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INTEGFIF|
Service Manual 1994
vnx.su
INTRODUCTION
How to Use This Manual
This manualis dividedinto 23 sections.The first pageof each section is markedwith a blacktab that linesup with its corresponding
thumb indextab on this page and the back cover. You can quickly
tind the tirst pageof each sectionwithout lookingthrougha full table of contents.The svmbolsprintedat the top cornerof each page
can also be used as a quick referencesystem.
Each section includes:
1. A table of contents.or an explodedview index showing:
a Partsdisassemblvsequence.
a Bolt toroues and thread sizes.
a Pagereferencesto descriptionsin text.
proceduresand tools.
2. Disassemblv/assembly
3. InsDection.
4. Testing/troubleshooting.
5. Repair.
6. Adiustments.
Specifications
trtl:{lt'
Ma i n te n a n c e
4Pi
Engine
I-""
SpecialInformation
lnai""tes a strong possibility of sevor pelsonal iniury
@
01 loss of life it instructions al not tollowed.
CAUTION: Indicates a possibility ot personal inlury or oquipmont
damage if instructions ale not followed.
NOTE: Gives helpful information.
CAUTfON: Detaifeddoscriptionsot standad workshop procedures,
salety principlosand servicaopelationsare not included Pleasonote
that this manual conlains warnings and cautions against somo spocific sgrvice methods which could cause PERSONALINJURY, damage
a vehicle or make it unsafe. Pleasounderstandthat those warnings
cannot cover all conceivablcwaYs in which service, whetheaor not
recommended bv HONDA, might be done, or of the possibla
hazardous consequences of svery conceivable way, nor could
HONDA investigateall such ways. Anyone using seryice plocedures
or toofa, whethor 01 not recomondedby HONDA, ,nust sttisfY himsett thoroughly that neither personal safty nor vhicle safety will
be jaopaldized.
All informationcontainedin this manualis basedon the latest product
informationavailableat the time of printing.We reservethe right
to makechangesat any time without notice.No part of this publication mav be reproduced,storedin retrievalsystem, or transmitted,
in any Jorm by any means,electronic,mechanical,photocopying,
recording,or otherwise,without the priorwritten permissionof the
publisher.This includestest. figures and tables.
Fueland Emissions
Za
*Transaxle
* S te e ri n g
r-\
* Brakes
(lncludins
!TEg)
l D l
\.t/
HONDA MOTORCO.,LTD,
1448 pages
First Edition7/93
Service Publication ottice
All Rights Reserved
and
Canada
Apply
to
U.S.A.
Specifications
*Electrical
As sections with r includ SRS components.
special precautions are lequiled when servicing.
vnx.su
(lncludins
ISBE)
J--*
, ,
SUPPLEMENTAL
RESTRAINT
SYSTEM(SRS}
The IntegraSRSincludesa driver's airbag,locatedin the steeringwheel hub. ln addition,all modlsexcepi
tna
Rs modelfor canada have a front passenger'sairbsglocatedin the dashboardabovethe glove box, InformaUon
necessaryto safely servicethe SRSis includedin this servica Manual.ltems markedwith an sstorisk(r)
on thr
contents page include,or are locatednear, SRScomponents.Servicing.disassemblingor roplacingthea6
ltems
will requirespecialprecautionsand tools, and shouldthoreiore be done by an authorhed Acura dealer.
' To avoid ronderingths sRS inoporativo,which could lard to porronll Injury or darth In thc
cvant ot. r.yr.
trontal collision, all sRs sorvico work must be pcrformcd by !n ruthorizcd Acu.! daerrr,
' lmpTopor3orvica proceduroa,including inco.roct r.movd r d Installation of tha SRS,could
Lld to pc[onc Inlury caussd by unintsntionalactivationot tho airbags.
' All sRs oloctrical wiring harnoa$! aro coverod with yallow In3ulatlon, Rcbtcd componcnts
arc bcrtad In tha
stoeringGolumn,front console,dsrhboa.d,and darhboardlowor plnol, lnd in thc d$hbolrd abovc tha gaov!
bor. Do not uas oloctdcalte$ oquipmonton thaaa citcuhs.
NoTE: The originalradiohas a codedthett protectioncircuit. Be sureto get the customer'scode numb6r
blore
* disconnecting
the battery.
- removingthe No. 32 (7.S A) fuse Jromthe undsr-hood
fuse/relaybox.
- removingthe radio.
After service,reconnectpowerto the radioandturn it on. Whenthe word ,,CODE,,is displayed,
enterthe cus_
tomer's 5-digit code to restoreradio oDerauon.
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GeneralInformation
Chassisand PaintCodes
ldentificationNumberLocations
Warning/CautionLabelLocations
Lift and SupportPoints
Lift
FloorJack
Safety Stands
Towing
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1-2
1-4
1-5
1-9
1-10
1 - 11
1-12
Chassisand PaintCodes
U.S.Model
VehicleldentificationNumber
EngineNumber
JH4DB754*RSOOOOO
1
8 l 8 B r ------T----r300@l
Engine Typ6
DB7:INTEGRA
4-door/B1
881
DB8:INTEGRA
4-door/81
8Cl
DC2:INTEGRA
3-door/B18C
1
DC4:INTEGRA
3-door/B1
8Bj
BodyType and Trsnsmission
Type
3: 2-doorHatchbackS-speedManual
4: 2-doot Hatchback4-speed
Automatic
5; 4-doorSedans-speedManual
6: 4-doorSedan4-speedAutomatic
Se al Numbel
Transmission
Numbsr
Y80- 1000@ I
Transmission
Type
Y80: Manual
MPTA:Automatic
Serial Numbel
Check Digit
Model Yaal
R: 1994
Factory Code
S: SuzukaFactoryin Japan
Paint Code
COLOR
BG.33P
Serial Numbl
Vehicleldntification
Numberand
FederalMotor VehicleSafety StandardCertification
3DOOR
4DOOR
1-2
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PaintCode
PaintCode
BG.33P
G-71P
NH-5O3P
NH-538
NH-575M
R-72P
R-81
RP.24P
YR.5O3M
Color
ParadiseBlue-g.enPeErl
LausanneGr6enPead
GrsnadaBlack Pea.l
Frost White
ThunderGrav Metallic
Torino Red Pearl
MilanoRed
Stealth Gray Pearl
RosewoodBrown Mtallic
CanadaModel
EngineNumber
VehicleldentificationNumbel
8 1 8 8 1 - 17 0 0 0 0 1
JH4DB753.RS800001
EnginType
Multi-port
81881: 1.8 I DOHCSequential
Fuel-injectedengine
B 1 8 C 1 :1 . 8 I D O H CV T E CS e q u e n t i a l
engrne
Multi-DortFuel-iniected
Manutacturer,Makeand
Type of vhicle
JH4: HONDAMOTORCO., LTD.
car
ACURAPassenger
Lino. Body and EngineTYPo
4-doot/Bl881
D87: INTEGRA
DC2:INTEGRA3-dootBl 8C1
3-dooriB18B1
DC4:INTEGRA
Body Type and TransmissionTYPo
3: 2-doorHatchback5-speedManual
4'. 2-doorHatchback4-speed
Automatic
5: 4-doorSedans-speedManual
6: 4-doorSedan4-speedAutomatic
VehicleGrade{Sedes}
SRSairbag
3: RS without passenger
4: RS with passengetSRSaitbag
SerialNumber
Number
Transmission
Y80-1000001
Type
Transmission
Y80: Manual
MPTA:Automatic
SerialNumbel
8: GS-R
Check Digit
Model Yeat
R: 1994
FactoryCode
S: SuzukaFactoryin Japan
Paint Code
COLOR
BG.33P
Serial Numbel
Numberand
Vehicleldentification
CanadianMotor Vehicle Safety Standard Certification
3DOOR
4DOOR
Paint Code
PaintCode
BG.33P
G-71P
NH-5O3P
NH-538
NH-575M
R-72P
R-81
RP-24P
YR-503M
Color
Pearl
ParadiseBlue-green
LausanneGreenPearl
GranadaElackPearl
Frost White
ThunderGrayMetallic
TorinoRedPearl
MilanoRed
StealthGrayPearl
RosewoodBrown Metallic
1-3
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II
I
ldentificationNumberLocations
Vehicle ldontification
NumberlvlNl
v.hiclo ldontificalion
NumbrlVlNl
Transmbsion Numbor
lAuromatic)
Transmissioh l\lumbor
lManuall
1-4
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LabelLocations
Warning/Caution
MODULEDANGR
E: DRIVER
A: CABLEREALCAUTIONA
MANUALFORDETAII'fDINSTRUCTION
SERVICE
BEFERTO-
B: CABLEBEALCAUTIONB
REFERTOSERVICEMAI{UAL FOROETAILEDINSTRUCTION
WHEEL OTICE
C: STEERII{G
]{OT|CE
ORINSTALLATION
WIIEELREMOVAL
STEERII{G
IMPROPEB
DAMAGESRSCOMPONENT.
CAREFULLY.
MANUALINSTRUCTION
FOLLOWSERVICE
D: DRIVERINFLATORWAR[{|NGTAG
WARNII{G
AND POSSIBLE
DPLOYMENT
TO PflEVE T ACCIDE]TTAL
INJURY:
SHORTCOI{NECTOR
ALWAYSII{STALLTHEPNOTECTIVE
IS
WHENTHEHARNESS
COI{I{ECTOR
O THEINFLATOR
DISCONNECTED.
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITHACID,WATERORHEAVYMETALSSUCH
HARM.
MAY PRODUCE
LEADOR MERCURY
AS COPPER,
FUL AND IRFITATINGGASES OR EXPLOSIVECOM.
POUNDS.
MUST NOT EXCEED2OOOF
STORAGETMPERATURES
(1OOOCI.
HANDLING.STORAGEAND DISFORPROPER
TO THE SERVICEMANUAL,
REFER
POSALPROCEDURES
SRSSUPPLEMEf{T.
POTSON
SODIUMAZIDEANDPOTASSIUM
POISONOUS
CONTAINS
I{ITRATE.
FIRSTAID
IF CONTENTSARESWALLOWED,INDUCEVOMITING.
FOR EYE CONTACT, FLUSH EYES WITH U'ATER 15
MINUTES.IF GASESIFROMACIDORWATERCONTACT}
ARE INHALED.SEEKFRESHAIR. IN EVERYCASE, GET
PROMPTMEDICALATTENTION.
KEEPOUT OF REACHOF CHILDREN
F: DRIVERMODULEWARNING
A, WABNING
AND' IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE
I{URTOR KILLYOU.
TALLYDEPIOYED,CAN SERIOUSLY
ORPROBTESTEOUIPMEI'IT
. DO NOTUSEELECTRICAL
ING DEVICES.
OEPLOYMENT.
THEYCAN CAUSEACCIOENTAL
PARTS INSIOE,DO NOT DISAS.
. NO SERVICEABLE
SEMALE.
. PLACEAIRBAGUPRIGXTWHENREMOVED'
. FOLLOW SERVICEMANUAL II{STRUCTIONS
CAREFULLY.
(cont'd)
1-5
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Warning/CautionLabel Locations
(cont'd)
G: DBIVEBTNFORMATTON
{SUNV|SORt
G: DBIVEBINFORMATTON
{SUNvtSORt.
ALWAYS WEARYOUNSCIT EELT
C.Ai IS EOUIPPEDWITH A DRIVERAIRBAG ANO
A_FRo_NTSEAT pASSENGERnrnslc nNo e raoNi
SEATPASSENGER
AIRBAGAS A SUPPIEMENTALBES.
TRAINT SYSTEM {SBSI
ro suppLEMENr
rHEsEArBEt-r.
:. BEFoRE
Lr_ll^gls_lglls
oRrvrNG,
ReeoL.qsetmsiDrrxE GLovEBox.
rThis vo.3ion
ot tho lsbl i! us6d in csrs wtth a,ront soat
paasngor'sairbag.
1-6
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M: AIRBAGLABEL
AIRBAG
J: GLOVEBOX INFORMATIOf{
AIBBAGINFORMANO
RESTiAINTSYSTEM(SRS)
SUPPLEMENTAL
TEN YEARSAFTERIT
. THE SRSMUST BE INSPECTED
IS SHOWN
TI{EDATEOFINSTALLATION
IS INSTALLED.
PLATE,LOCATEDON THE
ON THE CERTTFICATION
DOORJAMB.
DRIVER'S
OF SNS
. DIAGNOSTICCHECKSAND REPLACEMENT
MUST BE DONEBY AN AUTHORIZED
COMPONENTS
DEALER
. SEEYOUROWNER'SMANUALFORAODITIONALSRS
INFORMATION.
INFLATORWARNINGTAG
K: FRONTSEATPASSENGER
A WARNING
CAN SERIOUSLY
ACCIDENTALAIRBAG DEPLOYMENT
HURTOR KILLYOU.
WHENTHE INCONNECTOR
INSTALLTHE REDSERVICE
FLATORHARNESSIS DISCONNECTED
MODULEDANGER
L: FRONTSEATPASSENGER
A DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITHACID,WATERORHEAVYMETALSSUCH
HARM'
MAY PRODUCE
LEADOR MERCURY
AS COPPER.
FUL AND IRRITATINGGASES OR EXPLOSIVECOM.
POUNDS.
MUST NOT EXCEED2OOOF
STORGETEMPERATURES
AND DISSTORAG
HANDLIING,
tlOO"CI.FOBPROPER
MANUAL,
REFBTO THESERVICE
POSALPROCEDURES
SBS SUPPLEMENT.
POTSON
SODIUMAZIOEAND POTASSIUM
CONTAI'\'SPOISONOUS
NITRATE.
FIRSTAID
INDUCEVOMITING.
IF CONTENTSARESWALLOWED,
FOREYECONTACT,FLUSHEYESWITH WATERFOR15
MINUTES.
IF GASES(FROMACID OR WATERCONTACT)ARE IN.
HALED,SEEKFRESHAIR. IN EVERYCASE.GETPROMPT
ATTENTION.
MEDICAL
KEEPOUT OF REACI.IOF CHILDREN.
HOODI
N: SRSWARNINGIENGINE
SYSTEM(SBSI
RESTRAINT
SUPPLEMENTAL
WITH DRIVERSIDEAIRBAG.
THISVEHICLEIS EOUIPPED
ARE
WIRINGAND CONNECTORS
ALL SRS ELECTRICAL
YELLOW.
COLORED
ORUSINGELECTRIWITH,DISCONNECTING
TAMPERING
ON TI{E SRSWIRINGCAN MAKE
CAL TESTEOUIPMENT
FIR'
OB CAUSEACCIOENTAL
THESYSTEMINOPERATIVE
ING OF THE INFLATOR.
A. WANING
AND, IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE
HURTYOU'
CAf{ SERIOUSLY
TALLY DEPLOYED,
CAREFULLY.
MANUALINSTRUCTIONS
FOLLOWSERVICE
HOODIi
N: SRSWARNINGIENGINE
SYSTEM{SRSI
RESTRAINT
SUPPLEMENTAL
WITH DRIVERANO FRONT
THIS VEI{ICLEIS EOUIPPED
AIRBAGS.
SEATPASSENGER
ARE
WIRINGAND CONNECTORS
ALL SRS ELECTRICAL
YELLOW.
COLORED
ORUSI G ELECTRI'
WITI{, DISCONNECTING
TAMPENING
ON THESRSWIRINGCAN MAKE
CAL TESTEOUIPMENT
FIB'
ORCAUSEACCIDENTAL
THESYSTEMINOPERATIVE
ING OF THE INFLATOB.
A WABNING
AI{O, IF ACCIDENTHEAIRBAGINFLATORIS EXPLOSIVE
HURTYOU'
CAN SEBIOUSLY
TALI-YDEPLOYED,
CAREFULLY.
MANUALINSTRUCTIONS
FOLLOWSERVTCE
'This vorsionol tho labolis u36din cs.t with a front soat
passonger'sairbag.
A' WARNING
AND. IF ACCIDENIS EXPLOSIVE
THEAIRBAGINFLATOR
HURTOR KILLYOU.
CAN SERIOUSLY
TALLYDEPLOYEO,
ORPROB.
TESTEOUIPMENT
. DO NOTUSEELECTRICAL
INGDEVICES.
DEPLOYMENT.
THEYCAN CAUSEACCIOENTAL
. NO SERVICEAALE
PABTS INSIDE.OO NOT OISASSEMBLE.
. PLACEAIRBAGUPFIGHTWHENREMOVED.
. F O L L O W S E R V I C EM A N U A L I N S T R U C T I O N S
CAREFULLY.
{cont'd)
1-7
fi{lHfiFe*%
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Warning/Caution
LabelLocations
(cont'd)
SERVICEINFORMATION
C)
SPARKPtUG
II{FORMATION
BATTERY
CAUTION
AIR CLEAI{R,
RECOMMENDEO
OILand
FILTER
SERVICE
RADIATORCAP
CAUTIOI{
TIREINFORMATION
{300()R)
1-8
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TIREINFORMATIOII
t4DOOR)
can assist
NOTE: Sinceeachtire/wheelassemblyweighsapproximately14 kg (30 lbs),placingthe front wheelsin trunk
with the weight distribution.
POINT
FRONTSUPPORT
LIFTBLOCKS
POINT
BEARSUPPORT
1-9
vnx.su
not beinglifted.
2 . When
when tritrng
lifting the rear o
off the car, put the gearshift
lever in reverse(Automatictransmissionin
sition).
@ po-
Centerthe jsck
bracketin the middle
ot the jack lift platform.
JACK LIFTPLATFORM
Rear
JACK LIFTPLATFORM
Centerthe jack
bracketin the middle
of the jack Iift platform.
1-10
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Always uss satety standswhen working oo 01under any vehiclethat is supponedby only a jack.
Naverattompt to use a bumporiack fo. lifting or supporting tho car,
Safety Stands
ATTACHMENTS
RUBBER
t$
\F
FROI{TSUPFORTPOII{T
SAFETYSTANDS
POINT
REARSUPPORT
1-11
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Towing
It the car needsto be towed, call a professionaltowing
service.Nevertow the car behindanothercar with just
a rope or chain. lt is very dange.ous.
Front:
Emergency Towing
There are three popularmethodsof towing a car:
Flat-bedEquipmont-The operatorloadsthe car on the
back of a truck. This is the best way of transportingthe
car.
Whsol Lift Equipment-The tow truck uses two oivoting arms that go under the tires (front or rear)and lifts
them otf the ground. The other two wheels remainon
the ground.
rl
TOWING HOOKS
Real:
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SpecialTools
lndividual tool lists are located at the front of each section
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Specifications
3-2
Standardsand ServiceLimits .'-.'.'."-'-'
3-17
....'.'.'...."....."......
DesignSpecifications
3-20
'.....'.'.
BodySpecifications
vnx.su
Standardsand ServiceLimits
CylinderHead/Valve
Train(B188tenginel- Secti
Declron 6
Compression
Cylinderh.ad
Camshaft
MEASUREMENT
STANDARD
{NEWI
250rpmandwideopenth.ottl Nominal
1,370(14.0,199)
(kgflcm?,
psi)
kPa
Minimum
930(9.5,140)
Maximumvariation 200t2.0,2a)
W6rpage
Height
r 3 1 . 9 5 -1 3 2 . 0(55 . 1 9-5 5 . 1 9 9 )
Endplay
Camshaft-to-holder
oil clearance
Totalrunout
Camlobeheight
tN
EX
lN
EX
tN
EX
lN
EX
(Cold)*
Valveclearance
ValvestemO.D.
Stem-to-guide
clearance
width
tN
EX
tN
EX
Steminstslled
height
Valvespring
Valv6guide
Freelength{Reference}
lN
EX
NH
CH
Lu.
lN
Installed
height
EX
lN
3-2
vnx.su
- 0.0061
0.05- 0.15(0.002
- 0.0027)
0.030- 0.06910.0012
0.03(0.001)
max.
33.71611.327
1l
(1.3200)
33.528
- 0.005)
0.08- 0.12{0.003
0.'r6 - 0.20(0.006- 0.008)
- 0.2594)
6.580- 6.590(0.2591
- 0.2583)
6.550- 6.s60(0.2579
0.02- 0.0s(0.001- 0.002)
0.05- 0.08(0.002- 0.003)
- 0.061)
r.25- 1.55(0.049
- 0.061)
1.25- 1.55{0.049
- 41.235
- 1.6234)
(1.6049
40.765
- 1.7022)
12.763- 43.235t1,6a37
42.36(1.668)
47.09{1.854}
47.08(1.854)
- 0.261)
6.61- 6.63(0.260
6.61- 6.6s(0.260-0.261)
- 14.25
- 0.561}
13.75
{0.541
- 0.640)
r5.75- 16.2510.620
'
SERVICE
LIMIT
0.05(0.002)
0.5(0.02)
0.1s{0.006)
0.04(0.002)
6.s5(0.258)
6.52(0.257)
0.0810.003)
0.11(0.004)
2.0t0.08)
2.0(0.08)
(1.6333)
41.485
(1.7120)
43.485
41.s6{1.636)
46.27tl.A22l
46.21l1.a22l
6.65(0.262)
6.6510.2621
s cti 7
k (81881
EngineBlock
{Bl6E1 englnel- sectlon
(NEWI
STANDARD
0.0710.003)max.
- 3.190)
81.00- 81.02{3.189
MEASUNEMENT
Cylinderblock
Piston
Warpageot decksLrrface
Borediameter
BoretaPer
Reboringlimit
SkirtO.D.at 15 mm (0.6in)Irom bottom of skirt
in cylinder
Clearance
Top
Groovewidth (Forring)
Second
--
Pistonring
clearance
Ringto-groove
oil
top
Second
'....=-
Ringendgap
lop
rod
Connecting
Crankshaft
Bearing
Second
oit
rrstonrln
R
T
R
T
o.D.
clearance
Pin-to-piston
Pin-to-rodinterference
Smallendborediameter
Nominal
Largeendborediameter
on crankshatt
Endplayinstalled
Mainjournaldiameter
N o .1 ,2 , 4 a n d5 j o u r n a l s
No.3 iournal
Rodiournaldiameter
Taper
Out-ofround
Endplay
Runout
oil clearance
Mainbearing-to-iournal
No.1,2, 4 and5 journals
No.3 journal
oil clearance
Rodbearingto-iournal
- 3.189)
80.98- 80.99(3.188
- 0.0016)
0.01- 0.04(0.0004
- r.010(0.04060.0409)
1.030
- 0.0488)
- 1.210(0.0484
1.230
2 . 8 0 -5 2 . 8 2 (00 . 1 1 0 40 . 1 1 1 0 )
- 0.0028}
0.045- 0.070{0.0018
- 0.0026)
0.040- 0.065(0.0016
- 0.0028)
0.045- 0.070(0.0018
- 0.014)
0.20- 0.35(0.008
- 0.012)
0.20 0.30(0.008
0.40- 0.5s(0.0r6 - 0.022)
- 0.020)
0.20- 0.s0(0.008
- 0.0181
0.20- 0.45(0.008
- 0.8268)
- 21.000
(0.8265
20.994
- 0.0009)
0.0r0- 0.022(0.0004
- 0.0013)
0.013- 0.032(0.0005
20.968- 20.981(0.825s- 0.8260)
48.0(1.89)
- 0.012)
0.1s- 0.30(0.006
LIMIT
SERVICE
0.10(0.004)
81.07(3.192)
0.05(0.002)
0.25(0.010)
80.9713.188)
0.05(0.002)
1.0610.042)
1.26(0.050)
2.8410.112\
0.13{0.00s)
0.13(0.00s)
0.13(0.005)
0.60{0.024)
0.6010.024)
0.70(0.028)
0.70(0.028)
0.70(0.028)
- 2.1654)
54.976- 55.000(2.1644
- 2.1651)
54.970- 54.994(2.1642
- 1.7717}
- 45.000{1.7707
44.S76
max.
0.00510.0002)
max.
0.005(0.0002)
0.10- 0.35(0.004- 0.014)
max.
0.03(0.001)
0.010(0.0004)
0.010(0.0004)
0.45(0.018)
0.04{0.002)
- 0.0017)
0.024 0.042{0.0009
- 0.0019}
0.030 0.048{0.0012
- 0.0015)
0.020 0.038(0.0008
0.05010.0020)
0.060(0.0024)
0.050(0.0020)
Ri RIKENmanutacture
Pistonring
pistonring
RINGmanufacture
PISTON
T:TEIKOKU
3-3
vnx.su
Standardsand ServiceLimits
Cylander
Head/Valve
Train(B18Clenginel Section6
MEASUBEMENT
Compr6sion
Cylind6rhoad
C.mshsft
EX
Socondary
Primary
Mid
Secondary
Valvoclorrancelcoldl*
lN
EX
lN
EX
lN
EX
tN
EX
lN
EX
ValvestemO.D.
Stom-to-guid6
clerrsnco
Valvoseat
Width
Sr6minstalledhight
ValvBpring
Fre6length(Roferenca)
lN
Outer
Inner
EX
Valveguido
l.D.
NH
CH
NH
CH
tN
EX
lN
EX
Instslledhoight
Rockrerm
STA]TDARD
INEWI
Arm-to-shaft
clearance
lN
EX
3-4
vnx.su
SERV|C
UM|T
(19.0,
1,860
270)
930(9.s,140)
200t2.o,2a)
'r41.95
- 1C2.05
(5.s89
- 5.593)
0.05- 0.1s(0.002- 0.006)
- 0.0035)
0.050- 0.089(0.0020
0.015(0.0006)
max.
33.411{1.3154)
36.377tl.13221
(1.3601)
34.547
33.1110.3036)
35.72011.4063)
34.381
{1.3536)
0.15- 0.19{0.006- 0.007}
0.17- 0.21(0.007- 0.008)
- 0.21591
5.475- 5.48s(0.2156
- 0.21s0'
5.450- 5.460(0.2146
- 0.0022}
0.025- 0.055{0.00'10
- 0.0031)
0.050- 0.080(0.0020
- 0.06't)
1.25- 't.5s(0.049
'1.25
- 1.s5{0.049
- 0.061)
- 1.4935)
37.465- 37.935('1.4750
- 1.4817)
37.16s- 37.635t1.4632
41.05(r.6161
36.'16
{1.4241
36.19t1.425)
41.96(1.652)
4 1 . 9 {41 . 6 5 1 )
- 0.218)
5.51- 5.53(0.217
5.5r- 5.53{0.2r7- 0.218)
- r3.0s(0.494
- 0.514)
12.55
- 13.05(0.494
- 0.s14t
12.55
- 0.0020)
0.025- 0.0s2{0.0010
- 0.0020)
0.025- 0.0s2(0.0010
0.05{0.002)
0.5(0.02)
0.15{0.006)
0.03(0.001)
5.11510.21441
s.420{0.2134)
0.0810.003)
0.11{0.(x)4)
2.0(0.08)
2.0(0.08)
(1.5033)
38.185
(1.491s)
37.885
40.26(1.585)
35.30(1.390)
35.30(1.390)
40.95(1.612)
40.95(1.612)
5.55(0.219)
5.5s{0.219}
0.08(0.003)
0.08(0.003)
(818C1englnel- Section7
BI k (ltluur
Engrne]'ocK
Cyiinderblock
Piston
MEASUREMENT
warpageof decksurlace
Borediameter
BoretaPer
limit
Reboring
SkinO.D.ar 15mm (0.6in) {rom bottomot skirt
in cylinder
Clearance
ToP
Groovewidth (Forring)
Socond
oil
Pistonring
Ring-to-pistongrooveclearance Top
Second
I oP
Ringendgap
Socond
oil
rrstonrtn
rod
Connecting
crankshatt
Eearing
o.D.
clearance
Pin-to-piston
Pinto-rodintrference
Smallendborediameter
Nominal
Largeendborediameter
Endplay installedon crankshaft
Msinjournaldiameter
N o .1 , 2 , 4a n d5 i o u r n a l s
No.3 journal
Rodiournaldiameter
Taper
Out'olround
Endplay
Runout
oil clearance
Mainbsaring-to-journal
No.1,2, 4 and5 journals
No 3 journal
oil clearanc
Rodbearing-to-journal
(NEWI
STANDARD
0.05(0.002)max.
- 3.190)
81.00- 81.02{3.189
LIMIT
SERVIC
0.08(0.003)
81.0713.192)
0.05(0.002)
0.25(0.010)
- 3.189)
80.98- 80.9913.188
- 0.0016}
0.0r- 0.04{0.0004
- 0.0409)
1.030- 1.0,r0{0.0406
- 0.0488)
1.230- 1.240(0.0484
- 0.11101
2.805- 2.820(0.1104
- 0.0028}
0.045- 0.070{0.0018
- 0.0026)
0.010- 0.065(0.0016
0.20- 0.35{0.008- 0.014)
- 0.022)
0.40- 0,55(0.016
0.20- 0.s0{0.008- 0.020}
- 0.8268)
20.994- 21.000(0.8265
- 0.0009)
0.010- 0.022{0.0004
- 0.0014)
0.017- 0.035(0.0007
20.964- 20.997(0.8254- 0.8267)
.0 (1.89)
- 0.012)
0.15- 0.30(0.006
80.97(3.188)
0.05(0.002)
1.060(0.0417)
1.260(0.0496)
2 . 8 4 0( 0 . 1 1 1 8 )
0.13(0.005)
0.13(0.005)
0.60(0.024)
0.70(0.028)
0.7010.0281
- 2.16541
- 55.000
(2.1644
54.976
54.974- 54.998(2.'|643- 2.1553)
-' I.7717)
- 45.000
44.976
{1.7707
max.
0.005{0.0002}
max.
0.004{0.0002)
0.10- 0.35{0.00{- 0.014)
max.
0.020(0.0008)
-t-oou
lo.ooort
- 0.0017)
0.024- 0.042(0.0009
- 0.0019)
0.030- 0.048(0.0012
- 0.0020)
0.032- 0.050(0.0013
0.050(0.0020)
0.060{0.0024)
0.060(0.0024)
3-5
vnx.su
Standardsand ServiceLimits
- Section
EngineLubrication
eclton g
u _
MEASUREMENT
Engineoil
Capacity
f (USqt, lmp qt)
STANDARD
INEW}
O i lp u m p
Reliefvalve
SERVICELIMTT
Inner-to-outer
rotorclearance
Pumphorising-to-outer
rotorclearance
Pumphousing-to,rotor
axialclearance
rressuresettingat engineoil temp.176.F{gO.Ct
kPalkgtcm,,psi)
At idte
At 3,000rpm
0.20(0.008)
0.21(0.008)
0.1s(0.006)
70 (0.7,10)min.
3{0 {3.5,50)min.
Cooling- Sectiont0
Radialor
MEASUBEMENT
Coolant
capacity I {USqt, lmpq 0
8 1 8 8 1e n g i n e
engine,heater,I
I Including
I coolinglineandreservoir
I
Reservoircapacity:
0.61(0.63USqt,0.53tmpqt)
818C1engine
Radiatorcap
Thermostst
Openingpressure kPa(kgf/cm?,psi)
start to open oF(.C)
Fullyopen .F (.C)
Valvelift at fully open
Coolingfan
lhermoswitch"ON" temperature .F {oC)
"OFF"
Thermoswitch
temporature "F (.C)
ng the coolantin the reservoirandthat remainingin the engine.
3-6
vnx.su
STANDARD
INEWI
M/T:6.4(6.8,5.6)toroverhaul
4.4(4.6.3.9)
f6r s66lsn1gh66q.*
A,rf:6.7{7.1,5.9)for overhaul
4.7{5.0,4.1)for coolantchanoe*
M/T:6.7 {7.1,5.9}for overhaul
4.7{5.0,4.1)for coolantchanoe*
1 6 9- 1 7 6{76 80}
194(90,
8.0(0.31)
196- 203(91- 95)
Subtract5 - 14 (3 - 8) from actuat-ON', temperature
Section 11
sTAt{ItAno(Newl
MEASUREMENT
SERVICEUMIT
| 12011.1'1'21
I too (:.1, g.st
F aa3urorggulator
81881engine
in l2 V, 10seconds
Disolacoment
818C1engins
m, (fl oz,lmp oz)
Pressurewith regulatorvacuum hose disconnected
Bl8Bl engine
kPa (kgflcm',psi)
Bl8Cl engin
22217.5,7 -81min.
364(12.3,12.8)min.
tualt6nk
11.01
50(13.2,
En9in6
7501 50 (M/T:neut..ll
750I 50 {A/T:E or E position}
1,600i 2(x'lM/T:nsurr6l)
l,eooI 200(A/T:E or E po6itioo)
ldl6 CO
0.1 max.
.u.l pump
Clutch
Section 12
STAM'Ad' IiEWI
MEASUREMENT
clutch padsl
clutch disc
Pr6sur6 plat
P6d6lheight
Siroke
Pedalplay
Disengagementheight
to lloor
to floor
max,
0.0510.002)
Clutchsudace runout
Rivt had depth
Thickness
Warpage
Oiaphragmspringlingeralignment
SERVICEUMIT
164(6.46)
130- 140(5.12- 5.51)
12 - 21 (0.47- 0.83)
83 (3.27)min.
1.3(0.05)min.
8.4- 9.1 (0.3 - 0.36)
mrx.
0.03(0.001)
0-6(0.02)ma*
0.'15(0.006t
0.2(0.011
6.0(0.24)
0.15(0.006)
0.8(0.03)
3-7
{n+
vnx.su
ll
Standardsand ServiceLimits
ManualTransmission Section 13
MEASUREMENT
Transmission
oil
Mainshaft
End play
Diameterot ball bearingcontactarea
(clutchhousingside)
Diameterof 3rd gear contactarea
Diameterof ball besring contactarea
(transmission
housingside)
Runo!t
STANDARD{NEWI
SERVICEUMIT
2.2{2.3,1.9}loroilchange
2.3(2.4,2.0)lor assembly
Mainshafi
3rd and
4lh gears
t.D.
Endplay
Thickness
Mainshaft
5th gear
t.D.
Endplay
Thickness
Countershaft
Countershaft
lst gear
t.D.
Endplay
Countershaft
2nd gear
LD.
Endplay
Thickness
3rd
4th
Bunout
Spacercollar
(Countershaft
2nd gear)
t.D.
o.D.
Spacercollar
{l'rainshaft
4th and
sth gears)
t.D.
o.D.
81881engino
818C16ngine
Length
3 -8
Length
vnx.su
Adjust
2 7 . 9 3( 1 . 1 0 )
37.93{1.493)
21.94 /.1.10!'
0.02 (0.0008)max.
0.05 (0.002)
, 1.6939)
43.009- 43.02511.6933
0.06- 0.21(0.0024 0.0083)
- 1.3768)
- 31.97
(1.3748
34.92
- 1.23SOl
31.12- 31.1711.2370
43.08t 1.696)
0.3(0.012)
34.8(1.370)
31.3 (1.2321
43.08{1.696)
0.3 (0.012)
3 1 . 3( 1 . 2 3 2 )
- 1.6939)
43.009- 43.025(1.6933
0.06- 0.21 (0.0024- 0.0083)
31.42- 31.47t1.237-1.2391
33.000- 33.015(1.299- 1.300)
24.980- 24.993{0.9835- 0.9840)
- 1.4567)
36.984- 37.000(1.4561
max.
0.02 10.0008)
- 1.6545)
42.009- 42.02511.6539
- 0.0047)
0.04- 0.12(0.0016
- 1.85r4)
47.009- {7.02511.8507
- 0.0047)
0.05- 0.12(0.0020
- 1.3650)
34.62- 34.67(1.3630
- 1.1405)
28.92- 28.97(1.1386
- 1.4366)
36.48- 36.49(1.4352
- 1.6535)
41.989- 42.00011.6531
29.02- 29.04(1.r42s- 1.1433)
- 1.1453)
29.07- 29.09(1.1444
- '1.2209)
31.002 31.012(1.2205
- 1.4951)
37.989- 38.000(1.4956
- 2.22641
56.45- 56.5512.2224
- 1.0268)
26.03- 26.08(1.0248
32.95\1.297)
24.94(0.982)
36.93{1.454)
0.05 t0.002)
42.08(1.657)
Adjust
47.0811.854)
Adjust
3{.5 (1.358)
28.8(1.134)
36.5(1.437)
4 1 . 9 4( 1 . 6 5 1 )
31.06('1.223)
37.94(1.494)
ManualTransmission
Section 13
MEASUREMENI
Reverseidler
gear'1
Synchroring
LD.
gear shaft clearance
Gear-to-reverse
(ringpushedagainst99ar)
Ring-to-gear
clearance
O o u b l ec o n e
synchro ring *2
Clearance
{rin9pushedagainstgear)
Outersynchroring-to-gear
lnnersynchroring-to-gear
Outer synchro ring-to-synchrocone
Shitt fork
Shifttork fingerthickness
Fork-tosynchro sleeveclearance
Shift fork pawl groove width
Fork-to-reverseidler gear clearance
"1" groovewidth
at sth gearside
at reversegear side
shift piece pin clearance
Fork-to-5th/reverse
at 5th gear side
at reversegear side
piece
area
contact
Groovewidth of change
arm clearance
Changepiece-to-shift
qeverseshift
Shift arm
Shift piece
Selector
STANDARDINEW)
- 0.7891)
20.016- 20.043(0.7880
0.036- 0.084(0.0014- 0.0033)
0.85- 1.10(0.033- 0.043)
SERVICELIMIT
20.09(0.7909)
0.16(0.006)
0.4(0.0't6)
0.6(0.024)
0 . 3( 0 . 0 1 )
0.3 (0.01)
- 0.524)
13.0- 13.3(0.512
- 0.043)
0.5- 1.110.020
-0.303)
7.40- 7.70(0.291
- 0.28s)
7.05- 7.25(0.278
1.0(0.039)
13907)
- 0.03s)
0.4- 0.9{0.016
- 0.018)
0.05- 0.45(0.0020
11.8- 12.0(0.4646-0.4724)
0.05- 0.35(0.002- 0.014)
7.9- 8.0 (0.311-0.315)
0.10- 0.30(0.004- 0.012)
14.000- 14.068{0.551- 0.554)
- 0.0036,
0.011-0.092(0.0004
- 12.00(0.469- 0.472)
1'1.90
0.20- 0.50 (0.008- 0.020i
11.90- ' t2.00(0.469- 0.472)
0.05- 0.35{0.002- 0.014)
- 0.3996}
10.05- 10.15{0.3957
0.05- 0.2s(0.002- 0.010)
0.8010.031)
0.60(0.024)
0.150(0.0059)
osoto.oart
0.50(0.020)
0.50(0.020)
' 1 : 8 1 8 8 1e n g i n e
'2 818C1engine
Capacity
SERVICELIMIT
STANDARD{NEWI
MEASUREMENT
5.916.2,5.2)foroverhaul
2.7 (2.9,2.4)for lluid change
830 - 880 (8.5- 9.0, 120- 130)
780{8.0,110)
460 - 14.7,67)
throttleIully closed
4 1 0{ 4 . 2 . 6 0 )
throttle fully closed
II
780{8.0,110)
throttle more than
3/16opened
780(8.0,110)
780(8.0,110)
780(8.0,110)
0 - 1 s{ 0 - 0 . 1 5 , 02-1 )
830- 880(8.5- 9.0,120- 130)
2,200- 2,600
78018.0,110)
Below 2,200,
above 2,600
(cont'd)
3-9
vnx.su
Standardsand ServiceLimits
AutomaticTransmis3ion(cont'dl- Sostion14
MEASUFEME'YT
Clutch
Clutch initialcl6aranco
Clutch rdtu.n spring troe length
Clutchdisc thicknosg
Clulch plale thickn$3
Clutchond platothictnoss
('l8t)
STANDARD
{NEWI
lst, 2nd
3rd, 4th
lst-hold
lst, 3rd, 4th
2nd
lst-hold
MARK 1
MARK 2
MARK3
MARK4
MARK5
MARK6
MABK7
MABK8
MARK9
MARK10
MAFK 1,I
MARK12
MARK13
MAEK14
MARK 1
MARK2
MARK3
MARK 4
MARK 5
MARK6
MARK7
MARK8
MARK9
MARK10
MARK 1
MARK2
MARK3
MARK 4
NO MARK
MARK6
MARK7
vnx.su
2.052.152.252.352.452.552.65-
- 0.083)
2.10{0.081
2.20(0.085- 0.087)
- 0.091}
2.30{0.089
2.40(0.093- 0.0941
2.50(0.096- 0.098)
- 0.102)
2.6010.100
2.70(0.101-0.106)
SEBVICE
UM]T
29.0(1.14)
31.211.231
32.6(1.28)
Untilgroov6wornout
Discoloration
Discoloration
Discoloration
Oiscoloration
II
I
Discoloration
Discoloration
tI
I
Oiscolor6tion
r.t
a t c u a r r u r r 14
AutomaticTransmission- Section
SIANDARD {NEW}
MEASUREMENT
iransmission
Diameterof needlebearingcontactarea
On mainshattand stator shaft
On mainshaft2nd gear
On mainshaft4th gearcollar
On mainshaftlst gesrcollar
(leftside)
On countershaft
3rd gear
On countershatt
4th gear
On countershaft
On countershaftreversegear collar
lst gearcollar
On countershaft
on sub'shaft(leftside)
On sub-shaft4th gearcollar
On reverseidler gear shaft
Insidediameterof needlebearingconlactarea
On mainshaftlst gear
On mainshaft2nd gear
On mainshalt 4th gear
On countershaftlst gear
On countershaft3rd gear
On countershaft4th gear
On countershaftreversegear
On sub-shatt4th gear
On reverseidlergear
On statorshaft(rightside)
On stator shaft {statorside)
Reverseidlergearshaftholderl.D.
Endplay
Mainshaft1stgear
Mainshaft2nd gear
Mainshatt4th gear
1stgear
Countershaft
3rd gear
Countershaft
4th gear
Countershaft
Sub-shaft4th gear
Reverseidler gear
Countershaftreversegear
Selectorhub O.D.
Mainshaft4th gearcollarlength
Mainshatt'lstgearcollarlength
Ist garcollarflangethickness
lvlainshaft
C o u n t e r s h a f td i s t a n c e c o l l a r l e n g t h
reversegearcollarlength
Countershaft
reversegearcollarflange
Countershaft
thickness
1stgearcollarlength
Countershaft
'1st
Countershaft gearcollarflangethickness
Sub-shaft4th gearcollarlength
Sub-shaft4th gearcollarflangethickness
- 0.9052)
22.980- 22.993(0.9047
35.975- 35.9910.4163- 1.4169)
- 1.2595)
31.975- 31.99r(1.2589
30.975- 30.991t1.2195- 1.22011
36.004- 36.017{r.4r7s- 1.4' l80)
- 1.4172)
35.980- 35.996(1.4165
2 7 . 9 8-0 2 7 . 9 9 {31 . 1 0 1-61 . 1 0 2 1 )
3 1 . 9 7 5 - 3 1 . 9 9( 1 . 2 5 8-91 . 2 5 9 5 )
- 1.2595)
31.975-31.991(1.2589
25.991- 26.000(1.0233 1.0236)
2 7 . 9 8 -0 2 7 . 9 9 (31 . 1 0 1-61 . 1 0 2 1 )
- 0.5512)
13.990 11.000(0.5508
- 1.3786)
35.000- 35.016(1.3780
4 1 . 0 0-0 4 1 . 0 1 {61 . 6 1 4-2r . 6 1 4 8 }
- 1.49671
38.000- 38.016(1.4961
- 1.4967)
38.000- 38.0161' ].4961
4 1 . 0 0 -0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 )
- 1.2998)
33.000- 33.016(1.2992
38.000- 38.0160.4961- 1.4967)
32.000- 32.016fl.2598 1.2605)
18.007,18.020{0.7089 0.7094)
2 9 . 0 0-0 2 9 . 0 1 (31 . 1 4 r -7 1 . 1 4 2 2 )
- ' j.1638)
27.000- 21.021(1.0630
- 0.5683)
14.416- 14.43410.5676
0.08- 0.24(0.003- 0.009)
0.05- 0.13(0.002- 0.005)
0.045- 0.140(0.002- 0.006)
0.1- 0.5 (0.004 0.020)
0.04- 0.15(0.002- 0.006)
0.05- 0.13(0.002- 0.005)
0.05- 0.17(0.002- 0.007)
0.05- 0.r8 (0.002- 0.007)
- 0.010)
0.10- 0.2510.004
51.87- 51.90(2.042- 2.043)
49.00- 49.05(1.929- 1.931)
' |.069)
27.00- 27.15(1.0632.5 - 2.6 \2.098- 2.102)
38.97- 39.00 1.534 1.535)
39.02- 39.05 'r.536- 1.537)
39.07- 39.10 1.538- 1.539)
39.12- 39.r5 1 . 5 4 -0 1 . 5 4 1 )
39.17- 39.20 r.542- 1.543)
39.22- 39.25 1.544 1.545)
39.27- 39.30 1.546- 1.547)
- 1.53r)
38.87- 38.90 1 . 5 3 0
'1.532
- 1.533)
38.92- 38.95
14.5- 14.610.57r 0.575)
2.4- 2.6(0.094- 0.102)
'14.5
- 14.6(0.57'-l 0.575)
2.4- 2.6(0.094 0.102)
24.0, 24.1{0.945- 0.949}
3 . 0 0- 3 . 1 5{ 0 . 1 1 8 0 . r 2 4 )
SERVICELIMIT
Wearor damage
Wearor damage
Wearor damage
*rd"-"g"
Wearor damage
Wearor damage
Wearor damage
Wearor damage
Wearor damage
(cont'd)
3-11
vnx.su
Standardsand ServiceLimits
Automatic Transmission (cont'dl - Section 14
MEASUREMENT
Transmission
(contdl
STANDARD{NEW}
Thrust washerthickness
Mainshaftball bearing left side
Mainshaft 1st gear left side
Mainshatt1stgearrightside
Sub-shaft4th gearthrustwasherthickness
One-wayclutch contactarea l.D.
Countershaftlst gear
Parkinggear
MainshaftfeedpipA, O.D.{at 15mm trom end}
Mainshaftleed piDeB, O.O.{at30 mm from end)
Countershaft
leed pipeO.D.(at l5 mm from end)
Sub-shaftfeed pip O.D.(at 15 mm trom end)
Mainshaftsealingringthickness
{29mm and 35 mm)
MainshaftbushingLO.
MainshaftbushingLD.
Countershaft
bushingLD.
Sub-shaftbushingl.D.
Mainshattsealingring goovewidlh
Regulator
Shiftingdeviceand
parking brakecontrol
Servo body
Oil pump
4.00{0.1564.05(0.1584.10(0.r604.'15(0.1624.20(0.1644.25(0.1664.30{0.1681.35{0.1704.40(0.172-
0.'t57}
0.159)
0.1611
0.163)
0.' t65)
0.167)
0.169)
0.17r)
0.173)
3.451.453.432.93-
3.55(0.1361.50(0.0573.50(0.1353.00(0.115-
0.140)
0.059)
0.138)
0.1181
Drive
Drivn
vnx.su
SERVICE
t_tMtT
Wear or damage
II
I
Wearor damage
Wearlordamase
Woaror damage
- 3.2821)
83.339- 83.365(3.2810
66.685- 66.69812.6254- 2.6259)
8.97- 8.98 {0.353- 0.354)
5.97- 5.98(0.23s0- 0.2354f
- 0.3142)
7.97- 7.98(0.3138
- 0.3142)
7.97- 7.98{0.3138
1.980- 1.995(0.0780- 0.07851
t
Wearor damage
6,0189.0008.0008.0002.025-
6.045(0.2380)
9.03(0.356)
8.03(0.3r6)
8.03(0.3161
2.08(0.0821
- 0.2374)
6.030(0.2359
9.015(0.3s43- 0.3549)
- 0.3156)
8.01s(0.31s0
- 0.3156)
8.015(0.3150
- 0.0811)
2.060(0.0797
35.000 35.025{1.3780- 1.3782)
5.90- 6.00 {0.232- 0.236)
3-12
3.974.024.074.124.174.224.274.324.37-
8.95{0.352t
5.95(0.2341
7.95(0.313)
7.9s(0.313)
1.80{0.071)
35.050(1.3799)
5 . 4 O{ 0 . 2 1 3 )
lWear or other
t_'--'
37.045{1:4585}
0.07 (0.003)
W6aror damage
Wearor damage
tt [t!'tttltttt
Automatic Transmission
MEASUREMENT
Springs
Section 14
Regulatorvalve spring A
Regulatorvalve spring I
Stator ractionspring
Modulator valv body
Torque convortercheckvalve
Cooierchckvalve sprang
Reliefv6lvospring
2-3 orifice control valvo spring
Throttle valve B adiustingsPring
Throttle valve B spring
Throttlevalvo B 6pring
Throttle valve I spring
1-2 shift valve sprang
2-3 shift valve spring
3-4 shift valve spring
'lst-holdaccumulator
spring
1st accumulatorsprang
2nd accumulalorspdng
3rd accumulatorspring
4th accumulatorsPrang
Lock-upshift valve spring
Lock-uptiming B valve spring
Lock-upcontrol valve spring
CPCvalve spring
Kick-downvalvo spring
3-2 kick-downvalvo spring
Servo control valve spring
4th exhaustv6lve spring
Servo orifice controlvalve spring
STANDAND
INEWI
Wir. Di..
1.8{0.071}
1.8(0.071)
5.5(0.217)
1.3{0.0s1)
1.1{0.043}
1.1{0.043)
1.r (0.043)
0.9(0.035)
0.7(0.0281
1.4(0.055)
1.4(0.055)
1.1(0.055)
0.9(0.0351
0.9(0.0351
0.9{0.035)
4.0{0.157)
2.5(0.098)
3.6(0.142)
2.8(0.1r0)
2.6(0.102)
0.9(0.035t
0.8(0.0311
0.8(0.031)
1.3(0.051)
1.0(0.039t
1.3(0.051)
0.9{0.035)
1.0(0.039)
0.8(0.031)
o.D.
14.7(0.579)
9.6 (0.378)
26.4(1.039)
9.4 {0.370}
8.4 (0.331)
8.4(0.3:]t)
8.6 (0.3l9)
6.6 (0.2601
6.2 (0.244)
8.5 (0.335)
8.5 (0.335)
8.5 (0.335)
8.6 (0.339)
7.6 (0.299)
7.6 (0.2991
21.5(0.846t
16.3(0.642)
22.0 (0.866)
17.5(0.689)
16.3(0.642)
7.6 {0.299)
6.6 {0.260}
6.6 (0.260)
9.4 (0.370)
6.6 (0.260)
8.6 (0.339)
6.4 (0.252)
7.1(0.280)
6.6 (0.260)
Fr.. L.ngth
88.6 (3.488)
11.011.7321
30.3(1.193)
37.3{1.469)
33.8(1.331)
33.8(1.331)
37.1(1.461t
33.0(1.299)
34.0 fi.339)
41.5(1.634)
41.5(1.63i1)
41.6{1.638}
40.4(1.591)
57,0 12.2111
52.0(2.047)
71.1Q.A23l
't05.4(4.150)
108.9(4.287)
105.2(4.'142)
103.3{4.067)
73.7 12.9021
60.8 (2.394)
39.5(1.5s5)
35.3(1.390)
2a.5(.1221
45.6(1.795t
34.1{1.343)
60.3(2.374)
48.2{1.898}
t{o. of Colh
16.5
2.1
12.1
't2,5
12.5
13.4
14.9
10.5
11.2
12.1
14.5
26.8
E.3
16 + 8.6
15.2
19.'l
21.2
32.0
22.1
25.O
12.1
11.7
17.0
11.5
18.5
33.0
3-13
vnx.su
Standardsand ServiceLimits
Differential(Manualtransmissionl
Section 15
MASUREMENT
STANDARDINEW)
- 0.7093)
81881engine 18.000- 18.016(0.7087
- 0.7094)
8 1 8 C 1e n g i n e 18.000 18.018(0.7087
- 0.0018)
Carrier'to-pinion
clearance
81881engine 0.0r3 0.045(0.0005
- 0.047(0.0005 0.0019)
B18Ct engine 0.0'13
Driveshafvintermediate
shaft contactarea LD.
8 1 8 8 1e n g i n e 28.000- 28.021\1.1024-1.10321
818C1engine 28.005- 28.025(1.1026 1.'1033)
Carrierto driveshaftclearance
81881engine 0.020- 0.062(0.0008 0.0024)
- 0.0034)
BlSC'lengine 0.045, 0.086{0.0018
Carrier-to-intermediate
shatt clearance
B188l engine 0.050- 0.087(0.0020 0.0034)
- 0.0044)
818C1engine 0.075- 0.111(0.0030
(0.002
Differential
Eacklash
0.05 0.15
0.006)
'18.042
- 18.066(0.7103 0.7113)
prnrongear
t .D .
PiniongeaFto-pinion
0.055- 0.095(0.0022 0.0037)
shaftclearance
Sel ring-to-bearing
outerraceclearance
81881engin 0 - 0.10(0 0.004)
Differentialtaper roller bearing preload
- 3 r.0,13.0-18.7)
StartingtorqueN.m {kgfcm,lbf.in)
Bl8Cl engine 2.1r- 3.04{21.5
Differential
Differential
prnrongear
o.t aron,
0.1{0.006}
Adjust
0.15{0.006)
Adjust
Adjust
Section 15
MEASUREMENT
Difterential
carflr
SERVICELIMIT
PinionshaftcontactareaLD.
Backlash
t.D.
Piniongear-to-pinion
shaftclearance
STANDAROINEWI
- 0.7094)
18.000- 18.018{0.7087
- 0.0020)
0.016- 0.052{0.0006
- 1.1033)
28.00s 28.025{1.1026
- 0.0026)
0.025- 0.066(0.0010
0.05- 0.15(0.002- 0.006)
18.042- 18.066(0.7r03- 0.7113)
- 0.0037)
0.059- 0.095(0.0023
0 - 0.r5(0- 0.006)
Set ring-to-bearing
outerraceclearance
SERVICELIM]T
0.1{0.004)
0.12(0.005)
Adjust
0.15(0.006)
Adjust
Steering - Section 17
Steeringwheel
Gearbox
Purnp
Powersteering
tluid
Power steering
belt*
MEASUREMENT
play at steeringwheelcircumference
Rotational
Staninglosd at steeringwheelcircumference
N {kgf,lbfl
Enginerunning
Angle of rack-guide-screwloosenedfrom locked
position
Pumppressurewith shut-offvalveclosed
kPa(kgtlcm,,psi)
fluid
Recommended
Fluidcapacity
f (USqt, lmp q0
For overhaul
Forfluid change
Deflection
with 98 N (1okgt,22lhfl
betweenpulleys
BelttensionN lkgf,lbl)
Measuredwith belttensiongauge
STANDARDINEWI
0 - 10 {0 - 0.39)
3 4\ 3 . 5 , 7 . 7 1
20" i 5'
6,400 7.400165 75.920- 1.r00)
Hondapowersteeringfluid V
1 . 0 6( 1 . 1 2 , 0 . 9 8 )
0.79(0.83,0.70)
11.5- 13.5(0.45 0.53)withusedbelt
8.0- 10.010.310.39)withnew belt
390 - 540 (40- 55, 88 - 120)with used belt
740 880175 90. 170 200)with new belt
' When usinga new belt,adjustdetlectionor tensionto new values.Runthe enginelor 5 minutesthen turn it off.
Readiustdetlectionor tensionto usedbeltvalues.
vnx.su
Suspension
Sestion 18
STANDARD
I]{EWI
MEASUFEMENT
Camber
a gnment
Caster
Totaltoe
Frontwhelturningangle
Endplay
A1lclbearing
Rim runout(Aluminumwheel)
Rim runoutisteelwhgel)
Brake
Front
Rgar
Front
Front
Rear
Inwardwhel
Outwsrd whel
Front
Roaa
Axial
Radial
Axial
Radisl
-0. 10'1 1.
-0' 15' l$igl
1 . 1 0 ' rt "
0i2(010.081
rN3:i(0.121ff)
36'0o'r 2'
30. 30'
0 - 0.05(0- 0.002)
0 - 0.05{0- 0.002}
STANDARD
INEWI
0 - 0.7{0- 0.03)
0 - 0.7(0- 0.03)
0 - 1.0{0- 0.0{)
0 - 1.0(0- 0.04)
Section 19
STANDARD
{NEWI
MEASUREMENT
trrling brake
; oot brake
,adal
M/T
Freeplay
Vastercylinder
Piston-to-oushrodclearance
f,,s4brake
Oiscthickness
Disc runout
Disc parallolism
Padlhickness
Air Conditioning
Ar conditioning
Compressor
UMIT
SEBVICE
2.0(0.08)
1.5(0.06)
2.0(0.081
r.5(0.061
Front
Re6r
Front
R6ar
Front and rear
Front
Roar
160(6.30)
155(6.50)
1-5(0.04-0.20)
0 - 0.4(0- 0.2)
STANDARD
INEWI
20.9- 21.1t0.82- 0.83t
8.9- 9.1{0.35- 0.36)
SERVICELIM]T
19.0(0.75)
8.0 (0.31)
0.10 (0.004)
0.r0(0.00a)
0.015(0.0006t
r.6(0.06)
1.6(0.06)
Scction22
STANDABOIT{EWI
MEASUREMENT
Lubricantcapacitymf (ll oz)
Condnser
Evaporator
Lineor hose
Receiver
Lubricanttype: NO-OlL8{P/N38899- PR7- A0l)
Lubricantcapacitym{ (ll oz}
Lubricanttvge: ND-O|L8(P/N38899- PR7- A01)
Stator coil resistanceat 68'F (20'C)0
plate clearance
Pulley-to-pressure
25(5/6)
40t1 1/3)
1 0( l B t
10(1/31
140';u(4-23';")
3.4-3.8
0.5r 0.15{0.02r 0.006)
7.5- 9.5 {0.30- 0.37)with used blt*'
Compressor
Detlectionwith 98 N (10 kgf, 22 lbf)
8.5- 10.5{0.33- 0.41}witht/sodbelt'3
bh'r
betlveenpulleys
5.0 - 7.0 {0.20- 0.28)with new belt
Belt tnsion N (kgf, lbl)
390 - 540 {r0 - 55, 88 - 120}with used beh*'
Measuredwith beltlensiongauge
340- 490 {35 - 50, 77 - 110}with used belt*3
740 - 880 {75 - 90, 170- 200)with new belt
.1: Whenusinga new bek,adjustdellectionor tensionto new values.Runthe enginetor 5 minulesihen turn it ott.
Readiustdetlectionor tension to lsed beh values.
'2: 81881engine
'3: 818C1engine
3-15
vnx.su
Standardsand ServiceLimits
Electrical
Section23
MEASUREMENT
lgnilioncoil
lgnition wire
ll
il
Sparkplug
Tvpe
Gap
lgnition timing
At idling
" BTDC(Red)- rpm
Deflecrionwilh 98 N {10 kgf,22lbll
betweenpulleys
Alternatorblt'2
Alternator
STANDARD
{NEWI
Ratdvoltago V
Primarywinding resistanceat 58'F (20'C)O
Secondarywinding resistance6t 68'F (20"C)kO
Resistancear 68"F(20'C)k0
0.6- 0.8
12.4- 19.2
25 max.
STANDARDINEW}
See Section23
B18Blengine 1.0- 1.1{0.039- 0.043}
B18Clengine
M/T
SEN$CE UM]T
1.3{0.051)rl
STANDARD
INEWI
90
2.9
14.4t0.57)
r0.5(0.41)
3.210.33,
0.73)
Output
Mica depth
0.5- 0.8(0.02- 0.03)
Commulatot runout
0 - 0.02(0- 0.0008)
- 1.r81)
CommutatorO.D.
29.9- 30.0(1.177
Brushlength
15.0- 15.5(0.s9- 0.61)
- 5.3)
Brush spring tension (new) N lkgt, lbf)
17.7- 23.5fi.8- 2.4,4.0
*1: Do not adiust the gap, replacespark plug it it is out of spec.
*2r When using a new belt, adjust dtlctionor tension to new valus.Run tho enginelor 5 minutesthon turn it off.
Readiustde{lection
or tensionto usodbeltvalues.
SENUCEUMTT
tnnro.rrr
1.5(0.06t
Staner
vnx.su
0.2(0.0081
0.05t0.@2)
29.0(1.142)
10.0(0.39)
DesignSpecifications
]TEM
:' vENSTONS
3 DOOR
4 DOOR
Overalllength
OvrallWidth
OverallHeight
3 DOOR
4 DOOR
3 DOOR
4 DOOR
Wheelbase
,rerght(usA)
'le,ght {CANADA)
:\GINE
TrackF/R
GroundClearance
SeatingCapacity
WeightRating{GVWR)
crossVhicle
GrossVehiclsWeightRating{GVWR)
8 1 8 8 1e n g i n e
Type
818C1engine
CylinderArrangement
BoreandStroke
Displacement
Ratio
Compression
L!bricationSystom
OilPumpDisplacement
WsterPumpDisplacement
FuelRequired
8 1 8 8 1engrne
818C1engane
8 1 8 8 1engrne
B18CI engine
8 1 8 8 1engine
B18C1engine
8 1 8 8 1engine
8 1 8 C 1engine
8 1 8 8 1engrne
B18C1 engrne
8 1 8 8 1engine
B18C1engine
9 1 8 8 1engine
818C1engine
CLUTCH
Typo
NormalOutput
NominalVoltage
HourRating
Directionof Rotation
Weight
ClutchType
M/T
TRANSMISSION
Area
ClutchFacing
Transmission
Type
M/T
STARTER
PrimaryReduction
ENGLISH
METRIC
172.1in
4.380mm
178.1
in
4.525mm
'1,710
mm
67.3in
1,335mm
52.6in
1,370mm
101.2
in
2,570mm
in
103.1
2,620mm
't,475/1,470
mm 5|8.1/57.9
in
150mm
Four(3 DOOR)Five (4 DOOR)
3,680lbs
NOIES
1,670kg
4-strokeDOHC
Water-cooled,
gasoline
engine
Watercooled,4-strokeDOHC
VTECgasoline
engine
Inline4-cylinder,
transverse
3.19x 3.50in
81.0x 89.0mm
3.19x 3.43in
81.0x 87.2mm
112cu-in
1,834
cm3(mf)
110cu-in
1,797
cm3(m{)
9.2:1
10.0: 1
4 valvepercylinder
Eeltdriven,OOHC
Beltdriven,DOHCVTEC
4 valvepercylinder
Forcedandwet sump,trochoidpump
50, {53USqt, 44lmpqt)/minute'l
71 f {75USqt, 62 lmp qt)/minute"
140f (148USqt, 123lmpqt)/minute*!
140f (148USqt. 123lmpqt)/minute*'
gasoline
with86 Pump
UNLEADED
OctaneNumbror higher
gasoline
wilh
Premium
UNLEADED
91 PumpOctaneNumberor higher
Gearreduction
1 . 4k W
12V
30 seconds
Clockwiseasviewedlrom g6arend
3.7k9
8.3lbs
|
spring
Singleplatedry,diaphragm
Torq!e converter
31 sq-in
203cm'
I
5-speedforward,1 reverse
Synchronized
Electronically
controlled
4-speedautomatic.1 rcverse
Diract1 : 1
(cont'd)
'1: At 6,000enginerpm
'2: At 7,600enginerpm
3-17
vnx.su
DesignSpecifications
{cont'd}
lTEM
TRANSMISSION
M E T R I C I i I G L I S H I N O T E S
Type
Enginetypo
1st
2nd
3rd
4th
5th
Rovrs
G6arRatio
Fin6l Reduction
Geartype
Gear ratio
Type
Manual transmission
81881
818C1
|
3.230
r.9(X)
1.360
1.034
0.'t87
3.000
3.230
1.900
1.269
0.966
o.711
3.000
Singlehelicalge.r
4.266
4.400
Automatictransmission
'l6t
GearRatio
2.722
1.464
0.97s
0.638
1.954
znd
3rd
4th
Revelse
FinalRduction
AIR
CONDITIONING
CoolingCapacity
Compr6ssor
Cond6nsr
Evaporator
Blower
TemperatureControl
CompressorClutch
Refrigerant
STEERING
SYSTEM
SUSPENSION
Goartypo
Gear ratio
Type
OverallRatio
Turns, Lock-to-Lock
SreeringWheel Dia.
Type
14,166BTU/I
swash-plare/NIPPoNDENSO
10
150ml /rcv
|
9.15cu-in/rv
7,600rpm
140mf
1-2Blloz
|
I
l.;3 tmpoz
(P/N38899- PR7- A01)
ND-O|L8
3,570Kcal/h
Type/Make
No. ol Cylinder
CaPtcity
Max. Spsed
LubricantC6pacity
Lubricrnt Type
Type
Type
Type
Motor Input
SpeedContro
Max. Capachy
Type
PoworConsumption
Type
Ou.ntity
Front
Roar
3-18
Singlehelic6lgoar
4.357
vnx.su
Corrugatedfin
Corrugatodtin
Siroccotan
200w12 v
4-speed
450 m3/h
15,900cu lvh
|
Airmix type
Dry, singlo plate, poly-V-bltdriv6
40 W max./12V at 68"F{20'C)
(R-134a)
HFC-134a
zoo-Ss
24.7-l.aoe
I
Power assisted,rackand pinion
16.1
2.98
15.0in
380 mm
|
Independentdouble wishbono,
coil spring with st6bilizer
Independontdouble wishbong.
coil spring with stabilizer
Telescopic,hydraulic nitrogen gas-tilled
ITEM
WHEEL
ALIGNMENT
M E T R I C I E N G L I S H I M ) T E S
Camber
Front
Rear
Front
Front
Rear
Caster
TotalToe
BRAKESYSTEM
Type
PadSurfaceArea
ParkingBrake
TIRE
Size
Front
Rear
Front
Rear
Type
Front and rar
SpareTire
ELECTRICAL
8attery
Starter
Alternator
Fuses
In Under-dashFuse/RelayBox
In Under-hoodFuse/RelayBox
In Under-hoodABS Fuso/RolayBox
Headlights
High
FrontSideMarkerLights
FrontTurn SignauParkingLights
RearTurn SignalLighls
Stop/Taillights
High Mount BrakeLight'5
FearSideMarkerLights
Back-upLights
LiconsePlateLights
CeilingLights
CargoArea Lights (3 DOOR)
TrunkLightsl4 DOOR)
Spotlights
GloveBox Light
GaugeLights
IndicatorLights
llluminationand PilotLights
HeaterllluminationLights
omm
In 2 mm
-0.10'
-0.45'
1'1o'
oin
|
ln 0.08in
I
Power-assistedselt-adiusting
ventilateddisc
PoweFassistedself-adjustingsolid disc
io.u cm. x z
|
/,/5 so tn x z
21.0cm, x2
|
3.26sq in x 2
Mechanicalactuating,reartwo wheel brakes
P195/60R14
858*1
P195/55R15
84V*2
T115t0D14*3
T135/70O15.4
I2V-36AH6HR
'12V -'1.4 kW
12V-90A
7.5A, 10A, 15A, 20 A, 30 A
7.5 A, 10 A. 15 A, 20 A, 30 A, 40 A
50 A, 100A
1 0 A ,1 5 A , 2 0 A , 4 0 A
12V-6sW{HB3}
12V-55W(HB4)
12V-3CP
12V -32n CP
12V -32 CP
12V -32n CP
12V-21W
12V-3CP
12V -32 CP
12V-8W
12V-5W
12v-3.4W
12V-3.4W
12V-5W
12V-3.4W
12V-3.4W
v - 0.84w, 0.91w, 1.12W, 1.r W, 3 W
12 V - 0.84W. 0.91W, 1.4W. LEO
12V-1.4W
sAE 168
sAE1157
sAE 1't55
sAE1157
sAE7440
sAE 168
sA 1156
*1: RS,LS
*2: GS-R
*3: RS
*1: LS,GS-R
*5: Excepthigh mount brakelight installedin rcar spoiler.
vnx.su
3-19
Il
I
Body Specifications
Unit:mm (in)
3 DOOf,:
il
vnx.su
Unit mm {inl
. DOOR:
vnx.su
3-21
Maintenance
Points
Lubrication
MaintenanceSchedule
vnx.su
.........4-2
." 4'4
LubricationPoints
For the detailsol lubricationpoints and type of lubricantsto be spplied,reter to the illustratedindex and variouswork
procedure(such as Assembly/Reassembly,
Replacement,Overhaul,Instatlation,etc.) containedin each section.
No.
I
LUBRICATIONPOII\ITS
LUBRICAI\IT
API ServiceGrade:Use SG or SH "Energy Conserving
II" grade oil.
The oil containermay also displaythe API Certification
sal shown below. Make sure it says'For Gasoline
Engines.'
SAE Viscosity;See chan below.
Engine
Transmission
Manual
Automatic
Clutch line
Power steeringgearbox
SteoringgreaseP/N 08733-BO7OE
Releasefork (Manualtransmission)
Siliconegrease
'I 'l
17
18
BrakemastercvlinderDushrod
Clutch mastercylinderpushrod
Enginehood hingesand enginehood latch
Batte.v terminals
Fuel fill lid
Hatch hingesor trunk hinges
Door hinges.upper and lowet
Door oDendetent
19
Rear brakecalioers
Rust-p,eventive
agant
20
21
Air conditioningcompressor
12
13
14
15
to
.Multi-purposegrease
-20
-30
API CERTIFICATIONSEAL
0
-20
20
-'to
r}()
o
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10
ao
20
Recolnmendodengine oil
Engine oil viscosity tor
ambient tgmpelalure rangos
vnx.su
30
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vnx.su
Engine
E n g i n eR e m o v a l / l n s t a l l a t i o. .n. ' ' . . . . . . . .5 - 1
C y l i n d e rH e a d / V a l v eT r a i n . . ' . . . . . . . . . . . .6 - 1
......7-1
EngineBlock....
.........8-1
EngineLubrication
System ...... 9-1
IntakeManifold/Exhaust
.......1O-1
Cooling
vnx.su
EngineRemoval/lnstallation
.".....5-2
S p e c i aTl o o l s . . . . . . . .
..."........ 5-3
EngineRemoval/lnstallation
..' 5-16
Mount/BracketTorque
vnx.su
SpecialTools
ru
il
Rst. No.
Tool Numbor
07MAC-SLOO200
Dascription
Ball Joint Remover,28 mm
vnx.su
Oty
Pag Rterenco
EngineRemoval/lnstallation
2.
@
a
Make surejacks and safety stands aro placed ploperly and hoisl brackots arg attachod to the correct positions on tho engine (se ssction 1).
a Mak sure tho car willnot roll off stands and tallwhile
you are wotking under it'
8 x 1.25mm
24 N.m (2.4 kgf.m,
17 rbt.ft)
CAUTION:
a Use fendet covals to avoid damaging painted
sudaces.
r Unspecified itsms alo common
a Unplug tho widng connectots carefully while holding
the couplor and tha connector portion to avoid
oamage.
a Mark all wiring and hoses to avoid misconnection.
Also, be sulo that thsy do not contact other wiring
or hoses, or interfere with othl parts.
NOTE: Anti-theft radioshave a coded theft ptotection
circuit. Be sure to get the customer'scode numberbeJore
- Disconnectingthe batterY.
- Removingthe No. 32 (7.5 A) fuse from the underhood tuse/relaybox.
- Removingthe radio
Atter service,reconnectpower to the radio and turn it
"CODE" is displayed,enterthe cuson. Whenthe word
tomer's 5-digit code to restoreradio operataon.
1.
STRUTERACE
BATTERYCABLES
6 x l.O mm
9.8 N.m (1 .O kgf'm,
7.2 rbl.ftl
{cont'd)
5-3
vnx.su
EngineRemoval/lnstallation
(cont'd)
Removethe intakeair duct, air cleanerhousingassemblv and the bracket.
7.
6 x 1 . Om m
9.4 N.m {l.O ksf.m, 7.2 tbf,ftl
6 x'l.Omm
9.8 N-m ll.0 kgt.m.
8.
VACUUM HOSE
9.
SERVICE
BOLT
15 N.m (1.5 kgt.m,11 tbt.ftl
BAITJO EOLT
33 N.m 13.4 kgt.m,
25 tbt.ftt
THROTTI.EBODY
vnx.su
BRAKEBOOSTER
VACUUMHOSE
' t 2 . Removethe enginewire harnessconnectors,terminal and clamps on the left side ot engine comoartment.
6 x 1.0 mm
9.8 N.m {1 .O kgf.m,
7.2 tbt.ftl
ENGINEWIRE
HABNESS
BETURNHOSE
8 x 1.25mm
24 N.m (2,4 kgl.m,
17 lbf.Irl
CRUISECONTROL
ACTUATOR
LOCKNUT
AOJUSTINGNUT
5-5
vnx.su
EngineRemoval/lnstallation
(cont'd)
1 4 . Removethe engineground cable at the body end.
Removethe adiustingbolt and mountingbolt, then
remove the power steering (P/Sl belt and pump.
a Do not disconnect the P/S hoses.
SLAVE CYLINDER
8.0
8 r 1 . 2 5m m
24 N.m (2.4 kgf.m. 17 lbl.ftl
8 x 1.25mm
6 x 1 . Om m
1l N.m 11,1 kgt.m,
I tbt.ftl
IDLERPULLEYBOLT
10 x 1.25mm
44 N.m 14.5 kgt.m, 33 lbl.ftl
5-6
A/C COMPRESSORBELT
vnx.su
UPPERRADIATOR
LOWERRADIATOR
HOSE
6 x 1 . Om m
9.8 N.m (1.0 kgf'm'
7.2 tbf.ft)
HOSE
{cont'd)
5-7
vnx.su
*l
EngineRemoval/lnstallation
(cont'dl
27. Removethe radiatorassembly{see page 1O-4),
8188l engine:
GASKET
Replace.
GASKET
Replace.
SELF.LOCKINGNUT
I x 1.25mm
16 N.m (1.6kgt.m,
12 tbf.ft)
Replace.
8 x '1.25mm
24 N.m t2.4 kgf.m,17 lbl.ftl
I x 1.25mm
22 N-m 12.2 kgf.m, '16 lbf.ftl
I x 1.25mm
24 N.m (2.4 kgf.m,
17 rbt.ftt
Replace.
5-8
Ho2s
CONNECTOR
SELF-LOCKING
NUT
8 x 1.25mm
1 6 N . m 1 1 . 6k g f . m ,
12 tbl.ftl
Replace.
10 x 1.25mm
54 N.m (5.5 kgl.m,
40 tbt.ttl
Replace.
EXHAUST
PIPEA
SELF
1 0 x 1 . 2 5m m
54 N.m (5.5 ksf.m.4O lbf'ltl
Replace.
vnx.su
SHIFTROD
I x 1.25mm
22 f.m 12.2 kgl'rn'
16 tbl.ftl
CAUTION:
a Do not pull on tho ddv$halt, tho CV ioint mav
como apan.
a Uso caro whsn prying out tho assombly.
Pult it slraight to avoid damaging th6 differantial
oil soal or intormodiato shaft dust seal.
SHIFT CABLE
SHIFT CAALE
covER
locx usiea
Replace.
6 x 1.0 mm
14 N.m t1.4 kgf.m, 10 lbl'ftl
12 x 1.25mm
REMOVER28 mm
oTMAC-S100200
vnx.su
(cont'd)
5-9
EngineRemoval/lnstallation
(cont'd)
35. Lower the hoist.
I
I
I
vnx.su
WASHERS
Replace.
SIDE ENGIITE
MOUNTBOLT
LEFT FRONT
MOUNT
12 t 1.25nn
59 N.m {6.0 kgt.m,
43 lbf.trl
Replace.
MOUNT/BRACKET
38. Removethe rear mount bracket,
1 2 r 1 . 2 5m m
59 N.m (6.0
Replace.
43 rbf.ftl
REARMOUNT
12 r 1.25m|n
59 N.m {6.0 kgt.m,
43 tbt.frl
Replace.
14 x 1.5 mm
118 t{.m (12.O kgt.m,86.8 lbl.ft}
R6place.
(cont'dl
5-11
vnx.su
EngineRemoval/lnstallation
SIDE ENGITIE
MOUNT
5-12
vnx.su
Engine Installation
Installthe enginein the reverseorder of removal.
Reinstall
the mountbolts/nutsin the followingsequence.
Failureto tollow theseproceduresmay causeexcessive
noise and vibration,and reducebushinglife.
1.
10 x 1.25mm
52 N.m {5.3 kgf.m,
38 rbf.Itl
Replace.
A/T:
12 x 1.25mm
64 N.m (6.5 kgt.m,
47 rbf.ft)
3.
A/T:
M/T:
1 2 x 1 . 2 5m m
64 N.m 16.5 kgl.m,
47 tbt.frl
1 2 x 1. 2 5 n n
74 N.m (7.5 kgl.m,
54 rbf'ftt
M/T:
1 2 x 1 . 2 5m m
74 N.m (7.5 kgt.m,
54 tbt.ftl
{cont'd)
5-13
vnx.su
EngineRemoval/lnstallation
(cont'dl
4.
6.
A/T:
m'
.tE
12 x 1.25mm
74 N.m (7.5 kgf.m,
54 lbt.ttl
O 12 x 1.25mm
64 N.m 16.5 kgt.m,47 lbf.ftl
Replace.
5.
M/T:
@
' 1 0x 1 . 2 5 m m
44 N-m (4.5 kgf.m,
@ 12 x 1.25mm
59 N.m {6.0 kgf'm, 43 lbl'It)
Replace.
12 r 1.25mm
59 .m 16.0 kgl.m,
vnx.su
O 1 2 x 1 . 2 5m m
83 N'm (8.5 kgf.m,61 lbt.frl
O 12 x 1.25 ]n]n
83 N.m 18.5kst.m,61 lbt.ftl
Replace.
@ 1 2 r 1 . 2 5m m
59 N.m {6.0 kgl.n,
43 tb{.ftl
Replace.
@ 1 0 r 1 . 2 5m m
(cont'd)
5-15
k-
vnx.su
Mount/BracketTorque
Mount and BracketEolts/NutsTorque Valve Specification:
il
TRANSMISSION
MOUNT:
I
I
vnx.su
SIDEENGINE
MOUNT:
Torqus Spocifications:
A : 1 0 x 1 . 2 5m m
59 N.m (6.O kgf.m, 43 lbf.ft)
B: 12 x 1.25 mm
59 N.m {6.0 kgt.m. 43 lbt.ft}
Reolace.
C: 14 x 1.5mm
1 1 8 N . m { 1 2 . Ok g t . m , 8 6 . 8 l b t . t t }
Replace.
D: 12 x 1.25 mm
74 N.m {7.5 kgf.m, 54 lbf.tt}
E : 1 2 x 1 . 2 5m m
64 N.m (6.5 kgf.m, 47 lbf.ftl
F: 10 x 1.25 mm
52 N.m {5.3 kgl.m, 38 lbt.ft}
Replace.
G : 1 0 x 1 . 2 5m m
rt4 N.m (4.5 kgf.m, 33 lbf.ft)
H : 1 2 x 1 . 2 5m m
83 N.m (8.5 kgt.m. 61 lbl.ft)
l r 1 2 x 1 . 2 5m m
64 N.m (6.5 kgf.m, 38 lbf.tt)
Reolace.
LEFTFRONTMOUNT:
/>
{cont'd)
5-17
vnx.su
Mount/BracketTorque
(cont'd)
ALTERNATORBRACKET
REARSTIFFENER
10 x 1.25mm
'1.25mm
M/T: 12 x
57 N.m 15.8 kgf'm,
42 rbf.ft)
A/T: 10 x 1.25mm
/14 N.m {4.5 kgf.m,
32 tbt.ftl
8x1.25mm
24 N.m 12.4 kgf'm,
17 tbt.ftt
SIDEENGINEMOUNT
BRACKET
lO r 1.25mm
54 N'm (5.5 kgl.m,
40 tbf.ft)
t-*i;
f--^,c*;"*".*l q
I
-4M
5-18
Ghinein"onvt
ddv
'12 x 1 .25 mm
57 N.m 15.8 kgt.m,
42 tbf.fr)
8 x 1.25mm
24 N.m (2.4 kgf.m,
17 tbf.ft)
HEAT
INSULATOR
(818C1
10 x 1.25mm
44 N.m {4.5 kgf.m,
33 rbr.ftt
10 x 1.25mnl
44 N.m (4.5 kgf.m,
33 rbr.tt)
vnx.su
CylinderHead/ValveTrain
8 1 8 8 1engine
.............6-2
SpeciafTools
Valve Clearance
............6-3
Adiustment
ValveSeals
Replacement(cylinderhead
removalnot required) .....................
6-5
......6-27
Reconditioning
gelt
Timing
6-7
lllustratedIndex ...............................
..............
6-9
Inspection
6-9
TensionAdiustment ........................
.................6-10
Removal
.............6-12
Installation
CrankshaftPulleyBolt
.........6-8
Replacement
vnx.su
SpecialTools
-
t
Ref.No.
o
o
07GAD- PH70100
07JAB- 001020A
OTMAB_ PY3O1OA
07757- PJ10toA
07947- 6570100
07984- 657010C
@
@
Oty
Ocacription
Tool Numbrr
ValveGuidelnstaller
HolderHandle
PulleyHolderAttachment,HEX50 mm,
Offset
ValveSpringCompressorAttachment
ValveGuideDriver,6.6 mm
ValveGuideReamer,6,6 mm
I
o
e:=-4-b4altltgt
r-l-:ff:-b
vnx.su
Prgc R.terencc
1
1
6-8
1
1
1
1
6-8
6-22
6-25,26
6-26
ValveClearance
Adjustment
Set the No. 1 piston at top dead center(TDC)(see
p a g e6 - 1 2 ) ." U P " m a r k o n t h e p u l l e ys h o u l db e a t
the top, and the TDC grooveson the pulley should
align with the TDC groove on timing belt back
cover.TDC mark (paintedwhite) on the crankshaft
pulley should align with pointeron the timing belt
towercover.
NOTE:
. Valves should be adjustedcold; at a cylinder head
temperatureof lessthan 100'F(38"C).
Adjustmentis the same for both intakeand exhaust
valves.
. After adjusting,retorquethe crankshaftpulleybolt to
177N.m (18.0kgim, 130lbf.ft).
2.
1.
Removecylinderheadcover.
ADJUSTINGSCREWLOCATIONS:
"UP" MARKS
INTAKE
TDCGROOVES
EXHAUST
TDCMARKS
lPeintedwhitel
CRANKSHAFT
PULLEY
6-3
vnx.su
ValveClearance
Adjustmentlcont'dl
a
Adjustvalveclearances
on No. 1 cylinder.
7.
R o t a t et h e c r a n k s h a f t1 8 0 ' c o u n t e r c l o c k w i s t o
bring No. 4 piston to TDC.The'UP" mark should
be pointing straight down. Adjust valves on No. 4
cylinder.
LOCKNUT9x0.?5mm
25 N.m 12,5kgf.m, 18lbt'ft|
"UP'MARKS
8.
-UP" MARKS
.UP' MANKS
EXHAUST CAITISHAFT
PULI,IY
INTAKECAMSHAFT
PULLEY
vnx.su
ValveSeals
(cylinderheadremovalnot requiredl
Replacement
NOTE: Cylinder head removal is not required in this
procedure.
The procodureshown below applieswhen usingthe inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 5w i t h
Y AAA$-2A 718"attachment).
whcn u3ing this tool, a: with any tool,
@@
always u! agproved cyr Protcction. Using th.
right tool for cach iob hclps incraa3. produstivity
whilo 3ltrgu8rding tool!, cquipmcnt lnd the u3c1'
1. Turn the crankshaftso that the No. I and the No' 4
pistons are at top dad center (TDC).
2.
Removethe cylinderheadcover.
3.
Removethe distributor.
4.
5.
Select the 7E in. diameter long compressor attachment and fasten the attachmentto the No. 4 hole of
the leverarm with the speedpin supplied.
OIL PASSAGE
OIL PASSAGES
(cont'd)
6-5
vnx.su
ValveSeals
Replacement(cylinderhead removal not required) (cont'dl
'11.
Using a downward motion on the lever arm. compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring.
Removethe valveseals(seepage6-22).
'14. Installthevalve
seals(seepage6-23).
OIL PASSAGE
Using a downward motion on the lever arm, compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring.
1 9 . Selectthe 7/8 in. diameter short compressorattachment and fastenthe attachmentto the No. 4 hole of
the leverarm with the speedpin supplied.
20. Positionthe pistonat TDCand insertan air adaptor
into the spark plug hole. Pump air into the cylinder
to keepthe valveclosedwhile compressingsprings
and removingthe valvekeepers.
vnx.su
Timing Belt
lllustratedIndex
NOTE:
. Referto page6-12for positioningcrankshaftand pulleybeforeinstallingbelt.
. Mark the direction of rotation on the belt before removing.
. Replacethe rubbersealstor oil leakagbetweenthe cylinderheadand cover.
a Do not uss the middle cover and lower cover for storing itsms disassembled.
. Cleanthe middlecoverand lowercover beforeinstallation.
CAPNUT
6xl.0mm
9.8N'm (1.0kgf.m,7.2lbtft) WASHER
\o
Replacowhen damaged
or deteriorated.
CYLINDERHEADCOVER
Referto pago6-31when
installing.
RUBBERSEALS
Replacewhen damaged
or deleriorsled.
8 x 1.25mm
37 N.m 13.8kgl.m,27 lbf'ft)
BACK OOVER
AD.'USTINGBOLT
10x t.25mm
5/rN.m15.5kgl.m,,o lbtft)
Foradjustrnent
only,
do not rmove,
COVER
6x1.0mm
9.8 N'm (1.0kg{.m.t.2 lbf.tt}
6x1.0mm
9.8 N,m 11.0kg{.m,
7.2 lbl.frl
TIMIMi BELT
Inspection,page 6-9
Adlustment,pago 6-9
page6"10
Replacement,
ALTERNATOR
BELT
Adjustm6nt,
Soction23
lnstallwithconcave
surfacefacing in.
Clean.
TIMINGBELT
DBIVEPULLEY
Removeany oil
and clean,
LOWEn
COVER
lnstall with concave
surfacefacing out,
Removeany oil
ano ctean.
CRANKSHAFT
PULI"EY
Romov6any oil
and clgaaon thg
timing bolt guide
plato side.
BOLT
'14x 1,25mm
lt7 t{.m 118.0kgl.m, 130lbtftl
Replacsmenl,page 6-8
6-7
vnx.su
CrankshaftPulleyBolt
It
Replacement
NOTE:
. Crankshaftpulleybolt sizeand torquevalue:
1 4x 1 . 2 5m m
177N.m (18.0kgt.m.130lbf.ft)
. When installinga new crankshaftand/or new pulley
bolt:
Don't lubricatwasher.
HOI-DERHANDII
o'JAB -oo1020A
- PY3010A
19 mm
SOCrETWRENCH,
AVAILABI.I
COMMERCI,ALLY
vnx.su
Timing Belt
TensionAdjustment
Inspection
Removethe cylinderheadcover.
.
NOTE:
. The tensionetis spring-loadedto apply proper tension to the belt automaticallvaftermakingthe following adjustment.
. Always rotate the crankshaftcounterclockwisewhen
viewed trom the pulley side Rotating it clockwise
may result in improper adjustmentot the belt tension.
R e m o v et h e c y l i n d e rh e a d c o v e r . ( R e f e rt o p a g e
6-31when installing.)
Setthe No. 1 pistonat TDC(seepage6-12).
ADJUSNNGBOLT
54 N.m (5.5kqf.m,
a0 rbr.ftl
Foradiustmentonly,
do not remove,
Rotatepulley
and inspscrbell.
ol
Direction
rolatlon.
5.
6.
3-teethon
Rotatethe crankshaftcounterclockwise
the camshaftpulley.
7.
8.
6-9
vnx.su
Timing Belt
Removal
NOTE:
. Turn the crankshaftpulley so the No. 1 piston is at
top d6ad center (TDC)before removing the belt (see
page&12).
a Inspectthe water pump when removed the timing
bolt {see page 10-9}.
1.
Removethawhelwellsplashshield(seepage6-18).
2.
4,
AA,USNNG
MOUNTINGNUT
10x 1.25mm
a,lN.m{4.5kgl.m,33lbfftl
MOUivNNGBOLTS
8 x 1.25mm
2aN.m12.4kgf.m,17 lbtfrl
Removethe cruisecontrolactuator(seepage6-18).
EELT
Removethe sid6snginemount.
10x 1.25mm
52N.m{5.3kgr'm,38lbtft}
Replace.
ADJUSTING
IDLERPUI.IEYBRACKET
BOLT
l0 r 1.25mm
a/aN.m{1.5kgf.m.33lbf'ft}
12 x 1.25mm
74 N.m 17.5kgt m,
s4 tb{.ftl
vnx.su
1.
8.
Removethe cylinderheadcover.
. Referto page6-31when installing.
Removethe Dulleybolt and crankshaftpulley (see
page6-8).
Removethe middlecoverand the lower cover.
NOTE:
. Do not usethe middlecover and lower coverfor
storingitemsdisassembled.
. Cleanthe middle cover and lower cover before
installation.
CAPNUT 6 x 1.0 mm
7.2rbl.ftl
9.8N.m 11.0
WASHER
when damaged
Replace
or
NOTE:Pushthe tensionerpulleyto
loosenthe belt.
CYLINDEFHEAD
COVER
Reterto page 6-31when
installing.
ADJUSTINGBOLT
10 x 1.25mm
54 N.m 15.5kg{.m,
/r0 lbf.ftl
For adjustmentonly,
TIMINGBELT
Adiustment,Page6I
MIDOLECOVER
6x1.0mm
9.8 N.m 11.0kgJm, 7.2 lblftl
KE
6x1.0mm
9.8 N.m ('1.0kgt.m,7.2 lbl fr)
RemoveanYoiland clean
LOWEB@VER
NMING BELT
GUIOEPLATE
lnstallwithconcave
surfacefacingout.
and clean.
6x1.0mm
9.8N.m (1.0kgtm,7.2lbt'ftl
PULLEY
CRANKSHAFT
Removeany oil
and cleanon ihe
timing beltguide
platesido.
6-11
vnx.su
Timing Belt
Installation
Installthe timing belt in the revorceorderof removal;
Only key points are describedhere,
NOTE:Clanthe middle cover and lower cover before
installation.
L
2.
TDC MARK
6-12
vnx.su
CylinderHead
lllustratedlndex
CAUTION: To avoid damaging the cylind6r hoad, waii until ongin coolant temporature drop3 below lOO"F(38"C)bfore
rsmoving it.
NOTE:Use new O ringsand gasketswhen reassembling.
CAPNUT 6 x 1.0mtn
9.8 N.m 11.0kgtm,7.2lbtftl
et
CYLINDERHEAD
COVER
Referto page6-31when
installang.
I x 1.25mm
22 N.m 12.2kgt.m,
16 rbf.ft)
RUBBER
SEAL
Replace
whendamaged
or doteriorated.
INTAKECAMSHAFTHOI.DER
I x 1.25mm
24 N.m12.4kgf.m,-.\
--_r,_
17rbt.tr)
Seesection
__.|._
O-RING
Roplace.
EXHAUSTCAMSHAFT
HOI.DER
RUBBERCAP
Replacefor oil
leakage.
EXHAUST
CAMSHAFT
LOCKNUT
25 N.m {2.5kgf.m,
18 tbtfiJ
6x1.0mm
9.8 N.m {1.0kgl.m,7.2lbf.ft)
INTAKECAMSHAFT
Inspection,page5-21
6tal
SEAL
page6-30
Installation,
Replace.
--,
ffi;r
KEY
/
"
'@
SEAL
Replace.
@6
I x 1.25mm
37 N.m (3.8kgt.m,
27 rbtftt
ROCKERARM
CAMSHAFTPULLEYS
Removal,page6 19
page6,30
Installation,
8 x 1.25mm
37 N.m 13.8kg{.m,27 lbfftl
vnx.su
CAUTION: In h.ndling r m.t!l gr3kct, trko clrc not to fold it or dlmaga tho contact surfacr ol thr gaskat.
CYUNDEBHEAD
BOLT
&t N.m 18,5kgl'm,
61 tbf.ftl
Applyengineoilto
the threads.
VAIVE XEEPERS
SPRING
\n
\.\...i6
RETAINER
r*#:-3
STEMSEAL
--------ig
VALVEKEEPERS
I
JI
--../
ENDPIVOTBOLT
6:tN.ml6.akst'm,
,16lbl.ftl
ED..$---S---.----
VALVE SPRING
SEAT
SPf,ING RETAINEB
nrAxE vaLvESPRING
twtAKEvALvESTEMSEAL
sEAT
valvE SPRING
INTAKE VAI-VE GUIT'E
Inspction,pago S24
R6placom6nt,pago 6-25
Reaming,pag6-26
EXHAUSTVALVE
GUII'E
CYUNDERHEAD
Warpage,page6-28
DOWELPIN
TX)WELPIN
CYLINDERHEAD GASKET
{3 LAYERSOF METALI
Reolac6.
EXHAUSTVALVE
INTAKE VALVE
Replacement,Page6_22
O.RING
Replac.
OIL CONTROL
ORIFICE
Clean.
6-15
vnx.su
GylinderHead
Removal
Engineremovalis not requiredfor this procedure.
5,
Disconnect
the negativeterminalfromthe battery.
2.
3.
Relievefuel pressure(seeSection11).
Do not smoke whils working on tusl
@
systom, keep opon flame or spark away trom work
area.Drain fuol only inlo an approvod containsr.
4.
Disconnect
the fuel feed hose.
SERVIC
BOLT
WASHERS
Replace.
vnx.su
9 . Removethe throttlecable.
1 0 . Removethe throttlecontrolcable (automatictransmissiononly).
NOTE:
. Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
one.
. Adjust the throttlecableand throttlecontrol
cablewhen installing(seesection11 and 14).
CONTROL
THROTTLE
CABLE
HOSE
R e m o v et h e b r a k e b o o s t e rv a c u u m h o s e , w a t e r
bypasshoseand vacuumhose.
ERAKEBOOSTER
VACUUM HOSE
VACUUM HOSE
ATI'USTING
1 1 . R e m o v et h e e n g i n ew i r e h a r n e s sc o n n e c t o r sa n d
wire harnessclampstrom the cylinderheadand the
intakemanifold.
a Fourfuel injectorconnectors
a Intakeair temperature(lAT)sensorconnector
a Engine coolant temperature(ECT)sensor con-
a
a
a
a
a
a
necror
sensor connector
TDC/CKP/CYP
lgnitioncoil connector
ECTgaugesendingunit connector
Throttleposition(TP)sensorconnector
Manifold absolute Dressure(MAP) sensor connector
ldle air control(lAC)valveconnector
EVAPpurgecontrolsolenoidvalveconnector
HOSE
(cont'dl
6-17
vnx.su
CylinderHead
Removal(cont'dl
12. Rmovethe spark plug caps and distributorfrom
the cvlinderhead.
Removethe upper radiatorhose, heaterhose and
water bypass hose.
WATER BYPASS
6x1.0mm
9.8 N.m 11.0tgfm,
7.2 tbf.ftl
UPPERRAI'IAYOR
8 x 1.25mm
24 .m (2.akstm, 17lbf.ftl
P/S PUMP
t 8 Ramovethe cruisecontrolactuator.
8 x 1.25mm
2a N.m 12.4kgt m,
sHtEut
ACTUATOR
vnx.su
WASHERS
12 x 1.25mm
74 N.m {7.5kgf.m,
5{ rbtftl
BACKCOVER
CYLINDEBHEAD
NUT
SELF.LOOKING
8 x 1.25mm
BRACKET
(cont'd)
6-19
vnx.su
CylinderHead
Removal(cont'dl
2,0. Removethe intakemsnifold.
GASXET
IMTAXEMANIFOLD
ADJUSNNG SCNEWLOCATN)NS:
CYLINOER
HEADBOLTSLOOSENINGSEOUENCE
vnx.su
Camshafts
Inspection
1.
Loosenthe adjustingscrews.
2.
R e i n s t a ltl h e c a m s h a f ta n d h o l d e r s .T i g h t e nt h e
camshaftholderbolts in a crisscrosspattern,beginningwith the innerbolts.
9.8 N.m (1.0kgf.m,7.2lbf.ft)
PLASTIGAGE
6-21
vnx.su
07757- PJ10r0A
Installthe special tool as shown.
Remove the valve seal.
COMMERCIALLY
AVAILABLE
VALVEGUIDESEALREMOVER
LISLEP/N 5t9d) or KO3350
SEAL
REMOVER
vnx.su
InstallationSequence
NOTE:Exhaustand intakevalvesealsate NOTinterchangeable.
@/.-uo.**.r..",
NOTE: Placeth 6nd oI valve
springwith closelYwoundcoils
towrrd th cylinder head.
SPRNG NETAINER
EXHAUSTVALVESEAL
{8LACKSPRING}
Replace.
@*_-.tt*
NOTE:Installthv6lvospringsats
beforo instsllingthe valv6 sesls.
PLASTICMALIIT
6-23
.tIF"F-
vnx.su
Valves,ValveSpringsand
ValveSeals
ValveGuides
ValveMovement
Valvelnstallation
W h e n i n s t a l i i n gv a l v e s i n t h e c y l i n d e r h e a d ,c o a t
valve stemswith oil beforeinseningthem into valve
guides, and make sure valves move up and down
smoothlv.
When valvesand springsare in place,lightlytap the
end of each valve stem two or three times to snsure
properseatingof valvesand valve keepsrs(use plastic mallet).
NOTE:Tap the valvestem only along its axis so you
do not bendthe stem.
Measurethe guide-to-stem
clearancewith a dial indicator while rocking the stem in the direction of normal
thrust (wobblemethod).
lntake Valve Stsm-to-GuideClearance:
Strndlrd (Newl:0.0i1-0.10mm
(0.002- 0.004in)
Ssrvicc Limit: 0.16 mm {0.006in)
Exhsust Valye Stom-to-GuideClearance:
Standard{Nw):0.10- 0.16mm
{0.0O'l- 0.006in)
Slrvica Limit: 0.22 mm {0.000in)
Valveextended10 mm out from seat
PLASNC MALI.IT
?ur
6-24
vnx.su
Replacement
1. As illustrated in the removal steps of this proceair-impactdrivdure, use a commercially-available
er attachmentmodified to fit the diameter of the
valve guides. In most cases.tho same procedure
c a n b e d o n e u s i n g t h e V a l v e G u i d e D r i v e ra n d a
conventionalhammer.
-----T_|
sz-12.21i^l
COMMERCIALLYAVAILABI,I
VALVEGUIDEDRIVER
4.
l r l
11.3mm
lo.il,l in)
Turn the head over and drive the guide out towatd
the camshaftside of head.
lf a valveguide still won't move,drill it out with a 8
mm (5/16in) bit,then try again.
CAUTION: Drill guid$ only in oxtremo cases:You
could drmrgo tho cylinder hosd if ths guido br"akr.
RGmov.lrnd In3tlllation
6.6mm
VALVEGUIDEDRIVER,
0?942- 6570100
S e l e c tt h e p r o p e r r e p l a c e m e n tg u i d e s a n d c h i l l
t h e m i n t h e f r e e z e rs e c t i o no f a r e f r i g e r a t o rf o r
aboutan hour.
Use a hot plate or oven to evenly heat the cylinder
headto 300'F(150'Cl.Monitorthe temperaturewith
a cookingthermometer.
VALVEGUIDEDRIVER,6.6mm
07942 - 65701q)
CAUTION:
. Do not use a torch; it may warP the hgad.
. Do not get ths head hottq than 3OO'F1150"C);
excessivehgat may loosn thGvalvs soat3.
. To avoid burns, usa hoavy glov93whon handling
the heated cylinder hoad.
OO
",
O (V /rl
-1-- ) o
one
Removethe new guide{s}from the refrigerator,
at a time, as you needthem.
{cont'd)
6-25
vnx.su
Valve Guides
Reaming
Replacement
{cont'd}
7.
.,F-q-re
t
t
T
It
DRVEn
8,
6,5mm t0.25in)
WASHER
ATTACHMENT
V e r i f y t h a t t h e v a l v e s l i d e s i n t h e i n t a k e8 n d
exhaustvalveguideswithout exrtingpressure.
REAMERHANDLE
VALVEGUII'E REAMER,6.6 MM
079E4- 667ot0c
vnx.su
Valve Seats
Reconditioning
1.
2.
C a r e f u l l yc u t a 4 5 ' s e a t , r e m o v i n go n l y e n o u g h
materialto ensurea smoothand concentricseat.
3.
4.
7.
SEAT
WIDTH
8.
ACTUAL
SEATING
SUBFACE
VALVE
SEAT
PRUSSIAN
6-27
vnx.su
GylinderHead
Installation
orl coNtnol
OOWELPINS
ORIFICE
Clean.
O.RING
Replace.
vnx.su
CAUTION:
. Mlka 3uro thrt thc k.ywlyr on tho c.mthlttr lrc
facing up .nd No. I pi3ton i3 8t top d.rd clnt.r
(TDCt.
. Rcphct th! rocksr armr in thsir o.iginal potltlom.
6,
7.
lnstallthscamshafts,then installthcamshaftsosls
with ths open side (spring)facingin.
8.
A p p l y l i q u i d g a s k e ta r o u n dt h e r u b b e rc a p , t h e n
installtherubbercao.
Tightenthe intakemanifoldbracketbolts.
GASXET
Replace.
E x 1.25mm
2irN.ml2.itkg{.m,
17tbf.ftl
5.
8 x 1,25mm
23 N.m12.3kgf.m.
17tbl.frt
8 x 1.25mm
24 N.m (2,akgf.m, EXHAUST
11
SELF.LOCKING
NUT
8 x 1.25mm
31 N.m (3.2 kgt m,23lbfftl
Replace.
GASKEI
Replace.
m
l0 x 1.25mm
8 x 1.25mm
a,t N.m 14.5kgf.m, 2il N.m 12.4kg{.m,
33 tbt.ft)
17 rbtftl
(cont'd)
6-29
vnx.su
CylinderHead
Installation(cont'dl
9. Apply liquid gasketto the head mating surtacesof
the No. 1 and No. 6 camshaftholders,then install
t h e m ,a l o n gw i t h N o .2 , 3 , 4 , a n d5 .
NOTE:
o "1" or "E" marks are stamoedon the camshaft
holders.
. Do not apply oil to the holder mating surfaceof
camshaftseals.
. Apply liquidgasketto the shadedareas.
. T h e a r r o w s m a r k e do n t h e c a m s h a t th o l d e r s
shouldpoint to the timing belt.
6r1.0mm
9.8 N.m 11.0kgf.m,7.2lbtft)
INTAKECAMSHAFTHOLDERS
Installkeysinto camshaftgrooves.
No.6
No.5
No.2
N o .1
M a k e s u r e t h a t t h e r o c k e ra r m s a r e p r o p e r l y
positionedon the valvestems.
I r 1.25mm
37 N.m {3.8 kgf.m,27 lbf.ttl
6x1.0mm
9.8N.m(1.0kgf.m,
7.2tbtft)
vnx.su
Adjustthe valveclea.ance(seepage6-31.
1 6 . Installthe rubberseal in the grooveof the cylinder
head cover. Seat the seal in the recessesfor thg
camshaftfirst, thn work it into the groove around
the outside edges,
NOTE:
. B e f o r ei n s t a l l i n gt h e r u b b e r s e a l , t h o r o u g h l y
cleanthe sealand the groove.
. When installing, make sure the seal is seated
securelyin the cornersof the recassswith no
gap.
NOTE:
. Use liquidgaskst,PartNo. 08718- 0001.
. Checkthat the mating surfacesare clan and dry
beforeapplyingliquidgasket.
. Do not install the parts if 20 minutes or mor6
h a v s e l a p s o ds i n c o a p p l y i n g l i q u i d g a s k e t .
Instead,reapply liquid gasket after removing old
reaidue.
. After assembly, wait at lsast 20 minutes before
fillingthe enginewith oil.
RUBAER
SEAL
CYUNDERHEAD
COVER
(cont'd)
6-31
vnx.su
GylinderHead
lnstallation(cont'dl
18. When installingthe cylinder head cover, hold the
rubbersealin the grooveby placingyour fingerson
the camshaftcontactingsurfaces(top of the semicircles).
O n c e t h e c v l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head,slidethe cover slightlybackand forth to seat
the rubberseal.
NOTE:
. Beforeinstallingthe cylinder head cover, clean
the cylinder head contacting surfacesusing a
shoptowel.
. Do not touch the pans where liquid gasketwas
aDplied.
6x1.0mm
9.8 N.m 11.0kgt'm,
7.2 tbf.trl
6-32
vnx.su
'lllllllllmlmti'""
CylinderHead/ValveTrain
818C1engine
SpecialTools
.............
6-34
Rocker Arms
wEc
Removal
.................
6-60
Troubleshooting Flowchart
Location
.................
6-61
WEC SolenoidValve...................
lnspection
..............
6-36
6-62
VTECPressureSwitch .................
Arm-to-ShaftG|earance..................
6-38
6-63
Installation
VTECSolenoidValve Inspection....6-41
.............
5-64
RockerArms
Camshafts
ManualInspection.....,.................
6-42
Inspection
..............
6-65
InspectionUsingSpecial
Valve Guides
Tools ....................................,.....,..
6-/|i|
ValveMovement..............................
6-70
ValveGlearance
Replacement
.........6-71
Adiustment
............
6-44
Reaming
.................
6-72
Timing Belt
Valve Seals
lllustrated1ndex...............................
6-46
Reconditioning
......6-73
..............
Inspection
6-48
Valves. Valve Springs and Valve Seals
TensionAdiustment........................
6-48
.................
Removal
6-67
.................
Removal
6-4{l
lnstallationSequence..........,.......,...
6-69
.............
lnstallation
6-51
Valvelnstallation.............................
6-70
Pulley
Bolt
Crankshaft
Replacement
.........6-47
CylinderHead
lllustratedIndex ...............................
6-53
.................6-55
Removal
Warpage
................6-74
.............
lnstallation
6-75
vnx.su
SpecialTools
o
@
@
@
/.\
o
o
ToolNumbar
or
07HAH- PJ7010A
_ PJTOIOB
OTHAH
07JAB- 001020A
07LAA- PR30100
OTLAJ_ PR3O2OA
07MAB. PY3OlOA
OTMAF_ PRgO'IOA
07742- 0010100
07757- PJ1010A
ValveGuideReamer,5.5 mm
6-72
HolderHandle
6-17
&45
6-43
TappetAdiusterWrench
Air Stoppet
HEX50 mm,
PulleyHolderAttachment,
Offset
ValvSpringCompressorAttachment
Extension
ValveGuideDriver,5.5mm
ValveSpringCompressorAttachment
6-11
6-67
6-71,72
6-67
6-34
Plea Rctllanca
Dctcription
vnx.su
VTEC
Refrto page11-32thru I l-39 beforotroubleshooting.
-g:
-mi
\,__-:-/
\.---l-l
Iel-
(MlL)
indicates
Disenostic
rrouble
code(Drc)2r:Aproblem
inthewEc
!5*3ij'i:,*o:",,XTl.Lamp
-l 2,1l-
O o t h o o n g i n oc o n t r o lm o d u l e
(ECM)Rg3otProcgduro.
Do th RoadTest.'
' RoadTest:
Acceleratein 1st gear to 6n engino spoodovor 6000rpm.
Hold thst engine spedtor at leasttwo seconds.
lflhe MIL do6s not coms on during th first road tost,
reoeatthis test two more tim95.
lmormitt.m t ilur., .yrtom i. OK
!t thi.tim..
Chacl tor poor connactiont ot
loo.. wircr !l VTEC .ol.noid
v.lv. lnd ECM.
O i s c o n n e c tt h o 1 P c o n n s c t o r
lrom the VTECsolenoidvalvo.
ls there '14- 30 07
YES
(To pago G37l
6-36
vnx.su
ooooooooooo
ooooooooooo
ooooooooooooo
ooooooooooooo
'lP
Ch6ckfor continuity botw6en
and
A4
termiconnectortrminal
nal.
ContinuityT
6-37
vnx.su
wEc
TroubleshootingFlowchart- VTECPressureSwitch
Referto page11-32thru11-39beJoretroubleshooting'
-.+- l{{?l-
- l r @ l - | 2 21 -
D o t h e e n g i n ec o n t r o lm o d u l e
(ECM)Reset
Procedure.
* RoadTest:
Accoleratoin lst gear to an engine speedover 6000rpm
Hold that engine speedfor at leasttwo seconos'
lf the MIL does not come on during the first road test'
reoeatthis test two more limes.
Intc.mift.nt failu.o, ry3tom ia OK
at thi. tim..
Chack for pool connaction3ol
loo!. rvirat at VTEC Ptasturo
3whch and ECM.
D i s c o n n e c tt h e 2 P c o n n e c t o r
lrom the VTECPressureswitch.
C h e c kI o r c o n t i n u i t y b e t w e e n
BLKterminaland body ground.
Rcpair opcn in BLKwit. botwcon
2P connectorrnd body ground
tG101l.
C h e c kf o r c o n t i n u i t y b e t w e e n
8LU/8LKterminaland D6 termi'
nal.
6-38
vnx.su
(Frompage6-38)
Ropairopn in BLU/BLK$,iro be
tween ECM lD6) and 2P conn.ctor,
Checkfor continuity between D6
terminaland body ground.
Oooooo ooooo
o o o o o oo o o o o
D6
GAUGEJOINT ADAPTER
SNAPON MT2&17
10 x 1.0mm
. lJse new washerwhen
installingthe sealingbolt.
Coitlnuity?
Y AVAILAEII
GAUGE
OILPRESSURE
\n
C h e c ko i l p r e s s u r ea t e n g i n e
speeds of 1,000,3,000 and 5,000
rpm,
ls pressurebolow 50 kPa
(0.5kgflcm', 7 psi)?
\-
]L
NOTE:
Keep mgasuringtime as short as possiblebocausengine is
runningwith no load(lessthan one minute).
vtEc sot-NotD
YES
(To page 6-40)
Conlinuity?
(cont'd)
6-39
vnx.su
VTEC
Flowchart VTECPressureSwitch (cont'dl
u
Troubleshooting
lFrom pag6 6-39)
OOMMERCIALLYAVAILABII
OIL PRESSURE
GAUGE
D i s c o n n s c tl h e 1 P c o n n e c t o r
trom the VTECsol6noidvalve.
NOTE:
Keep moasuringtim6 as shon 6s possible becauseenginei5 runningwith no
load lless than ono minuto).
vnx.su
WEC SolenoidValveInspection
Disconnectthe 1P connector trom the VTEC
solenoidvalve.
Masurs resistancebetween th terminal 8nd body
grouno.
4.
l f V T E Cs o l s n o i d v a l v e i s n o r m a l , c h e c k t h e
enginsoil prssure.
R.3bt!nc!: 1l - 30 O
6x1.0mm
6-41
vnx.su
VTEC
Arms Rockerrtrrrri'
nlrungf
rYrorrtrcr
rrrDPEUtrl,rl
1.
2.
3.
4.
Removethe cylinderheadcover.
Pushthe mid rockerarm on the No. 1 cylindermanually.
Checkthat the mid rockerarm moves independently of the primaryand secondaryrockerarms.
6 x 1.0.nm
9.8 N.m 11.0lgfm, 7.2 lbf.ftl
SECONDARY
ROCKERARM
w
7.
vnx.su
RockerArms - InspectionUsingSpecialTools
Apply specified air pressure to the rocker arm pistons after looseningthe regulatorvalveon the valve
inspectiontool.
CAUTION:
. Boforo using tho valvo inspoctiontool. make 3uro
that th6 air prsssure gaugs on th6 air comprossol
indicatG over 250 kPa {2.5 kgf/cm',36 psi}
. Inspectthe valvs clearancobefors rockel lrm insPoction.
. Covor the timing belt with a shop towsl to plvent
qotting oil on lhe b6lt.
. Checkths mid rocker srm of oach cylindor at TDC.
1.
Removethe cylinderheadcover.
2.
P l u g t h e r e l i e f h o l e w i i h t h e s p e c i a lt o o l ( A i r
Stopper).
SpecifiedAir Presrure:
250 kPa (2.5 kgt/cm',36 psi)
- 500 kPa 15.0kgf/cm'. 71 Psi)
Make sure that the primary and secondaryrocker
a r m s a r e m e c h a n i c a l l cy o n n e c t e db y t h e p i s t o n s
and that the mid rocker arms do not move when
pushedmanuallv.
RELIEFHOLE
LOST MOTION
ASSEMALY
3.
VALVE
REGULATOR
. Pullthsleverand
turn to adjust.
6.
Removethe tools.
7.
8.
A f t e r i n s o e c t i o n ,c h e c k t h a t t h e M a l f u n c t i o n
IndicatorLamD(MlL)does not come on
INSPECTION
HOtt
WASHER
Replace.
PfiIMARY
ROCKERARM
10 x 1.0mm
20 N.m 12.0kgf.m,
1a tbt'ft|
TOOL
AVAILABLE}
ICOMMERCIALLY
6-43
vnx.su
ValveClearance
Adiustment
NOTE:
. Valves should be adjustedcold; at a cylinder head
temperatureof lessthan 100"F(38'C).
. Adjustmsnt is the same for intakeand exhaust
vatves.
o After adjusting, retorque the crankshaftpulloy bolt to
177 N.m ( 18.0kgf.m, 130 lbf.ft).
1.
FOI{IER Ot{
LOWEFCOVER
TDCMANK
lP.int d whit.t
Removecylinderheadcove..
BOLTLOCANONS:
ADJUSTING
IMTAKE
No.3 No. 2
No. 4
No. 1
Diroctionof
aotation.
No.4
No.3
No.2
EXHAUST
N o .1
4.
FEEENGAUGE
TAPPETAI\,USTEN WREI{CI{
O'LAA - PRIOIq'
7 x 0.75 mrn
20 f+|n (2.0kgf'm.14lbtftl
6-44
vnx.su
7.
Numb.r 4 pidon .t Tt C:
FEEI.IRGAUGE
8,
Nurrb.r3tittondTDC:
.UP' MANKS
6-45
vnx.su
TimingBelt
lllustrated lndex
NOTE:
.
.
.
.
.
WASHER
Replacewhen
CAP NUT
x 1,0mm
9.8 N.m 11.0kgf.m,7,2lbttrl
or deteriorated.
CYLINDER
HEAOCOVER
Reterto page 6'78
when installing.
RUBBER
SEALS
Replace
whendamaged
3-E
or deteriorated,
TIMINGBELT
page 6-48
Inspctaon,
Adjustment.page 6-48
Rplacement.page 6'49
MIDDLECOVER
5xl,0mm
9.8 N.m (1.0kgt m,
7.2 rbtftt
8 x 1.25mm
56 N.m 15.7kgt m,
41 tbtftl
6x1.0mm
9.8 N.m {1.0 kgl.m,
7.2lbf.ftl
6x1.0mm
9.8N.m (1.0kgt.m,7.2lbfftl
10 x 1.25mm
5a N.m 15.5kgl.m.
(} tbf.ftl
Foradiustmentonly
do not remove.
TIMINGSEL
Installwithconcave
DRIVEPULLEY
surfacetacing out.
COVER
R e m o v e a n y o i l a n d c l e a n . Removeany oiland clesn.
Installwithconcave
surfacelacingin.
Clean.
6-46
vnx.su
PULLEY
Removeany oil and clean
on the timing beltguide
plateside.
BOLT
1il x 1.25mm
177N.m 118,0kgtm, 130lbtft)
Replacement,page 6-47
GrankshaftPulleyBolt
Replacement
NOTE:
. Crankshaftpully bolt size and torqus value:
1,0x 1.25mm
177 N.m (18.0kgt.m, 130 lbf'ft)
. When instslling a new crankshaft 8nd/or now pulley
bolt:
ATTACHMEUT,
PULITYHOLDEB
HEXslt mm, OFFSET
- PY3O1OA
OTMAB
SOCKETWRENCH,19 mm
COi'MEBCI,ALLYAVAILABT.E
6-47
vnx.su
TimingBelt
TensionAdjustment
lnspection
Removethe cylinderheadcover.
.
NOTE:
. The tensioneris spring-loadedto apply proper tension to the belt automaticallyaftermakingthe following adjustment.
a Alwavs rotate the crankshaftcounterclockwisewhen
viewed trom the pulley side. Rotating it clockwise
may result in improper adjustmentof the belt tension.
Removethe cylinderhead cover. (Referto page 678 when installing.)
Setthe No. 1 pistonat TDC(seepage6-51).
Rotatethe crankshaft5-6 revolutionsto setthe belt.
4.
AINUSTINGAOLT
5/aN.m 15.5kg{.m,to lbtftl
For adjustmentonly,
\v-/
.//
Direction
rotat|on,
Rotatepulley
and inspectb6lt.
5.
6-48
vnx.su
7.
Tightenthe adjustingbolr.
8.
Removal
NOTE:
. Turn the crankshaftpulley so the No. 1 piston is at
top dead center {TDC)before removing the belt (see
page6-51).
. Inspectthe water pump when removed the timing
belt {seepage10-9).
4.
MOUNTINGNUT
10 x 1.25mm
4,t N.m lia.5 kgl.m,
33 tbt ftl
Removethe cruisecontrolactuator(seepageG58).
I x 1.25mm
2aN.ml2.akgt.m,17lbt ttl
10x 1.25mm
52N.m15.3kgtm, 38lbtftl
ADJUSNNG
CNGINC
MOUNT
D1IN
BOLT
10 x 1.25mm
ira N.m (4.5 kgf.m, 33 lbf'ttl
BELT
12 x 1.25mm
74 N.m (7.5kgt m,
s4 lbf.trl
(cont'd)
6-49
vnx.su
Timing Belt
Removal lcont'd)
1.
8.
Removethe cylinderheadcover.
6x1.0mm
9.8 N.m 11,0kgf'm, 7.2 lbl'ftl
CYLINDER
OOVER
Relrto pago 6-78
when inslalling.
NMING BELT
Adjustment,page 6-48
MIDDLE
COVER
@^R
RUABERSEALS
v@
R e p l a c 6w h e n
or deteriorated.
6x1.0mm
9.8 N.m {1.0 kgf.m,
7.2 rbnftl
LOWERCOVER
6r1.0mm
9.8N.m 11.0kgf.m,7.2lbtftl
CRANKSHAFT
PULl"EY
Removeany oil and
cleanon the timing belt
guideplat6side.
BELT
TENSIONER
TIMINGBELT
GUIDEPLATE
lnstallwithconcave
surfacefacing out.
Removeany oil
and clean.
ADJUSNI{G BOLT
10 x 1,25mm
5,t N.m 15.5kgf.m,
.(l rbf.ftt
For adjustmntonly,
vnx.su
PULI.TYBOLT
17?N m {18.0kgf.m,130lbtftl
TimingBelt
lnstallation
Installthe timing belt in the feverseorderof removal;
Only key pointsare describedthere.
NOTE:Cleanthe middle cover and lower cover before
installation.
1.
I n s t a l lt h e t i m i n g b e l t t i g h t l y i n t h e s e q u e n c e
shown.
O T i m i n g b e l t d r i v e p u l l e y ( c r a n k s h a t t*) @
A d j u s t i n gp u l l e y * @ w a t e r p u m p p u l l e y * @
Exhaustcamshaftpulley* @ Intakecamshaftpullev,
(cont'd)
6-51
vnx.su
Timing Belt
Installation(cont'dl
1
4.
Rotatethe crankshaftabout 4 or 6 turns countsrclockwiseso that the belt positions on the pulleys.
5.
1.
l f a c a m s h a f t p u l l e y i s n o t p o s i t i o n e da t T D C .
.emove the timing belt and adiust the positioning
following the procedureon page 6-51,th6n r6install
rhe riming belt.
NOTE: Refsrto page 6,19 for timing blt removal.
b.
CAMSHAFT PULI..EY:
"UP- MANKS
6-52
vnx.su
Cylinder Head
lllustratedIndex
CAUTION: To svoid dsmaging the cylindor h.ad, wsit until tho engino coollnt tomper.turo drop3 bolow 100'F (38'C)
bofore romoving it.
NOTE:
r Use new O-ringsand gasketswhen reassembling.
. Use liquidgasket,Pan No. 08718- 0001.
. Replacethe rubbersealsfor oil leakagebetweenthe cylinderheadandcover.
fterw
to anycontactparts.
drythem,andapplylubricant
cleanallthe partsin solvent,
,o reassembling,
8 x 1.25mm
27 N.m 12.8kgt m,
20 rbt ft)
6x1.0mm
9.8 N.m (1.0 kgt'm,
7.2tblftl
f,
6xl.0mm
9.8 N.m {1.0 kgl m, 7.2 lbf.ftl
4qi
CYLINDERHEAD
COVER
Referto psge 6-78
when instglling.
CAMSHAFT
INTAKE
CAMSHAFT
6 x 1.25mm
2it t*m 12.4kg[.m,
17 rbf.ftl
SEAL
Replace.
liquidgasket
to thos points.
Replacewhen damaged
or detriorated,
r 1.25mm
56 N.m 15.7kg{.m,
ial lbf.ft)
Replace.
6-53
vnx.su
ROCKEBARM ASSEMBLY
CYLINDERHEAD
BOLTS
1 1x 1 . 5m m
81 N m (8.3ks{ m, 60
INTAKEVALVESPRINGINNER
SPRINGRETAINER
INTAKEVALVESPRINGOUTER
VALVE
SPRINGSEAT
VALVESEAL
Replace.
SPRINGSEAT
VALVEGUIDE
SPRINGRETAINER
MOTION
ASSEMBLY
EXI{AUSTVAL
SPRING
INTAKEVALVE
VALVESEAL
Replace.
INTAKE ROCKER
ORIFICE
Clean.
VALVE
LOSTMOTION
ASSEMBLY
ROCKERSHAFT
DOWEL
PIN -,
EXHAUSTVAL
OOWEL
PIN
ROCKER
SHAFTORIFICE
CYLINDERHEAO
GASKET
13LAYEBSOF MET
Replace.
SEALINGBOLTS,20 mm
64 N.m 16.5kgf.m,47 lbtftl
vnx.su
Cylinder Head
Removal
Engineremovalis not requiredor this procedure.
CAUTION: To avoid damaging tho cylinder head, wail
u[tilths.nginc coolant tsmperaturo drops bolow 100"F
(38'Cl bafore loos6ningtho retaining bolts.
8 x 1.25mm
24 N.m (2.1kg[.m, 17 lbtftl
NOTE;
. Inspectthe timing belt before removingthe cylinder
head.
Turn the crankshaftpulleyso that the No. 1 piston is
at top deadcenter(TDc){page6-51).
a Markall emissionshosesbetoredisconnecting
them.
a Anti-theft radios have a coded theft protection circuit.
Be sure to get the customer's code number before
- Disconnectingthe battery.
- Removingthe No.32 (7.5A) fuse trom the underhood fuse/relaybox.
- Removingthe radio.
After service,reconnectpower to the radio 8nd turn it
on.
When the word "CODE"is displaved.enter the customer's5-digitcodeto restoreradiooperation,
'1. Disconnect
the negativeterminalfrom the battery.
Drainthe enginecoolant(seepage10-5).
.
Relievefuel pressure(seesection111.
Do not 3moke whilo working on fuel
l@
systgm. ko6p opon tlamo ot Sparkaway trom work
aroa. Drain fugl only into an approved containsr,
4.
INTAKE AIR
SERVICBOLT
15 N.m (1.5 kgtm, rl bf.tt)
WASHERS
Replace.
BANJOBOLT
(cont'd)
6-55
vnx.su
CylinderHead
Removal (cont'd)
7.
6x1.0mm
12N.m11.2kgf.n,8.t lbf.trl
EVAPCONTROL
CANISTERHOSE
PCV HOSE
NOTE:
o Taks care not to bsnd the cabl6 when removing
it. Always replaceany kinkedcable with a new
on6.
o Adiust the th.ottle cable when installing (sees6ction1l).
WATERBYPAss
HOS
AD.'USTING THROTTI,"E
NUT
CABI.T
vnx.su
1 5 . Removethe enginegroundcable.
Romovothe adjustingbolt and mountingbolts,then
remove the power steering (P/S)pump belt and P/S
pump.
. Do not disconnectthe P/S hoses.
WATER BYPASS
6x1.0mm
9.8 N.m 11.0kgl.m,
7.2 tbt.ttl
HOSE
(cont'dl
6-57
vnx.su
, l
Cylinder Head
Removal(cont'dl
1 6 . Removethe heat shield from the P/S bracket(see
p a g e5 - 1 8 ) .
'18. Remove
the alternatorbelt {sepage6-49).
'19.
ACTUATOR
24. Removethe exhaustmanifold.
SELF.LOCKING
NUT
8 x 1.25 mm
31 N.m {3.2 kgt m, 23 lbf.ftl
Replace.
SIDEENGINE
12 x 1.25mrn
7a N.m 17.5kgl.m,
5a rbtftl
6 -5 8
vnx.su
'ilffi{
CAMSHAFT
No. 4
INTAKE
No.3 No.2
No.3
N o .2
EXHAUST
No. 1
No. 1
6-59
vnx.su
RockerArms
Removal
Holdthe rockerarmstogetherwith a rubberbandto
oreventthem from seParating.
3.
BAND
RUBBER
EXHAUSTROCKER
SHAFTORIFICE
Clean.
O.RING
Replace.
INTAKE ROCKER
SHAFTOBIFICE
Clean.
O-RING
Replace.
vnx.su
ROCKERSHAFTS
Locations
tho orifice ls corrccdY
GAUTION: Aftcr in3tlllino th! roCk.r shrft o.ifice, trY to tum ihc tock r .hatt to makr luta thlt
not
turn'
in3artcd in the holc of tho lockor shrft. It the oritice b in placc' it should
NOTE:
in originallocdtions'
o ldentifypartsastheyareremovedto ensurereinstallation
. lnsoect rockershafts and rockerarms (see pages 6-62and 63)'
o Rocke.arms must be installed in the same position it reused'
. Cleanthe rockershaft orifices when installing.
I
erio, to ,einstalling,clesn all the parts in solvent, dry them and spply lubricantto any contact surfacos'
ARII,IASSEi/IBUES
NTAKEBOCXER
BA D
RUBBER
INTAKEROCXER
SHAFT
Cl6an.
&
tu
ry
o-nrM;s
R6placo.
ry
-%
HOII
TROCIGRSHAFT
oRrFrcEsl
EXHAUSTROC(ER
BOCXER
SHAFT
RUASERBA'{D
EXHAUSTB(rcKERARMASSEMBLIES
6-61
vnx.su
RockerArms
lnspection
N O T E :W h e n r e a s s e m b l i n gt h e) p r i m a r y r o c k e ra r m ,
oil passageof the
c a r e f u l l ya p p l y a i r p r e s s u r et o the
t
rockerarm.
ROCKERARM
Push
SECONDARY
PISTONS
\ xva
V/\'
Checkpistonmovement
.
.
6-62
vnx.su
LOSTMOTIONASSEMBLY
Arm-to-Shaft Clearance
Measureboth the intake rocker shaft and exhaust rocker
shaft.
1.
Rock6rA.m-iq.Shaft Clearance:
lntak. and Exhaust
Standald (Now): 0.025- 0.052mm
(0.0010- 0.0020in)
S.rvicc Limit:
0.08 mm {0.003in}
Surfacoshouldbe smooth.
2.
Zerogaugeto shaftdiameter.
Inspectrockerarm
facetor wear.
N O T E : l f a n y r o c k e ra r m n e e d s r e p l a c e m e n t ,
replaceall three rocker arms in that set (primary,
mid, and secondary).
6,63
vnx.su
RockerArms
Installation
1.
I n s t a l l t h e r o c k e r a r m s i n t h e r e v e r s eo r d e r o f
removal:
. Valveadjustinglocknutsshould be loosenedand
adjusting screw backedoff before installation.
. The componentparts must be reinstaltedin the
originallocations.
2.
Installthelost motionassemblies.
3.
4.
EXHAUSTROCKER
SHAFTORIFICE
INTAKEROCKER
SHAFTORIFICE
Clean.
Cl6an.
O.RING
Beplace.
Beplace.
'/'/
12 mm EOLT
6-64
vnx.su
Camshafts
Inspection
NOTE:
. Do not rotatethe camshaftduringinspection.
. Removethe rockerarms and rockershafts.
1.
P u t t h e c a m s h a f t sa n d c a m s h a f th o l d e r so n t h e
c y l i n d e rh e a d ,a n d t h e n t i g h t e n t h e b o l t s t o t h e
soecifiedtorque.
SpecifiedTorque:
O - @: 8 mm bolts 26 N.m {2.7 kgl.m,20 lbt'ftl
(D -(D:6 mm bolts 9.8 N.m {1.0kgt.m,7.2 lbf'ftl
4,
5.
1.
(cont'dl
vnx.su
Gamshafts
Inspection(cont'd)
10, lf camshaft-to-holderoil clearanceis out of lolerance:
CamehaftTotal Runout:
Sisndard (New): 0.015mm (0.0006inl
ServiceLimit:
0.03 mm (0.0012in)
IiITAKE
EXHAUST
PRIMARY
33.i{'l1 mm
( 1 . 3 1 5 4i n l
3 3 . 1 1 1m m
(1.3036in)
MID
36.377mm
l't.4322inl
35.720mm
(1.4063inl
SECONDARY
34.547mm
( 1 . 3 6 0 i1n )
34.381mm
(1.3536in)
Rotatcamshsft
while measuring
Crm Porition
INTAKE
Mto
CXHAUST
sEc
SEC MID
PRI
fTt-]--Tt-Tt-l
\ l l i l i l | /
\
t t t t l
LIL__H___}{-}U
ftB
6-66
vnx.su
ftB
Using an appropriate-sized
socketand plasticmallet. lightlytap the valve retainerto loosenthe valve
keepersbeforeinstallingthe valve spring compressor.
I n s t a l ls p r i n g c o m p r e s s o rC
. o m p r e s ss p r i n g a n d
remove valve keeper.
VALVESpRtNG
COMPRESSoR
ATTACHMENT
VALVESPRING
ATTACHMENT
COMPRESSoR
EXTENSION
Snap-onCFrll
(cont'd)
6-67
vnx.su
Valves,ValveSpringsand ValveSeals
Removal(cont'dl
3.
Installthespecialtoolas shown
Valve Dimensions
COMMERCIALLY
AVAILABLE
VALVEGUIDESEALREMOVER
Lrst"EP/N s79(x'OR KD3350
4.
lntrko ValYo
A Standsrd (N.wl: ilil.go - *t.10 mm
(1.295- 1.303inl
B Standard (Newl: 101.00- 101.30mm
(3.976- 3.988inl
C Standard (N.w): 5.a75- 5.185mm
(0.2156- 0.2159inl
C Sorvicc Limit
5.i!15(0.21.lt in)
D Standard (Ncw): 1.05- 1.35mm
(0.04i - 0.05:tin)
D Sorvicc Limh:
0.85 mm (0.033inl
Exhau3tValve
A Stand.rd (Ncwl 27.90- 28.10mm
- 1.106inl
11.098
B Standard (Ncwl: 1qr.6lt- loo.glt mm
(3.961- 3.972inl
- 5.460mm
C St.nd.rd (Now| 5./L51,
(0.2146- 0.215|,inl
C ServicoLimit:
5.a20(0.2134inl
D Standsrd lNewl: 1.65- 1.95mm
{0.065- 0.077inl
D Sorvicc Limit
1.45mm (0.057inl
6-68
vnx.su
InstallationSequence
NOTE:Exhaustand intakevalvesealsare NOT interchangeable.
VAIVE IGEPGNS
v^LvEsP'ittNG
*nt
/^no,n
/'=\/
INTAKEVALVESPAING
\y
VALVE SPRING
@--'**
9-**
EXHAUSTVALVESEAL
(BLACKSPRINGI
Replace.
SPRINGSEAT
NOTE: lnstallthe valvo spring se6t6
bsfore installingthe valv6 so6ls,
P.%
VALVE SEAL
Rplace.
6-69
vnx.su
Valves,Valve Springsand
Valve Guides
ValveSeals
ValveMovement
Valvelnstallation
When installingvalves in cylinder head, coat valve
stemswith oil beforeinsertinginto valveguides,and
makesurevalvesmove up and down smoothly.
ExhaugtVdve Stem-to-GuideClsarancg:
StandaldlNowl: 0.10- 0.16mm
(0.00'l- 0.006in)
Sorvics Limit:
0.22 {0.0m in)
Valveextended10 mm out from seat.
.
.
.
l f m e a s u r e m e n te x c e e d st h e s e r v i c e l i m i t .
recheckusinga new valve.
lf measurementis now within the servicelimit,
reassembleusinga new valve.
lf measurementstill exceedslimit, recheckusing
alternatemethod below,then replacevalve and
guide,if necessary.
6-70
vnx.su
COMMCRCIALLY.AVAILABLE
VALVEGUIDEDRIVER
5.3mm
(0.21inl
_{l
azmm +-
szmm
{3.43inl
tz.zt in)
Turn the head over and drive the guide out toward
the camshaftsideof head.
tfr
10.8mm
10.42inl
R.mov.l andIn3trll.tion
VALVEGUIDEDRIVER.
5.5mm
07742- q)101tt0
t uidesand chill
S e l e c tt h e p r o p e r r e p l a c e m e n g
them in the freezer section of a refrigerator for
aboutan hour.
Use a hot plate or oven to evenly heatthe cylinder
headto 300'F(150"c).Monitorthe temperaturewith
a cookingthermometer.
VALVEGUIDEDBIVER.
5.5mm
07742- 0010100
-_ -\
lo
CAUTION:
. Do not us9 a iorch; it may warp ths hsad.
. Do not get ths head hottor than 300"F (150"C);
excsssivohgat may loogenthe valvo soaG.
. To avoid burns, use hsaw glovo3whon handling
the heated cylindor had.
vnx.su
6.
oc)
one
Removethe new guide(s)from the refrigerator,
at a time, as vou needthem.
(cont'd)
Valve Guides
(cont'dl
Replacement
7.
Reaming
:=:-/--P
DRIVER
6 mm 10.2int
WASHER
ATTACHMENT
2,
3.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit from the bore.
4.
5.
Checkclearancewith a valve(seepage6-70).
.
REAMERHANDLE
Turn reamerin
clockwisedirection
onry.
C'
a
-'{
)
VALVEGUIDE
6-72
vnx.su
ValveSeats
Reconditioning
After resurfacingthe seat, inspect for even valve
s e a t i n g :A p p l y P r u s s i a nB l u e C o m p o u n dt o t h e
valve face, and insen valve in original location in
thc hea.l.then lift it and snap it closedagainstthe
seat severaltimes.
ACTUALSEATING
SURFACE
VALVE
SEAT
PRUSSIANBLUE
C a r e f u l l yc u t a 4 5 os e a t , r e m o v i n go n l y e n o u g h
materialtoensurea smoothand concentricseat.
1.
Bevelthe upperedge of the seatwith the 30' cutter
and the lower edge of the seat with the 60'cutter'
Checkwidth of seatand adjustaccordingly.
SEAI wlDTH
VALVE STEM
INSTALLEDHEIGHT
8.
6-73
vnx.su
GylinderHead
Warpage
NOTE: lf camshaft-to-holderoil clearances(see page
6-65)are not within specification.the head cannot be
.esurfaced.
lf camshaft-to-holder
oil clearancesare within sDecifications,checkthe headfor warpage.
lf warpage is less than 0.05 mm {0.002in) cylinder
headresurfacingis not required.
lf warpageis between0.05mm {0,002in) and 0.2 mm
{0.008in), resurfacecvlinderhead.
Maximum resurfacelimit is 0.2 mm {0.008in) based
on a heightof 142mm (5.59in).
PRECISION
STRAIGHTEDGE
6-74
vnx.su
lnstallation
Installthecylinderheadin the reverseorderof removal:
NOTE:
. Alwaysusea new headand manifoldgasket.
. The cylinderheadgasketis a metal gasket Takecare
not to bend it.
. Rotatethe crankshaft,set the No. 1 piston at TDC
(page6-51).
. D o n o t u s e t h e m i d d l ec o v e r a n d l o w e r c o v e rf o r
storingitemsdisassembled.
. Cleanthe middlecoverand lowercover beforeinstallation.
a Replacethe washerwhen damagedor deteriorated
1.
2.
1 1x 1 . 5m m
81 N.m{8.3kgf.m,60lbfft)
O.RING
Replace.
HEAD
OIL CONTROL
ORIFICE
Cloan.
8 x 1.25mm
23 N.m 12.3kgl.m.
17 tbf.ftt
8 x 1.25mm
kgf m,
24 N,m 12.,4
17 tbf.ft)
(cont'd)
6-75
vnx.su
CylinderHead
Installation{cont'd)
4.
5.
NOTE:
. Installthe camshaftswith keyway facing up.
o Installtheoil sealwith the springsidefacingin.
. The oil sealhousingsurfaceshouldbe dry,
. Set the O-ringand dowel pin in the oil passage
of th No. 3 camshaftholder
Usenew self-lockingnuts.
SELF.LOCKING
NUT
8 x 1.25mm
31 N.m 13.2kgf'm, 23 lbtltl
Replace.
8 r 1.25mm
2aN..n12.4lgtm,
r 7 tbf.ftl
EXHAUST
O-RING{ReDlace.)
GASKET
Replsco.
&,x
a.l N.m 14.5kgt m,
33 tbr.trl
Kgywayis lacingup.
A p p l y l i q u i d g a s k e ta r o u n dt h e r u b b e rc a p , t h e n
installthe rubbercap.
8 x 1.25mm
24 N.m (2.4 kgt m,
rt tbfft)
6-76
vnx.su
7.
Ho.a
r
t
No.3
l
t
1to.2
t /
l bl
d
ffi
rfl?x
888
ro
I
t
o o o
\trt
EXHAUST
Applyliquidgaskot
to lh6 3haddaroas.
CAMSHAFT
CAMSHAFT HOI,I'ER
10x 1.25mm
56 N.ln l5.t kgf.m,
4r lbl.trl
6x1.0mm
9.8 N.m 11.0kgtm, t.2lbf'ft)
(cont'd)
6-77
vnx.su
CylinderHead
Installation lcont'd)
1 1 . lnstallthetiming belt lsee page6-51).
NOTE:
. Use liquidgasket,PartNo. 08718- 0001.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
a Do not install the parts if 20 minutes or more
h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t .
Instead,.eapplyliquid gasketafter removingold
residue.
r After assembly, wait at least 20 minutes before
filling the enginewith oil.
Apply liquidgasketto
the shadedareas.
COVER
6-78
vnx.su
6x1.0mm
9,8 N.m 11.0kgt'm,
7.2 tffirl
6-79
vnx.su
EngineBlock
PistonRings
.............7'2
SpeciafTools
.........7-16
Replacement
7-3
lllustratedIndex ...................................
.................7-17
EndGap
Flywheel and Drive Plate
7 -17
Ring-To-Groove
C|earance,,,,.,,,......
.........7-7
Repfacement
..............7-18
Alignment
Main Bearings
Piston Pins
7-8
,..............
Clearance
........,........7-18
Removal
7-8
................
Selection
7-19
Installation(818B1engine) .............
Connecting Rod Bearings
(818C1
7-20
enginel .............
fnstaffation
...............
7-9
Clearance
..............7-2O
fnspection
7-9
................
Selection
Rods
Connecting
Crankshaft
.................7-21
.................7-10 End Play
Removal
..........,,,,,,7-22
.................7-12 Sefeetion
EndPlay
........,,,.,,7-12 Oil Seal
lnspection
.............7-25
fnstaffation
.............7'22
fnstallation
Installation
CylinderBlock
(engineremoval not requiredl.........7-26
..............7-13
Inspeetion
.....,.,,.7'14
BoreHoning
Pistons
..............7-15
Inspaction
.............7-16
Installation
vnx.su
SpecialTools
Raf.No.
07GAF- PF60300
07HAF- P120102
_ PR4O1OA
OTLAD
07LAF PR30100
07LAB- PV00100
or
07924- PD20003or
01924 - PD20002
07948- S800101
07749- 0010000
07973- PE00310
07973- PE00320
07973- 5570500
07973- 6570600
@
@
@
Tool Numbcr
Dcacription
Oty
1
I
1
'I
Driver Attachment
Driver
Piston Pin Driver Shaft
Piston Pin Driver Head
Piston Base
PistonBaseSpring
1
1
1
1
1
1
Pago Rotcrenc.
7-14,19,20
1-18,19,20
7-19,20
7-1
7-25,26
7-19,20
1-19.20
1 - 1 8 ,1 9 ,2 0
1-18
Eg
o
,a\
0
@
7-2
vnx.su
lllustrated Index
Lubricateall internalpartswith engineoil during
reassemory.
NOTE:
Apply liquidgasketto the matingsurfacesof the right
s i d e c o v e r a n d o i l p u m p h o u s i n gb e f o r ei n s t a l l i n g
them.
- 0001.
. U s el i q u i dg a s k e tP, a n N o . 0 8 7 1 8
. C l e a nt h e o i l p a n g a s k e t m a t i n g s u r f a c e sb e f o r e
installingit.
.
Bl8Bl engine:
6x1.0mm
12 N.m (1.2kgf.m,I lbf.ftl
OIL PAN
wAsHEF
DRAINPLUG
44 N.m {4.5kgf.m,
33 tbtfr)
6x1.0mm
11 N.m (1.1kgf.m,8lbtft)
GASKET
Replace.
OIL SCREEN
6x1.0mm
1'l N.m {1.1kgt.m, I lbtft)
12 x 1.0mm
103N.m (10.5kgf.m,?6lbf ft)
MANUAL
FLYWHEEL
'12x 1.0mm
74 N.m {7.5kgt m,54lbf.ftl
page7 7
Torquesequence,
GASKET
Replace.
WASHER
BEARINGCAP
AUTOMATICTRANSMISSION
DRIVE PLATE
Checkfor cracks,
Apply liquidgasket
to blockmatingsurface.
11 x 1.25mm
76 N.m
17.8kgl.m, 56 lbf ftl
Applyengineoilto the bolt
threadsand the washers.
NOTE: After torquing
each cap, turn crankshaft
to checklor binding.
CRANKSHAFT
End play,page7-12
Runout,Taper,and
pages7 12,13
Out-of-Round,
page7 22
Instsllation,
MAIN BEARING
page7-8
Radialclearance,
page7-8
Selction,
NOTE:New main bearings
must be selectedby matching
crankand blockidentification
markrngs.
6x1.0mm
11 N.m {1.1kgl.m,
8 tbf.frt
OIL SEAL
page7-25,
Installation,
RIGHT
SIDECOVER
DOWELPINS
THRUSTWASHERS
Groovedsidesfaceoutward.
NOTE:Thrustwasherthickness
is tixedand must not be changed
by grindingor shamming.
OIL PUMP
Overhaul,page 8-9
8 x 1.25 mm
2,1N.m {2.4kgt m,
17 tbt.ft)
O.RING
Applyengrne
orl.
Replace.
OIL SEAL
page8-11
Installation,
6x1.0mm
Apply liquidgasket '11N.m {1.1kgf'm, 8 lbl ft)
to blockmating
(conr'dl
7-3
vnx.su
lllustratedIndex
(cont'd)
NOTE:
. Apply liquidgasketto the matingsurfacesof the right
side cover and oil pump housing before installing
thsm.
. Useliquidgask6t,PartNo. 08718- 0001.
. C l e a nt h e o i l p a n g a s k e t m a t i n g s u r t a c sb e f o r e
innallingit.
Bl8Cl !ngin.:
DBAINPLUG
4,aN.mla.stgl.m.
33 rbr.ftt
6x1.0mm
11 N.m (1.1kgt m,
E |bfitl
OIL PAN
6x1.0mm
ti l*m 11.lkgf m,
I tbf.ftl
GASKET
Replace.
BAFFLEPLATE
6xl.0mm
ll N.m (1.1kgt m.
8 tbt frl
O|L SCAEEN
6 x 1.0 rim
11 N.m (1.1 kgf.m,
8 tbt ft)
FLWYHEEL
7-4
vnx.su
BEARING
CAPBRIDGE
CRANKSHAFT
Endplay,page7-12
Runout,Taper,and
pages7'12.13
Out-of-Round,
page7-22
Installation,
BEARINGCAP
YHRUSTWASHERS
Groovedsideslace outward.
NOTE: Thrust washerthickness
is fixedand must not be chanod
MAIN BEARING
page7 8
Radialclearance.
S6lction,page7-8
NOTE:New main bearings
must be selectedby matching
crank and block identification
marxrngs.
OIL SEAL
Installation,
pages7-25,26
Replace.
OIL JET
Inspection,
page 8-8
6r1.0mm
11 N.m 11.1kgt m,
8 lbf ftl
RIGHTSIDE
COVER
Applyliquidgasket
to block mating
surface.
OIL PUMP
Overhaul,page8-9
Apply liquidgasket
to block mating
surface.
6x1.0mm
11 N.m {1.1kSf.ft,
8 rbf.ftl
DOWELPIN
DOWELPIN
O.RING.
Apply engine
orl.
Replace.
OIL SEAL
Instellelion,
page8-11
Replace.
8 x 1.25mm
24 N.m {2.4 kgt m,
17 tbtft)
(cont'd)
7-5
vnx.su
lllustratedIndex
(cont'd)
Lubricateall internalpartswith engineoil during
reassemorv.
r@
-1@
PISTONINSTALLATIONDIRECTION
PISTONRINGS
page7'16
Replacement,
page7-17
Measurement.
Alignment,page7 18
EXHAUST
PISTONPIN
Removal,page7-18
pages7 19,20
lnstallation,
page7'20
Inspection,
INTAKE
Removal,page7'11
page7 15
Measurement,
CONNECTING
ROO
Endplay,page7-21
page7-22
Selection,
page7-21
Smallend measurement.
ROD
CONNECTING
EEARINGS
page7-9
Clearance,
Selection,page7-9
RODNUT
CONNECTING
818B1ongine
8 x 0 . 7 5m m
31 N.m {3.2 kgf.m,23 lbf ftl
818C1engine
9 x 0.75mm
a,aN.m (4.5kgt m, 33 lbf.ft|
Aftertorquingeachbearang
cap, rotate crankshaftto
checkfor binding.
BLOCX
page7 13
Cylinderboreinspection,
page7'14
Warpageinspection,
Cylinderborehoning,page7-14
CONNECTING
RODBEARINGCAP
page7'23
Installation,
NOTE:Installcapsso the bearingrecessis
on the samesideas the recessin the rod.
r-(,
vnx.su
AutomaticTransmission:
RINGGEARHOLOER
o?LAB- PV00100,
07924 - PO2IX)03or
07924 - PD20/m2
.t=?4
/ AK{:{AAo
fut!!-+-r
t=tz-21
I lvaz'Z
- +
rs#*ffi_9
ENGINE
BLOCK
r t.0 mm
t,l N.m
(7.5 kg{.m,54 lbf.ft}
-o.r
/ oo^t,
\..?bi
r10.5kgi.m,76lbt.ftl
7-7
vnx.su
Main Bearings
Selection
Clearance
T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e ,
removethe main capsand bearinghalves.
C l e a ne a c h m a i n j o u r n a la n d b e a r i n gh a l f w i t h a
cleanshop towel.
Placeone strip of plastigageacrosseach main iournal.
NOTE:lf the engineis still in the car when you bolt
the main caD down to checkclearance,the weight
of the crankshaftand flywheelwill flattenthe plastigage further than just the torque on the cap bolt,
and give you an incorrectreading.Fot an accurate
reading, support the crank with a iack under the
counterweightsand check only one bearing at a
trme.
Reinstallthe bearing caps and cap bridge (818C1
engineonly)then torquethe bolts.
81881engine:77N'm (7.8kgf'm,56lbl'ft)
818C1engine:
73 N'm (7.'lkgt'm,56lbf'ftl
No. 1,5 cap bolts
N'm (6.5 kgf'm, 49 lbf'ftl
6a
4
cap
bolts
No. 2, 3,
NOTE:Do not rotatethe crankshaftduring inspectron,
Removethe cap bridge (818C1engine only), caps
and bearingsagain,and measurethe widest part oJ
the plastigage.
Main Bearing-to-JournalOil Clarance:
Standard (Newl:
No. 1, 2, 4, 5: 0.024- 0.042mm
- 0.0017inl
10.0009
ServiceLimit: 0.050mm {0.0020inl
0.030- 0.0,18mm
No. 3:
- 0.0019inl
(0.0012
Ssrvice Limit: 0.060mm {0.0024inl
gaBl
STNIP
PLASTIGAGE
7-8
vnx.su
B..ring ld.ntificrtion
Colorcodeis
on the edge ot
the bearang.
Largercrank Dore
-------.r>
smaller bearing(thicker)
tr;;lIl
IlE;tl
t r -I tt l
l H l t
Smaller
bearing
(thicker)
G'een
Gre^
Blacr
Green
Elack
Blue
ConnectingRod Bearings
Selection
Clearance
1.
2.
3.
4.
A number has been stampedon the side of each connectingrod as a code for the sizeof the big end. Use it,
and the lettersstampedon the crank(codesfor rod journal size),to choosethe correctbearings.
Halfof numberis
stampedon bearing
cap and the other
half is stampedon
rod.
STRIP
PLASTIGAGE
Berring ldcntification
Colorcodeis
on the edgeof
the bearing.
lf the plastigageshows the clearanceis still incorrect,try the next la.geror smallerbearing{the color
listed above or below that one), and check clearanceagain.
NOTE: lf the proper clearancecannot be obtained
by usingthe appropriatelargeror smallerbearings,
reolacethe crankshaftand stan over.
vnx.su
3
Smallerbearing{thicker)
tF;l
It
l - l f
Grn
Red
l i B o r ' r lI l
lEalllt
I 1 o . , , ,L' l l
Smaller
rod
journal
Smaller
bearing
(thicker|
Elack
Blak
Blue
Crankshaft
Removal
NOTE:End play for th connectingrods and crankshaft
shouldbe inspectedbetoreremovingthe crankshaft.
1.
5,
OIL PAN
R e m o v et h e c a p b r i d g e { 8 1 8 C 1e n g i n eo n l y } a n d
in order.
Keepall caps/bearings
main caps/bearings.
Removethe baffleplate.
Turn the crankshaftso No.2 and 3 crankpinsar at
the bottom.
Removethe right side cover.
7 -1 0
vnx.su
CRANKSHAFT
9 . Removethe upper bearinghalvesfrom connecting
caDs.
rodsand setthem asidewith their resDective
1 0 . Reinstallmain caps and bearingson the engine in
oroDerorder.
1 1 .l f y o u c a n f e e l a r i d g e o f m e t a l o r h a r d c a r b o n
around the top of each cylinder, remove it with a
ndge reamer.
instructions.
Followthe reamermanufacturer's
CAUTION: It the ridge is not removed, it may damage the pistons as they are pushed oul.
RIDGEREAMER
7-11
vnx.su
Crankshaft
lnspection
End Play
NOTE;End play should be inspectedbefore removing
crankshaft.
Pushthe crankfirmly awav from the dial indicator,and
zerothe dial againstthe end of the crank.Then pull the
c r a n k f i r m l y b a c k t o w a r d t h e i n d i c a t o r ;d i a l r e a d i n g
shouldnot exceedservicelimit.
.
.
Alignment
Measurerunouton all main journalsto makesurethe
crankis not bent.
The differnce between measurementson each journal must not be more than the servicelimit.
Crank3haftTotal lndicatod Runout:
Bl8Bl engins:
Sisndod {Nsw): 0.03 mm {0.001in) max.
SorviceLimit: 0.05 mm {0.002inl
818C1engin:
Standard {Nsw): 0.020mm (0.0008in} mar.
SGrviceLimits: 0.030mm 10.0012in)
OIALINDICATOR
Rotatetlvo complete
revolutions.
CrankshaftEnd Play:
Standard(New):0.10- 0.35mm
(0.04- 0.01i|inl
SrvicLimit
0.i15mm (0.018inl
.
NOTE:
Thrust washer thickness is fixed and must not be
changedeitherby grindingor shimming.
Thrustwashersare installedwith groovedsidesfacing outward.
7-12
vnx.su
GylinderBlock
Inspection
Out-ot-Roundand Taper
1.
The differencebetween msasurementson each journal must not be more than the se.vicelimit.
6mm
Journal Oul-of-Round:
Bt8Bi.ngine:
Strndrrd (Now): 0.(x15mm
Scrvicr Limit
0.010mm
Bl8Cl cngins:
Strnd.rd {Nowl: 0.004mm
0.qt6 mm
Sorvicc Limit
(0.0002inl m!x.
(o.fixx inl
Meaauremonl
Second
Moa6urgmont
Thi.d
M063uremgnt
G mm {0.24in}
(0.(XD16inl m!x.
{0.qx!2,1 in}
near edggs.
frrgt
BOREGAUGE
CYUNDER
.t +
.
.
Measuretaper at the edges of each rod and main
journal.
The difference between measurementson each journal must not be more than the servicelimit.
Journal Tapor:
8l8Bl angino:
Standard (Newl: 0.q)5 mm l0.0(Xl2inl m.x.
0.010mm (0.0004inl
SorvicoLimit
BlSCl ongino:
Standrrd (Now): 0.005mm (0.0002inl m8x.
Scrvic Limit
l f m o a s u r m e n t si n a n y c y l i n d s r a r e b e y o n d
OversizeBore ServiceLimit, rsglacethe block.
lf the block is to be rebored, refer to Piston
ClearanceInspection(see page 7-151after reboring.
(cont'd)
7-13
vnx.su
CylinderBlock
Inspection(cont'dl
2. Checkthe top of the blockfor warpage.
Measurealong the edgesand acrossthe centeras
snown.
SURFACES
TO BE MEASURED
NOTE:
. Use only a rigid honewith 400grit or finer stone
suchas Sunnen,Ammco,or equivalent.
a Do not usestonesthat are worn or broken.
W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e
cylinderblockof all metal panicles.Wash the cylinder bores with hot soapy water, then dry and oil
immediatelyto preventrusting.
NOTE: Never use solvent, it will only redistribute
the grit on the cylinderwalls.
lf scoring or scralchesare still presentin cylinder
bores after honing to the service limit, reborethe
engineblock.
NOTErSome light venicalscoringand scratchingis
acceptableif it is not deepenoughto catchyour fingernailand does not run the full lengthof the bore.
CYLINDERHONE
.
.
7-14
vnx.su
Pistons
Inspection
1.
3,
2.
M o a s u r t h e p i s t o n d i a m e t e ra t a p o i n t l 5 m m
(0.6in) from the bottomof the skin.
C a l c u l a t et h e d i f f e r e n c eb e t w o nc v l i n d e r b o r e
diameteron (seepage7-13)and pistondiametsr.
Pbton-io"Cy'indorClea18nco:
Stsndard (Nrwl: 0.010- 0.0/O mm
{o.ofira- 0.0016in}
S.rvic. Limit: 0.05 mm {0.002in)
Pbion Diamat6r:
Standard lNowl: 80.S - 80.99mm
(3.188- 3.189inl
Limit
80.97
mm (3.188in)
Sorvica
rKI
lf the clearanceis near or xcedsthe servicelimit,
inspect the piston and cylinder block for excessive
wear.
Ov.rsizc Pilton Diamcter:
O.25t81,23- 81.21|rnm{3.1980- 3.198'lin)
7-1
vnx.su
Piston
PistonRings
lnstallation
Replacement
ROD
CONNECTING
OIL HOI-E(Br8Bl onginel
BINGCOMPRESSOR
Usethe woodenhandle
of a hammerto pushor
tap the pistonintothe
cylinderbore.
vnx.su
I
'1.
M e a s u r et h e p i s t o n r i n g e n d - g a pw i t h a f e e l e r
gauge:
SecondRing Clearance:
Standard {Newl: 0.040- 0.065mm
(0.0015- 0.0026inl'1
0.0i15- 0.070mm
- 0.0028in)',
(0.0018
ServiceLimit: 0.13 mm (0.005inl
iliiii
.--r.llli.j---.-
PISTONNING
ioi
---'z
ll
ENDGAP-11-RIKENmanufactured
pistonring
T E I K O K UP I S T O NR I N Gm a n u f a c t u r e do i s t o n r i n q
{ 8 1 8 8 1e n g i n eo n l y )
RIKENmanufacturedpistonring
T E I K O K UP I S T O NR I N Gm a n u f a c t u r e dD i s t o nr i n o
( B ' 1 8 8e1n g i n eo n l y )
7-17
vnx.su
PistonRings
PistonPins
Alignment
Removal
1.
1.
Installtheringsas shown.
ldentifytop and secondrings by the chamferon the
edge.Makesurethey are in their propergrooveson
the prston.
--r
otGAF- PH6{t1,0
--l
PISTON BASE SP '{G
07973 - 65r06{X'
SECONDRING
OIL RING
3.
SPACER
App.ox. 90"
OIL RING
ls" GAP
TOP BINGGAP
DO NOTpositionany ring gap
in linewith the pistonpin hole.
SPACERGAP
OIL RINGGAP
7 -1 8 ,
vnx.su
Installation(B18Bl engine)
2.
1.
PISTONPIN DRIVERSHAFT
07973- PE00310
The arrowmustfacethe
timing beltsideo{ the
engineand the connecting
rod oil hole mustfacethe
rearsideof the engine,
PILOI COLLAR
07LAF- PR30100
Embossedmarkfacingup.
otl Hols
2. AdjustthelengthB of the pistonpindriver.
B:49.70mm (1.957
inl
NOTE:Usea hydraulicpress.
When pressingpin in or out,
makesurethat the recessed
portionof the pistonaligns
with the lipson the collar.
PISTONPIN DRIVERHEAD
07973- PEfl)320
PISTONPIN DR|VENSHAFT
079?3- PE|X)310
Embossedmark
ffi*.r,"ror","l
PILOTCOLLAN
07LAF- PF301(x)
PISTONPIN BASEINSERT
07GAF- PH603oO
PISTONBASEHEAD
07HAF- PL20t02
PISTONBASE
079?3- 6570500
7-19
vnx.su
PistonPins
Inspection
Installation
lB18C1enginel
1.
When pressingpin in or out, be sure you position the recessedflst on the piston againstthe
lugs on the baseattachment,
(0.8265- 0.8:168inl
20.907- 21.(xxtmm
- 0.&16S
(0.8267
in)
PISTONPIN
-T-
fl--.l
j
I
ll t
\J ---..''
tl i-
- ,rH ,l l
ilil
Embossedm.rk ll ll-l!-lJ
facins up.
\
t
HEAD
DRr\rER
- PEm32o
07e73
PlsroNPtN
sHAFr
DRtvER
- PEoo3lo
07s73
2.
-4
r
PISTONPIN
PILOTCOLLAR
o?LAF-PR3o1n'
I =)ffi
ri _-r -_t, -l l l'll,llltllrl ll ll li l i l l
L-lt|lllltlll
_-
PrsroNPINBASEINSERT
- PH6O3q)
O?GAF
PISTONBASEHEAD
07HAF- P120102
PISTONBASE
07973 - 65705U)
7-20
vnx.su
ConnectingRods
End Play
3.
- o.(Xxlg
(0.(xto4
inl
pages7-10and 7-22)
4.
7-21
vnx.su
Crankshaft
ConnectingRods
Selection
lnstallation
CONNECNNGRODBORE
REFERENCE
NUMBER
HalfoI numberis stampedon
bearingcap.th otherhalfon
connectingrod.
Groovedsidetacing
o!tward
Insertbearinghalvesin the engine block and connectingrods.
Holdthe crankshaftso rod journalsfor cylindersNo.
2 and No.3 are straightup.
Lower the crankshaftinto the block. putting the rod
journalsinto connectingrods No.2 and No.3.
Installthe rod capsand nutsfinger-tight,
CONNECNNGROD
7 -22
vnx.su
8.
BEARINGCAP BOLTSTOROUESEOUENCE
Bl88l cngino:
Bl8Cl ongino:
EEARIlTG
7-23
vnx.su
Grankshaft
Installation(cont'd)
9.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
. Apply liquid gasket as an even bead, centered
betweenthe edges of the mating surface.
. To preventleakageof oil, apply liquid gasketto
the innerthreadsof the bolt holes.
. Do not install the parts if 20 minutes or more
have elapsedsince applying the liquid gasket.
Instead,reapplyliquid gasketafter removingthe
old residue.
. After assembly, wait at least 20 minutes before
fillingthe enginewith oil.
OILPUMP:
RIGHTSIDECOVER:
6x1,0mm
tl N.m {1.1kgr'm.
8 tbf.ftl
RIGHTSIDE
6x1.0mm
11 N.m {1.1tgl.m,
DOWELPIN
O.RING
R6plac.
OIL PUMP
DOWELPINS
7-24
vnx.su
8 x 1.25mm
2il l$m l2.iakg[.m.
1t rbf.ftl
Oil Seal
lnstallation
The sealsurfaceon the blockshouldbe dry.
Apply a light cost of oil to the crankshaftand to
the liDof the seal.
1 1 . lnstalltheoil screen.
Installtheoil pan.
1' I
DRIVER
07t,49- (xll(xtoo
lnstallsealwiththe
part numberside
tacing out.
2.
NOTE:Reterto right column and 8-10lor installation of the oil pump side oil seal.
7-25
vnx.su
Oil Seal
Installation(engineremovalnot
required)
The sealsurfaceon the blockshouldb dry.
Apply a light coat of greaseto the crankshaftand
to the lio of seal.
Using the specialtool, drive in the timing pullsyend seal until the driver bottoms against the oil
pump.
When the seal is in place,clean any excessgrease
off lhe crankshaftand checkthat the oil seal tiD is
not distoned.
SALDRIVEB
07LAD- PRimroA
lnstallse6lwith
tho
Pan number
tacing out.
7-26
vnx.su
EngineLubrication
........8-2
S p e c i aTf o o l s . . . . . . . .
."' 8-3
l l l u s t r a t e dI n d e x . . . . . . . .
EngineOil
. . . . . . . . . . . " ' . . .8' - 5
Inspection
R e p l a c e m e n. t. . . . . . . . . . . . .".". . . . . . . . ' . ' .8 - 5
Oil Filter
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . ." . . . . . . . 8 - 6
Oil Pressure
....' 8-8
Testing
Oil Jet
I n s p e c t i o n{ 8 1 8 C 1 e n g i n eo n l y } . . . . . 8 - 8
Oil Pump
... 8-9
Overhaul
Removal/lnspection/lnstallation. . ' . . . 8- 1O
vnx.su
SpecialTools
Rel. No.
Tool Numbel
OTLAD_ PR4OlOA
o 7 9 12 - 6 1 1 0 0 0 1
Descrlption
Oty
8-11
8-7
Seal Driver
Oil Filter Wrench
8-2
vnx.su
I Pago Roferenco
lllustrated Index
CAUTIOIiI: Do not ovortighten the drain plug.
NOTE;
o Use new O-ringswhen reassembling.
a Apply oil to O-ringsbetore installation,
. Use liquid gasket, Part No. O8718-OOO1.
a Cleanthe oil pan gasket mating surtacesbefore installingit.
6 x'l.omm
12 N.m {1.2 kgt.m,9 lbt.tt)
81881 sngine:
WASHER
Replace.
DRATTPIUG
44 .m (4.5 tgf.m, 33 lbf'ftl\
Do not ovgr tightgn.
\
\
\
-@5
\
OILPAI{
GASKET
R6placs,
6 r l.O mtn
121{.m11.2kol.m,
I lbl.ttl
6 x 1.0 mm
'11 N.m 11.1 kgt'm,8lbt.ftl
OIL SCREEN
O|L BNEATHER
TAIIK
6 x 1 . Om m
ll N.m {1.1kgf'm,
I tbt.ftl
GASKET
Replace.
BAFFLEPTATE
eq
nU2o@
\\
#-'
OIL FIL
Repl.cemont, p6gs 8-6
I x 1.25mm
24 N.m 12.4 kgf..n,
17 rbr.ftl
A
ENGINEOIL PRESSURE
,F
swlTcH
HEAD OIL
CONTROLORIFICE
CIean.
OIL PUMP
Overhaul,page 8-9
lnspectionpage, 8-1O
Apply liquid gasket to
block mating surlace.
6 x 1 . Om m
11 N-m(1.1kgt.m,8lbf.ft)
(cont'dl
8-3
vnx.su
lllustrated Index
(cont'dl
CAUTION: Do not overtighten rhe dlain ptug.
818C1 engine:
DRAINPLUG
44 N.m (4.5 kgf.m, 33 lbt.ftl
Do not overtighten.
NOTE:
a Use new O-ringswhen reassembling.
a Apply oil to O rings before installation.
. U s e l i q u i dg a s k e t .P a r tN o . 0 8 7 1 8 - O O O 1 .
a Cleanthe oil pan gasket mating surfacesbefore installingit.
OIL PAN
6 x 1.0mm
12 N.m 11.2 kgl.m, 9 lbf.ftl
6 x 1.0 mm
1 1 N . m 1 1 . 1k g t . m ,
S lbf.fil
OIL JET BOLT
16 N.m {'1.6kgf.m, '13 lbf.ft}
Replace.
OIL JET
Be careful not to damage.
Inspection,page 8-8
EAFFLEPLATE
O-RING
Replace.
6xl.0mm
11 N.m (1.1 kgt.m, I lbt.ft)
OIL SCREEN
GASKET
Replace.
Il
,--)e
6V
ENGINEOIL COOLER
6 r ' 1 . 0m m
l 1 N . m ( 1 . 1 K9-m,
8 rb-trl
ENGINEOIL FILTER
page 8-6
Replacement,
O-RING
Replace.
OIL COOLER
CE TER BOLT
74 N.m (7,5 kgf.m, 54 lbf.ft) ENGINEOIL PRSSURE
swtTcH
8-4
vnx.su
8 x 1.25mm
24 N.m (2.4 kg-m, 17 lb-ft)
OIL PUMP
Overhaul,page 8-9
Removal/lnspection/lnstallation,
page 8-10
Apply liquidgasketto mating
surfaceot the engineblock.
EngineOil
Replacement
lnspection
Check engine oil with the engine off and ths cal
parked on level ground,
Make cenain that the oil levelindicatedon the dipstick is between the upper and lower marks.
Drainthe engineoil.
3.
Requirement
Capacity
Change
"Energy
API ServiceGrade:Use
Conservingll" SG or SH grade oil.
SAE 5W-3O Drefered.
B 1 8 B 1e n g i n e :
3.51 (3.7 US qt, 3.1 lmpqtl
at oil change.
3.8 t (4.0 US qt, 3.3 lmp qt)
at change.includingfilter.
4.6 I 14.9US qt. 4.0 lmp qt)
after engineoverhaul.
B18Cl engine:
3.7 f (3.9 US qt, 3.3 lmp qt)
at oil change.
4.O t 14.2US qt, 3.5 lmp qt)
at change,includingfilter.
4.a I (5.1 US qt, 4.2 lmp qt)
after engineoverhaul.
Every 7,5OOmiles (12,OOokm) or
6 months
(cont'd)
8-5
vnx.su
EnglneOil
Oil Filter
Replacement{cont'd)
Replacement
CAUTION: Aftar the ongine has boan run. tho oxhaust
pipos will bo hot; b caretul when wo.king around tho
erhaust manitold,
Removethe oil tilter with the specialoil filter wrench.
Inspectthe threadsand rubbe.sealonthe new lilter.
Wipe off seat on engineblock.then apply a light coat
of oil to the tilter rubberseal,
NOTE: Useonly filrerswith a built-inbypasssystem.
ElrclltEs
Inspectthreadsand
rubbersealsurface-
APICERTIFICATION
SEAL
8-6
vnx.su
ENGINEOIL COOLER
(8'l8Cl ongino onlyl
After the rubbersesl seats,tighten the oil filter clockwise with the specialtool.
1) Makea markon the cvlinderblockunderthe number that shows al the bottom of the filter when
the rubberseal is seated.
CAUTION: Installationother than the abova plocedure could r6suh in serious engine damag due to
oil leakage.
OILFILTEBWRENCH
07912-6110001
MARK
Number when rubber
seal is seated.
Numberafter tightening.
Numberwhen rubber
seal is seated
Numberafter tightening 8
5.
6
o
8-7
_l-
vnx.su
.4
Oil Pressure
Oil Jet
Testing
Inspection(B18C1 engineonly|
1. Connecta tachometer.
2.
3.
4.
1 . 2 m m 1 0 . 0 5i n )
2.
8-8
vnx.su
Oil Pump
Overhaul
NOTE:
a Use new O-ringswhen reassembling.
a Apply oil to O-ringsbefore installation.
. U s e l i q u i dg a s k e t ,P a r tN o . 0 8 7 1 8 - O O 0 1 .
a After reassembly,check that the rotors move without binding.
6 x 1.0 mm
6 N.m 10.6 kgl.m, 4 lbt'ttl
O.RING
Replace.
OUTERROTOR
pagesI 10, 11
Inspection,
DOWEL PIN
6 x 1 . Om m
11 N.m (1.1kgf.m,
8 tbf.frl
PUMPCOVER
Inspection,page 8-10
8 x 1.25mm
24 N.m (2.4 kgf.m,
t7 tbt'ft)
INNERROTOR
Inspect|on,
page 8-1 1
OIL SEAL
Installation,Page8-1 1
Replace.
PUMP HOUSING
lnspection,pages8-10, 11
Apply liquidgasket
to matingsufaceoI
the cylinderblock
when installing.
RELIEFVALVE
Valve must slide treely
in housingbore.
Replacewhen scored.
SPRING
*\
8 x 1.25mm
24 N.m (2.4 kgl.m,
17 lbl.Irl
vnx.su
SEALINGBOLT
39 N'm 14.0 kgf.m,
29 tbt.ttt
Oil Pump
Removal/lnspection/lnstallation
1O. Removethe screws trom the pump housing,thsn
separate the housing and coveJ.
Drainthe engineoil.
Turn the crankshatt and align the white groove on
the crankshaltpulleywith the pointeron the lower
cover.
5.
4.
Removethe power steeringpump belt, air conditioner belt and the alternator belt.
7.
8.
9.
OILPUMP
HOUSING
OIL PAN
8-10
vnx.su
t5.
rotor radialclearance.
Check the housing-to-outer
Housing-to-Outer Rotol Radial Clearance:
Standard{Newl: O.1O-O.19 mm
(O.oO4-O.OO7in)
ServicLimit: O.2Omm {O,OO8in)
1'l
OIL PUMP
(cont'd)
8-11
vnx.su
Oil Pump
Removal/lnspection/lnstallation
(cont'd)
22. Installthe oil pump on the cylinderblock.
a Apply greaseto the lip of the oil pump seal.
Then, installthe oil pump onto the crankshaft.
When the pump is in place, clean any excess
greaseoll the crankshaftand checkthat the oil
seal lip is not distorted.
23. Installthe oil screen.
24. Installthe oil pan.
NOTE: Cleanthe oil pan gasket mating surtaces.
8 x 1 . 2 5m m
24 N.m (2.4 kgl.m,
17 tbt.ftl
6 r 1 . Om m
1'l N.m {1.1kgf.m,
8 rbf.fr)
OIL PUMP
Apply liquidgasketto
cylinderblock mating
sudace.
O-RING
Apply engineoil
DOWEL PINS
GASKET
Replace.
OIL SCREEN
6 x 1 . Om m
11 N.m ('l .1 kgf.m,
8 tbf.trl
OIL PAN
6 x 1 . Om m
12 N.m {1.2 kgf.m, 9 lbf.ft}
8-12
vnx.su
System
lntake Manifold/Exhaust
Intake Manifold
..
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 2
Exhaust Manifold
R e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .9.-. 4
..
Exhaust Pipe and Muffler
. .-. 5. .
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . 9
vnx.su
Intake Manifold
Replacement
NOTE: Use new O-ringsand gasketswhen reassembling.
CAUTION: Check for tolds or scratches on the aurface ot the gasket. Roplacewith a now gasket it damagod,
81881 engine:
5r0.8mm
6 N'm {0.6 kgl.m.
4 rbr.ftl
INTAKEAIR
TEMPERATURE
IIATI SENSOR
'*o*ot'u""'""N
PURGECONTROL
SOLENOIDVALVE
5xO.8mm
6 .m (0.6 kg{.m.
4 tbf.ftl
IiITAKE MANIFOLD
ReplaceiI cracked or
it mating s!rtaces aro
damago.
O-RING
Replace.
8 x 1.25mm
22 N.r 12.2 kgl.m,
'16 tbt.ftt
GASKETS
Replace.
I x 1 . 2 5m m
20 N.m (2.0 kgt.m.
14 rbf.ftl
IDLE AIR
{IACI VALVE
Be careful not
to damage.
O.RING
Replace.
THROTTLE
BODY
O-RINGS
Beplace.
8 x 1.25 mm
23 N.m (2.3 kgl.m,
17 lbf.frl
8 x 1.25mm
24 N.m (2.4 kgf'm,
17 rbf.ft)
"o
aY
c
BRACKET
8 x 1.25mm
24 N.m (2.4 kgl'm.
17 tbr.ftl
THERMO
VALVE
8e careful not to
damage.
8 x 1.25mm
24 N.m (2.4 kgl'm,
1 7 rbf'ft1
9-2
vnx.su
INTAKE MANIFOLD
Replaceil cracked or
il mating surfaces are
damageo.
l
I
IAT SENSOR
VALVE
? , /
5xO.8mm
6 N.m 10.6 kgf.m,
4 tbf.ftl
EVAP PURGECONTROL
/
GASKETS
Replace.
O.BI G
Replace.
INTAKE AIR
BYPASSVALVE
BODY
INTAKEMANIFOLD
CHAMBER
IAC VALVE
Be carelul not
lo oamage.
8 x 1.25mm
23 N.rn 12.3 kgt'm,
17 tbf.frl
BRACKET
O.RINGS
Replace.
I x 1.25 mm
22 N.m 12.2 kgl.ft,
t6 tbt.tt)
8 x t.25 mfi
24 N.m (2.4 lgf.m.
17 tbt.ft)
8 r 1.25mm
24 N.m {2.4 kgf.h,
t7 rbr.ftl
I r 1.25 lnm
24 N.m 12.4 kgt.m,
17 tbt.ftl
THROTTLE
AODY
8 x 1.25mm
20 .m (2.0 kgt.m,
14 tbf.ftl
HEATERBYPASS
PIPE
o-Rt Gs
Replace.
I x 1.25mm
24 N.m (2.4 kgl.m, 17lbf'ft|
9-3
vnx.su
Exhaust Manifold
Replacement
NOTE: Use new gasketsand seltiocking nuts when teassembling.
GASKET
Replace.
XHAUST MAt{IFOLD
I r 1.25 mm
24 N.ln (2.4 kgf.m, l7 lbt.ft)
Ss
Z \
tr l'A
|
i...1%\
/ \\-i
R
A\
1tr.
\
8 x '1.25mm
3l N.m {3.2 kgf.m. 23 lbf.ltl
Replace.
8 x 1.25mm
24 N.m {2.4 kgf.m,
1 7 tbf.ftl
10 x 1.25mm
44 .m {4.5 kgl.rh. 33 lbf.ft}
vnx.su
^1
e
HEAT SHILD
,@\
8 x 1.25mm
22 N.m 12.2 kgt.m, 16 lbf.ftl
Replace.
Tightenthe bolts in steps,
alternatingside-to-side.
SELF-LOCKIIIGNUT
1 0 x 1 . 2 5m m
33 N.m (3.4 kgt.m,
25 tbf.ftt
Replace.
COVER
HEATEOOXYGEN
SENSOR(HO2Sl
44 N.m 14.5 kgt.m,
33 rbf.ftl
I x 1.25mm
24 N.m 12.4 kgf.m,
17 tbl.frl
BRACKET
GASKETS
Replace.
GASKET
Replace.
THREEWAY
CATALYTIC
CONVERTER
COVER
SELF-LOCKINGNUTS
10 x 1,25mm
54 N'm 15.5 kgf'm,
40 tbf.ftl
Replace.
NUT
SELF-LOCKING
8 x 1.25mm
16 N.m {1.6kgf.m,
r2 tbt.frl
Replace.
6 x 1.0 mm
9.8 N.m l1.O kgf.m, 7.2 lbl.ttl
I x 1.25mm
Replace.
Tighten the flange nuts in steps,
alternating side-to-side.
vnx.su
(cont'd)
HEAT SHIELOS
EXHAUST PIPETIP
6 x 1.0 mm
9.8 N'm {1.O kgt.m, 7.2 lbf.ft)
HEAT SHIELD
EXHAUSTPIPEB
GASKET
Replace.
8 x 1.25mm
22 N.m 12.2 kgf.m, 16 lbf'ftl
Replace.
Tighten the bolts in steps,
alternating side'to-side.
NUT
SELF,LOCKING
10 x 1.25mm
33 N.m {3.4 kgf.m,
25 tbf.frl
Replace.
COVER
HO25
44 N.m {4.5 kgf.m,
33 tbf.fr)
I r 1.25mm
24 N.m 12.4 kgf.m,
17 lbf.ftl
BRACKET
GASKET
Replace.
GASKETS
Replace.
EXHAUST PIPEA
COVER
SELF.LOCKINGNUTS
10 x 1.25mm
54 N.m 15.5 kgl.m,
40 lbf.frl
Replace.
6 x 1 . Om m
9.8 N.m (1.0 kgf.m, 7.2 lbt'ft|
8 x 1.25mm
22 N.m 12.2 kgf.m, 16 lbl.ftl
Repiace.
Tighlenrhe flangenuts in sreps,
alternatingside-to-side.
SELF-LOCKINGNUT
8 x 1.25mm
1 6 N . m 1 1 . 6k g f . m ,
12lbf.ftl
Replace.
vnx.su
Cooling
10-2
lllustrated Index
Radiator
. .O. .-.4.
R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . 1
Engine Goolant Refilling and
Bleeding
10-5
. . . . . . . . . . . . .1. .0 - 6
.........10-6
C a pT e s t i n g
Testing
Pressure
Thermostat
. .O. .-.7.
R e p | a c e m e.n. t. . . . . . . . . . . . . . . . . . . . . . . 1
.....1O'7
Testing
Water Pump
. 10-8
Index.........
lllustrated
.10-9
Inspection
. .O. .-.9.
R e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . . . . . 1
vnx.su
lllustrated Index
sy"t". is under high plessurewhen engine
@
is hot. To avoid dsnger of relsssing scalding engine
coolant. remove cap only when engine is cool.
Total Cooling System Capacity (lncluding heater and
rservoirl
Bl8Bl engine:
Mfl: 6.4 | {6.8 US qt, 5.6 lmp qt}
AlTt 6.7 | {7.1 US qt, 5.9 lmp qt}
Bl8Cl engine:
Mfi: 6.7 t {7.1 US qt, 5.9 lmp qt}
CAUTION: lf any engine coolant spills on paintd portions ot the body, rinse it ofl immediately.
NOTE:
a Checkall coolingsystem hosesfor damage.leaksor
deteriorationand replaceif necessary.
a Check all hose clamps and retightenif necessary.
a Use new O-ringswhen reassembling.
RADIATOR
Enginecoolant refillingand bleeding,
page 10-5
'l0-6
Leaktest, page
Inspectsolderedjoints and
seamsfor leaks.
Elow out dirt from between
core fins with compressedair.
lf insects,etc., are clogging
.adiator,wash them off with
low pressurewater,
CONDENSER
FAN SHROUD
{soe soction 221
\*
S!
*)
ATF COOLER
HOSES
{81881 6ngine)
6 x 1 . Om m
7 N.m (O.7 kgt.m. 5 lbf.ftl
5x0.8mm
4.4 N.m (O.45kgf.m,
3.3 lbl.fr)
FAN SHROUD
10-2
vnx.su
R
U
COOLANT
RESERVOIR
ENGINECOMPARTMENTHOSECONNECTIONS:
Bl88l engine:
FAST IDLE
THERMOVALVE
THERMOSTAT
HOUSIITG
IDLEAIR CONTROL
IIAC} VALVE
BREATHERPIPE
O'RING
Replace.
O-RING
Replace.
HEATERHOSES
818C1 engine:
ENGINEOIL
COOLER
BREATHERPIPE
IAC VALVE
HEATERBYPASS
PIPE
FASTIDLE
THERMOVALVE
THERMOSTAT
HOUSING
HEATEBHOSES
10-3
vnx.su
Radiator
Replacement
1.
5.
Drainthe enginecoolant.
UPPERBRACKET
AND CUSHTOl{
RADIATOR
CAP 6 x l . O m m
9.8 N.m (1.O kgt.m,
7.2 rbf.ft)
6 x 1.0 mm
9.8 il.m 11.Okgt'm,
7.2 lbr.ftl
FAN MOTOR
CUSHION
O-RING
Replace.
SHROUD
6 x 1.0 mm
9.8 N.m ('l.O kgl.m,
7.2 tbl.ttl
DRAIN PLUG
LOWERRADIATOR
HOSE
vnx.su
EngineCoolantRefillingand Bleeding
ne-oving the radiatorcap while the engine
@
is hot can cause the engine coolant to splay out, seriously scalding you. Always let the engine and radiatol
cool down betore removing the radiator cap.
CAUTION: When poudngenginecoolant,be sure to shut
the relay box lid and not to let coolant spill on the electlical pans or the paint. ll any coolant spills, rinse it otf
immediately.
1.
2.
Removethe radiatorcao.
3.
NOTE:
. Use only HONDA-RECOMMENOED
antifreeze/
coolant.
a For best corrosionprotection,the enginecoolant
concentrationsmust be maintainedyear-roundat
50% MINIMUM.Coolantconcentrations
lessthan
50% may not provide sufficient protection
againstcorrosionor freezing.
CAUTION:
a Do not mix ditterent blands ot anti-freeze/
coolants.
a Do not use additional rust inhibitois or anti-rust
products; they may not bs compatibl with the
recommgndsd engins coolant.
Engin Coolant Retill Capacity: including reservoir
{0.6 t (0.6 US qt, 0.5 lmp qt)).
81881 engine:
MlTt 4.4 | (4.6 US qt, 3.9 lmp qr)
A f f t 4 . 7 [ ( 5 . OU S q t , 4 . 1 l m p q t ]
Bl8Cl engine:
Mnt 4.7 | (5.0 US qt.4.1 lmp qt)
8. Pourcoolantinto the radiatorup to the baseof the
filler neck.
9. Loosenthe bleedbolt on top of the engine.Tighten
it againwhen coolantcomesout in a steadystream
with no bubbles.
ENGINEDRAIN BOLT
78 N.m {8,O kgt.m, 58 lbt.ftl
Apply liquidgaskerto
BLEEDBOLT
WASHER
Replace.
6.
7.
10-5
vnx.su
Radiator
Cap Testing
1 . Removethe radiatorcap, wet its seal with engine
coolant,then installit on the pressuretester.
2 . Apply a pressureol:
9 3 - 1 2 3k P a
( O . 9 5 - 1 . 2 5 k g J / c m ' ,1 3 . 5 - 1 7 . 8 p s i )
PressureTesting
1 . Wait until the engineis cool, then carefullyremove
the radiatorcap and fill the radiator with engine
coolant to the top of the filler neck.
Attach the pressuretesterto the radiatorand apply
a pressureof:
93- 123 kPa
( O . 9 5 - 1 . 2 5 k g f / c m , .1 3 . 5 - 1 7 . 8 p s i )
Inspect for engine coolant leaks and a dfop in
pressure,
Removethe tester and reinstallthe radiatorcap.
NOTE:
a Checkfor engineoil in the enginecoolantand/or
coolant in the engineoil.
a Check for ATF in the engine coolant and/or
coolant in the ATF (A/T).
10-6
vnx.su
Thermostat
Replacement
NOTE:Use new gaskets and O-rings when reassembling,
6 x 1 . Om m
1 1 N . m 1 1 . 1k g t . m , 8 . Ol b t . f t l
THERMOSTAT
MOUIITINGRUBBER
Replace.
l
ECT SWITCH
22-25 N.m 12.2-2.6 ksl.m, 'l6-'19 lbl.ttl
Testing
Replacethermostatif it is open at room temperature.
To test a closed thrmostat:
SusDendthe thermostatin a containerof water as
shown.
THERMOMETER
THERMOSTAT
STANDARDTHERMOSTAT
Lift height: above 8.O mm (O.31 inl
Starts opening:169 - 176"F {76-8OoCl
Fully open: 194oF (90oCl
10-7
vnx.su
Water Pump
lllustratedIndex
NOTE:
a Usenew O-ringsandnew specialboltswhenreassembling.
a Useliquidgasket,PartNo. O8718-0OO1.
ENGI E COOLAI{T
3;iil3
TEMPERATURE
IECTI SENSOR
t8 N.m 11.8kot.m,13lbt'ttl
onsino:
B18c1
Bl8Bl cngln :
ECT SEI{SOR
ECTGAUGESEDINGU]{IT
I N.m (0.9 tgf.n, 7 lbf'tt)
Apply liquid gaskot
to tho threads.
6 r 1 . 0m m
11 N.m l1.l kgl.m,8.O lbl.ftl
6r1.Omm
1l t{.m ll.1 tgl.m.
8.O tbt.ftl
KNOCK SEI{SOR
3l N.m {3.2 kgf.m.
23 tbf.ftl
(8l8Cl .ngin onlyl
OUTIET
BLEEDBOLT
9.8 N.m (l.O rg[.m. 7.2 lbt'ft|
WATER OUTLET
COVER
Apply liquid gasket
to mating sudace.
ECTSIY]TCH
WATERPUMP
Inspectaon,
pagelO-9
22-26
.m 12.2-2.C )l{/l'nt.
16-19 tbr.ftl
o-Rtt{G
Roplaco.
o-itltc
Roplrco.
8r1.Orxtr
12 .|n ll.2 lgt.m,
8.7 n{.ftt
6xt.Omm
12 N'ft (1.2 kgf..n.8.7 lbt.ft)
10-8
vnx.su
Replacement
Inspection
J.
J.
BLEEDHOLE
DOWELPIN
6 r 1.O rnm
12 N.m {1.2 kgf.m,
4.7 bf.ftl
BI-EEDHOI-E
4.
10-9
vnx.su
Fueland Emissions
Fuel Supply System
. . . . . . . . . . . . . . .1. 1 - 2
S p o c i aTl o o l s
Systam TloubloshootingGuid. ..................1 1-97
Componnt Location
F u o lL i n o s
. . . . . . . . . . . . . . . . . . . .1. '.l- 9 8
. . . . . .1 1 - 3
l n d e x. . . . . . . . . . . . . . . . .
........ 11-100
System Description
System Description
F u o lP r a s s u r e
. . . . . . . . . . . . . . . .1.1 - 1 0 0
V a c u u mC o n n e c t i o n.a. . . . . . , . . . . . . . . . . . . . . . . .1.1. .- 8
. . . . . . . . . . . . . . . .1.1 - 1 0 2
E f e c t r i c aCl o n n e c t i o n.s. . . , . , . , . . . . . . , . . . , , . . . . . , ' 1 1 - 1 2 F u 6 lI n i 6 c t o r s
Fuel PressureRagulato.
.,. 11-106
S y s t mC o n n e c t o r s. . . , . . . , . . . . . . . . . . . . . . . . . -1. -1- -. 2 O
F u e lF i l t e r
. . . . . . . . . . . . . . . . . . . .1. 1
. -108
T.oubloshooting
F u a lP u m p
. . . . . . . . . . . . . . . . . . .1. .1 - 1 0 9
T r o u b l e s h o o t i nGgu i d o . . . . . . . . . . . . . . . . . . . . . . .1. .1.- 3 2
P G M - FM
l a i nF 6 l a y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .1. .".11 1
Self-diagnosticProcedures.,..,...............1 1-34
F u e lT a n k
. . . . . . . . . . . . . . . . . . . .t. 1. - 1 1 4
H o w t o R o a dF l o w c h a r t s. . . . . . . . . . . . . . . . . . . , 1
. .1. - 3 9
PGM-Fl System
Intake Air System
S y s t o mD e s c r i p t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . 1. .l.-.4 O
System TroubloshootingGuido ..................1 1-1 1 5
Troubleshooting Flowcharts
........ 11-116
Systom Dascription
E n g i n eC o n t r o lM o d u l s. . . . . . . . . . . . ...... . . . . . . . .1 1 - 4 2
. . . . . . . . . . . . . . . . . .1. .1 - 1 1 7
Air Cleanr
H e a t e dO x y g o nS e n s o r . . . . . . , . . . . . . . . . . . . . . .1. .1. - 4 6
T h r o t t l sC a b l e
................'11-118
HeatedOxygn Sonsol Heatel .....,......... 1 1-47
T h r o t t l 8B o d y
. . . . . . . . . . . . . . .1. 1 - 1 2 0
F u e lS u p p l yS y s t e m. . . . . . . . . . . . . . - . . . . . . . . . . .1. .1. -. 5 0
lntake Air Bypass Cont.ol Systsm
Manitold Absolute Pressure
. , . . . . . . . . .1 1 - 1 2 3
[B18Cl enginal
....
S s n s o r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1. .- .5. 2
Intake
.................
11-128
Manilold
onginol
[B1881
Top D6ad Cente./Crankshatr
Position/Cylindor
Positionsonsor ........ 1 1-56
Emission Control System
EngineCoolantTempsratureSonsor ....... 11-58
Systsm
TroubleshootingGuido ..................1 1-129
T h r o t t l oP o s i t i o nS o n s o r. . . . . . . . , . . , , . . . . . . . . 1. .1. - 6 0
........ 11-130
Systam Doscription
Intake Air TemperatursSensor...............11-62
........... 11-130
TailpipsEmission
B a r o m e tc P r s s s u r o
S e n s o r. . . . . . , . . . , . . . , . .1, .1 - 6 4
ThraeWay CatalyticConvortor ...,...,.........,11-131
l g n i t i o nO u t p u tS i g n a l. . . . . . . . . . . . . . . . . . . . . . . .1. 1
. .- 6 6
PositivaCrankcaEoV6ntilationSystcm .,....., 11-134
V e h i c l eS p e dS e n s o r. . . . . . . . . . . . . . . . . . . . . . . .1. 1
. .- 6 8
EvaporativoEmissionContro|,..,..,.,.,,.,,..,..,1 1-135
7
O
E l e c t d c aLl o a dD o t e c t o r. . . . , . . . , . . . . . . . . . . , . 1. .1.
K n o c kS e n s o r[ 8 1 8 C 1e n g i n e ]. . . . . . . . . . . . . .1. 1 - 7 4
A / T F l S i g n a lA / B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .-.7 6
ldle Contlol System
vnx.su
SpecialTools
Ref. No I
Tool Numbr
Description
I OtV I
A973X_041*XXXXX
Vacuum Pump/Gauge
,l
@
@
@
@
oTJAZ-O010008
OTLAJ_PT3O1OA
oTPAZ-0010100
o7406-OO40001
Vacuum/Pressure
Gauge0-4 in. Hg
Test Harness
SCS Short Connector
Fuel PressureGauge
1
1
'l
\t
1 1 -2
vnx.su
Page Reference.
1't-'t20, 124, ' 1 3 7 ,
140
1 1 - 1 3 91,4 0
't 1-37
I t -J.+
1 1 - t 0 11
, 06
Component Locations
lndex
81881 sngin6:
ABSOLUTE
MANIFOLD
PRESSURE
{MAP}SENSOR
EVAP
PURGECONTROL
VALVE
SOLENOID
Troubleshooting,
Troubleshooting,
11-137
THROTTLEPOSITIOIII{TP) SENSOR
Troubleshooting, page 1 1-60
THROTTLECABLE
page 1 1-118
Inspection/Adiustment,
Installation,page 11-1 18
swtTcH
ELECTRICAL
LOAD
OETECTOR
IELD}
page 11-93
Troubleshooting.
Troubleshooting.
page,l l-70
sq
MODULE{ICMI
IGNITION
Troubleshooting, page 1 1-66
IDLETHERMOVALVE
Inspection,page 11-94
ENGINECOOLANT TEMPERA
page I 1-58
Troubleshooting,
(ECTISENSOR
HEATEO
SENSORlHO2S}
pages 11-46, 47
Troubleshooting.
11-3
vnx.su
Component Locations
lndex
B18Cl ongino:
EVAP
PURGECONTROL
SOLEiIOIDVALVE
Troubleshooting,
p a g e1 1 - 1 3 7
AESOLUTE
MANIFOLD
(MAPISENSOR
PRESSURE
page 11-52
Troubleshooting,
THROTTLE
(TP}
POSITION
SENSOR
THROTTLECABLE
page 'l 1-119
Inspection/Adiustment,
page
1
1-1
19
lnstallation,
Troubleshooting,
page 1 1-6O
POWERSTEERINGPRESSURE(PS'I
swtTcH
page 1 1-93
Troubleshooting,
ELECTRICAL
LOAD
DETECTOR
IELD}
Troubleshooting,
page.11-70
IGNITIONCONTNOLMODULE OCMI
Troubleshooting, Psge 1'l-66
sElrlsoRtKsl
ENGIT{E
COOLANTTEMPERA
{ECT}SEI{SOR
Troubleshooting,
Pag11-58
VALVE
FAST IDLE
'l
Inspection, page 1 -94
11-4
vnx.su
AIR CLEAI{ERIACL)
Replacoment,
11-117
BODY(T8I
THROTTLE
page11-120
Inspsction,
page11'122
Disassembfy,
THROTTLE
CABLE
pages1l-'l 18, 119
InsDection/Adjustment,
pages1 1-118, 119
Inslallation,
INTAKE
AIR
BYPASS (IABI
co TROL
OIAPHRAGM
{Bl8C1 ongino onlyl
Troubleshooting,
page 11-124
INTAKE
AIR
EYPASS IIABI
co TnoL
SOLENOID
RESONATOR
POSITIVE
CRA KCASE
vEt{TtLATtOt{(PcVl VALVE
psgo1 l-134
Inspection,
MODULE{ECM)
ENGI]TE
CONTROL
page11-34
Procedures,
Selt-diagnostic
page11-42
Troubfeshooting,
SERVICECHECX CONNECTOR(2PI
page'l 1-34
56ll.diagnosticProcedures,
MAIN RELAY
RelayTesting,page 1 1-111
pag 1 1-112
Troubleshooting,
11-5
vnx.su
SystemDescription
Index
FUELGAUGESE]IIDINGU]{IT
Tgsting,sction23
FUELFILTER
page 11-l OB
Replacement,
FUEL PUMP
Tsting.page 11-1 10
Roplscamnt.page 11-l 10
FUELFEEDPIPE
FUELFIIL CAP
FUEL II{JECTORS
page 1 1-102
Troubleshooting,
page 1 1-105
Replacemont,
FUELTA K
R6placomont,
p a g el 1 - 1 1 4
EVAFORATIVE
EMISSION
IEVAP}TWO WAY VALVE
Testing,pag11-140
EVAPORATIVE
EMTSStOt{
{EVAP}PURGE
FUL
PNESSURE
REGUIATOR
Testing,page11-106
page11-107
Roplacmnt,
CONTROLDIAPHNAGM
VALVE
page'l 1-137
Troubleshooting,
FUELVAFONAPE
FUEL RAIL
EVAFORATIVCEMISSION
(EVAPI COI{TROLCANISTER
Troubl6shooting. pag6 1 1-'l 37
11-6
vnx.su
System Description
Vacuum Connections
81881 engin:
EVAPORATIVEEMISSIOT{
(EVAPI
PURGECONTROL
SOLENOIDVALVE
EVAPORATIVE
EMISSION
(EVAP}PURGECONTROL
To
DIAPHRAGM
VALVE
EVAPORATIVE
EMtSSTON
{EVAP}
TWO WAY
VALVE
EVAPORATIVEEMISSION
IEVAP) CONTROI-CANISTER
FRONTOF
VEHICLE
11-8
vnx.su
ENGINE
COOLANT
|l
U]
HEATEDOXYGEI{SEI{SOF(HO2S}
(MAP)SEI{SON
PRESSURE
MANIFOI.D
ABSOLUTE
ENGINECOOLANTTEMPERATURE
IECT}SENSOR
INTAKEAIRTEMPERATURE
IIAT} SEI'ISOR
IDLEAIR CONTROL
IIAC)VALVE
FASTIDLETHERMOVALVE
FUELII{JECTOR
FUELFILTER
REGULATON
FUELPRESSURE
FUELPUMPIFP)
FUELTAI{K
(EVAP}VALVE
EMISSION
@ FUELTAI{K EVAPORATIVE
DAMPER
G) FUELPULSATION
@ AIR CLEANER
@)RESONATOR
(TWC)
@ THREEWAY CATALYTICCONVEnTER
VEITITILAT|ON
IPCV)VALVE
CRANKCASE
o POS|TIVE
CANISIER
EMISSION
IEVAP)COI{TROL
@ EVAPOBATIVE
@ EvApoRATrvEEMrssroNIEVAP)PURGEcoNTRoL
VALVE
SOLENOID
(EVAP)PURGE
CONTROL
EMISSION
@ EVAPORATTVE
VALVE
DIAPHRAGM
(iDEVAPORATIVE
(EVAPITWOWAY VALVE
EMISSION
11-9
vnx.su
System Description
Vacuum Connections
818C1 engine:
INTAKEAIR
SYPASSIIAB}
CONTROLDIAPHRAGMVAI-VE
to
EVAPORATIVE
EMISStON
IEVAPI
TWO WAY
VALVE
MANIFOLOABSOLUTE
PRESSURE
{MAP) SENSOR
EVAPORATIVEEMISSION
{EVAP) PURGECONTROL
DIAPHRAGMVALVE
INTAKE
AIR
BYPASS IIAB}
VACUUM
TANK
EVAPORATIVEEMISSION
IEVAPI CONTROLCANISTER
INTAKEAIR
BYPASS IIABI
CONTROLSOLENOIDVALVE
PURGECONTROL
SOLENOIDVALVE
11-10
vnx.su
lHO2Sl
c) HEATEDOXYGENSENSOR
PRESSURE
IMAPISENSOB
) MANIFOLDABSOLUTE
{ECT}SENSOR
O EI{GINECOOLANTTEMPERATURE
{IAT)SENSOR
) INTAKEAIR TEMPERATURE
tKSl
@ KNOCKSENSOR
@ IDLEalR coNTRoL llAcl vALvE
O FASTIDLETHERMOVALVE
@ FUELINJECTOR
@ FUELFILTER
REGULATOR
@ FUELPRESSURE
O) FUELPUMP(FPI
@)FUELTANK
EMISSIONIEVAPIVALVE
@ FUELTANK EVAPORATIVE
DAMPER
G) FUELPUI-SATION
@ AIR CLEANER
(D RESONATOR
6 imrlre arR Bypass (tAB)coNTRoL DIAPHRAGM
VALVE
VALVE
(D)IITITP IIN BYPASS{IAB)COTROLSOLENOID
ds)INTIXT AIR EYPASSTIABIVACUUMTANK
rio'lrnrarg ltn BYPASS(lABl cHEcK vALvE
6 rsnee wav cATALYTtccoNvERTERlrwc)
6 posrnve cRAf{KcAsEvENTILATIoN{Pcv) vALVE
6 evlponlrtve EMtsstot{ tEvAPlcoNTBoL cANlsrER
coNTRoL
EMtssloN{EvAP}PURGE
6 evlponltvE
VALVE
SOLENOID
(EVAPIPURGE
CONTROL
EMISSION
6i EVAPORATIV
VALVE
DIAPHRAGM
Eutsstof{ IEVAPIrwo wAY vALvE
6o ivlpoalrtve
11-11
vnx.su
SystemDescription
ElectricalConnections
PGM.FI MAII{ RELAY
@
fUEL
PUMP
- rc2lL
IllL
i i \|
r--ri l {a/Tl
.i
FUELINJCTORS
DATA
LIIIK
To BAOIATORFAt!
RETAY,CONDENSER
FAI{ RELAY
co t{EcToR
To A/C SWITCH
A/C CLUTCH RELAY
A/T GEAR
FUSES
I1OOAI*
O BATTERY
@ oPTroNt50 alr
o rG {50 A).
@ sroP. HoBN{2OAl*
@ BACKUP(7.5 Al*
LIGHT{7.5 A)
@ No. 3 INTERIOR
O Ecu (EcMt(1s A)'
@)No. 24 ACG (ALTI0Gl
{15 A: 81881sngin6,
2OA:818C16n9ine)
@ No. 15 BAcK-uPLlcHTsllo Al
RELAY
@ No. 13 REARDEFROSTER
HEATERMOTORRELAY
FAN MOTORRELAYI7.5 A}
COOLING
SIGNAL
17.5A)
O No. l8 STARTER
*: UNDER-HOOD
BOX
FUSE/RELAY
11-12
vnx.su
ITIAP
sEl{SOR
TP SEI{SOR
..!L1.99'!.elsrl
VTEC SOLE]{O|O
EVAP
PURGECOT{TROL
SOLEI{OIOVALVE
ALT C 416
IUSA or yl
TERMINALLOCATIONS
ooooooooooooo
ooooooooooooo
oooooooo
oooooooo
ooooooooooo
ooooooooooo
(cont'd)
11-13
vnx.su
System Description
ElectricalConnections(cont'd)
rHriRED,
fl--fwl
I
Jftfi:]ff*-,
HO2S
cl13
- YvHrnEr-l | i|APsEIrsoFI
-cn AvHrr
ll_l
cl11
ECTSEI{SOR
c120
{E
, REDI'EL
GRI{/BLU
IAT SET{SOR
cl15
1E
YEL/BLU
RED/8U(
GR]I/BLU
cl19
wt{T/GRl{
wL?/nEor
WHT/GRT{
WHT/REDr
ALTERI{ATOF
cl to
tclrl
c131
".rro*.fl..Fl
- ll PnEssunE I
- atK'
swrcH
I
1l
11-14
vnx.su
-'-'--''''-''-'
D14 :wHT/nED'
TDC/CYP/CKPSENSOR
811
812
813
814
815
816
'- -----
:j:on 2-"''''-'
:-WHT--------'-''''-''''
:ji oRNi sLU =::::i-:jjjjjjj
:ji WHT/ALU jjji-::-:-:::i:jj
KS
t{o. 1 FUEI
II{JECTOR
c122
t{o. 2 FUEL
II{JECTOR
c123
No. 3 FUEL
NJECTOR
c124
YEL/ALX
YELI
YEL/BLK
- RED2
t{o. 4 FUEL
II{JECTOR
EVAP PURGE
cot{TRoL
soLE{otD
VAIVE
(cont'd)
11-15
vnx.su
System Description
ElectricalConnections (cont'dl
BLI(/YEL
oRI{r
BTKiYEL-JT---l
oR 1 ----l I vss
BLK'
{l
c't 16
v:r-,sr-*-J
l-----]
'o"
uo.u.
".*,".u
{l
lA18a1ongine,
lB18C1 6ngin)
".t t
enn__JlF-----l
r Brx_LlswrcH
il
tl
ll
c423 ! caor
-L
es-ot
c405
eaurvxrJ
r BLK -l
G401 :--
SERVICECHECK
COIIIIECTOR
c40a
BRN/BLKf
DATA LINK
LT BLUI
corrttIEcToR
WHT/RED
{
11-16
vnx.su
lBl lcl
I T
t Il
neonr-x
RED/WXT
GAUGE ASSEMALY
c449 -
C553
F-
{!L rNDrcAToR
GR[{/OR]{
["'
To RADIATORFAt{
RELAY, COI{DI{SER
FAI{ RELAY
To A/C COTT|PfiESSOR
CLUTCH RELAY
To A/C SWITCH
(cont'd)
11-17
vnx.su
System Description
ElectricalConnections(cont'dl
160Al
wnrneo
J
-l
,*rr"a*
fioo Al
c216
wHr/8ru
T
I
YEL/WHT--L
c214
wHvem {
sToP. HORI{t20 Al
auryet{
oR nED-l
-alx {
I "rti'
f_ c218
G20r
wxrneo
"a*,"ao {
c44t)
*utwxr
o. la STARTER
stGI{At- t7.5 Al
{
wHriRED--l
or-rrv:r{
c551
-{
nft
C4.
l|5^.llll.n'i'20r!|.c1q*,
Af,:
Ca13 f
-l
8rr(/nED
surwxr -{
el3t
F
w{T/GRr{_-]
cR ^i|Hrl
{Toptg 11-19,
11 - 1 8
vnx.su
{Frompago 1 1-'l8l
PGM-FI lrtAtt{
REL,AY
G502
11-19
vnx.su
System Description
SystemConnectorsIEngineCompartmentl
ENGINE
WIRE HARNESS
{818C1 onginol
o
t3
c132
c131
UNDER,
HOOO
FUSE/RELAY
aox
MAllrl
WIRE
HARI{ESS
ct 04
c220
c102
c222
11-20
vnx.su
c112
c111
cl10
cl1
r'ft]
r+
lrl2l
trtr
\:-/
lI-FErwHr
l-l l
1olGuNlert
IOTBLF------l
la lsLx/YEL
fo lanlr
c 132
tr
/ r \
\^y
IETYEL/Lh---l
----,,
lohED'
ldlcRr/vEr
ffi
c221
^Jl
r'fr]
c214
---l
c216
c215
I if,l.)
l;TYra-"wrrr.
I
le llel/nEo
I
I TcRNrwHrtl
I ,ITwHr^rJl
I
c 13 t
c117
lB18C1engine)
l]l
E:I
ffi
FFIN
fi'Twtl-rirllrlerrrltlerl-l
- lll
fr-Twrr
I@ LWHTTREO I
ohN/BLK
|/BL!
ALU/YEL
NOTE: a Different wires with the same color have been given a number suffix to distinguishthem (for example,
YEL/BLK1and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSystem.
a - Connectorof male terminals:View from terminalside
(cont'd)
- Connectorof temaleterminals:View from wire side
11-21
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System Description
SystemConnectors[EngineCompartment](cont'd)
c 120
{81881sngino}
(B18Cl onginol
11-22
vnx.su
cl16
FI
c117
lBl88l 6nginol
EI
/
\2
|@|iaf,-'6trlaltrlaru----1
toltEUB'.f----
c121
fr
|6-I!EUBLK
lO lhEo'
c122
ffi
ct 20
l8lSBt.nglnrl
ET
c119
RP
--'l
I
(Bl8Cl .ngln l
F,-f.
\?
16lwHiffiN----f
l@lwHrnco' I
| 3 l a L & Y E r --- I
frlwHrEru
l6TciN-6LU----loliEo/YEi----.
c 123
24
ffi
ffi
---------l
l6'lau,-r,
IO IYEL/8LX
cr20
l6-ltR,iEit---l@ IiEp/YcL
cr33
.2
--.-.1I
|o lhEo/8llJ
I-T-
c3t I
ct 34
,8.
\^y
tsF
f6-IPilK/BLu---l
I
IO IYEUBL(
NOTE: a Different wires with the same color have been given a numbe. suffix to distinguish them (for example
YEL/BLK1and YEL/BLK,are not the same).
O: Related to Fuel and EmissionsSystem.
a - Connector of male terminals: View from terminal sid6
- Connectorof female terminals:Viow from wire side
11-23
vnx.su
System Description
System Connectors [Dash and Floor]
ENGINE
COMPARTMENT
WIRE
PGM-FIMAIN
RELAY
DASHBOAROWIRE
HARNESS
REAR
WIRE
HARNESS
MAIN
WIRE
HARI{ESS
C1I44
UNDEN-OASH
FUSE/REALY
BOX
11-24
vnx.su
c4't9
2 3 4 5
7 8
e nc
t6| -
a ALUfYEL
YEL'
c431
lwlth
cruit
coniroll
c431
(wlthout
crui!a
control)
c423
|' l r l
-t
t t I
5
6
----'l
l6'TwHr/cnN----l
1ol cRN^vHr
BLU/YEL
lslnl
t3
12
13
1a
20
c432
c439
ffi
rfltrrn
c44il
riTLF-I
I'VCT,1
lETWrr;eo---f
-frlwHr.
l3l8rK
I t lBLx,REo
t 5
I 6 G R N / B L X-f?-TFEpcFN
ffi
14l51617l
YEL/BLK'
Ht/alu
I
I
|
I
iEO/YIL
15
16
't7
lO lGRt/8LU
ktlBrKr--
I o lYcL/Gnir
lao laLx./YEL
I "] IYEUBL(
ktlterwirr
a
BL&"/EL
YEL
Titfgruffir-----l
---
I
I
I
20
c444
ffir
trtr]
I6TLK^//Hr
L' l!!g!!r
-l
l
l o l s L k r F E D l]l I
|;TBLU'BLi
NOTE: a Ditterent wires with the same color have been given a number suttix to distinguishthem (fot example
YEL/BLKrand YEL/BLK,are not the samel.
O: Relatedto Fuel and EmissionsSystem.
a - Connectorof male terminals:View from terminalside
(cont'd)
- Connectorof femaleterminals:View from wire side
11-25
vnx.su
System Description
System Connectors [Dash and Floor] {cont'd}
DASHBOARD
HARNESS
UNDER-DASH
FUSE/RELAY
BOX
MAIN
WIRE
HARNESS
11-26
vnx.su
1 2 3
gL&YEL
BLK/YEL
BLK
GFN,YEL
5
2
GFN
YEL
15
LT GRII/SL(
6 7
REO/6LU
12
r0l1 11121131
114115116
8RN/8LK
3 BLU
9
12 BLUf/L
GRN/BLII
YEL/RED
13
YEL
YEL/6LK
16
BLU
t6
a DiJterentwires with the same color have been given a number sutfix to distinguishthem (for example
YEL/BLK1and YEL/BLK'are not the same).
O: Relatedto Fuel and EmissionsSystem.
a - Connectorot male terminals:View from terminalside
- Connectorof female terminals:View from wire side
{cont'd)
11-27
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System Description
SystemConnectors[Dashand Floorl (cont'd)
c/ro5
SERVICE
CHECK
CONI{ECTOR
11-28
vnx.su
c405
c406
fr
c410 tEGM-Al
r'tr--Jl
-----l
I6TBRN/B,L(-__-l
l, lwHr/uED l_l
l6TLr BN---
ffi
tt4
YEL'
| (jt
ALK/AED
1a
SLU
ALK
t(9
YEL
| 0o)
GRN/oRr
ALK'
ALK'
YEL/BLK
BLK
l@
c408 {ECM-Bl
3
2 4
9 1 t3tl5
8 1C l 2 4
BLK
2
YEL
I
ALU/REO
ALU/YEL
a Different wires with the same color have been given a number suffix to distinguishthem (for example
YEL/BLK1and YEL/BLK,are not the same).
O: Relatedto Fuel and EmissionsSystem.
a - Connectorof male terminals:View from terminalside
Connectorof femaleterminals:View from wire side
11-29
vnx.su
System Description
SystemConnectors[FuelPumpl
REARWIRE
HAFNESS
11-30
vnx.su
c510
NOTE: a Ditferent wiros with tho samo color hava been given a numbr sutfix to distinguish them {for example
YEL/BLKI and YEL/BLK, are not th same).
O: Rlated to Fuel and EmissionsSystom.
a - Connoctor ol malo tarminals: Vi6w from terminal side
- Connector ol f6msl tarminals: Viw from wire sid
11-31
vnx.su
Troubleshooting
TroubleshootingGuide
NOTE: Across each row in the chart. the systems that could be sourcesof a symptom are ranked in the order they should
be inspectedstaning with O. Find the symptom in the left column, read acrossto the most likely source.then refer
to the pagelistedat the top of that column.lf inspectionshows the systemis OK, try the next mosr likelysystemO, etc,
PGM.FI
TOPDEADCINTTR/ ENGINE
INfAKE AIR BARO.
MANIFOLO
ENGINE HEATEO
IGNITION vEHtct-E
CRANKSHAFT COOLANT THROTTTE
TEMPRA. METRIC
AESOLUTE
OUTPUT SPfED
POSTT|ON/ TEMPfRA. POStTtON
CONTROL OXYGEN
TURE PRESSURE
PRESSURE
TURT
CYLINDER
MOOULE S E N S O R
SENSOR sar,rs0RSENSOR SIGNAL SENSOR
SENSOR
POSITION
SENSOR SENSOR
11.42
SYMPTOM
MALFUNCTION
INOICATOR 1 l o r : t : ] :
L A M P( M I U " T U R N O
SN
4 6 ,4 7 , 5 0
lrmr:
-D:o.:@.
MALFUNCTION
INOICATOR
:O. or-8.
L A M P( M I L ) ' ' B L I N K S
o, O'
ENGINEWON'T STAffT
DIFFICULT
TO START
ENGIN
WHENCOLO
WHENCOTD
FASTIDLE
16l-
i;:i'
-tK3t-
l 3 l
/__-\
(9)
RPMTOO
LOW
WHILE
AFTER
FREOUENT
STALLING
MISFIREOR
ROUGH
RUNNING
POOn
PERFOEM. FAITS
EMISSION
ANCE
TEST
Loss0F
-r:+r-
-{"Pr:
\ --l-l
-l
r 0I
| t - /----\
/__-\
7
11-64
1t-66
-o_ -16l-.
z-\
1r-68
r6t
/_-\
\.--r--l
| 1 3|
z_---\
r5 -t
I t - /-]-\1 7t /.---\
o
@
@
@
POWER
-16l
/-----\
11-62
RPMTOO
HIGH
16l
' - \
1l-60
ROUGHIDLE
l1-58
ouT0f sPtc
IRREGULAR
IDLING
11-56
lf codes other then those listedabove are indicated,count the numberof blinksagain.It the MIL is in fact blinking
^ these codes, replacethe ECM.
qy, lf the MIL is on while the engineis running.connectthe SCS shon connectorto the servicecheck connector.It no
code is displayed{MlL stays on steady),the back-upsystem is in operation.
Substitutea known-goodECM and recheck.lf the indicationgoes away, replacethe originalECM.
USA:
MALFUNCTION
INDICATOR
LAMP {MIL)
CANADA:
CHECK
\ ----l
-ltGl-
ENGTNE
{ -1t-
LTGHT
* * *: 818C1engine
1-32
vnx.su
I O L EC O N T R O L
PGM-FI
VARIAEIEVALVEVARIABLEVALVE
TIMINC& VALVE TIMING& VATVE
ELECTRICALLIFTELECTRONIC
I-IFTILECTRONIC KNOCK
LOAO
stNsoR
cottTR0t
coNTRO|DETECTOR
PffESSURE
SOLENOID
s38
| 1"70
E
\.-r-l
-t l0 t---i-\
r6t-
- ---
t 2 tI
/ --i-\
--\-!-/
l 2j--\2 l
/--
11.74
-16l/-----..
IOLEAIR
OTHER
OTHER
FUEL
FUEL
IOLE
INJECTOR
SUPPTY
CONTROLS
FI
SIGNAL
FI
SIGNAT
c0NTR0r-
r 1-76
t 1-76
11-82
fl
\.--r-z
FUELSUPPLY
11-78
-o_
| 1-102
r 1-97
INTAKE
AIR
t 1 - 11 5
MtsstoN
CONTROLS
l l 129
,.''\
\.---l
30
t 3 rt - /----\
[|t 2 3l - -t
,--T-\ l- /-.--\
/--.i-\
I 1 6t\ -
/ _-i-
@
@
o
o
o
a,
Q)
@
@
o
(JJ
11-3
vnx.su
Troubleshooting
Procedures
Self-diagnostic
When the MalfunctionIndicatorLamp {MlL) has been reportedon, do the following:
'1.
Connect the SCS short connecto. to Service Check Connector as shown. (The 2P Service Check Connector is
locatedunder the dash on the passengerside of the car.) Turn the ignitionswitch on.
DATA LII{K
(3PI
CONNECTOR
NOTE:
Do not attach
jumperwire.
2. Note the DiagnosticTroubleCode (DTC):The MIL indicatesI code by the length8nd numbsrot blinks.The MIL
can indicatemultiplecomponentproblemsby blinkingseparatecodes,one after another.Codes 1 through Igre
indicatedby individualshon blinks.Codes 1Othrough 43 are indicatedby a seriesof long and shon blinks.Th
numberof long blinksequalsthe first digit, the numberot short blinks equalsthe seconddigit. Sometimesthe
firsr blink is difficult to see; always count the blinks at least twice to verify the code.
MALFUNCTIOI{
INDICATOR
LAMP
IMIL}
CANADA:
CHECK
ENGINE
LIGHT
Sgprrate Prcbaomr:
shT
-n-----n-=n+!+1].TL;I!!=-L
'"
,JU
Long .hon
"
"
= s.o DTc1
= s.. Drc 3
= Sce DTC 13
Multiplr Probl.ln.:
= S. DTC 1 lnd 3
J-l_tx-TL-n-ffu-r-J.rrU-L-r]tltlr'l- __-tnrua = Sce DTC 3 and 4
Jll-lrl-t-----Tt/'tnj]_
= S.. DTC 3 lnd 14
11-34
vnx.su
UNDER-HOOO
FUSE/RELAY
BOX
11-35
vnx.su
Troubleshooting
Self-diagnosticProcedures(cont'dl
DIAGNOSTIC
TROUBLE
CODE(DTCI
SYSTEMINDICATED
Psge
ENGINE
C O N T R O LM O D U L EI E C M )
11-42
,l
H E A T E DO X Y G E NS E N S O RI H O 2 5 )
11 - 4 6
MANIFOLDABSOLUTEPRESSURE
{MAP SENSOR)
CRANKSHAFTPOSITION(CKPSENSOR)
11-52
4
o
(ECTSENSOR)
ENGINE
TEMPERATURE
COOLANT
11-58
11-60
THROTTLEPOSITION(TP SENSOR}
11 - 5 6
11 - 5 6
10
(IAT SENSOR)
INTAKEAIR TEMPERATURE
11-62
13
(BAROSENSOR}
BAROMETRIC
PRESSURE
1|-64
14
11-42
t c
IGNITIONOUTPUTSIGNAL
to
FUELINJECTOR
17
VEHICLESPEEDSENSOR{VSSI
20
ELECTRICAT
LOAD DETECTOR(ELD)
21
6-36
22
6-38
23
K N O C KS E N S O R{ K S } -
1 1 - 74
30
A/T FI SIGNALA
11-76
3'r
A/T FI SIGNALB
11 - 7 6
4'l
HEATEDOXYGENSENSOR(HO25} HEATER
11-47
43
FUELSUPPLY
SYSTEM
11 - 5 6
11-66
1't-102
11-68
't 1-70
11 - 5 0
':818C1 engine
a lf codes other than those listed above are indicated, verifv the code. lf the code indicated is not listed above, replace
rhe ECM.
a The MIL may come on, indicatinga systemproblemwhen, in fact, there is a poor or intermittentelectricalconnection.
First, check the electricalconnections,clean or repairconnectionsit necessary.
o The MIL and @ indicatorlight may light simultaneously
when the DiagnosticTroubleCode (DTC)6, 7 or 17. Check
the PGM-Flsystem according to the PGM-Flsystem troubleshooting, then recheck the l!! indicator light. ll it lights,
s e e p a g e 1 4 - 5 O ,5 1 .
a The MIL does not come on when there is a malfunctionin the A/T Fl signalor ElectricalLoadDetector(ELDIcircuits.
However, it will indicate the codes when the Service Check Connector is shorted.
11-36
vnx.su
It the inspectionfor a particularcode requiresthe test harness.removethe right door sill moldingand kick panel. Pull
the carpet back to exposethe ECM, Unbottthe ECM cover. Turn the ignitionswitch off and connectthe test harness
Check the system accordingto the proceduredescribedfor the appropriatecode(s)listed on the following pages.
KICK
PANEL
TEST
HARNESS
OTLAJ_PT3OlOA
DIGITAL MULTIMETER
Commarciallyovribbla or
KS-AHM-32-OO3
NOT USED
o oooooooooooo oooooooo
ooooooooooooo oooooooo
TERMINAL LOCATIONS
ooooooooooo
ooooooooooo
(cont'd)
11-37
vnx.su
Troubleshooting
Self-diagnosticProcedures(cont'dl
a Punctudng th6 inruLtion on r wirc cln cruaa poo? or Int!finltttri
aLctrlcC connac,tlom.
a For tosting at connoctofs othor thsn tho taat hrmara, bdng thc tartar probc Into contact whh tha tarnilnal trom thr
connector ride of wilo hamclr conn.ctora In thc cnglnc comprnrnam. Foi t.|nab connactorr,lurt touch llgl ly whh
tha tostor probo and do not Inlcrt tho prcbc.
TES'EB PNOBE
TERflt]IAI
11-38
vnx.su
How to ReadFlowcharts
A flowchrrt is dasignedto be usd fiom start to final repair. lt's like a map showing you the shortest distanco. But be"map" anywhere but a "stop" symbol, you can easily get lost
ware: if you go off tho
l6rffil
(bold tyDo)
|TeTiONl
<:6Eei6io-fr\>
Asks you about the result of an action, then sends you in the appropriste troubleshooting direction.
I-SJTFI
(bold typel
The snd of a series ot actions and decisions, describes I tinal repair action and aomotimea diracts
you to 8n garlier part of the tlowchart to confirm your repair'
NOTE:
a Tha tarm ,,lntormittgnt Failure" is used in these chans. lt simply means a system may have had a failur6, but it chocks
out OK !t this time. lf th6 Msltunction Indicator Lamp (MlL) on ihe dash does not come on, check for poor connections
or loose wires at all connectors rolated to the cilcuit that you are troubleshooting (see illustration b6low).
a Most ot tho troublashootingflowchans have you reset the EngineControl Module (ECM)and try to duplicate the Disgnostic Troubls Cod6 (DTC). lf the problem is intermittent and you c8n't duplicat the cod6, do not continus through
the flowchart, To do so will only rosult in confusion and, possibly, a nedlessly replaced ECM
a ,,opon,'and ,,short,, are common electricalterms. An open is a break in a wir6 or at a connction.A short is an
accidontalconnaction ot a wir to ground or to another wire. In simple electronics,this usually means somthingwon't
work at all. In complex electronics (like ECM's), this can sometimes mean something wolks, but not the way it's suppoSadto,
a il th6 olectricsl readingsare not as specified when using the test harness, check the test harnessconnoctions bsfore
procooding.
LOOSE
11-39
vnx.su
PGM-FISystem
System Description
ENGINECONTROLMODULE(ECMI
TDC/CKP/CYP
Sensor
MAP Senso.
ECT Sensor
IAT Sensor
TP Sensor
HO2S
vss
BAROSensor
ELD
Starter Signal
ALT FR Signal
Air ConditioningSignal
A/T Gear Position Signal
BatteryVoltage{lcN. 1)
BrakeSwitch Signal
PSPSwitch Signal
Knock Sensor'
VTEC PressureSwitchr
lFuettnjectorTimingandDuration]
I Electr..l"ldle Contr;il
Fit'e' contr; Funcrfit
OUTPUTS
Fuel-lnjectors
PGM-FIMain Relay(FuelPump)
MIL
IAC Valve
A/C CompressorClutch Relay
Radiator Fan Relav
CondenserFan Relav
ALT
rcM
EVAP PurgeControlSolenoid
l6tio;
Ttntrlg c..trol
tEcM aack-,rpFunctiorlsl
HO2S Heater
VTEC SolenoidValve'
IAB Control Solenoid Valve*
PGM-Fl System
The PGM-Flsystem on this model is a sequentialmultipon fuel injectionsystem,
Fuol Iniector Timing and Duration
The ECM containsmemoriestor the basic dischargedurationsat variousenginespeedsand manifoldpressures.The
basicdischargeduration,after beingreadout from the memory,is turther modiliedby signalssent from vanoussensofs
to obtain the final dischargeduration.
ldle Air Control
ldle Air ControlValve (lAC Vatve)
When the engineis cold, the A/C compressoris on, the transmissionis in gear (A/T only) the brakepedalis depressed,
the P/Sloadis high,or the alternaloris charging,the ECMcontrolscurrentto the IAC Valveto maintaincorrectidlesoeed.
lgnition Timing Control
a The ECMcontainsmamoriesfor basicignitiontiming at variousenginespeedsand manifoldpressures.lgnitiontiming
is also adjustedfor enginecoolanttemperature.
a A KnockControlSystemis alsoused.when detonationis detectedby the knocksensof.the ignitiontiming is retarded
(B18Cl engine).
Other Control Functions
1. StartingControl
When the engineis started.the ECM providesa rich mixture by increasingfuel injectorduration.
2. Fuel Pump Control
a When the ignitionswitch is initiallyturned on, the ECM suppliesgroundto the PGM-Flmain relaythat supplies
currentto the fuel pump tor two secondsto pressurizethe tuel system.
a When the engineis running,the ECMsuppliesgfound to the PGM-Flmain relaythat suppliescurrentto the fuel pump.
a When the engineis not runningand the ignitionis on, the ECMcuts groundto the PGM-FImain relavwhich cuts
current to the fuel pump.
11-40
vnx.su
3.
4.
FunctionIMaltunctionIndicatorLamp {MlL)1
Self-diagnosis
Wh6n an abnormalityoccurs in a signalfrom a sensor,the ECM suppliesground for the MIL and stores the code
in erasablememory.When the ignitionis initiallyturned on, the ECM suppliesgroundtor the MIL tor two seconds
to check the MIL bulb condition.
4.
11-41
vnx.su
PGM-FISystem
EngineControlModule(ECM)
The Malfunction Indicator Lamp
(MlL) n6v6. com6s on lovon fol
lwo socondal aftor ignition is
tumed on.
InspectNo. 15 {BACK-UP
LIGHT}
l1O A) luse in the underdash
tuse/relay box.
I
Turn the ignitionswitch ON.
l s t h e M I Lo n ?
A13
I| | o o o o o o o o o o o o o I o o o o o o o o I o o o o o o l o o o o o o o o o o o I
- RsDlacotho MIL bulb.
- Ropairopon in GRN/ORNwi.e
betwoen ECM {A13} and
gaug a$6mbly.
lB18B1 onginoonlyl
Measure voltage between body
Oroundand the tollowingterminafs individuallv:423, 424.
11-42
vnx.su
G 10'l
NOTE:
a Whenthere is no code stored,the MIL willstay on if the servicecheckconnector is shorted.
a tf this svmotom is intermittent,check for:
- A loose ECM fuse (15A) in the under-hoodtuse/relaybox
- A looseNo. 24 fuse (ACG)(ALT)( 1 5A: B18B1 engine,2OA: B18C1 engine) in the under-dashfuse/relaybox
- An intermittentshort in the BRN/WHTwire betweenthe ECM (D4) and
the servicecheck connector
- An intermittentoDenin the BLK wire betweenthe servicecheck connector and G4O1
- An intermittentshon in the GRN/ORNwire betweenthe ECM(A 13) and
the gauge assembly.
- An intermittentshort in the YELMHT wire betweenthe ECM (D19)and
the MAP sensor
- An intermittentshort in the YEL/BLUwire betweenthe ECM (D20) and
the TP sensor
Go to iolfdiagnostic Proceduros
(se pago 11-34).
o o o o o o o o o o o o o l o o o o o o o o l i i i : $ A $ . P s ,ol o o o o o o o o o o
oooooooooo
ooooooooooooo I oooooooo
D22 t-l
D 4( + )
Turn the ignition switch OFF.
l"oo,o'.
uu,l
InsDoctECU{ECM)115A) tuse in
th6 undeFhood luse/relav box.
- R6pairopen in BRN/WHTwito
botwoon EcM lD4) and s6rvice chock connactor.
- Repoir opon in BLK wiro botwoon 36rvi@ chock connectoa
and G4Ol.
ls thereapprox.5 V?
- Rsolaco
ECU{ECM}(15 Allus.
- R6pairshon in YEL/WHT wilo
botw6on ECU lEcMl 115 A)
fuso and PGM-FI main rolay.
(cont'd)
lTo page 1 1-44)
11-43
vnx.su
PGM-FISystem
EngineControl Module (ECMI (cont'dl
(Frompage 11-43)
(Frompage 1 1-43)
Dt9
I
I o o o o o o o o o oo o o I o o o o o o o o I o m o o o l o o o o o o o o o o o |
I o o o o o o o o o o o o o I o o o o o o o o 1 o ( ' o e ( l oI o o o o o o o o o o o |
-
|
|
D2O
\-.J
Continuity?
{ T o p a g e1 1 - 4 5 }
11-44
vnx.su
(Frompage 1l-44)
BATTERY
VOLTAGET
ooooooooooo
ooooooooooo
oooooooo
ooooooo
ooooooooooo
ooooooooooo
Lssthan 1.0 V?
11-45
vnx.su
PGM-FISystem
HeatedOxygenSensorlHO2Sl
-fi-l:
-t6l--.:
\ /?\
The Malfunction Indicator Lamp (MlL) indicates Diagnostic Troubls Code (DTC) 1: A problsm in
the HeatedOxygen Sonsor(HO2S| circuit.
The Heated Oxygen Sensor IHO2S) detcts th6 oxygon contont in th6 exhaust gas and signals th6 ECM. In operation,
the ECM receivs th6 signals trom the sensor and varis the duration during which tu6l is iniocted. To stabilize thd senaor's output, tho sensor has 8n intarnal heater and the sensor olemant is coatod with a catslyst. The HO2S is installod
in TWC housing(B18Cl engine)or exhaustpipe B (Bl8Bl ngine).
sEl{SOR
TERMII{ALS
sTotcHtoltETnc
ztRcot{lA
VOLTAGE(V}
AIR-FUEL
BANO
ELEiIE'{T
HEATER
- --.'!-
-__-
l r P l _ l! l -
HEATEB
TEBMIT{ALS
1 1 -4 6
vnx.su
- LEAI{
RICH - AN.
FUEL
RATIO
mll
Y-
-.----r-
Diagnostic
TroubleCode(DTCI41: A problemin
Lamp(MlL)indicates
Indicator
TheMalfunction
the HeatedOxygenSensor{HO2S)Heatercircuit.
)ffltl
-:-
\-
l-l
-t
tt(gt- r - - - 7 r tt I
- Th6 MIL has boenroponod on.
- With the SCS rhort connocto. connociod (aoe pago
11-341. codo 41 is indic.tod.
trminal side
ls thero 1O-4O 0?
DIGITALMULTIMETEB
Commorciallyavailabloor
KS-AHM-32-OO3
(cont'd)
(To page 1 1-481
vnx.su
PGM-FISystem
HeatedOxygenSensorHeater(cont'd)
11-471
YEL/BLK
I+I
(-I
ORI{/BLK
wire side
HO2S
44 N.m
{4.5 kgt.m, 33 lbf.ft}
YES
connector
{ T o p a g e1 1 - 4 9 )
{ T o p a g e1 1 - 4 9 }
11-48
vnx.su
"A"
Connect the test harness
connector to the main wire har
ness only, not the ECM (seepage
11 - 3 7 1 .
BATTERY o o o o o o o o o o o o o I o o o o o o o o
VOLTAGE?o o Q o o o o o o o o o o I o o o o o o o o
L-E;
ooooooooooo
ooooooooooo
11-49
vnx.su
PGM-FISystem
Fuel Supply System
rj-t
-
T,-n
- L:!-i -
-+-
1 3|
l- t @"-t - -- t--i-'
(|ec
NOTE:
. UseDIGITAL
MULTIMETER.
. U6e2 Volt rang6.
o oooooo oooooo I oo oooooo
ooQooooo ooooo I oooo oooo
426
ooooooooooo
ooooooooooo
JUMPERWIRE
With the ignitionswitch OFF,wait
for at least two minutes.
lnstalla jumper wire on the test
harnessbetween A6 and A26.
1Topage 1 1-5'll
11-50
vnx.su
D 1 4{ + l
{Frompage I 1-5O)
Subdlht.
. known{ood ECM
.nd r..firck. ll rymptom/indic!tion goaa !w!y, .aphca rha otiglnll ECM.
(+)
WHT/RED
(-I
GRI{/BLU
wire side
DIGITALMULIIMETER
avallabloo.
Commarcially
KS-AHM-32-OO3
HO25
44 N.m (4.5 kgl.m, 33 lbf.ftl
11 - 5 1
vnx.su
PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor
fxai
-:-
- lfil1
-?-
OUTPUT
VOLTAGE
1.5
600 700
YEL/REDlBlSBl onginc)
YEL^YHTlBlaCl .ngin.l | + I
{+l
Disconnectthe 3P connectortrom
the MAP sensor,
{ T o p a g e1 1 - 5 3 )
1 1 -5 2
vnx.su
11,52)
ls there approx. 5 V?
ls there approx. 5 V?
(cont'd)
{ T o p a g e1 1 - 5 4 }
vnx.su
PGM-FISystem
ManifoldAbsolutePressure{MAPISensor(cont'd)
l F r o mp a g e1 1 - 5 3 )
(Frompaqe 1 1-53)
ls there approx.3 V?
approx.3 v?
D 1 7t i l D 2 1( - l
ooooooooooooo
I oooooooo l
o oooooooooooo ! oooooooo
ls there approx. 5 V?
l 5 o i E t d lo o o o o o o
ooooooooooo
NO
Substitute a known{ood ECM
and rochsck. It prdcribed voltrgo
b now availablo, rophce trie original ECM.
11-54
vnx.su
'
'
PGM-FISystem
TDC/CKP/CYP
Sensor
_f'=l_
t:l'6]-i-flG]l, -
fi_l
ftl
ft-]
The CKP Sensordeterminestiming tor fuel injectionand ignitionof each cylinderand also detects enginespeed.The
TDC Sensordeterminesignitiontiming at start-up(cranking)and when crank angleis abnormal.The CYPSensordetects
the positionof No. 1 cylindertor sequentialfudl injectionto each cylinder.
\.--r-l
-__l_-
tPJ:;LlJ:lEl--;?
l ,:
- Tho MIL hos beonroponod on.
- With rho SCS short connoctor
conneclod lsso pago I l-341,
code 4, 8 and/or 9 ar6 indicated.
Disconnectthe 8P connectorfrom
the TDC/CKP/CYP
sensor.
11-56
vnx.su
{ F r o mp a g e 1 1 - 5 6 )
SEIiSOF
TDC
ls there 35O-7O0 0?
DTC
SENSOR
ECM
TENMINAI
COLOR
815
ATU/GFN
816
BTUTVEI
813
ORN/BTU
a
9
814
B1t
ORN
s12
350-7000?
ls there 350
70O 0?
812
ls there continuity?
NO
11-57
vnx.su
PGM-FISystem
Engine Coolant Temperature(ECT) Sensor
- ,-!-t@l-
\ ---1- -l 6
| - The MalfunctionIndicatorLamp (MlL) indicatesDiagnosticTroubleCode (DTC)6: A problemin
the EngineCoolantTemperature(ECT)Sensorcircuit.
The ECT Sensoris a temperaturedependantresistor(thermistor).The resistanceoI the thermistordecreasesas th engine coolant tempe.atureincreasesas shown below.
RESISTANCE
{k0l
JrsG-11
\
- -\.--r-l
t 5|
/--i\
j 3 2 6 8 l O r rl a 0 t 7 6 2 t 2 2 a 8( . F l
-2tt 0 20 rto ao D r@ t20 (,cl
ENGII{ECOOLAI{TTCMPERATURE
- Th MIL has boon roDortodon.
- Wlth tho SCS shon connoctor
connoctod {s66 pag6 '11-34},
code 6 is indicatod.
Disconnectthe 2P conneclorlrom
the ECT sensor.
ls there 2OO-4OOO?
11-58
vnx.su
--
ECT SENSOR
ls there approx. 5 V?
A/T only
Sub3tituto a known-good CM
and rochock. lf 3ymptom/indication go6s away, roplacothe odginal ECM.
ls there approx. 5 V7
_i
Connect the test harnss "D"
connectorto the ECMonly. not to
the main wire harness {see page
11-37).
ls the.e approx. 5 V?
11-59
vnx.su
PGM-FISystem
ThrottlePosition(TPl Sensor
.:-\.----ll@l--l
BBUSH
HOLDER
OUTPUTVOLTAGEIV)
BNUSH
I
a
t
RESISTOF
t
I
o.|
o
IXNOTTII
;0rr- of no
TERMIIIAL
THNOTTIE
)ran1 )ril
-Y-
-?..
RED/BLK
{-I
Disconnecttho 3P connectorlrom
th TP sensor.
YEL/aLUl+l
cnn/BLuI - l
ls there approx. 5 V?
11-60
vnx.su
,,,----
TP SEITSOR
(From
1 1-60)
ls there approx. 5 V ?
Measure
voltagebetweenD11 {+ )
terminaland 022 (- I terminal.
Fr.
o.5 v n tua .b
drdn
A/T only
Turn the ignitionswitch OFF.
ls voltageapprox.O.5 V at lull
close throtlle. and approx. 4 v
at full open throttle?
NOTE:Thereshouldbe a
smooth transition as the throttle is depressed.
ls voltageapprox.0.5 V ar full
close throttle, and approx. 4 V
at tull open throttle?
NOTE:There shouldbe a
smooth transition as the throt'
tle is deprossod.
Replaco tho TP
aonsoa,
Repai. opon or ahon
in RED/BLKwir. btwoon ECM lDl1l,
TCM 6nd TP sonsor.
11-61
vnx.su
PGM-FISystem
IntakeAir Temperature(lAT) Sensor
\ ----:--
\ ---L
THERMISTOR
)1611:till
---l---i-\
/
Bl8Bl onglnc:
wi.a sido
Meosu.eresistonc
betweenthe
2 torminalson the IAT aengor.
11-62
vnx.su
IAT SEI{SOR
{Frompag6 l1-62}
ls thore approx. 5 V ?
ECM
Sub.lhul. a tnown{ood
lnd rachack. It rymptom/lndlc!don gort arv.y, t pl.c. dr! oilgln.l ECM.
ls thre spprox. 5 V ?
ECM
S0brlitrrt. . lnown{ood
'|d '.<hoc-l, tl p.slcribad voltlec
ta now lvarlblc, rlplaca tha original ECM.
11 - 6 3
vnx.su
PGM-FISystem
BarometricPressure(BAROISensor
fAl-
f;ff:
L--:g
-.+.-- \--r- /
t ( g t - t 1 3t '
11 -6 4
vnx.su
PGM-FISystem
lgnition Output Signal
i16;11
'--=--
:ffi1
. -r-
D|STNIBUTOB
wir6 sido
11-66
vnx.su
TTERYVOLTAGE4
421 (+l
Connoct th toat hamess bgtwe,sn
the ECM and connctors {see
pago 11-371.
ooooooooooooo
oooooooooooo
R.pl.c.
th! lC
(trr..ctlo[
23t.
11-67
vnx.su
PGM-FISystem
Vehicle Speed Sensor (VSS)
- _-_f_-.,
It6l-
\-=1_
The VSS generates a pulsing signal when the front wheels turn.
@4""r
Sub|tllul. ! knosn{ood
ECM
lnd r!ch.ck. lt .Vmgiom/lndlc.tlon g@.. .w.y, r.pLca di. orlgln.l ECM.
a 2 5{ - t
atol+l
0- 10V ?
NOTE:Transmission
in llj positionlA/Tl.
11-68
vnx.su
(Frompage 1 1-68)
'tov?
11 - 6 9
vnx.su
PGM-FISystem
ElectricalLoad Detector (ELDI
tft;-]/
-Li!-
The Maltunction Indicaror Lamp (MlL) indicatss Diagnostic Trouble Code IDTC) 20: A probtem in
tne ElectricalLoad Detecror{ELD}circuit.
lntennlna
tlllure, lyrtom lt Ol(
!t irl. dm. (lgtt driv. mly bo
na@raaryl.
Chrck for Door connactlona oa
loota wiro. rt C218 IELD, lnd
Ectrt.
View trom
wire side
B L K( - )
Romove the undgr-hood fusg/
relay box and remove the tus6/
relav box lowet cover.
GRn/iEDI - |
BLK/YELI + I
( T o p a g e1 1 - 7 ' l )
11-7 0
vnx.su
(Frompog6 1 1-7Ol
13the.e approx, 5 V?
wire side
B L K{ _ I
GR /NEDI-I
Turn tho ignition switch OFF.
BLKIEL { + }
11-71
vnx.su
PGM-FISystem
ElectricalLoad Detector (ELD) (cont'd)
While measuringvoltagebetween
D l O 1 + ) t e r m i n a al n d 4 2 6 l - )
terminal,turn the headlighrswitch
to the secondposition(a) {low).
425t-t
,
11-7 2
vnx.su
D 1 0l + )
DoosVolrago Orop?----------------J
PGM-FISystem
Knock Sensor(KS) tB18C1 enginel
ml-
nl:
The Malfunction
IndicatorLamp(MlL)indicatesDiagnostic
TroubteCode(DTC)23: A probtemin
the KnockSensor(KS)circuit.
a6l--fzt
.i--1/.---r+\
( T op a g e1 1 - 7 5 )
11-7 4
vnx.su
(Frompage 1 1-74)
KS
32 N.m (3.2
wire side
11-75
vnx.su
PGM-FISystem
A/T Fl Signal A/B (A/T only)
\[l0l-L=\
tItil-Li!-
\.__r_/
\.__r_/
Oo ths ECMResotProceduro{see
pag 'l 1-35).
ulty?
Continuity?
( T op a g e1 1 - 7 7 )
11-7 6
vnx.su
(Frompage 1 'l-76)
11-77
vnx.su
PAGE
11-95
SYMPTOM
11-42
11-84
11 - 8 6
11-88
DIFFICULTTO START
ENGINEWHEN COLD
WHEN COLD FAST IDLE OUT OF
SPECl1,0OO- 2,0OO rpm|
11-90
11-92
I 1-93
ROUGH IDLE
TOOLOW
WHEN
o
o
o
WHILE WARMING UP
AFTERWARMING UP
FREOUENT
STALLING
FAILS EMISSIONTEST
1 1 -7 8
11-94
vnx.su
SystemDescription
The idle speed ot lhe engineis controlledby the ldle Air Control {lAC) Valve.
The valve changes the amount ot air bypassing into the intake manifold in responseto electric current controlled by the
ECM. When the IAC Valve is activated,the valve opens to maintainthe proper idle speed.
#l' ----r
To FGM-FI
MAIN
RELAY
VARIOUS
SENSORS
FAST
IDLE
THERMO
VALVE
IAC VALVE
BLK
INTAKE MAI{IFOLD
(cont'd)
11-79
vnx.su
Atter the engineslarts.the IAC valveopensfor a censin time, The amountot air is increasedto raisethe idle soeed
about 15O-3OO rom.
2.
When the coolanttemperatureis low, the IAC valve is openedto obtain the properfast idle speed.The amount of
bypassedair is thus controlledin relationto the enginecoolanttemperature.
IDI-ESPEED
lrpm)
176
80
11-80
vnx.su
ENGINE
COOLANTTEMPERATURE
t"Fl
(oct
1. when the idls speedis out of specificationand the MalfunctionIndicatorLamp(MlLldoesnot blink DiagnosticTrouble Code (DTC) 14, check the tollowing items:
. Adiust the idle speed {see page I1-95)
. Air conditioningsignal (see page l1-84)
. ALT FR signal (seepage '11-86)
A/T gea, positionsignal(see page 11-88)
Erakeswitch signal (see page 1 1-90)
Starter switch signal(see page 1l-921
PSPswitch signal(see page 1 1-93)
Fast idl6 thormo valve (see page l1-94)
Hoses and connsctions
IAC valve and its mountingO-rings
2.
lf the above items are normal,substitutea known-goodIAC vslv and readjustthe idle speed (see page 11-95)'
. It the idle speed srill cannot be adjusted to speciJication(and the MIL does not blink code 14) after IAC valve
roplacement, substitute a known-good ECM and recheck. It symptom goes away, replsce the original ECM.
11 - 8 1
vnx.su
ffi:| \ r;611
/--T-\
-
Do the ECMResetProcedure(see
p a g e1 1 - 3 5 ) .
Disconnectthe 2P connectorfrom
the IAC valve.
Sub.iituto . known{ood
vdva lnd iotolt.
{ T o p a g e1 1 - 8 3 }
11-82
vnx.su
IAC
BLK/BLU{ _ }
Momentarilyconnect Ag torminal
to 423 terminol seveaaltims.
JUMPERWIRE
A9 l+)
A23{-l
1 1-83
vnx.su
.pprox. 5 V?
426 (- )
Measurevoltagebetween851+ )
lerminaland A26 l- I terrninal.
ls there approx. 5 V?
Sub.litut ! known{ood CM
rnd r6<tEck. ll p.lrcib.d vottrgo
i! now avalhbla, iaplaco tho o,igin.l ECM.
ooooooooooooo oooooooo
oooooooooooo oooooooo
ooooooooooo
ooooooooooo
lTo page
11-84
vnx.su
(Frompage 11-84)
I|
Measurevoltage between 85 {+ )
terminaland A26 (-) terminal.
ls voltagelessthan 1.O V?
Rpairopoi in BLU/RED
wiro btrYaen ECM lBSl
and A/C awilch.
11-85
vnx.su
ooo oo oooooo
ooooooooooo
Measurevoltage between D9 (+ )
terminaland A26 {-}terminal.
ls there approx. 5 V?
Voh.go?
D 9l + )
ooooooooooo
ooooooooooo
11 - 8 6
vnx.su
(Frompage 1 1-86)
11-87
vnx.su
appror. 5 V?
87l+)
Turn the ignitionswitch ON.
ooooooooooooo
oooooooooooo
A26 {-}
Measurevoltage between 87 (+ I
terminaland 426 1- ) terminal.
ls there approx. 5 V?
( T op a g e1 1 - 8 9 )
1 1 -8 8
vnx.su
-.
{Frompage 11-88)
ooooooooooooo
oooooooooooo
426 (- )
Measurevoltagebetween87l+)
terminal and A26 (-) teJqrinal
with the transmission in Lryl posataon.
Measurevoltage between 87 (+ I
terminal and A26 (-) reJqrinal
with the transmissionin lPl position.
t+t
o o o o o o o o o o o o o I o o o o o o o o I O O n P s O lo o o o o o o o o o o
ooooo ooooo ooo I oooooooo lQcosito I ooooooooooo
A26 (- )
Reprir open in GRNMHT wi.r bgtwoon gaugo ssrombly and A/T
goar poritlon 3witch.
BATTERYVOLTAGE? --;;
MeasurevoltagebetweenB7l+)
terminal and A26 l-) terminal
with the transmission in gear.
{+ I
A26 t- )
R6oai. short in LT Git{/BLK wire
botwo6n ECM (B7l and gaugoaraombly.
11-89
vnx.su
InspectSTOP,HORN(20 Alluse
in the undeFhoodfuse/relavbox.
- Ropalropon In WHT/GRNwiro
batwoan b'lka lwltch and
STOP, HORTI{20 Al lu!o.
- InlDect tho braka awitch la6a
.6cdon 19).
( T o p a g e' l 1 - 9 1 )
11-90
vnx.su
R.pl!c.
S T OP ,
HOR {2O A) tu...
R.pdr dbrt In WtlT/
GBI wlrr batu..n
b?!ka .wltch a.rd
sToP, HOR[{ (20 A}
lura.
(Frompage 11-9Ol
426 {-)
I-Measurcvohage between D2 (+ l
terminal and A25 (-) terminal
with the brake oedal deoressed.
BATTERY
VOLTAGE?
D 2( + l
Repair opon in GRI{/WHT wiro botwoen th6 b..ko rwitch .nd ECM
{D2}.
Brako lwitch signal ir OK,
11 - 9 1
vnx.su
ooooooooooooo
oooooooooooo
A 2 6{ - }
NOTE:
a M/T: Clutch pedal must be
oeprgsseo.
a A/T: Trsnsmission in lll or LIJ position.
InspectNo. 18 STARTERSIGNAL
{7.5 A) fuse in the under-dash
fuse/relav box.
- Roplac. No. 18
STARTER SIG AL
(7.5 A) lurc,
- Rrpsir lhort In BLU/
WHT wir. batwccn
ECM (89) .nd No.
18 STARTER SIG.
t{AL {7.5 Al 1u..,
PiGM-Fl fi.ln rol.y.
R.palr opon in BLU/WHT wir6 b6tw.n ECM lB9l and t{o, 18
STARTERSIGNAL 17.5 Al lu.o.
11-92
vnx.su
-;"nection.*."------'.ill]
-
;;;;;;;l
;:"r"tffa;i'
(see
connecrors
Measurevoltagebetween88 {+ )
terminaland A26 {-) terminal.
Disconnectthe 2P connectortrom
the PSPswitch.
ls there lessthan 1.0 V?
Tu.n the ignitionswitch ON.
Disconnectthe 2P connectorlrom
the PSPswitch.
wire side
GRN
PSP SWITCH
11-93
vnx.su
Inspaction
NOTE: The tast idle thermo valve is factory adiustsd;
it should not be disassombld.
1.
2.
3.
o-Rr{Gs
Replace
AIN EYPASSVALVE
11-94
vnx.su
2.
Connecta tachometer.
3.
4.
81881 ongino:
MTf
75O !
50 rpm
AIT
75O t 50 rpm
(in[]or@positionl
48O ! 50 rym
An
48O I 50 rpm
lin@or@oosition)
(cont'd)
11-95
vnx.su
M/T
750 i
An
75O t 50 rpm
{in $ or p] positionl
50 rpm
M/T
82O 1 50 rpm
AN
840 1 50 rpm
(in [N] or lll position)
818C1 engino:85O t 50 nm
NOTE: lf the idle speedis not within specitication,
see SystemTroubleshooting
Guideon page 1 1-78.
11-96
vnx.su
FUEL
LINES
11-98
SYI\4
PTOM
FUEL
FUEL
PRESSURE
INJECTOR
REGULATOR
11-102
11 , 1 0 6
FUEL
FILTER
FUEL
PUMP
PGM-FI
MAIN
RELAY
l1-toa
11-109
t'l 'nl
ENGINE
WON'TSTART
DIFFICULT
TO START
ENGINEWHENCOLDOR HOT
\4
ROUGHIDLE
MISFIRE
OR
ROUGH
RUNNING
LOSS OF
POWER
FREOUENT
STALLING
FAILS
POORPER.
EMtSSION
FORMANCE
CONTAM'
INATEO
FUEI
WHILE
WARMING
UP
AFTER
WARMING
UP
11-97
vnx.su
FuelSupplySystem
Fuel
NOTE:Check all fuel system lines and hoses for damage, leaks or deterioration, and replaco if ncessery.
11-98
vnx.su
Sot th centgr
l2 mm
(0.47 inl
12-15 mm
to.47-o.59 hl
t2 mm
{0.47 in}
11-99
vnx.su
FuelSupplySystem
SystemDescription
FuelPressure
2.
3.
4.
5.
SERVICEBOLT
15 N.m
(1.5 kgf.m,
11 rbr.ftl
FUELFILTER
NOTE:
a A fuel pressu.egaugecan be attachedat the 6
mm seryicebolt hole.
a Alwavs replacethe washerbetweenthe service
bolt and the specialbanio bolt. wheneverthe service bolt is loosened.
a Replace all washers whenever the bolts are
removeo.
11 - 1 0 0
vnx.su
Insp6ction
1.
2.
Removethe servicebolt on the tueltilter while holding the banjobolt with anotherwrench. Attach the
specialtool
3.
psil
818C1 ongine:
329-37a kPa (3.35-3.85 kgf/cmz,48-55
4.
pei)
FUEL PRESSUREGAUGE
07406 - OO4000 1
psi)
CLAMP
11 - 1 0 1
vnx.su
\-l-l
tc l1 1 6 l - /- l---i/---r-\
\
The Fuel Injectors a.e a solenoid-actuatedconstant-stroke pintle type consisting of a solenoid, plungel nedlevalvs and
housing. When cur.ent is appliedto the solsnoid coil, the vslve litts up and pressurizedfuel is injected. Becausethe needle valve litt and the luel pressureare constant, the iniection quantity is determined by the length of time that the valv
is open (i.e.,the durationthe cu.rent is suppliedto the solenoidcoill. The Ful Iniectoris sealedby an O-ringand seal
ring at the top and bottom. These seals also reduce operating nois6.
FILTER
O.RII{G
PTUNGER
-_--
- ___L-
- I| r.G
- -l -- :l t_o- l - Tho MIL has boen roportod on.
- Wilh tho SCS .hon connocto.
conoctod (soo pago 11-34),
code 16 is indicalod.
11-1 0 2
vnx.su
FUEL RAIL
lFrompsge11-1021
Mossur rggistancebatwson th
2 terminalEol fuol injocto..
FUEL
II{JECTOR
ls thoro 1O- 13 07
(cont'd)
11-103
vnx.su
A3{+)
oooooooooo
oooooooooooo
oooooooo
oooooooo
A2{+}
11-1 0 4
vnx.su
ooooooooooo
ooooooooooo
Rapl!c!ment
t'.
1.
2.
3.
4.
cusHloN
RING
Replace.
FUEI.RAIL
FUEL
MABKI'{GS
11-105
vnx.su
Te6ting
oo not smoko during the tst. Ko6p opon
@
flames away from your work area,
1. Attach a fuel pressuregaugeto the se.viceport of
t h e l u e l f i l t e r{ s e ep a g e 1 1 - 1 0 1 ) .
Prossuroshould be;
Bl88l ongin:
275-324 kPa (2.8-3.3 kgf/cm', 40-47 psil
B18Cl ngino:
329-378 kPa (3.35-3.85 kgf/cm' .48-55 pEi)
(with tho tuol pressurersgulator vacuum hoso dlsconnoctod and pinched)
CLOSE:
FUELPRESSURE
GAUGE
1
07406 - oO/IOOO
DIAPHRAGM
\r__l FUELINLET
INTAKE
MA'{IFOLD
VACUUM
Checkthat the tuel pressurerises when the vacuum hosefrom the fuel pressureregulatoris disconnected again.
a lf the fuel pressuredid not rise, replacethe fuel
pressure regulatot.
/1-
\J
FUELINLET
FUEL
RETURI{
11-106
vnx.su
Raplacoment
oo not amoko whil6 working on fuel sys@
tam. Koop open flamo away tlom your work atea'
1. Placea shop towel under the fuel pressureregulator, then relievtuel pressure(seepage 1l-10O).
2.
3.
Rsplace.
NOTE:
a Replacothe O-ring.
a When assemblingthe fuel pressureregulator,apply clean engineoil to the O-ringand assemble
it into its proper position, taking care not to
damagethe O-dng.
11-107
vnx.su
SPECIAL
BOLT
33 N.m
(3.4 kgt.h,
25 rbf.ft)
2.
3.
4.
11 - 1 0 8
vnx.su
SERVICEBOLT
15 N.m ll.5 kgt.m,
1 I rbr.ftl
WASHER
Replace
1Ottl.m
(1.Okgf.m,
7 tbt.ftl
[":::,::-'
Eecauseof its compactimpellerdesign,the fuel pump is installedinsidethe fueltank, therebysavingspaceand simplifyng the fuel line system.
FUELPUMP
FUEL FILTER
FUEL PUMP BRACKET
N lTop vi6w)
FUEL PUMP ASSEMBLY CROSSSECTION
D|SCHARGEFORT ^
PORT
. tNLEr P
PUMPCOVER
IMPELLERS
CHECK VALVE
GROOVES
PUMP CASING
IMPELLER
line systems,
The fuel oumo consistsof a DC motor, a circumferenceflow pump, a reliefvalve for ptotectingthe fuel lir
emblyconsistsof
a check valve for retainingresidualpressure,an inlet port, and a dischargeport. The fuel pump assembly
pump cover.
the impellers(drivenby the motor),the fuel pump casing{whichforms the pumpingchsmber),and the fuel p
OPERATION
togetherwith the
(1) When the engineis started.the PGi/t-Flmain relay actuatesthe fuel pump, and the motor turns togeth
impellers.
Differentialpressureis generatedby the numerousgroovesaroundthe impellers.
rgh th
the discha.ge
(2) Fuelenteringthe inlet porr flows insidethe motor from the pumpingchambe.and is forced through
port via the check valve.
ss the fuel to the
lf tuel flow is obstructedat the dischargeside of the tuel line, the relief valve will open to bypass
pressure.
prevent
port
fuel
excessive
inlet
and
t retainthe
avitv to
(3) When the enginestops,the tuel pump stops automatically.However,a checkvalve closesby gravity
residualpressurein the line, helpingthe engineto aestanmore easily.
(cont'd)
11-109
vnx.su
Roplacomont
1.
2.
Removethe accessoanel.
3.
4.
5.
6.
1.
-'2.
3.
4.
l.t,
.\
.--/
.
re
-Fl
6 N.m
lO.6 kgl.m,.
4 tbt.ftl
MAll{ RELAY
Jumper
27 .m
(2.4 kgt.m,
21 tbt.ftl
BL&
YEL
side
YEL/
GRN
11-110
vnx.su
PGM-FlMain Relay
Doscription
The PGM-Flmain relavactuallvcontainstwo individual
rerays.
This relay is locatedat the lett side of the cowl.
Onerelayis energizedwheneverthe ignitionis on which
suppliesthe battery voltageto the ECM, power to the
fuel injectors,and power for the secondrelay.
The secondrelay is energizedfor 2 secondswhen the
ignitionis switchedon, and when the engineis running,
to supply power to the fuel pump.
Relay Testing
NOTE: lf the car stans and continuesto rrun, the PGMFl main relay is OK.
1.
2.
PGM-FI
MAIN RELAY
No.2
FUEL PUMP
To lGN. I
To GROUND
8Ar C)
To ST. SWITCH
To ECM {47}
J To FUELPUMP
11-111
vnx.su
Checklor continuitvbetweenBLK
terminal@ and body ground.
Rapairopen in BLK wire botwoon
PGM-FImain.el6yand GIO'l llocatod at thormostot housingl.
Measure the voltage between
YELMHT terminal@ and body
ground.
- Roplacoth. ECUIECMI(15Al
lus6 in tho under-hoodfu!o/r6lay box.
- Ropair opan or short in the
YEL/WHT wil6 botwosn the
PGM-FImain rolayand the ECU
{EcMl 115 A} luso.
{ T o p a g e1 1 1 1 3 }
11-112
BLU
vnx.su
BLU/
wHt
Bt-x
BLK/
YEL
YEL/
BLK
( F r o mp a g e ' l ' l - 1 1 2 1
YES
Reconnct"4" connector to the
ECM.
Bstt.ry vohago?
r-----r_-l
A 2 3 ( - l A 2 5B l
Brttaiy voftago?
a7 (+l
A23(-)
Masurethe voltage betwen A7
(+)torminal and A23 { - } trminal when the ignition switch is
first turned ON for two soconds.
11-113
vnx.su
oo not smoke while working on fusl syltem. Koep opon flame rway from your wort ar6a.
FUEL
PUMP
FUEL
TANK
EVAP
TWO WAY VALVE
38 l{.m
(3.9 kgt'm,
28 rbl.ftl
EVAP
TWO WAY
VALVE
COVER
FUELTAI{K
STRAPS
tO t{.m
ll.O kgt'm,
7 lbl.frl
11-114
vnx.su
't
11-118
1-117
lB18Cl cngin.l
PAGE
I sue-svsreu
_\.-..\
sYMPToM
\---...-
THROTTLE
CABLE
THROTTLE
BODY
INTAKEAIR
BYPASS(IAB)
CONTROL
AIR CLEANER
AND INTAKE
AIR DUCT
1 11 1 9
1't-120
11-124
1 l 117
o
o
LOSSOF POWER
11-115
vnx.su
na
cot{TRoL
To
ffi -------------+
i'"ii'i''
SOLENOID
VALVE
RELAY
VARIOUS
SENSORS
IAB
CONTROL
DIAPHRAGM
VALVE
-BLK
--L EI{GINE
cooLnnt
FAST
IDLE
THERMO
VALVE
INTAKE
AIR
DUCT
11-116
vnx.su
INTAKE
AIR PIPE
Air CleanerIACL)
ACL Element Rsplacoment
ACL HOUSING
COVER
ACL ELEMENT
Clean air cleaner element everv
15,OOOmiles (24,OOOkm) or 'l2 months and reDlaceeverv 3O,OOOmiles
(48,00Okm) or 24 months underdusty conditions,rough or muddy roads.
11-117
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Installation
'I .
1.
Fullyopen the throttle valve.then installthe throttle cablein the throttle linkageand installthe cable
housingin the cable bracket.
2.
2.
3.
THBOTTLELII{K
-l-r
,)
i;
ITINERCABLE
DEFLECTION
1O-12 mm
1O.39-0.47 in.l
5.
LOCKNUT
4.
3 mm {0.12 in)
LOCKNUT
1ON.m
{1.O kgl.m,
7 tbt.ft)
1 1 - 11 8
vnx.su
Throttlecable [B18C1enginel
Inspection/Adiustment
1. Start the engine. Hold the engine at 3,O0Olpm with
no load in neutraluntil the radiatorfan comes on,
then let it idle.
2.
3.
lnstallation
1. Fullv open the throttle valve, then install the throttle cable in the throttle linkage and install th cable
housingin the cable bracket.
2.
CABLEBBACKET
I{UT
ADJUSTING
5.
DEFLECTIOI{
10-12 mm
(O.39-O.47in.l
4.
LOCKT{UT
lO t{.m (t.O kgl.m, pARTB
7 lbt.ftl
{Locked by bracket)
NUT
ADJUSTING
PABT A
LOCKNUT
NO GAP
AIUUSTING
NUT
5,
11-119
vnx.su
Insoection
CAUTION: Do not adiust the thlottle stop screw. lt is
preset at the lactory.
1.
2.
IOLEAOJUSTING
VACUUM PUMP
GAUGE
A973X-O41-XXXXX
THROTTLE
STOP SCREW
(Non-adiustsb16l
3.
11-120
vnx.su
818B1 engino:
There should be
no clearance.
THROTTLESTOP SCREW
(Non-adiustablel
818Cl engine:
THROTTLELINK
(Non-adjusrablel
11-121
vnx.su
IntakeAir System
Throttle Body (cont'dl
Dirarssmbly
GAUTION:
a Ths throttlo stop scrow is non-adrustablo.
a Aftar reassombly, adiust rhr throttlo Gablo(pago 11-118, 1 19). and A/T throttlo contlol cabl6 (section 14) for c!r8
rYith A/T.
a Tho TP sonaor ir not lomovablo
MAP
SENSOR
Troubleshooting
p a g e1 1 - 5 2
O.BING
I
d^'%
TP
SETSOR
Troubleshooting
poge1l-60
IDLEADJUSTING
SCREW
o-RtftG
Replace.
FASTIDLE
THERMO
VALVE
page11-94
Inspection,
1ON.m
11.Okgl.m.
7 tbf.ftl
11-122
vnx.su
IAB CONTROL
VALVES
To PGM-FI
MAIN RELAY
RELi
IAB
CHECK VALVE
(cont'dl
11-123
vnx.su
IntakeAir System
Troublcahooting
Inspction of IAB Conltol Sytt.m
tA8 COI{TROL
DIAPHRAGM
Start engino and allow to idle.
VACUUIIPUMP/GAUG
A973X-041-XXXXX
Rmove# 13 vacuumhosetrom
the IAB control diaph.agm and
connect vacuum gauge to the
hose.
Rmove # 12 vacuum hose from
th IAB vacuum tank, then check
tor vaccum at the IAB vacuum
tank.
Rcplir lh. block.g. ot
vacuufi laak boiwaao
tha IAB vacuum tank
m!nilnd th. intlk
fold.
Disconnect the 2P connctor lrom
the IAB control solenoid valve.
IAB CONTBOL
VALVE
SOLENOID
from
wiro haana
sid
PI{K/
B L UI - I
YEI/
a L Kl + l
ls thoro battery voltage?
vnx.su
(Frompage 1 1-124)
{Frompago 1 1-124}
Repsirop6n in YEL/BLK
wiro botwoon tho 2P
connector and FGM-FI
main relaY.
RopaiioponinP K/BLU
wiao botwoen ECM
lAl7l and tho 2P connectot.
Disconnectthe 2P connectortrom
the IAB control solenoidvalve.
Ropairshort to g.ound
at PNK/BLU wiro botwo6n ECM {A17) and
tho 2P connector.
11-125
vnx.su
a
Intake Air System
IntakeAir Bypass(lABl ControlValve IB18C1 enginel
Trlting
GAUTIOI{; Do not rdlust lho IAB control valvo tull-close screw. lt is prosot at th. t.ctoty.
1.
2.
3.
With the engine at idle, check that @ot the IAB control valve is in close contact with the stoppsr when vacuum
hose is disconnected.
With th ongine at idl6, check that @of the IAB control valve is in close contact with the full-closo acrew whsn
the vacuum hose is connectad.
a lf 8ny fault is lound, clean the linkage and shatts with carburetor claaner'
- lf the oroblam still exists after cleaning, disassemblethe intake manifold and check the IAB valvE body sss8mbly.
11-126
vnx.su
Dls!$.muy:
ITTAKE
MANIFOLD
23 N.m
12.3kgt.m.
17 tbt.ftl
a a
GASXET
Rgplace.
|AA VALVEAODY
I]{TAKE MANIFOLD
CHAMBER
24 N.m
(2.4 kgf.m,
t7 tbf.ftl
11-127
vnx.su
{ uuu
24 N.m
12.4 kgf.m,
t7 tbt.ftl
11-128
vnx.su
23 N'm
(2.3 kgt.m,
17 tbf.ftl
EmissionControl System
System TroubleshootingGuide
NOTE: Acrosseach row in the chart,the sub-systemsthat could be sourcesof a symptomare lanked in the ordrthey
should be inspected starting with O. Find the symptom in the lett column, read across to the most likely source, then
reJerto the page listd at the top of that column. lf inspection shows the system is OK, try the next most likely system
@, etc.
PAGE
SUB.SYSTEM
SYMPTOM
THREEWAY
CATALYTIC
CONVERTER
POSITIVE
CRANKCASE
VENTILATION
SYSTEM
1 1 - 1 3 21, 3 3
1 1 -1 3 4
1 1 tJo
ROUGHIDLE
POORPERFORMANCE
EVAPORATIVE
EMtSSTON
CONTROLS
FAILS
EMISStON
TEST
LOSSOF
POWER
11-129
vnx.su
EmissionControlSystem
SystemDescription
Tailpipe Emission
The emissioncontrol system includesa ThreeWay Catalytic Convener (TWC), Positive Crankcase Ventilation
(PCV)system and EvaporstiveEmission{EVAP)Contfol
systm. The emissioncontrol system is designedto meet
federsl and stats emissionstandards.
Inspection
f!fifil
11-130
vnx.su
maximum.
ThreeWay GatalyticConverterITWC)
Dr!criplion
Th6 Three Way Cstalytic Converter (TWC) is used to convert hydrocarbons (HCl, carbon monoxide (CO), and oxides
ot nitrogen{NOx) in the exhaustgas, to carbondioxide (COr},dinitrogen(N2land water vapo..
The illustrationshows the TWC tor the 818C1 engine.
THREEWAY
CATALYSTS
FBONTOF
VEHICLE
11-131
vnx.su
EmissionControl System
ThreeWay CatalyticConverter(TWC)(cont'dl
Inspection
lf sxcessive oxhaust system back-pressureis suspected. remove the TWC trom the car and make a visual check for plugging, meltingor crackingof ths catalyst. Replacethe TWC if any of the visiblearea is damagedor plugged.
81881 ongino:
T SHIELO
TI{REEWAY
CATALYTIC
CONVERTER{TWCI
Removsl/installation,see section 9
Inspecthousingfor cracksor
other damage.
Inspect element tor clogging
by lookingthroughthe inside.
HEAT SHIELD
11-132
vnx.su
818Cl engine:
HEAT SHIELO
THREEWAY
CATALYTIC
COI{VEBTEB{TWCI
Rmoval/installation.sso sction 9
Inspoct housing tor cracks or
othor damage.
Inspect elemont for clogging
by looking through the inside.
HEAT SHIELD
11-133
vnx.su
EmissionControlSystem
PositiveCrankcaseVentilation(PCVISystem
Description
Inspcdon
1.
FCV VALVE
.F: ILOW-BYVAFOR
er FRESHAIR
11-134
vnx.su
EvaporativeEmission(EVAPIControls
Da.cdptlon
Thg avaporstive omission controls are designed to minimize the smount of fusl vapor escaping to the atmosphero. The
system conaists ot the following componnts:
A . Evlporttly. Emlttbn (EVAPI Control Caniltot
An EVAP control canistor is used lor the temporary storage ot fuel vapor until the fuel vapor can be purged lrom
th EVAP control canister into the engin and burned.
vlpor hr]gG Cmt]ol Syst m
VAp control canistgr puroing is accomplished by drawing fresh air through tho EVAP control canister and into a
pon on th6 throttl body. Th purging vacuum is controllsd by the EVAP purge control diaphragm valve end the
EVAP purge control solenoid valve.
C.
(cont'd)
11-135
vnx.su
EmissionGontrol System
EvaporativeEmission(EVAPIControl(cont'd)
EVAP
TWO WAY VALVE
FUELTANK
EVAP
PURGE
CONTROL
SOLENOID
VALVE
EVAP VALVE
FUEL
FILLCAP
VARIOUS
sEt{soRs
EVAP CONTROL
CANISTEB
FRESH
AIR
11-136
vnx.su
BLK
#7 VACUUM HOSE
Troublclhooting
VACUUM PUMP/
GAUGE
A973X-O41-XXXXX
COI{TROL
EVAPPTJBGE
VALVE
DIAPHRAGM
Bl8Bl .noin.:
YEL/
B L KI + I
EVAP
PUBGECONTROL
VALVE
YEL/
B L K( + I
(-t
wirg aide
--\
EVAP
R'RGECOI{TROL
VALVE
SOLENOID
M e as u r o v o l t a g o b e t w e n
YEL/BLK{+) terminsl 6nd RED
l-) terminal.
Inapactvacuum hoa
ror.ring.
l| OK, toolrc. EVAP
purgo conttol solenoid
(cont'd)
11-137
vnx.su
EmissionGontrolSystem
EvaporativeEmission(EVAP)Gontrols(cont'd)
(Frompage 1 1-137)
{ F r o mp a g e 1 1 - 1 3 7 }
Oisconnectthe 2P connoctorfrom
the EVAP purge control solenoid
ls there manifoldvacuum?
Inrpoct for a short i|t REDwire bolwoen ECM {A2Ol and th6 connoclor.
ll wiro la OK, substituto a knowngood ECM 6nd .echock. lf symptom goes away, loplacetho original ECM.
11-138
vnx.su
VACUUMPRESSURE
GAUGEO-4 In.Hg
oTJAZ-OOIOOOB
PURGEAIR HOSE
ox.
(cont'd)
11-139
vnx.su
EmissionControl System
EvaporativeEmissionControls
(cont'dl
Evaporativ Emission {EVAPI Two Way Valvo Tasting
l.
2.
A973X-041-XXXXX
T-FITTING
J-.
fF
,T
. -,-/asr^:
4?e
Slowly pressurize
the vaporlinewhile watchingthe
gauge.
Pressure
shouldstabilizeat 1O-35 mmHg(0.4- 1.4
i n .H g ) .
a lf p.essuremomentarilystabilizes{valveopensl
a t 1 O - 3 5 m m H g ( O . 4 - 1 . 4 i n . H g ) t, h e v a l v ei s
oK.
a lf pressurestabilizesbelow 10 mmHg {O.4in.Hg)
or above35 mmHg(1.4 in.Hgl,installa new valve
and retest.
11-1 4 0
vnx.su
Transaxle
12-1
Clutch
M a n u aTl r a n s m i s s i o. .n. . . . . . . . . . . . . . . . 1
. .3. .- 1
A u t o m a t iT
c r a n s m i s s i o. .n. . . . . . . . . . . . . 14-1
...
Differential
ManualTransmission
15-1
81881 engine
15-9
818C1engine
15-19
AutomaticTransmission
...............
16-1
Driveshafts
vnx.su
Glutch
. . . . . . . .1 2 - 2
S p e c i aTf o o l s . . . . . . . .
.... 12-3
f f f u s t r a t e Idn d e x . . . . . . . .
Clutch Pedal
................12-4
Adjustment
Clutch Master Cylinder
.... 12-5
Removal/lnstallation
Slave Gylinder
.... 12-6
Removal/lnstallation
PressurePlate
..... 12'7
Removal/lnspection
Clutch Disc
..... 12-8
lnspection/Removal
Flywheel, Flywheel Bearing
. 12-9
fnspection
R e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .1.2. .-.9
Clutch Disc, PressurePlate
12-10
Installation
ReleaseBearing
12-11
Removal/lnspection
vnx.su
SpecialTools
Ref. No,
o
/^
ri)
@
@
Tool Number
OTJAF_PM7011A
OTLABPVOO1
OOor
o7 924-PD20003
07NAF-PR30100
07746-0010100
07749-OO10000
07936-3710100
Description
Clutch AlignmentDisc
Ring Gear Holder
Clutch AlignmentShaft
Attachment, 32 x 35 mm
Driver
Handle
12-2
vnx.su
Oty
'I
Page Reference
12,7
1 2 - 1 ,8 , 9 , 1 0
I
1
I
I
1 2 - 7, 8 , 1 0
12-10
12-10
1 2 - 1, 8 , 1 0
lllustrated Index
NOTE:
a Wheneverthe transmissionis removed,clean and greasethe releasebearingslidingsudace.
a It the pans marked r are removed.the clutch hydraulicsystem must be bled (see page 12-6).
a Inspectthe hoseslor damage,leaks,interterence,and twisting.
*RESERVOIR
HOSE
ASSISI SPRING
COTTER
Beplace.
N
n Il
6 x 1,0 mm
9.8 N.m ll.0 ksf.m, 7 lbf.tt)
9 t
v-_fl
PEDAL PIN
1 5 N . m 1 1 . 5k g l . m ,
11 tbt.ftl
TCLUTCHMASTER CYLINDER
page 12-5
Removal/lnstallation,
.CLUTCH PIPE
CLUTCH PEDAL
Adjustment,
page 12-4
15 N.m {1.5kgl.m,
1 1 rbf.ft)
JOtt{T
8 x 1.25mm
25 N.m (2.6 kgl.m,
19 lbt.ttl
FLYWHEEL
Inspection.page 12-9
page 12-9
Replacement,
RELEASEBEARING
Romovaf/lnspection, page 1 2-1 1
lnstaffation,page 12- 12
CLUTCH DISC
page'12-8
Removal/lnspection.
Installation,page 12-10
TRANSMISSION
Romoval. see
section 13
12 x 1.0 mm
103 N.m llO.5 kgt.m,
76 rbf.ftl
ICLUTCH PIPE
PRESSUREPLATE
page 12-7
Removal/lnspection.
Installation,page 12,10
8 x 1.25mm
22 N.m (2.2 kgf.m.
16 lbl.rr)
TSLAVE CYLINDER
Removaf/lnstallation. page 12-6
15 N. m {1.5kgf.m,
'| I tbf.ftl
12-3
vnx.su
Pedal
Pedat
Clutch
ctutch
Adjustment
[-],ll'"-""
| :;i:'":fff*tr#:?iff:".,*::,::".
| .#::J:::
|
"orr,O",
CAUTION: It there
there is no clearanco
clearancobetween
between the master
mastel
cylinder piston and push lod. the releasoboaringis held
diaphragm spring,
which can result
result in clutch
clutch
against
againsl the diaphragm
spring, which
problems.
slippage
slippage 01 othel
othel clutch
clutch problems.
1.
1 . Loosenlocknut A, and back otf the clutch switch
bolt) until it no longertouchesthe clutch
adjustingboltl
{or adiusting
pedal.
sb''''""
| |
NOTE:
a To check the clutch interlock switch and clutch
switch, see seclion 23.
a The clutch is selt-adjusting
to compensatefor wear.
6 . Tighten locknurA.
,.
switcl.
7. aoo""n
Loosenlocknut B and the clutch intertoct
interlockswitch.
|
|
|
|
|
I
|
I
I
I
p e d a l15-2O
1 5 - 2 0 mm
m m {(O.59-O.79
9.
9 . Release
R e l e a s the
teh e clutch
c l u t c hpedal
O.59-O.79 I
int
in) trom
from ttre
the fully depressedpositionand hold it there. I
Adiustthe positionof the clutch interlockswitch so
that the enginewill start with the clutchpedalin this
oosition.
I
I
floor boardand
8. Measuretne
the clearancebetweenthe tloor
depressed.
clutch pedalwith the clutch pedaltully deeressed.
I
|
I
push rod
in or
rurn
the
Loosenrocknut
locknut c,
C, and
and turn
the push
rod in
or out
out
,2 . ::":""
|
iliiiliffi:l1l:J"'1"-:H"l:tJ:i"i#fT:I
'-"'"'';*1,,0*
::***r**''
.,".,u"**;
|
II
,
to get the specifiedstroke(@)and height(O) at the
clutch pedal.
I tf
,:.;:,nterrockswitch3/4torrurrturnturtner.
1 1 . T i g h t e nl o c k n u tB .
. il*:*j':"'-(@)andheisht(olatthe
Tighten locknut C.
Turn the clutch switch (or adjustingbolt) until it contacts the clutch pedal.
ASSIST SPRING
LOCKNUTB
9.8 N.m (1.0 kgf.m,7 lbf.ftl
-6ll
CLUTCH INTERLOCK
PUSH ROD
swtrcH
CLUTCH SWITCH
{or AOJUSTING BOLTI
LOCKNUTA
9.8 {N.ml (1.0 kgl.m, 7 lbt.ftl
LOCKNUTC
l3 N.m l'l.3 kgf.m, 9
vnx.su
2.
CLUICH PIPE
15 N'm {1.5kgl.m,
1 1 tbf.ftl
OAMPER
CLU
CLUTCH
M
MASTER
AI
cYL
CYLINDER
!l rn
in Ine reverseorInstallthe clutch mastercylinder
der of removal.
(seepage
s\
c system
NOTE: Bleedthe clutchhydraulic
12-61.
CLUTCH
MASTER
CYLINDER
Pry out the cotter pin. and pull the pedal pin out ot
the yoke. Remove the nuts.
NUTS
13 N.m {1.3 kgf.m,
9 lbt.frl
12-5
vnx.su
Slave Cylinder
Removal/lnstallation
Install the slave cylinder in the reverseorder ol
removat.
CAUTION:
a Do not spill brake tluid on the car. it may damago tho
paint; it brake tluid doos conlacl tho paint, wash it
off immediately with watei.
a Plug tho nd of the clutch pipe with a shop lowsl to
plevcnt b.ake fluid from coming out.
-61,
08798-9002).
: BrakeAssemblyLubeor equivalentrubber
grease.
'1.
CLUTCH PIPE
15 N.m (1.5 kgf.m, 11 lbf'ftl
-Cl
tP/N08798-90021
8 x 1.25mm
22 N.m 12.2 kgl'm,
16 rbt'ft)
...::
:^.
Gil^lt
(BrakeA$embry
Lubol
4.
BOOT
Remove and check for signs ol leaking and deterioration.
12-6
vnx.su
PressurePlate
Removal/lnspection
Check the diaphragmspring fingers for height using the specialtools and a feeler gauge.
4.
FEELER
GAUGE
CLUTCHALIGNMENTOISC
OTJAF_PM7011A
DIAPHRAGM
SPRING
PRESSUREPLAT
07936-3710100
07NAF-PR30100
2.
Installthe specialtools.
3.
6.
STRAIGHTEOGE
CLUTCH ALIGNMENTSHAFT
07NAF-PR30100
HANDLE
07936-3710'l OO
FEELERGAUGE
RINGGEARHOLDER
07LAB-PVOOlOOor
07924-PD20003
PI
lf the warpage is more than
replace the pressure plate.
PRESSUREPLATE
12-7
vnx.su
Disc
Disc
ctutch
Glutch
'.#fu;;
Removal/lnspection
'1.
""-*":'--
''
inr
{o'oo8
=-.--']!
; i , n-\ ll
DISC
"LUrcH
CLUTCH Drsc
CLUTCHDISC
W@*-l
@
slbir":ix:l#
Ii!fr..;*'::l;'"o^"
\t'=f
|
CLUTCHALIGNMEI{T
SHAFT
07NAF-PR30100
HAt{DLE
07936-3710t0O
3.
thickness.
Measu.ethe clutch disc thic
LINING SURFACE
CLUTCH DISC
vnx.su
II
Inspection
Inspect the ring gear teeth for wear and damage.
FLYWHEEL
FLYWHEEL
MOUI{TII{G BOLTS
3.
DIALII{DICATOR
It the runout is more than the servicelimit, leplace
the flvwheel.
Turn the inner race of the flywheel bearingwith your
finger. The bearingshould turn smoothly and quietly, Checkthat the bearingouter race fits tightly in
the flvwheel.
FLYWHEEL
BEARING
It the racedoes not turn smoothly,quietly,or fit
tight in the flywheel, replacethe flywheel bearing.
(cont'd)
12-9
vnx.su
Flywheel,FlywheelBearing
Clutch Disc,
PressurePlate
Replacement(cont'd)
4.
Installation
l.
DRIVER
07749-O010000
CLUTCH DISC
ATTACHMENT.
32x35mm
07746-OOlO100
FLYWHEEL
FLYWHEELBEARING
RINGGEARHOLDER
OTLAB-PVOOI
O0ot
07924-PD20003
3.
CLUTCH ALIGNMENTSHAFT
07NAF-PR30100
HANDLE
07936-3710100
Instalithe pressureplate.
CLUTCH ALIGNMENTSHAFT
oTNAF-PR30100
HANDLE
FLYWHEEL
07936-3710100
PRESSUREPLATE
MOUNTINGBOLTS
12 x 1.0mm
1 0 3 N . m 1 1 0 . 5k g f . m ,
76 tbf.fr)
12-10
\_
vnx.su
ReleaseBearing
Removal/lnspection
4.
CLUTCHHOUSING
8 x 1.25mm
25 N.m 12.6 kgt'm,
19 tbt.ftl
RELEASEFORK
-24/--2,t'.2424?'
IJ
,F=:=
vnx.su
ReleaseBearing
Installation
1 . With the releasetork slid betweenthe releasebearing pawls, installthe releasebearingon the mainshaft while insertingthe releasefo.k through the hole
in the clutch housing.
-611
lPlN 08798-
-6
{P/N0879a- 9002)
4.
12-12
vnx.su
ManualTransmission
.............
13-2
SpecialToofs
Maintenance
Transmission
Oi1,...,........,........,.,.....
13-3
Back-upLight Switch
Replacement
.........13-3
TransmissionAssembly
Removal
..,.......,......
13-4
lllustratedIndex ...................................
13-8
TransmissionHousing
Removal
...........,.....
13-10
ReverseChangeHolder,Reverseldler Gear
lnspestion.......................
13-11
Glearance
Removaf
.................
13-12
ChangeHolderAssembly
Inspection.......................
13-13
Clearance
.................
13-15
Removal
Disassembly/Reassembly
...............
13-16
Mainshaft, Gountershaft,Shift Fork
...,.............
13-17
Removal
Shift Rod
13-18
Removal
.................
Shift Fork Assembly
Index ................
......13-19
13-20
Clearance
Inspection.......................
MainshaftAssembly
Index ................
......13-21
Clearancefnspection .......................
13-22
Disassembly
..........13-25
Inspection
..............
13-26
Reassembly
13-21
...........
Countershaft Assembly
Index ................
......13-28
13-29
ClearanceInspection .......................
Disassembly
..........13-30
Inspection
..............
13-31
Reassembly
...........
13-32
SynchroSleeve,SynchroHub
Inspection
..............
13-34
Installation
.............
13-34
SynchroRing,Gear
lnspection
..............
13-35
Clutch HousingBearing
Replacement
.........13-36
Mainshaft Thrust Clearance
Adiustment
............
13-38
Transmission
Reassembly
...........
13-tl1
TransmissionAssembly
.............
13-46
lnstallation
Gearshift Mechanism
................
13-50
Overhaul
vnx.su
SpecialTools
Rsf. No.
o
o
o
o
@
@
@
@
@
07GAJ- PG20110
07GAJ- PG20130
.07736 - A010004
07746- 0010300
07746- 0010400
07746- 0030r00
07746- 0030300
07746- 0030400
07745- 0041100
07749- 0010000
Oty
D!3cription
Tool Numbrr
MainshaftHolder
MainshaftBas
AdjustableBearingPuller,25 - 40 mm
Attachment,42 x 47 mm
Attachment,52 x 55 mm
Oriver,40 mm l.D.
Attachment,30 mm l.D.
Attachment,35 mm l.D,
Pilot,28 mm
Driver
1
1
1
1
1
1
1
1
1
1
13-40
13- 36,37
13-36
13- 36,37
1 3- 2 7 , 3 3
1 3- 2 7 , 3 3
1 3- 2 7 , 3 3
13-36
13- 36,37
ll
13-2
vnx.su
Prgc R.{.rcnc.
'13- 40
Back-upLightSwitch
Maintenance
- TransmissionOil
Replacement
removethe back-up
Disconnect
the connector,then rem(
]onnectorclamp.
light switchconnectortrom the conn
2.
33tbtftl
ProperLevel
Replace.
2 . T h e o i l l e v e lm u s t b e u p t o t h e f i l l e r h o l e .l f i t i s
below the hole. add oil until it runs out, then reinstallrhe oil filler plug.
3.
l f t h e t r a n s m i s s i o no i l i s d i r t y , r e m o v et h e d r a i n
p l u ga n dd r a i nt h e o i l .
4.
R e i n s t a ltlh e d r a i n p l u g w i t h a n e w w a s h e r ,a n d
refillthetransmissionoil to the properlevel.
NOTE:The drain plug washershouldbe replacedat
everyoil change.
BACX-UPLIGHTSWITCH
25 N.m 12.5kg[.m, 18 lbf.ftl
Replace.
ORAINPLUG
$ N.m 14.0kgf.m.
29 lbf.fr)
13-3
vnx.su
TransmissionAssembly
Removal
Mskc aurs iack! and safoty Etandsaro placod properly lsl8 saqtion 1|.
Apply parking brake tnd block rear whccl! to car
will not roll ofl stand3 and f.ll on you while wotking
undrr it.
4.
5,
AIR CITANER
HOUSING
lnaNsMttistoN
WIRE
GROUND
tnaNsi ssloN
HANGEBB
o.
1.
VSS OONNECTOR
13-4
vnx.su
11. Disconnectthe heatedoxygen sensor(HO2S)connector,lhsn rsmove the exhaust pipe A, and the
threeway catalyticconverter(B18ClEngine).
HO2S
IIUT
SELF.LOCK
Ropl.ce.
STARTEB
MOTOB
MOUNNNG
BOLT
co NEctoR
EXHAUST
PIPEA
MOUNNNG
BOLTS
NUT
SELF.LOCK
THBEEWAY
Replace.
CATALYTIC
CONVEEIER
engin6)
1818C1
13-5
vnx.su
vnx.su
Removethe transmissionmount.
TRANSMISSIONMOUNT
MOUNT/BRACKET
BRACKET
13-7
vnx.su
lllustratedIndex
Referto the drawingbelowfor the transmissiondisassembly/reassembly.
Cleanall the partsthoroughlyin solventand dry with compressedair.
I
NOTE:
the majorhousings;
useliquidgasket(P/N08718-0001)
. Thistransmission
between
usesno gaskets
page
13-43).
{see
a Alwavscleanthe magnet@ wheneverthe transmissionhousingis disassembled.
a Inspectall the bearingsfor wear and operation.
*N
o
@
o
@
@
@
@
@
@
(3
(,
@
@
@
lt
(9
@
^
I
'
Ej
11-4fi
,\|j Uh
@
B
t
o
@
@
@
[@.--oa
F5i,--@
:7
13-8
vnx.su
,
Bolt Size
6x1.0mm
6x1.0mm
I x 1 . 0m m
8 x 1 . 2 5m m
8 x 1 . 2 5m m
8 x 1 . 0m m
c
D
E
F
i)
e
9
A
O
.d
t
!)
O
1 2 N . m( 1 . 2k g i m , 9 l b n f t )
15 N.m (1.5kgnm,11 lbf.ft)
15 N.m (1.5kgf.m,11 lbf.ft)
24 N.m (2.4kgf.m,17 lbf'ft)
27 N.m (2.8kgnm,20lbnft)
30 N.m (3.1kgf.m,22 lbf'ft)
@ WASHERBeplace.
@ TRANSMISSIONHOUSING
BALLBEARING
sroPPER R|NG
TAPERRING
NEEDLEEEARING
SPACER
SYNCHRORING
sYNcHRo SPR|NG
sYNcHRo SLEEVE
5TH/REVEFSE
SYNCHROHUB
5TH/REVERSE
6980 mm SHIM(*1)
79.5mm SHIM{*21
@ THRUSTSHIM{*2I
T. 2.0 mm (0.079in)
@ BEARINGOUTERRACE{*2}
@ SHIFTPIECESHAFT
@ INTERLOCK
@ SHIFTPIECE
@ SHIFTARM HOLDER
@ SELECTARM
@ SELECTRETURNSPRING
@ 10 mm SHIM
6D 10 mm WASHER
q0 LOCKCOLLAR
nlruc
[0 sYrucxao
ii i) 5TH GEAR
O 38 x 43 x 26 mm NEEDLEBEARING
t3 SPACEECOLLAR
O 4TH GEAR
.iB SYNCHROFING
.Ii9SYNCHROSPRING
{, 3RD/,ITHSYNCHROHUB
@ 3RD/4THSYNCHBOSLEEVE
t9 3RDGEAR
O MAINSHAFT
3 x 16 mm SPRINGPIN Replace.
o
x8 mm SPRINGWASHER
v0 CHANGEPIECE
@ SETSCREW
O wasHER
@) SPRINGWASHER
40 BALLBEARING
O 28 x 41 x ? mm OIL SEALReplace.
ad 35 x 56 x 8 mm OIL SEALReplace.
a0 14 x 20 mm OOWELPIN
@ OIL CHAMBERPLATE
'A BEVERSEIDLENGEARSHAFT
@ SPRINGL.25.6mm {1.01inl
0! STEELBALLD. 5/16 in
IDLERGEAF
.A REVERSE
CHANGEHOLDER
O REVERSE
SHIFTPIECE
3A sTH/REVERSE
O 1ST/2NDSHIFTFORK
04 3RD/.TH sHlFr FoRK
SHIFTFORK
@ 5TH/REVERSE
O9'OIL GUTTERPLATE
6' SNAPRING
@ 72 mm THRUSTSHIM
) OIL GUIOEPLATE
i!0 10 mm WASHERReplace.
.4i]REVERSE
IDLERGEARSHAFTBOLT
54 N.m {5.5kgt m, 40lblftl
) TRANSMISSIONHANGERB
(3 BREATHER
CAP
@ TRANSMISSIONHANGERA
63 BACK.UPLIGHTSWITCH
25 N.m (2.5ksf.m,18lbfftl
@r 14 mrn waSHER Replace.
67 16 mm SEALINGBOLT
29 N.m (3.0kgl.m, 22 lbf ft)
@ 32 mm SEALINGBOLT
25 N.m (2.5kgf.m.18lbt'ft|
@ 40 x 62 x 9 mm OILSEALReplace.
D STEELBALLD. 5/16 in
Gl SPRINGL. 30 mm {1.2in}
@ 12 mm WASHERReplace.
63)SETSCREW
22 N.m 12.2kgl.m, 16 lbt'ft,
@ OILORAINPLUG
39 N.m {4.0 kgt.m,29 lbf'ftl
9 WASHERReplace.
@ oIL FILLERPLUG
4,1N.m14.5kgJm, 33 lblftl
61 BEARINGOUTERRACEI*2I
@ THRUSTSHIMI*2)
@ MAGNET
@ CLUTCHHOUSING
@ 14 x 25 x 16 mm OILSEALReplace.
@ SHIFTROD
ASSEMBLY
al DIFFERENTIAL
Seesection15
t-2)
@ wasHER
T. 2.5mm (0.098in,
SHIFTRODBOOT
OIL GUIDPLATE
33 x 60 x 20 mm NEEDLEBEARING
BEARINGRETAINERPLATE
LOCKWASHERReplace.
COUNTERSHAFT
THRUSTSHIM
37 x 42 x 25 mm NEEDLEBEARING
lST GEAR
FRICTIONDAMPER
SYNCHRORING
SYNCHROSPRING
lST/2ND SYNCHROHUB
REVERSE
GEAR
DOUBLECONESYNCHRO
I*2I
BINGI*1)
SYNCHRO
FRICTIONDAMPER
SPACER
42 x 6? x 24 mm NEEDLEBEARING
2NDGEAR
3RDGEAR
4TH GEAS
5TH GEAR
NEEDLEBEARING
BALLBEARING
SPRINGWASHER
LOCKNUTReplace.
108- 0- 108N.m
( 1 1 . 0- 0 * 1 1 . 0k g tm ,
80- 0- 80lbf.ft)
005 x 22 mm SPRINGPIN Replace.
*1:81881engine
*2:B18Clengine
13-9
vnx.su
Transmission
Housing
Removal
NOTE:
. l f t h e t r a n s m i s s i o nh o u s i n go r c l u t c h h o u s i n ga . e
r e p l a c e d ,t h e b e a r i n g p r o l o a d m u s t b e a d j u s t e d
(818C1
engine).
. Placethe clutchhousingon two piecesof wood thick
enough to keep the mainshaftfrom the hitting the
workbench.
1.
2.
Removethe transmissionhangerB,
3.
5.
Loosenthe transmissionhousingattachingbolts in
a crisscrosspattern in severalsteps.then remove
them.
TRANSMISSION
Tna sMtsstoN
ATTACHINGBOLT
SPBING
L. 30 mm
11.2inl
Removethe 32 mm sealingbolt.
7.
SETSCBEW
Expandthe snap ring on ths countershaftball bearing and removeit from the groove using a pair of
snap ring pliers.
WASHER
Replace.
4.
32 mm SEALINGBOLT
L
WASHER
Replace.
SNAPRING
REVERSE
13-10
vnx.su
ReverseChangeHolder,
ReverseldlerGear
ClearanceInspection
Separstethe transmissionhousingfrom the clutch
housing,and wipe it cleanof the sealant.
cnange
re
Measurethe clearancebetween the reverse
holder and the sth/revsrseshift piece p t n .
R e m o v et h e 7 2 m m t h r u s ts h i m a n d t h e o i l g u i d e
platefrom the transmissionhousing.
Standard:
BevorseSido: 0.05- O.ilsmm (0.002-. 0( . 0 1 8i n l
),1in)
5th Sido:
o.ia- 0.9 mm 10.02- 0.0,1
t2 mm
THRUST
SHIM
SHIFTPIECEPIN
REVERSE
CHANGE
,
mealf the clearanceare not within the standard,
sti
change
re
surethe width of the groovesin the reverse
holder.
HOUSING
TRANSMISSION
1 0 . Removethe 16 mm sealingbolt and the oil gutter
plate.
Standsrd:
(
in)
RovsreaSide: 7.05- 7.25 mm {0.278- 0.285
I inl
7.1-7.7 mm (0.29- 0.30
sth Sido:
REVERSC
SIOE
REVERSE
OIL GUTTERPLATE
'
'--
sTHSIDE
1 3 - 11
vnx.su
ReverseChangeHolder,Reverseldler Gear
ClearanceInspectionlcont'd)
Removal
1.
Standard:
0.5 - 1.1 mm (0.02- 0.04 inl
SorvicoLimit: 1.8 mm (0.07inl
REVERSECHAMiE HOII'ER
REVERSE
CHA'{GEHOLDER
4.
Removothe reversechangeholder.
2.
lf the clearanceis more than the service limit, measurethe width ofthe reversechangehold6r.
St.ndrrd: 13.0- 13.3mm (0.512- 0.52/tinl
REVERSE
IDI.TR
GEAFSHAFT
REVERSE
CHANGEHOTI'ER
13-12
vnx.su
ChangeHolderAssembly
ClearanceInspection
Measurethe clearancebetween the shift piece and
the shift arm holder.
3.
INTERLOCK
It the cloaranceis more than the service limit, measureth width of the groovein the shift piece.
4.
lf the clearanceis more than the servicelimit, measurethe width ot the interlock.
Stlndrrd: 9.9 - 10.0mm (0.391t- 0.39ain)
SHIFTPIECE
ll the width of the groove is not within the standard,replscethe shift piecswith a new one.
lf the width of the grooveis within the standard.
roolacethe shift arm holder with a new one.
13-13
vnx.su
ChangeHolderAssembly
ClearanceInspection{cont'd}
7,
Standard:
0.05- 0.35 10.002- 0.01i1in)
SorvicoLimit: 0.8 mm (0.03in)
SETICTABM
SHIFTARM HOLDER
10 mm SHIM
8.
1 0 . ll the clearanceis more than the servicelimit. measurethe grooveof the changepiece.
Standafd: 12.05- 12.15mm {0.47ilil- 0.iU83 in)
10 mm Shim
Part Numbsr
24435-689-000
B
24436-689-000
Thicknss
0.8 mm (0.03'lin)
'1.0mm (0.039
in)
24437-689-000
1 . 2m m ( 0 . 0 4 7i n l
24438-689-000
1 . 4m m { 0 . 0 5 5i n )
24439-689-000
1.6mm (0.063in)
13-14
vnx.su
Removal
Removs the shift piece shaft, then remove the shift
piecaand the interlock.
thochangepiece.
0.05- 0.35mm (0'002- 0'014in)
Sundrrd:
S.rvic. Limit 0.5mm 10.02Inl
SHAFT
SHIFTPIECE
SEI.ECTARl,l
2.
Removethe changeholderassembly.
1 2 . lf the clesranceis more than the servicelimit, measurethe width ofthe changePiece.
- o.'U&l in)
Strndrrd: 12.05- 12.15mm {0./17,11
CHANGEHOLDERASSEMBLY
PIECE
CHANGE
13-15
vnx.su
ChangeHolderAssembly
Disassembly/Reassembly
I
eriorto reassembling.
cleanall the partsin solvent,dry them and apply lubricantto any contactsurfaces.
10 mm SHIM
SELECTRETURNSPRING
3 mm PIN
13-16
vnx.su
Shift Fork
Mainshaft,Gountershaft,
- Removal
1.
4.
Removethe chamberplate.
CLUTCHHOUSING
CHAMBCRPLATE
CLUTCHHOUSING
13-17
vnx.su
Shift Rod
Removal
1.
2.
3.
4.
R e m o v t h o s h i t t r o d , t h e n r e m o v e t h e c h s n g e
piece.
5.
Removeth oilseal.
SETSCBEW
OIL SEAL
Roploc.
CHANGEPIECE
*q
SPRING
L 25.6
ll.0r in,
STEELAALL
(D.5/16
SPRINGWASHER
ACHINGBOLT
13-18
vnx.su
Shift ForkAssembly
I
erior,o ,"""sembling,cleanall the partsin solvent,dry them and apply lubricantto any contactparts
mm PIN PUNCH
5TH/REVEFSE
SHIFTFORK
3RD/{TH SHIFTFORK
13-19
vnx.su
1.
Strndard:
0.2 - 0.5 mm {0.qt8 - 0.02 in]
S.rvico Limit: 0.8 mm (0.03inl
IFT FORK
SYNCHROSLEEVE
SHIFTPIECE
SHIFTFORK
lf the clearanceis more than the servicelimit. measure the thicknessof the shift fork finoers.
lf the clearanceis more than the servicelimit, measurethe width of the shift piece.
1 3 -2 0
vnx.su
MainshaftAssembly
NOTE:The 3rd/4thand the 5th svnchrohubsare installedwith a press.
cleanall the partsin solvent,dry them and apply lubricantto any contactsurfaces,The
Priorto reassembling.
3rdl,lthand the sth synch.ohubs,however,shouldbe installedwith a pressbeforelubricatingthem.
SYNCHROBING
page'13_35
Inspection,
818Cl cngino:
Inirllstion dstailr, pag. 13-27
STOPPER
RING
TAPERRING
NEEDLEBEARING
lnspectfor wear
and operation.
3RD/'TH SYNCHROSLEEVE
3RD/'TH SYiICHROHUB
SPACER
Insp6clron,
page13-35
SPRING
SPRING
3RDGEAR
Inspectaon.
page 13-22
NCEDE AEARING
Inspocltor wear
and operalton.
SYNCHROHUB
SYNCHROSI..EEVE
SYNCHRO
SPRING
Inspectaon.
pag6 13-35
5TH GEAR
rnspec!on,
page13-24
SPACER
COLLAR
4TH GCAR
Inspection,
page13-23
13-21
vnx.su
MainshaftAssembly
ClearanceInspection
NOTE: lf replacementis required.always replacethe
synchrosleeveand the synchrohub as a set.
1.
2.
lf the clearanceis more than the servicelimit, measurethe thicknessof 3rd gear.
EngineType
Standard
Standard:
0.06- 0.21 mm {0.002- 0.008inl
Ssrvica Limit: 0.3 mm (0.01in)
ServiceLimit
818C1
34.92- 34.97mm
- 1 . 3 7 7i n )
(1.375
81881
34.42- 34.47mm
- 1 . 3 5 7i n )
(1.355
34.8 mm
( 1 . 3 7 0i n )
34.3mm
(1.350
in)
3RD GEAR
lf the thicknessof 3rd gear is lessthan the service limit, replace3rd gearwith a new one.
lf the thicknessof 3rd gear is within the service
limit, replacethe 3rd/4thsynchrohub with a new
one.
13-22
vnx.su
,
Measurethe clsarancebetwen,lth gear and the
soacercollar.
5.
EngineType
Standard
ServiceLimit
1.
818C1
3 1 . 4 2- 3 1 . 4 7m m
- 1.239
(1.237
in)
81881
30.92- 30.97mm
'1.2'19
inl
\1.211-
3 1 . 3m m
l'1.232inl
30.8mm
( 1 . 2 1i3n )
lf the thicknessof 4th gear is less than the service limit, replace4th gearwith a new one.
lf the thicknessof 4th gear is within the service
limit, replacothe 3rdl4thsynchrohub with a new
one.
SPACERGOLLAR
(cont'd)
13-23
vnx.su
MainshaftAssembly
GlearanceInspection(cont'd)
M e a s u r et h e c l e a r a n c eb e t w e e n5 t h g e a r a n d t h e
spacerco ar.
8.
sTH GEAR
sTH GEAR
SPACERCOLLAR
13-24
vnx.su
lf the thicknessof sth gear is lessthan the service limit,replacesth gearwith a new one.
lf the thicknessof 5th gear is within the service
l i m i t , r e p l a c et h e 5 t h s y n c h r oh u b w i t h a n e w
one,
- Disassembly
R e m o v et h e b a l l b e a r i n gu s i n ga b e a r i n gp u l l e ra s
3.
S u p p o r t3 r d g e a r o n s t e e l b l o c k s ,a n d p r e s st h e
mainshaftout of the 3rd/4thsynchrohub, as shown.
BEARING
PULLER
BALLBARING
13-25
vnx.su
MainshaftAssembly
Inspection
1 . Inspectthe gear surfacesand the bearingsurfacss
for wear and damage,then measurethe mainshaft
at pointsA, B. and C.
2.
Standord:
- 1.102'linl
A: 27.987- 28.000mm 11.1018
B: 37.98/r- 38.q)0 mm {1.il95il- l.il960 in}
Ct 27.977- 27.99Omm {1.1015- 1.1020in}
Inspectfor runout.
Stlnd.rd:
0.02 mm (0.(xxl8inl M!I.
S.rvic. Limit 0.05 mm (o.qP inl
N O T E : S u D p o r tt h e m a i n s h f ta t b o t h e n d s a s
shown.
SrvicoLimit;
A: 27.9{, mm (1.1(XXlin}
B:37.930mm 11.4933
inl
C: 27.930mm {1.0996in}
l f t h e r u n o u t i s m o r 6 t h a n t h s s e r v i c el i m i t ,
rsplacethe mainshaftwith a n6w one.
13-26
vnx.su
ReassemblV
1_
CAUTION:
o Pless the 3rd/ilth and the 5th synchro hubs on the
msinshafi without lubrication.
. When installing the 3rd/4th and the sth synchro
hubs, support the mainshaft on the steel blocks, and
install synchro hubs using a press,
. Install the 3rd/,lth and the sth synchro hubs with a
maximum pressureof 19.6kN (2.000kgf, 1+466lbt).
^JOTEiReferto page 13-21for reassemblysequence.
Support 2nd gear on steel blocks,then install the
3rd/4thsynchro hub using the specialtools and a
press,as shown.
2,
ATTACHMENT,
35 mm l.D.
PRESS
sTH SYNCHROHUB
077t6- 00304{x)
DRIVER.40 mm l.D.
07746- 0030100
3RD/4TH
SYNCHROHUB
2NO GEAR
DRIVER4o mm l.D.
07746- tD30100
3RD/TTH
SYNCHRO
SLEEVE
2NDGEAR
13-27
vnx.su
CountershaftAssembly
lndex
NOTE:The 4th and 5th gears are installedwith a press.
Priorto reassembling.
cleanall the pans in solvent,dry them and apply lubricantto any contactsurfaces.The 4th
and sth gears.however,shouldbe installedwith a pressbeforelubricatingthem.
SYNCHROSPBING
LOCKNUTReDlace.
l(E*0*10EN.m
/r1.0- 0 - 11.0kgtm,I
l8o- o-80rbf.ft
I
WASHER
BALLBEARING
Inspectfor wear
and operat|on,
NEEDLEBEARING
InspectIor wear
and operation.
SYNCHRORING
sTH GEAR
4TH GEAR
3RDGEAR
2ND GEAR
THRUST
BEARING
NEEDLEBEARING
Inspectfor wear
and operation.
SPACER
page13-29
Selection.
FRICTIONDAMPER
DOUB1I @NE
SYNCHROl818Cl .ngin.l
Inspection,page 13-35
SYNCHRORINGlBl8Bl .ngin )
Inspection,page 13-35
13-24
vnx.su
Inspection
Glearance
'L
3.
'HRUST SHIM
2.
23922-PKs-900
1.95mm (0.0768in)
1.96mm (0.0772in)
Part Numb"r
2 3 9 1 7 - P 2 1- 0 1 0
23918-P2r-010
Thicknces
23924-PKs-900
1.97mm (0.0776in)
1.98mm (0.0780in)
23925-PKs-900
1.99mm {0.0783in)
2 3 9 2 6 - P K s - 9 0 0 2.00mm (0.0787inl
23923-PK5-900
23927-PKs-900
H
23928-PKs-900
Spaccl
Thrust Shim
Part Numbar
23921- PKs- 900
4.
Thickncla
29.02- 29.0,{mm
( 1 . 1 4 2-5 1 . 1 4 3i3n )
29.07- 29.09mm
( 1 . 1 4 4-5 1 . 1 4 5 i3n )
2.01mm (0.0791in)
2.02mm (0.0795in)
2 3 9 2 9 - P K s - 9 0 0 2.03mm (0.0799in)
K
2 3 9 3 0 - P K s - 9 0 0 2.04mm {0.0803in)
2.05mm (0.0807inl
23931- PKs- 900
23932-PK5-900
23933-PKs-900
23934-PKs-900
23935-PKs-900
2 3 9 3 6 - P K s - 9 0 0 2.10mm (0.0827in)
2.06mm (0.0811in)
2.07mm (0.0815in)
2.08mm (0.0819in)
2.09mm (0.0823inl
13-29
vnx.su
CountershaftAssembly
Disassembly
't.
2.
S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.
4,
Raisethe locknuttab from the groove in the countershaft,then remove the locknut and the spring
washer.
BEARINGPULLER
BEARING
PULlTR
13-30
\
vnx.su
Inspection
1.
Inspgcttor runout.
0.02 mm {0.(xn8 inl Max.
Stlndrrd:
Srrvic. Limit 0.05 mm {0.(x)2in)
NOTE: Suppon the countershaftat both ends as
snown.
Inspecttor wear
6nd damage.
lor clogging.
Inspectoil passage
.
l f t h e r u n o u t i s m o r e t h a n t h e s e r v i c 6l i m i t ,
rgDlacethe countershaftwith a new one.
13-31
vnx.su
CountershaftAssembly
Reassembly
GAUTION:
. Pr93r 4th and 5th goar3 on the qountorshrft without
lubricrtion.
. Whon in3talling 4th and sth goa6, srpport the shaft
on st..l block3,8nd in3tall thc 9.116 uring a prors.
. Inst.ll 4th lnd 5th gcar with a maximum pro33urof
25.5 kN (2,6@ksr. 18,806lbo.
4.
Installthe reversegear.
I n s t a l lt h e s y n c h r os p r i n g , a n d t h e d o u b l e c o n e
s y n c h r o( 8 1 8 C ' le n g i n e ) ,o r s y n c h r or i n g ( 8 1 8 8 1
engine), as shown.
SYNCHRO
SPRING
NEEDLEBEARING
REVERSE
GEAfi
THRUSTSHIM
COUNTERSHAFT
Installthe spacer.
2ND GEAR
1ST/2ND
NEEDLEBEARING
SPACER
FRICTIONDAMPER
8.
lST GEAR
13-32
vnx.su
9 . S u p p o r t t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d
install4th gear usingthe specialtools and a press,
as snown.
PRESS
DRIVER.,l0
mm l.D.
07746- 0030100
DRIVER,40 mm l.O.
077{6 - 0030100
PRESS
ATTACHMENT,30 mm l.D.
07746 - d)30300
BALLBEARING
NEEDLEBEARING
1 0 . S u D D o r t h e c o u n t e r s h a f to n a s t e e l b l o c k , a n d
install5th gear using the specialtools and a press,
as shown.
12. S e c u r e l yc l a m p t h e c o u n t e r s h a f ta s s e m b l yi n a
benchvisewith wood blocks.
1 3 . Installthe spring washer.tighten the locknut,then
stakethe locknuttab into the groove.
LOCKNUT
1 0 8 * 0 * 1 0 8N . m ( 1 1 . 0- 0 - 1 1 . 0k g f . m ,
80+0*80lbf.ftl
DRIVER,40 mm l.O.
07746- 0030100
LOCKNUT
30 mm l.O.
ATTACHMENT,
0?7a6- (X)303(x)
wooo BLocKs
13-33
vnx.su
SynchroSleeve,SynchroHub
Installation
Inspection
'1. Inspectgear teeth on all synchrohubs and synchro
sleevesfor rounded off corners,which indicates
wear.
2.
I n s t a l le a c h s y n c h r o h u b i n i t s m a t i n g s y n c h r o
sleeveand checkfor Jrgedomof movement.
NOTE: lf replacementis required,always replace
the synchrosleeveand synchrohub as a set.
TEETH
LONGER
sYt{cHRo
HUBSLOT
SYNCHRO
HUB
SLEEVE
13-34
vnx.su
SynchroRing,Gear
r Inspection
1.
SYNCHROSPBING
SYNCHRORING
CC
GOODWORN
C: Inspectthe synchro sleeveteeth and matching
teethon the gearfor wear (roundedoffl.
oo
GOODWORN
D: Inspectthe gear hub thrustsurfacefor wear.
E: Inspectthe conesurfacefor wear and roughness.
F: Inspectthe teeth on all gears for uneven wear.
scoring,galling,and cracks.
Coatthe cone surfaceof the gearwith oil, and place
the synchroring on the matchinggear, Rotatethe
ring, makingsurethat it does not slip.
Measurethe clearancebetween the synchro ring
a n dg e a ra l l t h ew a y a r o u n d .
NOTE:Holdthe synchroring againstthe gear evenly while measuringthe clearance.
Synchro Ring-to-GgarClgarance
Standard: 0.85- 1.10mm
(0.033- 0.0/B in)
Limit:0.i1
mm 10.02inl
Service
Double Cone Synchro-to-GearCloaiance
Standald:
@: {Outer Synchro Ring to Synchro Cone)
0.5- 1.0mm 10.02- 0.0i1in)
@: lSynchroConeto Goar)
0.5- 1.0mm (0.02- 0.04in)
O: loutsr Synchro Ring to Gsarl
0.95- 1.68mm (0.037- 0.066inl
ServiceLimit:
6): 0.3 mm 10.01inl
@: 0.3 mm t0.01inl
G):0.6 mm (0.02in)
SYNCHROCONE
SYNCHRORING
13-35
vnx.su
ClutchHousingBearing
Replacement
Mainrhaft:
1.
3.
3/8' - 16SI.IDEHAMMCR
(commercially
av6ilable)
CTUTCH
ATTACHMEIVT,
a2 x 4t rnm
0r7a5- 0010300
()|L SEAI
Roplacs.
ADJUSTABIT
AEARING
PULER,25- a0mrn
07736- A01moA
2.
CLUTCHHOUSING
BATI.BEAMIO
13-36
vnx.su
3.
Countcr'h!ft:
'1. Bsnd the tab on the lock washer down, then remove
the bolt 8nd bearingretainerplate.
OIL GUIDCPLATE
CI-UTCH
HOUSING
CLUTCHHOUSING
3rE' - 16SUI'HAiiMER
availabls)
{commorcially
8 x 1 0m m
15N.mll.5 kd.m, 11lbf.ttl
LOCK
WASHEA
Repl6ce.
AD.'USTABIIBEARIITG
PULIIR, 25- ao mm
07t36- A0rm0a
13-37
vnx.su
MainshaftThrustGlearance
Adjustment
1.
72 mm THRUST
SHIM
TRANSMISSION
HOUSING
5.
OIL GUIDEPLATE
\.u
END of CLUTCHHOUSING
B
o
fr
INNEBRACEot BALLBEARltac
NOTE:
. Usea straightedgeand verniefcaliper.
. Measureat three locationsand averaoethe readIng.
ENDol
TRANSMISSION
HOUSING
MAINSHAFT
WASHER
2.61
- 0.93
1.68
AALLAEARING
13-38
vnx.su
7.
72 mm Thrust Shim
Part Number
23931- P21-000
2 3 9 3 2 - P 2- 0
100
c
D
23933- P21-000
-000
23934-P21
- P21-000
23935
F
-000
23936-P21
2 3 9 3 7 - P 2- 0
100
2 3 9 3 8 - P 2- 0
100
-000
23939-P21
J
23940-P2r-000
23941- P21-000
23912-P21-OOO
-000
23943-P21
2 3 9 4 4 - P 2 -10 0 0
23915- P21-000
23946- P21,000
L
M
N
o
P
23947-P21 -000
23948- P21 000
-000
23919-P21
-000
23950-P21
23951- P21-000
23952- P21 000
2 3 9 5 3 - P 2- 0
100
23954-P2r-000
-000
23955-P21
2 3 9 s 6 - P 2, 0
100
AB
2 3 9 5 7 - P 2 -10 0 0
23958- P21-000
23959- P21-000
AC
AD
AE
AH
AI
AK
AN
AO
- P21-000
23960
23961-P21 -000
23962 P21,000
-000
23963-P21
23964- P2'1-000
23965- P2'1-000
-000
23966-P21
-000
23967-P21
23968- P21-000
23969- P21 000
-000
23970-P21
23971 P21 000
Thickness
0.60mm (0.0236in)
0.63mm (0.0248in)
0.66mm {0.0260in}
0.69mm (0.0272in)
0.72mm (0.0283in)
0.75mm (0.0295in)
0.78mm (0.0307in)
in)
0.81mm (0.0319
in)
0.84mm (0.0331
0.87mm (0.0343
in)
in)
0.90mm (0.0354
in)
0.93mm (0.0366
0.96mm (0.0378
in)
0.99 mm (0.0390in)
in)
1.02mm (0.0402
in)
1.05mm (0.04'13
1.08mm (0.0425
in)
in}
1.11mm {0.0437
1.14mm (0.0449inl
1.17mm (0.0461in)
1.20mm {0.0472in)
1.23mm {0.0484in)
1.26mm (0.0496in)
1.29mm 10.0508
in)
in)
1.32mm 10.0520
in)
1.35mm (0.0531
1.38mm (0.0543
inl
1.41mm (0.0555
in)
1.44mm (0.0567
in)
1.47mm (0.0579
in)
1.50mm {0.0591in)
1.53mm {0.0602in)
1.56mm {0.0614in}
1.59mm (0.0626in)
1.62mm (0.0638in)
1.65mm (0.0650in)
1.68mm {0.0661in)
1.71mm 10.0673
in)
in)
1.74mm (0.0685
'1.77mm (0.0697
in)
1.80mm (0.0709
in)
?2 mm THRUST
otL
PLATE
TRANSMISSION
HOUSING
I n s t a l lt h e s p r i n g w a s h e ra n d w a s h e ro n t h e
ball bearing.
NOTE:
. Cleanthe springwasher,washerand thrust shim
throughlybeforeinstaliation.
. I n s t a l lt h e s p r i n g w a s h e r .w a s h e r a n d t h r u s t
shim properly.
a-=s-.r*os".^
.,,-B*^INGWASHER
Installthemainshaftin the clutchhousing.
- 4 . Placethe transmissionhousingover the main-
(cont'd)
13-39
vnx.su
MainshaftThrustClearance
Adjustment (cont'd)
-7. Slidethe mainshaftbaseover the mainshaft.
MAINSHAFT
12.Turnthe mainshaftholderbolt clockwise;stop turning when the dial gauge has reachedits maximum
m o v e m e n t .T h e r e a d i n go n t h e d i a l g a u g e i s t h e
amountof mainshaftend play.
CAUTION: Turning the mainshaft holder bolt mor
than 60 degrees after the needle ol the dial gauge
stops movingmay damagethe transmission,
DIALGAUGE
- ) , .
"7t/'-
'..' .'i'
i. ,
MAINSHAFTBASE
07GAJ- PG20130
NOTE:
. Back-outthe mainshaftholder bolt and loosen
the two hex bolts.
. F i t t h e h o l d e r o v e r t h e m a i n s h a f ts o i t s l i p i s
towardsthe transmission.
. A l i g n t h e m a i n s h a f th o l d e r ' sl i p a r o u n dt h e
g r o o v ea t t h e i n s i d eo t t h e m a i n s h a f ts p l i n e s ,
then tightenthe hex bolts.
MAINSHAFT
HOLOER
BOLT
f- t{-c
l\-_.r'
nrTh
|
MAINSHAFTHOLDER
07GAJ- PG201r0
l\nex
\ ._/_/lrl Borrs
L ___E_J
\
MAINSHAFT
HOLDER
07GAJ- PG20110
MAINSHAFTBASE
07cAJ _ PG20130
- 9 . S e a t t h e m a i n s h a f tf u l l y b y t a p p i n g i t s e n d w i t h a
plastic hammer.
- 1 0 . T h r e a dt h e m a i n s h a f th o l d e r b o l t i n u n t i l i t j u s t c o n tacts the wide surface of the mainshaft base.
1 3 -4 0
vnx.su
Transmission
ReassemblV
;
8. Installthe differentialassembly.
1 . l n s t a l l t h en e w o i l s e a l .
DIFFERENTIAL
ASSEMBLY
2.
Setthe changePiece.
3.
5.
lnstallthe changepieceattachingbolt.
6.
8x1.0mm
30 N.m 13.1kg{ m.
22 tbl.ltl
SETSCREW
1 2x ' 1 . 0m m
22N.m{2.2kg{.m,16lbl.ft}
SPRING
L. 25.6mm
N O T E :A l i g n t h e f i n g e r o t t h e i n t e r l o c kw i t h t h e
groovein the shiftfork shaft.
MAINSHAFT
I n s t a l l t h eo i l c h a m b e r P i a t e .
6x1.0mm
12 N.m (1.2kgt'm,9lbtft)
COUNTERSHAFT
SHIFTFORKS
(cont'd)
13-41
vnx.su
Transmission
(cont'd)
Reassembly
11. Install the change holder assembly.
6x1.0mm
15 N.m (1.5 kgf.m,
11 tbf.ftl
CHANGE
HOLDER
ASSEMBLY
REVERSE
IDLERGEAR
13-42
vnx.su
Installtheoil gutterplate.
15. Installthereversechangeholder.
BOLT
16mm SEAI-ING
29 N.m t3.0kgf m, 22 lbl'ftt
72 mm THRUSTSHIM
NOTE:
Liquid g.!k.t
(cont'd)
13-43
vnx.su
Transmission
(cont'd)
Reassembly
20. Installthedowel oins.
2 1 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n gb y a l i g n i n gt h e
groove in the housing with finger on the stopper
.ing.
GROOVE
TNANSMISSION
HOUSING
13-44
vnx.su
{
27. I n s t a l l t h e s t e s l b a l l s , t h e s p . i n g s , a n d t h e s e t
screws.
NOTE:Apply liquidgasket(P/N08718- 0001)to the
threads.
32 mm SEALING BOLT
25 N.m {2.5 kgl'm,
SWITCH
LTGHT
BAC|(-UP
2s N.m{2.5kg{.m,18lbtft)
,*"""."'"
HAiIGER B
SPRIMi
L. 30 mm
{1,2in}
8 x 1.25mm
24 N.m(2.4kgfm,
17lbtftl
/
I
l /
12x 1.0mm
22 N.m(2.2kgi.m.
10tbtft)
REVERSEIDI.^CR
SHAFT IOLT
l0 r 1.25rnm
5a t$m 15.5kg{.m.(} lbtftl
13-45
vnx.su
TransmissionAssembly
lnstallation
1.
2.
6,
N O T E :T o r q u et h e m o u n t i n gb o l t a n d n u t s i n t h e
sequenceshown.
Raisethe transmission,
then installthe transmission
mounI.
BELEASEFORKBOLT
29 N.m (3.0kgl.m,
22 tbt-ttl
O 12 x 1.25mm
54 N.m {6.5kgt m,
47 tbtfrl
@
I
RELEASE REEASE
FORK
FORK
BOOT
@ 12 x 1.25mm
7,1N.m 17.5kg{.m,
5/r lbtftl
7.
P l a c et h e t r a n s m i s s i o no n t h e t r a n s m i s s i o ni a c k ,
and raiseit to the enginelevel.
Replace.
1 4 x 1 . 5m m
1 2 x 1 . 2 5m m
64 N.m 16.5 kgf.m, 47 lbf.ftl
10 x 1.25mm
44 N.m lil,s kgt m,
33 tbf.ftl
13-4 6
vnx.su
8,
stiffnsrs.
SELF.LOCKINGBOLT
Replac.
12 x 1.25mm
12 x 1.25mm
5t N.tn {5.8
42 tbt ftt
8 x 1.25mm
24 N.m l2.a kgf.]n,
17 tbtftl
8 x 1.25
FROifTENGINE 2r N'm (2.4kg['m, 12 x 1.25ftm
5? N.rn l5.Ekg[.m,
17lbf.ttl
SnFFENERS
42 tbl.ft)
lBl8Cl lngin.l
RIGHT
10 x 1,25mm
il a N.m (i4.5kgf..n,
33 tbtftl
9.
NOTE:
. Installthe clip and the spring pin on the change
joint as shown.
. Turn the shift rod boot so the hole is facing
down as shown.
. Make sure the shift rod boot is installedon the
cnangeroo,
Installtheclutchcover.
8 x 1.25mm
22 N.rn 12.2kgl-m.
16 tbtftl
CHANGEROD
SPRINGPIN
Replace.
.
l3-
e-- nrr,l
I
ll'--PuNcH
CHANGE
EXTENSION
8 x 1.25mm
12 x 1.25mm
2il N'm 12.4kg{.m,
57 N.m ls.E kgf.m, 17 tbffrt
a:I lbl.trl
l818Bl .ngin.l
5xl.0mm
9.8 N.m 11.0kgt'm,
7 tbf.ftt
HEATSHIELD
(B18Cl .nginol
/^
"-*
sHtFTROOaOOt
2M
i@
qlL#
--7
C LIP
HOt.C
(cont'dl
13-47
vnx.su
Transmission
Assembly
Installation (cont'd)
1 4 . I n s t a l lt h e i n t e r m e d i a t e
s h a f ta n d t h e d r i v e s h a f t s
(seesection16)-
17. lnstall the exhaust pipe A, and the three way cata l y t i c c o n v e r t e r( B l 8 C ' 1e n g i n e ) ,a n d c o n n e c tt h e
heatedoxygensensor(HO2S)connector.
HO2S
CONNECTOR
2s tbtftt
-Sl
SET RING
Replace.
::.t
INTERMEDIATE
SHAFT
GASKET
Replace.
SELF.LOCKING
NUT
Replace.
8 x 1.25mm
THREEWAY
CATALYTIC 16 N'm 11.6kgt m,
CONVERTER l2tbt.ftl
1818C'l
enginel
10x 1.25mm
38 N.m (3.9 kgt m,
28 tbtft)
Replace.
15. Installthe ball joints onto the lower arm (see section18).
16. Installthe right damperfork (seesection18).
10x 1.25mm
43 N.m{4.oksf.m.32lbf.ft)
RIGHT
DAMPER
FOBK
LOWERARM
SELF.LOCKING
NUT
Replace.
12 x 1.25mm
64 N.m {6.5 kgf.m,
47 tbtft)
:\
CASTLENUT
12x 1.25mm
49 - 59 N.m 15.0- 6.0kgf m.
36 - 43 tbf.frl
COTTERPIN
Reptace.
13-44
L
vnx.su
SELF.LOCKING
NUT
Replace.
10 x 1 25 mm
54 N.m 15.5kgt m,
iro lbf.ftl
N O T E :U s e o n l y S u p e r H i g h T e m p U r e a G r e a s e
(P/N08798- 9002).
BACK.UPLIGI{T
SWITCHCONNECTOR
16 tbf.ftt
CLUTCHPIPE
6x1.0mm
9.8N.m {1.0kgf.m,7 lbfft)
GROUNDWIRE
8 x 1.25mm
22 N-m 12.2kgl.tr't,
tPlN 08798- 90021 16 rbf.ftl
HANGERB
24. Install the air cleaner housing assembly and the air
intake duct.
6x1.0mm
AIR CLEANER 9.8 N.m 11.0kgt'm,7 lbtftl
HOUSING
ASSEMALY
9 \
\<
8 x 1.25mm
8.8 N.m 10.9kgf.m,
6.s tbf.ft)
STARTER
MOTOR
CABLES
13-49
vnx.su
GearshiftMechanism
Overhaul
NOTE:
.Inspctrubberpartsforwearanddamagewhendisassembling;replaceanywornordamagedparts.
. lnstallthespringpin and the clip on the changejoint as shown.
. Turn the shift rod boot so the hole is facingdown as shown.
. Makesurethe shift rod boot is installedon the changerod.
t@)-I -/l
I t/
SHIFTIIVER KNoB
7.8N.m{0.8Isl.m, 6 lbt{tl
\U
8 x 1.25mm
22 N.m {2.2 kgt m, 16 tbtft)
#:
EXTENSION
END
WASHER
A
@-tHrFrLEVERaoor
SHIFTLEVER
DUSTSEALA
(7\
RUBBER
EXTENSION
WASHER
B
8x22mm
SPRINGPIN
Replace.
I
CHANGEROD
Replsc.
5x1.0mm
9.8 N.m 11.0kgf.m,
7 tbf.ftt
,,'/
"t't
9oo-
seu'locrtnc ruur
neptace.
8 x 1.25mm
22 N.m 12.2kg{ m, 16 tbtft)
SHIFTRODBOOT
;1tffi
=ff
NEARJOINT
BUSHING
O.RINGS
Replece.
REARJOINT BUSHING
THRUSTWASHER
13-50
vnx.su
CLIP
Automatic Transmission
'l4-2
H v d r a u l i cF l o w
L o c k - u pS y s t e m
14-3
't
4-6
14-8
14-14
14-23
. . . - - . . . . .1. 4 - 2 4
. . . . . . . .1 4 - 3 8
Eloctrical Systom
C o m p o n e nLt o c a t i o n. . . . . . . . . . . . , . . . , . . . . . . . . . . . .I.4. .-.4 5
. . . . . . . . . . . . 1. 4 - 4 6
C i r c u i tD i a g r a m
' T r o u b l e s h o o t i nPgr o c e d u r e.s. . . . . . . , . . . . . . . . . .l.4, - 4 8
Symptom-to-Component Chart
...... 14-50
ElectricalSystem
ElectricalTroubleshooting
T r o u b l e s h o o t i nFgl o w c h a r t. . . . . . . . . . . . . . . . . .1. .4 - 5 2
Lock-uoControl SolenoidValve A/8
- - . . . .\ 4 - 8 2
Test ..................
, . . . , . . . , . . ,1
. 4-82
ReDlacement
Shift Control SolenoidVslve A/B
. . . . . .1 4 - 8 3
Test ..................
. . . . . . . . . . . . .1. 4 - 8 3
Reolacement
TransmissionControl Module (TCM)
*ReDlacement
. . . . . . . . . . .1 4 - 8 4
SDeedSensors
Mainshalt/CountershaJt
. . . . . . . . . . . .1. 4 - 8 5
Reolacement
Hydraulic Systom
Symptom-to-Component Chart
HydraulicSystem
Road Test
Slall Speed
T e s t. . . . . . . . . . . . . . . . . .
FluidLevel
Checking/Changing
Pressu.e Testing
14-86
14-90
't4-92
14-93
14-94
Transmission
Transmission
. . . . . .1 4 - 9 9
R e m o v a. l. . . . . . . . . . . .
lllustratedIndex
R i g h tS i d eC o v e r. . . . . . . . . . . . . . . . . . . . . . . . . . .1. 4. .-.1.0. 4
.
T r a n s m i s s i oHn o u s i n 9. . . . . . . . . . . . . . . . . . , , . . . .I.4. .- 10 6
Torque Converter HousingNalve
. . . 1 4 -1 O 8
B o d y. . . . . . . . . . . . . . . . . .
Right Side Cover
. . . . . .1 4 - 1 1 0
R e m o v a. l. . . . . . . . . . . .
TransmissionHousing
. - . . - .1 4 - 1 1 2
R e m o v a. l. . . . . . . . . . . .
Torque ConvenerHousingNalveBody
. . . . . .1 4 - 1 1 4
R e m o v a. l. . . . . . . . . . . .
Valve Caps
.............1
. .4. - 1 1 6
Description
Valve Body
. . . - . .1 4 - 1 1 7
R e p a i .r . . . . . . . . . . . . . . .
Valve
A s s e m b l y. . . . . . . . . . .
Oil Pump
Inspection
vnx.su
SpecialTools
Rol. No.
Tool Numbsl
Description
OTGAB PF50lOO
oTGAB-PF50101
oTGAE-PG40200
oTHAC-PK4010A
oTHAE-PL50lOO
oTLAE-PX40100
OTLAJ PT30lOA
OTMAJ-PY4O'I
1A
oTMAJ-PY40120
-OO10100
oTPAZ
07406-OO20003
o7406 0070000
07736 A01000A
o7746-O010100
o7746-O010500
07746-OO10600
07746 0030100
o7749-O010000
07947-6340500
IA\
,6\
@
/
@
rt)
@
@
\9
@
@
@
@
@
@
Oty
Page Reference
MainshattHolder
'I
1 4 - 11 1 . 1 6 0
I
1
1
,1
14-144,147
1 4 - 113
1 4 -1 4 4 , 1 4 7
14 144,'t47
14-49,90
14-94
14-94
't
4-44
14-94
14-94
14-150,151
14-139,140
1 4 - 1 4 0 .510 , 15 1 , 15 2 ,15 3
14-150,152
14-134
14 - 13 9 , ' 1 4 01, 5 0 . 15 1 , 15 2
14,150
1
1
1
,|
1
1
1
1
1
I
I
'I
1
Edrn$r--
a)
a6l
14-2
vnx.su
The Automatic Transmissionis a combination of a 3-e,ement torque convefter and triple-shaft electfonically controlled
automatictransmissionwhich provides4 speedsforward and 1 speedreverse.The entireunit is positionedin line with
the engine.
Torque Converter, Gears and Clutches
The torqueconverterconsistsof a pump,turbineand statorassemblyin a singleunit, The torqueconverteris connected
to the enginecrankshaftso they turn togetheras a unit as the engineturns. Aroundthe outsideof the torque converter
is a ring gearwhich mesheswith the starterpinionwhen the engineis beingstaned. The entiretorqueconverterassembly servesas a flywheel while transmittingpower to the transmissionmainshaft.
The transmissionhas three parallelshafts,the mainshaft.countershaftand sub-shaft.The mainshattis in line with the
enginecrankshaft.
The mainshaftincludesthe clutchesfor 1st, and 2ndl4th, and gearsfor 3rd. 2nd, 4th, reverseand l st (3rd gear is integral with the mainshaft,while reversegear is integralwith the 4th gear).
The countershaftincludesthe 3rd clutch and gearsIor 3rd, 2nd,4th, reverse,lst and parking.Reverseand 4th gears
can be lockedto the countershaftat its center, providing4th gear or reverse,dependingon which way the selectoris moved.
The sub-shaftincludesthe lst-hold clutch and gearsfor 1st and 4th
The gearson the mainshaitare in constantmesh with those on the countershaftand sub-shaft.When certaincombinations of gearsin the transmissionare engagedby the clutches,power is transmittedfrom the mainshaftto the countershaft via the sub-shattto provide@, E, tr. tr and @ position.
Electronic Control
ControlModule{TCM),sensors,and 4 solenoidvalves.ShiftThe electroniccontrolsystemconsistsof the Transmission
ing and lock-upare electronicallycontrolledfor comfortabledriving under all conditions.
The TCM is locatedbelow the dashboard,behindthe left side kick panelon the driver's side.
Hydraulic Control
The valvebodiesincludethe mainvalvebody, secondaryvalvebody, regulatorvalvebody. servobody, and lock-upvalve
body throuqh the respectiveseparatorplates.
They are bolted on the torque converterhousing.
The main valve body containsthe manual valve, 1-2 shift valve, 2-3 shift valve, Clutch PressureCont.ol (CPC)valve,
4th exhaustvalve, relief valve, and oil pump gears.
The secondaryvalve body containsthe 4-3 kick-down valve,3-2 kick-down valve,2-3 orifice cont.ol valve, 3-4 shitt
valve, orifice control valve. modulatorvalve, and servo control valve
The regulatorvalve body containsthe pressureregulatorvalve.lock-upcontrolvalve,torqueconvertercheckvalve,and
cooler check valve.
The servo bodv containsthe servo valve which is integratedwith the reverseshift fork, throttle valve B, and accumulators.
The lock-ugvalve bodv containsthe lock-upshift valve and lock-uptiming B valve.and is boltedon the secondaryvalve
body.
Fluidfrom the regulatorpassesthrough the manualvalve to the variouscontrol valves.
Shitt Control Mochanism
Input to the TCM i.om varioussensorslocatedthroughoutthe car determineswhich shift controlsolenoidvalve should
be activated.
Activatinga shift control solenoidvalve changesmodulatorpressure,causinga shift valve to move. This pressurizes
a line to one of the clutches.engagingthat clutch and its correspondinggear.
Lock-up Mechanism
In @ position.in 2nd, 3rd and 4th, and E positionin 3rd, pressurizedtluid can be drainedfrom the back of the torque converterthroughan oil passage,causingthe lock-uppistonto be held againstthe torque convertercover. As this
takes Dlace,the mainshaftrotatesat the samespeedas the enginecrankshatt.Togetherwith hydrauliccontrol,the TCM
optimizesthe timing ol the lock-upmechanism.
The lock-upvalvescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and throttlevalveB
When lock-upcontrol solenoidvalves A and B activate,modulatorpressurechanges.Lock-upcontrol solenoidvalves
A and B are mountedon the torque converterhousing,and are controlledby the TCM.
(cont'd)
14-3
vnx.su
Description
(cont'd)
Gear Selection
The selectorlever has sevenposirions;E PARK,E REVERSE,
N NEUTRAL,@
, l 2 n d g e a ra n d [ ] 1 s t g e a r .
t h r o u g h3 r d p o s i t i o n sQ
Position
PARK
l3?]]
1st
Description
Front wheels locked; parkingpawl engagedwith parkinggear on countershatt.All clutches
reteaseo,
[R] REVERSE
N
NEUTRAL
'lst,
D+l DRIVE
shifts automaticallyto 2nd, 3rd, then 4th, dependingon vehicle
Generaldriving;starts off in
('lst through 4th) speed and throttle position.Do'vnshiftsthrough 3rd, 2nd and 1st on decelerationto stop.
The lock-upmechanismcomes into operationin 2nd, 3rd and 4th when the transmissionin lDt
posrtron.
Dgi DRIVE
For rapid accelerationat highway speedsand generaldriving; starts off in 1st. shifts automatical(1st through 3rd) ly to 2nd then 3rd, dependingon vehiclespeed and throttle position.Downshiftsthrough lower
gearson decelerationto stop. The lock-upmechanismcomes into operationin 3rd.
El SECOND
Drivingin 2nd geari stays in 2nd gear, does not shift up and down.
For enginebrakingor better traction starting off on loose or slipperysurfece.
L]l FIRST
Drivingin 1st gear; stays in lst gear, does not shilt up.
For enginebraking.
14-4
vnx.su
VALVE
BODIES
TOROUECONVERTER
ASSEMBLY
1ST-HOLDCLUTCH
VEHICLESPEEDSENSORIVSSI
3RD CLUTCH
SUB SHAFT
MAINSHAFT
SPEEDSENSOR
SPEEDSENSOR
1ST CLUTCH
COUNTERSHAFT
14-5
vnx.su
Description
Clutches
gears.
the transmission
The four speedautomatictransmission
useshydraulically
actuatedclutchesto engageor disengage
When clutch pressureis introducedinto the clutch drum, the clutch piston is applied.This pressesthe iriction discs and
steel platestogether,lockingthem so they don't slip. Power is then transmittedthrough the engagedclutch pack to
jts hub-mountedgear.
Likewise,when clutch pressureis bled from the clutch pack. the pistonreleasesthe friction discs and steel plates,and
they are {ree to slide past each other while disengaged.This allows the gear to spin independentlyon its shaft, transmitting no power.
1st Clutch
The l st clutch engages/disengages
1st gear,and is locatedat the end of the mainshaft,just behindthe right sidecover.
The 1st clutch is suppliedclutch pressureby its oil feed pipe within the mainshaft.
1st-holdclutch
The 1st-holdclutch engages/disengages
1st-holdor I Fosition,and is locatedat the centerol the sub-shaft.The 1sthold clutch is suppliedclulch pressureby its oil feed pipe within the sub-shait.
2nd Clutch
The 2nd clutch engages/disengages
2nd gear, and is locatedat the center of the mainshaft.The 2nd clutch is joined
back-to-backto the 4th clutch. The 2nd clutch is suppliedclutch pressurethroughthe mainshaftby a circuitconnected
to the regulatorvalve body.
3rd Clutch
The 3rd clutchengages/disengages
3rd gea..and is locatedat the end oJthe countershaft,oppositethe right sidecover.
The 3rd clutch is suppliedclutch pressureby its oil feed pipe within the countershaft,
4th clurch
The 4th clutch engages/disengages
4th gear. as well as reversegear, and is locatedat the center of the mainshaft.
The 4th clutch is joined back-to-backto the 2nd clutch. The 4th clutch is suppliedclutch pressureby its oil feed pipe
within the mainshalt.
One-way Clutch
The one-wayclutch is posjtionedbetweenthe parkinggear and 1st gear. with the parkinggear splinedto the countershaft. The 1st gear providesthe outer race, and the parkinggear providesthe inner race surface.The one-way clutch
locks up when power is transmittedfrom the mainshaft 1st gear to the countershaftlst ggel _
The 1st clutch and gears remainengagedin the 1st. 2nd. 3rd, and 4th gear rangesin the @, E or E position.
However,the one-way clutch disengageswhen the 2nd. 3rd, or 4th clutches/gearsare appliedin the E, lD.l o, E
oosttton.
This is becausethe increasedrotationalspeedof the gearson the countershaftover-ridethe locking"speed range" of
the one-way clutch. Thereafter,the one-way clutch free-wheelswith the lst clutch still engaged.
1ST GEAR
COUNTERSHAFT
LOCKS
aF
FREE
:>
NOTE:
Viewtrom rightsidecoverside.
14-6
vnx.su
MAINSHAFT
4TH GEAR
SUB.SHAFT4TH GEAR
MAINSHAFT3RD GEAR
lST,HOLD CLUTCH
MAINSHAFT
2ND GEAR
TOROUE
CONVERTER
SUB-SHAFT1ST GEAR
2ND CLUTCH
SUB.SHAFT
STARTER
NINGGEAR
4TH CLUTCH
MAINSHAFT1ST
GEAR
LOCK-UP
CLUTCH
1ST CLUTCH
DRIVE PLATE
MAINSHAFT
ONE-WAY CLUTCH
PARKINGGEAR
,IST GEAR
COUNTERSHAFTREVERSEGEAR
REVERSESELECTOR
HU8
REVERSE
SELECTOR
COUNTERSHAFT4TH GEAR
COUNTERSHAFT2ND GEAR
COUNTERSHAFT
3RD GEAR
FINALDRIVENGEAR
3RD CLUTCH
DIFFERENTIAL
14-7
vnx.su
Description
Power Flow
--.-.-___-t.-t*
REVERSE PARKING
4TH
1STGEAR2ND GEAR3RDGEAR
t5tGEAR
GEAR
3RD
2ND
1ST
HOLD
VERTER CLUTCH CLUTCH CLUTCH CLUTCH GEAR CLUTCH
TOROUE
coN-
tr
1ST
2ND
3RD
4TH
1ST
2ND
3RD
tr
tr
o
o
o
o
o
o
o
o
o
o
o
o
X
X
o
'o
X
X
X
X
x
X
.o
-o
o
-o
-o
.o
X
X
o
X
':
Q: Operates,X: Doesn'toperate, Althoughthe 1st clutch engages,drivingpowe. is not transmittedas the one-way
clutch sliDs.
14-8
vnx.su
@ Position
pressure
to the countershaJt.
Hydraulic
is not appliedto the clutches,Poweris not transmitted
@ Position
Hydraulicpressureis not sppliedto the clutches.Poweris not transmittedto the countetshaft.
the parkinggear.
is lockedby the parkingpawl interlocking
The countersha{t
TOROUECONVERTER
REVERSESELECTOR
HUB
PARKINGGEAR
REVERSESELECTOR
REVERSEGEAR
SERVOVALVE/
SHIFTFORKSHAFT
14-9
vnx.su
Description
Power Flow lcont'dl
Lll Position Acceloration
In f
Hydraulicpressureis appliedto the 1st clutch on the mainshaltand power is transmittedvia the lst clutch to the
mainshaft1st gear.
2.
3.
Power is transmittedto the finai drive gear and drivesthe final d.iven gear,
SUB.SHAFT 'IST GEAR
SUB-SHAFT4TH GEAR
lST-HOLD CLUTCH
SUB-SHAFT
MAINSHAFT1ST GEAR
1ST CLUTCH
COUNTERSHAFT
ONE-WAY CLUTCH
PARKINGGEAR
,IST GEAR
FINAL DRIVENGEAR
14-10
vnx.su
L!_jPosition Deceleration
The power tlow when deceleratingis as follows;
1.
Rollingresistancelrom the road surfacegoesthroughthe tront wheelsto the final drive gear,then to the sub-shaft
1st gear via the 4th gear, and lst-hold clutch which is appliedduring deceleration.
2.
3.
The counterforceconveyedto the countershaft4th gear turns the sub-shaft4th gear via the mainshaft4th gear.
At this time, sincehydraulicpressureis also appliedto the 1st clutch, counterfo.ceis alsotransmittedto the mainshaft. As a result, enginebrakingcan be obtainedwith lst gea.-
CLUTCH
TOROUECONVENTER
SUB-SHAFT
4TH GEAR
SUB-SHAFT1ST GEAR
SUB'STIAFT
lST CLUTCH
MAINSHAFT
COUNTERSHAFT
FINAL DRIVE
REVEFSESELECTORHUB
REVERSESELECTOR
4TI1 GEAB
(cont'dl
14-11
vnx.su
Description
Power Flow (cont'd)
Ll Position
@ Positionis providedto drive only 2nd speed.
1.
Hydraulicpressureis appliedto the 2nd clutch on the mainshattand power is transmittedvia the 2nd clutch to the
mainshaft2nd gear.
2.
Powertransmittedto the mainshalt2nd gearis conveyedvia the countershaft2nd gear,and drivesthe countersha{t.
3.
Power is transmittedto the final drive gear and drives the final driven gear.
NOTE:
Hydraulicpressureis also appliedto the lst clutch, but since the rotationspeedof the 2nd gear exceedsthat of
1st gear, power from 1st gear is cut off at the one-way clutch.
TOROUECONVERTER
2ND CLUTCH
MAINSHAFT
COUNTERSHAFT
FINAL DBIVE
2ND GEAR
FINALDRIVENGEAR
14-12
vnx.su
In [Q! or l!31 position.the optimumgear is automaticallyselectedfrom 1st, 2nd, 3rd and 4th speeds,accordingto conditionssuch as the balancebetween throttle opening(engineload) and vehiclespeed.
D! or lE.l Position, lst speed
1. Hydraulicpressureis appliedto the lst clutch. which rotatestogether with the mainshaft,and the mainshaftlst
gear rorares.
2.
Power is transmittedto the countershaft1st gear, and drivesthe countershaftvia the one-way clutch.
3.
Power is transmittedto the final drive gear and drives the final driven gear.
NOTE:
In lDil or [Dl]l position,hydraulicpressureis not appliedto the 1st-holdclutch.
TOROUECONVERTER
1ST CLUTCH
MAINSHAFT
COUNTERSHAFT
FINALDRIVEGEAR
FINALDRIVENGEAR
(cont'd)
14-13
vnx.su
Description
PowerFlow (cont'd)
JD.l or lD"l Position, 2nd speed
1.
Hydraulicpressureis appliedto the 2nd clutch, which rotatestogetherwith the mainshaft,and the mainshatt2nd
gear rotates.
2.
3.
Power is transmittedto the tinal drive gear and drives the final driven gear.
NOTE:
In @ or @ position,2nd speed,hydraulicpressureis also appliedto the lst clutch. but sincethe rotationspeed
of 2nd gear exceedsthat of 1st gear. power trom lst gear is cut off at the one-way clutch.
2ND CLUTCH
TOROUECONVERTER
MAINSHAFT
COUNTERSHAFT
FINAL DRIVE GEAR
14-14
vnx.su
Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshatt3rd gearis transmittedto the countershaft
3rd gear,
2.
Power is transmittedto the tinal drive geat and drives the final driven gear.
NOTE:
In ]Dil or lDJl position.3rd speed.hydraulicpressureis also appliedto the Ist clutch, but sincethe rotationspeed
of 3rd gear exceedsthat of 1st gear, power trom lst gear is cut ofJ at the one-way clutch,
TOROUECONVERTER
MAINSHAFT 3RD GEAR
MAINSHAFT
COUNTERSHAFT
FINAL DRIVE
GEAR
3RD CLUTCH
FINAL DBIVEN
GEAR
14-15
vnx.su
Description
Power Flow (cont'dl
E
1.
Hydraulic pressure is applied to the 4th clutch, which rotates together with the mainshatt, and th mainshaft 4th
gear rotates.
2.
Power is transmifted to the countershaft 4th gear, and drives the countershaj-t.
3.
Power is transmittedto the final drive gear and drivesthe final driven gear.
NOTE:
In @ Oosition,4th speed, hydraulic pressure is also applied to the 1st clutch, but since the rotation sped of 4th
gear exceedsthat oJ 1st gear, power from 1st gear is cut off at the one-way clutch.
TOROUECONVERTEB
4TH CLUTCH
MAII{SHAFT
COUI{TERSHAFT
REVERSE
SELECTOR
HUB
REVERSESELECTOR
14-16
vnx.su
llj
Po.ltbn
1.
Hydraulic pressure is swilched by the manual valve to the se.vo v8lve, which moves the reverse shilt tork to the
rverseposition. The reverseshiJt fork engageswith the reverseselector, reverseselsctor hub,and the countershaft
raverss gar.
2.
Hydraulic pr6ssure is also applid to the 4th clutch. Power is transmifted from the mainshaft reverse gear via the
revetse idler g6ar to the countershaft reverse gear.
3.
Rotation dirsction ol the countershsft reverse gear is changed via the .everse idler gear.
4.
Powef b transmitted to the linal drive gear and drives the final driven gear.
TOROUECONVEBTER
4TH CLUTCH
MAI SHAFTREVERSE
GEAR
COUNTERSHAFf
REVERSE
SELECTOR
HUB
FII{AL DRIVEGEAR
REVEFSESELECTOR
COUIITERSHAFT
REVERSE
GEAR
14-17
vnx.su
Description
ElectronicControlSystem
Electronic Control System
The electroniccontrolsystemconsistsof the TransmissionControlModule(TCM),sensors.and 4 solenoidvalves.Shifting and lock-upare elect.onicallycontrolledfor comfortabledriving under all conditions.
The TCM is locatedbelow the dashboard,behindthe left side kick panel on the driver's side.
Lock-up Control
Solonoid Valvo A
14-18
vnx.su
Lock-up Control
From sensorinput signals,the TCM determineswhether to turn the lock-upON or OFF and activateslock-upcontrol
solenoidvalve A and/or B accordingly.
The combinationof driving siqnalsto lock-upcontrol solenoidvalves A and B is shown in the table below.
Lock-upcontrol Solenoidvalve
\
B
Lock-upcondition
Lock-upOFF
OFF
OFF
Lock-up,slight
ON
OFF
Lock-up.halt
ON
ON
Lock-up.full
ON
ON
Lock-up
during deceleration
ON
Duty operation
OFF-ON
Shifl Conrrol
The TCM instantaneously
determineswhich gear shouldbe selectedby varioussignalssent trom sensors.and actuates
the shift controlsolenoidvalvesA and B controlshitting.Also. a GradeLogicControlSystemhas beenadoptedto control
shifting in E] positionwhile the vehicleis ascendingor descendinga slope, or reducingspeed.
E,E
E
a
tr
l-Rl
('lst)
(2ndl
OFF
ON
ON
ON
(3rd)
ON
OFF
(4th)
OFF
OFF
(2nd)
ON
ON
(lst)
ON
OFF
{Reverse)
ON
OFF
(cont'd)
14-19
vnx.su
Description
ElectronicControl System (cont'd)
.
How it works:
The TCM comparesactual drivingconditionswith drivingconditionsmemorizedin the TCM. basedon the input trom
the vehiclespeed sensor,throttle positionsensor,enginecoolanttemperaturesensor,brake switch signaland select
lever positionsignal,to control shifting while a vehicleis ascendingor descendinga slope. or reducingspeed.
SIGNALSDETECTED
Dliving Resistance
Engine Coolant
TemDerature Sensor
14-20
vnx.su
. Ascending Contlol
When the TCM determinesthat the vehicleis climbinga hill in @ position,the system extendsthe engagementarea
Irom frequenrlyshittingbetween3rd and 4th gears,so the vehiclecan run smooth
of 3rd gearto preventthe transmission
and have more power when needed.
NOTE: Shift schedulesbetween 3rd and 4th gear are stored in the TCM to enablethe transmissionto automatically
selectthe most suitablegear accordingto the magnitudeof a gradientby Fuzzylogic.
. Descending Control
When the TCM determinesthat the vehicleis going down a hill in @ position.the shift-upspeedfrom 3rd to 4th gear
when the throttle is closedbecomestaster than the set speedfor tlat road drivingto widen the 3rd gear drivingarea.
This, in combinationwith engine brake from the decelerationlock-up, achievessmooth driving when the vehicle is
descending.
Thereare two ascendingmodeswith different3rd gear driving areasaccordingto the magnitudeof a gradientstoredin
theTCM.
When the vehicleis in 4th gear, and you are deceleratingon a gradualhill, or when you are applyingthe brakeson a
steephill,the transmissionwill downshittto 3rd gear.When you acceleratethe transmissionwill then returnto 4th gear.
Vohicle SDood
. DecelerationControl
When the vehiclegoes around a corner,and needsto deceleratefirst and then accelerate,the TCM sets the data for
decelerationcontrolto reducethe numberof times the transmissionshiftsto obtain smooth driving.When the vehicle
is decelerating
from speedsabove27 mph (43 km/h).the TCM shiftsthe transmissionfrom 4thto 3rd earlierthan normal
to cope with upcomingacceleration
to maintainsmooth driving.
NOTE:
FuzzyLogic:Fuzzylogic is a from at artificialintelligencethat lets computersrespondto changingconditionsmuch like
a human mind would.
14-21
vnx.su
Description
ElectronicControl System {cont'dl
*t-l
777
TH
SCI
sHtfTc0mRoL
scs
ECM
SHFTCOI{rFOL
VALVEB
SOLINOIO
ACCL
AFSB
NEP
LG1
TOCK-UPCONTROL
SOLENOIOVALVE
A
LG2
SPEEO
SENSOF
COUNTE8SHAFI
SPEEO
SENSOR
L_______.1
tGcotL
LOC(- UPCONTROL
SOLENOIO
VALVEB
f-r,'__l
I Jll6
i
A/T CEANPOSITION
INDICATOR
14-22
vnx.su
Hydraulic Control
The valvebodiesincludethe main valvebody, secondaryvalvebody, regulatorvalvebody, servobody and lock-upvalve
body.
The oil pump is driven by splinesbehindthe torque converterwhich is attachedto the engine.Oil flows th.ough the
regulatorvalve to maintainspecifiedpressurethrough the main valve body to the manualvalve, directingpressureto
each of the clutches,
SHIFT CONTROLSOLEIIOID
VALVE ASSEMBLY
RTGHTSIDECOVER
LOCK.UPVALVEBODY
VALVEBODY
V
REGULATOR
BODY
4<.__i
:
)o.-
14-23
vnx.su
Description
HydraulicControl(cont'dl
Ragularol Valve Body
The .egulator valve body is located on the main valve body. The regulator valve body consists of th regulator valva,
toroue converter check valve, cooler check valve, and lock-up contlol valve.
VALVE
REGULATOR
VALVE
REGULATOR
BODY
COOLERCHECKVALVE
LOCT.UPCONTROI.
VALVE
TONOUECOI{VERTEB
CHECKVALVE
LOCK.UPSHIFT VALVE
TIMITG B VALVE
14-24
vnx.su
Rcgulator Valve
The rgulator valve maintains a constant hydraulic pressure from the oil pump to the hydraulic control system, whil
alEofurnishingoil to the lubricatingsystem and torque convener.
Oil flows through B and B'. The oil which entersthrough B flows thfough the valve orificeto A, pushingthe regulator
valve to the right. Acco.dingto the level of hydraulicpressurethrough B, the positionof the valve changes,and the
amount of the oil thlough D from B'thus changes.This operationis continued.thus maintainingthe line pressure.
IEI{GINE]IIOT RUNNINGI
{ENGINERUNNING)
TOR VALVE
STATOR SHAFT
(cont'd)
14-25
vnx.su
Description
Hydraulic Control (cont'dl
Main Valvo Body
The manualvalve, 1-2 shift valve, 2-3 shift valve. 4th exhaustvalve. CPC valve, and relief vatve are all assembledin
the main valve body,
The primaryfunctionof this valve body is switchingoil passageson and off and controllingthe hydraulicpressuregotng
to the hydrauliccontrol system.
CPC VALVE
4TH EXHAUSTVALVE
RELIEFVALVE
MANUAL VALVE
MAIN VALVE BODY
1.2 SHIFT VALVE
2-3 ORIFICECONTBOLVALVE
3.4 SHIFT VALVE
VALVE BODY
COITTROLVALVE
MOOULA
14-26
vnx.su
S6rvo Body
The servo bodv is locatedon the secondaryvalve body.
The servovalveis integratedwith the shiit fork shatt, throttlevalve B. and accumulatorpistons,which are all assembled
in the servo bodv.
SERVOVALVE/
SHIFTFORKSHAFT
THROTTLEVALVE B
SERVOBODY
THROTTLELONG VALVE
Accumulator Pislons
piston
The accumulatorpistonsare assembledin the servo body and right side cover. The l st-holdclutch accumulator
pistons
in
lhe
servo
body.
assembled
are
is in the right side cover, and the 1st, 2nd 3rd, and 4th accumulator
1ST-HOLDACCUMULATOR
RIGHTSIDECOVER
4TH ACCUMULATOR
IST ACCUMUI-ATOR
2ND ACCUMULATORPISTON
3RD ACCUMULATORPISTON
14-27
vnx.su
Description
HydraulicFlow
Genelal Chart ol Hydraulic Pressure
Line Pressure
Torque ConverterPressure
LubricationPressure
- , .
Ltne rressure
Torque ConverterPressure
]
LubricationPressure
L
. M a n u a lV a l v e
. ModulatorValve
ModulatorPressure
. 1-2ShiltValve
l
. 2-3 Shitt Valve
. 3 4 Shift Vlave
]
. Throttle Valve B
NO.
Clutch Pressure
Throttle B Pressure
D E S C R I P T I OONF P R E S S U R EN O .
LINE
6C
LINE
6D
LINE
3'
LINE
10
3"
LINE
LINE
D E S C R I P T I OONF P R E S S U R EN O .
MODULATOR
CONTROL
SOLENOID
VATVE
AI
ITOCK-UP
MODULATOR
(IOCX.UP
CONTROT
SOTENOID
VALVE
B)
D E S C R I P T I OONF P R E S S U R E
55
THROTTLEB
56
THROTTLEB
LINE
57
THROTTLEB
l ST CLUTCH
58
THROTTLEB
1ST-HOLD
CLUTCH
90
T O R O U EC O N V E R T E R
It)
l ST.HOLDCLUTCH
91
TOROUECONVERTER
LINE
18
LINE
92
T O R O U EC O N V E R T E R
LINE
20
2ND CLUTCH
93
O I LC O O L E R
5'
LINE
21
2ND CLUTCH
94
TOROUECONVERTER
5"
LIN E
25
LINE
95
LUBRICATION
MODULATOR
30
3RD CLUTCH
96
TOROUECONVERTER
6'
MODULATOR
31
3RD CLUTCH
97
TOROUECONVERTER
6A
MODULATOR
(SHIFT
CONTROL
SOTENOID
VALVE
A
MODULATOR
(SHIFT
CONTROL
VALVE
SOLENOID
B
40
4TH CLUTCH
99
SUCTION
41
4TH CLUTCH
6B
14-28
vnx.su
BLEED
E Position
(99) and disAs the engineturns, the oil pump also startsto operate.Automatictransmissionfluid (ATF)is drawn from
(
chargedinto (1). Then,ATF pressureis controlledby the regulatorvalve and becomesline pressure 1). The torqueconverter inlet pressure(92) enters (94) of torque converterthrough the orifice and dischargesinto {90}.
The torque convertercheck valve preventsthe torque converterpressurefrom rising'
Under this condition,the hydraulicpressureis not appliedto the clutches.
NOTE:
. When used, "left" or "right" indicatesdirectionon the llowchart
. SOL-@: Shift Control SolenoidValve A
' SOL{D:Shift ControlSolenoidValve B
. SOL@: Lock-upControl SolenoidValve A
. SOL-@: Lock-upControl SolenoidValve B
(cont'd)
14-29
vnx.su
Description
HydraulicFlow (cont'd)
L1l Position
The line pressure{1) becomesline pressure(4) at the manualvalve and passesto the lst clutch and 1st accumulator.
Then line pressure(41flows through the 1st-holdclutch and lst-hold accumulator.
Fluid flows by way of:
- LinePressure{4} - 1-2 Shitt Valve * 2-3 Shitt Valve - 3rd Clutch Pressure{31) - 3-4 Shift Valve - 4th Clutch
Pressure(41) - ManualValve - lst-hold Clutch Pressure{15) - 1st-holdClutch
The modulatorpressure(6) is suppliedto the 1-2 and 2-3 shift valves.
The line pressure(1) also flows to throttle valve B.
NOTE:
. When used. "left" or "right" indicatesdirectionon the flowchart.
. SOL-@: Shift Control SolenoidValve A
. SOL@: Shift Control SolenoidValve B
. SOL-@: Lock-upControlSolenoidValve A
. SOL-@: Lock-upControl SolenoidValve B
14-30
vnx.su
f4 Position
ihe line pressure(11becomesline pressure(41as it passesthrough the manualvalve.lt then goes through line l2O)
to the 2nd clutch via the 1-2 and 2-3 shift valves.Also, line pressure(1) goes to the modulatorvalve throughthe filter
and becomesthe modulatorpressure(6). Modulatorpressure(6) is not suppliedto the 1-2, 2-3 and 3-4 shift valves
becausethe shitt control solenoidvalves A and B are turned on by the TCM.
NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart
. SOL-@: Shift ControlSolenoidValve A
. SOL-@: Shilt Control SolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOt -@ : Lock-upControl SolenoidValve B
(cont'd)
14-31
vnx.su
Description
HydraulicFlow (cont'dl
@
or @
Position
1.
lst Sped
The flow of fluid throuth the torque convener circuit is the same as in S Oosition.
The line pressure( 1) becomesline pressure(4) and it becomesthe 1st clutch pressure(1O).The I st ctutchpressure
is appliedto the lst clutch and l st accumulator;consequently,the vehiclewill move as the enginepower is transmitted.
The line pressure(1) becomesthe modulatorpressure(6) by the modulatorvalve and travelsto 1-2 and 3-4 shift valves.
The 1-2 shift valve is movedto the right sidebecausethe shilt controlsolenoidvalveA is turnedoff and B is turned
on by the TCM. This valve stops 2nd clutch pressureand power is not transmittedto the 2nd clutcn.
Line pressu.e{4) also tlows to the seryo valve and line pressure(1} also flows to throttle valve B.
NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart.
. SOL-@: Shitt ControlSolenoidValve A
. SOL-@:Shift ControlSolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOL-@: Lock-upControlSolenoidValve B
14-32
vnx.su
2nd Sgeed
prescribed
The llow of fluid up the 1-2 shift valve is the same as in 1st speed.As the speedof the car reachesthe
to the left
is
moved
valve
the
1-2
shift
value,the solenoidvalve A is tulned on by meansot the TCM. As a result,
is
engaged'
2nd
clutch
and uncoversthe port leadingto the 2nd clutch; the
Fluidflows by way of:
- Line Dressurel4l -
'l-2
Shift Valve - 2-3 Shitt Valve - 2nd Clutch Pressure(2'1) * 2nd Clutch
{cont'd)
14-33
vnx.su
Description
HydraulicFlow (cont'd)
3rd Speed
The tlow of fluid up to the 1-2 and 2 3 shift valves is the same as in 2nd speed.As the speedof the car reaches
the prescribedvalue,the shift controlsolenoidvalve B is turned off {shilt controlsolenoidvalveA remainson). The
2-3 shift valve is then movedto the left, uncoveringthe oil port leadingto the 3rd clutch. Sincethe 3-4 shitt valve
is moved to the right to cover the oil port to the 4th clutch, the 3rd clutch is turned on.
Fluid tlows by way of:
- Line pressure l4l - 1-2 shift valve - 23 Shift Valve *
(not controlled) 3rd Clutch Pressure(3O) - 3rd Clutch
14-34
vnx.su
Lq4 Position
4.
4th Spe6d
The flow of tluid up to the 1-2, 2-3 and 3-4 shift valvesis the sameas in 3rd speed.As the speedof the car reaches
the prescribedvalue, the shift control solenoidvalve A is turned oJt (shift control solenoidvalve B remainsoff).
As this takes place,3-4 shift valve is moved to the left and uncoversthe oil port leadingto the 4th clutch. Since
the 1-2 and 2-3 shift valvesare kept on the left side,the fluid flows throughthe 4th clutch;the power is transmitted
through the 4th clutch.
Fluid flows by way of:
- Line Pressurel4l - 'l'2 Shift Valve -t 2-3 Shitt Valve - 3rd Clutch Pressure(31) 4th Clutch Pressure{4O) - 4th Clutch
4th Clutch pressure(41) - ManualValve
The hvdraulicpressurealsotlows to the
as in 2nd and 3rd soeed.
'1st
clutch.However,no power is transmittedbecauseof the one-wayclutch
NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchan.
. SOL-@: Shitt Control SolenoidValve A
. SOL-@: Shift Control SolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOL-@: Lock-upConttol SolenoidValve B
(cont'dl
14-35
vnx.su
Description
HydraulicFlow (cont'd)
LEI Position
The flow ot fluid throughthe torqueconvenercircuitis the same as in S position.The tluid ( 1) trom the oil pump flows
through the manualvalve and becomesline pressure(31.lt then flows through the 1-2 shift valve to the servo varve
via the servo control valve, causingthe shift tork shatt to be moved in the reversedirection.
Underthis condition,the shift control solenoidvalve A is turned on whereasthe valve B is turned ofJ as in 3rd speed
in [Dil or lDs]lposition.As a result,the 1-2 shift valve is also moved to the left. The ftuid (3'] will ftow throughthe servo valve and manualvalve to the 4th clutch; power is transmittedthrough the 4th clutch.
ReverseInhibitorControl
When the @ positionis selectedwhile the vehicleis movingforward at a speedover 6 mph ( 1Okm/h).the TCM outputs
1st signal (A: OFF, B: ON), and the 1-2 shift valve is moved to the right side. The line pressure{3) is interceptedbv
the 1-2 shift valve; consequently,power is not transmittedas the 4th clutch and servo valve are not oDerareo.
NOTE:
. When used, "lefl" ot "tight" indicatesdirectionon the flowchart.
. SOL-@: Shift Control SolenoidValve A
. SOL: Shift Control SolenoidValve B
. SOL: Lock-upControlSolenoidVatve A
. SOL-@: Lock-upControlSotenoidVatve B
14-36
vnx.su
Lll Position
The flow of fluid throughthe torque convertercircuit is the same as in I position.The line pressure( l ) becomesline
pressure(3) as it passesthroughthe manualvalve.Then line pressure(3) flows throughthe 1-2 shift valveto the servo
valve via the servo control valve. causingthe shift fork shaft to be moved to the reversepositionas in E position.
However.the hydraulicpressureis not suppliedto the clutches.Power is not transmitted.
NOTE:
. When used, "left" or "right" indicatesdirectionon the flowchart.
. SOL-@: Shitt ControlSolenoidValve A
. SOL-@: Shift Control SolenoidValve B
. SOL-O: Lock-upControlSolenoidValve A
. SOL-O: Lock-upControl SolenoidValve B
14-37
vnx.su
Description
Lock-up System
Lock-up Clutch
1. Operation(clutch on)
With the lock-upclutch on, the oil in the chamberbetweenthe torque convenercover and lock-uppiston is discharged,
and the converteroil exerts pressurethrough the piston againstthe convertercover. As a result,the converterturbine
is locked on the convertercover firmly. The etfect is to bypassthe converter,thereby placingthe car in direct drive.
tpowefJlo-wl
LOCK-UP
TURBINE
TOROUECONVERTER
COVER
To oil cooler
OUTLET
2. Operation(clutch off)
With the lock-upclutch off, the oil tlows in the reverseof CLUTCHON. As a result,the lock-uppiston is moved away
from the convertercover; that is, the torque converterlock-upis released.
Fowtttowl
Engine
I
Drive plate
I
Torque convertercover
TURBINE
Pump
I
Turbine
I
Mainshaft
14-38
vnx.su
fluid is drainedfrom the back of the torqueconIn E positionin 2nd, 3rd and 4th, and @ positionin 3rd, pressurized
verter through an oil passage,causingthe lock-uppiston to be held againstthe torque convertercover. As this takes
place,the mainshaftrotatesat the same speedas the enginecrankshaft.Togetherwith hydrauliccontrol,the TCM optimizedthe timing ot the lock-upsystem. Undercertainconditions,the lock-upclutch is appliedduringdeceleration,in
3rd and 4th sDeed.
The lock-upsystemcontrolsthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and B, and throttlevalveB.
When lock-upcontrol solenoidvalves A and B activate.modulatorpressurechanges.Lock-upcontrol solenoidvalves
A and B are mountedon the torque converterhousing,and are controlledby the TCM.
NOTE:
When used, "left" or " tight" indicatesdirectionon the tlowchart.
Solenoid valve
L""f."p
"."aiti""\
Lock-upOFF
OFF
OFF
Lock-up,slight
ON
OFF
Lock-up,half
ON
ON
Lock-up.full
ON
ON
ON
Duty operation
O F F- O N
Lock-up
during deceleration
ott cootR
{cont'd)
14-39
vnx.su
Description
Lock-upSystem(cont'dl
No Lock-uo
The pressurizedfluid regulatedby the modulatorworks on both ends of the lock-upshift valve and on the left side ot
the lock-upcontrolvalve.Underthis condition,the pressu.esworking on both ends ol the lock-upshitt valve ate equal.
the shift valve is moved to the right side by the tensionof the valve springalone.The tluid from the oil pump will flow
through the left side of the lock-upclutch to the torque converter;i,e., the lock-upclutch is in OFF condition.
NOTE: When used.
LOCK.UPCONTRO!
<-
L O C K . U PT I M I G A V A L V E
14-40
vnx.su
MOOULATOi PBfSSURE
{
Partial Lock-up
Lock-upControlSolenoidValve A: ON
Lock-upControl SolenoidValve B: OFF
The TCM switchesthe solenoidvalve A on to releasethe modulatorpressurein the left cavity ol the lock-upshift vatve.
The modulatorpressurein the right cavity of the lock-upshift valve overcomesthe springforce, thus the lockiup shifi
valve is moved to the left side.
The modulatorpressureis separatedto the two passages:
F1: Torque ConverterInner Pressure:enters into right side-toengagelock-upclutch
F2: Torque ConvenerBack Pressure:enters into left side-todisenqagelock-upclutch
The back pressure(F2) is regulatedby the lock-upcontrol valve whereasthe positionof the lock-uptiming B valve is
determined by the throttle B pressure, tension of the valve spring and pressure regulated by the modulator, Also the
positionof the lock-upcontrolvalveis determindedby the back pressureof the lock-upcontrolvalveand torqueconvener pressureregulatedby the check valve.With the lock-upcont.ol solenoidvalve B kept oft, the modulatorp.essu.eis
maintainedin the left end of the lock-upcontrolvalve;in other words, the lock-upcontrolvalveis moved slightlyto the
left side. This slight movementof the lock-upconlrol valve causesthe back pressureto be loweredslightly.resulting
in panial lock-up.
NOTE: When used. "left" or "right" indicatesdirectionon the flowchart.
LOCK.UPCOIIIROL
SO!ENO|o VALVE A
LOCK UP COIITROI
SOTENOIDVALVE B
<-
MODUI.AIOi
PAESSUFE
LOCK-UPIIMII{G B VATV
otl coolEn
l.ont'al
14-41
vnx.su
Description
Lock-upSystem (cont'dl
Halt Lock-up
Lock up Control SolenoidValve A: ON
Lock-upControl SolenoidValve B: ON
The modulatorpressureis releasedby the solenoidvalve B, causingthe modulatorpressurein the lett cavity of the lockuD control valve to lower.
Also the modulatorpressurein the left cavity of the lock-uptiming B valve is low. Howeverthe throttle B pressureis
still low at this time; consequently.the lock-uptiming B valve is kept on the right side by the spring force.
With the lock-upcontrolsolenoidvalve B turnedon, the lock-upcont.ol valve is moved somewhatto the Ieft side.caus
ing the back pressure(F2)to lower. This allows a greateramount of the fluid (F'1)to work on the lock,up clutch so as
to engagethe clutch. The back pressure(F2) which still exists preventsthe clutch from engagingtully
NOTE: When used, "left" or "right" indicatesdirectionon the flowcnarr.
LOCX UP CONTROL
r.oct( uP corlTRol
sorENoto vatvE a
<-_
orr coorER
14-42
vnx.su
MOOULATORPRESSTJBE
Full Lock-uo
Lock-upControlSolenoidValve B: ON
Lock-upControl SolenoidValve A: ON
When the vehiclespeedfufther increases,the throttle B pressureis increasedin accordancewith the throttle opening.
The lock-uptiming B valve overcomesthe spring force and moves to the left side. Also, this valve closesthe oil port
leadingto the torque convertercheck valve.
Underthis condition,the throttle B pressureworking on the right end of the lock-upcontrolvalve becomesgreaterthan
that on the left end (modulatorpressurein the lelt end hasalreadybeenreleasedby the solenoidvalveB); i.e.,the lock-up
control valve is moved to the left. As this happens,the torque convener back pressureis releasedfully, causingthe
lock-upclutch to be engagedfully.
"right" indicatesdirectionon the tlowchart.
NOTE: When used, "left" or
LOC( UP COi{TAO!
toc( uP coNtnol
SOIENOID
VAIVEB
THRO]TIE A PFESSURE
PNESSUFE
FEGUTATOFVAIVE
LOCK-UPTIMIIIG B VALVE
orl cootER
(cont'd)
14-43
vnx.su
Description
Lock-up System (cont'dl
Dacslsration Lock-uD
Lock-upcontrol solenoid valve A: oN
Lock-upcontrol solenoid valve B: Duty operation {oN - oFFl
The TCM switchessolenoidvalveB on and off rapidlyundercertainconditions.The slightlock-upand half lock-upregions
are maintainedso as to lock the torque converterproperly.
NOTE; When used, "left" or "right" indjcatesdirectionon the flowcnarr.
LOCK-I.PCOt{lFOt
loc(,uP cot{TRoL
SOIENOID
VATVEB
LOCI(,UPTtMt G B VAIVE
14-44i
vnx.su
Component Location
,/s\
)/
{ 7 v
A0t
COUNTERSHAFT
SPEEDSEf{SOR
VEHICLESPEED
SENSOR{VSSI
MAINSHAFTSPEED
THROTTLEPOSITION(TP}
SENSOR
SENSOR
at
,
(ECTI
ENGINECOOLANTTEMPERATURE
SENSOR
)''
14-45
vnx.su
Circuit Diagram
UNDERHOODFUSE/RELAY
80X
No.411100A)
(7.5A)
No.32
tGNtTtoN
c0 -
II
BLU
423 424
Ar0
A20
D2
TRANSMISSION
CONTROL
MOOUI.E
{TCM)
A19
A18
A21
A8
AN GEAR
POSITION
INDICATOR
A'
*---i.
A17
A15
A13
A-"
t2
t,,,:----<)
A/'I GEARPOSIIION
swtrcH
BLK
8LK
G201
G201
14-46
vnx.su
Alt
l1
. VEHICI.E
A/C
SPEED
COMPRESSOR SENSOR
. SPEEOOMETER
CLUTCH
REI.AY
SERVICE
CHECK
CONNECTOR
/8tK
'HBOTfLE ENE'NE
Postto^l coolAlvr
SENSOR TEMPERA.
TURE
SENSOR
D 9 0 1 3 0 1 1D l 6 D 3
D6
D7
D5 A25
A26
TMNSMISSION
CONTROL
MODULE
{TCM}
Dls
019
Dl2
A5
A3
I.OCK'UPCONTROL SHIFTCONTROL
VATVE SOLENOIO
VALVE
SOLENOID
COUNTERSHAFT
SPEEO
SENSOR
A3 A5
A9
A6 A8 A 1 (
A1:
MAINSHAFI
SPEED
SENSOR
421
,/1,/1,/A 1 t
TCMT6rmin6lLocations
14-47
vnx.su
Troubleshooting
Procedures
when the TcM sensesan abnormalityin the input or output systems.the
E]indicator light in the gaugoassemblywill
blink.
when the service check Connector{locatedunder the dash on the passengerside} is connectedwith the
specaat
tool
as shown, the E] indicatorlight will blink the DiagnosticTroubleiode {DTCI when the ignitionswitch is turned
on.
When the lDil indicator light has been reported on, connect the service check connector with the
special tool.
Then turn on the ignition switch and observethe
@ indicatorlight.
GAUGEASSEMSLY
DAI'A LI]TK
(3P)
cor{r{EcToR
't
NOTE:
Do not atlach
jumpe.wire.
scs sHoRTCO[{]{ECTOR
oTPAZ-OOl0too
codes 1 through I are indicatedby individualshort blinks,codes 1o through 15 are indicatedby a series tong
of
and
shon blinks.one long blinkequals l0 short blinks.Add the long and short blinkstogetherto dete;minsthe cod.
Aft6r
determiningthe code, refer to the erectricarsystem symptom-to-componentchart on pages 14-5o and 51.
ahon
f"l
Sc. DTCI
So. DTC2
S.. DTC14
some PGM-FIproblemswill also make the @ indicatorlight come on. After repairingthe pGM-Frsystem, disconnect
the BACK UP tuse (7.5 Al in the under-hoodfuse/relaybox tor more than 1o secondsto reset the TcM memorv.
NOTE:
a PGM-FIsvstem
The PGM-FIsystem on this model is a sequentialmultipon fuel iniectionsvstem.
' Disconnectingthe BACK UP tuse also cancelsthe radio anti-theftcode, presetstationsand the clock
setting. G6t
the customer's code numbe. and make note of the radio presets befote temoving the fuse so you can reset them.
14-48
vnx.su
CAUTIOI{:
a All SRS eloctdcal wiring harna$os are covcred whh
yollow lnaulation.
a Sofora disconnecting any pan ot tho SRS wirc har'
n6ss, connoct the short connoctots (s6 pago 23-701.
a Roplacs tho entiro aff.ct d SRS ham6t. rssombly it
ii has an opon circuil or damagcd wlrlng.
2.
BACKUP(7.5 A} FUSE
2.
a Finll hoc.dulr
2.
Resetthe TCM.
3,
DIG]TALMULTIMETER
Commrciallvavailable
KS-AHM-32-.003,
or gouivalEnt
) o o o o o o o o o o ) olo D o o o o o qoo o o o olo o o o o . o o o . c
To.miml Locrtlonr
14-49
vnx.su
Symptom-to-ComponentChart
ElectricalSystem
Numberof @
indicatorlight
blinks while
indicaror
Service Check @]
light
Connectoris
connectedwith
the specialtool.
Blinks
Blinks
Blinksor
OFF
Blinks
Blinks
OFF
Blinks
Blinks
Blinks
PossibleCause
Symptom
Referto
page
Disconnectedlock-upcontrol solenoid
valve A connector
Short or open in lock-upcontrol solenoid valve A wire
Faulty lock-upcontrol solenoidvalve A
Disconnectedlock-upcontrol solenoid
valve B connector
Short or open in lock-upcontrol solenoid valve B wire
Faulty lock-upcont.ol solenoidvalve B
14-52
Disconnectedvehiclespeed sensor
(VSS)connector
Short or open in VSS wire
Faulty VSS
14-58
14-60
14-50
vnx.su
14-56
't
4-57
14-62
't 4-64
Numberof @
indicatorlight
blinks while
indicator
ServiceCheck @
light
Connectoris
connectedwith
the specialtool.
'lo
Blinks
1l
OFF
13
Blinks
14
't5
Blinks
PossibleCause
Symptom
Disconnectedignitioncoil connector
Short or open in ignition coil wire
Faulty ignitioncoil
. Shon or open in LT GRN wire between
the D3 terminaland ECM
. Faulty barometricpressure{BARO)
sensor
NOTE:The BAROsensor is built into
the ECM
. Short of open in FAS {YEL}wire between the D16 terminaland ECM
. Faulty ECM
OFF
Disconnectedmainshaftspeed sensor
connecror
Short or open in mainshaftspeedsensor wire
Faulty mainshaftspeed sensor
Refer to
page
14-68
't4-70
. No specificsymptom
appears.
14-71
. Transmissionjerks hard
when shitting.
. Transmissionjerks hard
when shifting.
14-75
It the self-diagnosis
LQ4 indicatorlight does not blink, perform an inspectionaccordingto the table below.
Symptom
ProbableCause
Ret.page
14-77
14-78
14-80
14-41
a lf a customerdescribesthe symptoms for codes 3, (yet the LQ! indicatorlight is not blinkingl,6, 1 1 or 15, it will
be necessa.yto recreatethe symptom by test driving.and then checkingthe @ indicatorlight with the ignitionstill
oN.
e lt ttre @ indicatorlight displayscodes olher than those listed above or stays lit continuously,the TCM is faulty.
. Sometimesthe Lqd indicatorlight and the MalfunctionIndicatorLamp (MlL)/CheckEnginelight may come on simultaneously.lf so, check the PGM-Flsystem accordingto the numbe. of blinks on the MIL/CheckEnginelight. then
resetthe memoryby removingthe BACK UP fuse in the unde.-hoodfuse/relaybox for more than 1Oseconds.Drive
the vehicle for several minutes at speed over 30 mph (5O km/h), then recheck the MIL/Check Engine light.
NOTE:
. PGM-FIsystem
The PGM-Flsystem on this model is a sequentialmultiportfuel injectionsystem.
a Disconnectingthe BACK UP luse also cancelsthe radioanti-theftcode. presetstationsand the clock setting.Get
the customer'scode numberand make note ot the radio
the fuse so vou can resetthem.
14-51
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchart
Possible Cause
NO
Turn the ignitionswitch OFF.
ooooooooooo
oooooooo9oo
oooooooooooo
oooooooooooo
Turn the ignitionswitch ON.
f s t h e v o f t a g e4 . 7 5 5 . 2 5 V ?
YES
A25
Measurethe voltagebetweenthe
46 and A25 or A26 terminals-
ls there voltage?
NO
(-)
To page 14'53
14-52
vnx.su
Me6surethe resistancebetween
the 46 andA25 or A26terminals.
ls the resistance14
16 O?
Disconnectthe 2P connectorlrom
the lock-upcontrol solenoidvalve
ls there continuity?
ls the resistance14- 16 0?
Chck tor open in YEL wire botween the A6 terminal and the
lock-uDcontrol solenoidvalve A.
{cont'd}
14-53
vnx.su
ElectricalTroubleshooting
Troubleshooting
Flowchart(cont'dl
PossibleCause
. Disconnectedlock-up conlrol
solenoidvalve B connector
. Short or open in lock-up control
solenoid valve B wire
. Faultylock up controlsolenoid
valve B
ls the voltage4.75-5.25 V?
14-54
vnx.su
Measurethe resistancebetween
the A4 and A25 or A26 terminals.
is the resistance14- 16 0?
Disconnectthe 2P connectorfrom
the lock-upcontrol solenoidvalve
assemory,
2P CONNECTOR
View trom terminal side.
q
.UP CONTROL
ls the resistance14- 16 07
SOLENOID
VALVE
ASSEMBLY
(cont'd)
14-55
vnx.su
TroubleshootingFlowchart (cont'd)
Sof{irgnolis
D! indictor tight
blinks throo rim6s.
Possible Cause
. Disconnocted throttle position
{TP) sensoaconnoctor
. Short or oDenin TP snsorwire
. Faulty TP senaor
ls the voltage4.75-5.25 V?
ls the voltage0.4-0.6 V?
vnx.su
S. d.gno.b lql
bllnkr tour tlm...
indic.to. light
PossibleCaus6
. Disconnectsd vehicle speed
sensor{VSS}connector
. Short or open in VSS wire
. Faulty VSS
Shift t.nsmisiion
to A
position.
a Mak sure lifts,lacks, and safety stands aro placod ploporly {see Eaclion 1}.
a S6t th6 parking brake eecurely and block tho tear wh6ol3'
a Jack up tho f.ont ot tho car and rupport whh sstoty standa.
(cont'd)
14-57
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchartlcont'dl
Solt-diagno8isl!4 indicato. tight
blinks fiv6 timos.
PossibleCause
'Short in A/T gear posilion
switch wire
. Faulty A/T gear position switch
NOTE:Code 5 is causedwhen
the TCM receivestwo gear position inputsat the sametime.
Or
4 2 5t - |
Shilt to other than E position.
-l@r
A 1 9 l + ) A 2 5( - )
Measurethe voltage between the
419 and A25 or 426 terminals.
Ch6ck for 6hon in LT GRN/BLKwi.e borwoon tho A19 torminal and tho A/T goar position indicato., o. a shon in
GRN/WHT or GRN wiros botwson tho A/T goa. position indicato. and tho A/T goa. position swhch. ll wire is OK. chock
for looso TCM connactoE. lf nocos$sry, substituto a knowngood TCM and .ech6ck,
To page 1 4 , 5 9
14-5 8
vnx.su
14-58
posirion.
position.
oooooooooooo
oooooooooooo
ooooooooooo
oooooooo ooo
ls there batteryvoltage?
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
oosirion.
oooooooooooo
oooooooooooo
ll
ooooooooooo
ooooooooooo
YES
{cont'd)
14-59
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchart{cont'dl
Self-diagnosisE indicator light
blinkasix timos.
PossibleCause
. DisconnectedA/T gear position
swrtcn connector
' Open in A/T gear positionswitch
. FaultyA/T gear positionswitch
- r9t
a 2 1 ( +I A 2 5 { - )
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
Measurethe voltagebetweenthe
A21 and 425 or 426 terminals.
ls there voltage?
Shilt ro N or E position.
A25t-l
oooooooooooo
oooooooooooo
ls there voltage?
Ropairopen in LT GRN/BLKwire
btw6onthe 419 torminaland th
A/T gear position indicato..
NO
T o p a g el 4 - 6 1
14-60
vnx.su
ooooooooooo
ooooooooooo
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
voltage?
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
Measurethevoltagebetweenthe
A 1 5 a n dA 2 5 o r A 2 6 t e r m i n a l s .
Ropairopen in GRN/BLUwir6 bolwoen
the A15 r6.minal and tho A/T goar position switch.
oooooooooooo
oooooooooooo
ooooooooooo
ooOoooooooo
voltage?
All(+ I
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
voltageT
Ropaii opon in LT GRN/WIIT wiro botwen the A 11 te.minaland tho A/T goar
oosition switch.
(cont'dl
14-61
vnx.su
ElectricalTroubleshooting
Troubleshooting
Flowchart(cont'dl
Sltdiagno3b Lql indicaror lighr
blinks sovon timgs.
PossibleCause
. Discohnectedshift control solenoid valve A connector
. Short or open in shift control
solenoid valve A wire
. Faulty shill control solenoid
D l 8 (r I
Turn the ignitionswitch ON.
Measurethe voltage betwn the
D18 and A25 or A26 lerminals.
fs the voftage4.75-5.25 V?
oooooooooooo
ooooo oooooooa
ooooooooooo
t:tJio*ie*O:lt$!l$4lrulitEijt'lo oo oooooooo
vnx.su
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
Measurethe resistancebetween
the A5 and 425 or 426 terminals.
ls the resistance14-16 0?
NO
Disconnectthe 3P connectortrom
the shift control solenoidvalveassembly.
ls the resistance'14-16 0?
SHIFT CONTROL
SOLENOIDVALVE
ASSEMBLY
(cont'd)
14-63
vnx.su
ElectricalTroubleshooting
Troubleshooting
Flowchart(cont'dl
Solfdiagnolir [!4 Indicato. light
bllnk! eight tim6r.
PossibleCau6e
. Disconnected shift control solenoid valve B connector
. Short or open in shift control
solenoid valve B wire
. Faulty shilt control solenoid
valve B
A2s(- |
o oooooooooo
oooooooooooo
D l A (+ I
oooooo ooooo
oooo oooo
To page
vnx.su
Disconnctth6 3P conngctorfrom
the shift control solenoid valve
assembly.
oooooooooooo
Check for continuity between the
A3 and A25 or A26 terminals.
oooooooooooo
ooooooooooo
ooooooooooo
ls the rsistance14- 16 O?
(cont'd)
14-65
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchart{cont'dl
Self-diagnosisLq! indicator lighr
blinks nino timos.
PossibleCause
. Loose or faulty connection berween the TCM and car harness.
. Disconnectedcountershaft speed
sensor connector
. Short or open in the countershatt speed sensor wire
. Faulty counlershaft speed sensor
ls the countershaftspeed
sensor installed properly
Disconnectthe 2P conneclorlrom
the countershaft speed sensor
connector,
2P CONNECTOR
COUNTERSHAFT
SPEEDSENSOR
To page 14-67
14-6 6
vnx.su
ls the rsistance4OO-600 07
(cont'd)
vnx.su
4-67
ElectricalTroubleshooting
Troubleshooting
Flowchart(cont'dl
Self-diagnosisE indicator light
blinks ten times.
PossiblCaus6
. Disconnoctdengine coolant
tmprature (ECTI sensor connoctor
. Short or open in the ECT sensor
. Faulty ECT snsor
oooooooooooo
oooooooooooo
ooooooooooo
oooo oooo
Dlal+ I
ls the voltage4.75-5.25 V?
vnx.su
14-69
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchart(cont'd)
Solt-diagnosislq.l indicstor light
blinks elovon tim6s.
PossibleCause
. Disconnected ignition coil conneclor
. Short or open in ignition coil
. Faulty ignition coil
14-70
vnx.su
Possible Cause
. Short or open in LT GRNwire betweenthe D3
terminaland the ECM.
. Faukythe barometricpressure{8ARO}sensor.
NOTE:The BAROsensoris built into lhe ECM.
A25t-|
o o o o o o o o o o o o o o O O q g o p g I , o i O O O O ool o o o o o o o o o o
o o o o o o o o o o o o 0 ooocqooo:Joo.oipggl o oooooo o 9oo
ls the voltage4.75-5.25 V?
fo page 14-72
14-71
vnx.su
ElectricalTroubleshootang
TroubleshootingFlowchart (cont'd)
From page
'14-71
NOTE: View from wire side.
14-72
vnx.su
S.fdl.enorl!
L&l indicdor lighl
blinks fourtoon tlmoa.
PossibleCause
. Sh"rt ". "e"" i" FAS |YEU ,"rirt
. FsultyECM.
Shift to E position,
o oooooooooo
l:OOOOOO60 l.,OO{tO.O6,'l
Measure
lhe voltagebetwganths
o16l+ ) andA25 or A26(- | tormrnals.
ls thoro approx. 5 V?
Dkconnectthe TestHarnessfrom
the TcM.
Leaveconnectdto car harness.
fo page 14-74
lcont'd)
14-73
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchart(cont'd)
From page 14-73
o o o o o o o o O o O o O $:O.COOtt9O$:l:OtO:CtOiOi:l
Oo OO OOo Oo o O
o o o o o o o o o o o o O I:f(O.{iltltO{t{t:I:OFA:F:d:O:l o o o o o o o Oo o o
Measurethe voltage between the
D 1 6 { + ) a n dA 2 5 o r A 2 6 { - ) t e r mtnals.
ls there approx. 5 V?
oooooooooooo
oooooooooooo
ls there continuity?
NO
Ropairopon in YEL {FAS}wiro botrven TCM and ECM.
vnx.su
ooooooooooo
ooooooooooo
PossibleCause
. Disconnected mainshaft speed
sensor connecror
. Short or open in mainshalt
speedsensorwrre.
. Faulty mainshatt speed sensor.
NOTE:
. A code 15 on the TCM doesn't alwsys
mean there's an electrical problem in the
mainshaftor countershaftspeedsensorcir'15may also indicatea mechanicuit; code
cal Droblemin the transmission.
Disconnectthe 3P connectorlrom
the mainshaftspeedsensor.
3P CONNECTOR
ls the resistance4OO-600 O?
I o o o o o o o oo o o o o I:OtlO$O$g:Sl!:OlXOl*Ofill
o o o o o o o o o Oo |
I|
o oooop oo ooo | 6
I ooooooooooooo l Sciii:ddii:ijii:l:i$idi$;d6#:l
"
f
1(0) - L
Y
-!
Rcoair short in ORN/BLU ot
WHT/BLU wiros botween Dlg
and Dl2 to.minals and tho mainshatt speod ronsor.
Reconnectthe 3P connectorto
the mainshattspeedsensor,
To page 14-76
(cont'd)
14-75
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchalt (cont'd)
From page 14-75
ooooooooooooo
ooooooooooooo
ooooooooooo
ooooooooooo
Measurethe resistancebetween
D19 and D12terminals.
ls the resistance4O0-600 0?
Disconneclthe 3P connectorfrom
the mainshaft speed sensor.
RunElectricalTroubleshootingfol
code 9.
Check for loos6TCM connectors.
It nocessary,substitute a knowngood TCM and r.check.
ooooooooooooo
ooooooooooooo
oooooooooo
ooooooooooo
MAINSHAFTSPEEDSENSOR
ooooooooooooo
ooooooooooooo
ooooooooooo
ooooooooooo
3P CONNECTOR
View from terminalside
MAINSHAFTSPEEDSENSOR
14-76
vnx.su
o o o o oo o oo o oo o l:qssoo9pc,I:oocto:osil
oooQooooooooo
o o o oo o o o o oo
o ooooooo ooo
ls there voltage?
ls there volrage?
{cont'd)
14-77
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchaft (cont'dl
Lq4 indicatorlight do6s not come
on with the ignitionswitch ON. (lt
should come on Ior about 2
seconds.l
Does the @
come on?
indicatorlighr
A25
ooo oo oooooo I
| o ooooo o oo o ooo r:sjc.o.sl'1*st,li*os.s.4tcl
ooooooooooooq lifrif.S..n${5git:li$gg-:aiiigitll
ooooooooooo I
I| - - . -I T
..a26
YES
I + )A23A25l- l
(+ tA24426(- |
t \
@
Repaii open or short in BLK/YEL
wire between tho A23 and /ot
424 terminals and underhood
tuse /relav box.
To page 14-79
14-78
vnx.su
a26t- |
oooooooooooo
oooooooooooo
ooooooooooo
ooooooooooo
A8(+)
(cont'd)
14-79
vnx.su
ElectricalTroubleshooting
TroubleshootingFlowchart{cont'dl
BR /ALK
vnx.su
Symptom
Shift lever cannot be moved lrom
E position with the brake pedal
depressed.
Check thar the brake lights come
on with the brake pedal depressed.
cir-
A 2 5t - )
oooooooooooo
oooooooooooo
ooooooooooo
oooooooooo
D 2l + )
vnx.su
l.
2.
STANDARD:14- 16 O
2P CONI{ECTOR
View trom terminal side.
6 x 1.0 mm
12 N.m (1.2 kgf.m,8.7 lbf'ft)
Cleanthe mountingsudace
and oil passages.
VAI-VE
SoLENOTO
ASSEMBLY
?
4.
14-82
vnx.su
S T A N D A R D1: 4 - 1 6 O
6 x 1.0 mm
12 N'm (1.2kgl.m,4.7 lbl.ftl
SHIFT CONTROLSOLENOIO
VALVE ASSEMBLY
VALVE ASSMBLY
14-83
vnx.su
TransmissionControl Module
Replacement
I The Transmission
ControlModule(TCMIis locatedbelow the dashboard,behindthe lelt side kick panelon
the driver's side.
1.
CAUTION:
a All SRS electrical wiring hahesses are covered with
yellow insulation.
a Betore disconnecting any pan ot the SRS wile harness. connect the short connectorslsee page 23-7O).
a Replacethe entir6 affected SRS harness assmbly if
it has an open circuit or damaged wiring.
KICK PANEL
2.
6 x 1.0 mm
12 N'm
{1.2kgf.m,
8.7 tbf.Itl
WIREHARNESS/
CONNECTORS
14-84
vnx.su
6 x 1.0 mm
12 N.m
(1.2 kgf.m, 8.7 lbt.ftl
Mainshaft/Countershaft
SpeedSensors
Replacement
Disconnectthe speed sensorconnectors,then remove the harnessclampon the countershattspeed
sensorharnessfrom the harnessstay.
Removethe 6 mm boltssecuringthe mainshaftand
countershaltspeedsensorsfrom the transmission
housrng.
Remove the mainshaft and countershaft speed
sensors,
Installthemainshattand countershaltspeedsensors
in the reverseorder of the removal.
I{ARNESSSTAY
6 x'l,Omm
l2 N.m
{1.2kgf.m,
8.7 tbf.fr)
6 x 1 . Om m
12 N.m
(1.2kgf.m,
8.7 tbf.ltl
COUNTERSHAFT
SPEEDSENSOR
14-85
vnx.su
Chart
Symptom-to-Component
Hydraulic System
Check these items
on the NOTESList
SYMPTOM
Engineruns, but car does not move in any gear.
1, 6, 7, 16
K,L,R,S
a, 29, 44. 4a
c,M,o
9,30,49
C, L
c,L,o
1,8, 9, 10,11,46,47
C,D
position.
Excessiveidle vibration.
5, 1'1
B,K,L
6, 7, 16
C,L
No enginebrakingin E position.
12
C,D,L
8, 29, 44, 4A
c,N,o
C,L
C,L
1 1 ,2 3 , 3 2 , 4 4
C,L,N
11,32,34,44
C,N
3 , 1 5 ,2 3
E,L,V
Flareson2 3 upshilt.
E,L,V
E,L,N,V
14,19,
G, L
1 2 .1 9
G,L
Late upshift.
14
Erraticshitting.
2, 14,26
A , E ,H , I ,L , V
H a r s hs h i t t { 1 - 2 ) .
2 , 9 . 1 5 ,2 3
C,D,E,V
Harshs h i l t ( 2 - 3 ) .
C,D,E,H,L,V
Harshshift (3-4).
2 , | 1, 15, 23, 25
C , D , E ,I , L , V
Harshkick'down shifts.
E,L,O,V
Harshkick-downshift 12 1)
48
Harshdownshift at closedthrottle.
2 , 1 5 ,2 3
F T
33
43,50
43
L,O
6,7,38,39,40
K,L,O
3a,39,40
L,O
38,33,40,45
L,O
6, 11
K,L,O
39, 42
L,O
a, 13, 41
K,L,O
38, 42
L,O
1,21,24.32
17,36, 37
E,L,V
43
L,O
14-8 6
position
vnx.su
PROBABLECAUSE
1
o.
7.
8.
9.
10.
11
12.
13.
14.
lo.
18.
'I
9.
21
23.
26.
27.
24.
29.
30.
31
35.
36.
37.
38.
39.
40.
41
43.
44.
45.
47.
48.
49.
50.
vnx.su
Symptom-to-ComponentGhart
HydraulicSystem(cont'd)
Checkthese items on the
PROBABLECAUSEDUETO
IMPROPER
REPAIR
List
Carcreepsin E position.
R 1 ,R 2
R4
Excessivedrag in transmission.
Excessivevibration,rom related.
R6
R 3 ,R l 2
R7
R5
Variousshifting problems.
R9, R1O
Harshupshifts.
R11
R8
PROBABLE
CAUSEDUE TO IMPROPER
REPAIR
R1
Items on the
NOTESList
R2.
lmproperclutch cleatance.
lmDroDerqear clearance.
R3.
R4.
R5.
Reverseselectorhub installedupsidedown.
R6.
R7.
R8.
R9.
Springsimproperlyinstalled,
R10.
Valves improperlyinstalled.
R11
R12.
14-8 8
vnx.su
K.R
NOTES
A.
B.
E.
H.
K.
L.
M.
N.
o.
P.
o.
R.
q
T,
14-89
vnx.su
Road Test
NOTE: Warm up the engineto operatingtemperature(the coolingfan comes on).
1
Apply parking brake and block th wheels. Start the engine, them move the selector lever to E] position while
depressingthe brake pedal.Depressthe acceleratorpedal, and releaseit suddenly.The engineshould not stall,
2.
Repeatsame test in @
3.
Shift the selecto.lever to E position,and chock that the shift points occur at approximatespeedsshown. Also
check fof abnormalnoise and clutch slippage.
position.
TEST
HARI{ESS
OTLAJ_PT3OlOA
DIGITAL MULTIMETER
Commarciallyavsilablo o.
KS-AHM-32-OO3
0 1 1{ +
ooooooooooooo oooooooo oooooo ooooooooooo
o o o o o o o o o o o o o o o o o o o o o oooooo ooooooooooo
14-9 0
vnx.su
@ or @ Position
. Upshitt
Throftle Opening
Unit of spe6d
Throttle positionsensor
voltage:O.75 V
17,O 19.O
Km/h
27,30
20-22
3 2 . 5- 3 5 . 5
mph
Throttle positionsensor
v o l t a g e :2 . 5 V
3rd-4th
2nd-3rd
l st- 2nd
43.5-48.5
mpn
3 3 . 5- 3 6 . 5
30- 34
Km/h
mph
Km/h
Unit ot speed
Full-openedthrottle
49.O- 55.O
57.O-63.O
62-65
99.O- 105.O
89.O-95.O
98- 101
15 7 . O - 1 6 3 . O
4th- 3rd
3rd - 2nd
2nd- l Et
Downshift
Throttle Opning
1a-21
29.O-33.O
mph
Full-closedthrottle
Km/h
13 7 . O - 1 4 3 . 0
Km/h
23-27
37.0-43.O
54- 58
85-89
mph
Full-openedthrottle
87 . 0- 9 3 . 0
LOCK-Up
@ Position
Throttle Opening
Unit of speed
Throttle positionsensor
voltage: 2,5 V
km/h
throttle
Full-opened
mpn
mpn
tJ-
1 7- 2 0
2A.O-32.O
92-96
r48.0,1 54.O
to
21.O- 25.O
92-96
1 4 8 . O- 1 5 4 . 0
km/h
E
Throttlo Opening
Unit of sp6ed
Throttle positionsensor
v o l t a g e :1 . OV
mph
kmih
mph
Full-openedthrottle
b|-oJ
98- 102
85 89
137 143
km/h
4.
Position
Accelerateto about 35 mph {57 km/h) so the transmissionis in 4th, then shift from @
The car should immediatelybegin slowing down from enginebraking.
CAUTION: Do not shift from @
may damage the tlansmission,
or @
61 63
98- 102
85-89
137- 143
Oositionto E position.
14-91
vnx.su
Stall Speed
CAUTION:
a To plevent transmission damage, do not test stall speed fot mote than 1O seconds at a time.
a Do not shift the level while raising th engine speed.
a Be sure to remove the pressure gauge belot testing stall speed.
1.
2.
3.
4.
5.
6.
TROUBLE
Stallrpm hish in E,
posrtron
PROBABLE
CAUSE
and@
E, I
position
position
Stallrpm low in E,
position
Engineoutput low
Torque converterone-way clutch slipping
E, I
ana@
14-92
vnx.su
Fluid Level
Checking/Changing
Checking
Changing
1.
Removethe dipstick (yellow loop) from the transmission,and wipe it with a clean cloth.
3.
DIPSTICK(YELLOWLOOPI
4.
P
il
\---
1 8 x 1 . 5m m
49 N.m (5.0 kgl.m, 36 lbl.ft)
IT
{J.
t)-i-
U P P EM
RARK
LowERMARK
14-93
vnx.su
PressureTesting
a While testing, be caretul of the rotating flont wheels.
a Make aura litts, jacks, and satty stands alo placed
plop6rly {see section 1}.
4.
5.
Installa new washer and the sealingbolt in the inspectionhole and tighten to the specifiedtorque.
2.
3.
-3.
-4.
Measureline pressure.
or @ position.
LINEPRESSURE
INSPECTION
HOLE
A/T LOW PRESSURE
GAUGE W/PANEL
07/rO6-0O70300
PRESSURESELECTOR
POStTTON
Line
No'E
SYMPTOM
PROBABLE
CAUSE
FLUIDPRESSURE
Standard
No (or low)
Torque converter, 83O-88O kPa
lrne pressure orl pump, pressure ( 8 . 5 - 9 . O k g f / c m , ,
regulator,to.que
120- I 30 psi)
convener check
valve
Service Limit
78O kPa
{8.0 kgl/cm,,1lO psi}
14-94
vnx.su
@
1.
2.
-3.
-4.
-5.
INSPECTIONHOLE
rl|E!!UltE
1st Clutch
l st-hold
Clutch
SELECTOB
POST ON
Eo'E
tr
2nd Clutch
2nd Clutch
FLUIDPRESSURE
SYMPTOM
PROBABLE
CAUSE
1st Clutch
No or low
lst Pressure
No or low
1st-hold
pressure
1st-holdCIutch
83O-880 kPa
(8.5-9.O kgf/cm',
120- 130 psi)
Service Limit
78O kPa
{ 8 . Ok g f / c m ' ,1 1 O p s i )
2nd Clutch
No or low
2nd pressure
2nd Clutch
No or low
2nd pressure
3rd Clutch
3rd Clutch
No or low
3rd pressure
4th Clutch
4th clutch
No or low
4th pressure
Standard
4'l o kPa
460 kPa
(4.2 kgt/cm' , 60 psi)
|'4.7 kgtlcm2, 67 psil
throttle control lever
throttle control lever
fully closed
fully closed
78O kPa
830-880 kPa
(8.O kgf/cm' , 1 1O psi)
(8.5 - 9.0 kgt/cm' ,
throttle control lever
120- l30 psi)
m o r et h a n 3 / 1 6 o p e n e d
throttle control lever
m o r et h a n 3 / 1 6 o p e n e d
830-880 kPa
(8.5 9.0 kqf/cm' ,
120- 130 psi)
780 kPa
(8.0 kgf/cm' , 1 1O psi)
(cont'd)
14-95
vnx.su
PressureTesting
(cont'dl
a
-6.
CAALE END
-3.
-4.
-5.
position.
14-96
vnx.su
LOCK.UPCONTROL
SOLENOIDVALVE
SHIFT CONTROL
SOLENOIDVALVE
ASSEMBLY PROTECTOR
3RD CLUTCH PRESSURE
INSPECTIONHOLE
INSPECTIONHOLE
PRESSUNE
2nd Clutch
SELECTOR
POStTtON
SYMPTOM
PROBABLE
CAUSE
FLUIDPRESSURE
Standard
No or low
2nd Clutch
2nd pressure
3rd Clutch
No or low
3rd pressure
3rd Clutch
4th Clutch
No or low
4th pressure
4th Clutch
460-88O kPa
(4.7 -9.O kgtlcmt,
67- 130 psil
varies with throttle
openrn9
Service Limit
41OkPa
{4.2 kgf/cm,, 60 psi}
with throttle control
lever released
78O kPa
l8.O kgtlcm,, 1'lO psil
with throttle control
lever more than 3/1 6
opened
(cont'd)
vnx.su
14-97
PressureTesting
(cont'dl
a Throttle B Ptsssure Measuremcnt
wrril" resring, be caretut ot rhe rotaring
@@
front wheels.
1. Allow the front wheels to rotate treelv.
-2. Removethe cableend of the throttlecontrolcable
from the throttle control lever.
3.
-4.
-5.
-6.
-7.
PRESSURE
SELECTOR
SYMPTOM
POSTTTON
PROBABLECAUSE
Throttle B
loil orlDll
Thfottle Valve B
Pressuretoo
high
FLUIDPRESSURE
Standard
No or low
Throttle B
pressure
O-15 kPa
{ O - O . 15 k g f / c m , ,
0-2.1 psi)
throttle control lever
fully closed
83o 88O kPa
(8.5-9.O kgf/cmz,
120 130 psi)
thfottle control levet
fully closed
14-98
vnx.su
Srvica Limit
78O kPa
(8.O kgl/cm,, l lO psi)
throttle control lever
tully closed
Transmission
Removal
a Make sur lifts. iacks and safety stands are placad
properly, and hoist brackots are attachod to tho correct position on ths sngine {seo sectionl }.
o Apply parking brake and block rear wheels, so car will
not roll off stands and fall on you whil6 working undel it
4.
2.
HARNESSCLAMP
LOCK-UPCONTROL
SOLENOIDVALVE
CONNECTOR
AIR CLEAI{ER
HOUSINGASSEMBLY
SHIFT CONTROL
SOLENOIDVALVE
CONNECTOR
TRANSMISSION
GROUNDCABI-E
VEHICLESPEED
SENSORCONNECTOR
STARTERMOTOR CABLE
CABLE HOLDER
VEHICLESPEED
SENSOR
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
STARTERMOTOR
?/\
STARTERMOTOR CABLE
vnx.su
MAINSHAFTSPEED
SENSORCONNECTOR(cont,d)
4-99
Transmission
Removal{cont'd)
7.
Removethe transmissionhousingmountingbolts.
9. Removethe splashshield.
6 x 10
CLIP
S pcs.
Removethe drainpluganddrainthe automatictransmissiontluid (ATF).Reinstallthe drain plug with a
new sealingwasher lsee page 14-93).
PINCI{ BOLT
/\
SELF.LOCKING
NUT
Replace.
DAMPERFORK
DRAINPLUG
1 8 x 1 . 5m m
49 N'm 15.0 kgt-m,36 tbt-fr)
14-100
vnx.su
CASTLE NUT
COTTERPIN
Replace.
'14.
LOCKWASHER CONTROLLEVER
Replace.
SELF-LOCKING
NUT
Replace.
(cont'dl
Replace.
14-101
vnx.su
Transmission
Removal(cont'dl
'1
9. Removethe right tront mount/bracket,then remove
the end ol the throttle cont.ol cabletrom the throttle control lever.
23. Placea jack underthe transmission,raisethe lransmission just enough to take weight off ol the
mounts. then removethe transmissionmount.
'i
THROTTLE
CONTROL
"
z/'l e
(-J
t'
RrcHTFRoNTiiouNT/BRAcKET BoLTs
ATF COOLER
Replace. HOSES
WASHERS
Replace.
14-102
vnx.su
lllustrated Index
Right Side Cover
14-104
vnx.su
O RtcHTslDEcovERpRoTEcToR
@ RrcHTstDEcovER
spEEDsENsoR
O MAtt{sHAFr
@ o-RtNGReptace.
SPEEO
SENSOR
@ cour{TERSHAFT
STAY
@ HARNESS
O RoLLCR
@ COLLAR
O O-RINGReptace.
@ FEEDPIPEFLAI{GE
@ o-RrNG
@ sIrlAPRING
@ 3RDCIUTCHFEEDPIPE
LOCKNUT(FLAt{cEf{UTl Reptace.
@ COUNTERSHAFT
@ coultTERsHAFf col{tCAL SpRtt{cWASHERReotace.
@ PARKI G GEAR
@ oNE-waY cLUTcH
@ couNTERsHAFrlsr GEAR
BEARING
@ NEEDLE
@ couNTERsHAFrtsr GEARcoLLAB
@ O-RINGReptace.
@ l sT-HoLDaccuMuLAToR ptsToN
spBfi{c
@ isT-HoLD ACCUMULAToR
@ o-RtNGReptace.
covER
@ rsT-HoLDACGUMULAToR
@ SNAPRrr{G
@ PAFKINGBRAKEPAWL
BRAKEPAWLSPRII{G
@ PARKING
BRAKEPAWLSHAFT
@ PARKING
aRAKEPAWLSToPPER
@ PARKING
@ LOCKwasHEn Reptace.
@ PARKI G BRAKEs?oPPER
BRAI(ELEVER
@ PARKING
@ PARKI G BRAKELEVERSPBING
@ DowEL PrN
@ O-RltIGReptace.
stoE covER GASKETFeptace.
@ RTGHT
@ isT ct-uTcH FEEDptpE
@ o-RtNGReptace.
@ FEEDPIPEGUIDE
@ SNAPRING
NUT)ReDIace.
@ MAINSHAFTLocKNUT{FLANGE
SpRtNGWASHERReotsce.
@ MAfISHAFTCONTCAL
@ IsT cLUTcHASSEMBLY
@ O-RINGReptace.
@ THRUSTWASHER
BEARIG
@ THRUSINEEDLE
@ EEDLEBEARING
@ MAI'{SHAFTlsT GEAR
@ THRUSTWASHER
@ MAINSHAFTlsT GEARcoLLAR
@ RoLLER
@ coLLAR
@ O-Rlt{cReptace.
@ FEEoPIPEFLANGE
@ o-RINGRptace.
@ SNAPRING
@ lsr-HoLD cLUTcH FEEDptpE
LoCKNUTIFLAt{cNUTIReptace.
@ SUB-SHAFT
@ suB-sHAFr cot{tcAl spRtNGWASHERReptace.
lST GEAR
@ SU8-SHAFT
@ LOCKWASHERf,eptace.
@ THRoTILEcor{TRoL LEVER
@ THRoTTLEcoNTRoL I.EVERSPRING
@ oll sEAt Reptace.
coNTRoL CABLESTAY
@ THRoTTI"E
SOLEI{O|O
HARNESS
@ sHtFTCONTROL
@ Jor T BoLT
PIPE
@ ATF COOLER
Roptace.
@ SEAL|NGWASHERS
@ ATF cooLER P|PE
@ ATF LEVELGAUGE
@ JOINTEOLT
@ vEHtcLEspEEDsEf{soR
@ o-RtNGReptace.
@ DRAINPLUG
@ SEALINGWASHERReplace.
TOROUESPECIFICATIONS
Ret No.
B
D
F
Torque Value
'12 N.m (1
.2 kgf.m, 8.7 lbJ.tt)
14 N.m (1.4 kgf.m, 10lbf.ft)
22 N.m 12.2 kgf.m, 16 lbf.ft)
8 N.m (O.8 kgf.m, 6 lbf.ftl
28 N'm (2.9 kgf.m, 21 lbf.ttl
49 N.m (5.O kgf.m, 36 lbf'ft)
93 N.m {9.5 kgf.m, 69 lbt.ft}
Bolt Size
6 x 1 , Om m
6 x 1 . Om m
I x 1 . 2 5m m
5x0.8mm
12 x 1-25mm
'1.5
18 x
mm
t Y x t . z 5m m
1 0 3 N . m { 1 O . 5k g f . m , 7 5 . 9 l b f . f t l - O 1 O 3N . m ( 1 0 . 5 k g f ' m . 7 5 . 9 l b f . f t )
2 3 x 1 . 2 5m m
'19
x 1 . 2 5m m
Remarks
Specialbolt
14-105
vnx.su
lllustrated lndex
Transmission
Housing
I ',
TTI]
a''-.2
14-106
vnx.su
O) COUNTERSHAFTREVERSEGEAR COLLAR
@ NEEDLEBEARING
G) COUNTERSHAFTREVERSEGEAR
@ LOcK WASHERReptace.
sHIFT FoRK
@ REVERSE
@ BEVERSESELECToR
O REVERSESELECToRHUB
@ couNTERSHAFT 4TH GEAR
@ NEEDLEBEARING
@ DTSTANCECOLLAR, 29 mm Setecrivepart.
@ coUNTERSHAFT2ND GEAR
@ THRUSTNEEDLEBEARING
@ GoUNTERSHAFT3RD GEAR
@ NEEDLEBEARING
@ THRUSTNEEDLEEEARING
G) COUNTERSHAFT3RD GEAR COLI-AR
O 3RD cLuTcH ASSEMBLY
(!) O-RINGSReplace.
@ coUNTERSHAFT
@ REVERSEIDLERGEAR
@ SNAP RING
@ THRUSTWASHER
@ THRUSTNEEDLEBEARING
@ MAINSHAFT4TH GEAR
@) NEEDLEBEARINGS
@ THRUSTNEEDLEBEARING
@ MAINSHAFT 4TH GEAR coLLAR
@ 2ND/4TH cLUTcH ASSEMBLY
et O-RINGSReplace.
@ THRUSTwaSHER, 36.5 x 55 mm Setectivepan.
@ THRUSTNEEDLEEEARING
@ MA|NSHAFT2ND GEAR
, NEEDI.EBEARING
@ THRUSTNEEDLEEEARING
.O MAINSHAFT
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
@
SEAL|NGRtNGs, 3s mm
SEAL|NGR|NG,29 mm
NEEDLEBEARING
sET RING
1ST-HOLDCLUTCH
O-RINGReplace.
THRUST WASHER
THRUST NEEDLEBEARING
NEEDLEBEARING
SUB.SHAFT4TH GEAR
THRUST NEEDLEBEARING
SUB.SHAFT4TH GEAR COLLAR
SUB-SHAFT
SUB.SHAFTNEEDLEBEARING
NEEDLEBEARINGSToPPER
otL GUTDEcAP Reptace.
REVERSEIDLERGAR SIIAFT/HOLDER
NEEDLEBEARII{G
sHIFT GONTROLSOLENOIDvAI.vE ASSEMBLY
PROTECTOR
VALVE A/B
sHrFT CONTROLSOLENOTD
SHIFT CONTROLSOLENOIDVALVE A/B FILTER/GASKET
Replace.
TRANSMISSIONHANGR
TRANSMtsstoN MouI{T BRAGKET
oll SEAL Replace.
sET RING Replace.
TRANSMISSIONHOUSINGGASKET Replace.
DOWEL PrN
SNAP RI G
SUB-SHAFTIRANSMtSStON HOUSNG AEARTNG
MAINSHAFT TRANSMISSIONHOUSINGBEARING
coUNTERSHAFT TRANSMISSIONHOUSINGBEARING
DIFFERENTIALASSEMELY
OtL SEAL Replace.
CoNNECTORSTAY
TOROUESPECIFICATIONS
Rel No.
B
E
H
Bolt Size
Torque Value
1 2 N . m ( 1 . 2 k g f . m , 8 . 7l b t . t t )
1 4 N . m ( 1. 4 k g f. m . 1 0 l b f. f t )
44 N.m (4.5 kgt.m, 33 lbf.ft)
6 4 N . m ( 6 . 5 k g f. m , 4 7 l b f. f t )
6 x 1 . Om m
6 x 1 . Om m
' l Ox 1 . 2 5m m
Remarks
Specialbolt
1 2 x 1 . 2 5m m
14-107
vnx.su
lllustratedIndex
Torque Converter Housing/ValveBody
^\
14-108
vnx.su
OIL FEEDPIPE
ACCUMULATORCOVER
O-RINGReplace.
OIL FEEDPIPE
OIL FEEDPIPE
SERVOOETENTEASE
LOCNWASHERFeplace.
ATF STRAINER
SUCTIONPIPECOLLAR
SERVOBOOY
THROTTLECONTROLSHAFT
E RING
SERVOSEPARATORPLATE
1ST ACCUMULATORCHOKE
CHECKBALL
STOPPERSHAFT STAY
SECONDARYVALVE BODY
DOWEL PIN
SECONDARYSEPARATORPLATE
LUBRICATORPLATE
OIL FEEDPIPE
LOCK.UPVALVE BODY
DOWEL PIN
LOCK-UPSEPARATORPLATE
TOROUECONVERTERCHECKVALVE SPRING
TOROUECONVERTER
CHECKVALVE
COOLERCHECKVALVE SPRING
COOLERCHECKVALVE
@ REGULAToRvALvE BoDY
@ STOPPERSHAFT
@ O-RINGReptace.
@ STATOR SHAFT
@ otl FEEDPIPE
@ MAIN vALvE BoDY
@ CHECK EALL
@ DowEL PIN
@ oIL PUMP DRIVEGEAR
@ OIL PUMPDRIVENGEARSHAFT
Q9 OIL PUMPDRIVENGEAR
@ MAIN SEPARAToR PLATE
@ DowEL PrN
@ coNTBoL sHAFT
@ DETENTSPRING
@ DETENTARM SHAFT
@) DETENTARM
@ ATF MAGNET
TOROUECONVERTER
HOUSING
@ COUNTEBSHAFT
NEEDLEBEANING
@ oIL GUIDE PLATE
@ TOROUECONVERTERHoUSING
HOUSINGBEARING
@)MAINSHAFTTOROUECONVERTER
@ oll SEAL Reptace.
soLENotD
vALvEA/B
@ LocK-upcoNTRoL
STAY
@ coNNECTOR
VALVE A/B
@ LOCK-UPCONTROLSOLENOTD
FILTER/GASKET
Replace.
TOROUESPECIFICATIONS
ReI No.
Torque Value
Bolt Size
1 2 N . m ( 1. 2 k g f . m , 8 . 7 l b f . f t )
6 x 1 . Om m
Remarks
14-109
vnx.su
SUB.SHAFT
Replace.
CONICAL
SPRING
WASHER
Replace.
WASHER
Replace.
MAINSHAFT
1ST GEAR
PARKINGGEAR
ONE.WAYCLUTCH
1STGEAR
THRUST WASHER
,IST GEAB COLLAR
BEABING
NEEDLE
lST GEARCOLLAR
JOINT AOLT
ATF LEVELGAUGE
ATF COOLERPIPES
SEALINGWASHERS
Replace.
14-110
vnx.su
'1.
MAINSHAFTHOLOER
07GAB-PF50101
NOTE;
a Mainshaftand countershaftlocknuts have letthand threads.
a Cleanthe old countershaftlocknut,it is used to
installthe parkinggear on the countershaft.
a Always wear safety glasses.
CAUTION:
Keop all of th chisled panicles out of the
tlanamigsion.
llrF-"""*
LocKNUr
,fl(,-..-
@-.**'o'
7 . Removethe lock pin that was installedto hold the
sub-shaft.
3.
4.
Removethe 1st clutch and mainshaft1st gear assembly from the mainshaft.
MAINSHAFT
LOCKNUT
Replace.
8 mm pin.
commrcially
available
SU8-SHAFT
LOCKNUT
Replace.
PARKINGGEAR
14-111
vnx.su
Transmission Housing
Removal
TRANSMTSSTOIr
HOUSIIG
MOUNTING
BOLTS
fl
TSAt{SMtSStOt{
HANGER
TRANSMISSIO HOUSII{G
TRA[{SMrSSrOr{
MOUNTBRACKET
'RAI{SMTSSTOHOUS|IG
GASKET
Rgolace.
REVERSEGCAR COLLAR
]{EEDLEBEARII{G
NEVERSE
GEAR
MAINSHAFT
SUA.ASSEMBLY
LOCTWASHEF
Replace.
SHIFT FORX
REVERSE
SELCTON
COUI{TERS}IAFT
SUB-ASSEMEI.Y
DIFFEFEI{IIAL
ASSEMBIY
(-t\
14-112
vnx.su
NOTE:
a Clean all parts thoroughly in solvent o. carburetor
cleanerand d.y with compressedair.
a Blow out all passages.
a When removingthe transmissionhousing,replacethe
following:
. Transmissionhousinggasket
. Lock washer
1.
8.
Removethe ditferentialassemblv.
14-113
vnx.su
Torque GonverterHousing/ValveBody
Removal
Bolts, 7
\
LOCK-UP
VALVE
B . D Y \ u ll
DOWELPIN
LOCK-UPSEPARATOR
PI.ATE
REGULATORVALVE
AODY
otL
FEED
PIPES
OII- FEEDPIPES
TOR COVER
OIL FEEOPIPE
Ll
ll|i
8oll3.3
SERVODETENT
BASE
|]V
ATF STRAINER
SUCTION PIPE
COLLAR
8olts, 4 Boll
DOWEL PIN
MAIII VALVE
BODY
SECONDARYVALVE
BODY
MAIN SPARATOR
PLATE
ft--
rrr urcler
TOROUECONVERTER
HOUSING
14-114
vnx.su
NOTE:
a Clean all parts thoroughly in solvent or carbuetor
cleanerand dry with compressedair.
a Blow out all passages.
a Whenremovingthe valvebody replacethe following:
. O-rings
. Lock wsshers
1 5 .Cleanthe inlet opsningof the ATF strainerthoroughly with compressedair, then check that it is in good
condition,and the inlet openingis not clogged.
1 . Removethe oil feed pipes from the servo body, srvo detent base, accumulatofcover, lock-uDvalve
body and main valve body.
2, Removethe three bolts securingthe ATF strainerand
servo detent base, then remove them.
3. Removethe three bolts securingthe accumulator
cover. then removethe accumulatorcover.
4. Removethe six bolts secu.ing the servo body, then
removethe servo body and separatorplate.
5. Removethe bolt securingthe secondaryvalve body,
then removethe secondaryvalve body and separator plate.
6. Removethe eight boltssecuringthe lubricatorplate
and lock-upvalve body, then removethe lubricator
plate, lock-upvalve body and separatorplate.
II{LET OPENING
14-115
vnx.su
Valve Caps
Description
Caps with one projectedtip and one flat end are installedwith the llat end toward the insideot the valve
body.
Caps with a projectedtip on each end are installed
with the smallertip toward the insideof the valve
body. The small tip is a spring guide.
lrj taj u
rq
fq1 @.
Caps with one projected tip and hollow end are installed with the tip toward the inside of the valve body.
The tip is a springguide.
Sectional view
14-11 6
vnx.su
Valve Body
Repair
NOTE: This repairis only necessaryil one or more of
the valvesin a valve body do not slidesmoothlyin their
bores.You may use this procedureto lree the valvesin
the valve bodies.
1. Soak a sheet of #600 abrasivepaper in ATF for
about 30 minutes.
2.
3.
4.
Inspectthe valvetor any scuff marks.Usethe ATFsoaked# 600 pagperto polishoff any burrsthat are
on the valve,than wash the valvein solventand dry
it with compressedair.
VALVE BODY
W
7 . Remove the valve and thoroughly clean it and the
valve body with solvent. Dry all parts with com
pressed air, then reassemble using ATF as a
lubricant.
14-117
vnx.su
Valve
Assembly
NOTE:
Coat all parts with ATF belore assemblv.
-6^<
ROLLER
5-1
SPBINGSEAT
VALVE BODY
VALVE BODY
ROLLER
VALVE EODY
VALVE
CAP
14-118
vnx.su
Oil Pump
lnspection
l.
CHAMFER
GROOVE
YI
Grooved and chamfered side
faces separator plate.
OIL PUMP
DRIVENGEAR
Inspect teeth tor wear or damago.
DRIVEGEAR
Inspectteethlor wearor damaage.
Removethe oil pump drivengear shaft, and measure the thrust clearanceof the oil pump drivengearto-main valve body.
Oil pump Drive/DrivenGearthrust (Axiall Clearance:
Standard(Nawl:
0 . 0 3 - O . O 5 m m { O . O O-lO . O O 2i n )
Sorvice Limit:
O.O7mm {O.0O3in}
STRAIGHTEDGE
vnx.su
14-11 9
2.3 SHIFTVALVE
CHECK BALLS, 3
DETENTARM SHAFT
DETEfITARM
rrl\.
J ST VALVE
'-ir,
,^r @
q---
t'-'t @
RELIEFVALVE
\\ i f l
@
MANUAL
VALVE
VALVECAP CLIP
MAIN VALVE BODY
14-120
vnx.su
Qr
DETENTARM SHAFT
MANUAL VALVE
sPat G sPEctFtcaTtot{s
Unit ot length: mm (in)
Standard lNowl
o,
o
@
o
o
@
Epfng
Relief valve spring
4th oxhaust valve spring
2-3 shift valve spring
CPC valve spring
1-2 shift valv6 spring
Wiro Dia.
1. 1 { O . O 4 3 l
1. 0 { 0 . 0 3 9 t
0.9 {0.035t
1 . 3{ O . 0 5 1 )
0.9 {0.03s)
o.D.
8.6 (0.339)
7.1 (O.2801
7.6 (O.2991
9.4 (0.370)
8.6 (O.339)
F.oo Lsngth
3 7 . 1{1 . 4 6 1 )
60.3 12.3741
57.O 12.2441
3 5 . 3{ 1 . 3 9 O )
4 0 . 4{ 1 . s 9 1 t
No. ot Coils
13 . 4
18.5
26.4
12.4
14.5
14-121
vnx.su
RegulatorValve Body
Disassembly/lnspection/Reassembly
NOTE:
a Cleanall pans thoroughlyin solvent or carburetorcleaner,and dry with compressedait.
a Blow out all passages.
a Replacevalve body as an assemblyit any parts are worn or damaged.
a Check all valves for free movement.lf any fail to slide freely, see Valve Body Repairon page 14-117.
1.
Hold the .egulatorspring cap in place while removingthe lock bolt. Once the bolt is removed.releasethe spring
cap slowlv.
CAUTION: The .egulator spring c8p can pop out whsn the lock bolt is removod.
Reassemblyis in the reverseorder of the disassemblyprocedute.
2.
NOTE:
. Coat all pans with ATF.
a Align the hole in the regulatorspringcap with the hole in the valve body, pressthe springcap into the body and
tighten the lock bolt.
t,-V
REGULATORVALVE
,*6t'"
LOCK.BOLT
6 x 1 . 0m m
12 N.m (1.2 kgl.m,8.7 lbf.ftl
REGULATORSPRINGCAP
COOLERCHECK
OOWELPINS, 2
ROLLER
REGULATORVALVE BODY
"%=
.
I',.-2"
ll
VALVESLEEVE
SPRINGSPECIFICATIONS
Unit of length: mm (in)
Standard (New)
No.
o
/a
@
\9/
Spring
Regulatorvalve spring A
Regulatorvalve spring B
Stator reactionspring
Lock-upcontrol valve spring
Coolercheck valve spring
Torque convertercheck valve spring
Wiro Dia.
o.D.
1 . 8 0 ( O . O 7 1 ) 1 4 . 7 0( O . 5 7 9 18 8 . 6 0( 3 . 4 8 8 t
1 . 8 0 ( 0 . 0 7 1 ) 9 . 6 0 ( 0 . 3 7 8 ) 44.OOt't.7321
5 . 5 0 ( O . 2 1 7 1 ' 2 6 . 4 0 ( 1 . O 3 9 )3 0 . 3 0( 1. 19 3 t
14-122
Free Longlh
vnx.su
No. of Coils
16.5
2.1
25.O
'l2.5
12.5
Disassembly/lnspection/Reassembly
NOTE:
a Cleanall paris thoroughlyin solvent or carburetorcleaner,and dry with compressedair.
a Blow out all passages.
a Replacevalve body as an assemblyit any parts are worn or damaged.
a Check all valves tor free movement.lf any fail to slide frely, see Valve Body Repairon page 14-117.
a Coat all parts with ATF before reassembly.
LOCK-UPSHIFT VALVE
TIMING8 VALVE
LOCK.UP
,ar
CAP
\,/
SPRINGSPECIFICATIONS
Unit ot length; mm (in)
Standard {Nsw}
No.
Spring
Wile Di8.
o . 9 0( o . 0 3 5 )
o . 8 0( o . 0 3 1 )
o.D.
Flee Length
7 . 6 0 ( 0 . 2 9 9 ) 73.70 i.2.9021
6 . 6 0 { O . 2 6 0 ) 6 0 . 8 0( 2 . 3 9 4 )
No. of Coils
32.O
22.1
14-123
vnx.su
SecondaryValve Body
Disassembly/lnspection/Reassembly
NOTE:
a Cleanall parts thoroughlyin solvent or carburetorcleaner.and dry with compressedair.
a Blow out all passages.
a Replacevalve body as an assemblyif any parts are worn or damageo.
a check all valves for lree movement.rf any fair to sridetreery,see varve Body Repairon page
14-1r7.
a Coat all parts with ATF betore reassembly.
CAUTION: Do not use a magnetto removethe check balls; it may magnetizethe balls.
CHECKBALLS.7
1ST ACCUMULATOR
CHOKE
a/
\.^l
"i\
SPRINGSEAT
\ll /
'.'.)
'-
-\)--
o{
\
@
2.3 ORIFICECONTROL
VALVE
3-4 SHIFT VALVE
le
, r /
\i\
DOWEL PIN, 2
SECONDARYVALVE EODY
MODULATORVALVE
a
)
');fi
l"
a-/ xii;.
trd
\
VALVE
14-124
vnx.su
CHECK BALL
CHECKBALLS
FILTER
SPRINGSPECIFICATIONS
Unit ot length: mm (in)
Standard(Nwl
No.
o
@
tcl
\9
Spring
3-2 kick-down valve spring
4-3 kick-downvalve spring
Orifice control valve spring
2-3 orifjce control valve spring
3-4 shift valve spring
Servo control valve spring
Modulatorvalve spring
Wire Dia.
1. 3 { O . 0 5 1 )
1. O ( O . O 3 9 )
o.8 (o.031)
o.9 (o.03s)
0.9 {0.035)
o.9 (o.o35)
1.3(O.O51)
o.D.
8.6 tO.339)
6.6 (O.260)
6.6 (0.260)
6.6 (0.260)
7.6 (O.299)
6.4 lO.252l
9.4 (O.370)
Free Length
45.6
28.5
48.2
33.O
52.O
34.1
37.3
1.795)
1.1221
1.898)
1.299)
2.O47l
1.343)
1. 4 6 9 )
No. of Coils
1 7. O
14.7
33.O
14.9
26.8
12.4
14-125
vnx.su
Servo Body
Disassembly/lnspection/Reassernbly
NOTE:
a Cleanall pSrtsthotoughlyin solvent or carbu.etorcleaner,and dry with compressedair.
a Blow out all passages.
a Replacevalve body as an assembly it any parts are worn or damageo.
a Coat all parts with ATF before resssemblv.
a Replacethe O-rings.
THROTTLECAM
SYOPPER
\P
O-RING
Replace.
4TH
PISTON
6 r 1 . Om m
12 N.m
(1.2 kgf.m,
8.7 rbt.ftl
SERVOBODY
THROTTLEADJUSTIIIIGBOLT
CAUTION: Do not loo3on or
THROTTLE
VALVEB
o
LONG VALVE
'
r
Replace.
V8;lilSl
O-RING
Replace.
3RD ACCUMULATOR
PISTON
14-126
vnx.su
SPRINGSPECIFICATIONS
Unit of length: mm (in)
St8ndard {Newl
No.
o
rar
6\
ra\
@
(!,
Spring
Throttle valve B adiustingspring
Throttle valve B sp.ing
Throttle valve B spring
Throttle valve I spring
4th accumulatorspring
1st accumulatorspring
3rd accumulatorsp.ing
2nd accumulatorspring
Wire Dia.
0.7 (0.028)
1.4 (O.O55)
1.4 (O.O55)
1.4 (O.O55)
2.6 l0.102l
2.5 (O.O98)
2 . 8 ( O . 11 0 )
3.6 (O.142)
vnx.su
o.D.
6.2 t0.244l
8.5 (O.33s)
8.5 (O.3351
8.5 {0.33st
1 6 . 3( O . 6 4 2 )
1 6 . 3( O . 6 4 2 )
1 7 . 5( O . 6 8 9 )
2 2 . O( O . 8 6 6 )
Fre6 Longth
3 4 . O( 1 . 3 3 9 )
4 1 . 5 ( 1. 6 3 4 1
4 1 . 5 ( 1. 6 3 4 )
41.6(1.638)
103.3(4.067)
'l
05.4 (4. 150)
105.2 14.142].
108.9(4.287)
No. ot Coils
15.2
10.5
11.2
12.4
16 + 8.6
19.1
15.2
14-127
l ST.HOLOACCUMULATORCOVER
1ST-HOLDACCUMULATORSPRING
PISTON
IST.HOLDACCUMULATOR
O.BING
R6place.
SPRINGSPECIFICATIONS
Spring
No.
1st-hold accumulatorspring
14-128
Wlro Dia.
4 . 0 0 ( o . 15 7 )
vnx.su
o.D.
Froo Length
2 1 . 5 0 ( 0 . 8 4 6 ) 7 1 . 7 0l 2 . A 2 3 l
No. of Coils
8.3
Mainshaft
Disassembly/lnspection/Reassembly
NOTE:
a Lubricateall pans with ATF during reassembly.
a Installthe thrust needlebearingswith unrollededge of bearingretainerlacing washer.
a Inspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement.
a Betoreinstallingthe O-rings,wrap the shaft splineswith tape to preventdamagingthe O-rings.
a Locknut has lett-handthreads.
CONICAL SPRINGWASI{ER
Replace.
LOCKNUT(FLANGENUT)
19 x 1.25mm
93 N.m {9.5 kgf.m, 69 lbf.ftl
Replace.
Left-hand threads
lST CLUTCH
ASSEMBLY
SNAP RING
\
MAINSHAFT
Check splinestor excessive
wear or damage.
Check bearing surface for scoring,
scralches or excessive wear,
THRUSTWASHER
THRUSTNEEDLE
BEARING
4TH GEAR
o-ntNGs
Replace.
THRUSTWASHER
THRUSTNEEDLE
BEARING
BEANING
NEEOLEBEARIT{GS
lST GEAR
THRUST WASHER
1ST GEAR
COLLAR
O.RINGS
Replace.
THRUST WASHER, 36.5 x 55 mm
Solective part.
THRUST NEEDLE
BEAFING
SEALINGRINGS,
35 mm
SEALINGRING.
29 mm
NEEDLEBEARING
2ND GEAR
NEEDLEBEARING
THRUST NEEDLE
BEARING
SET RII{G
vnx.su
TRANSMISSION
HOUSINGBEARING
Mainshaft
Inspection
Torque the mainshaft locknut to 29 N.m (3.0
kgf.m, 22 lbf.ft).
a ClearanceMeasurement
NOTE: Lubricateall parts with ATF during assembly.
2.
1ST CLUTCHASSEMBLY
THRUSTWASHER
lST GEARCOLLAR
TBANSMISSION
HOUSINGBEARING
THRUSTWASHER
4.
Hold 2nd gear againstthe 2nd clutch. then measure the clearancebetween 2nd gear and 3rd gear
with a feelergauge.
in at leastthree Dlaces
NOTE: Takemeasurements
and take the averageas the actual clea.ance.
STANDARD:0.05-0.13 mm {0.002-0.005 inl
3RD GEAR
2ND GEAR
THRUSTWASHER
Selectivepart.
TI{RUSTNEEDLE
BEARING
2ND GEAR
NEEDLEBEARING
THRUSTNEEOLE
BEARING
THRUSTWASHER36.5 x 55 ftm
MAINSI.IAFT
3RD GEAR
14-130
vnx.su
2ND GEAR
5.
6.
THRUSTWASHER36.5 x 55 mm
No,
Thickness
9 0 4 4 1- P G 4 - O 1 0
4 . O Om m ( O . 15 7 i n )
90442 PG4-010
90443-PG4-O10
4 . 0 5 m m { O .15 9 i n )
4 . 1 Om m ( O . 1 6 1i n )
90444-PG4-O10
4 . 15 m m ( O . 1 6 3i n )
90445-PG4-O10
4 . 2 0 m m ( O . 1 6 5i n )
90446-PG4-Ol O
4 . 2 5 m m ( O . 1 6 7i n )
90447,PG4 0r0
4 . 3 O m m ( O . 1 6 9i n )
90448-PG4-O10
4 . 3 5 m m { O . 17 1 i n )
9 0 4 4 9 - P G 4 - O r0
4 . 4 O m m ( O . 17 3 i n )
7,
Part Number
vnx.su
14-131
Countershaft
Disassembly/lnspection/Reassembly
NOTE:
a Lubricateall parts with ATF belore reassembly.
a Installthe thrust needlebearingswith unrollededge of bearingretainerfacing washer.
a Inspectthe thrust needlebearingsand the needlebearingstor gallingand rough movement.
a Beforeinstallingthe O rings, wrap the shaft splineswith tape to preventdamagingthe O-rings.
a Locknut has left-handthreads.
CONICAL SPRING
WASHER
Replace.
REVERSE
GEARCOLLAR
NEEDLEEEARING
LOCKNUT{FLANGENUTI
23 x 1.25mm
1O3-0-lO3N.m
{10.5-O-'l0.5ksf.m,
75.9*O-75.9tbf.fr)
Replace.
Left-hand threads
PARKINGGEAR
REVERSE
GEAR
BEVERSE
SELECTOR
ONE.WAY
CLUTCH
.IST GEAR
REVERSESELECTOR
HUB
NEEDLEEEARING
4TH GEAR
NEEDLEBEARING
DISTANCECOLLAR,
28 mm
Selectivepart.
COUNTERSHAFT
Check splinesfor excessive
wear or damage.
Check bearingsurfacefor scoring,
scratchesor excessivewear_
2ND GEAE
THRUST NEEDLE
BEARING
3RD GEAR
NEEDLEBEARING
THRUSTNEEDLEBEARING
3RD GEARCOLLAR
O-RINGS
Replace.
vnx.su
TRANSMISSION
HOUSINGBEARING
Disassembly/Reassembly
1,
4TH GEAR
NEEDLEBEARING
DISTANCECOLLAR. 29 mm
Selectivepart.
2ND GEAR
THRUSTNEEDLEBEARING
3RD GEAR
NEEDLEBEARING
THRUSTNEEDLEBEARING
3RD GEAR COLLAR
3RD CLUTCHASSEMBLY
O-RINGS
Replace.
COUNTERSHAFT
{cont'd)
vnx.su
Countershaft
(cont'd)
Disassembly/Reassembly
a
Inspection
a ClearanceMeasurement
NOTE: Lubricateall parts with ATF during assembly.
1.
2.
REVERSESELECTOR
HUB
4TI{ GEAR
NEEDLEBEAFING
DISTANCECOLLAR, 28 m|n
Selective part.
COUNTERSHAFT
14-134
vnx.su
Install the parts below on the countershaftsubassembly,then torque the locknut to 29 N'm (3.O
kgf.m, 22 lbf.ft).
2ND GEAR
DISTANCECOLLAR,
28 mm
LOCKNUT
Left-hand threads
CONICALSPRI G
WASHER
PARKINGGEAR/ONE-WAY
CLUTCH/1STGEAR
ASSEMBLY
NEEEDLEBEARING
lST GEARCOLLAR
TRANSMISSIONHOUSING
BEARING
REVERSEGEAR
COLLAR
2ND GEAR
(cont'd)
14-135
vnx.su
Countershaft
Inspection(cont'dl
5.
6.
DISTANCECOLLAR,28 mm
No.
Part Number
Width
90503-PC9-OOO
3 9 . O 0m m ( 1. 5 3 5 i n )
90504-PC9-OOO
3 9 . 1 0m m ( 1 . 5 3 9i n )
3 9 . 2 0 m m ( 1 . 5 4 3i n l
90sos,Pc9-ooo
5
90508-PC9-000
3 9 . 3 0 m m ( 1 . 5 4 7i n )
3 9 . 0 5 m m ( 1. 5 3 7 i n l
6
7
90509-PC9-000
90510 PCg*000
3 9 . 15 m m { 1 . 5 4 1i n )
3 9 . 2 5m m ( 1 . 5 4 5i n )
9 0 5 1I - P C g - O O O
3 8 . 9 0 m m { 1 . 5 3 1i n )
3 8 . 9 5m m { 1 . 5 3 3i n )
90507-PC9-000
7,
14-136
vnx.su
One-way Clutch/ParkingGear
Disassembly/lnspection
1 . Separatecountershaft1st gearfrom the parkinggear
by turningthe parkinggear in the directionshown.
PARKII{GGEAR
Inspectthg parking
tor ws. or acoring.
COUNTERSHAFT1ST GEAR
O E.WAY
2.
courrERsHAFrlsr.EAR
9IlYlL9iY^t.?I
NOTE: lnstall in this direction.
l ST GEAR
Inspect counior6haft 1
tor wegr or scoaing.
3.
CLUTCH
O'TE.WAY
COUNTERSHAFTlST GEAR
1STGEAR
COU TERSHAFT
SCREWDRIVER
14-137
vnx.su
Sub-shaft
Disassembly/lnspection/Reassembly
NOTE:
a Lubricateall parts with ATF during reassembly.
a Installthe thrust needlebearingswith unrollededge ot bearingretainertacing washer.
a lnspectthe thrust needlebearingsand the needlebearingsfor gallingand rough movement.
a Beforeinstallingthe O-rings,wrap the shaft splineswith tape to preventdsmagingthe O-.ings.
TRANSMISSIOI{HOUSING
TRANSMISSION
HOUSINGBEARING
lST-HOLD CLUTCH
ASSEMELY
O.RINGS
Replace.
6 x 1.0 mm
12 N.m
(1.2 kgf.m, 8.7 lbf.ft)
THRUST WASHER
THRUST NEEDLE
BEARING
NEEDLEBEARING
SUB.SHAFT
Checksplinestor excessive
wear or damage.
Check bearingsurlacetor
sconng.scratchesor excessive
4TH GEAR
THRUST I{EEDLE
AEARIIIG
OIL GUIDECAP
Replace.
NEEDLEBEARIT{G
STOPPER
NEEDLEEEARING
vnx.su
Disassembly/Reassembly
Removethe oil guide cap by pushingthe sub-shaft
insidethe transmissionhousing.
Removethe 1st-holdclutchassemblyby pullingthe
sub-shaft,then removethe sub-shatt.
Installnew O-ringson the sub-shaft.
NOTE: Wrap the shaft splineswith tape to prevent
damagingthe O-rings.
Placethe sub-shaftin the transmissionhousingand
installthe 1st-holdclutch assembly.
Installnew oil guide cap usingthe specialtools as
snown.
DRIVER
07749-0010000
ATTACHMENT32x35mm
07746-0010100
,IST.HOLD CLUTCH
ASSEMBLY
14-139
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Sub-shaft Bearings
Replacement
Installthe new needlebearingin the transmlsston
anda pressas shown.
housingusingthe specialtools
PRESS
ATTACHMENT,
32 x 35 mm
07746-0010100
ATTACHMENT,
62 x 68 mm
07746-0010500
5 . Expandthe snap ring with snap ring pliers,then insert the ball bearingpart way into the housingusing the specialtoolsand a pressas describedin step
1. Installthebearingwith the groovefacingoutside
the housing.
Removethe needlebearingstopper.
Removethe needlebearingfrom the transmisslon
housingusing a drilt Punch.
DRIFTPUNCH
?A
SNAP RING
14-140
vnx.su
Clutch
lllustratedIndex
3RD CLUTCH
CLUTCH
DRUM
O-RINGS
Replace.
CLUTCH PISTON
DISC SPRING
RETURNSPRING
SPRINGRETAINER
SNAP RING
1ST CLUTCH
CLUTCHEND
CLUTCH DISCS
PLATE
Stsndard thickness:
1.94 mm {0.076 in)
SNAP RING
SNAP RING
O-RINGS
Replace.
SNAP RING
CLUTCH PLATES
Standard thicknass:
2.00 mm {0.079 in}
CHECKVALVE
(cont'd)
14-141
vnx.su
Clutch
lllustratedIndex (cont'd)
2ND/4TH CLUTCH
SNAP RING
CLUTCH END PLATE
CLUTCH DISCS
Standard thickno3s:
1.94 mm 10.076in)
CLUTCH PLATES
Standard thickness:
2.OOmm 10.079inl
SNAP RING
SPRINGRETAINER
RETURNSPRING
CLUTCH PISTON
SPRING
RETURNSPRING
CHECKVALVE
RETAINER
SNAP RING
4TH CLUTCHDRUM
CLUTCH PLATES
Standa.d thickness:
2.00 mm 10.079 in)
;;i;;;
( / \
Y)
CLUTCH DISCS
Stsndard ihicknss:
1.94 mm 10.076in)
CLUTCH END PLATE
SNAP RING
14-142
vnx.su
lST.HOLD CLUTCH
SNAP RING
CLUTCH END PLATE
CLUTCH DISCS
Standard thicknoss:
1.94 mm 10.076 inl
DISC SPRING
CLUTCH PISTON
O-RINGS
Roplace.
CLUTCH PLATES
Standard thickno3si
2.00 mm (0.o79 in)
14-143
vnx.su
Clutch
Disassembly
Removethe snap ring. then.emove the clutch end
plate, clutch discs and plates.
3.
SNAP RII{G
cLuTcHspnrc
2.
COMPNESSOR
ATTACHMET
oTHAE-Pr60tOO
otsc sPfit c
CLUTCH SPRII{C
COMPNESSOR
ATTACHi'ENT
OTLAE-PX,l{,TOO
2ND CLUTCH
DISC SPBING
CLUTCH SPBII{G
COMPRESSOR
ATTACHMEI{T
oTHAE-Pt50100
14-144.
vnx.su
S AP RING
Do not set horo.
6.
4.
Wrap a shop towel aroundthe clutch drum and apply air pressureto the oil passageto remove the
piston.Placea fingertip on the other end while applying air p.essure.
COMPRESSEDAIR
HOSE NOZZLE
OSHA-approved30 psi
rype onry
CLUTCH
RETURNSPRING
PISTON
14-145
vnx.su
Clutch
Reassembly
NOTE:
a Clean all psrts thoroughly in solvent or carburetor
cleaner.and dry them with compressedair.
a Blow out all passages.
a Lubricateall pans with ATF before .eassembly.
1.
3,
CHECKVAIVE
4.
SNAP RING
SPRINGRETAINER
RETURNSPRING
CLUTCHORUM
PISTON
14-146
vnx.su
r
5,
CAUTION: lf ithor end of the comprossor attachment is set over an area of the spring rotainerwhich
iE unsupportedby tho retum spring, the latainer may
bo damaged.
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE-PX40100
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
oTHAE-Pl50100
CLUTCH SPRING
COMPNESSOR
BOLT ASSEMBLY
oTGAE-FG40200
6,
CLUTCII SPRING
COMPRESSOR
ATTACHMENT
oTLAE-PX40100
CLUTCH SPRIIIG
COMPRESSOR
ATTACHMENT
oTHAE-Pl50100
CLUTCH SPRING
COMPRESSOR
AOLT ASSEMBLY
07GAE-PG40200
RETURNSPRING
(cont'd)
14-147
vnx.su
Clutch
Reassembly(cont'd)
7.
SNAP RING
Removethe specialtools.
Installthe disc spring.
NOTE: Installthediscspringin the directionshown.
DISCSPRING
1 2 . I n s t a l tl h e s n a p r i n g .
SCREWDRIVER
SNAP RING
.\
):ll
1ST, 3RD, 4TH and
l ST.HOLDCLUTCH
14-148
vnx.su
lst
2nd
3rd
4th
1st-hold
Service Limit
O.65 o.85 mm
O . 6 5- O . 8 5 m m
O . 4 O - O . 6 0m m
0.4O-0.60 mm
0.50-0.8O mm
( O . 0 2 6 O . O 3 3i n )
{ O . 0 2 6 - O . O 3 3i n )
( 0 . O 1 6 o . O 2 4i n )
(0.016-0.024 in)
{ O . 0 2 O - 0 . 0 3 1i n }
14
PartNumber
Thickness
2 . 1 m m 1 0 . 0 8 3i n )
22551-PF4-000
2 . 2 m m ( 0 . 0 8 7i n )
22552-PF4 000
2 . 3 m m ( 0 . 0 9 1i n )
22553 PF4 000
2 2 5 5 4 - P F 4 - O O O 2.4 mm (0.094in)
2 . 5 m m ( 0 . 0 9 8i n )
22555 PF4-000
2 . 6 m m { 0 . 1 0 2i n }
22556 PF4-000
2 . 7 m m i 0 . 1 0 6i n )
22557-PF4 000
in)
2 . 8m m ( 0 . 1 1 0
22558-PF4 000
2 . 9m m ( 0 . 11 4 i n )
2 2 5 5 9 -P F 4 -0 0 0
3 . 0 m m ( 0 . 11 8 i n )
22560-PF4 000
3 . 1 m m ( 0 . 12 2 i n l
22561 PF4-000
3 . 2 m m { 0 . 1 2 6i n }
22562-PF4 000
3 . 3 m m ( 0 . 13 0 i n )
22563-PF4 000
3 . 4 m m ( 0 . 1 3 4i n )
22564 PF4-OOO
IAL INDICATOR
PlateNo.
PartNumber
Thickness
1
2.
3
4
5
6
7
8
I
10
22551 P56,N00
22552-P56-N00
22553-P56-N00
2 2 5 5 4 -P 5 6- N 0 0
22555-P56 N00
22556 Ps6-N00
22557- P56 N00
22558 P56-N00
22559-P56 NOO
22560 P56-N00
2 . 1 m m ( 0 . 0 8 3i n )
2 . 2 m m ( 0 . 0 8 7i n )
2 . 3 m m ( 0 . 0 9 1i n )
2.4 mm (0.094in)
2 . 5 m m ( 0 . 0 9 8i n )
2 . 6 m m { 0 . 1 0 2i n )
2 . 7 m m { 0 . 1 0 6i n i
in)
2 . 8m m ( 0 . 1 1 0
2 . 9 m m ( 0 . 11 4 i n )
3 . 0 m m ( 0 . 11 8 i n )
22551-PS5 003
22552 PS5-003
22553-PS5 003
4
22554-PS5-003
5 (Nomark) 2 2 5 5 5 - P S 5 - 0 0 3
22556 PS5-003
6
7
22557 PS5-003
1
2
3
Part Number
ThicknEss
2 . 1 0m m ( 0 . 0 8 3i n )
2 . 2 0m m ( 0 . 0 8 7i n )
2.30 mm (0.09'1in)
2 . 4 0m m ( 0 . 0 9 4i n )
2 . 5 0m m { 0 . 0 9 8i n )
2 . 6 0m m { 0 . 1 0 2i n }
2 . 7 0m m ( 0 . 1 0 6i n )
Thicknss
CLUTCHEND PLATE
14-149
vnx.su
DRIVEN
07749 -OOIOOOO
ATTACHMENT,
62x68mm
07746-0010500
Slide Hammer
CommerciallyAvailable
3/8 in.x 16
ATTACHMENT,
72x75mm
07746-0010600
14-150
vnx.su
CountershaftBearingReplacement
l.
SlideHammer
CommerciallyAvailable
3/8 in. x 16
ADJUSTABLE
BEARING
PULLER,
25-40 mm
07736-AOIOOOA
K-i.<trE)t
'/'
',--CZ_
( (
-)
_-=\._
-) ))\
-:-:-:1.-=41"
Installthe oil guide plate.
14-151
vnx.su
TransmissionHousingBearings
Mainshaft/Countershaft
BearingReplacement
1. To removethe mainshaftand counte.shaftbearings
trom the transmissionhousing,expandeach snap
ring with snap ring pliers,then pushthe bearingout
using the specialtools and a press as shown,
PRESS
ATTACHMENT,
62x68mm
o7746-
DRIVER
o7749-OOIOOOO
GnoovE
---7i
\)
4.
MAINSHAFT
SNAP BING
TRANSMISSION
t|oustitc
14-152
vnx.su
Sub-shaftBearingReplacement
I.
To remove the sub-shaft bearinglrom the transmission housing,expandthe snap ring with snap ring
pliers, then push th bearing out using the special
tools and a Dressas shown.
NOTE: Do not remove the snap ring unless it's
necessary to clean the groove in the housing.
PNESS
GROOVE
4.
ATTACHMENT,
62x68m|n
07746-(Xr10500
El{DGAP:o-7 mm
HOUS[{G
14-153
vnx.su
Reverseldler Gear
ParkingBrake Stopper
Installation
1.
Inspection/Adjustment
ROLLERPIN
PANKING
BRAKE
LEVER
7A\
Meaauring
\v
PARKING
BBAKE
PAWLSHAFT
PARKINGBRAKE
STOPPER
6 x l.O mm
12 N'm 11.2 kgt.m.
4.7 lbf.ft)
PARKINGBRAKESTOPPER
Mark
1
4.
14-154
vnx.su
PartNumbol
Lz
- PA9-003 11 . 0 0m m
24537
{0.433in}
1 1 . 0 0m m
{0.433in)
-003
24538-PA9
10.80mm
(0.425in)
1 0 , 6 5m m
( 0 . 4 1 9i n l
24539- P49,003
1 0 . 6 0m m
( 0 . 4 1 7i n )
1 0 . 3 0m m
{0.406in)
Transmission
Reassembly
NOTE:
a Coat all parts with ATF.
a Replacethe parts below:
. O-rings
. Lock washers
. Gaskets
. Locknuts
. Conicalspring washers
. Sealingwashers
T O R O U E1: 2 N . m ( 1 . 2 k g t . m , 8 . 7 t b f . f r )
OIL FEEDPIPE
LUBRTcAToR orL
PLATE
FEED
PIPES
LOCK-UPVALVE
f| l n /
EODY
OOWELPINS,2
OIL FEEDPIPES
ACCUMULATOBCOVER
/""n
v{
e'f
*'
OIL FEEDPIPE
_\
_! 1.-...-]]
vaLVE spRtNGS
ToRouE coNvERTE
n \-\.-CHECK VALVE
----.-.
--'r
LOCKWASHER
"o't
\_(<
Bolts,3
e
E
SERVODETENT
BASE
CONTROL
SHAFT
COOLERCHECKVALVE
-. :-,.
REGULATORVALVE
BODY
OIL FEEDPIPES
Bolts,4
SERVOBODY
DOWELPINS.2
MAIN VALVE
.
EoDY
|
SERVOSEPARATOR
PLATE
"1-
Bolt
OIL PUMPDRIVEN
GEARSHAFT
SECONDARYVALVE
BODY
DOWELPINS,2
MAIN SPARATOR
PLATE
OOWELPINS,2
SECONDARYSEPARATOR
PLATE
ATF MAGNET
14-156
vnx.su
E
'.
Groovedand chamfered
side faces separator
plate.
6.
1 0 . T i g h t e nt h e f o u r b o l t st o 1 2 N . m ( 1 . 2 k g f ' m , 8 . 7
lbf.ft) on the main valve body.
Make sure the oil pump drive gear and oil pump
driven gear shaft move smoothly same as in the step
11. lf the oil pump drive gear and oil pump driven gear
shaft do not move freelY.loosenthe four bolts on
the main valve body and disassemblethe valve
bodies.
Realignthe oil pumpdrivengearshaft and reassemble the valvebodies,then retightenthe bolts to the
specifiedtorque,
OIL PUMP
ORIVENGEAR
J.
36
DETENT
SHAFT
SERVOSEPARATORPLATE
--- 8ixli"'
(l . . \. l
=L,1ffi#
.. N
j-*/:
OIL PUMP
DRIVEGEAB
OIL PUMP
DRIVENGEAR
OIL PUMP
DRIVENGEAR
SHAFT
DETENI SPRING
DETENTARM
MANUAL VALVE
(cont'dl
14-157
vnx.su
Transmission
(cont'dl
Reassembly
TRANSMISSIONHOUSING
MOUNTINGBOLTS,18
l0 x 1.25mm
44 N.m (4.5 kgl.m. 33 lbf.trl
fl
TRANSMISSION
HANGER
TRANSMISSIONHOUSING
TRANSMISSION
MOUNT BBACKET
12 x
'1.25
fifi
47 tbt'tr)
CONNECTORSTAY
T=
MAINSHAFT
SUB-ASSEMBLY
TRANSMISSION
HOUSING
GASKET
Replace.
REVERSEGEAR COLLAR
NEEOLEBEARING
REVEBSE
GEAR
LOCKWASHER
Replace.
SHIFTFORK
DOWELPINS,3
REVERSESELECTOR
COUNTERSHAFT
SUB.ASSEMBLY
DIFFERENTIAL
ASSEMBLY
TOROUECONVERTER
HOUSING
14-158
vnx.su
,,1
24. Align the spring pin of the control shaft with the
CONTROL
MAINSHAFT
SUB.ASSEMBLY
COUNTERSHAFT
SUB.ASSEMBLY
/K"\
// 2 " \
TRANSMISSION
HOUSING
2 2 . Turn the shift fork so the largechamteredhole is facing the fork bolr hole.then installtheshift fork with
the reverseselectorand torquethe lock bolt. Bend
the lock tab againstthe bolt head.
SHIFTFORK
LOCI( WASHER
Replace.
6 x 1.0 mm
4 N.m
(1.4 kgl.m, rO lbt.ft)
Largechamferedhole
faces this way.
vnx.su
14-159
Transmission
(cont'dl
Reassembly
27. Slip the specialtool onto the mainshaftas shown.
32. Use th6 old locknut and old conicsl spring washot
to tighten th parking gear to th spcifid torque,
then loosen the locknut.
MAII{SHAFT HOLDER
oTGAa - PF5010I
TOROUE:103
PARKII{GGEAR
SUB-SHAFT
14-160
MAIt{SHAFT
COU TERSHAFT
vnx.su
. COUNTERSHAFT
O,7- 1.2 mm
CONICAL DISC SPRINGS
lnstallin rhis direcrion.
0.7- 1.2 mm
in)
1O.03-O.05
SUB-SHAFTLOCKNUT
vnx.su
14-161
Transmission
Reassembly(cont'dl
40. Set rhe parkingbrakelever in the E position,then
verifythat the parkingbrakepawl engagesthe parkIng gear.
4 1 . l f t h e p a w l d o e sn o t e n g a g e f u l l yc,h e c k t h ep a r k i n g
brakepawl stopperclearanceas describedon page
14-154.
PARKINGGEAR
PARKINGBRAKEPAWL
14-162
vnx.su
Torque Converter/DrivePlate
6 x'l.Omm
12 N.m {1.2 kgf.m, 8.7 lbf'tt)
12 x 1.0mm
74 N.m {7.5 kgf.m, 54 lbl.ftl
Torquein a crisscrosspattern.
0d
DRIVE PLATE
TOROUECONVERTER
ASSEMELY
14-163
vnx.su
Transmission
Installation
1 . F l u s ht h e A T Fc o o l e ra s d e s c r i b eodn p a g e sI 4 - 1 6 8
'l
thru 69.
2.
5.
12 x 1.25mm
64 N.m 16.5 kgl.m, 47 lbf.ft)
STARTERMOTOR
Installthe transmissionmount.
'14 mm DOWELPIN
i.'l,i;
TOROUE
CONVERTER
J.
O-RING
Replace.
1 2 x 1 . 2 5m m
74 N.m 17.5kgf'm,
54 rbt'ft)
14 mm OOWELPIN
6.
Installthe transmissionhousingmountingbolts.
REARENGINE
MOUNT BOLTS
1 4 x 1 . 5m m
TRANSMISSION
HOUSING
MOUNTING BOLTS
12 x 1.25 rnm
74 N.m (7.5 kgf'm, 54 lbf.ftl
14-164
vnx.su
7 . Removethe transmissionjack.
12. Connectthe throttlecontrolcableto the throttlecontrol lever and installthe right front mount/bracket.
THROTTLECONTROLLEVER
THROTTLECONTROL
CABLEEND
JOINT PIPES
T O R O U E1: 2 N . m { 1 . 2 k g l . m . 8 . 7 l b f . f t }
ATF COOLERHOSES
10 x 1.25mm
RIGHT
44 N.m (4.5 kgf'm, FRONT
MoUNT/
33 rbl.ftl
BRACKT
t5.
1 2 x 1. 2 5 m m
64 N.m {6.5 kgf.m,
47 tbf.ftl
Replace.
10 x 1.25mm
44 N'm {4.5 kgf.m.
33 rbt'frl
SHIFTCABLE
CONTROL
SHAFT
8 x '1.25mm
24 N.m (2.4 kgl.m,
17 tbf.trl
1 2 N . m 1 1 . 2k g f . m ,
8.7 rbt.ft)
l O x ' 1 . 2 5m m
43 N.m
14.4 kgf.m, 32 lbf.ltl
6 x 1.0 mm
12 N.m
{1.2kgf.m,
8.7 lbl.rr)
CONTROLLEVER
6 x 1.0 mm
1 4 N . m 1 1 . 4k g l . m ,
10 lbf.fr)
(cont'dl
14-165
vnx.su
Transmission
Installation{cont'd)
1 4 . Installnew set ringson the end of the intermediate
shaft and the driveshaft.
1 5 . Installthe intermediateshaft.
32 tbr.ftl
SET RING
Beplace.
10 x 1
39 N.m
14.Okgf.m, 29 lbf.ftl
SHAFT
\
SELF.LOCKINGNUT
1 2 x 1. 2 5 m m
64 N.m (6.5 kgl.h, 47 lbt.ftl
Replace.
COTTER
Replace.
CASTLE NUT
1 2 x 1 . 2 5m m
49-59 N.m
{5.O-6.0 ksf.m, 36-43 rbt'ft1
1 9 . I n s t a l tl h e s p l a s hs h i e l d .
SELF-LOCKINGNUT
10 x 1.25mm
54 N.m (5.5 kgl.m,
40 rbt.trl
Replace.
GASKET
Replace.
SELF.LOCKINGNUTS
I x 1.25mm
22 N.m 12.2 kgl'n,
16 lbt.trl
Repl6ce.
14-166
vnx.su
6 x 10 mm BOLT
cltPs, 5
6 x 1 . 0m m
'12 N.m (1.2 kgf'm,8.7 lbt.tl)
N.m
STARTERCAELE
INTAKEAIR
DUCT
14-167
vnx.su
Transmission
CoolerFlushing
ro prevent iniury to tace and eyes, always
S!@
wear safety glas$esor a tace shieldwhen usingthe transmission flusher.
OFF
Usingthe measuring
cup, tillthe tank with 21 ounces
{approximately213 lulll of biodegradabletlushing
fluid (J35944-20).Do not substitutewith any other
fluid.
Followrhe handlingprocedure
on the fluidcontainer.
Securethe tlusherfillercap and pressurizethe tank
with compressedair to between 550-829 kPa
( 5 . 6 - 8 . 4 5 k g t / c m , ,8 0 - 1 2 0 p s i ) ,
NOTE: The air lineshouldbe equippedwith a water
trap to ensurea dry air system.
Hang the tool under the vehicle.
Attach the dischargehoseof the tank to the return
line of the transmissioncooler using a clamp.
6.
Connectthe drainhoseto the inlet lineof the transmissioncoolerusinga clamp.Securelyclampthe opposite end of the drain hoseto a bucket or floor drain.
DISCHARGEHOSE
BUCKET
TRANSMISSION
COOLERFLUSHEB
CommorciallyAvailablo
KENT MOORE#J38405_A
14-168
vnx.su
TOOL MAINTENANCE
Then fill the transmission with ATF and run the engins tor 30 sacondsor until spproximatelyons quart
iB discharged.
1.
Empty and rinse aftor each use. Fill the can with
water and pressurizethe can. Flush the discharge
line to ensurethat the unit is clean.
2.
3.
4.
5.
FILLERCAP
COUPLII{GI{UT
FILTER
---0--L--
O.BI G
ORIFICE
14-169
vnx.su
shift cable
Removal/lnstallation
a All SRS electrical wiring hamosses are covord with
yellow insulation.
a Before disconnecting any pan ot th SRS wire harnoss, connect the short connectorc(soepage 23-7O1.
a Roplaceth entiro attectd SRS haness assembly it
it has an open circuit ot damaged wi.ing.
3.
6x1.0mm
1 2 N . m 1 1 . 2k g f . m , 4 . 7l b f . f t l
uar"
@@[
section 1).
4.
5.
6.
1.
2.
@J^ll
AJUI
[qJ ]l tl
---l
LOCK NUT
7 N.m
(O.7 kgf.m, 5 lbf.ft)
14-170
vnx.su
Adjustment
CAUTION:
a All SRS electrical widng harnssesare covard with
yollow insulation.
a Before disconnecting any part of ths SRS wire harness, connect the shon connectors(seepage 23-701.
a Rplacethe entire affected SRS halnass asssmbly it
it has an opn circuit or damaged wiring.
ADJUSTER
Cable
I oo snon
Cable
Too Long
Exact
Alignment
'1.
''fidlfr
]H
@
@
@
t+@
\
\ /
CABLE
-.'.-_--l../
ADJUSTER
14-17 1
vnx.su
GearshiftSelector
Disassembly/Reassembly
CAUTION:
a All SRS electrical wiing halnssss are covered with
y6llow insulation.
a 8fore disconnecting 8ny pan of the SRS wire harneaa.connOctth6 short connectors(sse page 23-701.
a Roplacethe entire affected SRS hahess assembly if
il has an opon circuit or damaged wiring.
[E--__
rocK ptN
ADJUSTER
-6{
stLtcoNE
GREASE
e-
LEVERCOVER
-#q
SILICONEGREASE
CONTROLBRACKET
@6
SELECTLEVERBRACKET
AUTOMATIC TRANSAXLE
GEAR POSITIONSWITCH
Testing,see Section23
CONTROLSEAL
14-172
vnx.su
INDEXMARK
@
@
@
SRS MAIN HARNESS
MOUNTING SCREW
3 N'm lO.3 kst.m, 2 lbf.ftt
14-173
vnx.su
NOTE: Betoreinspecting
the throttlecontrolcable,make
sure:
a Throttle cable free play is correct (seesection 1 1).
a ldle speed is correct (see section 1l).
a To warm up the engineto normaloperatingtemperature {the coolingfan cor'reson)
1.
,r:
14-174
vnx.su
4.
F.o. play
14-175
vnx.su
4.
5.
Verify that the throttle control c8ble is clamDedcorrsctly with three positions.
THROTTLE
COI{TROL
CABLE
ATF COOLER
PIPE
Clamp on blu6
CLAMP
Verify that the throttle linkage is in the full-closed
position.
5.
After tightening the locknuts, inspect the synchronization and throttlg control l6ver movemenr.
LOCKI{UTS
14-176
vnx.su
Differential
ManualTransmission
81881 engine
15-1
8 1 8 C 1e n g i n e. . . . . . .
15-9
AutomaticTransmission
..................
15-19
vnx.su
Differential(81881 enginel
........15-2
S p e c i aTf o o l s. . . . . . . .
Differential
lllustrated
Index.........
. 15-3
BacklashInspection
.... 15-4
FinalDrivenGearReplacement
...... 15-4
15-5
BearingReplacement
....................
Oil SealRemoval
........15-5
SideClearance
Adiustment...........15-6
Oil Seallnstallation
..... 15-8
vnx.su
SpecialTools
Ref. No.
o
ra)
@
Tool Numbol
oTJAD-PH80101
07746-OO30100
o7749-OO10000
o7947-SO90200
Description
Oty
Seal DriverAttachment
D r i v e r ,4 0 m m l . D .
Driver
Seal DriverAttachment
15-8
15 - 5 . 6
15-8
15-8
(^
s
F
$-l)
o
15-2
vnx.su
I Pag Reference
Differential(B1881 engine)
lllustrated Index
DIFFERENTIALCARRIER
Inspection.page 15-4
BALL BEARING
Inspect lor wear and operation.
page 15 5
Replacement,
BALL BEARING
Inspect for wear and operation.
page'15-5
Replacement,
10 x 1.0 mm
101 N.m llO.3 kgt'm,74.5 lbf.ftl
Left-handthreads
80 mm SHIM
Selection,page 15-6
'l5-5
Removal,page
lnstallation,page 15-8
15-3
vnx.su
Differential(818B1 enginel
BacklashInspection
'1.
FinalDrivenGearReplacement
1 0 x 1 . 0m m
101 N.m llO.3 kgl.m,74.5 lbf.ftl
Lelt-handthreads
DIAL II{OICATOR
FINAL DRIVEIIIGEAR
Chamfer on inside diameter ot
linal driven gear taces carrier.
DIFFEREI{TIAL
CARBIER
3.
15-4
vnx.su
Bearing Replacement
NOTE: Checkthe ball bearingsfor wear and rough rotation. It bearingsare OK, removalis not necessary.
1.
80 mm SHIM
TRA[{SMtSStON
HOUSING
3.
4.
BALL BEARING
DRIVER,40 mm l.D.
07746-0030100
BALL BEARING
OIL SEAL
Rplac6.
15-5
vnx.su
Differential(81881 engine)
Side ClearanceAdjustment
l.
4.
tt.
HOUSING
2.
Installthe 80 mm shim.
NOTE: Instsllthe 80 mm shim that was removed.
mm SHIM
15-6
vnx.su
'l
8O mm Shim
Pan Number
Thicknoss
41441-PL3-BO0
41442-PL3-BOO
1 . Om m 1 0 . 0 3 9 4i n )
1 . 1 m m ( O . O 4 3 3i n )
1 . 2 m m ( O . O 4 7 2i n )
1 . 3 m m ( 0 . 0 5 1 2i n )
41444-PL3-BOO
41445-PL3-BO0
41446- PL3-BO0
1 . 4 m m { 0 . 0 5 5 1i n l
1 . 5 m m ( O . O 5 9 1i n )
41447-PL3 -BOO
1.6 mm (0.0630in)
41448-PL3- B00
41449-PL3- BO0
1 . 7 m m ( 0 . 0 6 6 9i n )
1 . 8 m m ( 0 . 0 7 0 9i n l
41450- PL3-BOO 1 . 0 5m m { o . o 4 1 3i n l
4 1 4 5 1 - P L 3 - B O O 1 . 1 5m m ( 0 . 0 4 5 3i n )
in)
4 1 4 5 2 - P L 3 - B O O 1.25 mm (O.O492
4 1 4 5 3 - P L 3 - B O 0 1. 3 5 m m ( 0 . 0 5 3 2i n )
41454-PL3-BOO
41455-PL3-BOO
1 . 4 5 m m ( 0 . 0 5 7 1i n )
1. 5 5 m m ( 0 . 0 6 1 Oi n )
41456-PL3-800
41457 - PL3-BOO
1 . 7 5m m ( 0 . 0 6 8 9i n )
41441-P21-OOO
1 . 8 5 m m ( 0 . 0 7 2 8i n )
41442-P21-OOO
1.90 mm (o.o748in)
41443-P21-OOO
1 . 9 5 m m ( 0 . O 7 6 8i n )
H
J
K
L
M
41443-PL3- BOO
1 . 6 5 m m ( 0 . O 6 5 0i n )
15-7
vnx.su
Differential(8188l enginel
Oil Seal Installation
1.
DRIVER
07749-0010000
DRIVER
07749-0010000
OIL SEAL
Replsce.
OIL SEAL
Replace.
HOUSING
15-8
vnx.su
Dif f er en ti a(8
l 18C1enginel
15 - 1 0
S p e c i aT
l ools ........
Differential
1 5 - 11
l l l u s t r a t e dI n d e x . . . . . . . . .
15-12
BacklashInspection
F i n a lD r i v e nG e a rR e p l a c e m e n.t. . . . . 15-12
TaperedRollerBearingReplacement.1 5 - 1 3
15-13
Oil Seal Removal
BearingOuter Race Replacement... 15-14
TaperedRollerBearingPreload
15-15
Adjustment
15-17
Oil Seal Installation
vnx.su
SpecialTools
Ref. No. I
(
,a\
@
r.l
@
TootNumber
oTHAJ-PK40201
oTJAD-PH80101
oTNAD-PX40100
o7746-O030'l
OO
o7749-OO10000
o7947-SD90200
Descriprion
PreloadInspectionTool
Seal DriverAttachment
DriverAttachment
Driver,40 mm l.D.
Driver
Seal Drive. Attachment
rt\
$
s
tl
15-10
vnx.su
Oty
I
I
1
I
I
1
aa\
I Page Reference
1 5 - 15
15- 14
1 5- 14
15-131 4
15- 14 1 7
15 - 1 7
Differential(B18C1 engine)
lllustrated Index
NOTE: lf the ' mark parts were replaced,the tape.ed roller bearingpreloadmust be adiusted(see page 15-15).
ROLLER
TAPERED
BEARING
Inspectfor wear and oporation.
page'15-13
Replacement,
*BEARING OUTERRACE
Inspect tor wear and damage.
page 15-14
Replacement.
10 x 1.0 mm
101 N.m 11O.3kgt.m,74.5 lbt.ft)
Left-hand threads
FINAL DRIVENGEAR
Inspectlor wear and damage.
page 15-12
Replacement,
}DIFFERNTIALCARRIER
Inspection,page 15-12
.TAPERED ROLLERBEARING
Inspect for wear and operation.
page 'l5-13
Replacement,
vnx.su
Differential(818C1 enginel
BacklashInspection
FinalDrivenGearReplacement
1 0 x 1 . Om m
101 N.m (10.3 kgt.m, 74.5 lbf.ftl
Left-hand threads.
FII{AL DN|VENGEAR
Chamfer on inside diameter
of linal drivengar taces carrier.
DIFFERETTTIAL
CABRIER
15-12
vnx.su
TaperedRollerBearingReplacement
NOTE:
a The tapered roller bearingand bearing outer race
should be replaced as a set.
a Inspectand adjustthe taperedrollerbearingpreload
whenevef the taperedrollef bearingis replaced.
a Checkthe taperedrollerbearingstor wear and rough
rotation.lf taperedrollerbearingsare OK, removalis
not necessary.
1.
oil SealRemoval
1 . Removethe differentialassembly.
Removethe oil sealfrom the transmissionhousing.
BEARING
BEARII{G
SEPANATOR
(Commercially
available)
3.
15-13
vnx.su
Differential(B18c1 eng:nel
BearingOuter RaceReplacement
CAUTION: Do not rous the thrust lhim and tho 79.8
mm shim il tho outer rac6 was ddvon out.
4.
NOTE;
a The bearing outer race and taperd toller bearing
should be reDlacedas a set.
a Inspect and adjust the tapered roller bearing proload
whenever th tapered rollf bearing is roplacd.
1.
2.
TRANSMtSStOl{
HOUStl{c
5.
15-14
vnx.su
Transmissionhousing
Clutch housing
Diffe.entialcarrier
Taperedrollerbearingand bea,ingouter race
Thrust shim
NOTE:
a Installthe bearingouter race squarely.
a Check that there is no clearancebetween the
bearingouter race.thrust shim and transmission
housing.
4.
CAUTION: Do not reuss lhe thrust shim it the bearing outer raco was driven out.
2.
Measurethe starting torque of the differenlialassembly with the specialtool and a torque wrench.
HOUSING
{cont'd}
15-15
vnx.su
Differential(B18C1 enginel
TaperedRollerBearingPreloadAdjustment(cont'dl
7.
Part Numbel
Thickness
41460-PY4-000
0 . 6 6 m m ( 0 . 0 2 6 0i n )
AB
41461-PY4-000
1 . 1 7 m m ( O . 0 4 6 1I n ,
AC
2 . 0 N . m { 2 0 k g f . c m ,1 8 l b t . i n }l e s s
AD
AE
41464-PY4-000
1 . 2 6 m m ( 0 . 0 4 9 6i n )
AF
41465-PY4-OOO 1 . 2 9 m m ( O . O 5 O i8n )
AG
41466-PY4-OOO 1 . 3 2 m m ( O . O 5 2 O
in)
AH
41 467-PY4-000
AI
1 . 3 5 m m { O . O 5 3 1i n )
41468-PY4-000 1 . 3 8 m m ( O . O 5 4 3i n )
AJ
41469-PY4-000
AK
AL
41470-PY4-OOO 1 . 4 4 m m ( 0 . 0 5 6 7i n )
41 47 1-PY4-OOO 1 . 4 7 m m ( 0 . 0 5 7 9i n )
AM
41 47 2-PY4-OOO
AN
41473-PY4-000
AO
1 . 5 6 m m ( 0 . 0 6 1 4i n )
'
4 1 4 7 5 - P Y 4 - O O O l. 5 9 m m ( O . 0 6 2 6i n )
4'1476-PY4-O00 1 . 6 2 m m ( 0 . 0 6 3 8 i n )
41 47 7 -PY4-OOO 1. 6 5 m m ( 0 . 0 6 5 0 i n )
AP
AO
AR
AS
AU
1. 4 1 m m ( O . 0 5 5 5i n )
1 . 5 0 m m { O . O 5 9 1i n )
1. 5 3 m m ( 0 . 0 6 0 2i n )
41 47 4-PY4-OOO
41478-PY4-000
1. 6 8 m m { 0 . 0 6 6 1 i n )
41479-PY4-OOO 1 . 7 1 m m ( O . 0 6 7 3i n )
41480-PY4-OOO 1 . 7 4 m m ( 0 . 0 6 8 5i n )
41481-PY4-OOO 1 . 7 7 m m { 0 . 0 6 9 7 i n }
41442-PY4-OOO 1 . 8 0 m m ( O . O 7 O i9n )
AX
8 x 1 . 2 5m m
27 N.m 12.8 kgt.m. 20 lbf.ttl
41483-PY4-OOO 1 . 8 3m m ( 0 . 0 7 2 0i n l
1 1 .Rotatethe diJJerential
assemblvin both directions
to seat the taperedrollerbearings.
15-16
vnx.su
DRIVER
07749-OOIOOOO
DRIVER
07749-OOlOO00
OIL SEAL
Replace.
OIL SEAL
Replace.
HOUStl{G
15-17
vnx.su
Differential(AutomaticTransmissionl
. . . . . . . .1 5 - 2 0
S p e c i aTl o o l s . . . . . . . .
Differential (Automatic Transmission)
.15-21
f l f u s t r a t eIdn d e x . . . . . . . . .
.... 15-22
BackfashInspection
B e a r i n gR e p l a c e m e n.t. . . . . . . . . . . . . . . . . 1 5 - 2 2
DifferentialCarrierReplacement.... 15-23
........15-24
O i l S e a fR e m o v a l
Oil Seal Installation/
15-24
S i d eC l e a r a n c .e. . . . . . . . . . . .
vnx.su
SpecialTools
Ref. No.
o
r^
aa)
@
Tool Number
Dascription
oTJAD-PH80200
oTNAD-P200100
07746-0030100
07749-0010000
o7947-SD90200
Oty
Pilot, 26 x 30 mm
Driver, 52 x 55 mm
Driver,40 mm l.D.
Driver
OriverAttachment
15-20
vnx.su
15-26
15-26
15-22,24,25
't 5-26
15-26
1
1
1
I
1
I Pago Retelonco
Differential(AutomaticTransmissionl
lllustrated Index
FINAL DRIVENGEAR
BALL BEARING
ENTIAL.ARRIER
--ttot"'
'
6
ROLLER.5xlOmm
BALL BEARING
15-21
vnx.su
Differential(Automatic Transmission)
BearingReplacement
BacklashInspection
1 . Placethe differentialassemblyon V-blocksand install both axles.
Check backlashof both pinion gears.
BALL BEAING
3.
DRIVER,40 mm l.D.
07746 0030100
15-22
vnx.su
DifferentialCarrierReplacement
1 . Remove the final driven gear from the differential
carrier.
5.
Align the hooked end of the snap ring with the pinion shaft as shown, then installthesnap ring in the
diffrential carrior groove.
SI{APRII{G
Installin this direction.
DRIVE GEAR
o.
5.
4.
BOLTS
10 r 1.0 mm
lOi N.m (1O.3 kgf.m,
74.5 tbt'ft)
Left-hand thrgads
SPEEDOMETEB
DRIVEGEAR
Instsllin this
diroction.
7.
15-23
vnx.su
Differential(Automatic Transmissionl
Oil Seal Removal
1 . Removethe differentialassembly.
1.
TRAt{SMtSStON
HOUSING
TRANSMISSIO
HOUSING
OIL SEAL
Replace.
seal from the rorque convener
DRIVER,40 mm l.D.
07746-OO30100
DIFFERENTIAL
ASSEMBLY
/-l
TOROUE
CONVERTER
HOUSING
TOROUECONVERTER
HOUSING
15-24
vnx.su
Tap on the transmissionhousingsideof the differential assembly with the special tool to seat the
dilferentialassemblyin the torque converterhousing.
Thickness
2.50 mm (O.O9843in)
2.60 mm {0. I 0236 in)
2 . 7 0 m m ( O . 1 0 6 3 0i n )
2 . 8 Om m ( O .1 1 O 2 4i n )
2 . 9 0 m m ( 0 . 11 4 1 6 i n )
3.OOmm{O.11811in)
9.
(cont'd)
15-25
vnx.su
Differential(Automatic Transmissionl
Oil Seal Installation/SideClearance
(cont'dl
9. Installtheoil sealin the transmissionhousingusing
the specialtools as shown.
DRIVER
07749-0010000
ATTACHMENT
07947 -SD90200
PILOT
26x30mm
oTJAD-PH80200
DFIVER
07749-0010000
DRIVER,52 x 55 mm
oTNAD-P200100
15-26
vnx.su
vnx.su
SpecialTools
R!t. No.
o
@
o
@
@
@
Tool Numbcr
07JAF- SH20400
07LAD- PW50601
07MAC- 5100200
07746- 0010300
07746- 0010400
07746- 0030400
07749- 0010000
07965- SD90100
D.lcription
Oty
Suppon BsseAttachment
Attachment,40 x 50 mm l.O.
BallJoint Remover,28 mm
Anachment, 42 x 47 mm
Attachment,52 x 55 mm
Attachment,35 mm l.D.
Driver
Support Bas
1
1
1
1
1
1
1
1
Psgo Rctcr.nct
1 6 -1 3
16-14
16-4
16-13
16-14
16-'r4
1 6 - 1 31, 4
16-13
(4,
16-2
vnx.su
Driveshafts
Inspection
Removal
DriveshaftBoot
Checkthe boots on the driveshaftfor cracks,damage,
leakinggreaseor looseboot bands.
l f a n y d a m a g e i s f o u n d , r e p l a c et h e b o o t a n d b o o t
Danos.
Looso Splines
Turn the driveshaftby hand and make sure the splines
and joint are not excessivelV
loose.
lf damageis found, replacethe inboardjoint,
Twistod or Cracked
Makesurethe driveshaftis not twistedor cracked.
Replaceit if necessarv.
R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut.
WHEELNUT
DBIVESTIAFT
Replace.
6.
EOOTBANDS
NUT
SELF-LOCKING
12 x 1.25mm
Replace.
(cont'dl
16-3
vnx.su
Driveshafts
Removal(cont'dl
8. Removetha cotter pin from the lower arm ball joint
castlenut, and removethe nut.
12. Pull the inboardjoint, and removeth6 right driveshaft from the differentialcase as an assemblv.
CAUTION:
. Do not pull on tha dlivo3haft, a! th! inborrd
ioint may comc !p!rt,
. U3c carc when prying out tha a$qnbly, lnd pull
it rtraight to lvoid drmlging thc diftcrrntial oil
soal or thc int.rmcdirto shrft outel saal.
SCREIYDRIVER
Left Driveshaft:
Removethe left driveshaftfrom the bearing support by tapping the inboard joint of the driveshaftwith I Dlastichammer.
SCREWDRIVER
BEARINGSUPPOFT
16-4
vnx.su
KNUCKLE
DRIVESHAFT
SET RING
Replace.
16-5
vnx.su
Driveshafts
Disassembly(cont'd)
3,
DYNAMICDAMPER
Marka
Mark the spider and driveshaftto identifythe position of the spideron the shaft.
Removethe spider using a commerciallyavailable
bearingremover.
OUTBOARD
BOOT
lnspectfor cracking,
splining
andwear.
13. Inspectthe outboardjoint for faulty movementand
wear. lf any roughnessor excessplay is felt, replace
the outboardjoint.
Removethe stopperring.
BEARING
,'0
STOPPER
RING
CIRCLIP
OUTBOARDJOINT
ROLI-RlFor loft ddvcshrfrl
16-6
vnx.su
Reassembly
NOTE:
panswith solvent,
o Cleanthe disassembled
anddrythemthroughly
with compressed
air.Donotwashthe rubberparts
with solvent.
o *.'.l|@l
: Thoroughlypackthe inboardjoint and both joint bootswith the joint greaseincludedin the new driveshaft
ser.
G.ea3o quontity:
120- 130g |'4.2- 4.6 ozl
90 - 100g {3.2- 3.5oz}
lnboardJoint
OutboardJoint
SETRING
Replace.
RIGHTINBOARDJOINT
ROLI.TR
{For lcft
b
,RDJOINT
INAOARDBOOT
---"-G1
-Gl
DYNAMICDAMPER
EOOTBANDS
Replace.
(cont'd)
16-7
vnx.su
Driveshafts
Reassembly(cont'dl
1.
2.
I n s t a l lt h e o u t b o a r d b o o t , d y n a m i c d a m p e r a n d
i n b o a r db o o t t o t h e d r i v e s h a f tt,h e n r e m o v et h e
vinyl tape.
6.
,.%
VINYLT
OUTBOARDBOOT
DYNAMICDAMPER
7.
INBOARD
BOOT
-r
+ {l-
STOPPER
RING
16-8
vnx.su
SPIDER
ROLLER
ROLLER
{For left driv8hattl
8.
9.
setsof lockingtabs.
Lightlyrap on the doubled-overportionsto reduce
their height.
\
/,.-:--\\\
di,ection
sotine
I
INBOARD
JOINT
A\
{(@}
HOLDER
{cont'd)
16-9
vnx.su
Driveshafts
(cont'dl
Reassembly
t5.
Installation
1.
KNUCIGE
DYNAMICDAMPERBANO
OUTBOARD
JOINT
RING
b
SET RINGGROOVE
16-10
vnx.su
INBOARD
JOINT
CAUTION:
. B careful not to damago tho ball ioint boot.
. Torqu tho castle nut to ths lower torquo 3paci.
fication, then tighlon it only tar snough to slign
the slot with th pin hole. Do not align tho nut
by loossning,
INAOARDJOINT
GROOVE
OIFFERENTIAL
5.
CASTLENUT
12 x 1.25rnm
L o o s e l yi n s t a l lt h e s e l f - l o c k i n gb o l t a n d t h e n e w
self-lockingnut.
FRONTWHEEL
SELF.LOCKING
BOLT
10 x 1.25mm
a:' N.m lir,4 kgt m, 32 lbf.ftt
COT1ERPIf{
On reassembly,
bend the cotter pin
as shown.
WHEELNUT 12 x 1.5 mm
108N.m (11.0kgf.m,80lbtft,
ALIGNINGTAB
NUT 22 x 1.5mm
kgl'm,134lbt'ftl
181N m 118.5
NOTE:Altortightening,usea driftto
nutshoulder
stakethesPindle
againstthe driveshaft
1 0 . Tightenrhe self-lockingbolt and the new self-locking nut with the vehicle'sweighton the damper.
1
SELF.LOCKING
NUT
12x 1.25mm
64 N.m (6.5 kgt m, 47 lbf.ftl
'I.
1 6 - 11
vnx.su
Intermediateshaft
Removal
2.
Disassembly
1.
2.
3.
Removethe eldernalcirclip.
16-12
vnx.su
OUTEBSEAL
Replsce.
t
SETRING
Replace.
1.
5.
Removethe internalcircliD.
Pmar
INTEBNALCIRCLIP
Pressthe intermediateshaft bearing out of th boaring support using ths spscialtools and a prsss as
snown.
Praa!
BASE
SUPPORT
ATTACHMENT
07JAF- SH2oalXt
FLOANNGRUBBR
DA'iIPER
Checkfor detrioration
and dama9e.
ATTACHMENT,
1i2xa7fim
07ta6 - 00ro:!00
SUPPORTBASE
ATTACHMENT
- SHZ!(|O
BEARINGSUPFORTRING
Chscktor damagg or distonion.
BASE
07965- Sll9or00
SUPPORTBASE
07965 - SDg,|q'
INIERiIEDIAIE SHAFT
Checkfor damage.
BEARINGSUPPORT
Checkfor damage.
NOTE:
. Cleanthe disassembledparts with solvent,and dry them thoroughlywith compressedair. Do not wash the rubber
parts with solvent.
. Be carful not to damagethe metal rings on the intermedists shaft during reassmbly
DOvvELBOLTS
10r 1.25ftm
:tlt N.m {a.Otgt m, 29 lbfftl
EXTENTALCIRCUP
ob.
Packthe intorior
of the outer saal.
2.0- 3.5 g {0.07- 0.12oz}
SETRING
Replace.
INTERMEOIATESHAFT BEABING
Reolaco.
BEARING
v
ourER SEAL
Rspbce.
vnx.su
{conr'd)
IntermediateShaft
(cont'dl
Reassembly
'1. Press
the intermediateshaft bearinginto the bearing support using the specialtools and a press as
shown.
ATTACHMENT,
52x55mm
07716- 001o/UX)
DRIVER
07749- 00t(xD0
Packthe interior
ol the olter seal.
2.0 - 3.5 g 10,07- 0.12 o2l
OUTERSEAL
ATTACHMENT,
aOx 5{)mm l.D.
07LAD - PW50601
Pross
16-1 4
vnx.su
lnstallation
lnsert tha intermediate shaft assembly into the differential.
CAUTION: Hold th inlorm.diltc ahrft horizontsl
to prryonl dsmrge to thc difflrontill oil taal.
INTERMEDIATESHAFT
2.
DOWELBOLTS
10x 1.25mm
39 N.m {a.Orgl.m, 29 lbl.ft}
INIERMEDIATESHAFT
16-15
vnx.su
Steering
.............
17-2
SpecialTools
Component Location
lndex ................
......17-3
System Description
Ffuid Flow Diagram .........................
17-1
17-5
SteeringPump .................................
17-7
SteeringGearbox.............................
Troubleshooting
17-10
GeneralTroubleshooting................
17-14
Noiseand Vibration.........................
.............
17-16
FluidLeaks
Inspection and Adiustment
17-14
SteoringOperation ..........................
Power Assist Check
with CarParked...........................
17-18
SteeringLinkageand Gearbox.......17-19
..............
17-20
Pump Beh
.....17-21
RackGuideAdjustment .............
......................
.....17-21
Ffuid Replacement
.... 17-22
Pump PressureCheck..................
17-23
FfuidLeakagelnspection ................
+Steering Wheel
Removal
..,,,,,,,........
17-24
-25
...............
17
Disassembly/Reassembly
17-26
fnstallation
,......,,,,,.
* SteeringColumn
Removaf
.................17-28
Inspection
..............
17-30
.............
17-31
Installation
Power Steering Hoses.Pipes
.........17-3tl
Replacemont
Power SteeringPump
Removal
.................
17-35
Disassembly
..........17-35
Reassembly
...........
17-'10
lnstallation
........,...,
l7-tltl
Steering Gearbox
.,.,.............
17-45
Removaf
..........17-/E
Disassembly
...........
17-53
Reassembly
.............
17-63
lnstallation
Ball Joint Boot Replacement..........17-65
SUPPLEMENTALRESTRAINTSYSTEM{SRSI
The IntegraSRS includesa driver's airbag.locatedin the steeringwheel hub, In addition,all modelsexcept the
RS modelfor Canadahave a front passenger'sairbaglocatedin the dashboardabovethe glove box. Information
necessarvto safelyservicethe SRS is includedin this ServiceManual.ltems markedwith an asterisk{') on the
or replacingthese items
contents page include,or are locatednear, SRS components.Servicing.disassembling
Acura dealer.
done
by
an
authorized
precautions
should
therefore
be
and tools, and
will requirespecial
a To avoid rsndering ths SRS inoporative, which could load to po.sonal iniury 01 dath in th event ot a ssvare
lrontal collision, all SRS service work muat be performod by an authorizod Acura deal6t.
a lmploper service procodules. including incorloct romoval and installation of the SRS,could lead to personaliniury caused by unintontional activation ot the airbags.
a All SRS elsctdcal wiring harnessesara covorod with ysllow insulation. Rolalod componnts 8re locatsd in tho
stse ng column, tront console, dashboard, and dashboard lower panel, and in the dashboard above the glove
box. Do not use oloctrical tost equipmoni on thosa cilcuits.
NOTE: The originalradiohas a codedthett protectioncircuit. Be sure to get the customer'scode numberbefore
- disconnectingthe battery.
- removingthe No. 32 (7.5 A) tuse from the under-hoodfuse/relaybox.
- removingthe radio.
"CODE" is displayed'enter the cusAlter service,reconnectpower to the radioand turn it on. When the word
tomer's 5-digit code to restoreradio operation.
vnx.su
Rcf. No.
Tool Numbl
07GAF- PH70100
07GAF- SD40700
07GAG- SD40100
07GAG- SD40200
07GAG- SD40400
07JGG- 0010104
07MAC- 5100200
07MAG - 5100100
07NAD- SR30200
07NAG- SR30900
OTNAK- SR3O11A
OTNAK- SR3O12A
07406- 0010001
07406- 0010300
07405- 0010400
07725- 0030000
07746- 0010100
07746- 0010200
007i$ - 0010000
07916- SA50001
07947- 6340500
07974- 6890801
0797,1- SA50200
@
@
(t
@
@
@
@
@
@
@
@
@.r
@-2
@
@
@
@
@
@
@
@
F--,'---l
@@
1
'I
1
1
1
1
vnx.su
17-22
1
1
'l
1
I
1
1
1
1
17-35,53
17-55,56
17-1'l
t7-55
17-2'l
17-11
17-57,58
17-55
6
w
@,2
^dN
17-2
17-50
17-5{
17-22
1 7- 2 2
't1-22
@:
@
17-20
't7-15
1
1
@-r
17-EO
lx:__E
1
1
1
1
@
16)
17-39
17-57
17-57
\v
,h
z6)
<Z
V,.)
@
'17-52
\,
P!9. Relrrrncc
t.-,
TJ
O'ty
PilotCollar
Hub DivAssembly Base
PistonSealRingGuide
PistonSealRingSizingTool
Cylinde.End Sealcuide
BeltTensionGauge
BallJoint Remover,28 mm
BallJoint BootClip Guide
Cylinder End Seal RemoverAttachment
ValveSsalRingSizingTool
P/SJoint Adapter(Pump)
P/SJoint Adapter (Hos6)
P/S PressureGsuge
PressureControl Valve
PressureGauge
UniversalHolder
Attachment,32 x 35 mm
Attachment,37 x 40 mm
Driver
LocknutWrench, i[0 mm
Driver Anachment
CylinderEnd SealSlider
SleeveSesl RingSizingTool
re
aL2
Dcscription
ComponentLocation
lndex
Powar Siooring:
NOTE:
It an intact airbag assmbly has been rmoved from a scrappedcar or has been found defective or damaged during
transit. storage or service,it should be doployd (seesection 23).
a Before removing tho gearbox, remove ths ignition key to keep the steering shaft Jrom turning.
a After installingthe gearbox,checkths whel alignmentand adiustif necessary.
CAUTION:
. All SRS aloctricll wiring h!m!|$a
rrc covcred with
yrllow in3uhtion.
. 8for disconnocling lny ptrt ol thc SRS wiro h!r'
ne*r, connect thc lhort conncctor{3l.
. Rcplsce lhc ontira ttfact d SRS harnccc a$embly il
it hs3 !n oprn circuh 01 dtm!9.d wiring.
SIEERING COLUiIN
Removal,page 17-28
Inspection,pago 17-30
Installation,p6ge 17-31
rcNMON SwlTCH
See s6ction23
STEERII{GGEARBOX
RackGuide Adjustment,pag.11-21
Removal,pags 17-45
Diossombly,page 17-{8
Bea65mbly,page 17-53
Installation,page 17-63
POWENSTEERINGPUMP
Pump Beft Inspoction.page 17-2O
Pump EeftAdjustm6nl, pago 17-2O
Pump PressurgChck,page 17-22
Removai,p6go 17-35
Disassembly,p3gs 17-35
Reassombly,psge l7-40
lnstallation,page 17-44
STEERINGWHEEL
Removal.page 17-24
page 17-25
Oisassembly/Reassembly,
page17-26
Installation,
TIE'RODEND BALLJOINT
Ball Joint Eoot Replacement,page 17-63
17-3
vnx.su
System Description
FluidFlow Diagram
The system is a compact rotary-valvs-typepower stssring, connoctedto the storing gearbox. Th6 fluid pressureis provided by a vane-type pump which is driven by the engine crank pulley. The amount of fluid and pressurs is regulsted by
the flow control valve built into ths pump, The fluid prssaursfrom th6 pump is dolivsred to tho valve unit sround the pinion of the steering garbox. The vslv inside the valvs unit controls the hydraulic prossurEnd changosthe direction ot
the flow. The fluid then flows to the power cylinder, where rack thrust is gen6rat6d.Fluid returning from th6 powsr cylinder flows backto the .eservoir,where the fluid is 'filtered" and supplied to the pump Egain.
17-4
vnx.su
Construetion
The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is driven by a V-beltfrom
the crank pulley. The pump features 10 vanes, Each vane performs two intake/dischsrgeoperations for every rotation of
the rotor.This meansthat the hydraulicfluid pressurepulsebecomesextremelysmallduringdischarge.
INLETPORT
CAM RING
VALVE
FLOWCONTBOL
DRIVESHAF'
VANE
Operation
The belt-drivenpulley rotatesthe rotor through the drive shaft,As the rotor rotates,the hydraulicpressureis appliedto
of the cam .ing.
the vanechamberof the rotor and the vaneswitl rotatewhile beingpushedonto the innercircumference
so the rollers
portion
of
the
shaft.
respect
to
the
center
with
ring
has
an
extonded
of
cam
inner
circumference
the
The
move downwardin the axialdirectionas the carrierrotates.As a resultof this rollermovemsnt,the internalvolumeof the
vane chamberwill change,resultingin fluid intakeand discharge.
STARTOF FLUIDINTAKE:
FLUIDMOVEMENT:
FLUIDINTAKE:
FLUIDDISCHABGE:
DISCHARGE
P('BT
T h 6 s u c k e d - i nf l u i d m o v e s
towsrd the discha196pon.
(cont'd)
vnx.su
System Description
SteeringPump(cont'dl
Flow Control
FLOWCURVE
The flow controlvalve in the pump performsthe following steps@ throughO to controlthe flow of fluid, i.e.to
increasethe dischargevolum wh6n engine speed is
low and to decreaseit when the enginespeedincreases.
The assistance
thrust of the steeringgearboxchangesin
compliancewith the changein the dischargevolume.
. J5
l o
tr o=
PUMPR.P,M.
@ A s t h e f l o w h a s a l r e a d y b e e n r e g u l a t e db y t h e
meteringorificewhen the enginespeedis at or near
the idle speed,a constantand regulatedamount ot
fluid is dischargeduntil the engine speed reaches
t h e m i d d l e s p e e d r a n g e .A s t h e e n g i n es p e e d
increases,
the pressuredifferencebetweenthe ends
of the meteringorificeincreases.A pressuredifference is createdbetweenthe top and bottom ends of
the flow controlvalve,too, pushingthe flow control
valveto open the by-passpassage.This allowsthe
excessfluid to return to the inlet pon preventing
pressureat the dischargeport trom rising excessively.
@ T h e o r i f i c e i n t h e r e t u r n p a s s a g er e g u l a t e sa n d
m a i n t a i n st h e f l o w o f f l u i d d i s c h a r g e df r o m t h e
pump at a given level until the enginespeedreaches the high speedrange.
17-6
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VALVE
PressureRelief
Pressu.6outside of the metering orifice is directedto
the bonom ot the flow control valve. When the pressure
buildsup, the relietvalvein the flow controlvalveopens
to relieve the pressure.As the flow control valve is
pushed back by the pressuredifferencethis time, the
convolling
flow of fluid in the bypasspasssgeincreases,
the pressureoutside the metering orifice. The above
operationsare repeatedto provide constantdischarge
prsssurelrom the pump,
VALVE
{Dacrarlai cxco33iva
Yibrationin iha valva.l
(cont'dl
17-7
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SystemDescription
SteeringGearbox
The rack-and-pinion
type steeringgearboxhas a valve unit incorporatedwith the pinionto controlthe steeringfluid pressure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve unit and is sentthroughthe cylinderpipe to
the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylinderreturns
throughthe cylinderpipe and valveunitto the reservoir.
VALVEUNIT
CYLINDERPIPE
POWEBCYLINDER
Valve Unit
Insidethe valve unit is the valve,which is coaxialwith the pinionshaft,and controlsthe steeringfluid pressure.The valve
housingis connectedwith the fluid pipe from the pump, return pipe to the pump, and the two cylinderpipesfrom the
respectivepowercylinder.
The pinionshaft is double- structuredwith the input shaftconnectedto the piniongear,both of which are interconnected
with the torsionbar.
The pin insenedin the valve and the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the
directionbetweenthe input shaftand the valve
Becauseof this construction,
the differencein angle in the circumferential
becomeslarger accordingto the torsional strength of the pinion or steering resistance.However,maximum torsion
betweenthe shaftsis regulatedby the engagedsplinesof the shaftsat the pin engagementsectionto hold the torsion bar
within the set value.
type steeringif the steeringfluid is not pressurThis allowsthe steeringsystemto lunctionas an ordinaryrack-and-pinion
izedbecauseof a faulty pump.
VALVE
Difforcnco in .ngl. bo{wcn tha
input shalt rnd pinion !h.tt
ln
-1
INPUTSHAFT
B
lEngagwith the pinion
shaft groove)
1 7 -8
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<sEcnoN B-B>
PressureControl
Low assistat higherspeeds:
When steeringresistanceis low. such as when driving at high speeds.or when driving straightahead,the input shaft is
near or in the neutralposition,so there is little or no flow to any of the power cylinderorifices,Most of the feed pressure
trom the pump is bypassedto the reservoir.Becauseof this, the pressurestaysthe same in both sidesof the power cylinder, resultingin low or no assist.
RESERVOIR
vALVE
az =- S
\->/
-\7/
F.om PUMP
RETURNPASSAGE
(To RESERVOIRI
VALVE UNIT
A
<sEcnoN A-A>
INPUTSHAFT
/t-:\
FLUIOPASSAGETO
POWERCYLINDER
From PUMP
v"=iJ
RETURN
PASSAGE
FLUIDPASSAGEFROM
POWERCYLINDER
<SECTIONA.A>
17-9
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Troubleshooting
GeneralTroubleshooting
Checkthe followingbetoreyou begin:
. Hasthe suspnsionbeenmodifiedin a way that would affectsteering?
. Are tire sizesand air pressurecorrect?
. ls the steeringwheloriginalsquipmentor equivalent?
. ls the power steering pump belt properly adiusted?
o ls steering fluid reservoirfilled to proper level?
o ls the engineidle speedcorrectand steady?
Normal
Abnormal
II
II
Goto patetu.lt
Faultyflowtontroi valve
17-10
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Normal
Abnormal -----|.
Faultygearbox
Abnormal
Normal
Chockthe gearbox.
Removethe goarbox and measurethe piniontorque.
The torqueshouldbe;
* 0.7- 1.2N.m (7 - 12 kgf.cm,6 '10lbt in) with the steering rack
in the straightdrivingposition.
|r
Normal
lmproperly adjustedrackguide
(cont'dl
17-11
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Troubleshooting
GeneralTroubleshooting{cont'd}
Assist (excessivelylight steering)at
high speed.
Rackguide is adjustedproprly.
Wheelwillnot returnsmoolhly.
1 7 -1 2
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Adjustrackguide(sepoge 17-21).
7-13
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Troubleshooting
Noiseand Vibration
NOTE:Pump noisein first 2 - 3 minutesafterstartingin cold weather(-20.C,-4"F or colder)is normal.
Humming
Reposhiontho line.
Rattleor chattering
C h e c ka n d t i g h t e n , o r r e p l a c e
pa s as necessary.
Replacecolumnassembly.
Adjust, if ncassry.
Rattlingsound and feeling when turning the steoringwheel right and lett with tho
engine OFFis a sound when th6 valve unit contactstho stopper.This is normal.
Striking sound wh6n turning the steringwhoglfully right o. left is a sound when
the r6ckend contactsth6 stopper.This is normal.
Pump noise. though not loud,lrom the vslvo bodv unit can be heard when turning the steeringwheel right or left. This is normsl.
17-14
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Checkfluid level.
l f l o w . f i l l r e s e r v o i rt o p r o p e r
level,and checktor laks.
Tighten or roplac6as ncessary.
Gratingnoisefrom pump
Pumpgearnoise
1 7 -1 5
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Troubleshooting
Fluid Leaks
Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points.dependingon locationof the
faultyoil seals/seal
rings.Checkthe followingbeforeremovingthe gearboxfrom the frame.
SteeringGearbox
R e o l a c et h e c v l i n d e r e n d s e a l .
Leakingfrom cylind6rpipeA or B
connection(attlarenut).
Leakingcausedby damagedcylinderpipeA or B.
R e p l a c et h e c y l i n d e r p i p e A o r B .
L e a k i n gf r o m f e e d p i p 6 a n d
returnpipe of the valvebody unit
(atflarenut).
17-16
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ReplacehousingO-rings.
lI the housingstill leaks,replace
the pump.
Reservoiroverfilled.
Pullotfthe hoseand drainto pro'
per tevet.
Low pressurehoses
Leakingat g6srboxconnection.
{atflarenut}.
17-17
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Inspectionand Adjustment
SteeringOperation
PowerAssist Gheckwith
GarParked
1.
Checkthe power steeringfluid level (see page 1721) and pump belttensionlsee page l7-20).
2.
Startthe engine,allow it to idle, and turn the steering wheel from lock-to-locksevraltimes to warm
uo the fluid.
ROTATIONALPLAY:0 - 10 mm l0 - o.:Xlinl
lf the plsy excsedsthe service limit, psrform rack guide
adjustment (see page 17-211.
lf the play is still excessiveafter rackguide adjustment,
inspectthe stsering linksgoand gearbox as described
on the next page.
ROTANONAL PLAY
il.
17 -18
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SteeringLinkageand Gearbox
STEERINGCOLUMN
lnsoecttor loosecolumn
mountingboltsand nuts.
BOOT
Inspect
f6r damage
anddeterior6tion.
STEERINGJOINTS
Checktor loosejoint bolts.
PINIONSHAFTGROMMET
Inspectlor damage and deterioration.
TIE.RODLOCKNUT
Checkfor looselocknut.
STEERING
Inspectlor loose mounting bolts.
GEARBOXMOUNTINGCUSHIONS
Inspectfor deterioration.
BALLJOINT BOOT
Inspecttor damageand deterioration.
Seepsge 17-63for replacement.
17-19
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Inspectionand Adjustment
PumpBelt
NOTE: When using a new bli, first adiust the deflection
or tnaion to the values for the new belt, thsn readiust
ths deflection or tension to the values tor the used blt
after running sngine for five minutss.
Adiu3tmant
1,
2.
Turn ths adiusting bolt to gst the propor bolt tension, then rstighten the bolts.
3,
lnspoction
Attach th belt tonsion gauge to th6 belt and measure
ths tension of the bslt.
Tanaion:
U3.d Brft: 391,- 5/O N (lO - 55 kgf, 88 - r20 |bf)
Ncw Bch: 7aO- 89, N (75 - 90 kgt, 170 - 20OlbO
AD'USN G BOLT
NOTE:
. lf thsre are cracksor any damage evident on the belt,
raplacait with a now ono.
. Follow the manufacturer'sinsructions for the tonsion
g8uge.
PUII"EY
07JGG- 00r0r0a
Inspectthe pump belt for cracksor any damage.
Replacethe belt with a new one if necssary.
Mc!3uramrnl without Bch Tcntion Grugr:
Apply a torce of 98 N (10 kgl, 22 lbll and measure ths
deflectionbetweentho power sterin9 pump and tho
crankshaftpulleys.
Daffaction:
U:ed Bch: 11.5- 13.5mm (0.,t5-0.53 inl
Nlw Brh: 8.0 - 10.0mm (0.31- 0.39 inl
here,
17-20
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the
Tightenthe rackguide screwuntil it compresses
springand seatsagainstthe .ackguide,then loosen
it.
R e t i g h t e nt h e r a c k g u i d e s c r e w t o 3 . 9 N . m { 0 . 4
kgf'm, 2.9 lbf.ft),then back it off to specifiedangle.
SYSTEMCAPACITY:
LO6 litor (1.12US. qt, 0.93lmp.qtl
at disasssmbly
RESERVOIR
CAPACITY:
0.79lit6r (0.8:lUS.qt, 0.70 lmp.qt)
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw.
LOWERLEVELLINE
Raisethe reservoirand disconnectthe return hose
that goesto the oil cooler.
Connecta hose of suitablediameterto the disconnectedreturn hose and put the hose end in a suitablecontainer.
RACKGUIDESCREW
25 N.m
12.5kgf.m, 18lbtftl
Startthe engine.let it run at idle.and turn the steering wheel from lock-to-lockseveraltimes. When
f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
engine.Discardthe fluid,
40 mm
L(rcKNUTWRENCH,
07916- SAs(xtOl
Performfollowinginspections:
. Steeringoperation(seepage 17-18).
. Power assistwith car parked.
7.
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lnspectionand Adjustment
PumpPressureCheck
C h e c kt h e f l u i d p r e s s u r ea s f o l l o w s t o d e t e r m i n e
whetherthe troubleis in the pump or gearbox.
NOTE: First check the power steering fluid level and
pump belttension,
CAUnON: Dilconnst the high pros3uroho3s with cale
!o e3 not to spill tho powor stooring fluid on th6 lramo
lnd olhor parG.
1.
2,
3.
Disconnect
the outlet hosefrom the oumo outletfitt i n g , 8 n d i n s t a l lt h e p u m p j o i n t a d a p t e ro n t h e
pump outlet.
Connectthe hose joint sdapterto the power steering pressuregauge,then connectthe outlet hoseto
the adaotor.
Instsll the power steering pressuregauge to the
pump joint adaptoras shown.
OUTLETHOSEFlTnNG
HOSEATTACHINGBOLT
1l Nm11.1kg{ m 8lbf.ftl
P/S PRESSURE
GAUGE
P/S JOINTADAPTORIPUMPI
o?NAK- SmolrA
PUMPOUTI.TT
FITIING
Openthe shut-offvalvefully.
Openthe pressurecontrolvalvefully.
1 7- 2 2
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FluidLeakageInspection
BOOT
Check
lor leaks.
GEARBOXrnd VALVEBODYUNIT
Checkfor leaksat the matingsurface
and rlare nut connections.
PUMPASSEMBLY
Chckfor leaksat the pump
seal, inlet and outlet fiftings.
Inspecthosesfor d6mage,leaks,
interferenceor tlvisting,
Inspectfluid linesfor damage,
rustingor leakage.
Inspectfor leaksat hose and
lineiointsor connections,
17-23
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Steering Wheel
Removal
Airbag Removal
1 . Disconnect
the negativeand positivecablefrom the
battery.
CAUTION:
. All SRS electrical wiring harnossesare covered with
yellow insulation.
. Before disconnecting any part oI the SRS wiro harness,connect the 3hort connector{g}.
. Replacethe entire sffected SRS harness assembly it
it has an opon circuit or damagedwiring.
CABLEREEL
CONNECTOR
R e m o v et h e l i d B a n d c r u i s ec o n t r o l s e t / r e s u m e
switch cover.
Removethe TORX@
T30 bit bolts then removethe
airbagassembly.
AIRBAGASSEMBLY
17-24
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Removal
Disconnect
the connectorstrom the horn and cruise
controlsevresumeswitches.
8.
HORN
Disassembly/Reassembly
store a removed airbag assembly with
@
the pad 3urfacs up. lf the airbag is improperly stored
face down, accidntaldaployment could propl tho unit
with enough forca to causeserious iniury.
NOTE:lf an intact airbag assemblyhas been removed
f r o m a s c r a g o e dc a r o r h a s b e e n f o u n d d e f e c t i v eo r
damagedduring transit.storageor service,it should be
deployed(seesection23).
TORX6BOLT
10 N.m {1.0 kgf m, Tlbt.ttl
CAUTION:
C8r{ully inspoct ihe sirbag assombly betors install.
ing. Do not install an airbag ass6mblythat 5how3
signs ol boing dtopped or improperly handled, such
as dents, crack3or deformation.
Always kgp tho short connector on the aitbag connector when ths harneggi9 disconnected.
Do not disassembleor tamper with the airbag assombly.
TORX6BOLT
10 N.m {1.0 kgf.m, 7lbf.ft)
HORNCONTACTPI-ATE
STEERINGWHEEL
LID
\s
SPACER
@
CRUISECONTROLSET/
NESUMESWITCHES
CRUISECONTROLSET/
RESUMESWITCHESCOVER
17-25
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SteeringWheel
Installation
Airbag installation
2.
CAUTION:
. Bfore inrtalling the stooring wheel, align tho front
who6l3 etraight ahead.
. Bo sure to install the harness wires so that thGy are
not pinched or intorfsring with othor car parts.
. Do not roplace thc original stsoring wheel with any
othor design. since it will maks it impo$ibla to properly install the airbag. {Only use genuine HONDA
replscomont parts)
. After rols3embly. confirm thai the whoels are still
straight ahoad 8nd that steoring wheel spoke anglo
is correct. lf minor spoke anglo adiustment is nocssrry, do so qnly by adlustment ol th tie-rods, not by
romoving and repositioning the steering wh|.
Installthe steeringwheel.
NOTE: Be sure the steeringwheel shaft engages
the cablereeland cancelingsleeve.
B e f o r e i n s t a l l i n gt h e s t e e r i n gw h e e l , c e n t e r t h e
cablereel.
Do this by tirst rotating the cable reel clockwise
until it stoos.
Then rotate it counterclockwise(approximatelytwo
turnsl until:
- The yellow gear tooth linesup with the mark on
the cover.
- The arrow on the cablereel label pointsstraight
UD.
YELI-OWGEAR
CRUISE
CONTROL
SET/NESUME
SWITCHES
CONNECTOR
ALIGNMENTMARK
17-26
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5.
YELLOWGEARTOOTH
BOLTS
TORXO
10N.m{1.0kgf'm.7lbfftl
ALIGNMENTMARK
17-27
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Steering Golumn
Removal
CAUTION:
. All SRS elctrical wiring hlrnesses are coversd with
yollow insuhtion.
. Bctore dieconnocting any part ol tho SRS wiro h!rnesa,connoct the thort connector (s).
. Roplacetho ontire aftected SRS harness asrmbly if
it has !n open circuit or d!mlgod wiring.
5.
HARNESS
R e m o v et h e c a b l e r e e l a n d t u r n s i g n a lc a n c e l i n g
steeve.
7.
LOWER
COVER
R e m o v et h e c o l u m n c o v e r s b y r e m o v i n g t h e
screws.
COMA|NANON SW]TCH
STEERING
COLUMN
scREws
17-2A
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CABI..E
REEL
8.
undor-dashfuse/relavbox.
'l1.
R e m o v et h o s t e e r i n g c o l u m n b y r e m o v i n g t h e
attaching nuts 8nd bolts.
JOIMTOOVER
STEERINGCOLUMN
BOITS
17-29
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SteeringColumn
lnspection
Checkthe steeringcolumn ball bearingand steering
joint bearingsfor play and propermovement.
lf there is noiseor excessiveplay,replacethe joint or
columnassembly.
STEERINGJOINT
BEARINGS
RETAININGCOLLAR
lf the preloadmeasuredis not within the sDecification. removethe 6 mm bolt and stoDDer.
Adjustthe preloadby retighteningthe rilt tockbolt
untilthe correctforcecan be obtained.
Reinstallthe stopperand 6 mm bolt and recheck
the Dreload.
TILT LOCKBOLT
ABSONBING
SLIDINGCAPSULE
This part is attached
to the columnbracket
with the plasticinjections.
17-30
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lnstallation
STEERINGCOLUMNASSEMBLY
RETAININGOOLLAR
STEERING
JOINTBOLIS
22 N.m{2.2tst m, 16lbf.ftl
FLANGEBOLT
22 N m 12,2kgl.m, 16lbf.ftl
FLAMiE NUT
13 N.rn {1.3kgt m, 9 lbt ftl
17-31
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SteeringColumn
Installation(cont'dl
CAUTION:
. All SRS electrical wiring hrrnossos are covgrod wilh
yellow insulation,
. When disconnctingthe SRS wire harness,install
the short connector on the airbag. thn dbconnoct
the wire harness.
. Replacathe entire alfected SRS harness assembly if
there is an open circuit or damage to tho wiring.
1.
I n s t a l lt h e s t e e r i n gc o l u m n w i t h t h e f l a n g e n u t s ,
then installthecolumnholderand flangebolts.
Tighten the upper and lower steering joint bolts
looselyinstalledin steD2,
Slip the upperend of the steeringjoint onto the column shaft {line up the bolt hole with the flat on the
shaft),and loosely install the upper steeringjoint
bolt.
Finaltorque:
22 N.m
{2.2kgf.m, 16lbt.ftl
UPPERSTEERING
JOINT BOLT
Bolt must line up with
flat on shaft.
FLANGEBOLTS
22 N.m
12.2ksi.m,16tbtftl
STEERING
JOINT
CLIP
1 7 -3 2
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9. Installthecolumncovers.
UPPER
COLUMNCOVER
coMatNATroN
swncH
scREws
TURNSIGNALCANCELING
SLEEVE
1 0 . lnstallthe driver'skneebolster.
1 1 . lnstallthe lowercover.
Installthe cablereel onto the steeringcolumn,then
connectthe SRS main harnessand cable reel wiro
harnessand installthe connectorholder.
't2. Installthesteeringwheel
'17-26).
{seepage
NOTE:Align the slot in the cablereel with the projectionon the cancelingsleeve.
17-33
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PowerSteeringHoses,Pipes
Replacement
CAUTION: Chock all clampsfor doterioration 8nd dstormation, and rsplacGwith new onss if n6co33!ry,
NOTE:
. Connecteachhosgto the correspondingpipe securgly until it stopsat the stoppron the pipe.
Installthe clamp or ad,ustableclamp at the specified
distancsfrom the hoseend as shown in the drawing.
. Add the power steeringfluid to the speciliedlevelon
the reservoirand checkfo. leaks(seepage17-23).
<HOSECLAMP:>
<AIUUSTABII HOSECLAMP:>
2.5 - 5.5 mm
{0.01- 0.22 inl
2.5 - 5.5 mm
10.01- 0.22 in)
2.0 - 4.0 mm
- 0.16inl
10.08
OUYI.fT HOSE
11 N.m
{1.1 kgl.m, 8 lbl.ftl
ABLECLAMP
INI."ETHOSE
RETURNHOSE
CLAMPS
coot"ER
CLAMPS
17 -34
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PowerSteeringPump
Disassembly
Removal
NOTE: Before disconnectingthe hoses from the pump,
placea suitablecontainsrunderthe car.
Pulley Removal
1.
2,
2.
3.
D i s c o n n e c t h e i n l e t a n d o u t l e t h o s e sf r o m t h e
pump and plug the hoses.
1.
4.
5.
OUTI.TTHOSE
tNt.THOSE
PULLEYNUT {Left-handthread)
(cont'dl
17-35
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PowerSteeringPump
(cont'dl
Disassembly
Flow GontrolValveRemoval/lnspoction
l.
2.
il.
Inspectthe bore for the flow control valvs for scratches or wear.
5.
FLOW
CONTROL
VALVE
Mark
Part Name
FLOWCONTROL
VALVEA
FLOWCONTROL
VALVEB
FLOW
OONTROLVALVE
6.
Outside Diameter
mm (in)
17.991- 17.996
(0.7083- 0.7085)
17.996- 18.001
{0.7085- 0.7087}
Ch6ckfor
damags to dgos.
FLOW CONTROLVALVE
17-36
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7 . Submergethe valve in a containerof power steering fluid or solvent,and blow in the hose.lf air bubb l e s l e a kt h r o u g h t h e v a l v e a t l e s s t h a n 1 0 0 k P a
11.0kgf/cm,,14.2psi),replaceor repairit as follows.
AIR PRESSURE
i-
POWERSTEEBING
FLUIDor SOLVENT
13x 1.9mm
O.RING
Replac.
'\)4.
nlll
RELIEFCHECKBALL
sHrM(sl
lf usd.
SEAT
13 N.m
11.3ks[.m, I lbf.tt]
2.
PUMPCOVER
Clampthisend in
a vise with sott iaws.
FLOWCONTROL
VALVE
REUEFvALvE
SPBING
58.5x 1.5mm
O.RING
Feplace.
10. Clean all the parts in solvent, dry them off, then
reassembleand retestthe valve.Sge page 17-43for
f low controlvalve installation.
NOTE: lf necessary,relief pressureis adiustedat
the facto.y by adding shims under the check ball
seat.lf you found shims in your valve,be sure you
reinstallas many as you took out,
(cont'd)
17-37
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N O T E : R e p l a c et h e p u m p a s a n a s s e m b l y i, f t h e
side platemust be replaced.
PUMPCAM RING
Checkfor damageor wear.
ROLI..ER
5 x 26.8 mm
SIDEPLATE
Checkfor damageor wear.
ROLLER
4,5 x 119.8
mm
7.
PUMPROTOR
Checklor damageor wear.
16.8x 1.9mm
O.RING
Replace.
54 x 1.9 mm
O-RING
Replace.
1734
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R e m o v t h e c i r c l i p ,t h e n r e m o v et h e d r i v e s h a f t
assemblyfrom the pump housing using a plastic
nammr.
ra-,"
Q'/
DRIVESHAFT
for bend,
damageor wear,
I{UB DIS/ASSEMBLYBASE
07GAF- SD40700
press.
Press
PUMPHOUSING
11. lnspectthe bearingby rotatingthe outar raceslowly. lf any play or roughnessis felt, replacethe bearing.
Installwiththe
red shieldedside
lacingdown.
07GAF- SDis)700
NOTE:Supportthe innerrace
with the tool securely.
17-39
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PowerSteeringPump
Reassembly
CAUTION: The power steering componsnts are mado of sluminum. Avoid dsmaging th componcnts during assombly,
NOTE:
. Cleanthe disassembledpans with a solventand dry them with compressedair. Do not dip the rubber parts in a sof
vent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply recommendedpower steeringfluid or steeringgrease(HondaP/N:08733- B070E)to the parts indicatedin the
assemblvprocedures.
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe powersteeringsystem.
. Replacethepump asan assemblyifthe partsindicatedwith asterisk(*) are worn or damaged.
ROLLER
5 x 26.8 mm
PUMPcovEn
.",orr*r,
-e^urrae
vrues
sirx1.smm
\
^ /
/
/
pratesl
{ro
{ro
Platesl
o_nrNc
o-ntNG
\Al
\A
I
/
I
Replace.
d A - h 1 / / E Z i l * l / / / ' ^ e e ' a c e
,h$;@:",n1
i'"otr
.PUMP HOUSING
xf:.i'/pp@6{fr;ry
tt.m,1a|t t.fti//
/-V#m
/
ROLLER
RoLLER
/
1.5
a.5 x 49.8
ag.amm /
68.5x 1.9 mm
O-R|NG
o-RING
Replace.
Reptace.
DRIVESHAFT
\E
PUMPSEAL
SPACER
|
I
//
>ei
INLETJO-INT
I
'PUMP
ROTOR
iiij:f:,ll-T;-,",,,,ll;il'- g--lblY""."*";
Replace.
$+--E
22.r x r.9 mm o-RfNG ------t@-<'t
Replace.
srntnc
-5.8x1.9mm
o^::t:\-G
Replace.
FLANGEBOLT
'11N.m
11.1kg-m,8lb-ftI
CONTROLVALVECOVEN
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I n s t a l lt h e n e w o i l s e a l i n t h e p u m p h o u s i n gb y
hand,then installthe pump sealspacer.
5 mm HOLE
38 mm
SIDEPLATE
crncuP
-
PRELOAD
SPRING
DRIVE
fu'/'i,Er
t\=zl4
PUMPSEAL
I"J
If /sprcen
x,
tY
,1.5mm
-ot seal
-Gll
ATTACHMENT,
37 x ,r0
07t,16- dt102d,
5.
16.8x 1.9mm
O.RING
5a x 1,9
O.RING
l
(cont'd)
SIDEPLATE
17-41
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PowerSteeringPump
(cont'dl
Reassembly
Set the pump cam ring over the two rollerswith the
"8" markon the cam ring upward.
PUMPCAM RING
1 3x 1 . 9
O.RING
T9
1 4 . Installthe 68.5x 1,9mm O-ringon the pump cover.
1 5 . Align the rollerset holesin the pump coverwith the
rollers.
'16. Align
20N.m
{2.0 kg .m, lil lbf.ftl
PUMPCOVER
PROJECTIONS
17 -42
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PulleyInstallation
2.
3.
4.
1.
2.
PULLEYNUT
FLOWCONTROL
VALVE
E;W
SPRING
11 N.m {1.1kgl.m,8lbtftl
PULLEY
NUT
6irN.m(6.5kgt.m,47lbt tt)
Checkthat the pump turns smoothlyby turningthe
pulrey.
17-43
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C o n n e c tt h e i n l e t a n d o u t l e t h o s e s .T i g h t e nt h e
pump fiftingssecurely.
5.
Looselyinstallthe pump in the pump bracketwith
mountingbolts.
11N.m
11.rkgf.m,8lbf.ftl
OUTIIT HOUSE
O-RING
Replaco.
INI.TTHOSE
ADJUSTING
BOLT
UP?ERI.fVEL LINE
IEVEI LINE
PUMPMOUNTINGBOLTS
2,r N.m {2.4 kgl.m. 17 lbf'ft}
Installthe DumDbelt.
CAUTION:
. Make surs that thg powor gtooring bslt i!
securglyon the grooyos of ths pulloy!.
. Do not get powor stggring fluid o. groaso in thg
power steering bclt or pulley trc6. Cloanoft 8ny
tluid or groa36belore installation.
BELT
POWER
STEERING
PULI..EY
17 -44
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SteeringGearbox
Removal
R e m o v et h e c o t t e r p i n t r o m t h e c a s t l e n u t a n d
removo the nut.
2.
3.
il.
SIEERINGJOIi{TCOVEB
28 mm
BALLJOlt{T REMOVER.
07MAC- SLqt2|X)
Removethe steering joint lower bolt, and move the
joint towardthe column.
1 0 . Disconnectthe heatedoxygen sensor (H02S)conngctor, and separatethe three way catalyticconverter by removing the slf-lockingnuts.
NOTE: Always replacethe gasketswith new ones.
HEATEDOXycEt{SNSOnOONNECTOR SELF.LOCKINGNUT
{cont'd)
Replacs.
IHREE WAY
CA?ALYTICCONVERTEN
17-45
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SteeringGearbox
Removal(cont'dl
1 1 . Removethe return pipe clamp from the left side of
the rear beam.and move the returnpiDeabovethe
steeringgearbox.
RETURNPIPECLAMP
NOTE:
. Placethe pipe disconnectedin the previous step
at the rear side of the gearboxso that they do
not hinderin the gearboxremoval.
. Do not loosen the cylinder pipes A and B betweenthe valvebody unit and cylinder,
RETUR]T
HOSE
I.TFTTIE-ROD
END
15. Removethe steeringgearboxmountingbolts.
17-46
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PINIONSHAFTGROMMET
STEEBINGGEARBOX
17-47
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Steering Gearbox
Disassembly
Stssring RackDisassembly
5.
NOTE:
. Before disassemblingthe gearbox,wash it off with
solventand a brush.
. Do not dip sealsand O-ringsin solvent.
1.
2.
3.
L o o s e nt h 6 l o c k n u t a n d r e m o v e t h a r a c k g u i d e
screw.
7.
CLIP
4.
TUBECLAMP
LOCKNUT
BOOT
17-48,
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RACKGUIDE
CYLINDERPIPEB
STAKEOPOINT
- 0.12inl
D.prh:2.5- 3,0mm 10.10
CYUNDER
END
PULLER
YOKE:
Commercirlly
Avrilablo
Sn.p-OnoT/N qrie'-1
oTcloT/N 7372
VALVEBODYUNIT
FLANGEBOLT
(cont'd)
17-49
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SteeringGearbox
Disassemblylcont'd)
13, Setthe gearboxin a pressso the gearhousingpoints
upward.
CAUTION:
Ksepthe tool straight to avoid damagingthacYlind.r
wall. Chscktis tool angls, and corrst if nrcolrary,
whsn rsmoving the cylinder end seal.
Use ! prors to r6movo tho cylinder end rgal. Do not
try to remove the soal by 3triking ths tool. h will
break the brckup ring and tho cylindr end leal will
romain in ths gsarbox.
Pre$
VINYL TAPE
STEERING
GEARBOX
Replace.
17-50
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2 3 . C h e c kf o . w e a r . b u r r s a n d o t h e r d a m a g et o t h e
edgesof the groovesin the sleeve.
SLEEVESEALRINGS
Ch6ckfor oeel off or
oamag0,
Vinyl t.p.
NOTE:
There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valvehousingonly the wall is stepped.
When the valve housingis replaced,installnew
3 2 m m s h i m ( s )o n t h e b e a r i n gs u r f a c eo f t h e
housingto adjustthe thickness.
(cont'd)
17-51
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SteeringGearbox
Disassembly(cont'dl
25. Using a cutter or an equivalenttool, cut and remove
the four seal rings from the sl6eve.
NOTE:
. Inspectthe ball bearing by rotating the outer
race slowly. lf thsre is excessiveplay, replacethe
pinionshaftand sleeveas an assembly.
. The pinion shaft and sleeve are a precisefiu do
not intermix old and new pinion shaftsand
steev8s,
SI-EEVE
28, Pressth6 valve oil sal and roller besring out ofthe
valve housing using a hydraulicpress and special
tool shown below.
17.52
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PILOTCOLLAR
O?GAF- PHTO1OO
Reassembly
NOTE:
. Cleanthe disassembledpartswith a solventand dry them with compressedair. Do not dip the rubberparts in a solvent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply power steering fluid or steering grease{HONDAP/N: 08733- 8070E)to the parts indicated in the assembly procedures.
. Do not allow dust,dirt. or otherforeignmaterialsto enterthe powersteeringsystem.
. Usethe appropriatespecialtoolswhere necessary.
FLANGCBOLT
20 N.m 12.0kg{.m, lil lbt'ftl
VALVEI{OUSING
CYLINDERPIPEA
26 N'm (2.7 kgf.m, 20 lbf.ftl
BOLI..ERBEARING
Replace.
VALVE SEAL RING
Replace.
+-cncl|P
SITEVE
O.RING
Replac.
LOCKNUT
PINIONSHAFT
CYLINDERHOUSING
BACKUPRING
SHIMS
O-RING
Replace.
O-RING
Replace.
CYUNDERENDSEAL
Reolace.
CYLINDEREND SEAL
Replaco.
GEARHOUSING
O.RING
Replace.
x$ Ynd#
PISTONSEALRING
Replace.
STEERINGRACK
(cont'd)
17-53
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SteeringGearbox
Reassembly
lcont'd)
Vllvc Body Rea3sombly
1.
2.
3.
4.
Apply vinyl tape to the steppedportion of the pinion shaft,and coat the surfaceof the vinyl tape with
the power steeringtluid,
I n s t a l lt h e b a c k u p r i n g w i t h i t s t a p e r e d s i d e a s
shown below.
Coat the inside surface of the new valve oil seal
with powersteeringfluid.
Slide the valve oil seal over the pinion shaft.being
carefulnot to damagethe sealinglip.
CAUTION: ln3tall the valve oil ssal with hs groovad
3idetacing opposits the besring.
Vinyl trpo
lst.ppcd ponion,
Taperedposition.
Groove side.
VALVESEALRING
VALVEOIL SEAL
Salinglip
E
Fit the new O-ringin the grooveof the pinion shaft.
Then slide the new valve seal ring over the shaft
and groovein on the pinionshaft.
Removethe vinyl tapefrom the pinionshaft.
NOTE:Do not over - expandthe valvesaalring.
PINION SHAFT
VALVESEALRING
17-54
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(H(ffi
Usethe widerdiameter
end ot the special
tool first to make
the valvesealring
fit in the pinion
shaft.
Apply powersteeringfluid to the surfaceof the specialtool. Set the new sealrings overthe specialtool
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l , a n d
expandthe seal rings.Do two rings at a time from
eachend of the sleeve,
NOTE:
. Do not over-expand
the seal ring.Installthe resin
seal rings with care so as not to damagethem.
After installation,be sure to contract the seal
rings usingthe specialtool{sizingtool}.
. There are two types of sleeve seal rings: black
a n d b r o w n . D o n o t m i x t h e d i f f e r e n tt y p e s o f
sleevesealringsas they are not compatible.
't7. Apply power steeringfluid to the surfaceol the pinion shaft,then assemblethe sleeveover the pinion
shaft,aligningthe locatingpin on the insideof the
sleevewith the cutoutin the shaft,
NOTE:Be carefulnot to damagethe valveseal ring
when insertingthe sleeve.
1 8 . Installthe circlipsecurelyin the pinionshaftgroove.
NOTE:Installrh circlipwith its taperedside facing
OUI.
Cutout,
ATTACHMENT,
32x35mm
077{6 - 0010100
VALVEOIL SEAL
{cont'd)
17-55
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ir
SteeringGearbox
(cont'd)
Reassembly
20. Pressthe new roller bearinginto the valve housing
usinga hydraulicpressand specialtool as shown.
NOTE:Placeths roller bearingon the valve housing with its letter stamped facing up towards the
valveside.
Pr.33,
2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
Dressas shown.
CAUTION: Before irserting the pinion 3haft, bo
suro that the backup ring is csntored with the pin.
ion shaft bearing,
ATTACHMENT,
32x35mm
- (x)1010O
077/aO
BACKUPBING
ROLLERBEARING
Letterstampedface
VALVCHOUSING
PINION
E
SI,-EEVESEAL RINGS
Be surethat the
searings are not
turnedup,then
install.
17-56
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NOTE:
. Do not over expand resin seal rings. Installthe
resin seal ring with care so as not to damage
them. After installation,be sure to contractthe
sealring usingthe specialtool (sizingtool).
. Replacepiston'sO-ringand sealring as a set.
sidefacingoppositethe specialtool.
Groovedside.
CYLINDEREND SEAL
PISTONSEALRING
GUIDE
07GAG- SD,OI00
CYLINDEREND
SEALSLIDER
0797a - 6890801
Apply a thin coat of greaseto the insideof the special tool, and installit on the steeringrack.
CAUTION:Make sure the rack teeth do not tace
the slot in the specialtool.
O.RING
PISTONSEALRING
CYLINOERENDSEAL
28. Coat the piston seal ring and inside of the special
toolwith power steeringfluid.
Carefullyslide the tool onto the rack and over the
pistonsealring.
30. Move the specialtool back and forth severaltimes
to makethe pistonsealring fit snuglyin the piston.
PISTON
E
SEALSLIDER
0t974 - 6890801
(cont'd)
17-57
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SteeringGearbox
Reassembly
lcont'dl
34. Separatethe cylinderend sealfrom the spscialtool,
then remove the tool from the steering .ack.
CYUNDERENDSEAL
I
12 x 170 mm FLANGEBOLT
12 mm FLANGENUT
lnstall the backup ring on the steering rack, then
placethe cylinderend sealto piston.
STEERINGRACK
BACKUPRING
CYUNDERENDSEAL
Greasethe steering rack teeth, then insert the steering rackinto the gear housing.
CAUTION: Be clrs{ul not to d.mage to inn9r !urftca of thc goar housing with th rsck cdg6.
c.oov.d3id...--#
<r|'
---_-EE]TmIrnTr--------EJl Li IL ll
CYUNDERENDSEAL
17-58
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- 2 . I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x ,a n d
tighten the flange bolts to the specitiedtorque
VALVEBODYUNIT
FLANGEBOLT
20 N.m {2.okgtm, 14lbt'ftl
SHIM SET
{foul thim.)
4.0 mm 10.15inl
CYLINDEREND
CYLINOER
69 N.m 17.0kgf.m, 51 lbtft)
(cont'd)
17-59
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SteeringGearbox
Reassembly
lcont'd)
- 4 . D e t e r m i n et h e r e q u i f e dt h i c k n e s so f t h e 3 2 m m
shims by subtractingthe clearanceobtainedin the
step-3 from the total thicknessof the four shims.
( T o t a lt h i c k n e s so f t h e 4 s h i m s ) - ( C l e a r a n c e=)
Requiredthicknessof the shims
CYLINDER
PIPEB
26 N.m (2.7kg{.m,20lbtft)
NOTE: Note the valve body unit installationposition (directionof pipe connection).
Tightenthe flangeboltsto the specifiedtorque.
FLANGEBOLT
20 N.m (2.0 kgt m, 14lbf.ft)
VALVEBODYUNIT
-6t
O-RING
-ffiti
LOCKNUT
NEEOLEBEARING
_#{
BACKGUIDESCREW
17-60
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64. l n s t s l l t h e b o o t s i n t h s r a c k e n d w i t h t h e t u b e
clamos.
o l
TUEE CLAJTIP
(cont'dl
17-61
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SteeringGearbox
Reassembly(cont'dl
65. Adjust the air hose fitting position of the boots by
turning it as shown below.
Front
AIR HOSEFITTING
70. Install the right and left tie-rod ends on the rack
ends.
C o n n e c t h e a i r h o s e b e t w e e nt h e r i g h t a n d l e f t
boot.then installthe clips on the cylinderpipe B as
snown.
Install
therightclip
in thisposition.
CLIP
17-62
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lnstallation
CAUTION; BGGlrc{ul not io bcnd or drm8go tho piping
whcn in3tllling tho gea.box.
1.
2.
3.
4.
5.
Installthe pinion shaft grommet and insertthe pinion shaft up throughthe bulkhead.
7.
YELLOWGEARTOOTH
MARK
ALIGNMEi'IT
Slip the lower end of the steeringjoint onto the pinion shaft(line up the bolt hole with the groove
aroundthe shaft),and tightenthe lower bolt.
NOTE:
. Connectthe steeringshaft and pinion with the
cablereeland steeringrackcentered.
. Be sure that the lower steeringioint bolt is securelyin the groove in the steeringgearboxpinion.
. lf the steeringwheel and rack are not centeted,
r e p o s i t i o nt h e s e r r a l i o n sa t l o w e r e n d o f t h e
steeringjoint.
6.
LOWERBOLT
22 N.m 12.2kgi.m, 16lbf.ftl
(cont'dl
38 N m 13.9kgl.m, 28 lbt.ftl
17-63
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SteeringGearbox
Installation(cont'd)
10. Installthe steeringjoint cover with the clampsand
cliDs.
1 2 . I n s t a l lt h e r e a r b e a m b r a c e r o d a n d r e t u r n p i p e
clampon the rearbeam.
N O T E : I n s t a l lt h e r e a r b e a m b r a c et o w a r d t h e
returnpipeclamp.
STEERINGJOINTCOVER
CLIP
HEATED
OXYGEN
SENSOR
CONNECTOF
SELF.LOCKING
NUT
33 N.m 13.4
SELF.LOCKING
NUT
22 N.m (2.2 kgt m, 16 lbt.ftl
17-64
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TIE-ROOEND
BALLPIN TAPERED
SECTION
Wipe off the grease.
BOOTINSTALLATION
SECTION
wiDe off the grease.
BOOTINSTALLATION
SECTION
Wipe off the grease.
CASILE NUT
39 - 47 N.m
14.0- a.8 kgf.m. 29 - 35 lbf ftl
COTTERPIN
On reassembly,bend
the cotterpin as shown.
SET RING
17-65
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R6ar Door:
'13.
"H"
GLASS
I
-4 Repeatsteps-2 and -3 until clearance"H" is
within the specifiedlimits.then fasten the center
glass guide and rollerguide.
Pressthe stopperplatesagainstthe glassstoppers, then fasten the stopper plates.
ROLLERGUIDE
204s
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Doors
GlassAdjustment(cont'dl
14. Adjust clearance"8" as follows.
-l
LOCKNUT
1 2 x 1 . 2 5m m
22 N.m 12.2kgf.m,
16 tbt.ft)
pushthe insidestabilizers
againstthe glssslightly. Fastenthe insidestabilizers.
NOTE: Checkthat the glassmoves smoothly.
*
GLASS
20-46
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WEATHERSTRIP
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Doors
Striker Adjustment
PositionAdjustment
NOTE: Placethe vehicleon a tirm, levelsurfacewhen
adjustingthe doors.
CAUTION: Plac a shop towsl on tho jack to prevent damage to the door when loosening the dool
and hingo mounting bolts for adjustmont.
BOLTS
DOORMOUNTING
8 x 1.25 mm 29 N.m l3.Okgl m, 22lbftrl
Loosen lhe door mo!nting bolts
slightlyto move the door lN or OUT
until ir's flush waththe body. It
necessary,you can installa shim behind one hingeto make the door
edgesPAFALLELwith the body.
DOOR
scREws
HIIGE xrruceMouNTTNG
BoLTs
I x 1.25mm
18 N.m ('1.8kgt.m, 13lbf.ttl
I x 1.25mm
29 N.m l3.O kgt'm,22 lbl'ft)
Loosenthe hingemounting
bolts, and move the door
BACKWARDoI FORWARD,
UP or DOWN as necessary
to equalizethe gaps.
SHOPTOWEL
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Mirrors
PowerDoor Mirror Replacement
Hstchback
Sedan
2.
HOOKS
2.
3.
^^
, A< : Scrow, 2
sxo.8mm
| l m-t uto.+
.+rg
r.m, I
rst..
l$9| +111
i
3 lbl'lrl
,"",''@
.I s ' 0 . 4(0.4
- ---J'/
4 N.m
, B< : Scr6w, I
I 66
|
kst.m, \
\3_!!t.rrr__
sro.'"e-.
\!Lbllq
cot{t{EcToB
(Doo. mirror ddol
DOOR MIRROR
CONNECTOR
lDoor harnoss
.ide)
CONNECTOR
3.
CONNECTOR
4.
20-49
vnx.su
Mirrors
Mirror Holder Replacement
1.
2.
< : Scrawlocation3,4
MIRRORHOLDER
2.
Hatchback
3.
JOINT PIN
Sedan
MIRRORVISOR
JOINT PIN
20-50
vnx.su
4.
Sedan
1,
2.
< : Scrowlocttions,3
8<: Screw, I
ACTUATOR
@
_ J
4E0 l
. _ J
MIRRORBASE
5,
{cont'd)
vnx.su
20-51
Mirrors
Mirror Visor and Mirrol Covel
Replacement{cont'd)
4.
RearviewMirror Replacement
1 . Pry the cover off using the end ot a flat tip screwdriver.
B { : S c r e w ,2
C < : S c . e w ,1
SCREW
5x0.8mm
4 N.m {0.4 kgf.m,
3 tbf.ftl
ACTUATOR
REARVIEW
MIRROR
SHOP TOWEL
3.
MIRRORCOVER
20-52
vnx.su
Windshield,RearWindow, OuarterGlass
lndex
NOTE: The numbersafter the part names show the quantitiesof the parts used.
Hatchback
UPPERMOLOING
UPPERRUBBERDAM
RIGHTSIDE
CLIP E. 2 Whir
Cl-lP F, 2 Loft. Whito
Right. Bluo
CLIP A, I Rod
RETAINER,6 Orengo
CLIP B, 2 O.an96
CLIPC, 2 Black
LEFTSIDEMOLDING
Removal,page 20-55
Installation,page 20-56
e.'.
CLIP D. 2 G.6en
RETAINER, 2 Ysllow
REARWINDOWMOLOING
page 2O-65
Replacement,
UPPERSEAL
UPPERFASTENER,2
(Slt-adh.sive-type,glass sid6l
UPPERFASTENER,2
(Self-6dhosiv6-type,hatch sidel
SIDERUAAER
DAM. 2
SIOESPACER.2
REARWINDOW
Removal,page 20'6'1
Instaflataon,page 20-62
f ? *
""'^i^r.{"'/\
LOWERFASTENER.2
{Self-adh6siv-type,
glass sidel
LOWERFASTENER,2
{Selt-adhosive-1ype,
hatch sid6)
ADHESIVETAPEB, 2
20-53
vnx.su
Windshield,RearWindow
lndex
NOTE: The numbersafter the part names show the quantitiesof the parts used.
Sodan
UPPER
MOLDII{G
UPPERRUEBEROAM
cLtP E, 2 Whir6
CLIP F, 2 L6ft. Whlto
Righl. Bluo
CLIP A, I Rod
&...
e
WINDSHIELD
Removal,page20-55
Installation,page20-56
*aro,nr*. 6 o'!.gc
CLIP B, 2 B?own
bq
,@
A
\
/ '
GLASSBRACKET,
2
RET
AINER. 2
Yollow
REARWINDOWMOLOING
2
UPPERFASTENER,
{S.ll-.dho!lvo-typo,gh$ .ldcl
g
.qB.....--
REARWINDOW
Removal, page 20-68
Installation,
page 20-69
urra" FAslEr{ER,2
(Cllp-typo, body .ld.l
R.-.......-"-.owER
FA'TENER.
2
LOWERCOVER
LOWERFASTENER,
2
(Solt-rdhe.lvo-typo.
body sidol
20-54
vnx.su
Windshield
Removal
CAUTION:
a Woar glovos to lmov and install the windshiold,
a Us saat covers to avoid damaging any surfaces.
3.
4.
ADHESIVE
WINDSHIELD
f-CLIPC, D
5.
>
lcont'd)
20-55
vnx.su
Windshield
Removal(cont'd)
6.
lnstallation
Apply protective tape to along the edge ot the dashboard and body as shown.
Usingan awl, make a hole throughthe rubberd8m
and adhesivefrom insidethe car. Pushthe pianowire
th.ought the hole, 8nd wrap each end arounda paece
of wood.
w|l{osHlELo
1.
2.
3.
WII{DSHIELD
PIANOWIRE
ADHESIVE
DAM
a Cleanthe shadowedarea.
a Cleanthe area@ as shown.
InCd.
CAUTION: Hold tho dano vyi]oas clos6to tho windshield as possible to prvsnt damag to ths body and
dashboard.
vn77777ri_
t
wtt{DsHtELo
WINDSHIELD
8.
Carefullyremovethe windshield.
20-56
vnx.su
.--
4.
6.
ALIGNMENTMARK
BRACKET,2
7.
12 mm {0.47 inl
RUBBER UPPERMOLDING
UPPER
DAM
1O mm 10.39ln)
8.
Removethe windshield.
20-57
vnx.su
Windshield
Installation(cont'd)
With a sponge.apply a light coal oJ glass primer
aroundthe edgeot the windshieldas shown, then
lightly wipe it olt with gauzeor cheesecloth.
NOTE:
a Do not apply body primerto the windshield,and
do not get body and glassprimerspongesmlxed
up.
a Nevertouch the primedsurfaceswith your hands.
ll you do, the adhesivemay not bondto the windshieldproperly,causinga leakafterthewindshield
is installed.
o Keep water, dust, and abrasivematerialsawaY
from the primed surface.
5 mm {0.19 inl
UPPER
UPPERRUBBER
WINDSHIELD
6 mm (0.23 in)
16 mm
1O.63inl
5mm
( O . 1 9i n l
RUBBER
-
DAM .YJ * o
16 mm
10.63inl
>\ast,
/
WINDSHIELD
\
UPPERMOLOING
7 mm 10.27in)
20-58
vnx.su
,*-
13. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the canridge
in a caulkinggun, and run a beadot adhesivearound
the edge ot the windshieldas shown.
l_/
f f i l
UPPER
RUBBER
: roxesrve
B < : C l i pB , 2
"___)
_)
8 m m lO.3'l inl
Make a slightlythicker
2mfi
lO.O7 inl
E V : C l i pE , 2
MOLDING
LOWER
RUBBEB
DAM
F)
F llelt. Whitel
lRight. Bluel
E lwhite)
A lRodl
'14.
SIDE
MOLDING
A (Rod)
It
B lHatchback, Orangel
lsedan, B.own)
C (Hstchback, Elack)
(Sodan, Orangel
SUCTION
D lHatchback, Green)
C (Sodan, O.ange)
vnx.su
20-59
Windshield
lnstallation(cont'd)
18. Let the adhesivedry tor at least one hour. then spray
water overthe windshieldand checkfor leaks.Mark
leakingareas,and let the windshielddry, then seal
with sealant.
NOTE:
a Let the car stand tor at leastfour hoursafter windshieldinstallation,lf the car hasto be used within the first four hours,it must be drivenslowly
a KeeDthe windshielddry for the first hour after
installation.
a Check that the ends of the side moldingare set
under the air scooP.
CLIPE
SIDEMOLOING
RETAINER
CLIP B
CLIP C, D
20-60
vnx.su
RearWindow
Removal
Hatchback
CAUTION;
a Use covsrs to avoid damaging tho interior.
a Wear gloves to romove and install the glass.
a Do not damags the defroster grid linss.
a Tako care not scratch th raar window molding,
4.
PROTECTIVETAPE
PROTECTIVE
TAPE
CONNECTOR
3.
MOLOING
20-61
vnx.su
-r
RearWndow
lnstallation
4.
NOTE:
a Do not scrapedown to the painted surface of the
body; damagedpaint will interferewith proper
bonding.
UPPERSEAL
F A S T E N E' R , 2
FASTENER,2
/
ALIGNMENT
sroE
SPACER,2
REARWINDOW
20-62
vnx.su
ALIGNMENT
MARKS
NOTE:
a Do not applybodyprimerto the rearwindow,and
do not get body and glassprimerspongesmixed
up.
a Nevertouch the primedsurfaceswith your hands.
lf you do, the adhesivemav not bondto the rear
window properly,causinga leak after the rear
window is installed.
a Keep water, dust. and abrasivematerialsawav
from the primed surlace.
////
15 mm
10.6inl
MOLOING 1 5 m m
{0.6 in}
REARWINDOW
MOLDING
(cont'd)
20-63
vnx.su
RearWindow
Installation(cont'd)
1 2 .With a sponge,apply a light coat ol body primerto
the originaladhesiveremainingaroundthe rearwindow openingflange.Let the body primerdry tor at
least 10 minutes.
NOTE:
a Do not apply glass primer to the body, and be
careful not to mix up glass and body primer
sponges.
a Nevertouch the primedsurfaceswith your hands
7//,
15. Pack adhesiveinto the cartridgewilhout air pockets to ensurecontinousdelivery.Put the cartridge
in a caulkinggun, and run a beadof adhesivearound
the edge of ihe rear window, as shown.
it.E\,",1/: ADHESTVE
UPPER 5 m m
SEAL
1 0 . 1 9I n l
8mm
10.31inl
10 mm
{0.4 in)
40 mm 11.6 Inl
16 mln 10.63Inl
1 mm {0.04 inl
fu.:*1",
lO.Oainl
16 mm {0.63 inl
t|nm
(O.35 Inl
)E--lT-*
-\
MOLDING
I J.
1O mm {0.39 inl
7 mm (0.27 inl
vnx.su
-C=
/
/
GLASS
MOLDING
RearWindow Molding
Replacement
16. Use suctioncups to hold the rear window over the
opening,align it with the alignmentmarks made in
step 7, and set it down on the adhesive.Lightly push
on the rear window until its edges are fulty seated
on the adhesiveall the way around,
1.
2.
ALIGNMEI{T MARKS
3.
REARWINDOW
4.
5.
6.
20-65
vnx.su
RearWindow Molding
Replacement(cont'd)
7.
JOINT
6mm
1O.23Inl
MOLOING
SUBFACE
INSIDESURFACE
6mm
(0.23inl
MOLDING
MOLDING
20-66
vnx.su
12. Scrape o. wipe the excess adhesiveofJ with a Dutty knife or gauge.
NOTE: Cleanthe moldingand rearwindow surface
with alcoholwhere upper seal is to be apptied.
{Gla*r Surtacel
Surfaco to be
wiped clean.
1 mm (0.04 In)
MOLDING LIP
20-67
vnx.su
RearWindow
Removal
4.
Sadan
CAUTION:
a Wear gloves to remove and install the leal window.
a Do not damage the delloster grid lines.
MOLOING
REARWINOOW
3.
wlNDow
Pull down the rear of the headliner (see page
20-101).
CAUTION: Take care not to bend the headlinerexcessively.
o.
ADHESIVE
/ - a,o*o*'*a
MOLDING
HEADLINER
PIANOWIRE
LOWERCOVER
LowERsPAcER/
;ru/
FASTENER
LowER
oore,srvr \3
PRorEcrtvE
rlee
20-68
vnx.su
---
Installation
7 . With a helperon the outside,pullthepianowire back
and torth in a sawing motion, and carelully cut
through the adhesivearoundthe entire rear window.
REARWINDOW
2.
3.
PIANO wlRE
ll the old rearwindow is to be reinstalled,usea Dutty knifeto scrapeoft all tracesof old adhesive.then
cleanthe rear window surfacewith alcoholwhere
new adhesiveis to be aDolied.
NOTE: Make sure the bondingsurfaceis kept free
of water, oil and grease.
8.
Cleanthe shadowedarea.
/s
\\--
t\
{cont'd)
20-69
vnx.su
RearWindow
lnstallation (cont'd)
4.
6.
lnside
5OOmm 119.7in)
ALIGNMENT MARKS
7.
5 O Om m 1 1 9 . 7
> : Spac6r,lastonellocations
SIDE
S P A C E R , 4^
lo, \./O
MOLDING
'7:^ c
rs
s-."
\\t--
MOLDING
l\ 4!9!llEN,r_r\,ry!s
q
la,Loqrcen.t
(4relycv!|I!"
l$;*
\'*'w
\ o.f9!T.nl"1"*"
ALIGNMENT
MARKS
20-70
vnx.su
i"lT
;o:d:';",
16 mm 10.63inl
16 mm 10.63inl
All around.
10 mm lO.4 inl
/.s
s
10 mm (0.39 in)
7 mm (0.27 inl
{cont'd)
20-71
vnx.su
RearWndow
Installation(cont'dl
14. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the cartridge
in a caulkinggun, and run a beadof adhesivearound
the edge oI the rear window, as shown.
NOTE: Apply the adhesivewithin 30 minutesafter
applyingthe glass Primer.
12 mm (O.47inl
[/
, aoxesrve
t-l
ADHESIVE
^X-"--"-,
s-_T--r-
8 mm (o,31inl
REAR WINDOW
I MOLOING
cr-rss
'18. Let the adhesivedry for at least one hour, then spray
water over the rear window and check Jor leaks'
Mark leakingareas,let the rearwindow dry, then seal
with sealant.
NOTE: Let the car stand Jo. at leastfour hoursafter rear window installation,lf the car has to be used
within the tirst tour hours,it must be drivenslowly'
ALIGNMENT
20-72
vnx.su
OuarterGlass
Replacement
a War glovs to romove and installthe quartol glass.
a Use seat covers to avoid damaging any surfaces.
3.
2.
Pullthe piano wire back and forth in a sawing motion, and carefullycut throughthe adhesivearound
the entire quarterglass.
CAUTION: Hold th tiano wire as closoto the qurter glass as possibleto prevent damage to th6 body
and quarter pillar trim panol.
Apply protectivetape to the edgeof the quarterpillar trim panel and body as shown.
Usingan awl. make a hole through the adhesivefrom
insidethe car. Pushthe pianowire throughtthe hole,
and wrap each end around a piece of wood.
OUARTERPILI.AR
TRIM PANEL
AOHESIVE
PROTECTIVE
TAPE
OUARTERGLASS
PIAI{O wlRE
PROTECTIVE
TAPE
OUARTERGLASS
CLIP
PROTECTIVE
TAPE
ADHESIVE
TAPE
ADHESIVE
OUARTERPILLAR
TRIM PANEL
ADHESIVE
PROTECTIVE
TAPE
4.
Carefullyremovethe quarterglass.
20-73
vnx.su
OuarterGlass
Replacement(cont'd)
Scrapethe old adhesivesmooth with a knife. to a
thicknessof about 2 mm (O.08in) on the bonding
surface around the entire quaner glass opening
flange.
8.
NOTE:
o Be careJulnot to touch the quarter glass where
adhesivewill be applied.
a Do not peel the separatoroff the double-taced
adhesivetaPes.
NOTE:
a Do not scrape down to the painted surface of the
body: damagedpaint will interferewith proper
bonding.
a Mask oft surroundingsurfacesbefore applying
orimer.
b-
srDE
sPAcERI
\ nrolonci
\ /
IfR-.s
-l
3 mm (0.12 inl
ADHESIVE
TAPE8
MOLDING
_c$$l
Cleanthe new quarter glass surface with alcohol
where adhesiveis to be aDDlied.
NOTE: Make surethe bondingsurfaceis kept tree
of water, oil and grease.
CAUTION: Avoid setting th quartsr glass on its
edgas; small chips may later dvelop into cracks.
195 mm
(?.68 in)
150 mm
15.9 inl
CLIP
4 . 5 m m 1 O . 1 8i n l
ADHESIVE
CLIP
MOLDING
vnx.su
MOLDING
9.
NOTE:
a Do not apply body primerto the quaner glass,and
do not get body and glassprimerspongesmixed
up.
a Nevertouch the primedsurlaceswith your hands.
lf you do, the adhesivemay not bond to the quaner glassproperly,causinga leakafter the quarter
glass is installed.
a Keepwater, dust. and abrasivematerialsawav
from the primedsurface.
V///
, AooV glass primer h6re1 1. With a sponge.apply a light coat of body primerto
the originaladhesiveremainingaroundthe quarte.
glass openingflange.
Let the body primer dry lor at least 1O minutes.
NOTE:
a Do not apply glass primerto the body, and be
careful no1 to mix up glass and body prime.
sponges.
a Nevertouchthe primedsurfaceswith your hands.
'////7, , aepty body p.imer here.
5 m m lO.2 inl
ffi
16 mm
6mm
10.24in) {0.63 in}
10 mm lO.4 inl
'16
mm
(0.63 inl
OUARTER
TRIM
10 mm lO,4 inl
5 mrr| 10.2inl
(cont'd )
20-75
vnx.su
OuarterGlass
(cont'd)
Replacement
12. Thoroughlymix the adhesiveand hardenertogether
on a glass or metal plate with a putty knife.
t5.
to.
NOTE:
a Cleanthe platewith a spongeand alcoholbefore
mixing.
a Follow the instructions that came with the
adhesive.
13. Beforetillinga cartridge,cut the end of the nozzle,
as shown.
Cut nozzleend,
as shown.
10 mm 10.39in)
7 mm {0.27 inl
14. Pack adhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Put the cartrige
in a caulkinggun, and run a beadof adhesivearound
the edge of the quarter glass as shown.
NOTE:
a After applyingthe adhesive,peel the separator
off the double-facedadhesivetapes.
a Apply the adhesivewithin 30 minutesafter applying the glass Primer.
t1;T,,1\
:ADt'Es'vE
I mm 10.3in)
8 mm lO.3 in)
AOHESIVETAPES 8
-1r
*-{6
2mm{0.08
IL_-_
J,
SIOE SPACER
'19.
ADHESIVE
TAPEA
'12 mm (0.47 inl
Reinstallall remaningremovedparts.
2 mm lO.O8in)
20-76
vnx.su
Moonroof
Index
Hatchback
CABLE ASSEMBLY
Replacement,page 2O-81
SUNSHADE
page 20-79
Replacement,
MOTOR
page 20-80
Replacement,
GLASS BRACKET
page 20-81
Replacement,
SUI{SHADE
RAIL
FRONT DRAII{
CHANNEL
a'# /
DRAIN CHANNL
-4
FRAMESEAL
GUIDERAIL
page 20 8l
Replacement,
FRONTRAIL
HOLDER
,**4
REAR ORAINTUBE
\a
FRAME
20-77
vnx.su
Moonroof
Troubleshooting
Probable Cause
Symptom
Water leaks
1 Cloggeddrain tube.
Gap between glass weatherstripand roof panel.
Defectiveor improperlyinstalledglass weatherstrip.
4 GaDbetween drain seal and roof panel.
Wind noise
Motor noise
1. Loosemotor.
2. Worn gear or bearing.
3. Cableassemblydeformed.
1 . B l o w nf u s e .
2. Faultyswitch.
3. Battery run down.
4. Defectivemotor.
5. Faulty realy.
GlassHeightAdiustment
The roof panelshouldbe even with the glassweathers t r i p ,t o w i t h i n l 8 t O . 5 m m ( O . O 7I 0 . O 2i n ) a l l t h e
way around. It not, slidethe sunshadeback, and:
Y : Bolt locstions, 6
1 . 8 1 0 . 5 m m l O . O 7i 0,O2 in)
ROOFPANEL
GLASS ERACKET
GLASS BRACKET
GLASS WEATI{ERSTRIP
4.
Side-to-side fit ot glass weatherstrip can be adjusted by loosening the frame mounting bolts and moving the frame right or lelt and forward or backward
by hand (see page 2O-8O).
f )
20-78
vnx.su
RearEdgeClosingAdjustment
Open the glass about a foot, then close it to check where
rear edge beginsto rise. lf it rises too soon and seats too
tightly againstthe roof panel,or too late and does not
seat tightly enough,adjust it.
1.
2.
Removethe glass.
3.
4.
2.
Tilt-upthe glass.
3.
GLASSBRACKET
4.
5.
II
SUNSI{ADE
l-t
20-79
vnx.su
Moonroof
Motor, DrainTube and FrameReplacement
CAUTION: B caretul not to damag lhe seats, dashboard and other interior trim.
4.
: Eolt locations, I
< : CliD locations. 2
6 x 1.0 mm
9.8 N.m (1.0kgt m,
7.2 rbr.ttl
)
CEILIINGLIGHT
TUBECI-IP
FRAME
FRAME
3.
DRAIN TUBE
To install,slidethe drain
tube over the ftame nozzle
at least 10 mm {O.4 in}.
6.
Pull the drain tubes out the front and rear pillars.
NOTE; Betorepullingout the draintube, tie a string
to the end of it so it can be reinstalled.
: Bolt, 2
B : N u t ,3
Ld
6x1.Omm
9.8 N.m
I
I
tt.o kgf.-,
,.?-", _,/I
FRONT
20-80
vnx.su
GlassBracket/Slider,
Lifter, GuideRailsand CableAssemblyReplacement
1 . Removethe frame from the car {see page 2O-8O).
5.
BV: Screw,
b.
7.
4.
BV : Sciow, 4
V : Clip locations,2
NOTE: To instalt,Iill the
gtoove rn each grommet with sealant,
GUIDERAIL
GUIDE RAIL
20-81
vnx.su
Moonroof
GlassBracket/SliderLifter GuideRailsand CableAssemblyReplacement
(cont'dl
8.
CABLE ASSEMBLY
STOPPER
GUIDERAIL
ROD
AIT|CHOB
GLASS
NOTE:
a Dsmsgedpansshouldbe replaced.
. Applygreaseto the slidingportion.
SLIOER
NOTE: To instll,apply multipurposegreaseto
the lifter and slide stooDer link.
20-82
vnx.su
200-290 N
(20- 30 kgf, rt4- 66 lbf)
GLASS
'r
coul{TERcLocKwrsE
To decrease
20-83
vnx.su
Moonroof
lndex
Ssdan
GLASS BRACKET
Replacement,page 20-88
----/_--4
DRAIN CHANNEL
SUNSHAOE
Replacement,page
SLIDE STOPPRLINK
SUNSHADERAIL
FRONTORAIN
GUIDERAIL
Replacement,page 20-88
REARRAIL
HOLDER
MOTOR
page20-87
Replacement,
SEAL
REAR DRAIN
('
V
\
FROi{TDRAINTUBE
FRAME
Repfacement,page 20-87
20-84
vnx.su
Symptom
Probable Cause
Water leaks
1. Cloggeddrain tube.
2. Gap between glass weatherstripand roof panel.
3. Defectiveor improperlyinstalledglass weatherstrip.
4. Gap between drain seal and roof panel.
Wind noise
Motor noise
1. Loosemotor.
2, Worn gear or bearing,
3. Cableassemblydeformed.
1.
2.
3.
4.
1 . B l o w nf u s e .
2. Faulty switch.
3, Battery run down.
4. Defectivemotor.
5. Faulty relay.
V : Eolt localions, 6
I
6x LOmm
"),
9 . 8 N . m 1 1 . Ok g f m
7.2 tbf.ttt
1 . Tilt-upthe glass.
4'/
10.5 mm lO.O7 1O.02 inl
ROOF PANEL
GLASS BRACKET
GLASS ERACKET
GLASSWEATHERSTRIP
4.
Side-to-side
fit of glassweatherstripcan be adjusted by looseningthe frame mountingbolts and moving the frame right or lett and forward or backward
by hand (see page 20-87).
vnx.su
12
Forward
Moonroof
Rear Edge Closing Adjustment
Open the glassabout a foot, then close it to check where
rear edge beginsto rise. It it risestoo soon and seats too
tightly againstthe roof panel,or too late and does not
seat tightly enough,adjust it.
2.
3,
Removethe glass.
3.
4.
BOLTS
6 x 1 . Om m
9.8 N'm lt O kgf m,
7.2 tbt.ftl
GLASS BRACKET
4.
5.
SUlTSHADE
RAIL
7.
Installthe headliner.
20-86
vnx.su
\/
CONNECTOR
FRAME
BOLT
6 x 1 . 0m m
9.8 N.m (1.Olg{.rn.
7.2 tbt.ttl
DRAINTUBE
To install,sladethe drain tube ov6r
the frame nozzleat least 10 mm lO.4 in).
SUNSHADE
RAILS
tt.
20-87
vnx.su
Moonroof
Lifter,GuideRailsand CableAssemblyReplacement
GlassBracket/Slider,
3.
4.
5.
6.
7.
Removethe screws @ attschingthe guide rail. then litt the guide rail.
8.
ITUT
6xl.Omm
9.8 t{.m {1.0 kgt.m,
7.2 tbf.ttl
REAR RAIL
HOLDER
SUB-SEAL
NUT
6 x 'l.O mm
9.8 N.m {1.O kgf.m,
7 .2 tbt-lrl
9,
20-88
vnx.su
INNERCABLE
LIFTER
GLASS
BRACKET
GUIDE RAIL
SLIDER
NOTE:To install,applymuttjpurpose
grcase
to th liftsr and slidestopperlink.
Applycaulking
before
instaing the guiderait.
1 3 .Removethe screws,then removethe cableassem1 1. Slidethe anchorrod forward, then removeit from
the guide rail.
STOPPER
NOTE:
a Damagedpsrts should be replaced.
a Apply greaseto the slidingportion.
20-89
vnx.su
Moonroof
Closing Force Check
lMotor Installed)
OpeningDragCheck
(Motor Removed)
Beforeinstallingthe motor. measurethe effort required
to open the glass using a springscale as shown
CAUTION: Whon using a spring scalo. protoct the
lading odge ol the glass with a shop towI.
lbf)
GLASS
clocKwlsE/i 1
Toincrease
\ l,
torce,
20-90
L.
vnx.su
coutrenctocKwlsE
Io decrease
force
InteriorTrim
Replacement
a Wal glovesto removeand installth trim and panols.
a When prying with a flat tip screwd.ivor. wrap it with
protective tap to prevent damaga.
NOTE: Take care not to bend or scratchthe trim and
Danels.
Hatchback
Rear trim panet/Sidetrim panel/Ouarterpillar trim p-l
16moval:
1. Open the hatch.
2.
l.
B< : Ctip,1
CV : C[p, 1
U ry-ry
J t l , M l *
REARSHELF
KICK PANEL
SPARETIRELID
FRONTPILLAR
TRUNKMAT
vnx.su
ao..t dr
20-91
lnteriorTrim
(cont'd)
Replacement
5.
7.
v : Clip locations,7
1 ) P u s ht h e i n n e rc l i p . - 2 ) D e t a c ht h e c l i p b y
pulling it.
NOTE:Do not push
W-tNj
w) !)
it in too lar.
INNERCLIP
@ M)
BD : Clip, 4
A> : Clip. 4
DV : Clip, 1
CD : Clip, 3
,Ull
,,zqzz4 |
A> : Bolt,2
B > : S c i o w ,2
@-,
PANEL
A> : Clip, 2
,e-,ff)
ffi
i,Gffi'^*^
,Kl^\
fo
CARGO AREA
LIG}IT
SPEAKER
LID
\
LEFT
accEss
PANEL
vnx.su
Btr: Clip3
.
S;+
)
BELT
1O. Removethe quartertiim and coat hangerfleft sidel.
: Screw locstions, 'l
'12.
t
Q-.-INNER
cLrP
(./ilk
\c4z )
\/
tl
\#
20-93
vnx.su
lnteriorTrim
Replacementlcont'dl
Removethe front and rear door trim
3.
Sodan
1.
e)
BELTHOLE
CAP
CENTERPILLAR
LOWERTRIM
2.
4.
A : Clip localions.2
nfa147zzn
trui
L_,)
*UPPER
EOLT
ANCHOR
7/t6-20 UNF
32 N m (3.3 kgf'm, 24 lbl ft)
ANCHOR COVER
FRONT
SEAT
EELT
CENTERPILLAR
TRIM
CENTERPILLAR
LOWERTRIM
ANCHOR CAP
LOWERANCHOR
BOLY
7/16-20 UNF
32 N.m 13.3 kgt.m,
24 lbt.ltl
20-94
vnx.su
NOTE:
a lf necessary,replaceany damagedclips.
a Beloreattachingthe centerpillarlower trim and
belt hole cap. make sure there are no twists or
kinks in the front seat belt.
2.
4.
V : Clip locrtions, 2
^affi-_--.]-"t't
Removethe upperportionof the reardoor sill molding, then pull the reardoor trim awav on each side.
Y,r\-J/
\t -
'/
-
REARsHEr-F
TRIMPANEL
5.
3.
REARSHELF
> i Cliplocalionr,12
W.,
REAR PILLAR
TRIM PANEL
6.
R e m o v et h e s e a tl o c kc o v e r{ s e ep a g e2 0 1 1 1 ) a n d
high mount brake lighr (seesection 23).
(cont'd)
20-95
vnx.su
lnteriorTrim
(cont'd)
Replacement
7.
NOTE:
a lf necessary,replaceany damagedclips.
a When installingthe rear shelf, make sure there
are no twists or kinks in the rear seat belt'
V : Clip locations
BV: Cllp,2
AV : Clip, 4
N i
==:
w "ff=
t
;
_)
8.
=)
AELTHOLE
CAP
REARSHELF
20-96
vnx.su
Trunk Trim
Replacement
NOTE: Take care not to bend or scratchthe panels.
'1.
2.
4.
@q lF
--
3.
t"
V : Clip loc.tlorE
AV : Clip, 4
- I l Push the inner clip.
NOTE: Do not push it
in too Iar.
II{NEB CLIP
ffi
gV I Cllp, 2
- I I Loosen the inner clip.
II{NER
w
{*
,/
(8r-ct-tp
hfr
)J"'J
eEdf,
..&G\
NOTE:
a lf necessary,replaceany damagedclips.
a When installingthe reartrim panel,installthe A
clip as follows.
t
4
Y_)
rd[h
H
tNt{ER
cLrP
20-97
vnx.su
Headliner
Replacement
CAUTION: Whon Fyhg with I flat tip sclewdrivsr, wrap
it whh protectivs tapo to prevent damaga.
NOTE:
a Take care not to bend and scratchthe headliner.
a Be caretulnot to damagethe dashboardand other interior lrim.
a Fold the front seat-backbackward.
3.
Halchback
B : Nut, 2
: Scrcw, 2
&) ?)
CONNECTOR
1. Remove;
. Door trim (see page 20-93)
a Front Dillartirm {see page 20-91)
a Ouartertrim (see page 20-93)
a Coat hanger(see page 20-93)
a Rearviewmirror {seepage 20-52)
2.
u)
LOCK WASHER
(Outside)
l
H
"^/
Aaqr+-
HOLDEB
SUNV|SOR
BRACKET
HOOK
ffi)
CONNECTOR
LENS
HOOK
NOTE:
a lf necessary,remove the sunvisor bracket as
shown.
a When installingthe sunvisorbracket,apply grease
and make sure it's installedproperly.
suNvlsoR
BRACKET
m)
H
,r--T-\
LENS
suNvrsoR
20-98
vnx.su
HOOKS
4.
Removethe grabhandle(frontpassenger.s)
and grab
hole caps (driver's),
: Scrowlocationsl2l
6.
7.
e)
A : Clip locotions,2
HEADLINER
HOOKS
_ t
ROOF TRIM
5.
socxET
FRAME
-@'
//Gr
HEADLII{ER
OUARTERPILLAR
TRIM PANEL
{ +=s
,
SOCKET
PLUG
(cont'dl
20-99
vnx.su
Headliner
{cont'd)
Replacement
9, Lower the headlineras shown.
NOTE: Take care not to bend and scratch the
headliner.
HEADLINER
Sodan
'1.
Remove:
a Center Dillarlower trim (seepage 20-94)
a Front and rear door trim lsee page 20-94)
a Front pillartrim (see page 2O-9 .
a Center pillartrim (seepage 20-94)
a Rear pillartrim panel (seepage 20 95)
a Rearview mirror (see Page 20-521
LEFT OUARTERPILLAR
TRIM PANEL
s,1
RIGHTOURTERPILLAR
TRIM PANEL
HOLDER
NOTE:
a When insertingthe headlinerthrough the hatch
opening,be carefulnot to fold or bend it. Also,
be carefulnot to scratchthe bodY.
a Checkthat both sidesof the headlineraresecurely attachedto the trim and Panels.
a When installingthe roof trim, install the Joint
toward the rear.
LOCKWASHER
loutsidel
$-.unu,"o"
BRACKET
/'
HEADLINER
NOTE:
a lf necessary,remove the sunvisor bracket as
shown.
a Wheninstalling
the sunvisorbracket,applygrease
and make sure it's installedproperly.
, @
suNvrsoR
20-100
vnx.su
3.
A : Screw,nut locations
A A : S c . 6 w 2,
4.
orlx
-A-i
B : N u r ,2
CONNECTOR
CEILING
.-L----- ----z
CONNECTOR
REARCEILING
LIGHT
HOOKS
20-101
vnx.su
Headliner
{cont'd)
Replacement
5.
6.
A : Clip locations,3
)
HEADLINER
door
Removethe headlinerthroughthe passenger's
opening.
HEADLINER
20-102
vnx.su
Seats
Front Seat Removal
NOTE: Take care not to scratch the seat covers and
bodY.
1.
3.
V:Boh locatlong
A V : Bolt, 1
> i Eolt locltlon..
I'
> : 8olt,
8 x '1.25mm
ii i.:iiil..i'xst.^.
I
16:t'ftt
-
/)
4.
CONNECTOR
vnx.su
20-103
Seats
Front Seat RePlacement
5,
2.
(see
Removethe front seat through the door opening
page 20-1O3).
lnnrnt
v)*
COVER
RECLINE
I
|
l O x 1 . 2 5m m
i
47 N'm 14.8kgl ln, I
SEAT.gACK
COVER
PAO
"?"!."t_J
SCREW
6.
PIVOT WASHER
SEATBELT
BUCKLE
'1
{seepage2O'1 7)
PLAIN
WASHER
PIVOT NUT
8 r 1.25mm
22Nm12.2kgl'm,
16 lbf.ftl
CENTERCOVER
7 . Removethe seat-back.
scREws
Removethe hook and fastener,then lold the seatback cover back.
20-104
vnx.su
sEAr-BAcK
8.
RECLINE
AOJUSTER
NOTE:
a B e f o r e s e p a r a t i n g ,s l i d e t h e s e a t c u s h i o n
backward.
a Take care not to bend the joint rod.
< : Bolt locations, 4
: Bolt, I
BY : Nut,2
j @i+ilJ
A;iil;iiry-,'_o()_
_/
_].'*",
RECLINE
ADJUSTER
JOINTBOD
Disconnect
the rearseataccesscable(hatchback
passenger'sl.
REARSEAT
ACCESSCABLE
20-105
vnx.su
Seats
Front Seat CoverRePlacement
CAUTION: Wear gloves to removo and install the 36at
covrs.
4.
\\
ilff-]s)
fH".,
5.
Cllp removrl:
,e,
c J /
6.
HEAOREST
SEAT.BACK
20-106
-
vnx.su
Cllp romoval:
CLIP
UPHOLSTERYRING PLIERS
NEW CLIP
PAD
WIRE {Pad sido}
SEAT CUSHIONCOVER
2
20-107
vnx.su
Seats
RearSeat Replacement
3.
Hatchback
NOTE: Take care not to scratch the seat covers and
body.
CLIPPIN
(seepage 20-1Og)
SEAT.BACK
SEAT.BACKS
2.
V: Clip locations,14
v /
J
TRUNKMAT
SEAT-BACK
20-108
vnx.su
PIVOTBRACKET
4.
LATCH COLIAR
6 r 1.0 mm
9.8Nm
SEAT-BACK
COVER
SEAT CUSHION
.a\
tDt@
<Jt
STRIKER
l
I
6x1.0mm
i
9 , 8 N . ml 1 . Ok g l . m , l
1.2lbl..ttl
._
/l
CUSHION
5.
8 ) : S c r e w ,1
l
l
'
.,,W
Gp" II
9 . 8N . m1 1 . 0k s fm . I
7 2 tP!ft!---/'
./
REARSEATEELT
LATCH COLLAR
.otc" rtroa
6.
El
LATCH COVER
SEAT LATCH
t'
T-8ACK
( c o n t ' d)
20-109
vnx.su
Seats
(cont'd)
RearSeat Replacement
3.
Sedan
TRUNK
MAT
a-^
Nry
Y
SEAT.BACK
I { \ t \
HOOK
TRUNK
MAT
SEAT-8ACK
2.
4.
Removethe clips.
V : Eolt locations,4
V : Clip locations,I
l
I
l
I E gel?"Til.*,,",
iI
7.2 tbt'trl
/-.;-\
----+tl
---M\r/ / I
,/
"
-----r"
TRUNKMAT
REARSEATLAICH/
LOCKCYLINDER
{seepage2O-'l11l
REARSEAT
PIVOTBRACKET
(seepage2O-111)
REARSEAT
PIVOT BRACKET
SEAT-BACK
SEAT.BACK
20-110
vnx.su
5.
Y: Bolt location. 1
-r
7.
i Hool loc.lion3. 2
SEAT CUSHION
V i Bolt. scrow locations
AV i Boll, 2
9:
9.8 l;o--'
tt.m
EI
v_
i
tgf .m,
lr.o kgf.m,
l1.O
I
7.2 tbf.ft!____//
BV : Sc?ow, 2
4x0.7mm
4 N.rrt
{O.4 kgf'm,
3tbt.ttt
I
)
SEATLOCK
COVER
SEATLOCK
covER\-_L/-R\
w
-"1/ -
LOCK
CYLINDER
Pry here.
LOCKROD
Removethe bolts, then removethe seat-backside
bolstersby lifting them upward.
: Bolt locationr, 2
6 r 1 . om m
9.8 N.m
( 1 . 0k g l ' m ,
7.2 tbt.fti
REARSEAT
LATCH
I
i
I
TOOTHED
BUSHTNGLOCKWASHER
REARSEAT
PIVOT BRAC(ET
PIVOT BOLT
8 x 1.25mm
22 N.m (2.2 kgf m,
16 tbf.ftt
WASHER
20-111
vnx.su
Seats
(cont'd)
RearSeat Replacement
8.
RearSeat CoverRePlacement
CAUTION: Wear glovs to lmovo and install tho seat
covgls.
NOTE:
a Take care not to tear the seamsor damagethe seat
covels,
a Removethe cliDsas shown.
SEAT-BACK
Soat-back cover romoval:
Hatchback
1 . Removethe seat-back(see page 20-108).
2.
SEAT.BACK
COVER
ilgF]
CLIP
4.
CLIP
20-112
vnx.su
Sodan
l.
2.
Harchbacr(
1.
2.
SEAT-BACKCOVER
V : Scrowlocations,2
/+r
v ,-.,)
CEITTER
J.
CLIP
covERs
3.
CLIP
4.
covEBs
CLIPS
CLIP
lconl'dl
20-113
vnx.su
Seats
Rear Seat Cover Replacement
(cont'd)
S6dan
1 . Removethe seat cushion (see page 20-1 1 1).
)rir
ry"M
CLIP
t)
ll
ll
CLIPS
{Cover sid6}
20-1 1 4
vnx.su
Seat Belts
Front Seat Belt Replacement
cAUTloN: chock tho tlont seal belts for damage and lsplace them if necessary.
B carelul not to damag then during
romoval and installation.
F.ont seat belt romoval:
Hatchback
1.
3.
UPPERANCHOR BOLT
7/16-20 UNF
32 N.m (33 kgl.m,
24 tbt.ttl
EELTGUIDE
RETRACTORMOUNTING
BOLT
6 x 1 . Om m
9.8 N.m (1.0 kgt.rn.
7.2 tbl.ftl
RETRACTOR
LOWERANCHORBOLT
7/'16-20UNF
32 N.m 13.3 kgl.m,
24 rbf.ft)
RETRACTORBOLT
7/16-20 UNF
32 ltl.m {3.3 kgl,m,
24 tbt.ftl
{cont'd)
vnx.su
20-115
Seat Belts
FrontSeat Belt Replacement
{cont'dl
Sedan
4.
< : Screwlocation,1
I
FRONTSEATBEI.T
FRONTSEAT
BELT
II
MOUNTING
RETRACTOB
BOLT
'l.O
mm
6x
BELTHOLE
CAP
7 .2 tbt.ltl
RCTRACTOR
)
CENTERPILLAR
LOWERTRIM
3.
SLIT
RETRACTOFSOLT
7/16-20 UI{F
32 N.m {3.3 kgl.m.
24 tbf.ftl
A : Clip locations, 2
f '"
f
-1t'-
r _Ju i
l
*UPPERANCHORBOLT
7/16-20UNF
32 N.m (3.3 ksf'm, 24 lbf.ftl
_.|
ANCHORCOVER
u-.
FRONT
SEAT
BELT
8 x 1.25mm
23 N.m 12.3 kgl.m,
17 tbt.ft)
ANCHORCAP
LOWERANCHOR
BOLT
7/16-20 UNF
32 N.m (3.3 kgt.m,
24 tbt.ftl
20-116
vnx.su
3.
SEATBELT
BUCKLE
CONNECTOR
LOCK
WASHER
COLLAR
PLAIN
WASI{ER
PLAIN WASHER
LOWERA CHOR
BOLT
BEARING
lcont'd)
20-117
vnx.su
Seat Belts
(cont'd)
Front Seat Belt Replacement
Sodan
.UPPER
ANCHOR
BOLT
BEARING
WAVE WASHER
20-118
vnx.su
Removeall the anchorbolts, the retractorbolt and the retractormountingbolt, then removethe rearseat belt and
center belt.
NOTE: When removingthe ancho. bolts and the retractorbolt, use a 17 mm socket or box-endwrench.
Check that the retractorlockingmechanismfunctions as describedon page 2O-122.
MOUNTING
RETRACTOR
BOLT
6xl.Omm
9.8 N.m {'l.Okgf.m,
7 .2 tbt.ttl
UPPERANCHORBOLT
7/16-20Ul{F
32 N.m (3.3 kgt.m,
24 tbt.ft)
RETRACTOB
REAR SEAT
AELT
NETRACTORBOLT
7/16-20 UNF
32 N.m (3.3 kgl.m,
24 tbt.fr)
LOWERANCHOR BOLT
7 t16-20 UNF
32 N'm 13.3 kgf.m,
24 tbt.ftl
CENTERANCHOR BOLT
7/16-20 UNF
32 N.m {3.3 kgl m,
24 lbf.ft)
vnx.su
BUCKLE
(cont'd)
Seat Belts
(cont'd)
RearSeat Belt Replacement
Sodan
'I .
Remove:
a
a
a
.
Remove all the anchor bolts, the retractor bolt and the retractor mounting bolts, then remove the rear sat belts
and center belts.
NOTE: When removingthe anchor bolts and the retractorbolt, use a 17 mm socket or box-endwrench.
Check thst the retractorlockingmchanismtunctions as describedon page 2O-122'
ANCHORBOLT
UPPER
7/16-20UNF
32 N.tn (3.3 kgf'm, 24 lbl ft)
RETRACTOR
MOUNTING
BOLT
6 x 1 . 0m m
9.8 il.m (1.0 kgt.m,
7.2 tbt.tll
RETRACTOR
BOLT
7/16-20UNF
32 .m (3.3 kgl.m,
24 tbt.ft)
RETRACTOR
REAR SEAT
BELT
AI{CHORBOLTS
CENTER
7/16-20UNF
32 N.m (3.3 ksl'm,
LOWERANCHORBOLT
7/16-20UNF
32 N.m (3.3 kgf.m,
24 tbf.ftl
24 lbl ftl
CENTERBELTS
20-120
vnx.su
Sedan
LOCK
WASHER
ANCHOR COVER
UPPERAI{CHOR
UPPERANCHOB
BEARING
COLLAR
TOOTHED
LOCKWASHEN
COLLAR
WASHER
LOWEBAI{CHORBOLT/
ANCHORBOLT
TOOTHED
LOCKWASHER
{Sedanl
/
J
l-n(
l$t".,-,fu
tYlf-\ u tY
\
TOOTHED
LOCKWASHER
b'ryd
TOOTHEO
LOCK WASHER
20-121
vnx.su
Seat Belts
lnspection
Retractol InsDection
1. Beforeinstallingthe retractor,check that the seat
belt can be pulledout freely.
2.
Rear:
RETRACTOR
3.
RETRACTOB
Forwald
removethe anchor
on the anchorbolts.lf necessary,
boltsandcheckthat the washersand otherpans are
not damagedor improperlyinstalled.
Rear:
Forward
Sedan
Front:
Forward
lnsido
20-122
vnx.su
TOOTHEDWASHER
NOTE:
a Do not removethe toothed washer from the child
seatanchorplate.Usethe childseatanchorplate
with the toothed washer attachedto it.
a When installinga childseat on the rearseat, follow the intructionsof the manufacturerof the
child seat,
a Additionalanchor platesare available.
ATTACHMENT POINTS
Sedan
NOTE: Removethe plug covers from the attachment points of the rear shelf (Canada).
Use a razor bladeor sharp knife to carefullycut a
1 inch diametercircleat the locationof the attachment point (USAI.
IOO mm
265 mm 13.94inl
( 1 0 . 4i n l
REAR SHELF
20-123
vnx.su
Garpet
Replacement
SRS wire harnessesare routed near the carpet.
1.
Remove:
Hatchback
CAUTION:
a All SRS slectrical wiring harnssosal covorod
with yollow insulation.
a Belore disconncting 8ny patt of th SRS wite
harness,connoct th short connectors {see pago
20-2721.
a ReDlacethe ntire affected SRS halnsa assambly if it has an opan cilcuit or damaged wiring.
a
a
a
a
a
a
a
.
a
a
Sedsn
ORIVER'SAIRBAG
a
a
a
a
a
a
a
a
o
2.
Removethe footrest.
V : Bolt locatios,2
6 x 1 . Om m
9.8 N.m {'l.o
7 .2 tbt.ftl
FOOTREST
20-124
vnx.su
V : Clip locatlons
AV : Clip, 2
------l.l\-\\\).\\\1,
| /rryz)'
C < : C l i p ,1
| ru4l
O > : C t 9 .r
rA
l_ w_)
MW
i -) _)I W I
: Push nut locations, 2
DOORSILL MOLDING
Sedan
A : Clip location3,
''*'N*
<l\lt.felt
EI
w /
CARPET I
I
I
I
{ NUr I
":-/
FRONTDOOR
SILL MOLDII{G
20-125
vnx.su
Carpet
(cont'd)
Replacement
4.
6.
PARKINGBRAKE
CARPET
Cut here.
7.
V : Bolt locatlona
B > : B o l t ,1
AV : Boll, 4
s x 1.2smm I
22 N.m
12.2ksf m,
16 tbt.ftl
I
I
/,/
l:?'o'!"t
C> : goli, 2
6 x 1.0 ftm
9.8Nm
11.0kst'm,
I
I
i
'1Y"!_/
SRS MAIN
20-126
vnx.su
6x1.Omm
9.8 N'm tl.O kgl m,
-'/
I
I
8.
V : Cllp loc6tions
AV : Clip, 3
B > : C l i p ,1
:ft
r,,-,
FASTENERS
Hatchback
FASTENERS
CARPET
CARPET
Ssdan
-3) Align the carpet with the fastener, then
pressthe carpet down securely.
FASTENERS
FASTENER
REARCONSOLE
BRACKET
CARPET
SILL MOLDING
SILL MOLDING
NOTE:
a Take care not to damage,wrinkle or twist the
carpet.
a Make sure the seat harnessis routed correctly.
a Slip the slits in the carpetover the rear console
bracket.
REARCONSOLE
BRACKET
Cut otf.
WIRETIE
SLIT
a lf necessary,replaceany damagedclips.
20-127
vnx.su
Frontand RearConsoles
Replacement
SRS wire harnessesare routed near the front console.
CAUTION:
a All SFS electrical wiring harnessesaro coverod
with y6llow insulalion.
a Betore disconnecting any part of lho SRS wire
harness,connect th short connoctorc (so pago
20-272t.
a Replacotho sntilo aftocted SRS halness assombly it it has an opon circuit or damaged wlring.
NOTE: Take care not to scratch the tront and rear consoles,and dashboard.
1.
Removethe accesscap.
CAUTION: liYhenprying with a flat tip scrwd.lvr,
wrap it with protoctivo tape to provent damag.
ACCESSCAP
FBONT
PASSENGER'SAIRBAG
2.
v : Scraw loctlona
At : Scr.w, 2
E)
20-128
vnx.su
Bv : Scrow, 2
w)
5.
NOTE:
a Lift up the parking brake lever.
a Oetach the hooks by lifting the front ot the rear
consoleand slidingit rearward.
A : Cllp,hook loc.tions
AA : Clip,2
BA : Cllp,2
CA : Hook,2
SHIFTI.EVER
KNOB
CONSOLEPANEL
IM/TI
TRIM RI'{G
\ r
"onroar
,"Hr"tz{o$
co soLE
4.
SELECTER
POStTtON LEVEB
INDICATOR
PANEL
Removethe screws.
> : Screwlocationr,4
6bo''
I
: . /
20-129
vnx.su
8.
NOTE: Wrsp the selecterlever and A/T gear position indicator psnel with a shop towel to prevent
damage.
: Scrowlocations,5
A
i
_Y_)
CONSOLEPANEL (MTI
SHIFT LEVER
BOOT (M/TI
CONSOLE
: Scraw locations, I
A
I
Y,/
ARMREST
REAR CONSOLE
PARKINGBRAKE
COVER
COVERSET
PLATE
cof{solE Box
9.
20-130
vnx.su
Dashboard
Component Removal/lnstallation
SRSwire harnessesare routednear the dashboardand
steeringcolumn.
CAUTION:
a All SRS olectrical wiring harnessesar6 covolod
with yallow insulation.
a Betoro disconnecting any paft ot th6 SRS wiro
harnss,connoct th shoi connectots (s66page
23-2721.
a Replacoth entire Itlocted SRS hsrness asaembly il h has an open circuh or damagod wiring.
2.
Remove the screws and detach the cliDs, then remove the instrumentpanel.
3.
4.
Removethe screws and detach the clips, then remove the dashboardlower cover.
Disconnectthe connector.
: Scraw
location3, 5
A
\ g
A i Clip locationg
AA: Cllp, 2
_:n
,,4<
-ft
B> : Clip, 2
I
|
,-__-,
l-l
L'l
itrvi
) 4Z)
INSTRUMENTPAI{EL
COIN POCKET
(cont'd)
20-131
vnx.su
Dashboard
Component Removal/lnstallation(cont'dl
5.
fi
CONNECTOR
6rt.omm
i Bolt locations. 2
6 x 1.0 mm
9.8 N.m {1.0kgl.m,
6 i;i'i#.,
7.2 tbr.ftl
CASSETTE
KNEE
6.
3,
HAZARD WARNING
swtTcH
20-132
vnx.su
REARWINOOW
DEFOGGERSWITCH
4.
Removethe screws.
Detachthe harnessclip and connectorclip.
> : Screwlocations,2
HEATER
CONTROI
PANEL
7,
CONNECTORCLIP
HEATERCONTROL
(cont'd)
20-133
vnx.su
Dashboard
(cont'd
ComponentRemoval/lnstallation
Side air vent .emoval:
Front passsngr's
Drivsi's
A : Clip,hook locationg
AA : Clip, 1
BV : Hook, 2
Hi
MOONROOF
swrTcH
1.''
CONI{ECTOR
11,/
SIDE AIR
VENT
SIDE AIR
VENT
PROTECTIVE
TAPE
3,
I
o@)
A< : Clip, 1
BV : Hook, 3
B A: Hook, 1
PROTECTIVE
SIDEAIR
VENT
4.
20-134
vnx.su
Clock rsmoval:
4.
CLOCK
B
\
: Scrow, 2
'
o
\ +t ] ! } l l aE l l
CONNECTOR
__,/
*'
,/
tl
@
2.
3.
5.
: Bolt, scr6wlocstions
A
: Bolt, 2
B < : S c r o w 1,
6)P)
20-135
vnx.su
Dashboard
Precautions
Replacement
2 . lnstallthe short connectors(RED)
Ddvar's:
Removethe accesspanel,then disconnectthe connector betweenthe cable reel and driver's airbag'
Connectthe short connector(RED)to the driver's
airbag connector lsee page 23-27 2l'
CAUTION:
a Alt SRS olectrical wiling harnesssale covorad
with Yollow insulation.
a Botore disconnecting any part ot the SRS wiro
harness,connect ths short connscto6 (seepage
23-2721.
a Roplac6ih entiro aflectod SRS halnoss assembly il it has an opon cilcuit or damagod wiling'
DRIVER'SAIRBAG
CABLEREEL
CONNECTOR
DRIVER'S
AIRBAG CONNECTOB
DRIVER'SAIREAG
SHORT
CONNECTOR
(RED)
ACCESSPAI{EL
Front passongor's:
Removethe glove box {seepage20-135},then disconnect the connector between the tront pas'
senger'sairbagand SRSmainharness Connectthe
short connector(RED)to the front passenger'sairbag connector(seePage 23-273).
SRS UNIT
LEFT DASH
SENSOR
FROf{T PASSENGER'S
AIRBAG
FRONT PASSET{GER'S
AIRBAG CONNECTON
20-136
vnx.su
SHORT
CONNECTOR
(REDI
Replacement
To removethe dashboard,first removethe:
a
a
a
a
a
.
a
a
3.
FRONTPASSENGER'S
: Bolt, 2
8 x 1 . 2 5m m
22 N-m 12.2ksl.m,
16 lbt.frl
: u t ,2
8 x 1.25mm
gill$"'l
FRONTPASSENGER'S
AIRBAG BRACKET
SRS MAIN
HARNESS
4.
STEERINGCOLUMN
CONNECTORS
(cont'dl
20-137
vnx.su
Dashboard
(cont'd)
Replacement
8 . Remove the bolts, then lift and remove the
Disconnectthe antennalead.
5.
dashboard.
CAUTION: Use protoctive tspe on the bottom ol tha
lront tillar trim;
NOTE:
a Take care not to scratchthe dashboard.
a To prevent damageto the shift lever (M/T) or
selecter lever and A/T gear position indicator
panel (A/T), wrap them with a shop towel.
V : Bolt locations,6
6.
6 x 1 . 0m m
9.8 N.m (1.0 kgt'm, I
7.2 tbt.ftt
____/
PROTECTIVE
CONNECTOR
(A/T only)
CONNECTORS
SHOPTOWEL
accEss
PANEL
HooK\
lcCesS Plnel /
___E--
ffiL
9.
RE=-cLrP
20-138
vnx.su
Bumpers
Front Bumper Replacement
NOTE:
a An assistantis helpfulwhen removingthe front bumper and lront bumper beam.
a Take care not to scratchthe front bumper.
a Open the hood.
3.
V : Bolt locations
: Clip locadrn., 2
A A
B V : B o l r ,2
A V : B o h ,I
+Et=
-+EP_
CONNECTORS
FNONTTURN
SIGNAL LIGHT
2.
FRONTBUMPER
: Scrow, 2
: Scr6w locations
A
NOTE: lf necessary,disassemble
the tront bumper.
8>: Bolr5
,
C V : B o l r I,
D < : S c r e w8,
q-l -ry-l_9, =g
BA: Scrow, 2
_A_,
__s_,
A : Clip locarions
AA : Clip, 2
/H\
-<L9'a-
BA : Ctip,4
i
I
/
FRONT
BUMPERr
{-r-*=\
__tr:i!uF&,
FRONTTURN
SIGNALLIGHT
HOLOER
nolt
Et2"
'l-eo
sroe
stoE
SEAL
CLIPS
fr:**M
INNERFEl{DER
BUMPER
LOWERBUMPER
20-139
vnx.su
Bumpers
Front Bumper RePlacement(cont'd)
4.
NOTE:
o Installthe holesin the front bumperbeamover
the hookson the bodY.
: Eolt locotions. 4
of the removalprocedure.
is the reverse
Installation
rcr
8 r 1.25mm
FRONTBUMPERBEAM
FrBo*sidor
HOLE
(Frontbumperbamsidel
FRONT
BUMPER
ABSORBER
20-140
vnx.su
4.
Hatchback
1.
: Scrow I
A
A\
REARBUMPER
REARBUMPER
5.
Openthe hatch, then removethe reartrim panel (see
page 20-921-
J.
: Scrw,4
/\
--E-
6x1.OmmI
Q) i;L'i$-.l
_':'y:) ,/
LEFTS|DE
B <: Sc.ow,4
@ s l
I
V: Cliplocations,
_ ' /
BIGHTSIDE
TRIM PANEL
.--r-Fl^
--lEr_\"., J
LICENSEPI-ATE
LIGHT HARNESS
L|CENSEPLATELtcHT
REARBUMPER
(cont'd)
20-141
vnx.su
Bumpers
(cont'dl
RearBumperReplacement
6.
Sadan
y: Boltlocalions,
4
: Sciow locations,2
I
1 2x 1 . 2 5m m
64Nm{65kgfm,I
* "r:,
)
ACCESSCAP
REARBUMPER
2.
3.
v: Cllploc.tions,5
\\rLlF/d,rft
#.,1
2
: 8ok locations,
6 x 1.0mm I
9 . 8N . m
l 1 . Ok g l m ,
7.2 rbr.ft)
REAREUMPER
BEAM
BEAM
EUMPER
GUSSET
lnstallationis the reverseof the removalprcedure.
NOTE: Make surethe licenseplate light connector
is connected,and the grommetis installedproperly,
GBOMMET
20-142
vnx.su
i
I
J
4.
5.
V i Bolt locatlons,4
12 x 1.25mm
64 .m (6.5 kgf. m ,
47 tbt.ftl
6.
I
j
)
REARBUMPER
REAR BUMPER
BEAM
BUMPERBEAM
GUSSET
20-143
vnx.su
Hood
Replacement
NOTE:
a An assistantis helplul when removingthe hood.
a Take care not to damagethe hood and body.
a When removingthe clips, use a clip remover.
a Open the hood.
1. It necessary,removethe hood edge protector.
I3;;,iH"-,,.,
I
.rtor"t
j
: Cliploc.tions,16
- )
HOOD HINGE
HOODEDGE
PROTECTOR
\
HOOD
2.
6x1.0mm
9.8 N'm
{l.O kgl m,
7.2 lbl.fr)
n
r)
HOOD
20-144
vnx.su
Adjustment
NOTE: Beforeadjustingthe hood, looseneach bolt slightly.
1. Adjust the hood hingesright and left as well as tore and att by using the elongatedholes.
2.
Turn the hood edge cushions,as necessary,to make the hood lit flush with the body at front and side edges.
3.
Adjust the hood latch to obtain the proper height at the forward edge.
NOTE: Move the hood latch right or left until the striker
is centeredin the hood latch, as shown.
HOOD LATCH
HOOD LATCH
6 r 1 . om m
4.
20-145
vnx.su
Hatch
Replacement
NOTE:
a An assistantis helpfulwhen removingthe hatch.
a Take care not to damagethe hatch and body.
a Take care not to scratchthe hatch sidetrims and hatch
tnm paner.
a Open the hatch.
a Removethe high mount brakelight {seesection23).
1.
HATCH
3.
4.
: Speclal bolt
locetlons,2
A
2.
A : Clip localions
::::/
l
)
BV : Clip, 3
W',dtri
R@t
@ ,/l ' L,/
AA : Clip, 11
BA: CliP,6
HATCI{
WIRE I{ARNESSES
_:_/
CONNECTORS
CONNECTOR
WIRE
HARNESS
5.
20-146
vnx.su
o.
NOTE:
a lf necessary,replacethe supportstrut.
a When scrappingthe suppon $rut, dispose ir as
describedon page 20-149.
I x 1 . 2 5m m
22Nm
12,2kgt'm,
16 tbt.ftl
SUPPORT
STRUT
9.
a : Nut locations,4
12.2kgl.m, I
HATCH
HINGE
HATCH
,6'y!:t ,/
HATCH
20-147
vnx.su
Hatch
Adjustment
NOTE:
a Beforead,usting
the hatch.looseneachbolt andnut slightly.
a Do not installthe suDDort
struts.
1 . Adjust the hatch hingesright and left as well as fore and aft by using the elongatedholes.
Turn the hatch edge cushions,as necessary.to make the hatch tit flush with the body at each side.
Adjust the hatch fit to the hatch openingby moving the striker,
4.
Use shims, as necessary,to make the hatch tit flush with the body at the rear edge.
HATCH
8 x 1.25mm
HATCH
EDGECUSHION
HATCH
+Q.
6x1.0mm
9.8 N m (1.0 kgl m,
7 .2 tbt.trl
5.
vnx.su
Trunk Lid
SupportStrut Disposal
Replacement
NOTE:
a An assistantis helpfulwhen removingthe trunk lid.
a Take care not to damagethe t.unk lid and body.
a Open the trunk lid.
Placethe support strut on a level surface with its rod extended,and drilla hole 2-3 mm (3/32"1diameterin the
body to releasethe gas.
1.
Disconnectthe connectorsand trunk lid openercable.Removethe wire harnessandt.unk lid opnercable from the trunk lid.
NOTE: Before pullingout the wire harness,tie a
stringto the end ot it so you can pull it backin when
the trunk lid is reinstalled.
B< : Clip, 1
CA : Clip, 5
e-i
20 mm (O.79inl
_rP
,/
WIRE HARNESS
TRUNKLID
OPENR
CABLE
CONNECTOR
CONIIECTOR
TRUNKLID
LATCH
{seepage20-157}
SUPPORTSTRUT
TRUNK LIO
OPENER
CABLE
A
A
(cont'd)
20-149
vnx.su
Trunk Lid
(cont'dl
Replacement
2.
V : Bolt locaitons,4
TRUNKLID
4.
NOTE:
a Removethe rearshelf{seepage20-95).
a Removethe torsionbarswith the torsionbar assembly tool.
TRUNKLID
HINGE
O =NormalPosition
O = Highertension
TORSION8AB
ASSEMBLYTOOL
20-150
vnx.su
Adjustment
NOTE: Beto.e adjustingthe trunk lid, looseneach bolt slightly.
1. Adjust the trunk lid hingesright and left as well as fore and aft by using rhe etongatedholes.
2.
Turnthe trunk lid edgecushions,as necessary,to makethe trunk lid fit flush with the body at the rearand sideedges.
3.
Adjust the lit betweenthe trunk lid and the trunk lid openingby moving the striker.
TRUNKLID EDGE
CUSHION
/21
ft(M
Y4Y
TRUNK LID
HINGE
TRUNI(LID
6r1.Omm
9.8 N.m 11.0 ksl m, 7.2 lbt'ft|
6 x '1.0mrn
9.8 N m 11.0 lo,f.m,
7.2 tbt.hl
STRIKER
STRIKER
4.
20-151
vnx.su
OpenerCables
Replacement
NOTE:
a Whenremoving
the clips,usea clip remover.
a Takecarenot to bendthe openercables.
HOODOPENER
CABLE
Av:CllP,5
M)
Bv:Clip.6
E \ I
:=r
,/
____lEt-
HOODRELEASE
HAI{DLE
(sepage20-154)
Otr" I
:_
_)
HOOD LATCH
(seepage 20"154)
-\-
INNER FENDER
8A : Clip,
2 ,
CA : CliP,
7 ,
DD : Cllp,
1 ,
Etr : Cllp,
I ,
FA : Cllp,
GA : Clip,
HA : C.bl6 cushlon, 5
HATCH LATCH
lsee page 2O-156)
Loft 3ido:
HATCH
OPENERCABLE
HATCH
LID
HATCH/FUEL
OPENER
{seepage2O-'l54)
20-152
vnx.su
BV:Clip,2
C A: Clip,,t
D >: Clip,3
E A r C l l p ,1
ws@:ffi;6,1
7--
TRUITIKLID LAICH
(sep6ge20-157)
FUEL LID
OPENER
{se6page 20-155)
FUEI.LID LATCH
(soopago20_'|55)
Installationis the reverseof the removalorocedure.
NOTE:
a Make sure each openercable is routed and connectedproperly.
a Make sure the hood, hatch. trunk lid and fuel lid open properlt.
20-153
vnx.su
Openerand Latch
Replacement
NOTE: Take care not to bend the openercables.
Hood Latch:
Hood RelsaseHandle:
6 x 'l.O mm
9.8Nm
1 1 . 0k g l m ,
7 .2 tbt ftl
HOODOPENER
CABLE
(seepage20'152)
HANDLE
,/
HOOD
LATCH
HOOD RELEASE
HANOLE
Removethe kick
panel (seepage
20-91).
HOOD
LATCH
HOOD
OPENER
CABLE
I
Hatch/FuelLid OpenerlHatchback):
< : Bolt, sclow locations
A<rBolt.2
HATCHiFUELLID
OPENER
the
6 x 1.0 mm
9.8 N m 11.0kgl'm,
7.2 tbl.fr)
OPENER
COVER
BV:Sc.sw, 1
6'\ I
v l
/
FUEL LID
OPENERCAELE
HATCH
OPENERCABLE
(seepage 20-152)
20-154
vnx.su
J't
o
@
t-
OPENER
COVER
A<:Bolr,2
OPENERLOCK
CYLINDER
*rr*@
6 r 1 . 0m m
9 . 8 N m 1 1 . Ok g l m ,
TRUNKLID/FUEL
LID OPENER
B V: Scrow, 1
A
-}{H.
II
_:_)
()t
FUELLID
OPNERCABLE
(seopage 2O-153)
TRUNKLID
OPENER
CABLE
(seepage20-153)
9 . 8 N m 1 1 . 0k s l ' m , i
7 '2 tbt'''l
------,//
FUELLIDOPNER
CAALE
( s e ep a g e s2 0 - 1 5 2 1, 5 3 )
FUEL LIO LATCH
Removethe fuel lid latch
by turning it 90o.
FUEL LID
LIO LATCH
Hatchbock: Remove the rear shelf and rear trim oanel.
then pull the rear edge ot the lett side
trim panelback (soepage 2O-91).
Sodan:Removethe rear trim panel,
then pull the rear edge of the left trunk side
panelback {seepage 2O-971.
20-155
vnx.su
2.
4.
HATCH LATCH
5.
CYLINDERROD
3.
^
{-D m
6x1.omm
I
s . e N m ( 1 . 0k s l m ,
,?tb:tn
__/
o.
HATCH LATCH
20-156
vnx.su
4.
l.
CLIP
Disconnect
the connectorand trunk lid openercable.
CONNECTOR
LID
CABLE
LOCKCYLINDER
COVER
CLIPS
5.
2.
Disconnectthe cylinderrod.
F 6xl.Omm
q;i!!"jy
LOCK
CYLINDER
CYLINDER
ROD
A : Bolt locations,3
6.
./,.,
,/'e4
20-157
vnx.su
Retainersand WeatherstriP
Replacement
CAUTION: Wear gloves to lemov and install tho itainrs'
NOTE: Take care not to bend the retarners.
< : Screwlocalions,19
!9
REAR CLIP
.\
!:
RETAINER
q
l{
SHOPTOWEL
CENTERPILLAR
MOLDING
WEATHERSTRIP
I
CENTERPILI-AR
MOLDING
NOTE: The numbers atter the part names
show the quantities ot the parts used
WEATHERSTRIP
RETAINER
20-158
vnx.su
Hatch Spoiler
WheelhouseProtector
Replacement
Replacement
2.
: Nut locations,4
6 x 1 . 0m m
Ch 9.8 N.m
(J
(1.0 ksl m,
__.
7,4b1!t
I
,/
coI{t{EcroR
ADHESIVE
3.
FENDERWELL
TRIM
20-159
vnx.su
ALIGNMENT MARK
ff6llowl
HATCH
WEATHERSTRIP
MAE(
ALIGI{MENT
(Whitol
TRUNKLID
WEATHERSTRIP
HATCH/TRUNKLID
WEATHERSTRIP
When installingthe hatchor ttunk lid weatherstrip.align
it with the alignmentmark on the hatch or trunk lid
openrng.
NOTE:
a Make surethere are no wrinklesin the weatherstrip.
a Check tor water leaks.
ALIGNMET{'
MARK
Forward
vnx.su
Roof Molding
Replacement
CAUTION: When prying with I flat tlp scrowddvr, wrap
it with protoctivo tapo to pravent damag6.
SIDEMOLOII{G
BRACKET
4.
Installation
is the reverse
of the removalorocedure.
NOTE:
a Takecare not to damagethe windshieldside
ROOF MOLDING
molding.
a Make sure the roof molding is installed securely.
R(X)F MOLDING
PIN
{Body ddq)
ROOF MOLDING
20-161
vnx.su
Dv: Cliplsodan,1)
STEEL
CLIP
Hatchbsck
l r >
r9
O '
NOTE:
a BeJoreinstatlingthe rear door molding,
scrapethe adhesivetape from the molding and body.
a Cleanthe motdingand door bondingsurJaceswith a spongedampenedin alcohol'
a Atter cleaning,keepoil, greaseand water
Jrom getting on the surface.
a Gluethe new adhesivetape to the molding as shown.
30mm
6mm
ls 2f 61 . t.l.18inl
REAR DOOR
MOLDING
30 mm
( 1 . 1 8i n l
lnstallationis the reverseoJ the removalProcedure.
NEW ADHESIVETAPE
Thicknoss:1.2 mm lo.o5 inl
20-162
vnx.su
Forward
q,
BA : Clip (Harchback,7)
{sodan,7l
SIDECLIP
Removethe side clips from rhe body
by turning them 45o
Hatchback
\y':
FENDER
NOTE:
a Take care not to twist the side sill panet.
a lf necessary,replaceany damagedside and lower
clips,
20-163
vnx.su
RearEmblems
lnstallation
Align the applicaliontape with the rearturn signallight and the gap betweenthe taillightand
tape'
the emblem into place. Removethe applicataon
NOTE:
a Beforeapplying,clean the body surlace with a spongedampenedin alcohol'
a After cleaning,keep oil, greaseand water from getting on the surface'
a When applying,make sure there are no wrinklesin the emblem'
Attachment Point:
REARTURN
SIGNALLIGHT
Hatchback
REARTURN
SIGNAL LIGHT
!---_-----------,-i-J
TAILLIGHT
20-164
vnx.su
Sub-frame
Sub-t.ame Torque Sequence:
cAUTloN: After rooseningtho rsar beam mounting borts be sura to repracothom with new onea.
6 x 'l.O mm
9,8 N.m (1.0 kgt.rn,
7.2 tbt-fll
REABBEAM BBACE
1 0 x 1 . 2 5m m
44 N.m {4.5 kgt.m,
33 rbr.ftl
FEAR BEAM
COLLAR
REAR BEAM
REARBEAM
14 x 1.5 mm
89 tt.m (9.1 kst.m,
66 lbf.ftl
Beplace.
20-165
vnx.su
FrameRepairGhart
-!
ar"tr*,,,ua
\
Model
Dls6ft-\
M/T
514.5
120.261
5 0 1. 5
(19.7)
U-)
2.5
(0.10)
25
{o.98)
(J
\---!e!s!
Distance
{10.53) 112.03)
Sedan
2150
2100
(84.6t
lE2.71
2642
2632
{103.6) {105.6}
J5
2 6 11
(102.8)
2657
2607
(102.6) (104.6)
t22.Ol
(104.8)
674
(26.5)
B A S EL I N E
d11.5
I cir (o-36;E;\ry+
Poinr
d l 1 . 5t O _
011.5
c r 1 . 5( 0 .
Aoad
9rl
lv
20-166
vnx.su
POINT w
d 2 5 l l . o l L o c a r eH o l e g
20-167
vnx.su
. . . . . . . .2 1 - 1
..22-1
RESTRAINTSYSTEM{SRS}
SUPPLEMENTAL
The IntegraSRS includesa driver'sairbag,locatedin the steeringwheel hub. In addition.all modelsexcept the
RS model for Canadahave a front passenge.'sairbaglocatedin the dashboardabove the glovs box. Information
necessaryto safely servicethe SRSis includedin this ServiceManual.ltems msrkd with an asterisk(') on the
conlents page include,or are locatednear, SRS components.Servicing,disassemblingor,eplacing thes items
will requirespecialprecautionsand tools, and shouldthereforebe done by an authorizedAcura dealer.
a To avoid r6nd6dng tho SRS inoporativo. which could lead to personal injury or dealh in tho svont ot a sevele
frontal collision, all SRS servica work musl b portormed by an authorized Acura dealer.
a lmpropor sorvico procaduro3,including incorrect romoval and installatlon of tho SRS,could load to porsonaliniury causod by uninlonlional activation of tho ailbag8.
a All SRS eloctdcal widng harnossosare covored with yollow in3ulation. Relatsd compononts a.o locatod in tha
stsering column, flont console, daehboard,and dashboafd low6r pan6l, and in lhe dsshboa.d above lh glove
box. Do not uao electdcal tost equipmont on theae circuhs.
NOTE: The originalradiohas a coded theft protectioncircuit. Be sureto get the customer'scode numberbeto.e
- disconnecting the battery.
- removingthe No. 32 (7.5 A) luse from the under-hoodfuse/relaybox.
- removingthe radio.
"CODE" is displayed,enter the cusAfter service,reconnectpower to the radioand turn it on. When the word
tomer's 5-digit code to restore radio operation.
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Heater
l f l u s t r a t eIdn d e x . . . . . . . . . . . . .
.........21-2
HeaterDoor Positions
.........,..,.21-3
C i r c u i tD i a g r a m
. . . . . . . . . . . . . . . . . . . .2. .1.- 6
Troubleshooting
S y m p t o mC h a r t . . . . . . . . . . . . .
......21-8
Flowcharts
B l o w e rM o t o rS p e e d. . . . . . . . . . . . . . . . . . . . . . . . . . 2. .1. -. .9
B f o w e rM o t o r
. . . . . . . . . , . . , , , , ,2. 1
. -11
M o d eC o n t r o M
l o t o . . . . . . . . . . ...... . . . . . . . . . . . . . .2. 1. - 1 4
Recircufation
ControlMotor ......,...,.,,,.,....
21 -17
Heater Control PanelInput/
O u t p u tS i g n a l s
..............21-19
Blower Unit
Repfacoment
. . . . . . . . . . . . . . . . . . . .2. .1.- 2 0
Overhaul
.......21-21
+HeaterUnit
Repfacement
. . . . . . . . . . . . . . . . . . . .2. .1. - 2 2
Overhaul
.......21-24
DefrosterDoor Adjustment ...,.............
......,, 21 -25
Heatel Control Panel
Repfacoment
. . . . . . . . . . . . . . . . . . . .2. .1. - 2 5
Overhaul
.......21-26
Heater Valve Cable
Adjustment
...21-27
Air Mix Control Cable
Adjustment
... 21-27
Mode Control Motol
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1.-. 2 e
Repfacement
. . , . . . . . . . . . . . . . . , , ,2, .1. - 2 8
Recirculation Control Motor
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1. -. 2 9
Repfacement
. . . . . . . . . . . . . . . . . . . .2. .1. - 2 9
Relay
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1. -. 3 0
Heater Fan Switch
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1.-. 3 0
Mode Control Switch
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1. -. 3 1
Recilculation Control Switch
T e s t. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .2. .1.-.3 1
*: Read SRS precautionsbefore working in this area.
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lllustratedIndex
CAUTION:
a All SRS electrical wiling harnessesare covered with
yllow insulation.
a Bafore disconnecting any pan of the SRS wile harness. connect the sholt connectorlsl.
a Replacethe sntire aflected SRS halness assembly if
it has an open circuit or damaged wiring.
NOTE: The originalradio has a coded thelt protection
circuit. Be sure to get the customer'scode numberbefore
- disconnectingthe battery.
- removingthe No. 32 (7.5 Al fuse lrom the underhood fuse/relavbox.
- removingthe radio.
After service,reconnectpower to the radio and turn it
"CODE" is displayed,enterthe cuson. when the word
5-digit
code
to restoreradio operation.
tomer's
BLOWERUNIT
Replacement,page 21-2O
O v e r h a u lp, a g e2 1 - 2 1
I{EATERVAIVE CABLE
Adjustment,page21-27
HEATERUNIT
page2l 22
Repfacement,
page21-24
Overhaul,
RECIRCULATIONCONTROLMOTOR
Test, page 21-29
Replacement,page 21 29
BLOWENRESISTOR
Test, page 21-9
W,
a/c swrTcH
(wirh A/cl
Test,page22-20
RECIRCULATION
CONTROLSWITCH
T e s t ,p a g e2 1 - 3 1
HEATERFAN
swtTcH
Test, page 2'l-3O
MODE CONTROLMOTOR
Test, page 21-28
Repfacement,page 21'28
MODE CONTROLSWITCH
T e s t ,p a g e2 1 ' 3 1
HEATERCONTROLPANEL
Repfacement, page 21 -25
Overhaul,page 21-26
TEMPERATURECONTROL
LEVER
(Adjustmonl: See AIR MIX
CONTROLCABLE}
21-2
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*)
xor
fr
coor.
VENTOOOR
-*)
(HEAT/VENTI
(cont'd)
21-3
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\)
IHEATI
El
IHEAT/DEF)
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CircuitDiagram
- OASH
UiIDEN
FUSE/RETAY
8OX
- HOOO
FUSE/REI.AY
8OX
UNOER
(7.5A1
N0.13
WtlT/BtK.+WtfT
RECIRCUI.ATION
Moron
coMTBor-
nrot
G401
21-6
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UGHTIG
swtTcH
RED/BI.K
I r . l .
| |
I
r t , /
I t v
A . t t A _
l t I
I
, f r r , /
I r v
A- l_t r r A- l.
|
, / t t
f
I r v
A
- f_ r r A- l.
| |
, f t t , /
I r v
A
- l -r l
, f I
HEATER
CONTROL
PANEI.
OASHIIGTTTS
EnrGFr ESS
coNTROU.IT
21-7
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Troubleshooting
Symptom Chart
NOTE: Check the enginecoolant level and allow the engineto warm up before troubleshooting.
REMEDY
SYMPTOM
Hot air flow is low.
F o l l o wt h e f l o w c h a r t( s e ep a g e2 l - l 1 l
Mode control motor does not run, or one or more modes are Follow the flowchart (see page 21-14).
inooerative.
Recirculationcontrol door does not changebetween FRESH Follow the flowchart (see page 21- 17).
and RECIRCULATE.
21-A
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-l
|t|
To pago 21-1O
\\
\
lI
iii
I!i
Measurethe rosistancebetwoen
the No. 2 and No. 4 terminalsoI
the blowr resistor.
T o p a g e2 1 - 1 0
(cont'd)
21-9
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Troubleshooting
Blower Motor Speed (cont'd)
From page 21-9
Iilil
-l
BLU/U,HT
Checkeach wire for continuitybetween the heater tan switch 6P
connector and body ground.
. BLU wire
. BLUMHT wire
. BLU/YELwke
. BLU/BLKwire
!\i
Bopair shon in the wir6{s} blwon lho heatot lan switch rnd
th6 blowor ro3bto?.
21-10
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--
BlowerMotor
Blowor motor doos noi iun at all.
To page 21-12
"uf"'\'
{-}.
,)
T o p a g e2 l - 1 3
(cont'dl
21-11
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Troubleshooting
Blower Motor (cont'dl
F r o mp a g e2 1 - 1 1
BLU/BLK{+ }
Turn the ignition switch OFF.
21-12
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Troubleshooting
Mode ControlMotor
Modo control motor dooa not nm,
or ono oa moto modo arc In_
oporgtivo.
To page 21-15
21-14
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Roprir any .hort in th. wlrol!) b.tworn tha moda control anotot
and tha holtar control pan6l.
Checkthe samewires lor vohage.
To psg6 2'l - 16
lconl'dl
21-15
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Troubleshooting
Mode Control Motor (cont'd)
View from wire side
From page 21-'l 5
21-16
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yEL
RecirculationControlMotor
Rocirculation control doo. dooa
not chsng botwoon FRESH6nd
RECIRCULATE.
ffi
T o p a g e2 1 - 1 8
{cont'd)
21-r7
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Troubleshooting
RecirculationControl Motor (cont'd)
F r o mp a g e2 1 - l 7
ls the recirculationcontrol
motor OK?
Removethe recirculationcontrol
motor (see pag. 21-291.
Do the recirculation
control linkage and door
move smoothly?
Ropalrtho ioclrculatioo
conirol linkaga ot dool.
No. 5 GRN/RED
o. 6 GRI{MHT
View from wire side
Check for continuity in the
GRNMHT and GRN/REDwires
between the recirculationcontrol
motor 6nd body ground.
21-18
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ffii
HeaterControlPanelInput/OutputSignals
BLU/WHT
Signsl
N o . Wire Color
HEAT
INPUT
YEL
I{EAT/DEF
INPUT
YEL/BLU
DEF
BLK
GROUND
GRN/RED
RECIRCULATE
GRN/WHT
YEL/RED
2
4
Si9n8l
GRN/YEL
HEATA/ENT
INPUT
RED/BLK COMBINATION
LIGHTSWITCH INPUT
INPUT 1 0
RED
BRIGHTNESS
CONTROLLER OUTPUT
OUTPUT 1 1 BLU/RED
A/C THERMOSTAT
INPUT
INPUT
12
FRESH
INPUT
1?
VENT
INPUT
't4
GRN
HEATERFAN SWITCH
OUTPUT
BLK/YEL
tG2
INPUT
21-19
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Blower Unit
Replacement
NOTE: The blower motor, recirculation control motor
and blower resistor can be replaced without lemoving
t h e b l o w e ru n i t ( s e ep a g e2 l - 2 1 ) .
1.
2.
CLIPS
6 x I
9.8 .ft 11.Okgt.m,
7.2 tbt.ftl
GLOVE BOX FRAME
4.
HEATERDUCT
6 x 1 . Om m
9.8 N'm (1.0 kgf'm.
7.2 tbt.ftl
6.
21-20
--
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Overhaul
NOTE:
' Before reassembly, make sure that the recirculation control door and linkage
move smoothly without binding.
' When teattaching the recirculationcontrol motor, make sure its positioning
will not allow the recirculationcontrotdoo.
to be pulled too fat. Attach the recirculationcontrol motor and 8ll links, then connect power
and ground, and watch
the movement ol the reci.culation control door.
m
BLOWERRESISTOR
Test. pags 2l-9
21-21
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HeaterUnit
Replacement
CAUTION:
a All SRS electrical witing hame$os are covoed wlth
yollow insulation.
a Before disconnecting any patt of tho SRS wito harneas, connect tha shott connoctol(s|.
a Roplacoth enlire sffacted SRS harnosr a$smbly if
it has an opon cilcult or dsmaged wiring.
3.
HEATERHOSES
4.
21-22
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5.
9.
7.
8 x 1,26 mln
PASSEIVGER'S
SRSEEAM
6 r 1 . 0m m
9.8 .m (l.O kgt.m,7.2 tbt.frl
MODE COI{TROLI,IOTOR
col{t{cToF
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21-23
HeaterUnit
Overhaul
1 . Remove the screw and the damper arm cover.
Disconnect the link from the dampar arm, and remove the screw and the damper arm.
4.
DAMPERARM COVER
HEATERCORE
DAMPEFARM
21-24
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HeaterControlPanel
DefrosterDoor Adjustment
Replacement
Disconned the air mix control cable from the heater unit lsee page 21-271.
AD.'USTII{G ARM
REARWITIDOW
DEFOGGER
swtTcH
ADJUSTI G SCREW
AIR MIX CONTROLCABLE
4.
CENTEBAIR VE T
21-25
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HeaterControlPanel
Overhaul
HEATERFAN SWITCH
Test, page 21-30
NoTE:Alterassemb|y,checkthatthetemperaturecontro||eve's|idessmooth|ythroughthe'u||strokefromright
to left.
21-26
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Adjustment
Adjustment
'l
2.
3,
4.
HEATERCOIITBOL
ARM
5.
HEATEBVALVE
CABLE
CLAMP
21-27
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Test
Using a jumper wire, short the No. 8 terminsl individuallyto the No. 1, 2, 3. 6 and 7 terminals,in
that order.
MODECONTROL
iioroR
a Eachtime the short circuit is mad,the mode control motor should run smoothly and stop.
NOTE: ll the modecontrolmotordoesnot run when
shortingthe tirst terminsl,short that trminalagain
after shortingthe other terminals.
The mode control motor is no.mal it it runs when
shortingthe tirst terminalagain.
3.
21-28
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lnst8ll in tho rsvsrse order of removal. After inst8llstion, make sur the modo control motor runs
smoothlv.
Recirculation
ControlMotor
Test
Replacement
Disconnectthe groundfrom the No. 2 or No. 4 terminals; the recirculation control motor should stoo
at FRESHor RECTRCULATE.
4P CONNECTOR
SCREWS
3.
REC|RCULAT|OII
CONTROL
MOTOR
Instsllin the reverseorderof removal.After installation, make sure tha tecirculationcontrol motor runs
smoothlv.
21-29
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Relay
There should be continuity btween the A and C terminals when Dower and ground are connectedto the B and
D terminals.
There should be no continuity when power is disconnected.
Terminal
Position
OFF
,l
3
4
rl
r?
I
I
21-30
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ooo-
-o
-o
-o
-o
RecirculationControl
Switch
Test
Check for continuity between the terminalsaccordingto
the table below.
Terminal
Position
Heat/Def
o --o
--o
o-
Def
Vent
o-
Heat/Vent
G-
Heat
Terminal
Position
Fresh
Recirculate
-O
oo-
--o
-- -o
--o
--o
21-31
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Air Conditioning
*Evaporator
Repfacement
Overhauf
Compressor
.........22-26
................
22-27
Description
............
22-28
fffustratedfndex ...............................
22-29
Replacement
.........22-30
Cfutch lnspection .......................
......22-32
Cfutch Overhaul...............................
22-33
Refief Vafve Replacement...............
22-34
A/C Compressor Belt
Repfacement
.........22-35
Adiustment
............22-36
Condenser
Replacement
.........22-37
A/C System Service
Evacuation
....,.......,22-38
Charging
................
22-39
LeakTest
...............22-40
+: Read SRS precautionsbefore working in
this area.
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SpecialTools
Ref. No.
Tool Numbel
OTLAJ- PT3O1OA
07JGG- 001010A
Test Harness
BeltTensionGauge
I
22-2
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lllustratedIndex
CAUTION:
. All SRS electrical wiring harnossosare coverd with
yellow insulation.
. Bfors disconnacting any part of the SRS wire harness,connsct the 3hort connsctor(s).
. Replacethe entirs affscted SRS harness assembly it
it has an open circuit or damaged wiring.
NOTE;The original radio has a coded theft protection
c i r c u i t . B e s u r e t o g e t t h e c u s t o m e r ' sc o d e n u m b e r
before
- disconnecting
the battery.
- r e m o v i n gt h e N o . 3 2 ( 7 . 5A ) f u s e f r o m t h e u n d e r hood fuse/relaybox.
- removingthe radio.
After service,reconnectDowerto the radio and turn it
on. When the word "CODE"is displayed,enter the customer's5-digitcodeto restoreradiooperation.
SRSMAIN HARNESS
lcoverd with yellow insulationl
EVAPORATOR
page22-26
Replacement,
Ovethaul.Oase22.27
SERVICE
VALVE
IHIGHPRESSURE
SIDE)
SERVICEVALVE
(LOWPRESSURE
SIDEI
RECEIVER/DRYER
CONDENSER
Replacement,
page22,37
A/C PRESSURE
SWITCH
W h e n t h e r e f r i g e r a n tp r e s s u r ei s b e l o w 2 0 0 k p a ( 2 . 0
kqflcm,,28 psi) due to refrigerantleakageor above3]OO
kPa (32 kgf/cm,, 460 psi) due to coolant btockage,the A,/C
pressureswitch opens the circuit to the A"/Cswitch and
stopsthe air conditionang
to protectthe compressor.
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COMPRESSOR
page22-30
Replacement,
22-3
Wiring/ConnectorLocations
A/C DIODE
CONNECTOR
(Loc.ted .bovo tho.ight kick p.n.ll
CONDENSERFAN
CONNECTOR
MAIN WIREHARNESS
A/C WIREHARNESS
CONNECTOR
RADIATORFAN
CONNECTOR
A/C WIREHARNESS
CLUTCH
COMPRESSOR
CONNECTOR
22-4
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A/C PRSSURESWTTCH
CONNECTOR
Circuit Diagram
N0.41l10oAl No.39{5OAl
No.1317,5A)
MOIATOR
REI.AY
22-5
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Description
Outline
refrigerantthroughthe sysThe air conditionersystemdeliverscooledair into the passengercompartmentby circulating
tem as shown below.
RECEIVER/DRYER
coMpRESsoR
-coNDENSER
Moreliquidified
vaPor
low Pressure
Absorptionof heat
VALVE
EXPANSION
EVAPORATOR
<-'----------.-
Less moisturized
low pressurevaPor
EVAFORATOR
CONDENSOR
to the following
{R-134a)refrigerantwhich does not containchlorofluorocarbonsPay attention
This car uses HFC-134a
service items:
(R-134a)They are not compatible'
Do not mix refrigerantsCFC-I2(R-l21and HFC-134a
designedfor the Rrefrigerantoil (ND-OIL8: P/N38899-PR7-A01)
potyatkytenegtycol
{PAG)
Use onty the recommended
oil
will resultin comrefrigerant
134acompressor.Intermixingthe recommended(PAG)refrigerantoil with any other
pressortailure.
.A||lvcsystemparts(compressor.dischargeIine,suotionIine,evaporator,condenser.receiver/dryer,expansionva|ve.
o-ringsforioints}havetobeproperforre'rigerantR-l34a.DonotconfusewithR.l2parts.
. Usea halogengas leakdetectordesignedfor refrigerantR-134a'
Only use a Recovery/Recyclins/Charging
. R-.12and C-l34a refrigerantservicingequipmentare not interchangeable.
J2210
to serviceR-134aair conditioningsyssAE
of
requirements
the
to
meet
and is certifLd
Systemthat is U.L.-listed
rems.
any
Systembeforedisconnecting
. Always recoverthe refrigerantR-134awith an approvedRecover/Recycling/Charging
A,/Cfitting.
.
.
22-6
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Troubleshooting
Reference
Ghart
.
.
REMEDY
22-7
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Troubleshooting
RadiatorFan
Redi.to. fan doo3 not run at all.
check rhe No. 33 {20 A) fuse in
the under-hoodluse/relaybox.
R e m o v et h e r a d i a t o rl a n r l a y
from the under-hoodIuse/relay
box and test it (seepage 22-19).
Raplacatha radiator tln rahy.
To p3ge 22-9
22-A
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Fromprge 22
22-9
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Troubleshooting
CondenserFan
BLK/WHTl+l
Removethe condenserfan relay
and test it (seepage22-19).
BLU/YEL
Viewlrom wireside
10 page 22-11
BLU/BLK
Reprir opn in th. BLU/BLKwiro
batwcen the condenrai lan rolay
and the condcntor ftn
22-10
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Frompage22-10
22-11
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Troubleshooting
Bolh tanr lradiltor and condan.arl do not run fot angina
cooling. bul th.y bolh tun whh
th. A/C on.
22-12
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Both Fans
Both tans do not run at all.
22-13
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Troubleshooting
Gompressor
R6movethe comPressorclutch
refayand test it (see Page22-19l..
BLK/YEL{+l
WHTl+l
BLK/RED
Viewfromwirside
To page22-15
22-14
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Frcm page22-11
Bdt ry vohro.?
Connectthe test harness"A" and
"8"
conoectorsto th6 main wire
harnessonly, not to the ECM(s6g
section11).
_@_____-l
Blttary vohago?
r_--@_
Bs {+)
(-).
22-15
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"
-1llltf,'tfrSfiiwiafi
Troubleshooting
A/G System
A/C ay3t6m doe3 not como on
(compro!3orand both f.ns).
D i s c o n n e c tt h e A / C p r e s s u r e
switch 2P connector.
Turnthe ignitionswitchOFF.
R e c on n e c t t h e A / C p r e s s u r e
switch2P connector.
10 page22-17
22-16
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YEL/WHT
BLU/RED{+l
Frompage22-15
YEL/WHTl+l
Measuretho voltage betweonthe
BLK/YELwire terminal (+) and
body ground(-).
ls there battoryvoltage?
Rconnectthe Ay'Cthermostat 3P
connctorand connectthe BLU/
REDwire terminalto groundwith
a l!mper wire,
To page 22-18
(cont'd)
22-17
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Troubleshooting
A/C System(cont'dl
Frcm page22'17
Removethe heatercontrolPanel
(seepage21 25)
D i s c o n n e c t h e h e a t e rc o n t r o l
panel14Pconnector'
No. 11 BLU/REDl+l
Measurethe voltagebetweenthe
w i r e t e r m i n a l( + ) a n d
BLU/RED
body ground{ }
Rop.i. opon in tho BLU/BEDwir.
b.twoon tha A/C thermort.t lnd
the haat.r control Panal
Turnthe ignitionswitchOFF.
22-18
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A/C Thermostat
Relays
Test
Connectbatterypower to terminalC and ground terminal B, and connecta test light betweenterminalsA and
N O T E :U s ea 1 2V , 3 W - 1 8 W t e s tl i g h t .
,r I
.I I
b
P
Radiatorfan relay
12V.3W-18W
a Condenser
fan relay
a Compressor
clutchrelay
22-19
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A/C Switch
Diode
Test
Test
NOTE: The diode is designedto pass current in one
directionwhile blockingit in the oppositedirection.
U s e a n a n a l o g o h m m e t e r ,o r a d i g i t a l o h m m e t e r
equippedwith a diodetester.
Checkfor currentflow in both directionsbetweenthe A
and B. and B and C terminals.There should be current
flow in onlv one direction.
22-20
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11
..............................
9.8N.m {1.0kgt.m,7.2lbf.ft)
. 9.8 N.m {1.0kgf.m,j.Z lbl.ftl
9.8N.m n.O kaf.m,t-2tbl.ftl
.........................
9.8N.m (1.0katm,7.2lbf.ft)
.........................
9.8N.m(1.0kttm. 7.2lbt.ft)
@ Receiverpipe A to th6 receiverpipe B ......................................
........13N.m {1.3kgt.m.9.4lbt'ft)
22-21
vnx.su
R.cov.rylR.cycling/Ch.rging
M e a s u r et h e a m o u n t o f r e f r i g e r a n to i l r e m o v e d
from the A/C system after the recovery process is
comoleted.
NOTE:Be sure to installthe same amount of new
r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o t e
charging.
22-22
vnx.su
Pf,ESSUFE
sy.t m.
PressureTest Chart
NOTE: PerformanceTest on page 22-24.
TESTRESULTS
RELATED
SYMPTOMS
Dischsrge
AftErstoppingcompressor,pressure
(high)pressure dropsto about200kPa(2.0kof/cmr.28
psi)quickly,andthenfallsgr;dua y.
abnormally
nrgn
PROAABLE
CAUSE
Air in system
E-\cessive
refrigerantin sys-
Cloggedcondenseror
radiato. fins
Condenser o. radiator fan
not working properly
Dischargepres- Excossive
bubblesin sightglass;
sure abnormal- condenser
is not hot.
Highand low pressures
arebalanced
soonafterstoppingcompressor.
Low
sideis higherthannormal,
Outletof expansionvslve is not frosted,low pressure
gaugeindicates
vacuum,
Suction(lowl
Excessive
bubblesin sightglass;
pressure
conqenser
rsnot hot_
abnormally
low
Insufficient refrigerant in
syslem
FaultycompressordiscnargevaNs
Faultycompressorseal
. Faultyexpansionvalve
. Moisturein sysiem
Insufficientrefrigerant
Expansion
valveis nottrostedandlow
pressurline is not cold. Low pressure
gaugeInorcates
vacuum.
. Restricted
lines
Checkfor leak
Charge system
Replacethe compressor.
. Replace
. Recover,evacuateand recharoe
with specifiedamount.
Reoairthe leaks.
Reaover,evacuateand recharoe
with sDecifisd
amount.
Charqeas required.
Replacethe expansion valve.
Frorenevaporator
Expansionvalveis frostd.
Receiver/dryer
outlet is cool and inlet
isrryarm(shouldbe warm duringoper-
Cloggedrceiver/dryr
Clanor replace.
Replace
'
Repairor replace.
REMEDY
Recover,evacuate and recharqo
with sDecifiedamount.
Evacuation:see Daqe22-38
Charoino:se6 D;op--2?-?q
Recover,evacuate and recharqe
with specitiedamount.
Clean
Checkvoltage and fan rpm
unecKlan ofeclton
Compressorbolt(s)are dirty.
Compressorgasketis wet with oil.
u"lu"oD"ntoo
ffin"nsion
. Looseexpansioncapillary
Excessive
refrigerantin sysrem
Recover,evacuateand recharqe
with sDecifidamount.
Faultv oasket
FaultyFigh pressurevalve
Foreign particle stuck in
high pressure valve
. Cloggedcondenseror
radiatorfins
. Condenseror radiatorfan
not working properly.
Replacethe compressor.
Excessive
refrigerantin sysrem
Cleancondenserand radiator
Checkvoltageand fan rpm
Checkfan direcrion
Repairor replace.
Compressorshaftsealleak-
Replacethe comDressor.
Tightenbolt(slor replace
compressor.
Replacethe compressor.
Ing
I Gasketleaking
22-23
vnx.su
Rocov.rylB.cycling/Ch!lging SFtrm.
Connecta R-134arefrigerantRecovery/Recycling/
ChargingSystem to the car, as shown, iollowing
instructions.
the equipmentmanufacturer's
2.
3.
Testconditions:
. Avoid directsunlight.
. Open hood.
. Openfront doors
. Set the temperaturecontrol leverto MAX COOL,
the mode control switch on VENTand the recirculationcontrolswitchon RECIRCULATE.
. Slidethe heaterfan switchon MAX
. Runthe engineat 1,500rPm
in vehicle.
. No driveror passengers
4.
A f t e r r u n n i n gt h e a i r c o n d i t i o n i n gf o r 1 0 m i n u t e s
under the above test conditions.read the delivery
temperaturefrom the thermometerin the dash vent
and the high and low systempressurefrom the A,/C
gauges.
22-24
vnx.su
LOWPRESSURE
To completethe chans:
. Markthe deliverytemperaiurealongth venicalline.
o Mark the intaketemperature (ambient air temperature)8long the bottom line.
o Drsw a line strsightup from the air temperatureto the humidity.
. Mark I point one line above and one line below the humidity l6vel (10 % above and 10 % below the humidity
l6vsl).
. Fromeachpoint,drawa horizontalline acrossthe deliverytemparaturs.
. The deliverytemperatureshouldfall betweenthe two lines,
. Completethe low side pressuretest and high side pressurtest in the sameway.
o Any measurementsoutside the line may indicatethe need for further inspection.
29q)
(301
Ii(t0l
kp.
lksf/cm')
lpril
at%
2stx'
t25)
t360l
kpr
lkgflclrfl
lpril
2qx)
t20l
t2q)l
500
15{Xt
{151
12r0t
,o0
OEUVERY
PRESSURE
9BO
t10l
t1()l
T'EUVERY
PRESSUNE
ts)
171!
{4)
tsTl
86
t30)
3q,
{3t
II
71
l25l
ax)
68
120,
l2l
t28t
INTAKE
PRESSUBE
30%
100
t1l
n4l
59
t15l
50
(101
11
ts)
DEUVERY
TEMPEMTURE
77
{25t
6
t30t
95
(35}
104
laltl
"F
fc}
INTAKETEMPERATURE
22-25
vnx.su
Evaporator
Replacement
CATION:
. All SRS eloctrical wiring harnessesare coverod with
yollow in3ulation.
. Btore disconnocting 8ny part of tho SRS wire harnsss,conngqtth 3hort connestor{sl.
. Roplacaths entire aftected SRS harness a$embly if
it has an opn circuit or damaged wiring.
3.
2.
NOTE:Plug or cap the lines immediatelyafter disconnectingto avoid moistureand dust contamination into the svstem.
SUCTIONLINE
6x1.0mm
9.8 N.m {1.019f.m,
1.2 tbl.ttl
6x1.0mm
9.8Nm{1.0kg{.m,
7.2 tbtft)
8.
RECEIVEB
LINE
APORATOR
22-26
vnx.su
Overhaul
L
2.
3.
C a r e f u l l ys e p a r a t et h e h o u s i n g sa n d r e m o v et h e
evaporator.
5.
4.
lf necessary,
removethe expansionvalve.
.
NOTE:When looseningthe expansionvalve nuts.
usea secondwrenchto hold the expansionvalveor
evaporatorpipe.Otherwise,they can be damaged.
1 2 0 1 5m m
14.72! 0.2 inl
EVAPOAATOR
blow dirt out of fins
with compressedair.
A/C THERMOSTAT
Test.page22-19
16 N,m 11.6kgl.m,
12 tbt.ttl
24 N.m (2.i1kg{.m,
17 rbt.ftl
EXPANSIONVALVE
LOWERHOUSING
CAPILLARY
TUBE
TAPE
Replace.
Make sure there is no foreign matter stuck between
the capillarytube and outletline.
22-27
vnx.su
Gompressor
Description
(R-' |34a).
A revolvinginclineddiscdrivesthe surThis compressoris a Nippondensopistontype compressorfor HFC-134a
protectedby a ceramicshoe,thus
pistons,
pushes
the
it
revolves.
disc
inclined
prstons.
As
the
rounding10 reciprocating
compressingthe refrigerant
/al
?-*:-=3
22-28
vnx.su
lllustrated lndex
CENTER
BOLT
CLUTCH
SET
Inspoc!on,
page 22-32
SNAPRINGA
Replace.
colL
Inspection, pag6 22 32
-t
f--
COMPRESSOR
COMPLETE
lDo nor disassemble)
RELIEFVALVE
R e p l a c e m e n t ,p a g e 2 2 - 3 4
22-29
'-f
vnx.su
Compressor
GlutchInspection
Checkthe platedpartsot the pressureplatetor color
changes.peelingor other damage.lf there is dam8ge,replacethe clutchset.
replacethe
lf resistanceis not within specifications,
field coil.
22-32
vnx.su
GlutchOverhaul
l.
A/C CLUTCHHOLDER
commorciallyavailsble
Robinair: P/N 10204
Kont.Moore:P/N J37872
CENTERBOLT
13.2N.m (1.35kgt.m,9.76lbf.ftl
R e m o v et h e s n a p r i n g B w i t h a s n a p r i n g p l i e r s ,
then removethe pulley.
NOTE:
. B e c a r e f u ln o t t o d a m a g et h e p u l l e ya n d c o m presso.during removal/installation.
a Oncethe snap ring B is removed,replaceit with
a new one,
SNAPRINGB
Replace.
sHrM{s)
(cont'd)
22-33
vnx.su
Compressor
ClutchOverhaul(cont'dl
Removethe screwfrom the field coil ground termanal. Removesnap ring A with snap rjng pliers,then
removethe field coil.
1.
NOTE:
. Do not let the compressoroil run out.
. Make sure there is no foreign matter in the system.
NOTE:
. Be carefulnot to damagethe field coil a n d c o m
pressorduring removal/installation.
. Once snap ring A is removed,replaceit with a
new one.
SNAPRINGA
Replace.
FIELD
corL
4t-N r-l\
\
-l/
RELIEFVALVE
13.2N.m {1.35kgtm,9.76lbtftl
2.
5.
t al
v a l v e ,a n d a p p l y a t h i n c o a t o f r e f r i g e r a no
(ND-OIL8: P/N38899- PR7- A01) beforeinstalling it.
NOTE:
. To avoid contamination,do not returnthe oil
t o t h e c o n t a i n e ro n c e d i s p e n s e da, n d n e v e r
mix it with other refrigerantoils.
. l m m e d i a t e l ya f t e r u s i n gt h e o i l , r e p l a c et h e
c a p o n t h e c o n t a i n e r ,a n d s e a l i t t o a v o i d
moistureabsorption.
. D o n o t s p i l l t h e r e f r i g e r a not i l o n t h e c a r ; l t
may damage the painu if the refrigerantoil
contactsthe paint,wash it off immediately.
Checkfor leaks,and insertthe cap in the top of
the valve.
22-34
vnx.su
A/C CompressorBelt
Replacement
Automatic TransmissionType
1. Loosenthe adjust pulley bracketpivot bolt and the
adjusting bolt, then remove the A/C compressor
beltfrom the oullevs.
Manual TransmissionType
1. Loosenthe adjust pulley bracketpivot bolt and the
adjusting bolt, then remove the A/C compressor
beltfrom the pullevs.
2,
2.
ADJUSTINGBOLT
ADJUSTPULLEYBRACKET
PIVOTBOLT
ADJUSTINGBOLT
ADJUSTPULLEYBRACKET
PIVOTEOLT
l!l',
14x 1.25mm
83 N.m 18.5kgl.m.
61 tbf.ft)
LEFTFRONT
ENGINEMOUNT
l
a ar10 x 1.25mm
54 N.m (5.5 kgf.m,
4(' rbr.ft)
WASHER
1 2x ' 1 . 2 5m m
69 N.m {7.0 kgf.m,
51 tbf.ftt
10 x 1.25mm
54 N.m (5.5 kgtm, irc lbf.ft)
22-35
"t.M'
vnx.su
A/C CompressorBelt
Adjustment
Dstlsqtion Method
1. Apply a force of 98 N (10 kgf, 22 lbf), and measure
the deflection between the A,/Ccompressor and the
crankshaftDullev.
A/C CompressorBelt
UsdEelt:81881engine7.5- 9.5 mm (0.3- 0.4 in)
Bl8Cl engine8.5- 10.5mm (0.3-0.11 inl
New Belt: 5.0- 7.0 mm (0.2- 0.3 inl
Power Stesring Pump Belt
'l1.5- 13.5mm (0.,[5- 0.53inl
UsedBeli:
New 8lt: 8.0- 10.0mm (0 3 - 0.39inl
NOTE:
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
for lessthan five minutes.
NOTE:
. lf there are cracksor any damageevidenton the
belt, replaceit with a new one.
. F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n sf o r t h e
belttensiongauge.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
tor lessthan five minutes,
2.
3.
2.
Recheck
the deflectionof the lvc compressorbelt
3,
4.
4.
22-36
vnx.su
Condenser
Replacement
Recoverthe relrigerantwith a Becovery/Recycling/
ChargingSystem (see page 22-221.
Removethe coolantreservoir,
NOTE: Do not disconnectthe reservoirhose from
the coolantreservoirand the radiator.
COOLANT
RESERVOIR
6x1.0mm
9.8 N.m (1.0kgl.m,7.2 lbt.ft)
......-.....
CONOENSER
LINE
R e m o . v teh e b o l t s a n d t h e r a d i a t o ru p p e r m o u n t
brackets,and removethe bolt from thg suctionhose
bracket.
9.8 N.m {1.0 kgf.m.7.2 lbtftl
RAOIATORUPPEN
MOUNT BRACKETS
22-37
'1Iffi
vnx.su
R.cov.ry/R.cycling/Chtroing
2234
vnx.su
aotnPRESSURE
SIDE
Syttom
Charging
Only use serviceequipmentthat is U.L.-listed
and is certified to meet the requirementsof SAE J2210 to remove
(R-134a)
HFC-134a
from the air conditionersvstsm.
R.cov.rylRccacling/Ch.rging Syrtom
22-39
vnx.su
Rocov.ry/R.cycling/Ch.tging Sy3tcm
LOW PRESSURE
SIDE
Connecta R-134aretrigerantRecovery/Recycling/
ChargingSystem to the car. as shown, following
instructions.
the equipmentmanufacturer's
NOTE:Be sure to installthe same amount of new
r e f r i g e r a n to i l b a c k i n t o t h e A / C s y s t e m b e f o r e
chargtng.
2.
3.
4.
l f y o u f i n d l e a k st h a t r e q u i r e t h e s y s t e m t o b e
opened (to repair or replacehouses,fittings,etc.),
recoverthe system accordingto the Recover
Procedureon page22-22.
5.
22-40
vnx.su
HIGH
SIDE
Electrical
Special Tools
Troubleshooting
T i p s a n d P r e c a u t i o n .s. . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3.-. 3
Five-stop
T l o u b l e s h o o t i n.g. . . . . . . . . . . . . , . . . - . . -Z. .3. - s
S c h e m a t i cS y m b o l s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. .3. _- 6.
w i r e C o l o rC o d s. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. -. 6
....
Relay and Control Unit Locations
E n g i n eC o m p a r t m e n .t . . . . . . . . , . . . . . . . . . . . .- - .2 3 - 7
Dsshboard
a n d D o o r . . , , . . . . . . . . . . . . . . . . . . . . . 2. .3. .- g
D a s h b o a ra
d n d F l o o r. . . . . . . . . . . . . . . . . . . . . . . . . 2. .3. .- t O
O u a n e rP a n e l
.....-.....23-12
Connector ldentification and Wire
HarnessRouting
........ 23-i 3
betore working
in these areas.
vnx.su
SpecialTools
Rel. No.
Tool Numbol
Description
o
o
DeploymentTool
07HAZ-SG00400
Antenna Nut Wrench
07JAA-001000c
0 7 J G G - 0 0 1 0 1 0 A Belt TensionGauge
@
Test HarnessC
07LAZ-S140300
@.'
Test HarnessD
oTLAZ-S140400
@'
Test HarnessA
oTMAZ-S100500
@'
Test HarnessB
oTMAZ-SP00500
o T N A C - S R 2 0 1 0 0 Fuel Senderwrench
@
SCS Short Connecto.
oTPAZ-0010100
@
lncludedin SRSToolSet oTHAz-SGoOooA
Included
in SRSToolSet OTMAZ-SLOo10A
o--
Oty.
I Pago R6toronce
23-300
23-195
23-108
23-201,248,285
23-247
23-241
23-244
23-124
23-89
o
@
z3-2
vnx.su
Troubleshooting
Tips and Precautions
Before Troubloshooting
a Check applicablefuses in the appropriatefuse/relay
DOX.
CAUTION:
a Do not quick-charg a battery unless the battery
ground cabla has ben disconnoctsd. othrwiso
you will damage the alternator diodss.
a Do not att6mpt to crank the engine with the battery ground cable looselyconnectsd or you will sevorsly damag tho widng.
a The original radio has a codod thatt plotection ci.cuit. Be sul to got tho customor's code numbet
before
- disconnecting th battery.
- lomoving tho No. 32 (7.5 Al tuso f.om the
under-hood tuse/lelay box.
- removing tho radio.
Aflor slvic. reconnct powet to tho radio and
turn it on. Whon the word "CODE" is displayed,
ntl the customer'E s-digit codo to .astore ladio
operation.
Handling Connectors
a Makesurethe connectorsarecleanand haveno loose
wire terminals.
a Make sure multiple cavity connectots are packedwith
grease(exceptwatertight connectors).
a All connectorshave push-downreleasetype locks.
LOCKII{GTAA
RETAINER
LOCKING
TAB
a Someconnectorshavea clio on their sideusedto attach them to a mount bracket on the body or on
anothercomponent.This clip has a pull type lock.
a Some mountedconnectorscannot be disconnected
unlessyou first releasethe lock and removethe connector from its bracket.
LOCKING
PAWL ON
OTHER
HALF OF
Pull to
CONNECTOR orsengage
BRACKET
(cont'd)
23-3
vnx.su
Troubleshooting
Tips and Precautions(cont'dl
a Seat grommets in theil grooves properly.
GOOD
Faca
opon and
cown
]TOTGOOD
n
ll
,
,,'
r
ll
,,
s*j
-:ut*/
--ry\
-.w-,
Stip pliers under the clip base and through the hole at an
angle,then squeezethe expansiontabs to releasethe
clio.
SI'IAP-ANG PLIERS
23-4
vnx.su
Five-stepTroubleshooting
1.
2.
4.
5.
23-5
vnx.su
Troubleshooting
ym
Schematic Symbols
le @l
l
l
e-
LIGHTER
COIL,SOLENOID CIGANETTE
FUSE
GROI,ltD
Componontground
Ground terminal
BATTERY
H t+j
A
+ ilHe
e H
+ + D
a 0
Y II
VARIABLERESISTOR
RESISTOR
THERMISTOR
tcNtTtol{
swTcH
-1o
MOTOR
PUMP
CIRCUITBREA(ER
BULB
HEATER
DIODE
SPEATER,BUZZER
oF
HORI'
TRA SISTORlTrl
ANTI INNA
Wire GolorCodes
Mast
*G
t-i- |
l l l
l'*^f
@
l
CONNECTION
Output
Inpur
f7
I
CO'IDENSER
I
T
LIGHTEMITTING
DIODE(LEDI
A[,
@
T T
l
CONNECTON
--+>-
tl' l
BEEDSWITCH
lril
23-6
vnx.su
WHT/ALK
, / t
, / l
/ l
--</
.
UNDER.HOOD
FUSE/RELAY
BOX
UNOER-HOOD
ABS
FUSE/BELAY
BOX
. ABS FRONTFAILSAFERELAY
I Wirc colors:WHT/GRN,BRN/BLK,
I
snd BLK
IYEL/GRN
I
. ABS REARFAILSAFERELAY
I Wire colors:WHT, BLU/BLK,
I
and BLK
I YEL/GRN
I
. CONDENSER
FAN RELAY
I Wi]o colors: WHT, BLUiBLK, I
I BLKMHT and 8LU/YEL
I
. A/C COMPRESSORCLUTCH RELAY
I Wiro colors: WHT, RED,I
I BLK/YELand BLK/RED I
23-7
vnx.su
MOONROOFRELAY
Wirs colors:
WHT,GBN/BLK,
GRN 6nd BLK
CRUISECONTROLUNIT
PGM-FI
MAIN RELAY
POWERWINDOW
RELAY
INTEGRATEO
CONTROLUNIT
TURN SIGI{AL/
HAZARDRELAY
23-8
vnx.su
IIORNRELAY
J wi.o color3:WHT/GRN,BLx,l
and BLU/RED I
I BLU/GBN,
UNDEB-OASH
FUSE/RELAY8OX
POWERDOOR LOCK
COI{TROLUNIT
ENGINECONTROLMODULE
(ECM}
23-9
vnx.su
23-10
vnx.su
MAINTENANCE
REMINOERUNIT
TRANSMISSIONCONTBOL
MODULEITCMI
23-11
vnx.su
ABS CONTROLUNIT
23-12
vnx.su
Engino Compartmont
Darhboard
G1 and O
Engineground cable A
T3
Engineground cable B
T4
G3
T5 and (D
Enginewire harness
C 1 0 1 t h r o u g hC 1 3 4
Tl Ol andT102
G1 0 1
C l 5 ' l t h r o u g hC 1 5 6
G151
C 1 6 1 t h r o u g hC 1 6 8
DashboSrdwire harness
C 6 0 1 t h r o u g hC 6 1 2
Heater sub-harnessA
Heatersub-hatnessB
ABS sub-harness
Tailgatewire harness(Hatchback)
Spoilersub-ha.ness(Hatchback)
c77'l
G771
23-13
vnx.su
Numbsr of
Cavities
Connects to
Location
Notos
T1
r2
@
B8ttory Ground Cable
Connctor or
Trminal
Numborof
Csvities
G1
\l
Connects to
Location
Right front shock tower
Battery
Notos
Number of
Cavities
Connocta to
Location
T3
Valve cover
G2
Notes
Number ol
Cavitios
Connocts to
Location
Nots
r4
G3
Numbor of
Cavities
cl51
cl52
c153
c154
c155
c156
I
4
4
Connects to
Location
Right side ol enginecomPartment
Left side of enginecompartment
Left side of engine comPartment
Lett side ot enginecompartment
Left side of enginecomPanment
Left side of enginecompartment
Notes
G151
Numbor ot
Cavitis
Connects lo
Localion
23-14
vnx.su
Notes
UNOER.HOOD
A8S
FUSE/RELAY
BOX CABLE
BATTEBYGROUND
CABLE
ENGIT{E
GROUND
CABLEB
EI{GINEGROUND
CABLEA
23-15
vnx.su
Numberof
Cavities
c10'l
c102
c103
c104
c105
c106
10
14
6
1
c107
c108
c108
c109
c110
c111
c113
c114
c115
L t t o
2
8
c117
c118
c119
c't 20
c121
c122
c123
cl24
c125
c't26
c127
c128
c129
c130
T1 0 1
r102
G1 0 1
2
)
2
8
14
2
2
Connectsio
Location
M a i n w i r e h a r n e s s( C 2 2 1 )
Main wire harness{C222}
Main wire harness(C223)
Main wire harness{C220)
Startersolenoid
Enginecoolanttemperature{ECT)
sensor
Enginecoolant temperature(ECT)
Right side ol engine
gauge sendingunit
Back'up light switch
Transmission
Lock-upcontrolsolenoidvalveA and B
Transmission
lgnitioncoil
Middle of engine
Top dead center/Crankshaft
lvliddleof engine
position
position/Cylinder
(TDC/CKP/CYP)
sensor
Enginecoolanttemperature(ECT)
Right side ot engine
switch
Right side of enginecompartment Vehiclespeedsensor (VSS)
ldiddlerearof enginecompartment Heatedoxygen sensor (HO2S)
MAP sensor
Middle of engine
Throttle position (TP)sensor
Middle ol engine
ldle air control (lAC) valve
Middleof engine
Evaporativeemission(EVAPIpurge
o
f
e
n
g
i
n
e
Middle
control solenoidvalve
Engineoil pressureswitch
Middle ot engine
Alternator
Left side of engine
Intake air temperature{lAT} sensor
engine
lvliddleof
'l
No. fuel injector
M i d d l eo f e n g i n e
No. 2 tuel injector
Middle of engine
No. 3 fuel injector
Middle ot engine
No. 4 fuel injector
ol
engine
Middle
Junction connector
Left side of enginecompartment
Enginecompartmentwire harness
Left side of enginecompartment
(c304)
Enginecompartmenlwire harness
compartment
of
engine
Left side
(c305)
Shift control solenoidvalve A and B
Transmission
Countershaitspeed sensor
Transmission
Mainshaftspeed sensor
Transmission
Right side of
Right side of
Right side of
Right side ol
Right side of
Right side of
Notes
enginecompartment
enginecompartment
enginecompartment
enginecompartment
enginecompartment
engine
Alternator
Lelt side oI engine
Right side of enginecompartment Under-hoodtuse/relaybox
Engine ground, via engine wire
harness
23-16
vnx.su
M/T
NT
NT
NT
ENGINEWIRE HARNESS
(B188i snginel
cl19
c126
clla
c121
c122
c123
c124
cl13
23-17
vnx.su
umbor ol
Cavitio8
c101
cl 02
c103
c104
c105
c106
4
10
14
,l
2
Right side of
Right side of
Right side ot
Right side of
Right side of
Righrside ot
enginecompartment
engine compartment
engine comPanment
engine compartmsnt
engine compartment
engine
c107
c108
c109
c110
2
8
Transmission
Middle ol engine
MiddleoJ engine
c111
cl12
c113
c114
c115
c116
c117
Connecla to
Location
4
3
'I
I
2
Middle of engine
Lelt side ot engine
Middle of engine
Middle of engine
Middle ol engine
Middle ot engine
Middle of engine
Left side of engine companment
Lelt side ot engine compartment
't4
EnginecomPanmentwire harness
T101
r102
Alternator
Under-hood fuse/relay box
G1 0 1
c1r8
c119
c120
cl2'l
c122
c123
c124
c125
c't26
c'127
c131
c132
c133
c134
{c304)
23-18
vnx.su
(c305)
f{orc!
EI{GINEWIRE HARNESS
lBl8C'l onginel
c126
c119
'13
crrs
cl17
cl14
23-19
vnx.su
c162
c163
c164
c165
c166
c't 67
c168
Numbor ot
CaviiieE
't4
2
2
Connocta to
Location
Right side of enginecomPartment
ABS modulatorunit
ABS modulatorunit
ABS modulatorunit
ABS modulatorunit
ABS modulatorunit
ABS modulatorunit
ABS modulatorunat
oies
c301
c302
c303
c304
c305
c306
c307
c308
c309
c310
c311
c312
c313
c314
c315
c316
c317
Numbd of
Cavilies
20
20
1
2
14
2
1
1
2
4
2
2
1
2
c318
c319
c320
G301
Connocta to
Location
Behindleft kick Panel
Behindleft kick panel
Behindlett kick Panel
Left side of engine compartment
Left side of enginecomPartment
Left side of enginecomPartment
Left side o{ engine comPartment
Left side of enginecomPartment
Left side of engine compartment
Lelt side oJ engine comPartment
Middle of engine comPartment
Left side of engine comPartment
Left side oJ enginecomPafiment
BehindleJt headlight
Behindleft headlight
Behindleft headlight
Behind left corner ot front
bumper
Behind lett corner ot front
DUmper
Behindleft corner of ftont
DUmper
Behindleft cornet of front
DUmper
Lett side of enginecomPartment
23-20
vnx.su
t{oioE
ABS MODULATOR
UI{IT
WIREHARI{ESS
Et{GI1{ECOMPARTMET{T
WIRE HARI{ESS
23-21
vnx.su
c201
c202
c203
Horn
Right tront turn signal/Parking
light
Right Iront side marker light
c213
c214
c215
c216
c217
c218
c219
c220
c204
c205
c206
c207
c208
c209
c210
c211
8
4
14
c212
c220
c221
c222
c223
(c902)
7
J
Under-hoodfuse/relaybox (C907)
Under-hoodtuse/relaYbox (C909)
Under-hoodfuse/relaybox (C9l Ol
Under-hoodfuse/relaYbox (C908)
Under-hoodfuse/relaYbox (C911)
Right front wheel sensor
Enginewire harness{C104)
(C'l04)
Righl side ot enginecomPartmenl Enginewire harness
(C101)
Right side of enginecompartmenl E n g i n ew i r e h a r n e s s
(Cl 02)
harness
wire
Engine
Right side of enginecomPartmen'
103)
harness
{C
wire
Engine
comPartment
Right side of engine
wire
Right side of enginecompartment Body ground, via main
harness
wire
Right side of enginecomPartment Body ground, via main
harness
23-22
vnx.su
UNDER.HOOD
FUSE/RELAY
BOX
c222
c221
c223
c220
c212
c213
Continuos on
pago 23-25
23-23
itfltfitfi
vnx.su
Numbsr of
Cavitis
c401
,E
c402
c403
c404
c405
c406
c407
c408
c409
c410
10
2
22
lo
22
26
Connscts to
Location
Front Passenger'sdoor
Under right side of dash
Under right side ot dash
Under right side of dash
Under right side of dash
Under right side ot dash
Behindright kick panel
Behindright kick panel
Behindright kick panel
Behindright kick panel
23-24
vnx.su
ttlotor
Continuos on
pago 23-27
Continuod from
pa90
23-25
vnx.su
Numbel ot
Cavities
c411
c412
c413
c414
c415
c416
c4'17
c418
c419
14
8
4
I
14
20
22
Centerfloor
Centerfloor
Centerfloor
Under left side ot dash
Behindleft kick panel
Behindleft kick panel
Behindleft kick panel
Behindleft kick panel
Behindleft kick panel
c420
26
c42'l
10
c423
20
c424
20
c425
c426
c427
c42A
c429
c430
c431
c43l
c432
c433
c434
c435
c436
c437
c438
c439
c440
c44'l
c442
c443
c444
c445
c446
c447
c448
c449
G401
't4
4
2
10
4
7
4
o
7
I
7
22
6
4
7
4
15
to
Connects to
Notes
Afi
AiT
Afi
Afi
Canada
Canada
Location
Arf
An
(c302)
dash
dash
dash
dash
dash
dash
dash
23-26
vnx.su
Canada
M/T
M/T
Atr
Canada
Canada
Canada
M/T
Canada
Continuod from
poge 23-25
c418
C430 9432
c412
c41t
c440
c449
UNDER.DASH
FUSE/RELAYBOX
23-27
vnx.su
Numbor of
Cavitios
Connecta to
Location
Behindleft kick panel
Behindleft kick panel
Behind dashboard lower cover
Behind dashboard lower cover
Behinddashboardlower cover
Driver's door
Center tloor
Center lloor
Left qusrter panel
Fueltank
Fueltsnk
Right quarter panel
Right quarter panel
Left quarter panel
Left quarter panel
Left quarter panel
Left quarter panel
Left side corner of cargo area
Lft side corner of cargo area
Left side corner of cargo area
Left rear corner of cargo area
Center ot cargo area bulkhead
Right rear cornor oJ cargo area
Center of cargo area bulkhsad
Right side of cargo area
Right side of cargo area
G501
G502
G503
c501
c502
c503
c504
c505
c506
c507
c508
c509
LStt
c 5 11
c512
c513
c514
c515
c516
c517
c 5 r8
c519
c520
c521
c522
c523
c524
c525
c526
10
'14
10
12
25
2
1
1
2
I
2
20
20
2
6
b
2
2
2
4
23-28
vnx.su
llotos
REARWIRE HARNESS
G503
23-29
vnx.su
Number ot
Caviti6s
c501
10
c503
c504
c505
c506
c507
c508
c509
c510
10
Connocts to
Locaiion
4
6
c52A
LCZY
1
,|
G501
G502
G503
aEt t
c512
L9
IJ
c514
c515
c516
c517
c518
c519
c520
c521
c522
c523
c527
c530
c531
c532
c533
c534
c535
c536
12
25
'I
1
a
1
2
2
20
20
2
6
4
2
1
I
4
4
(c656)
23-30
vnx.su
Notos
c528
c532
c533
13
REARWIRE HARNESS
23-31
vnx.su
Number of
Caviti6s
20
10
c553
c554
L55b
c556
c557
c558
c560
LCO
to
12
5
22
10
13
16
c563
c564
c565
c566
c567
c568
a 6ACl
10
6
to
Connects to
Location
Behinddashboardlower cover
Behinddashboardlower cover
Behinddashboardlower cover
Behinddashboardlower cover
Under lett side oJ dash
Under left side of dash
Behindgauges
Behindgauges
Behindgauges
Behindgauges
Behindmiddleof dash
Left side of dash
Behindmiddleof dash
Behindmiddleof dash
Right side of dash
Under middleof dash
Under middleof dash
Behinddashboardlower cover
Under middleof dash
Under-dashfuse/relaybox (C919)
Main wire harness(C43Ol
Main wire harness(C4491
Rear wire harness{C505)
Cruisemain switch
Junction connector
Gaugeassembly
Gaugeassembly
Gaugeassembly
Gaugeassembly
Clock
Dash lights brightnesscontroller
Hazardwarning switch
Rear window defoggerswitch
Glov box light
Stereo radio/cassette PlaYer
Chime
Maintenancereminde.unit
Cigarettelighter
23-32
vnx.su
Notes
Afi
c5P3 csor
cl6a cs,aa
"ru.,
DASI{BOARD
WIRE HARNESS
UNDER-DASH
FUSE/RELAY8OX
23-33
vnx.su
Number of
Cavitles
c601
c602
c603
c604
c605
c605
c606
25
2
4
14
I
I
Location
Connocts to
Driver'sdoor
Driver's door
Driver'sdoor
Driver'sdoor
Behindmirror panel
Driver'sdoor
Driver'sdoor
c607
c608
c609
c610
10
10
o
Driver'sdoor
Drivr's door
Driver's door
Driver's door
c611
c612
2
I
Oriver'sdoor
Driver'sdoor
Notos
23-34
vnx.su
Hatchback:
Sedan:
23-35
vnx.su
Numbel of
C8viti63
c626
c627
c628
25
2
2
c629
c629
c630
8
tt
c631
c632
Front Passonger'sdool
c633
c634
23-36
Connocts to
Locatlon
vnx.su
Not6s
Hatchback
S6dan
8 1 8 C1
6n9ino
Hatchback:
Sedan:
23-37
vnx.su
Number ot
Caviiies
Lbc I
c652
c653
c654
Connocta to
Locstion
23-38.
vnx.su
l{ot.t
LEFTREARDOOR
WIRE HARNESS
WIRE HARNESS
23-39
vnx.su
Number ot
Cavitiss
Connccts to
Location
Behindleft kick panel
Moonroot relay
c664
LOO5
Roof
Moonroof motor
LOOO
Roof
Spotlight
Roof
Ceilinglight
c661
c662
LOOJ
c667
23-40
vnx.su
Notct
with
moonroof
with
moonroof
with
moonroof
with
moonroot
with
moonroot
Hdchback:
FUSE/RELAY
BOX
Scdrn:
23-41
vnx.su
Number of
Cavities
c701
c702
c703
c704
c705
c705
c706
c706
22
G701
G702
20
22
2
2
Conncts to
Location
Behindright kick panel
Right side of Jloor
Right quarter panel
Bighl quarter panel
Right side of cargo area
Right side of trunk
LeJt side of cargo area
Left side ot trunk
23-42
vnx.su
Notas
Hatchback
Sedan
Hatchback
Sedan
Hatchback:
Sedan:
23-43
vnx.su
Numbor ol
Cavilies
c751
c752
L/5J
c754
c755
G751
Connscts to
Location
Right side oJ cargo area
Right side of cargo area
Right side of reat window
Right side of hatch
Rearwire harness(C526)
Rear wire harness(C5251
Rearwindow defogger(+ I
Spoilersub-harness(C761)
Middle of hatch
Middleof hatch
l{otos
8 1 8 C1
engine
8 18 8 1
engine
c761
c762
c763
Number ot
Cavitios
I
1
Connocls to
Localion
Right side of hatch
Middle of hatch
Middle of hatch
Notos
Numbor of
Caviti6s
c77'l
G771
Connoctg to
Location
Lett side ot rear window
Rearwindow defogger(-)
23-4r'i
vnx.su
Notes
HATCH
WIRE
BEARWII{DOW
DEFOGGER
GROUND
IVIBE
c763
SPOILERSUB.HAFIIESS
23-45
'r]fi
vnx.su
Numbr of
Cavities
'lo
c671
c672
c673
c674
c675
c676
c677
2
4
4
14
Conn6cts to
Location
Under right side ot dash
Under right side of dash
Under right side of dash
Behindglove box
Behindglove box
Behindglove box
Behindmiddleof dash
Notog
Hoator Sub-hameEsB
connoctor 01
T6rminal
Number of
CavitioE
c681
c682
c683
c684
14
I
6
14
Connocts to
Location
Behindmiddleof dash
Middle ol floor
Behindmiddleof dash
Behindmiddle of dash
Heatersub-harnessA (C677)
Mode control motor
HeaterJan switch
Heaterconttol Panel
HEATERSUB-HARI{ESSB
23-46
vnx.su
Notos
Number ol
Cavities
c801
c802
c803
c804
c805
c806
c807
2
4
G801
18
2
Location
Connocts to
I Behinddashboardlowet cover
J Under left side of dash
Under left side of dash
Middle of floor
Under left side of dash
Under right side of dash
Behindglove box
Middle of floor
l{otos
UNDER-DASH
FUSE/RELAYBOX
23-47
vnx.su
Fuses
Under-dashFuse/RelayBox
c919
lTo dashboardwire harness(C55'l)l
c918
c920
.elayl
lTo lurn signal/hszard
c928
lTo SRS luso block {C931}l
cg22
lTo powor window rclayl
Elnnnr.'trJnnrJn
1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 22
UUIJUIJULJLILIIJ
n|:]nnnnnn
1
t4l 5
(7) 8
LIIJLIULJUUU
r: Not usod
.: Canadd
| ): S6dan
23
UIJ
r''lN11
9. 1 0 1 1
U LILI
r . - - - - - - - l
c929
J To SRSmain I
{C8011I
I harnass
c930
I To ignitionl
i
I switch
c931
I To undrdash
I
I fuso/rolaybox {C928)I
23-48
vnx.su
30A
Wire Colol
WHT
2
3
7 . 5A
WHT/RED Integratedcontrol unit, Ceilinglight, Power antennamotor. Data link connector (DLC)
20A
YEL/BLK
20A
20A
WHT/GRN
20A
GRNiBLK
20A
1 0A
10
1 0A
11
Not used
12
Not used
13
7.5 A
BLK/YEL
14
'15
20A
GRN/BLK
1 0A
YEL
to
7.5A
YEL/BLK
17
1 0A
7.5A
1 0A
RED/BLK
'to
20
21
23
1 0A
RED/WHT
1 0A
RED/YEL
1 5A
YEL/RED
24
REO
BLK/YEL
25
1 0A
PNK
26
1 0A
YEL/BLK
SRS unit
PGM-FImain relay, TCM, Cruisecontrot unit, VSS, ELOunit IUSA)
SRS unit
Turn signal/hazard
relay
23-49
vnx.su
Fuses
Under-dashFuse/RelayBox (cont'd)
NOTE: View from the backside of the under-dashtuse/relay box
c916
[To m.in wlro h.rnr.t lol39]l
cgt5
tTo ..r wftt hJtr.r (CsOrDl
c9r4
c917
[To mrin wh.
c913
lTo m.in wlro hlni.rr
(qt38)l
c91
tTo r..r w|? hrt|.|t
(C6O3ll
23-50
vnx.su
Under-hoodABS Fuse/RelayBox
T5 [To undo]-hood ABS fuso/rolay box cabl.l
Wire Color
ABS 81
20A
WHT/GRN
ABS 82
1 5A
WHT
ABS MOTOR 4 0 A
ABS UNIT
1 0A
BRN/YEL
23-51
vnx.su
Fuses
Under-hoodFuse/RelayBox
n
F n nn
46 45 /t4 35 3l
ALTERI{ATOR
fTo .ngino wlto hsrno$ {Tlolll
UU U UU
n
32
U
n
42
33
r:r
n
43
[To rldidor
hn r.l.Yl
Not usod
r: l\lot u3.d
umbor Amps
Color
31
1 5A
32
7.5 A
WHT/BLU ECM, TCM. Clock, Stereo radio/cassette plsyer, Maintenance reminder unit
a2
204
BLK/RED
34
50A
37
38
40A
BLU/lVHT
Blower motor
30A
BLK/GRN
?q
50A
WHT/BLK
lgnitionswitch {BAT}
40
50A
WHT
41
1 0 0A
42
43
20A
WHT/GRN
1 0A
WHT/GRN
Turn signal/hazard.elay
35
204
WHT
44
Not used
45
Not used
46
Not used
23-52
vnx.su
(C216li
c911
lTo ftain wiro hamers(C218)l:USA
23-53
vnx.su
PowerDistribution
Gircuit ldentification
8OX
ABSFUSE/FEIAY
UNOER-HOOD
ABS81 {2OA)
WHT/GRN
f
r-
Bight
tromsotcooia
blt ) nas
A8682II5AI
ABSoumomotor
8n /YEL-
A8Scontol unit
Btx/YEL
<
tu!.
ib.l3l7.5Al
YER/RED
A&Scontrol
unit
BATTERY
Stldar motor
r BLKffEL
_o_
- HOODFUSE/RELAY
8OX
UNDER
No.43ll0Al
wHT/GRt{
Turnsi0nrl/h.z.rd|thY
WHT/GRN
tlom
llom mLy
Keyintodocklohnokl{A/Tl
ECM
Cruisocontrolunil
controlmodub(TcMl
Tran.mksion
ABScontiolunh
&6k lighl!
I
AL]ERNATOR
L"I
No.1l(100A)
no.42l20A)
.r"-
oiot
GRi{/REo
{Topsge23- 55)
G401
23-54
vnx.su
ECM
_HOODFUSE/NEUY
UNDER
8OX
{Fromp.So23- 541
YELJWHT
frcMt
-OASH
UI{DEF
FUSSRELAY
BOX
tTop!9c23- 581
n^OIATOR
FANREI-AY
8LK/RED
No.l317.5Al
FUSE
Radi.torfln molor
ENGII{E
COOTAMI
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swtTcH
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oiot
BTOWER
MOTOR
RETAY
'"---G20t
G40t
8bw.r motor
8LU/WHT
8tX/GRtl-f
E
WHT-----
R!!r windowd,.to![.r
Noiacondsn..r
Cord.nrorlan motor
IJC como.a.lorclutdt
1/-
y
ut{DER-oAsH
R sE/nEL
BoX(Toprs.23- 58I
-IB>
wHTnED
*,"r^*__E>
Fl,$SlrrrrTgl,*r,
No,40l50Al
COMBIMTON
UGHTSWTTCH
{Top!! 23-59 )
- DASIIFUSAREUY
UiIDER
BOXfTop{6 23- 58 llc$.d!l
23-55
vnx.su
PowerDistribution
Circuit ldentification
- DASHFUSE/REIAY
BOX
UNDER
IGNITION
SWITCH
sRsFusE
81-0cK
No.25l10Al
l r c z
Ml
-'-
\'-
_ ^ACC
p age23- 5 7 1
r 1 No.24115A):
81881
engin
No.24l20A):Bl8C16ngin.
Moonrcofrclay
Wind.hicldwipotmotor
Wirdlhildwaah6.motor
R6arwindowws3hormotot{Hrtchblctl
Int.gGtodcontrolunit
PowerwirdowtclaY
Int6lratdcontrclunit
GRN/8I..K
BLKffEt
No.l5{1041
N0.40{504)
FUSE
(Frompago23- 551
-EiT"h#,H#J:r"
YEt..--
* 2 N o . 1{71 0 4 1
bor sockstl
ShittlocksolenoU{Ml
-up lights
Eack
C924
optionconnctor:
Daytimo
runninglightsconttolunit
23-56
vnx.su
IGNITION
SWTCHISTI
lFromp.! 23- 561
f7
I
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STARTFP
Bffi,!'HT6u?'ili,iY
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1,,,,,,
;rui8rrH
--.5
BIK/RED
BLX/!\,HT
st.dersotenoid
BLKMHT-
Starlsrsolenoki
BLK/REO
fr
r---
uxrivnSr$!gfr*,r.,
L-eumo
-------J
-DASHFUSEiRELAY
UNDER
BOX
No.l817.5A)
ELUMHT--?(From
pag623-56
)
No.23ll5Al
lG2
lFromp.!623- 56 )
PGM_ Ftmsinrctay
ECM
lntgretodcontrol unit
--E
YEURED
boxsockotl
{Fus/relay
St6r6oradio/c$rtt6 playot
Cigronelightor
Optionconnoctor:
C927
Pow6rminor *tuetols
noarwandowdologgorswitch
indicrtorlight
+ l,lo,16
{7.5A1
R6dietorfan roby
Elowormotor rclay
fuC compr$sor clutch rsl6y
A/C lhomGtst
Cond6ns&tan ml6y
Mod6controlmotor
Rocicubtion control motor
H6atrcontrolpanol
Rearwindow deloggorrelay
ABS pompmotor tolay
ABSinspctionconnoctor
ABScontrcl unit
Optionconnoctor:C925
Daytimerunninglights
controlunit
23-57
vnx.su
PowerDistribution
Circuit ldentification
- OASHFUSE/REI-AY
UNOER
BOX
WHT/RED
-
TrunUcergo
.rur lght
Fbwer.nr.nn! moror
Spotlight(Wrt'hmoonmoll
C.ilin! light
Drl! link conn ctor lDLCl
WHT/REof
boxsockstl
WHT/GRN
optionconnoclor:
C923
No,14l20l
FUSE
{lntomalconnaclionl
*G20t
G40l
WHTIYEL
*
BLU/4X+l
vnx.su
Powor
windowconttolunrt
{&ih intoDoworwindowmarloirwhchl
p,i""1" *;n6o* no1o,
l_
| l,lssrng6r'swndowmotor
GRN/BLX
-
YEUE|-K
-
r: Sedln
23-58
|
l-
Leftrerrwindowmoror
ftenroar winoowmotor
- DASHFUSE/RELAY
UNOER
8OX
DIMMEN
No.9l10A)
neontu
REo/BLU
? o *c--i| No.lolloAl
ftghtl
b.rml
lHish
I hordlishr
--E:::::l-
i
|
No.2lll0A)
REDiU,HT+REo^wHT
I
I No.22ll0Al
-TiED,TEL-L.trr
|
l"JnJ"",,**".
Rgh,I
| h.rdliohtlLowbrml
l
optioncondsclor:
C926
RED/BLK
*
l_tft
Rishn.
Iro
REDALK ..-
REDEL(+
parung
rgnr
fff')t.'..,nt
tillisht{sdanl
f#t) inner
Lic.n! pbt li0hts
Truilorliglfi ng connoclor
tGNtTloN
swtTcH
ltcl)
p36
23- 56)
lFrom
V
I
l-
FUS
HOLDER
t
BLK,ryEL
#
tt
I
m.ze
rroo
YEUBTK-
Tumdgnd/hazrrdr6i.y
l
l
23-59
vnx.su
GroundDistribution
Gircuitldentification
Blttory
_d_
:
GI
Tnnll|iltirn
houinc
_d_
:
G3
Et -
ux_r]---..o eu{l{
"-
*" ",
iTl*;,,
t (TcMt
ECM(-G
ECMILG2I
Cnnkd|rft Doritiont
ICKPI$nlor
t
ECM
TDC!.No. t
Cylndaroolitirn f
ICYPI!.ir.o.
1
L-----------
on[/8LU-r-.
WHT/BI-U+
sLu/GRN-F
Co(||llanhrft !p.d
r.Bor WT)
BLUrYEL
-
23-60
vnx.su
I
I
frcMt
l-
Cor|danlor
lan motor
-f,
:
G15l
h.ldtgh
lLow be.ml
- HOOO
UI{DER
FUSE/RTAY
8OX
Elowormotorrolay
R6!r*indow dsloegrrrcby
G40t
fro p.g. 23- 62)
AB{iF np motor
au#eu
ABSpr..&r! lwltch
E , A/c*ir" tr".osr
unitwitchrrn.r
E : ABSdbduknor
:
Min
wirr
h.moB
Ul
23-61
vnx.su
GroundDistribution
Circuit ldentification
lHi0hberm)
'LK
H[l[llsf#"ff'"Jfl1"'o"
Homrol.y
lgdtionkoylrvitch
8r
-;rv@.nciw*'*.,
oq_
BIK -{
t .
|-{N|
l-
4.X -7
BIK
tr
tr
E
lub - hamar! A
@ :llort.|
23-62
vnx.su
F
L
Cftxchsvynch
{M/Twhhcruisccontroll
conlrclunit I lArt
Intorlocl
r-
l-
P!.rsong.r'!dootloct kcycylindrsYritch
doorbck 3witch
P!s!6n06r's
Windlhiald wio.r/w$h6r rwhch
G,Ol
lR!6t p.g! 23-621
cod$rionl
Porvlrwidow rlhy
Tlm demlftd.id nhy
Intaeiltadcontrolunh
*-----ilHHlifr,
JUNCtOI{
coif{EcroR
g..(
SRslidbnor loht/&dit
d{
Daahhhr Mchinalaconto{..
Clocl
Grler. .nd hdixor hhtr
Mdntandranrnlidarurlt
R.r rvlndoud.foglr r*hdr
n"K
Chino
Cigrfi.ItDt.r
Gbv! boxhhl
Crui$ contmlmin .witdr
Starao[do/clalatta pbyal
c56l
) snsu'*
G80r
E: MdnYdoh.m..!
E, ootrtoct ,lo ttetr"..
@: noor*in |trttan
E'sasnr*rtrrtu
23-63
vnx.su
GroundDistribution
Circuit ldentification
Hstchbsckl
Pow6r
doorlockcontolunh
Driver'B
doorlockectrrtor
Driv6r'sdoorlockk6ycylind6lswhch
Drivor'sdoorlockswitch
Powor
mirroa
swhch
] Pow6rwindowmanorswitch
8r-K
----BLK,lVHT
Fuolg&lge sodiogunil
R rl pump
nuo,
Poworsntonmmotor
Tnibr lighingconnctor
L
E
eLx -i]-
BLK-
;l:. I taillisht
Licnroph6 light3
HishrDunt br.k6tisht
BtK---------
) ABs*nuoruni
AIY_I
I_
BI.KA.VHT
Lrh
I ABScontolunh
ABScontrolunh
Rorrwirdowwipcrnotor
cirt
Ro window dfoggor
nirt
E
E
E
Roarwiroharnoss
Ddv6r's
doorwileham63s
@ :Tailgatowirc hamoss
@ : R6erwindow d6lo9grgro{nd wirc
ABSsub-hernoss
23-64
vnx.su
Sd8n:
,.-*-{.4rr-*
Powgrdoorlockcontrclunit
Drivor'sdoor lock actustor
D ve/s door lock key cylindl rwhch
Ddv6r'sdoor lock switch
] Powerwindow mrster switch
--E
Brx,4/vHr
*",r *n
lfr]ff;nj
G5o2
Irunk latchswhch
f l8iler lightingconnector
Licoruopl.to lights
RiohtI .
nnst rrn gnr
L-ft J
Riohr)
.... .
ran||gnr
L-ft J
Poweranlonnamotot
Highmo0ntbt'k6light
Rearwindow dotoggor
otoa
oo "onuo,unn
]
t,*----l
=,-"*-
,_^
ABscontrclunh
.:
G702
@:
@ :Ddvo/sdoorwir hemoss
23-65
vnx.su
Battery
a Battory tluid (6lectrolytl contains sulturic acid. lt may cauaa aevere burns iI it gots on your skin or in youl oyos.
Woar protoctivo clothing and I fac shield,
- ll aloctrolyt6 gots on youl skin or clothos, rimo it off with wator immediately,
- lf eloclrolyto g6ts in your oyos, tlush it out by splashingwat6r in youl eyes for at least 15 minutes; call a physiclan
immediately,
a A battery gives off hydrogon gas, lf ignit6d. tha hydrogsn will orploda and could crack tho baflory cas6 and splattor
acid on you. Koep spa*s. flames, and cigarottos away from the baftery.
a Overchargingwill raiso ths tempelature ot th electrolyte. This may force electrolyte to splay out of the battery venta.
Follow lhe chargor manutacturer's instluctions and chargo tho battory at a prop61rate.
NOTE: The originalradiohas a codedtheft protectioncircuit. lt serviceto the car requiresany of the lollowing, be sure
to get the customer'scode number before
- disconnectingthe battery.
- removingNo. 32 (7.5 Al fuse from the under-hoodfuse/relaybox
- removingthe radio,
After service,reconnectpower to the radioand turn it on. When the word "CODE" is displayed,enter the customer's
s-digir code to restore radio operation,
Use eithera JCI or BearARBSTtester, and follow the manufacturer'sprocedures.It you don'r have one of these computerized testers, follow this conventional test procedure:
To get accurateresults,the temperatureot the electrolytemust be between TOoF l21ool and IOOoF{38oCl.
23-66
vnx.su
BATTERY
ERY COOE
COOE
TEST LOAD CHART
Use the test load ot 112the cold crankingamps (CCA)printed on the labelon the top of the battery. lf neithe. is indicated, us the informationbelow:
BATTERY
CODE
COLD CRANKING
AMPS (CCA)
80
70
550
55
405
440
TESTLOAD
lamps,
270
220
200
23-67
vnx.su
Power Relays
RelayTest
t{ormally-opn Type:
1.
2.
T6rminal
A
(B- D)
PowEr
Connactod
Di!c!nnact6d
IP
tb
I
I
a
a
a
a
a
A
\
B
/
tffit
t[fT4r
\ C
23-68
vnx.su
D ,
vnx.su
23-69
lgnition Switch
CAUTION:
a All SRS electdcal wiring harnessssaro covotod whh
yollow insulation.
a Botore disconnocting any part ot th6 SRS wiro harn6ss. connoct tha shon connoctor(t).
a Replactho ontiro affected SRS hames! asllmbly It
it has an op6n circuit 01 damagod widng.
J.
1.
Terninal
BAT
tG1
ST
P6ition
--o
oI
KNEE BOLSTER
DASHBOARDLOWERCOVER
23-70
4.
vnx.su
ElectricalSwitch Replacement
a All SRS lectric8l wiring hamossesar covorsd with
yellow insulation,
a Befora disconnecting any pan of tho SRS wilo harneas. connect the short connoctor(sl.
a R6placethe entire attect6d SFS harnessassombly if
it has an opon circuit 01 damaged wiling.
4.
3.
7.
vnx.su
23-71
lgnition Switch
Steering Lock Replacement
CAUTION:
a All SRS electrical wiring harnessesale covsred with
yellow insulation.
a Belore disconnecting any parl ot the SRS wir halness, connecl the short connector{s).
a Replacethe entire alfected SRS harness a$6mbly il
it has an open circuit or damaged wiring.
1.
2.
3.
4.
5.
NUT
13 N.m
(1.3 kgf.m, 9.4 lbl'ftl
BOLT
22 N.m
12.2 kgl'm. 16 tbt.ftl
23-72
vnx.su
StartingSystem
GomponentLocationIndex
CLUTCHINTERLOCK
SWITCH(M/T}
Test, page 23-78
Switch Adiustment.section 12
BA
Test, page23-66
23-73
vnx.su
Starting System
GircuitDiagram(M/Tl
tGNtTt0t{
SWTCH
UNOERHOOO
FUSE/REI.AY
BOX
+O
/.^1\tOFr
\_:/
I
I
BT.KMHT
STARTER
CUTREIAY
EUqWHT
II
t*u*
I
I
8l-K
r H l
I STARTER
G 20r
G40r
vnx.su
Circuit Diagram(A/T)
G?{rao
swncH
-HOOD
UI{DER
FUSE/NEUY
BOX
N,0.41
{l00Al
-{ 6i\ o+
Io.39160t
\_v
I
Bl-torvHT
II
,(h\
A/I GEAR
g, ffi.:11?[:#ir11,",,
II
BI.K/BED
vnx.su
Starting System
Startel Test
NOTE: The air temDeraturemust be between 59 8nd
10OoF(15 and 38oC) beforetesting.
Recommendsd Procodure:
J.
4.
TERMINAL
NEGATIVE
NOTE: After this test, or any subsequent repair,
resetthe ECMto clearany codes (seesection 1 1)
23-76
vnx.su
5.
Check lor 8n opn in the BLKMHT wire circuit between the staner and ignition switch, and connectors.
6.
7,
a
a
a
a
a
23-77
vnx.su
Starting System
Starter Solenoid Test
2.
1.
Tsrminal
Coil
HOLD-IN
Trminal
A
PULL-IN
ClutchPedal
Housing
o- ---c
o- ---.o
RELEASED
PUSHED
23-78
vnx.su
Starter Replacement
1 . Disconnectthe negativecable from the batterv.
2.
4.
UPPER
MOUI{TII{GBOLT
44 N..h (4.5 kgl.m, 33 lbt,ftl
8 TERMII{ALMOUIITTI{G
NUT
9 .ln (0.9 kgf.m, 6.5 tbf.ttl
AIR CIEANER
HOUS|L
TERMINAL
6.
CAALES
23-79
vnx.su
StartingSystem
Startel Overhaul
CAUTION: Disconneclth battery ngativecable befole
lomoving the startet.
SOLENOID
PLUNGER
Inspection,page 23-85
STARTER
SOLENOID
Test, page 23-78
ARMATURE
PINIONGEAR
IDLERGEAR
ENOCOVER
t r . /
ERUSH
Inspection,page 23-11
COVER
SOLENOIDHOUSING
IDLERGEAR
@*
HARNESSBRACKET
ARMATURE
lnspection and Test,
page 23-82
ROLLERBEARINGS
and CAGE
Prevenl rollers trom being scattered and lost.
MOLYBDENUMDISULFIDE
STEELBALL
installsteel ball
from clutch side.
-s@]
MOLYBDENUM
DISULFIDE
CLUTCHASSEMBLY
OVERRUNNING
Inspection,page 23_84
_R1
MOLYADENUM
DISULFIDE
GEAR HOUSING
23-80
vnx.su
G) BRUSHHOLDER
O BRUSHI{OLDER
E BRUSHHOLOER
O BRUSHHOLDER
SPRINGSCLAE
23-81
vnx.su
StartingSystem
ArmatureInspectionand Test
1.
CommutrtorRunout
Standard(Naw):0-O.O2 mm (0-O.OO08inl
SowicoLimit: 0.O5 mm (O.O02inl
Inspectthe armaturefor wear or damagedue to contact with the field coil magnets.
COMMUTATOR
A dirtv or burnt commutator surface may be lsulfaced with emery cloth or a lathe within the following specilications.
Commutator Diametr
S t s n d a l d( N 6 w ) :2 9 . 9 - 3 O . O m m ( 1 . 1 7 - 1 . 1 8 I n l
Selvico Limit: 29 mm (1.14 lnl
VERNIEBCALIPER
23-82
vnx.su
ITOTGOOO
ARMATURETESTER
HACKSAW BLADE
MICA DEPTH
ARMATUFE
M
SHAFT
COMMUTATOR
23-83
vnx.su
StartingSystem
Starter Field Winding Test
OverrunningClutch InsPection
1.
2.
Check for continuity between each brushand the armature housing{ground) lf continuity exists, replace
the armatulehousing.
BRUSHES
CLUTCH GEAR
DRIVEGAR
23-8,4
vnx.su
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth ale
damaged.
Solenoid PlungerInspection
StarterReassembly
Check the contact points and the face of the staner solenoid plunger for burning, pitting or any other defects. lf
surfacas are rough, recondition them with a strio of
# 500 or #600 sandpaper.
2.
soLEr{otD
PIUNGER
a&T&'
s..
V
3.
BRUSH
23-85
vnx.su
StartingSystem
PerformanceTest
NOTE: Beforestaning the tollowing checks. disconnect
the wire Jrom te.minal M, and make a connectionas
describedbelow usingas heavya wire as possible{preferably equivalentto the wire used for the car).
Rotracting Test:
Connectthe starterto the battery as shown and contirm that the motor starts 8nd keeps rotating.
23-86
vnx.su
lgnition System
Gomponent Location Index
IGNITIONTIMINGCONTROLSYSTEM
a Troubleshooting,
section I1
a Inspectionand setting, page 23-89
DISTRIBUTOR
Top End Inspection,page 23-91
Removal/lnstallation,
pages23-91, 92
Overhaul,page 23-93
Reassemblv,
page 23,94
lgnitionCoil Test/Replacement,
page 23-95
lgnitionControlModule {lCM} Inpur Test, page 23-96
SPARK PLUGS
fnspection, Page 23-97
WIRES
Inspection, psge 23-94
23-87
vnx.su
lgnition System
Circuit Diagram
BOX
HOOO
FUSE/RELAY
UNOERECM
V
I
YEUGNiI
posilioo
sonsor
CKP:Cr6nk.halt
position
snsor
CYP|Cylindor
tG tTtoNc0NTROl(cMl
MoDUr.r
/ H8sbuilt in \
I OOrsO
I
TOC/CKP/CYP
SENSOR
-_r_1=__E
-J---L--L--Lr
U'+++
ORN
23-88
vnx.su
4.
NOTE:
a Shift lever must be in neutral.
a All electricalsystemsshould be turned OFF.
POINTER
SERVICE
CHECKCONNECTOR
I2.PI
NOTE:Locatedbehindthe right kick
oanel
REOMARK
TIMINGLIGHT
lcont'd)
23-89
vnx.su
lgnitionSystem
lgnition Timing lnspection and
Setting (cont'd)
5.
MOUNN G BOLTS
24 N.m (2.4 kgl.m, 17 lbt'ftl
b.
ldle sp6od
M/T: 750 t 50 rpm in neuttal
A/T: 75O t 50 rpm in @ or @
NOTE: Allelectricalsystemsshouldbe turnedOFF.
Adjustthe idlespeedil necessary(seesection 1 1).
23-90
vnx.su
Distributor Removal
1.
cap.
3.
23-91
vnx.su
lgnitionSystem
DistributorInstallation
Coat a new O-ring with engine oil, then install it.
5.
DISTRIBUTOR
END
CAMSHAFTEND
23-92
vnx.su
DistributorOverhaul
BLKTYEL
DlsTNIBUTOR
ROTORRETAII{IITGSCREW
lMust be madeof
diamagnsticmateriall
HOUSING
Check for cracks
oa damage.
IGNITIONCONTROLMODULE {ICM)
Troubleshooting,section 1 1
Input tost, page 23-96
23-93
vnx.su
lgnition System
Distributor Reassembly
1 . When reassemblingthe dislributor, install the distributor rotor so on the shaft that it faces in the direction shown (toward the No. 1 cylindetl,
Checkthe conditionof the wire terminals.lf any te.minalis corroded,cleanit. and if it is brokenor distorted. reolacethe wire.
IGNITION
WIRE
INDEX MARKS
IGNITIONWIRE
3.
23-94
vnx.su
lgnitionCoil Test
1.
With the ignition switch OFF, remove the disrributor cap, rotor, and cap seal, then remove the leak
cover.
CAP SEAL
I11
t L
B{-}
l
WHT/BLUWIRE
23-95
vnx.su
lgnition System
lgnition ControlModule(lCMl Input Test
NOTE:
a SeesectionI 1 if the malfunctionindicatorlamD(MlL)
blinks.
a Pertorman input test for the ignitioncontrol module
(lCM)after finishingthe fundamentaltests for the ignition system and the fuel and emissionssystems.
a The tachometershouldoperatenormally.
1.
2.
Disconnectthe BLK/YEL,WHT/BLU,YEL/GRN,and
BLU wires from the lCM.
4.
Turn the ignitionswitch ON. Checkfor voltagebetween the WHT/BLUwire and body ground.
There should be battery voltage.
a lf there is no battery voltage,check:
- lgnition coil
- WHT/BLUwire betweenthe ignitioncoil and
the ICM
a lf there is battery voltage. go to step 5.
Checkthe YEL/GRNwire betweenthe ECMand the
tcM.
rcM.
YEL/GRN
wlRE
3.
Turn the ignitionswitch ON. Checkfor voltagebetween the BLK/YELwire and body ground.
There should be battery voltage.
a lf there is no batteryvoltage,checkthe BLK^/EL
wire betweenthe ignitionswitch and the lCM.
a lf there is battery voltage,go to step 4.
23-96
vnx.su
.
.
.
.
Damaged
gask6t
rmpropergap
Oil-touling
Carbondeposits
Crackedcenter
electrodeinsulator
Bl8Cl engine:
a Make surethat the '1.4mm (0.055 in) wire-type
pluggaugedoes not go into the gap for the platinum tip plug. lf the gaugegoes into the gap, do
not attemptto adjustthe side electrode;replace
the plugwith a new one.Useonlythe sparkplugs
listed below.
ROUNDEOELECTRODE
Electrode Gap
Standard:1 .2-'l .3 mm
{0.047-O.051 in)
ServiceLimit: 1.4 mm
{0.055 in)
Z F R s F -11( N G K )
K J l 6 C R - 111
(Nippondenso)
Z F R 6 F -1 ( N G K )
KJ2OCR-11
1
(Nippondenso)
S p a r kp l u g sf o r t h e B ' l 8 C l e n g i n e :
P F R 6 G _ 1( N
3GK)
PK2OPR-113
I
I Forall normaldriving
{Nippondenso)
1 . 1m m
{0.0,$ in)
3.
23-97
vnx.su
ChargingSystem
ComponentLocationlndex
CHARGINGSYSTEM LIGHT
lln the gauge sssemblyl
Tst. pages23-1OO.101
Bulb Locations, page 23-1 15
BOX
UI{DER.HOOD
FUSE/BELAY
(USA:Hasbuilr-inELECTRICAL
LOADDETECTOR
{ELD)UNIT)
Troubleshooting
ot ELD,sction11
BATTERY
Tost,
ALTERNATORBELT
Inspoction and Adiustment, page 23-108
Alt6rnator/Regulator
Tosl, pags23-102, 1O3
Replacament.page 23-'l 04
Ovsrhaul, pago 23-105
23-98
vnx.su
CircuitDiagram
- HOODFUS/REI.AY
UI,IDER
8OX
No.4t11004) /a\
ilo.39l50Al
*1 :USA
+2 llo.24ll SAl:81881.min
tlo.24{2041:
818C| .niin6
UNDER_OASH
FUSE/REIAY
8OX
. NTEGRATED
COMTNOL
UMT
. aBscoilTRoruNn
VI
ECM
VI
Fr|'l)
wNort'lc
AI.TERNATOR
oiot
G401
23-99
vnx.su
ChargingSystem
Troubleshooting
Bofore troubleshooting check
- tightnessof the alternatorbelt (see page 23-1Og).
- that the malfunctionindicatortamp lMlL) of the ECM does not blink. lf it blinks,refer to section 1 1.
lf the charging system light is on, or th battery is dead or low, prtorm the following tests in the order listed below:
1.
2.
3.
o pago23-1011
BOX
FUSE/RELAY
(r..r tid.)
Turn the ignition switch otf.
I'{TEGRATED
CO]TTROLUI{IT
Disconnect the 4-P connoctor
lromt th altornator.
H.tchb.ck:
UNIT
ABS COI{TROL
tlo rhon o. opon h ih. WIfT/BLU
who. Porfom dtomrtor/rogdttol
rost beo pag. 23-l02l.
2A-P CONi{ECTOR
23-100
vnx.su
wirg side
L IWHT/BLUI
(cont'd)
23-101
vnx.su
ChargingSystem
Altornator/RegulatorTest
NOTE; Mske surethe battery is sufficientlychargod(sa
page 23-66).
LOADADJUSTER
ICARBONPILE)
FULLFIELD
TESTEB
LEAD(BLUI
VOLTMETER
t{EGATIVE
LEAD(8LK}
O IOAD
VOLT
SELECTON
TEST
swlTcH
II{DUCTIVE
FICK.I.|P
IGR '
VOLTMETER
POStTtVE
LEADIREDI
Releasethe acceleratorpedaland
let the enginoidle.
EGATIVETESTER
CABLE(BLKI
Make sure all electrical systems
are turned otf. Turn the selector
swilch to position2 (charging).
INDUCTIVE
PICK.UP
B TERMI]TAL
WIRE
Removethe inductivepick-upand
zero the ammeter.
NO
tropagezJ-ruJ,
23-102
vnx.su
(Frompage 23-1021
Apply a load wirh the VA'-4O until the battery voltagedropsto bet w e e n 1 2 - 1 3 . 5V .
NOTE; Attach a probeto the VAT-4Ofull field test lead and insert the orobe
into the full tield sccesshole at the back of the alternator.Switch the field selector
to the "A (Ground)" positionmomentarilyand check amperagereading.
CAUTION: The voltago will ris6 quickly whon the slternator is full-fiolded. Do
not allow th voltago to oxc66d 18 V 01 it may damage the elect.ical system
REGULATOR
{Locatod
the end cover)
FULL FIELD
ACCESSHOLE
4-P CONNECTOR
wire side
L IWHT/BLUI
23-103
vnx.su
ChargingSystem
Alternator Replacement
NOTE: The originalradio has a coded theft protection
circuit. Be sure to get the customer'scode numberbefore
- disconnectingthe battery.
- removingthe No. 32 {7.5 A) fusefrom the under-hood
fuse/relaybox.
- removingthe radio.
After service,reconnectpowet to the radioand turn it on.
"CODE" is displayed,enler the cusWhen the word
tomer's 5-digit code to restoreradio operation.
1.
2.
UPPERMOUNTII{G
BOLTS
BRACKET
il4 N.m {4.5 kgl'm, 33 lbl'ft}
,\\\- ( \ \
\(^
\-/ I
NUT
TERMINAL
B TERMINAL
BRACKET
BOLTS
BRACKET
44 N.m (4.5 ksl.m, 33 lbt'ft1
NUT
MOUNTING
44 N.m (4.5 kgt.m, 33 lbf'ftl
5. Removethe alternatorbelt from the alternatorpulley.
6.
23-104
w
vnx.su
AlternatorOverhaul
CAUTION: Do not rmove th pulley unlEsthe t.ont
bearing needs r6placsm6nt.
PULLEY
10 mm BOX WRENCH
PULLEYLOCKI{UT
1 ' l l N . m 1 1 1 . 3k g t . m , 8 2 t b f . t r l
rl
@n
FRONTBEARING
STATOR/DRIVEEND
HOUStt{G
BBUSHHOLDER
INSULA
TOR
ARUSH HOLOER
(@P
"
STATOR THROUGH
BOLT
VOLTAGEREGULATOR
%A
re
DIODEIRECTIFIER)ASSEMBLY
Test, page 23-106
PULLEYLOCKNUT
111 N.m (11.3 kgt.m,82 lbf.ft)
REAR HOUSING
Inspection,page 23-
TERMINALINSULATOR
qt
".,"
fu"- "o*n.r"
-
BRACKET
23-105
vnx.su
GhargingSystem
AlternatorBrushInspection
Rectifier Test
NOTE: The diodesare designedto allow currentto pass
in one directionwhile blockingit in the oppositedireclion. Each diode must be tested for continuitvin both
directionswith an ohmmeterthat has diode checking
capability.Since the alternatorrectifier is made up of
'16
checks,
eight diodes(four pairs),there are a total of
VERI{IEBCALIPEB
23-106
vnx.su
RotorSlip RingTest
1.
Stator Test
ROTORSHAFT
cotl coRE
23-107
vnx.su
ChargingSystem
AlternatorBelt Inspectionand Adjustment
Boh Tsnsion Gaug6 Mothod:
Foltowingthe gauge manuJacturer'sinstructions,attach
the belt tension gauge to the belt and measurethe
tension.
Deflection Method:
Apply a force of 100 N (1o kgt, 22 lbJ)and measurethe
deflection between the alternator and the crankshatt
pulley.
Detlsction:9-11 mm (0.35-O.43 inl
NUT
ADJUSTIT{G
ALTER'{ATOR
24 N.m {2.4 kgl'm, 17 lbl'ft1
MOUt{Tlt{G
NUT
44 t{.m (4.5 kgt.m,
33 tbf.ft)
PULLEY ALTEBNA
oTJGG-0O1010A
lf adiustment is nocessarY:
lf adi$tmsnt is nscaasary:
1.
2.
2.
3.
3.
23-108
vnx.su
22t.
Fan Gontrols
ComponentLocationIndex
For the A/C system, see section 22.
CONDCNSER
FAI{ BELAY
lwir6 color3:ELKnirHT,WHTI
IBLUryEL,and BLU/BL(
I
UNDER-HOOD
FUSE/RELAY
BOX
ENGII{E
cooLA T
TEMPERATURE
FAN MOTOR
Test, page 23-112
{ECT)
SwlTCH
Tesr,page23-'l12
BADIATORFAN MOTOR
Test,page23-112
23-109
vnx.su
FanControls
Circuit Diagram(WithoutA/Cl
- DAstl
ul{oR
GIINONSWITCH FUSC/RELAYBOX
- HOODFUS/REI.AY
BOX
UI{OER
No.4l{lmA,
No.39l50Al
.{
6r\
\-Y
ECM
Gtr{
l,*^,
($fffiHil'r"n.''
t?i'r?Tdf.ol
I
I
ffi,"'l
I
Btl(
II
:
G10l
23-110
FIIF.-
vnx.su
F'rrr^'l
-l
ots YEt{<\o*r
- HOOO
UNOER
FUSE/REIAY
BOX
No.41l100Al
G FIONSWIICH
,5
No.39l50At
RAOIATOR
FAN
REI.AY
GRt{
| ,*n,n,
,z*r CoOtAt{T
qU llffffarunErEcrr
t?i'i."1",i:"ol
monronI
FAN
I
MOTOR
BI-K
II
:
G10l
23-111
vnx.su
Fan Controls
NOTE: Bleedair from the cooling system atter installing the enginecoolanttemperature(ECT)switch (seesection 1O).
1.
2.
3.
2.
Terminal
B
;;,".,"---\
Above196 2O3"F
{91-95'C)
Switch
B e l o w1 8 1 - 1 8 9 o F
(83-87'C)
23-112
vnx.su
o_
-o
GaugeAssembly
ComponentLocationIndex
CAUTION:
a All SRS electrical wiring harnossesare covrod with
yellow insulation.
a Bofore disconnecting any prn ot th SRS wire harness, connect tho short connector(sl.
a Rplaceth6 entirs affGctedSRS halne$ assembly if
it has an open circuit o? damaged wiring.
GAUGE ASSEMBLY
GaugeLocationIndex,page 23-114
IndicatorLocationIndex,page 23-114
TerminalLocationIndex,page 23-114
Bulb Location.page 23-'l 15
Disassembly.page 23-119
Removal,page 23-118
VEHICLESPEEOSENSOBIVSS}
Test, page 23-120
fnput Test. page 23-120
Repfacement,page 23-122
PARKITTG
BRAKESWITCH
Test, page 23-127
BRAKE FLUID LEVELSWITCH
Tesr, page 23-127
EI{GINEOIL PBESSURESWITCH
Test, page 23-122
ENGINECOOLANTTEMPERATUREIECTI GAUGE
SENOINGUNIT
Test, page 23-126
23-113
vnx.su
GaugeAssembly
LocationIndex
Gauge/lndicator/Terminal
CAUTIOI{:
a All SRS olectrical wiring harnessosaro covorod with
yellow insulation,
Belol disconnecting any part ot tho SRS wiro hatnesa. connoct the short connoctol(El.
Replacoth6 entire aff6cted SRS hamess sssombly lf
it has an open circuil or damagod widng.
"8"
CoNNECTOR (c5601
Bi ----------+
co r{EcroR"c" (c558}
B16
Cl ----+ClO
A/T GEARPOSIT|O
IIDICATOR SYSTEI
Seepags23-132
TACHOMETER:
Indicatos lOO rpm at
20O pulss per minul
of the ignition control
modulllCM).
FUEL GAUGE:
GaugeTest, page 23-123
Sending Unit Tost, page 23-124
f',. /i)
)Y
- " b
\_./ \J
\-___--
E GI[{E COOLAI{TTEIIPEFATUREIECTI
c6uge TEst, p6g6 23-126
Sending Unit Tsst, pago 23-126
a1 -----> A5
Dl-------.>D13
SPEEDOMETER:
Indicates (60 mph 6i 1025 rpml or
{60 km/h at 637 rem) of th
vhicle spe6d sonsor lVSSl.
coNNECfOR
"A" (C557)
col{]{ECTOR"D" (C5591
23,-114
rtrF
--
vnx.su
BulbLocations
L|GHT{r.4 Wl
OOOR-OPEN
INDICATORLIGHT{1.4 WI
TOBLIGHT11.4WI
MALFUI{CTIONINDICATORLAMP
(MrLl fi.4 wt
iSRS INDICATORLIGHT(1.4 W}
LIGHTS
MAINTENANCE
REMINOER
LIGHTIT.4 WI
{3.4 W x 3}
cRutsE LTGHT
tl.4 Wl
ABS INDICATORLIGHT(1.4 W}
TAILGAT-OPENINDICATORI-IGHT{1.4 W): Harchback
TnUNK-OPENINDICATORLIGHT 11.4 W): Sodan
23-115
vnx.su
GaugeAssembly
GircuitDiagram
ulocn-DsH
&X
RISC/RELAY
Tw'lcu I
+ 3r,4ts.
r
t_gstr
sas
tNtT
I
I
A
FUSE
l{l(
6t0l
[fffi"vv
sns
txocAloR
UGTIT
.lsffiisl
{,MT
VI
- r Gin&no
".lJ
r l
I C,afi/ilD
GMVn!O
#n
ir ll
l8flfl*';
i| \()n
I RUNIiITGI
I uGfiTs \
ht0/Git{
Gn[/Ft0
6mii'
I
-
23-116
vnx.su
r
-"
|
.
| snrxt
I Rlp
ir |ffi.
l
Itrr
r l
it A
:
r6ii G30r
N'ElGAI.EE
sExDr6 ulllT
a{G|l|
c@lat{T
Il$EiA'l il
tErcTt
SAdTG
txt
IIFT
TURt{
stcll L
DtCATOn
UGHI
fircll
EAT
lotc ToR
TIGHT
r |l{rE|Arcc
Sfn 0ER
ucfir
6tc|l| Oh.
mEssunr
[oic Toi
IIGHT
.,tlvt
stAT Et T
gIDEN
IJGHT
M Ut[CrOrl
OG TOi
txtu
nooB-oPEtl
fptc^Ton
TIGHI
I|
tt,4w)
'
B1
a2
HflHh*'F:
trtc[iE
olL
FnISSUNE
s1vlrcH
I
OFVEFS
SCAT*LT
slvtTcH
1:
G501
G502
23-117
vnx.su
GaugeAssembly
Removal
Tilt the steeringwheel down with the tilt adjustment
tevet.
CAUTION:
a All SRS electrical wiling harnessesara cover6d with
yollow insulation.
a Eofore disconnecting any part ol the SRS wiro harn6ss, connoct lhe short connector(sl.
a Roplacetho entirs affocted SRS harneasassembly if
it has an open circuit 01 damaged wi.ing.
CLOTH
PROTECTIVE
Prythe gaugeassemblyout, and disconnectallconnectorsfrom it.
SBSMAIN HARI{ESS
(Covor6dwith Yollowin.ulationl
23-118
vnx.su
Disassembly
NOTE: Handlethe terminalsand printedcircuit boardscaretullyto avoid damagingthem.
TAGHOMETER
MOUI{TINGSCREW(x 3l
ENGINE
COOLA]TT
TEiIPERATURE
{ECT}
GAUGE
MOUNTING
SCREW(x 3)
SPEEDOMETER
MOUNTTNG
SCREWtx 4l
k)T
n
FUELGAUGE UNIT
Test, psge 23-123
. SPEEDOMETER
Specilication, pa96 23-1 14
Troubfeshooting. page 23-1 20
. ODOMETER
Troubleshooting,page 23-1 20
. TRIP METER
Troubfeshooting,page 23-120
23-119
vnx.su
Speedometer/TripMeter/Odometer
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence.
Item to be inspected
-9
lt)
a
; 6
+*
c.r i
. ( D
z c
*
;5
9 c
d)=
Symptom
Odometerand trip meter wotk, but speedometerdoes
not.
q)
'
qlv
'i
F
-9
(L
> g
o
o
BLK
BLK/YEL
ORN
lgnitionswitch ON (ll)
. Shon to ground
. An open in the wire
NOTE:A shortto groundin the ORN wire can be causedby a short in any componentconnectedto lt.
vSS Tost
Speedometerdoes not work.
3-P CONNECTOR
2 4 ( 1 5 A ) : 8 1 8 8 1 e n g i n e N o . 2 4 { 2 0 A ) : 8 1 8 C 1e n g i n e
23-120
vnx.su
ls there about 5 V?
Putthecar in neutralwithkevON.
Ropairopon in th6 OBil wire botween tho VSS and th6 3p.odomolgt.
23-121
vnx.su
VehideSpeedSensor(VSSI
Replacement
Disconnectthe 3-P connectortrom the vehiclespeed
sensor{VSS).
EngineOil Pressure
IndicatorSystem
EngineOil PressureSwitch Test
1.
ENGI'{EOIL PRESSURESWITCH
TERMII{AL
POSITIVE
23-122
nlmlliitl
vnx.su
FuelGauge
GaugeTest
NOTE: Referto page23-1 16 for the luelgaugesystem
circuit.
'1.
2.
3,
4.
o.
vnx.su
23-123
FuelGauge
SendingUnit Test/Replacement
oo not lmoke while working on tho fuol
@
system. Kaop open flamos away from your wotk aroa.
1.
2.
3.
4.
5.
Measurethe resistancebetween the A and B terminalsat E (empty),1/2 (halffull) and F (full)by moving the tloat.
Float Position
Resistance lO)
6.
E
1 0 5 - 1 1 0 25.5-39.5 2-5
23-124
vnx.su
Low FuelIndicator
IndicatorLight Test
UNEUCKLED
J.
A
C"**
o--
BUCKLED
ANCHOR
3-P CONI{ECTOB
23-125
vnx.su
EngineCoolantTemperature(ECTIGauge
GaugeTest
Make sure the ignitionswitch is OFF,then disconnect the YEL/GRNwire from the ECT gaugesending unit and g.ound it with a jumper wire.
TERMINAL
POSITIVE
Temperatu.e
Resistance(O)
5.
23-126
vnx.su
1330F(560C)
't37
185.F(850C)2 1 2 0 F( 1 0 0 0 c )
46-30
BrakeSystemlndicator
ParkingBrakeSwitch Test
Removethe tloor console, and disconnect the connector from the switch.
Torminal
L6vorposition
POSITIVE
EODY
Terminal
Floatposition
UP
NEGATIVE
POSITIVE
UP
DOWN
-o
DOWN
POStTtVE
CAP
RESERVOIR
DOWN POSITION
TERMINAL
Canada:
lf the parking brake switch is OK, but ths brake system indicator does not function, pertorm the input
test for the daytime running lights control unit (see
p a g e2 3 - 1 5 6 ) .
Switch contacts open at
proper fluid level.
4.
23-127
vnx.su
MaintenanceReminderS ystem
Gomponent Location Index
CAUTION:
a All SRS eloctrical wiring halnsses are coveled with
yllow insulation.
a Bsfore disconnocting any part of the SRS wire harne6a, connect tho shon connoctor(s).
a Replacethe entire affoctod SRS hsrness ass6mbly if
it has an open circuil or damagd wiring.
MAINTENAf{CEREMINDERLIGHT
(ln th6 gaugo 63.smblyl
GaugeAssembly.page 23-113
MAINT
REOD
VEHICLESPEEDSENSOR{VSS)
{On the t.ansmirsion houaingl
Test, page 23-120, 121
Input Test, page 23-120
page 23-122
Repfacement,
MAINTENANCEREMINDERUNIT
lBohind tho dashboard lowor covor)
Input Test, page 23-131
23-128
vnx.su
Description
Basedon signalsrecaivedtrom the vehiclespeedsensor (VSS),the microcomputerin the maintenanceremande,
unit,
which is located behind the dashboardlower cover, computes the distances traveled. When you turn the ignition switch
on, the reminder light in the gauge assembly will come on for two seconds (bulb check tunction).
Ar 9,650 t 160 km (6,000 t lOo miles)intervals,the reminderlight witl gtow for two secondsand then btankten
seconds attr you turn the ignitionswitch on. This will repeateverytime you turn the ignitionswitch on until the car reaches
12,O7O! 160 km (7,500 1 10O mites).
Beyondthe 12,O7O! 160 km (7,500 t IOO mite)interval,the tight will continuero gtow after the butb check until
you turn the ignition switch off or reset the unit.
To reset the unit, the car must be pa.ked and the ignition switch must be on. Pressthe reset button on the unit for mo.e
than three seconds,and the remindertight will go otf.
NOTE:
a Turn the ignitionswitch OFF bforeyou rmovethe 5-P connectorfrom the maintenancereminderunit.
otherwise
you will cancel all data in the memorv.
a The data will remainin the memoryeven when the ignitionswitch is turned ofJ, or if the unit is disconnected.
When
the ignitionswitch is turned on, and the car is driven. additionaldata will be stored.
sEt{son
tvss
-----------------l
MAINTENANCEREMINDENUN|T
23-129
vnx.su
Maintenance
ReminderSystem
CircuitDiagram
UNDER-HOOD
FUSE/REIAY
8OX
MAINIET,IAT,ICE
REMINOER
UiIIT
23-130
vnx.su
No.
Wire
BLK
Tost condltion
Unde. all conditions
Under all conditions
WHT/BLU
lgnitionON (lll
YEL
lgnitionON (ll)
B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e
under-dashfuse/relaybox
Blown bulb
An open in the wire
PNK
ORN
Test: DaEiredrasult
23-131
vnx.su
A/T GearPositionIndicator
ComponentLocationlndex
cAUTtOt{:
a All SRSolectdcalwiring harnossos
a16covarodwith
yellow insulation.
Boforo disconnocting any part ot the SRS wlr. harnoaa, conngct the short conn6ctor(sl.
Roplacotho entire aff6ct6d SRS harn$s assombly il
it has an op6n cilcuit or damagod wiling,
GAUGE ASSEMBLY
Bemoval,page 23-118
Disassombly,pag 23'1 19
Bulb Locations,pago 23-115
IiIIERLOCK SYSTEM
page 23-139
DGscription.
A/T GEARPOSITION
IlTDICATOR
InputTest,pago23-134
23-132
vnx.su
CircuitDiagram
IGNITION
UNOER-OASH
FUSSREI-AY
8OX
swrTcH
UNOER_HOOD
FUSE
/ REI.AY
8OX
wHT/BLX
+wHT+
/-?t CH-
\ty
ftrt*l
"l
Bl.x/Yt-+<.\-o+!
No.19ll0A)
FUSE
TMI{SMrSSr0r,l
c0IJTRor
i.IODULE
ITCMI
YEL
lln thogtugo8lsmbvl
fitMritc-;-
D4
CANCEL
AN GEAR
POSITION
INDICATOR
DIMMING
CIRCUIT
lgll
YELTWHTGRN/8L|(
II
.
INTERLOCK
coMtRot
TRANSMISSION
MODU|.! [TCM}
UNJ]_
o*nn,o_yTT
GRT'IMHT
pr{x/cR1
-J
No.19
{l
FUSE
GR |-U -l
GRiITYEt
LTGNNiW{T
A/TGEAN
POStTt0N
coNsot-E
LIGHT
0.4w)
M GEAR
PosrTroN
swncH
I
DASHI-IGHTS
BRIGHTNESS
CONTROI.IER
G201
G40t
G2ol
G401
23-133
vnx.su
"8"
CONI{ECTOR
SS
23-134
vnx.su
No.
Wila
BLK
Test condition
Under all conditions
lgnitionswitch ON {ll}
YEL
No.
Wile
Tost condition
RED/BLK
No.
Test condition
Shift lever in position@
GRN^^/HT NOTE:Don't pushthe
brakepedal.
GRN/RED Shift lever in position@
GRN
Shift lever in positionS
YELAA'HT
GRNA HT
GRNITEL
GRN/BLK
GRN/BLK
lgnitionswitch ON (ll)
and shift lever in any
positionexcept @
. Faultyt,ansmissioncontrol module
Check for voltageto ground:
(TCM)
There should be battery voltage
. An open in the wire
for two seconds after the
ignitionswitch is turned ON,
and less than 1 V two seconds
later.
3 YEL/vVHT
. Faultytransmissioncontrol modute
(TCMI
. An open in the wire
lgnitionswirch ON {ll}
LT.
GRN/BLK
23-135
vnx.su
A/T GearPositionIndicator
gear Position
I I Gea
A/T
Fosluon Dwtrcn
I esr Switch Test
1 . Removethe console.then disconnectthe 14-Pconnector from the switch.
tgrminal
90e
14-P CONI{ECTOR
Back-up
Ught Swhch
tr
a
ooooooo-
E
E
N
tr
tr
Terminal
_\
--o
-.o
-o
--o
tr
a
E
E
E
E
E
o- --o
oo-
--.o
o- --o
Back-up
Llght Swltch
P*,i-
--o
Noutrrl
Polition Swhch
oo- --o
t{outral
Potidon Swltch
J
--o
--o
G_
oo-
--o
23-136
vnx.su
o- --o
oo- --o
A/T GearPositionSwitch
Replacement
1.
2.
3.
swtTcH
SHIFTLEVER
NOTE:
a lf adiustmentis not possible.check for damage
to the shiJt lever detent and/or the bracket. lf
there is no damage,replacethe consoleswitch.
a The engineshouldstart when the shift leveris in
position LN] in the range of free play.
LOCKPIN
NUTS
23-137
vnx.su
Interlock System
ComponentLocationIndex
All SRS electrical wiring harnasssare covered with
yallow insulation.
Before disconnecting any part of the SRS wire harness, connect the shon connector(sl.
Replacethe entire affected SRS halness assmbly it
it has an open circuit or damagedwiring.
INTERLOCK
CONTROL
UNIT
fnput Test, page 23-141
KEY INTERLOCKSOLENOID
snd KEY INTERLOCKSWITCH
(ln the steeringlock assembly)
Test, page 23-142
23-138
vnx.su
Descraption
The car is squippod with thq following dovlc6. to prevont inadvoft.nt shitting:
a A/T selector with shift lock
a Key cylinder with interlocked ignition key
Shift Lock Syst6m;
The shitt lock system prevents the shift lever from moving to
@ or lDil from the @ position unless the brake pedal
is depressed and the accelerator is in its rest oosition.
NOTE:
a The shift lever cannot be shifted when the brake pedsl and the accelerator are depressed on at the same time.
a In case ot system malfunction, the shift lever can be releasedby pushing a key into the releaseslot near the shift lever.
SOLEI{OID
ON: LOCK
OFF:UNLOCK
KEY CYLINDER
II{TERLOCKLEVER
swtTcH
23-139
vnx.su
lnterlockSystem
CircuitDiagram
NOTE: Differentwires with the same color have beengiven a numbersuffix to distinguishthem (tor examplg,
GRNMHT 1 and GRNMHT 2 are not the same).
-HOODFUSE/REi.AY
BOX
UNOER
N0.41(1OCA)
No.39l50A)
W}IT/BLK+WHT
WHT/GRN
THROTTLE
POSITION
ITPI
SENSOR
,
IN/vt,H]
^'v"'
i I
I
if,f,trfi
I
l......................_GRNA,t/r{rz1
/r\ S'ftiei
f lJlT,ll*n""n,
23-140
vnx.su
'I
wn t/hEu
Tost condition
Tost: Dosiredresult
lgnitionswitch ON (ll)
Brakepedal pushed
lgnitionswitch ON I [ ) ,
brske pedal and
accelerator pushed at
the same time
Shift lever in @
lgnitionwitch ON (lll
GRN^/vHT'
YEL/BLK
BLK
23-141
vnx.su
Interlock System
I esr Interlock Dorenoro
Solenoid Test
Key
Kev IntenocK
CAUTION:
a All SRS electrical wiring harnessesar covered rYith
yollow insulation.
a 8eforc disconnecting any pan of the SRS wire harness. connecl tha short connoclol{s|.
a Raplacethe ontire affected SRS harness assembly if
it has an opon circuit or damaged wiring,
4.
\______________rry
Position
lonition
S hchAcc
Koypushdin
r
KoyroleEsod
o-
--o
--o
* : l5-20ohms
5,
Checkthat the key cannot be removedwhen the battery is connectedto the No. 6 8nd No. 7 terminals.
a It the kev cannot be removed, the key interlock
solenoidis OK.
a lf the key can be removed, replace the steering
lock assembly(key interlock solenoidis not available separately).
23-142
vnx.su
Replace.
SHIFT LOCK
LEVEB
LOCKPINGROOVE
a When the shift lock solenoidis OFF,make sure
that the lock pin is blocked bv the shift lock lever.
LOCK PIN
LOCK PIN
GROOVE
23-143
vnx.su
IntegratedControl Unit
Circuit Diagram
D.3c ptlon
An integratd control unit, located in the left kick panel, integratss the functions of tho keyin/seat beh r6mindr, sido
markar light {lasher, wiper/washer, lights-on r6minder, rear window dsfogger timer, brak system light bulb check, and
enging oil pressure indicator flasher circuitE,
NOTE: Difforent wires with the same color have be6n given a numbor suffix to distinguish them (for Example,
and GRN/RED'are not the same).
GRN/RED1
HOOD
FUSE/RELAY
8OX
UNOER-
- DASHFUS/RETAY
BOX
UNOER
WIPER/
WNOSHIELD
WASHER
SWITCH
IMT
OFFiINT
Ir l
I
I
I
I
I
I
I
I
I
I
I
I
I
I
t
P
r
r
r
3
8
e
l
t
i
;
t
I
t-0w
ErGrilE
0|l
PRESSI'RE
INDICATOR
LIGI{T
B
r
COI{TROI
UNIT
NTEGRATED
WINDSHIELO
WIPERAVASHER
YEUEE
swtTcH
tr-/
I
BLK/GRNBI
VOLTAGE
REGULATOR
{lnahamator,
WINDSHIELO
WIPER
MOTOR
{Asl
washef-wiproporation
lr ) : Withcombinod
23-144
vnx.su
Br-u/Brx
fr,rTrtl.*
r*r.,
+
/\
J L
r--------Y----__tfl
I moan
swtTcH
i PosrIoN
t,x*rt
BLK/RE9
-----J
- OASHFUSE/REI-AY
UNDR
8OX
ERAKE
SYSTEM
I.IGHT
ll.4wl
YEI-
SEAT8EI-T
REMIi/OER
LIGHT
t1.4Wl
a
E
t
.?
RED/BLU
I
a'u,[!
tsl
BI-K
*rt
(3CP,
QiftHl.
I
BI..K
G20r
G30l
G40l
RIGHT
FRONT
SIDE
MASKER
I,IGHT
t3cP'
23-145
vnx.su
IntegratedControlUnit
Input Test
CAUTION:
a All SRS elocttical widng hatnesssato covored with
yollow insulation.
a Botolo disconnocring any pan ot the SRS wile hal'
ness, connct tho shon connoctor(3l.
a Replaca tho ontlrg affsctod SRS hE noaa assombly if
it has an opon circuit or damag6d wifng.
Remove the dashboSrd lower cover and knee bolstar.
then disconnect the 1 5-P connector Jrom the integratsd
control unit.
Removethe integrated control unit from the under-dash
Juse/relavbox.
SRSMAII{ HARI{ESS
Inspect the connector and socket tetminals to be sure
they are all makinggood cont8ct.
a lf the terminalsare bent, looseot corrodd,repairthem
as necessary, and recheck the system
a lf the terminalslook OK, makethe tollowing input tssts
at the connector and under-dashtuse/relsy box.
- lf any test indicatesa problem,find and correct the
cause, then recheck the system.
- It all the input tests prove OK, the control unit must
be faulty; replace it.
NOTE:
a Diftorent wires with the sam color have been given
a number suffix to distinguish thn {for 6xample,
GRN/BLUIand GRN/BLU' arenot the same).
a Do not disconnect any connectors on tho under-dash
fu8e/relay box except the integratsd contlol unit.
H_____-t{
.BLK/GBI{ LT
15.P CONNECTOR
23-146
vnx.su
GRN/BLUI GRI{/RED
All Systems:
No. Tsrminal
1
Tst condition
YEL
Defoggerswitch
pushed
Faultydefoggerswitch
P o o rg r o u n d{ G 2 0 1 ,G 4 O 1 }
An open in the wire
lgnitionswitch ON (ll)
BLUiYEL
,|
lgnitionswitch ON (ll)
and windshieldwipet
YEL/BLU
switch INT
Windshieldwiper
BLU/WHT
switch OFF or INT
ano
and wiper bladesin
BLUiGRN
park position
.E
lgnitionswitch ON (lll
23-147
vnx.su
IntegratedControl Unit
Input Test (cont'd)
lgnitionswitch oFF
LT BLU
LT GRN/
RED
Driver'sdoor open
Front passenger'sdoor
switch open
NOTE:Betoretesting,
remove No. 3 (7.5 A)
tuse from the underdash fuse/relaybox.
lgnition key inserted
into the ignitionswitch
Insufficientoil
lmproper lubrication
Faulty engineoil pressureswitch
NOTE: Referto page 23-125 for the seat belt switch test.
23-148'
;.rqFft,
YEL/RED
GRN/BLU'
vnx.su
lgnitionswitch at
START
Lights-on Romind6rSystom:
Wire/
No, Toiminal
T6Et condition
GRN/8LU'
Connectthe I terminal
to the J terminal.
Combinationlight
switch ON
Blown bulb
P o o rg r o u n d( G 2 O 1 c, 3 O 1 , G 4 O 1 l
An open in the wire
lgnitionswitch ON {ll)
GRN/YEL and turn signalswitch
to "Right"
lgnitionswitch ON (ll)
GRN/WHT and turn signalswitch
to "Left (or Rightl":
Connectthe H terminal
GRN/REDl to the GRNMHT
(or GRN/REDl)terminal.
23-149
vnx.su
Key-in ReminderSystem
Door Switch Test
l.
2.
BASE PLATE
4.
Terminal
POSITIVE
BASEPLATE
Position
Checkfor continuitybetweenthe No. 2 and No. 4
terminalsin each conditionacco.dingto the table.
PUSHED
{doorclosedl
RELEASED
ldooro!en)
Terminal
Condition
KEYINSERTED
--o
KEYREMOVED
23-150
vnx.su
EngineOil Pressure
Indicator System
Lights-onReminder
System
Description
Description
NOTE: Referto page23-145 tor a diagramof the lightson remindercircuit, and to page 23-149 for the input
tests of the circuit.
ChimeTest
Removethe dashboardlower cover and knee bolster
{see page 23-70).
Disconnect the 2-P connector t.om the dashboard
wire hamess.
CHIME
23-151
vnx.su
Lighting System
ComponentLocationsIndex
All SRS elctrical wiring harnessesale covered with
yallow insulation.
Bfore disconnocting any pan of th SBS wire harness, connect the short connactor(sl.
Replacth6 entire affocted SRS harnessassembly it
it has an open circuit or damagod wiring.
COMBINATIONLIGHT SWITCH
page 23-160
Replacement,
Test, page 23- l58
OAYTIME
RESISTORlC.nodal
Test, page 23-160
HEAOLIGHTS
Adjustment, page 23-162
page 23-164
Replacement,
FRONT PARKING/FRONTTURN
SIGNAL LIGHT
page 23-165
Replacement,
FRONTSIDE
MARKERLIGHT
page 23-165
Replacement,
DAYTIME RUNNIT{GLIGHTS
CONTROLUNIT {C6nada)
Input Test, page 23-156
23-152
-
vnx.su
Hatchback:
LICENSEPLATE LIGHTS
page 23-169
Replacement.
TAILLIGHT
. Replacement,
page 23-166
. Eulb replacement,page 23-166
Sodan:
LICENSEPLATE LIGHTS
page 23'169
Roplacement,
INI{ER TAILLIGHT
. Replacement,
page 23-167
. Bulb replacement.page 23-168
TAILLIGHT
. Repfacement,page 23-167
. Bulb replacement,page 23-168
23-153
vnx.su
LightingSystem
CircuitDiagram(USAI
- HOOD
UNOER
RJSE/NELAY
8OX
-r
DIMMER
No.lo
tloAr
'1
No,22
(0oA)
lo|
,-.
otF
I'I
''t No.g
(floAr
No.2l
|l0A]
iil;
)
REO/GNN
HEADLIGHT
HIGHEEAM
INOICATOR
LIGHT
fi.4W)
8LK
8tK
G 20l
G401
G301
RIGHT
HEAOUGHT
G20'|
G40l
23-154
vnx.su
6p*
DASHUGI{TS
88rGr{TESS
CONTrcUTR
DASHUGHTS
. PAR(II{C
PAR(II{G
UGHI
UGHTS
. TAItUGt{TS
TAILUGI{TS
. UCENSE
PI.ATE
UGHTS
- D SH
UtrloER
RJSE/RELAY
sox
GircuitDiagram(Canadal
UNOER_HOOD
FUSEiRETAY
8OX
BATTERY
G"*
-il
/ d \
coMBrNAtor{
rcHrswnc
BAT
'.=r"
tlL-J
l l ' L
"- l-'li'
"orr ;-\d " ;j
I I *o\."
r.r-,9
I
L
I LI
RED/BLU
t'
REO/}VHT
RED,
GRN
UNDEN-DASH
FUSEiIEI,AY
8OX
I
I
I
I
i,"#
llrrff li'rrt,I
No.2l
fl0A)
(
Jm.tr
No.l9
|l04]
BLU REOr'
TVHT
RED/
GRtI
rGNrTrot{
tG2 swITcH
\9-l
NED/B
t10A)t
No.l6
{7.54}
WHTTYEL
. DASH
LGHTS
BRIGHTNESS
COI{TROLLER
. DASH
I-IGHTS
. PARKING
I-GHIS
. TAII,LIGHTS
. UCENSE
N"ATLIGI{TS
I a-r
jllA/Vr
neonru
oI
RED/GRI{
+\{H
I r-0
1651,1/) | l55W)
HIGHBEAM
INOICATOR
UGHT
fl.4W
l"
wxrinto
DAYTIME
RUNNING
UGI{TS
RESISTOR
RED/
GRN
Hr
f#
HI
t85W)
LO
t55Wl
RIGHT
HEADLIGHT
PARKIIIG
BRAKE
sw{TcH
I
23-155
vnx.su
Lighting System
DaytimeRunningLightsControlUnit Input Test (Canada)
CAUTION:
a All SRS eloc{dcal wi ng harnssesare covelod with
yollow insulation.
a Boforo dbconnocting any psrt of the SRS wir h8rnoss, connoct tho shon connector(s).
a Roplacethe entire affected SRS harness assombly it
it has an opon Gilcuit or damagod wifng.
1.
2.
3.
4-P CONI{ECTOR
8-P CONNECTOR
YEL/ALK
GRN/RED
WHT/RED
WHTA'EL
RED/GRI{
23-156
vnx.su
Tst condition
Combinationlight
switch in "O" position
B l o w n N o . 1 5 ( 1 OA ) t u s e i n t h e
under-hood fuse/relay box
Blown brake system light
An open in the wire
RED/WHT
Combinationlight
switch is OFF; connect
a iumper wire between
5 WHT/REOthe YEL/BLKand
WHT/REDterminals,
then turn th6 ignition
switch ON.
lgnition switch ON (ll),
brake fluid resrvoil
GRN/RED
full, and parking brake
lever down
RED/GRN
. P o o rg r o u n d{ G 2 0 1 ,G 4 0 1 )
. An open in the wire
. Blown No. 17 { 10 A} luse in the
under-dashtuse/relay box
. An ooen in the wiae
YEL/BLK
tt
BLK
WHT/YEL
23-157
vnx.su
Lighting System
Combination Light/Turn Signal Switch Test
CAUTION:
a Atl SRS Oloctricslwiring harnessesar6 covered with
yellow insulation.
a Bslor disconnecting any pan ot the SRS wire harness, connact the short connsctollsl.
a Replacethe sntire aftectad SRS harne$ assembly if
it has an opon circuit or damagod wiring.
1. Remove the dashboardlower cover and steering
column covers (see page 23-71).
2.
3.
4.
4-P CONI{ECTOR
B
D
G
H
7.P CONNECTOR
23-158
vnx.su
TErminsl
Position
Hsrdfightstvitch
t-
OFF
1J
--o
L0w
o
o
HIGH
OFF
Passing
switch
ON
/ t \
RIGHT
Tsrminal
A
Position
RIGHT
-o
NEIIIMT
uFr
(J
23-15,9
vnx.su
Lighting System
Combination Light Switch
Replacement
'1.
UPPRCOVER
Test lCanada)
CAUTION: The daytime running lights resistor becomas
vely hot when the daytime running lights are on; do not
touch it or the attaching hardware immediatelyaftel th
lights h8ve ben turned otf.
1.
DAYTIMERUNNING
LIGHTS RESISTOR
?nd
23-160
vnx.su
Headlight
Description
The low beam lightsare proiector-typelightswhich are more compactwhile maintainingsufficientbrightness.Bundling
the light raysreducesstray light and yieldsa spotlight-effect
which improvesvisibilityduringnight or foul weatherdriving.
For easieraiming,the headlightsare equippedwith vertical and horizontalgauges.
NOTE: As the oute. lensesare made oI a resin material,don't cover the headlightswhen they a.e turned on.
OUTER LENS
coNvExLEI{S
SUB-REFLECTOR
sEcoND FOCUS
INTERRUPTER
PLATE
REFLECTOB
FIRST FOCUS
BULB
23-161
vnx.su
Headlight
Adjustment
Belol adiusting lha hoadlights:
3.
Turn the low beams on. lJ necessary,align the vertical indicator with its "O" mark by turning the vertical adiuster with a Phillipsscrewdriver, and check
aiming with the chart on page 23-163.
4.
5.
23-162
vnx.su
Measurements (Standardl:
A: 9 fi 10 in (3000 mm)
B: 23 in (585 mm)
C: 46.1 in (1170 mml
D: 33.5 in (85O mm)
E; 1.2 in {31 mm}
FLOOR
Headlight Aiming
Low beam:
High besm:
HEADLIGHT
HIGH BEAM
HEADLIGHT
LOW BEAM
CEt{TER
FLOOR
CAUTION: Th6 out6r lonses get very hot when tho hoadlights are on; do not cover them.
23-163
vnx.su
Headlight
Headlight Replacement
1. Removethe front bumoer.
Bulb Replacement
CAUTION:
a Halogon headlights can bocomo voly hot in usa; do
not touc$ them or tho attaching hardware imm6diatoly
arter they hava been lurnod off,
a Do not try to roplaceor cl6an the headlights with the
lights on.
I.
FRONTBUMPR
coNlrtEcToR
2.
HEADLIGHT
23-164
vnx.su
Front Parking/Front
Turn
Signal Lights
Lights
Replacement
l.
Replacement
BULE{3 CPI
FRONTSIDE MARKERLIGHT
23-165
vnx.su
Taillights(Hatchbackl
Bulb Replacement
Replacement
1 . Open the resr hatch.
Removethe rearpanelliningandthe sidelining{see
section 20).
2.
ACCESS PANEL
4-P CON[{ECTOR
o: BACK-UPLIGHTBULB{32 CP}
BULB(32l3 CP)
@: ERAKE/TAILLIGHT
23-166
-
vnx.su
Taillights (Sedan)
Replacement
Tsillight:
1. Open the trunk lid, then removethe rar panel lining and side lining (seesection 20).
2.
3.
Innol Taillight:
1. Open the trunk lid.
2.
3.
4-P CONi{ECTOR
TAILLIGHT
NOTE:
a Inspect the gasket. Replaceit if it is distoned or stsys
compresseo.
a After installation, run water over the lights to make
sure thev don't leak.
23-167
vnx.su
Taillights(Sedanl
Bulb Replacement
Tsillight:
1. Open the trunk lid. then removethe rear panel lining and side lining {see section 20}.
lnnor T.illlght:
1. Open the trunk lid, then removethe bulb housing.
2.
2.
BULBHOUSII{G
BULB(32l3 CP}
@: BRAKE/TAILLIGHT
@: T U R NS I G N A LL I G H TB U L B( 3 2 C P }
O:
@: REARPARKINGLIGHTBULB{3 CP)
BULBI3213CP}
@: BRAKE/TAILLIGHT
23-168
l'r'qn'F',
vnx.su
LIGHTBULB(32 CP}
BACK-UP
LicensePlateLights
Replacement
Test
Turn the bulb socket 45o counterclockwise to remove it from the housing.
Trminal
B
Condition
PUSHED
{lidclosodl
REI"EASED
{lidoDen)
o-
/:\
\7
---o
BULB
(3.4 W)
ql
-----11
dl
cior
G4{t1
23-169
vnx.su
DashLightsBrightnessGontrol
CircuitDiagram
8OX
UNDER.HOOD
FUSE/REIAY
COMBII{ATION
LIGI{TSWTTCH
wnr-@-
UNDERDASH
8OX
FUSE/NETAY
neorenn
REO/BLK
. GATJGE
UGHTS
. CruEECOITNOL
DIMMING
CIRCUTT
. A/TGEAR
POSMON
N(ICATOR
DIMMII{G
CIRCUIT
' HAZAnD
LIG}fr
WARi{|NG
S:WltCH
. REAR
SiWTTCH
UGHT
WINOOW
OEFOGGER
. CFUISE
UGHT
COMTROT
MAINS,IVITCH
. A,ITGEAN
UGHT
POSITION
CONSO|.!
. HEATER
PANEL
UGHTS
COMTNOL
T
R D
BI.K
G201
G40t
23-170
vnx.su
OASH LIGHTS
COI{TROLIER
Wire
1
BLK
Tost condition
Headlightswitch ON
Headlightswitch ON
RED/BLK
RED
23-171
vnx.su
CEIIING LIGHT
Test/Replacmont.page 23-175
SPOTLIGHTS
Test/Rsplscement, page 23-1 74
.1 LEFT REAR
DOOR SWTCH
Test. page 23-150
FRONT
PASSEl{GER'S
DOOR
swtTcH
Test, pago23-150
*2 HATCH LATCH
11 RrcHTBEAR
DOORSWrCH
Tost. page23-150
swtTcH
Test/Replacement,
page 23-178
11 TRUNK LATCH
SWITCH
Test/Replacment,
page 23-178
23-172
rII-
vnx.su
CircuitDiagram
- HOOD
UNOER
FUSE/RELAY
8OX
- - - - -Hltcnb&n
--1
CARGO
ASEA
UGHT
t3.4Wl
U DEN-DASH
FUSE/RELAY
8OX
lS.d.nl
TBUi{K
UGHT
t3.4Wl
GRI{
l**,-0,,n
I rNorcAToR
I UGHT
IY
LT
II{IEGRATED
1
cotlrnor I
I,NIT
i'
GRN
GRr{/Bt
U t-t
Iq*",,.,
d_
f-
I DOOR
I swncH
II
FROiTT
PASSEiIGEB'S
DOOf,
SWTCH
23-173
vnx.su
3,
4.
5.
Hatchback:
;r,,-
CONNECTOR
tEFr
Torminal
----l
ON
BorB'
/:\
\:/
o-
OFF
ON
RIGHT
Sedan:
""li **li
BULB
23-174
vnx.su
--o
--o
o-
OFF
B'O
CorC'
5.
3.
re.mrnal
Position
OFF
DOOR
ON
8or8'
oo-
za
\7
G-
/1
\7
--o
--o
--o
\:.,/
3-P CONNECTOR
F om o.3l7.5Al FUSE
(ln th. snd.. - dr.h fu!./rby boxl
4.
23-175
vnx.su
5.
Without moonroot:
1. Turn the light switch OFF.
2.
3.
T6ninsl
P"riti""
DOOR
ooLF
BorB'
OFF
ON
/:\
\:.,/
A
--o
--o
/A
3-P
CONNECTOR
4.
F om o.3l7.5Al FUSE
tln thr uid.r - ddr h|. /,.LY borl
A
23-176
vnx.su
--o
4.
Hatchback:
2.P CONNECTOR
BULE13.4Wl
To HATCH
LATCH
A {+}
swtTcH
B{-)
Sedan:
2.P CONNECTOR
F om o.3 (7.5A1FUSE
{ln th. und.i- da.h
tur/r.hy box)
HOUSING
BULB{3.4 W)
To TRU K
LATCH
swtTcH
23-177
vnx.su
Area Lights,Spotlight
Ceiling/Trunk/Cargo
Latch Switch Test/Replacemsnt
Sedan:
lhtchb.ck:
1. Openthe trunk lid. and disconnectthe 2-P connector from the trunk latch switch.
1.
2.
2.
\j
C C
3 . lf necessary,removethe three mounting bolts to pull
out the hatch latch switch trom the latch, then disconnact the lock rod Jrom the hatch latch switch
4.
ll necessary,removethe three mounting bolts to pull
out the trunk latch switch from the trunk lid, then
disconnectthe lock rod from the trunk latch switch.
4.
23-178
vnx.su
Back-upLights
CircuitDiagram
UI{DER_
IIOOOFUSEiBEIAY
BOX
wHT/Bt(+WHT
A/TGEAR
Posrnotr
swrTcH
'l
f 8ek- uplioht
--------_J
L---------
23-179
vnx.su
Back-up Lights
Manual Transmigsion:
Automatic Transmission:
2.
It the back-uplightsdo not go on, check the backup light bulbs in the taillightassembly.
3.
2.
lf the back-uplights do not go on, checkthe backup light bulbs in the taillightassembly.
3.
4.
terminal sade
4.
23-180
vnx.su
BrakeLights
CircuitDiagram
UNDEE-HOOO
FUSE/NELAY
BOX
. HORi{
. IMTERI.OCK
SYSTEM
{u
8tK
{.
*H-i
{.
BLK
23-181
vnx.su
Brake Lights
HighMount BrakeLightReplacement
(LEDtypel
'|Frt
jr'li
C
HIGHltlOUt{T BRAKELIGHT{LEDTYPEI
3.
23-1A2
vnx.su
Sadan:
1. Openthe trunk lid, and disconnectthe 2-P connector trom the high mount brake light.
2.
3.
2.
2-P CONt{ECTOR
4.
Installthe high mount brakelight in the reverseorder of removal. Cleanthe rear window glass before
installingrhe light.
Installthe high mount brakelight in the reverseorder of removal,and cleanthe rearwindow glassbetore installing.
CAUTION: Whon installing ih6 high mount brake
light. make sur6 the rubber soal fits against the real
window ev6nly.
23-183
vnx.su
Side Marker/TurnSignal/HazardFlasherSystem
Component Location Index
GAUTION:
a All SRS electrical wiring harnessosar6 covered with
yellow insulation.
a Belor disconnocting any pan of the SRS wire harngss, connoct the short connector{s).
a Rsplacetho 6ntir affectd SRS harnoss sssembly il
it has an opn cilcuit or damaged widng.
UNDER-DASH
FUSE/RELAY8OX
TURN SIGNAL/HAZARORELAY
Input Test, page 23-186
23-184
-
vnx.su
GircuitDiagram
UNDEN-HOOD
FUSE/RELAY
8OX
N0.411100A) No.40(50A)
UNDER-DASH
FUSE/RELAY
8OX
COMBINATION
LIGHTSWTCH
A.
---of-RED/GRN
IGNITION
SWITCH
WHT/BTK
+WHT+
/6i\\
\jv
+-
FUSE
HOTJER
BIK/YET
GRN/BtU
TURNSIGiIAL
swtTcH
I
| l
+
MAFKER
SIOE
LIGHT
FLASHER
CIRCUIT
controlunitl
llnthointogruted
RIGHTTURNSIGNATTIGHTS
DASHTIGHTS
BRIGHTNESS
CONTROLLER
INOICATOR
I FRONTI REAR
L|GHT
I t32CD I t32CPl
(1.4W1
2 3 -185
vnx.su
Side Marker/TurnSignal/Hazard
FlasherSystem
Turn Signal/Hazard
RelayInput Test
CAUTION:
a All SRS electrical wiring harn6ss6sar covered with
yellow insulation.
a Bforo disconn6cting any part of th SRS wire harnoss, connoct tho short connector(s).
a Replacotho ontiro sftoctod SRS harness assmbly it
it has an open circuit or damagod wiring,
I.
2.
UI{DEB-DASH
FUSE/RELAY
BOX
Telminal
,l
TeEt condition
23-186
-
vnx.su
HazardWarningSwitch
Replacement
CAUTIOI{: Bo car.ful not to damag8 tho switch and conlolo panol.
1.
2.
I"j'!ld
Position
OFF
ON
10-PCO
@ r)
o
@
ECTOR
A B C D
\ uorr
) to.uwl
23-187
vnx.su
StereoSoundSystem
ComponentLocationIndex
CAUTION:
a All SRS elctrical wlring harneaseEare covered with
yallow insulation.
a Belore dbconnscting any part of the SRS wire harnass, connect tho short connector(sl.
a Replacetho entir6 affoctod SRS harn6ss assembly if
it has an opan circuit or damag6d widng.
NOTE: The original radio has a coded theft protection
circuit. Be sureto get the customet's code numberbelore
- disconnecting the battery.
- removingth No. 32 (7.5 A)tuse from the under-hood
fuse/relay box.
- removingthe radio.
After service, reconnct power to th radio and tutn it
"CODE" is displaved,enterthe cuson. Whenthe word
tomer's 5-digit code to restore radio opelation.
Hatchback:
STEBEORADIO/CASSETTE
PTAYER
paoe23-191
Removal.
page23-192
Terminals,
RIGHTREAR
SPEAKER
Replacement.
page23-193
DOOR
SPEAKER
page23-192
Repfacement,
LEFTTWEETER
page
Replacement,
23-192
DRIVER'S
DOOR
SPEAKER
Repfacement,page 23-192
LEFT
SPEAKER
Replacemenr.page 23-193
ANTENNA MOTOR
Test, page 23-194
page 23-196
Replacement,
23-188
!iltil;s'
vnx.su
Soden:
RADIO/CASSETTE
STEREO
PLAYER
paoe23-191
Rmoval,
FBONT PASSENGER'S
Trminals.page23-192
DOOR
i FIGHT TWEETER
page 23-192
Replacement,
*: USA
SPEAKER
page 23-192
Replacement,
RIGHTREAR
SPAKER
page2 3 - 1 9 3
Replacement,
DRIVER'S
DOOB
SPEAKER
Repfacement,p8ge 23-192
POWERANTENNA MOTOR
Test, page 23-194
page 23-196
Replacement,
23-189
vnx.su
StereoSoundSystem
CircuitDiagram
tGNtTOt{
SWTTCH
FUSE
BOX
UNDER-HOOO
i RETAY
tlo.4lllo0Al
No.39l50Al
+WHT
WHT/BI"K
No.l9ll0Al
RJSE
UNDEN-DASH
FUSENEIAY
8ox
SIEROMOO
CASSETTE
N.AYER
AI{TE?{NA
MAST
AMTEI{iIA
ITAD
-L-fl
-fi1
.a'J
POWER
AITNI{AMOTOF
ntrrct d fulvl
M_nhthoantanna
| : Excoot!ad!n of Crnede
23-190
vnx.su
RIGI{T
REAR
SPEAXER
Unit Removal
CAUTION:
a All SRS oloctrical wi ng harn.$.s ara covcrrd with
yellow insulation.
a Btoro disconnocting any part ot tho SRS wirc hrrnosa, connsct tho short conn6ctol(rl.
a Raplaco the sntirs sttoctod SRS hamoas asacmbly it
it has an opon circuil 01 damagod widng.
FRONTCONSOLE
2,
4.
16-P COi{i{ECTOR
ANTENlTASUB-LEAD
23-191
vnx.su
Front Speaker/Tweeter
Terminals
Replacement
Front Spoakor:
1. Carefullypry out the speakercover.
2.
*i,.,-terlll
A
r^lt
T I!NM[IAL
\
2.P CONNECTOR
SPEAKER
COVER
A9---------+A16
Twootor:
1. Removethe door paneland disconnectthe tweeter
2-P connector.
Connects to
A1
RED/GRN Frontpassenger's
door speakerO
A2
A3
A4
RED/BLK Lights-onsignal
WHT/8LU Constantpower {Tuningmemory)
A5
A6
A7
A8
A9
RED/YEL Rightrearspeaker@
BRN/BLK Frontpassenger's
door speakerO
A10
A
412
lnot used)
(notused)
A13
(not usedl
A14
BLK
2.
Ground(G551)
Al5
A16
BRNAA/HT Rightrearspeakere
23-192
vnx.su
RearSpeakerReplacement
Hatchback:
1 . Removethe three screwsfrom the trunk side,then
remove the soeaker cover.
1.
2.
LEFTREAR
SPEAKER
OUARTERTRIM PAI{EL
SPEAKERCOVER
,r--I
LEFT REAR
SPEAKEN
2-P CONNECTON
SPEAKERCOVER
REABTRAY
23-193
vnx.su
StereoSound System
Power AntennaMotor Test
Removethe quartertrim panel(Hatchback)or trunk
side trim panel (Sedan).
AI{TEI{I{A
LEAD
r.tr.ci.d
t|Ilyl
"4"
Sticking Ant6nna:
The antennasticks in either the up or down position.
*ft'^to
?r*
*r'
TIFIT
YEL/GRN
PLASTICSLEEVE
AIITENNA MAST
Cloan mast
housing
throads.
Usethe antennanut wrench and tightenthe antenna nut to 2.3 N.m (0.23 kgf-m, 1.7 lbf-tt). lJ you
overtightenedthe nut. the antenna may stick. lf
stickingoccurs, back the nut off a little, then turn
the radioon and off to raiseand lower the antenna
again. Repeatuntil the antennamoves treely.
23-194
fmft,
vnx.su
Antenna MastReplacement
Ramoval:
Installation:
1.
1.
2.
Carefullywithdraw the antennamast while extending it by turning the radio switch ON.
Holdthe antennaso that the teelh on the drive cable tace in the directionshown. then insen the cable into the antennahousing.
AI{TENNA I{UT
SPACER
Direction oI the
teeth
,
ANTENNA NUT
2.3 N.m 10.23kgl-m, 1.7 lbt-ft)
4.
POWERANTENNA
MOTOR UNIT
23-195
vnx.su
StereoSoundSystem
PowerAntennaMotor Replacement
1 . Removetho quartr trim panel (Hatchback)or trunk
side trim panel (Sedan).
Disconnectthe 3-P connectorand antennalead trom
the motor, then remove the antenna nut and motor
bracket nut.
AI{TENNA1{UT
2.3 l{.m
AT{TEI{]{AI{UT
WBEI{CH
oTJAA-OOlo(xrc
3+CO
ECTOR
DRAI HOSE
MOTOR
BRACKET
TUT
23-1 9 6
vnx.su
Circuit Diagram
STEREO
RADIO/
CASSTIE
PI-AYER
23-197
vnx.su
Clock
Terminals
Replacement
CAUTION:
a Pry th6 clock out at th left sido,
a Be carsful not to damage the clock and the dashboE d
whon prying the clock out.
1.
Pry the clock out from the dashboard,then disconnect the 4-P connector.
4-P COI{NECTOR
CLOCK
Torminal
A
Connecta to
Wiro
BLK
YEL
Ground
{Main clock power sup-
plv)
23-198
vnx.su
Constantpower
WHT/BLU (Time
memory)
Horn
Component Location Index
CAUTION:
a All SRS lectricsl wiring harnessesal covered with
yellow insulation.
a Bfore disconnecting any part of the SRS wiro harneaa, connect tho short connectol(sl.
a Replacothe entire aftected SRS harnessassembly if
it haa an open circuit ot damaged wiring.
HORN
Test,page23'2O3
HORNSWITCHES
Test, pago23-2Ol
<------\
-\----.....=
UNDER.DASH
FUSE/RELAYBOX
CABLE REEL
Repfacement,page 23-302
HORN RELAY
I Wiro coloB: BLU/RED,BLK, I
IWHT/GRN, and BLU/GR
l
Test, page 23-68
23-199
vnx.su
Horn
CircuitDiagram
MTTERY
------------.,1
r-T-l
lll-
l1'l
()
SHORT
c0ill{EcToR
L------------J
Wrthoutcrub6conlrol,
23-200
vnx.su
Switch Test
CAUTION:
a All SRS el6ctrical wiring harnossosare covarod with
yellow inaulation.
a Beforo disconnecting any pan ot the SRS wire harneaa, connoct ths short connector(s).
a Roplacethe entil afloctod SRS harne$ a$6mbly if
it has an open circuit or dsmagad wlring.
4.
2.
TESTHAR ESSC
oTLAz- SL/l{,3OO
CABLEREEL
3.P CO NECTOR
DRIVER'S
AIRBAG
3-PCO'TNECTOR COI{NECTOR
{RED}
ACCESS
PAI{EL
SHORT CONTIECTOR
{REO}
(cont'd)
23-201
vnx.su
Horn
Switch Test (cont'd)
Check for continuity between the horn positive terminal and the steering column shaft with the horn
switch pressed, There should be no continuity.
DB|vEN'S
HORNSwlTCH
TERMIITAL
POSITIVE
AIRBAGASSEMBLY
TORXO BOLT
(U!6 s TORxo T3O bitl
a lf there is continuitv:
- With cruise control: Test the set/resume
switch. lJ the switch is OK, replacethe cable
reel.
- Without cluise control: Replacethe cable reel.
a lJ there is no continuity. remove the steering
wheel and the four screws, then remove the
steering wheel cover. Replace the faulty horn
switch.
8.
23-202
vnx.su
Horn Test
t . Removethe front bumper (seepage 23-164).
2 . Disconnct the 2-P connector from the hofn.
5.
2-P COt{t{ECTOB
MOUNTI G AOLT
4.
5.
23-203
vnx.su
CigaretteLighter
CircuitDiagtam
UNOER-HOOD
FUSE/RELAY
BOX
No.tgll0Al
FUSE
UIIOER-DASH
FUSE/N[AY
BOX
BI.K
G20t
Gilol
23-204
vnx.su
Replacement
CAUTIOI{:
a All SRS sloctdcal wiring harnossasare covered whh
yollow insulatlon.
a B.tore disconnoctlng any part ot the SRS yyi16 h.rnosa, connrct tho short connoctot(al.
a Rsplaco th. onti.e !ffoct.d SRS hamoss a$ombly lf
It ha! an opon cilcuit or damagod wiring.
( r . 4w l
FROI{TCO|{SOLE
THERMOFUSE
CASE
RI G NUT
THERMALPAOTECTOR
scREws
23-205
vnx.su
.--
REABWINDOW
RELAY
DEFOGGER
Test,page23-68
UI{DER.DASHFUSE/RELAYBOX
REARWINDOW DEFOGGERTIMER CIRCUIT
{ln the integrated control unil)
fnput Test, page 23-147
The rear window defoggeris controlledby the integratedcontrol unit, Pushingthe defoggerswitch in the instrument
panel it sends a signalto the defoggertime. in the integratedcontrol unit, and the detoggerstays on tor 25 minutes
or until the ignitionswitch is turned off. The indicatorlight in the switch comes on when the deJoggerworks.
23-206
vnx.su
UNDERHOOO
FUSE,NE[AY
80X
B[K/GRN
I
[ql
t=l
BLK/GRN
trI
;ERI
NOISE
CONDENSER
I'
8LK
I
:
H.tchback:G77
Ssdan:G50
23-207
vnx.su
RearWindow Defogger
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence.
Item to be inspected
.E
o.-
9\
c g
*o-< f
o
0to
: E
g o <E
oP
'
Symptom
Defoggerworks, but indicator
light does not go on.
Defogger does not work and
indicatorlight does not go on.
lD
o!
o5
. E 6 ('r6
z i
z )
;5
i i
9 c
5.
o
o
o
o
o
=
3
o
ED
o
o
o-
g8
o o
o5
BLKTYEL
oTBLU/YEL
1
1
G201
G401
'1i G771
1
'1: Hatchback
'2: Sedan
23-208
IINIilfi
vnx.su
Switch Removal
Switch Test
1. Carefully pry the switch out of the heater control/center air vent.
2.
2.
P*il*__\
PUSHED
ooo-
RETEASED
D
\../
-\
-o o-
_o
-o
/\
\:,,t
o-
/:\
\7
REARWINDOWDEFOGGER
SWITCH
[-4
I
) ll:g'",li'T
to.a4wt
23-209
vnx.su
Function Test
1.
Lightly rub the area around the break with line steel
wool, then clean it with alcohol.
2.
OPEN
NEGATIVETERMIiIAL
TERMINAL
POSITIVE
Using a small brush,apply a heavy coat of silverconductive paint extendingabout 3 mm ( 1/8 inl on both
sides of the break. Allow 30 minutesto dry.
NOTE: Thoroughly mix the paint before use.
Turn the rearwindow detoggerswitch OFF,Check
for continuity between the negativeterminal and
body ground.
a It there is no continuity,checkto. an open in the
defoggerground wire.
a ll there is continuity,go to step 3.
Touch the voltmeter positive lead to the halfway
point of each defoggerwire, and the negativelead
to the negativeterminal.
Thereshouldbe apptoximately6 V with the ignition
switch and defoggerswitch ON.
a lf the voltageis as specified,the defoggerwire
is OK.
a lf the voltage is not as specified.repai,the defogger wire:
lf it is more than 6 V, look for the damageon
the negativehalf on the grid.
- lf it is less than 6 V. iook for the damageon
the positivehalf of the grid.
4.
23-210
vnx.su
Moonroof
GomponentLocationlndex
a All SRS oloctrical wiring harnessesaro covared with
yellow insulation,
a Eoforo disconnocting any part of tho SRS wire harneaa, connoct th6 shon connector(sl.
a Roplaceth6 entire 8ff6cted SRS harness assombly if
it has an open circuit or damaged widng.
MOO BOOFSWTTCH
page23-214
Remov8l,
MOO ROOFMOTOR
Test,pag23-215
Replacoment,
section20
23-211
vnx.su
Moonroof
CircuitDiagram
- --------f"-----------lo
i|OoNRoOFMOf0R H.rchb.ckl
MoOnOoFttoton 6.ddl
23-212
-
vnx.su
ElectricalTroubleshooting
NOTE: The numbers in the table show the troubleshooting sequence.
Itm to be insoected
es
( ! O
EE :
FE3
b 9
. o 6
; g :
'r3
oiSE
<-c
o 9
bE*
F 6
5 : 3
?t;
: - =
iE d
Symptom
-9
- . 9
:t<
o 6 6
z
c
3
9
a
9
t
c
3 E
.9
;o-
<
E-
3tr t
\ f i
3 l
.',
l
ct
z )
t5
dl=
> l
g
o
3E
o
o
o
o
o
o
o
o
o
o
o
o
.::
a-g
o 6
In all switch
positions
With OPEN
switch
with closE
switch
G201
G401
WHT, GRN/BLK,
GRN,BLK
GRN/REO
GRN/YEL
23-213
vnx.su
Moonroof
FunctionTest
CheckJor continuity between the No. 2 terminal and
body ground.
a ll
a lf
4.
KNEEBOLSTER
DASHBOARD
LOWER
COVER
2.
4-P CONI{ECTOR
SWITCH
MOOi{ROOF
. r - - r
l l l 2--t l
f--T
l 3 1 4 l
View from wire side
23-214
vnx.su
Switch Test
Motor Test
Removethe headliner(see section 20).
Carefully pry the switch out of the left side air vent
Danel, then disconnect the 4-P connector and remove the switch.
3.
Torminal
---__\
\
P"ri i-
o- --o
OPN
\
Condition
--o
G-
OFF
Te.minal
-- ---------l
OPEN
G-
CLOSE
o- --o
CLOSE
SWITCH
MOONROOF
lHatchblckl
(Scd!n)
4.
OPEiI
,l
Ir\./ dcLos
OFF
23-215
vnx.su
PowerMirrors
Component Location Index
POWERMIRRONS
Test, page 23'220
Repfacement,page 23'221
POWERMIRRORSWITCH
Function Test, page 23'219
Test, page 23-218
23-216
vnx.su
GircuitDiagram
- HOOO
FUSE/BELAY
UNDER
8OX
*,,^.-**Q
!.,$iii.,i
LEFTT
---il;---;--------------;
ln
rI
G501
G502
23-217
vnx.su
Power Mirrors
Switch Test
Removethe driver's door panel (see section 2O).
Checktor continuitvbetweenthe terminalsin each
switch positionaccordingto the table.
Mirror Switch
rermrnal
Position
OFF
G"
UP
o-
DOWN
-o
-o
-o
oo-
OFF
UP
-o
o-
DOWN
G-
tEFT
-(J_
-o
-o
-o
-o
G-
aaaaaaaa
A-------+J
o-
RIGHT
RIGHT
-<>-
o- -o
LEFT
-o
P -o
23-214
vnx.su
FunctionTest
NOTE: To test, removethe driver's door panel (seesection 20), then disconnectall of the connectorsfrom the
door oanel.
View from wire side
2.
23-219
vnx.su
Power Mirrors
Door MirrorTest
1,
TILT:
Terminal
Position
Sedan:
'|(H)
2(G)
UP
DOWN
tJ
SWING:
MIRNOR
Terminal
Position
LEFT
RIGHT
Hatchback:
3.
23-220
vnx.su
2(G)
3(Ft
o
(D
PowerMirror Replacement
l.
hca! hara to
rolalaa lha conn9clor
MIRRORPA]IEL
CO
ECTOR
Disconnectthe 8-P (Hatchbck)or 3-P (Sedan)connector from thg oower mirror actuator.
4.
23-221
vnx.su
PowerWindows
ComponentLocationIndex
POWERWINDOWRELAY
Test, page23-68
FOWERWINDOW
MASTERSWITCH
{Has built-in control unitl
fnput Test, page 23-226, 228
Tost, page 23-229, 23O
Ropfacement,page 23-231
UI{DER-DASH
FUSE/RELAYBOX
WII{DOWSWITCH
FRONTPASSEI{GER'S
Test, page23-230
Repfacement. page 23-231
FRONTPASSENGER'S
WII{DOWMOTOR
fosr, page 23-232
RIGHTREARWll{DOWSWITCH(Sodrn}
Tost, page23-230
page23-231
Replacement,
RIGHT REARWII{DOW
MOTOR (Sod.nl
Test, page 23-232
DBIVER'SWINDOW MOTOR
Test, page 23-232
23-222
vnx.su
CircuitDiagram(Sedanl
DASHFUSE/RELAY
BOX
UNDER_
UNOER-HOOO
FUSE/RELAY
8OX
DRiVER'S
WINOOW
MOTOR
RIGHT
REAN
WINOOW
MOTOR
LEFTREARWINDOW
MOTOR
FROI{T
PASSENGER'S
wrNoow
i,roToR
G501
G502
G20r
G401
23-223
vnx.su
PowerWindows
Circuit Diagram(Hatchback)
- HOODFUS/REI.AY
UNDER
BOX
UNOEROASHFUSE]NEI.AY
8OX
tlo.41l100Al ilo.39{50A)
8LXz
D PASSENGER'S
wrNDow
swITcH
PASSENGEN'S
wtN00wM0T0n
G50t
G502
23-224
vnx.su
G401
Troubleshooting
NOTE: The numbers in the table show the troubleshooting sequence
Item to be insoected
o
1 0 x
9 I
3E
<.i
S H
r!
Symptom
(t
o
SJ
t5
;
o-
3
I
-g
z )
9 c
.=
'
,i
E
!
F\
;
z
i
t
o
qt
i
o-
E
3
o
E
3
t
o
;
.=
;
E
3
t
=
()
I
a
o-
o-
x
.9
E
3
.E
: !
g 3
' . c
O E
G20r
G401
G50l
G502
WHT/YEL
BLU,
BLK/WHT
1
1
5
I
BLK/YEL
WHT/RED
BLUi BLK
GRN/BLK
YEL/BLK
23-225
vnx.su
PowerWindows
Master Switch Input Test (Sedan)
NOTE; The control unit is built into the Dowerwindow
maste. switch, and onlv controlsdriver'sdoor window
ooerations.
1. Removethe driver'sdoor paneland disconnectthe
16-P and 1-P connectorsfrom the master switch.
2.
BEDI'EL
8LU/YEL I
I GRN
YEL/BLK
23-226
vnx.su
Test condition
BLK2
ano
BLK3
GRN/BLK
YEL/BLK
Connectthe BLU/BLK
and BLU/GRNterminals,
BLU/YEL
and the BLU/YELand
and
BLK, terminalswith jumBLU/GRN
per wires, then turn the
ignitionswitch ON (ll).
. Faultyfront passenger'swindow
motOa
. An open in the wire
Connectthe YEL/BLK
and YEL/GRNterminals,
YEL/GRN
and the YEL and BLK,
and
terminalswith iumper
YEL
wires, then turn the ignition switch ON (ll).
Connectthe WHT/YEL
and RED/YEL1
terminals.
BLU
and the REo/BLU1and
ano
BLK3terminalswith jumBLK/VVHT
per wires. then turn the
ignitionswitch ON (ll).
Conned an analogohmmeterto
te.minalsBLU and BLK/wHT:
The meter needleshould move
back and lorth alternatelvas
the driver's window motor runs.
Faulty pulser
Faultydriver's window motor
An open in the wire
23-227
vnx.su
Power Windows
MasterSwitch lnput Test (Hatchback)
NOTE: The control unit is built into the power window
master switch, and onlv controls driver's door window
operations,
1. Removethe driver'sdoor panaland disconnectthe
1O-Pconnectol from the masterswitch.
2.
Wiro
1
BLK'
Tost condition
RED/YEL
RED/BLU
BLU/GR'{
BLU/BLK
Tost: Dashodrsuh
Underall conditions
lgnitionswitch ON {ll)
8LK3
WHT/YEL
BLU/BLK
Connectthe WHT/YEL
and REDfYELIterminals,
RED/BLU1
and the RED/BLU1
and
ano
BLK3terminalswith jumRED/YELI
per wires, then turn the
ignitionswitch ON {ll).
Connectthe BLU/BLK
and BLU/GRNterminals,
BLU/YEL
and the BLUTYEL
and
and
BLK2terminalswith jumBLU/GRN
per wires, then turn the
ignitionswitch ON {ll).
BLU
anq
BLKMHT
23-228
vnx.su
Faulty pulser
Faultv driver's window motor
An oDenin the wire
2.
3.
I Main \
Position I Swirch \
OFF
UP
DRIVER'S
SWTCH
ON
o-
OFF
G--
ON
OFF
LEFTREAR
MAtit swtTcH
DOWN
POWERwl DOW
MASTEBSW]TCH
j Main I
Position I Switch \
swtTcH
OFF
ON
OFF
UP
ON
ut'f
A B C D E
DOWN
O-
o-
ON
OFF
PASSEI{GER'S
ON
OFF
o- -_o
E
r)
--o
--o
--o
o- --o
o- o --o
o- --o
--o
o--o
o--o
oo- --o
G- --o
-o
If
I Main
Position I Switch \
OFF
OFF
UP
OFF
Ddv.r't Swh.tr;
Th6 drivr's switch is combined with the cont.ol unit so
you cannot isolatethe switch to t6st it. Instead , run the
maater switch input test procedurss No. 1, 2. 3, and 7
on page 23-226. lf the tests are normal, th6 driver,s
switch must be fsulty.
DOWN
ON
OFF
o --o
o- --o
--o
--o
G_
ON
ot'l
--o
o-
---o
o-
o- --o
G-
--o
o- -o
23-229
vnx.su
Power Windows
Window Switch Test
Passenger's
Front:
1 . Removethe passenger'sdoor panel {seesection 20).
2.
3.
pOWERWTNDOW PASSENGEB'S
MASTERSWTTCH SWITCH
Torminal
il;_\
i 1 \ i
OFF
o-
\4r-I^l,r
)rvti\
--o
o- --o
UP
G_
.Fi'ilj
Passengsl'r Switch:
Te.minsl
\
I Msin \
Position I Switch\
ON
OFF
OFF
UP
ON
OFF
ON
DOWN
OFF
Rear (Sedanl:
1. Removethe innr handle (seesection 2O)'
2,
3.
--o
o- -o
o---o
oo- -o
-o
o--o
o-o
o-
o-
--o
o- --o
DOWr.l
Drive.'s Switch:
The driver'sswitch is combinedwith the controlunit so
you cannotisolatethe switch to test it. Instead, run the
masterswitch input test proceduresNo. 1, 2, 3, and 5
on page 23-228, lf the tests are normal, the d.ivet's
switch must be faultv.
(J
Terminal
OFF
UP
DOWN
23-230
vnx.su
;;__\
G_
G_
--o
--o
o-
o-
--o
o- --o
--o
o-
Passenger's
Window Switch
Replacement
Hatchback:
Flont:
1.
2.
2.
3,
3.
swtTcl{
Roar (S6danl:
Sedan:
1.
2.
2.
3.
3.
w|I{Dow
.swtTcH
POWERMIRROR
swtTcH
INNERHANDLE
scREws
23-231
vnx.su
Power Windows
Window Motor Test
Passenger's
Motor Test:
l.
2.
NOTE:
a Frontpassenger'sdoor is symmetricaltodriver's
ooor.
a The illustrationshows the right reardoot, left rear
door is svmmetrical.
. ,-,.f,/ll/
NZJI
I
..Q]qql,fiftl\ I
$e /tE \
2.P CONNECTOR
4.P CONNECTOR
3.
Test the motor in each directionby connectingbattery power and ground accordingto the table.
Terminal
(B)
Direction
B
{A}
View from terminalside
UP
DOWN
@
3.
Test the motor in each direction by connecting battery power and ground accordingto the table.
Terminal
\
O***
UP
DOWN
{ }: Sodan
CAUTION: When the motor stops running. disconnect one lead immediately.
4.
PulserTest:
5.
6-
23-232
-'
vnx.su
FRONTPASSENGER'S
DOORKEY
CYLII{DER
SWITCH
Test,page23-240
FRONTPASSENGER'SDOOR LOCK ACTUATOR
Test. pago 23-239
Reolacement.section 20
FRONTPASSENGER'S
DOOR LOCK SWITCH
fest, page 23-241
1
DOOR
KEY CYLINDERSWITCH
Test. page 23-24O
DBIVER'S
LOCK ACTUATOR
Test, page 23-238
Roplacement,seclion 20
DOOR
LOCK SWITCH
'lest, page
23-241
POWEROOOR LOCK
CONTROLUNIT
fnput Tost, page 23-236
Description
For this model, a new door lock system has been adopted to improve convenienceand safety. lf the kev is insened into
the driver'sdoor key cylinder,turned to the unlock position,and pulledout immediatelythereafter,oNLy the driver.s
door will unlock. However,if the key is kept in the unlock positiontor one secondor more, ALL doors wi unlock.
23-233
vnx.su
PowerDoorLocks
CircuitDiagram
FUSE/RELAY
BOX
UiIDER-HOOD
BATTENY
No.41l100Al iJo,36l50A)
@'"t
DRIVER'S
OOOB
KEYCYI,INDER
swITcH
DRIVER'S
oooRrocK
swtTcH
o00Rtoc( KN08
L____
I
FRONT
PASSENGEN'S
DOOR
LOCK
OOOR
POWER
LOCKCONTROI.
swncH
FROMT
PASSENGER'S
oooRt-ocK
ACIUATOR
@r
I uFt REAR
000RLocK
ACTUATOR
@"
r RIGHT
REAR
000RLocK
ACTUATOR
@'
G501
G5o2
BLK
8rl(
8LK
.&
A
-l
G201
G401
GSot
G502
G501
G5o2
23-234
I
vnx.su
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence.
Item io be inspected
=
3-
-9
-.9
)x<
.=
3
o
o
:
o o
St
o o
z )
It
9 c
Symptom
All doors
All doors
O n eo r
more doors
One or
more ooors
All doors
All doors
One or
more ooors
o'o
;-s o
TL
(L
G501
1
- c
o-
G501
G502
WHT/GRN
GRN/REDor
GRN^/lr'HT
WHT/RED
or
YEL/RED
G 2 0 1 BLK/RED
or
G 4 0 1 BLK/WHT
WHT/REDor
YEL/RED
G501
G502
BLU/REDor
BLU/WHT
WHT/REDor
YEL/RED
O n eo r
more doors
Oriver's
ooor
'All doors
o)
O E
dl=
9 E
G 2 0 1 L T G R No r
G401 LT BLU
WHT/RED
or
YEL/RED
G501
G502
BRN,WHT/RED
or YEL/RED
Gsol BRN,WHT/RED
G502 or YEL/RED
23-235
vnx.su
POWERDOORLOCK
UNIT
CONTROL
t4-P COI{NECTOR
23-236
vnx.su
Wire
BLK
Tost condltlon
Under all conditions
Connectthe YEL/RED
tarminal to the WHT/
GRN terminal,and the
WHT/REOterminalto
WHT/REDthe BLK terminsl
momentarily.
2
and
YEL/RED Connectthe WHT/RED
terminal to the WHT/
GRNterminal,and the
YEL/REDterminalto
the BLK terminal
momentarilv.
Wlro
WHT/GRN
GRN/WHT
GRN/RED
BLK/wHT
BLK/RED
BLUMHT
BLU/RED
Driver'sdoor lock
knob in UNLOCK
Tost condition
Driver'sdoor key
cylinderin UNLOCK
LT BLU
Front passenge.'sdoot
key cylinderin LOCK
LT GRN
Front passenger'sdoor
key cylinderin UNLOCK
BRN
CAUTION: To provonl damago to tho molor, rpply battory voltago only momrntadly.
23-237
vnx.su
5.
Terminal
LOCK
UNLOCK
DOORLOCKKI{OB
Terminal
---\
;;"
LOCK
UNLOCK
lJ
il;----t
CAUTION: To prevont damagolo tho actualol, apply battery voltage only momentarily.
lf the actualor fails to work properly,replaceit.
23-238
vnx.su
o
o-
-o
2.
terminalside
Terminal
B
Position
2-P
CONNECTOR
LOCK
UNLOCK
ACTUATOR
@
,-,
CAUTION: To prevent damageto the actuator, apply battery voltage only momentarily.
4.
23-239
vnx.su
2.
2.
swtTcH
coN ECIOR
terminalside
3.
Terminal
Position
UNLOCK
3.
Terminal
P""ft;---l
LOCK
----o
OFF
OFF
UNLOCK
UNLOCK
UNLOCK
<
-r--O
I
I LOCK
tfil*rr
23-240
vnx.su
----o
termtnal
\
Position
LOCK
OFF
UNLOCK
23-241
vnx.su
CruiseControl
Component Location Index
a All SRS 6l6ctrical wiring harnessosaro covorod with
yallow insulation,
a Bofo.6 disconnecting any part of th6 SRS wire harness, connoct th shon conneclor(s).
a Replacothe ontiro affected SRS halness assombly if
it has an opn circuit or damagod widng.
MAINSWITCH
Test, page23-250
page23-250
Replacement,
CRUISELIGHT
(Builtinto gaugeassembly)
Bulb Locations,page 23-115
SET/RESUME
SWITCH
Test. page23-248
page23-248
Repfacemont,
BRAKESWITCH
Test. page 23-251
CLUTCH SWITCH (M/TI
Test, page 23-251
CRUISECONTROL
fnput Test, page 23-246
swtTcH
23-242
vnx.su
ACTUATORASSEMBLY
Test,page23-253
CableAdjustment,
page23-253
23-243
vnx.su
CruiseGontrol
CircuitDiagram
+ No.24
onoine
ll5Al:81881
No.24
ensine
l20Al:818C1
_HOODFUSE/RELAY
BOX
UNOER
FUSE/RELAY
BOX
UNDER-DASH
No.4l(100A)No.39l50A)
HORN
Y
INDICATOR
TIGHT
{0,91W}
IP
I D Suur
PNK
BTK
II
I
f7
VEHICLE
SPEED
SENSOR
iVSS)
6yffi
M/r : CLUTCH
SWITCHI
A/T: A/TGEAR
I
POS|T|oN
SWTTCH
I
Bi,G#,,'.
InIEI,E)
G201
G401
G201
G401
BI-K
23-244
vnx.su
Troubleshooting
NOTE:
a The numbersin the table show the troubleshootingsequence.
a Beforetroubleshooting,
- check the No.15 {10 A) and *No. 24 fuses in the under-dashfuse/relaybox, and the No.41 (1OOA), No.39
(50 A). and No.42 (20 Al fuses in the under-hoodfuse/relavbox.
- check that the horn sounds.
check the tachometerto see if it wo.ks pfoperly.
*No.24 {15A): Bl8B1engine
N o . 2 4 { 2 OA } : 8 1 8 C 1 e n g i n e
Item to be inspected
!
F
o)
'F
c
E
c
U)
.!o
-c.
!
Symptom
oi
a
a
E
c
3
.9
:
'.E
_q
E
dl
.9
_9
E
.E
o
2
'9o1 E
l
L
og
BLU/GBN,LT GRN/RED.
G301,
BLU, BLK/YEL,LT GRN,
G201,
GRY, ORN. BRN/WHT,
G401
BRN/BLK,BRN/REDor PNK
Cruisespeed is noticeablyhigher
or lower than what was set.
Excessiveovershootjngor
undershootingwhen trying to set
speed
3
2
LT GRN/BLK
LT GRN/RED
,1
G201,
YEL or RED/BLU
G401
'I
2
2
LT GRN/BLK
LT GRN/RED
23-245
vnx.su
CruiseControl
ControlUnit Input Test
CAUTION:
a All SRS olectrical wi ng harnessosare covored with
yellow insulation.
a Botore disconnecting any part of th6 SRS wire harneaa, connect the short connoctor(sl.
a Roplacethe ntir affectod SRS hamass assembly il
il has an opan circuit or damaged wifng.
1,
2.
CRUISECONTROLUNIT
14-P COI{NECTOR
23-246
vnx.su
tlo.
Wlfe
BLK
BLKryEL
Tost condition
lgnitionswitch ON (ll)
LT GRN
GRY
lgnitionswitch ON lll),
main switch ON and
brake pedal pushed,
then released
Brakepedal pushd,
then rleased
lgnitionswitch ON (ll)
Blown bulb
B l o w nN o . 1 5 ( 1 0 A ) f u s e i n t h e
under-dashfuse/relaybox
Faulty dimmingcircuit in the gauge
assembly
An open in the wire
Faulty SET/RESUME
switch
Faultycable reel
An open in the wire
lgnitionswitch ON (ll)
and main switch ON;
rsise the front of the
car, rotat one wheel
slowly.
RED/BLU
LT GRN/ RESUME
button
pushed
BLK
LT GRN/
RED
11
. P o o rg r o u n d( G 2 0 1 ,G 4 0 1 1
. An open in the wire
. Blown rNo. 24 fuse in the underdash fuse/relay box
. An open in the wire
. Faulty main switch
. An open in the wire
. Faulty brakeswitch
. An open in the wire
10
GRN/wHT
PNK
BLU
ORN
lD:I,orlE.l
. Faulty actuator
. An opsn in the wire
Faulty actuator
An open in the wire
Poor ground (G3O1)
to the BRN/WHT
terminaland ground to
1 3 BRN/BLK the BRN/BLKterminal.
23-247
vnx.su
CruiseGontrol
Set/ResumeSwitch Test/Replacement
CAUTION:
a All SRS ol6ct cal widng herne$a3 err covorod with
y6llow insulation.
a Bototo disconnecting any part ot tho SRS wiro h8rn6sa, connoct tho ghort connector(sl,
a Rsplacothe antire aftected SRS harness arsombly if
it has an op6n chcuit or damagod wiring.
2.
DRIVER'S
AIRBAG
3-P CONNECTOR
SHORT
CON]TECTON
(REDI
3.
4.
CABLE REEL
CONNECTOR
lHlrnoa!
Eidol
ACCESS
PANEL
23-248
vnx.su
5.
Terminal
Position
SETIONI
RESUME
{ONI
7.
8.
o- ---o
---o
o-
Tominal
A'
Position
OFF
SFT(ON)
RESUME
ION)
\_r-
oo-
-o
---o
swtTcHcovEF
23-249
vnx.su
CruiseGontrol
Main Switch Test/Replacement
NOTE: Be carefulnot to damagethe switch and the instrument oanel.
1.
2.
3.
Tenninrl
A
P".ii";--\
-o o-
OFF
A
ON
/a
A
\7
-o
y' ucsr
rxorcaToR
UCI{T
[ ()
to.grwl \ 7 lo.grwl
A B C D E
23-250
vnx.su
BrakeSwitch Test
'1.
2.
Terminal
il"*on---\
BELEASED
PUSHED
o-
-o
--o
| ormtnal
Clutchpodal
RELEASED
PUSHED
3.
3.
23-251
vnx.su
CruiseControl
A/T GearPositionSwitch Test
1 . Removethe center console,then disconnectthe
14-P connectortrom the switch.
Terminal
il;---t
tr
a
E
lu4l
o
o
o
3.
---o
B
E
23-252
vnx.su
Actuator AssemblyTest
Actuator CableAdjustment
FREEPLAY:
1 1 I 1.5 mm (0.43 r 0.06 int
FULLYCLOSED
POSITION
4.
4.
Output linkage
position
lf the free play is not within specs,loosenthe locknut and turn the adjustingnut as required.
NOTE: lf necessary,checkthe throttlecontrolsystem {seesection 1 I }, then recheckthe output linkage free play.
5.
FULLY M I D D L E FULLY
CLOSED POStTtON OPEN
The
B
Terminal Terminal molor
runs.
The
molor
runs.
The
molor
srops.
The
I
Terminal Terminal motor
stops.
The
motor
runs.
The
motor
runs.
FULLY CLOSED
23-253
vnx.su
Wipers/Washers
Component Location Index
WINDOW
WII{DSHIELD/REAR
SWITCH
WIPERAA'ASHEB
Test,page23-258
Replacement,
oase23 257_..
wtNosHlELDWIPER
ARMS/BLADES ___-=4,
Repfacemont,
Page23'261 /tt'
2
/
WINOSHIELD
IVIPERMOTOR
Test, page23-260
paee23-281
Repfacement,
FUSE/RELAY
BOX
INTERMITTENTWIPER
BELAY CIRCUIT
(ln the intgral.d control onitl
Input Test, page 23-146
REARWII{DOW WIPERMOTOR
Test, page 23-262
pago 23-263
Replacemont,
23-254
vnx.su
Circuit Diagram
UNOERDASH
FUSE/RELAY
BOX
- HOOO
UNOER
FUSENEUY
8OX
WHT/ll-X-FWHr
GRX/4X
WII{DSHIID
WIPERAIVASHER
S1VITCH
si 4.t,,1/'i;",ry)"'.,
8tK
REAR
WINOOW
WIPER
MOTOR
REARWINOOW
WIPER/WASHER
swtTcH
l*_
(ittwA!
Mor
8LK
BLK
REAR
wtN00w
WASHER
MOTOR
|-
8LK
BLK
G30l
G20r
G503
G101
G20'I
G401
G30l
23-255
,r-
vnx.su
Wipers/Washers
Troubleshooting
NOTE: The numbersin the table show the troubleshootingsequence
Item to be insDected
6
i
0,
(t
'96 ;5
a.P
> ;
e b
bE
: 6
rD!
otD
t 3
r!
z )
it
;E
E
ID
i 5
o .
cqt
=Y.
E P
3 3
.45
o
o
.9! O
:!
ot
E r
o c
o
o
o-
- c
o o
ln INT
YEL/BLU,8LU/GRN
In LO or Hl
BLU,BLU/YEL
ln MIST
BLU/YEL
GRN/BLK,GRN
LT GRN/BLK
Symptom
Wipers
do not
i=
o
o-;i
ln all
positions
GRN/BLK
I
G301,
G401
G503,
G751
BLU/wHT,
LT GRN/BLK
BLU/GRN
YEL/BLU.
2
G301
23-256
vnx.su
BLU/BLK
BLK/GRN,
BLK/GRN
Wipers/WashersSwitch Replacement
Disconnectthe 8-P and 6-p connectorsfrom the
switch.
A-P CONNECTOR
4.
6-P CONNECTOR
UPPERCOVER
23-257
vnx.su
Wipers/Washers
Switch Test
Wipers/Washers
CAUTION:
a All SRS electrical wiring harn6ss6salo covered with
yellow insulation.
a Belore dkconnecting any part ot th6 SRS wire harneaa. connect the short connoctor(sl.
a Replac6the 6ntire affoctod SRS harnessassembly it
it has an open cilcuit 01 damaged wiring.
1.
2.
scREws
23-258
vnx.su
Windshield WiperAi\laEhelSwitch
D
'w*+t+*i' 4l ?u
I-
l=f,.
o"/j^o-"-
_J
M|ST
M|ST
OFF/INT
E B
Terminal
il;----__\
o-
OFF
INT
o-
LO
G-
Mistswitch"ON'
Washer
switch"0N"
---o
o- *--o
---o
*-o
--o
---o
o-
HI
G--
---o
o-
,i1..___.______,x..
fr."ql|.fr
tiT
rermrnal
\
Position
L
\
Washer
switch"0N"
OFF
ON
Washer
switch"ON"
(withwiDer'0N")
o- ---o
o- -*o
--o
o---o
o-
o- ---o
o- ---o
23-259
vnx.su
Wipers/Washers
Windshield Wiper Motor Test
Open the hood and remove the cap nuts and the
wiper arms (see page 23-261).
NOTE: Removethe wiper arms carefullywithout
damagingthe hood.
A SLUTYEL}
D IGB /BLK)
B (BLUI
Terminal
Pi"i,i""---\
B
D
{GRN/BLK) {8LU)
LOW SPEED
H I G HS P E E D
(BLU/YEL}
23-260
vnx.su
o.
8.
23-261
vnx.su
Irflnfi]
Wipers/Washers
-Keal
I esr
wlper Motor
|Yloror Test
wlnqow Wiper
Rear Window
1.
4-P
CONNECTOR
A (GBN/BLK)
C IGRNI
Viewtrom terminal
side
2.
C (GRI{}
23-262
vnx.su
l.
2.
RESERVOIR
MOUNTINGNUT
14 N.m
11.4 kgf.m,
10 tbt.trl
WIPERARM
RUBBERSEAL
SPECIALNUT
8.8 N.m
{0.9 kgt'n,
6.5 rbt.fr)
6,
-4
)
WINDSHIELD
REAR
wrNDow
Test the motor by connectingbatterypower to the
A ( + ) terminaland ground to the B (- ) terminal.
a ll the motor does not run or fails to run smoothly, replaceit.
a lf the motor runssmoothly,but littleor no washer fluid is pumped.check for a disconnectedor
blockedwasherhose, or a cloggedpump outlet
in the motor.
23-263
vnx.su
Wipers/Washers
Washer Replacement
1 . Bemovethe Jront bumper (seesection 2Ol.
Removethe left lront inner fender.
Disconnectthe 2-P connectorand hose from the
washer motor.
Removethe three mountingbohs and the washer
reservorr.
5 . Removethe washer motor from the reservoir.
6.
WINDSHIELD
WASHER
NOZZLE
REAR
wtt{Dow
WASHER
t{ozzLE
n
V
..,.,,@
lH (
MOUNTING
BOLTS
9.8 N.m
{1.O kgf.m, 7.2 lbf.ftl
23-264
vnx.su
SupplementalRestraintSystem
(sRst
GomponentLocationIndex..................
23-266
Description
..23-267
Circuit Diagram
23-268
Wiring Locations
23-270
Precautions/Procedures
..23-271
Troubfeshooting
.............
..23-276
AirbagAssembly
Repfacement
..................
23-295
Disposal
....23-299
CableReel
Replacement
..................
23-301
DashSensor
Replacement
..................
23-305
SRSUnit
Replacement
..................
23-307
vnx.su
SupplementalRestraintSystem(SRS)
ComponentLocirtionIndex
SRSINDICATORLIGHT
(ln th6 gaug6 assembly)
page23-276
Troubleshooting,
Gaugeassembly,page23-113
CABLEREEL
Replacement,
page23-301
To CRUISECONTROL
SET/RESUMESWITCH
AIRBAG
page23.295
Beplacement,
UNDER.DASH
BOX
FUSE/RELAY
FRONTPASSENGER'S
AIRBAG
lExceptCanadsRS model)
page23-295
Replacement,
page23'299
Disposal,
RIGHTDASHSENSOR
page23-305
Replacement,
LEFTDASHSENSOR
R e p l a c e m e n t ,p a g e 2 3 - 3 0 5
SRSMAIN HARNESSFRONTPASSENGER'S
AIREAG
BRANCHlExcptCaned. RS modol)
23-266
vnx.su
Supplemental
RestraintSystem(SRSI
CircuitDiagram(WithoutFrontPassenger's
Airbagl
SRSINOICATOR
CIRCUIT
{lnthglugsssombv}
r---r n
r t l
ill
SADHUNOER_
HOOD
DRIVER'S
FUSE/
AIRBAG
RELAY
INFLATOR
80x
SAOC
BUC
GNO
o
a
a
@
o
a
a
@
a
@
a
@
rDc @
MI
23-268
vnx.su
a
a
GircuitDiagram(With FrontPassenger's
Airbagl
UNOE8DASH
FUSSRELAY
BOX
SRSINOICATOF
CIRCUIT
lln lh6 grugo.$.mblyl
I
I
I
I n
I ll
I tl
t U
I
SADH
UNDER
HOOD
FUSE/
REI.AY
80x
DRIVER'S
AIREAG
INFI.A]OR
o
@
o
FROI.IT
PASSENGER'S
AIREAG
INFLATOR
@
@
a
a
@
a
@
a
@
@
@
a
a
SRSUNITl8-P COI'INECTOR
23-269
vnx.su
SupplementalRestraintSystem (SRSI
Wiring Locations
CAUnON:Makesureall SRSgroundlocrtion3lrc clrln rnd ground3tra |.curalv rltachad.
NOTE:
withysllowinsulation.
arecovered
o AltSRSelectricsl
wiringharnesses
. RsDlace
the entireaffectedSRSharnessassemblyif it hasan opencircuitor damagedwiring.
CABIEREELto DdrrEFS AnaAC
3+ OOI{iECTOR
DASHBOARDWIRE HARNEi9
to INDICATOBUGHT in GAUGE ASSEMBLY
5-PCONNECTOB
b Ra nod.ll
SRSMAINHARNESS
to UNDER-DASH
FUSE/RELAY
BOX
2"P@NNECTOR
MAIN WIREHARNESS
to DASHBOARDWIRE
HARNESS
lGP CONNECTOR
o sHSErson
2+ OOt{tlEcT()R
23-270
vnx.su
GeneralPrecautions
SHORTCONNECTON
{REDI
vnx.su
23-271
SupplementalRestraintSystem(SRSI
Wiring Precautions
o Neverattemptto modify.spliceor repairSRSwiring.
2.
Connectthe shortconnector(s)
{RED):
Driver's Side:
. Removethe accesspanel from the steeringwheel.
t h e n r e m o v e t h e s h o r t c o n n e c t o r( R E D )f r o m t h e
Daner.
DRIVER'S
AIRBAG
CONNECTOR
IREDI
Disconnectthe 3-P connectorbetweenthe driver's
airbagand cablereel,then connectthe shortconnector {RED}to the airbagside oi the connector.
M a k e s u r e a l l S R S g r o u n d l o c a t i o n sa r e c l e a na n d
groundsare securelyfastenedfor optimum metal-tometal contact.Poorgroundingcan causeintermittent
problemsthat are difficultto diagnose.
23-272
vnx.su
Front Pas3enger'sSide:
. Removethe glove box damper (seesection20),and
then removethe glove box.
.
Disconnectthe 3-P connector between the front oassenger'sairbagand the SRSmain harness,then connect the short connector (RED)to the airbag side of
the connector.
SHORTCONNECTOR
(REDI
CONNECTOR
t_tD
SRSMAIN HARNESS
23-273
vnx.su
SupplementalRestraintSystem(SRS)
Steering-relatedPrecautions
SteeringWheel and CableReelAlignment
CAUTION:
. Bofore romoving tho 3l6oring column, first discon'
nect tha connector between ths cablo 16ol snd tho
SRSmain harness.
. lf th6 stssring column is going to be removed without dbmounting the stesring wh6el, lock the sl6sring by turning th ignition k.y to o-LOCKpo3ition or
removo tha ky llom ths ignilion so that th6 3loaring
wheel will not turn.
D o n o t r e p l a c et h e o r i g i n a ls t e e r i n gw h e e i w i t h a n y
other design,sinceit will make it impossibleto properly
instsllthe airbag(only use genuineHondareplacement
oans).
After reassemblvconfirmthat the wheelsare still turned
straightaheadand that the steeringwheel spokeangle
is correct,lf minor spokeangleadjustmentis necessary,
do so only by adjustmentof the tie-rods,not by removthe steeringwheel.
ing and repositioning
ALIGNMENTMARK
23-274
vnx.su
SensorInspection
InspectionAfter Deployment
2.
3.
4.
After the car is completelyrepaired.turn the ignition switch on. lf the SRS indicatorlight comes on
for about six secondsand then goes off, the SRS
systemis OK. lf the indicatorlight does not function
properly,go to SRSTroubleshooting
(nextpage).
DASHSENSOR
BOLTS
23-275
vnx.su
SupplementalRestraintSystem(SRSI
Troubleshooting
Self-diagnosisFunction
function.lf there
The SRS unit includesa self-diagnosis
is a failure in the sensors.SRSunit, inflator,or their circ u i t s ,t h e S R S i n d i c a t o rl i g h t i n t h e g a u g e s s s e m b l y
comesON.
Drivsr's Sido:
. R o m o v e t h e a c c o s sp a n e l t r o m t h e s t e e r i n g
wheel, then remove the shon connector(BED)
from the panel.
CABLEREL
DRIVER'S
AIRBAG
3-P
TroubleshootingPrecautions
a Always use the test harness.Do not use test probes
directlyon componentconnectorterminalsor wires;
you may damagethem or the SRSunit.
a When connectingany of the test harnessesto the
system,push the connectorsstraight-in;do not bend
the connectorterminals,
. Beforedisconnectingany part of the SRSwire harness,connectthe shon connector(RED)on the driver's airbag. On cars equippedwith a front passenger'sairbag,connectshortconnectorson the driver's
airbag.
airbagand the front passenger's
(REDI
. Disconnectthe connectorbetweenthe driver's
a i r b a g a n d c a b l e r e e l ,t h e n c o n n e c tt h e s h o r t
connector{RED}to the airbagside of the connector.
Possibloconditions:
1. SRS indicatorlight does not come on at all - see
page 23-278.
SRS indicatorlight stays on constantly- see page
23-242.
3.
ACCESS
PANEL
SHONTCONNESTOR
2.
(RED):
Connectthe shortconnector(s)
NOTE:
check
. Beforestartingthe applicabletroubleshooting.
t h e c o n d i t i o no f a l l S R Sc o n n e c t o r sa n d g r o u n d
points.
. lf the fault is not found after completingthe applicable troubleshooting,substitutea known-goodSRS
unit and checkwhetherthe indicatorlight goesoff.
23-276
vnx.su
MAIN HARNESS
Test Harnesses
and AttachmentPoints
TestHsrnessA
SRSUNIT
TESTHARNESSA
07MAZ - SL|D500
2
TESTHARNESSC
07LA:Z- SL.()3(X'
to n 12 l 3
1 6 16
Tast HarnessB
TESTHARNESSB
07MAZ - SP@500
ROWA ISRSUNfT ENDI
2
I
13
12
1 5 16 17 | l
1 5 l6
17 1A
ROW B IWIREHARNESSEND)
23-277
vnx.su
SupplementalRestraintSystem(SRS)
Troubleshooting
The SRSIndicatorDoesNot Light
CAUTION: Uss only a digital multimeter to check the system. lf it's not a Honda multimeter, make sure its output is
10 mA {0.01Al or less when switched to the smallest value in the ohmmeter rang. A tester with a highor ouiput could
damagethe airbag circuit or causeaccidentalairbag deployment and possibleiniury
NOTE:The originalradio has a codedtheft protectioncircuit.Be sure to get the customer'scode number beforedisconnectingthe batterycables.
Dilconn6ct the battory negaiive
cable rnd thon tho positive
cable.
Connest the short connectorlsl
to tho airbaglsl (seo p6ge 23272t.
Turnthe ignitionswitchOFF.
D i s c o n n e ctth e S R S m a i n h a r n e s s l 8 - P c o n n e c t o rf r o m t h e
SRSunit.
D o e st h e S R S i n d i c a t o r
lightcomeon?
I n s p e c tt h e N o . l 5 1 1 0A ) f u s e
(under-dash
tuse/relay
box).
ls No. 15fuseOK?
Repairopen in dashboardwir6
harnessbetween the No. 15 tus
and gauge a3sombly.
SRSMAIN HARNESS
18.PCONNECTOR
Io page 23'2791
23-274
vnx.su
SRSUNIT
SRSMAIN HABNESS
MAIN VNRE
HARNESS
D o o 3t h o S R S i n d i c . t o r
light com6 on?
i.t
ulty.
R o m o v ot h o g ! u 0 c ! s s . m b l y
th6n inrpoct ths SBS indicator
light bulb.
DASHBOARDWIFEHARNESS
5-PCONNECTOR
Raplacalh. indlc.toi llOht birlb.
(Top.go 2+280)
8tU{+
I
:
23-279
vnx.su
SupplementalRestraintS ystem(SRSI
Troubleshooting(cont'd)
(Frompage23-279)
ls therelesslhan8.5V ?
Turnthe ignitionswitchOFF
DASHBOARDWIREHARNESS
Connecttho voltmeter between
the No. 1 terminal(+)and the No.
3 terminal (-) of the dashbord
wire harness5-Pconnector.
YELI+,BLK{-I
Turn the ignitionswitchON (ll).
View lrom wire side.
Measurethe voltage betweenthe
No. 1 terminaland th No.3 termrnal,
ls there batteryvohage?
Turnthe ignitionswitchOFF.
{To page23-281}
23-280
vnx.su
TEST HARNESSA
07MAZ - S!IX)s{X'
4
10 It l2
13 l 4
15 16
23-2a1
vnx.su
,;l
SupplementalRestraintSystem(SRSI
Troubleshooting(cont'dl
SRSIndicatorLight Stayson Continuously
NOTE: Beforetroubleshooting,make sure that battery
voltageis 12 V or mo.e. Otherwiseyou'll obtain wrong
test readings.
1.
2.
to
ll
l2 t3
t l rt
TEST HANNESS
"battery
Voltagesin the chart assumethe car's
voltage"is about 12 volts.Lessthan 12 volts will
result in different or possiblytalse readings.
Do not disconnectthe airbags ftom the circuit
when checkingSRSunit voltages.
7.
F i r s t , c h e c k f o r v o l t a g e b e t w e e nT e s t H a r n o s s
TerminalNo. 12 (+)and ground(-).
lf no voltageis indicated,go to step I and continue checkingall the otherterminals.
o lf vottsge is indicated,there is a poor ground at
the SRSunit.Readthe followingNOTE,and then
go on to step 5.
.
TEST HARNESSB
07MAZ - SPqrS{X)
23-282
vnx.su
8.
4.5
12,O
1/4.3
I
/
".)6r-
4.6
It youcircld
alltheranges
in thisrow,tollowthe
procedure
troubleshooting
underfailuremode,,C"on the
followingpages.
4.5
12.O
5.5 - 14.3
at'9\r t.g
5.t
4,5
r2,o
-t4.3
2.9
rl.5
-5.5
12.0
- 14.3
2 . 91 8 . 7 | 3 . 7l - r r . 2 l
l..s lr2.ol | - 5 . 8l - r a . 3 l
a
SADC
4,3
4.3
5.4 -5.6
2.5
-3.7
2_A
4.5
12.0
-14.3
4.5
12.O
- 1rt.3
4.5
-5,5
12.0
14_3
8,6
a_6
l1_3-11.3
4,5
12.0
5.5 - 14.3
5_7
4.5
12.0
- 14.3
10
aucl
t1,5
- 14.5
GNO
t3
tDc
4.4
1 3 . 6 - 10.9
3.1
-4,9
11.5
- r4.5
11.5
14.5
2.O 8.4
4.5 - 1 0 . 9
11.2
-14.6
11.5
- 14.5
2.O
4.5
4.4
10.9
-9.7
r1,5
-14,5
2.O
4.5
8.4
to.9
2.O
-4,5
4.4
10.9
4.6
2.9
-3,7
4.5 1 2 , O
-5.5 -14.3
3,7
4.9
I1.5
l4_5
2.O
4.5
8.4
10.9
2.9
4.7
- 1 1. 2
4.5 '12.o
-5.5 -14.3
3.7
4.9
11.5
- 14.5
2.O
a_5
4.4
10.9
4,6
a_6
l1_3-t1.3
4.5
12.O
5.5 - 1 4 . 3
I t.5
- r4.5
2.O
-4,5
4.4
10.9
11.5
- t lt.5
2.O
-4.5
4.4
- 1o.9
11 . 5
- 14.5
4.3
-5,6
4.3
5.6
4.3
5,6
4_3
5.6
4.5
5.5
12.O
r4.3
-7.3
o 18.5 4.4
- 13.6 1 0 . 9
23-283
vnx.su
SupplementalRestraintSystem(SRSI
Troubleshooting(cont'd)
NOTE:Do not disconnectthe airbagwhen checkingSRSunit voltages.
Without lront Passongor'ssirbag:
l
SAOH
vcc
12.O
5.5 - 1 4 . 3
4,3
5.6
4.5
5.5
2.4
3.7
't2.o
14.3
4 . 5 12.O
5,5 - 1 4 . 3
4.6
-11.3
-5.5 - 14.3
12.O
saoc
10
BUCI
12
Gto
5,6
-7.3
11.5
- 14,5
13
t4
toc
a _ 5 8.:a
- 1 3 . 6 ro.9
11,5
-14.5
2 . O 8.4
-8.5 - r 0 . 9
11.5
-14,5
2 . O 8./a
-8.5 - r 0 . 9
11.2
- 14.6
11.5
14,5
2.O
8./t
-r0.9
8.1
-10.9
3.7
4.9
5.7
4.5
t2.o
14,3
-9.7
tt.5
- 14_5
-8.5
4.6
11.3
4.5 12.0
- 5 . 5 - 14.3
3.7
-4.9
1t.5
14.5
a.a
2.O
- 8 . 5 -r0.9
4.3
5,6
-7.3
11.5
14,5
4.3
-5.6
4.5
-5.5
12.O
- 14.3
-7.3
t1.5
- 14-5
H ll{o. 26 lo Al o.
o ta,5 E,4
- 1 3 . 0 t- 1 0 . 9
B
TESTHABT{ESS
Mods B:
. Short to driver's or Passonger'saitbag inflator body
(body groundl
. Short in dash sonsor
. Opsn in both cowl sgnsor contacts
A
B
8.it
,r0.9
3.
2,O
'...
23-284
vnx.su
7.
TESTHARNESS
B
o?MAZ- SFmSd)
TEST HABI{ESS C
07LAiZ- SLIO:loo
CABLENEEL&P CONNECTOR
(cont'd)
23-285
vnx.su
SupplementalRestraintSystem(SRS)
Troubleshooting{cont'd}
8.
FRONTPASSENGER'S
ANBAG
DRIVER'SAIRBAG
o7LAiZ- Slao:tq,
23-286
vnx.su
sRs MA[{
HARNESS
2-POOTTNECTOR
TESTHARNESS
D
o?LAiZ- SL()a(xt
TESTHARNESSD
otlA:z- sl(,(x)
rffi-l
TESTXARNESS
D
otlA:z - sl4|)4tx)
t'l
Measure the resistancebetween the l6ft dash sensor terminalsB'12and Bl6, and betweenthe right
dashsensorterminalsB4 and 86.
lf resistance
is 3.8- 4.2kO,the SRSmain harness
is faulty. Replaceit and recheckthe voltages
accordingto the chan on pag23-283.
lf resistanceis lessthan 3.8 kO,the dash sensor
is faulty. Replaceit and recheckthe vottages
accordingto the charton psge 23-283.
IESTHARNESS
B
07MAZ- SPqt500
(cont'd)
23-287
vnx.su
SupplementalRestraintSystem(SRS)
Troubleshooting(cont'd)
3.
Measure the resistancebetween the left dash sensor terminals812 and 816, and betweenthe right
dashsensorterminals84 and 86.
2.
23-2AA
vnx.su
4.
SBSMAIN
HARNESS
2-PCOI{NECTOR
2.
sRsuNtt
TEST
HARNESSD
orlA:a- sl{tarx)
TESTHARI{ESSD
OTLAZ- sl/to4{lo
Reconnect the driver's airbag connector, then measure the resistance between the 81 and the 87 ter,
m rn a l s .
lf resistance
is more than 5 kO,the dash sensoris
faulty.Replacethe dash sensorand recheckthe
voltagesaccordingto the charton page23-283.
TESTHARNESSB
o?MAZ - SP00500
lf resistance
is more than 0.2 kO,go to step4.
lf resistanceis lessthan 0.2 kO,the SRS unit is
f a u l t y .S u b s t i t u t ea k n o w n - g o o dS R S u n i r a n d
recheckthe voltages accordingto the chan on
page23-283.
(cont'd)
23-289
vnx.su
; r.il
SupplementalRestraintSystem(SRS)
Troubleshooting{cont'd}
4,
6.
DRIVER'SAIRBAG
TESTHARNESS
C
07LAZ- SLIO300
7.
TESTHARI{ESSC
OTLAZ- AL/|{,3OO
TEST HARI{ESS C
OTLAiZ- Sl/t{r3q)
23-290
vnx.su
Disconnectthe front passenger'sairbag 3-P connector from the SRS main harness,then connectTest
HarnessC to the front passenger'sairbag sids of
the connector,
FAONT
1,
2.
SRSUNIT
TESTHARNESS
C
- SL/O300
07LA,Z
Measurethe resistancebetweenthe No. 7 terminal
a n dt h e N o .8 t e r m i n a l .
07MAZ - SP|D500
TESTHARNESSB
oTMAZ - SP005(x)
23-291
vnx.su
SupplementalRestraintSystem(SRSI
Troubleshooting{cont'dl
Modc H: Blown SRSNo. 25 fur., ol opcn in the wire
NOTE:The original radio has a coded theft protection
circuit. Be sure to get the customer's code number
betore disconnectingthe battery cables.
1.
2.
3.
TESTHAN ESSB
oTMA:Z- SPOOs{X'
2
a
6
10 n
1o
ll
l3
12
1 6 1a 1 7
ra
1 6 1a 1 7 |a
SRSUNIT
23-292
vnx.su
WIREHABNESS
2.
Turn the ignitionswitchON (ll) 8nd wait for six seconds. Measu.s the voltage betweenths No. il terminal (+) in the SFS main harness4-P connectorand
body ground,
*-
F4
5.
6,
BLU
d.L
Vrowllom wi|! rftro.
NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code
number before disconnectingthe banery cables.
(cont'dl
23-293
vnx.su
SupplementalRestraintS ystem(SRSI
Troubleshooting(cont'dl
7.
Turn ths ignitionswitchON {ll} and wait for six seconds. Measurethe voltagebetweenthe No. 5 terminal (+)and body ground (-).
OASHSOAROIVIRE HARNESS
s.PCO ECTOR
TESTHARNESSB
07MAZ - SF|D500
Vrawfromsil! rira,
8.
l f t h e r e i s c o n t i n u i t y ,t h e S R S u n i t i s f a u l t y ,
Replaceit and recheckthe voltages according to
the charton page23-283.
DASHBOARDWIRE HARNESS
5.P OONNECTOR
23-294
vnx.su
AirbagAssemblyReplacement
storc a r.movcd
@E
p.d surfaco up, if tho lirbrg
down, accidontald.ploymert
cnough torcr lo causclariour
CAUTION:
. Do not inst.ll urld SRS plrts trom lnothar c!1,
Whon lepairing, uss only now SRSprrt!.
o Carefully inlpcct thc airblg rlrcmbly bltorc you
install it. Do not inst.ll an airbag !$.mbly thrt
3how! sign3 of bcing droppcd or improparly hrndlod, such as dont!. crack3or dstormation.
. Alwry! koop ths rhort connactor(3l (REDI on tha
airbrg{s} whon tho hsrnca3i! dirconnastld.
. Do not diras3ombl! or tampl with tha lirbrg
a$ombly.
SHOBTOONNECTOR
(REDI
2.
Drivo/s Sido:
a Removethe accesspanel from the steeringwhesl,
then ramove the short connector (REDI from th6
paner.
.
(cont'd)
23-295
vnx.su
SupplementalRestraintSystem(SRSI
AirbagAssemblyReplacement(cont'd)
3.
Removethe airbag(s):
Driver's Side:
.
Front Palsugor'r
.
Sidc:
23-296
vnx.su
4.
FRONTPASSENGER'S
AIRBAG
ASSEMALY
UPPER
MOUNTINGNUTS
TORXOBOLI
9,8 N'm l'1.0kgf.m,
7.2lbtftl Replaco.
Us. . TORX6T30 bit
LOWER
MOUNTINGNUTS
9.8 N.m (1.0lgtm, t.2lbtftl
Reolace.
CONNECTOR
IREDI
{cont'd)
23-297
vnx.su
SupplementalRestraintSystem(SRSI
(cont'd)
AirbagAssemblyReplacement
5.
Front Passngr'sSide:
. Remove the short connector (RED)from the front
p a s s e n g e r ' sa i r b a g c o n n e c t o r ,t h e n c o n n e c tt h e
airbag 3-P connectorto the SRS main harness3-P
connector.
SHORTCONNECTOR
FRONTPASSENGER'S ,,'
AIRBAG3.P CONNECTOR
8.
SHORTCONNECTOR
IRED)
DRIVER'S
AIRBAG3.P
CONNECTOR
23-294
vnx.su
Front Passonger'sAirbag:
4.
R e m o v et h e g l o v e b o x d a m p e r ( s e es e c t i o n2 O ) .
then removethe glove box. then disconnectthe 3-p
connectorbotweenthe front passenger,s
airbagand
SRSmain harness.
FRONT
PASSENGER'S
SHORT
CONNECTOR
AIRBAG3.PCONNECTOR IRED}
Doployingthe Airbag(sl:In-car
N O T E : l f a n S R S c a r i s t o b e e n t i r e l y s c r a p p e d .i t s
airbag(s)should be deployedwhile still in the car. The
a i r b a g ( s )s h o u l d n o t b e c o n s i d e r e da s s a l v a g e a b l e
pan(sland shouldneverbe installedin anothercar.
confirm that osch airbsg assemblyis
@
s6cursly mounted; oihorwis6. svoro parsonal iniury
could result from doployment.
1.
2.
SRSMAIN I{ARNESS
Driver's Airbag:
3.
CABLEREEL
3.P CONNECTOR
DRIVER'S
AIRBAG
FRONTPASSENGER'S
AIRBAG
ALLIGATOR
CLIPS
lY.llowl
12 V BATTERV
OPERATION
swrTcH
DEPLOYMENT
TOOI
(cont,dl
07HAZ- SG00400
23-299
vnx.su
SupplementalRestraintSystem(SRSI
AirbagAssemblyDisposal(cont'd)
Connecta l2 volt battervto the tool:
P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h 6 s i r b a g
should deploy (deploymentis both highly audible
and visibls- a loud noiseand raDidinflationof the
bag, followed by slow deflationl.
1.
2.
3.
5.
23-300
vnx.su
CableReelReplacement
store r rcmov.d
!!@
prd ruf.cc up. It th. .irb.g
down, sccid.ntd d.ploym.rf
rnough torca to caure a.?iour
5.
GAUTION:
o Clrdully in3pcct thc airbrg r$.mbly brtorc instll_
ling it. Do not inttrll !n lirb.g |3..mbly ihst fiow3
rignr of bring droppcd or improp.rly handled. ruch
.3 dant!, crrck3 or dafo?mation.
. Atw!$ krro th. tkroR connctot(3l on ths rtbrg\t\
connactor whan tha h|rn!|a l! dbconncstad,
. Do
dis.tlambla or tampar with thc ai.brg !rlo-t
t.mbly.
NOTE: The original radio has a codod theft Drotoction
c i r c u i t . B s s u r e t o g e t t h e c u s t o m e r , sc o d e n u m b e r
bsfore disconnectingth6 battery cables.
l.
2.
3.
IRED}
SRSMAIN HARNESS
R e m o v et h e d r i v e r ' s a i r b a g a s s e m b l yf r o m t h e
steerangwheel (two T30 TORXObolts), then remove
the steering wheet nut.
TOR)(' BOLTS
U.. . TORX. T30 bh
DRIVER'S
AIRBAG
ASSEMBLY
DASHBOANO
LOWEROOVER
Removs tho glove box damper (s6e sction 2O),
then removethe glove box,
(cont'd)
23-301
-
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SupplementalRestraintSystem(SRSI
GableReelReplacement(cont'd)
Disconnect
the connectorsfrom the horn and cruise
controlsevresumeswitches,then removethe cable
reel3-Pconnectorfrom its cliD.
CONNECTOFHOI-DER
8.
9.
COVER
UPPER
COLUMN
23-302
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GAUTION:
o Eatorainstdlingtho steoringwhosl,lha front whaels
1 4 . Installthesteeringcolumnupperano towercovers.
t5.
ALIGNMENTMARK
YELLOWGEAR
TOOTH
CABI.I REEL
't7.
CONNECTOR
HOLDER
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23-303
SupplementalRestraintSystem{SRSI
(cont'd)
CableReelReplacement
2 1 . Removeand properlystore the shon connector(s)
TORXOBOLTS
9.8 N.m (1.0kgf.m,7.2lbtftl
Replace.
Us6 a TORX6T30 bit
tive cable.
WHEELNUT
STEERING
,19N.m 15.0kgt m, 36 lbt ft)
Replace.
AIRBAG ASSEMBLY
1 9 . Installthe driver'sairbagassembly.
20. Connectthe cable reel 6-P connactorto the SRS
m a i n h a r n e s s ,t h e n i n s t a l lt h e k n e e b o l s t e ra n d
dashboardlower cover.
DASHBOARDLOWEROOVER
23-304
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DashSensorReplacement
GAUTION:
. Oo not drmrgc the sensor wiring.
. Do not instrll used SBS part3 from anothor c!t,
When repairing an SRS:use only new part3.
o Roplaco. 3onsor it it is dented, crackod,or doform.
od.
2.
PROTECTOR
5.
3. Connectthe shortconnector(s)
to the airbag(s).
DASH SENSOB
DRIVER'S
AIRBAG
DRNEN'S
ANAAG
3.P CONNECTOR
SHORT
CONNECTOR
IREDI
MOUNTIITGBOLTS
(cont'd)
23-305
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SupplementalRestraintSystem(SRSI
(cont'dl
DashSensorReplacement
CAUTION:
. Be 3ure to install the harnesswires so that theY ars
not pinchcd or interfering with othor car parte.
o Carefully inspest the dash sensorslor signs of boing
dropped or improperlyhandled,3uchas dents,
cracksor dsformation.
. For the SRS to lunction propotly, ths right and lsft
sensorsmust be installsd on the propor sidos.
6.
Installthe sensorsecurely.
DASH SENSOR
MOUNTINGBOLTS
8 mm x 1.25
22 N.m (2.2kgf.m, 16lbfftl
Replace.
7.
23-306
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SRSUnit Replacement
CAUTION:
. 8tor6 disconneciing any part of the SRS wire harness, connect the short connectorlsl (RED)to tho
sirbagl3).
o Do nol drmsgo thc SRS unit terminal! o. connocto.s.
. Do not disassemblotho SRS unit; it ha3 no rervico.blo parts.
. Storo tho SRS unit in a cleln, dry srea.
. Do not us lny SRS unit which h.s been subisctod
to wator damag or shows sign3 ol bing droppad or
improperly handl6d, such as dents. cracki or d6tormation.
4.
SRSUNIT
Disconnect
the batterynegativecable,then the pos_
itivecable.
Connectthe short connector(s)
to the airbag(s)(see
page 23-2721.
Removethe right sidecoverfrom the SRSunit.
(cont'd)
23-307
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SupplementalRestraintSystem{SRSI
(cont'd)
SRSUnit Replacement
Remove and properly storo the short connector{s),
thgn roconnectthe sirb8g connector(s)(and reinst8ll tho glove box).
SRS UNIT
SRSMAIN HARNESS
18.PCONNCTOR
TORX' BOLTS
9.8N.m11.0ksl'm.
7.2tbf.ftl
Replace.
U.. . TORX' T30bit
LEFTSIDECOVER
SRSUNIT
TOD(' BOLTS
9.8N.m(1.0tc[.m,
7.2tbf.ftl
Ur. . TORX.T30bit
COVER
23-308
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