nst the gl ass run channel .
Loosen t he r ol l er gui de bol t s, and adj ust t he
gl ass so i t i s paral l el wi th the gl ass run channel .
GLASS RUN
CHANNEL
ROLLER GUI DE BOLTS
(cont' d)
20-21
Doors
Glass Adjustment
{cont'd)
c. Ti ghten the rol l er gui de bol ts.
d. Loosen the front channel bol ts.
e. Lower the gl ass.
f. Push the front channel agai nst the gl ass, then
ti ghten the mounti ng bol ts.
MOUNTING
BOLT
3. Check that the gl ass moves smoothl y.
4. Rai se the gl ass ful l y and check for gaps.
5. Check the gl ass operati on.
NOTE: Check that the gl ass contacts the gl ass run
channel evenl y.
WEATHERSTRIP
GLASS
U
- \ ,
20-22
6. Check for water l eaks.
Spray water over the roof and on the seal i ng area
as shown.
NOTE:
. Adj ust the water pressure as shown.
. Do not squeeze the ti p of the hose.
0. 5 m {1. 6f t )
HOSE
Attach the pl asti c cover, then i nstal l the door panel
(see pages 20 4, 10, 16).
Instal l the regul ator handl e so i t poi nts forward and
up at a 45 degree angl e wi th the gl ass cl osed.
Forward -
1 .
HOSE
300 mm {11. 8 i n)
b
Position Adjustment
NOTE: Pl ace the vehi cl e on a fi rm, l evel surface when
adj usti ng the doors.
After i nstal l i ng the door, check for a fl ush fi t wi th the
body, then check for equal gaps between the front, rear,
and bot t om door edges and t he body. The door and
body edges shoul d al so be paral l el . Adj ust at the hi nges
as shown,
CAUTION: Pl ace a shop towel on the
i ack
to prevent
damage to the door when loosening the door and hinge
mounting bohs for adiustment.
DOOR MOUNTING BOLTS
8 x 1.25 mm
28 N.m {2.9 kgf.m.21 lbt'ft}
Loosen the door mounti ng bol ts sl i ghtl y
to move the door l N or OUT unti l
i t' s fl ush wi th the body. l f necessary,
vou
can i nstal l a shi m behi nd one
hi nge to make the door edges
PARALLEL wi t h t he body.
J
HINGE MOUNTING BOLTS
I x 1. 25 mm
28 N. m
(2. 9 kgf . m, 21 l bt f t )
Remove t he i nner f ender,
l oosen t he hi nge mount i ng
bol t s, and move t he door
BACKWARD or FORWARD,
UP or DOWN as necessary
t o equal i ze t he gaps.
Lower t he gl ass.
\
The door and body edges shoul d be par al l el -
ifF t
NOTE: Check for water l eaks.
20-23
Striker Adjustment
l vl ake sure the door l atches securel y wi thout sl ammi ng.
l f i t needs adj ustment:
NOTE; The stri ker nuts are fi xed, but the stri ker can be
adj usted sl i ghtl y up or down, and i n or out.
'L
Loosen the screws, then insert a shop towel between
the body and stri ker.
I nsert a shop t owel
bet ween t he body and
sc8Ews
8 x 1. 25 mm
18 N. m
(1. 8
kgf . m,
13 t bt f t l
PLASTIC
2. Li ghtl y ti ghten the screws.
3. Wrap the stri ker wi th a shop towel , then adj ust the
stri ker by tappi ng i t wi th a pl asti c hammer.
CAUTION: Do not tap the striker too hard.
4. Loosen the screws. and remove the shop towel .
Li ghtl y ti ghten the screws.
Hol d t he out er handl e out , and pus h t he door
agai nst the body to be sure the stri ker al l ows a fl ush
fit. lf the door latches properly, tighten the screws and
recheck.
5.
Mirrors
Mi rror Repl acement
NOTE: Take care not to scratch the mi rror. mi rror base
cover and door.
l Lower t he door gl ass.
2. Carel ul l y pry out the mi rror mount cover panel
by
nano.
Power mirro.:
MIRROR MOUNT
COVEB PANEL
Manual mirror:
Remove the cap, screw and knob, then remove the
mi rror mount cover panel .
MI RROR MOUNT
KNOB
20-24
3. Remove the mi rror mounti ng nuts whi l e supporti ng
the mi rror.
a: Nut l ocati ons,3
)CONNECTOR
(Nri rror
si de)
MIRROR
(Door
harness
si de)
CONNECTOR
Instal l ati on i s the reverse of the removal procedure.
NOTE: Make sure the connector i s connected prop-
erl y.
|}
Mi rror Hol der/Cover Repl acement
CAUTION: Put on gloves to
protecl your hands.
L Car ef ul l y
pr y out t he mi r r or hol der wi t h a f l at t i p
screwdri ver as shown.
Instal l ati on i s the reverse of the removal
procedure.
NOTE: Appl y grease to the l ocati ons i ndi cated by
the arrows.
>: Sc.ew locations
A > , 3
s > , 2
I
ry
To remove the screws,
pul l t he seal away.
PIVOT
-6r
JOINT PIN
-G{
J
6)drD
)
I
SHOP TOWEL
Rearview Mirror Replacement
1. Remove the rubber damper.
2. Pry the cover off usi ng the end of a fl at ti p screw-
dri vef.
CAUTION: When
prying with a flat-tip screwdriver,
wrap it with a shop towel to prgvant damage.
3. Remove the screws, then remove the rearvi ew mi r-
ror,
SCREW
5 x 0 . 8 mm
il
N.m lo.a kgf.m,
3 lbf.ftl
SHOP TOWEL
20-25
Wi ndshi el d, Rear Wi ndow and Ouarter Gl ass
Index
NOTE: The numbers after the part names show the quanti ti es
of the parts
used.
Wi ndshi el d
l 2Dl 3D/4D):
WINDSHIELD
Removal , page
20 28
I nst al l at i on, page 20-29
Rear Window
(2Dl4Dl:
UPPER RUBBER
DAM
FASTENER, 2
(Sel l -adhesi ve
t ype, gl ass si de)
FASTENER, 2
l Cl i p-t ype, body si de)
FASTENER, 4
(Sel f -adhesi ve-t ype,
gl ass
si de)
/
FASTENER, 4
/
l Sel f adhesi ve-t ype, body si del
* , /
M
SPACER,
w
/>
@
20-26
b
Rear Wi ndow l 3Dl :
SPACER,
I
|
,o"r.".". o
{ff*' *' YPe
bod' si de)
FASTENER, 4
gl ass
si de)
RUBBER DAM, 2
t
I
I
SEAL A, 1
= @
SEAL B, 2
e
Ouarter Glass:
3D:
OUARTER GLASS
Removal , page 20-40
I nst al l at i on, page 20 4l
OUARTER
GLASS TRIM
LOWER CLIP
l Sel f adhesi ve' t ype)
2D:
FASTENER
gl ass
si de)
FASTENER
(Sel f -adhesave
t ype,
body si de)
\
\
\)f\
n,
$ (
\il]
LOWER RUBBER
DAM
LOWER CLIP
(Sel f
adhesi ve-t ype)
J
20- 27
Windshield
Removal
CAUTION:
. Put on gloves to plotest your h8nds.
. Use seat covers to avoid damaging any surfaces.
1. To remove the wi ndshi el d, fi rst remove the:
. Rearvi ew mi rror
(see page 20-25)
. Sunvi sors and hol ders
(see page 20-64)
. Front pi l l ar tri m
(see pages 20-59, 60, 61)
! Wi ndshi el d wi per arms and cowl cover
(see page
20-1131
Peel off the mol di ng, and remove the gl ass
brack-
ers.
NOTE: When mol di ng removal i s di ffi cul t, cut the
mol di ng wi th a kni fe.
WINDSHIELO
3. Pul l down the front of the headl i ner (see page 20-
64) .
CAUTION: Take care not to bend the headl i net
excsssively.
MOLDING
20-24
4. Appl y protecti ve tape al ong the edge of the dash
boar d and body as shown. Usi ng an awl , make a
hol e t hr ough t he r ubber dam and adhesi ve f r om
i ns i de t he c ar . Pus h t he pi ano wi r e t hr ough t he
hol e, and wrap each end around a pi ece of wood-
PI ANO WI RE
PROTECTIVE
UPPER
RUBBER
|
'1"
DAM
WI NDSHI ELO
AOHESIVE
RUBBER
DAM
Wi t h a hel per on t he out si de, pul l t he pi ano wi r e
back and forth i n a sawi ng moti on, and careful l y cut
t hr ough t he r ubber dam and adhesi ve ar ound t he
enti re wi ndshi el d.
CAUTION: Hold the
piano
wile as close to ihe wind-
shield as possible to prevent damage to the body
and dashboard.
WI NDSHI ELD
6. Careful l y remove the wi ndshi el d.
t
Instal l ati on
Usi ng a kni fe, scrape the ol d adhesi ve smooth to a
thi ckness of about 2 mm
(0.08
i n.) on the bondi ng
surface around the enti re wi ndshi el d openi ng fl ange.
NOTE:
. Do not scrape down to the pai nted surface of the
body; damaged pai nt wi l l i nterfere wi th proper
bondi ng.
. Remove the rubber dams and tasteners from the
body.
. Mask off surroundi ng surfaces before
pai nti ng.
Cl ean the body bondi ng surface wi th a sponge damp-
ened i n al cohol .
NOTE: After cl eani ng, keep oi l , grease and water
from getti ng on the surface.
l f the ol d wi ndshi el d i s to be rei nstal l ed, use a putty
kni fe to scrape off al l traces of ol d adhesi ve, then
cl ean t he wi ndshi el d sur f ace wi t h al cohol wher e
new adhesi ve i s to be appl i ed.
NOTE: Make sure the bondi ng surface i s kept free
of water, oi l and grease.
CAUTION: Avoid setting the windshield on its edges;
small chips may later deyelop into cracks.
NOTE:
. Cl ean the shadowed area.
o Cl ean area @
as shown.
lnside
&
' 1.
2.
3.
C t
a4)
)
WI NDSHI ELD
J
WINDSHIELD
20-29
Gl ue t he r ubber dam and f ast ener s t o t he i nsi de
face of the wi ndshi el d as shown.
NOTE: Be careful not to touch the wi ndshi el d where
adhesi ve wi l l be appl i ed.
ALIGNMENT
MABK
13. 5 mm
(0. 53
i n. )
LOWER RUBBER
DAM
WINOSHILD
5. Al i gn and gl ue t he mol di ng t o t he edge of t he wi nd-
shi el d.
NOTE: Be caret ul not t o t ouch t he wi ndshi el d where
>: Faslener localions, 2
FASTENER
ALTGNMENT, \ -o
MARK
MOLOING
WINDSHIELO
100 mm
{3. 94 i n. l
Appl y pri mer (3M
N' 200, or equi val ent ) t o edSe (cont ' d)
of t he wi ndshi el d.
Wi ndshi el d
Installation
(cont'd)
Instal l the gl ass brackets and fasteners as shown.
NOTE: The numbers after the
part
names show the
quanti ti es
of the oarts used.
GLASS BRACKETS, 2
Set the wi ndshi el d on the gl ass
brackets, then cen-
ter i t i n the openi ng. Make al i gnment marks across
the wi ndshi el d and body wi th a grease penci l at the
four poi nts shown.
NOTE: Be careful not to touch the wi ndshi el d where
adhesi ve wi l l be aDol i ed.
7.
8. Remove the wi ndshi el d.
20- 30
>: Fastoner locations, 2
FASTENER
^
I
I
SCREW
9. Wi th a sponge, appl y a l i ght coat of gl ass pri mer
around the edge of the wi ndshi el d as shown. then
l i ghtl y wi pe i t off wi th
gauze
or cheesecl oth.
NOTE:
. Do not appl y body pri mer to the wi ndshi el d. and
do not get body and gl ass pri mer
sponges mi xed
up.
. Never touch the primed surfaces with your hands.
l f you do. the adhesi ve may not bond to the wi nd-
shi el d properl y, causi ng a l eak after the wi ndshi el d
i s i nstal l ed.
. Keep water. dust, and abrasrve
from the pri med surface.
t/////,
'/////l
I Apply glass p.imer here.
materaal s away
Appl y gl ass pri mer
t o t he mol di ng.
WINDSHIELD
10. Wi th a sponge. appl y a l i ght coat of body pri mer to
the ori gi nal adhesi ve remai ni ng around the wi nd-
shi el d openi ng fl ange. Let the body
pri mer
dry for
at l east 10 mi nutes.
NOTE:
. Do not apply glass primer to the body, and be care-
ful not to mix up glass and body primer sponges.
. Never touch the primed surfaces with your hands.
. Mask off the dashboard before painting the flange.
7////l
/////l
I Apply body p mer hcre.
6 mm
1 6 mm 5 mm
(0.6:|
in.) (0.2
in.l
16 mm
{0, 63 i n. }
/
MOLDING
3
1 1 . Thoroughl y mi x the adhesi ve and hardener together
on a glass or metal plate with a putty knife.
NOTE:
. Cl ean the pl ate wi th a sponge and al cohol before
mi xi ng.
. Fol l ow the i nstructi ons that come wi th the adhe-
stve.
Before fi l l i ng a cartri dge. cut the end of the nozzl e
as shown.
Cut nozzl e end
tu
10 mm 10. 39 i n. )
7 mm
(0. 27 i n. l
13. Pack adhesi ve i nto the cartri dge wi thout ai r pockets
to ensure conti nuous del i very. Put the cartri dge i n a
caul ki ng gun, and r un a bead of adhesi ve ar ound
the edge of the wi ndshi el d as shown.
NOTE: Appl y the adhesi ve wi thi n 30 mi nutes after
appl yi ng the gl ass pri mer.
12 mm
(0.47 i n.)
l_Z
oo*.t,ut
8 mm 10. 31 i n. l
UPPER
RUBBER
DAM
Make a sl i ght l y t hi cker
bead at each cor ner .
5 mm
(0. 2 i n )
='+
A\ulotoô
.
-.\\
/ w
WI NDSHI ELD
LOWEB
RUBBER
DAM
l mm
10. 04 i n. l
FASTENER
LOWER
RUBBER
DAM
)
MOLDI NG
WINDSHIELD
20-31
15.
16.
14. Use suct i on cups t o hol d t he wi ndshi el d over t he
openi ng, al i gn i t wi th the al i gnment marks made i n
st ep 7, and set i t down on t he adhesi ve. Li ght l y
push on the wi ndshi el d unti l i ts edge i s ful l y seated
on the adhesi ve al l the way around.
NOTE: Do not open or cl ose the doors unti l adhesi ve
r i vI
Y
ALTGNMENT MARK
Scrape or wipe the excess adhesive off with a putty
kni fe or towel .
NOTE: To remove adhesive from a painted surface or
the windshield, wipe with a soft shop towel dampened
wi th al cohol .
Let the adhesive dry for at least one hour, then spray
water over the wi ndshi el d and check for l eaks. Mark
the l eaki ng areas, l et the wi ndshi el d dry, then seal
wi th seal ant.
NOTE:
. Let the car stand for at least four hours after wind-
shi el d i nstal l ati on. l f the car has to be used wi thi n
the fi rst four hours, i t must be dri ven sl owl y.
. Keep the wi ndshi el d dry for the fi rst hour after
i nstal l ati on.
. Check that the ends of the si de mol di ng are set
under the cowl cover.
Rei nstal l al l remai ni ng removed parts.
NOTE:
. Instal l the rearvi ew mi rror rubber damper after
the adhesi ve has dri ed thoroughl ' ,.
. Advi se the customer not to do the fol l owi ng thi ngs
for two to three days:
-
Sl am the doors wi th al l the wi ndows rol l ed
up.
-
Twi st t he body excessi vel y
( such
as when
goi ng i n and out of dri veways at an angl e or
dri vi ng over rough, uneven roads).
' t7.
Rear Window
Removal
2DllDl
CAUTION:
. Put on gloves to protect your hands.
. Uso ssat covers to avoid damaging any surlaces,
. Do not damage thg roar window dofogggr grid linss,
window antenna grid lines, and tsrminalg.
1. To remove the rear wi ndow, fi rst remove the:
. Tr unk l i d
. Rear seat cushi on
(see pages
20-79, 81)
. Rear seat side bolsters {4D, see
page
20-79)
. Rear seat-back
(2D,
see page 20-81)
. Rear shel f {see
pages 20-59, 61}
. Rear pi l l ar tri m {4D, see page 20-59)
.
Si de tri m panel (2D,
see page 20-61)
. Ouarter tri m panel (2D,
see page
20-61)
. Rear roof trim
(see page
20-65)
2, Di sconnect the rear wi ndow defogger connector
from each si de.
3. Peel off the mol di ng.
NOTE: When mol di ng removal i s di ffi cul t, cut the
mol di ng wi th a kni l e.
F"*t,
MOLDING
ID_HESI.VE
---, ,/,/
REAR WINDOW
S
MOLDING
20-32
PIANO WIRE
4. Appl y protecti ve
tape al ong the edge of the body as
shown. Usi ng an awl , make a hol e t hr ough t he
adhesi ve from i nsi de the car. Push the
pi ano
wi re
t hr ough t he hol e, and wr ap each end ar ound a
piece of wood.
ADHESIVE
REAR WINDOW
PROTECTIVE
TAPE
TAPE
REAR WNDOW
PIANO WIRE
PROTECTIVE
TAPE
Wi th a hel per on the outsi de, pul l the pi ano wi re
back and forth i n a sawi ng moti on, and careful l y cut
through the adhesi ve around the enti re rear wi n-
dow.
CAUTION: Hold the piano wiro as close to the rear
window as possibls to prcyent damage to the body.
6. Careful l v remove the rear wi ndow.
ADHESIVE
I
l nstal l ati on
(0.08
sur f ace ar ound t he ent i r e r ear wi ndow openi ng
fl ange.
NOTE:
body; damaged pai nt wi l l i nterfere wi th proper
bondi ng
o Mask off surroundi ng surfaces before
pai nti ng.
. Remove t he f ast ener s and spacer s f r om t he
oooy.
Cl ean t he body bondi ng sur f ace wi t h a sponge
dampened i n al cohol .
NOTE: After cl eani ng, keep oi l . grease and water
l f the ol d rear wi ndow i s to be rei nstal l ed, use a putty
kni fe to scrape off al l traces of ol d adhesi ve and the
rubber dam, then cl ean the rear wi ndow surface wi th
al cohol where new adhesi ve i s to be appl i ed.
of water, oi l and
grease.
CAUTION: Avoi d setti ng the rear wi ndow on i ts
edges; small chips may later develop into cracks.
NOTE: Cl ean the shadowed area.
1 .
2.
)
)
REAR WINDOW
4. Appl y the doubl e-faced adhesi ve tape
(NITTO
501,
or equi val ent) to the edge of the rear wi ndow, then
i nstal l the mol di ng around the edge of the rear wi n-
dow as shown.
NOTE: Be car ef ul not t o t ouch t he r ear wi ndow
where adhesi ve wi l l be appl i ed.
ADHESIVE TAPE
867 mm 134. I in.)
5 mm
{0. 2 i n. }
ADHESIVE
TAPE
Thickness:
0. 16 mm
(0. 006
i n. l
GLASS
MOLDING
wtNoow
Gl ue the fasteners and spacers to the i nsi de face of
the rear wi ndow as shown.
NOTE; Be car ef ul not t o t ouch t he f ear wi ndow
5.
MOLDING
ALIGNMENT
MARK
T
ALIGNMENT
!\raRKs
a > , 2
Outside
>:Fa3lner, spacer
locations
A >, 4 FASTENER
(:r:^#-
ry
I
liGrtrrrrertrr
\..!44llc-'''
- -
SPACER
(cont' d)
20-33
ALIGNMENT MARK
REAR WINOOW
MOLOING
Rear Window
Installation
(cont'dl
6. Gl ue the fasteners to the body as shown.
Fastener locations, 4
FASTENER
\ - . * l
-E4,7-- ,.--
7 ) , / l
4 Y l
7.
F-L NGENY:,//
Set the rear wi ndow, then center i t i n the openi ng.
Make al i gnment marks across the rear wi ndow and
body with a grease pencll at the four points
shown.
ALIGNMENT MARK
-\
-.._s
-
8. Remove t he rear wi ndow.
20-34
9. Wi t h a sponge, appl y a l i ght coat o{ gl ass pr i mer
around the edge oI the rear wi ndow as shown, then
l i ghtl y wi pe i t off wi th gauze
or cheesecl oth.
NOTE:
. Do nol appl y body pr i mer t o t he r ear wi ndow.
and do not get body and gl ass pri mer sponges
mi xed up.
.
Never touch the pri med surfaces wi th your hands.
l f you do, the adhesi ve may not bond to the rear
wi ndow pr oper l y,
causi ng a l eak at t er t he . ear
wi ndow i s i nstal l ed.
. Keep water, dust, and abrasi ve materi al s away
'/fur1
: lppty gtass primer
here.
16 mm
(0. 63
i n. l
7 mm
{0. 28 i n. }
FASTENER
REAR WINDOW
10. Wi th a sponge, appl y a l i ght coat of body pri mer to
t he or i gi nal adhesi ve r emai ni ng ar ound t he r ear
wi ndow openi ng fl ange. Let the body pri mer dry for
NOTE:
. Do not appl y gl ass pri mer to the body. and be care,
ful not to mi x up gl ass and body pri mer
sponges.
. Never touch the pri med surfaces wi th your hands.
/fu/
: Apply boay primer here.
16 mm
(0.(I,
in.l
MOI-DING
l
6 mm r
{O. 24 i n. }
' 1 1 .
Thoroughl y mi x the adhesi ve and hardener together
on a gl ass or metal pl ate wi l h a putty kni fe.
NOTE:
mi xi ng.
. Fol l ow the i nstructi ons that came wi th the adhe-
si ve.
Before fi l l i ng a cartri dge, cut the end of the nozzl e
as shown.
10 mm { 0. 39 i n. )
7 mm
(0.27
i n.l
Pack adhesi ve i nto the cartri dge wi thout ai r pockets
to ensure conti nous del i very. Put the canri dge i n a
caul ki ng
gun, and r un a bead ol adhesi ve ar ound
the edge of the rear wi ndow as shown.
NOTE| Appl y the adhesi ve wi thi n 30 mi nutes after
12.
13.
J
12 mm 10. , U
i n. )
[/
oo*r.,u.
8 mm
(0. 31 i n. )
Make a sl i ght l y t hi cker
bead at each corner.
GLASS
FASTENER
SPACER
MOLDING
MOLDING
)
REAR WINDOW
FASTENER
20- 35
14. Use sucti on cups to hol d the rear wi ndow over the
openi ng, al i gn i t wi t h t he al i gnment mar ks made i n
st ep 7, and set i t down on t he adhesi ve. Li ght l y
push on t he r ear wi ndow unt i l i t s edges ar e { ul l y
seated on the adhesi ve al l the way around.
NOTE: Do not open or cl ose the doors unti l the adhe-
si ve i s dry.
SUCTI ON ALI GNMENT
CUPS MARK
Scrape or wi pe the excess adhesi ve off wi th a putty
kni fe or towel .
NOTE: To remove adhesi ve from a pai nted surface
or the rear wi ndow, use a soft shop towel damp-
ened wi th al cohol .
Let t he adhesi ve dr y f or at l east one hour , t hen
spr ay wat er over t he r ear wi ndow and check f or
l eaks. Mark the l eaki ng areas, l et the rear wi ndow
dry, then seal wi th seal ant.
NOTE: Let the car stand for at l east four hours after
rear wi ndow i nstal l ati on. l f the car has to be used
wi thi n the Ii rst tour hours, i t must be dri ven sl owl y
Rei nstal l al l remai ni ng removed
parts
NOTE: Advi se the customer not to do the fol l owi ng
thi ngs for two to three days:
. Sl am the doors wi th al l the wi ndows rol l ed up.
. Twi st the body excessi vel y
(such
as when goi ng
i n and out of dr i veways at an angl e or dr i vi ng
over rough. uneven roads).
16.
1-7 .
Rear Window
Removal
3D:
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 scratch the terr window molding.
' 1.
To remove the rear wi ndow, fi rsr remove the:
.
Rear center shel f (see page
20-60)
. Hat ch upper t r i m, hat ch t r i m panel
and hat ch
si de tri m
(see
page
20-63)
2.
. Rear wi ndow wi per arm
(see
page 2O-115)
.
Hatch spoi l er (see page
20 101)
Di sconnect t he r ear wi ndow def ogger connect or
from each si de.
Appl y protecti ve
tape to the i nner edge of the tai l _
gate.
From i nsi de the hatch, use a kni fe to cut through the
rear wi ndow adhesi ve al l the way around.
NOTE:
. l f the rear wi ndow i s to be rei nstal l ed,
take care
not to damage the mol di ng.
. l f the mol di ng i s damaged, repl ace the rear wi n_
dow and mol di ng as an assembl y.
HATCH
ffi#
REAR WINOOW
20-36
Upper portioni
TAPE
Side portion:
Lower portion;
Careful l y remove the rear wi ndow.
NOTE; Check the mol di ng for damage, and repl ace
the rear wi ndow i f necessary.
GLASS
ADHESIVE
t
l nstal l ati on
' 1.
3.
(0.08
sur f ace ar ound t he ent i r e r ear wi ndow openi ng
fl ange.
NOTE:
. Do not scrape down to the pai nted surface ol the
body; damaged
pai nt wi l l i nterfere wi th proper
bondi ng.
a Remove the rubber dams, spacers and fasteners
from the hatch.
. Mask of f sur r oundi ng sur f aces bef or e appl yi ng
pr i mer .
Cl ean t he hat ch bondi ng sur f ace wi t h a sponge
dampened i n al cohol .
NOTE: Af t er cl eani ng, keep oi l ,
gr ease or wat er
from
getti ng on the surface.
l f t he ol d r ear wi ndow i s t o be r ei nst al l ed, use a
putty kni fe to scrape off al l traces of ol d adhesi ve,
t hen cl ean t he r ear wi ndow sur f ace wi t h al cohol
where new adhesi ve i s to be appl i ed.
NOTE; Make sure the bondi ng surface i s kept free of
water, oi l and grease.
CAUTION: Avoi d setti ng the rear wi ndow on i ts
edges; the mol di ng can be permanentl y deformed.
NOTE: Cl ean the shadowed area
2.
O
)
REAR WINDOW
4. Gl ue the rubber dams to the i nsi de face of the rear
wi ndow, as shown, to contai n the adhesi ve duri ng
i nstal l ati on, and gl ue the fasteners, spacer and seal s
as shown.
NOTE:
. Gl ue the rubber dams usi ng the pri nted dots as a
g u i de.
. Be careful not to touch the rear wi ndow where
adhesi ve wi l l be aPPl i ed
>r Fastener, spacor and seal
locations
A > , 4 B> , 1
SPACER
D>
' 2
' EAL B
'W
/ l
s i
o.\6fif,",
j
ryt48rq _ _ ,,/
- \ l
19Pry/
FASTENER
PRINTED DOTS
REAR WINDOW
MOLOI NG
(cont' d)
20-37
FASTENER
"-*^1
w
AL.IGNMENT ]
IIARKS _ _,/
C>, 2 SEAL A
Rear Wi ndow
Instal l ati on
(cont' d)
Instal l the fasteners to the hatch as snown.
>: Fastener locations, 4
Set the rear wi ndow upri ght on the hatch, then cen-
ter i t i n the openi ng. Make al i gnment marks across
the rear wi ndow and body wi th a grease penci l
at
the four poi nts
shown.
NOTE: Be careful not to touch the rear window where
adhesi ve wi l l be appl i ed.
7. Remove t he rear wi ndow.
20-38
8. Wi t h a sponge. appl y a l i ght coat of gl ass pr i mer
ar ound t he edge of t he r ear wi ndow, t hen l i ght l y
wi pe i t off wi th gauze
or cheesecl oth.
NOTE:
. Do nol appl y body pri mer
to the rear wi ndow,
and do not get
body and gl ass pri mer
sponges
maxed up.
.
Never touch the pri med surfaces wi th your hands.
l f you do, the adhesi ve may not bond to the rear
wi ndow pr oper l y,
causi ng a l eak af t er t he r ear
wi ndow i s i nstal l ed.
RUBBER
DAM
15 mm
{0. 59 i n. l MOLDI NG
V/////f , apety
st,." o.imer
here.
I nsi de
I
---- - -t-
t Ut I
15mm
| @- L 10.59 in.l
NJ-l t
r l l \
, z N \
GLASS
\
SPACER
FASTENER
GLASS
REAR WINOOW
3
t
t he or i gi nal adhesi ve r emai ni ng ar ound t he r ear
wi ndow openi ng fl ange. Let the body
pri mer dry for
NOTE:
. Do not appl y gl ass pri mer to the body, and be care-
ful not to mi x up gl ass and body
pri mer sponges.
//////// ' acoV boay primer here.
1 1 .
on a gl ass or metal
pl ate wi th a putty kni fe.
NOTE:
ml xl ng.
si ve.
Before fi l l i ng a cartri dge, cut the end oJ the nozzl e
as shown.
Cut nozzl e
10.
I
10 mm {0. 39 i n. )
7 mm
(0. 27 i n. )
to ensure conti nuos del i very. Put the cartri dge i n a
caul ki ng
gun, and r un a bead of adhesi ve ar ound
the edge of the rear wi ndow as shown.
NOTE: Appl y the adhesi ve wi thi n 30 mi nutes after
ffi;fr' L/:ADHEs' vE
8 mm
{ 0. 31
i n. l
GLASS
MOLDI NG
GLASS ,R1
---$
f\+,,","
ffi-f
to.oa in.t
- . 17
MoLD|NG
/
\
(cont' d)
20-39
Rear Window
Ouarter
Glass
Installation
{cont'd)
13. Use sucti on cups to hol d the rear wi ndow over the
openi ng. al i gn i t wi th the al i gnment marks made i n
sl ep 6. and set i t down on the adhesi ve. Li ghtl y push
on the rea. wi ndow unti l i ts edges are ful l y seated
on the adhesi ve al l the way around.
NOTE: Do not open or cl ose the doors unti l the adhe_
sive is drv.
sucTtoN
CUPS
kni fe or towel .
NOTE: To remove adhesi ve from a pai nted
surface
or the rear wi ndow. use a soft shop towel damp-
ened wi th al cohol .
Let t he adhesi ve dr y f or at l east one hour . t hen
spray water over the rear wi ndow and check for
l eaks, Mark the l eaki ng areas, l et the rear wi ndow
rear wi ndow i nstal l ati on. l f the car has to be used
wi thi n the fi rst four hours, i t must be dri ven sl owl y.
.
Sl am the doors wi th al l the wi ndows rol l ed up.
. Tr,vi st the body excessi vel y
l such as when goi ng
i n and out of dri veways at an angl e or dri vi ng
over rough, uneven roads).
14.
15.
\
20-40
Removal
3D:
CAUTION:
a Pul on gloves
to protect your
hands.
.
Use seat covers to avoid damaging any surfaces,
1. To remove the quarter gl ass,
fi rst remove the:
. Rear seat-back and rear seat cushi on
(see
page
20_80)
.
Rear center shel f and rear si de shel f
l see
page
20_60)
. Rear t r i m panel
and si de t r i m panel ( see
page
20_60)
.
Upper anchor bol ts from the front and rear seat
bel ts {see
pages
20-86. 89)
. Ouarter tri m panel (see
page20-60)
2, From i nsi de the car, use a kni fe to cut through the
quarter gl ass
adhesi ve al l the way around.
NOTE:
. l f the cl i p on the rear edge i s broken, the quarter
gl ass can be rei nstal l ed usi ng butyl tape
(see
page
20-421.
. Appl y protecti ve
tape al ong the edge of the enti re
quarter gl ass
openi ng fl ange.
OUARTER
GLASS
Uppcr
portion:
Lower oortion:
PROTECTIVE
TAPE
l
ADHESI VE
Pi l l ar port i on:
Careful l y remove the quarter gl ass
NOTE: Check t he quar t er gl ass t r i m and cl i ps f or
damage, and repl ace them i f necessary'
3.
)
AOHESIVE
TAPE
CLIP
l nstal l ati on
1 . Usi ng a kni fe, scrape the ol d adhesi ve smooth to a
(0.08
sur t ace ar ound t he ent i r e
quar t er gl ass openi ng
fl ange.
NOTE:
body; damaged
pai nt wi l l i nterfere wi th proper
bondi ng.
r Remove the rubber dams from the body.
. l f any of the cl i ps are broken, remove them from
the body.
. Mask off surroundi ng surfaces before appl yi ng
pnmer .
Cl ean the body bondi ng surface wi th a sponge damp-
ened i n al cohol .
NOTE: Afi er cl eani ng, keep oi l ,
grease and water
l f the quarter gl ass i s to be rei nstal l ed, use a putty
kni fe to scrape off al l traces of ol d adhesi ve. then
cl ean the quaner gl ass surface wi th al cohol where
adhesi ve i s to be apPl i ed.
of water, oi l and grease.
CAUTION: Avoid setting the quarter glass on its
edges; small chips may later devglop into cracks.
NOTE: Cl ean rhe shadowed area.
(cont' d)
20-41
Quarter Glass
Installation
(cont'd)
4. Gl ue the upper and l ower rubber dams to the i nsi de
Iace of the quaner gl ass, as shown, to contai n the
adhesi ve dur i ng i nst al l at i on.
NOTE: Be car ef ul not t o t ouch t he quar t er gl ass
>: Al i gnment mark
l ocat i ons
GLASS
UPPER
RUBBER DAM
LOWER
RUBEER DAM
Instal l the quarter gl ass
tri m on the quarter gl ass,
then gl ue the upper and l ower cl i ps as shown.
NOTE: Be car ef ul not t o t ouch t he quar t er gl ass
OUARTER
GLASS TRIM
OUARTER
GLASS
GLASS TRIM
NOTE: Cont act t he cl j ps agai nst t he
quar t er gl ass
t r i m at t he ar eas
I ndi cat ed by t he ar r ows.
UPPER
20-42
6. l f the ol d quarter gl ass i s to be rei nstal l ed (and
the
cl i p on t he r ear edge i s br oken of f ) , appl y a l i ght
coat of pri mer (3I/
C-100, or equi val ent), then appl y
butyl tape to the quarter gl ass,
as shown. and seal
the body hol e wi th pi ece
of urethane tape.
NOTE:
. Be careful not to touch the quaner gl ass where
adhesi ve wi l l be appl i ed,
. Do not peel
the separator offthe butyl tape.
//////// '.
8u'Jt tape tocarions t3M 8628, or equivetenrl
'
Thi ckness:3.2 mm l o.t3 i n.l
Width: 6.4 mm
{0.25 in.)
BUTYL 13 mm
TAPE
(0. 5
i n. l
\
\ l
,7r--/r4--;
*--T-
.. GLASS
UPPER
RUEBER
DAM
t
l
7. Wi th a sponge, appl y a l i ght coat of gl ass pri mer to
the i nsi de face of the quarter gl ass, as shown, then
l i ghtl y wi pe i t off wi th gauze or cheesecl oth.
NOTE:
. Do not appl y body pri mer to the quarter gl ass,
mi xed up.
l f you do, the adhesi ve may not bond to the
quar
ter gl ass properl y, causi ng a l eak after the
quar-
ter gl ass i s i nstal l ed.
////////l
: ^pptv
stass
primer he.e.
21 mm 15 mm
{0. 83 i n. ) (0. 59 i n. )
UPPER
RUBBER
DAM
BUBBEB
DAM
OUARTER GLASS
15 mm
10. 59
i n. l
30 mm
(r. 2 i n. )
)
the ori gi nal adhesi ve remai ni ng around the quarter
gl ass openi ng fl ange. Let the body
pri mer dry for at
l east 10 mi nutes.
NOTE:
. Do not appl y
gl ass pri mer l o the body, and be
car ef ul not t o mi x up gl ass and body
pr i mer
sponges.
. Never touch the
pri med surfaces wi l h
your hands.
. Mask off the rear si de tri m
panel before
pai nti ng
t he f l ange.
///////// | apetl body
erimer
he,e.
16 mm
{0. 63 i n. l
on a gl ass or metal pl ate wi th a pufty kni fe.
NOTE:
. Cl ean the
pl ate wi th a sponge and al cohol before
m r xl ng.
si ve.
Bef ore f i l l i ng a cart ri dge, cut t he end of t he nozzl e
as shown.
Cut nozzl e end
10 mm
(0. 39
i n. l
(cont ' d)
9.
10.
7 mm
(0. 27 i n. )
20-43
Ouarter Glass
Installation (cont'd)
to ensure conti nuous del i very.
put
the canri dge i n a
caul ki ng gun,
and r un a bead of adhesi ve ar ound
the edge of the quarter gl ass
as shown.
NOTE:
. l f the ol d quarter gl ass i s to be rei nstal l ed, peel
the separator off the butyl tape after appl yi ng the
adhesi ve.
. Appl y the adhesi ve wi thi n 30 mi nutes after appl y_
i ng the gl ass pri mer.
i :.8i ".,1/:ADHES,' E
8 rnm
(0. 31
i n. l
OUARIER
GLASS TRIM
OUARTER
GLASS TFIM
BUTYI.
TAPE
OUARTER GLASS
[-4m,^,
GLASS
\
32 mm
{ 1. 3 i n. )
' ' = ' I
'"r"\
/
drt".
GLASS
TAPE
20-44
12. Use sucti on cups to hol d the quarter gl ass
over the
openi ng, al i gn the cl i ps, and set i t down on the adhe-
si ve. Li ghtl y push
on the quaner gl ass
unti l i ts edges
are ful l y seated on the adhesi ve al l the way around.
NOTE: Do not open or cl ose t he door s unt i l t he
adhesi ve i s drv.
kni fe or towel .
NOTE: To remove adhesi ve from a pai nted
surface
or the quarter gl ass, wi pe wi th a soft shop towel
dampened wi th al cohol .
spray water over the quarter gl ass
and check for
l eaks. Mark the l eaki ng areas, l et the quarter gl ass
quarter gl ass i nstal l ati on. l f the car has to be used
wi thi n the fi rst four hours, i t must be dri ven sl owl y.
.
Sl am the doors wi th al l the wi ndows rol l ed up.
(such
as when goi ng
an and out of dr i veways at an angl e or dr i vi ng
over rough, uneven roads).
15.
14.
CLI P
Removal
2Oi
CAUTION:
. Use seat covers to avoid damaging any surfaces.
1. To remove the
quarter gl ass, fi rst remove the:
(see page
20_81)
o Sl de tri m
panel (see page 20-611
. Rear shel f
(see page 20-61)
o Upper anchor bol t from the front seat bel t
(see
page 20-86)
. Ouarter tri m panel (see page 20-6' l )
2. From i nsi de the car. use a kni fe to cut through the
quarter gl ass adhesi ve al l the way around.
NOTE:
. l f the quarter gl ass i s to be rei nstal l ed, take care
not to damage the mol di ng.
. Appl y protecti ve tape al ong the edge ofthe enti re
quaner gl ass oPeni ng f l ange
D
I
GLASS
Upper portion:
ADHESIVE
PROTECTIVE
TAPE
Rear edge
portion:
Pillar
portion:
Careful l y remove the
quarter gl ass.
NOTE: Check the mol di ng for damage, and repl ace
i t i f necessary.
3.
TAPE
20-45
Ouarter Glass
1 .
Instal l ati on
(0.08
sur f ace ar ound t he ent i r e quar t er gl ass
openi ng
fl ange.
NOTE:
. Do not scrape down to the pai nted
surface of the
body; damaged pai nt
wi l l i nterfere wi th proper
a
a
bondi ng.
Remove the fastener from the body.
l f any of the cl i ps are broken, remove l hem from
the body.
Mask off surroundi ng surfaces before appl yi ng
pnmer.
Clean the body bonding surface with a sponge damp
ened i n al cohol .
NOTE: After cl eani ng, keep oi l , grease
and water
from getti ng
on the surface.
l f the quarter gl ass i s to be rei nstal l ed, use a putty
kni fe to scrape off al l traces of ol d adhesi ve. then
cl ean the quarter gl ass
surface wi th al cohol where
adhesi ve i s to be appl i ed.
of water. oi l and grease.
CAUTION: Avoid setting the quarter glass
on its
odges; small chips may later develop into cracks,
NOTE: Cl ean the shadowed area.
20-46
4. Instal l the mol di ng around the edge of the
quarter
gl ass
as shown.
NOTE:
. l f the ol d mol di ng i s to be rei nstal l ed, scrape off
t he ol d adhesi ve t ape f r om t he mol di ng, and
cl ean t he mol di ng sur f ace wi t h al cohol wher e
new adhesi ve tape i s to be appl i ed. Appl y the
doubl e-faced adhesi ve tape to the mol di ng and
quarter gl ass
as shown.
. Be careful not to touch the
quarter gl ass where
adhesi ve wi l l be aoDl i ed.
Adhesiv tspe A
(3M
4215, or equivalent)
Thicknsss: o.il mm
(0.02
in.l
Widih: 5 mm {0.2 in.}
Length: /140
mm {17.3 in.)
Adhesive tap6 I
(NITTO
501, or equivatontl
Thickness: 0.16 mm
{0.006 in.)
Width: I mm {0.3 in.}
Longlh: 4it0 mm
(17.3
in.)
Adhosiv tape C
(3M /P13.
or equivalentl
Thickness: 0.8 mm
(0.03
in.l
Wi dth: 5 mm
(0.2
i n.)
Length: 30 mm
(1.2
i n.)
ADHESIVE
t
\ b
5. l f the ol d quarter gl ass i s to be rei nstal l ed,
gl ue the
upper and l ower cl i ps and fastener as shown
NOTE: Be car ef ul not t o t ouch t he
quar t er gl ass
>: Clip, fastener locations
A> , 2
B> , 1
2. 5 mm
(0. m i n. )
Gl ue the fastener to the body as shown.
>: Fastener location, 1
6.
)
ALIGNMENT
7. Wi th a sponge, appl y a l i ght coat of gl ass pri mer to
the i nsi de face of the quaner gl ass, as shown, then
l i ghtl y wi pe i t off wi th gauze or cheesecl oth
NOTE:
. Do not appl y body pri mer to the
quarter gl ass,
mi xed up.
. Never touch the
pri med surfaces wi th your hands.
l f you do, the adhesi ve may not bond to the
quar
ter
gl ass properl y, causi ng a l eak after the
quar-
ter gl ass i s i nstal l ed.
from the
Pri med
surface
t///////7,
, aootv a"av
crimer
here'
MOLDING
15. 5 mm 10 mm
10. 61 i n. l {0. 39 i n. l
(cont' dl
20-47
Ouarter Glass
Instal l ati on
(cont' dl
8. Wi th a sponge, appl y a l i ght coat of body pri mer
to
the ori gi nal adhesi ve remai ni ng around the quarter
gl ass openi ng fl ange. Let the body pri mer
dry for at
l east l 0 mi nutes.
NOTE:
. Do not appl y gl ass pri mer
to the body, and be
car ef ul not t o mi x up gl ass
and body pr i mer
sponges.
. Never l ouch the pri med
surfaces wi th your hands.
. Mask off the rear si de tri m panel
before pai nti ng
the fl ange.
///ffi
: Appty aoay primer here.
16 mm
10. 63 i n. l
Thoroughl y mi x the adhesi ve and hardener togeth-
er on a gl ass or metal pl ate wi th a putty kni fe.
NOTE:
mi xi ng.
si ve.
Before fi l l i ng a cartri dge, cut the end of the nozzl e
as shown.
Cul nozzl e end
10 mrn (0. 39
i n. )
9.
10.
20-4A
7 mm
10. 27 i n. )
l ' 1. Pack adhesi ve i nto the canri dge wi thout ai r pockets
to ensure conti nuous del i very. Put the cartri ge i n a
caul ki ng gun,
and r un a bead of adhesi ve ar ound
the edge of the quarter gl ass as shown.
NOTE:
. l f the ol d quarter gl ass i s to be rei nstal l ed, peel
the separator off the butyl tape after appl yi ng the
adhesi ve.
. Peel the separator off the adhesi ve tape after
appl yi ng the adhesi ve.
. Appl y the adhesi ve wi thi n 30 mi nutes after appl y
i ng the gl ass pri mer.
1 2 m m 1 1
l o.tt tn.l
I l :ADHESIVE
8 mm
{0. 31 i n. )
CLIP
MOLDING
}
12. Use sucti on cups to hol d the quarter gl ass over the
openi ng, al i gn t he cl i ps, and set i t down on t he
adhesi ve. Li ghtl y
push on the
quarter gl ass unti l i ts
edges are ful l y seated on the adhesi ve al l the way
around.
NOTE: Do not open or cl ose t he doo. s unt i l t he
adhesi ve i s dry.
kni fe or towel ,
NOTE: To remove adhesi ve from a pai nted surface
or the quaner gl ass, wi pe wi th a soft shop towel
dampened wi th al cohol .
spray water over the
quarter gl ass and check for
l eaks. Mark the l eaki ng areas, l et the quarter gl ass
quarter gl ass i nstal l ati on. l f the car has to be used
wi thi n the fi rst four hours, i t must be dri ven sl owl y
Rei nstal l al l remai ni ng removed
parts-
. Sl am the doors wi th al l the wi ndows rol l ed up.
(such
as when goi ng
i n and out of dr i veways at an angl e or dr i vi ng
over rough, uneven roadsl .
13.
14.
)
CLIP
a
20-49
Moonroof
SWITCH PLATE
Adj ust ment , page 20 56
REAR DRAIN
TUBE
Y<
/ \ ?'''
u8E
l l /
Lf P
l l I
U 6
./w
FRONT ORAIN TUBE
CABLE ASSEMBLY
Repl acement , page
2O-55
Index
SUNSHADE
RAIL HOLDER B
RAIL HOLDER A
REAR DRAIN
VALVE
--:=::
0 \
g TNNER CAELE
20- 50
Troubl eshooti ng
Symptom Probable Cause
Water l eaks 1. Cl ogged dr ai n t ube.
2. Gap between gl ass weatherstrj p and roof panel .
3. Defecti ve or i mproperl y i nstal l ed gl ass weatherstri p.
4. Gap between drai n seal and roof panel .
Wi nd noi se
' 1.
Excessi ve cl earance between gl ass weatherstri p and roof panel .
Motor noi se 1. Loose motor.
2. Worn gear or beari ng.
3. Cabl e assembl y deformed.
Gl ass does not move, but motor turns
' 1.
Cl utch out of adj ustment.
2. Forei gn matter stuck between gui de rai l and sl i der.
3. l nner cabl e l oose.
4. Cabl e assembl y not attached properl y.
Gl ass does not move and motor does not turn
{gl ass can be moved wi th moonroof wrench)
1. Bl own fuse,
2. Faul ty swi tch.
3. Battery run down.
4. Defective motor.
5. Faul ty rel ay.
D
Glass Height Adjustment
The roof panel shoul d be even wi th the gl ass weather-
st r i p, t o wi t hi n 1. 7 : l r 3 mm
( 0. 07 : 3: 31 i n. ) al l t he way
around. l f not, open the gi ass ful l y, and:
GLASS WEATHERSTRIP
1. Remove the bracket cover.
Loosen the nuts, and i nstal l the shi ms between the
gl ass frame and gl ass bracket as shown.
Shi m thi ckness: Front max.3 mm 10,12 i n.l
Rear max. 2 mm 10.08 in.)
Repeat on opposi te si de i { necessary.
)
5 x 1 . 0 mm
9. 8 N. m 11. 0 kgf m,
7. 2 rbt f t )
SRACKET
COVEB
----------1>
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgt m,
7.2 tbf.ft)
1.7 tl.8 mm
{0.07 :3 3i in.}
20-51
Moonroof
Gl ass, Gl ass Bracket and Sunshade Repl acement
l . Cl ose the gl ass ful l y.
2. Sl i de the sunshade al l the way back.
3. Remove both bracket covers.
Forward
_--____->
4. Remove t he nut s f rom bot h gl ass
bracket s.
6 x 1 . 0 mm
9.8 N.m
(1.0
kgf.m,7.2l bt.ftl
Remove the gl ass by l i fti ng up and pul l i ng forward
as shown.
NOTE: Do not damage the roof panet.
ERACKET COVER
GLASS EBACKET
GLASS
\
20-52
DRAI N CHANNEL
6. Remove the drai n channel .
7. Remove t he hol der cover . t hen r emove t he
hol der B.
NUT
6 x 1 . 0 mm
9 N.m {0.9 kgf.m.
? tbtftl
{i;t'm
RAIL HOLDER B
Usi ng the moonroof wrench, move the gl ass
bracket
to the posi ti on where the moonroof normal l y
pi vots
down, and remove the screws.
scREws
b
D
9. Remove the rai l hol der A.
GLASS BRACKET
DRAIN CHANNEL ROO STOP
Rot at e as shown t o remove i t f rom t he gui de rai l .
10. Remove t he drai n channel rod sl i der by movi ng t he
cabl e sl i der f orward usi ng t he moonroof wrench.
' 11.
Det ach t he drai n channel rod st op f rom t he cut out
of t he gui de rai l as shown.
DRAI N CHANNEL
ROD
I
NUT
6 x 1 . 0 mm
I N.m
(0.9
kgf.m,
SUNSHAOE
\
' 14.
12. Sl i de the sunshade forward, then remove i t.
NOTE: Check the gl ass hei ght
(see page 20-51).
Check for water l eaks,
NOTE: Do not use hi gh-pressure water.
20- 53
Moonroof
Motor, Drai n Tube and Frame Repl acement
CAUTION:
. Put on
gloves to protecl your hands.
. Be careful not to damage the seats, dashboard and other interior trim.
' 1.
Remove the headl i ner {see
page 20-64).
2. Di sconnect the motor connector and gl ass posi ti on swi tch connector.
NOTE: When removi ng the motor, detach the connector from the frame, remove the bol ts and nuts, then remove the
motor.
3. Remove the gl ass
{see
page 20-52).
4. Di sconnect the drai n tubes, and detach the cei l i ng l i ght harness.
5. Remove the frame mounti ng bol ts.
NOTE;
. An assi stant i s hel pful when removi ng the bol ts.
. Remove the front bol ts l ast.
6. Detach the rear hooks by movi ng the frame forward, then remove the frame.
BOLT
6 x 1 . 0 mm
9. 8 N. m {1. 0 kgt m,
7.2 tht.hl
6 x 1 . 0 mm
9. 8 N m
(1. 0
kgl . m, 7. 2 l bt f t )
20-54
\
L
L
7. Pul l the drai n tubes out the front and rear pi l l ars.
NOTE: Before
pul l i ng
out the drai n tube, ti e a stri ng
to the end of i t so i t can be rei nstal l ed.
NOTE:
. Before i nstal l j ng the frame, cl ear the drai n tubes
and drai n val ves by usi ng compressed ai r.
. Check the frame seal .
. Cl ean the surface of the frame.
. When i nstal l i ng the frame, fi rst attach the rear
hooks i nto the body hol es.
. When connecti ng the drai n tube, sl i de i t over the
frame nozzl e at l east 10 mm
(0.39
i n.).
. Instal l the tube cl i p as shown.
Upward
I
I
I
TUBE CLI P
Check for water l eaks.
NOTE: Do not use hi gh-pressure water.
DRAIN TUBE
I t y
20- 55
Gui de Rai l s/Cabl e Assembl y
Repl acement
CAUTION: Put on gloves to
protect your hands,
1. Remove the frame.
Remove the motor and glass bracket
(see page 20-52).
Remove the nuts, and l i ft off each gui de rai l , then
remove the cabl e assembl y wi th sl i ders attached.
NOTE: Take care not to bend the cabl e tubes and
gui de rai l s.
NOTE:
. Oamaged
parts shoul d be repl aced.
. Grease the sl i di ng porti on wi th Super Hi gh Temp
Urea Grease, P/N 08758
-
9002.
. Fi l l the groove i n each grommet wi th seal ant.
a
a
Instal l the frame seal securel y.
Before i nstal l i ng the motor. make sure both sl i d-
ers are paral l el .
Before i nstal l i ng the motor. i nstal l the frame and
gl ass, then check the openi ng drag
(see page 20-
GROMMET
Moonroof
1 .
2 .
Switch Plate Adjustment
(Fully
Closed Positionl
3.
4.
5.
Remove the headl i ner {see
page 20-64).
Usi ng the moonroof wrench, cl ose the
gl ass ful l y.
NOTE: Check the gl ass fi t to the rool panel .
Usi ng an open-end wrench, l oosen the swi tch
pl ate mounti ng bol ts.
Adj ust posi ti on of the swi tch
pl ate (swi tch
cam) as shown.
Check the operati on of the
gl ass (from
ti l t-up
posi ti on to ful l y cl osed
posi ti on, from the ful l y open posi ti on to the ful l y
cl osed
posi ti on) by operati ng the moonroof swi tch.
NOTE: Check the gl ass hei ght
(see page 20-51).
SWITCH PLATE
GUI DE
PLATE
SWITCH CAM
Whi l e movi ng t he swi t ch
pl at e
pl at e at t he posi t i on wher e t he
a
( a
f ai nt cl i ck i s hear d) .
INNER CABLE END
l i t t l e bv l i t t l e, secur e t he swi t ch
swi t ch cam cont act s t he swi t ch
Cl ose t he gl ass f ul l y, and check f or wat er l eaks.
NOTE: Do not use hi gh-pressure wat er.
CAELE BRACKET
20- 56
Openi ng Drag Check
{Motor
Removed)
Before i nstal l i ng the motor, measure l he effort requi red
to open the gl ass usi ng a spri ng scal e as shown.
CAUTION: When using a spring scale, pfotest the lead-
ing edge ol the glass with a shop towel.
l f l oad i s over 40 N
(4
kgf,9 l bf), check the si de cl earance
and gl ass hei ght
( see page 20- 51) .
SHOP TOWEL
l , e
20-57
Closing Force Check
(Motor
Instal l edl
' 1.
Af t er i nst al l i ng al l r emoved par t s, have a hel per
hol d the swi tch to cl ose the
gl ass whi l e you mea-
sure the force requi red to stop i t. Attach a spri ng
scal e as shown. Read the force as soon as the gl ass
stops movi ng, then i mmedi atel y rel ease the swi tch
and spri ng scal e.
CAUTION: When using a spring scale,
protect the
lerding edge ol the glass with a shop towel.
Closing Force: 200
-
290 N
(20 -
30 kst, 44
-
66 lbfl
l f the torce i n not wi thi n speci fi cati on, i nstal l a new
l ock washer, adj ust the tensi on by turnang the motor
cl ut ch adj ust i ng nut , and bend t he l ock washer
agai nst the motor cl utch adj usti ng nut.
LOCK
WASHER
Repl ace.
COUNTER.
cLocKwrsE
To decr ease
SCALE
Interi or
Component Location Index
SRS comDonents are l ocated
j n
the
parts
areas marked wi th an asteri sk
(*).
Revi ew the SRS component l ocati ons, precau
ti ons, and
procedures i n the SRS secti on {24) before performi ng repai rs or servi ce.
2Dl3Dl4Dl
CENTER PILLAR
UPPER TRIM
{see
page 20 591
FRONT PILLAR
TRIM
{ see
pages 20 59, 60, 61)
REAR PILLAR
TRIM
TRUNK
TRIM
(see page 20-62)
SEAT
SIDE TRIM
{see
page 20-59)
{see
page 20 59}
CENTER PILLAR
LOWER TRIM PANEL
(see page 20-59)
REAR ROOF TRIM
(see page 20-65)
:
OUARTER
TRIM PANEL
{see
page 20' 61)
HEADLINER
Repl acement ,
Page
20' 64
*OASHBOARO
Component Removal / l nst al l at i on,
page 20 68
REAR
l see
page 20 59)
REAR TRIM PANEL
l see
page 20-62)
Removal ,
page 20-70
*CARPET
Repl acement ,
page 20 66
PANEL
Repl acement ,
page 20-67
3D:
REAR SIDE
SHEI-F
(see page 20-60)
OUARTER
TRIM PANEL
(see page 20-60)
SIDE TRIM PANEL
(see page 20-6' l )
2Dl
HATCH
SIDE TRIM
(see pase 20 63)
REAR ROOF TRIM
(see page 20 65)
REAR ROOF
TFIM
(see page 20' 65)
HATCH
UPPER
TRIM
l see page 20 63)
CENTER
SHELF
l see page 20 60)
REAR
PANEL
l see
page 20 60)
SIDE TRIM
{see
page 20 60)
REAR
PANEL
(see page 20 62)
1
HATCH
TRIM PANEL
(see page 20-63)
SIDE TRIM
PANEL
(see page 20-60)
20-54
Interi or Tri m
t
Replacement
CAUTION:
o When prying with a flat-tip screwdriver, wrap it with protective tape to prevent
damage.
NOTE: Take care not to bend or scratch the tri m and panel s.
4D:
>: Clip locations
a > , 2 c >, 2' l o > , 2
E > , 2
r*'"
n t-lt't
\wi, i
' \ t l
l
l /
_t r* @,
CENTER PILLAR
UPPER TRI M
REAR PILLAR
TRIM
LOCK CYLINDER TRIM
t l '
I
E'
v
BELT UPPER
ANCHOR
(see page 20-85)
Di sconnect t he
hi gh mount brake
l rght connect or.
T SIDE TRIM
Remove t he rear seat cushi on and rear
seat si de bol st er l see
page 20-19] ' .
)
NOTE:
. l f necessary, repl ace any damaged cl i ps.
. Before i nstal l i ng the front seat bel t upper anchor
and rear shel f. make sure there are no twi sts or
ki nks i n the seat bel ts.
(cont' d)
B > , 6
REAR SHELF
k"si
fEFT KICK
PANEL
20- 59
lnterior
Trim
Replacement
(cont'dl
3D:
>: Clip locations
A > , 2
CLI P
N;
nt-.l I
'"'\R\
I
")!
F >, l i l
TRI M
B > , 3
G > , 2 H > , 2
t
FRONT SEAT
BELT UPPEB
ANCHOR
l see
page 20 86)
SIDE TRIM PANEL
PROTECTOR
LEFT KICK
PANEL
c > , 8 o > , 3
PIVOT BRACKET
{see
page 20-80)
procedure
NOTE:
. l f necessary, repl ace any damaged cl i ps'
. Before i nstal l i ng the anchor bol ts, make sure there
are no tl vi sts or ki nks i n the seat bel ts'
E > , 8
>: Screw, bolt locations
A > , 3 8 > , 6
^ l l - l E F \
#,
A@ Y
*" 0
c > , 1
I "4"
\ s
o > , 2
l @@
\ - - -
s, 4,
f f i ; T
FRONT PILLAR
B
e V
REAR SIDE
SHELF
SIDE TRIM
PANEL
Remove t he rear seat -back and
rear seat cushi on
(see
Page
20_80)
Di sconnect t he rear speaker
connect or
(bot h si des,
f or some model s).
REAR TRIM
PANEL
q
RIGHT KICK
PANEL
"x-
20- 60
I l
2Di
>: Cl i p l ocat i ons
a > , 2
8 > , 3
CLI P
G > , 4 H > , 2
D > , 3
>i Screw location3.4
REAR SHELF
SIOE TRIM PANEL
Remove t he rear seat -back and
rear seat cushaon
(see page
20-a1l.
\ t ,
Di sconnect t he hi gh
mount brake l i ght
SEAT BELT
'
/ > "
RIGHT KICK
PANEL
)
TRIM
nJ
'.'rI\ZI
1\f-
F > , 8
N 4 ' d r
SIDE TRIM
LOWER ANCHOR
(see page 20-86)
c>, 14 E> , 2
NOTE:
. Before i nstal l i ng the anchor bol ts and rear shel f,
make sure there are no twi sts or ki nks i n the seat
bel ts.
FRONT PILLAR
FRONT SEAT
BELT UPPER
ANCHOR
v
. h,
't6d
\ r \
LEFT KICK
PANEL
20-61
Trunk Tri m
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:
. Take care not to bend or scratch the tri m and panel s.
. When removi ng the trunk si de tri m or trunk tri m panel , fol d the seat-back forward.
Japan-produced:
4D:
RIGHT TRUNK
SIDE TRIM
TRUNK MAT
1
B
REAR TRIM
PANEL
a > , 6
a: - ) , 2
I
g
cLlP
^
l#srq-'
|
'
| NNER
\\- crLP
B > , 6
NOTE: Do not push
t he i nner cl i p i n t oo f ar.
I J
L T r o
i
) :Hook locations
A i--)
, r
'
2D:
TRUNK TRIM
NOTE:
. l f necessary. repl ace any damaged cl i ps.
. To i nstal l the A cl i ps.
pul l the i nner cl i p up. i nstal l
the cl i p, then push the i nner cl i p unti l i t' s fl ush.
(
, -
- -
/ ' /
\ - -
/
- -
20-62
Hatch Trim
a > , 2
NOTE: Do not push th
l nner c l i p i n t oo f ar .
& ct-tp.
54d-
g + - \
2.
I NNF
I j y. \ \
"
\
. V f t
- s- - -
- k-"i-t-;-a-
Repl acement
CAUTION:
. Put on
gloves to protect your hands.
. When
prying with a flat-tip screwdrivel, wrap it with protestive tape to
prevent damage.
NOTE: Take care not to bend or scratch the tri m and panel .
LEFT HATCH
SIDE TRIM
HATCH
UPPER TRIM
NOTE:
. Toi nst al l t heAcl i ps, pul l t hei nner cl i pup. i nst al l t hecl i p, t henpusht hei nner cl i punt i l
i t ' sf l ush
a
I
20- 63
Headl i ner
Repl acement
CAUTION: When pryi ng wi th a fl at-ti p screwdri ver,
wrap it with proioctiva tap to prevsnt damage.
NOTE:
. Take care not to bend and scratch the headl i ner.
. Be car ef ul not t o damage t he dashboar d and ot her
i nt er i or t r i m.
' 1.
Remove:
4D:
(both
si des. see page 20-59)
. Center pi l l ar l ower tri m panel (both
si des, see page
20 59)
Upper anchor bol t from the front seat bel t
(both
sides, see page 20-85)
Center pi l l ar outer tri m and center pi l l ar upper tri m
(both
si des, see page 20-59)
Cei l i ng l i ght
(see
secti on 23)
Rearvi ew mi rror
(see page 20-25)
a
a
a
a
a
3D:
(both
. Ri ght rear seat-back and rear seat cushi on
(see
page 20-80)
. Rear center shel f
(see page 20-60)
. Rear si de shel f and si de t r i m panel ( r i ght
si de,
see page 20-60)
. Upper anchor bol ts from the front and rear seat
belts
(right
side. see pages 20-86, 89)
. Ouarter tri m panel (ri ght
si de, see page 20-60)
. Cei l i ng l i ght
( see
sect i on 23)
. Rearvi ew mi rror
(see page 20-25)
2Dl
(both
. Ri ght rear seat-back and rear seat cushi on
(see
page 20- 81)
Si de tri m panel (ri ght
Upper anchor bol t from the front seat bel t
(ri ght
Ouarter tri m panel (ri ght
si de, see page 20-6' l )
Cei l i ng l i ght
(see
secti on 23)
Rearvi ew mi rror (see page 20-25)
20-64
2. Remove the sunvi sor and hol der from each si de.
>: Screw l ocat i ons, 4
-A-,-
3. Remove t he grab handl es and coat hanger.
scREws
ACCESS
Lto
COAT HANGER
BRACKET
ACCESS
LID
COAT HANGER
t2D/3Dl
SCBEW
1 ^
4. Remove t he rear roof t ri m and cl i ps, and remove
t he roof t ri m and socket
pl ug (moonroof
model ).
>: Clip locations
A> 2DllD,7 B > With moonroof,
'l
3D. 5 Wi t hout moonroof , 3
[ i l ' , f E l
t% .l E .l
'::
=,/ _._- ,/
2D l3D l4Dl
REAR ROOF
TRIM
3D:
t
REAR ROOF
TRI M
2D:
5.
7.
OUARTER
IRIM PANEL
4D: Lower the rear pi l l ar tri m on both si des
3D: Remove the upper anchor bol ts from the front
and rear seat bel ts
(see pages 20-86, 89), then l ower
the quarter tri m panel on l eft si de.
2D: Remove t he upper anchor bol t f r om t he f r ont
seat bel t
(see page 20-86), then l ower the
quaner
tri m
panel on l eft si de.
Lower the headl i ner.
Careful l y remove the headl i ner through the passen-
ger' s door openi ng
(2Dl 4D) or hatch openi ng
(3D).
procedure.
NOTE:
. When i nserti ng the headl i ner through the open-
i ng, be careful not to fol d or bend i t. Al so, be care-
ful not to scratch the bodY.
. Chec k t hat bot h s i des of t he headl i ner ar e
securel y attached to the tri m.
. When i nst al l i ng t he r oof t r i m, i nst al l t he
j oi nt
toward the ri ght si de
(moonroot
model )
6.
8.
20- 65
Carpet
Repl acement
SRS components are l ocated i n thi s area. Revi ew the SRS
component l ocati ons, precauti ons, and procedures i n the
SRS secti on {24} before
1. Remove:
. Front seat
(see page 2O-7 4l
(see pages 20 79, 80, 81)
o Ki ck panel (see pages 20-59, 60, 61)
o
Center
pi l l ar l owertri m panel
i 4D, see page 20-59)
. Front seat bel t i ower anchor
(2Dl 3D,
see page 20-
86)
. Si de tri m
(see pages 20-59, 60,61)
o Front and rear consol es
. Consol e panel
Remove the SRS uni t covers.
Cut areas @
and
@
i n the carpet, then pul l i t back as
snown.
>: Cl i p l ocat i ons, 2
2.
3.
-lM- I
lMt
l
ry-l
LEFT SRS
UNI T COVER
20-66
4. Remove the tootrest and parki ng brake l ever mount-
i ng bol ts, and detach the cl i ps, then remove the car
pet.
>: Cl i p l ocal i ons,
:ft
\ / l
2D l3D l4D:
3 >: Bol t l ocat i ons
A > . 2 A > , 2
3
l 6 x 1 0 m m
e2 Y
9.8 N.m r1.o kgr' m,
H ) E /
7.2tbtrtl
::a /
5.
2D
I3D:
NOTE:
. Take care not to damage. wri nkl e or twi st the car-
pet.
. Make sure the wi re harnesses are routed correctl y.
. Sl i p the carpet under the seat si de tri m
(4D)
or
si de tri m panel (2Dl 3D)
on each si de properl y.
. Reattach the cut areas
@
and
@
i n the carpet
wi th wi re ti es.
FOOTREST
SI OE TBI M
Consol es/Consol e
Panel
Repl acement
NoTE: Takecar enot t oscr at cht hef r ont andr eal conso| es, f r ont seat andr e| at edpar t s.
Di sassembl e i n numbered sequence
>: Screw locations
a > , 8 B > , 4
>: Clip locations
A > , 2
B > . 2
' nnffir
:__)
"=)
:)
::r_l REAB CONSoLE
(wi th
armrest)
procedure
NOTE:
. Make sure the wi re harnesses are not pi nched.
. Make sure the connector i s connected
properl y.
]
FRONT CONSOLE
Remove t he shi f t l ever knob
( M/ T)
{ .
I
I
20-67
Dashboard
Component RemovaUl nstal l ati on
CAUTION: When pryi ng wi th a fl at-ti p screwdri ver,
wrap it with
protoctivo
tape, and apply
protective
tape
around tho r6lat6d parts, to prevent
damag6.
NOTE: Take care not to scratch the dashboard and related
pans.
Instrument Danel removal:
1 . Lower the steeri ng col umn.
Remove the screws, and detach the cl i ps, then care-
ful l y remove the i nstrument panel .
>: Clip locations, 2
. i l |
P i
t)_
_ ,/
^ l
@ s l
:)
PANEL
20- 68
Driver's dashboard lower cover and knee bolster removal:
SRS components are l ocated i n thi s area. Revi ew the SRS
component l ocati ons, precauti ons. and procedures i n the
SRS secti on
(24)
before performi ng repai rs or servi ce.
' 1.
Remove t he scr ews, and det ach t he cl i ps, t hen
r emove t he dr i ver ' s dashboar d l ower cover . l f
equi pped wi th power mi rrors and moonroof, di scon-
nect the connectors.
>: Screw, boh loc.tions
A> . 3 B > , 2
_- r r i I / a_6x1. 0mm
*\Y
@{[)
s 8 N'm tt o rst'm,
_-_- J _
\J- 7 2_rbtftl
-_
>: Clip locations
A> . 2 B > , 1
tu
DRIVER'S DASHBOARD
LOWER COVER
Remove the bol ts, then remove the knee bol ster.
Glove box removal:
Remove the bol ts, then remove the gl ove box.
proceoure
Side air vent/Side defogger trim removal:
SI OE DEFOGGER TRI M
SHOP
TOWET_
Car ef ul l y Pr Y
r t at t he
t hen r emove i t ,
si de edge,
SIDE AIR VENT
Remove t he dri ver' s dashboard
l ower
cover, or oPen t he
gl ove Dox,
HOOKS
t hen
push t he cl i Ps f r om each
openi ng by hand, and
Pul l
i t
out . Di sconnect t he connedor s
(dri ver' s si de).
HOOKS
DASH LIGHTS
BRIGHTNESS
CONTROLLER
CONNECTOR
{f or
some model s)
CFUISE CONTROL
MASTER SWITCH
CONNECTOR
(f or
some model s)
Center dashboard lower covel:
1. Remove:
. Dri ver' s dashboard
l ower cover
. Gl ove box
2. Remove the screws and bol t, then remove the cen-
ter dashboard
l ower cover. Di sconnect the accesso-
ry socket connector'
>i Boh, screw locations
a > , 1
B> ' 5
A s*o. e-- I A
@;*;ry'-1'-.J _e)
3. Instal l ati on i s the reverse of the removal
proceoure'
(cont' d)
20- 69
LOWER COVER
Dashboard
Gomponent Removal /l nstal l ati on
(cont'd)
Center panel removal:
1. Remove:
. Center dashboard l ower cover
(see page 20-69)
. Radi o {see secti on 23)
2. Remove the rear wi ndow defogger swi tch and haz-
ard warni ng swi tch, then di sconnect the connectors.
>: Screw locations, 5 >: Clip locations
A> , 4 B> , 3
fii*
- )
CENTER
PANEI.
rt-xR.
W
I
HAZARD
WARNING
swlTcH
r44
"
F.IZ
v l
I
I
REAR
wtNoow
OEFOGGER
swtrcH
Mtx
CONTNOL
CABLE
3. Di sconnect the ai r mi x control cabl e, and remove the
screws, then pul l out the center panel .
4. Di sconnect the connectors from the heater control
u ni t .
NOTE:
. Make sure the connectors are connected properl y.
. Adj ust the ai r mi x control cabl e
(see
secti on 21).
20-70
Removal
SRS component l ocati ons, precauti ons, and procedures
(24)
before preformi ng repai rs or ser-
vi ce.
NOTE:
. An assi stant i s hel pful when removi ng and i nstal l i ng
the dashboard.
. Take car e not t o scr at ch t he dashboar d, body and
rel ated parts.
1. Remove:
o Front and rear consol es
(see page 20-67)
. Consol e panel (see page 2O 67),
. Dri ver' s dashboard l ower cover and knee bol ster
(see page 20-68)
. Gl ove box
(see page 20-69)
. Center dashboard l ower cover
(see page 20-69i
2. Lower the steeri ng col umn
(see
secti on 17).
@
To avoi d acci dental depl ovment and
possi bl e i nj ury, al ways di sconnect the dri ver' s
airbag connector belore lowering the steering col-
umn lsee section 241.
NOTE: To prevent damage to the steeri ng col umn,
wrap i t wi th a shop towel .
3. Di sconnect the dashboard wi re harness connectors,
remove the nuts, then move the under-dash fuse/
rel ay box. Di sconnect the antenna l ead and moon-
roof rel ay connectors.
DASHBOARD
cltPs
CONNECTORS
( f or
some model s)
MOONROOF
RELAY
ANTENNA
LEAO
FRAME
SRS MAIN
HARNESS
9.8 N.m
(1.0
kgf m,
7.2lbt.ltl
DATA
CONNECTOR WIRE HARNESS
Detach. CONNECTORS
Remove the fol l owi ng
parts Irom the dashboard'
. Dri ver' s dashboard si de cover
o Passenger' s dashboard l ower cover
. Dashboard center l i d
Di sconnect the connectors and ai r mi x control cabl e'
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgl . m,
D> , 1
@
7 2'orftl
- ---// _._J
, { ni l Ll l , , " o
I ft#5 L
//Hl
W
l j %u | 5 i / / Wt
q T
W7 2 - t 1 1
7 ' : : - - J
A > , 1 B > , 1
Loosen t he bol t .
DASHBOARD
AIR MIX CONTROL
CONNECTORS
FRONT PASSENGER'S
AIRBAG CONNECTOR
Remove t he bol t s, t hen l i f t and remove t he dashboard'
CAUTION: Use
proteqtive plates on the bottom ot the front
pillar trim'
(cont' d)
20-71
M,::;:"lx3T:iJnif:3lilH:fl"*:1::f"*'il;ili"'"
disconnect rhe front
passeneer's airbas
>: Bolt, screw locaiions
A > , 7 B> , 1
, i ( \
8x 125mm
(!,@ 22 N.m t2.2
kstm,
-v,
16 tbf.ftl
8x l . 25mm
I
22 N.m 12.2
kgt'm,
I
'"tt:___J
c > , 1
@
c > , 6
Dashboard
Removal
(cont'd)
7. l f necessary, remove the dashboard frame from the dashboard.
>: Screw localions
a > , 2 1 B > , 4
a: Nut locations, 3
>: Clip locations
l ^ 1 . / ' \
I Shl:' Olb'
t v Y / l
\ - ] 1
ra
6 x
'1.0
mm
Yi.!i[11"-"'".
DASHBOARD BRACKET
SIDE COVER
Instal l ati on i s the reverse of the removal orocedure.
NOTE:
. Before ti ghteni ng the bol ts, make sure the dashboard wi re harnesses are not pi nched.
a Make sure the connectors, antenna l ead and ai r mi x control cabl e are connected properl y.
FRONT PASSENGER'S
OASHBOARD
20-72
Seats
and Seat Belts
Component
Location
Index
2Dl 3Dl 1Dl
SHOULDER
ANCHOR
ADJUSTER
(4D)
(see
Page
20-85i
FRONT SEAT BELT
Repl acement , Pages
20 85, 86
I nspect i on, Page
20-91
FRONT SEA
Removal , Page
20' 74
Repl acement , Page
20 75
Harness Wi ri ng and Recl i ne
Cabl e Locat i ons, Page
20-77
Seat Cover RePl acemenl , Page
2O' 77
3D:
BEAR SEAT BELT
Repl acement , Page
20' 89
I nspect i on,
page 20-91
REAB SEAT BELT
(2DI4DI
Repl acement,
page 20-88
l nspecti on,
page 20-91
REAR SEAT EELT BUCKLE/
CENTER BELT TONGUE
(2DI4DI
( see p6ge 20' 90)
REAR SEAT t2Dl4Dl
Removal,
pages 20-79, 8'l
Seat -back Lat ch Repl acement ,
page 20-82
Seat Cover RePlacement, Page
20-83
FRONT SEAT
BELT BUCKLES
{see
page 20-87)
REAR SEAT BELT BUCKLE/
CENTER BELT TONGUE
(see
Page
20' 90)
REAR SEAT
Removal ,
page 20 80
Seat back Lat ch Repl acement ,
page 20-8?
Seat Cover RePl acement , Page
20_83
20-73
Front Seat
Removal
CAUTION: When prying with a flat-tip screwdriver, wrap
it with protective
tape lo prevent
damage.
NOTE: Take care not to scratch the seat covers and body.
1. Remove the seat track end cover, then remove the
bol ts.
SEAT TRACK
COVER
FRONT SEAT
)
SEAT TRACK
END COVER
BOLT
8 x' 1. 25 mf t
22 N..n
12.2 kgl.m,
16 rbf.ft)
8 x 1. 25 mm
22 N.rn 12,2 kgl.m,
16 t bt f t )
20-74
2. Li ft the dri ver' s front seat, then di sconnect the seat
bel t swi tch connector.
SEAT BELT
swtTcH
CONNECTOR
4.
Remove the headrest.
Car ef ul l y r emove t he f r ont seat t hr ough t he door
openi ng.
Instal l ati on i s the reverse ol the removal procedure.
NOTE: Make sure the connector i s connected prop-
erry.
5.
Replacement
CAUTION: When
prying with a flat-tip screwdrivet, wrap it with protective tape to prevent damage'
NOTE:
. Take care not to scratch the seat covers and body
. Remove the front seat through the door openl ng'
Driver's:
NOTE: Refer to page 2O-77 for the seat bel t swi tch harness wi ri ng l ocati on'
SEAT CUSHION
CENTER COVER
I NNER SEAT
TBACK
PIVOT NUT
8 x 1. 25 mm
22 N.m l.2.2
16 tbf.ft)
v
l
35 tbt.ft)
10 x 1. 25 mm
47 N.m {4.8
kgf m,
10 x 1. 25 mm
47 N.m {i1.8
kgl m,
35 tbr.ft)
RECLINE ADJUSTER
LOW
d
ER CAP
l
RECLI NE
CONNECTING
WIRE
To connect , t wi st 180'
OUTER SEAT
TRACK
procedure'
NOTE:
. Make sur e t he bushi ng and
pi vot washer
i nstal l ed
ProPerl y.
. To pr event wr i nkl es when i nst al l i ng t he seat -
back cover, make sure the materi al i s stretched
evenl y over the
Pad.
. Grease the sl i di ng
Porti on
8 x 1. 25 mm
20 N.m 12.0 kgf.m,
14 tbt.ft)
a r e
RECLINE
KNOB
(cont' d)
20-75
10 x 1. 25 mm
47 N.m {4.8 kgf'm,
35 t bt f t l
Front Seat
Replacement
(cont'd)
Passenger's
(with
reclino cablel:
NOTE; Refer to page 20-77 for the recl i ne cabl e l ocati on.
HEADREST
PIVOT
WASHER
LOWER
CAP
PIVOT NUT
8 x 1.25 mm
22 N.m 12,2 kgl.m,
tbt.ftt
SEAT CUSHI ON
CENTER COVER
10 x 1, 25 mm
47 N.m (4.8
kgf.m,
10 x 1. 25 mm
47 N.m {4.8 kgf.m,
3s tbt.ft)
INNER SEAT
TRACK
35 tbf.ftl
RECLINE ADJUSTEB
RECLINE
COVER
i
LowER CAP
b
RECLINE
CABLE
x 1. 25 mm
47 N'm
(4.7
kgf.m,
35 tbtftl
SEAT
8 x 1. 25 mm
20 N.m {2.0 kgf.m,
14 rbf.ft)
ruf,
To connect, twist 180'.
NOTE:
. Make sur e t he bushi ng and pi vot washer ar e
i nstal l ed properl y.
. To prevent
wri nkl es when i nstal l i ng the seat-back
cover, make sure the material is stretched evenly
over the pad.
. Adj ust the recl i ne cabl e.
. G.ease the sl i di ng poni on.
SEAT-BACK
20-76
Harness
Wi ri ng and Recl i ne
Cable
Locations
NOTE: When i nstal l i ng the seat cushi on, make sure the
seat bel t swi tch harness, connector and recl i ne cabl e are
fastened correctl y on the seat cushi on frame'
Driver's:
Passenger's
(with lecline cablel:
TRACK
Seat Cover RePlacement
CAUTION:
Put on
gloves to
protest yout hands'
NOTE: Take care not to tear the seams or damage the
seat covers.
Seat-back cover removal:
1. Rel ease the hook, and fol d back the seat-back cover'
Rel ease al l i nsi de spri ngs, then fol d back the seat-
back cover.
Remove the headrest.
Remove the headrest
gui de, then remove the seat-
back cover.
l nst;l l ati on i s the reverse of the removal
procedure'
NOTE: To prevent wri nkl es when i nstal l i ng a seat-
back cover, make sure the materi al i s stretched evenl y
over the
pad before securi ng the i nsi de spri ngs and
hook.
3.
(cont' d)
20- 77
HEADREST
Front Seat
2.
1 .
3.
CUSHI ON
COVER
cover al l t he
remove t he
Seat Cover Replacement (cont'd)
Seat cushion cover removal:
Remove the seat cushi on
{see
pages
20,75,76).
Remove the cl i ps from under the seat cushi on, then
l oosen the seat cushi on cover.
>: Clip locataons
Pul l back l he edge of the seat cushi on
way around, then rel ease the cl i ps, and
seat cushaon cover.
>: Clip locations
SEAT
CUSHI ON
COVER
1 - .
v v v l
20- 7A
NOTE:
. To prevent wri nkl es when i nstal l i ng a seat cush-
i on cover, make sure the materi al i s stretched
evenl y over the pad before securi ng the cl i ps.
. Repl ace the rel eased cl i ps wi th new ones.
UPHOLSTERY RING PLIERS
NEW CLIP
SEAT FRAME
Rear Seat
Removal
NOTE: Take care not to scratch the seat covers and body.
4D:
>: Bol t l ocat i ons
l _) : Hook l oc at i ons , 2
b,,***-,,.1*
D> '
] > mr
;iffiP-"*'piii::#r-,'-,
@t,
V
.
se-ri-cusxo"
[-6*
v -
2u
2u
SEAT CUSHI ON
SEAT-BACK
Pivot boll conslruction:
SLITS
procedure
PIVOT BOLT ERACKET
8 x 1. 25 mm
22 N m
(2. 2 kgf m, 16l bt f t l
Appl y l i qui d t hread l ock
NOTE:
. Before attachi ng the seat-back and seat cushi on, make sure there are no twi sts or ki nks i n the rear seat bel ts and
center bel t.
. When i nstal l i ng the seat cushi on, sl i p the seat bel t buckl es through the sl i ts i n the seat cushron'
. Make sure the seat-back l ocks securel y.
. l f necessary, adi usr the seat-back l atch
(see page 20-82) and seat-back
(cont' d)
c > , 1
6 x 1 . o mm
l 1 Q- e " r . o - -
s.a ru.- tr.o rer-.
I
s.i N.- ir.o
lgr.,i
7.2 lbf.ft)
) E
7.2
'tJrftl
:-
'/
"@rz,
\
EE
E S /
_ _ o t
/
RI GHT SEAT
SIDE EOLSTER
CENTEB
PIVOT
BRACKET
20-79
Rear Seat
Removal
(cont' dl
3D:
A > , 6
':^2
STRIKER
Remove t he si de t . i m
panel (see page
20-60).
c > , 1
STBIKER
, . : )
: Hook l ocat i ons, 2 >: Cl i p l ocat i ons, 14
SEAT CUSHION
STRIKER
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgI . m,
7.2 tbf.ft)
V
RI GHT
SEAT-BACK
Pivot bolt constiuction:
TOOTHEO
LOCK
WASHER
BUSHI NG
PIVOT
NOTE:
Ptvor BoLT
BRACKET
I x 1. 25 mm
22 N.m {2.2 kgl.m. 16 lbf.ft)
Appl y l i qui d t hread l ock.
. Bei ore anachi ng the seat-back and seat cushi on, make sure there are no twi sts or ki nks i n the rear seat bel ts and
center bel t.
. When i nstal l i ng the seat cushi on, sl i p the seat bel t buckl es through the sl i ts i n the seat cushi on.
. l f necessary, adj ust the stri ker and seat-back.
20-ao
6xr . omm
I
9. 8 N. m
(1. 0
ksf . h, i
@,
E E )
qr
,/
6 x 1 o mm
I
22 N. m { 2. 2 kgf . m, l
,"rrr,n2
PIVOT
BRACKET
LEFT
SEAT.BACK
tt
A
CENTER
PIVOT
\---.---
6 x 1 . 0 mm
BRACKET
B > , 1
e
I
tr
-l : / *-
-"
HOOK
2Dt
a > , 6
O
: Hook l ocat i ons. 2 >: Cl i p l ocat i on3, 14
SEAT CUSHION
,r@.'
' - - - - EF- |
E H )
w , /
PIVOT
BRACKET
BUSXING
PIVOT
PIVOT BOLT BRACKET
I x 1 .25 mm
22 N.m
(2.2 kgt m. 16lblft)
procedure'
NOTE;
. Bef or eat t ac hi ngt hes eat - bac k ands eat c us hi on, mak es ur et her ear enot wi s t s or k i nk s i nt her ear s eat be| t s and
center bel t.
. wheni nst a| | i ngt heseat cushi on, sl i pt heseat be| t buckl est hr ought hes| i t si nt heseat cushi on.
. Make sure the seat-back l ocks securel y
. l f necessary, adj ust the seat-back l atch
(see page 20-82) and seat-back'
6 x r . o mm
]
9.8 N.m l 1.O kgf.m,i
,:r:2
B > , 1
ffi
I
g
It
c > , 1
6x r . omm I 8r . ' r . o- - r
22 N.m {2.2 kgtm,'
\ffz
s.e N.m tr.o *gf.m,'
,r:r",
_)
E
7.2rbf.ftl
)
v
v
PIVOT BRACKET
RIGHT SEAT.BACK
PIVOT BRACKET
Pivot bolt constauctaon:
TOOTHED
LOCK
WASHER
SEAT.BACK MAT
,^
20-41
Rear Seat
Seat-back Latch Replacement
2Dl4Dl
Remove t he l ock cyl i nder t r i m, t hen r emove t he r ear
shel f
( see pages 20 59, 61) .
NOTE: Take care not to bend each l ock rod.
>: Boh, screw locations
A > , 4
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgt . m,
7.2 rbf.ftl
LOCK CYLINOER
TRIM
.i.-::
LOCK
RODS
LEFT SEAT-
EACK I-ATCH
NOTE:
. Make sure each l ock rod i s connected securel y.
. [ / ake sur e each seat - back l ocks secur el y and
opens properl y.
. l f necessary, adj ust the seat-back l atch.
B > , 2
/+j
V
LOCK
CYLI NDER
20-82
3D:
Pul l the trunk mat away from the seat' back
(see page 20-
80) .
>: Boll, screw locations
a > , 2
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m,
7.2 tbl.ft)
B> , 1
@
LATCH COVEB
Instal l ati on i s the reverse ofthe removal procedure.
NOTE:
. l vl ake sure the seat-back l ocks securel y and opens
properl y.
SEAT"BACK
Seat Cover Replacement
CAUTION: Put on
gloves to protact your hands,
NOTE| Take care not to tear the seams or damage the seat
covers.
Seat-back cover removal:
2D l 4Dl
1. Remove the seat-back
(see pages 20-79,8' 1).
2. Loosen t he seat - back cover by r el easi ng al l t he
cl r ps.
>: Cl i p l ocati ons
LEFT SEAT-BACK
COVER
RIGHT SEAT.EACK
COVER
3. Pul l back t he edge of t he seat -back cover al l t he way
around. t hen rel ease t he cl i os.
RIGHT SEAT.BACK
1 .
2.
NOTE:
. To prevent wri nkl es when i nstal l l ng a seat cush-
i on cover. make sure the materi al i s stretched
evenl y over the
pad before securi ng the cl i ps.
. Repl ace the rel eased cl i ps wi th new ones
3D:
Remove the seat-back
(see page 20-80).
Loosen the seat-back cover by rel easi ng al l the cl i ps.
NOTE: Remove the l ock knob, l ock col l ar and l atch
cover.
SEAT-BACK
COVER
3. Pul l back the edge of the seat-back cover al l the way
around, then rel ease the cl i Ps.
>: Clip locations
SEAT.BACK
COVER
NOTE:
. To prevent wri nkl es when i nstal l i ng a seat-back
cover, make sure the materi al i s stretched evenl y
over the
(cont' d)
o
o
o
o
o
o
o
o
20-a3
Rear Seat
Seat Cover Replacement
(cont'dl
Seat side bolstor cover removal {,lDl
1. Remove the seat si de bol ster
(see page 20-79).
2. Loosen the seat si de bol ster cover by rel easi ng al l
the cl i os, then remove i t.
>: Clip locations
SEAT SIDE
BOLSTER
COVER
procedure.
NOTE:
. To
prevent
wri nkl es when i nstal l i ng a seat si de
bol ster cover, make sure the materi al i s stretched
evenl y over the
. Reol ace the rel eased cl i Ds wi th new ones,
Sat cushion covgr r6moval:
(see pages 20-79, 80, 81).
2. Loosen the seat cushi on cover by rel easi ng al l the
cl i ps.
>: Clip locrtion3
4D:
- - I . / a
l--lt___)l )
(
.)
Ll!!l^t!!l
1",
COVER
20-a4
SEAT FRAME
NEW CLI P
2DI3D:.
SEAT CUSXION
COVER
Pul l back the edge of the seat cushi on cover al l the
way around, rel ease the cl i ps, and remove the seat
cusnton cover.
>: Clip location3
/tD:
4. Instal l ati on i s the reverse ofthe removal
procedure.
NOTE:
. To
prevent wri nkl es when i nstal l i ng a seat cush-
i on cover. make sure the materi al i s stretched
evenl y over the pad before securi ng the cl i ps.
a Repl ace the rel eased cl i ps wi th new ones.
UPHOLSTERY RING PLIERS
{Commerci al l v avai l abl e)
a \
------)
t"
I FEF4+#
R-U
U
m
'J)
,.ofl
r_r
olJr
2Dl3Dl
COVER
Front Seat Belt
Replacement
CAUTION: Check the front seat belts for damage, and
repl ace them i t necessary. Be carol ul not to damage
them during removal and installation.
Front seat belt removal
(4Dl:
1 . Sl i de the front seat forward ful l y.
Remove the center
pi l l ar l ower tri m
panel (see page
20-59).
Remove the upper anchor cover and l ower anchor
cap.
SHOULDER
ANCHOR
UPPER ANCHOR BOLT
7/ 16-20 UNF
32 N.m
(3.3
kgit m,
24 lbf.ft)
2.
3.
FRONT SEAT
BELT
RETRACTOR
RETRACTOR
MOUNTING BOLT
6 x 1 . 0 mm
9. 8Nm( 1. 0kgf . m.
7.2 tbf.ftl
ER ANCHOR
Remove al l t he anchor bol t s and t he ret ract or bol t ,
remove t he ret ract or mount i ng bol t , t hen remove
t he f ront seat bel t and ret ract or.
1
I
I
LOW
CAP
7/ 1&20 UNF
32 N.m
(3.3
kgl.m.
24 rbl.ftl
7/ 16-20 UNF
32 N.m {3.3 kgf.m,24lbf.ft}
6.
8 x 1. 25 mm
23 N.m {2.3
kgt'm,
17 tbf.ft)
ANCHOR
ADJUSTER
7. Instal l ati on i s the reverse of the removal procedure
NOTE:
. Check that the retractor l ocki ng mechani sm func-
ti ons as descri bed on page 20-91.
. Make sure
you
assembl e the washers and col l ars
on the uDDer and l ower anchor bol ts as shown.
are no twists or kinks in the front seat belt.
Upper anchor boh construciion:
UPPER ANCHOR
BOLT
Remove the center pi l l ar upper tri m
(see page 20-59)
Remove the shoul der anchor adj uster.
UPPER
COLLAR
Appl y l i qui d t hread
(cont' d)
20-85
SUSHING
Front Seat Belt
Replacement
(cont'dl
Lower anchor bolt construction:
SPRING
WASHER
COLLARS BUSHING LOWER
ANCHOB
Retractor bolt construqtion :
TOOTHED
LocK W\HER
)r
t n l
tv-
RETRACTOR
BOLT
I
l l o1r", f f i )
\y
-"\s\,/
I
RETBACTOF
LOWER ANCHOR
WASHEBS
\
20- 86
Front seat belt removal
(2Dl3Dl:
1. Sl j de the front seat forward ful l y.
2. Removel
(see pages
20-80, 81)
. Rear cent er shel f and r ear si de shel f
( 3D.
see
page 20' 60)
. Rear trim panel (3D,
see page 20-60)
. Si de tri m panel (see pages 20' 60,61)
3. Remove the upper anchor cover and l ower anchor cap.
UPPER ANCHOR BOLT
7/ 16-20 UNF
32 N.m
(3.3
kgI.m,
24 tbf.ftl
@<-'-.-.-.- ,PPER aNcHoR
RETRACTOR
MOUNTI NG BOLT
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgt m,
7.2 tbtft)
LOWER ANCHOR BOLT
7/ 16-20 UNF
32 N. m
(3. 3
kgl m, 24l bt f t )
LOWEB
ANCHOR
CAP
I
I
t
o
4. Remove al l the anchor bol ts and the retractor bol t,
remove the retractor mounti ng bol t, then remove the
front seat bel t and retractor.
RETRACTOR BOLT
7/ 16-20 UNF
32 N m 13. 3 kgf m,
24 tbf.ftl
procedure.
NOTE:
ti ons as descri bed on page 20-91.
. Make sure you assembl e the washers and col l ars
on the uoDer and l ower anchor bol ts as shown.
are no twi sts or ki nks i n the front seat bel t.
SPRING
WASHER
SPRI NG
WASHER BUSHING
BUSHI NG
COLLARS
LOCKWASHER ANCHOR
Reiractor bolt construction:
TOOTHEO
LOCK WASHER
WASHERS
LowER
LOWER ANCHOR
BOLT
RETRACTOB
Seat belt buckle removal:
1. Remove t he f r ont seat t hr ough t he door openi ng
{see
page 20-74).
2. Remove the center cover
(see pages 20-75,76).
3. Remove the center anchor bol t, then remove the seat
bel t buckl e.
SEAT BELT
BUCKLE
ANCHOR BOLT
INNER SEAT
TRACK
TOOTHEO
LOCK WASHER
SPRI NG
WASHER
HARNESS 7/16.20 UNF
CLIP 32 N m
(3.3
kgt m, 24 lbf'ft)
4. Dri ver' s: Detach the seat bel t swi tch connector and
harness cl i p from the seat cushi on
(see page 20 77).
Remove the seat cushi on mounti ng bol ts from the
i nner seat track {see
page 20-75), and move the i nner
seat track, then
pul l
the seat bel t swi tch harness out.
NOTE: Take care not to damage the hi nge bracket.
Centsr anchor bolt construction:
CENTER ANCHOR
BOLT
WASHER
Installation is the reverse of the removal
procedure.
NOTE: Make sure
you assembl e the washers and
beari ng on the center anchor bol t as shown.
20-47
Rear Seat Belt
Repl acement
CAUTION: Chack the rear seat bel ts for damage, and
repl ace them i f necessary, 8e carol ul not to damage
lhem during removal and installation.
Rear seat belt removal {2Dl4D}:
1. Remove:
(see pages 20-79, 81)
. Rear seat-back
(2D,
see page 20-81)
. Si de tri m panel (2D,
see
page 20-61)
. Rear shel f
(see pages 20-59,61)
. Rear tri m
panel
{see
page 20-62}
. Trunk si de tri m, Japan-produced
(see page 20-62)
. Trunk tri m panel , USA-produced
(see page 20-62)
2. Remove al l t he anchor bol t s and ret ract or bol t , t hen
remove t he rear seat bel t and ret ract or.
UPPER ANCHOR BOLT
7/ 16-20 UNF
32 N.m
(3.3
kgf.m,2,1 lbtft)
RETNACTOR BOLT
7/ 1F20 UNF
32 N.m {3.3 kgf.m,
24 tbt.ft)
7/ 16-20 UNF
32 N.m {3.3 kgf.m,24lbt.ft)
20-88
RTRACTOB
NOTE:
ti ons as descri bed on
page 20-91.
. l vl ake sure
you assembl e the washers and col l ar
on the upper anchor bol t as shown.
. Before i nstal l i ng the anchor bol t. make sure there
are no twi sts or ki nks i n the rear seat bel t.
Upper anchor boh condruqtion:
SPRI NG
WASHER
LOWER ANCXOR
EOLT
LOWER ANCHOR
Retractor bolt construction:
RETRACTOR
BOLT
t7\ /7--^,
l/rn\ .----. A -nrfi|lH \
tr\7-\
/ \ \
TOOTHED
LOCK WASHER
Rear seal belt removal
(3Dl:
1. Remove:
(see page
20_80)
. Rear center shel f and rear si de shel f
(see page
20_60)
. Rear tri m
panel and si de tri m panel (see page 20
60)
2. Remove the upper anchor cover
UPPER ANCHOR BOLT
7/ 16-20 UNF
32 N.m {3.3 kgf.m,2it lblft)
UPPER
ANCHOR
RETRACTOR
RETRACTOR BOLT
7/ 16-20 UNF
32 N.m 13.3 kgl.m.
24 tbf.ft)
REAR SEAT
BELT
LOWEF
3.
7/ r6-20 UNF
32 N.m {3.3 kgl.m. 24 lbf.ftl
Remove al l the anchor bol ts and retractor bol t. then
remove the rear seat bel t and retractor.
NOTE:
. Check that the retractor l ocki ng mechani sm func
ti ons as descri bed on
page 20-91.
. Make sure
you assembl e the washers and col l ars
on the upper anchor bol t as shown.
. Betore i nstal l i ng the anchor bol t, make sure there
are no twi sts or ki nks i n the rear seat bel t.
Upper snchor boh construction:
COLLARS
LOWER ANCHOR
TOOTHED
LOCK WASHER
(cont ' d)
20-89
Rear Seat Belt
Replacement
(cont'dl
Soai belt buckle/Center bolt tongue removal:
1. Remove the rear seat cushi on
(see pages 20-79' 80,
81) .
Remove the center anchor bol ts, then remove the
seat bel t buckl es and center bel t tongue.
2Dl4Dl
CENTER BELT
BUCKLE
CENTER BELT TONGUE
3D:
CENTER ANCHOR BOLTS
7/ 1$20 UNF
32 N.m
(3.3
kgt.m,
2/r bl.ftl
20-90
CENTEN EELT
Center anchor bolt construction:
TOOTHED
LOCK WASHES
procedure
NOTE: Before attaching the seat-back and seat cush-
i on, make sure there are no twi sts or ki nks i n the cen
ter bel ts.
Seat Belts
Inspection
t .
Retractor InsDection
Before i nstal l i ng the retractor, check that the seat bel t
can be pul l ed out freel y.
Make sure that the seat bel t does not l ock when the
retractor i s l eaned sl owl y up to 15' from the mounted
posi ti on. The seat bel t shoul d l ock when the retractor
i s l eaned over 40' .
CAUTION: Do not attempt to disassemble the retrac-
tor.
Front:
*:
Mount ed Posi t i on
I nsi de
4D:
Forward
2D
l3D.
Rear:
2D l 4Di
* 10-
15 15'
i-Tl
I
],f
ForwaJd l nsi de
7 .
20-91
3D:
ao" 40' - -+
40.
. . ' ' 15' 15'
- -
(.
.-j-
,)
\ ,
RETRACTOR
3. Repl ace the seat bel t wi th a new one i f there i s any
abnor mal i t y.
On-lhe-Car Seat Belt Inspeqtion
2.
3.
1 .
5.
6.
4.
Check that the seat bel t i s not twi sted or caught on
anyrn I ng.
Af t er i nst al l i ng t he anchor s, check f or f r ee move
ment on the anchor bol ts. l f necessary, remove the
anchor bol ts and check that the washers and other
parts are not damaged or i mproperl y i nstal l ed
Check the seat bel ts for damage or di scol orati on.
Cl ean wi t h a shop t owel i l necessar y
CAUTION: Use only soap and water to clean.
NOTE: Di rt bui l d-up i n the metal l oops of the upper
anchors can cause the seat bel ts to retract sl owl y.
Wi pe the i nsi de ot the l oops wi th a cl ean cl oth damF
ened i n i sopropyl al cohol .
Check that the seat bel t does not l ock when pul l ed
out sl owl y. The seat bel t i s desi gned t o l ock onl y
duri ng a sudden stop or i mpact.
Make sure that the seat bel t wi l l retract automati cal l y
when rel eased.
For each passenger' s seat bel t, make sure that the
l ocki ng mechani sm i n t he seat bel t r et r act or wi l l
engage when the seat bel t i s pul l ed al l the way out.
Repl ace the seat bel t wi th a new one i l there i s any
abnormal i ty.
Seat Belts
Child Seat Anchor Plate
Attachment
points are provided for a rear seat mounted
chi l d restrai nt system whi ch uses a top tether. The attach-
ment
poi nts are l ocated on the rear shel f or rear tri m
panel , j ust
behi nd the rear seat-back. When usi ng a chi l d
seat wi th a top tether, i nstal l the chi l d seat anchor pl ates
securely.
2Dl4Di
NOTE; Remove the
pl ug covers from the attachment
poi nts of the rear shel f.
3D:
NOTE: The reartrim
panel has
perforations at each attach-
ment
point. Cut the rear trim
panel along the perforations
to make a hol e.
REAR TRIM
PANEL
PLUG COVERS
REAR SHELF
POINTS
20-92
NOTE:
TOOTHED WASHEB
Do not remove the toothed washer from the chi l d seat
anchor
pl ate. Use the chi l d seat anchor
pl ate wi th the
toothed washer attached to it.
When i nstal l i ng a chi l d seat on the rear seat, fol l ow
the i nstructi ons of the manufacturer of the chi l d seat
Addi ti onal anchor ol ates are avai l abl e.
@
r Do not us6 the child seat anchor
plate for any othel
purposs; it is designed exclusively tor installation of a
child 3eat.
. Make suro the rear seat-back is locked firmly when
installing 8 child seat.
Exterior
Component Locati on Index
NOTE: Refer to the Ci vi c BodV Repai r Manual ,
' 1996
Model Seri es, P/N.6150330,forthe hood, trunk l i d and hatch removal .
2Dl30llDl
LICENSE PLATE
TRIM
TRUNK LID
ROOF MOLOING
Repl acement ,
SIDE WINDOW
MOLDINGS
Repl acement ,
page 20- 102
Repl acement ,
page 20- 100
Adj ust ment , page 20-97
Tol si on Bar Removal ,
page 20-102 20 99
HOOD
Adiustment,
page 20 96
Hood Edge
protector
Repl acement ,
page 20 99
TRUNK LID
WEATHERSTRIP
Repl acement,
page 20-100
REAR BUMPER
Repl acement ,
page
2O-95
SILL PANEL
Repl acement , page 20 105
REAR AIR OUTLET
Repl acement ,
page 20-106
FUEL PIPE
PROTEfiOR
Repl acement ,
page 20-106
FENDERWELL TRIM
Repl acement ,
page 20- 106
3D:
HATCH
HATCH
Adj ust ment ,
page 20-98
WEATHERSTRIP
20-93
Front Bumper
Replacement
CAUTION: Put on glov$ to
protect your hands.
NOTE:
. An assi stant i s hel pful when removi ng the front bumper.
. Take care not to scratch the front bumDer and bodv.
FRONT BUMPER
SIDE SNFFENER
l nstal l ati on i s the reverse of the removal orocedure.
NOTE:
. Make sure the front bumper engages the front
bumper si de sti ffener on each si de securel y.
. lf necessary, adjust the front bumper side stiffener
to obtai n the proper gap.
>:
golt,
screw locations
a > , 2 B> , 2
>: Cl i p
locations, 7
i A e r r : o r e . A l m
L.'* fl'T;Ll'
o'n' -'
\5>_
JI
c > , 4
, D > , 4
| -.6a
8 x
't.25
mm
l,Rt o x 1.0 mm
l(Dl[m
22N.n'.t2.2kstnf'.
j(Qll@
s.e N.m rr.o rsf.m,
t'KJ)
16 tbf.ft, |.
-ll
7.2 tbf.hJ
ABSORBER
FRONT EUMPER
BEAM
FRONT BUMPER
SIDE STIFFENER
FRONT BUMPER BEAM
:l
I
i r
\
20-94
Rear Bumper
Repl acement
CAUTION: Put on gloveslo protect your hands.
NOTE:
. An assi stant i s hel pful when removi ng the rear bumper.
. Take care not to scratch the rear bumper and body.
. 2D and 4D shown here;3D removal procedures are the same as 4D.
>: Screw, boll locations
A > , 2 B > , 4
Instal l ati on i s the reverse of the removal Drocedure.
NOTE:
. Make sure the rear bumper engages the si de cl i p on each si de securel y.
n ,/_-\
E
rt
. -*E]s-
.A IVilIdfIT*ff
\r*,r/ \
\7
REAR BUMPER BEAM
REAR BUMPER
20-95
Hood
Adjustment
NOTE: Before adj usti ng the hood, l oosen each bol t sl i ghtl y.
1. Adj ust the hood hi nges ri ght and l eft, as wel l as fore and aft, by usi ng the el ongated hol es.
2. Turn the hood edge cushi ons, as necessary. to make the hood fi t fl ush wi th the body at front and si de edges.
3, Adj ust the hood l atch to obtai n the proper hei ght at the forward edge.
4. After adj ustment, ti ghten each bol t securel y.
6 x 1 . 0 mm
9.8 N.m
{1.0 kgt.m,
7.2 tbt.tll
NOTE: Move the hood l atch ri ght or l eft
i s centered i n the hood l atch as shown.
)
unti l the stri ker
6 x 1 . 0 mm
9.8 N.m {1.0 kgf.m,
7.2 tbf.ftl
\
20- 96
Trunk Li d
Adjustment
NOTE; Before adj usti ng the trunk l i d, l oosen each bol t sl i ghtl y.
1. Adj ust the trunk l i d hi nges ri ght and l eft, as wel l as fore and aft, by usi ng the el ongated hol es'
2. Turn the trunk l i d edge cushi ons, as necessary, to make the trunk l i d fi t fl ush wi th the body at the rear and si de edges.
3. Adi ust the fi t between the trunk l i d and the trunk l i d openi ng by movi ng the stri ker'
4. After adj ustment, ti ghten each bol t securel y
TRUNK LIO EDGE
CUSHION
TRUNK LID
NOTE: Take care not
t o hi t t he rear wi ndow
when l ooseni ng t he
bol t s.
NOTE: Move the stri ker ri ght or l eft unti l i t' s centered i n
the trunk l i d l atch as shown.
TRUNK LI O
9. 8 N. m {1. 0 kgf . m,
7 .2lbl.ltl
STRIKER
20-97
Hatch
Adjustment
NOTE:
. Before adj usti ng the hatch, l oosen each bol t and nut sl i ghtl y.
a The suDport struts shoul d be removed.
. To adj ust, remove both hatch si detri m
(see page 20-63) and the rear roof tri m
(see page 20-65).
1. Adj ust the hatch hi nges ri ght and l eft, as wel l as fore and aft. by usi ng the el ongated hol es
2. Turn the hatch edge cushi ons, as necessary, to make the hatch fi t fl ush wi th the body at each si de.
3. Adj ust the hatch fi t to the hatch openi ng by movi ng the stri ker.
4. After adi ustment, ti ghten each bol t and nut securel y.
6 x 1 . 0 m m
9. 8 N. m
( 1. 0
kgf . m,
HATCH
EDGE CUSHI ON
HATCH
HI NGE
Rearward
HA
EDGE
CUSHION
j ...
22
\ \,_1q
N.m
(2.2
kgf.m,
tbf.ftl
\
co
3 8 Nm( 3 . 9 k g f m,
2.8 rbf.ft)
NOTE: Move the stri ker ri ght or l eft unti l i t' s centered i n
the hatch l atch. as shown.
HATCH
HI NGE
STRIKER
l 0 x 1
VER
HATCH
EDGE
CUSHION
9. 8 N. m 11. 0 kst . m,
7.2 tbf.ft) HATCH
LATCH
20- 98
6 x 1 . 0 m m
Front Gri l l e/Hood
Edge
Protector
Trunk Li d Torsi on
Bars
Replacement
Front
grille:
NOTE: Take care not to scratch the front bumper'
Remove the front bumper
(see page 20-94) Bemove the
cl i ps and screws, then sl i de the front gri l l e forward by
detachi ng the hooks.
" q L
A
\t+lt
/
Hood edge
Ploteetor:
NOTE:
. When removi ng the cl i ps, use a cl l p remover.
>:Cl i p l ocati ons, 18
FRONT BUMPER
HOOD EDGE
/A.-
-----,_
,,, \-
' -l
o[ _]
20-99
Removal
CAUTION: Pui on gloves to protect your hands.
NOTE: Take care not to damage the body
Remove the torsi on bars wi th the torsi on bar assembl y
t ool whi l e hol di ng t he t r unk l i d as shown.
CENTER CLIP
E
procedure'
NOTE:
. Adj ust the torsi on bars fore or aft wi th the
si on bar assembl Y tool as shown
l l = Normal
Posrt l on
a
= Hi gher t ensron
. Make sure t he t runk l i d opens
properl y.
tor-
Trunk Li d/Hatch
Weatherstrip License Plate Trim
Replacement
When i nstal l i ng the trunk l i d/hatch weatherstri p. al i gn i t
wi th the al i gnment mark on the trunk l i d/hatch openi ng.
NOTE:
. Make sure there are no wri nkl es i n the weatherstri p.
. Check for water l eaks.
2DllDi
STEEI.
CORE
3D:
ALIGNMENT
MARK
(2Dl4D)
ALIGNMENT MARK
WEATHERSTRIP
ALIGNMENT MARK
BODY
\
20- 100
Replacement
CAUTION: Put on glovs to plotest your hands.
NOTE: Take care not to scratch the trunk l i d/hatch.
1. Remove the l i cense pl ate.
2, 3D: Remove the hatch tri m panel (see page 20-63).
3. Remove the nuts and cl i ps, and detach the cl i p, then
remove the l i cense pl ate
tri m.
NOTE: Take care not to drop the nuts i nsi de the trunk
l i d/hatch.
a: Nut l ocat i ons, 2
6f i \ 5x0. 8mm I
rvr?// 1,8 N.m {0.18 kst.m,l
-
j llrftl
,/
>: Cl i p l ocat i ons,
I
n A
aa# )
- , /
NOTE: l f necessary, repl ace any damaged cl i ps.
Hatch Spoi l er
Removal
NOTE: Take care not to scratch the hatch and body
1. Remove the hatch upper tri m
(see page 20-63)
2. Remove the nuts, and detach the cl i p, then l i ft the
hatch spoi l er uP.
a: Nut locations, 4
1 2lbt.ftl
_
j/
GROMMET
HI GH MOUNT BRAKE
LI GHT CONNECTOR
Di sconnect t he hi gh mount brake l i ght connect or and
r ear wi ndow washer t ube, t hen r emove t he hat ch
spoi l er.
------,*;)
4. l f necessary. remove the spoi l er tri m from the spoi l er
frame.
NOTE: The hatch spoi l er tri m for Canada
produced
cars cannot be di sassembl ed.
A > , 4
>: Scrw
procedure'
NOTEi
a Make sur e t he connect or and washer t ube ar e
connected ProPerl Y.
20-101
Si de Wi ndow Mol di ngs Roof Mol di ng
Replacement
CAUTION: Put on
glovos
to protect your hands.
NOTE:
. Take care not to scratch the body
. Remove the screw, and pul l th si de wi ndow mol di ng
by hand.
A> , 1 3
1 l
)
A
>: Screw locations,
*@
MOLOING
\
20-102
Replacement
CAUTION: When prying
with a flat-tip screwdriver, wrap
it with protestive
taps to prevent damage, and use pro-
toctiv tape on the body.
NOTE: Take care not to scratch the bodv.
WI NDSHI ELO
MOLDING
NOTE:
. Take care not to damage the wi ndshi el d mol di ng.
. Make sure the roof mol di ng i s i nstal l ed securel y.
K
PIN
l Body si de)
I
)
Door and Si de Mol di ngs
Replacement
CAUTION: When
prying with a flat-tip scr6wdrivgr, wrap it with
protective tape to prevent damags'
NOTE;
. To remove the front si de mol di ng, remove the i nner fender
(see page 20-106)'
. To remove the door moi di ng, remove the door panel
(see pages 20-4, 10, 16) and
pl asti c cover.
. To removethe rearsi de mol di ng, remove the si de tri m
panel (see pages 20-60,611'
. Take care not to bend the door mol di ngs.
. Before reassembl i ng, cl ean the door bondi ng surface wi th a sponge dampened i n al cohol '
. After cl eani ng, keep oi l , grease and water from
getti ng on the surface'
4D:
FRONT DOOR Adhesi ve areas.
2Dl3Dl
B > , 3
c > , 2
REAR SIDE
MOLOING
a: Plastic nut loction. 1
@)
(cont' dl
20- 103
MOLDING
A >: 4D, 11
2')13D,7
Door and Si de Mol di ngs
Replacement
(cont'dl
Door molding removal:
The fol l owi ng materi al s and tool s are requi red to repai r
the door mol di ngs.
NOTE: Fol l owthe manufacturer' s i nstructi ons.
Materi al s:
(Reference)
.
Stri pe remover
3M 08907
Stri pe adhesi ve remover
3M 08908
Adhesi ve tape
3M Super Automoti ve Attachment Tape
Tool s;
a Protecti ve tape
. Kni fe or Cutter
. Sponge or Shop towel
. Infrared dryer
. Fi l m
. Putty knife
. Al cohol
CAUTION: Put on gloves
to protect your hands,
Remove the door panel ,
and pul l
back the pl asti c
cover,
Appl y protecti ve
tape on and around the mol di ng.
3. Rel ease the cl i ps from i nsi de of the door. Careful l v
cut the adhesi ve tape wi th a kni fe or cutter whi l e
pul l i ng
the edge of the mol di ng away trom the door
as shown.
NOTE: Take care not to scratch or bend the mol d-
I ng.
1 .
KNI FE
DOOR MOLDI NG
\
20-104
Door molding installation:
1. Gl ue t he new adhesi ve t ape t o t he mol di ngs as
snown.
[\\\\\\l
: Adhesive tape tocations
60 mm
4D: t2 t i^l
40 mm
11. 6 i n)
Forward
L
REAR DOOR
2Dl3Dl
CLI P
HOLDER
100 mm
(3. 94
i nl
1, 050 mm 141. 34 i nl
Forward
!
DOOR MOLDING
DOOR MOLDING
5 mm {0. 2 i nl
ADHESIVE TAPE
Thickness: 1.2 mm 10.05 in)
I nst al l t he cl i ps on t he mol di ng.
Heat t he bondi ng sur f ace of t he door and door
mol di ng wi th an i nfrared dryer.
Door: 104
-
140"F (40 -
60.C)
Mol di ng: 68
-
86"F
(20 -
30.C)
NOTE: Use care when heati ng to prevent deforma-
ti on of the mol di ng.
Al i gn the mol di ng wi th the cl i p l ocati ons, and set
the mol di ng. Li ghtl y push
on the mol di ng unti l i ts
edge i s ful l y seated on the adhesi ve tape.
NOTE: Do not spray water on the motdi ng wi thi n
the fi rst 24 hours after i nstal l ati on.
Reassembl e al l removed pans.
Si de Si l l Panel
Replacement
NOTE:
. Take care not to scratch the body
. 4D shown here;2D and 3D removal
procedure i s the same as 4D'
W_1
NOTE: Loosen t he screw,
t hen remove t he l ower cl i P
usi ng a cl i p remover.
Remove t he si de cl i Ps f rom t he body
by t urni ng t hem 45"
To i nstal l the si de si l l panel , remove the si de cl i ps from the body.
panel on the car.
NOTE:
. Take care not to twi st the si de si l l panel .
. l f necessary, repl ace any damaged si de and l owercl i ps'
NOTEr When removi ng t he si de
si l l
panel , t he si de cl i ps wi l l
st ay i n t he body.
SIOE SILL PANEL
Remove t he l ower cl i Ps,
t hen remove t he si de si l l
Panel
by sliding it forward.
i nstal l them on the si de si l l
panel , then i nstal l the si de si l l
SIDE CLIP
\
20- 105
Inner Fender, Fenderwell rrim, Fuel Pipe
protector
and Rear
Air Outlet
Repl acement
Inner tender:
r\
tllpo" l
: , /
Fenderwell trim/Fuel pipe protector/Rea.
air outlet:
NOTE:
. Take care not to bend the fenderwel l tri m.
. Before l nstal l i ng the fenderwel l tri m, cl ean the body
bondi ng sur f ace wi t h a sponge dampened i n al cohol .
. After cl eani ng, keep oi l , grease
or water from getti ng on
the surface.
. To remove the fuel pipe protector, first remove the rear
wheel (see
secti on 18).
. To remove the rear ai r outl et, fi rst remove the rear
bumper
(see page 20 95).
STEEL FENDERWELL
>: Clip locations
A > , 4
B > , 4
l;1A
!--l1!
c > , 2
I
t Ah
'frv
\:
+
\-
20-106
Opener
Cabl e/Opener
and Latch/Wi per
and Washer
Component
Locati on Index
2Dt3DItD'
y"Tl,"nll,ib?*'r.*
o*t"
Repl acement , Page
20_1 13
Adi ust ment , Page
20' 1 17
WINDSHIELD
WASHER NOZZLES
Adj ust ment , Page
20_1 17
HOOD LATCH
{see
page 20-110)
REAR WINDOW WIPER
ARM and MOTOR
Repl acement , Page
20-1 15
Adj ust ment ,
page 20 117
LOCK CYLINDER
(see page 20 113)
LOCK CYLINDER
TRUNK LIO LATCH
{ see
page 20 112)
FUEL LI D OPENER
CABLE
(see page 20-108i
LID OPENER
CABLE
(see page 20 108)
LI D/ FUEL
LID OPENER
( see page 20 111)
RELEASE HANDLE
(see page 20-110)
3D:
REAR WINDOW
WASHER NOZZLE
Adi ustment,
page 20-1 17
REAR WINDOW
WASHER TUBE
(see page 20-116)
HATCH OPENER
CABLE
(see page 20 110)
WASHER RESERVOIR
Repl acement , Page
20-1 15
HATCH/
FUEL LI D OPENER
(see page 20 1' 11)
FUEL LI D OPENER
CABLE
(see page 20 110)
( s ee page 20 111)
20-107
Opener Cables
Replacement
NOTE:
t When removi ng the cl i ps. use a cl i p remover.
. Take care not to bend the opener cabl es.
Hood opne. cable:
NOTE; Remove the front bumper
(see
page 20-94) and
i nner fender
(see page
20-106).
>: Clip loc.tions
A > , 5 B>, 1
ry)
g
HOOD REI.TASE
HANDI.I
(see page
20-110)
cabl e through the
hote i n th6 body.
NOTE:
a Make sure the hood opener cabl e i s routed and
connected properly.
. Make sure the hood opens properl y.
20-10a
Tlunk lid/Fuel lid opener cabte
(2Dl4D):
NOTE: Remove the fol l owi ng parts
from rhe Ieft si de of
the vehi cl e, then pul l the carpet back, as necessary
{see
page 20-66).
(see pages
20-79, 81)
. Rear seat si de bol ster
(4D,
see page 20,79)
. Rear seat-back
(2D,
see page
20-81)
. Center pi l l ar l ower tri m panel (4D,
seepage20-59)
o Lower anchor bol t from the front seat bel t {2D. see
page
20-86)
. Si de tri m
(see pages
20-59, 61)
.
Seat si de tri m
(4D,
see page 20-59)
.
Si de tri m panel (2D,
see page
20-61)
. Trunk mat and spare ti re l i d
. Reartri m panel (see page
20-62)
. Trunk si de tri m, Japan-produced
(see page
20-62)
. Trunk tri m panel , USA-produced (see page 20-62)
>r Clip, cable cushion locations
A >, 4
B >, 4D_ 1 c >, 1 l 4D)
2D,2
t @
# l B
_ : _/ _-___)
E >, 4D, 1
2D, 2
@ i
_ _,, -/
D > , 3
TRUNK LID LATCH
(see page 20' 112)
?e-=....-
4D:
To t runk l i d
l at ch.
l at ch.
TRUNK LID/FUEL
LID OPENER
( see page 20 111)
TRUNK LI D
OPENER CABLE
a
A
'--!
\ -
-
- l
N"La
FUEL LID
OPENR CAELE
TRUNK LI D/ FUEL
LID OPENER
(see page 20-111)
FUEL
LATCH
(cont' d)
20- 109
( see page 20' 112)
Opener Cabl es
Opener and Latch
Repl acement
(cont' dl
Hatch/Fuel lid opener cable l3Dl:
NOTE: Remove the fol l owi ng parts,
then pul l
the carpet
back as necessary
(see
page 20-66).
. Rear seat cushi on and rear seat back
(see page 20-80)
. Lower anchor bol t from the front seat bel t
(see page
20 86)
. Si de tri m {see
page
20-60)
.
Spare ti re l i d
. Rear center shel f and rear si de shel f
{see
page
20-60)
. Rear tri m panel (see page 20-60)
. Si de tri m panel (see page 20,60)
>: Clip, cable cushion locations
a > . 9 B> , 1 c>, 1 D > , 5
W#)
FUEL LID LATCH
#,
Rout e t he opener
cabl e t hrough t he
hol e i n t he body.
HATCH/FUEL LIO
OPENER
NOTE:
. Make sure each opener cabl e i s routed and con-
nected properly.
. Make sure the hatch and fuel l i d open properl y.
page 20-112)
20-110
6 x 1 . 0 mm j
9 . 8 Nm
{1. 0 kgf . m,
i
Repl acement
NOTE: Take care not to bend the opener cabl es.
Hood release handle:
NOTE: Remove the ki ck panel (see pages 20-59, 60.61).
>: Bolt locations, 2
]
I
HOOO OPENER
CABLE
(see page
20-108)
Hood latch:
NOTE: Remove the front bumper
(see page
20-94).
I
6 x
' 1.0
mm
9. 8 N. m
11. 0 kgf . m,
NOTE:
. Make sure the opener cabl e i s connected properl y.
. Make sur e t he hood opens pr oper l y and l ocks
securel y.
Trunk l i d or Hatch/Fuel l i d opener:
NOTE: Remove t he si de t r i m
( see pages 20 59, 60. 61)
>: Bol l l ocat i ons, 2
OPENER LOCK
6 x l . 0 mm
9 . 8 Nm
11. 0 kgf . m,
7.2 tbl.ttl
a@-\
CYLINDER
Ya//t2't4Dl
ti
TBUNK LID/HATCH
OPENER CABLE
(see 20- 108, 110)
To t runk l i d l at ch
or st ri ker.
To f uel l i d l at ch.
\
FUEL LI D
OPENER CABLE
(see pages 20-108,
' 110)
Instal l ati on i s the reverse of the removal procedure
NOTE:
. l vake sure the opener cabl e i s connected
properl y.
. Make sur e t he t r unk l i d or hat ch and f uel l i d open
properl y.
l:'.j
Stri ker
(3Dl :
NOTE: Remove the rear tri m
panel (see page 20-60)
>: Bolt locations, 2
6 x l . 0 mm
HATCH
OPENER CAELE
(see page 20-110)
l nst al l at i on i s t he reverse of t he removal
procedure.
NOTE:
. N4ake sure each
erl Y.
. Make sur e t he
securel Y.
opener cabl e i s connected
ProP-
hatch opens
properl y and l ocks
(cont' d)
20- 111
Opener and Latch
Replacement (cont'd)
Fuel lid latch:
NOTE: Remove the fol l owi ng pa(s.
2D
l 4Dl
. Rear tri m panel (see page
20-62J
. Rear edge of the trunk si de tri m or trunk tri m panel
(l eft
si de, see page
20-62)
3D:
.
Access panel on the si de tri m panel
FUEL I-IO LATCH
I
I
FUEL LID OPENER
CABLE
(see pages
20, 108, 1' 10)
FUEL LID LATCH
Remove t he f uel l i d l at ch
by t urni ng i t 90o
NOTE;
o Make sure each opener cabl e i s connected
elty
. Make sure the fuel l i d opens properl y
and
securel y.
prop-
l ocks
|
r ' - \ 6 x 1 0 mm
9. 8 N. m
(1. 0
kgf . m,
I
FUEL LI D
Af t er i nst al l i ng check f or
a f l ush f i t wi t h t he body.
\
20- 112
Trunk lid latch/Lock cylinder:
>: Bolt locations
A > , 3
6 x 1 . o mm
i
9.8 N.m (1.0
kgf.m,
:::^ _=)
TRUNK LID
OPENER
CONNECTOR
Disconnect.
-\
TRUNK LID
OPENER
CABLE
8 > , 1
f f
e r t . omm
I
ZS
9. 8 N. l n (1. 0
kgt m,
.ty
7.2-tbr.ftt
,/
CYLINOER
TRUNK LID
LATCH
CYLINDER
ROD
NOTE:
. Grease the trunk l i d l atch.
. Make sure the trunk l i d opens properl y
and l ocks
securel y.
a Make sur e t he connect or and cyl i nder r od ar e
connected property.
Windshield
Wiper Arms
and Li nkage
Hatch latch/Lock cylinder:
NOTE: Remove the hatch tri m panel
(see page 20-63).
>: Bolt locations
A > , 3
6 x 1 . 0 mm I
9.8 N.m i 1.0
ksf m,l
1.2lbl.trl
/
B > , 1
E
6
'cr
CYLINDER
6;:il;l,lr'.",
. r \
LOCK
-
r\ cYLTNDER
L^ \
! . /
rAs<.L ,/
\faa"El
r l
procedure.
NOTE:
. Grease the hatch l atch.
. Make sure the hatch opens
properl y and l ocks
securel y.
. Make sure the cyl i nder rod i s connected
properl y.
Replacement
CAUTION: Pul on gloves to protect your hands
NOTE: Take care not to scratch the hood and body.
1. Remove the wi ndshi el d wi per arms, then remove
the hood seal and cowl cover.
>: Clip locations
A > , 9 B > , 9
WI NOSHI ELD
WIPER ABMS
\ j : _
Hw
u
cowl covER
Di sconnect the connector, then
shi el d wi per l i nkage assembl Y.
Japan/Canada-produced:
remove the wi nd-
10 x 1. 25 mm
18 N. m l l . 8 kgf m,
(cont' d)
20-113
Wi ndshi el d Wi per Arms and Li nkage
Repl acement
(cont' dl
USA-produced:
3. Separ at e t he wi ndshi el d wi per l i nkage and wi nd-
shi el d wi per motor.
Japan/Canada-produced:
NOTE: Scr i be a l i ne acr oss t he l i nk and wi ndshi el d
wi per l i nkage to show the ori gi nal adj ustment.
O
6 r 1 . 0 m m
EF
8 N. m {0. 8 kst m, i
g
5.8 tbf.ft)
)
NUT
10 x 1. 25 mm
l 8 N rn (1. 8
kgt m,
13 tbtftl
>r Bol t l ocat i ons, 3
WI PER LI NKAG
\
20- 114
USA-produced:
NOTE: Scri be a l i ne across the l i nk and wi ndshi el d
wi per motor to show the ori gi nal adj ustment.
R
6J( 1. 0 mm
Y
8 N. m t o. s kgt m, I
.E- 7Y.nt )
NUT
10 x 1. 25 mm
' 18
N. m {1. 8 kgf . m.
13 tbtft)
WI NDSHI ELD
WIPER MOTOR
NOTE:
. Make sure the connector i s connected properl y.
. l nst al l t he wi ndshi el d wi per ar ms as descr i bed
on page 20- 1' 17.
.
Check the wi ndshi el d wi per motor operati on.
. Grease the movi ng parts.
Rear Window Wiper
Arm and Motor
Washer Reservoir
Repl acement
' t .
2.
Remove the hatch tri m panel (see page 20 63).
Remove t he r ear wi ndow wi per ar m and wi per
motor as shown.
procedure
NOTE:
. Make sure the connector i s connected
properl y
.Instal l the rear wi ndow wi per arm as descri bed on
page 20- 117.
. Check the rear wi ndow wi per motor operati on.
. Grease the movi ng parts.
3.
NUT
6 x 1 . 0 mm
9. 8 N. m 11. 0 kgf . m,
7.2 tbf.ft)
WIPER MOTOR
L
2.
Repl acement
(see page 20-94).
Di sconnect the connectors and washer tubes from
the washer motors.
/ ) ^ 6 x t . o mm
Ql(S)
s.e ru.- tt.o ret '".
\./ 7 .2 tbf.ft)
/
Rout e t he washer t ubes
10 t he washe. r eser voi r
wtNDow
WASHER MOTOR
(3D,
f or some model s)
Remove the bol ts, then remove the washer reser-
voi r.
procedure.
NOTE:
a Make sur e t he washer mot or connect or s and
washer tubes are connected
properl y.
. Check the washer motor operati on.
3.
4.
20-1 1 5
Washer Tube
Repl acement
NOTE:
. To remove the wi ndshi el d washer tube, remove the
l eft i nner fender
(see
page 20-106),
. To remove the rear wi ndow washer tube {3D), remove
the fol l owi ng parts from the l eft si de of the vehi cl e.
-
Inner fender
(see page 20-106)
-
Ki ck panel and si de tri m
(see page 20-60)
-
Rear seat-back and rear seat cushi on
(see page 20-
80)
-
Spare ti re l i d
-
(see page 20-
60)
-
Rear tri m panel and si de tri m panel
60)
Ouarter tri m panel (see page 20-60)
-
Rear roof tri m {see
page 20-65)
-
Hatch spoi l er
(see page 20-101)
(see page 20
WIRE
HARNESS
>: W.sher nozzle, clip and cushion locations
a > , 2 B > , 3
"J>)
[q @"
F> , 1 1
c > , 1
wttrtosnteLo 6}
usxea
=-d
lNozzrE
cv
i q
! $ e
D> , 1 E> , 1
NtW)
Root e t he washer t ube
under t he wi re harness.
TUBE
A
to the washer reservoir
REAB WINDOW
WASHER TUBE
( I or
some model s)
REAR WINDOW
WASHER TUBE
washer nozzl e.
washer nozzl e
(see page 20-101).
oo\
Installation is the reverse of the removal procedure.
NOTE:
. Take care not to pi nch the washer tubes.
. After i nstal l i ng, adj ust the ai m of the washer noz-
zl es
(see page 20-117).
20- 116
WINDSHIELD
\ , - -
Wiper Arms/Washer Nozzles
Adjustment
Windshield wiper/Washer:
1. Adj ust the wi per arms so that thei r
park posi ti ons
match the i l l ustrati on.
View trom tront to rear
WINDSHIELD
WIPER ARMS
2. By i nser t i ng a t ack and movi ng i t as necessar y,
adj ust the washer nozzl es so that they ai m at
posi -
ti ons A, A' , B, and B' shown i n the i l l ustrati on.
NOTE: The fi ui d
j ets
shoul d hi t wi thi n a 50 mm
(2
0
i n.) radi us around each of poi nts A, A' , B, and B' .
.// \
A'
x . .
-.4
, ' l
x i
A
x
\
Di stance
M;r.";-lll
f rom cent er
l r ne
f rom bl ack
ceramrc eoge
A and A' 400 mm
(15.7
i n.) 255 mm
(10.0
i n.)
B and B' 115 mm
( 4. 5
i n. ) 322 mm \12.7
i n.)
Rear Window wiper/Washer
(3Dl:
1. Adj ust the rear wi ndow wi per arm so that i ts park
posi ti on matches the i l l ustrati on.
View trom raar to front
CERAMIC
EDGE
By i nser t i ng a t ack and movi ng i t as necessar y,
adj ust the washer nozzl e so that i t ai ms at posi ti on
C as shown i n the i l l ustrati on.
NOTE: The fl ui d
j et
shoul d hi t wi thi n a 50 mm
(2.0
i n,) radi us around
poi nt C.
REAR WINOOW
WIPER ARM
r-
---..J_.__11,:l
20-117
Embl ems
Instal l ati on
Appl y the embl ems where shown.
NOTE:
. Before appl yi ng, cl ean the body surface wi th a sponge dampened i n al cohol .
. After cl eani ng, keep oi l , grease and water from getti ng on the surface.
Aftachment Points
(Reterence):
CIVIC EMBLEM
Uni t : mm
( i n. )
CIVIC emblem
TFUNK LID
CIVIC emblem
TRUNK LID
Vorsion emblem Version emblem Version emblsm
20- 114
Sub-frame
Sub-frame Torque Sequence:
CAUTION: After loosning the sub-frame mounting bolts, be sure to replace them with new ones.
BOLTS
10 x 1. 25 mm
38Nm{ 3. 9kg{ . m:
14 x 1. 5 mm
90 N m
(9. 1
ks{ m,
66 rbf.ft)
Repl ace.
28 tbf.ft)
20-119
Frame Repai r Chart
Uni t : mm
( i n. )
o: I nner di amet er
CVT:
DETAI L AREA. Y
( 5. 121
177 {6. 971
20-120
I t : 3D
SECTION AA
012 {0. 47) Upper Arm
@20 {0.8) Locat. Hole
Lower Arm Cent er
Damoer Lower Bush Center
20-121
Body
(' 97
model )
Front Seat Belt
Removal /l nstal l atl on
....20-128
Rear Seat
....20-126
Washer Tube
Wi ndshi el d
fndex ..........
20-124
Outline of
' 97
Model Changes
The mol di ng si de seal was added.
The met hod of i nst al l i ng t he rear seat cushi on was changed
(2Dl 3D).
A mi ddl e f l oor gusset was added and t he met hod of det achi ng t he seat bel t ret ract or was changed
(2Dl 3D)
The i nst al l at i on
posi t i on of t he washer t ube was changed.
Wi ndshi el d
l ndex
NOTE: The numbers after the part names show the quanti ti es of the parts used.
wlNDSHIELD
MOLDING
UPPER RUBBER
DAM
FASTENER, 2
(Self-adhesive-type, glass side)
FASTENER, 2
{Clip-type, body sido)
WINDSHIELD
20-124
L-
..-
Mol di ng Si de Seal
l nstal l ati on
Gl ue t he mol di ng si de seal t o t he wi ndshi el d mol di ng on
each si de.
20-125
Rear Seat
3D:
>: Bolt locations
a > , 6
i_): Hook locations
4 i . , , 2
c > , 1
B t - ; , 1
T=ttJX,.)
MIOOLE FLOOR
CENTER GUSSET
6 x 1 . Omm
9. 8 N. m {1. 0
7.2 tbt.trl
STRIKER
Remove the side trim
panel (see page 20 60).
.2 tb,f.ft)
--::......... VV
STNIKER
l @n
I F F
( E E
\ q t
; * . . . 1 PIVOT
BRACKET
SEAT CUSHION
HOOK
A
c
Pivot boft con3truction:
TOOTXED
LOCK
WASHER
SEAT.BACK
A
Instai l ati on i s the reverse of the removal procedure.
NOTE:
. Before attachi ng the seat-back and seat cushi on, make sure there are
center bel t.
. When i nstal l i ng the seat cushi on, sl i p the seat bel t buckl es through the
. l f necessary, adj ust the stri ker and seat-back.
20-126
PIVOT BOLT
BRACKET
8 x 1. 25 mm
22 N.m 12,2 kgf,m, 16 lbl.ftl
no t wi st s or ki nks i n t he rear seat bel t s and
sl i t s i n t he seat cushi on.
i
I
*nt.]
j
6 x 1 . 0 mm
9. 8 N. m {1. 0
B>, ' t
I
-@e
' t . o. -
|
S=222
N.m 12.2 kg{.m,I
g 16 tbf.ft)
j
: , /
I
I
I
fgf..,i
l
)
l- --
, -.
): Hook l ocat i ons
^( : ) . z B( ) '
t
2D:
>: Bolt locations
A > , 6
c > , 1 B > . 1
6 l e
9rJ*'Ll-",-, i V
H 16 rbr'frl )
g
, / v
6 x 1 . o mm
i
9.8 N.m 11.0 ksf.m,l
7.2 rbf.ft)
i
>: Cl i o l ocat i ons, 14
PIVOT BRACKET
V
CENTER
RIGHT SEAT-BACK
LEFT
SEAT-BACK
SEAT CUSHION
procedure.
NOTE:
. Before attachi ng the seat-back and seat cushi on, make sure there are
center bel t.
. When i nstal l i ng the seat cushi on, sl i p the seat bel t buckl es through the
. Make sure the seat-back l ocks securel y
. l f necessary, adj ust the seat-back l atch and seat-back
BUSHING
PIVOT BOLT
BRACKET
8 x 1. 25 mm
22 N.m {2.2 kgf.m, 16 lbIft)
no twi sts or ki nks i n the rear seat bel ts and
sl i ts i n the seat cushi on.
SEAT-AACK MAT
V
V
TOOIHED
LOCK
WASHER
PIVOT BRACKET
20-127
Front Seat Belt
RemovaUlnstallation
2D l3Dl
1. Sl i de the front seat forward ful l y.
2. Remove:
(see pages
20-126,127l.
. Rear cent er shel f and r ear si de shel f
( 3D,
see
page 20-60)
. Resr trim panel (3D,
see page 2G60)
. Side trim panel (see pages 20-60, 61)
3. Pul l back the carpet as necessary, and remove the
bolts, then remove the middle floor gusset.
>: Boh l ocat i ons, 8
10 x 1. 25 mm
38 N.m
(3.9 kgf'm,
28 rbtftl
20-124
4. Remove the upper anchor cover and l ower anchor
cap.
UPPER ANCHOR EOLT
7/ 16-20 UNF
32 N.m {3.3 kgf.m,
24 tbf.ftt
UPPER ANCHOR
COVER
LOWER
ANCHOB
CAP
I
I
i
o
RETRACTOR
MOUNTING BOLT
6 x 1 . 0 mm
9. 8 N. m
(1. 0
kgf . m.
7.2 tbl.hl
LOWER ANCHOR BOLT
7/ 16-20 UNF
32 N.m
(3.3
kgt.m, 24 lbf.ft)
Remove al l the anchor bol ts and the retractor bol t.
remove the retractor mounting bolt, then remove the
Iront seat belt and retractor.
NOTE:
tions as described on page 20-91
o Make suri vou assembl e the washers and col l ars
on the upper and l ower anchor bol ts as shown.
. Before installing the anchor bolts, make sure there
are no twists or kinks in the front seat belt.
RETRACTOR AOLT
7/16-20 UNF
32 N.m 13.3 kgf.m,
24 tbttrl
6.
Washer Tube
Repl acement
NOTE: To remove the wi ndshi el d washer tube,
>: Washar nozzle, clip and cushion locations
a > , 2 B > , 1
remove the l eft i nner fender
(see page 20-106).
c > , 1 D> , ' t E > , 1
F > , 1 G> , 1
n,i#,T<g
l_<.
l_N.j
w)*)
l W) e)
I
9)
ECM/PCM
BRACKET
WIRE
HARNESS
WI NOSHI ELD
TUBE
A
Rout e t he washer t ube
under t he wi re harness
Rout e t he washer t ube
behi nd t he EcM/ PcM bracket .
(cont' d)
RESERVOIR
\ /
to the washer reservolr
under t he wi re harness.
NOTE:
. Take care not to Di nch the washer tubes.
. lf necessary, replace any damaged clips.
. After installing, adjust the aim of the washer nozzles
(see page 20-117l'
c-------.-
REAR WINDOW
WASHER TUBE
20-129
Washer Tube
Replacement
(cont'dl
NOTE: To remove the rear wi ndow washer tube
(3D),
remove the fol l owi ng parts from the l eft si de of the vehi cl e.
-
Inner fender
(see page 20-' 106)
-
Ki ck panel and si de tri m
(see page 20-60)
-
Rear seat-back and rear seat cushi on
(see page 20-80)
-
Spare ti re l i d
-
(see page 20-60)
-
Rear tri m panel and si de tri m panel (see page 20-60)
-
Ouarter tri m
panel (see page 20-60)
-
Rear roof tri m
(see page 20-65)
-
Hatch spoi l er
(see page 20-1011
>: Washer nozzle, clip and cushion locations
A > . 9 B> , 2 C> , 1
I s l
- . . . _,
1
a j \ < j Q i
_ ____/ _>_t _ _/
(see page 20 101).
REAR WINDOW
WASHER TUBE
(for
some model s)
Installation is the reverse ofthe removal procedure.
NOTE:
. Take care not to pi nch the washer tubes.
. lf necessary, replace any damaged clips.
. After i nstal l i ng, adj ustthe ai m ofthe washer nozzl es
(see page2O-1111.
motor.
20- 130
Body
(' 98
model)
Opener and Latch
Hood Latch Cover Replacement
""'.' 20-132
Hatch Handl e Repl acement
..' .' ....' ...' 20-132
Hatch Latch/Lock CYlinder
Repl acement
"...' .."..' .' ...
20-133
Outline of
' 98
Model Changes
.
The hood l at ch cover was added
.
The hat ch handl e was added
(3D)
Opener and Latch
Hood Latch Cover Replacement
NOTE: Take ca.e not to the hood l atch cover and body.
HOOO LATCH COVER
HOOD LATCH
I
20-132
' 1.
Hatch Handl e Repl acement
Remove the hatch tri m panel
{see
page 20-63).
Remove the hatch handl e bol ts,
>: Bolt locations,2
|
6 x 1 , 0 mm
9.8 N.m tl.O kgf.m,
I
7'2tbt':---J)
4. Note the
posi ti on of the
i oi nt
on the handl e rod
(A)'
Prv the handl e rod ol the
j oi nt
usi ng di agonal cut-
t er s; t ake car e not t o bend t he r od Remove t he
hatch handl e.
BUSHING
Repl ace.
l nst al l i n t he r ever se or der of r emoval , and not e
these i tems:
Mak e s ur e
the handl e rod i s connected
properl y
Before i nstal l i ng the hatch tri m
panel , make sure
the hatch opens
ProPerl Y.
@
Hatch Latch/Lock CYlinder
Replacement
1 .
2.
Remove the hatch tri m panel
(see page 20-63)'
Remove the hatch l atch screws
>: Screw locations,3
6 x 1 , 0 mm
9.8 N.m 11.0
kgf'm,
7.2 tbt f0
HATCH
LATCH
Di sconnect the l ock rod, the handl e rod, the l ock
cyl i nder rod. and the connector, then remove the
hatch l atch.
LOCK CYLINDER
ROD
' ' ---t
CONNECTOR
HANDLE
ROD
(cont ' d)
20-133
Opener and Latch
Hatch Latch/Lock Cylinder Replacement
(cont'd)
4. Pul l t he l ock r od out .
l f necessary, remove the l ock cyl i nder.
>: Bolt locelion. 1
6x r . omm
I
9.8 N.m
(1.0
kq
.m,
I
9.8 N.m
(1.0
kq
.m,
I
,:!!_J
6. I nst al l i n t he r ever se or der of r emoval , and not e
these atems:
. Appl y grease
to the hatch l atch.
. Make sure the connector i s connected properl y.
. Before i nstal l i ng the hatch tri m panel ,
make sure
the hatch opens properl y and l ocks securel y.
ry*)*,,
\ ""<, /
.z ,/\
20-134
Body
(' 99
model)
Dashboard
Center Panel Removal and
l nstal l ati on
Bumpers
Front Gri l l e Removal and
lnstallation
Front Ai r Spoi l er Repl acement
."' .....
Seats
Front Seat DisassemblY and
ReassemblY
20-138
Front Seat Torsion Bar
Repl acement
' . ' . . . ". ' . . . . ' . . .
20-139
Embl ems
tnstallation
20-140
20-136
20-136
20-137
Outline of
' 99
Model Changes
The center Danel removal and i nstal l ati on
procedures are di fferent'
The front gri l l e removal and i nstal l ati on
The front ai r spoi l er has been added for some model s of 2D'
A hei ght-adj ustabl e dri ver' s seat was added to some model s'
Embl ems were added for some model s ot 2D'
Dashboard
Bumpers
I
Center Panel Removal and
Installation
1. Remove the dashboard center l ower cover.
2. Remove the screws, then pul l out the center panel .
>: Sc.ew locationi,4 >: Clip locations
A > , 3
B> , 4
r l
@Y,
UPPER VENT I(NOB
Di sconnect the connectors from the heater control
uni t and hazard warni ng swi tch.
NOTE: Make sure the connectors are connected
propefl y.
20-136
FRONT BUMPER
a&
Front Gri l l e Removal and
Installation
NOTE: Take care not to scratch the front bumper.
Remove the front bumper. Remove the screws. then
sl i de the front gri l l e forward by detachi ng the hooks.
>: Scrow locltion3,6
I
dbp
i
Front Ai r SPoi l er RePl acement
CAUTION: Put on
gloves to protect your hands'
NOTE:
. An assi stant i s hel pful when removi ng the front bumper'
. Take care not to scratch the front bumper and body'
>: Bolt, screw localions
A > , 9 B > , 4
s*i
@l
BUMPER
l nstal l ati on
i s the reverse of the removal
procedure'
NOTE:
. Make sure the front bumper engages the front
bumper si de sti ffener on each si de securel y'
o l f necessary. adj ustthe front bumper si de sti ffener
to obtai n the
Proper
gap.
FRONT AIR SPOILER
20-137
Seats
Front Seat Disassembly
and Reassembly
CAUTION: When prying
with a flat-tip screwdriver, wrap it with protective
tape to prevent
damage.
NOTE:
SEAT-BACK
. Take care not to scratch the seat covers and body.
. Remove the front seat through the door openl ng.
Driver's:
SEAT CUSHION
HEADREST
PIVOT NUT
I x 1.25 mm
22 N.m
12.2 kgf,m,
16 tbf.ft)
CENTER COVER
8 x 1. 25 mm
LOWER CAP
RECLINE ADJUSTER
WASHER
20 N.m
12.0 kgf.m,
lil lbtftl
WASHERS
EUSHI NG
10 x 1. 25 mm
47 N.m (4.8
kgf.m,
3s rbl.ft)
INNER SEAT
TRACK
RECLINE
COVER
WASHER
8 x 1. 25 mm
20 N.m (2.0
kg,f.m,
14 tbf.fit
LOWER CAP
I
8 x 1. 25 mm
20 N.m
{2.0 kgI.rn,
l4 tbf.ft)
i\",-,"
20-13A
HEIGHT HANDLE
Reassembl e
i n the reverse order of di sassembl y' and
note these i tems:
. Make sure the bushi ng and
pi vot washer are i nstal l ed
properl y.
. To connect the connecti ng wi re, twi st i t 90' .
. Repl ace the back cover cl i ps wi th new ones
. To prevent wri nkl es when i nstal l i ng the seat-back
cover, make sure the materi al i s stretched evenl y
over the pad.
. Appl y mul ti purpose
grease to the movi ng
porti on of
the seat track.
Front Seat Torsion Bar
Repl acement
NOTE| Take care not to tear the seams or damage the
seat covers.
1. Remove the seat cushl on
2. Remove the torsi on bar from the hook wi th a fl at ti p
screwdri ver,
then
pul l out the torsi on bar from the
seat cushi on frame Put on gl oves to protect your
ha nds.
TORSION
SAR
SEAT CUSHION FNAME
TORSION BAR
SEAT CUSHION
FLAT TIP SCREWDRIVER
3. l nst al l i n t he reverse order of removal '
20- 139
Embl ems
Instal l ati on
Al i gn the appl i cati on tape wi th the tai l l i ght and body, as shown, then press
the embl em i nto pl ace.
Remove the appti cati on
tape.
NOTE:
o Before appl yi ng, cl ean the body surface wi th a sponge dampened i n al cohol .
. After cl eani ng, keep oi l , grease
and water from getti ng
on the surface.
. When appl yi ng, make sure there are no wri nkl es i n the embl em.
Attschment Point:
VERSION EMBLEM
20-140
DOHC VTEC aid omblom:
Vsrsion emblem:
Body
{'00
model}
Seat Belts
Child Seat Anchor Plate Removal/
f nstallation
20-142
Embl em
f nstallation
20-144
Outline of
' 00
Model Changes
The chi l d seat anchor
pl ate removal and i nstal l ati on
An embl em was added for some model of 3D.
Seat Belts
Chi l d Seat Anchor Pl ate Removal /l nstal l ati on
2DllDl
Attachment poi nts are provi ded for a rear-seal -mounted chi l d restrai nt system that uses
poi nts are l ocated on the rear shel f,
tust
behi nd the rear seat-back.
The chi l d seat anchor pl ates
are i nstal l ed i n the mi ddl e and on both si des of the rear shel f.
covered wi th the chi l d seat anchor ol ate cover.
a top tether. The attachment
Each chi l d seat anchor pl ate
i s
NOTE:
' Do not remove the toothed washer from the chi l d seat anchor pl ate,
Use the anchor pl ate
wi th the toothed washer
attached to i t.
. When i nstal l i ng a chi l d seat on the rear seat, fol l ow the i nstructi ons of the manufacturer of the chi l d seat.
. When i nstal l i ng the anchor pl ates,
the one wi th the shoner spacer goes
i n the mi ddl e.
. Make sure the rear seat-backs are l ocked fi rml y when i nstal l i ng a chi l d seat.
Uni t : mm
( i n. )
REAR SHELF
CIIILD SEAT ANCHOR
PLATE COVER
MIDOLE CHILD
SEAT ANCHOR
CHILO SEAT
ANCHOR
PLATE COVER
CHILD SEAT
ANCHOR
PLATE COVER
8 x 1. 25 mm
22 N.m 12.2 kgl m,
PLA
8 x 1. 25 mm
22 N.m
12.2 kgl.m,
I x 1. 25 mm
22 N.m
12.2 kgl.m,
16 tbt.ftt
17 {0. 67)
16 tbf.ft)
15
{0.s9)
WASHER
rl)
.t
TOOTHEO
ll
ff*,".rd,',i"'"o*
SIDE SEAT
I x 1, 25 mm
N.m
{2.2 kgf.m.
16 tbtftl
SIDE
16 tbf ftl
ANCHOR PLATE
SEAT ANCHOR
PLATE
ATTACHMENT POINTS
t orward .
20-142
TOOTHED
12lO.47l
19
(0. 75)
3D:
Attachment
poi nts are provi ded for a rear-seat mounted chi l d restrai nt system that uses a top tether' The attachment
poi nts are l ocated on the rear tri m
panel .
The chi l d seat anchor
pl ates are rnstal l ed i n the mi ddl e and on both si des of the rear tri m
panel Each chi l d seat anchor
pl al e i s cover ed wi t h t he chi l d seat anchor
pl at e cover '
NOTE:
. Do not remove the toothed washer from the chi l d seat anchor
pl ate. use the anchor
pl ate wi th the toothed washer
attached to i t.
. when i nstal l i ng a chi l d seat on the rear seat, fol l ow the i nstructi ons ol the manufacturer of the chi l d seat'
. Make sure the rear seat-backs are l ocked fi rml y when i nstal l i ng a chi l d seat'
gn; 1
6r n
( i n. )
ATTACHMENT POINTS
CHILO SEAT
ANCHOR PLATE
CHI LD SEAT
ANCHOB PLATE
COVER
8 x 1. 25 mm
22 N..n
(2.2 kgl'm.
16 t bf f t )
;x?',rff{-*.
20-143
Embl em
Instal l ati on
Appl y the embl em where shown.
NOTE:
. Before appl yi ng, cl ean the body surface wi th a sponge dampened i n al cohol .
.
After cl eani ng, keep oi l , grease
and water from getti ng
on the surface.
Attachment Point
(ReferencG):
Uni t : mm
( i n, )
CIVIC EMBLEM
Special EMBLEM
20-144
3D: Special emblem
{for Canada Sosciel Editionl
Heater and Ai r Condi ti oni ng
Heater
' .' ..""" 21' 1
Ai r Condi ti oni ng
......."' ..
"' 22-1
SUPPLEMENTAL
RESTRAINT SYSTEM
(SRS}
The ci vi c sRs i ncl udes a dri ver' s ai rbag l ocated i n the steeri ng wheel hub l n addi ti on, al l model s
(except some
model s for canada) have a
passenger' s ai rbag l ocated i n the dashboard above the
gl ove box'
Informati on necessary to safel y servi ce the sRS i s i ncl uded i n thi s servi ce Manual l tems marked wi th an asteri sk
(*)
on the contents
page i ncl ude, or are l ocated near, sRs components. servi ci ng, di sassembl i ng or repl aci ng these
i tems wi l l requi re speci al
precauti ons and tool s, and shoul d therefore be done by an authori zed Honda deal er'
@
-";;il rendsring the SRS inoperative, which could lead to
personal iniury or deaih in the svent of a sevre
frontal collision. all SRS service work must be pertormed by an authorized Honda daler'
. lmploper service
procedures, including incorrest removal and instsllation of the sRs, could lead to
personal
iniury caused by unintentional deployment of the airbags'
o Do not bump the SRS unit. Otherwise. the system may fait in case of a collision. or the airbags may deploy
when the ignition switch is ON {ll}'
. sRs electrical wiring harncsses are idntified by yellow colol coding. Related components ale located in lhe
steering column, front console, dashboard, dashboald lowet
panel, and in the dashboard above the
glove box'
Do not use electricaltest equipment on these circuits.
Heater
lllustrated Index
' 96
-
98 Model s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21' 2
' 99
-
00 Model s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21' 3
Circuit Diagram
' 96
-
98 Model s
. . . . . 21-4
' 99
-
00 Model s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-5
Troubleshooting
-
' 96
-
98 Models
Sympt om Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-6
Heater Control Panel Input/
Out put Si gnal s . . . . . . . . . . . . . . , . . . . . . . . . . . . . . 21-7
Flowcharts
Bl ower Mot or Speed . . . . . . . . . . . . . . . . . . . 21-8
Bf ower Motor ,...21' 10
Mode Cont rol Mot or . . . . . . . . . . . . . . . , . ' . ' 21-13
Recirculation control Motor ....... 21-16
Heater Control Panel ................ ... 21
-14
Troubleshooting
-
' 99
-
00 Models
Sympt om Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-19
Seff-diagnosis Function ............,,,.... 21-20
Flowcharts
Ai r Mi x Cont rol Mot or . . . . . . , . . . . . . . . . . 21-21
Mode Cont rol Mot or . . . . . . . . . . . . . . . . . . . . 21
-25
Recirculation Control Motor ....... 21-27
Bf ower Mot or Speed . . . . . . . . . . . . . . . . . . . 21' 29
Bf ower Motor ....21-31
Heat er Cont rol Panel . . . . . . . . . . . . . . . . , . . 21-35
Heater Control Panel Input/
Out put Si gnal s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-36
Blower Unit
Repf acement . . . . . . . . . 21-37
Overhaul
. . . . . . . . . . . . . . . . 21-38
*
Heater Unit
Repl acement
. . . . ' . . . . 21-39
overhaul
"""" """' 21-4' l
Heater Control Panel
Repf acement
. . . . . . . . . 21' 42
Overhaul
-' 96 -
98 Model s . . . . . . . . . . . 21-43
Temperature Control
Adjustment
-
'96
-
98 Models """" 21-44
Adiustment
-
' 99
-
00 Models .......21-45
Air Mix Control Motor
Test
-
' 99
-
00 Model s . . . . . . . . . . . ' . . . . . . . 21' 46
Replacement
-
' 99
-
00 Models ....21' 46
Mode Control Motol
Test . . . . . . . . . . . . . . . . ,
. , . . . ' . 21' 47
Replacement
' .' ."...21-47
Recirculation Control Motor
Test . . . . . . . . . . . . . . . . .
. . . . . . . 21-48
Repf acement
......." 21-48
Relays
Test . . . . . . . . . . . . . . . . .
. . . . . . . 2' l -49
Heater Fan Switch
Test
-
' 96
-
98 Model s . . . . . . . . . . . . . . . . . . . . 21-49
Mode Control Switch
Test
-' 96 -
98 Model s . . . . . . . . . . . ". . . . . . . 21-50
Power Transistor
Test
-
' 99
-
00 Models ....' ........ ....".21-50
*:
Read SRS Drecauti ons
before worki ng i n thi s area.
lllustrated Index
'96
-
98 Models
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons, and procedures i n the SRS
secti on {24) before performi ng repai rs or servi ce.
BLOWER UNIT
Overhaul ,
page 21-38
HEATER UNIT
Bepl acement, page 21-39
Overhaul , page 21-41
BLOWER
RESISTOB
Test,
CONTROL MOTOR
Test , page 21-48
a/c swtTcH
{wirh A/c)
MOO
MOTOR
Test, page 21 47
AIR MIX CONTROL CABLE
Adj ust ment , page 2' 1-44
Repl acement ,
page 21' 43
HEATER FAN
swtTcH
Test , page 2l ' 49
MODE HEATER CONTBOL
PANEL swrTcHEs
Test, page 21 50 Rgpl acement , page 2' l - 42
Over haul ,
page 21- 43
TEMPERATURE CONTROL
LEVER
Adi ust ment ,
page 21 44
Detroster-aqtivated A/C System
Turni ng the defroster on acti vates the A,/C and sets the ai r fl ow mode to FRESH. l t i s possi bl e to turn the A,/C off or to
change the ai r fl ow to RECIRCULATE by
pressi ng
the A/C bunon or the FRESH/RECIRCULATE button.
21- 2
'99
-
00 Models
SRS components are l ocated i n thi s area, Revi ew the SRS component l ocati ons, precauti ons, and
secti on
(24)
betore perfomi ng repai rs or servi ce.
HEATER UNI T
Repl acement ,
page 21' 39
Over haul ,
page 21- 41
BLOWEB UNIT
Repl acement ,
page 21-37
Overhaul ,
page 21 38
HEATER FAN
swtTcH
RECIRCULATION
CONTROL MOTOR
Test , page 21-48
Bepl acement , page 21-48
AIR MIX CONTROL MOTOB
Test ,
page 21-46
Repl acement ,
page 21 46
BLOWER
Test , page 21- 49
POWER TRANSISTOR
Test , page 21 50
HIGH RELAY
MODE CONTROL
DIAL
HEATER VALVE CABLE
Adj ust ment ,
page 21 45
TEMPERATURE CONTROL
DIAL
Adj ust ment ,
page 21-45
REAR WINDOW
DEFOGGER
swtrcH
See section 23
MODE
MOTOR
Test, page 21 47
Repl acement , page 2 l - 47
A/C SWTTCH
lwith A/cl
CONTROL SWITCH
21-3
Ci rcui t Di agram
'96
-
98 Models
LINDEF NoOD FUSETFELAY 30x
WNTTBLK +WFT
8L|(YEi
LIGHT
Y
I
No1l
lS0Al Ni42 (40A)
S;rt'
| | l i eti {,**i ' -t L-:} [:] | h
c r c a ( . - A - o \ \ \ 1 \ - r . \ \ - r - 1 \ ' \
! 9[ 1' ? _?__?' ? _t __?__t
21-4
'99
-
00 Models
UNDER,HOOO FUSE/RELAY 8OX
PUSN SWITCH
lHce nvosrar F)-
aLu neo
(Wirh IVC)
DASH LIGHTS -/1
BBTGNTNESS < l -
FEo
CONTROLLER
-!
IGN TION SW TCH
UNDEF DASH
FUSElRELAY BOX
**,',,* **",@ ",.
@f
u,n,",,
ELUAVHT
I
Y
BLUi BtK
BLOWER
MOTOR
ELOWER
MOTOR
HI GH
RELAY
PNK/BLK
FED''WHT
RED,YEL
GRY
BRN
YEL
YEL/FEO
6RNiYEL
8LU/!VHT
YEL/BLU
BRNfiHT
GFNM/HT
GRNi FED
O
: 8P CONNECTOR
!
: 20P CONNECTOF
E
: 12P CONNECToR
BLUi BLK
1
tic
HEATER CONTROL PANEL
VENT
MOOE
HEAT CONTFOL
MOTOF
-
M. COM
DEF
[[f&H,,4*,",,
BLK
Troubleshooting
-' 96 -
98 Models
Symptom Chart
NOTE;
. Check the engi ne cool ant l evel . and al l ow the engi ne to warm up before troubl eshooti ng.
. Any abnormal i ty must be corrected before conti nui ng the test.
. Because of the
preci se measurements needed. use a mul ti meter when testi ng.
o Before performi ng any troubl eshooti ng procedures check:
-
Fuses No. 41 11.5 Al , No. 55
(40
A) i n the under-hood fuse/rel ay box. and No. 17
(7.5
A) i n the under-dash fuse/rel ay
box
-
Grounds No. G401, G402
-
Cl eanl i ness and ti ghtness of al l connectors
Symptom Romedy
Hot ai r fl ow i s l ow. Bl ower motor runs. but one or more
speeds are i noperati ve.
Perform the procedures in the flowchart
(see page 21-8).
Bl ower runs properl y. Check for the fol l owi ng:
.
Cl ogged heater duct
.
Cl ogged heater outl et
.
Incorrect door position
No hot ai r fl ow. Bl ower motor does not run at al l , Perform the procedures i n the fl owchart
(see page 21-10).
Bl ower motor runs. Check for the fol l owi ng:
.
Clogged heater duct
.
Clogged blower outlet
.
Cl ogged heater val ve
.
Faul tv ai r mi x door
.
Heater val ve cabl e adj ustment
(see page 21-44)
.
Air mix control cable adiustment
(see page 2'l-441
.
Faul ty cool i ng system thermostat
(see
secti on 10)
.
Cl ogged evaporator
(wi th
ai r condi ti oni ng)
.
Frozen evaporator {wi th ai r condi ti oni ng)
Mode control motor does not run, or one or more modes
are i nooerati ve.
Perform the procedures in the flowchart
(see page
21-13).
Reci rcul ati on control door does not chanqe between
FRESH and RECIRCULATE.
Perform the procedu.es i n the fl owchan
(see page 21-16).
Both heater and A,/C do not work. Perform the procedures i n the fl owchart
(see page 21-18),
21-6
Heater Control Panel Input/Output Si gnal s
HEATER CONTROL PANEL lilP CONNECToR
21- 7
Termi nal
No.
Wire
col or
Si gnal
Terminal
No.
Wire
col or
Si gnal
1 YEL HEAT/DEF I NPUT 8 YEVRED VENT I NPUT
BLfi EL
I NPUT 9 G RNI/EL HEATIr'ENT INPUT
WHT/BLU +B I NPUT
' 10
BLK GROUND OUTPUT
4 YEUBLU DEF I NPUT 1 1 * BLU/RED A./C THERMOSTAT I NPUT
5 RED
DASH LIGHTS
BRIGHTNESS CONTROLLER
OUTPUT 12 GRN/WHT FRESH I NPUT
6 RE D/8LK
COMBINATION LIGHT
SWITCH
INPUT 1 3 GRN/RED RECIRCULATE I NPUT
1 BLUMHT HEAT INPUT 1 4 GRN HEATER FAN SWITCH OUTPUT
Troubl eshooti ng
-' 96 -
98 Model s
Blower Motor Speed
HEATER FAN SWITCH 6P CONNECTOR
21- a
Bl ower mot or runs. but one or
rnore speeds are inoperative,
Chsck for a short or an open in
t he wi re{s}:
Turn t he i gni t i on swi t ch ON {l l ),
and t he heat er f an swi t ch OFF.
Does t he bl ower mot or run?
Check for a shon in th6 wirels):
2. Di sconnect t he bl ower mot or
2P connect or,
3. Remove the center dashboard
l ower cover
(see
sect i on 20),
and di sconnect t he heat er l an
switch 6P connector,
4. Di sconnect t he bl ower resi s
t or 4P connect or,
t he No. 2, 3, 4 and 5l er mi nal s
of t he heat er f an swi t ch 6P
connect or and body
gr ound
i ndi vi dual l y.
l s t her e cont i nui t y? Reolace the heater fan switch,
Repai r shor t i n t he wi r e( s)
beiween the blower resistor, the
heater tan switch and the blower
motor,
To page 21 9
l s t here approx. 2
-
3 ohms?
Check f or an open i n t he wi re(s):
1. Reconnect t he bl ower resi st or
4P connect or,
2. Remove t he cent er dashboard
l ower cover
(see
sect i on 20),
and di sconnect t he heat er f an
(l l ).
4. Gr ound each of t hese t er mi -
nal s i ndi vi dual l y i n t he t ol l ow_
i ng order: No. 4, 2, 5 and 3.
Does t he bl ower mot or r un at
pr ogr essi vel y hi gher speeds?
Reolace the hoater fan switch.
Repair open or cause ol excessive
r esi st ance i n t he appr opr i at e
wire{sl between the blower resis-
tor and the heater {an switch.
Check the blower resislor:
1. Tur n t he i gni t j on swi t ch OFF.
2. Di sconnect t he bl ower r esi s
t or 4P connect or .
3 , N4 e a s u r e t h e r e s i s t a n c e
bet ween t he No. 2 and No. 4
t er mi nal s of t he bl ower r esi s-
t or ,
BLOWER RESISTOR
BLU/WHT
2
1 6
BLU BLU/YEL
BLU/BLK
JUMPER
WIRE
21-9
Troubl eshooti ng
-' 96 -
98 Model s
Blower Motor
BLOWER MOTOR 2P CONNECTOR
Wi . e si de of f ernal e t ermi nal s
f=
l 1 l
r,l
ruumifalulau
**'
I
Fl
gr-urwnr
l 1 | _ - _ - l
t4
,t
I
glower
motor does not run at all.
Check t he No. 55
(40A)l use
i n t he
under hood f use/ rel ay box, and
t h e No . 1 7
( 7 . 5
A) l u s e i n t h e
undeFdash luse/relay box.
Repl.ce th. fuse{rl, .nd rochack.
Check the blower motor:
1. Connect t he No. 2 t ermi nal of
t he bl ower mot or 2P connoc
t or t o body gr ound wi t h a
l umper
wrre.
(l l ).
Chock for an opsn in the wire:
1. Di sconnect t he
, umper
wi r e
and t he bl ower mot or 2P con-
nector,
t he No. 1 t ermi nal and body
ground.
Ch6ck tha blower motor relay:
2. Remove t he bl ower mot or
r el ay f r om t he under - hood
fuse/relay box, and test it
(see
page 21-49).
Replace tha blower moior reley.
To page 21- 11
f o page21' 12
21- 10
From page 2l 10
Check for an open in the wire:
1. Turn t he i gni t i on swi t ch OFF,
and di sconnect t he
i Lr mPer
2. Remove the center dashboard
l ower cover
(see
sect i on 20),
and di sconnect t he heat er f an
(l l ).
grou nd.
Repair op.n in th6 wiro betwen
the blower motor and tho heater
fan switch.
t he No. 1 t ermi nal of t he heat er
t an swi t ch 6P connect or and
body
ground.
Reolaco tho heater fan iwitch
Check t or an opn i n t he wi re
betw.en the heater tan switch
and body
ground. ll th wilo b OK,
check tor poor ground at G401 and
G102.
(cont' d)
21- 11
Troubl eshooti ng
-' 96 -
98 Model s
Fr om page 21- 10
Check the under-hood fuse/relay
DOX:
N/ l easure t he vol t age bet ween t he
No . 3 t e r mi n a l o f t h e b l o we r
mot or rel ay 4P socket and body
ground,
l s t here baf t ery vol t age?
Check lor an open in th wire:
(l l ).
t he No. 4 t ermi nal of t he bl ow-
er mot or rel ay 4P socket and
body ground.
Repair open in tho wire between
t he No. 17 f uss and t ho bl owel
motor rclay,
Check for en opon in the wire:
the No. 2 terminal of the blow-
er mot or rel ay 4P socket and
body
ground.
Check f oi an open i n t he wi re
betwen the blower motor relav
and body glound. lf the wiro is
OK, check f o. poor ground at
G{01 and G4O2.
Repai r open i n t he BLU/ WHT
wire btween the blower motor
relav and the blower motor.
Blower Motor
(cont'dl
BLOWER MOTOR RELAY 'P SOCKET
1 2 1 1
t t - l
_T
t
rv)
i
21-12
Mode Control Motor
To page 21- 14
MODE CONTROL MOTOR 7P CONNECTOR
'1
I 2 I 5 7
BLK/YEL
Mode control motor does not run,
or one of more modes are inoPela-
Check t he No.
' 17
(7. 5 A) f use i n
t he under-dash f use/ rel aY box.
Reolace the fuse, and recheck.
Check lor an open in the wire:
1. Di sconnect t he mode cont rol
mot or 7P connect or.
(l l ).
t he No. l t er mi nal and body
g rou nd.
t he No. 17 t use and t he mode
control motor.
l s t here bat t erY vol t age?
Check {or an open in the wire:
t he No. 7 t er mi nal of t he mode
c o nl r ol mot or 7P c onnec t or
and body gr ound.
batwen the mode contrcl motol
and body
ground. lf the wir is OK,
check for poor gtound at G/U)l and
G402.
Test t he mode cont rol mot or
(see
page21- 471.
Check t he mod cont r ol l i nkage
and door s:
1 . B e mo v e t h e mo d e c o n t r o l
mot or
( see page 21- 47) .
2. Check t he mode cont r ol l i nkage
and door s f or smoot h move
l s t he mode cont r ol mot or OK?
Do t he mode cont rol l i nkage
and doors move smoot hl Y?
Reolace the mode control motor,
I 3 4 5 6 1
BLK
[]
(cont' d)
Troubl eshooti ng
-' 96 -
98 Model s
Mode Control Motor
lcont'dl
Fr om page 2l - 13
HEATER CONTROL PANEL lilP CONNECTOR
Wi re si de of l emai e t ermi nal s
Check tor a short in the wi.e(s):
l ower cover
(see
sect i on 20),
and disconnect the heater con-
trol panel 14P connector.
t he No. 1, 4, 7, 8 and 9 t ermi -
nal s and body
ground i ndi vi d-
Rapri r. ny short i n t he wi re(s)
betwen the mode control motor
and the heater control
panel.
Check for a shon to
power:
Check the same wires {or voltage.
Repai r short t o
pow6r i n t he
wiro(3) betwoen the mode con-
lrol motor .nd tha heate. control
prnel, This short also damag.s
tho heater cont.ol
prnel. Repail
the short to
power
b{ore replac-
ing the heeter conlrol pan6l.
l s t here any vol t age?
To page 21 15
21- 14
Fr om page 21- 14
Check tor an open in the wire{s}:
f ol l owi ng t ermi nal s of t he mode
cont rol mot or 7P connect or and
t he heat er cont rol Panel
14P con-
nector-
7P: 14P:
No . 2
-
No . 4
No . 3
-
No . 1
No . 4
-
No . 7
No . 5
-
No . 9
N o . 6 - N o . 8
Repai r any opsn i n t he wi rel s)
bctwoan the mode control motor
and the hoator conlrol Panol
l s t here cont i nui t Y?
Check I o. l oo3. wi res or
Poor
connoctions at lhe hoatr control
Danel 14P connactor, and 3t the
mod6 conilol motot 7P connec-
tor. It tho connoctions ara
good.
rsDlaco the heatr coilttol
panel.
HEATER CONTROL PANEL 14P CONNECTOR
21
-1
5
Troubl eshooti ng
-' 96 -
98 Model s
Reci rcul ati on Control Motor
Beci rcul at i on cont rol door does
not change between FRESH and
RECIBCULATE.
check t he No- 17
( 7. 5
A) f use i n
Reolace the tuse. and recheck.
1. 0i sconnect t he r eci r cul at i on
cont rol mot or 4P connect or.
2. Tu. n t he i gni t i on swi t ch ON
(l l ).
t he No. l t ermi nal and body
gr ound.
Repair open in the wir6 between
t he No. 17I use and t he reci rcul a-
lion conlrol motor.
Check l he r eci r cul at i on cont r ol
2. Test t he r eci r cul at i on cont r ol
mot or { see
page 21 48) .
Check t he reci rcul at i on cont rol
linkage and door:
1. Remove t he reci rcul at i on con'
t rol mot or {see
page 21 48}.
2. Check t he reci rcul at i on cont rol
l i nkage and door f or smoot h
Do t he reci rcul at i on cont rol l i nk
age and door move smoot hl y?
Reoai r t he rci rcul at i on cont rol
l i nkage or door.
RECIRCULATION CONTROL MOTOR
4P CONNECTOR
BLK/YEI-
I o page 21 17
21- 16
Fr om page 21- 16
l s t her e any vol t age?
Check {or a short in the wire(s):
l ower cover
(see sect i on 20),
and di sconnect t he heat er con_
t rol
panel 14P connect or'
t he No. 12 and No. 13 t er mi -
nal s and body ground i ndi vi d-
Repair 5hort in the wire{sl between
the recirculation control motor and
the heater control Panel
Check Ior a short to
Power:
Check t he same wi res f or vol t age
Repai r s hor t t o
Power
i n t he
wire {s) between the recirculation
c ont r ol mot or and t he heat er
c ont r ol
panel . Thi s s hor t al s o
damages t he heat er c ont r ol
panel. Repair the short to
Power
betore replacing the heater con-
t r ol
panel .
Check lor an open in the wire(s):
f ol l owi ng t er mi nal s of t he r eci r cu
l at i on cont r ol mot or 4P connect or
and t he heat er cont r ol
Panel
14P
4P. 14P:
No . 2
-
No . 1 2
No . 4 No . 1 3
Repai r open i n t he wi r el s l
between the recirculation control
mot or and t he heat er c ont r ol
panel.
l s t her e cont i nui t Y?
Check f or l oose wi r es or
Poor
connections at the heater control
Danel 14P connect or , and at t he
r eci r cul at i on cont r ol mot or 4P
connector. lf the connections are
good, replace the heater control
Danel,
I
;-?
4 5
7 8 9 'o
lx
1 1 1 2 13 14
GRN/ WHT
0)
(0
GRN/ BED
GRN/ RED
GRN/ RED
4P CONNECTOR
Wi re si de of f emal e t et mi nal s
I 2 3
i--?
1 5 6
7 8 I ' ol x1 1 1 2 13 1 4
GRN/WHT
V)
( v
1
4 5
7 I I r ol \ l r r 12 1 3
GRN/WHT
r z l / l t
2 1 - 1 7
Troubl eshooti ng
-' 96 -
98 Model s
Both heater and A/C do not work.
Check t he No. 17 {7. 5 A) f use i n t he
underdash fuse/relay box, and the
No. 47
(7. 5
A) f use i n t he under
hood fuse/relay box.
R.phce the fuso{s), .nd rccheck.
Chack tor an open in the wi.e:
l ower cover
(see
sect i on 20),
and di sconnect t he heat er
cont rol panel
14P connect or.
2. Torn the ignition switch ON {ll).
t he No. 2 t er mi nal of t he
heat er cont rol panel
14P con-
Rcpair opGn in th wiro betwoon
t he No. 17 t use and t he hoat cl
control panel.
Check for an opon in the wiro:
2. Measure the voitage between
t h e No . 3 t e r mi n a l o f t h e
heat er cont rol panel 14P con-
Rgprii open in th6 wira btwacn
the No. il7
tui. and the heat.t
cont.ol p.nal.
Check foi an open in the wi.e:
No. 10 t ermi nal ot t he heat er con-
t r o l p a n e l 1 4 P c o n n e c t o r a n d
body ground.
Check l or an opon i n t ho wi re
b{w6on the hoator control oanel
and body ground. lI the wirc is
OK, check t or poor ground
at
G401 .nd G4O2.
Check f or l ooae wi aos or oool
connections at the hoater control
panol
14P connector. lf the con-
nactions dre good.
3ubstitute t
known- 9ood heat er cont r ol
panel,
and rech6ck. It tho symp-
t om/ i ndi cat i on
9oe3
. wr y,
repl ace t he ori gi nal heat el con-
trol oanol.
HEATER CONTROL PANEL 1,lP CONNECTOR
21- 18
Troubl eshooti ng
-' 99 -
00 Model s
Symptom
Mode control motor does not run, or one or more modes are i noperat' ve'
Reci rcul ati on control door does not change between Fresh and Reci rcul ate'
Bl ower motor onl y runs on hi gh speed
posi ti on; i t does not run i n any other speed
posi ti ons
Bl ower motor does not run at al l .
Both heater and Ay' C do not work
See pags
a1_t q
21-21
21-29
21-31
21 35
Symptom
Chart
For el ectri cal mal functi ons whi ch are i ndi cated by the sel f-di agnosti c system, refer to sel f-di agnosi s
functi on
(see
next
page).
Note these i tems before troubl eshooti ng
a symptom'
. Check the engi ne cool ant l evel , and al l ow the engi ne to warm up before troubl eshooti ng'
. Any abnormal i ty must be corrected before conti nui ng the test
. Bec aus eof t hepr ec | s emeas ur ement s needed, Us eadi gi t aI mu| t i met er wi t hanout put of l mAor | es s at t he20k o
range when testi ng
. Before
performi ng any troubl eshooti ng
procedures check:
-
Fuses No. 41 115 Al , No 55
(40 A)]n the under-hood
fuse/rel ay box' and No 17
(7
5 A) i n the under-dash
fuse/rel av
box
-
Grounds No. G401, G402
-
Cl eanl i ness and ti ghtness of al l connectors
21-19
Troubl eshooti ng
-' 99 -
00 Model s
Self-diagnosis Function
The heater control panel has a sel f-di agnosi s functi on.
Runni ng the Sel f-di agnosi s Funqti on
Set the mode control di al to the Vent posi ti on,
and turn the i gni ti on swi tch ON
fl l ). Wi thi n si x seconds after turnang the i gni _
ti on swi tch on. press
the reci rcul ati on control swi tch the requi red number of ti mes dependi ng on the reci rcul ati on i ndi cator
l i ght status:
. l f t hei ndi cat or l i ght i sON, pr esst her eci r cul at i oncont r ol swi t chf i vet r mes.
. l f t hei ndi cat or l i ght i sOFF, pr esst her eci r cul at i oncont r ol
swi t ch si x r r mes.
The reci rcul ati on i ndi cator l i ght wi l l come on for two seconds. then bl i nk the Di agnosti c Troubl e code
{DTc} to i ndi cate a
faul ty component. l f no DTc' s are found, the i ndi cator l i ght wi l l not bl i nk after the i ni ti al two second l i qht.
DTC Indication Pattern
(S6e
DTC 2l:
Recirculation
indicato.
l i ght on
Recirculation
indicator
light off
2 sec
,/
1. 5 soc
t
'
0,3 sec
Wi t hi n si x seconds at t er t he
ignition switch is turned ON
(lll,
pross
t he reci rcul at i on cont rol
switch the required number ot
times depending on the rocircu-
lation indicetor light status
0.3 sec
VENT POSITION
MODE CONTROL DIAL
RECIRCULATION
CONTROL SWTCH
DTC Troubleshooting Index
Diagnostic
trouble
code
(DTCI
Rgcirculation
indicator light
Component with problem
Possible cause See page
One bl i nk Ai r mi x cont rol mot or
Obst ruct ed door, l aul t y mot or 21-21
2 Two bl i nks Ai r mi x cont rol mot or
Open or short ci rcui t
21-23
l n case of mul ti pl e probl ems,
the reci rcul ati on i ndi cator l i ght wi l l i ndi cate onl y one DTc wi th the l east number of bl i nks.
Resetting the Self-diagnosis Function
Turni ng the i gni ti on swi tch OFF wi l l cancel the sel f-di agnosi s functi on, After compl eti ng repai r work, run the setf di agnosi s
functi on agai n to make sure that there are no other mal functi ons.
21-20
@
At
V'
Air Mix Gontrol Motor
Reci rcul ati on i ndi cator l i ght i ndi cates Di agnosti c Troubl e code
(DTC)
1l A probl em i n the ai r mi x control l i nkage, door and
motor.
The ai r mi x control motor regul ates the mi xture of cool /hot ai r accordi ng to outputs from the heater control
panel '
Self-diagnosis circuit check indi'
cat es a
Probl em
i n t he ai r mi x
conlrol motor circuit,
Check th6 aii mix conirol motor:
1. Di sconnect t he ai r mi x cont rol
2. Test t he ai r mi x cont rol mot or
(see page 21-46).
check the air mix control linkage
and doors:
1. Remove t he ai r mi x cont r ol
mot or
(see
Page
21-46)
2. Check t he ai r mi x cont rol l i nk-
age and door s l or smoot h
movement .
l s t he ai r mi x cont rol mot or OK?
Do t he ai r mi x cont r ol l i nkage and
door s move smool hl Y?
Rolace the air mix control motor'
Check tor a short in the wiles:
1. Di sconnect t he heat er cont r ol
panel 20P connect or -
2. Check f or cont i nui t Y bet ween
body
gr ound and t he heat er
c ont r ol
panel 20P c onnec t or
t er mi nal s No. 3 and 4 i ndi v i d'
uaI Y.
Ropai r any short i n t h wi re{s}
betweon the heater control
Panel
and the air mix control motor'
HEATER CONTROL PANEL 2OP CONNECTOR
RED/WHT
RED/YEL
(cont ' d)
f o page 21-22
21-21
Troubl eshooti ng
-' gg -
00 Model s
(cont'dl
Fr cm page21- 21
AIR MIX CONTROL MOTOR
5P CONNECTOR
Wi re si de ot femal e termi nal s
Check fo..n open in the wires:
Check for continuity between lol-
l owi ng t er mi nal s of t he heat er
cont rol panel 20P connect or and
t he ai r mi x cont rol mot or 5P con-
20P: 5P:
N o 3
_
N o . 1
No . 4
-
No . 5
Repai r any open i n t he wi ro(s)
bdtwoon tha hoator control panal
and air mix control motor.
Check f or l oo3e wi res or
poor
conneclions at the heater control
panol
20P connoctor and at the
air mix control motor 5P connoc-
to.. It the connections .rc good,
substitute a known-good hoaier
control panel,
and rech6ck. lf the
symptom/indicrtion goes away,
replac6 the original heater con-
trol panel.
21- 22
Reci r cul at i oni ndi cat or I i ght i ndi cat esDi agnost i cTr oubl ecode( DTc) 2: Apr obI emi nt heai r mi xcont r o| mot or ci r cui t .
The ai r mi x control motor regutates the mi )dure of cool /hot ai r accordi ng to outputs from the heater control
panel '
Self-diagnosis circuit check indi-
crl 6s a
probl gm i n t ho ai r mi x
contiol motor circuit.
Check th6 rir mix control motor:
1. Di sconnect t he ai r mi x cont rol
mot or 5P connect or'
2. Test t he ai r mi x cont rol mot or
(see page 21-46).
Check the air mix control linkage
and doors:
1. Remove t he ai r mi x cont r ol
mot or
(see page 21' 46).
2. Check t he ai r mi x cont rol l i nk-
age and door s f or smoot h
l s t he ai r mi x cont rol mot or OK?
Do t he ai r mi x cont rol l i nkage and
doors move smoot hl Y?
Roglace the air mix conlrol motor.
Check for r short in the wiresl
1. Di sconnect t he heat er cont rol
panel 20P connect or.
body
ground and t he heat er
cont rol
panel 20P connect or
t er mi naf s No. 3, 4. 12, 15 a^d
20 i ndi vi dual l y
Bep. i r any short i n t he wi re{s)
between the hrter control
panel
and th6 air mix control motor.
BEO/WHT
REO/YEL
PNK/BLK
(cont' d)
Io page 21-24
21-23
Troubl eshooti ng
-' 99 -
00 Model s
Check tor a short to power:
Ch e c k t h e s a me t e r mi n a l s f o r
vol t age.
Rapai r short t o
pow6r
i n t he
wirelsl botween the heater con-
trol
panel
and the ai. mix control
molor. This short also damag.s
the heater control panel. Ropair
the short to power
betoro replac-
ing the heater control panel.
l s t her e any vol t age?
Check for an open in the wire3:
Check f or cont i nui t y bet ween f ol
l owi ng t er mi nal s of t he heat er
cont rol panel 20P connect or and
t he ai r max cont rol mot or 5P con
nector.
20Pt 5P:
N o 3
_
N o . 1
No 4
_
No. 5
No_ 12
-
No. 2
No . 1 5
-
No . 4
No 20
-
No. 3
Bepai r any open i n t he wi re(s)
between the heator control panel
and air mix control motor,
Check t or l oose wi res or
poor
connections at the heator control
oanel 20P connector and at th.
air mix control motor 5P connec-
tor, ll the connections rre good,
substitute a known-good heater
control oanel. and recheck. lf the
symptom/indication goes awry,
repl ace t he ori gi nal heat er con-
trol oanel,
(cont'dl
From
page
21-23 HEATER CONTROL PANEL 2OP CONNECTOR
5P CONNECTOR
21-24
Mode control motor does not run.
or one or more modes arc inope]a-
tive.
Check t he No. 17
( 7. 5 A) f use i n
Replace the Iuse. and recheck.
1. Di sconnect t he mode cont rol
mot or 7P connect or,
(l l )-
3. MeasLrre t he vol t age bet ween
mode cont rol mot or 7P con
nect or and body ground
t he No. 17 l use and l he mode
control motor.
Check the mode control motor:
1- Tur n t he i gni t i on swi t ch OFF
2, Test t he mode cont r ol mot or
( see page 21 47) .
Check l he mode cont rol l i nkage
and doors:
1 . Re mo v e t h e mo d e c o n t r o l
mot or
(see page 21 47).
2. Check t he mode cont rol l i nkage
and doors f or smoot h move
l s t he mode cont rol mot or OK?
Do t he mode cont r ol l i nkage
and door s move smoot hl Y?
ReDlace the mode control motor'
Check for a short to
Power
in the
wires:
1. I ur n t he, gni t j on swi t ch ON
( l l ) .
2, Di sconnect t he heat er cont r ol
panel 20P connect or .
3. Chec k f or v ol t age bet ween
t he No. 2, 5, 6, 7, I and 9 t er '
mi nal s of t he heat er c ont r ol
p a n e l 2 0 P c o n n e c t o r a n d
body gr ound i ndi vi dual l Y.
Repai r s hor l t o power i n t he
wire{sl between the heater con-
trol oanel and the mode control
motor. This short also damages
t he heat er cont r ol Pan6l .
RePai r
the short to
power
before replac'
ing the heater control
Panel
l s l her e any vol t age?
t 2 3 1 5
BLK/YEL
HEATER CONIROL PANEL 2OP CONNECTOR
NO
(cont' d)
21-25
I o page 21 26
Troubl eshooti ng
-' gg -
00 Model s
Mode Gontrol Motor
(cont'dl
From page
21-25
MODE CONTROL MOTOR ?P CONNECTOR
Wi re sade of l emal e t ermi nal s
Chock tor a short to ground:
2. Check t he same t ermi nal s f or
cont i nui t y t o body ground.
Repai r any 3hort i n t he wi rel sl
between the heater control panel
and ihe mode control motor.
Check lor.n open in tho wires:
1, Di sconnect t he mode cont rol
t he f ol l owi ng t ermi nal s of t he
20P con
nect or and t he mode cont rol
2OP: l Pi
No . 2
-
No . 7
No . 5 - No . 2
No . 6 - No . 6
No . 7
-
No . 5
No . 8 - No . 4
No . I
-
No . 3
Repai r any opon i n t he wi re(s)
ttween the hater control panel
and tha modc contol motor.
Check f or l oose wi aes or ooor
panel
20P connector rnd at the
mode control motor 7P connec-
toa, lf the connoctions ere good,
substitute a known-good heater
control panol,
and recheck. lf the
syfiptom/indication goes
away,
replac the original hoater control
panel.
21-26
Recirculation control door does
not chango betwen Fresh and
Recirculate.
Check t he No. l 7
(7. 5
A) f use an t he
underdash fuse/relay box.
Replace the fuse, and recheck.
Check lor an oPen in the wite:
1. Di sconnect t he r eci r cul at i on
cont rol mot or 4P connect or.
(l l )
t he No. 1 t ermi nal of t he reci r
cul at i on cont r ol mot or 4P
connect or and body
ground.
the No. 17 luse and lhe recircula-
tion control motor.
Check t he rcci rcul at i on cont rol
motorr
' ]
2. Test t he reci rcul at i on cont rol
mot or
(see
Page
21 48i
Check t he reci rcul at i on cont rol
linkage and door:
1. Remove t he reci rcul at i on con_
t rol mot or l see Page
2l 48).
2. Check t he reci rcul at i on cont rol
l i nkage and door f or smoot h
movement .
Reoai r t he reci rcul at i on conl rol
linkag or door.
Do t he reci rcul at i on cont rol l i nk_
age and door move smoot hl Y?
CONTROL MOTOR
si de of t emal e t ermi nal s
RECIRCULATION CONTRC
,lP
CONNECTOR
q-?
--T--T--T-|
1 l 2 l / l 1 l
f
BLK/YEt
( v)
!
page
(cont' d)
Troubl eshooti ng
-' 99 -
00 Model s
(cont'd)
Frcm page
21-27
Check for a short to power in the
panel
8P connector.
3. Check for voltage between the
No. 2 and No. 3 t ermi nal s of t he
8P con,
nect or and body ground i ndi
vi dual l y.
Repai r 3hor t t o powe.
i n t he
wire{a) b.tween tho haetor con-
t rol panel
and t he reci rcul at i on
Gont rol mot o. . Thi s short al so
damagos t he heat e. cont r ol
panel.
Repair the short to
power
btore .eplecing the hater con-
trol panel.
l s t here any vol t age?
Check to. a short to ground:
2- Check t he same t ermi nal s f or
cont i nui t y t o ground.
Roprir lhon in tho wir.{s) btweo
the horter control
panel
and the
racircr alion conhol motoa.
Check for an open in the wires:
1. Di sconnect t he r eci r cul at i on
control motor 4P connector.
t he f ol l owi ng t ermi nal s of t he
reci rcul at i on cont rol mot or 4P
connect or and t he heat er con,
trol panel 8P connector.
8P: 4Pi
No . 2
-
No . 2
No . 3
-
No . 4
Repair open in ths wirolsl betwn
the heate. co.rkol panol
and the
recirculation control motor .
Check l or l oo3a wi res or poot
connctions at the hoater control
panel
8P connect or and at t he
aeci rcul at i on cont rol mot or i l P
connector, It tho connections are
good.
subst i t ut e known-good
heatei control
panel,
and aecheck.
lf th symptom/indication goes
away, replace the original hedter
contrcl Danel.
GRN/WHT
I
1
GRN/ RED
4P CONNECTOR
21-28
BIower Motor Speed
To page 21 30
NOTE: l f t he bl ower mot or does not
run at al l , ref er t o page 21-31.
POWEB TRANSISTOR 3P CONNECTOR
BLK
JUMPER
WIRE
LT GRN/ 8LK
(cont' d)
21-29
Bl ower mot or onl y runs on hi gh
speed
position; it does not run in
any other speed
Positions
Check for an open in lhe wire:
1. Di sconnect t he
power t ransi s
t or 3P connect or,
power t ransi st or 3P connect or
and body
ground.
bet ween t he Power t t ansi st or
and body
gt ound. l f t he wi re i s
OK, check f or
poor gr ound at
G401 and G402.
Check tor an open in the wire:
1. Connec t t he No. 1 and No 3
t er mi nal s of t he
Power
t r an_
s i s t o r 3 P c o n n e c t o r wl t h a
j umper wi r e.
2. Tur n t he i gni t i on swi t ch ON { l l )
the blower motor and the Powet
tranststor.
1. Tur n t he i gni t i on swi t ch OFF
2. Di sconnect t he
i umPer
wi r e.
panel 20P connect or .
heat er cont r ol
panel 20P con-
nect or and t he No. 2 t er mi nal
of t he
Power
t r ans i s t or 3P
the heater control
Panel
and tho
oower transistor,
l s t her e cont i nur t y)
3
o
Troubl eshooti ng
-' 99 -
00 Model s
Blower Motor Speed
(cont'dl
Wi re si de oJ f emal e t ermi nal s
Frcm page 21. 29
LT GRN/BLK
Check tor a short in the wi.a:
No. 1 t ermi nal of t he heat er con
t rol
panel
20P connect or and body
ground.
Repair short in ths wire betwsen
the hoater control panel
and the
oower transastoa.
panel 8P connector,
2. Turn t he i gnj t i on swi t ch ON 1l l ).
t h e No .
' l
t e r mi n a l o f t h e
8P con
Repeir open in the wiio between
the heater control panel
and the
blower motoa.
Check the
power
transistor:
2. Reconnect t he heat er cont rol
panel
8P and 20P connect ors.
3. Test the power transistor {see
page 21 50).
l s t he power
t ransi st or OK?
Check for loos wiras or poor
con-
nect i ons at t he hat r cont rol
panel
8P and 20P connectols and
at th6 power transistor 3P connc-
tor. lf the connections are good,
substituto a known-good hoater
control
panel,
and recheck. It the
symptom/indication goes
away,
replace the original heater control
oanel,
HEATER CONTNOL PANEL 8P CONNECTOR
21-30
Blower Motor
BLOWER MOTOR 2P CONNECTOR
JUMPER
WIRE
(cont' d)
21-31
Blower motor does not run at all.
Check t he No. 55
(40
A) I use i n
t he under-hood f use/ rel ay box,
and t he No. 17
(7. 5
A){use i n t he
undeFdash f use/ rel ay box.
Boplace th fuse(3), and rechock.
Check th blowr motor
Powel
supply circuit:
1. Di sconnect t he bl ower mot or
2P connect or.
3, Measure the voltage between
t he No. 1 t ermi nal oI t he bl ow
er mot or 2P connect or and
body
ground.
Check tha blower motor:
2. Reconnect t he bl ower mot or
2P connector.
3. Connect t he No. 2 t ermi nal o{
t he bl ower mot or 2P connec
t o r t o b o d v
g r o u n d wi t h a
t umper
wi re.
4. Turn t he i gni t i on swi t ch ON {l l }
fo page 21-32
To page 21-33
Troubl eshooti ng
-' 99 -
00 Model s
From page
21-31
Check the blower motor relay:
r el ay f r om t he under hood
fuse/relay box, and test it-
(see
page
21' 49).
Replace the blower motor relay.
Check the under-hood tuse/relay
box:
No . 3 t e r mi n a l o f t h e b l o we r
mot or rel ay 4P socket and body
ground.
(l l ).
bl ower mot or rel ay 4P socket
and body ground.
Repair opon in lhe wire between
t he No. 17 f use and t he bl owet
bl ower mot or rel ay 4P socket
and body ground.
Check l or an ooen i n t he wi re
between the blowor motor relay
and body ground.
It the wiie is
OK, check f or poor gr ound
at
G401 and G402.
l s t her e cont i nui t yl
Repai r open i n t he BLU/ WHT
wiae between the blower motor
relay and the blower motor,
BLOWER MOTOR RELAY 4P SOCKET
21-32
From page 21 31
YES
Check t he bl ower mot or hi gh
relay:
and di sconnect t he
i umPer
hi gh r el ay, and t est i t . { see
page 21 49).
1. Connect t he No. 1 t er mi nal of
t he bl ower mot or hi gh r el ay
4P connect or t o body
gr ound
wi t h a
j umPer wi r e.
( l l ) .
the blower motor and the blower
motor high rolay.
Check for an op6n in the wir6:
a n d d i s c o n n e c t t h e
i u mPe r
(l l ).
bl ower mot or hi gh r el ay 4P
connect or and body ground.
t he No. 17 f use and t he bl owor
motor high relay.
1. Turn t he i gni t aon swi t ch OFF.
t h e N o . 3 t e r mi n a l o f t h e
bl ower mot or hi gh r el ay 4P
connect or and body ground.
Ch6ck l or an op. n i n t he wi r e
botween the blower motor high
relay and body ground. ll the wire
is OK, ch6ck for poot ground at
G401 end G402.
To page 21 34
BLOWER MOTOR HIGH RELAY 4P CONNECTOR
JUMPER
WIRE
(cont' d)
21-33
Troubl eshooti ng
-' 99 -
00 Model s
Blower Motor
{cont'dl
BLOWER MOTOR HIGH RELAY 4P CONNECTOR
BLU/BLK
BLU/ALK
HEATER OONTROL PANEL 8P CONNECTOR
wir sido ot fmale torminals
HEATER CONTROL PANCL 2OP CONNECTOR
From page 21-33
Check tor an opgn in the wiro:
panel
8P connect or.
heat er cont rol
panel
8P con-
nect or and t he No. 1 t ermi nal
ot t he bl ower mot or hi gh
Repsi. opn in the wir. betw.en
the h..t.r contrcl p.ncl .nd tho
blowar motor high rahy.
Chck for an opon in the wir6:
t h e No . 1 3 t e r mi n a l o f t h e
heat er cont rol
panel 20P con-
of t he bl ower mot or hi gh
Ropair opon in tho wiro botwoon
tha hartor cor rol pangl
rnd tha
blower motor high .elay.
Ch. ck f or l ooso wi ros or poor
conndions at th6 heato. control
panel 8P and 20P connectoB and
at t he bl owol mot or hi gh rel t y
4P connoctor. It tho connoctions
are good, subst i t ut e a known-
good heat cr cont rol panel , and
recheck. It the symptom/indica-
tion goos away, rgplaco the oiigi-
nal heater control oanol.
2
3 4
o
t 2
a 5 6 8
I 2 3 a 5 0 7 8 I 10
11 12 13 15
,/1,/1,/
m
ORN/WHT
o
1 2
3 4
OBN/WHT
21-34
Both heater and A/C do nol work.
checkt he No. 47
(7. 5
A)f use i n t he
under-hood fuse/relay box, and the
No. 17 { 7. 5
A) f use i n t he under -
dash fuse/relay box.
ReDlace the tuse{s), and recheck.
panel 8P connect or ,
( l l ) .
3. Measur e t he vol t age bet ween
t h e No . I t e r mi n a l o f t h e
heat er c ont r ol
panel 8P c on-
nect or and body
gr ound.
t he No.
' 17
l use and t h6 heat er
control oanel,
3. Measure t he vol t age l l et ween
heat er cont rol
Panel
20P con-
nect or and body
ground.
Repair op6n in the wir between
t he No.
i l 7 t use and t he heat er
cont rol oanel ,
Check for an open in the wite:
No. 6 t er mi nal of t he heat er con
t r ol
panel 8P connect or and body
gr ound.
Ch6ck t or an open i n l he wi re
betwoen the heator control Panel
and bodv ground. l f t he wi re i s
OK, check f or poor gr ound at
G401 and G402.
Check f or l ooso wi r es or
Pool
conneciions at the heater control
oanel 8P and 20P connectors. lf
the connections are
good, substi'
t ut e a known- good heat r con-
t r ol Danel , and r echeck. l I t he
symptom/indication
goes awaY,
r 6pl ace t he or i gi nal hat er con-
t r ol oanel .
BLK/ YEL
HEATER CONTROL
PANEL 2OP CONNECTOR
I 2
1 5
7 8
BLK
o
1
4 I
v
Troubl eshooti ng
-' 99 -
00 Model s
Heater Control Panel Input/Output Si gnal s
HEATER CONTROL PANEL CONNECTORS
8P CONNECTOR 2OP CONNECTOR 12P CONNECTOR
8P CONNECTOR
(O qn
Circuit Diagram)
20P CONNECTOR {D on circuit Diagram}
*:
with Ay'c
12P CONNECTOR
(tr
on Ci rcui t Di agraml
Cavity Wire color Si gnal Cavily Whe color Signal
BLU/ 8LK BLOWER FEEDBACK I NPUT 5 RED
DASH LI GHTS BRI GHTNESS
CONTROLLER
OUTPUT
2 GRN/lVHT FRESH INPUT 6 BLK GBOU N D OUTPUT
3 GRN/ RED RECI RCULATE I NPUT 7 BLU/YEL
REAR WI NDOW DEFOGGER
RELAY
OUTPUT
4 RED/BLK
COMBI NATI ON LI GHT SWI TCH
(Vi a No. 30
(7. 5
A) f use)
I NPUT 8 8Lf i EL l G2 {Power) I NPUT
Cavity Wire color Si gnal Cavity Wire color Signal
LT
GRN/ BLK
POWER TRANSI STOR EASE OUTPUT
' t 1
BLU/ RED Ay'C THERMOSTAT I NPUT
2 BRNMHT
MODE CONTROL MOTOR
GROUND
I NPUT 12 BRN
AI R MI X CONTROL MOTOR
GROU ND
I NPUT
3 RE D/YEL AI R MI X HOT OUTPUT 1 3 ORNAA/HT
BLOWER MOTOR HI GH
RELAY
I NPUT
RED,ryvHI AI R MI X COOL OUTPUT 1 4
5 YEUBLU MODE DEF I NPUT PN K,/BLK AI R MI X POTENTI AL OUTPUT
6 YEURED MODE VENT I NPUT 16
7 GRNI / EL MODE HEAT/r'ENT I NPUT 1 1
I BLUAVHT MODE HEAT I NPUT 1 8
9 YEL MODE HEAT/ DEF I NPUT 1 9
1 0 WHT/BLU +B
( Power )
I NPUT 20 GRY AI R MI X POTENTI AL +5 V OUTPUT
Cavity Wilecolor Si gnal Cavity Wi.e colol Si gnal
l SWI TCH LED COMMON OUTPUT 1 SWITCH LIGHTS + OUTPUT
2 I SWI TCH LI GHTS
-
I NPUT
3 9 SWI TCH COMMON I NPUT
4
RECI RCULATI ON CONTROL
SWI TCH LED
I NPUT 1 0 A,/C SWITCH OUTPUT
5 A./C SWITCH LED I NPUT 1 1
RECI RCULATI ON CONTROL
SWI TCH
OUTPUT
6
REAR WI NDOW DEFOGGER
SWI TCH LED
I NPUT 12
REAR WI NDOW DEFOGGEB
SWI TCH
OUTPUT
21- 36
Blower Unit
Replacement
NOTE: The bl ower motor, reci rcul ati on control motor
and blower resistor can bs replacsd without rsmoving
th blower unit
(see
neld
Page).
1. Move the temperature control to
"HOT."
' 96-98:
Sl i de the temperature control l ever.
' 99-00:
Turn the i gni ti on swi tch ON (l l ), then turn
the temperature contol knob. Turn the i gni ti on
swi tch off,
Remove the
glovs box
(ses
ssction 20),
Rmove ths s6lf-tapping screw and ths
passsng6r's
dashboard l owr cover. Removo the bol t, the nut
and the kne bol str, then remove the fi v bol ts and
the
gl ove box trame,
Without Air Condhioning
4-a. Remove the wiro harness from the h68tr duct, then
remove the two self-tapping scrsws and the heatsr
duct.
KNEE
GLOVE BOX FRAME
HEATER DUCT
21-37
Wrth Air Conditioning
4-b. Removo th6 ev8porator
(sss pago
22-28).
6 x 1 . 0 m| n
9.8 N'm
6x 1. 0mm
9.8 N'm lt'o tgf'm, t.2 lb{'ttl
Disconnoct the connectors trom th blower motor,
blowor r6sistor {'96
-
98 models),
power transiator
('99 -
0O modsls), blowor motor high telay
('99 -
00
models) and recirculation control motor.
Rmov ths wiro harnoss clip from tho recirculation
control motor, and release the wir6 harnsss from ths
clamo on the blowor unit. Remove the two mount-
ing bolts, tho mounting nut and ths blowor unit'
9.8
.m
11.0 tgfm,
1.2 tblfrl
lnstall in ths reverso order of removal. Mako surs
that thsre i s no ai r l eaka96.
6 x 1 . 0 mm
9,t N'm 11.0lgi.m,
7.2 tbf.fil
Bl ower Uni t
Overhaul
NOTE:
RECIRCULATION
CONTROL MOTOR
Test , page 21-48
a Before reassembl y. make sure that the reci rcul ati on control door and l i nkage move smoothl y wi thout bi ndi ng.
When attachi ng the reci rcul ati on control motor, make sure i ts posi ti oni ng wi l l not al l ow the reci rcul ati on control door
to be pul l ed too far.
After aftachi ng the reci rcul ati on control motor, connect power and ground, and watch the movement of the reci rcul a-
ti on control door.
BLOWER
Test, page 2'l 9
{'96
-
98 modebl
POWER TRANSISTOR l'99
-
00 modebl
Test , page 21-50
Test , page 21' 10
(' 96
98 model s) or
page 21' 31
(' 99
00 model s)
m
MOTOR
2134
Heater Unit
Replacement
SRS components are l ocated i n thi s area. Revi ew the
SRS component l ocati ons, precauti ons, and
procedures
i n the SRS secti on {24} before
L Di sconnect the negati ve cabl e from the battery.
2. Frcm under the hood, open the cl amp, then di scon-
nect the heater val ve cabl e from the heater val ve
arm. Turn the heater val ve arm to the ful l y opened
posi ti on as shown.
When the engi ne i s cool . drai n the engi ne cool ant
from the radi ator
(see
secti on 10).
!@
Do not remove the radiator cap when
the engine is hot; the ongine coolant is under
pres'
surg and could severely scald you.
CLAMP
HEATER VALVC CABLE
4. Di sconnect the heater hoses from the heater uni t.
CAUTI ON: Engi ne cool ant wi l l damage
p8i nt .
Ouickly rinse any spilled engins coolant from painted
su aces,
NOTE: Engi ne cool ant wi l l run out when the hoses
are di sconnected; drai n i t i nto a cl ean dri p pan.
5. Remove the mounti ng nut from the heater uni t.
NOTE: When removi ng the mounti ng nut, take care
not t o damage or bend t he f uel l i nes, t he br ake
l i nes, etc.
I x 1 .25 mm
22 N.m {2.2 kgl.m, 16lblftl
21-39
Heater Unit
Replacement
(cont'dl
6.
7.
8.
9.
Remove the dashboard
(see
secti on 20).
Remove the heater duct
(see page 21-37) or evapo-
rator
(see page 22-28).
Di sconnect the connectors from the mode control
motor and ai r mi x control motor
(' 99 -
00 model s),
then remove the wi re harness cl i ps and wi re har-
ness from the heater uni t. Remove the cl i p from the
heater duct, then remove the two mounti ng nuts
and the heater uni t.
6 x 1 . 0 mm
9.8 N.m 11.0 kgl.m,7.2 lbf.ftl
HEATER UNIT
l nstal l i n the reverse order of removal . Make note of
the fol l owi ng i tems.
Appl y seal ant to the grommets.
Do not i nterchange the i nl et and outl et heater
hoses. Make sure that the cl amps are secure.
Ref i l l t he cool i ng syst em wi t h engi ne cool ant
(see
secti on 10).
Connect al l cabl es, and make sure they are
prop-
erl y adj usted
(see page 21-44
(96 -
98 model s)
or page 21-45
(' 99 -
00 model s)).
Make sure that there i s no ai r l eakage.
21-40
Overhaul
' 1.
Remove the two sel f-tappi ng screws and the heater
core cover.
2. Pul l out the grommet from the heater core pi pes.
3. Remove the sel f-tappi ng screw and the cl amp.
GROMMET
Pul l out the heater core from the heater uni t.
NOTE: Be careful not to bend the i nl et and outl et
pi pes duri ng heater core removal .
Assembl e i n the reverse order of di sassembl y.
HEATER CORE COVER
21-41
'95
-
98 modolsi
Remove the dri ver' s dashboard l ower cover, the
gl ove box and the center dashboard l ower cover
(see
section 20).
Di sconnect the ai r mi x control cabl s from the heater
uni t {see
page 21-44).
Remove the rear window defogger switch, the hazard
warning switch and the audio unit
(see
section 23).
Di sconnect the connectors from the heater control
panel . Remove the fi ve sel f-tappi ng screws and the
center panel together wi th the heater control panel .
NOTE: The l ocki ng tabs are on the bottom of the
connecrors.
Install in the .everse order of removal. Adjust the air
mi x control cabl e and the heater val ve cabl e {see
page 21-44)..
Replacement
1 .
Remove the four self-tapping screws and the heater
21- 42
1 .
'9!,
-
00 modols:
Remove the center panel together with the heater
control
panel (see
section 20).
Remove the self-tapping screws and the heater con-
trol
panel from
the center Danel .
Install in the reverse order of removal. After
tion, operate the heater control
panel
to see
whether it works properly.
i nstal l a-
Overhaul
-' 96 -
98 Model s
HEATER FAN SWITCH
Test , page 21-49
Air Mix Control Cable Replacomenl
1. Cut the i nner cabl e on the l ever si de of the cabl e hol der, then remove both
pi eces of the i nner cabl e.
2. Usi ng a sharp kni fe, cut compl etel y through the end of the cabl e housi ng at the two l ocati ons.
3. Sl i dethe l argesecti on ofthecabl e housi ng outofthe cabl e hol der, bei ng careful not to da mage the cabl e stops.
4. Careful l y remove the cut pi eces of the cabl e housi ng wi th a smal l fl at ti p screwdri ver.
5. Hook the ti p of the new ai r mi x control cabl e to the temperature control l ever, then push the cabl e housi ng i nto the
cabl e hol der unti l i t l ocks i nto pl ace.
NOTE: After assembl y, check that the temperature control l ever sl i des smoothl y through the ful l stroke l rom ri ght to l eft.
21-43
Temperature Control
Adj ustment
-' 96 -
98 Model s
1. From under the hood, di sconnect the heater val ve
cabl e from the heater val ve.
TER
VALVE
CABLE HEATER VALVE ARM
2. From under the dash, di sconnect the ai r mi x control
cabl e housi ng from the cabl e cl amp,
AIR MIX
CONTROL
ARM
3. Set the temperature control l ever to MAX. COOL.
Wi th the ai r mi x control cabl e attached to the ai r
mi x cont r ol ar m, gent l y pul l on t he out er cabl e
housi ng to ful l y cl ose the door and to remove any
sl ack i n t he cabl e. Don' t pul l t o har d, or t he t emper -
ature control l ever wi l l move.
Hol d the ai r mi x control arm agai nst the stop. then
snap t he ai r mi x cont r ol cabl e housi ng i nt o t he
cabl e cl amp.
21-44
6. From under the hood. move the heater val ve arm to
t he f ul l y cl osed
posi t i on.
t hen at t ach t he heat er
val ve cabl e to the heater val ve arm.
7. Hol d the heater val ve arm i n the cl osed posi ti on,
and gentl y pul l on the heater cabl e outer housi ng to
take up any sl ack. then i nstal l the heater val ve cabl e
housi ng i nto the cabl e cl amp.
HEATER VALVE ARM
Adjustment
-'99 -
00 Models
1. From under the hood, open the cabl e cl amp, then
di sconnect the heater val ve cabl e from the heater
val ve arm.
From under the dash. di sconnect the heater val ve
cabl e housi ng from the cabl e cl amp, and di sconnect
the heater val ve cabl e from the ai r mi x control arm.
HEATER VALVE CABLE
Set the temperature control di al on MAX COOL wi th
the i gni ti on swi tch ON {l l ).
Attach the heater val ve cabl e to the ai r mi x control
arm as shown above. Hol d the end of the heater
val ve cabl e housi ng agai nst the stop, then snap the
heater val ve cabl e housi ng i nto the cabl e cl amp.
HEATER VALVE ARM
5. From under the hood. turn the heater val ve arm to
t he f ul l v cl osed oosi t i on as shown, and hol d i t ,
Attach the heater val ve cabl e to the heater val ve
arm, and
gentl y pul l
on the heater val ve cabl e hous-
i ng to take up any sl ack, then i nstal l the heater val ve
cabl e housi ng i nto the cabl e cl amp.
HEATER VALVE ARM
21-45
Air Mix Gontrol Motor
' t.
Test
-'99 -
00 Models
Di sconnect the 5P connector from the ai r mi x con-
trol motor.
Connect battery power
to the No. 1 termi nal of the
ai r mi x control motor, and ground the No. 5 termi ,
nal ; the ai r mi x control motor shoul d run, and stop
at MAX HOT. l f i t doesn' t, reverse the connecti ons;
the ai r mi x control motor shoul d run, and stop at
MAX COOL.
l f the ai r mi x control motor does not run, remove
i t , t hen check t he ai r mi x cont r ol l i nkage and
doors for smooth movement.
l f they move smoothl y, repl ace the ai r mi x con-
trol motor.
Measure the resi stance between the No.2 and No.3
termi nal s. l t shoul d be approxi matel y 4.8 to 7.2 kO.
Measure the resistance between the No. 2 and No. 4
termi nal s. l t shoul d be approxi matel y 3.84 to 5.76 kO
at MAX HOT and approxi matel y 0.96 to 1.44 kO at
MAX COOL.
21-46
5P OONNECYOB
Repl acement
-' 99 -
00 Model s
1, Di sconnect the 5P connector from the ai r mi x con-
trol motor. Remove the sel f-tappi ng screws, the ai r
mi x control motor and the fl ange col l ar.
CONTROL
MOTOR
Install in the reverse order of removal. After installa-
t i on, make sur e t he ai r mi x cont r ol mot or r uns
smoothl y.
Mode Control Motor
2.
Test
1 .
4.
Di sconnect the 7P connector from the mode control
motor.
Connect battery
power
to the No, 1 termi nal , and
gr ound t he No. 7 t er mi nal ,
CAUTION: Never connecl the battery in iho oppo-
site direction.
Usi ng a
j umper
wi r e, connect t he No. 7 t er mi nal
i ndi vi dual l y t o t he No. 2, 3, 4, 5 and 6 t er mi nal s i n
that order. Each ti me the connecti on i s made, the
mode control motor shoul d run smoothl y and stop.
NOTE: l f the mode control motor does not run when
j umpi ng
the fi rst termi nal ,
j ump
that termi nal agai n
after
j umpi ng the other termi nal s. The mode control
motor i s OK i f i t runs when
j umpi ng
the fi rst termi -
nal agai n.
MODE CONTROL MOTOR
l f the mode control motor does not run i n step 3,
remove i t. then check the mode control l i nkage and
doors for smooth movement. l f they move smoothl y,
reol ace the mode control motor,
Repl acement
1. Di sconnect the 7P connector from the mode control
motor,
Remove the rod from the arm of the mode control
motor.
Remove the tyvo self-tapping screws and the mode
control motor.
l nstal l i n the reverse order of removal . After i nstal l a'
t i on, mak e s ur e t he mode c ont r ol mot or r uns
smoothl y.
7P CONNECTOR
21- 47
Test
L Di sconnect the 4P connector from the reci rcul ati on
control motor.
Connect battery power to the No. I termi nal , and
ground the No.2 and No. 4 termi nal s; the reci rcul a-
ti on control motor shoul d run smoothl y.
CAUTION: Never connest ths battery in the oppo-
site direction.
Di sconnect the No. 2 or No. 4 termi nal s from ground;
the reci rcul ati on control motor shoul d stop at FRESH
or RECIRCULATE.
NOTE: Don' t cycl e the reci rcul ati on control motor
for a l ong ti me.
4. lf the recirculation control motor does not run in step
2, remove i t, then check the reci rcul ati on control l i nk-
age and door for smooth movement. l f they move
smoothl y, repl ace the reci rcul ati on control motor.
21-48
Repl acement
L Di sconnect the 4P connector from the reci rcul ati on
cont r ol mot or , and r emove t he wi r e har ness cl i p
from i t.
Remove the two self-tapping screws and the recir-
cul ati on control motor.
Install in the reverse order of removal. After installa,
ti on, make sure the reci rcul ati on control motor runs
smoothl y.
4P CONNECTOR
CONTROL MOTOR
Rel ays
Heater Fan Switch
Test
There shoul d be conti nui ty between the No 1 and No. 3
termi nal s when
power and ground are connected to the
No.2 and No. 4 termi nal s, and there shoul d be no conta-
nui ty when
power i s di sconnected.
Bl ower motor rel aY
. Bl ower motor hi gh rel ay
(' 99
00 model s)
, I I
t ;
' Y
)
Test
-' 96 -
98 Model s
Check for conti nui ty between the termi nal s accordi ng to
the tabl e bel ow.
l er mi nal
Posi ti on
1 4 2 5 3
OFF
1 I
rJ
2
o
- o
3
o-
a
4
c)-
{
21-49
Mode Control Switch
Power Transistor
Test
-'96 -
98 Models
Check for conti nui ty between the termi nal s accordi nq to
the tabl e bel ow.
Termi nal
Posi ti on
' t0
7 1
Heat o
-o
HeaVDef o-
--o
Def o-
-o
Vent G
-o
HeaVVent o-
-o
1
;l
t
4
7 8 9
21-50
Test
-'99 -
00 Models
1. Di sconnsct the 3P connector from the oower tran-
stsror.
2, Careful l y rel ease the l ock tab on the No. 2 termi nal i n
the 3P connector, then remove the terminal and insu-
late it from body glound.
Connect a 1.2
-
3.4 W bul b between the No. 1 and
the No. 2 cavi ty on the 3P connector.
Reconnect the 3P connector to the power transl stor.
Turn the i gni ti on swi tch ON fl l ), and check that the
bl ower motor runs.
12V 1. 2- 3, 1W
No. 1 laLU/aLK)
Speci af Tool s
. . . . . . ' . . . . . ' 22-2
f f f ust rat ed f ndex . . . . . . . . . . . . . . . . . . . . . . . . . ". . . . . . . ' 22-3
Wi ri ng/ Connect or
Locat i ons' . . . . . . . . . ' . . . .
22' 4
Description
Out f i ne . . . . . . . . . . . .
. . . . . . . 22-s
Circuit Diagram
' 96
-
98 Model s . . . . . . ". . . . . . . . . . ". . . . . . . ' . . . .
22-6
' 99
Modef
"""""""' 22-7
Troubleshooting
Sympt om
Chart ". ' . . . . . . "". . . . . . . . . . . . . . . . .
22-8
Flowcharts
Condenser
Fan . . . . . . . . . ". . . . . . . . . . . . . . . . . , . . ' .
22-9
Compressor
.....""" 22-12
A/ C Syst em
. . . . . . . . . ' . 22' 17
A/C Thermostat
Test . . . . . . . . ' . . . . . . . '
"""' 22' 21
Relays
Test . . . . . "' . . . . . . . . .
. . ""' 22-21
A/C Service Tips and Precautions ......22-22
A/C System Torque Specifications
' ...22-23
A/C System Service
Perf ormance
Test . . . ' . ". . . . . . . . . ". . . . . . . . ' . . 22-24
Pressure Test Chart .................. .... "' 22-26
Recovery
. . . ". . . . . . . . . , " 22-27
Evaporator
Replacement
.....",' 22' 24
Overhauf
.....-.....""' 22' 29
Compressor {SANDEN}
Repf acement
......' .' 22-30
f f f ust rat ed f ndex . . . . . . ". . . . . . . . . . . . . . . . . . ' . . . .
22' 32
Cf utch Inspection ......... "............ ...... 22-33
Cl ut ch Overhau I . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 22-34
Thermal Protector Replacement
.... 22-36
Relief Valve Replacement
......' ..."". 22-36
Compressor
(DENSO)
Repfacement
..""' ,' 22-37
l f l ust rat ed I ndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22-39
Cl ut ch l nspect i on
. . . . . . . . . . . . . "' . . . . . . "' . . . . 22-40
Cf ut ch Overhaul
. . . . . . . . . . . . . . . . . . . . . ' . . . . . . . . .
22-41
Ref ief Valve Replacement' ..' ......"' ..
22-42
A/C Compressor
Belt
Adi ust ment
. . . . . . . . . . . . 22' 43
Condenser
Repfacement
.......,,22' 44
A/C System Service
Evacuat i on
. . . , , , . . . . . . . 22-45
Chargi ng
' . . . . . . . . . . --' . . 22' 46
Leak rest
"""""""' 22-46
Special Tools
Bef. No. Tool Number
Description
Qty
I
Page Reference
o
@
* 07JGG
-
00l 0l 0A
07sAz
-
0010004
07947
-
6340300
07965
-
6920500
Backprobe Set
Dri ver Attachment
Hub Assembl y Gul de Attachment
1
'1
1
22-43
22- 14, 16
22-34
22-35
'
Incl uded i n the Bel t Tensi on cauge Set, 07TGG-0010004.
a
6r
L
3r
22- 2
lllustrated
Index
A/C PRESSURE SWITCH
When t he ref ri gerant
pressure i s bel ow 200 kPa {2 0 kg7cm' ,
28
psi ) due t o ; f ri gerant l eakage or above 3200 kPa
(32
kgf / cm' '
455 psi ) due t o ref ri gerant bl ockage, t he l VC
pressure swrt ch
SERVICE VALVE
{LOW.PRESSURE
SIDE)
EVAPORATOR
Repl acement ,
page 22-28
Overhaul ,
page 22 29
Bepl acement , Page
22' 44
opens l he ci rcui t t o i he AVC swi t ch and st ops t he ai r condi l i oni ng
t o prot ect t he comPressor'
RECEIVER/DRYER
COMPRESSOR
SANDENI
Repl acement , Page
22 30
CI ut ch I nspect i on, Page
22 33
Thermal Prot ect or I nspect i on,
page 22 33
Cl ut ch Overhaul , Page
22' 34
Thermal Prot ect or Repl acement ,
page 22 36
Refief Vafve Replacemenl,
page 22'36
DENSO:
Repl acement , Page
22-37
Cl ut ch I nspect i on, Page
22-40
Cl ut ch Overhaul , Page
22_41
Rel i ef Val ve Repl acement ,
page 22-42
A/C THERMOSTAT
Test ,
page 22 21
22-3
Wiring/Gonnector
Locations
A/C DIODE.
CONDENSER FAN RELAY,
COMPRESSOR CLUTCH RELAY
(Located
in the under,hood fuse/relay box)
CONDNSER FAN
CONNECTOR
COMPARTMENT
WIRE HARNESS
CONNECTOR
22-4
Description
Outline
The ai r condi ti oner system removes heat from the
passenger compartment by ci rcul ati ng refri gerant through the system
as shown bel ow.
BLOWER FAN
EVAPORATOR
(Absorpt i on of heat i
EOUALIZING TUBE
(Met ers pressure and
i mproves t he expansi on
val ve react i on t i me)
i nt o t he evaporat or)
CAPILLATY TUBE SENSING BULB
l Cont rol s t he t emPerat ure of t he
ref ri gerant l eavi ng t he evaporat or
by met eri ng t he expansi on
val ve)
/ \
THERMOSTAT
A/C PRESSURE SWITCH
When t he ref ri gerant i s bel ow
200 kPa
(2. 0 kgt cm' , 28
Psi )
or above 3,200 kPa 132 kgflcm',
455
psi), the Ay'C pressure
swi t ch opens t he ci rcui t t o
the A,/C switch and stops the
EXPANSION VALVE
(Met ers t he requi red
amount of ref ri gerant
ai rcondi t i oni ng
t o
Prot ect
t he
compressor.
RECEIVER/DRYER
(Traps
debri s, and
removes morst urel
THERMAL PROTECTOR
{Opens t he comPressor
cl ut ch ci rcui t when t he
compressor t emPerat ure
becomes t oo hi gh)
RELIEF VALVE
(Rel i eves pressure at t he
compressor
when t he
pressure i s t oo hi gh)
(Radi at i on of heat )
I
f-r--; I
(Suct i on and comPressi on,
HIGH PRESSURE VAPOR
HtGH PRESSUBE LIOUID
LOW PRESSURE LIOUID
Thi s car uses HFC-134a
(R-134a) refri gerant whi ch does not contai n chl orofl uorocarbons
Pay attenti on to the fol l owi ng
service items:
. Do not mi x refri gerants CFC-12
(R-12)
and HFC-134a
(R-134a)' They are not compati bl e'
. Useonl ythe recommended
pol yal kyi enegl ycol
(PAG) refri gerant oi l desi gnedforthe
R-134a compressor
(SANDEN: SP-
10; DENSO: ND_OIL8). Intermi xi ng i he re-commended
(pAG)
refri gerant oi l wi th any other refri gerant oi l wi l l resul t i n
compressor fai l ure.
. Al l A,,i c system
parts
{compressor,
di scharge l i ne, sucti on l i ne, evaporator, condenser, recei ver/dryer,
expansi on val ve'
O-ri ngs for
j oi nts) have to be
proper for refri gerant R- 134a Do not confuse wi th R-l 2
parts'
. Use a hal ogen
gas l eak detector desi gned for refri gerant R-134a
. R-12 and R-134a refrigerant servacing equipment are not interchangeable.
Use only a recovery/recycling/charging
station
that is u,L.-listed and is certified to meet the requirements of sAE J2210 to service R-134a air conditioning systems'
. Always recover the refrigerant R-134a with an approved recovery/recycling/charging
station before disconnecting any
A,/C fitting.
S]
22-5
Ci rcui t Di agram
UNDER DASH
FUSE/RELAY 8OX
N0. 17 ( 7. 54)
' 96
-
98 Model s
UNDER.HOOD FUSEi BELAY BOX
WHT/SLU BLKYEL
BLK
+
G751
3
' o
I
8LK
I
G40l
G402
GNI TON SWI TCH
N0.41 (8rA) N0.42 (40A)
COMPBESSOR
CLUTCH
BELAY
BLUMHT
, l
( E)
i
, T'
BLUi BED
A/c I
THERMOSTAI BLU/REO
CONDENSEF
FAN MOTOR
*F,.X,
FAN r l
BLK
{
G401
G402
HEATER
swrlcH
3
2
22-6
'99
-
00 Models
UNDER DASH
FUSE/BELAY BOX
No. l 7 ( 7. 54)
BLK
I
G751
$*"
O
:8P coNNEcToF
n
:20P CONNECToF
E
12P coNNEcroR
BLK
d
-
G401
G402
UNDER HOOD FUSE/RELAY 8OX
N0.41 (P,0A) N0.42 (404)
COMPRESSOR
CLUTCH
FELAY
GNI TON SWTCH
HEATER CONTROL PANEL
22-7
Troubleshooting
Symptom Chart
NOTE:
. Any abnormal i ty must be corrected before conti nui ng the test.
. Because of the preci se
measurements needed. use a mul ti meter when testi nq.
. Before performi ng
any troubl eshooti ng procedures
check:
-
Fuses No. 47
l 7
-5 Al , No. 56
(20
A) i n the under-hood fuse/rel ay box, and No. 17
(7.5
A) i n the under_dash fuse/rel av
box
-
Grounds No. c401, c402, G751
-
Cl eanl i ness and ti ghtness of al t connectors
Symptom
Remedy
Condenser fan does not run at al l .
Perform the procedures
in the flowchart
{see
page
22-9).
Compressor cl utch does not engage.
Perform the procedures
in the flowchart
lsee
page
22-12).
Ay'C system does not come on
(compressor
and fan), Perform the procedures
in the flowchan (see page 22-17).
Both heater and A,/C do not work. .
'96
-
98 models-Perform the procedures
in the flowchart
{see
page 21-18).
.
'99
-
00 models-Perform the procedures in the flowchart
(see page 21-35).
22-8
Condenser
Fan
CONDENSER
FAN RELAY 4P SOCKET
JUMPER
wlRE
(cont ' d)
22-9
Conden3er fan does not run at all.
Check the No. 56
(20 A) fuse in the
unde.hood frJse/relaY box, and the
No. 17
(7. 5 A) f use i n t he under-
Reolace the fuse{s), and techeck
Remove the condenser lan rclaY'
and t est i t
(see page 22 21i
Replace the condensei fan relav.
Check the under-hood tus6/relaY
Measure t he vohage bet ween t he
No. 2 t ermi nal of t he condenser f an
relav 4P socket and bodv ground.
Check the condenser lan
Power
supply circuit:
Connect t he No. 1 and No. 2 t eF
mi nal s of t he condenser f an rel ay
4P socket wi t h a
j umper wi re
Does t he condenser f an run?
To page 22- 10
I o page 22 11
Troubleshooting
Condenser Fan
(cont'd)
CONDENSER FAN RELAY 4P SOCKET
CONDENSEB FAN 2P CONNECTOR
-=F_
l ! . l
I slx
@
I
Check tor an opon in the wi.o:
1. Di sconnect t he
j umper
wi re.
2. oi sconnect t he condenser t an
2P connect or.
t he No. 1 t ermi nal of t he con-
denser f an rel ay 4P socket and
t he No. 1 t ermi nal of t he con-
denser f an 2P connect or.
Rapair op6n in the wirs bgtwcon
the condcnsor tan rclay and the
condgnlar fan.
Check to. en open in the wire:
No. 2 t ermi nal ot t he condenser
f an 2P connect or and body
ground.
Check I or rn opon i n t h6 wi re
bctwoen the condcnser tan and
body ground,
lf iho wirc ii OK,
chcck for poor ground
at G751.
Replaco the condense. fan motor.
22-10
Check the diode:
1. Di sconnect t he
i umPer
wi re
2. Remove t he A/ C di ode f r om
t he under hood f use/ rel aY box
3. Check f or current f l ow i n bot h
di rect i ons bet ween t he A and
B t ermi nal s.
l s t here current f l ow i n onl Y
one di rect i on?
Chock for an open in the wire:
( l l ) .
t he No. 2 t ermi nal of t he AJC
di ode 2P socket and body
ground.
Repair opon in the wire betwen
t he No. 17 l use and t he A/ c
di ode.
B()-=iFA
A/C DIOOE 2P SOCKET
Troubleshooting
Compressor
.P SOCKET
JUMPER
WIRE
check the No. 56
(20
A) fuse in the
under'hood fuse/relay box, and the
No. 17
(7. 5
A) f use i n t he under,
Replace the fussls), and .echeck.
Remove t he compressor cl ut ch
rel ay, and t est i t {see
page
22 21).
Check th6 undr-hood tu3e/reby
No. 2 t ermi nal of t he compressor
cl ut ch rel ay 4P socket and body
ground.
Check t he compr essor cl ut ch
powr
supply circuit:
Connect the No. 1 and No. 2 termi-
nals of the compressor clutch relay
4P socket with a
jumper
wire.
Does t he compressor cl ut ch cl i ck? fo page
22-13
To page 22 14
22- 12
Ft om page 22 12
Check to. an opon in tho wire:
1. Di sconnect t he
j umper wi re
2. Di sconnect t he comPr essor
cl ut ch 1P connect or.
t he No. 1 t ermi nal o{ t he com_
pressor cl ut ch rel aY 4P socket
and t he t ermi nal of t he com-
pressor cl ut ch 1P connect or'
Repeir open in the wiro between
the compressoa clutch relaY and
the comDres3or clulch.
I nspect t he comPre3sor cl ut ch
clo.rance, lhe tharmal Protgdor
I SANDENI , and t ha compr6ssor
cl ut ch f i el d coi l {SANDEN: Soe
pag. 22-33; DENSO: See
Pag.
22-10t.
iaP SOCKET
r--------t RED
L-r-]-_l
l 2 l I
--r- |
l 1 l 3 l I
@
I
H I
1___J-RED
COMPRESSOR CLUTCH 1P CONNECTOR
(cont' d)
22-13
Troubl eshooti ng
Compressor
l cont' dl
4P SOCKET
l--;l
1 2 |
---r--]
l . l 3 |
L-J--J
]
BLK/YEL
A
(v)
!
ECM/PCM CONNECTOR A I32P}
Wi r e si de of f emal e t er mi nat s
*Howt o
use t he backpr obe set s
Connect t he backpr obe adapt er s t o t he st ackang pat ch
cor ds, and
connect t he cor ds t o a mul t i met er . Usi ng t he wi r e i nsul at i on as a
gui de f or t he cont our ed t i p of t he backpr obe adapt er , gent l y
sl i de
t he t i p i nt o t he connect or f r om t he wi r e si de unt i l i t comes i n con-
t act wi t h t he t er mi nal end of t he wi r e ( see
sect i on 11) .
Frcm page
22-12
To page
22-15
Check Ior an open in the wire;
1. Di sconnecl t he
j umper
wi re.
2. Turn t he i gni t i on swat ch ON
(l l ).
3. l \ 4easure t he vol t age bet ween
t he No. 4 t ermi nal of t he com-
pressor cl ut ch rel ay 4P socket
and body ground.
the No. 17 fuso and the compres-
sor clutch relav.
Check for an open in the wira:
t hen rei nst al l t he compressor
cl ut ch rel ay.
2. Make sur e t he A/ C swi t ch i s
OFF, t h e n t u r n t h e i g n i t i o n
swi t ch ON
(l l ).
3. Usi ng a
*Backprobe
Set
(T/ N
07SAZ 0010004) , measur e
t he vol t age bet ween t he No.
17 t er mi nal oI t he ECM/ PCM
connect or A
(32P)
and body
gr ound wi t h t he ECM/ PCM
connect ors connect ed.
Repair open in the wirc betweon
the compressor clutch relay and
the ECM/PCtvt.
Frcm
page 22-14
3. Turn t h i gni t i on swi t ch ON l l l ).
t he No. 1 t ermi nal of t he AJC
pressure swi t ch 2P connecl or
and body
ground.
Check the A/C
pressure switch:
t he No. 1 and No. 2 t er mi nal s
of the Ay'C pressure switch.
Check f or A/ C syst em pt essure.
l s t he pr essur e wi t hi n sPeci _
f c at i ons ?
Repair the A/C pressure
Problem
A/C PRESSURE SWITCH 2P CONNECTOR
wi re si de of {emal e t ermi nal s
A/C PRESSURE SWITCH
t he condenser f an rel ay t nd t he
A/C oressure switch.
1o page 22-16
(cont' d)
22-15
Troubleshooting
Gompressor
(cont'dl
'96
-98
models:
'9!t
-
00 mod.bi
*How
to use the backprobe sets
Connect the backprobe adapters to the stacking patch cords, and
connect t he cords t o a mul t i met er. Usi ng t he wi re i nsul at i on as a
gui de f or t he cont oured t i p of t he backprobe adapt er,
gent l y
sl i de
t he t i p i nt o t he connect or f rom t he wi re si de unt i l i t comes i n con-
t act wi t h t he t ermi nal end of t he wi re {see sect i on 11}.
From page 22-15
Check for an open in thg wire:
' 1.
Reconnect t he A"/ C pressure
2. Make sure t he A/ C swi t ch i s
OFF, t hen t ur n t he i gni t i on
swi t ch ON
(l l ).
3. Usi ng a
*Backprobe
Set {T/ N
07SAZ
-
001000A), measure
t he vol t age bet ween t he No. 5
t ermi nal of t he ECM/ PCM con-
n e c t o r C
( 3 1 P)
a n d b o d y
gr ound wi t h t he EcM/ PcM
connect ors connect ed
(' 96 -
98 model s), or bet ween t he
No . 2 7 t e r mi n a l o f t h e
ECM/ PCM connect or A
(32P)
and body gr ound wi t h t he
ECM/ PCM connect or s con
nect ed
(' 99 -
00 model s).
Rapdir open in tho wi?e botwaon
the A/C
pr..-ruro
lwitch rnd th.
ECM/PCM.
Check l or l oo3e wi res or oool
connect i ons at t he ECM/ PCM
connectoB A l32P) and at the A/C
pressure switch 2P connector, lf
the connections are
good,
substi-
t ut e a known-good ECM/ PCM,
and recheck. l f t he svmpt om/
indication goos
away, repbce the
original ECM/PCM.
3 1 5 0 1 E 9 10 1 1
t a t6 l 1 1E 19 21 22 23 21
BLU/RED
22-16
A/C System
CONDENSER FAN RELAY 4P SOCKET
A/ C syst em does not come on
{comDressor and fan).
Ch e c k t h e No . 5 6 f u s e i n t h e
under ' hood f use/ r el ay box and
t he No. 17 f use i n t he under-dash
f use/ rel ay box.
ReDlace the fus6{s}, and recheck.
Check for tn open in the wire:
1. Remove t he condenser l an
r el ay f r om t he u nder hood
luse/relay box.
2. Turn t he i gni t i on swi t ch ON {l l i .
3- Measure t he vol t age bet ween
t he No. 4 t ermi nal of t he con
denser f an r el av 4P socket
and body ground.
t he No. 17 f use and t he con-
denser fan r6lay,
Check the under-hood fus/r6lay
box:
No. 2 t ermi nal of t he condenser
f an r el ay 4P socket and body
ground,
YES
Io
page 22-18
(cont' d)
Troubl eshooti ng
A/C System
(cont'd)
From page 22-11
.
_Ff,, __
I 1 1 2 1 3 [
,r,il*"-T",-.r-'..o
wrRE
I
To page 22-19 1' 96
-
98 model s)
A/C THERMOSTAT 3P CONNECTOR
Wire side oI female terminals
2. Di sconnect t he A/ C t hermo
stat 3P connector.
(l l ).
t he No. 3 t ermi nal of t he Ay' C
t hermost at 3P connect or and
body ground.
Repai. open in the wire between
tho No. 17 tuso and the A/C the.-
mostat.
Check loi an open in the wi.e:
No. 1 t ermi nal of t he A, / C t hermo
st at 3P connect or and body
ground,
Ropair open in the wire betwoen
the condedlo. lan rolay and the
A/C thormostat.
Check the A/C th6rmostat:
2. Reconnect the A,/C thermostat
3P connect or.
3. Connect t he No. 2 t ermi nal t o
ground wi t h a
i umperwi re.
Do the fan run and the com-
pressor clutch engage?
To page 22-20
(' 99 -
00 model s)
22-18
Ft om page 22 18
i u
mper
l ower cover l see sect i on 20),
and di sconnect t he heat er con'
t rol
(l l ).
ground.
Repair op6n in the wire bstween
the A/C thrmostat and th6 hoater
control
panel.
2 . Di s c o n n e c t t h e h e a t e r I a n
swi t ch 6P connect or,
heat er cont rol
panel 14P con_
of the heater fan switch 6P con-
nector.
Repair open in the wiro betweGn
the heal.r control
Panel
and the
heater fan switch.
Check for an open in thG wire:
No. 1 t ermi nal of t he heat er l an
swat ch 6P connect or and bodY
gr ound.
Chock t or an open i n t ho wi r
between the heater lan switch
and body ground. lf the wire is OK,
check for
poor ground at G401 snd
G402.
l s t here cont i nu; t y?
ReDlace the heater tan switch. l s t he heat er f an swi t ch OK?
Check f or l oose wi aes or
poor
oanel 14P connoctor and hoeter
tan 3witch 5P connclor and at
t he A/ C t her most et 3P connec-
tor. ll the connections are good,
raplace the heator control
Panel.
r ' oA -
qe
m^ . l al al
HEATER CONTROL PANEL lilP CONNECTOR
t r
a 6
7 I I 'o
lx
' t 1
12 1 3 1 4
BLU/RED
HEATER CONTROL PANEL 1'P CONNECTOR
Wi re si de of f emal e t errni nal s
HEATER FAN SW]TCH 6P CONNECTOR
(cont' d)
1 2
;--?
4 5
7 I 10
X
' l l
12 13 1 4
GRN
1 2 3
a 5 6
GRN
22-19
Troubleshooting
(' 99
00 model s)
From page 22 18
j u
mper
3. Turn t he ; gni t i on swi t ch ON
{

i .
heat er cont rol panel 20P con-
Ropai. opan in tho wira batwaon
t he A/ C t her most at and t he
hoater control oanol.
Check the push switch:
2. Di sconnect t he push swi t ch
12P connect or.
t he No. I and No. 10 t ermi nal s
of t he
push
swi t ch 12P con-
nector with the A/C switch ON.
Check f or l oose wi . es or
poor
connections el the hgater control
panel 20P connect or and push
switch 12P connector and at the
A/C thermostat 3P connector. It
tha connections are
good,
substi-
tute a known-good heatea con-
t rol pan| , and recheck. l f t he
symptom/indication
goe3
away,
repl ace l he ori gi nal heal er con-
trol oan|,
HEATER CONTROL PANEL anP CONNECTOR
PUSH SW]TCH 12P CONNECTOR
,/1,/
1 5 6
7 8 1 9 t 0 1 1 12
I
I
I
A/C Thermostat Relays
Test
1 . Remove the Ay' C thermostat
(see page 22-29).
Connect baftery
power to the No. 3 termi nal ,
ground
the No. 2 termi nal , and connect a test l i ght between
the No. 1 and No. 3 termi nal s.
NOTEr Use a 12 V, 3 W- l 8 W t est l i ght .
Dip the IVC thermostat into a cup filled with ice water,
and check the test l i ght.
Serp6ntine-type evaporator
The l i ght shoul d
go off at 36
-
39' F {2
-
4"C} or l ess, and
shoul d come on at 39
-
41"F
(4 -
5"C) or more
Laminale-type evaporator
The l i ght shoul d
go off at 39
-
43' F
(4 -
6' C) or l ess, and
shoul d come on at 43
-
45"F
(6 -
7' C) or more
l f t he l i ght doesn' t come on and go of f as speci f i ed,
repl ace the PVC thermostat.
1 2 V , 3 W- 1 8 W
Test
There shoul d be conti nui ty between the No, 1 and No.2
termi nal s when
power and ground are connected to the
No.3 and No. 4 termi nal s, and there shoul d be no conti -
nui tv when Dower i s di sconnected.
2
Condenser fan rel ay
Compressor cl utch rel ay
a
a
, I I
b
I n I o
' r
I
t \ - - - - , '
t : n
,,l[4..-.
22- 21
A/C Service Tips and Precautions
The ai r condi ti oner system uses HFC-134a
(R-134a)
refri gerant and pol yal kyl enegl ycol (PAG)
refri gerant oi l *, whi ch are not
compati bl e wi th CFC-12
(R-12)
refri gerant and mi neral oi l . Do not use R-12 refri gerant or mi neral oi l i n thi s system, and do
not attempt to use R-12 servi ci ng equi pmenU damage to the ai r condi ti oner system or your servi ci ng equi pment wi l l resul t.
*Sanden
SP-10:
. P/N 38897
-
P13
-
A0l AH: 120 ml 14l l .oz, 4.2l mp.oz)
. P/N 38899
-
P13
-
A0l | 40 mf 11 1/3l l .oz,1.4 l mp' oz)
Use onl y servi ce equi pment that i s U.L. l i sted and i s certi fi ed to meet the requi rements of SAE J2210 to remove R 134a
from the ai r condi ti oner system.
CAUTION: Exposure to 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.
l f acci dental system di scharge occurs, venti l ate work area before resumi ng servi ce.
R-' 134a servi ce equi pment or vehi cl e ai r condi ti oner systems shoul d not be pressure tested or l eak tested wi th compressed
ai .
!@@
some mixtures of air and R-t3ila have been shown to be combustible at elevated pressures and can result
in tire or explosion causing iniury or property damage. Never use compressed air lo
pressure tesl R-134a service equip-
ment or vehicle 8ir conditioner systoms.
Addi ti onal heal th and safety i nformati on may be obtai ned from the refri gerant and Iubri cant manufacturers.
L Al ways di sconnect the negati ve cabl e from the battery whenever repl aci ng ai r condi ti oni ng pans.
2. Keep moi sture and dust out of the system. When di sconnecti ng any l i nes, pl ug or cap the fi tti ngs i mmedi atel y; don' t
remove the caps or pl ugs unti l
j ust
before you reconnect each l i ne.
3. Before connecti ng any hose or l i ne, appl y a few drops of refri gerant oi l to the O-ri ng.
4, When ti ghteni ng o. l ooseni ng a fi tti ng, use a second wrench to support the matchi ng fi tti ng.
5. When di schargi ng the system, use a R-134a refri gerant recovery/recycl i ng/chargi ng stati on; don' t rel ease refri gerant
i nto the atmosphere,
6. Add refri gerant oi l after repl aci ng the fol l owi ng parts:
NOTE:
. To avoi d contami nati on, do not return the oi l to the contai ner once di spensed, and never mi x i t wi th other refri ger-
ant oi l s.
. l mmedi atel y after usi ng the oi l , repl ace the cap on the contai ner, and seal i t to avoi d moi sture absorpti on.
. Do not spi l l the refri gerant oi l on the vehi cl e; i t may damage the pai nt; i f the refri gerant oi l contacts the pai nt, wash
i t off i mmedi atel y.
Condenser .......2o ml
(2/3
fl .oz, 0.7 l mp.ozl
Evaporator .,.,.,.
i[5
m{ 11 213 tl.oz,1,6lmp.ozl
Li ne or hose ..... 10 mf
(1/3
fl .oz, 0.4 l mp.ozl
Recei ver/Dryer 10 m{
(1/3
fl .oz,0.' l l mp.ozl
Leakage repair 25 m{
(5/6
fl.oz, 0.9 lmp.ozl
Comptessor ... For compressor repl acement. subtract the vol ume of oi l drai ned trom the
removed compressor from A, and drain the calculated volume of oilfrom the new
compressor: A
-
Volume of removed compressor: Volume to drain from new
comoressor.
A: SANDEN 130 mf l /t 113 l l .oz, 4.6 l mp' ozl ; DENSO 140 mf {4 213 l l ' oz, 1.9
l mp.oz),
NOTE: Even i f no oi l i s drai ned from the removed compressor, don' t drai n more
t han S0 m{ 112El l . oz, 1. 8 l mp. oz) f r omt he new compr essor .
REMOVED
NEW
COMPRESSOR
COMPRESSOR
*DENSO
ND-Ol L 8l
. P/N 38897
-
PR7
-
A01AH: 120 ml
(4
fl .oz)
. P/ N 38899 PR7- A01: 40mf
( 1
1/ 3f l ' oz)
r er e
W W
0 0 0 0
22- 22
-0_!- -0_a
T o l l 0 0 l
| | lffi 1
onrrrutrc
I
fi+-sAME
LEvEr...+jEf,voLUME
J
^
A/C System Torque Specifications
O
Di scharge hose to the compressor
(6
x 1.0 mml ............... .. .... ...............' 9.8 N' m {1.0
kgf' m,7.2 l bf' ftl
@
Di scharge hose to the condenser {6 x 1.0 mm1................... ' ... ...... . ......... 9.8 N' m 11.0 kgf' m, 7.2 l bf' ft}
O
Condenser
pi pe to the condenser 16 x 1,0 mm)...............' . . . . ...........' ..... 9.8 N' m
(1.0
kgl ' m, 7.2 l bt' ft)
@
Condensel
pi pe to the recei vel /dryer
(5
x 1.0 mml ......... ..... . ... . ' .......... 9.8 N' m
(1.0
kgl ' m, 7.2 l bt' ft)
O
Recei ver pi pe A to the l ecei ver/dryer {6 x 1.0 mm)......... ... .......... .. . . .... 9.8 N' m 11.0 kgf' m. 7.2 l bl ' ft)
@
Receiver
pipe B to the receiver pipe A
13 N m
(1.3
kgf'm, 9.'l lbf'ft)
O
Receiver pipe C to the receiver pipe B 13 N m
(1.3
kgf'm, 9.4 lbnftl
@
Recei ver
pi pe C to the evaporator {6
x 1.0 mm) ....... 9.8 N' m
(1.0
kgf' m, 7.2 l btftl
O
Sucti on
pi pe B to the evaporator
(6
x 1.0 mml ................ . .........' ......' ....... 9.8 N' m
(1.0
kgf m, 7.2 l bf' ftl
e0
Sucti on
pi pe A to the sucti on pi pe B ...' . . ...... . ... ...... 31 N' m
(3.2
kgt' m, 23 l bf' ftl
O
Sucti on hose to the sucti on pi pe A... ............ . . ' ......... 31 N' m
(3.2
kgl ' m, 23 l bf' ft|
@
Sucti on hose to the compressor
(6
x 1.0 mm)................... .. . ... .. ............ 9.8 N' m
(1.0
kgf' m' 7.2 l bf' ft|
@@ Compressor to the compressor bracket
(8 x 1.25 mm)... ..-........' .' ......-.......24 N' m
(2 ' l
kgf' m, 17 l bf ftl
@
Compressor bracket to the cytinder block
(10
x 1.25 mml 44 N'm l'1.5 kgf'm, 33 lbf ftl
@
Compressor bracket to the l eft front engi ne mounl {12
x 1.25 mm}..... . . . . .. ................. ... ... 59 N' m
(6.0
kgf' m,
' | i }
l bf ftl
22-23
A/C System Service
Performance Test
The
performance test wi l l hel p determi ne i f the ai r con-
di ti oner system i s operati ng wi thi n speci fi cati ons.
Use onl y servi ce equi pment that i s U.L.-l i sted and i s cer-
ti fi ed to meet the reoui rements of SAE J2210 to remove
HFC-134a
(R-134a)
CAUTION: Exposure to air conditionor rofrigerant and
l ubri cant vapor or mi st can i rri l al o yes, nose and
throat. Avoid breathing tho air conditioner rstrigerrnt
and lubricant vapor or mist,
l f acci dental system di scharge occurs, venti l ate work
area before resumi ng servi ce.
R-134a servi ce equi pment or vehi cl e ai r condi ti oner sys-
tems should not be pressure tested or leak tested with
compressed ai r.
@
some mixtur$ of air and R-134a have been
shown lo b9 combustible rt
glgvatad prssur63
and can
resul l i n ti re 01 oxpl osi on causi ng i nl ury ot
property
damage. Never uao compre33ed air to pressure t99t R-
134a ssrvico 6quipmsnt or vohicla air conditioner sys-
tems.
Additional health and safety information may be obtained
from the refrigerant and lubricant manufacturers.
' 1.
Connect a R-134a refri gerant recover/recycl i ng/
chargi ng stati on to the vehi cl e, as shown, fol l owi ng
2. l nser t a t her momet er i n t he cent er vent out l et .
Determi ne the rel ati ve humi di ty and ai r tempera-
ture,
Test condi ti ons:
. Avoi d di rect sunl i ght.
. Open hood.
. Open front doors.
. Set the temDerature control l ever or di al to MAX,
COOL, the mode control swi tch or di al on VENT
and the reci rcul ati on control swi tch on RECIRCU-
LATE.
. Turn the A,/C switch on. and the heater fan switch
on MAX.
. Run the engi ne at 1,500 rpm.
. No dri ver or
passengers i n vehi cl e
After runni ng the ai r condi ti oni ng for 10 mi nutes
under the above test condi ti ons, read the del i very
temperature from the thermometer i n the dash vent
and the high and low system
pressure from the A,/C
gauges.
Recovery/Rocycling/Charging Station
22-24
5. To compl ete the charts:
. Mark the del i very temperature al ong the veni cal l i ne.
. Mark the i ntake temperatu re
(am
bi ent a i r temperatu re) al ongthe bottom l i ne.
. Draw a l i ne strai ght up from the ai r temperature to the humi di ty.
. Mark a poi nt 10% above and 10% bel ow the humi di ty l evel .
. From each poi nt. draw a hori zontal l i ne across the del i very temperature.
. The del i verv temperature shoul d fal l between the two l i nes.
. Compl ete the l ow si de pressure test and hi gh si de
pressure test i n the same way.
. Any measurements outsi de the l i ne may i ndi cate the need for further i nspecti on.
rct
86
-l
r3ol
I
A,-]
I
6 8 -
{20r
I
, r - ]
" ' l
uo
--]
''o'
I
nt
300
{3}
I I
200
l2l
t28l
kPa
lkgf/cm'l
lpsil
aoy.
30io
2900
-
(30)
I OI
2500
-
(25)
13601
2000
-
t20l
t280t
1500
-
{ 151
12101
DELIVERY
PRESSURE
980
-
(101
l r40l
DELIVERY
PRESSURE
80%
kPa
{kgf/cm')
lpsil
400
-
{4)
t 571
INTAXE
PRESSURE
100
t l l
I NTAKE
1141
PRESSURE
0
DELIVERY
TEMPERATURE
68 77 86 95
10il
'F
(2ot
t2sl t3o) 135)
l4ol {"c)
INTAKE TEMPERATURE
22-25
A/C System Service
Pressure Test Chart
NOTE: Performance Test i s on page 22-24,
Test results Related symptoms Probabl cause Remedy
Di schar ge
( hi gh)
pressure aDnor-
mal l y hi gh
After stoppi ng compressor.
pres-
sure drops to about 200 kPa
{2.0 kgfl cm,,28 psi ) qui ckl y, and
then fal l s gradual l y.
Ai r i n system Recover, evacuate, and
recharge with specified amount.
Evacuation: see
page 22-45
Charging: see page 22-46
Reduced or no ai r fl ow through
condenser
.
Cl ogged condenser fi ns
.
Condenser fan not work-
i ng properl y
Cl ean.
Check vol tage and fan rpm.
Check fan di recti on.
Li ne to condenser i s excessi vel y
hot.
Restricted flow of refriger-
ant i n system
Restri cted l i nes
Di scharge pres-
sure abnormal l y
High and low pressures are bal-
anced soon after stopping compres-
sor, Low si de i s hi gher than normal .
.
Faul ty compressor di s-
charge val ve
.
Faul ty compressor seal
Repl ace the compressor.
Outl et of expansi on val ve i s not
frosted, l ow pressure gauge i ndi -
cal es vacuum.
.
Faul ty expansi on val ve
.
Moisture in system
.
Repl ace,
.
Recover, evacuate, and
recharge wi th speci fi ed
amount.
Sucti on
(l ow)
pressure abnor-
mal l y l ow
Expansion valve is not frosted, and
low oressure line is not cold. Low
pressure gauge i ndi cates vacuum.
.
Frozen expansi on val ve
.
Faul ty expansi on val ve
ReDl ace the exoansi on val ve.
Discharge temperature is low. and
the air flow from vents is restricted.
Frozen evaporator Run the fan wi th compressor
off. then check A,/C thermostat.
Exoansi on val ve i s frosted. Cl ogged expansi on val ve Cl ean or repl ace.
Recei ver/dryer outl et i s cool , and
i nl et i s warm
(shoul d
be warm
duri ng operati on).
Clogged receiver/dryer Repl ace.
Sucti on
pres-
sure abnormal l y
hi g h
Low pressure hose and check
j oi nt
are cool er than the tempera-
ture around evaporator.
.
Expansi on val ve open too
l ong
.
Loose expansi on capi l l ary
tube
Repai r or repl ace.
Sucti on oressure i s l owered when
condenser i s cool ed bv water.
Excessive refrigerant in sys-
tem
Recover. evacuate, and
recharge with specified amount.
Hi gh and l ow pressure are equal -
i zed as soon as the compressor i s
stopped, and both gauges fl uctu-
ate whi l e runni ng.
Faul ty gasket
Faul ty hi gh pressure val ve
Forei gn parti cl e stuck i n
hi gh pressure val ve
Repl ace the compressor.
Sucti on and di s-
charge
pres-
sures abnormal l y
h i gh
Reduced ai r fl ow through con-
denser.
.
Cl ogged condenser fi ns
.
Condenser fan not work-
i ng properl y
Cl ean condenser.
Check vol tage and fan rpm.
Check fan di recti on.
Sucti on and di s-
charge pressure
abnor mal l y l ow
Low pressure hose and metal end
areas are cool er than evaporator.
Cl ogged or ki nked l ow pres-
sure hose
parts
Repai r or repl ace.
Temperature around expansi on
val ve i s too l ow compared wi th
that around recei ver/dryer.
Cl ogged hi gh pressure l i ne Repai r or repl ace.
Ref ri gerant l eaks Compressor cl utch i s di ny, Compressor shaft seal leaking Repl ace the compressor.
Compressor bol t{s) are di ny. Leaki ng around bol t (s) Ti ghten bol t(s) or repl ace com-
pressor.
Compressor
gasket i s wet wi th oi l . Gasket l eaki ng Repl ace the compressor.
22-26
Recovery
ti fi ed to meet the requi rements of SAE J2210 to remove
HFC-134a
(R-134a)
from the ai r condi ti oner system
CAUTION: Exposure to air conditioner relrigerant and
l ubri cant vapor or mi st can i l l i tate eyes, noss and
throat. Avoid breathing the ail conditioner refrigerant
and lubricant vapor or mist.
area before resumi ng servi ce.
tems shoul d not be pressure tested or l eak tested wi th
compressed ai r.
!@@
some mixtures ot air and R'13'[a havo been
strown to be combustiblg at elevated
pressures and Gan
resuh in fire or explosion causing iniury or
property dam-
age, Never use compressed air to
pressure test R-134a
service equipment or vehicle air conditioner systems.
Addi ti onal heal th and safetv i nformati on may be obtai ned
from the refri gerant and l ubri cant manufacturers.
1, Connect a R-' 134a refri gerant recove ryl recycl i ng/
chargi ng stati on to the vehi cl e, as shown. tol l owi ng
the equi pment manufacturer' s i nstl ucti ons.
2. Measure the amount of refri gerant oi l removed from
the A/C svstem after the recovery process i s com-
pleted.
NOTE: Be sure to i nstal l the same amount of new
refrigerant oil back into the Iy'C system before charg-
t no.
Rcovery/Recyclin
g/Cha19ing Station
22-27
Evaporator
1 .
Replacement
4.
Move the temperature control to
"HOl "
' 96-98:
Sl i de the temoerature control l ever.
' 99-00:
Turn the i gni ti on swi tch ON (l l ), then turn
the temperature contol knob. Turn the i gni ti on
switch off.
Remove the battsry.
Rgcover the refrigerant with a rocovery/recycling/
charging station
(see page
22-271.
Remove the bolts, then disconnect th6 suction 8nd
receiver lines from th6 evaoorator.
NOTE: Plug or cap the lines immdiatoly after dis-
connecti ng them to avoi d moi sture and dust con-
tami nati on.
6 x l . 0 mm
9.8 n*ln ll.0 tg6m.
7.2 lbt frl
RECEiVER UNE
Remove the glov6 box
(see
section 20).
Removo the self-tapping scrw and the
passengr's
dashboard l ower cover. Removs the bol t. the nut
8nd the kne bolst6r, th6n r6mov6 th6 fiv6 bolts and
the
glove
box frame.
6.
srrcrrc u E
22-28
7. Disconnect the connector from th Ay'C thermostat,
and rmovs the wire harness from the ovaporator.
Remov6 tho four self-tapping screws, tho mounting
bol t and ths mounti ng nut. Di sconnect th drai n
hose, then remov th6 avagorator.
6 x l .0.nm
9.8 l$m lt.o ldm, 7.2 bl.tt)
Install in the reverse order of removal. Make note of
th following items.
o lf you'r6 installing a new evaporator, add rofriger-
ANt Oi I {SANDEN, SP-10 Or DENSO, ND-OIL 8)
lsas
page 22-221.
. Replace the O-rings with now ones 8t 68ch titting,
and apply 8 thin coat of rfrlgersd oil before
i nstal l i ng them.
NOTE: Be sure to use the right O-rings for HFC-
134a
(R-134a)
to avoid loakago.
. Apply salant to 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 .
3.
Pul l out the A,/C thermostat sensor from the evapo-
rator fi ns.
Remove the sel f-tappi ng screws and cl amps from
the housi ngs.
Careful l y separate the housi ngs, then remove the
evaporator.
l f necessary, remove the expansi on val ve.
NOTE: When l ooseni ng the expansi on val ve nuts, use
a second wrench to hold the expansion valve or the
evaporator
pipe. Otherwise, they can be damaged
5. Assembl e i n the reverse order of di sassembl y Make
note of fol l owi ng i tems.
. Repl ace the O-ri ngs wi th new ones at each fi tti ng,
and appl y a thi n coat of refri gerant oi l before
i nstal l i ng them.
NOTE: Be sure to use the ri ght O-ri ngs for HFC-
134a
(R-134a)
to avoi d l eakage.
. Instal l the expansi on val ve capi l l ary tube so that
i t i s i n di rect contact wi th the sucti on l i ne. Then
wrap wath taPe.
. Rei nstal l the Ay' C thermostat sensor to i ts ori gi nal
l ocati on.
6th tin lrom inld side
Serpentine type:
Laminate typo:
TAPE
Repl ace.
lvake sure there is no foreign matter stuck between
6 0 t 5 mm
l'2.1! O.2 inl
EVAPORATOR
bl ow di n out of l i ns
wi t h compressed ai r,
HOUSING
8 N.m 10.8 kgt m,
6 tbf.ftl
6th fin lrom outle't side
CAPILLARY TUAE
VALVE
N
u'
l l
6 \
N.m
(2.it kgt.m,
17 t bt f t l
1l
A/C THERMOST
f esr page 22 21
%
EVAPORA
LOWER
22-29
Compressor
(SANDENI
Replacement
1 . l f the compressor i s margi nal l y operabl e, run the
engi ne at i dl e speed, and l et t he ai r condi t i oner
work for a few mi nutes. then shut the engi ne off.
Disconnect the negative cable from the battery.
Recover the refri gerant wi th a recovery/recycl i ng/
charging station
(see page 22-27l..
Remove the bol ts, then di sconnect the sucti on and
di scharge l i nes from the compressor.
NOTE: Pl ug or cap the l i nes i mmedi atel y after di s-
tami nati on.
6 x l . 0 mm
Remove the condenser
(see page
22-44).
NOTE: Do not di sconnect the di scharge hose from
the condenser.
Remove the power
steeri ng pump bel t
(see
secti on
17 t .
22-30
24 N.m l2.ia kgt.m, 17 lbf.ftl
7. Loosen the center nut of the i dl er
pul l ey
and the
adjusting bolt. then remove the A,/C compressor belt
from the pul l eys. Remove the two mounti ng bol ts
from the left front mount, then remove the ly'C com-
pressor
belt by
passing
it through the gap befiiveen
the bodv and the left front mount.
ADJUSTING BOLT
1. 0 x 1. 25 mm
aa N.m
14.5 kgf,m, 33 bnft)
8. Remove the four mounting bolts and the compressor.
CENTER NUT
COMPRESSOR
9. l f necessary, remove the compressor bracket as fol -
l ows.
. Remove the nut and the washer.
NOTE: When ti ghteni ng the nut of the l eft front
mount, make sure the washer i s set
properl y on
the l eft front engi ne mount as shown.
. Remove the four mounti ng bol ts and the com-
pressor bracket.
12 x 1.25 rrirn
59 N.m 16.0
kgt'm,
43 tbf.ft)
COMPRESSOR
BRACKET
WASHER
1. 0 x 1. 25 mm
44 N.m
(i1.5
kg{.m, 33 lbl.ft)
LEFT FRONT
MOUNT
10. l nstal l i n the reverse order of removal . Make note of
. l f you' re i nstal l i ng a new compressor, drai n al l
the refri gerant oi l from the removed compressor,
and measure i ts vol ume. Subtract the vol ume of
drai ned oi l from
' 130m?
14 1/3 tl ' o2,4 6 l mp' oz);
the resul t i s the amount of oi l
you shoul d drai n
from the new compressor
(through the sucti on
fi fti ng).
. Repl ace the O-ri ngs wi th new ones at each fi t-
t i ng, and appl y a t hi n coat of r ef r i ger ant oi l
before i nstal l i ng them
NOTE: Be sure to use the ri ght O-ri ngs for HFC-
134a
(R-134a)
to avoi d l eakage
. Use refri gerant oi l
(SP-10) for R-134a Sanden and
Hadsys spi ral type compressors onl y'
o To avoi d contami nati on, do not return the oi l to
the contai ner once di spensed,
and never mi x i t
wi th other refri gerant oi l s.
. l mmedi atel Y
after usi ng the oi l , repl ace the cap
on the contai ner, and seal i t to avoi d moi sture
absorpti on.
. Do not spi l l the refri gerant oi l on the vehi cl e; i t
may damage the pai nu i f the refri gerant oi l con-
tacts the
pai nt, wash i t off i mmedi atel y
. Adjust the Ay'C compressor belt
(see page 22-43)
and the
power steering
pump belt
(see
section 17)'
. Charge the system
(see page 22-46), and test i ts
oerformance
(see
Page
22-241
22-31
Gompressor
(SANDEN)
lllustrated Index
CENTER NUT
Repl ace.
<-- ARMATURE PLATE
lnspection, page 22-33
SNAP RING B
Repl ace.
ROTOR PULLEY
I nspect i on, page
22-33
SNAP RING A
Replace.
FIELD COIL
lnspection, page
22-33
sHrM(s)
Repl ace.
COMPRESSoR ]
(Do
not disassembte
)
---------------->l
Repl acement . page 22, 36
THERMAL PROTECTOR
Replace.
I nspect i on, page
22-33
Repl acement , page
22-36
t v
i -
22-32
Clutch InsPection
Check the
pl ated parts of the armature
pl ate for col or
changes,
peel i ng or other damage l f there i s dam-
age. repl ace the cl utch set.
Check the rotor
pul l ey beari ng
pl ay and drag by rotat-
i ng the rotor
pul l ey by hand Repl ace the cl utch set
with a new one if it is noisy or has excessive
play/drag
Measure the cl earance between the rotor
pul l ey and
the armature
pl ate
al l the way around l f the cl ear-
ance i s not wi thi n speci fi ed l i mi ts, the armature
pl ate
must be removed and shi ms added or removed as
requi red, fol l owi ng the procedure on
page 22-34
Clarance: 0.5 ! 0.15 mm {0.020
t 0.006 in)
NOTE: The shi ms are avai l abl e i n four thi cknesses:
0. 1 mm, 0. 2 mm, 0. 4 mm and 0. 5 mm
. Rel ease the fi el d coi l connector from the hol der' then
di sconnect i t. Check the thermal
protector for conti -
nui ty. l f there i s no conti nui ty. repl ace the thermal
protecror,
NOTE: The thermal
protector wi l l have no conti nui ty
above 251.6 to 262.4oF 1122l o
128' C). When the tem-
perature drops bel ow 240 8 to 219.8"F
(116
to 104"C),
the thermal
protector wi l l have conti nui ty
. Check resi stance of the fi el d coi l
Field Coil Resistance: 3.05 to 3.35 O at 68"F
(20"C)
l f resi stance i s not wi thi n speci fi cati ons,
repl ace the
fi el d coi l .
22-33
Compressor
{SANDEN)
Clutch Overhaul
1. Remove the center nut whi l e hol di ng the armature
pl ate
wi th the tool .
CENTER NUT
17. 6 N. m {1. 8 kg{. m, ' t 3 t bnf t }
2. Remove the armature pl ate
by pul l i ng i t up by hand.
ARMATURE PLATE
A/C CLUTCH HOLDER
{Commerciallv aveilable)
Robinair: P/N 10204
Kent-Moore: P/N J37872
22-34
3. Remove snap ri ng B wi th snap ri ng pl i ers.
NOTE:
. Be careful not to damage the rotor pul l ey and
compressor duri ng removal /i nstal l ati on.
. Once snap ri ng B i s removed, repl ace i t wi th a
new one.
A
\ /
G::.
Remove the rotor pul l ey from the shaft wi th a pul l er
and the speci al tool .
NOTE: Pl ace the cl aws of the pul l er
on the back of
the rotor pul l ey,
not on the bel t area; otherwi se the
rotor pul l ey can be damaged.
.
r\t
\\:g2rl -/ /
. - ! L ; j ' /
TWO JAW PULLER
{Commercially
5. Remove the screw from the fi el d coi l ground termi -
nal , t hen di s c onnec t t he f i el d c oi l c onnec t or .
Remove snap r i ng A wi t h snap r i ng
pl i er s, t hen
remove the fi el d coi l
NOTE:
. Be careful not to damage the fi el d coi l and com-
pressor duri ng remove/i nstal l ati on.
. Once snap ri ng A i s removed, repl ace i t wi th a
new one.
. When i nstal l i ng the fi el d coi l , al i gn the boss on
the fi el d coi l wi th the hol e i n the compressor.
SNAP RI NG A
Repl ace.
Posi ti on the rotor pul l ey squarel y over the fi el d coi l .
Press the rotor
pul l ey
onto the compressor boss
wi th the speci al tool . l f the rotor
pul l ey does not
press on strai ght, remove i t, and check the rotor
pul l ey
and compressor boss for burrs or damage.
CAUTI ON: Maxi mum
pr ess l oad: 39, 200 kPa
(,[00
kgf/cm', 5,590
Psi)
Press
T
HUB ASSEMBLY
GUIDE ATTACHMENT
07965
-
6920500
ROTOR
PULLEY
t ' l
i,'
7. Assembl e i n t he r ever se or der of di sassembl y
Make note of the fol l owi ng i tems.
. l nstal l the fi el d coi l wi th the wi re si de faci ng down.
. Cl ean t he r ot or
pul l ey
and compr essor sl i di ng
surfaces wi th non-petrol eum sol vent.
. Make sure the snap ri ngs are ful l y seated i n the
groove.
. Make sure that the rotor
pul l ey turns smoothl y
after it's reassembled
. Route and cl amp the wi res
properl y or they can
be damaged bY the rotor
Pul l ey.
22-35
Compressor
(SANDENI
Thermal Protestor Replacement
1. Remove the bol t, the ground
termi nal and the hol d-
er. Di sconnect the fi el d coi l connector. then remove
the thermal Drotector.
7.{ N.m 10.75 ksf.m,5lbtfr)
/
SILICONE SEALANT
3. I nst al l i n t he reverse order of removal .
GROUND
IERMINAL
HOI.I'ER
PNOTECTOR
Repl ace the thermal protector
wi th a new one. and
appl y si l i cone seal ant to the top of the thermal
pro-
tector.
22-36
o o
' 1.
Remove the rel i ef val ve and the O-ri ng.
NOTE:
.
Do not l et the compressor oi l runout.
. Make sure that no foreign matter enters the sys-
tem,
RELIEF
VALVE
9.8 N.m {1.0 kgl.m,
7.2 tbl.lrl
O.RING
Replace.
Cl ean the mati ng surfaces.
Repl ace the O-ri ng wi th a new one at the rel i ef val ve.
and appl y a t hi n coat of r ef r i ger ant oi l bef or e
i nstal l i ng i t.
NOTE:
.
To avoi d contami nati on. do not return the oi l to
the contai ner once di spensed, and never mi x i t
o l mmedi atel y after usi ng the oi l , repl ace the cap
absorpti on.
. Do not spi l l the refri gerant oi l on the vehi cl e; i t
may damage the pai nt;
i f the refri gerant oi l con-
tacts the pai nt, wash i t off i mmedi atel y.
Instal l and ti ghten the rel i ef val ve.
Charge the system
{see
page 22-461, and test i ts
performance
1se6
page 22-241.
Compressor
(DENSO)
Replacement
1 . l f t he compr essor i s mar gi nal l y oper abl e, r un t he
engi ne at i dl e speed, and l et the ai r condi ti oni ng work
for a few mi nutes, then shut the engi ne off
Di sconnect the negati ve cabl e from the battery'
charging station lsee
page 22-271
Remove the each bol t, then di sconnect the sucti on
and di scharge l i nes from the compressor'
Pl ug or
cap the l i nes i mmedi atel y after di sconnecti ng
them
to avoi d moi sture and dust contami natl on.
6 x
' 1. 0
mm
9. 8 N. m
(1. 0 kgf m, 7. 2 l bf f t )
Remove the condenser, but do not di sconnect the di s-
charge hose from the condenser
(see page 22-441'
Remove the
power steeri ng
pump bel t
(see sectron
17]-.
7. Loosen the pi vot bol t of the i dl er
pul l ey bracket and
the adjusting bolt. then remove the A,/C compressor
belt from the pulleys. lf necessary, remove the mount-
ing bolts from the left front mount. then remove the
fuC compressor bel t through the
gap between the
bodv and the left front mount.
'10
x 1,25 mm
4,0 N.m
(,1.5 kgf'm. 33 lbt ftl
Di sconnect the compressor cl utch connector, then
remove the mounti ng bol ts and the compressor'
PIVOT BOLT
10 x 1.25 mm
4,1 N.m
(4.5 kgt'm,33 lbfft)
COMPRESSOR
24 N.m
(2.4 kgf m, 17 lbf ftl
(cont' d)
22-37
Compressor
(DENSOI
Repl acement
(cont' d)
9. Remove the bol ts, the sucti on servi ce val ve and the
O-ri ng from the compressor,
lf necessary, remove the compressor bracket as fol-
l ows.
. Remove the nut and the washer from the l eft front
mount. When ti ghteni ng the nut to the l eft front
mount, make sure the washer i s set p.operl y
on
the l eft front mount as shown.
a Remove the mounti ng bol ts and the compressor
bracket.
12 x 1,25 rnm
59 N.m 16.0 kgfrm,
10.
LEFT FRONT
MOUNT
rbf.fi)
Roplace.
WASHEB
x 1. 25 mm
2s.5 N.m {2.6 kgf.m. 18.8 tbtttl
4/r N.m {4.5 kgf.m, 33 lbt ft}
22-3A
1 1. Install in the reverse order of removal, and note these
rtems:
l f you' re i nstal l i ng a new compressor. drai n al l the
refrigerant oil from the removed compressor. and
measur e i t s vol ume. Subt r act t he vol ume of
drained oil from
'140
ml
(4
28 fl{,z, 4.9 lmpoz); the
resul t i s the amount of oi l you shoul d drai n from
the new compressor
(through
the suction fifting).
Repl ace the O-ri ngs wi th new ones at each fi ni ng,
and appl y a thi n coat of refri gerant oi l before
i nstal l i ng them. Be sure to use the ri ght O,ri ngs
for HFC-134a
(R-134a)
to avoi d l eakage.
Use refrigerant oil {DENSO, ND-OtL8) for HFC-134a
DENSO piston
type compressors only.
To avoi d contami nati on, do not return the oi l to
the contai ner once di spensed, and never mi x i t
l mmedi atel y after usi ng the oi l , repl ace the cap
absorpti on.
Do not spi l l the refri gerant oi l on the vehi cl e; i t
may damage the pai nt; i f the refri gerant oi l con-
tacts the pai nt,
wash i t off i mmedi atel v.
Adjust the ly'C compressor belt
(see page
22-43)
and the power
steering pump
belt
(see
section 17).
Charge the system
(see page
22-46), and test its
performance (see page
22-24!..
lllustrated
Index
).-
CENTER BOLT
PBESSURE PLATE
Inspecti on, Page
22 40
sHrM(s)
SNAP RING B
Repl ace.
PULLEY
Inspecti on, Page
22' 40
SNAP RING A
Replace.
FIELD COIL
I nspect i on,
page 22 40
SUCTION SERVICE VALVE
RELIEF VALVE
Repl acement ,
page 22' 42
22-39
Compressor
(DENSOI
Clutch Inspection
Check the pl ated parts
of the pressure pl ate
for col o.
changes, peel i ng
or other damage. l f there i s dam-
age, repl ace the cl utch set.
Check the pul l ey
beari ng pl ay
and drag by rotati ng
the pul l ey by hand, Repl ace the cl utch set wi th a new
one i f i t i s noi sy or has excessi ve pl ay/drag.
Measure the cl earance between the
pul l ev
and the
pressure pl ate al l the way around. l f the cl earance i s
not wi thi n speci fi ed l i mi ts, the pressure pl ate
must be
removed and shi m(s) added or removed as requi red,
fol l owi ng the procedure
on page
22-41.
Cl earanca:0.5 t 0.15 mm
{0.020 r 0.006 i n}
NOTE: The shi ms are avai l abte i n three thi cknesses:
0. 1 mm, 0. 3 mm and 0. 5 mm.
22-40
. Check resi stance of the fi el d coi l . l f resi stance i s not
wi thi n speci fi cati ons, repl ace the fi el d coi l .
Fiald Coil Resistanc: 3.it to 3.8 O at 20.C l68.Fl
Clutch Overhaul
1. Remove the center bol t whi l e hol di ng the
pressure
ol ate wi th the sPeci al tool .
CENTER BOLT
13.2 N.m
(1.35 ksl m, 9.?6 lbf'ft)
A/C CLUTCH HOLOER
(Commerci al l y avai l abl e)
Robi nai r: P/ N 10204
Kent -Moore: P/ N J37872
Remove the
pressure pl ate and shi m(s). taki ng care
not to l ose the shi m{sl .
PAESSURE
PLATE
3. Remove the snap ri ng B wi th snap ri ng pl i ers, then
remove the pul l ey Be careful not to damage the
pul l ey and comPressor'
SNAP RING B
Repl ace.
'.L-)
.'l
5$ f-t
1/ - - - (
l l l ,
v l l /
(cont' d)
22-41
Compressor
(DENSO)
Clutch Overhaul
(cont'd)
Remove the screw from the fi el d coi l ground
termi -
nal . Remove the snap ri ng A wi th snap ri ng pl i ers.
then remove the fi el d coi l . Be careful not to damaoe
the fi el d coi l and compressor.
SNAP NING A
Repl ace.
Reassembl e the compressor cl utch i n the reverse
order of di sassembl y, and note these rrems:
o I nst al l t he f i el d coi l wi t h t he wi r e si de f aci ng
down.
a Cl ean the pul l ey
and compressor sl i di ng surfaces
wi th non-petrol eum sol vent.
. Instal l new snap ri ngs, and make sure thev are
ful l y seated i n the groove.
. Make sure that the pul l ey
turns smoothl y after
i t' s reassembl ed.
. Route and cl amp the wi res p.operl y
or they can
be damaged by pul l ey.
FIELO
corL
22-42
13. 2 N. m
11. 35 kgt m, 9. 76l bt t t l
L
4.
charging station {see
page 22-27),
Remove the rel i ef val ve and the O-ri ng.
pl ug
the
openi ng to keep forei gn matter from enteri ng the
system and the compressor oi l from runni ng out.
Cl ean the mati ng surfaces.
Repl ace the O-ri ng wi th a new one at the rel i ef val ve.
and appl y a thi n coat of refri gerant oi l before i nstal l -
i ng i t.
Remove the pl ug,
and i nstal l and ti ghten the rel i ef
vatve.
Charge the system (see page 22-46), and test its per-
formance (see page 22-24),
A/G GomPressor
Belt
Adjustment
Detlection Method
' 1.
(10 kgf, 22 l bf), and measure
the defl ecti on between the A,/C compressor and the
crankshaft Pul l eY
A/C ComPressor Belt
Used Belt: 816A2 engine
6.0
-
9.5 mm 10 2' l
-
0.37 i nl
Except 816A2 engine
7.5
-
9.5 mm
(0.30
-
0.37 i n)
New Belt: 816A2 engine
4. 5- 6 5 mm
( 0. 18- 0. 26 i n)
Except 815A2 engine
5. 0- 5 5 mm
( 0. 20- 0. 26 i nl
Note these i tems when adj usti ng bel t tens' on:
. l f there are cracks or any damage evi dent on the
bel t, repl ace i t wi th a new one.
.
"Used
bel t" means a bel t whi ch has been used
for fi ve mi nutes or more.
.
"New
tor l ess than fi ve mi nutes.
2. Loosen, the center nut ofthe i dl er
pul l ey
(SANDEN), or
the
pi vot bol t of the i dl er pul l ey bracket and the l ock
nut ofthe adj usti ng bol t
(DENSO).
3. Turn the adj usti ng bol t to
get proper bel t tensi on'
4. Reti ghten the center nut of the i dl er
pul l ey
(SANDEN),
or the
nut of the adj usti ng bol t
(DENSO).
5. Recheck the defl ecti on of the A,/C compressor
bel t'
Tension Gauge Method
1. Attach the speci al tool to the IVC compressor bel t as
shown bel ow, and measure the tensi on of the bel t
A/C Compressor Belt
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
New Belt: B16A2 engine
?40
-
880 N {75
-
90 ksf' 170
-
200 lbf)
Except Bl642 engine
690
-
830 N
(70 -
85 ksf, 150
-
190 lbf)
Note these i tems when adj usti ng bel t tensi on:
. Fol l ow t he manuf act ur er ' s
i nst r uct i ons f or t he
bel t tensi on
gauge.
. l f there are cracks or any damage evi dent on the
bel t, rePl ace i t wi th a new one.
.
"Used
for fi ve mi nutes or more.
.
"New
for l ess than fi ve mi nutes
2 Loosen the center nut of the i dl er
pul l ey (SANDEN)' or
the
(DENSO).
3. Turn the adj usti ng bol t to get proper bel t tensi on
4. Reti ghten the center nut of the i dl er
pul l ey
(SANDEN),
or the
pivot bolt of the idler
pulley bracket and the lock
(DENSO)
5. Recheck the tensi on of the A/C compressor bel t'
22-43
Condenser
Replacement
1 . Recover the refri gerant wi th a recovery/recycl i ng/
charging station lsee
page
22-271.
Di sconnect the condenser fan connector from the
Ay'C wire harness, then remove the A,/C wire harness
from the condenser fan shroud.
Remove the bol ts, then di sconnect the di scharge
and condenser l i nes from the condenser.
NOTE: Pl ug or cap the l i nes i mmedi atel y after di s-
tami nati on,
6 r 1 . 0
6 x 1 . 0 mm
olscHARGE L|NE
9.8 N.m 11.0
9.8 N.m 11.0 kgl.m, 7.2 lbf.ftl
22-44
4. Remove the bol t from the sucti on hose bracket, and
remove the two bol ts and the upper mount bracket.
Remove the condenser assembl y by l i fti ng i t up.
NOTE: Be careful not to damage the condenser fi ns
when removi ng the condenser assembl y.
UPPER MOUNT BRACKET
5. Install in the reverse order of removal. Make note of
. l f you' re
i nstal l i ng a new condenser, add refri ger-
ant oi l
( SANDEN,
SP- 10 or DENSO, ND- O| L 8)
\see
page
22-22l.-
. Repl ace the O-ri ngs wi th new ones at each fi t-
t i ng, and appl y a t hi n coat of r ef r i ger ant oi l
befo.e i nstal l i ng them.
NOTE; Be sure to use the ri ght O-ri ngs for HFC,
134a
(R-134a)
to avoi d l eakage.
o Be car ef ul not t o damage t he condenser f i ns
when i nstal l i ng the condenser assembl y.
. Charge the system
(see page
22-46), and test its
performance (see page 22-24i.
6 x 1 . 0 mm
9, 8 N. m 11. 0 kg{. m, 7. 2l bt f t }
6 x 1 . 0 mm
9.8 N.m 11.0 kst m, 7.2 lbf.ftl
A/C System Service
Evacuation
Use onl y servi ce equi pment that i s U L.-l i sted and i s cer-
ti fi ed to meet the requi rements oJ SAE J2210 to remove
HFC-134a
(R-134a) from the ai r condi ti oner system'
CAUTION: Exposure to air conditioner reftiglant and
lubricant vapor or misi can irrhaie eyes. noso and throat'
Avoid breathing the ail condhioner lefrigelant and lubri
cant vapor or mist.
area before resumi ng servace.
tems should not be
pressure tested or leak tested with
comDressed
ai r.
!!@@
some mixtures of air and R-13'[8 haYo boon
ffiiE-n to be "ombustible at elovatod
pressurcs and can
resul t i n fi re or expl osi on causi ng i ni ury or
propsrtY
damag. Never uso complsssod air to
pre3surs tost R-
1344 ssrvico equipment or vehicle air conditioner sy3-
tems,
from the refrigerant and lubricant manuJacturers'
When an A,/C System has been opened to the atmo-
sphere, such as duri ng i nstal l ati on or repai r, i t must
be evacuated
usi ng a R-134a refri gerant recovery/
recycl i ng/chargi ng
stati on.
(l f
the system has been
open for several days, the recei ver/dryer
shoul d be
repl aced, and the system shoul d be evacuated for
several hours.)
Connec t a R- 134a r ef r i ger ant
r ec ov er y /
recycl i ng/chargi ng
stati on to the vehi cl e, as shown'
f ol l owi ng t he equi pment
manuf act ur er ' s
i nst r uc-
trons.
NOTE: lf low
pressure does not reach more than 93 3
kPa
(7OO mmHg,27.6 i n.Hgl i n 15 mi nutes, there i s
probabl y a l eak i n the system Parti al l y charge the
system, and check for leaks
(see
Leak Test)
1 .
R6covory/Recyclin
g/Chal9ing Station
22-45'
A/C System Service
Chargi ng
HFC-134a
(R-134a)
CAUTION: Exposure to air conditioner refrigerant and
l ubri cant vapor or mi st can i rri tal e eyes, nose and
throat. Avoid breathing the air conditioner retrigerant
and lubricant vaoor or mist,
ar ea bef or e r esumi ng ser vi ce, Addi t i onal heal t h and
safety i nformati on may be obtai ned from the refri gerant
and l ubri cant manufacturers.
Refrigerant capacityt 600
-
650 g
121.1
-
22.9 ozl
CAUnON: Do not overcharg the system; the comprcssor
will be damaged.
Connect a R-134a refrigerant recovery/recycling/charging
stati on to the vehi cl e, as shown, fol l owi ng the equi pment
manufacturer's instructions.
Recovery/Recycling/Charging Station
22-46
Leak Test
Use onl y servi ce equi pment that i s U.L,-l i sted and i s cer-
HFC-134a
(R-134a)
CAUTION: Exposure io air conditioner refrigerant and
lubricant vapot or mist can itritats eyes, no36 and thtoat.
Avoid breathing the air conditioner refrigeranl and lubri-
cant vapor or mist,
area betore resumi ng servi ce.
tems shoul d not be
pressure
tested or l eak tested wi th
comoressed ai r.
@
some mi xtures of ai r and R-134a have
been shown to be combugtibls at elevatgd prossures
and can resul t i n ti re or expl osi on causi ng i ni ul y or
plopgrty
damage. Nevr usc compre33od air to pressure
test R-13'la servica oquipment or
yohiclo
air conditionor
systems.
from the refrigerant and lubricant manufacturers.
1. Connect a R-134a refri gerant recove ryl recycl i ng/
chargi ng stati on to the vehi cl e, as shown i n the pre-
vi ous col umn, fol l owi ng the equi pment manufactur-
er' s i nstructi ons.
NOTE; Be sure to i nstal l the same amount of new
refrigerant oil back into the A,/C system before charg-
I n9.
Open the hi gh-pressure val ve to charge the system
t o t he speci f i ed capaci t y, t hen cl ose t he suppl y
val ve, and remove the chargi ng system coupl ers.
Rofrigerant capacity: 600
-
650 g (21.1 -
22.9 oz)
Check the system for leaks using a R-134a refriger-
ant l eak detector wi th an accuracy of 14
9
10.5 ozl
per yea.
or better.
lf you find leaks that require the system to be opened
(to
repair or replace hoses. fittings. etc.), recover the
system according to the Recovery Procedure on page
22-27.
After checking and repairing leaks. the system must
be evacuated
(see
System Evacuation on page 22-451.
l'f
.
El ectri cal
Speci al Toof s . , . . . . . . . . . . . . . . . . . . . . , 23- 2
Troubl eshooti ng
Ti ps and Pr ecaut i ons . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . 23- 3
Fi ve-step Troubl eshooti ng .............. ......... . . 23-5
wi r e col or codes . . . . . . . . . . , 23- 5
Schemat i c Symbol s . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . 23- 6
Rel ay and Control Uni t Locati ons
Engi ne Compartment ...,..................... ... .. . 23' 7
Dashboar d
. . . . . . . . . . . . . . . . . . . . . . 23- 8
Dashboar d/ Door
. . . . . . . . . 23- 12
*Ai rbags
................. ....... Secti on 24
......... Secti on 21
Af t el nat or
. . . . . . . . . . . " " " " " " " 23- 112
Anti -l ock Brake System {ABS)
Secti on 19
*A/T
Gear Posi ti on Indi cator .....................,. .... ... 23-149
Automati c Transmi ssi on Svstem .... . ....... Secti on 14
Bat t er v . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23- 91
Bl ower control s .. . ... Secti on 2l
Chargi ng System ....' ...........23' 112
Connector l denti l i cati on and Wi re Harness
Rout i ng . . . . . . . . . . . . . . . . . . . . . . . . 23' 13
Crui se Control
............,........23-240
Dash Li ghts Bri ghtness Control l er ............. ....... 23-180
Fan controfs "" 23'126
Fuel PumD . . . . . . . . . . . . . . . . . sect i on 11
Fuses/ Ref ay
. . . . . . . . . . . . . . . , . . , , . . 23' 62
PGM-FI Control System ......................,....... Secti on 1 1
*Gauges
Ci r cui t Di agr am . . . . , . , . . . . . . . 23- 131
Fuef Gauge . . . . . . . . . . . ' . ' . . . . . . . 23- 142
Gauge/l ndi cator
.. . .. 23-129
Ground Di stri buti on
.. . 23-75
Heatei control s .. . ..... Secti on 21
* Hor n. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 23- 196
* t gni t i on
Swi t ch
. . . . . . . . . . . . . . . . . . . . 23- 89
l gni t i on Syst em
. . . . . . . , . . . . 23- 102
* l nt egr at ed
Cont r ol Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23- 156
fnterl ock System ,........ . . , ,23-144
Li ghti ng System
. . . .. ......... 23-161
Lights, Exterior
Back-up Li ghts ..' ............23' 171
Brake Li ghts .................. 23' 174
Dayti me Bunni ng Li ghts
(Canadal ............... 23' 166
Fr ont Par ki ng Li ght s . . . . . . , . . . . . . . . . . . . . . . . . ' . . . . . . . . . . . 23- 167
Fr ont Tur n Si gnal Li ght s . . . . . . . . . . . . . . . . . . . . . . . . . . , . 23- 167
Headti ghts
....".' ....-... ..... 23' 167
Hi gh Mount Br ake Li ght . . . . . . . . . . . . . . . . . . . . . . . . . . 23' 179
Li cense Pl ate Li ghts
...... 23' 176
Tai t f i ght s . . . . . . . . . . . . . . . .
. . . . . . . 23' 171
l nteri or Li ghts
..-.......,, . 23-142
Moonr oof
. . , . . . . . . . . . . . . . . . . . , . . . . . . . . 23- 235
Power Di stri buti on
....... . . .23-61
Power Door Locks
.......,,,. .23' 251
Power Mi rrors ,..............,.,...23' 206
Power Rel ays
....... . ...... . . .. 23-86
Power Wi ndows
............,,....23-220
Rear Wi ndow Defogger .......................... . . ... . . 23-2OO
Spar k Pl ugs . . . . . . . . . . . . . . . . . . . . 23- 111
Sl ar t i ng Syst em
. . . . . . . . . . . . . . . . 23- 93
*stereo
Sound Svstem ,................. ..... ... . ... ,.,.,,23' 147
'Supplemental
Restraint System
(SRS)
... . Section 24
Turn Si gnal /Hazard Fl asher System .......' .' ....-... 23-173
*Undel -dash
Fuse/Rel ay Box ............,.................. 23-85
vehicfe soeed sensor
(VSSI """" ""' 23-140
+Wi pers/Washers
.........,.,.,...23-214
NOTE: Unl ess otherwi se speci fi ed, references to auto-
mati c transmi ssi on
(Mf)
i n thi s secti on i ncl ude the CVT.
Speci al Tool s
Ref. No. Tool Number Description Oty Page Reference
O)
@-
o
@
o
tol
A973X_041
_XXXXX
07JGG 00l 0l 0A
OTLAJ
-
PT3O2OA
07NAC
-
SR20100
07PM
-
0010r 00
07MAJ
-
SP00300
Vacuum Pump Gauge, 0
-
30 i n. Hg.
Test Harness
Fuel Sender Wrench
Keyl ess Entry Checker
1
1
'I
1
1
1
23-245
23-140,141
23-142
23-105
23-264
' :
I ncl uded i n Bel t Tensi on Gauge Set 07T66
-
0010004
or
/4,
(!
23- 2
Troubl eshooti ng
l l .
Tips and Precautions
Bef ore Troubleshooting
. Check appl i cabl e fuses i n the appropri ate fuse/rel ay
box.
. Check the battery for damage, state of charge, and
cl ean and ti ght connecti ons.
. Check the al ternator bel t tensi on.
CAUTION:
. Do not qui ck-charge a battery unl ess 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
damage the wi l i ng,
Handling Connectois
. Make sure the connectors are cl ean and have no l oose
wi re termi nal s.
. Make sure mul ti pl e cavi ty connectors are packed wi th
grease
(except
waterti ght connectors)
. Al l connectors have
push-down rel ease type l ocks.
Some connectors have a cl i p on thei r si de used to
attach them to a mount bracket on the body or on
another component. Thi s cl i p has a pul l type l ock.
Some mounted connectors cannot be di sconnected
unl ess you fi rst rel ease the l ock and remove the con-
nector from i ts mount bracket.
LOCKI NG
PAWL ON
OTHER
HALF OF
CONNECTOR
Pul l t o
drsengage
LOCKI NG TAB
BRACKET
Never t r y t o di sconnect connect or s by pul l i ng on
thei r wi res; pul l on the connector hal ves i nstead
Al wavs rei nstal l
pl asti c
covers.
Before connectang connectors,
nal s are i n pl ace and not bent.
make sure the terml -
. Check for l oose retai ner and rubber seal s.
RETAINER
The backs of some connect or s ar e packed wi t h
grease. Add
grease i f necessary. l f the
grease i s con-
tami nated, repl ace i t.
(cont ' d)
23-3
Troubl eshooti ng
Tips and Precautions
(cont'dl
Insert the connector al l the way and make sure i t i s
securel v l ocked.
Posi ti on wi res so that the open end of the cover faces
down.
After i nstal l i ng harness cl i ps, make sure the harness
doesn' t i nterfere wi th any movi ng pans.
Keep wi re harnesses away from exhaust pi pes
and
other hot parts. from sharp edges of brackets and
hol es, and from exDosed screws and bol ts.
V
F6c6
opn end
Handling Wires and Harnosscs
.
Secure wi res and wi re harnesses to the frame wi th
thei r respecti ve wi re ti es at the desi gnated l ocati ons,
. Remove cl i ps careful l y; don' t damage thei r l ocks.
Sl i p pl i ers under the cl i p base and through the hol e at
an angl e, then squeeze the expansi on tabs to rel ease the
cl r p.
SNAP-BING PLIERS
23-4
NOT GOOO
l l i l , /
s*' -.1}8."/
_Y- - _Y5\
il
,,
Testing and Repairs
o Do not use wi res or harnesses wi th broken i nsul ati on.
Repl ace them or repai r them by wrsppi ng the break
wi th el ectri cal taoe.
. After i nstal l i ng parts, make sure that no wi res are
pi nched
under them.
. When usi ng el ect r i cal t est equi pment , f ol l ow t he
manufacturer' s i nstructi ons and those descri bed i n
t hi s manual .
. l f possi bl e,
i nsert the
probe
of the tester from the
wire side
(except
waterproof connector).
.
Seat grommets i n thei r grooves properl y.
. Use a probe wi th a tapered ti p.
Refer to the i nstructi ons i n the Honda Termi nal Ki t for
i denti fi cati on and repl acement of connector termi -
nats.
t
Five-step Troubleshooting
2.
1 . Ver i f y The Compl ai nt
Turn on al l the components i n the probl em ci rcui t to
veri fy the customer compl ai nt. Note the symptoms.
Do not begi n di sassembl y or testi ng unti l you have
narrowed down the probl em area.
Anal yze The Schemati c
Look up t he s c hemat i c f or t he
pr obl em c i r c ui t .
Determi ne how the ci rcui t i s supposed to work by
t r aci ng t he cur r ent pat hs f r om t he power f eed
through the ci rcui t components to ground. l f several
ci rcui ts fai l at the same ti me, the fuse or ground i s a
l i kel y cause.
Based on the symptoms and your understandi ng of
the ci rcul t operati on, i denti fy one or more
possi bl e
causes of the
probl em.
l sol ate The Probl em By Testi ng The Ci rcui t
Make ci rcui t tests to check the di agnosi s
you made
i n step 2. Keep i n mi nd that a l ogi cal , si mpl e proce-
dure i s the key to effi ci ent troubl eshooti ng. Test for
the most l i kel y cause of fai l ure fi rst. Try to make
tests at poi nts that are easi l y accessi bl e.
Fi x The Probl em
Once t he speci f i c
pr obl em i s i dent i f i ed, make t he
repai r. Be sure to use proper tool s and safe proce-
dures.
Make Sure The Ci rcui t Works
Turn on al l components i n the repai red ci rcui t i n al l
modes to make sure you' ve fi xed the enti re
prob-
l em. l f t he pr obl em was a bl own f use, be sur e t o
test al l of the ci rcui ts on the fuse, Make sure no new
probl ems turn up and the ori gi nal probl em does not
recur.
3.
Wi re Col or Codes
The f ol l owi ng abbr evi at i ons ar e used t o i dent i f y wi r e
col ors i n the ci rcui t schemati cs:
wHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Whi t e
YEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yel l ow
BLK . . . . . . . . . . . . , . , . . . . . . . . . . . . . . . 81ack
BLU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bl ue
GRN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr een
RED . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . Red
ORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Or ange
PNK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pi nk
BRN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Br own
GRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gr ay
PUR . , . . . . . . . . . . . . . . . . . , . , . . . . . . . . Pur pl e
LT BLU . . . . . . . . . . . . . . . . . . . . . . . . . Li ght Bl ue
LT GRN . . . . . . . . . . . . . . . . . . . . . . . . Li ght Gr een
The wi r e i nsul at i on has one col or or one col or wi t h
another col or stri pe. The second col or i s the stri pe.
WHT/BLK
23-5
Troubleshooting
Schematic Symbols
BATTERY
E
@
GRO
GroLrnd t ermi nal
I
I
_d
:
UND
Component ground
I
I
_..
'-
FUSE
--cn-.e
COI L, SOLENOI D
r{r
t q l
'|
CIGARETTE LIGHTER
A
l r l
P
RESISTOR
I
f
VARIAELE RESISTOR
i l H
THERMI STOR
c
IGNITION SWITCH
-fo
o.t-
BULB
+
HEATEB
A
t - l
F
MOTOR
0
PUMP
H
CIRCUIT BREAKER
I
r
Yr
T
HORN
+
DI ODE
+
SPEAKER, BUZZER
D
Mast
Y
ANTt:f\,NA TRANSISTOR lTrl
I I
SWITCH
(ln
ni
Normally open
I
/F\
t t L I
\Y/
I
rrdal
positionl
Normally closed
'*i."n
@
I
LIGHT EMITTING
DIODE ILEDI
A+,
T T
RELAY lln no
Normal l y opon rel ay
|
....--1
'rl*r
t i l
t
"t^f
fmal poaitionl
Normally closed relay
ff
l - + - |
l r l
l r l
fff
CONDENSER
I
T
CONNT
I nput
V
I
:CTION
Out put
J
CONNECTOR
*>-
'l
!
REED SWITCH
A
t f t l
Y
Rel ay and Control Uni t Locati ons
Engi ne Compartment
UNDER.HOOD
ABS
FUSE/RELAY
BOX
CONDENSER FAN
RELAY
UNDER.HOOD
FUSE/RELAY BOX
MOTOR
RELAY
A/C COMPRESSOR
CLUTCH RELAY
RADIATOR
FAN RELAY
ELD UNI T
t :
tr
tr
u
I
I l
I t l I
23-7
Relay and Control Unit Locations
Dashboard:
' 96
-
97 model s
CRUISE CONINOL UNIT
DAYTIME
RUNNING LIG}ITS
CONTROL UNIT
lCan!dal
IWire
colo.s: GRN/ORN, GRN/RED,l
IWHT,
YEL, and BLK
I
.
MOONROOF CLOSE RELAY
fwir. colorc: GRN/ORru, Cnru/VeLl
IWHT.
GRN/RED, and ALK
I
DASH LIGHTS BRIGHTNESS CONTROLLER
{Has bui l t -i n cont rol uni t )
23-8
D
INTEGRATED
CONTROL UNIT
UNDER.OASH
FUSE/RELAY BOX
HORN RELAY
I Wire colors: WHT/GRttt, WXf/Cnru,l
[GRY,
and BLU/RED ,J
POWER WINDOW RELAY
INTERLOCK CONTROL UNIT
' g
t P" t at { } r )
( } t
/ t
t
- - - - - - , )
F;;snHn-nnn"nf-H-n
o
F
!r rr rr rr r,r Lr Ll u u l,r
F n n n n n n n r r r r - 1
F
rr rr rJ LJ rJ r-r t-r L-r LJ Lr ||J
u_::;_:_:_:_:_l_;I::
*TCM
(CVT)
*:
Coupe
23-9
Relay and Control Unit Locations
Dashboard:
'98
-
00 models
CRUISE CONTROL UNIT
DAYTIME
RUNNING LIGIfiS
CONTROL UNIT
lCrnrda)
DASH LIGHTS BRIGHTNESS CONTROLLER
{Has bui l t -i n cont rol uni t }
STARTEB CUI RELAY
[wi]e
color.: BLX/WHT, exnfxf,
I
IBLU/BLK,
|nd BLK/RED
j
coloE: WHT/GRN, BLU/REO,I
andWHT/ GRN
I
fwiro colors: GRN/O8ru. CnrulYel,l
IWHT,
GBN/RED, end BLK
I
23-10
O
UNDER.OASH
FUSE/NELAY BOX
.
TCM
(CVT):
Coupe
.
KEYLESS DOOR LOCK CONTROL UNIT:
'99
model {USAI
REAR WINDOW
DEFOGGEB
INTERLOCK CONTROL UNIT
POWER WINDOW RELAY
o F -
- = - - - - r r
J l r
c
23-11
Relay and Gontrol Unit Locations
Dashboard/Door
POWER DOOR LOCI(
CONTROL UNIT
AUOIO UNIT
(Has
bui l t -i n keyl ess recei ver ci rcui t )
ABS CONTROL UNIT
23-12
Connector ldentification and Wire Harness Routing
D
How to ldentify Connectors:
l denti fi cati on numbers have been assi gned to al l connectors. The number i s preceded by the l etter
"C"
for connectors,
"G"
for ground termi nal s or
"T"
for non-ground termi nal s.
Location
Harness
Engine Compartment Dashboard
Others {Floor, Door,
Trunk/Hatch, and Rootl
Starter cabl es
T1, T2 and @
Battery
ground cabl e G1 and O
Engi ne ground cabl e A T3
G2
Engi ne
gr ound cabl e B T4
Under-hood ABS fuse/rel ay box wi re
harness
(Wi th
ABS)
t 5 ano
( 9
Engi ne wi re harness Cl 01 t hr u C147
T101 and T102
G101
Engi ne compartmenl ware harness C201 thru C215
G201 and G202
Mai n wi re harness C301 thru C310
C351 thru C361
C401 thru C452
G401 and G402
Dashboard wi re harness
C501 thru C520
G501
FIoor wi re harness
C551 thru C573
G551 and G552
Rear wi re harness
C601 thru C62l
G601 and G602
Dri ver' s door wi re harness
C631 thru C640
Passenger' s door wi re harness
C651 thru C657
Left rear door wi re harness
(Sedan) C661 thru C664
Ri ght rear door wi re harness
(Sedan) C671 thru C674
Roof wi re harness
(Wi thout
moonroof)
C701 thru C719
Moonroof wi re harness {Wi th moon-
roof)
C7l ' l t hr u C719
Heater sub-harness A
C721 thru C729
Heater sub-harness B
C7 41 thtu C7 44
Ay'C wire harness C751 thru C754
G751
Hatch wi re harness
(Hatchback) C761 thru C768
Rear wi ndow defogger grgund wi re
c771
G171
Secondary heated orygen sensor sub-
narness
C781 and C782
Fuel tank
pressure sensor sub-harness
C791 thru C793
SRS mai n harness
C801 thru C807
G801
Rear wi ndow def ogger wi re
C831 thru C833
Connector ldentification
and Wire Harness Routing
Connector or
Termi nal
Number of
Cavities
Localion Connec{s to Notes
T,I
r2
Ri ght si de of engi ne compartment
Under-hood fuse/rel ay box
Starter motor
Battery Battery posi ti ve
termi nal
Starter Cables
A/C Wire Harness
Battery Ground Cable
Connector or
Terminal
Number of
Cavities
Location Conncts to Notos
Ri ght front shock tower Body ground,
vi a battery ground
caDte
o Baftery Battery negati ve termi nal
Engi ne Ground Cabl e A
Connqtor or
Termi nal
Number ot
Cavitios
Location Connects to Noles
T3 Left si de of engi ne Power steeri ng pump bracket
G2 Left si de of engi ne compartment Body ground, vi a engi ne ground
cabl e A
Engi ne Ground Cabl e B
Connector or
Terminal
Number of
Cavities
Location Connecls to Noles
T4 Ri ght si de of engi ne compartment Transmi ssi on
Ri ght si de of front frame Body ground, vi a engi ne ground
cabl e B
Under-hood ABS Fusa/Relay Box Wire Harness
Connector or
Tgrmi nal
Number oI
Cavities
Location Conneqts to Notes
T5 Ri ght si de of engi ne compartment Under-hood fuse/relay box
@ Banery Battery posi ti ve termi nal
Connector or
Termi nal
Number of
Cavities
Location Connects to Notes
c753
c754
1
2
Engi ne compartment wi re harness
(c209)
Compressor cl utch
Condenser fan motor
A,/C pressure switch
Left si de of engi ne compartment Body ground, vi a A,/C wi re harness
23-14
d
STARTER
CABLES
BATTERY
GROUND
CABLE
UNDER-HOOO
ABS FUSE,/RELAY
BOX WI RE
HARNESS
GROUND
CABLE B
A/ C WI RE
HARNESS
23-15
Engine Wire Harness
lD16Y5, D16Y8 enginss):
'96
-
98 models
Connector or
Torminal
Numbsr of
Cavitiss
Location
Connects to Nots
c 101
c102
c103
c104
c104
c105
c106
c107
c108
c 109
c110
c 1 1 1
c112
c113
c114
c115
c 1 1 6
cl17
c118
c119
c120
cl21
c122
c123
cl23
c124
c125
c127
c12A
c129
c130
c131
c132
c 133
c134
c135
c136
c138
c139
c140
c 141
c142
c 143
c144
cl 44
c145
c' 146
cl47
10
1
2
2
1 4
l 4
3
2
2
l 0
I
2
2
2
2
1
20
3 l
1 4
14
1
2
2
2
2
2
2
2
Left side of engine compartment
Mi ddl e of engi ne
Mi ddl e of engi ne
Lef t si de of engi ne companment
Lef t si de of engi ne compart ment
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
f vl i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Right side of engine companment
Behi nd ri ght ki ck panel
Under ri ght si de of dash
Under ri Oht si de of dash
Mi ddl e of engi ne
Mi ddl e ot engi ne
l i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of ongi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Ri ght si de of engi ne compart ment
Right side of engine compartment
USA
Canada
Afi
USA
-'
(A/r)
Mai n wi re harness (C303)
Crankshaft speed fluctuation (CKF)
sensor
Engi ne oi l pressure
swi tch
Al ternator
Alternator
No.
'l
fuel injector
No. 2 fuel injector
No.3 fuel i nj ector
No. 4 fuel i nj ector
IAC valve
Throttle position (TP)
sensor
l\4anifold absolute pressure (MAP)
sensor
Intake air temperature
(lAT)
sensor
Power steering pressure
{PSPI switch
EVAP purge control sol enoi d val ve
Juncti on connector
Juncti on connctor
Vehi cl e speed sensor {VSS}
Engine coolant temprature
(ECT)
switch A
Distributor
Engine coolant temperature
(ECT)
sending
unrt
Engine coolant temperature (ECT)
sensor
Pri mary HO2S
(sensor' l )
Pri mary HO2S
(sensor
1)
Back-up l i ght swi tch
Lock-up control sol enoi d val ve
Secondary HO2S
(sensor
2)
Mainshaft speed sensor
Li near sol gnoi d val ve
Shift control solsnoid valve
Starter solenoid
Juncti on connector
Mai n wi re harnesE (C446)
ECM/PCM
PCM
ECMiPCM
ECM/PCM
Mai n wi re harness
(C305)
Main wire harness (C305)
Mai n wi re harness
(C305)
Knock sensor (KS)
IAC valve
VTEC solenoid valve
VTEC pressure
switch
EVAP control cani ster vent shut val ve
EGR val ve
EGR val ve
Drive pulley
speed sensor
Sol enoi d connector {CVT)
Dri ven pul l ey
speed sensor
*,
(M/T)
M/T
*"
INT\
*,
tAtf)
NT:
' 96
model
*,(A,/T):
'97
-
98
mooets
moqets
M/T
-1
(l,/T)
*,
(A,/T)
-,(4,/T)
*1
{M/T)
*,
(A,/T)
*1
( CW)
*,
(A,T)
T101
r102
Ri ght si de of engi ne companment
Alternator
Under-hood fuse/relay box
G 1 0 1 Mi ddl e of engi ne Engi ne ground, vi a engi ne wi re harness
2
*1:
Dl 6Y5 engi ne
*2:
D16Y8 engi ne
*3:
D16Y5
(Ay' T),
D16Y8 engi nes
3- 16
t
'96
-
98 models:
c138 c113 T101
c109
c110
c141
r102
c1
ENGINE WIRE
HARNESS
c'I43
cl 17
c144
c110
c118
c139
c120
c129
c146
c145
c l l 5
c116
c13?
cr02
c105
c106
23-17
Gonnector ldentification
Engi ne Wi re Harness
(D16Y5,
Dl 6Yg engi nes):
,99
-
00 model s
Connectot or
Termi nal
Number ot
Cavities
Location
Conncts to Notes
c' 101
cl02
c103
c104
c 104
c10s
c107
c 108
c' r09
c 110
c 1 1 1
cl 12
c 113
cl 14
c l 1 5
c 1 1 6
cl17
c 118
c 1 1 9
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
1 0
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
No. 1 l uel i nj ector
I
No. 3 f uel i nj ect or
]
i
IAC valve
I
an
l TP) sensor
Manifold absolute pressure
{MAP) sensor
I
Intake ai r temperature
(l AT)
sensor
I
Power steering pressure (PSP)switch
USA
]
Mai n wi re harness
1C303)
Crankshaft speed fluctuation (CKF)
sensor
Engi ne oi l pressure swi t ch
Al t ernat or
Alternator
Lef t si de ot engi ne compart ment
l vl i ddl e of engi ne
Mi ddl e of engi ne
Lef t si de ot engi ne compart ment
Mi ddl e of engi ne
Mi ddl e ot engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e oI engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Nl i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
N4i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e ot engi ne
Mi ddl e ot engi ne
Mi ddl o of engi ne
Mi ddl e of engi ne
Mi ddl e ot engi ne
l rl i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e oI engi ne
Mi ddl e ot engi ne
Ri ght si de of engi ne compart menl
Behi nd ri ghr ki ck panel
Mi ddl e ot engi ne
[ , l i ddl e of engi ne
N4i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e oI engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Ri ght si de ol engi ne compart ment
USA
Canada
Junct i on connect or
JUnct | On COnnect or
Vehi cl e speed sensor l VSS)
Count ershaf t speed sensor
Engine coolant temperature {ECT} switch A
Di st ri but or
Distributor
Engi ne cool ant t emperat ure
(ECT)
sendi ng
uni t
(ECT)
sensor
Pri mary H02S
(sensor
1)
Pri mary HO2S
(sensor
1)
Pri mary HO2S
l sensor 1)
Back-up l i ght swi t ch
Lock' ! p cont rol sol enoi d val ve
Secondary HO2S (sensor
2)
Li near sol enoi d val ve
Shi f t cont rol sol enoi d val ve
Starter solenoid
Junct i on connect or
ECM/PCM
ECM/PCM
ECM/ PCM
PCtvt
Knock sensor
(KS)
I AC val ve
VTEC sol enoi d val ve
VTEC pressure switch
EGR cont rol sol enoi d val ve
Secondary gear shaf t speed sensor
EGR val ve
EGR val ve
Dri ve pul l ey speed sensor
Sol enoi d connect or
(CVT)
Dri ven pul l ey speed sensor
*'
(A/TI
*1
(CVT)
*,
(M/ T)
Mfi
a
(A/Tl
"
(A,/T)
.,
(4,/r)
-'
{AlrJ
*1
(M/ T)
tvliT
*1
(CVT)
*,
(cvT)
*'
(cw)
*1
(MiT)
*1
{CVT)
*1
{CVT)
*,
(cvr)
T101
T102
Ri ght si de ot engi ne companment
Al t ernat or
Under' hood f use/ rel ay box
G 1 0 1 Mi ddl e of engl ne
I
Engi ne ground, vi a engi ne wi re harness
* 1:
016Y5
*2:
D16Y8
* 3:
Dl 6Y5
engi ne
engi ne
(CW),
D16Y8 engi nes
23-14
D
'99
-
00 models:
c132
c133
c134
c135 c123
c138
c113
c130
c117
T102
Cli(l
c117
c1+l
c1{{)
c112
c119
cl ' l 1
WIRE
HARNESS
c t 18
c139
c120
c129
Clir6
c1a5
c t 15
cl 16
c137
c102
c126 C121
c125 C123 c122 C121
23-19
Engine Wire Harness
{D16Y7 engine}:
'96
model
Conneclor or
Terminal
Number ot
Cavhies
Location
Connects to Notes
c101
c102
c 103
c104
c104
c105
c' r06
c107
c 108
c 109
c110
c 1 1 1
c112
c l 1 3
c't14
L t t S
c l 1 6
cl17
c118
c l 1 9
c120
c121
c123
c124
c124
c125
c126
c' t27
c12a
c129
c130
c131
c132
c133
c134
c135
1 0
1
4
5
' 14
1 4
10
1
,,
2
2
1
22
31
16
I
No. 2 fuel injector
I
No,4 fuel i nj ector
IAC valve
l
Throttl e posi ti on (TP)sensor
I
Manifold absolute pressure (MAP)
sensor
Intake ai . temperature
(l AT)
sensor
]
Power steeri ng pressure (PSP)
swi tch
I
USA
EVAP purge
control sol enoi d val ve
I
Juncti on connector
Juncti on connector
I
Vehicle speed sensor
(VSS)
|
Countershaft speed sensor AlT
(ECT)
I
Mai n wi re harness
(C303)
Crankshaft speed fl uctuati on (CKF)
sensor
swi tch
Al ternator
Alternator
switch A
Distributor
Engi ne cool ant temperature (ECT)
sendi ng uni t
Engine coolant temperature lECT) sensor
Pri mary H02S
(sensor
1)
Back-up light switch
Secondary HO2S
(sensor
2)
Shi ft control sol enoi d val ve
Staner sol enoi d
Juncti on Connector
Mai n wi re harness
{C446)
ECM/PCM
PCM
ECM/PCM
ECM/PCM
Left si de of engi ne compartment
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
USA
Canada
M/T
AtJ
Afi
T101
T102
Al ternator
G101 Mi ddl e of engi ne
23-20
!
'96
model:
C135 C13, 1
ENGINE WIRE HARNESS
c106 c105
c' 107 c103
T102
cr 17
cl 19
c120
c l 18
c129
i',zz
ct2'
c108
23-21
{Dt6Y7 engi nel :
' 97
-
9g model s
Connectot or
Termi nal
Number of
Csvities
Location
Connects to Notes
c 101
c102
c103
c104
c104
c105
c106
c107
c 108
c109
c l 1 0
c l l l
c112
c l 1 3
c l 1 4
c 1 1 5
c1 l 6
c117
c118
cl 19
cl 20
c121
c122
c123
cl24
c124
c125
c126
c127
c128
c129
c 130
c 131
c132
c134
c135
c l 4 1
1 0
1
2
10
I
2
2
'>
4
t
20
3r
2
No. l fuel i nj ector
I
IAC val ve
]
Throttl e posi ti on (TP)
sensor
I
sensor
Intake ai r temperature (l AT)
sensor
]
Power steeri ng pressure (PSp)
swi tch
I
USA
Juncti on connector
I
Juncti on connector
I
(VSS)
I
en
(ECTI
Crankshaft speed fl uctuati on
(CKF)
sensor
swi tch
Alte|'nator
Al ternator
switch A
Di stri butor
(ECT)
sendi ng uni t
(ECT)
sensor
Pri mary HO2S
(sensor
1)
Secondary H02S (sensor
2)
Staner sol enoi d
Juncti on connector
Mai n wi re harness
(C446)
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
USA
Canada
Mtr
AIT
ECM/PCM
PcM
I
Arr
ECM/PCM
ECM/PCM
Mai n wi re harness
{C305)
|
Aft
T 101
r102
Al ternator
G 1 0 1 Mi ddl e of engi ne Engi ne ground, vi a engi ne wi re harness
23- 22
D
'97
-
98 models:
WIRE HARNESS
23-23
and Wire Harness
Routi ng
(D15Y?
engi ne):
,99
-
OO model s
c101
c102
cl 03
c' t04
c 104
c 105
cr 06
0107
c108
c109
c' t 10
c11 r
c112
c113
c114
c115
c 1 1 6
c117
c l 1 8
c119
c120
c121
c122
c123
c124
c124
c125
c127
c128
c129
c 130
c 131
c134
c135
1 0
3
'I
3
?
2
3
?
2
1 4
1 4
3
2
8
1
Mi ddl e of engi ne
fvl i ddl e of engi ne
Left si de of engi ne companment
Mi ddl e of engi ne
Mi ddl e of engi ne
Middlr ol sngins
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Ri ght si de ot engi ne compartment
sensor
swi tch
Al ternator
Al ternatOr
No. l fuel i nj ector
No. I fual itjecto,
IAC val ve
sensor
Manifold absolute pressure
{MAp) sensor
0AT) sensor
Power steeri ng pressure (PSp)
swi tch
EVAP purge
Juncti on connector
Juncti on connector
(VSS)
{ECT)
switch A
Di stri butor
sendi ng uni t
Engine coolant temperature (ECT)
sensor
Pri mary HO2S
(sensor
1)
Secondary HO2S
(sensor
2)
Starter sol enoi d
Juncti on Connector
ECM/PCM
ECM/PCM
PCM
USA
Canada
M/T
Atr
Atr
Alr
Al-|.
Mi ddl e of engi ne
Engi ne ground,
vi a engi ne wi re harness
23-24
1O
'99
-
00 models:
c117
c1
c110 cl 11
c114
cl 13
c108 ct07
23-25
and Wire Harness Routi ng
{81642 engi ne}:
.99
-
00 model s
c 101
c102
cl 03
c104
c 104
c' 105
c106
cl01
c108
c 1 1 0
c l 1 1
cl 12
c1' 13
c114
c 1 1 5
c117
c l 1 9
c120
c121
c122
c123
c124
c129
c130
c l 31
c133
c134
c137
c 138
c139
c140
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e ot engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e ot engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne compartment
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
l Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e ot engi ne
l Mi ddl e of engi ne
Mi ddl e of engi ne
1 0
2
,]
4
3
2
2
2
2
3
3
2
2
2
14
1 4
3
2
' 10
'I
2
4
2
1
20
22
25
31
2
2
I
sensor
swi tch
Al ternator
Al ternator
No. 2 tuel i nj ector
sensor
sensor
(l AT)
sensor
Power steeri ng pressure (PSP)
swj tch
EVAP purge
Juncti on connector
Juncti on connector
(VSS)
(ECT)
switch A
Di stri butor
sendi ng uni t
{ECT) sensor
Pri mary HO2S
(sensor
1)
Starter sol enoi d
Juncti on connector
ECM
ECtvl
Knock Sensor
{KS)
IAC val ve
VTEC pressure
swi tch
USA
Canada
'99
-
00 models:
c112
c l 17
T102
c119
c140
c13t)
c104
T101
c l t 5
c116
c137
c102
23-27
and Wire Harness Routi ng
Engine Compartment Wire Harness
conneqtor of
Termi nal
Number of
Cavities
Location
Connects to
Notes
c201
c202
c202
c203
c204
c205
c206
c207
c208
c209
c210
c210
c211
c212
c213
c214
c215
1 0
6
2
2
2
1
3
2
1
2
8
Behi nd front bumper
Mai n wi re harness
{C309)
Crui se actuator
Wi ndshi el d washer motor
Rear wi ndow washer motor
Left front turn si gnal /parki ng l i ght
Front fog l i ght
Left headl i ght
Ay' C wi re harness
1C751)
Horn
HOrn
Radi ator fan motor
Ri ght headl i ght
Ri ght front turn si gnal /parki ng l i ght
Mai n wi re harness
(C355)
Washer level switch
Opti onal
' 96
-
97
model s
'98
-
99
model s
Canada
' 99
model
G201
G202
Body ground,
vi a engi ne compartment
wi re harness
Body ground, vi a engi ne compartment
wrre harness
*1r
Wi th crui se control
*2:
Wi thout crui se control
23- 2A
c20l c202
ENGINE COMPARTMENT
WIRE HARNESS
23-29
Connector l denti fi cati on
and Wi re Harness
Routi ng
Main Wire Harness
lLeft side ot engine compartment branchl
Connector or
Termi nal
Number of
Cavities
Location
Connects to
Notes
c301
c302
c303
c304
c305
c305
c306
c307
c308
c309
c309
c310
5
2
1 0
3
14
8
1
I
1 0
2
2
Left si de ot engi ne companment
Wi ndsh i el d wi per motor
Test tachometer connector
Engi ne wi r e har ness
( C101)
Dayti me runni ng l i ghts resi stor
Engi ne wi re harness (C136)
Engi ne wi r e har ness ( C136)
Brake fl ui d l evel swi tch
(+)
Brake fl ui d l evel swi tch
(-)
Engi ne compartment wi re harness
(C201)
Engi ne companment wi re harness (C202)
Engi ne compartment wi re harness (C202)
Left front ABS wheel sensor
Canada
; | . '
ABS
* l r
D' 16Y5 engi ne
* 5: ' 96
9g model s
* 2:
D16Y8 engi ne
*3:
Wi th crui se control
*4r
Wi thout crui se control
* 1: ' 99
-
00 model s
Mai n Wi re Harness
(Ri ght
si de of engi ne compartment branch)
Connector or
Termi nal
Number of
Cavities
Location
Connects to Notes
c353
c354
c355
c356
c357
c359
c360
1 1
3
I
3
2
2
' 10
2
2
(CgoB)
(C906)
Underhood fuse/retay box
(C905)
Under-hood tuse/rel ay box
(C907)
Engi ne companment wi re harness
{C214)
Under-hood ABS fuse/rel ay box {C927)
Under-hood ABS fuse/retay box (C926)
Ri ght front ABS wheel sensor
ABS sol enoi d
ABS pump
motor
USA
ABS
ABS
ABS
ABS
ABS
G403 Ri ght si de of engi ne compartment Body ground,
vi a mai n wi re harness
23- 30
D
UNDER-HOOO
FUSE/RELAY BOX
MAIN WIRE HARNESS
(l ef t b. anch)
c301
23-31
Connector or
Terminal
Number of
Cavhios
Location Connocts io Notes
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c410
c411
c412
c413
c414
c415
c416
c417
c418
c4l 9
c420
c42'l
c423
c424
c425
c426
c427
c42A
c429
c430
c431
c432
c433
c434
c435
c431
c438
c439
' 14
' t4
I
I
1 0
' t2
24
16
7
o
18
20
18
7
6
I
o
4
7
8
1 4
1
Above under-dash fuss/relay box
Under l eft si de ot dash
Under l eft si d of dash
Under l eft si de of dash
Undr l eft si de of dash
Behind under-dash fuse/relay box
Above under-dash fuse/relay box
Under left side of dash
Above under-dash fuse/rlay box
Eehind under-dash fuse/relay box
In the steeri ng col umn cover
In the steering column cover
In the steeri ng col umn covEr
Under mi ddl e of dash
Eehind under-dash fus/relay box
Fl oo. wi re harness
(C555)
Fl oor wi re harness
(C554)
Security system
Crui se control uni t
Dayti me runni ng l i ghts control uni t
Roof wi re harness
(C701)
Moonroof wi re harness
(C7l 1)
Front fog l i ght connector
Integrated control uni t
Dashboard wire harness
(C504)
(C502)
SRS mai n harness
(C802)
Data l i nk connector
Starter cut relay
l gni ti on swi tch
Security system
Clutch switch
Clutch interlock switch
Under-dash fuss/relay box
(C9191
Undor-dash fuse/rlay box {C920)
Under-dash tuse/relay box
(C922)
Under-dash luse/relay box
(C914)
Under-dash fuse/rBlay box
(C915)
Horn rel ay
Brake swilch
Windshield wiper/washer switch
Rear window wiper/washer switch
Turn signal switch
Combi nati on l i ghvturn si gnal swi tch
Cable reel
l nterl ock control uni t
Secondary heated oxygen sensor sub-
harnss
(C781)
Ay'T gear position
switch
Shi ft l ock sol enoi d
Park pin switch and Ay'T gear position
consol e l i ght
Transmi ssi on control modul e
(TCM)
Transmi ssi on control modul e {TCM)
Under-dash fuse/relay box {C925)
ABS
Opti onal
Canada
Canada
Opti onal
Atr
MTT
Opti onal
Mlf
NT
Atf
CVT
CVT
Opti onal
AN
Atr
G401 Left kick panel
Body ground, vi a mai n wi re harness
Main Wir Harness
(Loft
side of da3h and floor branch):
'96
-
97 models
*2:Wi thout
moonroof
*4:
Wi th moonroof
*5:
M/T
(wi th
crui se control or for D16Y5 engi ne)
*6:
Wi th secondary heated oxygen sensor
(H02S)
23-32
t
' 96
-
97 model s:
MAIN WIRE
HARNESS
c412 C411 c410 c421
UNDER.DASH
FUSE,/RELAY BOX
o
- n - - - n n n - - n r
n - n - - n - - - n - n n -
! ! ! ! ! ! u u ! u ! u + u
23- 33
Connoctor or
Tgrminal
Number of
Cavities
Location Conneqts to Nots
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
' t4
l 4
8
,
1
1 0
1 2
24
7
6
18
20
18
7
6
8
7
8
1 4
2
Above under-dash fuse/rel ay box
Behind under-dash fuss/relay box
Under-dash rel ay box
Eehind under-dash fuse/relay box
Behind under-dash fuse/rslay box
(C555)
(C554)
Securi ty system
Roof wi ro harness
(C7011
Moonroof wi re harness
(C711)
Integrated control unit
(C504)
(C502)
SRS mai n harness
(C802)
Data l i nk connector
Starter cut relay
l gni ti on swi tch
Security system
Clutch switch
Cl utch i nl erl ock swi tch
Under-dash fuse/rel ay box
(C919)
Under-dash fuse/relay box
(C920)
(C922)
(C914)
(C915)
Horn rel ay
Brake switch
Wi ndshi el d wi per/washer swi tch
Rear window wiper/washer switch
Turn si gnal swi tch
Combi nati on l i ght/,turn si gnal swi tch
Cabl e reel
Secondary heated orygen sensor sub-
harness
(C781)
Ay'T gear position switch
Park pin switch and Aff gear position
consol e l i ght
(TCMI
(TCM)
ABS
Opti onal
Canada
Canada
Opti onal
M
MIT
Opti onsl
MlT
Alr
NT
NT
CVT
CVT
G401 Left kick panel
Body ground, vi a mai n wi re harness
Main Wire Harnss {Left side ot dash and floor branchl:
'98
model
*2:
Wi thout moonroof
*4:Wi th
moonroof
*5:
M/T
(wi th
crui se control or for D16Y5 engi ne)
*6:
With secondary heated oxygen sensor
(H02S)
23-34
t D
8 model: "n,
ctza j81
c121
cQa c0
I c129
WIRE
HARNESS
c,(},l
c112 c111 c110
UNDER-DASH
FUSE/RELAY BOX
: : : : : : : : : : : r l l :
23- 35
Connosto! ol
Tsrminal
Number of
Cavities
Location Connoqtg to Notes
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
c433
c434
c435
c447
c448
c449
c450
c451
20
4
1 4
I
6
1
10
12
24
16
4
7
6
2
18
20
18
7
4
8
o
7
8
1 4
22
18
Under-dash relay box
Under l ett si de of dash
(C555)
(C554)
Security system
Roof wi re harness
(C701)
Moonroof wi re harness {C711)
Intagrated control unit
(C504)
(C502)
SRS mai n ha.ness
(C802)
Data link connector
Starter cut relay
l gni ti on swi tch
Security system
Clutch switch
Under-dash fus/relay box
(C919)
(C920)
(C922)
(C914)
(C915)
Horn relay
Brake switch
Windshield wiper/washer switch
Rear window wiper/Washer switch
Turn si gnal swi tch
Combination light/turn signal switch
Cable reel
Secondary heaied oxygen sensor sub-
harness
(C781)
A/T
gear position
switch
Park pin switch and A,/T gar position
consol e l i ght
Security system
Security system
IVT gear posi ti on i ndi cator tri m l i ght
Security system
Keyl ess door l ock control uni t
ABS
Opti onal
Canada
Canada
Opti onal
At-|.
M/T
Opti onal
M/T
Atr
Opti onal
Opti onal
Opti onal
Atr
AIT
AJ-|.
G401 Left kick panel Body ground, vi a mai n wi re harness
Main Wire Halness lLoft side of dash 8nd lloor branchl:
'99
-
00 modls
*2:
Wi thout moonroof
*4:
Wi th moonroof
*5:
M/T
(wi th
crui se control or for Dl 6Y5 engi ne)
*6:
Wi th secondary heated oxygen sensor
(H02S)
23-36
D
'99
-
00 models:
c418 c425
c412 C411 C410
MAIN WIRE
HARNESS
c{33 Ca34
c121
UNDER.OASH
FUSE/RELAY BOX
o
- r - - - - - - - - - -
23-37
Gonnector ldentification and Wire Harness Routing
Msin Wire Harness
(Right
side oI dash branch)
Connector or
Termi nal
Number of
Cavities
c440
c441
c442
c443
c4M
c445
c446
c452
1 6
2
20
7
22
22
Behi nd ri ght si de of ki ck panel
Behi nd ri ght si de of ki ck panel
(C721)
Servi ce check connector
Juncti on connector
PGM-Fl mai n rel ay
ABS control uni t
ABS control uni t
Engi ne wi r e har ness
( C131)
ECM/PCM
G402 Ri ght ki ck panel Body ground, vi a mai n wi re harness
*' l :
' 99
-
00 model s
23-38
D
Dashboard Wi re Harness
Connect or ol
Termi nal
Numbel of
Cavi t i es
Location
Connects to Notes
c501
c502
c503
c504
c505
c507
c508
c509
c510
c513
c514
c515
c516
c518
c519
c520
20
24
t o
1 2
5
3
20
5
5
1 4
r 0
5
20
22
5
2
5
Behi nd dashboar d l ower panel
Above under-dash l use/rel ay box
Above under dash Iuse/rel ay box
Above under dash tuse/rel ay box
Left si de of steeri ng wheel
Bel ow gauges
Behi nd gauges
Behi nd gauges
Behi nd gauges
Behi nd gauges
Behi nd
gauges
Ri ght si de ot gauges
Ri ght si de oI gauges
Beh i nd mi ddl e of dash
Behi nd mi ddl e of dash
Behi nd gauges
Under - dash { use/ r el ay box
( C912)
Mai n wi r e har ness 1C411)
(C553)
Mai n wi r e har ness
( C410)
Crui se mai n swi tch
Dash l i ght s br i ght ness cont r ol l er
Juncti on connector
Gauge assembl y
Gauge assembl y
Gauge assembl y
Gauge assembl y
Gauge assembl y
Hazard warni ng swi tch
Rear wi ndow defogger swi tch
Audi o uni t
(Keyl ess recei ver ci rcui t)
Audi o uni t
Secur i t y cont r ol uni t
Audi o uni t
Securi ty system
Accessory power outl et
Gauge assembl y
A"r
SRS
A,/r
Opti o nal *'
Opti on al *'
ABS
G501 Under mi ddl e ol dash Body ground, vi a dashboard wi re harness
* 1:
Wi t h shi i t - up i ndi cat or or cr ui se cont r ol syst em
( ' 96
-
97 model s)
Wi th crui se control system
(' 98
model )
c509 C511 c510 c515
1 3 l c 5 l 7
*2:
' 96
98 model s
*3:
' 99
-
00 model s
c508
DASHSOARD WIRE
HARNESS
c501
c520
c502 c504
23-39
Floor Wire Harness lCoupe/Haichbackl
Connsclor or
Termi nal
Number of
Cavities
Locati on Connects to Notes
c551
c552
c553
c554
c556
c556
c557
c558
c560
c561
c562
c564
c56s
1 6
8
' 16
1 4
20
2
25
,)
,I
2
1
14
20
2
2
?
1
1 0
Behi nd underdash fuse/rel ay box
Behi nd under-dash fuse/rel ay box
Dri ver' s door
Dri ver' s door
Passenger' s door
Passenger' s door
Mi ddl e of fl oor
Left si de offl oor
Left B-pi l l ar
l nsi de of l eft rear wheel
Left c-pi l l ar
Left C-pi l l ar
Left C-pi l l ar
Fuel t ank
Fuel t ank
Insi de of ri ght rear wheel
Ri ght B-pi l l ar
Fuel t ank
Left side ot dash
Under-dash fuse/rel ay box {C923)
(C921)
Dashboard wi re harness {C503)
Mai n wi re harness
(C402)
Mai n wi re harness
(C401)
Mai n wi re harness {C401)
(C631)
(C631)
(C651)
(C651)
Parki ng brake swi tch
Dri ver' s seat bel t swi tch
Dri ver' s door swi tch
Left rear ABS wheel sensor
Rear wi re harness
(C601)
Rear wi re harness
(C601)
Rear wi re harness {C602}
Fuel gauge
sendi ng uni t
Fuel pump
Ri ght rear ABS wheel sensor
Passenger' s door swi tch
Fuel tank pressure sensor sub-harness
( c791)
Power mi rror swi tch
ABS
ABS
ABS
G551
G552
Left ki ck panel
Left si de of fl oor
Body ground, vi a fl oor wi re harness
Body ground. vi a fl oor wi re harness
*1r
Wi th power wi ndows
*2:
Wi thout power wi ndows
*3:
D16Y8 engi ne {Coupe)
*4:
' 96
-
98 model s
*5:
' 99
-
00 model s
23-40
l , -
FLOOR WIRE HARNESS
23-41
Connector ol
Termi nal
Number of
Cavities
c553
c554
c556
c557
c557
c558
c559
c560
c561
c562
c563
c564
c565
c566
c567
L5bY
c570
c511
c572
c513
6
1 4
25
2
25
'|
1
2
' t4
1
' 10
6
6
I
1
Behi nd underdash fuse/rel ay box
Drl ver' s door
Dri ver' s door
Passenger' s door
Passenger' s door
Mi ddl e of fl oor
Ri ght B-pi l l ar
l nsi de of l eft rear wheel
Left C-pi l l ar
Left C-pi l l ar
Fuel tank
Fuel tank
Insi de of ri ght rear wheel
Left B-pi l l ar
Left side of steering wheel
Ri ght B- pi l l ar
Left B-pi l l ar
Left quarter panel
Ri ght quarter panel
Under-dash fuse/rel ay box {C923)
(C921)
(C503)
Mai n wi re harness
(C402)
Mai n wi re harness
(C401)
(C631)
(C631)
Front passenger's doorwire harness
(C651)
Front passenge/s doorwire harness
(C651)
Driver's seat belt switch
Front passenger' s door swi tch
Rear wi re harness
(C601)
Rear wi re harness
(C602)
Fuel gauge sendi ng uni t
Fuel pump
{ FP)
Power mirror switch
(C671)
(C661)
Left rear door switch
Ri ght rear door swi tch
ABS
ABS
ABS
G552
Left ki ck panel
Left side of floor
Floor Wire Harness lSedanl:
'96
model
*l :Wi th
power wi ndows
*2;
Wi thout
power wi ndows
23-42
D
'96
model:
FLOOR WIRE HARNESS c570
c560
c573 C556 C564
23-43
Gonnector l denti fi cati on
and Wi re Harness Routi ng
Fl oor Wi re Harness
(Sedanl :
' 97
-
00 model s
Connector or
Termi nal
Number of
Cavities
c552
c553
c554
c555
c556
c557
c557
c558
c559
c560
c56'l
c562
c563
c564
c566
c568
c569
c570
c571
c572
1 6
8
14
20
25
2
2
1
2
1
20
2
2
2
1
l 0
1
1
Behi nd under dash fuse/rel ay box
Dri ver' s door
Dri ver' s door
Passenger' s door
Passenger' s door
Mi ddl e of fl oor
Ri ght B- pi l l ar
Insi de of l eft rear wheel
Left C-pi l l ar
Left C-pi l l ar
Left C-pi l l ar
Fuel t ank
Fuel t ank
Insi de of ri ghr rear wheel
Left B-pi l l ar
Fuel t ank
Ri ghr B, pi l l ar
Left B pi l l ar
I of r ^, , . r i ar ^. âl
(C923)
(C921)
(C503)
Mai n wi re harness
(C402)
Mai n wi re harness
(C401)
(C631)
Dri ver' s door wi re harness {C631}
Front passenger' s door wi re harness
(C651)
Front passenger' s door wi re harness
(C651)
Dri ver' s seat bel t swi tch
Front passenger' s
door swi tch
Rear wi re harness
(C601)
Rear wi re harness (C601)
Rear wi re harness
(C602)
Fuel gauge sendi ng uni t
Fuel pump ( FP)
Fuel tank pressure sensor sub-harness
( c791)
Power mi rror swi tch
(C671)
(C661)
Left rear door swi tch
Ri ght rear door swi tch
ABS
ABS
ABS
G551 Left ki ck panel
"1r
*2:
* 3: ' 97
-
' 98
model s
*4:
' 99
-
00 model s
23-44
D
'97
-
00 models:
HARNESS
23-45
Rear Wire Harness
(Halchbackl
Connector or
Termi nal
Number of
Cavitiss
c601
c601
c602
c603
c604
c605
c606
c607
c608
1 4
20
2
2
6
Left quarter panel
Left quarter panel
Left quaner panel
Left quarter panel
Left side of cargo area
Ri ght si de of cargo area
Ri ght quaner panel
{C562}
(C562)
Fl oof wi re harness
(C563)
Left rear speaker
Left outer tai l l i ght
Ri ght outer tai l l i ght
Ri ght rear speaker
Hatch wi re harness
(C761)
Hatch wi re harness
(C762)
Opt i onal
Opti onal
G601 Mi ddl e of cargo area Body ground, vi a rear wi re harness
* 1:
' 96
-
98 model s
*2:
' 99
-
00 model s
REAR WIRE
s\
23-46
D
Rear Wire Harness {Coupe:
'96
-
99 models/Sedan;
'96
-
98 modelsl
Connector or
Torminal
Numbsr of
Caviiies
Location
Connects to
Notes
c601
c601
c602
c603
c604
c605
c606
c609
c610
L O t l
c612
c613
c6' 1 4
c616
c617
t o
20
1
)
1
4
2
2
2
4
Left
quarter panel
Left quarter panel
Left
quarter panel
Left
quarter panel
Left si de of trunk
Ri ght si de of trunk
Ri ght
quarter
Panel
Left side of rear window
Mi ddl e of rear shel f
Ri ght si de of rear wi ndow
Left si de of trunk
Mi ddl e of trunk
Mi ddl e of trunk
Mi ddl e of trunk
(C562)
(C562)
(C563)
Left rear speaker
Left outer tai l l i ght
Ri ght rear speaker
Rear wi ndow defogger
(+)
Hi gh mount brake l i ght
Tr unk l i ght
(-l
Left i nner tai l l i ght
Left Ii cense
pl ate l i ght
Trunk l atch swi tch
Ri ght l i cense
Pl ate
l i ght
Ri ght i nner t ai l l i ght
G601
Mi ddl e of trunk
Body
ground, vi a rear wi re harness
REAR WIRE HARNESS
23-47
and WireHarness
Routing
Rear Wir Harnsss (Sedan):
'99
-
O0 models
Connactor or
Torminal
Numbr ot
Cavhios
Location
Connects to
Notog
c501
c603
c604
c605
c606
c610
c611
c6r3
c614
c617
c618
c619
c620
c621
c622
c623
20
4
3
2
a
1
Left quarter panel
Left quarter panl
Left side of trunk
Left side of trunk
Mi ddl e of trunk
Mi ddl e of trunk
Mi ddl e of trunk
Ri ght si de oftrunk
Left side of trunk
Left side of trunk
Ri ght si de oftrunk
Floor wir harness
(C562)
Left rear speaker
Left outer taillight
Right rear speaker
Trunk l i ght
Left i nn6r tai l l i ght
Left licenso plate
light
Trunk latch switch
Ri ght l i cense pl ate
l i ght
Ri ght i nner tai i ght
Left i nner tai l l i ght
Ri ght i nner tsi l l i ght
Wi ndow antenna coi l
Window antnna coil
G601
G602
Mi ddl e of trunk
Mi ddl e of rsar shel f
Body ground,
via rear wire harness
Body ground,
via rear wire harness
Roar Window Detogger Wire
Connectot or
Terminal
Numbor of
Cavitios
Loc!tion
Connrct3 to Note!
c831
u65Z
c833
2
1
1
Ri ght si de of rear wi ndow
Wi ndow antenna coi l
Rear window defogger O
Rear window defogger O
REAR WIRE HABNESS
c&tl
23-48
c603
c62
ID
* 1: Wi t h
power wi ndows
*2:
Wi thout
Power
wl ndows
"3:
Wi thout keyl ess
Dri ver' s Door Wi re Harness {Coupe/Hatchback}
Connect or ot
Termi nal
Numbei of
Cavities
Locati on
Connects to
Notes
c631
UOJ I
c632
c633
c634
c635
c636
c638
c639
c640
2
2
4
4
2
1 2
3
8
1 2
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Dri ver' s door
Insi de of l eft power mi rror
Dri ver' s door
(C556)
(C556)
Left front door speaker
Dri ver' s
power wi ndow motor
Dri ver' s door l ock actuator
Tweeter
Power wi ndow master swl tch
Dri ver' s door l ock swi tch
Left power mi rror
Power door l ock control unl t
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe*3
c639
DRIVER'S DOOR WIRE HARNESS
23-49
and Wire Harness
Routing
Passenger's Door Wire Harness
{Coupe/Hatchbackl
Connector or
Termi nal
Number of
Cavities
Location
Connests to Notgs
c651
c652
c653
c654
LO55
25
2
2
2
2
5
8
2
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Insi de of ri ght power mi rror
Passenger' s door
(C557)
Fl oor wi re harness {C557)
Ri ght front door speaker
Front passenger's power
window moror
Front passenger's
door lock actuator
Front passenger's power window switch
Ri ght power mi rror
Tweeter
Coupe
Coupe
Coupe
Coupe
Coupe
*1:
*2;
PASSENGER'S DOOR WIRE HANNESS
23- 50
'
Dri ver' s Door Wi re Harness
(Sedan)
Connector or
Termi nal
Number ol
Locat i on
Cavities
Connects to
Notes
c63 r
c632
c633
c634
c636
c637
c638
c639
c640
25 Dri ver' s door
2 Dri ver' s door
2 I Dri ver' s door
4 Dri ver' s door
4 Dr i ver ' s door
16 Dri ver' s door
1 Dri ver' s door
3 Dr i ver ' s door
8 Insi de of l eft
Power
mi rror
12 I Dri ver' s door
(C556)
Fl oor wi r e har ness 1C556)
Left front door sPeaker
Dri ver' s
power wi ndow motor
Dri ver' s door l ock actuator
Power wi ndow master swi tch
Power wi ndow master swi tch
Dri ver' s door l ock swi tch
Left
power mi rror
Power door l ock control unl t
* 1:
Wi t h
power wl ndows
*2:
Wi thout
power wl ndows
DRIVER'S DOOR
WIRE HARNESS
Front Passenget's Door Wire Harness
{Sedanl
Connector or
Termi nal
Number of
Cavities
Location
Connects to Notes
c651
c653
c654
c656
25
2
2
2
8
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
l nsi de of ri ght power mi rror
(C557)
(C557)
Ri ght front door speaker
Front passenge/s power wi ndow moror
Front passenger's
door lock actuator
Front passenger's power window switch
Ri ght power mi rror
*1:
*2:
23-52
D
Left Rear Door Wire Harness lSedan)
Conngctor or
Termi nal
Number of
Cavities
Loc.ti on
Connests to Notes
c661
c662
c663
c664
2
5
t
Left 8-pi l l er
Left rear door
Left rear door
Left rear door
Fl oor wi re harness {C571)
Left rear
power window motor
Left rear power window switch
Left rear door l ock actuator
Right Rear Door Wire Harness {Sedan)
Connector or
Trmi nal
Numbsr of
Cavities
Location
Connsts to
Notes
c671
c672
c67 4
6
2
5
2
Ri ght B-pi l l er
Ri ght rear door
Ri ght rear door
Ri ght rear door
(C570)
Ri ght rear
power wi ndow motor
Ri ght rear power wi ndow swi tch
Ri ght rear door l ock actuator
Left Rear Door:
Right Rear Door:
RIGHT REAR DOOR
WIRE HABNESS
23-53
t
LEFT REAR DOOR
WIRE HARNESS
Connector l denti fi cati on
and Wi re Harness Routi ng
Roof Wire Harness
(Coupe/Hatchback)
Connector ol
Termi nal
Number of
Cavities
Location
Connects to
Notes
c701
c701
c702
c719
2
6
2
1
Mi ddl e of roof
Front of roof
Cei l i ng l i ght
S potl i g ht
* 1:
' 96
-
98 model s
*2:
' 99
-
00 model s
Roof Wi re Harness
(Sedanl
' 96
-
98 model s
' 99
-
00 model s
* 1:
' 96
-
97 model s
"2:
' 98
model
*3:
' 99
00 model s
* l :
+2:
Connector or
Termi nal
Number of
Cavities
Location
Connects to Notes
c701
c701
c702
c703
c719
2
1
1
1
Mi ddl e of roof
Mi ddl e of roof
Front of roof
Cei l i ng l i ght ( Power )
Cei l i ng l i ght
( Gr ound)
Spotl i ghr
Moonroof Wi re Harness
{Coupe/Sedan}
Connector or
Termi nal
Number ot
Cavi ti es
Location
Connects to Notes
c711
c711
c1' t2
c713
c713
c714
c714
c715
c117
c718
c719
2
6
6
5
5
4
3
2
4
1
U nder l eft si de of dash
Behi nd dashboard l ower panel
Left si de of dashboard bracket
Mi ddl e of roof
Rear of roof
Rear of roof
Front of roof
Under-dash tuse/rel ay box
(C910)
Moonroof open rel ay
Moonroof open rel ay
Moonroof cl ose rel ay
Moonroof cl ose rel ay
Moonroof swi tch
Cei l i ng l i ght
Moonroof motor
Moonroof motor (Ti l t
swi tch)
Sporl i ght
Opti onal
23-54
/::
\,-d',
ROOF WIRE HARNESS
23- 55
Connector
ldentification
and Wi re Harness
Routi ng
Hatch Wiro Harness
(Hatchbackl
Connector or
Trmi nal
Number of
Cavities
Location
Connects to
Notes
c761
c762
c764
c768
6
2
'|
2
2
Ri ght quaner panel
Ri ght quaner panel
Rear of roof
Ri ght si de of hatch
Mi ddl e of hatch
Mi ddl e ot hatch
l Vi ddl e of hatch
Mi ddl e of hatch
Rear wi re harness (C607)
Rear wi re harness
(C608)
Rea. wi ndow defogger (+)
Ri ght l i cense l i ght
Left l i cense l i ght
Rear wi ndow wi per motor
Hatch l atch swi tch
Mi ddl e of t ai l gat e
Body ground,
vi a tai l gate wi re harness
Rear Window Dfoggr cround Wir
(Hatchbackl
Connoctor or
Termi nal
Number oI
Cavities
Location
Connects to
Notes
Left si de ot hatch
Rear wi ndow defogger (-)
G171
Left side of hatch
Body ground,
vi a rear wi ndow defogger
ground
wi re
23- 56
l ' -
REAR WINDOW DEFOGGER
GROUND WIRE
36
-
97 models:
'98
-
00 models:
GROUND WIRE
TCH WIRE HARNESS
WIRE HARNESS
23-57
and Wire Harness
Routing
Heater Sub-harness A:
'96
-
98 models
Connector or
Termi nal
Number ot
Cavities
Location
Conneqts to
Notes
c7 21
c722
c723
c724
c727
7
20
2
Behi nd gl ove
box
Behi nd gl ove
box
Behi nd gl ove
box
Behi nd gl ove
box
Behi nd gl ove
box
Behi nd gl ove
box
Mode control motor
Heater sub-harness B 1C741)
Ay'C thermostat
Bl ower motor
Bl ower resi ster
Reci rcul ati on control motor
Heater Sub-harness B:
'96
-
98 modls
HEATER SUB.HARNESS A
Connoctor 01
Terminal
Number of
Cavities
Location
Conngcts lo
Notes
c7 41
c142
c7 43
20
1 4
Behi nd gl ove
box
(C723)
Heater fan swi tch
Heater control panel
23- 58
HEATER SUB-HARNESS B
'
'99
-
00 models
Connector or
Termi nal
Number of
Cavities
Location
Connects to
Notes
c721
c722
c723
c724
c725
c726
c727
c728
c729
c730
7
24
3
2
4
1
5
4
Behi nd
gl ove box
Behi nd
gl ove box
Behi nd
gl ove box
Behi nd
gl ove box
Behi nd
gl ove box
Behi nd
gl ove box
Behi nd gl ove box
Behi nd gl ove box
Behi nd
gl ove box
Mai n wi re harness
(C440)
Mode control motor
Heater sub-harness
B
(C741)
lilc thermostat
Bl ower motor
Power transi stor
Reci rcui ati on control motor
Heater sub-harness
B
(C744)
Ai r mi x control motor
Bl ower motor hi gh rel aY
'99
-
00 models
Connector or
Termi nal
Number of
Cavities
Location
Connects to
Notes
c7 41
c'742
c143
c744
20
8
20
1
Behi nd gl ove box
Behi nd mi ddi e of dash
Behi nd
gl ove box
Heater sub-harness
A
(C723)
Heater control
Panel
Heater control
Panel
Heater sub-harness
A
(C728)
Rear Heatod Oxygen Sensor Sub-harness
Connector or
Terminal
Number of
Cavhies
Location
Connects to Notes
c7a1
c782
Mai n wi re harness
(C432)
Secondary heated oxygen sensor
(Secondarv
HO2S)
Fuel Tank Pressure Sensor Sub-harness
Connector or
Terminal
Number of
Cavities
Location
Conocts to Notes
c791
c192
c793
6 Mi ddl e of fl oor
Left si de of fuel tank
Left si de of fuel tank
(C568:
Coupe/
Hatchback, C574; Sedan)
Fuel tank pressure
sensor
EVAP two way valve
FUEL TANK PRESSURE SENSOR
23- 60
rt
SRS Main Harness
Conneclor or
Termi nal
Number of
Cavities
Location
Connects to
Notes
c801
c802
c803
c804
c805
c806
c807
2
?
2
2
2
18
Above under - dash f use/ r el aY
DOX
Ri ght si de of under - dash f use/
relay Dox
Mi ddl e of fl oor
Mi ddl e of fl oor
(C911)
N4ai n wi re harness
(C412)
Memory erase si gnal {MES)
connector
Cabl e reel
Passenger' s ai rbag assembl Y
Dummy resastor connector
SRS uni t
USA
Canada
G801
Mi ddl e of fl oor
Body
ground, vi a SRS mai n harness
SRS MAIN HARNESS
23-61
Fuses
Under-hood Fuse/Rel ay Box
cgo1
lTo condensor fan relayl
Gr02
lTo blower motor rlayl
c903
*:
Not usod
NOTE; Vi ew from the backsi de of the under-hood fuse/rel av box.
[To radi.lor tan rolayl
cto5
[To main wir6 harne$
(C3521]
fto
l/c comprdssor]
lclutch
relay
I
c905
lTo main wire ha.ness
(C353ll
DE
tr
tr
tr
r-1
IJ
r"l
17
LI
n
51
IJ
r"l
56
LI
r"l
57
IJ
23-62
ITo main w;re ha.ness (C351ll
( l ' -
Fuse Number Amps wi re Col or Component(s) or Circuitlsl Protectd
41 80A Power di stri buti on
42 4 0 A WHT/BLK To i gni ti on swi tch
(BAT)
43 7. 5 A WHT/RED Cei l i ng l i ght, data l i nk connector, trunk l i ght
44 1 5 A WHT/BLK PGM-Fl mai n rel ay
Not used
46 4 0 A WHT/BLU Power wi ndow motors
(vi a power wi ndow rel ay)
47 7. 5 A WHT/BLU Audi o uni t, cl ock, TCM
(CVT),
ECM/PCM
(VBU)
48 3 0 A WHT No.33
(7.5
A) fuse, To combi nati on l i ght swi tch
(headl i ght)
49
Not used
50 30A WHT/GRN Rear wi ndow defogger
(vi a
rear wi ndow defogger rel ay)
c l 2 0 A WHT/GRN Power door l ock control uni t, moonroof motor
1 5 A WHT/GRN Horn system, brake l i ghts, brake si gnal
1 0 A WHT/BLK Hazard warni ng l i ght , t urn si gnal / hazard rcl ay
54 4 0 4 WHT/RED Opt i on { +B)
55 4 0 A BLU,A/VHT Bl ower motor
(vi a
bl ower motor rel ay)
204
WHT Condenser fan motor
(vi a
condenser fan rel ay)
RED l ' l c compressor cl utch
(vi a
IVC compressor cl utch rel ay)
204 BLVBED Radi ator fan motor
(vi a
radi ator fan rel ay)
23-6
Fuses
Under-dash Fuse/Relay Box
c912
lTo d.rhborrd wire harnes lC50'l)l
cl 1
lTo SRS m.in
c9l0
lTo moonroofwiro h.tn6s 1C712)l
c913
[To ignition 3witchl lTo m.in wir. ha]n.3s {Cra2iIll
clr15
lTo m.in wiro h.Jna3r
lca23)l
lTo
powor window rcl.yl
c!17
lTo tu]n .ign.l/h.z.rd r.byl
d.fogg.r rol.yl
.: Canadt
*:
Not usod
O:
C326 loption
(+B)l
@: C927 loption ld.3h
light!)l
O: C!r28 loption tAOCll
@:
c!t29 loption
(lc2ll
: Not u3od l'96
-97
modelll
NOTE: Vi ew from the backsi de of the under-dash fuse/rel ay box.
Clt25
(96,
97 mod.bl
lTo m.in wiro ha]n.!.
(C439ll
a-) r"r r"t r-r n rl 11 r'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-r r-r Fr r-r r-r n n ra r-1 rat n r-1
t 2 t 3 r a 15 16 17 1A 1a 20 21 22
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
23-64
lTo m.in wiro h!rn..s 1C419)l
l r -
Fuse Number Amps wi re Col or Component{sl or Circuit(sl Protected
* 1r
' 96
-
98 model s
*2r
' 98
model
*3:
' 99
-
00 model s
,l
Not used
2 Not used
3 1 0 A GRN Rear wi ndow wi oer mot or, rear wi ndow washer mot or
4 1 0 A RED/BLU Ri ght headl i ghr t hi gh beam)
5 1 0 A RED/ GRN Left headl i ght
(hi gh
beam), hi gh beam i ndi cator l i ght
6
Not used
7 204 R E D/VVHT Left rear power wi ndow motor
8 20A. YEUBLK Ri ght rear power wi ndow mot or
9
Not used
(' 96 -
97 model s)
' t5
A RED Di stri butor
(i gni ti on
control modul e)
(' 98 -
99 model s)
1 0 204 G RN/BLK Front
passenger' s power wi ndow motor
1 1 2 0 A BLU/BLK Dri ver' s power wi ndow motor
12 7. 5 A YEUBLK Turn si gnal / hazard rel ay
(vi a
t urn si gnal / hazard swi t ch)
t 5 1 5 A
YEL/GRN PGM-Fl mai n rel ay
GRY or BLK,^/ELSRS u ni t
(VA)
14 1 . 5 4 B LK/YE L Crui se control system, audi o uni t*1, keyl ess door l ock control uni t*3
BLK/lr'r'HT
Al ternator, VSS, ELD uni t
(USA),
EVAP
purge vent shut val ve, oxygen
sensors, TCM
(CVT)*'
t 6 BLI(,/BLU ABS
pump
mot or, rear wi ndow def ogger.
power mi rror*3, mi rror del ogger*3
1 7 7. 5 A BLK,/YE L A,/C system,
power mi rror*r. opti on
(l G2)
1 8 YEUBTK Dayt i me runni ng l i ght s rel ay
(Canada)
1 9 7. 5 A YEURED Back' up l i ght s
20 1 0 A BLK/VVHT Dayti me runni ng l i ghts control uni t
(Canada)
21 1 0 A REDA/VHT Ri ght headl i ght
( l ow
beam)
22 1 0 A RE DI/E L Lef t headl i ght
(l ow
beam)
1 0 A GRY or PNK SRS UNi t
( VB)
24 7. 5 A GRN/ ORN Moonr oof r el ays
25 7. 5 A YEL Gauge and i ndi cator l i ghts. i nterl ock control uni t
204 GRN/ BLK
Wi ndshi el d wi per motor, wi ndshi el d washer motor,
i ntegrated control uni t {Canada)
1 5 A YEL/GRN Accessory socket
(ACC)
2a 10 A,/' ]5A' ' YE L/R ED Audi o uni t, opti on
(ACC)
29
Not used
30 7. 5 A R ED/BLK Dash l i ght s, opt i on
( dash l i ght s)
1. 5 A BLUA/VHT ECM/PCl \4, PGM-Fl maj n rel ay, i ntegrated control uni t
RED/BLK Front parki ng l i ght s, t ai l l i ght s, l i cense pl at e l i ght s
33 7 . 5 A WHT/GRN l nterl ock control uni t. key i nterl ock sol enoi d
23-65
Fuses
Under-hood ABS Fuse/Rel ay Box
lTo under-hood ABS tus/relay box wire harnossl
c926
lTo main wire harness (C357)l
@27
ITo main wir6 harno$
{C356}l
Wire Colol
c92E
[To ABS pump
motor relayl
Componont(s) or Circuit(sl Protscted Fusg Number
61 40A WHT ABS pump motor
(vi a
ABS pump motor rel ay)
63 BRN/YE L ABS control uni t
(motor
check)
204 WHT/GRN ABS control uni t
(+Bl
)
23-66
Power Distribution
t
Ci rcui t l denti fi cati on
CONTROL
V
I
GRNMHT
UNDER-HOODABS
FUSEi RELAY BOX
'96-98
models
: 99-00 models
WHT'GBN
- l ABs conlrorun
ABS
Aimp
molor
* 2
BRN,ryEL
YEURED
I
ABS conltolun t
Slaner molor
WHT/BLK
..........-
WHT/GRN
_-
WHTiGBN
GRN/RED
-
Hazard waming ligl
Tun signal/hazard re ay
{Via swlch)
HOTN
HOn re ay
ABs controllnil
ECMi PCM
TCM ( CW) r l
Cruise conlrol unil
Erake lrghls
EC}?VPCM
I-"-
G401
G402
I... UNOER.DASH
w_T BLU
-13
>
F-SE ?ELAY BCx
t -
Fa Nge23: t )
Audio unil
TCM ( CW) ' ,
ECM/PCM
Healer conlrolpanel
(cont' d)
23-67
UNDER HOOD
FUSEi RELAY BOX
ALTERNATOR
V
No 15 (7 sA) FUSE
Y
(From page 23 70)
|
f7
r_1
I_ .,.-.,
*,,,,,*
_$
lg|[|];gil.'
('^')
WHT/8LK
-
Ceiling lighl
Trunkllghr
Spollighl
*'
Dala link connecor (DLc)
Integraled control unil
PGM Fl main relay
Power Distribution
Circuit ldentification
(conf
dl
ECI4/PCM (Via A/C
Fsssure
switch)
,VC thmodA
Con(,ensef lan molor
A/C comFessor dulci
ECWPCM
UNDER HOOD FUSE/BELAY BOX
"*-f_
v{HT
-
BLI(/RED
-
UNDEN.DASH FUSE/REIAY BOX
flo
page
23-72)
COMBINATION LIGHT SWITCH
[Io
page 23 73, 74)
UNDER,DASH FUSgRELAY BOX
Oo
page 23'74)
wnc'N
---}>
Hlgl;%,s,1 lsu'r"'
*,
wHT/ GnN- Po#sr door lock control unil
Moonrool molor
*HT/RED
+ Hoo5f;oA'.j1fu,uttto"
*t
BLUMHT
-
Blowor fiolor
G()1
G402
BLu/rrit{t
-
BLU/lf {I
-
23- 68
BLI(RED
-
Radiator tan molor
t
BLI(BLU
-
ABS controlunit
r 96'9 models
: 99 modol
: GRY (96-97 models
: GRN
(9&00 models
Rear window d8loloer swilch indicalo. lht
::: ) mirroa dloQor
r?
Hrgn,
Ma
miror i;logger sYritch)
Miror dolog06r $ tdr indicalor lighl'2
191 ) oo*e, ri,,o, "qraor',
hEn,
ivra
pow mircr sMdr
odional conna.ior
1lG2)
* 2
* 3
REAR WINDOW DEFOGGER RELAY
{Via
Gar wndow deloggot sw ch)
fro
page
23-71
)
N0.42 (40A)FUSE
(Frofir page 23.67)
WHTi BLK
t
lFusdrelay
bor socl(el)
WHT/BLK
I
V
fro
page 23'70)
I
pag6 23-
0o
.
BLOWER MOTOR FELAY
.
CONDETISER FAN RETAY
.
,VC COMPRESSOR
CLWCH RELAY
.
NAONTOR FAN RELAY
0o
pag 2368)
12)
Healr conlrol
Pan6l
,ryC her|lDshl
Mode conlrol molor
Reorolalion conlol molor
Aowr molor iEh aelay
YEUBLK
-
YEUGRN
-
:rl l^r A k/YF l -
B./"|YEL
-
Ctr|s conlrcl Jn (Via main swildr)
l-
C'uEe ma'4 swildr 'ndicalot lEhl
L
Audio unil (Ky oss
rece'ver
drol4)
BLKryEL
-
Kevless door tock conlroi unit
UNDER.DASH FUSE/RELAY BOX
N0.16 (7.5A)
(To page 23'70)
No.l2 (7.5A)
N0. 13 ( 15A)
N0.14 (7.54)
IGN TION SWITCH
BA1 ;.'
1
' . . _
ACC
q, (/vrr
- |.fi I
I ::: I mrcr mircr aqua|ol'r
F\ DAY'IME FUNNING LIGHIS
vELrtsLK -113>
CONTFOL UN|T (Ceneda)
t'- (f o
We
23-71)
,F1J- ,n*,"',
'96-97
mod6ls
""j
'98-99
models
GRN
-
GRN
_
Rear window washer molof
Rear window wiper molor
Turn srgnal/hazard relay
(Viaswilch)
PGM-Flmain relay
SRS unii (VA)
(cont' d)
23-69
Power Distribution
(cont'd)
IGN|T 0N SWTTCH (ACo)
lFrom
page 23-69)
*3 (or
PNn
-
Anernal0r
VSS
HO2S
EVAP conlrol canister vent shr,,l vafoe
EVAP
Flrge
conrol so enord valve
ECM/ PCM"
Back-!p lighls
SRS unri (VB)
i . 1 : ' 96, 98 modes
r.2 : 99 mode
*3 :GRY ('96-97 models)
:GRN (98'00 models)
sLrwHT+
Ft"t:itJY;i
BLI { WHT
- } r cut cwt . ,
BLKr'r{HT
-
Chargir! syslem trghl
InteEalei conLol unft
Shin lock soenod
I r!/r\
lnleiock mnlrol un I J
'- '
Galge assmbly
SRS indicalor lighl
ABS indicrtor lghl
A/Igear posilion ndlorl
d,mmino
qrcu,l
uru6e notcaoa )
-
Inlegraled conlrcl un t
Windshield wiper molor
GRN,B-<
........-
ImeEaleo cortolull
|
(viawndshieLd wi9el swllci)
-
wrrdsi erd washer .nolor
(Via swrn)
Accessory power sockel (ACC)
oplioial conneclor (Acc)
Audio unil
UNDEF.DASH FUSE/REtAY BOX
No 1s (7 sA)
POWERWINDOW RELAY
(To page 23-71
)
N0.25 (7.5A)
GBN/OF\
--
Moolroolopel relay
-
MOOlrOOldOSe relav
(Fusoirelay box sockel)
YEL-
(Fuse/relay box socll)
Y_
*,n,,*
23-70
l ' -
No 54140A) FUSE
(From page 23 68)
N0. 16 ( 7. 5A) FUSE
(Via sw lch)
(From paqe 23'69)
UNDER.DASH FUSE RELAY BOX
N0.46 {40A)FUSE
(From paqe 23'67)
v
I
WHTi BLU
(Fuse/reay bor sockel)
opliona conneclor (+8)
"*-l_
BLU ts-^
-
towet
wiroow masle's,r;.h
L
Power wtndow COn[Ol Jnil
(Via power window master swilch)
GRN/BLK
-
I
Fronl passnger's power
GRN/BLK
_J wtnoow moor
/Via
power window masler sv
I
and fronl passengerb power
sr window masler swilch
\
I
passengers power
I
ooo,
c402
-:: -.:::: I Lell
'eat
Powe'w ndow
-olot
'/v'a
power wiroow masle'sw ch
\
\and lefl lear
Power
window swilch ./
':_:_:
I Rohl rear oolver witow molol
'rv
a @wer wlfoow masler swrlcl l
\end
gh1re power wndow swilch /
GRN/BLK
-
BL|(BLU
-
Rearwindow delogger
"*-f,_
(3OA)FUSE
page 23 68)
v
I
WHT/GRN
No 50
(Frcm
v
I
BLU/YEL
oit
G402
(cont' d)
23-71
(7.s4) FUSE
page 23 70)
7
POWER
WINDOW
RELAY
Power Distribution
(conf
dl
IM/T)
rGNrTtoN swrTcH (sT)
(From pag 23{9)
Y
BLK ,VHT
t-
I
r**"'.fffr,u,r.*@**-_
l i l .
BLT(-^,I'/HT
-|:1jl-
BLT(RED
T
BLK ^/HT
-
$aner solndd G401
STAFTER
CUT RELAY CLUTCH SWITCH
BLIVREO
L-
rGNrTroN swtTcH (sT)
{From
paoe 23{9)
f'7
I
I
BLK/WHT
NEUTFAL POSITION
swtTcH
/ln
lL/Tgeat
\
\posnion
swldr/
BLT(RED
-BLK4rrHr
-
srarrer sotsnoid
(Fusfelay lox sockol)
lrflagGtd conlrol unit
ELU VHT
-
PGM-F| main retay
BLUMHT
_
ECI\T/PCM
lH#|1'#i,'f,5>-**
l e ock connol unit
(via intedocf switdr)
Key ints ocl solenoid
23-72
wHr
+ &3T:$111.9|'ij""'n'"
!t
USA:
UNDER,DASH FUSEi RELAY BOX
COMEINATON
LIGHT SWITCH
No.48 (304)
FUSE
/Frcm
page
\
\23{8 /
No.a8
G0A)
FUSE
/Frcm
page
\
\23-72 )
l o
I
'
to"'to
RED/BLU
_
BED/GRN
_
FEO/GRN
-
REDMHT
-
REo/{EL
-
Figltl h6adlighl (High beam)
High beam inditor light
Lefl headlighl (High beam)
Right headlighl (Low beam)
Letl headlighl (Low beam)
(Fuse/relay box socl(el)
(Fuss/relay box sockel)
FEo/BLK
t
RED/BLK
t
optioml @nn6clor
loash
hghls)
InEgraled control unil
Hazard waming sMch ligld
Gaugelighls
Audio unil
near wndow delog0er swild lighl
Cruiso main switdr lighl
ctuisndrcalot
.. ]crmminocircu,t
A/ | qsar posrrcn nor@Ior J
Dash lighls brighhess mnlroller
l'/T gea. pGilion console lighl
Heald conlrol
panel ligtn
::: I lronl oarkino liohl
Hqm,
n-'i6 J
*t"' t"itt'9t'6
n-,sh
j
inn"t u'll'gl't'
:: 1 | hcense Dlale liohts
Hgnr i
(cont' d)
23-73
Power Distribution
(cont'd)
Canada:
COMBINATION
LIGHT SWITCH
N0.48
{30A)
RED/BLU
-
Right headlighl (High boam)
FEDiBLU
----<
REstsTOR
REo/GRN
-
HiJh beam indicator lighl
BEo/GRN
-
Left headlighl
iH,gh
beam)
L<REsrsroR
Fight headlight
{Low
beam)
FEo/YEL
-
Lll headlight (Low beam)
(Fuse/lelay box sockel)
Optional conneclor (oash lighs)
Inleg6led conlrcl unil
-
Hazard wanirE swilch lighl
i-
Gauge lEhts
l-
Audio unil
l-
Re& Yrindow delogg8r swili
t-
Ctuise main swrdr ligh
l-
C/uise indEator l
E
g"ffiry:'l,:1':::1
Refi window delog$r swildr light
Ctuise indicalor
1
dimming
,T
geal posilion
indicator J
circu(
Dasn lghls brignmess co oller
BRAKE
SYSTEM
LIGHT
V
I
l-
GFf
,,4,,0*,
l f t I F L U D
I I , j I LEVEL
Y
SWTCH
I
8LK
I
I
I
I
:
G401
G402
REo/BLK
-
l/T ged position console lqhl
-
Hqalor codrot
panel tighl
REO/BLK
-F-
Lefi ) .
l- g;n1J
lron
9arrn!
qm
FEDiBLK + Letl I
F
Rqn J
ouer larrqns
- I Al, I
{-
i'-;*;
inne' raittiotts
E
fifi]t'"nt"o't't'sn"
*ro,rru
-$
RcHT HEADLIGHT (Hrgh beam)
BEDiGRN
-+
LEFI H EADLIGHT (High beam)
I BLK
I
I
PARKING
I
EFAKE I
swrrcH
I
I
:
G401
G402
UNDER,DASH FUSE/RELAY 8OX
l o
|
| PASSTNG
t o
/Fforn
page\
\a-68 l
N0.48
{304)
FUSE
/From
page\
\23-72 )
N0.18 (7.54)
FUSE
/From
page
\
\?3-69 J
v
Y
I
YEUBLK
N0.48 (40A)
FUSE
/From
paqe
\
\23-68
-
,/
RED6RN
23-74
Ground Distribution
(To
I 8an6ry ground cable
: Engine ground caue A
Primary HO2S (M/I)
I
EGR valve (,tffT)
| {Ot6y5
engtne)
EGB conrol
I
sllenoid va ve (vT) l
wEc
flessure
switdr (Bl6A2engine)
vss
PSP swtch
Baaery
BLK
-*
bqiu"trl'ff
lso",ilE
o;l?f
;".,
L
ur,u" "ou.,,r,oo, "*'n",
Trlnsmission ho!gng
BLK
BLK
BLK
BRN/BLK
I
I
V
p?oe 23-76, 77)
'96-98
models
'99-00
models 816A2, D16Y7 engines
99-00 modors D16Y5, D16Y8 engines
s,-(
-i -t;l BL(-
pcM
Frman reray
'
E
)
tc"
't*'
tn''n''*t'''
wEC pressurc sMch
(016Y5, D16Y8 engines : 98-00 models)
@
E
E
fal
i Engine grcund cable B
:
Engrne wire hamess
(cont' d)
23-75
El
,
M"in ttire hatn"."
Ground Distribution
(conf
dl
'9&98
models:
(t[oileas6)>{ BRN/BLK
LGl
I
I EcM/PcM
lcz J
[..........{
BFNaLK
CKF sensor j
L
.-!l
8LU/FED
Knoct srlsor (KS)r'
::{
REDtsLU
Pi maryH02S*?- wHT
Matnsnafi
g]eo
sdnsoa
-'1
t I HEL)
Counlersiall speed sensor
--={Fl
BIU
Ecr#PcM
----Tal
WHT/BED
Dive
trjiley
speed seftsor
-1ll
FED,ALU
0 ven pulley speed sensor
.-lJ
WHT
Seconftry gear shalt speed sansor
.-!.1
WHT/RED
44:lil
ECIVPCM
) * "
Dl6YBengine
Dl6Y5, D16Y7 sngine
vtl
8BM/BLK
-
I
BBi1/BLK
_
I
^l^1ll'. I rcu rcwr
**'
-i
I
WHT/RED + ]
El
,
Engln" *lr" h"rn"""
- - - - - -
:
Shietorns
E
:
Main *re harness
23-76
* 1 : D16Y5, 016Y8 engi no
* 2 : Excepl Dl 6Y5 engine (i//T)
+3: D16Y5 engine (Mfi)
rt
'99-00
models:
(5i%ease)E>4 BRNiBLK
i.,.,].',,-
ERNi BtK
BRIVBLK
BFN/BLK
BRN/BLK
BRN]BLK
BRIl/8LK
BFN/BLK
r * s
r;l
ao^r,qt r
CKF snsor
1
t
-1ll
ELU/FEU
Knoq( sonsor (r15J
'-l
!l
r{EUl6LU
P maryHo2s*?H wHT
Mainshafl speeo ssnsor
-1ll
fiEU
Coutershall sped sensor
-+F
] BLU
)
..",r.u,.0n
016Y7, Dl6Y5 (CW) ongines
;;=-"r,i,-l
Ly"::::::::
I
Secondary Ho2s
:{
WHT/RED-
;'4:v-..1
RED/BLU
-
I
wHT
-
f rau,rru
(an
)
pgTpse-
J
*1i 016Y5, Dl 6Y8engi nes
*4: 016Y7, Bl 6AzerEi nes
l cont ' d)
*2: Excepl DI6YSengino ([VT) *5: D16Y5, D16Y7, D16Y8Bngines
* 3: Dl 6Y5 sngi ne ([ VT) *6: B16M, D16Y8, 016Y5 (CW)engi nes
015Y5 (LVT) sngine
41-.1
Dfiv6 prirEy speeo sonsot
-1l
l
hEL,bLU
Driven gr ley sped sensor
--
F I WHT
Secondary
gea sian sped sensor
.-ll
WHT/RED
E
: Engine w re harness
E
: Rear hal6d orygen sensor sLlb harness
IIJ
: Main wire harnsss
------
shielding
816A2, Dl6Ygengiftes
23-77
Ground Distribution
(cont'dl
E
Enqine compenme wrre harness
-
Erghr headlighr
; , . -
Fr gr : r cl l pa' hr r 3 r gr r
-
Srgn lronl rufnsqfal qhi
"'-fflri#*l:;:r.,,
Wrdshield washer molor
Rear window washer molor
Cruise confol actualor
lvasher level sw ch (Canada)
23-78
t
'96-98
models:
BLK
-..1
|-|d
BLIJ/REo
-
Horn
8LK
J
G402
/
To page
\ 23,81
6L^
--...........-- Munn'un' 5.nLi
?_
Moofrootooen retay
L
MOOnTOOI dose relay
B-(- Dash hghls bfrqrlless co
'oel
l-
ftyess door to* mnlror Lnil
-llerX + Seorriry @rl'ol Jn :
JUndon
connedor
BLK
BLK
BLK
Cnrise main swilch lighl
Cruise indicalor dirnming orcuil
Red window deloggel swilch lighl
A/T gear posilion indicalor dimming cilo./il
Accessory power sockel
SRS indicalor lighl circlil
Cauges end indicatols
ABS indicalor lighl cirq)rl
Gauge lights
El
:
Engine companmenl wire harness
E
,
M"in *it" h"n"..
E
:
oashboatd w haness
@
: Moonrool w re harness
UNOEB,DASH
FUSE/RELAY BOX
EL^
-
YY' i i snEo ' F " ' v' u'
-
Bfale llJ d levetswlci
q q . - _
E I
Dah Inl col"eclot 'D-cl
Windshield w perhvasher swildr
--l
,o ,? '.da.
Rear window wipr^vasher swtch
' ' ' " _ - - -
, r A / T l
l _
p a a
p i r s wi l c F t - ,
l-
Clulcf nlel ock sw lcr rVT)
Cruise conlrol unil
8LK
-
Da,'lm runnrng lrghts conltol unil (CanaJa)
(Fuserelay box sockel)
(Flserelay bor sockel)
(Fuse/relay box socke0
(Fuse/relay box sockel)
BL K-
(M/T wilh cruise conlfol or lor D16Y5 erEine)
Bear window delogger relay
Lnlegrated conlrol unil
Turn signal/hazad @lay
(cont' d)
23-79
oot
Ground Distribution
(conf
d)
'99-00
models:
E
Wir'rdshield wipe. nolor
BGke lluid level swildl
6L^
--
nrnon
y sv lo
a- )
l-
i
oala hnk connclol
lDlcl
8LK
BLK
Windshigld dper^vashr switdt
Re windo wiperlflasher ssitch
BLK
J
To 9aqe
23.A2-
tr
E
UNOEN.DASH
FUSgRELAYSOX
- r ^ - . . - -
t menoo( @ r ot unn
l . _.
l - pa*
oi n swhr h l \ 4t l
ClLrldr inlerlod swildr (M,T)
Cruis confol unit
BL( ----
Oay me running tights controtund (Canadal
_
Ctuldt sfich
(l,t/T vrith ruis cor rol)
Key'ess door lock control unit
(Fuserelay box sockst)
(Fus/relay box sod(8t)
(Fusdrelay bor sockel)
(Fuserelay box sockl)
8LK
BLK
BLK
BLK
8LK
near windoYr delogger rclay
htograted co.Ird unil
Tum signal/hazard lelay
SRS indicalor lighl cirqtil
,y'T goer position
indicator dimming cirdlit
Accessory poxer
sod@l
Gaugs and indicators
ABS indicalor light ciro.lil
Gauge lighb
Cruis main swil$ lEhl
Cruiso indicator dimming cirorit
oash lohls brighlness confolbt
Hazard s$tdl indicator liohl
G401
(
oh
---
Moonroot swnm
t-
iroonrool open relay
-
Moonroot dose reiay
t
fil BLK
-J
: Engine @mparlrnenl wire hamess
: Main wire haness
,JUncll0n
@nfreclol
E
:
El
,
Mo*tool *ite har"..
23-80
'96-98
models:
(wirh ABs)
oit
8LK
-
A/Tjear
Posilion
swilch
seNic check @nneclor
ABS
Flmp
motor
Audio unil
G552
@ :
fi-']
BLK
-
Powet doot lock @nlrolunil
i-
D vet s doot lock aclualor
l-
P
yg15
666110c1 swlgh
B"
t ]
po*er
sindow man sw ch
E'0,'""a.
*.,
*noo, ro,o,
Fuelunil
BLK-liJ#1!ll3n"**
E
Healer sub'harness A
E
: Healer sub harness B
(cont' d)
23-A1
-r-r:=' r
,!r'-,
t / l
O
- 1: r ' -
Dashboard wrre haness
U
: Floor wire harness
E
Drrve/s doorwire hamess
Ground Distribution
(cont'dl
'99-00
models:
(Wilholl ABS)
r'1
BL(
-<
6
| c40. tFror oaoe 23-BC.
I
I
L
E
UNDEF.H@D
FUSF]RELAY BOX
_::I
A,/I gefi posilion
swilch
ELD unil
Servi@ check connector
BL-_14BL-
rl--{ry--Browe,mororreray
L4
,r^
-.;--a-r,* -11-51
BLK
-
Hearer conrror o6n
t
n"*-fi-+aLx-lfuBLK- Hearer conrror panel
eLx
-iff
BLK
-
ff;?,m",:[:'
"n'
or*
ABS glmp motor
_tr
l
G501
Posr door lock cortaol unit
Divers door lock aclualor
Driver's door lock switch
Lefl miror delogger
BLK
--.+t
_
F
J
Power wndos man swdch
-.
Dive/s
Fo*gr
window motor
T
BLK
-.1
F--{
BLK
-
Fighr.niror detogger
tr
tr
E
: Healer sub-haness A
El
: Healer sub'harress B
: Floor wire hamess
:
Drve/sdoorwife haness
-
| , - " * T- " ^
t l I
v l
- L" . "
G551
ort,
El
'
Main *it" hanes
E
:
Dashboafd wirc harness
23-82
@
Passenger's doof w're hamess
G601
High molnl brake lighl
Rar window wper molor
Bigh mounl brake lighl
Rear window wiper molor
TrLrnk laldl swilch
ouo,
l"fn, )
o*"' ''*'nnt"
l",$')
'nnt' '"t'n"'
lt$|n')
''"nt"o'"'t,'nn"
Tronk lalci switch
High mounl brake lighl
(coupe/sedan : 96-98 models)
G601
li|n')
o*".'tt'nn''
l[., ]
'nn"' 't*'n*"
.,"'jn,
)
"""n"
o'"t"
''nnt"
Trunk laldr swlcll
(cont' d)
BLK
*'lli.,ilJ:"f_'$l
{Sedan : 99 00 models)
E
: Fearwrehaness
E
, H"t"h nit" h"tnes"
23-83
Ground Distribution
{conf d}
F, ' o . "
I
_a_
E]
,
,,vc *ite natness
0
: Rear window deloggs ground wile
E]
,
sns t"in h.rn*
-A-
Gi51
Condensr lan oDlor
Re wrndow d,ogger (Ftald|bac*)
t GFY :
'9&97
ftod.ts
GRN |
98-00 models
23-84
Under-dash
Fuse/Rel aY
Box
SRS component s ar e l ocat ed i n t hi s ar ea. Revi ew l he
precauti ons, and
procedures
(24)
before
vi ce.
Removal :
1. Make sure you have the anti -l heft code for the radi o
then wri te down the frequenci es l or the radi o' s
pre-
set buttons
(' 99
-
00 model sl .
2. Di sconnect the battery negati ve cabl e. then di scon
nect the
posi ti ve cabl e, and wai t at l east three mi n
utes,
3. Di sconnect the ai rbag connectors
(see secti on 24)'
4. Remove t he dr i ver ' s dashboar d
l ower cover and
knee bol ster
(see secti on 20)
5. Remove the two mounti ng nuts, and
pul l the under
dash fuse/rel ay box out from under the dash'
6. Di sconnect t he connect or s f r om t he under - dash
fuse/rel ay box, and take out the under-dash fuse/
rel ay box
(see
secti on 24).
l nstal l ati on:
1. Connect t he connect or s t o t he under - dash t use/
rel ay box, then i nstal l the under dash fuse/rel ay box
i n the reverse order of removal
(see
secti on 24)'
2. Instal l the dri ver' s dashboard l ower cover
(see
sec
t i on 20) .
3. Connect the ai rbag connectors {see
secti on 24)
4. Connect the battery
posi ti ve cabl e, then connect the
negati ve cabl e.
5. Enter the anti -theft code l or the radi o, then enter the
customer' s radi o stati on
presets
(' 99
-
00 model s)'
6. Confi rm that al l sYstems work
properl y'
23-45
Power Relays
Relay Test
Turn Si gnal /Hazard Rel ay:
See page 23-172
Normally-open type:
1. Check for conti nui ty between the termi nal s.
. There shoul d be conti nuj ty between the No. 1 and
No.3 termi nal s when power
and ground
are con-
nected to the No. 2 and No. 4 termi nal s.
. There shoul d be no conti nui ty between the No. 1
and No. 3 termi nal s when power i s di sconnected.
3
. Bl ower mot or rel ay
. ABS pump motor rel ay
\
Ter mi nal
-i *rt "r-*or\
1
3
Di sconnected
Connect ed
o
, I I
I Y F>
rr
, ? I
23-86
. Rear wi ndow defogger rel ay
Starter cut rel ayt
' 96
-
97 model s
Horn rel ayi
' 96
97 model s
Bl ower motor hi gh rel ay:
' 99
-
0O mooers
a
Normally-opsn tYPe:
1. Check for conti nui ty between the termi nal s
. There shoul d be conti nui ty between the No. 1 and
No. 2 termi nal s when
power and
ground are con-
nected to the No. 3 and No 4termi nal s.
o There shoul d be no conti nui ty between the No 1
and No.2 termi nal s when
power i s di sconnected'
\
Termi nal
Power i No.3
-
No,4) \
I
2
Disconnected
Connected o
o
a
a
a
Power wi ndow rel aY
Radi at or f an rel aY
Condenser
f an rel aY
A/ C compressor
cl ut ch rel aY
St art er cut rel ay:
' 98
-
00 model s
Horn rel ay:
' 98
-
00 model s
Five-ierminal type:
1. Check for conti nui tv between the termi nal s.
. There should be continuity betlveen the No. 1 and
power and ground are con-
nected to the No. 3 and No 5termi nal s.
. There shoul d be conti nui ty between the No 2 and
power i s di sconnected'
--1
I
I I
t
Moonroof open rel ay:
' 96
-
97 model s
Moonroof cl ose rel ay:
' 96
-
97 model s
(cont' d)
23-87
\
Termi nal
Power
(No.
3
-
No. 5)\
4
Di sconnected
o-
- o
Connected
o-
- o
Power Relays
Relay Test
(cont'd)
Five-terminsl type:
l . Check for conti nui ty between the termi nal s.
. There shoul d be conti nui ty between the No. 1
and No, 2 termi nal s when power
and ground
are
connected to the No. 5 and No. 3 termi nal s.
o There shoul d be conti nui ty between the No. 1
and No. 4 termi nal s when power
i s di sconnected.
. Moonroof open rel ay:
' 98-00model s
. Moonroof cl ose rel ay:
' 98
-
00 mooets
\
Termi nal
P" * " r { l t l " 5- N" . 3) - \
1 4
Disco n n ected o-
---o
Connected o-
----o
23-88
lgnition Switch
4.
Test
SRS components are l ocated i n thi s area Revi ew the
SRS component l ocati ons. precauti ons. and procedures
i n the SRS secti on {24} before
1. i / ake sur e you have t he ant i - t hef t code f or t he
r adi o, t hen wr i t e down t he f r equenci es f or t he
radi o' s
preset buttons
(' 99 -
00 model s).
2. Di sconnect the battery negati ve cabl e.
3. Remove the dri ver' s dashboard l ower cover and
knee bol ster
(see
secti on 20).
Di sconnect the 5P connector from the under dash
fuse/rel ay box and the 7P connector from the mai n
wi re harness.
Check for conti nui ty between the termi nal s i n each
swi tch
posi ti on accordi ng to the tabl e.
I I : 7P connect or
BLK/WHT {STI
WHT IBAT}
7P CONNECTOR
WHT/BLK
YEL
(I G2} BLK/ YEL {I G1)
Wi re si de of femal e termi nal s
6. l f the conti nui ty checks do not agree wi th the tabl e,
repl ace the el ectri cal swi tch.
\
Termi nal
Posi ti on
1
(ACC)
( 3)
(BAT)
5
{ t G1) G2)
( 1 )
(sr)
o
(LocK)
|
(ACC) o-
- o
l
( oN) o-
o
III
(START) o-
-o
1.
Electrical Switch RePlacement
SRS components are l ocated i n thi s area. Revi ew the
precauti ons, and procedures
i n the SRS secti on \24) bel ore performi ng repai rs or ser-
vtce.
1. Make sur e
you have t he ant i - t hef t code f or t he
radi o' s
preset buttons {' 99
-
00 model sl .
2. Di sconnect the battery negatl ve cabl e.
3. Remove t he dr i ver ' s dashboar d l ower cover { see
secti on 20).
Di sconnect the 5P connector from the under-dash
wi re harness
(see
l eft col umn).
Remove the steeri ng col umn covers {see secti on
11t.
l nsert the i gni ti on key, and turn i t to
"0
{LOCK)".
Remove the two screws and the el ectri cal swi tch
from the steeri ng l ock.
ELECTRICAL
swtTcH
8. Instal l i n the reverse order of removal .
23-a9
lgnition Switch
Steering Lock Replacement
SRS component l ocati ons. precauti ons,
and procedures
(24)
before performi ng
repai rs or ser-
vtce.
Remove:
L Make sur e you have t he ant i - t hef t code f or t he
r adi o, t hen wi r e down t he f r equenci es f or t he
radi o' s preset
buttons
(' 99 -
00 model s).
Di sconnect the battery negati ve cabl e.
Remove t he dr i ver ' s dashboar d l ower cover and
knee bol ster
(see
secti on 20).
Di sconnect the 5P connector from the under-dash
wi re harness
(see previ ous page).
Remove the steeri ng col umn covers, then remove
the mounti ng bol ts and nuts from the steeri ng col -
umn
(see
secti on l 7).
Lower the steeri ng col umn assembl y,
Center-punch each of the two shear bol ts, then dri l l
thei r heads off wi th a 5 mm
(3/16
i n) dri tt bi t.
CAUTION: Do not damago the steering lock body.
Remove the shear bol ts and the steeri ng l ock assem,
oty.
2.
1.
23-90
Installation:
l . Instal l the new steeri ng l ock assembl y wi thout the
key i nsened.
Loosel y ti ghten the new shear bol ts-
Insert the i gni ti on key, and check for proper
opera-
ti on of the steeri ng wheel l ock and that the i gni ti on
key turns freel y.
Ti ghten the shear bol ts unti l the hex heads twi st off.
TWIST.OFF FORTION
Instal l i n the reverse order of removar.
Enter the anti -theft code for the radi o, then enter the
customer's radio station presets.
sr{aR SroLT
Battery
Test
@l
. Battery lluid lelectrolytel
contalns sulfuric acid. lt may cause severe burns it it gets on your skin ol in your eyes Wear
protective clothing and a face shield.
-
It eleqtlolyte
gets on
your skin or clothes, rinse it off with watel immediately
-
lf electrolyte
gets in your eyes, flush it out by splashing water in your eyes for at least 15 minutes; call a
physician
i mmedi atel y.
. A battery
gives off hydrogen
gas. lf ignited, the hydrogen will explode and could crack the battery case and splatter
acid on
you. Keep sparks, flames, and Gigarettes away from the battery'
o Overchaiging will raise the temperature oI the electrolyte. This may force electrolyte to spray out ot ths battery vents'
Follow the charger manufacturel's instrustions, and chalge the battery at a propcr rate.
Use ei ther a JCI or Bear ARBST tester. and fol l ow the manufacturer' s
procedures. l f you don' t have one of these comput-
eri zed testers, fol l ow thi s conventi onal
test procedure:
Toqet accur at er esuI t s, t het emper at ur eof t heeI ect r o| yt emust bebet weenT0" F( 21. c) and100" F( 38. c} '
l f the case i s cracked or the posts are l oose, repl ace
the battery.
l f rhe i ndi cator shows l ow el ectrol yte, add di sti l l ed
water i f
Possi bl e.
EYE l ndi cates OK
Test Load CaPaci tY
(#l
)
.
Appl y 300 amp l oad f or 15 seconds
t o r emove
surface charge.
.
Al l ow 15 seconds recovery
Perl oo.
.
Appl y test l oad {see
Test Load Chan).
.
Record vol tage at the end of l 5 seconds.
Drops bel ow 9.6 vol ts.
Stays above 9.6 vol ts;
battery is OK.
(cont' d)
23-91
Battery
Test
(cont'd)
Charge on Hi gh Sefti ng
(40
amps)
Charge unti l EYE shows charge i s OK; pl us
an
addi ti onal 30 mi nutes to assure ful l charge.
NOTE: lf the battery charge is very tow, it may
be necessary to bypass the charger,s pol ari ty
protection
circuitry.
l f the EYE does not show charge i s OK wi thi n
three hours, the battery i s no-good; repl ace i t.
Wr i t e down how l ong t he bat t er y was
charged.
Test Load Capacity
(#2)
Appl y 300 amp l oad for 15 seconds to remove surface charoe.
Al l ow 15 seconds recovery peri od.
Appl y test l oad {see Test Load Chan).
Record vol tage at the end of 15 seconos.
Stays above 9.6 volts; battery is OK.
, ]
Drops below 9.6 volts; baftery is no-good.
tu,
TEST LOAD CHART
Use the test l oad or 1/2 the col d cranki ng amps {CCA)
pri nted
on the
l abel on the top of the banery. l f nei ther i s i ndi cated. use the
i nformati on bel ow:
BArrERy
coLb@
coDE
I
AMps
(ccAl
|
{amps)
405 ( * 410)
200
* : 558241
( S) -
MF
23-92
Starting System
Component
Location Index
A/T GEAR POSITION SW|TCH
Test , page 23' 154
Repl acement ,
page 23-155
STARTER CUT RELAY
(M/T}
Test,
page 23-86, 87
o
o
ool
CLUTCH INTERLOCK
swlTcH
BATTERY
Test, page 23-91
STARTER
Test,
page 23'95
Sol enoi d Test ,
Page
23 96
Repl acement , Page
23-100
Performance Test,
Page
23-101
23-93
Starting System
Component Locati on l ndex
GNI T ON
SW TCH
t , U , - * , - l
&T GEAR
POSITION SWITCH
( Cosed n posi l i on
N or
E)
ELKMHT
I
t l
81X,4{HT BLKIWHT
STARTER
CUT FELAY
STAPTER
(Permaneit nragnel type)
N0 4l (80A) N0 42 (40A)
UNDEF. HOOO FUSEi FELAY BOX
-
__l
23-94
-
Starter Test
NOTE; The ai r temoerature must be between 59 and
100' F
(15
and 38"C) before testi ng.
Recommended Procedure:
. Use a staner system tester.
. Connect and oper at e t he equi pment i n accor dance
wi th the manufacturer' s i nstructi ons.
. Test and troubl eshoot as descri bed,
Alternate Procedurg:
. Use the fol l owi ng equi pment:
-
Ammeter, 0
-
400 A
-
Vol tmeter, 0
-
20 V
(accurate
wi thi n 0.1 vol t)
-
Tachometer, 0
-
1,200 rpm
. Hook up a vol tmeter and ammeter as shown.
NEGATIVE
TERMINAL
NOTE: After thi s test, or any subsequent repai r. reset
the ECM/PCM to cl ear any codes
(see
secti on l 1)
Check the Startr Engagemont:
1. Remove the No. 44
(15
A) fuse from the under-hood
fuse/relay box,
2. Turn the ignition switch to START
(llll
with the shift
lever in E
or
E
position (rVT)
or with the clutch pedal
depressed {M/T). The starter should crank the engine.
. l f the starter does not crank the engi ne, go to
step 3.
. l f i t cr ankst he engi neer r at i cal l yor t oosl owl y,
go
to
"Check
for Wear and Damage" on the next
page.
Check the battery. battery
posi ti ve cabl e, ground,
starter cut rel ay, and the wi re connecti ons for l oose-
ness and corrosi on, Test agai n.
l f the starter sti l l does not crank the engi ne, go to
step 4,
Unpl ug the connector
(BLK,/WHT
wi re and sol enoi d
termi nal ) from the starter,
Connect a
j umper
wi re from the battery posi ti ve
(+)
termi nal to the sol enoi d termi nal .
The starter shoul d crank the engi ne.
. l f t he st ar t er st i l l does not cr ank t he engi ne,
remove i t, and di agnose i ts i nternal
probl em
. l f the startercranksthe engi ne,
goto step 6.
Check the i gni ti on swi tch
(see page 23-891.
Check the starter cut relay and clutch interlock switch
(see page 23-86,87).
Check the A/f gear position switch
(see page 23-154).
Check for an open i n the wi re between the i gni ti on
switch and starter.
7.
(cont' d)
23- 95
9.
Starting System
Starter Test
lcont'dl
Chck tor Wear and Damage
The st ar t er shoul d cr ank t he engi ne smoot hl y and
steadi l y, l f the starter engages. but cranks the engi ne
errati cal l y, remove i t, and i nspect the starter dri ve gear
and torque converter or fl ywheel ri ng gear for damage.
. Check the dri ve gear overrunni ng cl utch for bi ndi ng
or sl i ppi ng when t he ar mat ur e i s r ot at ed wi t h t he
dri ve gear hel d,
-
l f damaged. repl ace the gears.
Check Cranking Voltsge and Currnt Draw
Cranki ng vol tage shoul d be no l ess than 8.5 vol ts.
Current draw shoul d be no more than 350 amperes.
l f cranki ng vol tage i s too l ow, or current draw too hi gh,
check for;
. dead or low batterv.
. open ci r cui t i n st ar t er ar mat ur e commut at or seg-
ments,
. starter armature draggi ng.
. shorted armature wi ndi ng.
o excessi ve drag i n engi ne.
Check Cranking rpm
Engi ne speed duri ng cranki ng shoul d be above 100 rpm,
l f speed i s too l ow, check for:
. l oose battery or stanertermi nal s.
. excessi vel y worn starter brushes,
. open ci rcui t i n commutator segments.
o di rty or damaged hel i cal spl i ne or dri ve
gear.
. defecti ve dri ve
gear
overrunni ng cl utch.
Check Siarter Disengagment
Wi th the shi ft l ever i n
El
or
@
posi ti on (A/T)
or wi th the
cl utch pedal depressed
(M/T),
turn the i gni ti on swi tch to
START
(l l l ),
and rel ease to ON
(l l ).
The starter dri ve
gear
shoul d di sengage from the torque
converter or fl ywheel ri ng gear when you rel ease the
Key.
l f the dri ve gear hangs up on the torque converter or fl y-
wheel ri ng gear, check for:
. sol enoi d
pl unger and swi tch mal functi on,
. di rty dri ve
gear assembl y or damaged overrunni ng
cl utch.
Starter Solenoid Test
1. Check the hol d-i n coi l for conti nui tv between the S
t er mi nal and t he ar mat ur e housi ng
( gr ound) .
The
coi l i s OK i f there i s conti nui tv,
ARMATURE
HOUSI NG
(GROUND)
S TERMI NAL
M TERMINAL
B TERMI NAL
STARTER
CAELE B TERMINAL
MOUNTING NUT
I N.m {0.9 kgf.m,
7 tbf.ft)
Check t he
pul l -i n coi l f or cont i nui t y bet ween t he S
and M t ermi nal s. The coi l i s OK i f t here i s cont i nui t y.
J
Armature Inspection and Test
1 . Inspect the armature for wear or damage due to con-
tact wi th the permanent magnet or fi el d wi ndi ng.
. l f there i s wear or damage. repl ace the armature.
I nspect f or damage.
2. Check commutator surface and di ameter.
. lf the surface is dirty or burnt. resurface with emery
cl oth or a l athe wi thi n the fol l owi ng speci fi cati ons,
or recondition with #500 or #600 sandpaper.
. l f commutator di ameter i s bel ow the servi ce l i mi t,
repl ace the armature.
Commutator Diameter
Standard {NEW)
Servi ce Li mi t
28. 0
-
28. 1 mm
( 1. 102 -
1. 106 i n)
27. 5 mm
( 1. 083
i n)
VERNI ER CALI PEB
3. Measure the commutator runout.
. l f t he commut at or r unout i s wi t hi n t he ser vi ce
l i mi t, check the commutator for carbon dust or
brass chi ps betl veen the segments.
. l f the commutator runout i s not wi thi n the ser-
vi ce l i mi t, repl ace the armature.
Commutator Runout
Standard
(NEW) Servi ce Li mi t
0
-
0. 02 mm
(0 -
0.0008 i n)
u-u! r mm
(0. 002
i n)
COMMUTATOR
(cont' d)
23-97
Starting System
Armature Inspection and Test
(cont'dl
4. Check tor mi ca depth. l f necessary, undercut mi ca
with a hacksaw blade to achieve proper depth. l{ ser-
vi ce l i mi t cannot be mai ntai ned, repl ace the armature.
MICA DPTH
Commutator Mica Dpth
5. Check for conti nui ty between the segments of the
commutator. l f an open ci rcui t exi sts between any
segments, repl ace the armature.
NOT GOOD
Standard
(NEW)
Servi ce Li mi t
0. 4
-
0. 5 mm
( 0. 016 -
0. 02 i n)
0. 15 mm
(0.006
i n)
23-98
corL coFE COMMUTATOR
6. Pl ace the armature on an armature tester. Hol d a
hacksaw bl ade on the armature core.
ARMATURE TESTER
. l f the bl ade i s attracted to the core or vi brates
whi l e the core i s turned, the armature i s shorted.
Repl ace the armature.
7. Check wi th an ohmmeter that no conti nui ty exi sts
between the commutator and armature coi l core,
and between the commutator and armature shaft. l f
there i s conti nui ty, repl ace the armature.
ARMATURE
J
Brush Holder Test
1. Check that there i s no conti nui ty between the O and
o brush hol ders.
l f t her e i s cont i nui t y, r epl ace t he br ush hol der
assemol y.
O BRUSH HOLDER
@
BRUSH HOLDER
)
BRUSH HOLDER
2. Insert the brush i nto the brush hol der, and b.i ng the
brush i nto contact wi th the commutator, then attach
a spri ng scal e to the spri ng. Measure the spri ng ten-
si on at the moment the spri ng l i fts off the brush.
SPRI NG SCALE
Spri ng Tensi on
15.7
-
17.7 N
(1.60
-
1.80 kgf. 3.5
-
4.0 l bf)
ERUSH
Brush Inspection
Measure the brush l ength. l f not wi thi n the servi ce l i mi t,
repl ace the brush
(or
brush hol der assembl y).
Brush Length
NOTE: To seat new brushes after i nstal l i ng them i n thei r
hol ders, sl i p a stri p ot #500 or #600 sandpaper. wi th the
gri t si de up, over the commutator and smoothl y rotate
the armature. The contact surface of the brushes wi l l be
sanded to the same contour as the commutator.
Overrunning Clutch lnspection
Sl i de the overrunni ng cl utch al ong the shaft. Does i t
move freel y? l f not, repl ace i t.
Rotate the overrunni ng cl utch both ways. Does i t
l oc k i n one di r ec t i on and r ot at e s moot hl y i n
reverse? l f i t does not l ock i n ei ther di recti on or i t
l ocks i n both di recti ons, repl ace i t.
2.
L
Standard
(NEW) Servi ce Li mi t
15. 8
-
16. 2 mm
(0.62 -
0.64 i n)
1 1. 0 mm
{ 0. 43 i n)
CLUTCH GEAR
DRIVE GEAR
Starting System
Starter Replacement
1 . Make sur e you have t he ant i - t hef t code f or t he
radi o' s preset buttons
(' 99 -
00 model s).
Di sconnect the battery negati ve cabl e.
Di sconnect the starter cabl e from the B termi nal on
t he sol enoi d, t hen di sconnect t he BLK t r HT wi r e
from the S termi nal .
MOUNTING BOLT
44 N.m l/t.s kgf.m. 32 lbf.ft)
S TERMINAL
MOUNTING BOLT
6, 1 N. m {4. 5 kst m. 32l bt f t l
MOUNTING NUT
9 N,m {0.9 kgl.m,
6.s lbtftl
B TERMINAL
4. Remove t he t wo bol t s hol di ng t he st ar t er , t hen
remove the starter.
l nstal l i n the reverse order of removal .
NOTE: When i nstal l i ng the staner cabl e, make sure
that the cri mped si de ofthe ri ng termi nal i s faci ng out.
TERMINAL
Connect the battery positive cable and negative cable
to the battery.
customer' s radi o stati on presets (' 99 -
00 model s).
7.
Cr i mped si de of r i ng
23-100
Starter Reassembly
' 1.
Pry back each brush spri ng wi th a screwdri ver, then
posi ti on the brush about hal fway out of i ts hol der.
and rel ease the spri ng to hol d i t there.
Instal l the armature i n the housi ng. Next, pry back
each brush spri ng agai n, and push the brush down
unti l i t seats agai nst the commutator, then rel ease
the spri ng agai nst the end of the brush.
aw
3. Instal l the end cover on the brush hol der.
ERUSH HOLDER
-
Performance Test
NOTE: Before stani ng the fol l owi ng checks. di sconnect
t he wi r e f r om t er mi nal M. and make a connect i on as
described below using as heavy a wire as possible
(prefer-
abl y equi val ent to the wi re used for the car).
Pul l -i n Coi l Test:
Connect the battery as shown, l f the staner pi ni on pops
out. i t i s worki ng proPerl y.
CAUTION: Do not leavo tho batterv connostd for more
than 10 seconds.
Hold-in Coil Test:
Di sconnect the battery from the M termi nal ' l f the pi ni on
does not retract, the hol d-i n coi l i s worki ng
properl y.
CAUTION: Do not loavc lhe battsry connected for mot6
than 10 ssconds.
Retracting Tosi:
Di sconnect the battery al so from the body. l f the pi ni on
retracts i mmedi atel y, i t i s worki ng properl y.
GAUTION: Do not loave the baftery connctod tor more
than 10 seconds.
Startor No-load Tost:
Cl amp the starter fi rml y i n a vi se.
Connect the starter to the battery as descri bed i n
t he di agr am bel ow, and conf i r m t hat t he mot or
starts and keeps rotating.
1 .
3, l f the el ectri c current and motor speed
speci fi cati ons when the battery vol tage i s
the starter i s worki ng
ProPerl y.
Specifications:
80 A or l ess
( El ect r i c
cur r ent ) , 2, 600 r pm or mor e
(Motor-speed)
meet the
at 11. 5 V,
23-101
lgnition System
IGNITION TIMING CONTROL SYSTEM
. Troubl eshooti ng, secti on 11
. l dl e speed Inspecti on/Adj ustment. secti on 11
. Inspecti on and Setti ng, page 23-105
SERVICE CHECK CONNECTOR {2P}
Iwiie colors: 8RN and BLKI
TEST TACI{OMETER CONNECTOB
IGNITION WIRES
l nspect i on and Test , page 23-110
PLUGS
I nspect i on, page 23 1 11
Over haul , page 23- 107
l gni t i on Coi l Test , page 23' 110
l gni t i on Cont r ol Modul e l l CM)
I nput Test , page 23- 109
23-102
l gni ti on
System
-
Ci rcui t Di agram:
' 96
-
97 model s
.i-
8LU
I
n
BLU BLU
I
t l
l n
I
TEST
I
TACHOMETEF
\-7 CONNECTOR
TACHOMETER
TCM
(CW)
J-)
{sh, el di nsr
' t
I
tf
YEL BBN/ BLK
+ l
I
:
G101
$t +++
UNDER HOOD FUSE/ RELAY 8OX
BLh TEL YEL GBN
BLKlYEL
I
A l
BLK/ YEL YELI GFN
IGN]TION
COL
TDCr Top dead cenl er
CKP: Crankshall postion
CYP Cyl nder posl on
TDC] CKP] CYP SENSoR
"
* ] B L U '
*2 WHI BLU
I GNI TI ON CONI ROL
MODULE ( CM)
/
Has b'r ll n\
I
iorse
I
r USE
FE- AV BO}
*u r-. .-*---{<9ot
# u,,."r.
| |
\j/
El
v
t l
23-103
lgnition System
Ci rcui t Di agram :' 98-00 model s
UNDER HOOD FUSUFELAY BOX
'x'E;;;;-;;;;l
/;\ l-*;- Ecw.cM
ffiwFnBLK<-wHr\9-
Y
t l
BTKTYEL YEUGRN
IGN]TION
swtTcH
UNDER,DASH
FUSE/BELAY BOX
YEt
J
BLK
J
FED
+
* 1 : H TACHI
* 2 : TEC
9
* I B L U '
23-104
-
lgnition Timing Inspection and Setting
1 . Check the i dl e speed, and adj ust i t i t necessary
(see
section
'l '1
).
Pul l out the servi ce check connector 2P
(BRN
and BLK
wi res) from the connector hol der l ocated under the
dash on the front passenger si de, then connect the
(T/N
07PAZ
-
0010'100) to it.
Start the engi ne. Hol d the engi ne at 3.000 rpm wi th
no l oad {A,/T
i n
E
or
E.
M/T i n neutral ) unti l the
radi ator fan comes on, then l et i t i dl e.
Connect the ti mi ng l i ght to the No. 1 i gni ti on wi re,
then
poi nt the l i ght toward the poi nter on the ti mi ng
bel t cover.
Check t he i gni t i on t i mi ng i n no l oad condi t i ons:
headl i ghts. bl ower fan, rear wi ndow defogger, and
ai r condi ti oner are not operati ng.
l gnhi on Ti mi ng:
D15Y5. D16Y7, Dl 6Yg engi nes
816A2 engi ne
MIT
16" 12' BTDC
( RED)
dur i ng i dl i ng i n
neutral
M/T
12' t 2" BTDC
( RED)
neutral
l 2' r 2" BTDC { RED)
S
o r E
POINTEB
RED MARK
23-105
ro ADVANCE
-<;,
6. Adj ust the i gni ti on ti mi ng i f necessary, as fol l ows.
Loosen the di stri butor mounti ng bol ts. and turn the
di stri butor i gni ti on
(Dl )
housi ng countercl ockwi se to
advance the ti mi ng, or cl ockwi se to retard the ti m-
i ng.
MOUNTING BOLTS
18 N' m
(1.8
kgfm, 13l bl ftl
Ti ghten the di stri butor mounti ng bol ts, and recheck
the i gni ti on ti mi ng.
Di sconnect the SCS servi ce connector from the ser-
vi ce check connector.
7.
lgnition System
Distributor Replacement
Removal:
1. Di sconnect the connector from the di stri butor.
2. Di sconnect the i gni ti on wi res from the di stri butor
i gni t i on { Dl ) cap.
3. Remove the mounti ng bol ts from the di stri butor,
then remove the di stri butor from the cyl i nder head.
DISTRIBUTOR END CAMSHAFT END
MOUNTING BOLT
18 N.m 11.8 kgtm, 13l bf.l tl
lnstallation:
NOTE: Before you i nstal l the di stri butor. bri ng the No. 1
piston to compression stroke TDC.
1. Coat a new O-ri ng wi th engi ne oi l , then i nstal l i t.
2. Sl i p the di stri butor i nto
posi ti on
NOTE: The l ug on the end of the di stri butor and i ts
mating grooves in the camshaft end are both offset
to el i mi nate the possi bi l i ty of i nstal l i ng the di stri bu-
tor 180" out of ti me.
3. Instal l the mounti ng bol ts, and ti ghten them l i ghtl y.
23- 106
4, Connect the i gni ti on wi res to the di stri butor i gni ti on
(Dl )
cap as shown.
rracfit'
No. 1
CYLINDER
MARK
No. 1
CYLINDER
TEG:
5.
6.
7.
No. 2 No. a
Connect the connector to the di stri butor.
Set the i gni ti on ti mi ng
(see previ ous page).
After setti ng the i gni ti on ti mi ng, ti ghten the mount-
i ng bol ts.
el
-
Distributor Overhaul
HITACHI:
TOC/CKP/CYP
DI STRI BUTOR I GNI TI ON {DI } HOUSI NG
Check f or cracks and damage.
Tr oubl eshoot i ng, sect i on 1 1
Do not di sassembl e.
CAP SEAL
Check f or damage.
IGNITION CONTROL MODULE
(ICMI
I nput Test ,
page 23' 109
I GNI TI ON { DI ) CAP
Check f or cr acks, wear ,
damage, and f oul i ng.
Cl ean or r epl ace,
{cont' d)
23-107
Test , page 23_110
lgnition System
Distributor Overhaul
(cont'dl
TEC:
IGNITION CONTROL
MODULE
IICM'
I nput Test , page
23-1
DISTRIBUTOR IGNITION {DI} HOUSING
Check f or cr acks and damage.
COVER
DISTRIBUTOR IGNITION IDI) ROTOB
CAP SEAL
Check f or damage.
DISTRIBUTOR IGNITION {DII CAP
Check f or cracks, wear,
damage, and f oul i ng.
Cl ean or repl ace,
IGNITION COIL
Test , page
23-110
O-RI NG
Repl ace
\
I
@
TDC/CKP/CYP SNSOR
Troubl eshoot i ng, sect i on 1 1
Do not di sassembl e.
WHT/BLU
23-104
J
l gni ti on Control Modul e
(l CMl
Input Test
NOTE:
. See secti on 1' l when the mal functi on i ndi cator l amp
( Ml L) t ur ned on.
. Perform an i nput test for the i gni ti on control modul e
( l CM)
af t er f i ni shi ng t he f undament al t est s f or t he
i gni ti on system and the fuel and emi ssi ons systems
1. Remove the di stri butor i gni ti on
(Dl )
cap, the di stri b-
utor i gni ti on
(Dl )
rotor and the l eak cover
(TEC).
2. Di sconnect the wi res from the l CM.
HITACHI:
BLK/YEL
TEC:
Turn the i gni ti on swi tch ON
(l l ).
Check for vol tage
between the BLK/YEL wi re and body ground.
There shoul d be battery vol tage.
. l f there i s no battery vol tage, check the BLK/YEL
wi re between the under-dash fuse/rel ay box and
r he l cM.
. l f there i s battery vol tage,
go to step 4.
(l l ).
Check for vol tage
between the wi re*r and body
ground
. l fthere i s no battery vol tage, check:
-
the i gni ti on coi l .
-
the wi re*1 between the i gni ti on coi l and the
tcM.
. lf there is battery voltage,
go to step 5
* 1:
BLU' wi r e
( HI TACHI )
WHT/BLU wi re
(TEC)
Di sconnect the EcM/PCM connector A
(32P).
Check
for conti nui ty on the YEUGRN wi re between the
ECM/PCM and the l CM.
There shoul d be conti nui ty.
Check for conti nui ty on the YEUGRN wi re to body
ground.
There shoul d be no conti nui ty.
Check for conti nui ty on the BLUl wi re between the
test tachometer connector and the ICM
There shoul d be conti nui tY.
Check for continuity on the BLUl wire to body ground.
There shoul d be no conti nui ty.
l f al l the tests are normal , repl ace the ICM
7.
23- 109
lgnition System
lgnition Coil Test
Usi ng an ohmmeter, measure resi stance between the
termi nal s. l f the resi stance i s not wi thi n soeci fi cati ons.
repl ace the i gni ti on coi l .
NOTE: Resi stance wi l l vary wi th the coi l temperature;
speci fi cati ons are at 68' F
(20' C).
HITACHI:
Primary Winding Resistance
{Betwesn the A and B lerminalsl;
0.45
-
0.55 0
Secondary Winding Resistanc
(Between
the A and secondary winding terminals):
22.1
-
33.6 kA
TERMINAL B {-)
TERMINAL A
TEC:
Primary Winding Resistsnce
{Between the A and B terminalsl:
0.63
-
0.77 0
Secondary Winding Resistance
(Between
the A and secondary winding terminals):
12.8
-
19.2 kO
SECONDARY
WINDING
TERMI NAL
TERMINAL A
23-110
TERMINAL B
(-)
lgnition Wire lnspection and Test
CAUTI ON: Car el ul l y r emove t he i gni t i on wi r es by
pulling
on the rubber boots, Do not bend the wires; you
mi ght break them i nsi de.
' 1.
Check the condi ti on of the i gni ti on wi re termi nal s. l f
any termi nal i s corroded, cl ean i t, and i f i t i s broken
or di storted, repl ace the i gni ti on wi re.
Check f or broken,
corroded, and bent
l ermrnal s.
IGNITION WIRE
Connect ohmmeter probes and measure resi stance.
lgnition Wire Resistance:
25 k0 max. at 68"F
(20"C)
IGNITION WIRE
3. l f resi st ance exceeds 25 kO, repl ace t he i gni t i on wi re.
1. Inspect the el ectrodes and cerami c i nsul ator for:
Spark Pl ug l nspecti on
Cracked
insulator
2.
[
.
t . p, op", grp
|
.
Oi l - f oul i ng
i
.
Carbon deposi t s
|
.
Cracked cent er
I
el ect rode i nsul at or
Burned or worn el ectrodes may be causecl by:
. Advanced i gni t i on t i mi ng
. Loose spark pl ug
. Pl ug heat range too l ow
. Insuffi ci ent cool i ng
Foul ed
pl ugs may be caused bY:
. Ret ar ded i gni t i on t i mang
. Oi l i n combust i on chamber
. I ncor r ect spar k
pl ug gap
. Pl ug heat r anget oo hi gh
. Excessi ve i dl i ng/ l ow speed r unni ng
. Cl ogged ai r cl eaner el ement
. Deteri orated i gni ti on coi l or i gni ti on wares
D16Y5, D16Y7, D' 16Y8 engi nel
. Adj ust the gap wi th a sui tabl e gappi ng tool , and
repl ace the pl ug i l the center el ectrode i s round-
ed as shown bel ow.
El ectrode Gap:
1. 1 mm
{o.{X:l
in)
ROUNDED
ELECTRODE
St andar d
1. 1r 8 ' mm
( 0. 043i 800oi n)
Worn or detormed
1 T
23-111
3. 816A2 engi ne:
. Do not adj us t t he gap of a pl at i num t i p pl ug;
repl ace the spark pl ug i l the center el ectrode i s
rounded or i t the gap i s not wi thi n the speci fi ca
t r o ns.
El ectl ode Gap:
St andar d
1. 3181mm
( 0. 051 ! 3oo"
i n)
flOUNDED ELECTROOE
',/
@_
:
Platinum tip
NOTE: Use onl y the spark pl ugs l i sted bel ow
4. Appl y a smal l
quant i t y of ant i sei ze compound t o
t he pl ug t hreads, and screw t he pl ugs i nt o t he cyl i n
der head f i nger-t i ght . Then t orque t hem t o 18 N m
11. 8 kgf . m, 13l bnf t ) .
Engi ne Types Spark Pl ugs
D16Y5 ZFR4F 11
( NGK)
KJ14CR- 111
( DENSOi
D16Y7,
D, I 6Y8
ZFRSF- 11
( NGK)
KJ16CR- 111( DENSO)
81642
PFR6L. 13
( NGK)
PK2OPR. L13
( DENSO}
Charging System
/ *Has
repl aceabl e ELECTRI CAL LOAD I
I DETECTOR
(ELD)
UNI T '
23-1 14
Repl acement , page
23-120
Bect i f i er Removal , page
23, 121
Rect i f i er Test , page
23-122
Rear Beari ng Repl acement , page
23-j 24
*ELD
uni t: USA
CHARGING SYSTEM LIGHT
(l n
t he gauge
assembl y)
Test , page 23- l 14
BATTERY
Test, page
23-91
ALTERNATOR BELT
Inspecti on and Adj ustment, page
23-t25
[]
23-112
Ci rcui t Di agram
IJNDER HOOD FUSEi RELAY BOX
-
BATTERY
LGNlTION
SWITCH
I
,'-F\
I
BAT
I
\ Gl /
\l_/
I
GRN/RED
I
N0.41 (80A)
,-a\
No 42 (40A)
ECM/ PCM
f7
I
WHT/RED
CHARGING
SYSTEM
LIGHT
I
T
WHTi BLU
1 3 23-1
ALTERNATOF
Charging System
Troubleshooting
l f the chargi ng system l i ght does not come on
the order l i sted bel ow:
1. Baftery
(see page 23-91)
2. Chargi ng system l i ght
3. Vol tage
4. Al ternator control system
(USA)
5. Al ternator/regul ator
Charging Systom Light Test
or does not go off, or the battery i s dead or l ow, test the fol l owi ng i tems i n
ALTERNATOR 4P CONNECTOR
IUSA)
Wire side of
IG
(8LK/YEL}
lC.nadal
Wre si de of
t emal e t ermi nal s
[ ]: Canada
23-114
Charging Svstem Light Check-l :
l vl ake sure t he chargi ng syst em
l i ght comes on.
Check for a blown No. 15 t7.5 A)
fuso .nd a blown charging sys-
t om l i ght bul b. l l t he f use . nd
bulb .re OK, ropair the open in
th6 WHT/BLU wi16.
Does the charging system
l i ght come on?
Charging System Light Chec*-2:
St art t he enoi ne.
Does t he chargi ng syst em
light go off?
Volta96 Checkl
Measl re t he vol t age at t he No. 1
l No. 2l t ermi nal of t he 4P [ 3Pl con-
nector with the ignition switch ON
f l r).
R6p.ir the op6n in the BLK/YEL
wire btwsen tho altornator and
undr-dash tuso/.glay box.
-
Wi re si de of
L
twHT/8LUl
lCanada)
Wire side of
t emal e t ermi nal s
L
IWHT/BLUI
L
{W}IT/BLU)
.+1
l r l 2 l
l 3 T. l
-l-
ir/
(WHT/BLUI
(cont' d)
23-115
{From
previ ous page)
Check t or an open i n t ho L ci r'
cui t -1:
2. Di sconnect t he 4P [ 3Pl con-
nect or f rom t he al t ernat or.
3. Ground t he No. 3 t ermi nal of
t he 4P l 3Pl connect or.
(ll)
Turn the ignition swhch OFF, and
r ep. i r t ho open i n t ho wHT/
BLU wire.
l i ght come on?
Check f or an open i n t he L ci r-
cuit-2:
Di sconnect t he No 3 t ermi nal o{
t he 4P [ 3PI
connect or f rom t he
ground.
light
go off.r
Turn lhe ignition 3whch OFF, and
.epair the 3hort to
gtound in the
wHT/Bl-U wire.
(USAI
r?-r
l 1 l 2 l
FFI
]--
I
I l : canada
Charging System
Troubleshooting (cont'd)
Alternator Control System Test
(USA):
,96
-
98 modets,
,99
_
00 Dl6y5
(M/Tl
engine
NorE: Before testi ng. check proper
operati on of the ELD by confi rmi ng wi th the MrL {see secti on r 1).
BATTERY
CAUTION: Be 3ure to use a voltmot.
with its plus
terminal connected to b.t-
tery plus
and its minus terminal to the
{P connectoi tgmrinal No. 2.
c
{WHT/GRNt
Wi re si de oI
ALTERNATOR
.P CONNECTOB
Check for a 3hort in the circuit
IALTC linel:
t o t he al t ernat or,
2. St an t he engi ne, and t urn t he
headl i ght s
{hi gh beam) ON.
and t he posi t i ve
t ermi nal of
the battery.
l s t here 1V or l ess?
Check f or rn opon i n t ha wi re
(ALTC
linol:
1. Tur n t he headl i ght and i gni -
tion switch OFF.
trom the ECM/PCN4.
t he ECM/ PCM 32P connect or
t ermi nal No. 19 and al t ernat or
4P connect or t ermi nal No. 2.
Bspair open in thg wire lrstween
the rhern.tor .nd ECM/PCM.
Check for short in the wire (ALTC
l i nel :
1. Tur n t he headl i ght and i gni
tion switch OFF.
t rom t he ECM/ PCM.
gr ound.
Subslitute a known-good ECM/
PCM, .nd .och6ck.
It p.escribod
vohago i! now avail-
abl e, repl ace t he ori gi nal ECM/
PCM.
Ropair 3hort in the wiro betweon
the ahe.nator and ECM/PCM.
'I
a 1 8 I 10 1 1
12 1 3 14 1 5 1 7 18 t 9
7
20 2'l 22 21
26 27 30
Wi re si de of
ALTC
(WHT/GRNI
c
{WHT/GRNI
ALTERNATOR
Wire side oI
( [ l
T
1 2
1
ECM/PCM CONNECTOB A
(32PI
I 2 3 4 7 8 9 10 t 1
1 2 13 14 15 16 17 1 8 20 21 22 23 21
26 27 30
Wire side of
I
AITC
f emat e t ermi nat s
A
(WHT/ GRN|
23-116
-
Alternator Control System Test {USA}:
'99
-
0O models, except Dl6Y5 {M/T}
engine
NOTE: Before testi ng, check
proper operati on ofthe ELD by confi rmi ng
wi th the MIL
(see
secti on 11)'
BATTERY
CAUTION: Be sura lo use a voltmeter
with its
plus te.minal conneqted io bat-
tery
plus and it3 minus tgrminal to ths
4P connoctot tomrinal No. 2.
Wi re si de of
c
(WHT/GRNI
wi re si de of
ALTERNATOR
.P CONNECTOR
ECM/PCM CONNECTOR C
(31PI
(cont' d)
23-117
Check l or a sho. t i n t he ci rcui t
{ALTC
line):
1, Beconnect t he 4P connect or
t o t he al t ernat or.
2. St art t he engi ne, and t urn t he
headl i ght s
(hi gh
beam) ON.
and t he
Posi t i ve
t er mi nal of
the battery.
ls there 1 V or less?
Chcck f or rn opon i n t he wi re
(ALTC lin6l:
t i on swi t ch OFF
t rom t he ECM/ PCM.
3. Check f or cont i nui t y bet l veen
t ermi nal No. 2 and al t ernat or
Repair opcn in the wire botweon
the alternstoi.nd ECM/PCM.
Check tor short in the wire IALTC
l i ne):
t i on swi t ch OFF
f rom t he ECM/ PCM.
t e r mi n a l No . 2 a n d b o d y
ground.
PCM, and recheck.
It prscribed voltagg is now avail'
abl , repl ace t ho ori gi nal ECM/
PCM.
Raoair short in the wite between
the alle.nator and ECM/PCM,
1 2 3 5 6 1 8 I 10
/ 116
1 1l o 191 zo2122
23 25 2621 ?8 2930 J I
ALTC Wire side of
( WHT/ GRN) f emal e t er mi nal s
o
Charging System
Troubleshooting
(cont'd)
Alt6rnator/Regulator Test
NOTE: Make sure the baftery i s suffi ci entl y charged (see page
23-9j ).
FIELD
SELECTOR
LOAD AOJUSTER
{CARAON PILEI
FULL FIELO
TESTER
LEAD I BLUI
VOLTMETER
NEGATIVE
LEAD IBLKI
VOLTMETER
POStTtVE
LEAD (REDI
NEGATIVE TESTER
CABLE IBLKI
POSITIVE TESTER
CABLE IREDI
TEST SELECTOR
swrTcH
INDUCTIVE
PICK-UP
IGRNI
INDUCNVE
PICK.UP
TIVE
TEBMINAL
Alte.nator/Regulator Test'1 :
L Connect a Sun VAT 40
( or
equi val ent t est er ) , and t u r n
t he sel ect or sw; t ch t o posi t i on
1( st ani ng) .
2. Shi f t t o neut ral
(A/ T
i n
E or
E)
p o s i t i o n ,
a n d s t a r t t h e
e n g i n e . Ho l d t h e e n g i n e a t
3, 000 rpm wi t h no l oad unt i l
3 . Ra i s e t h e e n g i n e s p e e d t o
2, 000 rpm, and hol d i t t here.
l s t he vol t age over 15. 1 V?
Alternalor/Regulator Te3t-2:
1. Rel ease t he accel erat or pedal ,
and l et t he engi ne i dl e.
2. Make sure al l accessori es are
t urned of i . Turn t he sel ect or
swi t ch t o posi t i on
2
(chargi ng).
3. Bemove t he i nduct i ve pi ck-up,
and zero t he ammet er,
4. Pl ace t he i nduct i ve pi ck- up
over the battery ground cable
so t hat t he arrow poi nt s
t o t he
bat t ery negat l ve t ermi nal .
5. Rai se t he engi ne speed t o
2, 000 rpm, and hol d i t t here.
l s t he vol t age l ess t han 13. 5 V?
Alternator/Regulator Test-3:
Apply a load with a VAT-40 until
t he bat t er y vol t age dr ops t o
bet ween 12
-
13. 5 V.
tffil
rCI
[
@lBt*
. ,*n 'aHrl
L-;-;l
rs-
23-11A
To next page
The charging system is OK.
l s t he amperage 50 A or more?
Alternator/Regulator
Test-4:
Wi t h t he engi ne sPeed st i l l at
2, 000 rpm, f ul l t i ei d t he al t ernat or.
J
From previ ous page
CAUTION: The voltage will rise
quickly when the allGrnator is flll-fielded Do not ellow
the vollage to exceed 18 V; il may damage the electrical syslem
NOTE: At t ach a probe t o a VAT 40 f ul l f i el d t est l ead, and i nsert t he probe i nt o t he f ul l f i el d
access hol e at t he back of t he al t ernat or' Swi t ch t he f i el d sel ect or t o t he
"A
(GroLrnd)" posi
t i on moment ari l V, and check t he amperage
readl ng
23-119
Charging System
Alternator Replacement
NOTE: Remove the al ternator from bel ow the vehi cl e.
' 1.
Make sur e you have t he ant i - t hef t code f or t he
radi o' s preset
buttons
(' 99 -
00 model s).
2. Remove the battery negati ve cabl e, then di sconnect
the positive
cable.
3. Di sconnect the 4P
(or
3P) connector from the al ter-
naIor.
TERMINAL NUT
7.85 N.m
(0.8
kgf.m, 5.79lbf.ftl
{ }: Cansd.
4. Remove t he t er mi nal
t he B t er mi nal .
nut and the WHT wi re from
23-120
5. Remove t he adj ust i ng bol t and t hr ough bol t nut ,
then remove the al ternator bel t from the Dul l ev.
UPPER MOUNT
BRACKET BOLT
44 N.m
14.5 kgt.m, 33 lbl.ftl
ALTERNATOR
AD.'USTING BOLT
24 N.rh l2.a kgf.m, 17 lbtft)
ALTERNATOR
BOLT
a4 N. m 14. 5 kst m. 33l bf ' f t l
LOWER MOUNT
BRACKET BOLTS
a4 N.m l {.5 kgf.m,33l bfft)
Pul l out t he al t er nat or t hr ough bol t , t hen r emove
the al ternator.
l f necessary, remove the mount bracket bol ts. and
the upper and l ower mount brackets
Adj ust the al ternator bel t tensi on after i nstal l ati on
(see
page 23-125).
00 model s).
7.
J
Rectifier
Removal
1. Remove the four through bol ts.
Heat the rear beari ng seat wi th a 1,000 W hai r dri er
tor about fi ve mi nutes
(120 -
140' F, 50
-
60"C).
3. Separate the rear housi ng from the dri ve-end hous-
i ng by i nserti ng a fl st ti p screwdri ver i nto the open-
i ngs and
pryi ng them a part. Be careful not to dam-
age the stator with the tip of the screwdraver.
Seoarate the rear housi ng and dri ve-end housi ng
wi th the stator attached to the rear housi ng.
DEIVE-END HOUSING
STATOR
{cont'd)
23-121
REAR HOUSING
Charging System
Rectifier Removal
(cont'd)
Separate the rear housi ng from the stator/recti fi er
assembl y by removi ng the four screws and the ter-
mi nal nut.
TERMINAL NUT
Unsol der the recti fi er from the stator l eads,
. To avoi d damagi ng the di odes wi th heat, pi nch
the stator leads between pliers to carry heat off,
and appl y the sol deri ng i ron onl y l ong enough to
separate the l eads from the recti fi er.
. Use a 100 W sol deri ng i ron.
STATOR SOLDERING
7. Install the new rectifier in the reverse order of removal.
. Appl y t he sol der i ng i r on onl y l ong enough t o
ensure a good connecti on so the heat wi l l not
damage the di odes.
a Use onl y a rosi n core type sol der or sol der
j oi nts
wi l l corrode.
6.
SOLDERING
23-122
Rectifier Test
NOTE: The di odes are desi gned to al l ow current to pass
i n one di recti on whi l e bl ocki ng i t i n the opposi te di rec-
ti on. Si nce the al ternator recti fi er i s made up of ni ne
di odes, each di ode must be tested for conti nui ty i n both
di recti ons wi th an ohmmeter that has di ode checki no
capabi l i ty; a total of 18 checks.
1. Check for conti nui ty i n each di recti on between
-
the B and P termi nal s.
-
t he B' and P t er mi nal s.
-
E
{ground) and the P termi nal s.
Al l di odes shoul d have conti nui ty i n onl y one di rec-
UOn.
l f any of the di odes fai l s, repl ace the recti fi er assem-
bl y,
(Di odes
are not avai l abl e separatel y.)
J
Rotor Slip Ring Test
1. Check the resi stance betl veen the sl i p ri ngs
There shoul d be 1 8
-
3 0 ohms
. lf resistance meets the specification,
go to step 2.
. l f r esi st ance does not meet t he speci f i cat i on,
reol ace the al ternator'
SLI P BI NGS
2. Check that there i s no conti nui ty between the sl i p
ri ngs and the rotor or rotor shaft.
3. l f the rotor fai l s ei ther conti nui ty check, repl ace the
al ternator.
Stator Test
' 1.
Check that there i s conti nui ty between each
pai r of
l eads.
CORE
Check that there i s no conti nui ty between each l ead
and the coi l core.
l f the coi l fai l s ei ther conti nui ty check, repl ace the
al ternator.
ROTOR SHAFT
LEADS
1 .
Alternator Brush InsPection
Separate the dri ve-end housi ng from the rear hous-
i ng as descri bed on page 23-121
Separate the rear housi ng from the stator/recti fi er
assembl y by removi ng the four screws and the ter-
mi nal nutfrom the rear housi ng {see
page 23-121}
l vl easur e t he l engt h of t he br ushes wi t h ver nr er
cal rpers.
Alternator Brush Length:
O
Standard {NEW} @
Servi ce Li mi t
19. 0 mm
( 0. 75
i n)
1
5. 0 mm
( 0
20 i n)
l f the brushes are l ess than the servi ce l i mi t, repl ace
t hem.
23-123
Gharging System
Rear Bearing Replacement
1. Pul l offthe rear beari ng,
. Make sure the ti ps of the beari ng pul l er j aws
are
thi n enough to fi t between the beari ng and the
sl i p ri ngs.
. Do not reuse the beari ng.
SLIP RINGS BEARING PULLER
Use a hand press to i nstal l the new beari ng. Appl y
pressure onl y on the i nner race to avoi d damagi ng
the beari no.
REAB BEARING
23-124
Alternator Reassembly
1. Push t he br ushes i n, t hen i nser t a pi n
or dr i l l bi t
(about
1.8 mm di ameter) to hol d them there.
Heat the rear beari ng seat i n the rear housi ng as
descri bed on page 23-121. After heati ng, conti nue
i mmedi atel y wi th assembl i ng before the rear bear-
i ng seat cool s compl etel y,
Put the rear housi ng/stator assembl y and dri ve-end
housi ng/rotor assembl y together. ti ghten the four
through bol ts and pul l out the pi n.
REAR
STATOR ASSEMBLY
After assembl i ng the al ternator, turn the pul l ey
by
hand to make sure the rotor rotates smoothl v and
wi thout noi se.
BRUSHES
THROUGH BOLT
I
q
%*z
BRUSH AOCESS HOI."E
It
-
Alternator
Belt Inspection and Adiustment
Deflection Method:
(10
kgl ,22l bl l , and measure the
defl ecti on between the al ternator and the crankshaft
pul -
l ey.
Detl ecti on | 8.0
-
10.5 mm
(0.31 -
0.41 i n)
NOTE: On a brand-new belt {one that has been run for less
than fi ve mi nutes). the defl ecti on shoul d be 6.0
-
8.5 mm
(0.26 -
0.33 i n) when fi rst measured. If the bel t i s worn or
damaged, repl ace i t.
CRANKSHAFT
PULLEY
lf adiustmnt is necossary:
1. Loosen the l ower mounti ng nut and the upper mount-
i ng bol t.
2, Move the al ternator to obtai n the
proper bel t tensi on,
then reti ghten the upper mounti ng bol t and the l ower
mounti ng nut to the speci fi ed torques.
3. Recheckthe defl ecti on ofthe bel t.
24 N.m
(2.4
kgl m,
Belt Tnsion Gauge Method:
Fol l owi ng the
gauge manufacturer' s i nstructi ons. attach
the soeci al tool to the bel t, and measure the tensi on.
Tensi on 340
-
490 N
(35 -
50 kgf,77
-
110l bf)
NOTE: On a brand-new belt {one that has been run for less
than fi ve mi nutes), the tensi on shoul d be 540
-740
N
(55 -
75 kgf, 121
-
165 l bf) when fi rst measured. l f the bel t
i s worn or damaged, repl ace i t.
PULLEY BELT TENSION GAUGE
07JGG
-
0010104
It adiustment is necossary:
1, Loosen the l ower mounti ng nut and the upper mount-
i ng bol t.
2. Move the alternator to obtain the
proper belt tension.
then reti ghten the upper mounti ng bol t and the l ower
mounting nut to the specified torques
3. Recheck the tensi on of the bel t
23-125
Fan Controls
UNDER.HOOO
CONDENSER FAN RELAY
Test, page 23-87
RADIATOR FAN RELAY
Test, page 23 87
CONDENSER
FAN MOTOR
TOR FAN MOTOR
Removal , sect i on 10
ENGINE COOLANT
TEMPERATURE
(ECTI
swtTcH
Removal , secti on 10
Test, section l0
t l t l t l t t t l
t l Tt l n r - l
mU! L- J f l _l
'1
- f-t t-_l
-
I L--J L__J LJ f-----"1
o
ô
o" l
23-126
I J
Ci rcui t Di agram
UNDER DASH
I GNI T ON SWI TCH FUSEI RELAY 8OX
6\ |-;;;;l
ii
"ir"'t*Tl
- l
BLK
yEL -J
GRN
I
I
I
I
\.7
V
ECM/ PCM
ENG NE
COOLANT
l EMPERATURE ( ECT)
SWTCH
fclosed
: Above
'l
L
r 99"F ( 93"C)
_l
BLKTRED
I
I
1,,*"_
T-'
I
Bt K
I
I
G201
UNDER.HOOD FUSElRELAY BOX
No 41 (8041 No 42 (40A)
Gauge Assembl y
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons,
and
secti on
(24)
6 x 1 . 0 mm
9.8 N.m 11.0 kgf.m,
22lbt.lrl
VEHICLE SPEED SENSOR {VSS)
Troubl eshoot i ng,
page 23-1 40
GAUGE ASSEMBLY
Gau ge/lndicator/Terminal
Locat i on I ndex,
page 23-129
Removal ,
page 23-135
Bul b Locat i on, page 23-136
Di sassembl y,
page
23 138
PARKING BRAKE SWITCH
FLUIO LEVEL SW]TCH
23-128
ENGINE OIL PRSSURE SWITCH
J
Gau
ge/l ndi cator/Termi nal
With tachometer;
CONNECTOR
"A"
{A/T GEAR POSITION INDICATOR}
Location lndex
CONNECTOR
"8"
{GAUGE and INOICATOR)
CONNECTOB
"C"
CONNECTOR
"D"
{ABS INDICATORI
SPEEDOMETER:
I ndi cat es 60 km/ h at 637 rpm or
60 mph at 1, 025 rpm o{t he
vehi cl e speed sensor
(VSS).
A/T GEAR POSITION
INDICATOR
See
page 23 149
TACHOMETER:
I ndi cat es 100 r pm at
200 pul ses per mi nut e
ol t he i gni t i on cont r ol
modul e
( l CMi .
FUEL GAUGE ENGINE COOLANT TEMPERATURE
(ECT)
GAUGE
(cont' d)
23-129
(GAUGE
end INDICATORI
A 1 - - - - - - - - - - - + 8 1 6
JlltlllulllllrL
c 1
- - - - - - - - - > c 1 3
1ililil{ilrL
o o o o
o
0 0 0 6 ^
) o g @ @
o ^ o
@
)
' l
| .
o
Fl -
- ->
F5
E1_
_ -->E5
D1-
--+05
oo/ \ oo
Gauge/ Sendi ng Uni t Test , page 23-142
Gauge Assembl y
Gauge/l ndi cator/Termi nal Locati on Index
(cont' d)
Without tachometer:
CONNECTOR
"A"
IA/T GEAR POSITION INDICATORI
CONNECTOR
"8"
{GAUGE and INDICATOR}
CONNECTOR
"C"
(GAUGE
and INDICAIORI
CONNECTOR
"F"
{SRS INDICATOR)
CONNECTOR
"D"
{ABS INDICATORI
SPEEDOMETER:
I ndi cat es 60 km/ h at 637 rpm or
60 mph at 1, 025 rpm of t he
vehi cl e speed sensor
(VSS).
ENGINE COOLANT TEMPERATUFE
(ECT)
GAUGE
A/T GEAR POSITION
INDICATOF
See page 23 149
FUEL
A1
------>
46
---->
al 4
B1 .
- - - - - - - - - - - - - - - - > B1 6
JilililHililil1
C1 - -
- - - - - - - - - . . + C1 3
JililHililL
Oo_o-o
O
0006
l u s
0 0
Bu - .
)
oo/ \ oo
23-130
Gauge/ Sendi ng Uni t Test , page 23 142
IJNOER,DASH
FUSE/RELAY BOX
GAUGE
LIGHTS
l 3wx4 l
CHARGING
SYSTEM
LIGHT
0.4w)
Gi rcui t Di agram
UNDEN HOOD FUSE/RELAY BOX
I J
N0.30 (7.54)
FUSE
f7
I
t l
RED/BLK BEO/BLK
l " l "
8LK BLU
IJ
l'"^*
I
t
-
G401
G402
__l
t E2
I
FED/BLU
CRUI SE
CONTROT
UNI T
fl ,,1:
tH
I c12
I
FFD
V
DASH LIGHTS
BRIGHTNESS
CONTROLLEF
l"'
WHT/BLU
v
ALTERNATOR
(With shifi-up indicatd lighl) (wi1h cruise conlrcl system)
Gauge Assembly
(Wnh lachomolgr)
I
cNfldt--]
I CONTRoL I
I MODULE
I
0cM) :
t v l
i . l l
|
-i;,
i
TURN SIGNAU
HAZAROWARNING
swtTcH
Ci rcui t Di agram
{cont' d)
Fh"lurous
@)-
BLrcwHT + BLKryEL
fi'Sfvrous 16r.- veL
PAGE
RIGHT
V
I
GR&ryE
LEFT
V
I
No.s (104)
FUSE
V
I
BEO/GRN
l r u
8LU4RE0
ABS
CONTROL
UNIT
-rl
eLui'rvrr
G401
G402
G401
G442
23-132
BRAKE
SYSTEM
LIGHI
(1. 4w)
RED/GRN GFN/RED
T A
Yimi+" Yo
l[3&1"
;i:l"la',.l
l,,1!:,iT
"*,,
I lrb'ff"
;i#il;-"1
I ' i
_,L J-
: - l
G401
G()2
GRN/REO
I
TCM
(cont' d)
23- 133
8LK
I
G552
Gauge Assembly
Ci rcui t Di agram
(cont' dl
MATFUNCTION
INOICATOR
(M r)
WASHER
LEVEL
SWITCH
Tclosed
:Floatdownl
topen
Floal up .l
PNK
BLK
T
G401
G402
GRN/ORN
I
ECM/PCM
ENGI NE
orL
PRESSURE
SWITCH
fcbsed Enqine
BLU/BLK YEURED
HI
'f''#lu""',.'f
- -
RED/BLU
|
ffitt'*'
I V
t l
t l
REDi BLU
I
o, u,,,
/h,, SEii
Y rtt'J"T,r.0,.*"0
I
topen Buchred
BLK
T
G552
J
Removal
1. Remove the two screws from the i nstrument panel .
2. Remove t he i nst r ument
panel .
CAUTION: Careful l y remove the i nstrument
panel wi thout damagi ng the cl i ps.
3. Ti l t the steeri ng wheel down wi th the ti l t adj ustment l ever.
4. Spread a protecti ve cl oth over the steeri ng col umn.
5. Remove the four mounti ng screws from the gauge assembl y.
6. Pry the gauge assembl y out, and di sconnect al l connectors from i t
7- Take out the gauge assembl y.
GAUGE ASSEMBLY
I NSTRUMENT PANEL
23- 135
Gauge Assembl y
Bulb Locations
(With
Tachometer)
GAUGE LI GHT I I . ' WI
SEAT BELT
REMINDER LIGHT I1.4 WI
LOW FUEL
LIGHT 13 W)
RIGHT TURN SIGNAL
INDICATOR LIGHT I1.4 WI
A/T GEAR
GAUGE LIGHTS 13 W)
CI{ARGING SYSTEM LIGHT
(1.,1W)
GAUGE I-IGHT {1,4 WI
LOW ENGINE OIL PRESSURE
INDICATOR LIGHT
(1,' W}
HIGH EEAM
INDICATOR LIGHT
(1. 4
W)
GAUGE LIGHT l3.il Wl
MALFUNCTION
INDICATOR
LAMP {MIL}
BULE
(1. { Wl
WASHER I.'C VEL
INDICATOR LIGHT
{1. 4 Wl
(Canada)
LEFT TURN SIGNAL
INDICATOR LIGHT {1.4 WI
sRs TOB
(1. 4
Wl
{On t he
pri nt ed ci rcui t board)
I NDI CATOR (1. 12
x 6l
(On
t he pri nt ed
ci rcui t board)
ABS |ND|CATOR (1..
Wl
{On the
printed
circuit board)
CRUI SE or SHI FT-UP I NDI CATOR 11. 12 11.
{On t he ori nt ed ci rcui t board)
23-136
J
Bulb Locations {Without
Tachometer)
TRUNK INDICATOR
LIGHT {1.i 1W}
.4 Wl
CHARGING SYSTEM LIGHT 11,4 W}
LTGHT
(1. 4
W)
GAUGE LIGHT
SEAT BELT
REMINDER LIGHT
(1.4
WI
LOW ENGINE OIL PRESSUBE
INDICATOB LIGHT
(1.4 WI
LOW FUEL INDICATOR
LrGl{T
(3
W)
RIGHT TURN SIGNAL
INOICATOR LIGHT
( 1. 1Wt
GAUGE LIGHTS {3
WI
WASHER LEVEL
INDICATOR LIGHT
{1. 4 W} l canad. l
HIGH BEAM
INDICATOR LIGHT
MALFUNCTION
INDICATOR
LAMP
(MIL)
BULB {1. 4 WI
{ 1. i l W)
LEFT TURN SIGNAL
INDICATOR LIGHT {1.4 WI
A/T GEAR POSITION
INDICATOR
(1.12
x 6)
(On
t he pri nt ed
ci rcui t board)
sRs TND|CATOR 11.4 W)
{On the Dri nted ci rcui t board}
aBs tNDtcAToR t1.4 W)
(On
the
pri nted ci rcui t board)
(3.{
Wt
o / o
\ 7
o
23-137
Gauge Assembl y
Disassembly
(With
Tachometerl
NOTE: Handl e the termi nal s and Dri nted ci rcui t boards
careful l y to avoi d damagi ng them.
A/T GEAR POSITION INDICA
MOUNNNG SCREWS
tx 2)
FUEL and ENGINE COOLANT TEMPEMTURE
GAUGE MOUNTING SCREWS {x 6,
TACHOMETEB MOUNTING
SCREWS lx 3l
ao
,-o
ok+r
.,- ll $
t'{"{q.' El
I ..il
\:r
A/T GEAR POSITION INOICA
PRINTED CIRCUIT BOARD
INDICATOR
@
FUEL end ENGINE COOLANT TEMPERATURE
(ECTI
PRINTEO CIRCUIT
q,
6 \
ABS CRUISE or SHIFT-UP INDICATOR
PRINTED CIRCUTT EOARD
TACHOMETER
Speci l i cat i on,
page 23 129
METER PANEL
booo . - - : o' - . . oooo. A
:-F.-sr';
"?;"')
aFl l!
GAUGE
23-134
J
Disassembly {Without
Tachometerl
NOTE: Handl e the termi nal s and
pri nted ci rcui t boards
careful l y to avoi d damagi ng them.
SPEEDOMETER MOUNTING
SCREWS
(x
4)
A/T GEAR POSITION INDICA
MOUNTING SCREWS {x 2l
SRS INOICATOR
ENGINE COOLANT TEMPERATURE {ECT}
GAUGE
ABS INDICATOR
PRINTED CIRCUIT
METER PANEL
FUEL GAUGE
MOUNTING SCREWS {x 3)
ENGINE COOLANT TEMPERATUR
GAUGE MOUNTING SCREWS {x 3l
A/T GEAR POSITION INDICATOR
' a @
.-@
- - o
o"i^>
\ Er t\t
lmw
p \
d*re
\ *P
\
FUEL
Test,
GAUGE
page 23-142
oOo , . - ' ' - . , oOOo
- / \
3,'"
'
"$?'----"')
)a.'
' .,,' +
' :j
\ l l L t o
BOARD
METER LENS
METER VISOR
23-139
(VSSI
Troubl eshooti ng
Before testi ng, i nspect the No. 15
(7.5
A) fuse i n the under-dash fuse/rel ay box.
TEST HARNESS
OTLAJ
_
PT3O2OA
REO TEST HARNESS
CLI P
PROTECTIVE
TAPE
TEST HARNESS
OTLA'
.
PT3O2OA
(To
next page)
Test the BLK wire:
f r om t he vehi cl e speed sensor
(vss).
2 . Co n n e c t t h e t e s t h a r n e s s
(07LAJ
PT30200) only to the
engi ne wi re harness,
3. Connect t he RED t est harness
cl i p t o t he posi t i ve probe of a
t he RED t est harness cl i p and
body ground.
Repai r opon i n t he BLK wi r e
btwen the VSS and G101.
Te3t the BLK/YEL wire:
1. Connect the WHT test harness
cl i p t o t he posi t i ve probe of a
voltmeter, and connectthe RED
test harness clip to the negative
probe.
Repair open in iho BLK/YEL wire
between the VSS and the under-
d6sh tuse/relav box.
vss
GRN TEST HARNESS
RED TEST HARNESS
WHT TEST HARNESS CLIP
23-140
J
(From prevaous page)
WHT TEST HARNESS
CLIP
TEST HABNESS
07LAJ
-
Plil020a
RED TEST HARNESS
CLI P
PROTECTIVE
APE
GRN TEST HARNESS CLIP
"8"
BLU
23-141
Tost the BLU/WHT wirei
Connect l he GRN t est har ness
cl i p t o t he posi t i ve pr obe of a
vol t met er, and connect t he RED
t est harness cl i p t o t he negat i ve
probe.
Repair open in the BLU/WHT wiro
btwoon the VSS and ECM/PCM,
TCM
(CVT),
and cruise control untt.
l s t here about 5 V or more ?
Test the vss:
2. Connect t he ot her t est har
ness connect or t o t he VSS.
3. Rai se t he f ront ot t he vehi cl e,
st ands,
4. Put t he vehi cl e i n neut ral wi t h
t he i gni t i on swi t ch ON
(l l ).
5. Sl owl y rot at e one wheel wi t h
t he ot her wheel bl ocked.
Does vol t age
pul se f rom 0 t o
approx. 5 V or more ?
Speedometer Tosii
' 1.
" B"
f r om t he gauge assem-
bl v.
2. Touch a probe t o t he BLUMHT
wi re, and connect i t t o body
ground t hrough a vol t met er.
3. Sl owl y rot at e one wheel wi t h
t he ot her wheel bl ocked.
Repair open in the BLU/WHT wi.e
belween th VSS and the 3ped-
Does t he met er i ndi cat e
pul s-
i ng vol t age?
Fuel Gauge
Gauge/Sendi ng Uni t Test
!@
Do not smoke while working on tho fuel
system. Keep open tlame away trom your
wotk atea.
NOTE: Refer to page 23-133 for the fuel gauge system
ci rcui t.
' 1.
Check the No. 25
(7.5
A) fuse i n the under-dash fuse/
relay box before testing.
2. Remove the access
panel
from the fl oor.
ACCESS PANEL
Di sconnect the 3P connector from the fuel gauge
sendi ng uni t.
Connect the vol tmeter posi ti ve probe to the No. 2
termi nal and the negati ve probe to the No. I termi -
nal , then turn the i gni ti on swi tch ON
(l l ).
There shoul d be between 5 and 8 V.
. l f the vol tage i s as speci fi ed, go to step 5.
. l f the vol tage i s not as speci fi ed. check for:
-
an open i n the YEUBLK or BLK wi re.
-
poor ground (G552).
Turn the i gni ti on swi tch OFF.
Attach a
j umper
wi re between the No. 1 and No. 2
termi nal s, then turn the i gni ti on swi tch ON
(l l ).
)
\
23-142
1. Check that the
poi nter
of the fuel gauge
starts mov-
i ng toward the
"F"
mark.
CAUTION: Turn the ignition switch OFF before the
poinier reaches
"F"
on ihe gauge
dial. Failure to do
so may damage the fuel gauge.
NOTE: The fuel gauge i s a bobbi n
(cross-coi l )
type,
hence the fuel l evel i s conti nuousl y i ndi cated even
when t he i gni t i on swi t ch i s OFF, and t he
poi nt er
moves more slowly than that of a bimetaltype.
. l f the poi nter of the fuel gauge does not move at
al l , repl ace the gauge.
. l f the gauge i s OK. i nspect the fuel gauge send-
i ng uni t.
Remove the fuel gauge sendi ng uni t as shown.
Japan-produced
USA, Canada-produced
J
9. l Measure the resi stance between the No 1 and No. 2
t er mi nal s at E { EMPTY) ,
112 \ HALF
FULL) and F
(FULL) by movi ng the l l oat.
USA, Canada-produced {Cerami c
board type):
Too ot l he wor kbench
( Bot t om of t he f uel t ank)
l l the resi stance readi ngs are beyond the range. repl ace
t he f uel gauge sendi ng uni t
Fl oat Posi ti on E 1t2 F
Resi stance
(0) 105
-
108 29.5
-
35.5 3 . 5 - 5
Jaoan-Pl oduced
(Wi re-wound typel :
Fl oat Posi ti on
E 1/2 F
Resi stance
(O) 105
-
110 25. 5
-
39. 5
Low Fuel Indicator Light Test
NOTE: For the l ow fuel i ndi cator ci rcui t di agram, refer to
the
gauge assembl y ci rcui t di agram
(see page 23' 2311.
1. Check t he No. 25
( 7
5 A) l use i n t he dr i ver ' s under
dash fuse/rel ay box before testi ng
2. Par k t he vehi cl e on l evel gr ound.
3.
4.
Drai n the l uel i nto an approved contai ner. Rei nstal l
the fuel tank drai n bol t wi th a new washer.
Add l ess t han 4L
( 1
1 U. S Gal , 0. 9 l mp Gal ) of f uel ,
and t ur n t he i gni t i on swi t ch ON
( l l ) . The l ow f uel
i ndi cat or l i ght shoul d come on wi t hi n f our mi nut es'
. l f the l i ght comes on wi thi n four mi nutes,
go to
step 8.
. l f t he l i ght does not come on wi t hi n f our mi n-
utes,
go to step 5.
Remove the access
panel l rom the Il oor'
Tur n t he i gni t i on swi t ch OFF, t hen di sconnect t he
fuel tank sendi ng uni t 3P connector.
Connect t he f uel t ank sendi ng uni t 3P t er mi nal s No'
1 and No. 3 wi t h a
j umPer wi r e
. l f t he l i ght comes on, r epl ace t he f uel gauge
sendi ng uni t
(see
Page
23 1421
. l f the l i ght does not come on, check for:
-
An open i n t he GRN/ YEL wi r e bet ween t he
f uel gauge sendi ng uni t and t he f uel gauge
-
A bl own bul b.
-
A poor ground
(G552)
6.
1.
f emal e t er mi nal s
8. Add 4L { 1. 1 U. S. Gal , 0 9 l mp Gal ) of f uel The l i ght
shoul d
go off wi thi n four mi nutes.
23-143
Interlock System
INTERI.OCK
UNIT
Input Test, page
23-' 146
KEY INTEBLOCK SOLENOID
rnd KEY INTERLOCK SWITCH
(l n
t he st eeri ng l ock assembl yl
Test , page
23-147
PARK PIN SWITCH
Test , page 23-148
SHIFT LOCK SOLENOID
Test , page 23-147
23-144
J
UNDER HOOD FUSARELAY BOX
No 41 (80A) N0.42 (404)
GFNWHT
WHT/GFN
UNOEF,DASH
FUSE/RELAY
80x
SHIFT LOCK
soLENO|0
(O,l : UNLoCK)
I
5
5
3 INTERLOCK CONTFOL IJNIT
BLK
I
G401
G402
GRNAVI{I GR}.//WHT
r l
J I
V I
BRAI(E LIGHIS I
cRUrsE coNTROL UNIT
I
ABS CONTROT, UNIT
I
rcM (cw)
I
YEL
l r
rEt
till
l '
YEUBLK
M GEAR
POStT|ON
INDICATOF
f7
I
]
SENSOR
f7
I
RED/BLK
WHT/BLK
I
I
t,
/P1
ennr
Vl$"ilT?l*r e,."o r
lr I PUsh
bdon
frsno I
| \
Inpos on B )
BLK
I
I
I
:
G401
G402
KEY l l
TNTEnLOCK
|
|
swrTcH I I
KEY INTERLOCK CIRCUIT
GFNWHT
POSTTTON
swlTcH
(Closd : In
posilioa
lll )
23-145
Interlock System
Control Unit Input Test
1. Di sconnect the 8P connector from the i nterl ock con-
trol uni t.
2. I nspect t he connect or and socket t er mi nal s t o be
sure they are al l maki ng good
contact.
. l f the termi nal s are bent, l oose or corroded, repai r
them as necessary, and recheck the system.
. l f t he t er mi nal s l ook OK, make t he f ol l owi ng
i nput tests at the connector.
-
l f a test i ndi cates a probl em,
fi nd and correct
the cause, then recheck the system.
-
l f al l t he i nput t est s pr ove
OK, subst i t ut e a
known-good control uni t, and recheck the sys-
tem. l f the check i s OK, the control uni t must
be faul ty; repl ace i t.
NOTE: l f t he shi f t l ock sol enoi d cl i cks when t he
i gni ti on swi tch i s turned ON
{l l ) and you
step on the
brake pedal (wi th
the shi ft l ever i n
E), the shi ft l ock
system i s el ectroni cal l y normal ; i f the shi ft l eve.
cannot be shifted from
E], test the Aff gear position
swi tch, park pi n
swi tch, and see secti on 14.
Key Interlock System:
Cavity Wire Test condition
Reconnect the 8P connector to the i nterl ock control uni t.
Shift Lock System:
Cavity Wifs Test condition
INTERLOCK
CONTROL UNIT
Test: Desired result
Test: Dgsired result
Wire side of
Possible cause if result is not obtained
WHT/BLU
l gni t i on swi t ch t urned t o
ACC
(l l and
key pushed
i n
Check f or vol t age t o gr oundi
Ther e shoul d be baf t er y vol t age.
Bl own No. 48
(30
hood fuse/relay box
Bl own No. 33
(7. 5
dash fuse/relay box
Faul t y st eeri ng l ock assembl y
l key i nt erl ock sol enoi d)
An open i n t he wi re
5 WHT
BLK
Under al l condi t i ons Check f or cont i nui t y t o ground:
There shoul d be cont i nui t y.
'
Poor ground (G401,
G402)
.
6 BLK./BLU
Shi f t l ever i n
El Check f or cont i nu; t y t o ground:
Poor ground (G401,
G402)
Faul t y Ay' T gear posi t i on
swi t ch
2 YEL
l gni t i on swi t ch ON l l l ) Check f or vol t age t o gr ound:
Ther e shoul d be baner y vol t age.
.
Bl own No. 25
(7. 5
A) f use i n t he under,
dash fuse/relay box
.
3 YEUBLK
l gni t i on swi rch ON
(l l )
Check f or vol t age t o ground:
There shoul d be baf t ery vol t age.
Bl own No. 25
(7. 5
A) f use i n t he under-
dash fuse/relay box
Faul t y shi f t l ock sol enoi d
6 BLI (BLU
Shi f t l ever i n
I Check f or vol t age t o ground:
There shoul d be 1 V or l ess.
Poor ground (G401,
G402)
Faulty A,/T gear position switch
7 WHT/RED
l gni t i on swi t ch ON l l l )
Br ake pedal depr essed
Bl own No. 52
(15
A) I use i n t he under
hood f use/ rel ay box
Faul t y PCM
Faul t y brake swi t ch
(see
sect i on 1l )
Faul t y t hrot t l e posi t i on
{TP) sensor
(see
sect i on 1' l
)
l gni t i on swi t ch ON
(l l )
Br ake pedal and
accelerator depressed at
t he same t i me
There sho(Jld be battery voltage.
23-146
Key Interlock Solenoid
Test
Remove t he dr i ver ' s dashboar d
l ower cover and
knee bol ster
(see
secti on 20)
Di sconnect t he 7P connect or f r om t he mai n w' r e
harness.
3. Check Ior conti nui ty between the termi nal s i n each
kev oosi ti on accordi ng to the tabl e'
4. Check that the key cannot be removed wi th
power
and
ground connected to the No. 7 and No 6 termi -
nal s
. l f the key cannot be removed. the key i nterl ock
sol enoi d i s OK.
. l f the key can be removed, repl ace the steeri ng
l ock assembl y
(the i nterl ock sol enoi d i s not avai l -
abl e seParatel Y).
1 .
\
Ter mi nal
i*i,r"
- - --\ 7
l gni ti on
switch
ACC fl)
Key pushed i n o-
- o
Key rel eased
o-
-o
Shift Lock Solenoid
Test
' t .
Remove ths front consol e
(see
secti on 20)'
Di sconnect the shi ft l ock sol enoi d 2P connector'
Connect battery
power to the No. 1 termi nal and
ground to the No. 2 termi nal of the sol enoi d momen-
Iarrry.
NOTE: Do not connect
power to the No 2(-) termi -
nal
(reverse pol ari ty) or you wi l l damage the di ode
i nsi de the sol enoi d
Check that the shi ft l ock rel eases when the rel ease
l ever i s
pushed, and check that i t l ocks when the
rel ease l ever i s rel eased
l f the sol enoi d does not work, repl ace the sol enoi d'
23-147
Interlock System
Park Pin Switch Test
1, Remove the front consol e
(see
secti on 2Ol .
Di sconnect the 4P connector from the park pi n
swi tch.
Check for conti nui ty between the No. 3 and No. 4
termi nal s wi th:
-
the shi ft l ever any posi ti on
other than
E, or
-
the push
button pushed
i n
E.
Check for conti nui ty between the No. 3 and No. 4
termi nal s wi th the shi ft l ever i n
E
and the push
but-
ton rel eased. There shoul d be no conti nui w. l f nec-
essary, replace the park pin
switch.
NOTE: Park pi n
swi tch 4p connector No. 1 and No.2
termi nal s are l or Ay' T gear posi ti on
consol e l i ght.
refer to the ci rcui t di agram on page
23-1S0.
23-14A
A/T Gear
Position Indicator
Component
Location lndex
sRS components are l ocated i n thi s area. Revi ew the sRS component l ocati ons,
precauti ons, and
procedures i n the sRS
secti on
(241 before
performi ng repai rs or servi ce'
A/T GEAR POSITION INDICATOR
I nput Test , page 23-152
A/T GEAR POSITION SWITCH
Test , page 23 154
Repl acement ,
page 23-155
t
E
N
E
E
E
(A/TI
E
N
E
E
r
(cw)
23-149
A/T Gear Position Indicator
UNDER. DASH
FI.JSE/FELAY BOX
IGNITION
swrrcH
Ci rcui t Di agram
CW:
UNDER HOOD FUSE/RELAY BOX
6;\ |-;,,' r&l
\o3o' 75A
rr,/-TPLK+r,,' ri rac
coJ-aL("E1.<\c-t]
---
I Y
.
PCM"
:i3M)''
V
I
LT GRN
TqM
' l
f 7 v
t l
YEL GFN
8LK
G401
G442
*1 : 96'98 modeis
+2 i
'99t0
models
No 30
{7.5A)
V
I
RED/BLK
t ,
| | l
| ,k sfi0f, |
I t g ) c o N s o t E l
I Y
i1?ri
I
t l l
t '
RED
I
I
v
DASI| L GHTS
ERIGHTNESS
CONTNOLLER
l./TGEAR POSITION INDICAToR (h lhe gauge
assembty)
YYYY
A/ TGEAR
PostTtoN
swrTcH
A'/T GEAB POSITION NDICATOR OIMMING C]RCUIT
23-150
J
Ci rcui t
Di agram
A/T
UNDER HCCD FUSE BELAY BOX
PCi\4
V
I
I
. T Gq
GNIT ON
SW TCH
TJNDEF OASH
'â"
fr-.-r^ """- *
-l
6l\
U__t-
-t
ir_i ;_P
_+irh-
\:f
; h,:_
Ar T GEAR POS TI ON I ND CATOF
( n l hegauge assembyl
A 1 3 412
YEL
f333{'*)
f7
I
RED, ELK
PCM
V
I
GRNlBLK
I
l -
6LK 8LU
12
f7 f7 fl
I t l
WHT YEL GFN
r l \ 4 l 7 6 5 2 (Nol used)
{' }' }' 1,
I
A._.
--An i
t . - - i t -
L r l
9
_ P N K -
A'T GEAR
BLK
AI T GEAR POSTON NDLCA1ORD MM] NG CI RCUT
I
I
I
DASH L GHTS
BRIGHTNESS
CONTFOLLER
f7
I
SLU
\ . - Ti
i : 5A
FL] SE
V
I
F: I BLK
I
l ' ,
l l ^ , . , ^ , 1
L,-N
pos
r oN
I
I ( d ] . O N S C L E I
l Yi : i l |
I l
--f'-
I
RED
I
I
DASH L GHTS
BB GHTNESS
CONTFOLLER
BLK
I
oio,
G402
23-151
A/T Gear Position
Indicator
1 .
Indicator Input Test
Remove the gauge
assembl y from the dashboard (see
page
23 135), and di sconnect the 14p connector from rne gauge
assembl v.
Inspect the connector and socket termi nal s to be sure they are al l maki ng good
contact.
. l f the termi nal s are bent. l oose or corroded, repa i r them as necessary, and recheck the system.
. l f the termi nal s l ook OK, make the fol l owi ng i nput tests at the 14p connector.
-
l f a test i ndi cates a probl em,
fi nd and correct the cause, then recheck the system.
-
l f al l the i nput tests prove
OK, but the i ndi cator i s faul ty, repl ace the pri nted
ci rcui t board.
+1:
Not used
'2:
AIT
'3i
CVT
l{P CONNECTOR
"A"
REO
BLU 8RN
AI M A3 A4
A6
A8 A9 A10 A l l 412 A13 414
GRN
LT
BLK
GAUGE ASSEMBLY
23-152
Test condition
Test: Desired result
Possible cause it result is not obtained
Cavity
AI
YEL
(l l ) Check f or vol t age t o ground:
There shoul d be banerY vol t age.
.
Bl own No. 25
(7. 5
A) f use i n t he
under dash f use/ rel ay box
.
A2 RED/BLK
Combi nati on l i ght
swi tch ON and dash
l i ghts bri ghtness
control di al on ful l
bri ght
Check for vol tage between
RED/BLK and RED termi nal s:
There shoul d be batterY vol tage.
Bl own No. 30 {7.5
A) fuse i n the
under-dash tuse/rel ay box
Faul ty combi nati on l i ght swi tch
Faul ty dash l i ghts bri ghtness
control l er
An open i n t he wi r e
A3 RED
BLU Shi ft l ever i n
P
or
I
Check for conti nui ty to ground:
There shoul d be conti nui tY
NOTE: There shoul d be no
conti nui ty i n anY other
Posi ti on.
.
Faul ty A/T gear
Posi ti on
swi tch
.
An open i n the wi re
A10 GRN Shi ft l ever i n E or
E
A1 1
RED
Shi ft l ever i n
E
412
WHT Shi ft l ever i n
E
A13 BLK/BLU
Shi ft l ever i n
E
NOTE: Don' t depress
the brake pedal .
A9
YEL+
]
(l l )
and shi ft l ever i n any
posi ti on except Pi
Check for vol tage to ground:
There shoul d be battery vol tage for
two seconds after the i gni ti on
swi tch i s turned ON
(l l ),
and then
l ess than
' l
V.
Faul ty TCM*' , PCM*3
Faul ty PCM*r
GRN/err*'
l gni ti on swi tch ON {l l )
and shi ft l ever i n anY
posi ti on except E
A8 BLK
Under al l condi t i ons
Check for conti nui tv to ground:
There shoul d be conti nui tY.
.
Poor
ground (G401, G402)
.
414 LT GRN
( l l ) Check for vol tage to ground:
.
There shoul d be baftery vol tage*'
.
There shoul d be about 5 V*r
Faul ty TCM*' , ECM/PCM*'
Faul ty PCM*1
*2:
CVT
(' 96
-
98 model s)
*3r
CVT
(' 99
-
00 model sl
23-153
A/T Gear Position Switch Test
(see
secti on 2O).
2. Di sconnect the 14P connector from the A/T gear posi ti on
swi tch.
3. Check for conti nui ty between the termi nal s i n each swi tch posi ti on
accordi ng to the tabl e.
'
Move the shi ft l ever back and forth wi thout pushi ng
the shi ft l ever at each swi tch posi ti on,
and check for conti nui ty
wi thi n the range of free pl ay
of the shi ft l ever.
' l f there i s no conti nui ty wi thi n the range of free pl ay,
adj ust the posi ti on
of the swi tch as descri bed on the next
page.
+ 1 : With cruise controlsystem
23-154
Eack
-
up
Light Switch
Neutral
Position Switch
Repl acement
1 .
2.
7.
Remove the front consol e, then di sconnect the
connector from the A/f gear posi ti on swl tch
Remove the two mounti ng nuts
swrTcH
SLIDEB
MOUNT'NG NUTS
6 x 1 0 mm
98Nm( 10k gt m' 7l bl f t l
Posi t i on t he swi t ch sl i der t o
" Neut r al "
as shown
above.
Move the shi ft l ever to
"Neutral ",
then sl i p the swi tch
i nto posi ti on.
Aftach the swj tch wi th the two mounti ng nuts.
Test the swi tch i n the E
and E
posi ti on ofthe shi ft
l ever. The engi ne shoul d start when the shi ft l ever
i s i n posi ti on
fl
anywhere i n the range of free
pl ay
Connect the 14P connector, cl amp the harness, and
i nstal l the front consol e
14P
Adj ustment
1 .
3.
Shi ft to the E
posi ti on, and l oosen the nuts.
sl i de the swi tch i n the di recti on of El
or E
posi ti on
l wi thi n
2.0 mm
(0.079 i n.)l so that there i s conti nui ty
between the No. 1 and No 7 termi nal s i n the range
of free
pl ay of the shi ft l ever'
Recheck for conti nui ty between each of the termi -
nat s.
NOTE:
. l f adj ustment i s not
possi bl e, check for damage
t o t he shi f t l ever det ent and/ or t he br acket l f
there i s no damage. repl ace the consol e swi tch
. The engi ne shoul d start when the shi ft l ever i s i n
posi ti on
N
i n the range of free pl ay
E
position
A/ T GEAR
POSITION SWITCH
Dj r ect i on of
- on,
or Dl Posi t i on
lwithin
2.0 mm
(0.079 in)1
Fr ee pl ay
-lfr-
LOCK PI N
23-155
Integrated Control Unit
UNDER,DASH FUS/RELAY 8OX
IGNITION SWITCH
I
wNDSHTELD
I
I
wrPEtuwAsHEF
I
I swrTcH
I
i Y
**i,,*
I
wHT,tsLK
I
I
t_+
J
V
Circuit Diagram
INTEGRATED CONTROL UNIT
8LK
G40t
G402
WINOSHIELD WIPER/
WASHER S-W|iCI.]
,
OFF/INT INT
f7 Y7
I I
l l
t l
t t
BLU/BLK YEUELU
ELUMHT
I
I
WINDSHIELD
WI PEB
MOTOH
(As)
* 1 : Wilh mmbrned wiper washer operalion
*2 : 96-98 models
UNDES H@O FUSE/RELAY BOX
6
,8
-q
INTEEMITTENT
WIPER RELAY
CI RCUI T
"J
COMBI NEO
WIPER.WASHEN
ctncutT
WINOSHIELD
WASHER
MOTOR
23- 156
(A,4)
A,T GEAR
PosrfloN swlrcH _ _
(Closed h posilon
l?l
ot
[!l )
BLU/BLK
->
[h'#f-
|
COMEINATION
LIGHT SWITCH
V
I
REO/GRN
UNDEF.DASH FUSEi RELAY BOX
a
E
YEL
I
A
iEi,I,B"'T
vll".i,l
|
,rr.nrorro .orrro, ,*,,
t t -
t (
r f f i
| \
BEMI \ DEB crqcurl
l m
| / t I
t f f i
nEoTsru REDTBLU BLIJ/RED
clnculr
-
neoi eru
|
,,-,r.0
J
l,
"ulTo
/fP\ /Itr\
Y V
I onrveqs I
or rtor
l3fifl&''' l5frl'.'
l
(3'&T'
8iytr")
l
(3&Y
fiti'fJ"fl )
BLK BLK
T T
c552 G401
I
.
BRAKE FLUID
LEVEL SWITCH
.
PARKING ERAKE
swrTcH (usA)
'
CEILING LIGHT
.
KEYLESS RECE VER CIRCUIT
(ln lhe audio unil")
..aorr,rro
Y
A
Iu$ut,""'
I3fif'3#3trr,)
-::
DRIVER'S
DOOF
swtTcH
folosed
: Door open
)
(Open :Doordosed/
STARTER
CUT FELAY
a
-
GFNi RED
23-157
Input Test
and procedures
i n the SRS
secti on
{24) before performi ng repai rs or servi ce.
1. Remove the dri ver' s dashboard l ower cover and knee bol ster
(see
secti on 20),
2. Di sconnect the 10P connector from the i ntegrated control uni t.
3. Remove the i ntegrated control uni t from the under,dash fuse/rel ay box.
4. l nspect the connector and socket termi nal s to be sure they are al l makj ng good
contact.
. l f the termi nal s are bent, l oose or corroded, repai r them as necessary, and recheck the system.
. l f t het er mi nal sl ookOK, maket hef ol l owi ngi nput t est sat t heconnect or andt hef use/ r el ayboxsocket .
-
l f any test i ndi cates a probl em, fi nd and correct the cause, then recheck the system.
-
l f al l the i nput tests prove OK, the control uni t must be faul ty; repl ace i t.
I NTEGRATED CONTROL UNI T
l OP CONNECTOR
Wi re si de ot
23-158
All Systems:
Cavity Wire
Cavi ty Wi re
Intelmittent Wiper System:
Test condilion
Test condition
Test: Desired result Possible cause il rgsull is not obtained
Test: Desired result Possible cause if result is not obtained
Al 4 BLK
Under al l condi t i ons Check for conti nui ty to ground:
.
Poor ground
(G401,
G402)
.
A9
Under al l condi ti ons Check for vol tage to ground:
.
Bl own No. 43
(7.5
A) fuse i n the
under-hood fuse/rel ay box
.
A6
(l l )
Check for vol tage to
ground:
There shoul d be baftery vol tage.
.
Bl own No. 25
(7.5
A) fuse i n the
.
B1
82
BLU/BLK
and
BLU,^/VHT
( l l ) ,
and wi ndshi el d wi per
swi tch at OFF or INT
Check for conti nui ty between the
BLU/BLK and BLU/WHT termi nal s:
There shoul d be conti nuj ty.
Bl own No. 26 {20 A) fuse i n the
Faul ty wi ndshi el d wi per swi tch
Faul ty wi ndshi el d wi per motor
B3 YEUBLU
( l l ) ,
and wi ndshi el d wi per
swi tch at INT
ground:
Bl own No.26
(20
A) fuse i n the
Faul ty wi ndshi el d wi per swi tch
*A5
(l l )
Check tor vol tage to ground:
.
Bl own No.26
(20
A) fuse i n the
.
WHT/BLK
l gni ti on swi tch ON { l l ),
and wi ndshi el d washer
switch ON
ground:
.
Faul ty wi ndshi el d washer swi tch
.
*:
Wi t h combi ned wi per' washer operat l on
{ -
(cont' d)
Integrated Gontrol Unit
Input Test
(cont'dl
A 8 - - - - - - - - . - - a l l
Key-in/Seat Belt Rmindr, Lights-on Reminder Systom:
Cavity Wire Test condhion
Bulb Check System
(Brako
System Light):
Cavity Wire Test condilion
Tost: Dsirod rguh
T6st: Dosirad result
Possibls cause if rasuft b not obtainod
A8
swi tch ON
ground;
Bl own No. 30
( 7. 5
A) f use i n t he
B7 RED/BLU
(l l ),
and dri ver' s seat bel t
swi tch unbuckl ed
Poor ground (G552)
Faulty seat belt switch
B9 GRN
Dri ver' s door open Check for vol tage to ground:
.
Faul ty dri ver' s door swi tch
.
B l 0 BLU/RED
l gni ti on key i nserted
i nto the i gni ti on key
switch
Poor ground (G401.
G402)
Faul ty i gni ti on key swi tch
A4 GRN/RED
l gni ti on swi tch ON {l l ),
brake fl ui d reservoi r
ful l , and parki ng brake
tever oown
Connect to
ground: Brake system
l i ght shoul d come on.
Bl own No. 25
( 7. 5
Al f use i n t he
Bl own brake system l i ght bul b
A13 BLUA/1r'HT
l gni ti on swi tch at
START
(III)
Bl own No.31
(7.5
A) fuse i n the
Faul ty starter cut rel ay
23- 160
Lighting System
Component
Location Index
DAYTIME RUNNING LIGHTS
RESISTOR {Canada)
Test, page 23 167
DAYTIME RUNNING LIGHTS
CONTROL UNIT
(Canadal
I nput Test ,
Page
23 166
*HEADLIGHT
Adi ust ment ,
page 23-168
Repl acement ,
page 23-167
SIGNAL LIGHT
Repl acement ,
page 23 167
HIGH MOUNT BRAKE LIGHT
Repl acement ,
page 23-177
LICENSE PLATE LIGHTS
Repl acement , Page
23' 174
INNER TAILLIGHT
Repl acement ,
page 23- 169
OUTER TAILLIGHT
Repl acement ,
page 23 I 69
*:
Headl i ght and f ront parki ng/ f ront t urn si gnal l i ght cannot be separat ed.
(cont' d)
23-161
Lighting System
Gomponent Locati on Index
(cont' dl
TURN SI GNAL I NDI CATOR LI GHT
DASH LIGHTS BRIGHTNESS
CONTROLLER
Cont rol l er I nput Test ,
page 23-119
Test , page 23' 165
TURN SIGNAL/HAZARD RELAY
I nput Test , page 23-' 172
HI GH BEAM I NOI CATOR LI GHT
L ILI
LILI LT
rr Lr rJ|r LJ Lr Lr rr !.r rr Lr rr
I l
- nnr 1nr 1r 1r 1r 1| - 1nn L J J
r1 n11t'1n Ttr1 r1 - 11 t-1Tt-l T1
r-t L.l Lt r-t r-t LJ ! ! LJ LJ ! LJ !J r-l
23-162
Ci rcui t Di agram
(USA)
l | -
RED/ BLK
I
I
I
\?
PABK NG LIGHTS
TA LL GHTS
L CENSE PLATE L GHTS
RED/ELK
I
I
I
I
r'
DASH LIGHTS
DASH LIGHTS
ERI GHTNESS
CONTROLLER
HIGH BEAM
IND CATOR
LIGHT
(r 4w)
REDiGRN
I
BLK
I
G401
G4A2
UNDER,HOOD FUSEi NELAY 8OX
\
' - - - - - - - - . - r \ - - - - . ' r
-T
I "
T, , : i . .
T
o
UNDER DASH FUSE/RELAY 8OX
No 5
( 104)
No. 4
004)
No 30
(7.5A)
I
) N0. 32
A
{7.5A)
I
No 22
( r 0A)
A T
lilffl
(
I I
BLK
I
G201
8LK
I
:
G202
23-163
Lighting System
Ci rcui t Di agram
(Canada)
UNDER.HOOD FUSEi RELAY BOX
BATTERY
BFAKE SYSTEM
LIGHT
NTEGRATED
CONTROL UNIT
f-7
I
I
FED/GRN
REDi GFN
I
I
o
Yro*,
,,r' o
I
LEVEL SW TCH
t
|
lclosed
: Floal downl
BLK
I
-L
..
G401
G402
T
.:
BLK
n
:
G40l
G402
BLK
I
G201
RED/GRN RED/GBN
| .+_
t t L
| | las*,
| \_i-f
A l r
Y,o"
r.o"
I
liiqff'- |
BLK BLK
t l
d T
--
G401 G202
G402
l \ - - - - - - t r \ - 1
d, $, E"
T
d
RED/BLU RED/ REDiGEN
UNDEF DASH FUSE/RELAY BOX
I
)
)
N0.20
t l 0Al
) '
No. 1g
(7.5A)
No. 5
0
0A)
, l l - l
llltti /i[ii i
, I I
l l
llri,
zll",ll iu"x
T T
FEDi GRN RD
t l
!
-tl--l
ttuLj
il]-
YEL REDTWHT FED/BLU FED/8LK RED/ BLK
t t + +
I I V V
| |
. DASF
L. GHTS
. oAB( ^r G
- TGHTS
I I
. DA S - L GH' S . T A L L ' GCT S
| |
33''9+il4[','o
L.ENSEoLATELTG'TS
I l-,ro,u,rffl,
^ - ^ ^ - . * ^ , { * " ' " 0 -
t l
I
qsnl q, rr DAYT' ME
qUNNI NG
LIGHTS FES STOF
nd--f)
irt* | | Trt* Iorr I
t t I
---J \---J-------J
-rGHr
l t*"' ,'
I
I
YEL
/BLK
DAYTIME
RUNNING LIGHTS
CONTROL UNIT
RED/GHN R
I
5
[i.mi:-",,,
Combination Light Switch Test
1 . Remove the dri ver' s dashboard l ower cover and steeri ng col umn covers
(see
secti on 20)
Di sconnect the 4P and 7P connectors from the swi tch.
Inspect the connector and socket termi nal s to be sure they are al l maki ng good contact
. l f the termi nal s are bent, l oose. or corroded, repai r them as necessary, and recheck the system.
. l f thetermi nal s l ook OK, check for conti nui ty between them i neach swi tch posi ti on accordi ng tothetabl es l fthere
i s no conti nui ty between any of them. check for conti nui ty i n the swi tch harness
-
l f there i s conti nui ty i n the swi tch harness. repl ace the combi nati on l i ght swi tch
-
l f there i s no conti nui ty i n the swi tch harness, repl ace i t.
2.
4P CONNECTOR
7P CONNECTOR
HsadlighUDimmer/Passing Switch :
* : Canada
rrr r-l
l(rr mf I
tffi T
I
A3 A11l
Terminal
Position
B1 82 B3
* 8 4 B5 86
Headl i ght swi t ch
OFF
o-
--o
LOW
o-
--o
o--
---o
HIGH
o-
----o
o-
--o
Passing switch
OFF
ON o-
----o
Turn Signal Switch :
\
Temi nal
;',*;----__\
A 1 A2 A4
RIGHT o o
NEUTRAL
LEFT
o o
23- 165
Lighting System
Dayti me Runni ng Li ghts Control Uni t Input Test
(Canadal
2.
3.
L Remove t he dr i ver ' s dashboar d l ower cover and
knee bol ster
(see
secti on 20).
Di sconnect t he connect or s f r om t he dayt i me r un-
ni ng l i ghts control uni t.
Inspect the connector and socket termi nal s to be
sure they are al l maki ng good contact.
l f the termi nal s are bent, l oose or corroded. repai r
l f t he t er mi nal s l ook OK, make t he f ol l owi ng
i nput tests at the connector,
-
l f any test i ndi cates a probl em, fi nd and correct
the cause, then recheck the system.
-
l f al l the i nput tests
prove
OK, the control uni t
must be faul ty; repl ace i t.
Cavity Wire TGst condition Test: Desired result Possible cause it result is not obtained
BLK
U nderal l condi t i ons Check for conti nui ty to g.ound:
.
Poor ground (G401,
G402)
.
A2 BLK /VHT
Underal l condi t i ons Check for vol tage to ground:
Bl own No. 20
( 10
A) f use i n t he
et
YEUBLK
(l l )
Check for voi tage to ground:
Bl own No. 18 { 7. 5 A) f use i n t he
under-dash l use/rel ay box
Faul ty i gni ti on swi tch
A4 RED
swi tch i n
"
=D
"
posi -
UOn
Bl own No. 48
(30
A) tuse i n the
A1 WHT/RED
swi tch OFF; connect a
j umper
wi re between
the YEUBLK and
WHT/RED termi nal s,
then turn the i gni ti on
swi tch ON
(l l )
Headl i ght s
( hi gh
beam) shoul d
come on,
( and
hi gh beam
i ndi cat or shoul d come on).
.
Poor ground (G201,
G202, G40' 1,
G402)
.
Bl own bul bs
.
Faul ty dayti me runni ng l i ghts
resrstor
.
GRN/ RED
( l l ) ,
brake f l ui d reservoi r
f ul l , and parki ng brake
l ever down
Connect t o ground: The brake
syst em l i ght shoul d come on.
Bl own No. 25
( 7. 5
A) f use i n t he
under-dash f use/rel ay box
Bl own brake system l i ght
REDi GRN
Parki ng brake l ever Lrp Check f or cont i nui t y t o groundl
.
Faul ty parki ng brake swi tch
.
23-166
Headlights/Front Turn
Si gnal /Parki ng Li ghts
Dayti me Runni ng Li ghts Resi stor
Test
(Canada)
CAUTION: The daytime running lights resistor becomes
very hot when the daytime running lights are on; do not
touch i l or the attachi ng hardware i mmedi atel y after
the lights have been iurned off.
1. Di sconnect the 3P connector from the resi stor.
t er mi nal s
N4easure the resi stance between the resi stor termi
nal s
(No.
1 and No. 2) and the power termi nal No. 3.
Resistance: 1.6 O t 0.08 O
Repl ace the resi stor wi th a new one i f any of the
resi stances are beyond speci fi cati on.
I t -
Repl acement
CAUTION: Halogen headlights bcome very hot in use;
do not touch them or the attaching hardware immedi-
ately after they have been turned off.
1. Remove the front bumper
(see
secti on 20).
2. Remove the mounti ng bol ts,
3. Di sconnect each connector, then remove the head-
l i ghVfront turn si gnal /parki ng l i ght assembl y.
MOUNTING
EOLT
HEADLIGHT/FRONT TUFN SIGNAL/
PARKING LIGHT ASSEMBLY
HEADLIGHT: 60/55 W
FRONT TURN SIGNAL/PARKING LIGHT: 21l5 w
23-167
Headlights
Adjustment
Eoforo adiu3ting th h.adlights:
. Park the vehi cl e on l evel surface.
. Make sure the ti re
prgssures are correct.
a The dri ver or someone who wei ghs the same shoul d
sit in the driver's seat.
96
-
98 modols
1. Open the hood.
2. Check the hori zontal adj ustment i ndi cator.
The
" 0"
mar k on t he hor i zont al i ndi cat or
gear
shoul d be al i gned wi th the mark on the hori zontal
i ndi cator.
HORIZONTAL INDICATOR
Check the verti cal adj ustment i ndi cator. The bubbl e
shoul d be centered underneath the l ongest scri be
mark on the
gauge.
VERTICAL INDICATOR:
Headl i ght become very hot i n use; do not touch them
or any attachi ng hardware i mmedi atel y after they
have been turnsd off.
MARK
23-164
(Bubblol
l f ei ther i ndi cator i s not al i gned wi th i ts
"0"mark
as
descri bed l eft col umn, an adj ustment can be made
by usi ng a Phi l l i ps screwdri ver.
Adj ust the headl i ghts to l ocal requi rements by turn-
i ng the adj usters.
After headlight replacement, it may bs necessary to
readj ust the hori zontal i ndi cator
gear.
. Fi rst i nstal l the headl i oht, and adj ust i ts hori zon-
tal and verti cal ai mi ngs accordi ng to l ocal re-
qui rements.
. Then check that the arrow on the hori zontal i ndi -
cator
gear i s al i gned wi th the mark on the hori -
zontal i ndi cator.
-
l f t hey ar e not al i gned, r emove t he scr ew,
adi ust the i ndi cator
gear, and reti ghten the
screw.
NOTE: As the outer l enses are made ot an acryl i -
coated,
pol ycarbonated materi al , do not cover the
headl i ghts when they are turned on.
'99
-
00 models
1. Cl ean the outer l ens so that you can see the center
of the headl i ghts
(A).
l , -
2. Park the vehi cl e i n front of a wal l or a screen
(A).
A
4.
Open the hood.
Turn the hori zontal adj uster so that the arrow on
the hori zontal i ndi cator gear (A)
i s poi nti ng up.
7.5 m
(25
ft)
Headl i ghts
Adjustment
(cont'dl
Turn the l ow beams on.
Determi ne i f the headl i ghts are ai med properl y.
Vsrtical adiustmsnt:
Measure the hei ght of the headl i ghts
(A).
The l i ghts
shoul d refl ect 52 mm \2.1 i n.) bel ow
(B)
headl i ght
hei ght.
Horizontal adi$tment:
The wi dth of the refracti ng poi nts (C)
shoul d be the
same as the wi dth of the headl i ght central poi nts (D,
23-170
7. l f necessary, adj ust the headl i ghts to l ocal requi re-
ments by turni ng the hori zontal adj uster
(A)
and the
verti cal adj uster
(B).
After headlight replacement, it may be necessary to
readj ust the hori zontal i ndi cator gear.
. Fi rst i nstal l the headl i ght, and adj ust i ts hori zontal
and verti cal ai mi ngs accordi ng to l ocal requi re-
ments.
. Then check that the arrow on the hori zontal i ndi -
cator gear i s al i gned wi th the mark on the hori -
zontal i ndi cator,
-
lf they are not aligned, remove the screw, adjust
the indicator gear, and retighten the screw.
NOTE: As the outer l enses are made of an acryl i -
coated,
pol ycarbonated
materi al , do not cover the
headl i ghts when they are turned on.
Tai l l i ghts
Repl acement
(Except' 99
-
00 Sedanl
NOTE:
. Inspect the gasket; repl ace i t i l i t i s di storted or stays
compressed.
. After i nstal l i ng the tai l l i ghts, run water over them to
make sure they do not l eak.
Outer Tai l l i ghts
(' 96 -
00 model s, except' 99
-
00 Sedan):
1. Open t he t r unk l i d/ hat ch.
2. Di sconnect t he 4P or 6P connect or t r om t he out er
t ai l l i ght .
3. Remove t he f our mount i ng nut s, t hen pul l out t he
out er t ai l l i ght .
l -
Hatchback:
BRAKE/TAILLIGHT: 2115W
TURN SIGNAL LIGHT: 21 W
BACK-UP LIGHT: 21 W
4P or 6P CONNECTOR
BRAKEiTAILLIGHT: 2115 W
BACK-UP LIGHT: 21 W
Inner Tai l l i ghts
(Coupe' 96 -
00 model s/Sedan' 96
-
98
model s):
1. Open the trunk l i d, then remove the access panel .
2. Di sconnect the 4P connector from the i nner tai l l i ght.
3. Remove t he f our [ t hr ee]
mount i ng nut s, t hen pul l
out t he i nner t ai l l i ght .
I l : Sedan
Coupei
INNER TAILLIGHT
Sedan:
I NNER TAI LLI GHT
4P CONNECTOB
Tai l l i ghts
Replacement
('99
-
00 Sedanl
NOTE:
. Inspect the gasket; repl ace i t i f i t i s di storted or stays
compressed.
. After i nstal l i ng the tai l l i ghts, run water over them to
make sure they do not l eak.
Outer Taillights:
1. Open the trunk l i d/hatch.
2. Di sconnect the 4P and 2P connector trom the outer
tai l l i ght.
3. Remove the four mounti ng nuts, then pul l out the
outer tai l l i ght.
TAILLIG}fi
4P CONNECTOR
r * i
/ e t . /
23-172
Inner Taillights:
' 1.
Open the trunk l i d, then remove the access panel .
2. Di sconnect the 3P and 2P connector from the i nner
t ai l l i ght .
3. Remove the three mounti ng nuts, then
pul l out the
i nner t ai l l i ght .
[ ]: Sedan
BRAKE/TAILLIGHT: 2r15 W
BACK.UP LIGHT: 21 W
3P CONNECTOR
Turn SignallHazard
Flasher System
UNOER. DASH
FUSE/RELAY 80X
No. 12l 7 5A)
Gi rcui t Di agram
UNDER.HOOD FUSE/RELAY 8OX
I J
l*v
,'|,."J,- (NOt
GRN/YEL
t ,
I '
RED
I
I
I
I
I
J
DASH LJGIlTS
BRI GHTNESS
CONTROLLER
q
BLK
Turn SignallHazard Flasher System
1 .
Turn Signal/Hazard Relay Input Test
SRS component l ocati ons, precauti ons,
and procedures
i n the SRS secti on {24} before performi ng repai rs or ser-
vi ce.
Remove the turn si gnal /hazard rel ay from the under-
dash fuse/rel ay box.
Inspect the rel ay and fuse/rel ay box socket termi nal s
to be sure they are al l maki ng good contact.
. l f t he t er mi nal s ar e bent , l oos e or c or r oded,
repai r them as necessary, and recheck the system.
. l f t he t er mi nal s l ook OK, mak e t he f ol l owi ng
i nput tests at the fuse/rel ay box socket.
-
l f any test i ndi cates a probl em, fi nd and cor-
rect the cause, then recheck the system.
-
l f al l the i nput tests prove OK, the turn si gnal /
hazard rel ay must be faul ty; repl ace i t.
Test: Desired results
FUSE/RELAY
BOX
SOCKET
Possible cause it result is not obtained Cavity Test condi ti on
8Bffii
\ _
t - E
r l . ] l
|
-
l l
l \ n n ' r l
,.ff T-'
t:
Hazard warni ng swi t ch
ON; connect t he No. 1
t er mi nal t o t he No. 3
r er mt nat .
Hazar d l i ght s shoul d come on. Poor ground
\G201, G202, G401,
G402, Gs51, G552, G601, G761)
Faul ty hazard warni ng swi tch
( l l )
and
turn si gnal swi tch i n ri ght
or l eft; connect the No. 1
t er mi nal t o t he No. 3
t er mi nal .
Ri ght or l ef t t ur n si gnal l i ght s shoul d
come on.
.
Faul t y t urn si gnal swi t ch
2
.
Poor ground (G401,
G402)
.
3
(l l )
Connect for vol tage to ground:
Bl own No.
' 12
(7. 5
A) f use i n t he
under-dash f use/ rel ay box
Faul t y hazard warni ng swi t ch
Hazard warni ng swi t ch ON Connect for vol tage to ground:
Bl own No. 53
( 10
A) f use i n t he under -
hood f use/ rel ay box
Faul t y hazard warni ng swi t ch
23-174
Hazard Warning Switch Test
CAUTION: Be careful not to damage the hazard warn-
i ng swi tch or the center outl et
panel when pryi ng the
swi tch out.
' 96
-
98 model s:
' 1.
Pry the hazard warni ng swi tch out of the center out-
l et panel .
2. Di sconnect the
' l 0P
connector from the hazard warn-
i ng swi tch.
3. Check for conti nui ty between the termi nal s i n each
swi tch
posi ti on accordi ng to the tabl e
HAZARD
WARNING
l OP CONNECTOR
q-
Check for conti nui ty between the termi nal s i n
swi tch posi ti on accordi ng to the tabl e.
Ter mi nal No, 4 i s not used.
\
Termi nal
t** \
1 2 3 5 6 I 9 l 0
OFF
o
o
o
t !.1
o
ON
o
-o
o o
o
.o
o @
o
'99
-
00 models:
1. Remove the center
panel
l see secti on 20).
2. Remove the two screws, then remove the swi tch
from the center
Panel
scREws
HAZARD
WARNI NG
swlTcH
CENTER PANEL
.
License Plate Lights
Repl acement
'96
-
98 Sedan/Coupe:
L Remove the two screws from the l i cense pl ate l i ght,
and pul l the l i ght out pan ot the way.
2. Di sconnect the 2P connector trom the l i ght.
3. Take the l ens off, then repl ace the bul b.
Hatchback/'gg
-
00 Sedan:
1. Careful l y pry the l i cence pl ate l i ght out of the l i cense
pl ate tnm.
2. Di sconnect the 2P connector from the l i ght.
2P CONNECTOR
2P CONNECTOR
23-176
Back-up Li ghts
Ci rcui t Di agram
]GN TION
SWITCH
*HT/BLK +*HT*;L BLKTYEI -"--""\ -z-
I
fTil"liUiEEs,x','
YEURED
fr
l$*,'l
YEL
l^
.0.,. ,,
rb\ !'fi+l'
Y(ifi'frr-')
I
tcroseo'
n
rosrron El
GRNi BLK
q-,
UNOER HOOD FUSE/RELAY BOX
23- 177
Brake Lights
WNT/GRN
Ci rcui t Di agram
UNDEH HOOD
FUSEiRELAYBOX
BATTERY
/-l I
No s2 (1sA)
|
u/T'\--]-wHrGFNTwfciN_l
t v
HORN SYSTEM
I NNER
TAILL]GHT
GRNMHT
I
AE-'ii,t
Yut#l
I
BLK
ffi; I
I l,"l
I I''i
Li ;
GRN,4fiHT
l**,,,,
I P } BRAKE
Y
ilT'
I
I
I
I
gLK
I
I
:
flatchback
Coupe/Sedan
Sedan 99 mode
ffi; I
i $*i
i r i
Li*'']
GRNMHT
I
A b'rt^t-,
Yllf,ll
I
BLK
BLK
I
I
I
G601 r Halchback/Coupe/Sedan
BLK
I
I
I
I
I
G601 : Haldbackiooup/Sedan G761 :
G601 :
G602 :
+ 21W :Coup/Sedan
18W :Halchback
J I
: Wilh cruise control
23-178
Hi gh Mount Brake Li ght Repl acement
Hatchback:
1. Loos en t he t wo s c r ews , t hen r emov e t he hi gh
mount br ake l i ght . Be car ef ul not t o damage t he
hatch spoi l er.
2. Remove the bul b socket from the l i ght.
BULB SOCKET
l -
23-179
Coupe/sedan:
1. Remove the rear shel f
(see
secti on 20).
2 Remove t he t wo scr ews, t hen r emove t he hi gh
mount brake l i ght from the rear shel f.
HI GH MOUNT
BRAKE LIGHT
SCREWS
Dash Li ghts Bri ghtness
Control l er
UNDEF. DASH
FUSEi RELAY 8OX
|-;il;I
-l-*-Tl
I
I
REDi 8LK
cotvBiNATloN
LIGHT SW]TCH
Ci rcui t Di agram
,4.
wHT
-tlf-
RED/GBN
UNDEF HOOD FUSE/RELAY BOX
23-180
G401
G402
Control l er
Input test
NOTEr The control uni t i s bui l t i nto the dash l i ghts bri ght-
ness control l er.
' 1.
Careful l y pry the control l er out of the dashboard.
2. Di sconnect the 3P connector from the control l er'
3. Inspect the connector termi nal s to be sure they are
al l maki ng good cont act .
. l f the termi nal s are bent, l oose, or corroded, repai r
. l f the termi nal s l ook OK, make the fol l owi ng i nput
tests at the connector.
-
l f any test i ndi cates a probl em, fi nd and cor-
rect the cause, then recheck the system.
-
l f al l the i nput tests prove OK, the control l er
must be faul ty; repl ace i t
Cavity
Wi re si de of
l emal e t erml nal s
Test condition
Test Desited results Possible cause if rgsult is not obtainGd
1 RE D/B LK
Combi nat i on l i ght
swi t ch ON
There shoul d be bat t ery vol t age.
Bl own No.30
(7.5 A) fuse i n the
under-dash Iuse/rel ay box
2 BLK
.
Poor
gr ound
( G401,
G402)
.
RED
swi t ch ON
Connect to ground:
Dash Ii ghts shoul d come on ful l
bri ght.
.
23-181
lnterior Lights
SPOTLIGHTS
Test , page 23' 184
CEI LI NG LI GHT
Test , page 23-183
FRONT PASSENGER'S
DOOR SWITCH
DRIVER'S DOOR
RIGHT REAR DOOR SWITCH
TRUNK LIGHT
lcoupe/Sedan)
Test , page 23-184
TRUNK LATCH
{Coupe/Sedan)
HATCH BACK LATCH SWTTCH
lHatch bec(l
LEFT REAR DOOR SWITCH
23-1A2
Ci rcui t Di agram
(Wi thout
Spotl i ghtsl
BLUi BLK
I
I
l , **
I
l3g"
|
,J.,
ll
I
SLUl BLK
A
Jiuir,
l[3Fff'
Iflri:B::, ]
BLK
I
G601. G76l Halchback
G601 CoupeiSedan
3.4W . USA . Canada
ProdLrced
5W W lhoui moonrool
q -
LT GRN/ RED LT GRN/ RED
A A
Y;'.'; Y,"^t'
13fi?s" 13fi?'1"
|
3;::" B::::r".
1,3,;;:'
8::':tl"l
. L l
GRNi RED
DOOR
SWTCH
FRONT
PASSENGERS
folosed
: Door open
)
(Open
'
Door cosed -l
UNDEF HOOD FUSE]FELAY BOX
ON \
OFF
| l Fr +
|
-r--
l:'iil:
LT GFN/REO
23-183
Interi or Li ghts
Ci rcui t Di agram
(Wi th
Spotl i ghts)
SPOT.
LGHTS
2
LT GRNlRED
t_:kr
(Wilh key ess enlry syslem)
t-t
-
,
LTGRN/ BLK
KEYLESS RECEIVER
CI BCUI T
(ln the aLid o unil)
A
Y""
I
REAR
I
DooF
t;:x::
| |
333i"
GBN L
A
Ttp;:'
Itsl";g;" I
I3331."..,J
:
FFONT
PASSENGERS
DOOR
SWITCH
ictoseo
:
'l
I
Door open
I
Open :
L
Door closed
_J
x I 3. 4W : t i SA, Canada pr oduced
5W Japan produced
*2 8w W lh moofroot
5W Wl ho! l moonr oof
23-144
UNDEB HOOD FUSEi RELAY BOX
LTGRN/RED
WHT/RED WHT/RED
r * r
I T 1,,'-1
' F !
I
I
8LU/8LK
I
I
|
*ttt-
|
,Y.
I
BLUlBLK
A
Yiri'n
It3f.r'+m:r:r,l
BLK
{
G601 G761 rHalchbac(
G601 Coupe/Sedan
LTGRN/ RED
Ceiling Light Test
1. Turn the l i ght swi tch OFF
2. Pry off the l ens.
3. Remove the two mounti ng nuts
(or
a bol t) from the
housi ng, then remove the housi ng.
4. Di sconnect the connector{s) from the housi ng.
With moonroof:
3P CONNECTOR
\
rermrnal
Position \
1
2
or
2'
3
or
3'
OFF o-
/a\
- o
\7
MIDDLE o-
,.\ --o
\:/
ON o-
--o
\:/
23- 185
q,
Without moonroot:
Coupe/Hatchback:
BULB
(5
WI
/
2'
4
1
3
Interior Lights
Spotlights Test
1. Turn the spotl i ght swi tch OFF.
2. Pry off the l ens.
3. Remove the two screws and the housi ng.
4. Di sconnect the 1P connector from the housi ng.
\
Terminal
t*'*-__\
2 3 4
OFF
o-{
e,
//:\
--o
--o
\:,/
ON
o-
-*i
@
/a\
-_o
--o
\:.,/
23- 186
Trunk Light Test
1. Open the trunk l i ght cover from the housi ng.
2. Pry out the l i ght assembl y.
3. Di sconnect the 2P connector from the housi ng,
4. Make sure that the bul b i s OK. Check for conti nui ty
between the No. 1
(+)
and No.2
(-)
termi nal s.
EULB {. ' )
*1
3.4 W: USA, Canada-oroduced
5 W: Japan-produced
Stereo Sound System
Component
Locati on Index
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons,
precauti ons. and procedures i n the SRS
secti on
(24)
before
'96
-
98 models
AUDI O UNI T
(STEFEO
RADIO TUNERI
Termi nal s, page 23-190
ANTENNA MAST
Repl acement ,
page 23 193
RIGHT TWEETER
Repl acement , Page
23 191
LEFT TWEETER
Repl acement, Page
23 191
ANTENNA
LEAD
LEFT FRONT SPEAKER
Repl acement , Page
23' 191
SUB
RIGHT FRONT SPEAKER
Repl acement ,
page 23' 191
ANTENNA
LEAD
CASSETTE PLAYER
Repl acement , Page
23-189
REAR SPEAKERS
Repl acement ,
page 23- 19' l
(cont' d)
23-147
q-
Stereo Sound System
{cont'd)
SRS components are l ocated l n thi s area. Revi ew the SRS component l ocati ons, precauti ons,
and orocedures i n the sRS
secti on
(24)
before perl ormi ng
repai rs or servi ce.
'99
-
00 models
AUDIO UNIT
Fepl acement , page
23-189
Termi nal s, page 23-190
ANTENNA MAST (Coupe/Hatchbeck)
Repl acement , page 23, 193
RIGHT TWEETER
Repl acement , p6ge
23-191
LEFT TWEETER
Repl acement , page
23-191
ANTENNA LEAD
LEFT FRONT
Repl acement , page 23- 191
RIGHT FRONT SPEAKER
Repl acernent , page
23-191
WINDOW ANTENNA
{Sedanl
Wi re Test , page 23 192
Wi re Repai r, page 23-192
SUB
I.TAO
REAR SPEAKERS
Repl acemont , page
23-191
23-1AA
UNDER DASH
FUSE/RELAY 80X
r*.i,,";l
I
I
I
I
I
I
I
YEUFED WHTiELU
Ci rcui t Di agram
(' 96
-
98 model sl
A15 A16
NoJ0 (7 sA)
v
I
RED] BLK
RED
I
I
I
J
DASH LIGHTS
BRI GHTNESS
CONTROLLER
ANTENNA
LEAD
BRN/WHT
BLK
G501
LEFT FHONT
DOOF SPEAKER
I
RED,^/Er
I L
I l
RIGHT REAR
SPEAKER
I
BLU/YEL
I I
I t
SPEAKER
q-
IGN TION SWITCH
UNDER.HOOD FUSE/FELAY BOX
AUDI O UN T
(STEREO RAOLO TUNER)
@
LEFT
RIGHT
TWEETER
GRY]BLK
23- 189
Stereo Sound System
UNDER-DASI.]
FUSEi RELAY 8OX
l-
'-r,*;l
I
I
I
I
I
I
I
YEUFED
(Sedan)
--l
(Coupe/Horchbach)
Ci rcui t Di agram
(' 99
-
00 model s)
No 30 (7.54)
FUSE
V
I
RED/BLK
I
I
I
v
DASH LGHTS
BHIGHTNESS
CONTROLLER
F;*";
,,,[.J:, a*[rrl
BLK
G501
/
_-\
| neolcn
;diFnoNi
| |
DooR SPEAKEF
| |
Hl GHT
TWEETER
RIGHT REAF
SPEAKEB
LEFT REAR
SPEAKEF
LEFT
TWEETER
23- 190
Removal
Stereo Radi o Tuner
(' 96 -
98 model sl :
3.
1 .
2.
Remove the center dashboard l ower cover
(see
sec-
t i on 20) .
Remove the two mounti ng bol ts, and pul l the stereo
radao tuner out.
Di sconnect t he 16P connect or s, sub ant enna l ead
and DIN cord
(wi th
cassette pl ayerl , then remove
the stereo radi o tuner.
16P CONNECTORS
1 .
2.
Cassette Player
('96 -
98 modelsl:
Remove the front consol e panel (see
secti on 20).
Remove the DIN cord from the stereo radi o tuner.
Remove the four mounti ng bol ts, then remove the
cassette
pl ayer.
Stereo Radio/Cassette Player
('99 -
00 modelsl:
1. Make sur e you have t he ant i - t hef t code f or t he
radi o' s oreset but t ons.
Remove the center panel (see
secti on 20).
Remove the four mounti ng screws, and di sconnect
the 20P connector and antenna l ead, then remove
the stereo radi o/cassette pl ayer.
2.
3.
MOUNTING BOLTS
scREws
customer' s radi o stati on
Presets.
23-191
Stereo Sound System
Stereo Radi o Tuner Termi nal s
'96
-
98 models:
For keyless entry
. t6p coNNEcroR
(and
securrt y) sysl em
To DIN CORD
To DIN CORD
(f or
securi t y
syst em)
Cavity Wire
A1 RED/GRN
Ri ght front door speaker o,
ri ght tweeter @
BLU
Left front door speaker @,
left tweeter @
A3 RE D/B LK Li ght s-on si gnal
A4 WHT/BLU
Constant power (tuni ng
memoryl
A5 YEL/RED
ACC
(mai n
stereo power
suppr y)
A7 BLUI/EL Left rear speaker O
A8 RE DI/E L Ri ght rear speaker O
A9 BRN/BLK
Ri ght front door speaker O,
ri ght tweeter o
A10 GRY/BLK
Left tront door speaker O,
left tweeter O
412 RED
Dash l i ghts bri ghtness
cont r ol l er
A14 BLK Gr ound
( G501)
415 GRYMHT Left rear speaker O
Al 6 BR N/VVHT Ri ght rear speaker O
Ter mi nal s A6, A11 and A13: Not used
23-192
'99
-
00 models:
Csvity Connccts to Wire
2 YEL/RED
ACC
(mai n
stereo power
suppry)
5 RE DI/E L Ri ght rear speaker @
BLUI/EL Left rear speaker @
7 RED/GRN
Ri ght front door speaker @,
ri ght tweeter @
8 BLU
Left front door speaker @,
left tweeter @
9 RED/BLK Li ghts-on si gnal
1 0 WHT/BLU
Constant
power (tuni ng
memory)
1 5 BRN,ryVHT Ri ght rear speaker O
GRYMHT Left rear speaker O
1 7 BRN/BLK
Ri ght front door speaker O,
ri ght tweeter O
18 G RY/BLK
Left front door speaker O,
left tweeter O
' 19
RED
Dash l i ghts bri ghtness
control l er
20 BLK ur ouno t ( l 5u t ,
Ter mi nal s No. 1, 3, 4, 11, 12, 13, and 14: Not used
Speaker Replacement
Front speaker:
1. Remove the speaker cover.
2. Remove the three screws from the speaker.
3. Di sconnect the 2P connector, and remove the door
speaker.
Tweeter:
1. Remove the door panel
(see
secti on 20).
2. Di sconnect the 2P connector from the tweeter.
3. Remove the mi rror garni sh.
4, Remove the two screws, then remove the wveeter.
FRONT SPEAKER
TWEETER
( } -
23- 193
Rear speaker:
1. Remove the rear si de shel f or rear shel f
(see
secti on
20t.
2. Di sconnect the 2P connector from the speaker.
3. Remove the four screws, then remove the speaker.
Hatchback:
Coupe/Sedan:
2P CONNECTOF
2P CONNECTOR
REAR
Stereo Sound System
Window Antenna Wire Test
1. Wr ap al umi num f oi l ar ound t he t i p of t he t est er
probe as shown.
Touch one tester orobe to the wi ndow antenna ter-
mi nal near, and move the other tester probe al ong
the antenna wi res to check that conti nui ty exi sts.
WINDOW ANTENNA
23-194
OPEN
Wi ndow Antenna Wi re Repai r
NOTE: To make an effecti ve repai r, the broken secti on
must be no l onger than one i nch.
1. Li ghtl y rub the area around the broken secti on wi th
fi ne steel wool , then cl ean i t wi th al cohol .
2. Careful l y mask above and bel ow the broken porti on
of the wi ndow antenna wi re wi th cel l ophane tape.
CELLOPHANE
TAPE
Usi ng a smal l brush, appl y a heavy coat of si l ver
conduct i ve pai nt ext endi ng about 1/ 8" on bot h
si des of the break, Al l ow 30 mi nutes to dry.
NOTE| Thoroughl y mi x the pai nt betore use.
Check for conti nui ty i n the repai red wi re.
Appl y a second coat of pai nt i n the same way. Let i t
dry three hours before removi ng the tape.
Wi ndow Antenna Coi l Test
2.
1 .
wtNoow
ANTENNA
cotL
Remove t he rear shel f
(see
sect i on 20).
Di sconnect t he 2P and l P connect or s f r om t he wi n-
dow ant enna coi l .
1P CONNECTOB
2P
-l
CONNECTOR
3. Check for conti nui ty between termi nal A1 and body
gr ound and bet ween t er mi nal s 41 and 81.
l f there i s no conti nui ty at ei ther check, repl ace the
wi ndow ant enna coi l .
l q
8 1
1 l
t f - - l
l L B 2 l l
lL-,--rl
23- 195
Mast Antenna Repl acement
1 .
2.
Di sconnect the connector between the antenna l ead
and sub ant enna l ead.
Remove the two mounti ng screws, then remove the
mast ant enna.
MAST ANTENNA
MOUNTING SCREWS
Horn
SRS components are l ocated i n thi s area. Revi ew the SRS component l ocati ons, precauti ons, and procedures i n the SRS
secti on
(24)
CABLE REEL
Repl acement , sect i on 24
(:-,
,,/ t
. \
(6\'
\K2
HORN RELAY:
'98
-
00 models-
l Wi re
col orsr WHT/ GRN, cBY, l
IWHT/GRN,
BLU/RED
]
Test, page 23 87
HORN RELAY:
'96
-97
models-
lwire colors: WHT/GRN. GBY,I
IWHT/GRN,
BLU/RED
I
Test, page 23-86
UNDER-DASH FUSE/RELAY BOX
23-196
Ci rcui t Di agram:
' 96
-
97 model s
HORN
RELAY
WHT/GRN
I
( H ) H o R N
Y
I
BLU/REO
I
I
I
Bt K
I
t
-l
G40l
G1A2
BATTERY
l -
23-197
Horn Test:
'96
-
97 models
1. Remove the front bumper
(see
secti on 20).
2. Di sconnect the 2P connector from the horn.
Remove the horn.
Test the horn by connecti ng battery
power to one
termi nal and groundi ng the other, l f the horn fai l s to
sound, repl ace i t.
3.
LOW HORN
Hor n
Ci rcui t Di agram:
' 98
-
00 model s
HCRI]
t Et A' a
BATTEFY
1
'98
model: WHT/GRN
'99
-
00 modelsr BLU/RED
23494
Horn Test:
' 98
-
00 model s
' 1.
Remove the f.ont bumper
(see
secti on 20).
2. Di sconnect t he 1P connect or f r om t he hor n.
TERMI NAL
Test t he hor n by connect i ng
t er mi na I and gr oundi ng t he
hor n f ai l s t o sound, r epl ace i t .
bat t ery power t o t he
mou nt i ng bol t . l f t he
Switch Test
l Make sur e you have t he ant i - t hef t code f or t he
r adi o, t hen wr i t e down t he f r equenc i es f or t he
radi o' s preset buttons
(' 99
-
00 model s).
Disconnect the battery negative cable, then disconnect
the posi ti ve cabl e, and wai t at l east three mi nutes.
Di sconnect the dri ver' s ai rbag connector
(see
sec-
t i on 24) .
Remove t he dr i ver ' s dashboar d l ower cover
( see
secti on 20).
Di sconnect the cabl e reel sub-harness 3P connector
from the mai n wi re harness.
2.
3.
4.
5.
1 .
MAIN WIRE
HARNESS
3P CONNECTOR
SUB-HABNESS
3P CONNECTOR
REEL
6.
Termi nal si de ol
mal e t ermi nal s
Check for conti nui ty between the No. 2 termi nal of
the cabl e reel sub-harness and body
ground wi th
the horn swi tch
pressed.
a l f there i s conti nui ty, the horn swi tch i s OK.
l f there i s no conti nui ty,
go to step 6
l -
- \
1.
8.
10.
' I
1.
9.
Remove the dri ver' s ai rbag assembl y
(see
secti on
24), then di sconnect the horn connector from the
steeri ng wheel .
Check for conti nui ty between the No. 2 termi nal of
the cabl e reel sub-harness 3P connector and horn
posi ti ve termi nal .
l f there i s no conti nui ty, repl ace the cabl e reel
(see
secti on 24).
l f there i s conti nui ty, repai r or repl ace the horn
swtl cn,
l f al l t est s
pr ove OK, r ei nst al l t he dr i ver ' s ai r bag
assembl y
(see
secti on 24), and reconnect the cabl e
reel sub-harness connector.
Reconnect the dri ver' s ai rbag connector, and rei n-
stal l the access panel on the steeri ng wheel .
Reconnect the battery positive cable, then the negative
termtnar.
After i nstal l i ng the ai rbag assembl y, confi rm proper
system operati on:
12.
(l l );
t he SRS i ndi ca-
t or l i ght shoul d come on f or about si x seconds
and t hen go of f .
Make sure bot h horn but t ons work.
13. Enter the anti -theft code for the radi o, then enter the
00 model s).
HORN CONNECTOR
23- 199
Rear Window Defogger
Gomponent Location Index
36
-
98 modols:
UNDER.DASH FUSE/RELAY BOX
REAR WINDOW DEFOGGER SWITCH
I nput Test , page
23-203
REAR WINOOW DEFOGGER
RELAY
Test, page 23-86
REAR WINOOW OEFOGGER
Funct i on Test , page 23' 202
Defogger Wire Repair. page 23 202
23-200
'99
-
00 models:
UNDER.OASH FUSE/RELAY BOX
(Bui l t
i nt o cl i mat e cont rol uni t )
Test, page 23-86
ANTENNA COIL
(Sedsn)
f
l _ f =
L'
' ' r of i a
t r F. - l j
l -
I est ,
page l r - l v. t
23-201
Ci rcui t Di agram
36
-
98 models:
IGNITION
swtTcH
/ BAT \
+
ots't
\:7
|
I
I
I
YE
WHT/BLK +WHT
wtNDow
BLKBLU
I
t - l
t - l
T
BLK
UNOEF,HOOD FUSE/RELAY BOX
N0.41 (e,oA) No a2 (aoA)
G40l
G402
G601 : Coupe/Sedan
G77t :Nalchback
23-202
' 99
-
00 model s
I GNI TON
SWTCH
-fO
Ctsr
\j7
|
I
I
WHT/BLK +WHT
HEATER
PUSH
swtTcH
BLK
G40l
G402
BLK
G401
G402
UNDER HOOD FUSEi RELAY BOX
No 4r (80A) No 42 (40A)
8
CLIMATE CONTROL
UNIT
/
Rar window deloggt
\
I
I mer orcLril blill nlo
J
\climale conlro unil /
I
{/\A-4<-I
NDICATOS
(LE0)
I
I
<t-o-r
REAF WINDOW
DEFOGGEB
swtTcH
7 1 6
,ll
23-203
l -
Function Test
CAUTION: Bs careful nol to scralch or damage the defog-
ger wires with the tester probe,
' 1.
Check for vol tage between the posi ti ve
termi nal and
body ground wi th the i gni ti on swi tch and defogger
swi tch ON.
There shoul d be banery vol tage.
. l f there i s no vol tage, check for:
-
faul ty defogger rel ay.
-
faul ty defogger swi tch.
an ooen i n the BLK,/BLU wi re.
. l f there i s battery vol tage, go to step 2.
POSITIVE TERMINAL
2. Check for conti nui ty between the negati ve termi nal
and body ground.
l f there i s no conti nui ty, check for an open i n the
defogger ground wi re.
Touch the vol tmeter posi ti ve probe to the hal fway
poi nt of each defogger wi re, and the negati ve probe
to the negati ve termi nal .
There shoul d be approxi matel y 6 V wi th the i gni ti on
swi tch and the defogger swi tch ON.
. l f the vol tage i s as speci fi ed. the defogger wi re i s
oK.
. l f thevol tage i s not as speci fi ed, repai rthe defog-
ger wrre.
-
l f i t i s more than 6 V, there i s
negati ve hal f of the wi re.
-
l f i t i s l ess t han 6 V, t her e i s
posi ti ve hal f of the wi re.
a break i n the
a br eak i n t he
23-204
OPEN
?
Defogger Wi re Repai r
NOTE: To make an effecti ve repai r, the broken secti on
must be no l onger than one i nch.
1, Li ghtl y rub the area around the broken secti on wi th
fi ne steel wool , then cl ean i t wi th al cohol .
2. Careful l y mask above and bel ow the broken porti on
of the defogger wi re wi th cel l ophane tape.
CELLOPHANE
TAPE
Usi ng a smal l brush, appl y a heavy coat of si l ver
conduct i ve pai nt ext endi ng about 1/ 8" on bot h
si des of the break. Al l ow 30 mi nutes to dry.
NOTE: Thoroughl y mi x the pai nt before use.
Check for conti nui ty i n the repai red wi re.
Appl y a second coat of pai nt i n the same way. Let i t
dry three hours before removi ng the tape.
Switch Input Test
CAUTION: Be careful not to damagc the rear window
defogger switch or the center
panel when
prying the
switch out.
NOTE: Before testi ng, check for bl own No. 16
(7.5
A)
fuse i n the under-dash fuse/rel ay box,
1. Pry the switch out of the center
panel (see
section 20).
2. Di sconnect the 5P connector from the swi tch.
3. Turn the
j gni ti on
swi tch ON
(l l ),
and check the vol tage
between the BLVBLU {+) and the BLK
(-)termi nal s.
There shoul d be battery vol tage
. l f there i s no vol tage, check for an open i n the
BLVBLU wi re.
. l fthere i s baftery vol tage, go to step 4.
Wi re si de of famal e termi nal s
connect a
j umper wi re between the BLK/BLU and
the BLU/YEL termi nal s.
(l l ),
and check that the
rear wi ndow defogger works; i f i t does. repl ace the
defogger swi tch.
4.
RED
l -
23-205
Power Mi rrors
Powel Mi rror
Funct i on Test , page 23-2Oj
Power Mi rror Test , page 23-210
Act uat or Repl acement , page 23-2' 10
POWEB MIEROR SwlTCH
Test, page 23-209
23-206
Circuit
Diagram
(Without Defogger)
UNDER.HOOD
FUSE]FELAY BOX
eo;T
f-*---;' ,;r
j -_l
6\
OF+-*' .v-f
r' --;.' -"j -' a,_cy'
GN TION
SWI TCH
UNDER DASH
FUSEIRELAY
BOX
BLK]YEL
) I dRGHT
LEFTd
I
dFl GHr
' f -
- - - - - \ ,
T T
I
I
.t.
o l o
G551
23-207
( } -
Power Mirrors
UNDER.OASH
FUSE/FELAY BOX
Circuit Diagram
{With
Defogger)
BLK
G551
8LK
I
G551
YEURED
BLUMHT
8LK
I
I
-f,
:
G551
23-208
UNDER-HOOD FUSE/RELAY BOX
/ l r , - - - - - - - - - -
- - - z l r
I '
BLUELK
l '
YEUBEO
6
ORN/WHT
Function
Test
CAUTION: Be careful not to damage the mirror switch
or the dashboard drivel's lower covel when
prying the
swhch out.
Withoui defogger:
1. Pry the swi tch out of the dri ver' s dashboard l ower
cover.
lOP CONNECTOR
BLU/WHT
YEL/ RED
BLK/YEL BLK
4
5 6 8
YEL/ BLK
POWER MIRROR
swtTcH
\:/"*jgil*-(
Wi r e si de of f emal e t er manal s
Mirror Test
Both inoperative:
1. check for vol tage between the No. 2
(BLVYEL) ter
mi nal and body ground wi th the i gni ti on swi tch ON
0 r).
There shoul d be batterY vol tage
. If there i s no vol tage, check for:
-
bl own No. 17
(7
5 A) fuse i n the under-dash
tuse/rel ay box
-
an open i n the BLK' /YEL wi re.
o l f there i s battery vol tage,
go to step 2.
2. Check for conti nui ty between the No 4
(BLK)
termi -
nal and body
ground.
. l f there i s no conti nui ty, check for:
-
an open i n the BLK wi re.
-
poor gr ound
( G551) .
Left mirror inoporalive:
connect the No. 2 {BLK/YEL)
termi nal of the 10P connec-
tor to the No. 3
(YEURED) termi nal and the No 5
(or
No
6) termi nal to body ground wi th
j umper wi res The l eft
mi rror shoul d ti l t down
(or
swi ng l eft) when the i gni ti on
(l l )
. l f the mi rror does not ti l t down
(or
does not swi ng l eft),
remove the l eft door
panel . and check for an open i n
t he BLU/ WHT
( or
BLU/ BLK) wi r e bet ween t he l ef t
power mi rror and the swi tch
-
l f the wi re i s OK. check the l eft power mi rror actua-
tor.
l f the mi rror nei ther ti l ts down nor swi ngs l eft. repai r
the YEURED wi re.
l f the mi rror operates
properl y, check the mi rror swi tch'
Right mirror inoperative:
Connect the No. 2
(BLK /EL) termi nal of the 10P connector
to the No. 3
(YEURED) termi nal and the No. 9
(or
No 8)
termi nal to body
ground wi th
j umper wi res The ri ght mi r-
r or shoul d t i l t down
( or
swi ng l ef t ) when t he i gni t i on
(l l ).
(or
does not swl ng
l eft), remove the ri ght door panel . and check for an
open i n the GRN/WHT
(or
YEUBLK) wi re between the
ri ght
power mi rror and the swi tch.
-
l f the wi re i s OK, check the ri ght
power marror actu-
ator.
. l f the mi rror nei ther ti l ts down nor swi ngs l eft. repai r
the YEURED wi re
. l f t he mi r r or oper at es
pr oper l y, check t he mi r r or
switch.
(cont' d)
23-209
Power Mirrors
Funstion Test
(cont'dl
With dcfoggcr:
1. Pry the swi tch out ot the dri ver' s dashboard l ower
cover.
2. Disconnect the 10P coonector from the oower mir-
ror switch.
Mirror Test
Bolh inoparrtiv.:
1. Check for vol tage between the No. 1 termi nal and
body ground
wi th the i gni ti on swi tch ON fl t).
. lf there is no battery voltage, check to.:
-
bl own No. 16
(7.5
A) fuse i n the under-dash
tuse/relay box.
-
an open i n the BLVBLU wrre.
! lf thero is banery voltage, go
to step 2.
2. Check for conti nui ty btween the No. 2 termi nal and
body ground.
There shoul d be conti nui tv.
. l l there i s no conti nui ty, check tor:
-
an open i n the BLK wi re.
-
poor ground (G5511.
. l Jthere i s conti nui ty. check both mi rrors i ndi vi du-
al l y 8s descri bed i n the next col umn,
23-210
Laft mirror inopcrativ!:
Connect the No. 1 termi nal to the No. 7 termi nal . and the
No. 4
(or
Nb.9) termi nal to body ground
wi th
j umper
wi res. The l eft mi rror shoul d ti l t down (or
swi ng l eft)
wi th the i gni ti on swi tch ON
(l l ).
(o.
does not swi ng
l ett), check for an open i n the YEURED
(or
BLUMHT)
wi re between the l eft mi rror and the 10p connector. l f
the wi re i s OK, check the l eft mi rror actuator.
a l f the mi rror nei ther ti l ts down nor swi ngs l eft, repai r
the BLU/BLK wi re.
t l f the mi rror works properl y,
check the mi rror swi tch.
Right mi.ror inopcrativc:
Connect the No. 1 termi nal to the No. 8 termi nal , and the
No.4
(or
No. 10) termi nal to body ground wi th
l ' umper
wi .es. The ri ght mi rror shoul d ti l t down
(or
swi ng l ett)
(l l ).
. l f the mi rror does not ti l t down {or does not swi ng
l eft), check for an open i n the YEURED
{or YEUBLK)
wi re between the ri ght mi rror and the l 0P connector.
l f the wi re i s OK, check the ri ght mi rror actuator,
. l f the mi rror nei ther ti l ts down nor swi ngs l eft, repai r
the GRN/WHT wi re.
o l f the mi rror works properl y.
check the mi rro. swi tch,
Dafoggcr inoperEtivo:
1. Check for vol tage between the No. 3 termi nal and
body ground
(| | ).
There should be battery voltage.
a lf there is no battery voltage, check for;
-
bl own No. 16
(7.5
A) l use i n the under-dash
fuse/rel8y box,
-
An open i n the BLK,i BLU wi re.
. It there is battery voltage, go
to step 2.
2. Connsct the No. 3 tsrmi nal to the No. 6 termi nal
wi th a
i umpsr
wi re. Both mi rrors shoul d gradual l y
warm up when the i gni ti on swi tch ON fl t).
a
l f nei ther mi rror warms up, check for an open i n
the ORN/WHT wire.
.
It only on lails to warm up, check its mirror
dsfogger elem6nt.
.
lf both mirrors warm up, check ths switch.
I
r
Switch
Test
Without detoggr:
1. Remove the swi tch as dsscri bed i n Functi on Test
(see page 23-207).
2. Check for conti nui ty betwen the termi nal s i n each
swi tch
Mirror Switch:
POWER
MIRROB
swlTcH
\
Terminal
rL*"--_\
2 3 4 5 6
n
9
L
UP
-o
o-
DOWN
o-
-o
o-
-o
LEFT o- o-
-o
RIGHT
o-
-o
o-
-o
UP
o-
-o
o-
-o
DOWN o-
-o
o-
-o
LEFI o-
-o
o-
-o
RIGHT
-o
o-
-o
l -
23-211
1. Prv the switch out of the dashboard driver's lower
With defogger:
POWER MIRROR
swtTcH
Disconnect the 1OP connector from the switch'
switch
position according to the table
Mirror Switch:
\ Terminal
Position \
l 2 7 8 9
' t0
L
UP
o-
o-
-o
-o
DOWN
o-
o-
-o
-a
o-
o-
-o
--o
RI GHT
o-
-o
o-
-O
UP
G
o-
-o
-o
DOWN
o-
-o
G-
-o
LEFT
o-
-o
-o
o-
RI GHT
-o
o-
-o
Dofogger Swhch:
\
Terminal
Posilion \
2
ON o-
/l>\ -o
sv
OFF o-
--o
Power Mirrors
Power Mirror Test
1. Pry out the cover
panel (see
secti on 20).
Termi nal si de of
mal e termi nal s
*:
Canada
' 99
-
00 model s
Di sconnect the 8P connector from the power mi rror.
Check actuator operati on by connecti ng power
and
ground accordi ng to the tabl es.
Dofogger Test:
4. Check for conti nui ty between the No. 3 and No. 4
termi nal s of the 8P connector.
COVER
L___r"'ry1
Posi ti on
6 7 I
TILT UP o @
TILT DOWN @
SWING LEFT o @
SWING RIGHT @
23- 212
Mirror Actuator Replacement
(Donnel l y
Typel
' 1.
Remove the power mi rror from the door {see sec-
ti on 20). and di sconnect the 8P connector.
2. Remove t he mi r r or base cover f r om t he mi r r or
housi ng.
MIRROR HOLDER
Remove the mi rror hol der from the mi rror housi ng.
Gentl y pul l i t out by hand.
Remove the three screws from the actuator and the
two screws from the bracket at the base of the
assemory.
BRACKET
5. Remove the bracket from the housi nq.
4.
MIRROR HOUSING
7.
8.
6. Remove the two screws, cut the wi re harness, and
remove the actuator.
Record the termi nal l ocati ons and wi re col ors'
Route the wi re harness of the new actuator through
t he hol e i n t he br acket . Be sur e t o
pass t he wl r e
under the bracket cliP.
BRACKET
9. Pass the connector boot over the wi re harness
23-213
BLK/WHTi
,t
L,
.;{
I
o
a
LT GRN I
GRY
PNK
10, l nsert the termi nal s i nto the connector i n the ori gi -
nal ar r angement
( r ecor ded i n st ep 7) , as shown
Detow.
Right:
SLK/WHT*
BLU/REO'
":
Canada
' 99
-
00 model s
Appl y tape to seal the i ntersecti on of the connector
boot and the wi re harness.
Reassembl e i n the reverse order of di sassembl y
Be
careful not to break the mi rror when rei nstal l i ng i t
to the actuator.
Rei nstal l the mi rror assembl y to the door.
Operate the
power mi rror to check that the actuator
works smoothl Y.
Left:
1 1 .
12.
13.
't
4.
PNK
Wipers/Washers
SBS components are l ocated i n thi s area, Revi ew the SRS component l ocati ons, precauti ons,
and procedures
i n the SRS
secti on
(241
betore performi ng
WIPER/WASHER SWITCH
Test , page
23-215
REAR WINDOW WIPER
MOTOR lHatchback)
Test , page 23' 216
WINDSHIELD WIPER ARMS/BLADES
WINDSHIELD WIPER MOTOR
Test , page
23-215
WASHER FLUID
RESERVOIR
WASHER MOTOR {Hatchback)
Test , page 23' 216
INTERMITTENT WIPER RELAY
CI RCUI T (l n
t he i nt egrat ed
cont rol uni t )
t _l
Iilr
i
T
23-214
I J
Ci rcui t Di agram
(Wi ndshi el d)
UNDER DAS' I
FUSE F' - AY B3X
GRN Bt (
a /
BLK
G40l
G402
8LK
G401
G402
.r^_",,,*:
{ M }
WASHEF
Y
r,roroR
I
BLK
I
I
I
-
GzO2
COMB NED OPERAT ON WIPEF/WASHER
UNDER,HOOD FUSElFELAY BOX
o ooo?,
I
t
Y" , i
NTEGRATED
CONTROL
IINIT
/
Has b! ll.Ln
\
1
nlernrltent
I
\
w per reray
l
WLNDSHIELD W PEF MOTOR
23-215
l - '
Wipers/Washers
Ci rcui t Di agram
(Rear
Wi ndow)
UNDEN HOOD FUSE/RELAY BOX
"l-
WHTi BLK +WI]T
REAF WINDOW
WIPERMASHER
SWITCH
GRN/BLK
A
I
B!K
t
-
ouo,
G761
ooo,
G402
, ' / -t : <--
-----, -l
23-216
Wiper/Washer
Switch Test
Remove the dri ver' s dashboard l ower cover {see
secti on 20).
Remove the steeri ng col umn covers.
Di sconnect t he 8P and 6P connect or s f r om t he
swi tch, remove the two screws, and
pul l out the
swi tch.
4. Check tor conti nui ty between the termi nal s i n each
swi tch
posi ti on accordi ng to the tabl e
Windshield Wiper/Washer Switch:
\
Termi nal
Position
\
1 2 3 5 7 I
OFF o
o
INT
o
-o
o o
LO o
o
HI o
o
l \4i st swi tch"0N" o o
Washer switch
"0N "
o o
Rear Window WiPer/Washer Switch:
I
Termi nal
'i"*
--J
2 3 4 6
Washer swi tch
"0N"
(Wi per swi tch
"OFF"l o-
-o
o-
-o
OFF o-
-o
ON o-
-o
Washer swi tch
"0N"
{Wi per
swi tch
"0N") o-
-o
o-
-o
1 .
WIPER/WASHER
SWITCH
Wi ndshi el d:
l 1
2 3 1 4
|
li.l7a,lil
Rear Window:
1 1
z 3 l
lT-,rtl
Windshield Wiper Motor Test
1 . Open the hood, and remove the cap nuts. Careful l y
remove the wi per arms so that they do not touch
the hood.
Remove the cowl cover by pryi ng out the tri m cl i ps
(see
secti on 20).
Di sconnect t he 5P connect or l r om t he wi ndshi el d
wi per motor.
Test the motor by connecti ng battery
power
ground accordi ng to the tabl e.
l f the motor does not run or fai l s to run smoothi y,
repl ace i t.
5. Connect an anal og vol tmeter between the No. 5 {+)
and No.3 {-) termi nal s. and run the motor at l ow or
hi gh speed.
The vol tmeter shoul d i ndi cate 0 V and 4 V or l ess
al ternatel y.
\
Termi nal
i **l *-
-_\
1
4
LOW SPEED
o @
HIGH SPEED
o
@
23-217
Wipers/Washers
Rear Wiper Motor Test
(Hatchback)
1 . Remove the hatch lower trim panel (see
section 20).
Di sconnect the 4P connector from the wi per motor
assemDry,
Test the motor by connecting battery power
to the
No. 1 termi nal and ground
to the No. 3 termi nal .
l f the motor does not run or fai l s to run smoothl y,
reptace rI.
Reconnect the 4P connector to the wiper motor.
Connect an analog voltmeter between the No. 4
(+)
and No.2
(-)termi nal s,
Run the motor by turning the wiper switch ON.
The vol tmeter shoul d i ndi cate 0 V and 4 V or l ess
al ternatel y.
23-218
1 .
Washer Motor Test
(see
section 20).
Di sconnect the 2P connectors from the washer,
a
a
l f the motor fai l s to run smoothl y, repl ace i t.
l f the motor runs smoothl y. but l i ttl e or no wasner
f l ui d i s pumped.
check f or a di sconnecr o or
blocked washer hose, or a clogged pump
outlet in
the motor.
REAR WINDOW
WASHER MOTOR
(Hatchbackl
WASHER FLUIO
RESERVOIR
3. Test the washer motor by connecting battery power
and ground
L f:,ry1
Battery
1
Di sconnected
Connected
@
Washer LevelSwitch
Test
(Canadal
1. Remove the front bumper {see secti on 20)
2. Di sconnect the 2P connectors from the washer.
WASHER FLUIO
RESERVOIR WASHER LEVEL SWITCH
fl oat
\
Termi nal
;r"l,'t"--l
1
2
FLOAT UP
FLOAT DOWN
o
o
23-219
Power Windows
Gomponent Location Index
UNDER-DASH
FUSE/RELAY BOX
POWER WINDOW RELAY
Test,
paqe
23 87
FRONT PASSENGER'S WINDOW SWITCH
Test. page 23-230
FRONT PASSENGER'S WINDOW MOTOR
Test, page
23-232
POWER WINDOW
MASTER SWITCH
(Has
bui l t i n cont rol uni t )
I nput Test , page 23-226
f e$, page 23 224
RIGHT REAR WINOOW SWITCH {Sedanl
Test, page 23-230
BIGHT REAR WINDOW MOTOR
lSedanl
Test, page
23-232
DRIVER'S WINOOW MOTOR
Test , page 23-231
LEFT REAR WINDOW SWITCH
(Sedan)
Test, page 23-230
LEFT BEAR WINDOW MOTOR {Sedanl
f e$,
page
23-232
O
- r r - - - - r - - - -
_ f l ] l O
-. ---, ---; -;
n
- n - - n - n n - - r -
! l
I J
Circuit Diagram
('96-98
Coupe/Hatchbackl
WHT]BLK +WHT
WHTtsLU
l /
BLK
G551
PASSENGEB' S
WNDOW MOIOR
G401
G()2
23-221
l ,
Power Windows
Ci rcui t Di agram
(' 96-98
Sedan)
I.iASTER SWITCH
UNDER.DASH FUSUBELAYEOX
BLU/ELK
B3
3
I
BIGHT BEAR
l$',]ilP3,y
FBONT
PASSENGER'S
WINDOW
swtTcH
BLK
t
G551
LEFT HEAF WINDOW
MOTOR
23- 222
R GNT REAR WINDOW
MOTOR
BLK
I
G551
FRONT PASSENGER'S
WINOOW MOTOR
c401
G402
Ci rcui t Di agram
(' 99-00
Coupe/Hatchback)
BLU'YEL BLU/ORN
a /
BLU/RED
#*
l u l
PASSENGERS
WINDOW MOTOR
G401
G402
23-223
PASSENGER' S
UNDER.DASH FUS/RELAY BOX
DRIVER S W NDOW MOTOR
BLK
l
t ,
Power Windows
Gircuit Diagram
('99-00
Sedanl
UNDEF.HOOO FUSE/RELAY BOX
G401
G402
BLK
I
-.=
G551
23-224
FRONT
PASSENGER'S
|
' ' o
GRN,ryEL
l "
YEL
l s
4
2
l *
YEL
810
YEUGRN
3 I RIGHT REAB
BLU,YEL BLU/OFN
4 I 3 I F F ON T
^ l
YEUGRN
l z
UB
8LK
G55l
PASSENGER'S
wrNDow
BLdRED l Swl TCH
wINDOW
SWTCH
FEDI{EL
.I+
El.l
FRONT PASSENGER'S
WINDOW MOTOF
REDi BLU
RED/BLU
!
RIGHT REAF WINOOW
MOTOR
1
LEFT REAR W]NOOW
MOTOR
23-225
Power Windows
Master Switch Test
(Coupe/Hatchbackl
1. Remove the master swi tch from the dri ver' s door
panel (see page 23-2281.
Di sconnect t he 12P connect or f r om t he mast er
swi tch.
MAI N
SWITCH
swi tch
Driver's Switch:
The dri ver' s swi tch i s combi ned wi th the control uni t so
you cannot i sol ate the swi tch to test i t. Instead. run the
master swi tch i nput test
procedures at termi nal s 41. A3,
44. A8 and Al 2 on page 23-226. l f the tests are normal ,
the dri ver' s swi tch must be faul ty.
A1
I
A3 A4 A5
A1 A8
,/l/
412
23-226
Passenger's Switch:
\
Termi nal
P""*;l-m;\
A2 A5 A6 A7
OFF
ON
o-
--o
OFF
o-
--o
UP
ON
c'-
--o
o-
--o
OFF
o-
--o
DOWN
ON
o-
--o
--o
o-
OFF
o-
--o
Master Switch Test
(Sedan)
1 . Remove the armrest from the dri ver' s door
panel
(see page 23-228).
Di sconnect t he 16P and 1P connect or s f r om t he
master swi tch.
swi tch
posi ti on accordi ng to the tabl es
Drivr's Switch:
The dri ver' s swi tch i s combi ned wi th the control uni t so
you cannot i sol ate the swi tch to test i t. Instead, run the
master swi tch i nput test procedures at termi nal s 83, 84,
85. BO and 87 on
page 23-22A. l t the tests are normal ,
the dri ver' s swi tch must be faul ty.
MAIN SWITCH
rFl
l l " ' l l
t.:::::::l
B1 B3 B4 B5 B6 B7
B8 89 8108 1 1
/l/leu
Bl 5 816
Termi nal si de
of
mal e t ermi nal s
Front Passenger's Switch:
\
Termi nal
P*,j--f$t,l"\
B1 82 8 1 1 cl
OFF
ON
CF
--o
OFF
o
oo
UP
ON
o-
--o
o-
--o
OFF
c\-
--o
DOWN
ON
o
o o
- o
OFF
o o
Left Rear Swhch:
\
Termi nal
P".r,-'-f-mn\
8 1 4 815 8 1 6 c1
OFF
ON
G
--o
OFF
o o
UP
ON
o-
-oo
o-
--o
OFF
o- o
DOWN
ON
o-
o
--o
o
OFF o-
-_o
Right Rear Switch:
\
Termi nal
'**-T-*m
B8 89 B' t0 c1
OFF
ON
o- o
'o
OFF o-
--o
UP
ON
o-
--o
CF
--o
OFF
Cr-
--o
DOWN
ON
o-
--.o
--o
o-
OFF
o-
--o
23- 227
Power Windows
Master Switch Input Test
{Coupe/Hatchback)
NOTE: The control uni t i s bui l t i nto the power wi ndow master swi tch, and onl y control s dri ver' s door wi ndow operatl ons.
l Remove the dri ver' s door panel , and di sconnect the 12P connector from the master swi tch.
2. Inspect the connector and socket termi nal s to be sure they are al l maki ng good contact.
. l f the termi nal s are bent, l oose or corroded, repai rthem as necessary, and recheck the system.
. l f the termi nal s l ook OK, make the fol l owi ng i nput tests at the connector.
-
l f a test i ndi cates a probl em, fi nd and correct the cause. then recheck the system.
-
l f al l the i nput tests prove OK, the power wi ndow master swi tch must be faul ty; repl ace i t.
23-228
Ware si de of f emal e t ermi nal s
Cavi ty Wire Test condition
Test: Desired result Possible caus if result is not obtainsd
BLK
U nderal l condi t i ons Check for conti nui ty to ground:
.
Poor gr ound
( G551)
.
A8
A' ] BLU/BLK
l gni t l on swi t ch ON
(l l ) Check for vol tage to ground:
Bl own No. 10 or
' 11
(20
A) fuse i n
the under-dash fuse/rel ay box
Faul ty power wi ndow rel ay
A6 GRN/ BLK
R ED/B LU
Connect the BLU/BLK
termi nal to the RED/YEL
t er mi nal , and t he RED/
BLU termi nal to the
BLK t er mi nal , t hen t ur n
the i gni ti on swi l ch ON
(

) .
Check the dri ver' s wi ndow motor:
It shoul d run
(the
wi ndow moves
oown, .
Check t he passenger' s wi ndow
mot or: l t shoul d run
(t he
wi ndow
moves
qown, .
Check f or vol t age bet ween t he
BLU and BLK t ermi nal s: APProx. 6
V shoul d be i ndi cat ed as t he dri v-
er' s wi ndow mot or runs.
Faul t y dr i ver ' s wi ndow mot or
Faul ty passenger' s wi ndow motor
Faul ty passenger' s wi ndow swi tch
An open i n the ware
Faul t y pul ser
FaLi l ty dri ver' s wi ndow motor
A3 RE D/YE L
A7 BLUI/E L
connect the GRN/BLK
termi nal to the BLUryEL
t er mi nal , and t he BLU/
ORN t er mi nal t o t he
the i gni ti on swi tch ON
1

i .
A2 BLU/ORN
412 BLU
Connect the BLU/BLK
termi nal to the REDI/EL
t er mi nal , and t he BLK
t er mi nal t o t he RED/
BLU t er mi nal , t hen
turn the i gni ti on swi tch
oN
(| |
).
A8 BLK
23-229
Power Windows
Master Switch Input Test
(Sedan)
NOTE: Thecontrol uni t i s bui l t i ntothe power
wi ndow master swi tch, and onl y control s dri ver' s door wi ndow operati ons.
1. Remove the dri ver' s armrest, and di sconnect the 16P and 1P connectors from the master swi tch.
2. Inspect the connector and socket termi nal s to be sure they are al l maki ng good contact.
a l f the termi nal s a re bent, l oose orcorroded, repai rthem as necessary, and recheck the system.
-
l f a test i ndi cates a probl em, fi nd and correct the cause, then recheck the system.
-
l f al l the i nput tests prove OK. the power wi ndow maser swi tch must be faul ty; repl ace i t.
POWEB WINDOW MASTER SWITCH
23-230
Cavi ty Wire Test condition Test: Desired result Possible caus! d r"suh rs nol obtrincd
t o :
c1
BLK
Undera l l c o n d i t i o n s Check f or cont i nui t y t o gr oundl
,
An ope^
^
: he t t
. e
.
Bl own No. 7. 6
10
r '
"
20 A
f use i n t he unde. oast f . se
' e
a,
box
.
Faul ty power wi ndo$
' e
a,
.
B3 BLU/BLK
( l l )
Check for vol tage to grou nd:
B2 GRN/ BLK
YE L/BLK
R EDA/VHT 8 1 5
81 RED/ BLU
RED/YEL
Connect t he BLU/ BLK
t ermi nal t o t he RED/ YEL
t er mi nal , and t he RED/
BLU t er mi nal t o t he
1I i .
Check the dri ver' s wi ndow motorl
I t shoul d r un
( t he
wi ndow moves
oown) .
.
Faul ty dri ver' s wi ndow motor
.
B1 BLUIVEL
Connect t he GRN/ BLK
termi nal to the BLU| YEL
t er mi nal , and t he BLU/
Check the front passenger' s
wrnoow motor:
It shoul d run
(the
wi ndow moves
Fau l t y f ront passenger' s wi ndow
mot or
Faul t y f ront passenger' s wi ndow
8 1 1 BLU/ORN
the i gni ti on swi tch ON
0 r ) .
B9 YEL
connect t he YEL/ BLK
t ermi nal t o t he YEL t er-
mi nal , and t he YEU
GRN t er mi nal t o t he
0 r ) .
Check the ri ght rear motor:
I t shoul d r un
( t he
wi ndow moves
down) .
Faui ty ri ght rear wi ndow motor
Fau l ty ri ght wi ndow swi tch
B t 0 YEUGRN
814 GRNI/EL
connect t he RED, ryVHT
t ermi nal t o t he GRN/
YEL t er mi nal , and t he
GRN t er mi nal t o t he
0 r ) .
Check the l eft rear motor:
It shoul d run
(the
wi ndow moves
Faul ty l eft rear wi ndow motor
Faul ty l eft rear wi ndow swi tch
816 GRN
B6 BLU
Connect the BLU/BLK
termi nal to the RED/
YEL t er mi nal , and t he
BLK t er mi nal t o t he
RED/ BLU t er mi nal ,
t hen t ur n t he i gni t i on
swi t ch ON
( l l ) .
Check for vol tage between the
BLU and BLK t er mi nal sl
Approx. 6 V shoul d be i ndi cated as
the dri ver' s wi ndow motor runs.
Faul ty pul ser
Faul ty dri ver' s wi ndow motor
B4 BLK
23-231
Power Windows
Passenger's Window Switch Test
Coupo/H8tchback:
1. Remove the armrest
pocket from the door
panel
{see secti on 20}.
5P CONNECTOR
2. Disconnect the 5P connector from th passenger's
window switch.
Sodan:
1. Remove the armrest
(see
secti on 20).
Disconnect the 5P connector, then .emove the mount-
ing screw from the passenge/s switch.
PASSENGER'S WINDOW SWITCH
5P CONNECTOR
23-232
Switch sids of 5P t.rminal:
Termi nal si de ol
mal e termi nal s
switch position according to the table.
1 2 a 5
\
Terminal
il;--l
I 2 5
UP
-o
-o
OFF
-o
o-
-o
DOWN
o-
-o
Driver's Window Motor Test
Motor Test:
l . Remove the dri ver' s door panel (see
secti on 20).
Disconnect the 4P connector from the motor.
Test the motor i n each di recti on by connecti ng bat-
tery power and
ground accordi ng to the tabl e.
CAUTION: When th molor stops running, discon-
nct one lead immediatly.
4. l f the motor does not run or fai l s to run smoothl v.
reDl ace i t.
3.
l . , ,
\
Termi nal
;."t1."
-_l\
1
UP o @
DOWN o o
Pulsr Test:
5. Connect the test l eads of an anal og ohmmeter to the
No. 3 and No. 4 termi nal s.
6. Run the motor by connecti ng
power and ground to
the No. 1 and No.2 termi nal s. The ohmmeter needl e
shoul d move back and forth al ternatel y.
23-233
Power Windows
Passenger's Window Motor Test
Front:
1. Remove the passenger' s door panel (see
secti on
20t.
2. Di sconnect t he 2P connsct or f r om t he wi ndow
moIor.
2P CONNECTOR
\
Termi nal si de ot msl e
t ermi nal s
3. Check window motor operation by connecting
power
and ground accordi ng to the tabl e.
CAUTION: When the motor stops running. dbcon-
nest ono load immadiatoly.
4. l f the motor doas not run or fai l s to run smoothl y.
repl ace i t.
\
Termi nal
;;,r";--l
I
UP @ o
DOWN @
23-234
Re!r:
1. Remove the passenger' s door
panel
{see secti on
20).
2. Di sconnect t he 2P connect of f r om t he wi ndow
motor.
NOTE: The i l l ustrati on shows the ri ght rear wi ndow
motor; the l eft rear wi ndow motor i s symmetri cal .
2P CONNECTOR
3. Check window motor operation by connecting
power
and ground according to the table.
GAUTION: Whon the motor ctops running, discon-
nact one lead immodiatoly.
4. l J the moto. does not run or fai l s to run smoothl y.
rcDl ace i t,
\
Termi nal
DI;t;;---l
UP o @
DOWN @
Moonroof
a - /
MOONBOOF SWITCH
Test ,
page 23-236
.
lwire colors: WHT. GRN/YEL, l
I GRN/ oBN,
BLK, and GRN/ REDI
Test , page 23 87, 88
.
MOONROOF OPEN RELAY
f
wi re col ors: WHT, cRN/ RED, l
I GBN/ ORN,
BLK and YEL
l
Test, page
23'87, 88
MOONROOF MOTOR
Test,
page
23-236
l - ,
23-235
Moonroof
Circuit Diagram
JNDEB.FOOD FUSE
qELAY
BOX
*1 96 97 modes
:+2
r
'98-00
models
OPEN/CLOSE SWITCHI
.ourrE
lhe lifino ooglalron
{T[ ! b
-
F! yct o6ed)
A and C lerminals are connecled.
.
ourno lhe sldno o$ralron
(Fully?osed
*:
Futly opn)
A and Blermrnals are connecled.
TILT/CLOSE SWITCHI
.
Durinq lhe lihina oDeralion
[Ir]t uir
-
Fillyc osed)
D and F terninaliare connedd.
.
Durino lhe slidrno oDoraton
lFulv dossd
--:
Fllv ooenl
0 anil E lemnals are
(inhecied.
IGNITION SWTCH
BLK
I
_lr
--
G40t
G402
MOONFOOF SWITCH
23-236
Funstion Test
CAUTION: Bo careful not to damago the moonroof switch
or ths driv6r's dashboard lowsr cover when prying the
3witch out.
NOTE: Check the No. 51
(20
Al fuse i n the under-hood
tuse/rel ay box and No.24
(7.5
A) fuse i n the under-dash
fuse/relay box, before testing.
1. Prv the swi tch out of the dri ver' s dashboard l ower
cover.
swtTcH
2. Di sconnect t he 4P connect or f rom t he swi t ch
4P CONNECTOR
l - t
23-237
Connect the No. 1
(YELI
termi nal to body
ground
wi th a
j umper
wi re, then turn the i gni ti on swi tch ON
(l l ).
The moonroof shoul d open.
. l f the moonroot opens, check the swi tch.
. l f the moonroot does not open, check for:
-
an open i n the YEL wi re.
-
faul ty moonroof open rel ay.
-
faul ty moonroof cl ose rel ay,
-
poor ground
(G401,
G402).
-
fa u lty open/close switch.
Connect the No. 3
(YELnED)
termi nal to body
ground
wi th a
j umper
wi re. then turn the i gni ti on swi tch ON
(l l ).
The moonroof shoul d cl ose.
. l f the moonroof cl oses. check the swi tch.
. l f the moonrool does not cl ose, check for:
-
an open i n the YEURED or GRN/RED wi re'
-
faul ty moonroof cl ose rel aY.
-
faul ty moonroot oPen rel aY.
-
faul ty ti l vcl ose swi tch.
Connect the No. 2
(BLU)
termi nal to body
ground wi th
a
j umper
wi re, then turn the i gni ti on swi tch oN
(l l ).
The moonroof shoul d ti l t up.
. l f the moonroof ti l ts up, checkthe swi tch.
. l f the moonroof does notti l t up, checkfor:
-
an open i n the BLU wi re.
-
taul ty ti l vcl ose swi tch
Connect the No. 3
(YEURED)
terminal to bodY
ground
wi th a
j umper wi re, then turn the i gni ti on swi tch ON
(l l ),
The moonroof shoul d ti l t down.
l f the moonroof does not ti l t down, the open/cl ose
relay must be taulty.
Check for conti nui ty to body
ground on the No. 4
{ BLK} t er mi nal .
. l f there i s conti nui ty, check the swi tch
. l f there i s no conti nui ty, check for:
-
an open i n the BLK wi re
-
poor ground
(G401,
G402).
6.
7.
Moonroof
1 .
Switch Test
Careful l y remove the swi tch from the dri ver' s dash-
board l ower cover {see
page 23-205}.
Check for conti nui tv between the termi nal s i n each
swi tch
posi ti on
\
Terminal
t*',*-----__\
I 2 3 4
ut-t-
OPEN
o-
-o
CLOSE
o-
--o
TILT
o
--o
23-234
Motor Test
' 1.
Remove the headl i ner
(see
secti on 20).
Di sconnect t he 2P connect or f r om t he moonr oof
motor.
Check the motor by connecti ng power and ground
4. l f the motor does not run, repl ace i t
(see
secti on 20).
NOTE: See Cl osi ng Force Check i n secti on 20 for
motor cl utch test.
\_____lTr1
Posi ti on
,l
OPEN o @
CLOSE @
Open/Close-Tilt/Close
Switch Test
1. Remove the headl i ner
(see
secti on 20).
2. Di sconnect the 2P and 4P connectors from the moon-
roof motor and the swi tch.
swi tch
\
Termi nal
*r*"-
-\
1 2 3
CLOSE
.*
TILT o-
- o
o-
--o
CLOSE
..--.
OPEN o-
- o
4. l f there i s no conti nui ty, adi ust or repl ace the swi tch'
l - t
23-239
Gruise Control
MAIN SWITCH
TesVReplacement,
page 23-242
CABLE REEL
Replacement, section 24
BRAKE SWITCH
,
fest, page
23-244
.
Pedal Hei ght
Adj ust ment ,
sect i on 19 CRUISE CONTROI. UNIT
I nput Test , page
23-240
swrTcH
{M/T)
.
Test. page
23-244
.
Clutch Pedal Adjustment,
sect i on 12
atf
SWTTCH
.
Test, page 23-154
'
Replacment, page
23-'155
ACTUATOR CABLE
Adjustment, page 23-246
VACUUM TANK
TOR ASSEMBLY
.
Test, pag
23-245
.
Replacement, page
23-246
.
Sol enoi d Test , page
23-247
'
Disassembly, page 23-248
23-240
Ci rcui t Di agram
N0.30 (7.5A)
f/
I
REO/BtX
WNT/BLK
+WNT
BLU/RED
V
HORN
I J ,
JRN,/WH
V
gRAKE
LGHTS
UNDER.HOOD FUSEi RELAY 8OX
UNDEB.OASH FUSARELAY BOX
GRY + BLUiGRN
GAUGE
ASSEMBLY
CBUI SE
CONTROL
ACTUATOR
N0.41 (80A) N0.42
{40A)
INOICATOR
LIGHT
(0.84rY)
l P
I O SET
l o
I
Q suue
tGNlTtoN swlrcH
l - t
* : 99 00 models wlli A/T
23-241
Crui se Control
Gontrol Unit Input Test
and
procedures
i n the SRS
secti on
(24)
before performi ng
1. Remove the dri ver' s dashboard l ower cover and knee bol ster
(see
secti on 20).
2. Di sconnect the l 4P connector from the control uni t.
3. Inspect the connector and socket termi nal s to be sure they are al l maki ng good
contact.
l f the termi nal s are bent, l oose, or corroded, repai r them as necessary, and recheck the system.
l f the termi nal s l ook OK, make the fol l owi ng i npul tests at the connecror.
-
l f any test i ndi cates a probl em, fi nd and correct the cause, then recheck the system,
-
l f al l the i nput tests prove
OK, the control uni t must be faul ty; repl ace i t.
14P CONNECTOR
CRUISE CONTROL UNIT
*i
' 99
00 model s wi t h A/ T
23-242
GRN/WHT LT GRN/RED LT GRN/BI-K
8LU/ GRN*
)
Cavity Wi re Test condition
Test: Desired result Possible cause if result is not obtained
BRNA/VHT
Under al l condi t i ons Check for resi stance to ground:
There shoul d be 80
-
120 O.
Fau l ty actuator sol enoi d
Poor gr ound
( G202)
1 BRN
Under al l condi t i ons Check for resi stance to ground:
There shoul d be 40
-
60 0.
1 1 BRN/BLK
Check for resi stance to ground:
Ther e shoul d be 70
-
110 0.
2 GRY
l gn
j ti on
swi tch ON
(l l ),
mai n swi tch ON and
brake
pedal pushed,
then rel eased
ground:
There shoul d be 0 V wi th the
Pedal
pushed and battery vol tage wi th
the
pedal rel eased.
' Faul t y
br ake swi t ch
.
An open I n t he wl r e
3 BLK
U nderal l condi ti ons
Check for conti nui tY to groundl
There shoul d be conti nui ty
'
Poor gr ound
( G401, G402)
.
5 GRNA,A/HT
Brake
pedal pushed,
then rel eased
Check for vol tage to groundl
There shoul d be batterY vol tage
wi th the
Pedal Pushed.
and 0 V
wi th the pedal rel eased
.
Bl own No. 52
( 15
A) f use i n t he
under-hood fuse/rel aY box
.
Faul ty brake swi tch
.
LT GRN/
RED
Set but t on
pushed Check f or vol t age t o ground:
There shoul d be bat t erY vol t age.
Bl own No. 52
( 15 A) f use i n t he
under-hood
fuse/rel aY box
Faul ty horn rel ay
Faul ty sevresume swi tch
Faul ty cabl e reel
7
LT GRN/
BLK
Resume button
Pushed
1 0 RED/BLU
(l l ) At t ach t o ground:
Cr ui se i ndi cat or l i ght i n t he gauge
assembl y shoul d come on.
Bl own bul b
Bl own No. 25
(7.5
A) fuse i n the
under dash fuse/rel ay box
Faul t y di mmi ng ci r cui t i n t he
gauge assemDl y
BLU,A/VHT
(l l )
and mai n swi l ch ON;
rai se the front of the
car, and rotate one
wheel sl owl y wi th the
other wheel bl ocked.
Check for vol tage between the
BLUMHT @ and BLK O termi nal s:
Ther e shoul d be 0- 5 V or mor e
-0-
5 V or more repeatedl Y
.
Faul ty vehi cl e speed sensor {VSS)
.
LT GRN
(l l )
and mai n swi tch ON
ground:
Bl own No. 14
( 7. 5
A) f use i n t he
under-dash l use/rel aY box
Faul ty mai n swi tch
1 4 PNK
A,T: Shift lever in
E,
o j o r E
M/T: Cl utch
pedal
rel eased
NOTE: There shoul d be no conti -
nui ty when the cl utch
Pedal
i s
depressed or when the shi ft l ever
i s i n other posi ti ons.
Faul ty A/f gear posi ti on swi tch
Faul ty or mi sadj usted cl utch
swi tch
(M/T)
Poor
ground
(G401,
G402)
BLU/ GRN
Under al l condi t i ons Check for conti nui ty between No. I
termi nal and No. 5 termi nal of the
PCM connector A.
There shoul d be conti nui ty
.
*:
' 99
-
00 model s wi th A,/T
l - ,
23-243
Cruise Gontrol
3.
1 .
2.
Main Switch Test/Replacement
Remove the dri ver' s dashboard l ower cover
(see
sec-
ti on 20).
Careful l y push out the swi tch from behi nd the dash
board.
Di sconnect the connector from the swtrcn.
MAIN SWITCH
BULBS {0.84 Wt
Check f or cont i nui t y bet ween t he t ermi nal s i n each
swi t ch posi t i on accordi ng t o t he t abl e.
l f there i s no conti nui ty. reDl ace the swi tch.
4.
\
Terminal
r**
--\
2 3 5
OFF
o-
-o
G
a\
-o
\:./ \a/
ON
o-
/a
-o
o-
-o
\:/ \:/
23-244
Set/Resume Switch
5.
Test/Replacement
2.
1 .
MAIN WIRE
HARNESS
3P CONNECTOR
Make sur e you have t he ant i - t hef t code f or t he
radi o' s preset buttons. (' 99 -
00 model s).
Di sconnect the battery negati ve cabl e, then di scon-
nect the posi ti ve
cabl e, and wai t at l east three mi n-
utes.
Di sconnect the dri ver' s ai rbag connector (see
sec-
tion 24).
Remove the dashboard dri ver' s l ower cover
(see
sec,
ti on 20).
Di sconnect the cabl e reel sub harness 3p connector
from the mai n wi re harness.
CABLE BEEL
SUB-HARNESS
3P CONNECTOS
Termi nal si de of
mal e t ermi nal s
Check for conti nui ty between the termi nal s of the
cabl e reel sub-harness 3P connector i n each swi tch
L
Terminal
Position
1 2 3
SET
(ON}
o-
---o
BESUi,|E
IONI
o--
---o
l f t her e i s cont i nui t y, and i t mat ches t he t abl e,
the swi tch i s OK.
l f there i s no conti nui ty i n one or both posi ti ons,
go to step 7.
7. Remove th two screws, then remove the switch'
Check for continuity between the terminals in switch
\
Termi nal
t"-"t*
-\
2 3
SET
(ON)
o-
-o
RESUI\4E {ON} o-
---o
l f there i s conti nui ty, and i t matches the tabl e,
repl ace the cabl e reel .
l f there i s no conti nui ty i n one or both
posi ti ons,
reDlace the switch.
8.
SET/NESUME
l - l
23-245
1 1 .
q
10.
12.
l f al l tests
prove OK, reconnect the cabl e reel and
cabl e reel sub-harness connector, then rei nstal l the
steeri ng col umn covers
Reconnect the dri ver' s ai rbag connector. and rei n-
stal l the access
panel on the steeri ng wheel .
Reconnect the battery
posi ti ve cabl e, then the nega-
ti ve cabl e.
Af t er connect i ng t he ai r bag connect or s,
conf i r m
proper system operati on;
(l l );
the SRS i ndi cator l i ght shoul d come on for about
si x seconds and then
go off.
customer' s
radi o stati on
presel s {' 99
-00
model s)'
Crui se Control
Brake Switch Test
4P CONNECTOR
BRAKE
PEDAL
Check for conti nui ty between the termi nal s accord-
i ng to the tabl e.
\
Terminal
t"r.
** \
1 2 3
RELEASED
o-
--o
DEPRESSED
o o
3. l f necessar y. r epl ace t he swi t ch or adj ust
pedal
hei ght (see
secti onl 9).
23-246
clutch switch Test
(M/Tl
swtTcH
2. Check for conti nui ty between the termi nal s accord-
i ng to the tabl e.
\
Termi nal
. ***aal
-\
I 2
RELEASED
DEPRESSED
o-- o
3. l f necessar y, r epl ace t he swi t ch or adi ust
pedal
hei ght
(see
secti on
' 12).
)
Actuator Test
' t .
Di sconnect the actuator cabl e from the actuator rod
and the 4P connector.
Connect battery
power to the No 4 termi nal and
gr ound t o t he No. 1, No. 2 and No. 3 t er mi nal s.
Connect a vacuum
pump to the vacuum hose Then
appl y vacuum to the actuator.
2.
VACUUM PUMP
GAUGE, 0
-
30 i n. Hg.
{A973X
-
041
-
xxxxxl
ACTUATOR
,lP
CONNEcToR
Termi nal si de o{
mal e t ermrnal s
4. The actuator rod shoul d
pul l i n compl etel y. l f the rod
pul l s i n onl y pan-way or not at al l ' check for a l eak-
i ng vacuum l i ne or defecti ve sol enoi d.
ACTUATOF ROD
l - t
23-247
5. Wi th vol tage and vacuum sti l l appl i ed, try to
pul l the
actuator rod out by hand. You shoul d not be abl e to
oul l i t out. l l
you can, i t i s defecti ve
1 .
Di sconnect
ground from the No.3 termi nal . The actu-
ator rod should return lf it does not return, but the
vent hose and fi l ter are not pl ugged, the sol enoi d
val ve assembl y i s defecti ve.
Repeat steps 2 through 5, and di sconnect
ground
f r om t he No. 1 t er mi nal . The act uat or r od shoul d
return. l I i t does not return, but the vent hose and
fi l ter are not
pl ugged. the sol enoi d val ve assembl y
i s defecti ve.
It you repl ace the sol enoi d val ve assembl y, be sure
to use new O-ri ngs on each sol enoi d.
Disconnect
power and
ground from the 4P connector.
Disconnect the vent hose from the actuator. Connect
a vacuum
pump to the actuator vent hose
port, and
appl y vacuum. The actuator rod shoul d
pul l i n com-
pl et el y. l f not , t he vacuum val ve i s st uck open.
Replace the actuator'
8.
Cruise Control
t
D
=
t
Astuator Replacement
1 . Pul l back the boot, and l oosen the l ocknut. Then di s-
connect the cabl e from the bracket.
Di sconnect the cabl e end from the actuator rod.
Disconnect the 4P connector from the actuator.
Di sconnect the vacuum hosa from the vacuum tank.
Pul l out the vent hose.
Remove the three mounti ng bol ts and the actuator
with the bracket.
CABTI
aP CONNECTOR
l f necessary, di sconnect the cabl e end from the l i nk-
age over the accel erator pedal , then turn the grom-
met 90' i n the bul khead, and remove the cabl e,
Instal l i n the revers order of removal , and adj ust
free pl ay
at the actuator rod after connecti ng the
cabl e
(see
ne)d col umn).
7.
VACUUM HOSE
23-244
1 .
Actuator Cable Adjustment
Check that the actuator cabl e operates smoothl y
wi th no bi ndi ng or sti cki ng.
Stan the engi ne. Hol d the engi ne at 3,000 rpm wi th
no l oad
(Afl ' i n
N
or
E, M/T i n neutral ) unti t the
radi ator fan comes on, then l et i t i dl e.
Measure the amount of movement of the actuato.
rod unti l the cabl e pul l s
on the accel erator l ever
(engi ne
speed starts to i ncrease). Free Dl ay shoul d
be 11 t 1.0 mm
(0.43
I 0.04 i n).
LOCKNUT FREE PLAY: 11 1 1.0 mm
{o.i|:l r 0.oit in}
l f free pl ay
i s not wi thi n specs, l oosen the l ocknut,
and turn the adj usti ng nut as requi red.
NOTE: l f necessary. check the throttl e cabl e free
pl ay (see
secti on 11). then recheck the actuator rod
free play.
Retighten the locknut, and recheck the free play.
ACTUATOR ROD
)
Actuator Solenoid
Test
1. Di sconnect the 4P connector from the actuator'
ACTUATOR
2. Check for resi stance between the termi nal s accord-
i ng to the tabl e.
NOTE: Resi stance wi l l vary sl i ghtl y wi th tempera-
ture; sDeci fi ed resi stance i s at 70"F
(20' C).
SAFETY VALVE
VACUUMVALVE
J
From VENT
HOSE
+
To VACUUM
Termi nal si de ot
mal e t ermi nal s
\
Terminal
Resistance
(O)
\
2 3 4
VENT SOLENOID
40 600
o-
--o
VACUUM SOLENOID
30- 500
G-
--o
SAFETY SOLENOID
40- 600
o-
--o
l )
TANK
23-249
Grui se Control
Actuator Disassembly
ACTUAYOR CABLE
0
o
ACTUATOR BRACKET
WIRE SUPPORT BRACKET
ACTUATOR
Test, page
23 245
SOLENOID VAI-VES
Test, page 23 247
SOLENOID
SEAL
I
+*R
lAC
E
23-250
Power Door Locks
Component
Location Index
NOTE
(With
keyless entry systeml:
. It the doors unl ock or l ock wi th the transmi tter, but the LED on the transmi tter does not come on, the LED i s faul ty;
repl ace the transmi tter'
. when vou unl ock the doors wi th the transmi tter, the cei l i ng l i ght
(mi ddl e posi ti on) comes on for 30 seconds.
(However,
i f the audi o uni t i s not i nstal l ed, the l i ght does not come on )
. l f any door i s open,
you cannot l ock or unl ockthe doors wi th the transmi tter'
. The horn sounds onl y the fi rst ti me
you press a transmi tter button.
(Pressi ng repeatedl y does not acti vate the horn
agai n. )
o l f vou unl ocked the doors wi th the transmi tter, but do not open any of the doors wi thi n 30 seconds, the doors rel ock
automati cal l y.
. The doors do not l ock or unl ock wi th the transmi tter
i f the i gni ti on key i s i nserted i n the i gni ti on swi tch
. l f you press the PANIC button for more than two seconds, the horn sounds for about 30 seconds, and the transm' fer
LED comes on.
(The pani c mode wi l l not be acti vated i J the i gni ti on key i s i n the i gni ti on swi tch ) The pani c mode i s
cancel l ed by
pressi ng any of the transmi tter buttons'
o After repl aci ng the transmi tter battery,
press the l ock and unl ock buttons fi ve or si x ti mes to acti vate the transmi tter'
FRONT PASSENGER'S DOOR LOCK ACTUATOR
RIGHT REAR DOOR LOCK ACTUATOR
Test,
page 23-263
I.IFT REAR DOOR LOCK ACTUATOR
Test,
page 23 263
LOCK ACTUATOR
Test,
page 23-263
ORIVER'S DOOR LOCK SWITCH
Test,
page 23'262
DOOR L@X
CONTROL UN]T
I nput Test , page 23 255
23-251
Test, page 23-263
AUDIO UNIT
(STERO RADIO TUNER)
{' 96
-
98 model s)
l Has
bui l t -i n keyl essl
\ recei ver
ci rcui t I
Repl acement ,
page 23-189
Input Test, page 23-260
Termi nal s,
page 23-262
KEYLESS DOOR LOCK
CONTROL UNIT l'99
-
00 modelsl
Input Test,
Page
23-257
l - l
TRANSMITTER
99
-
0O t ransmi t t er shown; ' 96
-98
t ransmi f t er
al so has an OPTI ON but t on
Test, page 23-264
Transmi t t er Programmi ng,
page 23_265
Qi
,,a/
/ - - - -
L(ru
i'.-8,-'l
/'-'6
Power Door Locks
Circuit Diagram
(With
Keyless Entry System:
'96
-
98 modelsl
WHTi BLK
WHT/BED
WHT/BLU
LOCK KNOB
n
Y
KEY
| -----.f--;-)
i-q__!J
8LK
G551
l l ,o".,
L
I
PASSENGER' S
I
DoOF LOCK
I ACTUATOR
I
I
YEUREO
WHT/RED WHT/FED
l , l ,
tA-r rA] r.
qJ_*:[:,,,:
liqi*"""r llqi*'tr
YELI RED YELi RED
BLK
I
No.4l
180A)
N0.42 (40A)
WHT/GRN
UNDER.HOOD FUSEi RELAY BOX
POWER OOOR LOCK CONTROL UN T
uNLocK@ rocK
@
t'
8LU/ RED
I '
YELTRED
GRNiORN
GRN/]/VHT
BLK
G55l
23-252
) 1
I
TRUNK
LIGHT
GRNiRED LT GRN/ NED
A A
Ii,llh* T#,
I lctoseo : Door open ) |
(ctoseo
. ooo, open
I
Looen
Doot dosed J
I
Loner
:ooot closet
t l
l l
-: -l
@
w l
r,*1.,. ,,Tr,
,
I llltii irl:rx l5|i;e' ' lv
|
'r-1--
I
I
BLU/YEL
TGFI VRED
I *r.oro,ro
I
coNTRor uNrr
fF7
I Y \
I T \
| L<r )
GRN
A A
Y6su-' YFHrLo,,"
liili.}
',"**, r
liHi:
e*,**, r
l l
- ;
KEYLESS RECEIVER CIRCUIT
(ln lhe audio unrl)
l "' l "l ' '
o'*i*"
|
|
-"'i:"j^,"
l ' *t ect ot r o
I
coNTROL UNIT
I
,Y,
I
BLU/RED
A
Y.r'ro,u
l:!llT
-, ..".-
I
l-ope1
(ey
temoved
BLK
I
) ;
G402
23-253
Power Door Locks
Circuit Diagram
(With
Keyless Entry System :
'99-00
models)
BL(
I
G551
UNDEF.HOOO FUSE/RELAY BOX
N0.41
1804)
N0.51 (20
)
KEYLESS
DOOF LOCK
COIJTROL UNIT
DRIVEF'S
DOOF LOCK
SWITCH
23-254
) 1
Circuit Diagram
(Without
Keyless Entry System)
I r
l -,t
l '
8LK
G551
23-255
ORI VER' S
DOOR LOCK
SW TCH
BLK
G55l
POWER
DOOR LOCK
CONTROT UN T
Power Door Locks
Troubleshooting
NOTE: The numbers i n the tabl e show the troubl eshooti ng sequence.
*:
Wi th keyl ess entry system
NOTE:
. When the remote transmi tter button i s pressed the fi rst ti me, onl y the dri ver' s door wi l l unl ock. When the button i s
pressed the second ti me, al l the doors wi l l unl ock.
. Thedoorswi l l rel ock a utomati ca l l y after 30 seconds i f a door i s not opened, or the key i s out ot the i gn i ti on swi tch.
. The keyl ess entry system wi l l not l ock or unl ock the doors when the key i s i n the i gni ti on swi tch.
Item to be i nspected
Symptom
s
{ o
x 6
t n 6
l 5
5
5 O
o :
E ,
o o
o >
o
;
o
> t
6 <
o :
3
:
o
o
.9
' :
E
F
q)
< 5
I
E
c
Power door l ock svstem does not work at al l . 1
ucc I WHT/GRN
Doors don' t l ock wi th dri ver' s
door l ock knob swi tch.
Al l doors I 2
BLU,ryVHT
One or more
doors
YEURED or
WHT/RED
Doors don' t l ock or unl ock
wi th dri ver' s door l ock swi tch.
Al l doors
1
GRN/WHT,
GRN/ORN,
YEURED or
WHT/RED
One or more
ooors
YEURED or
WHT/RED
*The
power door l ock system works properl y but
the keyless entry system doesn't.
1
G401
G402
GRNAVHT or
GRNi ORN
23-256
Control Uni t Input Test
(' 96
-
98 model s and' 99
-
00 model s wi thout
Keyless Entry System)
1. Remove the dri ver' s door panel (see
secti on 20).
2. Di sconnect t he 12P connect or f r om t he cont r ol uni t .
3. Inspect the connector and socket termi nal s to be sure they are al l maki ng good contact
a l f the termi nal s are bent, l oose or corroded, repai r them as necessary, and recheck the svste-
-
l f any test i ndi cates a probl em, fi nd and correct the cause, then recheck the sysl em
l f al l the i nput tests
prove
OK, the control uni t must be faul ty; repl ace i t.
.I2P
CONNCTOR
Wi r e si de o{ f emel e t er mi nal s
*:
With keyless entry system
l - l
l cont d)
23-257
YEL/ RED
BLU/ RED
1 5
1 8 1 2
BLU/WHT
Power Door Locks
Control Uni t l nput Test
(' 96
-
98 model s and' 99
-
00 model s wi thout
Keyless Entry Systeml
(cont'dl
Di sconnect the 12P connector from the power door l ock control uni t.
CAUTION: To prevsnt damage to the actuator, apply battery voltage only momentarily.
Cavity Wire Test condition Test: Desired result Possible cause if result is nol obtained
*:
Wi th keyl ess entry system
Reconnect the 12P connector to the power door l ock control uni t.
Cavity Wire Test condition Tssl: Desirsd losull Possible cause it resull b not obtained
4 BLK
.
Poor ground (G55' l
)
.
WHT/GRN
Under al l condi t i ons Check for vol tage to ground:
.
Bl own No. 51
(20
A)fuse i n the
.
2 YEURED
Connect the YEURED
terminal to the WHT/
GRN termi nal , and the
WHT/RED termi nal to
the BLK termi nal
momenrafl ty.
Check door l ock operati on:
Al l passenger' s doors shoul d
unt ocK.
Bl own No. 51 {20
A) fuse i n the
Faul ty actuator
3 BLU/RED
Connect the BLU/RED
termi nal to the WHT/
GRN t er mi nal . and t he
the BLK termi nal
momenrafl ry.
Dri ver' s door shoul d unl ock.
5 WHT/RED
connect the WHT/RED
GRN t er mi nal , and t he
YEL/RED termi nal to
t he BLK t er mi nal
momenrafl ty.
Al l passenger doors shoul d l ock.
BLU/YEL
Under al l condi t i ons. Check for conti nui ty between the
power door l ock control uni t l 2P
connector No. 6 termi nal and
audi o uni t 16P connector No. 3 ter-
mi nal : The.e shoul d be conti nui ty.
GRN,ryVHT
Dri ver' s door l ock
swi t ch i n LOCK
Faul ty dri ver' s door l ock swi tch
Poor gr ound
{ G551)
8 GRN/ ORN
swi tch i n UNLOCK
7 BLUA/VHT
Dri ver' s door l ock knob
i n LOCK
Faul ty dri ver' s door l ock actuator
Poor gr ound
{ G551)
)
('99
-
00 models with Keyless Entry System)
1 . Remove the dri ver' s ki ck panel .
Di sconnect the 18P connector from the control uni t.
Inspect the connector and socket termi nal s to be sure they are al l maki ng good contacl .
. l f the termi nal s are bent, l oose or corroded, repai r them as necessary, and recheck the system
. l f the termi nal s l ook OK, make rhe fol l owi ng i nput tests at the connector.
-
l f anv test i ndi cates a
probl em,
fi nd and correct the cause, then recheck i he system
-
l f al l the i nput tests prove OK, the control uni t must be faul ty; repl ace i t
Di sconnect the 18P connector from the power door l ock control uni t.
CAUTION: To provent damage to the actuator, apply battery Yoltage only momentarily.
Cavity Wir Test condition Test: Desired result Possible cause if result is not obtained
BLK/YEL RED/SLK
2 5 6 1 8
9 1 0
/ , ' 2
, /
' 15
1 7 1 8
LT WHT
17 BLK
Under al l condi t i ons Check for contl nui ty to ground:
.
Poor gr ound
( G551)
.
t 8 WHT/GRN
Under al l condi ti ons Check tor vol tage to ground:
.
Bl own No. 5' 1
(20
A) l use i n the
under-hood tuse/rel ay box
.
4 B LK/YEL
(l l ) check for vol tage to ground:
Bl own No. l 4
(7.5 A) fuse i n the
(cont' d)
23-259
l - r
Power Door Locks
('99
-
00 models with Keyless Entry System)
(cont'd)
BLU/ RED WHT/ RED
8LU/ WHT 8LK/YEL RED/BLK
2 3 4 5 6 1 8
9 1 0 12
/t/
t 5 1 7 t d
LT GRN,/RED
BLK
Wi re si de of femal e termi nal s
Di sconnect the 18P connector from the oower door l ock control uni t.
CAUTION: To prevent damage to the actuator, apply baftery voltage only momentarily.
Cavi t y Wi l e Test condition Test: Desired result Possible cause if result is not obtained
BLU/ RED
YEL/ RED
WHT/GRN
GRN/ WHT
I YEURED
Connect the YEURED
GRN termi nal , and the
t he BLK t er mi nal
momenrafl ty,
Al l passenger' s doors shoul d
untocK.
Bl own No. 51
(20
A) fuse i n the
Faul ty actuator
5 BLU/RED
Connect rhe BLU/RED1
the BLK termi nal
momenl afl ry_
Dri ver' s door shoul d unl ock.
7 WHT/RED
Connect the WHT/RED
YEURED termi nal to
the BLK termi nal
momenl afl ry.
Check door l ock operat i on:
Al l passenger doors shoul d l ock.
23-260
I
Reconnect the 18P connector to the
power
door l ock control uni t
Cavitv Wire Test condition Tost: Desired result Possible cause it rsult is not obisinod
23-261
l - l
' 10
GRNA/VHT
swi tch i n LOCK
Check f or vol t age t o groundl
.
.
Poor gr ou nd
( G551)
.
9 GRN/ ORN
swi rch i n UNLOCK
2 BLU,ryVHT
Dri ver' s door l ock knob
i n LOCK
Faul ty dri ver' s door l ock actuator
Poor gr ound
{ G551)
3 BLU/ RED
swttcn
Check for vol tage to groundl
There shoul d be 1 V or l ess
There shoul d be 4 V or more
Ch."k f"r ".l t"r" t. g| ' "r^d
There shoul d be banery vol l age
Poor ground
(G401,
G402)
Faul t y i gni t i on key swi t ch
Shon i n t he wi r e
A o*n t t o
gO
, i 5 A' f r. " i n t f ' "
Lrnder hood f use/ rel ay box
Faul t y combi nat i on l i ght swi t ch
l gni ti on key removed
from the i gni ti on key
swtrcn
RED/BLK
swi tch i n
"
:m:
"
posi ti on
LT GRN/
RED
Each door open, one at
a t r me
Check tor vol tage to ground:
Faul ty door swi l ch
GRY
U nder al l condi t i ons
Bl own No. 52
( 15
Al f use i n t he
under hood f use/ rel ay box
Faul t y horn
Fau l t y horn rel ay
Connect to ground:
Hor n shoul d sound.
Power Door Locks
Audi o Uni t
{Keyl ess
Recei ver Ci rcui tl Input Test
(' 96
-
98 model s}
Remove t he audi o uni t , t hen di sconnect t he A and B connect or s
( see page 23- 189) .
I nspect t he connect or and socket t ermi nal s t o be sure t hey are al l maki ng good cont act
. l f t he t ermi nal s are bent , l oose or corroded, repai r t hem as necessary, and recheck t he syst em
. l f t he t ermi nal s l ook OK, make t he f ol l owi ng i nput t est s at t he connect or.
-
l f anv t est i ndi cat es a
probl em,
f i nd and correct t he cause, t hen recheck t he syst em
l f al l t he i nout t est s
prove
OK, t he cont rol uni t must be f aul t y; repl ace i t .
A CONNECTOB B CONNECTOR
16P CONNECTORS
AUDI O UNI T
L
2 .
WHT/BLU YEL/RED
{KEYLESS RECEI VER CI RCUI T}
23-262
)
l - l
Di sconnect the A and B connectors from the audi o uni t.
Cavi ty Wi re Test condition Test: Desired result Possible cause if result is not obtained
Reconnect the B connector onl y to the audi o uni t.
Cavi ty Wi re Test condi ti on Test: Desired result Possible cause iI result is not obtained
B9 GRN/ ORN
swi t ch i n UNLOCK
Ther e shoul d be 1 V or l ess.
.
Poor gr ound
1G551)
.
.
.
Shor t i n t he wi r e
swi t ch i n LOCK
Check f or vol t age t o grou nd:
There shoul d be 4 V or more.
8 1 0 G R NAr'r'HT
swi tch i n UNLOCK
.
Poor gr ound ( G551)
.
Faul t y dri ver' s door l ock swi t ch
.
.
Shon i n t he wi r e
swi t ch i n LOCK
Check l or vol t age t o ground:
There shoul d be I V or l ess.
23-263
A4 WHT/BLU
LJnder al l condi t i ons Check {or vol t age t o ground:
There shoul d be bat t ery vol t age.
.
Bl own No. 47
( 7. 5
A) t use i n t he
under hood f use, i r el ay box
.
An open
n t he w r e
A5 YEL/RED
l g ni ti on swi rch ACC
(l ) Check for vol tage to ground:
Bl own No. 28
,
I 0 A) f use i n t he
under dash
f use. el ay box
An open
"
: ne n r e
Check f or cont i nui t y t o
gr oundr
Ther e shoul d be cont i nui t y.
B o$. \ .
' . 1 -
5 A' i use n t he
, , ôe' aas_' - se r el ay box
A_ ooe^
'
: ne wr r e
Pc. '
E' o- - d
r G401, G402)
A- ooen n l he wi r e
B6 B LK,/YE L
l gni t i on swi t ch ON 0l )
815 8LK
B1 BLU/ RED
l gni t i on key i nsert ed
i nt o t he i gni t i on key
swrt ch
There shoul d be 1 V or l ess
Check f or vol t age t o gr ound:
Ther e shoul d be 4 V or mor e
Poor gr ound ( G401, G402)
Faul t y i gni t i on key swi t ch
Shor t i n t he wi r e
Check f or cont i nui t y ber wee. l Fe
audi o uni t 16P connect or l - o 3l er -
mi nal and power door l ock cont r ol
uni t 12P connect or No. 6 l er mr nal :
Ther e shoul d be cont i nu t y
l gni t i on key removed
f rom t he i g ni t i on key
swt l cn
B3 B LUlt/E L
U nderal l condi t i ons
B8
LT GRN/
BLK
Cei l i ng l i ght swi t ch i n
" mi ddl e
posi t i on"
Connect t o gr ound:
The cei l i ng l i ghr shoul dcome on.
Bl own No. 43
( 7. 5
A) f use i n t he
under-hood Iuse/rel ay box
Bl own cei l i ng l i ght bul b
Fau l t y cei l i ng l i ght
8 1 4
LT GRN/
RED
Each door open, one at
a t i me
Check t or vol t age t o gr ound:
Ther e shoul d be' l V or l ess.
.
Faul t y door swi t ch
.
Br6 GRY
U nderal l condi t i ons Connect to groundl
Hor n shoul d sound.
.
Bl own No. 52
(' 15
A) fuse i n the
.
Fau l ty horn
.
Faul t y hor n r el ay
.
Power Door Locks
Audio Unit lKeyless
Receiver
Ci rcui tl Termi nal s
(' 96
-
98 model sl
Cavity Wire Destination
16P CONNECTOR
B1 BLU/RED l gni t i on key swi t ch
* 82
LT GRN Trunk l atch swi tch
Ft2
BLU/YEL Unl ock
(Dri ver' s
door)
B4 BLU Val et swi tch
* 85
LT BLU Securi ty {l N)
B6 BLK/YE L No. 14
(7.5
A) fuse
* 81
ORN Securi ty
(D2)
B8 LT GRN/BLK Cei l i ng l i ght
B9 GRN/ORN Unl ock
(Al l
doors)
8 1 0 GRNA/VHT Lock
(OutPutl
* 8 1 1
BLU/WHT LED O
*812
WHT/BLK Securi ty
(D0)
+B
13 YEL/BLU Securi ty
(D' l
)
814 LT GRN/RED Door swi tch
B 1 5 BLK G round
(G401,
G402)
o t o GRY norn
*:
For securi ty system
(opti on)
23-264
Driver's Door Lock Switch Test
1. Remove the i nner handl e
(see
secti on 20).
2. Di sconnect t he 3P connect or f r om t he door l ock
swi tch.
swi tch
DRIVER'S
DOOR
LOCK
swtTcH
\
Terminal
Position
1 2 3
LOCK
o-
----o
OFF
UNLOCK o
----o
l
Driver's Door Lock Actuator Test
1. Remove the dri ver' s door
panel (see
secti on 20).
2. Di sconnect the 4P connector from the actuator.
J
Termi nal si de of
mal e termi nal s
knob swi tch
4. Check actuator operati on by connectl ng
power ano
ground accordi ng l o the tabl e. To prevent damage
to the actuator, appl y battery vol tage onl y momen-
tari l Y.
l - l
5. l f the actuator fai l s to work properl y. repl ace i t
23-265
\
Termi nal
F""lti*
- lll
LOCK
o
UNLOCK
\
Termi nal
Fo"JJ'-lrlon';"
-ll
1
LOCK
@ o
UNLOCK
Passenger's Door Lodr Actuator Test
1 .
2.
Remove the passenger' s doo.
paê see sect o'
201.
Di sconnect the 2P connector from l hq acl ual or
NOTE: The front passenger' s door l ock actual or
,s
shown; the l eft rear and ri ght rear door l ock act{,a
tors are si mi l ar.
3. Check actuator operati on by connecl rng
power and
ground accordi ng to the tabl e To
prevent damage
to the actuator, appl y banery vol tage onl y momen-
tari l y.
4. l f the actuator Iai l s to work properl y, repl ace i t.
\
Ter mi nal
, 2
Posi ti on
LOCK
O
@
UNLOCK
O o
Power Door Locks
Transmitter Test
NOTE:
. l f the doors unl ock or l ock wi th the transmi tter, but
t he LED on t he t r ansmi t t er does not come on, t he
LED i s faul ty; repl ace the transmi tter.
. l f any door i s open, you cannot l ock or unl ock the
door wi th the transmi tter.
. l f
you
unl ocked the doors wi th thetransmi tter, but do
not open any of t he door s wi t hi n 30 seconds, t he
doors rel ock automati cal l y.
. The doors do not l ock or unl ock wi th the transmi tter
i f the i gni ti on key i s i nserted i n the i gni ti on swi tch.
1. Usi ng a keyl ess entry checker
(07MAJ
-
SP003001:
. Pl ace the transmi tter on the keyl ess entry check-
er, and
press the transmi tter button.
-
l f the i ndi cator l i ght does not come on, check
for:
-
a dead or low batterv
-
Faul ty transmi tter
-
l f the ray i ndi cator l i ght comes on, the trans-
mi tter i s OK.
KEYLESS ENTRY CHECKER
INDICATOR LIGHT
TRANSMITTER
NOTE: Af t er a t r ansmi t t er bat t er y has been
repl aced, ai m the transmi tter at the recei ver, and
press the transmi tter button si x ti mes,
Confi rm
you can hear the sound of the door l ock
actuators when vou
press
the si )dh ti me.
23-266
)
Transmi tter Programmi ng
(' 96
-
98 model s)
Storing Transmitter Codes
. The codes of up to four transmi tters can be stored i n the control uni t. {l f a {i fth code i s stored, the code whi ch was
stored ti rst wi l l be erased.)
. When the system enters the regi strati on mode, al l previ ousl y sl ored codes wi l l be erased.
. The system l eaves the regi strati on mode and returns to the normal mode i f you
-
turn the val et swi rch OFF, or
-
t ur n t he i gni t i on swi t ch OFF, or
-
do not press the transmi tter button for more than 10 seconds
Procedure:
NOTE: l t i s i mportant to mai ntai n the ti me l i mi ts between steps
VALET SWITCH
NOTE: l f t he t uner i s t urned ON, i t wi l l
go of f and come on agai n when t he reg-
i st rat i on
procedure i s compl et ed-
l - l
NOTE: l f you want t o r egi st er t he codes
of more than one transmitter, repeat step
4 wi t hi n 10 seconds wi t h t he next t r ans'
mitter.
NOTE: Af t er st ori ng i t s code, make sure
t h e t r a n s mi t t e r wo r k s p r o p e r l y b Y
repeat edl y
pressi ng one ot i t s but t ons.
(The
syst em st art s t o work when
You
press any t ransmi t t er but t on si x t i mes-)
TRANSMTITTER
23-267
- -
I nsert t he i gni t i on key i nt o t he
i gni t i on swat ch.
Tur n t he i gni t ; on swi t ch ON
f l r).
Wi t hi n 10 seconds,
go t o st eP 3.
3. Press and hold the valet switch
for at least tive seconds.
( You
wi l l hear t he sound of t he
act uat or s t ur nang t o UNLOCK. )
Wi t hi n 10 seconds.
go t o st ep 4.
4. Press one of t he t ransmi t t er
buttons,
(You
wi l l hear t he sound of t he
act uat ors t urni ng t o UNLOCK. i
AUDIO UNIT
Power Door Locks
Transmi tter Programmi ng
(' 99
-
00 model sl
Storing transmitter codes;
The codes of up to three transmi tters can be read i nto
t he keyl ess r ecei ver uni t memor y.
( l f
a f our t h code i s
stored, the code whi ch was i nput fi rst wi l l be erased.)
NOTE: l t i s i mpor t ant t o mai nt ai n t he t i me l i mi t s
between the steps.
' 1.
(l l ).
2. Wi thi n 1 to 4 sec., push the transmi tter l ock or unl ock
button wi th the transmi tter ai med at the vehi cl e.
3. Wi thi n I to 4 sec., turn the i gni ti on swi tch OFF.
4. Wi thi n 1 to 4 sec., turn the i gni ti on swi tch ON 1l l ).
5. Wi t hi n 1 t o 4 sec. , push t he t r ansmi t t er l ock or
unl ock but t on wi t h t he t r ansmi t t er ai med at t he
vehi cl e.
6. Wi thi n 1 to 4 sec., turn the i gni ti on swi tch OFF.
7. Wi thi n 4 sec., turn the i gni ti on swi tch ON
(l l ).
8. Wi t hi n 1 t o 4 sec. , push t he t r ansmi t t er l ock or
vehi cl e.
9. Wi thi n 1 to 4 sec., turn the i gni ti on swi tch OFF.
Wi t hi n 4 sec. , t ur n t he i gni t i on swi t ch ON
( l l ) .
Wi t hi n
' 1
t o 4 sec. , push t he t r ansmi t t er l ock or
vehi cl e.
Confi rm you can hear the sound of the door l ock
acIuarors.
Wi t hi n 8 sec. , ai m t he t r ansmi t t er s
( up
t o t hr ee)
whose codes you want to store at the recei ver, and
press the transmi tter l ock or unl ock buttons.
Cont i r m t hat you can hear t he sound of t he door
l ock actuators after each transmi tter code i s stored.
Turn the i gni ti on swi tch OFF, and pul l out the key.
Confi rm proper operati on wi th the new code(s).
' 10.
1 1 .
12.
14.
23-268
)
Troubleshooting
Sef f
-dia
gnostic Proctdurcs ............. 2+13
Readi ng t he DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2+13
Erasing the DTC Mcnrory ................ 24-15
Troubleshooting h.ttnitt.nt
Fai l ures
. . . . . . . . . . . . . . 24-15
SRS U n it ldcntificrtion .................... 24- 1 6
Diagnostic Troublc Code
(DTC)
Chart
-
' 96
-
97 Model s. . . "' . ". . . . . . . 24-17
(DTCI
Chart
-
' $
-
00 Models ' .........""' 24' 19
SRS lndicaror Light Wire
connections
...' .,24-25
Ff owcharts
........,,,,.24-26
Airbag
Repfacemant
...' .' ...24-67
Di sposaf
. . . . . . . . . . . . . . . . . 24' 70
Cable Reel
Repfacement
.........24' 72
SRS Unh
Repfacement
..' ......24' 76
l - l
- +
sRs
Supplemental Restraint System
(SRSI
Speci af Tool s . . . . . . . . . . . . . . 24' 2
Component/Wirin
g Locations
f ndex . . . . . . . . . . . . . . . . . . . . . . 24-3
Descri pt i on
. . . . . . . . . . . . . . . . 24-5
Circuit Diagram ......." 24' 6
Precautions/Procedures
Generaf Precaut i ons . . . . . . . . . . . . . . . , , , , , , , . . 24-7
Airbag Handling and Storage .........24-7
SRS Unit Precautions ...................... 24-8
Inspection After Deployment ........' 24-8
Wi ri ng Precaut i ons . . . . . . . . . . . . . . . . . . . . . . . . . . 24' 9
Backprobing Spring-loaded Lock
Connectors .......,24-9
Spring-loaded Lock Connectol ....,,. 24-10
Spring-loaded Lock Connector with
Bui l t -i n Short Cont act . . . . . . . . . . . . . . . . . 24-10
Disconnecting the Airbag
Connector(sl
.....' 24' 11
Steering-related Precautions ...,.,.,,. 24' 12
Speci al Tool s
Ref, No, I Tool Number Description Oty
I
Page Reterence
o-,
an*r
@
o
/a*,
07HAz
-
SG00500
07PAZ 0010100
07sAz
-
TB4011A
0ITAZ
-
SZ5011A
07TAZ
-
001020A
Depl oyment Tool
SRS Infl ator Si mul ator
SRS Si mul ator Lead C
Backprobe Adapter, 17 mm
1
1
I
1
2
24 10
24-14
24-42
24-42
24-30
*
1r Incl uded i n SRS Tool Set 07N4M
-
SM5000B
*2:
Use wi th the stacki ng patch cords from T/N 07SM 001000A, Backprobe Set.
o
6\
o
t ,
4-2
Component/Wi ri ng
Locati ons
)
Index: With Front Passenger's Airbag
SRS I NDI CATOR LI GHT
(l n
t he
gauge assembl vl
24 13
Gauge assembl y, sect i on 23
CABLE
REEL
Repl acemenl
page 2! -t 2
To HORN SWI TCH
SRS UNIT
(l ncl udi ng saf i ng sensor
and i mPact sensorl
Repl acement Page
24 76
To DRIVER'S AIRBAG
DASHBOARD
WIRE HARNESS
to SRS INDICATOB LIGHT in
GAUGE ASSEMBLY
5P CONNECTOB
DBIVER'S AIRBAG
Bepl acement ,
page 24-61
Di sposal ,
page 24 70
FRONT PASSENGER' S
AI BBAG
Repl acement , Page
24_67
Di sposal , Page
24 70
t
SRS MAIN HARNESS
to CABI-E REL
2P CONNECTOR
SRS MAIN
SERVICE CHECK
CONNECTOR {2PI
IBRN,
BLK]
to UNOER-OASH
FUSE/RELAY BOX
2P CONNECTOR
SRS MAIN HARNESS
to FRONT PASSENGER'S
AIRBAG
2P CONNECTOB
SRS MAIN HARNESS
to SRS UNIT
r8P CONNECTOR
SBS MAIN HARNESS
to MAIN
WIRE HARNESS
3P CONNECTOR
MEMORY ERASE SIGNAL
(MES) CONNECTOR I2P)
[GRY,
GRYI or IGRN. GRNI
MAIN WIRE HARNESS
to DASHBOARD WIRE HARNESS
24P CONNECTOR
2+3
t ,
Gomponent/Wiring Locations
Index: Without Front Passenger's
Airbag
(some
Canada Modelsl
SRS I NDI CATOR LI GHT
(l n
t he gauge
assembl y)
Troubl eshoot i ng, page 24-13
Gauge assembl y, sect i on 23
DRIVER'S AIRSAG
Repl acement ,
page 24-67
Di sposal ,
page 24-70
SRS UNIT
GROUNO
To HORN SWITCH
SRS MAIN HARNESS
SRS UNIT
{l ncl udi ng saf i ng sensor
and i mpact sensor)
Repl acement . page
24, 76
To CRUISE CONTROL
SET/RESUME SWITCH
oo/ \ oo
To DRIVER,S AIRBAG
DASHBOARD WIRE HARNESS
to SRS INDICATOR LIGHT in
GAUGE ASSEMBLY
5P CONNECTOR
SERVICE CHECK
CONNECTOR {2P}
I B8N, BLKI
SRS MAIN
to UNDER-DASH
FUSE/RELAY BOX
2P CONNECTOR
SRS MAIN HARNESS
to SRS UNIT
18P CONNECTOR
SRS MAIN HARNESS
to MAIN
WIRE
HARNESS
3P CONNECTOR
MEMORY ERASE SIGNAL
(MES)
CONNECTON
(2P'
IGRY, GRYI o. IGRN, GRNI
MAIN WIRE HARNESS
to DASHBOARD WIRE HARNESS
24P CONNECTOR
24-4
DUMMY RESISTOB
Description
)
The sRS i s a safety devi ce whi ch, when used i n coni uncti on wi th the seat bel t, i s desi gned to hel p protect the dri ver l and
front passenger) i n a frontal i mpact exceedi ng a certai n set l i mi t. The system consi sts of the sRS uni t {i ncl udi ng
safi ng
sensor and i mpact sensor), the cabl e reel , the dri ver' s ai rbag
(and
front passenger' s ai rbag)
FRONT PASSENGEB' S
AIRAAG
DRIVER'S AIRBAG
CABLE REEL
SRS UNtT
t
Operation
The mai n ci rcui t i n the SRS uni t senses and
j udges the force of i mpact and, i f necessary, i gni tes the i nfl ator charge(s) l f
battery vol tage i s too l ow or power i s di sconnected due to the i mpact, the vol tage regul ator and the back-up
power cl rcul t
resoecti vel v wi l l keep vol tage at a constant l evel .
For the SRS to operate:
(1) The i mpact sensor must acti vate. and send el ectri c si gnal s to the ml croprocessor'
(2) The mi croprocessor must compute the si gnal s' and must send si gnal s to the ai rbag i nfl ator(s)'
{3) The i nfl ator(s) must i gni te and depl oy the ai rbag(s)'
_"-_-l
I
r 3 B ! # h
i
! . .
I
ffi,*
Self-diagnosis System
A sel f-di agnosi s
ci rcui t i s bui l t i nto the SRS uni t; when the i gni ti on swi tch i s turned ON
(l l ),
the SRS i ndi cator l i ght comes
on and goes off after about si x seconds i f the system i s operati ng normal l y
l f the l i gl t does not come on, or does not go off after si x seconds, or i f i t comes on whi l e dri vi ng, i t i ndi cates
an abnormal -
i ty i n the system. The system must be i nspected and repai red as soon as possi bl e
For better servi ceabi l i ty,
the memory wi l l store the cause of the mal functl on, and the data l i nk ci rcui t
passes on the i nfor-
mati on from the memory to the data l i nk connector
(DLC).
Thi s i ntormati on can be read wi th the Honda PGM Tesl er con-
nected to the DLC
(16P).
l ,
24-5
Circuit Diagram
UNDER-HOOD FUSE/RELAY 8OX
IGNITION
SWI TCH
WHT/8LI( +WHT
Brake systsm light
passenger's airbag
l - - - - l
t l
I DUMMY I
I
BESI STOR
I
tll
t l
l a
r l
MEMORY ERASE
SIGNAT IMES)
CONNECTOR I2P)
GRY
{GRN)
I
BRN BRN
t l
.-l- .-r-
\ . / \ . /
ECM/PCM SERVICE
CHECK
CONNECTOR
I
LT 8LU
I
t'7
DATA LINK
CONNECTOR
{DLC) {r6P)
GRY GRY
(GRN)
I GNN)
V
:
G801
Teminalside oi thal terminals
24-6
4 ' '
SRS UNIT TERMINALS
G40t
G402
SBS INDICATOR CIRCUIT
{ln the gauge assembly)
PGM_FI
DRIVER'S
AIRBAG
INFLATOR
10 14 r 13 6 7( VAl 3{ VBl
SRS UNIT
1 6 1 7 t 5 9 1 8 8
Precautions/
Procedures
)
General
Precauti ons
r Carefully
inspect any SRS
part before
you install it Do
not install any
part that shows signs of being dropped
or i mproperl y
handl ed' such as dents, cracks or defor-
mati on:
-
Ai rbags
-
Cabl e reel
-
SRS uni t
-
Use onl y a di gi tal mul ti meter to check the system l f
i t' s not a Honda mul ti meter,
make sure i ts output l s
1O mA
(0.01 A) or l ess when swi tched to the smal l est
val ue i n the ohmmeter range. A tester wi th a hi gher
output coul d damage the ai rbag ci rcui t or cause acci -
dental depl oyment and
possi bl e i nj ury'
I Do not i nstal l used SRS
parts from another vehi cl e
When maki ng SRS repai rs, use onl y new
pans'
) Ex c ept when
per f or mi ng el ec t r i c al i ns pec t i ons '
al ways di sconnect
both the negati ve cabl e and
posl -
ti ve cabl e from the battery, and wai t at l east three
mi nutes before begi nni ng work
r Repl acement
of t he combi nat i on
l i ght and wi per /
washer swi t ches and cr ui se cont r ol swi t ch can be
done wi thout removi ng the steeri ng wheel :
-
Combi nal i on
l i ght and wi per/washer
swi tch repl ace
ment, see secti on 23
-
Crui se control sevresume swi tch repl acement'
see
secti on 23.
. Whenever the i gni ti on swi tch i s ON {l l ),
or has been
turned OFF for l ess than three mi nutes' be careful not
to bump the SRS uni t; the ai rbag(s) coul d acci dental -
l y depl oy and cause damage or i nj ur y'
. Whenever t he ai r bag{ s)
has( have) been act i vat ed'
repl ace the SRS uni t.
l ,
2+7
Ai rbag Handl i ng and Storage
Do not t ry t o di sassembl e t he ai rbag assembl y. l t has no
ser vi ceabl e
par t s Once an ai r bag has been oper at ed
(depl oyed). i t cannot be repai red or reused'
For t emporary st orage of t he ai rbag assembl y duri ng ser-
vi ce. ol ease observe t he f ol l owi ng
precaut t ons:
. st ore t he
. emoved ai rbag assembl v wi t h t he
pad sur-
f ace uo The dr i ver ' s
( and f r ont
passenger ' s) ai r bag
connect o' ' s' - as
{ have) a bui l t . i n shor t cont act
( see
page 2a-l
1
:
| ..r r-+r-a k imninncrlv slorcd lace down,
-""dd.r6t
dtatltt-,tl
could
propel the unit whh enough
force lo c.usa 3a.ix!
intury
AIRBAG CONNECTORS
(Wi t h bui l t i n shon cont act )
. Store the removed ai rbag assembl y on a secure fl at
surface away from any hi gh heat source {exceedi ng
212"FI1OO"CJ
and free of any oi l '
grease, detergent or
water.
CAUTION: lmproper
handling or storage can intern'lJy
damage the airbag assembly, making it inoperativo
lf you suspect the airbag assembly
has been damcd'
inslall a new unit. and relsr lo the Deployment/DisPG'l
olocedules
for disposing ol the damaged airbag
Precautions/Procedu
res
SRS Uni t Precauti ons
Take extra care when pai nti ng
or doi ng body work i n
the area bel ow the dashboard. Avoi d di rect exDosure
of t he SRS uni t or wi r i ng t o heat guns, wel di ng. or
sprayang equi pment.
Di sconnect t he ai r bag connect or ( s) bef or e di scon-
necti ng SRS harness connectors
(see page24-1| 1J.
After any degree of frontal body damage, or after a
col l i si on wi thout ai rbag depl oyment, i nspect the SRS
uni t for physi cal
damage. l f i t i s dented. cracked, or
deformed, repl ace i t.
Be sure the SRS uni t i s i nstal l ed securel y.
Do not di sassembl e the SRS uni t.
Store the SRS uni t i n a cool
(l ess
than about 104.F/
40"C) and dry
(l ess
than 80% humi di ty, no moi sture)
pl ace. Do not spi l l water or oi l on the SRS uni t, and
keep i t away from dust.
Duri ng i nstal l ati on or repl acement, be careful not to
bump
(i mpact
wrench, hammer, etc.) the area around
the SRS uni t. The ai rbag(s) coul d acci dental l y deptoy
and cause damage or i nj ury.
24-8
Inspection After Deployment
Af t er a col l i si on l n whi ch t he ai r bag( s) was
( wer e)
depl oyed, repl ace the SRS uni t, and i nspect the fol l owi ng:
1. Inspect al l the SRS wi re harnesses. Repl ace. don,t
repai r, any damaged harnesses.
2. Inspect the cabl e reel for heat damage. l f there i s any
damage, repl ace the cabl e reel .
3. Af t er t he vehi cl e i s compl et el y r epai r ed, t ur n t he
i gni ti on swi tch on. l f the SRS i ndi cator l i ght comes
on for about si x seconds and then goes
off. the SRS
system i s OK. l f the i ndi cator l i ght does not functi on
properl y, go
to SRS Troubl eshooti ng.
)
Wiring Precautions
. Never attempt to modi fy, spl i ce or repai r SRS wi ri ng'
NOTE: SRS wi ri ng can be i denti fi ed by speci al
yel l ow
outer Protecti ve
coveri ng.
8e sure to i nstal l the harness wi res so that they are not
oi nched or i nterferi ng
wi th other
parts.
t
Make sur e al l SRS
gr ound l ocat i ons ar e cl ean and
grounds are securel y fastened for opti mum metal -to-
metal contact. Poor groundi ng can cause i ntermi ttent
probl ems that are di ffi cul t to di agnose.
a ,
24-9
Backprobing
Spring'loaded
Lock
Gonnectors
. When checki ng vol tage or resi stance on thi s type of
connector the fl rst ti me, i t i s necessary to remove l ne
retai ner to i nsert tester
probes from the wi re si de.
NOTE: l t i s not necessary to rei nstal l the removed
retai ner; the termi nal s
wi I stay l ocked i n the connec-
t or housr ng.
To remove the retai ner, i nsert a fl at ti p screwdri ver
between connector body and retai ner, and careful l y
pry out the retai ner.
NOTE: Take care not to break the connector.
FLAT TIP
SCBEWDRIVER
RETAINER
*
Di scard af t er removal .
RETAINER
Preca utions/Procedures
Spri ng-l oaded Lock Connector
Some SRS syst em connect ors have a spri ng-l oaded l ock.
Disconnecting
To rel ease t he l ock, pul l t he spri ng-l oaded sl eeve t oward
t he st op whi l e hol di ng t he opposi t e hal f of t he connecror.
Then pul l t he connect or hal ves apart .
NOTE: Be sur e t o pul l
connector hal f.
on t he sl eeve and not on t he
SPRING-LOADEO
SLEEVE
Do not pul l
on t hi s
hal f of t he connect or.
Connecti ng
1. Hol d the pawl -si de
connector hal f, and press
on the
back of the sl eeve-si de connector hal f i n the di recti on
shown. As t he t wo connect or hal ves ar e pr essed
together, the sl eeve i s pushed
back by the pawl .
NOTE: Do not touch the sl eeve.
When the connector hal ves are compl etel y connected,
the pawl i s rel eased, and the spri ng-l oaded sl eeve
locks the connector.
SPRING.LOADED
SLEEVE
24-10
Spring-loaded
Lock Connector with
Built-in Short Contact
The dr i ver ' s aj r bag
( and
f r ont passenger , s)
ai r bag has
( have)
a spr i ng- l oaded l ock connect or wi t h a bui l r - i n
short contact. When thi s connector i s di sconnected, the
power
t er mi nal and t he gr ound
t er mi nal i n t he ai r baa
connector are automati cal l y shoned.
Connector halves disconnected:
SHORT CONTACT
Conneqtor halves connected:
GROUND TERMINAL
CABLE REEL CONNECTOR
GROUND TERMINAL
)
Disconnecting
the Airbag Connector(sl
' 1.
Di sconnect
the negati ve battery cabl e, and wai t at
l east three mi nutes.
2. Di sconnect the ai rbag connector(sl .
Driver's Side:
. Remove the access
panel from the steeri ng
wheel '
then di sconnect
the dri ver' s ai rbag 2P connector and
cabl e reel 2P connector.
!@@
To prevent sccidental 8irbag deployment, turn th ignition switch oFF. disconncct th negative battery
ffi, "nd *"it thr"e minutes bfore disconnocting
any sRS conn'ctors'
. Before di sconnecti ng the SRS mai n harness
(A) from the SRS uni t' di sconnect both ai rbags
(C'
D)'
. Bef or edi sconnect i ngt hecab| er eel 2Pconnect or ( B) , di sconnect t hedr i ver , sai r bag2Pconnect or ( c) .
F ont PasEanga/3
Side:
. Remove the
gl ove box. then di sconnect the front
pas-
senger' s ai rbag 2P connector and SRS mai n harness
2P connector.
t
FRONT PASSENGER'S
AIRBAG
2P CONNECTOR
CABTT REEL
2?
CONNECTOR
AOCESS PANEL
a ,
24-11
Precautions/Procedu res
Steering-related Precautions
Stesring Wheel and Cable Reol Alignment
NOTE: To avoi d mi sal i gnment of the steeri ng wheel on
reassembl y, make sure the wheel s are turned strai ght
ahead before removi ng the steeri ng wheel .
Rotate the cabl e reel cl ockwi se unti l i t stops.
Then rotate it counterclockwise {approximately two and
a hal f turns) unti l the arrow mark on the cabl e reel l abel
poi nts
strai ght up.
24-12
:l
Strin9 Column Removal
CAUTION:
. Eefore removing thg stggring column. disconnect the
connsstor bqtween the cable rel and th SRS msin
harness.
. lf the stoering column is going
to be romoved with-
out dismounting th6 stoering wheel, lock the steer-
ing by turning the ignition key to o-LOCK position, or
remove the key trom the ignition switch so that the
steering wheel will not turn.
NOTE:
When t he ai r bag and cabl e r eel ar e di sconnect ed,
don' t reconnect the battery cabl e. l f the battery i s
reconnected and the i gni ti on swi tch i s turned ON
(l l ),
the SRS uni t wi l l store thi s as an open i n the dri ver' s
ai rbag i nfl ator, and the SRS i ndi cator l i ght wi l l come
on.
For di sconnecti ng the spri ng-l oaded l ock type con-
nector, refer to page 24-'10.
SRS MAIN HARNESS
2P CONNECTOR
Do not repl ace the ori gi nal steeri ng wheel wi th any other
desi gn because i t wi l l make i t i mpossi bl e to properl y
i nstal l the ai rbag
(onl y
use genui ne Honda repl acement
parts).
After reassembl y, confi rm the wheel s are sti l l turned
strai ght ahead and that the steeri ng wheel spoke angl e
i s correct. l f mi nor spoke angl e adj ustment i s necessary,
do so onl y by adj usti ng the ti e-rods, not by removi ng
and reposi ti oni ng the steeri ng wheel .
r l
Troubl eshooti ng
t )
Self-diagnostic
Procedures
The sel f-di agnosti c functi on of the SRS system al l ows i t to l ocate the causes of system
probl ems and to store thi s i nforma'
I
ti on i n memory. For easi er troubl eshooti ng,
thi s data can be retri eved vi a a data l i nk ci rcui t
l
. When
you turn the i gni ti on swi tch ON
(l l ), the SRS i ndi cator wi l l come on. l l i t goes off after si x seconds. the system i s
nor ma l .
. l f there i s an abnormal i ty, the system l ocates and defi nes the probl em, stores thi s i nformati on i n memory, and turns
the sRS i ndi cator l i ght on. The data wi l l remai n i n the memory even when the i gni ti on swi tch i s turned off or i f the bat-
tery i s di sconnected.
o when you connect the scs servi ce connector to the servi ce check connector
(2P),
and turn the i gni ti on swi tch oN
(l l ),
t hesRsi ndi cat or | i ght wi | | i ndi cat et hedi agnost i ct r oub| ecode( DTC) byt henumber of b| i nks.
. After readi ng and recordi ng the DTC.
proceed wi th the troubl eshooti ng
for thi s code'
Precauiions
. Us eon| y adi gi t a| mU| t i met er t oc hec k t hes y s t em' | f i t , s not aHondamu| t i met er , mak es ur ei t s out put i s l 0mA( 0. 01A)
o r | e s s wh e n Swi t c h e d t o t h e s ma | | e s t v a | u e i n t h e o h mme t e r r a n g e , At e s t e r wi t h a h i g h e r o Ut p Ut c o u l d d a ma g e t h e
ai rbag ci rcui t or cause acci dental ai rbag depl oyment and
possi bl e i nj ury'
r when-ever the i gni ti on swi tch i s oN
(l l ).
or has been turned oFF for l essthan three mi nutes, be careful nottobumpthe
SRS uni t; the ai rbags coul d acci dental l y depl oy and cause damage or i nj uri es
. Before
you ,"n1ou" th" SRS mai n harness, di sconnect the dri ver' s ai rbag connector
(and the front passenger' s ai rbag
connector).
. Make sure the battery i s suffi ci entl y charged {see secti on 23}. l f the battery i s dead or l ow, measuri ng val Ll es won t be
correct.
. Do not touch a tester
probe to the termi nal s i n the sRS uni t or harness connectors, and do not connect the termi nal s
wi th a
j umper wi re. Use onl y the backprobe set or the speci al tool s'
For backprobi ng spri ng-l oaded l ock type connectors,
refer to
page 24-9'
Reading the DTC
when the SRS i ndi cator l i ght i s on, read the DTC usi ng one of these methods:
A. Connect the Honda PGM Tester to the 16P Data Li nk Connector {DLC),
and fol l ow the tester' s
prompts l f the tester
i ndi c at es noDTc , DTc g- 1or DTc 9- 2, doub| e- c hec k by j umpi ngt hes er v i c ec hec k c onnec t or andwat c hi ngt hes RS
i ndi cator l i ght
(see next
Page)
HONDA PGM TESTER
DATA LINK CONNECTOR Il6PI
l ,
24-13
Troubleshooting
J
J
B. The SRS i ndi cator l i ght can al so i ndi cate the DTC by the number of bl i nks when the SCS servi ce connector i s connect-
ed to the servi ce check connector
(2P).
1. Turn the i gni ti on swi tch OFF, and wai t for ten seconds. Then connect the SCS servi ce connector to the servi ce check
connector
(2P).
l f you do not wai t ten seconds, the SRS uni t wi l l not be compl etel y reset and wi l l not output DTCS.
SERVICE CHECK
CONNECTOR {2PI
IGRY, GRYI or IGRN, cRN]
07PAZ
- (m10100
l . - zs
(l l ).
The SRS i ndi cator l i ght comes on for about si x seconds and goes off. Then i t wi l l i ndi ,
cate the DTC:
-
The DTC consi sts of a mai n code and a sub-code.
-
Incl udi ng the most recent probl em,
up to three di fferent mal functi ons can be i ndi cated.
-
In case of a conti nuous fai l ure, the DTC wi l l be i ndi cated repeatedl y (see
exampl e 1 bel ow).
-
In case of an i ntermi ttent fai l ure, the SRS i ndi cator l i ght wi l l i ndi cate the DTC one ti me, then i t wi l l stay on
(see
exam-
pl e 2 bel ow).
l f both a conti nuous and an i ntermi ttent fai l ure occur, both DTCS wi l l be i ndi cated as conti nuous fai l ures.
-
In case the system i s normal
(no
DTC), the SRS i ndi cator l i ght wi l l stay on
(see
exampl e 3).
3. Read the DTC.
4. Turn the i gni ti on swi tch OFF, and wai t for ten seconds. Then di sconnect the SCS servi ce connector from the servi ce
check connector
(2P).
Examples of DTC Indications:
1. Conti nuous fal l ure, SRS Indi cator Li ght i sl
-
Mai n @de
DT C2 1
Mosr raenr probtsm
Intermi ttent fai l ure, SRS l ndi cator Li ght i s:
- l F -
r
M.in code ir) Sub.code (2)
DT CI 2
-'l
F
--l
F
Mar n code ( 11
Sub code t 1t
D T C l 1
Thnd.most recenl
Lrghr srays on rn ca* ol
r - -
2.
3. No
ON
sutb chek
__.1
penod
24-14
rmal
(no
fai l ure), SRS
D T C 5 l
I ndi cat or Li ght i s:
rl
No OTC, system is norhal, rhe
)
Erasi ng the DTC Memory
To er ase t he DTC( s) f r om t he SRS uni t , use a Honda
PGM Test er
( see
t he Honda PGM Test er SRS vehi cl e
System Suppl ement) or the fol l owi ng
procedure
1. Make sure the i gni ti on swi tch i s OFF
2. Connect the SCS servi ce connector to the MES con-
nector
(2P).
Do not use a
j umper
wl re.
] P,
&
.!--J
MEMORY ERASE
SIGNAL
(MESI CONNECTOR I2PI
IGRY,
GRYI or [GRN,
GRNI
o?PAZ
-
0010100
t
7.
(l l ).
The SRS i ndi cator l i ght comes on for about si x sec-
onds and
goes off. Remove the SCS servi ce connec-
tor from the MES connector
(2P) wi thi n four seconds
after the SRS i ndi cator l i ght went off.
The SRS i ndi cator l i ght comes on agai n. Reconnect
the SCS servi ce connector to the l vl ES connector
(2P)
wi thi n the four seconds after the SRS i ndi cator
l i ght comes on.
The SRS i ndi cator l i ght goes off. Remove the SCS
ser vi ce connect or f r om t he MES connect or
( 2P)
wi thi n four seconds.
The SRS i ndi cator l i ght i ndi cates that the memory i s
erased by bl i nki ng two ti mes.
Turn the i gni ti on swi tch OFF, and wai t for ten sec-
onos.
8.
SRS indictlor
lighi
MES
conncclot
tcaminals
CONNECTED
O ,
DISCONI{ECTED
24-15
Troubleshooting Intermittent
Fai l ures
l f there was a mal functi on, but i t doesn' t recur, i t wi l l be
stored i n the memory as an i ntermi ttent fai l ure, and the
SRS i ndi cat or l i ght comes on.
Afte. checking the DTC, troubleshoot as lollows:
1. Read rhe DTC {see
"Readi ng
the DTC"}.
Er as e t he DTC memor y
( s ee
" Er as i ng
t he DTC
Memor y" ) .
Wi th the shi fi l ever i n neutral , turn the i gni ti on swi tch
ON
( l l ) ,
and l ei t he engi ne i dl e.
The SRS i ndi cator l i ght comes on for about si x sec-
onds and
goes off.
l * F
ON
t l
--
-l
Shake the wi re harness and the connector, take a test
dri ve
(qui ck
accel erati on,
qui ck braki ng, corneri ng),
and turn the steeri ng wheel ful l y l eft and ri ght, and
hold it there for five lo ten seconds to find the cause
of the i ntermi ttent fai l ure.
l f t he pr obl em r ecur s, t he SRS i ndi cat or l i ght wi l l
stay on.
-q
6a.c
f'-
:q
Problem recurs, light stays on
3.
4.
6. l f vou can' t dupl i cate the i ntermi ttent fai l ure, the sys-
tem i s OK at thi s ti me.
Troubleshooting
SRS Unit ldentification
+:
On
' 98
-
00 model s, the troubl eshooti ng procedures
are di fferent for each type of SRS uni t. l denti fv the SRS uni t i n the
vehi cl e usi ng the chart bel ow, then fol l ow the proper
fl owchan i n the fol l owi ng pages.
'98
-
00 Model SRS units
MAKER
IDENTIFICATION
MARK*
Remark
NEC
M1 Dri ver' s ai rbag onl y
M1 Dri ver' s & Passenger' s ai rbags
KEIHIN M2 Dri ver' s & Passenger' s ai rbags
SI EMENS M3 Dri ver' s & Passenger' s ai rbags
'96
-
97 Model SRS units
LABEL
IIDENTIFICATION MARK)
MAKER PARTS NUMBER
Remark
NEC
77960- S04- C81
Dri ver' s ai rbag onl y
77960- S04- N81 Dri ver' s & Passenger' s ai rbags
TAKATA 77960- S04- N82 Dri ver' s & Passenger' s ai rbags
SI EMENS 77960- S02- A81
Driver's & Passenger's airbags,
' 97
Model onl y
24-16
l r
l
(DTG)
Chart
-'96 -
97 Models
t
SRS indicator light DTC
Possible cause
Correctiv6 action Sae
page
doesn' t come on
none
(doesn' t
come on)
Faul ty SRS i ndi cator l i ght ci rcui t Troubl eshooti ng 24-26
comes on
none
*4
(doesn' t
go off)
Faul ty SRS i ndi cator l i ght ci rcui t, i nternal
fai l ure of SRS uni t, faul ty SRS
power suppl y.
Troubl eshooti ng
24-29
1-1 Open i n the dri ver' s ai rbag i nfl ator
24-42
l ncreased resi stance i n the dri ver' s aarbag
i nfl ator
24-42
l - 3
Short to another wi re i n the dri ver' s ai rbag
i nfl ator or decreased resi stance
Short to Dower i n the dri ver' s ai rbag i nfl ator
Short to ground i n the dri ver' s ai rbag i nfl ator
24-44
1- 4
24-46
1-5
24-48
2-1
Wi th front passenger' s ai rbag:
Open i n the passenger' s ai rbag i nfl ator
Wi thout front
Passenger' s
ai rbag:
ODen i n the dummy resi stor
24-50
24-54
Wi th front
passenger' s ai rbag:
Increased resi stance i n the
passenger' s ai rbag
i nfl ator
Wi thout front
Passenger' s
ai rbag:
l ncreased resi stance i n the dummy resi stor
24,50
24-54
2-3
Shon to another wi re i n the
passenger' s
ai rbag i nfl ator or decreased resi stance
Wi thout tront
Troubl eshooti ng
Short to another wi re i n the dummy resi stor
or decreased resi stance
24-52
24-59
2-4
Short to
power i n the passenger' s ai rbag
i nJl ator
Wi thout front
Passenger' s
ai rbag:
Short to
power i n the dummy resi stor
24-54
24-60
Wi th front
Short to ground i n the
passenger' s aarbag
inflator
without front
passenger's airbag:
Short to
ground i n the dummy resi stor
24-56
24-61
(cont' d)
24- 17
a ,
Troubleshooting
Di agnosti c Troubl e Code
(DTCI
Ghart
-' 96 -
97 Model s
(cont' d)
NOTE:
*
l : In case of an i ntermi ttent fai l ure DTC
g-1,
i t means there was an i nternal fai l ure of the SRS uni t or a faul tv SRS i ndi ca
tor l i ght ci rcui t. Do the troubl eshooti ng for i ntermi ttent fai l ures
(see page 24-15).
*2:
l t both DTC 9-2 and DTC 5-1 are i ndi cated, do the troubl eshooti ng for DTC
g-2.
*3:
Appl y to the
' 97
model coupe HX and DX.
*4:
DTC cannot be read wi th a Honda PGM Tester; check by
j umpi ng
the SCS servi ce connector.
24-18
.
Possiblg cause Cortestive action
5 3
I Internal fai l ure of the SRS uni t
SRS uni t
repl acement
l nternal fai l ure of the SRS uni t
SRS uni t
repl acement
Internal fai l ure of the SRS uni t
SRS uni t
repl acement
Internal fai l ure of the SRS uni t ortwo fai l ures at a
ti me
8-6*3 Internal fai l ure ofthe SRS uni t
Faul ty SRS power suppl y
(VB
l i ne)
SRS uni t repl acement code
(SRS
uni t must not
be used any l onge.)
J
)
(DTC)
Chart
-' 98 -
00 Model s
NEC SRS Unit
I r
SRS indicator light DTC Possible cause Correstive action See page
doesn' t come on
none
(doesn' t
come on)
Faul t y SRS i ndi cat or l i ght ci r cui t Troubl eshoot i ng 24-26
comes on
none*3
(doesn' t
go off)
fal l ure of SRS uni t, faul ty SRS power suppl y
( VB
l i ne)
Troubl eshooti ng 24-34
No DTC*3
( l i s
ht
comes on
after sel f-
di agnosi s)
Faul ty SRS power suppl y
(VA l i nel Troubl eshooti ng 24-39
l - 1 Open i n the dri ver' s ai rbag i nfl ator
Troubl eshooti ng
24 42
Increased resi stance i n the dri ver' s ai rbag
i nfl ator
24-42
inflator or decreased resistance
24-44
't
-4
Short to power i n the dri ver' s ai rbag i nfl ator 24-46
t - 5 Short to ground i n the dri ver' s ai rbag i nfl ator 24-48
Wi th front
passenger' s
ai rbag:
Open i n the passenger' s ai rbag i nfl ator
Wi thout front passenger' s ai rbag:
Open i n the dummv resi stor
24-50
24-54
Increased resi stance i n the passenger' s ai rbag
i nfl ator
Wi thout front
Increased resi stance i n the dummy resi stor
24-50
24-58
wi th front passenger' s ai rbag:
Short to another wi re i n the passenger' s
Short to another wi re i n the dummy resi stor
or decreased resi stance
Troubl eshooti ng
24-52
24,59
2-4
Short to power i n the passenger' s ai rbag
i nfl ator
Shon to power i n the dummy resi stor
24-54
24-60
Short to
ground i n the passenger' s ai rbag
i nfl ator
Short to ground i n the dummy resi stor
24-56
24-61
(cont' d)
24-19
l ,
Troubleshooting
(DTC)
Chart
-'98 -
00 Models
{cont'dl
NOTE:
*
1: In case of an i ntermi ttent fai l ure DTC 9-1, i t means there was an i nternal fai l ure of the SRS uni t or a faul ty SRS i ndi ca-
tor l i ght ci rcui t. Do the troubl eshooti ng for i ntermi ttent fai l ures
(page
24-' 15).
*2:
In case of an i ntermi ttent fai l ure DTC 9-2, i t means there was an i nternal fai l ure of the
power
suppl y {VB l i ne). Do the
troubl eshooti ng for i ntermi ftent fai l ures.
*3:
j umpi ng
24-20
\
SRS indicator light DTC Possible cause CorrectiYe action See page
comes on
5-1
SRS uni t
repl acemenl
24-76
5-4
6-1
SRS uni t
repl acement
24-7 6
6-2
o-5
6-4
7-1
SRS uni t
repl acement
24-76
7-3
8-1
SRS uni t
reptacement
24-7 6
8-2
8-6
Internal fai l ure of the SRS uni t or two fai l ures
at a trme
g_1* r * 3
SRS uni t
repl acement
24-7 6
9- 2+2
*3
5l | 5 Unt r
replacement
24-76
10- 1
SRS ai rbags depl oyed
(SRS
uni t must be
reDl aced)
SRS uni t
repl acement
24-76
) r
l , . l
I
KEIHIN SRS Unit
SRS indicator light DTC Possible cau3e Corrective astion See page
doesn' t come on
none
(doesn' t
come on)
Faul ty SRS i ndi cator l i ght ci rcui t Troubl eshooti ng 24-26
comes on
none*3
(doesn' t
go offl
Faul ty sRs i ndi cator l i ght ci rcui t, i nternal
power suppl y
{VB l i ne)
Open i n the dri ver' s ai rbag i nfl ator
Tr oubl eshoot i ng
24-42
1-2
Increased resi stance i n the dri ver' s ai rbag
i nfl ator
24-42
1-3
24-44
1- 4 Short to
power
i n the dri ver' s ai rbag i nfl ator
24-46
1-5 Short to ground i n the dri ver' s ai rbag i nfl ator
24-44
2-1 Open i n t he passenger' s ai rbag i nf l at or
Troubl eshooti ng
24-50
Increased resi stance i n the
i nfl ator
24-50
Short to another wi re i n the
passenger' s
24-52
2-4
Short to power i n the passenger' s ai rbag
i nfl ator
24-54
Short to ground i n the passenger' s ai rbag
i nfl ator
24-56
(cont' d)
24-21
Troubleshooting
(DTCI
Ghart
-'98 -
00 Models
(cont'd)
NOTE:
*l :
In case of an i ntermi ttent fai l ure DTC 9-1. i t means there was an i nternal fai l ure of the SRS uni t or a faul tv SRS i ndi ca-
tor l i ght ci rcui t. Do the troubl eshooti ng for i ntermi ftent fai l ures
(pa9e
24-15).
*2:
In case of an i ntermi ttent fai l ure DTC 9-2, i t means there was an i nternal fai l ure of the power suppl y
(VB
l i ne). Do the
troubl eshooti ng for i ntermi ttent fai l ures.
*3:
j umpi ng
SRS indicator light DTC Possible cause Corective action Seo page
comes on
5-2
5 3
5 4
SRS uni t
repl acement
24-7 6
6-1
6-2
_
64
SRS uni t
repl acement
24-16
n
-
8l
8S
9_1* r
* 3
SRS uni t
reptacement
24-76
SRS uni t
repl acement
24-76
SRS uni t
repl acement
24-76
Internal fai l ure of the SBS uni t
SRS uni t
reptacemenr
24-76
10- 1
(SRS
uni t must be
reDl aced)
SRS uni t
repl acement
24-76
24-22
) r
l - J
SIEMENS SRS Uni t
SRS indicator light DTC Possible cause Corregtive astion See page
doesn' t come on
none
(doesn' t
come on)
Faul W SRS i ndi cator l i ght ci rcui t Tr ou bl eshoot i ng 24-26
comes on
none*3
(doesn' t
go ofl)
power suppl y
{VB
l i ne)
1-1
Open or i ncreased resi stance i n the dri ver' s
ai rbag i nfl ator
Troubl eshooti ng
24,42
1-3
24-44
1- 4 Short to power i n the dri ver' s ai rbag i nfl ator
24-46
Shon to ground i n the dri ver' s ai rbag i nfl ator
24 48
2-1
Open or increased resistance in the
passengers
ai rbag i nfl ator
Troubl eshooti ng
24-50
2-3
Short to another wi re i n the
passenger' s
24-52
2-4
Short to power i n the
i nfl ator
24-54
2-5
Short to ground i n the passenger' s ai rbag
i nfl ator
24-56
,-. ^
l) t
(cont,d)
24-23
d
Troubleshooting
(DTG)
Chart
-' 98 -
00 Model s
(cont' dl
NOTE:
*' l :
In case of an i ntermi ttent fai l ure DTC 9-1. i t means there was an i nternal fai l ure of the SRS uni t or a faul ty SRS i ndi ca-
tor l i ght ci rcui t. Do the troubl eshooti ng for i ntermi ftent fai l u.es
(page
24-15).
*2:
In case ot an i ntermi ttent fai l ure DTC 9-2. i t means there was an i nternal fai l ure of the power suppl y
(VB
l i ne). Do the
troubl eshooti ng for i ntermi ft ent fai l ures.
*3:
j umpi ng
24-24
a,
SRS indicator light DTC Possible cause Corective action See page
comes on
SRS uni t
repracemenl
24-76
5-4
6-3
SRS uni t
reptacemenr
24-76
6-4
SRS uni t
repl acement
24-7 6
8-1
l nternal fai l ure ot the SRS uni t
SRS uni t
repl acement
24-7 6 8-2
8-6
g_1* r * r
SRS uni t
repl acement
24-16
SRS uni t
repracemenl
24-76
10- 1
(SRS
uni t must be
.epl aced)
SRS uni t
reptacemenl
24-76
SRS Indi cator Li ght Wi re Connecti ons
SRS Indi cator Li ght Power Ci rcui t
To UNDER-DASH
FUSE/RELAY BOX
-
20P CONNECTOR
SRS Indicato. Light Control Circuit
To SRS UNIT
t
I
SRS MAIN HARNESS
C41 1, C412 : Terminal sido of mdlo t6rminals
C501, C5O2, C508, C801. C802, C807 : Wi . 6 si dc of f omal o t . rmi nal s
MAIN WIBE HARNESS
BLU
C508
-+
To GAUGE ASSEMBLY
c41 1
To GAUGE ASSEMBLY
a t
C501 : DASHBOARDWI RE HARNESS 2oP CONNECTOR
C508 : DASHBOARD wlRE HARNESS 5P CONNECTOR
C801 : SRS MAI N HARNESS 2P CONNECTOR
C807 : SRS MAIN HARNESS 18P CONNECTOR
C802 : SRS MAIN HARNESS 3P CONNECTOR
C412 : MAI N WI RE HARNESS 3P CONNECTOR
C41 1 : MAIN WIRE HARNESS 24P CONNECTOR
C502 : DASHBOARD WIRE HARNESS 24P CONNECTOR
GRY
O I
24-25
Troubleshooting
The SRS Indicator Light Doesn't Come On
CAUTION: Whonever ths ignition switch is ON {ll}, or
has been turned OFF tor l ess than three mi nutes. be
careful not to bump the SRS uni t; the ai rbagl s) coul d
accidentally deploy .nd caus6 damage or iniuris.
Check tho powr supply
(fuse):
(l l ),
and check whet her t he ot her
i ndi cat or l i ght s come on
(brake
syst em, et c. ).
Oo the other indicator liohts como on?
YES NO
Check th6 fuso:
Check t he No. 25 { 7. 5 A) f use i n t he under - dash t use/ r el ay
b"t
ls th6 tu36 OK?
NO YES
Check the bulb:
Repl ace t he No. 25
(7. 5
A) f use, and check t hat t he
SRS i ndi cat or l i ght comes on.
Doos the SRS indicator liqhl come on7
I
YES No
END
Check tho wire harns btwecn fus6 and gauge aasambly:
Check f or an open i n t he wi re harness bet ween l use
No. 25 {7. 5 A) and t he gauge
assembl y, and repai r. Check
t hat t he SRS i ndi cat or l i ght comes on.
Doo. tho SRS indic.tor light como on?
I
yEs
No
I
END
Check tho SRS indicator light bulb:
2. Remove t he gauge assembl y.
3. Check f or bl own SRS i ndi cat or l i ght but b.
ls the SRS indicator light bulb OK?
NO
YES
Ch.ck the SnS indicator liglrt circuit:
Repl ace t he bul b, and reconnect t he gauge assembl y
connect ors. Then t urn t he i gni t i on swi t ch ON {l l }.
Ooes th6 SRS indicato. llght come on?
I
YEs
No
: ND
lAl To page 24-27
24-26
lB'J fo page 24-27
) )
No. 25
(7.5
Al FUSE
)
From
page 24-26
(A)
From page 24-26
( B) DASHBOARD WIRE HARNESS
5P CONNECTOR
I t
MAIN WIRE HARNESS
2,rP CONNECTOR
DASHAOARD WIRE
HARNESS 2irP
CONNECTOR
c41 1
(cont' d)
24-27
check the sRs indicator light circuit:
1. Di sconnect t he dashboard wi re harness 5P connect or
f rom t he
gauge assembl y.
2. Connect a vol t met er bet ween t he No. 1 t ermi nal
(+)
of
t he 5P connect or and
ground.
3. T! rn t he i gni t i on swi t ch ON 1l l ), and meas! re vol t age.
l s t here 8. 5 V or l oss l or si x seconds at t er t he i gni t i on
swilch has been turned ON {lll?
YES
NO
Faulty SRS indicator light circuit in the gauge e$embly;
repl ace t he SRS
pri nt ed ci rcui t boa. d i n t ho
gauge
assmblY.
Check the wire harness otthe SRS indicator light circuil {1):
' 1.
2. Di sconnect t he mai n wi re harness 24P connect or f rom
t he dashboard wi re harness.
3. Connect a vol t met er bet ween t he No. 5 t ermi nal {+) of
t he mai n wi re harness 24P connect or and
9round
4. Turn t he i gni t i on ON
(l l ),
and measure vol t age.
l s t hore 8. 5 V or l css t or t i x second3 . I t or t he i gni t i on
switch has b6en turned ON lll)?
YES
NO
Short to oower in the BLU wire ol the dashboald wiro
harness; rgpaii the hamss.
To page 24-28
a r
Troubleshooting
The SRS Indicator Light Doesn't Come On
(cont'dl
Frcm page 24. 21
Ch6ck tho wire h6rn6s of tho SRS indicator light circuir
(21:
2. Di sconnect t he SRS mai n harness 3P connect or f rom t he
mai n wi re harness,
(+)
of
t he SRS mai n harness 3P connect or and ground.
(l l ),
and measur vol t age.
13 t hore 8. 5 V or l ess f or 3i r sacond3 af t gr t ho i gni t i on
switch h.3 b.en turned ON llllT
YES NO
Short to power in tho BLU wi.e of lhe m.in wiro hrnroas;
rorir tho ham6as.
Chock the wi.e harness otthe SRS indicator ci.cuit l3l:
2. Disconnect the banery negative cable. th6n the
positive
cable, and wait three minutes.
3. Disconnect the driver's
(and
front passenger's)
airbag con-
nector{s}
(seo page 24-11).
4. Di sconnect t he SRS mai n harness 18P connect or t rom
5. Connect a vol t met er bet won t he No. 6l ermi nal {+} of
(ll),
and measure vollagg. There
should be 0.5 V or less.
ls voltago as specified?
YES NO
Faultv SRS unh; 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
SRS MAIN HARNESS
18P CONNECTOR
MAIN WIRE I{ARNESS
3P CONNECTOR
SRS MAIN I{ARNESS
3P CONNECTOR
c802
SRS UNIT
SRS MAIN HARNESS 1AP CONNECTOR
-
)
The SRS l ndi cator Li ght Doesn' t Go Off
-' 96 -
97 Model s
CAUTION: Whenever the ignition switch is ON
(ll),
or has been turned OFF for less than three minutes, be careful not to
bump the SRS uni t; the ai rbag{sl coul d acci dental l y depl oy and cause damage or i ni uri es
Try to reproduce lhe SRS indicator light:
1. Erase t he DTC memory
(see page 24' 15).
2. Turn t he i gni t i on swi t ch OFF, and wai t f or t en seconds.
3- Turn t he i gni t i on swi t ch ON {l l ), and check t hat t he SRS i ndi
cator light comes on for about six seconds and
goes off
Does the SRS indicEtor light stay on?
[*
NO
I nt ermi t t ent l ai l ure, syst em i s OK at t hi s t i me. See
Troubloshooting Int6rmittent Failures on page 24'15
Chck t he No. 13 {15 A} and No. 23
(10
A) f uses:
2. Check f or bl own No. 13
( 15
A) and No. 23
( 10
A) f uses i n
t he under dash f use/ rel ay box.
Are the fuses OK?
vEs
No
Replace the luses, and erase the memory
1. Repl ace t he f uses.
2. Connect t he SCS servi ce connect or t o t he MES con
nect or.
(see page 24 15).
4. Turn t he i gni t aon swi t ch OFF, t hen di sconnect t he SCS
servi ce connect or f rom t he MES connect or.
(l l ).
Does the sRS indicato, tigt t go or "ne. "ii--JJl
-
I YEs NO
1
END
i
Conlirm the DTC, and continue troubl6shootilg.
Check for an open in the SRS main harness {VA linell
' 1.
Tu. n t he i gni t i on swi t ch OFF.
2. Di sconnect t he bat t ery negat i ve cabl e, t hen di sconnect
t he
posi t i ve cabl e, and wai t f or t hree mi nut es.
3. Di sconnect t he dri ver' s
(and
f ront passenger' s) ai rbag
connect orl s)
(see page 24 11).
4. Di sconnect t he SBS mai n harness
' 18P
connect or f rom
t he sRS uni r.
5, Reconnect t he bat t ery
posi t i ve cabl e, t hen reconnect t he
negat i ve cabl e.
6. Connect a vol t met er bet ween t he No. 7 t et mi nal
(+)
of
7. Turn t he i gni t i on swi t ch on.
b there battery voltageT
YES
NO
(A)
To page 24 30
Open in the SRS main harness IVA line); replace the SRS
mai n harness.
l . J
SBS MAI N
(cont ' d)
No.
' t 3
{15 Al FUSE
SRS UNI T
HARNESS 18P CONNECTOR
I I
24-29
Troubleshooting
The SRS Indicator Light Doesn't Go Off
-'96 -
97 Models
(cont'd)
Frcm page 24-29
(A)
SRS MAIN HARNESS
18P CONNECTOR
24-30
SRS UNIT
Check the SRS unit:
Connect t he SRS mai n harness 18P connect or t ermi nal s No.
6 and No. 7 wi t h a i umDer wi re and
Feulty SRS unit or
poor cont.ct !tth. SRS ftain hsmeis
18P connector; ch6ck the conncctor,
lf the connector is OK, rcpl.c. tho SRS unh.
To page 24-31
07TAZ
-
001020A
JUMPER WI RE
)
From page 24' 30
( B)
To
page 24-33
5P CONNECTOF
mcsog
A#
I
Btu
lYEt
Wire side of fomale
lUUpeA Wtng
terminals
OASHBOARD WIRE HARNESS
I t
Wi re si de ol f emal e
t et mt nal s
SRS MAIN HARNESS
l AP CONNECTOR
( D)
To page 24'33
5P CONNECTOR
(cont' d)
DASHBOARD WINE HARNESS
Check th. SBS indicatot circuit:
2. Removo t he gauge assembl y.
NoTE: Do n;t disconnect the dashboard wire harness 5P
connsct or l rom t he gauge assembl y
(l l ).
4. Connect t h dashboard wi re harness 5P connect or t ermi -
nal s No. 1 and No. 5wi t h a
j umperwi ro.
Doo3th. SRS indicstor light
go offf
Fautty SRS indicltot light citouit in th.
grugc a$cmbly;
rcpl . ce t he SRS
pt i nt . d ci l cui t boaJd i n t hc
gt ugs
b 1 MO or more.
Ch.ck tor a ihort to
glound in th. SRS IndioltoJ light cir'
cuit:
f rom t he
gauge assembl Y
3. Check resistance between the No. 1 terminal of the dash
board wire harness 5P connector and
ground. There should
Ch.ck to. an opon in tho SnS indic.tor light circuh:
1. Ch6ck resistanc between the No 6 terminal of the SRS
msi n harness 18P connect or and No.
' l
t ermi nal ot t he
dashboard wi re harness 5P connect or; t here shoul d be
24-31
o r
Troubleshooting
The SRS Indi cator Li ght Doesn' t Go Off
-' 96 -
97 Model s
(cont' dl
From page 24-31
Ch6ck for a shon lo ground in tho m.in wire harness:
f rom t he mai n wi re harness,
2. Check resi st ance bet ween t he No. 5 t ermi nal of t he mai n
wi re harness 24P connect or and
ground.
There shoul d be
1 M0 or more.
Short to
ground in the dashboard wire harness; repair
the dashbo..d wire harnoss.
SRS MAIN HARNESS
3P CONNECTOR
Wi r e si de oI f emal e
t er mi nal s
24-32
\
MAIN WIRE HARNESS
HARNESS
Check for a short to ground
in the SRS main h..ness:
mai n wi re harness,
2. Check resi st ance bet ween t he No. 1 t ermi nal of t he SRS
mai n harness 3P connect or and ground. There shorrl d be
1 fu,|0 or more.
ls the resistance as specifisd?
Short t o ground i n t he mai n wi re harnoas; rpai r t he
main wire harness.
)
From
page 24-31
( Dl
DASHBOARD WIBE HARNESS
5P CONNECTOR
Wi re si de of t emal e
t ermt nars
From
page 24-31
( El
l r
SRS MAIN HARNESS
18P CONNECTOR
Check for an open in the dashboatd wir harness:
f rom t he mai n wi re harness.
mai n harness 18P connect or and No 5 t ermi nal of t he
mai n wi r e har ness 24P connect or ; t her e shoul d be
0 - 1 . 0 0 .
Ooen in tha BLU wire ot the dashboard wire harness;
the dashboard wiie harness.
MAI N WI RE HARNESS Termi nal si de ot mal e t erml nal s
24P CONNECTOR
SRS MAII{ HARI{ESS
l aP CONI {ECTOR
SRS MAIN HARNESS
3P CONNECTOR
Check lho SRS indicator Gircuit input voliage:
1. Reconnect t he SRS mai n harness 18P connect or l o t he
SRS uni t .
(+)
of
t he dashboard 5P connect or and
ground
(l l ),
and measure
ls there 8.5 V or more six seconds after lhe ignilion switch
has been turned ON
(lll?
The Droblem
h.s disappe.red due to disconnecting
antl
connecting
the connectors.
Be sure all lerminals mako
oood cont act , and r echeck t he sysl em l soe
iroubleshooting
Intermittent Failure3 on
page 2{-151'
Poor contact at the SRS main h.rn6s 18P connector; ch'ck
lI the
problem k still
present, replace the SRS main har'
Check for an open in the main wire harness:
mai n wi re harness.
2. Check resi st ance bet ween t he No 6 t ermi nal of t he SRS
mai n harness 18P connect or and No 1 t ermi nal of t he
SRS mai n harness 3P connect or; t here shoul d be 0
-
1 0 o
ls the resistance as spcilied?
ODen in the BLU wire of the main wire hamess; tepair
the main wire harness.
Ooen in the SRS main harness; replace lhe SRS main har
24-33
. L
Troubleshooting
-'98 -
00 Models
{ll}, or
has b66n turned OFF for l ess than three mi nutes, be
careful not to bump the SRS uni t; the ai rbags coutd
accidentally deploy and cause damage or iniuries.
No. 23 {10 Al FUSE
FUSE/RELAY BOX
SRS MAIN HARNESS 18P CONNECTOR
Try to reproduce the SRS indic.tor light:
1. Erase t he DTC memory (see page
24-15).
(l t ),
and check t hat t he SRS
i ndi cat or l i ght comes on f or about si x seconds and ooes
ol1.
Intormittent lailulo, systom is OK atthistime. Soo Trouble
l. o.mittgnl Failuros on
paqe24-15.
Check the No. 23
(10
Alfuse:
2. Check f or bl own No. 23 (10
A) t use i n t he under, dash
fuse/relay box.
Replace ihe fus, and 6.ase the momory
1. Repl ace t he No. 23
110 A) f use.
(see page 24, 15).
(l l ).
Doos the SRS indicator light go off after 3ix second3?
Check tor an open in the SRS msin harness
{VB lincl:
t he posi t i ve
cabl e, and wai t t or t hree mi nut es.
2. Di sconnect t he dri ver' s (and
f ront passenger, s)
ai rbag
connect or(s) (see page
24-11).
3. Di sconnect t he SRS mai n harness 18p connect or I rom
t he sRs uni t .
4. Reconnect the battery positive
cable, then reconnect the
negat i ve cabl e.
(+)
of
t he SRS mai n harness 18P connect or ano
qrouno.
( A)
To page
24-35
24-34
)
From
page 24-34
(A)
SRS MAIN HARNESS I8P CONNECTOR
( B)
To page 24-36
1 )
Wire sidg of lemale terminals
DASHBOARD
WIRE HARNESS
5P CONNECTOR
i c)
To
page 21'31
DASHBOARD
WIRE HARNESS
5P CONNECTOR
c508
t of l emal e
(cont' d)
24-35
SRS MAIN HARNESS
Chock iho SRS unit:
Connect t he SRS mai n harness 18P connect or t ermi nal s No'
6 and No. 3 wi t h a
j umper wi re and backprobe
Doos tho SRS indicator light
go off?
Faulw SRS unit or
poot co tact at the SRS ftain htmes!
18P connoctor; chack the connagtot.
ll tha connoctor b OK roplaca lho SRS unit'
oid tu3e No. 23 t10 A) blow?
Chcck for e short to
ground in th. SRS indicator lighi cir-
cuh:
2. Di sconnei t t he dashboard wi re harness 5P connect or
f rom t he gauge assembl y.
3. Check res-ista;ce between the No l terminai ofthdash-
board wi re harness 5P connect or and
ground There
shoul d be
' 1
M0 or more.
Short to
glound in th.
gaugs aslomblY; .6plac' th'
gtug'
JUMPEB WIRE
o !
Troubleshooting
-
'98
-
00 Models
(cont,dl
From page 24 35
1 B)
Check the SRS indicetor circuit:
2. Bemov e t he gauge as s embl y , Do not dl s c onnec t t he
dashboar d wi r e har ness 5P connect or f r om t he gauge
assemol y.
( l l )
4. Connect t he dashboar d wi r e har ness 5P connect or t er mi -
j umper
wi r e.
Does the SRS indicator light go
om
YES
NO
Faulty SRS indicator light circuit in the
9au96
assembly;
repl ace t he SRS pri nt ed
ci rcui t board i n t he gauge
essembly.
Check for an open in the SRS indicator light circuit:
r. rurn rne rqnrt on swrt ch ut -t -.
2. Di sconnect t he dashboar d wi r e har ness 5p connect or
f rom t he gauge assembl y.
3. Check resi st ance bet ween t he No. 6 t ermi nal of t he SBS
mai n harness 18P connect or and No. I t ermi nal of t he
dashboard wi re harness 5P connect or; t here shoul d be
0 1. 0 0.
ls the resistance as soecified?
NO
YES
( D)
To page
24 38
( E)
To page 24-38
5P CONNECTOR
OASHBOARD WIRE HAR'{ESS
5P CONNECTOR
llTf;rv;1c508
.1#
I
Bru
lYEr
JUMpER WI RE
rermi nat s
SRS MAIN HARi{ESS
I8P CONNECTOR
c807
24-36
DASHBOAED WIRE HARNESS
)
From
page 24-35
(c)
DASHEOARD
WIRE HARNESS
24P CONNECTOR
DASHBOARD WIRE
HARNESS 24P CONNECTOR
BLU
l )
Wke side oI female
t ermi nal s
MAIN WIBE HARNESS
3P CONNECTOR
3P CONNECTOR
SRS MAIN HARNESS
3P CONNECTOR
(cont' d)
MAIN WIRE HARNESS 24P CONNECTOR
Check lor a 3hort to
glound in tho main wira harno$:
f rom t he mai n wi re harness.
2, Check resi st ance bet ween t he No 5 t ermi nal of t hedash-
board wi re harness 24P connect or snd
ground There
shoul d be 1 M0 or more
Short to giound in tha dalhbo!]d wir! ha]n'$; t'plil
lho darhborrd wira hrrnos!.
Chock for ! shon to ground in tho SRS main herness:
2. Check resistanco botween the No. 1 terminal of the SRS
main harness 3P connector and
ground, There shor,lld be
Short to ground in tha main wir6 hainoss; r'Prir the
Short to
ground in thc SRS main harn6s; leplac' th' SRS
l 1 '
24-37
Troubl eshooti ng
-'98 -
00 Models
(cont'dl
From page 24 36
( D)
Check the SRS indicetor circuit input voltage:
1. Reconnect t he SRS mai n harness l 8P connect or t o t he
SRS uni t .
(+)
of
t he dashboard 5P connect or and ground.
( l l ) ,
wai t f or si x seconds,
t hen measure vol t age,
ls thre 8.5 V or more?
YES
NO
The problem
has disappared due to di3connecting and
conneding the connectors. Be su.e all te.minals make
good cont act , and recheck t he syst em
{see T. oubl e-
shooting Inte.miftent Failures on page 24-15).
Poor contact et the SRS main harnass 18p connactori check
the connector,
.
ll the connector is OK, substitute a known-good SRS unit,
and recheck.
'
It the problem is still present, replace the SRS main haF
ness.
From page 24-36
Check for an open in the dashboard wir6 harness:
1. Di sconnect t he mai n wi re harness 24P connect or f rom
t he dashboard wi re harness.
mai n harness 18P connect or and No. 5 t ermi nal of t he mai n
wi re harness 24P connect or; t here shoul d be 0
-
1. 0 0.
ls the resistance as 3pecitied?
YES
NO
Open i n t he BLU wi re ot t he dashboard wi re harness;
repair the dashboard wire harness.
Check tor an open in the main wire haanoss:
2. Check resi st ance bet ween t he No. 6 t ermanal of t he SRS
mai n harness 18P connect or and No. 1 t ermi nal of t he SRS
mai n harness 3P connect or; t here sho! l d be O
-
l . O 0.
ls the resistance a! specified?
YES
NO
Open in the BLU wire of the m.in wire ha.ness: .eoair
the main wire harness.
Open in the SFS main hrrness; replace the SRS main har-
ness.
5P CONNECTOR
c508
Termi nal si de of mal e l ermi nal s
SRS MAIN HARNESS
18P CONNECTOR
c807
c41 l
SRS MAIN HARNESS
18P CONNECTOR
cao2
SRS MAIN HARNESS
3P CONNECTOR
24-38
\
. J
No DTC
-' 98 -
00 Model s
CAUTION: Whenever the i gni ti on swi tch i s ON
(l l ),
or
has been turned OFF for l ess than three mi nui es. be
careful not to bump the SRS uni l ; the ai rbags coul d
accidentally
deploy and cause damage or iniuries
(A) To page 24' 40
Check for short to
ground betweon the under-dash
fuse/
relav box end the SRS unil
1. TLr r n t he i gni t i on swi t ch OFF
2, Di sconnect t he bat t er y negat i ve cabl e, t hen dr sconnect
t he
posi t i ve cabl e, and wai t f or t hr ee mi nut es'
3. Di sconnect t he dr i ver ' s { and f r ont
passenger ' s ai r bag)
connect or { s) { see
Page
24_11)
4. Di sconnect t he SRS mai n har ness 18P connect or i r om
5. Check r esi st ance bet ween t he No 7 t er mi nal of t he SRS
mai n har ness 18P connect or and
gr ound
Ther e shoul d be 1 M0 or mor e
(cont' d)
No. 13 {15 A) FUSE
sRs MAIN HARNESS
Check the tuse:
Check I or bl own No 13 {15 A) f use i n t he under dash f use/
Bepl ace t he f use. Turn t he i gni t i on swi t ch ON
(l l l , and check
t hat l he t use doesn' t bl ow
The oroblem
has disappeared. Test'drive thc vehicle and
s6e Troubleahoodng lntermittent Failures on pago 2&15
Faufty SRS uniu replace the SRS unii
(see page 21-761'
( 8)
To page 24 40
O1 '
24-39
Troubleshooting
No DTG
-' 98 -
00 Model s
(cont' dl
t rom page 24 39
SRS MAIN HARNESS
2P CONNECTOB
SRS MAIN HARTESS
18P CONNECTOR
FUSE/RELAY BOX
c807
c807
Wir side ot fsmale
t ermi nal s
SRS MAIN HAR ESS
l AP CONNECTOR
( Bi
Check for short to ground in iho SRS main ha.no$:
under-dash f use/ rel ay box.
2. Check resi st ance bet ween t he No. 7 t ermi nal of t he SFS
mai n harness 18P connect or and ground. There shoul d
be 1. 0 MO or more.
ls lha r6i3tlnce as sp.cilied?
YES NO
Short t o
ground
i n t he und. . -d. sh t u3a/ r. l ay box;
roplace the undsr-dlrh tu!6/rahy box.
Short to ground in fho SRS main harness; rsplecc the SRS
main htrnors.
Check lor an open in the SRS main harnls:
1- Turn t ho i gni t i on swi t ch OFF.
2. Di sconnect t he baf t ery negat i ve cabl e, t hen di sconnect
t he
posi t i ve
cabl e, and wai t f or t hree mi nut es.
3. Di sconnect t he dri ver' s (and
f ront passenger' s)
ai rbag
connect or(sl
(see page
24-11).
4. Di sconnect t he SBS mai n harness 18P connect or t rom
t he sRs uni t .
5. Reconnect t he bat t ery posi t i ve
cabl e, t hen reconnect t he
negat i ve cabl e.
6. Connect a vol t met er bet ween t he No. 7 t ermi nal ol t he
SFS mai n harness 18P connect or and
qro! nd.
(l l ),
and measure
Poor contact rt the SRS main harness 18P conn.ctor:
chock th 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.
(A)
From page 24 39
To page 24. 41
24-40
)
From
page 24-40
Check for an open in the SRS main harn6s:
under-dash fuse/relay box
3. Check resi st ance bet ween t he No. 1 t ermi nal ol t he SRS
mai n harness 2P connect or and No. 7 t ermi nal of t he
SRS mai n harness 18P connect or.
Th e r e s h o u l d b e 0
0 5 O
ls the resistance es specitied?
YES
Poor cont act at t he SRS mai n hat ness 2P connect or;
check the connector-
.
It the connector i3 OK, substitute a known-good undr-
dash fuse/relav box, and recheck.
. l l
t he Drobl em i 5 st i l l
presnt , repl ace l he SRS mai n
harness.
NO
Open in the SRS main hsrness; leplaco the SRS main har-
ness.
)
FUSE/RELAY BOX
SRS MAIN HARNESS
18P CONNECTOR
c807
Wi r e si de of f emal e
t er mi nal s
SRS MAI N HARNESS
2P CONNECTOR
24-41
l r t
Troubl eshooti ng
DTC 1-1 and DTG 1-2
CAUTION: Whenever the i gni ti on swi tch i s ON 0l ), or
has been turned OFF for l e33 than three mi nutes, be
careful not to bump the SRS unit; the airbagls) could
accidentally deploy and cause damage or inluries.
REEL
2P CONNECTOR
AZ
-
SZ5011A
07sAz-TB{0t1A
t2 0 JACKT
-
CABLE
REEL
2P CONNECTOR
07TAz
-
SZ5011A
DRIVER'S AIRBAG
SRS MAIN HARNESS
Try to reproduc the SRS indicator light:
l see
page 24, ' 15).
2. Turn t he i gni t i on swi t ch ON {l l ), and check t hat t he SRS i ndi -
cator light comes on lor about six seconds and goes off.
Does the SRS indicator liqht 3tav on?
Intermittent lailure. system is OK at this time. So Tlouble
Intermittent Failur6 on Deqe 24-15.
Check for en open in th driver's airbag inllator:
2. Disconnect the battery negative cable, then disconnect the
positive
cable, and wait for three minutes.
3. Disconnect the driver's airbag 2P connector from the cable
reel 2P connector.
CAUTION: Do not disconnect the pa9,!eng6.,s
ailbag con-
nector.
4. Connect t he speci al t ool {2 0)t o t he cabl e reel 2P connec,
t or.
5. Reconnect the battery positive cable, then reconnect the
negat i ve cabl e,
6. Erase t he DTC memory {see
page 24 15}.
7. Read t he DTC {see
paqe
24-13).
ls OTC 1-1 or DTC 1-2 indicatod?
Open or incroasd resistanc in the driver's ai.bag inoa-
tor; rplace the d ve/s airbag
lse6
pege
24?).
Check for an opgn in the cabl6 reel:
t he posi t i ve
2. Di sconnect t he speci al t ool {2 O) f rom t he cabl e reel 2p
connect or,
3. Remove t he dashboard l ower cover, and di sconnect t he
cabl e reel 2P connect or f rom t he SRS mai n harness.
4. Connect t he speci al t ool {2 0} t o t he SRS mai n harness
2P connect or,
{cont ,
To page
24-43
(2
0 JACK)
24-42
l !
)
1 J
From page 24-42
Check for an opgn in the cabl6 reel
(cont'd):
5. Reconnect the battery
positive cable, then roconnect the
negat i ve cabl e.
6. Eraset he DTC memory
(see page 24 15i
7. Read t he DTC
(see page 24-13).
l. DTC 1-l or DTC 1-2 indicrt.d?
Opan or incraGad rcsbtanca in tha crbla raal; rapllca
Chcck lor .n oDcn in th. SBS mtin harne$i
1. Disconnct the battery negative cabl, then disconnect
t he
posi t i ve cabl e, and wai t t or t hree mi nut es
2, Disconnect the lront passgnger's airbag connoctor from
the SRS main harness
(with
front psssengr's airbag).
3. Di sconnect t he SRS mai n harnss 18P connect or f rom
t he SRS uni t . Do not di sconnect t he speci al t ool {2 0)
from the SRS main harness 2P connector.
4. Check resistance betlveon terminals No. 1 and No 13 ot
the SRS main harness 18P connector.
There shoul d be approx. 2. 0
-
3. 0 O.
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 i ncr6asad r. si 3t l nca i n t ha SRS ml i n hat naar;
l f r
24-43
Troubleshooting
DTC 1-3
CAUTION: Whenever the i gni ti on swi tch i s ON {l l l , or
has been turned OFF l or l ess than thrEe mi nutes, be
caroful not to bump the SRS uni t; the ai rbag(s) coul d
accidenlally deploy and cause damage 01 iniuries.
DRIVER'S AIRBAG
ASSEMALY
REEL
2P CONNECTOR
AZ
-
SZ5011A
07saz
-
TB4011A
{2 0 JACK)
CABLE
REEL
2P CONNECTOR
07TAZ
-
SZ5011A
TrV to reproduce the SRS indicator light:
24-15).
(l l ),
and check t hat t he SRS i ndi
cator light comes on for about six seconds and goes
off.
Does the SRS indicalor light stav on?
YES
NO
Intermittent lailure. system is OK ai this tim. Se Troubl-
shooting Intermittent Failures on page
24-15.
Check tor a short lo another wire in the drivo.'s eirbrg in{la-
t he posi t i ve
3. Di sconnect t he dri ver' s ai rbag 2P connect or f rom t he
cabl e reel 2P connect or,
CAUTI ON: Do not di sconnect t he passenger' s
ai rb. g
connector,
4. Connect t he speci al t ool
(2
0)t o t he cabl e reel 2P connec
t or,
5. Reconnect the baftery positive cable, then reconnect the
negat i ve cabl e,
(see page 24 15).
7. Read t he DTC
(see page 24-13).
ls DTC 1-3 indicated?
NO
YES
Shon in the driver's airbag intlator; replace the driv-
er's airbag {see
page 24-67}.
Check lor a short in the ceble reel:
1. Di sconnect t he bat t er y negat i ve cabl e, t hen di sconnect
t he posi t i ve
cabl e, and wai t f or t hr ee mi nut es.
2. Di sconnect t he speci al t ool
( 2
O) f r om t he cabl e r eel 2p
3. Remove t he dashboar d l ower cover , and di sconnect t he
cabl e r eel 2P connect or f r om t he SRS mar n nar oess.
( 2
O) t o t he SRS mai n har ness
2P coonect or .
{ cont , di
f o page24- 45
SRS MAIN HARNESS
24-44
07sAz
-
TBr011A
t2 0 JACKI
)
Ftom
page 24-44
Check for a shon in the cable reel lcont'dl:
5, Reconnect t he bat t er v Dosi t i ve cabl e, t hen r econnect t he
negat i ve cabl e.
6. Er ase t he DTC memor y
( see page 24- 15) .
7. Read t he DTC l see
page 24' 13).
Chck tor a shon in the SRS main harness:
t he
2. Disconnect the front passenger's airbag connector from
t he SRS mai n harness
(wi t h
f ront passenger' s ai rbag).
t he SRS uni t . Do not di sconnect t he speci al t ool
(2
0)
f rom t he SRS mai n harness 2P connect or.
4. Check resi st ance bet ween t ermi nal s No. 1 and No. 13 of
t he SRS mai n harness
' 18P
connect or.
There shoul d be aDorox. 2. 0
-
3. 0 0.
SRS unit; replace lhe SRS unit lsee
ptge 21-
Short in the SRS m.in ha.ness; roplace the SRS mein hal-
Short i n t he cabl e reel ; repl ace t he cabl e reel
(see
page 21-721.
SRS UNIT
I J
o 1 |
24-45
Troubleshooting
! DTC 1-4
CAUTION: Whenever ths i gni ti on 3wi i ch i s ON {l l l , or
has boen turned OFF tor l oss than three mi nutes, bs
caroful not to bump the SRS unit; the airbagls) could
accidoDtally deploy and cause damage or iniulies.
07SAZ
-
TB,()11A
(2
0 JACKI
CABLE
REEL
2P CONNECTOR
07TAZ
-
Szsol'lA
24-46
DRIVER'S AIRBAG
CABLE REEL
2P CONNECTOR
Try to roproduc. the SRS indic.lor lightr
(see page
24-15).
(l l ),
and check t hat t he SRS i ndi -
cator light comes on tor about six seconds and
goes
off.
Ooes th6 SRS indicltor liqht stey on?
YES NO
Intermitid{ failure, 3y3tem b OK at this time. Se Troublo-
shooting Intormittont Failurss on pago 24.15.
Check for a 3hort to powo. in the d.iver's .irbag inflator:
the
positive
cable, and wait for three minut6s.
cabl e reel 2P connect or.
CAUTION: Do not disconnoct the parsengcr'r
airbag
connactoa.
4. Connect t he SRS servi ce connect or
(2
O) t o t he cabl e reel
2P connector.
5. Reconnect t he bat t ery
posi t i ve
negat i ve cabl e.
6. Eraset he DTC memory
(see page
24-15).
7. Read t h6 DTC {seo
page 24-13},
ls OTC 1-4 indic.tedT
YES NO
Short to pow.r in the driver'i rirbrg inilrtor; rpl.co
the driver'! airbag l!e.
paga 24-67).
Check for a ahort to Dowr in tha crblo.eet:
1. Di sconnect t he bat t ery negat i ve cabl , t hen di sconnect
t he posi t i ve cabl e, and wai t f or t hree mrnurs.
2. Di sconnect t he speci al t ool
(2
O) t rom t he cabl e reel 2P
cononect or.
3. Bemove t he dashboard l ower cover, and di sconnect t he
cabl e reel 2P connect or t rom t h SRS mai n harness.
4. Connect t he speci al t ool 12 0) t o t he SRS mai n harness
2P connect or. (cont ' d)
fo page 24-47
SRS MAIN HABNESS
t2 0 JACK)
)
From page 24-46
Chock for a short to
power in the cabls roel lcont'dl:
5. Reconnect the battery positive cable, then reconnect the
negat i ve cabl e.
6. Erase t he DTC memory l see
page 24-15).
7. Read t he DTC
(see pa1e24-131.
b DTC 1-4 indicatd?
YES NO
Short to
power in tho cable reel; roplac. tho cable reel
lsee Dase 24-721.
Chock for e short to
powot in the SRS main hornoas:
1. Di sconnect t he bat t ery nogat i ve cabl e, t hen di sconnect
t he
2- Di sconnect t he f ront passenger' s ai rbag connect or l rom
the SRS main harness
(with front passenger's airbag).
3. Remove t he speci al t ool
(2
0) t rom t he SRS mai n harnss
2P connector.
/ t . Di sconnect t he SRS mai n harness 18P connect or f rom
t he sRs uni t .
5. Reconn6ct the battery positive cable, then reconnect the
negat i ve cabl e.
6. Connect a vol t met er bet ween t he No. 1 {+i t ermi nal of
t he SRS mai n harness 18P connect or and body ground.
7. Turn t he i gni l i on swi t ch ON l l l ), and measure vol t age
There shoul d be 0. 5 V or l ess.
9. Connect a voltmeter between the No. 13
(+)
torminal ol
t he SRS mai n harness 18P connect or 8nd body ground.
l O. Turn t he i gni t i on swi t ch ON
(l l ),
and measure vol t age
Aro voltrges a3 specified?
YES
NO
Fauftv SRS unh; roplacc tho SRS unh {soe
pago 2+761'
Short to
power in the SRS main h.rness; .eplace rhe SRS
main harness.
SRS UNIT
I J
a 0
24-47
Troubl eshooti ng
DTC 1-5
CAUTION: Whenever the i gni ti on swi tch i s ON {l l ). or
has been turned OFF for l ess than three mi nutes, be
caretul not to bump ths SRS uni t; the ai rbag(sl coul d
J
DRIVER'S AIRBAG
2P CONNECTOR
SRS MAIN HARNESS
2P CONNECTOR
DRIVER'S AIRBAG
ASSEMBLY
REEL
07sAz
-
TB40't1A
(2
0 JACK)
2P CONNECTOR
AZ
-
SZ5011A
CABLE
REEL
2P CONNECTOR
I
07TAZ
-
SZ5011A
Try to rep.oduce the SRS indicator light:
1. Eraset he DTC memorv
(See page
24' 15).
(l l ),
cator light comes on tor about six seconds and goes off.
Ooes the SRS indicator light stay onl
YES NO
Intermittent lailure, system is OK at this time. See Trouble-
shooting lntormittent Failure3 on
page
24-15.
Check for a short to ground in lh driver's airbag inllator:
2. Di sconnect t he bat t er y negat i ve cabl e, t hen di sconnect
t he posi t i ve cabl e, and wai t f or t hr ee r ni nut es.
3. Di sconnect t he dr i ver ' s ai r bag 2P connect or f r om t he
cabl e r eel 2P connect or .
CAUTI ON: Do not di sconnect t ho p. ssenger ' s
ai r bag
connectoa.
( 2
0) t o t he cabl e r eel 2P connec
t or .
5. Reconnect t he bat l er y
posi t i ve
cabl e, t hen r econnect t he
negat i ve cabl e-
6. Er ase t he DTC memor y
( see page 24- 15) .
7. Read t he DTC
( see page 24- 131.
ls OTC 1-5 indicatedT
YES
NO
Short to ground in the drive/s airbeg inflator; rpl.ce the
driver's.iib.g
(see page
24d1.
Check lor a short to
ground
in the csble reer:
l . Di sconnect t he bat t ery negat i ve cabl e, t hen di sconnect
t he posi t i ve cabl e, and wai t f or t hree mi nut es.
2. Di sconnect t he speci al t ool {2
(})
f rom t he cabl e reel 2P
3. Remove t he dashboard l ower cover, and di sconnect t he
cabl e reel 2P connect or f rom t he SRS mai n harness.
4. Connect t he Speci al t ool {2 0} t o t he SRS mai n harness
2P connect or
(cont ' d).
To page 24- 49
{2 0 JACK)
24-44
. I
)
T J
From page 24-48
Check for a ahort to ground in th. cabl. r.el
(cont'd):
positive
nagativ cable.
(see page 24-15).
7. Read the DTC
(see page
24-13).
b DTC 1-5 indicli.d?
YES NO
Short to ground in tho crblc rocl; rophce the crble roel
k c orsa 2+721.
Chock for e short to ground in tha SRS main harneas:
1. Di sconnect t he bat t ery negat i ve cabl e, t hen di sconnoct
the
positive
cable, and wait lor three minutes.
2. Di sconnect t he t ront passenger' s ai rbag 2P connect or
f rom t he SRS mai n harnsss {wi t h f ront passengr' s
ai rbag).
3 Romove t he speci al t ool
(2
0)t rom t h6 SRS mai n harness
2P connoctor,
4. Chck resistance between the No. 1 terminal of the SRS
mai n harness 18P connect or and
ground.
and bet wgen
t he No. 13 t ermi nal of t he SRS mai n harness' l 8P connec-
tor and
grouncl.
There shoul d bo I Mo or more,
la tha raidrnc! .3 rDccified?
NO YES
Flulv SRS unit rcpl.c. th. SRS unit {re
prg.2+161,
Shon to
ground in th. SRS m.in h.rno$; r.pl.ce tho SRS
main harnaas.
SRS UN]T
I r ,
24-49
Troubleshooting
DTC 2-1 and DTC 2-2
-
With Front Passenger's Airbag
(ll),
or
has been turned OFF for l ess than thre mi nutes, be
careful not to bump th SRS uni t; the ai rbags coul d
accidntally deploy and cause damage 01 iniuries.
Try to reproduce the SRS indicator light:
(see page 24-15).
(l l ),
goes
off.
Does the SRS indicator liqht stay on?
NO YES
Intrmitlnl failure, sFtem is OK at thb time. Soe Trouble-
shooting Intermittent Failures on page 24-15.
Check tor an open in the pminger's
airbag inflator:
2. Di sconnect t he bat t ery negat i ve cabl e, t hen di scohnect
t he posi t i ve cabl e, and wai t t or t hree manut es-
3, Di sconnect t he f ront passenger' s
ai rbag connect or l rom
t he SRS mai n harness {see
page 24. 1 . . .
(2
0) t o t he SRS mai n harness
2P connect or,
CAUTION: Do not disconnect the driver's airbag connec-
tot,
positive
negat i ve cabl e.
(see page 24-' ! 5).
7. Read t he DTC
(see page 24-13).
ls DTC 2-l or DTC 2-2 indicated?
NO YES
Opon or increased rosistance in the pa$enger's
airbag
inflator; replace tho passnqor's
airbaq lsee
paEJe2a$71.
Io page
24-51
FRONT PASSENGER'S
AIRBAG 2P CONNECTOB
-
sz50r1A
07sAz
-
TB4011A
{2 0 JACK}
24-50
MAIN HARNESS
I
o 1
From
page 21 50
Check for an open in the SRS main ha.ness:
t he
posi t i ve cabl e, and wai t f or t hree mrnrrt es
cabl e reel 2P connect or
(see page 24 11)
3. Di sconnect t he SRS mai n harness 18P connect or f rom
t he SRS uni t . Do not di sconnect t he speci al t ool
(2
0)
f rom t he SRS mai n harness 2P connect or'
4- Check resi st ance bet ween t he No. 10 t ermi nal and No. 14
t ermi nal of t he SRS mai n harness 18P connect or' There
shoul d be apProx 2 0 3. 0 0
ls the resislance as specified?
NO
YES
Poor contact at the SRS m.in harness 18P connector;
check the connector'
.
ll the connector is OK, substituto a known_good SRS
unh. and rccheck,
.lf
the
problm is still
present, replace th SRS main
narness,
Ooen or i ncret sed resi st ance i n t he SRS m. i n harness;
replac6 the harness.
SRS UNI T
SRS MAIN
18P CONNECTOR
. J
l 0
24-51
Troubleshooting
DTC 2-3
-
CAUTIONT Whanever i he i gnhi on swi tch i s ON l l l ), or
has been turnod OFF l or l e33 than threo mi nutes. be
careful not to bump l he SRS uni t; ths ai rbags coul d
accidontally deploy lnd cause damage or inluries.
FRONT PASSENGER'S
AIRBAG 2P CONNECTOR
-
szsor la
{2 0 JACK)
Try to reproduce tho SRS indicator light:
1. Erase the DTC memory
(see page 24 15).
2. Turn t he i gni t i on swi t ch ON 1l l ), and check t hat t he SRS i ndi ,
goes
off.
Doe3 the SnS indicator light 3t.y on?
NO YES
Intermittort tailura, 3y3tem b OK at this time. Se Trouble-
shooting Intormittent Failuros on page 24-15.
Check tor a 3hort io another wire or dec.oasod relirtanct in
th6 passonger's airbag inflato.:
t he Dosi t i ve cabl e, and wai t f or t hree mi nut es.
3. Di sconnect t he t ront passenger' s ai rbag 2P connect or
f rom t he SFS mai n harness
(see page 24-11).
(2
O) t o t he SRS mai n harness
2P connect or.
CAUTION: Do not disconnct th6 driver's airbag connec-
tor.
5. Reconnect the baftery positive
cable, then .econnect tho
negative cable.
6. Erase t he DTC memory {see
page 24-15).
7. Read t he DTC
(see page 24 13).
l. DTC 2.3 indicated?
YES NO
Short io another wiao or dcreased rcsi3tanc6 in the prs-
3enger's airbag intlator; repl.ce the passong.r's
.irbag
lsee
page 2467).
To page
24-53
24-52
l
)
) J
Frcm page 24-52
Check tor a short to another wira or docroased tesistanco in
th SRS main hamess:
t he
posi t i ve cabl e, and wai t t or t hree manut es.
cable reel 2P connector.
the SRS unit. Do not disconnect the special tool
(2
0) Irom
the SRS main harness 2P connector.
4. Check rosi st ance bet ween t he No. 10 t ermi nal and No. 14
t ermi nal of t he SRS mai n harness 18P connoct or. There
shoul d be approx. 2. 0
-
3. 0 f ).
SRS MAIN HARNESS
18P CONNECTOR
I t t
24-53
Troubleshooting
J
DTC 2-4
-
CAUTION: Whenever the i gni ti on swi tch i s ON
l l l ), or
has been turnod OFF for l ess than throa mi nutes, be
car.Iul not to bump the SRS uni t; the ai rbags coul d
acci dental l y depl oy and cause damage or i ni uri es.
Try to rproducethe SRS indicalor light:
1. Erase t he DTC memory (see page 24 15).
(l l ),
cator light comes on Ior about six seconds and goes off.
Does the SRS indicator light stay on?
YES NO
lDtermittenl failure, syltom b OK at this tima. Se Trouble.
shooting Intrmittent Failuros on page 24-15.
Check lor a short to pow6r in the passenger's
airbag intla-
t or:
t he posi t i ve
3. Di sconnect t he f ront passenger' s
ai rbag 2P connect or
f rom t he SRS mai n harness l see
page 2/ t 11).
(2
O) t o t he SRS mai n harness
2P connector.
CAUTION: Do not disconnect the driver's airbag connec-
t or.
5, Reconnect t he bat t ery posi t ; ve
negat i ve cabl e.
6. Erase t he DTC memory (see page 24-15).
7. Bead t he DTC
(see page
24-13).
ls OTC 2-4 indicatod?
YES
NO
Short to power in the passenger's
airbag inflator; replace
tho passenger's
airbag lsee
page
24-67)
To page 24 55
AZ
-
SZ5011A
07sAz
-
TB4011A
12 0 JACKI
L
MAIN HARNESS
24-54
)
Ftom page 24-54
Check lor e short to power in lhe SRS main harness:
t he posi t i ve cabl e, and wai t I or t hree mi nut es.
2. Di sconnect t he dri ver' s ai rbag 2P connect or l rom t he
cabl e reel 2P connect or.
t he sRs uni t .
(2
o) f rom t he SRS mai n harness
2P connect or,
5. Reconnect the baftery
positive cable, then reconnect the
negat i ve cabl e.
6. Connect a vol t met er bet ween t he No. 10
(+)
t ermi nal of
SRS mai n harness 18P connect or and ground.
7. Turn t he i gni t i on swi t ch ON l l l ), and measure vol t age
L Connect a vol t met er bet ween t he No. 14
(+)
t ermi nal of
t he SRS mai n harness 18P connect or and ground, and
measure vol t age. There shoul d be 0. 5 V or l ess.
A16 voltages as specified?
YES
NO
Fauftv SRS unit; repl.ce the SRS unil
(see ptge 24-761
Shon to power in th. SRS main harness; roplace the SRS
main hanes3,
SRS UNIT
1 J
I t t
24-55
Troubleshooting
DTC 2-5
-
With Front Passenger's
Airbag
CAUTION: Whenever the ignition switch is ON 0l). or
has b6n turned OFF tor l oss than three mi nutes. be
careful not to bump tho SRS uni t; th ai rbags coul d
accidentally deploy and cause damage or injuriss.
FRONT PASSENGER'S
AIRBAG 2P CONNECTOR
tl
AZ
-
SZ50114
07sM
-
TB4011A
{2 0 JACK)
24-56
I
MAIN HARNESS
T.y lo reproduce the SRS indicator light:
24, 15).
2. Turn the ignition switch ON l), and check thatthe SRS indi-
cator light comes on for about six seconds and ooes off.
Intermiftem f.ilure, ty3tom ir OK at this timo. See Trouble-
Iniermittent Failuro3 on
paqe
24-15.
7. Read t he DTC { see
page
24- 13) .
Check to. a short to g.ound
in the passenger,s
ai.bag inflator:
2. Di sconnect
t he bat t ery negat i ve cabl e, t hen di sconnect
t he poshi ve
cabl e, and wai l f or t hree mi nut es.
3. Di sconnect t he f ronl passenger, s
ai rbag 2p connecl or
l rom t he SRS mai n harness {see page
24 l t
).
4. Connecl t he speci al t ool
(2
0) t o t he SRS mai n harness
2P connect or,
CAUTION: Do not disconnect the drivor,s airbag connec_
tor.
5. Reconnect t he bat t ery posi t i ve
negat i ve cabl e.
24 15).
Short to ground
in the p8,snger,s
ai.bag infleto.; replaoe
rhe passenger's
airbag
lso
page24{7).
To page
24-57
o !
)
From
page 24-56
Check lor a short to ground in tha SRS main haino$:
1. Di sconnect t h bat t ery negat i ve cabl e. t hen di sconnect
t he posi t i ve cabl e, and wai t f or t hree mi nut es
cable reel 2P connector'
t he sRS uni t .
(2
0) f rom t he SRS mai n harness
2P connector,
5. Check resistance btween the No. 10 terminal ol the SRS
mai n harness 18P connect or and
ground, and bet ween
t he No. 14 t ermi nal ot t he SRS mai n harnoss 18P connec
t or and ground. There shoul d be 1 N/ 10 or more'
k tho rod.tanco .3 3pocified?
YES
NO
Faulty SRS unit; topl.co the SRS unit
(seo page 24-761'
Short to giound in the SRS msin hamets; replacc th SBS
main harno33.
SRS UNlT
SRS MAIN HARNESS
18P CONNECTOR
O l,t
24-57
Troubl eshooti ng
DTC 2-1 and DTC 2-2
-
Wathout Front Passenger's
Airbag
CAUTION: Whenever the i gni ti on swi tch i s ON {l l l . or
has been turned OFF tor l ess than three mi nutes, be
caretul not to bump the SRS unit; the aidag could acci-
dental l y depl oy and causs damage or i ni uri es.
Try to reproduc the SRS indicator light:
1. Erase t he DTC memory {see page
24-15r.
(l l ),
cator light comes on lor about six seconds and ooes off.
SRS UNI T
Intermittent failu.e, system is OK at this time. Se Trouble-
Intermifient Failuies on paqe
24-15.
OUMMY RESISTOR
Check for an open oa increased resistance in the dummv
teslstot:
2. Remove t he dummy resi st or f rom t he SRS mai n harness
2P connect or,
3. Check t he resi st ance bet ween t he A and B t ermi nal s of
t he dummy resi st or. There shoul d be 1. 5
-
2. 5 0.
resistoa.
Check lor an open or incre.sed resisiance in the SRS main
harness:
' 1.
Di sconnect t he bat t ery negat i ve cabl e, t hen di sconnect
t he posi t i ve
l see
page
24 t t ).
3. Di sconnect t he SRS mai n harness t 8p connect or f rom
t he SBS uni t .
4. Connect t he dummy resi st or t o t he SRS mai n harness 2p
connect or.
5. Check resi st ance bet ween t he No- 1O t ermi nal and No. 14
t ermi nal of t he SRS mai n harness 18p connect or. There
shoul d be aDorox. 1. 5
-
2. 5 0.
SRS MAIN HARNESS
18P CONNECTOR
ls the resistance es specitid?
YES
Poor contact ar the SRS main hahess 18p connector;
check the 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.
24-5A
\
Ooes the SRS indicalor light stay on?
Open or i ncreased resi 3t anc6 i n t ho SRS mai n harness;
O U
I
)
DTC 2-3
-
Without Front Passenger's Airbag
CAUTION:
Whenever the i gni ti on swi tch i s ON
(l l l ,
ot
has been turned OFF for l ess than three mi nutes, be
careful not to bump thc SRS unit; the ailbag could acci-
dental l y depl oy and cause damage or i ni uri es.
Try to reproduce the SRS indicator light:
1. Erase t he DTC memory t see
page 24 15).
(l l ),
goes off
Ch6ck for a Short to another wile or decreased resistance in
the dummy resistor:
1. Turn t he i gni t aon swi t ch OFF.
2. Remove t he dummy resi st or f rom t he SRS mai n harness
2P connect or.
SRS UNIT
DUMMY
RESISTOR
3. Check t he resi st ance bet ween t he A and B t ermi nal s of
t he dummy resi st or. There shoul d be 1-5
-
2. 5 O.
Check for a short to another wile or decrea36d r6istance in
the SRS main harness:
1. Di sconnect t he bat t ery negat i ve cabl e, t hen d' sconnect
t he
posi t i ve cabl e, and wai t f or t hree m i nut es
2. Di sconnect t he dr i ver ' s ai r bag 2P connect or f r om t he
(see page 24-l l )
t he sRs uni t .
NOTE: Do not connect t he dummy resi st or t o t he SRS
mai n harness 2P connect or.
4. Check resi st ance bet ween t he No l O t errni nal andNo l i l
t ermi nal of t he SRS mai n harness 18P connect or' There
shoul d be 1 M0 or more.
ls the resistance as
YES
SRS MAIN HARNESS
2P CONNECTOR
I J
A B
ifti
|T'
tiî
DUMMY
RESISTOR
SRS UNIT
SRS MAIN HARNESS
18P CONNECTOR
24-59
Does the SRS indicator light staY on?
l nt ermi t t ent f ai l ure, syst em i s OK ai t hi s t i me See
Intrmittont Failures on
page 2/a'15
ls the resistance as specifiod?
Faufly SRS unit; replace tho SRS unit l3ee
page2+761'
Short to another wiro or decreased resistance in the SFS
main harness; replace the SRS main harne3s.
a t t
Troubleshooting
DTC 2-4
-
Without Front Passenger's
Airbag
CAUTION: Whenever the ignition switch is ON 0l). or
has been turned OFF for l sss l han three mi nutes. be
caretul not bump the SRS unit; the airbag could acci-
dentally doploy and causo damage or iniuries.
Try to rproduc tho SRS indic.to. light:
1. Erase the DTC memory (see page 24,15).
(ll),
and check that the SRS indi-
cator light comes on for about six seconds and gos
off.
Dorthe SRS indicrtor light stay on?
NO
rEs
lntormitteit t ilur., iyst m b OK at thb tim6. Sle Trouble
shooling Intdmitt.nt Frilu.os on pag6
2+lS.
Check for a short to power
in the SRS main h.rna3s:
t he posi t i ve
2. Dl sconnect t he dri ver' s ai rbag 2p connect or f rom t he
cabl e reel 2P connect or (see page
24, 11).
3. Dl sconnect t he SRS mai n harness l 8p connect or t rom
t he SRS uni t .
4. Beconnect the battory positiv
negative cable.
5. Connect a voltmeter between the No. lO
(+)
terminal of
t he SFS mai n hsrness 18P connect or and
qround.
6. Turn t he i gni t i on swi t ch ON {l l ), and me-asure vol t age.
7. Connect a vol t met er bet ween t he No. 14
(+)
t ermi nal of
t he SRS mai n harness 18P connoct or and ground,
and
measure vol t age. There shoul d be 0. 5 V or l ess.
A.e voltage. .3 spocifi.d?
YES
NO
F.ulty SRS uniC .epla"" tl,. SnS unn l"""
p"g"
2+7O:_l
Short to pow.r
in tha SRS mlin harnc$ or tho dummy
r*istor; chock lor contact bctwcen th. dummy r6ai3to. rnd
rnother wiro. lf there is no contrct, rcphcc the SRS msin
hame3s.
SBS UNIT
SRS MAIN
18P CONNECTOR
24-60
I
)
DTC 2-5
-
Without
Front Passenger's
Airbag
CAUTTON:
Whenever the i gni ti on swi tch
i s ON l l l )'
ol
has been turnsd OFF for l ess than three mi nutes'
be
careful
not to bump the SBS unit; the airbag could acci'
dentally
deploY and Gause damage or iniuries'
Tru to .oproduce
the SRS indic'tor light:
1 Eraset he DTC memory {see
page 24 15)'
z. irin tfie ignition s.itch ON
(ll),
and check that the SRS indi-
iatoi ligiricomes on for about six seconOs and
goes otf
Does the SRS indic.tor light stay on7
|
NO
YES
tn---t",-in"m
l"itrt", "v"tem is oK at thb lim' seo Troubl'-
3hooling
Intormitt6nt
Failures on
pago 2+15'
ffih",n"""'
i . oi ""onn""t
t t t e u"t t "ry negat i ve cabl e' t hen di sconnect
the Dositive
dable, and wait lor th ree mrnutes'
z. 6i "J-"""a
t t ' " dri ver' s ai rbag 2P connect or
{f rom
t he
(see page 24_11)'
s. b] ""onn""t , f ' "
SFS mai n harness 18P connect or
f rom
t he SRS uni t .
L di "l f i ""i "on. "
bet ween No l o t ermi nal of t he sRS
mai n harness
18P connect or and
ground and bet ween
i i e t ' l o. t a t ermi nat
of t he SRS mai n harnss 18P connec-
I
t or and
ground There shoul d be 1 Mo or more'
I btheresistanceasso444g14._._
NO
YES
-Faulty
sRs unit; ,epltce the sRs unit
(see page 2+761'
SRS UNIT
SRS MAIN HARNESS
18P CONNECTOR
I J
ness,
6lort to sround
in tho sRS main harness or the dummY
i""i"toi; "-ft""* fot "ont.ct bdtwon the dumTI
Iesbt9r.and
li"r"J.
n irt"t" is no contact. r6pl'co
the sRs mtin h6i'
24-61
o t t
Troubleshooting
DTC 8-6
CAUTION: Whonover the ignition switch is ON lll), or
has been turned OFF for l ess than thro mi nutes, be
careful not to bump th6 SRS uni t; the ai rbags coul d
Besi des i ndi cati ng an abnormal i ty i n the SRS uni t, DTC
8-6 may al so i ndi cate that two probl ems
equi val ent to
DTC 1-l and 2-4, 1-4 and 2-1, ot 1-4 and 2-4 occurred at
the same ti me. Proceed i n the order shown bel ow.
SRS MAIN HARNESS
18P CONNECTOR
\
24-62
Check th. SRS main harn6$:
t he
posi t i ve
2. Di sconnect t he dri ver' s ai rbag
(and
f ront passenger, s
airbag) connector(s) {see
page 21-111.
rhe sRS uni t .
positive
negative cable.
(l l ).
6, Connect a vol t met er and measure vol t age bot ween t he
No. 10 t ermi nal of t he SRS mai n harness 1BP connect or
and ground,
and bet l veen t he No. l { t ermi nal and
qround.
Th6re should be aoDrox. 0
-
0.5 V.
Aro voltages as spacified?
NO
YES
Sho.t to power in tho SRS mrin hamoss; rsplace th6 SRS
main haanac3.
Chacl the SRS main hrrne*s and the cabl. reel:
Connect a voltmeter and measure voltage between the
No. 1 t ermi nal of t he SRS mai n harness 18p connect or
and gr ound,
and bet ween t he No. 13 t er mi nal and
ground.
There shoul d be approx. 0
-
0. 5 V.
Are voltages o3 specilied?
YES
SRS unit; replace the SRS unit
lse6
page
2+76).
NO
To page
24-63
(A)
o 1 ,
, )
I J
t,
From
page 24' 62
(A)
Check the cable reel:
2. Di sconnei t t he cabl e reel 2P connect or f rom t he SRS
mal n harness,
3. Turn t he i gni t i on swi t ch ON {l l }
4. Connect a vol t met er and measure vol t age bet ween t he
No. 1 t ermi nal of t he SRS mai n harness 18P connect or
and
gr ound, and bet ween t he No 13 t er mi nal and
ground. There shoul d be approx. 0
-
0. 5 V'
Are vohtg6 as specifi"dT
-
YES
NO
Short to
powor in the cabto reel; replace thg cable rool
(see page 24'721.
Short to
powet in the SRS main h.rness; replace the SRS
mai n harness.
24-63
Troubleshooting
DTC 9-2
0l), of
has been turned OFF l or l ass than three mi nutes, be
careful not to bump the SRS uni t; the ai rbag(s) coul d
accidentally deploy lnd caqse damage or iniuries.
Check the tu.c:
2. Check f or bl own No. 23 (10
A) f use i n t he under, dash
fuse/relay box.
Repl ace t he t use. Turn t he i gni t i on swi t ch ON l l l ) , and check
t hat t he f use doesn' t bl ow.
Th6 problem
hs3 disappe.rod, TGt-dJiv the vehiclo and
3ee Troublerhooting Intermiftcnt Failuro3 on
paqo
2l-15.
Check tol short to ground
betwe.n tho unde.-da3h fus./
r.ley box and the SRS unit.
t he posi t i ve
cabl e, and wai t t ort hree mi nut es.
3. Di sconnect t he dri ver' s
(and
f ront passenger, s)
ai rbag
connect or(s) (see page
24-11).
4. Di sconnect t he SRS mai n harness 1gp connect or f rom
t he sRs uni t .
5. Check resistance between the No. 3 terminal of the SRS
marn harness 18P connect or and ground,
There shoul d be 1 MO or more.
Feufty SRS unh; rcphce the SRS unit lsee
pag.2+761.
(A)To page 24-65
To page
24-65
No. 23 lr0 Al FUSE
FUSE/RELAY BOX
!
SRS MAIN HARNESS
18P CONNECTOR
SRS UN'T
24-64
I
SRS MAI N HARNESS 18P CONNECTOR
Ot f
)
FUSE/BELAY
BOX
Chcck for an opn in th6 SRS main harness:
2. Di sconne; t t he bat t ery negat i ve cabl e, t hen di sconnect
t he
posi t i ve cabl e, and wai t f or t hree mi nut es'
3. Di sconnect t ho dri ver' s
(and f ront
passenger' s) ai rbag
connect or
(see
Page
24' 11).
t he SRS uni t
positive cable, then reconnect the
neoat i ve cabl e.
6. Co-nnect a voltmeter betlveen the No 3 terminal ol the
SFS mai n harness 18P connect or and
ground'
7. Turn t he swi t ch ON
(l l ),
and masure
(cont' d)
(B) from
page 24-64
Check tor ahort to
ground in the SRS main harn$s:
under-dash f use/ rel aY box.
mai n harness 18P connect or and ground There shoul d
be 1. 0 M0 or more.
ls the re3istance a3 specified?
-
NO
YES
Short t o
gi ound i n t ho undot -drl h l ut ' / rol ' y box;
replace the undel-da3h fusgtgEl!9l--------.-
Short to
ground in tho SRS m.in harn$s; ropleco the SRS
main harness.
(Al From page 24' 64
Poor contact at the SRS main harnoss 18P connoctor;
check lho 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
To page 24-66
SRS MAIN HARNESS
18P CONNECTOR
o 0
24-65
Troubleshooting
DTC 9-2
(cont'dl
2- Di sconnect t he SRS rnai n harness 2p connect or l rom t he
under-dash f use/ rel ay box.
3- Check resi st ance bet ween t he No. 2 t ermi nal of t he SRS
mai n harness 2P conneci or and No. 3 t ermi nal of t he
SFS mai n harness 18P connect or_
Poor cont act at t he SRS mai n ha. ness 2p connect or;
check the connecto..
.
lf the connector is Ol(, sub3titute a known-good under-
dash tuse/rlay box, and recheck.
' l t
t ho probl em
i s st i l l present ,
repl ece t he SRS mai n
Open in the SBS main harness; replace the SRS main har_
ness,
SRS MAIN HARNESS
2P CONNECTOR
24-66
I
\
From page 24-65
Chock tor an open in th SRS main hernss:
There shoul d be 0 0. 5 0
SRS MAIN
SRS MAIN HARNESS
18P CONNECTOR
o !
Ai rbag
)
Repl acement
After a col l i si on i n whi ch the ai rbags were depl oyed'
the
ai rbag assembl i es and the SRS uni t must be repl aced'
!!!@
Store a removed airbag with the
pad sur'
iFup. rr trt" airbag is improperly stored
face down'
acci dent al
depl oyment
coul d
pr opel t he uni t wi t h
enough force to cause serious iniury'
CAUTION:
. Always disconnsct
lhe airbag connctor(s)
when the
harness is disconnected.
. Do not disassemble
or tamper with the ailbag'
NOTE:
. Do not i nstal l used SRS
parts from another
vehi cl e'
When repai ri ng,
use onl y new SRS
parts'
o Careful l y
i nspect the ai rbag before
you i nstal l i t Do
not i ns i al l an ai r bag t hat s hows
s i gns oI bei ng
dropped or i mproperl y
handl ed, such as dents' cracks
or deformati on.
1. Di sconnect
the battery negati ve cabl e' then di scon-
nect the
posi ti ve cabl e from the battery' and wai t at
l east three mi nutes
2. Di sconnect
the ai rbag connector(s):
Driver's Side:
. Remove the access
panel from the steeri ng wheel '
then di sconnecl
the 2P connector
betl veen
the dri v-
er' s ai rbag and cabl e reel
NOTE: When di sconnected,
the ai rbag connector
l s
automati cal l Y
shorted
ORIVER'S
AIRBAG
DRIVEE'S AIRBAG
2P CONNECTOR
o o
Front Passengel's
Side:
. Di sconnect
the 2P connector between the front pas-
senger' s ai rbag and SRS mai n harness'
NOTE: When di sconnected,
the ai rbag connector i s
automati cal l Y
shorted. FRONT PASSENGER'S
AIRBAG
2P CONNECTOR
3. Bemove the ai rbag(s):
Driver's Side:
. Remove the two Torx bol ts usi ng a Torx T30 bi t' then
remove the dri ver' s ai rbag
(cont' d)
24-67
SRS MAIN HARNESS
Use a Torx T30 bit
TORX BOLTS
Airbag
Replacement
(cont'd)
Front Passenger's Side:
. Remove the three mounti ng nuts from the bracket,
then remove the harngss cl i p.
. Li ft the front passenger' s
ai rbag out of the dashboard
by coveri ng the l i d and dashboard wi th a cl oth, and
prying carefully with a flat-tip screwdflver.
NOTE: The l i d of the ai rbag has pawl s
on i ts si de
whi ch attach i t to the dashboard.
24-6a
CAUTION: B sure to inslall the SRS wiring so that it is
not pinched
or interforirg with other
parts.
4. Instal l the new ai rbag(s):
Driver's Side: Place the driver,s airbag into the steering
wheel , and secure i t wi th new Torx botrs.
TORX BOLTS
9.E N.m
(1,0
kgf.m, 7.2 tbt ftl
Replace.
Front Passngar's
Side:
. Pl ace t he f r ont passenger , s
ai r bag i nt o t he dash-
board.
. Ti ghten the front passenger,s
ai rbag mounti ng nuts.
ANAAG MOUNTING NUTS
9.8 N.m 11.0 kgf.m, 7.2lbf.frl
Repl ace.
DRIVER'S AIRBAG
)
5, Reconnect the ai rbag connector(s)'
Front Passengor's
Side:
a Attach the ai rbag connector to the connector hol der'
then rei nstal l the
gl ove box.
FRONT PASSENGER'S
AIRBAG
o o
24-69
Driver's Side:
a Connect the dri ver' s ai rbag 2P connector to the cabl e
reel 2P connector, then i nstal l the accss panel on the
steering wheel
DRIVER'S AIRBAG
2P CONNECTOR
6. Connect t he bat t ery
posi t i ve cabl e, t hen connect t he
negati ve cabl e.
7. After i nstal l i ng the
operatl on:
. Turn the i gni ti on
t or l i ght shoul d
and then
go off
a Make sure both horn buttons
work
ai rbag, confi rm Proper
sYstem
swi tch
ON
(l l );
the SRS i ndi ca-
come on for about si x seconds
Airbag
Disposal
Before scrappi ng any ai rbags
(i ncl udi ng
those i n a whol e
vehi cl e to be scrapped), the ai rbags must be depl oyed. l f
the vehi cl e i s sti l l wi thi n the warranty peri od,
before you
depl oy the ai rbags, the Honda Di stri ct Servi ce Manager
must gi ve approval and/or speci al i nstructi ons.
Onl v after
the ai rbags have been depl oyed (as
the resul t of vehi cl e
col l i si on, for exampl e), can they be scrapped.
l f the ai rbags appear i ntact
(not
depl oyed). treat them
wi th extreme cauti on.
Fol l ow thi s p.ocedure:
Deploying the Airbags: In.vehiclo
NOTE: l f an SRS vehi cl e i s to be enti rel y scrapped, i ts
ai rbags shoul d be depl oyed whi l e sti l l i n the vehi cl e. The
ai rbags shoul d not be consi dered as sal vageabl e parts
and shoul d never be i nstal l ed i n another veh;cl e.
! @
conf i r m t hst oach ai r bag assembt y i s
securel y mounted; otharwi so. sevre personal
i ni ury
could result lrom deployment.
1. Di sconnect
the baftery negati ve cabl e, then di scon_
nect the posi ti ve
cabl e.
2. Confi rm that the speci al tool i s functi oni ng properl y
by fol l owi ng the check procedure
on the tool l abel
or on page
24-'l'l .
Driver's Airbag:
3. Remove the access panel ,
then di sconnect the 2p
connector between the dri ver,s ai rbag and the cabl e
reet.
DRIVER' S
AIRBAG
2P CONNECTOR
24-70
BATTERY
. U
Front Passenger's
Airbag:
4. Remove the gl ove
box, then di sconnect the 2p con-
nector between the l ront passenger,s
ai rbag and
SRS mai n harness.
FRONT PASSENGER'S
AIREAG
2P CONNECTOB
SRS MAIN HARNESS
Cut off the ai rbag connector, stri p the ends of the
ai rbag wi res, and connect the depl oyment tool al l i _
gator
cl i ps to the ai rbag.
pl ace
the depl oyment tool
at l east thi rty feet (10
meters) away from the ai rbag.
a !
DRIVER'S
AIRBAG
FRONT PASSENGER'S
AIRBAG
ALLIGA
CLIPS
(Yellow)
ALLIGATOR
CLIPS
{Yellowl
At loast
thiny toet
(10
metorsl
E-
) I
Connect a 12 vol t battery to the tool :
. l f the
green l i ght on the tool comes on, the aar-
bag i gni ter ci rcui t i s defecti ve and cannot depl oy
t he ai r bag. Go t o Damaged Ai r bag Spec i al
Procedure.
. l f the red l i ght on the tool comes on, the ai rbag i s
ready to be depl oyed.
Push t he t ool ' s depl oyment swi t ch. The ai r bag
shoul d depl oY
(depl oyment
i s both hi ghl y audi bl e
and vi si bl e; a l oud noi se and rapi d i nfl ati on of the
bag, fol l owed by sl ow defl ati on).
. l f the ai rbags depl oy and the
green l i ght on the
tool comes on. conti nue wi th thi s
procedure.
. l { an ai rbag doesn' t depl oy, yet the
green l i ght
comes ON, i ts i gni ter i s defecti ve. Go to Dam-
aged Ai rbag Speci al Procedure.
!!@
During doployment, the airbag sssom'
bly can become hot enough to buln
you. Wait thir'
ty minutes aftsr deployment belore touching tho
assembly.
Di spose of the compl ete ai rbag assembl y. No part
of i t can be reused. Pl ace i t i n a sturdy
pl asti c bag,
and seal i t securel Y,
CAUTION:
. Wear a fsce shield and
gloves when handling a
deployed airbag.
. Wash
your hands and r i nse t hem wel l wi t h
wat6r after handl i ng. depl oyed ai rbag.
t ( '
24-71
7.
AIRAAG
Doploying th6 Airbag: Out-of-vehicle
NOTE: l f an i nt act ai r bag has been r emoved f r om a
scrapped vehi cl e. or has been found defecti ve or dam-
aged dur i ng t r ansi t , st or age or ser vi ce, i t shoul d be
depl oyed as fol l ows:
@
Po3ition the airbag laca up, outdoors on
flat ground at lsast thirty ft
(t0
ml from any obstacles
or people.
1. Confi rm that the speci al tool i s tuncti oni ng
properl y
by fol l owi ng the check
procedure on thi s
page or on
the tool l abel .
2. Fol l ow steps 5, 6, 7, and I of the i n-vehi cl e depl oy-
menl Drocequre.
Damaged Airbag Spacial Procedure
!@
r an airb.g cannot be deployed, it should
iiiTi-treatcd as normal scrap; il should still be consid-
srsd a
potontially oxplosive device that can cau3o ssti-
ous i ni ury.
1. l f i nstal l ed i n a vehi cl e, l ol l ow the removal
proce-
dure on
page 24-67.
2. In al l cases. make a short ci rcui t by twi sti ng together
the two ai rbag i nfl ator wi res.
3. Package the ai rbag i n exactl y the same
packagi ng
that the new repl acement
part came i n.
4. Mar k t he out si de of t he box
" DAMAGED
AI RBAG
NOT DEPLOYED" so i t does not get confused wi th
your
Parts
stock.
5. Contact
your Honda Di stri ct Servi ce Manager for
how and where to return i t for di sposal .
Deployment Tool: Check Procedur
1. Connect the yel l ow cl i ps to both swi tch
protector
handl es on the tool ; connect the tool to a battery.
2. Push the operati on swi tch:
green means the tool i s
OK: red means the tool i s faul ty
3. Di sconnect the battery and the
yel l ow cl i ps.
Gable Reel
Replacement
!@@
store a .emove airbag assambly with the
pad surtace up. lf the airbag is improperly stored face
down, accidental deploymont could propel the unit with
enough force to cause sorious iniury.
CAUTION:
. Alwsys disconnect the airbag connoctor(s) when ih
harness is disconngcted.
. Do not disassemble or tamper with the airbag.
NOTE: Car ef ul l y i nspect t he ai r bag assembl y bef or e
i nstal l i ng i t. Do not i nstal l an ai rbag that shows si gns of
bei ng dropped or i mproperl y handl ed. such as dents,
cracks or deformati on.
l . Di sconnect the battery negati ve cabl e. then di scon-
nect the posi ti ve
cabl e from the battery, and wai t at
Remove the access panel from the steeri ng wheel ,
then di sconnect the 2P connector between the dri v-
er' s ai rbag and cabl e reel .
NOTE: When di sconnected, the ai rbag connector i s
automati cal l y shorted.
DRIVER'S
AIRBAG
)
24-72
o r
TORX EOLTS
Use a Torx T30 bit.
DRIVEB'S DASHBOARD LOWER COVER
4.
Make sure the wheel s are al i gned strai ght ahead.
Remove the dri ver' s dashboard l ower cover.
5. Remove the two Torx bolts from the steering wheel,
and di sconnect the horn connector. Then remove
the dri ver' s ai rbag.
\
\
6. Di sconnect the connectors from the horn and crui se
control sevresume swi tches, then remove the steer-
i ng wheel nut.
STEERING
NUT
CRUISE CONTROL
SET/RESUME
SWITCH CONNECTOR
)
HORN CONNECTOR
Remove t he st eerl ng
pul r er .
CABLE REEL
2P CONNECYOR
wheel usi ng a st eeri ng wheel
7.
STEERING WHEEL PULLEF
{Commerci al l v_avai l abl e)
) U
8. Remove the col umn covers.
Disconnect the 3P connector between the main wire
harness and cabl e reel sub-harness, 8nd the 2P con-
nector between the cable reel and SRS main harness'
CONNECTOR
HOLOER
SRS MAIN HARNESS
2P CONNECTON
CABLE REEL SUB
HARNESS
3P CONNECTOR
10. Remove the cabl e reel from the col umn {cont' d}
24,73
--/
CABLE REEL
Cable Reel
Repl acement
(cont' d)
1 1 .
NOTE:
. Bef or e i nst al l i ng t he st eer i ng wheel , t he f r ont
wheel s shoul d be al i gned strai ght ahead.
. Be sure to i nstal l the harness wi res so that they
are not pi nched or i nterferi ng wi th other parts.
. Af t er r eassembl y. conf i r m t hat t he wheel s ar e
sti l l turned strai ght ahead and that the steeri ng
wheel spoke angl e i s correct
(road
test). l f mi nor
spoke angl e adj ustment i s necessary, do so onl y
by adj usti ng the ti e-rods, not by removi ng and
reposi ti oni ng the steeri ng wheel .
Set t he cancel sl eeve so t hat t he pr oj ect i ons
ar e
al i gned veni cal l y.
PROJECTIONS
12. Careful l y i nstal l the cabl e reel on the steeri ng col
umn shaft. Then connect the 3p connector to the
cabl e reel sub-harness, and connect the 2p connec-
tor to the SRS mai n harness.
.
24-74
Instal l the steeri ng col umn covers.
lf necessary, center the cable reel.
{New replacement
cable reels come centered.) Do this by first rotating the
cable reel clockwise until it stops. Then rotate tt coun
tercl ockwi se (approxi matel y
two and a hal f turns) unti l
the arrow mark on the cabl e reel l abel poi nts
strai ght
up.
ARROW MARK
15. l nst al l t he sl eer i ng wheel , t hen connect t he hor n
connecl or and crui se cont rol sevresume swi t ch con
14.
necl or.
STEERING WHEEL
CRUISE CONTROL
SET/ RESUM
16. Instal l the steeri ng wheel nut, and connect the horn
connect or t o t he st eer i ng wheel . Then i nst al l t he
dri ver' s ai rbag.
TORX SOLTS
9. 8 N m 11. 0 kgf m, 7. 2 l bt f t l
Repl ace.
Use a Torx T30 bit.
STEERI NG WHEEL NUT
50 N. m 15. 0 kgf . m, 36l bl f t )
Repl ace.
DRIVEB' S
AIRBAG
DRI VER' S
2P CONNECTOB
HORN CONNECTOB
I
17. Attach the cabl e reel 2P and 3P connector to the con-
nect or hol der . Then i nst al l t he dr i ver ' s dashboar d
l ower cover.
) U
DRIVER'S DASHBOARD LOWER COVER
24-75
18. Reconnect the dri ver' s ai rbag 2P connector to the
cabl e r eel 2P connect or . and r ei nst al l t he access
panel
on the steeri ng wheel .
19. Reconnect the battery posi ti ve cabl e, then the nega-
ti ve cabl e.
20. After i nstal l i ng the cabl e reel , confi rm proper sys-
tem operati on:
(l l );
the SRS i ndi ca-
tor l i ght shoul d come on for about si x seconds
and then go off.
Make sure both horn buttons work.
Make sur e t he headl i ght and wi per swi t ches
Go f or a t est dr i ve, and make sur e t he cr ui se con
trol switches work.
a
a
SRS Unit
Replacement
CAUTION:
. Betore disconnoqting lny pErt
of the SRS wire hal-
ness, disconnect th9 airbag conn"ctorlsl.
. Duri ng i nstal l l ti on or tepl acemsnt. do not bump
(impact
w.cnch, hammr stc.l the area noar tho SRS
unit.
NOTE:
o Do not damage the SRS uni t termi nal s or connectors.
. Do not di sassembl e the SRS uni t; i t has no servi ce-
abl e parts,
. Store the SRS uni t i n a cl ean, dry a.ea,
. Do not use any SRS uni t whi ch has ben subj ected to
water or shows si gns of bei ng dropped or i mproperl y
handl ed. such 8s dents, cracks or deformati on.
1. Di sconnect the bsttery negati ve cabl e. then di scon-
nect the posi ti ve
cabl e from the battery, and wai t at
2. Di sconnect the ai rbag connector{s}:
NOTE: When di sconnected, the ai rbag connector i s
automati cal l y shorted,
Driver's Side:
. Remove the access panel from the steeri ng wheel .
then di sconnect the 2P connector between the dri v_
er' s ai rbag and cabl e reel
(see
page 24-11).
Front Passenge/s Side:
. Di sconnect the 2P connector between the tront oas_
senger' s ai rbag and SRS mai n harness (see page
24-
11) .
24-76
o \
3. Remove the ri ght si de cover from the SRS uni t.
SRS UNTT
TOBX
BOLTS
Uge a Torx
T30 bit.
RIGHT SIOE
Remove the l eft si de cover from the SRS uni t, then
di sconnect t he SRS mai n har ness l gp connect or
from the SBS uni t.
SRS UNIT
5. Remove the four Torx bol ts from the SRS uni t, then
pul l
out the SRS uni t from the dri ver,s si de,
COVER
6. Instal l the new SRS uni t.
NOTE: Do not r eus e a t or x bol t t hat has r ed
threads. Repl ace the bol t wi th a new one.
)
7.
TORX BOLTS
9.8 N.m l'1.0 kg{.m, 7.2 lbf.ft}
Use a Torx T30 bit.
Connect the SRS mai n harness l 8P connector to the
SRS uni u
push i t i nto posj ti on unti l i t cl i cks.
I nst al l t he SRS uni t cover s
( r i 9ht
and l ef t ) . Make
sure the covers snap together i n the mi ddl e.
8.
TORX BOLTS
9.8 N.m 11.0 kgf.m, 7.2 lbf.ft)
U3e . Torx T30 bit.
SRS MAIN HARNESS
) ( l
9.
10.
' t 2.
Reconnect the dri ver' s ai bag 2P connector to the
cabl e r eel 2P connect or , t hen r ei nst al l t he access
panel on the steeri ng wheel .
Reconnect the tront passenger' s
ai rbag connector
to the SRS mai n harness.
Reconnect the battery posi ti ve cabl e, then the nega
ti ve cabl e.
After i nstal l i ng the SRS uni t, confi rm proper system
operati on: Turn the i gni ti on swi tch ON
(l l );
the SRS
i ndi cator l i ght shoul d come on for about si x seconds
and then
go oi f.
11.
24-77
.-
Contents
How to Use This Manual
I
Circuit Schematics (see Circuit Index)
Fuse/Rel ayl nformati on 6
Ground-to-Componentsl ndex 6-6
ComponentLocati onPhotooraohs 201
Conriector Views 202
Circuit Index
Accessory power
socket 155
Ai r condi ti oner
Ai r del i very
' 96198
model s 61
' 99-' 00
model s 61-2
Blower controls
'96198
models 60
' 99100
model s 60-1
Compressor controls 62
Fans 63
Anti-lock brake system (ABS) 44
A/T gear position indicator
CVT 89
All except CVT 89-1
Automatic transmission controls
All
'96-'98
models except CVT and GX 39
All
'99100
models except CVT 39-8
Al l GX model s 39-8
'96-'98
CVT 39-4
' 99100
cw 39-12
Back-up lights
Coupe and Sedan 110
Hatchback l ' 10-1
Brake lights
Al l Coupes and' 96-' 98 Sedans 110-15
' 99-' 00
Sedans 110-16
Hatchback 110-17
Brake system indicator light
'96198
models 7'1
' 99100
model s 71-1
Cei l i ng l i ght 114-3
Charging system 22
Condenser fan 63
Consol e l i ghts 114
Cruise control 34
Dash l i ghts 114
Dayti me runni ng l i ghts 110- 13
Engi ne cool ant temperature gauge 81-1
Fog l i ghts 110-10
Front parki ng l i ghts 110-2
Fuel gauge 81-1
Fuse/relay box
Under-dash 6
Under-hood 6-4
Underhood ABS 6-3
Gauges 81
Ground di stri buti on 14
Ground-to-Componentsl ndex 6-6
Hazard warning lights
Al l except
' 99100
Sedans 110-6
' 99100
Sedans 110-8
Headl i ghts 110-12
Headlight switch 100
Heater
-
See Ai r Condi ti oner
Horn
' 96197
model s 40
' 98
model 40-1
' 99100
model s 40-2
l gni ti on key remi nder 73
lgnition system
Al l
' 96198
model s except Dl 685 20
Al l
' 99100
model s except D16Y5 wi th Mn 2O-2
Al l D1685 engi nes 20-2
'99-'00
D 16Y5 with M/T 20
lndicators 80
Integrated control unit 70
lnterlock system
Al l except' 96J98 CVT 138
' 96198CVT
138- 1
Li cense pl ate l i ghts
Al l Coupes and
' 96-' 98
Sedans I l 0-3
' 99100
Sedans 1 10-4
Hatchback 110-5
Low fuel i ndi cator l i ght 74
Moonrool
' 96197
model s |22
' 98-' 00
model s 122-1
Odometer 81
Oi l pressure i ndi cator l i ght 80-3
Power distribution
Battery to ignition switch, fuses, and relays
Fuses to rel ays and components 10-2
Power door locks
Al l model s wi thout keyl ess entry 130
' 96-' 98
model s wi th keyl ess entry 130-2
' 99100
model s wi th keyl ess entry 130-12
Power mirrors
Wi thout detogger 141
Wi th defogger
' 141-2
Power wi ndows 120
Programmed fuel injection system (PGNr-Fl)
Al l
' 96-98
model s except D1685 23
Al l
' 99-' 00
model s except D16Y5
wi th M/T and D1685 24
Al l D1685 engi nes 25
' 99100
D16Y5 wi th M/T 23
Radiator fan 63
' 96-,98
model s 64
' 99100
model s 64-1
Seat belt reminder 73
Security system
' 96.' 98
USA HX, LX, EX 133
' 96-' 98
Canada EX, Si 133
' 99TOO
USA HX, LX, EX, DX.V Si 133-4
' 99100
Canada EX, Si 133-4
Al l CX and DX model s 133-8
Speedometer 81
Starting system
A./T (Al l except Dl 685) 21
A"/r (D16Bs) 21-1
Manual transmi ssi on 21-2
Slereo sound system 150
Supplemental rastraint system
(SRS) 47
Tachometer 81
Tai l l i qhts
Al l boupes and' 96-' 98 Sedans 110-3
' 99100
Sedans 1 10-4
Hatchback 110-5
Trunk l i ght 114-3
Turn si gnal l i ghts
Al l except' 99100 Sedans 110-6
' 99-' 00
Sedans 1 10-8
Vehicle speed sensor (VSS) 33
Wiper/washer
Front 91
Rear 92
1 0
How To Use This Manual
The next few pages
describe how this manual is organized. They also
explain what kind of information the manual contains, what that
informalion means, and how to use it to troubleshoot electrical
problems.
Circuit schematics break the entire electrical system into individual
systems, like the Low Fuel lndicator Light on the nelit page.
Only electrical components that work together are shown together,
so
you won't be distracted by unrelated wires.
Explanations of the abbreviations and svmbols used in the schematics
begin on
page
[Fl. You' ll need to know what they mean before
you
can use
a schematic effectively.
Circuit Schematics
oa
Each schematic represents one circult. A
circuit's wires and components are arranged
to show current flow, from
power
at the top of
the page, to
ground,
at the bottom.
Shared Circuits
Other circuits may share
power
or
ground
terminals or wiring with the circuit shown. A
wire that connects one circuit to another, for
example, is cut short and has an arrowhead
at the end of it pointing in the direction of
current flow. Nelit to the anowhead is the
name o{ the circuil or comoonent which
shares that wiring. To quickly check shared
wiring, check the operation of a component it
serves. lf that component works, you know
the shared wiring is OK.
Connectors
All in-line and fuse box connectors are
numbered
(C725,
C416, etc.).
Component connectors are not numbered
but are identiJied by the name of the
component. lf a componenl has more than
one connector, each connector is assigned
a letter
(A,
B, C, etc.). Below most connector
numbers and comDonent names are
PHOTO and VIEW numbers. The PHOTO
number refers to a Dhoto in the back of the
book that shows lhe conneclor's location on
the car. The VIEW number refers to an
illustration in the back of the book that
shows the connector face, wire colors,
connector cavity numbers, and other details.
The connector cavity numbering sequence
begins at the top left corner oJ the connector
as seen from either of the viewooints shown
on page ffl . Disregard any numbers
molded into the connector housino.
Wires
Wires are identilied by the abbreviated
names of their colors; the second color rs the
color of the stripe. Wires are also identified by
their location in a connector. The number
'2"
next to the male and female wire terminals at
C416, for example, means those terminals
join
in cavity 2 of connector C416.
Symbols
A complete description of schematic
symbols begins on page | 8
"HOT"
label tells you when
the ignition switch supplies
power to the fuse.
\
Artowhead means
wire connects to
another circuit;
Arrow with note rErng
other circuils conncct hre.
i t . a
l l u" : : ^, { i
i t See Power Distribution, .
I
t----t oaqe tO-3.
I
L* - - : - - - - - - - - J
2
Y
C723
Junction connector
YEL
I
Pao'o'8
more bus bars in it;
I
- " "
to two or more wire
l , /
- t
>?
See Power
Distribution,
page 10-3.
UNDER.
DASH
FUSE/
RELAY
BOX
has one ol
each connactg
terminala.
it ooints in direction
of current flow.
TheImletor
t _
I
Cavity number;
L ---
Jiili'iJi!--'
----->
'
shoin on page
S
.
Male
termi nal
L?*?l?,-
"'"'I
c725
vlEUt/ 75
Connector number;
index begins on
page 203.
Number ot photo
in back ol book
showing component
location on cat.
Number of
conneclor view
in back of book
7
GBN/FEO
See Ground
Soe Indicators
I ASSEMBLY
: - - - - - - - J
LOW FUEL
INDICATOF
LIGHT r-l
EI
A
"o' r"/
PHOTO 52 <-
\
FUEL
TANK
UNIT
Splice
---------)
O rr<i Distribution,
".* I
Page
14'4'
I
Broken wi re means | --^ -
iar";J.'It,;,rJ;ii;
-----i
Bffi,Bili*l
elsewhere.
I
0a0e
tn-a
I
BrK
I
cround
--->lL c301
: ptioro
21
Power Distribution Schematics
Power Distribution schematics show how power is supplied from the positive
battery terminal to
various circuits in the car. Refer to the Power Distribution section to get
a more detailed
picture
of how power is supplied to the circuit you' re working on.
From Battery to lgnition Switch, Fuses, and Relays
Individual circuit schematics begin with a fuse. The first half of Power Distribution, however,
shows the wiring
"upstream"
between the battery and the fuses.
CYLINDER
BLOCK
t l
t l
L. l t J
",-*
f ]fo,o
i BATTERY
I
I
I
I
-
- - - - - - - - - - - - - - - - Y - ? -
ruse so
I
ruse as
I
ruse
ga |
'
,s.
,a
I
=u.
- srl ruse aai ruse
qr
I
ruse so I ruse sr i ruse ia
powEF
\tcsw \
FUsE Bc, \F,.n
\
.;,cren \ ooon \coounc \ cor,r. \sun noor\
powrn
w' NDowf 50a
{*
. i 1-; . *"1l i T""f i 3f *
f 5#
f f f i ' *"f ' * f S?' *
- - -L - - -. ... Ji - -.J.- - - -e- - -l. - - -La - J- - - I - - -
"";%,,
Y
rtr,'
.9
l'
-%,t",,
vtEw47
I !
See Power Dastribution,
w
-
vH-,al r.
l t -
pages 10,10and 10-11.
' I
---il
9,1?-
l - - 4F- - ?-
i
I
t.urr, ' rrr.,
t
i!?' .,,?""
t::=.
l ty::.1----.-
-
i
a
I r(op-B) .{Noru3d) J$ifl#ii Jtocl }3fo**."".o'
t -L - - -L - - -: rJ:e'- - -Ei s+s-r -.Fl-J-Jrr.-.
I t -
STARTER | !
Pase 21
!
t FUSE 31
I "rn*i
I f
*
i.Jr;-t
i L_i***'" i
L - - - - - - - J
ilr------
!
FUSE
/I4
' FUSE 47 ' FUSE 5{' ' FUSE 51' FUSE 52
r l r
OOOB \COOLING \ CON. \SUN BOOF \ FOWER
t3f*
f5# fffi*" f'* fs?'*
See Power Dastribution,
pages 10' 10 and 10-11.
T101
34
ALK
4
GAN
I
I
I
I
I
\
\
I
I
I
FUSE 8
DF POWEF SEAT
204
FUSE 6
ECU
204
FUSE 5
A/C CLUICH
(FN HEATED
SEAD
204
C901 C921
{Not
PHoro zz
OPTION Used)
v/ EW22
CONNECTOB
See Power Distnbution, page 10-2.
1
FUSE 4
FADIO
104
c901
vlEw22
FUSE 12
(BUltNrrG
LIGHT)
FUSE 19
R/C MIRROF
YEL
7
i-f,
r--
't
PowER
I
uon-
I
Wlt{DOW
i
racrs
i
RELAY
. t
P^ da 1t
L-J
P;dr1i i -
FUSE 3
CONOENSEF FAN RELAY
COOLING FAN RELAY
To Fuses 17, 18, 21,
and 24, for details,
see Power Windows
page 120.
a
l l
l l
ALTER-
NATOR
Page 22
f102
c330
See Power Distribution, pages 10-4 and 10-5.
Power Distribution Schematics
(cont'd)
From Fuses to Relays and Components
The second half of Power Distribution shows the wiring
"From
Fuses to Relays and
Components." This can speed
your troubleshooting by showing which circuits share luses. lf
Power Distribution shows thal an inoperative circuit and another circuit share a fuse, check a
component in the other circuit. lf it works, you know the fuse is good and
power is available
to
the inoDerative circuit.
oa
UNDER.
DASH
FUSE/
RELAY
BOX
I i *. to i
ru..'.'
l
* tt
I
tust tt
\ ){nuo$rouc}rr) }g*"""' }t S }f f ***,
\
I
,
I
-- - ----\&- -----J
-------ir
9,s9:,.,
,.,'li"
'"rr'
' 'rll$vryglu
:
]:l.
,'
"'':r.,
,:ti.
.:1,,.,
*_lu*'.
'71ffi"
- -t**,-
vtEw &
04
18
g
C442
2 A
t l
12
.L e
t l
ALTENNATOR
Paoe 22
PHdro 29
l l
t l
L- - - - - - J
STEREO AMPLIFIER
Paoe 150-3
PHdfo 1s3
vtEw 106
121
'f,"c;93,.
:
'
f,t'ffi
l v' Ew6o ! 1, . " ,
l : l
N ' l l
^.o,r.u
I
i ".o,*",
I
l : t
l , l
u*,.11,2",
i
"l9*',g
11"""
:
l *' -
l : l
nEDisLu
|
; .
ED,w'
(
I ' l
P : l l
!
"
:
.1".,9t3
q -
'
I
v'Ew3e
h ; l l
l : l l
I
:
FED^rir{r
i
l : i
t i i
, . L i
s l c
r--1 :
r--1
t t : l l
l t l l l
t - - J
'
l - - J
DAYTIME
:
POWER
RUNNING ;
SEAT
LIGHTS . CONTROL
CONTROL
.
UNIT
UNIT
'
Paoe 143-2
paoe
1to-j 2
t
PHdro t2.
PHdTo 1so
i
wEw 110
vtEw 65
- - - '
Ca n a d a
' _ _ _
(cont'd)
Ground Di stri buti on Schemati cs
This sample Ground Distribution schematic shows all of the components that share two
ground points.
TCS
CONTROL
UNI T
Page 35
t l
t l
9 Y B
FRONT
PASSENGER' S
SEAT HEATER
Page 147
t l
FRONT
PASSENGER' S
SEAT BELT
SWITCH
Page 145
t l
l l
RIGHT
REAR DOOR
ASHTRAY
LIGHT
Page 114
r
\
u
t l
'T-'
2 9 3
l'::'"'^
I - Ut

Z
I
I
I
G601
c611
Component Locations
To see where a component or connector is located on the car, look up its photo number in the
Component Location section in the back of the book. The photo will also tell you the color of
the connector, and how many cavities it has.
To see where
connectors and
parts
are located, look up
their
photos
in the
Component
Location section.
I
I
3
r
-
1 GAUGE
| | I_S-9_EIBLY
l t ' ' " " '
r
-
1 cRUtsE
! !fi':*
r
-
1 POWERTRAIN
I I
CONTROL UNrr
a i[i9#r,
lf there is no
photo
number below or beside a component name or a connector, ground, or
terminal number, look up that name or number in the Connector-to-Harness Index that begins
on
page 203. The chart lists how many cavities a connector has, where it' s located, and what
it connects to. The related illustration shows the connector' s location on the harness, and the
harness routing.
Connactor ldontlticallon and Wke Harness Rouling
DFIVEF'S POWER
SEAT WIAE
HAFNESS
It a connector on a
schematic has no
photo number, look it
up in the Connector
ldentilication chart
c712
c7t 6
\
c702
c701
and related illustration.
203
203.1
Drlvor s Sea! wne Harnss
Lefts' d.Hrc hatu$ 1c2611
Loft s' d. src hamass 1c262)
F6ar up.dow^ n.moryki sor
l
E
oo
Connector Views
To see the configuration of a connector' s cavities, look up its view number in the Connector
View section in the back of the book. Each view includes the color of the connector, where it
is located, and what it connects to.
Use the Connector Views to help locate the
proper cavity when you need to
probe
a
connector. lt can be especially helpful if the connector has more than one wire of the same
cotor.
Connector views can also be used to help diagnose multiple symptoms in separate circuits
which could be caused by a single
problem in a connector shared by those circuits. Here' s
how:
1. Pick one of the multiple symptoms and look up the schematic for that circuit.
2. Make a list of all the in-line and fuse box connectors in that schematic
(include page
numbers).
3. Then, in the Connector View section, look up each connector on
your list to see il circuits
related to the other symptoms run through one of them. lf they do, inspect that connector
for the oroblem.
Example: The blower, rear window defogger, and the windshield wiper don' t work. List all
in-line and fuse box connectors in the blower controls circuit and then check the Connector
View section
(sample below). You find that C324 is common to the rear window defogger
circuit and wiper/washer circuit, so you inspect C324 and find the
problem, bent terminals.
5.
6.
7.
1 .
2.
WHT (Blower controls)
YEUBLU (Rear window
defogger)
BLK,ryVHT (Starting)
BLU/YEL
(Wiper/washe0
8LU (Wiper/washed
BLfi EL
(l gni ti on)
WHT/BLU
(ABS)
Connector
Views
(cont'd)
21. C324
Brown
Behi nd l eft ki ck panel
-
Connects left engine compartry'ent wire harness to
mai n wi re harness
l l , l l ,
5 6 7
How To Use Thi s Manual
Symbol s
oo
Wire Color Abbreviations
The following abbreviations are used to
identify wire colors in the circuit schematics:
B L K . . . . . . . . . . . . . b | a c k
B L U . . . . . . . . . . . . . b l u e
B R N . . . . , . . . . . . . b r o w n
G R N . . . . . . . . . . . . g r e e n
G R Y . . . . . . . . . . , . . g r a y
L T BL U . . . . . . l i g h t b t u e
L T GRN. . . . . l i g h t g r e e n
OR N . . . . . . . . . . . o r a n g e
P N K . . . . . . . . . . . , . . p i n k
P U R . . . . . . . . . . . . p u r p l e
R E D . . . . . . . . . . . . . . r e d
WH T . . . . . . . . . . . . w h i t e
Y E L . . . . . . . . . . . . y e l l o w
A broken line means this part of the circuit
is not shown; refer to the circuit listed for
the complete schematic.
"ral
o
-.1
See Ground
Distribution,
page 141.
I
G101
Where separate wires
j oi n,
onl y t he spl i ce i s
shown; for details on
the additional wiring,
refer to the circuits
listed.
ili::i
{ [
UNDER-
OASH
FUSE/
RELAY
BOX
Wires
A wavy line at the end of
a wire means lhe wire is
broken by the binding of
the book or by a
"choice"
bracket but continues on
the next page.
Wire insulation can be
one color, or one color
with another color stripe.
(The second color is
the stripe.)
This circuit continues on
another page. (The
arrow
shows direction o{ current
flow.) To tollow the RED/
BLK wire in this example,
you would turn to page
23-5
and look for the
"2"
anow.
This means the branch of the
wire connects to another
circuit. The arrow Doints to the
name of the circuit branch
where the wire continues.
8LK
-
Crui se Control ,
aaa
Gauges, Indrcal ors
!
YEUsLK
T
tl
Wire choices for options or
different models are labeled
and shown with a
"choice"
bracket like this.
This broken line means
both terminals are in
connect or C134.
a.
+##l:i""l
Manual
lransmission
ryil;::,
.""1
""'
"""1".'0
I
""^l
:-l
Name of Ci rcui t
Connectors
-
"C"
The cavities
(and
wire terminals) in each
connector are numbered starting from the
upper left, looking at the male terminals trom
the terminal side (or looking at the female
lerminals f rom the wire side. Both views are in
the same direction so the numbers are the
same.) All actual cavities are numbered, even
if they have no wire terminals in them.
Terminal Slde
ol
Male Tsrminals
{
T
_A
Wlre Slde
ot
Femalg Trrmlnala
The connector cavity number is listed next to
each terminal on the circuit schematic. The
cavity/terminal shown below is #6.
Terminal
This means the connector
connects directly to the
componenr.
This means the connector
connects to a lead (pigtail)
wired directly to the
component.
Cavlty/
Termlnsl 6
only the one affecting that
ciriuit will be shown. The
f
--f
!!*!"*F"#fi5';,Hy4
I
Remaining wires to
the same bus are
represented by a
broken line.
The name of the
component appears next
to its upper right corner
followed by notes about
its function.
This symbol represents
one bus inside the cao of a
iunction connector. A \
lr"ctb.
connectorcap
\ |
contains several buses, but
\
A
c103
t l
t l
*-
I ",.-"* I
a- - - a- - - a- - - a- - - o
- a
*"1 *-l *-l *-l *"1 *-l
See Gauges
Splices
Solices are shown as a dot. Their location
and the number of wires may vary
depending on the harness manufacturer.
Components
A solid border line means the
entire component is shown.
A broken border line indicales
that only
part
of the component
is shown.
t_J
l l
l l
BRAXE
swtTcH
Closed wilh
pedaldepressed.
Symbol s
Ground
-
"G"
This symbol means the end ol
the wire is attached
(grounded)
I
to the car frame or to a metal \ I
part connected to the frame.
\i
oro,|
-t'
Each wire ground (G) it
--/
numbered for reference.
o o
Switches
These switches move
together; the broken straight
line between them means the,
are mechanically connected.
Other types of switches are
controlled by a coil or a solid
state circuit. Unless otherwise
noted. all switches are shown
in their normal (rest) position,
with power
off.
This ground symbol
(dot
and 3 lines) overlapping the
component means the housing
of the component is grounded
to the car frame or to a metal
part
connected to the frame.
This symbol represents
the bus inside a
ground
connector. The dots
I
i:l*,':1,'^:*,:"
;"
r"L
I I I
terminals connect to.
The ground symbol (large dot)
is the connection between the
bus and metal (grounded) part
of the car.
Terminals
-
"T"
ffi
ffi
Solid-state
Fuses
This means power is supplied
when t he i gni t i on swi t ch i s i n ON (l l ).
Current rating
Diodes
A rectifier diode works like a one
way valve. lt allows current to
llow only in the direction of the
arrow.
A Zener diode blocks reverse
current at normal voltages
just
like
a rectifier diode. At high voltages.
however, a Zener diode allows
current to f low in reverse
oo
Each
"T"
lerminal
(ring
type)
is numbered for reference and
location. A
"T"
terminal is
secured with a screw or bolt.
Shi el di ng
This represents RFI
(Radio Frequency
Interference) shielding
around a wire. The
shielding is always
connected to ground.
f--l;j-i",..
I
\t,,,,
T
Five-Step Troubleshooting
L Verify The Complaint
Turn on all the components in the
problem
circuil lo check the accuracy of the customer
complaint. Note the symptoms. Do not begin
disassembly or testing until
you have
narrowed down the
problem area.
2. Analyze The Schematic
Look up the schematic for the
problem
circuit. Determine how the circuit is
supposed to work by tracing the current
paths lrom the power source through the
circuit components to
ground. Also, trace
circuits that share wiring with the
problem
circuit. The names of circuits that share the
same fuse,
ground, or switch, and so on, are
referred to in each circuit schematic. Try to
operate any shared circuits
you didn' t check
in step 1 . lt the shared circuits work, the
shared wiring is OK, and the cause must be
in the wiring used only by the problem
circuit. lf several circuits fail at the same
time, the fuse or
ground is a likely cause.
Based on the symptoms and
your
understanding of the circuit' s operation,
identify one or more
possible causes.
3. lsolate The Problem By Testing The Circuit
Make circuit tests to check the diagnosis
you made in step 2. Keep in mind that a
logical, simple
procedure is the key to
efficient troubleshooting. Test for the most
likely cause of failure first. Try to make tests
at
points
that are easily accessible.
4. Fix The Problem
Once the specific
problem is identified,
make the repair. Be sure to use
proper tools
and safe
procedures.
5. Make Sure The Circuit Works
Turn on all components in the repaired
circuit in all modes to make sure
you' ve
fixed the entire
problem. ll the problem was
a blown fuse, be sure to test all of the
circuits on that fuse. Make sure no new
problems turn up and the original
problem
does not recur.
Test Equipment
Most circuits include solid-state devices.
Test the voltages in these circuits only with
a 1o-megaohm or higher impedance digital
mUltimeter. Never use a test light or analog
meter on circuits that contain solid-state
devices. Damage to the devices may result.
Test Light and DVOM
On circuits without solid-state devices, use a
test light to check for voltage. A test light is
made up of a 12 volt bulb with a
pair of leads
attached. After grounding one lead, touch the
other lead to various
points along the circuit
where voltage should be
present. The bulb
will go on if there is voltage at the point being
tested. lf you need to know how much
voltage is present, use a digital
volVohmmeter
(DVOM).
Self-Powered Test Light and DVOM
Use a self-powered test light to check for
continuity. This tool is made up of a light bulb,
battery, and tlvo leads. To test it, touch the
leads together: the light should
go on.
Use a self-powered test light only on an
unoowered circuit. First, disconnect the
battery, or remove the fuse that feeds the
circuit
you
are working on. Select two points
in the circuit belween which
you want to
check continuity. Connecl one lead of the
self-powered test light to each
point. lf there
is continuity, the test light' s circuit will be
completed, and the light will
go on.
SELF-POWERED TEST LIGHT
lf, in addition,
you need lo know exacW
hc' .
much resistance there is between two oo' ^=
use a digital volUohmmeter
(DVOM)
acdrt'Cn
t 1
In the
"OHMS"
range, the DVOM will measure
resistance between two
points
along a circuit.
Low resistance means
good
continuity.
Diodes and solid-state devices in a circuit can
make a DVOM give a false reading. To check
a reading, reverse the leads, and take a
second reading. lf the readings differ, the
component is affecting lhe measurement.
Jumper Wire
Use a
jumper
wire to bypass an open circuit.
A
iumper
wire is made up ot an in-line fuse
holder connected to a set of test leads. lt
should have a five amoere fuse. Never
connect a
jumper
wire across a short circuit.
The direct battery short will blow the fuse.
Short Finder (Short
Circuit Locater)
Short finders are available to locale shorts to
ground. The short tinder creates a
pulsing
magnetic field in the shorted circuit whlch you
can follow to the location of the short. lts use
is explained on
page
15.
SHORT FINDER
To ordei any test equipment shown above,
contact your local tool supplier. For a list of
suppliers and tool numbers, refer to Honda
Required Special Tools and Equipment
Service Bulletin.
Test Equipment (cont'd)
o a
Troubleshooting Precautions
Before Troubleshooting
1. Check the main fuse and the fuse box.
2. Check the battery for damage, state of
charge, and clean and tight connections.
CAUTION:
. Do not quick-charge
a battery unlers
the battery
ground
cable has been
disconnected, or you will damage the
alternator diodes.
.
Do not attempt to crank the engine wlth
the ground cable disconnected or you
will severely damage the wiring.
While You' re Working
1. Make sure connectors are clean, and have
no loose terminals or receptacles.
2. Make sure lhat connectors without wire
seals are packed
with dielectric (silicone)
grease.
Part Number: 08798-9001 .
Pack wllh dlelectrlc (sillcons) greass
When connecting a connector,
push
it until it
"clicks"
into
place.
Do not pull on the wires when
disconnecting a connector. Pull
only on the connector houslngs.
Most circuits Include solid-state
devlces. Test the voltages In these
circuits only with a lo-megaohm or
higher impedance digital multlm6ter.
Never use a test light or analog meter
on chcuits that contain solld-state
devices. Damage to the devices
may result.
oo
Troubleshooting Tests
Testing for Voltage
When testing for voltage at a connector
without wire seals, you do not have to
seoarate the two halves of the connector.
Instead,
probe
the connector from the back.
Always check both sides of the connector
because dirty, corroded, and bent terminals
can cause
problems (no
electrical contact
=
an open).
1 . Connect one lead of the test light to a
known
good ground, or, if you' re using a
digital volt ohmmeter
(DVOM), place it in
the appropriate DC volts range, and
connect its negative lead to ground.
Connect the other lead of the test light or
DVOM to the point you want to check.
lf the test light
glows, there is voltage
present. lf you' re using a DVOM, note the
voltage reading. lt should be within one
volt of measured battery voltage.
A loss of more than one volt indicates
a problem.
NOTE: Always use a DVOM on high
impedance circuits. A test light may not
glow (even with baftery voltage
present).
connecthere [fl5tst-t
and light should
IJJ
comeon.
\" I
- - - - - - {
/'
BT
swrrcH
l h l
l
----.,
I
6m""*soLENo,D
I
connect here
I { l l l
I
3#Ji8iL,*
lj!!J
Testing for Continuity
When testing for continuity at a connector
without wire seals,
you do not have to
separate the two halves of the connector.
lnstead. Drobe the connector Jrom the back.
Always check both sides of the connector
because dirty, conoded, and bent terminals
can cause
problems (no
electrical contacl
=
an open).
1. Disconnect the negative cable from the car
battery. lf you' re using a DVOM,
place it in
the lowest
"OHMS"
range.
2. Connect one lead of a self-powered test
light or DVOM to one end of the
part of the
circuit vou want lo test.
Connect the other lead to the other end.
lf the self-powered test light glows, there is
continuity. lf you' re using a DVOM, a low
reading or no reading
(zero), means
good continuity.
. t .
A
r 3
Troubleshooting Tests
Testing for Voltage Drop
Wires, connectors, and switches are designed
to conduct current wilh a minimum loss of
voltage. A voltage drop of more than one volt
indicates a Droblem.
' 1.
Place the digital volVohmmeter (DVOM) in
the appropriate DC volts range. Connect
the
positive
lead to the end of the wire
(or to the connector or switch) closest to
the bafterv.
Connect the negative lead to the other
end of the wire (or the other side of the
connector or switch).
Turn on the components in the circuit.
The DVOM will show the difference
in voltage between the two points. A
difference, or drop, of more than one
volt indicates a oroblem. Check the
circuit for loose, dirty, or bent terminals.
co
Testing lor a Short with a Test Light or DVOM
1. Remove the blown fuse and disconnect
the load.
2. Connect a test light or digital \roltr'ohmmeter
(DVOM), switched to the appropnare DC
volts range, across the tuse lerminals to
make sure voltage is present.
You might
have to turn the ignition switch to ON:
check the schematic to see.
<-
s80RT TO
GFOUNO
Disconnecl lhe
load here.
Beginning near the luse box, wiggle the
harness. Continue this at convenient ooints
about six inches apart while watching the
test light or DVOM.
Where the test light goes off, or the DVOM
voltage drops to zero, there is a short to
ground in the wiring near that point.
NOTE: Always use a DVOM on high
impedance circuits. A test light may not
glow (even with battery voltage present).
3''
ffito.'"o'o
. t .
TEST LIGHT
ol
DVOM
Testing for a Short with a Sell-Powered
Test Light or DVOM
1. Remove the blown fuse and disconnect
the battery and load.
2. Connect one lead of a self-powered test
light or digital volUohmmeter
(DVOM)
(switched to the lowest
"OHMS"
range) to
the fuse terminal on the load side.
Dlsconnect the batlery.
FUSE
BOX
Remove the fuse.
<-
ssoRr ro
ciouNo
Dlsconnect the
load here.
.)"'
r| SOLENOID
Connect the other lead to a known
good ground.
Beginning near the fuse box, wiggle the
harness. Continue this at convenient
points
about six inches apart while
watching the test light or DVOM.
lf the self-powered
test light goes on or
the DVOM displays a low reading or no
reading
(zero), there is a short to
ground
in the wiring near that
Point.
SELF.
POWERED
TEST LIGHT
o1
DVOM
4.
5.
Testing tor a Short with a Short Circuit
Locator
(Short Finder)
1 . Remove the blown fuse. Leave the
battery connected.
2. Connect the short finder across the battery
terminals and the load
(component) side of
the fuse terminal.
SATTERY
SHORT
FINOER
FUSE
BOX
PULSING
MAGNETIC
FIELD
\
NO
PUISING
\
I swtrcH
I
<-
stl
Kl"
I-
-.T.1
"'at
\ 8
<l)
d)
. r .
r l l l <
,l
m
...uni l l the
needle slops
moving.
SHOFTT
GFOUNO
'llt
No
--t
PULS|NG
z
MAGNETTC
I
FIELD I
SoLENOTO
3. Close all switches in the circuil
you' re testing.
(co,f,O
r 5
Troubleshooting Tests (cont'd)
4. Turn on the short finder. This creates a
pulsing magnetic field around the wiring
between the fuse box and the short.
5. Beginning at the fuse box, slowly move
the short finder along the circuit wiring.
The meter will show current Dulses
through sheet metal and body trim. As
long as the meter is between the fuse and
lhe short, the needle will move with each
current pulse.
Once you move the meter
past
the point
of the short, the needle will
stop moving. Check the wiring and
connectors in this area to locate the cause
of the short.
c o
Fuse/Relay Information
-
Under-dash Fuse/Relay Box
Front View
c712
(To moonroof wire harness)
.
: Canada
i
: Not Used
O : C926
l opri on
(+B)l
@ : C927
loption
(dash lights)]
O : C928
[Option
(ACC]I
@ : C929
loption
(lc2)l
Rear View
css2
c421
(To main wire harness)
c801
CI-o
SRS main harness)
c501
(To dashboard wire harness)
^ : Not used
('96-'97
models)
c913
(To ignition switch)
INTEGRATED
CONTROL UNIT
CONNECTOR A
c419
Oo
main wire harness)
REAR WINDOW
DEFOGGER RELAY
TURN SIGNAUHAZARD RELAY
c423
co
c422
POWER
wtNDow
RELAY
c551
flo
lloor wire harness)
c439 f96.'97 MODELS
and ALL GX MOOELS)
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"1 r-t r-t T-l r"l r-r Fl r:1 n rJ n -
1 2 1 3 1 4 t 5 1 6 1 7
t 8
1 9
2 A
2 t 2 2
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
1 0 1 1
LI LI IJ LJ LJ I,J T-I I.J TJ IJ I.-I tJ
c420
6
(To floor wire harness)
Fuse
Number Amps Page Fuse Name
(RR WI PER
RR WASHER)
i
R Hi L HI GH BEAM
|
10
L H/L HIGH BEAM
|
(PAIV RR-L)
i
(P/vv RR-R)
(rGN CO|L)
1 0 I (P,^/V AS)
Component or Circuit Protected
Not used
Not used
Rear wiper, Security system (option)
(Vehicles pre-wired for accessory security system)
' 10
r 1n- 2
I
|
1 10- 12
i
Right headlight, DRL control unit (Canada)
Lett headlight, DRL control unit (Canada)
I
r o- r s Security system (option)
|
120-2
|
Left rear window motor
Right rear window motor
lgnition coil
(' 98-' 00 models except GX)
| 120-1 | Front
passenger' s window motor
i
(PiW DH)
|
20
1
12O
I
Driver' s window motor
TURN LIGHTS Hazard warning switch
FUEL PUMP
(SRS UNIT)
PGM-FI main relav, SRS unit
(cRUrsE CoNTROL)
/KtrVt trSS\
Stereo radio tuner (' 96-' 98 USA: LX, EX, and HX),
Cruise control main switch, Keyless door lock
control unit
(' 99-' 00 models with keyless entry)
1 5 ALTERNATOR
SP SENSOR
l - a 10- 4 I ELD unit, Gauge assembly, TCM (96-' 98 CW, PGM-FI
1 6
I
RR DEF RELAY 7. 5 10- 8
I
Rear window defogger
(' 96-' 98 models), ABS control
I unit. Power mirror switch
('99-'00
models except GX)
i-HEATER
r/C
I
RELAY
Power mirrors
(' 96-98 models and all GX models),
Air delivery, Blower controls, AilC compressor
controls, Fans
I
(RUNNI NG LI GHT
I
RELAY)
1
7. 5
1
t l
I
DRL control unit (Canada)
i
BACK-UP LTGHTS
i
Back-up lights
(RUNNING LIGHT)
DRL control unit
(Canada)
I R H/L LOW BEAM
' 1 0
l 1 1 o - 1 2 Right headlight
I
L H/L LOW BEAM
|
10
1110- 12 |
Lef t headl i ght
(cont'd)
(SRS) SRS unit
6-1
-
Under-dash Fuse/Relay Box (cont'd)
Fuse/Relay I nformation
Fuse
Number Fuse Name Amps
(P/W RELAY)
(S/R RELAY)
FR WIPER
FR WASHER
LO
Page
10-7 |
I
Component or Clrcuit Protected
i
Power window relay, Moonrool
Front wioer/washer
CIGARETTE
LIGHTER
ACC SOCKET
10-7 Accessory power
socket
I
RAD|O CLOCK
I
110 115) l
t l
1O-7
|
I
Stereo radio tuner ('96198 models), Audio unit ('99100
model)
Not used
i
7.5
i
1 1 4
i
Dash & console lights
I
srnnrensrorunl
|
7.s
lzl
,
zt
-t
,
!
eCU-n main retay, PCM/ECM, Integrated controt unit
I ot 21- 2
t
I LICENSE LIGHTS I 7.5
I
rerr uesls
I
Parking lights, License plate lights, Tail lights
| 1oo-1 |
t l
|
(f NTERLOCK UNIT)
|
7.5
|
10-12
I
Interlock system
*
=
' 98
model s
6-2
-
Under-hood ABS Fuse/Relay Box
Fuse
Number
(To underhood ABS fuse/relay box w re harness)
ABS
pump motor
| 10-14 I
ABS control unit
i
ABS control unit
component or circuit Proiected
Fuse Name
PUMP MOTOR
I ABS +B
ABS PUMP
MOTOR RELAY
(To rnain wlre harness)
I!,ITR CHECK
6.3
Fuse/Relay Information
lcont'd)
-
Under-hood Fuse/Relay Box
Front View
T'102
(To engine wire harness)
L O
T1
Oo
starter cables)
*:
Not Used
Rear View
c353
To main wire harness
DE
tr
tr
tr
t-l
IJ
n
tJ
t-l
51
IJ
n
IJ
n
5T
IJ
[[o
main wire harness)
6-4
ffo
main wire harness)
fto
main wire harness)
Fuse
Number Fuse Name Amps Page
BATTERY
Component or Circult Protected
Power distribution
lgnition switch
INTERIOR LIGHT
|
7.5
|
10-10
|
DLC, Ceiling light, Trunk light
FI E/M 1 5
i
(20 GX)
i
i
PGM-FI main relay, Fuel injection relay (GX)
Not used
POWER WINDOW | 10-10 | Power window relay
BACK UP Stereo radio iuner ('9G'98 modls), Audio unit
('99100
models), Heater control
panel, PCM/ECM, TCM (9e'98
cvr)
HEADLIGHT
REAR DEFROSTER I
DOOR LOCK UNIT,
ROOF
i
10- 12
i
Headlights
Not used
Rear window defogger relay
Power door lock control unit
(all except
'99-'00
models
with keyless), Keyless door lock control unit ('99-'00
models with keyless), Moonroof
i
HORN, SrOP Lr
i
10- 13
i
Horn relay, Brake switch
HAZARD
Hazard warning switch
OPTION
I 10- 13I Security system
(option)
i
HEATER MOTOR
I i
10-1
i
Blower motor relay
(CONDENSER
FAN)
COOLING FAN
l 1 o - 1
Condenser Jan relay, A'lC compressor clutch relay
Radiator tan relay
&5
Ground-to-Components
I ndex
f.,lO
NOTE: All ground
wires are BLK unless otherwise noted.
Ground Page Components or Circuit Grounded
Battery (BLKYEL)
Steering pump
bracket
t +- r g
I
Transmission housing
\ r l
G101
( - 1)
G101
(-2)
14-2
and
14-3
ano
14-1
Powertrain or engine control module (PG1
and
pG2
are BLK: LG1 and LG2 are
BRN/BLK), EGR control solenoid valve (CW, EGR valve and lift sensor (Dt6yS engine
with M,/T), Engine coolant temperature switch,
pGM-Fl
main relay,
power
steering
pressure
switch (USA), Primary HO2S (D16Y5 engine with l\/,/T), Vehicle speed sensor,
VTEC pressure
switch (D16Y5/D16Y8
engines), CKF sensor (BRN/BLK), Transmission
control module (CYf) (Pc1
is BLK: LG1 is BRN/BLK)
Shielding betvveen the PCM or ECM and these components
(all
have BRN/BLK wires):
CKF sensor, TDC/CKP/CYP sensor. Primary and secondary heated oxygen sensors.
Knock sensor (CWDl6YB engine), Mainshaft speed sensor
(AiT
except CVT),
I
Countershaft speed sensor (A/T except CVf)
Shielding between the TCM and these components (CVT) (all have BRN/BLK wires):
Drive pulley
speed sensor, Driven pulley
speed sensor, Secondary gear shaft
speed sensor
Powertrain or engine control module (PG1
and
pG2
are BLK; LG1 and LGz are
BRN/BLK), EGR control solenoid valve (D16Y5 engine), EGR valve (Dt685), Engine
coolant temperature switch, Fuel pressure
regulator shut-off solenoid valve (D1685),
PGM-FI main relay, Power steering pressure
switch (USA), Vehicle speed sensor, VTEC
pressure
switch (All except D16Y7 engine), CKF sensor (A

except 81642) (BRN/BLK)
Shielding between the PCM or ECM and these components (all have BRN/BLK wires):
CKF sensor, TDC/CKP/CYP sensor, Primary and secondary heated oxygen sensors,
Knock sensor (All except D16Y7 engine), i/ainshaft speed sensor (Arf
except CW),
Countershaft speed sensor (A,/T except CVf), Drive pulley
speed sensor (CW),
Driven
pulley
speed sensor (CVT),
Secondary gear
shaft speed sensor (CVf)
I
Badiator fan motor, Right front parking/turn
signat tight, Right headtight
G202 14-4 I Cruise control actuator, Left front parking/turn
signal lights, Left headlight, Rear window
I
washer motor, Windshield washer motor, Washer fluid level switch
(,99-' 00
Canada)
G401 | +-o
and
14-7
Accessory power
socket, Brake fluid level switch, Clutch interlock switch
(M/T),
Clutch
switch (lillT with cruise/D16Y5 engine with MfD, Combination wiper switch
(Z
wires),
Cruise control main switch, Cruise control unit, Dash lights brightness controller, Data
link connector, Daytime running lights control unit (Canada),
Gauge assembly, Horn
(' 96-' 97 models), Integrated control unit, Interlock control unit (ArI), Keyless door lock
control unit (' 99-' 00 models with keyless), Moonroof close and open relays, Moonroof
switch, Park pin
switch (A/r), Power window relay, Rear window defogger relay, Rear
window defogger switch (' 96-' 98
models), Steering lock, Stereo radio tuner (,96-,98
USA: LX, EX, and HX), Turn signal/hazard relay, Windshield wiper motor.....plus
everything grounded
through G402
6-6
Ground
G402
Components or Clrcult Grounded
Arr gear position switch, ABS control unit (3 wires), Blower motor high relay ('99-'00
models), Blower motor relay, ELD unit, Heater Jan switch
('96-'98 models), Heater
control
panel,
Mode control motor ('96.98 models), Power transistor
('99-'00 models),
Service check connector....plus everything
grounded through G401
|
14-13 |
ABS
pump
motor
1l-9
i
Stereo radio tuner (' 96-' 98 models), Audio unit (' 99-' 00 models)
Drivsr's door lock actuator, Driver's door lock switch, Drivefs window motor' Left mirror
defogger, Powr window master switch
(2 wires), Power door lock control unit
(all
except
'99-'00
with keyless), Power mirror switch
G552 14-9
i
Driver's sat belt switch, Fuel pump, Fuel tank unit, Right mkror defogger
G601
(Hatch-
back)
14-12
i
Left and right back-up lights, Left and right brake lighvtail lights, Lefl and right rear
turn signal lights, Left and right tail lights....plus eveMhing
G601
I
14-10
(All Coupesl
ano
(96198
S6dans)
High mount brake light, Left and right back-up lights, Left and right inner brake lighv
taiilights, Lett and right license plale lights, Lett and right outer brak lighvtail lights'
Left and right rear turn signal lights, Rear window deJogger, Trunk latch switch
G601
(99-'oo
Sedans)
G602
('ss-'00
Sedans)
G761
(Hatch-
back)
G771
(Hatch-
back)
14-11
14-12
i
High mount brake light, Left and right back-up lights, Left and right brake lighvouter
taillights, Left and right inner taillight, Left and right rear turn signal light' Rear window
deJogger
(GX), Trunk latch switch
Window antenna coil
Hatch latch switch
('98-'00 models), High mount brake light' Left and right license
plate
lights, Rear window wiper motor...plus everything
14-13
i
SRS unit
(2 wires)
*1
=
All
'96-98
models xcept Dl685,
'99100
D16Y5 with M/T
*2
=
'98
D1685, all
'99-'00
models except Dl6Y5 with M/T
e7
Power Distribution
-
From Battery to lgnition Switch, Fuses, and Relays
STARTER
Page 21,
21- 1, ot 21- 2
.d1.ro"rr"
i
I lsoLENorD
I
FUSE 42
tG1
BATTERY
To UndeF
hood ABS
Fuse/Rel ay
Box on
page 10- 14.
FUSE 47
EACK UP
T1
FUSE 41
AATTEiY
&A
I
OETECTOR (ELD) UNIT
tii::.':
UO
PHOfO U
,
I
I
I
t . - - - - - - J
ELECTRICAL LOAD
i --i r
L- - - - J
ELKml
!"
Gl
FUSE 4e
0ro{
Urod)
FUSE
'13
Ir|]EAtOA
UGHT
?.:ta
FUSE 46
POWEa
Wll'IDOW
FUSE
/t4
r| E/M
1{rA
204 (DrGa5)
FUS 48
TtEADL|a}fT
9|'A
FUSE 50
NEAA
OEFOCGER
304
+------, f
|
' ,
I
ruse sr
I
\ oooa
I
J
LOC|( uNrr
\
il-.
4
WHT/BLK
Itr
'\
\
I
I
I
c352
vlEW 27
c415
Se Powr Distribution,
pag6s 10-10 and 10-11.
See Power Distribution,
page 10-12.
I
\
L - - - - - -
BLK/VI/HT
1
- - - - - - - - J
c415
Vehicles
pre-wired for
accessory
security
system
c913
PHOTO 6A
FUSE 16
AR DEF
FEIAY
FUSE 17
HEATEA
!'/C FEIAY
FUSE 18
{RUNNINO
L|GHl
FET.AY)
7.54
FUSE 27
CIGAFETTE
L|oHTEA
ACC SOCKET
ta
arse ra f
BADIO \
?o?"*
\
15A ('94 raodcr)
f f ".
acc
0)
l l
L - - - - - - - - J
pages 10-8 and 10-9.
STARTER
CUT RELAY
Page 21-2
P/lolo 135 (99 00)
See Powet
Distribution,
page 10-7.
Vehicles pre-wired for acces-
sory security system
To Fuse 3'|, for delails, see Startrnq
System, page
21,21-1 , ot 21-2.
-
1 0
I
t
I
UNDER-HOOD
FUSE/RELAY BOX
FUSE 52
HO3 ,
9IO? LT
t3a
FUSE 53
SATAAD
10A
T102
PHOTO 9
l--
Se Power
Distrib$ion,
page 10-13.
WHT/RED
T101
PI1oIO 25
I
I
J
I
I
FUSE
ofiro{
{oa
ALTEBNATOR
Page 22
n
I
I
t
- - 1
UNDER.
s FUSE 55
IIEATER MOTON
atla
r^-::r BLowER
|
t,omacl
I MoToR
i lF5:ft
L--J or 50-1
Ptaofo9
FUSE 55
(co{DEtsER fAx}
204
FUSE 57
cooutag FAr
204
r^-::I RADIATOR
l*"*!F*x.
L--J
paoro p
HOOD
FUSE/
NELAY
BOX
UNDER-DASH
FUSE/RELAY BOX
PHO|O 58
FUSE 19
AACK UP
Llalni
75A
FUS 15
ALIIFI.IATOR
sF sErson
7.5A
\
I
I
I
f
r--1 coN- r--11' /C COM-
lContactt DENSER I
Contactl PFESSOR
i i[f*, i iFLug"
L--J Page 63 L--J Page 62
To Fus l, 2, and 6,
see oaos l Gl 3.
STEERING
LOCK
\
l,ut-
a- - - - - - - - - - - - J
gLXTYEI
FUSE 23
(sRs)
1(rA
Phofo 10
See Power
Distribdion,
pagos 10
and 10-7.
FUSE 3
tm w|PEa
in wAsr{ER}
10A
PHOTO 10
See Power
Distribution,
page 10-6.
FUSE 24
(P,ry AEUn
(s/n
QELAY)
FUSE 13
FUL PUIIP
(sns uRrT)
15A
See Power
Disaibution,
page 10-3.
FUSE 14
{cFrrsE
corrtRoL}
{rcYLESS)
c913
I
I
FUSE9 ,
FUSE 12
IURI{
UCHTS
7,trA
) | , i ] s i " i
i:-' r|r::::---'--- J/--_-r
i::{;iil i i".ii.l
,#,;:|'-
i-:'ff1tu;.,,, i
*=ft;;***
See Powsr Distribution,
pages 10-2 and 10-3.
*
=
' 99-' 00
model s wi th D16Y7/D16YB
Sea Power
Distribuiion,
page 10-4.
: !
i i i ' ^ ' :
i
i l B1 %" f ;
i
L-=r
-','lo' i !.---i..-^- i
i orsrnrauron i i
DtsrRtBUroR
:
' Page 20 Page 20 or 20'1 '
%[-#
I pHOfO
44 PHO|O 44
1 Gl
Power Distributiofl (cont'd)
-
R83
5 A
t l
t l
PGM.FI
MAIN RELAY
Pag$ 23,
24, ot 25
PHOfO U
GRY (r8)
or Cnl|
Gi Ul|T
llfllvrtl|n)
FUSE
,'2
nnx ucms
7.ta
I
\
\
I
I
c801
PHO|O 5A
c423 r'l
PHOTO 58
c501
PHO|O @
vtEw 55
t l
l l
HAZARD
WAFNING SWITCH
Page 110-6 or 110-8
vlEw 32
t t
t l
SRS UNIT
Pags 47
PUO|O 70
vtt:w 51
r
=
MaleFemale
lerminals
revgrsed for
'99-'00
models
onh
no'l Wipsr GRN)
w8r Boar Wipif
'9&'00
Vlhbl.. at?wM frr
docarssy 66ourily eldcn
@
r t
YELI *.
1
'f
ft?'},'
I
l,l
m*a" ,,l*i*-
SECURITYSYSTEi' SECURIW SYSTEM
F"ontnlSSto"tott'on' S"ontnl5S]ottott'onr
Gnx I
WHT I
r - - - l
l l
t l
COMBINATION
WIPER SWITCH
Page 92
vlEw 05
10-2
A/T
"ar"r"f
-L
I
I
\
FUSE 14
(cRu colrTnol)
((Ef[rss)
1,9'A
c501
PHO|O 60
vtEw 55
UNDER.
DASH
FUSE/
RELAY
BOX
PHOfO 58
2 | cssl
FUSE 19
BACX UP
LtGxTSi
7,5A
c4t 9
vtEw 49
FUSE 23
tsns)
' 8 Y C 4 l 9 ,
1 2
'
lI
P/rOrO 63
|
I
BIK/YEL
l l
(Not
l 0
Used)
c801
. - - t
YEL/REO GBY (17)
or GFN
*
=
'99-'00
models except 016Y5
M/T
I
I
"ar"ao
I
I
,::, *
g;%,,
'."
I
v/Er,v 5e
ll,*'
o""'":f.,
t l
l l
BACK.UP
LIGHT
swlTcH
Page 110
or 110- 1
?
I
I
l l :
L- . J
KEYLESS
:
DOOR LOCK ,
CONTROL
UNIT
Page 130-12
:
PHOTO 134
vtEw 75
-
'99-'OO
models . .:
with Keyless
Entry
CRUISE
CONTROL
MAIN
swrTcH
Page 34
l l
STEREO
RADIO
TUNER
Page 130-2
vlEw68
'96-'98
- -
USA| LX,
-
EX, and
HX
l l
A/T GEAR
POSITION
swtrcH
Page 110
or 1 10- 1
sns
UNIT
Page 47
(cont'd)
10-3
' 8 6
Power Distribution
-
From Fuses to Relays and Components (contd)
FUSE 15
AIITIFIIATOR
sP iE soa
754
J - l
c4t 9
12 I C421
PHO|O 63
virtu is--
: : I lj;:o,19^63
l ,
l l
l ,
n l
t l
i ! [8ig*'"*
: :
LOAD
, I DETECTOR
,
I GLD}
UI{17 '
|
(ELDI u
: i
Page 22
I
I
\
VEW 5A
{ )
I
L- - - - - - - J
TRANSMISSION
CONTROL
MODULE
[rCM]
Page 39-4
vtEw 69
815
t l
t l
GAUGE
ASSEMBLY
Page 22-1
, a PHO|O S
, UNDER-HOOD
'
FUSE/RELAY BOX
I PHO|O 7
- '96-'98
CVT
10-4
' 1
=
' 96
D16Y8 engi ne: Al l coupes
'97
D16Y7 engine: California Coupe, California Sedan LX
' 97
D16YB engi ne: Al l coupes, Cal i forni a Sedan
'98100
models: All except D1685
-.t
UNDER-DASH
I
I
\
'--1 $NEGRATED
| !s$il:'
Ptlofo a
vtEw 67
c42'l
PHO|O 63
vlEW 50
ct 01
vtEw28
FUSE/RELAY
BOX
\
I
T
D16Y8
13
c568
ELKAYTIT
BLKAVHT
1
143
EVAP BYPASS
: :
SOLENOIDVALVE . ,
Page 23-9,
23- 11, 23- 14, 24- 7, '
'
24-9, ot 24-11
H02S
Page 23-11
ot 24-11
pHoTolo4
; ;
PHoTo 43
( See S/ l V page 11- 9
l or' 99-' 00 model s)
,
i1[
":"[-lT:T
l+Tli'::f;:r i"'{'
l;;;]fip;:
I
Fs' [
**,
I il
i
I ii !-l s];$:i
i
Ii t--l
i
! i'*[
iEi.;*Ti
lii
'fl*-i
i li
itqii-*
i l i l [ l ? t i
l i i
i i i i ; : "
i : l i
i
t r r i I i . r ^. : . ' . ' . ' i : : : : ; j i ! ' i
: i i
,
I
i
,+e;::","
i :
!
i
i t I
i ! |
i
|
:".*l fi gi 3l i ;ts' s"";:tg;u' u^.i :
!
:
i v7"- - :
r A :
*' I
i i osl
:
; CoNTBOL , r--1
i
liiit-
i
i_j
i
i_j
#s,{;'i'
i
[__j
ffnih'*'
i
23: 11, 23-t 4, , EVAP PURGE
I pRt MARy
Ho2s
:
'
powERTRAt N
:
| 24-7, 24-9,
'
CONTFOL
;
Page 23-8, 23' 10, 23' 13, ,
;
CONTROL ,
'
ot 24-11
'
SOLENOI O , 24-7 . 24-8. 24-10. ot 25-8 '
, MOOULE
(PCM) ,
'
pHoTo
3s : VALVE I PHoro 40 '
' Paqe 39-8
'
|
(see s/M :
Pase23-s,23' 11,
: ii3l311l l3;ll Pl?191,.,"^,, :
'
orSe-12
:
'
PHoTo 39 I vALvE
|
' Paqe 39-6
:
(See S/M :
Page 23-9, 23'11.
'
lHqI94?199 99
0.16Y!i
-
i
'
or 5g-tz
:
i bi-gllt-g
i zs:tq, zc-i, zc-g',
' PHoro 733
ree
00 D16Y8/816A2)
i
'.
in6i "i
i
: ' : 1 T: 9 '
' , 9 1 " ? i ' l ;
i - - - - - - - - - - - - j
" . - ' : - * - ' 1 .
- - - - - j ( c o n t ' d )
- - - -::-:-l - - - - t PHO\O 37 to16Y7l
1(}5
Power Distribution
-
(cont'd)
@
FUSE 24
{PAr/
FELAY}
{S/R
RELAY)
?
_____
s7
FUsE 25 I
METEF
I
-------r-----l
r
I I \
I A 6 J
I
r*r tttrecnlreo
\-
| | l coNrRoLUNl r
\
I i i PaseTo
\
I
L__Jlj:p,l2uo
I
I
vtt|| bl
t f
l t
. - - - l - - -
" - - - t
I
- - - r - - ' g- - - - - - - - J
c s 0 1
' 1 6 Y C 4 1 9
PHata'a
'
a PHolo 6"
vtEw 55
'
yEL
a vtEw 49
: t
i;l-l-l.
i
' t t l l l
: r t t l
' L- - J ! - , J
.
SHIFT INTERLOCK .
:
LocK coNTRoL
,
; SOLENOID UNIT
' Page 138 Page 138
I
'
or 138-1 or 138-1
I DHOTO 7-
D4O| O
69
I
vtFW26
' A T - - - - - - - - -
. - - A / T
- - .
" . . i j # j - -
", l i , , l i i "l i i -l i i ^, l i ". l -l
i------------::r::-:-::'::---::r:-:-:--T--------1
t l
t l
a l
t - - - - - - -
- - - - - - - - J
.I
POWER
I
wrNDow
1
RELAY
j Page 120
uorl
I
I
c501
17
C420
11
r: : 1
I
uorr
I
l l
MOONROOF
OPEN RELAY
Page 122
ot 122 1
r=?1
I
uorr
I
l l
MOONROOF
CLOSE RELAY
Page 122
ot 122-1
vtEw 13
(Not (Not
Used) Used)
ABS
Crui se
Control
Shift-up
I nor cal or
' r
_
t
GAUGE ASSEMBLY
Pages 80, 80-1, 80' 2,
80-3, 81, 89, and 89-1
10-6
cs01
c928
l.l!9!9-e ofi|oN
CONNECTOR
PHO|O 62
'99.'00
modals
A4
2 A
t l
t l
AUDIO
UNIT
Page 150
COMBINATION ACCESSORY
POWER
SOCKET
t l
t l
STEREO
RAOIO
TUNER
Page 150
vlEw 6a
WI PER
swtTcH
Page 91
vlEv\/ 65
WINDSHIELD
WIPER
MOTOR
(cont'd)
10-7
Power Distribution
-
(cont'd)
I
I
I
FUSE 16
NN OEF NELAY
7,54
L - - - - -
.t0
ELIqBLU
. - - With Mirror Defoggers
- -
c421
PHOfO 63
vlEw 5a
' 8 3
I
: l l
.
ABS
:
coNTRoL
; UNIT
I Page 44-2
'
vtEw 63
' - -
Wr t h A B S
- -
c501
PHO|O 60
vlEw 55
t 2
'
au(aLu
'96198
models
'99-'00
modslS
vtEw 46
1 A
l l
t l
REAR
wl NDow
DEFOGGER
sw|lcH
Page 64
.l i ,*,.",onn".?,
i r - - - -
; - _ _ - t - - - - i I
t l
L - - - - - - - - - J
POWER
MI RROR SWI TCH
Page 141 or 141-2
vtEw 33
10-8
\
3 \
I
I
\
\
I
I
---+---,
c419
;
PHOTO 63
1 1 0 - 1 3
;
I
I
- -
a- - -
i
i
T
iTl
I
ll
I
r l
l l
t l
MOOE
CONTROL
MOTOR
Page 61-1
'
o( 61-2
a
r--1
PowER
| | utnnon
;
| |
swrrcH
;
L- - J
Page l 4l '
vtEw 33
- - -
' 96- ' 98
model s
- - r
and al l GX
mooers
FUSE 17
HATEN
I,/C FEI,AY
7,5A
16
c420
vtEw 53
c3s2
r::' l
I
uorr
I
t l
BLOWER
MOTOR
RELAY
Page 60
or 60-1
PHO|O9
'.a-4.1
I
uorr
I
t l
A,/C
CLUTCH
NELAY
Page 62
UNOER-DASH
FUSE/RELAY
BOX
ia;ij
t l
NAD|ATOR
\
\
I
(Not
Used)
BLK,YEL
' t6
BLI(YEL
c440
vlEw 45
BLK/ryEL
'96198
models
'9$'00
modls
I
c?23
vtEw 57
'
ALKTYEL
c723
vlEW 57
atK
2 ^
1 l
l l
HEATER
CONTROL
PANEL
Pages 61,
62-1, and
63-1
H EATER
CONTROL
PANEL
60- 1, 61- 2,
62 2, 63 2,
and 64- 1
TION A/C
THERMOSTAT
Pages 62-1,
62-2, 63-1,
and 63 2
PAO|O 82 f96- 98)
NELAY
Page 63
UNDER.HOOD
FUSE/RELAY
BOX
ssgj
lTlA/c
I I I DIODE
l +, PHor o1
t.lEf
Y
r::' r
I
uorr
I
l l
CONDENSEN
FAN
RELAY
Page 63
COMPRESSON FAN
- . i - - .
:
: t :
: l :
: l :
:
l,T.il
i
: l :
:
, Jl i
, r--' t
'
: l
l :
, t
t :
.
L- . J
;
;
BLOWEn ,
, MOTOR
. HI GH
'
RELAY
:
:
Page 60-1
,
,
(See
S/l\, '
I page 21-3)
'
1_
' ss, ' oo
l
mooets
r - - 1
t l
l l
RECI RCULATI (
CONTROL
MOTOR
Page 61 or 61, 2
10- 9
Power Distribution
-
(cont'd)
-",JX-
I
I
\
FUSE '3
n{fEtbR
UC|{T
7.'.4
FUSE 44
FI EA'
!aa
coa
Dr6lc)
FUSE
il8
POUGN
tvtl|Do{t
aoa
c351
c420
PHOTO 63
I
- . : C r J
WIIT/ELX
1
I
I
I
I
FUEL
INJECTION
RELAY
Page 25-1
PHOTO 135
DATA LINK
CONNECTOR
(DLc)
Page 23-4,
24-4, ot 25-4
PHOfO 50
01685 engi ne
-
c419
PHOTO 63
UNDER.DASH
FUSE/RELAY
BOX
PHO|Q 5A
POWEB
w]tDow
NELAY
PagE 120
H$fa8
L- - - - - - - - -
20
wlIT/RED
- t
c420 6
PHO|O 63
vtEw 53
WHT/FEO
c407
PHOTO 52
Y|EW 2 ( 9& 00 modsrs)
c5s'r
PHO|O 63
L- - - - - J
U DEN.DASH
FUSE/RELAY BOX
PHOfO 58
To Fuses 7, 8, 1 0, and I 1
;
tor deiails, s8 Power
VYindotts,
pa$
120.
Hatchback Coup & Sdan
WHT/FED
(Sedan 1)
(e6-
101
,,,
tr:::--*''.:lltut
(Not used)
i--l
t l
L- - J
TRUNK
LIGHT
Page 114-3
t l
t l
SPOT.
LIGHTS
Page 114-3
t l
t l
CEI LI NG
LI GHT
Page 114-3
*
=
Male-Female
terminals
reversed for
'99-'00
models
7 A
t l
t l
PGM-FI MAI N
RELAY
Page 23.
24, ot 25
vtLw 18
I
I
PGM-FI
RELAY
Page 23
24, ot 22
vtLw 18
i-,-x;-l
icontac{i
t l
INTEGNATED
l__i!ffi*
10- 10
*
=
' 96-98
model s except D1685,
'99100
D16Y5 with lVl/T
UNDER-HOOD
FUSE/RELAY
BOX
' 9 8 CW - - .
,
r - - 1
: l l :
, t t :
:
r - - J
;
, TRANSMI SSI ON
,
.
CONTROL
'
MODULE
OCM) :
'
Page 3g-4
;
I
PHOIO 121
I
vlEW 69
I
I
\
FUS 47
aAcx uP
c351
WHT/BLIJ
WHT/BLU
WHT/BLU
1 8 c4'l t
vlEw 60
WHT/ALU
WHT/ALU
1 1 c440
WHT/BLU
1 0
'
WHT/BLU
, 423
c131
vtEw 59
WHT/BITJ
'96-'98
models
I
t l
t l
STEREO
RADIO
TUNER
Page 150
'99-'m
models modeB
'99-'00
models
c723 c723
vtEw 57
wHr/atu
8 1 0
B21
cc10)
t l
l l
HEATER
CONTROL
PANEL
Pages 60-1,
61- 2, 62- 2,
and 63-2
vtEw 76
t l
t l
POWERTRAIN oT
ENGINE CONTROL
MODULE
(PCM or ECM)
Page 23, 24, ot 25
AUDIO
UNIT
Page 150
t l
HEATER
CONTROL
PANEL
Pages 62-1
and 63' 1
10-1 1
Power Distribution
-
From Fuse to Relays and Components (cont'd)
FUSE 48
HEAOL|SHT
30A
c3s2 3
vtEw 27
WTIT/GFN
FUSF 50
FEAF
DEFBOSTEF
30A
ooon r,ooxuxn
\
RooF
-'
I
204
I
I
I
I
5 t
FusE sr t
9 l
;:$*fiit"rl.ru'"'""
I i*il
:::*ffi,
""'_[
t a
l l t
r - - 1 r - - 1
l - = J i l l l l
;i ' i fr' i l rowi
| | | |
NEAN
DEFOGGER: L- - J L- - J
!EuI. !
powen
KEYLEss
3g9F
I oocin iocx DooR LocK
I CONTROL CONTROL
PHorobs
! Ut t f UN| T
L- - - - J
i i " j - , " n ^.
UNDER-DASH
r:d.r ppdro,u
FUSETRELAY Box
;;;; ""
,!Fw /)
;
- - - - - - ' - - - - - - - - - -
I I
P4atasa
;;"; i,
: - ; - r y
w H r / G F N
:
I . - . - . i
. -", I
' -' :
:-' I "o' ' .
I l
"ott
i
";L____j_lU*?,?"
|
.,"Iii;n*
:
f' 4. ii ;f' ii
,L-.-Ii"?,%'
;f5-"i4.-"' ";5-{"' "r' !|L1
: ! !
: : !
!
: ;
3 $ 3 i ' 9 , 1 "
r !
! I | | |
i l- l-
- - -
_:-
- ---------1 - - - - - - -
i I r'
- -
T
-
I
F$r".',lP,XiI
i i { *" . . 0
, '
1; ; ; i l - - l
\ l \ | l eox
i !
i pp
i i
l i ui r' -*i
|
' )l ' l
l i
'
r--t-----'-.r--rL--------J- -------t
I
/---L-I
i
"
l-----l
i
::[ir:;?:'
i
::[?:+:
|
"""1
'*'
i[.iiilr-il[-j,*---]d;1.*-;il;1,
: l
I r : l I
i :
t s 6 ' " " ? c r o *
i ! !
L - - i r - - J
i ilr--,.ir...^.._î I
'rr6-;i."
i:
!:lJ',"#,",,*.
i
i.itc-,tr# Bgg,FooF
u-oorinoor
'
RUNN|NG LrcHrs ,
'
LocK
; :
;
!!gEr_.. ;;,1'y RELAY
i
cournolûrtr
,
i
pase^138
:: i Swircn-
-- Fj.Ti,
pase
122
, Paoe 110- 13 or ' 138- 1 Paoes 100. 110 2 - : Y; ^: '
: ; ; ; ' ' " "
: i
; hoi ; , ;
; : vehi cr espr e_wi r ed ; ! i d- ?i Xi oi i . '
gl j : , ' ; :
f f l ?3; 1
i , - - c anada - - - - r l - - - - A, / T - - - , . - . f or ac c es s or y - , | ; r " * i r "
. n 5 v t Ev t l 13
10-12
secu.ity system
ie----1
\ {
i____J
WIIT/FED
FUSE 54
OPNOI
404
c351
vtEw 34
c419
FUSE 52
HOAT. ST(IP LT
154
c352
vlEw2/
FUSE 53
NAZABO
c352
vtEw 27
c4't 1
UNDER-
HOOD
FUSE/
RELAY
gox
1 5
_",":I WH' /BLK
(Not (Not 7
Used) Used)
UNDER-DASH
FUSE/RELAY BOX
PHOTA 58
c419 C926
110!0,63 oPTtoN
CONNECTOB
PHOTO 62
WHT/GRN
{with
Cruise
Control 4)
WHT
'9&'98
models
pre'wked tor
acteEsory
sacurity system
""'l
o
;l 1 0
vtEw 6a
cs16
'99'0O
models
pre-wired for
accessory
securfy system
SECURIry
SYSTEM
CONNECTOR
(oPTroN)
Page 133-4
l l
t l
BRAKE
SWITCH
Pages 23-4 , 24 4
,
25-4, 34-1, 39,
39-4, 39-8, 39-12,
44- 2, 110- 15,
110- 16, 110 17,
' 138,
and 138-1
l l
l l
HAZARD
WARNING
swrTcH
Page 110' 6
or 110- 8
vtEw 32
,rr
rrRt3,:i ]L-
SECURITY
SYSTEM
CONNECTOR
(oPTl ON)
Page 133-4
r - - - - =- : ' l
I
Uoll UonEcI
I
t l
L - - - - - - J
HORN BELAY
Page 40, 40-1,
ot 40-2
PHOTO 58 (96 97 models)
PHOIo 129 (98 mode)
c447
wEw 5a
sEcuRrw
SYSTEM
CONNECTOR
(oPTroN)
Page 133
10- 13
Power Distribution
-
From Fuse to Relays and Components (contd)
From Battery
on page 10.
i,
FUSE 62
ABS +8
204
UNDER-HOOD
ABS
FUSE/RELAY
BOX
FUSE 61
PUUP MOTOR
I
contact
I
t l
ABS PUMP
MOTOR RELAY
Page 44-1
To Fuse 63, tor
details, see ABS,
page 44-1.
""'"":[r*'
;IT
t l
t l
L - - - - - - J
ABS CONTROL UNI T
Page 44
10- 14
Ground Di stri buti on
-
Gl01 (All
'96-'98
models except D1685;
'99100
D16y5 with M/T)
NOTE: Wires shown without color codes
: - - -
CVr
- - '
D1 6 y 5 /
i rnl ts_
'
._
016y8
, M I S S I O N ' , e n g l n e s
: CONTROL
'
PGM.FI :
:
MODULE
i UAIH ;
VTEC
, TTCM) ; RELAY . PRESSURE
' Paae 39-5
'
Paoe 23
'
SWITCH
I pHdro
et
'
n 6roao
'
Page 23-4
I
vtEw 69
|
vtEw 1a
'
pHoro
44
'
r - - - . t
'
r - 1 I i - r
POWERTRAIN or
ENGINE CONTROL
MODULE (PCM or ECM)
Page 23-3
PHATO 86
vlEw 7a
;
r - - - 1
; r - 1 , r
,
I t , t |
, l
: I t : t |
: l
, L - - - J , L - J
'
L -
,
A26Y A13Y
,
3
, 2
i T T : I
I
I I , I t , , -
I T T : T
i
: I t : - - I - .
:
i I
\ l i :
;
- 4 , ;
! - - - - - - - - - - - - - l - i
'
' l F;%
:
21
,
vlEw 28
;
_ -
t\4/T
-
PRIMARY
HEATED
OXYGEN
SENSOR
(H02S)
Page 23-13
l l
t l
"i[",..
1 4
o---1
\
I
- - - - "
A / T
- - - - - t
DRIVEN PULLEY , ^.,.
;iftTBilis'".f l5Ftr,.""_
co'rinienixnn
'. Pase 23'2
SPEED SENSOR ;
.' -\.
SHI ELD
' F- - . 1
TDC/CKP/
CYP
SENSOR
SHIELD
Page 20
l l
r_:.-i
23-13
t 1
23- l 4
t l
PRIMARY SECONDARY
HO2S HO2S
SHIELD SHIELD
Pages 23-8, Pages 23-9,
23-10. and 23-11. and
- - -
C W
- - - - .
TRANSMISSION
;
CONTROL
MODULE(TCM)
,
Page 39-5
:
PHO|O 121
vlEw 69
r _ _ _ _ 1
,
t t :
t t :
L - - - - J ,
. D16Y8
engi ne
SECONDARY
.
HO2S
:
SHIELD ;
Page 23-11
l. - -..1
;
t t :
(D16Y/i D15Y8)
Page 39-1
l.--.1
1 l
r:--i
BFN/BLK ARN/BLK
A4
6FN/
BLK ' EFN/BI
i
i srco"oo"t :
'
I GEAR SHAFT
I
I
Or MAtN!'tAt I
.
II SPEED SENSOR '
CW
. - D16Y8 -
, engi ne
: N SENSoR SHTELD
,
i
!i?il3li*u,, i
CW
SHIELD
:
Pa g e 3 9 - 4 ,
CRANK-
SHAFT
SPEED
FLUCTU-
ATION
(cKF)
SENSOR
Page 23-2
t l
l l
;I;..
26
i
xNocx
' SENSOR
, (KS)
'
SHIELD
,
Fage zJ-5
: F--.1
: l l
i i l r-: i
- - - - : . - - - - - - - - :
c442
(Terminals 18-20)
c10.1
PHofo 125
\HOTO 21
VIEW 54
vtEw 29
' - - - - -
c w
- - - - '
DRIVE
BFN/BLK
PULLEY
:
SPEED
SENSOR
SHIELD
Page 39-4
:
1.---{
:
I t ;
cl 30
Oerml nal 8' l -10)
vtEw 52
14-',
Ground Distribution
-
Gl 01
(' 98 Dl 685;Al l
' 99-' 00
model s except D16YS wi th M/T)
NOTE: Wires shown without color codes are black.
01685/
_ D16Y5/ - .
016Y8
engrnes
. __- ; , #' - _, - - '
, engrne
;
,
wEc
:
PRESSURE
'
,
swtTcH
:
I Page24-4
i
I
PHOTO 150
: r
-' l
: t | :
: l
|
:
, L - J .
FUEL
PRESSURE
REGULATOR
ENGINE
SHUT.OFF
COOLANT
SOLENOID TEMPERATURE
VALVE
SWTTCH
Page 25-1 Page 63
PHOIO 143 PHOTA 33
r - 1 F - . |
l l l l
l l t l
L - J L - J
POWERTRAIN ol
ENGINE CONTROL
MODULE (PCM
or ECM)
Page 24-3 ot 25-3
PHOTO 86
----:y4
t l
t l
PGi,|.FI
MAI N
RELAY
Page 24
ol 25
vlEw 18
t l
t l
3 Y
' I ' I
excapt
D1685
VEHICLE
SPEED
SENSOR
(vss)
Page 33
6FN/
ELK
ERll/
EIK
cl 01
PHOTO 21
PHOTO 142
(o1685)
vtEw 28
c t 1 6
Cferml-
nals
8n 4)
FltaFt(
vttw 39
t -
. ' ' i i t i
' "
D1685/ D16Y5 engr nes
- - - '
t 2
.
ENGINE
: :
i
933'?il-; i
5"T,Yf,*' 33i,"o, i
i lgfft"
i
I
S.ir1".l^
soLNorD
:
' Pase 63
:
: ;;;;;
-
pase
24.i
:
'
PHOTO 63 |
| VtEWlO
pHOIa124
;
, r - 1 |
,
F- . t r - . r
: l
|
; : l
| ! | :
; t | : , t | | |
;
j,f
ii T.__.,|,,,,,.
j
--
----- --l
i
ot oas
I
Dr6y5
:
: - - - - - - . 1 . - - - - - - - - .
14-2
o-----J
PRIMARY
H02S
SHI ELD
Page 24-7 ,
24-8, ol
24 10
t l
r_i
. - - -
D1 6 8 5 e n g i n e
- - .
'
TNJECTOR
I
:
CoNTROL
;
; MoDULE ,
, Page 25-1
,
t
PHO\O 1aa
:
I
vtEw 77
i
r - -
- - r
I
, l l :
i l l ;
816lI
. - - - D 1 6 Y 8
I
engl nes
i
.
SECONDARY
I
Ho2s SHTELD
:
, Pages 23-11
I
'
and 24-11
I z- r
;
l.--.1 :
c131
(c101 D16Bs)
.
ORIVE PULLEY
:
SPEED sENsoR
I
. SHIELD ,
'
Page 39-12
l - - - :
:
1.--,1
;
: l
| :
c102
CKF
SENSOR
SHI ELD
Page 24 2
t l
\ . .
BFN/
BLK
- - - - - - _ I
SECONDARY
GEAR SHAFT
:
SENSOR SHI ELD ;
(D16Y5)
P.â
' l O,1
,
oifu-alisirrr
SPEED SENSOR
:
SHIELD
:
(016Y7/D16Y8)
Page 39-9
F--.1
t l
rJii
t
rDc/cKP/
CYP
SENSOR
SHIELD
Page 2O-2
t l
\ , .
T
""","a*
|
i
___r_
14- 3
Ground Distributiofl (cont'd)
-
G201 andG202
NOTE: Wires shown wrthout color codes are black.
RIGHT
HEAD.
LIGHT
Page
110-12
t l
t l
110- 9
{ }
t l
t l
LEFT FRONT
PARKING/
TURN
SIGNAL
LIGHT
Pages 110-2,
1 10-7, and
110- 9
( )
WIND.
SHIELD
WASHER
MOTOR
Page 91
PHOTA 3
l l
t l
REAR
wtNDow
WASHER
MOTOR
Page 92
t l
t t
c205
RIGHT FRONT
PARKING/
TURN
StcNAL
RADIATOR
LIGHT
FAN
Paoes 110-2,
MOTOR
11d-7, and
Page 63
'99-'00
. -
Ca n a d a
- l
i wnsxen
i cnurse
, FLUID
; CONTROL
'
LEVEL .
ACTUATOR
'
SWITCH
I paoe
34-2
;
Page 80-3
i
eu6ro re
' f - 1
' f - 1
2 Y 2
c211
14-4
I ' G201
'Lv
G2o2
-
G402
NOTES:
. Wires shown without color codes are black.
.
On
' 97-' 00
models, G402 may be represented by the use of a
junction
connector or ring terminals.
with ABS
- - - - -
I
.
ABS CONTROL I
'
ultt
'
HEATER
CONTROL HEATER HEATER
iili, BB-'fi",. Eiff* 5fi::g
PowER i,8;g'"'
;;; ;;; MoroR ;i l --"' . ;;1-;;
rRAN- H| GH
!if,6f1-
ease ot-t
Ino b5-.t
'
fi i
*-
slsroR FELAY-
,
pHaTa
t3z
pHoro
70
photoT.
iioro ^
Page 60-1 Page 60-1
vtEw 76 vlEW 17 V|EW 44 V|EW11 PHOTO139 PHOTO 83
r - 1 r - . ! r - 1 r - 1 r - . | r - 1
| | | | | | r l I l l l
| | | | | | I l l l l I
L - J L - J L - J L . J L - J L - J
Page 44
PHOTO 85
vtEW 63
I
I
- - - - - - J
I""IJ
Ifnn*"1 r'[
1"""LI ' - - -
A / l
- - - _ r
i
,
m cean
;
I
POStflON
,
:
swrrcH
:
'
,
Pages 34-3, 39-3,
:
'
| 39- 7, 39- 11, 39- 15, ;
:
'
89, 89-1, 138, and ,
;
:
138-1
|
|
PHO|OIA
:
'
, F- ' t .
'99-'00
mooel
'96-'98
moots
'9G'S
mod6ls
'99-'00
modol
a
12 c440
vtEw 45
From
G401
on page
14-6.
v
l-
SERVICE
CHECK
CONNECTOR
Pages 23-3,
24-3,25-3,
39, 39-4, 39-8,
39-12,44-1,
afid 47
c402
I
I
3 cass
l;l:,12,
l i
rc i
UNDER-HOOD
, FUSE/RELAY
BOX
PHAfa 7
I
elecrRrca- |
I
LOAD BLOWER I
:
DETECTOR MOTOR i
I
(ELD)
RELAY
I
I UNlf Paoe 60 |
a
W.': :;ffil i
I r - r F- ' r I
t t | | | |
t r
| | | |
I
L - J L - J
I
i
' r
Y
i
L--+---J--J
I
'I&%,14.,
I
14-5
Ground Distributioh (conrd)
)
-
G401
NOTE:
To G402
on page
14- 5.
WI NOSHI ELO
WI PER
MOTOR
Page 91-1
DAYTIME
RUNNI NG
LI GHTS
99.!rRoL cLUrcH
uNr I
swtTcH
:?99^
Pases 23-5
and 34-3
vtEw 66 PHA|A 55
I
I
INJECTOR
CONTROL
MODULE
Page 25-1
I
I
3
. Wires shown without color codes are black.
o
On Coupe and Sedan models, G401 is represented by ring terminals.
t l
t l
INTER.
LOCK
6611p99
PARK
UN| T
PI N
paoe j 38 SWITCH
or i ge_t
Page 138
PHoro6s of 138-1
vtEw 26 PHOfO /7
r - 1 r - ' t
t t t l
CLUTCH
INTER-
LOCK
SWITCH
Page 21-2
l l
l l
t t l
r l l
I
I
t t t l
'Ll;
I
n
t
M/T with 01685
Cruise/
D16Y5
engine
with M/T
BRAKE
FLUID
LEVEL
swtTcH
Page 71
ot 71- 1
t l
t l
DOOR LOCK .
CONTROL
STEERING
LOCK
Page / 3
t l
t l
UNIT
Page 130-12
;
t t l
t t :
model s
RN
te
40
I
I
(
I
I czor
l'i1l?,
' 97
mo
HORN
Page 4
I
I
N
F n l
s 9 c
. P
l v '
BLK/RED
t
IJ;--
',f-l
DATA LINK
CONNECTOR
(DLC)
Pages 23-4,
24- 4, 25 4,
44-1, and 47
30
14-6
G401
cRutsE
CONTROL
MAIN
swrTcH
Page 34
t l
l l
1 Y
.
- -'
accessory
:
security system
:
i
secun,rY
;
: SYSTEM
i coNNEcroR :
' (oPTroN)
'
Page |33
:
'.
rg;'3,, :
,
I
vrfl,v 58
i l i
; .
- - - - +
REAR
WINDOW DASH LIGHTS
DEFOGGER BBIGHTNESS
SWITCH CONTROLLER
:93' :gl"'
Goug:*:FTi\"
f3$??'o"'
l l l l
b i : 8 d ; f t t i e - i : 9 - 9 { E J
a a a l
, " | ; f l 9 , , f f % ; "
:f :1'L;,:;;-;__:_:::J
i:i
r
.:,;,-rr-E:
f
,-T,-"T-'-.
[_j,
I =
,
l i i
f ::'* ,I., l, I -l*,.
Oerminals
l
'6)
'96-'98
models
pr+wi.ed tor
'99'00
models
pre-wired
lor
- _ - - - - a c c e s s o r y
,
security system
I srcunrw sEcunrrY :
, SYSTEM SYSTEM ;
i
CONNECTOR CONi{ECTOR '
'
(oPTroN)
:
Page 133-4
PHO| O1 3 6 '
I -
A B S
- .
. - -
U S A : L X .
- ' . - '
v o - J l - - '
,
EX, and ilx
mooers
vtEw 56
MOONROOF
!!P:',t
MooN.
i*:r?, 33,o+"
'iii?,;)
i??3;?'
'
STEREO
'
RADTO TUNER
'
'
DASH LIGHTS ,
'
P. da11o- ,
'
'
BRI GHTNESS
'
' ,
,;;;;-
-
: :
coNTRoLLER
'
' ,
v,i w;;"
i
i
eage tte.t
:
,
r - 1
, r
r - 1
: | | : : l
I
I
: | |
' : l
I
.
L - J
.
L - J
i " ' r
i i ' I i
MOON-
ROOF
OPEN
RELAY
Page 122
ot 122-1
vtEw 15
l l
l l
' + - - a - - - ' - * - ' O
c50t
PHOIO 60
vtEw 55
r - 1 r - 1
t t t l
l t t l
L - J L - J
,l
POWEN
wrNDow
NELAY
Page 120
?HOm 59
l l
t l
.LIJ
14-7
Ground Distribution (cont'd)
1
-
G551
Page
I
I
'96-'98
Models:
DRIVER' S
wtNDow
MOTOR
4
120
91
I
I
c633
oRrvER' s
DOOR LOCK
ACTUATOR
Page 130-1
or 130-3
t l
t l
:f
;'*"
. - - a - - - -
sl )
POWER WINDOW
MASTER SWITCH
Pages 120, 120-1,
120-2, and 120-3
PHO|O AA
vlEW 36
t l
t l
L - - - - - J
POWER
DOOR
LOCK
CONTROL
UNIT
Page 130
or 130-3
vlEW3/
t l
t l
4
c556
vtEw 61
8
(Sedan
A4)
DRIVER' S
DOOR
LOCK
swrTcH
Page 130
or 130-3
t l
t l
,I
' - . o - . o -
POWER
MIRROR
swrTcH
Page 141
vlEw 33
l l
t l
4
(with
defogger 2)
G55t
14- 8
_ t
89
c559
Wrth
.
- - Milror
FUEL
, Detogger
TANK
UNIT
'
RIGHT
paoes
74 ;
POWER
anj sr
-r
,
MIBROR
PHofo 103 | Page 141-2
i -l
:
i -l
I l t l I
,,:l'it{;
FUEL
TANK
FUEL INTERNAL
PUMP SOLENOID
Paqe 23-1 VALVE
or1q: Page 25-1
PHOTO 103 PHOTO 145
r - . | r - ' r
t t t l
t t t l
L - J L - J
'l
:l'a,t,
-
G501 and G502
'9&'98
m@els
DRIVER' S
SEAT
BELT
SWITCH
Page 73
t l
t l
STEREO
RADIO AUDIO
TUNER UNIT
Page 150-1 Page 150-1
PHOTO 73 PHOTO 137
vtEw 6a vlEw 74
F - . | F - . 1
t t l l
t r t l
L - J L - J
-.I 'I
9 3 '
c557
vtEW 62
'99'00
model
excepr
Dl 685
1 4
G501
14-9
!-6ssz
l
RIGHT
OUTER
BRAKE LIGHT/
TAIL LIGHT
Pages 110-3
and 110- 15
( l
RIGHT
REAR
TURN
SIGNAL
LIGIIT
Page 110-7
l-
LEFT
REAR
TURN
SIGNAL
LIGHT
Page 110-7
l-
Ground Distributior (cont'd)
-
G601 (Al l
Coupes and' 96-' 98 Sedans)
LEFT
OUTER
BRAKE LIGHT/
TAIL LIGHT
Pages 110-3
and 110- 15
( )
LEFT
BACK.UP
LIGHT
Page 110
LEFT I NNER
BRAKE
LIGHT/
IAIL LIGHT
Pages 110-3
and 1 10-15
(
) 4
c604 c605
RIGHT
BACK.UP
LIGHT
Page 110
FIGHT
INNER
BRAKE
LIGHT/
TAIL LIGHT
Pages 110-3
and 110- 15
( )
TRUNK
LATCH
swtTcH
Pages 80-2
and 114-3
t l
! l
2
HIGH
IUOUNT RIGHT
BRAKE LICENSE
LIGHT PLATE
Paoe LIGHT
11d-15 Page 110-3
/-t /-t
\_/ \_/
I I
- a - - - - o
LEFT
LICENSE
PLATE
LIGHT
Page 110-3
\ , ,
REAR
wtNDow
DEFFOGER
Paoe &
' - ' 9 8
- ,
o r 5 a - 1
I mooet
'
r-.1
:
: r I
I
tl?l,r
i
L_J
i'l'*
i
'l
:
. - - - . - . - - -
a
c6't 3
G@1
14- 10
-
G601 ('99-'00 Sedan) and G602 ('99-'00 Sedan except GX)
. - - - G X - - - '
: REAR I
, LEFT BRAKE LEFT REAR RIGHT SRAKE RIGHT REAB
r/:rrT/|.rr rYEo Tr rDN
I':':XX:..
'
LIGHT/OUTER TURN LIGHT/OUTER TURN
I' s":"
'
;
TAILLIGHT Pages 110-4 LIGHT TAtLLtcHT Pages 110-4 LIGHT
i - ' ' !
' Page 110- 4
and 1t 0- 16 Page 110- 9 Page 110- 4 and t t o- t o Page 110- 9
I i I
/ - \
r - - r / - r / - \
, - - r / - r
L_j
i \ _, ,
l --,
\ _, , \ _, ,
t --,
\ _. ,
B T : l Y 2 Y 1 Y 1 Y 2 Y
, I
i l l l l l l , , * *
i I I I
UY8,f
I I li ll
: I l m, r . - 15f i [ 8" ] =. . 1" " " , l i r ^ l +: nv ^ i
$"o^',lJ I 33n'" I lffJ"* I l,8gJ". l:33ii
i bi['*.u, I Bigil" I r,Hll' |
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I i'&+" I i'&?t" |
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T T T
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I
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T :
: I I I I I I I I I I I l : " 9
: I T I T T T T I T T I T :
; I I I I I I I I I I I I ;
: I I T T I T T I I T I T :
: I I I I I I I I I I I I : t
: I T T I I T T T T T I T ; I
: I I t I I I I I I I I I : t
: I T I T T T T I T I T I : T
:
: I I I I I I I I I I I l : t
: . 1 I I I I I I I I I I l ; I
:
: I I I I I I I I I I I t : I
:
: I I T I I T T I T T T T ; T
: I I I T T T I I T T T I ; I
: I I I I I I I I I I I I : I :
, I I I I I I I I I I I l ; I :
; I I I I I I I I I I I I '
: I I I I I I I I I I I l . I
,
I I I I I I r I I I r r ;
I
14- 11
T R U N K T I I '
G X
: t :
l ' r ,
I
G601
: t
G602
:
: Ptl1fo 113
,
: PHafa
,
PHOrO 102
lGXl
142
:
Ground Distribution (cont'd)
-
G601 (Hatchback)
and G761 (Hatchback)
LEFT
REAR
TURN
SIGNAL
LIGHT
Page 110-7
LEFT
TAIL
LIGHT
Page 110-5
LEFT
ERAKE
LIGHT/
TAIL LIGHT
Pages 110-5
and 110- 17
( )
LEFT
BACK.UP
LIGHT
Page 1 10-1
RIGHT
REAR
TUNN FIGHT
SIGNAL TAIL
LIGHT LIGHT
Page 110-7 Page 110-5
RIGHT
BRAKE
LIGHTi
TAIL
LIGHT
Pages 110-5
and 110- 17
( )
:
HATCH
;
LATCH
, swrTcH
'
Page 80-2
'
PHO|O 11A
: l
I
; l
I
.
BLU/
I
BLK
i 2
'98-'00
models
'
:
: t I
i L-J
c z s a i z l c z s z
PHO|O 126
LEFT RIGHT
LICENSE LICENSE
PLATE PLATE
LIGHT LIGHT
Page 110-5 Page 110-5
/-.t r-t
\_,, \_,,
I
(98-'00
mooets
2)
G761
PHOTO 109
PHO|O 132
( 98i 00
RIGHT
BACK.UP
LIGHT
Page 1 10- l
c605
vlEw a
HIGH
MOUNT
BRAKE
LIGHT
Page
110- t7
G601
:
REAR
; wl NDow
. WIPER
,
MOTOR
'
Page 92
r-t lr-t
\_, \_,,
I I
l l
l-y-
14-12
' . !
-
Gl , G2, G3, and G403
BATTERY
t l
t l
ABS
PUMP
MOTOR STEERING
PUMP
BRACKET
I
I
TRANS-
MtsstoN
I
I
Page
PHOTO
I
44-
5
I
I
J
I
I
T3
PHOTO 20
I
I
r4
Ptlofo 13
I
L
BFI{
1
PHO|O 20
G3
PHOTO 13
c360
!.
c403 G1
-
G751, G771, and G801
CONDENSER
FAN
i,OTOR
Page
, l
I
I
I
SRS UNIT
Page 47
PHO|OT0
vtEw 51
I
t l
L - - - - - - J
1 7
c753
G751
GFY (20)
OTGFN
GFY (r9)
or GFN
!. G801
14- 13
lgnition System
-
Al l
' 96-' 98
Model s except Dl 685;
' 99-' 00
Dl 6Y5 wi th M/T
NOTE: For Service Check Connector details, see page 23-3.
@
CKP CYP
sensor sensor
input input
(CKPP) (CYPP)
X,*.,
rDc
sensor
Inpur
(IDCP)
POWERTRAIN
or ENGINE
CONTROL
MODULE
(PCM or ECM)
POWERTRAIN
or ENGINE
CONTROL
MODULE
(PCM or ECM)
xr*"
BLKI/EL
I
I
BLK/
YEL
I
See Power
H
Distribution,
J__99'"'_
I
I
I
I
I
I
UNOER-
OASH
FUSE/
RELAY
BOX
"a*,telfi
u
I
"""%t'3.
,rrrr.iFiFx".-,''ril'fi :T-
DASH l l
pagel o- 1.
FUSE/
I ( FUSE 9
F.itl, Lq::---
".:l
o63
10
BLK,YEL
1 0
c101
vlEW28
c'120
vlEW29
BLK
c14
c120
vlEW29
rIDcM) IGKPM)
(CYPM)
Sensor Sensor Sensol
ground ground
ground
L- - - - - - - - - - - J
PHor a 36
L - - - - - - - - - - - J
:L_1__I,
! iii:?ifq"l
I
**:'
*-"*,t";'
=
PHO|O 33
PHOTO 123ICW)
Secondary
t i
<. . - / 4
i
t
iLi:"_gl_i i
L- - - - - 1! - - - - - r
96- 97 models
I
98- 00 modets
20
Spark Pl ugs
, r -.--
.l
TBANSMTSS|ON
I
igF"![E#'
:.
lr-ri";l:';9""
POWERTRAIN
or ENGINE
CONTROL MODULE
(PCM or ECM)
PHO|O 86
lgoition
outElt
ofl-
YEUGFN
c' l 20
TEST
TACHOMETEB
CONNECTOR
DISTRIBUTOR
.I
GAUGE
I
ASSEMBLY
iw,tr?,'
I
I
J
BIU
9
ALU
BLU
c120
vtEw 29
c101
vtEw 28
'.
Y
F,fl}l.
BLU
I
viEw 60
c el
i i:*bi
rA*oxErEn
i rl g: l
L - - - - - - - - -
20-1
lgnition System
-
All Dl685 engines; All
'99-'00
Models except Dl6Y5 with M/T
NOTE: For Service Check Connector details, see page 24-4 (except D1685) or 25-4 (D1685).
STEERING
LOCK POWERTRAIN
lm-
sii.- s*-
iffffiEgr
I
'8f", '3#n '3#n
|
(Pcn' or EcM)
L- - - - - - - - - - - J
Wr o
86
',L_I__J,
!l ---+--l
!
'i---
j----i'
fl
'","?siii,xl
I I I
i *n"' . "
-"1 "-l '-l *"-^lr";J
I I I
='i.{i31i",,-
All except D1685
D1685
gLK.Yer
t
u
l9f#'
fi
"*1,[
F,*';.,
!'T-f*-'i"i
! {F+
Distdbution,
LJ_gg' n' _
i.x,r
9'x*"
-.t
iF--Hs-,mT-l
l l
pase l Gi .
I
l (
FUsEe
I
!Lig::___J
.I
UNDER-
I
DASH
a
FUSE/
!
RELAY
-
BOX
1
Y
C419
UNDER-
^,ol',lill,l?"u'
rlir?
IA)
RELAY
BOX
.t0
BLKI/EL
10
(D16Y7/D16Y8 s)
c101
PHO|O 142
lA1685)
vlEw 2a
c120
vtEw 29 OFN/ALU
LT BLU or
ALU/GRN
BLU,^VEL
c120
vtEw 29
ELK
WHT/BLU
7
FED
c21 c9
ALK
c30
;;--;;---o;;;l
Sensor Sonsor Sensor I
POWERTRAIN
or ENGINE
CONTROL
MODULE
(PCM or ECM)
ground ground
gtound
L - - - - - - - - - - - J
PHor o 36
Sec!l|dary
Sparh Pl ugs
20-2
POWEBTRAIN
or ENGINE
CONTROL MODULE
(PCM or ECM)
vtEw 70
lgnition
oulput
signat
flcM)
I
YEUGBN
c'120
vtEw 29
DISTRIBUTOR
D 1 6 8 5
- - - - - - - ,
BLU
_ 9 -
BLU
8
9LU
:'!'\?- - -
c101
vtEw 2a
----------<-
c442
I
frerminals
1-4]
a| -u a
ol o' 25
|
I
vlEw 54
19
g
C411
a
PHOTA 60
aru
I
vtrw oo
l ,
c BA
- -. t
GAUGF
i
f#f
rAcHoirErER
ift?i,?""i
l i i t r" i !
I L - - J I
L - - - - - - - - - J
TEST
TACHOMETER
cor.rNEcToR
PHO|O2l
lgniiion
nr pur
Fh^ i h-
signal
"p_il;
Ground output
Primary
outPut
contsol
20-3
-
Automatic Transmission
(All
except Dl685)
NOTE: For cars equipped with optional security system, see Security System,
page 133-3,
.133-7,
or 133-12
for starting system circuit schomatic.
Starting System
c3s2
PHO|O I
vlEw 27
ftxiE "2
E1
404
WHT/BLK
I
lta":
c415
=-mF,Uf.
--l
9,lLT
i
ld;f,,"-
I
I
I
t
I
I
I
I
I
I
I
I
pag 10.
slan?
(ll)
c415
I
J i
.I
ELECTRICAL
I
roAo
I DETECTOR
I
Gt
ol ulr
a Ptfifo I
I
J
BLKAIVHT
1
ELK./YEL
au(|vEL
BL'(4I/HT
4
c416
PHOTO 53
c4t 6
PHO|O 53
PHO|O 56 f98
'oo)
vtEw t2
c433
Vehiclss pre-wired for
accessory securaty system
(Not Used)
R'SE 4I
lA??tNY
,ol
ALXAVHY
' 10
Allsxcsptow aLKlvHr
cw
Soe Pow6r
I
Distibution,
!
page 10. a
- - - - - J
T1
PHOTO 9
BATTERY
BLKAVHT
7
L- - - - - L- - - J
BLKFED
13:;-1ifl;ft?R
!-
)2
' l PHoto
tg
a
BLI(RED
1 I
ELIVBED
ALKNED
c433
PHOTO 76
Soe Powr
Dslributbn,
Pao 10.
9 a c101
er.xiwxr
I ffo,rtfl't
c4r I
PHO|O 63
Ft
gg
3r
5? F En 3E ^r
7.94
4
r'
STARTER
PHO|O 34
UNDER.
DASH
FUSE/
RELAY
BOX
A13
t l
II{TEGRATED
co|{TnoL
UT{IT
PHOfOU
vtEw 67
, - - ==- - J
Sso PGM-FI, page
&1 ot 24-1.
21
l G l
-
Automati c Transmi ssi on (D1685)
c352
vtEw27
FUSE 42
tGt
ao
.I
ELECTRICAL
I
LOAD
r DETECIOn
|
(ELD) uNtr
I PHOTO 9
I
UNDER.HOOO
FUSE/RELAY
BOX
r=-----L-_-_-_-_-_-=_-_-Tl.*1"","1#"Ei]""
li F 3,"j,[',ul
WHT/BLK
.
J 9,1'3.
WHt a
V|EW 14
tcx,^ )
Page
10'
PHOTO 76
1--*---''!
N
"t-
\o3
b z
7
See Power
Distribution,
page 10.
c433
ALKRED
4
r-^==.1
Stador
control
POWERTRAIN
CONTROL
MODULE (PCM)
c101
vtEw 28
ll
"'{----1iLi.'
| |
Li-gl{l======i---i
"i*-iIr-m'
:il
See Power
Distribdion,
Page
'10.
".u,"i f---'
-,*!
s#;:{"
BLKAVHT
N V/EW a t
STARTER
CUT
FELAY
PHO|O 129
(99100)
A"/T GEAR
POStTtON
swrTcH
See PGlr-Fl,
page 25.
STARTER
c419
FUSE 31
STAffER Src{AI
7.54
UNDER-
DASH
FUSE/
NELAY
BOX
BLKREO
1 1
"'-";;tr
A't 3
BATTERY
21-1
-
Manual Transmission
NOTE: For cars equipped with optional security system, see Security System,
page
133-3, or 133-7, or 133-12
for starting system circuit schematic.
Starting System
c3s2
PHOTA 8
vtEw 27
WHT/BLK
c415
FUSE 42
to!
a0a
UNDER-HOOD
FUSE/RELAY
BOX
I
I
I
_l
I
ELECTBICAL
IOAD
DETECTOR
(ELO) UN|T
Ptloro I
Sae Po'/Yr
Dislibution,
pag 10.
- - - - - - J
T1
Se6 Ground
Dislribution,
page 14-6.
BATTERY
STARTER
CUT
RELAY
PHO|A 129198)
PllO|O r35
f99 00)
a
BLK/FED
9
BLKAVHT
ct 01
vlEW 2A
c4' t9
vtEw 49
FUSE 31
STAATER SICIIAL
7.5A
STARTER
4
Sse PGM-FI,
page 231
ot 2+1.
UNDER-
DASH
FUSE/
RELAY
BOX
At 3
t l
t l
INTEGRATED
col{tRoL
ut{ll
PHO|O U
r.------T-------------=;-*^:-lsrEERtNG
I i 1'----> R*.|?xf: iiiliffi'
t"t%?I,,
I Distribulion.
1j;cx
y' page 10.
(0)
it-jtr'tl
i
j
r---_-_rx^,:jF;f
;-;:.==: t A r , + l o
'tii:,J?"""
; - - ; * ; . - f
- -
^ . : - - -
. - - - 1 - -
,'rr-'OO
.o0"," 3,rffiEj,
---;;;;i[
cLUrcH TNTERLOCK
t
Closed wrlh clutch pedal
I
fully depressed.
ll
PHoro 1ra
I
"**"
!
Se Power
Distibution,
page
10.
4
('98100 models 3)
ALU/BLK
f2
l
E--r.---?q_l
srAFrEn
21-2
I- G1
Charging System
See Power
Distribution,
pag6 10.
UNDER-
HOOD
FUSE/
RELAY
BOX
FUSE 15
ALTIIIAION
sP SEII|SOF
7.5A
I
t
USA
' BLKAVHT
BLKI"VI/HT
- ) l
,
- - - - - - J
vtEw 50
See Power
Distribution,
page 10-5.
*
=
96-98rAl l model s
except 01685
' 99 ' 00:
D16Y5 wi th
i.4/T
**
=
' 96' 98:
Al l model s
' 99r00:
D16Y5 wi th
t\4/T, D1685
BATTERY
ALTERNATOR
See Power
Diskibution,
page 10.
FUSE 41
BATTEFY
804
T101
L - - - - -
ELECTFICAL
LOAD
DETECTOR
(ELO) UNIT
' l
; l
: l
: l
; l
: l
tl
, l
: l
: l
G1
!
- -I
POWER-
I -. ^
"'.1
,
I
rnlrn or
( . A1e) Y
' ( '
C17)
c 2 [
:
c s
i
ELD unit input
i
ietCrHe
!
'
!
coNrRoL
I I
MODULE
I
Artrnator
: lllerlato.r I
(PCM
or
i
controrsrsnar
i
t",fl?il"'
a:"^y]
L- ----, 1- - - - J
Pq_oro 3'
*.
B,'"',1;
:.i
i : 1E15_' _
_. i
GFN/FED
r
i 6
GFN/ RED
A30
f
D16)
WHT/REO *Fi
See Ground I
Distribution,
I
page
14-5.
I
Y T
L]
' " " -
P H A | O
,.^;?f,
:(' c;3)T
BLXYEL
I
i 'r",
".o I
I' HT/ ll ' U
, z s c n r l
: - ' o i
. l
, L
:
(c'r9ill-_-
'c11" 2)
u
l9nition
rnput
LOaO
Ground
ourpur
22
\
t
t 8 c501
PHOTO 60
vlEw 55
WiIT/BLU
3
I
I
cso1
PHOTO @
vtEw 55
A1
WIIT/BLU
6
WHI/BIU
' &zT---------1
Puoro 63
t
vtEW 50
|
c10' r
PHO|O 21
PHO|O 142 (O16e5)
vlEw 2a
u3t i
I
UNIT
a
Prafo 61
I
vtEtl$T
l . - - - - - - - - - J
Bl 5
i-Hffi--ryj[#'ff"'"
B,I6 Y
22-'1
PGM-FI
(All
'96-'98
Models except Dl685;
'99100
Dl6Y5 with M/T)
H$S..,E.Jgg" |
-
f
-r,-sfr.- -
?PJ.,
i
I
ffi**l
! |
se Pow{
I H
Oistribution,
l_l_iYi1_
'
r F,x?',
I
v' E!53
"a,-ro"n i
I
_______u.
't
I
I
I
J
rt4
FUE
flEfl
rta
c3st
7
ll ia"o"to u
fl
;x
See A,/T
Controls
vlEw u
Se6 PotYea
Distribution,
pago t0".11.
aa4
BLU
"lf
-
i
orrl
"lt---
c101
VEW 2A
cl 31
vtEW 59
BIK
1 0
23
NOT-E: Fu^se.31 is HO-f-with lgnition Switch in START (tD and clutch pedat
depressed or
A"iT Gear Selector in PARK (P) or NEUTRAL (N), see Siarting Systeni,
page
2i or 21-2.
See Intorated
Control Jnit.
page 70.
UNDER-
OASH
FUSE/
RELAY
BOX
PHOTO 58
c420
vtEw 53
PGM-FI
MAIN
RELAY
vtEW 18
|- flrn*',
""-"'l
""^"*l *L
I
016Y5/ D16Y8 D16,
; -ensnewrh", r-t
: --*f
3l 3yi : 131f f i , -' '
---
I
H; [ h-
N
i i i
j t
l i l T: { xsl I
ffifi:iil:"'""
il
-UTtl
i
ryffi$il:
i i
ffifrffi ,,1
_,_:_____r,"*,
, A124 ,
, A14A, A13A
'
416A C6A
POWERTRAIN
,
,
,^lAcy)
(iAcvP) (rAcv N)
| crnt $rs)
:
I
rAurr'arve
,
i
r--.-,
:
Fuel pump control Start input
! :rNGtNF
i
,
nt;*Y:l""
,
i
r--r
I
Fuel pump
conkol Stan input
| ;'NG|NE
l r
' uv"nv'
:
, I AC val ve cont rot
'
I CONTROL
\ I
,
I MODUL E
t ' - - - - -
' : - - - - - - - - - - - - i
l ( P c M o r E c M )
I t';[?,i?"*
L - - - - - -
- - - J
(cont'd)
---l-lf
-----=-------------=--:
i
"au*",
I
z I
23-1
PGM-FI (All
'9G'98
Models except D16B5;
'99-'00
D16Y5 with MiT)
bnilbn
out$rt
sionel
@r)
lDC CKP CYP
ansor aanaor snEor
ing'lt input input
fiDCP)
(O(PE (CYP4
CKF
s9nsor
inpul
&$n
I
t
I
A20
t-
I
(
)
I
:.
;{-r*:-:'${##*i
"H,,,*,"^.
I i * u.*
ruigffi?lFl-"44ffiil'i*-1 luffi::r- | [
m:#f:
1

J

Z

"

C 1 2 O
vlEW 29
lll9!9^- s A ctoz
'ry-li15fi,ffiYi"++#"
1|-l
"l*r
l-'"-L::___U-__-i.",*
"*l ,n*,,o.o I
[:fl:*
*l
v{'{r/REDI
r
l l l
| !
"""'"'*
|
"''ol ",r1, ! ruW*
!-=-n*-r=d*--,=-,.r-------t?il-1
PowEBTRAIN [
;aee
:+-:'
i
tr* dffi iffi ff*:
ifltBtr. I I
L------- -----Jffi-:cu1 lr-J
G1 0 l
PHO|O 33
PHOfO 123
lCVn
23-2
wEw lo
POWERTRAIN
ot
ENGINE
CONTROL
MODULE
(PCM or ECM)
85
ee ABS,
RS, A/T
rontrots (cw)
vlEw 59
See ABS
SRS, M
Controls
Y
I
-rJ
i -
i
,r.^
sewice
ili
\,
see,ence 3!13o, sensor
*ii!o* ru
i
oft,lo n[%!t?o oi8",,lo Glitid "oll,??9, ilffs,
n,&l]o 'no$.,
a:;
&- - - - - -
- - J
vl E
I
I
I
I
Se Ground
Dis ibution,
page 14-5.
Y
I
l t
L___l
-
:
G402
See Ground
Distribution,
page 14.
(cont'd)
23-3
LF
PHO|O 123 (C\.t)
PGM-FI (All
'9G'98
'99100
D16Y5 with MfI)
1@
i-l-,;;*--
L--LT-:
UNDER-
HOOD
FUSE/
RELAY
BOX
'f
9;u;,
'11
,c,i"',3,
wHT'REo
I
rrEt3'
see Powar
wHr/cFN
I
vrF 2/
aaa4 Distdbution, ll
wxTcnr
See
power
wnineo
I
page 1S10.
art Distibution,
r I
,r"ro""
!
Page
10-13
DATA LINK
, I
CONICTOR (DLC)
(With Cruise Controt i)
|
vtEw 48 rrF.t BRAKE SWtTCh
" ""f ":T
-C-l*
ffif{"s1
** ".,*.-,lf,1i
Fi3:{i'r'rs35:
,""oL.rr.
I
*-l
I
oauwxr
l
ffi;"i;ii"
I
t------j
F=Ln&1?i,inars'.rqr
i
-----=ffi,
o"n,n",
I H
;,?fl:&'"
,, L-----
--------=J
",.,
u+
lfii?iif.
21
F- - - - -
-
L' gi t r ! ^ o
.
1z
I
irlot,b as
TTELU
I
cRNu/Hr
I
v/EW )e
I
cel ouJl
inpW
ortsut
(K"UNB
18KSW)
Data B.ake
switch
input
wEc
valve
conkol
,
WEG
I
orgssure
:
h,vitch input inout
rPbPs
Ag
GRN/YEL
wEc
PRESSURE
swtTcH
POWER STEERING
PRESSURE (PSP)
SWITCH
I
ALK
Sg Ground
Distribltion,
page
14,
iu,**,"
L_jFiF,""*l
*.u_-ig:-l
d' Gr 01
23-4
PHO|O 123
IClr|)
r - - F- - - - - - - ' l UNDER-
I t FUSE 2s I
DASH
i )
rg'" see Power
i
5Eii"
I t-------)
gT:1*l3l
l""gT",,
r---*----i]1--]"-.t
-
aEnT
Y--
- -- - - -- --Y- - - -
'
I fierminals 1?'20) :
I
yEL
I
I
yEL
I
i uoros, i
I I
'
I vtw 56
T C 4 A
'
E s A
i r--.r---- t----,r-
I
.--+----
:----.1--
.1
cAucE
I
I Fff'"*'"
@
i
iafll-i
i
!ftTr:**' : A
.
: A
t , . \ _ - - . . ^ t
: l c t r c u n !
Sse Power
!
/tl\
MALFUNCTIOI{ (USA)
'
L-?-J
SlHi'#"
! Vl}8f{fiil E
i
AruE*f*mi
! I rc"""c"r :
\y' ucnr
Iu:
A18 A
'
A3O A
, t
------ ----, uE--
I
ritlt-tontrot
'
shin-uir ;l9tÊltg[F
,r
l al L' i oi trot
: th$-"n-' .
;l
oTEN(i TNE
|
,
i ndi cator control
'
l coNTRoL
' r MODULE
I
' I i - - -
- - - " " u A r O 8 6
I ; Ks Ctutch
,
I
v)tw zo
|
'
inout switch inPut
: I
I
'.
{xs)
,
:
(clsw)
,
:
Sae Powe.
i |
*""*l
I ii
i
"tl:"eererd
i I
I----.[:*s*' "!
i i !Bi i !' #s;
. - r H1
! I
lffi,
i
\+/il3ifii'"'[9i
I
L-J.---- -i ----J,-------;-J
""-:;'-f, i
"."K1(
:
' , L :
t A" o , ' :
i
outr
:
:
",_:I
i*'*n! i
I
:lt*,,.
i r g ) i i
^ T 1 ' " " "
i k t i - ; i l - I l Fi !
i
't'f
i*frw
ii
HFI*i.*'*
il--Uilli
I
I
i
, l
Fn=- - l r i l nar sl '
i l - *;
:
f915i3."5"
"""".*l
|n!?,*
I
:
i
"'*l
!
f
!
f
rlsl
l1t---J L__-f
.
r.,,!+J
c_
gr"9l,,
: :
*-erco--ol
:
PHoro 33
-
G4ul
'
PHoTa ln
lcw)
PHQra 57
- - - - -
CWDi 6 y 8 e n g i n e
- - - - - - -
D1 6 y 5 e n g r n e wi t h M/ T
- - - -
j
( COn t , d )
23-5
PGM-FI (All
'9G'98
Models except Dl685;
'99r0O
D16y5 with M/T)
TRANSMISSION
CONTROL
MODULE (TCM)
llEv/ 69
ECM ECM
control control
Reference
data data
vollage inDut
NREF)
OMA}
:q{.J
(VREF)
OMA) OMB)
Reference ECM ECM
control
data
jnput
EGR
control shift
'
I
solenoid
i
-l
"""'"x
:i1",'
sofenoid lock Pa(kl
vave
Circult neutr
; I
vave
circuit neutral
| |
control control inPut
, !
(EsOLr
{sru,
(A}FNP)
: L - - - - - -
voltag control
data
output
I
{
ta
i ; ; ; ; ' ; ;
. "
*
' i \ ,
' circuit neutral Reverse D4 D3 2 indtcator, ;
'
control input input input input input control
|
-,
|
(sLU) rAlPNPr TATPFI
{ATpO4i dlPD3) tAfPzr
rDa rNDl
|
/
[J=:ITTIT'{t
'
Interlock See Automatrc
: Svstem Transmission Controls I
i i controt
i
"'J;:;;,.,"^,
!
l1l
"lL
:1,.
i
".f:;;,.,"^,
1.,."n,
:
I lt ti.."stEBkTJBi
""il*l"*
: | / " I
SOLENOTD VALVE
i
\J
PHaro 12a
I
i
t'i!",,,
Bi"ifit**1
';
i
l
;;;a
',, pase 14
!'#$tl
ii{"Ff*,
i
*-1.
---f
!.gg1mr..
'
4 cror
|
-
PHAfO 123
23-6
:
, See ly'C
'
See
, See
'
Compressor
:
Charging
'
Fans
:
Controls
;
System
' Y I
Y : Y
: l : l l : [
i l : l : l
i *" 1
i
" *" . " 1
:
o" " , " . o1
,
r |
:
- ^ * l
i l i I
i
I
i .
*,
I i
rrz.l ,
;
ot. I
' . - - . . - - r -
/i**fffi'*
I r,rcffi"oro,
i
e.St*
I
; cornrd
'
clulcfi rday ' nput
|
. - , - - - ; - - - l
COn t r Ol
\ r
\ '
\ ;
t
'
Altsrnqtor
! Nc Altemator
:
conrol
/,
u.1;lf*
roqrsr rnpd FRfrgd
;
tSJ",
&r r r : r r
See
Charorno
Systein
-
:
Y :
! i
u".o I i
i :
o,. .!, i
POWERTRAIN
l*.]["n i 13'"',1+?3.'
:
I
MODULE
;
|
(PcM or EcM)
i lw,t?'"
Altornstor
;
I
conrol
i I
$:--lJ
"''I
',n,-
I
I
See Vehicle
Speed Sensor
ryss)
* [
".,^."
!
I
t
See NC
Compressor
Controls
.r_l
See Charging Sysetm
(cont'd)
23-7
PGM-FI (All
'9e'98
'99-'00
D16y5 with M/T)
-
D16Y7 Engi ne
'
I
pressure Retrence sensor ECT IAT
primary
I
'
i
sensor input
,
voltag input sensor rnput sensor inDut HO2S inout
I
|
!
praNKi '
OCc2) irpsr
(Ecr)'
,tAr)
'
l"no)si- I
,
r (Pr^Nn,
\wtz) {rPs) iEcr}
(AT)
{PHozs)
l L - - - - - - - J - - - - -
- - _ - _ _ J
:
Di s y j
or o
y
or y D2
y
D8y D7y
i . - - 1*. ". f f i , "[
' , [
] i l BLKr yEL
l='i$d""-""---ffi][.[
.l
I ul,
I
Iffiry
I IH;
iw|
irT_nHBRrfrnEBsi+lrplffii.;t
llffit!$il
i4[ffi- i
lfiJs+t-
lfj$l;?," rrrs.*r"se
a
r.ff
phu
Laa
i;ftffii
.]4 {_:{*;f,
i"# l
i:l'lz"
:
13
V"*3J
iclll
!
'e""
2 Y l Y
L r G R N
'll---o19;.?:.,,
GFN/
it io-rb
as ;
BtK
I
GFN BLX
I
GFN.BLK
ll
cRN BLk
(Termi-
r l
, lt
nals
,
' 97
model :
I
8-14)
r - - -
California Coupe,
ll
PHoro 46
Cal i t orni a Sedan LX I
I , E, J8
' 98
model : al l
r
(suzl
lPo2sHrc)
I
!
Sensor
i nmary'
| 6rl1d Ho2s
\
a
-
heater
\
t
control
I
,
L - - - - - - -
- - - - - J '
23-8
POWERTRAIN T
FUSE 15
AtTEii|AtOf,
^ -
aPsE|{aon see Fower
t5a
^
Distribution,
99coldary
---]-l-"jt='-.i HO2S iinBt
E*o,*.
!
CONTROL I
MODULE I
(PCMoTECM)
:
'i,l,llouu
ri
I
\T,T]K
DT4
WHT/NED
BLKAVHT
1
T
t
WHI/FED
IT GFN
c130
Oermlnals
1n0)
vtEw 52
')------------6;ffii----F'di---:--
----Ttgy.:!-
{
Strff' .'Sffi"? .uoFo?,*
|
su #33nno' ruo'ffiJ,
.\
srouno
i6is-*' #;,"1"-*
'
canistqvent sotenoid
l":iiEt$'[i,
i ffii$J' *H*"n' i :3Hl'5'*
varvaclntror,llg'r+,.'
I
. - _ _ - , _ _ - S J E C M)
f L- - - - - -
Pr l or o a6
t
UNDER.
DASH
FUSE/
RELAY
BOX
PHOTA 58
BLKAVHT
1I'j
c101
vtEw 2a
_ {
rn+5-m
.
c 115
, Oermlnals
,' t-71
I
vtEw 38
c401
c568
VIEW 4
ALKAVHT
BLKAVHT
,l
See Powr
Distribution,
page 10.5.
EVAPORATIVE
EMtSStON
(EVAP) PURGE
CONTROL
SOLENOID
VALVE
EVAPORA. '
TIVE
EMtSStON
'
(EVAP)
:
BYPASS
i
SOLENOID ,
VALVE
Evaponn-
2
TIVE
EMtSStON
(EVAP)
CONTROL
CANISTER
VENT SHUT
VALVE
PHATO 39
c125
BLU
1
BFN/BLK
' 97
model :
Calilornia Coupe,
Calilornia Sedan LX
'98
modei: all
c568
c401
c131
vlEw 59
Ses Grourd
DisMbdion,
pag 14-1.
NEO/YEL BLKNVHT
D13 A5
FED,^VEL
A15
LT GFNAIVHT
T1
G101
PHO|Q 33
M8
BIK/YEL
r+l
23-9
PGM-FI (All
'9e'98
Models except D1685;
'99-'00
D16YS with M/T)
-
D16Y8 Engi ne
I
I
- t - - - " "
, t ;
ii
hffi-
i
ffis* #""r, i"[
'
| (PTAN6
, gCC2l
fips)
' L - - - - - - - 4 - - - - -
i
-:l
i ,,,rt[
"'[ D2
lllHd,..--"ffi[il
iffi;',::l-l
'
anv l l
' 97
model : al l Coubes,
I
'
au I calitornia Sedan I
i n":, *t,*%,nof
'o0"" "",
lf1
fr3::fj* |
: "*i u, . ' o
'
l J l ; ' F#F.
I
id[fr?4;"
i
'[
i
i
+l
L'i':----i ---I- - - - - -::
'
iko,*o* [U!3v'0"
I
rrar)
'
lniczdt I
6i?----i''-v------J
BEO/^YEL
sensor nput
(ECo
NT
sensol lnpd
lnqrr
BA /BLK
)
. l
.a
I
I
t
k
PRIMARY
HEATED
OXYGEN
SENSOR
(H02S)
c123
cr23
PHOTO 42
_1
ALX
ALK
-i
INTAKE
AIR
TEMPER.
ATURE
OAT)
SENSOR
PHOTO 15
E33"ln'*' l-1-l
g.:;'$;lfj
H
t
,{
LT GA
2
GNN/BLK
8!(7YEL
c 5
(Terml-
nal a
8n4)
vtEw 38
GRN/BIK
D l l
BLI(AVHT
a
'
sSfl, *SffT3,.
{
I
grourd
heater'clntrot
r\
t !
I
L- - - - - - -
- - - - - - -
23-10
t )
POWERTRAIN
or
ENGINE
CONTROL
MODULE
(PCM or ECM)
BLKryVHT
f
FUSE 15
AL1EA|{A]OA
sP sExsoa
7.54
See Power
Distribution,
page 10-5.
UNDER.
DASH
FUSE/
RELAY
BOX
t
\ -
I
Secondary
!
HO2S input
,
(sf,o2sl
- - - - - - -
-
,.-".,
-^,o"::.f=_
rtl
ll
er-x'wnr
g
A cr er
""",".--*'i-"fj*"
c432
c7a2
-l--
:
$ i
see Power
SECOND-
F rl
EVAPORATIVE
'
f-tl-l
EVAPORA-
;
ARY I I I EMI SSI ON
' I
I I TI VE
8iiE,R I ltt l !'JiiABi*"'il ltt l Et,i"'J""
sENsoR I Jl l I sol eHor o ' l
) l l I i 9x1661
!t"93:t
IJJ
vs!:",
iLLl !Ailf*'",,
:
I ' l " u. t
". *, ^, ' "rf
I
, ----j
I l ' ; i "; ?' *
2
J:--;t,
C432
ll
96 model: all Coupes
ptlofo
/6
i
97 model a

coupes,
BLKI"V!/HT
--1"r",
' Y
:t f
i i i v!
3
Y iiol-o ao
onr.r wxr
I I ll catrfornra Sedan ll
9
g
c49
!
s8 mocJr, iri I a il!9.!a^5?
""""._l**t'
,L-
r I
i,,o"n,n",l
"f,",ul,,
-"-.1,=l
;^[::Ttn*- I i I
""1
,
+
g:%,,
*"[
il I
:
D13
A
A5A A15
A
,
A2gA 428
| '
-----=,--
-=-7-
tsHo2sc) tso2sHTci {Pcs)
|
{vs!,)
(2wBs)
Sensor Secondary EVAP purge
'
EVAP control EVAP bypass
ground HO2S hedter controisolenoid
:
canister vent solenoid
t
control valve control , shut valve valve control
t
,
conkgl
t
t b - - - - - -
BLKAA/HT
BLKAVHT
1
c401
c568
BLKTIVHT
BIK
FED
1
Distribution,
'
page 10-5.
:
,
BLK
' YEL
SHUT
BLU
(Termi nal s 1-10)
vtEw 52
! Ii{:',+'i":
I
I
23-11
PGM-FI (All
'9G'98
'99
D16Y5 with MiT)
-
D16Y5 Engi ne
23-12
>r4
FED/
YEL
! il'Jlilli:
Distribulon,
i
!
a a
i l -
"""r"a^ I
tl
+9,1:1o,,,
From
next page.
F
I
t
H
INTAKE
'
AIR
;
TEMPER. .
ATURE
(rAr)
SENSOR
'
PHO|O 4s
i
4
BRN/BLK
c123
PHO|O 40
vlEw 19
c123
PRIMARY
HEATED
OXYGEN
SENSOR
(HO2S)
PRIMARY
HEATED
OXYGEN
SENSOR
(H02S)
-- -.-g
c123
,7
,t1":.," I ::
'
t---o}
"",'"?",
vtEw 19
E r K l
i : : l l [ . _ _ _ _ _ _ _ _ i
l eggt qe" d! l l : : I | :
Distribution.
I I
,;
ll ll :
f f i 31i 1' 1
! l i i i l :
i
ioty I
er-rcrwr
| :
: i * - !
! i
: i
! ! i
-a--
Glol
: i
I I :
" u u ,
- - - - - - - - t ;
i g u l , . [ l :
g.ili'""'"t
i
11TI i
#?:?.'A6tr
i
F
-tt-*i -
I
- - - -(-Po"GFil
PowERTRAIN
i sdltGr i
irimari'
' I oR ENGINE
! ;il;n
i nciis'
'lcortnor
hear. r
' l
MODULE
| , haat . . . t MvuuLE
I
;
;;ii;r
i
|
(PcM oR EcM)
I
| - - - - - - r i P H O f O S 6
L - - - - - - - - - - - - - J
v t a e a l
(cont'd)
.
I
OR ENGINE
'
HOzS Primary
i
CONTROL
I
fruzs Fflmary a c(JNIHo
r
Label VS celt Dumo HOzS'
' , primary
|
MOOULE
i l"dqanc6
vohags Befe{ence bell
.
heater
i : !-1029 |
(p-Q!/| OB
:
red$snce voltag Beftrence
cll heater
'
:
HOzS
|
(PCM
OB
:
insJt input voltage
control control ; ;
inpul
I ECM)
,
(rABELt
Ms+) tlP-.vs-) (rp+) (Po2sHrc)
; ,
l"Y_
j
r;!J?.*
- - - - i - - -
i
-l "*
I'*l*'l
*l
i iill i r l r
I
: L + . 1
l - - - - ,
. (_l_.o-l
:
I
annar-x
|
:
: I I see Grourd
23-13
PGM-FI (All
'96-'98
'g$.'00
D16y5 with M/T)
-
D16Y5 engi ne (cont' d)
r - - - - - - - 1
POWERTRAIN
OJ
ENGINE
CONTROL
MODULE
(PCM or ECM)
c125
- - - - - - - - - 1
FUSE 15
$t"t!ilS8" see Power
t.5A
-
Distribution,
page 10-5.
UNDER-
DASH
FUSE/
RELAY
BOX
Secondary
H02S
anput
(sH02s)
D14
I'
,n"r,"ao
I
rtr
l t I
I
i,tj
c l t 5
(Iermi nal s'
1-7]T
I
1
vtEw 3a
HI
lffiq,m
, . ul
- ' '
:
3A- 3uA- - - g' A- - i - - * * - - - - f ' I
:
(sro2sc) (so2sHrc) (pcs)
,
ryse
-"-*"i -
l! 39Y.E!:
;:m
AA8r"y-
rvffi's"
i
euo8S:noo' E\"L'Yssl
'iH;in';'
hearer sorenoid : :ill*',":* ;:fl'".t"* iiF!ii"te'-
control val v6 control I controt
___-- l l ?| Et",".,:
T
$
See Pow6r
Distribution,
page 10-5.
BLK,/li!/HT
BLK,\II/HT
1
c401
c568
EVAPORATIVE
:
EM| SSTON
;
(EVAP) PUBGE .
CONTROL
SOLENOID
VALVE
PHOfO 38
EVAPORA.
TIVE
EMISSION
(EVAP)
CONTROL
CANISTEF
VENT
SHUT
VALVE
EVAPORA-
TIVE
EMtSStON
(EVAP)
BYPASS
SOLENOID
VALVE
(See
S/M
page | 1-9
for' 99-' 00
model s)
'98-'00
mooets
c568
c4o1 :
PHO|A A5
vlEW 59
1 1
g
Ct 3 1
See Ground
Distribution,
pag 14-1.
Y
I
anver.x
b9^
23-14
PGM-FI (All
'99-'00
Models except Dl6Y5 with M/T and Dt685)
@
r-T-------r UNDER. DASH
I t
FUSE ro
IFUSE/RELAY
I \
FUEL PUMP
I BOX
i {
{"rl"t*
i
PHarc 58
! |
see Power
I
I H Distribution. I
I I
page 1o-2.
I
L- Y, - - - - - - J
8 Y C420
FUSE 44
n E/u
r5A
FUSE/RELAY
BOX
:1,-
I
"l[-------]:"il",.,
|
'f -------;;[
#""r'6"'
l l _ _
i l
_mf i l ?9' "*, *, , ,
"f,r*r"rl"l
^*_"' l t -
I
-"1
$$f'Fl,[ I
"-Tf;f,{=l[
"rrl
Lj",,. il
"""'-l
m' m'm'm'fti:i";r""'
|
*i.
fl.iK""l
l I
'l
!
"'-lr4'iJ
",,,!,
+il!"'bt,"*",,N.
"j :l :l :l :l
i,rrr&---------;!%
---i*t---.
---f
I
back up. input inpd
Fuel injector cortrol \
t \
a t
L - - - - - -
_ _ _ _ _ _ J
@
BLU
sLu
24
NOTE: Fuse 3l is HOT with lgnition Switch in START
(lll)
and clutch
pedal
depressed or
A' /T Gear Selector in PARK (P) or NEUTRAL (N), see Starting System,
page
21 or 21-2.
FUSE 31
SIAilEfi SIGT{AL
7.fi
UNDER.
DASH
FUSE/
RELAY
BOX
PHOTO 58
See ldeoratod
Control Unit,
page 70.
1 1
10
c420
vtEv,/ 53
PGM-FI
MAI N
RELAY
vlEW 18
-:f]
' "
l ;;;,b"
YEUG8N
I
vtEw 40
i
fli,i{ry;g:l lr
R;::i8i3ll:13rffi:-''
'r
I
H[f#'-
il |r'ru*
ljT-.i|ff
|
-
Friofo 1id | |
I \ \ |
Plioio {-
n
, 1 Y LJirJ-J
plroio
4s tot6v7,
I I G552
' l t : i : P H o t o s a
I
[
: :
!
' l
r - - - - - -
'
e r - x l
i i a r - x f i
o n r l
i * " 1
l : " ' l
I
:
:
I i : I I :
i a z s A
i i e o A e r s | '
,
l t o l l c q l
.I
POWERTRAIN
,a1F--X-lo"i"r
t, "u*t
:
(FLF)
!
, lAcvatve
I i
rq;.,.-...,;
:
Fur pump controt s"liii'p",
! EHc,le : ; w ,
r u E r
P q r r P l J t r I u l
I
, connot
:; IAC vatve controt
,
!
CONTROL
(cont'd)
24-1
PGM-FI (All
'9$'00
Models except D16Y5 with M/T and D1685) (cont'd)
l t
r l
!
lgnition TDC CKP CYP CKF
\
I
output sensor sensor ssnsor sensor
I
signal inpt$ input input input
I
!
ncut
dDcB
(CKpPr
tdveel tCxepl
I
L- - - - - - -
- - - - - - J
]L
'iffi
,Tf;=44ff=''fiffi;^.,"^-
Lqsry:ffi_ tt-i ffilJ
ilffi:*'"
N N
ffiP
;
:ffi-qg;","
-;ffi' ", -
-" " ^^, | | i
gBri/
|
'
Pnoro,e
te'0A2,
------,1-I---L",,,
| |
(PcM or ECM)
r-Gtor
L______
___J
pHoTooa,
= ,*Zi Z1\r,"
:l :l] :l
ffi
i----=*:?, *Sru,-----
*fu-l!fl::'*'" I
I
!
"'
il;ffi6
ifttEtrh",
L-J
24-2
I
t
! c,orna
,
( LG1)
Reference
voltage
(vcc1)
Service
cnecK
connctor
Input
(scs)
POWERTRAIN
ol
ENGINE
CONTROL
MODULE
(PCM or ECM)
PHOfO 86
Map
sensor
input
Sensor
ground
(sGl)
A10
Ground Ground Ground
1LG2)
(PG1) (PG2)
See Ground
Distribution,
page 14-2.
MANIFOLD
ABSOLUTE
PRESSURE
(MAP}
SENSOR
PHO|A 49
p16v7l
See ABS,
SRS
Y
I
--J
SERVICE
CHECK
CONNECTOR
vtEw39 See Ground
Distribution,
page 14-5.
I
I
___J
Se Ground
:
c402
(cont' d)
24-3
PGM-FI (All
'9$"q)
@ @
i-l;;--
----1-:::=*"---l
!,8,:"ff
| )'rEnsuorr
(
tu
seo Power I hEiiY
'r9,1%, 'r
F,1%,
wHr/FEo
I
v/El/v 34
'HT/FED
se
power w111,6s1
|
vtew zz
a
1
oistribution, ll
wrlcnr
See
power
wrr neo
I
pa$i Gi o.
OF+ DstnbJtron.
t I
tn"to"n
!
Pa9o
1s13'
oAra LINK
z ll
CONN-ECTOR (DLC)
(with
cruise controt 4) A
vtEw 48
t?e1 BRAKE SWTTCH
isT-rrT ltf
!1.l'".e'.l;'[3J:5:
""[ ":T-:"C-l:.Frd*Fl
l l l ,
"""f "",T
""U]-t-.,-t-..*.",,""*î:#
[*iu'r;i:;r.';
'""o1""1
""l
l ;f=:&ri'n"*,,.,0r
[
.---+_s,:.;-,
"*,**il
[ff'ftrs,llr,
*,.!. ^* I A2r |' A32
A
: {r(LlN) KSW}
|
I Data Braks
fleu.rt} ft svyl
I
Data Braks
inpuv switch
I
output inpd \
\
' wEC VTEC PSP
I
PHaro 123lcvr)
D16y5/Dr6y8/
:
:
PHoro 123lcw)
- - - ' -
e i 6 A2 ' " n o i n " i
- - - - " - - -
u s A
;
L
Drssure vaNe
srlitoh input conkol
(Vnr)
0rs)
*{
---
"::l
fTlxlE8,u,. I
lc-- ll#il?i,",,*,
I
"il
I
I see crouno
!
Fi"frW
""",*f,f,',11,r,",.*,
-'l
I
""""iJ,,.lff*u"'"
yi
qr;;;i6;;o,E.6A',
:
PHOTO 33
sYvltctl
inDut
---u-r----
can
I
s
I
crer
"Tl t#ffl","
I-'I-I POWER STEERING
I ' I
PRESSURE (PSP)
lc_.ltg+I9i
,
f
ff&G{lfd
Drsribution,
""L----i
F*i,""," I
.----a-
-r*ro_*
|
"," I
vtEw 39
Lr----J
:
PHATO 33
\
I
I
pag 142.
24-4
i--I,*.;----l
I I
ffl* s Pow'
I
!---h=js:q-l
r'1ltii*",
! il"Jiisa"
;ll
i-[*-*"".""--l
! @ffi[+[ffI. !
! Ir6rer i
L--L-,sr@l
c 5 Y
UNDER.
DASH
FUSE/
RELAY
BOX
PHO|O 58
GAUGE
ASSEMBLY
; - - - - - - -
U S A
- - - - - - - ,
see ly'c
i
S""
:
Compressor , See Charging
;
Controts
, Fans System ,
POWERTRAIN
-
li*t*rr,,
".o^.of, i """f """,tr'
i
tff'$fit!
Tl,!,
"0o
-;;l
i
;;l ^*l
i
n"""j.F,rH;
I r s I
A1 7
A
: A2 o A
mo A
:
, ' - - - - - r i ; ) - - - 7 o l - - - - - - T - ; ; l - - - - , i l - - i - - - - - ' r
,'
r',lrr- di-ritror lvc "orip-E""or
:
Fa; ;;iror eldiinit
:
I
I
clutci relay conlrcl InPd
I
\
t r i - - - " - - - i
t ! 9- - .
i - ; t er " ; - - I
i { r , *+- i
1s" ' *. ' l
r I
t'lc
:
EGR control
: :
Atternator I
A[emator
]
'.
I
KS
:
requ6st
;
solenoid
;
VSS ' control , FR
I
a
, inDut : inout , \iave control , inpul
,
sional
'
sianal I
,
,
(Ks)
i
i*"1 ,
(Esor,
_jt,__.j-_JgL-.j__
,^:_j
3- - - - - - - - - - - - - - - - . 4- - - - - - , 1- - - -
i " f i t i " . , f f : l i " 111
i f f i l i f i l i " F" l
i * l
i
+ i I i
" +
i - " 1
: ' ' " 1
T '
Se e L i C
,
I
'
Se e v e h i c l e
t - - ' - - - ' - '
ComOressor
,
2
^C142 : Speed
Contiofs
|
|
PHoro124
i Sensor
i ft> i :"::l
'
".o
|
",o,o,,0
i lisi:
3i&S**n,"n
i
Lti-t
i i rh;ry,'s;3+r"" i
: I
""n, ". *l
i i l t l l l S' "", . ?^8"' $l l i ' t
i l
""n' "' *!
i i l -i l ]J5ff#f."ruuu
i ll.,*'o.* ! *o,o,no i i l'.lT- seecround
: FflSI8$" i
Btr"lifiiJ}':
i i
*i[
Bi,i"EL'""
;
f
lJffi""' !**;' i i":-lei'u!,7,,"
ws{u'
(cont'd)
24-5
I - . . t
iecnuaruerirt
Rererence rp
iiftii* l"*o, $'n"o.
t
.
i sensor Input voltaqe
sensor input
inpul input inp"r
I
I TEGFL' rvca?r
Opsl rFirir.rxt rECn i,ari
t
L- - - - - - -
_______. J
PGM-FI (All
'99-'00
Models except D16Y5 with M/T and D16B5) (cont,d)
-
D16Y5 Engi ne
BLK
c131
PHOTOss
vtEW 59
ENGINE
COOLANT
TEMPER.
ATURE
(ECr)
SENSOR
PBO|A 32
c130
Oerminals
18-20)
vtEW 52
YEUALU
20
YEUALU
YEUALU
YEUBLU
1
YEU
BLU
ALU
LT GFN
EXHAUST GAS
RECIRCULATION
(EGR) VALVE
LIFT SENSOR
PHO|O 36
TEMPER.
tllfrtr'l
I J tffiT,.:'
""",:I
1 r
:{
Slt or
lr;:
H
H#*iiff''I
fi[ffi,''""."'.1
"_
[;,l;,+.
N
: { I
c 1 t 5
(ferminals 8-14)
vtEw38
n"","*[
" r aI
r
-,^^:.I
POWERTRAIN
|
"ji""il,
I
corrnor
lu'"t !H"3fii:'
L __ J
V|EW 7a
24-6
POWERTRAIN
CONTFOL
MODULE
(PCM)
PHOTO 86
FUSE 15
AI'EiIIATOR
3F Stxsoe
?.5A
c10t
vtEw 28
See Powr
Disltbution,
page 10"5.
UNDER-
DASH
FUSE/
RELAY
BOX
PhoTo 58
r
)
BLXAVTIT
I
BLK]YEL
c l 15
ffiru
fiE$'-i-fi,#*,ryffi#
liltilf
*-"';
.,"Ht-tll3::l
L#
;FiiJshf#
!,n$f*'"., I
Pca'''
v/
$1-
{-r
j,=1#:llx
vtEw 59
:
(Pa2grTG)
I
Primary
I
HO2S
{s!2sHTC) {PCS)
(VSV) (2\4AS)
: a
p.ip-"0"'y evnF
-pirge
Evni'&mrot evrF biitass
I
l$lf"o.
HO2S conlrol canister venl solenoid | :.^^... -
|
[&? heator solenoid shut valve vatue cdntrol
I
lil9P-uLE
i
lffitsr conuot varv controt conaor
---
|
!:3,T),.
LJ - - - - - - - - - J
'"
Y F;o""L*
ELKArrHr
I
v/El, so
24-7
PGM-FI (All
'99-'q)
-
Dl 6Y7 Engi ne
ct 6
(
k
GRN
GRN/ALK
I
I
)
-l
.a
FUEL
TANK
PRES-
SURE
SENSOR
(See S/M
1
BLK
GFN/
BLK
GNN/
BLK
6
GAN/
8LX
8
GFiI/
BIK
tis3
:
INTAKE
AIR
TEMPER-
ATURE
(|AT)
SENSOR
PRIMARY
HEATED
OXYGEN
SENSOR
(HO2S)
c'123
c123
cs68
PHOTO 103
c401
vtEw 40
ct 31
vlEvt S9
FffiflH
{
r,Bi".'#
H
r{
t
f 5:o#'""'"n
rt rt
BLK
a t
I t
lFueltan*
TP
\
lprasura
Rg{grsncs
ssnsor ECT IAT Primary I
Fnsor
inpJt voltago input sensor input sensor inpul HO2S inout
I
| (rt^xn
Naca Crpsr lscn
-
--
1-ran
--
-(p,ioi3i--
,
L- - - - - - -
- - - - - J
BLKT^YEL
c l t 5
(Iermi nal s 8-14)
vlEw38
contaol
24-8
--.t
POWERTRAIN
I l o,
r
- - 1
UNDER.
FUSF 15 I DASH
,
, t OU*. _. i \ sr_es1, rr1pn l l 99E,
- I CONTROL I I
sPsxSoE lie Powe.
I RELAY
\ 1i l 6' di rt E-
l l t : i ----Di i ; ri , 6; . l a6;
I *PIl{y^ I ii'd-r'a-ol-ecul
I
f----------+
pase los I i6io.u
j
_ _ _ _ _ _ __ ]?S"Et _ _ _ i ,;t:;
y,,t
- -' ,!
i ;st*
-' i - - - r
*t
f
**"'!3a-
BL(YE!
w' r REo
!
"t^-"' !!
:$ffit----rrfrmt' ' f
ELKwHr
,_ifT* roTfl
*lt,"[
",.,:t*n'*
- I ,,","."1",
I lF:rf{.'!r
".--",1
-*-rflft*;,r''
I I
*"'"'"
|
"'*""
!
"*'*
!
l*l
;|-*J,*
,[ .l
Et#jil
1-I"ffijffiilpnurpn$*I
i*Hh
*l__JJ,J[__.fsm,
,[
'[
'*'",.
*,1
G-fil?il1".-",1
".""..i ,*","",1
'fnr+-
ffi TwN
*,N
I I
l l l ,*,,
I |
*,"
,f
____4;,,r,:+,.
|
","1.,."",
u^.1
",.,
"'*""'l "'""'il
il
--l
;[--Tn*" ^.1 -
+ F;%,,
24-9
PGM-FI (All
'9S"00
-
Dl 6Y8/816A2 Engi nes
c123
PHO|O 133
)
t
I
I
r
k
'l
ir
c27
3 crso
I
(Termlnals
ll
18-20)
li#?t?,"
It
ll
I ".r,".*
ll
lt
ll
I
lt
lL___3
H
'I
t
I
I
I
Rrol tank
ipressure
Fobrsnco
: ssnsot inDul volt4
| (Pr^No
0cca
L- - - - - - -
*'I
:*I-.
;iH$ffi1
l-Flitii!
lJri li::#'":l
"oil
??$j
"rt
*tinr+- l+-
*'.,9s,g';,, f
-:i*<'lrp !
-I$"";*",
o"",".,.
I
"rnLi':______I
ALK
INTAKE
AIR
TEMPER.
ATURE
(rAr)
SENSOR
PHO|O 15
PRIMARY
HEATED
OXYGEN
SENSOR
(H02S)
PHOTO 13i
F}$iH
:{
F#-H
{
c123
PHOTO 133
LT GFII
2
ORN/ALX
c 1r 5
(Iermlnalr
8-14)
PHOfO 16
I
I
I
I
24-10
--.I
POWERTRA
t l or I I
rusers
i
oasx
I
! EtR'+[i. i )
el'stwg^ seepower
i[EiFi
*'tr
_____:l*.'
#l:_l::i\--
$11*"1
;f;,_,
,,
lhtEffe.
i l
giTr**-
Bi:,ffiilsr
i
I
Secondary
i- - - - - - - - :84 - - - i
fis"'!r"'**,,i
*#i5
-''!
\ l i l $i i i E-
i l t 5t - - - - oi i , i b" t ; " . l Eb;
I
S.econdary
| iFCrrr-o,
eCn11l
I
-
page 1O-5.
I
Fa6io sa
_,a"3,____
j ",E"-o t"
y;rjrt...
A23
Y
BLKrt!/Hr
I
v4d5o
[t]
|
:iT[r""-l
*.--il''""'
: x l f ' ' i - ' l ! t r L w 1 8 I
. A r *
Seecr ound : GRNBLKI BLK\ "HI I
FEoYELI LT GRN wt t r
ii.ir'r;U: !
1 [
*"=[:-{r**,,"'^"'l
Fi{f},ff'
".**n,t
"-#::"""_
! 1""'"*..!.--":i^."^ I I lfuri+ta:"
| * |
,"",1*--".Jrr*,,
,l ,l
LSn*ur,"
Ll _,
ffii**
$
w**-
ry
*il
I
*i{tu
Page143. : I t I I i
-
Yi ' , , , u,
[!l
",,,
,F"
|
"."":.tun't
+ F,'"%*
- - - -
,
(sO2sHTc) (PCS) (vSV)
L2WBS)
i
Secondary EVAP pufge EVAP control EVAP bypass
!
r.
HO2S control canister venl solenoid
I
tt
heater solenoid shut valve valve control
I
! control valve control control
i
*' --
|
. E - - - - - - - - - - J
13
g
c401
POWER.
TRAI N or
ENGI NE
CONTROL
MODULE
(PCM or
ECM)
vtEW 70
24-11
Programmed Fuel Injection System
(PGM-F|) (D1685)
NOTE: Fuse 31 is HOT with lgnition Switch in START (lll) and A' /T Gear Selector in PARK (P) or NEUTRAL (N),
see Starting System,
page 21-1 .
@
ii6iir-
- -TFU'E;--- - -
I
gI3'5"
y#*i [HtF{,i i H.frIHHi
Ji ffi " ![' .i F{,
$SNAL
r5a Y 7.54
| - See Inleqratd
Sse Powr
| --+ ffii;l'i;
--
|
Phoro 58
i
ffi
ffi:-
|EHF?
i I
p--',b"
I
iffij*,**.,*
iFE^l
SACI( UP
7,ta
'[-------------'[&T:1,
L.[E"Jj!i_.f;ff:]_j
*L:*
ilTrr,*ii
"",""[*=
{ {-
--
;[n*n-
--ftr-' l f
t l
GFNYEI
T
HI
I
r v
J
&l?3.,"","' o-,rr
! ,o"on
!
#""?,*
I
'rT#
*"ll
'fi-----n
h,T5$B.I
J J lvA!::,
!
[--iI I
! t l
I
onr
I
can ver-
|
er-u onn
I t t
A arsl rrsl a24
;t--7;,i----&;-----
{
IAC valve mnt.ol
;Y
N
I
T / U
ll
v
ToBon
laclng
page
4
FED
I T------i:il;
,oln,.r
I
"""-f-T:
-l-Lri
| |d
l
wtl
Iil
i-,"ffifi
- - - - - - -- - -;s,nl - -ffi'J -.'"-
I
Oac* rjp input input
A
I
I
I
| . - - - - - - -
{F;H:{"
I
I
-"1
,,..!.
'-^-*'!
PowER-
f,mihHin.
I (PCM)
lif''?;"
25
BIU
From B
WHT/BED
WHT/REO
WHT/FED
W}ITIRED
2
c401
vlEw 73
WIIT/BED
LJ*
;.;.il,
m
:il
"u"T.l,
m
*
a
From A on
facing page.
v
I
*"rr"a^
|
, L-:l'il
mm-'
1:-
a PHO| O147
I See Ground
8LX
I oistribtnbn,
|
*'"J'.
v'
a -
FUEL
INJECTOR
RELAY
PHOTO 135
r
Ss Ground
arr< Dietribution.
FUEL PRESSURE
REGULATOR
SHUT.OFF
SOLENOID
VALVE
:
c4o'l
c150
vtEW 72
r-
IT
;.;..{
' m'
m'ill"'"-"'
,t ,iJ,-,
i{
it.;:;t"'-
INJECTOR
CONTROL
MODULE
See G.ound
Dislribution,
pag 14-3.
Y
!
BFN/BLK
I-J
I
I Distribr;tion,
I
pags r{-6.
ti
:
clot
y'o,J
PHOIO 86
G101
-"----.<
c.t 16
- -J
(Termi nal s' l -7)
""'7lw;8"'"
Ground Grouft
Ground Ground
fu*gr PorYgr fl[J2)
(rNJ3]
0NJ4]
;:[
2s-1
! - '
BFN/
BLK
PGM-FI (D1685) (cont' d)
I
t
I
I
I
!rurr
|
"'f8;i
h.
I
(
IGNITION
CONTBOL
MOOULE
0cM)
ct20
vtEw 29
DISTRIBUTOR
PHO|O 44
TDC/
c|(P/
CYP
Se3 Ground
Distrilutbn,
page 14-3.
Y
!
!
!
__.!, ",,0
I
I
: n l
I
POWERTRAIN
CONTROL
MODULE (PCM)
c9 A C30
I
I
L - - - - - -
it-{
{ti'o'i""'"
|
"i1lg,*
I ."" u.*o
|
3l"J:uel
l t
b;,.i,,
!'
-,'il"i -*-*i -.?'ii - - - - - -ri**i -''!
I
Sensor Saflsor Snsor Sansor !
I
ground ground ground ground
!
25-2
I
I
i c - - - - - -
a20Y B22 82
Sewica
chock
cottn6ct0r
fioul
'
(scs)
(Ierminals 8.14)
vtEv\/ 39
Ses Grolnd
)
ur"lro Ground
(PG1j
Se Ground
Distribution,
p8g 14-2.
Rsiernce
voltaoe
Ncto
Map
ssnBor Snsor
input ground
(MAP} (SGr)
POWERTRAIN
CONTROL
MODULE
(ECM)
PHO|O 86
vtEw 70
S Ground
Dlsr.ihJtion,
pags 14-5.
(cont'd)
Ground
(tcz)
Grornd
(PO2)
I
I
___l
F
3rr;rs'
-F
:
G4/l2
PHQTO 125
PHOTO 33
25-3
PGM-FI
(D1685) (cont'd)
(
UNDER-
HOOD
FUSE/
RELAY
BOX
Se3 Powet
Distribution,
pags 1&13-
uYt%%,
WHT/REO
I
vr6wJ,
aaz4
wxlnro
I
s I
DATA LINK
coNNECTOR
(DLC)
8
Y
C352
ll Proro 8
,""'o"n
I
u'* "
ll wwcnr
. 4
*"r,o"., ll
I
qA
SE Powsr
Bistribution,
pag 10-10.
i
ll
See ABS,
\ : (
i t 31
tlofo
t
'EW
59
c t 31
vtEw 5!
F - - - - - -
:
(x.irie
Pt9q
I
I oata Brako
a
inpuv switch
I
output input \
\
I
I
- - - J
POWER STEERING
PRESSURE
(PSP)
swtTcH
See Ground
Distribution,
pag 1+2.
WEC PSP
prossure
switch
switch inpllt inpui
(wU)
lPSPSvv)
;ry---
T
flffiii':Y- E
" l 2
t
--l
"*
|
t__________L
VIEC
vafue
contol
-----gl-
812I '
GFN,^YEL
i
I
!
I
I
o"n,,,.f,
F':t;"
r{r
*."
I Jll l!,[.fi"'"
l-i-J
l'?!-1 BRAKE SWTTCH
| / |
Closed with brake
!-l-ij
9;'3,1ff'**""
'T
"*'-.1,
25-4
@
- - - - t
UNDER.
I t
FUSE 2s
I
p.4:!
| )
Iff" ses Power
| ;"Eiii
I
l------+ 3l'i:?'J:"
tF,%.,
L--*----i l --l -J
-
'o
Y F;%.
YELI
v/Ew 55
f
--- - - - - - - - - - -;f
'-iminats
tz'zo1
I
c+ lv' rwto
Y
r--' 1r-:-----' l GAUGE
see Power
! f*
l"?i*,"..
!
f,s";"ty"tt
Disiribution,
I
,\
|
vtEwTl
pass10'6
i @$eFH,t* i
! T16r I
see see !y'c see I
I
-ruil
|
See Startrnq ComDressor Charorno L--V---J----J
Fans System Conliols Syste-m
-
C5 y
I I I I
"".11-lro,..
| | | |
o"no"n! f [ ?i Suo
GUN
I
BLUVHT
I
BLKnEo
I
GRNFED
f
sVC131
*o
I
o,
.1. o',
,l o.o
.l
o"*o*l
i[?1o"*
,r---U,a"i---strF-*-*"r"tr8*i-#%,.----;w;,---lneffi
[it^'"
\
tan control control ciutch reiay control Input
| (pCM)
\ -._ |
puoroea
r
AJc Atternaror Atternator
l.
iir*.
i
VSS rsquest FR controt
I
i
'[g3l i"R8!, ",gl,1o "'11'%,
I
r L - - - - - -
- - - - - - - - J
c23
l l ,
l 27Y "ur "rX
t l l l
BtUw}rI
I
BLU,FEo
I
w8r RED
I
wxr onr
I
I I I I
Y Y Y Y
See Vehicle See A,/C
-'-d
SpeedSensor Compressor
(vss)
contiot
3i:,""I"'n'"n
(cont'd)
25-5
I
PGM-FI
(D1685) (cont'd)
EGR
vdvo Fuer ia
( t
EGR In pres$uro
\
valvs smor nd*6nc6 lP i.snsor
h.tsl lank tenF,
I
cont ol inDut volt|ce s8fi8of inDul inbut ssnsof ifix,
I : control inDln voltac s{tlor input inout sonsol ingJl
;
I G.GF} GGf,q N@a fiPg'
.(PFoJ
fiFO) ,
L- - - - - - -
- - - - - - J
j
c28 87
c150
PHOTO 112
C'ro1
PHO|O sl
c575
vtEw 7i
(
FUEL
TA}IK
TEMPEB.
ATURE
SENSOR
H
1 Y
FUEL TANK
PRESSURE
SENSOn
PHOTO 116
THROTTLE
POSrT|0N
CIP)
SENSOR
EXHAUST
GAS RECIR.
CULATION
(EGR) VALVE
and LIFT
SENSOR
PHOfO 36
"""r":x
o
GRI{/BLK
4
GNN/BLK
GNN/gLK
c575
c401
PHOfO 57
vtEw 40
2
GRN/BL(
cl s0
a
POWERTBAIN
CONTROL
MOOULE
(PCM)
PHOfO 86
I
I
I
J
n"*r"a^[
' r
cai/BLX
ll
cre A
r--?
lsJiH,
I
ground
I
25-6
-.t
POWERTRAIN
l coNTRoL
Fuel I
MODULE
\.
. -,.^--
p{sssure
I llglllTP-. .
sansor sensor
.snsor i;ir*,o
;
sensor_rnpul
input input input
:
I
nFa (PF2)
GcD i|An I
r L - - - - - -
- - - - - - - - J
c13
I'
c14Y c26
FUEL
TEMPERATURE
SENSOR
From
facing
page.
v
!
_l
From
nen
page.
v
i
GFN/BLK lI
i
EG-f
flltur'ffi
,{J
ENGI NE
COOLANT
TEMPERATURE
(Ecr)
SENSOR
INTAKE
AIR
TEMPERATURE
(rAr)
SENSOR
c' t 15
(ferminals &14)
vtEw 38
(cont'd)
25-7
PGM-FI (Dl685) (cont'd)
\ ' (
UNDER-
DASH
FUSE/
RELAY
BOX
PHOTO 58
POWERTRAIN T
Primary
HO2S
Input
(PHO25)
Secondary
input
CONTROL
MODULE
(PcM)
PHO|O A6
vlEW 70
Ss Power
Distribution,
p6gs 1&5.
i
(PHozst (sHo?sr
L - - - - - - -
I
I
J,
Lti
J,
-'!
!
t
!
"l
See Ground
Distuibution,
pago 14-2.
G101
PHOfO 33
i'tj
I
:li
Sea Power
Dislibution,
pag'1G5.
c't23
c123
PRIMARY
HEATED
OXYGEN
SENSOR
(HO2S)
c125
c125
SECONDARY
HEATED
OXYGEN
SENSOR
(HO2S)
(
1
BLK
BLK
2
GFN/
ALK
HOzS'
HO2S
POWERTRAIN
CONTROL MODULE
(PcM)
nater
conlrol
hgater
control
I
25-8
Vehicle Speed Sensor (VSS)
il';;---l
I \ ALTENNATOA I
I I""::,",,", !
Lr_f1l_i
".*,1,[
9#":1"
\ . (
UNDER-DASH
FUSE/RELAY
BOX
PHO|O 5a
I v"ni"t"
l:g9qd
iineilt i
12
CRUISE
CONTROL
UNIT
vtEw 43
I v"ni"p I
l:p"gd I
I' T$, I
TRANS.
MtsstoN
CONTROL
MODULE
FCM)
vtEw 69
! !iio',6T""f
EtuwHr|
!y:ll*!Bb'î1?'J.'
!
so""oo-
!
iffii
lr*J l;6';irtE
!;i#:*! il il iiTs'l, iipEr',r"
L- - - J
I I
L - J
D. ^. . 1*
B11
Y [ [
( - C18)
Y
vt LNTo
l ;i "i ;' ! [ [
l ' ffi , l i i b-r,ro,ecu1
page 10-5. (
lgnitjon
Vohiele
speeo
ouptn
Ground
Y'
"""-'
Oerminats
1.t-13)
vlEw 52
VEHICLE
SPEED
SENSOR
(VSS)
PHATA 35
=
' 96-
98: Al l model s except D1685
'99
00: D 1 6Y5 w th Lr/T
=
' 96-' 98:
Al l model s
' 99-' 00:
D16Y5 wi t h M/ I D1685
. i ,
a
33
-
How the Gircuit Works
With the ignition switch in ON (ll) or START (lll),
battery voltage is supplied through fuse 15 and
the BLI(WHT and BLK/YEL wire to the vehicle
speed sensor (VSS). The sensor is grounded by
the BLK wire to G1 01 . The speedometer and
other control units in the circuit supply about 5
volts to the BLU/WHT wire. The vehicle soeed
sensor (VSS) intermittently grounds the
BLUMHT wire which generates a pulsed signal
in it. The number of
pulses per minute
increases/decreasos with the soeed of the car.
Reter to th Service Manual (Section 23, Electrical)
tor specific tosts or troubleshooting
procedures.
33-1
Cruise Control
(
UNDER.DASH
FUSE/RELAY
BOX
I t
FUSE i 4
| \
(CBUISE
CO{TAOL)
i f
tlfl*t.,
s"" P *",
a H
DistribulDn,
L--g----r9101_
".,."11[ftT:{.
! i,*f+*l
f:L[
See
Dash and
Console
Lights
"-T[_
CRUISE
CONTROL
MAIN
swtTcH
\ f a
See
Dash and
Console
Lights
I
' r
Lr cRN
I I
I """I
I
*"1
r t
,. L-----
---3-l
i---
r#e
-ffi$r------(
l l
L - - - - - - -
- - - - - - - - J
"oN"
It{otcAToR
depressed.
f--
Open with
brake pedal
34
i
;iil;------'l
onl|,
ATO9IT
l5a
- - - - l i - - - - J
8
WHT/GFN
c352
PHOTO 8
UNDER-HOOD
FUSE/RELAY
BOX
506 Po\rr
Dislrhulbn,
page l ot3.
*
=
'96-'97
models
*'
=
GX models
CABLE
REEL
,r:ill
ilifl'?H]"*,--*'
,rllI
g**.
---!
",
f,*,,-
":l
2
gu{
3
ItK
?
I
I
l r
I
Ss
llorns
I
I
I
I
Closed with
brak
pedal
.
deprcssed,
BRAKE
swtTcH
PHOTO 68
r - r - - - - - -
I
3l l '
|
\
o"n.t""t
I
L-
A ..ât ,,^"1,
\rnfig*,',,"1o,,
","*"
"+f--a=={
*-'*:'!
|s.triL!fl8;lp,*,;,, LT.FN,FEDI
--.'*""*-[
(s6
-'s7
moders i)J[
- -
(sl
g
-o9"95]I-( e6-e7 moders
lll
c430
- - - : - - l cRUl sE
f
Br?kp Sevdecel Resuma/
t Ctitrf-nlOr_
r^
swilch signal input acclsignal
i uNif
\ intut inp,n
-
|
p#ib
*
I
lvtEw
13
- - - - - J
CNU|sE
CONTNOL
SETngSUt E
swlTcH
1 CABLE
I REEL
I
J
STEERING
WHEEL
(cont'd)
Rlroma/
Accel
Sultch
34-1
Cruise Control (conrd)
""t===j
=
G401
Cruise control
actuator
qontol
4
BBT{
4
Se Ground Oistribution,
page
1+4.
BRt{lv}tT
3
RED/BLU
10
('96197 models 9)
'Cruige
control'
indlcator light codrol
wEw 56 Ss
po$/er
-r+ Distribution,
page 10-6.
CRUI6E I
c411
PHOTO 60
GAUGE
ASSEMBLY
\ t a
;lG;-
- - -
J,T"r"r,E;oAit r-usE z5
tusEi RELAY
IiF"
3g;g;; f,%,,
-------'
page.tG6. I
L: 4- - - : - - - J
See Dash
and Console
;I
CONTROL
rNrxcaTon
UGHT
t-ffiI
I
c0f 0r I
I
J
I
I
E3
BL|(
Se Ground Distribution,
pag61+7.
I
I
Gro{nd
('96198 models 8)
o
6nNAVST
""r1
I
1 1
ENN/ELX
aFt/Bu(
2
aLu
c202
PHOfO 23
VIEW 1
c203
PHOTO 18
CRUISE
CONTROL
ACTUATOR
\1
----*-
E2Y
34-2
l' G202
i
-
'99100
016Y7/D16Y8 with A"/T
-
Cruise
conrol
sgnal
i 8s) i
iil
POWERTRAIN
CONTROL
MODULE
(PcM)
*
=
'96-'98:
All models
'99100:
D16Y5 with M/T, 01685
- - - - - i - - - - - . l c R U | s E
| ;
Cruise control
'
I CONTROL
\
si gnal output
'
|oNi r
I
PHATO 55
I oisengage input vehicle speed input
'
vtEw 13
. - - - - - - - - ; - - - -
- - - J
See Vehicle
Sensor
rySS)
See Gfound
Digtribution,
page 14-5.
I
J
"{
,--r-s=-.
CLUTCH
swtTcH
Open with
clutch pedal
oepresseo.
A/T GEAR
POSITION
swtTcH
L- - - - -
ALU,ryVHT
3 x
ct30
Cferminals
11. 13)
PHATO E3
vlEw 52 See Grolnd
Dlslribution,
page 14-6.
I Y
l l
L__l
#
:
G401
lI:::1" I
I
output
I
VEHI CLE
SPEED
SENSOR
(vss)
O-a
34-3
Gruise Control
(cont'd)
-
How the Circuit Works
The cruise control system uses mechanical and
electrical devices to maintain the car' s sDeed at a
setting selected by the driver.
System Description
The cruise control unit receives command signals
from the crurse control main switch and the cruise
control SeVResume switch. With the ignition switch
in ON (ll) or START (lll), voltage is provided
to the
cruise control main switch through fuse 14. When
you push the switch to ON, power is provided to the
cruise control unit and the brake switch.
The cruise control unit receives information about
operating conditions from the brake switch, the
vehicle speed sensor (VSS), and the clutch switch
(manual transmission) or the A,/T gear position
switch
(automatic
transmission). The cruise control
unit then sends signals to the cruise control actuator
which regulates the throttle position to maintain the
selected speed. The conlrol unit compares the
actual speed of the car to the selected speed. The
control unit then uses the result of that comoarison
to open or close the throttle.
The brake switch releases the system's control of
the throttle at the instant you press
on the brake
pedal. The switch sends a signal to the control unit
by removing power from the normally closed brake
input (GRY wire), and
providing power at the
normally open brake input (GRN/vVHT wire). The
control unit responds by allowing the throttle to
close. The clutch switch or the A,/T gear position
switch sends a
"disengage"
signal to the control unit
that also allows the throttle to close.
The cruise control system will set and automatically
maintain any speed above 25 mph (40 km/h). To set
it, make sure the main switch is on and the switch
indicator is on. Then, after reaching the desired
speed, press the SET switch. This sends a
"set"
signal to the cruise control unit which, in turn,
controls the cruise control actuator to maintain the
set speed.
When you push the SET switch and the cruise
control system is on, the
"cruise
control" ON
indicator lights up.
34-4
(
You can cancel the cruise control system by
turning the main switch off . This removes power
to
the control unit and erases the set speed from
memory. lf the system is disengaged temporarily
by the brake switch, or clutch switch, and the car' s
speed is still above 25 mph,
press
the resume
switch: the car will automatically return to the
previously
set speed.
For gradual acceleration without pressing the
accelerator
pedal, push
the RESUME switch and
hold it there. This will send an
"acceleration"
signal
to the control unit. When you release the switch, the
system will be reprogrammed for the new speed. To
slow the car down. oush the SET switch in and hold
it there. This sends a
"deceleration"
signal to the
control unit, causing the car to coast. When the
desired speed is reached, release the SET switch.
This reprograms the system tor the new speed.
Refer to the Service Manual (Section 23, Electrical)
tor specific tests or troubleshooting procedures.
(
a
A/T Controls (All
'96-'98
Models except CW and GX)
r . (
r5A
see
power
I
--li$"i':,--i
L-.At-----
__*____..,,53-j "i __
8
Y 93^s_1-
8Y C352
'"'".u
I
iii'i"'
""'o"*
|
i#?1o.'
ll see
power ll wrr cnn
See Power
la---
oisirioution,
!
-t
6iri,iortion,
[--*
t"*tr*t1,'.':,:;i
. wHr GFN
l t
page 10-13.
, i
(wi th crurse 4) A
l"'rl(-1 BRAKE swrrcH
| \ l Cl osed.wi th
brake
Ir-I Il,?,|fll,"P'"""o
L*--J
c18l r 82
"ar-"t
I
I
See Vehicle
Speed Sensor
(vss)
ct 31
PHO|O 35
vtEw 59
r<
See
ABs'
UNDER"HOOD
FUSE/RELAY
BOX
I
I
I
BFN
9
BFN
o
""il
SERVI CE CHECK
CONNECTOR
See Ground
Distribution,
page 14-5.
I
YEL
c124
L__l
H:""".
:
G402
SHIFT
CONTROL
SOLENOID
VALVES
LOCK-UP
CONTROL
SOLENOID
VALVES
,. L
---- - - --.#ku"
::::: 'o
f
---------tty"c;11,,
l;-,f
l;?t?:if,
-:;tr *";.!,
*"
c10
, | Ds^'
I
Lvou,
(SKSV,
!
Battery input
Brake lwitch
I
service
nPUt
ehin
t
;;;;i- Vehrcte
Linear sotenoid Shift controt solnoid Lock-up conkol
iJ'[
'\
connector
speed
input valve conhol solenoid vatve controt
tliiJ"it \
uo t r ut t conrrol
t
:
(scs) (vss)
{Ls}) rLs )
{sHA' {SHB, (LCA) (LCB)
{S-U)
.
- - : - ' - - J
ct 28
39
GFN/ALK
\ (
@ @
i t
FusE 13
LJ::-i1":--.i
- - - 1
UNDET
| | ryql* !5ts?'n
|
) iL"'
li'r:,o,
r T I
LJ - - - - - - - - - J
--1
UNDER.DASH T
---1
UNDER-HOOD
i
l$5ffif{61 !F'[]:':'* itte*- l"l;?::*'
L- g- - - - - - - - Y- - - J
3
r-----
---------;r
".*
I
veuar-r<
|
,
t_____
_1ft9#;,,
"*
| ;-{
8pfitli*|
".'"'*
|
n"""
l ----l . rr^
Page
14
1
-Fliirn"r"a-rq)
1' i====f:a&l?f''inarsra-rzr
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w;?"*
! .._ _ .l .- " .l
*.*-
I
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-
lara-i--''
i I
@DP':,-rt
r=-
9,lo,l'
o.,., I *ol
- --t
PowER-
(rGPr) rrcP2l
I TRAIN
\
Countersllt
\
sod
\
sbneor
lJt
"":I ""1I BRNJELX
"r, | "'0 I
!-
-CIG; - - - - - - - -*-r- -
1 PowERTRAIN
t
sensor t"r'ii.
|
.c.gl,rfgL
I
gourd ground
I
F;-r,r;*
L- - - - - - - J i uor o ea
Mainshaft
spoed
sensor
inpd
Power input
# l v r r wz o
CONTROL
MODULE
(PCM)
PHOTO 86
(NM) (PG1)
{P62) {LG0
(LG2)
":[
;{
]1
::l
-X ;;
rfl
lfi*
*T'r+*
| | |
:T'-jru,,L#,
il
3.[iF;"
H
;,$5*"
I
n:'r:T'"'uo
l
#lt':.
See Grourd
Disttlbution,
page 14.
(cont'd)
BRN/
BLK
BFN/
BLK
39-1
A/T Controls (All
'96-'98
Models except CW and GX) (cont'o;
t (
E!@
- - - - . ! powERTRAt N
FT- - - - - - - . t uNDER_DASH
I
rp Fcr ;
coiir-noi-"
'
I I
ruse zs
i Fu5iiaer-av
I
l""'E,T*
n"ey i"l,"l'
!i[!!i* ! ]
rtr"
96;"g; !F,9"T"*
L-Eg-----st ____.tsg_.i;ffi',".""
L.E-Es:Jtr._.i
Dr o
l f
Di
Y
- - - : 4- r v' t w/ 0
Ll l - - - =: - - J
' ;[
"l
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|
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ffiffi:!*r** |
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-[T,"."""1
F*=t--^,1
ffi
ll I
cari'erxf
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I
'l
^'
I
T:l
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I I
cari,erxf
i;:::f::::F_-_-_-:f_-_-_;7
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_
RorrLE I
i i
i-::"rrri_:_;] (
i
n--TlIr:9;lIl,EM
a I i \
l - l $ . # N
i i 9 - l t ' , t .
' ; -i i l : , 811' *", !
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I
't"
! iLI-------L*J___-/ )
"",."',.1
I
N
'-*'r---::::::--^Fr-----
! !
L____.____+___{e,E-
tr*?,i. i
nl,,rl#t
\ (
(ferminals
D't 1
:
(sG2,
lD4 rNDr
I si,"#,
|
9round
!:;1",
i
".-l
I
L__l
o=--H
:
G401
c136
vtEw 2a
,il 'f,*u,*.
1
I
I
POWERTRAIN
CONTROL
MODULE (PCM)
*l
=
' 96
016Y8 engi nei Al l Coupes
'97
D16Y7 enoine: California
Coupe, Calitoinia Sedan LX
' 97
D16Y8 enorne: Al l Couoes.
Calrtornia Sed-an
' 98
model : Al l
*2
=
' 96
016Y8 enoi ne: Al l exceot
Coupes
' 97
D16Y7 enqrne: Al l exceol
Cal rf orni a Coupe and Cal i f df -
nia Sedan LX
' 97
D16Y8 enqt ne. A

exceot
Coupes and ealrfornra Sed;n
a
39-2
85
'[ru*,, 'l*u,*
wiz-"ln*"
-a
I
le
.il
c131
vtEW 59
----sgr
c410
vlEw 35
LT GFN
12
LT GFN
-----1
A/T GOrr
GAUGE ASSEMBLY
PHOTO 6/
vlEw 71
I
Posttlon
i
Indlcator
I
I
I
I
I
I
I
J
1 4
\
I
I
I
I
A
I
I
I
I
\
\
1
I
,
I
I
I
I
t
t
\
\
a )
Se A,/T
Gear
Position
Indicator
c4t 0
vlEvl 35
' 96
D16Y8 enqi ne: Al l Coupes
' 97
016Y7 engi ne: Cal i l orni a Coupe,
California Sedan LX
' 97
D16Yg engi ne: Al l Coupes,
California Sedan
' 98
model : Al l
' 96
D16Y8 enqrne: Al l exceot CouDes
' 97
D16Y7 en6t ne: Al l except Cal i i orni a
Coupe and Caftfornia Sedan LX
'97
Dl6Y8 enginei All except Coupes
and California Sedan
See A/T
Gear
Position
lndicator
*"r I
-
----s+----+="1--'-s
cFN/AlU ll
GRNryEL
ll vEwar
_- - - - F- - - - * - r
nr cenn
| | | POSITION
| ;
swlrcH
t I oTo78
I
see cruise control
I
{
GBN/RED N
' ---1;'
'--T-)tn
39-3
AIT Controls
('96-'98
CVT)
L-L----:-------J----L"egyJ*"'"'
!tr;:tl1tfl' i
*"?](
9;%,
8Y ge-q?
LJ-------,
;li,
!
*rr1-....^^
ss tuwer
*"to"n
!
if?'ror'
,r"r,o"n
- sse
power 14 y g4^1_q
--
I
I
o*"'clt.
*'"1,!.
tad;1di3]
t
-""
I HFr:{tv][[:F
I
*l """-tl-.
"*,
*-,-*l
t ;
^,.[
"-;;[
1#E;;;::";mi
.aa4
;;r;;",
:
----+
u,"i.,-uon,
i;;;;r.
i
{vBt) (sToP sw) (Gl)
flc1l
!
Battery input Brake switch lgnilion tgniuon
|
-^-,^^
'
inpui fipr,- i;;i;i
SeMce
input i;put iiput
t
|
#;if vehicle Engin Drive putley Dnven puttey
secondary
\-
I
cooneaor speed speed speeci sensor speed iens6r gsarshaft'speed
t
I
\ f a
I
input input input input input sn8or input
I
(scsJ
{vss}
(NE)
{ltm) INDN)
(vEL)
L _ _ _ _ - _ _
- _ _ _ _ _ _ J
".
I
*,ff
I
:l
[
"ili[_==___j
: : :
j
I
i:isi, fi, &ru"n
t$=:{:::==l
[:-,*';|i-.t[d
F'*,Y''"T:."".
H
Sig,il
H
F"ii${*
H
$':lry!}Hi"
3lT:T:gl ""lr *=f
__-*=!".*,
I
;$f
--l "ur
oFN' BLur
!i Ei ?20
I
-rJ-----i.:,-,----=,--^:lrRANsMtsstoN|
;;n' s' "
J i$f;:' Si$? $"'":Tiii:e{i.ii'i::^
Is
:*",:i !fi8}ltP.n*,
;-=:.=-
:
G402
I
sround
ground grouno
I
l,llir%lli
PHO, O 125
L___- ___
39-4
! ' cror
a I
I
coNrRoL
EcM EcM lllg?.Y.E
Relernce control data control
I H;,."
voftase output
ff.'nour a;i:;Y"*
- lug'L - - - - JS- - - - - J't3'- - - i
A25Y CgY C30Y
lL
I 1=,
-"'"'"1 ""1 "-l
rRANsM,ss,oN
,r,
,[
",
I
".
I
"oou".-o'"[3fl!
NnEF) O[,!A) OMB)
Beference ECM control ECM control
D..r.i.^
vollage data input data output
;;ii;
v
I
t
swrtch
\
CVT transmrssion conlrol solenoids
signal DTC
CVT grounds
j input output
lPcrr /pcl)
.t
HLC LS I iHLC LS+l {SC LS-)
tSC
LS-) (SH Ls-i ISH LS-l
ISOL
INH'
THBRK SWt {O' AG Hr {LGli {LGl) lPclr tpclj
:
{*n*
:".,1
:"::.1 i.lnu+
',sk,-[lr*:[l*':t'
*?:?'
"""",.0-fr;rt.o,1^,, *'ig"#"t I
""-t
cw
i
-"'
iiio lr.'t
l
lsel$tfis'! I !
izf-"{}Y
f,====i
iiu:'" !
I
ii,l;?:'
i
lt
r---L
4
9::1",-
(cont'd)
39-s
PH.PL START SHIFT
CONTFOL CLUTCH COITTROL
LINEAR CONTROL LINEAR
SOLENOID LINEAR SOLENOID
SOL:NOID
A/T Gontrols
('96-'98
CVT)
(conrd)
s f r
Dl 0
YEUALU
@
I J
-'u-.'-.i - - -
I
3X3'5"
L]Sffiflulilir:
lLlftT:l,',
"*,
3=:. fierminalslT-20)
*l
v 56
r+
r and
Lights
" , " I
;I
-JI!.
br
iee Dash
vtEw 56
I I
Ss Power
Disfibution,
page 10.6.
Se PGIV-FI,
page 23-12.
See Dash ar
Consol e Li gl
I FEo/ELK
l a z
I
MANIFOLD
ABSOLUTE
PRESSURE
(MAP}
il
'-
4
o
\ (
REO/ELK
-{
i["r.r,
RED/BLK
cl ' t 5
fferminals
8n4)
wEw 3a
#.1
!3"" r,
c' l 31
PHOfO 85
vtEw 59
1 l c410
vtEw 35
Se Ground
Distribution,
page 1+7.
ORN/BLK
Dl 1 D12
a
- - - - - 1
ENGI NE
I l-c_qllFgL
I
l8l,:',T* lffiff"
iF!&i:'
L_"S.f___ __y,' _j,ii!,J?"*
a
i
--r3 - -.
:F.
- - -.-o
,'i6i
I
rRANsMrssroN
I
TP MAP
i
iln'o, ;;;' iiaicato,
i[f[!!!
ftcM)
I
input input conkol
IVie-Jo:e'-
L - - - - - - - - - - - - - - J
39-6
ir=l*--:*"ii*lF.?}t?'
' - - - - - - J v t E wT a
\
.I
TRANSMISSION
I
pa*l
lcoNrRoL
a noutral Reverso
Driv inputs
iMODULE
I
noutral Revelse
lJriv inputi
I
MUuuLl
- l i l l l '
! tarp
pr)
(aTpF) (Arp D) (ar" s) {ArP
L)
:
Ploro^ t2'
;F"''^'*J
l *l*|
.l
i{*m ' vlEw 71
I
l l
, l
iatr=im*:l lJ l_L! !J
_____r|
AJT G6ar
trJnl_
) a
\ \ l s e e m
\ \ l -
caa,
\ \ I-
Position
\ I I
rrxrcaror
l l
t t
t l
I
. +- - - -
3- - { - - - - - r - - - -
" -T,[ i::I
"-1fi-*fiar+
-!d
I
FEO
BII(BLU
r 2A'
___
14, {
____134 _____Z_e______6i ____15" c_f J^ --oinir.-lf
i#fl''u cnNAVl{I ll GBN I GRN/REo ll
GBN/ORN
ll
GBN/BLU
lt
GFNT'EL
N rrtw.r,
{":
- t { -
8,
't'
I
POSTTTON
i
swrTcH
a PHO|O 78
r
- -
t-
-- - -
f
-- - - -
? =
-
:
- - -
f
- - - - --
r
- - - -
T
- -t
A,T GEaR
I
I
J
A/T Controls (All
GX and All
'99-'00
Models except CVI)
a
i-l-;;;
-rffi;----t
H*B'""i
!
l
r*-*
i
iflsln-
:eepower ii|iii
'
L_l____
_-i"utuiF#'i
8
Y 93-s_1
SY C3s2
:
""'".u
I
i,i?lol
*"'o"n
I
iffl,1of
ll
see eower
ll wxrcnl
-
see
power
:
@
c131
vlEw 59
See Ground
Distribulion,
page 14-5.
1
["*
t*,t*;,,
;ffi i-
iilnirir,
Distribution,
page 10-5.
, D 5
, ry8
SOr)
I Power source
BLI(
YEL
i l
10
WHT/BLU
821
(VBU)
Banery input
Service
check Vehicls Linear solnoid
conneclor speed nput
'
for solenoid valve
;
\
Lock-up control
solenoid valve
(
valve control
circuit
Shift lock
\
c'124
a
inpul input
{8KSW)
Brake switch
Input
Shilt control solenoid
valve control
:::l
",:::[""::
.
|
.ir:Til**'
' ' lizll:l,,'
i*
' " ; l ' - . - - - - . '
O rr<(
!!e"A65,
""il
SERVICE CHECK
CONNECTOR
c12A
LTGRN/
I
SH I FT
CONTROL
SOLENOI D
VALVES
LOCK.UP
CONTROL
SOLENOID
VALVES
L__l
+
:
G402
a
il*-
except GX
See Power
r?F.|
BRAKE SWTTCH
| \ |
Cl osed wi th brake
|
1-I
|
!;ja
oeo' """o
39-8
--1
UNDER.DASH TT---] UNDER.HOOD
ilryi'.
i t !,1f:,1:
FUSE 13
I FUSE/RELAY I ,'
FUSE 44
I
FUSE/RELAY
4a!c!!q : Box ! \rreu :
Box
I
J
ggr'"ti
R,ej.l?I::
liu-irou
Dislribution,
i h3: i l i *: : i i l "*
L. , g- - - - - - - - - J L
lFI'T
r -
Dr 6ys
- - r
I L____ _l
l ; l , zs; "
,
ensi nes
: a
f -------
---*l
l vi ; i i a-
i
g4urse
i ! .t
sPGtr'tn <.-!__J
,
CONTRC: _
'
LJ------===' --_-_-_-_-_=-_
_
rl..-
-'l
PGM.FI
I I
MA|N
-\
in:HY.
._I I
vtEw 1a
?
Prgyl / --. I FsesPGM-Fr . l $f$"
,
Unr i " ' - -
|
3
f - - - -
- - - - - 6-
',
pxoto
ss '
ar-x I vevglK
l!
; 5 y ' _ -
| z A
s Ac r o r
i
r--r
' 2
n-----
-----+F":%"
i
i ffi e! i -^l
soacround
-' ' -' "1ff?*t' ' "..' ' '
:
Lgg.i
' L=J"-,,.-t
8:ry#r
..-=t==-:
i "tf
i
-J:
[i]i*"""'nf
f===-=-a&l?$nasr+'rzr
i :l I
----Lffi=--r
;l
=-;tr
==
l'r';6=u''
I mA ,
E
puor o
ss Bl | | B9A
,.t-^-.Fl-.lT
-I$ir--,--r,u-*.i
lifffil;
!
, Cruseconuot
| -
: coNTRoL
I
,
sbnatinput
: .,-,*-_"
Power input
!
uooule
.
: -tpl:lyP$- -;
Marnshar
Power input
luooule
\:;;;-#--
;&c
r(PcM)
\
,pd sensd,
9ims9r
Grcund
1",f3tr7"*
i
irprt
input
f
otct {trM) PGr)
(PG4 rLGl'
(LG2)
, a = - - - - -
- - - - - _ - - - J
SBNS.'_ fffi-l
g$lh
I
fl:1T""'"'-'0,
I
f_i,;i,""'"
;ff$i"
lj
lf
lii!}"g'
|
'"'""
|
'f;r,"
See Ground
Oistribution,
page'14-2.
(cont'd)
I
t
, l
(.J
LI
" )
Dt 0
EIU
"":T ;I ABNSLK
;;;t ";;t
!-
iG;f
- - - - - - - -0il"": -
1 PoWERTRATN
i
;nri: fun
lfratlte.-
L------- J
puoro
aa
Ground
BAN/
ELK
BFN/
BLK
39-9
A/T Controls
('98
GX and All
'99-'00
Models except CW)
(cont'd)
(
\ l a
t
\
\
\
I
t
I
\
I
I
t
I
t
\
POWERTRAIN
!
t*,*"
ffi,v
i"lll
i[?Hl,1P.
L _gA _ _ _ _ _g'L _ _ _ _
yy
_
j
ii?i%'"
*:ll--
",."
-1
"-TX
YEL
.[-Qhuit"I
miftu.*
.Li--,1
""":l
iii
F=lm+';I
ii
,r-;.'_
I tiJ
.l______
i 1",,'"'."."-*{
TfleolTla's8.14)
I
"""'"'.
f
""r.:
I
",,1 ;il
UNDER-DASH
FUSE/RELAY
BOX
iT-*-.'-;---l
LJ5Effi$iJ
lL[9*?:{.
csoT
See Power
Distribution,
page 10-6.
===a
oerm|nars
17-20)
lJ'lll"-+
See Dash and Console Lights
l * ' r
L__l
+
:
G40t
See Ground
Distribution,
clge 14-7.
J:I
I
c410
vlEW 35
c136
vtEw 20
r--,"";----
-----^-_=--r
powERTRAtN
I s"""iy n' i' ^- lcoNTRoL
i
;a; iiii"rto,
i
MoDULE (PcM)
L-------
----:Slgrol- -j
ur-iic,
See
PGM-FI
39-10
POWERTRAIN
CONTROL
MODULE
(PCM)
t 1
fo 85
' 59
36 GX)
r
fo 142
' 20
=
lrale-Female
)rminals are also
)versed on GX
-I
POWET
I Parrv I
c-oNrF
i l"=9"' l?v.9rse
gll[gR'Y'
L-g-g-- Jg:l----i'11---iltP. ---:y!iii:;?""
::: I ::I ::I :1I :]:I
.-*1,*,.
",il**'*,
";l-i$;'r,,,. ,"*,f
r,h,h.
r::lnfft
:l*r*;'"1
l#+u"1
g_
'"
9?,o;1"",
.r n"n
I
u' t""
caucEAssE
nro I
PI
See
A/T Gear
Position
lndicator
* , , I
-l
See A,/T
Gear
Position
l ndi cator
,nrt
I
-
See !y'T
C*ar
hsition
Indicator
A/T Goar
Position
Indicaior
c410
V|EW35
WHT
o
1 3
GBN
12
GFNAVHI
.!
AiT GEAR
POSTTION
SWITCH
See Cruise Control
39-11
A/T Controls
('99-'00
CVT)
\ r l
i'TG;.----1313'5'.
i m- i [ [ r :
| |
Pase
1G5
l
LJ- - - - - - - J
*"''n*
tr' F&i'?;,,,,n^,
oF---+
**lI
UNDER-
HOOD
FUSE/
RELAY
BOX
S9 Power
Oistribution,
page
1G1 1.
Se Powt
Oistribulion,
page
1G13.
13 Y C421
aza4,
PHOTO 63
vlEw 5a
aLu
Se Power
Dislribution,
pag t$s,
10 v cl 31
PHOTO A5
vtEw 59
!'-*l---------A-*i-
---6''A)--
I
Bsttry input Brake switch
powr
sourc
|
.*l "i:1,""""'[ TI
;l
IJT."'(!) rlr iil
\ r a
I
.^-,1-
'
inpr.,t for sotenoid
t
r U3|'.A
I d;.i- vshicle Drive
puttev
Driven Dultev Scondaw
vatue
\
I
connector slcd speed senior speed iens6r gearshaft
-speed
t
I
inpg! inp{ input input snsor input
,
LJTS---Sl ----g?:t--__..i t:t' __-__5' r___
_______J'
!:.:s
iil
Lti-(+'-l
,*[,*"-
*"=titt-""'[T*"
[
3
-[d
&Ier,"","
CONNECTOR I''IF'I DFIVE F'FI DRIVEN F'
'iY"'i*,*
H#**HFIl*,:"-HFtrFiflf
|
"-{jf*,
I
Distribution, l-Jr
I
oao"te' s ' f ' f, ' f,
! !iireso:",
r
D12 A D16 A 07 |' ll anN,r
J
ig"*p
---s:m;---st'"",1[A{ffiil..
@
i#hff'
s:ir"{ fi{t!fi?}.u8il;,
;-=:.='
=
G402
PHor o 125
L_______ _______j r ' t *r o + 9L0- ]
39-12
3 ct or
?uTi'i'------l
UNDER.OASH
FUSE/RELAY
BOX
UNDER-HOOD
FUSE/RELAY
BOX
fI,! PtfiP
f#rntt)
See Power
Distribution,
iT;;*-l
rr:_i
y;lftr,.:{'
page 10-2.
t J- - - - - - - - - J
"
Y 3,,t"?:""
"""T
[']':.
i-?;;ffi;
i_f___
PGM-FI
MAIN
RELAY
;;II
;;;I
c't0'l
vtEw 28
TI
":{
c130
Oermi nal s
l 4-17)
vlEw 52
I
.
(rGP1)
i
1rGP2)
-
I
Power input
..
See
PGM,FI
POWER.
TRAIN
CONTROL
MODULE
(PcM)
PHO|O 86
(cont'd)
\ !
\
CW hansm|ssion_ control solonoids
Ground
I
t ( HLC LS- )
THLCLS+)
( SCLS- ) ( SCLS' I
i SH
LS I r SHLS+j
I SOLI NHI
l PGr )
( PO2) ( LG1) r LG2r
I
L - - - - - - - i : - - - - - - - - - - - - - J
-T1
Tj
:1
;
lruffil
GRN
BLII
c l 16
(Terminals
8-14)
vlEW 39
BLK
CVT
TRANS.
MISSION
SOLENOID
See Ground
Distribution,
page 14-2.
BRN/BLK
PH.PL START SHtF'
CONTROL CLUTCH CONTNOL
UNAR CONTNOL LINEAR
SOLENOID UI{EAR SOLENOID
soLEltotD
:_-:_-___1
-t
1- !
|
Ti11:a__J
BRN/
BLK
39-13
A/T Controls
('99-'00
CVT) (cont'd)
\)a
Y,
!@
Sa POM-FI,
page
t4-
YEUBU,I
THROTTLE
POStTtON
FP)
SENSOR
\ \
l t
t l
t t
t t
A9
I
I
I
I
L
A8
1
S GrdJrd
Disthutlon,
pagg 14-7.
c410
vtEw s5
c13 t
PHO|O A5
vtEw 59
AL
-'r PowERTRAtN
'
I
coNrBoL
-. I
MODULE (PCM)
:, I
PHO|O 86
|
|
vtEw 70
H$,{srt | ffiffir*Hl
.rud":[4:l
-
;i ",,1 ",[.,,[ ;['
i
- -*j;- -F- - -:m;
lmr
- - -
;'ril)-
I
ground snsor ground
sansof indicator
I
inp.,t input contml
L - - - - - -
I
E
F
t,
10
Y
c50t
"..1if?!o..6.o,
i-=1ffifiI"'""'3**",
I
--+;;ai *r
YELI
33:$:?AX'."
^,I xI
-HI-
I F- J- - - L- - - J- - - ,
f
i r r I
i i I
Dtmmhg chcutr
I I t
i i . - - - - - r - - . , 1 ,
t l
i i 6- l \
39-14
A9
LT GFr'l
12
LT GFN
A14
c410
vtEw 35
c131
PHATA E5
vtEw 59
D't 3
tT GRN/FED
1 5
GRN
See A./T
Gear
Position
lndicator
"""L
c131
vtEw 59
WHT
GAUGE
ASSEMBLY
PHO|O 67
vtEw 71
See Afr
Gear
Position
Indicator
wxr I
-
See
Art Gear
Position
Indi cator
" ' , , I
-l
I
l t
, l
t l
t t
\ \
\
I
I
t
,
,I
I
I
I
t
\
AII Gsar
Poclllon
kldlcrtor
a
S A/T
Gear
Position
Indicator
I i
fsn$t';
!d
c410
vtEw 35
c433
A/T GEAR
POStTtON
SWITCH
c433
BLK See Gaound
a-< Disaibdion,
|
*o"
to-t
"' *l
Y
t ________l
'---
-gcji-
PHOIO 125
--*
BLK
1
6LK
39- 15
Horn
-
'96-'97
Models
UNDER.
HOOD
FUSE/
RELAY
BOX
c353
PHOTOs
See Power
Oistribution,
pag610-13.
""^T.!,-
HORN
RELAY
PHA|O 58
c214
vtEw21
BLU/FEO
1
VHT/qRN
I
1
WHT/qRN
:
: i -I : : : --l
i
i
! !'-'! fevtess
!
a;fi."*
, , l r - - J
I
: : . - - - - - - - J
. , STEREO RAOIO TUNER
| | vtEw 68
HORN
l
h
:
c4o1
PHQ|A 57
c430
Sse Cruise
Control
Vehi cl es pre-wi red
---
lor accessory
security system
BLU
GBY
- - - - - - - J
- -. !
STEERI NG
WHEEL
6
g
c411
| _vtEw
60
a ,
- - - l i
cnv I
18 A C516
sEcuRtw
SYSTEM
CONNECTOR
(oPTroN)
PHO|O 73
VEW 5A
40
-
'98
Model
FUSE 52
floFft,
sroP tT
154
UNDER.
HOOD
FUSE/
RELAY
BOX
THI
I
I
I
c353
I Y C3s2
""',o"n
I
il?lo,'
wHT/cFN U
@.
So Powsl
Disfibdion,
page
1013.
HORN
RELAY
o
GFY
87
: l
; l
: l
' l
!'Gi-'!
c.oMBrNAroN
I UIio | !!9f1I
i
swrrcH
GBY
2
ELU
I
I
I
i q!ffi "
a *
: t
40-1
L- - - - - - -
Horn
-
'99-'00
Models
FUSE 52
HORI,
SfOP LT
t5a
UNDER.
HOOD
FUSE/
RELAY
BOX
HORN
RELAY
2
BIU/FED
I
o r
GRY
.,1 ,
J - - - a - - - - - r - - - O
i
;l i
;,1...,
'
r--1
: SECUR| TY
: l l : s Y s r E M
, i a , c o N N E c r o R
'
! !
(oPrl oN)
, L--J
,
i!,o!o 73
,
KEYLESS
I
vlEw 58
:
DooR LocK with
i coNTRoL Kevless
,
UNIT Entry
I PHOIO 134
I
vtEw 75
i
o. - - - - - - - - ;
: T :
'
cnvl
:
i " l
i
i ri-'--.|
coMBtNATtoN
:
lrft ! !',f,11"
I
'
| |
puot ozz
:
',
l--J vttw u
;
i - - - Er " " pt ex . ooer - - - - j
c214
v|EW21
c430
PHOTO 65
Vehicles pre-wired for
accessory security system
STEERING
WHEEL
CABLE
REEL
.l
I
I
I
I
See Cruise
Control
GRY
ELU
I
a \
I
GRY
HORN
---------^1
niffil" a!m"
40-2
Anti-Lock Brake System
(ABS)
UNDER.HOOD
H'.'""
ii[*:'*"
1
GFN
c357
PHOTO 4
c359
PHO|O 6
10
BEO
Grqlnd 2
{GX!2)
l"l
Fi* :l :l
! Ji I -J
.-L-----
i il
T
PHOIO 125
44
UNDER-HOOD
ABS FUSE/
RELAY BOX
r------1
c356
FUSE 63
MTN
CHECK
7.54
c357 2
FUSE 61
PUIiP
olon
c356
ABS
PUMP
MOTOR
i-.t_____l
*fitr
3
YEURED
A19
(PMR) (MCK)
I
Pump Motor I
comm6n motdr check
I
Right rear ABS LeftftontABS
;i; !
\
solenoid control solenoid controt
loni of
!
\ ^ l
i
Service.check DLC
I
/
connector input inpuvoltput
i
&- - - - - -
- - - _____J
11.I
A14
r
aBs coNrRor_lrNr
BRN
I
rr eru
I LT BLU
vttt 63
t r r t
s RS. ATc ont r ol s
t - ! v c c v nv
1
"Tl
' Tl ' :
c360
SERVICE DATA LINK
CHECK CONNECTOR
CONNECTOR (DLC)
PHoIo 83
See GrOUnd
pHOrO
so
Pll'lo.,jpn.
p y:l:!:1
*L_T'=Llj:t
See Ground
'--=-Ea; *---==4oi
Right
Rear
ABS
Solenold
(Out)
night
Reer
ABS
Soloroid
(ln)
Lett
Front
ABS
Solenoid
(od)
PHA|A 125 PHOfO,/
44-1
Anti-Lock Brake System
(ABS) (cont'd)
(
FUSE 16
iA DEF
lEtsY See Power
:ar Distribution,
page 10-8.
c421 10
vlEW 50
' 96-
97
Dl
mooel s
.I
UNDER-
page 1G6.
I
pHoro
5d
c501
vlEW 55
page 1S6.
AAS INDICATOR
LIG}IT
!'-r;us?;---l H5BE"
ilrryilrfi#ftilHri
L- g- - - - - - J L- g- - - - - - J
'tr
F,1%'
wHr/GRN
I
v/El.V 2Z
I t"r,o""
se Power
YEL
D5
GAUGE
ASSEMBLY
usA
Carsda
I
(
D3
',
\
',i:,tr?"""
!
P"g"
t+-z
".r',
*
! see cround Distributiofl,
"..,
I i"., I
".-l
I
;nl
i ffi t
L------J
'
n
:
G401
m I
i o t
T1*l
^*ry*l:-------l
8Bi"o.
'
used) ;
4t s5l nol cal or
i UH| T
r - - - - j . l i ght conl r ol
r .
i i ci b et
t,"LTfflo",
Input
1lo2)
lgnition 2
Speed sensor anputs
vlEw 63
(
{FLo) {FL1)
(FBo)
{FF1)
(Rr"o)
Sg____gT]-__g,l-j
Bl o
l f
B23Y B8Y B21l f B6Y Bl sY B4X B17f
i i
I i
o""l .,",-ul u.,"..1 o"",'..
I
r r t t l
| |
| I , l , l . I of " on"
ll ll
I ti
't---'+----"[
--f
!'?'%,'
""n*",lo"no""l *"1 *"*-l
*"1 .'"."1 *,*.[ "**.I
I r
L___t"" " t__t"." 1___!".""
"r.f_ "4::3' ;FJ,;::; ":f3:::1'' "lf-*i":''
t'
,.,Jtri"?r.
ll;l]flffi lFli.ft. lU]flqtfl
l l"#tgl I lt5T8?l I lt"F"Ti?l I lt;Tt?f
O--t Distribution,
'n"r,o^n
I
Page
10-13'
.tr
r -N-
.I
BRAKE
| \ |
swrrcH
igr:*
o"ntr"r
!
a'KBLU
It
""*[:-l
ftff^"n"o''''ot
I
", I
m;r""#,usi:",
".1
44-2
-
The anti-lock brake system (ABS) prevents locking
of the wheels as a result of heavy braking and/or
poor lraction. A vehicle with locked wheels cannot
be steered. The anti-lock brake system controls the
application of the brakes, allowing the driver to
maintain control of the steering.
Under anti-lock conditions, the antilock brake
system (ABS) modulates the pressure of the brake
tluid to each brake caliper. This system is a four
channel system: the pressure at each caliper is
controlled independently of the pressure al any
other caliper. Whenever a wheel is likely to lock
dunng braking, the anti-lock brake system
modulates the brake oressure at that wheel. When
the brake
pressure is reduced to the
point where
there is no longer any
possibility
of wheel locking,
the system returns to the conventional braking
system mode of operation.
Battery voltage is applied at all times through fuse
63 to the ABS control unit. When the ignition switch
is in ON (ll), battery voltage is supplied to the
control unit through fuse 16. The control unit is case
grounded. Inputs are received from the brake switch
and the individual wheel sensors located at each
wheel. The ABS control unit uses these inputs to
control the modulator solenoid unit. The solenoids
adjust the hydraulic
pressure applied to each
calioer.
The ABS control unit has a self-diagnosis function.
When the control unit detects a fault, it turns on the
"ABS"
indicator and disables the anti-lock brake
system. lf the fault is not in the conventional braking
system, the brakes will continue to operate normally
but without the anti-lock feature.
Refer to the Service Manual (Section
' 19,
Anti-Lock Brake System) for specific tests or
troubleshooting
procedures.
44-3
Supplemental Restraint System
(SRS)
(
FUSE 13
FUELPUUP
FBA
UMT)
15A
See Power
Distibution,
page 10-2.
FUSE 23
(sRs)
c801
PHOTO 58
SRS MEMORY ERASE
STGNAL
(MES)
CONNECTOR
PHO|O 111
.
To avoid accidental deployment and possible
iniury always disconnect the driver' s airbag and
f ront passenger' s
airbag connectors (automatically
shorted) before working near any SRS wiring.
.
CAUTION: Whenever the ignition switch is ON (tt),
or has been turned OFF for less than three minutes,
be caretul not to bump the SRS unit; the airbags
could accidentally deploy and cause damage or
iniuries.
UNDER-DASH
FUSE/RELAY
BOX
GFY
07)
or GFN
{ 18)
GFN
GFY
t2l
GFN
GRY
0)
GFN
2
ALK
J
(ii
t \
GFY
O4)
or GRN
SRS
UNIT
a
-ffiffi,*l-{
H!=";=_J
iffii'r:fi:*" i
t
H-
PHOIO 125
short contact)
|
-
FCqOt
L_________J
PHO| A 57
47
GAY ( 21) or GRN
lgnition
Input
(VA)
Driver's
cont.ol
lgnition
input
(VB)
MES connector input
SRS indicator
lighl control
Se r v i c e
t - - - - - -
check
:
Passengefs
;
connector
;
airbag control , Ground
Inpu
,
/+rr I
pir-r
Passenger's
ai|bag conlrol
;
prc..
t rnpuv
,
Ourpul
14
GRY
(5) or
GFN
rffi{{_ilil
i
ffi i""'"1*"o,"'.1''
i
lffil
ffirtu!-T:l
ir:r*::"."
i l stEl ' {s6.e8'
' "' Jl "Tl
,
I
oATA L|NK SERVTCE
:
CoNNECTOR (DLC) CHECK
,J
pi arasa
CONNECTOR
vtEw48
UNDER.DASH
FUSE/RELAY
BOX
PHO|O 5E
FUSE 25
IIEIEB
754
S88 Fowor
I
J L-L-iri:---
"l*no
rur"'""".,
c412
c41t
PHOTO @
VIEW N
GAUGE
ASSEMBLY
PHOfO 67
I
J
I
I
I
I
I
I
i
Btr.BR""Xi
I I
l l
L__l
=
G4ol
PHOfO 57
47-1
Blower Controls
'96-'98
Models
@
UNDER.
HOOD
FUSE/
RELAY
BOX
UNDER.DASH
FUSE/RELAY
BOX
PHOTO 5A
BLOWEF
noToR
BELAY
PEOfO I
HEATER FAN
SWITCH
6
calr
See
L/c
Compressor
Controls
(
See Ground
Dbtribution,
oaqg 14-5.
See Gror
Dbtributi
page 14.
I
I
_l
ar<
L
-
c402
BLU/
YEL
1 l
BLU/
1
BLK
BLK
BLK
60
- '99-'00
Models
i-F;;t
L-t'::-i
"d[ft?"l'
UNDER.HOOD
FUSE/RELAY
BOX
UNDER-
DASH
FUSE/
RELAY
BOX
PHOTO 58
iGi'i'-----'l
BEATEA
,'/C RE|AY
7.5A
".*1.[F*ft"
See Power
Dist.ibution,
FUSE 55
HEAIER
t/toToR
page 10"9.
L- * - - - - : : - - J
BLU
n
$
Se Powsr
Dl8tdbution,
pago 1O11.
ge
Powsr
Dlslribution,
pag lGg,
ALOWEF
moToR
REIAY
PHOTO I
l 1
BIU
BLIV
YEI
813
OFN/
WHT
BLK
2
BIK
G402 G402
"l
Si:lf:::'
>-1
-".. i c.u, I
--' ;-l P;!o;i :
I
- - - - - - - - - J
l ,f
3ffJ?il3'o'"o'o*'on
L __ f_---_-_ :::::: - --- r-- -- J
-f-***;
;Iru
I
' r
r
l-'n
BLowER
---: -----. l
I A l m-o-roC'
------------a---
E
eaoz
-
I (
M
r l Pr or aE3
PHoro 12s
I Y I
=----GG-a -
vtEvl 57
c440
Se Ground
".","i-l'
E a
JI
6
BLOWER
MOTOR
TIIGH
RELAY
PHO|O 83
UNDER.
HOOO
FUSE/
RELAY
BOX
t
!.-
1 HEATER I"-'FI POWER
t
Battory lgnition Blower
I CONTROL I | | rAlHStStOn
i
(brckup) input molor
i
pAHel
I I I
pHoro
13e
I
,,o*",
_ ffJtt'
t
PHoro tr7 | tt I
i
motor Power
' 'Jback
I
wr'vzo
I ;_\ |
!
high relay transislor
Ls::s1gl-tt:---J
lJ J I
A6
alK
See Ground
Oistribution,
page
'14-5.
z a
60-1
Air Delivery
- '96-'98
Models
SgE Porvst
DistrtbLditr,
pags I S9.
9
Y
C420
BLx,yEL
ELK/'(EL
I
PHora363
I t
FUSE 17
I
: \ HAITN :
! f
I9"",'
see Powsr !
i f
otsaibution,
i
LJ----':g':'--.i
UNOER-DASH
FUSEiRELAY
BOX
PHOTA 58
a
er.x,ter-
[
".*..
";:.it#?.9.,,
See Dash and
Console Ughts
RECIRCULATION
CONTROL
MOTOR
PHO|O A2
\
r
I
I
I
I
S6 IVC
Comprsssof Controls
a
c723
PHOTO 138
vtEw 57 GBN/IVHT
12
GBN/NED
1 3
61
\ ' a
I
MODE
CONTROL
MOTOR
;T
___"rt
1[
___l:il
,rlK
YEUBEO
_:o_
YEUBED
8
t
HEATER
CONTROL
PANEL
I
I
I
t
\
.l \rt
lleat
Swltch
c723
138
it
Venl
Swltch
\
I
I
I
I
c723
S9e Ground
Distribution,
page 14-5. h
-_l
G402
:",;[----
1
61- 1
Air Delivery
- '99-'00
Models
a
r--T----.I UNDER-HOOD UNDEB-DASH
| ,ry:i.l? IFUSE/RELAY I t::u:E^tt l:usE/RELAy
i
- -{-;;; -
I PJ,'.',8.J390 i
-
T;;
;
- - - - -
I H$3,',8
i 1;:t"* ];FPJ", i i
m'.u" sepower
i
"t8L,,
i t i a l'"0
r3l",lli"i:"
a
L--{..-----J L-J..----5::---:-J
"",":"rfi?ll,
'[r;T:1"
-",*"1-J
*-*..l
,n", ".u I lt I
l r !
I See Power I See Power Distnbution.
I
Distribution,
U
page 1o-9.
,, L::':l-------
*Y=l
"*o "."",,t
[
*,:.'.Y%
I r el -
l t
:'l-4riffi
MODE
CONTROL
MOTOR
;L:L{;I{,tt't{ {f
Sensor
Ground
grgund
venl
Air mix
5Y poientia,
reTgrano9 rnrrul
gIouno
Recirc
Swilcfi switch
common mput
Recirc S$,itch
tED LED
control common
RECIRCULATION
CONTROL
MOTOR
PHOTO 139
CONTROL
PANEL
vtEw 76
So Roar
I
I Windolv :
a
Htr Ttr =tr ;l *tr :tr *,tr T Htr Ttr =tr ;l *tr :tr *tr Ttr
'il
Ti
Battery lgnition Mod Mode Mode L4ode Mode l\tod
(back up) input detrost hav heat heav vent motor
Rcirculato Fresh
I
J
Delogger
L - - - - - - - - - - J
HEATER
PUSH
swtTcHEs
delrost
Air Air
mix mix
cool hot
;;-; J'J - - - J-JL i- 5:- - -
SLK
812
AFN
13
BFN
See Ground
Distribution,
page 14-5.
c4 t, cl
WHT I ONN
ft++il
c723
F ash/
Roclre
Swftch
Reclrc.
oat LEo
I Y
t t
L__l
--tGo3,
See Rear
Window
Oetogger
AIR MIXTURE
CONTROL
MOTOR
(
c9 Y cl 1
61-2
-
'96198
Models
The air delivery system directs the flow of air used
by the heater and air conditioner systems.
Mode Selection
Mode selection is controlled by the mode switches
in the heater control panel and the mode control
motor. When you select a specific mode, voltage is
applied through the dimming circuit to the LED,
which comes on, indicating the mode selected.
Ground is orovided to the mode control motor
though that mode switch. The motor then runs until
the air control door reaches the proper position.
Fresh/Recirculation 56lection
When
you press the fresh or recirculation button, a
ground signal is sent from the heater control
panel
to the recirculation control motor. The motor then
runs until the recirculation door reaches the
proper
position. Battery voltage is also applied through the
dimming circuit to the corresponding LED, and the
LED comes on.
Refer to the Service Manual (Section 21, Heater) for
specitic tests or troubleshooting
procdures.
'99J00
Models
The heater control
panel receives battery voltage at
all times through fuse 47. With the ignition switch in
ON (ll), voltage is supplied to the heater control
panel through fuse 17. The control
panel is
grounded at G402.
The heater control
panel
controls the air delivery
motors, and supplies a 5 VDC reterence voltage to
the air mixture control motor.
The air mixture and mode control motors each
receive inputs trom the heater control
panel. The air
mix motor regulates the mixture of cold and hot air
by varying the
position of the heater-evaporator doot
The mode control motor controls the direction and
volume of outlet air. The air flow can be directed to
the dashboard vents or the corner vents.
Both the air mixture control molor and mode control
motor are
grounded by the haler control
panel.
The recirculation control motor receives battery
voltage through fuso 17 when the ignition swilch is
in ON (ll). lt regulates the position of the fresh/recirc
door, and is controlled by two position inputs from
the heater control
panel ("Recirc" and
"Fresh").
Refer to the Service Manual (Section 21, Heater) tor
specific tests or troubleshooting
procedures.
61- 3
A/C Compressor Controls
-
Al l Model s
cc5)
M7
BLU/RED
?
\ a
@
&c
COMPRESSOR
CLUTCH
RELAY
PHOfO 10
a
! ,acc, :
POWERTRATN
!
arn.^-^,o..^, I or ENGINE
!
ii i"i-iiii"v i.,ii.r |
fi 3$18.
I
A/C request
!
(pCM or ECM)
I (ACSJ a pHOrO
a6
L- - - - - - J vt Ew 70
REO
BEO
1
RED
BLU/FEO
2
BLU/FEO
ct 31
: " 1' ! i ' - - - - - - ;
Fi :rz,
a
=' e6-' s8:
A|| moders except D1685
vtEw 21
'99100:
D16Y5 with l\illT
' *
=
96-' 98: Al l model s
ir'iio ,"
99. 00: Dt6y5 wth t\4/t Dl6Bb
atc
PRESSURE
swtTcH
c752
c1
".,n""t 1(
".r-".rf,
"tA% "
"."-:,fi tfr,]4.
v
To facing page ('96''98 models)
or page 62' 2 ( 99-' 00 model s).
- Y l
- t - - - - - - - - - J
c353
c2'14
vtEW21
c209
A,/C
COMPRESSOR
CLUTCH
COMPRESSOR
THERMAL
PROTECTOR
UNDER-HOOD
FUSE/RELAY
BOX
f-T-*-'.T'---l H53.',EPA?' i-l-------
i iflH* !F,?r",, i f6F"'.i:.",",
| tsBi":J;"#il ! a T
| | oaoe 1o-9. ! I I
See Power
L_J1_j :_-_j ! H
Di stri buri on.
e
Y
c42o
i
I
pase 1o-1.
***
f
ifi"l'
^ see
power
! |
62
!
(on bracket)
- '96-'98
Models
From C214 on
facing page.
v
"**il'ifr"e;
Se Fwvof
Distrih$on,
pags
10'11.
UNDER.
HOOD
FUSE/
RELAY
BOX
HEATER
co TROL
PANEL
- - - - 1
Di mmi no
I
Clrcult
-
L- - - - - - J
See Ait
Delivery
'l
ctte
l r c
I
I
I
I
1 0
HEATER
FAN
swtTcH
INDICATOR
62-1
AiC Compressor Gontrols (cont'd)
- '99-'00
Models
From page 62.
v
I
*"-ilii.,"r,
ihtli
4
BLUAVHT
1 5
6LUAVHT
UNDER.HOOD
FUSE/RELAY
BOX
Seg Pow6r
Distrlbutiofl,
pag
'l
Gl1-
c353
PHO|O 8
l[,,*
';.!,
"'""
,c,/c
Switch switch
common itput
a,/c
THERMOSTAT
Olt below
3" C ( 37" F) .
THERMISTOR
(
B11A A8A B' I O | '
r - - : =- - -
I
A/C lgnition Bttery
I
I
request input (backup)
:
".j:[ru*,,ry "..;X
{;[
vtEW 57
HEATER
CONTROL
PANEL
l'lC
switch Switch
LgD IED
codrol cormon Grouod
See Air
Dlivery,
Rgar
Window
Dfoggar
BIK
cl
ORN
c5
GBN
r,/c
Ot'l
lndicatof
HEATER
PUSH
swrTcHEs
t/c
Swltch
Se Air
Delivefy,
Rear
Window
Dslogg6f
See Ground
Dist.ibdion,
page 1,1-5.
Y
I
(
=ffi;
(
.I
UNDER.
I
HOOD
i FUSE/
I
RELAY
I Box
I
J
62-2
PHOfO 125
-
Battery voltage is supplied through tuse 56 to the
A,/C compressor clutch rlay contacts at all times.
With the ignition switch in ON (ll), vollage is applied
to the coil of the A,/C compressor clutch relay
through fuse 17. When you push the A,/C switch
ON, and the heater fan switch is in position |
,
2, 3,
or 4, a
"ground"
input is provided to the engine
control module (ECM) or
powertrain
control module
(PCM) through the l'lC thermostat and the l'lC
pressure
switch.
The A,/C compressor clutch relay is grounded by the
engine control module (ECM) or
powertrain
control
module (PCM). When energized, the A' lC
compressor clutch relay allows battery voltage to
turn on the A,/C comDressor clutch.
The A,/C ON indicator light comes on when the A,/C
system is requested.
A,/C Thermostat
The A'lC thermostat is located on the evaoorator
housing. The A,/C thermostat turns off the A,/C
compressor clutch if the temperature at the
evaporator
goes
below 3' C (37' F). This prevents
condensation from freezing on the evaporator fins
and blocking the air delivery into the passenger
compartment. The blower motor will keep running
when the sensor turns off the comDressor.
A,/C Pressure Switch
The fuC oressure switch is located in the condenser
outlet line where refrigerant is in a high
temperature/high
pressure liquid state. The switch
will sense abnormally high or low pressure, and
open the circuit. This removes ground,
and the
compressor will stop running.
Thermal Protectot
The thermal
protector, located on the A,/C
compressor, opens and turns the compressor off if it
senses high temperature. Once the compressor
cools, the switch will close and the compressor will
begin running again.
Refer to the Service Manual (Section 22,
Air Conditioning) for specific tests or
troubleshooting procedures.
62-3
Fans
-
Al l Model s
\ , 1 |
spl i ced
together
instead of in
the
junction
connector on
Dl6Y5 models
c211
PHOTO 11
FAN
RELAY
Prtofo 10
Se I'i C
Compresor
Cont ols
1
ALKAED
\ r a
c352
f
BLKaEo
u
Y 9,;%,.
cFN
I
vIEw 5e
;
"'
T
"; : : -: . . "-!
Y:.
---::Y
h!ii'in","
:
I :
""'I 'is.2o)
:
I i,o''ur,ff;,
l;l:'l?'*
i
I
r- - -,
| JBEI
:
I
;
I
control
|
;
I : L - - J :
I ' PoWERTRAIN or
du.
'
ENGI NE CONTROL '
'
MODULE
:
( PCMoTECM)
:
I
PHAfO 86
I
wEw 7a
l l q A
- - - - .
ENGINE
COOLANT
TEMPERATURE
swtrcH
BLL
PHO|O 33 ?
Ses Grolnd
Diskibution,
oaqe 14.
,I
H
:I
i:
"'*
1
_l
c753 1
BLU/BLK
ALK
2
BLK
RADIATOR
FAN
MOTOR
I
BLK
BLK
1
ELK
c753
CONDENSER
FAN
MOTOR
a
* czsr
page 14.
I
I
FJ
' G l o t
c211
Gro!nd
T
Se Ground
Ostribution,
Pago
14.4"
t1
-
' 96.f98:
Al l model s
'99-'00:
016Y5 with M/I 01685
"2
=
'99-'00:
Allmodels except
D16Y5 wi th M/T and 01685
cof{oENsR
*
czor 33
123lCVIl
63
- '96-'98
Models
Fromunder,hood
i-T
ig;Eili--l
UiB!'*
il-;;.;l
Fuse/Relay Box on
rac,nspaee
| 1"1
seepower
i $f" I i
tS^*
!
V
L-I----q,ryli"--Jr'i
L8ry-s:d-J
|
9
X ,cgr,g ""
wxr eru
I
vr'w i."
i-ITy::.;--l
Liff"
il;;
i llH**"", liEF; i ?r*'
I H
Ul SI r l OUI r On,
I
el l o' O58
Ll v- - - -
From Under-hood ;
( HEATEB
V
L-L---q'i.'g;-.1-
'
i-r-g-.'I.-
".,*"'l
::::ll6iirf{ffi.",".,i';
"
$r*,,,,
*iiiFr-
"
---
-
--'''lB;,zfz
Jl[1__::.fif-o
B:er.#:r
"f
r**"
Gll".-11yorror"-:'L
+asero
:'j'd",.,
I
L- - - r r - -
IF-F;I
!r---*l
, h
...
[
-1-'
Seo Powr
Disaibution,
page 10n 1.
UNDER.
HOOD
FUSE/
RELAY
BOX
HEATER
CONTROL
PANEL
r------, F-
L - - - - - - J
- - - - - J
, - - - - - - - - - - J
A/C ON
INOICATOR
See Ak
Delivery
Gate
tc
a,ic
Swltch
-:{l-lit't;;
L:_jftH+z
"*f
,"" n,ouno
___-i*-]
63-1
Fans (cont'd)
- '99-'00
Models
Switch"
common
a,/c
THERMOSTAT
Off below
3' C (37" F).
r l a
iTm,il-- l5;i;T iln"lgg1
L_t]stE"_i*-o* !-J-___i
*-"'
"W"u'
".*L[F*f,l"' -*,".'"[ftT,;.'
I I .-..
Sse Power
I I ',-.',
Sse Power
I
S Powr
?+ 3s;iT:3:' ?'4 3ff:?f?l:
OEE
I
Dbfibution,
I
pacp
10.9.
HEATER
CONTROL
PANEL
vlEw 76
A6
BLK
;+
::--
{***,Pase*11
I
t
I
r f a
r,/c
switch
input
L - - - - -
HEATER
PUSH
swtTcHEs
A/C
Swlbh
See Air
Dslivery,
n6ar
Window
Delogoor
Se Alt
Delivry,
Baar
Window
Dloggpr
See Ground
Distribution,
pag 1+5.
I
J
;-a;
I I
'l
rHERMrsroR
I I
l t |
23
9- - - - - - - - - - - - - - 2,
c723
q/
f,
,2tr
prtoroz!3a
t t t
l l l n
r
ar-x,ver-
|
tn*t,".u
I
I t I
o r l " t o l
---riliii"--
inplt
(backup)
i
I
N c l
svritcn Swikh
I
LED LED
control cofrrnon
Ground
_ _.i
2 Y l
^. . . _-_I t
*-*"!
t
2oV c723
I
- -_-\ Tgr?; u L
---rF------
requsi
63-2
a/c
ON
lrdlcalqr
-
Radiator Fan
Voltage is provided at all times to the radiator fan
relay (contacts) through fuse 57. With the ignition
swilch in ON (ll), voltage is provided
to the coil of
the relay through luse 17.
The radiator tan relay can be grounded through
either the engine coolant temperature switch or the
engine control module (ECM) or powertrain
control
module (PCM).
The engine coolant temperature switch grounds
the radiator fan relay (coil) when the engine
coolant temperature exceeds 199' F (83' C). The
switch opens when coolanl temperature
decreases 3' - 8' C.
Condenser Fan
Voltage is provided at all times to the condenser fan
relay (contacts) through fuse 56. With the ignition
switch in ON (ll), voltage is provided to the coil of
the relay through fuse 17. When you push the A' lC
switch and
put the heater fan switch in 1, 2,3, o( 4
position,
the ly'C thermostat comes on, the
condenser fan relay energizes, and the condenser
fan motor runs.
A,/C Thermostat
The A,/C thermostat is located on the evaporator
housing. The A,/C thermostat tums off the A/C
compressor clutch if the temperature at the
evaporator
goes
below 3'C (37'F). This prevents
condensation from freezing on the evaporator fins
and blocking the air delivery into the passenger
compartment. lf the temperature goes below 3'C
(37"F) tuming off the Ay'C thermostat, ground will be
removed from the condenser fan relay. This will
deenergize the relay and remove voltage from the
condenser fan motor causing the fan to stop running.
Reter to the Service Manual (Section 23, Eleckical)
for specific tests or troubleshooting procedures.
63-3
\ r l
- '96-'98
Models
See Dash and
Console Lights
rf
See Dash and
Console Lights
Se Ground
Distribution,
page 14-7.
L - - - - - - - -
c501
vtEw 55
il
l1c
FUSE 16
FR DEF RLAY
7_54
I
FUSE/RELAY
ff":;;1il,
l"'3|""
3"C3jgl-i
REAR
wtNDow
DEFOGGER
SWITCH
.I
UNDER-DASH
@
r - F- - - - 1
i-f:"'*rul
!._L:___J
UNDER-HOOD
FUSE/RELAY
BOX
FEO/
BL|< c351
vtEw 34
ll-,-
--:L::
NEAH
wtNDow
DEFOGGER
RELAY
P|1oTO 59
UNOER-
DASH
FUSE/
RELAY
BOX
co,pe ano seoanu
'1"[
FzT;4-
- - - - - - - J
Hatchback
See Ground
Distribution,
page 14-7.
Y
I
I
t___
"._,".trf
t*''
T^
fl[lfEex,"
"'-f
t
seecround
a rr( Distnbutron,
"r-
|
Pase
14-10
I
* coor
PHA|O 1A2
".^,"i'uI
g"x%,0,
'
*
9,g%,,,
eu,eul
I
|.Tl
nean
I .5 |
WTNDOW
IiIDEFoGGER
I "
I
*-l
I
I ^--.
PHOra 1AA
:
G401
64
- '99-'00
Model s
t@
J
See Power
0istribution,
pag 1&9.
r
I
I
L
c420
vtEw 53
".*:.f
!
"T.I
FUSE '7
HEJT'EF AIC RETAY
7JA
UNDER-DASH
FUSE/RELAY
BOX
PHOfO 58
r-r---1 UNDER-HOOD
|
(
#tt*
IFUsE/RELAY
I t
sl*t-'
'"o'o'
L- *- - - - J
3 Y C3s1
Ss6 Pows Dist bution,
pag 10-9.
Sn itch
LED
common
c420
PHOTO 63
vtEw 53
HEATER
CONTROL
PANEL
I
I
I
lgnition inpd
Swiich Slitoh
Groulld co{Y}rnon inM
LED
gontrol
Rear winoow
I
dofogger
I
gl",,ry'_l
A6
ALX
S9a round
Distr&dbn,
P.go
1it-7.
c12
YEL
c9
BLK
r '
c6
PUR
c1
ORN
A7
BLU/
YEL
21
BLU/
YEL
BLU/
YEL
4
(GX 10)
BLU/
YEL
8
- Se Air ;
D6livory
ON
Indlcitor
wlIT/GFI{
c723
PHO|O 138
c440
PHO|O 81
vtEw 45
c411
PHOTO 60
vtEw 60
c501
vtEwss 5
RaI
Wlndow
Dcrogger
Sultch
56 Air
Delivry
L- - - - - - - - - - J
HEATER PUSH SWITCHES
UNDEN.DASH
FUSE/RELAY
BOX
PHO|O 5e
I
I
I
I
See Gound
Distdbltion,
page 14-7.
NEAB
wlNooly
DEFOGGEN
FI.AY
Prrolo 59
I
I
I
I
I
cssl
vtEw 47
Halchback
"*1[
ftTi.:-
wtNDow
ANTENNA
cotL
{cx'l) T
9,*%,,
",-"",-,
1
[93ff''n'*'
t o
!.'IFI REAR
I J I
wrNDow
lll
DEFoGGER
".-i."tr
ftTi",,'
t
V
F,9"oB ",
erxialul
I
ffiff$Eex,"
*"r'
I
I
* cttr
PHOfO 10A
Sre Ground
DFtrtbditm,
pago 1+7.
I
t_
".":il
H
e Y
82
ALK *-r"
arr<
-.1
!
S9 Grolnd
Distribtdion,
pag 1+ 10
*r
:
G401
* csoz G601
I. G,rc2
PHOIO 57
BEAR
wtNDow
DEFOGGER
64-1
-
'96198
Models
Voltage is applied at all limes through tuse 50 to the
rear window detogger relay (contacts). With the
ignition switch in ON (ll), voltage is applied through
tuse 16 to the rear window defogger switch.
When you turn the switch ON, voltage is applied to
the defogger timer circuit. The timer circuit supplies
voltage to the rear window defogger relay (coil). The
relay energizes and supplies voltage to the rear
window defogger. The defogger grid then heats the
rear window to remove any condensation from the
glass.
The defogger timer circuit will automatically turn off
the rear window defogger after about 25 minutes.
'99100
Models
Voltage is applied at all times through fuse 50 to the
rear window delogger relay (contacts). With lhe
ignition switch in ON (ll), voltage is applied through
fuse 16 to the heater control oanel.
When you turn the rear window defogger switch
ON, a signal is sent to lhe defogger timer circuit
built-into the heater control oanel. The timer circuit
supplies voltage to the rear window defogger relay
(coil). The relay energizes and supplies voltage to
the rear window defogger. The defogger grid then
heats the rear window to remove anv condensation
from the glass.
The defogger timer circuit will automatically turn otf
the rear window defogger after about 25 minutes.
Refer to the Seryice Manual (Section 23, Electrical)
for specific tesls or troubleshooting procedures.
64-2
I
a
a
NOTE: Fuse 31 is hot with lgnition Switch in START (lll) and clutch
pedal
depressed or A,/T Gear Selector in
PARK (P) or NEUTRAL (N), see Starting System,
page
21,21-1, ot 21-2.
See Brake
System
lndicator
l i ^ h l
FUSE 3I
staaTEa
SIGI{AT
7AA
I
I
I
I
I
I
\
\
\
\
\
\
I
I
I
I
I
I
/
Ss Siarling
Syslsm,
pago
21,
21-1. or 21' 2.
SEs Brake
System
lndicetor
Light
A6
Ssa
ClharSrrE
Systom
Eog Gound
Distlbution,
page
l,l-7.
L- - - - - -
3 c420
PHO|O 63
vtEw 53
--r-r. . r'
FED/BLU
See
Cei l i ng
Light
See Seat Belt
and l gni ti on
Key Remindrs
t@
i'l-;;,-lH8B'r*
| \ rrmn1gn I
FUSEI
i f
t*"
ig8f"
LJr ____J
PHOTO 7
u'lf
tf,%,
S
vtEw 3a
wHr/FED
|
3fl3,n'"n
wHr,FED I
sYsteh
<--=-
!t
,r"r,".0
|
,n"r,".u
I
| .l
B*?r:""
,.!,.*,
See Wiper,ryVasher
@
FUSE 30
l|lslFl,|tEl{l
uotfT3
UNDER-
DASH
FUSE/
RELAY
BOX
I
t
I
I
I
.1 1
- t
\
\
\
Sea Power
Distfibution,
pag 10-5.
iz
FUSE 15
ALTEi}IATOR
sP 8S$80n
?.54
A8
7'5A
soe Headtight sss Power
- Switch, Distibution,
page 100-t. pags 1G7.
fo
INTEGRATED
CONTNOL
UNIT
vEw af
\
\
\
t
I
,
I
I
I
a - - - - - - -
FUSE 26
FR \I/IPg
Fi WASTIEF
204
Ught8.ON
nemhder
Circrti
lfllsnl|liter
Wip6r Relay
Circuit
Combind
l,Ylper/
Warhot
Cireuit
*I "'r
I I
I I
-----[---t-----
""r,".* I ".u-"r l
t t
\--
See WiperMasher
70-1
Brake System Indicator Light
- '96-'98
Models
NOTE: Fuse 31 is hot with lgnition Switch in START (lll) and clutch pedal depressed or A,/T gear selector in
PARK (P) or NEUTRAL (N), see Starting System, page 21
,
21-1, or 21-2.
a
FUS 31
atAirEn
8Gl{tt
7.all
UNDER-
DASH
FUSE/
RELAY
BOX
So Starling Sysl6m,
pag6
21, 2l -1, or el -2,
FUSE 25
ffR
s." Ponr"t
Distribulion,
page
10-6.
rry
I
;?l
r
I
I
I
I
I
I
I
c501
PHOTO 60
vtEw 55
Ss Pow6r
Dlstribution,
page 1G6.
---.I
GAUGE
$os Indicators
I
ASSEMBLY
i',i!i,I2'
I
I
(slt--95.:l-_i
l 8 s
: GRN/FED
r - - - C W
- - - - .
! 3 A
cso3
: . . ^. , " . . , " " , ^. ;
i
"lir%?u' '
rRANsMls-sloN
:
! ll virw ro : CONTROL ;
99
grqn'd
| ! s I iiiiir^
, vtLw 6s
i
o"^r"'o
|
'i'jri
|
"l w;t,
b - - - 4 - - -
-
31i3*:'.
--l:ffiffi--i
i
---- -.L- J- -:g,tgLesr.l - ---- J--:- J--i
:
!
3113'"0*
| :
-9tF":--T-tY-E;"41i'",
: :
lsrss9l;-;?--q1Al"
:L:W-J
i
-----.1- J- -tlb$Lsr'{.i------ J--:- J--i
:
!
31ffi "o*
| i
-trfr; - -
i
-TFr,lifu:i-|l
- -
.Tf"*;',r;,f'.F?f;l',
i
LTS-:
:
i
I ii
-""'"L--i:t--i3trFlr*n'"i
i
mooule
ficlrt)
i
I PHO|O 121
'
: !
: i
f f i t r e" ni nas ;
: l l t i n"", ". 0 l l : ---. [ : i , 119i 9. "'
'
' t l
: I : i a s
i :
' . I
i er i :
- - - - - ' : : : - - - :
i",",1
iiiffi_il$.t'ii: i"-,s*
vlEw 54
--
vtEot 66
,
Ffl anlxe rLUto
i*l
'
".","1;l,"p;a;
illJff*ttt**
u.-u.*il ii
[JFHi:"' l*iTfit*,".
I Y
i
frpanxrxc :' r#"Al[';u3*'""i
I
I
U il4.lFfffff'UJ:""
ii
EJi,fii,i,"-"
i
r-j
3"ilj*il
ii
"."""J[ft*,,tl-
i lilt:' ,' x;l
71
i
Ci or
I
t E^-
phoroTs
, l
-
:
pHoro
7s *
C+6t
F6r6sz
r-
usA.
- - - - - . t - - - - -
canada
Froi i t sz
- '99-'00
Models
NOTE: Fuse 31 isJtot with lgnition Switch in START (lll) and clutch pedal
depressed or A,,/T gear selector in
PARK (P) or NEUTRAL (N), see Starting System, page
21
,2i-1,
ot 21-2.
UNDER"
DASH
FUSEi
RELAY
BOX
I
I
I
I
I erouna
Brake
Bulb
Chsck
Cheuh
NTEGNATED
cot{TRoL
UNIT
ftoa 64
vEw a7
I
Bi?[lT':i,
S6 Ground
Distribution,
pago 14-7.
I
I
c420
PHO|O 6i
vtEw 53
c551
PHOfA 63
c419
PHO|O 63
|
(r;'
Used)
1 5 1 4
r----4(--.1
DAYnME
I q*
*
| RUNN| NG
Llt:i-ib'f#Iu'"''
i
---Y --
"""*
i
FED/ GFN I
c419
:
18 Jl
iE?'8'
:
f ?-' ! uloen-oasx
'
I I
I FUSE/RELAY
| | l P9l _- :
1
Y
Cs51
".o'o""
!
iffl1oru"
l :
I Sss Gfound
I Distribution.
I
pag 147.
T Y
t t
L_l
.'-4o.'
Fr,l rs 3i
--Ii l ;--------l
3m"
) 9ff" s""
po*"r
I
\,
See Starting system.
I
"-
.
Distribution.
l
-
pasezr.zi-t.'or'ztlz.
._____=Fl}_*t0"_____.1
l3.f
ftT:4""
Bulb
chek
outp$
L- - - - - - - - - -
,.. I
o"n"
tot'
c+l
i
- -
F-;
ffi ;-
- - -
I [i;"s"'"."
I rt^
amre
I
vir:i i,
t
(R
'
rNprcAroR uGHr
I
i
Y lBn
rcll6T6tl
I
|
|
(usA! (canrda) |
L - - * - : J - - : - - ' - - J
8 5 Y 8 5 Y
o""'"T|
"";%u,
"""'"';i"a#;",
\e#1k"
I
f,............ c44,
f
$?'#"ot'to'
-*'1;;
GBN/FED II PHOIO 22
5fi
ennxe rluro
I ' I LEVEL SWITCH
|
/_,?
lfJ",ii"."gl'.-
w::::"
"'-1":::::-.
!
3:"'lll"*l
".-l
I
L__l
+
:
G40l
PHOIO 57
l-rlrl
PARKTNG
I ' I
BRAKE SWITCH
,
lIdft"f[]r'"r'"
i
c"n"o":-
"igt-ol'-
- - - -
j
71-1
Brake System Indicator Light (cont'd)
-
The brake system indicator light comes on to alert
the driver that the parking brake is applied, or that
the brake fluid level is low. lt also comes on as a
bulb test when the engine is cranked.
Parking Brake
With the ignition switch in ON
(ll) or START (lll),
voltage is applied through fuse 25 to the brake
system light. When you
apply the parking brake, the
switch closes and provides a ground for the light.
The light then comes on to remind you that the
parking brake is applied.
Brake Fluid Level
voltage is applied through fuse 25 to the brake
system light. lf the brake fluid level is low, the brake
fluid level switch closes,
providing ground to the
circuit. The brake system light then comes on,
alerting the d verto a low brake fluid level in the
brake master cylinder. (Check brake
pad wear
before
you
add fluid).
Bulb Check
With the ignition switch in START (lll) and clutch
pedal
depressed or A'lT gear selector in PARK (P)
or NEUTRAL (N), voltage is applied through fuse 31
to the brake bulb check circuit. The brake bulb
check circuit closes, allowing current to flow through
the brake system light and bulb check circuit to
ground. The brake system light then comes on to
test the bulb.
for specific tests or troubleshooting
procedures.
71-2
a
\ f a
Seat Belt and lgnition Key Reminders
UNDEF-HOOD
FUSE/RELAY
BOX
S6s Powf
Distribrtion,
pe961&10.
FUS 25
UFIEN
?,irA
UNDER.DASH
FUSE/RELAY
BOX
PHOfO 58
+
Ss Power
Distribution,
Fag6
1G6. (Termlnals 17-20)
vlEw 56
r:f ftir
YEI
t
S Powt
Distibliion,
pag 10"6.
Tf
----rer,'-----l$Fffi
r"il-ffi3#-.-T-lii*"f
*'
*;-'-1,rffi{ru+"
iiw-Q!""
ffi. sL,' #*
lBffir'
i
iL_@__J_i
Inpu Inpur Inpr',t
| |
| 86
l'
=f,f-----J
| "'o'""I
-ni=of'"
!:*+',
--[--:p----j
',
I f--.
Erid*'i,ll*,
'"'"'"1
|
,,"."1
î:,:l"tt"#"'
,.*, I
,*'*.,
"'
.
t tx,,:.,
'"''"[
,*,,
*Fgt
it:- _ _ _,
.r..*;ff'"* o",ur*,.
I
Lqffi^j'-.
hl.u.1f*"
cFNI
t""ff*;---
'lt'-h*
I
'=es'oomode,sexcep,cx
i
ilT,.+ry,
".-l
ttr,'g$t
AgBBBBB$"l',il*
"'*tj
L:i
PHoro s6
:
G4ol
r--xr------
. I R T Y
iFn-
il-----*
L----a;.T' --
Secrou$ I
Distribr.niofl, >-a
Y:___L__
'lftf'*
I
I
-^l
I
see cround
I
il",jli'.91'
I
t t
*r
:
c4oj
PHO|O 57
--f*.?*-j
--LryJ
',J,trni:
. 4
Beeper o0tpul
Ssar
Door fy b6h
swiich sr'/itch switcfl
input inpul inpd
73
Seat Belt Warning
battery voltage is applied to the seat belt reminder
light. When the seat belt is not buckled, the seat
belt reminder/key-on beeper circuit in the
integrated control unit senses ground
through the
closed seat belt switch. The seat belt reminder light
comes on and stays on, and the beeper beeps for
6 seconds. The reminder light and beeper will stop
when the seat belt is buckled or the timer circuit
deactivates them.
lgnition Key Warning
Battery voltage is supplied at all times to the seat
belt reminder/key-on beeper circuit in the
integrated control unit. When you turn on the
ignition key switch the integrated control unit
senses ground. lf you
open the driver' s door, the
door switch closes, causing the beeper to sound
until the door is closed.
for specitic tests or troubleshootrng procedures.
73-1
Low Fuel Indicator Light
\ r l
't
I
I
I
I
J
pag6 106.
,
-ls,T,*-*:lligff*,
l',;l:'l?,'
A 3 A
!'-{ilril}-1 PowERTRAtN
I Lowtuel I CONTROL
I i$grtor I
MoD]LE (pcM)
i
S'
i18l7"*
UNDER.DASH
FUSE/RELAY
BOX
PHOTO 58
! r a
or*+* i
T F I i
--l ------i
"I
I
A oxcpt GX
c503
PHO|O 61
AFN/GFI{
9FN/GBN
1 5
BLU/FEO
c410
vlEw 3s
c' 131
PHO|O A5
vtEw 59
I TANK
: UNIT
Than|tlrlor
So
qauges
L- - - - - J - - - - - J
Sae Ground
Distribution,
pa$ 14-9.
74
How the Gi rcui t Works
All Except GX
Do not smoke while working on the fuel system.
Keep open flame away trom the work area. Drain
fuel only into an approved container.
A thermistor is mounted in the fuel tank unit. When
the thermistor is cool, its resistance is very high.
When the thermistor' s temperature increases, its
resistance decreases. Fuel in the fuel tank transters
heat away lrom the thermistor fast enough to keep it
cool so the thermistor's resistance stays high and
lhe low fuel indicator light does not come on. When
the fuel level drops below the thermistor, the
thermistor' s temoerature increases. Without the fuel
to cool it, the thermistor's resislance decreases,
allowing current to llow through the low fuel
indicator light and the thermistor to ground, and the
low fuel indicator light comes on.
GX
The PCM turns on the low fuel indicator light when
the fuel level is low. The PCM will also blink the
indicator light when a problem is detected by the
fuel tank
pressure
sensor or the fuel tank
temperature sensor.
Refer to the Service Manual GX Supplement
(Section 11
,
Fuel and Emissions) for specific tests
or troubleshooting procedures.
74-1
Indicators
! a
UNDER-DASH
FUSE/RELAY
BOX
PlloTO 58
'1.
Dim lgnition
input
lndicatof
Grolnd
contlol
I
I
I
I
I
&3?linars rz.zor
i33o,.no
3in""li"?''""
,
"i*l?""
"*o""tr ""**"tr' """"*l'
t t l
".[ ",1 ,.[
-;--1------T-----T
'"
lEil$fi' I I I
irffiPl
| | I
'ip^"rf'ffi"'?H""9
J [ i @) - l
r -
k -
|
I canada |
\-l
see Gauges
1t ; 1
#ra-tu1-*
N|GHT
TURI'l
slclrlAl
INOICATOR
LIGIIT
H
sns
IXDICATOR
LIG}IT
1
I
- - - - J
GAUGE
ASSEMBLY
PHOIO 67
vlEw 71
= [ =
See ABS
*l =
See sRs
c507
(Termlnals 1.6)
vlEw 56
BLU/NED
S
==:
Grouft
e 14-7.
Distribtltion, Ground
, 14- 7.
Se
(
page
(cont'd)
80-1
I
! l
i l s r
\ e
\
\
\
\
I
I
t
I
I
l ____l
-
G4o1
PHOIO 57
Indicators (cont'd)
I
I
I
I
' t 0 t
YEL
YEL
FUSE 2s
UETER
7.54
.I
UNDER-DASH
IFUSE/RELAY
!
F,gI".,
I
I
J
See Power
Distribution,
page
10.
@f,*+* @sv#ftn* G)ffig^,",
t
I
Se Powr Distribution,
page 10-6.
?-(: i#i',du)
,
c401 ^t , a
PHOf O 1J6
I pHOfO
57
v"r
vlEW 58
'99-
00 vehicles pre-wired for
accessory security system
I
:7
r----r
-7
ucHr
\
i l l El l H l t * l
' . ,
| | i r{rN/,6n1
I I I l\\y
\r//l
I
t
t--J-------Lfe---t---- ---J
B8Y Bs Y B3Y B8Y Bs Y
- ___B_3_Y_
,"' sfilJi:,
i
"*,*"
i
;
""'"'*
!
-
"*-i
F"EIi,6HiJttr"
so. sa venricres pre_w reo ror
I |
: ".u,"r"
!
ii|ot$,,
accessory securrtv svstem
+ + l - - - - - i l - - - - - - " r l ' ; r ' - - - - - - - - - - - - - i
i "Lu,"r"
!
rc;1rg
(oPrroN)
""""";:"J; !H;fi;"";Jt"'
l _ _ _ _ _ l l _ _ _ _ _ - v ' _ E \ s ! - _ _ _ _ _ _ _ _ _ _ - _ i
o
A
csoe
I
PsOrO 6t
, - - - - l - ' ' : y: -
i
"""'^
I ".u"."
-4
ELueLx
9 3B"rU"?'JYSJtttt
:
See Low See Brake 6
Zl
C503
Fuel lndicator System
]l
Paoro
o'
Li ght I nbi cat or
, ____l _' ' : Y" : -
, BLU BLK
l l _... _.._
q
SECURTW SYSTEM
,
I BLU'BLK
..
BLU/8!K
: nourpcrrip
Coupe and Sedan
'96197
models
"ar,"a^ fi
'tg::1",,,
BLU/BLK
Jf
v/Er,! e
'98-'00
models
TRUNK LATCH
SWITCH
Closed with
trunk open.
"arr"a*l
qF*til'-""
*
=
Male-Female
terminals reversed
f or' 99-' 00 model s
"'"'"i{
"^'
4r*liT;--'""
""'-it:':
Bi?fi,,ri"li
".*
|
Page
14"12'
+ Fla'|",.
""'"'-lt
aLU/aLK
see
i-<
I'dli
-*TT
"'*f
see cround
3rr<
Sl"JliT:?s
".*
I o*.,
0.1411'
*
'&3i311'"
,:*'* ""dan xcep, Gx)
80-2
, \
c2Y
I
I
PNK
I
I
I
I
I
,0.+.P,0;1""
, - - _ .
a i v t Ew6 0
'
l '
,
PNK
I
' T
i -t ^-. 3l ; 33;
"
' i ' H;"^
i
1n' ' n"o
:
:
" n*l
:
, l
i
z
f
czrs
; T
:
fTl Pt[?5'"
:
i l / |
LEVEL
:
l .-: I
swrrcH
_
,
I
Sae Grourd
:
,9c215 g:"Ji fl l '
;
, t
' l Y
I
l--t
v-
i ! czoz :
|
-
PHOfO 19
"""r::I
I
t
PGM.FI
B6 Y C3
"aor"au I
I
YEURE'
See Seat
Bell Rminder
o \
H
o l
c4t1
vlEw 60
ct01
vtEw 2e
ENGINE OIL
PRESSURE
swrTcH
Closed with
low oil pressure.
PHOfO 131
Gauges
#'t----lllgi' i i-r-; ffiffig'i
;;;;6;;-
-
ild;$ i fr{li,l[i
1 OTSTR|BUTOR r---
--.-^'l
POWERTRATN
![ElF{, I
i:tirtiifffii*
I ":"+J
(pclrrorEcM)
I
t**"**
iB,HFf !
L"T-liidfri"
|
î,i'llt"#,*'
-i]_Lryq_j""""
..-:i:I1;,,?--.,
_,1
lllftT":{"
r:l
#f,t,
I
!
v,erso
I
-
! ' Y
v
,
I : "
c442
#* i ;[. r;{
11;:
#r
i :;l
i1[----
11 :ff:*"'"'
'i"
f+Taj
i!!3lo_rrr."
See
Indicators
---{
rAcnoMErER
i
I
sfr"
iFSil
i il"+"+w "-1itl*" "
' LuqJ
I
F*l$"
I
i
mi+',ts'fi8$,* i''
=,i!,,ii.ii:yil',g",',0,u,,
I
t,
fri;J,, :,
-;;;U,+*r;l'd*o',
", I
- 7
I
I
I
I
\
\\
\
I
- l
L
82 "' I
"'u'"'!
I s,#!,,*",
!
Nsst, oaoe
so.
""1,i,
r--' !
vEHtcLE
! I
SPEED
L__j;,#39'n.',
S Ground
Oistribution,
page 1+7.
Y
I
I
I
+
:
c4ol
SPEEDOMElER
GAUGE
ASSEMBLY
f
l - *
, '
I
t
\
\
I
I
,
, :
ENGlrlE
COOLANT
TEiTPERATNE
GAI'GE
FUEL
GAUGE
- - - - - - - - J
GX model
Bl2
tr'
Altxcsp't Gx modt
B1o
I
YEUGFN I
, r,
A "ol l ". , ", "11 "
fi;rt"r4." ,1,"g[
s;g,,
YEUGFN
I
2l vt uea
r - - - - - . | F U E L
- A ^.^. I |fl
Fuer
lll,l5
-*"L[
F*H4''
L
t#4iorn-i'**
-
t
' -;5-
OFN/BLU
OFN/BLU
OFN
A4
c410
vlEw 35
c131
vtEw 59
r --=
.I
POWERTRAIN
!r+i-'' !fi8tsllP.
331ffi !i;E-i/'i
#."o,".
t
f
14
ii11"t:'f""'
*!--*
il?:+:ifl
l - - Jvt Ewzo
81- 1
Gauges
(cont'd)
-
How the Gircuit Works
When the ignition switch is in ON (ll) or START (lll),
battery voltage is supplied through fuse 25 to the
gauges in the gauge assembly.
Speedometer and Odometer
The odometer and soeedometer drive circuits
receive pulses from the vehicle speed sensor
(VSS). The pulse rate increases as the car
accelerates. The frequency and duration of these
input pulses are measured and displayed by the
speedometer, odometer and tripmeter.
Tachometer
The tachometer drive circuit receives pulses
from
the ignition control module (lCM) in the distributor
assembly or the ECM/PCM. The solid-state
lachometer then displays these pulses
as engine
speed. For each 200
pulses per minute from the
ignition control modul (lCM) or the ECM/PCM, the
tachometer displays 100 RPM.
Engine Coolant Temperature Gauge
The engine coolant temperature gauge has two
intersecting coils wound around a
permanent
magnet rotor. Voltage applied to the coils, through
fuse 25, generates
a magnetic lield. The magnetic
field, controlled by the coolant temperature sending
unit, causes the rotor to rotate and the gauge
needle to move. As the resistance in the sending
unit varies, current through the gauge
coils
changes. The gauge needle moves toward the coil
with the strongest magnetic field.
The 6ngine coolant temperature sending unit' s
resistance varies from about 137 ohms at low
engine temperature to between 3H6 ohms at high
temperature (radiator fan running).
81-2
(
Fuel Gauge (All except cX)
The fuel gauge has two intersecting coils wound
around a
permanent
magnet rotor. Voltage applied
to the coils, through tuse 25, generates
a magnetic
field. The magnetic field, controlled by the fuel
gauge sending unit, causes the rotor to rotate and
the gauge needle to move. As the resislance in the
sending unit varies, current through the gauge coils
changes. The gauge needle moves toward the coil
with the strongest magnetic field.
The fuel gauge
sending unit' s resistance varies
from about 2-5 ohms at full, to about 110 ohms at
empty. When you
turn the ignition switch off, the
gauge remains at the last reading until you turn the
ignition switch to ON (ll) or START (lll) again,
Fuel Gauge (GX)
The fuel gauge has two intersecting coils wound
around a
permanent
magnet rotor. Voltage applied
to the coils, through fuse 25, generates a magnetic
field. The magnetic field, controlled by the PCM,
causes the rotor to rotate and the gauge needle to
move. The PCM calculates the gas quantity in the
fuel tank by using the fuel pressure value detected
by the tuel tank pressure
sensor and the fuel
temperature value detected by the fuel tank
temperalure sensor, and outputs the signal to the
gauge assembly. The gauge needle moves toward
the coil with the strongest magnetic field.
When you
turn the ignition switch off
,
the gauge
remains at the last reading until
you turn the ignition
switch to ON (ll) or START (lll) again. When the
PCM detects a malfunction with the fuel pressure or
temperature, or detects a gas leak, the PCM
reduces the fuel meter to 0.
Refer to the Service Manual GX Supplement
(Section 11
,
Fuel and Emissions) for specific tests
or troubleshooting procedures.
a
a
{ \
- c w
@
UNDER-DASH
FUSE/RELAY
BOX
r
See A/T
Controls
"Ttr
See Dash and
Consol e Li ghts
-
A Y
l l t
FED I FED/BLK I
t l
YEL
A1
SEE A,TT
Controls,
PGM. FI
I
;l
A/T Gcar
Poiltlo{|
Indlc{or
GAUGE
ASSEMBLY
a \
t - - - - Y- - -
BLKBLU
12
GRNA!/HT
c410
vtEw 35
BLK
aLu
I

See A,/T
Controls
TI
:I
a
t
a
A.t 3
BLKBLU
7
BLK/BLU
eui
[S
BruI
See
l nterl ock
System
I
;+
a r
l
-;-----;++
-l-rl
c433
A/T
GEAR
POStTtON
swrTcH
Sec Ground
Distribution,
pag 1+7.
Y
I
I
a
L__l
+
:
G401
\
89
r T- - - ' - UNDER. DASH
I I
FU3E25
I
FUSE/RELAY
i i
m*
**J.e:1- iF,?T,'
. a
I l-----+
pags 1G6. I
L. * - - - - - - - - J
a
-
Al l except CW
@E
-1
I-i
See A"|T
Controls
."r'*"*",iFI
llIftr;1'
.-a---{ csoT
'..[--[Eq"Ti**,,
o' I
-
Pag
105'
:I GAUGE
I
ASSEMBLY
i'l;l:,tr?,'
I
I
I
I
I
I
I
I
I
_J-(y'g,--
f#**
"."i?
t - - - - g- -
a
A11
I
:+
a r
L
a
A13
BLVBLU
BlVBIU
Bu(
lF
BLU
I
See
lnterlock
System
BLX/BLU
Ga rryvST
A/T
GEAR
POSTTTON
SWITCH
: Se Gfound
I Disribution,
-
paga r.l- /.
L__i
=
G401
Se Cruise Conbol
See Gmund
DistrihJtion,
page 1+5.
c433
vtEw11
ALK
1
BLK
See Dash and
Console Lights
+ r
BEO I AED/BLX I
I T
AJ A AZ t
Se A,/T
Controls
;:I
ru
A/T Gear Position Indicator (conrd)
-
voltage is applied to the A,/T gear position indicator.
The A,/T gear position switch provides
a ground
for
each position. As an input is grounded, its indicator
light comes on. lf you select R, for example, ground
will be provided to the input of the A,/T gear position
indicato( and the R indicator will come on.
With the headlight switch in PARK or HEAD, voltage
is applied to the RED/BLK wire terminal. This
changes the indicator panel illumination from fixed
to controlled by the dash lights dimmer input
through the RED wire.
When the powertrain (all except
'96-'98
CVT) or
transmission (' 96198 CVT) control module (PCM or
TCM) detects an abnormality in the automatic
transmission control system, or when you request
diagnostic trouble codes through the service check
connector, the PCM or TCM will make the D4
(D
for
CVT) indicator light blink.
Automatic Transmission) for specific tests or
troubleshooting procedures.
\ i a
89-2
Front WiperMasher
a
I
I
Fi WIPER
fi YYAEIIER
c423
vtEw 3
A4
\ a
I
I
I
t \
t l
I
91
- - - - - 1
,
. l
I F
3 - - - - - - - - -
wEw 5a
"{
t a
i
BTA
t t l
i r '
I l l n t d m i i t a n t / h a . k
ot
r
se cround
ou
r
coMBrN\ill?H
I 3l'#ltgl I
'"Y;Isil
",.u,".*l
I
*-l
-'tEt165
! l ----l
aLU' wH
r
'"""""--:--
|
:
F#1.,
--.J---- ---------;
, r ___f
______ - __?F___?_r t
| NTE_
|
/ Intermittenvoark
H.t
rs"'ti-
| i $$p
\ f wioer contrcit
r \ \""-
--"-' tr' Psr
l litrlY,
\ \ |
cr ound l l 1 a
J !
J.
Inlerminanl wipsr Rolay Circuit
i
, r 1ao6Ttn
\ t
(
|lizlff,ll;'-
ffiI
'n"*-li3$H'o'
4
GFN/ELK
4
WINDSHIELD
WIPER MOTOR
r---':G-'---r
:
c4ol
PHOTO 57
Wlndshlrld
Wipor/
Warhar
Swltch
- - - - - - - - - J
B2

A5
1INTE.
-".ir--;;;;
.i.5^t Distribution,
"i]5
Park lgnition
Input
oFF ( Inr Lo,
tll
-a-
-4. I
UNDER-
DASH
FUSE/
RELAY
BOX
PHOTO 58
91- 1
Front WiperMasher (cont'd)
-
When the ignition switch is in ON (ll) or START (lll),
battery voltage is applied to lhe combination wiper
switch. and the windshield wiDer motor.
Low Speed
When you turn the wiper switch to LO, the wiper
motor's low speed winding is grounded through the
BLU wire and the LO speed contacts of the wipr
switch at G401, and the wipers run at low speed.
ParUOfl
When you turn the wiper switch OFF, the integrated
control unit (PARK input) grounds the wiper motor
through the BLUMHT wire. The cam switch on the
motor signals the integrated control unit that the
wipers are in the PARK position; the control unit
then removes ground from the motor, and the
wipers stop in the PARK position.
High Speed
When the wiper switch is in Hl, the high speed
windings of the windshield wiper motor are
grounded through the BLUIrEL wire and the Hl
contacts of the wiper switch at G401, and the
wipers run at high speed.
Intermittent
When the wiper switch is in lNT, battery voltage is
applied through the YEUBLU wire to the integrated
control unit (lntermittent wiper ON input). The
integrated control unit (lntrmittenvPark Wiper
Control)
grounds the low speed windings of the
wiper motor and the wipers make a single sweep
every few seconds (See Low Speed above). When
the wiper retums to the PARK position, the park
switch applies battery voltage through the
BLUMHT wire to the integrated control unit (PARK
input), and the wipers stop in the PARK position.
Mist
When you pull the wiper switch down to MIST
position, the high speed windings ot the wiper motor
are
grounded through the BLU^/EL wire and the
closed contacts ot the mist switch at G401, and the
wipers make one pass across the windshield at high
speed. The ParUOff function then takes over and
the wipers stop in the PARK
position.
Washel
When you pull the wiper switch toward you to turn
on the washer switch, battery vollage is applied to
the washer motor. The motor pumps fluid onto the
windshield until
you release the lever; on
' 98r99
models, the integrated control unit (windshield
washer ON input) snses power at the WHT/BLK
wire terminal and runs the wipers whenever the
washer motor runs.
Refer lo the Service Manual (Seclion 23, Electrical)
for specific tests or troubleshooting
procedures.
91-2
Rear WiperMasher
' l '
1 r
F
I
I
I
I
3
( ' 1: 2)
t:
!l
iL
BLU
6
GFN/BLK
4
GFN/BIK
1
FEO
FUSE 3
(RR WPEN
Rn waaHERl
c423 8
PHOfO 58
vtEw 3
GRN
1
Gf,N/BLK
GRIi
3
LT GFN
4
LT GRN
( t 1: 13)
LTGFN
4
( * 1: 3)
LT GAN
t
9i:;"*
Lr.RN/BLX
vlEw 30
c205
'1
=
'96-'98
models
*'
=
Male
-
Female
terminals reversed
lor
'99-'00
models
LT GRN/ELK
REAR
wtNoow
WIPER
MOTOR
GFN
4
{ . 1:
6)
GRN
c551
PHOTO 63
c562
**
PHOTO 101
c607
PHO|O 112
Lf GRN/BLK
4
ge
Qround
Distdbr{ion,
page
1+'12.
LI GRN/BLK
2
BLX
>-ra
c607
PHOTO 112
vtEw I
cs62
*
vlEW 42
c401
c767
6
PHOTO 126
c607
vlEw 9
c562
ri
vtEw 42
c40'l
B (C427\
c767
( . 1r 14)
".-
I
lrcFN/BlK
t
G761
lPhofo
132
'98100
oodsls)
a
REAR
wtNDow
WASHER
MOTOR
s (c427'l
Se Gound
Dietrlbution,
page t4"6.
LT GFN/BLK
BLK
BLK
c205
So Ground
Distribution,
page 14-4.
I I
L__l
+
:
G40l
a
92
--f
Headl i ght Swi tch
(
UNOER-OASH
FUSEiRELAY BOX
PHOTO 58
Sse Power
Disiribution,
page 10-12-
UNDER-HOOD
FUSE/RELAY
BOX
H
FUSE 22
L H/I
LOIY SEAfl
t0a
COMBI NATI ON
LI GHT
swtTcH
Head-
light
Swltch
L- - - - - J
' Se e Po we r
'
Distribution,
:
Page
10-12.
a
{
UNDER-DASH
FUSE/RELAY
BOX
FUSS 2t
F H/L
LOW EgAtl
FUSE 4
R TIIL
HIG|{ AEAM
t 0A
vtEw 53
_ ___:==
1-sr*r"
_
l_-.__
_,_.
i t :
".0-", i ".o ".u I
i
".o u.,
i t i
I t i
l l r
l l i
l l i
--' l --u{.sao,l,.
i
2
neour r r
I
nr oer ul ' / Ft r ' o : - - - ,
,.|,___ui
il--Tll''%i'sr"' ii
i t @4l i **"""l i -
;
s - i 5- r
i
.
I
I
i-t-;;l
1 J
lff*n"'
I
L- . J- - - - J
nrrl'?;Ii
ffif'illi!
i
*itn12
HI
-
-
)
ot[*o1-
-]
ot. "roo
a]ot.
HEAD
PAnK I
panx
IPAnK
! a
- -I
DAYTIME
I RUNNI NG
I
LIGHTS
!
RESTSTOR
' -
Paqe 110- 13
100
UNDER.DASH
FUSE/RELAY
BOX
PHOTO 58
I
I
I
I
I
I
FUSE 32
tpE SE UGfiTS
tan r|{rs
7,54
r--1 l ?EqnATEO
I uohts I co rRoL
; OFI I UNIT
!
input
! im?,t
I
1
f 12)
To Under-dash
Fus/Rglay 8ox
on n6xl
pag.
-J---------rt --- ----J
c4r9 15
Y
C501 c927
PHOfO 6i
OPTION
CONNECTOR
PHOTO 62
nEo/
ALK
REO/
ALK
*
=
'96-'98
models
*1[
"-"'['**,.1
_[ *[ ,*,
,
FED/
I t : t t ; t I
I l : l I l l I
L- - J
;
L- - J
. L- - J
HAZARD
,
REAR
'
CRUISE
WARNING. WINDOW :CONTROL
SwITcH
.
DEFoGGER; MAIN
Page 114-1; SWITCH
'
SWITCH
vt Ev/ 32 , Page114- 1
' Pago114- 1
c507
(Ierminals
11n6)
vtEw 56
REO/
EIK
1 4
RED/BLK
C't40
PHOTO El
c723
PHOfO 138
r--1
; -r
| | i i | i l |
| | |
l l I
: : A"rr GEAR !
- - - - - - J L - - J
EEil'J",-
p$i+bd'i
3333fi".' ilB?o'?u"."
PANEL
El i "i ra
Page114 (96-' 98 model s)
Page 114 PHoro 6, Page 1 14.1
pHOfO
71
VIEW 71 pHOfO
73
PHO|O 1i7 (g9'@l V|EW 6A
wEtt/ 41
ot
v/Ew761ee-oo)
irril?.rJll
Page 114-1
PHOfO 13/
vtEw 74
t l
t l
OASH LIGHT
BRI GHTNESS
CONTROLLER
Page 114-1
(cont'd)
FIJSE l0
100-1
100-2
Headlight Switch
(cont'd)
-.I
UNDER.DASH
Rom Uderdash
Fur/Bslay 8ox or
prevrous prge.
- - -ri-Y
c421 13 Y C5s1
'-
ll
PHoro 63
ll
esoro6J
neoialx
I
u/EW 50 BEDelfi
i
v'Edu7
' f
----
Hat chback
l ,
Coupe and Sedan
c2o1 : I !'--'l Itlt5i:^-
:
i"'oYizt
i i I
ri"Je'tl
i l3pfif.l-"o."-i
".o,".*l
=,a,e.Fema,e
, ll
L--J pe6161ja ,
ll terminals reversed
: tr_ _ _ _ _ _ _ _ _ _Y::_ _ _ _ _:
c202
PNO|O 23
ytEw
1
LEFT
BRAKE
LIGHT/
TAILLIGHT
Page 110-5
9
('99100 models 18)
FED/BLK
RI GHT
TAILLIGHT
Page 110-5
c562
.
vtEw42
c605
wEw a
RIGHT
BRAKE
LIGHT/
TAILLIGHT
Page 110-5
LEFT
LICENSE
PLATE
LIGHT
Page ! 10-5
for
'99-'00
models
FUSE/RELAY
BOX
1
(cruise 3)
c604 5
FEO/BLK
"ao,"a*
|
I
\ / ---l
I \ ---t
LEFT
TAILLIGHT
Page 110-5
\;,,
LEFT FRONT
PARKING/
TURN
SI GNAL
LIGHT
Page 110-2
RI GHT
LI CENSE
PLATE
LIGHT
Page 110-5
,rUrOO ro.",. ?,
I
r-\
\ _,
".,"-[TI
RIGHT FRONT
PARKING/
TURN SIGNAL
LIGHT
Page 1l 0- 2
I
\
)
FED/ALX
I
(GX 6)
('96-'98 Sedans except GX 14)
('99100
models except GX 18)
FED/BLX
t =Mal e- Femal e
terminals reversed
for' 99-' 00 model s
REO/ALK
All except
'99r00
Sedans
c562
r
vlEw 42
FED/BIX
All Excpt
'99'00
Sedang
FED/BLX
All except
'99100 '99'00
Sgdans Sdans
'99'00
godans
RI GHT
I NNER
TAILLIGHT
Page 110-4
c617
FED/ALK
'99r00
Sedans
All excpt
'99"'00
Sedans
'99-'00
Sodans
"'*.jx ""'r{
"*^*
".*:tr
t
"ao,"a"
I
q l
\ /
LEFT
INNER
TAILLIGHT
Page 110-4
c613
LEFT
BRAKE
LIGHT/
OUTER
TAILLIGHT
Page 110-4
RIGHT
BRAKE
LIGHT/
OUTER
TAILLIGHT
Page 110-4
c605 c604 3
FED/BLK
FED/
ELK
FEO/B!K
(99-'00
Sedans 1)
RED/BLX
Sedans
' l )
\
RI GHT I NNER
BRAKE
LIGHT/
TAILLIGHT
Page 110-3
LEFT
LI CENSE
PLATE
LIGHT
Page 1 10-3
or 110- 4
RI GHT
LI CENSE
PLATE
LIGHT
Page 110-3
or 110- 4
\ /
RIGHT
OUTER
BRAKE
LIGHT/
TAILLIGHT
Page 1 10-3
LEFT INNER
BRAKE
LIGHT/
TAILLIGHT
Page 110-3
LEFT
OUTER
BRAKE
LIGHT/
TAILLIGHT
Pag 110-3
Back-Up Lights
-
Coupe and Sedan
* =Mal e- Femal e
terminals reversed
for
'99100
models
! ,
(
I
1 0
YEURED
UNDER.DASH
FUSE/RELAY
BOX
PHOfO 58
T
I
:c,
x
FUSE 19
EACK UF UGH'S
754
- - - - - J
c419
A/T except CW
YEUNEO
1 5
('99-'00 except D16Y5 6)
YEL
2
GRN/BLK
c' 13' t
vlEw 59
c124
PHOTO 31
PHOrO 150 (Si)
vtEw 59
BACK-UP
LIGHT SWITCH
Closed with
transmission
in reverse.
PHO|O 75r (SD
cl24
PHOTO 15015)
3 ^ C433
yeL
a VIEW 41
.I
A/T GEAR
:+f't::
t D a
l ! - i
Af
;;-'i-
""",":lt
'lrry
l D .
l y*
Af
:t
| | | ?osllrgN
i
l"-3.^'
a
"s#[c#
i
"j ! *{b.
i *' o*
GFN/BLK
GRN/BIX
14
('99100 except 016Y5 18)
CRN/BL(
apl F- - 1 i
';".;t---'
o
*
"",0::","
o"n,".-*
[
u't' o '
! (
'99-'00
Sdan$
t
gg-
oo mooers l2ot
| #:;",,
,
rrr:eS;f""t"-!#
I ;;
t
All oxcept
'9$'oo
Sodans
"*^*f,
""::in;;'
ffi,*,,. T
@
GFN/BLK
l
o
@FLRI''
"*r
>-rO
@i[TJ+."
RIGHT
BACK.UP
LIGHT
2 2
See Ground
Distribution,
pags 1i1.1t.
".-
|
!
I
I
a
I
!
G601 G601
PHO|O 102
IAX)
1 1 0
\ (
I
Hatchback
tr@
UNDER-DASH
FUSE/RELAY
BOX
YEVRED
1 5
('99-'00 D16Y7 6)
YEL
GRN/BLK
GFN/BLK
1
GRN/BLK
14
(99-' 00 D16Y718)
GBN/ALK
c433
vtEW41
POSTTTON
swrTcH
c13t
PHOTO A5
vlEw 59
c'|24
,5i *
YEUREO
YEI
I
I
L
BACK"UP
LIGHT SWITCH
Closed with
transmtsston
in revetse.
c124
c131
PHOfO 85
vtEw 59
rl*--?
i
-;;1---'
o I co..
12
('99100 models 16)
GFN/BLK
4
(' 99-' 00 model s 19)
GFN/BLK
c401
c552
r
PHOTO 101
vlEW 42
o
* =i r al e- Femal e
terminals reversed
tor
'99'
00 models
@ i[T,'+'"
-*1
orr<
G
""",Jfi
fiT,,3,*
@|,LHI"'
secround
--l
i'""#'T?!:
t-Ti"...
I
"l9t*,,,
lJJ"''"'
I
I
BLK
ALK
c604
.! c6ol
110- 1
License Lights, Parking Lights, and Taillights
-
Coupe, Sedan, and Hatchback
I
I rusecs
I
Li5:_i
"^1,1fr!;?'
ar r *
HI
UNDER.DASH
FUSE/RELAY
BOX
UNDER.HOOO
FUSE/RELAY
BOX
go
Powr
Dlstrbutiofl,
page 101?.
B1
Y
FED/GFN ll -- -
:t!
- - - '--:gsg-l
3totur['JY3;tttu
vehicres pre'wired tor
: -i : : -- - - -.
c; A
(oPrroN)
ceucssu' Yi r
neoionlr lf C422
|
Ptloro 56
I
PHorc 58
7 A, vtEw t6
-)' 56. Hsadlqht
I
FUsEsr lYi-"'l;-.
I
: ] % r opnor . r t
cLl Essv' v . evu" r t Jt Jr e" '
ru9c ltz
DaO 10$1.
uclrlaEtlclllS
-
ta{- uotfls
7.lla
c927
13
Y
Cssl
oPTfoN I ltlglo
63
clNl.rEcroR
I
-" "'
t
FEoiEL(
|
I
I
v
To Daoe 110-3
(Al i C6upes and
' 96-
98 Sedans),
or
page 1 10-4 ( 99- 00 Sedans),
or
page 110-5
(Hal chback)
FED/8LK
1
(with cruise 3)
RED/BLI(
GAN/YEI
AED/ELX
'99100
moqels
c202 r
-'!
wiiri
| | xtYess
I I
Entry
I
KEYLESS
'
DOOR
LOCK
:
CONTROL ;
UNIT
RIGHT FRONT
PARKING/TURN
SIGNAL LIGHT
L.-r
/-1M\ LEFT FRONT
f b d I PARKTNGI uRN
\Y,Z
slcNAL LlcHr
' I
see Ground
"*
|
3$l''Tll
I I
l.?'J
! czoz
-
PHOfa 19
110-2
\
-
Al l Coupes and' 96-' 98 Sedans
1'so'sa
s"o"n" "*cept 491!]
('99-'00 models except GX l8)
* =Mal e- Femal e
terminals reversed
RED/BLK
c605
RI GHT
LI CENSE
PLATE
LI GHT
2 ^
@
LEFT
LICENSE
PLATE
LI GHT
2 ^
@
".,,*-fJr
RIGHT
OUTER
BRAKE
LIGHT/
TAILLIGHT
See Brake
Lights
r:d
*.-*L=t BLK
RIGHT
INNER
BRAKE
LIGHT/
TAILLIGHT
See Ground
Oistribution,
page 14-10.
c517
c613
PHOTO 115
c604
See Brake
:rd
ALK
INNER
BRAKE
LIGHT/
TAILLIGHT
o
V
l-
AlK
1
BLK
See Ground
Di6tribution,
page
1410.
Y
erx I
-l
Seo Ground
D istribution,
page 14-10.
c613
LEFT
OUTER
BRAKE
LIGHT/
TAIL.
LIGHT
4
BLK
C60s
4
BLK
c604
Se Ground
Distribution,
page 14-10.
I
From page 110-2.
ryI
erx I
.-
G60l
110- 3
License Lights, Parking Lights, and Taillights
(cont'd)
From page 110-2.
CBtl^lvl{t
3
- '99-'00
Sedans
c562
vtEw 42
FEO/BLK
1 8
(GX 5)
REO/BLK
See Brake
Lights
RIGHT
BRAKE
LIGHT/
OUTER
TAILLIGHT
RI GHT
LICENSE
PLATE
LIGHT
1 l
@
z Y
LEFT
LICENSE
PLATE
LIGHT
1 l
@
z Y
LEFT
BRAKE
LIGHT/
OUTER
TAIL.
LIGHT
RIGHT
INNEB
TAILLIGHT
LEFT
INNER
TAILLIGHT
2 ^
@
r Y
2 A
@
r Y
110- 4
-
Hatchback
\
* =l \ 4al e- Femal e
terminals reversed
l or' 99-' 00 model s
('99r00
FEO/ALK
RED/BI-K
c604
FED/BLK
2
RED/BLX
c607
PHO|O 112
REO/BLI(
5
RED/BLK
RI GHT
LI CENSE
PLATE
lx
@
itI
" l
--
I
F"al,,,
-1
PHoro 132
:
(98100 modets)
:!
".","*[ ""-.*":"::*l
"-_[
__[1-.EbkN,*_."0",.,,ffi
**"3
r'il'''"'
T
fl.flthf
.t#:." "".fl
-.
"*
| "*u,.,,,1
-i*-T:l-J
Se Cround
Dislribution,
pags 14-12,
Y
I
c605
PHOTO 118
vlEw a
2
c608
G601
I
See
Brake
Lights
110- 5
Turn Signal and Hazard Warning Lights
-
Al l except' 99-' 00 Sedans
c411
PHOTO 60
vlEw 60
1 5
5
see u
Lights
T
*x ll
_1
55
L
tBl FED/BLX
I
c501
vtEw 5!
I
L
FED/B
Dash
UNDER.
OASH
FUSE/
BELAY
BOX
HAZARD
WARNI NG
swtTcH
vtEw 32
See Ground
D$tribution,
page l4-7.
- - - - J
See Ground Distribution,
wge
14-7.
GAN/OFN
GAUGE
ASSEMBLY
Indicators
L- - - - - - - i
82
ALK
I
I ffi"ufi:I'oo
I t
t l
L___l
#
:
G401
PHOfO 5/
TUHII
SIGNAU
HAZARD
REI-AV
?nofo
g
:n-
PHOfO 57
l:r---
-";;r";;;------"-.";:l[-;.:r
?EEi *,.:ffi
-l
t """."1
.V
_]z_"*.-l
le?.:*"
To under-dash
GFN RED
|
-".r"-.'Frl*-?il,
I
5iiil3"J:Ui*
., L
ReravBoxonracinspase4
I
I
I LEFT TURI{
I
FIGHTTURN
I
i @iJ8l$,o" @tSS'* i
3""",n",,
IH TH
l{azAio
U'AN G
SW|TCH
UGHT
110- 6
\
* =l \ 4al e- Femal e
terminals reversed
Tum
Signal
Switch
From Splice or
facing page.
v
i
cnrineo
I
csor
" l"P'li'
?c- -
l
'f
"*f
B""i.Bfii'Jr'l
".^f
I see Gr ouno
ar - < pay6! , , - , v
>- r a
'|
Tt""""i*l}=J'..""."'.*i{{?;:*
k::
*-i;,
f#::*=i
COMBINATION
LIGHT
swtTcH
c423
vtEw 3
From Splice on
facing page.
v
il
o"nntt
|
"uo,
n I',tr[T?'*
UNDER. DASH
I
I
/7-T\
LEFr FRoNr
/A
LEFr REAR
./A
nrcxr nean
I
p q
I PARKI NG/ TURN I l e I TURNSI GNAL I b I TURNSI GNAL
\:9./
srcNAL LrcHr
\!r/
uorr
\tr ,/
LrcHr
Y 2
See Ground erx I
Distnbution, I
pages 14-10
>-rO
and 14-12. I
"'-
I
3:"":ix'5:
"'iI
."oo
and 1+12
"I
I ."n.
aLK
I
FUSE/RELAY
iF,?|",,
c421
vtEw50
\
-----'if,
u';%-
l-t?'o'
10
o""n. .
I
u' t * o'
cFN, yEL
, o l
('ee- oo moders except Cliti
I
{96j 98 Sedans excepl GX 16}
A C562.
l
---- -'f,
t:;?,''
o"n,^r..
I
.BN'YEL
c6o4 ,
1..0.
'iftr",'::"""^,,,
i
"^1,T?l:i""."".
Onrl,rer-
|
l 1
L.t
I
ru
Y
Lx%",
s""1,
15
o"n,
I
u't" uo
GRNTRED
*"1
"
l
riqrk"
1,so-,sa
seoans111
ru
| aEo/BLK .""
o"n'"]
,lrtrufli'""""
c201
vtEw 30
FED/BLX
See
Parking
Lights
!t
c2o2
4
c6ol
-
PHOTO 19
-
PHA|A 1A2
PHOIO 173 (Halchback)
110-7
Turn Signal and Hazard Warning Lights
- '99-'00
Sedans
@
i-f;.;l
H33'""
i ) i r - i l Et Ff
LJL- - - J
Box
3 Y c352
PHoro 7
vlEw 27
c411
PHOfO @
vlEw 60
I UNDER.
I
DASH
: FUSE/
tun
SIGIITJ
TOAZARD
RI.AY
psalo
I
I RELAY
I
BOX
i PHO|O 58
Se Ground Disldbution,
pag l4-7.
- - - - - - - - J
c501
S Ground
Distih.dion,
pag 14-7.
vtEw 55
s2
ALK
Se
g.ound
Dist$bution,
pag t4-7,
HAZARD
WARNING
swtTcH
vtEw 32
'--{
To Underdash
Fuse/Relay Box
on this page.
See
Gauggs,
lndicato.s
L- - - - -
GAUGE
ASSEMBLY
I
I ff;f#looo
l l
L___l
+
:
G401
PHOfO 57
""k
PHO|O 57
1 10- 8
\
COMBINATION
LIGHT
swrTcH
ytEW
64
Tum
Signal
Swltctl
A2
From Splice on
facing page.
v
i
cazs
o"nttt
I
csor
';l:J?'"
" l'El?,*
{
GRN/FED
60
6
UNDER-DASH
I
IFUSE/RELAY
i
Box
I
I
ffi
**;r',''-"'
"
"'J- *..
1
t*?'1,"
r z l
I
-or{n9"' ,,
' *t?%,,
; v1Fw4' i l
! / f wJo
- t -- | REo al K see
cFNYEL
I
GFNYEL
I l_<
i,tlll,
I t t
2x ' r - l f
7\
nrcxr nean
/-T\
RrcHr FRoNr
I b I TURNSI GNAL I | o
q
I PARKI NGi TURN
\U/
LrcHr
\:9,/
srcNAL LrcHr
' r ' r
t t
""1 I
g:"',gn*l
*
I
"'*
I
Pase
144
I t I
-l
V?'t
+ 9ao-1
L-J---11J.gs-l ---
!-
c2o2
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c6o1
-
e4of o , 9
-
Phat a t t 3
PHA|A 142
(GX)
' I
t I
seecr ound
I
8:":'Bn#
I
3:lj:i"lll:
""
|
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*1..--I
V-'
"' *f-
16
Y C421
(Not
Used) 15
"*:
[
;'m::'
.FN'BED
t
l
g,a%,,
ro*'lr
i
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GFNTRED
c""
I
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"'o
I F<
lffli:'
,tr_{ 2
/-T\
LEFr FRoNr
fi
lerrneaa
I Io
l
I PARKING/TURN I 15 | TURN SIGNAL
\l=E: /
srcNALLrcHr
\U,/
LrcHr
I
110- 9
Fog Lights
_
Vehicles pre'wired
for accessory
security system
SECURITY SYSTEM
CONNECTOR
(oPT|ON)
"!'19*13*
u,.*,"
a
c403
----.t
COMB| NAT| ON
:
swrrcH
I
PHOI OT2
lvtEw
u
I
I
FOG LIGHT
IN-LINE FUSE
FUSF
I H,'l
t.cw 8l
laa
BLKI
.--<
t_G2O2
gee
Ground
Distribution,
pag 144.
i t-' BsJ:?'tr!
li[?i,i'*'
L J - - - - - - J
_ _tlI',-Yfi::"*
*,*,,
a ,
\ ot'
tttr(
- - - g- - - - - J _ - -"il( -
see Hdbnt
;eo'q;r.
I-)
oaoe loo.
See Headlights '
(Canada)
l-l
1
aeomnr
k-j'/,-d
l 1 5 l
lJ
- -
oplronal Fog Light swttch Harness
- - -
.I
UNOER.DASH
I
FUSE/RELAY
FUSE2l I
BOx
R H/r- i
PHoro 5e
rrow BEA

I
---!':--J
--1frf':l,"
i::.,.n.*
BEo,naHT
I !7
*':#i,!J
^ L - - 8 -
i33o,,nno
t
f-
"-'-:E+
1 10- 10
- - - - .
Optional Fog Light Switch Harness
oFF
a-a
oN
FOG LIGHT ON
INDICATOR
LI GHT
SWITCH
'
BLU/REO
BLU/REO
c408
PHOTO 66
- - _ _ - - t
c201
VEW 3A
c207
::-*frt*,
ii
@r'ali
li
\
i
"Ttrr*,
".-
.:jlr*.,
ar-x
I
---+
narness
110- 11
Headl i ghts
-
Coupe and Sedan
Vehicles pre-wired
- - -
for accessory
security system
5 f | C419
PHQ| O63 vt EW4s
UNDER-HOOD
| /
FUSE 48
|
FUSE/RELAY
: \
HEADLTGHT
: BOX
I I
3oa
I
pHoroT
L J - - - - J
I
Y
C3s2
wHrl PYo-rg8- ulEY:?-
- - - - -
canada
WHT
Head-
ligtrt
Swlich
COMBI NATI ON
LIGHT
swrTcH
".;L
L- - { . . - - -
1
Y
Cs01
".o,o"n
I
i[?,lo,uo
^..?fiurti
ce.l,
*i;[fl?i
ve
/a V|EW z1
i--r------' ' i
/A
xrcx
geru
;".1p$31"f'"" I n o F Y ; ] j : : : - :
T_l Eqr
I
- - g - - - - - - J
RIGHT
HEADLIGHT
lL
r
-
:
G401
PHOTO 57
See Ground
Distdbution,
page 14-4.
Soe Ground
Distribution,
page 14-4.
SECURIry SYSTEM
CONNECTOR
(oPTloN)
i t-'d*ltr! lF"{il'.]'*'
ner o' t t - +- * . oo* j
pinx
I
pl66
HEAo
J
cmx
-
Canada
-
---J4- ----J
See Headl i oht
B1
Y
Swirch,
-.^^--
I#
oao6 100.
FUSE 21
F i/t
IOW AEAM
FUSE 4
B H/L
HIGll BEAM
UNDER.
DASH
FUSE/
RELAY
BOX
1IIGH
110-12
-
Canada
\
-
-
f Pdot o\ i
3 A
vttw.rs
UNDER.DASH
FUSE/RELAY
BOX
DAYTIME
RUNNING
LIGHTS
CONTROL
UNIT
vtEw 66
FUSE 2!
(EUXMtIG
7.5A
c420
vtEw 53
sE 20
xM G Uclfr)
r '
I
I
I
F
r
16
BIKWHT
See Brake
System
Indicator Light
l
cnvneo
I
asl
-il*'*
I Y
L_- J
+
:
G401
PHOTO 57
-
A4
B1
\
BED/GRN
OAYTIME
RUNNI NG
LI GHTS
RESISTOR
Se Ground
Dlstribution,
page 1,1-6.
PARKING
BRAKE
swtTcH
Closed with
parking brake
appl i ed.
H
Ughis-on Sattery
npur
Hoadl8hi cornrol
lgnition
b'rak8 input Ground
Brake sysiem
indicator light
control
FUSE ra
$r,rlxlxs ucl|l RlaY)
7.ta
110- 13
\
Headlights (cont' d)
-
Low Beams
With the headlight switch in HEAD and the dimmer
switch in LO, current tlows through the headlight
switch. fuse 21 . fuse 22. and the low beam
tilaments to ground, and the low beams come on.
High Beams
With the headlight switch in HEAD and the dimmer
switch in Hl, current flows through the headlight
switch, dimmer switch, fuses 4, 5, and the high
beam filaments to ground, and the high beams
come on.
Current also llows through the high beam indicator
light to ground. The high beam indicator comes on
to remind the driver that the high beams are on.
Flash-to-Pass
The flash feature works with the headlight switch in
OFF, PARK, or HEAD (low beams). When you
move
the flash-to-pass switch to ON, current flows
through the switch, fuses 4 and 5, and the high
beam filaments to ground,
and the high beams
flash. The high beam indicator also flashes during
the flash operation. The flash function has no effect
if the high beams are already on
Daytime Running Lights (Canada)
When you turn the ignition to ON (ll) with the
parking
brake released, the daytime running lights
control unit supplies battery voltage at the
WHT/RED wire. This voltage is applied to the high
beam headlights through the daytime running lights
resistor. Each high beam headlight receives less
than battery voltage causing them to come on at
reduced brightness.
lf the parking brake is set, a ground
signal is applied
to the daytime running lights control unit at the
RED/GRN wire. lf the parking
brake is set when you
first turn the ignition switch to ON (ll), the high beam
headlights will remain off until
you
release the
parking brake. Once the high beam headlights are
on, setting the parking
brake will not turn them ofi.
When low or high beam operation is requested,
battery voltage from the headlight switch is applied
to the daytime running light control unit via the RED
wire. The daytime running lights control unit then
turns off the headlights.
for specific tests or lroubleshootrng procedures.
110- 14
Brake Lights
-
Al l Coupes and' 96-' 98 Sedans
tl
UNDER-HOOD
FUSE/RELAY
BOX
? - - - - - - -
i t t!::o i
i ) SrTIr
gee Power
i
I t
154
Distribution,
L--E-]-p3n:"'1--.:
Without Cruise Control
See Power
Distribution,
page 1013.
BNAKE SWITCH
Closed with brake
pedal depressed.
PHOTO 68
8
Y
C3s2
*nrlo."
I i[o"'r?, *"r,o"n
o----a
wHr/GFN
i
With Cruise Control
t
*"r,n*[ ,r"r,o*[
r t 1 BRAKE SWTTCH l-'rt
LQlt'*'*t'**" l4J
n""n",.tr
I
o""*,1,
!
o"*n"",
I
* =Mal e- Femal e
terminals reversed
for
'99-'00
models
GFN/II/HT
1 3
('99100 models except GX 17)
GFN^^/HT
2
('99-'00 models except GX 10)
GFNMHT
c442
ffermi nal s' l
!
-14)
PHO|O 125
vtEw 54
c401
c563
(C562
'99100
models except GX)
*
V|EW 42 GFN,ryVHT
Without
optional spoiler
r-
t
PGM. FI
\
with
optional spoilar GAN/
GFN/
BLK
110- 15
+ 9,6,91o,",
\ a
Brake Lights
- '99100
Sedans
s
Y
c3s2
wHT/cBN
I
Ploroz'
wHrrGRN
o-l.
' _-. _-_: ----
UNDER. HOOD
t -u! E az I ErreE/ oEr Av
I
FUSE/RELAY
xonn,
aToP rr
t6a
Sso Power
Distrlbdlon,
a?,oJ.,
|
?--'-----------t oaoe tG13. I
L- - : t - - - - - - - - - - - - J
Se Power
Oigtribution,
pags
1G13.
wfrr/GBN
i
With Cruise Control
I
!--
$
PGI\,4-FI
Without Cruis Contd
BRAKE SWITCH
Closed with brake
pedal depressed.
PHOTO 8
o"na",
I
--f
(fermtnal s 1' l -' 14)
o""-",
I
ff,o*tuo.
t"
,o*11, I
Fol%'
-
, ,
-
v { w,
GR
{GX 131
I
PrOrO 5/
----
o"n*"t I ll
! tl
wrhout
rn ! n<ac I ootiona
,uil,lg,'"%,,, i
:$ly
*"*",1 if;#,,o1
|
-l-
__""*!m4",;,"'
l|
[
4 ; [
vfith
oplional
spoiter
,.Fr[\ RtcHT BRAKE /t\
rllcH
LE,,
ffL',61g."
\9/ $"'f,iJ
2Y
1Y
LI GHr
S Ground
Dist bution,
page 1+1t .
I
I
I
o
G601
110- 16
!
\
Hatchback
FUSEs2 I
ltOn||.
gTO?
LT
1l a
SBe Power
Dbtribution,
page 1G13.
Se Powor
BRAKE SWITCH
Closd with brake
pedal depressed.
PHOTO 6A
UNDER.HOOD
FUSE/RELAY
BOX
**TT **TI
BRAKE SWITCH I-I-T
Closed w{h brake
| | |
ffid"o'""""0
tld
*-."11
r r . l
. l I
l l - r I
*"*rtrl
"""^,"rf,
\ , ,
r =Mal e- Femal e
termanals reversed
lor
'99-'00
models
c607
c60s
vtEw I
HI GH MOUNT
BRAKE LIGHT
c608
@
".i.I
>-ra
BLK
2
BLK
\
+
g?o'1"'
110- 17
Dash and Consol e Li ghts
! ' - I -
- - - 1UNDER- HooD
| / FUSE
'18
| FUSETRELAY
| )
xeroucrr
l Box
I t . * |
Pl 1o t o
.
L - L - - - J
9
Y
C3s2
wHr
I
etoroa
See
power
arr-
Di st ri but i on.
wnr
I
-
Pagel Gl 2
86 l,
COMBINATION
I
r---F--' t Head
qhr
I
LtcHT
| | \ lswrtch- l"syllgl
| | HE A Da ) OF F r . : : : : : . '
|
|
"' oo\ )-o"
;
1, ; ; 7-a"'
I
L---95-.t
I
L - - - - g - - - - - - - - J
B1
Y
,
sEcuRtw SYSTEM
" . o o " l
[ _ _ _ _ _ _ _ _ - - - j
c o NNEc r o R ( o p T| o N)
; f nED/ ca
3
\ f
C403
- @
. - * - - - -
FED/GRN
II C422
7 A PHofose vlEw 16
-^---:-- --.l
UNDER-DASH
I f;.*--,Tl
333J'"#1nn''"n"n
iFiifiiiLA.v
INSTAUXENT
uGHTs
'
PHoro 58
t *
. , 1
Vehicles pre-wired
for accessory
secunry.sysrem
",o ".*
!
i[o',,Bu' ".o ".*
! !;91o,u,
poj;T;o6}
coNNEcroR
O
"ro ".*
!
"." Jlfr
;1+.,:.,,
"'o "'*
|
"'o ".."
|
"'o "'.*
|
"'"'"''*
|
F$S^ff".t -;t;'t
['jl' ,,
|
"'-'x----lgr-
-:'-l:t:!y!-
*,,,""::,:";illttS,iii',""0","'=ss.oomode's
I if----tg;-;'"t1*-:.1
ll r I I
Poshior
!!
Indicrtor
!i
t HErren t neAren I l .*. 94!r$f.._ l tndtcErol l l
ci rcu!
. .l !
I ;ffiF' I ;ffiF'
n=uu, !
i9d#"iufftl*;1#ff"'
"I
:l:-i!"' oo f
';dio-'" PU'H
ll
r-z-----' ,-.--j ";."..J:l qtT I i l ! !i 8noHt"
iI _:: i
- 7- - - - - 1
r - 4( . - 1 neo l - - - - 1
, . -1. -E ! ! A
i l f r.
!
JL-r--J
.i:i9:'::
i Bnl,r'i
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i
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1l-
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A "o.u
"t' A3 Y ' E1
l " f
I
114
r l r
*=' 96-98
model s
\
c50?
(Ierml nal s 11-16)
PHOTO 51
vtEw 56
DASH LIGHTS
BRIGHTNESS
CONTBOLLER
4
.I
HAZARD
I
WARNING
i
swrTcH
a
vtEw 32
I
I
I
J
3ml
lnput
I
Olm
signal
input
BLK
I
a3)
r;
t ;
l i r
Lr2)
' t 9
( , A
\
1 cRUrsE
I
CoNTROL
i
MAIN
I swrTcH
.l
REAR ;
I wrNDow
,
: DEFOG.
.
I GER :
I
swrrcH ,
STEREO
RADIO
TUNER
c96,'98
models)
vlEW 68
or
AUDIO
UNIT
(99-'00
models)
S Ground
Distributjon,
page 1.{-7.
I
I
I
J
" " [ __
ffermlnals 7-lo)
:
G401
iHorost
P4ofo 57
I
lr
I
I
f
i$
9 Y
114- 1
Cei l i ng Li ght, Trunk Li ght, and Spotl i ghts
LT GRN/ALK
'96.98
USA: CX, DX
'96.[98
Canada: All
'96-'98
USA:
LX, EX, and HX
'98:
GX
'99100:
All except DX
UNIT
"""*f,*u*
iiffiinFll,+l*
Lisi___i
c411
vtEw 6a
- - -
Canadar EX and Si
- - -
' ' "o","."
2
sEcuRl TY
-;,;(
3[t"l'$,o"
C516 (OpTtON)
PHO|O 73
vtEw 58
i
Door open
i
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Lsl__j
[:tf*
" Y
., o"n
I
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.ro"n,r.o
2
g5ggi.tw
?-
coNNECroR
,
I
"';'16 ''u
(ott'o"l
i
I
vtEw 58
- - - - - l -
lt
i
GFNi REo
i
t
IT
GFN/
RED
1 3
LT
GRN/
RED
See Power
Door Locks
irruot
L-T
: i " i i y @o
*
=
'99-'00
models except cX
IT GRN/fiED
LT GFN/AEO
1 1
( - 15)
LT GAN/RED
c401
-
Sedan
-
RIGHT
;
REAR
DOOR
SWITCH
:
Closed with
;
door open. ,
LEFT
REAR
DOOR
swtTcH
Cl osed wi th
door open.
--azt
*'*"n
6 n
LT GRN/FEO
LT GFN/
i
- - - -
;'T
- - - - -
I iig",BP'f;""
ii$fltfi'J$T'*"'=""'
"
L----:+-----Jf
ii
ln*i1,,
""**".!,
q;,{"i};}',,Hgt:$
pHoro
96
-
door o
LT
114-2
\ , f
r =Mal e- Femal e
terminals aeversed
Se Powr
Disfibution,
pag61o-t0.
_J _____ __J
PHot o 58
:I
DASH
FUSE/
RELAY
BOX
20
-",,".'"f
ftTll,'
Hatchback
I Coupe & Sdan
H'**
\ , ,
A sxcept
'9$'98
Sedan
wiliout
Moonroof
c407
(vtEw 2
'95-'98
Sedan
without
Moonroo{
fr
(e6-
lt
lt
I
I
I
Not used
Seo Ground
Distdbution,
pags t+10
ot 1+1' l .
"'"ll
^
BLU/ALK I
in?i"",o."
19
arn""r"aol
:
::.:ix:
qmg
swrTcH
Closed with
trunk open.
c407
(v/Fw2 98r0o modrs)
"il
\
)-rra
"*l
PHOTO 102
LT GAN/EIK or lT GRN/RED
+
114-3
Power Windows
-
Driver's Door and Front Passenger Door
FUSE 24
{s/n
nElav)
Se Powef
Distribution,
page 106.
l' l-'G'-.i
- -
I i',I3.',8J39"
i )
lo1*"
**oo*
i
f,?T" ,
L- 9- - - - - - J
'rF,*%,
*rtier-u
|
'ry'
6I i[ff'3"
PowER !
wtNDow
I
RELAY
PHOfO 6S
see Ground
Distribution,
page 14-7.
I
I
I
\
\
I
D ver'5
Switch
Contrsl
Unlt
POWER
wtNDow
MASTER
swtTcrl
PHATO 88
vlEw 36
I
I
I
(Sedan A4)
8
(Sedan A5)
REO/^YEL
1
FED or aEO/BLU
(Sedan A7)
4
RED/BLU
(Sedan A6)
1 2
ALU
c633
YEL o. REo/YEL LT BLU oT BLU
DRIVER'S
wlNDow
MOTOR
BLK
4
ALK
c633
See Ground
Distribution,
page 14-7.
I
I
I

See Ground Distibution,
page 14.
.---+<
-
G401
PHOIA 57
0
c42O I
Y
C552
ii,?;?,*
"., ".*
!
f[fflo,u,
2
e
C556
".,,".*
|
f[ff11r,
1
(Sedan A3)
l
1 2
G551
\
t
\
7and8
on Jollowing
p490.
liiciio'u
I
I
I
c653
GNN/BLK
1
GRN/ALK
1
c552
vtEw22
c557
PHOIO 93
vtEw 62
\
FRONT
PASSENGER' S
wtNDow
MOTOR
FRONT
PASSENGER' S
wtNDow
swtTcH
lwrNDow
I
MASTER
:
swrTcH
I
PHO|O 88
lvtEw
J6
I
*l]o,,-G
oow{
- UP
C}FF
BLU/YEL
Motor has a sell-resefting
circuit breaker.
7
(Sedan Al )
Frod PasSengsr'a
Swich
Sae Left and Hight
I
Rear Swilches :
----.,:,1":l -,:l --J
\
(cont'd)
| *:""fi:{t
Distribution'
I
- t
"'-!r+J
120-1
Power Windows (cont'd)
-
Rear Doors
BEDAI/IIT BEDAV}IT
c5?r
PtlQTO 99
VIEW 6
LEFT
REAR
wtNDow
swtTcH
LEFT
REAR
wtNDow
MOTOR
Motor has a selt-
resening
circuit breaker
2
YEUGBN
1
Lai Rraar Sfiici
c571
PHOTO
--
c556
vtEw 61
99
z
93
FEOAIVHT GRN,^/EL
10
GRN,^TEL
A14
|
| Sos Front Passonoer's i
-siq-r"a{::l=-.i
qR|i
1 1
GFN
At 6
:I
I 3s"qni'
"-l-'J
il
POWER
wlNDow
MASTEB
SWITCH
vtEw 36
DOWiI
t p
Oisuibdion,
120-2
\
r - - - - - - - - . | U N D E R . D A S H
r I
FUSE/RELAY
, I
r ur
t ' f - , , - - " J
i Fi o n a
\ 5l'.il;;, i -l
l "o^
|
L------- -"f-_-_=--_-=*"Er---,
vtEw 22
c570
PHOfO 99
RIGHT
REAR
wtNDow
MOTOR
Motor has a
self-resetiing
circurt breaker.
BLUMHT
I
or REO nED/BLU
"ru"ao
I
or YEL
2
neo,tea 4
c672
RI GHT
REAR
wtNDow
SWITCH
\ , ,
YEI
I
YEL
A9
POWER
wtNDow
MASTER
SWITCH
vtEw 36
orowt{
ofF
UP
f
' ,
120-3
Power Windows (contd)
-
CAUTION: You could iniure your
arms, hands, or
fingers if you
unintentionally switch the driver' s
window to
"automatic
down" while working in
that door with the
power
on. Disconnect the
window switch conneclot or the battery when
working in the driver's door.
System Description
The operation of the power windows is controlled by
the main switch in the power window master switch.
When the main switch is in OFF, only the driver's door
window can be opened or closed. With the main
switch ON, all windows can be ooened or closed
either by swtches in the master panel,
or swttches in
the doors. The driver's window switch also has an
automatic down mode which is tumed on by
pushing
the switch down to its second oosition.
The power windows are driven by reversible motors.
Each motor is protectd
by a built-in circuit breaker.
lf the window switch is held on too long (with the
window obstructed, or after the window is fully up or
down), the circuit breaker opens the circuit. The
circuit breaker resets automaticallv as it cools.
Driver's Window
With the ignition switch in ON, voltage is provided
to
the coil of the power window relay through fus 24.
The contacts of the power window relay close, and
voltage is applied to the driver's switch. When you
push the power window master switch to UP, voltage
is applied to the driver's window motor. (The motor's
ground path is back through the master power
window switch.) The driver's window motor then
drives the window up. When you push
the switch to
DOWN, voltage is applied in the opposite direction
and the motor drives the window down.
Automatic Down (Driver's Window)
With the ignition switch in ON or START, voltage is
applied to the coil of the power window relay. The
contacts of the power window relay close and
voltage is applied lo the power window master
switch. When you push
the driveas switch to the
AUTO DOWN position, voltage is applied through
the driver' s switch to the driver' s window motor. The
control unit receives pulses at the pulser
input while
the motor is running. When the window is fully
down, the motor stops, and pulses
are no longer
generated by the pulser. This is sensed by the
control unit at the pulser input, and voltage is no
longer applied to the driver' s window motor.
Passenger Windows
With the ignition switch in ON, voltage is applied to
the coil of the
power
window relay through fuse 24.
The contacts of the power
window relay then close,
applying voltage to the individual window switches
and the power window master switch. With the
master panel
main switch ON, the passenger
windows can be ooerated from the individual
window switches or from tho master panel
switches.
When you push the front passengsr's
window
switch to UP, voltage is applied to the f ront
passenger's
window motor. (The motor is grounded
through the contacts in the front passenger's
window switch and the oower window master
switch.) The window moves up as long as you hold
the switch in the UP
position.
lf you push the switch
to DOWN, voltage is applied in th opposite
direction to the front passenger's window motor, and
the window movss down as long as you hold the
switch in the DOWN Dosition. The window switches
in the other doors operate similarly.
When you push
the front passenger's switch in the
master panel to UP, voltage is applied through the
front passenger's
window switch contacts to the
front passengefs window motor. (The motor is
grounded through the contacts in the front
passenger's window switch and the
power
window
master switch.) The window moves up as long as
you hold the switch in the UP position. lf you push
the switch to DOWN, voltage is applied in the
opposite direction to lhe front passenger's
window
motor, and the window moves down as long as
you
hold the switch in the DOWN position. The other
passenger window switches in the master
panel
operate similarly.
120-4
Moonroof
' 96-' 97
Model s
@
---1
UNDER.DASH
FUSE 24
(PAV AELAY}
(slF FEraY)
GFN/OFN
i-tffil**l
ii3-.',BJi9g"
I J lff' liffio,
L- * - - - - - - J
9 Y C3s1
""tio"nr
! ffo"tfl,
I
wxt cnl
See Power
OF' Dr$nouton.
wHr cRN

C4l 9
Page
10-12.
B lii:;?"u'
l.-F'I
UNDER.DASH
! | |
ruserneuv
I
|
|
"B-gt..
L-*. . J
" "' ' ""
":.,1 Fl:,""*
IFUSE/RELAY
i""3Io,,
MOONROOF
OPEN
RELAY
vtEw 15
- a
__tu
c7' t8
MOONROOF
CLOSE
RELAY
vtEw 13
GFN/BED
'+
To A on this
page.
2
veL
GFN/FEO
c717
PHOTO 107
1
MOONROOF
MOTOR
OPEN/
CLOSE
swtTcH
TILT/
CLOSE
swtTcH
MOONROOF
swtTcH
2
BLU
2
Se Ground
Distributiofl,
page 14-7.
OPEN crosE TILT
122
'98-'00
Models
@
\
I
I
I
I
---1
UNDER.DASH
c7' 12
PHOfO s8
trr-ii--'lH$3.'A.|39"
ffi**'iF,?T",
- - - - - J
MOONROOF
OPEN
RELAY
MOONROOF
closE
RELAY
PHO|O 51
vtEw 13
I
Y
C3s1
""t,cntr
! fflo"tL'
I
wrricnl
So Powsr
a->
DsrrDul'on
wuicnr ll
C419
't"
l',i'!,11"*
pag
t&12.
UTIDER.DASH
FUSE/RELAY
BOX
PHOTO 58
,al ,cl:,z,,
- a
_iu
\ l r
-
4 s
To splice on
tnrs page.
c717
c718
OPEN/
CLOSE
swrTcH
TILT/
CLOSE
swficH
MOONROOF
swtrcH
2
9LU
c7t 8
o*ir CLOAE
lltl
Sa Grolx|d
Distribution,
pag
1+7-
122-1
Moonroof
(cont' d)
-
Moonroof Open
When
you push the moonroof switch to the OPEN
position, the moonroof open switch applies ground
to the moonroof
"open"
relay through the YEL wire.
The moonroof
"open"
relay applies battery voltage
to the moonroof motor through the GRN/RED wire.
The moonroof
"close"
relay supplies ground to the
moonroof motor through its normally closed relay
conlacls. When the moonroof moves out of the fully
closed oosition. the tilvclose switch moves to the
OPEN
position; the open/close switch moves to the
OPEN oosition.
Moonrool Tilt
When
you push the moonroof switch to the TILT
position, the moonroot tilt switch applies ground to
the moonroof
"close"
relay through the BLU wire,
tilvclose switch and RED wire. The moonroof
"close"
relay applies battery voltage to the
GRNff EL wire to the moonroof motor. The
moonroof
"open"
relay supplies ground to the
contacts. When the moonroof is in the tilt oosition,
the trlvclose switch moves to the TILTED position;
the open/close switch moves to the TILTED
Dosition.
Moonroof Close trom the Open Position
When you push the moonroof switch to the CLOSE
position, the moonroof
"close"
switch applies ground
to the moonroof
"close"
relay through the YEURED
wire, tilvclose switch and GRN/RED.wire. The
moonroof
"close"
relay applies battery voltage to the
GRNI/EL wire to the moonroof motor. The
moonroof
"open"
relay suppfies ground to the
contacts. When the moonroof is fully closed, the
tilvclose switch moves to the closed position; the
open/close switch moves to the CLOSED
position.
122-2
Moonroot Close from the Tilt Position
When
you push
the moonroof switch to the CLOSE
posilion,
the moonroof
"open"
switch applies
ground
to the moonroof
"close"
relay through the YEURED
wire, open/close switch and moonroof
"open"
relay.
The moonroof
"open"
relay applies battery voltage to
the moonroof motor through the GRN/RED wire. The
moonroof
"close"
relay supplies
ground to the
contacts. When the moonroof is fully closed, the
tilvclose switch moves to the closed oosition and the
open/close switch moves to the CLOSED
position.
Power Door Locks
-
All Models Without Keyless Entry
G551
[ t . dE-l =
- ---- --: [
l ' ! f i : i -
" . " , . 1
l ' !
l - - - - - - - -
r
I
li I I
*"I!'k------#-r*.*rq;,pft?is,,,flr::fi
|
:
I I
c"u,',", i c"",o"" i
21
i
cs03
security'
I i"x[v*fl
i$k------+-----=#f;ffi
svseni
I i t I
ou*."jJ*"'l
'** '"*J"l
^,,**0, #'#[""j,%
i
I i ! I
&H'E5o
I
,ig^* d$n*
|
.e&.s8usA
usA
;
'o'"rto
i
t , I i
lrr!
-"ll'**n*ru;X,*#",XHm,
i
l i l I
|
: . - - ! - - - i
| .L-J
iiriioflil",
iffffliii
F$fl,H"-
itJ !F$$,i$",
i
I l-T;1-li"3g5"=
iioriibl-r'-"
1 iffi !
I lunr.ocx I rccK IswrrcH
: Lunl----i L!flJ
I l"' *^1
*-l-
-
i
sreREo RADro srEREo RADro
t --t , ,---
",r*-
:
UNDER.HOOD
FUSE/RELAY
BOX
i--r?Grs;-'i
r
\ oooF Locx
I
L__{g:":l
9
Y
C3sl
'n',o"n
I
iE?Loo'
I see Power
Il Distribution.
I ^r â l l r - i ,
"*,:TI
Bdt6ry
npur
Unlock Lock
Ground
input input
130
' =' 99-' 00
model s
\ l r
POWER
oooR LocK
CONTROL UNIT
PHOfO90
vtEw37
UnlocU
Lock lock
Unlock
input control
ot lput
Lock
ourpur
YEUBED
1
YEUFED
\ r r
c557
PHO|Q93
vlEw 62
c654
FRONT
.
PASSENGER'S '
DOOR LOCK
, 6
ACTUATOR
vlEW 6
c664
DooR LocK
i
ACTUATOR ,
DOOR
KEY
4
BLU/
WHT/RED
cA14
iu-o16ez
wHT/
FEO
DRIVER' S
DOOR
4
LOCK
ACTUATOR
c634 FED
LEFT REAR
.
DOOR LOCK
ACTUATOR
PHA|O 95 WHT/
REO
WHT/FEO
FED
I
YEL/
c654
PHO|A 92
1
YEUBED
c67 4
c570
vlEW 5
YEURED
BLK
BLK
WHT/BEO
,
WHT/FED
I
wHT/REo
c664
c571
\
;ffi
130- 1
Power Door Locks
- '96-'98
Models With Keyless Entry
(NotUsed)
c562
(Ssdan 5)
lOY,laE
ntcalYatr
t oil
See
Cei l i ng
"*. I
PHaTo 611
""#!
__ It
See
norns
,J:l
ffi
!l*1' *
Rf,Ltr: a ?'*
seePower
IU6il'
il"d!rui'
i.^h::Eii:,_J"'"'ou
t
12
't(
9_s!-1 .
",.*.*,.
1
".*..1
i#??'o
sYsrEM coNNEcroR (oPTroN)
-?
1 UNDER-
FUAE 14
I t
rusE r4
: \ Grul8E COirIFOL)
I / 0(Enr38)
See Power
i ?
7.1
c.. o.
Di8tributlon. ! | X;i*:
I
DASH
I
FUSE/
I RELAY
STEREO RADIO
TUNER
PHOTO 73
vlEW 68
cs03
css6
;f,;z3,'9,*
-
14n 22
BLU/
N
WHT/
II
YEU
WHTI ALK I ALU
B1 1 l ' B1 2 l . B1 3
'I
tF;?,'
-xlru
c5l 6
86 |' 83
''tl
*, **
t"
[ro**:"[fi*'
""i,
;: I
;"il"."'Y'
o-ft
3[tnlt$ro"
Fi:a
I "*
|
F,%',3,,
(o"''on)
ir?rt,:*,"."
I """,,":
See lgnition
Key Reminder
door ooen.
'
pHoro
s7 .
- - - - - - - S a . l a n -
f - |
csre
iofiib$'-"
"c,s;rg,_
!
'
| !
"*
I
"i3tr9""
'LU,RED
I
GnNioR,.
!=4 ,.
L----- --,1"n,,' .
-' -l i
i*-i---- ll}gii I
*,*"1
I r7r------' t TNTEGMTED I RELAY I I
r r l l l , l
.I
INTECru$ED I RELAY
| *
s
|
cotlrRol
lBox
LJaBIEIIL i9,Fis,"
ieHo'osa
BLU/HEO
2
Btu/,|\mr
C415 STEERING
PHOTO 60 LOCK
I
I
I
BLUAIIXT
Hffirp;,ruml*-*i E;ffi*,ru
4
ALK
- - - - - - J
c415
YtEw 14
sss G,g{rnd
arr< Olstrlhdion,
RI GHT
REAR
DOOR
swrTcH
Closed with
door open.
""L___J
G401
130-2
r l
l t ,
I
vevneo
I
veuneo
. 1
I
YEUFED
UNDER-
HOOD
FUSE/
RELAY
BOX
i-iffiri
""',;Xftf*',I.'
c557
vtEw 62
c654
FRONT
;l
I
see Power
i
Distribution.
I
**t"t:.""."
I
------*-,7
O E
n"r,n"n
I
il.",":['
".,"-fifiT""'
I
-:iii[::f
PASSENGER' S
DOOR LOCK
ACTUATOR
c554
c557
. VIEW 62
cs56
vtEw61
WHT/REO
POWER
DOOR
LOCK
CONTROL
UNIT
GRN/OBN
t u
GFI{/OBN
:
GRN/OFN
ALUAViIT
DOOR
KEY
4
BLUAVHT
c556
PHOfO93
vtEw 61
BLU/NED
c634
92 YEURED
DRIVER' S
DOOR
LOCK
ACTUATOR
DOOR
LOCK
KNOB
DRIVER' S
DOOR LOCK
swlTcH
WHT/FED
1
I
BLK
22
BLK
I -
c556
vtEw61
BLK
YEUFEO
=__-
,
YEUFEO
c5zo
:
s
PHO|O 99
,
VIEW 5
-
YEUFEO
C674
'
1
PHO|O95
PHOTO 95
I
WHI/REO
C674
PHOTO9s
I WHT/FED
c570
PHOTO
gg
vtEw 5
. _ryHi/!E9
ACTUATOR
.-.:
PHO|O 95
FED
c664 2
PHA|A9S
wxf/FED
c571 2
VIEW6 WHT/BEO
Driver'sdoor Battry
unlock input input
Unlock Lock
anput input
Unlock/loc*
ouIpur
Ground
Unlock/lock
Lock output
input
[-:I
l_l
t fl!@K locx
eLxlrat-{
3'i#i:T:'
!- cssr
Il
r
Ss Ground
130-3
Power Door Locks (cont'd)
-
Keyless Entry System
The keyless door locks combine the
power
door
locks with a remote keyJob transmitter. The keyless
receiver unit is part of the radio. The keyless
receiver unit receives direct inputs f rom the ignition
key switch, the
passenger door switches, and an
indirect input trom the driver' s door switch through
the integrated control unit.
Power Door Locks (With or Wlthout Keyless)
The
power
door lock system is made up of the
oower door lock control unit. driver' s door lock
switch, and individual door lock actuators. The
power
door locks are controlled by the driver's door
lock switch and the driver's door lock actuator
switch.
Transmitter (With Keyless Entry)
The transmitter sends coded radio wave signals to
the keyless receiver unit when one ot its buttons is
pressed. Each transmitter has a unique code that
must be
'laught"
to the keyless receiver unit before
it can operate the door locks or any other lunction.
Up to 4 transmitters can be
programmed to operate
the keyless door locks.
Door Locking (With or without Keyless Entry)
When
you push the driver's door lock switch to the
lock
position, ground is applied to the GBN/IVHT
wire to the oower door lock control unit. The control
unit then applies battery voltage to the WHT/RED
wire and
ground to the YEURED wire. The
passenger door lock actuators then activate to lock
the corresponding door locks.
When you lock the driver's door with the key or door
lock knob, it is mechanically locked, and the driver' s
door lock actuator switch applies
ground to the
oower door lock control unit. The control unit then
applies battery voltage to the WHT/RED wire and
ground to the YEURED wire, activating the
passenger door lock actuators which lock the doors.
Dool Locking with Transmitter
When
you press the LOCK button on the remote
transmitter, the
power door lock control unit applies
battery voltage to the WHT/RED wire and ground to
the YEURED wire. The
passenger
door lock
actuators then activate and lock the doors. A ground
slgnal is also applied to the BLU/RED wire to lock
the driver's door. lf any door is open,
you cannot lock
it using the remote transmitter.
Door Unlocking
(With or Without Keyless Entry)
When you push the driver' s
power
door lock switch
to the unlock
position, ground is applied to the
GRN/ORN wire to the power door lock control unit.
The control unit then applies battery voltage to the
YEURED and BLU/RED wires and
ground to the
WHT/RED wire. The door lock actuators then
activate to unlock the doors.
When
you
unlock the driver' s door with the key or
the door lock knob, it is mechanically unlocked; the
other doors do not unlock.
Door Unlocking (With Transmltter)
When
you press the UNLOCK button on lhe remote
transmitter once. the
power
door lock control unit
ground to the BLU/RED wire to unlock the driver's
door. When you press the UNLOCK button twice,
the control unit then applies
ground to the YEURED
wires to activate the
passenger door locks. lf you do
not open a door within 30 seconds after unlocking
the doors with the transmitter, the doors
automatically relock.
Transmltter Programming
1 . Turn the ignition switch ON (ll).
2. Press and hold the Valet-Disarm button on the
radio
(between the AM/FM button and the
CD/TAPE button) to enter the programming
mode. (Continue to hold the button during the
procedure, or
programming will be cancelled.)
Check that the
power door locks cycle to confirm
that you're in the programming mode.
3. Press the
"LOCK'
or
"UNLOCK'
button on the
transmitter. Check that the
power door locks
cycle to confirm that the code was accepted.
4. Press the
"LOCK"
or
"UNLOCK"
button on each
of the remaining transmitters.
(You can
program
up to four transmitters
per
vehicle.)
5. After all the transmitters have been
programmed, release lhe Valet-Disarm button to
exit the programming mode.
Beep On/Oft Feature
'I
. Press and hold the LOCK and OPTION buttons
on the transmitter.
2. Watch the transmitter's LED:
One flash: Beeo activated.
Two tlashes: Beeo deactivated.
130-4
Keyless Receiver Unit Troubleshooting
lf a faulty keyless receiver unit has one of the symptoms below, turn to the
page listed and follow the
appropriate troubleshooting procedure. lf the symptom seems related to an input problem, or is not covered
by the troubleshooting procedures,
do the Input Tests on
page
130-6. Refer to the circuit schematic on pages
1 30-2 and 130-3 as needed.
Symptom Index
Keyless Entry Does Not Work In Any Mode
Ceiling Light Does Not Come On When The Doors Are Unlocked
Wi t hTheTransmi t t er . . . .
Doors Do Not Unlock Or Lock With The Transmitter . . . .
Horn Does Not Sound With The Transmitter
"Beeo"
Feature On
Hor n Does Not St op Soundi ng . . . . . . .
Input Tests
Page 130-8
Page 130-9
Page 130-1 0
Page 130-11
Page 130-11
Page 130-11
Page 130-6
.1,
Power Door Locks
(cont'd)
Keyless Receiver Unit Input Test
The following tests are pertormed with A (Main) and B (Keyless) disconnected from the audio unit.
Terminal
No.
Wire
Color
Test Conditlon Test: Desired Rasult Possible Cause it resull is not obtained
4 WHT/BLU Under al l condi ti ons
Check for vollage to ground:
There should bs battery
voltage.
a Blown No. 47 (7.5A) tuse in the
under-hood fuss/relay box
An open in the wire o
5 YEURED lgnition switch ACC (l)
Check lor voltage to ground:
Thre should be battery
voltage.
a Bl own No. 28 (10A) fuse i n the
underdash fusg/relay box
An open in the wire a
Terminal
No.
Wire
Col or
Test Condiiion Test: Desired Result Possible Cause if rssult i3 not obtalned
BLU/RED
lgnition key inserted
into the ignition key
switch
Check for voltage to ground:
There shoul d bs 1 V or l ess.
a
Poor ground (G401, G402)
Faulty ignition key switch
An open in the wire
Short in the wire
a
a
a
lgnition key rmoved
trom the i gni ti on key
switch
3 BLUI/EL Under al l condi ti ons
Check for continuity between
the audio unit 16P connector
No- 3 terminal and power door
l ock control uni t 12P connsctor
No. 6 termi nal : There shoul d
be continuity.
I An open i n the wi re
6 BLK/YEL l gni ti on swi tch ON (l l )
Thers should be battery
vollage.
.
Bl own No. 14
(7.5A)
fuse i n the
. An open i n the wi re
8
LT GRN/
BLK
Cei l j ng l i ght swi tch i n
"mi ddl e
posi ti on"
Connect to ground: The cei l i ng
a Blown No. 43 (7.5A) fuse in the
undsr-hood fuse/relay box
Bl own cei l i ng l i ght bul b
Faul ty cei l i ng l i ght
a
a
o
1 4
LT GRN/
RED
Each door oponed,
one at a ti me
Check for continuity to ground:
There should be continuity.
a Faulty door switch
An open i n l he wi re a
t c BLK Under al l condi ti ons
Check for continuity to ground:
There should b continuity.
a Poor ground (G401, G402)
An open i n the wi re a
16 GRY Under al l condi ti ons
Connct to ground:
Horn shoul d sound.
.
Bl own No.52 (15A) fuse i n the
under-hood tuse/relay box
. Faulty horn
. Faulty horn relay
130-6
\
The following tests are
performed
with A (Main) reconnected to the audio unit.
B
\
Termi nal
No.
Wire
Col or
Test Condi l i on Test: Desired Result Possible Cause it result is not obtained
9 GRN/ORN
swi tch i n UNLOCK
Check tor voltage to ground:
There shoul d be l V or l ess.
o Poor ground (G551)
.
Faulty driver's door lock switch
.
.
Short i n the wi re
Dri ver door l ock
swi tch i n LOCK
1 0 GRN/vvHT
swi tch i n UNLOCK
r
Poor ground (G551)
.
Faulty driver's door lock switch
o An open i n the wi re
o Short in the wire
Driver's door lock
switch in LOCK
\
130-7
Power Door Locks
(cont'd)
Keyless Entry Does Not Work In Any
Mode
NOTE: Before beginning, verify that all the
transmitters are
programmed to the vehicle.
1 . Does the radio work
properly?
Yes
-
Go to step 9.
No
-
Go to the neld step.
NOTE: For steos 2
-
8. refer to the schematic dia-
gram for the Stereo Sound System on
page 150.
2. Are fuses 28 (in the under-dash fuse box) and
fuse 47 (in the under-hood fuse box) OK?
Yes
-
Go to step 4.
No
-
Replace the blown fuse, then go to the
nen steo.
3. Does the fuse blow again?
Yes
-
Locate and repair the short.
No- Retest the system.
4. ls the vehicle equipped with the optional security
system?
Yes
-
Go to the next steP.
No
-
Go to steD 6.
5. Does the keyless entry work correctly when the
security control unit connector is disconnected?
Yes
-
Faulty security system, go to security
system for f urther troubleshooting.
No
-
Go to the next step.
6. ls there battery voltage at terminal 4 of the radio
main harness connector
(A)?
7.
= A
Yes
-
Go to the nen step.
No
-
Locate the open in the wiring between
tuse 47 and the radio.
ls there battery voltage at terminal 5 of the radio
main harness connector
(A), when the ignition
switch is in the ACC (l) or ON (ll) position?
Yes
-
No
-
fuse 28 and the radio.
130-8
8. ls there continuity from terminal 14 of the radio
main harness connector (A) to ground?
Yes
-
Replace the radio.
No
-
Repair the open in the wiring between the
radio and the
ground (G501).
9. Does the transmitter LED come on when any ot
the buttons are oressed?
Yes
-
Go to steo 12.
No
-
Go to the next steo.
'10.ls
the transmitter battery installed with the
positive side facing up?
Yes
-
Ensure that the battery contact tabs are
repositioned, then replace the battery.
Remove the key from the ignition, then
close the doors and trunk. Press the
LOCK button on the transmitter six times,
then
go to the next step.
No
-
Ensure that the baftery contact tabs are
repositioned, then reinstall the batlery
correctly. Then reprogram the transmitter
and retest it. Use the
procedure on
page
1 30-4 f or transmitter
programming.
11 . Does the transmitter LED come on when any of
Yes
-
No
-
Replace the transmitter and program it by
using the
procedure on page 130-4.
12.Does the system work properly in all modes?
Yes
-
Finished. The system is OK.
No
-
Go to the next steD.
\ , 1
13. Recheck with a known good transmitler
reprogrammed to the vehicle. Does the system
work properly
in all modes?
Yes
-
Replace the transmitter and program it by
using the procedure
on
page 130-4.
No
-
ReDlace the radio.
\ l r
\
Ceiling Light Does Not Come On When
The Doors Are Unlocked With The
Transmitter
NOTE: The vehicle must have a tactory radio installed.
1 . ls the ceiling light switch in the center
position?
Yes
-
Go to the nexl steo.
No
-
Reposition the ceiling light switch and
retest.
2. Does the ceiling light come on with the ceiling
light switch in the ON position?
Yes
-
No
-
Repair the ceiling light circuit.
3. Does the transmitter LED come on when anv of
Yes
-
No
-
Check the transmitter battery, then retest.
lf the ceiling light still does not work, go to
the next steD.
4. Recheck with a known good transmitter
work properly in all modes?
Yes
-
Replace the transmitter and
program it by
using the procedure on page 130-4.
No
-
Go to the ne)d steo.
5. With the keyless entry harness connector (B)
disconnected from the radio. run a
jumper
wire
f rom terminal 8 to ground.
Does the ceiling light come on?
Yes
-
Replace the radio.
No
-
Repairthe open in the keyless entry
harness connector {B) terminal 8
(LT
GRN/BLK) wire.
130-9
Power Door Locks (contd)
Doors Do Not Unlock Or Lock With
The Transmitter
1. Do the door' s unlock and lock when usinq the
driver' s door lock switch?
Yes
-
No
-
Repair the power door lock system.
Yes
-
No
-
It lhe doors still do not unlock or lock with
the transmitte( go to the next step.
Recheck with a known good transmitter
work
properly in all modes.
Yes
-
Replace and
program the transmitter,
then retest. Use the procedure
on
page
programming.
No- Got ot he next st ep.
Run a
jumper
wire from terminal I of the keyless
entry harness connector
(B) to ground.
Do the doors unlock?
Yes
-
No
-
Repair the open in the terminal 9
(GRN/ORN)
wire.
130- 10
5. Run a
jumper
wire from terminal 10 ol the
keyless entry harness connector (B) to ground.
Do the doors lock?
ves
-
Go to ttie next steo.
No
-
(GRN/vVHT) wire.
Does the voltage at terminal 1 of the keyless
entry harness connector (B) change from battery
voltage when the key is not in the ignition, to
less than 1 volt when the key is in the ignition?
7.
Yes
-
No
-
Replace the ignition switch or repair the
damaged terminal 1 (BLU/RED) wire.
Does the voltage at terminal 14 of the keyless
(B) change from battery
voltage when all the doors are closed, to less
than 1 volt when any door is opened?
Yes
-
Replace the radio.
No
-
(LT
GRN/RED) wire.
a
Horn Does Not Sound In The Panic
Mode Or With The Transmitter
"Beep"
Feature On
NOTE: The transmitter has a Beep On/Off feature.
Refer to
page 130-4 for how to tum the beep on or
off.
1. Does the horn sound when the HORN button is
oressed?
Yes
-
No
-
Repair the horn circuit.
2. Does the transmittor LED come on when any of
the buttons are
pressed?
Yes
-
No
-
Check the transmitter battery then retest.
ll the beep feature still does not work, go
to the next steo.
3. Recheck with a known
good transmitter
work
properly in all modes?
Yes
-
Replace and
then retest. Use the procedure on page
programming.
No
-
4. With the keyless entry harness connector
(B)
disconnected from the radio, run a.iumper wire
f rom terminal 16 to ground.
Does the horn sound?
Yes
-
Reglace the radio.
No
-
Repair the open in the terminal 16 (GRY)
wire.
\
Horn Does Not Stop Sounding
system?
Yes
-
No
-
Go to step 3.
Dos the horn stop sounding when the security
control unit connector is disconnected?
Yes
-
Replace the security control unit.
No- Go to the next step.
Does the horn stop sounding when the keyless
(B) is disconnected?
Yes
-
Reolace the radio.
No
-
Reoair the hom circuit.
130- 11
Power Door Locks
- '99-'00
Models with Keyless Entry
@
i-f?G;.-----l
i ?f*""t:::", i
L-,H-i{*q-J
UNDER-
DASH
FUSE/
RELAY
BOX
8 Y C419
vtEW49
See
HOrns
15
Horn
control
Grgund
lgnltion
input
Door
open
input
Ky
switch
Inpul
Lighls
tlash
control
1 7
ALK
c447
vtEw 5a
'12
LT GFN/RED
See Ground
Distribution,
page I +6,
Y
I
I
F--.--.r-
G401
I
3
ALU/f,EO
!r.l FN' z
sEcugl w
t5
REO
SYSTEM
tsb'*nii'cro*
=2
a, o"nt"ao
1l
vlEw 58
(Not
(oPTroN)
c447
See Headl i ght
Switch
C415 STEERING
PHora 6a LOCK
VlEtt\/ 14 PHO|O 71
lgntlion Kay
SYrftch
Closed with key
in ignition.
LT GRN/
FED
LT GFN/RED
See lgnition
Key Reminder
UNDER-
DASH
FUSE/
RELAY
BOX
ALU/IVITT
a9
GFN
'14
GRN
130-12
I
YEI/BEO
c57o
,
5
PHOfO 99
V\EW 5
' YEL/BED
c6?4 :
1
PHOfAgs
, YEUFED
I WHT/FED
c674 i z
PHoro 95
i wrvneo
c570
, a
',;f,tr?"n
l-1"1/1.9
I
I
9
WIIT/GRN
f*-.l'il
TryJ
UNDER.
HOOO
FUSE/
RELAY
BOX
c557
vlEw 62
c654
c351
vlEW 31
FRONT
aaa
!
".u".o
!
t
+
See Power
Distribution,
page 1S12.
PASSENGER'S
DOOR LOCK
ACTUATOR
c654
c557
. vtEw 62
' t8
9
GRN/OBN
1
GBN/ONN
1 9
GRN/OFN
KEYLESS
DOOR
LOCK
CONTROL
UNIT
WHT/FED
1 2
c556
vlEw 61
BLU/BED
;;;
oTYEL
BLUAVHT
aLU/'$/HT
4
ALUMHT
(?
***
[J
BLU/FED
' t5
WHT/REO
c634
PHOfa 92
DRIVER' S
oooR
LOCK
ACTUATOR
DRIVER' S
DOOR
LOCK
swtTcH
DOOR
LOCK
KNOB
c634
PHO|A 92
BLK
BLK
"iI-.
l:
cssr
Battsrv Unloclvlock
ingJt
'
otttput
UnlocKlock
outpul
Look Unlock/lock
input output
Unbck Lock
Input input
fff
LJ- T- >J
wrccr I mc.
\ .
130- 13
Power Door Locks (conrd)
-
Keyless Entry System
The keyless door locks combine the
power
door
locks with a remote key-fob transmitter. The keyless
door lock control unit receives direct inputs from the
ignition key switch, the
passenger
door switches,
and an indirect inDut from the driver' s door switch
through the integrated control unit.
Power Door Locks
The power door lock system rs made up ot the
keyless door lock control unit, driver' s door lock
switch, and individual door lock actuators. The
power door locks are controlled by the driver' s door
lock switch and the driver's door lock actuator
switch.
Transmittel
The transmitter sends coded radio wave signals to
the keyless door lock conlrol unit when one of its
buttons is pressed. Each transmitter has a unique
code that must be
'laught"
to the conlrol unit before
it can operate the door locks or any other function.
Up to 4 transmitters can be
programmed
to operate
the keyless door locks.
Door Locking
When you push
the driveas door lock switch to the
lock position, ground is applied to the GRNMHT
wire to the keyless door lock control unit. The
control unit then applies battery voltage to the
WHT/RED wire and ground to the YEURED wire.
The passenger door lock actuators then activate to
lock the corresponding door locks.
When you lock the dnver' s door with the key or door
lock knob, it is mechanically locked, and the driver' s
door lock actuator switch applies ground
to the
oower door lock control unit. The control unit then
ground to the YEURED wire, activating the
passenger
door lock actuators which lock the doors.
Door Locking with Transmitter
When you press the LOCK button on the remote
transmitter, the keyless door lock control unil applies
battery voltage to the WHT/RED wire and ground to
the YEURED wire. The passenger
door lock
actuators then activate and lock the doors. A ground
signal is also applied to the BLU/RED wire to lock
the driver's door. lf any door is open, you
cannot lock
it using the remote transmitter.
Door Unlocking
When you push the driver' s power
door lock switch
to the unlock position, ground is applied to the
GRN/ORN wire to the keyless door lock control unil.
The control unit then applies battery voltage to the
YEUREO and BLU/RED wires and oround to the
WHT/RED wire. The door lock actuators then
activate to unlock the doors.
When you unlock the driver' s door with the key or
the door lock knob, it is mechanically unlocked; the
other doors do not unlock.
Door Unlocking with Transmitter
When you press
the UNLOCK button on the remote
transmitter once, the keyless door lock control unit
ground to the BLU/RED wire to unlock the driver' s
door. When you press the UNLOCK button twice,
the control unit then applies ground to the YEURED
wires lo activate the passenger
door locks. lf you do
not open a door within 30 seconds after unlocking
the doors with the transmitter, the doors
automatically relock.
Transmitter Programming
.
Entering the programming mode cancels all
learned transmitter codes, so none of the
previously programmed transmitters will work.
You must reprogram all the transmitters once
you' re in the programming mode.
.
To keep the system from exiting the
programming mode, complete each step within 5
seconds of the previous
step, and
program
the
transmitters within 10 seconds of each other.
' 1
. Turn the ignition switch ON (ll).
2. Press the
"LOCK"
or
"UNLOCK"
button on one
of the transmitters. (A non-programmed
transmitter can be used for this step.)
3. Turn the ignition switch OFF (0).
4. Repeat steps 1, 2, and 3 two more times with
the transmitter used in step 2.
5. Turn the ignition switch ON (ll).
6. Press the
"LOCK"
or
"UNLOCK"
button on the
same transmitter. Check that the
power
door
locks cycle to confirm that you' re in the
programmrng
mooe.
7. Press the
"LOCK"
or
"UNLOCK"
button on each
lransmitter. (You can
program
up to four
lransmitters per vehicle.) Check that the power
door locks cycle after
you push
each transmitter
button, contirming that the system has accepted
the transmitter' s code.
Beep On/Off Feature
1 . Press and hold the LOCK and OPTION buttons
on the transmitter.
2. Watch the transmitter' s LED:
One flash: BeeD activated.
Two flashes: Beep deactivated.
130- 14
Keyless Receiver Unit Troubleshooting
lf a faulty keyless door lock control unit has one of the symptoms below, turn to the
page listed and tollow the
appropriate troubleshooting
procedure. lf the symptom seems relatod to an input problem, or is not covered
by the troubleshooting
procedures,
do the Input Tests on page 130-16. Refer to the circuit schematic on
pages 130-12 and 130-13 as needed.
Symptom Index
Keyless Entry Does Not Work In Any Mode
Ceiling Light Does Not Come On When The Doors Are Unlocked
Wi t h TheTransmi t t er . . . .
Doors Do Not Unlock Or Lock With The Transmitter . .
Horn Does Not Sound Wi t h The Transmi t t er
' Beep"
Feat ure On . . . . . . . . .
Horn Does Not Sound In The Panic Mode ..
Ho r n Do e s No t St o p So u n d i n g . . . . . . . . . . . . . . .
Page 1 30-17
Page 130- 18
Page 130-1 I
Page 130-19
Page 130-19
Page 1 30-19
Page 130-16
Input Tests
\ .
130- 15
Keyless Door Lock Control Unit Input Test
The following tests are performed with the keyless door lock control unit connector disconnected.
Terminal
No.
Wire
Color
Test Condition Test: Desird Result Possible Cause if result ls not obtaind
1
LT GRN/
BLK
Cei l i ng l i ght swi tch i n
"middle
position"
Connect to ground: The ceiling
a
Blown No. 43 (7.5A) luse in the
under-hood tuse/relay box
Blown ceiling light bulb
Faul ty cei l i ng l i ght
An open in the wire
o
a
a
3 BLU/RED
lgnition key inserted
into the ignition key
switch
Chck lor voltage to ground:
There should be I V or less.
a Poor ground (G401,
G402)
An open in the wire
Short in the wire
a
a
o
lgnition key removed
lrom the ignition key
switch
There should be 4 V or more.
BLfiEt l gni ti on swi tch ON (l l )
There should be battery
voltage.
. Bl own No. 14
(7.54)
fuse i n the
. An open in the wire
b REO/BLK
Headl i ght swi tch i n
PARK OT HEAD
voltage.
a
Blown No. 32 (7.5A) luse in the
A faulty headlight switch
An open in the wire
a
o
LT GRN/
RED
Each door opened,
one at a time
Check lor continuity to ground:
There should be continuitv.
o Faulty door switch
An open in the wire
o
1 5 GRY Under al l condi ti ons
Connect to ground:
Horn shoul d sound.
. Bl own No. 52 (154) fuse i n the
under-hood fuse/relay box
. Faulty horn
.
Faulty horn relay
o
An open in the wire
BLK Under al l condi ti ons
Check lor continuity to ground:
There should be continuity.
a Poor ground (G401
,
G402)
An open in the wire
a
130- 16
r l ,
\ r ;
Keyless Entry Does Not Work ln Any
Mode
NOTE: Before beginning, verify that all the
transmitters are
programmed
to the vehicle.
system?
Yes
-
No
-
Go to step 3.
2. Does lhe keyless entry work correctly when the
security control unit connector is disconnected?
Yes
-
Faulty security system, go to security
system for f urther lroubleshooting.
No
-
the buttons are
pressed?
Yes
-
Go to step 6.
No
-
4. ls the transmitter battery installed with the
positive side facing up?
Yes
-
repositioned, then replace the battery.
Remove the key trom the ignition, then
close the doors and trunk. Press the
LOCK button on the transmitter six times,
then go to the next step.
No
-
repositioned, then reinstall the battery
correctly. Then reprogram the transmitter
and retest it. Use the procedure on page
1 30-1 4 for transmitter
programming.
\ r
130- 17
7.
Does the transmitter LED come on when anv of
Yes
-
No
-
program it by
using the procedure on
page 130-14.
Does the system work properly in all modes?
Yes
-
Finished. The system is OK.
No
-
Recheck with a known good transmitter
Yes
-
program it by
using the
procedure on page 130-14.
No
-
Replace the keyless door lock control unit.
Ceiling Light Does Not Come On When
The Doors Are Unlocked With The
Transmitter
1 . ls the ceiling light switch in the center position?
Yes
-
No
-
Reposition the ceiling light switch and
relesI.
2. Does the ceiling light come on with the ceiling
light switch in the ON
position?
Yes
-
No
-
Repau the ceiling light circuit.
Yes
-
No
-
lf the ceiling light still does not work, go to
the next step.
Yes
-
program it by
using the procedure on
page 130-14.
No
-
5. With the keyless door lock control unit connector
disconnected, run a
jumper
wire from terminal 1
to ground.
Does the ceiling light come on?
Yes
-
Replace the keyless door lock control
un [ .
No
-
Repair the open in the terminal I
(LT
GRN/BLK) wire.
130- 18
Doors Do Not Unlock Or Lock With
The Transmitter
1 . Do the door' s unlock and lock when using the
drivefs door lock switch?
Yes
-
No
-
Repair the
power
door lock system.
Yes
-
No
-
Check the transmitter batlery, then retest.
lf the doors still do not unlock or lock with
the transmitter, go to the next step.
work properly in all modes.
Yes
-
Replace and
then retest. Use the procedure on
page
programming.
No
-
4. Does the voltage at terminal 3 of the keyless
door lock control unit connector change from
battery voltage when the key is not in the
ignition, to less than 1 volt when the key is in
the ignition?
Yes
-
No
-
Replace the ignition switch or repair the
damaged terminal 3 (BLU/RED) wire.
5. Does the voltage at terminal 12 of the keyless
door lock control unit connector change from
battery voltage when all the doors are closed, to
less than I volt when any door is opened?
Reoair the ooen in the terminal 12
(LT
GRN/RED) wire.
Horn Does Not Sound In The Panic
Mode Or With The Transmitter
"Beep"
Feature On
NOTE: The transmitter has a Beep On/Ott toature.
Refer to
page 130-14 for how lo turn the bep on or
off.
1. Does the horn sound whon the HORN button is
oressed?
Yes
-
No
-
Repair the horn circuit.
2. Does the transmitter LED come on when any of
the buttons are Dressed?
Yes
-
No
-
lf the beep feature still does not work, go
to the next steo.
3. Recheck with a known
good transmitter
work
properly in all modes?
Yes
-
Replace and
then retest. Use the procadure on
pag
programming.
No
-
Go to the neLt siep.
4. With the keyless door lock control unit connector
disconnected, run a
iumper
wire from terminal
15 to ground.
Yes
-
No
-
Repair the open in th terminal 15 (GRY)
wire.
\ l r
130. 19
Horn Does Not Stop Sounding
system?
Yes
-
No
-
Go to steD 3.
Does the horn stop sounding when the security
control unit connoctor is disconnected?
Yes
-
Replace the sEcurity control unit.
No
-
Go to the nsxt step.
Does the horn stop sounding when the keyless
door lock control unit connector is disconnected?
Yes
-
No
-
ReDair the horn circuit.
Security System
- '96-'98
USA: HX, LX, EX;
'96-'98
Canada: EX. Si
UNDER-
HOOD
FUSE/
RELAY
BOX
t"'1,",*
,";;;i[ftT"fi'
'lffi;?'- 1
Dfstnoul on.
fuO
wnr
I
yEL
,-l_""__
UNDER.
DASH
FUSE/
RELAY
BOX
@ @
.-"*luuu'
",-f
*'^'*'
,..1
f::T;J
I I
-Tl[3,*,,,*-"""
| |
%;1 l
FUSE 3
I I C5s1 !
- - J t - - J
C423 (Not
,i!r13 "
u".al
_::;=ffi
HORN
RELAY
PHA|O 129 (9A nodel)
{'96-97
models 3)
i'"---i[
il il
'98
model
'96-97
models
I
Horn Baitery tgnition
I
: control
\
lgnition key I
I i*iiirr inilt
eround
I
L - - - - - -
- - - - - J
- - l - s- f - - - -
- - - - - - - - t i Y
8LU FEo
ll BLU aED I
;t,-
fon:*,
vlEw 21
8LU/
FED
1
GAN
t
'I
HORN
a- . =- -
e.r,".o ll
,
Ag::l^.
aLu neo
l l
v,rwoo-' gr-u.neo
sersarr R, I
v,rw DU
BLU/BEo
See Seat Belt
O
-(
and tgnition Key
eru neo
l l
Remi nders
' + c4i s
.,u*i,l(
il,?l?.uo
r - { - - - - sTEERTNG ;:E[t-:--.rsrEERrNG *.1
i l-flb'fitg"# i".e"er;;
-
|
l l - Ukevi ni sni t i on l
I
:r:["_-----r
ilrff,i$t !
ilr,tlp:
lgnltion Ksy
I LOCK
Swftch I PHoro z1
Closed with
c201
vlEw 30
133
J!@i---;""i
".*l
o"n"'o''
]t ____ __ __ _ _ _i__ _ _ _ _ _ I
' ;;;1;
I r1--
--' I
UNDE'
------J-i
i I 11' .1' .11 lSBi' "
Dr i ver
. r
'
\ HEADI I Or i T
' : :
door
! : t {
t - -
l PHo' o7
unlock Unlock Lock
| : L
j,-
-- -J
inpd input
lpr,_j
:
-9lT1u.r^ -
- - - -
C a n a d a
- - - ' - - - - - - l
POWER DOOR LOCK
;
CONTROL UNIT ,
k;i
L______j g:_l =,_______
j uj _.r,
_r_f 9_.-u:
'F":;!-_
--",*tI
i
!**
""""I
*",*"[T*Fi
i
.",1
o*u*u'
,*
-".11
t-J--'-----'-hff I
"ll-_-_il
|semooeri i r
f,
' t
tr
18
f
i a-ei i ,
L______d
" t " ; t l o" n, o" n|
" " " *" , | f t " t ' i
f
sEcuRrwLED, ,
L--J---------J", 0.
|
| -l i f f i *
,i,Hfil
_[l!,ffisHdsh
i ,of.--s
L--d,---t--------cl-+-' dl
"."""" !
- - - - - - - t
-
I
,
t
-
Drivgr's door Unlock Lock I Light
I U
ii -F-o-:y-"1 - -:i"-1i3y. -TTi- - - - - :"ll'i - - ; 13'*" i
q._"u_n'r
!
- - 1- - - -
- - - ' l 99, t r RoL
I
: \ var st : l ; #" b" I
; ; $vitch Securiiv Bus Remote Bus Bus
i I vttwte ll C422
, f
inqrt outDut d,.az LED control data 0 data l ,
: I
P1oTo 58
- a - - -
'
s Y---â---.;f
--.;Y---^;Y---:Y
- - - -
r
;-.tr' ---
. ; UNIT
i
*t
Drtusr's door untock
Lock i ugnt
i t
-
uavgrs ooor untocx LocK I Lrgn'
: LED control
unloc* outpul outrut outpul
'
flash - ':
'
iontrot I sEcuRlw
- - 1- " '
- - - '
I
c oNr RoL
' ' i uNl r
i \
vatst
, I
Var Er
t l
PHQ| AT3
: ; s,vitch Securiiy Bus Remote Bus Bus
t)vtEwte
, f i nar r or nout d' de2 LED c ont r ol dat a 0 dat a l :
7-1
e4re4lon
lfil
Iffi;*l
[I$'':r*il
:
84
| ,
85A 87A 811
| '
Bt2
| '
813
| '
vtEw68
|
! sae r.teadl i
i i'=::t:::ti------r------s------r, -"**
i
:
! 8yJfu;
; I I
Vabt Scurity 8us Remot Bus Bus
I
Reieiver
! ; --_ _.._ ll
:i
iffi$
input data2
ffiDul
datao datal
iunrr
!:""'"^l
(cont'd)
133-1
Security System
- '96-'98
USA: HX, LX, EX;
'96-'98
Canada: EX, Si
(cont'd)
I
ooor
| #Ifl input
-----l
sEcuRl rY
LT CRN/FED
LT GFN/RED
LT GBN/REO
a
[
" *
LT.FN,BED
i
.l:T,lT_t
i _ _ ;T_-----l
Hui.'n*f'
ffi i
|. :-:?-'IINTEGB]ATED
I PHoro 58
ll ,
!Eilf8t+ lffi'il* ! !
:
LE:E,jJ_i*- | I
i
c503
c562
vtEvl 42
BLU/BLK
EAA
-{
i,i-"i
See Ground
DislrihJtion,
pag 1*10.
c401
- - - - - - S e d a n
Inpur
---{
F6,i,",. ooo. i:< "?;",o,"
t r l l nx
switch
I
CoNTROL
! UNI T
I PHora 73
Jvt Ew
sB
2
BLU/ALK
6
BLU/ALK
12
(Sedan
'15)
BLU/BLK
c411
PHOIO 60
vtEw 60
H
":-f
Or--<
".^
|
l- G601
Light
TRUNK LATCH
swrTcH
Closed with
vunK open.
LTGRN/FED
t___:'I______l
Tll """,
l-.'F-l
DRtvER.s
| 1 I
DooR
Ir-Il3)lll8l,*
=-
ooor open.
-
PHOfOg6
LTGRN/REO
i ;
LT GFN/
T , F E D
*'^l ft?{,,'
I i
FRONT
PASSENGER'S
'
DOOR SWI CH:
Closed with
:
door open.
PHOTO 96
H H
LEFT
REAR
DOOR
SWITCH
Closed with
door open.
rflf5ii'
:
lCJEfii:t*,,,'i
-
. l ^^r ^^6^ |
PHOfO 97
133-2
\ .
!l f-+ iffi,iiilili. lsivvncrr
I
ii^ / _;l"d:lt' :"i
i
:l l *cK
(
- t*.r.$r I
i!tff^.I^-.-f
fl''i"
I
r
i !
t i ' t | l
! r
L---------J-{,5=;==---)
"'*TA
"o'u
etxret
I
Pflllodo
l:'iI
SECURITY
STARTER
CUT RELAY
PHOTO 53
PTOIO 56 ( 98 modsls)
vlEW 12
STEERING
LOCK
a
lll except CW
!'G";1
cut
ouiput
SECURIry
CONTROL
UNIT
vtEw 58
Mrr CVT
\ r ;
BLKTTVHT
('98 model 5)
"a*-",
I
o
.I
A/T GEAR
I
POSTflON
a swtTcH
PHOfO 78
STARTER
CUT
RELAY
f r
c433
Bt( vHT
1 0
aL|( vHr
('98 model 3)
4
BLU/BLK
--T6-';'d"r
tlf
3 l
".,u".o
I
T
I
cLUrcH ll
TNTERLoCK
I
Slig:i* J,
clutch
pedal f ul l y
oepresseo.
8LK/FED
1 1
t A/T GEAR
I
POSTTTON
a
swrTcH
I
I
I
J
c433
o
t - r
\
L !
BLKRED
".o"ro!
BLvFEo
. @
"'o"'r"f,
"'ot
ro'ffzr----,
See
Starting
System
Se G.ound
Distribution,
page l4$.
BLKAVHT
T Y
I I
L____l
+.
:
G401
PHOTO 57
STARTER
r::1 STARIER
I
uo'r
I
soLE orD
t l
; -
".orr.i
tr-
- -
to :l cat t
*"1.;
[;z*e'
an
L - - - J - - -
ALI(RED
",#"It#f;,.+,"
rl r
L- - - - - - - - J
133-3
Security System
- '99-'00
USA: HX, LX, EX,
@
DX-V Si;
'99-'00
Canada: EX, Si
@@ t@
i
-
|
ffii:-
- - - -
I
i['"",llae'
i
-
1
F;
- - - - - - -
F,...
- - -
I
i"t]:.:*'
L-i:i--:::.J L-t----------i::=t s:i
2 lf c353 8 Y C352 7 t' C4l9 1 v C423 {Not
F#r""
",-^:"\P;!i?," ...'*lii:i',," I lft:i:3''.I::,
wHr'cuN
I
*nr
l
"..
I
**l
-"'"""[q
;Tto"
--^*[ftFi" --f
;ntn"
"..f
t*x;,3''
u:;
-"r,"""Iq
- - t - - - -
See Powsr
Disti brrtion,
C4il8
i
!,"1{}"'
Batiery
IEBP*'
rsnidon
f
!
tgnition key vabr
\.
L-----t:gg-____ _gs___ggg___-,r
lgdIon Kry
Swhch
Gbssd with
key in ignition.
- - - - - J
STEERING
LOCK
1
ELK
c450
o
-^l
I
:':l
BLUAAIHT
See Ground
Distribrtion,
pag
l+7.
fl
r:
[-
- -;;----.T - - - -
--i C214
BLU/FEo
I I BLU
;iP,li: 3o-.o< ffi8i?;g"'fu,
I . 1"*.
".u,"?!..,u
R8fr.,!3"Iii,
".^l
.+i"ili""
swtTcH
'l?,ii;'?,-
ffi8lli"?,1
".*
I
Pag
14-6.
!---J
r
133-4
HORN
a \
i
- ----' canada
;;;;-gr"Srri f,f I
@
"
*i'[?'29
:
r1----1
qNPEE-llqgo
i r - - - - -
:
|
3;::,
-=l
i
I l[+'ffi !l[?::'*'
I
I
unl ock unl ock
l ock I : LJ,----.1
:
L-j 5----j !g-------' :g:-j
sf_e_3s-?
'
6l -----r-T--------
1T
;
wHr
l wi :i i z-
i e""e'I o"no"n!
_
o"n-"'!
i
iff*f{#i!
i t
ffil *smi i""' iF' asi;; ,
I
cnnronr
I
or
i I I i - , dI i " " r l - - - ] r l
i ' uf ---ri l f ------
l sYef . i f y, ' ,
f i l l Tl i -i x11, ,
i
".u.".,.1 o"no""i *n,",1' ' ",u,i
lEqlJF,:*:;
i ,
zof ----f -------t t i t ! ; k"' : ' f ------T
i ".u"..
I
o"n,o"u
I
o"n,""'
I
i "ro
[
"ro,c"n
I
i
| | | i
i *i
!
"' oo*
: I l
i I I I
i
i ?asee' ead' sht
;
zl -----8l ---------qf------rJ
*""""
I
i
rl-,:f'-,."",rr
-l:'.:=il
.. . :::::'.1.. i-tt'ilr'iiililil [
r---l-------------'--------------------
--il'-- -":
iii:;i"'"
l'"i::""
, 3 - - - - - - - - - - - i J
7 ^
v E w 1 6
i
"I-----'1------1
i
i-T;-'*-'-"*trJnll'fFi"
i I I
. . "1 i
! 1. , 9, . : ' -' ! [ a*:
i
*"
|
*'*'.! *..*"!
i
!
lN+;** i*o'o"
i
,,
[-----[-----,J
i
"-i";f
"-**,-'
i i-ffi;----;;------'"i-l
[ib,!".p."- i
I;yJ;l*,-
I i
!33lY"o
i
i -- --
-; ----i*o i
"'""t1'ffi"'r3o-
I
13tr8"?*1
I
+
(cont'd)
\ l r
r l r
)
133-5
Security System
- '99-'00
USA: HX, LX, EX, DX-V Si;
'99-'00
Canada: EX, Si
(cont'd)
LTGFN/REO
13
LT GBN/RED PHOTO 113
?-a@
c41r
i
"i:,1'**
I
I
Lr cRNi BED
I
T
' l l - - - - - - ' l
I
B s l
I
LT GFN/REO
LT GFN/BED
c401
- - - - - - S e d a n
! i-------T-'lsFs6l'"
l : t !
u x r
l l :nJffeffi i *4' aw"o' "
! L- - - - - - J- J
L_____":r----__
UNDER.DASH
FUSE/RELAY
BOX
RIGHT
REAR
DOOR
SWITCH
:
Closed with ;
door open. ,
a
*l;;
'
IT GBN/FED
E
FRONT
PASSENGER' S
DOOR SWITCH
Closed with
door open.
LT ONN/BED
133-6
I-'r| DRIVER'S
I
q
I DooR
Ir-\l3l3ll3T*
H
door open.
-
PHO\O 96
STEEBING
LOCK
SECURITY
SIARTEF
CUT RELAY
PHO|O 56
vtEw 12
Mrt A/f sxcept CW cw
BLKAIIIfIT
I
o
"'li'l
t**,"
BLK,^,HI
ll V/Ew 4 r
c433
PHOIO 76
BLKr{VHT
' t0
BLK/IIT/HT
TX
a.
t
a
t
I
I
,I
I
I
I
I
I
POSTTtON
swrTcH
STARTER
cur
RELAY
PHO|O 135
\*
l : l
I
------;r
I
",-o"ao
I
T
I
cLUrcH i
$fri*'fl:J I
clutch
-
pedal f ul l y
oepresseo.
PHO|O 130
c433
I
t -
BLK/FED
A/T GEAR
POStTtON
swtTcH
*\"
L L
"."JJ"!F;?',?,-
".o"ro!
BLKFED
o @
See
Starting
STARTER
Seo Gfound
Distribution,
page 14-6.
) 2 1
I
c101
vtEw 2l 2A
il
System
START
r::-1 STAHTER
I
uo"
l soLENotD
t l
ii-=1;-i*r*iTfifil I
il.^-.. ./ _ r.n:'o !
r
!!r3"'.rhil.1ilr- i !
--ii-;;;I'-----==----
**,^r..!
i'i"i'
"-dI
iryissu'Y
\ .
L - - - - - - - - J
34
133-7
Security System
(cont'd)
- ' 96-' 97
CX and DX Model s (cont' d
on
page 133-10)
NOTE: Wires that look like this e:=---{ are pan of the optional Security System harness installed
between factorv harness connectors.
@
FUSE 52
toRr{,
sTorlrotir
t5a
STEERING
LOCK
c20'l
PHO|O 23
vtEw 3a
HORN
RELAY
".,,".:J[--
'I
"""'
[*u
""''"h
GAY
GRY
.--.tf
r v
l l
a :
" l l
114 H(
a l
c (
. - t
+
)e florns
Horn Relay
Connecto.
sEcuRrw
IN.LINE
FUSE
HOLDER
ALK,YEL
1 1
Horn Batiary lgnition
SECURITY
CONTROL
UNIT
vtEw 58
c214
vtEw21
/1H?#,
See Seat Belt
O
___________1F_(
ano ronrl|on
".u "eo
l l
c415
KeY Remi nder
" U
c+ts
' i !,1fl 0
eLu,,,viiY ll9,'9.60
BLU/FED
BLK
gd!ryi--],.,,.*,"o
ilnffi"* !"*"
I
L+
kev In ignition.
I
L- - l l - - - - - - J
"'utTf,
"o',u
oLK
ll
PHofo46a
G401
"",,""i"1---"-",-,""rf
&f,.f,,,
t
A-----1.:A
Ho' n Reray
l l l l
Connector
"""o"n
ll
*""T
ll
1 A- - - - - - - / {
r - - - - - - -
'l
lonltion I
iltr? _ili*
!'"*'
i
! i *. 1-/ *. , i !
I
L - - - * - - J I
t--"-.*-*t------J
u A c g t
ar-x,ver"
ll
eroro oo
133-8
V
- ' 98-' 00
CX and DX Model s
(cont' d
on
page
133-10)
NOTE: Wires that look like this e=-* are
part
of the optional Security System harness installed
between lactory harness connectors.
STEERING
LOCK
UNOER-HOOD
FUSE/RELAY
BOX
HORN
RELAY
PHOIO t35 ( 99 0o models)
;.;l
HOBN
c926
OPTION
i-t
t
-fii;r,'im:";
9""
cnv
l l Connector
Hor ns
l l
PHO|O 62
sEcuRrw
IN.LINE
FUSE
HOLDER
,"" l-l--';]
L
ii+
TBriE:,, ;.'".*"'
ll
'Jl
''
lL--l[JL---:-----------C
i.
rl::t
;;;[.?jsor+3r
i
lff],
-,
;,:"1.
- . :-
- -
;_:
- - -
tt*
I
ii}"*:*
't--J'''*uo
lc,o,na
i
Y#,iln,"o*
i
9JlflB'],iff,
iw,E"
L: ; ; - ' - - - - J - - - . l . - - - - J- - - - - - - J
rs
y-
- -i'. - -s-J[- - - -
l-
-
]sf
ll
; eLu
ll
'
BLU REo
| |
".r,".o
2 gLu
neo
see seat
i
'fi
i ".,".oii----iiiu
-
[tJ.li'fll5"t
i r{i
y*sr.. : z!9X;2""|"i!'}?.""
ll
i
l/rlu'-'u"i
"i-jttz---'rsrEER,
Fii;i,"
ll
;i'".'J^ ,#
i iQffi*"it*"
l l
:
l l
L- - I F- - - - - J
*-
l l
' BLK
l l i
"' u*TI
"o,u
'
11 '
---
--;'
Bett and
SWITCH
'
BLU^YHr
f i;;;i;
"
l { - l - ' -
'
- ' ; r { i ss" -
STEERTNG
,
r
a t v
r
- lt PHofo 60
. - - - - .
_8! K l l
v/ Ew ' 4
:
G401
fl
-1[::_5J*nt
s
Y
c3s1
,n"r,".o
I
i[o"to,'
, tr ft?;","
liuF;lt"ls'rs?rl
iL:"::Ifui i
'--T'Il,].----r
I t r
133-9
Security System
SECURITY
-
AIICX and DX Model s (cont' d)
NOTE: Wires that look like this
-:=
are
part
of the optional Security System harness installed
between factorv harness connactors.
LT GFN/BLK
Lf GRN/REO
2
LT GFN/BLK
(' 99' 00 modsls LT GBN/RED)
1 4
LT GFN/REO
13
c407
PHO|O 52
Y/El4 ? ( 98' 00 modrs)
c41t
PHO|O 6A
vtEw 60
'99-'00
models
(Not
useo)
c411
vtFw 20
LI GFN/BEO
a, o^n,"ao
I
r-----{-
I
asl
RIGHT :
REAB
DOOR
swtTcH
Closed with
;
door open.
-
door open.
IT
REAR
SWITCH
= Closed with
- - - - - 1
LT GBN/RED
LTGFN/FED
UNDER.OASH
FUSE/RELAY
BOX 11
PHoro 5a (,99_,00 models 15)
LT GAN/BED
FRONT
PASSENGER'S
DOOR
swtTcH
Closed with
door open.
c40'r
rui=ifl
Sedan
- - -
H H
l' il-
- - -l.-
1 INTEGRATD
ififlLliF"#t::-
fTl33'J"*''
lldi$"",""',:;ll
PHO|O96
133- 10
I
PHO|OqT PHO|A9T
UNDER.HOOD
l t FUsE4s I
FUSEiRELAY
! \ xamucnr !
BoX
I I . A I
PHor o 7
LJ, - - - - J
c352
vtEw 27
Soe Powr Distdbulion,
page 1&12,
Combination Light
Switch Connector
E2
See
lndicators
COMBINATION
I I LIGHT SWITCH
| |
v;i w;
-
LIGHT
FLASHER
RELAY
4
aLU or ALU/YEI
c503
iTFffiliBi+B,il
:"'s#Ji"" I
coNrRoL
i # $ i
I
i nput
I
L - - - - J
3 Y
BLU/ BLK
l l
: a
Brui 8rK
ll
*,rlfr
ftT-f.","
,^ftslllfl liîr,,
Ha,chback
vtEw 58
Coupa tnd
Sedan
Combination Light
Switqh Connector
r
=
l\,lale
-
Female
termrnals reversed
l or' 99-' 00 model s
See Headlight
Swiich,
peg61(n.
EXTERIOR
LIGHTS
Seo Ground
Distribution
"'u'"t*X
".u,"."
aE,<
-*;"1
See
Trunk
Light
'9+
97 models
aau,"a"
fi
' *9#1", , ,
BLU/BLKrf
vEwe
g8-,oo
modets
l
qi*$qli-
TRUNK
LATCH
swrTcH
":^f
se Ground
5--r<
!#itl8
".*
I
o"o'
or 14-11
.|- PHOIO ro2lorcoDr' 99 oo sedan)
:
PHofo 113
";-f
"^'
FE
I-I-t HATCH LATCH
I I I swtrcx
lljij::,:}#x
""'*if
"tut
seecround
o
tr<i Distribution,
e.*
|
Page
14-12'
+ 9131",,,
133- 11
Security System
-
All CX and DX Models (cont'd)
NOTE: Wires that look like this
S--------S
are
part
ol the optional Security System
harness installed between lactory
harness connectors.
From
page
j 33_9.
@
aLI(AVHI
I
AIKWHT
STEERING
LOCK
v
""'ll
'99198
models
( l or
1T
Jl.
'99100
models
sEcuRrw
LEO
c415
vlEw 14
l -
SECURITY
STARTER
CUT RELAY
PHO|O 53
vtEw 12
BLI(FEO
' t 1
au(/FEo
c433
Aubrnatb Transmission
c4r 5
PHOTO N
AU(WHT
' t0
BLXAVI{T BLKT'!VHT
2
('98-'00 modls 5)
('98100 models 3)
4
A"IT GEAR
POStTTON
swtTcH
".**"rI
[ :,i
STARTER
CUT
RELAY
PHO|O 54
PHO|O 129
( 9 model)
( 9+ 00 models)
?
I
I
I
I
I
1-sel-oo
rnJ"ls z1'[
".*"9tr
c433
CLUTCH
INTERLOCK SWITCH
Closed with clutch
pedaltully depressed.
".o""0!
".o".0
see
aE4 Starting
ar-rvneo
ll
System
'f,
"";%,,
BLK
TTBT
I
vrEw28
r - 11- - - - - - . | STABTER
! r3r smnren
I
PHoro 34
|
1
coit
;
SoLENOID
I
i !.__J i
L - - - - - - - - J
"===-F=F*F,Ff
Tfo?"
It -,/
Pase
10
l
!ltb3'-fi:-#-1iln i
ll
.",;T;
"":JI------;;lt
l l
* " l l
l l
ELKBEDI I
,JL-----
' dl *------ ' l l t{
paso 14.
"
y
I
*-l
L_______l
.------+;_ -
PHO|OST
133- 12
Arming the Security System
The security system can be armed:
r By pressing the remote control LOCK button
(if equipped)
. 20 seconds atter closing all doors (C)UDX only)
Arming with the Transmitter
The security system can be armed by removing the
ignition key from the ignition switch, closing all
doors and the trunk, and
pressing
the LOCK button
on the transmitter. When you arm the system in this
way, the remote control LED comes on, the status
LED flashes once
per second, the parking lights
flash once. the doors lock. and the horn sounds
once if the beeo sound mode is on.
Passive Arming (CX and Dx only)
When
you
turn the ignition to OFF, remove the
ignition key from the ignition switch, and close all
the doors and the trunk; the system will
automatically arm itself 20 seconds after the trunk
or last door is closed. When you arm the system
this way, the status LED tlashes 4 times
per
second
during the exit delay time, and once
per
second
after the system is armed; the parking lights will
flash once to confirm that the system is armed.
Triggering the Alarm
Atter you've armed the system, it will trigger the
alarm if any door or the trunldhatch is opened. lf the
battery is disconnected when the system is armed or
in the alarm mode, reconnecting it will immediately
trigger the alarm. When the alarm is triggered, the
following will occur for 30 seconds:
.
the horn sounds
o the parking lights flash once
per
second
. the status LED flashes hvice oer second
. the starter is disabled
After 30 seconds, the alarm will stop and the
system will rearm. Pressing the transmitter
UNLOCK button will disarm the svstem.
t l r
133- 13
Disarming the System without the Remote
Transmitter (HX, LX, and EX)
You can disarm the system by turning the ignition
switch to ON (ll) and
pressing the disarm/valet
switch on the right side ol the stereo tuner face. The
disarm switch will also disarm the svstem after the
system has been triggered.
Disarming the System with the Remote
Transmitter
(Hx, Lx, Ex, DX-V, and Si)
Pressing the transmitter UNLOCK button will disarm
the system. The
parking lights llash t\ivice if the
alarm has not been tnggered. The
parking lights
flash three times if the alarm has been triggered.
The driver' s door will unlock. lf you press the unlock
button twice, it will unlock all doors. lf a door is not
opened within 30 seconds, the system will lock all
doors and rearm.
Disarming the System (CX and DX only)
lf the system arms itself, there is a 20 second delay
after you open a door before the alarm will trigger.
To disarm the system in this mode, simply turn the
ignition switch to the ON
position
ldentitying Tripped Sensors
The system identifies which sensor trips the alarm
by flashing the status LED. To display the trip
sensor flash code, press the disarm/valet switch 3
times within 5 seconds after the system has been
disarmed. The status sensor will blink according to
the followino codes:
Sensors Number of Flashes
Door
TrunldHatch
System Switches
1 blink,
pause, repeat
2 blinks,
pause, repeat
3 blinks,
pause, repeat
For further operating instructions, see the security
syslem owner' s manual.
(cont'd)
Security System
(cont'd)
Security Control Unit Troubleshootlng
lf a faulty security system has one of the symptoms below, turn to the page listed and follow the appropriate
troubleshooting
procedure. lf the symplom seems related to an input problem,
or is not covered by the
troubleshooting
procedures,
do the Input Tests on
page 133-15. Refer to the circuit schematic on
pages 133
through 133-12 as needed.
Symptom lndex
Security Sysiem Does Not Work In Any Mode (HX, LX, EX)
Security System Does Not Work In Any Mode (CX, DX)
Security System Does Not Arm (CX, DX)
Security System Does Not Arm (HX, LX, EX, DX-V, SD
Security System Does Not Disarm With The Transmitler
(HX, LX, EX, DX-V, Si)
Security System Does Not Disarm (CX, DX) . . . .
Security System Does Not Disarm With The Valet Switch
c96-' 98
HX, LX, EX) .
Security System Does Not Disarm With The Valet Switch
('99 models) . . .
Security System Dos Not Work In The Valet Mode
(' 96.,98
HX, LX, EX) .
Securi t y Syst em Does Not Work I nTheVal et Mode (' 99 model s) . . . . . . . .
Security System Alaim Does Not Trigger When The System ls Armed
And The Trunk Or A Door ls Ooened
Security System Does Not'Beep" 3 Times When The System ls Armed
With The Trunk Or A Door Open
(HX, LX, EX, DX-V Si)
Parking Lights Do Not Flash (CX, DX)
Parking Lights Do Not Flash (HX, LX, EX, DX-V Si)
Security System Status LED Stays On (HX, LX, EX, DX-V Si)
Security System Status LED Does Not Com On (HX, LX, EX, DX-V, Si) .
Starter Cut Does Not Work Properly ('96198 HX, LX, EX, DX-V, SD . . . . . .
Starter Cut Does Not Work Properly (CX, DX) . . . . .
Hom Does Not Sound When Alarm ls Triggered
Input Tests
Page 133-17
Page 133-18
Page 133-18
Page 133-19
Page 133-20
Page 133-20
Page 133-21
Page 133-22
Page 133-21
Page 133-22
Page 133-23
Page 133-23
Page 133-24
Page 133-25
Page 133-26
Page 133-26
Page 133-27
Page 133-28
Page 133-29
Page 133- l5
133- 14
I r
Security Control Unit Input Test
The following tests are performed with the electrical conneclor disconnected from the security control unit.
\ ;
1 2 3 4 5
X
6 7 I 9 1 0
1 1 1 2 1 3 1 4 1 5 r ol 1 7 1 8 1 9 20 21 22
Termi nal
No.
Wi re
Col or
Test Condition Test: Desired Result Possible Cause il result is not obtained
2
LT GRN/
RED
Each door opened,
one at a ti me
Check for conl i nui ty to ground:
Faulty door switch
3 BLU/BLK TrunUHatch open
a
Faulty trunldhatch latch switch
a
1 0 WHT Under al l condi ti ons
voltage.
.
Bl own No. 6 (3A) fuse i n the
(HX, LX, EX, DX-V Si )
.
Blown No. 54 (40A) fuse in the
under-hood fuse/rel ay box (CX, DX)
. Bl own (3A) fuse i n securi ty i n-l i ne
fuse hol der (CX, DX)
11
YEL
(BLK/YEL
cx, DX)
l gni ti on swi tch ON (l l )
vol tage.
.
Bl own No 3 (10A) fuse i n the
under-dash tuse/relay box
(HX, LX, EX, DX.V, Si )
. Bl own (3A) fuse i n the securi ty i n-l i ne
fuse hol der (CX, DX)
BLK Under al l condi ti ons
a
t 5 BLU/RED
switch
Short i n the wi re
a
a
a
l gni ti on key removed
from the i gni ti on key
switch
1 8 GRY Under al l condi ti ons
Connect to ground:
Horn shoul d sound.
. Bl own No.52 (15A) l use i n the
under-hood luse/relay box
. Faul ty horn
. Faul ty horn rel ay
133- 15
Security System
(cont'd)
The following tests are
performed with the electrical connector connected to the security control unit.
133- 16
Termi nal
No.
Wi re
Color
Test Condition Test: Desired Result Possible Cause il result is not obtained
1 YEUBLU Under al l condi ti ons
There should be approximately
5 volts.
a Bl own No. 6 (3A) fuse i n the
Faulty security control unit a
5 BLU Valet switch pressed
Shoul d change from
approximately 5 volts to less
than 1 volt when valet switch is
prsssed.
a Faulty radio ('96-98 models)
or valet switch
('99 models)
12 ORN Under al l condi ti ons
5 vol ts.
a Blown No 6 (3A) tuse in tho
under-dash tuse/relay box
Faulty security control unit o
1 4
BLU/WHT
( BED
CX, DX)
Under al l condi ti ons
4 volts.
. Faulty radio
('96198 models)
or security LED ('99 models)
1 7
RED/
WHT
Security system in
PANIC mode
Should change from battery
voltage to less then 1 volt when
i n the PANIC mode.
a Blown No. 48 (30A) luse in the
under-hood fuse/relay box
Faulty light flasher relay
Faulty security conlrol unit
An open in the wire
a
a
a
1 9
REDI/EL
(GRN
cx, DX)
Security system
alarm triggered
Check tor voltags to ground:
Should change from battery
voltage to less then 1 volt when
security system alarm is
triggsred.
a Faulty security starler cut relay
Faulty security control unit
An open in the wire
I
a
22
BLUA/EL
/' oa-' oq
mooel s
WHT/BLK)
Under al l condi ti ons
5 volts.
a
Blown No. 6 (3A) fuse in the
Faulty security control unit a
\ .
\ i u
Security System Does Not Work In Any
Mode (HX,
LX, EX, DX-V, Si)
1. ls fuse 6 (in the under-dash box) OK?
Yes
-
No
-
Replace the blown tuse, then go
to the
next sleD.
Yes
-
No
-
Retest the system.
3. Disconnect the security control unit connector.
4. ls there continuity from terminals 1, 10, 12, ot 22
to oround?
5.
Yes
-
Locate the short in the wiring between the
security control unit and the radio (' 96-' 98
models) or keyless door lock control unit
(' 99 model).
No
-
ls there battery voltage at terminal 10 of the
securitv control unil connector?
Yes
-
No
-
fuse 6 and the securitv control unit.
133- 17
rfe
6. ls there continuity f rom terminal 13 ot the
security control unit connector to ground?
7.
Yes
-
' 96-' 98
models: Go to the next steD.
' 99
models: Replace the security control
uni t .
No
-
Locate the open in the wiring between the
security control unit and ground (G401
).
With the security control unil connector
reconnected, is there battery voltage at terminal
21 ot the securitv control unit connector?
Yes
-
No- Beplace the security control unit.
keyless entry harness connector (B)?
Yes
-
Replace the radio.
No- Repair the damaged LT BLU wire
between the security control unit and
the radio.
8.
Security System
(cont'd)
Security System Does Not Work ln Any
Mode
(CX,
DX)
1. ls luse 54 (in the under-hood fuse box) OK?
Yes
-
No
-
Repiace the blown fuse, then go to the
next step.
2. ls the fuse in the securiiy in-line fuse holder OK?
Yes
-
No
-
Replace the blown fuse, then go to next
srep.
3. Does either fuse blow again?
Yes
-
Locate and repair the short.
No
-
Retest the system.
4. ls there battery voltage at terminal 10 of the
security control unit connector?
Yes
-
No
-
fuse 54 and the security control unit.
ls there continuity from terminal 13 ol the
security control unit connector to
ground?
Yes
-
No
-
Locate the open in the wiring between the
securitv control unit and G401.
5.
133- 18
Security System Does Not Arm (CX, DX)
1. Place the ceiling light in the center
position.
Does the ceiling light come on, even with all the
doors closed?
Yes
-
Faulty door switch or short in wiring to
door switches.
No
-
2. With the ignition switch in the ON (ll) position,
does the trunk open indicator in the gauge
assembly come on, even with the trunk closed?
Yes
-
Faulty trunk latch switch or short in the
BLU/BLK wire.
No
-
3. Does voltage at terminal 2 of the security control
unit connector change from battery voltage with
all doors closed, to less than 1 volt when any
door is ooened?
Yes
-
No
-
(LT GRN/BLK or LT GRN/RED) wire.
Does voltage at terminal 3 of the security control
unit connector change from battery voltage with
the trunk closed, to less than 1 volt when the
trunk is oDened?
v]"
-
R"pt"." tne security control unit.
No
-
Bepair the open in the terminal 3
(BLU/BLK) wire.
Security System Does Not Arm
1. With all the doors closed, do the doors lock
when you press the transmitter LOCK button?
Yes
-
No
-
Go to Doors Do Not Lock With The
Transmitter, on page 130-11 (' 96-98
models) or 1 30-18 (' 99 models).
Check the trunk open indicator in the gauge
assembly. With the ignition switch in the ON (ll)
position,
does the trunk open indicator come on
even with the trunk closed?
Yes
-
Faulty trunk latch switch or shod in
BLU/BLK wire.
No
-
Does the voltage at terminal 2 of the security
control unit connector change from
approximately 5 volts with all doors closed, to
less than 1 volt when any door is opened?
Yes
-
No
-
Repair the damaged terminal 2
(LT
GRN/RED) wire.
control unit connector change from battery
voltage with the trunk closed, to less than 1 volt
when the trunk is ooened?
Yes
-
No
-
{BLU/BLK) wire.
voltage the key is not in the ignition, to less than
1 volt when the key is in the ignition?
5.
o.
Yes
-
Go to the-next step.
No
-
(BLU/RED) wire.
ls ihere approximately 5 volts at terminal 22 of
the security control unit connector?
Yes
-
No
-
7. ls there approximately 5 volts at terminal 12
(' 96-' 98 models) or 14 (' 99 models) of the
keyless receiver unit (' 96-98 models) or the
keyless door lock control unit (' 99 models)?
' 96198
model si
Yes
-
Replace the radio (' 96-' 98 models) or the
keyless door lock control unit (' 99
models).
No
-
Repair the damaged WHT/BLK (' 96-' 98
models) or BLU/YEL (' 99 models) wire
between the security control unit and the
radio (' 96-98 models) or the keyless door
lock control unit (' 99 models).
133- 19
Security System
(cont'd)
Security System Does Not Disarm With
The Transmitter
1 . With all the doors closed and locked, do the
doors unlock when the transmitter UNLOCK
button is pressed?
Yes
-
No
-
Go to
"Doors
Do Not Unlock With The
Transmitte/' on
page 130-11 (' 96-98
models) or 130-18 (' 99 models).
2. ls there approximately 5 volts at terminal 1 of the
securitv control unit connector?
Yes
-
No
-
Security control unit.
3. ls there battery voltage at terminal 13 ofthe
keyless receiver unit (' 96-98 models) or the
keyless door lock control unit (' 99 models)?
96.98 model s:
' 99
model s:
Yes
-
Beplace the radio (' 96-' 98 models) or the
keyless door lock control unit (' 99
models).
No
-
Repair the damaged YEUBLU wire
between the security control unit and
the radio.
133-20
Security System Does Not Disarm
(cx, Dx)
1. ls the tuse in the security in-line luse holder OK?
Yes
-
No
-
nexl sreD.
Yes
-
Locate and repair lhe short.
security control unit connector, when the ignition
switch is in the ON
(ll) position?
Yes
-
Replace the security control unil.
No
-
Locate the open i n the wi ri ng between
the i gni ti on swi tch and l he securi l y control
uni t .
rl ,
The Valet Switch
Security System Does Not Work ln The
Valet Mode ('96-'98 HX, LX, EX)
1. ls luse 3
(in the under-dash fuse box) OK?
Yes
-
No
-
next step.
Yes
-
Locate and reoair the short.
No
-
Retest the system.
security control unit connecto( when the ignition
switch is in the ON
(ll) position?
Yes
-
No
-
luse 3 and the security control unit.
ls lhere approximately 5 volts at terminal 4 of the
keyless entry harness connector (B)?
Yes
-
No
-
Replace the radio.
rl e
133- 21
Yes
-
No
-
Locate the open in the BLU wire between
the security control unit and the radio.
ls the voltage at terminal 5 oJ the security control
unit connector changed from approximately 5
volts to 0 volts when the valet switch is pressed?
Yes
-
No
-
ReDlace the radio.
6.
Security System
(cont'd)
3.
The Valet Switch
Security System Does Not Work In The
Valet Mode ('99-'00 models)
1. ls fuse 3 (in the under-dash fuse box) (HX, LX,
EX, DX-V, Si) or the fuse in the securily in-line
luse holder
(CX,
DX) OK?
Yes
-
No
-
Replace the blown fuse, then go
to the
next step.
Does the fuse blow again?
Yes
-
Locate and reoair the short.
ls there battery voltage al terminal 11 of the
security control unit connector, when the ignition
switch is in the ON (ll) position?
Yes
-
No
-
fuse 3 (HX, LX, EX, DX-V, Si) or the luse
in the security inline fuse holder (CX,
DX) and the securiv control unit.
133-22
Yes
-
No
-
ls the voltage at terminal 5 of the security control
unil connector changed from approximately 5
volts to 0 volts when the valet switch is pressed?
Yes
-
No
-
Check that the valet switch is working
properly, then check for an open in the
wiring between the valet switch and the
security control unit.
Security System Alarm Does Not Trigger
When The System ls Armed And The
Trunk Or A Door ls Opened
Security System Does Not
"Bep"
3 Times
When The System is Armed With The Trunk
Or A Door Open
(HX, LX, EX, Dx-V SD
1. Place the ceiling light in the center
position, then
open and close the doors one at a time. Do all
the doors operate the ceiling light properly?
Yes
-
No
-
Repair the ceiling light circuit.
With the ignition switch in the ON (ll) position,
does the trunk open indicator in the gauge
assembly come on with the trunk open?
Yes
-
No
-
Faulty trunk latch switch or an open in the
BLU/BLK wire.
control unit connector change trom battery
voltage with all doors closed, to less than I volt
when any door is opened?
Yes
-
No
-
(LT
GRN/RED) wire.
4. Does the voltage at terminal 3 of the security
voltage with the trunk closed, to less than 1 volt
when the trunk is opened?
Yes
-
No
-
ReDair the oDen in the terminal 3
(BLU/BLK)
wire.
133-23
Security System (conrd)
Parking Lights Do Not Flash (CX,
DX)
1 . Do the parking lights, headlights, and taillights
come on with the headlight switch in the HEAD
position?
Yes
-
No
-
Repair the parking lights, headlights, or
taillights circuit.
2. ls there battery voltage at terminals 1 and 2 of
the light flasher relay connector?
dHl
.t.
Yes
-
No
-
Repair the open in the WHT wire
between fuse 48 and the light flasher
relay.
ls there battery voltage at terminal 4 of the light
flasher relay connector?
-F-,
tlllJ
t 3 l 4 l
I
n
t v l
r
=
Yes
-
No
-
Replace the light flasher relay.
With the light flasher relay connector
disconnected, run a
jumper
to terminal 3.
Do the parking lights and taillights come on?
Yes
-
No
-
Repair the open in the RED/GRN wire.
133-24
5. Does the voltage at terminal 4 of the light flasher
relay connector change from battery voltage to 0
volts repeatedly when the system is in the alarm
triggered mode?
Yes
-
No
-
With the security control unit connector
disconnected, run a
jumper
wire from termrnal
17 to ground.
Do the
parking
lights come on?
Yes
-
No
-
(REDAIVHT)
wire.
q
I
=
Parking Lights Do Not Flash In Any Mode
(HX, LX, EX, DX-V Si)
1. Do the parking lights, headlights, and taillights
come on with the headlight switch in the HEAD
oosition?
Yes
-
No
-
Repair the
parking light, headlight, or
taillight circuit.
2. Does the horn sound when the transmitter
PANIC button is oressed?
Yes
-
No
-
Go to the
"Horn
Does Not Sound In the
Panic Mode" test on
page 130-11 (' 96-98
models) or 1 30-18
(' 99 models).
3. ls there battery voltage at terminals 1 and 2 of
the light flasher relay connector?
Yes
-
No
-
Reoair the open in the WHT wire
behveen fuse 48 and the liqht flasher
reray.
ls there battery voltage at terminal 4 ol the light
flasher relay connector?
Yes
-
No
-
\ t
133-25
5. With the light flasher relay connector
disconnected, run a
jumper
wire from terminal
.l
to terminal 3.
Do the
parking lights and taillights come on?
o.
Yes
-
No
-
Repair the open in the RED/GRN wire.
Does the voltage at terminal 4 of the light flasher
relay connector (C403) change from battery
voltage to 0 volts repeatedly when the security
svstem is in the PANIC mode?
Yes
-
No
-
7. With the security control unit connector
disconnected, run a
jumper
wire from terminal
17 to ground.
Do the
parking lights and taillights come on?
Yes
-
Replace the security conlrol unit.
No
-
(REDMHT)
wire.
q
I
=
Security System (cont'd)
Security System Status LED Stays On
1 . Does the security system status LED go out
when the security control unit connector is
disconnected?
Yes
-
No
-
' 96-' 98
models: Go to the next steD.
' 99
models: Locate and repair the short in
the BLUMHT wire between the security
LED and the security control unit
connector.
2. Does the security system status LED go
out
when the keyless entry connector (B) is
disconnected?
Yes
-
Locate and repair the short in the
BLU,ryVHT wire behveen the keyless entry
harness connector (B) and the security
control unil connector.
No
-
Beplace the radio,
133-26
Security System Status LED Does Not
Come On
('96-'98
HX, LX, EX)
1 . ls there voltage at terminal 11 of the keyless
entry harness connector (B)?
Yes
-
No
-
Replace the radio.
ls there voltage at terminal 14 of the security
control unit connector?
Yes
-
Go to the next steo,
No- Locate and repair the open in the
BLUMHT wire.
With the keyless entry harness connector (B)
connected, run a
jumper
from terminal 14 of the
security control unit connector to ground.
Does the securitv status LED come on?
Yes
-
No
-
Reolace the radio.
Starter Cut Does Not Work Properly
1 . With the security system connector
disconnected, run a
jumper
wire f rom terminal
19 t o ground.
Does the starter motor operate when the ignition
switch is turned to START
(lll)?
2.
Yes
-
No
-
ls there baltery voltage at terminals 2 and 3 of
the security starter cut relay connector, when the
ignition switch is in the START (lll) position?
Yes
-
Go to the next step,
No
-
Reoair the ooen in the BLK/YEL wire
between the ignition switch and the
security starter cut relay.
securitv starter cut relav?
Yes
-
No
-
Repl ace the securi ty starter cut rel ay.
3.
@
I
=
\ r r
133-27
4. With the security starter cut relay connector
disconnected, run a
jumper
to terminal 4.
Does the slarter motor operate when the ignition
(lll)?
5.
Yes
-
Go to the next step,
No
-
Repair the starting system.
With the security starter cut relay connector
reconnected, does the voltage at terminal 6
change from battery voltage to 0 volts when the
system is in the Alarm Triggered Mode?
Yes
-
Replace the security starter cut relay.
No
-
Repair the open in terminal 19
(BED/YEL)
wire.
4
I
=
Security System (cont'd)
Starter Cut Does Not Work Properly
(cx, Dx)
1 . With the security system connector
disconnected, run a
jumper
wire f rom terminal
19 t o ground,
switch is turned to START (lll)?
Yes
-
No
-
ls there battery voltage at terminals 2 and 3 of
the security starter cut relay connector, when the
ignition switch is in the START (lll) position?
Yes
-
No
-
Repair the open in the BLKMHT wire
between the ignition switch and the
security starter cut relay.
securitv starter cut relav?
Yes
-
No
-
Beplace the security starter cut relay.
4
o
t_
=
133-28
4. With the security starter cut relay connector
disconnected, run a
jumper
to terminal 4.
(lll)?
Yes
-
No
-
Repair lhe starting system.
starter cut relay change trom battery voltage to 0
volts when the system is in the Alarm Triggered
Mode?
Yes
-
Replace the security starter cut relay.
No
-
Repair the open in the terminal 19 (GRN)
wtre.
q
I
=
.1,
Horn Does Not Sound When Alarm ls
Triggered
1. Does the horn sound when the horn button is
pressed?
Yes
-
No- Repair the horn circuit.
2. With the security control connector
disconnected, run a
jumper
wire f rom terminal
' 18
to ground.
Yes
-
No
-
Repair the open in the lerminal 18
(GRY)
wire.
l r I
133-29
lnterlock System
-
Al l except' 96-' 98 CVT
page 10-12.
FUSE 33
{INTEBLCICK
uNrI)
WHIICRN
OASH
I HOOD
H:"
- IlEiE" i ) iifl*
8i?[',ffii
i[".tfi
;GE-st----l
glD^:R-
page 10-13.
I Box
L. J - - - - - - - - J PHot oi
*1
=
96 D16Y8 engi ne: Al l except
uoupes
' 97
D16Y7 engi ne: Al l except
California Coupe and California
Sedan LX
' 97
D16Y8 engi ne: Al l except
Coupes and Cal i l orni a Sedan
D1685 engi ne: Al l
*2
=
' 96
D16Y8 engi ne: Al l Coupes
' 97
D16Y7 engi ne: Cal i f orni a
Coupe, California Sedan LX
' 97
D16Y8 engl ne: Al l Coupes,
Cal i l orni a Sedan
' 98
model : Al l
*3
=
' 99
model : Al l
)rq
,'",:[*nu'
=-CF'!,n:E!-l
Hfl*gff*
i
l#?;"'"
-,,;:::?i-ili:itlll:
|
=
lr.u:;.Br-*
i-{Ji6i1!-- !,*;L$il{:*
|
,wrn cruse;r
tr,
;"6;dii--
Lr7 r
ii\l,B".i
o,",,,
i-l o,"*",!
'""'o*-''
x?!
| -$-.",.,
.ÂX-----.,'dtA--"^",."
lfl.iil F]iH*,"'i''t#'---.r=23[11
eowen.
lElJP-".'.'
-
L;tT'#:yTltijF.iu.
'f,
*or.,
,.il3,
f,
iii"^'?o'
| !^:?::^?l:t:9"
*r
w' raeof,
*2 *3
t:l*ii** ffi
"""'"
!
fit:'/:,:iffJff
,",'3,fii;1,1,''
'trii'df,'
tr
I
near lne snrn rever
-
TNTERLOCK
l l
wxrneo
t
CONTROL UNIT
--4-------------Lt,
*?,1fl 92
T- - - - - 1 UNDER-
FUSE 25
See Power
I BOt
Disilibution,
:
pHb'ro
ss
.----<
BLK/BLU
page 10-6. I
8 i, C352
- - - - - J
'
c419
""'''A\Fi#"i:
wHr/cRN
see
power
'[il:'ff*,,,,**
.,
J*:]l
., '"*""
;.-9,[ aL(BLU
GFN/
I
See A/T Gear
Position Indicator
A/T GEAR
POSITION
swtTcH
c433
BLK
I-
i -*t '
BLK
1
BLK
f, 9e
urut se
I
I
I
I
Control
ilt:tfi'F1
'-i_:{
BLK
O-<(
See Ground
Distribution,
page 14-5.
-l
#
:
G401
PHO|O 57
Key Intedock
Clrcuit
Allows key
intrlock
solenoid to
be energized
unless shift
lever is in
"P"
Shltt Lock Chcuil
Prevents shifi bck
solenoid trom
energizing unless
brake pdal is
dpfessed ard
accle{ator pedal is
not deprssed.
";t-,".f";,
138
- '96-'98
CVT
l-l-'l BRAKE SWTTCH
r--'l THROTTLE
| | l cl osed
wr l h
I . . - .
- , I
Posl r l oN
l&l!fii{+f i.:1r1'jflI$s"
o""*"tr[
"o'ouloo,
".o"i
I
.f#
ffiqll"
jilll
I
lllb
;s"",
!
-
r r , . l * " - " oI
+ |
i.'*-w-
- - - -,r-.1
j
If$$Bi,
e* !;;iiffi :,?H,,,
ry*:' !fi3$lt3'
l6,i8
L"':__"f# *'_lgs,g;
fl*UB;t;"
ii'";i;'
"*l
u't""
i-u;-*"--- ,s l [ltsff?.
Lj:'sri:--::l itjs[-
=ffan+'
INTERLOCK
CONTROL
UNIT
vtEw 26
;-;5[ BLKBIU
I
BLKBTU See A/f Gear
ar<
Posi ti on
i lndicator
NOTE:
ln case of system
mal f unct i on, t he
shift lever can be
released by pushing
t he i gni t i on key i nt o
the release slot near
the shitt lever.
- - - - - - - r
A/ T GEAR
il{t iffi'dqF"
I
l ,' -
-\-"
l ;#i ;",;
l " \
i ' - !
L - - - J . - - - J
BLK I C433
"IYW!'"
:."qsrqft
r E. = = = - - - -
F-
Shltt Lock Clrcuil
Prevents shift lock
solenoid lrom
nergizing unlees
brake
pdal is
depressed and
accelerator
pedal is
not depressed.
Key ldedock
Clrcult
Allows ky
interlock
solenoid to
be energized
unl6ss shitt
l ever i s i n' P"
;;.r";;
l l e
138- 1
Power Mirrors
-
Without Defogger
r,-;;---j
\
HEAIEF
1
/ A/C FEIAY
I
t uo
s"" Po*",
!
f-----f
Distribution, I
L_i:i:_J
UNDER-
DASH
RELAY
BOX
UNDER-
OASH
FUSE/
RELAY
BOX
I
I
I
I
I
BLK/BLU
1 0
BLK/BLU
-l
I
I
I
I
I
J
f,-G;---
I
See Power
lF---t
Distribution,
L_i:i'i_
rt;%,"
*'ii%.,
L
vtEW 46
vlEw 22
'96-'98
models
and all GX models
'99r00
models
except GX
a -
c639
vlEW23
c656
POWER
MIRBOR
swtTcH
vtEw 33
See Ground
Distribution,
page 14-8.
LEFT
MIRROR
RIGHT
MIRROR
G-t
BLU/BLK
('98 00
mooets
2't)
1 5
BLU/ALK
LT GRN
G551
141
How the Ci rcui t Works
The two outside mirrors are controlled by the power
mirror switch. Each mirror has two reversible
motors: one motor moves the mirror up and down
and the other motor moves the mirror lett and right.
The power mirror switch contains four switches to
control mirror adjustment, and two switches to
select the left or right mirror With the ignition in ON
(ll), battery voltage is supplied to the
power
mirror
swrtch. The mirror selector switch directs voltage
from two of the direction switches to either the left
or the right mirror.
Mirror Up
When you press the
"up"
edge of the mirror
adjustment button, ground is supplied from one of
the up/down switch contacts to both mirrors; battery
voltage is supplied from the opposite up/down
switch contact through the mirror select switch. lf
the mirror select switch is in the left or right position,
battery voltage is supplied to the corresponding
mirror uo/down motor which then tilts the selected
mtrror uD.
Mirror Down
When you press the
"down"
edge of the mirror
adjustment button, battery voltage is supplied Irom
one of the up/down swilch contacts to both mirrors;
a ground is supplied from the opposite up/down
mirror up/down motor which then tilts the selected
mrrror oown.
Mirror Left
When you press the
"|eft"
edge of the mirror
adjustment button, battery voltage is supplied from
one of the lefuright switch contacts to both mirrors;
a ground is supplied from the opposite lefuright
mirror lefvright motor which then tilts the selected
mirror to the lett.
Mirror Right
When you press the
"right"
edge of the mirror
adjustment button, ground
is supplied from one of
the lefvright switch contacts to both mirrors; battery
voltage is supplied from the opposite left/right switch
contact through the mirror select switch. lf the mirror
select switch is in the left or right position,
battery
voltage is supplied to the corresponding mirror
lefuright motor which then tilts the selected mirror to
the right.
for speclfic tests of troubleshooting procedures
141-1
Power Mirrors
-
With Defogger
ORN/
i I
;;;
- - - - - -
I
HJ.o.',8.3.f;,"
i )tlf*"'*"
geePower
if,g}"",
!-,i::-i4tir-J
f
9;%.,
BLKBLU
I
V'EW55
' o
l 9, ; %, ,
BL(/B!U
I
V/EW 46
a
T'|[
a a a
OFN/
24
ORN/
BLU/
RED
--
YEL/FED
20
--
BLUA!/HT
21
cs56
OBN/WHf
c639
4
vtEw23
FEO
c557
vlEw 62
c656
ORN
BLK/
BLK
LEFT
BLKryVHT
POWER 3
MTRROR
BLK
".*
|
..- Gs52
".^
|
... G551
c639
vlEw2i
See Ground Distribution,
page 14-8.
c656
vlEw 24
See Ground Dislribution,
page 14-9.
Minor Selecto.
Switch
O
=
Neutral
1
=
Lelt
2
=
Rlght
' ,41-2
How the Ci rcui t Works
The two outside mirrors are controlled by the
power
mirror switch. Each mirror has two reversible
motors: one motor moves lhe mirror uo and down
and the other motor moves the mirror left and right.
The power mirror switch contains four switches to
control mirror adjustment, and a switch lo select
the left or right mirror. With the ignition ON (ll),
battery voltage is supplied to the power mirror
switch. The mirror selector switch directs voltage
Irom the direction switches to either the left or rioht
mtrror.
Mirror Up
When you press
the
"up"
edge of the mirror
adjustment button, voltage is supplied from one of
the UP switch contacts to both mirrors. With the
mirror select switch in the LEFT or RIGHT Dosition.
ground is provjded
for the corresponding up/down
motor through the opposite UP switch contact.
Battery voltage is supplied to the mirror up/down
motor which then tilts the selected mirror uo.
Mirror Down
When you press the
"down"
edge of the mirror
adjustment button, ground is provided
through one
of the DOWN switch contacts to both mirrors.
With the mirror select switch in the LEFT or RIGHT
position, voltage is supplied to the corresponding
up/down motor through the opposite DOWN switch
contact. Battery voltage is supplied to the mirror
up/down motor which then tilts the selected
mtrror down.
Mirror Left
When the mirror select switch is in the LEFT or
RIGHT position,
and you press the
"lett"
edge of the
mirror adjustment button, voltage is supplied to both
corresponding mirror motors through one of the
LEFT switch contacts. Ground is provided for the
corresponding lefvright motor through the opposite
LEFT switch contact, 8attery voltage is supplied to
the mirror left /right motor which then tilts the
selected mirror left.
I , J
141- 3
Mirror Right
When the mirror select switch is in the LEFT or
RIGHT position, and you press the
' ?ight"
edge of
the mirror adjustment button, ground is provided to
both corresponding mirror motors through one of
the RIGHT switch contacts. Voltage is supplied to
the corresponding leruright motor through the
opposite RIGHT switch contact. Battery voltage is
supplied to the mirror left /right motor which then
tilts the selected mirror right.
Mirror Detoggers
With the ignition switch in ON (ll), battery voltage is
supplied to the mirror defogger switch. When you
press
the mirror defogger switch ON, voltage is
supplied to both mirror defoggers, causing them to
heat up and remove any fog from the mirrors. The
opposite side of each defogger grid is connected to
g rou no.
Body Electrical) for specific tests and
troubleshooting
procedures.
Stereo Sound System
i.l
-"r,"atrf
;;-;l
P,)r'=.,8-Jl3g"
BA.K.IJP
|
?pJ" ,
I
I
c351
FUSE 28
RAOIO
CLOCK
(15A 9A no{br.)
c501
vlEw 55
UNDER-DASH
FUSE/RELAY
BOX
' t9
c928
OPTION
CONNECTOR
*
=
' 96.98
model s
aa4,
See Power
Distribution,
page 10- 11.
1 8 c411
vlEw 60
See Dash and
Consol e Li ght s
.^fi;l ;,tr
rA2)
8
BLU
1 4
BLU
1
(wi t h power mi rrors 16)
REO/ GFN
or BLU
I RED/ GRN I
' ( 96 s7 moder s BLU)
r
ra10)
1 8
GRY/BLK
1 3
(wi t h power mi rror6 17)
BRN/BLK
or GRYIBIK
rAe)
17
BFN/ALK
BRN/BLK
(with power mirrors 7)
RED/GRN
1
C556 (with
oower milors 6)
PHA| O93
vtEw 61 aLU
or RED/GRN
, E L U ,
'
( s6 97 modes FEO/ GFN)
ra1)
?
REO/GFN
c503
GFY/BLK
or BRN/ALK
c557
vtEw 62
' RED
,
BLU
, 1
.'I LEFT
I I TWEETER
RIGHT
.
1
TWEETER.
c6s7
GFY/BLK
BFN/BLK)
150
Tweeters
*
=
96-98 model s
-
'96-'98
f'4odels
See Power Door Locks
(with Keyless Entry)
LT
ELU
GFYA!/HT
7
(AI ' 99-' 00 6)
(' 96-' 98 Sedans l 3)
STEREO
RADIO IUNER
('96.98 models)
vtEw 6a
or
AUDIO UNIT
(99
' 00
model s)
:l"l :[:I: ilil'
LI
GRN/
at K
' BLU/
I
FEO
' 8 1
fA7)
BLU/ryEL
BLU/YEL
rA8)
REO/YEL
(.A14)
20
BLK
c503
BED/YEL
(Alt
'99-'00
9)
('96-'98 Sedans 10)
**=
Mal e- Femal e
t ermi nal s
reversed
f or' 99-' 00
c562
*
2
(A

'99-'00
7)
('96-98 Sedans 12)
BLU/YEL
J I
G501
150- 1
RI GHT
REAR
SPEAKER
REAR
SPEAKER
Accessory Power Socket
-.t
UNDER-DASH
|
)
ruse zr
|
[N1e'ne*"
|
)33$ifl*
lPHoroia
t__tglll__J
"
[ffi']''
i
"..""" I
I
I
, I
l'-l-l
AccEssoRY
lQli{y#lfr
See Ground
Distribution,
page 14-7.
l v
l l
t t
L__l
#
:
c4o1
PHAfa 57
155
1. Behi nd Fr ont Gr i l l e
Component Locati on
4. Ri ght Rear Corner of Engi ne Compart ment
2. Behi nd Lef t Si de of Front Bumper 5. Ri ght Si de of Engi ne Compart ment
\
\b
3. Behi nd Lef t Si de of Front Bumper 6. Ri ght Si de of Engi ne Compart ment
201
\
7. Ri ght Rear Corner of Engi ne Compartment 10. Ri ght Rear Corner of Engi ne Compart ment
b
8. Ri ght Rear Corner of Engi ne Compartment 11. Ri ght Front Corner of Engi ne Compart ment
\
9. Right Rear Corner of Engine Compartment 12. Ri ght Front Gorner of Engi ne Compartment
L
tr
201
-1
13. Lower Ri ght Front of Engi ne Compart ment
Component Locati on
\
16. Lef t Front Corner of Engi ne Compart ment
14. Front of Engi ne Compart ment 17. Left Front Corner of Engi ne Compartment
\
15. !-ower Left Front of Engine Compartment 18. Left Front Corner of Engi ne Compartment
*
201-2
\
\
\
19. Left Front Corner of Engine Compartment 22. Letl Rear Corner of Engine Compartment
20. Left Front of Engi ne Compartment 23. Left Rear Corner of Engi ne Compartment
21. Left Rear Corner of Engine Compartment 24. Lower Left Rear of Engine Compartment
POWER STEERI NG I
\
201
-3
25. Lower Left Rear of Engi ne
Component Locati on
\ 28. Lower Ri ght Si de of Engi ne Compartment
26. Left Si de of Engi ne (Al l Except 816A2) 29. Lower Ri ght Front of Engi ne
\
27. Right Front of Engine 30. Lower Front of Transmission
201-4
\
\
\
31. Ri ght Si de of Engi ne Compartment (Mff) 34. Lower Ri ght Si de of Engi ne
32. Ri ght Front of Engi ne Compartment 35. Lower Ri ght Rear of Engi ne
SPEED
SENSOR
(vss)
33. Ri ght Si de of Engi ne 36. Right Side of D16Y5 Engine (D1685 Similar)
201
-5
37. Top Ri ght Si de of D16Y7 Engi ne
Component Locati on
J \
40. Front of D16Y5 Engi ne (D1685/ D16Y7 Si mi l ar) \,
38. Top Center of Engi ne (except Dl 685) 41. Fr ont of Dl 6Y5 Engi ne ( DI 685/ D16Y7
Si mi l ar )
39. Ri ght Rear of Engi ne Compartment 42. Front of Dl6Y8 Engine (' 96-' 98)
201
-6
t
43. Undersi de of Vehi cl e (' 96-' 98 D16Y8) 46. Lower Rear of D16YB Engine (Others Similar)
44. Ri ght Si de of D16Y8 Engi ne (Others Si mi l ar) 47. Rear of D16Y8 Engine (D16Y5 and D1685 Similar)
\
45. Rear of D16Y8 Engi ne (Al l except D16Y7) 48. Top Left Side of D16Y7 Engine
201-7
Component Locati on
49. Top of D16Y7 Engi ne 52. Behi nd Left Si de of Dash Panel \
\
50. Left Si de of Dash Panel 53. Behi nd Left Si de of Dash Panel (' 96-' 97)
51. Behi nd Lef t Si de of Dash Panel 54. Behi nd Lef t Si de of Dash Panel (' 96-' 97 Model s)
201
-g
\
55. Behi nd Left Si de of Dash Panel 58. Behi nd Left Si de of Dash Panel
c712
(3-BRN) (' 96 Model)
(3-GRN) (' 97-' 00 Models)
56. Upper Left Ki ck Panel 59. Behind Left Side of Dash Panel
57. Left Kick Panel Area 60. Behind Left Side of Dash Panel
201
-9
Cornponent Locati on
61. Behi nd Lef t Si de of Dash Panel \
\
64. Rear of Under-dash Fuse/Rel ay Box
62. Behi nd Left Si de of Dash Panel 65. Undersi de of St eeri ng Col umn
63. Rear of Under-dash Fuse/Rel ay Box 66. Behi nd Left Si de of Dash Panel
201
-'l
0
\
\
\
\
67. Rear of Gauge Assembl y 70. Behi nd Left Si de of Front Consol e
68. Behi nd Left Si de of Dash Panel 71. Ri ght Si de of St eeri ng Col umn
69. Behi nd Left Si de of Dash Panel 72. Lett Side of Steering Column
:FFF
: l : : : aal rl f f i i i l f f i : : -E--:
201
-1
1
Gomponent Locatl on
73. Rear of Radi o (' 96-' 98) 76. Bel ow Front Consol e
74. Undersi de of Heater Control Panel (' 96-' 98) 77. Lett Si de of Center Consol e
75. Behi nd Front Consol e
78. Ri ght Si de of Center Consol e
2Q1-12
79. Bel ow Center Consol e 82. Behi nd Gl ove Box (' 96-' 98)
\
\
80. Bel ow Front Consol e (' 96-' 98)
83. Bel ow Ri ght Si de of Dash Panel
8' 1. Behi nd Ri ght Si de of Dash Panel 84. Behi nd Gl ove Box
\
201
-'l
3
Cornponent
Location
85. Behi nd Ri ght Ki ck Panel
\
\
88. Dri ver' s Door
CONNECTOR B i i
86. Behi nd Ri ght Ki ck Panel 89. Top Front of Dri ver' s Door (Frt. Pass. Si mi l ar)
87. Undersi de of Dri ver' s Seat 90. Front of Driver' s Door (Frt. Pass. Similar)
201-14
\
\
91. Front of Dri ver' s Door (Frt . Pass. Si mi l ar) 94" Front of Lef t Rear Door (Ri ght Si mi l ar)
92. Rear of Dri ver' s Door (Frt . Pass. Si mi l ar) 95. Rear of l -eft Rear Door (Ri ght Si mi l ar)
93. Dri ver' s Door (Frt" Pass. Si mi l ar) 96. At Driver' s Door Striker Area (Frt. Pass. Similar)
\
201
-15
Component Locati on
97. Left Rear Door Stri ker Area (Ri ght Si mi l ar)
\
\
100. Bel ow Left Si de of Rear Seat (Ri ght Si mi l ar)
98. Dri ver' s Door Si l l 101. Left of Rear Seat (Sedan Shown, Others Si mi l ar)
99. Lef t Cent er Pi l l ar (Ri ght Si mi l ar) 102. Genter of Rear Shelf (Coupe/Sedan)
201
-16
\
103. Bel ow Center of Rear Seat 106. I nsi de of Lef t Rear Wheel (Ri ght Si mi l ar)
104. Left Front Corner of Fuel Tank (' 96-' 98) 107. Undersi de of Roof
105. l nsi de of Lef t Front Wheel (Ri ght Si mi l ar) 108. Lef t Undersi de of Hat ch Li d
\
201-17
Component Locati on
109. Undersi de of Hat ch Li d (' 96-' 97 Model s) 112. Ri ght Si de of Cargo Area (Hat chback)
\
\,
110. Undersi de of Hat ch Li d 113. Cent er of End Panel
111. Behi nd Lef t Si de of Dash Panel 1'14. Lett Side of Trunk Lid (with Optional Trunk Spoiler)
201
-18
\,
115. Left Si de of Trunk Li d (except
' 99-' 00
Sedan) 118. Left Rear of Trunk/Cargo Area (except
'99-'00
Sed.)
b
\
116. Cent er of Trunk Li d 119. Top of Transmi ssi on (CVT)
117. Rear Spoi l er on Trunk Li d 120. Ri ght Si de Rear of Engi ne Compartment (CVT)
L
ffi=
201
-19
Gomponent Locati on
121. Behi nd Lef t Ki ck Panel (' 96-' 98 CVT)
\
124. Rear of Engi ne Compartment (CVT)
TRANSMI SSI ON
CONTROL MODULE
(rcM)
122. Ri ght Si de Lower Engi ne Compart ment (CVT) 125. Behi nd Ri ght Si de of Dash Panel
\
123. Ri ght Front of Engi ne (CVT) 126. Undersi de of Hat ch Li d
k
2A1-20
\
127.Letl Rear of Trunk (' 98) 130. Behi nd Lef t Si de of Dash
\
128. Rear of Dl6Y8 Engine with n/VT (B16AZD16Y5 Similar) 131. Undersi de of Vehi cl e, Rear of Engi ne
129. Behi nd Left Si de of Dash (' 98) 132. Undersi de of Hat ch Li d (' 98-' 00)
b
201-21
Component Locati on
133. Below Rear of D16Y8 Eng. (816A2 Similar) ('99-'00)
I
\
\
136. Behi nd Left Si de of Front Consol e (' 99-' 00)
134. Behi nd Ki ck Panel (' 99-' 00)
137. Behi nd Center Panel (' 99-' 00)
135" Behi nd Left Si de of Dash Panel (' 99-' 00) 138. Behi nd Front Consol e
c723
(20-GRY) (' 96-' 98 Models)
(24-BLU) (' 99-' 00 Model s)
201-22
t,![!!til**}t$]Sl1Ht:!i!ifj*#
139. Behind Glove Box (' 99-' 00) 142. Lett Rear Corner Engine Gompartment (GX)
140. Undersi de of Rear Shel f (' 99-' 00 Sedans) 143. Ri ght Rear of Engi ne Compartment (GX)
141. Top Center of Engi ne (GX) 144. Behi nd Left Ki ck Panel (GX)
201-23
145. Left Si de of Trunk (GX)
Gomponent Location
\
148. Bel ow Ri ght Si de of Center Consol e
146. Behi nd Back Seat (GX)
FUEL TANK PRESSURE
SENSOR AND FUEL TANK
TEMPERATURE SENSOR
(rNSrDE)
149. Undersi de of Vehi cl e, Left Rear of Engi ne (Si )
l 47.Behi nd Left Si de of Back Seat (GX) 150. Ri ght Front of Engi ne (Si )
201-24
I O
151. Lower Front of Transmission (Si)
152. Left Center of End Panel (' 99-' 00 Sedan)
201-25
Connector Views
Cavi ty Numberi ng System u
WI RE SI DE
of
TERMINAL SIDE
ot
MALE TERMINALS
FEMALE TERMINALS
LOCKING DEVICE
Must be at top.
In-Line Connector View Index (views
begi 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
C604
( Hat chback)
. . . . . . . . 7
C605 ( Hat chback) . . . . . . . . I
C607
( Hat chback)
. . . . . . . . 9
c 6 3 9 . . . . . . . . . . . . . . . . . 2 3
c 6 5 6 . . . . . . . . . . . . . . . . . . 2 4
c 7 2 3 . . . . . . . . . . . . . . . . . . 5 7
202
-
Component Connector View Index (Views begin on
page 202-21
Connector View
ABS Co n t r o l Un i t . . . . . . . . . . . . . . 6 3
Audi o Uni t
( ' 99- ' 00
model s) . . . . . . 74
Combination Light Switch . . . . . . . . . . . . . . . 64
Combination Wiper Switch . . . . . . . . . . . . . . 65
Cr ui s e Cont r ol Uni t . . . . . . . . . 43
C\ TTTr ansmi ssi on Sol enoi d . . . . . . . . . . . . . 25
Dat a Li nk Connect or (DLC) . . . . . 48
Dayt i me Runnl ng Li ght s Cont rol Uni t . . . . . 66
Engi ne c ont r ol Modul e ( ECM) . . . . . . . . . . . 70
Exhaust Gas Recirculation (EGR) Valve
and Lift Sensor (D16Y5 Mfl, D1685) . . . . 10
Ga u g e As s e mb l y . . . . . . . . . . . . . 7 1
Ha z a r d Wa r n l n g Swi t c h , , . . , , , . . . , , , , . . . 3 2
Heat er Cont rol Panel (' 96-' 98 model s) . . . . . 44
Heat er Cont rol Panel (' 99-' 00 model s) . . . . , 76
Heat er Fan Swi t ch (' 96-' 98 model s) , , , . . . . 11
f ni ect or Cont r ol Modul e ( GX) . . . . . . . . . . . . 77
I /
202-1
Connector View
I nt egr at ed Cont r ol Uni t . . . . . . . , . 67
f nt er f ock Cont r ol Uni t . . . . . . . . . . 26
Keyfess Door Lock Control Unit . . . . , . . . . . 75
Mode Cont r ol Mot or . . . . . . . . . . . ' 17
Moonr oof Cl os e Rel ay . . . . . . . . . 13
Moonr oof Open Rel ay . . . . . . . . . . 15
PGM- FI Mai n Rel ay . . . . . . . . . . . . 18
Power Door Lock Conl r ol Uni l . . . . . . . . . . . 37
Power Mi r r or Swi t ch . , . . . . . . . . . 33
Power Wi ndow Mast er Swi t ch . , . . . . . . . . . 36
Power t r ai n Cont r ol Modul e ( PCM) . . . . . . . 70
Secur i t y Cont r ol Uni t . . . , . . , , . . . 58
Sec ur i t y St ar t er Cut Bel ay . . . . . . , , , . . . . , , 12
S R S U n i t . . . . . . . . . . . . . 5 1
St ereo Radi o Tuner (' 96-' 98 model s) . . . . . . 68
Transmi ssi on Cont rol Modul e
CI CM)
. . . . . 69
Connector
Views
(cont'd)
1. C202
(wi th Crui se Control )
-
Gray
-
Left side ol engine compartment
-
Connects mai n wi re harness to engi ne
compartment wre harness
gRN/BLK
(Crui se control )
BRN,ryVHT
(Cruise control)
RED/BLK
(Headl i ght swi tch)
BRN
{Crui se
conkol )
WHT/BLK
(Front wipetwashel)
5
4. c568
-
Gray
-
Bel ow Juel tank uni t connector
-
Connects fl oor wi re harness to tuel tank
pressure suo-narness
BLU (PGi .4-Fr)
LT GRN (PGM-FI)
BLl(WHT (PGI\4-FD
YEUBLU (PGM, FI )
GRN/BLK (PGI\,4.FD
4
5
2. C407
('98-'00 Models)
-
Gray
-
Behi nd l eft si de ol dash, above ki ck panel
-
Connects main wire harness to roof or moonroo{
wtre harness
WHT/ RED
(Cei l i ng l i ght )
l\4ale
-
LT GRN/RED
Female
-
LT GRN/BLK
or LT GRN/ RED
5
5. c570
-
Bl ue
-
In ri ght door
pi l l ar
-
Connects floor wire harness to right rear door
wlre hafness
2
3
YEL
(Power windows)
WHT/RED
(Power door l ocks)
YEUGRN
(Power wrndows)
YEL/BLK
(Power windows)
YEURED
(Power door locks)
5
6
3. c423
-
Green
-
On Jront of under-dash tuse/relay box
-
On mai n wi re harness
*1:
YEL (Fuse 3)
*2:
GRN
(Rear wiper/washe4
GRN/ YEL
(Turn signals)
GRN/ ORN
{Tu. n
si gnal s)
GRN/ BLK
(Front wiper/washer)
GRN/ RED
(Turn signals)
5
6 2
3
*1=
USA: tX, EX, HX, DX-V Si
Canada: EX, Si
*2=
Hatchback
202-2
6. c571
-
Bl ue
-
In l ett door pi l l ar
-
Connects floor wire harness to lett rear door
wlre harness
MaI e
_
YEL
Femal e
-
GBN/ YEL
(Power windows)
WHT/ RED
(Power door l ocks)
Mal e
-
YEUGRN
Femal e
-
GBN
(Power windows)
5
6
N4ale YEUBLK
Female
-
RED,ryVHT
(Power windows)
YEURED
(Power door locks)
\
7. C604 (Hatchback)
GRN/ BLK
(Back-up l i ght s)
l\4ale GRNIYEL
Femal e
-
GRN/ RED
(Turn si gnal and hazard
warni ng l i ght s)
BLK (G601)
-
Gray
-
Left rear ol cargo area
-
Connects rear wire harness to left outer
tai l l i ght assembl y
4
5
6
1
2
GRNAVHT
(Brake lights)
FED/ BLK
(Headl l ght swi t ch)
10. Exhaust Gas Reci rcul ati on
(EGR) Valve and Lift Sensor
1
2
3
(D16Y5 MfI D1685)
-
Gray
-
Top ri ght si de of engi ne
-
On engi ne wi re harness
WHT/BLK (EGR i nput)
GRN/BLK
(Sensor ground)
YEUBLU
(Reference voltage)
4
5
6
BLK (Ground)
PNK (EGR cont rol )
of cargo area
rear wi re harness to ri ght outer
assembl y
n- -n
a t | _ a 2 a
l 3 I 4 t 5 t t t l
IJ
I
8. C605
(Hatchback)
-
Gray
-
Ri ght rear
-
Connects
tai l l i ght
GRN/BLK
(Back-up l i ghts)
GRNTYEL
(Turn si gnal and hazard
warni ng l i ghts)
3
4
5
6
1
2
BLK (G601)
GFNAVHT (Brake lights)
RED/BLK
11. Heater Fan Swi tch
('96-'98 Models)
-
Brown
Center of dash
-
On heater-sub B wi re harness
BLK (Ground)
BLUAVHT (L4edi um
LO speed i nput)
BLU/BLK
(Hl speed i nput)
4
5
6
1
2
3
BLU (LO speed input)
BLU/YEL (Medi um
Hl speed i nput)
GFIN (Bl ower
switch ON input)
9. C607 (Hatchback)
-
Bl ue
-
Ri ght si de o{ cargo area
-
On rear wire harness
BLU/ BLK (l ndi cat ors)
RED/ BLK
(Li cense l i ght s)
GBN,ryVHT (8rake lights)
LT GBN
(Rear wiper/washe0
5
6
1
2
3
4
GRN
(Rear wiper/washer)
LT GRN/ BLK
(Rear \ / i per washer)
) /
202-3
12. Securi ty Starter Cut Rel ay/C416
-
Natural
*
Upper left kick panel
-
1
2 Al l except CX and DXI
[,4ale: BLK,^r'r'HT
Femal e: BLKI / EL
CX and DXi BLI(WHT
(Battery input)
All except CX and DX:
BLK^/EL
CX and DX: BLK/ WHT
(Baftery input)
[.4ale
-
BLK/WHT
Femal e
-
BLKAVHT
or BLKRED
(Starter output)
Al l excepi CX and DX:
RED/ YEL
CX and DX: GRN
(Security starter c!1
rel ay cont rol i npul )
5
6
t l
3 '
Connector Views (cont'd)
13. Moonroof Cl ose Rel ay
' 96-97
Model s:
1 WHT (Battery input)
2 GRN/ / EL
{Motor
conirol)
3 GRN/ ORN
(l gni t i on l nput )
-
Brown (' 96-' 97 model s) or Gray
(' 98-' 00 model s)
-
Upper left kick panel
-
On moonroof wi re harness
5
6
BLK (Ground)
GBN/ RED (Coi l conkol )
'98r00
Models:
GRN/YEL
(Motor control)
WHT (Battery input)
GRN/RED
(Coil control)
4 BLK (G401)
5 GRN/ ORN
(l gni t i on i nput ) 2
3
15. Moonroof Open Rel ay
-
Brown (' 96-' 97 model s) or Gray (' 98-' 00 model s)
-
Upper l eft ki ck panel
-
On moonrool wire harness
' 96. 97
Model s:
1 WHT (Battery input)
2 GRN/FED
(lvlotor control)
3 GRN/ORN
(l gni ti on i nput)
'98r00
Modelsi
BLK (Ground)
YEL (Coi l conkol )
5
6
GBN/RED
(lvlotor control)
WHT (Battery input)
YEL (Coil control)
4 BLK (G401)
5 GRN/ ORN
(l gni t i on i nput ) 2
3
, 1 ^ t
6
14. C415
-
Brown
-
Above underdash fuse/relay box
-
Connects mai n wi re harness to steeri ng l ock pi gtai l
*
1: [,4ale BLKryEL
Femal e
-
BLKMHT
*2:
BLK,/WHT
(Start oulput)
l\.4ale
-
BLU/RED
Female
-
BLUruVHT
(l gni l i on key swi tch
outpur)
N4ale
-
WHT/BLK
Female
-
WHT
(Battery input)
l\,4ale BLK
Femal e
-
BLU^VHT
(Ground)
Ani Male
-
WHT
Femal e
-
WHT
/ EL
(Key interlock switch
ourpur)
A/ T: WHT/ BLU
(Key i nt erl ock
solenold control)
A"rT: WHT/GRN
(Battery inpul)
*1=
Vehicles pre-wired for accessory security system
*2=
Vehicles not pre wired for accessory security system
202-4
16. C422
-
Green
-
On tront ol under-dash tuse/relay box
-
On main wire harness
7
l
2
3
4
5
6
7
FED/ BLU (Headl i ght s)
REDAVHT (Headl i ght s)
WHT (Fuse 48)
BED/GRN
(Headlight switch)
-
17. Mode Control Motor
-
Green
-
Behi nd dash, ri ght of steeri ng col umn
-
On heater sub-harness-A
1 BLK,TYEL (lgnition input)
2 YEUBLU (Detrost input)
3 YEL (H/DEF i nput)
4 BLUA/VHT (Heat input)
5 GRN/YEL (BI-LEV i nput)
YEURED (Vent input)
' 96.98:
BLK (G402)
' 99-' 00r
BRNAVHT
{Motor
ground input)
6
7
18. PGM-FI Mai n Rel ay
-
Brown
-
Behi nd ri ght si de o{ dash
-
'l
4
1 GRN/YEL
(Fuel pump control )
2 BLUAVHT (Fuse 31)
3 BLK ( G101)
* 1:
YEUGRN
(Fuel pump output)
*2:
WHT/RED
(Fuel supply control)
YEUGRN (Fuse 13)
YEUBLK (Power output)
WHT/BLK (Fuse 44)
6
7
*1=
Al l except Dl 685
*2=
D16Bs
19. Cl 23
(D16Y5 M/T)
2
3
BLI(WHT
{Heater
control)
BLK (Heater ground)
GRN/BLK
(Sensor ground)
-
cray
-
Ri ght tront o{ engi ne
-
Connects engine wire harness to primary
HO2S pi gtai l
5
6
7
8
WHT (Hgater control)
WHT (Sensor input)
BLK (Sensor i nput)
RED (Sensor ground)
20. c136
-
Gray
-
Left rear of engine compartment
-
Connects engine wire harness to main wire harness
'96198
D't6Y5:
1 Male
-
BLUAVHT
Female
-
BLU|/EL
(A"/T controls)
2 GRN,^WHT (A,/T controls)
3 YEL (A/T controls)
4 GRN/YEL (A/T controls)
5 PN(BLK (fff
gs6lrq;s;
6 PNI(BLU (A/T controls)
7 GRN/BLK (Ar/T controls)
8 RED/BLU (A/T controls)
9 WHT (A/T controls)
'96198
D16Y7/D16Y8:
GRN/BLK (A/T controls)
WHT/RED
(lnterlock system)
10 WHT/RED (A"/T controls)
11
' 98
model s: GRN/BLK
(PGr,4-Fr)
12 GRN (A/T controls)
13 l\4ale
-
REDMHT
Femal e
-
RED/BLU
(4,/T controls)
14 N4ale
-
BLIVWHT
Femal e
-
ORN/BLU
(A/T controls)
5 WHT (A/T controls)
6 BLU (Antf se11re;s;
7
A

01685:
3
1
2
3
4
5
6
7
8
BRN (PGM-FD
RED (PGIV-FD
BLU (PGI\4-FD
YEL (PGI,4,F|)
l\4ale
-
GFN
Female
-
WHT/RED
(PGM-FD
GRN/BLK (A'tl
gs6trels;
BLU (A/T controls)
wHT (A/I controls)
202-5
21. C214
-
Gray
-
-
Connects engi ne wi re harness to mai n wi re harness
'96-
97 models:
Male
-
WHT/GRN
Female
-
BLU/FED
(Horn)
' 98-' 00
model s:
BLU/ RED (Horn)
BLKRED (Fans)
WHT (Fans)
4
5
6
7
*io
t0,,"
compressor controls)
BLU/RED (A,/C
BLU,ryVHT (I'/C
2
3
23. C639
-
Black,ryVhite
-
Top front ot driver's door
-
Connects dri ver' s door wi re harness to dri ver' s
power mirror pigtail
Without Defogger:
1
2
4
6 Male
-
LT GRN
Fema|e
-
BLU/BLK
(Left/right control)
With Oelogger:
1
2
3 l\,lale
-
BLKAVHT
Femal e
-
BLK
(Ground)
4 lvlale
-
BLU/RED
Female ORNAVHT
(Delogge4
lvlale PNK
Female
-
YEURED
(Common)
MaIe
_
GRY
Female BLUA/VHT
(Up/down control)
lvlale
-
LT GRN
Female BLU/BLK
(Corrmon)
i.4ale
-
PNK
Femal e
-
YEURED
(Up/down conkol)
Mal e
-
GRY
Female
-
BLU,ryVHT
(Lett/right control)
22. C552
-
Green
-
On rear of under-dash fuse/relay box
-
On tloor wire harness
1
*1:
FEDA/ VHT
(Power windows)
2
*1:
YEL/ BLK
(Power windows)
3
* 1: YEL/ BLK
(Power windows)
4
*1
| RED/WHT
(Power windows)
*1=
Sedan onl y
*2=' 96' ' 98: Al l
' 99-' 00r
GX
6
7
GRN/ BLK
(Power windows)
GRN/ BLK
(Power windows)
*2:
BLK/YEL
(Power mifiors)
BLU/BLK
{Power
windows)
202-6
24. C556
-
Black,ryVhite
-
Top front of front passenger's door
-
Connects tront passengefs door wire harness
to passenger' s power mi rror pi gtai l
Without Defogger:
l
2
3 l\4ale
-
Femal e BLK
(Not Used)
4 l\4ale
-
Femal e
-
ORN/ WHT
(Not Used)
With Delogger:
1
2
3 Male
-
BLK^VHT
Female
-
BLK
(Ground)
4 l\.4ale
-
BLU/RED
Female
-
ORNAVHT
(Defogger)
Mal e OBN
Female
-
YEUBLK
(LefVright control)
l\4ale
-
PNK
Female
-
YEL/RED
(Common)
Mal e BRN
Female
-
GRNA/VHT
(Up/down conkol)
[.4ale
-
ORN
Female
-
YEL/BLK
(Left/right control)
l ral e
-
PNK
Femal e
-
YEURED
(Up/down conkol)
l\,lale
-
BFN
Femal e' GFi N
(Common)
-
25. CW Transmission Solenoid
-
Gray
-
Lower front of transmission
-
1
2 GRNAVHT
(H LC LS +)
3 BLUAVHT (SH LS +)
4 YEL (SC LS +)
5
6
7
8
GRN/ BLK (SOL I N H)
PNK/ BLK (HLC LS
_)
GRN| VEL (SH LS
-)
PNK/ BLU (SC LS
_)
26. Interl ock Control Uni t
-
Gray
-
Behi nd l eft si de oJ dash, ri ght of steeri ng col umn
-
1
7
2
3
4
WHT/BLU (Key interlock
sol enoi d control )
YEL (l gni ti on i nput)
YEUBLK (Shi ft l ock
sol enoi d control )
BLK (G401)
WHT (Key
interlock switch input)
BLKBLU (Park l nput)
WHT/RED (Shi n
lock circuit control)
WHI/BLK
(Park pln switch input)
6
7
27. C352
-
Gray
-
On bottom of under-hood {use/relay box
-
1
7 8 9
I
1
2
3
4
GRN (Fans)
BLUAVHT (fuC
compressor controlS)
WHT/BLK
(Hazard warning lights)
WHT/BLK (Fuse 42)
BLKRED (A/C
compressor clutch
relay control)
BLK,/YEL (Fuse 17)
WHT/GRN (Fuse 52)
WHT (Fuse 48)
6
7
8
I
28. C101
-
Gtay
-
-
Connecl s engi ne wi re harness to mai n wi re harness
1 l\,4ale
-
BLK/YEL
Female
-
BLK,ryVHT
(Fuse 15)
2 BLK ( G101)
3 YEURED (Oi l
pressure i ndi cator l i ght)
4
* 1/ * 4:
BRN/ BLK ( G101)
5 YEUBLK (PGI\4,FD
6 WHT/BLU
(Charging system)
7 YEL/GRN (Gauges)
I
*1:
BLU (l gni ti on
sYstem)
9 Male
-
BLK VHT
Femal e
-
BLKRED
(Slarting system)
10
*2:
BLKryEL
(l gni ti on system)
*3:
Male
-
BLK/YEL
Femal e
-
RED
(l gni ti on system)
*1=
96-' 98 model s: Al l
'99:
D16Y5 with M,iT
*2=
' 96-' 97
model s: Al l
' 98-' 99
model sr GX
*3=
'96-'98
models: All except GX
*4=:
' 98' ' 00
Model s: GX
202-7
29. C120
-
Gray
-
Top center of engine
-
Connects engine wire harness to distributor
assembl y pi gtai l
All except
'99-'00
016Y7/D16Y8:
l YEUGRN
(l gni ti on i nput si gnal )
2 l\.4ale
-
LT BLU
Female
-
BLU
(CKP sensor output)
3 Mal e
-
ORN/BLU
Female
-
GRN
[tDC
sensor output)
4 l\.4ale
-
ORN
Female
-
YEL
(CYP sensor output)
- = ' 96j 98:
Al l
' 99100:
D1685
'99-'00
016Y7/D16Y8:
l YEUGRN
(l gni ti on i nput si gnal )
2 Male
-
LT BLU
Femal e
-
BLU
(CKP sensor output)
3 Mal e
-
ORN/BLU
Femal e
-
GRN
CIDC
sensor output)
4 Mal e
-
ORN
Femal e
-
YEL
{CYP
sensor output)
l\4ale
-
BLU/YEL
Female
-
WHT
(CKP sensor ground)
l\.4ale
-
WHT/BLU
FCMAIE
_
HtsL'
(TDC sensor ground)
l\4ale
-
WHT
Female
-
BLK
(CYP sensor ground)
Mal e
-
BLU
Femal e
- . -
*:
BLU
(Engi ne speed output)
BLK/YEL (lgnition input)
BLK/YEL (lgnition input)
WHT
(CKP sensor ground)
Male
-
WHT/BLU
Femal e
-
RED
ffDC
sensor ground)
BLK
(CYP sensor ground)
1 0
202-8
30. c201
-
Bl ue
-
-
Connects mai n wi re harness to engi ne
compartment wi re harness
l GRNA/EL
(Turn signal and hazard
warni ng l i ght s)
2 RED/ BLK
(Headl i ght swi t ch)
3 REDAVHT
4 D16Y5:
Mal e
-
GRN/ BLK
Female
-
Hat chbacki GRN/ BLK
{Bear
wipetwashe0
7
I
9b- 9/ mooet s:
lvlale
-
BLU/RED
Femal e BLK (Horns)
'99-'00:
Canada
-
PNK (lndicators)
RED/BLU
BLU/RED (Fog lights)
GRN/ RED
Cturn
signal and
hazard warning lights)
BED/ GRN
(Headlight switch)
RED/YEL
(Headlight switch)
31. C359
-
Orange
-
-
Connects main wire harness to ABS modulator unit
1 0
l\4ale
-
REDAVHT
Female
-
GRNA/VHT
(Power)
l\,4ale
-
BLK
Femal e
-
YEVBLK
(FL-OUr)
Mal e
-
8RN
Female BLIJ
{RR-OLrr)
l\4ale BLU
Female
-
RED/BLK
(FL-rN)
Mal e
-
PUR
Female
-
RED&VHT
(RR-rN)
6 Mal e
-
WHT
Female
-
YEUBLU
(FR-OUr)
7 YEL (RL-OUr)
I Mal e
-
ORN
Female
-
RED/BLU
(FR rN)
I Mal e GRN
Femal e
-
RED (RL-| N)
10 Mal e RED
Female
-
BLK,ryVHT
(scol\,1)
-
32. Hazard Warning Switch
-
Gray
-
Center ol dash
-
On dashboard wire harness
l GRN/ RED
(Left turn signal
indicator light output)
2 GRN/YEL
(Ri ght t urn si gnal
indicator light output)
3 GRN/ ORN
Ourn
signal/hazard
relay control)
4
5 YEL/ BLK (l gni t i on i nput )
6 WHT/BLK (Battery inpul)
7
8 RED/BLK (Dash and
console lights)
g
RED (Dash and
consol e l i ght s)
1O GRNAVHT
(Turn signal/hazard
relay power)
34. C351
-
Gray
-
On bottom of under-hood fuse/relay box
-
1 4
6 7 I I 9 I 1 0
1 1
2 WHT/BLU
(Power wi ndows)
3 WHT/GRN
(Rear window defogger)
4 BLK (G402)
5 WHT/FED
(Fuse 54)
6 WHT/RED (Fuse 43)
7 WHT/BLK (PGM-Fl )
8 WHT/BLU (Fuse 47)
I WHT/GRN
(Fuse 51)
1 0
_
11 BLUAVHT
(Blower controls)
33,
Without Oelogger:
1
2
*1:
BLK, | YEL
*2r
BLKBLU
(lgnition input)
3 YEURED (Common)
4 BLK (G551)
5 8LU,ryVHT
(Left up/down control)
With Delogger:
1 BLI VBLU
(l gni t i on i nput )
2 BLK (G551)
3 BLI VBLU (l gni t i on i nPut )
4 YEURED (Common)
6 ORNMHT
(Detogger control)
'96198
models,
'98-'00
GX
'99
00 models except GX
Power Mirror Switch
-
Green or White or Gray
-
Left of steering column
-
On fl oor wi re harness
6 BLU/BLK
(Left left/right control)
8 YEUBLK
(Right left/right control)
9 GRNAVHT
(Right up/down control)
1 0
7 BLU/BLK
(Lett left/right control)
8 GRNMHT
(Right up/down control)
9 BLU/WHT
(Lett up/down control)
1O YEL/BLK
(Right left/right connol)
I
-
202-9
35. C41o
(A/T)
-
Gray
-
lilounted to top of underdash {use/relay box
-
Connects main wire harness and dashboard
wtre narness
2
3 GX: BLU/ GRN
{Low
fuel indicator)
4 GX: ORN/ BLU
(Fuel gauge)
5 WHT (A/T gear
posi t i on i ndi cat or)
6 RED (A,/T controls)
7 BLI(BLU (A,rT controls)
8 All except CVT:
BRN (AiT gear
position indicator)
I BLU (Aft gear
position indicator)
10 GRN (A/I gear
position indicator)
11 D16Y7/ D16Y8:
Mal e
-
GRN/ BLK
Female YEL
(A/T conkols)
D1685/ D16Y5:
GRN/ BLK
(M controls)
12 LT GRN
(A/T controls)
36. Power Window Master Switch
Coupe/Hatchback:
-
Gray
-
Driver's door armrest
-
On dri ver' s door wi re harness
3
5
BLU/BLK (l gni ti on i nput)
BLU/ORN
(RF motor control)
RED/YEL
(LF motor control)
FED/BLU
(LF motor control)
BLK (G551)
6 GRN/BLK
7 BLU/YEL
(RF motor control )
8 BLK (G551)
1 0
12 BLU (Auto
control)
I YEL (RR motor control)
1O YEUGRN
(RR motor control)
11 BLU/ ORN
(RF motor control)
14 GRN/ YEL
(LR motor control)
15 REDMHT (lgnition input)
16 GRN (LR mot or cont rol )
Sedan:
-
In dri ver' s door armrest
Connector A
-
Gray
-
On driver's door wire harness
l BLU/YEL
(RF motor control)
2 GRN/BLK (lgnition input)
3 BLU/BLK (l gni ti on i nput)
4 BLK (G551)
5 RED/YEL
(LF motor control)
6 8LU (Auto control)
7 RED/BLU
(LF motor control)
8 YEUBLK (lgnition input)
Connector B
-
Brown
-
On driver's
1 BLK (Gss1)
door wire harness
E
202-10
Terminals grouped together are connected by the same bus bar
37. Power Door Lock Control Unit
(All except'99-'00 models with
keyless)
-
Gray
-
In dri ver' s door
-
On dri vers door wi re harness
1 GRNMHT (Lock i nput)
2 YEURED
(Unlock/lock output)
3 BLU/RED
(unlock/lock
control)
4 BLK
{Ground)
5 WHT/RED (Lock output)
6 BLU/YEL (Dri vefs
door unl ock i nput)
7 BLU/WHT (Lock input)
B GRN/ ORN
(Unl ock i nput )
1 0
1 1
12 WHT/ GRN
(Battery input)
38. Cl 15
-
Bl ue
-
Rear of engine, below intake manifold
-
Engi ne wi re harness
j uncti on
connector
r - - - - - - - - - - l r - - - - - - - - - " 1
1 8LK?ryEL (Fuse 15)
2 BLK/YEL (Fuse 15)
3 BLK TEL (Fuse 15)
4 BLK/YEL (Fuse 15)
5 BLK,/YEL (Fuse 15)
6 BLK/YEL (Fuse 15)
7 BLK,TYEL (Fuse 15)
8 GRN/8LK (PGM FD
9 GRN/BLK (PGM.FD
10 GRN/BLK (PGr\,4-Fr)
11 GBN/BLK (PGM-Fr)
12 GRN/BLK (PGM-FD
13 GRN/BLK (PGM-FD
14 GRN/BLK (PGM-Fr)
L _ _ _ _ _ _ _ - J L _ _ _ _ _ _ - - _ J
-
39. Cl 16
-
Gray
-
Rear ol engi ne, bel ow i ntake mani fol d
-
j uncti on connector
41. C433
-
Gray
-
Below center console
-
Connects main wire harness to A'/T gear position
switch
pigtail
i - ' - j - - - - - l
r-:-_-::::^-_---' 1
8 BLK ( G101)
s BLK ( G101)
10 BLK ( G101)
11 BLK ( G101)
12 BLK ( G101)
13 USA: BLK ( G101)
14 BLK ( G101)
L _ _ _ - - - - - J
2
*1:
YEL/BLK
* 2i YEURED
(PGM-Fr)
3
* 1:
YEUBLK
(PGl\4-Fr)
4
* l : YEUBLK
*2T
YEURED
(PGr\4-F|)
5
*1i
YEL/BLK
*2:
YEURED
(PGM-Fr)
6
* 1:
YEUBLK
*2:
YEURED
(PGM Fr)
7
*1:
YEUBLK
*2:
YEURED
1 BLK (Cruise conlrol)
2 l\,1ale
-
LT GRN
Female
(Not used)
3 Mal e
-
YEL
Femal e
-
YEURED
(Back-up lights)
4 GRN/ BLK
(Back-up lights)
5 f,rale
-
GRN/YEL
Female
-
BLU
(A,/T controls)
6 l\.4ale
-
GRN/BLU
Femal e GRN
(A,/T controls)
7 Mal e
-
GRN/ ORN
Female
-
YEL
(A/T conkols)
9 PNK (Cruise control)
1O BLI(WHT
(Starting system)
11 BLI(RED
(Starting system)
12 Mal e
-
GRNIVHT
Female
-
BLK/BLU
(A,/T controls)
13 Mal e
-
GRN/RED
Female
-
WHT
(A,/T controls)
14 Mal e
-
GRN
Femal e
-
RED
(A,/T controls)
\ t
L_i 9yj ' L____i
' 1:
Al l except GX
' 2:
GX
Terminals grouped together are
connected by the same bus bar.
40. c401
-
Gray
-
Behind left kick panel
-
Connects main wire harness to floor wire harness
All
'96-'98
Models and
'99100
GX Models:
1
*1:
BLKWHT (PGM-F| )
*2: YEL/ BLU
(PGl \ 4' Fl )
2 Hatchbacki
LT GRN/ BLK
(Rear wiper/washer)
. 2:
BLU/ YEL
{PGM-Fl )
3 Hatchback: LT GRN
(Rear wiper)
. 2:
GRN/ BLK
(PGM' Fl )
4
* 1: YEUBLU
( PGM Fl )
*2:
GRN/VEL
(PGl,I-Fl)
5
*1:
GRN/ BLK
(PGM-FI )
*2:
WHT/ RED (PGl \ 4-Fl )
* 1=
D16Y5i Al l
' 98
model s
D16Y7r
' 97
Cal i f orni a Coupe and Sedan LX, al l
' 98
model s
D16Y8: Al l
' 96-97
Coupes,
' 97
Cal i l orni a Sedans, al l
' 98
model s
*2=
GX model s
'99-'00
Models except Gx:
6 BED/ BLU
(Seat belt reminder)
7 WHT/ GRN (Fuse 51)
8 1. : LT GRN
(PGM' F| )
I 1. i BLU (PGl \ . 4-Fl )
10 GRN
(l gni t i on key
remrnoer)
11 LT GRN/ RED
12 GRN/ BLK
(Back-up lights)
13 GFN,TVHT
(Brake lights)
14 Except GX: YEUGBN
{PGM-Fr)
1 GRN/ORN
(Power door locks)
2 BLK,ryVHT
(PGM-Fl)
3 Coupe/Sedani
GRNA/VHT
(Power door locks)
Hatchback:
LT GRN/BLK
(Rear
wiper)
4 Coupe/Sedan: BLU/BLK
(Security system)
Hatchback:
LT GRN (Rear wi peo
5 YEUBLU (PGl\4-Fl)
6 GRN/BLK
(PGM,FD
7 RED/BLU
(Seat belt reminder)
8
*3:
WHT/RED
(Power door locks)
9
*3:
BLU/RED
(Power door locks)
10
' 3:
BLU^VHT
(Power door locks)
11 l\.4ale
-
Female
-
WHT/GRN
(Fuse 51)
12 LT GRN (PGM-FD
13 BLU (PGr\4 Fr)
14 GRN
(lgnition key reminder)
15 LT GRN/ RED
16 GRN/ BLK
(Back-up lights)
17 GRN,ryVHT
(Brake l i ght s)
18 YEUGRN (PGI \ 4. FD
19
*3:
YEURED
(Power door locks)
20 Canada: BLU/YEL
(Power door locks) -
*3=
USA HX, LX, EX OX-V Si
202-11
Connector Views (conrd)
42. C562
-
Gray
-
Behind left side ol rear seat back
-
Connects floor wire harness and rear wire harness
'96-'98
CouDe/Hatchbaqk:
*
=
Male terminal not used on Hatchback models
'96-'98
Sedan except GX:
1 LT GRN
(Power door locks)
2 BLU/YEL
(Stereo sound system)
3 RED/YEL
4 GRN/BLK
(Back-up lights)
5
*WHT/BED
(Fuse 43)
6 Hatchback: GRN
(Rear wiper/washer)
7 GRYAVHT
l GRN/RED
(Turn signal lights)
2 _
3 l,4ale
-
YEUBLK
Femal e
-
(Not used)
4 ftrale
-
WHT/BLU
Femal e
-
{Not
used)
5 LT GRN
(Power door locks)
8 WHT/RED
(Trunk light)
9 GRN/BLK
(Back-up lights)
8 BRNMHT
(Stereo
sound system)
9 RED/BLK (Headlight
switch)
1O GFN/ YEL
l 1 GRN/ RED
Ourn
si gnal l i ght s)
12 BLU/ BLK (l ndi cat ors)
13 Hat chback: LT GBN
(Rear wiper/washer)
14 Hat chback:
LT GRN/BLK
(Rear wiper/washer)
1O RED/YEL
(Stereo
sound system)
11 BRNA,ryHT
12 BLU/YEL
{Stereo
sound system)
13 GRYA/VHT
{Stereo
sound system)
14 RED/8LK
(Headlight switch)
15 BLU/BLK (l ndi cators)
16 GRN/TEL
(Turn
si gnal l i ghts)
202-12
'99-'00
Models exceDl GX:
1
2
11:
LT GRN/BLK
(Rear wiper/washe0
3
* 1:
LT GRN
(Rear wiper/washe0
4
a1r
c RN
(Rear wiper/washe0
6 GRYMHT
7 BLU/YEL
8 BRN,^/VHT
9 REDA/EL
(Stereo sound systern)
10 GRN,^/VHT
(Brake lights)
Al l GX Model s:
GRN/RED
(Turn
signal lights)
GBN/BLK
(Back-up lights)
11 GRN/RED
12 GRN/YEL
Ourn
signal lights)
13 BLU/BLK (l ndi cators)
1 4
1 6
17 BLI (BLU
(Reaf window defogger)
18 RED/ BLK
(Headlight switch)
19 GRN/ BLK
(Back-up l i ght s)
20
*2:
WHT/ FED (Fuse 43)
*
1
=
Hatchback
*
2= Female terminal not
used on Hatchback
mooers
RED/BLK
(Headlight switch)
BLU/BLK (lndicators)
GRN/YEL
6
7
I
2
3
4
5
'I
2
4 t 5 6 I 7
I 9 10
' t1
1 2 1 4 1 5 16 1 7
' t8
1 9 20
-
43. Crui se Control Uni t
-
Gray (' 96-' 97 model s) or Bl ue (' 98-' 00 model s)
-
Behind lett side ol dash
-
'96-'97
Models:
1 BRN (Crui se control
actuator control)
2 GBY
(Brake switch input)
3 BLK (Ground)
4 GRN,ryVHT
(Brake switch Input)
5 LT GRN/RED
(Set/decel signal inPUt)
6 LT GRN/BLK
(Resume/accel i nPut)
7
'98-'00
Models:
'I
BBN
(Actuator control)
2 GRY
(Brake switch input)
3 BLK (G401)
4
5 GRN,^/VHT
(8rake swi t ch rnput )
6 LT GRN/ RED
(Set/decel signal inPut)
7 LT GRN/ BLK
(Resume/ accel
si gnal i nput )
8 BRN,AiVHT
(Vent solenoid control)
9 RED/BLU
("Crui se Control "
i ndi cator l i ght conkol )
10 BRN/BLK (Vacuum
solenoid controi)
12 BLUMHT
(Vehi cl e speed i nput)
13 LT GRN
(Power i nput)
14 PNK (Dl sengage i nput)
8
*1:
BLU/ GRN
(Crui se si gnal )
9 BFN/ WHT
{Actuator
control)
1O RED/ ALU
(l ndi cat or l i ght conkol )
11 BRN/ BLK
(Actuator control)
12 BLU,ryVHT
(Vehicle speed input)
13 LT GRN
(Power i nput )
14 PNK (Dl sengage i nput )
\
1 7
I I 1 0 1 1
'12
1 3 1 4
*1=
99-' 00 w(h A/ T
202-13
44. Heater Control Panel ('96-'98)
-
Green
-
Center ol dash
-
On heater-sub-B wi re harness
1 YEL (H/DEF control )
2 BLKTYEL
3 WHT/BLU
(Battery input)
4 YEUBLU
(Defrost control)
5 RED (l l l umi nati on
-)
6 RED/BLK (lllumination +)
7 ELUruVHT
(Heat conkol)
8 YEL/RED (Vent control)
9 GRN/YEL
(Bl ' LEV control )
10 BLK (Ground)
11 BLU/ FED
(lVC thermostat input)
12 GRNMHT
(Fresh control)
13 GRN/ FED
(Recirc. control)
14 GRN
(A/ C ON i nput )
45. c440
-
Bl ue
-
Bel ow ri ght si de of dash
-
Connects main wire harness to heater-sub-A
wrre narness
2 BLK (G402)
3 BLU/WHT
(Bl ower cont rol s)
4
' 99-' 00:
BLU/ YEL
(Rear window defoggeo
7
9
1 0
11 WHT/BLU (Fuse 47)
12 BLK (G402)
13 RED (Dash and
consol e Ii ghts)
14 RED/BLK (Dash and
console lights)
15 BLUAVHT
(FVC
compressor conkol s)
16 BLK/YEL (Air delivery)
Gonnector Views (conrd)
46. C503
B
9
* 1:
GBN/ ORN
(Power door locks)
*1r
BLU| /EL
(Power door locks)
GRN/RED (Brake
system indicator light)
* 1r
LT GRN
(Power
door l ocks)
*3:
GRN/YEL (Low
fuel i ndi cator l i ght)
BLU/BLK (lndicators)
*3:
BLU/YEL
*3:
YEUBLK (Gauges)
*3:
GRY/WHT
10
*1:
GRNAVHT
(Power
door locks)
*2:
BL(BLU
(Power mirfors)
11
*3:
BRNMHT
(Stereo
sound system)
12
*3:
RED/YEL
13 GRY/BLK
14 BLU
(Stereo
sound system)
15 BRN/BLK
(Stereo
sound system)
16 RED/GBN
(Stereo
sound system)
-
Bl ue
-
lvlounted to side of under-dash fuse/relay box
-
Connects floor wire harness to dashboard
wtre narness
1
2
3
5
6
7
*1=
' 96-' 98
model s
*2:
' 99-' 00
model s
*3=
All except GX models
48. Data Link Connector (DLC)
-
Gray
-
Below left side of dash, above kick panel
-
4
6 LT BLU (SRS)
7
8 WHT/BED
(Battery input)
9
1 0
12 BLK (G401)
13 BLK (G401)
1 4
15 BLU/ YEL
(DLC i npuVout put )
47. C551
-
Green
-
On rear of under-dash tuse/relay box
-
On floor wire harness
1 BED/ GRN (Brake
2
4 BLI(BLU
5 GBN/ RED (Brake
system indicator llght)
6
* 1:
WHT/ RED
(Trunk l i ght )
7
8 Hat chback: GBN
(Rear wiper/washer)
9
1 0
11 GRN/ YEL
(Turn signal and
13 RED/ BLK
(Headlight switch)
1 4
15 GRN/ RED
(Turn signal and
202-14
*1=
Al l except GX model s
49. C419
-
Green
-
-
1
' 98' ' 00
model s: RED
(l gni t i on
syst em)
2 WHT/RED (Fuse s4)
3 Canada: WHT (Fuse 48)
4 BLI(RED
(Starting system)
5 WHT (Fuse 48)
6 WHT/RED (Fuse 43)
7 1* : WHT
(Security system)
I
*2:
BLK,TYEL
{Power
door locks)
I Canada: YEL/BLK
(Headlights)
1O YEURED
(Back up lights)
1 1
13 WHT/GRN (Fuse 51)
14
'96-'98
CVT: BLKWHT
(A/T controls)
15 Canada: GRN/RED
(Headl i ghts)
16 A/Ti YEL (lnterlock
system)
17 RED/BLK
(Headlight
switch)
18 Canada: RED/GRN
(Headlights)
"1
=
USA: LX, EX, HX, DX-V Si
Canada: EX, Si
12
=
'99100
USA: LX, EX, HX, DX-V Si
-
50. c421
-
Green
-
-
I
l RED/YEL
2 BLIVBLU (ABS)
3 RED/GRN
4 GFIN/BLK
5 FED/BLU
(Headl i ght swrtch)
6 WHT/BLU
(Charging systern)
7
9 REDAVHT
10 GRN/ YEL
(Turn si gnal
and hazard lights)
1 1
12 USA: BLKAVHT
(Chargi ng syst em)
13 BLKryVHT (Fuse 15)
14 GRN/ RED (Brake
i ndi cat or syst em l i ght )
16 GRN/ RED
(Turn si gnal
and hazard lights)
17 BED/ BLK
18 RED/ BLK
52. C130
-
Brown
-
Bel ow ri ght si de ot dash
panel
-
j uncti on
connector
T- - - - - - - - - " 1
1 8RN/ BLK ( G101)
2 BRN/ BLK ( G101)
3 BRN/ BLK (G101)
4 BRN/ BLK (G101)
5 BRN/ BLK (G101)
6 BRN/ BLK (G101)
7 BRN/ BLK (G101)
I BRN/ BLK ( G101)
9 BRN/ BLK ( G101)
10 BBN/ BLK ( G101)
L - - - - - - - - - J
Terminals grouped together are
connected by the sarre bus bar.
*1=
96- 98 model s: Al l except D16Y5
' 99-' 00
model s: D1685
*2=
96-98 model s: D16Y5/D1685
' 99-
00r Al l except D1685
11 BLUMHT (VSS)
12 BLU,ryVHT
(VSS)
13 BLU,^/VHT (VSS)
L _ - _ _ _ _ _ - - J
r - - - - - - - - - ' 1
14 YEL/BLK (PGl \4-Fl )
15 YEL/BLK (PGr\4'Fr)
16 YEUBLK
(PGI\4,FI)
17 YEUBLK (PGr\4,Fr)
L _ _ _ _ _ _ - - - J
T - - - - - - - - - - 1
18
* 1:
GRN
( Fans)
*2:
YEUBLU (PGM-Fl )
19
* 1:
GRN ( Fans)
.2:
YEUBLU (PGM-Fl )
20
*1:
GRN
(Fans)
.2:
YEUBLU (PGM-Fl )
_ _ _ _ _ _ _ - - J
51. SRS Uni t
-
Yellow
-
Below center oJ dash
-
On SRS marn wi re harness
1 GFY
( 1) or GRN
(Drivefs nflator)
2
3 GRY
(17) or GRN
(l gn t i on i nput )
6 GRY (21) or GRN
(SRS i ndi cal or cont rol )
7 GRY (18) or GRN
(l gni t i on nput )
8 GBY
(14) or GRN (MES)
9 GBY
( 13) of GRN
(Service check
connect or i nput )
10 GRY (4) or GRN
(Frt. pass. inflato4
1 1
13 GBY
(2) or GRN
(Dri vef s nf l at or)
14 GBY ( 5) or GRN
(Frt. pass. inflator)
15 GRY (3) or GRN
(DLC input/output)
16 GRY ( 19) or GRN
(G801)
17 GRY (20) or GRN
( G801)
1B GRY
(6) or GRN (MES)
1 3 6 7 8
10 I l 1 2 1 3 1 4 1 5
' t7 ' t8
53. C420
-
Green
-
-
1 Canadar RED/ BLU
(Headl i ght s)
2
3 8LK (G401)
5 WHT/ GRN
6 WHT/BLU
(Power windows)
7
8 YEL/ GRN (PGM-FD
I BLK/ / EL
(Fuse 17)
1O BLUAVHT
(PGM, FI )
1 1 BLUMHT
(PGI , 4-FI )
1 4
16 Canada: BLKAVHT
(Headl i ght s)
18 A/ Tr WHT/ GRN
(lnterlock system)
1 9
20 WHT/RED
202-15
54. c442
-
Whi te or Orange
-
-
l \,l ai n wi re harness
j uncti on
connector
r - - - - - - - - - T r - - - - - - - - - " 1
1 BLU (l gni t i on syst em
or Gauges)
2 BLU (l gni t i on sysl em
or Gauges)
or Gauges)
L_
or causes)
L_- : - : : : ' - ' ____J
t - - - - - - - - - - - 1
11 GRN/ WHT
( PGM- FD
12 GRN/ WHT
(A/T controls)
13 GRNMHT
(ABS)
14 GRNMHT
L_
lc,r' ."
.oIr"D_
_ _.j
r - - - - - - - - - - _ l
5
6
7
L - - - - - - - - - J
T - - - - - - - - - - l
8 GRN/RED
(Brake
9 GRN/RED
(Brake
10 GRN/RED (Brake
_
system indicator ligh0
-..1
|
15 BLUMHT (vSS)
|
I 16 BLUMHT (VSS)
I
L
T?_BLUSTrySS)--..]
l - - - - - - - - -
- - l
|
18 BFN/ BLK ( G101)
I
|
19 BBN/ BLK ( G101)
|
| 20 BRN/BLK
(c101)
|
L - - - - - - - - - J
Termi nal s grouped
together are connected
by the same bus bar.
55. C501
-
Green
-
On tront of under-dash tuse/relay box
-
On dashboard wi re harness
l RED/ GFN
2
*1
: BLKBLU
(Fuse 16)
3 WHT/BLU
(Chargi ng syst ern)
4 BLK (G401)
5 GRNMHT
(Turn si gnal l i ght s)
6 GRN/ RED
7 GRN/ ORN
8 8LU/ YEL
(Rear w ndow del ogger)
9 GFN/ YEL
(Turn
si gnal l i ght s)
' 10
YEL (Fuse 25)
11 YEL/BLK
(Turn si gnal l i ghts)
12 BLKTYEL (Fuse 14)
13 YEUGRN (Accessory
power socket)
15 RED/BLK
1B BLK/WHT
(Chargl ng system)
19 YEL/RED
20
202-16
-1
=Al l
e), cept GX
s6. c507
-
Whi te or Bl ue
-
Behind left side oJ dash
-
j uncti on
connector
r
- - - - - - - - ' l
T - - - - - - - - - l
7 BED (Dash and
consol e l i ght s)
B BED (Dash and
consol e l i ght s)
I RED (Dash and
consol e l i ght s)
10 RFD (Dash and
consol e l i ght s)
11 RED/ BLK (Dash
and consol e l i ght s)
12 RED/ 8LK (Dash
13 RED/ BLK
{Dash
14 RED/ BLK (Dash
15 RED/ BLK (Dash
16 RED/ BLK
(Dash
L - - - - - - - - J
T - - - - - - - - T
L - - - _ - - - _ J
1 BLK (G401)
2 BLK (G401)
3 8LK
{G401)
4 8LK (G401)
5 BLK (G401)
6 8LK (G401)
L _ _ _ _ _ _ _ _ J
T- - - - - - - - " 1
17 YEL (Fuse 25)
18 YEL (Fuse 25)
19 YEL (Fuse 25)
20 YEL (Fuse 25)
L - - - - - - - - J
Term nals grouped together are connected by the same bus bat
-
57. c723
-
Connects heater-sub-A wi re harness to
heater-sub-B wi re harness
'96-'98
Models:
-
Gray
-
Bel ow ri ght si de of dash
l BLUAVHT
(Blower controls)
2 BLU (Blower controls)
3 YEL (Ai r del i very)
4 WHT/BLU (A/C
compressor control s)
5 RED (Dash l i ghts)
6 GRN^VHT
(Ai r del i very)
7 GRN/RED (A r del i very)
I BLUAVHT (Air delivery)
9 BLK,ryEL (Air delivery)
10 YEUBLU (Ai r del i very)
11 BLU/YEL
(Blower controls)
12 BED/BLK (Dash l i ghts)
13 BLK (G402)
t 4
15 BLK (Bl ower conl rol s)
16 BLU/ BLK
(Blower controls)
18 BLU/ RED (A/ C
compressor cont rol s)
19 GRN/ YEL (Ai r del i very)
20 YEURED (Ai r del i very)
'99-'00
Models:
-
Bl ue
-
Behi nd center ot dash
1 RED/ BLK (Dash l i ght s)
2 BRNMHT (Au del i very)
4 GRNA/ VHT (Ai r del very)
5 GBN/ BED (Ai r del i very)
6 GRN/ YEL (Al r del i very)
7 YEURED (Ai r del i very)
8 BLU,ryVHT (Au delivery)
9 YEL (An del i very)
10 YEUBLU (Arr del i very)
11 LT GRN/ BLK
12 ORN,AiVHT
13 BBN (Ai r del i very)
14 RED (Dash l i ght s)
15 GRY (Ai r del rvery)
16 RED,ryVHT (Air delivery)
17 RED/ YEL (Ai r del i very)
18 PNK/ BLK (Ai r del i very)
1 9
20 BLU/RED (A/C
21 BLUI / EL
(Bear wi ndow def ogger)
22 WHT/ BLU (Fuse 47)
23 BLKryEL (Fuse 17)
24 BLK
\G402)
I
1
4 1 5 6 1 7
I 9 1 0
1 l 1 2 1 3
1 4 1 6 1 7
1 8 1 9 20
58. Securi ty Control Uni ti C447l C516
-
Green
-
Above radio ('96-98) or right of steering column
(99-'00)
USA: HX, LX, EX, DX-V Si ; Canada: EX, Si :
1 USA: YEUBLU
(Set)
2 LT GRN/ RED
(Door swiich input)
3 BLU/ BLK
(Trunk switch rnput)
4
5 BLU (valet switch inpu0
6 Canadai GFNAVHT
(Lock output)
7 Canada: BLU/YEL
(Dri ver' s door l ock
oulpurJ
I Canada: GRN/ OBN
(Unl ock out put )
9
10 WHT (Battery)
11 YEL (l gni t i on)
12 USA: OHN (Al arm i n)
CX and DX:
1
2 LT GRN/ BLK
(Door open i nput )
3 BLU/ BLK
(Trunk/hatch open
i nput )
5
' 96 ' 98:
BLU (Securi t y
ndi cat or cont rol )
99- 00: BLU
(Val el swi t ch i nput )
6
7
B
I
10 WHT (Bat t ery i nput )
13 BLK (G401)
14 BLUMHT
(Security LED conkol)
15 BLU/ RED (l gni t i on
key swi t ch i nput )
17 REDAVHI
(Li ght f l ash cont rol )
18 GRY (Horn conkol )
19 RED/ YEL
(Starter cut output)
20 Canada: LT GRN
(Nol used)
21
, 96-, 98
USA: LT BLU
(Security output)
22
'96
98 USA: WHT/BLK
(Bus data 0)
' 99-' 00
USA: BLU/ YEL
(Unset )
11 BLK/ YEL (l gni t i on i nput )
13 BLK (Ground)
14 RED (Securi t y i ndi cat or
control)
15 BLU/ RED
(Key i n i gni t i on i nput )
1 6
17 BLU or BLU/ YEL
(Light tlash control)
18 GRY (Horn cont rol )
1 9 GRN
(Slarter cut control)
20
22
1
><
6 7 8 9 10
1 1 1 2 1 3 1 4 1 5 rGl xl l T 1 8 1 9 20 21 22
202-17
Connector
Views (cont'd)
59. Cl 31
-
Green
-
-
Connects mai n wi re harness to engi ne wi re harness
' 96. ' 98
D16Y5, ' 99-' 00 D16Y5 wi t h M/ T:
1
' 98-' 00
model s: LT GRN
(PGl\4-Fl)
2' 991001
Mal e' LT GRNMHT
Femal e (Not used)
A/Tr RED/BLK
(A/T controls)
3
' 98r00
model s:
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:
Mal e
-
RED/ GRN
Female
-
WHT/BED
(PGl\,4-Fl)
A/T: WHT/RED
(l nt erl ock)
6 GRN (Fans)
7 BLU/RED (A/T
I GFN/ OnN
(PGl \ 4-Fl )
I BRN
(PGr\,4-Fr)
10 WHT/ BLU (PGM-Fl )
11
' 98-' 00
model s: BLU
(PGi r-Fr)
12 A,/T: WHT/RED (PG|VI-FD
13 A/T: RED/GRN
(A/T controls)
M/T: GRN/BLK
(PGr\,1-Fr)
14 A/T: PNK (PGM-FD
M/T; GRN/BLK
(Back-up lights)
15 A/T: GRY (PGl\,l-Fl)
l\,4,rT: Male
-
YEURED
Female YEL
(Back-up l i ghts)
16 USA GRN/RED
(Chargi ng)
17 GRN,ryVHT
(PGM FD
18 BLUAVHT (Vehi cl e
speeo senso4
19 BLK/RED (A,IT
20 GRN/YEL (PGM-FD
21 N,4ale
-
BLU/YEL
Female
-
LT BLU
(PGM-Fr)
22 Male
-
BLU/WHT
Female BLU/ORN
(PGt4,Ft)
202-18
' 96. ' 98
016Y7:
1
*1:
LT GRN (PGM-F| )
2
*2:
GRN/ BLK
(A/T controls)
3
*2:
WHT (A/T controls)
' 98
model s:
[rale
-
WHT/RED
Femal e- (Not used)
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
I GRN/ ORN
(PGl vl -Fl )
9 BRN (PGT, I -FD
10 WHT/ BLU (PGM-Fl )
11
* 1r
BLU ( PGL4- F| )
' 96-' 98
016Y8:
1
*3:
LT GRN (PGl vl ' Fl )
2 lvlale
-
GRNIVHT
Femal e
-
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
8 GRN/ORN (PGr\4'F|)
9 BRN (PG|\4-F|)
10 WHT/ BLU (PG[ , 4-Fr)
11
*3:
BLU (PG[ . 4-F| )
12 BLK,ryVHT
(PGl\4-Fl)
13
*3r
GBN/ BLK
(PGM-Fl )
14 A/T: YEL (A,rT controls)
M/ T: GRN/ BLK
(Back-up l i ght s)
13
*1i
GFN/ BLK
(PGl \ 4' Fl )
*2:
BLU (A/T controls)
14 A/Ti YEL (A/T conlrols)
M/T: GRN/BLK
(Back-up lights)
15 A/ Ti Mal e
-
GRN
Femal e
-
PNK
(A/T conkols)
lvl/tT: Male
-
YEL/RED
Femal e
-
YEL
(Back up l i ght s)
16 USA: GRN/ BED
(Chargi ng)
17 GRN,^/VHT
(PGIVI.FD
18 BLU,ryVHT
(Vehi cl e speed sensor)
19 BLI (RED (A/ C
20 GRN/ YEL (PGM-Fr)
21 ftIale BLUffEL
Female
-
LT BLU
(PGM, Fl )
22 Mal e
-
ELUMHT
Female
-
BLU/ORN
(PGrvl,Fr)
15 A/Tr l\,4ale
-
GRN
Femal e
-
PNK
(A/T controls)
lVl/T: [/ale YEUBED
Femal e
-
YEL
(Back'up lights)
16 USA: GRN/ RED
(Chargl ng)
17 GRN, ryVHT (PG[ r-Fl )
18 BLUAVHT
(Vehicle speed senso4
19 BLK/ RED (A/ T
20 GRN/ YEL (PG[ ' Fl )
21 Male
-
BLU//EL
Femal e
-
LT BLU
(PGr, 1-FD
22 l\,4ale
-
BLUMHT
Fernal e BLU/ ORN
(PGt\r-Ft)
*1
=
' 97
model s: Cal i f orni a coupes, Cal i f ornl a sedan LX
' 98
model si al l model s
*2
=
'96
models: all A,rT
'97
modelsr all A"lT except Coupe DX
*3
=
' 96
model s: al l coupes
' 97
model s: al l coupes, Cal i f orni a Sedans
' 98
model s: al l model s
Dt 685:
1 RED (PG[,1-F0
2 BRN (PGM,F| )
3 Mal e BLU/BLK
Femal e
-
BLUMHT
(Starting
system)
4 lrale ORN/8LU
Femal e ORN
(Fuel gauge)
5 LT GRN (PGM-FD
6 GRN (Fans)
7 BLU/RED (r,/C
8 GRN/ORN (PGM-Fr)
9 BRN (PGM-FD
1O WHT/BLU (PGM.FO
11 BLU (PGM-F| )
12 YEL (PGM-FI)
13 WHT/BED
(lnterlock system)
1 4
15 l\.4ale
-
BLU/GRN
Femal e
-
BLU/ RED
(Low fuel indicator)
16 GRN/ RED
(Chargi ng syst em)
17 GRNA/VHT (PGl\.4 FD
18 BLUAVHT
(Vehicle speed sensor)
19 BLTVRED (r,/C
20 GBN/YEL (PGr\.4-FD
21 N4ale
-
BLU/YEL
Female
-
LT BLU
(PG r\,,r- Fr)
22 l\4ale BLU&VHT
Female
-
BLU/ORN
(PGr,4-Fr)
\
)
'99-'00
Models exceot D16Y5 with M/T and D1685:
1 D16Y5/D16Y7:
BLI(WHT (PGM.FI)
2 D16Ys/D16Y7:
wHr/RED (PGt\4-Ft)
3 A,rT: WHT (4,/T controls)
4
*1:
LT GRN
(A/T
controls)
6 M/T: Male
-
YEURED
Female
-
YEL
(Back up l i ghts)
7 GRN (Fans)
8 GRN/8LK (PG[,4-Fr)
9 USA: GRN (PGf.4 Fl )
1O WHT/BLU (PGM-FD
13
*1:
BLU (A/T conkol s)
14
* 1:
YEL
*2:
GRN/ BLK
(A/T controls)
15
* 1:
Mal e GRN
Femal e
-
PNK
(A/T controls)
*2:
Mal e
-
GRN
Femal e
-
LT GRN/ RED
(A,fT conkols)
18 M/ T: GRN/ BLK
(Back up l i ght s)
19 BLUMHT
(Vehicle speed sensor)
20 YEUBLU (PGI \ 4-FD
21 RED/YEL (PGt\,'l,FD
22 BRN/ BLK (G101)
*1
=
A/T except CVT
202-19
Connector Views
(cont'd)
60. c411
-
Bl ue
-
Mounted to top ol under-dash fuse/relay box
-
Connects main wire harness to dashboard harness
'95198
Models excepl GXI
1
*1:
RED/ GRN
(PGrvr-FD
2
A2:
WHT
(Security system)
(Security system)
4
5 BLU (SRS)
6
*2r
GRY
(Cruise control)
7
*2:
BLU/RED
(Security system)
8 RED/BLU
(Crui se control )
9 LT GRN (Cruise control)
10
' 96-97
model s:
BLU/YEL (ABS)
11 YEUGRN (Gauges)
12 RED (Dash and
console lights)
' 13
LT GRN/RED
(Cei l i ng l i ght)
*1
=
Wi t h shi t t -up i ndi cat or
14 USA LX, EX, and HX:
LT GRN/BLK
{Cei l i ng
l i ght)
Except USA LX,
EX and HX:
ftrale
-
LT GRN/RED
Female
-
LT GRN/BLK
(Cei l i ng l i ght)
15 WHT/BLK
16
*2:
RED| YEL
(Security system)
17
*2:
REDA/VHT
(Security system)
18 WHT/BLU (Stereo
sound system)
19 BLU (l gni ti on system)
20 RED/BLU
(Seat bett reminder)
21 GRN/OBN (PGN4 FD
22 BLUAVHT (VSS)
23 YEURED (Oi l pressure
indicator system)
24 BLU/RED (ABS)
USA: LX: EX, HX
Canadar EX, Si
202-20
' 98
GX and Al l
' 99-' 00
Model s:
1
2
4 All except GX: BLU/YEL
5 BLU (SRS)
7
B RED/ BLU
(Crui se cont rol )
9 LT GRN
{Cruise
control)
10
*1:
PNK (l nd cat ors)
GX: BLU/YEL (Bear
window defo9ger)
1l YEL/ GBN
(Gauges)
12 RED (Dash and
console lights)
13
*2:
Mal e
-
LT GRN/ RED
Female
-
Not used
1 4
15 WHT/BLK
18 WHT/BLU
19 BLU (l gni ti on system
ano gaugesl
20 RED/BLU
(Seat bell reminder)
21 GRN/ORN (PG[,4-Fl )
22 BLU,ryVHT
O/SS)
23 YEURED
(Oil pressure indicator)
24 BLU/RED (ABS)
*1
=
Al l except CW and GX
*2=
Al l except GX
\
61. C556 (with Power Door Locks)
-
Gray
-
In dri ver' s door
j amb
-
Connects tloor wire harness to driver's door
wtre narnss
\
1
' 9:
GRN/BLK
(Power windows)
2
*9:
BLU/BLK
(Power windows)
3
*7:
YEUBLK
(Power windows)
4
*7:
REDMHT
(Power windows)
5
.3:
WHT/GRN
14r
BLU,TWHT
(Power door locks)
6
i9:
BLU//EL
(Power windows)
7
'9:
BLU/ORN
(Power windows)
I
*7:
YEL
(Power windows)
9
*7:
YEUGRN
(Power windows)
10
*7:
GRN/VEL
(Power windows)
11
* 7i
GRN
(Power windows)
12 WHT/RED
(Power door locks)
13
"3:
YEUBED
(Power door locks)
14
*1:
YEURED
*2:
BLU/BLK
(Power mirrors)
15
' 96-' 97model s:
BLU/BLK
(Power mirrors)
13:
BLU/YEL
(Power door locks
*4:
BLU/BED
(Power door locks)
Power mirrors without
Power mirrors with
deloggers
'98
model: All
'99-'00
models: Without
Keyress
'99r00
models: With
Keyress
' 98
model r Al l
'99-'00
models: Power
16
' 96.97
model s: BLU
'98-'00
models:
Mal e
-
RED/GRN
Female
-
BLU
17
' 96197
model sl
GRY/BLK
'98r00
modelsl
Male
-
BRN/BLK
Female
-
GRY/BLK
18
*8:
GRN/WHT
(Power door locks)
19
*8r
GRN/ORN
(Power door locks)
20
t1
| BLU,TWHT
r2:YEURED
(Power mirrors)
21
' 96-' 97
model s:
BLU/TEL
(Power
door locks)
*5:
BLU/BLK
(Power mirrors)
*6:
BLU,TWHT
(Power mir.ors)
22 BLK (Gssl )
23 BLK (G551)
24
*2:
ORNMHT
(Power mirrors)
mirrors without deloggers
'6=
99100 mod6ls: Power
mirrors with deloggers
*7=
Sedan
*8=
' 96-98
USA: LX, HX, EX
' 99-' 00
USA: Al l
*9=
All except
'00
Canada
DX-V: With Power Door
Locks Only
)
'I
2 4
7 8 9 10
1 1 1 3 1 4 1 5
1 6 1 7 1 8 1 9 20
21 22 23 24
62. C557
(with Power Door Locks)
-
Gray
-
In front passenger's door
jamb
-
Connects floor wire harness to passenger's
door wire harness
l GRN/BLK
{Power
windows)
2 BLU/YEL
(Power windows)
3 BLU/ORN
(Power windows)
4 WHT/RED
(Power door locks)
5 YEURED
(Power door locks)
6
'96197
models:
RED/GRN
'98-'00
modelsl
l\4ale
-
BLU
Femal e
-
RED/GRN
7
' 96-' 97
model s:
BRN/BLK
' 98-' 00
model s:
Male
-
GRY/BLK
Female
-
BRN/BLK
*2:
GRN,TWHT
(Power mirrors)
9 YEUBLK
(Powr mirrors)
10
*1:
GRNA/VHT
*2r
YEURED
(Power mirrors)
1 2
13
12:
ORNMHT
(Power mirrors)
14
*2:
BLK
(Power mirrors)
1 8
2 0 -
23
r1=
Wi t hout mi rror def oggers
*2=
Wi t h mi rror def oggers
4 5
7 8 9 1 0
1 1 1 2 t 3 1 4 1 5
1 6 1 7 1 8 1 9 20
2'l 22 24 25
202-21
Connector
Views
(cont'd)
63.
ABS Control Uni t
-
Above right kick
Panel
Connector
A
-
Orange
-
1 RED/BLU
(FR-|N)
3 -
4 BRN (SCS)
7 BLU/BED
(WALP)
8
'96197
models:
BLU|YEL
(Not used)
9 _
10 YEUBLK
(FL-OUT)
11 RED/ BLK
(FL-| N)
Connector
B
-
Orange
-
1 GRN^VHT
(PCOM)
2 BLr(wHT
{SCOM)
3 BLIVBLU
(lG2)
4 BLU/fEL
(RRo)
6 GRY (RLo)
8 GRN
(FRo)
9 GRNAVHT
(STOP)
10 BRNAVHT
(FLo)
12 YEL (RL-OUT)
13 REDAVHT
(RR"IN)
12 YEUBLU
(FR.OUT)
14 LT BLU (DLC)
1 6
-
17 BRN/YEL
(MCK)
18
-
19 YEURED
(PlVlR)
21 BLU
(RR-OUI)
22 BLK
(GND1)
14 WHT/GRN
(+81)
15 WHT/GRN
(+82)
16 BLK
{GND2)
17 GRN/yEL
(FRl )
1 8
-
19 LT BLU
(RL1)
21 GRN/BLK
(FRl )
2 2 _
23 GRN/ORN
(FL1)
25 RED (RL-IN)
26 BLK
{GND3)
202-22
64. Combination
Light Switch
-
Lett side of steering column
Connector
A
-
Natural
-
GRN/ORN Ourn
signal
switch
power input)
GRN/RED
(Lett turn
signal
power outqut)
3
Connector
B
-
Natural
-
RED/GRN
(Headl i ght
switch outpUt)
WHT (Fuse 48)
REDAvHT
(Dimmer
switch LO outpu0
Canadar RED
(DRL output)
GRN/YEL
(Right turn
signal
power output)
FED/BLU
(Dimmer
switch Hl output)
WHT (Fuse 48)
'98100
models: GRY
{Horns)
6
7
65. Combination Wiper Switch
-
Ri ght si de ot steeri ng col umn
Connector A
-
Natural
-
1 BLU (Windshield wiper
motor LOW conkol)
BLU/YEL
(Wi ndshi el d wi per
motor HIGH control)
YEUBLU (lntermittent
wi per ON i nput)
lilale
-
GRN
Female
-
LT GRN
(Rear window wiper
motor conkol)
lrale
-
LT GRN
Fema|e
_
LT GRN/BLK
(Rear wi ndow wi per
motor control)
4 GnN/BLK (Fuse 26)
5 BLK (G401)
7 BLU/BLK(l ntermi ttenv
park wiper control)
8 WHT/BLK (Windshield
washer motor)
BLK (G401)
Male
-
WHT
Femal e
-
GRN (Fuse 3)
Male
-
BLU
Fmale
_
GRN/BLK
(Rear window washer
motor control)
\
Connector B (C4271 (with
Rear Wiper)
-
White
-
3
5
6
)
I 3
6 8
1 3
4
66. Daytime Running Lights Control
Uni t
-
Behind left side ol dash
Connector A
-
Natural
-
On mai n wi re
WHT/RED
(Hadlight control)
BLKAVHT (Battery)
RED (Lights-on input)
Connector B
-
Gray
-
narness
ffi
3 1
2
1
2
3
BLK (Ground)
YEUBLK (l gni ti on)
GRN/RED
(Brake system
indicator light conkol)
RED/GRN
(Parking brake input)
4
5
6
7
8
202-23
Gonnector Views (cont'd)
67. Integrated Control Unit
-
On underdash fuse/relay box
Connector A
-
Connects control unit to under-dash fuse/relay box
1 Not used
4 Erake bulb check output
5 l gni ti on i nput
6 l gni ti on i nput
7 lgnjtion input
Connectol B
-
Natural
-
l BLU/BLK
{Front
wiper/washer)
2 BLUA/VHT
(Front wiper/washe0
3 YEUBLU
4
'98-'00
models:
WHT/BLK
8 Lights ON input
9 Battery input
1 1
_
13 Start input
14 Ground
7 RED/BLU (Driver's
seat blt switch input)
8 LT GRN/RED
(Door open input)
I GRN (Oriver's
door switch input)
't0
BLU/RED (Key in
ignition input)
202-24
68. Stereo Radio Tuner
('96-'98)
-
Center ot dash
Connector A
-
Gray
-
1 RED/GRN
(RF speaker +)
2 BLU (LF speaker +)
3 RED/BLK
(lllumination control)
4 WHT/BLU
(Battery input)
5 YEURED (l gni ti on i nput)
6 -
7 BLU/YEL
(LR speaker +)
8 RED/TEL
(RR speaker +)
9 BRN/BLK
(RF speaker
-)
1O GRY/BLK
(LF speaker
-)
12 RED
(lllumination control)
14 BLK (Ground)
15 GFY,4/VHT
(LR speaker
-)
16 BRNAVHT
(RR speaker
-)
Connector B (USA HX, UX, and EX;
Canada EX and Si)
-
Green
-
l BLU/RED
(Key switch input)
2 LT GRN
(Not used)
3 BLU/'EL (Drivels
door unlock output)
4 BLU (Security system)
5 LT BLU
{Security
system)
6 BLIVYEL (lgnition input)
7 ORN (Security system)
8 LT GRN/BLK
(Door open output)
9 GRN/ORN
1O GRNAVHT
1 1 BLU/WHT
(Security system)
'2 WHT/BLK
(Security system)
13 YEUBLU
(Security system)
14 LT GRN/RED
(Door open input)
15 BLK (Ground)
16 GRY (Horn conkol)
-
69. Transmission Control Module (TCM) ('96-'98
CVT)
-
Connector A
-
Gray
-
\
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 (ATP D)
1O LT GRN
(ATP PN)
11 WHT (ATP R)
12 BL(WHr (rG1)
13 BLK (PG1)
14 YEL (SC LS +)
15 GRNMHI (H LC LS +)
16 BLU/YEL (SH LS +)
17 BRN/BLK (LG1)
1 8
1 9
_
20 GRN/BLK (D IND)
23 WHT/BLU
ryBU)
24
2s BLI(WHT (rG1)
26 BLK (PG1)
)
Connector B
-
Gray
-
1 GRN/BLK (SOL rNH)
2 RED/GRN (MAP)
4 RED/BLK
|rPS)
5 BLUMHT (VSS)
6 PNK
[rMB)
7 GRY
rrMA)
8 RED/BLU (NDN
SG)
9 WHT (NDN)
1O RED/BLU (NDR)
12 GRNAVHT (STOP
SVV)
13 LT BLU (DIAG-H)
14 BRN (SCS)
15 WHT/RED (VEL)
16 ORN/BLU (vEr SG)
17 GRN (NDR SG)
18 GRN/RED (H BRK SW)
1 9
20 WHT/RED (VREF)
202-25
Connector Views
(cont'd)
70. PCM or ECM
(All
'96-'98
'99-'00
D16Y5 MfO
Note: For all other models, see
page
202-28.
-
Below right tront footrest
Connector A
-
Gray
-
On engine wire harness
1 2 3 4 6 I 9 1 0 1 1
1 2 13 1 4 1 5
' t6
1 7
' 18
20 21 22 23 24
25 26 2? 28 29 30 3'r 32
1 YEL (rNJ4)
2 BLU (rNJ3)
3 RED (rNJ2)
4 BRN ( NJ1)
5 BLI(WHT (SO2SHTC)
6 BL(WHT (PO2SHTC)
7 D16Ys with M/Tl
PNK (E-EGR)
CWi RED (ESOL)
8 D16Y5/016Y8:
GRN/rEL (wS)
9 BRNi BLK
(LG1)
10 BLK (PGl )
11 YEUBLK (l GPl )
12 D16Y5/016Y8
BLI(BLU
0ACV)
13
11:
ORN
{IACV
N)
14
11r
BLKBLU (IACV P)
15 RED/yEL (PCS)
16 GRNffEL (FLB)
17 BLI(FED (ACC)
18 GRN/ORN (MrL)
19 USA: WHT/GRN (ALTC)
20 YEUGnN (CM)
22 BRN/BLK (LG2)
23 BLK (PG2)
24 YEUBLK (tGP2)
2s CW: WHT/REO (VBEF)
27 USA| GRN (FANC)
28
.2r
BLU (2WBS)
29
.2r
LT GRNAVHT
(VSV)
30 with shift-up indicator:
WHT/RED (Shift-up
indjcator control)
CW; WHTiRED (SLU)
*1
=
D16Y5/D16Y8: A"/T
D16Y7: Al l
202-26
Connector B (A/T only
-
except CW)
-
Gray
-
I wHT (LS
-)
2 RED (LS +)
3 BLU/YEL (SHA)
4 GRNi BLK (LC B)
s YEL (LC A)
8 PNK (ATP D3)
9 _
1 0
_
11 GRN,4 HT (SHB)
12 WHT/RED (SLU)
13 GRN/BLK (D4 rND)
14 WHT (NM SG)
1s RED (NM)
16 WHT (ATP R)
17 BLU (ATP 2)
18
-
19
-
22 GRN
(NC SG)
23 BLU (NC)
24 YEL (ATP D4)
25 LT GRN (ATP NP)
\
Connector C
-
Bl ue
-
\
1 BLU/RED (CKF P)
2 BLU (CKP P)
3 GRN
[rDC
P)
4 YEL (CYP P)
5 BLU/REO (ACS)
6 BLU/ORN (STS)
7 BRN (SCS)
8 LT BLU (K.LINE)
I CVT: GRY
[rMA)
10 WHT/BLU (VBU)
11 WHT/RED (CKF M)
12 WHT (CKP M)
13 RED
[rDC
M)
14 BLK (CYP M)
1s Dl 6Ys/D16Y8i
BLU/BLK (VTM)
16 USA: GRN (PSPSW)
17 WHT/RED
{ALTF)
18 BLUA/VHT (VSS)
19
-,.
20
21
22
23 016Y5 with l\.4/T:
BLK (l P +)
24 D 16Y5 with M/T:
RED (rP
-,
VS
-)
25 D16Y5 with M/T:
wHT (VS +)
2 6 _
2 7 _
28
29 CW: LT GRN (ATP NP)
D16Y5 with l\4/T:
RED (CLSW
30 CW: PNK
OMB)
t
'I
4 8 9 1 0
1 1 12 13 1 4
' t5 ' t6
1 7 1 8 1 9 20 21 22
23 24 25 26 27 2a 29 30 31
L
1 2 4
7 8 9 10 1 1 12
13 1 4 1 5 16
Connector D
-
Gray
-
1 RED/BLK
[TPS)
2 REDMHT (ECI)
3 RED/GRN (MAP)
4 YEURED (vCC1)
5 GRN,A/VHT
(BKSW)
6 CWD16Y8:
RED/BLU (KS)
7 WHT (All except D16Y5
M/'T
-
PHO2S)
(D16Y5 M/T
-
LABEL)
8 RED/YEL (IAT)
I D16Y5i WHT/BLK
(EGRr)
10 YEUBLU (VCC2)
11 GRN/BLK (SG2)
12 GRN,ryVHT (SG1)
13 016Y5/D16Y8:
GRN/BLK
D16Y7: RED//EL
(sHo2sG)
14 WHT/REO (SHO2S)
15
'2:
LT GRN (PTANI9
16 USA: GRN/RED (EL)
*2
=
' 96
D16Y8 enoi ne: Al l Coupes
97 D16Y7 enoi ne. Cal i torni a Couoe and Cal i forni a
Sedan LX
'97
D16Yg engine: All Coupes and California Sedan
' 98-99:Al l
202-27
70. PCM or ECM (D1685, All
'99-'00
Models except Dl6Y5 Mff)
Note: For all other models, see
page
202-26.
-
Connector A
-
Gray
-
On main wire harness ('99100
except 01685)
-
On engi ne wi re harness (D1685)
2 4 6 7 8 9 t 0 1 1
' t2
1 3 1 4 t 5 1 6
'17 ' 18
1 9 20 21 22 23 24
25 26 27 2a 29 30 31 32
1
*1:
BLUAVHT
(srs cHrL)
2
*1:
GRNffEL
[rFO)
3
-1I
BLU/RED (FWARN)
14:
BLU
{2WBS)
4
* 1: ORN
( F METER)
.ar
LT GRN/WHT
(VSV)
5
*2:
BLU/GFN (CRS)
6
.4r
RED/YEL (PCS)
7 CVT: YEL
iATP
D)
I BLI(WHT (SO2S HTC)
9 CW: LT GRN (ATP DN)
10 BRN (SCS)
14
13:
GRN/BLK (D4| ND)
16 GRN/yEL
(FLR)
' 1
=
D16B5
"2
=
D 16Y7/D 1 6Y8 with A"/T
a3
=
A,/T except CW
*4
=
Except D1685
17 BU(RED (ACC)
18 GRN/ORN (Mrr)
19
.4:
BLU (NEP)
20 GRN (FANC)
21
*1:
LT BLU (K-LINE)
.4:
BLU/YEL (K-LINE)
22
*1:
BLU/YEL (PFO)
CVT: ALU (ATP L)
23 WHT/RED (SHO2S)
24
*1
: BLU/ORN (STS)
*4:
BLU/^,iVHT (STS)
26 GRN (PSPSW)
27 BLU/BED (ACS)
28 A"/T: WHT/RED
29
*4:
LT GRN (PTANK)
30 GRNi RED (EL)
32 GRNAVHT (BKSW)
202-28
Connector B
-
Gray
-
I YEUBLK (IGP1)
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
(HLC LSI\,!)
9 YEUBLK (IGP2)
1o BLK (PG2)
11 BRN ( NJ1)
12
'2:
GRN/YEL (VTS)
13 YEUGRN (CM)
14 01685: LT GRN
(NJ MOD)
15
.4r
ORN (IACV N)
1 6
_
17
. 1r
RED ( LS+)
CW: GRN/WHT
(HLC LSP)
18 CW: PNKBLK
(sc LsM)
1 9
20 BRN/BLK (LGl)
21 WHT/BLU (VBU)
22 BRN/BLK (LG2)
23
r3:
BL(BLU (IACV)
25 CW: YEL (SCLSP)
a1
=
A"fT except CVT
a2
=
Except 016Y7
'3
=
M,/T except D16Y7
14
=
A/T, All D16Y7
\ I
Connector C
-
Bl ue
-
1 BLK/WHT
(PO2SHTC)
2 WHT/GRN (ALTC)
3
al :
RED/BLU (KS)
5 WHT/RED
(ALTP)
6
12
WHT/BLK (EGR2)
7 GRNAVHT
(SGl )
8 BLU (CKPP)
9 WHT (CKPM)
10
*3:
BLU/BLK (VTM)
13 D1685: GRN/RED
OF2)
14 01685: BLU/RED (PF2)
16 WHT (PHO2S)
17 RED/GRN (MAP)
18 GRN/BLK
(SG2)
1s YEURED (VCC1)
20 GRN (TDCP)
21 RED
fiDcl\4)
22 BLU/RED
(CKFP)
23 BLU,ryVHT
(VSS)
24
25 RED/yEL (lAT)
26 REDAVHT (ECT)
27 RED/BLK (TPS)
28 YEUBLU (VCC2)
29 YEL (CYPP)
30 BLK (CYPr,,t)
31 WHTiRED (CKFrVr)
cw D16Y8,816A2
cw D1685
Except D l6Y7
t
1 s l
' t0
2 3 4 6 7 8
1 1 12 13 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22
23 24 25 26 27 2A 29 30 31
Connector D
-
Gray
-
D1685,
'99100
except CW:
1 YEL (LCA)
2 GRN,ryVHT
(SHB)
3 GRN/BLK
(LCB)
5
.1
: BLIVYEL (VBSOL)
6 WHT (ATPR)
7 BLU/YEL
{SHA)
8 PNK (ATPD3)
*1=
Except D1685
'99100
cw:
1 WHT/RED (VEL)
2 GRN/BLK
(rNH SOL)
3 GRN/vEL
(SHLS l\4)
4 BLUAVHT
(SHLS P)
5 BLK^fEL
(VBSOL)
6 WHT (ATPR)
7 BLKWHT
(VEL SG)
8
9 YEL (ATP D4)
10 BLU (NC)
11 RED (Nt vl )
12 WHT (NMSG)
13 LT GRN
(ATPNP)
14 8LU
{ATP
P2)
16 GRN (NCS G)
I
1O WHT (NDN)
11 RED/BLU
(NDR)
12 GRN
(NDR SG)
13 LT GRN/RED
(ATP S)
14 GRN/BLK
(DIND)
16 REDMHT
(NDNSG)
I
J
1 4
6
o
10 r r
l l
r z
13 1 4 1 5 1 6
202-29
71. Gauge Assembl y
-
Left side of dash
Connector A (A/T only)
-
Green
-
1 YEL (l gni ti on i nput)
2 RED/BLK (Headl i ght
switch ON input)
3 RED
(Dash light brightness
controller input)
4 BLU (L or 2
indicator control)
6 D16Y7/D16Y8:
BRN (Not used)
8 BLK (G401)
Connector B
-
Bl ue
-
2 BLK (G401)
3 BLU/BLK (Trunk open
indicator light control)
4 GRN/YEL (Hazard
warning switch input)
5 GRN/ RED
(Brake
system indicator
l i ght cont rol )
6 RED/BLU (Seat belt
7
'96-'97
model: BLU,ryEL
(not used)
8 Except GX: GRN/YEL
GX: 8LU/ GRN
(Low f uel i ndi cat or l i ght
control)
9 D16Y7/D16Y8: YEL
01685/016Y5:
GRN/BLK
(D4 or D indicator
control)
10 GRN (03 or S
indicator control)
11 RED
(N indicator control)
12 WHT
(F indicator control)
13 BLI(BLU
(P indicator control)
14 LT GBN
(Park/neutral output)
10 Except GX: YEUBLK
cX: ORN/BLU
(Fuel gauge control
i nput)
11 BLUAVHT
(Vehicle speed sensor
(VSS) input)
12 YEUGRN (Engi ne
coolant temperature
sendi ng uni t i nput)
1 4
15 BLI(IVHT
(l gni t i on i nput )
16 WHT/ BLU
(Charging
system
202-30
Connector C
-
Bl ue
-
1
*:
YEL (l gni ti on i nput)
2
*:
PNK (Washer l l ui d
level input)
3 YEUBED
(Low oil pressure
4 YEL (l gni ti on i nput)
5 GRN/ORN (Malfunction
6 RED/GRN
{Lights
on Hl input)
7 GBN/RED (Hazard
warning switch input)
*=
'99-'00:
All except CVT
Connector D
-
Orange
-
BLU/RED (ABS
i ndi cator l i ght control )
8 BLU
(Engine speed input)
1 0
12 FED
(Dash light brightness
controller input)
13 RED/BLK (Headl i ght
switch ON input)
I
2
3
4
5
BLK (G401)
YEL (l gni t i on i nput )
\
Connector E
-
Groen
-
T
Wllh Crulss:
1 -
2 RED/BLU (Cruise conkol
indicator control)
3 BLK (G401)
Wlth Shtft-up Indlcator:
1 RED
(Dash lights brightnss
controller inPut)
2 RED/BLU (Shift-up
indicator control)
4 RED/BLK (Headlight
switch ON input)
5 YEL (lgnition input)
BLK (G401)
RED/BLK (Headl i ght
switch ON input)
YEL (lgnition input)
BLK (G401)
YEL (lgnition input)
3
5
1
2
Connector F
-
Yellow
-
On dashboard wir harness
BLU (SRS indicator
light control)
) -
202-31
72. C1s0 (GX Model )
1 YEUBLU (PGM-FI)
2 GRN/BLK (PGM.FD
3 LT GRN (A/t controls)
4 YEURED (PGM-FD
5 GRN/rEL (PG|\,1-FD
-
Light green
-
-
Connects engine wire harness to main wire harness
6
7
BLU/IEL (PGM-FD
Mal e
-
PNK
Femal e
-
GRN
(4,/T convols)
YEL (A,/T
controls)
74. Audi o Uni t (' 99-' 00 Model s)
-
Li ght Bl ue
-
Center ol dash
-
On dashbaord wi re harness
2 YEURED (l gni ti on i nput)
5 RED/YEL
(RF speaker f)
6 BLU/YEL
(LR speaker +)
7 RED/GRN
(BF speaker +)
I BLU (LF speaker +)
9 RED/BLK
(l l l umi nati on
control )
10 WHT/BLU
(Battery input)
' ] ] ] -
1 2 *
1 4
15 BRN,^/VHT
{RR
speaker
-)
16 GRYAVHT
(LR
speaker
-)
17 BRN/BLK
(RF speaker
-)
18 GRY/BLK
{LF
speaker
-)
19 RED
(l l l umi nati on
control )
20 BLK (G501)
73. C575 (GX Model)
BLK (PGM.FD
WHT/RED (PGI\4-FD
GRN/YEL (PGM.FI)
-
Gray
-
Behind left side of rear seat back
-
Connects floor wire harness to sub luel cord
5
1
2
3
GRN/BLK (PGr\4-Fr)
BLU/YEL (PGI\'-FD
YEUBLU (PGI\,4,FD
202-32
75. Keyless Door Lock Control Unit
(USA Only)
-
Gray
-
At lett kick panel
-
l LT GRN/BLK
(Door open output)
2 BLU,ryVHT
(Lock i nput)
3 BLU/RED
(Key switch input)
4 BLK/YEL
5 BLU/RED
(Unlock/lock
control)
6 FED/BLK
(Light flash control)
7 WHT/RED
8 YEURED
9 GRN/ORN
(Unl ock i nput)
'10
GRNA/VHT
(Lock input)
11 ORN
{Securi i y
system)
12 LT GRN/RED
{Door
open input)
13 YEUBLU
(Security
system)
14 BLU/YEL
(Security system)
15 GRY (Horn control )
17 BLK (G401)
18 WHT/GRN
(Battery input)
76. Heater Control Panel
('99100 Models)
-
Center of dash
Conneclor A
-
Gray
-
On heater sub-harness A
BLUi BLK
(Blower controls)
GRNAVHT
(Air delivery)
GRN/RED
(Air
delivery)
RED/BLK (Dash lights)
Connector B
-
Black
-
On heater sub-harness A
7
8
1
4
RED (Dash lights)
BLK (G402)
BLUfYEL
(Rear window defogg0
BLK,TYEL (Fuse 17)
\
)
1 LT GRN/BLK
(Blower controls)
2 BRN,A/VHT
(Air delivery)
(Air delivery)
4 REDA/VHT
(Air delivery)
5 YEUBLU
(Air delivery)
6 YEURED
(Air delivery)
7 GRN/YEL
(Air delivery)
8 BLU,ryVHT
(Air delivery)
9 YEL
{Air
delivery)
1O WHT/BLU
(Fuse 47)
11 BLU/RED
WC
12 BRN
(Air delivery)
13 ORNAVHT
(Blower controls)
1 4
-
15 PN(BLK
(Air delivery)
1 6
_
1 9
_
20 GRY
(Air delivery)
Connector C
-
Black
-
To heater push switches
1 ORN (Air delivery)
2
4 WHT (Air delivery)
5 GRN (ry'C compressor
control)
6 PUR (Roar window
delogge4
7 RED (Dash lights)
8 BLU (Dash lights)
I BLK (Air delivery)
10 GRY (Ay'C compressor
controls)
1'1 BRN (Air delivery)
12 YEL (Rear window
defogge0
77. Injector control Module
(GX Model)
-
Gray
-
-
1 RED (rNJ2)
2 BRN (rNJl
)
3 BLK (G401)
4 _
8 YEL (TNJCNTL4)
9 BLU
(TNJCNTL3)
1o RED (tNJCNTL2)
11 BRN
0NJCNTL1)
12 BRN/BLK (G101)
13 YEURED (Switched
i gni ti on i nput)
14 YEL (t NJ4)
15 BLU (rNJ3)
16 BLK (G401)
1 9
-
2 0 -
21
24 LI GRN
(I NJMODE)
25 BRN/ BLK (Gr 01)
26 YEURED (Switched
ignition input)
202-33
Connector
or
Terminal
Number of
Cavities/
Color
Starter Cables
T1
r2
Ri ght si de of engi ne
Under-hood luse/relay box
Staner motor
t + l Battery Battery positive
terminal
Battery Ground Cable
Right front shock tower Body ground, via battery
ground
cable
o
Battery Battery negative terminal
Engine Ground Cable A
t ! t Left end of engi ne Power steering pump bracket
Too left side ot bulkhead Body ground, via engine ground
cable A
Engine Ground Cable B
T4 Bight side of engine compartment Transmission
(rit
Right side of front frame Body
ground,
via engine ground
Under-hood ABS Fuse/Relay Box Wire Harness
t c Right side of engine compartment Under-hood ABS fuse/relay box
o
Battery Battery positive terminal
A,/C Wire Harness
c209
wt J l
/,\-7Ee
c754
4-GRY
1. GRY
2-GRY
2-GRY
Lefl front of engine compartment
Left front of engine compartment
Lefl front of engine compartment
Left tront of engine compartment
Engine compartment wire harness
A,/C compressor clutch
Condenser fan motor
A,/C pressure
switch
G751 Left front of engine compartment Body ground, via A,/C wire
harness
\ . .
STARTER
CABLES
\ . .
UNDER.HOOD
ABS FUSE/RELAY
BOX WIRE
HARNESS
BATTERY
GROUND
cAELE
ENGINE
GROUND
CAELE B
A/C WIRE
HARNESS
) -
203-1
Connector
or
Terminal
Number ot
Cavities/
Golor
Engine Wire Harness (Dl6Y5, D16Y8 engines):
'96-98
models and
'99;00
D16Y5 dM/T
c 101
c102
c 103
c104
Q104
c105
c106
c107
cl 08
cl 09
cl 10
c 1l 1
cl'12
c 1 1 3
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
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
Mi ddl e of engi ne
I at t . i . l a ^f anî ^6
Left side ot engine
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
[,l i ddl e of engi ne
Mi ddl e ot engi ne
Mi ddl e ot engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
l\,liddle of engine
Mi ddl e ot engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
l\,liddle of engine
Mi ddl e ot engi ne
Mi ddl e of engi ne
Mi ddl e ot engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Below right front footrest
Below right front tootrest
Left side ot engine compartment
Mi ddl e of engi ne
l i l i ddl e ot engi ne
Mi ddl e of engi ne
Nri ddl e ol engi ne
Mi ddl e ol engi ne
Mi ddl e of engi ne
N,l i ddl e of engi ne
Bi ght si de of engi ne compartment
Mai n wi re harness
CKF sensor
swi tch
Alternator
Alternator
No. 2 fuel injector
No. 3 fuel injector
IAC valve
TP sensor
MAP sensor
IAT sensor
Power steering pressure switch
EVAP purge control solnoid valve
Junction connector
Junction connector
Vehicle speed sensor (VSS)
Countershatt speed sensor
Engine coolant temperature switch
Distributor
Engi ne cool ant temp. sendi ng uni t
ECT sensor
' 1)
' 1)
Lock-up control solenoid valves
Secondary HO2S (sensor 2)
lvlainshafl speed sensor
Lanear sol enoi d
Shift control solenoid valves
Starter solenoid
Juncti on connector
Mai n wi re harness
ECM/PCM connector A
PCM connector B
ECM/PCNI connector C
ECM/PCl\,,| connector D
Mai n wi re harness
Maln wire harness
Knock sensor (KS)
IAC valve
VTEC solenoid valve
VTEC pressure switch
EVAP control canister vent shut valv
Secondary gear shatt speed sensor
EGR val ve
EGR val ve
Drive pulley
speed sensor
CVT transmi ssi on sol enoi d
USA
Canada
AlT
USA
' 2(
t r\
' 3
-1
(M/r)
t\4/T
' 2
(Anl
' 1
'2
(An)
'2
(Nr)
'2
(AtT)
'2
(Atr)
-1
(An)
-2(
f i |
M/T
.1
(Arr)
.1
(A,T)
"1
(A/r)
-1
(M/r)
.1
(CVT)
,1
(cw)
'1
(CVT)
203-2
Connector
or
Terminal
Number of
Cavitiesl
Color
Location
Connects to Notes
Engine Wire Harness
(D16Y5, D16Y8 engines):
'9&98
models and'9$'fl) D16Y5 dIWT
(cont'd)
T101
r102
Lett side of engine
Alternator
G101 Ri ght of engi ne Engine ground. via engine wire hamess
' 1:
D16Y5 engi ne
.2:
D16Yg engi ne
' 3:
D16Y5
(A,/T).
D16Y8 enoi nes
' 4: ' 96
model : dtl coupes,' 97 model : al l coupes, Cal i forni a Sedan,' 98-' 00 model : al l
'96-'98
models and
'99-'00
D16Y5 dM/T:
I
c138 cl 13 Tl or
c l l l
cr 19 I
c109
c110
c141.
T102.
c147-
cl 4:t'
c l 17'
cl al
c1|{)
cl 18
c139
cl 20
c129
c1a6
c1a5
NGINE wlRE
HARNESS
cl l 5
c116
c137
cr02
c105
c106
) - f
203-3
Connector
or
Terminal
Number of
Cavities/
Color
Location
Connects to Notes
Engine wire Harness (Dl6Y5,
Dl6Y8 engines):
'99-'00
models except D16y5 w/M/T
c 101
c102
c103
cl 04
c104
c105
c106
c107
c108
c109
c 1 1 0
c111
cl 12
c 1 1 3
c115
c117
c118
c119
c120
c120
c12' l
cl22
c123
c124
c124
c125
c126
c127
c128
c129
c130
c' 131
c133
ct 34
c 135
c137
c138
c139
c 140
c142
c143
c144
c' |45
c147
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 si de of engi ne
Mi ddl e of engi ne
Mi ddl e ot engi ne
Mi ddl e of engi ne
l \4i ddl e of engi ne
Mi ddl e of engi ne
Ni l i ddl e of engi ne
N,,liddle of engine
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Rj ght si de of engi ne compartment
Mi ddl e of engi ne
Ml ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
[i l i ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e of engi ne
Mi ddl e ol engi ne
Mi ddl e of engi ne
Under right side of dash
Below right front tootrest
Below right lront footrest
[i l i ddl e of engi ne
l\,liddle of engine
Mi ddl e of engi ne
Mi ddl e of engi ne
L4i ddl e of engi ne
Mi ddl e of engi ne
Mai n wi re harness
CKF sensor
swi tch
Alternator
Alternator
No. 2l uel i nj ector
No. 3 fuel injector
No.4 fuel i nj ecl or
IAC valve
TP sensor
MAP sensor
IAT sensor
switch
EVAP purge
Junction connector
Juncti on connector
Distributor
Distributor
Engi ne cool ant temp. sendi ng uni t
ECT sensor
Pri mary HO2S (sensor 1)
Pri mary HO2S (sensor 1)
Mainshait speed sensor
Li near sol enoi d
Shi ft control sol enoi d val ves
Starter solenoid
Juncti on Connector
Mai n wi re harness
ECN4/PCM connector B
ECM/PCM connector C
PCM connector D
Knock sensor (KS)
IAC valve
VTEC pressure
switch
EGR control solenoid valve
EGR val ve
Dri ve pul l ey
speed sensor
CVT transmission solenoid
USA
Canada
ATT
USA
' 2
(An\
' 1
-1
(cw)
Mft
'2
lNr)
' 1
'2
(Afil
'2
(An)
' 2
(Anl
Atf
t\4/T
-1
(CVr)
'1
(CVT)
.1
(CW)
-1
(CVT)
'1
(CVT)
.1
(cw
203-4
\ -
I .
.1
: D16Y5 engine
-2:
D16Y8 engi ne
'99;00
models except Dl6Y5 w/M/T:
C134
-\ -
\
c133
ctrg
c123 ('21
c112
cr0g
l . t t o
cr38
ct 13
c130
Clilt
T102
Ctit3
cl 17
G1a4
cl tt
c139
ct20
c1?9
cr$
C1'15
Connector
ol
Terminal
Number of
Cavities/
Color
Location Connects to Notos
Engine Wire Harness (Dl6Y5, D16Y8 engines):
'99-'00
models except D16Y5 dM/T
(cont'd)
T101
T102
Right side oI engin compartment
Alternator
Under-hood tuse/relay box
G101 Ri ght si de ot engi ne Engine ground. via engine wire hamess
) . .
c1l5 C124
cl25 c1z2 c121
203-5
Connector
or
Terminal
Number of
Cavities/
Color
Location
Connects to Notes
Engine Wire Harness (Dl6Y7):
'96
model
c101
c102
c103
cl 04
c104
c 105
c106
c107
c108
c109
c110
c111
c112
c11 3
c114
c115
c116
c117
c118
c119
c120
c121
c122
c123
c124
cl24
c125
c126
c127
cl28
c129
c130
c131
cl32
n l 2 ?
c134
a l e R
1O. GRY
3-GRY
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
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
Left side of engine
Middle of engine
Left side of engine
Lefl side 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
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
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Right side of engine
Behind right kick panel
Main wire harness
CKF sensor
Engine oil
pressure
switch
Alternator
Altemator
No. 1 fuel injector
No. 2 fuel injector
No. 3 fuel injector
No. 4 fuel injector
IAC valve
TP sensor
MAP sensor
IAT sensor
switch
EVAP purge
Junction connector
Junction connector
Distributor
sending unit
ECT sensor
Primary HO2S (sensor 1)
Linear solenoid
Starter solenoid
Junction Connector
Main wire harness
ECM/PCM connector A
PCM connector B
ECM/PCM connector C
ECM/PCM connector D
USA
Canada
A/T
USA
Atf
Aff
M/T
Arl
AtT
A/T
Afi
T101
T102
Alternator
G101 Ri ght si de of engl ne Engine ground,
via engine wire
narness
203-6
a
'96
model:
c135 cl 3a
ENGINE WIRE HAFNESS
c106
cr07 c103
c133 cl 32
I
c12E
ci2s ."r. "irt cltr "\r,
c121
bros
) . .
203-7
Connector
or
Terminal
Number of
Cavities/
Color
Location
Connects to Noles
Engine Wire Harness (Dl6Y7
engine):
'97-'98
models
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
cl 30
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
l O. 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
Lefl side of engine compartment
Lett side of engine
Middle of engine
Left side of engine
Lefl side 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
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Right side of ongine compartmont
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middl of engine
Middle of engine
Middle of engine
Middle of engine
Under right sido of dash
Right side of engine compartmsnt
Main wire hamess
CKF sensor
Engine oil
pressure
switch
Alternator
Altemator
No. 1 fuel injector
No. 2 fuel iniector
No. 3 fuel iniector
No. 4 fuel injector
IAC valve
TP sensor
MAP sensor
IAT sensor
Power steering pressur
switch
EVAP purge control solenoid valve
Junction connector
Junction connector
Distributor
Engine coolant temperatu re
senorng unI
ECT sensor
Linear solenoid
Shift conirol solenoid valves
Starter solenoid
Junclion connector
Main wire harness
ECM/PCM connector A
PCM connector B
ECM/PCM connector C
ECM/PCM connsctor D
Main wire harness
EVAP control canister vent shut
VAIVE
USA
Canada
USA
Nf
A/T
M/T
A/T
Atl
An
AIT
NT
T101
T102
Left side of engine
Altemator
G101 Right side of engine Engine ground, via engine
wtre narness
203-8
'97-'98
models:
c l 30 c l 3l
T1
c117
c119
c120
l'qii
ENGINE WIRE HARNESS
cl21
22
c101
\ t
T10l
c104
c102
cl 09
c11s
c l t 6
203-9
Connector ldentification and Wire Harness Routino
Conneclor
or
Terminal
Number of
Cavities/
Color
Engine Wire Harness (Dl6Y7 engine):
'99100
models
c101
Q102
c103
c104
c104
c105
U I U O
c107
c108
c109
c110
c111
c112
c113
c114
c11s
c116
c117
c118
c119
c120
c121
c122
c123
c124
cl 24
c126
c\ 27
cl28
cl29
c 130
c131
c' 133
c134
v t J c
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
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
Left side of engine
Middle of engine
Left side of engine
Left side 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
Middle ol 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
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Main wire harness
CKF sensor
Engine oil
pressure
switch
Alternator
Altemator
No. 1 fuel injector
No. 2 fuel injector
No. 3 fuel injector
No. 4 fuel injector
IAC valve
TP sensor
MAP sensor
IAT sensor
Power steering
pressure
switch
EVAP purge control solenoid valve
Junction connector
Junction connector
Engino coolant temperature switch
Distributor
sending unit
ECT sensor
Secondary H02S (sensor 2)
Mainshatt speed sensor
Linear solenoid
Shifi control solenoid valves
Starter solenoid
Junction connector
Main wire harness
ECM/PCM connector B
ECM/PCM connector C
PCM connector D
USA
Canada
USA
AIT
Mrl
Atf
AN
A/T
AlT
Afi
T101
r'l02
Left side of engine
Alternator
G 101 Ri ght si de of engi ne Engine ground, via engine wire
narness
203-10
I
'99-'00
models:
cl 17
cr
WIRE HARNCSS
I I
cr 10
c111 c112
ct 14
c113
1101
c10a
15
c102
ciz, cizs
cizs cizz
c121
c1o8 c1o7
203-11
and Wire Harness Routinq
Connector
oa
Terminal
Number ot
Cavities/
Color
Location
Connects to Notes
Engine Wire Harness (816A2
engine):
'99;00
models
c101
c102
c103
c104
c104
cl 05
c106
c107
c108
c110
c111
c112
c113
c114
c 1 1 5
c116
cl17
c119
c120
c121
c' t 22
c123
c124
c129
c130
c131
c133
c134
c137
c138
c140
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
2-BLK
14-BLU
14-GRY
3-GRY
2-GRY
1O-GRY
1-BLK
2-GRY
4-GRY
2-GRY
1-BLK
2O.BRN
22-GRN
25-GRY
31-BLU
2-GRY
2-GRY
1-GRY
2-GRY
Left side of engine compartmenl
Lett side of engine
Middle of engine
Left side of engine
Left side of engine
Middle of engine
Middle of engine
Middle of engine
Middle ol engine
Middle of engine
Middle of engine
Middle of engine
Middle ot engine
Middle of engine
Middle of engine
Middle of engine
Right side of engine companment
Middle ot engine
Middle of engine
Middle of engine
Middle ot engine
Middle ot engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Main wire harness
CKF sensor
Engine oil pressure
switch
Alternator
Altemator
No. 1 fuel injector
No. 2 fuel injector
No. 3 fuel injector
No. 4 fuel injector
TP sensor
MAP sensor
IAT sensor
switch
EVAP purge
Junction connector
Junction connector
Distributor
sending unit
ECT sensor
Starter solenoid
Junction connector
Main wire harness
ECM connector B
ECM connector C
Knock Sensor (KS)
IAC valve
VTEC solenoid valve
VTEC pressure
switch
USA
Canada
USA
T101
T102
Lett side of engine
Alternator
G101 Right side of engine Engine ground, via engine wire
narness
203-12
a
\ -
) . -
'99-'00
models:
cl 12
c117
T102
cti 9
ClO,l
Tl 0t
c115
ct 16
cr37
c102
c1:19
c120
c129
c12l
) < l
c1a2 cl oE
203-13
and Wire Harness Routino
Connector
or
Terminal
Number ot
Cavities
Location
Connects to Notes
Engine Wire Harness (D1685)
c101
cl 02
c103
c104
c105
c106
c107
c108
c109
c110
c111
cl12
c113
cl 15
cl 16
c117
c118
c119
c120
c121
c122
c123
c124
wt l c
u t z o
c127
c128
c129
c130
c131
c132
t / I JO
c134
U I J C
l J t . t o
c139
c140
c144
c150
c151
c152
c153
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
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-LT GRN
2-GRY
2.BLK
3.N/A
Left side of engine compartmenl
Left side ot engine
Middle of engine
Left side 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
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle ot engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle ol engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Main wire harness
CKF sensor
Engine oil pressure
switch
Alternator
No. 1 tuel injector
No. 2 fuel injector
No. 3 fuel injector
No. 4 fuel injector
IAC valve
TP sensor
MAP sensor
IAT sensor
swilch
Junction connector
Junction connector
Distributor
sending unit
EU I SenSOr
Linear solenoid
Starter solenoid
Junction connector
Main wire harness
PCM connector A
PCM connector B
PCM connector C
PCM connector D
Main wire harness
WEC solenoid valve
VTEC pressure
switch
EGR valve
Main wire harness
Fuel temperature sensor
Fuel pressure regulator shut-oft
solenoid valve
Fuel pressure sensor
T101
7102
Left side of engine
Alternator
G101 Ri ght si de of engi ne Engine ground, via engine wire
narness
203-14
-
c1l t cl t 1
ftog ctto
clts
c113 T10t
cr
16
12
I I
EMIINE IVIRE
HAFT{ESS
203-15
Connector
or
Terminal
Number of
Cavities/
Color
Locatlon Connects to Notes
Engine Compartment Wire Harness
c201
c202
c202
UZUJ
c204
c205
c206
c207
c208
c209
c210
c210
c212
c213
c214
c215
1O-BLU
6.GRY
2.GRY
4-GRY
2-GRN
2-BRN/VVHT
3-GRY
1. BRN
q-u11
r
2.GRY
1-BLU
or BLK
2-GRY
3-BLK
3-GRY
8.GRY
2-GRY
Lefl side of engine compartment
Left side ol engine compartment
Behrnd front bumper
Behind front bumper
Behind front bumper
Left front of engine compartment
Behind front bumoer
Behind front bumoer
Right front of engine compartment
Right side ot engine compartment
Right side of engine compartmont
Behind front bumoer
Main wire harness
Main wire harness
Main wire harness
Cruise control actuator
Windshield washer motor
Rear window washer motor
Left front turn signal/parking light
Front tog light
Left headlight
A,/C wire harness
Horn
Horn
Radiator fan motor
Right headlight
Right tront turn signal/parking light
Main wire harness
Washer level switch
' 1
" 1
Optional
' 96-' 97
models
'98-'00
models
Canada
' 99r00
models
G201
G202
Body ground,
via engine
compartment wire harness
Body ground, via engine
comDartment wire harness
' 1
: With cruise control
'2:
Without cruise control
203- 16
qroo
c207
ENGINE OOMPA
WIRE HARNESS
) < >
203-17
Connector
or
Terminal
Number ot
Cavities/
Color
Main Wire Harness (Left side of engine compartment branch)
c101
cI 36
c136
c150
c201
c202
c202
c301
c302
c304
UOUO
c307
c310
1O.GRY
14-GRY
8.GRY
8.LT GRN
1O-BLU
6.GRY
2-GRY
5.GRY
2.NAT
3-N/A
1. BLK
1-BLK
2.ORN
Letl side of engine compartment
Lett side of engine compaftment
Engine wire harness
Engine wire hamess
Engine wire hamess
Windshield wiper motor
Test tachomeier connector
Daytime running lights resistor
Brake fluid level switch
(+)
Brake fluid level switch
(-)
Left front ABS wheel sensor
. 1
' r . q
r5
.4
Canada
ABS
.1
:
' 96-98
A/T with D16Y5 enoine
' 2: ' 96-98
A,/T with D16Y7/D16Y8 enoines
.3:
With cruise control
*4:
Without cruise control
.5:
GX model
Main Wire Harness
(Right
side of engine compartment 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
Right side of engine comparlment
Right side ot engine compartment
Right side ot engine companment
Engine compartment wire hamess
Undef-hood tuse/relay box
ELD unit
Under-hood ABS fuse/relay box
Underhood ABS fuse/relay box
Right front ABS wheel sensor
ABS modulator unit
ABS
pump
motor
EVAP control canister vent
shut valve
USA
ABS
ABS
Al'D
A E 5
ABS
- 1
G403 Bight side of engine compartment Body ground, via main
wtre narness
ABS
.1: ' 99-' 00
models except GX model
203-18
-
I
)
203- 19
Connector
ldentification and Wire Harness Routing
Connector
or
Terminal
Number ol
Cavities/
Color
Main Wire Harness (Left side of dash and floor branch):
'96-'97
models
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c410
c411
c412
c413
c414
c415
c416
c417
c418
c419
c420
c421
c422
w+4J
c424
c425
c427
c428
c429
c430
c431
c432
c433
c434
lJ+OC
c437
v+.to
c439
14-GRY
4-ORN
4-NAT
14-GRY
4-NAT
8-GRY
2-GRY
2-GRY
1-BRN
1O-WHT
12-GRY
24-BLU
3-YEL
16-GRY
4.BLU
7-BRN
6.NAT
2-N/A
2-YEL
18-GRN
2O.GRN
18-GRN
7-GRN
6-GRN
4-NAT
4-WHT
8.WHT
6-WHT
4-NAT
7-NAT
3-GRY
8-GRY
4.GRY
14-GRY
2-GRY
4-GRY
26-GRY
22-GRY
1-GRN
Under left side ot dash
Under lett side ot dash
Front of under-dash iuse/relay box
Front of under-dash fuse/relay box
Behind steering column cover
Below front console
Below front console
Below front console
Below front console
Behind lett kick panel
Floor wire harness
Floor wire harness
Light flasher relay connector
(Security)
Cruise control unit
DRL control unit connector A
DRL control unit connector B
Roof wire harness
Moonroof wire harness
Front fog light connector
SRS main harness
Data link connector
Starter cut relay
lgnition switch
Security starter cut relay conneclor
Clutch switch
Underdash fuse/relay box
Horn relay
Brake switch
Combination wiper switch
connector A
Combination wiper switch
connector B
Combination light swilch
connector A
Combination light switch
connector B
Cable reel
lnterlock control unit
sub-narness
A,/T gear position switch
Shift lock solenoid
Park pin switch and A,/T gear
position
console light
TCM connector A
TCM connector B
Under-dash luse/relay box
ABS
Optional
Canada
Canada
-2
'4
Optional
AtT
M/T
Optional
' 5
M/T
Atl
' 6
AN
AN
Atf
CVT
CVT
G401 Left kick panel Body ground, via main wire
harness
.2:
Without moonroof
.5:
M/T (with cruise control or for D16Y5 engine)
"4:
With moonroof
.6:
With secondary heated oxygen sensor (HO2S)
203-20
-
'96-'97
models:
0 C428
C426
C429 I C4271
C431
8 C
c425
i,lAlN WIRE
HARNESS
t
UNDER.OASH
FUSE/RELAY BOX
c421
c424 c420
203-21
Connector
or
Terminal
Number of
Cavities/
Color
s
Main Wire Harness
(Left
side of dash and tloor branch):
'98
model and 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
c433
c434
c435
c437
c438
c439
c447
c448
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
14-GRY
2.GRY
4.GRY
26.GRY
22-GRY
1. GRN
4-N/A
26-GRY
Under lett side of dash
Under lett side ol dash
Under lft side of dash
Behind undsr-dash tuse/rBlay box
Above under-dash tuse/relay box
Behind under-dash tuse/relay box
Front of under-dash tuse/relay box
Front ol under-dash fuss/relay box
Behi nd steeri ng col umn cover
Undr left side of dash
Bel ow front consol e
Below front console
Floor wire harness
Floor wire harness
Light tlasher relay connector (Security)
Cruise control unit
DRL control unit connector B
Boot wire harnsss
Moonroof wire harness
Boof wire harness
Front fog light connector
SRS main harness
Data link connector
Starler cut rslay
lgnition switch
Security strarter cut relay connector
Clutch switch
Under-dash fuso/rolay box
UndeFdash fuse/relay box
Horn relay
Brake switch
Combination wiper switch connector A
Combinalion wiper srvitch connector B
Combinalion light switch connector A
Combinalion lighi swilch connector B
Cable reel
lnterlock control unil
suD-narness
A,/T gear position switch
Park pin switch and A/T gear
posi ti on consol e l i ght
TCM connector A
TCM connector B
Underdash lus/relay box
Fuel injector relay
Injector control module
ABS
Optional
Canada
Canada
,2
,4
' 7
Optional
AIf
Mtf
Oplional
' 5
M/T
AN
'6
An
A,/T
Alf
CW
CVT
'7
'7
' 7
G401 Left kick panel Body ground, via main wire harness
-2:
Without moonroof (except GX)
-4:
With moonroof
' 5:
' 6:
With secondary heated oxygen sensor (H02S)
t7:
GX model
203-22
t
'98
models and all GX models:
c408
c417
c418
C412
C411 C4l 0
c425
MAI N WI RE
HARNESS
c413
c401
) e
c438
OT
c448
c439 (Gx)
c421
) - j
UNOER-DASH
FUSE/ BELAY BOX
o
- - - - - n n - - - - -
203-23
Connector
ol
Terminal
Number ot
Cavlties/
Color
\
Main Wire Harness
(Left
side of dash and floor branch):
'9$00
models except GX model
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c4t 0
Q411
c412
c413
c414
c415
c416
c417
c418
c419
c420
c42'l
c423
c424
c425
c426
c42A
c429
c430
c431
c432
c433
c434
c435
c447
c448
c450
c451
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
14-GRY
2-GFY
4-GRY
22.GRN
2-GRY
3-GRY
18- GRY
Under lett side oI dash
Under letl side ol dash
Under lett side oI dash
Under letl side oI dash
Under lefl sids ol dash
Under left side ot dash
Behind under-dash fuss/relay box
Under loft side ot dash
Bohind steering column cov6r
B6hind stesring column cover
Under l ett si de ot dash
Below fronl console
Below front console
Below front console
Below front console
Floor wire harness
Floor wire harness
Light flasher relay connector
(Sscurity)
Cruise control unil
DRL control unit connctor B
Roof wire harness
Moonroof wire harnsss
Front tog light connector
Intsgratgd control unit
Dashboard wire harnss
SRS main harness
Data link connector
Starter cut relay
lgnition switch
Scurity starter cut relay connector
Clutch switch
Clulch interlock switch
Under-dash tuse/ralay box
Under-dash tuse/ralay box
Horn relay
Brake switch
Combination wiper switch connector A
Combination wiper switch connctor B
Combination light switch connector A
Combination light switch connctor B
Cable reel
lnterlock control unit
sub-narnsss
A/T gsar position
switch
Shitt lock solenoid
Park pin switch and A/T gear
position
consolo light
Security control unit connactor
Security LED connector
Valet switch connector (Security)
Keyless door lock control unit
ABS
Optional
Canada
Canada
Optional
AN
Mrl
Optional
'5
M/T
AN
' 6
An
Atf
Atf
Optional
Optional
Optional
MKoyloss
G401 Left kick panel Body ground, via main wire
narness
'2:
Without moonroof
"4:
With moonroof
' 5:
' 6:
With secondary heated oxygen sensor (HO2S)
203-24
5'
'99-'00
models except GX model:
MAIN WIRE
HARNESS
c435
) t
c432 c433 C434
c421
) - :
-rr3OOO
FUSE/RELAY BOX
203-25
Connector
or
Terminal
Number ol
Cavities,/
Color
Main Wire Harness (Right side of dash branch)
c131
c440
c441
c442
c443
c444
c445
c452
22.GRN
16-BLU
2.BLU
2O-WHT
or GRN
7-BRN
22-ORN
26-ORN
32.GRY
Under middle of dash
Engine wire harness
Service check connector
Junction connector
PGM-Fl main relay
ABS control unit connector A
ABS control unit connector B
ECM/PCM connector A
G402 Right kick panel Body ground, via main wire
namess
.1
:
' 99100
models exceot D l6Y5 with M/T and D1685
MAIN WIRE HARNESS
203-26
) \
) - ,
.'
'1:
With shift-up indicator or cruise control system
('96-'97 models)
With cruise control system
('98-'00 models)
.2: ' 96198
model s
.3: ' 99-' 00
model s
c5o9 csrr c510 c515
13 1c 517
DISHAOABD w|RE
IIARNESS
Connector
or
Terminal
Number of
Cavities/
Color
Location
Connects to Notes
Dashboard Wire Harness
c410
c411
c501
c503
TJJUC
UCUO
( Jcu/
c508
cs09
c510
t J c t l
c512
uc t . t
c514
c515
c516
c518
c520
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
20-N/A
22.GRN
16-GRY
5.N/A
2-BLK
5-ORN
Below under-dash fuse/relay box
Left of steering wheel
Below
gauges
Left side of dash
Lett side of dash
Left side of dash
Lefl side of dash
Left side of dash
Center ot dash
Csnter of dash
Behind middle of dash
Behind middle ol dash
Left side of dash
Main wire harness
Main wire harness
Floor wire harness
Cruise main switch
Dash lights brightness controller
Junction connector
Gauge assembly connector F
Gauge assembly connector E
Gauge assembly connector A
Gauge assembly connector B
Gauge assembly connector C
Hazard warning switch
Rear window defogger switch
Audio unit connector B (Keyless
receiver circuit)
Audio unil
Security control unit
Audio unit connector A
Security LED connector
Accessory
power outlet
Gauge assembly connector D
Afi
SRS
. 1
AN
.2
-2
Optional
-2
.2
Optional
("2
Canada)
ABS
G501 Under middle of dash Body
ground, via dashboard wire
narness
203-27
Connector
or
Terminal
Number ot
Cavities/
Color
l l -
Floor Wire Harness (Coupe/Hatchback)
c401
c401
c402
c503
v)az
ucco
ucc/
t rcc/
u556
uccv
UCOU
c561
u30z
UCOZ
UCOJ
c564
u5b5
ucoo
uco/
trco.'
vcov
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
1O-GRY
Driveas door
Driver' s door
Passenger's door
Passenger's door
Lett side of floor
Left B-pillar
Below left side of rear seat
Left quarter panel
Left quarter panel
Left quarter panel
Top of fuel tank
Top of fuel tank
Below right side of rear seat
Right B-pillar
Top ot fuel tank
Left side of dash
Main wire harness
Main wire harness
Main wire harness
Driver' s door wire harness
Drivefs door wire harness
Passenger's door wire harness
Passenger's door wire harness
Parking brake switch
Driver's seat belt switch
Driver's door switch
Rear wire harness
Rear wire harness
Rear wire harness
Fuel tank unit
Fuel pump
Right rear ABS wheel sensor
Passenger' s door switch
Fuel tank pressure sensor
sub-harness
Power mirror switch
" 1
' 1
' 2
"5
ABS
AEIJ
' 4
' 5
'tI'D
-3
G552
Left kick panel
Left side of tloor
Body ground. via floor wire hamess
Body ground, via floor wire hamess
-1:
With power windows
"4: ' 96-98
models
.2:
Without oower windows
.5: ' 99-' 00
models
.3:
With fuel tank oressure sensor
203-28
) \
FLOOR WIRE HARNESS
) t
c558 C555
) -tt
c402
qo1
203-29
Connector
ol
Terminal
Number of
Cavities/
Color
Location
Connects to Notes
\
Floor Wire 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
TJ C/ J
v 3 / c
14-GRY
2O-GRY
4.ORN
16-GRN
16-GRN
8-GRN
25-GRY
2-NAT
25-GRY
2-NAT
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
1O-GRY
6-BLU
6.BLU
' 1-WHT
1. WHT
6-GRN
Driver' s door
Driver' s door
Passenger' s door
Passengels door
Left side of floor
Right B-pillar
Below left side of rear seat
Left C-pillar
Left C-pillar
Left C-pillar
Left C-pillar
Top of fuel tank
Top ol fuel tank
Below right side of rear seat
Left B-pillar
Top of tuel tank
Left side of dash
Right B-pillar
Left B-pillar
Left quarter panel
Right quarter panel
Behind left side of rear seat
Main wire harness
Main wire harness
Main wire harness
Front passengeas
door wire
harness
Front passenger' s
door wire
harness
Parking brake switch
Driver' s seat belt switch
Front passenger' s
door switch
Rear wire harness
Rear wire harness
Rear wire harness
Bear wire harness
Fuel tank unit
Fuel pump
Right rear ABS wheel sensor
Driver' s door switch
Fuel tank pressure
sensor sub-
harness
Power mirror switch
Right rear door wire harness
Lett rear door wire harness
Left rear door switch
Right rear door switch
Fuel sub-harness
-3,
GX
"4
ABS
" 1
' 1
ABS
GX
o
-3,
GX
except GX
except GX
ABS
except GX
GX
G551
t f t cz
Left kick panel
Left side of floor
Body ground, via floor wire hamess
Body ground,
via floor wire hamess
.1
: With power windows
-3: ' 96-' 98
models except GX
.2:
Without power windows
.4: ' 99-' 00
models except GX
203-30
I . r
) - l
Sedan:
FLq)N w|RE HARNESS
cs64 c565
) ,
203-31
Connectol
or
Terminal
Number of
Cavlties/
Color
I \
.1: ' 96-' 98
models
.l: ' 99-' 00
models
Rear Wire 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
Lett quarter panel
Left quarter panel
Left quarter panel
Lett quarler panel
Left side of cargo area
Right side of cargo area
Right quarter panel
Right quarter panel
Right quarter panel
Floor wire harness
Floor wire harness
Floor wire harness
Left rear speaker
Right outer taillight
Right rear speaker
Hatch wiro harness
Hatch wire harness
" 1
,2
Optional
Optional
G601 Middle of cargo area Body ground, via rear wire harness
203-32
) \
) r l
) -:'
.1:
CouDe:
' 96198
model s, Sedan:
' 96-98
model s except GX
' 2:
CouDe:
' 99r00
model s
Connector
or
Terminal
Number ot
Cavities/
Color
Locatlon Connects to Notes
Rear Wire Harness (Coupe:
'96-'00
models/Sedan:
'96-'98
models)
UCOZ
w?oz
c562
tJJO.t
c603
c604
TJOUC
TJOUO
c609
c610
c611
c612
c613
c614
c615
c616
u o t /
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
Left
quarter panel
Left
quarter panel
Left quarter panel
Left
quarter panel
Left quarter panel
Left side of trunk
Right side of trunk
Right quarter panel
Middle of rear shelf
Right side of rear window
Left side of trunk lid
Middle of trunk lid
Middle ot trunk lid
Middle of trunk lid
Right side of trunk lid
Floor wire harness
Floor wire harness
Floor wire harness
Floor wire harness
Left rear speaker
Righl outer taillight
Right rear speaker
Rear window defogger (+)
High mount brake light
Trunk light
(-)
Left inner taillight
Left license
plate light
Trunk latch switch
Right license
plate lighl
Right inner taillight
GX
" 1
' 96r98
Optional
Optional
G601
Middle of trunk Body ground, via rear wire hamess
EEAR WIRE HARNESS
203-33
Connector ldentification and Wire Harness Routinq
Connector
ol
Terminal
Number of
Cavities/
Color
l l . .
Rear Wire Harness (Sedan):
'99-'00
models
G601 (GX) or
G602 (excepi GX)
c619
c605
c617
ca21
c616
c610
c615
G6O1 (excrpt
GX)
c562 Cs63 C609
c603
canl
c614
c6t 3
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
Left quarter panel
Left quarter panel
Left quarter panel
Left quarter panel
Left side of trunk
Ri ght si de ot trunk
Bight quarter panel
Lett side of rear window
Right side ol rear window
Lett side ot trunk lid
Mi ddl e ot trunk l i d
Middle ot trunk lid
Mi ddl e of trunk l i d
Right side oI trunk lid
Left side of trunk
Lett sids oI lrunk lid
Ri ght si de of trunk l i d
Mlddle ol rear shell
Mlddle ol rear shelf
Floor wire harnss
Floor wir harness
Floor wire harness
Left rar spgaker
Lett brake lighvouter taillight
Right brake lighuouter taillight
Right rsar speaker
Rear window detogger (+)
Trunk light
Rear window defogger (-)
Lett back-up lighl
Lett license plate light
Trunk latch switch
Right license plate light
Right back-up light
Lett rear turn signal light
Bight rear turn signal light
Lefl inner taillight
Ri ght i nner tai l l i ght
Window antsnna coil connector C
Window antenna coil connector A
except GX
GX
GX
Optional
Optional
GX
GX
except GX
excspt GX
G601
G602
Mi ddl e of trunk
Mlddle ot rear shelf
Body ground, via rear wire hamess
Body ground, via rear wire hamess except GX
Rear Window Defogger Wire (except
GX)
c831
c832
c883
2-BRN
' 1-BLK
' 1-BLK
Middle of rar shelt
Lelt side ot rear window
Right side of rear window
Window antenna coil connector B
(+)
Rear window defogger (-)
203-34
REAR WIRE HAFNESS
c62,.
c6m
) \
.1
: With oower windows
*2:
Without
power windows
.5'
nii;gO: Sl'e models with
power
door locks,
'99-'OO
models with
power door locks but without keyless entry
)
Connector
or
Terminal
Number ot
Cavities/
Color
Location
Connects to Noteg
Driver's Door Wire Harness
(Coupe/Hatchback)
. E<A
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's door
Driver' s door
Driver's door
Driver's door
Driver' s door
Drivefs door
Driver's door
Driver's door
Inside of left
power mirror
Driver' s door
Floor wire harness
Floor wire harness
Left front door speaker
Driver's oowr window motor
Driver's door lock actuator
Tweeter
Power window master switch
Left oower mirror
" 1
' 2
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe
Coupo
(-3)
DRTVER' S OOOR WIRE HARNESS
203.3s
and Wire Harness Routinq
Connector
or
Terminal
Number of
CavitieV
Color
Location
Connects to Notes
Passenger's Door Wire Harness (Coupe/Hatchback)
ucc/
ucc/
lJOCZ
r,ro3J
c654
uocc
c656
uoc/
25-GRY
2-NAT
2-GRY
2-GRY
2.GRY
5-NAT
8.BLKMHT
Z- ( l HY
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Passenger' s door
Inside of right power mirror
Passenger' s door
Floor wire harness
Floor wire harness
Right front door speaker
Front passenger' s powsr window
molor
Front passnger's
door lock
actualor
Front passenger' s power window
switch
Right power minor
Tweeter
Coupe
Coupe
Coupe
Coupe
Coupe
. 1
.1
: With power windows
.2:
PASSENGER' S DOOR WIRE HARNESS
203-36
) \ :
) - ' ,
' 1
: With Dower windows
'2:
'3:
All
'96198
models with
power
door locks,
'99-00
models with
power door locks but without keyless entry
Connector
or
Terminal
Number of
Cavltles/
Color
Driver's Door Wire Harness (Sedan)
t cco
ucco
c632
c633
c634
c636
c637
c638
c639
c640
25-GRY
2.NAT
2-GRY
4.GRY
4-GRY
16-GRY
l . BRN
3.GRY
S.BLKAVHT
12. GRY
Driver' s door
Driver' s door
Driver's door
Driver's door
Driveis door
Driveis door
Driver's door
Driver's door
Inside ol left power mirror
Driver's door
Floor wire hamess
Floor wire harness
Left tront door speaker
Driver's power window motor
Driver's door lock actuator
connector A
connector B
Left power mirror
' 1
",1
.,1
' 1
' 3
c638
) t
203-37
and Wire Harness Routino
Connector
or
Terminal
Number ot
Cavities/
Color
Location
Connects to Notes
Front Passenger's Door Wire Harness (Sedan)
t - J5/
c652
UOCJ
t/OC+
L,occ
uoco
25-GRY
2-NAT
2-GRY
2-GRY
2-GRY
5-NAT
8.BLKMHT
Passenger' s door
Passenger's door
Passengeis door
Passenger' s door
Passenger' s door
Passenger' s door
Inside of right power
mirror
Floor wire harness
Floor wire harness
Right front door speaker
Front passenger' s power
window
motor
Front passenger' s
door lock
actuator
Front passenger's power
window switch
Right power
mirror
' 1
' 2
' 1
' 1
' 1
" 1
*1
: With oower windows
'2:
Without power windows
FRONT PASSENGER' S
DOOR WIRE HARNESS
203-38
) \
) 0
LEFT REAR DOOR
WIRE HARNESS
RI GHT REAR DOOR
WI RE HARNESS
)
Connector
or
Terminal
Number of
Cavities,/
Color
Left Rear Door Wire Harness (Sedan)
c571
UOOZ
uoo.t
c664
6-BLU
2.GRY
5-NAT
2-GRY
Left B-pillar
Left rear door
Left rear door
Left rear door
Floor wire harness
Left rear Dower window motor
Lett rear oower window switch
Left rear door lock actuator
Right Rear Door Wire Harness
(Sedan)
c570
wo t l
uo/ . t
c674
6-BLU
2.GRY
5.NAT
2.GRY
Right B-pillar
Right rear door
Right rear door
Right rear door
Floor wire harness
Right rear power window motor
Right rear power window switch
Rioht rear door lock actuator
Left Rear Door:
Right Rear Door:
203-39
Connector
or
Terminal
Number of
Cavities/
Color
Roof Wire Harness (Coupe/Hatchback)
c407
c407
c702
c719
2-GRY
6-GRY
2-WHT
1-WHT
Middle of roof
Front of roof
Main wire harness
Main wire harness
Ceiling light
Spotlight
.2
' l
:
' 96-' 98
models
' 2: ' 99-' 00
models
Rool Wire Harness (Sedan)
.1
:
' 96-' 98
models
.2: ' 99100
models
Moonroof Wire Harness (Coupe/Sedanl
*1: ' 96' 97
models
' 2: ' 98
models
"3: ' 99r00
models
c407
c407
c702
c703
c719
2-GRY
6-GRY
1-WHT
1-WHT
1-WHT
Middle of roof
Middle of roof
Front of roof
Main wire harnss
Main wire hamess
Ceiling light (Power)
Ceiling light (Ground)
Spotlight
" 1
-2,
GX
.2
c407
c407
c712
c713
c713
c715
u / t o
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
Left side of dashboard bracket
Lett side of dashboard bracket
Middle of roof
Rear of roof
Rar of root
Front of roof
Main wire harness
Main wire harness
Undsr-dash fuse/relay box
Moonroof open relay
Moonroot open relay
Moonrool closa relay
Moonroof close relay
Moonroot switch
Ceiling light
Moonroof motor
Open/close and tiluclose switches
Spotlight
.3
' 1
' 2, . 3
- 1
' 2, ' 3
' 2, . 3
203-40
I \.,
)
,-i'
) -
203-41
Gonnector ldentification and Wire Harness Routinq
Connector
ot
Terminal
Number of
Cavities/
Color
\ \
Hatch Wire 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
Right quarter panel
Right quarter panel
Rear of roof
Right side of hatch lid
Middle of hatch lid
Middle of hatch lid
Middle of hatch lid
Middle of hatch lid
Rear wire harness
Rear wire harness
Rear window defogger (+)
Right license light
Lett license light
Rear window wiper motor
Hatch latch switch
\ r / o l Middle of hatch lid Body ground, via tailgate wire
namess
Rear Window Delogger Ground Wire (Hatchback)
c771
'1-BLK
Left side of hatch lid Rear window defogger (-)
G771 Lett side of hatch lid Body grouM, via rear window
defogger wire
203-42
) \
) . t l
'96-'97
models:
GROUND
WIRE
WIRE HARNESS
TCH WIRE HARNESS
)
203-43
Connectol
or
Terminal
Number of
Cavities/
Color
Location
Connects to Notes
Connector
ldentification and Wire Harness Routing
HEATER SUB.HARNESS
A
1" t -
Heater Sub-harness
A:
'96-'98
models
c440
c722
c723
c724
c725
c726
c727
1 6-BLU
7.GRN
2O.GRY
3-GRY
2.NAT
4-BRN
4.GRN
Behind middle ot dash
Behind front console
Behind
glove box
Below right side of dash
Behind glove box
Behind glove box
Main wire harness
Mode control motor
A,/C thermostat
Blower motor
Blower motor resistor
Recirculation control motor
Heater Sub-harness
Bt
'96;98
models
c743
2O-GRY
6-BRN
14-GRN
Heater fan switch
Heater control
panel
u .
HEATER SUB.HARNESS B
l\-
203-44
) . _ '
Connectol
o1
Terminal
Number ot
Cavltles/
Color
'99-'00
models
c440
c722
c723
c724
wl zc
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
Behind glove box
Below right side of dash
Behind
glove box
Behind glove box
Behind
glove box
Behind glove box
Main wire harness
Mode control motor
A'lC thermostat
Blower motor
Power transistor
Recirculation control motor
Air mix control motor
Blower motor high relay
'99-'00
models
c723
c728
c742
c743
24.BLU
1-BRN
8-GRY
2O.BLK
Heater control
panel connctor A
Heater control oanel connector B
HEATER SUB-HARNESS B
203-45
Connector
or
Terminal
Number ot
Cavities/
Color
Location
Connects to Notes
Rear Heated Oxygen Sensor Sub-harness
c782
4-GRY
4-GRY
Below front console
Below front console
Main wire harness
Secondary heated oxvoen sensor
(Secondaiy
HO2S)
--
lrrr-
\y,.-
FUEL TANK PRESSURE SENSOR
SUB-Ti ARNESS
Fuel Tank Pressure Sensor Sensor Sub-harness
ucot'
c792
c793
6.GRY
3-BRN
2.BRN
Top of fuel tank
Left side of fuel tank
Left side of fuel tank
Floor wire harness
Fuel tank pressure
sensor
EVAP two way valve
203-46
! ' t
l --i
Lg
Connector
ol
Terminal
Number ot
Cavities/
Color
SRS Main Harness
c412
c801
c803
c804
c805
c806
c807
3-YEL
2.YEL
2.YEL
2-YEL
2-YEL
2.YEL
1 8-YEL
Right side of under-dash fuse/
relay box
Under center of dash
Middle of floor
Middle of floor
Main wire harness
Memory erase signal (MES)
connector
Cable reel
Passenger' s airbag assembly
Dummy resistor connector
SRS unit
USA
Canada
G801 Mi ddl e of fl oor Body ground, via SRS
main hamess
SRS MAI N HARNESS
203-47
Connector
ot
Terminal
Numbor ot
Cavities
Location Connects to Notes t
t
Fuel Sub-Harness
(GX)
uc / c
c682
c683
c684
6-GRN
2-GRY
3-N/A
2-GRY
Behind left side of rear seal
Left side of trunk
Middle ot trunk
Middle of trunk
Floor wire harness
Fuel lank internal solenoid valve
Fuel lank oressure sensor
Fuel tank temoerature sensor
FUEL SUB.HARNESS
203-48

Civic EJ6, EJ7, EJ8 (96-00) Service Manual

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