INTRODUCTION -— How to Use This Manual This supplement contains information for HONDA ACCORD. Refer to following shop manual for service procedures and data not in- cluded in this supplement. HONDA ACCORD MAINTENANCE, REPAIR AND CONSTRUCTION, (Code no. 628N700) This first page of each section is marked with a black tab that lines Up with one of the thumb index tabs on this page. You can quickly find the first page of each section without looking through a full table of contents. The symbols printed at the top corner of each page can also be used as a quick reference system, General Info Special Tools Specifications Maintenance Engine — Special Information ERMINE Indicates a strong possibility of severe personal injury 0 loss of Ife if instructions are not followed. CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information. CAUTION: Detailed descriptions of standard workshop pro: cedures, safety principles and service operations are not included. Please note that this manual contains warnings and cautions against some specific service methods which could cause PER- SONAL INJURY, damage a vehicle or make it unsafe. Please understand that these warnings cannot cover all conceivable ways service, whether or not recommended by HONDA MOTOR, ‘might be done, or of the possible hazardous consequences of every conceivable way, nor could HONDA MOTOR investigate all such ways. Anyone using service procedures or tools, whether or not recommended by HONDA MOTOR, must satisfy himself thoroughly that neither personal safety not vehicle safety will be jeopardized. All information contained in this manual is based on the latest pro- duct information available at the time of printing. We reserve the right to meke changes at any time without notice. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. This includes text, figures and tables. ‘marked sections are not included in this manual First Edition /93 232 pages HONDA MOTOR CO. LTD. All Rights Reserved Service Publication Office Cooling Fuel and Emissions Transaxle Brakes * Electrical (Including | SRS }) [Rs sections with * Include SRS components, special precautions are required when ‘servicing.Outline of Model Changes The following summarizes changes made on the base shop manual (Code No. 62SN700). Tem DESCRIPTION ‘CODE NO. 628N720 REFERENCE SECTION, General 2.3 & model added ° 1,3, 4,5, 8,7, 8, 9, 10, 11, 14, 19, 20, 23 2.0 ¢ KS type added ° 13,4 Engine H23A3 engine type added F2021, F20Z2 engines valve clearance modified 1.3, 6,6, 7,8, 9,10 PGM-FI Changed for 2.3 € model addition + Vacuum connections + Electrical connections + Heated oxygen sensor {HO2S) TOC/CKPICYP sensor Starting air vaive Fast idle thermo valve Throttle body Intake air bypass (IAB) control system Intake air control system u ‘Automatic Transmission Changed for 2.3 € model addition + Road test shift schedule + Stall speed RPM + Pressure testing fluid pressure + _1st/2nd clutch assembly 14 Brake Application of brake pads changed due to 2.36 model addition Body ‘Added + Front spoiler for 2.3 ¢ model + Trunk spoiler for 2.3 £ model 20 Electrical ‘Changed * Ignition system (2.3 ¢ model) + Power supply circuit + Starter mounting bolt torque value changed (M/T) Keyless entry system added (KE) 23General Information Chassis and Engine Numbers . 1-2 Identification Number Locations 1:3 Warning/Caution Label Locations ...... 1-4 Lift and Support Points Lift .... Floor Jack . . 1-8 Safety Stands . .1-9 Towing . . 1-10 Abbreviations . 1-11HONDA ACCORD Engine Number and Abbreviation Shop Manual News Applicable Materials and Corresponding Pages Please collect serial number of engine and add abbreviation for intake air bypass in your shop manual. Shop Manual Number Corresponding Page ACCORD SUPPLEMENT 93 62SN720 12, 41 © Engine Serial Number (page 1-2) Engine Number Engine Number F2021-1000101 £F20Z1-1000101, Engine Type Engine Type F20Z1: 2.01 Sequential Mult-port F20Z1: 2.01 Sequenital Malt Fuckinjected 131 PS engine Fuelinjected 131 PS engine Unleaded gasoline with CATA Unleaded gasoline with CATA F2022; 2.01 Sequential Mult-port 2022: 2.01 Sequential Mult-port Fuehinjected 115 PS engine Fucl-injected 115 PS engine Unleaded gasoline with CATA Unleaded gasoline with CATA H23A3: 2.31 Sequential Multi:port H23A3: 231 Sequential Multi-port Fuekinjected 180 PS engine Fuclinjected 160 PS engine Unleaded gasoline with CATA Unleaded gasoline with CATA Serial Number Serial Number F20Z1 (Wako plant in Japan): 1000101~ © Abbreviation (page 1-11) IAB Intake Air Bypass F20Z1 (U.K. MFG. in England): E100001~ F202 (U-K. MEG. in England): E100001~ H23A3 (U.K. MFG. in England): E100001~ HONDA MOTOR CO, LTD. SERVICE PUBLICATION OFFICE. LoftChassis and Engine Numbers Vehicle Identification Number (VIN) ‘SHHCC75400U000001 Manufacturer, Make and Type of Vehicle ‘SHH: HONDA OF THE U.K.MEG., LTD. England. HONDA Passenger cer Body Type c7: ACCORD Body and Transmission Type '5: 4-door Sedan 5-speed Manual 6: 4-doar Sedan 4-speed Automatic Vehicle Grade 4: 2.01 5: 2.01 S, | 6: 2.0iLs. | 7: 2.01 €S. 8: 2.31 SR Fixed Code Auxiliary Number ————_! Factory Code U: Honds of the U.K. Manufacturing in England ‘Model Year 0: 1993 Serial Noor ————_________! (- Engine Number £2021-1000101 Engine Type ———_—______ | F20Z1: 2.0 ¢ Sequenital Mutti-port Fuelinjected 131 PS engine Unleaded gasoline with CATA 2.0 € Sequential Multi-port Fuolinjected 118 PS engine Unleaded gasoline with CATA | H23A3: 2.3 € Sequential Multi-port | Fuet.injected 160 PS engine Unleaded gasoline with CATA Serial Number F2022: F20Z1 (Wako plant in Japan): 1000101 ~ 2021 (U.K. MFG. in England}: £10001 ~ 2022 (U.K. MFG. in England): £10001 ~ H23A3 (U.K. MFG. in England): E100001 ~ [— Transmission Number ‘MP6A-2000001 Tranamiadon Type | MP6A: Automatic for F20Z1, H23A3 engines N2C4: Manual for F20Z2 engine N2D4: Manual for H23A3 engine N2S4: Manual for F20Z1 engine Serial NumberIdentification Number Locations 2 5 i 3 i i i Vehicle Kdentification Number (VIN) 1-3Warning/Caution Label Locations A: MAINTENANCE LID CAUTION ua” [sR] SASACU FPL AI {arb ay AE oF EVoT HEFCE. CAUTION [SRS BEFORE MAINTENANCE. SWITCH OFF THE IGNITION. ATTENTION. AVANT TOUT ENTRETIEN, COUPER LE CONTACT. ACHTUNG: VOR WARTUNG ZUNDUNG AUSSCHALTEN. Ler op. | ZET HET KONTAKTSLOT AF ALVORENS MET HET ONDERHOUD TE BEGINNEN, 8: SLIP RING CAUTION tt arn ile cauTion REFER TO THE SHOP MANUAL. ACHTUNG WERKSTATT HANDBUCH LESEN, ATTENTION SE REPORTER AU MANUEL | D-ATELIER. WAARSCHUWING LEES HET WERKPLAATS HANDBOEK, (©: MONITOR CAUTION NOTICE — ae (© REFER TO SERVICE (SHOP) MANUAL FOR DETAILED. INSTRUCTIONS, REMARQUE ‘© POUR LEs INSTRUCTIONS DETAILLEES, SE REPORTER ‘AU MANUEL DE REPARAIONS, Let op. ‘© PAADPLEEG HET WERKPLAASHANDDOEK VOOR NaDERE AANWIJINGEN. ACHTUNG. @ AUSFUHRLICHE ANWEISUNGEN SIND DEM WERKSTATTHANDBUCH ZU ENTNEHMEN. D: DRIVER INFORMATION (SUNVISOR) KS. [SRS] ALWAYS WEAR vOUR SEAT BELT ‘© THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM (S.A) IT'S DESIGNED To SUPPLEMENT THE SEAT BELT. © IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER ANVAND ALLTID BILBALTET ©°DETTA FORDON HAR EN LUFTKUODE FOR FORARSATET SOM ETT KOMPLETTERANDE SKYDO. SSYSTEM (SRS) ¢ DET An AMHAT ATT KOMPLETTERA BILGALTET. © OM ‘SRS.INDIATORN TANDS. UNDER KORNING SKALL OU KONTAKTA EN AUKTORISERAD HONDA, ATERFORGALIARE. [SRS] KAYTA aia TURVAVYOTA © TAMA AUTO ON VARUSTETTU AJAJAN MMATYYNYLLX JOKA. ON LISASUOJAJARIES TEIMANA(S.R3). (© SE ON SUUNNITELTU TAYDENTAMAKN TURVA- vyorA © JOS SRS-MERKKIVALO SYTTYY AJON AIKANA. OT- TAKA YHTEYS VALTUUTETTUUN HONDA. HUOLTOON. D: KG iKF) [SAS] ALWAYS Wear YOUR SEAT BELT ‘© THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A ‘SUPPLEMENTAL RESTRAINT SYSTEM (S.R.5.). IT 1S DESIGNED TO SUPPLEMENT THE SEAT BELT. © IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER, ATTACHEZ TOUJOURS VOTRE CEINTURE ‘CE VEHICULE EST EQUIPE D'UN COUSSIN D’AIR QUI (CONSTITUE UN SYSTEME DE SECURITE COMPLEMEN- TAIRE POUR LE CONDUCTEUR (S.8.81). ‘© CE COUSSIN D’AIR COMPLETE LA FONCTION DE LA CEINTURE DE SECURITE. (© SI LE TEMOIN SRS S’ALLUME PENDANT LA Con. | DUITE. ADRESSEZ-VOUS A VOTRE CONCESSION. NAIRE OFFICIEL HONDA. (SRS) sicHennerrscunTe 6c1 JEDER FAHRT ANLEGEN © DIESES FAHRZEUG BESITZT EINEN FAHRER-AIRBAG ALS ZUSATZLICHES RUCKHALTESYSTEM (S.A.5.), ‘© DAS RUCKHALTESYSTEM IST EINE ERGANZUNG ZUM. ‘SICHERHEITSGUAT. © SOLLTE WAHREND DER FAHRT DIE sRs- KONTROLLEUCHTE AUFLEUCHTEN, SUCHEN. SIE BITTE EINEN HONDA HANDLER 2UR FAHRZEUG OBER PRUFUNG AUF. [Sis] Draac uw veiicHeIDscoRDEL ALTD ‘© DIT VOERTUIG IS UITGERUST MET EEN AIRBAG (S.R.S.) AAN DE BESTUURDERSKANT VOOR EXTRA VEILIGHEID. © DIT IS ONTWORPEN ALS EXTRA BESCHERMING NAAST DE VEILIGHEIDSGORDELS. (© ALS HET. SRS-WAARSCHUWINGSLAMPJE ONDER, HET RIJDEN GAAT BRANDEN, NEEM DAN KONTAKT. (OP MET EEN HONDA DEALER, 1-4D:KE EKG (KF), KE ‘ALWAYS WEAR YOUR SEAT BELT ‘© THIS CAR IS EQUIPPED WITH A DRIVER AIRBAG AS A SUPPLEMENTAL RESTRAINT SYSTEM (S.R.S.) | @ IT IS DESIGNED TO SUPPLEMENT THE SEAT BELT. | © IF YOUR SRS INDICATOR LIGHTS WHILE DRIVING SEE YOUR AUTHORIZED HONDA DEALER. E: WARNING (ENGINE HOOD) KS WARNING [SAS ‘THIS VEHICLE IS EQUIPPED WITH A AIRBAG SYSTEM AS ‘A SUPPLEMENTAL RESTRAINT SYSTEM. (S.R.S.) | ALLS.R.S. ELECTRICAL WIRING AND CONNECTORS ARE | cotonep veLtow. | DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS. TAMPERING WITH OR DISCONNECTING THE 5.5. | WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE SYSTEM INOPERATIVE, WHICH MAY RESULT IN SERIOUS INJURY. ‘VARNI DETTA FORDON HAR EN LUFTKUDDE FOR FORARSATET ‘SOM ETT KOMPLETTERANDE SKYDDSSYSTEM (5.R.5.). SAMTLIGA ELLEDNINGAR OCH KONTAKTER I SRS- ‘SYSTEMET AR GULFARGADE. ANVAND INTE ELEKTRISK PROVUTRUSTNING FOR DESSA KRETSAR. OM DU ANDRAR ELLER LOSSAR EN SRS-LEDNING KAN DET RESULTERA | EN OAVSIKTLIG UTLOSNING AV TRYCKPUMPEN ELLER GORA ATT SYSTEMET SLUTAR FUNGERA. DA KAN EN ALLVARLIG OLYCKA UPPSTA varorus. TASSA AUTOSSA ON YLIMAAISENA TUKWARJES- TELMANA AJAJAN ILMATYYNY. 5.8.5.) KAIKKI SRS-SAHKOJOHDOT JA’ -LIITTIMET OVAT KELTAISET, ALA KAYTA SAHKOKOELAITTEITA NAISSA VIRTAPIREISAA, SRS-JOHTOJEN TUKKEAMINEN TAI | IRROTTAMINEN SAATTAA SYTYTTAA VAHINGOSSA | PUMPUN TAI TEHDA JARJESTELMAN KAYTTOKEL- | VOTTOMAKS! TASTA TAAS SAATTAA AIHEUTUA VAKAVIA Lvauniorra. WARNING [SRS] ‘THIS VEHICLE IS EQUIPPED WITH A AIRBAG AS A SUP- PLEMENTAL RESTRAINT SYSTEM (S.R.S.). ALL S.R.S. ELECTRICAL WIRING AND CONNECTORS ARE COLORED YELLOW. DO NOT USE ELECTRICAL TEST EQUIPMENT ON THESE CIRCUITS. TAMPERING WITH OR DISCONNECTING THE §.R.S. WIRING COULD RESULT IN ACCIDENTAL FIRING OF THE INFLATOR OR MAKE THE ‘SYSTEM INOPERATIVE, WHICH MAY RESULT IN SERIOUS. insur ATTENTION (585) CE VEHICULE EST EQUIPE D'UN COUSSION D’AIR QUI CONSTITUE UN SYSTEME DE RETENUE COMPLEMEN- TAIRE (8.8.8.). TOUR LES FILS ET CONNECTEURS ELECTRIQUES DU | SYSTEME DE RETENUE COMPLEMENTAIRE (S.R.S.) SONT. DE COULEUR JAUNE. N’UTILISEZ PAS UN EQUIPEMENT D'ESSAIS ELECTRIQUES SUR CES CIRCUITS. NE TOUCHEZ PAS ET NE DEBRANCHEZ PAS LES FILS DU ‘SYSTEME 5.R.5, CAR CECI POURRAIT DE TRADUIRE PAR, LE DECLENCHEMENT ACCIDENTEL DU GONFLEUR OU RENDRE LE SYSTEME INOPERANT ET VOUS EXPOSER AINSI A DE GRAVES BLESSURES. WARNUNG (SRS) DIESES FAHRZEUG IST MIT EINEM FAHRER-AIRBAG (S.R.S.) ALS ZUSATZLICHEM RUCKHALTESYSTEM AUSGERUSTET. ALLE ELEKTRISCHEN KABEL, SOWIE DIE ZUGEHORIGEN | STECKVERBINOER DES 5.2.5. -SYSTEMS SIND IN | GELBER FARBE AUSGEFOHAT. KEINE ELEKTRISCHEN PRUGERATE AN DIE S.RS. ‘VERKABELUNG ANSCHLIEBEN. VERANDERN ODER UNTERBRECHEN DER 'S.R.S. -VERKABELUNG KANN UNKONTROLLIERTES Z20NDEN DES GASGENERATORS. AUSLOSEN. ODER DAS. SYSTEM AUBER FUNKTION SETZEN. WAS ZU ERNSTHAFTEN. VERLETZUNGEN FUHREN KANN, WAARSCHUWING DIT VOERTUIG IS UITGERUST MET EEN LUCHTKUSSEN ‘AN DE BESTUURDERSKANT ALS EXTRA BESCHERMING (SRS). ‘ALLE ELEKTRISCHE LEIDINGEN EN AANSLUITINGEN VAN DE S.RS. ZIJN GEEL GEKLEURD. GEGRUIK GEEN ELEKTRISCHE TESTAPPARATUUR VOOR DEZE CIRCUITS. KNOEIEN MET OF LOSKOPPELEN VAN DE S.A. LEIDINGEN KAN LEIDEN TOT BRAND IN DE VULINRICHTING OF TOT UITSCHAKELEN VAN. HET SYSTEM: DIT KAN TO ERNSTIGE ONGELUKKEN LEIDEN. F: COVER CAUTION | caution, | "ACHTUNG e SASH dy FHL AME PEA wath | | epmrace, REFER TO THE SHOP MANUAL. SE REPORTER AU MANUEL ’ATELIER, ‘© WERKSTATT HANDBUCH LESEN. LEES HET WERKPLAATSHANDBOEK, (cont'd) 1-5Warning/Caution Label Locations r (cont’d) BATTERY FLUID FROZEN CAUTION KG (KF), KE) BATTERY FLUID FROZEN CAUTION (KS) ABS CAUTIONLift and Support Points | r- Lift When heavy rear components such as suspension, fuel tank, spare tyre and trunk lid are to be removed, place additional weight in the trunk before hoisting. When substantial weight is removed from the rear of the car, the ‘center of gravity may change and can cause the car to tip forward on the holst. NOTE: Since each tyre/wheel assembly weighs approximately 14 kg (30 Ibs), placing the front wheels in the trunk can assist with weight distribution. 1. Place the lift blocks as shown, 2. Raise the hoist until the tyres are slightly off the ground and rock the car to be sure itis firmly supported 3. Raise the hoist to full height and inspect lift points for solid support. FRONT SUPPORT POINT ur BiocKs REAR SUPPORT POINT 1-7Lift and Support Points r Floor Jack 1. Set the parking brake and block the wheels that are not being lifted. 2. When lifting the rear of the car, put the gearshift lever in reverse (Automatic transmission in[P] posi- © Never attempt to use a bumper jack for lifting or . ‘supporting the car. 3. Raise the car high enough to insert the safety stands. 4. Adjust and place the safety stands as shown on age 1-9 so the car will be approximately level, then lower the car onto them. Front CENTER BEAM CContor the jacking bracket in the middle (of the jack life platform. OFT PLateonm Rear Centar the jacking bracket in the middle (of the jock lft platform, er PLATFORM, 1-8—_ cy) ATowing If the car needs to be towed, call a professional towing service. Never tow the car behind another car with just ‘2 rope or chain. It is very dangerous. Emergency Towing There are three popular methods of towing a car: Flat-bed Equipment — The operator loads the car on the back of a truck. This is the best way of tow- ing the cer. Wheel Lift Equipment — The tow truck uses two pivoting arms that go under the tyres (front or rear) and lifts them off the ground. The other two wheels: remain on the ground. Sling-type Equipment — The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension and the cables lift that end of the car off the ground. The car's suspension and body can be seriously damag- 21 if this method of towing is attempted. If the car cannot be transported by flat-bed, it should be towed with the front wheels off the ground. If due to damage, the car must be towed with the front wheels (on the ground, do the following: Manual Transmission © Release the parking brake. © Shift the transmission to Neutral Automatic Transmission © Release the parking brake. © Start the engine. © Shift to [Ds] position, then to [Ni] position. © Turn off the engine. NOTICE: Improper towing preparation will damage the transmission. Follow the above procedure exactly. if you can not shift the transmission or start the engine (automatic transmission), your car must be transported ‘on a flat-bed. © It is best to tow the car no farther then 60 miles (80, km), and keep the speed below 35 mph (55 km/h). NOTICE: Trying to lift or tow the car by the bumpers will cause serious damage. The bumpers are not design- fed to support the car's weight. TE DOWN HOOKS TOWING HOOK 1-10Abbreviations F FP. Fwo FR FL FSR GAL GND HB Ho2s HC 1B lac Ic lat. ima IN IG or IGN, 1D 1D or 1.0. INJ INT ks ty tH LHD uc tso uF LR La teD List of automotive abbreviations which may be used in shop manuel. alc Ai Conditioning, Air conditioner ACG Alternator ABS | Antilock Brake System AT Automatic Transmission ATF ‘Automatic Transmission Fluid AF ‘Ait Fuel Ratio AMP | Ampere (s) ANT Antenna ASSY | Assembly AUX ‘Auxiliary APPROX. | Approximately ATDC | After Top Dead Center AUTO — | Automatic ATT Attachment ACL Air cleaner API ‘American Petroleum institute BARO | Barometric BAT Battery Toc Bofore Top Dead Center BoC Bottom Dead Center KP Crankshaft Position eye Cylinder Position caT Catalytic Converter co Carbon Monoxide eye Cylinder cPc Clutch Pressure Control cans — | Carburetor comp — | Complete cpu Central Processing Unit cHe Charge oD Distributor Ignition bic Data Link Connector Tc Diagnostic Trouble Code DIFF Differential DOHC —_| Double Overhead Camshaft DPI Dual Point Injection evap Evaporative EGR Exhaust Gas Recirculation ECM Engine Control Module ect Engine Coolant Temperature EX Exhaust ELD Electrical Load Detector EFL Electronic Fue! Injection EPS | Electrical Power Steering | Front | Fuct Pump Front Wheel Drive | Front Right | Front Left Fail Safe Relay Gallon Ground Hatchback Heated Oxygen Sensor Hydrocarbons Intake Air Bypass {dle Air Control Ignition Control Module Intake Air Temperature Idle Mixture Adjustment Intake Ignition Identification Inside Diameter Injection Intermittent Knock Sensor Lott | Lert Handie | Left Handle Drive Lock-up Clutch Limited Slip Differential | Loft Front | Lett Rear In-line four cylinder (engine) Light Emitting Diode (cont’e) 1-11Abbreviations r (cont'd) ms | Manual Stering scs | Servicé Check Signal Mar | Manifold Absolute Pressure sec | Second Mi Malfunctin indicator Light Secondary tar | Menuet 1 Mex | Motor check t Torque Max. — | Maximum tom | Transmission Control Module Min. | Minimum twe __| Three Way Catalytic Converter met Multi Point Iniction wo | Top bead Center B Throttle Body N Neutral Throttle Pesition Nox | Nitorogen. Oxides of te Torque Converter re Timing Belt 02s | oxygen Sensor TIN | Tool Number 08D _| On-Board Diagnostic TCS | Treotion Comtrot System OD or 0.9, | Outside Diameter vss___| Vehicle Speed Sensor D Perk Vtec | Variable Valve Timing & Valve Lift Pan | Pulsed Secondary Air injection | Electronic Control psr. | Power Steering Prossure ve Viscous Coupling Pov _| Positive Crenkease Ventilation vin Vehicle Identfication Number Proportioning Control Valve vvis | Variable Volume Intake System pis Power Steering Pom-rt | Programmed:fuel Injection w with PEMIG | Programmed Ignition wio | Without Pat Primery Wor | Wide Open Throttle PIN Part Number PL Prot Light 2wo | Two Whee! Drive Pir | Pump Motor Relay 4wo —_| Four Wheel Drive psw | Pressure Switch 2ws | Two Wheel Steering PSF | Power Steering Fiid 4ws | Four Wheel Steering 4at | 4apeed Automatic Transmission avy ousntity swT | S-speed Manual Transmission ee Park R Right fk) Reverse RR Rear Right Ww) Neutral RHD | Right Handle Drive [Bs] | Drive (tet through ath gear) ‘REF Reference Drive (1st through 3rd gear) RL Rear Left B ‘Second RON | Research Octane Number a First 7st | Low (ger saz | society of Automotive Engineers 2nd —_| Second (gear SOHC | Single Overhead Camshatt 3aD | Thre Ygean Sot. | Solenoia 4TH | Fourth tgean SPEC | Specification std | Fifth (gear Sm Sun Root SRS | Supplemental Restraint System sD | Standera sw Switch 1-12Special Tools Individual too! lists are located at the front of each section.Specifications Standards and Service Limits Design Specifications Body Specifications . 3-2 3-15 . 3-18Standards and Service Limits r~ Cylinder Head/Valve Train (F20Z1, F20Z2 engines) — Section 6 ———H——____ MEASUREMENT | STANDARD (NEW) SERVICE LMT Compression | 50min pm and ‘Nominal [aaso28. Har wide open throttle Minimum | 950195. 135) KPa thaiom’, psi Maximum variation | 200 20,28) Cylinderhesd | Werpage = 1 eos toa 1 Height 99.95 100.05 13.995-3999) | | Camhat End play (005-015 (0.002 0.008 OB aoa) 1 | Comshattto-holde ol clearance 0.050 -0.089.0.0020-0.00381 | 0 150.006) i Total runout 0.03 (0.001) max 8.04 (0.002) Cemiobereigh £2021 engine ww | aa7a1 250 yo ex | aB972 11380) 7 £2022 engine IN | 38.095 1.4998), 7 ex __| 37.890(1.49971 7 Valve Valve clearance iN [024-026 0009-001 = ex | 026-032 10011 0013 = Valve stem 0.0 W | 5485-8495 (02159-02160 — | 5.455 10.2148) ex | 5450-8.480102148-0.21501 | 5.220 (02198) Stemto-guide clearance ww | 0.020-0.045 (0.0008-0.50201 | 6.080.003), | ex __| .085-o.080 0.0022~0.00311 | 0.120.005), Valve sont wa IN| 125-158 0009 -o08m 2.0 (0.08 x | 125-188 (0049-0961) | 20.08) | Stem instatted height iN 48.245 - 46.715 (7.899¢~ 1.9179) | 48.915 (3.9248), Ex_| 50.315 - 50.785 (1.9809~1.9998)_| $1,036 12.0092 Valve spring Free enath F202 engine ww] $3.16 700a1-7 = 53.15 (2.0931 -2 = ex | sse0i2 19-1 = 95.78 2.196) -2 = F2022 engine ww | Sessiatea 1 = 5e5¢ (2147) 72 = ex__| seesiz67 = Vaive ouide 1B, IN| 5818-ssg002171-0277) —] Sea (028) ex | 5515-553002171-0217 | $83 0218) Instaied neight iN | 235-2425 10935-0958, = &x__| 1505-15155 10593-06121 = Foer are Bemtorah clearance iw | 0.017 -0.080.0.0007 - oco2a, | 008 00a) €x__| 018-0056 10.0007 0.00211 __| 0.08 (0.008) <1 CHUO HATSUJO manufactured valve spring *2: NIHON HATSUJO manufactured valve spring(— Engine Block (F20Z1, F20Z2 engines) — Section 7 Unit of Fength: mm find | MEASUREMENT | 'STANDARO (NEW) | _ service uimir Cylinder biack | Warpage of deck surface T a.07 0.003) max 100.008) Bore diameter Aor | 85.010~85.020 (33068-33472) | #5.070(3.3¢821, Boru | 85.000-85.010(3.3465- 3.3468) | £5,070 (3.3482) Bore taper - 0.05 (0.002), Reboring limit = 0.5 (0.02) Fistor ‘Skit OD, Jat Zimam (OSini wom) No Leter | 84980 ~Be 800 39087-33261) | 84.970 (0.3450 lpottom of skirt. Lewers | 84970-64990 (3.3489-3.3457) | s4960(3.3445) Clearance in evlinaer 0.020 0.040 0.0008 .0016) | 0.05 (0.002) Groove width for ring) Top | 1.220-1.230/00180- 0.0088) | 125.0088) Second | 1220-1230 i0.0480- 0.0884) | 1.25 10.049) on 21805-2625 0.1104 ~0.1112) __| 2.85 (0.112) Piston ing ing to groove clearance Top. 0.035 ~ 0.060 0.0014 0.0028] 0.1310.008) Second _ | 0.099 0.085 (0.0012 0.0022) __| 0.130.005) ing end gop Too (020 -0:35 (0.008 - 0.014) ‘o.e0 10.028) Second | 0:40-085 10.016 - 0.0221 07010028), | on 8.20 -0.70 10.008 - 0.026), 0.80 (0030) Piston Pin OD. 21,998 - 72,000 (0.8659 - 08867) | — Pin-to-piston clearance (0.612 0.024 (0.0008 0.00091 | — Connecting tod | Pinto-od interference 0.073 - 0,092 0.0008 - 0.0073) | — ‘Small end bore diameter 21.968 21.98% (0.8849 0.8654) | — Large end bore diameter Nominal | $8.0(0.89) = End play netaed on erankshaft 0.15 ~0.30 (0.006 0.012 0.400.018) Crankshare ‘Main journal diameter No. Vand 2 journale “9.876 - 60.000 (1.9676 - 19605) [ — | | No.3 journal 49.972 «9.996 (19674-19583) | — | No. 429.984 s0.008 (1.9679 - 1.9686) | — No. 49.988 50.012 (1,9680- 1.9690) | — fod journal diameter 44976 —68,000(1.7707 = 1.77971 | — Taper (0.005 (0.0002) max | 0.008 ¢0.0008) Out-otround 10,008 (0.0002) max 0.006 10.0008), End play 0.10 - 0.35 10004 ~0.014) 0.45 (0.018) | Runout 0.93 0.001), 9.08 (0.002) Bearings ‘Wain beavingtoyournal No. sad journals ‘9.021 0.045 @.0008 60078) | 0.050 (6.00201 oilelesrance No. 3 journal 6.925-0.049 10.0010 000191 | 0.085 (0.0022) No. journat (00:3 0.037 0.0005 0.0015) 0.080 (0.0020) No. § journal 0.008 -002310.0004 0.00331 | 0.040 (0.0016) Rod bearing-tojourna ol clearance 0.018 ~0.043 10.0008 0.0017) _| 0.080 (0.0020) Balancer sham | Journal diameter No. 1 front journal @2.7a8 42.734 (1.8890 16820) | 42.71 11.681) | No.1 rear journal | 20.938 - 20.950 0.8243-o.s248) | 20.92 10824) No.2 front and rear journals 38.712 - 98,724 (15241-15246) | 38.70 1.524) No.3 front and rear journals 34722-34734 (1.3670 - 1.3675) | 36.71 (1.367) Journal taper (0.008 (0.0002), = End play Front (010-035 (0.004 - 0.014) = Rear 9.05 0.18 (0.002 - 0.007) = otal nour 0.02 10.601) max 0.03 2.000) Shatt-to bearing oil clearance No. rear journal 0.050 0.075 10.0020- 0.0090 | 0.09 10.008) Nol front. No.3 front and rear journats | 0,066 -0.098 (0.0026 - 0.0039 | 0.12 0.005), No.2 front and rear journals. G97 0.108 0.0020 - 0.0043) __| 0-13 10.005), _| Balancer sha] 10. No. 1 front journal “42.800 62.620 11.6850 - 1.6858) | 42.03.0.686), bearing No.1 rear journal 24,000 - 21.073 10.6268 0.8273) | 21.02(0.828) No.2 front and rear journals ‘38.800 28.820 (1.5276 - 15283) | 38.83(1.525) { No.3 fant and rear journals 34.800 ~ 34.820 (1.3703 -1.3708)_| 38.89.0370) 3-3Standards and Service Limits r- Cylinder Head/Valve Train (H23A3 engine) — Section 6 —_, MEASUREMENT STANDARD (NEW) SERVICE UMIT Compression 250 min" Wem) and Nominal 72801128, 78) wide open throtte. Minimum 9509.5, 135) ka kgiom’, paid Maxirmum va 2002.0, 28) Gyinderheed | Warpage = (0.05 1002) Height 131.95 ~ 132.05 16.195-5.199) | Camshar Ena play 1.05 0.15 0.002 - 0.608) os (00a) Camshatt-to-holder ol clearance 0.050 ~ 0,089 (0.0020 - 0.00351 +1 | 0:18 0.006)+1 0.100 - 0,199 (0.0038 - 0.0088) +2 | 9.20,0.008)+2 Total runout 0.03 10.00%) mex. 0.08 10.002) Cam lobe height IN | 33.661 113252) 5 ex __| 33.725 113278) = vai Valve dlearance IN| 807~0.11 10.003 0.000) *3 = €x | 0.15-0.1910.006- 0.0071 «3 = Valve stem 00. Ww | 8380-6580 10.2591-0.2594 | 6.550.258) Ex | 6860-6560 10.2579 -0.2583) | 65210257) Stem-to-guide clearance IN | 062-005 0.001 0.0021 | 0.08 0.003) €x__| 005-008 10.002 - 0,003) [21110008 Valve seat Wan TN | 725-155 (0049-006 20 0.08 Ex | 125~ 185 (0.089 - 0.06 2010.08) ‘Stor installed height Iw | 29365-39.835(1.5498- 1.568% | 40085 (1.5760) Ex__| 39.165 39.635 (1.5019- 1.560¢)_| 38.885 (1.5703) Valve spring Free length (Reference) TAC = I Ex | arte iiase, = Vatve guide 1D. IN [661-643 10260-0260 S701 26H, ex | 661-663 (0260-0261) 6.70 (0.264), Instatied height Ww | 1325-r375\0522-05e | Ex__| 1375-1425 10541-0561) = "1: Except exhaust No. 6 jounal Exhaust No.5 journal +3 Measured betwoen the camshaft and rocker arm.-— Engine Block (H23A3 engine) — Section 7 Unit of fength: men in) MEASUREMENT STANDARD (NEW SERVICE LNT Cylinder bios | Warpage aoe surace 387 668) max 37070.004) Bore diamater a Sroio~e7 020 (342s6-2.4260) | S7070184279) 5 7.000 e7a10 sese 3.4250) | 87070 (24279 ore taper = 8.05 0.002) Rebering tet = 83510010) Fiaon Ski 0.0. [ar EmmlOsin Fam) —Wolene’ | G6Gs= B71 009 aap SAREH | 67980 3.4658 fouomarsin | towers, | 8686005999 a.c2e4—3.4zeo) | 7.970 (.a63e) Clearance in eyinder aor e920 ones —oaote) | a4 (0.002 | Groove wet Yor rina) top $20 ‘245 o0%e4 0.0490) | 3 26010040 Sevona | 1250-1248 0.0¢e4-oo490) | 1268100808) | on Yaos=2e26loto4-o.tr21__| Pasion") oy Ring wo-groave Gearance Top 065 0076 ;.0nr8—o0R20. 0.131.051 Second 8.040- 0.070 (0.00%6-0.0028) _| 0.13 0.005) Ting and ge Top 335-035 0010-0019 98070.028) Setond | a@0 0 75 (0024 oan) 930 (0.038), on 20-0s0\0008—o020) 1 | G0 10.20 020-070 (0008-0078) “2 | 98010031) 2 ooo oD Tis9s- 72066 (08689-08607 | — | Pinto paton clearance abre- oor taco0s-o.0010 | — Tenneding vod | Pintowrod iteterenee 0130.02 @ Gos 0.00731 | — Small end bore dire | 2tsce~arser wases~oeese) | — Large end bore diameter Nominat | Sre0(2.0001 = End play netaliod on crankshaft 315-00 10006-0012 240 0.016) Grankahak | Min journal ameter Nov and jourals | «9 875- 50.00 1.9676 196851 | — | No.3 journal feera-aaage user i9s00) | — No journal S3e04 30.008 tger9- 13800) | — No. Sovrna ‘Soaes -so0n7 (19690-13600) | — fod journal diameter Shere eso tases 18890) | — Teper 8 008 0.0002 max 2006 00008) Outotound 008 0.0002) mon 6.006 (0.0008 Ee play 700.35 (000" 0.014) O45 0018 oneut 0.03 10.0001 mex 998 (0.002 Beara Main bearing oournalNo-T and2jourle] 0821 - 0045 (00008 O0D18 | 0.050 (0.0000 oil clearance ‘No. 3 journal | 0.025- 0.089 0.0010- 0.0018) | 0.086 10.0022) Ned fournat 8913-0037 (20006-00015) | oso 0.0020 No, § journal 009-9082 00008 0.0012 | oxo 0.0018 Rod besringtojourna oilclesance Sazr-o0ss 0000800019 | aoGb 0.0020 Balarcarshak | Journal iometerNo-7 Font journal 7a 722 ~ 42.734 (8880 - 1982] «BT C88T) No.1 yeorjoural zogas 20980 (08219-0820) | 209200820) Nec2fton ond rearjournals | S8.7r2=aeraetnsze) -ss24s) | 3870(3.520) No. Bfom and renrfournate | a4722~34 rae ttae70~ 1367s) | 3471 0.367) Journstapar 3 008 (0.000 = tnaiay 090-0 35 (0004- 0018) 7 Sos o.istocor 0007) = Total runout 8.2 0.008) max G3 (0000 Shaft te bering ol terance No. 1 Year journal 0050-0075 0020-00030) | 0.090.008 Noli font Nera ont and rearjournats | 0.068.096 2.9000-o.00%5) | © 12(0005) No.2 Wont and rearfournal Gore=o.08 0030 ~o008s! | 0.1340.005) Salaneershan | No. 1 front journal ‘woo «2.80 16850-15650) | «2.89 ( oT boring No. wear journal Tiboo 21019 (0826s -o.z7a | 21.02 (0820) No.l end rear journats | 36800 ~38820(15276- 15288) | 3883 (1.829) | No. hon and rear fovrnals Sesto 3eaz0 (av01=1370a1_| 3es900379) +1" TEIKOKU PISTON RING manufactured piston ring +2: RIKEN manutaetured piston ring.Standard -— Engine Lubrication — Section 8 Is and Service Limits (MEASUREMENT | STANDARD (NEW) ‘SERVICE LIMIT Engine oil Capacity F2021, F2022 engines | 4915.2, 431 for engine overhaul (US at Imp at) 38 (40, 23) for oil change, including fier 3.5 (8.7.3.1 for oil change, without fter H23A3 engine 5.4 (5.7, 6.1) for engine overhaul | 4.3166, 3.8) for oil change, including fier | 4.0 (4.2, 3.5) for oil change, without fter | Otbume | Inner-to-outer rotor clearance '002 - 0.16 (0.001 - 0.006) ] 920;0.0087 Pump body-to-outer rotor clearance (0.10 -0.19 0.004 - 0.007) 0.21 (0.008) Pump body-to-rotor axial clearance | 0.02 0.07 (0.001 - 0.003), 0.12 (0.005) vave Pressure setting at engine oll temp, 80°C (176771 kPa kafer™, psi) atidle 7010.7, 10) min 1 3,000 min (rom) 350 (35, 50) min, Thermoswitch “OFF” temperature °C PFI Fan timer “ON” temperature °C Fan timer “OFF" temperature CF [Cooling — Section 49} ma MEASUREMENT | STANDARD (NEW) Faaioror Coolant capacity (US at imp at) F20Z¥ engine | WAT” 63167, 58) or overhaul | [including engine. neater, 23 (29,24 for coolant change Cooling line and reservoir AMT: 6266.55) for overhaul Reservoir capacity 26 (217,23) fer coolant change 061 1063 US q..0.53 Imp qv) F202 engine | MIT: 6.316.755) for overhau! 27 (28, 2.4 for coolant change 2343 engine | MM: 7.0(7-4, 6.21 for overhaul 33 (35, 30) for coolant change AMT 6317.3. 6.1\ for overnaul 3.2(3.4, 28) for coolant change Radiator cap Opening pressure KPa (gle, pal 35125 (085-125, 135-178) Thermostat Star to open "CCF 76-80 1168-176) Fully open °C 1° 90 (198) Valve it at fully open 80.0.3) min, Coating fan ‘Thermoswitch “ON” temperature CF) | 90-96 (194-208) ‘Subtract 2~ 7 (413) from actual “ON* temperature 4303 - 109 (217 - 228), Subtract 2-5 (4-8) from actual “ON” temperature 3-61 Fuel and Emissions — Section 11 Mot of eng men (nt | MEASUREMENT STANDARD (NEW) SERVICE LIMIT Fuel pump ‘Displacement in 10 seconds mi (US o7, Imp oF BOT Bi) TOT, 39) Relief valve opening pressure KPa (lem. ps 450 - 600 (45-60 64-85) Pressure regulator | Pressure with regulator vacuum hose disconnected wlan | ka thgtem’. psi agrees Foeitank T capacity? (US gal. imp gal) era Engine Fast idle speed mi! (rp) 34002 200 Tale speed min" (rom) 7702 80 (MT neural (with headlights and coating fan off), 7702 50(A/T:IN) oF F] position) Tale CO % 02% mex [— Clutch — Section 12 MEASUREMENT STANDARD (NEW? [service unr Catch peda Clutch pedal height tothe Waar [aoe Stoke at pedal 326) (= Towel clutch pedal free play 8-15(04-06) Disengagement height to the floor 9035) min. tothe carpet 80 (3.11 min : Flywheel ‘Clute surface runout 0.65 0.0021 max 0.15 10.006) Civich dis [Rivet head depth 7 (0.08) min 02007) Surfece runout 0.6 (0.02) max. io ro0s) Thickness 85-9210.33 0.36) 651028) Pressure plate | Finger height (06 10.02) max 0.8 (003) warpage (0.03 0.00%) mex. [0.15 0.008), [— Manual Transmission — Section 13 MEASUREMENT STANDARD (NEW) SERVICE LMT Transmission ot | Capacky (US at, Imp at TB{2O. Hi foreil change 2.0.2.3, 18) for overhaul Wainahate End play 0.10 0.16 (0.004 - 0.008 [ Adjust with shir Diameter of ball bearing contact area C 27977-27:990(1.1015~ 1.2020) | 2.93(1-100) Diameter of needie bearing contact aree & 37.984 26.000 (14954 1.4961) | 37.93(1.493), Diameter of ball bearing contact area A | 27.980 - 28.000 (1 1018-1.1024) | 27.9411.100, Runout 0.020.001) max 0.05 (2.002), | Wainahaf Sed and | 10. “23.008 = «3.025 (1.6555 16558) | 43.080 (7.6861) ath gears End play 0.08 -0.21 10.002 - 0.008) 0.30 (0.0121, ‘Thickness Sed gear 3242-3247 (1.276 1.278) 3231127) ith gear 30.92 — 3097 (1.217 = 1.219) 308020 Mainehaf Sh gear | 10. 725.008 - «3.026 (1.6009 - 16996) | 43.080 (1.6969) End piay 0.96 -0.21 0.002 - 0.008) 030 (0012) Thickness. 3092-3097 (1.217 - 1.219), 30.8021) Countershar End play 0,050.40 (0.0019 - 0.0757) 0500.02) Diameter of needle bearing contact area A 38.000 38.015 (1.4961 - 1.4967) | 37.95 (7.490) Diameter of ball bearing and needle bearing contact | 24.967 ~25,000 (0.9637 -09845) | 24.94 (0.982) areac Diameter of 1st gear contact area B } 39.986 - 40.000 (1.8742 1.5748) | 39.93.11572) Runout 0.02 10.001) max 0.050.602, Counterahat iat | 10. 46009 - 46.025 (111818720) | #08 CBT gear End play (0.04 -0.10 0.002 - 0.004) Adjust with a shir Countarshaft nd | 1. 47.008 - 47.025 (18507 - T8EIA | 47.08 (1858) gear End play 0.94 -0.10 0.002 - 0.008) ‘Adjust with 9 collar, “Thickness [ s4te2—'34.67 1.963 ~ 1.365) 5451.30), (cont'd) 3-7Standards and Service Limits r- Manual Transmission — Section 13 (cont'd) MEASUREMENT |___stanoano inew senvice una Spacer cater [1 FEdB 964914952 - 14965) 36BDAIT iGountesnar — | 0.8 969-200 nssar~ veses) | ea3e (i082) nd gen tena avenzer-re1-o | oa-asoeritasiias | — BPN 23916-21010) | 2907-2000 (neds at rasa) | — Spacer colar] 1 SHooe-a1.012 7705-12208) | 3106 aT (Mainshaft 4th 00. 2 37.989 - 38.000 (1.4956 ~ 1.4961) | 37.94 (1.494) and Sth gears) Length A 8 A (56.45 ~ $6.55 (2.222 - 2.226) |- | B | 26.03 - 26.08 (1.025 - 1.027) 26.01 (1.024) Reversed gear | 10 T 20016-20009 07880-0781" | 20.08 0 7808 Gearto-rverse oer shat clerance | 0036" 008¢,@00%e~ 00089) "| ago 02006 Synchro ing | ing-oaear clearance rng pushed against gear) | 086-170 0023-c0K o010018) Shilton Finger tckness 62-64 1024-038) = Fororynan sleeve clearance das-oesioort 0026) | 1010039) Tevarse RTO | Pow groove wih Tis0-waa0s-o5 = Fonctovevere der ger clearance os 14 m-o00) | Tawon Groove width** ata 7.05 ~ 7.25 (0.278 - 0.285) {- | me | ja-71028-030 jr ForktoSthreverse shit shaft clearances? | | wx | 005-025,0002-0019) esio02) se __| b4-oboa-oaa Soteoe Saar : 15973 16000:06269- 05299) | — Shit armto-shatcearance 005-0059 0062 acoza) | — Shit fork comets contct aes 128-130(0508-0512) | — Shitarmt-sf fork shaft clearance 03-05 0008-0091 aeoore Seieaiever | Shaft over diameter Wet 1868 0607-089) [= Snitarmcovercesrance dioa2 002 a0ots-o0040 | — Shik ever 30 16941-15968 06976-082a71 | Transmission ovsing lerance | oGzr-a'nsioaors cose) | — Tneriock Gore diameter 1600- 160510690069 | — Shit srmlerance | 032 o%e8 00tsso0043) | — “1: Measuring points 2 Measuring points A “ 5 ° 3-8[— Automatic Transmission — Section 14 Unit of length mm tin ‘throttle more than 3/16 open MEASUREMENT STANDARD (NEW) SERVICE Lit Transmission Waid | Copaciy? WS at imp @ E0164 6:2) for overnaul | 24126 2. for Muid change Tiydraule pressure | Line pressure 2000 min" rpm | 600 (80,114) 7200.5 TOF (£2021 engine) | {ior [Bl postion) throttle tty closed throta more than 316 Wa tle, pa) 850.85, 121) throttle more than 3/16 open “th clutch pressure at 2000 min® rpm 530 (53,75) ao 6, {5 postion? trot fllyctosed throttle " 1 850 85, 121) 750 75, 107) thotle more than 3/16 open id and 2nd clutch pressure at 2,000 min" (rpm) (Bd position) 50050, 77) throtle fullycloses 850 (85, 121) throttle more than 3/16 open 250 (45, 64) throttle flly-closed i 7507.5, 107) throttle more than 3/36 open (H23A3 engine) Ka tkoler’, psi) (Bor BI position throttle fully closed 9009.0, 128) throttle more than 3/16 open 2nd eluch presaure at 2000 min" (rpm B00 B5U GOES, THe Ta | 7807S, 16) position | lstand tst-nold clutch pressure at 2,000 min pm) | 600-850(80-B5, 114-12) | 750075, 107) (Gi position) Throttle 5 pressure Throwie fully closed | O10) = Throttle fully open 800~850(8.0-85, 116-121) _| 750175, 1071 Hydraulic pressure | Line pressure at 2,000 min" (rpm) 850185, 1270 0016.0, 178) throtle more than 3/16 open “th clutch pressure at 2,000 min (rpm) (BE position) 530155, 78) throttle flly-closed 1 900 9.0, 128) throttle mo than 3/16 open 08, 6a) role 800 8.0, 114) ‘throttle more than 36 open ‘Std and 2nd clutch pressure at 2,000 rin” (rpm) {8 position) 500150, 77) theotle fully closed 1 1200 9.0, 128) throttle more thon 3/16 open 350 (48, 6H) throttle fllyclosed yaaa 00 (8.0, 136), ‘throttle more than 3/16 pen ‘ad clutch pressure at 2,000 min fm) 350-800 (85-80, 121 12) | BOO WO, Tia) GFposttiony ‘st and Tst-hold clutch pressure at 2,000 min" (rpm | 68080018580, 121128) | 6008.0, TTa) Gi postion) Throttle 8 pressure Throne fully closed | 070, 6) = Throttle fully open 850 900(85-9.0, 121-128) | 800180, 118 ‘Stall speed min" ire F20Z1 engine 2500 72350- 2,650 (Chozk with car on evel ground) H23A9 engine 2700 2560-2880, (cont'd) 3-9Standards and Service Limits [- Automatic Transmission — Section 14 (cont'd) MEASUREMENT STANDARO INEW) SERVICE LT | Cioten ‘Clutch initial clearance Tst-hold | ‘0.80 - 1.00 (0.031 - 0.039) = | 1st 2nd | 065 - 085 10.026 - 0.033) = dren a4-ograore-aezn = Clutch return spring free length ‘st, 2nd, 3rd, 4th | sas 132) 31.5 (1.24) ten di mikes 388-200 (0074-0079) Unt grooves worn out teh late tckness ‘et tschote 195-205 0077-081) Discoloration 2d, 2021 engine 255265 (0.009 0.093 Hea engine 1198-205 0077 -008n) ara. tn 225-298 10080-0081 istration | Gieh ana pie ckness Waki | 305-2 1010081 - 0.08 Dacooraton | Man? | 246-220 (90850087) Maka | 225-230(0099 00st Mone | 236-240(0083-0050) Mans | 245-280(0096-00s8) Mans | 255-26010 10-0102) Mon? | 2es-a7000t00-0106 | Mone | 275-2600 08-0100) | Mans | 2a6-2s0\0 112-0118 isfotoraton Valve body | iat shatt edie bearing combat 1D “Torgue converter ede 2.000 27.021(1.0620- 1.05381. | wer of camage Oi pump sise 2000 agora hae -1seza) | Oi pump pear se clearance {43a 0001 0.002 807 (0.0001 Siipump geartorbody clearence Drive 210-008 ooaes-cowoe | Biven | Qaro-o.t2s(a0028-c0oss) | — il pump driven gear |.0. | 14.016 ~ 14.036 (05518-05525) | Wear or damage Oi pump shah OD. | 13500~ 13890 (0550¢—0 58081 _| Weer or camage Shing device, —| Reverse shi fork agar 1 330-600 072-0795) 54010778) Daring broke and_| Paring bate ratchet pow = Wear or other detect forte convo! | Parking brake gear = Wier orator detect rae “Three cam stopper heioht Wo-17110860-08 _| Serve body Shi fork shah bore 1D 14000-14010 05512-05810 = Shi fork hah valve bore 7.000 = 370394867 1.4562) | 37.045 4565) Regulaor vale | Sealing ing contact. 35 000=36 025 1137@0= 1.3768) 35.05 1.3780 ody | Tesumatarorboay_| Sealing ing cornea. GEoG0-SEOTATTRRGE 1380) | BADSOTRBTO) Sutor sha Sealing ing contact [0 5000 = 28.0791. 4H7 = 1.1480) | 29.05011.1687) Transmission | Diameter of neele bearing contact area ‘Onmainat af stator sha 22904 22,000109049- 0058) | Weer or damage On mainahat of rd gear ola {9544600018104 18110) | On manana of th gear ollar S984 92000112592 12590) | Sn countershat oft ge colar 40984 43000116135 - 16142) On countersef of ah gear S975 9199112569 12595) | Oncounterenat of parsing oear $904 40.0001 8742-15 On countersat of overs geat 35.979 9800014165 — 1.4179) ‘On Secondary het at gear 31975 3499 12569-12598) On seconcay ahah of 2c geo Stove 31901 12569-12595) Sneeverse ler esr sna 13.00 14.000 105808 03812) | Inside ameter Wainanat 9d gear 52.000 5201920472 - 2.0400) Mainahet ah gear Se.00s-anaz" 14003 14965) | ountersat et gear 7000-49 018 1 2504-18511 ountershat tn gear 36.000 a8018 14961-14967 Countersnat reverse gear | {2000 —azore e535 esta ountrshat car goo {000 ast 18008-18908 Secondary shalt 1 gear | $7000“ ar 016 naser = Lasra, Secondary shat 2nd pear | S100 37046 aser— 4573) fevers ler gears holder [eases tase rasere-oseear | Wearor damage 3-10[— Automatic Transmission — Section 14 MEASUREMENT Unit of length: mm inh SERVICE Unarr Mainshal rd gear collar length “Mainshat ath gear collar length Countershatt 1st gear collar length Thrust washer thickness ‘Counteraheft tet geer Countershat idler gear CCountershatt parking gear length Secondary shaft 1st gear distance collar length TSO 19.55 (0768-0770) 4750 47.55 (1.870 - 1.872) 2750~ 27.58 (1.089 ~ 1.085) 1145 - 1.50 100057 - 0.059) 345-3155 (0.136 0.140), 25.030 - 25.048 (0.9854 - 0.9861) 4.98 - 5.00 (0.195 ~0.1971 Wear or damage Wear or damage Wear or damage Wear or damage Weer or damage Wear or damage ‘Secondary shaft 2nd gear spline wash ‘thickness 35 x53 mm | STANDARD (NEW! | T 02 = 4.05 (0.168 0.159) 407 = 4.100.160 0.161), 4.12 4.15 (0.162 - 0.163), | 417 4.20 (0.168 - 0.165), 422 4.25.(0.168- 0.187), 4427 ~ 6.300.168 - 0.169), 432-435(0.170-0.171) 437 449(0.172- 0.173) 442 ~ 445 (0.176-0.175) STANDARD (NEW) MEASUREMENT Wire Bis OD. | Freetenath | No.of Colle Regulatar valve spring A 2021 engine re@orn | 1470579 | 96519-4081 185. H2343 engine toon | 147.057) | aeeraaesl 165. Rogulstor valve spring 8 3.80070) 9610378) | 44011732) 2 ‘Stator reaction spring 450177) | 3540.30) | 30301193) 192 Torque converter check valve spring 110.083), eaioas) | 364(1.833) 120 Relief valve spring to(ooss) } B4iosan | 33.1 (1539), 151 Cooler reli valve spring 2.1 (0083), sais | 46811863) 19 2nd orifice cantrol valve spring 08 100281 55402601 | §5312295) 158 Oniiee control valve spring oeioos | 6610260) | 52.5:2087 330 4th exhaust valve spring 0.9 (0.0351 7110280) | 608 (2.384) 233 ‘Throttle valve B adjusting spring Bios) | 62,028) | 3001118) 20 ‘Throttle valve B spring 414 (0.055), 85.0335) | 415(1834) 105 | 14 (0.055) a5cosss) | 41517538) m2 14 (0.055), 8510335) | 41617836) wa 1-2 shift valve spring 100.038), ssoss | saiee | 169 2/4 shift valve spring 0910035) 7510.29) | 57012248) 23 evnold accumulator spring 4010367) | 25000984) | 68712547) 73 Ast accumulator spring ra@orn | 163106 | 115.1854) 188 | ath seeumutator spring oir) | 22010860) | ‘90.1547 103 2nd accumulator spring Sso1m | 22010860) | 77.1035) 100 Sard aczumulator spring davon | sie | 9420709) 161 | teck-up shitt valve spring 0.910035 | 7.610.229) 73. (2902) 320 LLock-up timing valve spring oaioosn | 6610260 | sry aor a7 Serva contrat valve spring 1.0 (0.038), sicosi) | s26207 224 spring 1.410055), secoa7 | 3301299) 105 valve spring 1.410.088), sear) | 33011200) 105. Look-up contral valve spring 0.7 0028) 8610260) | 380/1.496) 141 Std wick down spring 120.983), 7.51029) | 483119021 23 | 32 kickdown spring 1.210.087) 730200) | 46911846) 208 3-11Standards and Service Limits n) — Section 15. [— Differential (Manual transmi (MEASUREMENT STANDARD NEW! |___ service una Final driven gear_| Backlash (0.085 — 07145 (00083-00057) | 02010.008) ‘Differential cartier | Pinion sha contadi area lb. 78.000 18.018 (0.7087 - 0.7098) | — | Carriertospinion clearance 0.017 - 0047 (0.0007 - 0.0018) | 100.008 Driveshaft contact 28,005 - 28.025 (1.1026 - 1.1033), 0.12 (0.005) | 00025-0056 0.0010-o.0026 | L_| 0.055 - 0.091 10.0022 0.0036) __|_ 0.15 10.006), Differential pinion | Backlash (0.05 - 0.15 0.002 - 0.006) T= gear 10, 18.042 - 18.066 (07103-07119) | — Pinion gearto-pinion shat clearance 0.059 - 0.095 (0.0023- 0.0037) _| 0.15 «0.0061, Topered role [Lvearing pretoad Starting torque Nem tkg-em, Iba) 142.6 (18-26, 12-20) Adjust with 2 shim [— Differential (Automatic transmission) — Section 15 (MEASUREMENT STANDARD (NEW) SERVICE LIMIT Final driven gear | Backlash (0.085 - 0.142 (0.0033 - 0.0056) | 02070.008) Differential caier | Pinion shaft contact area1.0. ¥8.000 — 18.018 (0.7087 -0.7088) | — ~ | Carie-to-pinion clearance 0.017 ~ 0,047 (0.0007 0.0018) | 0.100.008 || Driveshat contact area 1.0. 28,008 - 28.025 (1.1026 1.1033) | — Carvierto-driveshatt clearance 0.025 ~ 0.066 10.0010 0.0026) _| 0.12 10.0061 Diferential pinion | Backlash 0.05 - 0.15 0.002 - 0.006) ‘Adjust with a shim gear jo 18.042 - 18.066 (0.7103 -0.7113) | — | Finion gear-to-pinion shat clearance 0.059 - 0,095 (0.0023-0.0037) | 0.12 10.005) Tapered roller | Storing torque ‘New bearing 28-40 (28-40, 24-35) ‘Adjust with @ shim | bearing preload _| Nm (kg-cm,Ib-in) Reused bearing 25-3: (25-37, 2-32) } [- Steering — Section 17 (MEASUREMENT ‘STANDARD (NEW) Steering wheel | Rotational play at steering wheel creurnference o- 1010-08 ‘Gearbox “Angle of rack-guide-serew loosened from locked position | 29.4 Pump Pump pressure with shutoff valve closed KPa (kgfem™. pail | 000 6,000 100-90, 1,198 - 1.260) Power steering | Recommended fluid Honda power steering fluid fuie | Fluid capacity System 18118, 16) | rust imp ath Reservoir 05105.08) Power steering | Deflection with 100 N (10 Kg, 22 bs) between pulleys 725 ~ 16.0 (050-062) with used belt bett® | 8.5- 11.5 (0:37 - 045) with new beit | Beittension Nig, Iba) 360 600 135 - 60,77 110) with used be Measured with belt tension gauge 700 - 800 170 - 90, 154 - 200) with new belt + When using a new belt, agjust defection or tension to new values. Run the engine for 5 minutes then turn i off Readjust deflection or tension touted belt valves 3-12[— Suspension — Section 18 Unit of length: men find MEASUREMENT | STANDARD (NEW! senviceummn | Whe slanea | Cama Foi roa cone from Soo : Tia toe For asso Rear | IN 2.0 £ 2.0 10.08 + 0.08) Frontwhesl tring ale twa hal aeons Scar eat 0 Whe io an wT al] Oa OTT 730m fan | 8207-000) 100% fi runout Stet whee er) 9ztoloe0n oem | fdol_| 821918-908 ‘Stes Hl Wheel beatng | End ay Front] 0-0051-000m) : | fear | 0-9050-0002) [= ,- Brakes — Section 19 MEASUREMENT |___srawoano ww senvice ut | Porking breke Pay in stroke 200 N (20 kg, #4 Ibs) lever force: ‘To be locked when pulled 7 - 71 ier notches Foot brake pedal | Pedal height (with floor mat removed) MT 1907.5) = mr | sen = fee or Teste 1980 = aie evinder —| Piston pinhrod Sanrnee d= ami 00018 = Di brake Dae heiness rant a aa aey for | Footose, foro Dit unout fron E Stvrec00 | i 7 838.090) | Oe pea Frontangeenr | = Sore o.oo Pactheaness” From or at Bee) ‘Soe 20UAtanazae | Hower stom | hear sovaas 18098 __| a OW oa 920 9.4120) minimum wanow as seine | Zul 5800600) minum eonen | dots 8506. ate) min 1 a0 Tore 10183 120 minimum win ass worn | ou, oo e290) minmur | [site | dota #3021200) mnimam 3-13Standards and Service Limits ir Conditioning — Section 22 Unit of length: mm tn) | MEASUREMENT STANDARD (NEW) ‘conditioning | Lubricant eapaciy Condenser T7011 - 2, 04-7) system ‘iho, imp o2) Evaporator 20-30123-1,0.7-1.1) Line or hose 101113,0.8) Receiver 10113.0.8) Compressor [Lubricant capacity mt (iloz, Imp 02) ‘Stator coil asistance at 20°C (68°F) 0 Pulley-to-pressure plate clearance 08 £0.18 (0.020: 0006) | Compressor Deflection with 100 N (10 kg 22 ibs) Y00-12.01038 0.47) wih used belt | bet | between the pulleys 45-7.0(0.18- 0.28) with new belt _ ‘ait tension N kg, bel Measured with bet tension gauge $50 ~ 600 45 60,99 152) with used ber 950 ~ 1,150 (95 ~ 115, 209254) with new belt (- Electrical — Section 23 MEASUREMENT STANDARD INEW) Tpnition coi Fated vonage V @ Primary winding resistance fat 20°C (68°F) 06-08 Secondary winding resistance kt at 20°C (68°F) 13-19 Spark Plug Type ‘See Section 23 Gap 1.0- 1.110.039 - 00431 Ipsilon ining ‘Aviaing = e706, 1522 Red ‘Alternator belt™ | Without AE Deflection with 100N (10 kg, 22 Toa) 10-12 (0.39-0.47) wih used beh between pulleys 85 11 (0.33 0.43) with new belt Beit tension N (kg, fs) "300 = 480 30 - 45, 65-89] with used bell Measurec with bet tension gauge 450 ~ 650 (45 65, 99 143) with new belt win AE Deflection with 100 N 10 kg, 22 Iba) 10-12 (0.39 -0.47) with used belt between pulleys 457 (0.18 0.28) with new belt Belt onsion N (kG, Ts) Measured with bet tension gouge 150 - 600 145 - 60, 99 - 132) with used belt 950 1,150 (95 ~ 115, 209 - 254) with new belt ‘MEASUREMENT ‘STANDARD (NEW) ‘SERVICE LMT “Aiernator Ouipat BBV athO A 70780 = Coil resistance (rotor) @ 28-30 = Slip ing 0.0. 16.4057) 140055), Brush length 105 10.41) | 550022) Brush spring tension 9 (e2) 300-360 (10.6 - 127) 5 Saermotor | Type ‘Spur gear reduction. permanent magnet ‘Mica depth 04-05 10006-0.020) 0.15 (0.006) | runout 0-002 (0- 0.0008), | 005 10.002) oo. 280-28. 11.102- 1.106) | 27.51108), Brush length 158 1621082- 0.64) 100 10.39), Brash spring tension (new!_N (Ag bs) 16-18116-18.35-40) | — J When using a new be to used belt values, 3-14 just deflection or tension to new values. Run the engine for § minutes then turn kof, Reacjust deflection or tensionDesign Specifications TEM METRIC ENGLISH Notes DIMENSIONS ‘Gverall Longin E75 men 186. in Overall Wiath 1215 mm 6.51 Overall Height 1380 men Se3in Wheelbase 23720 mar s01.31n Track FronuReat) 1475/1,480 mm 58.1/88.3 6 | g5 emm ria Seating Capachy Five WEIGHT Care Weight 2a wT Take | 2aSe Tbe | 201s wt 1255 ks 21767 be without ABs: 2018 wir 1285 kg 21855 ibs win ABs 2018 AT 132569 2821 bs 2oits wT 1300 ke 21865 bs 201s AT 1330 kg 2,932 Ibs 2oieS MIT 1.335 kg 2,983 bs 2018S AT 13859 3,008 lbs 231 SRM 13209 2.910 lbs 23SRAT 1385 48 2.985 lbs Weight Distributions (FronuRear) 201. MT 745/495 ko 1,682/1,091 os 2018 wT y95500kg | 1884/1102 ns | Without ABS. 2018 MT 760/515 k3 472011135 Ibs | With ABS 208 ArT 810/515 ks 1786/1135 Ibs 2orts Wt 780/520 3 1:720/1,148 Ibs 20: aT 8101520 kg 1785/1.148 bs 2oEs wT 1875)520 #9 179711.148 bs 2OES AT 84520 ko | 1869/1148 Ibe 23.5R MT 8001520 3 1768/1 365 Ibe 2asRAT 8251520 3 1BT0/1,148 bs Max, Permissible Weight (European) 200 NT 1920 kg 4012 Ibs 2or am 11380 ko 4.145 bs 231 MT and AT 1180 kg 4145 bs ENGINE Wee FIOZ', F20Z2 engines Water-cooled, &atvoke SOHC ‘gasoline engine H23A3 engine Water-cooted, ¢stvoke DOHC ‘gssoline engine Cylinder Arrangement ‘veylinders inline, ansverse Bore and Stroke £2021, £2022 engines | 65.0. 98.0 mmm 3363.45 in H23Ad engine 87.0x950mm 342%374in Displacement F20z%, F20Z2 engines | 1.997 em int) i218 euin H23A3 engine | 2.259 em imi) 1378 euin Compression Ratio F20Z1 engine 95:1 F2022 engine 90:1 | H23A2 engine 9a: | Valve Train F 2021, F2022 engines Belt driven, 4 valves per cylinder ‘single overhead comshatt 2343 engine Beit criven, 4 valves per evlinder, double overhead camshaft Lubrication System Forced and wet sump, wachaid pump Oi Pump Displacement (Aroll temp. 36.5°C (88°F) 2021, F2022 engines | 53.7¥/minute ot 6,000 pump min" (rpm) H23A3 engine 58.1{ minute at 8,000 pump mir’ rpm} Fuel Required Premium UNLEADED grade gasoline with 195 Research Octane Number oF higher Water Pump Displacement {At coolant temp. 40°C (108F) 2021, F2022 engines | 1$0¢/minute t 6,000 pump min” Ire) H23A3 engine {__152¢/minute at 6.000 purmp min (FB) (con's) 3-15Design Specifications [— (cont'd) METRIC | enoush | em Noves ‘STARTER Tye Spur gear edusion, pstmanent magnet Normal Output ‘vanw. tekw Nominal Votage "av Hour Rating 30 seconds Direstion of Rotation Counterclockwise as viewed fom geo end Weight sew ‘35 K9 7 tbe X6kw 3743 826 cuuTeH Gian Tope ar ingle plate ai. daphragm spring at “Torque converter Chtch Facing Area wr aire So sgin TRANSMISSION | Transmission wr Sypehonized Bapeed foward, reverse | aT Electroneally controlled dual range {apeed forwaré automat, ev Primary Reduction Dect 1 | aA ET Automate Engine pe | FAO F20za_| WAT Gaara 1 j 3307] 3307 | sa07 | — 2708 | tne 1609 | 1909 | ta00 | Tee | ars 1200 | tes | 26 | tome | ry ass | o90s | 0966 | or th a7? | 0735 | o7 |S Reverse | 3000 | 3000 | 3000 | 2047 Final Redaction Gear wpe Singlohalea gear Gear ato 6268 | 4205 TAR CONDITIONING | Coating Capachy “roo Keaim | 16265 8TUm Compressor Typehtakes ‘SwachplateNIFPONDENSO |] No of Cylinder "0 Capeciy Veemrey | 109 euinrer Max Speed 81800 min rpm Lubricant Copscty 160m S19 Mr, Sbimee:__| No-oWe Condaraar Tipe Carragated fin [Evaporator Type Corrgated fin Blower Type Sroeco fan Motor input 209 Wmaxs12V Spoed Contr! Sapeed Mox.Cepociy £20 mh [14.934 cut Temp. Conve icmbetvpe Compressor Clich Type Diy, file plate, poly-W-beR ave Power Consumetion | AoW max 2 Reigerant Type ECT (TDA tianity woh | 265.twor_| 3-16rem MeTRIC [_enousn NoTES STEERING SYSTEM | Type Power assisted, rack and pinion Overall Ratio. 164 Turns, Lock-to-Lock 313 Steering Whee! Diameter 380. mm 15.09 ‘SUSPENSION Type, Front Independent double wishbone, ~ coil spring with stabilizer Type, Rear Independent double wishbone, ‘Shock Absorber, Front and Rear ‘call spring with stbilizer Telescopic, hydraulic nitrogen gas-filled WHEEL ALIGNMENT Comber Front 0 00 Rear 0°30 Caster ‘3° 00 Total Toe Front ome oin Rear 10.08 in ‘RARE SYSTEM ive" Front Rear Pad Surface Aras “Powerassisted selvadjusting ventilated dise Power-essisted selladjusting solid dise Front 200 NIT s94em'x? 7.66 sain x2 208 AT and 23¢ S8.0em' x2 299 enn x2 | Rear 20.7 en x? 4.60 sain x2 Parking Brake Mechanical actuating, ear two whee! brakes TRE Size and Prossuve See tyre information label [see page 7-5) ELECTRICAL Banery KG (KF). 12 V— 57 AHO HR T KE: 12-47 AH/20 HR KS: 12 V 55 AH20 HR ‘tarer 12V~ 1.4 kW, 1.8 KW Alternator 12V-80A, 708, Fuses In the under-desh fuserrelay box Inthe under-hood fuserreley box Inte underhood ABS fuse/relay box Heactights Front Turn Signal Lights 158104, 188.904 7SA.OA18A, 208,20, 404.504. 608 visswint 12 V-2 WIAMBER) Front Position Lights wV-sW ‘Side Turn Signal Lights v-sw Rear Turn Signal Lights av_aw StoprTalights w2V-218W Backup Lighte wav-nw Rear Fog Light aav_ zw LUcense Plate Lights Rv-sw Ceiling interior Lights Front Rv-sw Rear v-sw “Trunk (Boot Lights 2v-5w Door Courtesy Lights ev-sw Glove Box Lights wav-5W Gauge Lights 2V-44,3W Indicator LightsiLamps 12-086, 1.12, 1.4W, LED Warning Lights 1BV-1.4 Iiuemination and Pilot Lights 12V-056, 0.86, 112, .4W Heater llumination Lights wV-ew i 3-17Body Specifications Unit: tnMaintenance Lubrication Points .... Maintenance Schedule ...Lubrication Points For the details of lubrication points and types of lubricants to be applied, refer to the Illustrated Index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Instal ion, etc.) contained in each section. No. LUBRICATION POINTS I LUBRICANT [1] Engine | Always use @ fuel-efficient oil is that says “API Service SF or SG.” SAE Viscosity: See chart below _ 2 | Transmission Manual | API Service Grade: SF or SG | | SAE viscosity: 10 W-30 or 10 W—40 ‘Automatic Honda Premium Formula Automatic Transmission Fluid or an equivalent DEXRON® II Automatic transmission fluid 3 | Brake Line Brake fluid DOTS or DOTA 4 | Gluteh Line __|_ Brake fluid DOTS or DOTA _ 5 | Power steering gearbox Steering grease PIN 08733—B070E 6 | _ Shift lever pivots (Manual Transmission) Grease with molybdenum disulfide 7 | Release fork (Manual Transmission) 8 | Steering boots 9.| Throttle cable end 10 | Steering ball joints 11 | Select lever (Automatic Transmission) 12 | Pedal linkage 13 | Intermediate shaft ts 14 | Brake master cylinder pushrod luki-purpose grease 15 | Trunk hinges and latches 16 | Door hinges upper/iower and latches 17 | Door opening detents 18 | Fuel til tia 19 | Engine hood hinges and engine hood latch 20 | Clutch master cylinder pushrod 21 | AIC compressor Compressor oll ND-OIL8 P/N 38899—PR7—003 22 | Broke pipe joint (Front and rear wheel house) Fust-preventive agent 23 | Caliper Piston seal, Dust seal, I Caliper pin, Piston meee aaa 24 | Power steering system Honda power steering fluid Select the oil for the car ‘according to this chart: CAUTION: Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle us- oo. ed oll on a daily basis, itis stil advisable to thoroughly ‘wash your hands with soap and water as soon as possi- 208308080 00"r ble after handling used oil ‘Ambient temperature 4-2‘9 oj 43‘w 090'0E i : BISNIS 1894 19HBRLGD 2 Tyo 7 ‘Vowspuod pus waisks 16a 29) Peacinb3) BFy SMMBsaId YONy WaIEAS ByEq POFAUY 7 (Gay 20) Paddinba) uoneiedo woisks oyeq OHI r (Gay Suipneur sun pus sesoy oyere (Sav Supnisu pny o¥eG 7 1 ¥ t o o Byuow Zt Biwoa Zi SRW GOST WAL va | zz | 09 oY ve | zz | o9 | ev 08 Maintenance Schedule‘ves2000u j) 8904401 10 4403“ (2 “tanlpe‘uonsadsu oxy ‘s0dsu) = 1 soeqday =o TOOTH FRAT 7 aes Ba Too Tasos nwo Zt 79 (ona 000TH O00 07 M=nG H i 8p oe OU aioeav | x '000°37 00001 Hana 1 aa0+8v oyu o00"e1 w4 ooo'02 Keng | eases iw 000") wH OOO" Oz Aang ¥ 3 = oA 9 9 apa 000°E) WH 900"S Ara ¥ deer ev wouendo ai aoueUeNHEHH won open BymoL ‘suouipuoo Buip e29A28 sepun pasn Ajeuiou $129 UO AjueNbO}} ex0W paowUes 0q YSnWs SU ‘p80 Appr o7pue yBros w BuIANG syeuorew enisou0d soylo 40 yes peo! Bsn Seave w BUAYO, feom pj a19n98 U! BURG ‘suoripuos Aisnp ut Bung, ‘Suanp eoversip 104s poreadsy ‘pnyut su0npu0> BuINIP B2N9 48065e ‘jena ooueuswew steudoidde ax 10} Mojeq WeYD BUN 0 9}0H Bumoyo au. suomipuog Buaug a10n05 TanenG woes TROTTING “ia SeppueY 1609 "sen JO SEHUIER|D ‘Bujieodo preoausep “Ayegeis "SSION) BAUD 150) {om Apod fue SaBcwrep Weg ‘rans 1560s ‘ueea wa peau pus voneIedo SiGBA “rena 196850 [aieds Buipaiauy aanssand pur 18am “UONIPUOD BorA] TT4 Tompuee Aenea | ‘iene weds) 59001 “auono@uu0d pur $6504 UONTUn) Bunaals Jamo 'i60q nue KOqeRB SpuB por fr woHToUN) BUTEAIG cio ‘siuavedwoo vamuedsng ve | [a oe | | a oo | or | 0 ‘aURUaNUEN yon “supuow 0 s9quane arsy eno ay 12 mag 1 sow0> 9p 30} W9 000 re ‘fieesa90u 4 o2ej0o1 10 wed "do Tenipe ‘weap wonzedsuy yy —Aeedsu—| eoedoy—y 4-5Engine Engine Removal/Installation Cylinder Head/Valve Train .. Engine Block .. Engine Lubrication Intake Manifold/Exhaust System . Cooling ...Engine Removal/Installation ,— Outline of Model Change To +The H23A3 engine type has been added.Special Tools fet. to. | Toot umber Oescpion ay_| Pee Reerance | G7MAC=SL60160 | Ba Joins Remover. 32 mm T+ [se @ |__07KAK~SL40101 Engine Tilt Hanger Set oo 5-10 5-2Engine Removal/Installation be] jacks and safety stands are placed prope ly and hoist brackets are attached to the correct positions on the engine. '@ Make sure the car will not roll off stands and fall while you are working under cauTION: © Use fender covers to avoid damaging painted surface. ‘© Unspecified items are common ‘© Unplug the wiring connectors carefully while holding ‘the connector portion to avoid damage ‘© Make all wiring and hoses to avoid misconnection Aso, be sure that they do not contact other wiring or hoses or interference with ather parts. 1. Secure the hood as far open as possible. 2. Disconnect the battery negative terminal first, then the positive terminal. 3. Remove the radiator cap PRINT se care when removing the radiator cap to avoid scalding by hot coolant or steam. 4. Raise the hoist to full height. 5. Remove the front wheels and the engine splash shield fi ENGINE SPLASH eal ‘SHIELD 6. Loosen the drain plug from the radiator. 7. Drain the transmission oil oF fluid. Reinstall the drain plug using a new washer 8. Drain the engine ail. Reinstall the drain bolt using @ new washer, then lower the hoist, CAUTION: Do not overtighten the drain bolt 9, Remove the intake air duct and air cleaner AIR CLEANER INTAKE AiR DUCT 10. Remove the battery, battery base and battery cable, 81.25 mm 22 Nim (2.2 kgm 16-1) BATTERY BASE 61.0 mm YO Ninn (1.0 ko-m, Tet BATTERY CABLE (cont'd) 5-3Engine Removal/installation r- (cont'd) 11. Remove the starter cable and transmission ground cable. STARTER CABLE TRANSMISSION GROUND CABLE 8x 1.25 mm 3 Nem (0.9 kom, 6x 1.0 mm Tita 10 Nem (1.0 kgm, Tet by slowly loosening the ser- bout one turn. fuel system. Keep away from work area. Drain fuel ‘only into an approved container. ‘CAUTION: © Before disconnecting any fuel line, re {uel pressure as described above. © Place a shop towel over the fuel rail to prevent Pressurized fuel from splaying over the engine. the 13. Remove the fuel feed hose and fuel return hose. BANJO NUT 2 16 mA SERVICE BOLT (2.2 kgm, WASHERS 15 Nem (1.5 ko-m, Replace. 11 itt FUEL RETURN HOSE 14, Remove the left side engine wire harness and ‘ground cable 6x 1.0mm 10 Nem (1.0 kgm, Theft LEFT SIDE ENGINE WIRE HARNESS. 6x 1.0mm 30 N-m (1.0 ko-m, 7-10 GROUND CABLE 18. Remove the throttle cable by loosening the locknut, then slip the cable end out of the throttle linkage. NoTE: © Do not loosen the adjusting nut ‘© Take care not to bend the cable when removing it, Always replace any kinked cable with a new © Adjust the throttle cable when installing, CABLE END ADJUSTING NUT 16, Remove the engine wire harness connectors, ter: minal and clamps on the right side of engine compartment.17. Remove the power cable from the under-hood fuse/relay box. UNDER-HOOD POWER CABLE FUSE/RELAY 80x ENGINE WIRE HARNESS. 6x 1.0mm 10 Nem (1.0 kgien. 7 thf) 18, Remove the evaporative emission (EVAP) control Canister hose and emission control vacuum tubes from the intake manifold. EMISSION CONTROL VACUUM TUBES Evap contRoL CANISTER HOSE 19, Remove the brake booster vacuum hose and engine mount control vacuum tube (A/T only) from the in: rake manifold. BRAKE BOOSTER VACUUM HOSE ENGINE MOUNT CONTROL VACUUM TUBE (A/T only] 20. Remove the connectors and the control box. coNTROL Box 6x t0mm 10 Nem {1.0 ke 7 est CONNECTORS (cont’a) 5-5Engine Removal/Installation r (cont'd) 21. Remove the engine ground cable on the cylinder head, 22. Remove the power steering (PIS) pipe and mount: ing boltinut. Loosen the adjusting bolt, then remove the P/S pump belt and pump. NoTE: © Plug the pipe and the pump port. © Do not disconnect the hose 6x 1.0 mm PIS PIPE AY Nem (1.1 kgm, Biot PIs PUMP. ‘MOUNTING BOLT 10. 1.25 mm 45 Nem (4.5 kg-m, 33 PIS PUMP. < ADJUSTING Bou MOUNTING NUT 8x 1.25 mm 22Nem (2.2 kom, 16 ttt 23. Remove the condenser fan shroud then install a protector plate to the radiator. ‘CONDENSER 631.0 mm FAN SHROUD ONem (1.0 kgm, 7 ete PROTECTOR PLATE 24. Loosen the adjusting bolt and mounting boltinut from the alternator, then remove the alternator belt MOUNTING BOLT 10 x 1.25 mm 45 Nem (4.5 kg-m, 33 A) ALTERNATOR ‘CONNECTOR ALTERNATOR MOUNTING NUT TERMINAL ADJUSTING — 8 x 1.25 mm BolT 22 Nim (2.2 kg-m, 16 mA 25. Loosen the mounting bolt, then remove the air con- ditioning (A/C) compressor. NOTE: © Do not disconnect the A/C hose. © Disconnect the connector, arc. ‘Compressor MOUNTING BOLTS Bx 1.25 mm 22 Nim (2.2 kgm, 16 A) Remove the connector 5-626, Remove the upper and lower radiator hoses and the heater hoses. HEATER OUTLET HOSE HEATER INLET Hose LOWER RADIATOR e Hos UPPER RADIATOR Hose 27, Remove the automatic transmission fluid (ATF) cooler hoses (A/T). ATE COOLER Hoses 28. Remove the shift cable and select cable (M/T). NOTE © Take care not to bend the cable when removing it, Always replace any kinked cable with a new © Adjust the shift cable and select cable when in: stalling. 8x 1.25 mm 22 Nim (2.2 kg-m, 16 thst 0 not remove. corten pin Replace. Plastic WASHER COTTER PIN, Replace. PLAsTic WASHER STEEL WASHER 29, Remove the clutch slave cylinder and the pipeihose assembly (M/T) NOTE: ‘© Do not operate the clutch pedal once the slave cylinder has been removed. © Toke care, not to bend the pipe: CLUTCH HOSE Sow 8x 1.25 mm 22 Nem (2.2 kg-m, Teen (cont'd) 5-7Engine Removal/Installation 7 (cont'd) 30. Remove the clutch damper assembly (M/T). NOTE: Take care, not to bend the pipe. CLUTCH DAMPER ASSEMBLY 8x 1.28 mm 22 Nim (2.2 kg-m, 16 tte 31. Remove the vehicle speed sensor (VSS)/power steering speed sensor assembly. NOTE: Do not disconnect the hoses. 18 Nem (1.8 kgm, Bb \Vss/POWER STEERING ‘SPEED SENSOR, ‘O-RING Repiace. 92. Raise the hoist to full height. 33. Remove the exhaust pipe A. NOTE: Remove the heated oxygen sensor (HO2S) connector asker ‘SELF-LOCKING NUT Replace 18 Wm (1.8 kgm, nos 33 Replace SELF-LOCKING NUT 55 Nem (5.5 kg-m, 40 Ib-t) EXHAUST PIPE A Replace. 34. Remove the A/T shift cable (A/T) Note © Take care not to bend the cable when removing it, Always replace any kinked cable with a new © Adjust the shift cable when installing LOCK WASHER Replace. SHIFT CABLE35. Remove the damper fork. CAUTION: Replace the self-locking bolts if you can easily thread a non-self-locking nut past thelr nylon locking inserts (It should require 1 N-m (0.1 kg-m, 0.7 Ib-ft) of torque to turn the nut on the bolt SELF-LOCKING BOLT 10 x 1.25 mm SELF-LOCKING 44 Nom (4.8 kgm, 32 lb-ft) BOLT DAMPER FORK —_SELF-LOCKING NUT 12.5 1.25 mm 65 Nom (6.5 kg-m, 47 lb-ft) Res ‘38. Disconnect the suspension lower arm ball joint with the special. tool. [5.06.0 kgm, 36—43 16-1) corer Pin BALL JOINT REMOVER, 32 mm ‘O7Mac~SL00100 37, Remove the driveshatts. CAUTION: Take care not to damage the oil seal when removing the driveshaft. NOTE: © Coat all precision finished surfaces with clean ‘engine oll or grease. © Tie plastic bags over the driveshatt ends. DRIVESHAFT 38, Swing the driveshaft under the fender. NOTE: © Coat all precision-tinished surfaces with clean engine oil or grease. © Tie plastic bags over the driveshaft ends, DRIVESHAFT SUSPENSION LOWER ARM (cont'd 5-9Engine Removal/Installation r- (cont'd) 39. Lower the hoist 5-10b=] 41, Remove the rear mount bolt, REAR MOUNT BOLT REAR MOUNT REAR MOUNT BRACKET 42. Remove the front mount bolt. FRONT MOUNT TORQUE ROD BOLT FRONT MOUNT BRACKET 43. Remove the left side engine mount. SIDE ENGINE MOUNT 4B, Raise the chain hoist to remove all slack from the chain 46. Check that the engine is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring, 47. Slowly raise the engine approximately 150 mm (6 inl Check once again that all hoses and wires have been disconnected from the engine. 48. Raise the engine all the way and remove it from the (cont'd 5-11Engine Removal/Installation r (cont'd) 49. Install the engine in the reverse order of removal. NOTE: After the engine is in place: © Torque the engine mount bolts/nuts in the se quence shown below. CAUTION: Failure to tighten the bolts/nuts in the sequence can cause exces: ion, and reduce bushing Wi bushings are not twisted or offset. 10 x 1.25 mm © 39 Nem ‘TRANSMISSION MOUNT (3.9 kgm. 28 bt) 8s ZS. | \ a ©) Tighten snug oniy. 3°25 mm © 65 Nem (6.5 ko-m, mr 12x 1.25 mm O65 Nemi6.5 kom, a7 bf Replace. FRONT MOUNT 12. 1.25 mm O65 Nem (6.5 kom, 47 bd Replace, ‘© Chock that the spring clip on the end of each driveshatt clicks in to place. CAUTION: Install new spring clips. © Bleed air from the cooling system at the bleed bolt with the heater valve open. © Adjust the throttle cable tension. © Check the clutch pedal freeplay (M/T) © Check that the transmission shift into gear smoothly, REAR MOUNT (Tighten snug only 1241.25 mm © 65 Nem (6.5 kom, NOTE: Torque the mounting bolts/nuts the 471A) numbered sequence as shown (7)~“6). 5-12© Adjust the tension of the following drive belts: © Inspect for fuel leakage, Alternator belt. After connecting all fuel line parts, turn on the Power steering pump belt. ignition switch (do not operate the starter! so Air conditioning compressor belt that the fue! pump operates for approximately © Clean battery posts and cable terminals with ‘two seconds and the fuel line is pressurized. sandpaper, assemble, then apply grease to pre- Repeat this operation two or three times and check whether any fuel leakage has occurred at any point in the fuel line, vent corrosion. ‘Mount and Bracket Bolts/Nuts Torque Value Specifications: 10 «1.25 mm 60 Nem (6.0 kg-m, 43 bt) ® 1001.25 mm 21 Nem 2.1 kom, pra) Tighten after @ TRANSMISSION MOUNT jy, 25 mm 85 Nem (6.8 kg-m. 40 Ib) 39 Nem (3.9 kgm, 28 bn Tighten betore ® mit: BRACKET ® 30 1.25 mm BRACKET 39 Nem (3.9 kg-m, 10 x 1.25 mm 39 Nem (3.9 kg-m, 2am BRACKET 6 8x 1.25 mm 22 Nem (2.2 kg-m, 16 wee) 12.41.25 mm BRACKET A. 65 Nem (6.5 ko-m. 47 Bo Replace. 10x 1.25 mm 45 Nem (2.8 kam, 33 1b10 8x 1.25 mm 22 Nem (2.2 ka-m, Ye mean ENGINE MOUNT BRACKET 10 x 1.28 mm _ (cont'd 48 Nem (2.8 kom, 35 bf (KE AMT onty) 5-13Engine Removal/Installation r- (cont'd) Additional Torque Value Specifications: PIS BRACKET 65 Nem (6.5 kg-m, 47 Ib-ft) ‘TRANSMISSION MOUNT BOLTS 10 x 1.25 mm 50 Wim (5.0 kgm, 36 tote) ALTERNATOR BRACKET 10 x'1.25 mm 10x 1.25 mm 50 Nem (5.0 kg-m, 50 Nem (5.0 kg-m, AIC BRACKET eee 36 tbett) Apply liquia gasket to the bolt threadsCylinder Head/Valve Train Special Tools 62 Mlustrated Index 63 Cylinder Head Removal ...... 6-5 Warpage . 6-14 Installation 6-17 Camshaft Pulleys Removal 6-10 Camshafts Inspection ...... soe 6-10 Valves, Valve Springs and Valve Seals Removal 6-12 Installation Sequence 6-16 Valve Installation .... - 6-16 Valve Seats Reconditioning 6-13 Valve Movement 6-14 Replacement .... . 6-15 Reaming 6-15 [ Outline of Model Change — +The H23A3 engine type has been added Rocker Arms/Camshafts and Seals/Pulleys Installation : z 6-18 Timing Belt and Timing Balancer Belt Mlustrated Index 6-20 Replacement . 6-24 Timing Belt Inspection . Tension Adjustment .... Positioning Crankshaft Before Installing Timing Belt .. Timing Balancer Belt Inspection . Valve Clearance AdjustmentSpecial Tools Ret.No. | Tool Number Description |_oty | Page Reference @ | ‘07GAD—PH70100 Valve Seal installer 1 | 616 ® | 07saa—0010200 | Socket Wrench, 19 mm 1 | 625, 28 @ | 074aB~0010200 | Handle 1 | 625, 28 ® O7LAG—PT20100 | Balancer Shaft Lock Pin 1 | 627 ® O7MAB—PY30100 | Pulley Holder Attachment, HEX 50 mm 1 | 6.25, 28 ® | 07742~0010200 | Valve Guide Driver, 6.6 mm | 1 |ets ® 077440010800 | Pin Driver, 5.0 mm | 2 | 68, 10, 19, 23 ® 07757—0010000 | Valve Spring Compressor | 4 | en ® 07984—6570101 Valve Guide Reamar, 6.6 mm 1 615 6-2Ilustrated Index CAUTION: To avoid 4 before removing it. aging the cylinder head, wait until the engine coolant temperature drops below 38°C (100°F) NOTE: Use new O-rings and gaskets when reassembling. 6 x10 mm TO N-m (1.0 kgm, 7 tot) CYLINDER HEAD 6x % RUBBER SEALS. Replace when damaged of deteriorated 1.25 mm 22 Nom (2.2 kgm, 16 t-te 6x10 a 12 Nem (1.2 kgm, 9 tb-tt), 6x10 mm 10 Nm U2 kgm, 7 Hof f INTAKE CAMSHAFT HOLDER a8 i # 3 8 = i f INTAKE CAMSHAFT inspection page 6-10 SEALS Installation, page 6-18 CAMSHAFT PULLEYS. Femoval, page 6-10 Installation, page 6-18 DISTRIBUTOR EXHAUST CAMSHAFT ROCKER ARM ADJUSTING SCREW. ‘Adjustment. page 6-29 LockwuT (_. 38 Nm (3.8 kg-m.27 Ib-f) HEX for mangal re-alignment of camshatt (cont'ar 6-3Illustrated Index (cont'd) CAUTION: In handling a metal gasket, take care not to fold it or damage the contact surface of the gasket. NOTE: Clean the oil control orifice before installing. 7B Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to any contact pars. INTAKE VALVE GUIDE CYLINDER HEAD Inspection, page 6-14 BOLTS Replacement, page 6-15 121.25 mm Reaming, page 6-15 100 Nem (10.0 kg-m, 72 bt) Apply clean engine oil te threads and under the bolt heads ‘SPRING RETAINER VALVE KEEPERS EXHAUST VALVE SPRING. 8 | nrceceerere some rane ee ene eee nace eae ——"*. j Cy EXHAUST VALVE SEAL Replacement, pages 6-12 and 16 Replace VALVE SPRING SEAT- NS BACK CQVER CYLINDER HEAD Removal, page 6- Same moun Reconaorng vave BRACKET 6. seat, page 6-13 Warpage, page 6-14 10 x 1.25 mm Installation, page 6-17 45 Nem (4.5 kgm, 33 iba [CYLINDER HEAD GASKET (METAL GASKET) Replace. DOWEL PIN 81.25 mm 22. Nm ‘ol CONTROL (22 kgm, 16 A ORIFICE Clean, INTAKE VALVE Replacement, Dimension, page 6:12. Reconditioning valve seat, page 6-13 O-RING Replace. ‘Timine BELT Inspection/Adjustment, page 6-21 Replacement, page 6-24 ‘ADJUSTING NUT 10x 1.25 mm 45 Nem (4.5 kgm, 33 bt Loosen, but do not remove. 6-4Cylinder Head 1 r Removal Engine removal is not required for this procedure jacks and safety stands are placed proper: ly and hoist brackets are attached to the correct positions on the engi © Make sure the car will not roll off stands and fall while you are working under it. CAUTION © Use fender covers to avoid damaging painted surface, ‘© Unspecified items are common. © Unplug the wiring connectors carefully while holding the connector portion to avoid damage. ‘© Mark all wiring and hoses to avoid misconnection. ‘Also, be sure that they do not contact other wiring or hoses or interfere with other parts. ‘© To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 38°C (100°F} before loosening the retaining bolts. NOTE: ‘© Inspect the timing belt before removing the cylinder head. ‘© Turn the crankshaft pulley s0 that the No. 1 piston is at top dead center (TDC) {see page 6-23) ‘© Mark all emission hoses before disconnecting them. 1. Disconnect the negative terminal from the battery. 2. Drain the engine coolant, ‘© Remove the radiator cap to speed draining. 3. Relieve the fuel pressure. MY 00 not smoke while working on fuel system, keep open flame or spark away from work area. Drain fuel only into an approved container, 4. Remove the fuel feed hose and fuel return hose. BANJO NUT WASHERS SERVICE BOLT 22 Nem (2.2 kom, Replace. 15 Nem (1.5 kgm, 11 Ib-ft) 36 bt FUEL FEED HOSE FUEL RETURN HOSE 5, Remove the water bypass hose, breather hose and 6. Remove the positive crankcase ventilation (PCV) intake air duct. hose. [BREATHER HOSE Pov HOSE INTAKE AIR WATER BYPASS. puer Hose 7. Flemove the evaporative emission (EVAP) control canister hose and emission control vacuum tubes from the intake manifold EMISSION CONTROL VACUUM TUBES. EVAP HOSE (cont’a) 6-5Cylinder Head 7 Removal (cont'd) 8. Remove the rake booster vacuum hose and engine ‘mount control vacuum tube (A/T only) from the in- take manifold. BRAKE BOOSTER VACUUM HOSE ENGINE MOUNT CONTROL VACUUM TUBE 9. Remove the throttle control cable from the throttle body (A/T only) NOTE: © Take care not to bend the cable when removing it. Always replace any kinked cable with a new one. © Adjust the throttle cable when installing. ‘THROTTLE CONTROL CABLE Locknut ‘ADJUSTING NUT 10. Remove the following engine wire harness connec. tors and clamps from the cylinder head and the in- take manifold, © Four fuel injector connector take air temperature (IAT) sensor connector le air control (IAC) valve connector hrottle position (TP) sensor connector (© Exhaust gas recirculation (EGR) valve lift sensor ‘connector © Ground cable terminals © Engine coolant temperature (ECT) switch A con- nector © Heated oxygen sensor (HO2S) connector © ECT sensor connector © ECT gauge sending unit connector © Vehicle speed sensor connector © TDC/CKPICYP sensor connector © Ignition coil connector 111. Remove the upper and lower radiator hoses and heat: er hoses. HEATER HOSES UPPER RADIATOR LOWER RADIATOR HOSE HOSE 12, Remove the water bypass hose and the thermostat housing 6x 1.0 mm 12Nem (1.2 kgm, BYPASS HOSE a ‘THERMOSTAT HOUSING13, Remove the engine ground cable from the cylinder head cover. 14. Remove the power steering (P/S} pipe and mount- ing boltinut. Loosen the adjusting bolt, then remove the P/S pump belt and pump, NOTE: @ Plug the pipe and the pump port © Do not disconnect the hose © After instaling, adjust the tension of the P/S pump, bets fvTING NUT Be tnze nm Ps Boum SS bom, x wm Pis PUMP BELT. BOLT MOUNTING BOLT 10 1.25 mm 45 Nem (8.6 kg-m, 33 Ib-f) 18, Disconnect the alternator terminal and connector, then remove the engine wire harness from the cylinder head cover. ENGINE WIRE HARNESS 16. Remove the intake manifold bracket and intake manifold. GasKeT Replace. INTAKE MANIFOLD 17. Remove the self-locking nuts and disconnect the ex haust manifold and exhaust pipe A. 18, Remove the heat insulator (cars equipped with AIC), exhaust manifold bracket and exhaust manifold. Gasket Replace. EXHAUST MANIFOLD cover HEAT INSULATOR (care equipped with A/C) EXHAUST PIPE A lcont'a) 6-7Cylinder Head r Removal (cont’d) 19. Remove the cylinder head cover. 20. Remove the middle cover. 21. Loosen the adjusting nut 180°. 22. Push the tensi ing belt, then ighten the adjusting nut. ‘AouusTNG NUT Do not remove. 23. Remove the timing belt from the camshaft pulleys. CAUTION: Do not crimp or bend the timing belt more than 90 ° or less than 25 mm (1 in} in diameter. ) “Lr Good No Good ) | “es | | to release tension trom the tim: 24. Remove the camshatt pulleys. NOTE: To set the camshafts at TOC for No. 1 piston, align the holes in the camshafts with the holes in the No.1 camshaft holders and insert 5.0 mm pin driver, IN DRIVER, 5.0 mm 077440010400 25. Loosen the rocker arm adjusting screws, then re: move the camshaft holders and camshafts, ADJUSTING SCREWS ‘ADJUSTING SCREWS26. Remove the side engine mount bracket B and back ENGINE MOUNT BRACKET & 30x 1,25 mm 45 Nim (8.5 kg-m, 33 bet) 8x 1.25/mm ENGINE‘MOUNT 22 Nem (2.2 kgm, BRACKET 16 et 27. Remove the cylinder head bolts, then remove the cylinder head. CAUTION: To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat until all bolts are loosened. CYLINDER HEAD BOLT LOOSENING SEQUENCE rewdriver as shown. 6-9Camshaft Pulleys Camshafts r Removal —————————————_—- Inspection 1, To ease reassembly, turn the pulley until the “UP NOTE: Do not rotate camshaft during inspection. marks face up, an the front timing marks are agned with the marks on the pulleys 1. Remove the rocker arms. NOTE: Rocker arms must be installed in the same position if reused. "UR marks: 2. Put the camshafts and the camshaft holders on the ‘cylinder head, then tighten the bolts to the specified torque. Specified torque: Except Intake ©, @. Exhaust @, @: 10 Nim (1.0 kgm, 7 thf) Intake @, ©. Exhaust ©, ©: 12 Nem (1.2 kgm, 9 lb-ft) TIGHTENING SEQUENCE B® Oo 9 2 29 @® ‘Align the marks on the pulleys 2. Remove the timing belt 3. Remove the pulley bolts, then remove the camshaft pulleys. NOTE: To set the camshafts at TOC for No. 1 piston, align the holes in the camshafts with the holes in the No.1 camshaft holders and insert 5.0, mm pin driver. PIN DRIVER. 5.0 mm 07744—0010400 PULLEY BOLTSbe] ‘Seat camshafts by pushing them toward distributor end of cylinder head. Zero dial indicator against end of camshaft, then push camshaft back and forth, and read the end play. Camshaft End Play: Standard (New! 05—0.15 mm (0.002—0.006 in) Service Limit: 0.5 mm (0.02 in) Remove the camshaft holder bolts from the cylinder head. @ Lift camshaft out of cylinder head, wipe clean, then inpsect lift ramps. Replace camshaft if lobes are pitted, scored, or excessively worn. © Clean the camshaft bearing surfaces in the cylinder head, then set camshaft back in place. ‘© Insert plastigage strip across each journal © install the camshaft holders and torque bolts to the values and in the sequence shown on page 6-10, Measure widest portion of plastigage on each journal Camshaft-to-Holder Oil Clearance: Standard (New): 0.050—0.089 mm (0.0020~0.0035 in) Service Limit: 0.15 mm (0.006 in} Exhaust No. 5 Journal Standard (New): 0,100—0.139 mm (0.0039~0.0055 in} ice Limit: 0.20 mm (0.008 in} Rotate camshaft while measuring MW camshatt-to-holder oil clearance is out of tolerance: ‘© And the camshatt has already been replaced, you ‘must replace the cylinder head. ‘@ If camshaft has not been replaced, first check to- tal runout with the camshaft supported on V- blocks. Camshaft Total Runout: ‘Standard (New): 0.03 mm (0.001 in) max. Service Limit: 0.04 mm (0.002 in) = Ifthe total runout of the camshatt is within toler ‘ance, replace the cylinder head. — If the total runout is out of tolerance, replace the ‘camshaft and recheck. If the oil clearance is still ‘out of tolerance, replace the cylinder head. Measure camshaft lobe height. Intake Standard: 33.661 mm (1.3252 in} Exhaust Standard: 33.725 mm (1.3278 in} Inspect this are for wear 6-11Valves, Valve Springs and Valve Seals r Removal NOTE: Identify valves and valve springs as they are re: ‘moved so that each item can be reinstalled in its original position, 1. Tap each valve stem with a plastic mallet to loosen valve keepers before installing the spring com- pressor. 2. Install the spring compressor. Compress spring and remove valve keeper. VALVE SPRING COMPRESSOR (07787-0010000 3. Install the special tools as shown, 4, Remove the valve guide sei Sa oh Ll Intake Valve Dimensions A Standard (New): 33.90—34.10 mm (1.335—1.343 in} 8B Standard (New): 102.50— 102.80 mm (4.035—4.047 in} € Standard (New): 6.580—6.590 mm (0.2591—0.2594 in) € Service Limit: 6.55 mm (0.258 in) D Standard (New): 0.85—1.15 mm. (0.033-0.045 in) D Service Limit: 0.65 mm (0.026 in) Exhaust Valve Dimensions A Standard (New): 28.90—29.10 mm (1.138—1.146 in) B Standard (New): 101.40—101.70 mm (3.992—4.004 in) © Standard (New): 6.550—6.560 mm (0.2579-0.2583 in} © Service Limit; 6.52 mm (0.287 in) D Standard (New): 1.05—1.35 mm (0.041—0.053 in) Limit: 0.85 mm (0.033 in) D Ser 6-12- Reconditioning Valve Seats 1, Renew the valve seats in the cylinder head using @ valve seat cutter. NOTE: if guides are worn (see page 6-14), replace them (see page 6-15) before cutting the valve seats. Carefully cut a 45° seat, removing only enough material to ensure a smooth and concentvic seat. Bevel the upper edge of the seat with the 30° cutter {and the lower edge of the seat with the 60° cutter Check width of seat and adjust accordingly. ‘Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cutters. Valve Seat Width Intake and exhaust Standard: 1.25—1.55 mm (0.049—0.061 in) Service Limit: 2.0 mm (0.08 in) as° 60" SEAT WIDTH: Z After resurfacing the seat, inspect for even valve seating: Apply Prussian Blue compound to the valve face, and insert valve in original location in the head, then lift it and snap it closed against the seat sever- al times, actuat SEATING Z ‘SURFACE PY vawve sear PRUSSIAN BLUE COMPOUND ‘The actual vaive seating surface, as shown by the blue compound, should be centered on the seat. © If itis too high (closer to the valve stem}, you must make a second cut with the 60° cutter to move it down, then one more cut with the 45° cutter to restore seat width. «© If itis too low (close to the valve edge), you must make a second cut with the 30° cutter to move it up, then one more cut with the 45° cutter to restore seat width. NOTE: The final eut should always be made with the 45° cutter Insert intake and exhaust valves in the head and measure valve stem installed height. Intake Valve Stem installed Height: ‘Standard (New): 39.365—39.835 mm (1.5498— 1.5683 in} Service Limit: 40.085 (1.8781 in) Exhaust Valve Stem Installed Height: ‘Standard (New): 39.165—39.635 mm (1.5419—1.5604 in} Service Limit: 39.885 mm (1.5703 in} — "? ¢ (VALVE sTEM axe HEIGHT valve stem installed height is over the service limit, replace valve anc recheck. If still over the service limit, replace cylinder head: the valve seat in the head 's too deep. 6-13Cylinder Head - Warpage NOTE: If camshatt-to-holder oil clearances (see page 6-11) are not within specification, the cylinder head can- not be resurfaced. It camshaft-to-holder oil clearances are within specifica- tons, check the cylinder head for warpage. «© 1f warpageis less than 0.05 mm (0,002 in} cylinderhead resurfacing is not required, © If warpage is between 0.05 mm (0.002 in) and 0.2 ‘mm (0.008 in), resurface cylinder head. '¢ Maximum resurface limit is 0.2.mm (0.008 in} based on ‘a height of 132.0 mm (5.20 in) PRECISION STRAIGHT EDGE Case S OC BeSeSESy I pee OU Nee Cylinder Head Height: Standard (New): 131.95~ 132,05 mm (5.195—5.199 in) Valve Guides [- Valve Movement Measure the guide-to-stem clearance with a dial indicator while rocking the stem in the direction of normal thrust {wobble method) Intake Valve Stem-to-Guide Clearance: Standard (New: 0.04—0.10 mm (0.002-0.004 in) Service Limit: 0.16 mm (0.006 in} Exhaust Valve Stem-to-Guide Clearance: ‘Stamdard (New):0.10—0.16 mm {0.004—0.006 in) 0.22 mm (0.009 in} Service Limit Valve extended 10 mm out from seat. © If measurement exceeds the service limit, recheck using a new valve. © If measurement is now within the service limit, reassemble using a new valve. © If measurement still exceeds limit, recheck using alternate method below, then replace valve and guide, if necessary, NOTE: An alternate method of checking guide to stem clearance is to subtract the 0.0. of the valve stem, measured with a micrometer, from the I.D. of the valve guide, measured with an inside microme: ter or ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measure- ment and the smallest stem measurement should not ‘exceed the service limit Intake Valve Stem-t0-Guide Clearance: Standatd (New): 0.02-0.05 mm (0.001 -0.002 in) 0.08 mm (0.003 in) Service Limit Exhaust Valve Stem-to-Guide Clearance: Standard (New): 0.05—0.08 mm {0.002-0.003 in) Service Limit: 0.11 mm (0,004 in} 6-14r- Replacement NOTE: ‘© For best results, heat cylinder head to 150 °C (300 °F} before removing or installing guides. © itmay be necessary to use an air hammer to guides. Remove some valve guides. CAUTION: To avoid burns, use heavy gloves when han: dling heated cylinder head. 1, Drive the valve guide out from the bottom of the cylinder head. VALVE GUIDE DRIVER, 6.6 mm 077420010200 2. Drive in a new valve guide to the specified depth. VALVE GUIDE DRIVER, 6.6 mm 077420010200 Valve Guide Installed Height: Intake: 13.25—13.75 mm (0.220.541 in} Exhaust: 13.75— 14.25 mm (0.541—0.561 in} VANE SUES ‘ T be - Reaming NOTE: For new valve guides only. 1. Coat both reamer and valve guide with cutting oil 2. Rotate the reamer clockwise the full length of the valve guide bore. 3. Continue to rotate the reamer clockwise while removing it from the bore. 4. Thoroughly wash the guide in detergent and water to remove any cutting residue. 5. Check clearance with a valve (see page 6-14) © Verity that the valve slides in the intake and ex- haust valve guides without exerting pressure. REAMER HANDLE Turn reamer in only VALVE GUIDE REAMER, 6.6 mm (07984—6570101 6-15Valves, Valve Springs and Valve Seals > Installation Sequence NOTE: Exhaust and intake valve seals are NOT interchangeable. Oe vasvenecens NOTE: Pace the end of valve ‘pring with elosely wound cols Toward the cylinder head, INTAKE VALVE SEAL ‘ VALVE RETAINER (WHITE SPRING) Replace VALVE SPRING VALVE SEAL INSTALLER (07GAD—PH70100 S , exaust vatve Seat teuack sonn Pepace vatve Seat eoice ‘SPRING SEAT NOTE: Install the valve spring seats before instaling the valve seals r Valve Installation ‘When installing valves in eylinder head, coat valve stems with oil before inserting into valve guides, and make sure valves move up and down smoothly. When valves and springs are in place, lightly tap the end of ‘each valve stem two or three times with a plastic mallet to ensure proper seating of vaive and valve keeprs. NOTE: Tap the valve stem only along its axis so youdo not bend the stem, STEMS 6-16Cylinder Head 1, r Installation Install the cylinder head in the reverse order of removal: NOTE: © Always use a new head gasket. '* Cylinder head and engine block surface must be clean. © “UP” marks on camshatt pulleys should be at the top. © Turn the crankshaft so the No. 1 piston is at TOC (see page 6-23). © Clean the oil contro! orifice before installing 1. Cylinder head dowel pins and oil control orifice must be aligned. cYUNDER HEAD GASKET Roplace. \ bowel rn one ‘ou conrrot oplace. Oniice Clean 2, Tighten the cylinder head bolts sequentially in three steps. Jet step torque: 40 N-m (4.0 kg-m, 29 Ib-ft) 2nd step torque: 70 Nem (7.0 kg-m. 51 Ib-ft) 3rd step torque: 100 Nem (10.0 kg-m, 72 Ib-ft) NOTE: © We recommend using a beam-type torque wrench. ‘When using a preset-type torque wrench, be sure to tighten slowly and not to overtighten. ‘© fa bolt makes any noise while you are torauing it. loosen the bolt and retighten it from the Ist step. GYLINDER HEAD BOLTS TORQUE SEQUENCE CYLINDER HEAD BOLTS 32% 1.25 mm 100 N-m (10.0 kg-m, 72 tb-t Apply engine oil bolt threads ‘and under bolt heads. (cont'd) 6-17Cylinder Head Installation (cont'd) 3. Install the intake manifold and tighten the nuts in a crisscross pattern in 2 oF 3 steps, beginning with the inner nuts. 8x1.25mm Intake 22 Nem (2.2 kgm, MANIFOLD nee 8x1.28mm 22 Nim (2.2 kom, 16H) 44, Install the exhaust manifold and bracket. Tighten the ‘nuts in a crisscross pattern in 2 or 3 steps, begin: ing with the inner nuts. asker 8x1.26mm —— Revlace 32 Nem (3.2 kom, 23 wan 22.Nim (22 kgm, 16 tot) GasKeT Replace 9 tote WEAT INSULATOR ‘SELF-LOCKING NUT 10x 1.25 mm 55 Nem (5.5 kg-m, 40 tb-tt) Replace. 12. Nem (1.2 kgm, Rocker Arms/Camshafts and Seals/Pulleys r Installation CAUTION: (¢ Make sure that the keyways on the camshatts ar ing up. (No. 1 piston TDC) © Valve locknuts should be loosened and before screws backed off before installation. © Replace the rocker arms in their fac: iginal positions. 1. Place the rocker arms on the pivot bolts and the valve stems 2. Install the camshafts and seals with the open side (spring) facing in CAMSHAFT ROCKER ARM 3. Apply liquid gasket to the head mating surfaces of the No.1 and No. 6 camshaft holdets, then install along with No. 2, 3, 4 and 5. NoTE: er or holders. {© Do not apply oil to the holder mating surface of seals. © Apply liquid gasket to the shaded areas. © The arrows marked on the camshatt holders should point toward the timing belt. me pp SE ad 1E” marks are stamped on the camshaft | rane EXHAUST cu 6-184, Tighten the camshatt holders temporarily (© Make sure that the rocker arms are properly posi tioned on the valve stems 5. Press in the seals securely, 6. Tighten each bolt in two steps to ensure that the rock ‘ers do not bind on the valves, Specified Torque: Intake 10 Nem (1.0 kg-m, 7 Ib-ft) 12 Nem (1.2 kg-m. 9 lb-ft) > INTAKE 3 9 2 Specified Torque: Exhaust Except ®,@: 10 Nem (1.0 kg-m, 7 lb-ft) ©.®: 12 Nem (1.2 kg-m, 9 lb-ft) o@ ® exaust 7. Install the back cover, 8. Install keys into camshatt grooves. NOTE: To set the camshafts at TDC position for No. 1 piston, align the holes in the camshafts with the holes in No. 1 camshaft holders and insert 5.0 mm pin driver in the holes. PIN DRIVER, 5.0 mm key (077440010800, camsHarT PULLEY 38 Nem (3.8 kg-m, 27 tb-tt) 9. Push camshaft pulleys onto camshafts, then tighten, the retaining bolts to the torque specified 10. Adjust the valve clearance (see page 6-29) 11, After installation, check that the all tubes, hoses and connectors are installed correctly 6-19Timing Belt and Timing Balancer Belt Mustrated Index NOTE ‘© Refer to page 6-23 for positioning crankshaft and pulley before installing timing belt. ‘© Before removing, mark direction of rotation on each belt. POWER STEERING (PIS) ALTERNATOR LOWER COVER: PUMP BELT BELT ADJUSTING NUT MIDDLE COVER femove the five bolts 45 Nim (6.5 kg-m, 33 b-ft 12 Nom (1-2 kof ‘cApNUT 8x 1.0mm 10 Nem (1.0 kg-m, 7 tot) CYLINDER HEAD cover 6x10 fn!” 32.Nom (1-2 wn K ™. CRANKSHAFT 9 ht) puntey sour” Puy nen —s $s 14% 1.25 mm move any oll. RUBBER SEALS £220 Nem (22.0 kgm, 159 lb-ft) Replace when demaged Apply engine ail the bol oF deteriorated threads, but not tothe 7 surface that contacts the 841.25 mm washer. 38 Nom (3.8 kg-m, 27 tht) ‘TENSIONER ‘SPRING TENSIONER. SPRING: TIMING BELT ADJUSTING BOLT 68 Nom (6.8 kg-m, 49 Ib-t) ‘Tiwi BELT Inspection, page 6.21 Adjustment, page 6-21 Replacement, page 6-24 6x 1.0mm AZ Nem (1.2 kgm, 9 tote) ‘Metall with concave ‘TIMING BALANCER BELT surface facing in Inspection, page 6-22 Remove any oil. 6-20Timing Belt - Inspection 1. Disconnect the alternator terminal and the connector then remove the engine wire harness from the cylinder head cover. 2. Remove the cylinder head cover. 3. Remove the middle cover. 4, Inspect the timing belt for cracks and oi! or coolant soaking NoTE: ‘© Replace the belt if cil or coolant soaked ‘¢ Remove any oil or solvent that gets on the belt Inspect this Rotate pulley andinspect bet 5. After inspecting, retorque the crankshaft pulley bolt to 220 Nem (22.0 kg-m, 159 lb-ft) r Tension Adjustment CAUTION: Always adjust timing belt tension with thew ‘engine cold NoTe: ‘© The tensioner is spring loaded to apply proper tension to the belt automatically after making the following ad: justment, © Always rotate the crankshaft counterclockwise when viewed from the pulley side. Rotating it clockwise may result in improper adjustment of the belt tension. © Ingpect the timing balancer bett before adjusting the belt © Donot loosen the adjusting nut mare than one full tur. 1. Disconnect the alternator terminal and the connector ‘then remove the engine wire harness from the cylinder head cover. 2. Remove the cylinder head cover. 3, Set the No. 1 piston at TOC (see page 6-23) 4. Loosen the adjusting nut 2/3-1 tun, then tighten it. ‘AQuUSTING NUT 495 Nem (4.4 kg-m, 33 to Direction of eal 5. Rotate the crankshaft counteclockwise 3-teeth on the. camshaft pulley. then reloosen the adjusting nut to create tension on the timing belt 6. Tighten the adjusting nut 7. After adjusting, retorque the crankshaft pulley bolt to 220 Nem (22.0 kg-m, 159 lb-ft). 6-21Timing Balancer Belt r Inspection 1. Disconnect the alternator terminal and the connector, then remove the engine wire harness from the cylinder head cover. 2. Remove the cylinder head cover 3. Remove the midale cover. 4. Remove the crankshaft pulley. 5. Remove the lower cover. 6. Install the crankshaft pulley. 7. Inspect the timing balancer belt for cracks and oil or coolant soaking, NOTE: ‘© Replace the belt if oil or coolant soaked, '* Remove any oil or solvent that gets on the belt. Inspect this 2109 for wea Rotate pulley ‘and inspect bel. 8. After inspecting, retorque the crankshaft pulley bolt to 220 Nem (22.0 kg-m, 189 lb-ft) NOTE: Refer to page 6-27 for timing balancer belt tension adjustment 6-22Timing Belt NOTE: ‘© Install the timing belt with the No. 1 piston at TOC. © After installing, retorque the crankshaft pulley bolt to 220 Nem (22.0 kg-m, 159 lb-ft. CRANKSHAFT TDC POSITION. ar wr: POINTERS ow Bock. INSPECTION HOLE Toc MARKS «woarTe) FLYWHEEL DRIVE PLATE Direction of rotation NOTE: When turning the crankshaft with a socket wrench, install the crankshaft pulley and the pulley bok. - Positioning Crankshaft Before Installing Timing Belt CAMSHAFT TDC POSITION: “pe MARKS ‘ToC MARKS. Align the marks fon the pulleys, PIN DRIVER, 5.0 mm (07744-0010300 CAUTION: Remove the pin driver after installing the timing belt 6-23Timing Belt and Timing Balancer Belt - Replacement CAUTION: Inspect the water pump when replacing the timing belt. NOTE: Turn the crankshaft so that the No. 1 piston is at TOC (see page 6-23) 1, Remove the splash shiel. 6x 1.0 mm 10 Nem {1.0 kg-m, Tete [SPLASH SHIELD 2. Loosen the adjusting bolt and mounting boltinut then remove the power steering (P/S} pump belt. NOTE: © Do not disconnect the P/S pipe and hose. © After installing, adjust the tension of the P/S. pump belt MOUNTING BOLT ADJUSTING 10x 1.25 mm sour 45 Nem (2.5 kgm, 4) MOUNTING NUT 8x 1.25 mm 22NemiZ2kgm, IS PUMP 16 mA BELT 3. Disconnect the alternator terminal and the connec: tor, then remove the engine wire harness from the cylinder head cover, 4. Loosen the mounting boltinut and the adjusting bolt then remove the alternator belt. NOTE: After installing, adjust the tension of the alternator belt ‘MOUNTING BOLT 10x 1.25 mm 45 Nem (4.5 kgm, 33 bt ALTERNATOR ‘CONNECTOR ALTERNATOR MOUNTING NUT TERMINAL ADJUSTING 8 x 1.25 mm soit 22Nim (2.2 kgm, 16 mr) 6-24exoo Remove the cylinder head cover. Remove the middle cover Remove the side engine mount. Remove the dipstick and the pipe. biestick/ PPE tt onc ___+ Replace. HANDLE (07AB-0010200 PULLEY HOLDER ATTACHMENT, HEX 50 mm (O7MAB—PY30100 MIDDLE COVER SOCKET WRENCH, 19 mm (07JAA—0010200 1.0mm ‘ 32 Win (12 kg | ait es ous Puuiey eour fan 128 mm 220 win (220 kor, Yeo bor0 Apply engine oto the bolt threads, but not NN, CRANKSHAFT ARLE) ‘ADJUSTING NUT Remove any oil, 10x 1.26 mm 45 Nem 18.5 kam. 33 tet) 9. Remove the pulley bolt and the crankshaft pulley. Remove the two rear bolts from the center beam to allow the engine to drop down and give clearance to remove the lower cover. 10. Remove the rubber seal around the adjusting nut. Do not loosen the adjusting nut. 11. Remove the lower caver 12x 1.25 mm 55 Nem (5.5 kam. 40-0 CYLINDER HEAD CovER 12.01.25 mm 65 Wm (6.5 kom, 47 etn) RUBBER SEALS Replace when damaged or Setenorated, RUBBER SEALS Replace when damaged or Seterirated. TIMING BELT Inspection, page 6.21 ‘Adjusting, page 6.21 © 1.0 mm $2nim (112 kgm, TIMING BALANCER BELT ott Inspection, page 6-22 tcont'd) 6-25Timing Belt and Timing Balancer Belt r Replacement (cont'd) 12, Lock the timing belt adjuster arm in place by install ing one of the 6 x 1.0 mm lower cover mounting bolts, 13, Loosen the timing belt adjusting nut. Push on the pul ley to remove tension from the timing balancer belt, then tighten the adjusting nut, 14, Remove the timing balancer belt NOTE: If you are removing only the timing balancer belt, go to step 20. If you are removing both belts, Continue with this procedure. ‘TIMING BELT ‘ADJUSTER ARM [ADJUSTING NUT Lock with 8x 1.0 mm, bolt. DRIVE PULLEY OF ‘ADJUSTER 495 Nem (4.6 kgm, 33 lb-ft) by TIMING BALANCER BELT 15. Loosen 6 x 1.0 mm lock bolt and the adjusting nut Push on the timing belt adjuster pulley to remove ten- sion from the belt, then tighten the adjusting nut. 16. Remove the timing belt 117. Install the timing belt in the reverse order of removal — Before installing the timing belt, position the crank shaft and camshaft pulleys a5 shown on page 6-23, 18. Perform the timing belt tension adjustment (see page 6-21) 19. Tighten the 6 x 1,0 mm bolt to lock the timing belt ad juster arm, TIMING BALANCER BELT DUSTER20. Make sure the crankshaft is positioned with the No. 1 piston at TOC. 21. Align the groove on the front balancer shaft pulley with the pointer on the oll pump housing as shown. 22. Align the rear timing balancer belt driven pulley by inserting the special too! through the maintenance hole. 23. Loosen the adjusting nut and verify that the timing balancer belt adjuster moves freely. 24. Install the timing balancer belt REAR BALANCER SHAFT BALANCER, SHAFT LOCK PIN o7LaG—PT20100 Lock with Gx 1.0 mm FRONT TIMING BALANCER BELT DRIVEN PULLEY Align the groove of the front driven pulley with the pointer on the ol TIMING BELT ADJUSTMENT 25, Turn the crankshaft pulley about one turn counter clockwise, then tighten the adjusting nut to the specified torque. NOTE: Both belt adjusters are spring-loaded to properly tension the belts. Do not apply any extra pressure to the pulleys or tensioners while perform- ing the adjustment REAR BALANCER SHAFT MAINTENANCE HOLE WASHER. Replace. BALANCER SHAFT LOCK PIN O7LAG~PT20100 12 mm SEALING BOLT 30 Nem (8.0 kgem, 22 tbett) NOTE: Tighten the bott after instaling the belt ADJUSTING NUT REAR TIMING BALANCER BELT DRIVEN PULLEY TIMING BALANCER BELT DRIVE PULLEY Set the crankshaft at ToC. (cont’s) 6-27Timing Belt and Timing Balancer Belt r Replacement (cont‘d) 26. Remove the 6 x 1.0 mm bolt from the timing belt 30. Install the middle cover. adjuster arm. 31. Install the crankshaft pulley. 27. Remove the crankshaft pulley. 32. Coat the threads and seating face of the pulley bolt with engine oil. Install and tighten to the specified torque. 28. Install the lower cover. 29. Install @ rubber seal around the adjusting nut, Do not loosen the nut. Specified torque: 220 N-m (22.0 kg-m, 169 tot) RUBBER SEALS Replace when damaged oF deteriorated MIDDLE CovER 6x 1.0 mm ; 12 Nem (1.2 kgm, , ey olds NE PULLEY BOLT tax 125mm * 220 Nim (220 kgm, ERA iso mm Apby engine ci tothe Saree Sant we 1 the surface that om contacts the washer SE” towen coven CRANKSHAFT Se 1.0 wm PULLEY, ADJUSTING NUT 32 Nem (1.2 kgm, Remove any oil alo 9 Mbt) aShemies tom, 33m PULLEY HOLDER ATTACHMENT, HEX 50 mm ‘O7MABPY30100 SOCKET WRENCH, 19 mm ‘07JAA~0010200 6-28Valve Clearance WTAKE Nod No.3 No.2 Not exnausT 2. SetNo. 1 piston at TDC. "UP" marks on the camshaft pulleys should be at tap, and TOC grooves on the cam: shaft pulleys should align with cylinder head surface. Number 1 piston at TDC: “UP MARKS ‘TOC MARKS Align the marks fon the pulleys r Adjustment Note: 3. Adjust valves on No. 1 cylinder > Valves should be adjustad cold when the evlinder head Temperature is loss than 38°C (100°F). Vole Clearance: 1 After adjusting, retorque the crankshaft pulley bolt to Intake; 0,070.11 mm (0,003~0.004 in) 220 Nim (22.0 kgm, 159 1b Exhaust: 0.15—0.19 mm (0.006~0.007 in} 1. Remove the eyinder head cover 44, Loosen locknut and turn adjusting serew until feeter 5, ‘gauge slides back and forth with slight amount of drag Locknuy 27 Nem (2.7 kg-m, 20 Ib) ‘Apply engine ot apuustine screw Tighten the locknut and check clearance again. Repeat adjustment if necessary FEELER GAUGE (cont'd) 6-29Valve Clearance r Adjustment (cont'd) "UP" MARKS: 6-30Engine Block Mlustrated Index .. . Cylinder Block Bore Honing Piston Rings * Alignment [ Outline of Model Change. $$ a aa +_The 1239 engine type hes been added |Illustrated Index 6x 10mm 12 Nm (1.2 kgm, 9 Io-F) o1L PAN, ow scrEEN 6x 10mm GASKET Yeti (12 kom, 9 of Replace. 641.0 mm rom 112 kgm, sib asker Replace. BAFFLE PLATE BEARING CAP 111.25 mm ae 175 Nem (7.5 ko-m, 54 tot) Apply engine oi tothe bok threads, NOTE: After torquing each cap, turn crankshatt te check for binding. DoweL Pin 1241.0 mm ae" Nem (75 kg-m, 64 tot) \e WASHER * TORQUE CONVERTER cover (A/T) Dowel Pins DRIVE PLATE (A/T) Check for eracks cLutcH cover arn 6x1.0 mm Yoni 12 kgm, stb CYLINDER BLock FLYWHEEL (MT) 12410mm 105 Nem [105 kom, 76 bf}7B] Lubricate alt internal pars with engine oll during reassembly. NoTE: ‘© Apply liquid gasket to the mating surfaces of the right side cover and oil pump housing before installing them (MAIN BEARINGS. ‘© Use liquid gasket, part No. 0740 - 99986. NOTE: New main bearings must be selected by matening rank and block identification markings, (CRANKSHAFT ‘THRUST WASHERS Grooved sides face outward NOTE: Thrust washer thickness Is fixed and must not be changes nding chem Ww BALANCER SHAFT REAR BALANCER SHAFT eet) RETAINER NOTE: Retainer {thickness is fixed tnd must not be Ehanged by grinding orahimming. FRONT BALANCER SHAFT CRANKSHAFT OL SEAL 6x1.0mm 20 Nm (20 kgm, fait 6x 1.0mm 12 Nem (12 kom, 9 tt) Apply liquid gasket alk mace Ss ima sioe coven Ropes SEAL Jogi CAR fos eee aoaees ; EN ores someon BALANCER DRIVEN 8 A RS ed e 8x125 mm patron ee Sor tc gett aan « oes bitten og? sete erie en extomm Saeed Hes aaron Be add get oreo Eien reer leone DRIVEN PULLEY Replece. 7-3Illustrated Index (cont'd) 7B Lubricate alt internal parts with engine cil during reassembly, PISTON INSTALLATION DIRECTION NOTE: New rod bearings must be selected by matching connecting rod and erankshatt identification markings exnaust AQOS Piston nines [ we SE, Alignment, page 7-6 >| INTAKE ston NOTE: To maincain proper clearance, ‘match the letter an the piston fop with the leter for each evinger stamped on the black On the piston top On the block No letter ‘aor! eo Bort mston pnt —__ ¢-——) eS CYLINDER BLOCK ‘Cylinder bore honing. page 7:5 Inspect top of eacn cylinder bore for carbon build-up ar ndge betore ‘CONNECTING ROD BEARINGS ‘CONNECTING ROD BEARING CAP NOTE: Insta eap so the bearing recess is fon the same side as the recess in the od, CYLINDER BoRE sizes. (orl, Borah NOTE! To maintain proper piston clearance, match thess leters with the leters on the pistons. The letters, CONNECTING ROD NUT ame Dock read at oh 9x075 mm SS. fo. Through No. t cylinders, 47 Nem (8.7 kgm, 34 Ub @ One biock On the piston top Aer torquing each bearing cap, or No letter rotate crankshaft to check for Bore binging, 7-4Cylinder Block b=] [- Bore Honing CAUTION: This cylinder uses FRM (Fiber Reinforced Metal). Hone only as directed below. 1. Measure cylinder bores, if the block is to be reused, hone the cylinders and remeasure the bores. 2. To hone cylinder bores: ‘© Use only a rigid hone '* Honing stone: GC - 600 J or finer stone (for nonferrous metals) © Pressure: 200 - 300 kPa (2-3 kg/om?, 28-43 psi) ‘© Honing rem: 45-50 rpm © Honing thickness: Less than 0.02 mm (0.0008 in) Do not hone more than 20 cycles © Honing lubricant: Oil type © Roughness of finished surfaces: VVV or 1.28 '* Honing pattern: 60 degree cross-hatch CAUTION: Clean the honing stone every 5 cycles. When honing is complete, thoroughly clean the cylinder block of all metal particles. Wash the cylin- der bores with hot soapy water, then dry and oil immediately to prevent rusting, NOTE: Never use solvent, it will only redistribute the grit on the cylinder walls. If scoring or scratches are still present in cylinder bores after horning to service limit, rebore the eylin- der block. NOTE: Some light vertical scoring and scratching is acceptable if itis not deep enough to catch your fin gerail and does not run the full length of the bore. CYLINDER BLOCK CYLINDER HONE 7-5Piston Rings r Alignment 1. Install the rings as shown, Identify top and second rings by the chamfer on the edge. Make sure they are in their proper grooves on the piston NOTE: The manufacturing marks must be facing SECOND RING 2. Rotate the rings in their grooves to make sure they do not bind. ~ Sas “ 3. Position the ring end gaps as shown: DO NOT position any ring 938 ‘at piston thrust surfaces, Q ‘SECOND RING GAP Approx. 90: onan ps no) GAP ‘Tor RING GAP pranen can DO NOT position any ring gap inline with the piston pin hale. OIL RING GAP 7-6Engine Lubrication Special Tools .. Mlustrated Index .... Oil Filter Replacement ... Oil Pressure Testing ... - 8-2 [ Outline of Model Change, $$ _________, +The H23A3 engine type has been added |Special Tools fut-tio. | __TaotNumber Deseption ae ® | eraoe-oosc000 | oi Pressure Gave Adenter ealge @ 07506 - 3000000 Oil Pressure Gauge Set 1 87 S| grvzsencco | ontmerwranen faded 3 cee ASIA Pur 76 ulesIllustrated Index NOTE: ‘Use new O-rings when reassembling © Apply oil to O-rings before installation. ‘© Use liquid gasket, Part No. 0740 — 98886, © Clean the oil control orifice before installing ow pump ‘Apply iquid gesket to block mating surface. o-nincs Reploce. CAUTION: Do not overtighten the drain bolt 8x 125mm Turust 25Nmi2Z5kg-m, 18 bt) WASHER, FRONT TIMING BALANCER BELT DRIVEN PULLEY _ = S OIL CONTROL ORIFICE BOS Sten 8125 mm \\e , Sonim Gobo, ‘ne zn A 5 a Replce BALANCER, KNOCK SENSOR GEAR CASE 32.Nem (3.2 kg-m, 23 Ibe) 841.25 mm 28. (2.5 kgm, 18 bt) O-RING bowel pin’ ENGINE OIL PRESSURE _ 7 SWITCH A TEN m 1.8 kg-m, 13 bt) GasKer Y Replace Ol SCREEN 6x 10mm Y2Nm (12 kom. 9 Ib tee Replace, TaN (1.2 kg-m, 9 1b-F RAIN BOLT 14x15 mm 45 Nim 5 kg-m, 33 tot Donat overtighten, onan wasterOil Filter r- Replacement JAPAN-MADE ‘© After the engine has been run, the exhaust pipe will be hot: be careful when working around the exhaust pipe. ‘+ Be careful when loosening the drain bolt while the engine is hot. Burns can result because the oil tem- perature is very high. filter: 1. Remove the oil filter with the special oil filter wreneh, 2. Inspect the threads and rubber seal on the now fil- ter. Wipe off seat on engine block, then apply a light coat of oil to the filter rubber seal. NOTE: Use only filters with a built-in bypass sys- ‘Apply oil rubber seat before installing. exoneort rubber seal surface COOLER 3. Install the oil filter by hand, 4. After the rubber seal seats, tighten the oil filter clockwise with the special too! ighten: 7/8 turn clockwise ightening torque: 22 Nem (2.2 kg-m, 16 lb-ft) CAUTION: Installation using other than the above procedure could result in serious engine damage due to oil leakage. ENGINE Olt COOLER OL FILTER WRENCH ‘79126110001 8-4be Eight numbers (1 to 8) are printed on the surface of the fiter. The ters using these numbers. v 2 Number when rubber following explains the procedure for tightening fil Make 2 mark on the engine oil cooler under the umber that shows at the bottom of the filter when the rubber seal is seated, Tighten the filter by turning it clockwise seven num- bers from the marked point. For example, if a mark is made under the number 2 when the rubber seal is seated, the filter should be tightened until the number 1:comes up to the marked point. 778 tuen clockwise Number when rubber T al ig seated I Number attertightoning |8/1/2/3|4]/5|6|7 s. After installation, fill the engine with oll up to the specified level, run the engine for more than 3 min- tutes, then check for oil leakage. FRANCE-MADE oil filter: ‘After the engine has been run, the exhaust pipe will be hot: be careful when working around the exhaust pipe. ‘© Be careful when loosening the drain bolt while the engine is hot. Burns can result because the oil tem- perature is very high 1, Remove the oil filter with the special oil filter wrench 2. Inspect the threads and rubber seal on the now fil ter, Wipe off seat on engine block, then apply a light coat of oil to the filter rubber seal NOTE: Use only filters with 2 built-in bypass sys- ENGINE on, COOLER. ‘Apply oll to rubber sea! tore installing, Inspect tnreads and ‘rubber seal surface. (cont'd) 8-5Oil 3 4 Filter Instat the oil filter by hand. After the rubber seal seats, tighten the oil filter clockwise with the special too! Tighten: three quarter turn clockwise, Tightening torque: 22 Nem (2.2 kg-m, 16 Ib-ft) CAUTION: installation using other than the above procedure could result in serious engine damage due to oll leakage. ENGINE OWL COOLER RABINAL-Purtlox 78 -- Replacement (cont?) ADP Four numbers (1 to 4) are printed on the surface of the fiter. The following explains the procedure for tightening fi ters using these numbers. 1) Make @ mark on the engine oil cooler under the umber that shows at the bottom of the filter when the rubber seal is seated 2). Tighten the filter by turning it clockwise three num- bers from the marked point. For example, if @ mark is made under the number 2 when the rubber seal is seated, the filter should be tightened until the umber 1 comes up to the marked point. Number when eubber seal ie seated Number atter tightening T Number when rubber seal isseated | 1] 2] 3 | 4 Number after tightening alrlefa 5. After installation, fill the engine with oll up to the specified level, run the engine for more than 3 min: utes, then check for oil leakage. 8-6Oil Pressure [- Testing If the oil pressure warning light stays on with the engine running, check the engine oi level. Ifthe oil level is cor rect 1. Connect a tachometer. 2. Remove the engine oil pressure switch and install anol pressure gauge. 3. Start the engine. Shut it off immediately if the gauge registers no oll pressure, Repair the problem before continuing. 4. Allow the engine to reach operating temperature (fan comes on at least twice). The pressure should be: Engine Oil Tempe: Engine Oil Pressure: ture: 80°C (176°F) Atidle: 70 kPa (0.7 kg/em?, 10 psi) At 3,000 rpm: 350 kPa (3.5 kg/em:, 50 psil # Ifoil pressure is within specifications, replace the oll pressure switch and recheck. # I oil pressure is NOT within specifications, inspect the oil pump. O1L PRESSURE GAUGE SET ENGINE ONL COOLER 07508 ~ 3000000 (lL PRESSURE ‘GAUGE ADAPTER ‘07406 ~ 0930000, ENGINE OIL PRESSURE ‘SWITCH MOUNTING HOLEIntake Manifold/Exhaust System Intake Manifold Replacement . Exhaust Manifold Replacement ... Exhaust Pipe and Muffler Replacement ... Outline of Model ChangeIntake Manifold p Replacement NOTE: Use new O-rings and gaskets when reassembling. ‘CAUTION: © Check for folds or scratches on the surface of the gasket, © Replace with a new gasket if damaged. 8x 1.25 mm 22 Nem (2.2 kg-m, 16 tb-tt) STARTING AIR VALVE O-RING 6x 1.0 mm Replace. 12 Nem (1.2 kom, 9 ttt) INTAKE MANIFOLD CHAMBER Replace if cracked or IDLE AIR CONTROL if mating surfaces are 9 wae) VALVE damaged. @ x 1.25 mm o-nina. 22 Nem (2.2 kg-m, 16 Ib-tt) ore Cun 108 VALVE ACTUATOR THROTTLE BODY o-nines. Replace, asker Replace. FAST IDLE INTAKE AIR BYPASS cea (ap) VALVE Replace if cracked or if mating surfaces are damaged. ext 4.0 mm 2 Nem (1.2 kgm, 8 Ib-ft) <2? N GASKET exnausy cas Weaeaatune 0 } secnebLAion (IAT) SENSOR ZO 2 f " one Ponte. INTAKE MAKIFOLD Replace if cracked or it'mating surfaces are Gamaged Nv ® : : Batam, 16 wee S GASKET & . 8x 025 mm 22 nim 22 kg-m, 16 bet) 8x 1.25 mm 2 5 22 Nem (2.2 kgm, 16 Ib) ———~ rake maniroLo eracker 9-2Exhaust Manifold - Replacement NOTE: Use new gaskets and self-locking nuts when reassembling cauTion: ‘© Check for folds or scratches on the surface of the gasket. © Replace with @ new gasket if damaged. SELF-LOCKING NUT Bx 125mm 32 Nem (3.2 kg-m, 23 Ib-tt) casket Replace. Replace. 1.25 mm 22 Nem (2.2 ko-m, 16 lb-ft EXHAUST MANIFOLD. BRACKET 10x 1.25 mm 2 \ 45 Nem (4.5 kom. 39 lb-ft) casKers, J: S88 1.25 mm Replace. S) 22 Nem (2.2 kgm, 16 tb) cover Cover 10x 1.25 mm 45 Nem (4.5 kg-m, 33 lb-ft) 6x 1.0 mm exnaust Are A 12 Nem (1-2 kgm, 9 Ib-f SELF-LOCKING NUT eI 10x 1.25 mm 5 55 Nem (5.5 kam, 40 lb-ft) 9-3Exhaust Pipe and Muffler r Replacement NOTE: Use new gaskets and self-locking nuts when reassembling. HEAT SHIELD 6x1.0 mm 10 Nem (1.0 kgm, 7 Ib-tt) MUFFLER EXHAUST PIFE TIPS 6x 1.0mm es SELF-LOCKING NUT 10x 1.26 mm 58 Nem (5.5 kg-m, 40 tb-tt THREE WAY CATALYTIC Replace. CONVERTER (TW) ~ ‘TORQUE SEQUENCE ~ SELF-LOCKING NUT 30 x 1.25 mm 38 Nem (3.4 kom, 25-10 asker EXHAUST PIPE 6 asker Replace. casket 6.0mm JO Nim (1.0 kom Tes SELF-LOCKING NUTS Bx 1.25 mm 18 Nem (1.8 kg-m, 13 Ib-f) Replace. Gaskets = Replace. SELF-LOCKING NUT 10x 1.25 mm 34 Nem (3.4 kgm, 25 tb-ft) Replace, SELF-LOCKING NUT 10x 1.25 mm 55 Nem (5.5 kg-m, 40 tbr) Replace EXHAUST PIPE A HEATED OXYGEN ‘SENSOR (HO25) 9-4Cooling Radiator Illustrated Index ... . 10-2 Water Pump Illustrated Index .. . 10-4 tine of Mode Change Atta eeeRadiator Illustrated Index FERED system is under high pressure when engine ts hot. To avoid danger of relessing scalding engine coolant, remove cap only when engine fe cold. Total Cooling System Capacity (Including heater and MIT: 7.0 £ (7.4 US at. 6.2 Imp at) A/T: 6.9 € (7.3 US at. 6.1 Imp at) Reservoir capacity: 0.6 ¢ (0.6 US at. 0.5 Imp at) UPPER RADIATOR HOSE 61.0 mm 10 Nem (1.0 kg-m, Tid 6 «1.0 mm 30 Nem (1.0 kgm, ‘ATE COOLER Tio HOSES (aT) FAN SHROUD 10-2 DRAW PLUG o NSS ~e TSO Fp. RO Sone 5 yom 4.5 Nem (0.85 kg-m. CAUTION: When pouring engine coolant. be sure to shut the relay box lid and not to let coolant spill on the electrical parts or the paint. If any coolant spills, rinse it off immediately NOTE: © Check all cooling system hoses for damage, leaks ‘or deterioration and replace if necessary. © Check all hose clamps and retighten if necessary. © Use new O-rings when reassembling RADIATOR Inspect soldered joints and ‘seams for leaks. Blow out dirt from between core fins with compressed sir. Winseets, etc, are clogaing radiator. wash them off with low pressure water RADIATOR CAP. @, o-nine 3.3 ete) Repiace. COOLANT RESERVOIR Lower RADIATOR HOSE IM/T: Manual transmission AIT: Automatic transmission ATE: Automatic transmission fluidEngine Hose Connections: POSITIVE CRANKCASE VENTILATION (PCV) PIPE IDLE AIR CONTROL, aac vatve FAST IDLE THERMO VALVE BYPASS HOSES Ed ir Pee ENGINE OIL COOLER HEATER INLET BYPASS HOSE Hose O-RING Replace. Heater ouTLeT HOSE 10-3Water Pump Mlustrated Index NOTE: Use new O-rings when reassembling. WATER OUTLET HOUSING, O-RING Replace. ENGINE COOLANT ‘TEMPERATURE (ECT) SENSOR 18 Nem (1.8 kgm. 13m 8 x 1.25 mm 22 Nem (2.2 kg-m, 16 wn) ECT GAUGE SENDING. UNIT 9. Nem (0.9 kg-m, 7 tb-) O-RING ECT SWITCH 8 24 Nem (2.4 kg-m, 17 Ib-te) ECT swiTcH A 28 Nem (2.8 kg-m, 20 t-te) BLEED BOLT 10x 1.25 mm 30 Nem (1.0 kg. 7 ite RINGS Replace. 58.01.25 mm 22.Nm (2.2 kg-m, 16 wy WATER PUMP o-niNes CONNECTING PIPE Replace. ‘=: CORROSION RESISTANT BOLT 10-4Fuel and Emissions Special Tools 11-2 Component Locations. Index 11.3 ‘System Description Vacuum Connections .. Electrical Connections Troubleshooting 11-4 11-6 Troubleshooting Guide 18 PGM-FI System System Description 11-10, Troubleshooting Flowcharts. Heated Oxygen Sensor ante Heated Oxygen Sensor Heater .. Fuel Supply System .. Top Dead Center/Crankshaft Position/ Cylinder Position Sensor Ignition Output Signal 114 11-18 11-20 11-22 Outline of Model Changes Idle Control System System Troubleshooting Guide System Description Starting Air Valve Fast Idle Thermo Vaive Intake Air System System Troubleshooting Guide System Description Throttle Body ... Intake Air Bypass (IAB) Control System Intake Air Control System ‘The H23A3 engine has been added, Compare to F20Z1, F2022 engine main differences are: Vacuum Connections Electrical Connections Heated Oxygen Sensor (HO2S) Top Dead Center/Crankshaft Position/Cylinder Position (TOCICKP/CYP) Sensor Starting Air Vaive Fast Idle Thermo Valve Throttle Body Intake Air Bypass (IAB) Control System Intake Air Control SystemSpecial Tools ret.Ne. | Tool Number ow Remarks o G7LAA = PTs0107 | Oxyaun Seoor Soaks Wrench ; 8 crentonetoco.__| bigs rear fener i ° @ 11-2Component Locations Index EXHAUST GAS RECIRCULATION (EGR) VALVE LIFT SENSOR EXHAUST GAS RECIRCULATION (EGR) VALVE FAST IDLE THERMO VALVE inspection, page 11-28 conTRoL Box THROTTLE POSITION (TP) SENSOR TOP DEAD CENTER/CRANKSHAFT POSITION/CYLINDER POSITION (TDC/CKP/CYP) ‘SENSOR Troubleshooting, page 11:20 ‘STARTING AIR VALVE Deseription, page 11-28 wraKe ain yess ae) IGhmioN conTROL MODULE Hem Semtng:page trae Troubleshooting, page 11-22, INJECTOR RESISTER wwTaKe AiR CONTROL ‘SOLENOID VALVE Troubleshooting, page 11-39) INTAKE ai CONTROL, DIAPHRAGM Troubleshooting, pege 11539 INTAKE AIR TEMPERATURE (IAT) SENSOR IDLE AIR CONTROL (IACI VALVE INTAKE AIR BYPASS, (Wa) CONTROL ‘SOLENOID VALVE Troubleshooting, page 11-34 HEATED OXYGEN SENSOR |HO?S) Troubleshooting, page 11-12 ENGINE COOLANT TEMPERATURE (ECT) SENSOR 11-3System Description Vacuum Conneetionss» AAA S$ ‘CONTROL Box exHaust Gas RECIRCULATION (EGR) Vatve LT SENSOR To EVAPORATIVE EMISSION (EVAP) ‘TWO WAY VALVE. STARTING AIR VALVE men Eegnane wou, ag sae eoaa vara an ean rn erase sone (eGR) VALVE INTAKE ain BYPASS (WA) CONTROL SOLENOID VALVE exaust cas RECIRCULATION FRONT OF VEHICLE FUEL PRESSURE REGULATOR INTAKE AIR CONTROL DIAPHRAGM 11-49 1aG006 a 2OS920 HEATED OXYGEN SENSOR (Ho2s) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR INTAKE AIR TEMPERATURE (IAT) SENSOR, IDLE AIR CONTROL {tAC) VALVE. IDLE ADJUSTING SCREW FAST IDLE THERMO VALVE STARTING AIR VALVE FUEL INJECTOR FUEL FILTER FUEL PRESSURE REGULATOR FUEL PUMP FUEL TANK ‘AIR CLEANER INTAKE AIR BYPASS (IAB) CONTROL DIAPHRAGM INTAKE AIR BYPASS (IAB] CONTROL SOLENOID VALVE INTAKE AIR BYPASS IAB} VACUUM TANK INTAKE AIR BYPASS (IAB) CHECK VALVE Se & seegEENeS 8 INTAKE AIR CONTROL DIAPHRAGM INTAKE AIR CONTROL SOLENOID VALVE INTAKE AIR CONTROL VACUUM TANK INTAKE AIR CONTROL CHECK VALVE ‘THREE WAY CATALYTIC CONVERTER (TWC} POSITIVE CRANKCASE VENTILATION (PCV) VALVE EXHAUST GAS RECIRCULATION (EGR) VALVE EXHAUST GAS RECIRCULATION (EGR) VALVE LIFT SENSOR EXHAUST GAS RECIRCULATION (EGR) VACUUM CONTROL VALVE EXHAUST GAS RECIRCULATION [EGRI CONTROL SOLENOID VALVE EVAPORATIVE EMISSION (EVAP) CONTROL CANISTER EVAPORATIVE EMISSION (EVAP) PURGE CONTROL SOLENOID EVAPORATIVE EMISSION (EVAP) PURGE CONTROL DIAPHRAGM VALVE. EVAPORATIVE EMISSION (EVAP] TWO WAY VALVE FUEL TANK EVAPORATIVE EMISSION (EVAP) VALVE 11-5System Description Electrical Connections venTia swircH UKE only) PGM-FIMAIN RELAY B2 G2 | é roetimuecrons ||| | a Tew PT at pono t son! B12 CYP M| ina as? Some on Barer mate ree ||| SENSOR Bis TOC M| inva az gee $ {| car Bis KP P wuector | || | ‘SENSOR| Bie CKP M) RESISTOR | AC VALVE. | | || ‘ ares vss Hi} &| rat ee ne sen eg a aE ean SE cron ae STATE PN z i N ‘ Fuses GAUGE ASSEMBLY @ BACK UP (RADION (75 AI : @ BATTERY (s0.A)" AITGEAR i @ IGN Sw iso ale POSITION, H @ EcuVEcM) (10 A SWITCH i @ No.2 (ECU, ECM (15.4) @ No.8 (TURN SIGNALS) (10 41 @ No.9 (A/C CLUTCH RELAY! (7.5 A) @ No. 12 (STARTER SIGNAL) (7.5 8) rin the under nad fuserrelay bow 11-6sensor | fe ons | co ty ‘om fave eam” SENSOR As 0n5 TE Yo NoT USED }o. -GR CONTROL SOLENOID VALVE {INTAKE AiR CONTROL SOLENOID VALVE Stab conTROL SOLENOID VALVE [VAP PURGE CONTROL SOLENOIO VALVE ON Od00000000000 000000000000 ‘00000000 29000000 0055 Go000000000 0000000000 TERMINAL LOCATIONS 11-7Troubleshooting Troubleshooting Guide At$pN$Ymij NOTE: Across each row in the char, the systems that could be sources of a symptom are ranked in the order they should be inspected starting with ©. Find the symptom in the left column, read across to the most likely source, then reter re ihe Page listed at the top of that column. If inspection shows the system is OK, try the next most likely system @, ete Pace vere Gr sro] FOPCEAD CENTER| ENGINE Trace an] eanowe syons | seareo nero ahacousr "| coder | mmorna [STARE A] PROM Govtmo. | oxyaen |-ReCUTE|“rosmow | Tewrens|posmon | TEMPERA | TC woouie | sensor [FSERSMRE] | crunoes |"srune | senson | ,fuae. [raessun {rosmionsenson| stuson sywerom =a T= 1120 MALFUNCTION INDICATOR awe ta TURNS ON MALFUNCTION iNDIeATOR Uinta aun Secen sernean ® ® orrcuLT 0 staRT t ENGINE wien COLD ® ® ® ® wren COLD — - FAST IDLE OUT | oreree } noucH inte ® | InREGULAR . is "Dune Tae wana Bene oe | Soman Wien WAR enters | @ soo tow wane | wants uP erequent . STALLING aeren | Warmuncur | @ ® TaSARE OR Roush @ RUNNIN | | roon rans PERFORM. | EMISSION ® @®@ ance | eer oss or rowen |. ® @ | | | * MW eodes other those listed above are indicated, count the number of blinks again. ifthe MIL isin fact blinking these codes, replace the ECM. If the MIL is on while the engine is running, jump the service check connector. if no code is displayed (MIL stays on steady), the back-up system ig in operation. Substitute a known-good ECM and recheck. Ifthe indication goes away, replace the original ECM. 11-8EMISSION CONTROL jon contro | EMISSION. contre oven 8| ©} e|9 @| ©| Oe}PGM-FI System -- System Description PUT ENGINE CONTROL MODULE (ECM) outputs | TOCIKPICYP Sensors ~~ — |] | Fuet injectors | ECT Sensor ML | IAC Valve | IAT Sensor TP Sensor Ho2s. Fuel injector Timing and Duration | vss BARO Sensor (Tale Air Conver) EGR Valve Lift Sensor Starter Signal ALTFR Signal ———— Air Conditioning Signal Gition Timing Conver | i Gear Position Signal | re | Battery Voltage (IGN. 1) ECM Back-up Func ‘AIC Compressor Clutch Relay cm HO2S Heater EVAP Purge Control Solenoid Valve EGR Control Solenoid Valve Intake Air Control Solenoid Valve IAB Control Solenoid Valve PGM-FI System ‘The PGM-FI system on this model is @ sequential multiport fuel injection system, Fuel injector Timing and Duration The ECM contains memories for the basic discharge durations at various engine speeds and manifold pressures. The basic discharge duration, after being read out from the memary, is further modified by signals sent from various sensors {0 obtain the final discharge duration Idle Air Control Idle Air Control Valve (IAC Valve) Wher the engine is cold, the A/C compressor is on, the transmission is in gear (A/T only) oF the alternator (ALT) ie charg ing, the ECM controls current to the IAC valve to maintain correct idle speed. Ignition Timing Control The ECM contains memories for basic ignition timing at various engine speeds and manifold pressures. Ignition timing is also adjusted for engine coolant temperature, Other Control Functions 1. Starting Control! When the engine is started, the ECM provides a rich mixture by increasing fuel injector duration. 2. Fuel Pump Control ‘© When the ignition switch is initially turned on, the ECM supplies ground to the PGM-FI main relay that supplies current to the fuel pump for two seconds to pressurize the fuel system. '* When the engine is running, the ECM supplies ground to the PGM-Fi main relay that supplies current to the fuel pump. When the engine is not running and the ignition is on, the ECM cuts ground to the PGM-Fl main relay which cuts current to the fuel pump, 11-10i Eom Fi Fuel Cut-off Controt # During deceleration with the throttle valve closed, current to the fuel injectors is cut off to improve fuel economy at speeds over 1,500 min-* (rpm. ‘© Fuel cut-off action also takes place when engine speed exceeds, 6,800 min” (rpm) regardless of the position of the throttle valve to protect the engine from over ‘AIC Compressor Clutch Relay ‘When the ECM receives a demand for cooling from the air conditioning system, it delays the compressor from being energized, and enriches the mixture to assure smooth transition to the A/C mode. Intake Air Control Solenoid Valve ‘When the engine speed is below 3,900 min” (rpm!, the ECM supplies a ground to the intake air contro! solenoid valve. ‘This opens the solenoid valve sending intake manifold vacuum to the intake air control diaphragm. Intake Air Bypass (IAB) Control Solenoid Valve When the engine speed is below 4,800 min’ (rpm) the IAB control solenoid valve is activated by a signal from the ECM, intake air flows through the long intake path, then high torque is delivered. At speeds higher than 4,800 min” (rpm), the solenoid valve is deactivated by the ECM, and intake air flows through the short intake path in order to reduce the resistance in airflow. Evaporative Emission (EVAP) Purge Control Solenoid Valve When the engine coolant temperature is below 167°F (75°C), the ECM supplies @ ground to the EVAP purge control solenoid valve which cuts vacuum to the EVAP purge control diaphragm valve, Exhaust Gas Recirculation (EGR) Control Solenoid Vaive When the EGR is required for control of oxides of nitrogen (NOx) emissions, the ECM supplies ground to the EGR control solenoid valve which supplies regulated vacuum to the EGR valve. ssafe/Back-up Functions fail-safe Function When an abnormality occurs in @ signal from a sensor, the ECM ignores that signal and assumes a pre. value for that sensor that allows the engine to continue to run. rogrammed Back-up Function When an abnormality occurs in the ECM itself, the fuel injectors are controlled by a back-up circuit independent of the system in order to permit minimal driving. Self-diagnosis Function [Maifunction Indicator Lamp (MILI When an abnormality occurs in a signal from a sensor, the ECM lights the MIL and stores the Diagnostic Trouble Code (DTC) in erasable memory. When the ignition is initially turned on, the ECM supplies ground for the MIL. for two seconds to check MIL bulb condition. 11-11PGM-FI System nearer AES: IE Motes Oxygen Sener oss) cieut PROTECTION ZIRCONIA HEATER TUBE ELEMENT TERMINALS , TERMINALS 4 = The MIL has been repor — With service check connector jumped, code Tis indicated ————_________ [Bethe cM Reset Procedure. | Warm up engine to normal oper ating temperature (the radiator fan comes-on) Road test withthe automatic rane: ‘mission in @) position (Mit: ath ‘gear Starting at 1.600 min pm, 8e- celerate using wide open throttle for at east 5 seconds, Then dece- lerate for st least 8 seconds with the throwle completely closed. | Lemme peter eee ene ves a Go to page 11-18 and perform Intermittent failure, system is OK | Is the Mil. on and does NO_| at this time. Check for poor ton | ingicate code 1? nections or loose wires between, [- Troubleshooting Flowchart — Heated Oxygen Sensor (HO2S) voUTaGE (wv) The Malfunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (DTC) 1: A problem in the ‘The heated oxygen sensor detects the oxygen content in the exhaust gas and signals the ECM. In operation, the ECM receives the signals from the sensor and varies the duration during which fuel is injected. The heated oxygen sensor has {an internal heater. The heater stabilizes the sensor’s output. The heated oxygen sensor is installed in the exhaust pipe A. | sToicHiomerRic AIR-FUEL RATIO. RICH AIR > LEAN FUEL RATIO 11-1211-13PGM-FI System Troubleshooting Flowchart — Heated Oxygen Sensor Heater Heated Oxygen Sensor (HO2S) Heater circuit ‘The Malfunction Indicator Lamp (MiL) indicates Diagnostic Trouble Code (DTC) 41: A problem in the With service check connector = Engine is running = The ML has been reported on. Do the ECM Reset Procedure, [Santen] ves ‘Tarn the ignition switeh OFF. Disconnect the 4P connector from the HORS. Measure resistance between ter- is Cand D on the HO2S. No) Check for continuity between ter ‘minal & and terminate C and © Indivisual. No No [-———_— Is there 10 —40 07 Replace the HO2S. Yes | Check for continuity t body grouna [_oneach termine! on the HOZS ves View from terminal side [termite faire, system is OK) at this time (test grive may be necessary Check for poor connections or inthe HO2S loose wires betwi |__sna'ecna icra Gincurr resreR hobs (07411 ~ 0020000 Replace the HO2S. ——— ae [_femae ne ns. a (To page 11-15) 7 z 11-14(From page 11-14) “Turn the ignition switch ON, ‘At HO2S harness, meacure volt: | age between VELIBLK (s) termi: [_natland ORN/BLK (+) terminal 1 yes. 's there battery voltage? Turn the ignition switeh OFF. Disconnect the “A” connector from | mecca [turn the ignition switeh ON. [At HO2S harness, measure volt ‘age between YEL/BLK Io) term: ‘nal and ORNIBLK (+ terminal No tery volta Yes Repair open in VELIBLK wire between HO2S: ‘0d PGMA main relay. _usumesens(naesers=es [Torn tne ignition switen OFF. “Turn the ignition switch OFF. Reconnect the 4P connector to the HORS. Connect the test harness “A” con rector to the main wire harness iy, not the ECM. (To page 11-16) Reconnect the HO2S connector. ‘Connect the test harness “Ac ‘nector to the main wire harness nly, not the ECM ‘Connect an ammeter between ter minal AB () 2c AZ6 lL “Turn the ignition switch ON Is the current lese than 0.1 A? f a sey ORN/BLK (+) YEL/BLK (+) ‘View from terminal side (6) and the HOZS. [Biel | wine inoeyvainger >| eps cat no *Monitor over 2 § minutes perioa oplace the HO2S. No Substitute « known-good ECM land recheck. If symptom/ingica tion goes eway, replace the origi nal en (con's) 11-15PGM-FI System [ Troubleshooting Flowchart — Heated Oxygen Sensor Heater (cont'd) (From page 11.18) Tuen the ignition switeh ON, Measure voltage between AG (+) terminal and A23 (+) terminal ona No ir open in ORN/BLK wi er between ECM (AB) and the HO2S, ves ~ — BATTERY Substitute « known-good ECM VOLTAGE? AZ 4) nd recheck. W symptomyingica- Tooo0GG500b0 [5505S FEBSEEB] 06000000000 on goes away, reptece the ig 20g0000000000 | 00000000 fagHeHs| 00000000000 AB (61 11-1611-17PGM-FI System = wien ———______, — The MIL has beon reported on jumped , code 43 is indicated Is the 43 code accompanied by the MIL and poor driveability? Do the ECM Reset Procedure, service check connector No ‘Warm up engine to normal of ating temperature (the radiator fan comes on) Hold engine at 3.000 min" (rpm) for 2 minutes (AT: Transmission inf) or [B) positon) ts the MIL on and does it oO) 37 indicate code ves Turn the ignition switch OFF. Connect the test harness between [- Troubleshooting Flowchart — Fuel Supply System Go to Fuel Supply System evessary. | Check for poor connections or loose wires between the HO2S and ECM Note + Use DIGITAL CIRCUIT TESTER (07411 ~ 0020000) or equivatent. + Use 2 Voit range. (ES). TLET]E The Molfunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (OTC) 43: A problem in the OSTES ALSEUS Heated Oxygen Sensor (HO2S) circuit or a problem in the Fuel Supply System From code 1 troubleshooting (pay 2 edon “Measure voltage between D14 (+) terminal and 26 (+) torminal 88 ‘00m as the ignition switch i tur To page 11-19) ‘withthe ignition switch OFF, wait fort least 2 minutos. TSSGISTTOGTOG ] SSSSSHSS [EABGETS] SOSSTOOOOOS paneanEEEe| 2000090000000] 9000000 [8aHSNG| cood00q0000 [Turn the ignition switch ON 225 4) Did Votage should start at 0.4 — 05 V when the ignition switch i first ned on, and decr 2 to below 0.1 Vin logs than 2 minute 11-18(From page 11-18) is there 0.1 V or lass when the ignition switch is first turned on? ves Disconnect the 4P connector from the HOS, NO Measure voltage between O14 (+) termine and A26(-I terminal | ————— yes Isthera more than 0.1 V7 Replace the HO2S. No Disconnect the 4P connector from Disconnect the “D" connector | the HOZS, from the main wire harness. | ‘Measure voltage between D14 I+) terminal and A26 (] terminal lGusatmacwnreiee | ves. Ee uel ences feptece No a — : cer: Reconnect the connector. Bis : TISTSSSSSOSO | Dodd |RBBBBB] Sos aooooOoS 0090000000000] 00000009 | 848868] 00000000000 Bie Connect the test harness to the 8 ago —s00 a7. main wire herness only, not to tos: | mete | ea T 3555555505500 | 50500050 [EREHEG] 00d 0STOOSOS 2000000000000] 00000090 | 868638] 00000000000, Tun Oa Measure resitance between te. 260 — 50007 1 | Iminals ofthe indleated sensor on ove: | _terthemess eos tao) a ae eee eee 2000000000000] 00000900 | Besese| oooc0000000 82 260 — 500 17 co eae Sera NO_[ Repair open inthe indicated sen- << rireeata 00m | erate ta ves ‘Cheek fr continuity 1 body ground ves | Repair short to body ground in Ie there continuity? ‘the indicoted sensor wires (se tabi No Liebe —___! —__" ___ [Substitute » known-good ECM id recheck. I symptom indica goes away, replace the origi- [_narecna 11-21PGM-FI System [ Troubleshooting Flowchart — Ignition Output Signal ———____ PAg]T The Malfunction indicator Lamp (MIL) indicates Diagnostic Trouble Code (OTC) 15: A problem in the 2UEJ. ignition Ourput Signal circuit — The MIL has beon reported — With service check connector jumped, code 15 is inci } Do the ECM Reset Procedure Star the engine, Is the WIL on and does it indicate code 15? ves ‘Turn the ignition switch OFF Disconnect the 2° connector from ctibutor “Turn the ignition ewitch ON. Measure voltage between BLK/ YEL (terminal and body ground No_| Repsie open in BLK/VEL wi 's there battery voltage? tween 2P connector and ignition switch, ves Turn the ignition switch OFF, Reconnect the 2P connector. (To page 11-23) 11-22{From page 11-22) Disconnect the 8P connector from il iatibutor Turn the ignition switeh ON. | cee Measure voltage between termi | fal A an body ground a No Is there approx. 10 V7 [ves “Turn the ignition switch OFF. Connect the test harness between | the ECM and connectors. ‘Turn the ignition switch ON. ‘Measure voltage individually be- tween A2' (6), AZ? (4) terminsls land 26 (-] terminal. we tion goes away, replace the origi nal om ‘open or short YEL/GRN nthe distributor WS ECM {A21 or AZZ.Idle Control System System Troubleshooting Guide NoTE: ‘* Across each row in the chart, the sub-systems that could be sources of a symptom are ranked in the order they should be inspected, starting with @. Find the symptom in the left colurnn, read across to the most likely source, then refer to the page listed at the top of that column. If inspection shows the system is OK. try the next system @, ete ‘If the idle speed is out of specification and the Malfunction Indicator Lamp (MIL) does not blink Diagnostic Trouble Code (DTC) 14, go to inspection described on page 11-27. PAGE sussvsten ] pi an | acter. [AUTOMATE] east | nose g 1E | roca \TER. | TRANSAXLE] STARTER | STARTING a apuusr. ono. | NaTOR = vou | “ano conTAot ean | siren | ° an ey | vane | TONG | FR | rositow | siowat | vaive | THERMO | CONNEC. screw signa | signa. | *OSTO | vawe | “rons svupro t DIFFICULT TO START ENGINE WHEN co | | @ ‘nen cou sr ous OUT OF Pee thor 2000 np ® ROUGH IOLE e/e ° 8 Iwotoae) wren warm enane seecoroo wan @) @ ©/8/ 8/9; O/90 8 ENGINE | mate wansmielon, the | SPEED | Kae souee nein ee | _ ‘seeonditioneriwON | | we wane uP | rseavenr = STALLING arrenwanuneur | FAS EMISSION TEST | | ® 11-24rm (- System Description ‘The idle speed of the engine is controlled by the Idle Air Control (VAC) Valve. ‘The valve changes the amount of air bypassing into the intake manifold in response to electric current controlled by the ecm, When the IAC Valve is activated, the valve opens to maintain the proper idle speed. ety PoMrt [- Bux > main RELAY | various rc — fom SENSORS zs aux - VY) wou [ADJUSTING f ‘ScREW | FASTIDLE THERMO VALVE STARTING AIR VALVE conta 11-25Idle Control System [ System Description (cont'd), A ‘After the engine starts, the IAC valve opens for a certain time. The amount of air is increased to raise the Idle speed about 150 — 300 min! (rpm). the proper fast idle speed. The 2. When the engine coolant temperature is low, the IAC valve is opened to obta amount of bypassed air is thus controlled in relation to the engine coolant temperature. IDLE SPEED (nin, rpm) SS eee eee eee ee 176 CF 4 2 3 108 0 -20 ° 20 « 60 8 re) ENGINE COOLANT TEMPERATURE 11-26nak When the idle speed is out of specification and the Malfunction Indicator Lamp (MIL) does not blink Diagnostic ‘Trouble Code (DTC) 14, check the following items: I the above items are normal, substitute @ known-good IAC valve and readjust the idle speed. ‘Adjust the idle speed. Air conditioning signal. Alternator FR signal. AIT gear position signal. Starter switch signal Starting air vaive (see page 11-28) Fast idle thermo valve (see page 11-28), Hoses and connections IAC valve and its mounting O-rings ‘¢ If the idle speed still cannot be adjusted to specification (and the MIL. does not blink code 14} after IAC valve replacement, substitute a known-good ECM and recheck. If symptom goes away, replace the original ECM. 11-27Idle Control System [- Starting Air Valve Description When cracking the engine, the starting air valve supplies additional air to the intake manifold to ease engine stert ino. Tomrace Manitou Adaitionss —— Co eu LS titres AIRCLEANER Col [ Fast Idle Thermo Valve Description To prevent erratic running when the engine is warming up, itis necessary to raise the idle speed, The fast idle thermo valve is controlled by a thermowax plunger. When the engine is cold, the engine coolant surround. ing the termowax contracts the plunger, allowing addi- tional air to be bypassed into the intake manifold so that, the engine idles faster. When the engine reaches operat- ing temperature, the valve closes, reducing the amount Of air bypassing into the intake manifold, oe TAKE THROTTLE ADJUSTING MANIFOLD Boy ‘scREW CHAMBER 7 \rast rae item wae -AIR BYPASS VALVE WAX 11-28NOTE: The fast idle thermo valve is factory adjusted: it should not be disassembled. 1. Remove the intake air duct from the throttle body. 2. Start the engine, 3. Put your finger over the lower port in throttle body and make sure that there is air flow with the engine cold (engine coolant temperature below 30°C, 86°F) Fast DLE THERMO vatve # If not, replace the fast idle thermo valve and retest. o-nines. Replace 10m (.0.Kg-m, 7 to Warm up the engine (the radiator fan comes on). 5. Check that the valve is completely closed. If not, air suction ean be felt at the lower port in the throttle body. ‘© If any suction is felt, the valve is leaking. Check coolant level and for air in the cooling system (see section 10) If OK, replace the fast idle thermo valve and recheck. 11-29Intake Air System System Troubleshooting Guide —_______________ NOTE: Across each row in the chart, the sub-systems that could be sources of @ symptom are ranked in the order they should be inspected starting with ©. Find the symptom in the left column, read across to the most likely source, then refer to the page listed at the top of that column. If inspection shows the system is OK, try the next system @, etc. PAGE sua svsrEM IWTAREAR | INTAKE AR | An CLEANER THROTTLE | THROTTLE | svpnssiam | ‘ConTRGL | anoiReaee | CONTROL. | ‘Svsten | “Ain over ‘SYMPTOM. =] ess tae _ WHEN WARM IDLE SPEED TOO HIGH ®@ ® Loss oF Powen ® | ®@ | ® ® 11-30[- System Description my vacuum TANK maa contao. SOLENOID VALVE Throttle Body (TB), Idle Air Control (IAC) valve, Intal the intake air pipe provides additional silencing as air is drawn into the system. ap CONTROL, DIAPHRAGM, CHAMBER taKé MANIFOLD ag VALVE i BODY ASSEMBLY El INTAKE MANIFOLD. INTAKE AIR CONTROL, SOLENOID VALVE. {uvraKe ain ‘CONTROL, Heck VALVE THROTTLE soy rz The system supplies air for all engine needs. It consists of the intake air control system, Air Cleaner (ACL), intake air duct, ‘Air Bypass (IAB) control system and intake manifold. A resonator in INTAKE AIR CONTROL, VACUUM TANK Bux) To No.2 1€CU, ECM YEL > (15 ab fuse vaRious ecm J sensors aK. INTAKE AIR ‘CONTROL. DIAPHRAGM 11-31Intake Air System - Throttle Body Disassembly: Gasket Replace ‘THROTTLE CABLE "AIT THROTTLE 22m ‘CONTROL CABLE (22kg-m, 16 1b-H ‘CAUTION: © The throttle stop screw is © After reassembly, adjust n-adjustable. ‘throttle cable, and A/T throttle control cable (see section 14) for cars with A/T. O-RING THROTTLE POSITION a) SENSOR one Replace FAST IDLE THERMO VALVE = 100m (Oo kg-m, 7 tbe) 11-32[- Intake Air Bypass (IAB) Control System Description ‘Two air intake paths are provided in the intake manifold to allow the selection of the intake path most favorable for @ given engine speed. Satisfactory power performance is achieved by closing and opening the Intake Air Bypass (IAB) control valves. High torque at low engine speed is achieved when the valves are closed, whereas high power at high engine speed is achieved by when the valves are opened. 1B CONTROL ToNo.2(€CU,ECM) gure. SOLENOID VALVE (15) FUSE — | PNK/eLU las vacuum TANK, ecm tap CHECK VALVE 148 CONTROL DIAPHRAGM ae VALVES lrake MANIFOLD INTAKE Alf BYPASS (IAB) CONTROL SOLENOID VALVE OFF | ENGINE SPEED IS ABOVE 4,800 min" (rps 11-33Intake Air System ‘Troubleshooting Flowchart Inspection of JAB Control System | ‘Start engine and allow toile Remove #13 vacuum hose from the IAB contol diaphragm and connect vacuum gauge to the te ves 1 (To page 11-35) [ Intake Air Bypass (IAB) Control System wo vacuum PUMP; GauGe “4, Remave #12 vacuum hose from the IA vacuum tank, then check for vacuum at the IAB vacuum tank. ves Disconnect the 2° connector from the IAB control solenoid valve Measure voltage between BLK/ YEL (+) terminal ang PNRIBLU (-) #1 HOSE nz 188 CONTROL SOLENOID VALVE TAB CONTROL, DIAPHRAGM, [ Repeir the brooke jum leak between IAB vacuum tank the intake mani= SS) terminal ide PNK/ oe BLU Replace the AB con- | No Measure voltage betw YEU (e) terminal an ground (To page 11-35) {Wel solenoid valve, 11-34(rom page 11-34) Toms wae seed anomie | e creck vocuum mi vaccum | IAB control system is OK. (From page 11-34), No Is there battery voltage? ves. “Turn the ignition switch OFF. Connect the test harness be. ween the ECM and connectors. ————— ‘Turn the ignition switch ON and connect 8 Jumper wire between AAT terminal and A26 terminal a ves Substitute @ known-good ECM. and recheck. If symptom/indica: tion goes away, replace the origi ‘Does the solenoid vaive click No when the jumpers connected? Check for an open in BLK/VEL wire between the 2P connector and No.2 ECU (ECM) 15 A) fuse in the under-dash fuse/relay box Repair open in PNK/ BLU wire between | ECM (A17) and the 2P nal EM, ay sumpen | [S5500000b0000 | 50000000 Puaaaea] co0DD0000GS wire 2000000000009 | 00000000}.099900| oocc0000000 ves [ Disconnect the 2P connector from the IAB control solenoid NO Turn the ignition switeh OFF. L_Tern he ignition eve [disconnect “A ecw. connector from (Check for continuity to ground on the PNK/BLU wire. NO Substitute a known-good ECM | and recheck. if symptom goes __ sway. replace the original ECM, Replace the IAB con- ‘tol solenoid valve. Repair short to ground PNK/BLU” wire (conta) 11-35Intake Air System 7 Intake Air Bypass (IAB) Control System (cont'd) Intake Air Bypass (IAB) Valve Testing CAUTION: Do not adjust the IAB valve full-close screw. It is preset at the factory. 1. Check the IAB valve shaft for binding or sticking 2. Check the IAB valve for smooth movement. 3. With the engine at idle, check that @ of the IAB. valve is in close contact with the stopper when vac- uum hose is disconnected INST slorren 4, With the engine at idle, check that @ of the IAB, valve is in close contact with the full-close screw when the vacuum hose is connected. ee i paws IE) mass If any fauit is found, clean the linkage and shafts with carburetor cleaner. — If the problem still exists after cleaning, disas: semble the intake manifold and check the IAB. valve body assembly (see page 11-37) (cont'd) 11-36(- Intake Air Bypass (IAB) Control System (cont'd) Zam (22 kgm, 161-4 a i ST q INTAKE MANIFOLD CHAMBER Disassembly asker as VALE Bot oY ASSEMBLY GASKET Replace INTAKE MANIFOLD. tas CONTROL, SOLENOID VALVE (22 kgm, 16 be) 11-37Intake Air System r- Intake Air Control System, ——£@————— ——___________ Description ‘The intake air control system decreases air intake noise INTAKE AIR CONTROL SOLENOID eux, To No. 2(€CU, ECM) VALVE y vet > as altuse INTAKE i AIR war conrRoL. vacuum | TANK various Eom — sensors | INTAKE ain INTAKE AIR canna CONTROL BK oa DIAPHRAGM VALVE = When the engine speed is below 3,900 min” (rpm), the ECM supplies current to the intake air control solenoid valve. This ‘opens the solenoid valve sending intake manifold vacuum to the intake air control diaphragm, 11-38‘Troubleshooting Flowchart Inspection of Iota System, ir Cont Star engine and allow to idle | Remove the upper vacuum nose from the intake ait control solenoid valve and connect ¢ jum gauge t0 the eolengid INTAKE AIR CONTROL, SOLENOID VALVE VACUUM PUMP) GAUGE. [Baconpert ne tower aun] No_| hose of the intake sir contral < Is there vacuum? Solenoid valve from the intake se ontral vacuum tank ang connect ves. a vacuum gauge to the hose, (To page 11-40 ves. Disconnect the 2P connector | from the intake air control solenoid valve. ‘Measure voltage between BLK/ YEL (+) terminal and WHT (-)ter- rival fa BLK body Messure vottage betwi YEL (+) terminal an round, (To page 11-40) — Check the vacuum line for proper eon- nection, Blockage or discon: nected hose. Replace racks, View trom, BLK/YEL (+) terminal side (conve 11-39Intake Air System [- Intake Air Control System (cont'd) Raise. (cor (From page 11-39) ‘engine speed t0 3,900 mine" —eeeeeeee (From ps ye 11-39) 2P connector and No. 2 ECU (ECM) (15A) fuse ip the under-dash use! relay box Turn the ignition switch OFF, [__ Reconnect the 2P connector ] Connect the test harness be- | wean the ECM. T Turn the ignition ewiten ON, [ Connect» jumper wire ber AIS terminal and A26 termina JUMPER WIRE aio 33 guasesscuy|sseeuess BSUaaa|sssossssce = ves. oniginal ECM Is there vacuum? ves. {Disconnect the 2° connector. 11-40 NO (To page 11-41) NO) “Tura the ignition switch OFF. ane anes Disconnect “A” connector fram | ECM. Ss ae ‘check for continuity to ground on | (ro page 19-41) ae | Replace the intake air control solenoid valve(From page 11-40), 1 —__1__ Connect # vacuum pump to the 16 vacuum nose. Apply the vacuum. ] No Does it hold vacuum? ves. (From page 11-40) xo ‘Substitute @ known-good ECM ‘and recheck. I symptom goes ‘sway, replace the original ECM. ‘Check the vacuum line for proper connection or disconnected hose, WOK, replace the intake air con: ‘tol diaphragm, #8 VACUUM HOSE ja DIAPHRAGM’ Cheek for a snort co | ground in Wit wire | Setween'ecH (Ato) andthe 2? connector. 11-41Automatic Transmission Special Tools we 14-2 Road Test .. 14-3 Stall Speed Test ... 1. 14-6 Pressure Testing ... .14-7 Clutch Illustrated Index .... . 14-12 Outline of Model Changes The H23A3 engine mode! has been added. Compare to F2021/F20Z2 engine models main differences are: + Road test shift schedule + Stall speed RPM + Pressure testing fluid pressure + _Ist/2nd clutch assemblySpecial Tools Ret. No. “Too! Number Description Loy | o O7LAJ—PT30100 or | Test Harness 7 O7LAI—PT30108 ® O7MAJ—PY40100 | A/T Pressure Gauge Hose Assembiy 1 | 167 @1 | o7MAJ—py40110 | Oil Pressure Gauge Hose ay | 167 @2 | o7Mas—Py40120 | Oil Pressure Joint ay | 147 ® 07406 —0020003 AMT Oil Pressure Gauge Set 1 | 167 @1 | 07406-0020201 ‘AIT Oil Pressure Gauge Hose wy | 187 @ 07406—0070000 ‘AIT Low Pressure Gauge i 147 ® 07411-0020000__| Digital Circuit Tester 1 |e Zz @2 | 14-2Road Test - NOTE: Warm up the engine to notmal operating temperature (the radiator fan comes ont) 1. Apply parking brake and block the wheels. Start the engine, then move the selector lever to [ Ds] position while ‘depressing the brake pedal. Depress the accelerator pedal and release it suddenly. Engine should not sta 2, Repeat same test in[ D3 | position. 3. Shift the selector lever to| Ds | position and check that the shift points occur at approximate speeds shown. Also check {or abnormal noise and clutch slippage. Nore: Throttle position sensor voltage represents the throttle opening. =1 Connect the Test Hames between the ECM and connector (see section 11), -2. Set the digital multimeter to check voltage between D1 (+) terminal and D22 (—) terminal for the throttle position sensor. picitat cincurr TESTER 074110020000 ‘Test HARNESS O7LAS~PT30100 o7LaJ-PT30100 pine 595600000000] 00000000] 000000] 00000000000 2000000000000] 00000000] 000000] 0000000000 s 221- (cont’a 14-3Road Test r- (cont'd) [Bi] Position: Normal Mode (S Switch OFF) + Upshift Ist — 2nd 2nd — 3rd 3rd ~ 4th —_Lock-up Clutch ON Throttle position sensor voltage: kmh [| 22-24 | 41-45 | seca | 22-26 0.836 V (0.7/8 throttle) Coasting dowrill from a stop mph 14-15 | 25-28 | 36-40 14-16 Throttle position sensor voltage: kmin [28-34 | 62-68 | 91-99 95-103 2.184 V (3.5/8 throttle} mph 17-21 | 39-42 | 57-62 59-64 km | 47-54 [107—115| 145-154 138-146 ‘Acceleration from a stop mon | 29-34 | 66-71 | 80-86 | 0-91 + Downshitt Lockup Clutch OFF 4th ~ 3rd 3rd — 2nd = 2nd = Ist Throttle position sensor voltage: kmih_[ 21-25 —— [24-30 4m = an] 10-16 0.836 V (0.7/8 throttle) je ing or braking to @ stop mph 13-16 — _|is-19 1m ana | 6-10 Throttle position sensor voltage: , 2.184 V (3.5/8 throttle) pene | aiomce | Sic When car is slowed by increased grede, wind, eto mph | 47-52 — — — Full-throti kev | 131-139 [126-135] 86-94 39-46 When car is slowed by increased ao : grade. wind, ete. mph ares | 78-84 | 53-58 24-20 Position: § Mode (S Switch ON) Upshitt Tet — 2nd 2nd — 3rd 3rd = 4th —_Lockup Clutch ON Throttle position sensor volteg. kmh | 23-25 | 46-50 | 77-83 37-41 0.836 V (0.7/8 throttle) Coasting down-hill from a stop mph aa—16_ | 29-91 | 48-82 | 23-28 Throttle position sensor voltag. kmm | 32-38 | 70-76 | 100-108 105-113 2.184 V (3.5/8 throttle) Acceleration from a stop mph 20-24 | 43-47 | 62-67 65-70 Full-throttle km | 47-54 [107-115] 145-154 138-146 Acceleration from a stop mph 29-34 | 66-71 | 90-96 | 86-91 + Downshitt lock-up Cutch OFF 4th ~ 3rd Std — 2nd___—_2nd — tot Throttle position sensor voltage: kmh | 35-39 —]28-36 tan = ana [10-16 0.836 V (0.7/8 throttle) 7 Coasting or braking to a stop mph | 22-24 —_[ 18-22 44m ~ ana) | 6-10 Throttle position sensor voltage: 2.184 V (3.5/8 throttle) pore emoomas When car is slowed by increased i grade, wind, ete. moh 52-87 _ — )] = Full-throttie km | 131-139 [126-135/ 8694 39-46 When car is slowed by increased grade, wind, etc. moh | 81-86 | 78-04 | 5388 24-29 14-4Accelerate to about 35 mph (57 km/h) so the transmission is in 4th, then shift [Dz] to [2] position. The car should immediately begin slowing down from engine braking. CAUTION: Do not shift from [Ds] or [Ds] position to [2] o [1] pos damage the transmission. ion at speeds over 62 mph (100 km/h); you may Check for abnormal noise and clutch slippage in the following positions. [ist Gear Postion "TT. Acoslrate from sop at fl thot, Chock that hare eno abnormal nola oF chic fone. 2 | (2nd Gear) Position =1. Accelerate from a stop at full throttle. Check that there is no abnormel noise or clutch slippage. —2. Upshifts and downshifts should not occur with the selector in this position. [7] thverses Postion Zceuarte trom stop at ul trot, and check fr abnormal noise and etch sippene. Test in[ P ] Parking) Position Park car on slope (approx. 16°), apply the par ing brake, and eit into[P] poution Release the bake: the car should 14-5Stall Speed r Test CAUTION: ‘* To prevent transmission damage, do not test stall speed for more than 10 seconds at a time. ‘* Do not shift the lovor while raising the engine speed. += Be sure to remove the pressure gauge before testing stall speed. £Engaoe parking brake and biock the front wheels. Connect tachometer, and start the engine. Make sure the AIC switch is OFF. After the engine has warmed up to normal operating temperature (the radiator fan comes on), shift into[Z] position Fuly depress the brake pedal and accelerator for 6 to 8 seconds, and note engine speed Allow 2 minutes for cooling, then repeat same test in [Da], [7]. and [Fi] positions. oe nen NOTE: © Stall speed tests should be used for diagnostic purposes only © Stall speed should be the same in [Ds], [2] [1]. and [fi positions. ‘Stall Speed RPM: 2,550—2,850 min-' (rpm) TROUBLE I PROBABLE CAUSE Stall rpm high in [Ds], [id end [fl] positions | = Low fluid level or oi! pump output | = clogged ATF straine + Pressure regulator valve stuck closed eam = Slipping clutch _ Stall_rpm high in [R] position + Slippage of 4th clutch _| Stall rpm high in [2] and [De] positions = Slippage of 2nd clutch Stall 1pm high in [1] position = Slippage of 1st clutch or Ist gear one-way clutch Stall rpm low in [Ds} [2]. ‘and [Ri] positions | = Engine output low “Torque converter one-way clutch slipping 14-6Pressure Testing a Seas cai oe meee eens eee ee Sines Ma eaten cane naa eee asta CAUTION: Before testing, be sure the transmission fluid is filled to the proper level. 6. 1. Raise the car. (see section 1). 2 Warm up the engine (the radiator fan comes on} then stop the engine and connect a tachometer, 3. Connect the oil pressure gauge to each inspection TORQUE: 18 Nem(1.8 kom, 13 b-ft) Connect the oil pressure gauge securely: be sure not inspection hole. AIT lL PRESSURE GAUGE SET ‘d7406--0020003, (O1L PRESSURE JOINT Ow PRESSURE GAUGE HOSE o7Mas—PYa0110 AIT LOW PRESSURE GAUGE ‘o7406~-0070000 NOTE: © Use the A/T Oil Pressure Gauge Set (07408— 0020003) or A/T Low Pressure Gauge (07406 — 0070000), and the oil pressure gauge hoses and joints shown above. © The A/T Oil Pressure Gauge Hose (07406— 0020201) may also be used. CAUTION: 2 to allow dust and other foreign particles to enter the 3 Start the engine, and measure the respective Pressure as follows: Line Pressure Clutch Pressure Throttle B Pressure Clutch Low/High Pressure Install 9 new washer and the sealing bok in the inspection hole, and tighten to the specified torque. TORQUE: 18 Nem(1.8 kgm, 13 Ib-ft) NOTE: Do not reuse old aluminum washers. hole, © Line Pressure Measurement =1. Set the parking brake end block both rear wheels secu ly. Fun the engine at 2,000 min (rpm). Shift the select lever to [Hl] or (F] position Nore: Higher pressures may be indicated if measure: ments are made in selector positions other than [N] oF [F] position. ‘ArT OlL PRESSURE GAUGE —4, Measure line pressure. fose ASSemauy OrmasP¥a0T00 Afi LOCK-UP CONTROL SOLENOID VALVE OS ASSEMBLY LINE PRESSURE INSPECTION HOLE | regulator, torque converter check valve T FLUID PRESSURE pressure | SELECTOR | svumprom | prosaste cause |——_THIP PRESSURE | Standard Service Limit Line IN] or [P) | No (or low) | Torque converter, | 850-900 kPa 800 kPa | | line pressure | oi! pump, pressure | (8.59.0 kg/em?, | (8.0 kgiem?.114 psi | (conrad 14-7Pressure Testing -1 (cont’d) ‘* Clutch Pressure Measurment While testing, be careful of the rotating front wheels. ‘Set the parking brake and block both reer wheels securely. =2. Raise the front of the car and support it with ssfety stands. =3. Allow the front wheels to rotate freely =. Run the engine at 2,000 min" (rpm). —5. Measure each clutch pressure, 4ST cLuTCH PRESSURE INSPECTION HOLE 2ND CLUTCH PRESSURE INSPECTION HOLE 4gr.HoLo cLuTeH PRESSURE 4TH cLuToH pressuRE INSPECTION HOLE. INSPECTION HOLE. INSPECTION HOLE” ceNTER BEAM T T FLUID PRESSURE |} seurctor | PRESSURE symptom | PROBABLE CAUSE POSITION | Standard Service Limit Tat Guten | EiJor[Bi]) | Noortow | tet Chutch {50-900 kPa 800 KPa tet pressure | (8.5-9.0 kgiem’, | (8.0 kg/em2, Techod | Li) [No or tow tat-| Tethoid Clutch SE) een Clutch | hold pressure } 2nd cwwtch | 2) ‘No or tow | 2nd Chatch 2nd pressure 2nd lurch | (Da}or[Ba])| No orlow | 2nd Clutch 00 kPa “450 KPa 2nd pressure (5.0 kgiem?, 71 psi | (4.5 kg/em?, 64 psit | | | (Throttle fuly closed) (Throttle fully closed 1 900 kPa 800 kPa 3rd Clutch No oF low 3rd Clutch | (9.0 kg/em?, 128 psi) | (8.0 kg/em*, 114 psi) ) 3rd pressure | (rhrottie more than | (Throttle more than | | 3/16 openes! 3116 opened) 4th Clutch ] No or low 4th Clutch 530 kPa 480 kPa 4th pressure (5.3 kglem?, 75 psi) | (4.8 kglem?, 68 paid (Totte fully closed) (Throttle fully closeal } 900 KPa 800 kPa (9.0 kglem, 128 psil | (8.0 kgiem?, 114 psi) | (throttle more than | (Throttle more than 3/16 opened! 3/46 opened) | Serve Valve or | 850-900 KPa ‘B00 kPa | 4m Clutch } 18.5—9.0 kgiem?, | 18.0 kg/em, I l | 121=128 psi 114 psit 14-8© Throttle B fessure Measurement 1. Set the parking brake securely and block the wheels. 2. Run the engine at 1,000 min-* (rpm) 3. Disconnect the throttle control cable from the throttle control lever and set the throttle control lever in full throttle position. ‘THROTTLE B PRESSURE INSPECTION HOLE THROTTLE CONTROL Lever THROTTLE CONTROL, CABLE FLUID PRESSURE pressure | SELECTOR | svuprom | pnosaste cause = Siandara Servic Uni Throttle B | @e Pressure too | Throttle Valve B | O kPa (0 kg/cm?, high 0.0 psi) throttle lever fully closed | | No orew | 350-900 Ke | 800 KP | pressure | (8.5—9.0 kg/cm?, (8.0 kg/cm?, [Sarctae pan | Sia pei | teow toverfuly- | throttle lever fully | | opened opened (cont'd 14-9Pressure Testing 3, r (cont‘d) * Low/High Pressur a rest ‘Set the parking brake and block the rear wheels securely. Reise the car and support with safety stands. Attach the gauge set to the appropriate pressure in- spection holes. Remove the throttle control cable end of the throttle contra! lever, NOTE: Do not loosen the locknuts; simply unhook the throt te control cable end. THROTTLE CONTROL ‘Warm up the engine to normal operating temperature (the radiator fan comes on} With the engine idling, move the selector lever to [Dz] position, Slowly move the throttle linkage to increase engine Fpm until pressure is indicated on the appropriate ‘gauge. Then release the throttle linkage, allowing the engine to return to an idle, and record the pressure reading. THROTTLE LINKAGE 9. With the engine idling, ift the throttle control lever up approximately 1/2 of its possible trave the engine rpm until pressure is indicated on the appropriate gauge. Record the highest pressure reading obtained. THROTTLE CONTROL teveR Repest steps 7 and 8 for each clutch pressure being inspected. 14-10ro: 4TH CLUTCH PRESSURE INSPECTIONHOLE 2ND CLUTCH PRESSURE INSPECTIONHOLE CENTER BEAM varies with throttle opening een Reena PRESSURE SELECTOR ‘SYMPTOM PROBABLE CAUSE — POSITION ‘Standard Service Limit 3a Gite Wo erlow, | Bd Guih Hae ieeel loc ania eae iene ano Sco=soo riage [soos ‘78—128 psi) | (Throttle fully closed)} 1800 kPa (8.0 kg/em=, 114 psid (Throttle more than 3/16 opened 14-11Clutch Mlustrated Index ‘1ST/2ND CLUTCH ASSEMBLY [SNAP RING Cos) CLUTCH END PLATE es o-nINGS CLUTCH PLATES Replace. ‘Standard thickness: 200 mm {0.078 in) PisTON soomome—_ ES SPRING seraner—_ ‘SNAP RING ——35 cuurcn Discs ‘Standard thickness: 1.98 mm (0.076 in) SNAP RING SS SPRING wane ES RETURN SPRING cuvron mates Stondrd tater: = 200mm (0079 S cuurenoises isc SPAIN ‘Standard thickness: SH) 1.94 mm (0.076 i) PISTON: CLUTCH END PLATE o-niNas: ‘SNAP RING——./ 14-12Conventional Brakes Front Brake Pads Inspection and Replacement .......... 19-2 Outline of Model Change ———_________ The front brake pad inspection and replacement descriptions has been changed for the 2.3 ¢ model. Refer, to the ‘93 Accord Shop Manual (No. 62SN700) for 2.0 ¢ KS models. |Front Brake Pads use an air hose or dry brush to clean brake assemblies. © Use @ vacuum cleaner, to avoid breathing brake dust. 1. Loosen the front wheel nuts slightly, then raise the car and support on safety stands. Remove the front, wheels 2. Remove the caliper bolt and pivot the caliper body Lup out of the way. CALIPER BOLT CALIPER BOOY, NOTE: Check the hoses and pin boots for damage or deterioration, 3. Remove the inner and outer pads. INNER PAD ourer pad r Inspection and Replacement. —-————~——_—_____________ 4. Using vernier calipers, measure the thickness of each brake pad lining Brake Pad Thickness: Standard: 11.0 mm (0.43 i Service Limit: 1.6 mm (0.06 NOTE: Measurement does not include pad backing plate thickness. BACKING PLATE 5. If the brake pad thickness is less than service limit, replace the front pads as a set. 6. Remove the pad retainers. 7. Clean the caliper thoroughly; remove any rust, and, check for grooves or cracks. 8. Check the brake dise for damage or cracks 9. Install the pad retainers. PAD RETAINERS. Check for wear CALIPER BRACKET Check for cracks. 19-2©) 10. Install the brake pads correctly. 11. Push in the piston so that the caliper will fit over the pads. Make sure that the piston boot is in position to prevent damaging it when pivoting the caliper ‘© When reusing the pads. always reinstall the down. brake pads in their original positions to prevent oss of braking efficiency. 12. Pivot the caliper down into position, then install © Contaminated brake discs or pads reduce stop: caliper bolt and tighten it ping ability. Keep grease off the discs and pads. NOTE: Install the inner pad with the wear indicator ‘on the inside. CALIPER BOLT 50 Nem (5.0 kgm, 36 ibe) PISTON CAPER BODY WEAR INDICATOR INNER PAD. outer PAD 13, Deprese the brake pedal several times to make sure, the brakes work, then road-test NOTE: Engagement of the brake may require a ‘greater pedal stroke immediately after the brake pads have been replaced as a set. Several applica~ tions of the brake pedal will restore the normal pedal stroke. 14. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. 19-3Body Front Spoiler Replacement ... +. 20-2 Trunk Spoiler Replacement ... 20-3 + The front spoiler has been added (for some type. Outline of Model Changes [ + The trunk spoiler has been added (for some type’.Front Spoiler [- Replacement Remove the front spoiler as shown, NOTE: Take care not to scratch the front bumper and front spoiler ‘4: Spoiler bracket locations. 7 ‘A: Spoiler side bracket locations, 2 FRONT BUMPER FRONT BUMPER ‘SPOILER | Bracke | NM OF aman kN tron seonen © FRONT BUMPER screw FRONT SPOILER Installation is the reverse of the removal procedure. NOTE: Check that the front spoiler is securely attached to the front bumper 20-2Trunk Spoiler [- Replacement NOTE: Take care not to scratch the body. 1, Open the trunk li. 2. Remove the nuts. NOTE: Take care not to drop the nuts inside the trunk li, ‘A: Nut locations, 5 6x 1.0mm 10 Nm 11.0 kg-m, 72 ot) TRUNK UD ‘TRUNK SPOILER 3, Lift and remove the trunk spoiler. TRUNK SPOILER ‘SPOILER EMBLEM 6. Remove the push nuts, then remove the spoiler emblem. NOTE: The numbers after the part name show the ‘quantities of the parts used. TRUNK SPOILER SPOILER EMBLEM PUSH NUT, 2 a Replace. If necessary, replace the protection tapes on each side. Align the application tape with the outer taillight and body as shown, then press the protection tape into place. Remove the application tape. Note: * Before applying, clean the body surface with a sponge dampened in alcohol. © After cleaning, keep oll, grease or water from {getting on the surface. Boy PROTECTION TAPE [APPLICATION TAPE. ae \\ TAILLIGHT Installation is the reverse of the removal procedure. 20-3Electrical Special Tools .... Relay and Control U 23-2 23-3 23-4 23-9 23-11 Power Distribution .. Ground Distribution ... Starting System Starter Replacement *Ignition System Ignition Timing Inspection and Setting Idle Speed Inspection . Spark Plug Inspection 23-12 23-13 23-14 23-15 Keyless Entry System (KE) Circuit Diagram Control Unit Input Test Passenger’s Door Lock Actuator Tet wnrscerne Key Cylinder Switch Test Wiring Diagrams - 23-16 23-17 - 23-19 - 23-19 . 23-20 *Read SRS precautions on page 23-306 in the ‘Shop Manual (62SN700) before working in these areas. uate @ Mode ranges. Aaa + Relay and Control Unit Locations: As the Keyless Entry System has been adde baen rewritten, the related items have Wire Harness and Ground Locations: As the wire harness has partly changed, the related items have been rewritten, + Starting System: Starter Replacement has partly changed. + Ignition System: As the 2.3 (H23A3) type engine has been added, the related items have been rewritten. + Keyless Entry System (KE): As the Keyless Entry System has been added, the related items have been Wiring Diagrams, All of the above-mentioned changes have been reflected in Power Distribution, Ground Distribution andSpecial Tools Ref. No. Too! Number Description 7 (07PAZ— 0010100 SCS short connector 23:13 + 23-2Relay and Control Unit Locations 23-3nd Loc and Grou! 23-4Wire Harness and Ground Locations Dashboard (RHD)Power Distribution Circuit Identification (LHD) NOTE: This page corresponds to page 23-41 in the Shop Manual (62SN700) and reflects the model changes. igymion Siren ana ‘UNDER DASH FUSEIRELAY BOX Wot 7A) No2(18A) Noa 0A) No.8 7A) No.6 (08) No.8 (108) BLKVE —————— Ignition eat yewtT ——— cya nty ane seurty exe, ——p— Patt-Fimainrny uxive., Engine mount conta unit Engine maunt onal sno | 1A] EGA convo! soerld vale Evaprati erin EVAP) purge corral soo Vote regu tc) Intl ar bypass UAB) convo} felon valve asa) Intake sir conrl olen vale ®t. ——4— } sein coal med Tm suxrve. (Carsing sytem ett i, Janam Saute veuora Power mors Power mirer defogger Jeroen crete 22 sect ey POWER WINDOW RELAY crvaux at Windstiald wiser motor Wish wiper intrmiten ety tere connection) lotgited control anit — Gok FE tate waa htt ‘Ghuge and warnpindetor ghee ry ArT ger poston switch, EE tints eed er) Beckop ge ra connection) Integrated coma unt 23-9Power Distribution Circuit Identification (RAD )ARPAAAAaAAJ$p A NOTE: This page corresponds to page 23-48 in the Shop Manual (62SN70O) and reflects the model changes. LUNDER DASH FUSERRELAY BOX. sgumon, SMTP > seve, suxrret Nec 754) H yew = Kye ony ad vecty ele por oo ok, 7 {Some mode versions of KE) Noztisay i j—— aver Engine mount conto unt Engee mount ontolunt (A/T) send vave EGR coal seid vave Evspornive encson(EVAPI purge conto sland vabe eure owe Rosato fan corr node ‘otage puto) Irae ot boas 488 otc Siena valve aaa) Intake antl solenoid aie ~ SYEL ——p— tess cont ‘modaie Lo auxiven Charging syste ght Ne (108) : Fe. sr unit Noss TAT vevonn Power more Power mor detopger ) rates Re" } net retey eat washer cont uit a i POWER WINDOW RELAY No 10) rex Wondhils wpa moter Washer mtore ! Winshit wiperincermitent lsy {tart conection! L_j__ tren connec sonar coatit nt Nog 08) ve Cock FE ito warn totatty : : Gage and wariegiadestor hts — 1A gear poston awit TE tine ient so) Back opighte H 1 tevena canscton) i tree canteen) agate contoluit 23-10Ground Distribution Circuit Identification (RHD) NOTE: This page corresponds to pege 23~ 58 in the Shop Manual (625N700) and reflects the model changes. $F Front} 9 fa-saevelay a. Fight outer tight Fight rer tur ra oe Boh argh cr} ‘nine sen ‘ky einer ten Tena (Ste) cio cen patght ‘eee sower aos tout ‘Seine od versana oF KE (Do: Rar ite ress 23-11Starting System (- Starter Replacement 1. Disconnect the negative cable from the battery. 2, Remove the engine wire harness from the harness clip on the starter motor. 3. Disconnect the starter cable from the B terminal on the solenoid by removing the mounting nut, and disconnect the BLKWHT wire from the S terminal. NOTE: In case of an A/T model, the starter cable also has to be removed from the bracket on the transmission housing. 4. Remove the two mounting bolts holding the starter, then remove the starter motor, arr: MOUNTING BOLT BLKWHT WIRE 45 Nm (4.5 Kg-m, 32 Ib-t) MOUNTING BOLT 45 Nem (6.5 kg-m, 22 Ibet) ‘S TERMINAL 8 TERMINAL STARTER, CABLE MOUNTING NUT 9Nm (0.9 kg-m, 6.5 Ib-t) wit MouNTING BOLT BuKwaT 451m (45 kg-m, 22 Ib) WIRE 8 TERMINAL, STARTER chat MOUNTING BOLT 75 Nem (7.5 kg-m, 54 Ib) MOUNTING NUT 9 Nim (0.9 kg-m, 6. 5. Install in the reverse order of removal. NOTE: When installing the starter cable, make sure that the crimped side of the ring terminal is facing out. Crimped side of ring terminal 23-12Ignition System CAUTION: © All SRS electrical wiring harnesses are covered with yellow outer insulation ‘© Replace the entire affected SRS harness assembly if, it has an open circuit or damaged wiring. © Before disconnecting the SRS wiring harness, turn ‘the ignition switch off, disconnect the negative and positive battery cables, and wait at least three min- AIRBAG ASSEMBLY ‘SRS MAIN HARNESS {Covered with yellow outer insulation) 1. Start the engine and allow it to warm up (radiator fan comes on two times). Then let it run for more than two minutes at 3000 min” (rpm) with the shift lever in (B] (A/T) or neutral (MT). 2. Pull out the service check connector located under the passenger's side of dash. Connect the GRN/ WHT and ORN/RED terminals with the SCS short ‘SERVICE CHECK CONNECTOR (2-P) Wire colors GAN/werT, ORN/RED, ‘SCS SHORT CONNECTOR 7PAz~ 0010100 NOTE: The illustration shows LHD type, RHD type: is symmetrical 3. Chock the idle speed (see next page’. Ignition Timing Inspection and Setting (H23A3) Connect a timing light to the No, 1 ignition wire and remove the rubber plug from the inspection win: dow in the flywheel or drive plate housing. While the engine idles, point the light toward the pointer on the flywheel (for M/T) or on the drive plate (AT). “TIMING LIGHT inspection ‘window Check if the pointer and the red mark are aligned. If necessary, adjust ignition timing to the following specifications: Ignition Timing: 15 + 2° BTDC (RED) at 770 + 50 min” (rpm) with shift lever in neutral position and elec- trical systems turned off WHITE MARK (TDC! POINTER RED MARK DRIVE PLATE NOTE: The illustration shows AVT. 23-13Ignition System - Ignition Timing Inspection and —— Setting (H23A3 cont'd) 7. To adjust the ignition timing, loosen the distributor mounting bolts, and turn the distributor housing counterclockwise to advance the timing, or clock wise to retard the timing. ‘To ADVANCE BN (1.8 kg-m, 13 Ibe) 8, Tighten the mounting bolts and recheck timing, 9. Remove the SCS short connector from the service check connector (2-P) and reinstall the rubber plug into the inspection window. 1 3 Pr Idle Speed Inspection (H23A3) ——, Start the engine and allow it to warm up (radiator fan comes on two times). Then let it run for more than two minutes at 3000 min” (rpm) with the shift lever in [5 (A/T) oF neutral (M/T) Connect a tachometer to the test tachometer con ‘TEST TACHOMETER CONNECTOR (2-P) TACHOMETER ‘CONNECTOR (2.P) ~ sartery lle speed: 770 + 50 min neutral position and ‘turned off Adjust the idle speed if necessary (see section 11) 23-14-- Spark Plug Inspection (H23A3) 1. Inspect the electrodes and ceramic insulator for: Worn or daformed \ + improper gap + Oitfouting + Corbon deposits lectrodes Damaged jacket racked inculator Burned or worn electrodes may be caused by: + advanced ignition timing, + loose spark plug. to0 low plug heat range. + insufficient cooling, Fouled plug may be caused by: + retarded ignition timing. + oil in combustion chamber. + 100 high plug heat range. + excessive idling/low speed running. + clogged air cleaner element. deteriorated ignition coil or ignition wires. + incorrect spark plug gap. 2. Adjust the gap with a suitable gapping tool. Electrode Gap: 1.0 1.1 mn (0.039 ~0.043 in} 10-14 mm (0.039 - 0.043 in) 3. Replace the plug if the center electrode is rounded as shown below. ROUNDED ELECTRODE, 4. Replace the plug if itis fouled or worn, NOTE: Use only the spark plugs listed below. ZFREF-11 (NGK) KJ20CR-L11 “(NOD ZFRIF-11 (NGK) For ell normal driving For hot climates or continue Ku22CR-L11 *(ND)_| ous high speed driving *(NDI: NIPPONDENSO, 5. Apply @ small quantity of anti-seize compound to the plug threads. 6. Screw the plugs into the cylinder head finger-tight, then torque them to 18 Nem (1.8 kg-m, 13 lb-ft) 23-15Keyless Entry System (KE) [- Circuit Diagram Igumon UNDER-oase ‘UNERHOOD FUSEIRELAY 80x. Swine FUSEREIAY BOX. Tes5(608) — ne.8(508) [ras 750 ST OL wx, LOS earteRy ‘TRANSMITTER RECEIVER UNIT GaNWHT" wore crac KEYLESS POWER 0008 LOCK CONTROL UNT L0KO UMOK® | veuneo? we | 2 onWRED? rneuy? Gorwineo' sui ties ‘s.r canal? sake . . . . poo Pt BLK BLK’ ‘YEURED” ‘YEURED® ‘YEURED’ “YEURED’ LOCK a = N08 =) a : : U V er] yt ris} ocx] | [bsetoce 5 ' rz z z 7z OREN ' ‘ou REAR RAEAR fo DOOR LOCK 1 PASSENGER'S GooRtoce | BB6Alock | eSncens % ! oe RevWaron | ACTUATOR | booatock {TURTON i Grawoen aeruavon ' Suter WHT/RED WHTIRED = WHT/RED WHTIRED BLK * aux uy tock pavers | iaxmon gi Boor” ® | Rey" avers Swiren | Swrcn Bogner Svinoet Sure auc ax 701 701 501 z 23-16r Control Unit Input Test 1. Remove the right trunk side trim panel, then discon- rect the 26-P and 22-P connectors from the keyless power door lock control unit 2. Inspect the connector and the socket terminals to be sure they are all making good contact. © If the terminals are bent, loose or corroded, repair them as necessary, and recheck the sys. tem, © If the terminals look OK, make the following input tests at the connector. — Ifa test incicates 2 problem, find and correct the cause, then recheck the system, = If all the input test prove OK, the control unit must be faulty; replace it. NOTE: Different wires with the same color have been given a number suffix to distinguish them (for example, GRN/WHT! and GRN/WHT? are not the same). suunwir BL BLu/RED® Yew “| i ud View from wie side sLurwaT Bux! YeLRED? = *GrnywuT! — GRN/RED anyevut ‘GRN/RED 7 View from wire side TIRED SGRN/BLK *WHT/BLUE ae b 7BLU GrNvEL? GRN/WHT *: Check for continuity in this wire between control unit and receiver. For detlls feler to “Keyless Entry System Test” on page 23-282 in Shop Manvel (S25N700) 23-17Keyless Entry System (KE) Control Unit Input Test (cont'd) No. Wire Test condition Tost: Desired result Possible cause if result is not obtained |_| Under all conditions | Check for continuity to ground: | » Poor ground (G701) : BLK | There should be continuity. | + An open in the wire Under all conditions | Check for continuity to ground: a BLK | There should be continuity. Under il conditions | Check for voltage to ground ~ Blown No 21 20 A) fuse in the 3 | waretut There should be battery voltage. |” under-hood fuse/relay box + Anonen inthe wire ~~ [ignition switch ON ‘Check for voltage to ground: + Blown No. 1(7.8 A) fuse in the | veuwar There should be battery voltage, | _under-dash fuse/relay box | « Anopen in the wire Tenition Key inserted | Check Tor continuity vo ground? | » Faulty ignition key switch 5 | BLuHT?| into the ignition switch | There should be continuity + Poor ground (Gé01) | | * am open in tho wire | Biiver's door open | *Check or continuity to ground’ | > Faulty criver’s door switch 8 | GRNRED There should be continuity. + An open in the wire Toner | Driver's door Key evlin- | Check for continuity to ground) | » Faulty driver's door Key cylinder 7. | GRNVRED® | dor switch in UNLOCK | There should be continuity switch Driver's door key evlin- + Poor ground (G501) 8 | GANAWHT?| Gor switch in LOCK + An open in the wire Front passenger's door | Check for continuity to ground: | + Faulty front passenger's door key 9 | GrN/eLu*| key cylinder switch in| There should be continuity. cylinder switch UNLOCK + Poor ground (G451) Front passenger's door enone a aeudte 10 | GRN/vEL: | key cylinder switch in Lock I | Driver's door lock knob | Check for continuity to ground! * Poor ground (G501) 17 [BLUMWHT? | in Lock ‘There should be continuity. | An open in the wire ‘Driver's door lock knob 12 | BLURED? | in UNLOCK ‘Connect the VEUIRED? | Check the door lock actuators: + Faulty actuator and WHT/BLU' termi- | All doors should unlock as the bat- | + An open in the wire nals and the WHT/RED | tery is connected momentarily. and BLK" terminals WHTIRED | momentarily 13 | and VeUneD: | Connect the WHT/RED | Check the door lock actuators ‘and WHT/BLU' termi- | All doors should lack as the battery | nals and the YEL/RED? | is connected momentarily. and BLK" terminals momentarily * Before testing, remove No. 29 (15 A) fuse in the under-hood fuse/telay box and No. 8 (10 A) fuse in the under-dash fuse/relay box. 23-18- Passenger’s Door Lock Actuator — Test 1. Remove the passenger's door panel (see section 201, 2. Disconnect the 2:P or 6-P connector from the door lock actuator, Front Passenger’s Door — View trom wie side 6 CONNECTOR Rear Passenger’s Door: View from 2. CONNECTOR 3._Test the actuator Terminal 3m 40 | Position [Hock ® ® UNLOCK ® S (Rear CAUTION: To prevent damage to the actuator, connect battery power only momentarily 4. Ifthe sctuator does not work properly, replace it 7 Key Cylinder Switch Test NOTE: This test applies to the Keyless Entry and Security Alarm System, too. 1. Remove the front door panel 2. Disconnect the 3-P connector from the key cylinder switch 3. Check for continuity between the terminals in each switch position according to the table. Terminal 1 2 3 Postion tock O—f—-0 uwiock of 13 2 3-P CONNECTOR View trom wire sige 23-19