Civic Manual EP3 Tyre R Manual

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Manual Service lndex

NOTE: Refertothe lollowing listto look up DTCS, symptoms, fuses, connectors, wire harnesses, specifications, maintenance schedules, general and service inlormation: DTCTroubleshooting Indexes ABS/TCS Components ........................ 19-34 '17-22 EPS Components ................................. Fueland missions E 11-i Heating/Ventilation ................................ 21-9 A/C Pressure Switch Circuit Troubleshooting ...-.-....-...-.-.-....-..21-32 ......... B A/C SignalCircuit Troubleshooting.........................-...... 11-'133 A/F lAir FuelRatiol Sensor Replacement ....................................... 11-113
Back-up LightSwitch Test......................................................... 13'3 Back-up Li9ht3 Circuit Diagram
22-75 A-Dillar Corner Trim Replacement ...............-.....-..............-.... BallJoint Boots 20,96 . . 3 .. . s R S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 . . - 2.8. . . . . . . . . . . . . . . . . Replacement ...... 1 81 6 ABS IndicatorCircuit SymptomTroubleshooting Indexes Troubleshooting ... 19-52 BallJoints ABS/TCSComponents........................ 1935 R e m o v a 1 . . . . . . . . . . . . . - . . ................ . . . 1 8 - 1 0 Cruise Control System..........................4 ABSModulator-contml 38 Unit EPS Components ................................. Bemoval/lnstallation 17-23 ............................ 19-57 Betterv FanControls 10,12 .......22 50 Fueland Emissions .............................. 11-10 ABS/TCS Comoonents Heating/Ventilation..............................21 10 Component Location Index................. 19-30 Beverage Holder . .u S R S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.' .3 0. . . . . .C.i.r.c . .i.t.D i a q r a m . . . . . . . . . . . . . . . . . . . . . 9.' .4 2 2 . .. 1 . .. Blower Motor Fuse/Relay lndexes Accessory PoworSocket Front Replacement ..... 2 14 1 Power 0istribution ...............................22-46 TesVReplacement .............................. 22'149 Under-dash Fuse/Relay ............... Box 22 45 Blowor PowrTransistor Under-hood Fuse/Belay ...............22 Box 44 Accessory PowerSockets 21-38 Circuit Oiagram .................................. 22-149 Connector and Wire Harness lndexes Blower Unit Component Connectors Air Cleaner Removal/lnstallation ............................ 21-39 (to harness) ......2214 Rep1acemen1.....................................11-162
Meintenence section.................... 3 Section Gene.allnlormationsection........ Section1
Air MixControl Motor Replacement ......................................... Brake 21'34 Celipers Test ......................21-34 Overhaul
19-14,23
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Airbag.Driver's Irake Discs Replacement ....................................... Inspection 23 1'l3 .................... ................... 19-13,22 R e p a i.r. . . . . . . . . . - . . . . . . . . . . . . . . . . . . .2 . . 11.6. . . . . . . . . . . . .3 .. . A BrakeFluidLevelSwitch Airbag.Front Passenger's Test 19.10 Beplacement....................................... 23-1 14 AIC BrakeLights Location fndex...................21-3 Altemator Component CircuitDiagram....................................22-7 D e s c r i p t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - e.p .l 2 1 e ml e. n.t. . . . . . .............. . . . . . . . . . . 4.2.9 . . . . . B . . ac'1' . . . . CircuitDiagram....................................21-14 Overhaul .................................................4-30 Brake Lines and Hoses 21.57 Inspection ............................................. 19-24 AhernatorFRSignalCircuit R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1.9 - . . 5 . .. 2 . A/C Compressol T r o u b l e s h o o t i n.g . . . . . . . . . . - . . . . . . .1 3.4 1 . . .. 1 -41 Replacement .......-...-............................. 21 BiekeMeder Cylinder Antenna Rep1acement......................................... 19-15 A/C Comprssor Clulch Replacement .........22-103 Inspection ............................................. 19-16 Inspecton........ 21-44 .......... Overhaul 2l-49 AudioUnit BrakePads Removal/lnstallation ..........................22-100 Inspection/Rep1acement................ 19-11,20 A/C Compressor ClutchCircuit Troubleshooting ................................... AudioUnitConnector 21-30 Brake Pedal Replacement 22101 Adjustment.............. 19,6 ArfCComoressor ReliefValvc Replacement ..........-...-.......................... Audio/Entertainment 21-51 Breke Pedal Posilion Switch Component Location dex.................22-9A Test..... In ..-.............. 22-84 A/C Compr$sor ThermalProtector CircuitDiagram R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . . .2 . . - 5.1. . . . . . . . . . . . . 1 .. . BrakePedalPositionSwitch SignalClrcuit Troubleshooting 11-137 A/C Condenser Replacement,., .....252 1 A/C Condenser Circuit Fan Troubleshooting .................... .....21-28 ....
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Service ManualIndex
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BrakeSystemIndicatorCircuit Circuit Diagram Conventional Brake Components..... 19-9 Troubleshooting ABS/TCS Components ....... 19-55 .... ...... Bulb,Geuge R e p | a c e m e n l . . . . . . . . . . . .......... . . . . . . . 2 2 6 3 CombinationLight Swilch CylinderHeadAssembly TesVReplacement ..............................22 Component 80 Location Index..................... 6-3 Inspection ................................................. 66 Connecting Rod Bearings Removal .......... &23 R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .-.. . . . 7 - 8 I n s t a 1 1 a l .i . . n. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. . . . . . . . . . . . . o. 63.
Connecting Rod Bolts CylinderHeadCover fnspection ....................-.-.-.-.................... 7-24 8emova1 ..............-.-................................. 6-22 Installation ..............................................6-41 Bulb,Headlight ConnectingRods Replacement ......................................... Inspection 22-A1 ........,,.,.,...,.,.,.,.,,,,.,,,.,.,.,.,.,.,.,.. 75 CylinderHead,Bare
Inspecton..,.....,.
Bumper,Front Removal/1nsra11ation ............................ 20 85 Bumper,Rear R e m o v a l / l n s t a l l a t i o.n . . . . . . . . . 2 0 . 8 6 .
Connectors (See firstpageof thisIndex) Conventional BrakeComponent3 D Component Location Index................... 19'3 Troub1eshootin9 ..................................... 19-4 R e p a i.r. . . . . . . . . . . . . . . . . 19-8 Dampers. Front R e p l a c e m e n t . . . . . . . . .. .. .. .. .. .. .. .. . . . . . . 1.82.0 . . .. . Coolant I n s p e c t i o.n . . . . . . . . . . . ........ . . . . .1 0 6 Oampers, Rear R e p l a c e m e n t . . . . . . . . . . . . ....... . . . .1 06 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . 1.8 .-.3 . . . . . . . . . . . . . . . . .4
CableReel Replacement....................................... CoolantTemperature 23-1 19 Gat|ge DashVents T r o u b 1 e s h o o t i n 9 . . . . . . . . . . . . . . . . .2 . . 6.4 . . . . . . Bemoval/lnstallation .2. . ...... .-.......................... 20-64 Camshaft Inspection .......................-...-................... 6-29 CoolingSyslem Dashboard Component Location Index................... 10-2 Bemoval/1nsta11ation ............................ 20-66 CargoArea Light TesVRep1acement ................................ Countershaft 22-97 Bearings Oashboard CenterPanel R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . 1.3.-.4 . . . .2 Removal/1nstaf ............................ 1ation 20 62 Carpet R e p l a c e m e n t . . . . . - . . ..- . . . .... . . . . - . 2 0 - 5 5 . Cowl Cover Dashboard Lower Cover R e p l a c e m e n t . . . . . . . . . . . ........ . . . . . 2 0 - 9 5 Removal/lnstallation ...................... 63 20-59, CeilingLight -estrReplacement ................................ 22.96 Crankshaft Dashboard UnderCover R e m o v a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . 2. . . . . .Removal/lnstallation .. .-1 . ........ ............................ 20 60 ChargingSystem Inspec(on,,,,, ........14 Location Index................... 4-20 l n s t a l l a t i o n . . . . . . . . . ... . . . . . . . . . . . . . 1 - 2 4 Component DifferentialCarrierBearings, M/T . . .1 C i r c u i t i a g r a m. . . . . . . . . . . . . . . . . . . . . . .4.-.2 . . . . . . . . . . D Rep1acement,,......,...,...,.,.,,,.,.,,,........,.,. 13-54 Troubleshooting . . . . . . . 4 - 2 2 Crankshalt Main Bearings R e p l a c e m e n t . . . . . . . . - . - . . . . . . . . . . . . .7.-.6 . . . . . .Ditferential Seals,M/T . . . . . . . . . . . . . Oil ChildSeatTetherAnchor 8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1 . .- 5.5 . . . . . . . . . . . . .3 .. . R e m o v a l / l n sa a;fo n.. . . . . . . . . . . . . . . .2 .3 . .1. . l tt . . .1 . CrankshaftOilSeal,Transmission End 1nstanation .............................................. 7 28 Differential PinionGears,M/T CKP(Crankshaft Position) Sonsor I n s p e c t i o. n. . . . - , . , , , . , . . , . - , . , . . . . . .1 . .5 . , . , , , , .3 ,3 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .11.-.1 . . 6. . . . . CrankshaflPulley .. . 1 . ..... Removal/lnstallation -..................-.......... OLCCircuit 6-1 1 Clutch Troubleshooting ................................ 11-109 ComponentLocation 1ndex................... 12-3 CruiseControlActuator R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . . . .1 . . - 9. . . . . .Test . . . . . .2 .. ..... ...................... 4-43 Door Glass R e p I a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . 4.-. 4.4 . . . . . R e.p . . a.c e m e n t . , . , , , , , , , , , , , . , , , , , , , 2,0.-,9 , . , . , . , , , , , , . , , . . . ... . 1 . , , . ClutchInteYlock Switch Adjustment. .. .....................20-11 T e s t . . . . . - . . . . . . . . - . . . - .......-.-.-. .. - . . . . . . . 4 - 6 CruiseControlActuatorCable . Adjustment ............................................. 4 45 Door GlassWeathelstrips ClutchMasterCylinder R e p l a c e m e n.t. . . . . . . . . . - .. .. . . . . . . . . - . . . 1.02 0 .. . . . R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . 1.2. . . . . . . . Cruise. . . .5 . . . . . . . ControlMain Switch TesVRep1acement .................................. Door Latches 4 42 clutch Pedal Replacement ..........-.-.............................. 20-7 Adjustment ............................................. 12 4 CruiseControlSet/Resume/Cancel Switch TesVRep1acement .................................. Door LockActuators 4 42 ClutchPedalPositionSwitch Test...................................................... 22-154 T e s t . , . , , , , , . , , , . , . , , , , , , . , . ,.,.,.,.,.,.,4 , . 5, , , , . . CruiseControlSystom ,4, Component Localion Inde\................... 4-36 Door LockKnob Switches Clutch Slave Cylindor C i r c u i t i a g r a m. . . - . . . . . . . . . . . . . . . . . . .4 .3 7. . . . . . .Test-......... . - . . . . . . . . ......22-160 D . . .. ... .. Beplacemeit... 12-1 CruiseControl Unit Door LockSwitches CMP{Camshaft PositionlSenso] I n p u t T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4., 4 0 . T e s t. . . . . . . ........ . . . . . . . . . . . . . ..................2.2.-. 1 6 0 .. . R e p l a c e m e n t . . . . - . . . - . . . . . . . . . . . .11 . .1 2.8 . . . . . . . . . . .. - .. . Door Outer Handles CMP(TDC) Sensors Rep1acemen1 ........................................... 20-6 R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . .11.11.4 . . . . . . . . . . . .. .. .
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Door Panels Removal/lnstallation -............................. 20-4 EPSConirol Unit Removal/1nsta11ation ..................-......... 17-67 Front Speakers Rep|acement....................................... 22-102 Front Suspension ComponentLocation Index................... 18-3 Fueland Emissions Description ........................................... 11-12 FuelFill Door Adjustment ..........-................................ 20 93
Door SashTrim EPSIndicatorCircuit Rep1acement......................................... 20 10 Troubleshooting ................................... 17-47 Door Strikers EPSMotor Adiustment ........................................... Removal/lnstallation 20-13 .-.......................... 17-49 Door Weatherst ps EVAPCanister Beplacement...........-............................. e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . 1.1 . . 8 9 20 11 R . . ,1 OriveBeh Inspecaron ................ 4-26 R e p | a c e m e n t . . . . . . . . . ................ . . . . . . . . .6. . . 42.
EVAPControlSystm FuelFill Door Openet ComponentLocation Index ..............'11-170 B e p l a c e m e n t . . . . . . . . . . . ... . . . . . . . .2.0 . 1 0 9 . .
EVAPTwo-WeyValve FuelFill Door OpenerCable DriveBelt Auto-tensionel T e s t. . . . . . . . . . - . . . . . . . . . . . . . - . . . . . . . . 1.1. . 8.6 . . . . . .Replacement....................................... . .1. . ...... 20-lO7 lnspection ............................................... 4 21 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . .....4.-.2 . . . . . . . . . . . .8 Evaporetor Core FuelFilter R e p 1 a c e m e n t . . . . . . . . . . . . ... . . . . . . . 2.1 - 4 2 . . R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .11.-.1.5 2. . . . . . . . .. . .. Driver'sPocket Removal/lnstallation -........................... 20-60 Evaporator Tomperature Sensor FuelGaugeSendingUnit Replacement......................................... e s t. . . . . . . . . . . . . . . . . . . . . . - . - . . . . . . . . 1.1 . 1.5.6 . . . . . . . . 21-37 T . - '. . . Driver'sTray Test..................................... 2137 Removal/lnstallation .........................-.20-65 FuelInjectionSyslem (PGM"FIl EvaporrtoFHeater Unit Component Location 1ndex................. 11-49 DRL{DaytimeRunningLightsl R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2.1 4.3 . . . . . . . . . . . . . .. . Control Unit FuelIniectors lnputTest ..................... . . ......22-16 ........ ExhaustManifold R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . . .1 .11l. . . . . . . . . . . 1 . .. Removal/1nsta11ation ................................ I 7 DTCs FuelLinesand Hoses (See firstpageolthis Index) ExhaustPipe I n s p e c t i o n. . . . . . . . . . . . . . . . . . . . . . . . .11.' .1 4.6. . . . . . . .. .. .. . 8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . .9 - . . . . . . . .R.e . . .o . .a l . . . . . . . . . . . . . ... . . . . . . . . . . . 1 - 1 4 9 ..8 . . m . v .. . 1 Dust and PollenFiller I n s t a | 1 a t i.o .n . . . . . . . . . . . . . . . . . . . . . . 1. . . . 5.0 . . . . . . . . . . .1 1. . R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2.1 - . .9. . . . . . . . . . . . . ..3 . FuelPipeProtectol DynamicDamper,Driveshafts R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2 . .- 1.0 .4 . . . . . . . .0 .. . . R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . 1.6 .-.8 . . . . . . . . . . . . . . . . . FuelPressure Regulatot FanControls R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .11.-.1.5 2. . . . . . . . .. . .. C o m p o n e n t c a t i oIn d e x . . . . . . . . . .1.0 . l. . . Lo n . .' 1 C i r c u i t i a g r a m. . . . . .. . .. . . . . . . . . . . . .1 .0 1.3 D . . .. . FuelPulsationDamper R e p l a c e m e n l . . . . . . . . . . . . . . . . . . . . .1.1 1.5 .4 . . . . . . . .. . . FenderFairing,Front ECTSensor R e p l a c e m e n t . . . - . . . . . . . . . . . . . . . . .2 0.-.1.0 . . . . . . FuelPump .. . .3 ..... R e p l a c e m e n t . , . , , , . , . , , , , , , , , , , , ,11.-.1 .4 . . . . . . . . . . . ,, 1 . . R e p l a c e m e n t , , , , , . , . , . , , , . , , , , , , ,1 , , - 1.5.3 . , , , . . , , 1 ,, , , FinalDrivenGear.M/T Elctrical PowerSteeringIEPS) R e p l a c e m e n t.... . . . . . . . . . . . . . . . . . . . . 1.3.-.5 . . . . . . FuelPumpCircuit . . .3 SignalCircuit T r o u b l e s h o o t i-n g. . . . . - . . . . . . . . . . .11.-. 1.4 . . . . . .. .. . . 1 T r o u b l e s h o o t i n.g . . . . . . . . . . . .1 1 - 1 3 5 Frame R e p a iC h a n . . . . . . . . . ...... . . . . . . . . . . . .2 . . 1.1 . . r 4 .0 . . FuelSupplySystem Emblems Component Location lndex ..............140 11 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2 - .-.1.0 . . . . . . FrameStiffenel .0 . .0 ..... A d j u s t m e n t . . . . . . . . . . . . . . . . . . . . 1.1 . . . 4.4 . . . . . . . .-1 . . R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .2 0.-. .' . . 3. . . . . T.e .s. t . . . . . . . . - . . . - . . . . . ....... . . . . . . . . . . . . 1-- 1 4 5 .. J 1 . . . 1. EngineAssembly R e m o v a 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. . . . . . .FrontConsole .. . . .......... FuelTank Installation ............._.................................. 5-9 Removal/lnstallation ............................ 20 5l B e p l a c e m e n l . . . . . . . .. . . . . . . . .1 11 5 5 DisassembJy/Reassemb|y ................... 20 58 EngineBlockAssembly FuelTankVapor ControlValve Lo n C o m p o n e n t c a t i oIn d e r. . . . . . . . . . . . . . . . 3. . . . Front Doors 7 . T e s t. . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . 1 1 - 1 8 7 . Component Location Index................... 20-2 R e p l a c e m e n t , , . , , . . . , . , , , . ,. . , ,.,., .1 . 1 8 9 .1 EngineBlock,Bare A d i u s t m e n .t . . . . . . . . . . . . . . . . . . . . . . . . .2 . . . 1.2 . . . . . . . . . . .0 . . Inspect|on ................7-15 Fuses Repair . . . . . . . . . . . . .1 1. 1 .. Front DriveshaftAssembly firstpageofthis Index) {See I n s p e c l i o.n . . . . . . . . . . . . . . . . . . . . . 1 6 3 . . Entry Light ControlSystem R e m o v a 1 . . . . . . . . . . . . . . . ....... - .. .. .. .. .. .1 6 - 3 Component Location Index...............-. 22-89 D i s a s s e m b l y. . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 .. 1. . Circuit Dia9ram.................................... Resassemb|y 22 90 ................................-......... 16-9 I n s t a 1 1 a r.i.o . . . . . . . . . . . . . . . . .......... . . . l 6. . 7 .n .. 1 EPSComponents Component Location 1ndex..........-...... 17-!7 Front lmpact Sensors D e s c r i p t i o n. . . . . . . . . . . . . ............. . . . . 1 7 - 2 4 .. R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . 3. 1.2.5 2. . . . C i r c u i tD i a g r a m 1 12 6 (cont'd)
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HeaterValveCable A d j u s t m e n . . . . . . . . . . . . . . . . . . . . . . . . . .? .1 - . .6 .t . ..4 .
lmmobilizerSystem Component Location dex .............. In 22-162 Description High Mount BrakeLight C i r c u i t D i a g r a.m. . . . . . . . . . . . . . . . . . . . . . . . . 2 2 - 1 6 4 . GaugeA3sembly 8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . . 2.2 . . 2. . . . . . .Troubleshooting............................ . .8. ...... 22,165 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2.2 6.4 . . . . . . . . . . . . . . .. . Hood InnerFender, Fronl Gaugs Adjuslment Repf acemenl....................................... 20-102 Component Location Index..........-...... 22 54 H o w - t on f o r m a t i o n. . . . . . . . . . . . . . . . . . . . . . . 2 2 - 5Hoodlnsulator l . 6 InsideRearviewMirror Circuit Diagram 22-54 Replacement......................................... e p l a c e m e n t . . . . . . . . . . - . . . . . . . . . . .2 . . 1.6 . . . . . . . . . . . . . 20-89 R .0. . GenoralInformation (Seeseclion 1) GloveBox Removal/1nsta11ation .......................-.... 20-63 Hood Latch R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .1 0 8 2 HoodOpenerCable ComponentLocation Index ..............20 105 R e p l a c e m e n.t. . . . . . . . . . ...... . . . . . . . . . 2 0 0 6 .. 1 InstrumentPanel Removal/1nsta11ation................. ....... 20-59 IntakeAir Bypass ControlThermalValve T e s r . . . . . . . . . . . . . . . . . . . ........... . .....1 . . - 1 6 1 .1
Grille IntakeAir System Replacement...........-............................. 20-94 Hood Seal Component Location Index...-.-........ 11-159 Beplacement.-...........................-........... 20-88 IntakeManitold Horn Removal/1nsta11ation ................................ I 2 H TesVReplacement. ................ 22-122 . ...... lntermediateShaft Assembly Horn Switch R e m o v a 1. . . . . . . . . . . . . . - . - . . . - . . . . . . . . 6.-.1.9 . . . . . . . . . . . .. 1. . . Test ............-........ 22-122 D i s a s s e m b | y . . . . . . . . . . . . . . . . . . . . . - . . 6., 2 0 1. Adiustment ....... R e s a s s e m b. |. y. . . . . . . . . . . . . . . . . . . . . .1.62.2 . . . . . . . . . . . .. . Horns Installation .........-...-.............................. 16-24 HatchHandle Component Location Index. . . . . . . . . . . . . . 2 2 - 1 2 0 Replacement 20-110 Circ!itDiagram 22 121 Hatch Latch Replacement
Hatch Latch Switch
H02S.Secondary
20-'110
K
. . . 1 11 1 3 .
Replacement
Test H.tch Lock Actuator Test 22-159
Hubs Keyless Entry Transmitter R e p l a c e m e n.t.. . . . . . . . . . . . . . . . . . . . . . 1.A2.6 . . . . . . Repair . . .. . ............... 22-161 T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 . .1. . . . . . . . . . . . . 2 . .6 . Keyless Entry/SecurityAlarm System Componenl Index..............150 Location 22 C i r c u i l i a g r a m. . . . . . . . . . . . . . . . . . . . 2.2.1 5 1 D . . . .
HatchLockCylinder R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .2 . . ,. 1.1 . . . . . . . . . . . .0 . .1 IAT {lntakeAir Temperature} Sensor Keyless Receiver Unit '11 HatchSpoiler Replacement.,.........-... 115 lnputTest ............................................ 22-153 Replacement ldle ControlSystem KnockSensor HatchSupport Struts ComponentLocation Index .............. 11-129 R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .11.1.1 5. . . . . . . . . . . .. . .. Beplacement..... 20-91 I n s p e c t i o n , . , . . . . . . . . . - . . . . . . . , . , . , ,',l, , 3.8 , , . , . , . . . . . 1 1, , Knuckles HatchWeatherstrio lgnition Coillsl Replacement Replacement.... 20-92 Bemoval/lnstallation ...............-.............. 4 18 F r o nS u s p e n s r o .n . . . . . . . . . . . . . . . . . 8.-.1 . . . . . t . . 1. . Rear Suspension ........ .................-... 18-28 Hazard WarningSwitch lgnition Key Light test .................... 22_88 T e s t , , . , , , , . , . . . , . . . . . . -....................... . 22-91
H6adlight Adjustment lgnition Key Switch
..22-78
Test lgnition Switch Test .,,,.,.,.,,,,.,.,.
. . . . . . . . . . . . . . .2 2.-. 9.1 . .. . . ......22-53 License Plate Light R e p l a c e m e n t . . . . . . .-. . . . . . . . .....22-83
ReQ\ace$ent Hcadlights Diagram.............................. Circuit 22-71, 72 Headliner Removal/lnstallalion ............................ 20-54
lgnition System License Trim Component Location Index................... 4-15 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . - . . .2 0.-. 9.8 . . . . - . . . . . . . -. . . C i r c u i t D i a 9 r a. m . . . . . . . . . . . . . . . . . . . . .4 . 1.6 . . . . . . . .. .'. . 1nspection ............................................... 4-17 Lights,Exterior HeaterControlPanel Index.................22 Component Localion 68 Removal/1nsta11ation ............................ 21-38 lmmobilizerControl Unit-Receiver 22-161 Lights,Interior HeaterControl Powerand GroundCircuits Component Index................. Location 22-94 T r o u b f e s h o o t i n g . ................ . . . . . . . . . . . . . . . 2 1 - 2 7 C i r c u i t D i a g r.a m . . . . . . . . . . . . 2 2 - 9 5 .
)
Low Fuellndicator Test.............
MoonroofDrainChannel Slider Oil Pressure Switch 20'44 T ..4 . . . . . . . . 1 1 - 1 5 8 Replacement......................................... e s t. . . . . . . . . . . . . . . . - . - . . . . . . . . - . . . . . . . . .8 - . . . . . . . . . . . R e p l a c e m e n t . . . . . . . . . - . . . . . . . . . . . . .8.-.1 . . . . . . . . . . . . .6 Moonroof Frame LowerArms 18 19 R , ,4 , Oil . . . . Removal/1nsta11ation............................ e p 1 a c e m e n t , , , , , , , , , , . , . , . , . , . , . 2.0 , ,2, , . . . . . . . .Pump,Engine 8-8 Overhau1 .................................................. MoonroolGlass Lubrication System 20-37 Location Index..................... 8-3 Adiustment ........................................... Oil, Engine Component Re . . . . . .. . T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. 4. . . . . . . R e.p.1 a.c . . m e n t . . . . . . . . . . . . . . . . . . . . . 2.0 3.7. . . . . . . . . . p.l.a c e m e n t . . . - . . . . . . . . . . . . . . . . - . - .8.-.5 . . . . . . . . . . . ... . .. . e ..
OPDSUnit Moonroot Limit Switch 20 46 .3 1 . . . Adjustment ........................................-.- R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2 . .- .2.4 . . . . . . . . . T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 . .3. . . . . . . . . . . . . 2 . .1 . M OutsideMirror Holders 20-15 Beplacement......................................... Moonrool Motor R e p l a c e m e n t . . . . - . . . . . . . . . . . . . . . . .2 . . .-.4 . . . . . . . . . . . . . . D .1 M/TAssembly Test . . . . . . . . . . . . . .2.2 . .1 2. . .- .. OutsidePower Mirror Actuators Removal .......... 13-4 22-117 Test...................................................... . . . . .1 3 - 8 . lnstallation....... 22-1 14 Bepf acement..-.................................... D i s a s s e m b.l.y . . . . . . . . . . . . . . . . . . . . . . .1 . .- 1.4 . . . . .Moonrool Sunshade . .3 .. . ... R e p 1 a c e m e n t . . . . . . . . . . . ....................2.. .4 0 .. 0 . . . R e s a s s e m b . y . . . . . . . . . . . . . . . . 1.3 .- 4 6 l. OutsidePower Mirror Switch 22-111 Test..-................................................... MoonroofSwitch M/TChangeLever .............................. 22-l 12 .............................................TesVRep1acement 13-19 lnspection OutsidPower Mirrors 13-20 8eassemb1y ................... Disassembly R e p l a c e m e n t . . . . . . . . . . . . . . . . .. .. . .....2.0 - . .5 . ..1 Mooniool Wind Deflector lndex ..............114 22Location R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2- . - 3.8. . . . . Component . 0 .. . ....... M/T Countershaft Assembly Diagram .................................. 22-115 Circuit .. 1.3. . . I n s p e c t i o n. . . . . . . . . . . . . . . . . . . . . . . . 3. . 1.,3.3 . . . . . 22-116 Test-..................................................... . . .. . . ... D i s a s s e m b.1.y . . . . . . . . . . . . . . . . . . . . . .1 3.-. 3.2 . . . . .Moonroof/Sunroof 22-108 ........................................ ComponentLocationIndex ...20-35, 13-34 Resassemb|y .. . . T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 0.-.4.8 . . . . . . . . . . . . . . r . 2 . 1 .. C f c u i t i a g r a m. . . . . . . . . . . . . . . . . . . . . .2.-. .0 9. . . . . D M/T Differential P Index................. 13-52 ComponentLocation .t . 3 .. . .... A d i u s l m e n . . . . . . . . . . . . . . . . . . . . . . . . . .1 . . - 5.6. . . . .MTF I n s p e c t i o n / R e p 1 a c e.m.e.n ........ . . . .1 3.- 3 . . .t .. Parking Erake M/T Maifthaft Assembly I n s p e c t i o n d j u s t m e n t . . . . . . . . . . . . . . . . . 1.9 . 7 A . . .13-23, 26 MuhiplexControlSystem 1nspection ................................... ... lndex ..............22 168 1325 Disassembly ......................................... ComponentLocation 22-169 Parking Brake Cable 13 28 Diagram .................................. Resassembly ........................................ Circuit 1 . . .6 ......................................... R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 .-.2 . . . . . . . . . . 22-17 ........................................... 0escription 13-43 Adjustment ................................ 22-17 2 Troubleshooting ParkingErakeSwitch M/T Reverse Shift Fork . . . .1 9 - 1 0 . Test................. l3 .. I n s p e c t i o. n. . . . . . . . . . ................ . . . . . . . . . . .1 9. . . Muliiplex ControlUnit, Under-dash . InputTest Passenger's TraV 22-92 EntryLightControl Sysiem............. M/T Shift Level ............................ 20-65 Removal/lnstallation Alarm Keyless Entry/Security R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1.3 . . . 1. . . . . . . . . . . . . .-5 . 22-155 .-....................................... Systern 115 PCVValve MultiplexControl System.............22 MainshaftBearings 22'1 41 .. .. . R e p l a c e m e n t . . . . , . . . . . . . . . . . . . . . . .1.34.1 . . . . . . . . Wiper/Washer................................. B e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .11.'.1 6.9. . . . . . . . . . .. . ..... T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 1. 1.6 . . . . . . . . .. . .9 Mairtenance PistonRings 3) lSeesection 8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .7 . . . 1. . . . - . - . . .-2 . N MIL Pistons ............................. 11.46 How to Informatron R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . - . . .7.-.1 . . . . . . . . . . . . .8 NoiseReduction Condenser .. . . . . . . . . . . . . . . . .1 0 1 .22 1 n s t a | 1 a t.i .o n. . . . . . . . . . . . . . . . . . . . . . . . . 1.-.2.3 . . . Test,, MIL Circuit .11 Troubleshooting .......... . . . . ......... 97 PowerRlay 22-51 Test...............-.-...................................... Mirrors 20'14 Index................. ComponentLocation PowerWindow Motor, Driver's t e s l . . . . . , ,.,,,. , , , . . . . . . . . . . . . Mode ControlMotor . . . . . . . . . 2 1 , 3 5 Oil Filte] Replacement .. ...... T e s t . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 2 1 3 5 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. - 6. . . . . . . PowerWindow Motors, Passenger's
Oil Filter Feed Pipe MoonroofAuto Stop Switchos 22'113 R Test...................................................... e p l a c e m e n t . . . . . . . . . . . . .....- , . . . , . , , , , , , , , 8 - 7
l' ,e
PowerWindow Switch, Master 22-126 lnputTest ..........-.........-....................... T e s r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 . . 4. . . . . . . . . 2 . .2 . Oil Pan Moon.oot ControlUnil 22-133 22-110 . . .... lnputTest ............................................ R e m o v a l. . . . . . . . . . . . . , . , , , , , , , , , , , , . , . , , , .7 .1.1. . . . - . . .Replacement.......................................
. - .. l n s t a l l a t i o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. .2 7. . . . . . . . . . n
MoonroofDreinChannel .0. . B e p l a c e m e n.t .. . . . . . . . . . . . . . . . . . . . . .2 . .3.9 . . . .
(cont'd)
Manual Service lndex

(cont'dl
PowerWindow Switch, Passenger's lnputTest .............-...... 22-130 22 132 Replacement...,-.-.-...,.. 22-133
C o m p o n e n t L o c a t i o nI n d e x . . . . . . . . . . . . . . 21 2 4 2 C i r c u i D i a 9 r a m. . . . . . . . . . . . ............ . . . . .2 2. . 2 5 t .. 1
RockerArm Assembly Removal 6-26 D;sassembly/Reassembly ..................... 6-27 lnstallation 6-38 RockerArms Test Inspecton Roof Moldings Replacement 6-7 6-28
Specifications (See section 2)
sRs
Location Index................. Component 23-13 D e s c r i p t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . 3.-.3.1 . . . . . . . 2. . . C i r c uDt; a g r a m. . . . . . . . . . . . . . . . . 2 3 3 4 i . lnspection/Replacemenl ...................12 23 1 SRSlndicatorCircuil Troubleshooting 23 105
o
Ouaner Window Glass 8ep1acement ......................................... 20-29
s
Seat Belts Component Location Index................... 23-3 Seat8ehs, Front Replacement rnspec!on
SRSUnit Replacement..-.................................... 23-122 StabilizerBar Replacement Front Suspension Rear Suspension StabilizerLinks Removal/lnstallation Front Suspension Rear Suspension Startel Test Replacement Overhaul StarterSolenoid Test 4-7
R
Radiator Test......
R e p l a c e m e n t. . . . . . . . . . .
1A-17 18-30
23-9 23-1 20-75 20-84
10-3 10-10
1 81 8 18-31
SeatBehs,Rear
Replacement
Radiatorand Condenser Fans CommonCircuit T r o u b l e s h o o l i n g . . . ........... . . . . . . . . . 2 1 9 2 RadialorCap Test..-.-... 10-3
SeatCover,Front Replacement SeatCushionCover,R6ar

Replacement
RadiatorFanAssembly Test ........................ r0-4 RadiatorFanCircuit Troubleshooting RadiatorFanSwhch Replacement Test RadiatorFanSwitch Circuit Troubleshooting RearAir Outlet Replacement 10-14 10-17 10-17 1 01 6
2Q-104
Seat,Driver's Removaf/lnstaf ............................ lation 20 11 Disassembly/Reassemb1y ................... 20-73 Sedt,FaontPassenger's Disassembly/Reassemb1y ................... 20-74 Seat,Rear Removal/lnstallation ............................ 20-80 Seat-back Cover,Reer
Replacement Seat-back Latch, ReaI Replacement
StartingSystem Component Location Index...............-..... 4-3 CircuitDia9ram ........................................ 44

Troubleshooting
\'
Steering Component Location Index................-.. 17-3 Inspectaon ................... 11-4 SteeringColumn Removal/lnstallation
Inspection
17-9 1 11 1 17-51 1 75 5 17 63 20 68
SteeringGearbox
Removal Overhaul lnstallation
RearWindow Defogger Index ..............22 104 ComponentLocalion Diagram 22-105 Circuil Test 22 106 RearWindow Drogger Wires Repair RearWindow Glass
Replacement
Seat-back Striker.Rear Replacement Seats Component Location Index....-............ 20-70 Shift Forks 13,21 Disassembly/Reassembly ................... 13-22
Inspectton
SteeringHangerBeam
Replacement
SteeringLinkage 22-106 20-25 Shitt Lever Trim Removal/lnstallation ............................ 20 61 2l-36 21 36 21 25 SideAirbag,Drivel's
Replacement Inspefiron
Steering Lock
Replacement
.....11-12
17-13
Secirculation ControlMotor Replacement Test.....

Recirculation Control Motor Circuit Troubleshooting
SteeringRackGuide Adiustment
23-115
174 Removal 17-6 D i s a s s e m b l y / R e a s s e m b l.y . . . . . . . . . . . . . . .1 . . . . .7 7 1 n s t a 1 1 a t i o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.-.8. . . . . .n 1. .
Sidelmpact Sensors
Replacement 23 123 Refrigerant Replacement ..-.-.-...................... 55 21 53,54, Side Marker Light Test........................................................ p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 .-.A.3 . . . 21-56 Re . . . .
Sublrames Replacement
20 112
Retrigerant Oil Spark Plugs R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . 2.1 .-.6 . . - . . . . . . . . . . . . . .
. .._..4_19
Suspension A d j u s t m e n t . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . .V . . . . . . . 1 8 4 .
Component Location Index................. 20-17
SynchroRing,Triple-cone WindshieldGless I n s p e c t i o n . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . .V . . l.v e G 9 i d e s . a 133u R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . . .2 . . 1.9 . . . . . . . . . . .0. Inspection ............-.-................................ 6 32 SynchroSleeve Beplacement ..........-................................ 6 33 WiperIntermittent Control Unit, Inspectaon/Reassemb1y ....................... 1339 RearWindow ValveSeats InputTest .....22-134 R e p a i .r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5. . . . . . . . . . . . . . . . 6. . WiDerMotor, RearWindow Rep1acement....................................... 22-1 46 Adjustment .-.-....... 6-9 Removal ...-...-......................................-... 6-31 WiDer Motor,windshield Taillight Inspec!on .....6-32 Test.......-..........-.....-.........................
Thermostai Test ........................ 10 4 R e p l a c e m e n t . . . . . - . . . . . . . . . . . . . . . . . 1.0I. . . . . . .
Vehicle Speed Signal Circuit Wiper/WasheI Troubleshooting ..........................22-65 .....-... Component Location dex ..............22-134 In Circuit Diagram .......................... 131 22-136,
Throttle Body Replacement -.............. .............22 ............ 61 Test.................. 11-160 Removal/lnstallation . . . .. ... 11-'165 .. . . VTCActuator Disassembly/Feassemb|y................-11-166 Inspection .................68 ThrottleCable A d j u s t m e n t. . . . . . . . . - . . . . . . . . . . . .1 .1 1.6 .3 . .. . . V T C i lC o n l r o l S o l e n o i d l v e O Va R e m o v a l / 1 n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . . . .e m o v a l4. . R ..1116 . . - . . . - . . .- 1 2 7 |1 Tie-rodBallJoint Boots VTCSystem B e p l a c e m e n t . . . . . . . . . - . . . . . . . . . . . .1.7 . .7. . . . . . C o.m p o n e n t L o c a t i o n l n d e x . . . . 1.1 . .1 1.7. . .6 . ... ... . . - .. . Timing/CamChain ...612
lnstallation . . . . . . . . . . . 6. .1 5 . ..
vss
Wiper/Washor Switch TesVReplacement .............................. 22-1 40 WireHarnesses
(S R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . .4. . . . . . . . . e e f i r s t p a g e o f t h i s l n d e x ) .. . 2.
Wi.ing System H o w t o I n { o r m a t i o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 .n Belay andControl Unit Locations .-....-.............. 22-7, 11, 12 -.-.-....- 4,
t s
VTECSolenoidValve Femoval/lnspection....-......................11-128
Timing/Cam Chain Auto-tensionel R e m o v a l / 1 n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -W9 1
Timing/CamChainCaseOilSeal Installation......................-......................6,21 FluidLevel Washer Switch TesVReplacement .............................. 22 144 TrailingArms Removal/lnstallation .............. . ..... 33 ... 18 Washer FluidReservoir Replacement ....................................... 46 22-1 tnm Component Location lndex................20 49 Washer Motor,Windshield R e m o v a l / l n s t a l l a t i o.n . . . .5 0 , 5 1 , 5 2 , 5 3 ..-. . 20 T e s t- . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . .1 . . 4. 2 2 .4 . Troubleshooting firstpageot thisIndex) {See Turn SignalLight Replacement Turn Signal/Hazard Relay InputTest........ .........22 A4
22-87
WasherTube,Windshield Replacement......-...-............................ 22 147 W.ter Outlet '10-9 Installation ..................-........................... Weter Passage
lnstallation
. . . . . . . . . . .1 0.I. . ..
Turn Signal/Hazard WarningLights Component Location dex.................22 In 85 Circu Diagram it ................-................... 22-86
Water Pump Inspection ........................... ....... 5 .. . . . 10 Replacement .-......................................... 10 5

WheelBearings I n s p e c | i o n . . . . . . . . . . . . . . . . . . . . . . . . . ............1.8 8. . . . .. . . Wheel Speed Sensors I n s p e c t i o n . . - . . , . , . , , . , , , , , . , . , , , . . . . . . . . . . . .1 . .- 5.9. . . .9 .. . R e p l a c m e n t . . . . . . - . . . ..... . . . . . - . . . 1 9 - 5 9 .. .
],s
UndeFdash Fuse/Rlay Box Removal/lnstaf ............................ lation 22-49 UpperArms R e m o v a l / | n s t a 1 1 a t i o n . . . . . . . .. .. ..1.8 - . . 2 . .. 3 .
WheelsandTires
Inspect|on
INTRODUCTION
How to Use This Manual This manualis dividedinto 23 sections. The first pageof each seclionis markedwith a blacktab that linesup with its corresponding thumb indextab on this pageand the backcover. You can quicklyfind the first pageof eachsectionwithout lookingthrougha full tableof contents. The symbolsprintedat the top cornerof each pagecan also be used as a quick re{erence system. Eachsectionincludes: 1. A tableof contents, an exploded or view index showingl . Partsdisassembly sequence. . Bolttorquesand threadsizes. . Pagereferences descriptions text. to in procedures 2. Disassembly/assembly and tools. 3 . Inspefiron. g. 4. Testing/troubleshootin 5. Repair. 6. Adjustments.
S p e c i fi c a ti o n s M a i n te n a n c e
1)ll:{l+'
Safety
Your safety, and the satetyof others,is very important. help To you makeinformeddecisions, have providedsafety we messages, and othersafetyinformation throughoutthis manual. Of course, is not practical possible warn you aboutall the it or to hazards associated with servicing this vehicle. You must use your own good judgment. You will find impoftantsafetyinformationin a varietyof forms including: . SatetyLabels on the vehicle. . Satetv Messages preceded by a salety alert symbol A and one of threesignalwords, DANGEF, WARNING, CAUTION. or Thesesignalwords mean:
Emissions
sR H tmEnEErily;,: i":5*i5"?;rE IousLY uBrir H,ll HURT ir E$EEEE ys,: f#,ff ,:hl:3,:JjERrousLY
tlGtltT]llilll YoucAN b HUBT vou don'tfollow if . lnstructionshowto service vehicle this correctlv safelv. and
All information in contained this manualis basedon the latest productinformation We reserve available the time of printing. at the right to makechanges any time without notice.No part of at this Oublication maVbe reDrodLrced, storedin a retrieval or in system,or transmitted, any form by any means,electronic, photocopying, mechanical, recording, otherwise, or without the priorwritten permission the publisher. o{ This includes text, figures, and tablesAs vou readthis manual,vou will tind information that is preceded a @ by symbol.The purposeof this message is to help preventdamageto your vehicle, other property, the or environment, pages FirstEdition 8/2002 1,168 HONDA MOTOR CO..LTD. All RightsReserved ServicePublication Office Specifications to U.S.A. Canada apply and
As seclion3 with *inclode SRS comoonentsi special precautionsare required when servicing.
*Body
z-tl!
^ t l
*Restraints
Information General
Ghassis and PaintCodes -2002 odel M Chassis and PaintCodes -2003 odel M . . . . . . . . . . . . . 1.-.2 . . . . . . . . . . . . . . .1.-.3 . .
ldentification NumberLocations ........ 1-4 Warning/Caution LabelLocations......1-5 Under-hood Emission ControlLabel ........... .... 1-7
L i f ta n dS u p p o r P o i n t s. . . . . . . . . , . . . . , . . .1 . .8 , . t .- . Towing ......1-9
PaftsMarkingLocations...................... 1-10
GeneralInformation
Model Chassis and PaintCodes- 2OO2
Vehicle ldentffi cationNumber
SHHEP3 5'2 3 U 300001
Engine Number
K2OA3 1700001 a
a. EngineType K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injected engine b. Serial Number
[[tttrtF
c d e f g h
a. Manufacturer, Make and Type of Vehicle S H H ; H O N D A O F T H E . K .M F G . ,L T D .U . K . U v H O N D AP a s s e n g e re h i c l e b. Line, Body and EngineType EP3: CIVIC/K20A3 c. Body Type and Transmission Type Manual 3: 2-door HatchbacUs-speed d. VehicleGrade lSeries) 5:Si {U.S.} 5 ; S i R( C a n a d a ) 6: Si with side airbagsystem (U,S.) 6: SiR with side airbagsystem (Canada) e. CheckDigit l. ModelYear 2i 2002 g. Factory Code n U : H o n d ao f U . K .M a n u f a c t u r i nig S w i n d o n , En gl a n d h. Serial Number U.S,: 00001 3 1-
Transmission Number
NBH3 I
1000001
a
Transmission Type N R H 3 ; s - s D e eM a n u a l d
0
u.s.
Canada
PaintCode
Code
B-92P
NH-578 NH-623M R-81
Y-62P
Color Niqhthawk Black Pearl TaffetaWhite Satin Silver lvletallic M i l a n oR e d E u r oY e l i o wP e a r l
Vhicle ldentif ication Numbo. and Federal Motor Vehicle Safety Standard Certification/ Color Label.
1-2
Chassis and PaintCodes- 2003Model

Vehicle ldentif icationNumber
SHHEP3 5*3 3 U 400001
EngineNumber
K2OA3 2700001
[--t-rlF
c d e fg h
I
a
a. EngineType K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injected engine b. SerialNumber
Manufacturer, Make and Type of Vehicle S H H : H O N D A O F T H E . K .M F G . , T D .U . K . U L HONDAPassenger vehicle Line. Body and EngineType EP3: CIVIC/K20A3 G . Body Type and Transmission Type Manual 3: 2-door HatchbacldS-speed d . Vehicle Grade (Series) 5:Si (U.S.) 5 : S i R( C a n a d a ) 6: Si with side airbagsystem (U.S.) 6: SiRwith side airbagsystem (Canada) Check Digir f. Model Year 3: 2003 Factory Code U: Hondaof U.K. Manufacturing Swindon, in England SerialNumber U.S.:400001 :700001
Transmission Number
NRH3 - 2000001
I
a
Transmission Type N R H 3 : 5 - s p e eM a n u a l d Serial Number
PaintCode
Code
B-92P B-520P
NH-578
NH-623M
R-81
Y-62P
Color Niohthawk Black Pearl V i v i d B l u eP e a r l Taffeta White Satin Silver N4etallic M i l a n oR e d EuroYellow Pearl
U , S . Canada
Vehicleldentification Number and FederalMotor Vehicle Saletv Standard Certif ication/ Color Label.
)_.
1-3
Information General
ldentificationNumber Locations
(
Vehicle ldentif ication Number {vlN}
Vehicle ldentificalion Numbe.lvlN)
0
EngineNumber
t)
1-4
, I O
warning/cautionLabelLocations
NOTE: FRONT PASSENGER AIRBAG WARNING TAG (CHILD is SEAT) installed the glovebox on the U.S. on mooet. Passenger's Compartment:
SRSINFORMATION U.Smodel .
SRS WARNING INFORMATION FRONTPASSENGER MODULE DANGER
Steering Wheel: DRIVER MODULE DANGER CABLEREEL CAUTION
MONITOR NOTICE
!
,/
FRONT SEATBELT TENSIONER CAUTION SIDEMODULE DANGER
SIDEAIRBAG CAUTION Located on driver's ano passen9er s doorjamb(not shown)
..r'
(cont'd)
1-5
General Information
Warning/Caution LabelLocations(cont'dl
SERVICE INFORMATIONLABEL (Undor-hood Emission Control Informationlabl)and ENGINE COOLANTINFORMATION
SRS WARNING LABEL
TIREINFORMATION
RADIATOR CAPCAUTION
BATTERY CAUTION
1-6
Emission ControlLabel Under-hood

ication Groupldentif Emission
2002model Example:
Families: Engine and Evaporative

EngineFamily:
rr-tt--[ t t l
a b c d
2 T TO . V CO T H I S E H I C L E N F O R M S U . S E P A I E R B I N5 APPLICABLE 2002 TO LEVREGULATIONS AND NLEV CARS NEWPASSENGER AND MODEL YEAR TO APPLICABLE 2OO2 REGULATIONS CALIFORNIA CARS. YEAR NEWLEVIi LEVPASSENGER MODEL Example: 2003model
2 HNX V O2.O VBP
c. d. e.
ModelYear 2:2002 3: 2003 Subcode Manulacturer H HNX: ONDA Type Family V: LDV Displacement Sequence Characters V B P2 0 0 2 : X K C2 0 0 3 :
Evaporative Family:
rH/
TO CONFORMS U.S. EPATIER2 BIN 5 THISVEHICLE TO APPLICABLE 2O03 AND NLEVLEVREGULATIONS CARS NEWPASSENGER AND MODEL YEAR TO APPLICABLE 2OO3 REGULATIONS CALIFORNIA CARS, YEAR NEWLEVII LEVPASSENGER MODEL
a b
t[-l=[
c d
2 HNX R OO99 AAH
Model Year 2t 2002 3: 2003 Manufacturer Subcode H N X :H O N D A c. Family Type R: EVAP/ORVR d . Canister Work Capacity e . Sequence Charactets AAH: 2002 AAA: 2003
1-7
General Information
Lift and Support Points
NOTE:If you are going to remove heavycomponents such as suspensionor the fuel tank from the rear of the vehicle,first supportthe front ofthe vehiclewith tall safetystands.When substantialweightis removed from the rear of the vehicle,the centerof gravity can changeand causethe vehicleto tip forward on the hoist.
FloorJack
1. Set the parkingbrake. 2. Blockthe wheels that are not being lifted. 3. When liftingthe rear of the vehicle.put the gearshiftIever in reverse. 4. Positionthe floor jack underthe front jacking bracket(A) or rearjackingbracket(B),centerthe jacking bracketin the jack lift ptatform(C),and jack up the vehiclehigh enoughto fit the safetystands u n d e ri t .
FrameHoist
1. Positionthe hoist lift blocks(A),or safetystands, under the vehicle'sfront support points (B)and rear support points (C).
0
2. Raisethe hoist a few inches,and rock the vehicle gentlyto be sure it is firmly supported. 3. Raisethe hoistto full height,and inspectthe lift pointsfor solid contactwith the lift blocks.
c
Positionthe safetystandsunderthe support points and adjustthem so the vehiclewill tevet. Lower the vehicleonto the stands.
Safety Stands
To supportthe vehicleon safetystands.use the same suppon points (B and C) as for a frame hoist,Always use satetystandswhen working on or under any vehiclethat is supportedonly by a jack.
1- 8
Towing
lf the vehicleneedsto be towed, call a professional towing service.Nevertow the vehiclebehind another vehiclewith just a rope or chain.lt is very dangerous. Towing Emergency m o T h e r ea r et h r e ep o p u l a r e t h o d s f t o w i n g a v e h i c l e . Flat-bedEquipment The operatorloadsthe vehicle on the backof a truck.This is the bestway of transportingthe vehicle. flat-bedequipment.the vehicleis To accommodate with towing hooks(A)and tie down hooks{B). equipped The towing hook can be usedwith a winch to pull the vehicleonto the truck, and the tie down hooks slotscan be used to securethe vehicleto truck. Wheel Lift Equipment The tow truck usestwo pivoting arms that go underthe tires (front or rear)and lifts them off the ground.The other two wheels remain way of towing the on the ground.This is an acceptable vehicle. Sling-typeEquipment The tow truck uses metal T w c a b l e s i t h h o o k so n t h e e n d s . h e s eh o o k sg o a r o u n d parts of the frame or suspensionand the cableslift that T o e n d o f t h e v e h i c l e f f t h e g r o u n d . h ev e h i c l e ' s d i a n d b o d yc a n b e s e r i o u s l y a m a g e d f t h i s suspension method of towing is attemPted. lf the vehiclecannot be transportedby flat-bed,it should be towed with the front wheels off the ground lf due to damage,the vehiclemust be towed with the front wheels on the ground, do the following: . Release parkingbrake. the . s h i f t t h e t r a n s m i s s i o in N e u t r a l . n It is bestto tow the vehicleno farther than 50 miles (80 km), and keepthe speed below 35 mph (55 km/h).
. l m p r o p e r o w i n g p r e p a r a t i ow i l l d a m a g e h e n t t Follow the above procedureexactly.lf transmission. the you cannot shift the transmission, vehicle must on be transDorted a flat-bed. . Trying to lift or tow the vehicle by the bumperswill a d , c a u s es e r i o u s a m a g e T h e b u m p e r s r e n o t designedto supportthe vehicle'sweight.
1-9
GeneralInformation
PartsMarking
To deter vehicletheft, certainmajor componentsare markedwith the vehicleidentification number (VlN).Original partshave self-adhesive labels.Replacement body parts have genericself-adhesive labels.The originalengrneor transmissionVIN plate is transferredlo a replacement engine or transmissionand attachedwith break-offbolts. NOTE:Be careful not to damagethe parts marking labelsduring body repair.Maskthe labelsbefore repairingthe part.
r a
1-10
ra
Specifications
Standards Service and Limits

EnqineElectrical ne
Item
Measurement
Rated voltage F i r i n go r d e r
Oualification
lgnition coil plug Spark
Standard or New
Service Limit
Type
Gap
l g n i t i o nt i m i n g
A t i d l e ( c h e c kr h e
12V 1 3-4 2 N G Kt Z F B 6 K 1 1 : DENSO: SKJ20DR-M11 1 . 0 1 . 1 m m ( 0 . 0 3 9 . 0 4 3n . ) 0 i in neutral: 8t2' ETDC 650150rpm at
1 . 3 m m ( O . OiS 1) n.
Alternator
Output
Coillrotor)resistance
5|lp flng u.u.
Starter
Brushlength Brushspring tension Output Commutator micadepth Commutator tunout Commutator O.D. Brushlength
At 13.5 and V 80A normalengine temperature At 68.F(20'C) 2.2 3.0 A 14.4 mm {0_57 in.) 14.0 mm (0.55 in.) 10.5 mm (0.41 in.l 1.5mm {0.06 in.) 2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs) 0.50 0.80mm (0.020-0.031 in.) 0.20mm 1O.OO8 in.)
o:BlalqryL4i) max
2 8 . 0 m ( 1 . 1 0n . ) m i 14.0 14.5 mm {0.55 0.57in.)
o.o5 (0.002 mm in.)

2 7 . 0 m ( 1 . 0 6n . ) m i 9.0mm {0.35 in.)
Enqtne
Item Measurement Compression Pressure checkat 250rpm with wide openthroftle. (SeeDesignSpecsfor rato,
Oualification Standard or New Service Limit
Minimum Maximum vanatton
930kPa(9.5 kgflcmr, psi) 135 200kPa{2.0kgf/cm',28 psi)
e_
.l
2-2
nder Head
Item Head Measur6ment Warpage Height Endplay
C a m s h a f tt o h o l d e r o i l c l e a r a n c e No.l journal N o . 2 , 3 ,4 , 5 journals
Oualification
Standard or New
Service Limit
in.) 0.05mm {0.002 '103.95104.05 mm (4.093 4.096 in.) in.) 0.05 0.20mm (0.002 0.008 mm 0.030 0.069 in.) {0.001 0.003 mm 0.060 0.099 (0.002-0.004 in.) in.) 0.03mrn (0.001 max. in.) mm (1.3356 33.925 i 2 9 . 6 3m m ( l . 1 6 6 8n . ) 8 mm in.) 34.092 (1.3422 in.) 0.21 0.2smm 10.0080.010 in.) 0.28 0.32mm (0.011 0.013 in.) mm 10.21560.2159 5.475 5.485 in mm (0.2146 0.2150 ) 5.450 5.460 mm (0.0012 0.0022in.| 0.030 0.055 in mm (0.0022 0.0031 ) 0.055 0.080 in.) mm (0.049 0.061 1.25 1.55 in.) 1.25 1.55 mm (0.049 0.061 m 4 0 . 8 -4 1 . 0 m ( 1 . 6 0 6 1 . 6 1 4 i n . ) i m 5 4 . 6 5 4 . 8 m ( 2 . 1 5 02 . 1 5 7n . ) (1.874 in.) 47.61 mm in.) 49.64 mm (1.954 mm 5.515 5.530 |.0.21710.2117 4n.1 m 5.515 5.530 m in.l \0.2111 0.2177 m 1 5 . 2" 1 6 . 2 m ( 0 . 5 9 80 . 6 3 8 i n . ) in.) mm (0.610 0.650 15.5 16.5 mm 0.025 0.052 (0.00'10 in.) 0.0020 mm 0.018 0.056 (0.0007 0.0022 in.)
Camshaft
in.) 0.4mm (0.02 n m 0 . 1 5 m { 0 . 0 0i6 . ) in.) 0.15mm (0.006 in.) 0.04mm {0.002
Totalrunout
Cam lobe height
primary Intake, Intake, Exhaust
(cold) clearance StemO.DS t e m - t o - g L r i dc l e a r a n c e e
lntake
Exhaust
lnlaKe
Exhaust
lntake
height stem installed Valve springs length Free LD.
Exhaust lntake Exhaust lntake Exhaust lntake Exhaust

Intake Exhaust
in.) 5.445 mm (0.214 n 5 . 4 2 m ( 0 . 2 1i3 . ) m in.) 0.08mm (0.003 in.) 0.11mm (0.004 in.) 2.00mm {0.079 in.) 2.00mm {0.079
Valveguides
in.) 5.55mm (0.219 n 5 . 5 5 m { 0 . 2 1i9 . ) m
I n s t a l l e dh e i g h t
lntaKe
Exhaust Rocker arms Arm-to-shaft clearance

lntaKe Exhaust
in.) 0.08mm (0.003 in.) 0.08mm (0.003
lo
2-3
Standardsand ServiceLimits
Enqine n q t n e Block
Item Block
Measurement of I Warpage deck tsore diameter
Oualification
Aori Borll
Standardor New 0.07mm (0.003 max. in.) 86.010 86.020 mm (3.3862 3.3866in.) 86.000 86.010 mm (3.3858 3.3862 in.)
ServiceLimir
foro.. (ulur^^-"1
86.070 mm (3.3886 in.) 86.070 mm (3.3886 in.)
0 . 0 5m m ( 0 . 0 0 2n . J I
R e b o r i n gl r m i t
Piston
SkirtO.D. 11mm (0.4in.)from at bottom of skirt
Piston ring
",";"* lFis,.-"'"
Lo.D.
Ringend gap
0 . 2 5 m ( 00 l i n . ) m 85.980 85.990 mm (3.3850 3.3854 85.930 in.) mm (3.383'l in.) F" LetterB s.980 r"i33846 85.920 mm (3.3827 l-il?0 in.) 0.020 0.040 mm (0 0008 0.0016 in.) 0.05mm {0.002 in.) Top 1.220 1.230 mm (0.0481 0.0484 in.) 1.25 mm 10.049 ) rn Second 1 . 2 2 0 1 . 2 3 0 m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25 m mm 10.049 in.) mm (0.0789 0.0797 in.) ?.09rrl9.091lt i 2.005 2.025 ) o.ooza 0.13mm (0.005 ) lo.oora i.'.f fo.o:s o.oto.rn in rn. OOO2 i") 0 . 1 3 m ( 0 . 0 0i5 . ) m n EO3t 0 056 {OJ01r (FEDEHAL 0.025 0.060 Second mm (0.0010 0.0024 in.) 0.13mm (0.005 ) in I\4OGUL) Top 0.20 0.35mm (0.008 0.014 in.) 0.60mm (0.024 in.)
btt"' "' A
Second
OiI(REKEN) OiI(FEDERAL I\4OG L) U pin Piston Pin'to-piston clearance Connecting rod

Pin to-rod clearance Small end bore diameler L a r g e - e n db o r e d i a m e t e r ( N o r m a l )
0.40 0.55mm {0.016 0.022 in.) 0.25 0.65mm (0.010 0.026 in.) 0 20 0.70mm i0.008 0.028 in.)
0.70mm (0.028 in.) 0.75mm (0.030 in.) 0.80mm 10.031 in.)
21.961 21.965 {0.8646 0.8648 2 1 . 9 5 3m m l 0 8 6 4 3 i n mm in.) 0.005-*0.002 ( 0.00020 mm + 0.005 mm (0.0002 in.)
0.00008 in.)
0.005 0.015 mm (0.0002 0.0006 in.) 0 . 0 2 m m l O 0 O O 8n I i 21.970 21.976 mm (0.8650 0.8652 in.) 4 8 . 0 m ( 1 . 8 9n . ) m i 0.15 0.30mm (0.006 0.012 in.) 0 . 4 0 m ( 0 . 0 1i6 . ) m n s4.e84 s5.008 mm (2.1648=16illl
c_
Endplayinslalled crankshaft on
Crankshaft Main journal diameter
No. l journal No.2 journal N o .4 j o u r n a l No.5 journal No.3 journal
5 4 . 9 7 65 5 . 0 0 m m ( 2 . 1 6 4 4 - 1 6 5 4 i n ) 0 2
4 4 . 9 7 6 4 5 . 0 0 0m m ( 1 . 1 7 0 7 1 . 1 7 1 7i n . l
Rodjournal diameter Rod/main
Rod/main out iournal of,round E n dp l a y Runout . . - ' . : - - ' +

Deaflngs M a r n o e a r , n 9 - t o J o u r n a o t t c t e a r a n c e No. l journal t
0.005 mm 10.0002 max. in.) 0.005 mm (0.0002 max. in.) 0.10 0.35mm (0.004 0.0'14 in.) 0.03mm (0.0012 max. in.) 0 . 0 1 7 0 . 0 4 1 m ( 0 . 0 0 0 70 . 0 0 1i6 . ) m n
0.010 mm (0.0004 in.) 0.010 mm (0.0004 in.) 0.45 m10.018.) m in 0.04mm {0.0016 in.) 0.050 mm (0.0020 in.)
No.2 journal No.4 journal

No.5
No.3 journa/ Bodbearing clearance
q0rr034, -rn {O'o010 0-o01r|"tl 0.055 (0.0022 mm in.)

0.021 0.049 mm (0.0008 0.0019 in.) 0.060 mm (0.0024 in.)
2-4
o i
nqlne
|tem
Lubrication
Measurement Capacity Oualificalion ServiceLimil Standerdor New overhaul 5.30 (5.6US qt)for engine filter including 4.20 (4.4US qt)for oil change, withoutfilter 4.00 (4.2US qt)for oil change, in.) in.) 0.20mm (0.008 0.02 0.16mm {0.001 0.006 in.) in.) 0.23mm (0.009 0-15 0.21mm {0.006-0.008 in.) 0.02 0.07mm (0.001 0.003 front No.1 journal, shaft
No 1 journal,rearshaft
Engine oil
Oilpump
lnner-to outerrotorclearance to Pumphousing outerrotor clearance axial Pumphousing-to-rotor clearance journal Balancer shafts, diameter
0.12mm (0.005 in.)
mm (0.784 in.) in.) 19.92 mm 19.938 19.950 10.78500.7854
journal taper Ealancer shafts, shafts, play end Balancer shatts,shaft-to'bear;ng Balancer clearance
in.) in.) mm (0.942 mm (0.9424 0.9429 23.92 23.938 23.950 mm (1.296 in.) in.l mm 11.29121.2911 32.93 frontand 32.949 32.961 No.2 journal, rearshaft in.) 0.005 rnm (0.0002 max. in.) in.) 0.15mm (0.006 mm (0.0028 0.0053 0.070 0.135 Front (0.0028 0.0053 in.) in.) 0.15mm (0.006 mm 0.070 0.135 Rear m n in.) 0 . 1 0 m ( 0 . 0 0i4 . ) mm (0.0020 0.0032 front 0.050 0.082 No. 1 iournal, shaft
N o . 1 J o u r n a l ,r e a r s h a f t N o . 2 j o u r n a l ,f r o n t a n d rear shafl
in.) mm (0.0020 0.0032 0.050 0.082 in.) mm (0.0024 0.0047 0.060-0.120
in.i 0.10mm (0.004 in.) 0.15mm (0.006
LD. shaftbearings, Balancer
a
Thermostat
mm (0.789 in.) in.l mm (0.1814 0.7442 20.03 front 20.000 20.020 No. 1 journal, shaft in.) ir'.) 24.03 mm (0.946 OSa57 ZI.OZO tOSa+emrearshaft Z+.OOO No. 1 iournal, in.) in.) mm {1.303 mm (1.3000 1.3019 33.09 No.2 journal, frontand 33.021 33.069 rearshaft
At idle 7 0 k P a ( 0 . 7k q ? c m , 1 0 p s r )m i n .
R e l i e f v a l v e ,o i l p r e s s u r ew i t h o i l t e m p e r a t u r ea t 1 7 6 ' F ( 8 0 " C )
rpm At 3,000
psi)min. ksf/cm',44 300kPa{3.1
engine, Coolant capacity {includes hoses, reservoir) and heater,
Standardor New 6 . 7L ( 7 . 1 S U US 0.53L (0.56 kqtcm , 14 18psi) 93 123kPa(0.95 1.25 't69 176'F (76 80'C) in.) 8.0mm {0.31 min. TurnsOFF actual ON 5 Subtract 15'F(3 8"C)from
ServiceLimit
OPeningtemPerature
a
2-5
Fueland Emissions
Item Fuelpressure regulator Fueltank Engine idle Measulement Oualification Pressure with fuel pressure gauge connected Capacity ldlespeed with headlights radiator Neutral and fan off
F a s ti d l e
Standardor New ServiceLimit 320-370kPa13.3-'3.8 kgtcm',47 52psi) 5 04 ( 1 3 . 2 Sg a l i U 750 50 rpm 1,600150 rpm
f
. \
Neutral
Clutch
Item pedal Clutch Mea3uremnl Height fromthe floor Stroke
D i s e n g a g e m e n th e i g h t f r o m t h e f l o o r
Oualification
Clutch disc plate Pressure
Bunout clutch on matingsurface Bivetheaddepth Ihickness Warpage

Heightof diaphragm spring fingers
Measured with specialtool and gauge feeler
Slandardor New 193mm (7.60 in.) 130 140 m15.15.5in.) m 10 16mm (0.39 0.63in.) 1 ' 1 5 m ( 4 . 5 3n . ) i n . m i m 0.05mm 10.002 max. in.) 1.65 2.25mm (0.065 0.089 in.) 8.3 8.9mm (0.33 0.35in.) 0.03mm (0.001 in.)max. 0.6mm (0.02 max. in.)
ServiceLimit
0.15mm (0.006 in.) 0.7mm {0.03 in.) 6.0mm (0.24 in.) 0 . 1 5 m ( 0 . 0 0i1 . ) m n 0.8mm (0-03 in.)
r a
\ < c
2-6
O E
and M/T Differential nualTransmission

Item Masurement Oualification Standardor New 1.5 Forfluidchange: 0 (1.6US qt) F o ro v e r h a u1:. 7 1 1 . 8 Sq t ) l 0 U ' 0 . 1l - 0 . 1 7m m ( 0 . 0 0 40 . 0 0 7 i n . ) in.) 20.80 20.85 mm {0.819 0.821 mm in.) 31.984-32.000 (1.2594 1.2598 n m 2 7 . 9 7 72 7 s 9 0 m \ 1 . 1 0 1 - 1 . 1 0 2i0 . ) 5 mm (1.5348 38.984 39.000 '1.5354 in.) Se.viceLimit
Transmission Capacity fluid Endplav Mainshaft Diameter bushing of surface

D i a m e t e ro f d i s t a n c ec o l l a r
contact area Diameter ballbearing of (clutch housing side) contact Diameter needle of bearing area area Diameter ballbearing of contact (transmission housing side) Runout Mainshaft 3rd, t.D. 4th and sth Endplay gears Thickness Countershaft Diameterof needlebearingcontact side) area(clutch housing of collarcontact Diameter distance alea
D i a m e t e ro f b a l l b e a r i n gc o n t a c t a r e a ( t r a n s m i s s i o nh o u s i n g s i d e )
Adiust 20.75 mm 10.817 in.) 3 ' 1 . 9m m ( 1 . 2 5i7 . ) 3 n n 2 7 . 9 2 m ( 1 . 0 9i9 . ) m 4n.) 38.93 mm (1.533 n 2 7 . 9 3 m { 1 . 1 0i0 . ) m in.) 0.05mm (0.002 44.08 mm (1.735 in.) m n 0 . 2 5 m ( 0 . 0 1i0 . ) 23.80 mm (0.937 in.) in.) 34.95 mm (1.376 39.88 mm (1.570 in.) n 2 9 . 9 7 m ( 1 . 1 8i0 . ) m in.) 0.05mm (0.002 Adjust in.) 52.08 mm (2.050 m in 0.25 m10.010.) 22.87 mm (0.900 in.) mm {2.050 in.} 52.08 4n.) 0.25mm 10.010 in.) 27.87 mm 11.097 mm (1.574 in.) 39.97 mm (l.848in.) 46.94 mm (1.574 in.) 39.97 in.) 46.94 mm (1.848
in.) mm 27.987 28.000 (1.10'191.1024 in.) 0.02mm (0.001 max. mm in.) 44.009 44.025 11.73261.7333 0.06 0.16mm {0.002 0.006;n.) in.) 23.92 23.97 mm (0.94'10.944 '1.3785 in.) mm 35.000-35.015 (1.3780 39.937 39 950mm (1.5723 1.512ain.| n 3 0 . 0 2 0 - 3 0 . 0 m3 ( 1 . 1 8 1 91 . 1 8 2i4 . ) 3m in.) 0.02mm {0.001 max. in.) 0.04 0.10mm (0.0016 0.0039 in.i mm (2.0476-2.0484 52.010 52.029 (0.002 0.006 in.) 0.06 0.16mm -0.904in.) $m 10.902 22.92 22.91 in.) mm 52.010 52.029 (2.0476 2.0484 in.) 0.06 0.16mm (0.002 0.006 mtn \1.099 1.101 in.) 21.92 27.91 in.) mm (1.572a 1.5132 39.95 39.96 in.) mm 1.8504 46.989-47.000 (1.8499in.i mm (0.907-0.909 23.03 23.08 1.5732 in.l mm {1.5728'39.95 39.96 in.) 46.989 47.000 (1.8499 1.8504 mm m 28.03 28.08 m (l.104 1.106in.)
Runout innerrace 35 mm shim-to'bearing
Countershaft
clearance LD.
End play
Thickness Countershaft 2ndgear Countershaft 'lst gear
t.D.
Endplay Thickness LD.
o.D.
collar Length distance Countersha{l l . D . o.o. 2ndgear distance coliar L e n g t h
o
2-7
ManualTransmission anuatI ransm and Differentialcont'
Item
?
ServiccLimit 3 2 . 0 2 m ( 1 . 2 6i1 . ) m n 38.94 mm (1.533 in.)
Measutemenl
Oualification
Nlainshaft 4th and5thgears
LD.
o.D.
B
distance collar L e n g t h
Standardor New 32.00-32.01 mm (1.2598 1.2602 in.) 38.989 39.000 mm (1.5350 1.5354 in.) 51.95 52.05 mm (2.045 2.049 in.) 24.03 24.08 mm (0.946-0.947 in.)
MBSdistance LD.
Len9th
Reverse idler gear Synchro ring Triple cone
t.D.
G e a r l o r e v e r s eg e a r s h a f i c l e a r a n c e
Bingto'gearclearance Outer synchro ring-to synchro cone clearance Synchro cone-to-gear clearance Outersynchro ring-to-gear cone clearance Finger thickness Forkto-synchro sleeve clearance Finger thinkness
F o r k - t o - r e v e r s ed l e r g e a r c l e a r a n c e i
Ringpushed gear against Ringpushed qear against pushed Ring gear against Ringpushed gear against
(1.102 1.103 28.00 28.01mm in.) 23.95 24.05 mm (0.943 0.947 in.) 20.016 20.043 mm (0.7880 0.7891 in.) 0.036 0.08a mm (0.0014 0.0033 in.) 0.70 1.49 mm (0.028 0 059in ) 0.70- '1.19 {0.028 0.047 mm in.) 0.50 1.04 mm (0.020 0.041 in.) 0.95 1.68 mm (0.037 0.066 in.) 7.4 7.6mm 10.29 0.30in.) 0.35 0.65mm (0.014 0.026 in.i 13.4 13.7 mm (0.527 0.539 in.) 0.20 0.59mm (0.007 0.024 in.) 13.973 '14.000 (0.5501 0.5512 mm in.) 16.9 '17.0 (0.665 0.669 mm in.) 0.2 0.5mm (0.008 0.020 in.) 14.85 '14.95 (0.585 0.589 mm in.) 0.05 0.25mm (0.002 0.010 in.) 15.00 15.10 mm {0.591 0.594 in.) 0.013 0.07mm (0.0005 0.003 in.) 18.010 18.028 (0.7091 0.7098 mm in.) 0.027 0.057 mm (0.0011 0.0022 in.) 28.025 28.045 (1.1033 1.1041 mm in.) 0.05 0.15mm {0.002 0.006 in.) 1 8 . 0 4 21 8 . 0 6m m ( 0 . 7 1 0 30 . 7 1 1 3 i n . ) 6 0.059 0.095 mm (0.0023 0.0037 in.) 0 0.10mm (0 0.0039 in.)
2 8 . 0 2 m ( 1 . 1 0i3 . ) m n 20.90 mm (0.832 in.) 0 . 1 6 m { 0 . 0 0i6 . ) m n 0.4mm (0.016 4n.) 0.3mm (0.012 in.) 0.3mm (0.012 in.) 0.6mm (0.024 in.)
Shift fork Reverse shift fork Shiftarm
1.0mm (0.039 in.) 1.3mm (0.051 in.)
t.D.
S h i f t f o r k d i a m e t e ra t c o n l a c ta r e a S h i f t a r m ' t o - s h i f t l e v e rc l e a r a n c e
0 . 6 2 m ( 0 . 0 2i4 . ) m n 0.50mm (0.020 in.) 0.1mm {0.004 in.) 0.1mm (0.004 in.l
Select lever Shiftlever
Finger width -to-select Shaft leverclearance Groove{to selectlever) Shaftto shiftarm clearance Pinionshaftcontactareal.D.
Carrier-to-pinion haftclearance s
L O
Mfi differential carrier Mfi differential pinionqear 80 mm shim
Driveshaft contactareaLD. Backlash
t.D.
P i n i o ng e a r t o p i n i o n s h a f t c l e a r a n c e
80 mm shim to-bearing outerrace clearance transmission in housing
0.15mm (0.006 in.) Adjust
2-8
o
n
Rotational measured outside at olav loadmeasured outside at Starting

A n g l e o f r a c kg u i d e s c r e w l o o s e n e d
0 10mm (0 0.39in.) 2 9N ( 3 . 0 g f . 6 . 6 l b s ) k
Item W h e e l a l i g n m e nCamber t Caster TotalToe
Measurement
Oualitication Front Rear Front
Standardor New 0'00' 45' 0'45'- 45

1"33' 11"
ServiceLimit
lrytt
Rear
l n s i d ew h e e l
Frontwheel turningangle wheelrunout Aluminum

Wheelbearing
wheel Outside
Axial Radial Front
Endplay
Rear
i 0 - 3 m m ( 0 : : 0 . 1 2n . ) lN 2 ' , mm (0.08"' ,, in.) 37'40'-2' 29'50'(Reference) 0 0.7mm (0 0.03in.) 0 - 0 . 7m m ( 0 0 . 0 3 i n . ) in.) 0 0.05mm (0 0.002 in.) 0 0.05mm (0 0.002
2.0mm (0.08 in.) l.5mm{0.06in.)
a
2-9
Brakes
Item Parking brake lever pedal Brake Master cylinder Erake disc Masurement Distance traveled when leverpulled with 196N (20kgf, 44 lbs) ol force (carpet Pedal height removed) Freeplay Piston-to-pushrod clearance Thickness Runout
Parallelism
Oualification
Standardor New 7 8 clicks

1 8 4m m ( 7 4 / 1 6i n . )
ServiceLimit
Front Rear Front Rear Frontand rear

Front llear
0 . 4 3 . 0m m ( 00 1 6 0 ' 1 1 8n . ) i 0 0.4mm (0 0.02in.) 2 1 . 0 m ( 0 . 8 3n . ) m i 9.0mm {0.35 in.)
pads Brake
Thickness
10.0 mm (0.39 in.) 9.0mm {0.35 in.)
1 9 . 0 m m ( 0 . 7 5n . ) 0 i 8-0mm (0.31 in.i 0.10mm (0.004 in.) 0.10mm (0.004 in.) 0.015 mm (0.0006 in.) 1 . 6 m ( 0 . 0 6n . ) m i 1 . 6 m ( 0 . 0 6n . ) m i
Air Gonditionin
Item Refrige.ant Refrigerant oil Moasurement Oualilication
Standard or New Service Limit
Tvpe
Capacity system of Type Capacity ofcomponents Condenser Evaporator
Eachline and hose
4 H F C1 3 4 ( B - 1 3a ) a 500 550g 117.6 19.4 oz) S P1 O (P/N 38897-P13-A01AH or 38899-P13-A01 ) 25 m0,15/6fl ozl 45 mA111/2fl ozt 10m0 (1/3 or) fl 130 150 014 /3 5floz) m 1 3.05 3.350 0.35 0.6mm (0.014 0.024 in.) Autotensioner no lneeds adjustment)
Compressor Drivebelt
Startercoil resistance plate Pulley-to-pressure clearance
Compressor At 68"F(20"C)
e-
2-10
Design Specifications
|tem
Measurement
Overalllength
Oualification 4 , 2 1 0 m { 1 6 5 .i8 . ) m n mm 166.7 in.) 1,695 i 1 , 4 4 m m ( 5 6 . 7n . ) 0 n m 2 , 5 7 0 m ( 1 0 1 .i2 . ) mm (57.9 in.) 1,470 '1,470 (57.9 mm in.i in.) 152mm (5.98 four {4) rbs 3,660 1,660 kg
Specilication
DIMENSIONS
Overallwidth
Overallheight
Track Ground clearance

S e a t i n gc a p a c i t y
rront Rear
wEtGt-iT {u.s.A.)
WEIGHT (CANADA)
ENGINE
G r o s s V e h i c l eW e i g h t R a t i n g (GVWR)
Vehicle WeightRating Gross {GVWR) Tvpe arrangement Cylinder Boreand stroke

Displacement
ratio Compression Valve train system Lubrication Oil pumpdisplacement Waterpumpdisplacement F!el required STARTER
At 6,000 engine rpm At 3,400 engine
4 V-ECengin( Watercooled. stroke DOHC 4'cylinder, transverse Inline x 86 x 86 mm (3.39 3.39in.) c 1,99cm'(122uin.) 8 9.8 per 4 VTEC valves cylinder Chain drive.DOHC pumP withtrochoid Forced, sump, wet 54.30 (57.4 qo/minute US 82 0 (87US qt)/minute gasoline number higher with 86 pumpoctane or UNLEADED Gearreduction 12V 30 seconds
C l o c k w i s ea s v i e w e c lf r o m g e a r e n d S i n q l e p l a t ed r y , d i a p h r a g m s p r i n g
Tvpe
Normaloutput
Nominalvoltage
o
CLUTCH
Hourrating Direction rotation of

C l u t c ht v p e
material area Clutch friction surface
Tvpe I\,1AN UAL reduction TRANSMISSIONPrimarv Gearratio
lst 2nd 3rd

4th
Finalreduction
5th Reverse Type Gearratio
1 7 4 m ' { 2 6 . 9s q i n . ) c 7 forward,1 reverse s-speed Svnchronized, D i r e c1 : 1 t 3.062 1.769 1.212 0.921 0.738 3.583 helicalgear Sinole 4.164
o
2-11
DesignSpecifications
cont'
Item STEERING Measuremeni Type Overall ratio Turns,lock to-lock Steering wheeldiameter Type Shock absorber Oualification Specilication Electric, Powerassisted and pinion rack 15.1 3 6 0m m ( 1 4 . 2n ) i
I n d e p e n d e n ts r r u l w i t h s t a b i l i T e rc o i l s p r i n g .
SUSPENSION
Rear Front Rear Front Bear Front

Front
D o u b l ew i s h b o n e
Telescopic, hydraulic. gas-frlled nitrogen Telescopic, hydraulic, gas,filled nitrogen
WHEEL ALIGNMENT
Camber Caster
Totaltoe
0"00'
0.45' 1'33' 0 mm (0 in.)
In2 mm (1/16n.) i P o w e r a s s i s t e ds e l f - a d j u s l i n g e n t i l a t e dd i s c v
BRAKES
Typeof servicebrake Typeof parkingbrake Padfriction surfacearea
Rear Front Bear Front Rear
TIRES AIR CONDITIONING
Sizeoffront and reartires Sizeo{ sparetire Compressor
Type Numberof cylinders Capacity Maximumspeed

L u b r i c a n tc a p a c i t y
Power-assisted self-adjusting disc solid Mechanical actuating, wheels rear 4 5c m ' ( 7 . 0 q i n . ) x 2 s 2 8c m ' ( 4 . 3 q i n . ) 2 s x Pl95/60 81588V T125r0 D1595M Scroll
Condenser Evaporator Blower
Lubricanttype Type
Tvpe
Type Motor type
Speed control
85.7m015.23 in.)/rev. cu 12,000 rpm 130m0 {4 1/3floz) (P/N SP-10 38897'P13-A01AH or38899-P13 A01) Corrugated fin Corrugated fin Siroccofan 220 Wl12 V
4 Speeo
M a x i m u m c a p a c i t y 480m" 116.900 ft)/h cu T e m p e r a t u r ec o n t r o l
Compressor clutch
Tvpe
Electricalpower cons!mptron at 68"F(20.C) Type
Capacity
Airmixtype plate, poly-V Dry,single beltdrive 42W maximum 12V at
Refrigerant
(R-134a) HFC134a 500 550g (17.6 19.4 oz)
../a
2-12
Item ELECTRICAL RATINGS
Measurement
Oualilication
Battery
Starter Alternator Fuses
Under-hood fuse Under'dash Iuse
Specitication 1 2 V 3 6A H / 5 o u r s h 1 2V - . 1 . 1 W ,1 . 2 W k k 12V 95A,90A 80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A A 3 04 , 2 0 a , 1 5A , 1 0A , 7 . 5
Light bulbs
Headlight high beam Headlight low beam Frontturn signal liqhts

Front parlinq lights
'12 60w v.'

12V 55W 12V 21W 12V 5W 1 2 V" 2 1 W
Bear turn signal lights FronVrear side marker lights

Brale/taillighls H i g h m o L r n tb r a k e light
12V 5W
12V 21/5W 12V 5W 12V 21W 12V 5W
Backup lights platelight License Ceiling light

Cargoarea light
'12 v'.8 w
Spotlights
Gauge lights I n d i c a t o rl i g h t s
12V 5W 12V 5W LED 12V 5W
Sideturn signal light
a
2-13
Body Specifications
Unit: mm {in.) 1.555{61.6) (56.71 1,i140
2-14
Maintenance
Lubricants and Fluids Maintenance Schedule Normal for Conditions
Listed by Distance/Time
Maintenance Schedule Severe for Gonditions

Listedby Distance/Time
Maintenance Schedule
Listed Maintenance for Normal by ltem Conditions ................... 3-8 Listedby Maintenance ltem for Severe Conditions ...................3-9
\.4
Lubricants and Fluids
to For detailsof lubricationpoints and type of lubricants be applied,referto the illustratedindex and variouswork i o v e r h a u l . n s t a l l a t i o n .t c . ) o n t a i n e dn e a c hs e c t i o n . l e c ures{such Assem as
NO.
1 Eng ine
LUBBICATION POINTS
LUBBICANT
The Honda Motor Oil (P/N08798-9023). oil container seal shown below. must disolavthe API Cenification E " M a k es u r ei t s a y s" F o r G a s o l i n e n g i n e s . S A E Viscositv:See chart below.
2 3
4
Transmission
ABS line) Brakesvstem (includes C l u t c hl i n e l R e l e a s eo r k ( m a n u a t r a n s m i s s i o n l f Throftlecableend (throttleIink) Shift and selectcable ends (manual transmission) lower panel hole) Throttlecable end (dashboard Brakeboosterclevis CIutchboosterclevis Shift lever pivot Pedalinkage Batteryterminals F u e lf i l l d o o r H o o dh i n g e sa n d h o o d l a t c h H a t c hh i n g e s , a D o o rh i n o e s u o D e r n d l o w e r Caliperpiston boot, caliperpins and boots Air conditionincompressor g
Honda MTF*'(P/N 08798-9016)

HondaDOT 3 BrakeFluid*' (P/N08798-9008) S u p e rH i g hT e m p U r e aG r e a s e P / N0 8 7 9 8 - 9 0 0 2 ) { g Silicone rease
5 6
7 I 9 10 11
1'
grease Multi-purpose
14 16 17 18 19
HondaCaliDer Grease(P/N08C30-80234lvl) ( oH C o m p r e s s o r o i S P - 1 0 P / N3 8 8 9 7 - P 1 3 - A 0 1 A r l: 38899-P'13-A01) a a F o rr e f r i q e r a nH F C ' 1 3 4 ( R - 1 3 4 ) t;
Recommond6dEngineOil f f E n g i n e i l v i s c o s i l yo r a m b e n t t e m p e r a l u r ea n g e s o
-30 -20
-10
t0
20
* 1 : Always use HondaManualTransmission Fluid (MTF).Using motor oii can causestiffershifting becauseit does not containthe Drooeradditives. " 2 : Always use HondaDOT 3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decrease the life of the system.
3-2
t
o o o o o
o@@ a9
3-3
for Listedby Distance/Time Normal Conditions
Thistwo pagel/lanitenance Schedule outlines minimunrequired the maintenance. Service the indicated at distance time,whichever or comes if in first.use the lvlaintenance Schedule Severe for conditions the vehicle meets anyof the qualifiers the Severe Conditions schedule if the or vehicle normally is driven Canada. in
(cold) (see page6-321r in.) valveclearance. Intake: 0.21-0.25mm (0.008 0.010 Exhaust: in.) 0.28 0.32mm (0.011 0.013 Inspect (NGK) SKJ20DR-M11 (DENSO). plugs.UseIZFR6K'11 Replace or spark 1 . 0 1 . 1m m km/ 120,000 192,000 6 years mi/ page13-3). fluid.UseHonda MTF(see I Replace transmission ! Do items in A,B,alqq.,
/ / Y vcdrs
120,000 192,000 mil (see page106).Capacity: 0 (5.3US qt).UseHonda Season Type 5.0 All Antifreeze/Coolant 2. Beplace coolant andlederal regulations, tailure do the maintenance to itemsmarked with an asterisk will not voidthe customer's According state to {*) interval ensure to long-term warranties, However, Honda recommends all maintenance that services doneat the recommended be emissions reliability.
3-4
Dothe itemsin partsA, B, C, D, andE as required mileage/time for interval listed. A Replace engine oillseepage8-5i. Capacity withoutlilterchange: S (4.2US qt, 3.5lmp qt) 4.0 Rotate tires. Follow pattern the shownin the Owner's Manual Checktire information condition. and B Replace engine filterlseepage8-6). Capacity oil with filterchange: (4.4US qt,3.7lmp qt) 4.20 (see page19 3i. Inspect frontandrearbrakes . Check padsand djscs wear(thickness), for damage, cracks. and ' Check calipers damage, tor leaks, tjghtness mountbolts. and ot parking Check brake adjustment. ShouldbeIullyapplied within7 to I clicks. gearbox, boots{seepage17 5). Inspect rod ends, tie steering and . Check grease steering rack linkage. and . Check grease bootsfor damage and leaking . Chack fluidline{or damage and leaks. lnspectsuspension components. . Chock boltsfor tightness. . Check condition balliointboots deterioration damage. of lor and Inspect driveshaftboots.Checkbootsfor cracksand boot bandsfor tightness(seepage16-3). proponioning Inspct brake hoses ABS). Checkthe andlines{including mastercylinder, valve, control andABSmodulator{or damage andleakage. Check fluidlevels condition tluids; all and ot check leaks. necessary, MTFlseepage13'3), for lf add engioe coolant, brake fluid,and windshield washer fluid. pipeand mufflerfordamage,leaks, tightness system*. L lnspectexhaust Check catalytic converter heatshield, exhaust and {soepage9,8). lnspect linesandconnections*. {uel Check loose for connections, cracks deterioration; and retighten loose connoctions replace and parts(sepage11 146). damaged and l InsDect adiust drivebelt. . Lookfor cracks damage, inspect (needs adjustment). and and autotensioner no page21 39). Replace dustandpollen the lilter(see . Replacethe dustandpollen filterwhenever low lrom the heating cooling airf and system lessthan is normal.
D E
Replace cleaner air element every30,000 miles(48,000 (independent time). km) of
i I Replace brake fluidevery3 years(independent mileage). oI
* According state to andfederal regulations, failure do the maintenance to itemsmarked with asterisk( ) will not voidcustomer's emissions warranties. However, Honda recommends all maintsnance that service doneat the recommended interval ensure longterm reliability. be to
3-5
for Listedby Distance/Time SevereConditions
or comes first.Usethisschedule the vehicle drivenMAINLY Canada in anyof the Service the indicated at distance time,whichever if is in or (see il in tollowing conditions; onlyOCCASIONALLY driven these conditions, the Normal use Conditions schedule page3-4). SevereDrivingConditions . Driving less than5 miles{8 km) pertrip or, in freezing temperatures, drivingless than 10miles(16km)pertrip . Driving extremely (over hot 90"F/32"C) conditions in . Extensive suchasa taxior a commercial delivery vehicle. idl;ng longperiods stopand go driving, or of . Trailer with a car-top carrier, drivingin mountainous or conditions. towing,driving . Driving muddy, roads on dusty, de'iced or
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F { s e e p a g e 1 3 3 ) .
(seepage6 32):lntake: (cold) in.) in.) 0.28 0.32mm (0.011 0.013 Inspect valveclearance. 0.21 0.25mm (0.008 0.010 Exhaust: 11 11 Replace sparkplugs.Use IZFR6K (NGK)or SKJ20DR'M {DENSO)
km/ 6 years R e p l a c e r a n s m i s s i o nf l u i d . U s e H o n d a M T F ( s e ep a g e 1 3 3 ) . t
mi/ km/ mil 192,000 10years, km/ thenevery60,000 96,000 5 years 5.0 All Antifreeze/coo Type2. lant Replace coolant(seepage10-6). Capacity: 015.3 qt) UseHonda Season US
3-6
Dothe itemsin parts B, C,D, E,F,and G as required mileage/time A, for interval listed. A q Feplace engine oil(seepageS5). Capacity withoutlilter change:4.0 (4.2US qt,3.5lmpqt) I Replace engjne filter(seepageI 6). Capacity oil with filterchange: 0 14.4 qt,3.7lmp qt) 4.2 US Insoect frontand rearbrakes, . Check padsanddiscsforwearlthickness), damage, andcracks. . Check calipers damage, for leaks, tightness mountbolts. and of Lubricate doorlocks, latches hinges and with Honda whitelithiumgrease. Rotate tires,if the vehicle beendriven distance has the listed. Follow pattern the shownin the Owner's Manual-Check inflaronaoo tire condition, (seepage17,5). gearbox, boots Inspecttie ends, rod steering and . Check rackgrease steering linkage. and . Check grease. bootsfor damage and leaking . Checklluid linefordamage leaks. and L Inspect suspensron components . Check boltsfor tightness. . Check condition balljointbootsfor deterioration damage. of and (seepage16-3). Inspect driveshaft boots. Check bootsfor cracks and bootbands tightness for parking Check brake adjustment. Should fullyapplied be within7 to 9 clicks. (including Inspct hoses proportioning brake andlioes. ABS). Check master the cylinder, control valve, andABSmodulator damage for (see and leakage page19-24). (see page13 3),engine Check fluidlevels condition lluids;check leaks. necessary, MTF all and ot for lf add coolant, brake fluid,and windshield washer luid. f (see Inspect pipeand muffler damage, page9 8). exhaust system*. Check catalytic converter heatshield, exhaust for leaks, tightness and Inspect lines fuel andconnections*. for Check looseconnections, cracks deterioration; and retighten loose connections replace and pans(seo page11'146). damaged (see Check alllights. Checkfunction otallinterior andexterior lights, andtheposition ofthe headlights page22-68). Inspect vhicle the underbody. Check paintfor damage, the scratches, stonechippin0, dents. and
L
D
InsDect and adiustdrive belt. . Looktor cracks damage, inspect and and autotensioner no {needs adjustment). Reolace dustand oollen filter.
E
Replace cleaner air element every15,000 miles124,000 in dustvcondition km) ol use Conditions {independent timei otherwise Normal (see scredule page11-162).
F
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162). Replace fluidevery3 years(independent mileagei. brake oJ

H
Replacethe andpollen Iilterevery15,000 dust milesifvehicle drivenmostlywhere hashighconcentration is air olsootfrom industryand dieselpowered vehiclesj replace dustand pollen also the filteranytime aarflow less is thanussal(seepags21-39).
A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s , a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k( * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s f w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d s t h a t a l l m a i n t e n a n c es e r v i c e sb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g - t e r m r e l i a b i l i t y ,
3-7
ltem for NormalConditions Listedby Maintenance
on for Conditions the nextpagedo in Schedule Severe if driving conditions specified the lMaintenance Follow NormalSchedule the severe the driving conditions. drivenin severe and if onlyOCCASIONALLY not apply, if is in schedule the vehicle drivenMAINLY Canada. Follow Severe the Conditions ortime, distance Service atthe indicated comes first. whichever milesx 1,000 km x 1,000 months oil Replace engine
R o t a t et i r e s { C h e c kt i r e i n t l a t i o na n d c o n d i t i o n a t l e a s t o n c e p e r m o n t h )
c
70 96 112 48 80 128 90
144
t0 16 12
20 32
30
48
40
64
50 80 3
100
160
110
r20
192
24
60
12
oil Replace engine filter Inspect frontand rearbrakes

C h e c kp a r k i n g b r a k e a d j u s t m e n t
items: inspect following the Visually . Tie-rod gearbox and boots ends,steering . Suspension components . Driveshaft boots . Brake ABSi hoses and lines(including . Allfluidlevels andcondition of{luids . Exhaust system* . Fuellinesandconnections* Inspect adjust drivebelt and filter Replace dustand pollen fluid Reolace transmission intervals Servicethefollowing items at the recommended
R e p l a c ea i r c l e a n e re l e m e n t
a a
km) Every 30,000 (48,000 miles Lm) Every 110,000 (176,000 miles km), adiusl if Inspect 110,000 {176,000 otherwise only noisy. miles every km) Every 160.000 es1256,000 or8 years mr km) 60,000 (96,000 or5 miles km) then At 120,000 (192,000 or 10years, every miles Every years 3
Replace sparkplugs Inspect valveclearance

I n s p e c ti d l e s p e e d * R e p l a c ee n g i n e c o o l a n t
brake fluid Replace
(*) emissions * : According state with asterisk will not voidcustomer's itemsmarked failure do the maintenance to andlederal regulations, to reliabilityinterval ensure to long-term service doneat the recommended be recommends all maintenance that However, Honda warranties.
3-8
Listedby Maintenance ltem for SevereConditions

Usethisschedule the vehicle drivenMAINLY Canada in anvof thefollowina if is in or conditions. NOTE: onlyOCCASIONALLY it drivenin these conditions, the Normal use Conditions schedute. SovereDrivingConditions . Driving less than5 miles(8 km)pertrip or, in lreezing temperatures, drivingless than 10miles(16km)pertrip. 'C)conditions. . Driving extremely over90 "F 132 in hot . Extensive idling, longperiods stop-and-go-driving, as a taxior a commercial or ot such delivery vehicle. . Trailer towing,driving with a cartop carrier, drivingin mountainous or conditions. . Driving muddy, on dusty, de icedroads. or Service the indicated at distance time, or whichever comes first. milesx 1,000 km x 1,000 months Replace engine oil Rotate tires intlation condition leastonce monthi per and {Checktire at
R e p l a c ee n g i n e o i l f i h e r
10 16 12
20
30 48 24
40
64
50
80 36
60 96
70
112
80 128 48
90
144
100 160
110 176 72
120 192
60
Replace 5,000 every miies km)or months 6 18,000
Inspect frontand rearbrakes

L u b r i c a t ea l l l o c k s ,h i n g e s ,a n d l a t c h e s
Visually inspect following the items: . Tie rod ends, gearbox steering and boots . Suspension components ' Driveshaft boots Checlparking braleadjuslment Visually inspect following the items: . Brake hoses and lines ABSi {including . Allfluidlevels condition and oflluids . Exhaust system* . Fuellines andconnections* . Lights andcontrols, vehicle underbody Inspect adjust and drivebeh
R e p l a c ed u s t a n d p o l l e n f i l t e r " o ' t '
a a
a a
Replace transmission lluid Service following items atthe recommended the interuals Replace cleaner air element plugs Replace spark Inspect valveclearance
I n s p e c ti d l e s p e e d '
(24,000 in dusty Every 15,000 miies km) conditions, otheMise normal use schedule. Every 110,000 (176,000 miles km) Inspect 110,000 (176,000 otheMise every miles km), adiust if noisy. only Every 160,000 (256,000 miles km)or8 vears At 120,000 (192,000 of 10years,lhen 60,000 (96,000 miles km) every miles km)or 5 Every years 3
Replace engine coolant Replace brake fluid
* : A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s , a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k1 * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s f w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d st h a t a l l m a i n t e n a n c es e r v i c eb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g { e r m r e l i a b i l i t v . N O T E 1 : R e p l a c et h e d u s t a n d p o l l e n f i l t e r a t 1 5 , 0 0 0m i l e s / 2 4 , 0 0 0 m i f t h e v e h i c l e i s d r i v e n m o s t l y i n u r b a n a r e a st h a t h a v e h i g h c o n c e n t r a t i o n s k o f s o o t i n t h e a i r f r o m i n d u s t r va n d d i e s e l - D o w e r e d e h i c l e s . v
t,
3-9
EngineElectrical
Engine Electrical
SpecialTools 4-2
4-J
StartingSystem
Comoonent Location Index ............... Circuit Diagram Starter it Circu Troubleshooting ClutchInterlock SwitchTest Starter Solenoid Test .............. StarterPerformance Test Reolacement Starter ............... Starter Overhaul ....................... 4-4 4-5 4-6 4-7 4-8 4-9 4-10
ENGINE
lgnition System
Component Location Index ............... 4-15 Circuit Diagram 4-16 lgnition TimingInspection 4-17 lgnition CoilRemoval/1nsta11ation ....................... 4-18 PlugInspection Spark 4-19
ChargingSystem
Component Location Index .................................. 4-2O Circuit Diagram ........................... 4-21 Charging Troubleshooting ....................... 4-22 Circuit Drive BeltInspection ................... 4-26 Drive BeftReplacement .............. 4-26 Drive BeftAuto-tensioner Inspection .................. 4-27 Drive Beft Auto-tensioner Replacement .............. 4-28 Alternator Reolacement ............. 4-29 Alternator ................ .... 4-30 Overhaul
CruiseControl
Component Location Index .................................. 4-36 Circuit Diagram ........................... 4-37 Troubleshooting Index ....................... 4-38 Symptom Cruise Control UnitlnDut Test ............................. 4-40 MainSwitch TesVReolacement ........................... 4-42 .. SeVResume/Cancel SwitchTesVReplacement 4-42 Cruise Control Actuator Test ......4-43 Cruise Actuator/Cable Replacement 4-44 ...... Control Actuator Cable Adjustment .................................. 4-45 Pedal Clutch Position Switch Test ....................... 4-45
\.
EngineElectrical
SpecialTools
Number
\ C
Tool Number Description Attachment,52 x 55 mm Driver
otv
1 1
07746-0010400 07749-0010000
\(a
4-2
Starting System
ComponentLocationIndex
- l - ar]]]ll -i I
UNDER-DASH FUSE/RELAYBOX
-_rt_.1 -. _-- _. / Itti: : - l t . i t - t! i t !t:!|STARTER CUTRELAY page Test, 22-51
CLUTCH INTERLOCK SWITCH Test,page4-6
\ r \ ' l \'\l I
\r\, l,
/
, . \ \ \ \ / \-
'....",r.v
\:,...)
\ /'\ t l
STARTER page4 5 StanerCircuitTroubleshoot,ng, SolenoidTest,page 4-7 Performance Test,page4-8 page4-9 Replacement, '10 Overhaul,page4
4-3
Starting System
CircuitDiagram
ilo.20lOA) :USA motkl No.2!l50A) : C.nid. model
UiIOEN H@D fUSE/REI.IY BOX
STHOT STA8T in illl
UNDEiOASTI FUST/ifLAY 80x
Y.
cLuTot [{Tr8LocK swtlcH
a
4-4
StarterCircuitTroubleshooting
NOTE: . Airtemperaturemust be between59'and 100'F(15' and 38'C) during this procedure. . After this test, or any subsequent repair,resetthe to enginecontrolemodule (ECM) clear any diagnostlc trouble codes (DTCS) {seepage 11-4). . The batterymust be in good conditionand fully charged. . lf you disconnect the baftery,do the ECM idle learn ( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) . Procedure: Recommended . Use a startersystemtester. . Connectand operatethe equipmentin accordance with the manufacturer'sinstructions. Alternate Procedure 1. Hook up the following equipment: . Ammeter,0 400A . Voltmeter,0 20 V (accurate within 0.1 volt) . Tachometer,0 1200rpm 4. Checkthe batterycondition.Checkelectrical at connections the battery,the negativebaftery cableto body, the engine ground cablesand the and corrosion.Then try starterfor looseness startingthe engine again. Did the statter crank the engine? YES Repairing the looseconnectionfixed the problem.The startingsystem is now OK.! a n N O l f s t a r t e r w i l l o t c r a n k t h e e n g i n e t a l l ,g o t o step 5. lf it cranksthe engine erraticallyor too from the slowly, go to step 7. lf it won't disengage flywheel ring gear when you releasethe key, check for the following until you find the cause. . Solenoidplungerand switch malfunction . Dirty drive gear or damagedoverrunningclutch 5. Make sure the transmissionis in neutral,then 1P disconnect startersubharness connector(A) the 'lP from the enginewire harness connector(B). Connecta jumper wire from the batterypositive 'l terminalto the startersubharness P connector.
2 . Removethe No. 17 (15A)fuse from the under-dash

fuse/relaybox. turn the ignition 3 . With the clutch pedal pressed, switchto start (lll). Did the starter crank the enginenormally? YES-The startingsystem is OK.I YES-Go to step 6. NO-Go to step 4. wire betweenthe starter NO Checkthe BLK,ANHT 1P subharness connectorand the starter.lf wire is OK, removethe starter,and repairor replaceas necessary. Did the starter crank the engine?
L
(cont'd)
4-5
StartingSystem
StarterCircuitTroubleshooting (cont'dl
6. Checkthe following items in the order listeduntil you find the open circuit. . Checkthe BLIVWHT wire and connectors betweenthe under-dash fuse/relaybox and the ignition switch,and betweenthe under-dash fuse/relaybox and the starter. . Checkthe ignition switch {seepage 22-53). . Checkthe clutch interlockswitch and connector. . Checkthe startercut relay (seepage 22-51). . CheckLT GRNwire betweenthe startercut relayl under-dash fuse/relaybox and the clutch interlockswitch. . Checkthe BLKwire betweenthe clutch interlock switch and G501. 7, Checkthe crankingvoltageand currentdraw. ls ctanking voltagegreatet than or equal to 8.7 V and current draw less than or equal to 230 A? YES-Go to step8. NO Replace starter.or remove and the disassemble and checkthese items until you find it, thecause. . Starterarmaturedragging . Shortedarmature winding . E x c e s s i vd r a g i n e n g i n e e 8 . C h e c k h e e n g i n e p e e dw h i l ec r a n k i n g h e e n g i n e . t s t ls the engine speed above 100 tpm? YES Go to step 9. NO-Replace the starter,or remove and disassemble and checkfor the following until it, y o u f i n dt h e c a u s e . . Excessively worn starterbrushes . Open circuit in commutator brushes . Open circuit in starterarmaturecommutator segments . D i r t yo r d a m a g e d e l i c as p l i n e s r d r i v eg e a r h l o . Faultydrive gear clutch 9. Removethe starter,and inspectits drive gear and the flywheel ring gear for damage.Replace any p damaged ans.I
Terminal \ Cl","f ri"t.tf ."tS""*Jrl
ClutchInterlockSwitch Test
1. Disconnect clutchinterlock the switch connector. 2P
2. Removethe clutch interlockswitch (A). Checkfor continuitybetweenthe terminals accordingto the table. . lf the continuityis not as specified,replacethe clutch interlockswitch. . lf OK, installclutch interlockswitch and adjust the pedal height (seepage 12-4l.. 2
PRESSED RELEASED
o--
- --o
4-6
StarterSolenoidTest
from thestarter 1. Disconnect S andlvlconnectors the solenoid.
2. Checkthe hold-incoil for continuitybetweenthe S terminal and the armaturehousing(ground).There should be continuity. . lf there is continuity,goto step 3. . lf there is no continuity,replacethe solenoid,
et
n 3. Checkthe pull-incoil for continuitybetwee the S . t e r m i n a a n d M t e r m i n a l T h e r es h o u l db e l continuity, . lf there is continuity,the solenoidis OK. . lf there is no continuity,replacethe solenoid,
4-7
StartingSystem
Starter Performance Test
1 , Disconnect wires from the S terminal and the M the termrnal. Make a connectionas describedbelow using as heavya wire as possible(preterably equivalentto the wire used for the vehicle). avoid damaging To the starter,never leavethe batteryconnected for more than 10 seconds, Connectthe batteryas shown. Be sure to disconnect the startermotor wire from the solenoid. lf the starterpinion moves out, it is working propefly. 5. Disconnect batteryfrom the starterbody. lfthe the pinion retractsimmediately,it is working properly.
6 . Clampthe starterfirmly in a vise.

7 . Connect the starterto the batteryas describedin the diagram below,and confirm that the motor starts and keepsrotating.
Disconnect batteryfrom the M terminal.lf the the pinion does not retract,the hold-incoil of the solenoidis working properly.
lf the eiectriccurrent and motor speedmeet the specifications when the batteryvoltage is at 11.5V, the staner is working properly, Specifications: 1.1 kw 90 A or less (Electric current), ot more
4-8
Starter Replacement
code for the radio. 1. Make sure you havethe anti-theft for then write down the frequencies the radio's presetbuttons. the 2. Disconnect negativecablefrom the batteryfirst, the positivecable. then disconnect the 3. Disconnect knocksensorconnector. 4. Removethe bolt (A) securingthe harnessbracket, then removethe intakemanifold bracket(B).
A 6x1,0mm 12 N.m {1.2kgf.m, 8.7 tbt.ft)
8 x 1 . 2 5m m 9Nm kgf.m,7 lbl ft) 10.9
the 5. Disconnect startercable (A)from the B terminal wire the BLK,/WHT on the solenoid,then disconnect
{ B )f r o mt h eS t e r m i n a l .
10x 1.25 mm kgf.m,33lblft) 44N.m{a.5
2
S'-12x12smm
6ilNm
{ 6 . 5k g l m , 4 7 l b f f t )
Removethe two bolts holdingthe starter,then removethe starter. mm 8 x 1.25 kgt.m, 22 N,m 12.2 16rbf.ftl 7 . lnstallthe starterin the reverseorder of removal. Make sure the crimped side of the ring terminal (A) is facing out.
I
Connectthe positivecable and negativecableto the batterY.
9 . Start the engineto make sure the starteroperates

propeny.
'10.Enterthe anti-theftcode for the radio,then enter

the customer'sradio stationpresets. 1 1 .Set the clock.
' t 2 .Performthe enginecontrol module (EcM) idle learn

procedure(seepage 1'1- ). 139
4-9
StartingSystem
Starter Overhaul
Disassembly/Reassembly
@ @
STARTERSOLENOID
rw.h \:!@a
,/ 1(-\
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----_2<-
G
SOLENOID LEVER
q
b-.-
- @-A
-z\hsc6
," OVERRUNNING
CLUTCHASSEMBLY
7:- o
S#o
o*"lu*.
V*rN*
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END COVER
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ffiA
'!4/ t/ BRUSHHOLDER
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a<-4 t^ fr/ / -v
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4-10
\
Armature Inspection and Test 1. Removethe starter(seepage 4-9). h a 2 . D i s a s s e m b lte e s t a r t e r s s h o w na t t h e b e g i n n i n g of this procedure. 3. Inspectthe armaturefor wear or damagefrom contactwith the permanentmagnet.lf there is wear or damage,replacethe armature. Commutator Diameter Standard(Newl: 28.0mm (1.10in.l ServiceLimit: 27.0 mm (1.06in.) 5. Checkthe commutatordiameter.lf the diameteris below the servicelimit, replacethe armature.
6 . Measurethe commutator (A) runout. . lf the commutator runout is within the service limit, checkthe commutatorfor carbondust or brasschips betweenthe segments. . lf the commutator runout is not within the service limit, reolacethe armature. Commutator Runout in.) StandardlNew): 0.02mm 10.001 max. in.) ServiceLimit: 0.05mm (0.002
?.-
Checkthe commutator(A) surface.lf the surfaceis with emery cloth or a lathe dirty or burnt, resurface in within the specifications step 5, or recondition with # 500 or # 600 sandpaper(B).
(cont'd)
4-11
StartingSystem
StarterOverhaul(cont'dl
7. Checkthe mica depth (A).lf the mica is too high {B), undercutthe mica with a hacksawbladeto the properdepth.Cut away allthe mica (C)between the commutatorsegments. The undercutshould not be too shallow,too narrow,or V-shaped(D). Commutator Mica Depth Standard(New):0.50-0.80 mm {0.020-0.031in.) ServiceLimit: 0.20 mm (0.008in.) 9. Placethe armature(A) on an armaturetester (B). Hold a hacksawblade (C)on the armaturecore. lf the blade is attracted the core or vibrateswhile to t h e c o r ei s t u r n e d , h e a r m a t u r e s s h o n e d .R e p l a c e t i thearmature.
1 0 ,Checkwith an ohmmeterthat no continuityexists

betweenthe commutator(A) and armaturecoll core (B),and betweenthe commutatorand armatureshaft (C).lf continuityexists,replacethe armature.
Checkfor continuitybetweenthe segmentsof the commutator.lf an open circuitexists betweenany segments,replacethe armature.
M
\
4-12
Starter Brush Inspection 11. lvleasure brush length.lf it is not within the the servicelimit, replacethe brush holder assembly. Brush Length Standard{New): 14.0-14.5 mm (0.55-0.57 in.) 9.0 mm {0.35 in.) Service Limit:
Starter Brush Holder Test 14, Checkthat there is no continuitybetweenthe (+ ) b r u s hh o l d e r{ A )a n d ( ) b r u s hh o l d e r( B } .l f t h e r e is continuity,replacethe brush holder assembly.
Brush Spring Inspection Starter Field Winding Test 12. Checkfor continuitybetweenthe brushes(A).lf there is no continuity.replacethe armature ( housing B). 15. Insen the brush (A) into the brush holder,and bring the brush into contactwith the commutator,then attacha spring scale(B)to the spring (C).Measure the spring tensionat the moment the spring lifts off the brush.lf the springtension is not within replacethe spring. specification, Spring Tension: 13.7-17.7 N {1.40-1.80 kgf, 3.09 3.97lbf)
1 3 .Checkfor continuitybetweeneach brush (A) and

the armaturehousing(B).li there is continuity, replacethe armaturehousing.
(cont'd)
4-13
StartingSystem
StarterOverhaul(cont'dl
Planetary Gear Inspection 1 6 . C h e c k h e p l a n e t a r y e a r s( A )a n d r i n g g e a r{ B ) . g t Replace them if they are worn or damaged. Starter Reassembly 20, Pry backeach brush spring with a screwdriver, then positionthe brush about halfwayout of its holder, a n d r e l e a s eh e s p r i n gt o h o l d i t t h e r e . t NOTE:To seatthe new brushes.slip a strip of #5OO or # 600 sandpaper. with the grit side out, be&veen the commutatorand each brush,and smoothly rotatethe armature.The contactsurfaceof the brusheswill be sandedto the same contouras the commutator.
OverrunningCluich Inspection 17. Slidethe overrunningclutchalong the shaft. Replaceit if it does not slide smoothly. 18. Rotatethe overrunningclutch(A) both ways. Doesit lock in one directionand rotatesmoothly in reverse? it does not lock in eitherdirectionor it lf locksin both directions,replaceit. 21 l n s t a l l t h e r m a t u r en t h e h o u s i n ga n d i n s t a l l t h e a i , brush holder.Next, pry backeach brush spring a g a i n , n d p u s ht h e b r u s hd o w n u n t i li t s e a t s a againstthe commutator,then release the spring againstthe end of the brush.
s
1 9 .lf the starterdrive gear (B) is worn or damaged,
replacethe overrunningclutch assembly; the gear is not availableseparately. Checkthe conditionof the flywheel ring gear. Replaceit if the starterdrive gear teeth are oamageo. Installthe starterend cover to retainthe brush holder.
i.-
4-14
lgnition System
SPARK PLUG page Inspection, 4-'19
IGNITION COIL page Timing Inspection, 4-17 lgnition page Removal/lnstallation, 4-18
4-15
lgnition System
Gircuit Diagram
'No.20lOA) :USAmo&l No.A model l50A):Cmrda
UNDEB HOOD FUST/8TIAY M)(
lG1tioT in 0N {ll) rd SIARIilll)
4-16
lgnition Timing Inspection

1 . Connectthe Honda PGM Testerto the data link connector(DTC), and checkfor DTC'S. a DTCis lf present,diagnoseand repairthe causebefore inspectinthe ignitioniming. g t Startthe engine.Holdthe engine at 3,000rpm with no load (in Neutral)until the radiatorfan comes on, then let it idle. C h e c k h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) . t
4. Follow the tester'sprompts in the
6. Pointthe light toward the pointer (A) on the cam t c h a i nc a s e . h e c k h e i g n i t i o n i m i n g u n d e rn o l o a d C t conditions:headlights, blower fan. rearwindow defogger,and air conditionerare not operaling.lf the ignitiontiming differsfrom the specification, and there are no enginecontrol module {ECM)DTcs, r e p l a c eh e E C M( s e ep a g e1 1 - 4 ) t lgnition Timing: 8"+2" BTDC{REDmark {B))during idling in neutral A
"SCS" menu
{seethe testeroperator'smanual),
5 . Connectthe timing light to the serviceloop.
7. Turn the ignition switch OFF. a D i s c o n n e c t t hH o n d aP G MT e s t e r n dt h e t i m i n g e light.
4-17
lgnition System
lgnitionCoilRemoval/lnstallation
1. Removethe ignition coil cover (A),then removethe i g n i t i o n o i l s( B ) . c 6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf ftl
2. Installthe ignition coils in the reverseorder of removal.
--a
4-18
SparkPlug Inspection
1 . Inspectthe electrodes and ceramicinsulator. Burned or worn electrodes may be caused by: . Advancedignitiontiming . Loosespark plug . Plug heat rangetoo hot .Insufficientcooling Fouledplug may be causedby: . Retardedignitiontiming . Oilin combustionhamber c . Incorrect spark plug gap . Plug heat rangetoo cold . Excessive idling/lowspeed running . C l o g g e d i rc l e a n e r l e m e n t a e . Deteriorated ignitioncoils Worn or deformed electrodes 3. Replace the plug at the specifiedinterval,or if the centerelectrodeis rounded{A). Use onlVthe spark plugs listedbelow. Spark Plugs: lZFR6Kl1(NGK) (DENSO) SKJ2ODR-M11
gap f .lmproper I J.Oil-touling . Cs6on deposits 'r- 1I . Cracked center insulator \ electrode
compoundto 4 . Apply a small quantityof anti-seize the plug threads,and screwthe plugs into the Then torque them to cylinder headfinger-tight. 1 8 N m ( 1 . 8k g f . m ,1 3 l b f f t ) .
Do not adjustthe gap of iridium tip plugs (A); replacethe spark plug if the gap is out of specification. Electrode Gap: Standard(New): ServiceLimit:
1.0 1.1 mm {0.039-0.0 in.) 1.3 mm {0.051in.l
4-19
Gharging System
CHARGING INDICATOR SYSTEM (ln the gaugeassembly)
q*o
BATTERY page22-50 Test, ALTEBNATOR page Troubleshooting, 4-22 page Replacement, 4-29 page4-30 Overhaul,
DRIVE BELT page4 26 Inspection, page Replacement, 4 26
4-20
CircuitDiagram
'flo. {l0Al :uSAhod.l ilo.20l50Al:C.n.d.mod.l
UNDTR XOOD FUSI/RILAY MX
+--, I fmlil*t"t'
TL
+ilt = l
4-21
Gharging System
Charging CircuitTroubleshooting
lf the chargingsystem indicatordoes not come on or does not go off, or the batteryis dead or low, test these items in the order listedbelow: Battery(seepage 22-50) Chargingsystem indicator Alternatorand regulatorcircuit Alternatorcontrol system 6. Measurethe voltageat the No. 3 terminal of the e n g i n e i r e h a r n e s s P c o n n e c t ow i t h t h e i g n i t i o n w 6 r s w i t c hO N {l l ) .
WIREHARNESS CONNECTOR ENGINE 6P
IBLK/YEL}
Charging SystemIndicator Test

1 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s Does the chatging system indicator come on? YES Go to step 2. NO Go to step 3. ls there battery voltage? 2. Startthe engine. YES-Go to step 7. Does the charging system indicator go off? YES-Charging system indicatorcircuitis OK. Go to the Alternatorand Regulator circuitTest.t NO-Go to step 3. 7 . Turn the ignition switch OFF. 3. Turn the ignitionswitch OFF. 4. Troubleshoot multiplexcontrol system (see the page 22 172). ls the multiplex control system OK? YES Go to step 5. NO Checkthe multiplexcontrol system as indicatedby the diagnostic trouble code (DTC) (see s t e p8 o n p a g e2 2 - 1 7 2 ) . 1
ACGL WHT/BLU) {
Wiresideof female terminals
N O - C h e c k f o r a b l o w nN o . 4{ 1 0 A ) u s e i n t h e f under-dash fuse/relaybox. lf the fuse is OK, repair open in the wire betweenthe alternatorand the under-dash fuse/relaybox.I
8 . Disconnect enginecontrol module (ECM)connector (24P). B
9 . Checkcontinuitybetweenthe ECMconnector
t e r m i n a lB ' 1 0 n d e n g i n e i r e h a r n e s s Pc o n n e c t o r w a 6 t e r m i n a lN o . 6 .
ECM CONNECTOB A (24P)
5. Disconnect enginewire harness6P connector the from the startersub harness6P connector.
ENGINE IBE W HARNESS 6P
L (WHT/BLUI
W i r e s i d eo f f e m a l e t e r m i n a s
ls there continuity? YES Go to step 10. NO-Repair open in the wire betweenthe a l t e r n a t oa n dt h e E C N 4 . I r
\"4
4-22
'10.
Checkcontinuitybetweenthe ECMconnector t e r m i n a l8 1 0 a n d b o d y g r o u n d . ECMCONNECTOR I24PI S
Alternator and RegulatorCircuitTest

1. Be sure the batteryis sufficientlychargedand in good condition{seepage 22-50), and the connections the fuse box and alternatorare at clean and tight. 2. Raisethe hoist to full height. 3. Hook up the ammeter,0 subharness. 400 A, to the starter
2 3 t 4t 5 8 I 10 ,/1,/ 3 1 1 8 ,N nt,/ 21
6 7 15
23
ACGL(WHT/BLUI t1'
Wire side ol femaleterminals
ls there continuity? YES- Repairshort to ground in the wire between the ECMand the enginewire harness6P connector. t NO-Go to alternatorand regulatortest.
Lower the hoist. Hook up the voltmeter,0 0.1V),toT101. 20 V (accurate within
(cont'd)
4-23
GhargingSystem
(cont'd) Charging CircuitTroubleshooting
6. Startthe engine.Hold the engineat 3,000rpm with no load (in Neutral)until the radiatorfan comes on, then let it idle. 7. Raisethe engine speedto 2,000rpm, and hold it there. 8. Turn the headlights(high beam)on, and measure voltageat the under-hoodfuse/relaybox terminal. ls the voltagebetween 13.9and 15.1v? YES-Go to step 9. NO Repairor replacethe alternatorcomponents (seepage 4-30).1 9. Readthe amperageat '13.5 V.
Alternator Control SystemTest

performthe engine NOTE:After troubleshooting, control module (ECM)idle learn procedure(seepage 11-139). 1. Checkfor proper operationof the electricalload detector(ELD)by checkingthe malfunction i n d i c a t o lra m p ( M l L ) ( s e ep a g e1l - 3 ) .l f a D T Ci s present,diagnoseand repairthe causebefore continuingwith this test. 2. Disconnect enginewire harness6P connector the from the startersub harness6P connector. 3. Start the engine,and turn the headlights(high b e a m )O N , 4. Measurevoltage betweenthe enginewire harness 6P connectorterminal No. 2 and the positive terminal of lhe battery. BATTERY
NOTE:Adjust the voltage by turning the blower motor, rearwindow defogger,brakelights.etc.ON. ls the amperage604 ot morc? YES-Alternator/regulator operationis OK.I NO Repairor replacethe alternatorcomponents (seepage 4-30).1
C {WHT/GRN)
ENGINE WIRE HARNESS CONNECTOR 6P Wiresideof female terminals ls there 1 V or less? YES Go to step 8. N O - G o t o s t e p5 . 5 . T u r nt h e h e a d l i g h t a n d i g n i t i o n w i t c hO F F . s s ECMconnectorB (24P). 6 . Disconnect
\,
4-24
\
7, Checkfor continuitybetweenECMconnector t e r m i n a l8 1 8 a n d b o d y g r o u n d .
ECM CONNECTOR {24PI B
10. Checkfor continuitybetweenECMconnector t e r m i n a l8 1 8 a n d e n g i n e i r e h a r n e s s Pc o n n e c t o r w 6 t e r m i n a lN o . 2 .

ECM CONNECTOR l2,lPI B
1 2 3 t 4t 5
6 1
5
8 9 10 ,/1,/ 3
11o
nt,/21
23
1 2 3 1 4 l 5 l l6l 7 8 9 10 15 t.) 11o 21 23
ACGC {WHT/GRN}
(WHT/GRN) ACGC
o
Wire side ot femaleterminals
o
2 5
C (WHT/GRN)
3
6
ENGINE WIREHARNESS CONNECTOR 6P Wire side oI lemale terminals
ls there continuity? ls therc continuity? YES-Repair short to ground in the wire between the alternatorand the ECM.I NO-Check that the terminalsare firmly seatedat the ECMconnectorB. lf OK, substitutea knowngood ECM,and recheck(seepage 11-6). lf prescribed voltage is now available.replacethe o r i g i n aE C M , I l Turn the headlights and ignition switch OFF. 9 . Disconnect ECMconnectorB (24P). YES Repairor replacethe startersubharness or the alternator(seepage 4-30).I NO Repairopen in the wire betweenthe a l t e r n a t oa n d t h e E C M . I r
4-25
Charging System
DriveBelt Inspection
(A) indicator is withinthe Check the auto-tensioner that (B) range asshown. it is out of thestandard lf standard page4-26). range, replace drivebelt(see the
DriveBelt Replacement
(A) 1, Move the auto-tensioner to relievetensionfrom the drive belt (B).and removethe drive belt.
2. Installthe new belt in the reverseorder of removal.
4-26
DriveBelt Auto-tensioner Inspection

1 . Checkwhether there is a changein the positionof
(seepage 4-28). Removethe auto-tensioner I n s t a ltlh e t e n s i o n e p u l l e y . r (A) 7 . Clampthe auto-tensioner by using two 8 mm bolts (B)and a vise (C)as shown. Do not clamp the auto-tensioner itself.
the auto-tensioner indicatorbeforestartingthe engineand after startingthe engine.lf there is a , c h a n g e n t h e p o s i t i o nr e p l a c eh e a u t o - t e n s i o n e r . i t
C h e c k o r a b n o r m a n o i s ef r o m t h e t e n s i o n e p u l l e y . f l r l f a b n o r m a n o i s ei s h e a r d ,r e p l a c eh e t e n s i o n e r l t pulley.
3 . Removethe drive belt (seepage 4-26).

8 . Set the torque wrench (D)on the pulley bolt. lMove the auto-tensioner within its limit with the belt tension release tool in the directionshown. Checkthat the tensionermoves smoothly and without any abnormal noise.lf the tensionerdoes not move smoothly or there is abnormal noise, replacethe auto-tensioner. 9 . Align the indicator{E)on the tensionerbasewith c e n t e rm a r k( F )o n t h e t e n s i o n e a r m b y u s i n gt h e r torque wrench, and measurethe torque. lf the torque value is out of specification, replacethe auto-tensioner, NOTE;lf the indicatorexceeds the centermark, recheck torque. the Auto-tensioner spring torque: 26.5-36.3 N.m 12.7-3.7 kg.m, 19.5-26.8lbt.ft)
4-27
System Charging
Replacement DriveBelt Auto-tensioner
1. Removethe drive belt (seepage 4'26). t 2 . R e m o v e h e i d l e rp u l l e y .
6xl.0mm 9.8 N.m (1,0kgl.m, 7.2 tbf.ft)
4. Removethe auto-tensioner,
6x1,0mm 12 N.m ('1.2 kgt.m.8.7lbt.ft)
22 N.m
x 1.25mm
{2.2 kgt m, 16 lbf ft} 8 x 1.25mm 22 N.m (2.2kgf.m, 16lbt.ft) 5. lnstall in the reverse order of removal.
3. Removethe tensionerpulley.
\-a
4-28
l\-
AlternatorReplacement
1. Make sure you havethe anti-theft code for the radio, then write down the frequencies the radio's for preset buttons, 2. Disconnect negativecablefrom the batteryfirst, the then disconnect the positivecable. 3. Removethe front bumper (seepage 20-85).
tt.
9 . Removethe alternator. 1 0 . Installthe alternatorand drive belt in the reverse order of removal. 'I 1 . Connectthe positivecable and negativecableto the battery. Enterthe anti-theft code for the radio,then enter the customer'sradio station presets.
4. Removethe right side headlight(seepage 22-79). 5. Removethe reservetank from the bracket. 6. Removethe drive belt (seepage 4-26). 7. Removethe three bolts securingthe alternator.
8 x 1 . 2 5m m 22 N.n 12.2kgl.m,
1 3 .Set the clock. 1 4 . Performthe enginecontrol module {ECM)idle learn

( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) .
Disconnect alternatorconnector(A) and BLK the wire (B)from the alternator.

8 N.m kgf.m,6lbf.ft) 10.8
4-29
ChargingSystem
AlternatorOverhaul
ExplodedView
ROTOR .oy." W|UF., / REARBEARING

\ \
,/
./
FRoNr B BEARING
@b.J.y{=RE+LN'"' I vVFko"-% \ /
qtr*njlv
BRUSH HOLDER \ \ VOLTAGE REGULATOR \
V ( rV , " )
BRUSH HOLOER TNSULATOR \ \\11 -\\ \l } (-
PULLEY / \
PULLEY LOCKNUT
-\: @*F,
/@
v_re*î
\gP^@'I
\-a
*ffilw9
TERMINAL INSULATOR REARHOUSING ASSEMBLY
INSULATOR BUSHING
4-30
L
Special Tools Required . Driver07749-0010000 . Attachment,52x 55 mm 07746-0010400 NOTE:Referto the ExplodedView as neededduring this procedure. 1, Testthe alternatorand regulatorbeforeyou remove them (see page 4-22l,. 2. Removethe alternator(seepage 4-29). 3. lf the front bearingneedsreplacing,removethe pulley locknutwith a 10 mm wrench (A) and a 22 mm wrench (B).lf necessary, use an impact wrencn. 5 . R e m o v e h e e n d c o v e r( A )a n d d u s t s e a l{ B ) . t
6 . Removethe brush holder (A),voltage regulator(B),

a n dt h e r u b b e rs e a l{ C } .
, (( , t tI ; r _l L t
Removethe harnessbracket(A),insulator(B).three flange nuts (C),and the screw (D),then removethe p l a t et e r m i n a l( E ) .
L1i.21---^
tqLJ
B-"--|.
1!q[-dr,:l
(cont'd)
4-31
ChargingSystem
AlternatorOverhaul(cont'dl
7. Removethe four screws,then removethe rectifier ( A )a n d f o u r i n s u l a t o r ( B ) . s
the and/or 9. lf you arenot replacing frontbearing '16. go the rearbearing, to step Remove rotorfrom the stator driveendhousing.
1 0 .Inspectthe rotor shaftfor scoring,and inspectthe

bearingjournal surfacein the statorhousingfor setzure arks. m Removethe four flange nuts,then removethe rear ( h o u s i n g A )a n dw a s h e r( B ) . . l f e i t h e r t h er o t o r o r s t a t o r h o u s i n g d a m a g e d , is replacethe alternator, . lf both the rotor and the stator housingare OK, g o t o s t e p1 1 . 'l
\"
1 . R e m o v e h e r e a rb e a r i n g s i n ga p u l l e ra s s h o w n . t u
o\
f.r,e
4-32
\1 2 . W i t h a h a m m e ra n d c o m m e r c i a l l a v a i l a b l eo o l s y t shown, installa new rear bearingon the rotor shaft. NOTE:Installthe bearingusing the inner race. 14. Supportthe stator housingin a vise, and drive out the front bearingwith a brassdrift and hammer.
1 5 . W i t h a h a m m e ra n d t h e s p e c i a l t o o l si , s t a l a n e w n l front bearingin the stator housing. 13. Removethe front bearingretainerplate.
f-\ \r-:1 \s---'^/
6 u
s H
q E
e s
07749-0010000
07746-0010400
(cont'd )
4-33
ChargingSystem
AlternatorOverhaul(cont'd)
Rectitier Test 16. Checkfor continuityin each direction,betweenthe B terminal and P terminals,and betweenthe E t e r m i n a a n d P t e r m i n a l s f e a c hd i o d ep a i r . l o A l l d i o d e ss h o u l dh a v ec o n t i n u i t yn o n l y o n e i direction.Because the rectifierdiodes are designed to allow currentto pass in one direction,and the rectifieris made up of eight diodes (four pairs).you musttest each diode in both directionsfor continuitywith an ohmmeterthat has diode checkingcapability: total of 16 checks. a . lf any diode is faulty. replacethe rectifier assembly.{Diodesare not availableseparately.) ' lf all the diodes are OK, go to step 17. Alternator Brush Inspection ( 1 7 . M e a s u r eh e l e n g t ho f b o t h b r u s h e s A ) w i t ha t vernier aliper B). c { . l f e i t h e rb r u s hi s s h o r t e r t h a n t h e e r v i c e i m i t , l s r e p l a c eh e b r u s ha s s e m b l y . t . lf brush length is OK, go to step '18. Alternator Brush Length: Standard(New): 10.5mm (0.41in.) ServiceLimit: 1.5 mm (0.06in.)
/--:',t-L -o \--
. -l'-=
\"
Rotor Slip Bing Test 18. Checkthat there is continuitybetweenthe slip rings {A). B P " . lf there is continuity,go to step 19. . lf there is no continuity,replacethealternator.
P, P. P, P.
1 9 . Checkthat there is no continuitybetweeneach slip ring and the rotor (B) and the rotor shaft (C). . lf there is no continuity,goto step 20. . lf there is continuity,replacethe alternator.
\r'a
4-34
Stator Test 20. Checkthatthereis continuitybetweeneach pair of leads(A). lf there is continuity,go to step 21. lf there is no continuity,replacethe alternator.
'--l-- --i
2 1 .Checkfor no continuitybetweeneach lead and the
coil core (B). . lf there is no continuity,goto step 22. . lfthere is continuity,replacethe alternator.
22. Assemblethe alternatorin reverseorder of

disassembly, and note these items: . Be carefulnot to get any greaseor oil on lhe slip nn g s . . lf you removedlhe pulley,tighten its locknutto 1 1 1N . m ( 1 1 . 3 g f m , 8 1 . 7l b f . f t ) w h e n y o u n s t a l l k i it.
4-35
GruiseControl
INDICATOR CRUISE CONTROL (Builtinto gaug6assembly)
CLUTCH PEDAL POSITION swtTcH page 4-45 Test, Pedal Adjustment, Clutch page12-4
CRUISE CONTROL UNIT page lnputTest, 4-40 BRAKE PEDAL POSITION SWITCH Test,page22-84 page'19-6 Pedal Height Adjustment,
t.-
_,-
CRUISE CONTROL ACTUATOR page Test, 4'43 page Replacement, 4-44
ACTUATORCABLE Adjustment,page4-45
\-a
4-36
CircuitDiagram
' fUS'/iILAY IOX UISEF NOOD No.aloAl No.20 itoAl USAnod.l C.md! modrl
-to
ots
BU/YIL
lcl H0Tii0llilll mdSTARTlllll
1 Honilsffroi
1 uNtT cnu6EcoNTnoL
3 l0
PEDAL CTuICII
P0sm0 swtrct
4-37
Cruise Control
Symptom Troubleshooting Index
NOTE: ' The numbersin the table showthetroubleshootingsequence. . Beforetroubleshooting. - checkthe No, 10 (7.5A)and No. 4 (10A)fuses in the under-dash fuse/relaybox. and the No. 7 (15A)fuse in the under-hoodfuse/relaybox, - checkthat the horn sounds. - checkthe tachometerto see if it works properly. - checkthe speedometer see if it works properly. lo
Symptom
Cruisecontrol cannot be set
Diagnostic procedure 1. Checkmain switch (seepage 4-42) 2. CheckSET/RESUME/CANCEL switch (seepage 4-42) 3. Test brakepedal positionswitch (seepage 22-84)and check its adjustment{seepage 19,6) 4. Test clutch pedal positionswitch (seepage 4-45)and check its adjustment(seepage 12-41 5. Checkcruisecontrol unit {seepage 4-40} 6. Checkvehiclespeed sensor(VSS)(seepage 22-65)
. Poorground: G501 . Opencircuit, loose or disconnected t e r mn a l s : i L TG R N , BLI(ORN. GRY/RED, BLU. LTBLU, BLUAA/HT
. Poor ground: G501 . Open circuit, looseor disconnected termrnats: YEL,BLUA/EL
Also check for
Cruisecontrol can be set but indicatorlight does not go on
1. Check cruise controlindicator bulbin gauge assembly {see page 22-631 2. Check cruise controlunit(seepage4-40)
ar, 'i.a
câa.l
ic
n o t i c e a b l h i g h e ro r y lower than what was set Excessive overshooting or undershooting when trying to set speed Speedfluctuationon a flat road with cruise control set Vehicledoes not decelerate accelerate or accordingly when SET/ RESUME/CANCEL button is pushed Set speed does not cancel(enginerpm stays h i g h )w h e n c l u t c hp e d a l is pushed Set speeddoes not cancelwhen brakepedal is pushed
1. Checkvehiclespeed sensor(VSS){seepage 22-65) Checkcruisecontrol actuator{seepage 4-43) 2. Checkcruisecontrol unit (seepage 4-40) 1. Checkcruisecontrol actuator(seepage 4-43) 2. Checkvehiclespeed sensor(VSS)(seepage 22-65) Checkcruisecontrol unit (seepage 4-40) 3. 1. Checkvehiclespeedsensor(VSS)(seepage22-65) Checkcruisecontrol actuator(seepage 4-43) 2. Checkcruisecontrol unit (seepage 4-40) 1. CheckSET/RESU ME/CANCEL switch (seepage 4-42) 2. Checkcruisecontrol unit {seepage 4-40)
Open circuit,loose or disconnected terminals: GRY/RED, LT GRN/BLK
1. Testclutch pedal positionswitch (seepage 4-45)and check its adjustment(see page 12-4) 2. Checkcruisecontrol unit (seepage 4-40) '1. 2.
Shortto groundin the LTBLUwire
Test brakepedal positionswitch (seepage 22-84)and check Open circuit,loose its adjustment(seepage 19-6) or disconnected Checkcruisecontrol unit (seepage 4-40) terminals: WHT/BLK
g ,
4-38
svmptom
Set speeddoes not cancelwhen main switch is oushed FF O Set speeddoes not c a n c ew h e n C A N C E L l button is pushed
Diagnosticprocedure 1. Checkmain switch (seepage 4-42) 2. Checkcruisecontrol unit (seepage 4-40) ME/CANCEL switch (seepage 4-42) 1. CheckSET/RESU 2. Checkcruisecontrol unit (seepage 4-40)
Also check for Short to power in the LT GRNwire.
loose Open circuit, or disconnected terminals: GRYiRED, LTGRN/BLK

Open circuit,loose or disconnected terminals: L TG R N / B L K
Set speedwill not resume henRESUME w button is pushed(with main switch on, and set speedtemporarily cancelledby pressingthe brakeDedal)
switch (seepage 4-42) 1. CheckSET/RESU ME/CANCEL 2. Checkcruisecontrol unit {seepage 4-40)
4-39
Cruise Gontrol
CruiseControl Unit Input Test
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13) and precautions and (seepage 23-14)in the SRSsectionbefore performingrepairsor service. procedures 1. Disconnect 14Pconnectorfrom the control unit. the 2. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf the terminalsare bent, loose,orcorroded, repairthem as necessary, and recheckthesystem. . lf the terminalslook OK, go to step 3.
Wire sideof femaleterminals
3. With the 14Pconnectordisconnected, make these inDuttests. Cavity
Wire Test condition BRN/WHT Connectbattery

power
Test:Desired result
Checkthe operationof the magneticclutch:Clutch s h o u l dc l i c ka n d o u t p u tl i n k should be locked. Checkfor voltageto ground; There should be 0 V with lhe pedal pressedand battery voltagewith the pedal released.
BLU
lgnitionswitch ON (ll),main swltch ON and brakepedal pressed, then reteaseo
U n d e ra l l c o n d i t i o n s Checkfor continuityto grouno: There should be continuitv BLIVORN l g n i t i o n w i t c hO N s Checkfor voltageto ground: Thereshould be battery flr) vottaqe. WHT/BLK Brakepedal pressed, Checkfor voltageto ground: then released There should be battery voltagewith the pedal pressed,and 0 V with the pedal released.
BLK
Possiblecause is notobtained ifresuh Faultyactuator P o o rg r o u n d( G 3 0 1 ) An open in the wire Shon to ground (arcswhen Doweris connected) . Faultybrakepedal position switch . A n o p e ni n t h e w i r e . Open in cruisecontrol main swrtcn . B l o w nN o . 4 ( 1 0A ) f u s e i n t h e under/dash fuse/relavbox . P o o rg r o u n d( G 5 0 1 ) . An open in the wire ' . . . B l o w nN o . 4 ( 1 0A ) f u s e i n t h e under-dash use/relay f box An oDenin the wire B l o w nN o . 7 { 1 5A ) f u s ei n t h e under-hoodfuse/relaybox Faultybrakepedal position
SWIICN
A n o D e ni n t h e w i r e
4-40
Cavity
Test condition Wire GRYiRED Setbuttonpushed
result Test:Desired
Checkfor voltageto ground: Thereshould be battery voltage, W h e nt e s t i n g e r m i n a lN o . 6 , t there should be no voltageon t e r m i n a lN o . 7 . Checkfor voltageto ground: Thereshould be battery voltage. W h e nt e s t i n g e r m i n a lN o . 7 , t there should be no voltageon t e r m i n a lN o . 6 . Checkthe operationof the actuatormotor: You should be ableto hear the motor.
LT GRN/ BLK
Resume button pusneo
is Possible il result notobtained cause B l o w nN o . 7 ( 1 5A ) f u s e i n t h e under-hoodfuse/relaybox Faultyhorn relay Faultysevresume/cancel swrtch Faultycable reel An open in the wire Shon to ground (horn sounds when button is pressed)
BRN 11
Connectbattery t e r m i n a la n d g r o u n d to the BRNIVEL termrnal lgnitionswitch ON
BRNI/EL power to the BRN
. Faultyactuator . An open in the wire
10
L BLUIVE
0r)
Attachto groundi i r C r u i s e n d i c a t o l i g h ti n t h e g a u g ea s s e m b l y h o u l dc o m e s on. Checkfor voltage between (+) thE BLU/VVHT ANdBLK ( )terminals: T h e r e s h o u l d b e 05 V o r more repeatedly.
Blown No. 10 (7.5A) fuse in fuse/relaybox the under-dash Blown cruise indicatorbulfl g F a u l t y a u g ea s s e m b l y An open in the wire
12
BLU/VVHT lgnitionswitch ON
(ll) and main switch ON; raisethe front of the vehicle,and rotateone wheel s l o w l yw h i l e h o l d i n g the other wheel
Faulty VSS An openin thewire Shortto ground
13
LTGRN
lgnition switchoN { l l )a n dm a i ns w i t c h ON
C l u t c hp e d a l reteaseo
for to Check voltage ground: There shouldbe battery voltage.

Checkfor continuityto grouno: T h e r es h o u l db e c o n t i n u i t y . N O T E : T h e r s h o u l db e n o e continuitywhen the clutch oedal is Dressed.
14
LT BLU
B l o w nN o . 4 ( 1 0A ) f u s e i n t h e fuse/relaybox under-dash Faultymain switch An oDenin the wire Faultyclutch pedal position swtlcn P o o rg r o u n d( G 5 0 1 ) Incorrect clutchswitch adjustment An open in the wire
the system.lf all the input tests prove OK, lf any test indicatesa problem,find and correctthe cause,then recheck cruisecontrol unit may be faulty. Substitutea known-goodcruisecontrol unit and retest.lf the system works the properly,replacethe cruisecontrol unit.
4-41
CruiseControl
Main Switch Test/Replacement
1 . Removethe driver's dashboardlower cover (see page 20-59). 1. Removethe two screws.then removethe switch. Release clips of the main switch and push the the main switch 1A)out of the panel,then disconnect the 5P connector(B)from the main switch.
Set/Resume/Cancel Switch Test/ Replacement
Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. . lfthere is continuity,and it matchesthe table, but switchfailure occurredon the cruisecontrol unit input test, checkand repairthe switch circult. . lf there is no continuityin one or both positions, replacethe switch.
\ 1 4 ;"itl* Terminal '\
Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. lf the continuityis not as specified,replaceillumination bulbs (C)or the switch.
\-------11v1
Position OFF
2 CF
(9
ON
o @ o \J
sET(ONt
RESUME ION)
CANCEL {ON}
o o
--o
--o
r\--
4-42
CruiseControlActuatorTest
1. Disconnect 4P connector(A) from the cruise the control actuator(B). 6. Checkthe operationof the actuatormotor in each output linkagepositionaccordingto the table.You should be able to hear the motor. power Battery Dolarities Output linkageposition
FUtL FULt MIDDLE OPEN CLOSE PO$TION The The The No.3 No,4 Terminal Terminal motor motor motor runs. runs. stoDs, The The The No.3 N o .4 Terminal Terminal motor motor motor sIoos. runs. runs.
OUTPUTLINKAGE
2. Removethe cover (A),and checkthe output linkage

(B)for smooth movement. ,to
FULLCLOSE
1 . lf the actuatormotor does not operateas specified, replacethe cruisecontrol actuatorassembly,
Connectbatterypower to the No, 2 terminal and g r o u n dt o t h e N o . 1 t e r m i n a l . c s f C h e c k o r a c l i c k i n g o u n df r o m t h e m a g n e t i c l u t c h . The output linkageshould be locked. 5 . lf the output linkageis not locked,replacethe cruisecontrol actuatorassembly,
4-43
Cruise Control
CruiseControlActuator/Cable Replacement
1 . Fully open the cruisecontrol link by hand,then removethe cruisecontrol cable{A) from link. Loosenthe locknut(B),and removethe cablefrom the bracket.
3 . Removethe actuatorcover (A),then removethe

actuatorcable (B)from the cruisecontrol actuator.
2 . Disconnect 4P connector,and removethe three the

bolts securingthe cruisecontrol actuator.
4 . Installin the reverseorder of removal,and adjust the free play at the throttle linkageafter connecting the actuatorcable.
6x1,0mm 12 N.m (1.2kgf.m,8.7lbf.ft)
\rla
4-44
ActuatorCableAdiustment
1. Checkthat the actuatorcable{A) moves smoothly with no binding or sticking.
ClutchPedalPositionSwitch Test
the 1. Disconnect 2P connectorfrom the clutch pedal positionswitch (A), 2P POSITION SWITCH CONNECTOR CLUTCH PEOAL
T e r m i n a l s i do f e m a l et e r m i n a l s
2. Startthe engine. 3. Measurethe amount of movementof the output linkage(B) until the engine speedstartsto increase. At first, the output linkageshould be locatedat the fully closedposition(C).The free play (D)should be i 3 . 7 5 1 0 . 5m m ( 0 . 1 5 1 0 . 0 2n , ) . 4. lf the free play is not within specs,loosenthe locknut(E).and turn the adjustingnut (F)untilthe then retightenthe locknut free play is as specified,
Removethe clutch pedal positionswitch. Checkfor continuitybetweenthe terminals accordingto the table. . lf the continuityis not as specified,replacethe clutch pedal positionswitch. . lf OK, installtheclutch pedal positionswitch and adjustthe pedal height (seepage 12-4). Terminal Cl"t"h P"d"l I PositionSwitch
PRESSED 1
RELEASED
4-45
Engine Assembly
Engine Removal
Special Tools Required FrontsubframeadapterEOS02C00001 1 NOTE: . Usefender coversto avoid damagingpainted surfaces. . To avoid damage,unplug the wiring connectors carefullywhile holdingthe connectorportion. . Mark all wiring and hosesto avoid misconnection. Also, be sure that they do not contactother wiring or hoses,or interferewith other parts. 1. Securethe hood in the wide open position(support rod in the lower hole). 2. Make sure you have the anti-theft code for the radio, then write down the frequencies the radio's for presetbuttons. 3. Disconnect negativecablefrom the batteryfirst, the then disconnect positivecable. the 4. Removethe battery. 5. Removethe intakemanifoldcover. 6. Disconnecttheintakeairtemperature(lAT)sensor connector(A),removethe breatherhose (B)and v a c u u mh o s e( C ) , h e n r e m o v e h e a i r c l e a n e r t t housingcover/intake duct assemblv(D). air
\,
7 . R e m o v e t h e a i r c l e a n e rh o u s i n g .
II
5-2
8. Removethe intakeair duct.
10. Fullv ooen the throttle link and cruisecontrol link by hand,then removethe throttlecable (A) and t c c r u i s ec o n t r o l a b l e( B ) f r o mt h e l i n k s .L o o s e n h e locknuts{C),and removethe cablesfrom the bracket.
9. Removethe batterycables{A) fromthe under-hood fuse/relaybox. then removethe harnessclamp (B) a n d g r o u n dc a b l e( C ) .
( 1 1 . R e l i e v e f u ep r e s s u r e s e ep a g e1 1 - 1 4 4 ) . l t 1 2 . R e m o v eh ef u e ll i n e ( s e e p a g e l l - 1 4 9 ) . canister emission(EVAP) 13. Removethe evaporative hose {A) and brakeboostervacuum hose (B).
(cont'd)
5-3
Engine Assembly
EngineRemoval(cont'dl
1 4 . R e m o v e h e c l u t c hs l a v ec y l i n d e r A )a n d c l u t c h l i n e t { bracketmounting bolt (B). 16. Disconnect engine control module (ECM) the connectors(A) and main wire harnessconnector (B).
..4,
15. Removethe shift cable (A) and selectcable (B).
't7. Remove the harnessclamps (A) and grommet (B),

t h e n p u l l t h ee n g i n e i r e h a r n e s sh r o u g ht h e w t bulkhead.
\l,
5-4
1 8 .Removethe drive belt (seepage 4-26).

t 1 9 .R e m o v e h e l v C l i n e m o u n t i n gb o l t .
sensorconnector the 30. Disconnect air fuel ratio {4,/F) (A) and secondaryheatedoxygen sensor (secondary HO2S)connector(B),then removethe three way catalyticconverter{TWC)assembly{C).
20. Removethe radiatorcap. 2 1 . R a i s e h e h o i s tt o f u l l h e i g h t . t 22. Removethe front tires/wheels. 23. Removethe splashshield. t 3 1 . R e m o v e h e l o w e rh o s e .
o@
d 2 4 . L o o s e n h e d r a i np l u g i n t h e r a d i a t o r t o r a i nt h e t enginecoolant(seepage 10-6). l 2 5 . D r a i nt h e t r a n s m i s s i ofn u i d ( s e ep a g e1 3 ' 3 ) . 26. Drainthe engineoil {seepage8-5). i 2 7 . D i s c o n n e c h e s t a b i l i z el r n k s( s e ep a g e1 8 - 1 8 ) . tt lower arm ball joints the 28. Disconnect suspension ( s e es t e p3 o n p a g e1 8 - 1 9 ) . Coat all 29. Removethe driveshafts {seepage 16-3). p r e c i s i o ni n i s h e d u r f a c e s i t h c l e a ne n g i n e i l . w o f s Tie plasticbags over the driveshaftends.
(cont'd)
5-5
Engine Assembly
(cont'd) Engine Removal
32. Lower hoist. the (B). 33. Remove upperhose(A)andheater the hoses 36. Remove transmission the mountbracket support boltandnuts.
34. Bemovethe radiator(seepage 10-10). 35. Attachthe chain hoist to the engine as shown.
37. Remove upperbracket the mounting andnut. bolt
(.g
\a
5-6
Make sure the hoist brackets are positioned properly.Raisethe hoist to full height.
41. Attach subframe the adapterto frontofthe subframe, thentighten knurled the knob.
39. Removethe rear mount mounting bolts.
Raisethe jack. Line up the slots in the arms with the bolt holeson the corner of the jack base,then attachthe adaDter the iack basewith the bolts. to
40. Remove frontmountbracket the mountinq bolt.
(cont'd)
5-7
Engine Assembly
(cont'd) Engine Removal
43. Use a markerto make alignmentmarks on the referencelines(A) that align with the centersof the r e a rs u b f r a m e o u n t i n gb o l t s( B ) . m 45. Disconnect compressorclutchconnector(A), the then removethe Ay'C compressor(B)without disconnecting A'./C the hoses.
!:_- _l.=
:r
--
---.-','-
ffi4 ffit'"
46. Checkthat the engine/transmission completely is free of vacuum hoses,fuel and coolanthoses,and electrical iring. w 4 7 . S l o w l yl o w e rt h e e n g i n e b o u t1 5 0m m ( 6 i n . ) . a C h e c k n c ea g a i nt h a t a l l h o s e sa n d w i r e sa r e o disconnected trom the engine/transmission. 48. Lowerthe engineall the way. Removethe chain hoistfrom the engine. 4 9 . Removethe enginefrom under the vehicle. 44. Removethe front subframe(C).
5-8
Engine lnstallation
Special Tools Required FrontsubframeadapterEOS02C00001 1 1. lnstallthe accessory brackets, and tighten their bolts and nuts to the specifiedtorques. ENGINE MOUNTBRACKET
1 0x 1 . 2 5m m il4 N.m {4.5kgf.m,33lbl.ft)
A/C COMPRESSOR BRACKET
10 x 1,25mm 44 N.m {4.5kgf.m,33lbt.ft)
(cont'dl
5-9
Engine Assembly
(cont'd) Engine Installation
Positionlhe engine under the vehicle.Attachthe chain hoistto the engine,then lift the engine into p o s i t i o nn t h e v e h i c l e . i
(A). 5. Install subframe Alignthe reference the marks (B)on the subframe withthe center the bolt of h e a d s , e nt i g h t e nh eb o l t s . th t
- - -.'.: --=---=-.-..'tt-
R e i n s t a l l t h e o u n t i n gb o l t s / s u p p o r tu t si n m n the sequencegiven. Failureto follow this sequencemay causeexcessive noiseand vibration,and reducebushinglife. 3. Installthe A,/C compressor(A),and connectthe compressorclutchconnector{B).
---:- -
6r"
6-_-'-
1 4 x 1 . 5m m 103Nm k {10,5 gfm. 76 rbt.ftl Replace.
6. Tightenthe rear mount mounting bolts. 8 x 1.25 mm 22 N.m 12.2 m. 16 lbf.ft) kgf 4. Supportthe subframewith the subframeadapter a n da j a c k .
l 0 x 1 . 2 5m m 59 N.m (6.0 kgf.m, 4:] lbI.ft)
5- 10
7. Looselytightenthe front mount bracketmounting bolt.
10. Tightenthe transmissionmount bracketsupport bolt and nuts. 1 2x 1 . 2 5 m m 54 N m {5.5kgt m, 40 lbf.ft}
8 . Lower the hoist. 9 . Tightenthe upper bracketmounting bolt and nut. 'l '1.
Raisethe hoistto full height.
' t 2 . Tighten the front engine mount bracketmounting bolt. 12x 1.25rnrn 64 N.m{6.5 kgf.m, 47 tbt.ftl
:l
13. Lower the hoist. 1 4 . R e m o v e h e c h a i nh o i s tf r o m t h e e n g i n e . t '15. ( I n s t a l l t h e a d i a t o r s e ep a g e1 0 - 1 0 ) . r '16. R a i s e h e h o i s tt o f u l l h e i g h t . t 17. Installa new set ring on the end of each driveshaft, then installthe driveshafts. Make sure each ring "clicks" into place in the differentialand intermediate shaft. (cont'd)
5-11
Assembly Engine
EngineInstallation{cont'dl
1 8 . Connectthe suspension lower arm ball joints (see s t e p6 o n p a g e1 8 - 1 9 ) . 1 9 . Connectthe stabilizer links (seepage 18-18). 20. Installthe three way catalyticconverter(TWC) assembly(A);use new gaskets(B) and new selflockingnuts {C). 10x 1.25 mm 33 N.m{3.i1kgf.m, 25 tbt.ftl 23. Installthe plash hield. s s
-t-
-- -
-- --r
24. Lower hoist. the e 25. I n s t a l l t hd r i v e e l t . b 26. Installthe linemounting A,/C bolt.
6 x '!.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt.ftl
-d
6\
\
,ry
8 x 1.25 mm 22N.m |.2.2kgl m, 16tbt.ft)
2 1 . Connectthe air fuel ratio (4,/F) sensorconnector(D)

and secondaryheatedoxygen sensor(secondary HO2S)connector(E). Installthe lower radiatorhose.
v
5-12
27. lnstallthe upper radiatorhose {A) and heaterhoses (B).
30. Connectthe ECI\4 connectors(A) and main wire harnessconnector(B).
(ECM) Push engine control module the connectors t h r o u g hh eb u l k h e a t h e ni n s t a l l t hg r o m m e(tA ) . t d, e 3 1 .Installthe throttlecable (seepage 11-164), then
a d j u s t t h e a b l e{ s e ep a g e1 1 - ' 1 6 3 ) . c
3 2 . Installthecruisecontrol cable (seepage 4-44), then

adjustthe cable (seepage 4-45),
33. Installthe brakeboostervacuum hose (A) and the

evaporative emission(EVAP) canisterhose (B).
2 9 . I n s t a l l t h e a r n e s s l a m p s( B ) . h c
3 4 . I n s t a l l t h e u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) . f
(cont'd)
5-13
Assembly Engine
Installation Engine {cont'dl
Installthe selectcable (A) and shift cable(B) using the plasticwashers(C),washers(D),and new cotter p i n s( E ) . 6x1.0mm kgf.m, 9.8N.m(1.0 7.2tbl.ftl 37. Installthe batterycables(A) on the under-hood fuse/relaybox, then installthe harnessclamp (B).
\"
6x1.0mm 12Nm{1.2kgt.m, 8.7rbf.ft)
"-.----->) "------'6
g I n s t a l l t h e r o u n dc a b l e( C ) .
3 9 . I n s t a l l t h en t a k e i r d u c t . i a
( I n s t a ltlh e c l u t c hs l a v ec y l i n d e r A )a n d c l u t c hl i n e bracketmounting bolt (B).
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ft) 6x1.0mm 12Nm{1.2kgf.m, 8.7 tbf.ft)
\-
8 x '1.25 mm 24 N.m (2.4kgl.m,
5-14
4 0 . I n s t a ltlh e a i r c l e a n e r o u s i n q . h
6x1.0mm 12 N m (1.2kgf.m,8.7lbt.ft)
4 3 . I n s t a l l t h en t a k e a n i f o l d o v e r . i m c
6x1.0mm 12Nm11.2kgf.m. 8.7 tbf.ft)
4 1 . I n s t a ltl h e a i r c l e a n e r o u s i n g o v e r( A )a n d h c connectthe intakeair temperature(lAT)sensor connector(B),
44. Installthe battery.Cleanthe batterypostsand c a b l et e r m i n a l s i t h s a n d p a p e r , e n a s s e m b l e w th them and apply greaseto preventcorrosion.

]tE
Checkthat the transmissionshifts into gear smoothly.
46. Inspectfor fuel leaks. Turn the ignition switch ON (ll) {do not operatethe starter)so that the fuel pump runs for about 2 secondsand pressurizes fuel the line. Repeat this operationtwo or three times, then checkfor fuel leakageat any point in the fuel line. 41. R e f i l l t h e n g i n e i t h e n g i n eo i l ( s e ep a g e8 - 5 ) . e w 48. R e f i l t h e t r a n s m i s s i ow i t h f l u i d ( s e ep a g e1 3 - 3 ) . l n 4 9 . Refillthe radiatorwith enginecoolant,and bleed air from the cooling system with the heatervalve o p e n ( s e ep a g e1 0 - 6 ) . 4 2 . I n s t a l l t h e r e a t h e h o s e( C )a n d v a c u u mh o s e1 D ) . b r
5 0 . P e r f o r m h e e n g i n ec o n t r o lm o d u l e( E C M ) d l el e a r n t i
( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) . 5 1 . Inspectthe idle speed (seepage 11-138).
52. I n s p e ctth e i g n i t i o n i m i n g ( s e ep a g e4 - 1 7 ) . t 5 3 . C h e c k h e w h e e la l i g n m e n { s e ep a g e1 8 - 4 ) . t t 54. Enterthe anti-theftcode for the radio,then enter

the customer'sradio station presets. 55. Set the clock.
5-15
EngineMechanical
Cylinder Head
Special Tools 6-2 Comoonent Location Index 6-3 Engine Compression Inspection b-t' VTEC Rocker Arm Test ........... ............ 6-7 VTCActuator Inspection .................... 6-8 Valve Clearance Adjustment ............. 6-9 Crankshaft Pulley Removal Installation and .............. 6-11 C a mC h a i n e m o v a l R . . . . . . . . . . . . . . . . . . . . - 1.2. . . 6 .. . C a mC h a i nn s t a l l a t i o n I . . . . . . . . . . . . . . . .6 .-.1 . . . . .5 Auto-Tensioner Removal/1nsta11ation ......................... 6-19 Chain Case SealInstallation Oil ........ 6-21 Cyf inderHead Removal Cover .......... 6-22 Head Cylinder Removal ..................... 6-23 WC Actuator. Exhaust Camshaft Sorocket R e pa c e m e n t f .........6-24 Head Cylinder Inspection Warpage...................... for 6-25 Rocker Arm Assembly Removal................................. 6-26 Rocker ArmsandShafts Disassembly/Reassembly .............. 6-27 Rocker ArmsandShafts Inspection ............................ 6-28 Camshaft Inspection .......................... 6-29 Valves, Springs, Valve and Seals Removal................ 6-31 Valve Insoection ...................... ........... 6-32 Valve Stem-to-Guide Clearance Insoection ............... 6-32 Valve Reolacement Guide ................. 6-33 Valve SeatReconditioning ................ 6-35 Valves, Springs, Valve and Seals Installation ............ 6-37 Rocker Arm Assemblv Installation .... 6-38 C v l i n d e r e a d n s t a l l a t i o.n . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 3.9. . . . . . . . . H I . 6 .. . Cylinder Head Cover Installation ......6-41
Head Cylinder
SpecialTools
Ref. No. Tool Number
a
Description
R Air Pressure egulator V a l v eG u i d eR e a m e r5 . 5m m , Socket,19 mm H o l d e rH a n d l e HolderAttachment,50 mm Attachment Valve Spring Compressor VTECAir Adapter VTECAlr Stopper Air Joint Adapter m V a l v eGu i d eD r i v e r , 5 . 5 m Attachment,52 x 55 mm Driver
Oty
1 1 1 1 1 1 2 1 1
O .D
o
@ o G) E] O tro @ (D
ozoa I oz..rae-oot
OTAAJ.PNAA'IOO OTHAH-PJ7O1OB
07JAB-0010204 07NAB-0010404 07VAE-001010A OTZAJ.PNAAlOO OTZAJ-PNAA2OO I 07ZAJ-PNAA300 07742-0010100 07746-001o4oo 07749-0010000
--
l-:
,.
'a- ti-',..)-)--'
- -- -i
-
- 1jr-
r-
o ..'.,i2
,-
''
,.-/
,)
a:-t'"
r--\ Lq-,
5'r'
/":
.<:'':'v'' a
l?
a,/'/'
..# ..a:-"
@
-- -'''
't'tY-,l
OD
@
6-2
Component Location lndex
IGNITION COIL COVER
CYLINDER HEAD COVER page Removal, 6-22 page lnstallation, 6-41
CAM CHAIN Bemoval,page6-'12 page6-15 Installation,
frn "p
|]tJ ,
TENSIONER ARM
CAM CHAINGUIDEB
CAM CHAINGUIDEA
VALVE VARIABLE TIMING CONTROL twc) olL soLENotD VALVE
PULLEY CRANKSHAFT R e p l a c e m e np a g e6 1 1 t,
AUTO.TENSIONER page6-'lI Replacement,
O-RING
(cont'd)
6-3
Cylinder Head
ComponentLocationIndex(cont'd)
Y f\ R LI T
F]
F g
CAMSHAFT HOLDER
fr
EEI
g-----
CAMCHAIN B GUIDE
CAMSHAFTPOSITION ICMP}SENSOR
-"-oowetew
TOPDEADCENTER (TDC) SENSOR

EXHAUSTCAMSHAFT SPROCKET page6 24 Removal, page6-25 Installation,
EXHAUSTCAMSHAFT
ROCKER ARM ASSEMBLY page6 27 Overhaul, page 6-28 Inspection,
6-4
EXHAUST VALVE SEAL
.\ ll" --.i
SPRING RETAINER
vALvE
.""or", uo.u,
aFl
d:l.\
>il(
,H
| |
l* I / uo.ur.r","o l l
T1 l l
\ l g g
II
tl Y I I
G\-r_
.--
spntruc
H e ,
EI 1.U _-/
U-
^-'--
vALVE -/ TNTAKE
9E4L Replacement,
6-31 Page
|NTAKE VALVE GUIDE page Replacement, 6-33
,p
2bw
9) \
HEAD CYLINDER Removal,page6'23 page6-25 Inspection, page6-39 Installation, EXHAUSTVALVE page6-31 Removal, page6-37 Installation, INTAKEVALVE Removal,page6 31 page6 37 Installation,
\*""'RArNERcovER wcsrRArNER
HEATSHIELD
CYLINDER HEAD GASKET
6-5
Head Cylinder
EngineCompression Inspection
1 . W a r m u p t h e e n g i n e o n o r m a lo p e r a t i n g t temperature(coolingfan comes on). 2. Turn the ignition switch OFF. 3. Removethe intakemanifoldcover (seestep 1 on page6-22). 4, Disconnect four injectorconnectors. all 5. Startthe engine,and let it run until it stalls. 6 . R e m o v e h e i o u r i g n i t i o n o i l s( s e ep a g e4 - 1 8 ) . t c 7. Removethe four spark plugs. 8. Attachthe compressiongaugeto the spark plug note. Maximum vadation Within 200 kPa (2.0 kgf/cm', 28 psi) 1 1 .lf the compressionis not within specifications, checkthese items,then remeasure the compressron. . . . . Damagedorworn valvesand seats Damagedcylinder head gasket Damagedor worn piston rings Damagedorworn piston and cylinderbore
\ 9 . Open the throttlefully, then crankthe enginewith

the startermotor and measurethe compression. Compression Pressure Above 930 kpa (9.5 kgf/cm', 135 psi)
1 0 .Measurethe compressionon the remaining

cylinders,
\-
V,
6-6
WEC Rocker ArmsTest

Special Tools Required . Air pressureregulator07AAJ-PNAA100 . VTECair adaoter07ZAJ-PNAA100 . WEC air stoDoer 07ZAJ-PNAA200 . Air joint adapter07ZAJ-PNAA300 1. Removethe cylinder headcover (seepage 6-22). (see 2. Set the No. 1 pistonat top dead center(TDC) step 1 on page6-12). 3. Verify that the intakeprimary rockerarm (A) moves of independently the intakesecondaryrockerarm (B). . lf the intakeprimary rockerarm does not move, removethe primary and secondaryrockerarms as an assemblyand checkthat the pistonsin the secondaryand primary rockerarms move smoothly.lf any rockerarm needs replacing, replacethe primary and secondaryrockerarms as an assemblv,and test. . lfthe intakeprimary rockerarm moves freely,go to step 4. Repeatstep 3 on the remainingintakeprimary rockerarms with each piston at TDC.When all the primary rockerarms passthe test, go to step 5. Checkthat the air pressureon the shop air compressorgauge indicatesover 400 kPa (4 kgflcm',57 psi). (seepage 6-9). 6 . Inspectthe valve clearance 7 . Removethe sealingbolt (A)from the relief hole, and installthe VTECair stopper(B).
OTAAJ.PNAAlOO
D OTZAJ-PNAA3OO
OTZAJ.PNAAlOO
Removethe No. 2 and No. 3 camshaftholder bolts, and installthe VTECair adapters(C)finger-tight. Connectthe air joint adapter(D),and air pressure regulatorwith a 0-100psi gauge (E).
(cont'd)
6-7
CylinderHead
WEC RockerArms Test (cont'dl
'10. Loosenthe valve on the regulator,and apply the specifiedair pressure.
VTGActuator Inspection
'11. Removethe cylinder headcover (seepage 6-22lr. (seepage6-19). 2. Removethe auto-tensioner 3. Loosenthe rockerarm adjustingscrewslsee step 2 on page6-26). 4. Removethe camshaftholder (seestep 3 on page 6-
Specified air pressure: 290 kPa 13.0kgt/cm', 42 psi) NOTE:lf the synchronizing piston does not move after applyingair pressure; move the primary or secondaryrockerarm up and down manuallyby rotatingthe crankshaft clockwise. 1 1 . W i t h t h e s p e c i f i e d i r p r e s s u r e p p l i e d m o v et h e a a , p i n t a k e r i m a r yr o c k e r r m ( A ) f o r t h e N o , 1 c y l i n d e r . a The primary rockerarm and secondaryrockerarm ( B )s h o u l dm o v e t o g e t h e r . lf the intakesecondaryrockerarm does not move, removethe primary and secondaryrockerarms as an assembly,and checkthat the pistonsin the primary and secondaryrockerarms move smoothly.lf any rockerarm needsreplacing, replacethe primary and secondaryrockerarms as an assembly,and test.
26t.
5. Removethe intakecamshaft. 6, Checkthat the variablevalve timing control (VTC) actuatoris lockedby turning the VTCactuator clockwiseand counterclockwise. the VTC actuator lf is not locked,replacethe VTCactuator. 7 . S e a lt h e a d v a n c e o l e s( A ) a n dr e t a r dh o l e s( B )i n h the No. 1 camshaftjournal with tape.
Puncha hole through the tape over one of the advanceholes.
1 2 .Removethe specialtools. 1 3 .Tightenthe camshaftholder mounting boltslo

22N m 12.2 kgf.m, 16 lbf.ft). 1 4 . T i g h t e n h e s e a l i n g o l t t o 2 0 N . m ( 2 . 0k g f . m , t b 14 tbf.ft).
t5.
I n s t a l l t h e y l i n d e r e a dc o v e r( s e ep a g e6 - 4 1 ) . c h
6-8
Adiustment ValveGlearance
the lock. 9. Apply air to the advancehole to release NOTE:Adjust the valvesonly when the cylinder head temperatureis lessthan 100'F (38'C). 1. Removethe cylinderhead cover (seepage6-22). The 2. Set the No. 1 piston at top dead center(TDC). punch mark (A) on the variablevalve timing control (VTC)actuatorand the punch mark (B)on the exhaustcamshaftsprocketshould be at the top. Align the TDC marks (C)on the VTC actuatorand exhaustcamshaftsprocket.
1 0 .Checkthat the VTCactuatormoves smoothly.lf the

VTC actuatordoes not move smoothly, replacethe VTC acluator.
{cont'd)
6-9
GylinderHead
ValveClearance Adjustment (cont'd)
3. Select correct the thickness feelergauge the for you'regoingto check. valves Intake: 0.21 0.25mm (0.008-0.010 in.) Exhaust; 0.28 0.32mm (0.011 0.013 in.) Adiustingscrew locations:
EXHAUST
No. 1
\.
5 . l f y o u f e e lt o o m u c h o r t o o l i t t l e d r a g ,l o o s e n t h e locknut(A),and turn the adjustingscrew {B) until the drag on the feelergauge is correct..
N o .2
No.3
N o .4
No. 1
No.4
Tightenthe locknut,and recheck clearance. the Repeatthe adjustmentif necessary 7 . Rotatethe crankshaft180"clockwise(camshaft p u l l e yt u r n s9 0 ' ) .
4. Insertthe feeler gauge {A) betweenthe adjusting
s c r e w( B )a n d t h e e n d o f t h e v a l v es t e m ,a n d s l i d ei t backand forth; you should feel a slight amount of d rag.
t.
\-
8. Checkand, if necessary, adjustthe valve clearance o n N o .3 c y l i n d e r .
6-10
PulleyRemovaland Crankshaft Installation

9. Rotatethe crankshaft180"clockwise(camshaft pullevturns 90'). Special Tools Required . Holder handle07JAB-001020A . Holderattachment, mm 07NAB-001040A 50 . Socket,19 mm 07JAA-001020,4 a commercially or 1 a v a i l a b l e 9m m s o c k e t
Removal
1. Removefront tires/wheels. 2. Removethe splashshield (seestep 23 on page 5-5). ( 3 . H o l dt h e p u l l e yw i t h h o l d e rh a n d l e A )a n d h o l d e r attachment(B). adjustthe valve clearance 1 0 .Checkand, if necessary, on No.4 cylinder. 1 1 .Rotatethe crankshaft180"clockwise(camshaft p u l l e yt u r n s9 0 " ) . B 07NAB-001040A
el
/ f
/ Srroo.oo,oroo (or
commercially available)
Removethe bolt with a 19 mm socket(C)and breakerbar.
adjustthe valve clearance 1 2 .Checkand, if necessary, o n N o .2 c y l i n d e r . Installthe cylinder headcover (seepage 6-41).
(cont'd)
6-11
CylinderHead
Crankshaft PulleyRemovaland (cont'dl Installation
Installation
1. Cleanthe crankshaftpulley (A),crankshaft (B),bolt (C).and washer (D).Lubricateas shown below. . .: Clean O; Lubricate
CamChainRemoval
NOTE:Keepthe cam chain away from magneticfields. 1. Turn the crankshaft pulley so ils top dead center ( T D C ) a r k( A )l i n e su p w i t h t h e p o i n r e r B ) . ( m
t[] rL
-'....-----=a
ll ll
(-,
5U-1J It
t 2 . Removethe front tires/wheels.
I n s t a l l t h e r a n k s h a fp u l l e y , n d h o l dt h e p u l l e y c t a with holder handle(A) and holder attachment{B). B 07NAB-0010iroA
3 . R e m o v e h e s p l a s hs h i e l d . t - , , - - . = . - - - - - _ _ - - _ \
A 07JAB-001020A
4. Removethe drive belt (seepage 4-26). Tightenthe bolt to 245 N.m (25.0kgf.m, 181 tbf.ft) with a torque wrench and 19 mm socket(C).Do not use an impactwrench. I n s t a ltl h e s p l a s h h i e l d( s e es t e p2 0 o n p a g e5 - 1 2 ) . s 5 . Insta front tires/wheels. ll 5. Removethe cylinder headcover (see page6-22). 6 . R e m o v e h e c r a n k s h a fp u l l e y( s e ep a g e6 - 1 1 ) . t t
\-
6-12
position(CKP) sensor 7. Disconnectthe crankshaft connector{A) and variablevalvetiming control {VTC)oil control solenoidvalve connector(B).
1 1 . R e m o v e h e s i d ee n g i n em o u n tb r a c k e t . t
t 1 2 . R e m o v e h e c h a i nc a s e .
Removethe VTC oil control solenoidvalve (see s t e p1 o n p a g e1 1 - 1 2 7 ) . 9 . Supportthe enginewith a iack and wood block u n d e rt h e o i l p a n .
1 0 .Removethe ground cable (A).and removethe

upper bracket(B).
(cont'd)
6-13
CylinderHead
(cont'd) CamChainRemoval
Looselyinstallthe crankshaft pulley. 1 4 . Turn the crankshaft counterclockwise compress to the auto-lensioner, 16. Removethe auto-tensioner.
1 7 . R e m o v e h e c a m c h a i ng u i d eB . t
gffi
llll
t5.
Align the holes on the lock (A) and the autot e n s i o n e ( B ) , h e n i n s e na 1 . 5m m ( 0 . 0 6 n . ) r t i diameterpin (C)into the holes.Turn the crankshaft clockwiseto securethe Din.
U U
\-
6 -14
CamChainInstallation
1 8 . R e m o v e h e c a m c h a i ng u i d eA ( A )a n d t e n s i o n e r t a r m( B ) . t./6. | \ {n$1J; NOTE:Keepthe cam chain away from magneticfields. Align to 1. Set the crankshaft top dead center(TDC). sprocketwith the TDC mark {A) on the crankshaft ( b t h e p o i n t e r B )o n t h e c y l i n d e r l o c k .
,o
g"'1 9 . R e m o v et h e c a m c h a i n .
Setthe camshaftsto TDC.The punch mark (A) on the variablevalve timing control {VTC)actuatorand t t h e p u n c hm a r k( B )o n t h e e x h a u s c a m s h a f t sprocketshould be at the top. Align the TDC marks (C)on the VTC actuatorand exhaustcamshaft sprocKet.
(cont'd )
6-15
Gylinder Head
(cont'dl CamChainInstallation
3. Installthe camchainon the crankshaft sprocket (A) piece aligned with thecolored withthe punch mark(B)on the crankshaft sprocket.
5 . I n s t a l l t h e a m c h a i ng u i d eA ( A )a n d t e n s i o n ea r m c r (B).
6x1.0mm 1 2N . m {1,2kgf.m, 8.7 tbf.ftt
'6I
Installthecam chain on the VTCactuatorand exhaustcamshaftsprocketwith the punch marks (A) alignedwith the two colored pieces(B). B 6. Installthe auto-tensi
8 x 1.25 m m 22 N.m 12.2kgt.m, 16tbf.ft)
a
6x1,0mm 12Nm (1.2kgt.m,8.7 lbf ti)
a
6-16
7 , I n s t a ltlh e c a m c h a i ng u i d eB .
1 0 .Removeold liquid gasketfrom the chain case

8 x 1.25 mm 22 N.m (2.2 kgf.m, 16lbt.ft) bolts,and bolt holes. mating surfaces, 1 1 .Cleanand dry the chain case mating surfaces. evenlyto the Apply liquid gasket.P/N 08718-0009, cylinder block mating surfaceofthe chain caseand o t o t h e i n n e rt h r e a d s f t h e h o l e s .
H4 \ilt
H g
q
8. Removethe Dinfrom the auto-tensioner,
Apply liquid gasket alongthe brokenline.
Apply liquid gasketto the cylinder blockupper surfacecontactareas(A) on the chaincase. evenlyto the 1 4 . Apply liquid gasket,PiN 08718-0009, oil pan mating surfaceof the chain caseand to the innerthreadsof the holes. NOTE:Do not installthe parts it 5 minutesor more have elapsedsinceapplying liquid gasket.lnstead, reapplyliquid gasketafter removing old residue.
9 . Checkthe chain caseoil sealfor damage.lf the oil seal is damaged,replacethe chain case oil seal ( s e ep a g e6 - 2 1 ) .
(cont'd)
6-17
Gylinder Head
(cont'd) CamChainInstallation
'15. Installthe new O-ring(A) on the chain case.Set the edge of the chain case (B)to the edge of the oil pan ( C ) , h e n i n s t a ltl h e c h a i nc a s eo n t h e c v l i n d e r l o c k t b (D). 1 6 . l n s t a l l t h e i d ee n g i n em o u n t . b r a c k e t . s
NOTE:When installingthe chain case,do not slide the bottom surfaceon the oil pan mounting surface.
rbf.ft)
',.9
17. Installthe upper bracket(A),then tightenthe bolv nuts in the numberedseouence shown.
6 x 1 . 0m m 12 N.m {1.2kgl m, 8.7 lbf ft} 1 2 x 1 . 2m m 5 54 N.m (5.5 kgt m, 40 lbf.ft)
6x1.0mm 1 2N . m (1.2kgt.m.8.7lbf.ft)
6x1.0mm 12Nm (1.2kgf.m,8.7lbf.ft)
1 8 . I n s t a ltl h e g r o u n dc a b l e( B ) .
\-
6-18
Auto-Tensioner RemovaU lnstallation

1 9 . lnstallthe variablevalve timing control (VTC)oil c o n t r o l o l e n o i d a l v e( s e es t e p 1 o n p a g e1 1 ' 1 2 7 ) . s v
Removal:
20. Connectthe crankshaftposition(CKP) sensor
connector{A) and VTC oil control solenoidvalve connector(B). 1 . R e m o v e h e c h a i nc a s ec o v e r . t
pulley (seepage 6-12). 21. Installthe crankshaft h 2 2 . I n s t a l l t h e y l i n d e r e a dc o v e r( s e ep a g e6 - 4 1 ) . c 2 3 . I n s t a l l t h e r i v eb e l t . d 24. Installthe plash hield. s s
to counterclockwise compress Turn the crankshaft the auto-tensroner.
D@
{cont'd)
6-19
GylinderHead
Auto-Tensioner Removal/l nstallation(cont'dl
3. Align the holes on the lock (A) and the autot e n s i o n e ( B ) , h e n i n s e r ta 1 . 5m m ( 0 . 0 6 n . ) r t i diameterpin (C)into the holes.Turn the crankshaft clockwiseto securethe oin.
Installation:
1. Installthe auto-tensioner.
4. Removethe auto-tensioner.
6x1.0mm 12 N.m {1.2kgt.m,8.7 lbt.tt) Remove the pin from the auto-tensioner.
\-
6-20
ChainCase SealInstallation Oil

Removeold liquid gasketfrom the chain casecover mating surfaces, bolts,and bolt holes.
4 . Cleanand dry the chain casecover mating surfaces.
SpecialToolsRequired . Driver07749-0010000 . Attachment,52 x 55 mm 07746-0010400 1 . U s et h e s p e c i atl o o l st o d r i v ea n e w o l l s e a l squarelyinto the chain caseto the specified installed eight. h
Apply liquid gasket,P/N 08718-0009, evenlyto the chain case mating surfaceof the chain casecover and to the innerthreadsof the holes. NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplyingliquid gasket.Instead, reapplyliquid gasketafter removing old residue.
07749-0010000
Apply liquid gasket l a l o n gt h e b r o k e n i n e .
2. Measurethe distancebetweenthe chain case ( s u r f a c e A )a n d o i l s e a l1 B ) . Oil Seal InstalledHeight: 3 3 . 0 - 3 3 . 7m m ( 1 . 3 0 -1 . 3 3i n . )
6 . I n s t a l l t h e h a i nc a s ec o v e r . c
6x1.0mm 1 2N . m {1.2kgt.m, 8.7 tbf.ft)
33.0 33.7mm i { 1 . 3 0 1 . 3 3n . l
6-21
Gylinder Head
CylinderHeadCoverRemoval
1. Removethe intakemanifoldcover. 4, Removethe cylinder headcover
V:t :;t 1
|,'.i/
2. Removethe four ignition coils (seepage 4-'18). 3. Removethe dipstick(A) and breatherhose (B).
\-
6-22
GylinderHeadRemoval
NOTE: . Usefender painted covers avoiddamaging to surfaces.
To avoid damage,unplug the wiring connectors carefullywhlle holdingthe connectorportion. To avoid damagingthe cylinderhead,wait until the enginecoolanttemperaturedrops below 100'F(38"C) betore looseningthe cylinder head bolts. Mark all wiring and hosesto avoid misconnection. Also, be sure that they do not contactother wiring or hoses,or interferewith other parts. 8. Removethe enginewire harnessconnectors and wire harnessclampsfrom the cylinder head. . Enginecoolanttemperature(ECT) sensor conneclor . Camshaftposition(Cl\4P) (top dead center(TDC)) sensor B connector . Camshaftposilion (CMP)sensorA connector 9. Removethe upper radiatorhose (A) and heater h o s e( B ) .
' 1 .Drainthe
enginecoolant(seepage 10-6).
2 . Removethe drive belt (seepage 4-26). 3 . Removethe intakemanifold {seepage 9-3).

Removethe air cleanerhousing(seestep 7 on page 5-2t. 5. Removethe water bypasshose (A).
'10.
Removethe harnessholder (A)from the bracket, then removethe connectingpipe mounting boh {B) and brakeboostervacuum line mounting bolts {C).
6 . Removethe exhaustmanifold (seepage9-7) . 7 . Removethe cam chain (seepage 6-12).
11. Removethe water bvpasshose (D).
(cont'd)
6-23
Head Cylinder
CylinderHeadRemoval(cont'd)
Removethe rockerarm assembly(seepage 6-26).
tJ.
VTCActuator, Exhaust Camshaft

SprocketReplacement
Removal:
1 . R e m o v e h e c a m c h a i n( s e ep a g e6 - 1 2 ) . t 2. Hold the camshaftwith an open-endwrench,then loosenthe variablevalve timing control (VTC) actuatormounting bolt and exhaustcamshaft sprocketmounting bolt.
Removethe cylinderhead bolts.To prevent warpage,unscrewthe bolts in sequence1/3turn at u a t i m e ; r e p e a t h e s e q u e n c e n t i la l l b o l t sa r e loosened. HEADBOLTSLOOSENING CYLINDER SEQUENGE:
h 1 4 . R e m o v eh e c y l i n d e r e a d . t
I
Removethe VTC actuatorand exhaustcamshaft sprocket.
I
6-24
Installation:
1. Installthe VTC actuatorand exhaustcamshaft sprocket. 2. Apply engineoil to the th readsof the VTC actuato r mounting bolt and exhaustcamshaftmounting bolt, then installthem. 3. Hold the camshaftwith an open-endwrench,then tighten the bolts. Specified torque: VTC actuator mounting bolt: 1 1 3N . m ( 1 1 . 5 g l . m , 8 3l b l . f t ) k Exhaust camshaft sprocket mounting bolt: 72 N m (7.3 kgf.m, 53 lbf.ft)
CylinderHeadInspection for Warpage

1 , Removethe cylinder head{see page 6-23).
Inspectthe camshaft(seepage 6-29). Checkthe cylinder headfor warpage.Measure along the edges,and three ways acrossthe center. . lf warpage is lessthan 0.05mm (0.002in.) cylinder head resurfacing not required. is . lf warpage is between0.05 mm (0.002in.) and 0.2 mm (0.008in.),resurface cylinder head. the . Maximum resurface limit is 0.2 mm (0.008in,) basedon a height of 104mm (4.09in.). Cylinder Head Height; Standard{New}: 103.95 104.05 mm {4.093 4.096in.}
4 . I n s t a ltl h e c a m c h a i n{ s e ep a g e6 - 1 5 ) .
6-25
CylinderHead
RockerArm AssemblyRemoval
'1. Removethe cam chain (seepage 6-12). 4 . Removethe cam chain guide B, camshaftholders, and camshafts. 5 . Insertthe bolts (A) Into the rockershaft holder,then removethe rockerarm assembly(B).
2 . Loosenthe rockerarm adjustingscrews (A), A
3. Removethe camshaftholder bolts.To Drevent damagingthe camshafts,unscrewthe bolts two pattern. turns at a time, in a crisscross CAMSHAFTHOLDERBOLTS LOOSENING SEOUENCE:
\-
6-26
RockerArms and ShaftsDisassembly/Reassembly

NOTE:
ldentifypartsas they are removedto ensurereinstallation original location. in Inspect the rockershaftsand rockerarms (seepage 6-28). The rockerarms must be installedin the same positionsif reused. When removing or installingthe rockerarm assembly,do not removethe camshaftholder bolts.The bolts will keep the holders,springsand rockerarms on the shaft. Priorto reassembling, cleanall the parts in solvent,dry them, and apply lubricantto any contactpoints. Bundlethe rockerarms with rubber bandsto keeD them tooetheras a set. EXHAUST ROCKER SHAFT EXHAUST ROCKER ARM
wASHEB
\nl I ltnrllln
IJI_J;-L,JLI []1_L^|l]
o
'rl) 70)
Yr
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t:l P
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o
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INTAKE ROCKER ARM ASSEMBLY
INTAKEROCKER SHAFT
6-27
CylinderHead
Arms and ShaftsInspection Rocker
1 . Removethe rockerarm assembly(seepage 6-26). 2 . Measurethe diameterof the shaft at the first rocker location. 4. Measurethe insidediameterofthe rockerarm, and condition. checkit for an out-of-round Rocker Arm-to-Shaflt Clearance: Standard lNew): 0.025 0.052 mm lntake: (0.0010 0.0020in.) Exhaust: 0.018 0.056mm (0.0007 0.0022in.) 0.08 mm (0.003in.) Service Limit:
3. Zero the gauge (A)to the shaft diameter.
5. Repeatfor all rockerarms and both shafts.lfthe clearance over the Ilmit. replacethe rockershaft is rockerarms. lf any VTEC and all overtolerance replacethe rocker rockerarm needs replacement, as arms (primaryand secondary) a set. 6. Inspectthe rockerarm pistons{A}.Pusheach p i s t o nm a n u a l l y . lf it does not move smoothly,replacethe rocker arm set. NOTE:Apply oil to the pistonswhen reassembling.
\.
,,,@@
6-28
Gamshaft Inspection
NOTE:Do not rotatethe camshaftduring inspection. 1. Removethe rockerarm assembly(seepage 6-26). and disassemble (seepage6-27). it 2. Putthe rockershaft holders,camshaft,and camshaftholderson the cylinderhead,then tighten the bolts to the specifiedtorque. Specified torque: I mm bolis: 22 N.m {2.2kgt m, 16lbf.ft} 6 mm bolts: 12 N.m {1.2kgf.m,8.7 tbf.ftl 6 mm bolts: @, 0, @ 3. Seatthe camshaftby pushing it away from the c a m s h a f p u l l e ye n d o f t h e c y l i n d e r e a d . t h 4. Zero the dial indicatoragainstthe end of the camshaft,then push the camshaftbackand forth and read the end play. lf the end play is beyondthe servicelimit, replacethe camshafthead and recheck. it is still beyondthe servicelimit, replace lf thecylinder. CamshaftEnd Play: Standard{New}:0.05 0.20 mm (0.002 0.008in.l ServiceLimit: 0.4 mm (0.02in.)
(cont'd)
6-29
Head Cylinder
CamshaftInspection(cont'dl
Unscrewthe camshaftholder boltstwo turns at a pattern.Then removethe time, in a crisscross camshaftholdersfrom the cylinder head. Lift the camshaftsout of the cylinder head,wipe them clean.then inspectthe lift ramps.Replace the camshaftif any lobes are pitted,scored,or worn, excessively i 1 . C l e a n h e c a m s h a fjto u r n a ls u r f a c e sn t h e c y l i n d e r t head,then set the camshaftsbackin place.Placea plastigage strip acrosseachjournal. Installthe camshaftholders,then tighten the bolts to the specified torque as shown in step 2. 9 . Removethe camshaftholders.Measurethe widest portionof plastigage eachjournal. on . lf the camshaft-to-holder clearance within is l i m i t s ,g o t o s t e p 11 . . lf the camshaft-to-holder clearance beyondthe is servicelimit and the camshafthas been replaced, replacethe cylinder head. . lf the camshaft-to-holder clearance beyondthe is servicelimit and the camshafthas not been go replaced, to step 10. Camshaft-to-Holder Oil Clearance: Standard (New): No. 1 Journal: 0.030 0.069 mm No.2,3,4,5 Journals: ServiceLimit: 10. Checkthe total runoutwith the camshaftsupported on V-blocks, . l f t h e t o t a l r u n o u to f t h e c a m s h a f its w i t h i nt h e servicelimit, replacethe cylinder head. . lf the total runout is beyondthe servicelimit, replacethe camshaftand recheck camshaftthe lf to-holderoil clearance. the oil clearanceis still beyondthe servicelimit, replacethe cylinder neao. Camshaft Total Runout: Standard(New):0.03mm (0.001in.) max. ServiceLimit: 0.04mm {0.002in.)
\,
1 1 . M e a s u r e a m l o b eh e i g h t . c Cam Lobe HeiohtStandard(New
in-) {0.001 0.003 mm 0.060*0.099 in.) {0.002 0.004 0 . 1 5 m { 0 . 0 0i6 . ) m n
INTAKE
PRI SEC m 33.925 m ( 1 . 3 3 5 6n . ) i
EXHAUST
34.092mm \1.3422in.l
2 9 . 6 3m m 8 ( 1 . 1 6 6n . ) i8 P R IP r i m a r y : C/C: CamChain
SEC:Secondary
\-
6-30
Valves,Springs,and ValveSealsRemoval
Special Tools Bequired Valvespring compressorattachment07VAE-001010A ldentifythe valvesand valve springsas they are removedso that each item can be reinstalledin its original position. 1. Removethe cylinder head (seepage 6-23). 2. Using an appropriate-sized socket(A) and plastic mallet {B),lightly tap the valve retainerto loosen the valve keepers. 4 . I n s t a l l t h e a l v eg u i d es e a lr e m o v e r . v
5 . Removet h e v a l v es e a l .
\
Installthe spring compressor. Compressthe spring, and removelhe valve keepers.
6-31
Head Gylinder
ValveInspection
1 . R e m o v e h e v a l v e s( s e ep a g e6 - 3 1 ) , t
ValveStem-to-Guide Clearance Inspection

1 . Removethe valves (seepage6-3'1). S l i d et h e v a l v eo u t o f i t s g u i d ea b o u t1 0 m m . t h e n with a dial measurethe guide-to-stem clearance indicatorwhile rockingthe stem in the directionof normal thrust (wobble method). . l f t h e m e a s u r e m e n tx c e e d s t h e e r v i c ei m i t , e s l recheckit using a new valve. . lf the measurementis nowwithin the service limit, reassemble using a new valve. . l f t h e m e a s u r e m e n t w i t a n e w v a l v es t i l l h exceeds the servicelimit, go to step 3. lntake Valve Stem-to-Guide Clearance: StandardlNew): 0.06 0.11 mm {0.002 0.004in.} ServiceLimil: 0.16mm {0.006in.) Exhaust Valve Stem-to-Guide Clearance: S t a n d a r d N e w l : 0 . 1 1- 0 . 1 6 m m l 10.004 0.006in.) in.) ServiceLimit: 0.22 mm 10.009
2 . Measurethe valve in these areas.

lntake Valve Dimensions A StandardlNewl: 34.85 35.15mm i { 1 . 3 7 2 1 . 3 8 4n . l B Standard{Newl: 108.7 109.5mm 14.280-4.311in.) C StandardlNew): 5.475 5.485 mm i9 1 0 . 2 1 5 6 - 0 . 2 1 5n . ) C ServiceLimit: 5.445mm {0.214in.l ExhaustValve Dimensions A Standard(New):29.85-30.15 mm ( 1 . 1 7 5 -1 . 1 8 7 n . ) i (New):108.3 109.1mm B Standard (4.264- 4.295 in.l (New): 5.450 5.460mm C Standard (0.2146 0.2150in.) C Service Limit: 5.42mm (0.213in.)
.<
4,.
3 . Subtractthe O.D.of the valve stem. measuredwith

a micrometer,from the LD. of the valve guide, m e a s u r e d i t h a n i n s i d em i c r o m e t eo r b a l lg a u g e . w r Takethe measurements three placesalong the in v a l v es t e m a n dt h r e ep l a c e s n s i d e h e v a l v eg u i d e . i t The differencebetweenthe largestguide m e a s u r e m e n t n dt h e s m a l l e s s t e m m e a s u r e m e n t a t should not exceedthe servicelimit lntake Valve Stem-to-Guide Clearance: Standard(New):0.030 0.055mm {0.0012 0.0022in.) in.l ServiceLimit; 0.08mm (0.003 ExhaustValve Stem-to-Guide Clearance: Standard{Newl: 0.055 0.080mm (0.0022-0.003rin.l ServiceLimit: 0.11mm (0.004in.)
t-
6-32
ValveGuideReplacement
Special ToolsRequired . Valve guidedriver, mm 07742-0010100 5.5 . Valveguidereamer, mm 07HAH-PJ7o108 5.5
(seepage 61 . Inspectvalve stem-to-guide clearance Working from the camshaftside. usethe driver and an aarhammerto drive the guide about 2 mm (0.1 in.)towardsthe combustionchamber.This will knockoff some of the carbon and make removal easier.Hold the air hammer directlyin line with the valve guide to preventdamagingthe driver. Turn lhe head over, and drive the guide out toward the camshaftside of the head.
32t.
As illustratedbelow, use a commerciallyavailable air-impactvalve guide driver (A) modifiedto fit the diameterof the valve guides.In most cases, the same procedurecan be done usingthe specialtool and a conventional hammer.
-_|Jfillr-.-4fi'11., tT 10.8mm {0.,|2in.)
guides,and chill 3. Selectthe proper replacement lhem in the freezersectionof a refriqerator for about an hour. 4. Use a hot plate or oven to evenly heatthe cylinder headto 300'F (150"C). Monitor the temperature with a cookingthermometer.Do not getthe head hotterthan 300'F (150"C); excessiveheat may loosenthe valve seats. 7 . lf a valve guide won't move, drill it out with a I mm ( 5 / 1 6i n c h )b i t .t h e nt r y a g a i n .D r i l lg u i d e so n l y i n extremecases;youcould damagethe cylinder head if the guide breaks. Removethe new guide(s) from the freezer,one at a time, as vou needthem.
(cont'd)
6-33
Head Cylinder
(cont'dl ValveGuideReplacement
Apply a thin coat of clean engineoil to the outside of the new valve guide. Installthe guide from the camshaftside of the head;usethe specialtool to drive the guide in to the specifiedinstalledheight ( A )o { t h e g u i d e( B ) .l f y o u h a v ea l l 1 6 g u i d e s t od o , you may have to reheatthe head. Valve Guide Installed Height: 15.2 16.2mm (0.598-0.638in.) Intake: Exhaust: 15.5 16.5mm (0.610-0.650in.)
\ 1 0 .Coat both reamerand valve guide with cutting oil.

1 1 .Rotatethe reamerclockwisethe full length of the v a l v eg u i d eb o r e .
O7HAH.PJ7O1OB
' - \
Continueto rotatethe reamerclockwisewhile removing it from the bore. Thoroughlywash the guide in detergentand water to remove any cutting residue. 1 4 . C h e c k h e c l e a r a n c ew i t h a v a l v e( s e ep a g e6 3 2 ) . t s Verifythat a valve slidesin the intakeand exhaust valve guideswithout exening pressure.
6-34
ValveSeat Reconditioning
1. Inspectvalve stem-to-guide clearance(seepage 632).lf the valve guidesare worn, replacethem (see page6-33)beforecuttingthe valve seats. 2 . R e n e w h e v a l v es e a t si n t h e c y l i n d e r e a du s i n ga t h valve seat cutter. 5. Make one more very light passwith the 45" cutter to removeany possibleburrs causedby the other cutters. Valve Seat Width: Standard(New): 1.25 1.55mm {0.049 0.061in.) ServiceLimit: 2.00 mm (0.079in.) 6. After resurfacing seat,inspectfor even valve the s e a t i n gA p p l y P r u s s i a n l u ec o m p o u n d( A )t o t h e : B v a l v ef a c e .I n s e r t h e v a l v ei n i t s o r i g i n a l o c a t i o nn i the head,then lift it and snap it closedagainstthe seat severaltrmes.
3 , C a r e f u l l y u t a 4 5 ' s e a t ,r e m o v i n g n l y e n o u g h c o
materialto ensurea smooth and concentricseat. 4 . Bevelthe upper and lower edgesat the angles shown in the illustration. Checkthe width of the seat and adjustaccordingly. INTAKE:35" EXHAUST:30'
- 45' , { 67.5'
1 . The actualvalve seatingsurface(B),as shown by the blue compound,should be centeredon the seat. . lf it is too high (closer the valve stem),you to must make a secondcut with the 67.5' cutterto move it down, then one more cut with the 45" cutterto restoreseatwidth. . lf it is too low (closeto the valve edge),you must make a secondcut with the 35'cutter (intake sidel or the 30" cutter (exhaustside)to move it up, then make one more cut with the 45" cutterto restoreseatwidth. N O T E T h e f i n a lc u t s h o u l da l w a y sb e m a d ew i t h : the 45'cutter.
(cont'd)
6-35
Head Cylinder
(cont'dl ValveSeat Reconditioning
8 . Insen the intakeand exhaustvalves in the head, and measurevalve stem installedheight (A). Intake Valve Stem Installed Height: Standard{New):40.8 41.0mm ( 1 . 6 0 6 1 . 6 1 4n . ) i Exhaust Valve Stem Installed Height: Standard(New):54.6-54.8 mm -2.157 in.l |'2.150
L lf valve stem installedheight is over the standard, replacethe valve and recheck. it is still over the lf standard,replacethe cylinder head;the valve seat in the head is too deeD.
\-
\-
6-36
Valves,Springs,and Valve SealsInstallation

Special Tools Required Valve spring compressorattachment07VAE-00101 0A 1. Coatthe valve stemswith engine oil. lnstallthe valves in the valve guides. 2. Checkthat the valves move up and down smoothly. Installthespring seatson the cylinder head. Installthe new valve seals(A) usingthe valve guide r s e a li n s t a l l e( B ) . NOTE:The exhaustvalve seal (C)has a blackspring (D),and the intakevalve seal (E)has a white spring (F).They are not interchangeable. l n s t a l l t h e a l v es p r i n g . l a c e h e e n d o f t h e v a l v e v P t spring with closelywound coils toward the cylinder ne a o . 6 . Installthe valve retainer. 7 . Installthevalve spring compressor, Compressthe spring, and installthe valve keepers. Removethe valve spring compressor.
Lightlytap the end of each valve stem two or three times with a plasticmallet (A)to ensureproper Tap the seatingof the valve and valve keepers. valve stem only along its axis so you do not bend the stem.
6-37
Head Cylinder
Arm AssemblyInstallation Rocker
:,ean and dry the No. 5 rockershaft holder mating surfaces. eeassemble rockerarm assembly(seepage 6the 2 1t . Apply liquid gasket,P/N 08718-0009, evenlyto the :ylinder head mating surfaceofthe No. 5 rocker shaft holder. \OTE: Do not lnstallthe partsif 5 minutesor more r a v e e l a p s e d i n c ea p p l y i n g i q u i dg a s k e tI.n s t e a d , l s 'eapply liquid gasketafter removingold residue.
\ 5 . Removethe bolts from the rockershaft holder.

v m 6 . M a k es u r et h e D U n c h a r k so n t h e v a r i a b l e a l v e actuatorand exhaustcamshaft timing control (VTC) sprocketare facing up. then set the camshafts(A) in the holder.
fl
c
\7 . Set the camshaftholders(B) and cam chain guide B ( C )i n p l a c e . torque. Tightenthe bolts to the specified Specified torque: 8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft) 6 mm bolts: 12 N.m {1.2kgf.m,8.7 lbf.fil 6 mm bolts: @),@.@
Insertthe bolts (A) into the rockershaft holder,then installthe rockerarm assembly(B)on the cylinder head.
lnstallthe cam chain (seepage 6-15).and adjustthe (seepage 6-9). valve clearance
l-
6-38
CylinderHeadInstallation
Installthe cylinder head in the reverseorder of removat: 1. Cleanthe cylinderhead and blocksurface.
f.f
5. Measurethe diameterof each cylinder head bolt at ooint A and DointB. a 50mm (2.0 in.l
)>-
2. Installthe new cylinder headgasket(A) anddowel pins (B)on the cylinderblock.Always use a new cylinder headgasket.
A '15mm {'1.8 in.) " < > .
i i l f e i t h e rd i a m e t e r s l e s st h a n 1 0 . 6m m { 0 . 4 2 n . ) , replacethe cvlinder head bolt. Align to Set the crankshaft top dead center{TDC). sprocketwith the TDC mark (A) on the crankshaft the pointer(B)on the cylinderblock.
4. Installthe cylinderhead on the block.
( c o n td )
6-39
Cylinder Head
CylinderHeadlnstallation(cont'd)
7 . Apply engine oil to the bolt threadsand under the b o l t h e a d s f a l l t h e c y l i n d e r e a db o l t s . o h 10. Installthe rockerarm assembly{seepage6-38).
8 . Tightenthe cylinder head bolts in sequenceto 39

N.m {4.0 kgf.m,29 lbf.ft).Use a beam-type torque wrench.When using a preset-type torque wrench, be sure to tighten slowly and do not overtighten.lf a bolt makesany noisewhile you are torquing it, loosenthe bolt and retightenit from the first step.
1 ' . Installthe water bypasshose (A). t

---l.-.
B 6x1.0mm 'r2N.m c (1.2 kgl.m,8.7 lbf.ftl 6xl.0mm '12 N,m(1.2 kgt.m,8.7 lbf.ft) 9 . After torquing,tighten all cylinderhead bolts in two steps(90" per step).lf you are using a new cylinder head bolt,tighten the bolt an extra 90..
1 2 .Tightenthe connectingpipe mounting bolt (B)and

brakeboostervacuum line mounting bolts (C),then i n s t a l l t h e a r n e s s o l d e r( D )o n t h e b r a c k e t . h h
't3. Installthe
(B).
FIRSTSTEP
upper radiatorhose {A) and heaterhose
SECOND STEP
6-40
GylinderHeadCoverlnstallation
h 1 4 . I n s t a l l t h e a t e rb v p a s s o s e . w 1. Thoroughlycleanthe headcover gasketand the groove. 2. Installthe head cover gasket(A) in the groove of h t h e c y l i n d e r e a dc o v e r( B ) .
( h 1 5 . I n s t a l l t h e i r c l e a n e r o u s i n g s e es t e p3 7 o n p a g e a 5-15). ( i m 1 6 . I n s t a l l t h en t a k e a n i f o l d s e ep a g e9 - 5 ) . ( m e 1 7 . I n s t a l l t h e x h a u s t a n i f o l d s e ep a g e9 - 7 ) . '18. c I n s t a l l t h e a m c h a i n ( s e ep a g e6 - 1 5 ) . ( 1 9 . A d j u s tt h e v a l v ec l e a r a n c e s e e p a g e 6 - 9 ) . d 2 0 . I n s t a l l t h e r i v eb e l t( s e ep a g e4 - 2 6 ) . 21. Cleanthe batterypostsand cableterminalswith t t, s a n d p a p e r h e n a s s e m b l eh e m a n d a p p l yg r e a s e to preventcorrosion. ch 2 2 . A f t e ri n s t a l l a t i o n , e c k t h a t a ltl u b e s ,h o s e s a n d connectors are installedcorrectly. s . 2 3 . I n s p e c t f o r f u elle a k sT u r nt h e i g n i t i o n w i t c hO N {ll) {do not operatethe starter)so that the fuel pump the runs for about 2 secondsand pressurizes fuel line. Repeatthls operationtwo or three times, then a c h e c k o r f u e l l e a k a g e t a n y p o i n ti n t h e f u e l l i n e . f 24. Refillthe radiatorwith enginecoolant,and bleed air from the cooling systemwith the heatervalve open (seepage 10-6). 2 5 . I n s p e ctth e i d l es p e e d( s e ep a g e1 1 - ' 1 3 8 ) . t 2 6 . I n s p e ctth e i g n i t i o n i m i n g ( s e ep a g e4 - 1 7 ) . Checkthat the mating surfacesare clean and dry. on Apply liquid gasket.P/N 08718-0009, the chain caseand the No.5 rockershaft holder mating areas. NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.
(cont'd)
6-41
GylinderHead
CylinderHeadGoverInstallation(cont'd)
Set the spark plug seals(A) on the spark plug tubes. O n c et h e c y l i n d e r e a dc o v e r( B )i s o n t h e c y l i n d e r h head,slide the cover slightly backand forth to seat the head cover gasket. 7. Tightenthe bolts in two or three steps.In the final s t e p , i g h t e na l l b o l t s ,i n s e q u e n c e , 9 . 8 N . m ( 1 . 0 t to kgf.m,7.2 lbf.ft).
( 8 . I n s t a ltlh e d i p s t i c k A )a n d b r e a t h e h o s ei B ) . r
Inspectthe cover washers(C).Replace any washer that is damagedor deteriorated.
\l
6-42
9 . Installthe four ignition coils (seepage 4-'18). 1 0 . Checkthat all tubes, hoses,and connectorsare installedcorrectly. 1 1 .lnstallthe intakemanifoldcover. 6x 1,0 m '12 m kgf m. N.m{1.2 8.7tbf.ftl
wait at least30 minutesbefore 12. After assemblv, w f i l l i n gt h e e n g i n e i t h o i l .
6-43
EngineMechanical
Engine Block
7 . . . . . . . . . . . .-.2 T S o e c i a lo o l s . . In d e x . . . . . . . . . . . . . . . . . . . . . . . . . . .7.-.3 . . . . . . . . . . n L C o m o o n e n to c a t i o End Rod Connecting andCrankshaft Play 7-5 .............. InsDection 7-6 ...................... Replacement MainBearing Crankshaft 7-8 ...................... Replacement Rod Connecting Bearing . . . . . . . .7 . 1 1 .l O i lP a nR e m o v a . . . . . . . . . . . . . . . . . . . . . . . 7-12 ........ Removal and Piston Crankshaft 7-14 ........................ Inspection Crankshaft 7 .. . . I B l o c k n dP i s t o nn s o e c t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . .- 1.5. . . . . . . . a . " . . . . . . . . . . . . .7- . 1.7. ..' . . H C y f i n d e r o n i n g. . . . . . . . . . . . 7-18 .......... Rod Piston, andConnecting Replacement Pin 7 -21 ................... RingReplacement Piston 7-23 ........... .................... Piston lnstallation 7 .......' -24 RodBoltInspection Connecting 7-24 .....................'. lnstallation Crankshaft . . . . . . . . .7-.2 7 . . O i lP a nl n s t a l l a t i o .n . . . . . . . . . . . . . . . . Seal End Transmission Crankshaft ........' -28 7 Car lnstallation-ln ...................
EngineBlock
SpecialTools
Ref.No.
\
Description Oil Seal DriverAttachment96 Attachment,24 x 26 mm Driver Oty 1 1 1
6
@
Tool Number OTZAD-PNAAlOO 07746-0010700 07749,0010000
I
o
\ {
7-2
BAFFLEPLATE
BLOCK LOWER
fr "
fi E
-4
MAINBEARINGS pa 7 O i l c l e a r a n c e ,g e - 6 page Selection, 7-6
FLYWHEEL
CRANKSHAFT SEAL. OIL END TRANSMISSION 7-26 Installation, 21on page step
THRUST WASHERS
CRANKSHAFT End play,page7-5 R u n o u t p a g e7 - 1 4 , page7-14 Out-of-Round, page7-12 Removal, page7-24 lnstallation,
(cont'd)
7-3
Engine Block
D-><
Y1
/^.,
|
l-"t
nrrucs _,-ersroru Benlacement. 7-21

Page
ffil
rkrej,
rG\ AalQ [= ôJ l

PISTON page7-'12 Removal, page7-15 Measurement,
CONNECTINGROD End play, page7-5 page7-19 Small end measurement,
f,
6
PISTONPIN page7-18 Removal, p I n s p e c t i o n ,a g e7 - 1 9 page7,20 Installation,
ENGINE BLOCK page7-'15 Cylinderbore inspection, page7-15 Warpageinspection, p C y l i n d e b o r eh o n i n g , a g e1 - 1 1 r Ridgeremovai,step 13 on page7-13 CONNECTING ROD
CONNECTING ROD BOLT page7 24 lnspectaon,
7-4
End PlayInspection Rod and Crankshaft Connecting

page8-9). 1 . Remove oil pump(see the (see plates 1 Remove baffle the step6 on page -12).
3. Measurethe connectingrod end play with a feeler gauge betweenthe connectingrod and crankshaft. ConnectingRod End Play Standard{New):0.15 0.30mm (0.006-0.012in.l 0.40mm (0.016in.l ServiceLimit 5. lnstalla dial indicatoras shown. Pushthe firmly away from the dial indicator,and crankshaft Then zerothe dial againstthe end of the crankshaft. pull the crankshaft firmly backtoward the indicator; the dial readingshould not exceedthe servicelimit. Crankshaft End Plav StandardlNew): 0.10-0.35 mm i { 0 . 0 0 4 - 0 . 0 1 4n . l ServiceLimit: 0.45mm {0.018in.)
4 . lf the connectingrod end play is out-of-tolerance,
lf installa new connectingrod, and recheck. it is (see replacethe crankshaft still out-of-tolerance, page 7 -12],.
replacethe thrust lf the end play is out-of-tolerance, lf washersand recheck. it is still out-of-tolerance, replacethe crankshaft.
7-5
EngineBlock
Crankshaft Main BearingReplacement
MainBearing Clearance Inspection
1. To checkmain bearing-to-jou I oil clearance. rna removethe lower block and bearinghalves(see page 1 -12).. 2 , C l e a n a c hm a i nj o u r n a la n d b e a r i n g a l fw i t h a e h cleanshop towel. 3. Placeone strip of plastigage acrosseach main l o ur n a l . 4 . R e i n s t a l l t h e e a r i n g s n d l o w e rb l o c k t h e nt o r q u e b a , the bolts to 29 N.m {3.0kgf.m,22 lbf.ft) + 56'. NOTE:Do not rotatethe crankshaft during Inspeclton. 5 . R e m o v e h e l o w e rb l o c ka n d b e a r i n g s g a i n , n d t a a measurethe widest part of the plastigage. Main Bearing-to-Journal Clearance Oil N o . 1 , 2 ,4 , 5 J o u r n a l s : Standard(New):0.017 0.041mm Service Limit: No.3 Journal: 6. lf the plastigagemeasures too wide or too narrow, removethe crankshaft. and removethe upper half ofthe bearing.Installa new, completebearingwith the same color code{s), and recheck clearance. the Do not file, shim, or scrapethe bearingsor the caps to adjustclearance. 7. lf the plastigage shows the clearance still is incorrect, the next largeror smaller bearing(the try color listedabove or below that one),and check again.lf the proper clearance cannot be obtained b y u s i n gt h e a p p r o p r i a t ea r g e ro r s m a l l e rb e a r i n g s , l replacethe crankshaft and start over.
10.0007 0.0016 in.l 0.050 mm {0.0020 in.)
Standard{Newl:0.025- 0.049mm (0.0010 0.0019 in.) Service Limit: 0.055 mm (0.0022 in.l
\.
7-6
Main Bearing Selection

Crankshaft Bore Code Location 1. Numbersor lettersor bars have been stampedon the end of the block as a code for the sizeof each of the five main journal bores.Write down the crank bore codes.lf you can't readthe codes becauseof dirt and dust, do not scrub them with accumulated a wire brush or scraper.Cleanthem only with solventor detergent.
No. 5 JOURNAL END) {FLYWHEEL No. 1 JOURNAL END} IPULLEY
Main Journal Code Location 2. The main journal codesa{e stampedon the cran kshaft.
No. 1 JOURNAL
No. 5 JOURNAL
(cont'd)
7-7
Engine Block
Crankshaft Main Bearing (cont'd) Replacement
3. Usethe crank bore codes and crankjournal codes to selectthe appropriatereplacement bearings from the following table. NOTE: . Color code is on the edge of the bearing. . When using bearinghalvesof differentcolors.it does not matterwhich color is used in the top or bottom. Lalgercrankbore 3or c oi__-l C o r l l l D o r t t t It
Connecting RodBearing Replacement

RodBearing Clearance lnspection
1 . R e m o v e h e o i l p u m p ( s e ep a g e8 - 9 ) . t 2. Bemovethe baffle plates(seestep 6 on page7-12). 3. Removethe connectingrod cap and bearinghalf. 4 . C l e a n h e c r a n k s h a frto d j o u r n a la n d b e a r i n g h a l f t with a clean shop towel. 5. Placeplastigage acrossthe rod journal. 6 . R e i n s t a l l t h b e a r i n g a l fa n d c a p ,a n dt o r q u et h e e h b o l t st o 2 0 N . m ( 2 . 0k g f . m ,1 4 l b f . f t ) l 9 0 " . NOTE:Do not rotatethe crankshaft during inspection. 7 . R e m o v e h e r o d c a pa n d b e a r i n g a l f ,a n d m e a s u r e t h the widest part of the plastigage. ConnectingRod Bearing-to-Journal Oil Clearance: Standard{Newl: 0.020 0.050mm --0.0020in.l (0.0008 ServiceLimit: 0.060mm (0.0024 in.)
Main iournsl cooe

1 2
Crank ---=-> bore | 1or code IAorl

--
2ot Borll
--> Smaller bearing {Thickerl
Pink f!1f;* v"rro* c,""n
v"no* f111f;,," c,""" $;;fl

cr""n $ffi ero-n
Creen ; g=jiff;i Brown Black
4 5
;;lT]*Brown
ffi#Tr,.*" i.,""* '---l-'o"*,

Black 6il;
\-
Brack !l;kr
(Thicker)
ar*
7-8
8 . lf the plastigagemeasures wide or too narrow, too

removethe upper half of the bearing,installa new, completebearingwith the same color code(s), and recheck clearance. not file. shim, or scrape Do the the bearingsor the capsto adjustclearance.
RodBearing Selection
1. Inspecteach connectingrod for cracksand heat damage. Connecting Rod Big End Eore Code Locations
9 . lf the plastigage shows the clearance still is

incorrect, the next largeror smaller bearing(the try color listedabove or below that one),and check clearance agaln.lf the properclearance cannot be obtainedby usingthe appropriatelarger or smaller bearing,replacethe crankshaft and stan over. 2 . E a c hr o d h a sa t o l e r a n c ea n g ef r o m 0 0 . 0 2 4 m r m (0.0009 in.) in.),in 0.006mm (0.0002 increments, dependingon the sizeof its big end bore. lt's then w s t a m p e d i t h a n u m b e ro r b a r ( 1 ,2 , 3 o r 4 / 1 l,l , l l l ,o l Y l l l l )i n d i c a t i n gh e r a n g e . o u m a y f i n d a n y t c o m b i n a t i o n f n u m b e r s n d b a r si n a n y e n g i n e . o a ( H a l ft h e n u m b e ro r b a r i s s t a m p e d n t h e b e a r i n g o cap,the other half on the rod.) lf you can't readthe code becauseof an accumulation oil and varnish.do not scrub it of with a wire brush or scraper.Cleanit only with solventor detergent. Normal Bore Size: 48.0 mm 11.89 in.l
(cont'd)
7-9
Block Engine
(cont'dl Rod BearingReplacement Connecting
Connecting Rod Journal Code Location 3. The connectingrod journalcodesare stampedon the crankshaft. Connecting Rod Journal Code Location (Letters or Bars) 4. Use the big end bore codes and rod journalcodes to selectappropriatereplacement bearingsfrom the followingtable. NOTE: . Color code is on the edge of the bearing. . When using bearinghalvesof differentcolors,it does not matter which color is used in the top or bottom. Big end ----------> bore codo
lorl
Rod
Larger end bore big

3 ol lll 4 orllll
2oJll
---------> Smallsrb.aring {Thickerl Pink Pink/ Yollow/ Yellow Grecn Green
Yellow Yellow/ Green Green Brown
Green/ Brown Brown

Black
c
D
Green/ Erown/ Brown Black Brown/ Black Black/ Blue
Blue
\
(Thicker)
No.l JOURNAL No.4 JOURNAL
7-10
OilPanRemoval
1 . Drainthe engineoil (seepage8-5). lf the engine is still in the vehicle,removethe subframe. -1 Attachthe chain hoistto the engine (seestep 35 on page 5-6). -2 Disconnectthe suspension lower arm ball joints (seestep 3 on page 18-19). -3 Removethe rear mounl mounting bolts (see step 39 on page 5-7). -4 Removethe front mount mounting bolt (see step 40 on page 5-7). -5 Use a markerto make alignmentmarks on the referencelinesthat align with the centersof the rear subframemounting bolts.Removethe front subframe(seestep 43 on page 5-8). 6. Removeheoil pan. t Removethe bolts/nutssecuringthe oil pan. Drivean oil pan seal cutter betweenthe oil pan and cylinderblock.
l 5 . C u tt h eo i l p a n s e ab y s t r i k i n g t h e s i d e o f t h e c u t t e r to slidethecutteralong oil pan. the
7-11
EngineBlock
and PistonRemoval Crankshaft
( 1 . R e m o v e h e e n g i n e s s e m b l y s e ep a g e5 - 2 ) . t a t n 2 . R e m o v e h e t r a n s m i s s i o ( s e ep a g e1 3 - 4 ) . 3 . R e m o v e h e o i l p a n ( s e ep a g e7 - 11 ) . t 4. Removethe oil pump {seepage8-9). 5. Removethe cylinderhead (seepage 6-23). 6. Removethe baffle plates.
E
8. Removethe bearingcap bolts.To preventwarpage, unscrewthe bolts in sequence1/3turn at a time: repeatthe sequenceuntil all bolts are loosened.
7. Removethe 8 mm bolts.
L Removethe lower blockand bearings,Keepall bearingsin order.
7-12
1 0 .Removethe rod caps/bearings. Keepall caps/

b e a r i n g sn o r d e r . i 1 1 .Liftthe crankshaft out ofthe engine,being careful n o tt o d a m a g e h ej o u r n a l s . t
14. Use the wooden handleof a hammer (A)to drive out the pistons(B).
1 5 . Reinstall the lower block and bearingson the engine in the proper order,
to.
R e i n s t a l l t h c o n n e c t i n go d b e a r i n g s n d c a p s e r a after removingeach piston/connecting rod assembly.
1 7 .To avoid mixup on reassembly. mark each piston/ connectingrod assemblywith its cylinder number. Removethe upper bearinghalvesfrom the connectingrods.and set them asidewith their respective caps.
t.J.
NOTE:The existingnumber on the connectingrod does not indicateits positionin the engine,it indicates the rod bore size.
lf you can feel a ridge of metal or hard carbon aroundthe top of eachcylinder,remove it with a r i d g er e a m e r A ) .F o l l o w t h er e a m e rm a n u f a c t u r e r ' s { instructions. the ridge is not removed,it may lf damagethe pistonsas they are pushedout.
7-13
EngineBlock
lnspection Crankshaft
Out-ol-Round and Taper 1. Removethe crankshaft from the cylinder block(see page7-121. with pipe 2. Cleanthe crankshaft passages oil cleaners r a suitable rush. o b 3. Cleanthe keywayand threads. 4. Measureout-of round at the middle of each rod and The differencebetween main journal in two places. measurements each journal must not be more on than the serviceIimit. Journal Out-ot-Round Standard(New):0.005mm (0.0002 max. in.) ServiceLimit; 0.010mm (0.0004 in.) . 9 . M e a s u r e u n o u to n a l l m a i nj o u r n a l sR o t a t e h e r t crankshaft two completerevolutlons. The differencebetweenmeasurements eachjournal on must not be more than the servicelimit. Crankshaft Total Runout Standard(New):0.03mm 10.0012 max. in.l ServiceLimit: 0.04mm (0.0016 in.l Straightness 6. Placethe cylinder blockon the surfaceplate. 7 . C l e a n n d i n s t a l l t h e e a r i g n s n t h e N o . 1a n d N o . 5 a b o j o u r n a lo f t h e c y l i n d e r l o c k . b 8. Lowerthe crankshaft into the block.
I_JJ fl
5. Measuretaper at the edgesof each rod and main journal.The differencebetweenmeasurements on eachjournal must not be more than the service limit. JournalTaper in.) StandardlNewl: 0.005mm (0.0002 max. in.) ServiceLimit: 0.010mm {0.0004
7- 14
Blockand PistonInspection
1 . Removethe crankshaft and pistons(see pageT -121. Checkthe pistonfor distortionor cracks, M e a s u r eh e p i s t o nd i a m e t e r t a p o i n t I 1 m m { 0 . 4 t a in.)from the bottom of the skirt.There are two pistons(No Letteror A, and B).The standard-size letteris stampedon the top of the piston.Letters are also stampedon the blockas cylinder bore stzes. Piston Diameter: Standard(Newl: No Letter {or A): 85.980 85.990 mm (3.3850 3.3854in.) B: 85.970-85.980mm (3.3846-3.3850 in.) Service Limit: No Lefter lor A): 85.930mm (3.3831 in.) B: 85.920mm 13.3827 in.) 4. Measurewear and taper in directionX and Y at t h r e el e v e l si n e a c hc y l i n d e r s s h o w n .l f a measurements any cylinder are beyondthe in oversizebore servicelimit. replacethe block.lf the block is to be rebored,referto step 7 after reboring. CylinderBore Size Standard(New): A or l: 86.010 86.020mm 13.3862 3.3866in.) B or ll: 86.000 86.010mm (3.3858 3.3862in.) Service Limit: 86.070 mm (3.3886in.) Oversize: O.25t 96.250 86.260 mm (3.3957 3.3961 in.) Reboringlimit: 0.25mm (0.01in.l max. Bore Taper: Limit: (Differencebetween first and third measurement) 0.05mm (0.002in.)
6 mm {0.2in.} First Measurement Second Measutement Third Measurement 6 mm {0.2in.}
Oversize Piston Diameter: -3.3953 in.l 0.25: 86.230-85.240mm (3.3949
(cont'd)
7-15
EngineBlock
Blockand PistonInspection(cont'd)
Scoredor scratched cylinderbores must be honed. Checkthe top of the blockfor warpage.Measure along the edgesand acrossthe centeras shown. Engine Block Warpage StandardlNew): 0.07mm (0.003in.) max. ServiceLimit: 0.10mm (0.004in.l 7. Calculate differencebetweenthe cylinder bore the diameterand the plstondiameter.lf the clearance is near or exceeds the servicelimit, inspectthe pistonand cvlinder blockfor excessive wear. Piston-to-Cylinder Clearance StandardlNew): 0.020 0.040mm {0.0008 0.0016in.) ServiceLimit: 0.05mm (0.002in.l
PISTON-TO-CYLINDER CLEARANCE
++
PRECISION STRAIGHT EDGE
7-16
Cylinder Honing
Only a scoredor scratched cylinderbore should be noneo. 'L M e a s u r eh e c y l i n d e r o r e s{ s e ep a g e7 - 1 5 ) . t b lf the block is to be reused,hone the cylindersand remeasure the bores. H o n et h e c y l i n d e r o r e sw i t h h o n i n go i l a n d a f i n e b (400grit) stone in a 60 degreecross-hatch pattern (A).Use only a rigid hone with 400 grit or finer stone such as Sunnen,Ammco, or equivalent.Do not use stonesthat are worn or broken.
3 . W h e n h o n i n gi s c o m p l e t et,h o r o u g h l y l e a nt h e c
engine blockof all metal particles. Wash the cylinder boreswith hot soapywater,then dry and oil them immediatelyto preventrusting.Never use solvent,it will only redistribute grit on the the cylinder alls. w lf scoringor scratches still presentin the are cylinderboresafter honing to the servicelimit, reborethe cylinder block.Some light vertical scoringand scratchingis acceptable it is not deep if enoughto catchyour fingernailand does not run the full length of the bore.
7-17
EngineBlock
Piston,Pin,and Connecting Rod Replacement
Disassembly
1. Removethe pistonfrom the cylinderblock (see page7 -12). 2 . A p p l ye n g i n e i l t o t h e p i s t o np i n s n a p r i n g s( A ) , o and turn them in the ring grooves until the end gaps are lined up with the cutoutsin the piston pin b o r e s( B ) . NOTE;Takecare not to damagethe ring grooves. 4 . Heatthe piston and connectingrod assemblyto about 158'F(70"C), then removethe piston pin.
\
Removeboth snap rings (A).Start at the cutout in t h e p i s t o np i n b o r e .R e m o v e h e s n a pr i n g s t carefullyso they do not go flying or get lost.Wear eve protection.
\"
7-18
Inspection
NOTE:Inspectthe piston,piston pin, and connecting rod when they are at room temperature. 1. Measurethe diameterof the piston pin. Piston Pin Diameter Standard(New):21.961 21.965mm (0.8646-0.8648in.) ServiceLimit: 21.953mm 10.8643 in.l
3. Checkthe differencebetweenthe DistonDin d i a m e t e r n d p i s t o np i n h o l ed i a m e t e r n t h e p i s t o n . a i Piston Pin-to-Piston Clearance Standard(Newl: -0.005 to +0.002 mm (-0.00020 to +0.00008 in.) ServiceLimit: 0.005mm (0.0002 in.)
4 . Measurethe piston pin-to-connecting clearance. rod Piston Pin.to-Connecting Rod Clearance Standard(New):0.005 0.015mm {0.0002 0.0006in.} ServiceLimil: 0.02mm (0.0008 in.l
2. Zerc the dial indicatorto the piston pin diameter.
v
(cont'd)
7-19
EngineBlock
(cont'd) RodReplacement Piston, Pin,and Connecting
Reassembly
1 . I n s t a l a p i s t o np i n s n a pr i n g ( A ) . l 4. Installthe piston pin (A).Assemblethe piston (B) and connectingrod (C)with the arrow (D)and the m e m b o s s e d a r k ( E )o n t h e s a m es i d e . -
Coatthe piston pin bore in the piston,the bore in the connectingrod, and the piston pin with engine oil.
3 . Heatthe pistonto about 158"F(70'C).
s 5 . I n s t a ltlh e r e m a i n i n g n a pr i n g ( F ) . 6 . T u r nt h e s n a pr i n g si n t h e r i n gg r o o v e su n t i l t h e end gaps are positionedat the bottom of the piston.
7 -20
PistonRing Replacement
1. Removethe piston{rom the cylinder block(see page 7 -121. 2. Using a ring expander(A),removethe old piston r i n g s( B ) . 4. Using a piston,push a new ring (A) into the c y l i n d e r o r e 1 5 - 2 0 m m { 0 . 6 - 0 . 8 i n . )f r o m t h e b bottom.
15 20 mm (0.6 0.8 in.)
I
B 3. Cleanall ring groovesthoroughlywith a squaredoff brokenring or ring groovecleanerwith a blade to fit the pislon grooves.The top and 2nd ring g r o o v e s r e 1 . 2m m ( 0 . 0 5 n , ) w i d e T h e o i l r i n g a i . groove is 2.0 mm (0.08in.) wide. Filedown a blade lf necessary. not use a wire brush to cleanthe Do ring grooves,or cut the ring groovesdeeperwith t h e c l e a n i n go o l s . t NOTE:lf the piston is to be separated from the connectingrod, do not installnew rings yet. Measurethe piston ring end-gap(B)with a feeler g au g e : . l f t h e g a p i s t o o s m a l l ,c h e c k t os e ei f y o u h a v e t h e p r o p e rr i n g sf o r y o u r e n g i n e . . l f t h e g a p i s t o o l a r g e ,r e c h e c k t h e c y l i n d e ro r e b diameteragainstthe wear limits (seeslep 4 on p a g e7 - 1 5 ) . . l f t h e b o r e i s o v e r t h es e r v i c e i m i t ,t h e c y l i n d e r l block must be rebored. PistonRing End-Gap Top Fing Standard(Newl: 0.20 0.35 mm (0.008 0.014in.l ServiceLimit: 0.60mm (0.024in.. SecondRing Standard(New):0.40-0.55 mm {0.016 0.022in.) ServiceLimit: 0.70mm (0.028in.) Oil Ring REKEN manufacturedring Standard(Newl: 0.25 0.65 mm (0.010 0.026in.l ServiceLimit: 0.75mm (0.030in.) FEDERAL MOGUL manufacturedrino StandardlNew): 0.20 0.70mm {0.008 0.028in.} ServiceLimit: 0.80mm (0.031in.)
(cont'd)
7-21
EngineBlock
(cont'd) PistonRing Replacement
6. Installthe top ring and secondring as shown.The t o p r i n g ( A )h a sa 1 R m a r ko r n o m a r ka n dt h e r s e c o n d i n g ( B )h a sa 2 R m a r ko r 2 N D m a r k .T h e marks must be facing upward. 8. Positionthe ring end gaps as shown:
OIL RINGGAP
About 90' SECOND RINGGAP
About 45"
TOP RINGGAP and SPACER RINGGAP
OIL RINGGAP PISTONPIN
o\,"16. s \
9. After installinga new set of rings,measurethe ring-to-groove clearances:
\5
=:-=2
V" 12-) V
P'ffi+a
\aq*-pogd
Top RingClearance Standard {New}: mm {0.0014-0.0024 in.) 0.035-0.060 ServiceLimit: 0.13mm (0.005in.) SecondRing Clearance StandardlNew): REKENmanutactured ring in.) 0.030-0.055 mm (0.0012-0.0022 FEDERAL MOGUL manulactured ring 0.025-0.060mm (0.001 0-0.0024in.) 0.13 mm (0.005 in.) ServiceLimit:
.ZR, V
Piston Ringoimensions: | | A| | t J o ToPRing{Standardl: A :3 . 1m m { 0 . 1 2n . l i m i B : 1 . 2 m { 0 . 0 5n . ) Socond Ring{Standard): A : 3 . 4 m { 0 . 1 3n . } m i B:'1.2 (0.05 mm in.i
7, Rotatethe rings in their groovesto make sure they do notbind.
7-22
PistonInstallation
lf the crankshaft already is installed
1. Setthe crankshafttobottom dead center(BDC) for e a c hc y l i n d e r . 2. Removethe connectingrod caps,then installthe ring compressor, and checkthat the bearingis securelyin place, 3. Positionthe arrow {A) facingthe cam chain side of r n ee n g t n e .
lf the crankshaft not installed is

1 . Removethe connectingrod caps.then installthe r i n g c o m p r e s s o ra n d c h e c k h a tt h e b e a r i n g s , t i s e c u r e l yn p l a c e . i
2. P o s i t i o nh e a r r o w( A ) f a c i n g h e c a m c h a i ns i d eo f t t
Ineengrne.
\--lno
n\-.--l. û
Positionthe piston in the cylinder,and tap it in u s i n gt h e w o o d e nh a n d l e f a h a m m e r( A ) . o N4aintain downward force on the ring compressor (B)to preventthe rings from expandingbefore enteringthe cylinder bore.
Positionthe piston in the cylinder,and tap it in u s i n gt h e w o o d e nh a n d l e f a h a m m e r( A ) , o Maintaindownward force on the ring compressor (B)to preventthe rings from expandingbefore enteringthe cylinder bore.
>-*/zi .,.'_\pf{
Stop afterthe ring compressorpops free, and journal checkthe connectingrod-to-crank alignmentbeforepushingthe piston into place. 6 . Checkthe connectingrod bearingclearance with plastigage(seepage7-8). 7 . lnspectthe connectingrod bolts (seepage 7 241. Apply engine oil to the bolt threads,then installthe rod capswith bearings. Torquethe bolts to 20 N.m {2.0kgf m, 14 lbf ft) + 90'.
wr
(( 'V,/ :
4. Positionall pistonsattop dead center.
7-23
EngineBlock
Rod Bolt Inspection Connecting
1 . Measurethe diameterof each connectinqrod bolt at DointA and ooint B.
35 mm
Installation Crankshaft
Special Tools Bequired . Driver07749-0010000 . Attachment, x 26 mm 07746-0010700 24 . Oil seal driver attachment o7ZAD-PNAAl00 96 1 . I n s t a ltl h e c r a n k s h a fe n d b u s h i n g i t h t h e s p e c i a l w t Drive in the tools when replacingthe crankshaft. c r a n k s h a fe n d b u s h i n gu n t i lt h e s p e c i atl o o l s t bottom aqainstthe crankshaft.
mm
07749-0010000
07746-00'l
Calculate differencein diameterbetweenpoint the A a n d p o i n tB . Point A-Point B = Difference in Diameter Diflerence in Diameter: Specification:0 0.1 mm (0 0.004in.)
I
\-
3 , lf the differencein diameteris out of tolerance,

replacethe connectingrod bolt. r c e C h e c k h e c o n n e c t i n go d b e a r i n g l e a r a n c w i t h t plastigage {seepage7-8). C h e c k h e m a i n b e a r i n g l e a r a n cw i t h p l a s t i g a g e t c e ( s e ep a g e7 - 6 ) .
4 . lnspecttheconnectingrod bolts (seepageT-241.
\-
7-24
5 . I n s t a l l t h e e a r i n g a l v e s n t h e c y l i n d e r l o c ka n d b h i b conneclrngrods. 6 . A p p l ya c o a to f e n g i n eo i l t o t h e m a i n b e a r i n g s n d a rod bearings. 7 . H o l dt h e c r a n k s h a f to r o d j o u r n a lN o . 2 a n d r o d s journal No. 3 are straightup, and lower the crankshaft into the block. ( 8 . l n s t a l l t h e h r u s tw a s h e r s A )i n t h e N o . 4 j o u r n a lo f t the cylinder block.
12. Tightenthe connectingrod bolts to 20 N.m (2.0kgf.m, 14 lbf.ft). 13. Tightenthe connectingrod bolts an additional90". 14. Removeold liquid gasketfrom the lower block mating surfaces, bolts and bolt holes. 15. Cleanand dry the lower block mating surfaces. 16. Apply liquid gasket,P/N 08718-0009, evenlyto the cylinderblock mating surfaceof the lower block a n dt o t h e i n n e r t h r e a d o f t h e b o l t h o l e s . s NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.
.\
,i,
\-1
Apply liquid gasket alongthe broken line.
9 . Apply engine oil to the threadsot the connecting rod bolts,
1 0 .Seatthe rod journals into connectingrod No. 1 and

connectingrod No. 4. Line up the mark (B)on the connectingrod and cap,then installthe caps and bolts finger-tight. '11 Rotate . the crankshaft clockwise,and seatthe j o u r n a l s n t oc o n n e c t i n go d N o . 2 a n d c o n n e c t i n g i r rod No. 3. Line up the mark on the connectingrod and cap, then installthe caps and bolts finger-tight.
(cont'd)
7-25
EngineBlock
Installation(cont'd) Crankshaft
'17 . Putthe lower blockon lhe cylinderblock. 1 8 . Tightenthe bearingcap bolts in sequence to 29 N.m (3.0kgf m, 22 lbf.ft). 2'1. Use the specialtoolsto drive a new oil seal squarelyinto the blockto the specifiedinstalled height.
07749-0010000
07zAo-PNAA100 (A) Measurethe distancebetweenthe crankshaft a n d o i l s e a l( B ) . Oil Seal InsialledHeight: 5.5 6.5 mm |10.22 0.26 in.l
5.5-6.5 mm {0.22 0.26in.l
1 9 . Tightenthe bearingcap bolts an additional56". 20. Tightenthe I mm bolts in sequence 22 N.m 12.2 to kgf m, 16 lbf.ft).
7-26
OilPanlnstallation
23. Installthe baffle plates. 6x1.0mm 1 2N . m (1.2ksf m, 8.7lbf ft) 1 . Removeold liquid gasketfrom the oil pan mating surfaces, bolts,and bolt holes. 2 . Cleanand dry the oil pan mating surfaces. 3 . Apply liquid gasket,P/N 08718-0009, evenlyto the cylinderblock mating surfaceof the oil pan and to the innerthreadsof the bolt holes. NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.
2 4 . I n s t a l l t h e i l p u m p ( s e ep a g e8 - 1 4 ) . o 25. Installtheoil pan (seepage7-27). 26. Installthecylinderhead (seepage 6-39). 27. Installthetransmission(seepage 13-8). 28. Installtheengine assembly(seepage 5-9).
Apply liquid gasket alongthe brokenline. 4. I n s t a l l t h e i l p a n . o 5. Tightenthe bolts in two or three steps.In the final
to s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c e , 1 2 N . m ( 1 . 2 kgf m, 8.7 lbf.ft). ( } @
(cont'd)
7-27
Engine Block
Oil PanInstallation(cont'dl
6 . l f t h e e n g i n ei s s t i l l i n t h e v e h i c l e i,n s t a l t h e l subframe, - 1 I n s t a l l t h e u b f r a m eA l i g nt h e r e f e r e n c e n e s s . li on the subframewith the bolt head center,then tighten the bolts (seestep 5 on page 5-10). -2 Tightenthe front mounting bolt (seestep 6 on p a g e5 - 1 0 ) . -3 Tightenthe rear mount mounting bolts (see s t e p7 o n p a g e5 - 1 1 ) . -4 Connectthe suspension lower arm ball joints (seestep 6 on page 18-19). 7. After assembly,wait at least30 minutes before f i l l i n gt h e e n g i n e i t h o i l . w Special Tools Required . Driver07749-0010000 . Oil seal driver attach ment 96 07ZAD-PNAA100 '1. D r y t h e c r a n k s h a f t i l s e a lh o u s i n g . o
Transmission EndGrankshaft Seal Installation In Car
2. Use the specialtools to drive a new oil seal squarelyinto the blockto the specifiedinstalled height. 07749-0010000
tr*W(r -]t fl\

OTZAD.PNAAlOO (A) Measurethe distancebetweenthe crankshaft a n d o i l s e a l( B ) . Oil Seal InstalledHeight: 5.5 6.5 mm 10.22-0.26in.l
5.5 6.5 mm l0.22- O.26in .l
/$rRfr4T
v
7-28
EngineMechanical
r_::::-l
t--l
EngineLubrication
SpecialTools
Ref. No.
\
Descriotion Oil FilterWrench
Tool Number 07HAA-PJ70100
Otv
I
\-
8-2
WASHER
DRAINBOLT
OILPAN R e m o v ap , g e 1 1 la 7 page Installataon, 7-27
OILPUMP page OverhaLrl, 8-8
HL]
BAFFLEPLATE
OILPUMP CHAINTENSIONER
OILCONTROL ORIFICE
-&\JrI
ksrarr cKEr
PIPE OIL FILTER FEED page8-7 Replacement,
--t
lN-? dczt$)
N\
\
# 1
OILFILTER page8-6 Replacement, SWITCH OIL PRESSURE SwitchTest,page8 4 test, page8'4 Oil Pressure p, R e p l a c e m e n t a g e8 1 6
OIL PUMP CHAINGUIDE
8-3
EngineLubrication
Oil Pressure Switch Test
1 . R e m o v e h e Y E U R E D i r e ( A ) f r o mt h e e n g i n e i l w t o pressureswitch (B).
Oil Pressure Test

lf the oil pressureindicatorstayson with the engine r u n n i n g c h e c k h e e n g i n e i l l e v e l . f t h e o i l l e v e li s . t o l correct: '1. Connecta tachometer. Removethe engine oil pressureswitch,and install g a n o i l p r e s s u r e a u g e{ A ) .
2. Checkfor continuitybetweenthe positiveterminal

( C )a n d t h e e n g i n e( g r o u n d )T h e r es h o u l db e . continuitywith the engine stopped.There should be no continuitywith the engine running. lf the switch fails to operate,checkthe engineoil l e v e l . f t h e e n g i n eo i l l e v e li s O K .c h e c k h e e n g i n e l t oil pressure. the oil pressureis OK, replacelhe oil lf Dressure switch. Start the engine.Shut it off immediatelyif the gauge registersno oil pressure. Repairlhe problem beforecontinuing. 4. Allow the engineto reachoperatingtemperature (fan comes on at leasttwice),The pressureshould be: EngineOil Temperature: 176'F (80'Cl EngineOil Pressure: At ldle: 70 kPa (0.7kgf/cm', 10 psi) mtntmum At 3,000rpm: 300 kPa (3.1kgf/cm',44 psi) minimum lf the oil pressureis NOT within specifications, inspectthese items: . C h e c kh e o i l s c r e e n f o r c l o g g i n g . t . Checkthe oil pump (seepage8-8). . Checkcrankshaft and connectingrod bearing clearances.
\.
I
8-4
Engine Replacement Oil

1 . Warm up the engine. 2 . R e m o v e h e d r a i nb o l t ( A ) ,a n d d r a i nt h e e n g i n eo i l . t
A 44 N.m {i1.5 kgf.m,33lbf.ft) Donotovertighten.
3 . Reinstall drain bolt with a new washer (B). the

R e f i l l w i t h h e r e c o m m e n d e o i l ( s e ep a g e3 - 2 ) . d t Capacity 4.0 0 (4.2US qt) at oilchange. 4.2 014.4US qt) at oilchange includingfilter. 5.3 015.6US $) after engineoverhaul. 5 . Run the enginefor more than 3 minutes.then check for oil leakage.
8-5
EngineLubrication
Engine FilterReplacement Oil
Special Tool Fequired Oil filter wrench 07HAA-PJ70100 5. lf 4 numbersor marks (1 to 4 or V to VVVV) are printedaroundthe outsideof the filter, usethe following procedure tighten the filter. to . Spin the filter on until its seal lightly seatsagainst t h e b l o c k , n d n o t ew h i c h n u m b e ro r m a r ki s a t a the bottom. . Tightenthe filter by turning it clockwise3 numbersor marksfrom the one you noted.For example,if number 2 is at the bottom when the seal is seated,tightenthe filter until the number 1 comes around the bottom.
Engine Filter(3/4-turn Oil type)

1 . R e m o v e h e o i l f i l t e r w i t h t h e s D e c i ao o l . t tl 2. Inspectthe threads{A) and rubber seal (B)on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filterswith a built-inbypasssystem.
Number when rubber seal is seated.
Number aftertightening.
\.. 2 or VV
1
I n s t a l l t h e i l f i l t e rb y h a n d . o After the rubberseal seats,tightenthe oil filter clockwisewith the specialtool. Tighten: Tighteningtorque: 3/4 turn clockwise. 12 N.m (r.2 kgf.m,8.7 lbf.ft)
N u m b eo r r Mark hen w r u b b es e a l s r i
N u m b e ro r Mark after tightening
1 or V
4
3 or VVV 2 or VV
4 or VVVV 3 or VVV
vvvv. v
or
or
6 . A f t e ri n s t a l l a t i o ni,l l t h e e n g i n e w i t ho i l u p t o t h e f specifiedlevel,run the enginefor more than 3 m i n u t e st,h e n c h e c k o r o i l l e a k a g e . f
07HAA-PJ70100
\,
8-6
Oil FilterFeedPipeReplacement
1 . Removethe oilfilter (seepage8-6). Removethe oil filter feed pipe.
3 . l n s t a l l t h e t w o 2 x 1 . 5 m m n u t s ( Ao n t o t h e n e w 0 ) oil filter feed pipe. Holdthe nut with a wrench,then tighten the other nut.
4 4 . T i g h t e n t ho i lf i l t e r f e e p i p e t o t h e l o c k t o 9N . e d b m {5.0kgf.m, lbf ft),thenremove nutsfrom 36 the the oil filterfeedoiDe.
8-7
EngineLubrication
OilPumpOverhaul
ExplodedView
BAFFLE PLATE 6x1.0mm 1 2N . m kgf {1.2 m,8.7lbf.ft)
6x1.0mm 12 N.m kgf.m,8.7 lbt ft) 11.2
P UI I "
EU
Ptr
(2.8kst m, 20 lbt ft) Apply nginoilto e e the boltthreads.
x 1 . 2 5m m 27 N.m
UPPER BALANCER SHAFTHOLDER
$--."Dowetem
DOWEL PIN BALANCER SHAFT BEARINGS
REAR BALANCER SHAFT

/=.---'n
t w
fs/
FRONT BALANCER SHAFT
SEALINGBOLT 39 N.m {4.0kgf.m,29lbf.ftl
LOWER BALANCER HOLDER SHAFT
\-
8-8
Oil PumpRemoval
1. Setthe No. 1 piston attop deadcenter{TDC) {see s t e p1 o n p a g e6 - 1 2 ) . 2 . R e m o v eh e o i l p a n ( s e e p a g e T - 1 1 ) . t 3 . R e m o v e n dd i s c a r dh e o i l p u m p c h a i n t e n s i o n e r . a t
6. Removethe oil pump sprocket(A),then removethe oil pump(B).
4. To hold the rear balancershaft,inserta 6 mm pin driver (A) into the maintenance hole in the lower balancershaft holderand through the rear balancer shaft.
5. Loosenthe oil pump sprocketmounting bolt.
(cont'd)
8-9
Engine Lubrication
Oil PumpOverhaul {cont'dl
Oil PumpInspection
1. Removehe pumphousing. t 3. Checkth e h ousing-to-roto axiaI clearance r between ( t h e r o t o r( A )a n d p u m p h o u s i n g B ) .l f t h e h o u s i n g to-rotoraxial clearance exceeds the servicelimit. r e p l a c eh e o i l p u m p . t Housing"to-Rotor Axial Clearance -0.003 in.l Standard(New):0.02 0.07 mm (0.001 (0.005in.l ServiceLimit: 0.12mm
Checkthe inner-to-outer rotor radialclearance betweenthe inner rotor (A) and outer rotor {B).lf the inner-to-outer rotor radialclearance exceeds the servicelimit, replacethe oil pump. Inner Rotor-to-Outer Botor Radial Clearance -0.006 in.) Standard{New):0.02 0.16mm (0.001 ServiceLimit: 0.20mm (0.008in.,
4 . Checkthe housing-to-outer rotor radialclearance
betweenthe outer rotor (A) and pump housing(B). lf the housing-to-outer rotor radialclearance exceeds the servicelimit, replacethe oil pump. Housing-to-Outer Rotor Radial Clearance StandardlNewl: 0.15 0.21mm (0.006-0.008in.l ServiceLimit; 0.23mm (0.009 in.)
\,
1'[1e-\1.-,-2
1 'a :.: ,-'r'
Inspectboth rotors and the pump housingfor parts if scoringor other damage.Replace necessary.
\-
8- 10
Balancer Shaft Inspection

1 . Seatthe balancershaft by pushingit away from the o i l p u m p s p r o c k ee n d o f t h e o i l p u m p . t
3. Removethe baffle plate (A) and upper balancer shaft holder {with bearings)(B),then removethe front balancershaft (C)and rear balancershaft (D).
9 H
L=] R j/
2 . Zero the dial indicatoragainstthe end of the

balancershaft,then push the balancershaft back and forth and readthe end olav. Balancer Shaft End Play: Fronl Balancer Shaft: Standard{Newl: 0.070 0.135mm {0.0028 0.0053in.} ServiceLimit: 0.15mm (0.006in.) Rear Balancer Shaft: Standard{New):0.070-0.135 mm (0.0028 0.0053in.l ServiceLimit: 0.15mm (0.006in.)
.r
''/
Rfl|] 3 eI ]U U B
+-
(cont'd)
8-11
Engine Lubrication
Oil PumpOverhaul(cont'dl
4. Measure innerdiameter the No. 1 bearing the of for thefrontbalancer shaftholeandthe rearbalancer shafthole. Bearing InnerDiameier: Front: (New): Standard 20.000-20.020 mm (0.7874 0.7882 in.) Service Limit; 20.03 mm (0.789 in.) Rear: Standard(New):24.000-24.020 mm in.) 10.9/t49-0.9457 ServiceLimit: 24.03mm (0.946 in.) Front: 5 . Measurethe diametersof the No. 1 journalson the
front balancershaft and rear balancershaft. NO.1Journal Diameter: Front: StandardlNew): 19.938 19.950 mm (0.7850 0.7854in.) ServiceLimit: 19.92mm {0.784in.) Rear: StandardlNewl: 23.938 23.950mm in.) {0.9424-0.9/129 ServiceLimit: 23.92mm (0.942in.) Front:
a
Rear:
8-12
6. Cleanboth balancershaft No. 2 journalsand bearinghalveswith a cleanshop towel. 7. Placeone strip of plastigage acrosseach No.2 journal.
1 0 . A l i g nt h e p u n c hm a r ko n t h e r e a rb a l a n c es h a f t r with the centerof the two punch marks on the front balancershaft,then install'thebalancershaftsin the lower balancershaft holder
8 . Reinstall bearingsand upper balancershaft the

holder,then torque the bolts. NOTE;Do not rotatethe balancershaft durinq insDection. 9 . Removethe uooer balancershaft holder and bearingsagain,and measurethe widest part of the plastigage. the balancershaft No. 2 journal oil lf is installthe new clearance out-of-tolerance. lf bearings,and recheck. it is still out-of-tolerance, replacethe balancershafts. No. 2 Journal Oil Clearance: StandardlNewl; 0.060 0.120mm ServiceLimit:
(0.0024 0.0047 in.l 0.15mm {0.006 in.)

1 1 .Apply engine oil to the threads of the 8 mm bolts
(A). 6x1.0mm '12N.m (1.2kgt.m,8.7 lbt ft)
1 2 . I n s t a l l t h e p p e rb a l a n c es h a f th o l d e r( B )a n d u r bafile plate (C).
(cont'd)
8-13
Engine Lubrication
Oil PumpOverhaul(cont'd)
p 13. lnstallthe umphousing.
Oil PumpInstallation
1. Make sure the No. 1 piston is at TDC (seestep 1 on p a g e6 - 1 2 ) . 2. Align the dowel pin{A} on the rear balancershaft with the mark (B)on the oil pump.
9%ttrc
6x1,0mm 1 2N . m (1.2kgt.m,8.7lbf.ft)
+:.:4.4 /
o/.-lY\
t\
To hold the rear balancershaft, inserta 6 mm pin driver {A) into the maintenance hole in the lower balancershaft holder and through the rear balancer shaft.
\,-
f,o-;
-rrdv
:aa:'
8- 14
4. Apply engine oil to the threadsof the oil pump sprocketmounting bolt (A).
8. Squeeze the new oil pump chain tensioner(A),then installthe set clip (B)on it as shown. N O T E T h e s e tc l i p i s s u p p l i e d i t h t h e o i l p u m p : w chain tensioner.
A 10x 1.25 mm {4 N.m (a.5kg{ m, 33 rbf.ftl
I
6x1.0mm 12N.m(1.2 kgf.m, 8.7rbf.ft)
9. Installthe oil DumD chain tensioner.
1 0 x1 . 2 5 m m ,l,t N.m {4.5kgf.m, 33 tbt.ftl
8 x 1,25 m m 22N m l2.2kot m.
r6 tbt.fti
, 5 . L o o s e l y n s t a l l t h e i l p u m p( B ) t h e ni n s t a l l t ho i l i o e pump sprocket(C).
Removethe pin driver (D). 7 . Tightenlhe oil pump mounting bolts.
(cont'd)
8-15
I
EngineLubrication
Oil PumpOverhaul(cont'dl
1 0 . R e m o v e h e s e t c l i pf r o m t h e o i l p u m p c h a i n t tensioner.
I
Oif Pressure Switch Replacement
1. Discon nectthe oil pressureswitchconnector, then removethe oil pressureswitch.
1 1 . I n s t a ltl h e o i l p a n ( s e ep a g e T - 2 7 ) .
2. Apply liquid gasketto the oil pressureswitch threads,then installthe oil pressureswitch.
8-16
EngineMechanical
IntakeManifoldand ExhaustSystem
lntake Manifold Removal Installation and ................. 9-2 Exhaust Manifold Removal Installation and .............. 9-7 Exhaust Pipe and Muffler Replacement ..................... 9-8
r-!i!1
System IntakeManifoldand Exhaust

and Installation lntakeManifoldRemoval
Exploded View:
8 x 1,25 m m 22 N.m {2.2kgf.m, 16 lbf ft}
I
INTAKE MANIFOLD or Replace cracked if if mating surfaceis
GASKET Replace.
'e) w)
INTAKE MANIFOLDPLATE if or Replace cracked if matingsurfaceis damaged. 6x1.0mm 1 2N . m {1.2kgf.m,8.7lbf.ft)
k
\ t9 \
8 x 1.255 x . 2 mm 22 ' m 2 2 Nm
'!
ksf kgf.m, 1 6 12.2
8 x 1.25 m m 22 N.m (2.2kgf m. 16 lbt.ft)
\-
9-2
Removal:
'1. Removethe intakemanifoldcover.
3. Disconnecttheintakeairtemperature(lAT)sensor connector(A),and removethe breatherhose (B), then removethe air cleanerhousingcover/intake ( a i r d u c ta s s e m b l y C ) .
2 . Removethe evaporative emission(EVAP) canister

hose (A),brakeboostervacuum hose (B),and vacuum hoses{C). 4. Fully open the throttle link and cruisecontrol link by hand,then removethe throttlecable (A) and cruisecontrol cable(B)from the links.Loosenthe locknuts{C).and removethe cablesfrom the bracket.
(cont'd)
9-3
IntakeManifoldand ExhaustSystem
IntakeManifoldRemovaland Installation(cont'dl
5. Be preparedto catch and clean up spilledcoolant. Removethe water bypasshoses,then plug the water bypasshoses. 9 . Removethe enginewire harnessconnectors and wireharness lamps romthe intake anifold. c f m . . . . Four injectorconnectors ldle air control (lAC)valve connector Throttleposition(TP)sensorconnector fvlanifold absolutepressure{lvlAP) sensor connector . Evaporative purge emission(EVAP)canister valve connector
'1 Removethe bolt securingthe intakemanifoldand 0.

bracket.
l 6 . R e l i e v e f u ep r e s s u r e( s e ep a g e1 1 - ' 1 4 4 ) . 7 . R e m o v eh e f u e ll i n e ( s e e p a g e l l - 1 4 9 ) . t 8. Removethe positivecrankcase ventilation(PCV) hose (A),harnessholder mounting bolt (B)and h a r n e s s l a m pm o u n t i n g o l t ( C ) . c b
1 1 .Removeallthe intakemanifold mounting bolts/ nuts.
1'>
Removethe two stud bolts (A),then removethe ( intake anifold B). m
\-
9-4
1. Installthe intakemanifold (A)with a new gasket(B), then installand tighten the two stud bolts (C).
4 . Installthe PCVhose {A), harnessholder mounting b o l t ( B ) ,a n d h a r n e s s l a m pm o u n t i n gb o l t( C ) . c
w
*& \
8 x 1.25 mm 22 N.m |.2.2k91.m. 16 tbt.ft) 8 x 1.25 mm 22 N.rn (2.2kgf m. 16 lbf.ttl
e-li*h,r
2. Tightenall intakemanifold mountlng bolts/nutsin a

patternin two or three steps,beginning crisscross with the inner bolt.
?
6x1.0mm 12N.m(1.2 kgf.m,8.7 lbf.ft) 5 . I n s t a l l t h e u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) . f 6 . Installthewater bypasshoses.
Tightenthe bolt securingthe intakemanifold and bracket.
8 x 1.25mm 22 N.m (2.2ksf m, 16lbf.ft)
7 . I n s t a ltl h e t h r o t t l ec a b l e( s e ep a g e11 - 1 6 4 ) , e n th a d j u s t h e c a b l e( s e ep a g e1 1 - 1 6 3 ) . 8 . Installthe cruisecontrol cable (seepage 4-44). then adjustthe cable (seepage 4-45).
(cont'd)
9-5
lntake Manifoldand ExhaustSystem

IntakeManifoldRemovaland Installation(cont'd)
a h c 9 . l n s t a l l t h e i r c l e a n e r o u s i n g o v e r( A ) ,a n d connectthe IAT sensorconnector(B). 1 2 . I n s t a l l t h en t a k e a n i f o l d o v e r . i m c
6x1.0mm 1 2N . m l.1.2k91.m, 8.7 tbf.ftl
B hose(C). 1 0 .Installthe breather
C l e a nu p a n y s p i l l e d n g i n e o o l a n t . e c After installation, checkthat all tubes,hoses,and connectors are installedcorrectly. Inspectfor fuel leaks.Turn the ignition switch ON (ll) (do not operatethe starter)so that the fuel pump the runs for about 2 secondsand pressurizes fuel line. Repeat this operationtwo or three times,then checkfor fuel leakageat any point in the fuel line.
to.
hose(A),brake booster 1 1 .lnstallthe EVAP canister ( , h v a c u u m o s e B ) a n dv a c u u m o s e sC ) . h {
\-
Refillthe radiatorwith enginecoolant,and bleed air from the cooling systemwith the heatervalve open (seepage 10-6).
9-6
Exhaust ManifoldRemoval and Installation

1 . Removethe VTECsolenoidvalve (seepage 1'1-128). 2 . Removethe driveshaftheat shield(seepage 16-19). 3 . Removethe cover and exhaustmanifold bracket, then removethe exhaustmanifold.
8x 1.25 m m 22 N.m (2.2 kgf.m, 16lbt.ftl
#'-.GASKET Replace.
SELF-LOCKING NUT 10x 1.25 mm 44 N.m {4.5ksf.m, 33lbt.ftl Beplace.
1 0x 1 . 2 5 m m 44 N.m (4.5kgt.m, 33 lbl ftl Replace.
WASHEB 10x 1.25 mm 14 N.m {4.5kgl.rn, 33lbf.ft)
8 x 1-25 mm 22 N.m (2.2kgI m, 16lbf.ft) Replace. Tighten boltsin steps, the alternating to side. side
Installthe exhaustmanifoldand tighten the bolts/nutsin a crisscross patternin two or three steps,beginningwith the inner bolt. 5 . Installtheother parts in the reverseorder of removal.
9-7
lntake Manifoldand ExhaustSystem

ExhaustPipeand Muffler Replacement
nuts when reassembling. NOTE:Use new gasketsand self-locking
m 8 x 1.25 m 22 N.m (2.2kst.m. 16lbf.ftl Replace. Tightenthe bolts in steps, alternating side'to side. EXHAUST PIPE B HEATSHIELD
\,
6x1.0mm 9.8 N.m {1.0kgt.m,7.2 lbf ft}
GASKET Replace.
NUT SELF-LOCKING 1 0x 1 . 2 5 m m kgf.m, 33N.m{3.4 25 rbf.ft) Beplace.
SECONDARY HEATED OXYGEN SENSOR HO2SI {SECONDARY

il4Nm (4.5 ksf.m,33 lbf.ftl
8 x 1.25mm 22 N.m {2.2kgf m, 16lbf.ft) Replace. Tightenthe bolts in steps, alternating side to-side.
AIR FUELRATIO {A/F) SENSOR 44 N.m (it.s kgf.m, 33 lbf ftl
\-.
9-8
Engine Cooling
CoolingSystem
Component Location Index ......................................... 10-2 Radiator Test ..................... Cap .......... 10-3 RadiatorTest ............. 10-3 FanMotorTest .......... l0-4 Thermostat Test ...................... ........... 10-4 WaterPumpInspection ..................... 10-5 WaterPumpReplacement ................. 10-5 C o o l a nC h e c k. . . . . . . . . . . . . . t . . . . . . . . . . . . . . . .1.0 . .6 . . .- . Coolant Replacement ......................... 10-6 Thermostat Replacement .................. 10-8 WaterPassage Installation ................ 10-9 Water Installation Outlet .................... 10-9 Radiator FanReplacement and ................................... 10-10
FanControls
C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.-.1 .1 . . . . . . L n . . . . Symptom Troubleshooting Index ............................... 10-12 Circuit Diagram ......... 10-13 Radiator CircuitTroubleshooting Fan ........................ 10-14 Radiator Switch Fan Circuit Troubleshooting (Open) ........... . . . . . . . .1 0 - 1 6 . Radiator Switch Fan Circuit Troubleshooting (Short)........... . . . . . . . .1 0 - 1 6 . Radiator Switch Fan Test ................... 10-17 Radiator Switch Fan Reolacement .............................. 10-17
CoolingSystem
\
WATER OUTLET, pa I n s t a l l a t i o n ,g e ' 1 0 - g
WATER PUMP page Inspection, 10-5 page Replacement. 10-5 PIPE CONNECTING RESERVE TANK WATER PASSAGE page Installation, 10-9
\\f
RADIATOR CAP
THERMOSTAT page 4 10 Test, page Replacement, 108
RAOIATORFAN SWITCH Test,page 10-17 page 10'17 Replacement,
RADIATOR page 10-'l0 Replacement, RADIATORFAN ASSEMgLY p, R e p l a c e m e n ta g e1 0 - 1 0 Fan MotorTest,page 10 4
A/C CONDENSER FAN ASSEMBLY page 10 10 Replacement, Fan Motor Test,page '10-4
\J
10-2
RadiatorCapTest
1. Removethe radiatorcap {A),wet its sealwith engine coolant,then installit on the pressure tester ( B )( c o m m e r c i a l la v a i l a b l e ) . y
RadiatorTest
1 . Wait untilthe engine is cool, then carefullyremove the radiatorcap and fill the radiatorwith engine coolantto the top of the filler neck. Attachthe pressure tester (A) (commercially a v a i l a b l et) t h e r a d i a t o r . o
Apply a pressureof 93 kgf/cm', l4 18 psi).
'123 kPa{0.95 1.25
3 . Checkfor a drop in pressure. 4 . lf the pressuredrops, replacethe cap. 3 . Apply a pressureot 93 '123kPa(0.95 1.25
kgf/cm', '14 18 psi).
4 . I n s p e cfto r e n g i n ec o o l a n t e a k s n d a d r o p i n l a
pressu re. Removethe tester,and reinstallthe radiatorcap.
10-3
CoolingSystem
FanMotor Test
1. Disconnect 2P connectors the from the radiatorfan motor and condenserfan motor.
ThermostatTest
Replace thermostatif it is open at room the remperalure. To test a closedthermostatl 1. Suspendthe thermostat(A) in a containerof water. Do not let the thermometer{B)touch the bottom of t h e h o tc o n t a i n e r .
Testthe motor by connectingbatterypower to the B t e r m i n a a n d g r o u n dt o t h e A t e r m i n a l . l lf the motor fails to run or does not run smoothly, r e p t a c eL r
2. Heatthe water, and checkthe temDerature with a

thermometer.Checkthe temperatureat which the thermostatfirst opens,and at which it is fully open.
\.
3 . Measurethe lift height of the thermostatwhen it is

f u l l vo o e n . STANDARD THERMOSTAT Lift height; above 8.0 mm (0.31in.) Starts opening: 169 176"F(76 80"C) Fullyopen: 194"F{90'Cl
10- 4
Water Pump Inspection

1 . Removethe drive belt (seepage 4-26), 2 . Turn the water pump pulleycounterclockwise. Checkthat it turns freely. Checkfor signs of seal leakage. small amount of A "weeping" from the bleed holes(A) is normal.
Water Pump Replacement

1. Removethe drive belt (seepage 4-26). 2 . D r a i nt h e e n g i n e o o l a n t s e ep a g e1 0 - 6 ) . c { 3 . R e m o v e h e c r a n k s h a fp u l l e y( s e ep a g e6 - 1 1 ) . t t 4. Removethe six bolts securingthe water pump, then removethe water pump (A).
6x1.0mm 1 2 N m { 1 . 2k g t m , 8.7 rbf.ft)
Inspectand cleanthe O-ring groove and mating surfacewith the water passage. I n s t a l l t h e a t e r p u m pw i t h n e w O r i n g si n t h e w reverseorder of removal. 7 . C l e a nu p a n y s p i l l e d n g i n e o o l a n t . e c 8 . I n s t a l l t h e r a n k s h a fp u l l e y( s e ep a g e6 - 1 2 ) . c t L R e f i l t h e r a d i a t ow i t h e n g i n e o o l a n ta n d b l e e d l r c , air from the cooling system with the heatervalve o p e n{ s e ep a g e1 0 - 6 } .
10-5
CoolingSystem
Goolant Check
1. Look at the coolantlevel in the reservetank. Make sure it is betweenthe MAX mark (A) and MIN mark (B),
CoolantReplacement
1 . Startthe engine.Set the heatertemperaturecontrol dial to maximum heat.then turn off the ignition switch.Make surethe engine and radiatorare cool to the touch. Removethe radiatorcap. Removethe splashshield(seestep 23 on page5-5). Loosenthe drain plug (A),and drain the coolant.
lf the coolantlevel in the reservetank is at or below the MIN mark, add coolantto bring it up to the l\4AX mark, and inspectthe cooling system for leaks.
\
Removethe reservetank drain cap (A),and drain the coolant.
\-
10-6
After the coolanthas drained,tighten the radiator and installthe reservetank drain plug securely. drain cap securely. 1 . Fillthe reservetank to the MAX mark (A) with Tvpe 2 HondaAll SeasonAntifreeze/Coolant (P/NO1999-9001).
Type 2 8. Pour HondaAll SeasonAntifreeze/Coolant into the radiatorup to the baseof the filler neck. NOTE: . Always use HondaAll SeasonAntifreeze/Coolant Type 2 {P/N01999-9001). Using a non-Honda c , t c o o l a n t a n r e s u l ti n c o r r o s i o nc a u s i n g h e cooling systemto malfunctionor fail. . HondaAll SeasonAntifreeze/Coolant Type 2 is a water. Premixture of 50% antifreeze and 507o m i x i n gi s n o t r e q u i r e d . EngineCoolant RefillCapacity includingthe reserve tank capacity of 0.53 4 (0.56 US gtl : 5.0 0 (s.3US qt)
r r L I n s t a l l t h e a d i a t o c a pl o o s e l y .
1 0 .Startthe engine,and let it run until it warms up (the

radiatorfan comes on at leasttwice). 1 1 .Turn off the engine.Checkthe level in the radiator, Type and add HondaAll SeasonAntifreeze/Coolant 2 if needed. r t P u tt h e r a d i a t o c a p o n t i g h t l y , h e n r u n t h e e n g i n e f a g a i na n d c h e c k o r l e a k s .
tJ.
lnstallthe splashshield(seestep 22 on page 5-12).
10-7
GoolingSystem
ThermostatReplacement
1 . D r a i nt h e e n g i n e o o l a n t( s e ep a g e1 0 - 6 ) . c 2. Removethe splashshield (seestep 23 on page 5-5). 3. Removethe lower hose,then removethe thermostat. 6x 1.0 m m 9.8N.m (1.0 gf.m,7.2lbf ) k ft
i*
THERMOSTAT LOWER HOSE 4. Installthethermostatwith a new O-ring,then installthe lower hose. 5 . I n s t a l l t h e p l a s h h i e l d( s e es t e p2 2 o n p a g e5 - 1 2 ) . s s 6. Refillthe radiatorwith engine coolant,and bleed air from the cooling systemwith the heatervalve open (seepage 10_6).
\_
10-8
Water Passage Installation

1 . Cleanand dry the water passagemating surfaces. Apply liquid gasketP/N 08718-0009, evenlyto the c y l i n d e r l o c km a t i n gs u r f a c e f t h e w a t e r p a s s a g e b o and to the inner threadsof the bolt holes. NOTE:Do not installthe parts if 5 minutesor more . h a v ee l a p s e d i n c ea p p l y i n g i q u i dg a s k e t I n s t e a d , s l reapplyliquid gasketafter removing old residue.
Water Outlet lnstallation

I n s t a l l t hw a t e r u t l e ( A ) w i t h n e wO - r i n gB ) , e o t a {
1 2 N m ( 1 . 2k g t m , 8 , 7 l b ff t )
( w 3 . I n s t a l l t h e a t e rp a s s a g e A ) w i t ha n e w O - r i n g( B ) .
.t':.:
m 1 0x 1 . 2 5 m 44N m {4.5 m.33 lbf.ft} kgt 4. After assembly,wait at least30 minutes before f i l l i n gt h e e n g i n e i t h o i l . w
10-9
Cooling System
Radiator and FansReplacement
1. Drainthe enginecoolant(seepage 10-6). 2. Removethe front bumper {seepage 20,85). 3. Removethe bulkhead. 4. Removethe upper radiatorhose and lower radiatorhose.
DRAINPLUG UPPER BADIATOR HOSE BADIATOB BAOIATOA FAN ASSEMBLY O.RING RADIATOR CAP
\LOWERCUSHION RADIATOR FAN
swtTcH
24Nm
{ 2 . 1k g l m . 1 7 l b l h l t
LOWER FADIATOR HOSE
RESERVETANK A/C CONDENSER FANASSEMBLY 9 . 8N m { 1 . 0 g f m , 7 . 2l b ff t ) k CONNECTORS RADIATOB FANSWITCH CONNECTOB
5. Disconnect fan motor connectors the and radiatorfan switch connector, then pull the radiatorup and out. 6. Removethe fan shroud assemblies and other partsfrom the radiator. 7 . I n s t a l l t h e a d i a t o r n t h e r e v e r s e r d e ro f r e m o v a l M a k es u r et h e u p p e ra n d l o w e rc u s h i o n s r e s e t s e c u r e l V . r i . o a 8 . I n s t a ltlh e b u l k h e a dn t h e r e v e r s e r d e ro f r e m o v a l A p p l y b o d y p a i n tt o t h e b u l k h e a d o u n t i n gb o l t s . i o . m 9 . F i l lt h e r a d i a t o w i t h e n g i n e o o l a n t n d b l e e dt h e a i r ( s e ep a g e1 0 - 6 ) . r c a
\.
10-10
FanControls
UNDER.HOOD FUSE/RELAY BOX
RADIATORFAN RELAY
RADIATOBFAN SWITCH Test,page 10'17 p, R e p l a c e m e n ta g e ' 1 0 - 1 7 CONDENSER FAN ASSEMBLY Motor Test,page 10-4
RADIATORFAN ASSEMBLY Motor Test,page 10 4
10-11
FanControls
Symptom Troubleshooting Index
Beforeperformingany troubleshootingprocedures check: . Fuses . Grounds . Cleanliness and tightnessof all connectors
SYMPTOM
Radiator fan does not run at all Radiator fan does not run for enginecooling, but it runs with A,/CON Radiator fan runs with ignition switch ON (ll),Ay'C OFF, and enginetemperaturebelow 199"F(93"C)
PROCEDURE
(seepage 1O-14). RadiatorFanCircuilTroubleshooting RadiatorFan Switch CircuitTroubleshooting (Open) ( s e ep a g e1 0 - 1 6 ) . (Short) RadiatorFan Switch CircuitTroubleshooting (seepage 10-'16).
\ , 4
\-
10-12
CircuitDiagram
' : No.20loA)USA modd : Cm.de mod.l No.20l50A) UNDEN DASX FUSE/RELAY BOX
BOX UIIDEF HOOD FJSE/NILAY
lG2H0TiiAClill, 0N{lllrndSTABI llll)
10-13
FanGontrols
RadiatorFanCircuitTroubleshooting
1. Checkthe No. 4 (20A)fuse in the under-hood fuse/relaybox, and the No. 14 (10A)fuse in the under-dash fuse/relaybox. ls the tuse (s) OK? YES-Go to step 2. NO- Replace fuse (s) and recheck.l the 2. Removethe radiatorfan relayfrom the under-hood fuse/relaybox, and test it (seepage 22-51). ls the relay OK? YES Go to step 3. NO Replace the radiatorfan relay.t Does the radiatot fan run? 3. Measurethe voltage betweenthe No. 2 terminal of the radiatorfan relay 4P socketand body ground. YES Go to step 5. NO Go to step 6. RADIATOR FAN RELAY SOCKET 4P Disconnect jumper, and turn the ignition switch the ON {ll}. Checkfor voltage betweenthe No. 3 terminal of the radiatorfan relay 4P socketand b o d yg r o u n d . T e r m i n a li d e f I e m a l t e r m i n a l s s o e JUMPER WIRE 4 . C o n n e c t e N o .l a n d N o . 2 t e r m i n a l s o f t h e th radiatorfan relay 4P socketwith a jumper wire.
RADIATORFAN RELAY4P SOCKET
\-
BADIATOB RELAY SOCKET FAN 4P
Terminalside of femaleterminals
ls therebatteryvoltage? YES Goto step4. NO Replace under-hood the fuse/relay I box.

Termlnal of female side terminals
ls there battety voltage? YES-Go to step 9. NO Checkfor an open in the wire betweenthe under-hood fuse/relaybox and under-dash fuse/ relay box.l
\-
10-14
Disconnect radiatorfan motor 2P connector. the 7 . Checkfor continuitybetweenthe No. 1 terminal of the radiatorfan relay 4P socketand the No. 2 terminal of the radiatorfan motor 2P connector.
9 . Reinstall radiatorfan relay. the 1 0 .Disconnect radiatorfan switch 2P connector. the

1 1 .Connectthe No. 1 and No. 2 terminals,of the radiatorfan switch 2P connectorwith a jumper wire.
RAOIATOR SWITCH FAN 2P CONNECTOR
RAOIATOR REI-AY SOCKET FAN 4P
Terminal sideof female terminals
f-;
5\-'fl \ \r--
IJUMPER
I wrRE
Wiresideof female terminals FAN MOTOR2P CONNECTOR RADIATOR
Does the radiator fan run?
ls thete continuity?
YES- Replace radiatorfan switch.l the
YES-Go to step8.
N O - G o t o s t e p1 2 .
the NO Repair openin the wire between underhoodfuse/relay andthe radiator motor2P box fan terminal 2,I No. connector
8. Checkfor continuitybetweenthe No, 1terminal of the radiatorfan motor 2P connectorand bodv g round.
RADIATOR AN MOTOR2P CONNECTOR F
Removethe jumper wire, and measurethe voltage betweenthe No, 2 terminal of the radiatorfan switch connectorand body ground,
RADIATOR FANSWITCH 2P CONNECTOR
rftr
T-
ls there battery voltage? YES Checkfor an open in the wire between radiatorfan switch 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1 NO Repairopen in the wire betweenthe radiator fan switchterminal No. 2 and the under-hood fuse/relaybox.l
Wire side of femaleterminals
ls there continuity? YES Replace the radiatorfan motor.l NO Checkfor an open in the wire between radiatorfan motor 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1
10-15
FanControls
RadiatorFanSwitch Circuit (Openl Troubleshooting
1. Disconnect radiatorfan switch 2P connector. the 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 3 . M e a s u r e o l t a g eb e t w e e n h e N o . 2 t e r m i n a lo f t h e v t radiatorfan switch 2P connectorand body ground.
RADIATOR FAN SWITCH2P CONNECTOR
RadiatorFanSwitch Circuit (Short) Troubleshooting

NOTE:After troubleshooting, perform the engine ( c o n t r o lm o d u l e( E C M ) i d l ee a r np r o c e d u r es e ep a g e l 11 , 1 3 9 ) . 1 . R e m o v e h e r a d i a t o f a n r e l a yf r o m t h e u n d e r - h o o d t r fuse/relaybox, and test it (seepage 22-51). ls the relay OK? YES Go to step 2. NO Replace radiatorfan relay.I the
2. Removethe radiatorfan switch,and test it (see p a g e1 0 - 1 7. ) Is the radiatot tan switch OK? YES Go to step 3. ls there battety voltage? YES-Go to step 4. NO- Repairopen in the wire betweenthe radiator fan switch 2P connectorterminal No. 2 and underhood fuse/relaybox.l Turn the ignition switch OFF,and checkfor continuitybetweenthe No. '1terminal of the radiatorfan switch 2P connectorand body ground.
RADIATOB FAN SWITCX2P CONNECTOR
NO
Replace radiatorfan switch.I the
Disconnect batterynegativecablefrom the the battery. 4 . Disconnect enginecontrol module {ECM)connector ) B ( 2 4 P a n d t h e u n d e r h o o df u s er e l a yb o x 1 4 P connector. Checkfor continuitybetweenthe No. 2 terminal of the radiatorfan switch 2P connectorand body grouno.
RADIATORFAN SWITCH 2P CONNECTOR
ls there continuity? YES Replace the radiatorfan switch.t NO Checkfor an open in the wire betweenthe radiatorfan switch 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1
lstnere continuity? YES Repairshort in the wire betweenthe radiator f a n s w i t c h2 P c o n n e c t otre r m i n a lN o . 2 a n d u n d e r hood fuse/relaybox.l NO Replace under-hoodfuse/relaybox.t the
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10-16
RadiatorFanSwitch Test
NOTE:Bleedair from the cooling system after installing the radiatorfan switch (seepage 10-6). 1, Removethe radiatorfan switchfrom the radiator ( s e ep a g e1 0 - 1 7 ) . 2 . S u s p e n dh e r a d i a t ofra n s w i t c h( A )i n a c o n t a i n e r t of water as shown.
RadiatorFanSwitch Replacement
1 . Disconnect radiatorfan switch connector, the then removethe radiatorfan switch (A). A 24 N m (2.4kgt.m,17lbt.ftl
2. Installthe radiatorfan switchwith a new O-ring(B).
3. Heatthe water, and checkthe temperaturewith a thermometer.Do not let the thermometer(B)touch the bottom of the hot conlainer. 4. Measurethe continuitybetweenterminal No. 1 and terminal No. 2 accordingto the table.
\ Operation Termina lTemperature 203'F ON 196" gs"C) (91" swtTcH 5' 15'F {3' 8'C) lowel OFF than the temoerature when it goes on 1
10-17
Fueland Emissions
Fueland Emissions Systems
SpecialTools 1't-2 General Troubleshooting Information I I-J DTC Troubleshooting lndex .... 11-7 Troubleshooting Symptom 1ndex............... 11 - 1 0 Descriptions System ................ 11-12 Howto SetReadiness Codes.. 11-46 F u e P r e s s u r e T e s.t. . . . . . . . . . . . . 1.-.1 4 5 l . 1. . F u e L i n e sn s p e c t i o.n . . . . . . . . .1.1 . 1 4 6 l I . . .FuelLine/Ouick-Connect Fittings Precautions ............. 11-148 FuelLine/Ou ick-Con nect F i t t i n gR e m o v a l. . . . . . . . . . . . .11.-.1 4 9 s .. . FuelLine/Ou ick-Con nect F i t t i n gls s t a l l a t i o.n. . . . . . . . .1.1 . 1 5 0 n . . .FuelPressure Regu lator R e p l a c e m e . .t. . . . . . . . . . . . . . . 1.1.-.1 . . 2 n . . .5 FuelFifter Replacement ........... 11-152 FuelPump/Fuel Gauge Sending . . . t . . . . . . . . 1.1.-.1 5 3 . . UnitReDlacemen . F u e P u l s a t i oD a m o e r l n R e p 1 a c e m e n.t. . . . . . . . . . . . . . 1.1.-.1 . . 4 .. . . .5 1. F u eT a n k e o l a c e m e n.t. . . . . . . . 1 - 1 5 5 l R . F u eG a u g e S e n d i n i t T e s . . . . .1 1 - 1 5 6 l U g .t . 11-158 Low lndicatorTest Fuel .................
PGM-FlSystem
Component Location Index .... 11-49 D T C r o u b l e s h o o t i n.g . . . . . . . . . . . T . . 11-52 MILCircuit Troubleshooting 11-97 ... DLCCircuit Troubleshooting 1 1 - 1 0 9 .. Injector Replacement ............... - 1 1 1 11 A,/F Replacement ......... 1 - 1 1 3 1 Sensor HO2S Secondary Replacement 11-113 ECT Reolacement Sensor ....... 1 - 1 1 4 1 CMPSensor {TDC B Sensor) Replacement 11-114 I A TS e n s oR e p l a c e m e.n t . . . . 1.1 - 1 1 5 r .. . Knock Replacement 1 1 - 1 1 5 .... Sensor CKP Sensor Reolacement ....... 1 - 1 1 6 1
IntakeAir System
I C o m o o n e nL o c a t i o nn d e x . . . . 1 1 - 1 5 9 t T h r o t t l e o d y T e s t . . . . . . . . . . . . . . 1.1.-.1 6 0 B . . Intake Bypass Air Control T h e r m a V a l v eT e s t . . . . . . . . . . .1.1 - 1 6 1 l . . A i r C l e a n e R e o l a c e m e n .t . . . . . .1 1 - 1 6 2 . r A i r C l e a n eE l e m e n t r R e o l a c e m e n.t. . . . . . . . . . . . . . . . . 1.1.-.1 . 2 . . .6 ThrottleCableAdjustment ...... 11-163 ThrottleCable Removal/lnstallation ............1-164 1 Th rottleBody Removal/ Installation .. 11-165 Th rottleBody Disassembly/ R e a s s e m b l v . . . . . . . . . . . . . . . . . .1.1 . . . 6 6 . . .-1 .
VTEC/VTC
Location Index .... 11-117 Comoonent D T C r o u b l e s h o o t i n.g . . . . . . . . .1 . 1 8 T . . 1 .- 1 VTCOil Control Solenoid Valve Removal/Test ............. 11-127 CMPSensor Replacement 11-128 A ... VTEC Valve Solenoid R e m o v a l / l n s o e c t.i . . n. . . . . .11-128 o. ...
ldle ControlSystem
11-129 . . D T CT r o u b l e s h o o t i n g. . . . . . . . . .1.I.- 1 3 0 A,/C SignalCircuit T r o u b l e s h o o t i n.S . . . . . . . . . . . . .I .t.-. t.5 5 . Alternator SignalCircu FR it T r o u b l e s h o o t i n.S . . . . . . . . . . . . . . 1.- 1 3 4 . 1. . EPSSignalCircuit T r o u b l e s h o o t i n.S . . . . . . . . . . . . . .1 .1 3 5 . 1 . -. Brake Pedal Position Switch Signal Troubleshooting .............1 - 1 3 7 Circuit 1 ldle SpeedInspection 11 - 1 3 8 E C Ml d l el e a r nP r o c e d u r e. . . . . . . 1 - 1 3 9 1
CatalyticConverter System
D T C r o u b l e s h o o t i n.g . . . . . . . . .1 . 1 6 7 T . . 1 .-
Location Index Component
PCVSystem
D T CT r o u b l e s h o o t i n g. . . . . . . . . .1. .- 1 6 8 . .1 PCVValveInsDection a n dT e s t . . . . . .11 -1 6 9 P C V a l v eR e o l a c e m e n.t. . . . . . . . .1 - 1 6 9 V 1
EVAPSystem
C o m p o n e nL o c a t i o nn d e x . . . . 1 1 - 1 7 0 t I . . . D T C T r o u b l e s h o o t i n.g. . . . . . . . .1.1 - 1 7 1 EVAPTwo Way ValveTest ......11-186 FuelTank VaoorControl ValveTest ... 11-187 E V A P a n i s t eR e p l a c e m e n.t. . 1 1 - 1 8 9 C r FuelTank VaoorControl V a l v eR e o l a c e m e n.t. . . . . . . . . .1. .- 1 8 9 .1
FuelSupplySystem
ComponentLocationIndex 11 - 1 4 0 Fuel Pump Circuit Troubleshooting 1 1 - 1 4 1 F u e lP r e s s r e R e l i e v i n g . . . . . . . .1.1 - 1 4 4 u . .

SpecialTools
Rel. No. Tool Number
\,
Description V a c u u mP u m p / G a u g e , 3 0 i n . H g 0 Vacuum/Pressure Gauge.0 4 in.Hg Backprobe Set Fuel Pressure GaugeAdapter Pressure GaugeAdapter FuelSenderWrench Hose,Oil Pressure A,/TPressure Hose A,/TLow Pressure GaugeW/Panel A,/TPressure Hose ,2,210 mm A,/TPressure HoseAdapter F u e lP r e s s u r e a u g e G FuelPressure GauoeSet
(L) @
otv
1 1
o o
@ @ @ @-t @-2 O-3 @-4 @ (iD
A973X-041-XXXXX 07JAZ-0010008 07sAz-001000A 07vAJ-0040100 07NAJ-P07010A 07xAA-001010A 07zAJ-S5AA200 07406-0020201 07406-0070300 OTMAJ-PY4O11A 07MAJ-PY40120 07406-004000A 07zAJ-S5A0100
2
1 1 1
I
*.'l)
UtB o
ffi
/'r';-:'-;--' At-''
o
-'-,---=---1,-'.
a=:t=' (F
--1
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\7
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ut/t
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o
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-1,40-2, -3,@-4
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11-2
Troubleshooting General Information

Intermittent Failures
The term "intermittentfailure" means a svstem mav have had a failure.but it checksOK now. lf the MalfunctionIndicatorLamp (MlL)on the dash does not come on, checkfor Doorconnections looseterminals or at all connectorsrelatedto the circuitthat Vou are troubleshooting. 2. lf the MIL stayson, connectthe HondaPGM Tester (A) or an OBD ll scantool to the Data Link Connector{DLC)(B) locatedunderthe driver'sside o f t h ed a s h b o a r d .
Opensand Shorts
"Ooen" and "Short" are common electrical terms.An open is a breakin a wire or at a connection. short is A an accidental connectionof a wire to ground or to anotherwire. In simple electronics, this usuallymeans somethingwon't work at all. With complex electronics ( s u c h s E C M s ) t h i s a n s o m e t i m e s e a ns o m e t h i n g a c m works, but not the way it's supposedto.
How to Usethe PGMTesteror a ScanTool

3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
lf the MIL {Malfunction Indicator Lamp} has come on '1. S t a r tt h e e n g i n e n d c h e c k h e M I L { A ) . a t N O T E l f t h e i g n i t i o n w i t c hi s t u r n e dO N ( l l ) ,a n d : s the engine is not started, the MIL will stay on for ( 1 5 2 0 s e c o n d s s e ep a g e1 1 - 4 6 ) . Checkthe Diagnostic TroubleCode (DTC) and note it. Also checkthe freezedata.Referto the DTC T r o u b l e s h o o t i nIg d e x , n d b e g i nt h e a p p r o p r i a t e n a procedure. troubleshooting go 5 . lf you do not find any DTCS, to MIL circuit s t r o u b l e s h o o t i n(g e ep a g e1 1 - 9 7 ) . NOTE: . Freeze data indicates the engineconditionswhen the first malfunction,misfire,or fuel trim malfunction was detected. . The scantool and the Honda PGM Testercan readthe DTC,freezedata,currentdata,and other Engine Controll\4odule data. {EClvl) . For specificoperations, referto the user's manual that came with the scantool or HondaPGl\4Tester. lf the MIL did not stay lf the MIL did not come on but there is a driveability problem,referto the Symptom Troubleshooting Index i n t h i ss e c t i o n . lf you can't duplicate the DTC in Some of the troubleshooting this sectionrequires you to resetthe ECM and try to duplicatethe DTC.lf rhe problem is intermittentand you can't duplicatethe code, T d o n o t c o n t i n u eh r o u g ht h e p r o c e d u r e . o d o s o w i l l t , o n l y r e s u l t n c o n f u s i o n n d ,p o s s i b l ya n e e d l e s s l y i a replaced CM. E
;"PN/.- -:::--d V-: ! K->
w:ix&K#
(cont'd)
11-3

Information(cont'dl GeneralTroubleshooting
How to Resetthe ECM
You can resetthe ECM in eitherof two ways: . U s et h e O B Dl l s c a n t o o lo r H o n d aP G M T e s t e r t o resetthe ECM memory. Testeruser's Seethe OBD ll scantool or HondaPGI\4 manualsfor specificinstructions. ' Turn the ignition switch OFF,and removethe No. 6 ECU{ECM}(15A)fuse (A)from the under-hoodfuse/ r e l a vb o x ( B l f o r 1 0 s e c o n d s .
How to Removethe ECMfor Testing

1. Removethe passenger's dashboardlower cover kick panel (see the {seepage 20-63), passenger's page 20-63), and the glove box (seepage 20-63). 2. Removethe ECM mounting bolts (B)and the ECM
(c),
9.8 N.m {1.0kgf.m,7.2lbt.ft} 3 . R e m o v et h e E C M ( B ) .
How to Enda TroubleshootingSession (required afterany troubleshootingl

1. Resetthe ECM as describedabove. ( 2 . D o t h e E C Mi d l e l e a r np r o c e d u r es e ep a g e1 1 - 1 3 9 ) 3. Turn the ignition switch OFF. 4. Disconnectthe OBD ll scantool or Honda PGM Testerfrom the DLC. NOTE:The ECM is part of the immobilizersystem. lf vou replacethe ECM,it will have a different immobilizercode. In order for the engineto start, you must rewritethe immobilizercode with the Honda PGM Tester.
4. Installthe ECM in the reverseorder of removal.
\- ta
11-4
How to TroubleshootCircuitsat the ECM

Special Tools Required . DigitalMultimeterKS-AHM-32-003 or a (1) commerciallyavailabledigital multimeter . Backprobe (2) Set 07SAZ-0010004 1. Connect the backprobe adapters(A) to the stacking patchcords (B),and connectthe cords to a digital multimete(C). r
2 . U s i n gt h e w i r e i n s u l a t i o n s a g u i d ef o r t h e a contouredtip ofthe backprobeadapter,gently slide the tip into the connectorfrom the wire side until it touchesthe end of the wire terminal. 3. lf you cannot get to the wire side of the connector or the wire side is sealed(A),disconnect the connectorand probe the terminals(B)from the terminal side. Do not force the Drobeinto the connector.
Do not puncturethe insulationon a wire. Punctures can causeDooror intermittent electrical connections.
07sAz-001000A
(cont'd)
11-5

(cont'd) Information Troubleshooting General
for ECMUpdatingand Substitution Testing
Special Tools Bequired HondaInterfaceModule (HlM) EOS05435570 Usethis procedurewhen you haveto substitute a procedure. known-goodECM in a troubleshooting does not alreadyhave U pdatethe ECMonly if the ECN4 the latestsoftwareloaded, NOTE; . lMake sure the batteryis fully chargedbeforeyou updatethe ECN4. . To preventECMdamageduring the update,do not turn the ignition switch OFF,and do not use any of the vehicle'selectrical devices(light,horn, radio,etc. ). How to Update the ECM 1. Turn the ignition switch ON (ll).Do not startthe e n gI n e . 2. Connect the HondalnterfaceModule (HlM)to the Data Link Connector{DLC)(A) locatedunderthe s d r i v e r ' s i d eo f d a s h b o a r d . How to Substitute the ECM '1. Removethe ECMf rom the vehicle.
2. Installa known-goodECM in the vehicle. 3 . R e w r i t e h e i m m o b i l i z ec o d ew i t h t h e E C M t r procedurefrom the Honda PGM replacement Tester.lt allows you to startthe engine. 4. After completingyour tests,reinstall the original E C Ma n d r e w r i t e h e i m m o b i l i z ec o d ew i t h t h e r t p E C Mr e p l a c e m e n tr o c e d u r e n t h e H o n d aP G M o Tester gain. a
EOS05A35570
Do the ECM updateprocedureas describedon the HlN4 label and in the ECM updatesystem.
\-
11-6
DTCTroubleshooting Index
DTC Temporary DTC Detection ltem indication*) {MlL P 0 0 1( 5 6 ) 0 VariableValveTiming Control{VTC)Oil Control P 0 0 1( 5 6 ) 1 P 0 1 0( 3 ) 7 P 0 1 0( 3 ) 8
( P 0 1 1 21 0 ) P001 1 S o l e n o i d a l v eM a l f u n c t i o n V VariableValveTiming Control(WC) System Malfunction Note { s e ep a g e11 ' 11 8 ) ( s e ep a g e1 1 - 1 9 ) 1 ( s e ep a g e1 ' l - 5 2 1
(MAP) Manifold Absolute Pressure Circuit Sensor LowVoltaqe (MAP) Manifold Absolute Pressure Circuit Sensor HiqhVoltaqe
IntakeAir Temperature(lAT)SensorCircuitLow Voltaoe IntakeAir Temperature(lAT)SensorCircuitHigh Voltaoe EnglneCoolantTemperature(ECT) Sensor Range/ Performance Problem
(see age 1-53) p 1

(seepage 11-55) (seepage '11-56) { s e ep a g e1 1 - 5 7 ) ( s e ep a g e1 1 - 5 8 ) { s e ep a g e1 1 - 5 9 ) ( s e eD a q e1 1 - 6 0 ) ( s e ep a q e1 1 - 6 2 ) ( s e eD a q e1 1 - 6 4 ) ( s e ep a g e1 1 - 6 5 ) ( s e ep a g e1 1 - 6 5 ) ( s e ep a g e1 1 - 6 6 ) ( s e ep a g e1 1 - 6 7 ) ( s e ep a g e1 1 - 6 8 ) ( s e ep a q e1 1 - 7 0 ) ( s e eo a o e1 1 - 7 0 ) ( s e ep a g e1 1 - 7 1 )
( P 0 1 r 31 0 )
P 0 1 1 68 6 ) { P 0 1 1 76 ) { P0116
(ECT) Engine Coolant Temperature Sensor Circuit LowVoltaqe

EngineCoolantTemperature(ECT) SensorCircuit Hiqh Voltaqe Throttle Position(TP)SensorCircuitLow Voltaqe Throttle Posltion(TP)SensorCircuitHiqh Voltaoe CoolinqSVStem Malfunction Air Fuel Ratio(Ay'F) Sensor(Sensor1) No Activity Detected SecondaryHeatedOxygen Sensor (Secondary HO2S) (Sensor2) CircuitLow Voltaqe SecondaryHeatedOxygen Sensor (Secondary HO2S) ( S e n s o 2 ) C i r c u i t i q hV o l t a q e r H SecondaryHeatedOxygen Sensor (Secondary H02S) ( S e n s o2 ) S l o w R e s D o n s e r SecondaryHeatedOxygen Sensor(Secondary H02S) (Sensor2) HeaterCircuitMalfunction
P 0 1 1{8 ) 6 P 0 1 2t 7 \ 2 P 0 1 2{ 7 ) 3
( P012887) ( P013441)
P0128
P 0 1 3( 6 3 ) 7
( P013863)
P0137
P0138 P0139
P 0 1 3( 6 3 ) 9
( P014165) ( P017145) PO112 l'45)
PO\11 PO\l2
FuelSvstem Too Lean

FuelSystemToo Rich R a n d o mM i s f i r e
{ s e ep a g e1 1 - 7 2 ) { s e ep a q e11 - 7 2 ) (73) ( s e eo a q e1 1 - 7 2 ) P0303 P0304{74) P0304 N o . 4 C v l nder Misfire {seeDaqe11-72) " ; T h e s e D T C s r e i n d i c a t e d y a b l i n k i n g a l f u n c t i o nn d i c a t o lra m p ( M l L ) w h e nt h e S C Ss e r v i c e i g n a l i n e i s a b m i s jumped with the Honda PGM Tester. P0302(721
P0300 any and of P 0 3 0( 7 1 ) 1 (721 PO302 (73) P0303 (74) P0304 (7'1) P0301
P0300 any and of P0301 P0302 P0303 P0304 P0301 No. 1 Cyl n d e rM i s f i r e P0302 No.2 Cvl n d e rM i s f i r e P0303 N o . 3 C v l nder Misfire
{cont'd)
11-7

Index(cont'd) DTCTroubleshooting
\ (
KnockSensorCircuitN4alfunction Position(CKP) Crankshaft SensorIntermittent CamshaftPosition(CMP)SensorA No CamshaftPosition(CMP)SensorA Intermiftent ( s e ep a g e1 1 - 7 8 ) ( s e e a q e1 1 - 1 2 1 o i s e ep a g e1 1 - 1 2 1 )
PO4i{ ( P045191)
TU45I
Phqse G Yetrgb-le TiTing Velye _controlll/T!)
s e eo a o e1 1 - 1 2 2 CqJalyst SystemElficie-ncy Below Threshold s e eo a q e11 -1 6 7 ( ) F u e lT a n kP r e s s u r eF T PS e n s o r a n g e / P e r f o r m a n c e( s e e p a g e l l 1 7 1 ) R SensorCircuitLow V (FTP) FuelTank Pressure SensorCircuitHigh V Vehicle Deed ensor M S S C i r c u i t a l fu n c t i o n E n g i n e o n t r o M o d u l e( E C N 4 )o w e rS o u r c e i r c u i l C l P C S e r i a C o m m u n i c a t i o L i n kM a l f u n c t i o n l n 11-172
P0452
s e eD a q e1 1 - 1 3 0 ) ( s e ep a g e11 - 8 1 ) Referto the l\4ultiplex ControlSystem Troubleshooting ee {s ( s e ep a g e11 - 8 3 ) ( s e ep a S e11 ' 8 3 ) { s e ep a g e1 1 - 8 3 ) l\."
1 P 1 1 0(6 3 ) 1 P 1 1 0(? 3 P1 08ts' 1 ( P1121 11) P1122 J ll ( i j 1 1 2 85 )

P 11 2 9( 5 ) ( P115748) Pr 158 (48) P 11 5 9( 4 8 ) ( P 1 1 6 36 1 ( P 1 1 6 46 1 ) P 11 6 6( 4 1 ) P't121 Pl122 P11f,.8
(BARO) Barometric Pressure Sensor Range/ P e r f o r m a n Peo b l e m cr

( ) B a r o m e t r i P r e s s u r eB A R O S e n s o r i r c u i t o w c C L ( ) B a r o m e t r i P r e s s u r eB A R O S e n s o r i r c u i t i g h c C H T h r o t t l e o s i t i o n T P iS e n s o r i g n a lL o w e rT h a n P { S ( T h r o t t l e o s i t i o n T P ) e n s o r i g n a lH i g h e r h a n P T S S
(see age 1-63) p 1

tsee page I r-oJ,
( M a n i { o l d b s o l u t e r e s s u r el \ , 4 A P } n s o r i g n a l A P Se S G;tp"s" 1154) Loqer Than Expected ( * " p a S e11 5 4 ) ManifoldAbsolutePreisure (MAP)SeiiioiSgnul H i q h e r h a nE x T ) ( ( s e ep a g e1 1 - 8 4 ) A i r F u e lR a t i o( A V FS e n s o r S e n s o r ) R a n g e / 1 R e r f o r m a n cP r o b l e m e A i r F u e lR a t i o { A " FS e n s o r S e n s o 1 ) A F S T e r m i n a l ( s e ep a g e11 - 8 5 ) ) { r 'l) A i r F u e lR a t i o1 A V F )e n s o r s e n s o r A F S+ T e r m i n a l ( s e ep a g e11 - 8 6 ) S i Air FuelRatio{A,/F) Sensor{SensorI ) Slow Response ( ( s e ep a g e 11 - 8 8 ) A i r F u e lR a t i o( A / F ) e n s o r S e n s o r ) R a n g e / 1 S
( s e ep a g e1 1 - 8 9 ) Air Fuel Ratio(4,/F) Sensor(Sensor1) HeaterCircuit Malfunction p Air Fuel Ratio(A,/F) Sensor(Sensor1) HeaterSystem ( s e e a g e1 1 - 9 1 ) P 11 6 7( 4 1 )' Malfunction " : T h e s eD T C S r e i n d i c a t e d y a b l i n k i n g I L w h e n t h e S C Ss e r v l c e i g n a l i n e i s j u m p e dw i t h t h e H o n d aP G M b M s a Tester. * 1 r' 0 2 m o d e l
\.
11-8
DTC Temporary DTC Detectionltem indication*l {MlL P1259 VTECSystem l\4alfunction t22J P1291t20\ Electrical Load Detector(ELD) CircuitLow Voltaqe (20) P1298 Electrical Load Detector(ELD) CircuitHiqh Voltaqe
( P13618)
Page ( s e eD a q e1 1 - 1 2 3 ) ( s e eD a q el 1 - 9 2 ) ( s e eo a o e1 1 - 9 3 ) ( s e ep a g e1 1 - 9 5 ) ( s e ep a g e1 1 - 9 5 ) ( s e ep a g e1 1 - 1 7 5 ) ( s e ep a g e1 ' l - 1 8 0 ) ( s e eo a q e1 1 - 1 6 8 1 { s e ep a q e1 1 - 1 3 1 ) ( s e ep a g e11 - 9 6 )
P 1 3 6( 8 ) 2 (90) P'r456 ( P 1 4 s 79 0 ) P 1 5 0( 1 0 9 ) 5
( P 1 5 1 91 4 ) ( P1607 ) P1456 P1457 P1505
CamshaftPosition(CMP)SensorB (Top DeadCenter (TDC) Sensor)Intermittent Sional InterruDtion CamshaftPosition(CMP)Sensor B (Top DeadCenter (TDC) ensorNo Siqnal S ) Evaporative Emissions(EVAP) ControlSystem Leakaqe(FuelTank Svstem) Evaporative Emissions(EVAP) ControlSystem Leakaqe(EVAP Canister Svstem) PositiveCrankcase Ventilation(PCV) Leakaqe Air ldle Air Control(lAC)ValveCircuitMalfunction
( E n g i n C o n t r oM o d u l e E C MI)n t e r n a l i r c u i t e l C Malfunction
" : TheseDTCS indicatedby a blinking MIL when the SCSservicesignal line is jumped with the Honda PGM are Tester.
11-9
Systems Fueland Emissions

Index Symptom Troubleshooting
with the scantool. lf there is no trouble code (DTC) When the vehiclehas one of these symptoms,checkthe diagnostic for DTC,do the diagnosticprocedure the symptom, in the sequencelisted,until you find the cause. Svmotom E n g i n e i l l n o t s t ar t w (MlL works OK, no DTCS set) Diaqnostic procedure 1. Testthe battery{seepage 22-50). 2. Testthe starter(seepage 4-8). 3. Troubleshoot fuel pump circult(seepage 11 the 141). '1-97). Also check lor Low compressron No ignition park s lntake irleaks a Locked p engine u t B r o k e n i m i n gc h a i n fuel Contaminated
w E n g i n e i l l n o t s t a r t( M l L comes on and stayson, or n e v e rc o m e so n a t a l l ,n o DTCSset) Enginewill not start (immobilizerindicatorstays on or flashs)
Troubleshoot the l\4lLcircuit(seepage 1
Troubleshoot the immobilizersystem (seepage 22-165).
Hardstarting (MlLworksOK,no DTCS set)

Coldfast idle too low (MlL works OK. no DTCS set) Coldfast idle too high (MlL works OK, no DTCS set)
1. Testthe battery(seepage22-50). ( 2 . C h e c k t h e u e l p r e s s u r e s e ep a g e1 1 - 1 4 5 ) . f
Low compression Intake irleaks a fuel Contaminated
ldle speedfluctuates (MlL works OK, no DTCS set)
After warming up, idle speed with is below specifications no load set) {MlL works OK, no DTCS After warming up, idle speed with is above specifications no toao (MlL works OK. no DTCS set) Low power (MlL works OK, no DTCS set)
( 1 . D o t h e E C Mi d l e l e a r np r o c e d u r es e ep a g e1 1 - 1 3 9 ) . ( s e ep a q e1 1 - 1 3 8 ) . i 2 . C h e c k t h ed l es D e e d ' ] D o t h e E C I \ 4d l e l e a r np r o c e d u r es e ep a g e11 -1 3 9 ) . ( i 2. C h e c k t h e d l es p e e d{ s e ep a g e1 1 - 1 3 8 ) . i '1-'163). the 3 . Inspect/adjust throttlecable (seepage 1 Inspectand test the throttle body {seepage 11-160}. ( a 1 . D o t h e E C Mi d l e l e a r np r o c e d u r es e ep a g e1 1 - ' 1 3 9 ) .I n t a k e i r l e a k s 2 . C h e c k h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) . t 3, Inspecvadjust e throttlecable (seepage 11''163). th 4. Insoectand test the throttle bodv (seepaqe 11-160) ( 1 . D o t h e E C I V d l e l e a r np r o c e d u r es e ep a g e11 -1 3 9 ) . Vacuum hose clogged/ iI FRsignalcircuit (see cracked/poor 2. Troubleshootthealternator p a g e1 1 - ' 1 3 4 ) . connectron 3. InsDect and test the throttle bodv {seepaqe 11-160). 1 . D o t h e E C Mi d l e l e a r np r o c e d u r es e ep a g e1 ' j - 1 3 9 ) . { 2 . T r o u b l e s h o o h e a l t e r n a t oF Rs i g n a lc i r c u i t ( s e e tt r p a g e1 1 - 1 3 4 ) . 1 . C h e c kh ef u e lp r e s s u r e ( s e e p a g e l l - 1 4 5 ) . t 2. Inspectand test the th roftle body (seepage 11-160). st c 3 . I n s p e c v a d j u t h e t h r o t t l e a b l e( s e ep a g e1 1 - ' 1 6 3 ) . Low compressron C a m s h a ftti m i n g problem o Engine il level prootem lntake irleaks a h a Faulty arness nd sensorconnections
\-
Engine talls s (MlL works OK. no DTCS set)
1. 2. 3. 4.
( D o t h e E C Mi d l el e a r np r o c e d u r es e ep a g e1 ' l ' 1 3 9 ) . C h e c kh ef u e lp r e s s u r e { s e e p a g e l l - 1 4 5 ) . t C h e c k h e i d l es p e e d( s e ep a g eI 1 - 1 3 8 ) . t Troubleshootthebrakepedal positionswitch signal ( c i r c u i t s e ep a q e1 1 - 1 3 7 ) .
\-
11-10
Symptom
Difficultto refuel (MlL works OK. no DTCS set)
Fueloverflowsduring refueling (No DTCS set)
Diagnosticprocedure 1 . T e s t t h e f u e lt a n kv a p o rc o n t r o l a l v e { s e e p a g e ' l v 1 2. 1471. I n s p e ctth e f u e lt a n kv a p o rc o n t r o l i g n a lt u b e s 3. betweenthe fuel pipe and the fuel tank vapor control valve. 4. Inspectthe fuel tank vapor vent tube betweenthe EVAPcanisterand the fuel tank vapor control valve. Checkthe EVAPcanister. Replace fuel tank vapor control valve (seepage '1 the 1 189).
Also checktor
M a l f u n c t i o n i ng a s g s t a t i o n i l l i n gn o z z l e . f
Malfunctioning gas stationfilling nozzle.
11-11

SystemDescriptions
ElectronicControl System
The functionsof the fuel and emlssioncontrol systemsare managedby the enginecontrol module (ECM). Fail-safeFunction ignoresthat signaland assumesa pre-programmed When an abnormalityoccursin the signalfrom a sensor,the ECI\4 value for that sensorthat allowsthe enqineto continueto run. Back-up Function of When an abnormalityoccursin the ECM,the injectorsare controlledby a back-upcircuitindependent the systemto p e r m i tm i n i m a ld r i v i n g . Self-diagnosis When an abnormalityoccursin the signalfrom a sensor,the ECM suppliesground for the malfunctionindicatorlamp trouble code {DTC)in erasablememory.When the ignition is first turned on, the EClvl {MlL) and storesthe diagnostic for suppliesground to the l\4lL 15 to 20 secondsto checkthe M lL bulb condition. Two Driving Cycle Detection Method functions. the "two driving cycle detectionmethod" is usedfor some self-diagnostic To preventfalse indications, When an abnormalityoccurs,the ECM storesit in its memory. When the same abnormalityrecursafterthe ignition t s w i t c hi s t u r n e dO F Fa n d O N ( l l )a g a i n , h e E C Mt u r n so n t h e M l L .
\.
11-12
ECMData
You can retrievedata from the ECI\4 connectingthe OBD ll scantool or the Honda PGM Testerto the data link by connector(DLC). The items listedin the table below conform to SAE recommendedpractice. The HondaPGM Tester also readsdata beyondthat recommendedby SAEto help you find the causesof intermittentproblems. The "operatingvalues" listedare approximateand may vary dependingon the environmentand the individual vehicle. Unlessnoted otherwise,"at idle speed" means idling with the enginecompletelywarmed up in the neutralposition, and the A,/C and all Diagnostic Trouble Code (DTC} lf the ECM delectsa problem, it will store it as a code consistingof one letterand four numbers.Dependingon the problem,an SAE-defined code (Poxxx) a Honda, or definedcode {P1xxx)will be output to the tester. l f n o p r o b l e mi s detected, there is no ourpul. YES
TheECI\4 computes fromthe signals engine speed sent N e a r l y h e s a m ea s t position (CKP) fromthe crankshaft sensor. Thisdatais tachometerindication for used determining timeandamount injected the fuel. At idle speed; of
The ECMconvertspulsesignalsfrom the vehiclespeed sensor(VSS). Manifold Absolute Pressure (MAP) The absolutepressurecausedin the intakemanifold by e n g i n el o a da n d s p e e d . N e a r l y h e s a m ea s t speedometer indication
Withengine stopped:
YES
Nearlythe same as almospnencpressure. At idle speed:about 20 4'1kPa ( 1 5 0 3 1 0m m H g , 6 - 1 2 i n . H q ) . 0 . 71 . 3V The ECTsensorconvertscoolanttemperatureinto voltage W i t h c o l d e n g i n e : and signalsthe ECM.The sensor is a thermistorwhose S a m ea s a m b i e n t internalresistance changeswith coolanttempetature.The temperatureand IAT ECM usesthe voltagesignalsfrom the ECTsensorto With enginewarmed determinethe amount of injectedfuel. u p ; a b o u t1 1 6 2 ' 1 2 " F The A,/F sensordetectsthe oxygen content in the exhaust 0.0- 1.25 V g a s a n d s e n d sv o l t a g e i g n a l s o t h e E c l v l , a s e d o n t h e s e 8 . 0 1 1 . 0 m A ( P G M s t B signals,the ECMcontrolsthe airlfuel ratio.When the I Tester) oxygen contentis high (that is, when the ratio is leaner At idle speed: than the stoichiometric ratio),the voltagesignal is Iower. about 0.1 0.9 V When the oxygencontent is low (that is, when the ralio is richerthan the stoichiometric ratio).the voltagesignal is higher.The A'lFsensorsignalsare electrical currentthat are indicatedas voltaqe on the The HO2Sdetectsthe oxygen contentin the exhaustgas 0.0 1.25 V a n d s e n d sv o l t a g e i g n a l s o t h e E C M .B a s e d n t h e s e s t At idle speed: o signals,the ECMcontrolsthe airlfuel ratio.When the a b o u t0 . 1 0 . 9V oxygen contentis high (that is, when the ratio is leaner than the stoichiometric ratio),the voltagesignal is lower. When the oxygen content is low (that is, when the ratio is r i c h e r h a nt h e s t o i c h i o m e t r irc t i o ) t h e v o l t a g e i g n a li s t a , s
1 0 0 ' c ) . 0 . 5 - 0 .v 8
Air Fuel Ratio ( A y ' F )e n s o r . S (Sensor1)
Secondary Heated Oxygen Sensor (Secondary H02S, Sensor2)
NO
(cont'd)
11-13

(cont'd) SystemDescriptions
ECMData(cont'd)
Data FuelSystem Status Description "open" or "closed". Fuelsystem statusis indicatedas Sensoroutput,the ECM Closed:Basedon the A,/F determinesthe airlfuel ratio and controlsthe amount of injectedfuel. Sensoroutput,the ECM refersto Open: lgnoringAy'F signalsfrom the throttle position{TP),manifoldabsolute pressure(MAP),intakeair temperature(lAT),barometric pressure(BARO), and enginecoolanttemperature(ECT)) sensorsto controlthe amount of iniectedfuel. for The airlfuel ratio correctioncoefficient correctingthe Short Term amount of injectedfuel when the fuel system status FuelTrim is "closed." When the ratio is leanerthan the short term fuel sloichiometricratio,the ECM increases trim gradually,and the amount of iniectedfuel increases. The airlfuel ratio graduallygets richer,causinga lower the oxygen content in the exhaustgas. Consequently, short term fuel trim is lowered,and the ECM reducesthe amount of injectedfuel. This cvcle keepsthe airlfuelratio closeto the ratio when in closedloop status. stoichiometric Long term fuel trim is computedfrom short term fuel trim LongTerm changesoccurringin the fuel supply system and indicates F u eT r i m l long period. over a l f l o n gt e r m f u e lt r l m i s h i g h e rt h a n 1 . 0 0t,h e a m o u n lo f the lf injectedfuel must be increased. it is lower than 1.00, amount of injectedfuel must be reduced. The IAT sensorconvertsintakeair temperatureinto Intake Air a t Temperature v o l t a g ea n d s i g n a l s h e E C M .W h e n i n t a k e i r ofthe sensor temperatureis low, the internalresistance {IAT) increases, and the voltagesignal is higher. pedal position,the opening Basedon the accelerator Throttle throttlevalve is indicated. anole of the Position lgnitiontiming is the ignition advanceangle set by the lgnition ECM.The ECM matchesignitiontiming to driving Timing conditions. Opera'tingValue At idle speed:closed Freeze Data
r a
YES
o.7 1.5
YES
0.8 1.2
YES
w
W i t h c o l de n g i n e : S a m ea s a m b i e n t a t e m p e r a t u r e n dE C T At idle speed: a b o u t1 0% At idle speed:8" t 5" | ' t u L w n e nr n e > L ) s e r v i c e i g n a l i n ei s s jumped with the Honda PGM Tester At idle speed: 12 34% At 2.500rpm with no toao: 't4- 34%
YES
YES NO
Calculated L o a dV a l u e (cLV)
from IMAP data. cLV is the enoine load calculated
YES
\.,
11-14
J/-\ -1\_/
BEIAY2
A/C CLUTCHRELAY
I
)
RAOIATOR
T
UNDER.HOOD FUSE/RELAY BOX: (8oA) ONo. 19BATTERY (ECM) (15A1 ONo.6 ECU (3)No.20lG {40A1 {Canada:50A} ONo.l4 OPTION {40A1 uP )No.9 BACK (7.5A1 lo)No. HORN, 7 STOP {15A} UNDER.DASH FUSE/RELAY BOX: PUMP ONo. 17FUEL {15A} ,t ACG{10A) @No. (1sA) ONo.1 IGNCOIL q)No.10METER (7.5A) 0)No.14A/C CLUTCH RELAY IlOA) @No.2+B LAF(A/F) (2OA) HEATER
(cont'd)
11-15

(cont'dl SystemDescriptions
ECMElectrical Connections
\
MAPSENSON No. INJECTOR
No,2INJECTOR TPSENSOR
No.3 INJEC]OB
No./tINJECTOF
IATSENSOR
ECTSENSOB
\'
CMP SENSOR B (TDCSENSOSJ
CKPSENSOR
FVERSE LOCK SOLENOIDVAIVE
\-
11-16
A/FSENSOR
EVAPCANISTE6 PURGEVAIVE
EVAPCANISTER VENTSHUTVATVE
A/FSENSOR (sENSOn 1)
sotENotovAtvE
CMP SENSOFA
VIC OIL CONTROL SO!ENOIDVALVE No. 1 IGNITIONCOIL
wEcorl
N o . 2 l G N l l l O NC O I L
PRESSUSE SWTICH
No. 3 IGNITION COIL
VTEC SOLENOID
No. a IGNITIONCOIL
{cont'd)
11-17

ECMElectrical Connections
\
ARAKEPEDAL POStTtON SWTTCH
GAUGEASSEMBLY
IMMOBILPENUN|T
EPSCONTROT UNIT
TERMINALLOCATIONS
\-
11-18
ECMInputsand Outputsat Connector (31P) A
2 1 AFS]TC ]GP2 '10 SG2 22 t1
3 IGPl
^:^ I -:,
6 AFS+
1 CKP
I KS 18 1 9 2A V S S IVAP vcc2
12 ACV
15 T6 TPS AFS_ 26 25 CMPB CMPA(rDc)
vccl
21
23 HTC+ LG2
27 28 29 30 tGPts,lrcPts3 tGPts2GPLS 1
Wire side ol femaleterminals NOTE: Standardbatteryvoltageis 12V. Terminal Who color numbr ELKAVHT forminal name (AIR AFSHTC FUEL RATIO (4./F)SENSOR HEATER CONTROL} (POWEB IGP2 SOURCE) IGPl {POWER SOURCE) Description DrivesAy'F sensorheater Power source the ECM for circuit Power source the ECM for Ground forthe ECMcircuit Ground forthe ECMcircuit Detects sensor Ay'F 1) {sensor signal Detects CKP sensor signal Detects knock sensor siqnal qrounr Sensor qroun( Sensor DrivesIACvalve Detects sensor TP signal Detects sensor !y'F ( s e n s o r) s i g n a l 1 Detects VSSsignal Wath ignition switch (lli andfrontwheels ON rotating: cycles from about0 V to about5 V or Signal Withignit'on switch {ll):battery ON voltage Withfullywarmedup engine runnang:V 0 Withthe ignition switchON 1ll): battery voltage Withthe ionition switchOFF: about0 V Withthe ignition swatch {ll):battery ON voltage Withthe ionition switchOFF: about0 V Less than 1.0V at all times Less than 1.0V at all times
2
3 4 5 6 1 9 10 12
YEUBLK
YEUBLK BLK
18
PG2(POWER GROUND PG1(POWER GROUND AFS+ (AIR FUEL RATIO (A,/F}SENSOR, SENSOR 1 + stDE) 8LU CKP(CRANKSHAFT POSITION SENSOR) BED/BLU ) KS E N S O B ) YEL 2 {SENSOR R O U N D ) ; G 1{ S E N S O R O U N D ) ;R BLIVRED IACV(IDLE CONTROL AIR (IAC)VALVE) RED/BLK TPS(THROTTLE POSITION SENSOR) REDI/EL AFS (AIR FUEL RATIO (4,/F)SENSOR, SENSOB 1 SIDE) WHT/GRN V S S ( V E H I C L E P E E D S
BLK RED
pulses Withengine running: pulses Withenqine knocking: Lessthan 1.0Vat elltimes L e s s t h a 1 . 0 Va t a l l t i m e s n Withengine runningr dutycontrolled Withthrottle fullyopen:about4.8V Withthronle fullvclosed: ahout0-5V
SENSOR)
(cont'd)
11-19

SystemDescriptions {cont'd)
A ECMInputsand Outputsat Connector (31P)
\. il
1 AFS]TC
2 GP2
3 IGPl
4 PG2
12 10 11 SG2 sG1 IACV

22 23 AFS LG2 HTC+
5 6 PG.1 AFS+ '15 1 6 TPS AFS_
1 CKP
I KS
18 1 9 20 V S S IVAP vcc2
vccl
21
26 25 CMPB Ct\.4PA (rDc)
29 30 27 28 IGPLS,I IGPLS4 IGPLS3 IGPLS2
Wire side of femaleterminals voltage 12V. is NOTE: Standard battery [rminal namo Description Jorminal Wirecolor number MAPsensor 19 Detects signal GRN/RED MAP(MANIFOLD PRESSURE ABSOLUTE SENSOR) (SENSOR YEUBLU VCC2 VOLTAGE) P r o v i d e ss e n s o r v o l t a g e 20
Signal With ignitionswitchON (ll):about3 V A t i d l e : a b o u t 1 . 0V ( d e p e n d i n go n e n g i n e s p e e d )
21
22 23 24 25 26
voltage YEURED VCC](SENSOB VOLTAGE) Provides sensor a,/F AFSHTC (AIRFUEL Detects sensorheater (A"iFiSENSOR RATIO voltage + HEATER CONTROL SIDE) BRN?ryE L LG2(LOGIC GROUND roundfor the ECMcircu 1(L roundfor the ECMcircu BRN?ryE L D e t e c t sC M P s e n s o r A BLU,^/VHT CMPA (CAMSHAFT A) stonal POSITION SENSOR Detects 8 GRN CMPB CAMSHAFT CMPsensor (TDc (CMP)SENSOB sensor) POSITION (TOP B (TDC DEAD CENTER SENSORi) I G P L S 4 N o .4 I G N I T I O N DrivesNo, 4 ignitioncoi BRN { WHT/BLU
COILPULSE) I G P L S 3N o . 3 I G N I T I O N { COILPULSE) O r i v e s N o . 3 r g n i t i o nc o i DrivesNo.2 ignitioncoil
With ignition switch {ll):about5 V ON Withionition switch OFF: about0V Withignition switch {ll):about5 V ON With ionition switch OFF: about0V
W i t h i g n ; t i o ns w i t c h O N l l l ) : b a n e r y v o l t a g e
\.
1.0 Lessthan V at alltimes
L e s st h a n '1.0 V at alltimes
pulses Withengine running: pulses Withengine running:
27 28 29
Withignition switch (ll)r ON about0 v pulses running: Withengine
30
IG BLU/RED l G P L S 2 l N o . 2 N I T I O N COIL PTJLSE) (No.1 IGNITION YEUGRN IGPLSI co PlltsF)
Drives No. I ignition coil
\.
11-20
Wire side o{ femaleterminals
NOTE: Standardbafteryvoltageis 12V. Terminal numot 2 3 4 5 6 7 8 9 Wire color [erminal name Description Signal 0 switch (ll): V ON Withignition At idle:dutycontrolled
VTCoilcontrol BLUAvHT VTC+ lVTCOILCONTBOL Drives VALVE +SIDE) SOLENOID lNJa{No.4INJECTOR) Jo.3INJECTORI BL )TOR) R1 lNJl 1No. INJECTOR) I BRN (RAOIATOR FAN FANC GRN CONTROL) LOCK GRN/vVHT RVS(REVERSE VALVE) SOLENOID Drives o. 4 iniector Drives o.3 iniector Drives o . 2 i n i e c t o r No. 1 iniector Drives Drivesradiatorfan relay
10
fan about0 V With radiator running: With radiatorfan stopped:battervvoltaoe speed below9.4mph (15km/h): Drivesreverselocksolenoid Withvehicle batteryvoltage mph (20km/h): V 0 above12.5 Withvehicle speed (ENGINE switch (ll):about0.1 4.8V ON Withthe ignition ECTsensorsignal Detects COOLANT REDAVHT ECT temDerature) ideoendino enoine on coolant TFMPFRATURE SENSOR) speed: about0 . at VTEc pressure Withengine low engine oil Detects OIL BLU/BLK VTPSW(VTEC voltaqe batterv Wirhenoine hiohenoine at soeed: PRFSSTIRF SWITCH) switch sional about0 V swit'ch (ll): ON L L Detects alternator signal With ignition WHT/BLU ALTL(ALTEBNATOR voltaqe Whh enoine runnino: batterv SIGNAI I running: about0 V- 5 V alternator signal Withengine FB FR Detecls WHT/RED ALTF(ALTERNATOR load) on SIG ALI N {deoendinq electrical valve A t i d l e : a b o u t 0 V Drives VIECsolenoid SOLENOID GRN/YEL VTS {VTEC ON With ignition switch {ll):about0.1V 4.8v l.lcnen.iino intake temoerature) on air running: about0 V 5 V Withengine control Sends alternator (.lcocn.lino electrical on ioad) coolant below149'F purge Withengine running, engine Drives EVAPcanister voltage battery valve 165'C): coolant above149'F running, engine Withengine 165"C): controlled dutv W i t h t h e i g n i t i o n s w i t c h O N ( l l ) :0 V VTCoilcontrol OIL BLK/Vr'HT VTC (VTC CONTROL Drives SOIFNOID VALVE SIDE)
'17
18 21
IAT(INTAKE AIR TEMPERATURE SENSOR) WHT/GRN ALTC(ALTERNATOR CONTROL) YEUBLU PCS{EVAPORATIVE EMISSION CANISTER PURGE VALVE)
REDI/EL
IAT signal Detects sensor
23
(confd)
11-21

ECMlnputsand Outputsat Connector (31P} E
1 iMo FPR
sr-{]zsLG3
4 SG3
22 23 24 BKSW K-LINE SEFMJ
6 1 $1025 MRLY HTC 16 14 15 18 FTP ELD EPS ACC LD 21 26 rMo NEP CD
8 AFS HTCR
20 21 Z/VBS VSV
scs
29
30 31 WEN MIL
Wire side of femaleterminals NOTE: Standardbatteryvoltageis '12 V. Terminal Wire color number GRNI/EL 2 ferminal name Description Signal 0Vfor2 seconds afterturningignition switchON {ll).then battervvoltaoe Withthrottle Jully opened from idlewith fully warmedup engine: above 0.6V quickly Withthrottle closed: below0.4V Less than1.0V at all times Less than 1.0V at all times With ignition switch (ll):about5 V ON With ionition switch OFF: about0 V With ignitionswitch ON (ll):bafteryvoltage Wilh fullvwarmedup engine running: dul, controlled Withignition switch (ll): ON about0 V With ignitionswitchOFF:batteryvoltage Withignition swirch {ll):0 V ON
With ignition switch ON (ll): battery voltage With iqnition switch OFF: about 0 V
3 4 5 6
(IMMOBILIZER D r i v e s P G M F l m a i n r e l a y 2 IMOFPR FLJEL PUMP RELAYI (SECONDARY WHT/RED SHO2S Detectssecondary HO2S HEATED OXYGEN SENSOR {sensor signal 2) (SECONDARY HO2S), SENSOR 2r BRN/YEL LG3(LOGIC GROUND) cround forthe ECM/PCM controlcircuit PNK SG3{SENSOR GBOUND) Sensor oround YEUELU VCC3 VOLTAGE) Provides {SENSOR sensorvoltage (SECONDARY Drives BLKATr'HT SO25HTC secondary HO2S HEATED OXYGEN SENSOR heater (SECONDARY H02S) HEATER CONTROL) REDA/EL MRLY(PGM.FI MAIN Drives PGM-Flmain relay1 RELAY} Powersourceforthe DTC ORN AFSHTCR FUEL BATIO Drives fuel ratiosensor {AIR air (Iy'F)SENSOR HEATER heaterrelay CONTROL RELAY)
IGl (IGNITION IGNAL) S D e t e c r si g n i t i o n s i g n a l
1
I
YEUBLK
LT GRN
't4
FIP lFUEL TANK (FTP) PRESSURE SENSOR) GRN/RED ELD(ELECTRICAL LOAD DETECTOF) (ELECIRICAL LTGRN/8LK EPSLD POWEB STEEBING LOAD DETECT) RED
Withignition switch (ll)andfuelfill capopen: ON about2.5V Detects signal ELD Withignition swjtch itt):aOoutO.t l-gV ON V (deDendino electrical on load) DetectsPowersteeringload At idlewith steering wheelin straight ahead srgnal position: about V 0 At idlewith steering wheelatfulllock: momentary Detects sensor FTP signal Withcompressor about0 V ON: With comoressor OFF: battervvoltaoe
'18
ACC(Ay'C CLUTCH RELAY) DrivesP,/C clutch relay
\-
11-22
E ECMInputsand Outputsat Connector (31P)
2 t M o $.c2s FPR
6 1 SFIO2S IVRLY HTC

14 FTP
I AFS HTCR t8
9 tGl
15 ELD 26 NEP
16 EPS LD
21 20 2,4/BS VSV
22 23 24 K BKSW LINESEFMJ
21 lvo CD
scs
29
30 31 WEN MIL
is NOTE: Standard battery voltage 12V. Terminal Wire color 20 21 Terminalname Description Signal voltage Withignition switch (ll):baftery ON
W i t h i g n i l i o n s w i t c h O N ( l l ) :b a t t e r y v o l t a g e
22 23
Drives EVAP bypass (EVAP)BYPASSsolenoid valve EMISSION SOLENOID VALVE) vent Drives EVAP canister LT GRN/RED VSV (EVAPORATIVE shutvalve EI\4ISSION iEVAP) VENT SHUT CANISTEB VALVE) PEDAL Detects brake pedal WHT/BLK BKSW lBRAKE POSITION SWITCH) o o s i t i o ns w i t c h s i o n a l scan LT BLU K-LIN E Sends and receives YEL
SEFMJ C o m m u n i c a t e sw i t h mrltinleYeontrolunit
BLU/RED 2WBS(EVAPORATIVE
pedalreleased: With brake about0 V

With hrake nedal nresse.l: batterv voltaoe
pulses battery or With ignition switch (li)r ON
26 21 29 30
( E N E P E N G I NS P E E D PULSE) RED/BLU \40CDfl\4MOBTLTZER CODE) BRN SCS(SERVICE HECK C
BLU
With ignition switch (ll):about5 V ON Withenoine runnino underload:DUlses pulses pulse Withengine running: Outputs engine speed
D e t e c t si m r n o b i l i z e rs i g n a l
with the PGM check signal shorted O e t e c t ss e r v i c ec h e c k s i g n a l Withthe service Tester: about0 V Wiih rheservice check sional ooened: about5 V
D e t e c t sw r i t e e n a b l e s i g n a l W i t h i g n i t i o n s w i t c h O N ( l l ) :a b o u t 0 V
SIGNAL)
ENABLE RED,A/VHT WEN(WRITE SIGNALi GRN/ORN MIL(MALFUNCTION LAMP) INDICATOR
Drives N4lL
WithMILturnedON:about0 V voltaqe WithMILturnedOFF: batterv
(cont'd)
11-23

VacuumHoseRouting
INTAKEAIR BYPASSCONTROL THERMALVALVE
\*
FRONTOF VEHICLE EVAPORATIVE EMISSION {EVAP}CANISTERPURGEVALVE
\,
11-24
VacuumHoseRouting
1} RATIO SENSOR {SENSOR IA/F) O AIRFUEL HEATED OXYGEN SENSOR O SECONDARY 2} HO2S} {SENSOR ISECONDARY (MAPISENSOR PRESSURE ABSOLUTE O MANIFOLD SENSOR TEMPERATURE COOLANT {ECT) O ENGINE (IAT) AIR O INTAKE TEMPERATURE SENSOR (CKP) SENSOR POSITION O CRANKSHAFT SENSOR O KNOCK (CMPI B POSITION SENSOR O CAMSHAFT SENSOR) CENTER DEAD ITDC) ITOP A SENSOR POSITION O CAMSHAFT ICMPI (IACI VALVE AIR @ IDLE CONTROL BODY O THRONLE .OINJECTOR PULSATION OAMPER @ FUEL FILTER [I FUEL PRESSURE REGULATOR @ FUEL PUMP @ FUEL TANK @ FUEL
@ RESONATOR (9 AIRCLEANER VENTILATION CRANKCASE {PCVIVALVE @ POSITIVE CONVERTER WAYCATALYTIC @ THREE EMISSION CANISTER {EVAPI @ EVAPORATIVE CANISTER EMISSION {EVAP) @ EVAPORATIVE PURGE VALVE (EVAPI CANISTER EMISSION {} EVAPORATIVE VALVE VENTSHUT TWOWAYVALVE EMISSION {EVAP) {' EVAPORATIVE BYPASS EMISSION IEVAPI @ EVAPORATIVE VALVE SOLENOID (FTP) TANKPRESSURE SENSOR @ FUEL VALVE EMISSION IEVAP} @ EVAPORATIVE VALVE CONTROL TANKVAPOR @ FUEL VALVE TANKVAPOR RECIRCULATION FUEL 60) VALVE THERMAL AIR CONTROL O INTAKE BYPASS
(cont'd)
11-25

PGM-FI System
The ProgrammedFuel Injection(PGM-Fl) system is a sequentialmultiport fuel injectionsystem. Air Conditioning {A/C) Compressor Glutch Relay When the ECfM receives demandfor coolingfrom the a Ay'C system,it delaysthe compressorfrom being energized, and enrichesthe mixture to assuresmooth transitionto the AVC mode. Air Fuel Ratio lA/Fl Sensor The Ay'F Sensoroperatesover a wide airlfuel range.The Ay'F Sensoris installedupstreamof the TWC, and sends signalsto the ECMwhich variesthe durationof fuel injectionaccordingly.
SENSOR TERMINALS
Camshaft Position(CMPI SensorB (TopDeadCenter (TDCI Sensor) TheCMP sensor (TDC B sensor) detects position the of the No.1 cylinder a reference sequential as for fuel injection each to cylinder.
MAGNET
ztRcoNta ELEMENT
Crankshaft Position (CKPISensor The CKPsensordetectscrankshaft soeedand determinesignitiontiming and timing for fuel injection of each cylinderas well as detectingengine misfire.
HEATER
HEATER TERMINALS
Barometric Pressure {BAROI Sensor The BAROsensoris insidethe ECM.lt convens atmosphericpressureinto a voltagesignalthat the ECM usesto modify the basicdurationof the fuel injection discharge.
Engine Coolant Temperature (ECT)Sensor The ECTsensoris a temperaturedependentresistor (thermistor). The resistance the thermistordecreases of as the enginecoolanttemperatureincreases.
TERMINAL
\,
11-26
lgnition Timing Control The ECMcontainsthe memory for basicignitiontiming at variousengine speedsand manifold absolute pressure. also adjuststhe timing accordingto engine lt coolanttemperature. Iniector Timing and Duration The ECM containsthe memory for basicdischarge e a d u r a t i o n t v a r i o u s n g i n es p e e d s n d m a n i f o l d a pressures. The basicdischargeduration,after being read out from the memory, is further modified by signalssent from varioussensorsto obtain the final discharge uration. d By monitoring long term fuel trim, the ECMdetectslong in term malfunctions the fuel systemand sets a Trouble Code{DTC). Diagnostic Intake Air Temperature (lAT) Sensor The IAT sensoris a temperaturedependentresistor The resistance the thermistor decreases of {thermistor). increases. as the intakeair temDerature
MalfunctionIndicatorLamp lMlLl Indication{ln relation to ReadinessCodes) "readinesscodes" that are part The vehiclehas certain for of the on-boarddiagnostics the emissionssystems. or lf the vehicle'sbafteryhas been disconnected gone have been cleared,or if the ECM has dead.if the DTCS been reset.these codesare set to incomplete.In some states,part of the emissionstesting is to make sure lf these codes are set to comDlete. all of them are not set to complete,the vehiclemay fail the test and the test cannot be finished. codes are set to complete, To checkif the readiness turn the ignition switch ON (ll). but do not startthe l e n g i n e . T h e M I L w clo m e o n f o r l S 2 0 s e c o n d sf. i t i l codesare set to complete, then goes off, the readiness codes lf it blinksseveraltimes,one or more readiness are not set to comolete.To set each code, drive the i v e h i c l e r r u n t h e e n g i n ea s d e s c r i b e dn t h e o procedures set them in this section(seepage 11-46). to Manifold Absolute Pressure {MAP) Senso] The MAP sensorconvertsmanifoldabsolutepressure s t i n t oe l e c t r i c a li g n a l s o t h e E C M . SENSOR UNIT
Knock Sensor The knockcontrol system adjuststhe ignitiontiming to minimizeknock.
PIEZO CERAMIC
(cont'd)
11-27

Secondary Heated Oxygen Sensor (Secondary HO2S) The secondaryHO2Sdetectsthe oxygen content in the exhaustgas downstreamof the three way catalytic converter(TWC)and sendssignalsto the ECMwhich checksthe efficiencyof the TWC.To stabilizeits output, the sensorhas an internalheater.The secondarvHO2S i s i n s t a l l e dn t h e T W C . i Vehicle Speed Sensor (VSS) The VSS is driven by the differential. generates lt a pulsedsignalfrom an input of 5 volts.The number of pulsesper minute increases/decreases the speed with of the vehicle.
BEARING
ztRcoNta ELEMENT
SENSOR TERMINALS
HEATER TERMINALS
Starting Control When the engine is started,the ECM providesa rich mixture by increasinginjectorduration.
(
Throttle Position ITP)Sensor The TP sensoris a potentiometer connected the to throttlevalve shaft.As the throttle positionchanges, the sensorvariesthe signalvoltageto the ECM.The TP sensoris not replaceable apart from the throftle body.
ELEMENT
BRUSH HOLDER
gRUSH
11-28
wEc/wc
The i-WEC has a VTC (Variable ValveTiming Control)mechanismon the intakecamshaftin additionto the usual VTEC. This mechanismimprovesfuel efficiencyand reducesexhaustemissionsat all Ievelsof engine speed,vehiclespeed. a n d e n g i n el o a d . The VTECmechanismchangesthe valve lift and timing by using more than one cam profile. lt The VTCchangesthe phaseof the intakecamshaftvia oil pressure. changesthe intakevalve timing continuously.
HIGH
LOW<DrivinoCondition Qr Light-load VTC Control B a s eP o s i t i o n
ENGINE SPEED
?l M edium/high-load
AdvanceControl
) High speed
Advance-Base Position
DescriDtion Cam angle is retardedto reducethe entry of exhaust gas into the intakeport and to achievestablefuel c o n s u m D t i o d u r i n ql e a nb ur n . n Cam angle is advancedfor EGReffectand to reduce this pumping loss.The intakevalve is closedquickly to help reducethe entry of airlfuel mixture into the intakeport and improve the chargingeffect. f C a m p h a s ea n g l ei s c o n t r o l l e do r o p t i m u mv a l v e t i m i n qa n d m a x i m u me n o i n eo o w e r .
{cont'd)
11-29

VTC system . The VTC system makescontinuousintakevalvetiming changesbasedon operatingconditions. . Intakevalve timing is optimizedto allow the engineto producemaximum power. 'CamangleisadvancedtoobtaintheEGReffectandreducethepumpingloss.Theintakevalveisclosedquicklyto reducethe entry of the airlfuel mixture into the intakeport and improvethe chargingeffect. . Cam angle is reducedat idle to stabilize combustionand reducesenginespeed. ' l f a m a l f u n c t i o n o c c u r s , t h e V T C s y s t e m c o n t r io l d i s a b l e d n dt h e v a l v et i m i n g i s f i x e da t t h e f u l l y r e t a r d e d o s i t i o n . s a p TDC MAXIMUM VTCADVANCE 50'
MAXIMUM VTC ADVANCE50'
i '+-|l
l(-4
sHoRT oVERLAP LoNG oVERLAP
VTEC system ' The VTECsystemchangesthe cam profileto correspond enginespeed.lt maximizes to torque at low enginespeed and output at high engine speed. . The low lift cam is used at low engine speeds,and the high lift cam is used at high enginespeeds.
LOWSPEED VALVETIMING
HIGHSPEED VALVETIMING
11-30
System Diagram
CMPSENSOR A From No. il ACC{10A)fuse
INTAKE
CAMSHAFT
BRN/YEL
-:-
BLU/WHT BLU/WHT BLK/WHT GRN/YEL BLU/BLK VARIOUS SENSORS
BLK
I t
:5i.T,""
Camshaft Position {CMP}Sensor The CMP sensordetectscamshaftangle positionfor the VTC system.
{cont'd}
11-31

ldle Control System
When the engine is cold, the Ay'C compressoris on, the transmissionis in gear,the brakepedal is pressed. the power steeringload is high, or the alternatoris charging,the ECIM controlscurrentto the ldle Air Control(lAC)valveto maintainthe correctidle speed. Referto the System Diagramto seethe functional layout of the system. Brake Pedal Position Switch The brakepedal positionswitch signalsthe ECMwhen the brakepedal is oressed. Electrical Power Steering (EPS)Senser The EPSsensorsignalsthe ECMwhen the power s t e e r i n go a di s h i g h . l ldle Air Control llACl Valve To maintainthe proper idle speed,the IACvalve changesthe amount of air bypassingthe throttle body in responseto an electrical signalfrom the ECM.
From AIR CLEANER To INTAKE MANIFOLD
FuelSupply System
Fuel Cut-off Control Duringdeceleration with the throttle valve closed, currentto the injectorsis cut off to improve fuel economy at enginespeedsover 1,030rpm. Fuelcut-off actionalso occurswhen enginespeedexceeds 6,900rpm, regardless the positionof the throttle of valve,to protectthe enginefrom over-rewing. When the vehicleis stopped.the ECMcuts the fuel at engine speedsover 6,500rpm. Fuel Pump Control When the ignition is turned on, the ECMgroundsthe PGM-Flmain relay which feeds currentto the fuel pump for 2 secondsto pressurize fuel system,With the the e n g i n er u n n i n gt.h e E C Mg r o u n d s h e P G M - Fm a i n t l relay and feeds currentto the fuel pump. When the engine is not running and the ignition is on, the ECI\4 cuts ground to the PGM-Flmain relaywhich cuts currentto the fuel pump. PGM-FIMain Relay1 and 2 The PGM-Flmain relay consistsof two separaterelays. Relay1 is energized wheneverthe ignition switch is ON (ll)to supply batteryvoltageto the ECM power to the injectors, and power for relay,Relay2 is energized to supply power to the fuel pump for 2 secondswhen the i g n i t i o n w i t c hi s t u r n e dO N ( l l ) ,a n d w h e n t h e e n g i n ei s s runnrng.
IAC VALVE
11-32
IntakeAir System
Referto the SystemDiagramto seethe functional layout of the system. Intake Air Bypass Control Thermal Valve W h e nt h e e n g i n ei s r u n n i n g t h e i n t a k e i r b y p a s s , a controlthermal valve sendsair to the iniectors,
Throttle Body The throttle body is a single-barrel side draft type. lt housesthe TP senserand the IACvalve.The lower portion of the IAC valve is heatedby enginecoolant fromthecylinder ead. h
IACVALVE
INJECTOR
{cont'd)
11-33

GatalyticConverterSystem
ThreeWay CatalyticConverter(TWC) (HC), TheTWCconverts hydrocarbons carbon (NOx) the monoxide and of {CO), oxides nitrogen in (C02), gas (N2), exhaust to carbon dioxide dinitrogen andwatervaDor. {
PositiveCrankcase Ventilation (PCVISystem

The PCVvalve preventsblow-by gassesfrom escaping into the atmosphereby ventingthem into the intake manifold.
BREATHER PIPE
THREE WAY CATALYST
FRONTOF VEHICLE
:: :
BLOW-BY VAPOR FRESH AIR
11-34
(EVAPI Evaporative Emission Control System

Referto the SystemDiagramto see the functional layout of the system. EVAPCanister The EVAPcanistertemporarilystoresfuel vapor from the fuel tank until it can be purged back into the engine a n db u r n e d . EVAP Canister Purge Valve When the enginecoolanttemperatu is below 149'F re (65'C),the ECMturns off the EVAPcanisterpurge valve which cuts vacuum to the EVAPcanister. FuelTank Pressure (FTP)Sensor The FTPsensorconvertsfueltank absolutepressure into an electricalinputto the ECMduring the EVAPleak cnecK. SENSOR UNIT
EVAP Two Way Valve and EVAP Eyp8s Solenoid Valve The EVAPtwo way valve is installedbetweenthe fuel tank and the EVAPcanisterline. The EVAPtwo way valve sendsfuel vapor to the EVAP canistercorresponding the pressureinsidethe tuel to tank. lt also relievesexcessvacuum in the tank by allowingfresh air to be drawn into the tank through the EVAPcanister. The EVAPbypasssolenoidvalve opensto bypassthe two way valve during the EVAPleakcheck.
EVAP BYPASS SOLENOID VALVE
VALVE
To FUELTANK
(cont'd)
11-35

ldle Control System Diagram
The idle speedof the engine is controlledby the ldle Air Control(lAC)varve: 'Aftertheenginestarts,theIACvalveopensforacertainamountoftime.Theamountofairisincreasedtoraisethe i d l es D e e d . . When the engine coolanttemperatureis low, the IACvalve is openedto obtain the properfast idle speed.The amount of bypassedair is controlledin relationto enginecoolanttemperature.
INTAKE MANIFOLD
IACVALVE
AKEAIR DUCT
CLEANER
YEL/BLK ---< BLK/ REO
From PGM.FI MAIN RELAY
THROTTLE AODY
VARIOUS SENSOnS
BLK
IntakeAir SystemDiagram
This systemsuppliesair for engine needs.A resonatorin the intakeair pipe providesadditionalsilencingas air is drawn into the svstem.
THROTTLE AODY
VARIOUS SENSORS
BLK
11-36
(EVAPI Evaporative Emission ControlDiagram

The EVAPcontrolsminimizethe amount of fuel vapor escaping the atmosphere. to Vapor from the fuel tanKrs temporarilystoredin the EVAPcanisteruntil it can be purgedfrom the canisterinto the engine and burneo.
. The EVAPcanisteris purged by drawing fresh air through it and into a port on the intakemanifold. The purgingvacuum is controlledby the EVAPcanisterpurge valve,which operateswheneverengine cootant temperatureis above 149'F(65"C). 'WhenvaporpressureinthefueltankishigherthanthesetvalueoftheEVAPtwowayvalve,thevalveopensan regulates flow of fuel vapor to the EVAPcanister. the ' D u r i n g r e f u e l i n g , t h e f u e l t a n k v a p o r c o n t rv a l v eo p e n sw i t h t h e p r e s s u r en t h e f u e lt a n k ,a n d f e e d st h e f u e lv a D o r ol i to the EVAPcanister.
FUEL TANK VAPOR RECIRCULATION VALVE
FUEL TANK VAPOR SIGNAL TUBE BLU/RED
BLK
FUELFILLCAP
FUELTANK VAPOR RECIRCULATION TUBE
FUELTANK
EVAP + CANISTER VENTSHUT VALVE From BLK/YEL --<No. 4 Acc
A {10 }fuse
EVAP CANISTER EVAPTWOWAY VALVE
(cont'd)
11-37

ECM Circuit Diagram
I
mrrrrn
CONNECTOi
B CMP SENSOR (TDCSENSOn)
I-BRN/YEr-
\,
11-38
wEc solENorD
_YEL/aLU -RED/aLK |-GFN/YEL
__f -----l _l
+
I
Y
I
F=-1 Hi I t_r I I?SCNSOn
L!l
I
croz
ff:l_l *'*"_-ll-t
-KnocK lSENSOn
l
I
-l-
Ll]
wcoLcoNTnoL
SoLENO|OVAIVE
(cont'd)
11-39

ECMCircuitDiagram{cont'd) \
---1t-|
-{ffi]
IATSENSOR
-{Ell -----ECTSENSOS
T_""",,..
I-BFN/YEL
CMPSENSOAA
L-
IJUNCTION I CONNECTOR
ft^--l
,","., J | t- : '
I +
I I REVERSE LocK
soleloto vaLvE
t!j]]
11-40
_1ffi1
-'----1 | | Fahdl
G8N
'--rBLU/
'8r-K-L-|
l -r l
l
J.L9l
HcoNNEcroR
-l .lurcrroru
EVAPCANISTEB
ALK/YEL WHT/ALU WHT/NED

WHI/GRN
JUNCTION CONNECTOR
rrrn
tcM
No.2IGNITION Olt C
PLUG
PLUG No.3IGNITION COIL
(cont'd)
11-41

ECMCircuitDiagramlcont'dl
YEI/BLK
IGP2
VET/BLK
---rF-rl -lF-forl --JliD\l

--t-l
MAIN BETAV2
t_,",
tr
:t r, l-,r'l
-,uI SENSOS
f-"'*'o""
IMMOAIL|zER UNIT
a
11-42
SECONDAFY H02S (sNsoR2l
TPSNSOR
m tlil
'--{=l
-{r
CANISTER VEAIT SHUTVALVE
--lti l
solENorD
EVAP EYPASS ToPS CONTROLUNIT
t-_]
CPU
GAUGE ASSEMBTY
(cont'd)
11-43

(cont'd) ECM Circuit Diagram
UNDER.HOOD FUSE/RELAY9OX CONNCTOF
CONNECTOi
WHI/NED BLK/YET
lalLREllY _l _
a
11-44
CONNECTOR E
""rr"a*J
r''lHr/cnN 1
CONNECTOi K
IGNITIONSWITCH lG2
' I
CONNECTOFJ /GRN
TEST TACHOMETER CONNECTO8
UNDER.HOOD
UNDER.DASH FUSE/FELAYBOX
UNDER.DASH FUSE/RELAY BOX: 4 ACG (1oAt 1 tGN CO|Lt15A) 2 A/F HEATER{2OA) 17 FUELPUMPI15A} 1OMETER {7.5AI 14 A/C CLUTCH RELAY{1OA}
POStTtON SWTTCH
,or"-9J3{51 "_.rl re* _{F

Brake pedal pressed: closed Brake pedal releasedropen
11-45

How to Set Readiness Codes
Lamp(MlL)Indication Malfunction lndicator (ln relationto Readiness Codesl
The vehiclehas certain"readinesscodes" that are part for of the on-boarddiagnostics the emissionssystems. lf the vehicle'sbatteryhas beendisconnected gone or have beencleared,or if the ECM has dead,if the DTCS been reset,these codesare set to incomplete.In some states,part of the emissiontesting is to make sure these codesare set to complete.lf all of them are not set to complete,the vehiclemay fail the emissiontest, or the test cannot be finished. To checkifthe readiness codesare complete,turn the ignitionswitch ON (ll), but do not startthe engine.The MIL will come on for 15 20 seconds.lf it then goes off, the readiness codesare complete.lf it blinksseveral codes are not complete. times, one or more readiness To set readlness codesfrom incompleteto complete. code. do the procedurefor the appropriate
L
Catalytic Converter Monitorand Readiness Code
NOTE: . Do not turn the ignition switch off during the procedure. . All readiness codes are clearedwhen the batteryis disconnected when the ECM is clearedwith the or OBD ll scantool or HondaPGlvlTester. . Low ambienttemperatures excessive or slop-and-go traffic may increase the drive time neededto switch the readiness code from incompleteto complete. ' The readiness code will not switchto com Dleteuntil a l lt h e e n a b l e r i t e r i a r em e t . c a . lf a fault in the secondaryHO2Ssystemcausedthe MIL to come on. the readiness code cannot be set to comDleteuntil vou correctthe fault.
Enable Criteria
. E C Ta t 1 5 8 " F 7 0 ' C ) r h i g h e r . ( o . I n t a k e i r t e m p e r a t u r el A T )a t 2 0 " F( - 7 ' C ) o r h i g h e r . ( a . Vehiclespeed is steady,and vehiclespeedsensor ( V S S ) e a d sm o r et h e n 2 5 m p h ( 1 3 k m / h ) . r
Procedure
1 . C o n n e ctth e s c a nt o o l t o t h e v e h i c l e ' s a t al i n k d , c o n n e c t o( D L C i a n d b r i n gu p t h e t o o l ' sg e n e r i c r O B Dl l m o d e . \ \"
2 . Startthe engine.
the conditions 3 . Test-drive vehicleunder stop-and-go with short periodsof steadycruise.After about 5 miles (3 km),the readiness code should switch from incompleteto complete. lf the readiness check code is still set to incomplete, for a temporary DTC.lf there is no DTC,one or more of the enablecrlteriawere probablynot met;
11-46
Evaporative Emissions(EVAP) Control SystemMonitor and Readiness code

NOTE:
All readiness code are clearedwhen the batterVis disconnected when the ECM is clearedwith the or OBD ll scantool or HondaPGM Tester. The enablecriteriamust be repeatedif the intakeair temperature(lAT)drops lower than 36'F (20"C) from i t s v a l u ea t e n g i n e a n u p . $
Air FuelRatio(A/FlSensorMonitorand Readiness Code

NOTE: . Do not turn the ignitionswitch off during the orocedure. . All readiness codesare clearedwhen the bafteryis disconnected when the ECM is clearedwith the or OBD ll scantool or Honda PGM Tester.
Enable Criteria
At enginestart up, ECTand IAT are higherthan 32'F (0"C), but lower than 95'F (35"C). At enginestart up, the ECTand IAT are within 12'F (7'C)of each other.
Enable Criteria
ECTat 140'F(60"C) higher. or
Procedure
1. Connectthe scantoolto the vehicle'sdata link connector(DLC), and bring up the tool's generic O B Dl l m o d e . 2. Start the engine. 3. Test-drive vehicle under stop-and-go the conditions with short periodsof steadycruise.Duringthe (wirh the throttlefully closed)for drive, decelerate 5 seconds. After about 3.5 miles (2.2km).the readiness code should switch from incomDlete to complete. 4 . l f t h e r e a d i n e s s c o d e i s s t isle tt o i n c o m p l e t e ,h e c k l c for a temporary DTC.lfthere is no DTC,the enable criteriawas probablynot meU repeatthe procedure.
Procedure
1. Connect the scantool to the vehicle'sdata link connector(DLC), and bring up the tool's generic O B Dl l m o d e . 2. Startthe engine. 3. Test-drive vehicleunder stop-and-go the conditions with short periodsof steadycruise.After about 2 . 5m i l e s( 1 . 6k m ) ,t h e r e a d i n e sc o d es h o u l d s switchf rom incompleteto complete. 4. lf the readinesscode isstill setto incomplete, check for a temporaryDTC.lf there is no DTC,one or more of the enablecriteriawere probably not met; repeatthe procedure.
Air/FuelRatio(A/FlSensorHeater Monitor Readiness Code

NOTE;All readiness codes are clearedwhen the battery is disconnected when the ECM is clearedwith the or OBD ll scantool or HondaPGM Tester,
Procedure
'1. Connectthe scantool to the vehicle'sdata link connector{DLC), and bring up the tool's generic O B Dl l m o d e .
2. Startthe engine,and let it idle for 1 minute.The readiness code should switch from incompleteto comDlete. 3. lf the readiness code is still set to incomplete,check for a temporary DTC.lf there is no DTC,repeatthe proceoure.
(cont'd)
11-47

How to Set Readiness Codes(cont'd)
Code MisfireMonitorand Readiness
. This readiness code is alwaysset to available becausemisfiring is continuouslymonitored. . l\4onitoring pauses, and the misfirecounterresets,if the vehicleis driven over a rough road. . Monitoringalso pauses,and the misfire counter holds at its currentvalue.if the throttle position value,or if changesmore than a predetermined driving conditionsfall outsidethe rangeof any relatedenablecriteria,
\-
Code FuelSystemMonitorand Readiness

. This readiness code is always setto available because fuel system is continuouslymonitored the during closedloop operation. . Monitoringpauseswhen the catalyticconverter, EVAPcontrol system,and Ay'F sensor monitorsare active. . Monitoringalso pauseswhen any relatedenable criteriaare not being met. Monitoring resumeswhen lhe enablecriteriais again being met.
Monitorand Component Comprehensive Readiness Code

This readiness code is always set to availablebecause the comprehensive componentmonitor is continuously o r u n n i n g h e n e v e t h e e n g i n ei s c r a n k i n g r r u n n i n g . w r
a
11-48
PGM-FI System
CAMSHAFTPOS]TION{CMP)SENSORB (TOPDEAD CENTER(TDC} SENSORI Troubleshootina. oaoe 11-95 p;ge 1-1.1 Replacement, 14
ii'- r'1
.I11---:,I
''.!,i(..,.?:fir-J-
.....,..:--.
ELECTRICAL LOAD DETECTOR {ELDI Troubleshooting, -92 page1'l INTAKE TEMPERATURE AIR {IATISENSOR Troubleshooting, page'l'l-55 page Replacement, 11-'l 15
f \
ENGINE COOLANT TEMPERATURE (ECTI SENSOR page Troubleshooting, 11-57 R e p l a c e m ep a , e 11 1 4 ntg 1 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR page Troubleshooting, 11-52
POSITION CRANKSHAFT ICKPISENSOR page'l1-78 Troubleshooting, page 11-'l16 Beplacement,
THROTTLE POSITION ITP}SENSOR page Troubleshooting, 11-60 KNOCK SENSOR page Troubleshooting, 11-77 B e p l a c e m ep a , e 11 1 5 nt g 1
AIR FUELRATIO{A/F) SENSOR ISENSOR 1} page 11-84 Trorrbleshooting, page 11-113 Replacement,
{cont'd)
11-49
PGM-Fl System
\
\.,
v
11-50
'}
DATALINKCONNECTOR IDLCI page 1l 3 General Troubleshooting Information,
PGM.FI MAINRELAY 1 page Troubleshooting, 11-97
ENGINECONTROLMODULE g General Troubleshootin Information, p a g e1 1 3 page I 1-96 Troubleshooting,
11-51
PGM-FI System
DTCTroubleshooting
DTCP0107: MAPSensor Circuit LowVoltage
1 . T u r nt h e i g n i t i o n w i t c hO N ( l l i . s 2. Checkthe MAP with the scantool. ls about 101kPa (760 mmHg,30 in.Hg)or 2.9 V indicated? YES Intermittent failure, system is OK at this time. Checkfor poor connections looseterminalsat or t h e M A Ps e n s o r n d a t t h e E C M . I a N O - G o t o s t e p3 . 3. Turn the ignition switch OFF. YES-Go to step 9. 4. Disconnect MAP sensor3P connector. the NO Replace the lvlAPsensor.l 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l l . s NO Updatethe ECMif it does not havethe latest software,or substitulea known-goodECM,then recheck(seepage 'l1-6).lf the symptom/indication goes away with a known-goodECfvl, replacethe originaECM.I l 8 . Checkthe MAP with the scantool. ls 2 kPa (15 mmHg,0.6 in.Hg) ot lessor 0 V indicated? ls there about 5 V? YES-Repair open in the wire betweenthe Eclvl ( A 2 1 ) a n d h e M A Ps e n s o r . l t
9 . Turn the ignitionswitch OFF.

6. lvleasure voltage betweenMAP sensor3P c o n n e c l o tre r m i n a l s o . 1 a n d N o . 3 . N
MAP SENSOR3P CONNECTOF
'10.Disconnect
ECMconnectorA (31P).
11. Checkfor continuitybetweenMAP sensor

connectorterminal No. 2 and body ground.
MAP SENSON3P CONNECTOA
sGl {GRN/WHTI
Wires de of femaleterminais
ls there about 5 V? YES Go to step8. ls therc continuity? N O - G o t o s t e p7 . 1 . Measurevoltage betweenEClvl connector t e r m i n a l s 1 1 a n d4 2 ' 1 . 4
ECM CONNECTOR 13'IP} A
YES-Repair short in the wire betweenthe ECM ( A 1 9 ) n d t h e M A Ps e n s o r . l a NO Updatethe ECM if it does not have the latest software,or substitute known-goodECM,then a recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C M . I l
vccr
{YEL/BED)
sGr
{GRN/WHT}
Wire side of female terminals
11-52
MAPSensor CircuitHighVoltage DTCP0108:

'1. Startthe engine.Holdthe engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle.
MAPsensor 9. Measure voltage between 3P No. connector terminals 1 andNo.3.

MAP SENSOR 3PCONNECTOF
2. Checkthe MAP with the scantool. le about 101kPa (780 nmHg, 30 in.Hg)ot highet, or about2.9 V or higher indicated? YES Go to step 3. NO-lntermittent failure,system is OK at this time. or Checkfor poor connections looseterminalsat the MAP sensorand at the ECM.I 3. Turn the ignitionswitch OFF. 4. DisconnecttheMAP sensor3P connector. 5, ConnectMAP sensor3P connectorterminalsNo. 2 and No. 3 with a jumper wire.
MAP SNSOR3P CONNECTOR
vccl { Y E L / Rl El D ) , o cl l . l . r l I lsct d) l{GRN/wHrr
Y
i
I
l
W i r es i d eo f f e m a l el e r m i n a l s
ls there about 5 V? YES Go to step 10. NO Repairopen in the wire betweenthe ECM (A11) and the MAP sensor.I
1 0 .Turn the ignitionswitch OFF.

A 1 1 .C o n n e c E C Mc o n n e c t otre r m i n a l s 1 1 a n d A 1 9 t with a jumper wire.
1 2 3
MAP {GRN/REO}
A ECMCONNECTOR {31PI
SG1(GRN/WHTI
JUMPER WIRE
W JUMPER IAE
Wiresideof female terminals 6. Turn the ignition switch ON (ll).
Wire side of fema e te.minals
s T u r nt h e i g n i t i o n w i t c hO N ( l l ) . 7. Checkthe MAP with the scantool. Checkthe MAP with the scantool. ls about 101kPa (760 mmHg,30 in.Hg) ot higher, or about2.9 V or higher indicated? YES-Go to step 8. NO Replace MAP sensor.I the 8 . R e m o v e h e j u m p e rw i r e . t YES Updatethe ECM if it does not have the lalest software,or substitutea known-goodECM,lhen recheck(seepage 11-6).lf the symptom/indication goes away with a known good ECM,replacethe originaECM.I l NO-Repair open in the wire betlveenthe ECI\il ( A 1 9 ) n dt h e M A P s e n s o r . I a ls about 101kPa (760 mmHg,30 in.Hg)or higher, or about2.9 V ot higher indicated?
11-53
PGM-FI System
(cont'dl DTCTroubleshooting
DTCPl128: MAPSensor Signal Lower Than Expected
1. Turn the ignition switch ON (ll). 2. Checkthe MAP with the scantool. ls 54.1 kPa(406mmHg, 16.0in.Hg),1.6 V, or higher indicated? YES- Intermittent failure.system is OK at this time.I NO Replace the MAP sensor.l
DTCPl129: MAPSensor Higher Signal Than Expected

1. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then Iet it idle. 2. Checkthe MAP with the scantoot. ls 36.9 kPa (277 mmHg, 10.9 in.Hg),1.1 V , or less indicated? YES- lntermittentfailure,system is OK at this time.l NO Replace the MAP sensor.l
11-54
DTCP0112: Sensor IAT Circuit LowVoltage

1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe IAT with the scantool. ls 302'F (150'C) or highet (or H-Limit in Honda node of PGM Tester),ot 0 V indicated? VES-Go to step 3. NO Go to step 8.
8. Checkthe temperaturereadingon the scantool. Be aware that if the engine is warm, the reading l. w i l l b e h i g h e r h a na m b i e n t e m p e r a t u r e I t h e t engine is cold, the IAT and ECTwill have the same v al u e . ls the correct ambient temperatureindicated? YES lntermittentfailure,system is OK at this time or Checkfor poor connections looseterminalsat t h e I A Ts e n s o r n d a t t h e E C M . I a NO Replace IAT sensor.l the
Disconnect IAT sensor2P connector. the

4 . Checkthe IAT with the scantool.
ls 302'F(150'C)or higher (or H-Limit in Honda mode of PGM Testet),ot 0 V indicated? YES-Go to step 5. NO- Replace IAT sensor.I the 5 . Turn the ignition switch OFF. ECMconnectorB (24P). 6 . Disconnect 7 . Checkfor continuitybetweenIAT sensor2P c o n n e c t otre r m i n a lN o . 2 a n d b o d y g r o u n d ,
IAT SENSOR2P CONNECTOR
,^\ , l r 2 l
t
-----Tr---
II
l IAT _t{RED/YELI
W i r es i d eo f f e m a l e e r m i n a i s t
ls there continuity? YES Repairshon in the wire betweenthe ECM ( B ' 1 7a n d t h e I A Ts e n s o r . l ) NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l
11-55
PGM-FI System
DTCP0113: Sensor IAT Circuit HighVoltage
1. Turnthe ignition switch (ll). ON 2. Check IATwith the scan the tool.
YES Go to step 8. 7. Checkthe IAT with the scantool. ls - 4"F ( 20'C) or less(or L-Limitin Honda mode ot PGM Tester) or 5 V indicated?
ls 4'F (-20'C) or less(or L-Limit Honda in modeot PGM Tester)or 5 V indicated?

YES-Go to step 3. NO Intermitent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the IAT sensorand at the ECM.I
NO - Replace IAT sensor.l the 8. Turn the ignition switch OFF. 9 . R e m o v e h e j u m p e rw i r e . t 1 0 . C o n n e c E C Mc o n n e c t otre r m i n a l s 1 0 a n d 8 1 7 t A w i t h a j u m p e rw i r e .
ECM CONNECTORS
3 . Turn the ignitionswitch OFF. 4. Disconnect IAT sensor2P connector. the

ConnectIAT sensor2P connectorterminalsNo. 1 a n d N o . 2 w i t h a j u m p e rw i r e . IATSENSOR CONNECTOR 2P
JUMPERWIRE A (31 P)
B {24 P)
rJ--
:---
\"
l ' l L l
-'_-l--_----r--_
sG2 rAT I {GRN/YEL) IRED/YEL) I L ] WIRE JUMPER Wiresideof female terminals
Wiresideof female terminals 1 1 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 12. Checkthe IAT with the scantool. ls - 4"F ( 20"C) or less (or L-Limitin Honda mode of PGM Tester) or 5 V indicated? YES Updatethe ECMif it does not have the latest software,or substitutea known-goodECI\4 then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM.replacethe originaECM! l . NO Repairopen in the wire betweenthe ECM ( A 1 0 ,8 1 7 )a n dt h e I A Ts e n s o r . I
6 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s
11-56
ECT DTCP0116: SensorRange/Performance Problem

and/or P0118 are storedat the NOTE:lf DTCP0117 those DTCS first, troubleshoot same time as DTCP0116, for then recheck DTCP0116, 1. Stanthe engine.Hold the engineat 3,000rpm with no load {in neutral)until the radiatorfan comes on, then let it idle. 2. Checkthe ECTwith the scantool. ls 176- 212'F (80 indicated? 100"C)or0.5 0.8V
failure.system is OK at this time. YES Intermittent Checkthe thermostatand the cooling system.l NO-Checkthe thermostatand the cooling system. lf they are OK, replacethe ECTsensor.l
11-57
PGM-FISystem
DTCP0117: SensorCircuitLow Voltage ECT
1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe ECTwith the scantool. ls 150'C (302'F)or higher (ot H-Limit in Honda mode of PGM Tester) or 0 V indicated? YES Go to step 3. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the ECTsensorand at the ECM.t
\
7. Checkfor continuitybetweenthe ECTsensor2P connectorterminal No. 1 and bodv oround. ECTSENSOR CONNECTOR 2P
3. Disconnect ECTsensor2P connector. the 4. Checkthe ECTwith the scantool. ls 150'C (302"F)or higher (ot H-Limit in Honda mode ot PGM Tester) or 0 V indicated? YES-Go to step 5. NO Replace ECTsensor. the ! ls there continuity? YES-Repair short in the wire betweenthe ECM ( B 8 )a n d t h e E C Ts e n s o r . l NO-Update the ECMif it does not havethe latest software,orsubstitute known-goodECM,then a recheck{seepage 11-6). the symptom/indication lf goes away with a known-goodEClvl, replacethe originaECM.I l
5. Turn the ignition switch OFF. 6. Disconnect ECMconnectorB (24P).
11-58
HighVoltage DTCP0118: Sensor ECT Circuit

1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe ECTwith the scantool.
1 . Checkthe ECTwith the scantool. ls 20"C ( 4"F)or less (or L-Limitin Honda mode ot PGM Tester) or 5 V indicated? YES-Go to step 8.
ls 20'C ( 4'F)or less(or L-Limitin Honda mode of PGM Tester) or 5 V indicated? YES Go to step 3. NO lntermittentfailure,system is OK at this time. Checkfor poor connections looseterminalsat or the ECTsensorand at the ECM.I
?
N O R e p l a c eh e E C Ts e n s o r . I t 8 . Turn the ignition switch OFF. t 9 . R e m o v e h e j u m p e rw i r e . 1 0 . ConnectECMconnectorterminalsA10 and Bg with a j u m p e rw i r e .

ECM CONNECTORS
Turn the ignitionswitch OFF. Disconnect ECTsensor2P connector. the
5 . Connectthe ECTsensor2P connectorterminals N o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .

ECTSENSOR2P CONNECTOR
a {31P}
B {24P)
JUMPERWIRE
Ecr (RED/WHT)
lt t .l t l l t -I-l*,
{GRN/YEL)
terminals Wiresideof female s 1 1 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) . 1 2 . Checkthe ECTwith the scantool.
t l WIRE JUMPER wire sideoI Iemale terminals
ls 20"C ( 4"F) or less (or L-Limitin Honda mode of PGM Tester) ot 5 V indicated? s 6 . T u r nt h e l g n i t i o n w i t c hO N ( l l ) . YES- Updatethe ECM if it does not havethe latest then a software,or substitute known-goodECI\4, recheck(seepage 11-6).If the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l NO Repairopen in the wire betweenthe ECM ( A 1 0 ,8 8 ) a n d t h e E C Ts e n s o r . l
11-59
PGM-FI System
DTCP0122: Sensor TP CircuitLowVoltage
1 . T u r nt h e i g n i t i o n w i t c ho N ( 1 1 1 . s 2. Checkthe throttle positionwith the scantool. ls there about 10./.or 0.5 V when the thrcttle is fully closed and about 90% or 4.5 V when the throttle is fully opened? YES Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the TP sensorand at the ECM. t NO Go to step 3. 3. Turn the ignition switch OFF, 4. Disconnect TP sensor3P connector. the 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 6. Measurevoltagebetweenthe TP sensor3P connectorterminals No. 1 and No. 3.
TP SENSOR3P CONNECTOR
8. At the sensorside, measureresistance betweenthe TP sensor3P connectorterminalsNo. 1 and No. 2 with the throttlefully closed.
TP SENSOR CONNECTOR 3P
T e r m i n a li d e f m a l e e r m i n a l s s o t
Is there about 0.5 0.9 kQ ? YES Go to step 9. NO Replace throttle body (theTP sensoris not the a v a i l a b l e e p a r a t e l yI) . s 9 . Measureresistance betweenthe TP sensor3P connectorterminalsNo. 2 and No. 3 with the throttlefully closed. TPSENSOR CONNECTOB 3P
ls thereabout5 V?
Terminal of male side terminals
YES-Go to step7. N O G ot o s t e p1 4 .
1 . Turnthe ignition switch OFF. ls there about 4.5k{l ? YES Go to step 10. NO Replace throttle body (theTP sensoris not the a v a i l a b l e e p a r a t e l yI) . s 1 0 . D i s c o n n e c t C Mc o n n e c t oA ( 3 1 P ) . E r
11-60
for side, check continuity 11. At thewire harness terminal 2 No, TP 3P between sensor connector a n db o d yg r o u n d .
check continuity for side, 13. At thewire harness terminal 2 No. TP 3P between sensor connector a n db o d yg r o u n d .
11 2 1 3
'PS REO /BLKI
1 2 3
TPS (RED/BLX}
Wire sideof female terminals
Wire side ot Iemaleterminals
ls there continuity?
ls thetecontinuity? the YES-Repair shortin the wire between ECM { A 1 5a n dt h eT Ps e n s o r . l l ) N O - G o t o s t e p1 2 . A15to body ECM connector terminal 12. Connect ground with a jumperwire.
A ECMCONNECTOR 131P)
YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO- Repairopen in the wire betweenthe ECM ( A 1 5 ) n dt h e T P s e n s o r . l a voltage betweenECMconnector 14. lvleasure 4 t e r m i n a l s 1 0 a n dA 2 0 .
A ECMCONNECTOB 131P}
9 1 1 2 1 34 5 6 7 19t2021 tc 6 10 1 1 1 1 2 8
23124
28129130
wrne ,tf$,rr*, ];uueen

vcc2
terminals Wire side oJ.female (YEL/8LU)
ls there about 5 V? YES Repairopen in the wire betlveenthe ECM ( A 2 0 ) n dt h e T P s e n s o r . I a NO Updatethe ECM if it does nor have the latest software,or substilutea known-goodECM,then ( r e c h e c k s e ep a g e11 - 6 ) l.f t h e s y m p l o m i n d i c a t i o n goes away with a known-goodECM.replacelhe originaECM.I l
11-61
PGM-FI System
(cont'd) DTCTroubleshooting
DTCP0123: Sensor TP Circuit HighVoltage
1 . T u r nt h e i g n i t i o n w i t c ho N ( l l ) s 2. Checkthe throttle positionwith the scantool. ls there about 10%or 0.5 V when the throttle is fully closed and about 90% or 4.5 V when the throttle is f ully opened? YES lntermittentfailure.system is OK at this time. Checkfor poor connections looseterminalsat or t h eT Ps e n s o r n da t t h e E C MI a , NO Go to step 3. 3. Turn the ignition switch OFF. Is there about 5 V? 4. Disconnect TP sensor3P connector. the 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 6. At the wire harnessside, measurevoltage between the TP sensor3P connectorterminalsNo. 1 and No.3.
(
7. Measurevoltage betweenECMconnector terminalsA10 and A20.
ECMCONNECTOR 131PI A
YES- Repairopen in the wire betweenthe ECM (A10)and the TP sensor. t NO Updatethe ECMif it does not havethe latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C M . I l
W;resideof female terminals
ls thete about 5 V? YES-Replace the throttle body (theTP sensor is not availableseparately). I NO Go to step 7.
11-62
TP Lower Than DTCPl121: Sensor Signal Expected

1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe throttle positionwith the scantool. ls 12.9'/.,0.6 V, or higher indicated when the throttle is tully opened? YES- Intermittent failure,system is OK at this time.I NO-Replace the TP sensor(the TP sensor is not availableseparately). I
Higher Than DTCP1122:.fP Sensor Signal Expected

1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2. Checkthe throttle positionwith the scantool. ls 12.9%,0.6 V, or lessindicated when the throttle is f ully closed? failure,system is OK at this YES Intermittent time.l NO Replace TP sensor(theTP sensoris not the availableseparately). I
11-63
PGM-FI System
(cont'dl DTGTroubleshootang
DTCP0128: CoolingSystemMalfunction
NOTE;lf the DTCS listedbelow are stored at the same time as DTCP0128. troubleshootthose DTCS first, then recheck P0128. for P 0 1 0 7P 0 1 0 8P 1 1 2 8P 1 1 2 9N 4 a n i f o la b s o l u t e , , , : d pressure(MAP)sensor P] I06, P1107,P1108:Barometricpressure(BARO) sensor P1259: VTECsystem P0116,P0117, P0118:Enginecoolanttemperature(ECT) sensor P0112,P0113: Intakeair temperature(lAT)sensor P0500: Vehiclespeedsensor{VSS) position(CKP) P0335, P0336: Crankshaft sensor P0300: Randommisfire P 0 3 0 1P 0 3 0 2P 0 3 0 3P 0 3 0 4N o . 1 , N o . 2 , N o . 3 o r N o . 4 , , , : cylinder misfire P0505: ldle control system malfunction P 1 5 1 9l:d l ea i r c o n t r o l( l A C ) v a l v e DTCP0128 can occasionally when the hood is set o p e n e d h i l e t h e e n g i n ei s r u n n i n g . w 1. Checkthe enginecoolant level Is the engine coolantlevel low? VES Refillthe enginecoolant.lf necessary, repair t h e c o o l a n tl e a k a g e . l NO Go to step 2. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d m a k es u r et h e s A,/Cis off. 3. Checkthe radiatorfan. Does the tadiator fan keep running? YES Checkthe radiator fan circuit(seepage 1014),the radiatorfan switch circuit(Short)(seepage 10-'16), the radiatorfan switch (seepage 10-17). and Also, inspectthe ECTand IAT circuitsand terminal connections. the circuits, lf the switch,and the connections are OK, updatethe ECI\4 it does not if have the latestsoftware.or substitutea knowngood ECM,then recheck(seepage 11-6).lf the goes away with a known-good symptom/indication E C M ,r e p l a c eh e o r i g i n a E C M . I t l NO Replace thermostat(seepage 10-8).1 the
11-64
1) DTCP0134: Sensor(Sensor No Activity Ay'F Detected

1. Checkthe attachmentstateof the A,/F sensor (Sensor ). 1 ls it slacked f rom the exhaust pipe? YES- Reinstall Ay'F the sensor(Seneor1) (seepage 11-113).t NO-Go to step 2. 2 . R e s e t h e E C M( s e ep a g e11 - 4 ) . 3 . S t a nt h e e n g i n e H o l dt h e e n g i n e p e e da t . s 3,000rpmwith no load (in neutral)until the radiator fan comes on, then let it idle for 2 minute. ls DTC PO134 indicated? YES-Replacethe Ay'F sensor{Seneor1) (seepage 11-113).t failure, sistem is OK at this time. NO - Intermittent or Checkfor poor connections looseterminalsat the Ay'F sensor(Seneor1) and the ECM.I
(Sensor DTCP0137: Secondary HO2S 2) LowVoltage Circuit

1 . R e s e t h e E C M( s e ep a g eI 1 - 4 ) 2. Start the engine.Holdthe engine at 3,000rpm wilh no load (in neutral)until the radiatorfan comes on. 3. Checkthe secondaryHO2S(Sensor2) output voltageat 3,000rpm with the scantool. ls there 0.3 V or less? YES Go to step 4. NO-lntermittent failure,system is OK at this time. or Checkfor poor connections looseterminalsat the secondaryHO2S(Sensor2) and at the ECM.I s 4. T u r nt h e i g n i t i o n w i t c hO F F . the secondaryHO2S(Sensor2) 4P 5 . Disconnect connector. 6 . Turn the ignition switch ON (ll). 7 . Checkthe secondaryHO2S(Sensor2) output voltagewith the scantool. ls there 0.3 V or less? YES Go to step 8. r H N O R e p l a c eh e s e c o n d a r y O 2 S( S e n s o 2 ) . 1 t 8 . Turn the ignition switch OFF. E r 9 . D i s c o n n e c t C Mc o n n e c t oE ( 3 1 P ) .
icont'd)
11-65
PGM-FISystem
10. Checkfor continuitybetweenthe secondaryHO2S (Sensor2) 4P connectorterminal No. 2 and body ground. SECONDARY H02S 2) ISENSOR 4PCONNECTOR
a
(Sensor DTCP0138: Secondary HO2S 2) Circuit HighVoltage
1 . R e s e t t h e C M{ s e ep a g e ' 1 1 - 4 ) . E 2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on. 3. Checkthe secondaryHO2S(Sensor2) output voltageat 3,000rpm with the scantool. ls thete 1.0 V or morc? YES Go to step 4.
Terminalside of male terminals
NO-lntermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the secondaryHO2S(Sensor2) and at the ECM.I 4. Turn the ignition switch OFF.
ls there continuity? YES-Repair shon in the wire betweenthe ECM (E2)and the secondaryHO2S(Sensor2).t NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I| l
5. Disconnect secondaryHO2S(Sensor2) 4P the connector. ConnectsecondaryH02S (Sensor2) 4P connector t e r m i n a l s o . 1 a n d N o . 2 w i t h a j u m p e rw i r e . N

SECONDARY HO2S 2) {SENSOR 4P CONNECTOR JUMPERWIRE
SG3 (PNKI
SHO25(WHT/RED)
T e r m i n as i d eo Jm a l et e r m i n a l s l 7. Turn the ignitionswitch ON (ll).
11-66
8 . Checkthe secondaryH02S (Sensor2) output

voltagewith the scantool, ls there 1.0 V ot mote? YES-Go to step 9. NO Replace secondaryHO2S(Sensor2).1 the
(Sensor Slow HO2S 2l DTCP0139: Secondary Response

E 1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . Start the engine.Holdthe engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on.
3 . Checkthe secondaryHO2S(Sensor2) output

9 . Turn the ignitionswitch OFF. 1 0 . ConnectECMconnectorterminalsE2 and E4 with a J U m p ew r r e . r E ECMCONNECTOR 131PI voltageat 3,000rpm with the scantool. ls thete 0.3- 0.8 V, fot 2 minutes? YES Replace secondaryHO2S(Sensor2).! the NO- lntermittentfailure,system is OK at this time. or Checkfor poor connections looseterminaisat the secondaryHO2S(Sensor2) and at the ECM.I
JUMPER WIRE
Wiresideof female terminals 1 1 .Turn the ignition switch ON (ll). 1 2 . Checkthe secondaryHO2S(Sensor2) output voltagewith the scantool. ls there 1.0 V or more? YES Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM.replacethe originaECM.I l NO Repairopen in the wire betweenthe ECM (E2, E4)and the secondaryHO2S{Sensor2).I
11-67
PGM-FISystem
(Sensor DTCP0141: Secondary HO2S 2l Heater Malfunction Circuit
1. Resetthe ECM(seepage 1 l-4) 2. Startthe engine. ls DTC P0141indicated? YES-Go to step 3. NO-lntermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the secondaryHO2S(Sensor2) and at the ECM.I 6. Checkfor continuitybetweenbody ground and secondaryH02S (Sensor2) 4P connectorterminals N o . 3 a n d N o .4 i n d i v i d u a l l y . SECONDARY HO2S 21 {SENSOR 4PCONNECTOR

Disconnect secondaryH02S (Sensor2) 4P the connecror. 5 . At the secondaryHO2S(Sensor2) side, measure resistance betweenH02S 4P connectorterminals N o . 3 a n d N o .4 . (SENSOR 4PCONNECTOR HO2S SECONDARY 21
ls therecontinuity? (Sensor YES- Replace secondary the HO2S 2).1 NO-Go to step7.
7 . Turnthe ignition switch (ll). ON 8 . Measure voltage between secondary H02S4P
connector terminals 3 andNo.4, No.

SECONDARY HO2S (SENSOR ilP CONNECTOR 2l
s02sHTc {BLK/WHTI
Wire side ol lemale terminals
IG1(BLK/ORN}
ls thereabout3.3 Q ? YES Goto step6. (Sensor t NO- Replace secondary the HO2S 2).
T e r m i n a li d e f m a l e e r m i n a l s s o t
ls there battery voltage? YES Go to step 9. NO Go to step 12. 9 . Turn the ignition switch OFF. 1 0 . Disconnect ECMconnectorE {31P)
11-68
11. Check continuity for between ECM connector terminal andbodyground. E6

E ECM CONNECTOR {31PI
1 3 .Turn the ignitionswitch OFF.

1 4 . Reconnect secondaryHO2S(Sensor2) 4P the connector.
t5.
Disconnect ECMconnectorE (31P). Turn the ignition switch ON (ll).
to.
1 7 . Measurevoltage betweenECMconnectorterminal E 6a n d A 5 . ECMCONNECTORS

Wire side o{f Iemaleterminals
A (31 P)
ls therc continuity? YES-Repair short in the wire betweenthe ECM r ( E 6 ) n d t h e s e c o n d a r y O 2 S( S e n s o 2 ) . 1 a H NO-Update the ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l MeasurevoltagebetweensecondaryHO2S (Sensor2) 4P connectorterminal No. 4 and body g round. HO2S 2I SECONDARY {SENSOR 4PCONNECTOR
E {31P}
Is there 0-1 V or less? YES-Repair open in the wire betweenthe ECM (E6)and the secondaryHO2S(Sensor2).! NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe . o r i g i n aE C Ma l
tFff I
l[faJl--ro' 14 |
IBLK/OFN)
Y I
Terminal of male terminals side ls there battety voltage? YES Go to step 13. N O - C h e c k t h e N o . 4 A C G( 1 0 A ) u s ei n t h e u n d e r f dash fuse/relaybox. lf the fuse is OK, repair open in the wire betweenthe secondaryHO2S(Sensor2) f a n d N o . 4 A C G( 1 0 A ) u s e . l
11-69
PGM-FI System
Fuel Too Lean DTCP0171: System Too Rich DTCP0172: FuelSystem
listedbelow are storedat NOTE:lf some of the DTCS the same time as DfC PO17'l and/ot PO172, for first, then recheck P0171 troubleshootthose DTCS andlot P0112. . a P 0 1 0 7P 0 1 0 8P 11 2 8 .P 11 2 9 :M a n i f o l d b s o l u t e , ( p r e s s u r eM A P ) e n s o r s P1162.P1166,P 1167:4,,/F sensor(Sensor1) heater r H : P 0 1 3 7P 0 1 3 8S e c o n d a r y O 2 S( S e n s o 2 ) , P014'l: SecondaryHO2S(Sensor2) heater P1259: VTECsystem ( 1 . C h e c k h e f u e l p r e s s u r e s e ep a g e1 1 - ' 1 4 5 ) . t ' ls luel pressure OK? YES Go to step 2. Does it hold vacuum? NO Checkthese items: . lf the pressureis too high, replacethe fuel p r e s s u r e e g u l a t o( s e ep a g e1 1 - 1 5 2 ) . 1 r r . l f t h e p r e s s u r es t o o l o w . c h e c k t h e f u ep u m p , i l the fuel feed pipe,the fuel filter, and replacethe r r f u e l p r e s s u r e e g u l a t o ( s e ep a g e1 1 - 1 5 2 ) . I 2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on. and adjust YES-Check the enginevalve clearances lf are if necessary, the valve clearances OK, replace ( 1 t h e i n j e c t o r ss e ep a g e11 - 1 1 ) . 1 NO-Replace the EVAPcanisterpurge valve.l A973AX-041-XXXXX 3. Turn the ignition switch OFF. 4. With a vacuum pump, apply vacuum to the emission(EVAP) canisterpurge valve evaporative (A) from the evaporative emission(EVAP) canister side.
11-70
DTCP0300: Random Misfire andAny Combination the Following: of DTCP0301: 1 Cylinder No. Misfire No. Misfire DTCP0302: 2 Cvlinder DTCP0303: 3 Cvlinder No, Misfire DTCP0304: 4 Cvlinder No. Misfire
NOTE: . lfthe misfiring is frequentenoughto trigger detectionof increased driving cycles. emissionsduring two consecutive will be stored. the MIL will come on, and DTCP0300(and some comlrinationof P0301 through P0304) . lf the misfiring is frequentenoughto damagethe catalyst, the MIL will blink wheneverthe misfiring occurs,and OTC P0300(and some combinationof P0301 through P0304) will be stored.When the misfirlng stops,the MIL will remain on. 1. Troubleshoot following DTCsfirst if any of them were stored along with the random misfire DTC(s): the ( p P 0 ' 1 0 7 ,0 1 0 8P 1 1 2 8P 1 1 2 9N 4 a n i f o la b s o l u t e r e s s u r eM A P )s e n s o r P , , r d P0111. P0'172t Fuelsvstem position(CKP) P0335. P0336: Crankshaft sensor P0505: ldle control system sensor P1149,Pl 162,P1163,P1164,P 1165:Air fuel ratio (Ay'F) VTECsystem P1259: P1361, P1362: sensor) Camshaftposition(CMP)sensorB {Top dead center(TDC) P 1 5 1 9l:d l ea i r c o n t r o l( l A C ) a l v e v 2. Test-drive vehicleto verify the symptom. the in 3. Findthesymptom inthechart below, and dothe relatedprocedures the order listeduntil you find the cause. Symptom Random isfire nly m o at low RPMand under load Random isfire nly m o du ring acceleration Randommisfire at h i g h R P M ,u n d e r l o a d ,o r u n d e r random conditions
Procedure(sl
Checkfuel pressure(seepage 11-145).
Also check foi:
. Lowcompressron. . Lowquality fuel. in Malfunction the (see page VTEC system 1' t-123).
Correctenginevalve (seepage 6clearances 91.
Checkfuel pressure(seepage 11-145).
( C h e c k u e l p r e s s u r es e ep a g e1 1 - 1 4 5 ) . f
11-71
PGM-FI System
No. Misfire DTCP0301: 1 Cylinder No. Misfire DTCP0302: 2 Cylinder No. Misfire DTCP0303: 3 Cylinder
YES Replace faulty ignitioncoil.! the 1 . Determine which cylinder(s) had the misfire. Does the misf ire occur in the cylinder where the ignition coil was exchanged?
No. Misfire DTCP0304: 4 Cylinder

NO-Go to step 8. 1. After checkingand recordingthe freezedata,reset the ECM (seepage 11-4).lf there is no freezedata of the misfire,just clearthe DTC. 2. Startthe engine,and listenfor a clickingsound from the injectorat the problemcylinder. 8 . Turn the ignition switch OFF. 9 . Exchange spark plug from the problemcylinder the with one from anothercylinder.
1 0 .Test-drive vehiclefor severalminutes in the the

rangeof the freezedata or under various conditionsif there was no freezedata.
Does the injector click? YES-Go to step 3. NO-Go to step 30. 3. Turn the ignition switch OFF. YES Go to step 12. 4. Exchange ignition coil from the problem the cylinderwith one from anothercylinder, the 5. Test-drive vehiclefor severalminutesin the range of the freezedata or under va rious conditionsif there was no freezedata. 6. Checkfor a DTCor a TemporaryDTCwith the scan root. ls DTC or Tempotaty DTC P0301, P0302, P0303 or P0304 ind icated? YES Go to step7. misfire due to poor contactat the NO Intermittent a i g n i t i o n o i l c o n n e c t o r { n o m i s f i r e t t h i st i m e ) . c s are Make sure the coil connections secure.l NO Intermittentmisfiredue to spark plug fouling, e t c .( n o m i s f i r ea t t h i st i m e ) . 1 D e t e r m i n e h i c h c y l i n d e r ( sh a dt h e m i s f i r e . w ) Does the misl ire occur in the cylinder where the spark plug was exchanged? Y E S R e p l a c eh e f a u l t ys p a r kp l u g . l t NO Go to step 13. Turn the ignition switch OFF. 1 4 . Exchange lnjectorfrom the problemcylinder the w i t h o n ef r o m a n o t h e r y l i n d e r . c
t5.
1 1 .Checkfor a DTCor TemporaryDTCwith the scan Tool. ls DTC ot Tempotary DTC P0301, P0302, P0303 or P0304indicated?
L e tt h e e n g i n ei d l ef o r 2 m i n u t e s .
11-72
1 6 .Test-drive vehiclefor severalminutesin the the rangeof the freezedata or under various conditionsif there was no freezedata.
22. Measurevoltage betweenignition coil 3P connectorterminal No. 3 and body ground.

IGNITIONCOIL3P CONNECTOR
't7. Checkfor a DTCor a TemporaryDTCwith the scan

Tool. ls DTC or TemporaryDTC P0301,P0302, P0303 or P0304 indicated? YES Go to step 18. NO lntermittentmisfire due to bad contactat the injectorconnector(no misfireat this time). Make surethe injectorconnectionis secure.Checkfor poor connections looseterminalsat the or injector.l
ls there battery voltage?
1 8 .Determinewhich cylinder(s) had the misfire.

YES-Go to step 23. Does the misf ire occur in the cylinder where the i njector w as exchanged ? YES- Replace faulty injector.I the NO Repairopen in the wire betweenthe No. 1 I G NC O I L( 1 5 A ) f u s e n dt h e i g n i t i o n o i l . I a c
2 3 . Turn the ignitionswitch OFF.

NO-Go to step19.
24. Checkfor continuitybetweenignitioncoil 3P 1 9 .Turn the ignitionswitch OFF. 20. Disconnect ignitioncoil 3P connectorfrom the the
problemcylinder. Turn the ignition switch ON (ll). connectorterminal No. 2 and body ground. IGNITION COIL3PCONNECTOR
ls there continuity? YES Go to step 25. NO Repairopen in the wire betweenthe ignition G coiland 101.1 ECMconnectorA {31P) Disconnect
(cont'd)
11-73
PGM-FI System
26. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable). ECMCONNECTOR {31PI A 28. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable).
ECMCONNECTOR {31P} A
PROB IVI LE CYLINDER

N o .1 No.2 No.3 No,4
DTC P0301 P0302 P0303 P0304
ECM WIRE TERMINAL COLOR
PROBLEM CYLINDER
No.1 N o .2 N o .3 N o .4
DTC P0301 P0302 P0303 P0304
430 A.29 428 421
YEUGRN BLU/RED WHT/BLU BRN
ECM WIRE TERI\4INAL COLOR A30 YEL/GRN 429 BLU/RED A.28 WHT/BLU A.21 BRN
ls there continuity? YES Repairshon in the wire betweenthe EClvl a n dt h e i g n i t i o n o i l . l c NO-Go to step 27. 2 7 . C o n n e c itg n i t i o n o i l 3 P c o nn e c t o r e r mi n a l N o . 1 t o c t body ground with a jumper wire (seetable).
IGNITIONCOII 3PCONNECTOR
ls there continuity? YES-Go to step 29. NO Repairopen in the wire betweenthe ECMand the ignition oil.l c 29. Checkthe engine compression
ls the compression OK? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECI\4.I l
Wire s de of femaleterminals
NO- Repaithe engine.l r
3 0 . Disconnect ECMconnectorB (24P). PROBLEM CYLINDER

No.1 N o .2 N o .3 N o .4
DTC P0301 P0302 P0303 P0304
WIRECOLOR
T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
YEUGR N BLU/RED WHT/BLU

BRN
11-74
32. fvleasure voltage between bodygroundandECM (see connector terminal table).

ECMCONNECTOR (24P) B
36. Exchange injectorfrom the problemcylinder the

w i t h o n ef r o m a n o t h e r y l i n d e r . c
3 7 . L e t t h ee n g i n ei d l ef o r 2 m i n u t e s . 3 8 . Test-drive vehiclefor severalminutes in the the

r a n g eo I t h e l r e e z e a t ao r u n d e rv a r i o u s d condilionsif there was no freezedata.
39. Checkfor a DTCor TemporaryDTCwith the scan

tool. ls DTC or TemporaryDTC P0301,P0302, P0303, or P0304 indicated?
W i r e s i d e o f f e m a l et e r m r n a l s
YES Go to step 40. PROBLEM CYLINDER No. 1 No.2 No.3 No.4
DTC P0301 P0302 P0303 P0304
EC t\4 TERMINAL B5 B4 B3
WIRE COLOR BRN RED BLU YEL
NO Intermittentmisfiredue to injector malfunction,etc. Make sure the injector connections are secure.Checkfor poor connections or looseterminalsat the injectorconnector.l D e t e r m i n e h i c hc y l i n d e r { sh a d t h e m i s f i r e . w }
ls there battery voltage? YES-Go to step 33, N O G o t o s t e p4 1 . Does the mislirc occur in the cylinder whete the i nj ector w as exchanged ? YES Replace faulty injector.l the NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 1'l-6).lf the symptom/indication goes away with a known-goodEClvl, replacethe originaECM.I l
33. Turn the ignitionswitch OFF,and removethe

engine cover.
34. Disconnect injector2P connectorfrom the the

problem ylinder. c
3 5 , Measurethe resistance betweeninjector2P

c o n n e c t otre r m i n a l s o . 1 a n d N o . 2 . N
4 1 .Turn the ignition switch OFF. 42. Removethe enginecover.
INJECTOB CONNECTOR 2P
43. Disconnect injector2P connectorfrom the the

p r o b l e mc y l i n d e r . 4 4 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) s
Terminal side of male terminals
l s t h e r e 1 0Q
13A?
YES-Go to step 36. ( N O R e p l a c eh e i n j e c t o r s e ep a g e11 -1 1I ) .t t (cont'd)
11-75
PGM-FI System
45. Measure voltage between injector connector 2P N t e r m i n a l o .1 a n db o d yg r o u n d .
INJECTOR CONNECTOR 2P
48. Connect injector connector 2P terminalNo.2to with a jumper wire {see table). bodyground
INJECTOR2P CONNECTOR
tll-z] -lt,o,,"=rrrr*, o I
tll-Z-l -]_r-l_rNJ
IJUMPER
IwrBE
Wire side of {emaleterminals
ls there battery voltage? YES-Go to step 46. NO-Repair open in the wire betweenthe injector l a n d t h e P G M - Fm a i n r e l a yl . l PROBLEM CYLINDER No.1 No.2 N o .3 N o .4
DTC P0301 P0302 P0303 P0304
WIRECOLOR BRN RED BLU YEL
46. Turn the ignitionswitch OFF. 4 7 .Checkfor continuitybetweenbody ground and

ECMconnectorterminal (seetable).
B ECMCONNECTOR {24P)
49. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable).

ECM CONNECTOR I24P) B
Wire side oJtemaleterminals t W i r es i d eo f f e m a l e e r m i n a l s
PROBLEM CYLINDER N o .1 No.2 No.3 N o .4
ECM TERMINAL P030'1 B5 B4 P0302 P0303 B3 P0304 82 DTC
WIRE COLOR
BRN
RED BLU YEL
PROBLEM CYLINDER No.1 N o .2 N o .3 N o .4
DTC P0301 P0302 P0303 P0304
ECM TERMINAL B5 B4 B3 82
WIRE COLOR BRN RED BLU YEL
ls therc continuity? ls there continuity? YES Replace injector,then recheck.l the YES-Repair short in the wire betweenthe ECM a n dt h e ; n j e c t o r . I N O - G o t o s t e p4 8 . NO Repairopen in the wire betweenthe ECM and the injector.I
11-76
DTG P0325: Malfunction KnockSensor in Circu it

1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle. 3. Holdthe engineat 3,000-4,000 rpm for at least 60 seconds. ls DTC P0325 indicated?
7. Connect staner subharness connector 6P terminal r N o .5 t o b o d yg r o u n d i t ha j u m p e w i r e . w

STARTER SUAHARNESS 6P CONNECTOR
l1l213l
l,/l5l6l ._
KS IJUMPER |RED/BLU) IW|RE I Wiresideof female terminals
YES-Go to step 4. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the knocksensorand at the ECM.I 4. Turn the ignition switch OFF. 5. Disconnect startersubharness connector. the 6P 6. Checkfor continuitybetweenECMconnector terminalAg and body ground. ECMCONNECTOR 131P) A
8 . Check continuity for between bodygroundand ECM connector terminal A9.

ECMCONNECTOR {31PI A
ls there continuity? YES-Go to step 9. NO Repairopen in the wire betweenthe ECM (A9) and the startersubharness connector.l 6P
Wire side of lemaleterminals
betweenthe 6P 9 . Checkthe startersubharness
ls therecontinuity? YES-Repair shortin thewire between ECM the (A9)andthe starter subharness connector.l 6P NO Goto step7.
connectorand the knocksensorfor an open or short. lf it's OK, substitutea known-goodknock sensorand recheck. ls DTC P0325 indicated? YES Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck{seepage '11-6). the sym ptomlindication lf goes away with a known good ECM,replacethe originaECM.I l N O R e p l a c eh e o r i g i n a k n o c ks e n s o r n d / o r t l a starter subharness.l
11-77
PGM-FI System
DTCP0335: CKPSensorNo Signal CKPSensorIntermittent DTCP0336: Interruption
'1-4). '1. Reset the ECM (seepage 1 2. Start the engine. ls DTC P0335 and/or P0336 indicated? YES Go to step 3.
Wire side of female tefminals
7. Measurevoltage betweenCKPsensor3P connector t e r m i n a lN o , 1 a n d b o d y g r o u n d

CKPSENSOR CONNECTOR 3P
failure,system is OK at this time. NO Intermittent or Checkfor poor connections looseterminalsat t h e C K Ps e n s o r n d a t t h e E C M . I a 3. Turn the ignition switch OFF. 4. Disconnect CKPsensor3P connector. the 5. Turn the ignitionswitch ON {ll). 6. Measurevoltage betweenCKPsensor3P connector t e r m i n a lN o . 3 a n d b o d y g r o u n d .
CKPSENSOR CONNECTOF 3P
IGP
ls thereabout5 V? YES Goto stepL N O G ot o s t e p1 0 . voltage between CKP sensor connector 3P 8. Measure t e r m i n a lN o . 2a n dN o .3 . s
CKPSENSOR 3PCONNECTOR
L " l
LGl {BRN/YELI
,llYtL
1 2 3
(YEL/BLK}
W i r e s i d eo f f e m a l e e r m i n a l s t
Wiresade female of terminals
ls there battery voltage? YES Go to step 9.
Is therebattery voltage? YES- Goto step7. main PGM-Fl NO Repair openln thewire between 1 s r e l a y a n dt h eC K P e n s o r . !
NO Repairopen in the wire betweenthe CKP . s e n s o r n d G1 0 1 I a 9. Substitutea known-goodCKPsensorand recheck. ls DTC P0335 and/or P0336 indicated? YES Updatethe ECM if it does not have the latest software.or substitutea known good ECM,then recheck {seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l t l N O R e p l a c eh e o r i g i n a C K Ps e n s o r . l
11-78
'10.l\4easure voltage between ECM connector terminal A7 andbodyground,

ECMCONNECTOR 13lPI A
Wiresideot female terminals
ls there about 5 V? YES-Repair open in the wire betweenthe ECM (A7)and the CKPsensor. t N O - G o t o s t e p1 1 . 1 1 .Turn the ignitionswitch OFF. Disconnect ECMconnectorA (31P) 1 3 . Checkfor continuitybetweenECMconnector terminal 47 and body ground.
ECMCONNEfiORA (31P)
ls there continuity? YES-Repair short in the wire betweenthe ECM (A7)and the CKPsensor. t NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECI\4, then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.t l
11-79
PGM-Fl System
DTCP0500: VSSCircuitMalfunction
1. Test-drive vehicle. the 2. Checkthe vehiclespeedwith the scantool. ls the correct speed indicated? YES-lntermiftent failure,system is OK at this time. or Checkfor poor connections looseterminalsat t h e V S Sa n d a t t h e E C M . I NO Go to step 3. 3. Turn the ignition switch OFF. 4. Blockthe rearwheels,and set the parkingbrake. 5. Raisethe front ofthe vehicle,and make sure it is securelysupported, 6 . Turn the ignition switch ON (ll). 1 . Blockthe right front wheel, and slowly rotatethe left front wheel. 8. Measurevoltage betweenECMconnector t e r m i n a l s 1 8a n dA 2 4 . A
A ECMCONNECTOR {31P)
9. Turn the ignitionswitch OFF. 10. Disconnect ECMconnectorA (3'1P). 11 . T u r nt h e i g n i t i o n w i t c hO N { l l } . s 12. Blockthe right front wheel. and slowly rotatethe left front wheel. '!3. lMeasure voltage betweenECMconnector A t e r m i n a l s 1 8a n dA 2 4 .
A ECMCONNECTOR I31PI
Does the voltage pulse between 0 V and 5 V ol between0V and battety voltage? YES Updatethe ECM if it does not have the latest software,or substitute known-goodECM,then a recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe origlnaECM.I l NO Checkthese items: . A short or an open in the wire betweenthe ECM ( A 1 8 ) n dt h e V S S . I a . l f t h e w i r e i s O K , t e s t t h e V S S s e ep a g e2 2 7 1 ) . 1 (
Does the voltage pulse between 0 V and 5 V or between 0V and battery voltage? YES-Update the ECM if it does not havethe latest software,or substitutea known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECN4.l l NO Go to step 9.
11-80
DTCP0563: ECMPowerSource Circuit Unexpected Voltage

1 . R e s e t h e E C I \ { s e ep a g el 1 - 4 } . 4 2. Turn the ignitionswitch OFF. 3. Wait 5 seconds. 4 . T u r nt h e i g n i t i o n w i t c hO N { l l l . s ls DTC P0563 indicated? YES Go to step 5. NO-lntermiltent failure,system is OK at this time. Checkfor poor connections looseterminalsat or t h e N o . 6 E C U( E C M ) 1 5A ) f u s ei n t h e u n d e r - h o o d { fuse/relaybox and at the ECM.I Turn the ignitionswitch OFF.
9 . Removethe glove box (seepage20-63). 1 0 .Removethe PGM-FImain relay 1 (A7.
1 1 .Checkfor continuitybetweenECMconnector terminal E7 and body ground.

ECMCONNECTOR 131P) E
6 . Disconnect ECI\4 connectorE {31P). 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 8 . lvleasure voltagebetweenECMconnectorterminal

E7 and body ground.
ECMCONNECTOR {31P} E MRLY
MRLY {RED/YEL)
Wiresideof {emale terminals
ls there continuity? YES-Repair short in the wire betweenthe ECM l a { E 7 ) n d t h e P G M - Fm a i n r e l a y1, I Wiresideol remale terminals
tt.
N O R e p l a c eh e P G M - Fm a i n r e l a y1 . 1 t l Turn the ignition suitchOFF. c o n n e c t oE ( 3 1 P ) . r
ls there battery voltage? YES Go to step 12. NO Go to step 9.
'13.R e c o n n e cE C M t
(conl'd)
11-81
PGM-FISystem
14. Measurevoltage betweenECMconnectorterminal E7 and body ground.
ECMCONNECTOR 13lPI E MRLY IBEO/YEL)
1 8 .Removethe glove box (seepage 20-63). 1 9 .Removethe PGM-FImain relay '1{A).
W i r es i d eo f f e m a l e e r m i n a l s t
ls there battery voltage? YES Go to step 15. NO-Update the ECM if it does not have the latest software,or substitutea known-goodEClvl, then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C M . I l 1 5 . Disconnect ECI\4 connectorA (31P).
to.
20. Measure voltage
between body ground and ECM connector terminals A3 and A2 individually. ECMCONNECTOR {31PI A IGP2 (YEL/BLK) IGP1 (YEL/BLK)
1 7 . Measurevoltage betweenbody ground and ECIM c o n n e c t otre r m i n a l s 3 a n d4 2 i n d i v i d u a l l y . 4

ECMCONNECTOR {3.IP) A IGP2 (YEI./BLX) IGP1 (YEL/BLKI
I s there battery v oltage? YES Repairshortto power in the wire between ( ) t h e E C I \ 4A 2 . A 3a n d t h e P G M - Fm a i n r e l a y1 . 1 l

W i r es i d eo f f e m a l e e r m i n a l s l
N O R e p l a c e t h e G M F l m a i n r e l a y1 . ! P
ls there battery voltage? YES-Go to step 18. NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originalECM/PCl\4.1
11-82
DTGPl106:BARO SensorRange/Perfomance Problem

1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.Holdthe engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle. Test-drive with the transmissionin 4th gear. Accelerate 5 secondsusingwide open throttle. for Checkfor a TemporaryDTCwith the scantool. Is TemporaryDTC Pl106 indicated? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C M! l . NO Intermittent failure,system is OK at this time.I
DTCPl107: BARO Sensor Circuit LowVoltage DTCPl108: BARO Circuit High Sensor Voltage
1 . R e s e t h e E C M{ s e ep a g e11 - 4 ) . 2. Turn the ignition switch ON (ll). l s D T C P 1 1 0 7o r P 1 1 0 8 n d i c a t e d ? i YES-Update the ECM if it does not havethe iatest software,or substitutea known-goodECI\4, then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECI\4.I l NO- Intermittent failure,system is OK at this trme.l
11-83
PGM-FI System
(cont'dl DTGTroubleshooting
(Sensor Range/ DTC Pl157: Sensor Ay'F 1) Performance Problem
( 1 . R e s e t t h e C I Ms e ep a g e1 1 - 4 ) . E 2. Startthe engine. ls DTC Pl157 indicated? YES-Go to step 3. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the Ay'F sensor(Sensor1) and at the ECN4.I
L
6. Check continuity for between ECM connector t e r m i n a l4 6 a n dA 1 6 . s
ECMCONNECTOR {3IP) A

Disconnect Ay'F the sensor(Sensor1) 4P connector a n d E C Mc o n n e c t oA ( 3 1 P ) . r ConnectA,/F sensor(Sensor1) 4P connector t e r m i n a l s o . 1 a n d N o . 2 w i t h a j u m p e rw i r e . N (SENSOR 4PCONNECTOR A/F SENSOR 1) AFS+ {BLU)
A/F SENSOR 1I {SENSOR 4P CONNECTOR
ls therecontinuity? YES Goto step9. NO Goto step7. (Sensor 4Pconnecror 7 . Connect sensor A/F 1) r g t e r m i n a l o .1 t o b o d y r o u n d i t ha j u m p e w i r e . N w (
JUMPER WIRE
11-84
ECM connector for between 8. Check continuity 46 terminals andbodyground.

A ECMCONNECTOR 131P}
(Sensor AFS1) Ay'F DTCPl158: Sensor Terminal LowVoltage

E 1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine. ls DTC P1158 indicated? YES Go to step 3. NO-lntermittent failure,system is OK at this time at or Checkfor poor connections loosetermanals I the Ay'F sensor(Sensor1) and at the ECIM
Wire side ol lemaleterminals
3. Turn the ignition switch OFF. ls there continuity? YES-Repair open in the wire betweenthe Ay'F sensor(Sensor1) and the ECM(416).1 NO-Repair open in the wire betweenthe Ay'F sensor(Sensor1) and the ECM (46).1 sensor(Sensor1) and 9 . Substitutea known-goodAy'F recheck. ls DTC P1157 indicated? YES- Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).if the symptom/indication goes away with a known-goodECM,replacethe original ECM.! the sensor{Sensor1).! NO- Replace Ay'F ls thete continuity? YES-Repair shon in the wire betweenthe A,/F ( 1 s e n s o r S e n s o r ) a n dt h e E C M( A 1 6 ) . 1 NO Go to step 6. Ay'F sensor(Sensor1) 4P connector, 4, Disconnectthe r a n d E C Mc o n n e c t oA ( 3 1 P ) . 5. Checkfor continuitybetweenECMconnector t e r m i n a 4 1 6 a n d b o d yg r o u n d . l A ECMCONNECTOR (31P)
Wire side oJfemaleterminals
' c o n td )
11-85
PGM-FI System
6. Substitutea known-goodAy'F sensor(Sensor1)and recheck. Is DTC P1158 indicated? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).if the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO- Replace Ay'F the sensor(Sensor1).t
DTCPl159:A,/F Sensor(Sensor AFS + 1) Terminal LowVoltage

1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . E 2. Start the engine. ls DTC P1159 indicated? YES-Go to step 3. NO-lntermiftent failure.system is OK at this time. Checkfor poor connections looseterminaisat or the A,/F sensor(Sensor1) and at the ECM.I 3. Turn the ignition switch OFF. 4. Disconnect Ay'F the sensor(Sensor1) 4P connector a n d E c M c o n n e c t oA ( 3 1 P ) . r 5. Checkfor continuitybetweenECMconnector terminal 46 and body ground.
ls therecontinuity? YES-Repair shortin thewire between Ay'F the r ( s e n s o(rS e n s o1 )a n dt h eE C M A O ) . I NO Goto step6.
11-86
6. Substitutea known-goodAy'F sensor(Sensor1i and recnecK. i l s D T C P 1 1 5 9n d i c a t e d ? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then if recheck(seepage 11-6). the symptom/indication goes away with a known-goodECN4, replacethe o r i g i n aE C M . I l ( 1 N O R e p l a c eh e A y ' F e n s o r S e n s o r ) . 1 t s
11-87
PGM-FI System
DTCPl163:Ay'F Sensor(Sensor ) Slow 1 Response
NOTE:lf DTCP1162is storedat the same time as DTC P1163. troubleshootDTCP1162 first, then recheckfor D T CP 1 1 6 3 . 1 . R e s e t h e E C M( s e ep a g e11 - 4 ) . 2. Startthe engine.Hold the engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on. 3. Test-driveunderthe following conditions: . 55 mph (89 km/h) steadyspeed ' Transmissionin sth gear ' Until the Ay'F sensorreadiness code or TemporaryDTCPl163 comes on 4. Checkfor a TemporaryDTCwith the scantool. ls Temporary DTC P 1163indicated? YES Replace Ay'F the sensor(Sensor1).I NO Intermittent failure, system is OK at this time. Checkfor poor connections looseterminalsat or the A'lFsensor (Sensor1) and at the ECM.t
(Sensor Circuit DTCPl164: Sensor A,/F 1) Range/Performance Problem

( 1 . R e s e t t h e C I \ 4s e ep a g e1 t - 4 ) . E 2 . S t a r tt h e e n g i n e . o l d t h e e n g i n e a t 3 , 0 0r p m w i t h H 0 no load (in neutral)until the radiatorfan comes on, 3. Test-drive 3rd gear.Startingat 1,600rpm, in accelerate using wide open throttlefor at least 5 seconds. Then decelerate at least5 seconds for with the throttle completelycloseduntil the A,/F sensorreadiness code is set to completeor TemporaryDTCP1164comes on. 4. Checkfor a TemporaryDTCwith the scantool. ls TemporaryDTC P1164indicated? YES- Replace A,,/F the sensor(Sensor1).I NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the Ay'F sensor relay,at the Ay'F sensor(Sensor1), a n da t t h e E c M . l
11-88
(Sensor Heater 1) Ay'F DTCPl166: Sensor Malfunction Circuit

1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . E 2. Startthe engine. ls DTC P1166indicated?
Is therc battery voltage? YES-Update the ECM if it does not have the latest a soflware,or substitute known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l NO-Go to step 5.
YES-Go to step 3. NO-lntermittent failure,system is OK at this lime. or Checkfor poor connections looseterminalsat sensor(Sensor1),and the Ay'F sensorrelay,the A,/F t h e E c M .! 3. Checkthe following fuse: . No. 14 OPTION(30A)fusein under-hoodfuse/ rerayDox. . No. 2*B LAF (Ay'F) (20A)fuse in underHEATER dash fuse/relaybox. . No. 4 ACG (10A)in underdash fuse/relaybox. Are any of the fuses blown? YES Repairshort in the wire betweenthe Ay'F sensorrelay and the fuses.I NO Go to step 4. 4. MeasurevoltagebetweenECMconnector terminalsA1 and A24. 30 secondsafter the ignition s w i t c hi s t u r n e dO N ( l l ) .
A ECMCONNECTOR I31P) Wire side of femaleterminals
5. MeasurevoltagebetweenECMconnector terminalsA22 and A24.

A ECMCONNECTOR {31P}
ls therebattery voltage? YES Goto step6. N O - G o t o s t e p1 0 . OFF. switch 6. Turnthe ignition E 7. Disconnect connector (31P). ECM s O 8 . T u r nt h ei g n i t i o n w i t c h N{ l l ) .
W i r es r d eo f l e m a l et e r m i n a l s
(cont'd)
11-89
PGM-FI System
9. ConnectECMconnectorterminal EStobody ground with a jumper wire, then measurevoltage betweenECMconnectorterminalsA1 and 424. ECMCONNECTORS ls there continuity? YES Repairshort in the wire betweenthe A|/F sensorrelay,A,/F sensor{Sensor1) and ECM lA22J.a NO Go to step 13.
t5.
Turn the ignition switch ON (ll).
1 4 . Measurevoltage betweenECMconnector terminalsE8 and A24.

ECM CONNECTORS
E {31P)
ls there battery voltage? YES- Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECMt l . NO Repairopen in the wire betweenthe Ay'F ( r s e n s o r S e n s o 1 ) a n d E C M( A 1 ) t. a {31P)
Wiresideof female terminals ls there battety voltage? YES-Repair open in the wire betweenthe ECM (A22)and the IVF sensor(Sensor1).I N O - G o t o s t e p1 5 . Checkfor continuityin the wires betweenthe Ay'F sensorand the fuses. ls there continuity? (SENSOR 4PCONNECTOR A/F SENSOR 1) YES-The wires are OK. Replace A,/F the sensor relay.l NO Repairopen in the wire betweenthe Ay'F sensorrelay and the fuses.l
1 0 .Turn the ignitionswitch OFF. 1 1 .Disconnecl ECfM the connectorA (31P) and the Ay'F
sensor(Sensor1) 4P connector. 1 2 . Checkfor continuitybetweenthe Ay'F sensor ( S e n s o r ) 4 Pc o n n e c t otre r m i n a lN o . 3 a n d b o d y 1 ground.
11-90
(Sensor Heater 1) Ay'F DTCPl167: Sensor Malfunction Circuit

NOTE:lf DTCP1162is storedat the same time as DTC first, then troubleshoot P1167, troubleshootDTCP1162 D T CP 1 1 6 7 . E 4 1 . R e s e t t h e C I \ ( s e ep a g e1 1 - 4 ) 2. Startthe engine.Wait for at least80 seconds. ls DTC P01167 indicated? YES Go to step 3.
6. Checkfor continuitybetweenECMconnector , t e r m i n a l s4 6a n d 4 1 6 . A ECMCONNECTOR {31P) AFS- {RED)
trTzTil,ils l t l
t8
9 2C21
IRED/YEL)
l?rlzsIels
AFS
Wire side of lemale terminals
NO-lntermittent failure,system is OK at this time. or Checkfor poor connections looseterminalsat sensor(Sensor1), the Ay'F sensorrelay,at the Ay'F a n da t t h e E C M . I
?
ls thetecontinuity? r th Y E S - R e p l a c e eA / Fs e n s o(rS e n s o1 ) . 1 the NO-Repairopenin thewire between Ay'F ( r s e n s o(rS e n s o1) a n dt h eE C M 4 6o r A 1 6 ) . I
Turn the ignitionswitch OFF. sensor4P connectorand ECM Disconnect A,/F the connectorA (31P).
sensor(Sensor1) 4P connector 5 . Connectthe Ay'F N t e r m i n a l s o . 2 a n d N o . 1 w i t h a j u m p e rw i r e .

(SENSOR 1) A/F SENSOR 4P CONNECTOR JUMPERWIRE
Wire side of femaleerminals t
11-91
PGM-FI System
DTCPl297: ELD Circuit LowVoltage
1 . R e s e t h e E C M{ s e ep a g e1 1 - 4 ) . 2. Startthe engine. 3 . T u r no n t h e h e a d l i g h t s . ls DTC P1297 indicated? YES Go to step 4. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or t h e E L Da n d a t t h e E C M . I 4. Turn the ignition switch and the headlightsOFF. 5. DisconnecttheELD3P connector. 6. Turn the ignition switch ON {ll). ls there continuity? 7. Measurevoltage betweenbody ground and ELD3P connectorterminal No. 3. ELO3P CONNECTOB ELD{GRN/REDI YES-Repair short in the wire betweenthe ECM ( E1 5 )a n d t h e E L D r . NO- U pdatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l
I
8. Turn the ignition switch OFF. 9. Disconnect ECMconnectorE {31P). 10. Checkfor continuitybetweenbody ground and E C Mc o n n e c t otre r m i n a lE 1 5 . ECMCONNECTOR 131PI E
I l 2 l 34 5 6 1 7
to ,2 2al2/
td
8 I 21 / 120 31
tA
7\'
ELD (GRN/RED}
ls thereabout5 V? YES Replace ELD. the t NO-Gotostep . 8
11-92
ELD Circuit HighVoltage DTCPl298:

1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) E 2. Stan the engine.
8. T u r nt h e i g n i t i o n w i t c hO F F . s 9 . ConnectELD3P connectorterminal No. 3 to body g r o u n dw i t h a j u m p e rw i r e .

ELD3P CONNECTOR
3. Turn on the headlights. ls DTC P1298 indicated? YES-Go to step 4. failure.system is OK at this time. NO- Intermittent or Checkfor poor connections looseterminalsat t h e E L Da n d a t t h e E C M . I 4. Turn the ignition switch and headlightsOFF. ELD3P connector. 5. Disconnectthe 6. Turn the ignition switch ON (ll).
---F-------
ELD (GRN/RED)
l 1 l 2: r l
wrRE IJUMPER
Wire side of temaleterminals
1 0 .Disconnect ECMconnectorE (31P). 11. Checkfor continuitybetweenbody ground and

ECMconnectorterminal E15. E ECMCONNECTOR 131PI
7. Measurevoltagebetweenbody ground and ELD3P connectorterminal No. 1. ELD3PCONNECTOR
1 2 1 34 5
IG1IBLK/ORNI
14
L C
o t /
22123 24
I I 6 l / 1 8 2C 21 21./ 2Q 30 J
ELD
i1' IGRN/RED)
Wire side of femaleterminals Wire side ot {emaleterminals
Is thetecontinuity?
Y E S - G ot o s t e p1 2 .
YES-Go to step 8. i N O - C h e c k t h e N o . 4 A C G ( 1 0 A ) f u s en t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repairopen in the wire betweenthe No. 4 ACG (10A)fuse and the ELD.I
the openin thewire between ECM NO Repair ( E 1 5a n dt h eE L D . )
(cont'd)
11-93
PGM-FI System
12, Checkfor continuitybetweenELD3P connector t e r m i n a lN o . 2 a n d b o d y g r o u n d .
E L D 3 PC O N N E C T O R
W i r e s i d eo f f e m a l e e r m i n a l s t
ls there continuity? YES Go to step 13. NO- Repairopen in the wire betweenthe ELDand G 2 0 1I. Reconnect ELD3P connectorand ECM the connectorE (31P). 1 4 . Startthe engineand let it idle.
t5_
While measuringvoltage betweenECMconnector t e r m i n a l s 2 4 a n d E 1 5 , u r nt h e h e a d l i g h to n 4 t s t hi g h ) .

ECM CONNECTORS
W i . e s i d eo f f e m a l et e r m i n a l s
Does the voltage drop? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck{seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l N O R e p l a c eh e E L D . I t
11-94
(CMP) DTCPl361:Camshaft Position Sensor B (TDC Sensor) Intermittent Interruption (CMP) DTCPl362:Camshaft Position Sensor (TDC B Sensor) Signal No
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine. ls DTC P1361and/or P1362 indicated? YES Go to step 3. NO- Intermittent failure.system is OK at this time. Checkfor poor connections looseterminalsat or t h e C M Ps e n s o r ( T D C e n s o r a n d a t t h e E C M . I B s )
7. l\4easure voltage betweenCMP sensorB {TDC sensor)3P connectorterminal No. 1 and body ground.
CMP SNSOR 8 ITDCSENSOR)3P CONNECTOR
Wlres de ollemaleterminals
ls thereabout5 V? YES-Go to step8.
3 . Turn the ignitionswitch OFF. N O - G o t o s t e p1 0 .

4 . DisconnecttheCMP sensorB (TDCsensor)3P
connector.
voltage Cl\ilP sensor (TDC B 8. Measure between s e n s o r )Pc o n n e c t oe r m i n a lN o .2 a n dN o ,3 . 3 tr s

CMPSENSON llOC SENSOfi) CONNECTOF B 3P
5 . Turn the ignitionswitch ON (ll). 6 . Measurevoltage betweenCMP sensorB (TDC

sensor)3P connectorterminal No. 3 and body grouno. B CMP SENSOR {TDC SENSOR) CONNECTOR 3P
IGP
Wire s de olfema etefminals
1 2 3
{YEL/BLK}
ls there battery voltage? Y E S - G o t o s t e p9 . NO Repairopen in the wire betweenthe CMP s ) s e n s o rB ( T D C e n s o r a n d G 1 0 1 . 1
Wiresideol temale terminals
a 9. Substitute known-goodCMP sensorB (TDC sensor)and recheck. ls DTC P1361and/or P1362 indicated? YES Updatethe ECMif it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l N O R e p l a c eh e o r i g i n a C M P s e n s o r B ( T D C t l sensor).1
ls there battety voltage? YES Go to step 7. NO-Repair open in the wire betweenthe PGM-Fl m a i n r e l a y1 a n dt h e C M Ps e n s o r ( T D C e n s o r ) . I I s
(cont'd)
11-95
PGM-FI System
10. Measure voltage between ECI\4 connectorterminal A26andbodyground.
ECM CONNECTOR A (31P)
DTCPl607: Malfunction ECMInternal in Circuit

1. ResettheEC|\il lsee page 11-4). 2 , T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d w a i t f o r s 40 seconds. ls DTC P 1607 indicated? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11 6). lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l NO Intermittent failure,system is OK at this time. A low batterycan causethis problem . Ask the customerif there has been any recenttrouble s t a r t i n gh e e n g i n e . l t
1 2 3 4 5 6 1 7 I 0 1 11 2 1 . / 61,/18 I 2C2l 2324 21m 30

TDC {GRN}
Wire side oI temaleterminals
ls thereabout5 V ? YES Repair openin thewire between ECM the (426) and CMPsensor (TDC B sensor).1 N O - G o t o s t e p1 1 .
1 1 .Turnthe ignition switchOFF. 1 2 . Disconnect ECIM A connector (31P)
Check continuity for between ECM connector terminal 426 andbodyground.

ls there continuity? YES Repairshort in the wire betweenthe ECM (426)and the CMP sensor B (TDCsensor).1 NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l
11-96
MIL CircuitTroubleshooting
1. Connectan OBD ll scantool/HondaPGM Tester ( s e ep a g e1 1 - 3 ) . 2. Turn the ignition switch ON (ll) and readthe OBD ll scantool/HondaPGM Tester. Does the OBD ll scan tool/Honda PGM Tester communicatewith the ECM? YES Go to step 3. " NO Go to troubleshooting DLCCircuit T r o u b l e s h o o t i n g ( s e ep a g e1 1 - 1 0 9 ) . " 3. Checkthe OBD ll scantool/HondaPGM Testerfor DTCs. Are any DTCs indicated? Index. YES Go to the DTCTroubleshooting NO-Go to step 4. 4. Turn the ignitionswitch OFF. 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) a n dw a t c ht h e s r l M a l f u n c t i oIn d i c a t oL a m p( M l L ) . Does the MIL come on and stay on for more than 20 secondsaftet turning the ignition switch . A l o o s eN o . 1 7 F U E LP U M P( 1 5 A ) f u s en t h e i fuse/relaybox. under-dash . A p o o r c o n n e c t i o n t E C Mt e r m i n a E 3 1 . l a . An intermittentopen in the GRN/ORN wire ) b e t w e e n h e E C M( E 3 1 a n d t h e g a u g ea s s e m b l y . t . An intermittentshort in the wire betweenthe ECM(A21)and the manifold absolutepressure (MAP) ensor. s . An intermittentshort in the wire betweenthe (A20)and the throttle posilion (TPisensor. ECI\4 . An intermittentshort in the wire betweenthe ECM (E5)and the fuel tank pressure(FTP) sensor. 6. Turn the ignition switch OFF. 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s ls the low oil pressure light on? YES Go to step 10. N O - G o t o s t e p8 . i N R 8 . I n s p e c t t h e o . 1 0 l \ 4 E T E( 7 . 5 A ) f u s en t h e u n d e r dash fuse/relaybox. ls the luse OK? YES Go to step L N N O R e p a i r h o n i n t h ew i r e b e t w e e n o . 1 0 s ( . M E T E R 7 . 5 A ) f u s e n d t h e g a u g ea s s e m b l yA l s o a r e p l a c e t h e o . 1 0M E T E R7 . 5 Af u s e . l N { ) 50A)fuse in 9. Inspectthe No. 20 lG1 (40A)(Canada: fuse/relaybox. the under-hood ls the f use OK? YES Repairopen in the wire betweenthe No. 20 a l G ( 4 0 A ) C a n a d a5 0 A ) f u s e n d t h e g a u g e { r assembly.lf the wire is OK, test the ignition switch {seepage 22 53). N N O R e p a i r h o r ti n t h e w i r e b e t w e e n o . 2 0 l G s ( 4 0 A ) C a n a d a5 0 A ) f u s e n d t h e u n d e r ' d a s hu s e l f a l : r e l a yb o x .A l s o r e p l a c eh e N o . 2 0 l G ( 4 0 A i t ( C a n a d a5 0 A )f u s e . I :
oN (tr)?
YES lf the MIL alwayscomes on and stayson, go to step 76. But if the lMlLsometimesworks normally,first checkfor these problems. . An intermittentshort in the wire betweenthe ( ) E C I M E 2 9 a n dt h e d a t al i n kc o n n e c t o( D L C ) . r . An intermittentshort in the wire betweenthe ) E C M( E 3 1 a n dt h e g a u g ea s s e m b l y . NO lf the MIL is alwaysoff, go to step 6. But if the lvllLsometimesworks normally,first checkfor these problems. . A l o o s eN o . 1 0 M E T E R 7 . 5 A f u s ei n t h e u n d e r ( ) dash fuse/relaybox. . A l o o s eN o . 2 0 l G ( 4 0 A ) C a n a d a5 0 A ) I u s e n t h e ( : i fuse/relaybox. under-hood . A i o o s eN o . 6 E C U( E C M ) 1 5 A ) u s ei n t h e u n d e r ( f hood fuse/relaybox.
(conr'd)
11-97
PGM-FI System
(cont'dl MIL CircuitTroubleshooting
1 0 .Tryto startthe engine. Doesthe enginestart? Y E S - G ot o s t e p1 1 . N O - G o t o s t e p1 4 .
1 1 .Turnthe ignition switch OFF. 1 7 . Removethe glove box (seepage 20-63) and the P G M ' F I a i n r e l a y1 . m
to.
(154)fuse Removethe blown No. 6 ECU{ECfU) from the under-hood fuse/relaybox.
12. Connect ECM connector terminal to body E31 ground with a jumperwire.
ECMCONNECTOR 13lPI E
l l 2 l 34 5 6 1 7 l1 8I 4 1 5161,/ 118 2( 2t 2' 23 24 z7l/ 129 31

JUMPER MIL (GRN/ORN} WIRE
1 8 . Checkfor continuitybetweenbody ground and P G M - Fm a i n r e l a y1 4 P c o n n e c t otre r m i n a l s o . 2 l N a n d N o .4 i n d i v i d u a l l v .

PGM-FI MAIN RELAY1 4P CONNECTOR
Turn the ignition switch ON (ll). ls the M lL on? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECIM, replacethe o r i g i n aE C M . I l NO-Check for an open in the wire betweenthe ) E C M( E 3 1 a n d t h e g a u g ea s s e m b l yA l s o c h e c k o r . f a b l o w nM I L b u l b .l f t h e w i r e sa n d t h e b u l ba r e O K , replacethe gauge assembly.l
f V (wHr/ B v) BLK)( IA
W r r es r d eo l l e m a l e e r m r n a l s t
ls there continuity? Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nh e N o . 6 t () E C U( E C l \ 4 1 5 A ) u s ea n d t h e P G M - Fm a i n r e l a y1 . f l ( A l s o r e p l a c eh e N o . 6 E C U( E C M ) 1 5 A ) u s e . l t f N O - G o t o s t e p1 9 .
't4. Turn the ignltion switch OFF,

(15A)fuse in the 1 5 . Inspectthe No. 6 ECU (ECIM) under-hood fuse/relaybox. ls the f use OK? YES-Go to step 22. N O - G o t o s t e p1 6 .
11-98
19. Disconnect each of the componentsor the connectorsbelow, one at a time, and checkfor continuitybetweenPGM-FI main relay 1 4P connectorterminal No. 1 and body ground. . . . . . PGfvl-Fl main relay 2 ECMconnectorA (31P) Eachinjector2P connector ldle air control (lAC)valve3P connector CamshaftPosition(CMP)sensorB (Topdead center(TDC) sensor)3P connector . Crankshaft position(CKP) sensor3P connector PGM-FI MAIN RELAY1 4PCONNECTOR
21. Checkfor continuitybetweenPGM-FI main relay 1 4P connectortermlnal No. 1 and body ground.
PGM-FIMAIN RELAY1 4P CONNECTOR
ls there continuity? YES Repairshort in the wire betweenthe PGM-Fl main relay 1 and each item. Also replacethe No. 6 ( E C U{ E C M ) 1 5 A ) u s e . l f l N O - R e p l a c et h e P G M - Fm a i n r e l a y1 .A l s o r e p l a c e (1 f t h e N o 6 E C U{ E C I M ) 5 A ) u s e . I
( N i 22. I n s p e c t t h e o . 1 7 F U E LP U I \ 4 P1 5 A ) f u s en t h e ls thete continuity? YES Go to step 20. NO- Replace componentthat made continuity the lf to body ground go away when disconnected. the item is the ECM,updatethe ECM if it does not have the latestsoftware.or substitutea known-good ECM,then recheck(seepage 11-6). the symptom/ lf indicationgoes away with a known'good ECM, r e p l a c eh e o r i g i n a E C M . t l Also replacethe No. 6 ECU(ECM)(15 A) fuse, f box. under-dash use/relay ls the tuse OK? YES Go to step 34. NO Go to step 23. f 23. R e m o v e h e b l o w nN o , 1 7 F UE LP U M P( 1 5 A ) u s e t fuse/relaybox. from the under-dash ECfvl connectorE (31P). 2 4 . Disconnect
20. Disconnect connectorsof all these components. the

. . . . . P G M - Fm a i n r e l a y2 l E C Mc o n n e c t oA ( 3 1 P ) r lnjectors ( l d l ea i r c o n t r o l l A C ) v a l v e CamshaftPosition{CMP)sensorB (Top dead center(TDC) sensor) . Crankshaft position(CKP) sensor
(conr'd)
11-99
PGM-FI System
25. Checkfor continuitybetweenECMconnector
terminal E9 and body ground. ECMCONNECTOR (31P) E
27. Check continuity for between ECIVI connector terminal andbodyground. Eg

Wire side o{ {emaleterminals
Wire side oI Jemale terminals
ls therc continuity? YES-Go to step 26. N O R e p l a cte e N o . l T F U E L P U M P ( 1 5 A ) f u s e , h and updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM.replacethe originaECM.I l 26. Removethe PGM-Flmain relay 2 (A).
ls there continuity? YES Repairshort in the wire betweenthe No. 17 , F UE LP U M P( 1 5 A ) f u s e n d t h e E C M( E 9 ) o r a betweenthe No. 17 FUELPUMP (15A) fuse and the P G M - Fm a i n r e l a y2 . A l s o r e p l a c eh e N o . 1 7 F U E L I t P U M P( 1 5 A ) f u s e . l NO Go to step 28.
28. Removethe rear seatcushion (seepage 20-80). 29. Removethe accesspanelfrom the floor. 30. Disconnect fuel pump 5P connector. the
11-100
for 31. Check continuity between pump5P fuel connector terminal 5 andbodyground. No.
FUELPUMP5PCONNECTOR
33. Check continuity for between pump5P fuel connector No. terminal 5 andbodyground.
FUELPUMP5P CONNECTOR
=
Wire side ol lemal rerminals
ls therc continuity? YES Repair shortin thewire between fuel the p u m pa n dt h eP G M - F l a i nr e l a y .A l s or e p l a c e m 2 ( t h EN O . 7F U E L U M P 1 5 Af)U S E . T 1 P NO-Go to step32. 32. Reinstallthe PGM-Fl mainrelay (A). 2
YES Replace the PGM-Flmain relay 2. Also r e p l a c eh e N o . 1 7 F U E LP U M P( 1 5 A ) u s e . l t f NO Checkthe iuel pump, and replaceil if necessary. Also replacethe No. 17 FUELPUMP (15A)use.! f 34. Disconnect ECMconnectorE (31P). 3 5 . T u r nt h e i g n i t i o n w i r c hO N { 1 1 1 . s 36. Measurevoltage betweenECMconnectorterminal E9 and body ground.
ECfl CON|{CCIORE (3rPt
Wire side ol female lerminals
ls there battery voltage? YES Go to step 37. NO Repairopen in the wire betweenthe No. 17 F U E LP U M P( 1 5 A ) f u s e n d t h e E C M( E 9 ) . 1 a
(cont'd)
11-101
PGM-FI System
37. lvleasure voltage between ECM/PCM connector E t e r m i n a l 7a n db o d yg r o u n d .
ECM CONNECTOR {31PI E MRLY
40. lvleasure voltage betweenPGN4-Fl main relay 1 4P c o n n e c t otre r m i n a lN o . 4 a n d b o d vq r o u n d .

PGM-FIMAIN RELAY1 ilP CONNECTOR
Wire side of femaleterminals Wire side ot lemale terminals
ls there battery voltage? YES Go to step 42. NO Go to step38.
ls there battery voltage? Y E S - G o t o s t e p4 1 . NO Repairopen in the wire betweenthe No. 6 ( E C U( E C M ) 1 5 A ) u s ea n d t h e P G f M - F l a i n r e l a y1 . f m I

4 1 . Checkfor continuitybetweenPGM-FI main relay 1
38. Turn the ignitionswitch OFF. 3 9 . Removethe PGM-FImain relay 1 {A}

-A
4P connectorterminal No. 3 and ECMconnector t e r m i n a lE 7 .

PGM.FIMAIN RELAY1 4P CONNECTOR
(RED/YEL) MRLY
ECMCONNECTOR 131PI E
(RED/YEL) MRLY
ls there continuity? YES-Testthe PGM-Flmain relay 1 (seepage2251). lf the relay is OK, updatethe ECM if it does not have the latestsoftware,or substitute knowna good ECM,then recheck{seepage 11'6).lf the goes away with a known-good symptom/indication E C M ,r e p l a c eh e o r i g i n a E C M . I t l NO*Repair open in the wire betweenthe PGM-FI m a i n r e l a y1 a n d t h e E C M( E 7 ) . 1
11-102
42. Reconnect ECI\4 connectorE {31P). 4 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 44. Measurevoltage betweenbody ground and ECM
connectorterminals42 and 43 individually.
48. Measure voltage between PGM-FI mainrelay1 4P connector terminal 2 andbodyground. No.
PGM.FIMAIN RELAY1 4PCONNECTOR

YES Go to step 49. ls there battery voltage? YES Go to step 51. NO Go to step 45. 4 5 . T u r nt h e i g n i t i o n w i t c hO F F . s 46. R e m o v e h e P G M ' F m a i n r e l a y1 {A) l t ,A N O R e p a i r p e ni n t h e w i r e b e t w e e n h e N o . 6 o t ( E C U{ E C M ) 1 5 A } f u s e n d t h e P G M - Fm a i n a l r e l a y1. ! 4 9 . T u r nt h e i g n i t i o n w i t c hO F F . s 5 0 . Checkfor continuitybetweenPGM-Flmain relay 1 4P connectorterminal No. 1 and ECMconnector t e r m i n a l s 2 a n d4 3 i n d i v i d u a l l y . 4
PGM.FI MAIN RELAYI ilP CONNECTOR
IGPl (YEL/BLK)
4 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
ls there continuity? Y E S R e p l a c eh e P G M - Fm a i n r e l a y1 . 1 t l NO Repairopen in the wire betweenthe PGM-FI '1 m a i n r e l a y a n d t h e E C M( A 2 ,A 3 ) . 1
{cont'd}
11-103
PGM-FI System
51. Measure voltage between bodygroundandECM 44, connector terminals A5,423,and424 individuallv.
ECM CONNECTOR A 131P) (BLK) PG2 PG1 IBLKI
53. Turn the ignitionswitch OFF. 54. Disconnect manifoldabsolutepressure(MAP) the

sensor3P connector. 55. T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 56. Measurevoltage betweenbody ground and ECM c o n n e c t otre r m i n a A 2 1 . l
ECMCONNECTOR {31P) A
ls there morc than 1.0 V ? YES Go to step 52. N O - R e p a i r o p e n i n t h e w i r e ( s ) h a t h a d m o r et h a n t 1.0V betweenG 10'l and the ECM (A4,A5, A23, A24l.a Measurevoltagebetweenbody ground and ECM c o n n e c t otre r m i n a 4 2 1 . l
ECMCONNECTOR 131P) A
Wiresideof female terminals ls there about 5 V? YES Replace MAP sensor.l the NO Go to step 57. 5 7 . Turn the ignition switch OFF. 5 8 . D i s c o n n e c t C Mc o n n e c t oA ( 3 1 P ) . E r
Wiresideof female terminals ls there about 5 V? YES-Go to step 60. N O - G o t o s t e p5 3 .
11-104
59. Check continuitv for between ECIM connector t e r m i n a l 2 1a n db o d yg r o u n d . 4

ECM CONNECTOR {3,IPI A
t t,
Turn the ignition switch OFF.
o z , Disconnect throttle position(TP)sensor3P the connector.
6 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 64. Measurevoltage betweenbody ground and ECM

connectorterminal 420,
ls there continuity? YES*Repair short in the wire betweenthe ECM ( 4 2 1 )a n d t h e M A P s e n s o r . l NO Updatethe ECM it it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 1'l-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l Wiresideof female terminals ls there about 5 V? YES Replace thronle body (theTP sensoris the not availableseparately). I NO Go to step 65. 65. Turn the ignition switch oFF. 66. Disconnect ECMconnectorA (31P).
6 0 . Measurevoltagebetweenbody ground and ECM

connectorterminal 420.
ECMCONNECTOR {3TP} A
1 1 2 14 5 o t / 3 I 1 0 11112 5 6 / 1189 2t 21 2' 231?4 ? q Tln 29
vcc2
IYEL/ BLU)
W i r e i d e tf e m a l t e r m i n a l s e s o ls there about 5 V? YES-Go to step 68. N O - G o t o s t e p6 1 .
conlo
11-105
PGM-FI System
(cont'd) MIL CircuitTroubleshooting
6 7 . Check continuity for between ECIM connector A t e r m i n a l 2 0a n db o d yg r o u n d .
ECMCONNECTOR (31P) A
68. Measurevoltage betweenbody ground and ECM c o n n e c t otre r m i n a lE 5 . ECMCONNECTOR (31PI E
r l 2 l 3 1 5 4
o t / ta,
10 t1 121,/ 1516 1,/ 22 '3 241 125 26
9 2A21
vcc2
{YEL/ BLU}
Wire side of femaleterminals Wire side of femaleterminals
ls there continuity? YES Repairshon in the wire betweenthe ECN4 {A20)and the TP sensor,or repairshort in the wire betweenthe ECM (A8) and the knocksensor. t NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage l1-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.t l
Is there about 5 V? YES U pdatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodEClvl, replacethe o r i g i n aE C M . t l NO-Go to step 69. 6 9 . Turn the ignition switchOFF.
7 0 . Disconnect fuel tank pressure(FTP) the sensor3P

connector. 1 1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
11-106
72. Measure voltage between bodygroundandECM connector terminal E5.

ECMCONNECTOR 131P} E
7 6 . T u r nt h e i g n i t i o n w i t c hO F F . s 7 7 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 7 8 . Measurevoltage betweenECMconnectorterminal
E 2 9a n d b o d y g r o u n d . ECMCONNECTOR (31P) E
r l 2 l 3 1 4 6 1 5
22
23 241 l,/
1 ,/1,/1145 6
8 9 2A21 2930 scstBRN)
ls there about 5 V? Wiresideof female terminals YES Replace the FTPsensor.t NO Go to step 73. ls there about 5 V (or battery voltage)? YES-Go to step 82. NO Go to step 79.
1 3 . Turn the ignitionswitch OFF. 7 4 . Disconnect ECMconnectorE (3'lP). 7 5 .Checkfor continuitybetweenECMconnector

t e r m i n a lE 5 a n d b o d y g r o u n d .
7 9 . Turn the ignitionswitch OFF. 8 0 . Disconnect ECMconnectorE (31P).
ECMCONNECTOR {31PI E
Is there continuity? YES Repairshort in the wire betweenthe ECM ( E 5 ) n dt h e F T Ps e n s o r . l a NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l (cont'd)
11-107
PGM-FISystem
(cont'd) MIL GircuitTroubleshooting
81. Checkfor continuitybetweenECMconnector t e r m i n a lE 2 9a n d b o d y g r o u n d . ECMCONNECTOR 131P} E
r l 2 l 34 5
14 t c
22123124
61,/118 2A21 271./ 3031
scs(BRN)
ls there continuity? YES-Repair short in the wire betweenthe data link and the ECM(E29).1 connector(DLC) NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C I \ 4 , I l Turn the ignition switch OFF. Disconnect ECMconnectorE (31P). T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s Does the MIL stay on? YES-Repair short in the wire betweenthe gauge a s s e m b l y n dt h e E C M( E 3 1. l f t h e w i r e i s O K , a ) r e p l a c eh e g a u g ea s s e m b l y . l t NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l
11-108
DLCCircuitTroubleshooting
lf the ECMdoes not communicatewith the OBD ll scan tool, HondaPGfM Tester,or l/M test equipment,do this procedure. troubleshooting 1. Measurevoltage betweenDLCterminal No. 16 and body ground. DATALINKCONNECTOR {DLCI 3. Measurevoltage betweenDLCterminalsNo. 5 and No. 16. DATALINKCONNECTOR {DLC)
(WHT/RED)
ls there battery voltage? Terminal of lemale side terminals YES Go to step 4. ls therc battery voltage? YES-Go to step 2. 4 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s NO-Repair open in the wire betweenDLCterminal N o . 1 6 a n d t h e N o . 9 B A C KU P ( 7 . 5 ) f u s ei n t h e A f under-hood use/relaybox.I Measurevoltage betweenDLCterminalsNo. 4 and No.16.
(DLCI DATA LINK CONNECTOR
NO- Repairopen in the wire betweenDLCterminal N o . 5 a n dt h e E C M( E 3 )t.
5 . M e a s u r e o l t a g eb e t w e e n L Ct e r m i n a l s o . 5 a n d v D N No.7.
DATA LINKCONNECTOR {DLCI
T e r m i n a li d e f l e m a l ee r m i n a l s s o t
Terminal of Jemale side terminals
ls there 8.5 V or more? YES Go to step 10.
Is there battery voltage? NO Go to step 6. YES Go to step 3. 6. Turn the ignition switch OFF. NO Repairopen in the wire betweenDLCterminal N o . 4 a n d b o d yg r o u n d . l
(cont'd)
11-109
PGM-FI System
DLCCircuitTroubleshooting {cont'dl
Make sure the 7. Disconnect EClvl connectorE (31P). O B Dl l s c a nt o o l o r H o n d aP G MT e s t e r s i disconnected from the DLC. 8. Checkfor continuitybetweenDLCterminal No. 7 a n d b o d yg r o u n d . DATALINKCONNECTOR IDLC) ls there continuity? YES U pdatethe ECMif it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECI\4.I l NO Repairopen in the wire betweenDLCterminal N o . 7 a n dt h e E C M{ E 2 3 )A f t e rr e p a i r i n gh e w i r e , t . checkthe DTCwith the OBD ll scantool/Honda PGl\4Tester,and go to the DTCTroubleshooting Index.l
1 0 .T u r nt h e i g n i t i o ns w i t c hO F F .
1
Ierminal side of femaleterminals
' I.
l\4ake Disconnect ECI\4 connectorE (31P). sure the O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s disconnected from the DLC. T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
tJ.
YES-Repair short to ground in the wire between After DLCterminal No. 7 and the ECM {E23). r e p a i r i n gh e w i r e ,c h e c k h e D T Cw i t h t h e O B Dl l t t scantool/HondaPGM Tester,and go to the DTC Troubleshooting index.I NO Go to step 9.
Measurevoltage betweenDLCterminalsNo. 5 and No.7. DATALINKCONNECTOR {DLC}
9 . Checkfor continuitybetweenDLCterminal No. 7

a n d E C Mt e r m i n a lE 2 3 ,
ECMCONNECTOR {31PI E Terminalside of femaleterminals
K-LINE{LTBLU)
DATA LINK CONNECTOR
Is there 0 V? YES Updatethe ECMif it does not havethe latest then software,or substitutea known-goodECI\4, lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO Repairshort to power in the wire betweenthe . D L Ct e r m i n a lN o . 7 a n d t h e E C M( E 2 3 )A f t e r repairingthe wire, checkthe DTCwith the OBD ll scantool/HondaPGMTester,and go to the DTC T r o u b l e s h o o t i ni g d e x I n .
11-110
InjectorReplacement
(see page1l-144). 1 . Relieve pressure fuel (A), 2 . Disconnect connectors the fromthe injectors disconnect ground (C). the cable(B), andremove bracket the
(2.2 kgf.m, l6 lbf.ftl
*\
ffi\t\
3. Disconnect quick-connect the fittings (D). 4 . R e m o v e t h e f u erl a i lm o u n t i n g n u t s ( Ef)r o m t h e f u e l r a i l( F ) t h e nr e m o v e t h e f u e r a i la n d i n j e c t o r s s a n a s s e m b l y . l a 5. Removethe injectorclip (G)from the injector. 6. Removethe injectorfrom the fuel rail.
(cont'd)
11-111
PGM-FI System
(cont'd) InjectorReplacement
7 . C o a t t h e n e w o - r i n g s ( A ) w i t h c l e a n e n g i n e o l l , a n d i n s e r t t h e i n j e c t o ris (tB ) h e f u e lr a i l( C ) . n ot
r 8 , l n s t a ltl h e i n j e c t o c l i p { D ) . 9. Coatthe injectoro-rings(E)with cleanengine oil. 1 0 . I n s t a l l t h en j e c t o r sn t o t h e f u e lr a i l ,t h e n i n s t a l t h e f u e l r a i li n t o t h e i n t a k e m a n i f o l d ( G ) . i i l 1'1. Installthe fuel rail mounting nuts,ground cable.and bracket. 12. Connect the connectors the injectors. to 13. Connect fittings. the quick-connect 1 4 . T u r n t h ei g n i t i o n w i t c hO N ( l l ) ,b u t d o n o t o p e r a t e t h e t a r t e rA f t e r t h e f u e lp u m p r u n sf o r a b o u t2 s e c o n d st,h e s s . fuel pressurein the fuel line rises.Repeat this two or three times. then checkfor fuel leakage.
11-112
A/F SensorReplacement
Special Tools Required O2 sensorwrench,Snap-onYA8875.SPTools 93750, o r e q u i v a l e n t ,o m m e r c i a l l a v a i l a b r e c y 1. Disconnect A,/F the sensor4P connector(A),then removethe A,/F sensor{B).
Secondary HO2SReplacement
Special Tools Fequired 02 sensorwrench,Snap-onYA8875,SP Tools 93750, o r e q u i v a l e n t ,o m m e r c i a l l a v a i l a b l e c V 1. Disconnect secondaryHO2S4P connector(A), the then removethe secondaryH02S (B).
ffi
\I
B 44N.m
InstalltheIVF sensorin the reverseorder of removal.
2 . InstallthesecondaryHO2Sin the reverseorder of

removal.
11-113
PGM-Fl System
ECTSensorReplacement
'1. R e m o v e h e a i r c l e a n e r s e ep a g e1 1 - 1 6 2 ) . t {
CMPSensorB (TDC Sensorl Replacement

' t . R e m o v e h e a i r c l e a n e r s e ep a g e1 1 - 1 6 2 ) . ( t 2. Disconnect CN4P the sensorB (TDCsensor)3P
conneclor. Removethe CMP sensorB (TDCsensor)(A).
2. Disconnect ECTsensor2P connector. the 3. Removethe ECTsensor(A).
{1.2kgt m.8.7 lbt.ft}
---8.7tbf.ftl
r, ".- ,',',., *nr...
i l n s t a l l t h e e n s o r n t h e reverse order of removal s with a new o-ring {B).
4 . lnstallthe sensorin the reverseorder of removal with a new o-ring {B).
11-114
IAT SensorReplacement
1, Dlsconnect IAT sensor2P connector. the 2. Removethe clip (A) and the IAT sensor(B).
KnockSensorReplacement
1. Removethe intakemanifold bracket(A).
3. lnstallthe sensorin the reverseorder of removal.
24Nm (2.4kgt.m,17lbt.ftl
2. Disconnect knocksensor 1Pconnector. the 3 . R e m o v e h e k n o c ks e n s o r( B ) . t

4 . Installthesensorin the reverseorder of removal.
11-115
PGM-FI System
GKPSensorReplacement
sensor connector. 3P 1. Disconnect CKP the 2. Remove CKP the sensor {A).
12 N.m (1.2kgt m. 8.7 tbf.ftl
3. lnstallthe sensorin the reverseorder of removal with a new o-ring (B).
11-116
VTEC/VTC
-gl
:1
ia
i@'-;'
r-:
-
--tl
)
lt i..,,
;'l--i
',..
-'
'--'-
tt
VTCOILCONTROL VALVE SOLENOID page Troubleshooting, 11-118 11-'l27 Test,page VALVE VTCSOLENOID page Troubleshooting, 11-123 page Removal/lnspection, 11-128
CAMSHAFTPOSITION A ICMPISENSOR page 11-121 Troubleshooting, Replacement, Pagel'!-128
11-117
VTEC/VTC
DTGTroubleshooting
DTCP0010: WC Oil ControlSolenoid Valve Malfunction
1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . E 2. Start the engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, t h e nl e t i t i d l e . 3. Test-drive a steadyspeed between20-40mph at (30-60 km/h)for 10 minutes. ls DTC P0010indicated? YES Go to step 4. NO- Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or the VTC oil control solenoidvalve and at the ECM.I 4. Turn the ignition switch OFF. 5. Disconnect ECMconnectorB {24P). the 6. Measureresistance betweenECrU connector terminals 1and 823. B ECMCONNECTOR I24P) B
T e r m i n a s i d 6 o t m a t e t e r m i n as
8. Measureresistance betweenVTCoil control s o l e n o i d a l v e2 Pt e r m i n a l s o . 1 a n d N o . 2 . v N

VTC OIL CONTAOLSOLENOID VAI"VE2P CONNECTOB
ls there 6.75 8.25 Q ? YES-Go to step L NO-Replace the VTC oil control solenoidvalve (seepage 11-1271.a 9 . C o n n e cV T Co i l c o n t r o l o l e n o i d v a l v e 2 P t s connectorterminalsNo. 1 and No. 2 to body g r o u n dw i t h a j u m p e r w i r ei n d i v i d u a l l y . wc otl coNTBoL sotENoto
VALVE 2P CONNECTOR
-4-t t 1
wc I
tBr-K/wHT) | liELU/WHT) JUMPER WTREI IJUMPEnW|RE
2 l lwc*
W i r e s i d eo f 1 6 m a l e e . m i n a t s t
10. Checkfor continuitybetweenECMconnector t e r m i n a l s 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y . B Wiresideof female terminals
ls there 6.75 8.25 Q ? YES Go to step 11. NO Go to step7. 7. Disconnect VTC oil control solenoidvalve2P the connector. ls there continuity? Y E S G o t o s t e p1 1 . NO- Repairopen in the wire betweenthe ECM (B1, B23)and the VTCoil control solenoidvalve.I
11-118
11. Checkfor continuitybetweenECMconnector B t e r m i n a l s 1 a n d B 2 3a n d b o d y g r o u n di n d i v i d u a l l y .
VTCSystemMalfunction DTCP0011:
(seepage 11-4). 1. Reset the EClvl r H 2 . S t a r tt h e e n g i n e . o l dt h e e n g i n ea t 3 , 0 0 0 p m w i t h r ) n o l o a d ( i n n e u t r a l u n t i lt h e r a d i a t o f a n c o m e so n . 3. Test-drive a steadyspeed between20 40 mph at (30 60 km/h)for 10 minutes. with the scantool 4 . Checkfor TemporaryDTCP0011 ls Tempotaty DTC P0011indicated?
VTC (BtK/WHT)
ls there continuity? YES Go to step 12. NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe original EClvl. !
YES-Go to step 5. failure, system is OK at this time. NO- Intermittent or Checkfor poor connections loosewires at the v V T Co i l c o n t r o ls o l e n o i d a l v ea n d a t t h e E C M . I Watch the low oil pressurelight with the engine r un n i n g . ls the low oil pressute light on?
12. Disconnect VTC oil control solenoidvalve 2P the connector. 1 3 .Checkfor continuitybetweenECMconnector
B t e r m i n a l s 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y .
YES- Checkthe oil pressure(seepage 8-4).I N O - G o t o s t e p6 . 6 . Turn the ignition switch OFF. (seepage 4-28). 7 . Removethe auto-tensioner
vfc
(8LK/WHT)
W i r e s i d eo f f e m a l er e r m i n as
ls there continuity? t Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e n h e E C M( B 1 , B23)and the VTCoil control solenoidvalve.l the NO Replace VTC oil control solenoidvalve (seepage 11-1211.a
(cont'd)
11-119
VTEC/VTC
Removethe VTC strainer(A).Checkthe WC s t r a i n ef o r c l o g g i n g . r 13. ConnectECM connectorterminalsA3 and 81 witha j u m p e rw i r e m o m e n t a r i l y . NOTE:Do not jump for more than 1 minute,
ECM CONNECTORS
ls the strainet OK?

YES Go to step g. NO-Clean the VTC strainer, then replacethe e n g i n eo i l f i l t e ra n d t h e e n g i n eo i l . l 9. Checkthe VTCoil control solenoidvalve{seepage 11-127 ). ls the VTC oilcontrol solenoid valve OK? YES Go to step 10. NO Cleanthe ports of the WC oil control solenoid valve,or replacethe VTCoil control solenoidvalve {seepage 11-127).a Did the engine stall or run rough? YES Test-drive a steadyspeedbetween at 20 40 mph (30 60 km/h)for 10 minutes. lf temporaryDTCP00'l is indicated,updatethe 1 ECIVI it does not have the latestsoftware,or if substitute known-goodECM,then recheck(see a page 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe original ECM! . NO Go to step 14. 1 4 . Checkthe VTC actuator(seepage6,8). ls the VTC actuatot OK? (see page 4-281, YES Removethe auto-tensioner and clean or replacethe VTC oil strainer.Update the ECI\4 it does not have the latestsoftware,or if substitutea known-goodECM,then recheck(see page 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe original ECM. T NO Replace VTC actuator.t the
1 0 .InstalltheVTCoil control solenoidvalve. 1 1 .Startthe engine.Hold the engine at 700 1,000rpm.

1 2 . C o n n e c E C Mc o n n e c t otre r m i n a lB 2 3 t o b o d v t g r o u n dw i t h a j u m p e rw i r e .
ECMCONNECTOR {24PI B
213415
8 1
e l1a ,/1,/
181./l l./ 21
6 7 15
23 vTc JUMPER (BLK/WHT} WIRE
11-120
A DTCP0340: CMPSensor No Signal A CMPSensor Intermittent DTGP0344: Interruption

'11-4). 1 . R e s e t h e E C M( s e ep a g e 2. Startthe engine. ls DTC P0340and/or P0344indicated? YES-Go to step 3. failure,system is OK at this time. NO Intermittent or Checkfor poor connections looseterminalsat A t h e C M Ps e n s o r a n d a t t h e E C M . I 3. Turn the ignition switch OFF.
A voltage between CMPsensor 3P 7. Measure No. terminal 1 andbodyground. connector

CMP SENSORA 3P CONNECTOR
W i r e s i d eo l f e m a l e t e r m i n as
ls thercabout5 V? YES-Go to step8. NO-Go to step10.
4. Disconnect CMPsensorA 3P connector. the s 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . 6. Measurevoltage betweenCMPsensorA 3P connectorterminal No. 3 and body ground.
A CMPSENSOR 3P CONNECTOR tG1
A CMPsensor 3P voltage between 8. Measure tr s c o n n e c t oe r m i n a lN o .2 a n dN o .3 .

CMP SENSORA 3P CONNECTOF
;f-;-1 J ,o,,r.*,"r., I l1 l-t ,-or---T--I

{8RN/YEL) ni-
1 2 3
(BLK/YEL}
ls there battety voltage? YES Go to step 9. terminals Wiresideof female NO-Repair open in the wire betweenthe Cl\4P s e n s oA a n dG 1 0 1 . 1 r 9. Substitute known-goodCMPsensorA and a recheck. ls DTC P0340and/ot P0344indicated? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l A t l N O R e p l a c eh e o r i g i n a C M Ps e n s o r { s e ep a g e 11-128).t (cont'd)
ls there battety voltage? YES Go to step 7. f N O C h e c k h e N o . 4 A C G{ 1 0 A ) u s ei n t h e u n d e r t dash fuse/relaybox. lf the fuse is OK, repairopen in sensorA and No. 4 ACG the wire betweenthe CN4P (10A)use.I f
11-121
VTEC/VTC
1 0 .Measurevoltage betweenECMconnectorterminal
A25 and body ground.
DTCP0341: WC Phase Gap

1 . R e s e t t h e C M{ s e ep a g e1 1 - 4 ) . E 2. Startthe engine. ls DTC P0341indicated? YES Go to step 3. NO Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or t h e C M Ps e n s o r a n d a t t h e E C M . I A
Wiresideof female te.minals
3. Checkthe VTC oil control solenoidvalve (seepage 11_127]-. Isthe VTC oil control solenoid valve OK? YES-Go to step 4. NO-CIean the VTCoil control solenoidvalve,or r e p l a c et ( s e ep a g e1 1 - ' l 2 7 l . a i 4. Removethe head cover,and checkthe cam chain {seepage 6-12). ls the cam chain OK? YES Go to slep 5. N O R e p l a c eh e c a m c h a i n( s e ep a g e6 - 1 2 ) . 1 t 5. Checkthe VTC actuator(seepage 6-8). ls the VTC actuator OK? YES- U pdatethe ECM if it does not have the tatest soflware,or substitutea known-goodECI\4, then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l NO- Replace VTC actuator.l the
ls there about 5 V? YES-Repair open in the wire betweenthe ECM ( A 2 5 ) n d C M Ps e n s o r . I a A N O - G o t o s t e p1 1 . 1 1 .Turn the ignition switch OFF. 't2. Disconnect ECMconnectorA (31P) Checkfor continuitybetweenECMconnecror terminal A25 and body ground.
ECMCONNECTON 131P} A
Wiresideof femaleterminals
ls tnere continuity? YES-Repair short in the wire betweenthe ECM (A25)and the CMP sensorA. t NO Updatethe ECt\4 it does not have the latest if software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l
11-122
DTCPl259:WEC SystemMalfunction
SpecialToolsRequired . Pressure gaugeadapter07NAJ P07010A . A/T low pressuregaugew/panel 07406-0070300 . A/T pressurehose 07406-0020201 . Av/T pressurehose,2,210mm 07IMAJ-PY4o11A . l"/T pressureadapter07MAJ-PY40120 . Oil pressurehose 07ZAJ-S54,4200 1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . a o 2 . C h e c k h e e n g i n e i l l e v e l , n d r e f i l li f n e c e s s a r y . t 3. Startthe engine.Hold the engineat 3,000rpm with no load {in neutral)until the radiatorfan comes on. 4. Roadtestthe vehicle: in Accelerate the 1stgear to an engine speedover lf 4.000rpm. Holdthe speedfor at least2 seconds. DTCP1259is not repeatedduring the first road test, repeatthe test two more times. ls DTC P1259 indicated? YES Go to step 5. NO-lntermittent failure,system is OK at this time Checkthe oil consumptionif oil was added in step or 2. Checkfor poor connections looseterminalsat the VTECsolenoidvalve,the VTECoil pressure I switch,and at the ECI\4. 5, Turn the ignitjon switch OFF.
the 6. Disconnect VTECoil pressureswitch2P connector. 7. Checkfor continuitybetweenVTECoil pressure switch 2P connectorterminals No. 1 and No. 2 SWITCH VTECOILPRESSURE 2PCONNECTOR
T e r m i n as i d eo f m a l et e r m i n a l s l
Is therecontinuity? YES-Go to step8. switch.l oil the NO Replace VTEC pressure s O 8 . T u r nt h ei g n i t i o n w i t c h N( l l ) . switch oil VTEC pressure voltage between 9. Measure No. terminal 1 andbodyground 2Pconnector
SWITCH VTEC PRESSURE OIL 2PCONNECTOR VTPSW /T\ {BLU/BLK}
{.--rr-l'--.l
\rJ
I I
o I
t W i r es i d eo f f e m a l e e r m i n a l s
ls there battety voltage? Y E S G o t o s t e P1 4 . NO-Go to step 10.
(cont'd)
11-123
VTEC/VTC
10. Measurevoltage betweenECMconnectorterminal 89 and body ground.
ECMCONNECTOR (24P) B
14. fMeasure voltage between VTEC pressure oil switch 2 Pc o n n e c t oe r m i n a lN o .1 a n dN o .2 , tr s

VTECOILPRESSURE SWITCH 2P CONNECTOR
213415 o 1 8 I a t / t / n 3 15
WPSW {BLU/BLK}
VTPSW (BLU/BLK) (BRN/YELI
Wire side Iemale of terminals ls there battery voltage?
Wire side of Iemaleterminals
ls there battery voltage? YES Repairopen in the wire betweenthe VTECoil pressureswitch and the ECM(89).t N O - G o t o s t e p1 1 . 1 1 .Turn the ignition switch OFF. Turn the ignition switch OFF. Disconnect ECMconnectorB {24P).
to.
Y E S - G o t o s t e p1 5 . NO Repairopen in the wire betweenthe VTECoil p r e s s u r e w i t c ha n d G 1 0 1 . 1 s
Disconnect VTECsolenoidvalve 2P connector. the
Checkfor continuitybetweenECMconnector t e r m i n a lB g a n d b o d y g r o u n d .
ECMCONNECTOR {24P) B
1 7 . Checkfor resistance betweenVTECsolenoidvalve 2 Pc o n n e c t otre r m i n a l s o , 1 a n d N o . 2 . N VTECSOLENOID VALVE 2PCONNECTOR
2 3 415 I 9 ol./ ./ 13
6 7 15
VTPSW {BLU/BLK}
Wrre side of femaleterminals
T e r m i n a li d e f m a l e e r m i n a l s s o t ls there continuity? YES Repairshort in the wire betweenthe VTECoil pressureswitch and the ECM (89).I NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECN4. l ! ls there 14- 30 Sl ? YES Go to step 18. NO Replace VTECsolenoidvalve (seepage the 11-128).t
11-124
1 8 . Removethe VTECoil pressureswitch (A) and i n s t a l l t h e p e c i a l t o o l a s s h o w n ,t h e n r e i n s t a ltlh e s s switch. VTECoil pressure 07406-0020201 ot 07MAJ-PY,lo11A and 07MAJ-PY40120
23. Turn the ignitionswitch OFF.

the 24. Disconnect VTECsolenoidvalve 2P connector.
25. Aftachthe batterypositiveterminalto VTEC

v s o l e n o i d a l v e2 P c o n n e c t otre r m i n a lN o . 2 .
07406-0070300
\lsl
t:={
26. Startthe engine,then connectthe batterynegative

A 22 N.m l2.2kgt.m, 16rbf.ft)
07NAJ-P07010A
s v t e r m i n a l t oV T E C o l e n o i d a l v e2 P c o n n e c t o r a t t e r m i n a lN o . 1 , a n d c h e c k h e o i l p r e s s u r e t a n engine speedof 3,000rpm. ls the oil pressure above 390 kPa (4.0 kgt/crtf , 57 psi)? YES Go to step 27. NO InspecttheVTECsolenoidvalve (seepage I112Al.a
1 9 .Reconnect VTECsolenoidvalve 2P connector the

and VTECoil pressureswitch 2P connector.
20. Connecta tachometeror OBD ll scantool/Honda

PGM Testerto the DLC.
27. With the batteryterminalsstill connectedtothe VTECsolenoidvalve connector,measurevoltage betweenECMconnectorterminal 89 and bodv oround. B ECMCONNECTOR {24P)
2 1 . Startthe engine.Holdthe engine at 3,000rpm with

no load (in neutral)until the radiatorfan comes on.
22. Checktheoil pressureat enginespeedsof 1,000

and 2.000rpm. Keepthe measuringtime as shon b t t a s p o s s i b l e l e s s h a n 1 m i n u t e ) e c a u s eh e e n g i n e { w is running ith no load. ls the oil ptessure below 49 kPa (0.5 kgf/cnf, 7 psi)? YES Go to step 23. NO Inspectthe VTECsolenoidvalve (seepage 11't28l.a
ls there battery voltageabove 4,000 tpm? YES Go to step 28. NO-Replace the VTECoil pressureswitch (see p a g e1 1 ' 1 2 8 ) . 1

the 29. Disconnect batteryterminalsfrom the VTEC solenoidvalve terminal connector.
(cont'd)
11-125
WEC/VTC
30. Disconnect ECMconnector B (24P)
Checkfor continuitybetweenECMconnector t e r m i n a l8 1 5 a n d b o d y g r o u n d .
ECM CONNECTOR {24P) B
32. ConnectVTECsolenoidvalve 2P connector terminal No. 2 to body ground with a jumper wire.
VTEC SOLENOIDVALVL 2P CONNECTOR
r-.'-r.---.1
t 1 t 2 l
JUMPER VtS I WIRE I IGRN/YEL)
Checkfor continuitybetweenECMconnector t e r m i n a l8 1 5 a n d b o d y g r o u n d .
ECM CONNECTOR {24PI B
ls therecontinuity? YES-Repair shortin thewire between VTEC the ( s o l e n o iv a l v e n dt h eE C M 8 1 5 ) . 1 d a NO Goto step32.
Wiresideof female terminals ls thete continuity? YES Updatethe ECM if it does not have the latest software,or substitute known-goodECM,then a recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l NO Repairopen in the wire betweenthe VTEC v s o l e n o i d a l v ea n dt h e E C M( 8 1 5 ) . I
11-126
ValveRemoval/Test WC OilControlSolenoid
v 1 . R e m o v e h e W C o i l c o n t r o l o l e n o i d a l v e( A ) . t s NOTE:lnstallthe valve in the reverseorder of removalwith a new o-ring (B),then checkthese tlems: Cleanand dry the VTCoil control solenoidvalve mating surface. Coatthe O-ringwith engineoil. Do not installthe VTC oilcontrol solenoidvalve while wearingfibrous gloves, Be carefulnot to contaminate the cylinder head openrng. BATTERY Connectthe batterynegativeterminalto VTC oil s v c o n t r o l o l e n o i d a l v e2 Pc o n n e c t otre r m i n a lN o . 1 , t h e n m a k es u r et h e v a l v e( A )o p e n sf u l l y . Connectthe batterypositiveterminal to VTC oil control solenoidvalve 2P connectorterminal No. 2. VTCOILCONTROL SOLENOID VALVE CONNECTOR 2P
Terminalside oJ m a l et e r m i n a l s
Checkthe VTC oil control solenoidvalve filter for clogging.lf it is clogged,replacethe VTC oil control solenoidvalve. betweenthe port (advance Checkthe clearance (A) side)and the valve.The clearance should be at ( 1 / 8i n . ) . l e a s t2 . 8m m
11-127
VTEC/WC
CMPSensorA Replacement
( 1 . R e m o v e h e a i r c l e a n e r s e ep a g e11 - 1 6 2 ) . t Disconnect CMP sensorA 3P connector. the Removethe CMPsensorA (A). 1 . Disconnect VTECsolenoidvalve 2P connector. the Measureresistance betweenVTECsolenoidvalve c o n n e c t otre r m i n a l s o . 1 a n d N o . 2 . N Resistance:14-30 Q
WEC SolenoidValveRemoval/ Inspection
B-'-----'-l:,",14*
Installthe sensorin the reverseorder of removal with a new o-ring (B). 3. lf the resistance within specifications, is removethe VTECsolenoidvalve assemblv(A)from the cylinder head,and checkthe VTECsolenoidvalve f i l t e r( B ) f o rc l o g g i n g l.f i t i s c l o g g e d r e p l a c eh e , t solenoidvalve filter,the engine oilfilter, and the engine il. o
6x1.0mm 9.8 N.m (1.0kgf.m, 7,2 lbf.ftl
11-128
ldleGontrol System
TE'
IDLEAIRCONTROL {IAC)VALVE page Troubleshooting, 11-'131
11-129
ldle ControlSystem
DTCTroubleshooting
DTCP0505: ControlSystemMalfunction ldle
NOTE:lf DTCP1519is storedatthe same time as DTC P0505, troubleshootDTCP1519 first, then recheck for DTCP0505. 1. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle, 2. Checktheengine speedat idle with no,load conditions:headlights, blower fan, rear defogger, radiatorfan, and air conditioneroff. Is the engine running at 750t50 rpm? YES- Intermittent failure,system is OK at this trme.I NO lf the idle speed is lessthan 700 rpm, go to step 3; if it's 800 rpm or higher,go to step 4. 3 . D i s c o n n e c h e i d l ea i r c o n t r o l l A C ) a l v e 3 P tt v { connector. Does the engine speed increase or fluctuate? YES- Checkthe idle speed{seepage 1 1-138). the lf idle will not adjust properly,cleanthe passagein the throttle body, and then adjustthe idle.I N O - R e p l a c eh e I A Cv a l v e . I t 4. Turn the ignition switch OFF. 5. Removethe intakeair duct from the throttle body. 6. Startthe engine,and let it idle. 7 . P u ty o u r f i n g e r s n t h e l o w e rp o n ( A )i n t h e t h r o t t l e o oooy.
Does the enginestall? Y E S C h e c k t h e d l es p e e d( s e ep a g e1 1 - 1 3 8 ) f i t ' s i l. out of specification, replacethe IACvalve.l NO With the throttlevalve completelyclosed, c h e c k o r v a c u u ml e a k sa n d r e p a i ra s n e c e s s a r y . l f ,
11-130
DTCPl519:IACValveCircuitMalfunction
1 . R e s e t t h e C M( s e ep a g e1 1 - 4 ) . E 2. Turn the ignition switch ON (ll) ls DTC P 1519indicated? YES Go to step 3. NO-lntermittent failure,system is OK at this time. or Checkfor poor connections looseterminalsat the IACvalve and at the ECM.I 3. Turn the ignition switch OFF. 4. Disconnect IACvalve 3P connector. the
8, Checkfor continuitybetweenbody ground and IAC v a l v e3 Pc o n n e c t otre r m i n a lN o . 1 . IACVALVE CONNECTOR 3P
PG1{BLK}
a.
Is there continuity? 5. Turn the ignitionswitch ON (ll). Y E S - G o t o s t e p9 . 6. Measurevoltage betlveenIACvalve 3P connector terminal No. 2 and body ground. IACVALVE3PCONNECTOR NO Repairopen in the wire betweenthe IACvalve a n dG ' 1 0 1 . 1 ECMconnectorA (31P) 9 . Disconnect
1 0 . Checkfor continuitybetweenbody ground and l E C Mc o n n e c t otre r m i n a A 1 2 .

A ECM CONNECTOR 131P)
IGP {YEL/BLK)
r0 1l 12./
s r l 2 l 3 l 45 6 1 7 2C21 / 115 6 ./11819 da 25126 l27ln2930

IACV{BLK/RED}
ls therebattery voltage? YES Goto step7. the NO-Repairopenin thewire between IACvalve 1 m a n dt h eP G M - F l a i nr e l a y . 1 switchOFF. 7 . Turnthe ignition
1,)
terminals WiresideoJJemale ls there continuity? YES-Repair short in the wire betweenthe IAC v a l v ea n dt h e E C M( A 1 2 ) . 1 N O G o t o s t e p 11 .
LCOnIOl
11-131
ldle ControlSystem
11. Connect valve3Pconnector IAC terminal No.3to bodyground with a jumperwire.
IACVALVE CONNCTOR 3P 15. Measurevoltagebetweenbody ground and ECM c o n n e c t otre r m i n a A 1 2 . l ECMCONNECTOR 131P} A
r l 2 l 3 1 5 6 1 7 4
IACV IBLK/REO} JUMPER WIRE
t 0 1tl12l,/l/
22
tc
231?4l| 12.
9 6 ,/ 118 2C21 zil28 30
IACVIBLK/RED)
Wire side of femaleterminals Wire side ol femaleterminals
Checkfor continuitybetweenECMconnector t e r m i n a l A l 2 a n d b o d yg r o u n d . ECMCONNECTOR 131P) A
I s there battery voltage? YES-Update the ECI\4 it does not have the latest if software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n aE C I \ 4 . 1 l N O - R e p l a c et h e I A Cv a l v e . I
ls therecontinuity? YES Goto step13. NO-Repairopenin thewire between IACvalve the a n dr h eE c M( A 1 2 ) . r 1 3 .Reconnect IACvalve3Pconnector. the 1 4 .Turnthe ignition switch (ll). ON
11-132
A/G SignalCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll). 2 . MomentarilyconnectECMconnectorterminals424 and E18with a jumper wire severaltimes. 6. Momentarilyconnectunder-hoodtuse/relaybox 14Pconnectorterminal No. 10 to body ground with a jumper wire severaltimes. UNDER.HOOD FUSE/RELAY BOX I4P CONNECTOR
1 2 3 1 8 9 10 11
5 6
I J
14
ACC (RED) JUMPERWIRE
terminals Wiresideof female

ls there a clicking noise I rom the NC compressor clutch? YES Go to step 3. NO-Go to step 6. Start the engine. Turn the blower switch ON.
ls there a clicking noise f rom the NC compressor clutch? YES- Repairopen in the wire betweenthe ECM (E'18) and the Ay'C clutch relay.l NO- Checkthe A/C systemfor other symptoms.l
5. Turn the Ay'C switch ON.

Does the NC operate? Y E S - T h e a i r c o n d i t i o n i n s i g n a li s O K . I g NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe o r i g i n a C M . l l
11-133
ldle GontrolSystem
AlternatorFRSignalCircuitTroubleshooting
' t . Disconnect alternator4P the
alternalor. connectorfrom the '11. Connectalternator4P connector term inal No.4 to body ground with a jumper wire.
ALTERNATOR4P CONNECTOR
2. T u r nt h e i g n i t i o n w i t c hO N { l l ) . s 3 . Measurevoltage betweenECMconnector
4 terminals 24 and813.
ECM CONNECTORS
2
4
ALTFIWHT/RED)
JUMPERWIRE
A l31Pl
1 2 1 3 4 5 6 1 1| 1 . , 'I 10 1 1 1 1 2 , / 5 6 , / r8119l2C 21 23124 28129130

L (BRN/ EL) Y ALTF (WHT /REDI
213 4t5
8
9ltal,/l/
6 1 15
1 2 .Checkfor continuitybetweenbody ground and

EClvl connectorterminal 813. ECMCONNECTOB(24PI B
ls there about 5 V? YES Go to step 4. N O - G o t o s t e p1 3 . 4. Turn the ignition switch OFF. the 5. Reconnect alternator4P connector. 6. Slan the engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle. 7. lvleasure voltagebetweenECMconnector t e r m i n a l s 2 4a n d B1 3 . A Does the voltage decrease when the headlights and rear window defogger arc tutned on? Y E S T h e a l t e r n a t oF Rs i g n a li s O K . l r N O - G o t o s t e p8 . 8. Turn the ignition switch OFF. ECMconnectorB (24P). 9. Disconnect 10. Disconnect alternator4P connector. the
ls there continuity? YES-Testthe alternator(seepage 4-22).1 NO Repairopen in the wire betweenthe ECM ( B1 3 )a n dt h e a l t e r n a t o r . l
1 3 .Turn the ignitionswitch OFF. 't4. Disconnect ECMconnectorB (24P).
11-134
Electrical PowerSteering(EPSI SignalCircuitTroubleshooting

15. Checkfor continuitybetweenbody ground and ECIM connectorterminal 813.
ECM CONNECTOR I24P} B
1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 2 . l\4easure voltage betweenECMconnector terminals 24 andE16. 4
YES Repairshort in the wire betweenthe ECM ( 8 1 3 )a n dt h e a l t e r n a t o r . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then rechecklsee page 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l
ls there battery voltage? YES Go to step 6. NO Go to step 3.
3 . Startthe engine. 4 . Turn the steeringwheel lo the full lock position. 5 . l\4easure voltage betweenECMconnector
A t e r m i n a l s 2 4a n d E 1 6 . ls there momentatybattery voltage? Y E S T h e E P Ss i g n a li s O K . t N O G o t o s t e p1 0 . s 6 . T u r nt h e i g n i t i o n w i t c hO F F . 7. Disconnect EPScontrol unit 20Pconnector. the 8 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
(cont'd)
11-135
ldle ControlSystem
(cont'd) Electrical PowerSteering(EPSI SignalCircuitTroubleshooting
9. Measure voltage between control EPS unitterminal N o . l 7a n db o d yg r o u n d .
'13. l\4easure voltagebetweenEPScontrol unitterminal N o . 1 7a n d t h e b o d y g r o u n d .
EPSCONTROL UNIT2OP CONNECTOR
EPSCONTROL UNIT2OP CONNECTOR
ls there battery voltage? ls there battety voltage? YES-Substitute a known-goodEPScontrol unit a n dr e c h e c k . I NO- Repairopen in the wire betweenthe ECM ( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l YES Substitutea known-goodEPScontrol unit andrecheck.l N O - G o t o s t e p1 4 , 1 4 . Turn the ignition switch OFF.
t5_
D i s c o n n e c t t hE C Mc o n n e c t oE { 3 1 P ) . e r
1 0 .Turn the ignitionswitch OFF. I ' I. Disconnect EPScontrol unit 20Pconnector. the 12. Turn the ignitionswitch ON (ll).
1 6 .Checkfor continuitybetweenbody ground and E C I \ c o n n e c t otre r m i n a E 1 6 . 4 l

ECMCONNECTOR {31PI E
1 2 3 4 5 6 1 7 l1 89 5 6 . / 1 8 2A21 22 23 zi ./ 2930 o l
a,
lsthere continuity?
EPSLD {LTGRN/BLK)
Wiresideot Iemale terminals
YES Repairshort in the wire betweenthe ECN4 ( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l
11-136
BrakePedalPositionSwitch SignalCircuitTroubleshooting
1. Checkthe brakelights. Are the brake lights on without pressing the brake pedal? YES Inspectthebrakepedal positionswitch ( s e ep a g e1 9 - 6 ) . I NO Go to step 2. 2. Pressthe brakepedal. Do the brake lights come on? YES-Go to step 3. NO Go to step 4. 3. MeasurevoltagebetweenECMconnector terminalsA24 and E22with the brakepedal presseo. 4 . I n s p e ctth e N o . 7 H O R N S T O P( 1 5 A ) u s el n t h e , f under-hoodfuse/relaybox. ls the tuse OK? YES- Repairopen in the wire betweenthe brake pedal positionswitch and the No.7 HORN,STOP ( l5A) fuse, Inspectthe brakepedal positionswitch ( s e ep a g e1 9 - 1 0 ) . 1 NO Repairshort in the wire betweenthe ECM ( E 2 2 ) n dt h e N o . 7 H O R N , T O P 1 5 A ) f u s e . ( a S (15A)fuse.t R e p l a c eh e N o . 7 H O R N S T O P t ,
ls there battery voltage? YES-The brakepedal positionswitch signal is
oK,I
NO Repairopen in the wire betweenthe Eclvl (E22) and the brakepedal positionswitch.l
11-137
ldle ControlSystem
ldle Speedlnspection
NOTE: ' Leavethe idle air control (lAC)valve connecled. . Beforecheckingthe idle speed,checkthese items: - T h e m a l f u n c t i o nn d i c a t o lra m p ( M l L )h a s n o t b e e n i reportedon. - lgnitioniming t - S p a r kp l u g s - Aircleaner - PCVsystem . P u l l t h ep a r k i n g r a k el e v e ru p . S t a r tt h e e n g i n e a n d b , make sure the headlightsare off. 1. Disconnect evaporative the emission(EVAP) canisterpurge valve 2P connector. 2. Connecta tachometer(A)to the test tachometer connector(B),or connectthe HondaPGM Tester(C) or an OBD ll scantool to the data link connector (DLC)(D) locatedunder the driver'sside of the dashboard.
3 . Startthe engine.Holdthe engineat 3,000rpm with

n o l o a d ( i n n e u t r a l u n t i lt h e r a d i a t ofra n c o m e so n , ) t h e nl e t i t i d l e . 4 . Checkthe idle speedwith no-loadconditions; headlights, blower fan, radiatorfan, and air conditioneroff. ldle speedshould be: 750 t 50 rpm 5 . Let the engine idle for 1 minute with the heaterfan switch on Hl and air conditioneron, then checkthe i d l es p e e d . ldle speedshould be: 750 t 50 rpm NOTE:lf the idle speed is not wilhin specification, go to the Symptom Troubleshooting Index, 6 . Reconnect EVAPcanisterpurgevalve 2P the connector.
11-138
ECMldle LearnProcedure
The idle learn proceduremust be done so the ECMcan learnthe engine idle characteristics. Do the idle learn procedure wheneveryou do any of these actions: . Disconnect battery. the Replace ECMor disconnect connector. the its Resetthe ECM. NOTE:ErasingDTCS with the HondaPGM Tester does not requireyou to do the idle learn procedure. Removethe No.6 ECU{ECM)( 15A)fuse from the under-hood fuse/relaybox. Removethe No.19baftery(80A)fuse from the underhood fuse/relaybox. R e m o v e G M - Fm a i n r e l a y1 . P I Removeany of the wires from the under-hoodfuse/ retayDox. Disconnect any of the connectors from the under hood fuse/relaybox. Disconnect connectorbetweenthe engine the compartmentwire harnessand ECMwire harness. Disconnect G2 terminal from the transmission the h ous r n g . Disconnectthe terminal from the body. G'l D i s c o n n e c t t hG 1 0 1 e r m i n a f r o m t h e c y l i n d e r e a d e t l h cover.
Procedure:
To completethe idle learn procedure, this: do 1. Make sure all electricalitems (Ay'C, audio, rear defogger,l:ghts,etc.,)are off. 2. Startthe engine,and hold it at 3,000rpm with no l o a d{ i n n e u t r a l u n t i lt h e r a d i a t o f a n c o m e so n , o r ) r u n t i lt h e e n g i n e o o l a n t t e m p e r a t u r e a c h e s 9 4 " F c 1
(90'c).
3. Let the engine idle for about 5 minuteswith the throttlefully closed. NOTE:lf the radiatorfan comes on, do not includeits r u n n i n g i m ei n t h e5 m i n u t e s . t
11-139
FuelSupplySystem
p T e s t , a g e1 1 - 1 4 1 page 11'153 Fleplacement, FUELFILTER page 11-1 Replacement, 52 FUELGAUGESENDING UNIT p a g e1 1 - 1 5 6 Test, page 11-153 Replacement, FUELPRESSUN REGULATOR page'1 Replacement, 1-'152
PUMP
FUELFILLCAP
FUEL TANK R e p l a c e m ep a , e '1 - 1 5 5 ntg l

FUELTUBE/OUICK.CONNECT FITTINGS page 11-148 Precautions, p a g e1 1 - ' 1 4 9 Removal, page 11-'l50 Installation,
FUELFEED LINE FUELPULSATION DAMPER page Replacement, 11'154
FUELVAPORLINE
PGM.FIMAIN RELAY1
2 PGM.FI MAINRELAY T r o u b l e s h o o t ip a g e ' l ' l - 1 4 1 ng,
11-140
FuelPumpCircuitTroubleshooting
lf you suspecta problemwith the fuel pump, checkthat the fuel pump actuallyruns;when it is on, you will hear some noise if you listento the fuel fill port with the fuel fill cap removed.The fuel pump should run for 2 secondswhen the ignition switch is first turned on. lf the fuel pump does not make noise,checkas follows: 1. Turn the ignition switch OFF. 2. Removethe glove box {seepage 20-63), then removethe PGM-FI main relay 2 (A). 5. N4easure voltage betweenPGM-Flmain relay 2 5P connectorterminal No. 1 and body ground.
PGM.FI MAIN RELAY2 5P CONNECTOR
Wire side oJfemaleterminals
ls there battery voltage? YES Go to step 6. NO Repairopen in the wire betweenthe underd a s hf u s e / r e l a y o x a n d P G M - Fm a i n r e l a y2 . 1 b l 6. Turn the ignition switch OFF.
3 . Turn the ignitionswitch ON {ll).

Measurevoltage betweenPGM-Flmain relay 2 5P connectorlerminal No. 5 and body ground.
PGM.FI MAIN RELAY 2 5P CONNECTOR
7. Disconnect ECMconnectorE (31P). 8. Checkfor continuitybetweenPGM-FI mainrelay2 5P connectorterminal No. 3 and ECMconnector t e r m i n a lE 1 . PGM-FI MAIN RELAY 5PCONNECTOB 2
IGPl (YEL/BLK}
7 -
Ftxm
E2 t
z
IMOFPR (GBN/ YEL) Wiresideof female terminals
ECMCONNECTOR 131P} E
ls therecontinuity?
YES-Go to step 5.
YES-Go to step9.
NO Repairopen in the wire betweenthe PGM'Fl m a i n r e l a y1 a n dt h e P G M - Fm a i n r e l a y2 . t l
NO-Repairopenin thewire between PGMFl the ( m a i nr e l a y a n dt h eE C M E 1 ) . 1 2
(cont'd)
11-141
FuelSupply System
(cont'dl FuelPumpCircuitTroubleshooting
l L R e i n s t a l l t h P G M - Fm a i n r e l a y2 . e ls there battery voltage? YES U pdatethe ECM if it does not havethe latest so{1ware, substitute known-goodECM.then or a recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l NO Go to step 15.
t5. to.
1 0 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 1 ' ] .Measurevoltage betweenECI\4/PCM connector

t e r m i n a lE 1a n d b o d y g r o u n d .
ECMCONNECTOB {31P) E
Turn the ignition switch OFF. Removethe rear seat cushion (seepage 20-80).
1 1 . Removethe accesspanelfrom the floor. 1 8 . Measurevoltage betweenfuel pump 5P connector terminal No. 5 and body ground within the first 2 secondsafter the ignition switchwas turned ON (ll).
ls there battety voltage? YES Go to step 12. l N O - R e p l a c et h e P G M - Fm a i n r e l a y2 . 1
(
Turn the ignition switch OFF. ECMconnectorE (31P). 1 3 .Reconnecl
1 4 .Turn the ignitionswitch ON (ll),and measure

voltagebetweenECMconnectorterminal E1 and body ground within the first 2 secondsafterthe i g n i t i o n w i t c hw a s t u r n e dO N ( l l ) . s
E ECMCONNECTOR (31PI
wire sideoI female terminals
ls there battery voltage? YES Go to step 24. N O - G o t o s t e p1 9 . 1 9 . Turn the ignition switch OFF. 20. R e m o v e h e P G M - Fm a i n r e l a y2 . t l
11-142
21. ConnectPGM-Flmain relay 2 5P connector terminalsNo. 1 and No. 2 with a iumDerwire.

PGM.FIMAIN RELAY2 5P CONNECTOR
25. Checkfor continuitybetweenfuel pump 5P connectorterminal No. 4 and body ground.

FUEL PUMP (YEL/ GRN) JUMPER WIRE
rcr fv {YEL/BLK) A
tri
FNI
dffi
Wiresideof {emale terminals
22. Turn the ignitionswitch ON (ll). 23. Measurevoltagebetweenfuel pump 5P connector

terminal No. 5 and body ground. FUELPUMP5PCONNECTOR
ls therecontinuity? Y E S R e p l a cte ef u e lp u m p . l h NO-Repairopenin thewire between fuel the p u m p5 Pc o n n e c t o rn dG 5 5 1 . 1 a
Wiresideol female terminals
ls there battery voltage? Y E S R e p l a c e t h e G M - Fm a i n r e l a y 2 . t P l NO-Repair open in the wire betweenthe PGM-Fl main relay 2 and the fuel pump 5P connector.l
11-143
FuelSupply System
Relieving FuelPressure
fuel lines or hoses,relieve Beforedisconnecting pressure from the system by disconnecting fuel the tube/quickconnectfitting in the enginecompartment. 1 . T u r nt h e i g n i t i o n w i t c hO F F , s 2 . R e m o v e h e P G M - Fm a i n r e l a y2 ( A ) . t l 9. Placea rag or shop towel over the quick-connect fitting (A).
fifting (A):Hold the 1 0 .Disconnect quick-connect the the connector(B)with one hand and squeeze retainertabs (C)with the other handto release them from the lockingpawls {D).Pullthe connector off.
3 . S t a r t t h ee n g i n e a n d l e t i t i d l e u n t i li t i s s t a l l s . ,
P0301. P0302, NOTE:The DTCS TemporaryDTCS or P0303, P0304may come on during this procedure. lf any DTCS stored,ignorethem. are
Removethe fuel fill cap, and relievefuel pressure inthefueltank. 6 . Removethe enginecover. the 7 . Disconnect negativecablefrom the battery. fitting for dirt, and 8 . Checkthe fuel quick-connect cleanit if necessary.
NOTE: . P r e v e ntth e r e m a i n i n gu e l i n t h e f u e lf e e d l i n e o r f hosefrom flowing out with a rag or shop towel. . Be carefulnotto damagethe line (E)or other parts. . Do not use tools. . l f t h e c o n n e c t o r d o e n o t m o v e ,k e e p t h er e t a i n e r s pull and push tabs presseddown, and alternately it comes off easily. the connectoruntil . Do not removethe retainerfrom the line; once removed,the retainermust be replacedwith a new one.
fifting, check 1 1 After disconnecting quick-connect the i t f o r d i r t o r d a m a g e( s e ep a g e11 - 1 4 9 ) .
11-144
FuelPressure Test
Special Tools Required . Fuel pressure gauge 07406-0040004 . Fuel pressuregaugesel 07ZAJ-S5A0100 ( 1 . R e l i e v eh e f u e l p r e s s u r e s e ep a g e1 ' 1 - 1 4 4 ) . t 2. Disconnect quick-connect fitting (A).Aftachthe the fuel pressuregaugeset and fuel pressuregauge.
Startthe engineand let it idle. . lf the enginestarts,goto step 5. . lf the enginedoes not start,goto step 4. Checkto see if the fuel pump is running:listento the fuel fill port with the fuel fill cap removed.The fuel pump should run for 2 secondswhen the ignitionswitch is first turned on. . lf the pump runs,go to step 5. . l f t h e p u m p d o e sn o t r u n ,d o t h e f u e l p u m pc i r c u i t s t r o u b l e s h o o t i n(g e ep a g e11 - 1 1) . 4 5 . Readthe pressuregauge.The pressureshould be 320-370 kpa (3.3-3.8 kgf/cm',a7-52 psi) . lf the pressureis OK, the test is complete. . lf the pressureis out of specification, replacethe fuel pressureregulatorand the fuel filter (see p a g e1 1 - 1 5 2 t h e n r e c h e c kh e f u e l p r e s s u r e . ), t
11-145
FuelSupply System
FuelLineInspection
Checkthe fuel system lines,hoses,and fuel filter for damage,leaks,and deterioration. Replace any damagedparts.
Makesurethe connection is secureand the quick-connect fitting cover is firmly lockedinto place.
11-146
Check clamps all andretighten necessary. if A: Do notdisconnect hosefromthe lineat theseioints. the
Settheboltflange T h e r es h o u l d b e n o
W.W
C l a m pi n t h e m i d d l e . C l a m pi n t h e m i d d l e . t h e f u e l { i l lt u b e , a l i g nt h e m a r k s on the tubeand t h el i n e .
Setthispart
11-147
FuelSupply System
FuelLine/Ouick-Connect FittingsPrecaution
The fuel tube/quick-connect fittings connectthe fuel rail (A)to fuel feed hose (B),the fuel feed hose (B)to the f u e l l i n e( C ) ,a n dt h e f u e l t u b e( D )t o t h e f u e l p u m p ( W a s s e m b l y E ) . h e n r e m o v i n g r i n s t a l l i n gh e f u e l f e e d o t hose,fuel pump assembly,or fuel tank, it is necessary to disconnect connectthe quick-connect or fittings. Pay attentionto the following: . T h e f u e lf e e dh o s e( B ) ,f u e lt u b e ( D ) ,a n d q u i c k connectfittings (F)are not heat-resistanU careful be not to damagethem during welding or other heatgeneralrng proceoures. . T h ef u e l f e e dh o s e( B ) ,f u e l t u b e( D )a n d q u i c k connectfittings (F)are not acid-proof; not touch do them with a shop towel which was used for wiping Replace batteryelectrolyte. them if they came into contactwith electrolyte somethingsimilar. or . When connectingor disconnecting fuel feed hose the (B),fuel tube (D),and quick'connect fittings (F).be carefulnot to bend or twist them excessivelv. ReDlace them it they are damaged. quick-connect A disconnected fitting can be reconnected, the retaineron the mating line cannot but be reusedonce it has been removedfrom the line. Replace retainerwhen the . . . . . . . replacing the fuel rail. r e p l a c i n gh e f u e l l i n e . t replacing the fuel pump. replacing the fuel filter, replacing the fuel gaugesendingunit. it has been removedfrom the line. it isdamaged.
I\4ANUFACTUREB RETAINER COLOR EN GN E I TOKAI GREEN COI\4PARTMENT ( F U EF E E D L HOSE;U L F E LINE IDE) S EN INE TOKAI G BLU COIVIPARTMENT ( F U EF E E D L HOSE:UEL F RAIL IDE) S FUELTANK WHITE SANOH UNIT
PART
11-148
FittingsRemoval FuelLine/Ouick-Gonnect
( 1 . R e l i e v eu e l p r e s s u r e s e ep a g e1 ' l - 1 4 4 ) . f fiftingsfor din, and 2 . Checkthe fuel quick-connect clean if necessary. Hold the connector(A) with one hand and squeeze the retainertabs(B)with the other hand to release them from the lockingpaws (C).Pullthe connector off. NOTE: . B e c a r e f u l o t t o d a m a g e h e l i n ei D ) o r o t h e r t n parts.Do not usetools. . lf the connectordoesnot move, keepthe retainer pull and push tabs presseddown, and alternately the connectoruntil it comes off easily. . Do not removethe retainerfrom the line; once removed,the retainermust be replacedwith a new one. 4. Checkthe contactarea (A) of the line (B)for dirt and d am a g e . . lf the surfaceis dirty, clean it. . if the surfaceis rusty or damaged,replacethe , f u e l p u m p ,f u e l f i l t e r f u e l f e e dl i n e .
=k
To preventdamagedand keepforeign matter out, connectorand line end with cover the disconnected plasticbags (A). NOTE: . The retainercannot be reusedonce it has been f removedromthe line. the Replaced retainerwhen - r e p l a c i n gh e f u e l r a i l . t - r e p l a c i n gh e f u e lf e e dI i n e . t - r e p l a c i n gh e f u e l p u m P . t - replacing the fuel filter. - r e p l a c i n gh e f u e l g a u g es e n d i n g n i t u t - it has been removedfrom the line. - it is damaged.
11-149
FuelSupply System
FuelLine/Ouick-Connect Fittingslnstallation
1. Checkthe contacta rea (A) of the line (B)for dirt and damage,and clean if necessary. 3. Beforeconnectinga new fueltube/quick-connect fitting assembly(A),removethe old retainerfrom t h e m a t i n ol i n e ,
Inserta new retainer(A) into the connector(B) if the retaineris damaged,or after . r e p l a c i n gh e f u e l r a i l . t . replacingthe fuelfeed line. . replacingthe fuel pump. . replacingthe fuel filter. . r e p l a c i n gh e f u e l g a u g es e n d i n g n i t t u . removingthe retainerfrom the line.
11-150
fittingswith the line (A). 4. Align the quick-connect ( B )l o c k i n g a w l sw i t h t h e p a n d a l i g nt h e r e t a i n e r connector{C)grooves.Then pressthe quickconnectfittings onto the line until both retainer p a w l sl o c kw i t h a c l i c k i n g o u n d . s l , N O T E ; f i t i s h a r dt o c o n n e c tp u t a s m a l la m o u n to f n e w e n g i n e i l o n t h e l i n ee n d . o Connectionwith new retainer:
5. lvlake sure the connectionis secureand that the ; v p a w l sa r ef i r m l y l o c k e d n t o p l a c e c h e c k i s u a l l y i and by pullingthe connector.
negativecableto the battery,and 6. Reconnectthe T s t u r n t h e i g n i t i o n w i t c hO N ( l l ) . h e f u e l p u m p w i l l will rise and fuel pressure run for about 2 seconds, Repeat2 or 3 times, and checkthat there are no fuel leaks.
Reconnectionto existing retainer:
11-151
FuelSupply System
FuelPressure Regulator Replacement
1 . R e m o v e h e f u e l p u m p ( s e ep a g e11 - 1 5 3 ) . t 2 . Removethe fuel pressureregulator(A).
FuelFilterReplacement
The fuel filter should be replacedwheneverthe fuel pressuredrops belowthe specifiedvalue {270 320 kpa, 2.8 3.3 kgflcm', 40 47 psi),after makingsure that the fuel pump and the fuel pressureregulatorare OK. 1 . R e m o v e h e f u e lp u m p ( s e e p a g e l l - ' 1 5 3 ) . t 2. Removethe fuel filter (A).
@-to
IJ
e"^
g s
s g
Installthe part in the reverseorder of removalwith a n e w o - r i n g( B ) .
Re
AR
@n-)
^ e
...\
Installin the reverseorder of removalwith a new basegasket(B)and a new o-ring (C),then check these items: ' When connectingthe wire harness, make sure the connectionis secureand the terminal (D) is firmly lockedinto place. . W h e n i n s t a l l i n gh e f u e l g a u g es e n d i n g n i ti E ) , t u make sure the connectionis secureand the connectoris firmly lockedinto place.Be careful not to bend or twist it excessively.
11-152
GaugeSendingUnit Replacement FuelPump/Fuel

SpecialToolsRequired w F u e ls e n d e r r e n c h0 7 X A A - 0 0 1 0 1 0 A ( t 1 . R e l i e v eh e f u e l p r e s s u r es e ep a g e1 1 - 1 4 4 ) . Removethe fuel fill cap. Removethe seat cushion(seepage 20-80). Removethe accesspanel (A)from the floor. t t 8 . R e m o v e h e l o c k n u ( A )a n d t h e f u e lt a n k u n i t .
r tt 5 . D i s c o n n e c h e f u e l p u m p 5 Pc o n n e c t o( B ) . fitting {C)from the the Disconnect quick-connect f u e lt a n ku n i t . t 7 . U s i n gt h e s p e c i atlo o l ,l o o s e n h e f u e lt a n ku n i t locknut(A).
t t { 9 . R e m o v e h e s t o p p e r O ) .R e l e a s eh e h o o k ( P )a n d t r e m o v e h e f u e lf i l t e r( B ) , h e f u e l g a u g es e n d i n g t ( a t t u n i t ( C ) . h e c a s e( D ) , h e w i r e h a r n e s s E ) , n d t h e fuel pressureregulator(F). t 1 0 . W h e nc o n n e c t i n gh e f u e lt a n k u n i t ,m a k es u r et h e f a i c o n n e c t i o ns s e c u r e n d t h e s u c t i o n i l t e r( G )i s t f i r m l y c o n n e c t e do t h e f u e l p u m p ( H ) . o 1 1 . I n s t a ltl h e f u e lt a n ku n i t i n t h e r e v e r s e r d e ro f ( r e m o v a w i t h a n e w b a s eg a s k e t l ) a n dn e w o - r i n g s l ( J ) ,t h e nc h e c k h e s ei t e m s : t . W h e nc o n n e c t i n t h e w i r e h a r n e s sm a k es u r e , g r a i t h e c o n n e c t i o ns s e c u r e n d t h e c o n n e c t o( K )i s i f i r m l y l o c k e d n t ot h e p l a c e . . W h e n i n s t a l l i n gh e f u e l g a u g es e n d i n g n i t , u t make sure the connectionis secureand the i B c o n n e c t oirs f i r m l y l o c k e d n t o p l a c e . e c a r e f u l not to bend or twist the connectorexcessively. . W h e n i n s t a l l i n gh e f u e l t a n ku n i t ,a l i g nt h e m a r k s t ( L )o n t h e f u e lt a n k( M ) a n d t h e f u e lt a n k u n i t( N i
93 N.m kgf.m,69 lbf.ftl 19.5
11-153
FuelSupply System
FuelPulsationDamperReplacement
1 . R e l i e v eh e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 4 ) . t 2. Removethe enginecover. 3. Removethe fuel rail mounting nuts from the fuel rail. 4 . R e m o v e h e g r o u n dc a b l e( G1 0 1 . t 5 . R a i s eh ef u e l r a i l . t 6 . P l a c e w r e n c h( A )o n t h e f u e l r a i l( B ) . a
7 . P l a c e w r e n c h( C )o n t h e f u e l p u l s a t i o n a m p e r( D ) . a d 8. Removethe pulsationdamper. 9. Installthefuel pulsationdamper in lhe reverse order of removalwith new washers. NOTE: . Replace washerswhenever the fuel pulsation all damper is loosenedor removed, . l f t h e d r a i nh o l e( A )o f t h e f u e l p u l s a t i o n d a m p e r cover does not face bottom, reinstallit as shown.
11-154
FuelTank Replacement
( 1 . R e l i e v e t h e f u ep r e s s u r es e ep a g e1 1 - 1 4 4 ) . l f a r . t 2 . D r a i nt h e f u e lt a n k :R e m o v e h e f u e l p u m p ( s e ep a g e11 - 1 5 3 )U s i n ga h a n dp u m p ,h o s e , n d c o n t a i n es u i t a b l eo r gasoline.draw the fuel from the fuel tank.
3 . Jack up the vehicle,and suppon it with safetystands.

fittings. the Removethe fuel pipe cover (A).Disconnect fuel vapor hose and quick-connect backthe clamps (B),then twist the hosesas you pull to avoid damagingthem. the Disconnect hoses.Slide
(}
A 5. Placea jack or other supportunder the tank. s 6 . R e m o v e t h e t r a pb o l t s ,a n d l e t t h e s t r a p( C )h a n g f r e e .
38N.m (3.9 ksf.m,28lbfft)
p i t 7 . R e m o v e h e f u e lt a n k ( D ) .l f i t s t i c k s t o t h eu n d e r c o a t o nt s m o u n t ,c a r e f u l l y r y i t o f f t h e m o u n t 8. Installthe parts in the reverseorder of removal.
11-155
FuelSupply System
FuelGaugeSendingUnit Test
Special Tools Required Fuelsenderwrench 07XAA-001010A NOTE;For the fuel gauge system circuitdiagram,refer to the GaugesCircuitDiagram(see page 22-58||. 1 . C h e c k t h e o . 1 0 f U E T E R . 5 A ) f u s en t h e u n d e r N i {7 dash fuse/relaybox beforetesting. 2. Do the gauge drive circuitcheck(see page 22-56|l. ' lf the fuel gauge needlesweepsfrom minimuni to maximum positionand then returnsto the m i n i m u mp o s i t i o nt.h e g a u g ei s O K .G o t o s t e p3 . . lf the fuel gauge needle does not sweep from m i n i m u mt o m a x i m u mp o s i t i o n o s i t i o n n d p a then returnto the minimum position,replacethe gauge assemblyand retest. 3 . T u r nt h e i g n i t i o n w i t c hO F F . s 4. Removethe rear seat cushion{seepage 20-80). 5. Removethe accesspanel (A)from the floor. Turn the ignition switch OFF.Removethe No. 9 BACKUP (7.5A)fusefrom the under-hoodfuse/ relay box for at least 10 seconds, lhen reinstallit. Installa 2 Q resistorbetweenfuel pump 5P connectorlerminals No. 1 and No. 2, then turn the i g n i t i o n w i t c hO N ( l l ) . s FUELPUMP5P CONNECTOR Wiresideof female terminals FUELPUMP5PCONNECTOR 7. Measurevoltage betweenfuel pump 5P connector terminalsNo. 1 and No. 2 with the ignition switch ON (ll).There should be batteryvoltage. . lf the voltage is as specified, to step 8. go . lfthevoltages notasspecified,checkfor: i - a n o p e n i n t h e Y E U B L K r B L Kw i r e . o - p o o r g r o u n d( G 5 5 1 ) .
-ztr
-VVV{YEL/BLK) {Y 2 9 RESISTOR,
(elrt \
=-a
\
//,
\ 4
5 /
6. Disconnect fuel pump 5P connector{B). the
11-156
p 1 0 . C h e c k t h a t t h e o i n t e r o ft h e f u e lg a u g ei n d i c a t e s "F". . lf the pointerdoes not indicate"F", replacethe g au g e . . lf the pointerindicates"F", inspectthe fuel gauge sendingunit. NOTE: The pointerof the fuel gauge returns to the bottom of the gaugedial when the ignition switch is OFF,regardless the fuel level.of 11. Relieve the fuel pressure(seepage 11-144\. 1 2 . R e m o v e h ef u e l f i l lc a p . t fittingsfrom the fuel 13. Disconnect quick-connect the pump. t 1 4 . U s i n gt h e s p e c i atlo o l ,l o o s e n h e f u e lt a n ku n i t locknut(A).
1 5 . M e a s u r e e s i s t a n cb e t w e e n h e N o . 1 a n d N o . 2 r e t 'l12 terminalswith the float at E (EN4PTY), \HALF F U L L )a n d F { F U L L p o s i t i o n s . , ) lf you do not get the following readings,replacethe f u e l g a u g es e n d i n g n i t{ s e ep a g e1 ' 1 - 1 6 3 ) . u F Float Position Resistance 1 1 {0) to 13
'U2
68,5 to 74.5
LOW
114.4 130 to 126.6 to 132
fuse from NOTE:Removethe No. 9 BACKUP (7.5A) fuse/relaybox for at least 10 the under-hood secondsafter completingtroubleshooting, otherwiseit may take up to 20 minutesfor the fuel gaugeto indicatethe correctfuel level.
A 93Nm {9.5ksf.m,69 lbf.ft}
11-157
FuelSupply System
Low FuelIndicatorTest
1 . Do the fuel gauge sendingunit test (seepage 11, rcol. . lf the system is OK, go to step 2. . lf the system has any malfunction,repair it. Turn the ignition switch OFF.Removethe No. 9 BACKUP (10A)fuse from the under-hoodfuse/ relay box for at least30 seconds, then reinstallit. Turn the ignition switch ON (ll)with the float at the E (EMPry) position. . lf the low fuel indicatoris on, go to step 4. . lf the low fuel indicatoris not on, referto the low fuel indicatorCircuitDiagram(seepage 22-58) and checkthe circuit.
4, Turn the ignition switch OFF.Removethe No. 9
BACKUP (10A)fuse from the under-hood fuse/ relay box for at least30 seconds, then reinstallit. Lift the float above the LOW position. . l f t h e l o w f u e l i n d i c a t o r g o e o f f , t h es y s t e mi s O K . s . lf the low fuel indicatoris still on, referto the low fuel indicatorCircuitDiagram{seepage 22-58), and checkthe circuit.
\,
11-158
IntakeAir System
Component Location Index
l .
INTAKE AIR BYPASSCONTROL THERMALVALVE Test,page 1'1-161
AIR CLEANER p, R e p l a c e m e n t a g e11 ' 1 6 2 ELEMENT AIR CLEANER p, R e p l a c e m e n ta g e11 - 1 6 2
THROTTLEBODY Test,page l'l-160 page 11-165 Removal/lnstallation, page Disassembly/Reassembly, 11 166
THROTTLE CABLE page11-163 Adjustment, R e m o v a l / l n s t a l l ap ao n11 - 1 6 4 t i g e,
11-159
IntakeAir System
Throttle BodyTest
NOTE: . Do not adjustthe throttlestop screw. lt is presetat the factory. . l f t h e m a l f u n c t i o nn d i c a t o lra m p ( M l L )h a sb e e n i reportedon, checkfor diagnostictrouble codes ( D L C S()s e ep a g e1 1 3 ) . 1. With the engine off, checkthe throttle cable movement.The cableshould move without binding or sticking. . lf lhe cable moves OK, goto step 2. . lf the cable binds or sticks,checkit and its routing. . l f t h e c a b l ei s f a u l t y ,r e r o u t e t o r r e p l a c et a n d i i a d j u s ti t ( s e ep a g e1 1 - 1 6 3 ) h e ng o t o s t e p2 . t, 2. l\4ove throttle lever by hand to see if the throftle the valve and/or shaft are too looseor too tight. . lf there is excessive play in the throttlevalve shaft,or any binding in the throttlevalve at the fully closedposition,replacethe throttle body. . l f t h e t h r o t t l e v a l v e n d s h a f ta r e O K ,g o t o s t e p 3 . a 3. Connectthe scantoolto the DLC. T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 5 . Checkthe throttle positionwith the scantool. The readingshould be about 10%when the throttle is fully closedand about 90% when the throttle is fully openeo. . lf the throttle positionis correct,the throttle body is OK. . lf thethrottle positionis notcorrect,replacethe throttle body.
11-160
Test IntakeAir Bypass GontrolThermalValve

Special Tools Required Vacuum Pump/Gauge,0 30 in. Hg A973X-041-XXXXX 1 . S t a n t h e e n g i n e T h e nl e t i t i d l . . NOTE:The enginecoolanttemperaturemust be b e l o w1 4 9 ' F ( 6 5 ' C ) . 2 . R e m o v e h e v a c u u mh o s e( A ) f r o mt h e i n t a k e i r t a duct, and connecta vacuum pump/gaugeto the nose. checkfor these lf the vacuum readingchanges, proorems: . l\4isrouted, leaking,broken,or cloggedintakeair bypasscontrol systemvacuum lines. . A crackedor damagedintakeair bypasscontrol t h e r m a lv a l v e . , 5 . R a i s e n d l o w e rt h e e n g i n es p e e d a n d m a k es u r e a the vacuum gauge readingdoes not changeas the rpm cnanges.
. 3 . R a i s e n d l o w e r t h ee n g i n es p e e d a n d m a k es u r e a c a t h e v a c u u mg a u g er e a d i n g h a n g e s s t h e e n g i n e speeocnanges. lf the vacuum readingdoes not change,checkfor these problems: . M i s r o u t e dl,e a k i n gb r o k e n o r c l o g g e d n t a k e i r i a , , bypasscontrol system vacuum lines. . A crackedor damagedintakeair bypasscontrol t h e r m a lv a l v e . 4 . H o l dt h e e n g i n e t 3 , 0 0 0 p m w i t h n o l o a d( i n a r neutral)until the radiatorfan comes on, then let it i dl e .
11-161
IntakeAir System
Air Cleaner Replacement
1. Removethe nuts (A) and the stud (B).
Air Cleaner Element Replacement

1 . D i s c o n n e c h e P C Vh o s e1 A ) . tt
{0.3kgf m,2lbf.ft)
2. Removethe air cleaner(C). 3 . Installin the reverseorder of removal.
2 . O p e nt h e a i r c l e a n e r o u s i n g o v e r( B ) . h c ( 3 . R e m o v e h e a i r c l e a n e r C )f r o m t h e a i r c l e a n e r t ( housing D). 4 . Installin the reverseorder of removal.
\,
11-162
Throttle CableAdjustment
1 . Checkcablefree play at the throttle linkage.Cable f r e e p fa v ( A )s h o u l db e 1 0 1 2 m m ( 3 / 8 1 / 2i n . ) .
lf the free play is not within spec (10- 12 mm, t t 3 1 8 - 1 1 2 l n . l , l o o s etn e l o c k n u ( B ) , u r n t h e h adjustingnut (C)untilthe free play is as specified, then retightenthe locknut. With the cable properlyadjusted, checkthe throttle valve to be sure it opens fully when you push the pedalto the floor. Also checkthe accelerator throttlevalve to be sure it returnsto the idle positionwheneveryou releasethe accelerator peoar.
11-163
IntakeAir System
Throttle CableRemoval/lnstallation
1. Fully open the throttlevalve,then removethe throttle cable (A)from the throttle link (B). Installin the reverseorder of removal. 5 . After installing, startthe engine.Holdthe engine at 3,000rpm with no load (in neutral)untilthe radiator fan comes on, then let it idle. H o l dt h e c a b l e ,r e m o v i n g l l s l a c k r o m i t . f a 7 . Set the locknuton the cable bracket{A). Turn the adjustingnut (B)so that its free play is 0 mm.
T h e s h o u l db e no crearance.
(P/N08?98-9002)
2 . R e m o v e h e c a b l eh o u s i n g( C ) f r o mt h e c a b l e t
bracket(D).
('1.0 kgf.m, 7.2 tbf.ftl
3 . Removethe throttlecable (A)from the accelerator

p e d a l( B ) .
!
8 . Removethe cablefrom the cable bracket(A).Set
the adjustingnut on the other side of the throttle bracket, then tightenthe locknut{C}. 9 . With the cable properlyadjusted, checkthe throttle valve to be sure it opensfully when you push the pedalto the floor. Also checkthe accelerator throttlevalveto be sure it returnsto the idle positionwheneveryou release the accelerator Deoat.
SILICONE GREASE B (P/N08798-9002)
11-164
Throttle Body Removal/lnstallation

NOTE: ' Do not adjustthe throttle stop screw. . A f t e r r e a s s e m b l y , a d j u s t t h e t h r o t t l e c a b l e { s e e p a g e l l - 1 6 3 ) h e c r u i s e o n t r o l a b l e( s e ep a g e4 - 4 5 ) . a n dt c c . The throttle position(TP)sensoris not removable.
THROTTLE LEVER
Thereshould be noclearance
THROTTLECABLE MANIFOLD ABSOLUTE PRESSURE {MAP}SENSOR 22Nm (2.2 kgt.m, 16 lbf.ft)
EVAPORATIVE EMISSION{EVAPI CANISTERPURGEVALVE
IDLEAIR CONTROL {IACI VALVE
11-165
IntakeAir System
Throttle Body Disassembly/Reassembly
2 N.m {0.2 kgt m, 1 lbf.ft)
V
MAPSENSOR
EMISSION EVAPORATIVE {EVAP) PURGE VALVE CANISTER
L
TPSENSOR THROTTLE BODY
3.5 N.m (0.35kgf m.2.5lbf ft)
11-166
CatalyticConverterSystem
DTCTroubleshooting
DTCP0420: Catalytic SystemEfficiency Below Threshold
NOTE:lf some of the DTCS listedbelow are storedat the same time as DTCP0420, troubleshootthose DTCS first, then recheck DTCP0420. for P 0 1 3 7P 0 1 3 8S e c o n d a r y e a t e d x y g e nS e n s o r , : H O (secondary HO2S)(Sensor2) r P 0 1 4 1S e c o n d a r y O 2 S( S e n s o 2 ) h e a t e r : H 1 . R e s e t h e E C M{ s e ep a g e1 ' l - 4 }t,h e nc o n t i n u e o t step 2 through 5 to resetthe readiness code. 2. Startthe engine.Hold the engineat 3,000rpm with n o l o a d( i n n e u t r a lu n t i l t h er a d i a t o f a n c o m e so n . ) r D r i v ef o r a b o u t l 0 m i n u t e s i t h o u ts t o p p i n gY o u r w . speeocan vary. 4 . With the transmissionin 4th gear,drive at a steady speed between50 62 mph (80-'100 km/h)for 30 seconds. Repeatstep 4 three times. Betweeneach repetition, closethe throttlecompletelyfor 1 2 seconds.lf the engine is stoppedduring this part of the procedure, repeatsteps3, 4 and 5. Checkfor a TemporaryDTCwith the scantool. Does the scan tool indicate Temporaty DTC P0420? YES Checkthe TWC. lf necessary, replacethe TWC.I N O C h e c k o r r e a d i n e s c o d ec o m p l e t i o nl.f t h e f s readiness complete,it was a interminentfailure, is and the system is OK at this time. lf the readiness code is incomplete,repeatsteps2 through 5.1
11-167
PCVSystem
DTCTroubleshooting
Air PCV Leakage DTCP1505:
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.Hold the engineat 3,000rpm with r ) n o l o a d( i n n e u t r a l u n t i lt h e r a d i a t o f a n c o m e so n 3. Letthe engineidle tor al least40 secondswith the throttlefully closed. with the scantool 4. Checkfor a DTCP1505 ls DTC P1505 indicated? YES-Check these partsfor vacuum leaks l . . . . . PCVvalve PCVhose EVAPcanisterpurge valve Throttlebody Brakeboosterhose
failure,system is OK at this NO - Intermittent time.l
11-168
PCVValve Inspection and Test

1. Checkthe PCVvalve (A),hoses{B),and connections leaksor restrictions. for
PCVValve Replacement
'L Disconnect PCVhose. the Removethe PCVvalve (A).
2 . At idle, make sure there is a clickingsound from the

PCVvalve when the hose betweenthe PCVvalve a n d i n t a k e a n i f o l d s l i g h t l yp i n c h e d A ) w i t hy o u r m i { fingers r pliers. o lf there is no clickingsound,checkthe PCVvalve grommet for cracksor damage.lf the grommet is the OK. reDlace PCVvalve and recheck.
(4.5 kgf.m,33 lbf.ft) l 3 . I n s t a lthe parts in the reverseorder of removal ( with a n e w g a s k e t B ) .
11-169
EVAPSystem
EMISSIONIEVAPI EVAPORATIVE CANISTERPURGEVALVE Troubleshooting, 'l1-175, step 3 on page s t e p1 o n p a g e1 1 - 1 8 0
FUELTANK VAPORCONTROLVALVE Test,page 11'187 p, R e p l a c e m e n t a g e1 1 1 8 9 EMISSION{EVAPI EVAPORATIVE CANISTER Troubleshooting, step 28 on page 11'183 page 11-189 Replacement,
SENSOR FUELTANKPRESSURE T r o u b l e s h o o t ip a g e 1 - 1 7 1 ng, 1

EVAPORATIVE EMISSION{EVAP} BYPASSSOLENOIDVALVE Troubleshooting, 1 ' 1 7 6 , '1 s t e p1 2o n p a g e '10 s t e p o n p a g e1 1 1 8 1
EMISSION{EVAP) EVAPORATIVE CANISTER VENT SHUT VALVE Troubleshooting, step 23 on page 1'l 178, s t e p1 go n p a g el 1 - 1 8 2
EVAPOBATIVE EMISSON{EVAP) VALVE TWO WAY 'l1-'186 Test,page
11-170
DTCTroubleshooting
DTCP0451: SensorRange/Performa FTP nce Problem
SpecialTools Required Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX 1 . R e m o v e h e f u e lf i l l c a p . t 2. Turn the ignition switch ON (ll) 3. l\4onitor fuel tank pressure(FTP) sensorvoltage with the HondaPGM Tester,or medsurevoltage betweenECMconnectorterminals and E14. E4
6. Connecta vacuum pump to the open end of the hose.
7 . Turn the ignition switch ON {ll). 8 . l\4onitor FTPsensorvoltagewith the Honds PGM Tester,or measurevoltage betweenECM E a c o n n e c t otre r m i n a l s 4 a n d E 1 4 , n d c a r e f u l l y s q u e e z eh e v a c u u mp u m p a l i t t l e . t ECMCONNECTOR 13lPI E
W i r e i d e ff e m a l t e r m i n a l s s o e
ls there about 2.5V? YES-Go to step 4. NO Replace FTPsensor.I the 4 . Turn the ignitionswitch OFF. Wiresideof lemale terminals the 5 . Disconnect hose betweenthe EVAPtwo way valve and the FTPsensorat the EVAPtwo way valve end.
9 . The voltageshould smoothly drop from about 2.5 V v t o a b o u t1 . 5V . S t o pa p p l y i n g a c u u mw h e n t h e voltagedrops to about 1.5V or damageto the FTP sensormay occur. Does the voltage drop to about 1.5 V and hold? YES Checkfor misrouted,leaking,or brokenFTP v l s e n s o r a c u u ml i n e s . f t h e v a c u u ml i n e sa r e O K , updatethe ECM if it does not havethe latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO Replace FTPsensor.! the
11-171
EVAP System
FTP DTCP0452: SensorCircuitLow Voltage
1. Checkthe vacuum lines at the FTPsensorfor breakage, clogging. or misrouting,leakage. Are the vacuumlines OK? 9. Turn the ignition switch ON (ll) YES Go to step 2. NO Repairor replacevacuum lines as necessary. I 2 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . t 3 . R e m o v e h e f u e l f i l lc a p . 4. Turn the ignition switch ON (ll) 5. Monitor FTPsensorvoltagewith the HondaPGM Tester,or measurevoltage betweenbody ground and ECMconnectorterminal E14. E ECMCONNECTOR 131PI terminals Wiresideof female VCgl {YEL/BLU} 10. Measurevoltage betweenFTPsensor3P connector terminals o.1 andNo.2. N 3P FUEL TANK PRESSURE SENSOR CONNECTOR 6. Turn the ignition switch OFF. 7 . R e i n s t a l l t h f u e lf i l l c a p . e 8. Disconnect FTPsensor3P connector. the
1 2 t 3 t 45
././114
tc
8 9
ls there about 5 V? '1. YES Go to step 1 NO-Repair open in the wire betweenthe FTP a s e n s o r n dt h e E C M{ E 5 ) . 1
61./18 2C 21
271/ 29 31
22123 241 t
26
TP (LTGRN)
ls thete about2.5 V? failure,system is OK at this time. YES- Intermittent or Checkfor poor connections looseterminalsat the FTPsensorand at the ECrM.l NO Go to step 6.
11-172
11. MeasurevoltagebetweenFTPsensor3P connector t e r m i n a l s o .2 a n d N o . 3 . N

FUELTANKPRESSUBE SENSOR CONNECTOR 3P
DTCP0453: Sensor FTP CircuitHighVoltage

1. Checkthe vacuum lines at the FTPsensorfor misrouting,leakage, breakage, clogging. or Are the vacuumlines OK? Y E S - G o t o s t e p2 . N O R e p a i r r r e p l a c e a c u u ml i n e sa s o v necessary.I
FTP(LT GBN)
W i r e s i d eo f f e m a l e t e r m i n a l s
2 . R e s e t h e E C M{ s e ep a g e1 1 ' 4 ) . 3. Removethe fuel fill cap.
ls there about 5 V? YES- Replace FTPsensor. the t N O - G o t o s t e p1 2 . 4 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 5. lvlonitorFTPsensorvoltagewith the Honda PGM Tester,or measurevoltage betweenbody ground a n d E C Mc o n n e c t otre r m i n a lE ' 1 4 . ECMCONNECTOR 131PI E
' t 2 .Turn
the ignitionswitch OFF.
1 3 .Disconnect ECMconnectorE (31P), 1 4 .Checkfor continuitybetweenFTPsensor3P

connectorterminal No. 3 and body ground.
FTPSENSOR CONNECTOB 3P
1 1 2 1 34 5 6 7 I 9 5 6 / t18 2C 21 24 2il./ 29 30 31
TP {LTGRN}

FTP (LT GRNI
Is there about 2.5 V? YES Intermittent failure,system is OK at this time. Checkfor poor connections looseterminalsat or t h e F T Ps e n s o r n d a t t h e E C M . I a NO Go to step 6.
W i r es i d eo f f e m a l e l e r m i n a t s
ls there continuity? YES Repairshort in the wire betweenthe FTP s e n s o r n dt h e E C I \ { E 1 4 ) . I a 4 NO-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodEClvl, replacethe originaECM.I l
{cont'd)
11-173
EVAPSystem
6. Turn the ignitionswitch OFF. 7 . R e i n s t a l h e f u e lf i l l c a p . l 8. Disconnect FTPsensor3P connector. the 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s '10. l\4easure voltage betweenFTPsensor3P connector N terminals o.1 andNo.2.
FTPSENSOR3P CONNECTOR FTPILT GRN}
11, Measurevoltage betweenFTPsensor3P connector t e r m i n a l N o . 2 a n dN o . 3 . s

FTPSENSOR3P CONNECTOR
(YEL/BLU) VCC3
terminals Wiresideof female ls there about 5 V? YES Replace FTPsensor.l the NO Go to step 12.
l\4easure voltage betweenECMconnector t e r m i n a l s 4 a n d E1 4 , E ECMCONNECTOR (31P) E
ls there about 5 V? Y E S G o t o s t e p1 1 . NO-Repair open in the wire betweenthe FTP sensorand the ECM (E4). !
W i r es i d e f f e m a l t e r m i n a l s o e
ls there about 5 V? YES Repairopen in the wire betweenthe FTP s e n s o r n d t h e E C M( E 1 4 ) . I a NO Updatethe ECM if it does not have the latest then software,or substitutea known-goodECN4. lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l
11-174
DTCPl456:EVAP ControlSystemLeakage (Fuel TankSvstem)

The fuel system is designedto allow specified maximum vacuum and pressureconditions.Do not deviatefrom the vacuum and pressure tests as indicatedin these procedures. pressure/ Excessive vacuum would damagethe EVAPcomponentsor cause eventualfuel tank failure. Special Tools Required Vacuum Pump/Gauge, 0-30 in. Hg A973X-041-XXXXX This is a two-trip code. Oncecleared,it cannot be reproducedin one trip. Also, cenain specificdriving and ambientconditionsmust occur beforethe ECMwill completethe systemchecks.Additionaltest drives may still not meet the specificconditionsneededto reproduce the code.
EVAP Canister Purge Valve Test 3. Disconnect vacuum hose from the EVAP the canisterpurge valve (A),and connecta vacuum oumo to the hose.
A973X-041-XXXXX T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
procedures Follow thesetroubleshooting carefullyto ensurethe integrityof the system and to confirm the causeof the problemor code. NOTE:Freshfuel has a highervolatilitythat creates greaterpressure/vacuum. optimum condltlonfor The testing is fresh fuel, and must be lessthan a full tank. lf possible, assistin leakdetection, to add 1 gallon of fresh fuel to the tank (as long as it will not fill the tank). just beforestartingthese procedures. Fuel Fill Cap Check 1. Checkthe fuel fill cap (the cap must say "lf not tightened3 clickscheckengine light may come o n ") . ls the proper luel till cap installed and properly tightened? YES Go to step 2. NO- Replace tightenthe cap.I or 2. Checkthe fuel fill cap seal. ls the tuel fill cap seal missing or damaged? Y E S - R e p l a c eh e f u e lf i l l c a p . I t N O T h e f u e l f i l lc a p i s O K .G o t o s t e p3 .
5 . Apply vacuum to the hose. Does the valve hold vacuum? YES-The EVAPcanisterpurge valve is OK. Go to s t e p1 1 . NO-Go to step 6. Turn the ignition switch OFF. 7 . Disconnect EVAPcanisterpurge valve 2P the connecror.
{cont'd)
11-175
EVAPSystem
purge EVAP canister for between 8. Check continuity No. valve2Pconnenctor terminal 2 andbody grou no.
EVAP CANISTERPURGE VALVE 2P CONNECTOR
EVAP Bypass Solenoid Valve Test 11, Disconnect both vacuum hosesfrom the EVAPtwo way valve (A),and connecta vacuum pump to the canisterport on the EVAPtwo way valve.
A973X-041-XXXXX
F-
ls therecontinuity? YES Goto step9. purge valve.l canister NO Replace EVAP the B ECM connector (24P). 9 . Disconnect purge EVAP canister for between 1 0 . Check continuity terminal 2 andbodyground. No. valve2Pconnector
PURGE EVAPCANISTER VALVE2PCONNECTOR Turn the EVAPbypasssolenoidvalve on with the Honda PGM Tester,or connectECMconnecter terminal E20to body ground with a jumper wire. E ECMCONNECTOR 131P)
1 2 3 4 5 6 1 7 l1 8 9 4 5 6 / 118 2C21 2 2 t 2 ? 24 z7l./29

2WBS (BLU/RED} JUMPER WIRE
1 2
'.\'
PCS {YEL/BLU)
1 3 .Turn the ignitionswitch ON (ll).

1 4 .Apply vacuum to the hose.

Does the valve hold vacuum?
ls there continuity? Y E S - G o t o s t e p1 5 , YES Repairshort in the wire betweenthe EVAP 4 c a n i s t e p u r g ev a l v ea n dt h e E C I \ { 8 2 1 ) . 1 r NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe originaECM.I l NO Go to step 20.
11-176
1 5 . Turn the ignition switch OFF.

to.
'19.
Measurevoltage betweenEVAPbypasssolenoid valve 2P connectorterminal No. 1 and body ground. EVAPBYPASS SOLENOID VALVE CONNECTOR 2P
Disconnect EVAPbypasssolenoidvalve 2P the connecror.
1 7 . Checkfor continuitybetweenEVAPbypass solenoidvalve 2P connectorterminal No. 2 and body ground.

EVAP BYPASSSOLENOID VALVE 2P CONNECTOR tG'l
2
{BLK/ORN)
Wire side oI Iemaleterminals
ls there continuity? YES Go to step 18. NO-Repair open in the wire bet\iveen EVAP the bypasssolenoidvalve and the ECM (E20).1
'18. u r nt h e i g n i t i o n w i t c hO N ( l l ) . T s
ls there battery voltage? YES Replace EVAPtwo way/bypasssolenoid the v a l v e( A ) . 1 NO-Repair open in the wire betweenthe EVAP bypasssolenoidvalve and the No. 4 ACG (10A) fuse.l
{cont'd)
11-177
EVAPSystem
2 0 . P l u gt h e f u e l t a n kp o r t ( A )o f t h e E V A P t w o w a y valve, EVAP Canister Vent Shut Valve Test 22. Disconnect vacuum hosefrom the EVAP the canistervent filter (A),and connecta vacuum pump to the hose.
While monitoring FTPsensorvoltagewith the HondaPGM Tester,or measuringthe voltage E E b e t w e e n C Mc o n n e c t otre r m i n a l s 4a n d E1 4 , slowly pump the vacuum pump until the voitage droDS about 1.5volts. to ECMCONNECTOR {31PI E
T u r nt h e i g n i t l o n w i t c hO N ( l l ) . s Apply vacuum to the hosewith five strokesof the pump. Does the valve hold vacuum? YES Go to step 25. NO The EVAPcanistervent shut valve is OK. Go to step 30.
25. T u r nt h e i g n i t i o n w i t c hO F F . s 26. Disconnect EVAPcanistervent shut valve 2P the

Wiresideof female terminals conneclor. 2 1 . Checkfor continuitybetweenEVAPcanistervent s h u tv a l v e2 Pc o n n e c t otre r m i n a lN o . 2 a n d b o d y ground. EVAPCANISTEB VENTSHUT VALVE CONNECTOR 2P
Does the voltagedtop to 1.5 V and hold fot at Ieast 20 seconds? YES-The EVAPbypasssolenoidvalve/EVAP two way valve is OK. Go to step 22. N O R e p a i r h e l e a kf r o m t h e E V A Pb y p a s s t solenoidvalve, EVAPtwo way valve.or F T Ps e n s o r . l
{LTGRN/REOI
11-178
VacuumHoses and Connections Test 3 0 . Do the fuel tank vapor control valve test (seepage
11 - 1 8 7 ) . ls the fuel tank vapot control valve OK? Y E S - G o t o s t e p3 1 . v N O R e p l a c eh e f u e l t a n kv a p o rc o n t r o l a l v e . l t
5 t .
Tightenthe fuel cap 3 "clicks", then monitorthe FTPsensor readingswith the Honda PGM Tester. Startthe engine.and let it idle for 5 minutes.
ls thete continuity? Checkthe FTPsensor readings. YES-Go to step 28. NO-Replace the EVAPcanistervent shut valve (A) a n d o - r i n g( B ) . 1
28. Disconnect ECMconnectorE (31P). 29. Checkfor continuitybetweenEVAPcanistervent

s o l e n o i d a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d v body ground. VENTSHUT EVAPCANISTER VALVE CONNECTOR 2P
ls the reading above 0.5 kpa (4 mm Hg, 0.16 in. Hg) pressure, or about 3 V? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck{seepage 11-6).lf the symptom/indication goes away with a known-goodECfvl, replacethe originaECM.t l NO Checkthe following partsfor leaks:l ls there continuity? YES-Repair short in the wire betweenthe EVAP c a n i s t e v e n ts h u tv a l v ea n dt h e E C M( E 2 1 ) . 1 r NO Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE C M . I l . . . . . . . . . ( Fueltank A) F u e lf i l l c a p ( B ) F u e lf i l l p i p e ( C ) v F u e l t a n k a p o rc o n t r o l a l v e ( D ) v n F u e l t a n k a p o rr e c i r c u l a t i ov a l v e( E ) v u F u e l t a n k a p o rr e c i r c u l a t i otn b e ( F ) v ( v F u e l t a n k a p o rs i g n a l t u b e G ) v v F u e l t a n k a p o rc o n t r o l e n t t u b e ( H ) FTPsensor(J) - Repair r replace nyleaking arts. p a o
11-179
EVAPSystem
DTCPl457:EVAP ControlSystemLeakage (EVAP Canister System)
The fuel system is designedto allow specified maximum vacuum and pressureconditions.Do not deviatefrom the vacuum and pressure tests as pressure/ indicatedin these procedures. Excessive vacuum would damagethe EVAPcomponentsor causeeventualfuel tank systemfailure. SpecialToolsRequired Vacuum pump/gauge, 0-30 in.HgA973X-041-XXXXX
W i r e s i d eo f l e m a l et e r m i n a l s
2. Turn the EVAPcanisterpurge valve on with the HondaPGM Tester,or connectECMconnector terminal 821 to body ground with a jumper wire.
ECMCONNECTOR I24P' A
This is a two-trip code.Once cleared,it cannot be reproducedin one trip. Also, certainspecificdriving and ambientconditionsmust occur beforethe ECfM will completethe system checks, Additionaltest drives may still not meet the specificconditionsneededto
16^r^.1' '^6 rh6 ^^.16
Turn the ignition switch ON (ll).

4 . Apply vacuum to the hose.
Does the valve hold vacuum? procedures Followthesetroubleshooting carefullyto ensurethe integrityof the system and to confirm the causeof the problem or code. NOTE:Freshfuel has a highervolatilitylhat creates greaterpressure/vacuum. optimum conditionfor The testing is fresh fuel, and there must be lessthan a full tank. lf possible, assistin leakdetection, to add I gallon of fresh fuel to the tank (as long as it will not fill the tank),just beforestartingthese procedures. EVAPCanister Purge Valve Test 1. Disconnect vacuum hose from the EVAP the canisterpurge valve (A),and connecta vacuum pump to the hose. YES-Go to step 5. NO-The EVAPcanisterpurge valve is OK. Go to step 10. Turn the ignition switch OFF.
b.
Disconnect EVAPcanisterpurge valve 2P the conneclor,
7 . Checkfor continuitybetweenEVAPcanisterpurge valve 2P connectorterminal No. 2 and body ground.

EVAPCANISTEN PURG VALVE CONNECTOR 2P
-4lll2l -fircs
(f])
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I
W i r e s i d eo f f e m a l e l e r m i n a l s
ls therecontinuity? YES-Goto step8.

4973X-041-XXXXX
NO Repair openin thewire between EVAP the p c a n i s t e ru r g e a l v e n dt h eE C M / P C( 8 2 1 ) . I v a M 8 . T u r nt h ei g n i t i o n w i t c h N( l l ) . s O
11-180
purge voltage between EVAP canister 9. Measure terminal 1 andbodyground. No. valve2Pconnector
PURGE EVAPCANISTER VALVE2PCONNECTOR
EVAP Bypass Solenoid Valve Test both vacuum hosesfrom the EVAPtwo 10. Disconnect way valve {A),and connecta vacuum pump to the canisterport on the two way valve.
Wire side oI lemaleterminals
ls thetebatteryvoltage? purgevalve.l canister the YES- Replace EVAP the NO Repair openin thewire between EVAP purge valveandthe No.4 ACG(10A) canister fuse.I
s 1 1 .T u r nt h e i g n i t i o n w i t c hO N ( l l ) .
'It
Apply vacuum to the hose. Does the valve hold vacuum? YES The EVAPtwo way/bypasssolenoid valveis O K . G o t o s t e p1 8 . N O - G o t o s t e p1 3 . Turn the ignition switch OFF.
the 1 4 . Disconnect EVAPbypasssolenoidvalve 2P connector. Checkfor continuitybetweenEVAPbypass v s o l e n o i d a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d b o d yg r o u n d .

SOLENOID EVAPBYPASS VALVE2P CONNECTOR
Wire sideof female terminals
(cont'd)
11-181
EVAPSystem
EVAP Canisler Vent Shut Valve Test 18. Disconnect vacuum hosefrom the EVAP the canistervent filter (A),and connecta vacuum pump to the hose.
ls there continuity? YES Go to step 16. NO- Replace EVAPtwo waylbypasssolenoid the valve (A).1
to.
Disconnect ECMconnectorE {31P). Checkfor continuitybetweenEVAPbypass solenoidvalve 2P connectorterminal No. 2 and body ground.
EVAPBYPASS SOLENOID VALVE2P CONNECTOR
't7.
19. Turn the EVAPcanistervent shut valve on with the HondaPGM Tester,or connectECMconnector terminal E21to body ground with a jumper wire. ECMCONNECTOR (3TP) E
11213 5 4
1/
l l tl - 2 l I l
2WBS -[BLU/REo) ())
\ ,
1 5tal/la
z3lz4
zil./
8 9 vsv GBN/RED) {LT( 2A21 m 31

JUMPER WIRE
I
Wiresideol lemale terminals
20. Turn the ignitionswitch ON (ll)

2 1 .Apply vacuum to the hose.

YES Repairthe short in the wire betweenthe EVAPbypasssolenoidvalve and the ECM{E20). f NO Updatethe ECI\4 it does not havethe latest if software.or substitutea known-goodEClvl, then recheck(seepage 11-6). the symptom/indlcation lf goes away with a known-goodECM,replacethe o r i g i n aE C M . I l Does the valve hold vacuum? YES-The EVAPcanistervent shut valve is OK. Go to step 27. NO Go to step 22.
2 2 . Turn the ignitionswitch OFF. 2 3 . Disconnect EVAPcanistervent shut valve 2P the

connector.
11-182
24. Checkfor continuitybetweenEVAPcanistervent N s h u t v a l v e2 P c o n n e c t o r t e r m i n a lo . 2 a n d b o d y ground.

2P VATVE CONNECTOR
Canister System Leak Test 27. Turn the ignition switch oFF. ( T 2 8 , C o n n e c t t w ot,h r e e - w a y - f i t t i n g sA )i n t o t h e h o s e from the EVAPcanisterto the EVAPtwo way valve. the FTPsensorto one of the T-fittingsand Connect t h e v a c u u mp u m p t o t h e o t h e l
-4l-T_*u l r 2
ILTGFN/REDI
@
wn s de ol lma1e terminals
ls therc continuity? YES Go to step 25. NO Repairopen in the wire betweenthe EVAP ( c a n i s t e v e n ts h u tv a l v ea n dt h e E C I V IE 2 1 ) . 1 r s 25. T u r nt h e i g n i t i o n w i t c ho N ( l l ) .
26. Measurevoltage betweenEVAPcanistervent shut

v a l v e2 P c o n n e c t otre r m i n a lN o . 1 a n d b o d yg r o u n d .
VENTSHUT EVAPCANISTER VALVE 2PCONNECTOR
29. Removethe vent hosefrom the EVAPcanistervent shut valve (A),and cap the port (B)to sealthe fresh air vent of the EVAPcanister.
Wlreside oflem. rerm na s
s 3 0 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) .
ls there battery voltage? the YES Replace EVAPcanistervent shut valve ( A )a n d t h e o - r i n g( B ) . I NO Repairopen in the wire betweenthe EVAP c a n i s t e v e n ts h u tv a l v ea n dt h e N o . 4 A C G ( 1 0 A ) r fuse.I
(cont'd)
11-183
EVAPSystem
31. While monitoring FTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between ECMconnectorterminalsE4 and E14,slowly pump the vacuum oumD. ECMCONNECTOR 13lPI E 37. While monitoringFTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between E C Mc o n n e c t otre r m i n a l s 4a n d E1 4 ,s l o w l yp u m p E t h e v a c u u mp u m p . ECMCONNECTOR {31PI E
Wiresideof lemale terminals
32. Continueto pump vacuum until the voltagedrops to about 1.5V. Make sure the enginecoolant temperatureis still above 95'F 135.C) and your v a c u u mp u m p h a s n o l e a k . 33. Monitor the voltagefor 20 seconds. Does the voltage drop 1.5V and hold for at least 20 seconds? YES Inspectthe EVAPcanistervent shut valve l i n ea n d c o n n e c t i o n s . l NO-Go to step 34.
38. Continueto pump vacuum until the voltagedrops

to about 1.5V.Make sure the enginecoolant temperatureis still above95"F (35"C) and your vacuum pump has no leak.
39. Monitor the voltagefor 20 seconds

Does the voltage hold for at least 20 seconds? YES Inspeclthe fuel tank vapor control lineand connections.I NO Go to step 40.
40. T u r nt h e i g n i t i o n w i t c hO F F . s
34. Turn the ignition switch OFF. 35. Discon nectthe quick-con nectfitting (A) fromthe EVAPcanister, and plug the canisterport {B).
4 1 .Disconnect purge line hose {A) from the the

c a n i s t e a t t h e m e t a ll i n e a n d p l u gt h e h o s e( B ) . r
11-184
43. While monitoringFTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between ECMconnectorterminalsE4 and E14,slowly pump t h e v a c u u mp u m p . E ECMCONNECTOR {31P)
4 4 . Continueto pump vacuum until the voltagedrops to about 1.5V.Make sure the enginecoolant temperatureis still above 95'F (35'C)and your v a c u u mp u m p h a sn o l e a k .
45. Monitor the voltagecontinuouslyfor 20 seconds.

Does the voltage drop to 1.5 V and hold f or at least 20 seconds? YES Inspectthe EVAPcanisterpurge valve line lf and connections. they are OK, perform the EVAP and the fuel two way valvetest (seepage 11-186) tank vapor controlvalve test (seepage 1'l-187)l NO-Replace the EVAP canister ( s e ep a g e1 1 - 1 8 9 ) . 1
11-185
EVAPSystem
EVAPTwo Way ValveTest
Special Tools Required . V a c u u mp u m p / G a u g e , 0 - 3 0i n . H g A973X-041-XXXXX . Vacuum/Pressure cauge.0-4 in. Hg 07JAZ-0010008 1 . R e m o v e h e f u e l f i l lc a p . t 2. Disconnect vapor line from the EVAPtwo way the valve (A).Connectit to a T-fitting(B)from the v a c u u mg a u g ea n d t h e v a c u u mp u m p a s s h o w n , 4. Move the vacuum pump hosefrom the vacuum fitting to the pressure fitting,and move the vacuum gauge hosefrom the vacuum side to the pressure side (A) as shown.
07JAZ-0010008
Slowly pressurize vapor line while watchingthe the gauge.The pressureshould stabilize momentarilV a b o v e1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) . . lfthe pressuremomentarilystabilizes (valve o p e n s ) b o v e1 . 0k P a( 8 m m H g , 0 . 3i n . H g )t,h e a v a l v ei s O K . . lf the pressurestabilizes below 1.0 kPa(8 mmHg, 0.3 in.Hg),installa new valve and retest.
Apply vacuum slowly and continuouslywhile watchingthe gauge.The vacuum should stabilize m o m e n t a r i l y t 0 . 8 2 . 1 k P a( 6 1 6 m m H g , a 0 , 2 0 . 6i n . H g ) . lf the vacuum stabilizes {valveopens)below 0.8 kpa ( 6 m m H g , 0 . 2i n . H g ) r a b o v e2 . 1k P a( 1 6m m H g , o 0.6 in.Hg),installa new valve and retest.
11-186
VaporControlValveTest FuelTank
ToolsRequired Special 0-30 in. HgA973X-041-XXXXX Pump/Gauge, Vacuum
ValveTest
1 . N 4 a ks u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l e t 2 . R e m o v eh e f u e lf i l l c a p . the 3. Disconnect fuel tank vapor signaltube (A).
FloatTest
1 . M a k es u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l . 2. Removethe fuel fill cap to relievefuel tank pressure, then reinstallthe cap. tube the 3. Disconnect fuel tank vapor recirculation t t { A ) ,a n d c o n n e c a v a c u u mP u m P o i t .
the vacuum hoses(A)from the EVAP 4 . Disconnect canister(B),then plug the ports with plugs (C)
A973X-041-XXXXX P l u gt h e l i n e( B ) . 5 . Apply vacuum to the fuel tank vapor recirculation tuDe. lf the vacuum holds, replacethe fuel tank vapor c o n t r o l a l v e( s e ep a g e1 1 - 1 8 9 ) . v lf the vacuum does not hold, the float is OK. Do the valve test.
A973X-O41-XXXXX the 5. Disconnect vacuum hose (D)from the EVAP canistervent shut valve (E),and connecta vacuum pump to the vacuum hose. 6 . P u m pt h e v a c u u mp u m p 8 0 t i m e s . . l f t h e v a c u u mh o l d s , o t o s t e P . g 7 . l f t h e v a c u u md o e sn o 1h o l d ,g o t o s t e p 1 0 .
(cont'd)
11-187
EVAPSystem
FuelTank VaporControlValve Test (cont'd)
7. Connecta secondvacuum pump to the fuel tank ( v a p o rs i g n a l t u b e A ) . Fill the fuel tank with fuel, then checkfor fuel in the EVAPtwo way valve (A),and fuel tank vapor recirculation hose (B). NOTE: either location, At tiny dropletsof fuel are normal. . lf fuel runs out of th e hosesat either location, replacethe fuel tank vapor control valve. . l f t h e f u e l d o e sn o t r u n o u t o f t h e h o s e s t h e f u e l , tank vapor systemfunction is normal.
8. Apply vacuum (1 pump) to the fuel tank vapor signaltube (A).then checkthe vacuum on the pump in step 6. . lf the vacuum holds,replacethe fueltank vapor c o n t r o l a l v e{ s e ep a g e1 1 - 1 8 9 ) . v . If the vacuum is released, goto step 9.
Checkfor fuel rirnningout.
Checkfor fuel runningout.
1 0 .Disconnect fuel tank vapor quickdisconnect the

from the EVAPcanister, then plug lhe port on the canister.Reapplyvacuum (80 pumps). . lf the vacuum holds,replacethe fuel tank control v a l v e( s e ep a g e11 - 1 8 9 ) . . lf the vacuum does not hold, insDect EVAP the canistervent shut valve o-ring.lf the o-ring is OK, replacethe EVAPcanister, and repeatstep 4.
11-188
EVAPCanisterReplacement
l. Removethe vacuum hoses(A).
FuelTankVapor ControlValve Replacement

t 1 . R e m o v e h e f u e lt a n k ( s e e p a g e l l - 1 5 5 ) . v t 2 . R e m o v e h e f u e l t a n kv a p o rc o n t r o l a l v e ( A )f r o m t h e f u e lt a n k( B ) .
2. Removethe boit (B). 3. Removethe EVAPcanister(C). 4. Installin the reverseorder of removal.
3 . Installthe fuel tank vapor control valve.

'l 4 , Installthe fuel tank (seepage 1 -155).
11-189
Clutch
......... 12-2 Tools Special n .2 .. Lto c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . , .1 . .- 3. . . . . . . Comoonen and Position Switch, Pedal Pedal, Clutch Clutch 12-4 .................... Adiustment Interlock Switch Clutch 12-5 ..................... Rep|acement Cylinder CfutchMaster 12-7 .'........ Replacement Cylinder Slave .....12-9 ................... Replacement Clutch
Clutch
SpecialTools
Ref. No.
a
Description
Clutch lignment isc A D R i n gG e a rH o l d e r Clutch lignment haft A S Remover andle H
(1, @
Tool Number OTJAF-PM7O11A 07LAB-PV001or 07924-PD20003 00 07zAF-PR8A100 07936-3710100
Oty
,l 1 1 1
l _ l
l .
'l-r
o
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12-2
""*--/ \,L_.Ei
INTERLOCK SWITCH CLUTCH page12-4 Adjustment,
/i (,'.'
RETAININGCLIP Replace.
_,___-,-s\
O-RING Replace. CYLINDER CLUTCH MASTER page Replacement, l2-5
CLUTCHDISC Bemoval,page 12-9 I n s t a l l a t i op a g e ' 1 2 - 1 2 n,
PEDAL CLUTCH POSTTTON SWITCH p, A d j u s t m e n ta g e ' 1 2 - 4
UTCHPEDAL A d j u s t m e n tP a g e1 2 4 ,
PRESSURE PLATE page'12-9 Removal, pa 1 l n s t a l l a t i o n ,g e 2 - 1 2 RELEASE BEARING B e p l a c e m ep a , e 2 - 1 3 nt g 1
FLYWHEEL page'12-1 1 Inspection, page 1 Replacement, 12-1

CLUTCHHOSE CLIP
SLAVECYLINDER page 12-7 Replacement,
\".rr"*"o*
12-3
Clutch
ClutchPedal,ClutchPedalPositionSwitch, and ClutchInterlockSwitch Adjustment
NOTE: . To checkthe clutch pedal positionswitch (seepage 4-45). . To checkthe clutch interlockswitch (seepage 4-6). . Removethe driver's side floor mat beforeadjusting the clutch pedal. . The clutch is self-adjusting compensate wear. to for . lf there is no clearance betweenthe mastercylinder pistonand push rod, the releasebearingwill be held againstthe diaphragmspring.which can resultin clutchslippageor other clutch problems. 1. Loosenthe clutch pedal positionswitch locknut(A), and backoff the clutch pedal positionswitch (B) until it no longertouchesthe clutch pedal (C).
J 9.8 N.m (1.0kgf.m,7.2lbf.ft)
3. Tightenthe clutch push-rodlocknut(D). 4. With the clutch pedal released. turn the clutch pedal positionswitch (B) in until it contactsthe clutch pedal (C). 5. Turn the clutch pedal positionswitch {B) in an additional3/4 to 1 turn. 6. Tightenthe clutch pedal positionswitch locknut(A). 7. Loosenlocknut(J)and the clutch interlockswitch (K). 8. Pressthe clutch pedalto the floor. 9 . R e l e a s t h e c l u t c hp e d a l1 0 ' l 6 m m ( 0 , 3 9 0 . 6 3 i n . ) e from the fully pressedposition,and hold it there. Adjust the positionof the clutchinterlockswitch (K) so that the enginewill startwith the clutch pedal in thls position. 10. Tightenthe clutch interlockswitch locknut(J).
A 9.8 N.m kgf.m,7.2 lbf.ft) 11.0
18 N.m {1.8kgf.m, 13 tbf.ftl
Loosenthe clutch push-rodlocknut(D).and turn the push rod (E)in or out to get the specifiedheight (F),stroke(G).free play (H)and disengagement h e i g h t( l ) a t t h e c l u t c hp e d a l . 130 140 mm ( 5 . 1 2 5 . 5 1i n . l Clutch PedalFreePlay: l0 16 mm (0.39-0.63 in.) Clutch PedalHeight: 193 mm (7.60in.) Disengagement Height: 115 mm (4.53in.) Between Floor And Carpet Height (ApproximateValuel: 38 mm {1.50in.l Clutch PedalStroke:
12-4
ClutchMasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may damagethe paint; if brakefluid does contactthe paint, wash it off immediatelV with water. 1 . P r yo u t t h e l o c kp i n ( A ) ,a n d p u l l t h e p e d a lp i n ( B ) out of the yoke. Removethe mastercylinder mounting nuts (C). 6. Disconnect reservoirhose (D)fromtheclutch the mastercylinder reservoir.Plugthe end of the reservoirhose with a shop towel to preventbrake fluid from coming out. 7. Removethe O-ring(E)and the clutch master cylinderseal (F)from the mastercylinder. 8. Installtheclutch mastercylinder in the reverse order of removal.Installa new O-ring. 9. Make sure the hose clamps (A) are positionedon the mastercylinder (B)and reservoir(C)as shown.
UP
R e m o v e h e a i r c l e a n e r o u s i n g o v e ra n dt h e a i r h t c cleanerhousing (seestep 6 on page 5-2).
3 . Removethe brakefluid from the clutch master

cylinder reservoirwith a syringe. Removethe clutchline bracketfrom the frame rail, and removethe clutch line clip. Removethe clutch mastercylinder(A),and pull it toward the middle of the enginecompartment. Removethe retainingclip (B).Disconnect clutch the line (C).Plugthe end of the clutch line with a shop towelto preventbrakefluid from coming out.
g-E
(cont'd)
12-5
Clutch
(cont'd) ClutchMasterCylinderReplacement
10. To preventthe retainingclip (A)from coming off, pry open the tip of the retainingclip (B)with a screwdriver,
1 1 .Tightenthe mastercylindermounting nuts to 13 N m ( 1 . 3k g f m , 9 . 4 l b f . f t ) . Bleedthe clutch masterhydraulicsystem (seestep 11 o n p a g e 1 2 - 8 ) . i N O T ET h e r e s e r v o ifri l l i n gi s c o v e r e d n t h e : bleedingprocedure. h l n s t a l l t h e i r c l e a n e r o u s i n g( s e es t e p3 7 o n p a g e a 5-15).
12-6
SlaveCylinder Replacement
NOTE: . U s ef e n d e rc o v e r s o a v o i dd a m a g i n g a i n t e d p t surfaces. . D o n o t s p i l lb r a k e l u i d o n t h e v e h i c l e i; t m a y d a m a g e f the paint; if brakefluid does contactthe paint,wash it off immediatelywith water. 1. Write down the frequencies the radio's preset for buttons.Disconnect negative( ) cablefirst, the then the positive(+)cable from the battery. Removethe battery. 2. Removethe batterytray. 6. Removethe mounting bolts (A) andtheslave ( cylinder B).
7 . Removethe roll pins (C).Disconnect clutch line the ( D ) ,a n d r e m o v et h e O - r i n g( E ) .P l u gt h e e n d o f t h e clutch line with a shop towel to preventbrakefluid f rom coming out. Installtheslavecylinder in the reverseorder of removal.Installa new O-ring (A).
R e m o v e h e a i r c l e a n e r o u s i n g o v e ra n dt h e a i r t h c ( c l e a n e r o u s i n g s e es t e p6 o n p a g e5 - 2 ) . h
4 . Removethe intakeair duct (seestep 8 on page 5-3).
,,6NJ'
=-#.q!4sEn (P/N 08798-90021
5 . Removethe clutch line bracket(A).
(Brak6 Assembly Lube) a 9 . P u l l t h eb o o t ( B )b a c k , n d a p p l yb r a k ea s s e m b l y l u b et o t h e b o o ta n d s l a v ec y l i n d e r o d ( C ) .R e i n s t a l l the boot.
1 0 .Apply super high temp urea grease(P/N087989 0 0 2 ) o t h e p u s h r o d o f t h e s l a v ec y l i n d e rT i g h t e n t . t h e s l a v ec y l i n d e r o u n t i n gb o l t st o 2 2 N m ( 2 . 2 m kgfm, 16lbf.ft).
(cont'd)
12-7
Clutch
(cont'd) SlaveCylinderReplacement
11. Bleedthe clutch hydraulicsystem. . Aftach a hoseto the bleederscrew (A),and suspendthe hose in a containerof brakefluid. . M a k es u r et h e r ei s a n a d e q u a t e u p p l yo f f l u i d i n s the clutch mastercylinder,then slowly pump the clutch pedal until no more bubblesappearatthe bleederhose. . lt may be necessary llmit the movement of the to releasefork (B)with a blockof wood to remove all the air from the system. . Tightenthe bleedscrewto I N.m (0.8kgf.m,6 lbf ft); do not ovenightenit, . Refillthe clutch mastercylinderwith fluid when done. . Always use only Honda DOT3 brakefluid.
L
12. Installthe intakeair duct (seestep 36 on page 5-14). 1 3 .I n s t a l l t h e i r c l e a n e r o u s i n g( s e es t e p3 7 o n p a g e a h
5-15). 1 4 . Installthe batterytray.
t5.
Installthe battery,connectthe positive(+) cable first, then the negative(- ) cable.
1 6 . Resetthe frequencies the radio stationpreset for buttons,
12-8
ClutchReplacement
Spscial Tools Required . Clutchalignmentdisc 07JAF-PM701 1A . Ringgear holder07LAB-PV00100 or 07924-PD20003 . Clutchalignmentshaft 07ZAF-PR8A100 . Removerhandle07936-3710100 2 . I n s t a l l t h e p e c i atl o o l s . s
A
\-
Pressure Plateand GlutchDiscRemoval

1 . C h e c k h e d i a p h r a g m p r i n gf i n g e r s o r h e i g h t t s f using lhe speciallool and feelergauge.lf the height is more than the servicelimit, replacethe pressure ptate. StandardlNewl: ServiceLimit: 0.6 mm (0.02in.) max. 0.8 mm {0.03in.)
A-.-
\ffim
9fra-I
nl I
tP
|-
07LAB-PV00100 or 07924-PD20003
07zAF-PR8A100 07936-3710100 OTJAF-PM7O11A
plate To prevent warping, unscrew pressure the pattern several mounting bolts(A)in a crisscross in plate(B). steps, then remove pressure the Inspect fingers the diaphragm the of spring(A)for wearat the release bearing contact area.
5. Inspectthe pressureplate 1A)surfaceforwear, cracks.and burning.
(cont'd)
12-9
Clutch
(cont'd) ClutchReplacement
6. Inspeclfor warpage using a straightedge (A) and feeler gauge (B).l\4easure acrossthe pressureplate (C).lf the warpage is more than the servicelimit, replacethe pressureplate. Standard{New): ServiceLimit: 0.03mm (0.001in.) max. 0.15mm (0.006in.) 9. lvleasu th e clutchd isc th ickness. re lfthethickness is lessthan the servicelimit, replacethe clutchdisc. StandardlNew): ServiceLimit: 8.3 8.9 mm (0.33 0.35in.) 6.0 mm {0.24in.)
1 0 .Measurethe rivet depthfrom the clutchdisc lining

7 . R e m o v e h e c l u t c hd i s ca n d s D e c i a l t o o l s . t surface(A) to the rivets(B)on both sides.lf the rivet depth is lessthan the servicelimit, replacethe c l u t c hd i s c . Standard(New): ServiceLimit: 1.65 2.25 mm (0.065 0.089in.) 0.7 mm (0.03in.)
1 d
I n s p e c t t h ei n i n go f t h e c l u t c hd i s cf o r s i g n so f l s l i p p i n g r o i l . l f t h e c l u t c hd i s ci s b u r n e db l a c ko r o oil soaked.reolaceit.
12-10
FlywheelInspection
1. Inspectthe ring gear teeth for wear and damage. 2. Inspectthe clutchdisc mating surfaceon the flywheel for wear, cracks,and burning. 3. Measurethe flywheel (A) runout using a dial indicator(B)through at leasttwo full turns. Push againstthe flywheel eachtime you turn it to take up the crankshaft th rust washerclearance.lf the runout is more than the servicelimit, replacethe flywheel and recheck the runout.Resurfacing the flywheel is not recommended. Standard(New): 0.05mm (0.002in.) max. ServiceLimit: 0.15mm (0.006in.)
FlywheelReplacement
1 . I n s t a l l t h e p e c i atlo o l . s
2 . Removethe flywheel mounting bolts in a crisscross

patternin severalsteps,then removethe tlywheel.
3 . Installtheflywheel on the crankshaft, and install

the mounting bolts fingertight.
4 . I n s t a l l t h e p e c i a l t o o lt,h e nt o r q u et h e f l y w h e e l s
patternin several mounting bolts in a crisscross sreps.
1 2 x 1 . 0m m 103 N.m (10,skst.m. 76 lbf ftl
(cont'd)
12-11
Glutch
(cont'dl ClutchReplacement
PlateInstallation ClutchDiscand Pressure
'L T e m p o r a r i l yn s t a ltl h e c l u t c hd i s co n t o t h e s p l i n e s i of the transmissionmainshaft,Make sure the clutch disc slidesfreely on the mainshaft.
pattern, 5. Torque mounting the boltsin a crisscross Tighten boltsin several steps prevent to the w a r p i n gh ed i a p h r a g mp r i n g . s t PRESSURE PLATE MOUNTING BOLT TOROUE: 25 N.m{2.6kgt.m, lbt.ft) 19
2 . l n s t a l l t h e i n g g e a rh o l d e r . r
O?ZAF.PRSAIOO
\---,
/v
07936-3710100
{P/N08798-9002) 07LAB-PVo0'100 or 0792,1-PD20003
3 . Apply super high temp urea grease(P/N087989002)to lhe splines(A) of the clutch disc (B),then installthe clutchdisc usingthe specialtools. Removethe specialtools. Installthe pressureplate (A) and the mounting ht. bolts (B)finger-tig 1 . Make sure the diaphragmspringfingers are all the s a m eh e i g h t .
12-12
Release Bearing Replacement

'L Removethe releasefork boot (A)from the clutch ( housing B).
4 . Apply super high temp urea grease{P/N087989002)to the releasefork (A),the release fork bolt ( B ) ,t h e r e l e a s e e a r i n g C ) , n d t h e r e l e a s e e a r i n g ( a b b g ui d e ( D )i n t h e s h a d e da r e a s .
1 . 0 1 . 6g 10.04 0.06oz)
\\
l-'..\
\\ \ ) ) / /-/
!ac
Xrl-Rl It\'1
f-l\-._ -A 0 . 4 1 . 0g 10.01 0.04o
{re\
"
I L!),l-*E
0.t 1.09 (0.01 0.04 oz)
2 . Removethe release fork (C)from the clutch

( h o u s i n g B )b y s q u e e z i n t h e r e l e a s eo r k s e ts p r i n g g f ( D ) w i t hp l i e r s R e m o v e h e r e l e a s e e a r i n g E ) . ( . t b With the releasefork slid betweenthe release p b e a r i n g a w l s .i n s t a l l t h e e l e a s e e a r i n g n t h e r b o m a i n s h a fw h i l e i n s e r t i n gh e r e l e a s eo r kt h r o u g h t f t t h e h o l ei n t h e c l u t c hh o u s i n g . 6 . Align the detentof the releasefork with the release fork bolt,lhen pressthe releasefork over the r e l e a s eo r k b o l ts q u a r e l yM a k es u r et h e r e l e a s e f . f o r k s e t s p r i n g( F )i s p r o p e r l y e t . s 7 . I n s t a l l t h e e l e a s eo r k b o o t{ E ) .M a k es u r et h e b o o t r f f s e a l sa r o u n dt h e r e l e a s eo r k a n d c l u t c hh o u s i n g . fork (A) right and left to make 8 . Move the release i t f i t s p r o p e r l y g a i n st h e r e l e a s e e a r i n g a b s u r et h a t ( B )a n d t h a tt h e r e l e a s e e a r i n g l i d e ss m o o t h l y . b s
3 . Checkthe releasebearingfor play and noise by

p s p i n n i n g t b y h a n d .l f t h e r ei s e x c e s s i v e l a yo r i n o i s e , e p l a c eh e r e l e a s e e a r i n g i t h a n e w o n e . r t b w NOTE:The releasebearingis packedwith grease. Do not wash it in solvent.
12-13
ManualTransmission
SpecialTools 13-2 Transmission Inspection Fluid a n dR e o 1 a c e m e n.t. . . . . . . . . . . .|.5-J. - . .. .. Back-Up LightSwitch Test ..........J - 5 t Transmission Removal 13-4 Transmission Installation ........... I J-at Transmission Disassemblv ........ 3 - 1 4 1 Reverse ShiftFork Clearance lnsoection 13-19 Lever Change Clearance lnsoection 13-19 Lever Assembly Change Disassembly/Reassembly 13-20 ....... ShiftForks Clearance Inspection 13-21 ShiftForks Disassembly/Reassembly 13-22 ....... Mainshaft Assemblv Clearance Inspection 13-23 't3-25 Mainshaft Disassembly Mainshaft lnsoection 13-26 Mainshaft Reassembly | 5-2.5 Countershaft Assemblv Clearance Inspection 13-31 Disassembly Countershaft ......... 13-32 Inspection ............. Countershaft 13-33 Reassembly Countershaft .......... 13-34 Synchro Sleeve Hub and Inspection Reassembly 13-39 and .... Synchro RingandGear Insoection ....... 13-39 Mainshaft Bearing OilSeal and R e p l a c e m e n.t. . . . . . . . . . . . . . . . .1.3 . .4 . . . . . . - ,1 Cou ntershaft Bearing ReDlacement .. 13-42 Mainshaft Thrust Clearance Adiustment .....13-43 Transmission ......... 13-46 Reassemblv Gearshift Mechanism R e p l a c e m e n.t. . . . . . . . . . . . . . . . .1.3 . .5 . . . . . . - .1
M/T Differential
Comoonent Location Index ........ 13-52 Backlash Inspection ..................... 13-53 Final Driven Gear/Carrier Replacement .. 13-53 Bearings ... Carrier Replacement 13-54 Oil SealReplacement 13-55 .................. Differential Thrust Clearance Adiustment .....13-56
ManualTransmission
SpecialTools
Ref.No. Description A 2 E n g i n eH a n g e r d a p t e r , . 0t o 2 . 4 L i t e r E n g i n eH a n g e r ral M a i n s h a fH o l d e r t 07GAJ-PG20' ]10 07GAJ-PG20130 M a i n s h a fB a s e t @ 07JAD-P190100 O i l S e a lD r i v e r 07NAD-P20A100 Oil Seal DriverAftachment AdjustableBearingPuller,20-40mm 07736-A01000B ri) Attachment,42 x 47 mm 07746-0010300 Driver,40 mm LD. 07746-0030100 @ Driver,30 mm LD. 07746-0030300 @ Driver 07749-0010000 @ of Mainshaft Inspection o o l S e t .0 7 G A J - P G 2 0 1 0 2 . on T Tool Set, '16 3 S l i d eH a m m e r . M u s t b e u s e dw i t h c o m m e r c i a l la v a i l a b l e / 8 " y
ToolNumber
Oty
(!l ar\
vs802c000015 vs802c000018
o o
l l
,l
Z-'
-4
@
I
\'---'' @
A n r f; D \".,i'i
I rS'D
IN
@
Q)-'' o
-a ,/
@
-4
13-2
Transmission FluidInspection and Replacement

'1. Parkthe vehicleon level ground,and turn the e n g i n eO F F .
Back-UpLight Switch Test

1. Disconnecttheback-uplight switch (A) connector.
2 . R e m o v e h e o i l f i l l e rp l u g ( A )a n d w a s h e r( B ) ,c h e c k t the conditionof the fluid, and make sure the fluid is at the proper level (C).
2 . Checkfor continuitybetweenthe back up light

s w i l c h2 P c o n n e c t o N o . 1 a n d N o . 2 t e r m i n a l s . r There should be continuitywhen the shift lever is in reverse. l f t h e t r a n s m i s s i ofn u i d i s d i n y , r e m o v e h e d r a i n l t p l u g( D )a n d d r a i nt h e f l u i d . replacethe back-uplight switch. 3 . lf necessary, ( a, l A p p l y l i q u i dg a s k e t P / N0 8 7 1 8 - 0 0 0 1 )n d i n s t a l i t o n t h et r a n s m i s s i oh o u s i n g . n
A 44 N.m{4.5kgt.m,
33rbr.ftl
R e i n s t a t lh e d r a i np l u gw i t h a n e w w a s h e r , n d l a refillthe transmission fluid to the proper level. Oil Capacity 1.50 (1.6US (F) at tluid change 1.70 {1.8US qt) at overhaul Always use Honda ManualTransmissionFluid (MTF).Using motor oil can causestiffer shifting and noise becauseit does not containthe proper additives. 5 . R e i n s t a t lh e o i l f i l l e rp l u gw i t h a n e w w a s h e r . l
13-3
ManualTransmission
Transmission Removal
SpecialToolsRequired . E n g i n e a n g e r d a p t e r . 2 . t o 2 . 4l i t e rV S B 0 2 C 0 0 0 0 1 5 h a 0 . E n g i n eh a n g e rV S B 0 2 C 0 0 0 0 1 8 . Enginesupport hanger,A & RedsAAR'T 12566' ' . SubframeadaDter EOS02C000011 * A v a i l a b l eh r o u g ht h e H o n d aT o o l a n d E q u i p m e n t t Program888-424-6857 NOTE:Use fender coversto avoid damaging painted surfaces. 1 . Write down the frequencies the radio'spreset for buttons.Disconnect negative( ) cablefirst, the then the positive( )cable from the battery. Removethe battery. Removethe intakemanifoldcover {seepageg-3). ( R e m o v e h e a i r c l e a n e r o u s i n g s e ep a g e11 - 1 6 2 ) . t h
4 . Removethe intakeair duct {seestep 8 on page 5-3).
8. Removethe cable bracket(A).then disconnect the ( c a b l e s B )f r o m t h e t o p o f t h e t r a n s m i s s i o h o u s i n g . n Carefullyremove both cablesand the bracket togetherso as not to bend the cables.
A i l
@ B
Removethe batterytray (A). 9. Removeheharness lip. t c
D i s c o n n e c h e t r a n s m i s s i o g r o u n dc a b l e( B ) . tt n 7 . Disconnect back-uplight switch connector(A) the ( s c r a n dv e h i c l e p e e ds e n s o r V S S ) o n n e c t o( B ) .
13-4
10. Carefullyremovethe slavecylinderand clutchline bracketso as not to bend the clutch line. Do not operatethe clutch pedalonce the slavecylinder has been removed,
12. Attach the specialtool to the threaded hole in the c y l i n d e rh e a d .
vsB02c00001s
tJ.
1 1 .Removethe enginewire harnesscover (A) by lifting up on the locktab (B),then slidethe harness f o r w a r do f f t h e a i r c l e a n e r o u s i n g o u n t i n g h m bracket{C).
I n s t a l l t h e n g i n eh a n g e r( A ) a n d t h e e n g i n es u p p o r t e hanger {B) to the vehicle,then attachthe hook to the sDeciai tool.
vs802c000015
1 4 . Removethe two upper transmissionmounting bolts.
(cont'd)
13-5
ManualTransmission
(cont'd) Removal Transmission
15. Removethe transmissionmount bracket(A) and t r a n s m i s s i o m o u n t i n gb o l t ( B ) . n
20. Removethe three way catalyticconverter(TWC)

assembly(seestep 30 on page 5-5)
2 1 . Removethe driveshafts(seepage 16-3). 22. Removethe intermediate shaft {seepage 16-19). 23. Removethe front enginemount bracketmounting
bolt.
to.
b t R e m o v e h e a i rc l e a n e r r a c k e{ C ) . t
, 1 7 . R a i s e h e v e h i c l e a n d m a k es u r ei t i s s e c u r e l y t supponed. l 1 8 . D r a i nt h e t r a n s m i s s i o f l u i d .R e i n s t a t lh e d r a i nb o l t n w i t h a n e w w a s h e r( s e ep a g e1 3 - 3 ) . 1 9 .R e m o v eh e s p l a s h h i e l d . t s
24. Removethe three bolts securingthe transmission

r e a rm o u n I .
db-qF
Ds
1 3- 6
25. Supportthe subframewith the subframeadapter and a jack.
27. Removethe clutchcover.
---
EOS02C000011 2 8 . R e m o v e h e f r o n t e n g i n em o u n t . t
marks (A) on the front suspension 26. Make reference subframe(B)and mounting bolts (C).then remove subframe. the front suspension
29. P l a c e h e t r a n s m i s s i oin c ku n d e rt h e t r a n s m i s s i o n , t a
and removethe transmissionmounting bolts.
(cont'd)
13-7
Manual Transmission
Transmission Removal(cont'd)
30. Pullthe transmissionaway from the engine until
the transmissionmainshaftclearsthe clutch pressureplate,then lower the transmissionon the jack. transmission Removethe transmissionrear mount (A) and the transmissionrear mount bracket{B).
Transmission Installation
Special Tools Required . Enginehangeradapter,2.0to 2.4 liter VS802C000015 . En g i n eh a n g e rV S 8 0 2 C 0 0 0 0 1 8 . Enginesupport hanger,A & RedsAAR-T-12566" . subframe adaDterEoS02c000011 * Availablethrough the HondaTool and Equipment Program888-424-6857 1. Checkthe two dowel pins are installedin the clutch h o u sn g . r Apply super high temp urea grease(P/N087989002)to the releasefork (A) and the releasebearing (B).Installthe releasefork and the releasebearing.
g 1.0 '1.6 {0.04 0.06oz)
3 2 . Removethe boot (A),the releasefork {B).and the

( r e l e a s e e a r i n g C )f r o m t h e t r a n s m i s s i o ( D ) . b n
0.4 1.0g {0.01 0.04 ozl 3 . I n s t a l l t h er a n s m i s s i o r e a rm o u n tb r a c k e ( A ) a n d t n t t h e t r a n s m i s s i o r e a rm o u n t( B ) . n 't2x 1 . 2 5 m m 64 N m {6.5kgf.m, 47

1 2x 1 . 2 5 m m 64 N.m {6.5 ksf.m, 47 tbf.ft)
P l a c eh e t r a n s m i s s i oo n t h e t r a n s m i s s i o i a c k . t n n and raiseit to the engine level.
13-8
5 . I n s t a l lt h e t r a n s m i s s i o nm o u n t i n g bolts. 1 2 x 1 . 2 5m m 64 N.m 16.5 m.47 lbt ft) kgf
8. Supportthe subframewith the subframeadapter a n da j a c k .
1 2x 1 . 2 5 m m 64 N.m (6.5kgf.m,47 lbf.ft) 6 . I n s t a l l t h ef r o n t e n g i n e m o u n t .
( f n 9 . I n s t a l l t h er o n t s u s p e n s i o s u b f r a m e A )i n i t s t b o r i g i n a p o s i t i o n y a l i g n i n g h e m a r k s( B )y o u l made in the removal procedure,
12 x 1.25ftrn 64 N.m (6.5 kgf m. 47 lbf.ft)
12x 1.25mm 64 N.m (6.5kst.m,47 lbf ft) 7 . l n s t a l l t h e c l u t c hc o v e r . 1 4x 1 . 5m m
6x1.0mm 12 N.m {1.2kgI.m,9 lbf ftl
(cont'd)
13-9
Manual Transmission
(cont'dl Transmission Installation
'10. Installthethree rear mounting bolls for the transmissionrear mount.
1 5 .Installthe transmissionmount bracket(A) and the

t r a n s m i s s i o m o u n t i n gb o l t{ B ) . n
6x1.0mm 12Nm 1 2x 1 . 2 5 m m 54 N.m {5.5ksf.m, 40lbf.ft) 12x 1.25nn 54 N.m (5.5kgf.m, 40 tbt.ft)
/t':::= -)
12 x 1.25 mm 54 N.m (5.5kgf.m, 40 tbf.ftl
1 6 . Installthe air cleanerbracket(C). 59 N.m(6.0 kgf.m,43 tbf.ft) 1 1 .Looselytighten the front engine mount bracket mounting bolt.
10 x 1.25mm
1 7 . Installthe two uppertransmissionmounting bolts.
12x 1.25 mrn 64 N.m(6.5 kgt.m,47 lbf.ftl
12. Installthe intermediateshaft (seepage 16-24).

t5.
1 8 . R e m o v e h e e n g i n eh a n g e ra n d s p e c i atlo o l f r o m t engrne.
(seepage 16-17). Installthedrivershafts
1 4 . lnstallthe three way catalyticconverter(TWC) assembly(seestep 17 on page 5-12).
13-10
19. Tightenthe front engine mount bracketmounting bolt.

'12x 1.25mm 64 N.m 16.5 kgf.m, il7 lbf.ft)
21. lnstallthe brakeboosterand EVAPline bracket mounting bolts (A).and air cleanerhousing bracket h T t m o u n t i n gb o l t ( B ) . i g h t e n h e a i r c l e a n e r o u s i n g bracketmounting bolt (C),and installthe water pipe mounting bolt (D). A 9.8N.m (1,0 qf k
s 2 0 . I n s t a ltl h e s p l a s h h i e l d .
%,
22N.m l2.2kglm, 16rbt.ft) 9.8Nm (1.0 m. kgf 'B 7.2tbl{rl 22Nm {2.2kgf m, 16 lbf ft)
c e 22. I n s t a l l t h e n g i n eh a r n e s s o v e r .
(cont'd)
13-11
Manual Transmission
(cont'dl Transmission Installation
(P/N08798Applysuperhightemp ureagrease 9002) the endof the slave to cylinder rod.Install the slave cylinder the clutchlinebracket. and Take care
not to bend the clutch line. 8 x 1.25mm 22 N.m (2.2 kgf.m, 16 lbf ft) 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt.ftl
2 5 . I n s t a l l t h e a b l eb r a c k e ( A )a n d c a b l e s B ) . ( c t
BWZ[i:i'u'T!'*n'-'
#._gEEa9En (P/N08798-9002)
a^_
lPlN 08798-9002)
24. Installthe arness lip. h c
26. Apply a light coat of super high temp urea grease

(P/N08798- 9002)to the cable ends.
t1
Connectthe back-uplight switch connector(A) and (r t h e v e h i c l e p e e ds e n s o r V S S ) c o n n e c t o B ) . s {
13-12
ground cable (A). 28. Connectthe transmission

8 x 1.25mm 22 N.m (2.2kgf.m, 16lbf.ft)
[---.-.---e e
6x1,0mm 9.8 N.m {1.0kgl m. 7 lbf ftl
8x125mm 22Nm kgt 12.2 m, 16lbf ft)
29. lnstallthe batterytray (B). 30. Installthe intakeair duct (seestep 36 on page 5-14).
( h I n s t a l l t h e i r c l e a n e r o u s i n g s e es t e p3 9 o n p a g e a 5-15).
3 2 . Installthe intakemanifoldcover (seestep 41 on

p a g e5 - 1 5 ) .
33. Installthe battery.Connectthepositive(+) cable

first, then the negative(-)cable to the battery. l t 34. R e f l l l t h e r a n s m i s s i ofn u i d ( s e ep a g e1 3 - 3 ) . the 35. Test-drive vehicle.
36. Checkthe clutchoperation. 3 1 .Checkthe front wheel alignment(seepage 18-4). 38. Enterthe anti-theftcode for the radio,then enter
the customer'sradio stationpresets. i 39. D o t h e e n g i n ec o n t r o lm o d u l e( E C M ) d l e l e a r n ( p r o c e d u r e s e ep a g e1 1 - 1 3 9 ) .
13-13
Manual Transmission
Transmission Disassembly
Exploded View-Clutch Housing
,.Y
' r'<__J'.@t / ,, tl j=-X ri ,1.-6
'-==-Yh,_-9
n""
-',ot/u
,tA'
v i6
\? q'/V^
-1 t3l
t4
.!) DIFFERENTTAL ASSEMBLY r2lSHIFTFORK ASSEMBLY 6 a9l mm FLANGEBOLT 1 2 N . m ( 1 . 2k g f m , 9 l b f f t l ..4] BEARINGsET PLATE ASSEMBLY G, COUNTERSHAFT BEARING O NEEDLE C 3 OIL GUIDEPLATE e 14 x 20 mm DOWELPIN MAGNET .9-i i.!! MAINSHAFTASSEMBLY U 28 mm WASHER
i[, 28 mm SPRINGWASHER iO BALLBEARING (l 28 x 43 x 7 mm OIL SEAL Replace. .D REVERSE GEARSHAFT IDLER GEAR 1' REVERSE f lr 6 mm SPECIALBOLT 15 N.m (1.5kgt.m, 11 lbf.ft) (!I REVERSE SHIFTFORK LOCKCAM .4' REVERSE Q-t x 58 x 8 mm OIL SEAL 35 Replace.
?]] BACK-UPLIGHTSWITCH 29 N m (3.0kgf.m,22 lbf ftl .?1 O.RING Replace.
(Vss) VEHICLE SPEEo sENsoR 1!)

.O 8 mm FLANGE BOLT 22 N.m (2.2kgf m, 16lbf.ftl .' CLUTCH HOUSING iI6) TRANSMISSIONHANGER BOLT tl 10 mm FLANGE 44 N.m {4.5kgt.m,33 lbf.ft}
13-14
Housing Exploded View-Transmission

tt-P "=-@
@
z-W :
iq { "
@------
'\b e P\B o,. @\
rai \:/
dd
f /
\ @
O=-rl
F,z
,-1 _\ (g/----------__"^\
\-/r*---------..-,
HOUSING O TRANSMISSION O 10 mm WASHER Replace. @ 10 mm FLANGEBOLT 44 N.m {4.5kgf.m,33lbf.ft) O 8 mm FLANGEBOLT kgf 27 N.m 12.8 m,20lbl.ft) TRANSMISSIONHANGERA .' BOLT O INTERLOCK 39N m (4.0ksf.m,29lbf.ft) PLATEM O OILGUIOE 72 .1 mm SHIM .' OIL GUTTEBPLATE
{i) 80 mm SHIM PIN 0 8 x 14mm DOWEL LEVER ASSEMBLY [A CHANGE a06 mm FLANGE BOLT kgf.m,9lbfft} 12N m {1.2 BOLT O DETENT 22 N.m{2.2 kgf.m, 16lbf.ft) O 12mm waSHER
@)20 mm WASHER Replace. q,]FILLERPLUG 44 N m {4.5kgf.m,33 lbf.ft) @ 40 x 56 x 8 mm OILSEAL Replace. qO14 mm WASHER Replace. q' DRAIN PLUG 39 N.m (4.0kgf.m,29 lbf.ftl @ 32 mm SEALINGCAP 34 N m (3.5 kgf.m, 25 lbf.ft)
ReDlace. (D SPRING [I STEELBALL (D TRANSMISSION B HANGER (9 CLUTCHLINE CLIPBRACKET
(cont'd)
13-15
Transmission Manual
(cont'd) Disassembly Transmission
NOTE:Placethe clutch housingon two piecesof wood thick enoughto keepthe mainshaftfrom hittingthe workbench. 1. Removethe detent bolts (A),springs,steel balls, and back-uplight switch (B). 3, Removethe interlockbolt (A),the changelever ( a a s s e m b l y B ) ,8 x 1 4 m m d o w e lp i n s( C ) , n d t h e t c l u t c hl i n ec l i p b r a c k e{ D ) .
R e m o v e h e d r a i np l u g( A ) ,f i l l e rp l u g( B ) ,a n d t 1 0 m m f l a n g eb o l t ( C ) . Removethe vehiclespeedsensor(VSS)(A) and O - r i n g( B ) .
13-16
5. Removethe 8 mm flange bolts in a crisscross Datternin severalsteos.
10. Removethe reverselock cam.
g t.l Y g
(,
Â
6 . Removethe transmissionhangerA, and t r a n s m i s s i o h a n g e rB . n c 7 . R e m o v e h e 3 2 m m s e a l i n g a p( A ) . t
1 1 .Removethe reverseidler gear {A) and reversegear s h a f t{ B ) .
E x p a n d h e 7 2 m m s n a pr i n g ( B )o n t h e t ball bearing,and remove it from the countershaft groove using a pair of snap ring pliers. ( L R e m o v e h e t r a n s m i s s i o h o u s i n g C )a n d t n 1 4 x 2 0 m m d o w e l p i n s( D ) .
(cont'd)
13-17
ManualTransmission
(cont'd) Transmission Disassembly
12. Removethe reverseshift fork. 15. Removethe differential assembly(A) and magnet ( B) .
t7
I
t1
Apply vinyl tape to the mainshaftsplinesto protect the seal,then removethe mainshaftassembly(A) and countershaft assembly(B)with the shift forks ( { C ) f r o mt h e c l u t c hh o u s i n g D ) .
1 6 . Removethe oil gutter plate (A),72mm shim (B), a n d o i l g u i d ep l a t eM .
1 4 . R e m o v e h e 2 8 m m s p r i n gw a s h e r( E )a n d 2 8 m m t w a s h e r( F ) .
13-18
Reverse Shift ForkClearance Inspection

betweenthe reverseidler 1. Measurethe clearance gear {A) and the reverseshift fork (B)with a feeler gauge (C).lf the clearance more than the service is limit, go to step 2. 0.20-0.59 mm (o.oo7 0.024 in.l Standard: ServiceLimit: r.3 mm {0.051in.)
Inspection ChangeLeverClearance
1 . Measurethe clearancebetweenchangelever (Al and the selectlever (B)with a feelergauge (Cf.lf i l t h e c l e a r a n c es m o r et h a nt h e s e r v i c e i m i t ,g o r o step 2. 0.05 0.25 mm (0.002-0.010in.) Standard: ServiceLimit: 0.50mm {0.020in.)
2. Measurethe groove of the changelever'

Measure the width of the reverseshift fork. . l f d i s t a n c es n o t w i t h i n t h e s t a n d a r d , p l a c e t h e re i reverseshift fork with a new one. . lf distanceis within the standard,replacethe reversegear wrln a new one. Standard: 13.4 13.7mm (0.527 0.539in.l . lf distanceis not within the standard,replacethe c h a n g el e v e rw i t h a n e w o n e . . l f d i s t a n c es w i t h i n t h es t a n d a r dr,e p l a c e t h e i selectlever with a new one. i m Standard: 1 5 . 0 0 1 5 . 1 0 m ( 0 . 5 9 1 - 0 . 5 9 4n . )
qI
,tl
13-19
ManualTransmission
ChangeLeverAssemblyDisassembly/Reassembly
Priorto reassembling, clean all the parts in solvent,dry them, and apply lubricantto any contactsurface. LEVER SELECT Becareful to damage dustseal not the w h e ni n s t a l l i n t . ig DUST COVEB
BREATHER CAP Turnthe arrow toward {ront the and it. o{thevehicle, install
r rrl
I
@).1 l L
I l
7 Fr"irr6-rooa
SHIFTARM COVER
a^^
ROLLER (P/N 08798-9002) 6x1.0mm 12 N.m (1.2kgl.m,8.7 lbf.ft)
\op
(g)'
'^
Fl q )-=^l
WASHER
\r'
E-='1sr/2No !-d
sELEcr
/-r,s \__/
,/
-, OILSEAL
ReDlace.
,.* (A) tace. ix#,,l
sPntruc
INTERLOCK
H\ lV
SHIFT ARM
srx
r
/
-z:-=:l-':
tr7
,/u
SELECTSTOP PLATE 9.8Nm {1.0kgf.m,7.2 lbf.ft)
SELECT SPRING
LOCKCAM REVERSE STRIKER
13-20
Inspection Shift ForksGlearance

NOTE:The synchrosleeveand synchrohub should be replacedas a set. 1. Measure the clearance betweeneach shift fork (A) and its matchingsynchrosleeve(B).lf the exceeds the servicelimit, go to step 2. clearance Standard: 0.35 0.65 mm {0.014 0.026in.1 in.l ServiceLimit: 1.0 mm 10.039 betweenthe shift fork (A) 3. Measurethe clearance exceeds the the shift arm (B).lf the clearance and servicelimit, go to slep 4. 0.2-0.5 mm (0.007 0.020in.) Standard: ServiceLimit: 0.62mm (0.024in.)
4 . Measurethe width of the shift arm. . l f t h e w i d t h o f t h e s h i f t a r mi s n o t w i t h i n t h e standard,replacethe shift arm with a new one. . l f t h e w i d t h o f t h e s h i f ta r m i s w i t h i n t h es t a n d a r d , replacethe shift fork and shift piecewith a new one. Standard: 16.9-17.0 mm (0.665-0.669in.)
2 . l\4easure thicknessof the shift fork fingers. the

. l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s n o t within the standard,replacethe shift fork with a new one. . l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s w i t h i n the standard,replacethe synchrosleevewith a new one. Standard:7.4 7.6 mm (0.29-0.30 in.)
13-21
ManualTransmission
Shift ForksDisassembly/Reassembly
Priorto reassembling, clean all the parts in solvent,dry them, and apply lubricantto any contactparts.
sTH SHIFTFORK
PINDRIVER, mm 5
13-22
MainshaftAssemblyClearance Inspection
NOTE:lf replacement required,always replacethe is synchrosleeveand hub as a set. 1. Supportthe bearinginner racewith an appropriate sizedsocket(A).and push down on the mainshaft (B). 4. Measurethe clearance between4th gear (A) and ( B )w i t h a d i a l i n d i c a t o ( C ) . thedistance ollar c r . lf the clearance more than the servicelimit, go is to step 5. . lf the clearance within the servicelimit, go to is step 7. Standard: ServiceLimit: 0.06 0.16 mnl (0.002 0.006in.) 0.25mm {0.010in.)
Measurethe clearance bet\iveen 2nd (C)and 3rd (D) gearswith a feelergauge {E). . l f t h e c l e a r a n c i s m o r et h a nt h e s e r v i c e i m i t .g o l e to step 3. . lf the clearance within the servicelimit, go to is step 4. MeasuredistanceO on the distanceco[ar. Standard: ServiceLimit: 0.06 0.16mm {0.002 0.006in.l 0.25 mm (0.010 in.l . lf distance't is notwithin the standard,replace the distancecollarwith a new one. . lf distancee is within the standard,go to step 6. Standard: . l f t h e t h i c k n e s o f 3 r d g e a r i sl e s s t h a n t h e e r v i c e s s l i m i t ,r e p l a c e r d g e a r w i t ha n e w o n e . 3 . l f t h e t h i c k n e s o f 3 r dg e a r i s w i t h i n t h e s e r v i c e s limit, replacethe 3rd/4thsynchrohub with a new one. Standard: ServiceLimit: 23.92-23.97 mm (0.941 0.944in.) 23.80mm (0.937in.)
Measurethe thickness 3rd gear. of
24.03 24.08mm in.} {0.946-0.9/u
(cont'd)
13-23
ManualTransmission
Inspection(cont'd) MainshaftAssemblyClearance
of 6. Measurethe thlckness 4th gear. . l f t h e t h i c k n e s o f 4 t h g e a ri s l e s s t h a n t h e s e r v i c e s limit, replace4th gear with a new one. . l f t h e t h i c k n e s s o4 t h g e a r i s w i t h i nt h e s e r v i c e f limit. replacethe 3rd/4thsynchrohub with a new one. Standard: ServiceLimit: 23.92 23.97mm (0.941 0.944in.) 23.80mm (0.937in.) 8. MeasuredistanceO on the distancecollar. . lf distance is notwithinthestandard, place re O the distancecollar with a new one. ' l f d i s t a n c e Oi s w i t h i n t h es t a n d a r dg o t o s t e p 9 . , Standard:
mm 24.03 24.08 (0.946 0.947 in.)
of 9. Measurethe thickness 5th gear. . l f t h e t h i c k n e s s o5 t h g e a r i s l e s s t h a n t h e s e r v i c e f limit, replace5th gear with a new one. . lf the thickness sth gear iswithin the service of limit. replacethe 5th synchrohub with a new one. Standard: Service Limit:
betweenthe distancecollar 7. l\4easure clearance the ( A )a n d s t h g e a r( B )w i t h a d i a l i n d i c a t o ( C ) . f t h e r l is clearance more than the servicelimit. go to step l i 8 . l f t h e c l e a r a n c es w i t hi n t h e s e r v i c e i m i t ,g o t o steD10. Standard: ServiceLimit: 0.06 0.16mm (0.002-0.006in.) in.) 0.25 mm (0.010
23-92 23.97mm in.l 10.9410.944 in.l 23.80 mm (0.937
13-24
MainshaftDisassembly
'10. M e a s u r eh e t h i c k n e s s f t h e M B S d i s t a n c e o l l a r . t o c . l f t h e t h i c k n e s o f M B S d i s t a n c e o l l a ri s l e s s s c than the standard,replacethe MBS distance c o l l a rw i t h a n e w o n e . Standard: ( 1 . R e m o v e h e a n g u l a r a l l b e a r i n g A )a n d t h e b t ring using a commerciallyavailable taperedcone b e a r i n g e p a r a t o{ B )a n d a c o m m e r c i a l l a v a i l a b l e s r y p s b e a r i n g u l l e r{ C ) .B e s u r et h e b e a r i n g e p a r a t oirs c u n d e rt h e t a p e r e d o n er i n g .
23.95 24.05 mm in.) {0.9(3 0.947
E-f
Support5th gear (A) on steel blocks,and pressthe mainshaftout of the sth synchrohub (B).Use of a jaw-typepuller can damagethe gear teeth.
(cont'd)
13-25
Transmission Manual
(cont'dl MainshaftDisassembly
3. Supportthe 3rd gear (A) on steel blocks,and press the mainshaftout of the 3rd/4thsynchrohub (B). Use of a jaw-type puller can damagethe gear teeth.
Mainshaft Inspection
1. Inspectthe gear surfaceand bearingsurfacefor w e a r a n d d a m a g et,h e n m e a s u r eh e m a i n s h a fa t t t pointsA, B, C, D, and E. lf any part of the mainshaft is lessthan the servicelimit, reDlace with a new it on e . Standard: A Ball bearingsurface(transmission housingside): 27.987 28.000 m (1.1019 1.1024in.) m B Distance collar surtace: 31.984 32.000mm {1.2594 1.2598in.) C Needle bearing surlace: 38.984-39.000mm (1.53/t8 1.5354 in.) D Ball bearingsurface(clutchhousingside): 2 7. 9 7 7 2 7 . 9 9 0m m ( 1 . 1 0 1 5 1 . 1 0 2 0 i n . ) E Bushing surface: 20.80 20.85mm (0.819 0.821in.) ServiceLimit; A : 2 7 . 9 3 m 1 1 . 1 0 i0 . l m n B: 31.93 mm |.1.257 in.l C: 38.93mm 11.533 in.l Di 27.92mm {1.099 in.l E: 20.75mm 10.817 in.l
13-26
2. Inspectthe runout by supponing both ends of the mainshaft.Rotatethe mainshafttwo complete revolutions when measuringthe runout. lf the runout is more than the servicelimit. reolacethe mainshaftwith a new one. Standard: 0.02mm (0.001in.) max. ServiceLimit: 0.05mm (0.002in.)
13-27
ManualTransmission
MainshaftReassembly
Exploded View
QJ'
3RD/4TH SYNCHRO SLEEVE 3RD/4TH

SYNCHRO HUB SYNCHRO SPRING
ANGULAB BALL BEARING Checkfor wear and operation. Note the directionof installation. TAPEBED CONERING MBS DISTANCECOLLAR
frfl Y7
SYNCHROSLEEVE SYNCHRORING
NEEDLE BEARING Check wearandoperation. for
MAINSHAFT
NEEDLE BEARING
Checkfor wear and operation. GEAR 4TH/5TH GEAB DISTANCECOLLAR SYNCHRORING SPRING SYNCHRO
a
13-28
SpecialTools Required . Driver,40 m 1.D.07746-0030100 m . Attachment,30mm l.D.07746-0030300 NOTE:Referto the ExplodedView as neededduring this procedu re. '1. Cleanall the parts in solvent,dry them, and apply lubricantto all contactsurfacesexceptthe 3rd/4th and 5th synchrohubs.
6. Installthe3rd/4thsynchrosleeve(A) by aligning the stops (B)with the 3rd/4thsynchrosleeveand hub. After installing, checkthe operationof the 3rd/ 4th synchrohub set.
@--
2. I n s t a l l t h e e e d l e e a r i n g n d 3 r d g e a ro n t h e n b a
mainshaft. I n s t a l l t h e y n c h r o i n g a n dt h e s y n c h r o p r i n g . s r s
4 . I n s t a l l t h e r d / 4 t h y n c h r o u b ( A )b y a l i g n i n g h e 3 s h t
synchroring fingers (B)with 3rd/4thsynchrohub grooves(C).

-A
7 . I n s t a l l t h e y n c h r o p r i n g( A ) . s s
lnstallthe 3rd/4thsynchrohub {A) usingthe special tool.
I n s t a l l t h e y n c h r or i n g ( B )b y a l i g i n g h e s y n c h r o s t cone fingers (C)with 3rd/4thsynchrohub grooves (D). 9 . I n s t a l l t h e t h g e a r ,n e e d l e e a r i n gd i s t a n c e o l l a r , 4 b , c n e e d l e e a r i n ga n d s t h g e a r . b ,
07746-0030100
(cont'd)
13-29
ManualTransmission
(cont'dl MainshaftReassembly
1 0 . I n s t a l l t h e y n c h r o i n ga n dt h e s y n c h r o p r i n g . s r s 1 '1. I n s t a l l t h e t h s y n c h r oh u b ( A )b y a l i g n i n g h e s t synchrocone fingers (B)with sth synchrohub grooves(C). 1 4 . I n s t a l l t h e y n c h r o p r i n g( A ) . s s
t5.
I n s t a l l t h e y n c h r o i n g ( B )b y a l i g n i n g h e s y n c h r o s r t cone fingers (C)with sth synchrohub grooves(D).
12. I n s t a l l t h e t h s y n c h r oh u b ( A )u s i n gt h e s p e c i a l 5
tools.
1 6 . I n s t a l l t h e B S d i s t a n c e o l l a ra n dt h e t a p e r e d M c c o n er i n g . 1 1 . I n s t a l l t h e e w b a l l b e a r i n g A ) u s i n gt h e s p e c i a l n { t o o l sa n d a p r e s s( B ) .
U
07746-0030100 07746-0030300 07746-0030100
1 3 . I n s t a l l t h e t hs y n c h r o l e e v e . 5 s
\.
13-30
Countershaft AssemblyClearance lnspection

1 . Measurethe clearance betweenthe 1st gear (A) a n dt h e d i s t a n c e o l l a r( B ) w i t ha f e e l e rg a u g e( C ) . c . l f t h e c l e a r a n c es m o r et h a nt h e s e r v i c e i m i t ,g o i l to step 2. . l f t h e c l e a r a n c es w i t h i nt h e s e r v i c e i m i t .g o t o i l step 4. Standard: 0.06 0.16mm 10.002 0.006in.l ServiceLimit: 0.25 mm (0.010 in.l 3. Measure the thicknessof the 1st oear. . l f t h e t h i c k n e s s o lfs t g e a r i s l e s s t h a n t h e e r v i c e s l i m i t ,r e p l a c e s t g e a r w i t h a n e w o n e . l . lf the thicknessof '1st gear is within the service limit, replacethe lst/2nd synchro hub with a new one. 22-92 22.97 mm 10.902 0.904 in.l Standard: ServiceLimit; 22.87mm {0.900in.)
2. fvleasure thickness the distancecollar. the of . l f t h e t h i c k n e s i s n o t w i t h i nt h e s t a n d a r dr,e p l a c e s t h e d i s t a n c e o l l a rw i t h a n e w o n e . c ' lf the thicknessis within the standard,go to
4. Measurethe clearance betweenthe 2nd gear (A)
a n d 3 r d g e a r( B )w i t h a f e e l e rg a u g e( C ) .l f t h e clearance more than the servicelimit, go to is steD5. Standard: 0.06 0.16 mm (0.002 0.006in.) ServiceLimit: 0.25mm {0.010in.l
Standard:
23.03 23.08 mm (0.907 0.909 in.l
(cont'd)
13-31
Transmission Manual
AssemblyClearance Countershaft Inspection(cont'd)
of 5. Measurethe th ickness the distancecollar. . l f t h e t h i c k n e s ss n o t w i t h i nt h e s t a n d a r dr,e p l a c e i the distancecollar with a new one. . l f t h e t h i c k n e s ss w i t h i n t h es t a n d a r dg o t o i , step 6. Standard: 28.03 28.08mm {1.104-1.106in.)
Countershaft Disassembly
1 . Securelyclamp the countershaft assemblyin a benchvlse with wood blocks.
Removethe specialbolt (left-hand threads). Supportthe ball bearing(A) on steel blocks,then use a press (B)and an attachment(C)to pressthe countershaft of the ball bearing. out 6. Measurethe thicknessof the 2nd qear. . l f t h e t h i c k n e s o f 2 n dg e a r i sl e s s t h a n h e t s servicelimit, replace2nd gear with a new one. . l f t h e t h i c k n e s s o2 n d g e a r i s w i t h i n t h e s e r v i c e f synchro hub with a new limit, replacelhe 1sV2nd one. 27-92-21.97 mm|.1.099 1.r01 in.l Standard: in.) ServiceLimit: 27.87mm 11.097
c 4 . R e m o v e h e 3 5 m m s h i m a n dd i s t a n c e o l l a r . t
I
13-32
Countershaftlnspection
5. Support gear(A)on steelblocks, 4th thenusea (B) press andan attachment to press the (C) countershaft out ofthe 5thgear.
1. Inspectthe gear surfaceand bearingsurfacefor w e a r a n d d a m a g e t h e n m e a s u r eh e c o u n t e r s h a f t , t at pointsA, B, and C. lf any part of the countershaft is lessthan the servicelimit, replaceit with a new one. Standard: A Ballbearingsurfaceltransmissionhousingsidel: 3 0 . 0 2 0 3 0 . 0 3 3m m { 1 . 1 8 1 9 1 . 1 8 2 4 i n . ) B Distancecollar surface; 39.937- 39.950mm 11.5723 1.572A in.l C Needlebearingsurface(clutchhousingside): 3 5 . 0 0 0 3 5 . 0 1 5 m { r . 3 7 8 0 - 1 . 3 7 8 5n . ) m i Service Limit: A : 2 9 . 9 7 m { 1 . 1 8 0n . ) m i B: 39.88mm {1.570in.l C: 34.95mm {1.376in.) 6 . Support2nd gear (A) on steel blocks,then use a Dressand an attachment{B}to pressthe (C) countershaft out of the 3rd gear.
2 . lnspectthe runout by supportingboth ends of lhe

countershaft. Rotatethe countershaft two complete revolutionswhen measuringthe runout. lf the runout exceedsthe serviceIimit, replacethe countershaft with a new one. Standard: ServiceLimit: 0.02mm (0.001in.) max. 0.05mm (0.002in.)
13-33
Transmission Manual
Reassembly Countershaft
View Exploded
SPECIAL BOLT Eeplace. ( 1 2k g fm ,8 7l b ff t ) 118 .m N

BALL BEARING Checkfor wear and operation. Note the directionof installation. 35 mm SHIM ANCE COLLAR
REVERSE GEAR 1ST/2ND SYNCHRO HUB

SPRING TRIPLECONESYNCHRO
GEAR 4THGEAR
1ST GEAR
NEEDLE BEARING Check wear for anoopera!on. DISTANCE COLLAR
Check wear and for operation. DISTANCECOLLAR DAMPER FRICTION Checkfor wear and damage.
(
COUNTERSHAFT
TRIPLECONESYNCHRO
SYNCHROSPRING
13-34
ToolsRequired Special . Driver, mm l.D.07746-0030100 40 . Aftachment.30 07746-0030300 mm NOTE: Refer the Exploded to Viewas needed during lhis procedure. 1. Clean partsin solvent, them,andapply all dry lubricantto contact all surfaces.
I n s t a l l t h e i s l a n c e o l l a r , e e d l e e a r i n ga n d 1 s t n d c b , gear onto the countershaft.
6 . I n s t a l l t h e y n c h r o p r i n g( A ) . s s
3 . Installthe triple cone synchroassembly(A) by
'lst gear aligningthe synchrocone fingers (B)with grooves(C),then installthe synchrospring {D). 1 . lnstallthe triple cone synchroassembly(B) by aligningthe synchrocone fingers (C)with the 1sv2ndsynchro hub grooves(D). 8 . Installthedistancecollar (A) and friction damper (B) by aligningthe friction damper fingers (C)with the 1sv2ndsynchro hub grooves(D).
'1st/2nd Installthe s y n c h r o u b ( A )b y a l i g n i n g h e h t synchrocone fingers (B)with 1sV2ndsynchrohub grooves(C).
g r 5. Installtheeverse ear.
(cont'd)
13-35
ManualTransmission
(cont'dl Reassembly Countershaft
9 . I n s t a ltl h e n e e d l e e a r i n g . b l 1 2 . I n s t a ltlh e 4 t h g e a r( A )u s i n gt h e s p e c i a l t o oa n d a press(B).Do not exceedthe maximum pressure. B 14,700 {1,500 N kgt, lbf) 3,307 max. 07746-0030100
L,
1 0 .I n s t a l l t h e n d g e a r( A )b y a l i g n i n g h e s y n c h r o 2 t
cone fingers (B)with znd gear grooves(C).
'l
(A) 1 . Supoortthe countershaft on the steel blocks, g e a r( B )u s i n gt h e s p e c i atlo o l t h e n i n s t a ltl h e 3 r d and a press(C).Do not exceedthe maximum Dressure.
14,700 (1,500 N kgf, 3,307lbflmax.
I n s t a l l t h e t h g e a r( A )u s i n gt h e s p e c i atl o o l a n d a 5 press(B).Do not exceedthe maximum pressure.

kgl, 14,700 (1.500 N 3.307lbf) max. 07746-0030100
07746-0030100
13-36
1 4 . I n s t a ltlh e d i s t a n c e o l l a r( A ) ,3 5 m m s h i m ,a n d o l d c ball bearing(B)using the specialtools and a press
(c).
16. lf the clearance more than the standard, is selecta new shim from the following table. lf the clearance measuredin step 15 is within the standard,replace o n l yt h e b a l lb e a r i n g . 35 mm Shim
c
F
D E
11
K L M
N
o
t5.
R
Measurethe clearance betweenthe old bearing(A) a n dt h e 3 5 m m s h i m ( B )w i t h a f e e l e rg a u g e( C ) . Standard: 0.04 0.10mm 10.002 0.004in.)
PartNumber Thickness n 23981-PPP-0000.87mm (0.0343 . 23981-PPP-9000 . 9 1 m { 0 . 0 3 5 8 , m n 23982-PPP-0000 . 9 5 m ( 0 . 0 3 7 4 . m n 23982-PPP-9000.99mm (0.0390 , n m 23983-PPP-0001 . 0 3 m 1 0 . 0 4 0n , 6 23983-PPP-9001 . 0 7m m ( 0 . 0 4 2 1n . 1 23984-PPP-0001 . 1 m m ( 0 . 0 4 3 7 . n 23984-PPP-9001 . 1 5 m ( 0 . 0 4 5 3 . m n m 23985-PPP-0001 . ' 1 9 m ( 0 . 0 4 6 9n . m n 23985-PPP-9001 . 2 3 m ( 0 . 0 4 8 4 m n 23986-PPP-0001 . 2 7 m ( 0 . 0 5 0 0 . i 23986-PPP-9001 . 3 1m m ( 0 . 0 5 1 6n . i 23987-PPP-0001 . 3 5m m ( 0 . 0 5 3 1n . n 23987-PPP-9001 . 3 9m m ( 0 . 0 5 4 7 . i 23988-PPP-0001 . 4 3m m ( 0 . 0 5 6 3n . i 23988-PPP-9001 . 4 7m m ( 0 . 0 5 7 9n
i 23989-PPP-000 1 . 5 1m m ( 0 . 0 5 9 4n i 23989-PPP-900 1 . 5 5m m ( 0 . 0 6 1 0n
T U X
Y
m n 23990-PPP-0001 . 5 9 m { 0 . 0 6 2i6 . m n 23990-PPP-9001 . 6 3 m { 0 , 0 6 4i2 . i 23991-PPP-0001 . 6 7m m ( 0 , 0 6 5 7n

i 23991-PPP-900 1 . 7 1m m { 0 . 0 6 7 3n i 23992-PPP-0001 . 7 5m m ( 0 . 0 6 8 9n 23992-PPP-9001 . 7 9m m ( 0 . 0 7 0 5n i
AB
AC
AD AE
AF
m n 23993-PPP-0001 . 8 3 m ( 0 . 0 7 2i0 i 23993-PPP-9001 . 8 7m m ( 0 . 0 7 3 6n m i 23994-PPP-000' 1 . 9 1 m ( 0 . 0 7 5 2n

i 23994'PPP-900 1 . 9 5m m ( 0 . 0 7 6 8n . i 23995PPP-000 1 . 9 9m m ( 0 . 0 7 8 3n .
{cont'd)
13-37
ManualTransmission
(cont'd) Countershaft Reassembly
(A) (B), 1 1 . Support ballbearing on steelblocks then (C) (D) usea press andan attachment to press the (E) countershaft out of the ballbearing.
20. Tightenthe new specialbolt (A) (left-hand threads).
'l18 N.m (12kgf.m, 87 tbf.ftl
1 8 . l f n e c e s s a r yn s t a l l t h e 5 m m s h i m s e l e c t e dn i, 3 i step 16,then recheck clearance, the 1 9 . Installthe distancecollar (A).35 mm shim, and new ( b a l l b e a r i n g B )u s i n gt h e s p e c i a l t o o l a n d a p r e s s s
(c).
46-0030r00
13-38
SynchroSleeveand Hub Inspection and Reassembly

1. lnspectthegearteeth on ali synchro hubs and synchrosleevesfor roundedoff corners,which indicatewear. 2. Installeach synchrohub (A) in its mating synchro sleeve(B),and checkfor freedom of movement.Be sure to match the three sets of longerteeth (C)(120 degreesapart)on the synchrosleevewith the three sets of deepergrooves(D) in the synchrohub. Do not installthe synchrosleevewith its longerteeth in the 1sv2ndsynchrohub slots (E)becauseit will t d a m a g e h e s p r i n gr i n g . is NOTE;lf replacement required,always replace the svnchrosleeveand svnchrohub as a set.
SynchroRingand GearInspection
1 . Inspectthe insideof each synchroring (A) for wear. Inspectthe teeth (Bi on each synchro ring for wear (roundedoff).
Exampleof synchroring teeth
I
GOOD
I
WORN
Inspectthe teeth (C)on each synchrosleeveand matchingteeth on each gear for wear (roundedoff).
Exampleof synchro sleeve teeth and gearteeth
t
GOOD WORN
\
(cont'd)
13-39
Manual Transmission
SynchroRing and GearInspection(cont'dl
3. Inspectthe thrust surface{D)on each gear hub for wear. 7. Measurethe clearance betweeneach gear (A) and i t s s y n c h r o i n g ( B )a l l t h ew a y a r o u n d . o l dt h e r H synchroring againstthe gear evenlywhile measuringthe clearance. the clearance less lf is than the servicelimit, replacethe synchro ring and gear. Synchro Ring.to.Gear Clearance Standard: 0.70 1.49mm 10.028 0.059in.) ServiceLimit: 0.4 mm {0.016in.) Triple Cone Synchro-to-Gear Clearance Slandard: O: Outer Synchro Ring {B}to SynchroCone (Cl 0-70 1.19mm (0.028-0.047in.) @: Synchro Cone lC) to cear (A) 0.50- 1.04mm (0.020-0.041in.) O: Outer Synchro Ring (B) to Gear (Al 0.95 1.68mm 10.037 0.066in.) ServiceLimit: O: 0.3 mm (0.012in.) : 0.3 mm (0.012in.) in.l O; 0.6 mm 10.024
Inspectthe cone surface(E)on each gear hub for wear ano rougnness. Inspectthe teeth on all gears(F)for unevenwear, , s c o r i n gg a l l i n g a n d c r a c k s . , Coatthe cone surfaceof each gear (E)with oil, and placeits synchro ring on it. Rotatethe synchroring, m a k i n gs u r et h a t i t d o e sn o t s l i p .
13-40
Bearing Mainshaft and Oil SealReplacement

Special Tools Required . O i l s e a ld r i v e r0 7 J A D - P 1 9 0 1 0 0 . Adjustable earing uller,20 40mm p b 07736-4010008 . Driver07749-0010000 . Attachment,42x 47 mm 07746-0010300 . S l i d eh a m m e r , o m m e r c i a l l a v a i l a b l e c y assembly, 1. Removethe differential ( 2 . R e m o v e h e b a l l b e a r i n g A ) f r o mt h e c l u t c h t ( l h o u s i n g B )u s i n gt h e s p e c i a l t o oa n d a 3 c o m m e r c i a l la v a i l a b l e / 8 " - l 6 s l i d eh a m m e r( C ) . y
4 . Drive the new oil seal in from the transmissionside
using the specialtools.
07749-0010000 07746-0010300
Drivethe new ball bearing(A) in from the t r a n s m i s s i o s i d eu s i n gt h e s p e c i a l t o o l . n
Removethe oil seal (A) from the clutch side. Be carefulwhen removingthe seal so the clutch i h o u s i n g s n o td a m a g e d .
13-41
ManualTransmission
Countershaft BearingReplacement
Special Tools Required . Adiustablebearingpuller,20-40 mm 07736-A0tOOOB . Oil seal driver 07JAD-AP190100 . S l i d eh a m m e r ,c o m m e r c i a l l a v a i l a b l e y 1. Removethe bearingset plate (A)from the clutch h o u s i n g( B ) . 3. Positionthe oil guide plate C and new needle bearing(A) in the bore of the clutchhousing(B).
I n s t a l l t h e e e d l e e a r i n g s i n gt h e s p e c i a l t o o l . n b u Installthe bearingset plate (A)wirh bolts (B). Removethe needlebearing(A) usingthe special tool and a commerciallyavailable3/8" - 16 slide hammer (B),then removethe oil guide plate C. B 6x 1.0 n n 12N.m kgt m, {1.2
8.7 tbf.ft)
07736-A010008
13-42
Adiustment MainshaftThrust Clearance

Special Tools Required . Mainshaftbase07GAJ-PG20130 . M a i n s h a fh o l d e r0 7 G A J - P G 2 0 1 1 0 t 1 . R e m o v e h e 7 2 m m s h i m ( A )a n d o i l g u i d ep l a t eM t from the transmissionhousing(B).
5 . Measuredistance@ betweenthe end of the clutch

( i h o u s i n g A )a n d t h e b e a r i n g n n e rr a c e( B ) w i t ha straightedge and depth gauge.Measureat three locationsand averagethe readings. A
,5---o v/
Shim Selection Formula: Installthe3rd/4thsynchrohub (A),the distance h c t c o l l a r( B ) , h e 5 t h s y n c h r o u b { C ) .d i s t a n c e o l l a r ( ( D ) ,a n d b a l l b e a r i n g E )o n t h e m a i n s h a f(t F ) , h e n t m a i n s t a l l t h e s s e m b l e d a i n s h a fitn t h e t r a n s m i s s i o n ( housing G). 6, Selectthe proper 72 mm shim from the chan. Follow the examplebelow, and use the you made in steps4 and 5: measurements (Basic ormula) F ( ( 0 . 8* 0 . 1 1 ) s h i m t h i c k n e s sm a x i m u m ) = O+@ ( ( 0 . 8+ 0 . 1 7 ) s h i m t h i c k n e s sm i n i m u m ) = + O O . Add distanceO (step5) to distanceO (step4) . 0 . 8m m ( 0 . 0 3 1n ) :S p r i n gw a s h e r , d i m e n s i o nn i a i the installation. . 0 . 1 1m m ( 0 . 0 0 4n ) :l v l i n i m u mh r u s tc l e a r a n c e t i . 0 . 1 7m m ( 0 . 0 0 7n ) :M a x i m u mt h r u s tc l e a r a n c e . i ( F o re x a m p l e ) i 2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 1 ) =1 . 5 6m m ( 0 . 0 6 1n . ) i 2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 7 ) =1 . 5 0m m ( 0 . 0 5 9n . ) T a k et h e m i d d l ev a l u eo f t h e m i n i m u mv a l u ea n d t h e m a x i m u mv a l u e ,a n d s e l e c t h e 1 . 5 3m m ( 0 . 0 6 0n . )s h i m . i
lnstallthe washer (H) on the mainshaft. MeasuredistanceO betweenthe end of the transmissionhousingand washerwith a straight edge and verniercaliper.Measureat three locationsand averagethe reading.
{cont'd)
13-/li|
ManualTransmission
MainshaftThrust Clearance Adjustment (cont'dl
72 mm Shim
c
F
D E J
L
M N
o
P
o
R
T U
X
z
AB
AC
AD AE
AF AG AH AI AJ
AK
AL
AM
AN
PartNumber Thickness 2 3 9 3 1 - P 2 1 - 0 0 0 . 6 0 m { 0 . 0 2 3i6 . ) 0 m n 23932-P21-000 0.63mm (0.0248 in. 2 3 9 3 3 - P 2 1 - 0 0 0 . 6 6 m ( 0 . 0 2 6i0 . 0 m n 2 3 9 3 4 - P 2 1 - 0 0 0 . 6 9m m ( 0 . 0 2 7 1n . 0 i 23935-P21-000 0 . 7 2 m ( 0 . 0 2 8i3 . m n 23936-P21-000 0 . 7 5 m ( 0 . 0 2 9i5 . m n 23931-P21-000 0 . 7 8 m ( 0 . 0 3 0i7 . m n 23938-P2'l-000 0 . 8 1 m ( 0 . 0 3 1i9 m n 23939-P21-000 0 . 8 4 m ( 0 . 0 3 3i1 m n 23940-P21-000 0 . 8 7m m { 0 . 0 3 4 3n , i 23941-P21-000 0.90 mm (0.0354 in. 23942.P21-000 0.93mm (0.0366 in. 23943-P21-000 0 . 9 6 m ( 0 . 0 3 7i8 . m n .000 23944-P21 0 . 9 9 m ( 0 . 0 3 9i0 . m n 23945-P21-000 1 . 0 2 m ( 0 . 0 4 0i2 . m n 23946-P21-000 1 . 0 5m m ( 0 . 0 4 1 3n . i 23941-P2't-000 'l.08mm (0.0425 in 23948-P2'l-000 ' 11 m m { 0 . 0 4 3i7 . 1 n 23949-P21-000 ' 1 . 1 4 m ( 0 . 0 4 4 9n m i 23950-P21-000 1 . 1 7m m { 0 . 0 4 6 1n . 23951-P21-000 1.20 mm 10.0472. n 23952-P21-000 1.23mm (0.0484n . 23953-P21-000 1 . 2 6 m { 0 . 0 4 9 6 . m n 23954-P21-000 1 . 2 9m m ( 0 . 0 5 0 8n . 23955-P21-000 1 . 3 2 m ( 0 . 0 5 2 0 . m n 23956-P21,000 1 . 3 5 m ( 0 . 0 5 3i1 m n 23957-P21-000 1 . 3 8 m ( 0 . 0 5 4i3 m n 23958-P21-000 1 . 4 1m m ( 0 . 0 5 5 5n 23959-P21-000 1 . 4 4 m ( 0 . 0 5 6 7 . m n 23960-P21-000 1.47mm (0.0579n . 2 3 9 6 1 - P 2 1 - 0 0 0 . 5 0m m ( 0 . 0 5 9 1 . 1 n 23962-P21-OOO 1 . 5 3 m ( 0 . 0 6 0 2 . m n 23963-P21-000 1 5 6 m m ( 0 . 0 6 1 4n . 23964-P21-000 1 . 5 9m m ( 0 . 0 6 2 6n . 23965-P21-000 1 . 6 2m m ( 0 . 0 6 3 8n i 23966-P21-000 1 . 6 5 m ( 0 . 0 6 5i0 m n 23967-P21-000 1 . 6 8 m ( 0 . 0 6 6i1 m n -000 1 . 7 1 m ( 0 . 0 6 7i3 . 23968-P2r m n 23969-P21-000 1 . 7 4 m ( 0 . 0 6 8i5 . m n 2397 0-P21-000 1 . 7 7 m ( 0 . 0 6 9i7 . m n
2 3 9 7 1 - P 2 ' t - O O O . 8 0m m ( 0 . 0 7 0 9n . 1 i
7 . I n s t a l l t h e 2 m m s h i m ( A )s e l e c t e d n d o i l g u i d e 7 a p l a t eM i n t h e t r a n s m i s s i o h o u s i n g B ) . ( n
,6,,-o V
8 . Thoroughlycleanthe spring washer (A) and

washer (B) before installing them on the clutch h o u s i n g i d eb a l l b e a r i n g C ) .N o t et h e i n s t a l l a t i o n s { directionof the spring washer.
9 . l n s t a l l t h e a i n s h a fitn t h e c l u t c hh o u s i n g . m
1 0 .Placethe transmissionhousingover the mainshaft

and onto the clutchhousing. 1 1 .Tightenthe clutchand transmissionhousingswith several8 mm bolts. NOTE:lt is not necessary use sealingagent to betweenthe housings.
AO
12. Tap the mainshaftwith a plastichammer.
13-44
13. Attachthe specialtool to the mainshaftas follows: . B a c k - o ut th e m a i n s h a fh o l d e rb o l t{ A )a n d l o o s e n t the two hex bolts (B). . Fit the holderover the mainshaftso its lip is towards the transmission. . Align the mainshaftholder'slip aroundthe groove at the insideof the mainshaftsplines, then tightenthe hex bolts.
1 6 . Z e r oa d i a l g a u g e{ A )o n t h e e n d o f t h e m a i n s h a f t .
07GAJ-PG20130 stop 1 7 . Turn the mainshaftholder bolt (B)clockwise; turning when the dial gauge (A) has reachedits maximum movement.The readingon the dial gauge is the amount of mainshaftend play NOTE:Do not turn the mainshaftholder bolt more than 60 degreesafter the needleof the dial gauge stops moving,this may damagethe transmission. the 1 8 .lf the readingis within the standard, clearance Threadthe mainshaftholder bolt in until it just contactsthe wide surfaceof the mainshaftbase. is correct.lf the readingis not within the standard, recheck shim thickness. the Standard:0.11-0.17 mm (0.004 0.007in.)
07GAJ-PG20130
1 4 . Seatthe mainshaftfully by tapping its end with a plastic ammer. h
13-45
ManualTransmission
Transmission Reassembly
N O T E : r i o r t or e a s s e m b l i n g , e a na l l t h e p a r t si n P cl solvent,dry them, and apply lubricantto any contact surfaces. 1. Installthe magnet (A) and differential assembly(B). 4. Installthe reverseshift fork.
6x1.0mm 15 N.m (1.5kgf.m,11 lbf.ft)
n-",-o
l;-D
f.)
Installthe reverseidler gear (A) and reversegear s h a f t( B )b y a l i g n i n g h e m a r k{ C ) w i t ht h e r e v e r s e t g e a rs h a f th o l e( D ) .
Installthe 28 mm spring washer (A) and 28 mm washer (B) over the ball bearing(C).Note the installation directionof the spring washer {A).
Apply vinyl tape to the mainshaftsplines(D)to p r o t e c t t h e e a l .I n s t a l l t h e a i n s h a fa n d s m t (E) countershaft into the shift forks {F}.and install themas an assembly.
13-46
l r 6 , l n s t a l l t h e e v e r s eo c kc a m .
z/ --' t - 2 6 x 1 , 0m m / 15 N.m / {1 5 kgf m, 11 tbf.ft) I
Fl g
8. Removethe dirt and oil f rom the tramsmission ( h o u s i n g e a l i n g u r f a c eA p p l y l i q u i dg a s k e t P / N s s . to the sealingsurface.Be sure to seai 08718-0001) of the entirecircumference the bolt holesto preventoil leakage. NOTE:lf 5 minuteshave passedafter applying liquid gasket,reapplyit and assemblethe housings. Allow it to cure at least20 minutesafter assembly with oil. beforefilling the transmission
7 . Selectthe proper size72 mm shim (A) accordingto made during the Mainshaft the measurements '13-43), Adjustment(seepage Thrust Clearance , o I n s t a l l t h e i l g u t t e rp l a t e( B ) ,o i l g u i d e p l a t el \ 4 a n d ( n 7 2 m m s h i m i n t ot h e t r a n s m i s s i o h o u s i n g C ) .
- -
-Liquid gasket
{cont'd)
13-47
Manual Transmission
(cont'dl Transmission Reassembly
9 . I n s t a ltlh e 1 4x 2 0 m m d o w e lp i n s( A ) .
34 N.m (3.5 kgf.m, 25 rbf.ft)
(
11. Lowerthe transmissionhousingthe rest of the way as you expandthe 72 mm snap ring {C).Release the snap ring so it seatsin the groove of the countershaft bearing. 12. Checkthat the 52 mm snap ring is securelyseated in the groove of the countershaft bearing. DimensionO as instalted: 3.3 6.0 mm { 0 . 1 3 0 . 2 4i n . l
1 3 .Apply liquid gasket(P/N08718-0001) the threads to

o f t h e 3 2 m m s e a l i n g a p { D ) ,a n d i n s t a l i t o n t h e c l transmissiohousing, n
't4.
I n s t a ltl h e t r a n s m i s s i o h a n g e r s . a n d B , a n d t h e n A 8 mm flange bolts finger-tight.
\A
e./
./
1 5 . Tightenthe 8 mm flange bolts in a crisscross PatternIn severalsteDs.
8 x 1.25mm 27 N.m (2.8kgf.m. 20 rbf.ft)
1 0 .Set the taperedcone ring (B)as shown. Placethe

transmissionhousingover the clutch housing, being carefulto line up the shafts.
(t
13-48
16. Removethe dirt and oil from the shift iever cover ( s e a l i n g u r f a c eA p p l y l i q u i dg a s k e t P / N0 8 7 1 8 s . 0001)to the sealingsurface. NOTE:lf 5 minuteshave passedafter applylng liquid gasket.reapplyit and assemblethe housings. Allow it to cure at least20 minutesafter assembly b e f o r e i l l i n gt h e t r a n s m i s s i ow i t h o i l . f n
1 9 . I n s t a l l t h e r a i np l u g( A ) ,f i l l e rp l u g ( B ) ,a n d 1 0 m m d f l a n g eb o l t ( C )w i t h n e w w a s h e r s .
@ Ut !?iJl'.'l,''
R\-: \
A 39Nm (4.0 kgf m, 33 tbl.ft)
/..l-.=,'-B g ^
44N.m
-.-t
?0,,.ru ^
44 N m {4.5kgt m,33lbf.ft}
20. Installthedetent bolts (A),spring,and steel balls

with new washers. - -Liquidgasket
1 7 . I n s t a l l t h e x 1 4 m m d o w e lp i n s( A ) .c l u t c hl i n ec l i p 8 ( l b r a c k e ( B ) ,a n d c h a n g e e v e ra s s e m b l y C ) . t
{3.0kgf.m.22lbf.ft)
h 2 1 . A p p l y l i q u i dg a s k e t P / N0 8 7 1 8 - 0 0 0 1 } t o e t h r e a d s { l l o i t h e b a c k - u pi g h ts w i t c h( B ) ,a n d i n s t a l i t i n t h e transmissiohousing. n
6x1.0mm
kgf.m,9lbt ft) 12N.m(1.2
( N 1 8 . A p p l y l i q u i dg a s k e t P i 0 8 7 1 8 - 0 0 0 t o t h e t h r e a d s 1) of the interlockbolt (D),and installit on the transmissiohousing. n
(cont'd)
13-49
Manual Transmission
(cont'dl Transmission Reassembly
22. Installthevehiclespeedsensor(VSS){A)and O - r i n g( B ) .
22 N.m (2.2kgf.m,r6 lbf.ft)
13-50
GearshiftMechanismReplacement
KNOB --SHIFT LEVER 8 N m {0.8ksr.m.5.8lbf.ft}
8 x 1.25mm 22 N.m (2.2 kgf.m, 16 lbt ftl
,.-,'-'
l'/
HOUSING SHIFTLEVER
{P/N 08798-9002}
SHIFT CABLE CLIP Replace.
r-Ll Rotatethe shift cable t o w a r dt h e o p e n i n g .
6x1.0mm 9.8Nm (1.0kgf.m, 7.2 tbf.fr) COTTERPINS {P/N 08798-9002) qrBemovethe shift cable from the shift leverbracket.
13-51
M/T Differential
\ (
DRIVENGEAR page 13-53 Beplacement,
\
Backlash Insoection. oaoe 13-53 paoe I 3-5-3 Feplacemeni,
,<-=-
I \c1
\ =
l/
,/
,/BALL BEARING page 13-54 Beplacemenl,
13-52
Backlash lnspection
1 . Placethe differential assemblyon V-blocks(A),and installboth axles.
FinalDrivenGear/Carrier Replacement
1. Removethe bolts (left-hand threads)in a crisscross patternin severalsteps,then removethe final driven gear (A)from the differential carrier{B).
\tt
1 2 1N m (12.3kgf m, 89 rbt.ft)
x t . om m { t o )
M e a s u r eh e b a c k l a s h f b o t h p i n i o ng e a r s( B )w i t h t o a dial indicator(C).lf the backlashis not within the standard,replacethe differential carrier. Standard(New):0.05 0.15mm (0.002 0.006in.) Installthe final driven gear with the chamferon the i n s i d ed i a m e t e f a c i n gt h e c a r r i e rA l i g nt h e m a r k s r . t o n t h e f i n a ld r i v e ng e a ra n d t h e c a r r i e rT i g h t e n h e . patternin severalsteps. bolts in a crisscross
13-53
M/T Differential
CarrierBearingsReplacement
Special Tool Bequired Driver,40 mm l.D.07746-0030100 1. Checkthe carrierbearingsfor wear and rough rotation.lf they rotatesmoothly and their rollers show no signs of wear, the bearingsare OK, 2. Removethe carrierbearing(A) with a p c o m m e r c i a l l y - a v a i l a b le a r i n g u l l e r( B ) . be 3. Installthe new bearings(A)with the specialtool and a press.Presseach bearingon until it bottoms. There should be no clearance betweenthe bearinos and the carrier. NOTE: Turn the sealed(B)side of the bearingaway from the differentialtoinstallit.
077i16-0030100
07746-0030100
13-54
Oil SealReplacement
Special Tools Required . Driver07749-0010000 . Oil seal driver attachment07NAD-P20A100 1. Removethe differential assembly. 2. Removethe oil seal (A) from the transmission ( housing B). 4 . I n s t a l l t h e e w o i l s e a li n t h e t r a n s m i s s i o h o u s i n q n n with the specialtools.
n w 5 . I n s t a l l t h e e w o i l s e a li n t h e c l u t c hh o u s i n g i t h the specialtools.
( 3 . R e m o v e t h e o i s e a l( A )f r o m t h e c l u t c hh o u s i n g B ) . l
13-55
M/T Differential
Differential Thrust Clearance Adjustment
SpecialToolRequired Driver.40 mm LD.07746-0030100 1 . I n s t a la n 8 0 m m s h i m t h a t ' st h e s a m es i z ea s t h e l one you removeo. Installthe transmissionhousingonto the clutch housing,then tightenthe 8 mm flange bolts in a patternin severalsteps(seestep 15 on crisscross page 13-48). 8 x 1 . 2 5m m 27 N m (2.8 kgf'm, 20 lbf.ft) Use the specialtoolto bottom the differential i a s s e m b l yn t h e c l u t c hh o u s i n g .
00746-0030100
2 . Installthe differentialassemblyinto the clutch

housing.
5 . Measurethe clearance betweenthe 80 mm shim a n d b e a r i n g u t e rr a c ei n t h e t r a n s m i s s i o h o u s i n g . o n Standard:0 0.10mm l0 0.004in.)
-i.
w
.t
-- --
..1
:,- -=.
13-56
6. lf the clearanceis more than the standard,selecta n e w s h i m f r o m t h e f o l l o w i n g a b l e .l f t h e c l e a r a n c e t m e a s u r e dn s t e p5 i s w i t h i nt h e s t a n d a r dg o t o i , step 9. 80 mm Shim Part Number
c
F
rt
Thickness 4 1 4 4 1 L 3 - 8 0 0 1 1 . 0m m ( 0 . 0 3 9 4 . P n 41442-PL3-B001 1 mm (0.0433. n 4 1 4 4 3 - P L 3 - 8 0 0 1 1 . 2m m ( 0 . 0 4 7 2 . n

4 1 4 4 4 - P L 3 - B 0 0 1 1 . 3m m { 0 . 0 5 1 2 . n 4 1 4 4 5 - P L 3 - 8 1 0 1 . 4m m 1 0 . 0 5 5 1 . 0 n 4 1 4 4 6 - P L 3 - 8 0 0 1 1 . 5m m { 0 . 0 5 9 1n . 4 1 4 4 7 - P L 3 - 8 0 0 1 . 6m m ( 0 . 0 6 3 0n . 1 4 1 4 4 8 - P L 3 - B 0 0 1 1 . 7m m { 0 . 0 6 6 9n . 4 1 4 4 9 - P L 3 - 8 0 0 1 . 8m m ( 0 . 0 7 0 9n . 41450-PL3-8000 . 0 5m m ( 0 . 0 4 1 3n . ) 1 4 1 4 5 1 - P L 3 - 8 0 0 01. 1 5m m ( 0 . 0 4 5 3n . l 41452-PL3-8000 . 2 5m m ( 0 . 0 4 9 2n . l 1 41453-PL3-8000 1 . 3 5m m ( 0 . 0 5 3 ' ln . ) 41454-PL3-8000 . 4 5m m ( 0 . 0 5 7 1n . l 1 41455-PL3-8000 . 5 5m m ( 0 . 0 6 1 0n . ) 1 41457-PL3-8000 1 . 7 5m m ( 0 . 0 6 8 9n . ) i
D E
tvl
N P
o
R
' 5 41456-PL3-8000 1 . 6m m ( 0 . 0 6 5i0 . ) n
7 . R e m o v e h e b o l t sa n dt r a n s m i s s i o h o u s i n g . t n 8 . Replace thrust shim selectedin step 6, then the recheck clearance. the 9 . R e i n s t at h e t r a n s m i s s i o n . ll
13-57
Driveline/Axle
............. 16-2 SpecialTools ......................... 16-3 Driveshaft Inspection Driveshafts Removal .......................... 16-3 ................... 16-5 Driveshafts Disassembly Dynamic Damper Replacement ........ 16-8 .................... 16-9 Driveshafts Reassembly ...................... 16-17 Driveshafts lnstallation .............. 16-19 lntermediate ShaftRemoval Intermediate ................................. 16-20 ShaftDisassembly lntermediate .................................. 16-22 ShaftReassembly 16-24 lntermediate Shaftlnstallation ....................................
Driveline/Axle
SpecialTools
Ref. No.
L
DescriDtion O i l S e a lD r i v e r B a l l J o i n tR e m o v e r2 8 m m , Half Shaft Base ThreadedAdapter,22 x 1.5mm Attachment,52 x 55 mm u f l v e r ,J 5 m m L U . Driver O i l S e a lD r i v e r
n]
@
o
t9
6)
(D
ToolNumber 07GAD-PH70201 07MAC-S100200 0 7N A F - S R 3 0 1 0 1 07xAc-001010A 07746-0010400 07746-0030400 07749-0010000 07947-S800100
Orv
1 1 1 1 1 1 1 1
t g[]
r?) \J
,0)
\*
16-2
Driveshaft Inspection
1. Checkthe inboardboot (A) andthe outboardboot (B)on the driveshaft(C)for cracks,damage,leaking grease,and loose boot bands (D).lf any damageis found, reDlace boot and boot bands. the
Driveshafts Removal
Special Tool Required B a l l j o i n tr e m o v e r 2 8 m m 0 7 M A C - S 1 0 0 2 0 0 , 1. Loosenthe wheel nuts slightly 2. Raisethe front of the vehicle,and support it with safetystandsin the proper locations(seepage 1-8). 3. Removethe wheel nuts and front wheels.
Turn the driveshaftby hand,and make sure the splines(E)and joint are not excessively loose. Make sure the driveshaftis not twisted or cracked; if it is, replaceit.
4 . Lift up the lockingtab (A) on the spindle nut (B),
then removethe nut. lf the !eft driveshaftor the intermediate shaft is to be removed,drain the transmissionfluid. Reinstall t h e d r a i np l u g u s i n ga n e w w a s h e r( s e ep a g e1 3 - 3 ) . H o l dt h e s t a b i l i z eb a l l j o i n tp i n ( A )w i t h a h e x r wrench {B),and removethe flange nut (C). the front stabilizerlink (D)from the lower Separate ar m .
(cont'd)
16-3
Driveline/Axle
Driveshafts Removal(cont'd)
7 . R e m o v e h e l o c kp i n { A ) f r o mt h e l o w e ra r m b a l l t joint castlenut (B),and removethe nut. NOTE: . T o a v o i dd a m a g i n g h e b a l l j o i n t ,i n s t a l a h e x n u t t l on to the threadsof the ball joint, . Be carefulnot to damagethe balljoint boot when installingthe remover. 10. Left driveshaft: Pry the inboardjoint (A)from the differential casewith a prybar.Rightdriveshaft: Drivethe inboardjoint (A) off of the intermediate shaft with a drift and hammer. Removethe driveshaftas an assembly.Do not pull on the driveshaft(B),because the inboardjoint may come apart.Draw the driveshaftstraightout to avoid d a m a g i n gh e o i l s e a l . t Left driveshaft:
t
07MAC-S100200
w^ 'e
.."8
Separate the ball joint from the lower arm (C)with the specialtool (seestep 3 on page 18-19). Be carefulnot to dislodgethe lower ball joint from the knuckle. 9 . Pullthe knuckleoutward,and removethe driveshaftoutboardjoint from the front wheel hub u s i n ga p l a s t i c a m m e r . h
Right driveshaft:
16-4
Driveshafts Disassembly
Special Tools Required . T h r e a d e d d a D t e r . 2 x 1 . 5m m 0 7 X A C - 0 0 1 0 1 0 A a 2 . S l i d eh a m m e r , o m m e r c i a l l a v a i l a b l e c y . Boot band pincers,commerciallyavailable
Inboard Joint Side:

1. Removethe set rlng from the inboardjoint.
Low Profile Type
Removethe boot bands.Be carefulnot to damage the boot and dynamic damper. . lf the boot band is a welded type (A),cut the boot b a n d( B ) . . lf the boot band is a double loop type (C),lift up t h e b a n db e n d( D ) ,a n d p u s hi t i n t ot h e c l i p ( E ) . . lf the boot band is a low profiletype (F),pinch the b o o t b a n du s i n ga c o m m e r c i a l l a v a i l a b l e o o t y b ( b a n dp i n c e r s G ) . Welded Type
(cont'd)
16-5
Driveline/Axle
Driveshafts Disassembly {cont'd)
j M a k ea m a r k( A )o n e a c hr o l l e r( B )a n d i n b o a r d o i n t (C)to identifythe locationsof rollersand grooves j j i n t h e i n b o a r d o i n t .T h e n r e m o v e h e l n b o a r d o i n t t on the shop towel (D).Be carefulnot to drop the rollerswhen separating them from the inboard Jornt. 8. Wrap the splineson the driveshaft with vinyl tape (A)to preventdamageto the boot.
9 . R e m o v e h e i n b o a r db o o t .B e c a r e f u n o t t o d a m a o e t l the boot. 10. Removethe vinyl tape. N4ake mark (A) on the rollers(B) and spider (C)to a identifythe locationsof rollerson the spider,then removethe rollers.
R e m o v e h e c i r c l i p{ D ) . t
6 . Mark the spider (C)and driveshaft(E)to identifythe

positionof the spider on the shaft, 7 . R e m o v e h e s p i d e r( C ) . t
16-6
OutboardJoint Side:
1 . R e m o v e h e b o o tb a n d s . ec a r e f u n o t t o d a m a g e t B l t h e b o o ta n d d y n a m i c a m p e r . d . l f t h e b o o t b a n di s a n e a r c l a m p t y p e A ) ,l i f t u p ( the three tabs (B)with a screwdriver. Ear Clamp Type
Wipe off the greaseto exposethe driveshaftand j t h e o u t b o a r d o i n t i n n e rr a c e .

4 . Make a mark (A) on the driveshaft(B) at the same
positionof the outboardjoint end {C).
5. Carefullvclamp the driveshaftin a vise.
2 . Slidethe outboardboot (A)to the inboard ioint side.

Be carefulnot to damaoethe boot.
Removethe outboardjoint (A) usingthe special t o o l a n d a c o m m e r c i a l l a v a i l a b l e / 8 " x 1 8s l i d e y 5 h a m m e r( B ) . 7 . Removethe driveshaftfrom the vise.
(cont'd)
16-7
Driveline/Axle
(cont'dl Disassembly Driveshafts
the 8. Remove stopringtromthe driveshaft.
Dynamic DamperReplacement
j 1 . R e m o v e h e i n b o a r d o i n t ( s e ep a g e1 6 - 5 ) . t 2, Removethe dynamic damper bands.Be carefulnot to damagethe dynamic damper (seepage 16-5). . l f t h e b o o l b a n di s a w e l d e d t y p e . c u t t h e o o t b band. . l f t h e b o o t b a n di s a d o u b l el o o p t y p e ,l i f t u p t h e band bend, and push it into the clip. . lfthe boot band is a low profiletype, pinch the b o o t b a n du s i n ga c o m m e r c i a l l a v a i l a b l e o o t y b band pincers. with vinyl tape 3. Wrap the splineson the driveshaft (A)to preventdamageto the dynamic damper.
9 . Wrap the splineson the driveshaftwith vinyl tape (A) to preventdamageto the boot.
Removethe dynamic damper. Be carefulnot to damagehe dynamic amper. t d 5 . Adjust the positionof the new dynamic damper to the figure below. 1 0 . Removethe outboardboot. Be careful not to damagethe boot. 1 1 .Removethe vinyl tape. 296 300mm ( 1 1 . 6 -1 1 . 8 n . ) i Right driveshaft(Directionall: 301 305 mm ( 1 1 . 9 1 2 . 0i n . l Left driveshaft{Directionall:
6 . I n s t a l l t h e y n a m i cd a m p e rb a n d( s e es t e pI o n d p a g e1 6 ' 1 2 ) . j 1 7 . I n s t a ltlh e i n b o a r d o i n t ( s e ep a g e1 6 - 1 ) .
16-8
Driveshafts Reassembly
ExplodedView
'02 model SETRING Replace.
0e
\)
//ROLLER
6)
/''"oH?"'
/ #'g!!a$il
YJ
II t,//>\
Usethe greaseincludedin the inboardboot set.
// /,/7\
.?-// "\
, I
Includedin the Use the greaserr inboardboot set inboard boot set.
\\1lg n r.
.'(9
-< OOUBLE LOOPBAND Replace.
{\
--.-
l>I I
/'..-:'\ .-\
|
DYNAMTC DAMPER ,/
.''
, \ V L/ A
.^-.1 //^\l
r\
// DOUBLE LOOP BAND Replace.
STOP RING Replace.
EAR CLAMP BANDS
JOINT OUTBOARD
Usethe greaseincludedin the outboardboot set,
(cont'd)
16-9
Driveline/Axle
(cont'dl Driveshafts Reassembly
Exploded View
'03 model
SET RING / Replace. INBOARO JOINT ROLLEB CIRCLIP
I
DOUBLE LOOP BAND Replace. (Boot bandreplacement only.)
s l
Usethe greaseincluded in the nboard boot set.
E.
-"-,,,
@(
(^Y \ \_,/
>
Usethe greaseincluded in the inboardboot set.
LOWPROFILE BAND Beplace. DOUBLE LOOPBAND Replace.
(Boot band replacement only.) DYNAMIC DAMPER
OUTBOARDJOINT
BOOT OUTBOARD ITPI
at-
Usethe greaseincludedin the outboardboot set.
16-10
Special Tools Required . Boot band tool, KD-3191 equivalent, or commercially available . Boot band pincers,Kent-Moore J-359'10 equivalent, or commerclallyavailable . Boot band pincers,commercially available NOTE:Referto the ExplodedView as neededduring this procedure.
3. Installthe spider (A) onto the driveshaftby aligning the marks (B)on the spider and the end of the driveshaft.
lnboardJoint Side:
1. Wrap the splineswith vinyl tape (A)to prevent damageto the inboardboot.
4 . Fit the circlip (C)into the driveshaftgroove.Always rotatethe circlip in its groove to make sure it is fully seated.
5
Fit the rollers (A) onto the spider {B)with their high shouldersfacing outward,and note these items: ' Reinstalltherollers in their original positionson the spider by aligningthe marks (C). . Holdthe driveshaftpointed up to preventthe rollersfrom falling off.
Installthe inboardboot onto the driveshaft, then removethe vinyl tape, Be carefulnot to damageI n e inboardboot.
(u
@\
(cont'd)
16-11
Driveline/Axle
(cont'd) Driveshafts Reassembly
jointwith thejointgrease 6 . Pack inboard the included the newdriveshaft in set. quantity Grease Inboard ioint: 130 140g (4.6-4.9oz)
Usethe greaseincludedin the inboardboot set.
I
8 . Make sure the ends of the boot are sealedin the
groovesin the driveshaftand joint, then installthe boot bands. . For the double loop type, go to step 12. (Replacement boot bands only) . For the low profiletype, go to step 9. 9 . Installthe new low profile band {A) onto the boot {B).then hook the tab (C)of the band,
7 . Fit the inboardjoint onto the driveshaft, and note these items: . Reinstall the inboardjoint onto the driveshaftby j a l i g n i n g h e m a r k s( A )o n t h e i n b o a r d o i n ta n d t the rollers. . Hold the driveshaftso the inboardjoint is pointing up to preventit trom falling off.
1 0 .Closethe hook portionof the band (A) with a

commerciallyavailableboot band pincers(B),then hook the tabs of the band.
1 1 .Installthe boot band on the other end of the boot, and reoeatsteos9 and 10.
16-12
Fit the boot ends onto the driveshaftand the inboardjoint, then installthe new double loop band {A) onto the boot.
15. Threadthe free end ofthe band through the nose sectionof the commerciallyavailableboot band or tool KD-3191 equivalent(A),and into the slot on ( t h e w i n d i n gm a n d r e l B ) .
P u l lu p t h e s l a c ki n t h e b a n db y h a n d ( M a r ka p o s i t i o n A )o n t h e b a n d 1 0 - 1 4 m m ( 0 . 4 0 . 6i n . )f r o m t h e c l i p { B ) .
1 6 . Placea wrench on the winding mandrelof the boot band tool, and tightenthe band until the marked spot (C)on the band meetsthe edge of the clip 1 7 . L i f tu Dt h e b o o t b a n dt o o l t o b e n d t h e f r e e e n d o f the the band 90 degreesto the clip. Center-punch t f o l d o v e rt h e r e m a i n i n ga i l o n t ot h e c l i p . c l i o ,t h e n
(cont'd)
16-13
Driveline/Axle
(cont'dl Driveshafts Reassembly
18. Unwind the boot band tool, and cut off the excess free end of the bandto leavea 5- 10 mm (0.2-0.4 in.) tail protrudingfrom the clip 2 ' 1 .I n s t a l l t h e e w s e t r i n g . n
19. Bendthe band end (A) by tapping it down with a nammer. NOTE; . Make sure the band and clip do not interferewith anythingand the band does not move. . Removeany greaseremainingon the surroundingsurfaces
20. Repeatsteps 12through 19 for the band on the other end of the boot.
16-14
Outboard Joint Side:

1. Wrap the splineswith vinyl tape (A) to prevent damageto the outboardboot.
4. Insertthe driveshaft(A) into the outboardjoint (B) until the stop ring (C)is closeto the joint.
n I n s t a l l t h e e w e a r c l a m pb a n d s( B )a n d o u t b o a r d boot,then removethe vinyl tape. Be carefulnot to damagethe outboardboot.
3 . Installthe new stop ring into the driveshaftgroove

(A).
5 . To completelyseatthe outboardjoint, pick up the driveshaftand joint, and drop them from about 10 cm (4 in.) onto a hard surface.Do not use a force may damagethe hammer as excessive Be driveshaft. carefulnot to damagethe threaded section(A) of the outboardjoint.
1 0c m ( 4i n . )
- ..,..,1;,t,:-,;
{cont'd)
16-15
Driveline/Axle
(cont'd) Driveshafts Reassembly
Checkthe alignmentof the paint mark (A)with the j o u t b o a r do i n t e n d ( B ) . 8. Adjust the length of the driveshafts the figure to below,then adjustthe boots to halfwaybetween full compressionand full extension.Make sure the ends of the boots seat in the groovesof the driveshaftand joint. Leftdriveshaft:497 mm (19.6 19.8in.) 502
-tTfi'.D.ilTD
Rightdriveshaft: 475 480 mm {18.7 1 8 . 9i n . l
7. Packthe outboardjoint (A)with the joint grease includedin the new ioint boot set. Grease quantity Outboardioint: 105 115g (3.7 4.1 ozl
/,)r llt -*>

\{(
9 . Fit the boot (A) ends onto the driveshaft(B)and j o u t b o a r do i n l ( C ) .
'., "o o :;,"0'A?g.fff :l:f
16-16
Installataon Driveshafts
10. Closethe ear portion (A) of the band with a commerciallyavailableboot band pincersKentor Moore J-35910 equivalent(B). 1. Installa new set ring onto the set ring groove of the driveshaft{left driveshaft ).
betweenthe closedear portlon 1 1 .Checkthe clearance is lf the clearance not within the of the bands. standard, closethe ear podion of the bandsfarther. in.) 6.0mm 10.24 MAX
Apply 0.5 1.0g {0.02 0.04oz) of specifiedgrease ( s t o t h e w h o l e s p l i n e d u r f a c e A )o f t h e r i g h t After applyinggrease,removethe driveshaft. greasefrom the splinedgroovesat intervalsof 2a 3 s p l i n e s n d f r o m t h e s e t r i n gg r o o v e( B )s o t h a t shaft. air can bleedfrom the intermediate
3.0 mm {0.12in.} MAX
12. R e p e as t e p s1 0 a n d 1 1 f o r t h e b a n do n t h e o t h e r t
end of the boot.
(cont'd)
16-17
Driveline/Axle
Driveshafts Installation(cont'd)
Cleanthe areaswhere the driveshaftcontactsthe differential thoroughlywith solvent,and dry with c o m p r e s s e a i r .I n s e n t h ei n b o a r d n d { A )o f t h e d e driveshaftinto the differential(B)or intermediate shaft {C) until the set ring (D)locks in the groove (E). 5 . W i p e o f f t h e g r e a s e r o m t h e b a l l i o i n ta n d l o w e r f arm taperedsurfaces. Installtheknuckle(A) onto the lower arm {B).Be careful not to damagethe ball joint boot.Wipe off the greasebeforetightening the nut at the ball joint. Torquethe new castlenut (C)to the lower torque specification, then tighten it o n l y f a r e n o u g ht o a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t a l i g nt h e n u t b y l o o s e n i n gt . i NOTE:Make sure the ball joint boot is not damage or cracks.
"-'t-
4. Installthe outboardjoint (A) into the front hub (B).

1 2x 1 . 2 5 m m 59 69 N.m -7.0 kgf m, (6.0 43 51 tbt.ftl
I n s t a l l t h e e w l o c kp i n { D )i n t ot h e b a l l j o i n tp i n n hole from the insideto the outsideof the vehicle. 7 . Connectthe front stabilizer link {A)to the lower arm. H o l dt h e s t a b i l i z elr n kb a l l j o i n tp i n ( B )w i t h a h e x i w r e n c h{ C ) ,a n d t i g h t e n h e n e w f l a n g en u t { D ) . t
'10 1.25mm x 39 N.m {4.0kgf.m,29 lbf.ft)
16-18
lntermediateShaft Removal
the nut thentighten nut. a 8. Install newspindle {A), nut the use Aftertightening, a driftto stake spindle the shoulder against driveshaft. {B)
1 . Removethe right driveshaft(seepage 16-3). t 2 . R e m o v e h e h e a ts h i e l d .
108N.m (11.0kgf.m, 80 tbt.ft)
/ o oo e
t 3 . R e m o v e h e f l a n g eb o l t{ A )a n d t w o d o w e l b o l t s ( B ) .
22x 1.5 mm 1 8 1N . m
134lbt.ft) kgf.m, {18.5
.---2"
E J /
9. Cleanthe mating surfacesofthe brakedisc and the front wheel, then installthe front wheel with the wheel nuts. 10. Turn the front wheel by hand,and make sure the betweenthe driveshaftand clearance parts. circumference with recommended 1l. Refillthe transmission fluid (seepage 13-3). transmission 12. Checkthe front wheel alignment,and adjust it if (seepage 18-4). necessary
(cont'd)
16-19
Driveline/Axle
Intermediate Shaft Removal (cont'dl
4. Removethe intermediate shaft (A) from the differential. Hold the intermediate shaft horizontal until it is clear of the differential preventdamage to to the differentialoil seal (B).
Intermediate Shaft Disassembly

Special Tools Required . Oil seal driver 07947-5800100 . Half shaft base07NAF-SR30101 1 . R e m o v e t h e s e r i n g ( A ) ,o u t e r s e a ( B ) ,a n d e x t e r n a l t l s n a pr i n g ( C ) .
Pressthe intermediate shaft (A) out of the intermediate shaft bearing(B) using a press.Be carefulnot to damagethe metal rings (C)on the intermediate shaft during disassembly.
PRESS
16-20
3. Removethe internalsnap ring.
shaft bearing(A) out of the 4. Pressthe intermediate ( b e a r i n g u p p o r t B )u s i n gt h e s p e c i atl o o l sa n d a s oress. 07947-s800100
07NAF-SR30101
16-21
Driveline/Axle
Intermediate Shaft Reassembly
Exploded View
INTERMEDIATE SHAFTRING
FLANGEBOLT 10 x '1.25 mm 39IVm {4.0kgf.m,29lbt.ftl
\^
,tto", *,"o p
\--'+7\ E
BEARING SUPPOBT
Packthe interiorof the outer seal.
16-22
Special Tools Required . Driver07749-0010000 . Attachment,52x 55 mm 07746-0010400 . Attachment,35 mm 1.D.07746-0030400 . Oil seal driver 07GAD-PH70201 NOTE:Referto the ExplodedView as neededduring this procedure. , t d 1 . C l e a n h e d i s a s s e m b l ep a r t sw i t h s o l v e n t a n d d r y air. Do not wash the rubber them with compressed partswith solvent. shaft bearing(A) intothe 2. Pressthe intermediate ( b e a r i n g u p p o r t B )u s i n gt h e s p e c i atl o o l sa n d a s press. ES PR
shaft (A) intotheshaft 4. Pressthe intermediate ( B )u s i n gt h e s p e c i atl o o l a n d a p r e s s . bearing

PRESS
07746-0030400 l I n s t a l lt,h e n s e a tt h e e x t e r n as n a pr i n g { A ) i n t ot h e groove of the intermediate shaft (B). 07746-0010400
l 3 . I n s t a l lt,h e n s e a tt h e i n t e r n as n a pr i n g i n t ot h e groove ofthe bearingsupPort.
(cont'd)
16-23
Driveline/Axle
Intermediate Shaft Reassembly (cont'd)
6 . l n s t a l l t h e u t e rs e a l( A )i n t o t h e b e a r i n g s u p p o r t ( B ) o usingthe specialtool and a press.
PRESS
Intermediate Shaft Installation

1 . U s es o l v e n t r b r a k ec l e a n e t o t h o r o u g h l y l e a n o r c the areaswhere the intermediate shaft {A) contacts the transmission(differential), and dry with compressed air. Insertthe intermediate shaft assemblyinto the differential. Hold the intermediate shaft horizontal preventdamageto to the differential seal (B). oil
Packthe interior ofthe outer seal.
7. Installthe etring. s
2 . I n s t a l l t h el a n g eb o l t( A )a n d t w o d o w e lb o l t s( B l . l
A 10 x 1.25mm 39Nm (4.0kgf.m,29lbf.ft) B l 0 x 1 . 2 5m m 39 N.m (4.0kgf.m, 29 tbf.ftl
16-24
3. Installthe heat shield,and tightenthe three bolts.

8 x 1.25mm 22Nm
12.2
r 4 . I n s t a l l t h e i g h td r i v e s h a f(ts e ep a g e1 6 - 1 7 ) ,
16-25
Steering
Steering
. . . . . . . . . .1 . .- 2 .7 T S p e c i a lo o l s 1.7.-.3 . . . . . . . . n L C o m o o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4 Play WheelRotational Check.....................". Steering 17-4 .......... Power Assist Check.................. 17-5 ................. Inspection Linkage Gearbox and Steering . 7 .. l S t e e r i nW h e e R e m o v a.l . . . . . . . . . . . . . . . . . . . . . . . . , . . . .1 . . - 6. . . . . . . . . . g 17-7 ................ WheelDisassembly/Reassembly Steering 17-8 ............... WheelInstallation Steering 17-9 ...........'... and Removal Installation Steering Column 17-11 .............. Inspection Column Steering 17-'12 .......................................'. Replacement Lock Steering . . . . . " . . . . . . . . '1 . ' . . 3 . 7-1 A Rack uide diustment G
PowerSteering(EPS) Electrical
17-15
Steering
SpecialTools
Ref.No.
Tool Number 07MAA-S100200
Description
LocknulWrench.43 mm
Oty
---<,/ L\2 r
-.tt)-
6Y
.Vo
1 7-2
DRIVER'S AIRBAG ASSEMBLY Removal/lnstallation, page 3-113 2
WHEEL STEERING page 17-6 Removal, Disassembly/Reassembly, page 17-7 page 17-8 Installation,
STEERING COLUMN SteeringColumnRemovaland Installation, p a g e1 7 ' 9 SteeringColumn Inspection, p a g e1 7 - 1 ' l SteeringLockReplacement, page 11-12
STEERING GEARBOX page'17-13 Rack Adjustment, Guide
17-3
Steering
SteeringWheelRotationalPlay Check
1. Turn the front wheelsto the straightaheadposition. 2. Measurehow far you can turn the steeringwheel left and right without moving the front wheels. . lf the play is within the limit, the gearboxand l i n k a g e r eO K . a . l f t h e p l a y e x c e e d s t h ei m i t ,a d j u s t t h er a c kg u i d e l '17-13). lf the play is still excessive after {seepage rackguide adjustment,inspectthe steering l i n k a g e n d g e a r b o x s e ep a g e1 7 - 5 ) . a { BOTATIONAL PLAY: 10mm (0-0.39in.l 0
PowerAssistCheck
1 . Startthe engine,and let it idle. Attach a commerciallyavailablespring scaleto the s t e e r i n g h e e l .W i t h t h e e n g i n ei d l i n ga n d t h e w v e h i c l e n a c l e a n , r y f l o o r ,p u l lt h e s c a l ea s o d shown, and read it as soon as the tires begin to turn.
+ :
3 . l f t h e s c a l er e a d sn o m o r e t h a n2 9 N ( 3 . 0k g f , 6 . 6l b f ) , the power assistis OK. lf it readsmore, checkthese items: . . . . Fronttire pressure Steeringlinkage(seepage 17-5) Rackgulde adjustment(seepage 17-13) EPSsystem (seepage 17-18)
17-4
SteeringLinkageand GearboxInspection
BOOT Inspect damage deterioration. Ior and
Checkfor looseness, a n db i n d i n g .
12 mm BOLTS Inspect looseness. for
I
TIE.RODLOCKNUTS Checkfor looseness.
STEERING COLUMN Inspect loose for column mounting hardware STEERING JOINTS Check looseioint bolts, for andloose binding or ioints.
STEERING GEARBOX Inspect loosemounting hardware. for GEARBOXMOUNTING CUSHIONS Inspect deterioration. for
TIE.ROD ENOBALLJOINT lnsoect looseness, tor b i n d i n g ,n dd a m a g e . a
BALLJOINT BOOT Inspect damage deterioration. for and
17-5
Steering
SteeringWheelRemoval
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13), and (seepage 23-14)in the SRS precautions and procedures sectionbeforeperformingrepairsor service. 1. Align the front wheels straightahead,then remove the driver'sairbagfrom the steeringwheel (see p a g e2 3 - 1 1 3 ) . 2. Disconnect cruisecontrol sevresumeswitch the connector(A),and loosenthe steeringwheel nut {B). 3. Installa commerciallyavailablesteeringwheel puller {A) on the steeringwheel (B).Freethe steeringwheel from the steeringcolumn shaft by t u r n i n gt h e p r e s s u r e o l t( C )o f t h e p u l l e r . b Note these items when removing the steering wheel: . Do not tap on the steeringwheel orthesteering column shaft when removingthe steeringwheel. . l f y o u t h r e a dt h e p u l l e rb o l t s( D )i n t o t h e w h e e l hub more than 5 threads,the bolts will hit the cable reel and damageit. To preventthis, install a p a i ro f j a m n u t s5 t h r e a d s p o n e a c hp u l l e rb o l t . u D
i
Bemovethe steeringwheel puller,then removethe steeringwheel nut and steeringwheel from the sleerinocolumn.
17-6
SteeringWheelDisassembly/Reassembly
WHEEL STEERING CONTACTPLATE ACCESSPANELA
HOLDERS CONNECTOR
75*-=offi
MOOULE SETBRACKET REAB STEERING WHEEL COVER
ffi)Y
-f b
CRUISECONTROLSWITCH
,/*
accEss PANEL B
17-7
Steering
WheelInstallation Steering
1 . B e f o r e n s t a l l i n gh e s t e e r i n g h e e l ,m a k es u r et h e i w t front wheels are alignedstraightahead,then center the cable reel (A).Do this by first rotatingthe cable reel clockwiseuntil it stops.Then rotate it counterclockwise about two and a half turns.The a r r o w m a r k( B )o n t h e c a b l er e e ll a b e ls h o u l dp o i n t straightup. 3. Installthe steeringwheel nut (A),and tighten it to the specified torgue. A 39 N.m(4.0 m.29lbt ftl kgf _ B
lr,',,t
;. _,:! '' '1i::..'.'l
Connect the cruisecontrol set/resume switch connector(B).fvlake sure the wire harnessis routed and fastenedproperly. Positionthe two tabs (A) of the turn signal ( c a n c e l i n g l e e v e B )a s s h o w n .I n s t a l l t h e t e e r i n g s s wheel onto the steeringcolumn shaft, makingsure the steerlngwheel hub (C)engagesthe pins (D) of the cable reel and tabs of the cancelingsleeve.Do not tap on the steeringwheel or steeringcolumn shaft when installingthe steeringwheel. I n s t a ltlh e d r i v e r ' s i r b a g a n d c o n f i r mt h a tt h e a , system is operatingproperly{seepage 23-113). C h e c k h e h o r n ,t u r n s i g n a lc a n c e l i n g n d c r u i s e t a control switchesfor proper operation. 7 . Reconnect batteryand do the following: the . D o t h e e n g i n ec o n t r o l o d u l e( E C M ) d l e l e a r n m i ( p r o c e d u r es e ep a g e1 l - 1 3 9 ) , . Powerwindow control unit resettingprocedure \see page 22-1281. . Enterthe anti-theft cord for the radio,then enter the custmer'sradio stationpresets. . Set the clock.
17-8
SteeringColumnRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautions and (seepage 23-14)in the SRSsectionbefore performingrepairsor service. procedures
Removal
1, Recordthe radio stationpresets, and disconnect the battery. 2 . R e m o v e t h e d r i v e r ' s a i r b a g a s s e m b l y ( s e e p a g e 2 3 -a n dt)h e s t e e r i n g h e e l( s e ep a g e1 7 - 6 ) . 113 w p p 3 . R e m o v e t h e r i v e r ' s a s h b o a r do w e r c o v e r ( s e e a g e2 0 - 5 9 a n d u n d e r c o v e r ( s e e a g e2 0 - 6 0 ) . d d l ) 4. Removethe column covers(A:
I x 1.25mm 16 N.m (1.6kgf.m, 12 lbl.fr)
the from the combinationswitch assembly{B). 5 . Disconnect wire harnessconnectors
6 . Removethe combinationswitch assemblyfrom the steeringcolumn shaft by removingthe screw (C)on the top of
the combinationswitch. 7. Disconnect connectors from the ignition switch,and releasethe wire harnessclips from the steeringcolumn. the 8. Disconnect steeringjoint (D),and remove it from the column shaft. the 9. Removethe steeringcolumn {E)by removingthe attachingnuts and bolts.
\
(cont'd)
17-9
Steering
(cont'd) SteeringColumnRemovaland Installation
lnstallation
c 1 . I n s t a ltl h e s t e e r i n g o l u m n ,a n d m a k es u r et h e wires are not caught or pinchedby any parts. Insertthe upper end ofthe steeringjoint onto the steeringshaft {A) (line up the bolt hole (B)with the flat portion (C)on the shaft).
8 x 1 , 2 5m m 28 N.m {2.9 kgf m,
21rbr.ft)
A
Slip the lower end of the steeringjoint onto the pinion shaft {D) (line up the bolt hole with the g r o o v e( E )a r o u n dt h e s h a f t )a n d l o o s e l y n s t a l l t h e l , lower joint bolt. Be sure that the lower joint bolt is securelyin the groove in the pinion shaft. 4 . Pull on the steeringjoint to make sure that the j u . s t e e r i n go i n t i s f u l l y s e a t e dT h e n i n s t a l l t h e p p e r joint bolt, and tighten it to the specifiedtorque. Tightenthe lower joint bolt to the specifiedtorque. and note these items: Finishthe installation, . Make surethe wire harnessis routed and fastenedproperly. . Make sure the connectorsare properlyconnected. . R e i n s t a l l t h s t e e r i n g h e e l( s e ep a g e1 7 - 8 ) . w e . Reconnect battery. the - Do the power window control unitreset procedure{seepage 22-128). - Enterthe anti-theftcode for the radio,then enterthe custmer'sradio stationpresets. - Set the clock. . Verify horn, turn signalswitch,and cruisecontrol switch operation. . Checkwheel alignment,if necessary (seepage 18-4). . D o t h e e n g i n e o n t r o lm o d u l e( E C M ) d l el e a r n i c p r o c e d ue { s e ep a g e' 1 1 - 1 3 9 ) . r
17-10
SteeringColumnInspection
. C h e c k h e s t e e r i n g o l u m nb a l l b e a r i n g ( A a n d t h e s t e e r i n g j o i n t b e a r i n g s ( B ) f o r p l a y a n d p r o p e r m o v e m efn tn y t c ) l a. play, replacethe steeringcolumn as an assembly, bearingis noisy or has excessive ' C h e c k t h e a b s o r b i n g p l a t e s ( C ) , a b s o r b i n g p l a t e g u i d e s ( D ) , s t o p ( E ) , a n d c o a t i n g p l a oe s (i F t o r t i o n n d ft rd s) a breakage. there is distortionor breakage, lf replacethe steeringcolumn as an assembly.
17-11
Steering
SteeringLockReplacement
NOTE:Do not try to re-keya replacement steeringlock. lf necessary, re-keythe other locks. 1 . R e m o v e h e s t e e r i n g o l u m n( s e ep a g e1 7 - 9 ) . t c 2. Centerpunch each ofthe two shear bolts (A),and drill their headsoff with a 5 mm (3i16 in.) drill bit. Be carefulnot to damagethe switch body when removingthe shear bolts, 7. Tightenthe shearbolts (A) untilthe hex heads(B) twist off.
A
:..'-":'
3. Removethe shear bolts from the switch body. 4. Installtheswitch body without the key inserted. 5. Looselytighten the new shear bolts. 6. Insertthe ignition key,and checkfor proper operationof the steeringwheel lock and that the ignition key turns freely.
17-12
RackGuideAdjustment
Special Tool Required Locknutwrench, 43 mm 07MAA-S100200 1. Set the wheels in the straightaheadposition.
j
6. Tighten rackguidescrew(A)ro25 N.m (2.5 the kgf.m, 18lbf.ft). thenloosen it.

5" Max.
i-rrrr-,
2. Removethe heat shield(A).
'-.i. ''
'
9 . 8N . m ( r . 0 k g f . m , 7 . 2 l b t f t ) I 4il N.m
3 . Removethe transmissionmount bracket(seestep

32 on page 13-8). Loosenthe rackguide screw locknut(A)with the specialtool, then removethe rack guide screw (B).
07MAA-S100200
kgf.m,33lbt.ft) {a.5 7 . Retighten the rack guide screw to 6 N.m (0.6kgf m, 4 lbf.ft),then back it off to the specifiedangle. Specified Return Angle: 5' Max. Hold the rack guide screw stationarywith a wrench, and tighten the locknutby hand until it's fully seated. 9 . I n s t a l l t h e p e c i atl o o l o n t h e l o c k n u ( B ) ,a n d h o l d s t the rackguide screw (A) stationarywith a wrench, Tightenthe locknutan additional30" with the specialtool.
1 0 .Reinstall transmissionmount bracketand heat the

s hi el d , Removethe old sealantfrom rackguide screw,and apply new sealantto the middle of the threads(A). Looselyinstallthe rackguide screw on the steering gearDox. 1 1 .Checkfor unusualsteeringeffort through the c o m p l e t e u r n i n gt r a v e l . t
12. Checkthe steeringwheel rotationplay (seepage

17-4)and the power assist(seepage 17-4).
17-13
Electrical PowerSteering(EPSI
SpecialTools . . . . . . . . . .1 . - 1 6 .7 . C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.-.1.7 . . . . . . L n 1. . . Troubleshooting General Information....................... 17-18 DTC Troubleshooting Index .............. 17-22 Symptom Troubleshooting Index ............................... 17-23 Description System ................. ........... 17-24 Circuit Diagram ......... 17-26 DTC Troubleshooting ............... .......... 17-28 EPS lndicator Circuit Troubleshooting ....................... 17-47 MotorRemoval/lnstallation ............... 17-49 Steering Gearbox Removal ............... 17-51 Steering Gearbox Overhaul ............... 17-55 Steering Gearbox Installation ........... 17-63 EPS Control l/lnsta llation....................... UnitRemova 17-67 Tie-rod JointBootReplacement Ball .......................... 17-67
EPSComponents
SpecialTools
Rel.No. Tool Number (!) 07MAC-S100200 at' 070AD-P0A0100
\ Description
B a l lJ o i n t R e m o v e r2 8 m m , Attachment,42 mm LocknutWrench
otv
'1 1 'l
07zAA-S5A0100
_---1t
,.^G) C\
-)
t t ) \L-,
h5--d-'
u_r-.c_-
a
17-16
GAUGE ASSEMBLY UNDER.DASH FUSE/RELAY BOX
-,'/.,....
'.,i,
X \ ]
DATA LINK CONNECTOR I16P)
TOROUE SENSOR
STEERING GEARBOX SteeringGearboxRemoval,page 17-51 page 17-55 SteeringGearboxOverhaul, page 17-63 SteeringGearboxInstallation,
EPS CONTROL UNIT EPS Control UnitRemoval/lnstallation, page17-67 MOTOR

Removal/lnstallation, page l7-49
17-17
EPSComponents
General Troubleshooting Information
EPSIndicator
Under normal conditions, EPS the indicator comes when on the ignitlon switch turned theON(ll)position, is to thengoes is This off after engine started. indicates thebulband the that itscircuit operating correctly. are lf thereis anytrouble thesystem in after engine started, the is indicator stayon,andthe power will is theEPS assist turned off. WhenEPS indicator comes thecontrol light unit on, memorizes DTC. thiscase, control will not In the the unit system after engine starts again, it activate EPS the the but keeps EPS indicator the on. WhenDTC12,16,17,18or 67 is stored thecontrol in unit, the EPS indicator stayon untiltheDTC erased. will is Whena problem detected the EPS is and indicator comes thereare on, whenthe indicator stays untilthe on ignition switch is cases goes whenthe indicator off turned 0FF,andcases when returns normal. to Even though automatically thesystem thesystem operating is normally, EPS the indicator come will on under following the conditions: '1: Condition . Thevehicle traveling least 12.4 mph(20km/h), was at then . A rapid changein vehiclespeedwas detected, then . Thevehicle thevehicle (or speed sensor signal) for stopped at least seconds 5 ' . T h ee n g i n s p e e d a ss t i l l l , 6 4 0 r p m o r h i g h e r f o r a t l e a s t S w e seconds Condition : 2 (or speed sensor signal) has After vehicle thevehicle the yet for 10 speed wasstill stopped at least seconds, theengine 1,640 or higherfor least seconds. rpm at 20 Condition : 3 When engine is rpm and vehicletraveling is the speed 280 or less, the at (10 for a speed 6,2 of mph km/h) more 3 seconds. or question To determine actual the cause ofthe problem, the the during whichthe problem customer about conditions taking above the conditions consideration. into occured, . TheDTCS memorized theEEPRO| (non-volatile are in memory) therefore memorized the DTCS cannot erased be by disconnecting battery. the Perform specified the procedures clear to DTCS.
a
Self-diagnosis
Self-diagnosis be classifiedinto two categories: can . I n i t i a l d i a g n o s i sp e r f o r m e d i g h ta f t e rt h e e n g i n e : r startsand until the EPSindicatorgoes off. . Regulardiagnosis:performedright after the initial d i a g n o s i s n t i lt h e i g n i t i o n w i t c hi s t u r n e dO F F . u s The EPScontrol unit performsthe following functions when a problem is detectedby self-diagnosis; '1. T u r n so n t h e E P Si n d i c a t o r . 2. Memorizes the DTC. 3. Stops power assistand manual steeringoperation begrns. NOTE: . When DTC23 (a problemwith the circuitfor enginespeedsignal)is detected, the power a s s i s w i l l r e t u r n o n o r m a lw h e n t h e v e h i c l e t t s p e e di s 0 . 6 2m p h ( 1 k m / h )o r a b o v e . . Fot DfCs 22,23, 64, or 66 the EPSindicatorgoes when the system relurnsto off automatically n o r m a l . o ra l l o t h e rc o d e s t h e E P Si n d i c a t o r F , goes off when the system is OK afterthe ignition switch is turned from OFFto ON (ll).
Restriction PowerAssistOperation on
Repeated extremesteeringforce.such as turning the steeringwheel continuouslyback-and-forth with the vehiclestopped,causesan increaseof power consumptionin the EPSmotor. The increase electric of t c u r r e n t a u s e s h e m o t o rt o h e a tu p . B e c a u s eh i s h e a t c t adverselyaffectsthe system,the control unit monitors the electriccurrent of the motor. When the control unit detectsheat build-upin the motor, it reducesthe electriccurrentto the motor graduallyto protectthe system,and it restricts the power assist o p e r a t i o nT h e E P Si n d i c a t o d o e sn o t c o m e o n d u r i n g . r t h i sf u n c t i o n . When steeringtorque is not appliedto the steering wheel, or when the ignition is turned off, and the motor cools,the control unit will restorethe power assist graduallyuntil it's fully restored(afterapproximately15 m i n u t e sm a x i m u m ) .
Diagnostic TroubleCode(DTCI
. lf theCPU EPS indicator cannot activated, itfails,the be or on, is comes butthe DTC notmemorized. . Thememory holdanynumber DTCS. of However, when can thesame DTC detected is morethanonce, mostrecent the is therefore one only DTC written overthe priorDTC, occurrence memorized. is . TheDTCS indicated are repeatedly untiltheignition switch is turned OFF. . lf theDTC not memorized,the indicator is EPS blinks.
17-18
How to TroubleshootEPSDTCs
flowchart procedures assumethat The troubleshooting the causeof the problem is still presentand the EPS indicatoris still on, Followingthe flowchartwhen the EPSindicatordoes not come on can result in incorrect diagnosis. show the female terminal The connectoriliustrations a c o n n e c t o rw i t h a s i n g l eo u t l i n e n d t h e m a l et e r m i n a l s with a double outline. connectors 1. Ouestionthe customeraboutthe conditionswhen the the problem occured,and try to reproduce Find out same conditionsfor troubleshooting. when the EPSindicatorcame on, such as while w a , t u r n i n g . f t e r t u r n i n gw h e n t h e v e h i c l e a s a t a certain speed,etc. 2. When the EPSindicatordoes not come on during is the test drive, but troubleshooting done basedon poor terminal the DTC,checkfor looseconnectors, contact.etc in the affectedcircuit,beforeyou start troubleshooting. clearthe DTCand test-drive 3. After troubleshooting, the vehicle.Be sure the EPSindicatordoes not c o m eo n .
O o 2 . T u r nt h e i g n i t i o n N ( l l ) ,a n d f o l l o wt h e p r o m p t s n on the PGM Testerto displaythe DTC(s) the screen. After determiningthe DTC,referto the DTC Index. Troubleshooting NOTE:See the HondaPGM Testeruser's manual for specificinstructions. ServiceCheckSignalCircuit Method: c 1 . W i t h t h e i g n i t i o n w i t c hO F F , o n n e c t h e H o n d a s ( r P G MT e s t e r A ) t o t h e 1 6 Pd a t al i n kc o n n e c t o( D L C ) (B) locatedunderthe dash on the driver'sside of the vehicle.
How to RetrieveEPSDTCs
Honda PGM Tester Method: 1, With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) (B) locatedunderthe dash on the driver'sside of thevehicle. Short the SCScircuitto body ground using the Tester. HondaPGN4 s T u r nt h e i g n i t i o n w i t c hO N { l l ) . Recordthe DTC.
(cont'd)
17-19
EPS Components
Troubleshooting General Information(cont'dl
5. The blinkingfrequencyindicates the DTC.DTCS are indicatedby a seriesof long and short blinks.One l o n g b l i n ke q u a l s1 0 s h o r tb l i n k s A d d t h e l o n g a n d . short blinkstogetherto determinethe DTC.After determiningthe DTC,referto the DTC Troubleshooting Index. The system will not indicatethe DTCunlessthese conditionsare met: . Set the front wheels in the straightaheaddriving position. . The ignition switch is turned ON (ll). . The engine is stopped. . The SCScircuit is shortedto body ground before the ignition switch is turned ON (ll).
How to ClearEPSDTCs
Honda PGM Tesler Method: 1. With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) ( B )l o c a t e d n d e rt h e d a s ho n t h e d r i v e r ' s i d eo f u s the vehicle.
Example DTC23 of
Long blinks Short blinks (two times) (three timesl
Turn the ignition switch ON (ll),and clearthe DTC{s) following the screenpromptson the by PGM Tester. NOTE:Seethe Honda PGMTesteruser'smanual for specificinstructions.

7 . Disconnect Honda PGM Testerfrom the DLC. the
17-20
Service Check Signal Circuit Method: NOTE:Use this procedure when the PGM Tester softwaredoes not matchthe yearlmodelvehicleyou are working on. 1. With the ignitionswitch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector{DLC) (B) locatedunderthe dash on the driver'sside of the vehicle.
1 . Within 4 secondsafter the EPSindicatorgoes off, returnthe steeringwheel to the straightahead driving positionagain and releasethe steering wheel.The EPSindicatorblinkstwice 4 seconds after releasing the steeringwheel, indicatingthat the DTCwas erased. NOTE:If the EPSindicatordoes not blinktwice, an error was made in the procedureand the DTCwas not erased.Turn the ignition switch OFF,and repeatthe operationfrom step 3. Turn the ignition switch OFFafterthe EPSindicator blinkstwice. 9. Disconnect Honda PGM Testerfrom the DLC. the 10. Performthe DTCcode output operation,and be sure that the code has been erased.
With the vehicleon the ground,set the front wheels in the straightaheaddriving position. Short the SCScircuitto body ground using the HondaPGM Tester.
4. Turn the ignition switch ON (ll).The EPSindicator
Within 4 secondsof comes on for about 6 seconds. turning the switch ON, while the EPSindicatoris on, turn the steeringwheel 45 degreesto the left from the straightaheaddriving position,and hold the steeringwheel in that positionuntil the EPS indicatorgoes off. Within 4 secondsafterthe EPSindicatorgoes off, returnthe steeringwheel to the straightahead the steeringwheel. driving positionand release The EPSindicatorcomes on again 4 secondsafter releasing the steeringwheel, Within 4 secondsafter the EPSindicatorcomes on, turn the steeringwheel 45 degreesto the left again and hold it in that position. The EPSindicatorgoes off after 4 seconds.
17-21
EPS Components
DTC DTC; 12 D T C1 6 :
DTC:17 DTC:18 Detection ltem A problem with voltagefor torque sensorT/SlG A problemwith averageof voltagefor torque sensorVT3 and VT6 Note (seepage 17-28) (seepage 17-29) ( s e ep a g e1 7 - 3 1 ) ( s e ep a g e1 7 - 3 1 ) ( s e ep a g e1 7 - 3 3 ) {seepage 17-33) ( s e ep a g e1 7 - 3 3 ) (seepage 17-35) ( s e ep a g e1 7 3 6 ) (seepage '17-38) ( s e ep a g e1 7 - 4 1 ) (seepage 17-38) { s e ep a g e1 7 - 4 2 ) ( s e ep a g e1 7 - 4 3 ) (seepage 17-43) ( s e ep a g e1 7 - 4 4 ) (seepage 17-44) (seepage 17-44) {seepage 17 45) ( s e ep a g e1 7 ' 4 5 ) {seepage 17-45) ( s e ep a g e1 7 - 4 6 )
A problem with thevoltage torquesensor V powersource 1 for 12 Vcc

A problemwith the voltagefor torque sensor5 V power sourceVcc 2 A problemwith the averagefor vehiclespeedand enginespeed Excessive changeof the vehiclespeed sensorsignal
DfC:22
DTC: 23 DTC: 37
DTC:41 DfC: 42
A problemwith the engine speedsignal circuit A problemwith the circuitfor input motor voltage in the EPScontrol unit A problemwith the motor voltage A problemwith the motor driven current (opencircuitor short to grounol A problem with the motor driven current (shortto power) A problemwith the motor driven current (opencircuitor short to grounol A problemwith the motor relav in the EPScontrol unit A problem with the CPU in the EPScontrol unit
DTC: 43
DTC:45 DfC: 47
DTC: 50
DTC: 1 5
A problem with EEPROM the EPS in controlunlt

Fail-safe relay stuckON A problem with low batteryvoltage Fail-safe relay contactfailure
DTC: 62 DTC: 64
DTC: 66 DTC: 67
DTC:68 DTC:69
A problem with the motor driven voltage A problemwith the torque sensorl/F circuit A problemwith the interlockcircuit (torque) A p r o b l e mw i t h t h e i n t e r l o c k i r c u i t( c u r r e n t ) c
17-22

Symptom
EPSindicatordoes not come on EPSindicatordoes not go off and no DTC is stored EPSindicatordoes not stay on, no DTCis stored,and there is no power assist Diagnostic procedure (seepage 17-47) EPSlndicatorCircuitTroubleshooting Also check fo]
(seepage 17-47) EPSIndicatorCircuitTroubleshooting
1. Checkthe motor wires betweenthe EPScontrol unit and the motor for a short to ground. Repairas needed. 2. lf the motor wires are OK, replacethe steeringgearbox {short in the motor).
17-23
EPS Gomponents
SystemDescription
EPS GontrolUnit Inputsand Outputsat Connector (2pl A
EPSCONTROLUNIT CONNECTOR {2P) A
Wire side of femaleterminals Termanal Wire color numbol
Terminalsign (Terminal namel
Description Power source the for actuatormotor Ground forthe actuator
WHT/BLU -' BAT (Plus bafterv)

2 8LK PG
Measurement Conditions lqnitiqr switch ON (lll l Ground Constant Terminals 2-Ground
Voltage
Battery voltage
EPS ControlUnit Inputsand Outputsat Connector (2P) B

EPSCONTROL UNITCONNECTOB {2P} B
Wire side of femaleterminals Terminal Wire colol numDer

1
Terminalsign {Te.mioalname)
M1 (Motor 1
Description Terminals Drives actuator lhe motor

Drives the actuator motor
RED
GRN
Measuremenl Conditions lqnition switch ON llll
Voltage
1-Ground 2'Ground
M2
17-24
C EPS GontrolUnit Inputsand Outputsat Connestor (20P1

EPSCONTROL UNITCONNECTOR (2OP) C
Terminal
numbel 2
Wire color
PNK
Terminalsign name} {Terminel
Descriplion Terminals
Measuremeni Conditions {lqnitionswitch ON {lll)
Voltage
for T/SGND Ground the torque (Torque qround) sensor 3-Ground tarttheenqrne Power source fortorque ORN vccl (Voltaqe common1 and engine Detects torque sensor 5 Ground Startthe YEUBED VT6 (Voltaqe turnthe steerino wheel stonal torque 6) ON Drives EPS the indicator 6 Ground E P S YEUBLU (Warninq lidhr uTltnotcatol lamp) Raise vehicleoff the the Detects vehiclespeed the BLUAVHT VSP ( V e h i c l es p e e d p u l s e i groundandspinthe inputsignal the speed for sensor the ECM(4 pulse/ or BRN SCS siqnal) check {Servjco IG1 1 llqnition Detects servicecheck 8-Ground SCSnot grounded on switch (ll) ON on switch OFF 1'l-Ground tan the enoine
on switch OFF
voltaqe Ba$erv OV About OV voltaqe Banerv Alternating voltage about OV 5V OV-5V Batteryvoltage Battervvoltaqe About5V
10
11
YEL
GRN//EL
Powersourcefor activating 10-Ground Drives torquesensor the Detects torque sensor Detects torque sensor srgnal
vcc2
(Voltaqe common2)
8LU/ORN VT3
(Voltaoe toroue 3)
YEUBLK T/SIG (Torque F/S sensor

1'l
About engine and 13-GroundStartthe trrrnthe steerino wheel 5 - 0 v Momentarily V 5 15-GroundStartthe engine 0-12V engine and l7-Ground Startthe nrrnthe steerino wheel engine, and let 19-GroundStartthe ;t idte 5V 20-Ground PGMTesternot
LT GRN/ B IK
19 20
BLU
GRY
power steering Provides PSW iPowersteerinoswitch) switchsional Detects enginepulse the NEP DIAG-H with Communications HondaPGNI Tester
17-25
EPSComponents
CircuitDiagram
\
SPEDSENSOR 3P CONNECTOR
GAUGEASSEMBLY 22PCONNECTON
@
GAUGEASSEMATY 22PCONNECTOR TOFOUESENSOR 6P CONNECTOR
lli2l3F r;T;T-I (=J_:_LvJ

Wn. !ide ot f.m.l r.fmin.ls
17-26
EPS COI{IFOIUNIT cou{EcToR A (2P) F-l
(T6P) OATA !IN( CONNCTOA
A
EPSCONTNOL UNIT co|lNEcTofi 8 {2P} | l l MOTOF CONNECTOR
vTTrvaEvnrv
wwzna
t2)
Wir. !.le ol l.m.l. t.tman.r.
riTt
T.rmin.l.id.
oll.m.l.r.rmin.l.
17-27
EPSComponents
DTCTroubleshooting
DTC12: TorqueSensor T/SIG
1. Clear he DTC. t 2 . S t a nt h e e n g i n e . 3. Wait at least 10 seconds. Does the EPS indicatot come on? YES Go to step 4. NO Checkfor loosewires or poor connections. lf the connections good, the system is OK at this are time.l 4 . Stop the engine,and verify the DTC. ls DTC12 indicated? I s there battery v oltage? YES Go to slep 5. NO-Perform the appropriate troubleshooting for the code indicated. t YES-Repair short to power in the + circuitwire betweenthe torque sensorand EPScontrol unit.l NO Go to step 9.
Wire side ot lemaleterminals
1 . Turn the ignition switch ON (ll). 8 . Measurethe voltage betweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 5 a n d b o d y g r o u n d . r N EPS CONTROL UNITCONNECTOR(2OP) C
2 3
5 6 1 8
T/SIG {YEL/BLK)
5 . Make sure the ignitionswitch is OFF,then

disconnectEPScontrol unit connectorC (20P) and the torque sensor6P connector. Checkfor continuitybetweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 5 a n d b o d y g r o u n d . r N EPS CONTROL UNITCONNECTOR{2OP) C 9 . Turn the ignition switch OFF. 1 0 . Checkfor continuitybetweenEPScontrol unit connectorC (20P) terminal No. 15 and the torque sensor6P connectorterminal No. 4. EPS CONTROL UNITCONNECTOR(2OPI C
T/SIG (YEL/BLK)
TOROUE SENSOR 6PCONNECTOR

T/SIG (YEL/BLK) Wire side of femaleterminals Wire side ot femaleterminals
ls therecontinuity? YES- Repair shortto bodygroundin thewire between torque the sensor EPS and control unit.l NO Go to step7.
ls there continuity? YES Go to step 1'1, NO Repairopen in the wire betweenthe torque sensorand the EPScontrol unit.I
17-28
'I 1 . Substitute known-goodEPScontrol unit, and a connectthe all disconnected connectors.
DTC16:Torque Sensor VT3andW6

1. Clear he DTC. t 2. Startthe engine. 3 . W a i t a t l e a s t1 0 s e c o n d s . Does the EPS indicator come on?
1 2 .Start the engine.

Does the EPS indicator come on? YES Go to step 13.
YES Go to step 4. lf NO Checkfor loose EPScontrol unitconnectors. necessary, replacethe EPScontrol unit and retest.l lf NO Checkfor loosewires or poor connnections. the connections are good,the system is OK at this time.l 4. Stop the engine,and verify the DTC. ls DTCl2 indicated? ls DTC16 indicated? YES Checkfor loosetorque sensorconnectors. lf necessary, substitutea known-goodsteering gearboxand recheck.l for NO-Perform the appropriate troubleshooting the code indicated. ! YES-Go to step 5. troubleshooting for NO Performthe appropriate the code indicated. t 5. Make sure the ignition switch is OFF,then and disconnectEPScontrol unit connectorC (20P) the torque sensor6P connector. 6, Checkfor continuitybetweenthe appropriateEPS terminal and body control unit connectorC (20P) ground (seetable). Terminal name Vccl C EPS control connector unit No. terminal
1 3 .Stop the engine,and verify the DTC.
3
11
Vcc2 VT3 VT6

T/S GND
13
5 2
EPS UNITCONNECIOR (2OP) C CONINOT
W re s d oltemalelermi.als
ls there continuity? YES- Repairshort to body ground in the appropriatesensorcircuit betweenthe torque sensorand EPScontrol unit,! NO Go to step7. {cont'd)
17-29
EPSComponents
7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 8 . Measurethe voltage betweenthe appropriateEPS control unit connectorC (20P) terminal and body ground (seetable). Terminal name Vccl 9 . Turn the ignition switch OFF. 1 0 . Checkfor continuitybetweenthe appropriateEPS control unit connectorC {20P) terminal and the torque sensorterminal (seetable).
EPS control connector unit C t e r m i nNlo . a 3

11
Vcc2 VT3 VT6

T/S GND
13
5
EPSCONTROL UNITCONNECTOR {2OP} C
T e r m i n a l Torque Sensor EPS control name t e r m i n aN o , unitconnector l C t e r m i n aN o . l Vccl 2 3 Vcc2 3 11 'l 't3 VT3 VT6 6 5 6 T/S GND 2
TOROUE SENSOR CONNECTOR 6P Vccz (GRN/YELI
Wire side of femaleerminals t
VT6 {YEL/RED)
T/S GND {PNK) Wire side of femaleterminals
EPSCONTROL UNIT CONNECTOR I2OP) C VT6{YEL/RED}
ls thete battery voltage? YES Repairshon to power in the + circuitwire betweenthe EPScontrol unit and torque sensor.l NO Go to step 9.
ls therecontinuty? Y E S G ot o s t e p1 1 . NO Repair openin the appropriate torque sensor wirecircuitbetween EPS the control unitandthe torque ensor.l s
17-30
1 1 .Substitutea known-goodEPScontrol unit, and reconnect disconnected the connectors.
DTC17: Torque Sensor Vccl DTC18:Torque Sensor Vcc2
't2.
Start the engine. 1. Clear heDTC. t Does the EPS indicator come on? 2 . S t a r tt h e e n g i n e .
YES Go to step 13. 3. Wait at least 10 seconds. NO Checkfor looseor poor connections the at EPScontrol unit and the torque sensorconneclors. lf the connections good, replacethe EPScontrol are u n i ta n d r e c h e c k . I Does the EPS indicator come on? YES Go to step 4. lf NO Checkfor loosewires or poor connections. are good, the system is OK at this the connections time.I
4 . Stop the engine,and verify the DTC.
1 3 .Stop the engine,and verify the DTC.

ls DTC16 indicated? YES Replace steeringgearboxand recheck.l the for NO Performthe appropriate troubleshooting the code indicated.l
Is DTCl7 or DTCl8 indicated? YES Go to step 5. for NO Do the troubleshooting the DTc indicated.I Make sure the ignition switch is OFF,then and disconnectEPScontrol unit connectorC (20P) the torque sensor6P connector. Checkfor continuitybetweenEPScontrol unit N c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 3 a n d b o d y g r o u n d . r UNIT C (2OP) EPS CONTROL CONNECTOR
Wiresideo{ female terminals
ls there continuity? s Y E S R e p a i r h o n t o b o d y g r o u n di n t h e w i r e betweenthe torque sensorand EPScontrol unit.I NO Go to step 7. (cont'd)
17-31
EPS Components
7. Checkfor continultybetweenEPScontrol unit ) c o n n e c t oC ( 2 0 P t e r m i n a lN o . 3 a n d t h e t o r q u e r sensor6P connectorterminal No. 2. EPS CONTROL UNITCONNECTORI2OP) C 9. Checkfor continuitybetweenEPScontrol unit connectorC {20P) terminal No. 11 and the torque sensor6P connectorterminal No. 3. EPS CONTROL UNITCONNECTOR(2OP} C
Vcc2(GRN/YEL)
ls thete continuity? YES Go to step 8. NO Repairopen in the wire betweenthe torque s e n s o r n d E P Sc o n t r o lu n i t . I a
ls therc continuity? YES-Go to step 10. NO Repairopen in the wire betweenthe torque sensorand EPScontrol unit.l
8 . Checkfor continuitybetweenEPScontrol unit

) c o n n e c t oC ( 2 0 P t e r m i n a lN o . 1 1 a n d b o d y g r o u n d . r EPS CONTROL UNITCONNECTOR(2OP) C
1 0 .Substitutea known-goodEPScontrol unit, and

connectall the disconnected connectors. 1 1 .Start the engine. Does the EPS indicator come on?
2 3
lvcc2
5 6 1 8
YES Go to step 12. NO Checkfor looseor poor connections the at EPScontrol unit and the torque sensorconnectors. lf the connections good, replacethe EPScontrol are u n i ta n d r e c h e c k . l
{GRN/YEL)
12. Stop the engine,and verity the DTC.

ls DTC17 or DTC18 indicated?
ls therecontinuity?
YES-Replace the steeringgearboxand recheck.l
YES Repair shortto bodygroundin thewire between torquesensor EPS the and control unit. t NO Goto step9.
NO Performthe appropriate for troubleshooting the code indicated.l
17-32
22: DTC Vehicle Speed Sensor Signal DTC Engine 23: Speed Signal
3 . Blockthe rearwheels and raisethe vehicle,and

make sure it is securelysupported.
4 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
NOTE: . lf the MIL indicatoris ON, troubleshoot the PGIVI-Fl systemfirst. . Eventhough the system is operatingnormally,the EPSindicatorwill come on underthe following conditions. - Condition : 1 . The vehiclewas travelingat least '12.4 mph (20 km/h),then . A rapld changein vehiclespeedwas detected, then . T h e v e h i c l e o rt h e v e h i c l e p e e ds e n s o r i g n a l ) ( s s and stoppedfor at least5 seconds, . The engine speedwas still 1,640rpm or higherfor at least5 seconds - Condition2: After the vehicle(or the vehiclespeedsensor yetthe signal)has stoppedfor at least10 seconds, w r e n g i n e p e e d a s s t i l l 1 , 6 4 0 p m o r h i g h e rf o r a t s least20 seconds. - Condition3: W h e nt h e v e h i c l e p e e di s 1 0 k m / h ( 6 . 2m p h )o r s a b o v ea n d t h e e n g i n ei s r u n n i n g t 2 8 0 r p m o r a below for 3 seconds. 1. Startthe engineand checkthe tachometer. ls the tachometer working correctly? YES- Go to step 2. N O - G o t o s t e p9 . 2. Test-drive vehicleabove 15 km/h {9.3mph). the ls the speedometerworking correctly? YES Go to step 3. system NO-Perform the speedometer troubleshooting {see page22-651.a
5 . Blockthe right front wheel, and slowly rotatethe left front wheel, and measurethe voltage between N E P Sc o n t r o lu n i tc o n n e c t oC ( 2 0 P ) t e r m i n a l o . 7 r a n d b o d yg r o u n d . EPS CONTROL CONNECTOR UNIT C {2OP)
Does the voltagepulse 0 V and 5 V? YES Go to step 6. NO Repairopen in the wire betweenthe EPS for control unit and the VSS. lf the wire is OK,check at a loose or poor connections the EPScontrol unit. lf necessary, substitutea known-goodEPScontrol u n i t ,a n d r e c h e c k . l
(conr'd)
17-33
EPSGomponents
Turn the ignition switch OFF,and disconnect EPS control unit connectorC (20P). 7 . Startthe engine,and let it idle. 8 . Measurethe voltage betweenEPScontrol unit c o n n e c t oC { 2 0 P t e r m i n a lN o . 1 9a n d b o d y g r o u n d . r ) EPS CONTROL UNITCONNECTOR{2OP) C 11. Measurethe voltage betweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 9 a n d b o d y g r o u n d . r N EPSCONTROL UNITCONNECTOR {2OPI C
ls there about 6 V at idle? (With the metet set tor trequency, is therc 33 Hz per 1,000 engine rpn?)
ls there about 6 V at idle? (With the meter set lol t requency,is there 33 Hz per 1,000engine rpm?) YES Checkfor loose EPScontrol unit connectors. lf necessary, substitutea known-goodEPScontrol u n i ta n d r e c h e c k . l NO Repairopen in the wire betweenthe EPS c o n t r o lu n i ta n d t h e E C M . I 9 . Turn the ignition switch OFF,and disconnect EPS control unit connectorC (20P).
YES Checkfor loose EPScontrol unitconnectors. lf necessary, substitutea known-goodEPScontrol u n i ta n d r e c h e c k . I NO Go to step '12.
1 2 .Turn the ignition switch OFF. 1 3 .Disconnect ECMconnectorE (31P)connector. the
1 0 .Startthe engine,and let it idle.
!
17-34
'14. Checkfor continultvbetweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 9 a n d E C M r N connectorE (31P) terminal No. 26. ECM CONNECTOR E {31PI
DTC EPS 37: Control UnitInternal Circuit (lnputCircuit MotorVoltage) For

1 . C l e a rt h e D T C . 2. Startthe engine. several 3. Turn the steeringwheel from lock-to-lock times, and wait 10 secondsor more. Does the EPS indicator come on? YES Go to step 4. lf NO Checkfor loosewires or poor connections. the connections are good,the system is OK at this trme.l
ls thete continuity? YES-Go to step 15. N O - R e p a i ro p e ni n t h e w i r e b e t w e e n h e E P S t c o n t r o lu n i ta n d E C M . I 1 5 . Disconnect gauge assembly22Pconnector. the Checkfor continuitybetweenEPScontrol unit N c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 9 a n d b o d y g r o u n d , r EPS CONTROL UNITCONNECTOR(2OP} C
4. Stop the engine,and verify the DTC. ls DTC 37 indicated? YS Checkfor loose EPScontrol unit conneclors. lf necessary, substitutea known-goodEPScontrol u n i ta n d r e c h e c k . l for troubleshooting NO Performthe appropriate the code indicated.l
ls there continuity? Y E S R e p a i r h o r t t ob o d y g r o u n di n t h e w i r e s betweenthe EPScontrol unit, the test tachometer the connector, gaugeassembly,and the ECM.I NO Checkfor loose ECMcontrol unit connectors. lf necessary, substitutea known-goodECMcontrol u n i ta n d r e c h e c k . I
17-35
EPSComponents
41: For DTC Voltage Motor
1. Clearhe DTC. t 2 . S t a r tt h e e n g i n e . several 3. Turn the steeringwheel from lock-to-lock times, and wait 10 secondsor more, Does the EPS indicator come on? YES-Go to step 4. NO Checkfor loosewires or poor connections. lf are good,the system is OK at this the connections time.l 4. Stop the engine,and verify the DTC. ls DTC 41 indicated? YES Go to step 5. NO Go to step 8. troubleshooting for NO Performthe appropriate t h e c o d ei n d i c a t e d . l 5. Make sure the ignition switch is OFF,then disconnectEPScontrol unit connectorB (2P)and the motor 2P conneclor. 6. Checkfor continuitybetweenEPScontrol unit t c o n n e c t o B ( 2 P ) e r m i n a lN o . 1 a n d b o d y g r o u n d . r
UNIT CONNECTOR {2P} B EPSCONTROL M2 (GRNI
.l
7. Checkfor continuitybetweenEPScontrol unit N c o n n e c t o B ( 2 P ) t e r m i n a l o . 2 a n d b o d yg r o u n d . r EPSCONTROL UNITCONNECTOR I2P) B
Tit M2 {GRN) FJ
o)
I
-r
ls there continuity? Y E S - R e p a i rs h o r tt o b o d y g r o u n di n t h e G R Nw i r e betweenthe EPScontrol unit and the motor,l
Checkfor continuitybetweenEPScontrol unit N c o n n e c t oB ( 2 P ) t e r m i n a l o . 1 a n d N o . 2 . r B EPS CONTROL UNITCONNECTOR{2P)
M1 (RED}H
Itr (f))
,L
F---t||
ls there continuity? YES Repairshort betweenthe REDand GRN wires in the motor circuit betweenthe EPScontrol u n i t a n dt h e m o t o r . l NO Go to step 9.
ls there continuity? YES Repairshort to body ground in the REDwire betweenthe EPScontrol unit and the motor.! N O - G o t o s t e p7 .
17-36
9. Turn the ignition switch ON (ll),and measurethe voltagebetweenEPScontrol unit connectorB (2P) terminal No. 1 and body ground EPSCONTROL UNITCONNECTOR (2P) B
1 1 .T urn the ignition switch is OFF. Substitutea known-goodEPScontrol unit, and connectall the disconnected connectors.
1 3 .Start the engine,and turn the steeringwheel from

lockto lock severaltimes.
M1 IREDIH r-_-1 ||
,<.)\ uL,/ Y
tr
Does the EPS indicator come on? Y E S - G o t o s t e p1 4 . NO-Check for loose or poor connections atthe lfthe EPScontrol unit and the motor connections. connections are good, replacethe EPScontrol unit andrecheck.l 1 4 . S t o pt h e e n g i n e a n d v e r i t yt h e D T C . ,
WiresideoI female terminals
Is there battety voltage? ls DTC 41 indicated? YES Repairshort to power in the + circuitwire betweenthe EPScontrol unit and the motor.I N O - G o t o s t e p1 0 . YES Replace steeringgearboxmotor and the recheck.l NO Performthe appropriate troubleshooting for t h e c o d ei n d i c a t e d . l
1 0 .Measurethe voltagebetweenEPScontrol unit

c o n n e c t oB ( 2 P ) t e r m i n a l o . 2 a n d b o d y g r o u n d . r N EPS CONTROL B UNITCONNECTOR(2P)
raz rcnrrrr l{ I . l-t
I (v)
Y I
ls there battery voltage? YES-Repair shortto power in the - circuitwire betweenthe EPScontrol unit and the motor.! N O G o t o s t e p1 1 .
17-37
EPSComponents
DTC42,45: MotorDrivenCurrent
1. Clearthe DTC. 2. Start the engine. 3. Turn the steeringwheel from lock-to-lock several t i m e s ,a n d w a i t 1 0 s e c o n d s r m o r e . o Does the EPS indicator come on? YES- Go to step 4. NO-Check for loosewires or poor connections. lf the connections are good, the system is OK at this time.I Stop the engine,and verify the DTC. ls DTC 42 or 45 indicated? YES-Go to step 5. NO Go to step 8. NO- Performthe appropriate troubleshooting for t h e c o d ei n d i c a t e d . I M a k es u r et h e i g n i t i o n w i t c hi s O F F , h e n s t EPScontrol unit B connector(2P)and disconnect the motor 2P connector. Checkfor continuitybetweenEPScontrol unit c o n n e c t oB ( 2 P ) e r m i n a lN o . 1 a n d N o . 2 . r t EPS CONTROL UNITCONNECTOR{2P) B EPSCONTROL UNITCONNECTOR I2PI B 7. Checkfor continuitybetweenEPScontrol unit l c o n n e c t oB ( 2 P l t e r m i n aN o . 2 a n d b o d y g r o u n d . r
r',rz ll tcnnrt
-](o)
I
lsthere continuity? YES Repairshort to body ground in the GRNwire betweenthe EPScontrol unit and the motor.l
6 . Checkfor continuitybetweenEPScontrol unit

c o n n e c t o B ( 2 P ) t e r m i n a l o . 1 a n d b o d yg r o u n d . r N EPS CONTROL UNITCONNECTORI2P) B
M2 {GRN)
M1 IRED}H
I
I
f2-l
(C))
ls there continuity? YES Repairshort betweenthe REDand GRN wires in the motor circuit betweenthe EPScontrol u n i ta n d t h e m o t o r . l NO Go to step 9.
ls there continuity? YES Repairshort to body ground in the REDwire betweenthe EPScontrol unit and the motor,I N O - G o t o s t e p7 .
17-38
9. Turn the ignition switch ON (ll),and measurethe voltage betweenEPScontrol unit connectorB (2P) t e r m i n a lN o . I a n d b o d y g r o u n d . EPSCONTROL UNITCONNECTOR (2PI B
11. Checkfor continuitybetweenEPScontrol unit connectorB (2P)terminal No. 1 and the motor 2P connectorterminal No. 2. EPSCONTROL UNIT B 12P) CONNECTOR MOTOR CONNECTOR {2PI
M1{RED} H T-----l | |
M1 IRED)
M1 (RED}
(v)
I
lil
I
Wiresideo{ Iemale terminals
ls there battety voltage? YES-Repair short to power in the + circuitwire betweenthe EPScontrol unit and motor.l NO Go to step 10.
ls therecontinuity? YES-Go to step'12. NO-Repairopenin the RED wire between EPS the controlunitandthe motor.l
1 0 .Measurethe voltage betweenEPScontrol unit

c o n n e c t oB { 2 P } t e r m i n a l o . 2 a n d b o d y g r o u n d . r N EPS CONTROL CONNECTOR UNIT B (2P}
mzrcnrur ll-l
A (v)
Y I
ls there battery voltage? Y E S R e p a i r h o r tt o p o w e ri n t h e + c i r c u i t w i r e s betweenthe EPScontrol unit and the motor.a N O - G o t o s t e p1 1 .
(cont'd)
17-39
EPS Gomponents
(cont'd) DTGTroubleshooting
12. Checkfor continuitybetweenEPScontrol unit c o n n e c t o B ( 2 P ) t e r m i n a l o . 2 a n d t h e m o t o r2 P r N c o n n e c t otre r m i n a lN o . 1 .
EPSCONTROLUNIT CONNECTOR I2PI B
L
15. Stop the engine,and verify the DTC. ls DTC 42 or 45 indicated? YES Replace steeringgearboxmotor and the recheck.l NO Performthe appropriate for troubleshooting the code indicated.l
MOTOR CONNECTOR {2P)
M2 IGRN)
ls there continuity? Y E S - G o t o s t e p1 3 . NO-Repair open in the GRNwire betweenthe EPS control unit and the motor.l Checkfor loosewires or poor connections, the if connections are good. substitutea known-good EPScontrol unit, and connectallthe disconnected connectors. 1 4 . Startthe engine,and turn the steeringwheel from lockto lock severaltimes. Does the EPS indicatot come on? YES Go to step 15. NO Checkfor loose EPScontrol unitconnectors. lf necessary, replacethe EPScontrol unit and recheck. a
17-40
tli|: DTC MotorDriven Current Excessively is Hish

1. Clear he DTC. t 2. Startthe engine. 3. Turn the steeringwheel from lock-to-lock several '10 times, and wait secondsor more. Does the EPS indicator come on? YES Go to step 4. NO-Check for loosewires or poor connections. lf the connections good,the system is OK at this are ttme.I 4. Stop the engine,and verify the DTC. ls DTC 43 indicated? YES Go to step 5. NO-Perform the appropriate troubleshooting for the code indicated.I 5. Make sure the ignition switch is OFF,then disconnect EPScontrol unit connectorB (2P)and the motor 2P connector. 6. Turn the ignition switch ON (ll). 7. Measurethe voltage betweenEPScontrol unit '1 c o n n e c t oB ( 2 P ) t e r m i n a l o . a n d b o d y g r o u n d . r N EPSCONTROL UNITCONNECTOR {2P} B
8. Measurethe voltagebetweenEPScontrol unit c o n n e c t o B ( 2 P ) t e r m i n a l o . 2 a n d b o d yg r o u n d . r N EPS CONTROL CONNECTOR UNIT B I2PI
M2tcRNl F-l
f---1 z I
Til
(v)
I
Y
ls there battety voltage? YES- Repairshort to power in the - circuitwire betweenthe EPScontorl unit and the motor.! NO-Go to step 9. 9 . Turn the ignition switch OFF. 1 0 . Checkfor continuitybetweenEPScontrol unit c o n n e c t o B ( 2 P ) e r m i n a l s o . 1 a n d N o .2 . r t N EPS CONTROL UNITCONNECTOR{2P) B
M2 {GBN)
M 1 { R E o )H
T------t
It (v)r
T -L
I I
ls there continuity? YES Repairshort betweenthe GRN and RED wires in the motor circuitbetweenthe EPScontrol u n i ta n d t h e m o t o r . l N O G o t o s t e p1 1 .
Wiresideot Iemale terminals
ls therc battery voltage? YES Repairshort to power in the + circuitwire betweenEPScontrol unit and motor.l N O - G o t o s t e p8 . ( c o n td )
17-41
EPSComponents
1 1 .Substitutea known-goodEPScontrol unit, and connectall the disconnected connectors.
DTC 47: EPS Control Unitlnternal Circuit (Power Relay)

1. Clearthe DTC. 2. Startthe engine.
1 2 .Start the engine,and turn the steeringwheel from

lockto lock severaltimes. Does the EPS indicator come on?
Does the EPS indicator come on? YES Go to step 13. NO -Check for loose or poor connections the at EPScontrol unit and the motor connections. the lf connections good, replacethe EPScontrol unit are and recheck.l YES-Go to step 3, NO-Check for loosewires or poor connections, lf the connections good, the system is OK at this are time.I 3. Stop the engine,and verify the DTC. ls DTC 47 indicated? YES Checkfor loose EPScontrol unit connectors. lf necessary, substitute known-goodEPScontrol a u n i ta n d r e c h e c k . l NO Performthe appropriate troubleshooting for the code indicated.I
1 3 .Stop the engine,and verity the DTC.

ls DTC 43 indicated? YES-Replacethe steeringgearboxmotor and recheck.tl NO-Perform the appropriate troubleshooting for the code indicated.l
17-42
DTC50: EPS ControlUnit Internal Circuit (CPU Microcomputer) or

1. Clearthe DTC. 2. Start the engine. Does the EPS indicator come on? YES Go to step 3. NO Checkfor loosewires or poor connections. lf the connections good. the system is OK at this are t i m e .t 3. Stop the engine,and verify the DTC. ls DTC 50 indicated? YES-Check for looseor poor connections the at EPScontrol unit connections. the connections lf are good, substitutea known-goodEPScontrol unit. lf goes away, replacethe the symptom/indication original EPScontrol unit.l NO Performthe appropriate troubleshooting for the code indicated. t
DTC 51: EPS Control UnitInternal Circuit (EEPROM)

1. Clear he DTC. t 2. Start the engine. Does the EPS indicatot come on? YES-Go to step 3. NO-Check for loosewires or poor connections. lf the connections good, the system is OK at this are time.I 3. Stop the engine,and verify the DTC. ls DTC 51 indicated? YES-Check for looseor poor connections the at EPScontrol unit connections. the connections lf are good. substitutea known-goodEPScontrol unit. lf goes away, replacethe the symptom/indication original EPScontrol unit.! NO Performthe appropriate troubleshooting for the code indicated. t
17-43
EPSComponents
(cont'dl DTC Troubleshootang
Circuit DTC62: EPS ControlUnit Internal (Fail-safe ON) Relay Stuck
'1. Clearthe DTC. 1. Clear he DTC. t 2. Startthe engine. Does the EPS indicatot come on? YES Go to step 3. lf NO Checkfor loosewires or poor connections. the connections are good,the system is OK at this trme.l 3. Stop the engine,and verify the DTC. ls DTC 64 indicated? YES Go to step 4. for troubleshooting NO Performthe appropriate the code indicated. '18(604) fuse/ 4. Checkthe No. fuse in the under-hood relay box, and reinstallthefuse if it is OK. Is the f use OK? YES Go to step 5. NO Replace fuse and recheck.l the 5. Disconnect EPScontrol unit connectorA (2P). 6. Measurethe voltage betweenEPScontrol unit t c o n n e c t oA ( 2 P ) e r m i n a lN o . 1 a n d b o d y g r o u n d . r
is Low DTC64: Battery Voltage Excessively (Fail-safe Relay Contact Failure Motor and FallOff) Voltage
2. Startthe engine. Does the EPS indicator come on? YES-Go to step 3. lf NO-Check for loosewires or poor connections. are the connections good, the system is OK at this time.I 3. Stop the engine,and verify the DTC. ls DTC 62 indicated? at YES-Check for loose or poor connections the are EPScontrol unit. lf the connections good, substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication originalEPScontrol unit and recheck.l troubleshooting for NO-Perform the appropriate the code indicated. t
-Blwt{r/Bl.urH l \9
ls there battety voltage? at YES- Checkfor loose or poor connections the and checkfor a poor EPScontrol unit connectors, ground at G 151. lf necessary, a substitute knowngood EPScontrol unit and recheck.l NO Repairopen in the WHT/BLUwire between e c t h e N o . 1 8 ( 6 0 , 4 ) f u sa n d E P S o n t r o lu n i t . l
17-44
DTC 66,68: EPS Control Unitlnternal Circuit

1. Clear he DTC. t 2. Start the engine. 3. Turn the steeringwheel from lock-to-lock several times, and wait 10 secondsor more. Does the EPS indicator come on? YES-Go to step 4. NO-Check for loosewires or poor connections. lf the connections good.the system is OK at this are time.l 4. Stop the engine.and verify the DTC.
DTC67: TorqueSensorl/FCircuit
1. Clearthe DTC. 2 . S t a r tt h e e n g i n e . 3. Turn the steeringwheelfrom lock-to-lock several times, and wait 10 secondsor more. Does the EPS indicator come on? YES-Go to step 4. NO Checkfor loose wires or poor connections.lf the connectionsare good, the system is OK at this time. ! 4. Stop the engine,and verify the DTC. ls DTC 67 indicated?
ls DTC 66 or 68 indicated? YES-Check for looseor poor connections the at EPScontrol unit. lf the conneclionsare good, substitute known-goodEPScontrol unit. lf the a goes away, replacethe symptom/indication original EPScontrol unit and recheck.I NO Performthe appropriate troubleshooting for the code indicated. t YES Checkfor looseor poor connections the at EPScontrol unit. lf the connections are good, substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication original EPScontrol unit and recheck. ! NO-Perform the appropriate for troubleshooting the code indicated.I
17-45
EPS Components
DTC69: EPS ControlUnit Internal Circuit
1. Clear he DTC. t 2. Startthe engine. several 3. Turn the steeringwheel from lock-to-lock times, and wait 10 secondsor more, Does the EPS indicator come on? YES Go to step 4. NO-Check for loosewires or poor connections. lf the connections are good, the system is OK at this time.l 4. Stop the engine,and verify the DTC. ls DTC 69 indicated? YES-Check for loose or poor connections the at are good, EPScontrol unit. lf the connections substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication original EPScontrol unit and recheck.l troubleshooting for NO- Performthe appropriate the code indicated.l
17-46
EPSIndicatorCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll),startthe engine, and watch the EPSindicator. Does the EPS indicator come on? 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s YES lf the EPSindicatorcomes on and goes off, it's OK. lf the EPSindicatorstayson or blinks.go to s t e p1 2 . NO Go to step 2. Turn the ignition switch OFF,then ON (ll) again, and watch the brakesystem indicator, Does the brake system indicator come on? YES-Go to step 3. NO Repairopen in the indicatorpower source circuit.l . B l o w nN o . 1 0 ( 7 . 5 A ) f u s e . . Open in the wire betweenthe No. 10 (7.5A) fuse and gaugeassembly. . Open circuitinsidethe under-dash fuse/relaybox, . Faultygauge assembly.
s Wire s d oflemale16rmina
5. Turn the ignition switch OFF. EPScontrol u n it connectorC (20P). 6. Disconnect
8. ConnectEPScontrol unit connectorC (20P) terminal No. 6 to body ground with a jumper wire.
EPSCONTBOLUNIT CONNECTOBC {2OP)
Does the EPS indicatot come on? YES Go to step 9. NO Repairopen in the wire betweenthe gauge assemblyand the EPScontrol unit.l
3 . Turn the ignitionswitch OFF, 9 . Turn the ignitionswitch OFF.

4 . Connecta jumper wire betweenthe gauge
assembly22Pconnectorterminal No. 13 and body g r o u n d , h e nt u r n t h e i g n i t i o n w i t c hO N ( l l ) . t s (Blue ASSEMBLY CONNECTOR connector) 22P GAUGE
1 0 .Disconnect EPScontrol unit connectorA (2P), ' l1 .

Checkfor continuitybetweenEPScontrol unit connectorA terminal No. 2 and body ground.
A I2PI EPS CONTROL UNITCONNECTOA
w i r e s d e o f t e m a l et e r m i n a l s
Wiresideof female terminals ls there continuity? Does the EPS indicator come on? YES-Go to step 5. N O I n s p e ctth e E P Si n d i c a t o b u l b ,i f t h e b u l b i s r O K , r e p l a c eh e b u l bc i r c u i tb o a r di n t h e g a u g e t assembly.l YES Checkfor loose or poor connections the at E P Sc o n t r o lu n i t .l f t h e c o n n e c t i o na r e g o o d , s substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication o r i g i n a E P Sc o n t r o lu n i ta n d r e c h e c k . I l N O R e p a i r p e ni n t h e w i r e o r a b a d g r o u n da t o G151,t (cont'd)
17-47
EPS Components
(cont'dl EPSIndicatorCircuitTroubleshooting
1 2 .Turn the ignitionswitch OFF. 1 3 .Disconnect EPScontrol unit connectorC (20P). 1 4 .Turn the ignitionswitch ON (ll).
Does the EPS indicator come on? YES-Repair short to ground in the YEUBLUwire betweenthe gaugeassemblyand the EPScontrol unit,or replacethe bulb circuit board in the gauge assembly.l NO-Go to step 15. Measurethe voltagebetweenEPScontrol unit c o n n e c t oC ( 2 0 P ) t e r m i n a l o . 1 0 a n d b o d y g r o u n d . r N EPS CONTROL UNITCONNECTORI2OP) C EPS CONTROL UNITCONNECTON A (2P} 16. Measurethe voltagebetweenEPScontrol unit '1 connectorA (2P)terminalNo. and body ground.
+B (WHT/BLUI H
v
-L
YES-Go to step 17.
Itr
NO-Check for a blown No. 18 (604)fuse in the under-hood fuse/relaybox or open/shortin the WHT/BLUwire betweenthe under-hoodfuse/relay box and the EPScontrol unit.l 1 7 . Turn the ignition switch OFF. 1 8 , Reconnect EPScontrol unit connectorA (2P). 1 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 20. Measurethe voltage betweenEPScontrol unit connectorC (20P)terminal No. 8 and body ground.
ls therebatteryvoltage? Y E S - G ot o s t e p1 6 . NO-Repairopenin thewire between control EPS unitconnector (20P) the No, 10(7.5A) C and fuse. t
EPS CONTROL CONNECTOR UNIT C (2OP)
ls therc about 10 V? YES Checkfor looseor poor connections the at EPScontrol unit. lf the connections good, are substitutea known-goodEPScontrol unit. lf the goes away, replacethe symptom/indication originalEPScontrol unit and recheck.l NO Repairshort to ground in the BRNwire betweenthe data link connectorand the EPS c o n t r o lu n i t . I
17-48
Motor Removal/lnstallation
Bemoval 1. Make sure you havethe anti-theftcode for the radio, then write down the frequencies the preset for buttons. 2. Disconnect negativecablefrom the battery,and the wait 3 minutesbefore beginningwork. 3. Removethe air cleanerassembly(A). 4. Removethe connectorbracket(A) onthegearbox housing,and disconnect the motor 2P connector (B).
9.8 N.m {1.0kgf.m,
5. Removethe motor {A) from the gearboxhousing.
6. Removethe O-ring (B)and discardit.
(cont'd)
17-49
EPSComponents
(cont'dl Motor RemovaUlnstallation
lnsiallation 7. Cleanthe mating surfaceof the motor (A) and gearbox. 8 x '1.25 mm 20 N.m kgt.m,7.2lbl ftl 12.0
r 0 .Installthe motor on the gearboxby engagingthe

motor shaft and worm shaft (D).Note the motor position{directionof motor wires). installation 1 1 .Beforetighteningthe bolts,turn the motor two or three times right and left about 45 degrees.lvlake sure the motor is evenlyseatedon the steering gearboxand that the O-ring is not pinchedbetlveen the mating surfaces.
q
E
1 2 .Installthe removedDartsin the reverseorder of

removal.and note these items: lvlake sure the motor 2P connectoris properly connected. lvlake surethe motor and EPSwires are not caughtor pinchedby any parts. Reconnect negativecableto the battery. the D o t h e e n g i n e o n t r o l o d u l e( E C M ) d l e l e a r n c m i ( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) . Enterthe anti-theft code for the radio station Dresets. Resetthe clock, Do the oower window control unit reset procedure(seepage 22-1241.
c].E@
L==-
Apply a thin coat of siliconegrease(P/N087338070E)tothe new O-ring(B),and carefullyfit it on the motor. 9 . Apply grease{Nippon GreaseWR-S or equivalent steeringgear grease)into the motor shaft (C).
1 3 .After installation, startthe engine,and let it idle.

Turn the steeringwheel from lock-to-lock several times. Checkthat the EPSindicatordoes not come on.
17- 5 0
SteeringGearboxRemoval
Special Tool Required Ball ioint remover,2Smm 0TlvlAC-S100200 1. Raisethe front of vehicle,and make sure it is securelysupponed. 2. Removethe front wheels. a R e m o v eh e d r i v e r ' s i r b a g ( s e e p a g e 2 3 - 1 1 3 ) . t 4 . Removethe steeringwheel (seepage 17-6). 5 . Removethe motor on the steeringgearbox (see p a g el T - 4 9 ) .
l,a.: '/ --L-
8. Removethe cotter pin (A)from the tie-rod balljoint nut {B),and loosenthe nut.
_t\
6 . Removethe driver'sdashboardlower cover (see

page20-59)and under cover {seepage20-60). 7 . Removethe steeringjoint bolts (A),and disconnect the steeringjoint by moving the steeringjoint (B) toward the column.
r0 mm HEXNUT
07MAC-S100200
9 . Separatethe tie-rod balljoint and damper steering

Repeat arm usingthe specialtool (seepage 18-10). on the other side of the vehicle. , 1 0 .G r a s pt h e r i g h ts i d et i e - r o d a n d p u l lt h e r a c ka l l t h e side, way to the passenger's 1 1 . Removethe heat shield (A) mounting bolts from the body stiffener,and let the heat shield lay againstthe exhaust.
'
(cont'd)
17-51
EPS Components
SteeringGearboxRemoval(cont'd)
12. Disconnect EPS the (A), wire harness connector 6P (B) andremove EPS the wire harness andmountino (C). bracket
1 4 . R e m o v e h e e n g i n e i r e h a r n e s s l a m p s{ A ) f r o m t w c the three mounting brackets.
-a--zi
i
F--_1
t5.
Removethe heaterhose {B)from the bracket.
(A) 1 3 . Remove ground the cable terminal fromthe gearbox steering housing.
.,/
..(
ry T,-.lt'^ \
'" \--
a b- \ H
1 6 . Open the heatervalve cableclamp (A),and disconnect heatervalve cable(B).Removethe the heatervalve (C)from the bulkhead, and move jt aside.
_ - 1 . . 1 . - '
17-52
17. Removethe bodv stiffener(A).
19. Removethe steeringstiffenerB from the right side of the steeringgearbox.
i t1-:: .,
1 8 .Removelhe steeringstiffenerA from the left side

of the steeringgearbox.
20. Lower the steeringgearbox,and rotateit so the pinion shaft points upward. 21. Removethe pinion shaft grommet (A)from the top of the torque sensor.
(cont'd)
17-53
EPS Components
SteeringGearboxRemoval{cont'd)
22. Move the steeringgearboxand tie-rod ends as an assemblyto the wheelwellopening on the passenger's side. 23. Carefullyraisethe driver'sside (pinionside)ofthe steeringgearbox(A) and tie-rod (B) until clearsthe mastercylinderand under-hood fuse relay box, then removethe steeringgearbox.Be careful not to damagethe hoses,linesand wtre narnesses.
17-51
SteeringGearboxOverhaul
ExplodedView
mm I x '1.25 ftl 20 N.m(2.0 kgf.m,7.2lbt O.RING Replace. PINION SHAFT GROMMET
CONNECTOR
RACKGUIDE
-@ . WASHEB @'--. DISC g
-sPRrNG
SCREW
' v---\
L)-RACKGUIDE 6
\.oc**u.
6^:,;
BOOT BAND Beplace. '"''/
v \>--. -*\{i#rî i
.
GUIDE \ SLTDER {îl \J" \
-'t
''
s(./t' J -l
\ \ \ stot *,tttc Renrace
SRACKET
@ I I
rtE-ROD
\ LocKscREw '162
W LOCK ASHER Replace.

54 N m {5.5kgf.m,40lbf ft)
\ BOOTBAND - Replace.
N.m l t o . sr g f m , 1 1 9 l bfft ) Beqtace.
TIE.ROD END
44 N m {4.5 kgf.m, 33 tbt.ft)
(cont'd)
17-55
EPSComponents
SteeringGearboxOverhaul(cont'dl
Special Tools Required . Locknutwrench 07ZAA-S5A0100 . Pincers, Oetiker1098or equivalent, commercially available. NOTE: . Referto the ExplodedView as neededduring this procedure. . Do not allow dust, dirt, or other foreign materialsto enter into the steeringgearbox. Eemoval 1, Removethe steeringgearbox(seepage 17-b1). Disassembly 2. Unbendthe lock washer (A). 4. Removethe stop plate (A).the 12 mm flange bolts (B),the O-rings(C),and the bracket(D)from the sleeringgearbox.
-,'i. . Loosenthe locknut(A),then removethe rack guide screw (B),sprlng (C),disc washer (D),and rack g u i d e( E )f r o m t h e s t e e r i n g e a r b o x . g
i::..:4,. , - -. -
:.--. '
Holdthe bracket(A) with one wrencn, anq unscrew both tie-rod ends (B)with anotherwrench. Remove the lockwashers.
1 7-56
6. Removethe two boot bands (A)from boot (B). Compressthe boot by hand,and apply vinyl tape (C)so the boot ends stay collapsedand pulled back
8. Installthespecialtool (A) on the lock screw (B) securely. then loosenand removethe lock screw from the steeringgearboxhousing.
07zAA-S5A0r00
1 . Attachthe yoke (A) of a universalpullerto the steeringgearboxmounts with bolts.Securely clamp the yoke in a vise as shown. Do not clamp the steeringgearboxhousingin the vise.
Removethe specialtool.
1 0 .Pull on the rackhousing(A)to remove it from the

steeringgearboxhousing,Removethe boot {B) and s l i d e rg u i d e( C )f r o m t h e c y l i n d e r .
(cont'd)
17-57
EPSComponents
SteeringGearboxOverhaul(cont'd)
'll. Checkthe slider guide for damageand cracks. Using verniercalipersto measurethe thicknessof the slider guide. lf the thicknessis lessthan service l i m i t ,r e p l a c eh e s l i d e rg u i d e , t
15. Applymultipurpose grease the indicated part to part)of theoutersurface the rack {shaded of housing. not applyto the dents Do andgrooves.
(fr--', -.---I il ( t t l
f Z,-----:-r-.--------.t.t'E-r
i @ r
25.3mm in.} {0.925
,)))
/i\
I
|
25.3 mm in.l {0.925
12
Remove discard stopring{A)onthe and the cylinder expanding with snapringpliers. by it Remove discard lockscrew{B}. and the
13. Installthe new lock screw on the rack housing. 1 4 . I n s t a l l t h e e w s t o p r i n g i n t h e g r o o v e( C ) o nt h e n cylinderby expandingit with a snap ring pliers.Be carefulnot to scratchor damagethe housing surfacewith the stop ring edges.
I
17-58
16. Set the new boot bands (A) on the band installation groovesof the boot (B) by aligningthe tabs (C)with the holes (D)of the band.Do not closethe ear of the boot band in this step.
'19. Pushthe rack housing(A) into the steeringgearbox housing(B) so the notch (C)is alignedwith the pin (D)on the bottom of the gearboxhousinginside
1 1 . Compressthe boot by hand,and apply vinyl tape (E)to the bellowsso the boot ends stay collapsed and pulled back. Passthe boot over the rack housingso the smaller diameterend of the boot facesthe steering gearboxhousing.
20. Tightenthe lock screw {A) by hand first, then install the specialtool (B)on the lock screw. Lightly tighten the lock screw.Do not tighten the lock screwto the specifiedtorque Yet.
1 8 .Attachthe yoke (A) of a universalpuller to the

gearboxhousingmounts with bolts.then securely clamp the yoke in a vise as shown. Do not clamp the steeringgearboxhousingin a vise.
21. Removethe specialtool.
(cont'd)
17-59
EPSComponents
22. Apply multipurposegreaseto the sliding surface and circumference ofthe rackguide (A),and install it onto the gearboxhousing.Wipe the greaseoff the threadedsectionofthe housrno. 25. Centerthesteeringrackwithin its stroke,and align t h e s l i d e rg u i d e( A ) w i t ht h e h o t e s( B )i n t h e b o o t ( C ) . Fit the slider guide to the boot by pressingaround the edgesof the holessecurely
'1
- .- =-1, ...'. ,. ,l
.j
2 3 . I n s t a l l t h e i s cw a s h e r( B ) w i t hi t s c o n v e xs i d e d f a c i n gt h e r a c kg u i d e .I n s t a l l t h e p r i n g( C ) . p p t y s A sealantto the middle of the threadson the rack guide screw (D),then installand tighten it to 25 N m (2.5kgf.m, 18 lbf.ft).Looselyinstatlrhetocknut (E). 24. Apply multipurposegreaseto the sliding surfaceof the slider guide (A).Keepgreaseoff of the rack-toslider guide mating surfacesand the boot-to-slider guide mating surfaces. Slidethe steeringrack all the way to left, and place t h e s l i d e rg u i d eo n t h e s t e e r i n g a c kb y a l i g n i n g h e r t bolt holes (B).
E 25 N.m 12.5 kgt.m,18tbt.ft) 26. Beforeinstallingthe bracket(D),cleanthe mating surfaceofthe 12 mm flange bolts (E)and the bracket. Coatthe new O-rings{F)with multipurpose g r e a s ea n d i n s t a l l t h e m n t h e ' 1 2 m f l a n g eb o l t s . , o m 27. Looselyinstallthe bracketon the steeringrack by tighteningthe 12 mm flange boltsto 25 N.m (2.5 kgf.m, 18lbf.ft). 28. Hold the gearboxhousingusing a yoke,then install the specialtoolon the lock screw (A).Retighten the lock screwto the specified torque values.
A
{ 1 6 . 5k g t . m , 1 1 9 l b f . f t }
29. Removethe specialtool.
17-60
30, Retighten the 12 mm flange bolts (A) to the soecified toroue value.
74 N.m (7.5kgf.m,5irlbf.ft)
t 3 4 . C l o s e h e e a r p o r t i o n( A )o f t h e b a n d s( B ) w i t h p , 1 c o m m e r c i a l l a v a i l a b l e i n c e r sO e t i k e r 0 9 8o r v e q u i v a l e n(tC ) .
5 t .
After tighteningthe 12 mm flange bolts, installa new stop plate (B)over one of the bolt heads.Be surethe tabs (C)of the stop plate are alignedwith of the flat surfaces the bolt head. from the Cleanoff any greaseor contamination o b o o t i n s t a l l a t i og r o o v e s n t h e h o u s i n g . n Expandthe boot (A) by removingthe vinyltape, grooves and fit the boot ends (B) in the installation h o n t h ec y l i n d e r o u s i n g . n 3 5 . I n s t a l l t h e e w l o c kw a s h e r( A )w i t h i t s r a d i u s e d side facing (B)the tie-rod (C),and screwthe tie-rod this stepfor the other on the bracket(D).Repeat of the tie-rod.Hold the bracketwith one side wrench,and tightenthe tie-rodsto the specified torque with anotherwrench.
32,
,,";=-. . . , . , *=,,',
(cont'd)
17-61
EPSComponents
36. Bendthe lock washer againstthe flat spots on the bracketwitha Iarge pair of pliers.
37. Adjust the rackguide screw {seepage 17-13).
17-62
SteeringGearboxInstallation
'1. Beforeinstallingthe steeringgearbox,slidethe side (right rack all the way to the passenger's direction). 4. Insertthe pinion shaft up through the bulkhead, then slip the right side of the steeringgearbox housing(A) over the mounting stud (C)on the gearboxmounting bracket.
\--' '.'', i
2 . Passthe right side of the steeringgearboxtogether

with the tie-rodsthrough the wheelwell openingon the passenger's side.Continuemoving the steering gearboxtoward the passenger's side untilthe driver'sside tie-rodend and gearboxclearsthe fuse Ielay box. mastercylinderand under-hood Lower the steeringgearbox.and move it toward g i s t h e d r i v e r ' s i d eu n t i l t h es t e e r i n g e a r b o x s l n Dosition.
:-1
. . . .
Be carefulnot to damagethe hoses,lines and wire harnesses.

10 x '1.25 mm 61 N.m
{62 kgl m, 45 lb{ ftl
Installthe steeringstiffenerB, and lightlytighten the steeringgearboxmounting nuts. Installthe steeringstiffenerA with the gearbox T m o u n t i n gb o l t s . h e nt i g h t e na l l t h e s t e e r i n g gearboxmounting hardwareto the specifiedtorque.
1 0x 1 . 2 5m m 6l N.m (6.2 kgt.m, 45 lbt.ft)
p 3 . I n s t a l l t h e i n i o ns h a f tg r o m m e t( A ) .
: . . --.-{
(cont'd )
17-63
EPSComponents
SteeringGearboxInstallation(cont'd)
(A), 7. Installthe bodystiffener andtorque the mounting bolts the specified to torque.
8 x 1.25mm 29 N.m {3.0kgf.m,22lbf.ftl
9. Reinstall heaterhose (A) on the hose bracket. the
1 0 .Installthe enginewire harnessclamps (B)to the

three harnessbrackets.
L Installthe heatervalve (A) on the bulkhead,and

connectthe heatervalve cableend (B)to the heater valve arm (C).Readjust the heatervalve cable{see page21-46).
' It . Under the steeringgearbox,installthe ground

cableterminal (A) on the steeringgearboxhousing.
9 . 8N . m {1.0kgf.m,7.2lbf.ft)
:.i.t'
L-t
9.8N.m (1.0 m, kgf 7.2tbf.ftl
17-64
(A) EPS wire harness bracket on the 12. lnstallthe (B) gearbox the housing, connect 6Pconnector and propefly.
9.8 N.m {1.0kgt m,7.2 lbt.ftl
1 4 . Centerthe steeringrackwithin its stroke. from lhe ball 1 5 . Wipe off any greasecontamination joint taperedsectionand threads.Then reconnect the tie-rod ends 1A)tothe damper steeringarms. lnstallthe ball joint nut (B) and tighten them.
,-', ''l
: 1 )
h 1 3 . I n s t a l l t h e e a ts h i e l d( A ) .
i N.m {4.4 kgf.m. 32 tbt.ftl
B 10x 1.25 mm
to.
Installthe new cotter pins (C),and bend them as shown.
,.!,..6 ''
(cont'd)
17-65
EPS Components
SteeringGearboxInstallation(cont'dl
1 7 . Installthe motor on the steeringgearbox(seepage 17-49). performthe following checks. 22. After installation, . Performthe front toe inspection. . C h e c k h e s t e e r i n g h e e ls p o k e a n g l el.f s t e e r i n g t w spokeanglesto the right and left are not equal (steering wheel and rackare not centered), correctthe engagementof the joinvpinion shaft serrations, then adjustthe front toe by turning the tie-rods,if necessarv.
1 8 . lnstallthe steeringjoint (A).and reconnect the

steeringshaft (B) and pinion shaft (C).Make sure the steeringjoint is connectedas follows: . I n s e r t t h e p p e r e n do f t h e s t e e r i n go i n t o n t o t h e j u steeringshaft (line up the bolt hole (D)with the flat portion (E)on the shaft). . Slip the lower end of the steeringjoint onto the pinion shaft (line up the bolt hole with the groove (F)around the shaft),and looselyinstallthe lower joint bolt. Be sure that the lower joint bolt is securelyin the groove in the pinion shaft. . Pull on the steeringjoint to make surethat the steeringjoint is fully seated.Then installthe upper joint bolt, and tighten it to the specified torque.Tightenthe lower joint bolt to the specifiedtorque.
\
8 x '1.25 mm 28 N.m {2.9kgf.m, 21 tbt.ft)
1 9 .Installthedriver's dashboardlower cover (see

page 20-59) and under cover (seepage 20-60).
20. lf the steeringwheel was turned,centerthe cable

reel by first rotatingit clockwiseuntil it stops.Then (abouttwo and half rotateit counterclockwise turns) untilthe arrow mark on the label points straightup. Reinstall steeringwheel (seepage the 17-8).
)1
Installthe front wheels.
17-66
EPSControlUnit Removal/ Installation

1. Removethe passenger's under panel. 2. Turn up the floor carpel,removelhe EPScontrol untr.
Tie-rodBallJoint Boot Replacement

Special Tool Required Attachment,42 mm 07OAD-P0A0100 l. Removethe boot from the tie-rod end, and wipe the old greaseoff the ball pin. 2 . P a c k h e l o w e ra r e ao f t h e b a l l p i n ( A ) w i l h f r e s h t mulr purposegrease.
d______i.l+_D
r/\-,
*-4
-6rA
the 3 . Disconnect EPScontrol unit connectors. lnstallthe EPScontrol unit in the reverseorder of removal.
E
3. Packthe interiorof the new boot (B) and lip (C)with fresh multipurposegrease. Note these items when installingnew grease; . Keepgreaseoffthe boot installation section(D) and the taperedsection(E)of the ball pin. . Do not allow dust, dirt, or other foreign materials to enterthe boot. 4. Installthe new boot (A) usingthe specialtool.The boot must not have a gap at the boot installation sections(B).After installingthe boot.checkthe ball pin taperedsectionfor greasecontamination, and wipe it if necessary. 07(lAD-P0A0100
After installation, startthe engine,and let it idle. Turn the steeringwheelfrom lock-to-lock several times. Checkthat the EPSindicatordoes not come on.
17-67
Suspension
Frontand RearSuspension
SpecialTools ............. 18-2 Component Location Index ......................................... 18-3 1. W h e eA l i g n m e n .t . . . . . . . . . . . . . . . . . . . . l . . . . . . . . . .8 - 4 18-8 WheelBearing PlayInspection End ............................ 18-9 WheelRunout Inspection .................. ... 18-10 B a l J o i n tR e m o v a l l
FrontSuspension
Knuckle/H bAVheel BearingReplacement u BallJoint Boot Reolacement.................. Stabilizer Rep|acement.................... Bar Link Removal/lnstallation Stabilizer LowerArm Removal/lnstallation ............... Damper/Spring Replacement
18-1 18-16 18-17 18-18 18-19 18-20
RearSuspension
H u bB e a r i n U n i tR e p l a c e m e . . t . . . . . . . . . . . . . . . . . . 18-26 g n. 18-28 Knuckle Reolacement 18-30 Stabilizer Replacement Bar .................... Link 18-31 Stabilizer Removal/lnstallation .......................... 18-32 Upper Arm Removal/lnstallation ............... Trailing Arm Removal/lnstallation 18-33 Damper/Spring Replacement 18-34
SpecialTools
Ref.No.
Tool Number
o
G)
07GAF-SE00100 07MAC-S100200 07746-0010500 07749-0010000 07965-SA50500 07965-SD90100
Description Hub Dis/Assembly Tool B a l lJ o i n t R e m o v e r2 8 m m , Attachment, x 68 mm 62 Driver Front Hub Dis/Assembly Tool Support Base
otv
[]
a6,l
18-2
FrontSuspension:
DAMPER/SPRING page Replacement, 18-20 STABILIZER BAR page Replacement, 18-17 STABILIZER LINK page Removal/lnstallation, 18 18
KNUCKLE/HU8/WHEEL BEARING page 18-1 Replacement, 1 Ball Joint Boot page'18-16 Replacement,
LOWEBARM page 18 19 Removal/lnstallation,
Rear Suspension:
STABILIZER BAR page Replacement. 18-30
ARM UPPER Removal/lnstallation, page'18-32
DAMPER/SPRING page'18-34 Replacement,
UNIT HUBBEARING page Replacement, 18'26 KNUCKLE page Replacement, 18-28

TRAILINGARM page 18 33 Removal/lnstallation,
18-3
WheelAlignment
The suspension can be adjustedfor front camber,front toe, and reartoe. However,each of these adjustments to are interrelated each other. For example,when you you Therefore, adjustthe toe, the camberchanges. must adjustthe front wheel alignmentwheneveryou adjustthe camberor toe.
Front Casterlnspection
fo U s ec o m m e r c i a l l a v a i l a b l e o m D u t e r i z e d u r w h e e l v c w a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t t (caster, camber,toe, and turning angle).Follow the instructions. eouiomentmanufacturer's Checkthe casterangle.lf the casterangle is not within the specification, checkfor bent or damaged susoensron comoonents. Front casterangle: 1'40't 1"
Pre-Alignment Checks
For proper inspection and adjustmentof the wheel alignment,do these checks: 1. Release parkingbraketo avoid an incorrect the measurement.
2 . Make sure the suspensionis not modified.

t 3 . C h e c k h e t i r e s i z ea n d t i r e p r e s s u r e Tire size: Front/rear: 195/60R15 Tire pressure: 230 kPa {2.3kgf/cm',33 psil Front: Rear: 210 kPa |'2.1kgf/cm', 30 psi) Checkthe runout of the wheels and tires. Checkthe suspensionball joints. (Holda wheel with your hands,and move it up and down and right and left to checkfor wobbling),
Bouncethe vehicleup and down severaltimes to the stabilize suspension.
18-4
Front CamberInspection
Use commerciallyavailablecomputerized four wheel alignmentequipmentto measurewheel alignment (caster, camber,toe, and turning angle).Follow the equipmentmanufacturer's instructions. Checkthe camberangle.lf the camberangle is not within the specification, adjustthe camber. Front camber angle: 0"30' t 45'
Front CamberAdjustment
The front cambercan be adjustedby exchangingone or both of the damDerDinchbolts with the smaller The differencebetweenthe diameteradjustingbolt(s). adjustingbolt diameterand the pinch bolt hole d i a m e t e r l l o w sa s m a l lr a n g eo f a d j u s t m e n t . a
DamDer PinchBolt:
AdiustingBoh: P/N 90188-55A-000
1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. L o o s e n h e d a m p e rp i n c h n u t sa n d b o l t s( A ) ,a n d t adjustthe camber by moving the bottom of the d a m p e rw i t h i nt h e r a n g eo f t h e d a m p e rp i n c hb o l t free play.
-+
+t
A 1 6 x 1 . 5m m 157 N.m (16.0kgf.m, 116 tbf.ftl
3 . Tightenthe boltsto the specifiedtorque.

4 . Reinstall the front wheels.Lower the front of the
t v e hi c l et o t h e g r o u n d , n d b o u n c e h e v e h i c l e a s e v e r atl i m e st o s t a b i l i z t h e s u s p e n s i o n . e l 5 . C h e c k h e c a m b e ra n g l e . f i t i s w i t h i nt h e t specification, checkthe front toe. lf it is not within go the specification, to step 6. (cont'dl
18-5
WheelAlignment (cont'd)
Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. 7 . Replace damper pinch boltswith the adjusting the bolts (A),and adjustthe camber angle. NOTE:The camberangle can be adjustedup to t 15' (centerof tolerance)by replacingone damper pinch bolt with the adjustingbolt. The camber angle can be adjustedup to a 30' by replacingboth upper and lower damper pinch bolts with the adjustingbolts.
RearCamber Inspection
Use commercially-available computerized four wheel alignmentequipmentto measurewheel alignment (caster, camber,toe, and turning angle).Followthe instructions. eouiDmentmanufacturer's l C h e c k h e c a m b e ra n g l e . f l h e c a m b e ra n g l ei s n o t t within the specification, checkfor bent or damaged susDenston comoonenrs. Rearcamberangle: 0 0"55' t 45'
NOn-dEl
Do not loosenthe specialb o l t so n t h e t r a i l i n g r m . a
'rntr
.:r,//
i,iY. a
1 5 x 1 . 5m m 157N.m {16.0kgt.m, 116tbf.ft)
8 . Tightenthe boltsto the specified torque. Reinstall front wheels.Lower the front of the the vehicleto the ground, and bouncethe vehicle severaltimes to stabilize the suspension.
1 0 .Checkthe camber angle.lf it is within the

specification, checkthe front toe. and adjust it if necessary. it is not within the specification, lf readjust,and recheck. the camber anglecannot lJ checkfor bent or be adjustedto the specification, damagedsuspension components.
18-6
Front Toe Inspection/Adjustment

Use commercially-available four wheel computerized a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t t w (caster, camber,toe, and turning angle).Followthe equipmentmanufacturer's instructions, 1. Centerthe steeringwheel spokes. 2. Checkthetoe.lf it is not with in the specif ication,go to step 3. Front toe-in: 0 t 3 mm {0 t 0.12in.) 3. Loosenthe locknut(A) while holdingthe tie-rod end ( B) .
RearToe Inspection/Adiustment
Use commercially-available computerized four wheel a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t t w (caster, camber,toe, and turning angle).Followthe equipmentmanufacturer's instructions. 1 , R e l e a s eh e p a r k i n g r a k e . t b go 2. Checkthetoe. lf it is not within the specification. to step 3. Reartoe-in {inspection): 1 1 3 mm (0.04a 0.12 in.) 3. Loosenthe self-locking (A)while holdingthe nut adjustingbolt (B).
1,;
A 1 4 x 1 . 5m m ,14N.m (a.5 kgt m,33 lbt.ftl
Do not loosenlhe specialbolts (C)on the lower arm to adjustthe alignment.
Turn the tie-rod(C)untilthe toe is correct. 5 . After adjusting, tighten the locknutwhile holding the tie-rodend. Make sure the toe settingdoes not change.
4. Replace self-locking with a new one, and nut the l i g h t l yt i g h t e n . nut NOTE: Always use a new self-locking whenever it has been loosened. Turn the adjustingbolt until the toe is correct. Rear toe.in (adiustment): 2 ' , mm {0.08 "' ,. in.} nut Tightenthe self-locking to the specifiedtorque w h i l eh o l d i n g h e a d j u s t i n g o l t . t b
(cont'd )
18-7
WheelAlignment (cont'dl
TurningAngleInspection
Use commercially-available computerized four wheel a l i g n m e ne q u i p m e ntto m e a s u r e h e e la l i g n m e n t t w (caster. camber,toe, and turning angle).Followthe equiDmentmanufacturer's instructions. 1 . T u r nt h e s t e e r i n g h e e lf u l l y t o t h e r i g h t a n d l e f t w while applyingthe brake,and checkthe turning anglesof both front wheels, lf the turning angle is not within the specification the inward turning or anglesdiffer betweenthe right and left side,go to steD2. Turning angle: lnward: 34'00'+ 2' Outward: 28'00' {reference)
WheelBearingEnd PlayInspec'tion
1. Raiselhe vehicle,and support it with safetystands in the proper location(seepage 1-8).Removethe wheels. 2. Installsuitable f lat washers (A) and wheel nuts,and tighten the nuts to the specified torque to hold the b r a k ed i s cs e c u r e l y g a i n s t h e h u b . a Front:
108N.m (11.0kgf.m, 80 rbf.ft)
Rear: \
Checkthe toe. lf it is correct,but the turning angle is not within the specification, checkior bent or damagedsuspension components,
108N.m (11.0kgf.m,80 lbf.ft)
3 . S e t u p t h e d i a lg a u g ea g a i n s t h e h u b f l a n g ea s shown, and measurethe bearingend play moving the brakedisc inward and outward. Bearing end play: Standard: Front/rear: 0 0.05 mm {0 0.002in.} 4. lf the bearingend play is more than the standard, replacethe wheel bearing.
18-8
WheelRunoutInspection
1 . Raisethe vehicle,and supportit with safetystands in the proper location(seepage 1-5,. Checkfor a bent or deformedwheel. Set up the dial gauge as shown, and measurethe axial runout by turning the wheel. Front and rear wheel axial runout: Standard: Aluminum wheel: 0-0.7 mm (0-0.03 in.) Servicelimit: 2.0 mm {0.08in.l 4 . R e s e t h e d i a l g a u g e t o t h ep o s i t i o n h o w n ,a n d s measurethe radial runout. Front and rear wheel radial runout: Standard: Aluminum wheel: 0 0.7 mm (0 0.03io.) 1.5 mm {0.06in.} Servicelimit:
lf the wheel runout is not within the specification, checkthe wheel bearingend play (seepage 18-8), and make sure the mating surfaceson the brake disc and the insideof the wheel are clean. lf the bearingend play is within the specification but the wheel runout is more than the servicelimit. replacethe wheel.
18-9
BallJointRemoval
Special Tools Required Ball ioint remover.2Smm 07MAC-SL00200 3. Loosenthe pressurebolt (A),and installthe special tool as shown. Insen the jaws carefully,making sure not to damagethe ball joint boot. Adjustthe jaw spacingby turning the adjustingbolt (B). 10 mm HEXNUT
Always use a ball joint removerto disconnect ball a joint. Do not strikethe housingor any other part of the ball joint connectionto disconnectit. '1, I n s t a la h e x n u t ( A ) o n t o t h e t h r e a d s o f t h e b a l l j o i n t l { B ) .M a k es u r et h e n u t i s f l u s hw i t h t h e b a l l j o i n tp i n end to preventdamageto the threadedend of the b a l l i o i n to i n .
07MAC-S100200 After adjustingthe adjustingbolt, make sure the head (C)of the adjustingbolt is in the position shown to allow the jaw to pivot. 5 . With a wrench,tighten the pressurebolt until the a b a l li o i n t p i n p o p sl o o s ef r o m t h e s t e e r i n g r m o r type knuckle.lf necessary. apply penetrating lubricantto loosenthe ball joint pin
2 . Apply greaseto the specialtool on the areasshown

(A).This will easeinstallation the tool and of preventdamageto the pressurebolt {B)threads. NOTE:Do not use pneumaticor electrictools on the pressurebolt.
6 . Removethe tool, then removethe nut from the end

o f t h e b a l l j o i n tp i n ,a n d p u l l t h eb a l l j o i n to u t o f t h e s t e e r i n g r m o r k n u c k l eI.n s p e c t t h e a l l j o i n tb o o t , a b and replaceit if damaged.
18-10
FrontSuspension
Knuckle/Hub/Wheel BearingReplacement
ExplodedView
WHEELBEARING Replace. SNAPRING
5 mm SCREWS Replace.
FLAT SCREWS 6x1.0mm 9.8Nm (1.0 kgf.m,7.2 lbf.ft)
KNUCKLE
Checkfor delormation a n oo a m a g e .
SPLASHGUARD Checkfor corrosion. delormation. and damage. if Replace rusted.
BRAKE DISC
NUT SPINDLE 22 x 1.5mm 181 m N (18.5kgf.m, 134 lbt.ft) Replace.
'--7.l
'tq
I A p p ya s m a la m o u no f e n g i n o i l l t e to theseating surface.
lcont'd)
18-11
FrontSuspension
BearingReplacement Knuckle/Hub/Wheel {cont'dl
Special Tools Required . Hub dis/assembly tool 07GAF-SE00100 . Balljoint remover,2Smm 0TlvlAC-S100200 . Attachment62 x 68 mm 07746-0010500 . Driver07749-0010000 . SuDDort base07965-5D90'100 1. Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). 2. Removethe wheel cap,wheel nuts, and front wheel.
1 0 8N . m (11.0kgf m, 80 rbf.ftl
5. Raisethe stake(A),and removethe spindle nut (B).
' ,
B 22x1.5mm 181 .m N ('18.s kgf.m, 134tbt.ft)
6. Removethe brakedisc retainingflat screws(A).
3. Removethe brakehose bracketmounting bolt (A). A 8 x 1.25 mm 22N.m 12.2ksl.m, 26 tbf.ftl
A 6x1.0mm 9.8 N.m {1.0kgt.m, 7.2 tbl.ttl
B 12 x 1.25mm 108N.m {11.0kgf.m, 80 rbf.ftl
7. Screwtwo 8 x 1.25mm bolts (B)into the discto oush it awav from the hub. Turn each bolt two turns at a time to preventcockingthe disc excessively,
4 . Removethe caliperbracketmounting bolts (B),and removethe caliperassembly(C)from the knuckle. To preventdamageto the caliperassemblyor brakehose,use a short pieceof wire to hang the Do caliperassemblyfrom the undercarriage. not twist the brakehose with force.
18-12
8. Removethe flange bolt {A) andwheel sensor(B) from the knuckle.Do not disconnect wheel the sensorconneclor.
A 5x1.0mm 9.8 N.m (1.0kgl.m, 7.2 tbt.ftl
10. Removethe lock pin (A)from the lower arm ball joint, and removethe castlenut (B). insertthe lock pin into NOTE:During installation, t t h e b a l l j o i n tp i n f r o m t h e l n s i d e o t h e o u t s i d e f o the vehicle.The closedend of the lock Din must be i n t h e r a n g es h o w n .
07MAC-SL00200 'R.
--....-"
12x 1.25 mm 59 69N m
(6.0 7.0 kgl m, 43 -51 lbf tt)
9 . Removethe flange nut (A) while holdingthe joint pin (B)with a hex wrench (C),and disconnect the i s t a b i l i z el r n k{ D )f r o m t h e l o w e ra r m ( E ) .
1 1 .Disconnect lower arm from the knuckleusing the the specialtool (seepage l8-10).
12. Loosenthe damper pinch bolts (A) while holding

the nuts (B),and removethe bolts and nuts.
10 x 1.25mm kgf.m,29lbf.ft) 39 N.m (,1.0
'13.Removethe driveshaftoutboardjoint
{C)fromthe knuckle(D) by tappingthe driveshaftend (E)with a plastichammer while drawing the knuckleoutward, then removethe knuckle. NOTE:Do not Dullthe driveshaftend outward.The driveshaftjoint may come off.
(cont'd)
18-13
FrontSuspension
(cont'd) Knuckle/Hub/Wheel Bearing Replacement
14. Separate the hub (A)from the knuckle(B) usingthe specialtool and a hydraulicpress.Be carefulnotto deform the splashguard. Hold onto the hub to keep it from falling when pressedclear. 07GAF-SE00100 g 1 6 . R e m o v e h e s n a pr i n g ( A )a n dt h e s p l a s h u a r d( B ) t ( fromtheknuckleC).
./
.-''-
.|
a'\s
1 1 . Pressthe wheel bearing(A) out of the knuckle(B usingthe specialtool and a press. 1 5 . Pressthe wheel bearinginner race(A) off of the h u b ( B )u s i n gt h e s p e i i a l t o o l , c o m m e r c i a l l y a a v a i l a b l e e a r i n g e p a r a t o( C ) , n d a p r e s s . b s r a 07GAF-SE00100 \ Pross
+
\
\r
Press
18-14
i a 1 8 . W a s ht h e k n u c k l e n d h u b t h o r o u g h l y n h l g hf l a s h point solventbefore reassembly. 1 9 . Pressa new wheel bearing(A) into the knuckle(B) usingthe old bearing(C),a steel plate {D).the specialtool, and a press.Placethe wheel bearing on the knucklewith the packseal side facing (metal color)toward the inside.Be careful not to damage the sleeveof the packseal.
u 2 2 . P r e s s n e w h u b b e a r i n g n i t{ A )o n t o t h e h u b ( B ) a usingthe specialtools and a press.
"-t-_"*,,''
_,.' . . a-.) ../

..-.
u be k 23. I n s t a l l t h e n u c k l e / h u b / h u b a r i n g n i t i n t h e reverseorder of removal,and notethese items: . B e c a r e f u n o t t o d a m a g e t h e a l l j o i n tb o o t w h e n b l i n s t a l l i n gh e k n u c k l e . t . Tightenall mounting hardwareto the specified v lOrque alues. . Torquethe castlenut to the lower torque then tighten it only far enoughto specification, a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t align the castlenut by looseningit. . Installa new look pin on the castlenut after torquing. . U s ea n e w s p i n d l e u t o n r e a s s e m b l y . n . B e f o r e n s t a l l i n gh e s p i n d l e u t ,a p p l ya s m a l l n i t amount of engine oil to the seatingsurfaceof the nut. After tightening,use a drift to stakethe a n s p i n d l e u t s h o u l d e r g a i n st h e d r i v e s h a f t . . B e f o r e n s t a l l l n gh e b r a k ed i s c ,c l e a nt h e m a t i n g i t surfaceof the front hub and the insideof the b r a k ed i s c . . B e f o r e n s t a l l i n gh e w h e e l ,c l e a nt h e m a t i n g t i surfaceof the brakedisc and the insideof the wneet. . Checkthe front wheel alignment,and adjustit if (seepage 18-4). necessary
( i 2 0 . I n s t a ltlh e s n a pr i n g ( A )s e c u r e l yn t h e k n u c k l e B ) .
D kgf.m,4lbf ft) 6 N.m10.6 lnstallthe splashguard (C),and tighten the screws (D)to the specifiedtorque.
18-15
FrontSuspension
BallJoint Boot Replacement
Special Tools Required Front hub dis/assembly tool 07965-5450500 1. Removethe boot. 2. Packthe interiorand lip (A) of a new boot with fresh grease.Keepthe greaseoff of the boot-to-knuckle mating surfaces(B). Pressthe boot with the specialtool until the bottom seatson the knuckle(A) evenly around. pross 07965-SA50500 Instllthe boot onto the ball joint pin, then squeeze it gentlyto force out any air. Do not let dlrt or other foreign materialsget into the boot.
rffi
-
-6r
B
t
6 . After installinga boot,wipe any greaseoff the exposedportion of the ball joint pin.
Wipe the greaseoff the taperedsectionof the pin (C),and packfresh greaseonto the base (D).
18-16
StabilizerBar Replacement
1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. nuts (A)while holdingthe Removethe self-locking joint pin (B)with a hex wrench (C),and disconnect i r t h e s t a b i l i z el r n k s( D ) f r o mt h e s t a b i l i z eb a r ( E )o n the right and left. D bar in the reverseorder of 4. lnstallthe stabilizer removal.and note these itemsl . Use new self-locking nuts on reassembly. . Note the right and left directionof the stabilizer oar. . A l i g nt h e e n d so f t h e p a i n tm a r k s( A )o n t h e bar stabilizer with each end of the bushings(8). . Note the forelaft directionofthe bushing holders. . Referto stabilizerLink Replacement connect to t h e s t a b i l i z eb a r t o t h e l i n k s( s e ep a g e1 8 - 1 8 ) . r
''i] ,.'i i
. i.',.:-l I
_:
,r',' \'r'j-- r-'1
i-ii::;i
;4-llt,-'j--;
i :.. i'
1 0x 1 . 2 5m m 39Nm (4.0 kgf m, 29 tbl,ft)
Removethe flange bolts {A) and bushingholders {B),then removethe bushings(C)and the stabilizer b a r( D ) .
FORWARD
A 1 0x 1 . 2 5m m 39Nm (4.0ksf.m, 29lbl.ftl
18-17
Front Suspension
StabilizerLink Removal/lnstallation
1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe self-locking (A) and flange nut {B) nut joint pin (C)with a hex while holdingthe respective wrench (D),and removethe stabilizer link (E). 4. Installthe self-locking and flange nut, and nut lightlytighten them. NOTE:Use a new self-locking on reassembly. nut 5. Placethe floor jack under the lower arm balljoint, and raisethe suspension load it with the vehicle's to weaght.
mri-dEl
Do not placethe jack againstthe lower arm balljoint. 6. Tightenthe self-locking (A) and flange nut (B)to nut the specified torque valueswhile holdingthe joint pins (C)with a hex wrench (D). respective
A 10 x 1.25mm 38 N.m (3.9kgf m,28 lbf.ft)
\
3 . l n s t a l l t h e t a b i l i z el r n k( A )o n t h e s t a b i l i z eb a r { B ) s i r and lower arm (C)with the joint pins (D)set at the centerof their rangeof movement.
..,
B 10 x 1.25mm 39 N.m {4.0kgf.m,29lbf.ft}
1 . After 5 minutesof driving, re-tighten self, the lockingnut again to the specified torque.
18-18
Lower Arm Removal/lnstallation

SpecialToolsRequired Balljoint remover,2Smm 07|MAC-S100200 1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe flange nut (A) while holdingthe joint pin {B)with a hex wrench (C),and disconnect the i s t a b i l i z el r n k( D ) f r o mt h e l o w e ra r m ( E ) . 5. Removethe flange bolts (A),and removethe lower arm {B}.
1 4x 1 . 5m m kgf.m,61 lbf.ft) 83 N.m(8.5 6. Installthe lower arm in the reverseorder of removal,and note these items: . Be carefulnot to damagethe ball joint boot when connectingthe lower arm to the knuckle. ' Tightenall mounting hardwareto the specified torque values, . F i r s t i n s t a la l l t h e c o m p o n e n t s n d l i g h t l y t i g h t e n a l to the bolts and nuts.then raisethe suspension load it with the vehicle'sweight beforefully tighteningit to the specifiedtorques. . Torque the castlenut to the lower torque then tighten it only far enoughto specification, align the slot with the ball joint pin hole. Do not allgn the castlenut by looseningit. . Installa new lock pin on the castlenut after torquing. . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneet. . C h e c k h e w h e e la l i g n m e n ta n d a d j u s t i t i f , t (seepage '18-4). necessary
mm 10x 1.25 39 N.m {4.0kgf m, 29 lbt.ft)
3 . Removethe lock pin (A) from the lower arm ball

joint, and removethe castlenut (B). insertthe lock pin into NOTE:During installation, the ball joint pin from the insideto the outsideof the vehicle.The closed end of the lock pin must be i n t h e r a n g es h o w n .
6--__
@a
oTMAc-sloo2oo
1 2x 1 . 2 5 m m 59 69Nm kgt-m, 16.0-7.0 43 51 lbf.ft)
the 4 . Disconnect lower arm from the knuckleusing t h e s p e c i atl o o l ( s e ep a g e1 8 - 1 0 ) .
18-19
Front Suspension
Damper/Spring Replacement
ExplodedView
/.' â ta ,/ ,,/ NUT ./ SELF-LOCK|NG 12 x 1.25inm 44 N.m {4.5kgt.m,33lbf.ftl neDtace.
e9 -.-
1, @-:'\--""' lF \-:-./ - ,
MOUNTING - DAMPER BASE checkfor delormation
E9-
DAMPER MOUNTING BEARING
UPPER SPRING MOUNTING CUSHION Check deterioration for anooamage,
DAMPER SPRING for Check lreelength.
DAMPER UNIT Checkfor oil leaks, gas leaks, and smooth operatron.
18-20
ToolsRequired Special mm Balljoint remover,28 07MAC-S100200
5. Removethe damper pinch bolts (A)while holding t h e n u t s( B ) .
Removal
1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe cotterpin (A) from the tie-rod end ball ioint, and removethe nut (B).
6. Removethe flange nuts (A)from the top ofthe damper, A 'l.25 mm 10x 10 mm HEXNUT 07MAC-S1002000 tie-rodend from the steeringarm Disconnectthe o n t h e d a m p e ru s i n gt h e s p e c i a l t o o(l s e ep a g e1 8 1 0) . 4. Removethe bolts,and removethe wheel sensor harnessbracket{A) and brakehose bracket(B) the from the damper.Do not disconnect wheel sensorconnector. A
6x1.0mm x 1.25nm
7. Lower the lower arm, and removethe damper ( assemblyB).
/.8
(cont'd)
18-21
FrontSuspension
(cont'd) Damper/Spring Replacement
Disassembly/lnspection
1 . C o m p r e s sh e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y t availablestrut spring compressor(A) accordingto the manufacturer's instructions. then removethe s e l f - l o c k i nn u t ( B ) w h i l eh o l d i n g h e d a m p e rs h a f t g t (C)with a hex wrench (D).Do not compressthe spring more than necessary removethe nut, to Reassemble the pans, exceptfor the upper all s p r i n gs e a ta n d s p r i n g .
4. Compress the damper assemblyby hand,and
checkfor smooth operationthrough a full stroke. both compressionand extension. The damper should extend smoothly and constantlywhen compressionis released. it does not, the gas is lf leakingand the damper should be replaced.
Release pressure the from the strut spring compressor, then disassemble damper as the shown in the ExplodedView.
C h e c k o r o i l l e a k s a b n o r m a n o i s e sa n d b i n d i n g f , l , during thesetests.
18-22
FrontSuspension
(cont'dl Damper/Spring Replacement
Right side:
Installation
1. Lower the lower arm, and positionthe damper assemblyin the body, Turn the damper mounting baseso the "AL" or "AR" mark (A)facestoward the outsideof the vehicle. B 10x 1.25 mm ,14 N.m kgt.m,33 lbf.ft) {4.5
Hold the bottom of the damper with your hand,and compressthe spring. Do not compressthe spring excessively.
9 . I n s t a l l t h e 2 m m n u t ( A )o n t h e d a m p e rs h a f t( B ) . 1
Hold the damper shaft with a hex wrench (C),and tighten the 12 mm nut to the specifiedtorque.
,1,6
Looselyinstallthe flange nuts (A) onto the top of the damper.
(4.5 kgt.m, 33 lbf ft)
1 0 .Remove damper the assembly fromthe strutspring compressor.
18-24
, 3 . P o s i t i o nh e d a m p e ro n t h e k n u c k l ea n d i n s t a l l t h e t new damper pinch bolts (A) and nuts (B),and lightlytighten the nuts.
8. Connect the tie-rod end to the steeringarm, and torque. Install tightenthe nut (A)to the specified the cotterpin (B)after tightening,and bend lts end asshown.
B 1 6 x 1 , 5m m 157N.m (16.0kgt m, 116tbt.ftl
4 . P l a c e h e f l o o rj a c ku n d e rt h e l o w e ra r m b a l l j o i n t , t to and raisethe suspension load it with the vehicle's weight.
Do not placethe jack againstthe lower arm balljoint. 5 . Tightenthe flange nuts on the top of the damperto the specifiedtorque. Tightenthe damper pinch nuts to the specified torque. 1 . Installthe brakehose bracket(A) and the wheel sensorharnessbracket(B)onto the damper,and torque. tighten the bolt to the specified 9.8N.m kgf.m, 7.2lbf.ftl 11.0 22N|rl. kgI 12.2 m, 16rbr,ftl
9. Cleanthe mating surfaceofthe brakedisc and the insideof the wheel,then installthe front wheels. t , 1 0 . C h e c k h e w h e e la l i g n m e n ta n d a d j u s t i t i f necessary {seepage 18-4).
18-25
RearSuspension
Hub BearingUnit Replacement
Exploded View
SPLASHGUARD Check deformation. for
x 1.0 mm 9.8 N.m (1.0kgf.m,?1 lbf ftl
Checkfor wear and damage.
',[ ',, / -o ' 0 \
KNUCKLE
Checkfor delormation.
un
Y
HUBBEARING UNIT Check faultymovement for andwear.
6x1.0mm 9,8 N.m {1.0kgf.m,7 lbf.ft} HUB CAP Replace. NUT SPINDLE 22 x 1.5mm 181 N.m {18.5kgt.m, 134lbf.ft} Beplace.
-A
T
Appy a small amount oI engineoil to the seatingsurface.
18-26
1 . Raisethe rear of the vehicle,and support it with 'l-8). safetystandsin the proper location(seepage Removethe wheel cap. wheel nuts, and rearwheel.
Release parkingbrakelever. the 5 . Removethe brakehose mounting bolt (A). B 1 0x 1 . 2 5 m m 55Nm kgf {5.6 m.41lbf.ft}
108N.m(11.0 kgf.m,80 ftl lbf Removethe hub cap (A), raisethe stake(B),and n remove hespindle ut(C). t (2.2 m, 16lbt.ftl kgt Removethe caliperbracketmounting bolts (B),and hang the caliper(C)to one side.To preventdamage to the caliperor brakehose,use a short pieceof f w i r e t o h a n gt h e c a l i p e r r o m t h e u n d e r c a r r i a g e . 7 . Removethe brakedisc retainingscrews(A).
O
\
A
ap
2 2 x 1 , 5m m 1 8 1N . m (18.5kgf.m, 134lbf.ftl
t
\
I A 6x1.0mm 9 . 8N . m (1.0kgf.m,?.2lbf.ftl
Screwtwo 8 x 1.25mm bolts (B) into the disc {C)to oush it awav from the hub. Turn each bolt two turns at a time to preventcockingthe disc excessively. Removethe brakedisc.
(cont'd)
18-27
Rear Suspension
Hub Bearing Unit Replacement (cont'd)
9. Removethe hub bearingunit (A) from the spindle.
Knuckle Replacement
1 . Raisethe rear of the vehicle,and suppon it with safetystandsin the proper location(seepage 1-8). Removethe rear wheels. R e m o v e h e b r a k ed i s ca n d h u b b e a r i n g n i t( s e e t u s t e p 1 o n p a g e1 8 - 2 7 ) . Removethe flange bolts (A) and splashguard (B) from the knuckle.
,=,,,
1 0 .Installthe hub bearingunit in the reverseorder of

removal,and note these items: . Tightenall mounting hardwareto the specified torque values, . Beforeinstallingthe brakedisc,cleanthe mating surfaceot the hub and the insideof the brake disc. . Use a new spindle nut on reassembly. . After tightening,use a drift to stakethe spindle n u t s h o u l d e r g a i n st h e s p i n d l e . a . Use a new hub cap on reassembly. . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneel.
kgf.m, lbf ft) 7.2 11.0 4. Removethe wheel sensor(A),braKenose m o u n t i n gb r a c k e ( B ) ,a n d p a r k i n g a b l em o u n t i n g t c bracket(C)from the knuckle.Do not disconnect the wheel sensorconnector.
tt
8 x 1.25 mm 22 N.m kgf {2.2 m, 16lbf ftl
6x1.0mm 9.8 N,m {I.0 kgt.m,7.2lbf ft)
18-28
5. Placethe floor jack underthe trailing arm {A),to support it.
k i o 9 . I n s t a l l t h e n u c k l e n t h e r e v e r s e r d e ro f r e m o v a l , and note these items: . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s , n d l n a lightlytighten the bolts and nuls,then placea floor jack under the lower a rm, and raisethe suspension load it with the vehicle'sweight to beforefully tighteningthe bolts and nutsto the specified torque values. . Align the cam positionsof the adjustingbolt (A) and adjustingcam (B)with the markedpositions w h e nt i g h t e n i n g . . Use a new self-locking on reassembly. nut . T i g h t e n l l t h e m o u n t i n gh a r d w a r eo t h e t a specifiedtorque values. . U s ea n e w s p i n d l e u t o n r e a s s e m b l y . n . B e f o r e n s t a l l i n gh e s p i n d l e u t ,a p p l ya s m a l l n i t amount of engine oil to the seatingsurfaceof the nut. After tightening,use a drift to stakethe a s p i n d l e u t s h o u l d e r g a i n st h e d r i v e s h a f t . n . Beforeinstallingthe brakedisc,cleanthe mating surfaceof the hub and the insideof the brake drsc. . U s ea n e w h u b c a po n r e a s s e m b l y . . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wheel. . Checkthe wheel alignment,and adjust it if necessary {seepage 18-4).
Do not placethe jack againstthe plate sectionof the lower arm, Be carefulnot to components. damageany suspension
12x 1.25 mm 59 N.m {6.0ksf.m.43lbf.ft)
the Removethe flange bolt (B),and disconnect upper arm {C)from the knuckle. 1 . Mark the cam positionsof the adjustingbolt (A) and nut adjustingcam (B),the removethe self-locking {C},adjustingcam, and adjustingbolt. Discardthe nut. self-locking
12x 1.25 mm 59 N.m {6.0kgf m,43lbl.ft)
12x 1.25 mm 59Nm(6.0kgf.m, 43 tbI.ftl
8. Remove the flange bolt (D), and remove the k n u c k l e{ E ) .
18-29
RearSuspension
StabilizerBar Replacement
1 . Raisethe rear of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe rearwheels. Removethe self-locking nuts (A)while holdingthe joint pins (B)with a hex wrench (C),and disconnect t h e s t a b i l i z el r n k s( D )f r o m t h e s t a b i l i z eb a r { E )o n i r the right and left.
A 1 0 x 1 . 2 5m m 38 N.m (3.9 kgf.m,28 lbf.ft)
4. Inslallthestabilizerbar in the reverseorder of removal,and notethese items: . Use new self-locking nuts on reassembly. . lMake sure the right and left ends of the stabilizer bar are installedon their respective sidesof the vehicle. . Align the ends of the paint marks (A) on the ( s t a b i l i z eb a r w i t h t h e b u s h i n g s B ) . r . Referto StabilizerLink ReDlacement connect to t h e s t a b i l i z eb a rt o t h e l i n k s{ s e ep a g e1 8 - 3 1 ) . r
'..: \.... .
Al
.----'';-r'--\---r-
-tt'.,'t),
Removethe flange bolts (A) and bushing holders (B),then removethe bushings{C)and the stabilizer bar(D).
18-30
StabilizerLink Removal/lnstallation
1. Raisethe rear of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe rearwheels. 2. Removethe self-locking (A) and flange nut (B) nut joint pin {C)wilh a hex while holdingthe respective wrench (D),and removethe stabilizer link (E). 4. lnstallthe self-locking and flange nut, and nut lightlytighten them. NOTE:Use a new self-locking on reassembly. nut Placea jack under the trailing arm at the knuckle side end. and raisethe suspension load it with lo the vehicle'sweight. Tightenthe selflocking nut (A) and flange nut {B)to the specifiedtorque valueswhile holdingthe joint pins (C)with a hex wrench (D). respective
A 1 0 x 1 . 2 5m m 38 N.m 13.9 kgf.m,28lbf.ftl
\,1 i
i'-r d
*l'',:
3 . I n s t a l l t h e t a b i l i z el r n k( A )o n t h e s t a b i l i z eb a r { B ) s i r a n dt r a i l i n g r m ( C )w i t h t h e j o i n t p i n s( D )s e ta t t h e a centerof each moving range,
7. After 5 minutesof driving, re-tighten selfthe lockingnut again to the specified torque.
18-31
Rear Suspension
UpperArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and supportlt with safetystandsin the proper location(seepage 1-8). Removethe rearwheels. P l a c e f l o o rj a c ku n d e rt h e t r a i l i n ga r m , a n d a supportthe suspensron. Removethe flange bolt (A) and wheel sensor h a r n e s s r a c k e( B ) . b t 5. Installthe upper arm in the reverseorder of renloval,and note these items: . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s n d l n a lightlytighten the bolts and nuts,then placea j a c ku n d e rt h e t r a i l i n g r m , a n d r a i s e h e a t suspension load it with the vehicle'sweight to beforefully tighteningthe bolts and nuts to the specifiedtorque values. . T i g h t e n l l t h e m o u n t i n g a r d w a r eo t h e a h t specified torque values. ' B e f o r e n s t a l l i n gh e w h e e l ,c l e a nt h e m a t i n g i t surfaceof the brakedisc and the insideof the wheel. . Checkthe wheel alignment,and adjustit if (seepage 18-4). necessary
8 x 1.25 m m 22 N.m(2.2 kgf.m, 16rbf.ft) Removethe flange bolts (A),and removethe upper arm{B).
1 2 x 1 . 2 5m m 59 N.m {6.0kgf.m, ir3 lbf.ft)
1 2x 1 . 2 5 m m 59 N.m 16.0 m, kgf 43 tbf.ft)
18-32
Trailing Arm Removal/lnstallation

1 . Raisethe rear of the vehicle,and suppon it with safetystandsin the proper location(seepage 1,8). Removethe rearwheels. Removethe knuckle(seepage 18-28). 7. Removethe trailing arm rear mounting bolt (A).
Do not loosenthe specialbolts (B)on the t r a i l i n ga r m .

A 12 x 1.25mm
3 . P l a c e h e f l o o rj a c ku n d e rt h e t r a i l i n g r m ( A )t o t a
support it.
59 N.m
-----\':,'.ttg
'.,--1..-r.':1
B 1 0x 1 . 2 5 m m 38Nm (3.9 kgl.m, 28 tbf.ftl
1 2x 1 . 2 5 m m 61N m (6.2 m. kgt 4s tbf,ft)
8 . Lower the jack,and removethe trailing arm. 9 . Installthe trailing arm in the reverseorder of
removal,and note these items: . F i r s ti n s t a l a l l t h e s u s p e n s i o c o m p o n e n t s n d l n a lightly tlghtenthe bolts and nuts,then placea j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s e h e t suspension load it with the vehicle'sweight to beforefully tighteningthe bolts and nuts to the specified torque values. . Tightenallthe mounting hardwareto the specif torque values. ied . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneei. . Checkthe wheel alignment,and adjust it if (seepage'18-4). necessary
Removethe flange nut (B),and disconnect the s t a b i l i z el r n k( C )f r o m t h e t r a i l i n g r m . i a Removethe flange bolt {D),and disconnect the d a m p e r( E )f r o m t h e t r a i l i n g r m . a Removethe trailing arm front mounting bolts (A).
,'a':r
A 12 x 1.25Jnm 108N.m {11.0kgt.m, 80 tbf.ft)
18-33
RearSuspension
Replacement Damper/Spring
ExplodedView
I
NUT SELF-LoCK|NG 10 x 1.25mm 29 N m {3.0kgf.m,22 lbf.ft} Replace.
9-----.---.-. -=\
ItI t=J
DAMPER MOUNlING COLLAR
DUSTCOVER
-tr) \ qnJ/
9...
E Z n \ lt \
BUMP sroP PLArE
/t
SPRING DAMPER Checkfor weakened and damage. compression
\ BUMPSTOP
and damage.
tor Check weakness
OAMPER UNIT for Check oil leaks, gas leaks, and smooth operation,
18-34
Removal
1. Raisethe rear of the vehicle.and support it with safetystandsin the proper location(seepage 1-8). Removethe rearwheels.
5. Removethe damper assemblyfrom the body.
i
2. Removethe flange bolt {A) from the bottom of the damper.
3 . Removethe rear bulkheadcover (seepage 20-51).

Removethe flange nuts (A) from the top of the damper in the trunk.
( c o n td )
18-35
RearSuspension
(cont'dl Damper/Spring Replacement
Disassembly/lnspection
1 . C o m p r e s sh e d a m p e rs p r i n g i t h a c o m m e r c i a l l y t w to availablestrut compressor(A) according the instructions. then removethe selfmanufacturer's l o c k i n g u t ( B ) w h i l eh o l d i n g h e d a m p e rs h a f t( C ) n t with a hex wrench (D).Do not compressthe spring to more than necessarv removethe nut.
Reassembly
1 . I n s t a la l l t h e p a r t s e x c e p t t h e e l f - l o c k i nn u t o n t o l s g the damper unit by referringto the ExplodedView. Align the bottom of the spring {A} and the stepped part of the lower spring seat (B),and align the d a m p e rm o u n t i n gb a s ea s s h o w n ,
,, '161\
from the strut spring Release pressure the then disassemble damper as the compressor, shown ln the ExplodedView.
?
7fi)1,, \3P qY/
"
I n s t a l l t h e a m p e ra s s e m b l y n a c o m m e r c i a l l y o d availablestrut spring compressor(C). C o m p r e s t h e d a m p e rs p r i n gw i t h t h e s p r i n g s compressor. Installthenew self'lockingnut (A) on the damper shaft.
Reassemble the pans, exceptfor the spring. all
4 . Compress the damper assemblyby hand,and
checkfor smooth operationthrough a full stroke, The damper both compressionand extension. should extend smoothly and constantlywhen lf compressionis released. it does not, the gas is leakingand the damper should be replaced.
10 x 1.25mm 29Nm (3.0kgt m,22 lbt.ft)
5. Hold the damper shaft {B)with a hex wrench (C), nut and tighten the self-locking to the specified torque. Checkfor oil leaks,abnormal noises,or binding during thesetests.
18-36
Installation
1. Positionthe damper assemblyin the body. Note the directionof the damper mounting base so that the small hole dot on it is toward the front and insideof the vehicle.
3. Looselyinstallthe flange bolt (A) on the bottom of thedamper.
1 2 x1 . 2 5 m m 45 61N m {6.2 kgf.m. lbf.ft) Raisethe suspension with a floor jack to load the vehicleweight, and tighten the nuts and bolt to the specifiedtorque values. C l e a n h e m a t i n gs u r f a c e f t h e b r a k ed i s ca n d t h e t o i n s i d e f t h e w h e e l ,t h e n i n s t a ltl h e r e a rw h e e l . o Checkthe wheel alignment,and adjust it if (seepage 18-4). necessary
Looselyinstallthe flange nuts (A) onto the top of the damper,
A 1 0 x 1 . 2 5m m 59 N.m 16.0kgt.m, ia lbt ft)
18-37
Brakes
Conventional BrakeComponents
Tools Special ........ l9-2 ... C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9.-.3 . . . . . . . . L n . . . Brake SystemInspection and Tests............... .......... 19-4 Brake Pedal and Brake PedalPosition Switch Adjustment .............. 19-6 Parking Brake Check and Adjustment .............. 19-7 Brake System Bleeding ...................... 19-8 Brake SystemIndicator Circuit Diagram . . . . . . . . . . . . . . . 9.-.9 1. . Parking Brake Switch Test ................. 19-10 Brake FluidLevel Test ...................................... Switch 19-10 Front Brake Pads lnsoection and Replacement ........... 19-11 Front Brake DiscInspection ............... 19-13 Front Brake Calioer Overhaul...................................... 19-14 Master Replacement Cylinder ........... 19-15 Master Cylinder Inspection ................ 19-16 Brake Booster Pushrod Adjustment................................ Clearance 19-16 Brake BoosterTest ................... .......... 19-18 Brake Booster Reolacement .............. 19-19 Rear Brake Pads Inspection and Reolacement ........... 19-20 Rear Brake DiscInspection ................ 19-22 Rear Brake Caliper Overhaul....................................... 19-23 Brake Hoses Lines and Insoection .... 19-24 Brake Hose Reolacement ................... 19-25 Parking Brake Replacement Cable .............................. 19-26
ABS (Anti-lockBrakeSystem) Gomponents
... 19-29
BrakeComponents Conventional
SpecialTools
Ref.No.
Tool Number
100 07JAG-SD40
DescriDtion PushrodAdiustmentGauoe
Qty 1
19-2
Component Location Index
INDICATOR BrakeSystemIndicatorCircuit D i a g r a mp a g e1 9 - 9 , ParkingBrakeSwitch Test,page 19 10 BrakeFluidLevelSwitch Test,page 19-10
BRAKE CABLE
Parking rake able B C page 19 26 Replacement,
FRONT BRAKES FrontBrakePads,Inspection and page 19-1 Replacement, 1 FrontBrakeDisc page 19'13 Inspection, FrontBrakeCaliper O v e r h a u lp a g e1 9 - 1 4 , BRAKEBOOSTER BrakeBooster Test,page 19-18 BrakeEooster page 19 19 Replacement, BRAKE HOSES and LINES BrakeHosesand Lines page 19 24 Inspection, BrakeHoses page 19 25 Replacement, MASTER CYLINDER MasterCylinder
Fl6^1.^6m6nr ^2ô 1O-18
REARDISCBRAKE RearBrakePads Inspection and page l9-20 Replacement, RearBrakeDisc page 19'22 Inspection, R e a rB r a k e a l i p e O v e r h a u l , C r page 19'23
PARKING BRAKE LEVER Parkino Brake page19-7 Check Adjustment, and BRAKE PEDAL Brake Pedal Erake and Pedal Position Switch pagel9-6 Adjustment,
p M a s t e r y l i n d eIrn s p e c t i o n ,a g e1 9 - 1 6 C BrakeBoosterPushrodClearance p A d j u s t m e n t ,a g e ' 1 9 - 1 6 page 19-8 BrakeSystemBleeding,
19-3
BrakeComponents Gonventional
and Tests BrakeSystemInspection
Component l\4aster Cylinder
Procedure
Look for damageor signs of fluid leakageat; . Reservoir reservoirgrommets or . L i n ej o i n t s . Betweenmastercvlinderand booster Look for damageor signs of fluid leakageat: . Line joints and banjo bolt connections . Hosesand lines.also inspectfor twisting or damaqe Lookfor damageor signs of fluid leakageat: . Pistonseal . Banjo bolt connections . Bleederscrew at: Lookfor damageor signs of fluid leakage . Linejoints . Modulator
Also check for:
Brake Hoses
Bulging,twisted or bent lines.
Caliper
p c Seized r sticking aliper ins. o
ABS l\ilodulator
BrakeSystemTest
Brake pedal sinks/fades when braking 1. Startthe engine,and let it warm up to operatingtemperature. 2. Attacha 2-inchpieceof maskingtape along the bottom of the steeringwheel, and draw a horizontalreference mark acrossit. the 3 . With the transmissionin Neutral,pressand hold the brakepedal lightly,then release parkingbrake. While still holdingthe brakepedal,hook the end of the tape measurebehind it. Then pull the tape up to the mark you made on the maskingtape. steeringwheel, noting where the tape measurelines up with the reference 5 . Apply steadypressureto the brakepedalfor 3 minutes. 6 . Watch the tape measure. . if it moves lessthan 10 mm, the mastercylinderis OK. . if it moves more than 10 mm replacethe mastercylinder.
t-
19-4
Rapid brake pad wear. Vehicle vibration {after a long drivel, or High, hard brake pedal 1 . D r i v et h e v e h i c l e n t i lt h e b r a k e s r a go r u n t i l t h e u d pedal is high and hard.This can take 20 or more brakepedal applications during an extendedtest drive. 2 . W i t h t h e e n g i n er u n n i n g r a i s e h e v e h i c l e n a l i f t , , t o a n d s p i n a l l f o u r w h e e l sb y h a n d . ls there btake drag at any of the wheels?
5. Loosenthe hydrauliclines at the mastercylinder, then spin the wheelsto checkfor brakedrag. ls there brake drag at any of the wheels? YES Go to step 6. NO- Replace mastercylinder.l the 6. Loosenthe bleederscrewsat each caliper,then spin the wheels to checkfor brakedrag. Is there brake drag at any of the wheels?
YES Go to step 3. NO Lookfor other causesof the pad wear, high pedal, r vehicle ibration.I o v 3. Turn the engineoff, pump the brakepedalto depletethe vacuum in the brakebooster,and then spin the wheels againto checkfor brakedrag. ls therc brake dtag at any ot the wheels? YES-Go to step 4. NO Replace brakebooster.I the 4. Without removingthe brakelines,unbolt and separate the mastercylinderfrom the booster,then spin the wheelslo checkfor brakedrag. ls there btake drag at any of the wheels? YES Go to step 5, NO-Check the brakepedal positionswitch adjustmentand pedalfree play.I YES Disassemble and repairthe caliperon the w h e e l ( s w i t h b r a k ed r a g . l ) NO Inspectbrakehose (s)/line(s).
19-5
BrakePedaland BrakePedalPosition SwitchAdjustment
Height Pedal
1 . Disconnect brakepedal positionswitch the connector, turn the brakepedal positionswitch (A) c o u n t e r c l o c k w i sa n d p u l l i t b a c ku n t i li t i s n o e, l o n g e rt o u c h i n g h e b r a k ep e d a l . t Lift up the carpetand the insulatorcutout (B). l\4easure pedal height (C)from the middle of the the left side of the pedal pad (D). StandardPedalHeight (with carpet removed): 184 mm (7 4/16in.)
PedalFreePlay
4. With the engineoff, inspectthe play (A) on the p e d a lp a d ( B )b y p u s h i n g h e p e d a lb y h a n d . t F r e eP l a y :0 . 4 - 3 . 0 m m { 0 . 0 1 6 0 . ' l 1 8 i n . )
lf the pedalfree play is out of specification, adjust the brakepedal positionswitch (C).lf the pedalfree p l a yi s i n s u f f i c i e n itt, m a y r e s u l ti n b r a k ed r a g . 6 . Pushin the brakeoedal oositionswitch until its ( d p l u n g e r s f u l l yp r e s s e d t h r e a d e e n d ( A ) t o u c h i n g i the pad (B)on the pedal arm).Then,turn the switch 45" clockwiseto lock it. The gap betweenthe brake pedal positionswitch and the pad is automatically i t a d j u s t e do 0 . 4t o 3 . 0m m ( 0 . 0 1 6 0 . 1 1 8 n . )b y l o c k i n g h e s w i t c h . a k es u r et h e b r a k el i g h t sg o t M otf when the pedal is released.
Loosenthe pushrodlocknut(A),and screwthe pushrodin or out with pliers until the standard pedal heightfrom the floor is reached. After adjustment, tighten the locknutfirmly. Do not adjustthe pedal heightwith the pushrodpressed.
1 5N . m (1.5kgl m. 11lbl ft)
7 . C h e c k h e b r a k ep e d a lf r e e p l a ya s d e s c r i b e d e l o w . b t
19-6
ParkingBrakeCheckand Adiustment
Check
1. Pullthe parkingbrakelever {A) with 196 N (20 kgf, 44 lbf) of forceto fully apply the parkingbrake.The parkingbrakelever should be lockedwithin the specifiednumber of clicks(B). Leverlockedclicks: 7-8 Removethe rear console{seepage 20-57). Pull the parkingbrakelever up one click,
l2okqf,a4lbl)
if 2. Adjust parking the brake the leverclicks not are withinthe specification.
7, Tightenthe adjustingnut {A} until the parking brakesdrag slightlywhen the rear wheels are t ur n e d . A /
Adjustment
1. Release parkingbrakeleverfully. the Loosenthe parkingbrakeadjustingnut, startthe engine,and pressthe brakepedal severaltimes to set the self-adjusting brakebeforeadjustingthe parkingbrake. Blockthe front wheels,then raisethe rear of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Make sure the parkingbrakearm (A) on the rear brakecalipercontacts the brakecaliperpin (B), The parkingbrakearm will only contactthe NOTE: brakecaliperpin when the parkingbrakeadjusting nut is loosened. 8 . Release parkingbrakelever fully, and check the that the parkingbrakesdo not drag when the rear wheels are turned. Readjustif necessary. 9 . Make surethe parkingbrakesare fully applied when the parkingbrakelever is pulled up fully. 1 0 . Reinstall the rear console.
19-7
BrakeSystemBleeding
NOTE: . Do not spill brakefluid on the vehicle;it may damage the painUif brakefluid does contactthe paint.wash it off immediatelywith water. . The reservoiron the mastercylindermust be at the MAX (upper)level mark at the start of the bleeding procedureand checkedafter bleedingeach brake c a l i p e rA d d f l u i da s r e q u i r e d . . . Do not reusethe drainedfluid. . Always use Honda DOT3 brakefluid. Non-Honda brakefluid can causecorrosionand shortenthe life of the system. . Make sure no din or other foreign matter is allowed to contaminate the brakefluid. 1 . M a k es u r et h e b r a k ef l u i d l e v e li n t h e r e s e r v o i irs a t t h e M A X ( u p p e r ) e v e ll i n e( A ) . l Refillthe mastercylinder reservoir the MAX to {upper)level line. FRONTBRAKE: procedurefor eachwheel in the 5. ReDeatthe sequence shown below until air bubblesno longer appearn thefluid. i
BLEEDING SEOUENCE: OFront Right ORe.r Right
O Front Left
ORoar Loft
9 N.m 10.9 kgf.m,7 lbl.ft)
t-
2 . Slide a pieceof clear plastichoseover the flrst

bleed screw,and submergethe other end in a containerof new brakefluid. Havesomeoneslowly pump the brakepedal severaltimes, then apply steadypressure. Startingat the left-front,loosenthe brakebleed screwto allow air to escapefrom the system.Then tighten the bleedscrew securely.
REARBRAKE:
9 N m 10.9kgf.m, 7 lbf ft)
19-8
BrakeSystemIndicatorCircuitDiagram
UNDER.OASH FUSE/FELAYBOX
A Y
BtK
GRN/ORN
EBAKFLUID IEVELSwlICH
(b, 3s1E8,.""",,"
oPEN,Leve,down
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19-9
Conventional Brake Components

ParkingBrakeSwitch Test
1. Removethe rear console,and disconnect the connector(A)from the switch (B).
BrakeFluidLevelSwitch Test
Checkfor continuitybetweenthe terminals(A) with the float in the down positionand the up position. . Removethe brakefluid completelyfrom the reservoir. With the float down, there should be continuity. . F j l l t h er e s e r v o iw i t h b r a k e f l u i d t oM A X ( u p p e r ) e v e l r l (B).With the float up, there should be no continuity.
'dFu !UF\!E
Checkfor continuitybetweenthe switchterminal a n d b o d yg r o u n d : . With the brakelever up, there should be continuity. . With the brakelever down, there should be no continuity.
19-10
and Replacement Front BrakePadsInspection

Replacement
s o F r e q u e nitn h a l a t i o n f b r a k ep a d d u s t ,r e g a r d l e so f o c m a t e r i ac o m p o s i t i o n ,o u l db e h a z a r d o uts y o u r l . Avoid breathingdust particles. . N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k e va U a s s e m b l i e s . s ea n O S H A - a p p r o v e d c u u m cleaner. ( 1 . R e m o v e h e b o l t( A ) ,a n d p i v o tt h e c a l i p e r B )u p o u t t of the way. Checkthe hose and pin boots for d a m a g ea n d d e t e r i o r a t i o n .
lnspection
1. Raisethe front of the vehicle,and support it with safetystandsin the proper location{seepage 1'8). Removethe front wheels. of 2. Checkthe thickness the inner pad iA) and outer p a d { B ) .D o n o t i n c l u d e h e t h i c k n e s s f t h e b r a k e t o pad backingplate. Brakepad thickness: 9.5 10.5mm (0.37 0.41 in.l Standard: Servicelimit: 1.6 mm (0.06in.)
Innerpad:
&
\ A
t 2 . R e m o v e h e p a ds h i m i A ) a n d p a d s { B ) .
' . . '
, .a
Outer pad:
.^hv/
lf the brakeDadthicknessis lessthan the service l i m i t ,r e p l a c e l l t h e p a d sa s a s e t . a
\ \ \t J I ."r------B v
(cont'd)
19-11
Conventional BrakeGomponents
Front BrakePadsInspection (cont'dl and Replacement
3. Removethe pad retainers(A),and checkthe caliper pins for free movement. 10. Push in the piston (A) so the caliperwill fitoverthe pads.Checkthe brakefluid level.The brakefluid may overflow if the reservoiris too full. lvlake sure the piston boot is in positionto preventdamagingit when pivotingthe caliperdown
/:-." t-.. . .,.';i.:

i '1=' r
.. a.-
8x1.0mm 34 N.m 3.5 kgt m. 25 tbf.ft)
4. Cleanthe caliperthoroughly;remove any rust,and checkfor groovesand cracks. 5. Checkthebrakedisc for damageand cracks. 6. Apply Dow CorningMolykoteM77 greaseto the retainers their mating surfacesagainstthe on caliperbracket. 7. Installthe pad retainers. Wipe excessgreaseoffthe retainers. Contaminated brakediscsand pads reducestoppingability.Keepgreaseoff the discs andpads. greaseto both sidesof the 8. Apply Molykote l\477 p a d s h i m { A ) ,t h e b a c ko f t h e p a d s( B ) ,a n d t h e o t h e r areasindicatedby the arrows. Wipe excessgreaseoff the shim. Contaminated brakediscsand pads reducestoppingability.Keep greaseoff the discs and pads.
11. Pivotthe caliperdown into position.Beingcareful not to damagethe pin boots,installthe bolt (B),and tighten it to the specified torque. 1 2 . P r e s s h e b r a k ep e d a ls e v e r atli m e s t o m a k e s u r e t the brakeworks,then test drive. N O T E E n g a g e m e n t f t h e b r a k em a y r e q u i r e : o a greaterpedal strokeimmediatelyafter the brake pads have been replacedas a set.Several applications lhe brakepedalwill restorethe of normal pedalstroke. 13. After installation, checkfor leaksat hose and line joantsor connections, and retightenif necessary.
, a .).
Installthe brakepads and pad shim correctly. Installthe padswith the wear indicators(C)on the inside. lf you are reusingthe pads,always reinstall the brakepads in their original positionsto preventa momentary loss of brakingefficiency.
19-12
Front BrakeDisclnspection
Runout
1. Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. 2 . R e m o v e h e b r a k ep a d s( s e ep a g e1 9 - 1 1 ) . t 3. Inspect the disc surfacefor damageand cracks. Cleanthe discthoroughly,and removeall rust 4. lnstallsuitable flat washers(A) andwheel nuts,and torque to hold the tightenthe nuts to the specified brakedisc securelyagainstthe hub.
Thickness Parallelism and

1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels. 2. Removethe brakepads (seepage 19-11). 3. Using a micrometer,measurediscthicknessat eight points,approximately45" apart and 10 mm {0.4 in.) in from the outer edge of the disc. Brake Oisc Thickness: Standard:20.9 21.8mm {0.82-0.86 in.} in.) Limit: 19.0mm 10.75 Max. Refinishing in.) Brake Disc Parallelism: 0.015 mm 10.0(X)6 max. NOTE:This is the maximum allowabledifference betweenthe thicknessmeasurements
10 mm lo.itin.l
': . --'t-'"'t , . Set up the dial gaugeagainstthe brakedisc as shown, and measurethe runout at 10 mm (0 4 in.) from the outer edge of the disc. BrakeDiscRunout: in.l ServiceLimit: 0.10mm (0.00tt lf the disc is beyondthe servicelimit, refinishthe brakedisc. Max. RetinishLimit: 19.0mm (0.75in.) NOTE: . l f t h e b r a k e d i s cs b e y o n d t h e s e r v i c le m i t f o r i i 1 i r e f i n i s h i n g , p l a c et ( s e ep a g e1 8 - 1 ) . re . A new disc should be refinishedif its runout is g r e a t e r h a n0 . 1 0m m ( 0 . 0 0 4n . ) . i t
s 4 . l f t h e s m a l l e s m e a s u r e m e ni t l e s st h a nt h e m a x . t refinishinglimit, replacethe brakedisc (seepage 18-11). lf the disc is beyondthe servicelimit for parallelism, refinishthe brakedisc with an on-carbrakelathe. producedby Kwik-way The Kwik-Lathe "Front BrakeDisc Co. and the Manufacturing Lathe" offered by Snap-onTools Co. are approved for this operation.
19-13
Front BrakeCaliperOverhaul
{
Frequentinhalationof brakepad dust, regardless materialcomposition, of could be hazardous your health. to . Avoid breathingdust particles. ' N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k ea s s e m b l i e s .s e a n o s H A - a p p r o v e d u v a c u u mc l e a n e r . Remove,disassemble, inspect,reassemble, and installthe caliper,and note these items: ' D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n t ;i f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f immediatelywith water. . To preventdripping,cover disconnected hose joints with rags or shop towels. . C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a lp a s s a g e s w i t c o m p r e s s e d i r . l h a . Beforereassembling, checkthat all parts are free of dust and other foreign particles. . Replacepartswith new ones as specifiedin the illustration. . Make sure no dirt or other foreign matter is allowedto contaminate the brakefluid, ' When reusingpads,always reinstallthemin their original positions to preventloss of brakingefficiency. . Do not reusedrainedbrakefluid. 'AlwaysuseHondaDOT3brakefluid.Non'Hondabrakefluidcancausecorrosionandshortenthelifeofthesvstem. . Do not mix differentbrandsof brakefluid as they may not be compatible. . C o a t t h ep i s t o n , i s t o ns e a lg r o o v e , n d c a l i p e r o r e w i t h c l e a n r a k e f l u i d . p a b b . Make sure no greaseor oil gets on the brakediscs or pads. . Replace rubber partswith new ones wheneverdisassembled. all . After installingthe caliper,checkthe brakehose and line for leaks,interference, and twistinq.
>:@:Honda caliper sreaso tplN 08C30-80234M)
Boors
-ffiFA
3i,l'1.'"
BRAKE HOSE/ / / / / / /
,
isli\ii ^ zswttt
SCREW /8LEEO /eNm (o.s kgr'm. / | itbt.ftl /caLl
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l l [
3.4N.m kef {3.5 m,
25 lbf ft) ---=-? .===?
-ffi \--l -ffi PINA \:7 CALIPER

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1 0 8N . m 1 1 1 . 0 g f . m , k 80 tbt.ft)
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RepracF #.'@ PAD RETATNERS \
//' SEAL|NG WASHEaS WAStrtXS
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19-14
MasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may damagethe paint;if brakefluid does contactthe paint, wash it off immediatelywith water, ( t r 1 , R e m o v eh e a i rc l e a n ea s s e m b l yA ) . r t 3 . R e m o v e h e c l u t c hr e s e r v o i ( B )a n d e n g i n e w i r e harnessclip (C)from the mastercylindermounting b a s e( D ) . 4. Removethe reservoircap and brakefuid from the reservoir. 5. Removethe reservoir(E)on the mastercylinder D mountrng ase. the 6, Disconnect brakelines (F)from the master cylinder (G).To preventspills,cover the hosejoints with rags or shop towels. 7. Removethe mastercylinder mounting nuts {H)and washers. 8. Removethe mastercylinderfrom the brakebooster. Be carefulnot to bend or damagethe brakelines when removingthe mastercylinder. the 2, Disconnect brakefluid level sensorconnector (A). 9. Removethe rod seal (l) from the mastercylinder. 10. Installthe mastercylinder in the reverseorder of removal,and note these items: . Replace the rubber partswith new ones all wheneverthe mastercylinder is removed. . Checkthe pushrodclearance beforeinstallingthe (see mastercylinder.and adjust it if necessary p a g e1 9 - 1 6 ) . . Use a new rod seal on reassemblY . Coatthe inner bore lip and outer circumference of the new rod seal {A) with the recommended seal greasein the mastercylinderset. . I n s t a l l t h e o d s e a lo n t o t h e m a s t e r y l i n d e r i t h w c r its groovedside (B)towardthe mastercylinder. . Checkthe brakepedal height and free play after c , t i n s t a l l i n gh e m a s t e r y l i n d e ra n d a d j u s ti t i f (seepage 19-6). necessary
1 5N . m {1.5kgt.m,11 lbt.ft)
19-15
MasterCylinderInspection
NOTE: . Beforereassembling, checkthat alI partsare f ree of dust and other foreign particles. . D o n o t t r y t o d i s a s s e m b l e t hm a s t e r c y l i n d e r e assembly.Replace the mastercylinder assemblywith a new part if necessary. . Do not allow dirt or foreign matterto contaminate the brake luid. f I
,--l
BrakeBoosterPushrodClearance Adjustment
SpecialToolsRequired Pushrodadjustmentgauge07JAG-SD40100 NOTE:Brakeboosterpushrod-to-piston clearance must be checkedand adjustmentsmade, if necessarV, before installingthe mastercylinder. 1 . S e t t h e s p e c i atlo o l ( A )o n t h e m a s t e r c y l i n d eb o d v r (B),push in the centershaft (C)until the top of it contacts the end of the secondarypiston {D) by t u r n i n gt h e a d j u s t i n g u t ( E ) . n
RESERVOIB CAP unecK otocKage Ior

of vent holes. RESERvOIR SEAL Checklor damaoe and deterioration. STRAINER Removeaccumulated seotment.
RESERVOIR
r ' , , . J \ +
RESERVOIR HOSES Inspecthosesfor damage,leaks, and deterioration.
MASTER CYLINDER Check leaks, for rust,anddamage
Without disturbingthe centershaft'sposition, installthe specialtool(A) backwards the booster. on

1 5N m { r . 5 11tbf.ftl
Installthe mastercylinder nuts (B),and tighten them to the specifiedtorque. Conneclthe boosterin line with a vacuum gauge { C )0 - 1 0 1 k P a{ 0 ' - 7 6 0m m H g ,3 0 i n . H g ) o t h e t booster'senginevacuum supply,and maintainan e n g i n es p e e d h a tw i l l d e l i v e r 6 k P a( 5 0 0m m H g , t 6 20 in.Hg) acuum. v
19-16
5. With a feelergauge (A),measurethe clearance betweenthe gauge body and the adjustingnut (B) as snown, betweenthe gauge body and the lf the clearance adjustingnut is 0.4 mm (0.02in.),the pushrod-topistonclearance 0 mm. However.if the clearance is betweenthe gauge body and the adjustingnut is is clearance 0 4 mm 0 mm, the pushrod-to-piston {0.02in.) or more. Thereforeit must be adjusted and rechecked. Clearance: 0-0./t mm (0-0.02 in.)
l t 9 . C h e c k h e p u s h r o d e n g t h( A )a s s h o w n i f t h e boosteris removed,lf the length is incorrect, loosenthe pushrodlocknut(B),and turn the clevis (C)in or out to adjust. A m i 1 1 6 m { 4 . 6n . )
1 0 x 1 . 0m m 1.5 N'm kgf.m,11 lbf.ftl 11.5
( m c 1 0 . I n s t a l l t h e a s t e r y l i n d e r s e ep a g el 9 - 1 5 )
is lf the clearance incorrect,loosenthe star locknut (A).and turn the adjuster(B)in or out to adjust. . Adjustthe clearance while the specifiedvacuum is appiiedto the booster. . Holdthe clevis(C)while adjusting. A 22N.n in.) 0 0.4mm l0 -0.02
07JAG-SO40100 7. Tightenthe star locknutsecurely. 8. Removethe specialtool (D).
19-17
Gonventional BrakeComponents
Brake Booster Test
Functional Test
1. With the enginestopped,pressthe brakepedal severaltimes to depletethe vacuum reservoir, then pressthe pedal hard, and hold itfor 15 seconds.lf the pedalsinks,eitherthe mastercylinderis bypassinginternally,or the brakesystem (master c y l i n d e rl,i n e s . o d u l a t o ro r c a l i p e r si)s l e a k i n g . m , 2. Startthe enginewith the brakepedal pressed.lf the pedal sinksslightly,the vacuum boosteris working properly.lf the pedal heightdoes not vary, the boosteror checkvalve is faulty. 3. With the engine running,pressthe brakepedal l i g h t l y . f t h e b r a k ep e d a ls i n k sm o r e t h a n 1 Om m l {3/8 in,) in 3 minutes,the mastercylinder is faulty. A slight changein pedal heightwhen the Ay'C compressorcycleson and off is normal.(TheA,/C compressorload changesthe vacuum availableto the booster.) 3. Disconnect brakeboostervacuum hose (check the valve built-in)(A) at the boosterside.
LeakTest
1. Pressthe brakepedalwith the engine running,then stop the engine.lf the pedal height does not vary while pressedfor 30 seconds, vacuum booster the is OK. lf the pedal rises,the boosteris faulty. 2. With the engine stopped,pressthe brakepedal severaltimes using normal pressure. When the pedal is first pressed,it should oe row. On consecutive applications, pedal height the s h o u l dg r a d u a l l y i s e .l f t h e p e d a lp o s i t i o n o e s n o t r d varv, checkthe boostercheckvalve.
4 . Startthe engine,and let it idle.Thereshould be v a c u u ma v a i l a b l el . n o v a c u u mi s a v a i l a b l e , e f th checkvalve is not working properly.Repiace the brakeboostervacuum hose and checkvalve,and relesI. 5 . Reconnect brakeboostervacuum nose. the Startthe engine,and then pinch the brakebooster vacuum hose betweenthe checkvalve and the booster, Turn the ignition switch OFF,and wait 30 seconds, Pressthe brakepedal severaltimes using normal pressu re, When the pedal is first pressed, should be low. it On consecutive applications, pedal height the s h o u l dg r a d u a l l y i s e . r . lf the pedal positiondoes notvary, replacethe brakebooster. . lf the pedal positionvaries,replacethe brake boostervacuum hose/check valve assembly.
19-18
BrakeBoosterReplacement
( c 1 . R e m o v e h e m a s t e r y l i n d e r s e ep a g e1 9 - 1 5 ) . t Removethe mastercylinder brakelines {A) from t h e b r a k el i n ec l i p . t 5 . R e m o v e h e c l i p ( A )a n dt h e j o i n t p i n ( B ) .a n d disconnecttheyoke from the brakepedal.
.,.,....
alu
i '..
' - /
c
6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbf.ft)
{'l.3kgf.m,9lbf.ftl Removethe brakeboostermounting nuts (C). 7 . Removethe brakebooster(A)from the engine comparlmenr.
Removethe vacuum hose mounting bracket(B). Disconnect vacuum hose {C)from the brake the booster.
INdAdEI
. Be carefulnot to damagethe booster surfacesand threadsof the boosterstud bolts. . Be carefulnot to bend or damagethe b r a k el i n e s .
lnstallthe brakeboosterin the reverseorder of removal,and note these items: . Adjustthe pushrodclearance beforeinstalling the brakebooster(seepage 19-16). . U s ea n e w c l i pw h e n e v e r n s t a l l i n g . i . After installingthe brakeboosterand master cylinder,fill the reservoirwith new brakefluid, and bleedthe brakesystem (seepage 19-8), adjustthe brakepedal height and free play (see p a g e1 9 - 6 ) ,
19-19
Conventional Brake Components

RearBrakePadsInspection and Replacement
Replacement
Frequentinhalationof brakepad dust, regardless of materialcomposition,could be hazardous your to h e ah h . . Avoid breathingdust particles. . Never use an air hose or brushto clean brake assemblies, Use an OSHA-approved vacuum cleaner. 1. Removethe bolt (A) and brakehose {B}from the mounting bracket.
Inspection
'1. Raisethe rear of the vehicle,and supportjt with safetystandsin the proper location(seepage 1-8). Removethe rearwheels,
2. Checkthe thickness the inner pad (A) andouter of pad (B).Do not includethe thicknessof the brake pad backingplate. Brakepad thickness: Standard: 8.5 9.5 mm {0.33-0.37 in.} Servicelimit: 1.6 mm (0.06in.)
Removethe caliperbolts (C),and removethe caliper(D)from the caliperbracket.
3 . R e m o v e h e p a d s h i m s( A )a n d p a d s( B ) . t
A
B -::-A
t {
\
3 . lf the brakepad thicknessis lessthan the service

l i m i t ,r e p l a c e l l t h e p a d sa s a s e t . a
t I
A
r\
) \
19-20
4. Removethe pad retainers(A).and checkthe caliper pins for free movement.

:.i _ _l
11. Rotatethe caliperpiston clockwiseinto the cylinder, then align the cutout (A) in the pistonwith the tab {B) on the inner pad by turning the piston backso o c t h e c a l i p e r a n b e i n s t a l l e d n t h e p a d .L u b r i c a t e the boot with rubbergreaseto avoid twisting the Distonboot. lf the piston boot is twisted,back it out so it is positionedproperly.
5. Cleanthe caliperthoroughly;remove any rust.and checkfor groovesand cracks. 6, Checkthe brakedisc for damageand cracks. 7 . Apply Dow CorningMolykoteM77 greaseto the retainerson their mating surfacesagainstthe caliperbracket,
.ar
m 8 x 1.25 m 22 N.m l2.2kgt m, 16rbl.ttl
Wipe excessgreaseoffthe 8 . Installthe pad retainers. brakediscs and pads retainers. Contaminated reducestoppingability.Keepgreaseoff the discs a n dp a d s . 9 . Apply Dow CorningMolykotelvl77greaseto both sidesof the pad shims {A),the backof the pads (B), and the other areasindicatedby the arrows.Wipe brake excessgreaseoff the shim. Contaminated discs and pads reducestoppingability.Keep greaseoff the discsand pads.
D mm 8 x 1.25 23Nm kgf.m, {2.3 17rbf.ft)
. .-.
( b I n s t a l l t h e r a k ec a l i p e r C )a n d c a l i p e r o l t s( D ) . b and tighten the boltsto the specifiedtorque. b 1 3 .I n s t a l l t h e r a k eh o s e( E ) . 1 4 . Pressthe brakepedal severaltimes to make sure the brakeworks, then test-drive. of NOTE:Engagement the brakemay requirea greeterpedal strokeimmediatelyafterthe brake pads have been replacedas a set. Several of applications the brakepedalwill restorethe n o r m a lp e d a ls t r o k e , b 1 5 . C h e c k h e p a r k i n g r a k ea d j u s t m e n{ts e ep a g e1 9 - 7 ) . t
1 0 . I n s t a l l t h e r a k ep a d sa n d p a d s h i m sc o r r e c t l y . b p s I n s t a l l t h e a d sw i r h t h e w e a r i n d i c a t o r { C )o n t h e inside. lf you are reusingthe pads,always reinstallthe brakepads in their originalpositionsto preventa momentaryloss of brakingefficiency.
a f ch 1 6 . A f t e ri n s t a l l a t i o n , e c k o r l e a k s t h o s ea n d l i n e joints or connections, and retightenif necessarY.
19-21
RearBrakeDiscInspection
Runout
1. Raisethe rear of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe rear wheels, 2. Removethe brakepads (seepage 19-20). 3. Inspectthe disc surfacefor damageand cracks. Cleanthe discthoroughly,and remove all rust, 4. lnstallsuitable f lat washers(A) and wheel nuts, and tighten the nuts to the specifiedtorque to hold the brakedisc securelyagainstthe hub.
Thickness Parallelism and

1. Raisethe rear of the vehicle,and supportwith safetystandsin the proper location(seepage l-g). Removethe rearwheels. 2. Removethe brakepads {seepage 19 20). 3, Using a micrometer,measurediscthicknessat , e i g h tp o i n t s a p p r o x i m a t e l4 5 ' a p a r ta n d 1 0 m m y {0.4 in.)from the outer edge of the disc. BrakeDiscThickness: Standard:9.9-10.1 mm (0.389 0.397in.l Max. Retinishing Limit: 9.0 mm (0.35in.) BrakeDiscParallelism: 0.016mm 10.0006 in.) max.
108N.m (11.0 kgf.m,80lbf.ft) Set up the dial gauge againstthe brakedisc as shown. and measurethe runout at 10 mm (0.4in.) from the outer edge of the disc. Brake Disc Runout; ServiceLimit: 0.10mm {0.004in.) lf the disc is beyondthe servicelimit, refinishthe brakedisc. Max. RefinishLimit: 9.0 mm (0.35in.) NOTE: . l f t h e b r a k ed i s ci s b e y o n d t h e s e r v i c le m i t f o r i refinishing,replaceit (seepage 18-26). . A new disc should be refinishedif its runout is g r e a t e r h a n0 . 1 0m m ( 0 . 0 0 4n . ) . t i 4 . lf the smallestmeasurementis lessthan the max. refinishinglimit, replacethe brakedisc (seepage 18-26). lf the disc is beyondthe servicelimit for parallelism, refinishthe brakedisc with an on-carbrakelathe.
19-22
Overhaul RearBrakeCaliper
to of Frequentinhalationof brakepad dust, regardless materialcomposition,could be hazardous your health. ' Avoid breathingdust particles. . Never use an air hose or brushto clean brakeassemblies. vacuum cleaner' Use an OSHA-approved and installthe caliper,and note these items: inspect,reassemble, Remove,disassemble, . D o n o t s p i l lb r a k e l u i d o n t h e v e h i c l e i;t m a y d a m a g e h e p a i n t ;i f b r a k ef l u i d g e t so n t h e p a i n t , a s h i t o f f w t f immediatelywith water. . To preventdripping.cover disconnected hosejoints with rags or shop towels. . C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a l l a s s a g e s w i t c o m p r e s s e a i r ' p h d . Beforereassembling, parts are free of dust and other foreign particles checkthat all . Replace pans with new ones as specifiedin the illustration. . Make sure no dirt or other foreign matter contaminates brakefluid. the . When reusingpads,always reinstallthemin their originalpositionsto preventloss of b raking efficie ncy. . Do not reusedrainedbrakefluid. . U s eo n l y c l e a nH o n d aD O T3 b r a k e l u i d .N o n - H o n d a r a k e l u i d c a nc a u s ec o r r o s i o n n d s h o r t e n h e l i f eo f t h e t a b f f system. . Do not mix differentbrandsot brakefluid as they may not be compatible. . C o a t t h ep i s t o n , i s t o ns e a lg r o o v e , n d c a l i p e r o r ew i t h c l e a nb r a k ef l u i d . p b a . Make sure no greaseor oil gets on the brakediscsor pads. . R e p l a c e a lrlu b b e rp a r t sw i t h n e w o n e sw h e n e v e r i s a s s e m b l e d . d . After installingthe caliper,checkthe brakehose and line for leaks,interference. and twisting.
oG , nonau."rip6r qreaslP/N 08c30-aoa4Ml BOLT 3 4 N . m( 3 . 5 g f m , 2 5 l b t f t ) k WASHERS BRAKE HOSE
\-"o, V((rA
a
i,,'IltE" !!;,ff /
.ARKING NUr
27Nm{2.8kgtm,, f.m 20 tbf.ftr
t H\a \l / t,i*t'*" ?,,.t/*"^.,,.:,"", l, /"V4#

,/
",1 ;[.,.JF /;;;;---
ADJUSTING BOLT
olT-J,.o"c.
lii.'i rz.r rgr..
O.RING Beplace.
CUP Beplace.
Gd
ffi
PADSPRING
A,n
INNEBPA'SHIM /
Na
--t\)(*ff '(
.r.:._U
: .:r=,9!q!q}l
l^7k
i*E
',,0,n, \ ,,:,o"\ 7lfl,lif,loffi
''"'t!1'ry#'
":;*" *dF
fr.x{_>@
,,.-"iV
,/q &'"o.,"."""o"^.,
fftt **-->**^'"
,.2>a>-
10 MM FLANGE BOLTS 55 N m (5.6 lgf-m, 4r lbt ft)
19-23
BrakeHosesand LinesInspection
1. Inspectthe brakehosesfordamage,deterioration, leaks,interference, andtwisting. 2. Checkthe brakelinesfor damage,rusting.and leakage. Also checkfor bent brakelines. 3. Checkfor leaksat hose and line joints or connections, and retightenif necessary. 4. Checkthe mastercylinderand ABS modulator unit for damageand leakage. NOTE:Replace the brakehose clip wheneverthe brakehose is serviced.
BRAKE LINE-to-BRAKE HOSE

15 N.m (1.5kgf.m, 11 lbf.ftl
BRAKE HOSE-to-CALIPER lBANJOBOLTI 3il N.m {3.5kgf.m.25lbt'ft) BLEEO SCREW 9 N.m{0.9 kgf.m,7lbf.ftl ABS MODULATOR UNIT-Io-BRAKE LINE 15N.m{1.5 m.11lbf.ftl kgf
t''
/,i'i'
,/ ,l
t t,.. -)
MASTERCYLINDEB-to-BRAKE LINE 15 N m {1.5kgt.m,ll lbf.ft)
BRAKEHOSE.tO-CALIPER {BANJO BOLTI 34 N.m {3.5kgf.m,25 lbl.ft) BLEEDSCBEW 9 N.m 10.9kgf.m, 7 lbf ft)
BRAKE LINE 15N.m11.5 m, 11lbf.ft) kgf

BRAKELINE-Io-BRAKE HOSE 15 N.m (1.5kgf.m,11lbf.ftl
CONTROLVALVE-to-
19-24
BrakeHoseReplacement
NOTE: . Do not spill brakefluid on the vehicle;it may damage the paint;if brakefluid gets on the paint,wash it off immediatelywith water. . To preventdripping,cover disconnected line joints with rags or shop towels. . Beforereassembling, checkthat all parts are free of dust and other foreign particles. . Replace partswith new ones wheneverspecifiedto do so. 1. Replace brakehose (A) if the hose is twisted, the cracked, if it leaks. or 6. Installthe brakehose bracket(A)on the damper with the flange bolt (B)first, then connectthe brake hose (C)to the caliperwith the banjo bolt {D) and ( newsealing ashers E). w
7. lnstallthe hose onto the hose bracketon the bodv with a new hose clip (A).
1 0 x 1 . 0m m 15 N.m (1.5kgf.m, 1t tbt.ftl
i !
Disconnect brakehosefrom the brakeline (B) the using a 10 mm flare nut wrench {C) Removethe flange bolt (A),and removethe brake from the damper. hose brackets
the brakeline to the brakehose. Connect the brakehose,bleedthe brake 9 . After installing system (seepage l9-8).
1 0 .Do the following checks:

I x 1 . 2 5m m
. Checkthe brakehose and line joint for leaks,and tighten if necessary. . Checkthe brakehosesfor interference and twisting.
4. R e m o v e n d d i s c a r d h e h o s ec l i p ( B ) . t a
Removethe banjo bolt (C),and removethe brake h o s e( D ){ r o m t h e c a l i p e r .
19-25
ParkingBrakeCableReplacement
Exploded View
ADJUSTING NUT
PARKING BRAKE swtTcH
L
e
PARKING BRAKE CABLE for Check stiffness, binding, damage. and
8 x 1.25 22 N.m 12.2kgl
19-26
NOTE: . The parkingbrakecablesmust not be bent or distorted.This will leadto stiff operationand prematurefailure. . Referto the ExplodedView as neededduring this proceoure. 1 . R e l e a s t h e p a r k i n g r a k el e v e rf u l l y . e b 2. Removethe rearconsole(seepage 20-57).
7 . l n s t a l l t h e e w c a b l ei n t h e r e v e r s e r d e ro f n o removal.and note these items: . Be careful not to bend or distortthe cable. . M a k es u r et h e p a r k i n g r a k ec a b l ec l i p i s f u l l y b seatedon the cable housing. . Do the parkingbrakecable adjuslment(seepage 1 9 - 7. )
4 . Removethe parkingbrakecableclip (A) from the
b r a k e a b l e( B ) . c
parkingbrakecablefrom the lever Disconnectthe
{c).
6 . Removethe parkingbrakecable mounting hardware, then removethe cable.
19-27
Brakes
BrakeComponents................ 19-1 Conventional ABS (Anti-lockBrakeSystem)Components
C o m o o n e n to c a t i oln d e x . . . . . . . . . . . . . , . . . . . . . . . . . . . 1.9.-.3 . . . . . . . . L n . . .0 Troubleshooting Information ....................... 19-31 General .............. 19-34 DTC Troubleshooting Index 19-35 Symptom Troubleshooting Index ...,........................... ................. ........... 19-36 System Description 19-42 Diagram ......... Circuit .......... 19-45 DTC Troubleshooting ............... 19-52 ABSIndicator ...................... CircuitTroubleshooting Brake System Indicator Circuit T r o u b l e s h o o t i n. . . . . . . . . . . . . . . . . . . . . .g . . . . . .1 9 - 5 5 . ABSModulator-Control Removal Unit and ............. 19-57 lnstallation 19-59 WheelSensor Insoection ................... .............. 19-59 WheelSensor Reolacement
ABSGomponents
Location Component Index
(
RIGHT-REAR WHEEL SENSOR page Inspection, 19-59 page Replacement, 19-59

UNDER.OASH FUSE/RELAY BOX
\L
LEFT.REAR WHEEL SENSOR page 19-59 Inspection, page 19-59 Replacement, DATA LINKCONNECTOR I16PI RIGHT.FRONT WHEEL SENSOR page 19-59 Inspection, page 19-59 Replacement,
ABSMODULATOR.CONTROL UNIT page Removal Installation, 19'57 and
LEFT-FRONT WHEEL SENSOR page Inspection, 19-59 page Replacement, 1959
19-30
Troubleshooting General Information

ABS Indicator
. lf the system is OK,theABS indicatorgoes off 2 secondsafter turning the ignition switch ON (ll) without startingthe engine,and then comes on again and goes off 2 secondslater after startingthe engine. This occursbecause ABS control unitisturned the on by the lG2 power source. . The ABS indicatorcomes on when the ABS control unit detectsa problem in the system.However,even though the system is operatingproperly,the indicator will come on underthese conditions: - Only the drive wheels rotate - One drive wheel is stuck - The vehiclegoes into a spin - The ABS continuesto operatefor a long time. - The vehicleis subjected an electrical to signal disturbance To determinethe actualcauseof the problem,question the customeraboutthe problem.taking the above condilionsinto consideration. . When a Droblemis detectedand lhe ABS indicator comes on, there are caseswhen the indicatorstays on until the ignition switch is turned OFF,and cases when the when the indicatorgoes off automatically sYstemreturnsto normal. - DTC61: The ABS indicatorgoes off automatically when the system returnsto normal. - D T C1 1 ,1 3 , 1 5 , 1 73 1 , 3 2 , 3 3 ,3 4 ,3 5 ,3 6 ,3 7 ,3 8 ,5 4 , , or 81: The ABS indicatorstayson until the ignition switch is turned OFFwhether or not the system returnsto normal. - D f C 1 2 ,1 4 ,1 6 ,1 a , 2 1 , 5 1 , 5 2o r 5 3 ;T h e A B S , indicatorgoes off when the vehicleis driven again and the system is OK afterthe ignition switch is t u r n e df r o m O F Ft o O N { l l } .
Diagnostic TroubleCode{DTCI
. The memory can hold three DTCS. However,when the same DTCis detectedmore than once,the more recentDTCis written over the earlierone. when the same problem is detected Therefore, repeatedly, is memorizedas a single DTC. it . The DTCsare in the order they occurred,beginning with the most recent. . The DTCS (nonare memorizedin the EEPROM volatile memory).Therefore. the memorizedDTCs the are not clearedwhen the batteryis disconnected, ignition switch is turned off, or the system returnsto to normal. Do the specifiedprocedures clearthe DTCs.
Self-diagnosis
. Self-diagnosis be classifiedinto two categories: can - I n i t i ad i a g n o s i s : l Done right after the enginestarts and until the ABS indicatorgoes off - R e g u l ad i a g n o s i s : r D o n er i g h t a f t e r t h e n i t i a d i a g n o s i s n t i lt h e i l u ignition switch is turned OFF . When a problem is detectedby self-diagnosis, the system does the following: - Turnsthe ABS indicatoron - Memorizes the DTC - StopsABS control
Kickback
The pump motor operateswhen the ABS is functioning, and the fluid in the reservoiris forced out to the master k k c y l i n d e rc a u s i n g i c k b a c a t t h e b r a k ep e d a l . ,
PumpMotor
. The pump motor operates when the ABS is functioning. . The ABS control unit checksthe pump motor operationwhen the vehicleis startedthe first time after the ignition switch is turned ON (ll).You may hearthe motor operateat this time, but it is normal.
(cont'd)
19-31
ABSComponents
Troubleshooting Information(cont'd) General
How to TroubleshootABS DTCs
The troubleshooting flowchartprocedures assumethat the causeof the oroblem is still Dresent and the ABS indicatoris still on. Followingthe flowchartwhen the ABS indicatordoes not come on can resultin incorrect diagnosis. The connectorillustrations show the female terminal connectors with a singleoutline and the male terminal with a double outline. connectors 1. Ouestionthe customeraboutthe conditionswhen the problem occured,and try to reproduce the Find out same conditionsfor troubleshooting. when the ABS indicatorcame on, such as during ABS control,after ABS control,when the vehicle was at a certainspeed,etc. 2. When the ABS indicatordoes not come on during the test-drive, troubleshooting done basedon but is poor terminal the DTC,checkfor looseconnectors. contact,etc.,beforeyou starttroubleshooting. clearthe DTC,disconnect 3. After troubleshooting, the HondaPGM Tester.and test-drive vehicle. the Make sure the ABS indicatordoes not come on. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n df o l l o wt h e s prompts on the PGM Testerto displaythe DTC{S) on the screen.After determiningthe DTC,referto the DTCTroubleshooting Index. NOTE:Seethe HondaPGM Testeruser'smanual for specificinstructions. Service Check Signal (SCS)Circuit Method: 1. With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) (BI underthe driver'sside of the dashboard.
How to RetrieveABS DTCs

Honda PGM Tester Method: 1, Wjth the ignition switch OFF,connectthe Honda PGMTester(A)to the 16Pdata link connector(DLC) (B) under the driver'sside of the dashboard. 2. Short the SCScircuitto body ground usingthe HondaPGM Tester. 3. Turn the ignition switch ON (ll).
19-32
4. The blinkingfrequencyindicates the DTC.DTCS are indicatedby a seriesof long and short blinks.One l o n gb l i n ke q u a l s1 0 s h o n b l i n k s A d d t h e l o n g a n d . short blinkstogetherto determinethe DTC.After determiningthe DTC,referto the DTC Troubleshooting dex. In NOTE: . lf the DTCis not memorized, ABS indicator the will go off for 3.6 seconds, and then come back on. . lf the ABS indicatorstayson, troubleshootfor "ABS indicator does not go off" (seestep 1 on page 19-53). Th system will not indicate the DTC unless these conditions are met: . The brakepedal is not pressed. . The ignitionswitch is turned ON {ll). . The SCScircuitis shortedto body ground before t h e i g n i t i o n w i t c hi s t u r n e dO N ( l l ) . s Example DTC ot 15
Long blink Short blinks {five timesl
How to ClearABS DTCs

Honda PGM Tester Method: 1. With the ignition switch OFF,connectthe Honda ( P G MT e s t e r A ) t o t h e l 6 P d a t a l i n kc o n n e c t o ( D L C ) r { B }u n d e rt h e d r i v e r ' s i d eo f t h e d a s h b o a r d . s
T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c l e a r t h e s DTC(s) following the screenprompts on the by PGM Tester. NOTE:Seethe HondaPGl\4Testeruser's manual for sDeclf instructions. ic Cycling the lgnition Switch Method: C l e a rt h e D T Cb y t u r n i n gt h e i g n i t i o n w i t c hO N ( l l )t h e n s O F Fa t l e a s t2 0 t i m e s .
Examole of DTC 22 Long blinks (two times)
5 . Turn the ignition swltch OFF, Disconnect HondaPGM Testerfrom the DLC. the
19-33
ABSGomponents
Index DTCTroubleshooting
DTC
DTC:11 Detection ltem to to Rioht-front wheel sensor{ooen/short bodv qround/short power) Faultv riqht-frontwheel sensoroulse siqnal to to Left-front wheel sensor{oDen/short bodv qround/short power) Faultvleft-frontwheel sensorDulsesrqnal to to Riqht-rear wheel sensor(oDen/short bodv qround/short power) r r F a u l t v i q h t - r e aw h e e ls e n s o r u l s es i q n a l o to to Left-rear wheel sensor (open/short bodv qround/short power) Faultvleft-rear wheel sensorDulsesiqnal d C o n t i n u o uo D e r a t i o( c h i o D e D u l s e r ) s n Solenoid Solenoid Solenoid Solenoid Solenoid S ol en oi d S ol en o i d n S o l e oi d lvlotor Iocked lvlotor stuck off lMotorstuckon Main relav stuckoff lG2 voltaqe Unit) cPU (CentralProcessinq Note (seeoaoe 19-45) {seeoaoe 19-46) (seeoaqe 19-45) (seepaqe 19-46) (seeDaqe19-45) (seepaqe 19-46) (seeDaoe'19-45) (seeDaqe'19-46) (seepaqe 19-47) (seeDaoe19-48) { s e eD a q e1 9 - 4 8 ) {seeDaoe19'48) lsee oaqe 19-48) (seepaqe 19-48) (seeDaqe19-48) (seeDaqe19-48) (seeDaoe19-48) ( s e eD a q e1 9 - 4 8 ) (seeDaoe19-49) (seeDaoe19-50) ( s e ep a q e1 9 - 5 1 { s e eo a q e1 9 - 5 ' l {seepaqe 19-52)
DTC:12 DTC:13
DTC:14 DTC;15
DTC:16
DTC:17
DTC:18
Drc:2l
DTC:3'l DTC:32 DTC:33 DTC:34 DTC:35 DTC;36 DTC:37 DTC:38
DTC:51
DTC:52 DTC:53
DTC:54 DTC:61
DTC:81
19-34
g Symptom Troubleshootin Index

Symptom ABS indicatordoes nol come on ABS indicatordoes not go off and no ABS DTCis stored Brakesystem indicatordoes nol come on Brakesystem indicatordoes not go off and no ABS DTCis stored Diagnostic procedure (seepage ABS IndicatorCircuitTroubleshooting 19-52) ABS IndicatorCircuitTroubleshooting {seestep 1 on Daqe19-53) BrakeSystem lndicatorCircuitTroubleshooting (seepaqe 19-55) Also check for
Brake Indicator System Circuit Troubleshooting (see steo1 on Daqe 19-55)
19-35
ABS Gomponents
SystemDescription
ABSControlUnit Inputsand Outputsfor 31PConnector
1 2
4 5 6 7 B I
1 6 1 1 1B 1 9
20 ?1/t/t/l/t/
1112
1 41 5
Terminal number
Wire color BLU/ YEL GRN/ YEL BLU
Terminal sign RRS
Description Detects righfrear wneetsensor srgnal

Detects right-front wneetsensor srgnal
Measurement Terminals Conditionsllgnition

switch ON (ll))
Voltage
( R R S+ )
F R S( - )
;a-_-l
V S p i n h e e l a t AC:0.053 or w I turn/second above Wheel Oscilloscope 0.15 p-p r V o above
5
6 7 8 9 11
GRN/ BLK
( F R S+ )
F L S( _ )
BRN/ WHT BLU/ ORN

GRY/ RED
FLS+) {
R L SH
Detects left-front wneet sensor srgnal

Detects left-rear wneetsensor srgnal Communications with Honda PGM rester DTC indication
6-7
8 9
YEU RED LT BLU

BRN
( RLS +) DIAG K
DIAG L
12
19-36
Terminal number 14
t5
Wire color WHT/ BLK BLV ORN BLK WHT/ RED WHT/ GRN BLK BLU/ RED
BRN/ YEL
Terminalsign
Description
Detects brake switch siqnal
Measurement Terminals Conditions {lgnition

I 4 - GN D 15-GND switch oN lll)) pedal Pressed Brake Released
Voltage
STOP
rG2
M-GND + B-MR + B-FSR
GND
16
Power for source activating the svstem Ground the for motor 0umD
Powersource for the oumD motor Powersource for thevalve relav Ground the for modulator assemDtv
Eattery voltaoe Baftery voltage Below V 0.3
16-GN D
17-GND ,18-GND Atalltimes Atalltimes
Battery voltaoe
Battery voltaoe
18
'19
19.GND 20-GND ON
OFF OFF
Below V 0.3 A b o u t 1V 1
Below 1 V
20
ABS
Drives ABS indicator
EBD Drives brake (Electronic brake system indicator distribution)
ABS indicator 2 1 - G N D Brake system indicator
ONfor bulb cnecK
Below V 0.3 8attery voltage
(cont'd )
19-37
ABS Gomponents
(cont'd) SystemDescription
Features
When the brakepedal is pressedduring driving,the wheels can lock beforethe vehiclecomesto a stop. In such an event.the maneuverability the vehicleis reducedif the front wheels are locked,and the stabilityof the vehicleis of reducedif the rearwheels are locked,creatingan extremelyunstablecondition.The ABS precisely controlsthe slip rate of the wheelsto ensuremaximum grip force from the tires,therebyensuringthe maneuverability and stabilityof thevehicle. The ABS calculates slip rate of the wheels basedon the vehiclespeedand the wheel speed,then it controlsthe the to brakefluid pressure reachthe target slip rate. Grip Force of Tire and Road Surface
TARGET SLIPRATE
OF COEFFICIENT FRICTION
SLIPRATE
19-38
ABSControlUnit
Main Control The ABS control unit detectsthe wheel speed basedon the wheel sensorsignal it received, then it calculates the vehiclespeed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring deceleration basedon the rate of deceleration. The ABS control unit calculates slip rate of eachwheel and transmitsthe control signalto the modulatorunit the solenoidvalve when the slip rate is high. The pressurereductioncontrol hasthree modes: pressurereducing,pressureretaining,and pressureintensifying.
T---
Function Self-diagnosis 1 . T h e A B S c o n t r o ln i t i s e q u i p p e d w i t h a m a i n C P U a n d a s u b - C P U . E a c h C P U c h e c k s t h e o t h e r f o r p r o b l e m s . u 2. The CPUS checkthe circuitof the system. p l w 3 . T h e A B S c o n t r ou n i t t u r n so n t h e A B S i n di c a t o r h e n t h e u n i t d e t e c t s a r o b l e ma n d t h e u n i ts t o p st h e s y s t e m . 4. The self-diagnosis be classifiedinto thesetwo categories: can . l n i t i a ld i a g n o s i s . R e g u l ad i a g n o s i s r On-boardDiagnosisFunction The ABS can be diagnosedwith the Honda PGM Tester. The ALB Checker cannot be usedwith this system.For air bleedingand checkingwheel sensorsignals.usethe Honda PGM Tester.Seethe Honda PGMTesteruser's manualfor specificoperatinginstructions.
(cont'd)
19-39
ABSComponents
(cont'd) SystemDescription
ABSModulator
The ABS modulatorconsistsof the inlet solenoidvalves,outlet solenoidvalves,reservoir, pump, pump motor, and the damping chamber.The modulator reducesthe caliperfluid pressuredirectly.lt is a circulating-type modulator becausethe rakefluidcirculatesthroughthecaliper,reservoir,andthemastercylinder.Thehydrauliccontrol b has pressureretaining,and pressurereducing. three modes:pressureintensifying, The hydrauliccircuitis an independent f o u r - c h a n n e l t y p e , e c h a n n efl o r e a c hw h e e l . on
Pressure intensifyingmode: Inletvalveopen,outlel valve closed M a s t e r y l i n d e f l u i d i s p u m p e do u t t o t h e c a l i p e r . c r Pressure retainingmode: lnlet valve closed,outlet valve closed Caliperfluid is retainedby the inlet valve and outlet valve. Inletvalve closed,outlet valve open Caliperfluid flows through the outlet valveto the reservoir. When startingthe pressurereducingmode,the pump motor is ON. When stoppingABS operation, the pump motor is OFF. T h e c a l i p e r l u i d i s p u m p e do u t b y t h e p u m p ,t h r o u g ht h e d a m p i n gc h a m b e rt,o t h e f master vlinder. c
Pressure reducingmode:
lvlotoroperationmode:
19-40
t
WheelSensors
type. As the gear pulserteeth rotate pastthe wheel sensor'smagnetic The wheel sensorsare the magneticcontactless with the wheel speed.The ABS control unit The AC frequencychangesin accordance coil, AC current is generated. and therebydetectsthe wheel speed. detectsthe wheel sensorsignalfrequency
GEARPULSER WHEEL SNSOR .r HIGXSPEED
!t LOW SPEED
Wheel Speed and Modulator Control VEJ!q!ESPEEq 8E!EEETqE
PRESSURE
OUTLET VALVE 9p OFF INLET VALVE oN OFF
MoroR
-,. OFF
I
l t l
the When the wheel speeddrops sharplybelow the vehiclespeed,the inlet valve closesand il necessary, outlet valve pressure. The pump motor startsat this time. As the wheel speed is opens momentarilyto reducethe caliperfluid the caliperfluid pressure. and the outlet valve closes,the inlet valve opens momentarilyto increase restored,
19-41
ABSGomponents
CircuitDiagram
"'----G50l
L "*'*" lJ5 Il
I Gu ^ csl
r * *r + t ? l 'l I
lo+-sN LqF**,
19-42
*- :ffrre, *riq.r.srbm r.l I q_ L md/Y4
7--:::
19-43
ABSComponents
(cont'd) CircuitDiagram
UNDER-HOOD FUSE/RELAY CONNECTORS BOX CONNECTOR {12P) CONNECTOR{12P) A CONNECTOR{2P} B BRAKE PEDALPOSITION SWITCH CONNECTOR 4P
UNDER.DASH FUSE/RELAY CONNECTORS BOX CONNECTOR{5P) I CONNECTOR I17P) K
MULTIPLEX CONTROL UNIT13PCONNECTOR
1l2l3l,/15 1 2 3 4
8
5 67 1011121 3 415 1 1 1
CONNECTOR I22PI B
1 2 3
,/ ,/
6 7 8 9 10 11n2 13
GAUGE ASSEMBLY CONNECTORS CONNECTORI22P) A
ABSCONTROL 3IP CONNECTOR UNIT
q,
1 2
4 5 6 7 8 I
16 1 1 1 8 1 9
1112 1 415 20 21/1,/1,/vl,/l
/t,/t/t,/t/
OATA LINK CONNECTOR {16P)
WHEEL SENSOR CONNECTORS 2P FRONT

J --T:-l L t q t t / ) l 'l L_.:-:J r \-r-----Tr'
e:l
RIGHT.REAR
LEFT-REAR
tslTt?t I tL |
/J 1T-1\ J \t rlzi
T e r m i n as i d eo f m a l el e r m i n a l s l
19-44
DTCTroubleshooting
DTC11,13,15,17:WheelSensor (Open/Short BodyGround/Short Power) to to
the 1. Disconnect ABS control unit 31Pconnector.
the for between appropriate 5. Check continuity (+ andbodyground terminal wheelsensor ) circuit t { s e ea b l e ) . DTC
Appropriate Terminal 11 (Riqht-front)
2. Start the engine. 3. Measurethe voltagebetweenthe appropriate ( w h e e ls e n s o r * ) c i r c u i t t e r m i n a lo f t h e A B S control unit 31Pconnectorand body ground (see table).
( N o .5 : F R S + )
N o . 7 : F L S( * )
13(Left-front) 1 5( R i o h t - r e a r ) 17(Left-rear)
( N o . 2R R S* ) : ( N o . 9R L S + l
ABS CONTROL UNIT31PCONNECTOR
DTC 11(Rioht-front) 13(Left-front)

15 {Riqht-rear} 17 (Left-rear)
ADpropriate Terminal ( N o . 5 :F R S t ) (*) N o ,7 : F L S
( N o .2 : R R S * ) N o . 9R t S( f )
ABS CONTROLUNIT 31P CONNECTOR
FRS+IIGNR/BLK} FLS +I (BLU I { RRS+) { (GNR/YEL)

Wire side W i r es i d eof femaleterminals
ls therecontinuity? YES Goto step6. NO-Go to step7.

terminals Wiresideof female ls thete battery voltage? YES Repairshort to power in the (+) circuitwire unit and the betweenthe ABS modulator-control wheel sensor. I appropriate NO Go to step 4. 4. Turn the ignition switch OFF. Disconnect harness2P connectorfrom the the wheel sensor,then checkfor continuity appropriate o t b e t w e e nh e 1 + ) a n d ( ) t e r m i n a l s f t h e h a r n e s s and body ground. ls there continuity? Y E S - R e p a i rs h o r t t o b o d y g r o u n di n t h e ( + ) o r { ) circuitwire betweenthe ABS modulator-control unit and the wheel sensor.l the NO Repiace wheel sensor.l
(cont'd)
19-45
ABS Components
7. Checkthe resistance betweenthe appropriate ( w h e e ls e n s o r + ) a n d ( ) c i r c u i t e r m i n a l s s e e { ta ble).
DTC12,14, 18:Wheel 16, Sensor Putse Signal

NOTE:lf the ABS indicatorcomes on for the reasons describedbelow,the indicatorgoes off when you testd r i v et h e v e h i c l e t 3 1 m p h ( 5 0k m / n l . a . Only the drive wheel rotated . T h ev e h i c l e p u n s . Electrical noise 1 . V i s u a l l y h e c k o r a p p r o p r i a t w h e e ls e n s o r a n d c f e pulserinstallation and condition(seetable).
DTC
11 {Riqht-front)
'13 {Left-front)
1 5( R i o h t - r e a r ) 17 (Left-rear)
Appropriate Terminal *lSide l+) Side No.5: RS*) N o . 4 : F R S ) F ( 1N o .7 : F L S + i N o . 6F L S{ : ( ( No. RBS 2: {+) N o .1 : R B S- ) N o . 9 : L S - N o . 8B L SR 1 : (
DTC 12
14 18
Appropriate Wheel Sensor Riqht-front Left-front Riqht-rear Left-rear
Ate they installed correctly and not damaged? YES-Go to step 2,

NO Reinstall replacethe appropriate or wheel sensor r pulser,I o Is the rcsistance between 450 2,000 A ?
\\|D
YES Checkfor a looseABS control unit3lP connector.lf necessary. substitutea known-good ABS modulator-control unit, and recheck.l NO Go to step 8.
2. Disconnect ABS control unit 31Pconnector. the 3 . Measurethe resistance betweenthe appropriate
( w h e e ls e n s o r f ) a n d ( ) c i r c u i t e r m i n a l s s e e ( table).
DTC
Disconnect harness2P connectorfrom the the appropriate wheel sensor,and checkthe resistance b e t w e e nh e ( + ) a n d { ) t e r m i n a l s o f h e w h e e l t t sensor. ls the resistance between 450- 2,000 Q ? Y E S - R e p a i ro p e ni n t h e ( + ) o r ( - ) c i r c u i t i r e ,o r w short betweenthe (+) circuitwire and the { ) circuitwire betweenthe ABS modulator-control u n i ta n d t h e w h e e ls e n s o r . l N O R e p l a c eh e w h e e ls e n s o r . l t 12 {Rioht-front) 14 (Left-front) 1 6( R i q h t . r e a r ) 18 (Left-read
Appropriate Terminal l*) Side ) Side N o . 5 : F ( *S B No.4:FBS N o . 7 ; F L*S l No,6:FLS N o . 2 : R( * R S N o1 : B R S . N o . 9B L S : 1 No.8:RLS
ls therc less than 450 Q ? YES Go to step 1. N O - G o t o s t e p4 .
19-46
4. Checkfor continuitybetweenthe appropriate ( a w h e e ls e n s o r + ) c i r c u i t t e r m l n a l n d o t h e r w h e e l ( ( s e n s o r + ) c i r c u i t e r m i n a l s s e et a b l e ) .
(Chipped Operation DTC21:Continuous pulser)

the HondaPGM 1. Clearthe DTC,then disconnect tesler. 2. Test-drive vehicleat 19 mph (30 km/h)or more. the Doesthe ABS indicator come on and is DTC 21 indicated? YES Go to step 3.
DTC Appropiate Terminal 12 No.5: ( FRW*i '14 No.7: FLWIT.) to No.2; RRW(T-) No.9: 18 ( RLW *)
Other Terminal No.7 No.5 No.5 No.5 No.2 No.2 No.7 N o .7 No.9 No.9 No.9 No.2
NO The system is OK at this time.l 3. Checkthe pulsergear for a chippedtooth. ls the pulser OK? YES Checkfor a looseABS control unit 31P substitutea known-good connector.lf necessary, unit, and recheck.l ABS modulator-control the NO Replace driveshaftor hub unit (chipped pulser ear).1 g
YES Repairshort in the wires betweenthe wheel sensorand the other wheel appropriate sensor arnesses.l h the Honda PGM NO Clearthe DTC,disconnect the vehicle.lf the ABS Tester,and test-drive indicatorcomes on and the same DTCis indicated, unit.l replacethe ABS modulator-control Disconnect harness2P connectorfrom the the wheel sensorand checkthe resistance appropriate t b e t w e e n h e ( + ) s i d ea n dt h e ( - ) s i d eo f t h e w h e e l sensor. ls there lessthan 450 Q ? the YES Replace wheel sensor. NO- Repairshort to wire betweenthe appropriate ( w h e e ls e n s o r + ) a n d ( - ) c i r c u i t s . l
1g-47
ABSComponents
DTC31,32.33,34,35,36,37,38:Solenoid
1. Clear DTC, the thendisconnect Honda the PGN4 Tester. 2. Test-drive vehicle. the Doesthe ABSindicator comeon and are DTCs 31, 32, 33, 34, 35, 36, 37, 38 indicated? YES Replace ABSmodulator-control the unit.t NO Thesystem OKat thistime.t is
DTC51:Motor Locked
'1. C h e c k h e N o . 1 0 ( 4 0 A ) f u s en t h e u n d e r - h o o d f u s e / t i retayDox. ls the tuse OK? YES-Reinstall the fuse, and go to step 2. NO- Replace fuse, and recheck.l the 2. Disconnect ABS control unit 31Pconnector. the 3. Measurethe voltagebetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o . 1 7a n d b o d y g r o u n d . ABS CONTROL UNIT31PCONNECTOR
I
Wiresideof female terminals ls thete battery voltage? YES Go to step 4. NO Repairopen in the wire betweenthe N o . 1 0 (40A)fuse and the ABS control unit.l
19-48
4. Checkfor continuitybetweenthe ABS control unit 31P connectorterminal No. 16 and body ground. ABS CONTROL UNIT31PCONNECTOR
DTG52:MotorStuckOFF
u 1 . C h e c t h eN o .1 0 ( 4 0 Af ) s ei n t h eu n d e r - h o o d k box. fuse/relay ls thef useOK?
YES-Reinstall the fuse, and go to step 2. NO-Replace the fuse, and recheck.l| the 2. Disconnect ABS control unit 31Pconnector.
3 . Measurethe voltage betweenthe ABS control unit

3 1 Pc o n n e c t otre r m i n a lN o . 1 7 a n d b o d y g r o u n d UNIT31PCONNECTOR ABSCONTROL
ls there continuity? YES-Go to step 5. NO Repairopen in the wire betweenthe ABS control unit and body ground (G202).1 the Reconnect ABS control unit 31Pconnector. the HondaPGM 6. Clearthe DTC,then disconnect tester. 7 . Test-drive vehicleat 6 mph (10 km/h) or more. the
ls there battery voltage? Doesthe ABSindicator come on, and is DTC 51 indicated? unit.l the YES Replace ABS modulator-control NO The system is OK at this time.l YES-Go to step 4. NO Repairopen in the wire betweenthe N o . 1 0 (40A)fuse and the ABS control unit.l
(cont'di
19-49
ABS Components
4. Checkfor continuitvbetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o . 1 6 a n db o d y g r o u n d . ABSCONTROL UNIT31PCONNECTOR
DTC53:MotorStuckON
1 . C l e a r h e D T C t h e n d i s c o n n e c t e H o n d ap GM t , th Tester. 2. Test-drive vehicle. the Does the ABS indicatot come on and is DTC 53 indicated? YES -Go to step 3. NO- lntermittentfailure,the system is OK at this trme.l
Wiresideol female terminals
3 . Disconnect ABS control unit 31Pconnector. the

ls there continuity? YES-Check for looseterminalsin the ABS control unit 31Pconnector.lf necessary, substitutea known-goodABS modulator-control unit, and recheck.l NO Repairopen in the wire betweenthe ABS c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . 1 Checkfor continuitybetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o , 1 6 a n d b o d y g r o u n d . ABSCONTROL UNIT3,IPCONNECTOR
ls therc continuity? YES-Replacethe ABS modulator-control unit.t NO-Repair open in the wire betweenthe ABS c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . I
19-50
Stuck OFF DTC MainRelay 54:

f d 1 . C h e c k t h e o . 8 ( 2 0 A ) u s ei n t h e u n d e r - h o o f u s e / N f r e l a yb o x ,a n d r e i n s t a l l t h eu s ei f i t i s O K . ls the f use OK? YES-Go to step 2.
DTC lG2Voltage 61:

) t N O T E C h e c k h e N o . 1 1 ( 7 . 5 A f u s ei n t h e u n d e r - d a s h : fuse/relaybox beforetroubleshooting. th t t 1 . C l e a r h e D T C , h e n d i s c o n n e c t e H o n d aP G M tesler. 2. Test drive the vehicle.
the NO Replace fuse, and recheck.l the 2. Disconnect ABS control unit 31Pconnector. the 3. l\4easure voltagebetweenthe ABS control unit c o n n e c t otre r m i n a lN o . 1 8 a n d b o d y g r o u n d . ABSCONTROL 31PCONNECIOR UNIT Doesthe ABS indicator come on and is DTC 61 indicated? YES Go to step 3. NO The system is OK at this time.l tt 3 . D i s c o n n e c h e A B S c o n t r o lu n i t 3 l P c o n n e c t o r . 4 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 5. Measurethe voltage betweenthe ABS control unit N 3 1 Pc o n n e c t o r t e r m i n a l o . 1 5 a n d b o d y g r o u n d . ABSCONTROL 31P UNIT CONNECTOR
Is there battety voltage? unit.l YES Replace ABS modulator-control the NO-Repair open in the wire betweenthe ABS fuse/relaybox.I control unit and the under-hood
ls there battery voltage? unit.l the YES Replace ABS modulator-control NO - Repairopen in the wire betweenthe ABS control unit and the under-hood{use/relaybox.l
19-51
ABSComponents
DTC CPU(Central 81: Processing Unit)
1. Clearthe DTC,then disconnect the HondaPGM Tester. 2. Test-drive vehicle. the Does the ABS indicator come on and is DTC 81 indicated? YES Replace ABS modulator-control the unit.l NO Go to step 2, NO-The system is OK at this time. t Pull up the parkingbrakelever. Does the btake system indicator come on? YES Go to step 3. NO Repairopen in the indicatorpower source circuit.lf necassary, substitute known-goodABS a modulator-control unit, and recheck. I . Blown No, 10 (7.5A) fuse. . O p e ni n t h e w i r e b e t w e e n h e N o . 1 0 ( 7 . 5 A ) f u s e t a n dl h e g a u g ea s s e m b l y , . Open circuitinsidethe fuse box.
ABS IndicatorGircuit Troubleshooting

ABS indicator does not come on
1 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d w a t c ht h e A B S s indicator. Does the ABS indicator come on? YES The system is OK at this time.I

Disconnect ABS control unit 31Pconnector. the
5. T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
Does the ABS indicator come on? YES-Check for looseterminalsin the ABS control unit 31Pconnector.lf necessary, substitutea known-goodABS modulator-control unit, and recheck.l NO Go to step 6. 6 . Turn the ignition switch OFF. 7 . Removethe gauge assembly(seepage 22-64).
19-52
the 8 . Disconnect gaugeassemblyconnectorA (22P).
ABS indicator does not go off

fuse/ in 1. Checkthe 8 (20Alfuse the under-hood No. relaybox,andreinstall fuseif it is OK. the ls the fuse OK? YES Goto step2. lf NO-Replace fuse,andrecheck. thefuseis the blown, check a shonto bodygroundin thisfuse for is the ll circuit. thecircuit OK,replace ABS modulator-control I unit.
fuse in the under-dash Checkthe No. 11 (7.5A) fuse/relaybox, and reinstallthe fuse if it is OK.
9 . Checkfor continuitybetweengauge assembly

connectorA {22P) terminal No, 12 and body ground. A ASSEMBLY CONNECTOR(22P) GAUGE
ls the f use OK? ls there continuity? YES- Repairshon to body ground in the wire betweenthe gaugeassemblyand the ABS control unit.l NO Go to step 10. YES Go to step 3. If NO Replace fuse, and recheck. the fuse is the blown, checkfor a shortto body ground in this fuse circuit.lf the circuit is OK, replacethe ABS unit.I modulator-control the 3 . Disconnect ABS control unit 31Pconnector. Measurethe voltage betweenterminal No. l8 and body ground. UNIT3lP CONNECTOR A8S CONTROL B GAUGE ASSEMBLY CONNECTOR(22PI
'10.Disconnect gaugeassemblyconnectorB (22P). the 1 1 .Checkfor continuitybetweengauge assembly

terminal No. 12 and body ground. connectorB (22P)
terminals Wiresideol Iemale ls there battery voltage? ls there continuity? YES-Go to step 5. YES Checkfor looseterminalsin the gauge lf are OK, assemblyconnectors. the connectors replacethe gaugeassembly.l NO Repairopen in the wire betweenthe gauge a s s e m b l y n d b o d y g r o u n d( G 5 0 1 ) . 1 a (cont'd) NO Repairopen in the wire betweenthe No. 8 (20A)fuse and the ABS control unit.l
19-53
ABSComponents
(cont'dl ABS IndicatorCircuitTroubleshooting
5. Turn the ignitionswitch ON (ll). 6 . Measurethe voltage betweenthe ABS control unit
31PconnectorterminaI No. 15 and body ground. ABSCONTROL UNIT3IP CONNECTOR
ABSCONTROL UNIT31PCONNECTOR
10. Connect the ABS control unit3lPconnector t e r m i n a lN o . 2 0 a n d b o d y g r o u n dw i t h a j u m p e r wire.
Wire side of femaleterminats
Wiresideof female terminals Is there battety voltage? YES-Go to step 7. NO-Repair open in the wire betweenthe No. 11 (7.5A) fuse and the ABS control unit.I 1 . Turn the ignition switch OFF. 8 . Checkfor continuitybetweenthe ABS control unit 31Pconnectorterminal No. 19 and body ground. ABSCONTROL UNIT31PCONNECTOB 'l '1.
Does the ABS indicator go off? YES-Check for looseterminalsin the ABS control unil 31Pconnector.lf necessary, substitutea known-goodABS modulator-control unit, and recheck.I NO Go to step 11. Removethe gaugeassembly,and leavethe connectors connected. Connectthe gauge ) a s s e m b l y o n n e c t oA ( 2 2 P t e r m i n a lN o . ' 1 2 n d c r a body ground with a jumper wire. GAUGE ASSEMBLY CONNECTOR(22P) A
ls there continuity? YES Go to step 9. NO-Repair open in the wire betweenthe ABS control unit and body ground (G202). t 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
Does the ABS indicator go off? YES-Repair open in the wire betweenthe gauge a s s e m b l y n d t h e A B S c o n t r o lu n i t . I a NO-Check for loosegauge assemblyconnectors. lf the connectorsare OK, replacethe printedcircuit b o a r di n t h e g a u g ea s s e m b l y . l
19-54
BrakeSystemIndicatorGircuitTroubleshooting
Brakesystem indicator does not come on
'1. nectthe m ultiplexcontroI unit l3Pconnector Discon and the ABS control unit 31Pconnector.
Brakesystem indicatordoes not go off

1 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s t b 2 . R e l e a s eh e p a r k i n g r a k e .
2. Checkfor continuitybetweenthe ABS control unit 3 l P c o n n e c t otre r m i n a lN o , 2 1 a n d b o d y g r o u n d .

UNIT31PCONNECTOR ABS CONTROL
Does the brake system indicatot go ofl after several seconds? YES The system is OK at this time.l NO Go to step 3. 3. Checkthe brakefluid level. ls the level OK? YES Go to step 4.
NO Refillthe brakefluid, and recheck.l 4. Checkthe ABS indicator.
ls there continuity? Does the ABS indicator stay on? YES Repairshort to body ground in the wire betweenthe multiplexcontrol unit and the ABS c o n t r o lu n i t . l NO Go to multiplexcontrol system trou bleshootinglsee page 22''172).a YES Readthe ABS DTC(seestep 1 on page 19-32). for troubleshooting the DTC and do the applicable NO Go to step 5. 5. Turn the ignition switch OFF. tt 6 . D i s c o n n e c h e A B S c o n t r o lu n i t 3 l P c o n n e c t o r . 7 . C o n n e ctth e A B S c o n t r o lu n i t3 1 Pc o n n e c t o r t e r m i n a lN o . 2 1 a n d b o d y g r o u n dw i t h a j u m p e r
W i r es r d eo f l e m a l el e r m i n a l s
(cont'd )
19-55
ABSComponents
BrakeSystemIndicatorGircuitTroubleshooting (cont'd)
8 . Turn the ignititonswitch ON (ll). 9 . Checkthe brakesystem indicator. Does the brake system indicatot go off? YES-Replace the ABS modulator-control unit.l NO-Go to step 10.
1 0 .Turn the ignitionswitch OFF. 1 1 .Connectthe multiplexcontrol unit 13Pconnector

'l t e r m i n a lN o . a n d b o d y g r o u n dw i t h a j u m p e rw i r e . MULTIPLEX CONTROL UNIT13P CONNECTOR
JUMPER WIRE
\
12. Turn the ignitionswitch ON (ll). 1 3 .Checkthe brakesystem indicator.

Does the btake system indicatot go off? YES Repairopen in the wire betweenthe multiplexcontrol unit and the ABS control unit.l NO Go to multiplexcontrol system g troubleshootin (seepage22-17 a 2).
19-56
ABS Modulator-Control Unit Removaland lnstallation

NOTE: . D o n o t s p i l lb r a k e l u i d o n t h e v e h i c l e i;t m a y d a m a g e h e p a i n U f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f f t i immediatelywith water. . Becarefulnot to damageor deform the brakelines during removal and installation. . To preventthe brakefluid from flowing, plug and cover the hose ends and joints with a shop towel orequivalent malenal.
Removal
'1. Turn the ignitionswitch OFF.
2 . P u l lu p t h e l o c k ( A )o f t h e A B S c o n t r o u n i t 3 l P c o n n e c t o r ( B ) , t h e n d i s c o n n e c t t h e c o n n e c t o r . l
FLARE NUT l5 N.m (1.5kgt.m,11 lbt.ftl
6)o
CI
I mm NUT 8.8N.m {0.9kgl m.6.5lbfft)
--/Q
\---'
\.
\,
6 mm BOLT 9.8N.m ksf.m,7.2lbf.ft) 11.0
(cont'd)
19-57
ABS Gomponents
ABS Modulator-Control Unit Removaland Installation{cont'dl
3. Disconnectthe brakelines. six 4. Removethe two I mm nuts. 5. Removethe ABS modulator-control unit (C).
Installation
'1. I n s t a l l t h e A B S o d u l a t o r c o n t r o l n i t ,t h e nt i g h t e n h e t w o 8 m m n u t s . m u t
2. Align the connectingsurfaceofthe ABS control unit 3'lP connector. . 3 . P u s h i n t h e l o c k o f t h e A B S c o n t r o l n i t3 1 Pc o n n e c t o u n t i ly o u h e a ri t c l i c ki n t o p l a c e t h e nc o n n e c t h e c o n n e c t o r . u r 4. Connect the six brakeIines. 5. Bleedthe brakesystem,startingwith the front wheels. 6. Connectthe PGMTester,and do the solenoidfunctiontest for each wheel. 7. Bleedthe brakesystem again,staning with the front wheels. 8. Startthe engine,and checkthat the ABS indicatorand brakesystem indicatorgo off. 9. Disconnect Honda PGMTester.Test-drive vehicle,and checkthat the ABS indicatorand brakeqvqtem the the i n d i c a t od o n o t c o m e o n . r
19-58
WheelSensorInspection
1 . Inspectthe front and rear pulsersfor chippedor damagedteeth.
WheelSensorReplacement
NOTE:Inslallthe sensorscarefullyto avoid twisting the wtres. Front:
6 mm BOLT 9.8 N.m {1.0kgf.m,7.2lbf.ftl
2. Measurethe air gap betweenthe wheel sensorand

the pulserall the way around while rotatingthe pulser.Removethe rear brakedisc to measurethe gap on the rearwheel sensor.lf the gap exceeds 1 . 0m m ( 0 . 0 4 n . ) , h e c k o r a b e n ts u s p e n s i o a r m . i f c n Standard: Front; 0.4- 1.0mm (0.02-0.04 in.) Rear: 0.2 1.0mm (0.01 0.04 in.l Front:
0.4 '1.0 mm 10.02 0.0'l in.l
6 mm BOLT 9.8 N.m {1.0kgf.m,7.2lbf.ftl
WHEEL SENSOR
Rear: 6 mmBOLT
9.8 N.m kgf.m,7.2lbf.ft) 11.0 6 mm BOLT 9.8 N.m (1.0kgf'm,
7.2rbr.ft)
Bear:
0.2 1.0mm in.} {0.01 0.04
19-59
Body
Doors
C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . L n 20-2 D o o rP a n eR e m o v a l / l n s t a l l a t i o.n . . , . . . . . .20,4 l . . .... DoorOuterHandle Replacement 20-6 DoorLatchReplacement 20-7 DoorGlassand Regulator Replacement 20-9 . . . . D o o rS a s h r i mR e p l a c e m e n.t. . . . . . . . . . . . . . 2.0 .t.0. T DoorGlassOuterWeatherstrip Replacement 20- 10 Beplacement DoorWeatherstrip 20-11 D o o rG l a s s d j u s t m e n t . . . . . . . . . . . . . . . . . . . . . .20-11. . . . A . ...... D o o rP o s i t i oA d j u s t m e n . . . . . . . . . . . . . . . . . . . .20-12 . . n t ....... D o o rS t r i k eA d i u s t m e n.t. . . . . . . . . . . . . . . . . . . . .2 .0 . . 3. . . . r . .1. L n ....... C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . . . .20-14 . P o w e r i r r o r e p l a c e m e n . . . . . . . . . . . . . . . . . .2 0.- 1.5 . M R .t .. .. . M i r r o r o l d e R e p l a c e m e n.t. . . . . . . . . . . . . . . . .20-15. . H r . ...... R e a r v i e w i r r o r e p 1 a c e m e.n t . . . . . . . . . . . . . . 0.-.1.6 M R .. 2. .
Dashboard
Instrument Panel Removal/lnstallation ........ 20-59 Driver's Dashboard LowerCover Removat Installation 20-59 Driver's Dashboard UnderCover Remova Insta llation 20-60 t Oriver's Pocket Removal/lnstallation ............ 20,60 ShiftLever Trim Removal/lnstallation .......... 0 6 1 2 C e n t eP a n eR e m o v a l / l n s t a l l a t i. o.n . . . . . . .20-62 r l . . .... Passenger's Dashboard LowerCover Remova l/lnsta ion llat 20-63 x GloveBox Removal/lnstallation 20-63 Dashboard SideVent R e m o v a l / l n s t a l l a t i. o.n . . . . . . . . . . . . . . . . . . . 2.0.-.6 . . . . . . . . . .4 Beverage HolderRemoval/lnstallation ........ 20-64 Driver'sTray Removal/lnstallation ............... 20-65 Passenger's Removal/lnstallation Tray ........ 65 20 * Dashboard Removal/lnstallation .................. 20-66 S t e e r i" H a n q eB e a mR e o l a c e m e n.t. . . . . . . . 0 - 6 8 nq r . 2. Component Location Index ........................... 20-10 * FrontSeatRemoval/lnstallation ................... 20-11 * FrontSeatDisassembly/ R e a s s e m b l y - D r i v e . . s. . . . . . . . . . . . . . . . . . . 2.0 .-.7 . . . . . .r'. . . .3 * FrontSeatDisassembly/ R e a s s e m b l y - P a s s e n g . .r '.s . . . . . . . . . . . . .2 0.- 7.4 . .e . . .. .. . * F r o n t e a t o v e r e p l a c e m e n . . . . . . . . . . . . . .2 . . .-.7 5 S C R .t .O . R e a r e a tR e m o v a l / 1 n s t a 1 1.a t i o.n . . . . . . . .2 . . - . .0 .... . . 0 .8 S RearSeat-back LatchReplacement .............. 20-81 RearSeat-backStriker Replacement ............ 20-81 RearSeat-back CoverReplacement ............. 20-82 R e a r e a t u s h i o n o v e r e p l a c e m e n . . . . .2 0 . 8 4 R S C C .t .
Mirrors
Glass
Seats
Moonroof
C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . . . .2 0. 1.1. . L n .. . . W i n d s h i e lR e p l a c e m e n t d 20-19 .t ...... B e a r i n d o wR e p 1 a c e m e.n . . . . . . . . . . . . . . . . .20-25 . . W R .t ...... O u a r t eG l a s s e p l a c e m e n . . . . . . . . . . . . . . . . . 20-29. . r C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . . . .20,35. . L n ...... Index SymptomTroubleshooting 20-36 H t ....... G l a s s e i g hA d j u s t m e n.t. . . . . . . . . . . . . . . . . . . . 20-37. . . R 20-31 Glass eplacement W i n dD e f e c t o r e p 1 a c e m e n.t. . . . . . . . . . . . . . .20-38 l 8 . ....... R D r a i n h a n n e l e p 1 a c e m e.n.t. . . . . . . . . . . . . . .20 . . . . . C . . . . 39 . ...... S u n s h a dR e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . .20-40. . . . e Motor Replacement 20-41 Frame and DrainTubeReplacement ............ 20,42 A D r a i n h a n n e l l i d e a n dC a b l e s s e m b l y C S r Replacement 20 44 L i m i tS w i t c h d j u s t m e n . . . . . . . . . . . . . . . . . . . . . 20-46. . . A t ....... Closino Force and ODenina DraqCheck ......20,44
Bumpers
lnterioiTrim
F r o n t u m p e R e m o v a l / l n s t a l l a t . o.n. . . . . .20,85 B r i. . ... R e a r u m o e R e m o v a l / l n s t a l l a t.i.o . . . . . . . .20-86 B r .n .... Hood Adjustment 20-47 H o o dS e a l e p l a c e m e n t R 20,88 H o o dI n s u l a t o r e p 1 a c e m e.n.t. . . . . . . . . . . . . . . . . . . . . . R . 20,89
Consoles
L n ...... C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . .20-49. . Trim Removal/lnstallation DoorArea .......... 50 20 Trim Removal/lnstallation -Rear SideArea 20-51 Trim Removal/lnstallation -Cargo FloorArea 20-52 Trim Removal/lnstallation-Hatch ......... Area 20-53 Headliner Removal/lnstallation 20-54 * C a r p eR e p 1 a c e m e.n.t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55 t Frontand Rear Consoles, Remova l/lnsta llation 20-57 FrontConsole Disassembly/Reassembly 20-58 .....
Hatch
FuelFill Door Exterior Trim

Adiustment
Adjustment . . . . . . . . . . . . . .2 0.-. 9 0 .. . H a t c h u p p o n t r u tR e p l a c e m e n.t. . . . . . . . . .2 . .- 9 1 S S . .0 . Hatch WeatherstriD Reo1acement ................. 20-92 . . . . . . . . . . . . . .2 0.-. 9 3 .. .
F r o n t r i l l e e p l a c e m e n.t. . . . . . . . . . . . R . 20-94 G CowlCovers Replac"rn""t .. . ..................... 20-95 A p i l l a r o r n eT r i mR e p l a c e m e n.t. . . . . . . . . .20-96 C r . .... R o o fl M o l d i nR e p l a c e m e n.t. . . . . . . . . . . . . . . . .20-97 . . g . ...... RearLicense Trim Replacement 20,98 H a t c h p o i l e8 e p 1 a c e m e . .t. . . . . . . . . . . . . . . . .20-99 . S r n ....... E m b l e m e p 1 a c e m e.n.t. . . . . . . . . . . . . . . . . . . . . . 0 - 1 0 0 R . 2
Fenderwell
FrontInnerFender Replacement 20-102 F r o n t e n d eF a i r i n g e p l a c e m e n . . . . . . . . . .2.0 . 1 0 3 F r R .t . .FuelPipeProtector Replacement 20-104 R e a r i r O u t l e R e p 1 a c e m e.n.t. . . . . . . . . . . . . . . . . . . . . . A t . 20-'to4
Openers
Frame
n C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . . . .2 . . - 1.0.5 L . 0 .. . H o o dO p e n eC a b l e e p l a c e m e n . . . . . . . . . . .2 . .- 1 0 6 R r .t .0 . * F u e F i l lD o o rO p e n eC a b l e l r Replacement 20 107 H o o dL a t c h e p 1 a c e m e . . t. . . . . . . . . . . . . . . . . . .2 0.-.1.0 . . R n .. . . 8 F u e F i l lD o o rO p e n eR e p l a c e m e n.t. . . . . . . . . .0.- 1 0 9 l r . 2. H a t c h a n d l e e p l a c e m e n.t. . . . . . . . . . . . . . . . .2 . . - 1. . . H R . . 0 . .1 0 H a t c h a t c h e p l a c e m e n.t. . . . . . . . . . . . . . . . . . .2 . .- 1.1.0 L R . .0 .. . . H a t c h o c k y l i n d eR e p l a c e m e n.t. . . . . . . . . .20-111 L C r . .... rameReplacement Subf ................................. 20-112 Frame Stiffener, Brace, and Gusset Replacement ............. 20-113
r Fremp RFnrir Chrrr . . . . . . . . . . . . . .2 0 - 1 1 4 ..
Doors
a
DOOR TRIM OUTER
DOORSASHTRIM page20-10 Replacement,
DOOR GLASS OUTER WEATHERSTRIP
page20-10 Replacement,
DOOR Adiustment, Position page 20-12
K-p IJ
dq
A'A
W2"'
Ya
\J aita.
t
DOOR WEATHERSTRIP page Replacement, 20-'l'l
POWER WINDOW swtTcH
\
POWER DOOR LOCKSWITCH (Driver's)
20-2
GLASS page20-9 Replacement, Adjustment,page20-11
IMMOBILIZER LABEL
@
REGULATOR page Replacement, 20-9
RETAINER CLIP
LOCK CYLINDER \ LOCKKNOB O

ROO CYLINDER PROTECTOR
OUTER HANDLE PROTECTOR
tt
,-\
v4,,(, E ) i l
- /6X@ ( W
STRIKER Adjustment,page20-13
LATCH page20-7 Replacement, POWERDOOR LOCKACTUATOR
20-3
Doors
Door PanelRemoval/lnstallation
SpecialToolsRequired Trim pad remover,Snap-onA 177Aor equivalent, c o m m e r c i a l la v a i l a b l e . y wrap it NOTE:When prying with a flat-tipscrewdriver, tape around tape, and apply protective with protective the relatedparts.to preventdamage. 1. Removethe mirror mount cover (seepage 20-15). 2. Inserta hex wrench through the hole (A) in the door grip base(B),Pushthe door grip cover (C)out to a r e l e a s eh e h o o k( D )a n d t a b ( E ) , n d p u l l o u t t h e t cover to releasethe tabs (F)and hook (G) by hand, then removethe cover. 3. Removethe armrestcover (A).Takecare not to scratchthe door panel. -1 Pry out the front edge of the cover to release the hooks(B). -2 Pry out the bottom and rear edge of the cover to releasethe hooks(C). -3 Pry out along the top to release tabs (D). the
the tabs (C), 4 . Removethe screws(A, B), and release then removethe door grip base(D).Removethe screw (A) securingthe door panelfrom the armrest portion. Fastgngr Locations A> : Screw,3 B > : Screw,5
20-4
5. Pull out the switch panel (A)to releasethe hook (B), then removethe panelfrom the door panel. Disconnect power window switch connector(C). the
7. Disconnect inner handlecable {A) from the the ( i n n e rh a n d l e B ) ,a n d d i s c o n n e c t t h p o w e rd o o r e lock switch connector(C){driver's). Takecare not to bend the cable.
8. Detachthe harnessclip (A)from the door panel (B). B Release clipsthat hold the door panel (A) with a the commerciallyavailabletrim pad remover (B),then removethe door panel by pulling it upward. Removethe door panelwith as little bendingas possibleto avoid creasingor breakingit,
FastenerLocations 95 mm (3.74 in.l
> : Clip,9
ffi EtA
12 mm r q---------i.0.17in.l r <_--'rlmm in.l {0.04 45 mm {1.77 in.l
9 . Installthe door panel in the reverseorder of removal,and note these items: . Replace any damagedclips. . Make sure the cable is connectedsecurely,and the connectoris plugged in properly. . Checkthe window and power door lock operatrons,
20-5
Doors
Door Outer HandleReplacement
your hands. Put NOTE: on gloves protect to 1, Remove theseitems:
. Door panel (seepage 20-4) . Plasticcover,as necessary (seepage 20-2) 4. Disconnect cylinder rod (A),and release the the retainerclip (B).then removethe lock cylinder(C).
2 . R a i s e h e g l a s sf u l l y . t
5.
Removethe lock rod protector(A). -l Removethe screw. -2 Release protectorfrom the latch protector the (B). -3 Pullthe protectordown to release the hook (C) from the door. Fastener Location ) : Screw,1 Disconnect outer handle rod (A). the Fastenor Locations > : Bolt,2
6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ft')
cap (B),and removethe 6 . Removethe maintenance b o l t ss e c u r i n gh e o u t e rh a n d l e( C )w h i l e h o l d i n g t the the handlefrom outside.Release hook (D).then removethe outer handleprotector(E).
20-6
Door LatchReplacement
7. Pull out the outer handle(A),then remove it. NOTE:Put on glovesto protectyour hands. 1. Removethese items: . Door panel (seepage 20-4) . Plasticcover,as necessary (seepage 20-2) Raisethe glassfully.
3 . Removethe lock rod protector(seestep 3 on page

20-6).
4 . Pullthe glass run channel(A) away as necessary,
and removethe bolt, then removethe centerlower channel(B) by pulling il downward Installthe handlein the reverseorder of removal, and note these items: . Make sure each rod is connectedsecurelv. . Make sure the door locksand opens properly. . W h e n i n s t a l l i n t h e l o c kc y l i n d e rl.e a v e t h e o u t e r g door handlebolts looseso the inner protector does not interferewith the lock cylinder installation, then tighten the handle bolts. . Installthe lockcylinder retainingclip on the handle,then installthe lockcylinder.Be sure the i c l i p i s f u l l y s e a t e d n t h e s l o to n t h e l o c kc y l i n d e r . . W h e n r e i n s t a l l i ntg e d o o r p a n e l , a k es u r et h e h m plasticcover is installedproperly,and is sealed aroundthe coversDerimeter. Fastenor Location
1 > : Bolt, IIilE
q
6x1.0mm 8 N.m {0.8 kgf.m, 6 lbf.ftl
(cont'd)
20-7
Doors
(cont'dl Door LatchReplacement
5 . Disconnect cylinder rod (seestep 4 on page 20the 6). 6 . Disconnect outer handle rod (seestep 5 on the page 20-6). 7 . Disconnect actuatorconnectors(A),and release the t h e i n n e rh a n d l e a b l e( B ) f r o mt h e d o o r b y c d e t a c h i n gh e c a b l ec l i p ( C i . t 9. Installthe latch in the reverseorder of removal,and notethese rtems: . [Vlake sure the actuatorconneclorsare pluggedin properly,and that each rod and cable are connectedsecurely. . W h e n r e i n s t a l l i ntg e d o o r p a n e l , a k es u r et h e h m plasticcover is installedproperly,and is sealed aroundthe coversperimeter. . M a k es u r et h e d o o r l o c k sa n d o p e n sp r o p e r l y .
8 . Removethe screws,then removethe latch{A) through the hole in the door. Takecare not to bend the outer handle rod (B),cylinderrod (C),lock rod ( D ) ,a n d i n n e rh a n d l e a b l e( E ) . c Fastener Locations ) : Screw U.#
6x1.0mm 5Nm {0.5kgf.m, 4 tbf.ft)
20-8
Door Glassand RegulatorReplacement

NOTE:Put on glovesto protectyour hands. 1. Removethese items: . Door panel (seepage 20-4) . Plasticcover.as necessary (seepage 20-2) 2 . C a r e f u l l ya i s e h e g l a s s( A )u n t i ly o u c a n s e e t h e r t bolts,then removethem. Carefullypull the glass out through the window slot.Takecare not to drop the glass insidethe door. Fastener Locations ):Boh,2 3. Disconnect and detachthe connector(A) and h a r n e s s l i p ( B )f r o m t h e d o o r . c Fastonor Locations C>: Bolt.1 D>: Bolt,5
6x1.0mm 8 N.m (0.8 kgf.m, 6 rbf.ftl
@
Remove bolts(C), andloosen bolts(D), the then the (E) the remove regulator through holein the the door, grease allthe sliding to Applymultipurpose (A) surfaces the regulator whereshown. of
6x1.0mm 9.8 N m {1.0kgl.m, 7.2 lbf.ftl
Installtheglassand regulatorin the reverseorder of removal,and note these items: . R o l l t h eg l a s su p a n d d o w n t o s e ei f i t m o v e s freely without binding. . Make sure that there is no clearance betweenthe g l a s sa n d g l a s sr u n c h a n n e w h e n t h e g l a s si s l ctoseo. . Adjust the positionof the glassas necessary (see p a g e2 0 - 1 ) . 1 . Checkfor water leaks(seestep 7 on page20-121. . Test-drive and checkfor wind noiseand rattles. . W h e n r e i n s t a l l i ntg e d o o r p a n e l , a k es u r et h e h m plasticcover is installedproperlyand sealed around its perimeter.
20-9
Doors
Door SashTrim Replacement
NOTE: Takecare not to scratchthe door. 1. Removethe door glassouter weatherstrip. (A) 2. Pull backthe door weatherstrip at the rear upper corner,and removethe screw.
Fasten6r Location ) : Screw, I
Door GlassOuterWeatherstrip Replacement

NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe door 1 . R e m o v e h e p o w e rm i r r o r( s e ep a g e2 0 - 1 5 ) . t 2. Startingat the front, pry the door glassouter weatherstrip(A) up to detachthe clips (B),and release weatherstrip the from the door sashtrim (C),then removethe weatherstrip.
Fastener Locations
B>:Clip,s
3 . Lift up the door sashtrim {B)to release hooks the

(C),then removethe trim. lnstallthe trim in the reverseorder of removal.
3 . Installthe weatherstripin the reverseorder ot

removal,and replaceany damagedclips.
20-10
Door WeatherstripReplacement
NOTE: . Takecare not to scratchthe door. . Use a clip removerto removethe clips. 1. At the A-pillar,removethe door stop mounting bolt (A). Fastener Locations A > : B o t t ,1 B>:Clip,1 C>:Clip, 8 1
Door GlassAdjustment
NOTE: . Checkthe weatherstrips and glassrun channelfor and replacethem if damageor deterioration, necessary. . Wipe the run channelcleanwith a shop towel. . Lubricate grease the run channelwith Shin-Etsu P/N 08798-9013. 1. Placethe vehicleon a firm, level surface. 2. Removethese items: . Door panel (seepage 20-4) . Plasticcover {see page20'2) 3. Carefullymove the glass (A) until you can seethe glass mounting bolts (B),then loosenthem.
' 14.----' 'r, .,'o-,,tL' .
.rrt
B 6x1.0mm kgf.m, 7.2lbf.ft) 9.8N.m(1.0 Pushthe glassagainstthe channel(C),then tighten the glass mounting bolts. Detachthe clips (8, C),then removethe door (D). weatherstrip in Installthe weatherstrip the reverseorder of removaland note these items: . Replace any damagedclips. . Make sure the weatherstripis installedln the h o l d e r( E )s e c u r e l y . . A p p l y l i q u i dt h r e a dl o c kt o d o o r s t o p m o u n t i n g bolt beforeinstallation. . Checkfor water leaks(seestep 7 on page20-'121. . Test-drive and checkfor wind noase. Checkthat the glassmoves smoothly.
(cont'd)
20-11
Doors
DoorGlass Adiustment {cont'd)
6. Raisethe glassfully, and checkfor gaps.Checkthat the glass(A) contactsthe glass run channel(B) evenrv.
Door PositionAdiustment
NOTE;Checkfor equal gaps betweenthe front, rear, and bottom door edgesand the body. Checkthat the door and body edges are parallel. 1. Placethe vehicleon a firm, levelsurfacewhen adjustingthe door. 2. Adjust at the hinges{A): . Removethe front innerfender (seepage 20-102) and front fenderfairing (seepage 20-103). Loosenthe hinge mounting bolts (B) slightly,and move the door backwardor forward, uD or down as necessary equalize to the gaps. . Placea shop towel (C)on the jack (D)to prevent damageto the door when adjustingthe door.
7 . Checkfor water leaks.Run water over the roof and on the sealingarea as shown, and note these items: . . . . U s ea 1 2 m m ( 1 / 2i n . )d i a m e t e r o s e( A ) . h Adjust the rate of water flow as shown {B). Do not use a nozzle. H o l dt h e h o s ea b o u t3 0 0 m m ( 1 2i n . )a w a y f r o m the door (C).
t, 12mm1112in,l !
\
29 N.m (3.0kgf.m, 22 tbt.trl
8x1.25mm
\e
300mm {12in.l
Attachthe plasticcover,and installthe door panel (seepage 20-4). 9. Test-drive and checkfor wind noise.
20-12
Door StrikerAdjustment
3. Checkthat the door and body edges are parallel.lf necessary, adjustthe door cushions(A)to make the rear of the door flush with the bodv. w M a k es u r et h e d o o r l a t c h e s e c u r e l y i t h o u ts l a m m i n g it. lf necessary, adjustthe striker(A):The strikernuts u c s a r ef i x e d ,b u t t h e s t r i k e r a n b e a d j u s t e d l i g h t l y p o r d o w n ,a n d i n o r o u t . 1. Loosenthe screws(B),rhen inserta shop towel (C) betweenthe body and striker.
Apply body paintto the hinge mounting bolts and a r o u n dt h e h i n g e s . 5 . Checkfor water leaks(seestep 7 on page 20-12). and checkfor wind noise. Test-drive
m 8 x 1.25 m kgf m, 13 lbf.ft) 18 N.m 11.8
Lightlytlghten the screws. Wrap the strikerwith a shop towel, then adjustthe h s t r i k e r y t a p p i n gi t w i t h a p l a s t i c a m m e r( D ) .D o b not tap the strikertoo hard. Loosenthe screws,and removethe shop towel.
5 . Lightlytighten the screws.

6 . Hold the outer handleout, and push the door againstthe body to be sure the strikerallows a flush fit, lf the door latchesproperly,tighten the screwsand recheck.
20-13
Mirrors
POWER MIRROR ACTUATOR page Replacement, 22-1'18
.a\ b\.\ | \ \-r<,,/

\.J \.4
\ TWEETER
\\
TWEETER
MIRROR MOUNTCOVER
POWER MIRROR page Replacement, 20-15
MIRROR HOLDER page20 '15 Replacement,
__.Q
-'-'
MOUNT /
REARVIEW MIRROR page Replacement, 20 16
20-14
PowerMirror Replacement
1 . Lower the door glassfully.
Mirror HolderReplacement
p 1 . C a r e f u l l y u l l o u t t h eb o t t o me d g eo f t h e m i r r o r holder (A) by hand.Takecare not to scratchthe mrrror.
2. Carefullypry out the mirror mount cover (A) by

the shown. Disconnect hand in the sequence tweeterconnector(B),and releasethe wire harness (C)from the hook (D). Fastener Location
) : Clip,1
t 3 . R e m o v e h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) . connector(A),and detachthe 4. Disconnectthe W t h a r n e s s l i p ( B ) . h i l eh o l d i n g h e m i r r o r{ C ) , c removethe nuts,then removethe mirror. Takecare not to scratchthe door. Fastener Locrtions O: Nut.3
the mirror holderfrom the actuator(B) by Separate slowly pullingthem apart while detachingthe clips (C).lf equipped,disconnect the mirror defogger from the heaterpad terminals. connectors{D) the mirror defogger lf equipped,reconnect connectors. Reattach clips of the mirror holderto the the then positionthe mirror holderon the actuator, actuator.Carefullypush on the clip portionsof the m i r r o rh o l d e ru n t i l t h em i r r o rh o l d e rl o c k si n t o prace. 5 . Checkthe operationof the actuator
5 . lnstallthe mirror in the reverseorder of removal, and note these items: . Make sure the connectoris plugged in properly. . Attachthe harnessclip.
20-15
Mirrors
RearviewMirror Replacement
1. Turnthe mirrorbase(A)90.in eitherdirection.
4, Fit the mirror base over the mount, and securethe mirror by turning the base90".
2. Slide the rearviewmirror (A) down toward the

bottom of the windshield,then detachit from the spring (B) in the mount (C),and removethe rearviewmirror. Takecare notto scratchthe mirror Dase.
3. lf necessary, removethe spring from the mount.
20-16
Glass
FASTENER,2 glassside) {Self-adhesive-type,
PASSENGER'S AIRSAG CAUTION LABEL
DAM SIDERUBBER WINDSHIELD SIDETRIM
4
WINDSHIELD page20-19 Beplacement,
', m-_-==}lny'
S{|---..------'RErA'NER,6
f..N ;\tJ e \ N8*?'

CLIP,4 Blue CLIP RUBBER DAM LOWER DAM,4 UPPER RUBBER
SPOILER 2 FASTENER, (Selt-adhesive-type)
'9>
DAM LOWER RUBBER
(cont'd)
20-17
Glass
OUARTER GLASS FRONT SEAL ..,////
- UPPER CLIP tsetl adhesive-typel
\n iT-
/ LowERcLrp
vI
-.,-''
l / Pl l /
/ J l" n
.--"..---.-_
OUARTER GLASS page Beplacement, 20-29
R AR CLIP (Self-adhesive-type)
(Self-adhesive-type)
LEV EMBLEM
('03model) page20-100 Replacement.
20-18
WindshieldReplacement
NOTE: . Puton gloves protect your hands, to . Weareyeprotection whilecutting glass the adhesive with piano wire. . Useseatcovers avoiddamaging seats. to the items: 1. Remove these . Rearview page20-16) mirror(see . Windshield page22-145) wiperarms(see 2. Pullup the sidetrim (A)to release clips(B)from the (C), to the retainers andpullthetrim rearward the release fromthecliD(D)thenremove trim it from eachsideof thewindshield.
Removethe cowl covers(seepage 20-95).
4. Removethe molding (A) from the upper edge of the
cut windshield(B).lf necessary, the molding with a utility knife.
make lf the old windshieldis to be reinstalled, alignmentmarks acrossthe glassand body with a greasepencil. Pull down the front portionof the headliner(see page 20-54). Takecare not to bend the headliner or excessively, you may creaseor breakit. tape along the edge of the 7 . Apply protective dashboardand body. Using an awl, make a hole and dashboard through the rubber dam, adhesive. sealfrom insidethe vehicleat the corner ponion ot the windshield.Pusha pieceof piano wire through the hole, and wrap each end around a pieceof wood.
(cont'd)
20-19
Glass
(cont'd) WindshieldReplacement
W i t h a h e l p e r n t h e o u t s i d e p u l l t h e p i a n ow i r e { A ) o , backand forth in a sawing motion. Hold the piano wire as closeto the windshield(B)as possibleto preventdamageto the body and dashboard. Carefullycut through the rubber dam and adhesive ( C )a r o u n dt h e e n t i r ew i n d s h i e l d .
-A
10. With a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entirewindshieldopening flange: . Do not scrapedown to the paintedsurfaceofthe body; damagedpaint will interferewith proper bonding. . Removethe rubber dam and fasteners from the oooy. 11. Cleanthe body bonding surfacewith a sponge dampenedin alcohol.After cleaning,keepoil, greaseand water from getting on the cleansurface.
\,
,.-
,,t""""""""',-\ i-..
-1:-, -
-= -.--
12. lf the old windshieldis to be reinstalled, use a puttv knifeto scrapeoff all of the old adhesive, the fastenersand the rubber dam from the windshield. Cleanthe insideface and the edge of the windshieldwith alcoholwhere new adhesiveis to be applied.Make sure the bondingsurfaceis kept free of water, oil, and grease.
20-20
t5.
Glue the side rubber dams (A) and lower rubber dam (B)with adhesive tape (NITTO501M,or equivalent). Glue the fasteners(C)with adhesive tape (3M 4215,or equivalent) the insideface of to t h e w i n d s h i e l d D )a s s h o w n : { . Be sure the rubber dams and fastenersline uD w i t h t h e a l i g n m e n m a r k s( E ) . t . Be carefulnot to touch the windshieldwhere adhesive ill beaoolied. w
t 1 4 . G l u et h e m o l d i n g( A ) w i t ha d h e s i v ea p e{ B ) ( 3 M 4 2 1 2 , r e q u i v a l e n t ) t t h e u p p e re d g eo f t h e o o ( w i n d s h i e l dC ) ; . B e s u r et h e a l i g n m e n m a r k( D )o f t h e m o l d i n g t l i n e su p w i t h t h e a l i g n m e n m a r k( E )o f t h e t windshield. . Be carefulnot to touch the windshieldwhere w adhesive ill beapplied.
t3.
Installthe fasteners(A),retalners(B, C),and clips (D)to lhe body. Fastener Locations A>:Fastener.2 B>:Retainer,2
q\
O C> : R e t a i n e r , 6 > : C l i p , 2
(cont'd)
20-21
Glass
(cont'dl WindshieldReplacement
t o . Set the windshieldin the opening,and centerit.
Make alignmentmarks (A) acrossthe windshield and body with a greasepencilat the four points shown. Be careful not to touch the windshield w h e r ea d h e s i v e i l l b e a p p l i e d . w
18. With a sponge,apply a light coat of glassprimer aroundthe edge of the windshield(A) betweenthe d a m s ( B )a n d m o l d i n g{ C )a s s h o w n ,t h e n l i g h t l y wipe it off with gauzeor cheesecloth: . A p p l yg l a s sp r i m e rt o t h e m o l d i n g . . Do not apply body primer to the windshield,and do not get body and glassprimer spongesmixed
up.
. Nevertouch the primed surfaces with your hands. lf you do, the adhesivemay not bond to the p . w i n d s h i e l d r o p e r l yc a u s i n g l e a ka f t e r t h e a w i n d s h i e l ds i n s t a l l e d . i . Keepwater. dust, and abrasivematerialsaway from the primed surface. 'l',,1rr Applyglassprimerhere.
1 7 . R e m o v eh ew i n d s h i e l d . t
) - ' G1)'r'
B
lnside
,,/ ll\ tl
ol
l l
-A
20-22
19. With a sponge,apply a light coat of body primer to the originaladhesiveremainingaroundthe windshieldopeningflange, Letthe body primer dry for at least 10 minutes: . Do not apply glassprimer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaces with your hands. . l\4ask the dashboardbefore paintingthe off flange. 20 mm (0.79 in.l
21. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) aroundthe edge of the windshield(B) betweenthe d a m s ( C )a n d m o l d i n g( D )a s s h o w n .A p p l yt h e adhesivewithin 30 minutesafter applyingthe glass primer. Make a slightlythickerbead at each corner.
l'1fifr.,1: ?mm
in.l 10.28 A.. )t
n ,..-
$?I.",x1"u.80."., trl
Inside
.,r []\"
- '
20. Beforefilling a cartridge,cut a

( n o z z l e A )a s s h o w n .
"V"
in the end of the
c.. N
2 m m I 'Zn l in.} {0.08 I l
A
\F1
./"
12 mm (0.47in.)
o U s es u c t i o n u p st o h o l dt h e w i n d s h i e l d v e rt h e c t o p e n i n g a l i g ni t w i t h t h e a l i g n m e n m a r k sm a d ei n , step 16,and set it down on the adhesive.Lightly p u s ho n t h e w i n d s h i e l d n t i li t s e d g e sa r ef u l l y u D a s e a t e d n t h e a d h e s i v e l l t h ew a y a r o u n d . o n o t o open or closethe doors until the adhesiveis dry.
7 mm {0.27in.)
(cont'd)
20-23
Glass
(cont'd) WindshieldReplacement
23. Scrapeor wipe the excessadhesiveoff with a putty
knife or towel. To remove adhesivefrom a painted surfaceor the windshield,wipe with a soft shop towel dampensdwith alcohol. 27. On both sidesofthe windshield,installthe side trim (Alto the clip (B),then set the bottom edge of the side trim over the cowl cover (C),and align the c l i p s( D ) w i t ht h e r e t a i n e r ( E ) , n d p u s ho n t h e c l i p s a portionsof the trim until the trim is fully seatedon thewindshield.
24. Let the adhesivedry for at least t hour, then spray

water over the windshieldand checkfor leaks. Mark Ieakingareas,and let the windshielddry, then seal with sealant: . Let the vehiclestand for at least4 hours after windshieldinstallation. the vehiclehas to be lf usedwithin the first 4 hours,it must be driven slowly. . Keepthe windshielddry for the first hour after installation. Reinstallthecowl covers(seepage 20-95). NOTE:Thecowl cover clips may not set properlyif the windshieldadhesiveis too wet. Installthe clips (A, B) on both side trim {C).lf the clip (D) is damaged,replacethe side trim and clips as an assembly. A: Grey B :B l u e
28. R e i n s t a al l l r e m a i n i n g e m o v e dp a r t s .I n s t a l l t h e l r
rearviewmirror afterthe adhesivehas dried thoroughly. NOTE: Advise the customernot to do the following things for 2 to 3 days: . S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p . . Twist the body excessively (suchas when going i n a n d o u t o f d r i v e w a y s t a n a n g l eo r d r i v i n g a over rough, unevenroads).
20-24
RearWindow Replacement
NOTE: . Put on glovesto protectyour hands. . Wear eye protection while cuttingthe glassadhesive w i t h p i a n ow i r e . . Use seatcoversto avoid damagingany surfaces. . Do not damagethe rearwindow defoggergrid lines a n dt e r m i n a l s . 1 . Removethese items: . Hatchlower trim panel (seepage 20-53) . Hatchspoiler(seepage 20-99) Removethese items: . High mount brakelight {seepage 22-821 . Rearwindow wiper motor {see page22-1461 Disconnect rearwindow defoggerconnectors the (A). 6. With a helperon the outside,pull the piano wire (A) backand Jorthin a sawing motion. Holdthe piano wire as closeto the rearwindow (B)as possibleto preventdamageto the hatch,and carefullycut t h r o u g ht h e a d h e s i v e C }a r o u n dt h e e n t i r er e a r {
Cutting positions:
make 4 . lf the old rear window is to be reinstalled, alignmentmarksacrossthe glassand body with a grease encrl, p r 7 . C a r e f u l l ye m o v et h e r e a rw i n d o w . Apply protective tape along the insideand outside U e d g e so f t h e h a t c h . s i n ga n a w l , m a k ea h o l e a f t t h r o u g ht h e a d h e s i v er o m i n s i d e h e v e h i c l e t t h e corner portionof the rearwindow. Pushthe piano w i r e t h r o u g ht h e h o l e ,a n d w r a p e a c he n d a r o u n da pieceof wood,
(cont'd)
20-25
Glass
(cont'd) RearWindow Replacement
With a putty kniie. scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entire rear window openingflange: . Do not scraDe down to the Dainted surfaceof the body; damagedpaint will interferewith proper bonding . Removethe fastenersfrom the tailqate. Cleanthe hatch bonding surfacewith a sponge dampenedin alcohol.After cleaning,keepoil, greaseand water from getting on the surface, ( 1 1 . G l u et h e s i d eu p p e rf a s t e n e r sA )a n d s i d e l o w e r fasteners{B)with adhesivetape {3M 5312,or e q u i v a l e n t G l u et h e u p p e rr u b b e rd a m s ( C ) w i t h ). adhesive tape (NITTO501fM, equivalent) or and glue the lower rubberdam (D)with adhesive tape (3M 4216,or equivalent) the insideface of the to rearwindow (E)as shown. Beforeinstallingthe lower rubber dam, apply primer (3M N-200,or equivalent) the areasbetweenthe alignment to marks {F),then glue the rubber dam on. lf glue the spoilerfasteners(G)with necessary, adhesive tape (3M 5671,or equivalent) the to outsideface of the rearwindow: . Be sure the side upper fasteners, and upper r u b b e rd a m s l i n e u p w i t h a l i g n m e n m a r k s{ H ,l ) . t . Be sure both ends of the lower rubber dam line up with the edge of the glass, . Be sure the spoilerfastenersline up with a l i g n m e n m a r k s{ J ) . t . Be carefulnot to touch the rearwindow where adhesive ill beaDolied. w 1,1,.,1,' : Applyprimerhere. G E
1 0 .lf the old rearwindow is to be reinstalled, a use

putty knifeto scrapeoff all of the old adhesive, the fastenersand the rubberdams from the rear window. Cleanthe insideface and the edge oi the rear window with alcoholwhere new adhesiveis to be applied.Make sure the bonding surfaceis kept free of water, oil and grease.
"6'J1r-,
20-26
12. Glue the side upperfasteners(A) andsidelower fasteners(B)with adhesive tape (3M 5312,or equivalent)tothe hatch as shown. Fastoner Locations A>: Fastener, 2
2 B >: Fastener,
1 5 . W i t h a s p o n g e a p p l ya l i g h tc o a to f g l a s sp r i m e r , along the edge of the rear window (A),upper rubber dams (B),and lower rubberdam (C)as shown, then lightly wipe it off with gauzeor cheesecloth: . With the printeddots (D) on the rearwindow as a guide, apply the glassprimer to both side portionsof the rearwindow. . Do not apply body primer to the rearwindow, and do not get hatchand glass primer sponges m i x e du p . . Nevertouch the primed surfaces with your hands. lf you do, the adhesivemay not bond to the rear window properly.causinga leak afterthe rear w i n d o wi s i n s t a l l e d . . Keepwater, dust, and abrasivematerialsaway from the primed surface. .. : Applyglasspiimer here.
T-8.
ar\\
itf,
cl
t5.
Set the rearwindow in the opening,and centerit. Align the clips (A) of the rearwindow with the holes i n t h e o p e n i n g l a n g e . a k ea l i g n m e n m a r k s( B ) f M t acrossthe rearwindow, hatch,and body with a greasepencilat the four pointsshown. Be careful not to touch the rearwindow where adhesivewill beapplied.
1 4 . R e m o v e h e r e a rw i n d o w . t
(cont'd)
20-27
Glass
(cont'd) RearWindow Replacement
1 6 .With a sponge,apply a light coat of body primer to
t h e o r i g i n a a d h e s i v e e m a i n i n g r o u n dt h e r e a r l r a window openingflange. Letthe body primer dry for at least 10 minutes; . Do not apply glassprimer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaces with your hands. ',,,,,': Applybodyprimer he.e. 18. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) aroundthe edge of the rearwindow (B)as shown. With the glassprimer (C)you appliedin step 15 as a guide,apply the adhesive both side portionsof to the rearwindow. Apply the adhesivewithin 30 minutesafter applyingthe glassprimer. fMake slightlythicker a bead at each corner.
12 mm r, in.) 10.47 ,\
ii'(0.28
in.l
20 mm in.l 10.79
2mm {0.08in.)
aru'.1{-----"
1 7 . Beforefilling a cartridge,cut a nozzle as shown. {A}
"V" in the end ofthe
7 mm (0.27in.)
20-28
OuarterGlassReplacement
19. Use suctioncups to hold the rearwindow over the opening.align it with the alignmentmarks you '13, made in step and set it down on the adhesive. Lightlypush on the rearwindow until its edgesare fully seatedon the adhesiveall the way around.Do not open or closethe doors until the adhesiveis dry. 20. Scrapeor wipe the excessadhesiveoff with a putty knife or towel. To removeadhesivefrom a painted surfaceor the rearwindow, use a soft shop towel dampenedwith alcohol. 21. Letthe adhesivedry for at least 'l hour,thenspray water over the rear window and checkfor leaks. Mark the leakingareas,let the rear window dry, then sealwith sealant.Let the vehiclestandfor at least4 hours after rearwindow installation, the lf vehiclehas to be used within the first 4 hours,it must be driven slowly. p 2 2 . R e i n s t a l l a lrle m a i n i n g e m o v e d a r t s . r NOTE: Advise the customernot to do the following things for 2 to 3 days: . S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p . . Twist the body excessively (suchas when going i n a n d o u t o f d r i v e w a y s t a n a n g l eo r d r i v i n g a over rough, unevenroads). NOTE: . Put on glovesto protectyour hands. . Wear eye protectionwhile cuftingthe glassadhesive with piano wire, . Use seatcoversto avoid damagingany surfaces. 1 . R e m o v e h e C - p i l l atrr i m ( s e ep a g e2 0 - 5 1 ) . t lf necessary, removethe rear side trim panel (see page 20-51 and B-pillarupper trim (seepage 20) 50). 2. Removethe front seal {A) from the front edge of the glass (B).lf necessary, the seal with a utility cut knife.
(cont'd)
20-29
Glass
(cont'dl OuarterGlassReplacement
3 . Apply protectivetape to along the insideand
outsideedgesof the body. Using an awl, make a hole through the adhesive from insidethe vehicle. Pusha pieceof piano wire through the hole, and wrap each end around a pieceof wood. With a helperon the outside,pull the piano wire (A) backand forth in a sawing motion. Holdthe piano wire as closeto the quarterglass(B) as possibleto preventdamageto the body, and carefullycut through the adhesive(C)aroundthe entirequarter grass.
6 . With a putty knife,scrapethe old adhesivesmooth

to a thickness about 2 mm (0.08in.) on the of bonding surfacearoundthe entirequaner glass f openinglange: . Do not scrapedown to the paintedsurfaceof the body; damagedpaint will interferewith proper bonding . Removethe clips from the body. 7 . Cleanthe body bondingsurfacewith a sponge d a m p e n e dn a l c o h o lA f t e rc l e a n i n gk e e po i l , i . . greaseand water from getting on the surface. use a lf the old quarter glassis to be reinstalled, putty knifeto scrapeoff all of the old adhesiveand the rubberdam from the glass.Cleanthe inside face and the edge of the glasswith alcoholwhere new adhesiveis to be applied.Make sure the bonding surfaceis keptfree of water, oil, and grease.
Cuttingpositions:
5. Carefullyremovethe quarterglass.
20-30
9. Set the quarterglass(A) in the opening,and center i t . F r o mi n s i d e h e v e h i c l e m a k ea n a l i g n m e n m a r k t , t (B)to the quarterglasswhere the rear clip will be installedwith a greasepencil.Be careful not to w l o u c ht h e g l a s sw h e r ea d h e s i v e i l l b e a p p l i e d .
11 . A l i g nt h e u p p e rc l i p { A )a n d l o w e rc l i p ( B )w i t h t h e edge of the quarter glass(C),then anachthem with adhesive tape (NITTO571,or equivalent) the to insideface of the quarter glass,and align the center of the rearclip (D)with the alignmentmark (E)you made in step 9, and attach it with adhesivetape (3 M 4215,or equivalent) the insideface of the to quarterglassas shown. Be carefulnot to touch the glasswhere the adhesive tape will be applied.
25.5mm { 1 . 0i n . )
10. Removethe quarterglass.
(cont'd)
20-31
Glass
(cont'dl OuarterGlassReplacement
Firstglue the front seal (A)with adhesive tape {31\4 4 2 1 3 , r e q u i v a l e n t a.n d g l u et h e r u b b e rd a m ( B ) o ) with adhesive tape (NITTO501M,or equivalent) to the insldeface of the quarterglass(C)as shown. Beforeinstalling the front seal and rubber dam, a p p l yp r i m e r( 3 M N - 2 0 0 o r e q u i v a l e n t ) t t h e i n s i d e , o tace of the glass.then glue the seal on: . Be sure the front seal lines upwiththe bottom and front edgesof the glass. . Be careful not to touch the glasswhere adhesive will beaoolied. .,1.,,/:/| Apply prlJnerhete. '13. With a sponge,apply a light coat of glassprimer along the edge of the rubber dam (A) and front seal (B)as shown, then lightly wipe it off with gauzeor cheesecloth: With the printeddots (C)on the quarterglass(D) as a guide, apply the glass primer to the upper and lower corner ponions of the quarterglass. Do not apply body primer to the quaner glass, and do not get body and glassprimer sponges m r x e du p . Nevertouch the primed surfaces with your hands. lf you do, the adhesivemay not bond to the quarterglassproperly,causinga leak afterthe quarterglassis inslalled. Keepwater, dust, and abrasivematerialsaway from the primed surface.
-"-c
30 mm n 1 1 . 1i8 . l 50 mm I {1.97in.1 /
\ t
nL
v - -
i--l
'100 mm {3.9i1in.)
45 mm i { 1 . 7 7n . } 6 mm (0.24in.) 3.5 mm {0.r4 in.l
1 1m m lo.i(} in.)
20-32
14, With a sponge.apply a light coat of body primer to t h e o r i g i n a a d h e s i v e e m a i n i n g r o u n dt h e q u a r t e r l r a glassopeningflange.Let the body primer dry for at least 10 minutes: . Do not apply glass primer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaces with your hands. )'/ii,/ii. I Apply bodv prime. here, (0.08 in.l
mm
16. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) around the edge of the rubber dam (B) as shown. W i t h t h e g l a s sp r i m e r( C ) y o ua p p l i e d n s t e p 1 3 o n i the quarterglass (D)as a guide. apply the adhesive to the upper and lower corner portionsof the quarterglass.Apply the adhesivewithin 30 minutesafter applyingthe glass primer. lvlake a slightlythickerbead at each corner.
20 mm (0.79 in.)
2mm {0.08in.)
l.:J611, ;\
7mm {0.28in.)
3mm { 0 . ' 1 2i n . }
20 mm in.) {0.79
t5.
Beforefilling a cartridge, a "V" in the end ofthe cut nozzle(A) as shown.
'10mm (0.39in.)
7 mm 10.27 in.)
( c o n l ' d)
20-33
Glass
(cont'd) OuarterGlassReplacement
17. Use suctioncups (A)to hold the quarterglassover the opening.align it with the clips (B)and set it down on the adhesive.Lightly push on the quarter glass until its edges are fully seatedon the adhesiveall the way around.Do not open or close the doors untilthe adhesiveis drv.
18. Scrapeor wipe the excessadhesiveoff with a putty from a painted knife or towel. To remove adhesive surfaceor the quarterglass,use a soft shop towel dampenedwith alcohol. 19. Let the adhesivedry for at least t hour,thenspray water over the quarterglassand checkfor leaks, Mark the leakingareas,let the quarterglassdry, then sealwith sealant.Let the vehiclestand for at lf least4 hours after quarterglassinstallation. the vehiclehasto be usedwithin the first 4 hours.it must be driven slowlv. 20. Reinstall remainingremoved parts. all NOTE:Advisethe customernot to do the following things for 2 to 3 days: . Slam the doors with all the windows rolled up. . Twist the body excessively (suchas when going in and out of drivewaysat an angle or driving over rough, unevenroads).
20-34
Moonroof
GLASS HeightAdjustment,page 20 37 paqe 20-37 Replacement, F C l o s i n o o r c e n dO o e n i n o r a o a " D Check;page20-48 DRAINCHANNEL page20-39 Replacement,
COVER /,BR^CKEI
,5
?a<&, _-""-\\q @
..t'- ? .@ -@c I
WIND DEFLECTOR page20-38 Replacement,
E @
_a
LIMITSWITCH (AUTO.STOP SWITCH) page 20-46 Adjustment, E R
CABLE TUBE REAR BRACKET
E STOP
.a'
CABLEASSEMBLY page20-44 Beplacement, page20'41 Replacement, gJ -.- REARDRA'N TUBE
*\
MOONROOF CONTROL UNIT
)
REARDRAIN VAI-VE FRAME page 20-42 Replacement,
20-35
Moonroof
Symptom Water leaks '1. Diagnosticprocedure Checkfor a cloggeddrain tube. and the roof 2. Checkfor a gap betweenthe glassweatherstrip panel. 3. Checkfor a defectiveor an improperlyinstalledglass w e a t h e r s t r i o r d r a i nc h a n n e l . p 4. Checkfor a gap betweenthe drain seal and the roof panel. Also check for Gl a s sh e i g h t adJustment
W i n dn o l s e
Deflector noise
1. Checkfor excessive clearancebetweenthe glassweatherstrip G l a s sh e i g h t panel. adjustment and the root betweendeflectorseal and 1. Checkfor a imDrooerclearance roof panel. deflectorextension. 2, Checkfor a insufficient 3. Checkfor a deformeddeflector. 1. Checkfor a loose motor. 2 . C h e c k o r a w o r n g e a ro r b e a r i n g . f 3. Checkfor a deformedcable assembly. Checkclosingforce
Motor noise
g f Glassdoes not move, 1 . C h e c k o r a d e f e c t i v e e a ro r i n n e rc a b l e . 2. Checkfor foreign matter stuck betweenthe guide rail and the but motor turns r slide . f 3 . C h e c k o r a l o o s ei n n e rc a b l e . 4. l\,4ake sure the cableassemblyis attachedproperly. Glassdoes not move and motor does nol c t u r n( g l a s s a n b e moved with moonroofwrench) 1. 2. 3. 4. 5. 6. Checkfor a blown fuse. Checkfor a faulty moonroof switch. Checkthe limit switch. Checkfor a run down battery. Checkfor a defectivemotor. Checkfor a faulty relay.
20-36
GlassHeightAdjustment
The roof panel (A) should be even with the glass weatherstrip(B).to within 2*0.5/ 1 mm (0.08+0.02l 0.04 in.) all the way around.lf not, make the following adjustment: B
2 + 0.5/ 1mm {0.08+ 0.02/-0.0i1in.}
GlassReplacement
'L C l o s e h e g l a s sf u l l y . t S l i d et h e s u n s h a d e l l t h e w a y b a c k . a Removethe screws (A),then remove both bracket covers (B).Removethe nuts (C)and shims {D)from both glassbrackets(E). Fastengr Locations
A } : Screw, 2
c O ,Nut.
il
@
E
\o
1 , Removethe bracketcover from each side.
2. L o o s e n h e n u t s{ A ) ,a n d i n s t a l l t h e h i m s( B ) t s
betweenthe glassframe (C)and glass bracket(D) on each side. Shim ihickness: Front and rear max. 2 mm 10.08 in.l 6x1.0mm 9 N.m {0.9kgf.m,7 lbf.ft} 4. Removethe glass{A) by lifting it up. Do not damagethe roof panel.
B \
Forward
A 6x1.0mm I N.m(0.9 kgf.m,7lbt.ft) 3. lf necessary, repeaton the oppositeside. 5. Installthe glassin the reverseorder of the removal, a n d a d j u s t h e g l a s sh e i g h ta l i g n m e n t . 6. Checkfor water leaks.Use free-flowingwater from a hose without a nozzle. not use high-pressure Do water.
20-37
Moonroof
Wind DeflectorReplacement
1 . O p e nt h e g l a s sf u l l y . 3. Installthedeflector(A) in the reverseorder of removal,and checkthat lhe deflectorarm base (B) and deflectorlink pivot base (C)line up with the s a m ea l i g n m e n lti n e s( D ) .l f n e c e s s a r y ,d j u s t h e m a forward or backwardso the edge of the deflector seal (E)touchesthe roof panel (F)evenly.Each base must be moved the same amount for adjustment.lf the deflectorseal and roof panel make a rubbing sound, move the deflector backwardas necessary positionit properly. to
4il mm (1.7n.) i
_ l
2 . Removethe screws(A, B), and releasethe hooks

(C),then removethe wind deflector(D).
Fastener Locations
A>:Screw,2B>:
Screw, 2
'a- ' -
20-38
DrainChannel Replacement
1 . Removethe moonroof glass(seepage 20-37). 2 . With the moonroofwrench,move both glass (A) brackets to the positionwhere the moonroof normally pivots down, and removethe screws s e c u r i n gh e d r a i nc h a n n e ( B ) . t l Fastener Locations ) : Screw,2 4 . R e m o v e h e d r a i nc h a n n e ( A ) . t l
I n s t a l l t h e h a n n e il n t h e r e v e r s e r d e ro f r e m o v a l , o c and notethese items: P u s ht h e d r a i nc h a n n e o n t ot h e h o o k su n t i la l faint click is heard. Checkthe glass height adjustment(seepage 2031). Checkfor water leaks.Letthe water run freely from Do a hose without a nozzle. not use a high-pressure spray.
Release drain channel(A)from both hooks{B) the o f t h e d r a i nc h a n n e s l i d e rb y p u l l i n g h e d r a i n l t channelforward,
20-39
Moonroof
Replacement Sunshade
1 . R e m o v e h e d r a i nc h a n n e l . t Slidethe sunshade(A) until you can see both ( s u n s h a d e l i d e rs p a c e r s B ) . s Fastener Locations > : Screw,4 4. While liftingthe front portionofthe sunshade(A), move the sunshadeforward until you can see both s u n s h a d e e a rh o o k s( B ) .D o n o t d a m a g e h e r t s u n s h a d e n dh o o k s . a Fastener Locations ) : Screw,4
tF
(F
3. Removethe screws,then remove both spacers.
5. Removethe screws,then remove both hooks.
20-40
Motor Replacement
6. Removethe sunshade(A), 1 . Removethe headliner(seepage 20-54). Put on glovesto protectyour hands.Disconnecl the connector(A),and removethe bolts,then remove the motor (B). Fastener Locations >:Bolt,2 A
::lll' =r'"'------.-.. --.,
\
?
'l'i
,
@@
..
7 . Removeboth front sunshadebasesliders (A) and ( b o t h r e a rs u n s h a d e a s es l i d e r s B ) b kgf.m. {0.9 7 rbf.ftl
t'-^'
Installthe motor in the reverseorder of removal, and note these items: . lvlake surethe connectoris plugged in properly. . Checkthe motor operation.
' a {
s i o 8 . I n s t a l l t h e u n s h a d en t h e r e v e r s e r d e ro f r e m o v a l , and checkthe glassheight adjustment(seepage 20-37). 9 . Checkfor water leaks.Let the water run freely from Do a hose without a nozzle. not use a high-pressure spray.
20-41
Moonroof
Frame and DrainTubeReplacement
1 . Removethese items: . Headliner(seepage 20-54) . Moonroof glass(seepage20-37)
2. Put on glovesto protectyou r hands.Disconnect motor connector(A),open/close-tilt/close the switch connector

{B),moonroof control unit connector{C),auto-stopswitch connector(D),and the drain tubes (Ei,and removethe
(F). moonroof relays

FastenorLocations
10 > : Bolt,
{um
irl
/^
6x1.0mm 9.8N.m (1.0 kgf.m,7.2lbf ft) Removethe interiorharness(G) by detaching the harnessclips (H).
4 . With an assistant holdingthe frame (l). removethe bolts,startingat the rear,and release the rear hooks (J) by
moving the f rame forward,then removethe frame. 5 . With the help of an assistant, carefullyremovethe frame through the passenger's door opening.Takecare not to scratchthe interiortrim and body, or tear the seat covers.
20-42
6. To removea front drain valve (A)from the body, removethe kick panel,left or right (seepage 20-50). Tie a string to the end of the drain tube, then pull the front drain tube (B)down out of the front pillar.
f o 8 . I n s t a l l t h er a m ea n d d r a i nt u b e i n t h e r e v e r s e r d e r of removal,and note these items: . B e f o r e n s t a l l i n gh e f r a m e ,c l e a rt h e d r a i nt u b e s i t air. and drain valves using compressed . Checkthe frame seal. . Cleanhesurface fthe frame. t o . When installingthe frame, first attachthe rear hooks into the body holes. . Make sure the connectors are plugged in properly. . When connectingthe drain tube, slide it overthe i f r a m en o z z l e t l e a s t1 0 m m ( 0 . 3 9 n . ) . a . I n s t a l l t h e t u b e c l i p ( A ) t h e d r a i n u b e( B )a s t on shown.
1 . To remove a rear drain valve (A)from the cargo compartment,removethe rear side trim panel (see p a g e2 0 - 5 1 ) . D e t a t h e c l i p s( B ) , h e n r e m o v e h e t t ch d r a i nt u b e ( C ) , B
Upward
t I
I
B 9 . Checkfor water leaks.Let the water run freely from Do a hosewithout a nozzle. not use a high-pressure spray.
20-43
Moonroof
DrainChannel Sliderand Cable Assembly Replacement
1. Removethe frame (seepage 20-42). 2. Removethese partsfrom the frame: . Sunshade(seepage 20-40) . Moonroof motor (seepage 20-41) 3. Put on glovesto protectyour hands,Removethe screws(A, B),then removethe slide stops (C)and (D).Removethe bolts (E) cabletube rear brackets from the cabletube side bracket(F)and the cable tube mounting screws(G)from both sidesof the f r a m e( H ) . Fastener Locations A> rScrew.2 B): Screw,2 E > : B o l t , 2 g 5 . P i v o t t h e l a s sb r a c k e ( A )d o w n b y s l i d i n g h e l i n k t t lifter (B) back,then slide both glassbracketsback with the link lifter.
@
r):
Screw 6\-'1
@
( S l i d et h e c a b l ea s s e m b l y A )a n d b o t hg l a s s brackets(B) back,then removethem from the f r a m e( C ) .
Position switch side: 6x1.0mm g , aN . m c A
No switch sidel
o
B
6x1.0mm 9.8 N.m kgf.m,7.2 lbf.ft) 11.0
Detachthe onen switch connectorclip {l)from the frame.
20-44
f l 7 . R e m o v e h e d r a i nc h a n n e s l i d e r ( A ) r o m t h e g l a s s t bracket(B).
i s 8 . I n s t a l l t h e l i d e ra n d c a b l ea s s e m b l yn t h e r e v e r s e , o r d e ro f r e m o v a l a n d n o t et h e s ei t e m s ; . D a m a g e d a r t ss h o u l db e r e p l a c e d . p ' Apply multipurposegreaseto the glassbracket ( A )a n d g u i d er a i lp o r t i o no f t h e f r a m e ( B ) indicatedby the arrows. . Beforereinstalling the motor, make sure both , l i n kl i f t e r s r e p a r a l l e la n d i n t h e f u l l y c l o s e d a position. . Beforereinstalling the motor, installtheframe , t a n d g l a s s t h e nc h e c k h e o p e n i n gd r a g ( s e ep a g e 20-481.
B \
\ ----lll
---':rdrt'Irrt fl u,t La/J' I ll l$=-r:-
20-45
Moonroof
Limit Switch Adjustment
1. Removethe headliner(seepage 20-54).
Fullyclosedpositionadiustment
2. With the moonroof wrench,closethe glass(A) fully: . Make sure both link lifters(B)are parallel,and in the positionshown. . Checkthe g lassfit to the roof panel and the glass height (seepage 20-37).
5x0.8mm 5 N.m {0.5kgf.m,4lbf.ft)
3 . W i t h a n o p e n - e n d r e n c h ,l o o s e n h e l i m i ts w i t c hm o u n t i n gb o l t s( C ) . w t 4. Adjust the limit switch (D): ' Move the switch plate (E)a little at a time, then secureit atthe positionwhere you hear a faint clickwhen the switch cam (F) pushesthe positionswitch (open/close). . Checkthat the switch plate contacts the switch bracket(G).
20-46
Auto-stop position adiustment

5. With the moonroofwrench.operatethe glass(A)to the auto-stopposition.
/--:.!Jtr+rtl
. ,
G
\_-_:_t+#1 <F / \ / \
i! .. I
5 N.m {0.5kgt.m,4 lbt ft)
With an open-endwrench, loosenthe auto-stopswitch m o u n t i n g b o l t s ( C ) . switch (D): 7 . Adjustthe auto-stop . N 4 o v e t h s w i t c hp l a t e( E )a l i t t l e a t a t i m e , t h e n s e c u r e i t a t t h e p o s i t i o n w h e r e y o u h e a r a f a i n t c l i c k w h e n t h e e switch cam (F)pushesthe switch (auto-stop). . Checkthat the switch platecontactsthe switch bracket(G). 8 . Checkthe operationof the glassby operatingthe moonroof switch:From the tilt-up positionto the fully closed position,from the fully open positionto the auto-stopposition,from the auto-stoppositionto the fully closed posltron. spray Do L Checkfor water leaks.Letthe water run fleely from a hosewithout a nozzle. not use a high-pressure
20-41
Moonroof
Closing Force and Opening DragCheck
1 . R e m o v e h e h e a d l i n e( s e ep a g e2 0 - 5 4 ) . t r 2. Closingforce check: . With a shop towel {A) on the leadingedge of the g l a s s( B ) ,a f t a c h s p r i n gs c a l e( C )a s s h o w n . a . Havean assistanthold the switchto closethe glasswhile you measurethe force requiredto stop it. . Readthe force as soon as the glassstops moving, then immediatelyrelease the switch and spring scale. Closing Force; 200 290 N (20 30 kgf,44 66 tbl) 4. Openingdrag check:Protectthe leadingedge of the glasswith a shop towel (A).Measurethe effort requiredto open the glass using a spring scale(B) as shown.
5 . lf the load is over 40 N (4 kgf,9 lbf),check; . The side clearance and glass heightadjustment (seepage 20'37), . F o r b r o k e n r d a m a g e d l i d i n gp a r t s . f a n y o s l s l i d i n gp a r t sa r e d a m a g e d r e p l a c eh e m . , t
lf the force in not within specification, removethe moonroof motor (seepage 20-41), then check: . The gear portion and the inner cablefor breakage and damage.lf the gear portion is broken, r e p l a c eh e m o t o r .l f t h e i n n e rc a b l ei s d a m a g e d , t removethe frame (seepage 20-42), and replace the cable assembly(seepage20-44). ' T h e m o o n r o o fm o t o r ( s e ep a g e2 2 - 1 1 2 ) . t h e If motor fails to run or doesn'ttu rn smoothlv. replaceit (seepage 20-41), . The opening drag. Go to step 4.
20-48
InteriorTrim
TRIM PANEL LOWER HATCH oaoe 20-53 HATCH SIDETRIM page 53 20 TRIM C-PILLAR page 20'51
B.PILLARUPPEBTRIM page20-50 TRIM DOOROPENING page20-50
TRIM A.PILLAR page20-50

R e m o v a l / l n s t a l l a t ip a g e2 0 5 4 on, KICKPANEL page20 50 Replacement, page20-55
DOORSILLTRIM page20-50
CARGOAREA FLOOR page20-52 REAR SIDESHELF page20 5l SHELF CENTER REAR page20-51 REARSIDETRIM PANEL page20-51 CARGOFLOORMAT page20-52 TRIM PANEL REAR page 20-52
20-49
InteriorTrim
Trim Removal/lnstallation Door Area
NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Takecare not to bend or scratchthe trim and panels. 1 . R e m o v e h e t r i m a s s h o w n . o r e m o v et h e d o o r s i l l t r i m a n d B - p i l l a u p p e rt r i m , r e m o v et h e r e a rs i d et r i m p a n e l t T r (seepage 20-51). as necessary 2. Installthetrim in the reverseorder of removal,and note these items: . Replace nydamaged lips. a c . Apply liquid thread lockto the anchor bolts before reinstallatior,. . Beforeinstallingthe anchorbolts, make sure there are no twists or kinks in the belts. Fastener Locations
A>: Clip,2 B > r C l i p , 3 C > : C l i p , ?

(Black) {White)
2ffi Tl|t
,"lF \r{
FRONT SEAT BELT UPPER ANCHOR BOLT 7/16-20 UNF 32 N m (3.3 m,24 lbf.ft) kgf A-PILLAR TRIM
il-::7
KICKPANEL
ao-----
LowER ANcHoR cAP
FRONTSEAT BELTLOWER ANCHOR BOLT 7/16-20UNF (3.3kgt.m,24lbl.ftl 32 N.m REARSIDETRIM PANEL
20-50
Trim Removal/lnstallation RearSideArea

NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Takecare not to bend or scratchthe trim and panels. '1. To removethe rear side trim panel,removethese items: . Rearseat cushionand rear seat-back (seepage20-80) . Cargofloor mat and cargo areafloor (seepage 20-52) . R e a r r i m p a n e l{ s e ep a g e 2 0 - 5 2 ) t 2 . Removethe trim as shown. On the right side,disconnect cargo compartmentlight connector. the
3 . Installthetrim in the reverseorder of removal,and note these items:

. Replace nydamaged lips. a c . Make sure the cargo compartmentlight connectoris pluggedin properly. . l f t h e t h r e a d s o n t h e r e a r s i d e t r i m p a n e l o u n t i n g e l f - t a p p i nE Ts c r e w sa r ew o r n o u t , u s ea n o v e r s i z e s e l f d m s g o t a p p i n gE T s c r e w( P / N9 0 1 3 7 - S 1 A - E1 )1 a d es p e c i f i c a l lfy r t h i s a p p l i c a t i o n . om . W h e n i n s t a l l i n gh e r e a rs i d es h e l f ,s l i pt h e r e a rs e a tb e l tt h r o u g ht h e s l i t i n t h e t r i m . t ' A p p l y i i q u i dt h r e a dl o c k t ot h e a n c h o rb o l t sb e f o r er e i n s t a l l a t i o n . . Beforeinstallingthe anchorbolts,make sure there are no twists or kinks in the belt.
Fastenr Locations A>:Clip,11 B> rClip,2
c>rClap,l -..:.:'
TRIM S I D ES H E L F
SEATSELT REAR
SIDETRIM PANEL SEAT
STRIKER CAP
S I L LT R I M SELF-TAI
scREws
5x0.8mm { 0 . 4k g f m , 3 l b f . f t )
.. F . -\ *: :- . n\ : :
,/\
R E A RB U L K H E A O COVER REARSPEAKERCOVER
,/
\*J
FRONTSEAT AELT LOWERANCHORBOLT REARSEAT BELTLOWER \ 7/16-20UNF ANCHOF BOLT \ 32 N.m 7/16-20UNF \ { 3 . 3k g f m , 2 4 l b t . t t ) 32 N m (3.3 kgf m, 24 lbf ft, \ LOWER ANCHORCAP
20-51
Trim lnterior
- CargoFloorArea Trim Removal/lnstallation
NOTE: . Put on glovesto protectyour hands. tape to preventdamage' . When jrying with a flat-tipscrewdriver, wrap it with protective panels. . Takecare notto bend or scratchthe trim and ( s e ep a g e2 3 - 1 1 ) ' t r t 1 . T o r e m o v e h e r e a rt r i m p a n e l , e m o v e h e c h i l ds e a tt e t h e ra n c h o r 2. Removethe trim as shown. c a , o t 3 . I n s t a l l t h er i m i n t h e r e v e r s e r d e ro f r e m o v a l a n d r e p l a c e n y d a m a g e d l i p s '
Fastener Locations
A > :C l i p , 3 B > : C l i p . 4
j-= E T r
\t
FLOORMAT
COVER REAR SEAT-BACK
-t
CARGOAREA FLO
7
To rearsade trim panel.
To rearsidetrim panel.
REAR TBIM PANEL
20-52
Trim Removal/lnstallation HatchArea

NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Takecare not to bend or scratchthe trim and panels. 1. Removethe trim in the sequenceshown. . . . . Hatchuppertrim panel Left hatchside trim Righthatchside trim Hatchlower trim panel
c 2 . I n s t a l l t h er i m i n t h e r e v e r s e r d e ro f r e m o v a l a n d r e p l a c e n y d a m a g e d l i p s . t o , a
Fastener Locations
o> A>;crip,a B>:crip,2 .>,l,l,Jil,l3
3il;1,
E>:crip.2
"-{q .1. \
Y,]
n g g l f nl t
itr^
HATCH LOWER TRIMPANEL
LowER TRrM O HATCH PANEL
t7,
f.
a- ,,) I
=- -1
->
HATCH UPPER TRIM PANEL
.D HATCHUPPER TRIM PANEL
HATCHSIDETRIM
20-53
InteriorTrim
Headliner RemovaUlnstallation
NOTE: . When prying with a flat-tip screwdriver, wrap itwith protective tape to preventdamage. . Takecare not to bend and scratchthe headliner. . Be carefulnot to damagethe dashboardand other interiortrim. 1. Removethese items: . A-pillartrim, both sides(seepage 20-50) . B - p i l l a u p p e r t r i m ,b o t h s i d e s( s e ep a g e2 0 - 5 0 ) r . Hatchweatherstrip, necessary as {seepage 2092\ . C - p i l l atrr i m , b o t hs i d e s( s e ep a g e2 0 - 5 1 ) . Moonroof switch (seepage22-'112) . Spotlights(seepage 22-961 . Ceilinglight (seepage 22-96) Removethe sunvisor{A) and holder {B)from both srdes. -1 -2 -3 -4 Removethe caps {C). Removethe screws. Removethe sunvisorfrom the body and holder. Using a flat-tipscrewdriver,push the hook (D), a n d t u r n t h e h o l d e r9 0 ' . t h e n p u l l i t o u t .
5x0.8mm 4 N.m {0.4 kgf.m, 3 lbf.ft}
3. From both rear passenger's, removethe caps (A), removethe screws,then removethe grab and ( handlesB). Fastener Locations > : Screw,4 t , t;---iJ
)e
Fastener Locations > : Screw,4
r(\'-r \)*
5x0.8mm 5 N.m {0.5kst m.4lbf ft}
20-54
CarpetReplacement
4. Removethe headliner. -1 Removethe socketplug (A). - 2 R e m o v e h e r e m a i n i n g o o ro p e n i n g r i m { B } t d t from each roof portion. -3 Detach the clips (C),and releasethe fasteners ( D )b y p u l l i n g h e f r o n t p o r t i o no f t h e h e a d l i n e r t (E)down. -4 With the help of an assislant, release the clips (F)of the headlinerfrom the moonroof frame ( G ) ,a n d r e l e a s eh e h e a d l i n efrr o m t h e c l i p s( H ) t by slidingthe headlinerforward, and lowering the headliner. -5 Removethe headlinerthrough the passenger's opening. Fastener Locations
C>:Clip,3
SRScomponentsare locatedin this area.Reviewthe and the SRScomponentlocations(seepage 23-13) (seepage23-14)in the SRS precautions and procedures sectionbefore performingrepairsor service. NOTE: . Put on glovesto protectyour hands. . Takecare not to damage,wrinkle. or twist the carpet. . Be carefulnot to damagethe dashboardor other interiortrim pieces. 1. Removethese items: . Frontseats,both sides(seepage 20-111 . Driver'sdashboardunder cover (seepage 20-60) . Passenger's dashboardIower cover (seepage 20-631 . Rearseatcushion(seepage 20-80) . Kick panels,both sides(seepage 20-50) . Door silltrim, both sides(seepage 20-50) . Consoles, front and rear (seepage20-57) 2 . R e m o v e h e n u t ( A ) ,a n d u s i n ga h e xw r e n c h , t release the clip (B),then removethe footrest(C). Fastener Locations Aa:Nut,1 B):Clip,'l
--'1 I
F>:Clip,2
H>:Clip,2
tj I =\-/
5 . Installthe headlinerin the reverseorder of removal, and note these items: . W h e n r e i n s t a l l i ntg e h e a d l i n etrh r o u g ht h e h passenger's door opening,be carefulnot to fold or bend it, Also, be carefulnot to scratchthe DOOy. . C h e c k h a t b o t hs i d e so f t h e h e a d l i n ea r e t r securelyattached the trim. to . R e p l a c e n y c l i p st h a t r e m a i ni n t h e r o o f d u r i n g a r e m o v a l R e i n s t a l l t h c l i p sb a c ki n t h e h e a d l i n e r . e before installation.
--\
;tt4f
l[il
-JrL
A 6x1.0mm 9.8Nm kgf m,7.2 lbf.ft) 11.0
-o
(cont'd)
20-55
InteriorTrim
(cont'dl CarpetReplacement
Using a utility knife,cut the carpet(A) underthe heaterareas(B),and cut out the parkingbrakelever area (C)as shown, then pull backthe carpet. A B 5. Installthecarpetin the reverseorder of removal, and note these items: . T a k ec a r en o t t o d a m a g e w r i n k l e , r t w i s t t h e , o carpeL . Make sure the seat harnesses routed are correctly. . S l i pt h e c a r p e tu n d e rt h e r e a rs i d et r i m p a n e lo n each side properly. . R e p l a c eh e c l i p i f i t ' sd a m a g e d . t . Reattach cut areasunder the heateraround the the parkingbrakelever with a wire tie. . When installingnew carpet,cut the carpet(A) underthe heaterareas(B),and around the parkingbrakelever (C).After installingthe new carpet,slip the carpetfrom the driver's and passenger's side through the spacebetweenthe heaterunit and body, and reattach the cut area {C)around the parkingbrakeleverwith wire ties.
4 . Removethe clip (A),and release the fasteners(B). Pullthe carpetout from both rear side trim panels (D),then removethe carpet(C). Fastener Location A >: Clip.1
&z
tr
20-56
Consoles
Frontand RearRemoval/lnstallation Console,
NOTE:Takecare not to scratchthe front seal, dashboard, and relatedparts. ( 1 . R e m o v e h e r e a rc o n s o l e A ) . t -1 Slidethe front seatforward fully on each side. -2 Removethe screws{B)from the rear portionof the rearconsole, -3 Slidethe front seat rearwardfully on each side. - 4 P u l l t h ef r o n t p o r t i o no f t h e r e a rc o n s o l e p t o u detachthe clips (C)and hooks (D),then release the rearconsolefrom the front console(E). - 5 S t a r t i n g t t h e r e a r ,p u l l t h e r e a rc o n s o l e p , a u then remove it. Fastener Locations C >: Clip, 2 B >:Screw,2 2. Removethe front console(A). - 1 P u l lo u t t h e d a s h b o a r d e n t e rl o w e rc o v e r{ B ) c to detachthe clips (C). -2 Dlsconnect accessory power socket the c o n n e c t o( D ) . r b 3 R e m o v eh e c o n s o l e o x m a t( E ) . t - 4 R e m o v e h e b o l t s( F ) , c r e w s( G ) ,a n d c l i p s( H ) . t s -5 Gently pull out the front consoleto release the h o o k s( l ) a n dp i n s ( J ) . Locations Fastener C > : C l i p , 3 F > i B o l t , 2 G > : S c r e w . 2H ) : C l i p , 2
..4-* q ' 4!-- L } * fF-\ . / -,-('E9'/ * ' J J d
98Nm (1.0 kgt.m,7.2lbf.ft) Installthe consolein the reverseorder of removal, and note these ltems: . R e p l a c e n yd a m a g e d l i p s . a c . Make sure the accessory power socketconnector i s p l u g g e di n p r o p e r l y . . P u s ht h e c l i p si n t o p l a c es e c u r e l y .
6x1.0mm
20-57
Consoles
Front ConsoleDisassembly/Reassembly
NOTE;Takecare not to scratchthe consoleand relatedparts.
Fastener Locations ):Screw,8
C*
FRONTCONSOLE
\
BEVERAGE HOLDER ASSEMBLY
',/ BOX CONSOLE
,/
20-58
Dashboard
InstrumentPanelRemoval/ Installation
NOTE: . When prying with a flat-tipscrewdriver, wrap it with protective tape, and apply protective tape aroundthe relatedparts,to preventdamage. . Takecare not to scratchthe dashboardand related parts. 1. Tilt the steeringcolumn down. 2. Removethe steeringcolumn upper cover {seepage 17,9). Removethe instrumentpanel (A). -1 Gently pull out along the bottom to release the c l i p s( B )a n d h o o k s( C ) . -2 Gently pull out the upper portionto release the c l i p s( D )a n d h o o k s( E ) .
FastenerLocations
Driver'sDashboard Lower Cover Removal/lnstallation

NOTE:Takecare not to scratchthe dashboardand relatedParts. 1. Removethe driver'sdashboardlower cover (A). -1 Turn the lock knob (B)90". -2 Gently pull out the left side to release the h o o k s( C ) , -3 Pull out the panelto release the hooks (D).
B> : c l i p . 2
D D:,C l i p , 2 ^*,
Installthecover in the reverseorder of removal, and push the hook portions into placesecurely.
4 . Installthe panel in the reverseorder of removal, and push the clip and hook portionsinto place securery.
20-59
Dashboard
Driver'sDashboard UnderCover Removal/lnstallation
NOTE:Takecare not to scratchthe dashboardand relatedparts. 1. Removethe driver'sdashboardunder cover (A). - 1 T u r nt h e l o c kk n o b( B )9 0 ' . -2 Gentlypull down the rear edgeto releasethe clip(C). -3 Pullthe cover away to releaseit from the clip {D). Fastener Locations C >: Clip.1
Driver'sPocketRemoval/ lnstallation
NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe dashboardand related p an s . 1. Removethe driver's pocket(A) -1 Removethe driver'sdashboardunder cover. -2 Removethe screws(B). -3 From behindthe dashboard, push the pocket b a c kb y h a n dt o r e l e a s eh e c l i p s( C ) . t 4 R e l e a s eh e h o o k( D ) . t Fastener Locations B):Screw,2 C>: Clip,2
','"\5
;;t='
Installthecover in the reverseorder of removal, and push the clip portion into placesecurely.
2 . Installthe pocketin the reverseorder of removal, and push the clip portionsinto placesecurely.
20-60
Shift LeverTrim Removal/lnstallation

NOTE: . Takecare not to scratchthe dashboardand related parts. . Put on glovesto protectyour hands. 1. Removethe glove box (seepage20-63). 2. Removethe shift knob. 4. Pull outthe shift levertrim (A) by hand to release t h e r e m a i n i n g l l p s( 8 , C ) a n d h o o k s( D ) ,a n d c disconnect the hazardwarning switch connector(El, then removethe trim. Fastener Locations B >:Clip,1 C > : C l ; p1 ,
D>: Hook,3
,,.;w,
, ,
U s i n ga r a t c h ew r e n c ha n d a n 1 1 i n c he x t e n s i o n t (A)wrapped with a shop towel (B),carefullyinsert the extensionthrough the glove box opening,and push the shift levertrim (C)from underthe trim to releasethe clips (D)and hooks (E)of the left side.
Fastener Locations
Installthe trim in the reverseorder of removal,and note these rtems. . Make sure the hazardwarning switch connectot is plugged in properly. . Pushthe clip and hook portionsinto place securely,
D>clip, 2 i:F \V
E> H o o k , 2
.-a7 \rt1
20-61
Dashboard
CenterPanelRemoval/lnstallation Dashboard
NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, wrap it with protective tape around the tape, and apply protective relatedparts,to preventdamage. . Takecare not to scratchthe dashboardand related parts. code for the radio, 1. Make sure you have the anti-theft for the write down the frequencies the preset buttons. the clips (B) 4. Pull out the centerpanel (A)to release and hooks (C),and removethe harnessholder (D) from the bracket(E).Disconnect audio unit the connector(F),antennalead (G),heaterswitch connector(H)and heatercontrol unit connectors(l). Fastener Locations B ): Clip, 8
*4
, F
2 . Removethese items:
. Driver'sdashboardlower cover (seepage20-59) . Passenger's dashboardlower cover (seepage 20-63). . Glove box (seepage20-63). . Shift levertrim {seepage20-61). From the glove box and driver'sdashboardIower cover openings,loosenthe bolts (A) securingthe centerpanel (B).
Fastener Locations A): Bolt,2 x 0.8 mm 5Nm
Installthe panel in the reverseorder of removal, and note these items: Make sure eachconnectoris pluggedin properly, and antennalead is connectedproperly. Pushthe clip portionsinto placesecurely. Reconnect the negativecableto the battery. idle Do the ECN4/PCt\4 learn procedure{seepage 1l-139). Enterthe anti-theft code for the radio.then enter the customer'sradio stationpresets. Resetthe clock.
;.'
20-62
Passenger's Dashboard Lower CoverRemoval/lnstallation

NOTE: Takecare not to scratchthe dashboardand relatedparts. 1. Removethe passenger's dashboardlower cover (A). -1 Gently pull down the rear edge to release the c t i p s( B ) . -2 Pullthe cover away to releasethe pins (C)from ( the holders D). Fastener Locations B>: Clip,3
GloveBox Removal/lnstallation
SRScomponentsare locatedin this area.Reviewthe ( S R Sc o m p o n e n lto c a t i o n ss e ep a g e2 3 - 1 3 a n d t h e ) p r e c a u t i o na n d p r o c e d u r e ( s e ep a g e2 3 1 4 )i n t h e S R S s s sectionbeforeperformingrepairsor service. NOTE:Takecare not to scratchthe dashboardand relatedparts. 1. Removethe passenger's dashboardlower cover. 2. While holding the glove box (A),removethe glove box stop (B)on each side. Fastener Localions >Boh.2 .-6\
I jl
{Ill fir-"b .-<,/

B
tJ
r-3t.oi,t-'
kgf m, 10.5 4 tbf.ft)
Installthe under cover in the reverseorder of removal,and push the clip ponions into place securety.
Removethe bolts,then removethe glove box. g 4 . l n s t a l l t h e l o v eb o x i n t h e r e v e r s e r d e ro f o removal.
20-63
Dashboard
Dashboard Side Vent RemovaU Installation
NOTE: . Takecare not to scratchthe dashboard. . Put on glovesto protectyour hands. 1. Removethe dashboard(seepage 20-66). 2. Removethe steeringhangerbeam from the dashboard(seepage 20-68). 3. Removethe screws,then removethe air duct (A) ( f r o m t h e d a s h b o a r dB ) . Locations Fastener
):Screw, 7
Beverage HolderRemoval/ lnstallation

NOTE: . Takecare not to scratchthe dashboard, . Put on glovesto protectyour hands. 1. Removethe dashboard(seepage20-66). 2. Removethe screws,then removethe beverage h o l d e r( A ) . Fastener Locations ):Screw.2
6hD
t
4 . Remove the screws, lhen remove the slde vent (A). Fastener Locations ):Screw,4
3 . Installthe beverageholder in the reverseorder of

removat.
o 5 . l n s t a l l t h e i d ev e n t i n t h e r e v e r s e r d e ro f r e m o v a l . s
20-64
Driver'sTray Removal/lnstallation
NOTE: . Takecare not to scratchthe dashboard. . Put on glovesto protectyour hands. 1. Removethe dashboard(seepage 20-66). 2. Removethe beverageholder(seepage 20-64). 3. Removethe screws,then removethe driver'stray (A). Fastener Locations ):Screw.3
Passenger's Tray Removal/ Installation

NOTE: . Take carenotto scratch dashboard. the . Puton gloves protect yourhands. to
1 . Removethe dashboard(seepage 20-66), 2 . Removethe steeringhanger beam from the dashboard(seepage 20-68).
3 . Removethe air duct (seestep 3 on page20-64).

4 . Removethe screws,then removethe passenger's
tray(A). Fastener Locations ):Screw, 8
4, lnstallthe tray in the reverseorder of removal.
5. lnstallthe trav in the reverseorder of removal.
20-65
Dashboard
Dashboard Removal/lnstallation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-13)and the (seepage23-14)in the SRS precautions and procedures sectionbeforeperformingrepairsor service. NOTE: . When prying with a flat-tipscrewdriver, wrap it with protective tape aroundthe tape, and apply protective relatedpartsto preventdamage. . Havean assistant help you when removing and r i n s t a l l i n gh e d a s h b o ad . t . Takecare not to scratchthe dashboard, body, and other relatedparts. . Put on glovesto protectyour hands. code for the radio, 1. Make sure you have the anti-theft for then write down the frequencies the preset buttons. the Disconnect negativecablefrom the battery,and wait at leastthree minutesbefore beginningwork. Removethese items: . Driver'sdashboardlower cover (seepage 20-59) . Driver'sdashboardunder cover (seepage 20-60) . Passenger's dashboardlower cover (seepage 20-63) . Glove box (seepage 20-63) . Consoles, front and rear (seepage 20-57) . Shift levertrim {seepage 20-61) . Centerpanel (seepage 20-62) . Kick panels,both sides(seepage 20-50) . A-pillartrim. both sides(seepage 20-50) . Steeringcolumn (seepage 17-9) Removethe shift lever (seepage 13-51). door, gently pull From outsideof the passenger's out along the edge of the dashboardside cover (A) the upper to release the hooks (B),then release (C),to removethe cover. hook 4. From the centerpanelopening,removethe screws, then removethe centerbracket(A).
FastenerLocations ):Screw,2
20-66
Driver's side: 7. From underthe dash,disconnect the interiorwire harnessconnector(A),driver'sdoor wire harness (B),side turn signallight connector(C). connectors roof antennaconnector(D),antennalead (E).clutch (F), switch connectors and brakeswitch connector (G),and disconnect floor wire harness the connectors(H)and engine compartmentwire (l)from the under-dash harnessconnectors fuse/ r e l a vb o x ( J ) .
Middle portion: 8. Disconnect floor wire harnessconnectors(A) the a n d c o m b i n a t i o n u b h a r n e sc o n n e c t o ( B ) . s s r
Passenger's side: 9. From under the dash,disconnect the dashboard (A),EPSsubharness wire harnessconnectors connectors(B),enginecompartmentwire harness connectors(C),A,/C subharness connectors(D), passenger's door wire harnessconnectors {E),and s i d et u r n s i g n a l i g h tc o n n e c t o( F ) . r
1 0 . D e t a c h l l o f t h e h a r n e s s n d c o n n e c t oc l i p s . a a r
(cont'd)
20-67
Dashboard
Dashboard Removal/lnstallation (cont'd)
11. From outsidethe driver'sdoor, removethe caps (A), then removethe bolts (8, C, D),and lift up on the dashboard(E)to releaseit from the guide pins (F.G) on the body. Fastener Locations B>rBolt.3 C>: Bolt,2 D>: Bolt,2
Steering Hanger Beam Replacement

NOTE:Put on glovesto protectyour hands. 1, Removethe dashboard(seepage 20-66). 2. Removethese items from the dashboard: . . . . lnstrumentpanel (seepage 20-59) Driver'spocket(seepage20-60) ( G a u g e s s e m b l y s e ep a g e2 2 - 6 4 ) a Passenger's airbag(seepage 23-'l14)
m6[-,,,,",",,-,F6't---'' ffi'!-v{/-
Kr*
w-
Remove screws, thenremove glovebox the the (A). striker

FasteneaLocations ):Screw,4
^/761:
/ , {2.2kgf m, 16lbf.ftl
$7:
mm ,. r:; 8 x 1.25 22Nm (2.2 kgf.m, 16lbf.ft)
through the front Carefullyremovethe dashboard d o o ro p e n i n g .
1 3 .lnstallthe dashboardin the reverseorder of

removal,and note these items: . Make sure the dashboardfits onto the guide pins correctly. . A p p l y l i q u i dt h r e a dl o c kt o t h e d a s h b o a r d mounting bolts of the middle portion before reinstallation. . Beforetighteningthe bolts,make sure eachwire harnessand control cablesare not pinched. . Make sure the connectorsare plugged in properly,and the antennalead is connected propeny. . Reconnect negativecableto the battery. the . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . D o t h e E C M / P C Md l el e a r np r o c e d u r es e ep a g e i i '1-139). 1
20-68
4. Removethe bolts (A) and screws(B)securingthe ( d a s h b o a r dC )a n d s t e e r i n g a n g e rb e a m( D ) ,a n d h disconnect the power mirror switch connector(E) and cruisecontrol main switchconnector(F). S e p a r a t eh e d a s h b o a r d n d s t e e r i n g a n g e rb e a m . t a h Faslener Locations A>rBolt,4 B>:Screw,9
5 . I n s t a l l t h e e a mi n t h e r e v e r s e r d e ro f r e m o v a l , b o and note these items: . N 4 a ks u r et h e d a s h b o a r d i r e h a r n e s s G ) i s n o t ( e w pinched. . Make sure the connectorsare plugged in properly.
5 N.m {0.5kgf m,4lbf,ftl
20-69
Seats
REAR SEAT page20-80 Removal/lnstallation, LatchReplacement, Seat-back page20-81 Seat-back StrikerReplacement, page20-81 Seat'back CoverReplacement, page 20-82 SeatCushionCoverReplacement, page20-84
FRONTSEAT page20-i 1 Removal/lnstallation, page Disassembly/Reassembly-Driver's, 20 73 page Disassembly/Reassembly-Passenger's, 20-74 page20-75 SeatCoverReplacement,
20-70
Front Seat Removal/lnstallation

For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage (seepage 23-'13) the precautions and and procedures 23-14)in the SRSsectionbefore performingrepairsor service. NOTE . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Takecare not to scratchthe body or tear the seat covers. . Put on glovesto protectyour hands. 1, Make sure you have the anti-theft code for the radio, then write down the frequencies the preset for butlons. Disconnect negativecablefrom the battery,and the wait at least3 minutesbefore beginningwork. 4. Removethe bolts securingthe front seat. Fastener Locations
> : Bolt,
3 . Removethe seattrackend covers(A)from the back

of both seattracks. Outef:
1 0 x 1 . 2 5m m
lnner:
(cont'd)
20-71
Seats
(cont'dl FrontSeatRemoval/lnstallation
Lift up the front seat,then detachthe harnessclip (A).and disconnect the seat belt switch connector ( B )a n d s e a tb e l tb u c k l e e n s i o n ec o n n e c t o( C ) .l f t r r th w , e q u i p p e d i t h a s i d ea i r b a g d i s c o n n e c t e s i d e s a i r b a g o n n e c t o ( D ) ,a n d o n t h e p a s s e n g e r 's e a t , c r r T th d i s c o n n e c t e O P D Su n i tc o n n e c t o( E ) . h e p a s s e n g e r 's e a ti s s h o w n ,t h e d r i v e r ' s e a ti s s s e x c e p ti t h a sn o O P D Su n i tc o n n e c t o r . similar
carefullyremovethe 6 . With the help of an assistant, front seatth rough the front door opening. o , s 7 . I n s t a l l t h e e a ti n t h e r e v e r s e r d e ro f r e m o v a l a n d notethese rtems: . l\4ake sure each connectoris plugged in properly. . A p p l y l i q u i dt h r e a dl o c kt o t h e s e a tm o u n t i n g bolts before reinstallatlon. . Reconnect negativecableto the battery. the . Enterthe anti-theft code for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . Do the ECM/PCM idle learn procedure(seepage 11 - 1 3 9 ) .
20-72
- Driver's FrontSeat Disassembly/Reassembly

For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13) (seepage 23-14)in the SRSsectionbefore performingrepairsor service. and the precautions and procedures NOTE: . Takecare not to tear the seamsor damagethe seatcovers, . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver. wrap it with protective tape to preventdamage. ' Apply multipurposegreasetothe moving portion of the seattrack. . To preventwrinklesin the seat cushioncover,stretchthe materialevenlyoverthe pad.
Release seatcushion the coverfrom the cushion f r a m es p r i n g .
SEAT-BACK
10 x 'l.25mm 47 N.m {4.8kgf.m, 35 rbt.ft)
WIRETIE
RECLINE COVER
RECLINE KNOB
20-73
Seats
- Passenger's FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-'13) (seepage 23-14)beforedoing repairsor service. and procedures and the precautions NOTE; . Takecare not to tear the seamsor damagethe seatcovers . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver, tape to preventdamage wrap it with protective . Apply multipurposegreaseto the moving portion of the seattrack . To Drevent wrinklesin the seat cushioncover,stretchthe materialevenlyover the pad. . lvlake cable is connectedproperlyon each side sure the rear seat access . Replace any damagedclips,and replacethe wire ties with new ones SEAT"BACK
SIDEAIRBAG HARNESS Release seatcushion the coverfrom the cushion f r a m es p r i n g .
10 x 1.25mm 47 N.m (4.8kgf.m, 3s rbf.ft) OPDSHARNESS HANGER SPRING
COVER CENTEB WIRETIE CUSHION SEAT FRAME/SEAT TRACKS
/
REAR SEAT CABLE ACCSS
,/CLIP
*r(".o, ACCESSKNOB
,/
/-
N
/
v/
I
SLIDE LEVER
/ H o o K RECLINE KNOB
RECLINE COVER
20-74
Front SeatCoverReplacement
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage (seepage 23 13)and the precautions and procedures 23-'14) the SRSsectionbeforeperforming repairsor in service, NOTE: . Takecare not to tear the seamsor damagethe seat covers, . On the passenger's seatwith side airbag,do not pad, and keep touch the OPDSsensorin the seat-back it away from oil. Oil can corrodethe sensorcausingit to fail. . Puton glovesto protectyour hands. forward. 3 . Foldthe seat-back t 4 . R e l e a s eh e h o o k s( A ) ,a n d u n z i p h e s e a t - b a c k t c o v e r( B ) .
Cover Seat-back
'L Removethe front seat isee page 20-71).
F 2. W i t h s i d ea i r b a g : r o mu n d e rt h e s e a tc u s h i o n , detachthe side airbagconnectorclip (A),and on seat,detachthe OPDSunit the passenger's ( e c o n n e c t oc l i p ( B ) .R e l e a s t h e h o o ks p r i n g s C ) r f f r o m t h e s e a tc u s h i o n r a m es p r i n g{ D ) ,t h e n p u l l the guide cover (E)back,and removethe wire ties (F).The passenger's seat is shown, the driver'sseat is svmmetricalexceptit has no OPDSunit connector.
(cont'd)
20-75
8 . Using a flat-tipscrewdriverwrappedwith
protective tape, insert it into the hook portions ( s e v e n l a c e so f t h e h e a d r e srte a rt r i m i A ) f r o m t h e p ) headrest front trim side. Prv up the hooks (B)to front trim (Di release labs (C)of the headrest the p u l l i n g h e h e a d r e sftr o n tt r i m f o r w a r d , n d a t while removethe tflm. D /
cover 9. Unzipthe headrestportionof the seat-back ( A ) ,t h e n r e m o v et h e z i p p e r B ) ,a n d r e m o v et h e i cover.
1 0 .installthe cover in the reverseorder of removal,

and note these items: . Fit all the hooksof the headrest front trim into the t h o l e si n t h e h e a d r e sr e a rt r i m ,t h e n p u s ho n t h e h e a d r e sttr i m u n t i lt h e h o o k ss n a pi n t o p l a c e . . To preventwrinkleswhen installinga seat back cover, make sure the materialis stretchedevenly over the pad beforesecuringthe clips, hooks, a n d h o o ks p r i n g s . . M a k es u r et h e s i d ea i r b a gh a r n e s sO P D S , seat).and rear seataccess harness{passenger's seati are routed properly. cable(passenger's . lf necessary, reinitialize OPDScontrol unit the ( s e ep a g e2 3 - 1 2 4 ) .
(cont'd)
20-77
Seats
Front Seat CoverReplacement {cont'd)
SeatCushion Cover
1. Removethe front seat (seepage 20,71). 2. Removethese items from the front seat: . Reclinecover,driver's seat (seepage 20-73) passenger's seat {seepage 20-7 4l . Frontseat belt buckle{seestep 4 on page 23-6) 3. From underthe seat cushion,detachthe side airbagconnectorclip, and on the passenger's seat, detachthe OPDSunit connectorclip. Release the hook springsfrom the seatcushionframe spring, then pull the guide cover back,and removethe wire ties. 4. Release hooks(A). the Inside: Release seat-back the cover (A)from the cushion frame spring (B),and release the hooks(C)from u n d e rt h e s e a tc u s h i o n .
Outside:
20-78
c 6 . R e m o v e h e s e a tc u s h i o n o v e r( A )w i t h t h e s e a t t cushion pad from the seat cushionframe.
8. Installthecover in the reverseorder of removal, and note these items; . To preventwrinkleswhen installlnga seat cushioncover, make sure the materialis stretchedevenlyover the pad beforesecuring t h e c l i p sa n d h o o k s . . Make sure the side airbag harnessand OPDS seat)are routed properly. harness(passenger's . Replace any clips you removedwith new ones ( A ) .I n s t a l l t h e m i t h c o m m e r c i a l l a v a i l a b l e w y upholsteryring pliers (B).
1 . Pull backthe edge of the seatcushioncover all the the clips {A),then remove way around.and release the seat cushioncover (B).
r
: r * F +
{,
r ?
20-79
Seats
RearSeat Removal/lnstallation
NOTE: Takecare not to scratchthe body or tear the seatcovers. '1. Removethe rear seat as shown.To removethe seat-back, removethe front portion of the cargofloor mar lsee page 20-52).
2. Installthe seat in the reverseorder of removal,and note these items: 'Beforeinstallingthecenteranchorboltsontheseat-backwiththecentershoulderbelt,makesurethereareno twists or kinksin the belt. . Make sure the seat-backs lock securelv.
Fastener Locations
A > : B o l t , 2 B > r B o l t 1 C > : B o t t1 , ,

/-<.{\.-K\| J ] . P F.i\-- H A P t-
D >: Clip, 2 lltl agr f ( 1
r_r+*.
VtSEAT.BACK CENTER HINGE

BUSHING
8 x 1.25mm 22 N.m 12.2 m, 16lbf.ft) kgt
CENTER PIVOTBOLT 8 x 1.25 mm 22 N.m

{2.2kgf.m, 16lbf.ftl RIGHTSEAT-BACK
\'7
LEFT SEAT.BACK
CENTER BELT
PIVOTBUSHING
PIVOT BUSHING
CENTER ANCHOR BOLT 7/16-20UNF 32Nm (3.3kgf m.24 lbt ftl
SEATBELTBUCKLE
6x1.0mm 9.8Nm {1.0kgf.m,7.2lbf.ft)
HOOK SEAT CUSHION
20-80
LatchReplacement RearSeat-back
(seepage 20-80). 1 . Removethe seat-back cover (seepage 20-82). Removethe seat-back pad {A) from the seat-back Removethe seat-back with centershoulder frame (B).On right seat-back belt,passthe centerbelt (C)through the hole in the pad. seat-back
Striker Replacement RearSeat-back

NOTE: Takecare not to scratchthe interiortrim. 1 . R e m o v e h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 ' l ) . t 2. Removethe bolts,then removethe seat-back striker(A). Fastener Locations ) : Bolt,2
,-;1
8 x 1.25mm 22 N m 12.2kgl rn, 16 tbf.ft)
latch Removethe bolts,then removethe seat-back (A)from the seat-back frame (B),and releasethe pivot pin {C)of the latch lever (D)from the seat' backf rame. Fastener Locations
i o s 3 . l n s t a l l t h e t r i k e r n t h e r e v e r s e r d e ro f r e m o v a l , and move the striker(A) up or down until it is latch {B). centeredin the seat-back
lnstallthe latch in the reverseorder of removal,and locksand unlocksproperly. make sure the seat-back
20-81
Seats
RearSeat-back CoverReplacement
NOTE: . Takecare not to tear the seamsor damagethe seat covers. . Put on glovesto protectyour hands. '1. (seepage 20-80). Removethe seat-back Removethe headrest. Pull up the latchcover (A)to teleasethe clips.then remove it.
Fastener Locations ) : Clip,4
5. On right seat-backi Using a Torx T30 bit, remove the bolts,then removethe belt holdertrim (A),and removethe trim from the centerbelt (B). Fastener Locations ) : Bolt, A*\./6x1.0mm 9.8Nm (1.0kgf.m,7.2lbf.ft)
1W
Release hook (A),and unzipthe seat-back the cover (B).The right seat-back shown. the left seat-back is i ss i m i l a r .
4 . Pull up the outsideedge of the latch lever cover (A)
to releasethe clips, and release the cover from the p i v o tp i n s( B )o f t h e l a t c hl e v e r{ C )w h i l e p u l l j n g h e t

latch lever. Fastener Locations D : Clip,2 i\r*
rJ
20-82
cover (A),and 7. Pull backthe edge of the seat-back r e l e a s eh e c l i p s{ B ) . t
cover (A)from the seat-back 9. Removethe seat-back pad (B).On right seat-back with centershoulder belt, passthe centerbelt (C)through the hole in the cover. seat-bacl(
cover,and pull Pull backthe edge of the seat-back pad frame {A) from the seat-back out the seat-back t { B ) ,t h e n p u l l o u t t h e h e a d r e sg u i d e( C )w h i l e , p i n c h i n g h e e n d o f t h e g u i d e s a n d r e m o v et h e m . t
1 0 ,lnstallthe cover in the reverseorder of removal,

and note these items: . To preventwrinkleswhen installinga seat-back cover, make sure the materialis stretchedevenly over the pad beforesecuringthe hooksand clips . On right seat-back: When installingthe seat-back frame to the pad, slip the centerbeltthrough the cover and pad. hole in the seat-back . Replace you removedwith new ones. any clips y I n s t a ltlh e m w i t h c o m m e r c i a l l a v a i l a b l e upholsteryring pliers.
20-83
Seats
RearSeat CushionCoverReplacement
'1. Removethe rear seat cushion (seepage 2O-80). Release the clips (A)from under the seat all c u s h i o n a n d f o l d b a c kt h e s e a tc u s h i o n o v e r( B ) . , c 4. Installthecover in the reverseorder of removal, and note these items; . To preventwrinkles,make surethe materialis stretchedevenlyover the pad beforesecuring t h ec l i p s . . Replace any clips {A) you removedwith new o n e s .I n s t a ltlh e m w i t h c o m m e r c i a l l a v a i l a b l e y u p h o l s t e r yi n g p l i e r s( B ) . r
B Pull backthe edge of the seatcushioncover all the way around,and release the clips (A),then remove the seatcushioncover.
\
iw F 1., 1L +. ts+'
l-,+
,+
r
l
20-84
Bumpers
Front BumperRemovaUlnstallation
NOTE: . H a v ea n a s s i s t a nh e l py o u w h e n r e m o v i n g n d i n s t a l l i n gh e f r o n t b u m p e r . a t t . Takecare not to scratchthe front bumper and body. . Puton glovesto protectyour hands. 'L Removethe front bumper as shown.
, o 2 . I n s t a l l t h e u m p e ri n t h e r e v e r s e r d e ro f r e m o v a l a n d n o t et h e s ei t e m s : b . Make sure both front side markerlight connectors are plugged in properly. . Make sure the front bumper engagesthe hooksof the side spacersand upper beamson both sidessecurely. . Replace nydamaged lips. a c Fastener Locations
A ) , Screw, 2
B >: Screw,2
C>:Bolt.4
D>:Clip,7
E>:Clip,2
{D[]
k/- '
*S
=$
t
ABSORBER
SIDESPACER UPPER BEAM LEFTFRONT SIDEMARKER LIGHT CONNECTOR
' * D BUMPER
e 3
INNER FRONT FENDER BUMPER FEONT

C l
ti-\
I
A E
AIR SPOILER FRONT SPOILER PLATE AIR SPOILER PLATE 6 x 1 . 0m m 9.8 N.m (1.0kgt.m,7.2lbf.ft)
20-85
Bumpers
RearBumperRemovaUlnstallation
NOTE: ' Havean assistanthelp you when removingand installingthe rear bumper. . Takecare not to scratchthe rear bumper and body. . When prying with a flat-tipscrewdriver, wrap it with protective tape to preventdamage. . Put on glovesto protectyour hands. L R e m o v e h e r e a rb u m D e r s s h o w n . t a 2. Installthe bumper in the reverseorder of removal,and note these items: . Make sure both rear side marker light connectorsare pluggedin properly. 'Makesuretherearbumperengagesthehooksofthesidespacers,sidebrackets,andupperbracketsonboth sidessecurely. . Make sure the upper spacersof the rear bumper engagethe clips on the body securely. . Replace nydamaged lips. a c
Fastener Locations
A>:Bolt,2
B)
: Screw, 2
c >: Screw, 2
XJ
) : Clip,
/h-
\-P-
ffiI"ut ^*
\s
I
? ri)
SIDEBRACKET
UPPER BRACKET
m , 6x 1 . 0 m / 9.eN.n kgl ,/ 11.0 m, 1.2tbt.ttl ./

SIDESPACER
a
'\
:r
LEFTREARSIDEMARKER LIGHTCONNECTOR
A CAP
A
UPPER SPACER
REAR BUMPER
20-86
Hood
Adjustment
'1. Slightly looseneach hood hinge bolt, 2 . Adjustthe hood (A) alignmentin this sequence. . A d j u s t t h e h o o d r i g h t a n d l e f t , a s w e al s f o r w a r da n d r e a r w a r db y u s i n gt h e e l o n g a t e d o l e so n t h e h o o dh i n g e h , l (B). . Turn the hood edge cushions(C),as necessary, makethe hood iit flush with the body at the front and side to edges.
6x1.0mm 9.8 N.m {1.0kgl.m,7.2 lbf.ftl
6x1.0mm 9.8 N.m {1.0kgf.m,7.2lbf.ft}
3 . Adjustthe hood latch (D)to obtainthe proper height at the forward edge,and move the hood latch right or left until the striker(E)is centeredin the hood latch. Tighteneach bolt securely.
(contd)
20-87
Hood
Adjustment(cont'd)
5. Checkthat the hood opens properlyand locks securely. 6. Apply body paint to the hinge mounting bolts and a r o u n dt h e h i n g e s . 7. Apply multipurposegreaseto each locationof the hood latch and hood hinge as indicatedby the arrows.
HoodSealReplacement
1 . Using a clip remover,detachthe clips,then remove the hood seal (A).Takecare not to scratchthe hood. Fastener Locations
I n s t a l l t h e e a li n t h e r e v e r s e r d e ro f r e m o v a l a n d s o , note these items: . Replace nydamaged lips. a c . P u s ht h e c l i p si n t o p l a c es e c u r e l y .
. :I
20-88
Replacement HoodInsulator
w 1 . D i s c o n n e c h e w i n d s h i e l d a s h e rt u b e s( A ) . tt Fastener Locations : Clip,'10 )
t*'-&
,2V..=-'
( \
the Using a clip remover,detachthe clips. Release t r T h o o k s( B ) , h e n r e m o v e h e h o o di n s u l a t o ( C ) . a k e t care not to scratchthe hood. i o I n s t a l l t h en s u l a t o irn t h e r e v e r s e r d e ro f r e m o v a l , and note these items: . R e p l a c e n yd a m a g e d l i p s . a c . Pushthe clips into placesecurely.
20-89
Hatch
Adjustment
1. Removethe support strut from each side (seepage 20-91). 2 . R e m o v e t h e C - p i l l a r t r i m f r o m e a c h s i d e ( s e e p a g e 2 0 - 5 ' l ) ,d o w n t h l r e a r p o n i o n o f t h e h e a d l i n e r ( s e e andpule page20-54). Takecare not to bend the headlinerexcessively. 3. Removethe reartrim panel (seepage 20-52). 4, Slightly looseneach bolt and nut. 5 . A d j u s t t h eh a t c h( A )a l i g n m e n i n t h e f o l l o w i n g e q u e n c e . t s . Adjustthe hatch hinges(B) right and left, as well as forward and rearward,using th e elongatedholes. 'Turnthehatchedgecushions(C),inoroutasnecessary,tomakethehatch(D).fitflushwiththebodyattheside edges. . Adjustthe fit betweenthe hatch and hatchopening by moving the striker(D).
8 x 1.25 mm 22 N.m {2.2kgf.m,16lbf.ft}
8 x 1.25mm 18 N.m 11.8 kgf.m, 13 lbf.ft)
20-90
HatchSupportStrut Replacement
Tighteneach bolt and nut securely. 7 . Checkthat the hatchopens properlyand locks securery. Reinstall supportstruts securely. the l r 9 . R e i n s t a la l l r e m a i n i n g e m o v e dp a r t s . 1 . With the help of an assistant, use a flat-tip screwdriver(A)to pry the supportstrut clips (B) from each end of the supportstrut (C)at the hatch and body, then release the supportstrut from the pivot bolts (D).Do not removethe clips from the supportstrut.
1 0 .Apply multipurposegreaseto the pivot portion of

the hatch hinges{A) as indicatedby the arrows.
D 8 x 1.25 mm 22 N.m(2.2 kgf.m, lbf ft) 16 2 . Set the clips (A) to the original position,then reattach the supportstrut (B)on the pivot bolts (C) pushingon the supportstrut. by
20-91
Hatch
HatchWeatherstripReplacement
p 1 . R e m o v e h e h a t c hw e a t h e r s t r i{ A ) b y p u l l i n g o u t t on it.
a t 2 . L o c a t eh e p a i n t e d l i g n m e n m a r k{ B )o n t h e h a t c h t Allgn the paintedmark with the weatherstrip. alignmenttab in the the centerof the hatchopening, p l a n d i n s t a l t h e h a t c hw e a t h e r s t r i a l l t h ew a y around in the directionshown. Make surethere are no wrinklesin the weatherstrip. 3. Checkfor water leaks.
20-92
FuelFill Door
Adjustment
1. Removethe nut (A),and removethe fuel fill door o p e ns p r i n g{ B ) . 7. Apply multipurposegreaseto each location indicatedby the arrows.
5x0.8mm 1.8Nm (0.18kgf.m, 1.3rbf.ft) >t=r'
8 . Apply body paint to the hinge mounting bolts and around the hinges,
2 . S l i g h t l y o o s e n h e h i n g em o u n t i n gb o l t s( A ) . l t 3 . A d j u s tt h e f u e lf i l l d o o r ( B )i n o r o u t u n t i li t ' sf l u s h
with the body, and up or down as necessary to
a^rr.li7a tha n.nc
T i g h t e n h e h i n g em o u n t i n gb o l t s . t 5 . R e i n s t a l l t h f u e lf i l l d o o r s p r i n g . e 6 . Checkthat the fuel f ill door opens properlyand lockssecurely, and checkthat the rear of the door is flush with the body.
20-93
Exterior Trim
FrontGrille Replacement
1 . Removethe front bumper (seepage 20-85).
2 . Removethe front grille (A),Takecare not to scratch

the front bumper (B). -1 -2 -3 -4 Removethe screws (C). Removethe clips (D). Release bottom hooks(E)ofthe grille, the Pull out the boftom of the grille to release the u p p e rh o o k s( F ) . - 5 P u l lo u t t h e g r i l l et o r e l e a s eh e s l i t s( G ) f r o m t the ribs {H),then removethe grille.
FastqnErLocations C >:Screw.4 D ) : Clip, 4 ll
-S---:
F
i")
g o 3 . I n s t a l l t h e r i l l ei n t h e r e v e r s e r d e ro f r e m o v a l , a n d r e p l a c e n yd a m a g e d l i p s . a c Reinstall front bumper. the
20-94
Cowl CoversReplacement
1 . R e m o v e h e w i n d s h i e l d i p e r a r m s ( s e ep a g e2 2 - 1 4 5 ) . t w 2. Removethe windshieldsidetrim from both sides(seestep 2 on page 20-19). 3. Pullthe hood rear seal (A) away from the cowl covers,then remove it, and using a clip remover,detachthe clips (B)from the cowl covers.Takecare not to scratchthe cowl covers. Fastener Locations B> rClip,3 C>:Clip,8
:- :::: = - --::;-:
4 . Detachthe clips (C)by carefullypulling the passenger's cowl cover {D) upward,to release the hooks{E),and pull out the cover forward to release the hooks(F),then removethe cover.Takecare not to scratchthe body, Detachthe clips (C)by carefullypulling the driver'scowl cover (G) upward.and pull out the cover forward to releasethe hooks(H),then removethe cover.Takecare not to scratchthe body. Installthecovers in the reverseorder of removal,and note these items: . Replace nydamaged lips. a c . Pushthe clip portionsinto placesecurely. . Reinstallboth windshieldside trim properly(seestep 26 on page 20-24).
20-95
Trim Exterior
A-Pillar Corner Trim Replacement
1 . Open the door. Wrap a flat-tipscrewdriverwith protective tape, tape aroundlhe body to and apply protective preventdamage.Carefullyinserta flat-tip screwdrivernext to the upper clip, and detachthe c l i p b y p r y i n go n t h e A - p i l l a r o r n e rt r i m ( A ) .T a k e c care not to scratchthe body and relatedparts. Location Fastener 5 . R e p l a c e n yd a m a g e d l i p s . a c H o l dt h e t r i m u p , a n df i t t h e u p p e rc l i p a n d l o w e r c l i p si n t ot h e h o l e si n t h e b o d y ,t h e n p u s ho n t h e t r i m u n t i lt h e c l i p ss n a pi n t op i a c e .
3 . Closethe door half-way.

Pullthe A-pillercornertrim (A) out to detachthe lower clips,then removethe trim. Fastener Locations
20-96
RoofMolding Replacement
1 . Apply protective tape to the body (A).Using a flat-tipscrewdriver wrapped with protective tape (B),pry up on the roof molding (C).Takecare not to scratchthe bodv. 4, Pull up and release the rear bracket(A)from the pin (B),then removethe roof molding (C).
..:.::.l. g
5 . Installthe molding in the reverseorder of removal, and note these items: . T a k ec a r en o t t o d a m a g e h e w i n d s h i e l d o l d i n g . t m . Make sure the roof molding is installedsecurely. Pull up and slidethe roof molding to release the front bracket(D)from the pin (E). Pull up the front portion of roof molding.
20-97
Exterior Trim
RearLicense Trim Replacement
NOTE:Put on glovesto protectyour hands. 1. Removethe hatch lower trim panel (seepage 20r 3 . F r o mi n s i d e h e h a t c h , e l e a s eh e c l i p s( A , B ) w h i l e t t h o l d i n g h e r e a rl i c e n s er i m ( C ) , h e n r e m o v e h e t t t l trim, Takecare not to scratchthe hatch. Fastener Locations 2. On insidethe hatch.removethe bolts securingthe ( r e a rl i c e n s er i m ( A )a n d h a t c hl o c kc y l i n d e r B ) . t Fastener Locations > : Bolt,2 A>:Clip,2 B>:Clip.2
cHl
:t+
\ ! -
-)
4 . I n s t a l l t h er i m i n t h e r e v e r s e r d e ro f r e m o v a l a n d , t o
note these rtems: . Replace any damagedclips. . Pushthe clip portionsinto placesecurely.
6x1.0mm 9.8 N.m (1.0kgf.m,7.2lbf.ftl
20-98
HatchSpoilerReplacement
NOTE:Put on glovesto protectyour hands. 'l. Removethe hatch upper trim (seepage 20-53). 4 . F r o mi n s i d e h e h a t c h , e l e a s eh e c l i p s , h i l e t r t w ( p u l l i n g h e h a t c hs p o i l e r A )a w a y ,a n d r e l e a s eh e t t fasteners(B),then removethe spoiler.Takecare not to scratchthe body. Fastener Locations . > : C l i p2 3. From insidethe hatch,removethe bolts {A} and n u t s( B ) .
Fastener Locaiions
2. Removethe high mount brakelight (seepage2282).
A>: Bolt,2 Bar Nut,
fi'f$t-uLt*
/,fl v_/
$A .
5 . I n s t a l l t h e p o i l e ri n t h e r e v e r s e r d e ro f r e m o v a l , s o and note these items:
5x1.0mm 9.8Nm (1.0kgf.m.7.2lbf.ft)
Replace nydamaged lips. a c Replace any damagedfasteners. Before installingthe fastenerto the spoiler,cleanthe spoilerbonding surfacewith a sponge d a m p e n e dn a l c o h o l G l u et h e f a s t e n e w i t h i r . a d h e s i v ea p e( 3 M 5 6 7 1 , r e q u i v a l e n t ) t t h e t o o spoiler. Pushthe clip and fastenerportions into place securely.
20-99
Trim Exterior
EmblemReplacement
NOTE: When removingthe emblem,take care not to scratchthe body. 1. To removethe front "H" emblem and front type emblem, removethe front bumper (seepage 20-85)
2. Cleanthe bonding surfacewith a spongedampenedin alcohol.After cleaning,keepoil, grease,and water from getting on the surface. w 3 . A p p l yt h e e m b l e m , h e r es h o w n . . W h e n i n s t a l l i n gh e s i d ei - V T E C m b l e mo n t h e b o d y ,a l i g nt h e a p p l i c a t i otn p ew i t h t h e e d g eo f t h e w h e e la r c h , e a t tape. then pressthe emblem into place,and removethe application . ' 0 3 m o d e l : h e n i n s t a l l i n gh e L E Ve m b l e mo n t h e q u a r t e r l a s s , l i g nt h e a p p l i c a t i o t a p ew i t h t h e e d g eo f t h e g a n W t , g , t b l a c kc e r a m i c n d a l i g n m e n m a r ko n t h e q u a r t e r l a s s t h e n p r e s s h e e m b l e mi n t o p l a c e a n d r e m o v et h e a t a p p l i c a t i ot a p e . n
FRONT TYPEEMBLEM
FBONT"H" EMBLEM FRONT"H" EMBLEMBASE FBONTGRILLE SCREWS
FRONT EMBLEMPLATE Si NUTS PUSH
PINS FRONT GRILLE FRONT GRILLE
20-100
REARCIVICEMBLEM
LEVEMBLEM (Left sideonly) ('03model)

REAR VERSION EMBLEM SIDE|-VTEC EMBLEM
"H" REAR EMBLEM

Unit: mm {in.l Adhesive tape: 3M 4213E, equivalent o. Thickness:0.8 mm (0.03in.) "H'' EMBLEM REAR APPLICATION TAPE Edoeol the blackceramic.
Align. HATCHLINE REARLICENSE TRIM REAR EMBLEM si
LEVEMBLEM Ontoinside face

REARSiR EMBLEM (Canada)
of the guarterglass.
34 11.3)
, ilg
(1.93)
=-t
I
50 {'!,9?)
.,!!ll,'nt (1.s31
CIVICEMBLEM
E d g eo f t h e hatch.
ADHESIVE TAPE i.WEC SIDE EMBLEM

Right Side:
Edge of the hatch.
SIDEi-VTECEMBLEM
Left Side: . 114(4.49)
63 (2.5)
F.l^6
^l
rh-
wheelarch.
.=4,
BODY LINE
y' Li.Est
BODY LINE TAPE
112
Edgeof the wheel arch.
APPLICATION TAPE
o"f,r,ao.o"
(5'5s)
4. After installingthe front "H" enblem and front type emblem, reinstallthe front bumper.
20-101
Fenderwell
Replacement FrontInnerFender
NOTE:Takecare not to scratchthe body. 1, Removethe front inner fender (A). -1 On the backofthe wheel arch,removethe screws(B). - 2 F r o mu n d e r t h e f r o n tb u m p e r ( C )r e m o v e t h e s c r e w B )s e c u i n gt h e f r o n t b u m p e r . p l a s h h i e l d( D ) ,a n d f r o n t ( r s s , fender,and removethe clip (E)securingthe front air spoiler,front bumper,and front inner fender. inner - 3 F r o m t h e w h e e la r c h ,r e m o v e h e c l i p s{ F ,G ) s e c u r i n gh e f r o n t i n n e rf e n d e r( a n ds p l a s h h i e l d ) n t h e b o d y . o t t s - 4 R e l e a s t h e h o o k( H )o f t h e s p l a s h h i e l d , t h e n e m o v e t h e f r o n i n n e r f e n d e r . r t e s Locations Fastener B):Screw,4 E>:Clip,1
F > : C l i p ,1
0*
,ws
G):Clip,8
2. Installthe inner fender in the reverseorder of removal,and note these items:

. R e p l a c e n yd a m a g e d l i p s . a c . P u s ht h e c l i p si n t o p l a c es e c u r e l y .
20-102
Front FenderFairingReplacement
(see 1 . Removethe front inner fender as necessary p a g e2 0 - 1 O 2 1 . Open the front door. From outsidethe door, t r e m o v e h e u p p e rc l i p ( A ) ,a n d f r o m i n s i d e h e d o o r , t removethe lower clip (A) securingthe front fender f a i r i n g( B )a n d f r o n tf e n d e r( C ) . Fastener Locations 3. From the wheel arch, removethe clip (A),and releasethe clip (B),then removethe front fender f a i r i n g( C ) . Locations Fastener A > : C l i p1 , B > : C l i p1 ,
J*.' -@
A>:Clip,2
J<a-'
4 . Installthe fender fairing in the reverseorder of
removal,and note these items: . Replace nydamaged lips. a c . R o u t e h e s i d et u r n s i g n a l i g h t h a r n e s s ( A ) t through the slit (B)of the front fender fairing (C). . B e f o r ei n s t a l l i n gh e c l i p so f t h e d o o r u p p e ra n d t lower ponions, installthe front fender fairing (A) to the front fender (B) properlyas shown. . Pushthe clips into placesecurely.
o --____--
20-103
Fenderwell
FuelPipeProtectorReplacement
1 . R e m o v e h e c l i p s , h e n r e m o v et h e f u e l p i p e t t
RearAir Outlet Replacement

1 . R e m o v e h e r e a rb u m p e r( s e ep a g e2 0 - 8 6 ) . t r n e r e a ra t r the body.
protector(A).Takecare not to scratchthe body.

Fastener Locations > : Clip,4
p I n s t a l l t h e r o t e c t o irn t h e r e v e r s e r d e ro f r e m o v a l , o and note these items: . R e p l a c e n yd a m a g e d l i p s . a c . P u s ht h e c l i p si n t o p l a c es e c u r e l v .
I n s t a l l t h e i ro u t l e t s y p u s h i n g n t h e h o o k a b o p o r t i o n s n t i l t h eh o o k ss n a pi n t o p l a c e . u
20-104
Openers
HATCH LOCK CYLINDER page Replacement, 20-1'l 1 HATCH HANDLE Replacement, page 0-110 2
HATCHLATCH page20'110 Replacement,
FUELFILLDOORLATCH page 20-107
FUELFILLDOOROPENEB CABLE page 20-107 Replacement, FUELFILLDOOROPENER page20-109 Replacement, I{OOD RELEASE HANDLE page20-'106 HOODOPENERCABLE page20-106 Replacement,
z)-105
Openers
Hood OpenerCableReplacement
NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe body and relatedparts. l. Removethese items: . Front bumper (seepage 20-85) . F r o n ti n n e rf e n d e r , e f t s i d e ( s e e p a g e 2 0 - 1 0 2 ) l . Kick panel,left side (seepage 20-50) 2. Disconnect hood openercable(A) from the hood latch {B) (seepage20-108), the and removethe bolts (C),then removethe hood releasehandle(D)from the body. Fastener Locations C>:Bolt,2 E >:Clip,3
6x1.0mm 9,8 N.m kgl.m, 7.2 lbl.ft) 11.0
@m
l,.t'.
W:"
Using a clip remover,detachthe clips (E),and removethe grommet (F)from the body, then removethe hood openercablefrom the vehicle.Takecare not to bend the cable. 4 . I n s t a l l t h e a b l ei n t h e r e v e r s e r d e ro f r e m o v a l a n d r e p l a c e n y d a m a g e d l i p s . c o , a c
20-106
FuelFill Door OpenerCableReplacement

and the precautions SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13) (seepage 23-14)in the SRSsectionbeforeperformingrepairsor service. and procedures NOTE; . Put on glovesto protectyour hands. . Takecare notto scratchthe body and relatedparts. 1. Removethese items from the left side of the vehicle: . D o o rs i l l t r i m { s e ep a g e2 0 - 5 0 ) . R e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 ) (seepage 20-55). 2 . Pullthe carpetbackas necessary
5.
Disconnect fuel fill door openercable (A)from the opener(B) (seestep 3 on page 20-109). the Fastener Locations 1 C >:Cushiontape, , D > : C l i p1
2 E > : Clip,
( g l R 4 . K C m o d e l : e m o v e t h e e f tm i d d l ef l o o rc r o s s - m e m b e ru s s e t s e ep a g e2 0 - 1 1 3 ) . a t t 5 . R e m o v e h e c u s h i o n a p e{ C ) , n d r e l e a s eh e c a b l ef r o m t h e c l i p s( D ,E ) . t 6 . R e m o v e t h e f u efli l l d o o r l a t c h( F ) f r o m t h eb o d y b y t u r n i n gi t 9 0 ' . 7. Removethe fuel fill door openercablefrom the vehicle.Takecare not to bend the cable 8 . I n s t a lt lh e o p e n e r c a b l e i n t h e r e v e r s e o r d e r o f r e m o v a l , r e p l a c e t h e c u s h i o n t a p e , a n d r e p l a c e t h e c l i p i f i t i s oamageo.
20-107
Openers
Hood LatchReplacement
NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe body. 1. Removethe bolts,then removethe hood latch (A) from the body. Fastener Locations > i Bolt,3 Installthe hood latch in the reverseorder of removal,and note these items: . Apply multipurposegreaseto each locationof the hood latch indicatedby the arrows. . Make sure the hood openercable is connected properly. . Make sure the cableactuates the latch beforeyou closethe hood, . Adjustthe hood latchalignment(seestep 3 on page 20-87). . M a k es u r et h e h o o do p e n sp r o p e r l y n d l o c k s a securely.
--------------'
6x1.0mm 9.8 N.m (1.0kgf.m,7.2lbf.ft)
Disconnect hood openercable (B)from the the hood latch.Takecare not to bend the cable.
20-108
Replacement FuelFillDoorOpener
1 . Using a flat-tipscrewdriverwrapped with protective tape, detachthe hooks(A) by prying the front side cap (B),then remove it from the left door a t t s i l l t r i m ( C ) , n d l o o s e n h e b o l t ( D )s e c u r i n gh e f u e lf i l l d o o r o p e n e r . 4. Disconnect fuel fill door openercable (A),then the removethe openeriB). Takecare not to bend the c ao t e .
6x1.0mm 9.8 N.m kgf 11.0 m,7.2 lbf.ft)
5 . Installthe opener in the reverseorder of removal, and note these items: lMake sure the openercable is connected properly. lvlake sure the fuel fill door opens properlyand lockssecurely.
2. Removethe left door sill trim (seepage 20-50i. 3 . R e m o v e h e o p e n e r( A l f r o m t h e b o l t{ B ) . t
20-109
Openers
HatchHandleReplacement
NOTE:Put on glovesto protectyour hands. 1. Removethese items: . Hatchlower trim panel (seepage 20-53) . Rear licensetrim panel (seepage 20-98) 2. Removethe rearwindow wiper motor (seepage 22-1461. 3. Disconnect hatch o p e n e rc a b l e1 A ) f r o m h e the t ( h a t c hh a n d l e B ) ,a n d removethe nuts.
Fastener Locations
HatchLatchReplacement
NOTE:Put on glovesto protectyour hands. '1. Removethe hatch lowertrim panel (seepage 2053).
2. Disconnect hatch openercable (A),cylinder rod the (B).hatchactuatorconnector(C).and hatch latch switch connector{D).and detachthe hatch actuator connectorand hatch latch switch connectorfrom the hatch. Faslener Locations ) : Bolt,3
a : Nut,
6x1.0mm 9.8N.m
(1.0 kg{.m,7 2 tbt.{t\
ttb
()rI
a
,t.
4. Pull outthe hatch handle(A),then remove it.
i-'-3;li9#k 1 1 , 0 g tm , 7 . 2 l bfft l
R e m o v e h e b o l t s , h e n p u l l t h eh a t c hl a t c h( E )o u t , t t then remove it. I n s t a l l t h ea t c hi n t h e r e v e r s e r d e ro f r e m o v a l a n d l o , notethese items: . Make sure each connectoris plugged in properly, and the rod and cableare connectedproperly. . l\4ake sure the cable actuates the latch beforeyou c l o s et h e h a t c h . . Make sure the hatch opens properlyand locks securely. I n s t a l l t h e a n d l ei n t h e r e v e r s e r d e ro f r e m o v a l . h o and note these items:
lMake surethe hatch opener cableis connected securely. p M a k e u r e h eh a t c h p e n s r o p e r l y . s t o
20-110
HatchLockCylinderReplacement
NOTE;Put on glovesto protectyour hands. '1. Removethese items: . Hatchlower trim panel (seepage 20-53). . Rearlicensetrim (seepage 20-98). 2. Disconnect cylinder rod (A) the 4. Installthe lock cylinder in the reverseorder of removal,and note these items: . Make sure the rod is connectedproperly. . Make sure the hatchopens properlyand locks securely.
- . .
From outsidethe hatch,removethe bolt securing the lock cylinder{A}.From insidethe hatch,pull the g o l o c kc y l i n d e r u t b y r e l e a s i n t h e h o o k( B ) .
Fastener Location 6x 1.0 m m 9.8Nm (1.0kgf m,7.2lbt.ftl
> : Bolt,1
rS'l-. u-ar
*/t
20-111
Frame
SubframeReplacement
SubframeTorque
NOTE: After looseningthe subframemounting bolts,be sureto replacethem with new ones.
Reference holesalignment:
SUBFRAME
REFERENCE HOLE (Body ide) S
INSTALLATION REFERENCE HOLE (Subframe side)
INSTALLATION REFERENCE HOLE
SCREWDRIVER or TAPERED PUNCH
FRONTSUSPENSION To body. INSTALLATION REFERENCE HOLE
To body. I
n E
SPECIALBOLTS ' 1 4 1 . 5m m x 103 N.m (10.5kgf.m,75lbf.ft) Replace.
20-112
FrameStiffener,Brace, and GussetReplacement

Torque Frame Stiffener, Brace, and Gusset
torque the mounting hardwarein the NOTE:When installingthe middle floor cross member braceor gussets, to following sequence avoid damageto the quarterpanel.
MIDDLE FLOOR CROSS-MEMgER BRACE/GUSSET

SIDEFRAME STIFFENER
m 8 x 1.25 m 29 N.m (3.0kgf m,22 lbf ft)
To body.
U.S.model: 1 0x 1 . 2 5 m m 38 N.m (3.9kgf.m.28lbf.ftl
model: Canada
MIODLE FLOOR CROSS-MEMBER BRACE
MIDDLE FLOOR CROSS.MEMBER GUSSET
..
__!:::-| -
1 0 x 1 . 2 5m m 38 N m (3.9 kgt.m, 28 lbf.ftl
1 0 x 1 . 2 5m m 38Nm (3.9kgf.m,28 lbl.ftl
20-113
Frame
FrameRepairChart
Top view
Unit:mm {in.} o: Inner diametel
a b1 b2 b3 cl c2 c3
Forsublrame o1510.59) Forengine mount e13 (0.511 Forengine mount o13 (0.51) Forengine mount rl3 (0.51) Formanual transmission mouoto13{0.5' Formanual transmission mounto13 10.5' Formanual t.ansmission mo!nt d13{0.51)
o I g h
Fordampermounts11.5{0.45} For damper centero78 (3.07) Fordampermounts11.5(0.451 Fordampeimountd11.5 10.45) Forsubframe o15 {0.591 Localinghole s25 {0.98} Locating holee50 (1.97)
VEFTICAL UNE
20-114
m n p q
Locatinghole d25 (0.981 Fortrailing.rm rl3 10.51) Locatinghole o25 (0.981 Locatinghole s20 (0.79) Trailingarm center Reardampercenter Forupperarm o13 (0.51)
t1, t2
x1 x2
Fortrailingarm d13 (0.511 For upper arm bracketcenterrl5 {0.59) Locating holes13 (0.51) Foruppe.arm o13{0.511 For rear lower arm centr holes50 (1.97) Locating Locatinghole s20 (0.79) Locatinghole o25 (0.981
(cont'd)
20-115
Frame
FrameRepair Chart(cont'dl
Sideview
I
o e I Fordampermounto11.5 {0.45) For damper centerr78 {3.07} (0.45) Fordampermounto11.5 Fordampermountr11.5{0./t5l Forsubtrame el5 10.591 Locatinghole o25 (0.98) Locatinghole s 11.97)
Unitrmm {in.) o: InnerdiameteJ
a b1 b2 b3 cl c2 c3
For subframe015 {0.59} Forengine mount o13 (0.511 Forengine mount 01310.51) Forengine mount 113(0.511 Formanual transmission mount 013{0.51) Formanual trensmission mount 613{0.51} Formanual trrnsmission mounro13{0.51}
s
h i
SECTIOiI AA
BASE UNE
trr2xt.6
VERTICAI LINE
20-116
Frame
FrameRepair Chart(cont'dl
Sideview
I
o e I Fordampermounto11.5 {0.45) For damper centerr78 {3.07} (0.45) Fordampermounto11.5 Fordampermountr11.5{0./t5l Forsubtrame el5 10.591 Locatinghole o25 (0.98) Locatinghole s 11.97)
Unitrmm {in.) o: InnerdiameteJ
a b1 b2 b3 cl c2 c3
For subframe015 {0.59} Forengine mount o13 (0.511 Forengine mount 01310.51) Forengine mount 113(0.511 Formanual transmission mount 013{0.51) Formanual trensmission mount 613{0.51} Formanual trrnsmission mounro13{0.51}
s
h i
SECTIOiI AA
BASE UNE
trr2xt.6
VERTICAI LINE
20-116
m p q
Locatinghole o25 {0.98) Fortrailingarm 613 {0.511 Locatinghole d25 {0.98} Locatinghole r20 {0.79) Trailingarm center Reardamper centel Forupperarm o13 (0.51)
11,t2
xl x2
Fortrailingarm s13 {0.51} For upper arm bracketcenter o15 {0.591 Locating holeo13{0.51} Forupperarm d13{0.51) For rear lower arm centei Locating holeo50{1.97} Locatinghole a20 {0.79} Locetinghole s25 (0.98)
20-117
(Heating, HVAC Ventilation, Air Gonditioningl and

Heating andAir Conditioning
21-2 SpecialTools z Comoonent Location lndex ........ t-'5 A/CService Tiosand Precautions z t-o A,/C Refrigerant Oil ReDlacement z t-o Troubleshooting General lnformation 21-8 Troubleshooting Index ....... 21-9 DTC Symptom Troubleshooting 1ndex.............. 21-10 Description ..................... 21-11 System Circuit Diagram 21-14 D T C r o u b l e s h o o t i n.g. . . . . . . . . .z. . . .t . T . . t- o Recirculation Motor Control .......... CircuitTroubleshooting 21-25 Power Heater Control andGround Troubleshooting ........ 21-27 Circuits Condenser Circuit Fan Troubleshooting ...................... 21-28 Fans Radiator Condenser and Circuit Common ...................... 21-29 Troubfeshooting Compressor Clutch Circuit T r o u b l e s h o o t i n.g . . . . . . . . . . . . 2.1.-.3 . . . . . .0 A,/C Pressure SwitchCircuit ...................... 21-32 Troubleshooting Motor Air Mix Control ............. 21-34 TestandReolacement ModeControl Motor ............. 21-35 TestandReplacement Motor Recirculation Control ............. 21-36 TestandReolacement Evaporator Temperature Sensor and 21-31 Reolacement Test ............. Test ................. 21-38 Power Transistor Heater Panel and Control Push Switch Assemblv ........ 21-38 Removal Installation and DustandPollen Filter Reolacement ..21-39 Blower UnitRemoval and ......21-39 lnstallation Blower UnitComoonents R e D l a c e m e . . t. . . . . . . . . . . . . . . . .2.1 . . . 1. . n . .-4 . Evaporator Core ..21-42 Reolacement *Heater Unit/Core ..21-43 ReDlacement Heater Valve Cable .....21-46 Adjustment .......... CompressorReplacement 21-47 21-48 Check .......... Comoressor Clutch Comoressor Clutch Overhaul.....21-49 Thermal Protector Compressor . . .-5 . R e o 1 a c e m e.n .t . . . . . . . . . . . . . . . .2.1 . . . 1. . Relief Valve Comoressor R e o l a c e m e n.t. . . . . . . . . . . . . . . . .2.1 . . . 1. . . . .-5 . ............ 21-52 Reolacement Condenser Recovery .................. 21-53 Refrigerant ...................... 21-54 Evacuation System 21-55 ......................... CharginS System 21-56 LeakTest.................. Refrigerant 21-57 Tests ........................ A,/C Svstem
HVAC{Heating, Ventilation, and Air Conditioning)

SpecialTools
Ret.No.
Tool Number
DescriDtion Backprobe Set
07sAz-001000A
Otv 2
att-,,/'Tt e^t"'
---2
"-t--'
KCe
T
21-2
Heating and Air Gonditioning

VALVE SERVICE {LOW.PRESSUBE SIDEI
EVAPORATOR CORE (Built-in heater the unit) B e p l a c e m ep a , e 1 4 2 nt g 2
SERVICE VALVE {HIGH-PRESSURE SIDEI
RECEIVER/DRYER
COMPRESSOR page21 47 Beplacement, CONOENSEB ClutchCheck,page21-48 page 21-52 Replacement, C l u t c h v e r h a u lp a g e2 1 - 4 9 O , page21-48 ThermalProtector Check, page21 51 ThermalProtector Replacement, p, R e l i eV a l v eR e p l a c e m e n ta g e2 1 5 1 f
Heating and Air Conditioning

ComponentLocationIndex(cont'dl
RADIATOR FAN RELAY Test,page22-51

Tesl, page 22-51
CLUTCH RELAY
Test, page 22-5I
MOTOR RELAY
'-t
t_]]l
BOX UNDER.HOOD FUSE/RELAY
/l
-::--
l-
-l
FAN CONDENSER Test, page 22-51
.\\ -
... A/C PRESSURE SWITCH
RADIATORFAN FAN CONOENSER
21-4
HEATER UNIT/CORE page Beplacement, 21-43
BLOWEN UNIT page Removal Installation, 21-39 and BLOWER UNITCOMPONENTS page Replacement, 21-41
HEATER VALVECABLE page Adjustment, 21-46
DUSTAND POLLEN FILTER page Replacement, 21'39 RECIRCULATION CONTROL MOTOR page Test, 21-36 page Replacement, 21-36
MODE CONTROLMOTOR Test,page21-35 page21-35 Replacement, POWERTRANSISTOR Test,page 21-38
AIR MIX CONTROL MOTOR page Test, 21'34 page Replacement, 21'34
EVAPORATOR TEMPERATURE SENSOR page 21-37 Replacement, Test,page21-37 PUSH SWITCHASSEMBLY page21'38 Removaland Installation,
HEATERCONTROLPANEL page21 38 RemovalandInstallation,
21-5
Heating Air Conditioning and

A/C ServiceTips and Precautions A/C Refrigerant Replacement Oll
R e c o m m e n d eP A Go i l : K E I H I N P 1 0 : d S forms a Compressed mixed with R-134a air c o m b u s t i b l ea p o r . v T h e v a p o rc a n b u r n o r e x p l o d e a u s i n g e r i o u s c s injury. Never use compressedair to pressure test R - 1 3 4 a e r v i c e q u i p m e no r v e h i c l e i r s e t a conditioninsystems. g '120 . P/N38897-P l3-A01AH: m0 i4 fl oz) . P/N38899-P13'A01: m0 i1 1/3fl oz) 40 Add the recommendedrefrigerantoil in the amount listedif you replaceany of the following parts. . T o a v o i dc o n t a m i n a t i o n .o n o t r e t u r n h e o i l t o t h e d t c o n t a i n eo n c ed i s p e n s e d , n d n e v e rm i x i t w i t h o t h e r r a refrigerant oils. . l m m e d i a t e l a f ' t e u s i n gt h e o i l , r e i n s t a l l t h e a po n y r c the container,and seal it to avoid moisture aosorpron. . D o n o t s p i l lt h e r e f r i g e r a no i l o n t h e v e h i c l e i;t m a y t damagethe paint. lf it gets on the paint,wash it off immediately. m t , C o n d e n s e r. . . . . . . . . . . 2 5A\ 5 1 6 l . o z 0 . 9l m p . o z ) '1.4 E v a p o r a t o r . . . . . . . .4 5 m 0 ( 1 1 1 3 I l . o z , l m p . o z ) . .. '10 l L i n eo r h o s e . . . . . . . . . m 0 { 1 / 3f l . o z , 0 . 4m p . o z ) '10 R e c e i v e r / D r y e.r . . m 0 ( ' 1 1f3. o z , 0 . 4m p . o z ) . l l Leakage repair ....25 m0,1516 oz,0.9 lmp.oz) Il . . r C o m p r e s s o r . . . . . . F.o rc o m p r e s s or e p l a c e m e n l , s u b t r a ctth e v o l u m eo f o i l d r a i n e d from the removedcompressorfrom , 1 3 0m 0 ( 4 1 / 3 f l . o z4 . 6 l m p . o z )a n d , d r a i nt h e c a l c u l a t e v o l u m eo f o i l d '130 f rom the new compressor: m0 l i . 4 1 1 f l . o z , 4 . 6m p . o z ) V o l u m eo f 3 removedcompressor= Volume to d r a i nf r o m n e w c o m p r e s s o r . NOTE:Evenif no oil is drainedfrom the removedcompressor, don't d rain more than 50 m0 \1 2/3 fl.oz, ' 1 . 8m p l o z ) f r o mt h e n e w compressor. REMOVED COMPBESSOR NEW COMPRESSOR
t A i r c o n d i t i o n i n ge f r i g e r a no r l u b r i c a nv a p o r r t can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerant vapor. or R T h e a i r c o n d i t i o n i n s y s t e mu s e sH F C - 1 3 4(a - 1 3 4 a ) g P r t r e fr i g e r a n a n d p o l y a l k y l e n e g l y c(o l A G ) e fr i g e r a n o i l , t ( ) w w h i c h a r e n o t c o m p a t i b l e i t h C F C ' 1 2 R - 1 2r e f r i g e r a n t r t l a n d m i n e r a o i l . D o n o t u s e R - ' 1 2e f r i g e r a no r m i n e r a l oil in this system,and do not aftemptto use R 12 t s e r v i c i n g q u i p m e n td a m a g e o t h e a i r c o n d i t i o n i n g e ; e t s y s t e mo r y o u r s e r v i c i n g q u i p m e nw i l l r e s u l t . e d U s eo n l y s e r v i c e q u i p m e ntth a t i s U . L . - l i s t ea n d i s of certifiedto meet the requirements SAE J2210to f r e m o v eR - 1 3 4 ar o m t h e a i r c o n d i t i o n i n s y s t e m . g lf accidental system dischargeoccurs,ventilatethe s w o r k a r e ab e f o r er e s u m i n g e r v i c e . e t a R - 1 3 4 a e r v i c e q u i p m e no r v e h i c l e i r c o n d i t i o n i n g s tested or leaktested systemsshould not be pressure withcompressed ir. a m A d d i t i o n ah e a l t h n d s a f e t yi n f o r m a t i o n a y b e l a obtainedfrom the refrigerantand lubricant manufacturers. . Always disconnect the negativecablefrom the p w a b a t t e r y h e n e v e r e p l a c i n g i rc o n d i t i o n i n g a r t s . . Keepmoistureand dirt out of the system.When p d i s c o n n e c t i na n y l i n e s , l u go r c a pt h e f i t t i n g s g don't removethe caps or plugs until immediately; iust be{oreyou reconnecteach line. ' B e f o r e o n n e c t i n g n y h o s eo r l i n e ,a p p l ya f e w d r o p s c a of relrigerantoil to the O-ring. . W h e nt i g h t e n i n g r l o o s e n i n g f i t t i n g ,u s ea s e c o n d o a wrench to supportthe matchingfitting. . W h e n d i s c h a r g i ntg e s y s t e m u s ea R - ' 1 3 4 a h , station;don't refrigerantrecovery/recycling/charging releaserefrigerantinto the atmosphere.
r \
l i
rJ
/- a\
t l
\..
r /
\:)-) -/
_ 0L
\tb
'r:l_
I I I DRAINING
I "o*tttu" _*lH ,lEL.-
I voLUME
],^
A: 130 m0 {4 l/3 tl.oz,4.6lmp.oz)
21-6
RECEIVER A LINE
RECEIVER/DRYER
CONDENSER LINE
Discharge hoseto the compressor x 1.0 mm) : 9.8 N.m {1.0kgf.m,7.2 lbl.ft} {6 (5 Discharge hoseto the condenser x 1.0mml : 9.8 N.m {1.0kgt.m,7.2 lbf ft) (6 x 1.0mm) : 9.8 N.m {1.0kgf,m,7.2 lbt.ft} Condenser line to the condenser Condenserine to the receiver/dryer x 1.0mm} : 9.8 N.m (1.0kgt.fi,7.2lbt.ltl f {6 Receiver lineAtothe receiver/dryer x 1.0mm} : 9.8 N.m {1.0kgf.m. 7.2 lbf.ft} {6 Receiver line A to the receiveiline B : 13 N.m (1.3kgr.m,9.4 lbf.ft) Receiver line B and the suctionline to the evaporator(6 x 1.0mm) :9.8 N.m 11.0 kgf.m,7,2 lbf.ft) Suction line to the suction hose : 3l N m {3.2 kgf.m, 23 lbf ftl (6 Suctionhose1o the compressor x 1.0mm) : 9.8 N.m 11.0 kgf.m.?.2 lbf.lt) Compressorto the compressor b.acket {8 x 1.25 mm) : 22 N m {2.2 kgt.m, 16 lbf.ft) Comprssor bracketto the engineblock {10 x 1.25mm} : ,14 N.m 14.5 kgf.m,33 lbf.ft)
21-7

How to Retrievea DTC
The heatercontrol panel has a self-diagnosis function.To run the self-diagnosis function,do the following: 1 . T u r nt h e f a n s w i t c hO F F . 2. Pressandholdthe recirculation control switch andthe rearwindow defoooerswitch down. s 3 . T u r nt h e i g n i t i o n w i t c ho N { l l i . indicatorand the rearwindow defoggerindicatorcome on. The 4. Release both switches.The recirculation recirculation indicatorgoes off 3 secondslater and the Ay'C indicatorcomes on. then the self-diagnosis begin. will will indicatorgoes off. About 10 secondslater,the self-diagnosis finish and the A,/C .lfanytroubleisfound.therecirculationindicatorblinksthediagnostictroublecode(DTC)toindicateafaulty circuil or comDonent. . lf the system is OK, the recirculation indicatorstaysoff.
atc INOICATOR
BECIRCULATION INDICATOB REAR WINDOW INDICATOR OEFOGGER
/A\
RECIRCULATION CONTROL SWITCH
-:@
@r
REAR WINDOW DEFOGGER SWITCH
Examole of DTC indication Pattern IDTC7)
DTC 7 Recirculation + indicatot Recirculation+ indicalor go6s oft
----->
Reseiting the Selt-diagnosis Function function.After completingrepairwork, run the self-diagnosis Turn the ignition switch OFFto cancelthe self-diagnosis f u n c t i o n o a i nt o m a k es u r et h a t t h e r ea r e n o o t h e rm a l f u n c t i o n s . a
21-8
DTC{Recirculation Indication Blinks)
7 8 9 Detection ltem A n o p e n i n t h e a i r m i x c o n t r o lm o t o rc i r c u i t A short ln the air mix control motor circuit A p r o b l e mi n t h e a i r m i x c o n t r o l i n k a q ed o o r ,o r m o t o r , An open or shon in the mode control motor circuit A p r o b l e mi n t h e m o d ec o n t r o l i n k a g ed o o r s ,o r m o t o r , A p r o b l e mi n t h e b l o w e rm o t o rc i r c u i t A problem in the EEPROM the heatercontrol panel; in the control oanel must be reolaced An ooen in the evaDorator temDerature sensorcircuit A short in the evaDoralor temoeraturesensorcircuit Page ( s e ep a q e2 1 - 1 6 ) ( s e eD a o e 1 - ' 1 6 ) 2 ( s e ep a q e2 1 -1 7 ) ( s e eo a q e2 1 - 1 8 ) ( s e ep a q e2 1 1 9 1 ( s e ep a q e2 1 - 2 0 ) ( s e ep a g e2 1 - 3 8 ) (seepaqe 21-23) ( s e eo a q e2 1 - 2 4 1
10
11
12 13
14
In case of multiple problems,the recirculation indicatorwill indicateonly the DTCwith the least number of blinks. ln caseof an intermittentfailure,the heatercontrol panelwill storethe DTCuntil the ignition is turned off.
21-9
Heatingand Air Conditioning

Index SymptomTroubleshooting
Also check for Svmptom Diagnosticprocedure Recirculation o Recirculation control doors do not Control Motor C l e a n l i n e sa n d t i g h t n e s s f a l l s (seepage connectors changebetweenFreshand Recirculate CircuitTroubleshooting 21 251 '14 Heater Power f do Control andGround B l o w n u s eN o . ( 1 0 Ai)n t h e Both heaterand Ay'C not work
(see Circuits Troubleshooting page21-27)

Condenser fan does not run at all (but radiatorfan runs with the Ay'C on) Both fans do not run with the A,/C on C o n d e n s eF a nC i r c u i t r Troubleshooting {seepage 21-28)
fuse/relay box under-dash Poorgroundat G501 C l e a n l i n ea n dt i g h t n e so f a l l ss s conneclors
clutchdoes not engage Compressor (both fans run with A,/C on) A/C system does not come on (both fans and compressor)
. P o o rg r o u n da t G 3 0 1 . C l e a n l i n e sa n d t i g h t n e s s f a l l s o connectors R a d i a t o rn dC o n d e n s e r n s Fa B l o w nf u s eN o . 1 ( 2 0 A ) n d N o . 4 a a fuse/relay Common Circuit Troubleshooting (20A)in the under-hood (see age 1-29) p 2 box P o o rg r o u n da t G 3 0 l C l e a n l i n e sa n dt i g h t n e s s f a l l s o connectors Compressor ClutchCircuit C l e a n l i n e sa n dt i g h t n e s s f a l l s o s T r o u b l e s h o o t i n(q e eD a q e 1 - 3 0 ) connectors 2 Ay'C Pressure B l o w nf u s eN o . 1 ( 2 0 A ) n d N o . 4 a Switch Circuit (20A)in the under-hood s fuse/relay T r o u b l e s h o o t i n(g e ep a g e2 1 - 3 2 ) box Poor ground at G301 o C l e a n l i n e sa n dt i g h t n e s s f a l l s connectors
!
21-10
SystemDescription
HeaterControlPanelInputsandOutputs
HEATER CONTFOLPANELCONNECIORS
CONNECTOR{r/rP) A
CONNECTOR (22P) B
W res deoitema eterm nals
CONNECTOR Cavity _ | 2 3
5 6 7 8 I
Wire color
\ln Y
Sional AIRMIXPOTENTIAL +5V S E N S OC O M M O N R O U N D R G

AIR MIX HOT
OUTPUT
INPUT
LT GRN PNK/BLU BLU GRNA/EL GRNA/VHT BLUI/EL BLU/RED

GRN
A,/C PRESSURE SWITCH RECIRCULATE

FRESH
10
11
14
YEL/RED YEVBTU YEL/BLK BLK BLK/YEL on

Wire color
POWER TRANSISTOR BLOWER FEEDBACK AIR MIX COOL MODEDEF MODEVENT REAR WINDOWDEFOGGER RELAY GROUND
l G 2( P o w e r )
OUTPUT INPUT INPUT INPUT OUTPUT INPUT OUTPUT OUTPUT OUTPUT INPUT OUTPUT INPUT
CONNECTOR B
Cavity
1
Siqnal
--T
2 3
4
BLIVRED
LT GRN L TG R N / B L K
5 6 7 8 9
PNVBLK
BRN
R E A R I N D O WD E F O G G ES W I T C H E D W R L A./C SWITCHLED RECIRCULATION NTROL WITCH ED CO S L AIR MIX POTENTIAL
EVAPORATOR TEIMPERATURE SENSOR
INPUT INPUT INPUT OUTPUT OUTPUT
10
11
RED RED/BLK BLU LT GRN/RED YEVRED YEUGRN WHT/BLU RED/BLU RED/YEL

BRN^,^/HT
GAUGE SSEMBLY A
TAILLIGHTS RELAY
al' 'TDr ri
INPUT
INPUT
14
ic
REAR WINDOWDEFOGGER SWITCH

A/C SWITCH RECIRCULATION NTROL WITCH CO S
16 17 18 19 20
MODE4 MODE3
M O D E2 M O D E1 I G N( P o w e d (Not used)
INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT

(cont'd)
22
REDA/r'HT
21-11

(cont'dl SystemDescription
The air conditioningsystem removesheatfrom the passenger compartmentby circulatingrefrigerant through the system as shown below.
BLOWER FAN \
EXPANSION VALVE
\r \,u
(Metersthe required amount of refrigerant into the evaporator)
APOBATOR TEMPERATURE
SENSOR THERMAL PROTECTOR (Opens the compressor clutchcircuit when the compressot temperature becomes too high)
A/C PRESSURE SWITCH is When the refriqerant below (2.0kgi/cm',28psi) 196kPa (32 kgf/cm' or above3,140kPa 455 psi),the Py'cpressure switchopensthe circuitto the Py'C switch and stopsthe air conditioning protectthe to compressor-
RELIEF VALVE (Relieves pressure thecompressor at w h e n h ep r e s s u r et o oh i g h ) is t
RECEIVER/DRYER (Traps and debris, \-^ removes morsturel
A/C COMPRESSOR (Suction and comoression)
/CONDENSER (Radiation heat) of
vAPoR HrcH PRESSURE
-:--l [ '.... Low PREsSUBE LrourD tffi Low PREssURE vAPoR
(R-'134a) Pay refrigerant which does not containchlorofluorocarbons. attentionto the This vehicleuses HFC-134a following serviceitems: . D o n o t m i x r e f r i g e r a n tC F C - 1 2R - 1 2a n d H F C - 1 3 4(a - 1 3 4 aT.h e ya r e n o t c o m p a t i b l e . ( ) R ) s . U s eo n l y t h e r e c o m m e n d e p o l y a l k y l e n e g l y c(o l A G r e f r i g e r n t o i l ( K E l H l N P ' ! 0 )d e s i g n e d f o r t h e R - 1 3 4 a P ) a d S compressor.Intermixingthe recommended(PAG)refrigerantoil with any other retrigerantoil will resultin compressorfailure. . AllAy'C expansion system parts (compressor, dischargeline, suction line,evaporator, condenser,receiver/dryer. parts. valve,O-ringsfor joints) have to be designedfor refrigerantR 134a.Do not exchangewith R-'12 . Use a halogengas leakdetectordesignedfor refrigerantR-134a. . R-12and R-134arefrigerantservicingequipmentare not interchangeable. only a recovery/recycling/charging Use R t d t s t s t a t i o n h a t i s U . L . - l i s t ea n d i s c e r t i f i e do m e e tt h e r e q u i r e m e n to f S A EJ 2 2 1 0 o s e r v i c e - 1 3 4 a i r c o n d i t i o n i n g system. . Always recoverthe refrigerantR-134a with an approvedrecovery/recycling/charging stationbeforedisconnecting fifting. any Ay'C
21-12

Diagram Gircuit
UNDEN rcODFUSVRELIYSOX
|GNUION SWTCfi HoI ii 0l\lllll lG2
UNOER DASN fUSE/8EIlYBOX BLK/RED
+. \
C}F rG2/
.I
\ IHEFMAI
lTlI *n*,*, | <l CLUTCH

tf
_l MUITIPLD( CONTFOI UNITI
PBorEcro8 I
I
I
I I n
.
G301 A/C PnESSUEt swTOt
-!10.
irgF 8Ll
t...iCF
BLU
RADIATOS NADIATOS \ ) tAl'/ / swtlcll oT0n
CONDEN$N MOTOB
B LX
I
21-14
19S"F 193"C) l
G301
I I
8u(
I ilnthoundor dasiluse/lelay box
BU/YEL
-8lU/wH'I
EVAPORATOB TEMPERATUNESENSOR
sn 4-Lrenil
m
::-:::: ., . a/c
YEUBLU YEL/NED BED/YEI RED/8LU WHT/8LU YEL/GRN LTGRI'l

M DEF MODEl Mq)EI M002 M00t3 MOOE3 MOOEI
M00l co TnoL
MOTOS
ffftH,, F*u,*
GNNMHT GRN/YEL
8U
8LK--..-...-l ( f
coNNEcroFrir.Pt mxr{EcroB ! {2P)

G5'1
I
21-15
G602

Troubleshooting DTC
Motor DTC An Openin theAir Mix Control 7: Circuit
1. Test the air mix control motor {seepage 2'l-341. ls the air mix control motor OK? YES-Go to step 2. N O - R e p l a c et h e a i r m i x c o n t r o lm o t o r . l the 2. Disconnect air mix control motor 5P connector. A heatercontrol panel connectors {14P) 3. Disconnect a n dB ( 2 2 P ) . 4. Checkfor continuitybetweenthe following A terminalsof heatercontrol panel connectors (14P) and B (22P)and the air mix control motor 5P connector, 14P: 5P: No.5 N o .1 No.4 No.2 No.2 No.3 N o .1 No.9 22P: No.6 5P: No.3
Motor DTC A Shortin theAir Mix Control 8: Circuit

1. Testthe air mix control motor(see page 21-341. ls the ait mix control motor OK? YES-Go to step 2. NO-Replace the air mix contorol motor.I 2. Disconnect air mix control motor 5P connector. the A heatercontrol panelconnectors (14P) 3. Disconnect B (22P). and 4. Checkfor continuitybetweenbody ground and terminals heatercontrol panelconnectorA (14P) and betweenbody No. 1, 2, 3, and 9 individually, ground and heatercontrol panelconnectorB (22P) t e r m i n a lN o . 6 .
A HEATERCONTROL PANELCONNECTOR {I4PI
W i r e s i d eo f f e m a l et e r m i n a l s
B HEATERCONTFOL PANELCONNECTOR I22P1
Wire side ol lem.letehi.6ls
ls there continuity? at YES-Check for loosewires or poor connections A heatercontrol oanel connectors (14P)and B (22P) and at the air mix control motor 5P connector.lf the are good. substitutea known-goodair connections lf mix control motor, and recheck, the symptom/ indicationgoes away, replacethe originalair mix continues, control motor. lf the symptom/indication substitutea known-goodheatercontrol panel,and goes away, recheck. the symptom/indication lf replacethe original heatercontrol panel.l a k N O R e p a i r n yo p e ni n t h e w i r e ( s ) e t w e e n t h e heatercontrol panel and the air mix control motor.l
W i r e s i d eo i l e m a e l e r m i n a l s
ls therc continuity? Y E S - R e p a i ra n y s h o r t t o b o d y g r o u n dl n t h e wire(s)betweenthe heatercontrol panel and the air mix control motor.l N O - G o t o s t e p5 .
21-16
5. Turn the ignition switch ON (ll),and checkthe same terminalsfor voltage. HEATER CONTROL PANELCONNECTOR {14PI A
DTC9: A Problem the Air Mix Control in Linkage, Door, Motor or

1, Test the air mix control motor (seepage 21-34). ls the air mix control motor OK? YES-Substitute a known-goodheatercontrol panel,and recheck. the symptom/indication goes lf away, replacethe original heatercontrol panel.l NO-Replace the air mix control motor, or repair a t h e l i n k a g e n dd o o r . l
HEATER CONTROL PANELCONNECTOR I22PI B
ls there any voltage? YES-Repair any short to power in the wire(s) betweenthe heatercontrol panel and the air mix control motor. This short may also damagethe heatercontrol panel.Repairthe short to power before replacing the heatercontrol panel.l NO Substitutea known-goodair mix control goes motor, and recheck. the symptom/indication lf away, replacethe originalair mix control motor. lf the symptom/indication continues, substitutea known-goodheatercontrol panel,and recheck. lf goes away, replacethe the symptom/indication c o r i g i n a h e a t e r o n t r o lp a n e l . I l
21-17

DTCTroubleshooting.(cont'd)
DTC10:An Openor Shortin the Mode Control MotorCircuit
1. Test the mode control motor (seepage 21-35). ls the mode cottol motor OK? YES Go to step 2. NO Replace the mode control motor.I 5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h e s a m e s t t e r m i n a l so r v o l t a g e . f HEATEB CONTROL PANEL CONNECTOR A {14P)
2. Disconnect mode control motor 10Pconnector. the

h c s 3 . D i s c o n n e c t e a t e r o n t r o lp a n e lc o n n e c t o r A ( 1 4 P ) and B \22P1. Checkfor continuitybetweenbody ground and ) h e a t e r o n t r o lp a n e lc o n n e c t oA ( 1 4 P t e r m i n a l s c r N o . 2 , 1 0 ,a n d 1 1 i n d i v i d u a l l y ,n d b e t w e e n o d y a b g r o u n da n d h e a t e r o n t r o lp a n e lc o n n e c t o B ( 2 2 P ) c r '17, N 1 8 ,1 9 ,a n d 2 0 i n d i v i d u a l l y . terminals o. HEATER CONTROL PANEL CONNECTOR A {14PI
Wire side of femaleterminal
HEATER PANELCONNECTOR {22PI B CONTROL

3
tl 12 5
X
WHT
15 T6
1 1 1 8 t 9 2A 21 22
RED/YEL
ls there any voltage? YES-. Repairany short to power in the wire(s) betweenthe heatercontrol panel and the mode control motor. This short may also damagethe heatercontrol panel.Repairthe short to power before replacing the heatercontrol panel.l NO- Go to step 6.
HEATER CONTROL PANELCONNECTOR {22P) B
W i r e s i d e o f f e m a L el e r m i n a l s
ls there continuity? Y E S R e p a i r n y s h o r t t o b o d y g r o u n di n t h e a wire(s)betweenthe heatercontrol panel and the mode control motor.l NO Go to step 5.
21-18
Turn the ignition switch OFF,and checkfor continuitybetweenthe following terminalsof heatercontrol panel connectors (14P)and B (22P) A and the mode control motor 10Pconnector. 14P: 10P: '10 N o .2 No. No.10 No,1 N o .1 1 No.2 22P: N o .1 7 N o .1 8 No.19 N o .2 0 10P: No.8 No.6,9 No.5 N o .4 , 7
DTC11:A Problem the ModeControl in Linkage, Doors, Motor or

1. Testthe mode control motor (seepage 21-35). ls the mode control motor OK? YES Substitutea known-goodheatercontrol panel,and recheck. the symptom/indication goes lf away, replacethe original heatercontrol panel.l NO Replace the mode control motor, or repairthe l i n k a g e n dd o o r s . l a
HEATER PANEL CONNECTOR(14PI A CONTROL Wiresideof lemale terminals
MODECONTROL MOTORlOPCONNECTOR Wiresideof female terminals
B HEATERCONTROLPANELCONNECTOR {22PI Wire side of femaleterminals
ls there continuity? YES-Check for loosewires or poor connections at A heatercontrol panelconnectors (14P)and B (22P), and at the mode control motor 10Pconnector.lf the connections good, substitutea known-good are mode control motor, and recheck. the symptom/ lf indicationgoes away. replacethe original mode continues, control motor.lfthe symptom/indication substitute known-goodheatercontrol panel,and a goes away, recheck. the symptom/indication lf replacethe originalheatercontrol panel.l NO Repairany open in the wire(s)betweenthe heatercontrol Daneland the mode control motor.l
21-19
Heating Air Gonditioning and

DTCTroubleshooting {cont'd)
in Motor DTC12:A Problem the Blower Circuit
'1. i C h e c k h e N o . 1 2 ( 4 0 A ) f u s en t h e u n d e r - h o o d t fuse/relaybox, and the No. 14 (10A)fuse in the f under-dash use/relaybox. Are the tuses OK? YES-Go to step 2. and recheck.l NO Replace fuse(s), the 2. Connect the No. 2 terminal of the blower motor 2P connectorto body ground with a jumper wire. BLOWER MOTOB2PCONNECTOR 7. Checkfor continuitybetweenthe No. 3 terminal of the power transistor4P connectorand body ground.
POWERTRANSISTOR4P CONNECTOR
2 3
4
BLK
o
Wire side ol temaleterminals
ls there continuity? YES-Go to step 8. NO-Check for an open in the wire betweenthe power transistorand body ground. lf the wire is OK, checkfor poor ground at G502.I
JUMPER] BLU/BLK
8 . Connectthe No. 1 and No. 3 terminalsof the power

transistor4P connectorwith a jumper wire. terminals Wiresideol female TRANSISTOR CONNECTOR 4P POWER s 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . Does the blowet motor run? YES Go to step 4, NO Go to step 17. 4. Turn the ignition switch OFF. terminals Wiresideof female the 5. Disconnect jumper wire. 6. Disconnect power transistor4P connector. the s 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . Does the blower motor tun at high speed? Y E S - G o t o s t e p1 0 . NO-Repair open in the wire betweenthe power transistorand the blower motor.l 1 0 . Turn the ignition switch OFF. 1 1 . Disconnect jumper wire. lhe
21-20
1a
heatercontrol panelconnectorA (14P). Disconnect
heatercontrol panel connectorA (14P). 1 5 . Reconnect

lo.
1 3 .Checkfor continuitybetweenthe No. 7 and No. 8

terminalsof heatercontrol panel connectorA (14P) a n d b o d y g r o u n di n d i v i d u a l l y . HEATER CONTNOL PANEL CONNECTOR A {14PI
Test the power transistor(seepage 21-38). ls the power transistorOK? YES Checkfor loosewires or poor connections at heatercontrol panel connectorA (14P) and at the power transistor4P connector.lf the connections are good, substitutea known-goodheatercontrol goes panel,and recheck. the symptom/indication lf away, replacethe original heatercontrol panel.l NO Replace power transistor.I the
1 7 . Disconnect jumper wire. the 1 8 . Disconnect blower motor 2P connector. the ls there continuity? YES Repairany shortto body ground in the wire(s)betweenthe heatercontrol panel and the power transistor.I NO Go to step 14, 1 4 . Checkfor continuitybetweenthe following terminalsof heatercontrol panelconnectorA ( 14P) and power transistor4P connector. 'l4Pt 4P: No.4 No.7 No.8 No.2 HEATER CONTROL PANEL CONNECTOR A (14P)
I
1 9 . Measurethe voltagebetweenthe No, 1 terminal of the blower motor 2P connectorand body ground. 2P BLOWER MOTOR CONNECTOR BLU/WHT
z 3
9
4 1 5 1 6
T 8
roxlI l
ls thete battery voltage? the blower motor.l YES- Replace
1 2 l1 3l 1 4
BLU/YEL
)
8LU/RED
NO Go to step 20.

ILU/YEL 4P POWER TRANSISTOR CONNECTOR Wiresideof female terminals ls thete continuity? YES Go to step 15. NO Repairany open in the wire(s)betweenthe heatercontrol paneland the power transistor.l (cont'd)
2 1 .Removethe blower motor relayfrom the underhood fuse/relaybox, and test it (seepage 22-511. ls the relay OK? YES Go to step 22. the NO- Replace blower motor relay.l
21-21

DTCTroubleshooting lcont'd)
22. Measurethe voltage betweenthe No. 3 terminal of the blower motor relay 4P socketand body ground.
25. Turn the ignition switch OFF, 26. Checkfor continuitybetweenthe No. 1 terminal of
the blower motor relay 4P socketand body ground.
BLOWER MOTORRELAY SOCKET 4P
2
4
BLOWER MOTOR RELAY SOCKET 4P
ls there battety voltage? YES-Go to step 23. NO Replace the under-hoodfuse/relaybox.t ls there continuity? YES-Repair open in the BLUIr'/HT wire between the blower motor relay and the blower motor.l NO Checkfor an open in the wire betweenthe blower motor relay and body ground. lf the wire is O K ,c h e c k o r p o o r g r o u n da t G 3 0 1 . 1 f
23. Turn the ignitionswitch ON {ll).

Measurethe voltage betweenthe No. 2 terminal of the blower motor relay 4P socketand body ground,
BLOWER MOTORRELAY SOCKET 4P
ls therebattery voltage? YES-Go to step25. NO Repair openin thewire between No.14 the fusein the under-dash fuse/relay andthe box blowermotorrelay.I
21-22
DTC14:An Openin the Evaporator Temperature Sensor Circuit

1. Removethe evaporator temperaturesensor(see p a g e2 1 - 3 7 ) . betweenthe No. l and 2. Measurethe resistance No. 2 terminalsof the evaporatortemperature sensor. x D i pt h e s e n s o r n i c ew a t e r ,a n d m e a s u r e i resistance. Then pour hot water on the sensor,and f i checkor changen resistance.
EVAPORA TOR TEMPERATURE SENSOR
4. Checkfor continuitybetweenthe No. 7 terminal of heatercontrol panelconnectorB (22P) and the No. 1 terminal of the evaporalortemperature s e n s o r Pc o n n e c t o r . 2 B HEATER CONTROL PANELCONNECTOR {22P) Wiresideof female terminals
ll#l
t-l
SENSOR CONNECTOR 2P EVAPORATOR TEMPERATURE Wiresideof female terminals
l UT-TU , I l l l , l I ---r---T-t
11c))-l
\9/
ls there continuity? YES Go to step 5. NO Repairopen in the wire betweenthe heater control panel and the evaporatortemperature sensor.I
RESISTANCE k0
heatercontrol panelconnectorA (14P). 5. Disconnect
50 10
68 20
86'F
30'c
TEMPERATURE ls the tesistancewithin the specificationsshown on the graph? Y E S - G o t o s t e p3 . NO Replace evaporatortemperature the sensor.I heatercontrol panelconnectorB {22P). 3. Disconnect
(cont'd)
21-23
Heatingand Air Gonditioning

6. Checkfor continuitybetweenthe No. 2 terminal of heatercontrol panel connectorA (14P)and the No, 2 terminal of the evaporalortemperature sensor2P connector. HEATER CONTROL PANEL CONNECTOR{14PI A Wiresideof female terminals LT GRN
DTC15:A Shortin the Evaporator Temperature Sensor Circuit

1. Removethe evaporator temperaturesensor(see p a g e2 1 - 3 7 ) . 2. Testthe evaporatortemperaturesensor(seepage 21-37J. ls the resistance within the specifications shown on the graph? YES Go to step 3. NO Replace evaporator the temperature sensor. !
EVAFORATOR TEMPERATURE SENSOR CONNECTOR 2P Wiresideof female terminals
Disconnect heatercontrol panel connectorB l22Pl.

4. Checkfor continuitybetweenthe No. 7 terminal of
ls there continuity? YES-Check for loosewires or Doorconnections at heatercontrol panel connectorA ('l4P)and B l22Pl and at the evaporatortemperaturesensor2P connector.lf the connections are good, substitutea known-goodheatercontrol panel,and recheck. lf goes away, replacethe the symptom/indication original heatercontrol panel.l NO Reoairooen in the wire betweenthe heater control panel and the evaporatortemperature sensor.I
heatercontrol panel connectorB {22P)and body ground. HEATER CONTROL PANEL CONNECTOR(22P) B
ls there continuity? YES Repairshort to body ground in the wire betvveen heatercontrol paneland the the evaporator temperaturesensor. I NO-Substitute a known-goodheatercontrol panel, goes away, and recheck. the symptom/indication lf replacethe original heatercontrol panel.I
21-24
Recirculation ControlMotor CircuitTroubleshooting

n 1 . C h e c k h e N o . 1 4 ( ' 1 0 A ) f u sie t h e u n d e r - d a s h f u s e / t relay box. ls the f use OK? YES Go to step 2. NO- Replace fuse, and recheck.l the control motor 5P 2. Disconnect recirculation the conneclor. A HEATER CONTROL PANEL CONNECTORI14P) 8. Checkfor continuitybetweenthe No. 5 and No. 6 terminalsof heatercontrol panelconnectorA (14P) and body ground individually.
3 . Turn the ignitionswitch ON (ll).

lvleasure voltage betweenthe No. 5 terminal of the control motor 5P connectorand the recirculation body ground.
CONTROLMOTOR RECIRCULATION 5P CONNECTOR
ls there continuity? YES Repairany shortto body ground in the wire(s)betweenthe heatercontrol panel and the recirculation control motor.l NO-Go to step 9. 9. Turn the ignition switch ON (ll),and checkthe same wires for voltage.
A PANEL CONNECTORIl4PI HEATER CONTROL
ls there battery voltage? YES Go to step 5. NO- Repairopen in the wire betweenthe No. 14 fuse/relaybox and the fuse in the under-dash recirculation control motor .l 5 . Turn the ignitionswitch OFF. control motor {seepage 216 . Testthe recirculation 36), ls the recirculationcontrol motor OK? YES Go to step 7. the control motor, or NO- Replace recirculation r e p a i r h e l i n k a g e n dd o o r s . I t a heatercontrol panel connectorA (14P). 7 . Disconnect terminals Wiresideof lemale
ls therc any voltage? a Y E S R e p a i r n y s h o n t o p o w e ri n t h e w i r e ( s ) betweenthe heatercontrol panel and the recirculation control motor. This shon may also R t c d a m a g e h e h e a t e r o n t r o lp a n e l . e p a i r h e s h o n t to power before replacingthe heatercontrol p an e l .I N O - G o t o s t e p1 0 .
{cont d r
21-25

Recirculation (cont'd! Control Motor CircuitTroubleshooting
10. Turn the ignition swirchOFF. 11. Checkfor continuitybetweenthe following terminalsof heatercontrol panel connectorA ( 14P) and the recirculation control motor 5P connector. 'l4Pt 5P: No.5 N o .1 No.6 No.2 HEATER CONTROL PANEL CONNECTOR A {14P} Wiresideol temale terminats
RECIRCULATION CONTROL MOTOR CONNECTOR 5P Wiresideol lemale terminals ls there continuity? YES Checkfor loosewires or poor connections at heatercontrol panel connectorA ( 14P)and at the recirculation control motor 5P conneclor.lf the connectionsare good, substitutea known-good heatercontrol panel,and recheck. the symptom/ lf indicationgoes away, replacethe original heater control panel,I NO Repairany open in the wire{s)betweenthe heatercontrol panel and the recirculation control motor.l
21-26
HeaterControlPowerand GroundCircuitsTroubleshooting
i 1 . C h e c k h e N o . 1 4( 1 0 A ) f u s en t h e u n d e r - d a s h t fuse/relaybox. ls the f use OK? YES-Go to step 2. N O - R e p l a c et h e f u s e ,a n d r e c h e c k . l heatercontrol panelconnectorA{'14P). 2. Disconnect 3. Turn the ignition switch oN (ll). 4. Measurethe voltage betweenthe No. l4terminal and body of heatercontrol panelconnectorA (14P) grouno. A PANEL CONNECTOR{14P} HEATER CONTROL A PANEL CONNEcToR (1ilP) HEATER CONTRoL 6. Checkfor continuitybetweenthe No. l3terminal of and body heatercontrol panelconnectorA (14P) g round.
1 2 3
I
4 5 6
8 9
r0t, 1 l 12
14
.o
ls therc continuity?
BLK
2 3 7 8 I 1 0l ,
5 6
14
11 12
BLK/YEL
at YES Checkfor loosewires or poor connections lfthe healercontrol panel connectorA (14P). a are good, substitute known-good connections lf heatercontrol panel,and recheck. the symptom/ indicationgoes away, replacethe original heater control panel.l NO Checkfor an open in the wire betweenthe heatercontrol paneland body ground. lf the wire is f O K ,c h e c k o r p o o r g r o u n da t G 5 0 1I.
ls there battery voltage? YES-Go to step 5. the NO Repairopen in the wire betvveen No. 14 fuse/relaybox and the fuse in the under-dash heatercontrol panel.l Turn the ignitionswitch OFF.
21-27

Condenser FanCircuitTroubleshooting
NOTE:lf neitherthe condenser fan nor the radiatorfan work, go to Radiatorand Condenser FansCommon (seepage21-29). CircuitTroubleshooting 1. Checkthe No. 1 (20A)fuse in the under-hood f u s e / r e l a y o x ,a n d t h e N o . 1 4 ( 1 0 A ) f u s en t h e b i under-dash use/relaybox. f Are the tuses OK? YES-Go to step 2. NO Replace fuse(s), the and recheck. t 2. Removethe condenserfan relayfrom the under-hoodfuse/relaybox, and test it ( s e ep a g e2 2 - 5 1 ) . Does the condenser lan tun? ls the relay OK? YES-Go to step 5. YES Go to step 3. NO Go to step8. NO- Replace condenser the fan relay.l 5. Disconnect jumper wire. the 3. Measurethe voltage betweenthe No, 2 terminal of the condenserfan relay 4P socketand body ground.
CONDENSER FAN RELAYilP SOCKET
4 . C o n n e ctth e N o . l a n d N o . 2 t e r m i n a l s o f t h e condenserfan relay 4P socketwith a jumper wire.

CONDENSER FAN RELAYitP SOCKET
WIRE JUMPER
6. Turn the ignition switch ON (ll). 7. Measurethe voltage betweenthe No, 3 terminal of the condenser fan relay 4P socketand body ground. CONDENSER FELAY4PSOCKET FAN
r-,_-l
Flr
\----1--rl
2 |
IELK/YEL
d,
ls thete battery voltage? YES-Go to step 4. ls there battery voltage? NO-Replace the under-hood fuse/relaybox.l
YES Replace under-hoodfuse/relaybox.t the N O - R e p a i r o p e ni n t h e w i r e b e t w e e n h e N o . 1 4 t fuse in the under-dash fuse/relaybox and the c o n d e n s efra n r e l a y . l Disconnect jumper wire. the
21-28
Fans Radiator and Condenser CommonCircuitTroubleshooting

9 . Disconnect condenserfan 2P connector, the 1 0 .Checkfor continuitybetweenthe No. 1 terminal of
the condenser fan relay 4P socketand the No. 2 terminal of the condenser fan 2P connector. CONDENSER RELAY SOCKET FAN 4P NOTE;lf both fans and the Ay'C compressorclutchdo not work when the Ay'C switch is on, go to Ay'CPressure (seepage 21-32l, . Switch CircuitTroubleshooting 1. Checkthe No. 1 {20A}and No. 4 (20A)fuses in the under-hoodfuse/relaybox, and the No. 14 (10A) fuse in the under-dash fuse/relaybox. Are the tuses OK? YES Go to steD2. NO Replace fuse(s), the and recheck.l fan relavfrom the 2. Removethe condenser f under-hood use/relaybox. s 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ; . Is there continuity? YES Go to step 11. NO- Repairopen in the wire betweenthe c o n d e n s efra n r e l a ya n d t h e c o n d e n s efra n , I '11 . Checkfor continuitybetweenthe No. 1 terminal of fan 2P connectorand body ground. the condenser FAN CONDENSER 2PCONNECTOR 4. Measurethe voltage betweenthe No. 3 terminal of fan relay 4P socketand body ground. the condenser 4P FAN CONDENSER RELAY SOCKET
FAN 2P CONNECTOR CONDENSER Wire side of femaleterminals
-l r-,
o I
1 2 l f---r---
l,l,l
lar-vverl
1 BLK
o
ls there battery voltage? YES Go to step 5. NO Repairopen in the wire betweenthe No. 14 fuse/relaybox and the fuse in the under-dash radiatorfan relay,and the condenserfan relay.l 5. Turn the ignition switch OFF. ll 6 . R e i n s t a t h e c o n d e n s efra n r e l a y . 7 . M a k es u r et h e I V Cs w i t c hi s O F F . s 8 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) .
ls there continuity? the fan motor.I YES- Replace condenser NO Checkfor an open in the wire betweenthe fan and body ground. lf the wire is oK, condenser f c h e c k o r p o o rg r o u n da t G 3 0 1 . 1
(cont'd)
21-29

Radiatorand Condenser Fans Common CircuitTroubleshooting Compressor ClutchCircuit Troubleshooting
1. Checkthe No. 1 (20A)fuse in the under-hood f u s e / r e l a y o x ,a n dt h e N o . 1 4 { 1 0 A ) f u s en t h e b i under-dash fuse/relaybox. Are the tuses OK? YES Go to step 2. NO Replace fuse(s), the and recheck.I 2. Checkthe enginecoolanttemperature, throttle the positionsensor,and the idle speed (usethe Honda PGMTesterPGM-Fldata list if possible). ls the coolant temperaturc above nomal, the throttle position sensor rcading too high, or the idle speed too low?
(cont'dl
9. Using a Backprobe Set, measurethe voltage betweenthe No. 6 terminal of ECN4 connectorB {24P)and body ground with the ECMconnectors connecteo. ECMCONNECTOR {24P} B
ls there battery voltage? YES UDdate the ECM if it does not have the latest so{tware,or substitutea known-goodECM,then recheck(seepage 11-6). the symptom/indication lf goes away with a known-goodECM,replacethe originaECM.I l NO Repairopen in the wire betweenthe radiator fan relay,the condenserfan relay and the ECM.t
YES Troubleshootand repairthe causeof the high enginecoolanttemperature, high throttle positionsensor reading,or low idle speed.l NO-Go to step 3. 3. Removethe compressorclutchrelay from the under-hoodfuse/relaybox, and test it (seepage 225 1) . ls the relay OK? YES Go to step 4. NO Replace compressorclutch relay.I the 4. Measurethe voltage betweenthe No. 2 terminal of the compressorclutch relay 4P socketand body ground.
COMPfiESSON CLUTCH BELAY SOCKET 'P
ls there battery voltage? YES Go to step 5. NO Replace under-hoodfuse/relaybox.I the
21-30
5. Connectthe No. 1 and No. 2 terminalsof the compressorclutch relay 4P socketwith a jumper wire.
CLUTCHRELAY4P SOCKET COMPRESSOR
L Turn the ignition switch OFF. 10. Reinstallthecompressorclutch relay. 11. l\4ake sure the Ay'C switch is OFF. 1 2 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s Set, measurethe voltage 13. Uslng the Backprobe connector betweenthe No. 18 termina!of ECI\4 E {31P)and body ground with the ECMconnectors connected. ECMCONNECTOR 131P} E
2
WIRE JUMPER
3 t 4 5
26
9 21
1 4 1 5 16
m
27
29
Does the compressor clutch click ? YES Go to step 6. N O - G o t o s t e p1 4 . 6. Disconnect jumper wire. the s 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) .
22 23 24
31
RED
ls there battery voltage? 8. Measurethe voltagebetweenthe No. 3 terminal of the compressorclutch relay 4P socketand body ground. 4P COMPRESSOR CLUTCH RELAY SOCKET YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then lf recheck(seepage 11-6). the symptom/indication goes away with a known-goodECIM, replacethe o r i g i n aE C M . I l NO Repairopen in the wire betweenthe c o m p r e s s oc l u t c hr e l a ya n d t h e E C M . I r 1 4 . D i s c o n n e c h e j u m p e rw i r e . tt 15. Disconnect compressorclutch lPconnector. the
ls there battery voltage? YES-Go to step 9. NO Repairopen in the wire betweenthe No. 1 4 fuse/relaybox and the fuse in the under-dash compressorclutch relay,I
{cont'd)
21-31

Compressor Clutch Circuit
(cont'dl Troubleshooting
16. Checkfor continuitybetweenthe No. lterminal of the compressorclutch relav 4P socketand the No. l terminal of the compressorclutch 1Pconneclor. COMPRESSON CLUTCH RELAY SOCKET 4P
A/C Pressure Switch Circuit Troubleshooting

'1. Turn the ignition switch ON {ll).
2. Turn the blower switch on, and checkfor blower motor operatron. Does the blower motor run on all speeds? YES Go to step 3. NO Troubleshoot the blower motor circuit(see page21-20). 3. Turn the ignition switch OFF. 4. Disconnect heatercontrol panelconnectorA ('14P).
COMPRESSOR CLUTCH1P CONNECTOR Terminalside of male terminals
5 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 6. Measurethe voltage betweenthe No, 4 terminal of heatercontrol panelconnectorA {14P)and body ground. HEATER CONTROL PANEL CONNECTOR(I4P} A
ls therc continuity? YES-Check the compressorclutchclearance, the thermal protector,and the compressorclutchfield c o i l ( s e ep a g e2 1 - 4 8 ) . I NO-Repair open in the wire betweenthe compressorclutch relay and the compressor clutch.l
Wire side of femaletermina's
ls there battety voltage? YES Go to step 7. N O - G o t o s t e p9 . 1 . S t a nt h e e n g i n e .
21-32
8. Connectthe No.4terminal ofheatercontrol connectorA (14P) body ground with a jumper to wire,
HEATER PANEL CONTROL CONNECTOR I14P} A
11. Checkfor continuitybetweenthe No. 2 terminal of pressureswitch 2P connectorand the No. 9 the A,/C fuse relav box connector terminal of under-dash F t12Pt.
A/C PRESSURE SWITCH2PCONNECTOR W i r e s i d eo f f e m a l et e r m i n a l s
BLU
2 3 7 8 I 4 5 6
r 0 l x 11
12 l 3 t 4
JUMPER WIBE
Wire side female of terminals
BOX CONNECTOR (12P) F UNDER.OASH FUSE/RELAY W i r es i d eo f f e n a l e l e r r r i n a l '
Does the A/C system come on? YES Replace heatercontrol panel.! the NO Referto the multiplexcontrol system (see p a g e2 2 - 1 6 8 ) . 1 Set,connectthe No. 9 9 . Usingthe Backprobe fuse/relaybox connector terminal of under-dash ) F ( 1 2 P t o b o d y g r o u n dw i t h a j u m p e rw i r e . BOX F{12P} UNOER.DASH FUSE/RELAY CONNECTOR
2 6 1 5 l2
ls there continuity? YES Go to step 12. NO Repairopen in the wire betweenthe pressure under-dash fuse/relaybox and the A,,/C switch.I 1 2 . Checkfor continuitybetweenthe No. 1 and No. 2 terminalsof the A,/Cpressureswitch.
A/C PRESSURE SWITCH
B g l r ot l
BLU/WHT JUMPER WIRE
ls there continuity? Does the NC system come on? YES Go to step 10. NO- Referto the multiplexcontrol system (see p a g e2 2 - 1 6 8 ) . 1 '1. N O T E C h e c k o r m u l t i p l e x o d e si n m o d e F o l l o w : f c {or the troubleshooting any codesfound. lf no codesare found, subsititutea known-9ood m u l t i p l e x o n t r o lu n i ta n d a E C Mo n e a t a t i m e . c pressureswitch 2P connector 1 0 . Disconnect Ay'C the fuse/relaybox connectorF { 12P). and under-dash YES Repairopen in the wire betweenthe heater control panel and the A,/Cpressureswitch.l N O G o t o s t e p1 3 .
'13.check for properAy'C system pressure.

ls the pressure within specitications? YES Replace AilCpressureswitch.l the NO Repairthe AilCpressureproblem.I
21-33

Air Mix ControlMotorTest
1. Disconnect 5P connectorfrom the air mix the control motor. 2. Connectbatterypowertothe No. l terminal ofthe air mix control motor, and ground the No. 2 t e r m i n a l t h e a i r m i x c o n t r o lm o t o rs h o u l dr u n ,a n d ; stop at Max Cool.lf it doesn't,reversethe connections;the mix control motor should run, air and stop at Max Hot. lf the air mix control motor does not run, remove it. then checkthe air mix control linkageand door for smooth movement. . lf the linkageand door move smoothly,replace the air mix control motor. . l f t h e l i n k a g e r d o o r s t i c k o rb i n d ,r e p a i r t h e m s o a needed. . lf the air mix control motor runs smoothly,go to step 3. AIRMIX CONTROL MOTOR
Air Mix ControlMotor Replacement

1 . Removethe under-dash fuse/relaybox (seepage 22-491. Disconnect 5P connector{A) from the air mix the control motor (B).Removethe self-tapping screws and the air mix control motor from the heaterunit. R e m o v e h e r o d ( C )f r o m t h e a r m ( D )o f t h e a i r m i x t controi motor.
,.,:l'
3 . Installthe motor in the reverseorder of removal.

After installation, make surethe motor runs smoothly.
\'
3 . Measurethe resistance betweenthe No. 4 and

No. 5 terminals.lt should be between2.1 k to 3 . 9k Q .
4 . Reconnect the air mix control motor 5P connector,
t h e nt u r n t h e i g n i t i o n w i t c hO N { l l ) . s Using the Backprobe Set, measurethe voltage betweenthe No. 3 and No. 4 terminals. Max Cool about 1V Max Hot about 4 V lf eitherthe resistance voltage readingsare not or as specified,replacethe air mix cotrol motor.
21-34
Mode ControlMotor Test

'1. Disconnect 10Pconnectorfrom the mode the control motor.
Mode ControlMotor Replacement

1 . R e m o v e h e E C M( s e ep a g e 1 1 - 4 ) . t
2. Removethe relay mount bracketbolt, and move

Connectbatterypower to the No. 1 terminal of the mode control motor, and groundthe No. 2 terminal;the mode control motor should run smoothly and stop at Defrost.lf it doesn't,reverse the connections; mode control motor should the run smoothly and stop at Vent.When the mode control motor stops running,disconnectbattery power immediately. MOTOR MODECONTROL the relaysout of the way. the 3 . Disconnect 10Pconnector{A) from the mode screws control motor (B).Removethe self-tapping and the mode control motor from the heaterunit.
3. lfthe mode control motor does not run in step 2, remove it, then checkthe mode control linkageand doors for smooth movement. . lf the linkageand doors move smoothly. replace the mode control motor. . l f t h e l i n k a g e r d o o r s s t i c k r b i n d ,r e p a i r t h e m o o as neeoeo. . lfthe mode control motor runs smoothly,go to step 4. 4 . Use a digital multimeterwith an output of 1 mA or lessat the 20 k Q range.With the mode control motor running as in step 2, checkfor continuity a b e t w e e nh e N o . 4 , 5 , 6 , 7 , 8 , a n d 9 t e r m i n a l s n d t T t h e N o . 1 0t e r m i n a li n d i v i d u a l l y .h e r es h o u l db e f c o n t i n u i t yo r a m o m e n ta t e a c ht e r m i n a la s t h e motor moves past each mode position. lf there is no continuityfor a moment at each terminal. replacethe mode control motor.
4 . lnstallthe motor in the reverseorder of removal. lvlake sure the pin on the linkageis properly make engagedwith the motor. After installation. sure the motor runs smoothly.
21-35

Recirculation ControlMotor Test
1. Disconnect 5P connectorfrom the recirculation the control motor. 1 . R e m o v e h e E C M( s e ep a g e1 1 - 4 ) . t Incorrectly applying power and ground to the recirculation control motor will damge it. Follow the instructions carefullv. 2. Connectbattervoower to the No. 5 terminal ofthe recirculation control motor, and ground the No. 1 and No. 2 terminals;the recirculation control motor should run smoothly.To avoid damagingthe recirculation control motor, do not reversepower and ground. Disconnect No. 1 or No. 2 the terminalsfrom ground;the recirculation control motor should stop at Freshor Recirculate. Don't cyclethe recirculation control motor {or a long time. RECIRCULATION CONTROL MOTOR Removethe relay mount bracketbolt.and move the relaysout of the way, Disconnect 5P connector(A)from the the recirculation control motor (B),Removethe selftapping screwsand the recirculation control motor from the blower unit.
Recirculation ControlMotor Replacement
Installthe motor in the reverseorder of removal. Make sure the pin on the motor is properly engagedwith the linkage. After installation. make sure the motor runs smoothly.
lf the recirculation control motor does not run in step 2, remove it, then checkthe recirculation control linkageand doors for smooth movement. . lfthe linkageand doors move smoothly,replace the recirculation control motor. . l f t h e l i n k a g e o r d o o r s s t i c k ob i n d ,r e p a i r t h e m r as neeoeo.
21-36
Evaporator Temperature Sensor Replacement

1 . Removethe driver'sdashboardlower cover (see page 20-59)and the under cover (seepage 20-60). Removethe under-dash fuse/relaybox (seepage 22-491. Disconnect 2P connector(A)from the the evaporator temperaturesensor(B),then remove the connectorclip (C).Removethe self-tapping screw,and carefullypull out the evaporator temperature.
Evaporator Temperature Sensor Test

l. Dip the sensorin ice water, and measurethe resistance betweenits terminals EVAPORATOR TEMPERATURE SENSOR
Terminalside ol male terminals
2 . Then pour hot water on the sensor,and check{or a

changein resistance.
3 . Comparethe resistance readingswith the

specifications shown in the graph;the resistance should be within the specifications
4. Installthe sensorin the reverseorder of removal,

RESISTANCE k9
t0
32 0
50 10
68 20
86 'F 30'c
TEMPERATURE
21-37

PowerTransistor Test
1. Disconnect 4P connectorfrom the power the Iranslslor. betweenthe No. 1 and 2, Measurethe resistance No. 2 terminalsof the power transistor.lt should be '1.4 1 . 5k Q . about . lf the resistance go iswithln the specifications, to step 3. . lf the resistance notwithin the specifications, is replacethe power transistor.
POWER TRANSISTOB
HeaterControlPaneland Push Switch AssemblyRemovaland Installation

1 . Removethe centerpanel (seepage 20-62). Removethe dials (A),then removethe self-tapping screwsand the heatercontrol panel (B)from the centerpanel (Cl. Removethe self-tapping screws and the push switch assembly(D)from the center panel.
r t C a r e f u l l ye l e a s eh e l o c kt a b o n t h e N o . 4 t e r m i n a l (BLUI/EL)(A) in the 4P connector, then removethe i t e r m i n a a n d i n s u l a t et f r o m b o d y g r o u n d . l
\ 3 . lnstallthe control panel and push switch assembly

in the reverseorder of removal.After installation, operatethe control panel controlsto see whether it worKspropeny. functionto confirm that 4 . Runthe self-diagnosis there are no problemsin the system (seepage218).
(To1 2V power o u r c e n vehicle) 12 p o w e rsource v e h i c l e ) s o on Reconnect 4P connectorto the power transistor. the S u p p l y1 2v o l t st o t h e N o . 4 c a v i t yw i t h a j u m p e r wire. t T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h a tt h e s b l o w e rm o t o r r u n s . . lf the blower motor does not run, replacethe power rranstsror. . l f t h e b l o w e rm o t o r r u n s , t h ep o w e r t r a n s i s t o r i s
oK.
21-38
Dustand Pollen FilterReplacement

The dust and pollenfilters should be replacedevery 3 0 , 0 0 0 i l e s( 4 8 . 0 0 0 m ) o r 2 4 m o n t h sw h i c h e v e r m k comes first. Replace filters more often if the air flow the i s l e s st h a n u s u a l . 1. Openthe glove box. Removeboth glove box stops, then let the glove box hang down (seepage 20 63). 2 . R e m o v e h e f i l t e rl i d ( A ) f r o mt h e b l o w e ru n i t ,t h e n t p u l l o u t t h e f i r s td u s ta n d p o l l e nf i l t e r( B ) .S l i d et h e secondfilter to the left,and pull it out.
BlowerUnit Removal and lnstallation

For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage (seepage 23-14) 23-13)and precautions and procedures performing repairsor service. in the SRSsectionbefore 1. Make sure you havethe anti-theftcode for the radio, then write down the frequencies the preset for buttons. 2. Disconnect batterynegativecable,and wait 3 the minutesbefore beginningworK. 3. Removethe right kick panel (see page 20-50), passenger's dashboardlower cover,and the glove box {seepage 20-63). 4. Cut the plasticcross bracein the glove box opening with diagonalcuttersin the area shown. Remove and discardthe plasticcross brace,
Removethe filter {A) from the housing (B),and replacethe filter.
Cut heare.
4. Installthe filters in the reverseorder of removal.
{cont'd)
21-39
Heatingand Air Gonditioning

Blower Unit Removaland Installation{cont'd}
Removethe steeringhangerbeam bracketcover from the right side of the glove box opening,then removethe bolts and the olove box frame. 10. Disconnectthe connector{A) from the recirculation control motor, then removethe wire harnessclip {B).Removethe mounting bolts,the mounting nuts a n d t h e b l o w e ru n i t ( C ) .
Removethe ECM(seepage 11-4). 1 . Removethe EPScontrol unit (seepage 17-67). and removethe PGM-Flmain relays 8 . Disconnect and bracketassembly, then removethe ECM bracket. 9 . Disconnect connectors from the blower the {A) motor and the power transistor, then removethe wire harnessclips (B)and the connectors(C). Removethe self-tapping screwsand the bracket(D). A 6x 1.0 m m I kgt.m, 9.8N.m(1.0 7.2tbt.ftl
6x1.0mm 9.8 N.m (1.0kgf.m, ?.2 tbf.ft)
1 1 .I n s t a l l l h e n i t i n t h e r e v e r s e r d e ro f r e m o v a l . u o M a k es u r et h a tt h e r ei s n o a i r l e a k a g e . Reconnect negativebatteryterminal. the
'13.
i D o t h e e n g i n ec o n t r o lm o d u l e( E C M ) d l e l e a r n p r o c e d u r es e ep a g e1 1 - 1 3 9 ) . {
1 4 . Enterthe anti-theft code for the radio,then enter the customer'sradio station presets.
21-40
Blower Unit ComponentsReplacement

Nole these items when overhaulingthe blower unit; ' The recirculation control motor (A),the power transistor(B),the blower motor (C),and the dust and pollenfiltefs (D) can be replacedwithout removingthe blower unit. . Beforereassembly, make surethatthe recirculation control linkageand doors move smoothly. . After reassembly, make surethe recirculation control motorruns smoothly (seepage 2j-36).
21-41

Evaporator CoreReplacement
1 . Recover the refrigerant with a recovery/recycling/ chargingstation(seepage 21-53). Removethe bolt, then disconnect the suctionline (A) and the receiverline (B)from the evaporator core. 5. Carefullypull out the evaporatorcore without bendingthe pipes.
6x10mm 9.8N.m(1.0 kgt.m, 7.2lbf.ft) Removethe blower unit (seepage 21-39). Removethe self-tapping screwsand the expansion valve cover.
6 . Installthecore in the reverseorder of removal,and note these items. . lfyou're installinga new evaporatorcore, add r e f r i g e r a n t i l ( K E l H l N P - ] 0 )( s e ep a g e2 1 - 6 ) . o S . Replace O-ringswith new ones at eachfitting, the and apply a thin coat of refrigerantoil before installingthem. Be sure to use the correctO-rings R f o r H F C - 1 3 4(a - ' 1 3 4 ta ) a v o i dl e a k a g e . o . l m m e d i a t e l y a f t e rs i n g t h eo i l , r e i n s t a l l t h e c a p u on the container,and seal it to avoid moisture absorotion. . Do not spill the refrigerantoil on the vehicle;it may damagethe paint. lf the refrigerantoil contactsthe paint,wash it off immediately. . Chargethe system (seepage 21-55).
21-42
HeaterUnit/CoreReplacement
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23'13),and (seepage 23-14)in the SRS precautions and procedures performingrepairsor service. sectionbefore 1. Make sure you have the anti-theft code forthe radio, then write down the freouencies the radio's for Dresetbuttons. Disconnect negativecablefrom the battery, the Disconnect suctionand receiverlinesfrom the the evaporator core (see page 21-42). 4 . From underthe hood, open the cableclamp (A), then disconnect the heatervalve cable (B)from the heatervalve arm (C).Turn the heatervalve arm to the fully openedpositionas shown 6. Slidethe hose clamps (A) back,then d isconnect the inlet heaterhose (B)and the outlet heaterhose (C) from the heatercore. Enginecoolantwill run out when the hosesare disconnected; drain it into a clean drip pan. Be sure not to let coolantspill on the electricalpartsor the paintedsurfaces. any lf coolantspills,rinse it off immediately.
7 . Removethe bolt and the heatervalve,then remove the mounting nut from the heaterunit. Takecare not to damageor bend the fuel lines and the brake lines,etc.
W h e nt h e e n g i n ei s c o o l ,d r a i nt h e e n g i n e o o l a n t c from the radiator(seepage 10-6).
8 x 1.25mm 12 N.m (1.2kgf.m,8.7lbf.ft)
(cont'd)
21-43

(cont'd) HeaterUnit/CoreReplacement
8. Removethe dashboard{seepage 20-66). 9. Disconnectthe connectors(A) from the blower motor, the recirculation control motor, the mode then control motor, and the power transistor, removethe wire harnessclips (B)and the connector(C).Removethe self-tapping screwsand the bracket(D). 1 1 . R e m o v e h e m o u n t i n g o l t s , h e m o u n t i n gn u t s , t b t and the heaterunit.
7 t , 5 x 1 . 0m m 9.8 N.m kgl 11.0 m, 7.2 tbf.ftl
12. Removethe self-tapping screwsand the expansion

valve cover (A).Carefullypull out the evaporator core (B)so you don't bendthe inlet and outlet pipes. Removethe grommet (C),then removethe selftapping screwsand the flange cover (D).Bemove the self-tapping screwsand the pipe cover (E),then carefullypull out the heatercore (F)so you don't bend the inlet and outlet oioes.
the 1 0 ,Disconnect connectors(A) from the evaporator temperaturesensorand the air mix control motor, then removethe wire harnessclips (B) and the connector(C).Removethe self-tapping screw and the cover (D).Disconnect heatervalve cable (E). the
21-44
13. Installthe heatercore and the evaporatorcore in the reverseorder of removal. 14. Installthe heaterunit in the reverseorder of removal,and note these items: . Do not interchange inlet and outlet heater the hoses,and installthe hoseclamps securely. . Refillthecooling systemwith engine coolant(see page 10-6). . Adjust the heatervalve cable (see page2'l-461. . Make sure that there is no coolantleakage. . Make sure that there is no air leakage. . Referto evaporatorcore replacement {seestep 6 o n p a g e2 1 - 4 2 ) . . Do the enginecontrol module (ECl\4) learn idle ( p r o c e d u r es e ep a g e1 1 - 1 3 9 ) . . Enterthe anti-theft code for the radio,then enter the customer'sradio stationDresets.
21-45

HeaterValveCableAdjustment
1 . F r o mu n d e r t h eh o o d ,o p e nt h e c a b l ec l a m p{ A ) , then disconnect the heatervalve cable (B)from the heatervalve arm {C). 5, From under the hood,turn the heatervalve arm {C) to the fully closedpositionas shown, and hold it. Attachthe heatervalve cable (B)to the heatervalve v a r m ,a n d g e n t l yp u l l o n t h e h e a t e r a l v ec a b l e housingto take up any slack,then installthe heater i v a l v ec a b l eh o u s i n g n t ot h e c a b l ec l a m p( A ) .
.'.-:',,
- " l l
......
t
the heatervalve From under the dash,disconnect f c a b l eh o u s i n g r o m t h e c a b l ec l a m p( A ) ,a n d the heatervalve cable (B)from the air disconnect mix control inkageC). {
\
, t.- l
\'r2t'
'
''' '
::"'
Set the temperaturecontrol dial on Max Cool with the ignition switch ON (ll). Attachthe heatervalve cable (B)to the air mix control linkage(C)as shown above,then snap the i h e a t e r a l v ec a b l eh o u s i n g n t ot h e c a b l ec l a m p( A ) . v
21-46
Compressor Replacement
1 . l f t h e c o m p r e s s oirs m a r g i n a l l y p e r a b l er,u n t h e o engineat idle speed,and let the air conditioning work for a few minutes,then shut the engine off. 2. Make sure you have the anti-theftcode for the radio, then write down the frequencies the radio's for presetbuttons. 3. Disconnect negativecablefrom the battery. the 4. Recover the refrigerant with a recovery/recycling/ chargingstation(seepage 21-53). 5. Removethe alternator(seepage 4-29). 6. Removethe Ay'C condenserfan assembly(seepage 10-10). 7. Disconnectthe compressorclutchconnector(A), removethe bolts,then disconnect the suction line ( B )a n d t h e d i s c h a r g ei n e( C ) f r o mt h e c o m p r e s s o r . l Plug or cap the lines immediatelyafter disconnecting them to avoid moistureand dust contamination.
6 x '1.0 mm 9.8 N.m kgt.m, 11.0 7.2 tbl.ttl
8. Removethe mounting bolts and the compressor.
8 x 1.25 m m 22 N.m12.2 kgf.m. 9 . I n s t a l l t h e o m p r e s s oirn t h e r e v e r s e r d e ro f c o removal,and note these items: . Beforeinstallingthe new compressor, checkfor m e t a lo r o t h e rc o n t a m i n a t i o in t h e l i n e .R e p l a c e n parts. any contaminated . lf you're installinga newcompressor,you must calculate the amount of refrigerantoil to be removedfrom it (seepage 21-6). . Replace O-ringswith new ones at each fitting, the and apply a thin coat of refrigerantoil before installingthem. Be sure to use the correctO-rings f o r H F C - 1 3 4{a - 1 3 4 a o a v o i dl e a k a g e , t) R . U s er e f r i g e r a no i l ( K E l H l N P - ' 1 0 o r H F C - 1 3 4 a t f) S K E I H I N p i r a lt y p e c o m p r e s s oo n l y . s r . To avoid contaminatlon, not returnthe oilto do the containeronce dispensed,and never mix it with other refrigerantoils. . l m m e d i a t e l y f t e ru s i n gt h e o i l , r e i n s t a l l t h e a p a c on the container,and seal it to avoid moisture absorption. . Do not spill the refrigerantoil on the vehicle;it may damagethe paint. lf the refrlgerantoil contactsthe paint,wash it off immediately. . Chargethe system (seepage 21-55). . D o t h e e n g i n ec o n t r o lm o d u l e( E C M ) d l e l e a r n i ( p r o c e d u r e s e ep a g e1 1 - ' 1 3 9 ) . . Enterthe antitheft code for the radio,then enter the customer'sradio station presets.
u1/
(
21-47

ClutchCheck Compressor
peeling, 1 . Checkthe armatureplatefor discoloration, or other damage.lf there is damage,replacethe clutch set (seepage 21-49), Checkthe rotor pulley bearingplay and drag by rotatingthe rotor pulley by hand.Beplace the clutchset with a new one if it is noisy or has play/drag(seepage 21-49). excessive 4. Release field coil connectorf rom the holder, the then disconnectit. Checkthe thermal protectorfor continuity.lf there is no continuity,replacethe r t h e r m a lp r o t e c t o ( s e ep a g e2 1 - 5 1 ) . NOTE:The thermal Drotector will have no . c o n t i n u i t y b o v e2 5 2 t o 2 7 0 " F 1 2 2 l o 1 3 2 ' C )W h e n a \ t t h e t e m p e r a t u r e r o p sb e l o w2 4 1t o 2 1 9 ' F( 1 1 6 o d 104'C), thermal protectorwill have continuity. the
,\.
Measurethe clearancebetweenthe rotor pulley (A) and the armatureplate (B)all the way around.lf the is clearance not within specifiedlimits, removethe armatureplate (seepage 21-49)and add or remove clearance. shims as neededto increaseor decrease in.) Clearance: 0.510.15 mm {0.02010.006 i N O T E T h e s h i m sa r e a v a i l a b l en f o u r t h i c k n e s s e s : : 0 . 1m m . 0 . 2m m , 0 . 4m m , a n d0 . 5m m . is Checkresistance the field coil. lf resistance not of within specifications, replacethe field coil ( s e ep a g e2 1 - 4 9 ) . FieldCoil Resistance: 3.05 3.35ohmsat68"F
t20"c)
21-48
Compressor ClutchOverhaul
Special Tool Required A,/C clutch holder,Robinair10204. Kent-Moore J37872, or HondaTool and EquipmentKMT-J33939, c o m m e r c i a l la v a i l a b l e y 1 . R e m o v e h e c e n t e rn u t ( A )w h i l e h o l d i n g h e t t armatureplatewith a commerciallyavailableA,/C c l u t c hh o l d e r( B ) .
1 7 . 6N . m {1.8kgf.m, 13 tbt.ft)
3. lf you are replacing the field coil, removethe snap ring (A) with snap ring pliers,then removethe rotor pulley (B).Be careful not to damagethe rotor pulley or tne compressor.
-@
\ot
.ffi
Removethe armatureplate (A) and shim(s)(B), taking care not to losethe shim(s).lf the clutch needsadjustment,increase decrease or the number and thicknessof shims as necessary, then reinstallthearmatureDlate, and recheckits (see page21-481. clearance N O T ET h e s h i m sa r e a v a i l a b l en f o u r t h i c k n e s s e s : : i 0 . 1 m m , 0 . 2 m m , 0 . 4 m m , a n d 0 . 5m m .
/@h"
4. Removethe bolt and holder (A).then disconnect the field coil connector(B).Loosenthe clamp screw (C)to iree the field coil wire. Removethe snap ring , { D ) w i t hs n a pr i n g p l i e r s t h e n r e m o v et h e f i e l dc o i l (E).Be careful not to damagethe field coil or the comoressor.
9-=-g
7.4 N.m (0.75kgf m, 5 tbf.ft) ----------------
"\)
(cont'd)
21-49

Compressor ClutchOverhaul(cont'd)
5. Reassemble clutch in the reverseorder of the disassembly, and note these items: . I n s t a l l t h e i e l dc o i lw i t h t h e w i r e s i d ef a c i n g f down, and align the boss on the field coil with the h o l ei n t h e c o m p r e s s o r . . Cleanthe rotor pulley and compressorsliding surfaceswith contactcleaneror other non-petroleum solvent. . I n s t a l l n e w s n a pr i n g s ,n o t et h e i n s t a l l a t i o n direction,and make surethey are fully seatedin the groove. . Make sure that the rotor pulleyturns smoothly after it's reassembled, . R o u t ea n d c l a m pt h e w i r e sp r o p e r l y r t h e y c a n o be damagedby the rotor pulley.
21-50
Compressor ThermalProtector Replacement

1. Removethe bolt,the ground terminal (A),and the holder (B).Disconnect field coil connector(C). the then removethe thermal protector(D).
Compressor ReliefValve Replacement

with a recovery/recycling/ 1 . Recover the refrigerant chargingstation(seepage 21-53).
2 . Removethe reliefvalve (A) and the O-ring (B).Plug

the openingto keepforeign mafterfrom entering the system and the compressoroil from running out.
7.4 N.m (0.75kgf.m, 5 rbf.ftl
A Replace thermal protector(A)with a new one, the and apply siliconesealant(B)to the bottom of the thermal Drotector.
9,8 N.m (1.0kgf m,7.2lbf.ft) Clean the mating surfaces. 4 . Installa new O-ringon the reliefvalve, and apply a
thin coat of refrigerantoil to the O-ring. Removethe plug, and installand tightenthe relief valve. Chargethe system (seepage21-55).
A 3. lnstall in the reverse order of removal.
21-51

Gondenser Replacement
1 . Recover the refrigerant with a recovery/recycling/ chargingstation(seepage 21-53). Removethe front bumper {seepage 20-85). Removethe bolts,then disconnect the discharge line (A) and the condenserline (B)from the Plug or cap the lines immediatelyafter condenser. disconnecting them to avoid moistureand dust conlamtnaflon. 4, Removethe mounting bolts,then removethe condenserby lifting it up. Be carefulnot to damage t h e r a d i a t o o r t h e c o n d e n s efri n s w h e n r e m o v i n o r the condenser.
6 x '1.0 mm 9.8 N.m ('1.0 kgf.m, 7.2 tbl.ftl
t
-li
-"'. f,
- -'
.:)-
t-
:.--\ ----
5 . l n s t a l l t h e o n d e n s eirn t h e r e v e r s e r d e ro f c o removal,and note these items.

6x1.0mm kgf.m,7.2lbf.ft) 9.8 N.m ('1.0
,t\
. l f y o u ' r ei n s t a l l i n g n e w c o n d e n s e r ,d d a a r e f r i g e r a n t i l ( K E l H l N P - 0 )l s e ep a g e2 1 ' 6 ) . o S 1 . Replace O-ringswith new ones at eachfitting, the and apply a thin coat of refrigerantoil before installing them. Be sure to usethe correctO-rings R tv f o r H F C - 1 3 4(a - ' 1 3 4 a ) ao o i dl e a k a g e . . lmmediatelyafter using the oil, reinstallthecap on the container,and seal it to avoid moisture absorption. . D o n o t s p i l l t h er e f r i g e r a n t i l o n t h e v e h i c l e ; i t o may damagethe paint.lf the refrigerant oil contacts the paint,wash it off immediately. . Be carefulnot to damagethe radiatoror the condenser fins when installingthe condenser. . Chargethe system (seepage 21-55).
6x1.0mm 9.8 N.m (1.0kgt.m.7.2lbf.ft)
21-52
Recovery Refrigerant
refrigerantrecovery/recycling/ 1. Connecta R-134a service chargingstation{A) to the high-pressure port (B)and the low-pressure serviceport (C),as shown, following the equipmentmanufacturer's instructions.
1!l r: i t: -:
Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose.or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor
and is Use only serviceequipmentthat is U.L.-listed of certifiedto meet the requirements SAE J2210to R f) r e m o v eH F C - 1 3 4(a - 1 3 4 a r o m t h e a i r c o n d i t i o n i n g system. systemdischargeoccurs,ventilatethe lf accidental work area before resumingservice Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricant manufacturers.
-'',
'=i
( -
lvleasure amount of refrigerantoil removed the from the Ay'C system after the recoveryprocessis completed.Be sure to put the same amount of new system before refrigerantoil backinto the Ay'C chargrng.
21-53

SystemEvacuation
2. Connecta R-134arefrigerantrecovery/recycling/ chargingstation(A)to the high-pressure service pon (B)and the low-pressure serviceport (C),as shown,following the equipmentmanufacturer's instructions. Evacuate system. the
. Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throat. . Be carefulwhen connectingserviceequipment. . Do not breatherefrigerantor vapor.
Use only serviceequipmentthat is U.L.-listed and is certifiedto meet the requirements SAE J2210to of R r e m o v eH F C - 1 3 4(a - 1 3 4 a ) f r o m e a i r c o n d i t i o n i n q th system. lf accidental system dischargeoccurs,ventilatethe work area before resumingservice. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers. 1. When an Ay'C system has been openedto the atmosphere, such as during installation repair,it or must be evacuatedusing a R-134a refrigerant recovery/recycling/charging station(lf the system has been open for severaldays,the receiver/dryer should be replaced, and the system should be for evacuated severalhours.)
-i -
r4.t
lf the low-pressure does not reachmore than 93.3 k P a{ 7 0 0m m H g ,2 7 . 6i n . H g ) n 1 5 m i n u t e st,h e r ei s i probablya leak in the system.Partially chargethe system,and checkfor leaks(seestep 3 on page 2156).
21-54
SystemCharging
2 . Evacuate system(seepage 21'54). the
Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor,
3 . Add the same amount of new refrigerantoil to the

systemthat was removedduring recovery.Use only KEIHIN SP-10refrigerantoil.
4 . Chargethe system with the specifiedamount of
e d U s eo n l y s e r v i c e q u i p m e ntth a t i s U . L . ' l i s t e a n d i s of certifiedto meet the requirements SAEJ2210to f) r e m o v eH F C - 1 3 4{a - 1 3 4 a r o m t h e a i r c o n d i t i o n i n g R system. lf accidental system dischargeoccurs,ventilatethe work area before resumingservice Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricant manufacturers. refrigerantrecovery/recycling/ 1. Connecta R-134a ( e c h a r g i n g t a t i o n A )t o t h e h i g h - p r e s s u rse r v i c e s pon (B)and the low-pressure serviceport {C),as shown, following the equipmentmanufacturer's instructions.
Do the system; R-134arefrigerant. not overcharge the compressorwill be damaged. Selectthe appropriateunits of measurefor your refrigerantchargingstation. Refrigerant capacity: 500 to 550 g 0.50to 0.55 kg 1 . 1 0 o 1 . 2 1l b s t 17.6to 19.4oz Checkfor refrigerantleaks(seepage 21'56). Checkfor system performance(seepage 21-58).
21-55

Refrigerant LeakTest
Special Tool Required Leakdetector,HondaTool and EquipmentYGK-H-10PM c o m m e r c i a l la v a i l a b l e v 1. Connecta R-134a refrigerantrecovery/recycling/ chargingstation(A)to the high-pressure service port (B)and the low-pressure serviceport (C),as shown, following the equipmentmanufacturer's anstructions.
Compressed mixed with R-134a air forms a combustiblevapor. The vapor can burn or explodecausingserious
injury. Never compressedto pressure use air test

R - 1 3 4 a e r v i c e q u i p m e no r v e h i c l e i r s e t a conditioningsystem.
A i r c o n d i t i o n i n ge f r i g e r a no r l u b r i c a nv a p o r r t t can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor
Use only serviceequipmentthat is U.L.-listed and is certiifiedto meet the requirements SAE J2210to of R r e m o v eH F C - 1 3 4(a - 1 3 4 a r o m t h e a i r c o n d i t i o n i n g f) system. lf accidental system dischargeoccurs,ventilatethe work area before resumingservice. R - 1 3 4 a e r v i c e q u i p m e no r v e h i c l e i r c o n d i t i o n i n g s e t a systemsshould not be pressure testedor leaktested with compressedair. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers. Open the high pressurevalve to chargethe system to the specifiedcapacity, then closethe supply valve,and removethe chargingsystem couplers. Selectthe appropriateunits of measurefor your refrigerantchargingstation. Refrigerant capacity: 500 to 550 g 0.50to 0.55kg 1 . 1 0 o 1 . 2 1l b s t 17.6to 19.4oz
3 . Checkthe systemfor leaksusing a R-134a

refrigerantleak detectorwith an accuracyof 14 g (0.5oz) per year or better. lf you find leaksthat requirethe systemto be opened(to repair or replacehoses,fittings,etc.), recoverthe system. After checkingand repairingleaks,evacuate the system.
21-56
A/C SystemTests
Pressure Test
Test results (high) Discharge pressure abnormally high svmotom3 pressure Afterstopping compressor, to and dropsquickly, thencontinues Beduced no airflow through or condenser hot. Lineto condenser excessively is
DGaUSe
Air in system Clogged condenser radiator or fins or fan Condenser radiator not flow of refrigerantin Restricted
(seepage21-54), Recover, evacuate with specified amount and recharge {seeoaoe21 55). Clean fan and rpm. Check voltage fan Check direction. restricted lines. Replace the Beplace compressor. . Replace expansion valve. the . Recover, for evacuate at least with 30 minutes,and recharge sDecified amount. for Recover, evacuate at least with and 30 minutes, recharge amount. specified valve. the Beplace expansion off, Runthe fan with compressor then sensor. checkevaooratottemoerature eanor reolace, receaver/dryer. Replace or Bepair replace. with evacuate, and recharge Recover,
qnp.ifie.lamo'rnr
discharge pressure Highand low pressures balanced . Faulty are compressor Discharge valve Low soonafterstopping compressor, . Faultv comoressor seal sideis hioherthan normal. valve Faulty expansion valve is not Outletof expansion gaugeindicates in Moisture system low pressure frosted,
(low) Suction pressure low abnormally
and Expansion valveis not frosted, line low-pressure is not cold.Low pressure gaugeindicates vacuum,
' Frozen valve expansion (Moisture system) in . Faulty valve expansion
pressure Suction high abnormally
evaporator is Discharge temperature low,andthe Frozen air flow from vents is restricted. Exoansion valveis frosted. Receivetdryer outletis cool,and inlet Cloggedreceiver/dryer is warm (should warm during be ooeralton), jointare E x p a n s i o nv a l v e o p e n t o o l o n g Low pressure hoseandcheck around thanthetemperature cooler evaoorator, in pressure lowered refrigerant system when Excessive is Suction
..nrlenser is cooled bv water.
are Highand low pressure equalized is assoonasthecompressor stopped, while fluctuate andbothgauges and Suction dascharge pressures abnormallv hioh Suction and pressure discharge abnormally low leaks Fefrigerant
gasket Faulty valve high pressure Faulty panicle in Foreign stuck high
Replace compressor. the
condenser radiator or Reduced flow throughcondenser. . Clogged air fins ' Condenser radiator not fan or workinoorooerlv low-pressure Clogged kinked or hose Low-pressure and metalend hoseoarts areas coolerthan are evaoorator, expansion valve C l o g g e d h i g h - p r e s s u r el i n e Temperature around with thataround is too low compared :omoressor clulchis dirtv. lomoressor bolt(s) dirtv. are
; o m D r e s s o ro a s k e t i s w e t w i t h o i l .
Clean voltageand fan rpm. Check fan Check direction. Repair replace. or Repair replace, or Reolace comDressor, the comDressor, Tiohten bolt{s) reolace ot acethe comoressor.
:omoressor shaftsealleakinq no aroundbolt(s) iet no
(cont'd)
21-57

A/C System Tests(cont'd)
Performance Test
Open the glove box. Removeboth glove box stops, then let the glove box hang down (seepage 20-63). 4 . Inserta thermometer(A) in the centervent, and placeanotherthermometer{B) nearthe blower unit.
' Compressed mixed with R-134a air forms a combustiblevapor. . T h e v a p o rc a n b u r n o r e x p l o d e a u s i n g e r i o u s c s Injury. . Never use compressedair to pressure test R - 1 3 4 a e r v i c e q u i p m e no r v e h i c l e i r s e t a c o n d i t i o n i n gy s t e m s . s
Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throar. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor. Test conditions: Avoid direct sunlight. Open the hood. Open the front doors. Sel the temperaturecontrol dial on Max Cool,the mode control dial on Vent,and the recirculation control switch on Recirculate. . Turn the A,/C switch on and the fan switch on Max. . R u nt h e e n g i n ea t 7 5 0 r p m . . N o d r i v e ro r p a s s e n g e ris v e h i c l e . n A f t e rr u n n i n g h e a i rc o n d i t i o n i n f o r I 0 m i n u t e s t g underthe above test conditjons,read the delivery temperaturefrom the thermometerin the center vent, the intaketemperaturenear the blower unit, and the high and low system pressurefrom the Ay'C g au g e s . . . . .
The performance test will help determineif the air conditionersystem is operatingwithin specifications. Use only serviceequipmentthat is U.L.-listed and is cenified to meet the requirements SAE J2210to of R r e m o v eH F C - 1 3 4(a - 1 3 4 a l f r o m e a i r c o n d i t i o n i n g th system. lf accidental system dischargeoccurs,ventilatethe work area before resumingservice R - 1 3 4 a e r v i c e q u i p m e no r v e h i c l e i r c o n d i t i o n i n g s e t a systemsshould not be pressuretestedor leaktested with compressedair. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers.
1 . Connecta R-134a refrigerantrecover/recycling/
chargingstationto the high-pressure serviceport and the low-pressure serviceport, following the equipmentmanufacturer's instructions. D e t e r m i n eh e r e l a t i v e u m i d i t ya n d a i r t h Iemperaru re.
21-58
7. To completethe charts: . . . . . . . . M a r k t h ed e l i v e r y t e m p e r a t u aeo n gt h e v e r t i c a l i n e . rl along the bottom line. Mark the intaketemperature(ambientair temperature) Draw a line straightup from the air temperatureto the humidity. l M a r ka p o i n t 1 0% a b o v ea n d 1 0% b e l o w t h eh u m i d i t y e v e l . From each point. drawa horizontalline acrossthe deliverytemperature. should fall betweenthetwo lines The delivervtemperature test in the same way. test and high-sidepressure Completethe low-sidepressure outsidethe line may indicatethe needfor further inspection. Anv measurements kPa (ksl{cm') Lpsrl 2500[25) _ 360l {kgflcm') Lpsil 600 {6t
tssl
80 yo a0 0/" HUMIDITY LEVEL
2000 (201 1280
fcl
1500 {1s} ,21o) 1000 (101 :1401 500 {5) 171l DELIVERY PRESSURE 100 {11 h4l INTAKE PRESSURE
30 9o 30% 80%
OELIVERY TEMPERATURE
68 t20l
I I 86 77 t30) t25l INTAKE TEMPEBATURE
95 (35)
104 {40)
.F
{'cl
21-59
BodyElectrical
Body Electrical SpecialTools Troubleshooting General tntorrnaiion.'...... 22,3
Entry Lightscontrol system

Component Location Index ....................... 22-89 C i r c u iD i a g r a m t . . . . . . . 2.2 9 0 . lgnitionKeySwitchTest .....................,...... 22-9'l l g n i t i o n e yL i g h t e s t . . . . . . . . . . . . . . . . . . . . . 2.2.-.9 . . . . K T . . .1 C o n t r oU n i tI n p u t e s t . . . . . . . . . . , . . . . . . . . . . 2.2.9 2. . . . l T . . ..
Relay andControlUnit Locations.....22-7 Connectors Harnesses and 22-13
Fuse/Relay Boxes............................... 22-44 Power Distribution ............................. 22-46 Ground Distribution ........................... 22-4A Under-dash Fuse/Relay .............. Box 22-49 Battery .............. Relays ................ *lgnitionSwitch .............. *Gauges
C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . 22-54 L n ....... e S e l f - d i a g n o sPirc c e d u r . . . . . . . . . . . . . . . . . . 22-56. . t o ...... Circuit Diagram 22-54 G a u g e u l bR e p l a c e m e n . . . . . . . . . . . . . . . . .22 . . . . . B .t . . . 63 Gauge Assembly Replacement 22-64 Temperature Coolant T . ...... G a u g e r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . 22-64 Vehicle Speed SignalCircuit Troubleshooting 22-65 VSSReplacement 22 61
InteriorLights
Component Location Index ....................... 22-94 Circuit Diagram ......... 22-95 Ceiling LighVSpotlights T e s V R e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . .2 .2 - . .6. . . . .. . ..9 . Rear Ceiling LightTesVReplacem ........ ent 22-96 Cargo AreaLightTest/Replacem ......... ent 22-97 HatchLatchSwitchTest ..,..,....................... 22-97
22-50 22-51 22-53
*Audio System
Component Location Index ....................... 22-98 CircuitDiagram ......... 22,99 AudioUnit Removal/lnstallation ............... 22-1OO Audio Unit Connector Replacement ......... 22-101 Replacement Speaker ................................ 22-102 RoofAntenna Rep1acement ....................-.. 22-103 Rear Window Defogger Component Location Index ........... 22-104 C i r c u iD i a s r a m. . . . . . . . . . . . . . . . . . . . . : : : : : . : :22-105 t .::. Function Test D e f o g g e r i r eR e p a i r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W . 22-106 N o i s e o n d e n s e ra p a c i t y T e s t . . . . . . . . . .22-107 C C .. ....
Moonroof
C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . 2.2 . .1 . B L n . . - .O Circuit Diagram ......... 22-109 MoonroofControlUnitInputTest ............. 22-'l10 S w i t c h e s V R e p l a c e m e n.t. . . . . , . . . . . , . . .2.2 . .1 .2 T .. . .- 1 . . MotorTest ................. 22-112 LimitSwilchTest ......22-'l'13 Auto-stop SwitchTest ................................ 22-1 13
Exterior Lights
n C o m p o n e n to c a t i oIn d e x . . . . . . . . . . . . . . . . 22-68. L ...... C i r c u iD i a g r a m t 22--71 Daytime Running LightsControi ) T U n i tI n p u t e s t( C a n a d a . . . . . . . . . . . . . . . . .22-7. . ..... 6 H e a d l i g h td , u s t m e n . . . . . . . . . . . . . . . . . . . 22-74 A t H e a d l i g h r e p l a c e m e n.t. . . . . . . . . . . . . . . . . . .22-79 . . R . ....... Combination LightSwitch Test/Replacement 22-AO B u l bR e p l a c e m e n t 22-41 T a i l l i g hR e p l a c e m e n . . . . . . . . . . . . . . . . . . . . .22-82 t .t .... HighMountBrake LightReplacement ......22-42 License PlateLightReplacement .............. 22-43 S i d eM a r k e L i g h t e p l a c e m e n.t. . . . . . . . . .22-43 r R . .... Brake Pedal Position SwitchTest .............. 22-44 SideTurn SignalLightReplacement ........ 22-84 Turn Signal/Hazard Flasher System L n C o m p o n e n to c a t i o I n d e x . . . . . . . . . . . . . . . . 22-85. ...... C i r c u iD i a g r a m t 22 A6 Turn Signal/Hazard RelaylnputTest ........ 22-87 Hazard WarningSwitchTest 22-88
PowerMirrors
Component Location Index ....................... 22-114 Diagram Circuit ......... 22-115 Function Test ............. 22-116 P o w e r i r r o r w i t c h e s t . . . . . . . . . . . . . . . . . . 2.2 . .l . . . M T S . . - l7 PowerMirrorActuator Test ....................... 22-117 PowerMirrorActuator Replacement ........ 22-11A
* Horns
Component Location Index ....................... 22-120 Diagram Circuit ......... 22-121 H o r nT e s V R e p l a c e m e n.t. . . . . . . . . . . . . . . . .2.2 - . . 2-2 .. . .. 1 . . HornSwitchTest .,....22-122
PowerWindows
Index .......... 22 124 Component Location D ::::.: c i r c u i t i a g r a m. . . . . . . . . . . . . .......... . . . . : . : : : : .22-125 M a s t e S w i t c h n p u t e s t . . . . . . . . . . . . . . . . . . .22-126. r I T ....... 22-128 Master SwitchTest ...... D r i v e r 'W i n d o wM o t o rT e s t . . . . . . . . . . . . . . .22-129 s Passenger's WindowSwitchlnputTest ... 22- t30 Passenger's WindowSwitchTest ............. 22-132 22 Passenger's WindowMotorTest .............. 132 ...................... 22-133 lMaster SwitchReplacement Passenger's WindowSwitch 22-133 Replacement
Multiplex ControlSystem
Index ........... 22,164 Component Location D :.:..:.: c i r c u i t i a g r a m. . . . .... . . . . . . . . . . . . . . . . . . . . . . :22-169 : . : 22-17'l SvstemDescriDtion 22,112 Troubleshooting t 2. M u l t i o l e C o n t r oU n i tI n D uT e s t . . . . . . . . . . . .2 - 1 7 5 x l
Wipers/Washers
Index ....................... 22-134 Location Component C i r c u iD i a g r a m t Rear WindowWiperIntermiftent T ....... C o n t r oU n i tI n p u t e s t . . . . . . . . . . . . . . . . . . .22-138. l Wiper/Washer Switch 22-140 TesVReplacement T 2 . . .. C o n t r oU n i tI n p u t e s t . . . . . . . . . . . . . . . . . . . . . . .2.-.1.4 1. l WiperMotorTest 22-143 MotorTest 22-144 Washer Washer FluidLevelSwitchTesV C ....... R e p l a c e m e(n t a n a d a.l . . . . . . . . . . . . . . . . . .22-144 .... Windshield WiperMotor Replacement 22-145 WindowWiperMotor Rear Replacement 22-146 . .... W a s h e R e s e r v oR e p l a c e m e n.t. . . . . . . . . .22-146 r ir . .. ... W a s h eT u b e s e p l a c e m e n.t. . . . . . . . . . . . . .22. 147 r B Accessory Power Socket ......... 22-149 Circuit Diagram AccessoryPowerSocket .. . .-1 9 . T e s V R e p l a c e m e n.t. . . . . . . . . . . . . . . . . . . . .2.2 . .4 . . . . . Keyless/Power Door Lock System 22-150 Location Index ....................... Component ......... 22-151 CircuitDiagram 22-153 Keyless Receiver Unit InputTest ............... 22-155 ControlUnit InputTest ............................... . 2 . . .8 D o o rL o c k A c t u a t o r T e s.t. . . . . . . , . . . . . . . , . . , 2,-.1.5 . . . 2 .. . H a t c h o c k A c t u a t o r T e s.t. . . . . . . . . . . . . . . . .2 . . - 1.5.9 L 22-160 DoorLockKnobSwitchTest ...................... 22-160 DoorLockSwitchTest ................................ Test .......22-161 Transmitter 2. . . T r a n s m i t t e rr o g r a m m i n . . . . . . . . . . . . . . . . . . . 2.-.1.6 1 P g
lmmobilizer System
Index ........... 22-162 componentLocation D n . 22-163 System escriptio....... .........:..:..:.:... 22-164 Diagram Circuit Troubleshooting lmmobilizer ControlUnit - R e c e i v e re p l a c e m e n.t. . . . . . . . . . . . . . . . .22-167 . ........ R
BodyElectrical
SpecialTools
Ref. No.
Q)
o) o
Tool Number 07wAz-001010A O7 -PT3 2OA LAJ O 07TAz-001020A
Description
MPCSServiceConnector Test Harness BackProbeAdaotet
Otv
1 1 1
22-2

Tipsand Precautions
Before Troubleshooting fuses in the appropriate 1. Checkapplicable fuse/relay oox. 2. Checkthe batteryfor damage.stateof charge,and cleanand tight connections. Some connectorshave a clip on their side used to attachthem to a mount bracketon the body or on a n o t h e r o m p o n e n tT h i sc l i p h a sa p u l lt y p e l o c k . c . Some mountedconnectors cannot be disconnected unlessyou first releasethe lock and removethe connectorfrom its mount bracket(A).
. Do not quick-charge batteryunlessthe battery a ground cable has been disconnected, otherwise you will damagethe alternatordiodes. . Do not attemptto crankthe enginewith the batteryground cable looselyconnectedor you w i l l s e v e r e l y a m a g e h ew i r i n g . d t Handling Connectors . Make surethe connectors are clean and have no l o o s ew i r e t e r m i n a l s . . Make sure multiplecavity connectors are packedwith dielectricgrease(exceptwatertight connectors). . All connectorshave push-downreleasetype locks(A).
Nevertry to disconnect connectors pulling on their by wires; pull on the connectorhalvesinstead. Alwavs reinstallDlastic covers,
make sure the Beforeconnectingconnectors, terminals(A) are in placeand not bent.
(cont'd)
22-3
BodyElectrical
GeneralTroubleshooting Information(cont'd)
(A) (B). Check looseretainer andrubber for seals
HandlingWires and Harnesses . Securewires and wire harnesses lhe frame with to their respective wire ties at the designated locations. . Removeclips carefully;don't damagetheir locks(A).
The backsof some connectors are packedwith dielectricgrease.Add greaseif necessary. the lf greaseis contaminated, replaceit.
S l i p p l i e r s( A ) u n d e rt h e c l i p b a s ea n dt h r o u g ht h e hole at an angle,then squeeze expansiontabs to the r e l e a s eh e c l i p . t
lnsertthe connectorall the way and make sure it is securelvlocked. Positionwires so that the open end of the cover faces oown.
After installingharnessclips, make sure the harness doesn't interferewith any moving pans. Keepwire harnesses away from exhaustpipes and other hot parts,from sharp edgesof brackets and holes,and from exposedscrewsand bolts. Seatgrommets in their grooves properly{A). Do not leavegrommets distorted(B).
.ll ----E;
| . , ./ f
t/
l tl"/ w /
\--------\
'l/ F.
I
tflr'---'..-
It
22-4
Testingand Repairs . Do not usewires or harnesses with brokeninsulation. Replace them or repairthem by wrappingthe break withelectricaltape. . After installingparts,make surethat no wires are o i n c h e d n d e rt h e m . u . When using electricaltest equipment,followthe manufacturer's instructions and those describedin t h i sm a n u a l . . l f p o s s i b l ei , s e r t t h ep r o b eo f t h e t e s t e r f r o m t h e i r e w n side (exceptwaterproofconnector).
Useback Drobe adaotor 07TM-0010204.
in Referto the instructions the HondaTerminal Kit for identification and reolacement connectorterminals. of
( c o n td )
22-5
BodyElectrical
GeneralTroubleshooting Information(cont'dl
Five-step Troubleshooting
'1. Verify The Complaint T u r n o n a l l t h e c o m p o n e n t sn t h e p r o b l e m i r c u i t i c to verify the customercomplaint.Note the symptoms.Do not begin disassembly testing or until you have narroweddown the problem area.
Wire Color Codes

The following abbreviations usedto identifywire are colors in the circuitschematics:
2. AnalyzeThe Schematic Look up the schematic the problem circuit. for Determinehow the circuit is supposedto work by tracingthe currentpathsfrom the power feed through the circuitcomponentsto ground. lf severalcircuitsfail at the same time, the fuse or g r o u n di s a I i k e l y a u s e . c Basedon the symptoms and your understanding of the circuitoperation,identifyone or more possible causesof the problem. 3. lsolateThe ProblemBy TestingThe Circuit Make circuitteststo checkthe diagnosisyou made i n s t e p2 . K e e pi n m i n d t h a t a l o g i c a ls i m p l e , procedureis the key to efficienttroubleshooting. Testfor the most likelycauseof failure first, Try to make tests at pointsthat are easilyaccessible. 4. Fix The Problem Oncethe specificproblem is identified.make the repair.Be sure to use propertools and safe proceoures. 5. Make Sure The CircuitWorks Turn on all componentsin the repairedcircuit in all modes to make sure you've fixed the entire problem.lf the problemwas a blown fuse, be sure to test all of the circuitson the fuse. Make sure no n e w p r o b l e m su r n u p a n dt h e o r i g i n a p r o b l e m t l does not recur.
w H T . . . . . . . . . . . . . . . . . . . . , . , . White . . . . . ....... Y E L . . . . . . . . . . . . . . . . . . . . . . , , . . . .l.l . . w. . . . . . Ye o , B 1 K . . . . . . . . . . . . . . . . . . . . . . . . . . .B.l.a.c k. . . . . . .. B L U. . . . , . . . . . . . . . . . . . . . . . . . . . . .B.l.u . . . . . . .e G R N . . . . . . . . . . . . . . . . . . . . . . . .G.r.e . .n. . . . . . . .e. R E D . . . . . . . . . . . . . . . . . . . . . . . . . . .Red. . . . , . .... o R N . . . . . . . . . . . . . . . . . . . . . . . . Orange . . . . ......... P N K . . . . . . . . . . . . . . . . . . . . . . . . P.i,n k. . . . . . . . . .. B R N . . . . . . . . . . . . . . . . . . . . . . . .Brown. . . . . . ....... G R Y . . . . . . . . . . . . . . . . . . . . . . . .Gray. . . . . . . , ..... P U R . . . . . . . . . . . . . . . . . . . . . . . .P.u . . .l.e . . . . . . . rp . 1 T 8 1 U . . . . . . . . . . . . . . . . . . . . . LightBlue .....,..... 1 T G R N . . . . . . . . . . . . . . . . . . . . L.i.g h.G,r.e . n . . . t. . e
The wire insulationhas one color or one color with anothercolor stripe.The secondcolor is the stripe.
22-6
Relayand Control Unit Locations

Engine Compartment
BLOWER MOTOR RELAY
RADIATOR FAN RELAY HORNRELAY

CONDENSER FAN RELAY
ELDUNIT UNDER-HOOD FUSE/RELAY BOX
\...
,-:1-'...
22-7
Relayand GontrolUnit Locations

Dashboard
RUNNING LIGHTS _DAYTIME EELAYlCanada) RED, RED/YEL,I lWirecolorsr and LRED/BLK RED/8LU I BEAMCUTRELAY lcanada) _ _LOW REDMHT, RED/BLK,I colors: lWire and LBEDA/EL RED/BLU I KEYLESS RECEIVER UNIT CRUISE CONTROL UNIT
' '-.:':
..? ;,
POWERWINOOW RELAY TURN SIGNAL/HAZARDRELAY
TAILLIGHT RELAY
.[:_- -
UNDER.DASH FUSE/RELAY BOX
-l:r
--
MULTIPLEX CONTROL UNIT
22-8
(cont'd)
22-9
Relayand Control Unit Locations

(cont'd) Dashboard
L
\
SRSUNIT
EPSCONTROL UNIT AIR/FUEL RATIO RELAY SENSOR colorsr WHT, WHT/RED, I [Wire OBNandBLK/ORN I
MAINRELAY 1 PGM.FI YEUBLK, lWirecolors: WHT/BLK and RED/YEL LWHT/BLK, PGM.FI MAN RELAY 2 YEUBLK, fwirecolors: I YEUBLKand GRN/YEL LYEUGRN, I
22-10
Rearand Roof
OPEN RELAY MOONROOF Wirecolors: GRNI/EL, GRN, I BLK LRED/YEL, andYEL/GRN I MOONROOF CLOSE RELAY GRN/BLK, GRN, l fwire colors: BLK IGRN,AtVHT, and YEL/GRNI
REAR WINDOWWIPER INTERMITTENT CONTBOL UNIT
22-11
Relay and ControlUnit Locations

Door and Seat
Driver'sDoor:
l\:
].\
POWER WINDOWMASTER SWITCH lHasbuilt-in control unit)
Passenger's Seat:
22-12
Gonnectors Harnesses and
Gonnector Index
"C" for connectors, for ground "G" ldentification numbers havebeenassigned in-line to connectors. number preceded the letter The is by terminals "T" for non ground or terminals. Hamess EngineCompartment Starter subharness C 1 0 2 n dC 1 0 3 a T1 andT2 T 1 0 1 n dT 1 0 2 a T3 G'l and ( T4 Dashboard
Location
Others{Floor,Door, Trunk.and Roo{l
Nots (see page22-15)
groundcable Battery groundcable Engine Engine wire harness
{seepage22-l!) {seepage22-14) (seepage22 16) (seepage22 18) (seepage22 18) (seepage22-18) c401 C451and C452 C501 throughC503 c551 c851 G402
C 1 5 1a n d C 1 5 2 G'151
Cl0lthrough 104 C G1 0 1 Engine compartment wire harness G201 andG202 {riohtbranchi Engine compartment wire harness G301 (leftbrench) Engine compartment wire harness (dashboard)
EPS subharness Dashboard harness wire A lleftbranch)

L e f ts i d et u r n s i g n a l l i g h t
\seepage22 241 (seepage22-26) (seepage22-26) (seepage22-26)
C504 through C510 G501 andG503
c506
C50lthroughC503 C5ll through 515 C C852 andC853 G502
Dashboard harness wire A (rightbranch)

Rightside turn si9nal light sub harness
lseepage22-26)
Dashboard harness wire B ECMwire harness
C40l through C403 c510 G40l c101 cl52 C451 through C453 c511
G451
(see page22-30) {seepage22-32}
(front Floorwire harness side)
C402 C403 and c453 C508 C509 and c512

C 5 5 1a n . l C 5 5 ?
G551
(see page 22'34)
(rear Floor wire harness side) Roo{wire harness Hatch wire harness Driver's doorwire harness
Passenqer's oor wi.e harness d T eh a r n e s s
C553 and C554 c507 C553 andC554 C504 andC505 5 1 4a n dC 5 1 5 )552

c851 rhrouoh c853
(seepage22-34) (seepaqe22-38)
( s 6 ep a q e 2 2 ' 3 9 ) (see paqe 22-40) ( s e eo a o e 2 2 - 4 1
(see oaqe22-42i
( s e ep a q e 2 2 . 4 3 i
/C wire harness
22-13
and Connectors Harnesses

Gonnector Harness to lndex
BatteryGroundCable
Connector Terminal or T3 2 Cavities
Location Left side of enqinecompartment Left side of enginecompartment Batterv
Connectsto Bodygroundviabattery qround car)le

B a t t e r vn e o a t i v et e r m i n a l
Notes
EngineGround Cable
r4
Connector Terminal or 5 4
Cavities
focation Riohtsideof enoine Rightsideof engine compartment
Connec{sto Bodygroundviaengine
Notes
ENGINE GROUND CABLE
BATTERY GROUND CABLE
\.....
22-14
StarterSubharness
Connectoror Terminal Alternator Knock sensor Starter solenoid c102 c103 T1 Ret 10 8 5 7 6 Cavities 4 1 1 6 1 Location
Right side of eng;necompartment Front of engine Middle of enginecompartment Front of enginecompartment Frontof engane ompartment c
Connoc,ts to
Notes
r2
T101
2
4 1 I
r102
Ltt sideof enginecompartment Middleor enoine comDanment Under-hood fuse/relay box Alternator Batterv
(see Engine wire harness page22 16) (see Engine wire harness oaae 2-16) 2 Underhoodfuse/relay box Stanermotor positive Batterv terminal
STARTER SUB HARNESS
22-15
and Harnesses Connectors

Index(cont'dl Connector Harness to
Engine WireHarness
2 3 3 24 2 28 18 4 5 6 7 25 24 20 19 12 8 11 10 27 29 30 3 22 1 2 3 3 3 3 3 2 2 2 2 2 3 3 3 2 2 2 20 Transmission housing Leftsideof engine Rightsideofengine glovebox Under Underglovebox Leftside of engine BightsideoI engine Leftside of intakemanifold Left sideof intakemanifold Middleof engine compartment Middleof engine compartment Middleof engine compartment Middleof engine compartment Middleof engine compartment Middleof engine compartment Middleof engine compartment Middleof engine companment manifold Leftsideof intake Leftsideof engine Left side of intakemanifold housing Transmission Right sideo{ engine Rightsideof engine Rightsideof engine Underrightsideof dash Frontof engine companment Frontof engine compartment
(CMP) position Camshaft sensor Lllr sensor A EC[,4 connector ECI/lconnectorB (ECT) temperature Engine coolant sensor Engine pressure oil switch purgevalve EVAP canister (lAC)valve ldleair control lgnition No. l coil lgnition No.2 coil lgnition No.3 coil lgnition No.4 coil Iniector 1 No. No.2 Inlector Iniector No.3 Iniector 4 No. Intake temperature air sensor {lAT) TDCsensor Throttleposition(TP)sensor (VSSI Vehicle speed sensor valve VTCoil control solenoid VTECoil pressure switch valve VTEC solenoid c 101 c102
ECMwire harness {seepage 22-321 (see Starter subharness page 22-15) (see subharness page Starter 22 151
22-16
....-
10 11
13
14
22-17
Connectors and Harnesses

to Index{cont'dl Connector Harness
(Rightbranch) Wire Harness EngineCompartment
Connsctoror Terminal ABSmodulator-control unit Bearwasher motor Right frontABSwheelsensor Right frontairbag snsor parking light Bightfront Right frontsidemarker light Right light frontturn signal Right headlight Right horn washrfluidlevel switch Windshield washer motor Cavitiss 8 12 1 10 11 2 7 6 2 2 2 2 2 2 I 2 2 Location Bightsideo{ engine compartment Behind rightsideof {rontbumper Rightsideot engine compartment Behind rightsideof frontbumper Behind rightheadlight Behind rightside Jrontbumper of Behind rightheadlight rightheadlight Behind Behind frontbumper Behind rightside trontbumper of Behind riohtsideof frontbumoer rightside trontbumper Behind of rightside Jrontbumper Behind of to Connects Notes
Canada Bodygroundviangine compartment harness wtre Bodygroundviaengine

.omnerhent wire harness
G201
G202
22-18
ENGINE COMPARTMENT WIRE HARNESS
(cont'd)
22-19
Connectors Harnesses and

Connector Harness to Index (cont'dl
EngineCompartmentWire Harness(Left branch)
24 22 2 25 1 9 12 17 13 20 21 23 3 11 7 I 10 5 6
l
AirJuel(A,,/F) sensor ratio Brake fluidlevelswitch Condenser motor fan Cruise control actuator ELDunit Foglightconnector LeftfrontABSwheelsensor Leftfrontairbag sensor Leftfrontparking light Leftfrontsidemarker light Leftlrontturnsignal light Leftheadlight Lefthorn Radiator motor fan Radiator switch fan (SHO2S) Secondary heated oxygen Testtachometer connector Windshield wipermotor Under'hood fuse/relay box connector {seepage22-44) A Under-hood f use/relay box connector (seepage22-44) B Underhoodfuse/relay box connector (seepage22-44) C Underhoodfuse/relay box page22 44) D connector (see fuse/relay Under-hood box
2 2 2 4 3 ,l 2 2 2 2 2 3
l
2 2
4
Frontof engine companment Leftsideof engine compartment Leftsideof engine compartment Leftsideo{ engine compartment Frontof engine compartment Underrightsideof cowlcover Under'hooduse/relay f box Leftsideof engine compartment Leftsideof engine companment Behind sideof frontbumper left Behind headlight left Behind sideof frontbumper left Eehind headlight left Behind headlight left Behind frontbumper Leftsideof engine compartment Frontof engine compartment Leftsideof engine compartment Leftsideof engine companment L.Jnder sideof cowlcover left L.Jnder hoodfuse/relay box L.Jnder hoodfuse/relay box L.Jnder'hood f use/relay box underhoodfuse/relay box fuse/relay Under-hood box
2 5 2 5 12
22-20
l'
\-
ENGINECOMPARTMENTWIRE HARNESS
(conr'd)
22-21
and Connectors Harnesses

Connector Harness to Index (cont'd)
(Dashboard)lcont'dl EngineCompartment Wire Harness
Connector Terminal or Cavities Location 1 Undermaddle dash of 12 Underleftsideof dash 10 3 2 5 8 2 Underleftsideof dash Underleftsideof dash Underleftsideof dash Underleftsideol dash Underrightsideof dash Underrightsideot dash Underrightsideot dash UnderrightsideoJdash '10 4 8 5 10 UnderrightsideoI dash Underrightsideol dash UnderrightsideoJdash UnderrightsideoJdash Undermiddleof dash Underrightsideof dash EPS subharness page22{see 24) wire B Dashboard harness (see page22-30) (see page ECMwire harness 22-321 (seo page ECMwire harness 22 32) Dashboard harness wire A (see page22-26) Dashboard harness wire A USA lsee page 22-261 Dashboard harness wire A Canada (seepage22-26) Dashboard harness wire A (see page22-26) (seepage Floorwire harness 22-34l' ,VCwire harness lsee page 22-43\ Eodygroundviaengine
..mdarlma.t w,rc harncss
Connectsto
Notes
Oplion
Fog light connector Under'dash fuse/relay box page connector(see F 22-45) Underdash fuse/relay box page G 22-45) connector (see Underdash fuse/relay box page connector(see H 22'45) fuse/relay Under-dash box page connector | (see 22'45) Under-dash fuse/relay box connector page J (see 22-45) c151 c401 c451 c452 c501 c502 c502 c503
3
12
1 I
9 10 6 6
c851
G402
'14 1' I
22-22
BOX FUSE/RELAY UNDER-DASH WIRE ENGINE COMPARTMENT
D
' -.,.i
ifa.: ,, ..j
' 1_-1.:,
, . -,,
-g'-.t
';.-a
22-23

Connector Harness to lndex (cont'dl
EPS Subharness
Connector Terminal or EPS control unitconnectorA EPS control unitconnector B EPS control unitconnector C EPS motor EPS torquesensor c151 c152 G151 2 ,l 3 1 6 4 5 Cavities 2 2 20 2 6 2 I
Location
Underrightside ofdash Underrightsideof dash Underrighrsideof dash Middleof engine companment Middleof engine compartment Underrightsideof dash Underrightsideof dash
Connects to
Notes
Engine compartment wire (seepage22-18) harness ECI\,4 harness(seepage wire 22-321 aodygroundvia EPS
22-24
EPSSUB HARNESS
22-25

Dashboard Wire Harness {Leftbranchl A
Connectoror Terminal power socket Accessory Audioantenna Brakepedalpositionswitch Clutchinterlockswitch pedalpoistion Clutch switch Cruise controlunit Cruise mainswitch Daytime r!nning lights control unit Daytime running lightsrelay Gauge assembly connector A Gauge assembly connector B Hazard warningswitch Heatercontrol panelconnector A Heater control panelconnectorB HVACpush switch assembly Keyless receiver unit Low beamcut relay Optionalsecurityconnector Power mirrorswitch Under-dash fuse/relay box page22-45) connector (see K Under'dash fuse/relaybox L {seepage22-45} Underdash fuse/relay box connectorM lsee page22'45) Under-dash fuse/relay box page22-45) connector (see N UndeFdash fuse/relay box connector (seepage22-45) O UndeFdash fuse/relay box (see page22 45) connectorY c504 c505 c506 c507 c508 c509 c510 G501 G503 24 25 1 21 12 34 1
22 2 26 30 29 6 28
I 8
20 11 18 19 10 5 3 27 ,I4
2 2 4 2 2 14 5 14 4 22 22 10 22 '14 10 5 5 16 13 17 l0
Undermiddleof dash Underleftsideof dash ] Underleftsideof dash of ] Underleftsrde dash | Underleftsideof dash I Underleftsideof dash Underleftsideof dash Underlettsideof dash Underlettsideof dash gauge assembly I Behind gauge assembly i Behind Behind hazard warnning switch Behind panel heater control Behind panel heater control HVAC switch assembly ] Behind of I Undermiddle dash lUnderleftsideofdash Underlefrsideof dash UnderleftsideoI dash ln the under-dash fuse/relay box In the under-dash fuse/relay box In the undeFdash fuse/relay box In the underdash fuse/relay box
ffi
Canada Canada
12
12 11
Inthe under-dash fuse/relay box In the under-dash fuse/relay box Underleftsideof dash Underleftsideot dash Underleftsideof dash Underleftsideof dash Undermiddleof dash Undermiddleof dash Undermiddleol dash gaugeassembly Under Underleftsideof dash Driver's doorwire harness (seepage22'40) Driver's doorwire harness (see page22-40) Leftsideturo signal light suonarness (see page Roofwire harness 22 3Al Floor wire harness {seepage 22-341 (seepage Floor wire harness 22 34J Dashboard harness wire B (see oaoe22-30)
Body ground via dashboard Body ground via dashboard
Left Side Turn Signal Light Sub harness

Connectoror Terminal Leftsideturn signallight c506 35 34 Cavities Location 2 B e h i n d l e f t s i d e t u r n s i g n a ll i g h t 2 Under left side of dash Connects to Dashboard harness wire A
Noles
22-26
WIRE DASHBOARD A HARNESS
,./
-19
20
34 LEFTSIDETURN SIGNAL LIGHT SUB HARNESS
2s
30
). \'u
)t
(cont'd)
22-27

Dashboard Wire Harness (Rightbranch) A
Audio nitconnector u c501 c502 c502 c503 c5' 11 c512
12 8 8 2 Connecloror Terminal 6 5 5 4 Cavities Location 20 Eehind audiounit 10 Underrightsideof dash 4 8 5 Underrightsideof dash Underrightsideof dash tJnder rightsideof dash Undermiddleof dash Undermiddleof dash Underrightsideof dash Underrightsideof dash 6 21 'l Underrightsideof dash Undermiddleofdash Undermiddleof dash Underrightsideof dash Connects to Engine compartment wire (seepage22,18) harness Engine companmentwire (see page22-18) harness Engine compartment wire (seepage22-18) harness Engine compartment wire (seepage22-18) harness (see ECN4 harness page wire 22-321 Floor wire harness {seepage 22-341 Rightsideturn signal light suonarness Passenger's wire door (see page22 4l) harness Passenger's wire door (seepage22 4'l) harness A,/C wire harness(seepage 22-43) (see ly'Cwire harness page 22-431 Eodygroundvia dashboard Notes
USA Canada
c514
9 10
ca52 c853
G502
Right Side Turn Signal Light Sub harness

Connector orTorminal Right sideturn signal light c5't3 1 8 Cavities Location 2 Eehind rightsideturn signal light 2 Underriohtsideof dash Connectsto Dashboard harness wire A Nots
22-28
WIBE DASHBOARO HARNESS A
'---/...'
I
22-29

Connector Harness to Index(cont'd)
Dashboard Wire Harness B
Collqctor or Terminal
C a b l e reel
Combination switch light Driver's airbag inflator lgnitionkey switch lgnition switch lmmobilizer control unit receiver Passenger's airbag lator inf SRSunitconnector A Wiper/washer switch Underdashfuse/relay box connectorA lseepage22,45) Under dashluse/relaybox connector (seepage22-45) B Under'dash fuse/relay box connectorC (seepage22-45) Under-dash fuse/relay box connector lseepage22-45) S Under'dash fuse/relay box (see page22 45) connectorX c401 c402
2 1 17 16 't9 18 I 3 5 6
Cavities Locatiol| 5 In steering column cover In steering column cover 4 In steering column cover In steering column cover 1 In steering columncover 1 In steering column cover 4 Undermiddleof dash 18 Undermiddleofdash 14 In steering column cover 5 Underleft sideof dash 6 14 Underleftsideofdash Underleftsideof dash Underlettsideof dash Under left sideof dash Underrightsideof dash 10 4 12 Undermiddleof dash Undermiddleof dash Undermiddlesideof dash Undergauge assembly
Connectsto
Notes
1 8 10 12 11 14
2 8
c403
G510 G40l
Engine compartment wire (seepage22-'18) harness (see page Floor wire harness 22-34J (see page Floor wire harness 22-341 Dashboard harness wire A (see oaoe22-26) Bodygroundviadashboard
22-30
WIRE OASHBOARD HARNESS B
22-31

ECMWire Harness
Connector TerminiF or Arrruert/vrl ralo sensor retay Datalinkconnector EC[/lconnectorE PGM-Fl mainrelay1 PGM-Fl mainrelay2 Under-dash fuse/relay box connector (seepage22 45) D Underdash fuse/relay box connectorE lsee page22-45) under-dashfuse/relaybox connectorR lsee page22-45) c10'1 c152 c451 c452 c453 c511 G451
I Re- lcavities
8 7 6 1 2 3 4 1' I I 10 14 12 4 6 6 20 8
Location
4 4
glovebox Eehind Undermiddleof dash glovebox Behind glovebox Behind glovebox Behind In the under-dash fuse/relay box Inthe under-dash fuse/relay box In the under-dash fuse/relay box Underrlghtsideof dash Underrightsideof dash Underrightsideof dash Underrightsideot dash UndermiddleoI dash Undermiddleof dash Undergauge assembly
Connectsto
Notes
(see Engine wire harness page22'16) (see EPS page subharness 22-24) Engine companment wire harness {seepage22-18) Engine compartment wire harness {seepage22-18) Floorwire harness(seepage 22-34) Dashboard harness wire A {seeoaoe22-26) Bodygroundvia ECMwire harness
22-32
ECMWIREHARNESS
22-33

Connector Harness to lndex (cont'd)
(Frontsidel FloorWire Harness
Connec-tor Terminal or I Driver's seatbeltswitch Driver's sideairbag inflator Driver's sideimpact sensor Leftside seatbelt buckletensioner (MES) Memoryerase signal connector Parkingbrakeswitch Passenger's seatbelt switch Passenger's airbag side inflator Passenger's impact side sensor Right sideseatbeltbuckle tensioner SRSunitconnector B SRSunitconnector C Under-dash fuse/relaybox connector {seepage22-45) P Under-dash fuse/relay box connector (seepage22,45) O c402 c403 c453 c508 c509 c512 2 14 1
Ref
11 l0 13 12 19 9 5 3 7 4 20 21 11
uavftres
Location
3 2 2 4 2 1 3 2 2 4 18 8 18 8 10 4 6 4 6 8 10
seat I Underdriver's seat i Underdriver's I Leftside offloor Underdriver's seat Underdashfuse/relay box 1Middleoffloor Underpassenger's seat Underpassenger's seat Rightsideoffloor Underpassenger's seat of I Undermiddle dash Undermiddleof dash Underdash fuse/relay box Underdashfuse/relay box ] I Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleof dash Undermiddleofdash Undermiddleof dash I Undermiddleof dash
connects to
Nol6s
'r8
22 23
6 G551
I
] Unaermiddleof aasn passenger's L,nder seat
Dashboard harness wire B {seepage22 30) Dashboard harness wire B (seepage22-30) (see ECMwire harness page 22-321 Dashboard harness wire A (seepage22-26) Dashboard harness wire A \see page 22-26) Dashboard harness wire A {seepage22-26) Engine compartment wire (seepage22 18) harness (seepage OPDS unitharness 22-421 Bodygroundviafloorwire
22-34
- 10 11
WIREHARNESS FLOOR
(cont'd )
22-35
Gonnectors Harnesses and

Connector Harness to Index (cont'dl
Floor Wire Harness {Rear side}(cont'dl
Cargo area Driver's doorswitch EVAP emission bypass solenoid valve EVAP emission control canister vent shutvalve Fuelpump/sending unit Fuel tankpressure sensor Left back-uplight Left rearABS wheel sensor Leftrearsidemarker light Left rear speaker Leftrearturn signal light Leftsideseatbelttensioner LefttaillighVbrake light (rear Noise condenser window defogger) (rear Noise condenser windowwiper) Passenger's door switch Rear windowwiperintermiftent controlunit Rightback-up light Right taillighvbrake tight Rightrearturn signal light BightrearABSwheelsensor Rightrearsidemarker light Rightrearspeaker Right sideseatbelttensioner c554 2 1 2 2 5 3 2 2 2 2 2 2 3 2 2 1 20 2 3 2 2 2 2 2 12 12
side of cargo area
6 2 24 I 3 25 1 26 4 2A 5 27 '13 18 10 11 22 20 21 15 19 12 11 7 I
LeftB pillar Fueltank Fueltank Fueltank Fueltank Lefttaillight Left rear offloor Behind sideof rearbumper left panel Leftquarter Lefttaillight LeftB-pillar Lefttaillight panel Rightquarter quarter panel Right R i g hB p i l l a r t q panel Right uarter Right ight tai Right taillight Right taillight Right sideof cargoarea Behind rightsideof rearbumper Rightquanerpanel RightB-pillar Rightquanerpanel quanerpanel Right
rearseal bdcl
H a t c hw i r e h a r n e s s( s e ep a g e 22 39) H a t c hw i r e h a r n e s s( s e e p a g e Bodv ground vta
Right sideof cargoarea
Bodygroundviafloorwire
22-36
WIREHARNESS FLOOR
22-37

RoofWire Harnsss
Connectoror Terminal Moonroofclose relay Moonrool control unit Moonroof motor Moonroot openrelay position Moonroof sensor 1 positionsensor2 N4oonroof Moonroofswitch Rear ceiling light SpotlighVceiling light c507 6 I 7 8 5 1 2 10 Cavities 5 5 2 5 2 4 5 3 4 8 tocation Middleof roof Middleof roof Middleof roof Middleof roof MiddleoI roof Middleof roof Frontof roof N4iddle roof of Frontof roof Underleftsideof dash Connectsto Notes
Dashboard harness wire A (see oaoe22-261
22-38
HatchWire Harness
Connector Torminal or Hatchlatchswitch Hatchlockactuator Highmountbrake light platelight connector License A platelight connectorB License Rear windowde{ogger connector A windowdetogger connector B Bear 7 8 I 3 10 6 2
l
Cavities 2 2 2 2 2 1 1 4 12 2
Location Middleo{ hatch Middleof hatch Behind highmountbrake light Middleof hatch Middleof hatch Right C-pillar LeftC-pillar Middleof hatch quanerpanel Right quanerpanel Right
Connects to
Notes
( )
Bear window wiper moto. c553 c554
(see page Floor wire harness 22-341 (see page Floor wire harness )2-34\
22-39

Connector Harness to lndex (cont'd)
Driver'sDoorWire Harness
Connector Terminal or Driver'sdoor lockactuator Driver's doorlockknobswitch Driver'sdoor lockswitch Driver's doorspeaker Driver'spowerwindow motor Left power mirror actuator Left tlveeter Powerwindow masterswitch c504 c505 ReI 9 10 1 7 2 3 8 5 6 Cavities 2 3 3 2 6 2 20 't3
Location
\,
Connectsto
Notes
Driver's door Driver's door Driver's door Driver's dooa Driver's door Driver's door Driver's door Driver's door Underleftsideof dash Underleftsideof dash
A Dashboard harness wire \seepage22-261 A Dashboard harness wire
DRIVER'S OOOR WIREHABNESS
22-40
Passenger'sDoor Wire Harness

Connector Terminal or Passenger's lockactuator door Passenger's speaker door powerwindowmotor Passenger's powerwindowswitch Passenger's Rightpowermirroractuator Righttweeter c514 Rel 6 I 5 1 4 3 2 1
Cavities Location
Connectsto
Notes
2 2 2 5 6 2 13 6
Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Underrightsideof dash Underrightsideof dash
Dashboard harness wire A (see page22'26) A Dashboard harness wire lsee oeoe 22-26\
PASSENGER'S DOORWIREHABNESS
22-41
and Gonnectors Harnesses

Connector Harness to lndex {cont'dl
OPDS Unit Harness
Connoctor orTorminal OPDS unit Cavitios 2 1
I
Location In frontpassenger's seat Under frontpassenger's seat
Connectsto (seepage Floor ware harness 22-34)
Notes
FLOOR WIBEHARNESS
22-42
A/C Wire Harness

Connoctor Terminal or Air mix control motor Blower motor Evaporator temperature sensor Modecontrol motor Powertransistor Recirculation control motor c851 c852 c853 Rel I 2 8 3 4 1 1 6 5 Cavities 5 2 2 10 5 1 21
Location Connec'tsto
Notes
Undermaddle dash of Underrightsideof dash Undermiddleof dash Underrightsideof dash Underrightsideof dash Underrightsideof dash Undermiddleol dash Undermiddleofdash Undermiddleo{ dash
,]
Engine wire compartment (seepage22-18) harness Dashboard harness wire A {seepage22 26i Dashboard harness wire A lsee oaoe 22-261
22-43
Fuse/Relay Boxes
Connector Fuse/Relay to Box Index
Under-hoodFuse/Relay Box Socket Ay'C compressorclutch relay B Blower motor relay Ref 14 2 Terminal Connects to 2 Enginecompartmentwire harness(seepage 22-18) 4 5 Enginecompartmentwire harness(seepage22-18) 4 Enginecompartmentwire harness(seepage 22-18) 4 14 Enginecompartmentwire harness(seepage 22-18) ( 7 E n g i n e o m p a r t m e nw i r e h a r n e s s s e ep a g e2 2 - 1 8 ) c t 3 Enginecompartmentwire harness{seepage 22-18) 4 4 4 4 (seeoaqe22-15) Startersubharness Startersubharness {seeoaoe22-'15}
c
C o n d e n s efr n r e l a y a D E E L Du n i t H e a d l i g hrte l a y1 Headlightrelay 2 Horn relay Radiator fan relay Rearwindow defoqqerrelay T1 (Batterv) T101 (Alternator)
15 9
1'
11
to
5 6 10 'l
J
8 7
tt
-
a-------) |
||
|
t t
t L _ _ . 1I |
t L " "
T---r .-:-
""""-lI r^l
L'
tr T T tTt Tr ,/^-------lFr -/1-l szl:!)
t t-l t t_l t tIl L l L l t l ' " . -
lrt
lview of tront sidel
{View of back side)
22-44
Under-dash Fuse/Relay Box

Socket Ref Terminal
2 3 1 5 19 9 I 20 24 22 27 26 7 6 10 25 14 18 11
l5 to
5 6 14 13 12 10 3 : 11 '10 1:
.o^
D E F G H J K M N
o
P Powerwindow relay
o
R S Startercut relay T Taillightrelay Turn signal/hazard relay U W ( M e m o r ye r a s e i g n a l( M E S ) s connector) X Y
;; 4 8
Connects to Dashboard wire harnessB {seepage 22-30) Dashboard wire harnessB {seepage 22-30) Dashboard wire harnessB (seepage 22-30) ECMwire harness(seepage 22-32) ECI\4 wire harness(seepage 22-32) Enginecompartmentwire harness(seepage 22-'l8l Enginecompartmentwire harness(see page 22-181 ( E n g i n e o m p a r t m e nw i r e h a r n e s s s e ep a g e2 2 - 1 8 ) c t Enginecompartmentwire harness(see page 22-18) Enginecompartmentwire harness(seepage 22-18) Dashboard wire harnessA (seepage 22-26) Dashboard wire harnessA (seepage 22-26) Dashboard wire harnessA (seepage 22-26) Dashboard wire harnessA (seepage 22-26) Dashboard wire harnessA (seepage 22-26) Floorwire harness(seepage 22-34) Floorwire harness(seepage 22-34) ECMwire harness(seepage 22-32) Dashboard wire harnessB (seepage 22-30)
2 i n
a
2
Multiplexcontrol unit servicecheckconnector
l
Optionalconnector Optionalconnector Floorwire harness(seepage22-34) {Plugsdirectly into the multiplexcontrol unat) ( P l u q s i r e c t l v n t ot h e m u l t i D l e c o n t r o lunrl) i x d
17
l t
28
I 13
tn--rl I U LI L.]L.J h - - n UL]L]UL]

I] L] L] LI L]
!3
12
22-45
PowerDistribution
Fuseto Componentslndex
Fuse/Relay Box Under-hood Fuse Number
'I
Amps 204 15A

7.5A
WireColor
Component(sl or Circuit(s) Protected
BLUI/EL Condenser motor fan BLU/RED Ay'C compressorclutch WHT/GRN Dashlights,Front parkinglights,Frontside marker lights,Licenseplate
l i q h t ,R e a rs i d em a r k e rl i q h t s T a i l l i q h t s ,
204 10A
15A
WHT/BLU C a r q oa r e al i q h t ,C e i l i n q i q h t s l. q n i t i o nK e v l i q h t .S o o t l i o h t s l BLU/BLK Radiatorfan motor WHT/BLK Turn siqnal/hazard relav,Turn siqnal liqhts WHT/BLK CKPsensor,ECM,IACvalve, lmmobilizercontrol unit-receiver, Injectors,
P G M - Fm a i n r e l a v1 a n d 2 . T D Cs e n s o r I
15A
WHT/GRN Brakelights,Brakesignals(to ABS modulator-control unit, Cruisecontrol

unit, ECM)
8 9
20A 10A
40A
B L U / R E D i1Orns WHT/GRN ABS modulatorcontrol unit , WHT/RED A u d i o u n i t ,D a t al i n kc o n n e c t o( D L C )G a u g ea s s e m b l yl,m m o b i l i z e r r

control unit-receiver, lmmobilizerindicatorlight. Keylessreceiverunil, lvlultiDlex control unit
10
11
IJ
30A
40A 40A
14
t5
40A
15A
WHT/RED ABSmodulator-control unit BLK/YE Noisecondenser,Rearwindow defoqqer L BLU^^/HT Blower motor WHT/BLK No. 7 fuse (in the under-dash fuse/relavbox), Powerwindow relav WHT/RED No.2 and No.3 fuses (in the under-dash fuse/relavbox) REDI/EL Daytimerunning lightscontrol unit (Canada), Daytimerunning lights relay
H { C a n a d a ) , i o hb e a mi n d i c a t o lri q h t .L e f th e a d l i q h t
16 17
204
15A 60A
18 19 20
* 1 :U S A " 2. Canada
WHT Multiplexcontrol unit RED D a v t i m e u n n i n ql i q h t sc o n t r o l n i t ( C a n a d a ) . i o h th e a d l i o h t r R u WHTiBLU EPScontrol unit WHT

Batterv.Power distribution lgnition switch (BAT)
80A
40A' 50A'?
t " t| 4
l l - - -
l I
I I
E'l
t__J i; i6'!/' E,l E,l r--r r---r Eol E l f__--l | |
l'lr r L__J,a ] n ,..r^{-------l^-,
E,l E,l E,l
n[:]$"Lrt
" N2,
nf
- r^l
fuse O: Spare
22-46
Under-dash Fuse/Relay Box Fuse Number

1
Amps
15A
Wire Color
Component(s) or Circuit(s) Protected
2 3
204
10A
10A
BLKA/VHT l g n i t i o n o i l s c WHT/RED Airlfuel ratiosensor, ECM RED/BLU D a y t i m e u n n i n gI i g h t s o n t r o lu n i t{ C a n a d a ) r c BLI(ORN Air/fuel ratio sensorrelay,Alternator,CMP sensor,Cruisecontrol main
switch,Cruisecontrol unit. ELDunit, Evaporative emission(EVAP) bypass solenoidvalve, Evaporative purge valve, emission(EVAP)canister Evaporative emission(EVAP) canistervent shut valve,SecondaryH02S, Vehiclespeed sensor Not used Y E U G R N Moonroof control unit, Moonroof open and close relay,Powerwindow relaV GRN Moonroof motor YEURED A u d i o u n i t GRN OPDSunit, Rearwindow wiper motor, Rearwindow washer motor, Rear window wiper intermittentcontrol unit YEL Back-uplights,Cruiseindicatorlight, EPScontrol unit, Gaugeassembly, Keylessreceiverunit, Multiplexcontrol unit, Securitycontrol unit connector(optional) BLIVORN ABS modulator-control unit YEURED D a y t i m e u n n i n ol i o h t sc o n t r o lu n i t ( C a n a d a ) r PNK S R Su n i t BLK/YE A,,/C L compressorclutch relay,Blower motor relay,Condenser fan relay, Heatercontrol panel,Power mirror actuator,Power mirror defogger (Canada), Radiatorfan relay,Rearwindow defoggerrelay,Recirculation control motor Not used
6
7
7.5A
204
7.5A
I
9
10A
7.54
10
11
12 13 't4
7.5A 7.5A
10A 10A
1E lo
17 18 19
15A 15A 7.5A
20 21 22 23 24 25
30A 204 20A.
Notused YEL/BLK E C M ,F u e lp u m p BLK/YE >H> Unrr L Y E U G R N Accessorypower socket Y E U B L K T u r ns i q n a l / h a z a rrd l a v T u r n s i q n a l i o h t s e , G R N / B L K M u l t i p l e x o n t r o lu n i t ,W i n d s h i e l d a s h e rm o t o r .W i n d s h i e l d i o e r m o t o r c w w

Not used
G R N / B L K Passenqer's window motor GRN,A/VHT Driver'swindow motor

Not used
Notused
_ _ ^ : Hr tl_l f at-t
at\t I
r^,rl fl
!339,i;s!!s f :
Fnf |rnITf
!!;r -
22-47
Distribution Ground
Index Groundto Components
Ground
Batterv, Transmission housinq En g i n e G1 0 1 Componentor circuit qrounded
G 15' ]
(PGis BLK; is BRN/YEL) LG ECM valve IAC lgnition coils, Vehicle speed sensor, VTEC solenoid BLK: valve, (CMP) VTEC pressure switch sensor. CKP sensor, TDCsensor. oil BRNA/EL: Camshaft oosition EPS control unit
ELDunit. Multiplexcontrol inspection connector,Multiplexcontrol unit, Powerwindow relay,Rear window washer motor, Rightfront parkinglight, Rightfront side marker light, Rightfront turn signal relay,Washerfluid level sensor(Canada) Windshieldwasher motor, light,Turn signal/hazard , WindshieldwiDer motor
G201
G202 G301 G401 G402

G4 5 1 G501
ABSmodulator-control unit
fan motor, Cruisecontrol actuator,Leftfront Blower motor relay,Brakefluid level switch,Condensor parkinglight, Leftfront side marker light, Leftfront turn signallight, Radiator fan motor, Radiator fan swrtcn Wiper/wasfrer sr,virch Combinationliqht switch,lqnitlon kev srvitch, Left and riqht airbaqsensors,SRS unit Datalink connector(DLC) Clutchinterlockswitchm Clutchpedal positionswitch (for cruisecontrol),Cruisecontrol main switch, Driver'sdoor lock knob switch, Cruisecontrol unit, Daytimerunning lightscontrol unit (Canada), Driver'sdoor lockswitch,Driver'spower window motor, Heatercontrol panel,Left power mirror left defogger(Canada), side turn signal light, Moonroof control unit, Monroof open and close relays, '1, Moonroof positionsensor Moonroof seitch,Power mirror switch,Powertransistor,Powerwindow masterswitch.SDotliqhts control unit, Right power Accessorypower socket,Gaugeassembly,Keylessreceiverunit, lvlultiplex m i r r o rd e f o g g e { C a n a d a ) r A u d i ou n i t connector, Driver'sseat belt switch,Fuelgauge sendingunit, Fuelpump, Memory erasesignal(IMES) OPDSunit. Riohtseat belt switch High mount brakelight, Licenseplate lights,Rearwindow defogger,Rearwindow defoggernoise condenser. Rearwindow wioer motor, Hatchlatch switch Back-uplights,Brakelights,Rearside marker lights,Rearturn signal lights,Rearwindow wiper noise condenser,Rearwindow wiper intermittentcontrol unit, Taillights
G502 G503
G551
G552
22-48
Under-dash Fuse/Relay Box

Removaland Installation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations{seepage 23-13)and (seepage23-14)in the SRS precautions and procedures sectionbeforeperformingrepairsor service. 5. Removethe mounting bolt, and slidethe underdash fuse/relaybox (A) down from the bracket{B). 6. Disconnect backside from connectors the from the back of the under-dash fuse/relaybox, and remove the fuse/relaybox. N O T E : T h e R Sc o n n e c t o irs a s p r i n g - l o a d eld c k S o type (seepage 23-1 1).
Removal
1. Make sure you have the anti-theft code for the radio, then write down the frequencies the radio's for presetbuttons. 2. Disconnectthe batterynegativecable,then disconnect the positivecable,and wait at least three minutes. 3. Removethe driver'sdashboardlower cover (see page 20-59). 4. Disconnect connectors the from the fuse side of the under-dash fuse/relaybox.
lnstallation
1. Installthe under-dash fuse/relaybox in the reverse order of removal and connectall connectors the to under-dash fuse/relaybox. 2 . I n s t a l l t h e r i v e r ' s a s h b o a r do w e rc o v e r . d l d 3. Connectboth the negativecable and positivecable to the battery. 4. Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. 5. Confirmthat all systemswork properly, 6 . D o t h e e n g i n ec o n t r o lm o d u l e( E C M ) d l e l e a r n i ( p r o c e d u r e s e ep a g e1 1 - 1 3 9 ) .
22-49
Battery
Battery Test
{
A batterycan explodeif you do not follow the proper procedure, causingseriousinjury to anyone nearby.Follow all procedures carefullyand keep sparksand open flames away from the battery. Use eithera JCI or BearARBSTtester,and follow the procedures. Vou don't have one of lf manufacturer's these computerized testers,follow this conventional test procedure: 1. Be sure the temperatureof the electrolyteis between70'F (21"C) and 100'F(38'C). 2. Inspectthe batterycasefor cracksor leaks. . l f t h e c a s ei s d a m a g e d r e p l a c e t h e a t t e r y . l , b . lf the case looksOK, go to step 3. 3. Checkthe indicatorEYE. . lf the EYEindicatesthebafteryischarged,goto step 4. . l f t h e E Y Ei n d i c a t e s ao w c h a r g e , o t o s t e p 7 . g l 4. Apply a 300 amp load for 15 secondsto removethe surfacecharge. then apply a test load of 280 amps 5, Wait 15 seconds, for 15 seconds. 6. Recordbatteryvoltage. . l f v o l t a g ei s a b o v e 9 . 6 v o l t s , t h e a t t e r y s O K . l b i . l f v o l t a g ei s b e l o w 9 . 6 v o l t sg o t o s t e p T . , 7 . C h a r g e h e b a t t e r y n H i g h( 4 0a m p s )u n t i lt h e E Y E t o shows the batteryis charged,plus an additional30 minutes.lf the batterychargeis very low, it may be necessary bypassthe charger'spolarity to protectioncircuitry. . l f t h e E Y Ei n d i c a t e s t h e a t t e r y s c h a r g e d w i t h i n b i 3 hours,the batteryis OK.l . lf the EYEindicatesthebatteryis notcharged within 3 hours,replacethe battery.l
22-50
Relays
PowerRelayTest
Usethischanto identify typeof relay, the thendo the testlisted it. for NOTE: Turnsignal/hazard inputtest(seepage22relay 87).
Relay type 1:
Test
Normally-open type A
A'lC comoressor clutchrelav

Airlfuel ratio sensorrelav Condenser fan relay H e a d l i o hrte l a v1 H e a d l i q hrte l a v2 H o r nr e l a v Powerwindow relay R a d i a t oIra n r e l a y Reverserelav Startercut relav T a i l l i q hr e l a V t D a y t i m e u n n i n gl i g h t sr e l a y r { C a n a d) a
type 2:
P G M - F I a i nr e l a v m 1
P G M - Fm a i n r e l a v2 l Blower motor relav Rearwindow defoqoerrelav Moonroofclose relay Moonroof oDenrelav Low beam cut relav {Canada) Normally-open tvpe B F i v et e r m i n a l type PGM-FImain relay 1 PGM-FImain relay 2 type 1:
Normally-open type A:
Checkfor continuitvbetweenthe terminals. . Thereshould be continuitybetweenthe No. 1 and N o , 2 t e r m i n a l s h e n p o w e ra n d g r o u n da r e w connected the No. 3 and No. 4 terminals. to . Thereshould be no continuitybetweenthe No. 1 and N o . 2 t e r m i n a l s h e n p o w e ri s d i s c o n n e c t e d . w
type 2:
(cont'd)
22-51
Relays
PowerRelayTest (confdl
Normally-open type B:
Checkfor continuitybetweenthe terminals. . Thereshould be continuitybetweenthe No. 1 and N o . 3 t e r m i n a l s h e n p o w e ra n d g r o u n da r e w c o n n e c t e do t h e N o . 2 a n d N o . 4 t e r m i n a l s . t ' Thereshould be no continuitybetweenthe No, 'l and No. 3 terminalswhen power is disconnected.
Five-terminal type
f C h e c k o r c o n t i n u i t y e t w e e nh e t e r m i n a l s . b t . T h e r es h o u l db e c o n t i n u i t y e t w e e n h e N o . 1 a n d b t N o . 2 t e r m i n a l s h e n p o w e ra n d g r o u n da r e w c o n n e c t e t o t h e N o .3 a n d N o .5 t e r m i n a l s . d . T h e r es h o u l db e c o n t i n u i t y e t w e e n h e N o . 1 a n d b t N o . 4 t e r m i n a l s h e n p o w e ri s d i s c o n n e c t e d . w
tF-gr tJ 1l
Rearwindow defonn* *O,
type 1:
.r{{ \ n ( F, t )
Blower motor relay type 1:
6:) rc*V
\
s3.
type2:
type 2;
22-52
lgnition Switch
Test
SRScomponentsare locatedin this area.Reviewthe ( S R Sc o m p o n e n lto c a t i o n ss e ep a g e2 3 - 1 3 a n d ) precautions and procedures {seepage 23-'l4)in the SRS sectionbefore performingrepairsor service. 1, Removethe driver's dashboardlower cover {see page 20-59). 2. Disconnect 5P connectorfrom the under-dash the fuse/relaybox. WHT/RED Wiresideof femalterminals e BLK/WHT BLK/RED BLK/YEL
Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

\ Terminal WHT/
RED YEL RED p.J,i""-\ (ACC) WHT flGl) trc2t WHT (BAT) (sr) o (LocK) | (ACC) o- --o _H [ (oN) c)III (START) o _H
BLK/ BLK/ BLK/
lf the continuitychecksdo not agreewith the table, replacethe steeringlock assembly(seepage'17-121.
22-53
Gauges
\-
PARKINGBRAKESWITCH p a g e1 9 - 1 0
SWITCH OIL ENGINE PRESSURE page 8-4
FUELGAUGESENDING page 1-156 1
GAUGEASSEMBLY page22-56 Procedure, SelJ-diaqnostic page22 63 Gauqedulb Replacement, page22-64 Rep6cement, Gauge CoolantTemperature page22'64 TroLrbleshooting,
SENSOR SPEED {VSS) VEHICLE page22-65 Troubleshooting, page22-67 Beplacement,
SWITCH FLUIDLEVEL BRAKE page 9-10 1
22-54
CONNECTOR A (bluel
CONNECTOR B lgreenJ SPEEDOMETER Signal Circuit Vehicle Speed page Troubleshooting, 22-65
TACHOMETEB
\7
t----/ \
_ / \
GAUGE FUEL page11-156 Test,
i . . _ METER ODO/TRIP
22-55
Gauges
Self-diagnostic Procedure
The gaugeassemblyhas a self-diagnosis function. . T h e B e e p e r r i v eC i r c u i C h e c k D t . The IndicatorDrive CircuitChecL . The LCDSegmentsCheck . The GaugesDrive CircuitCheck(Speedometer, Tachometer, Fuelgauge,Coolanttemperaturegauge) . T h e C o m m u n i c a t i oL i n eC h e c k t h ec o o l a n t t e m p e r a t u r eg n a l i n e b e t w e e n h e g a u g ea n d E C M ) ( n si t NOTE:Indicators are also controlledvia the communicationline.
Entering self-diagnosis the f unction:

Beforedoing the self-diagnosis function,checkthe No. 9 (10A)fuse in the under-hoodfuse/relaybox and No. 10 {7.5A) fuse in the under'dashfuse/relaybox. 1. Pushand hold the trip/resetbutton. 2 . T u r nt h e l i g h t i n g w i t c hO N . s 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 4 . W i t h i n5 s e c . , u r n t h e l i g h t i n g w i t c hO F F , h e n O N a n d O F Fa g a i n . t s t 5. Within 5 sec.,release trip/resetbutton,then push and release the the buttonfour times reDeatedlv. NOTE: . While in the self-diagnosis mode, the dash lights brightnesscontrolleroperatesnormally. 'Whileintheself-diagnosismode,thetrip/resetbuttonisusedtostartthebeeperdrivecircuitcheckandthegauge drive cicuit check. . lf the vehiclespeedexceeds1.2 mph 12km/h)orthe ignition switch is tu rned OFF,the self,diag nosis mode ends.
oN flrl
lgnition OFF Switch Lighting Switch Trip/Reset Switch 5 sec. 5 sec. -> Move to selt-diagnosis mode.
The Beeper DriveCircuitCheck:

When enteringthe self-diagnosis mode, the beepersoundsfive times
TheIndicator DriveCircuitCheck:
When enteringthe self-diagnosis mode,the following indicatorsblink. Seatbelt indicator,Door/hatch indicator,Brakesystem,Lowfuel indicator,Maintenance requiredindicator(USA), ), W a s h e r l u i d l e v e li n d i c a t o ( C a n a d a O i l p r e s s u r ei g h t . f r l
22-56
The LCDSegmentCheck:
s b W h e ne n t e r i n g h e s e l f - d i a g n o s m o d e ,t h e o d o / t r i p e g m e n t l i n k sf i v et i m e s . t is
TheGaugeDriveCircuitCheck:
r, th a W h e ne n t e r i n g h e s e l f - d i a g n o s m o d e ,t h e s p e e d o m e t e t h e t a c h o m e t e r , e f u e l g a u g e , n d t h e c o o l a n t t is g s t t e m p e r a t u r e a u g en e e d l e s w e e pf r o m t h e m i n i m u mp o s i t i o n o m a x i m u mp o s i t i o nt,h e n r e t u r nt o t h e m i n i m u m posrtron. NOTE:After the beeperstops soundingand the needlesreturnto the minimum position,pushingthe trip/resetbutton c c s t a r t s h e b e e p e r r i v ec i r c u i t h e c k( o n eb e e p )a n d t h e g a u g ed r i v ec i r c u i t h e c ka g a i n . t d u r t T h e c h e c k a n n o tb e s t a r t e d n t i l t h en e e d l e s e t u r n o t h e m i n i m u mp o s i t i o n . c
Self-diagnosis mode Trip/Reset switch
ON OFF
9l- _--oFF
ON
r
r-r r-r r-r .-1 r-r
n =--llJL-[-----l
r-r
needlesXl" cause
Beeper
f---U---------l
;;
lll u u l_lL__l I
5 sec
l-l
@,
The needles sweepfrom the minimum positionto the maximum position, then return t o t h e m i n i m u mp o s i t i o n -
The Communication Line Check:

startsthe communicationline In the self-diagnosis mode, after the odo/trip LCDsegmentscheck,the self-diagnosis cnecK. i l f a l l s e g m e n t s o m e so n , t h e c o m m u n i c a t i o ln n e i s O K . c " E r r o r "i s i n d i c a t e d , t i n l f t h ew o r d t h e r ei s a m a l f u n c t i o nn t h e c o m m u n i c a t i o l i n e b e t w e e n h e g a u g ea s s e m b l yt.h e m u l t i D l e c o n t r o lu n i t .a n d t h e E C M . x
Normal:
Faulty:
:-l!:!!JlJ!J
t l
i-
iD
t
--
,,ri-
O i -
f l
| | | t t f
ir-
function: Endingthe self-diagnosis

s T u r nt h e i g n i t i o n w i t c hO F F . , f s 1 N O T E l f t h e v e h i c l e p e e de x c e e d s . 2m p h { 2 k m / h ) t h e s e l f d i a g n o s i su n c t i o ne n d s . r
22-57
Gauges
CircuitDiagram
'
UflOEN fiOOO FUSE/8ILAY 8OX
N o 2 0 i o A lU S A :
ECM/PCM
V I -r'
r--l
I
I 8|
l J ,
ii-ciorurnn
coNNECron
COOLANI TEMPfNAIUFT SPIEDOMEIEN TACHOMEIIR FUTLGAUGI GAUGE
Norll0AlFUSE
8L(
-o-
22-58
ti) l To mxr I
MAi{IIiIANCE
ft0unlD [{0tcaTo8
LIGH] (LEDI
(cont'd)
22-59
Gauges
(cont'dl CircuitDiagram
No2il5AlFUSE ilnlh.undi hooq llu!./rcl.ybox r
DASH LGHTS
Y t
t
'-t
Y l
l
WASHEF Itut0 I!VEL 6t0tc ToR UGHT (tDl
ls?2
BLUIYEL
I
I
J
cSutsE m n0L
a
22-60
'-
--t
./
ib-n'rnoL
UNIT
tNGniEorL PRESSUBE swtTcH lCld.d Eisin.3topp.d l iopd Ersin.runni.s i
I ! i I I
DAYTIME BUNN|NG LIGHTS @NTROL UNII
I ; I i
-.-..
I
icmadd
(cont'd)
22-61
Gauges
CircuitDiagram(cont'dl
\"
GRNIfiED I
\""'7
GAUGIASSEi|BLY
LEFTTUN SIGI'IAL II'{DICATOR LTCHTS
HIGHSEAM
ltDtcATon r/: \ tilucaToB
-|.
IMMOBITIZER
f,il
vll9i,]
\,
CoME|NAT|ON LtctlTswtTclt
tMf,tOBtUZEn @l\tTRoL UN|I ftCtIVER
J
22-62
GaugeBulb Replacement
LIGHT{1.4WI RIGHTTURN SIGNALINDICATOR
CRUISE HIGHBEAMINOICATOR LIGHT{1.4W)
ITOR LIGHT W) {I.4 LEFT TURNSIGNALINDICATOR LIGHTl1.il wl GAUG LIGHT WI {1.4
GAUGELIGHT{1.4W}
INDICATOR IMMOBILIZEN LTGHT Wl {1.4
22-63
Gauges
GaugeAssemblyReplacement
1 . Removethe instrumentpanel (seepage 20-59), t h e n r e m o v et h e u p p e rc o l u m nc o v e r{ s e ep a g e1 7 Beforetesting,checkthe No. I { 10A)fuse in the underhood fuse/relaybox and the No. '10(7.5A) fuse in the under dash fuse/relaybox. 1. Startthe engine,and checkthe malfunction i n d i c a t o lra m p ( M l L ) . Does the MIL come on? YES- Troubleshoot causeof the ECM DTC(see the p a g e11 - 5 7 )a n d r e c h e c k . , NO-Go to step 2. 2. Checkfor a multiplexcontrol unit DTC(seepage 22,168). ls a DTC indicated? YES Troubleshooting causeof the multiplex the control unit DTC{seepage 22-168), and recheck. NO Go to step 3. 3 . D o t h e c o m m u n i c a t i o ln n ec h e c k i t h t h e s e l f i w diagnosisprocedure(seepage 22-56). ls the word "Error" indicated on the odo/ttip d isplay ? YES The gaugecannot receivethe signalfrom the multiplexcontrol unit and the ECI\,4. Checkfor an open in the WHT/GRNwire (gaugeconnector t e r m i n a lB1 3 ) .l f n o o p e ni s f o u n d ,g o t o s t e p5 . NO Go to step 4. 4. Do the gaugedrive circuitcheckwith the self( p d i a g n o s i s r o c e d u r es e ep a g e2 2 - 5 6 ) . Does the temperaturegauge needle sweep lrom the minimum position to the maximum, then tetutn to the minimumposition? YES Go to step 5. N O R e p l a c eh e g a u g ea s s e m b l y . l t 5. Substitutea known-goodECM and recheck. Did the symptom/ ind ication go away? Y E S R e p l a c eh e E C M . t NO Substitutea known good gaugeassembly.lf goes away, replacethe the symptom/indication g a u g ea s s e m b l y . l
Coolant Temperature Gauge Troubleshooting
2. P l a c e c l e a ns h o pt o w e l ( A )u n d e rt h e g a u g e a
assemblyto preventscratching steering the c o l u mn o r d a s hp a n e l .
3 . Removethe screwsfrom the gauge assembly(B).
4. Disconnect the connectors(C),and removethe
g a u g ea s s e m D r y . g I n s t a l l t h e a u g ea s s e m b l yn t h e r e v e r s e r d e ro f i o removal.
22-64
Vehicle Speed SignalCircuitTroubleshooting

Special Tools Required: Test Harness 07LAJ-PT3020A Beforetesting,inspectthe No. 4 (10A)and No. 10 (7.5A) fuse/relaybox. fuses in the under-dash 1. Disconnect 3P connectorfrom the vehicle the speedsensor(VSS){A). 5. Connectthe WHT test harnesscliD(B)to the positiveprobe of a voltmeter,and connectthe RED test harnessclip (C)to the negativeprobe.
le thara h2ltarv v^ltada?
Y E S - G o t o s t e p7 . Connectthe test harnessonly to the enginewire harness. wire betweenthe NO Repairopen in the BLK,/YEL VSS and the under-dash fuse/relaybox.l 7 . Disconnect WHT test harnessclip (B). the 8 . C o n n e ctth e G R Nt e s th a r n e s s l i p{ D )t o t h e c positiveprobe of a voltmeter.
3 . Connectthe REDtest harnessclip (B)to the positive

probe of an ohmmeter.Coverthe white (C)and green {D)test harnessleadswith protective tape (E). 4 . Checkfor continuitybetweenthe REDtest harness c l i p a n d b o d yg r o u n d , ls there continuity? YES Go to step 5. N O R e p a i r p e ni n t h e B L Kw i r e b e t w e e n h e V S S o t a n dG1 0 1 . I
Is there 5 V or more? YES- Go to step 9. NO Repairshort or open in the BLUMHT or WHT/ GRNwire betweenthe VSS and the cruisecontrol u n i t ,o r t h e E C M . I
(cont'd)
22-65
Gauges
(cont'dl VehicleSpeedSignalCircuitTroubleshooting
9 . Turn the ignitionswitch OFF. 1 0 .Connectthe other test harnessconnector(A)to the
V S S( B ) , GAUGE ASSEMBLY CONNECTOR B (22P) 14. Disconnect 22Pconnector"8" from the gauge the assemDry.
'15. Connectthe positiveprobe of a voltmeterto the BLU/WHT wire and the negativeprobeto ground. 1 1 .R aisethe front of the vehicle,and make sure it is securelysupported. '16. Slowly rotateone wheel with the other wheel blocked. Does voltage pulse f rom 0 to about 5 V or more? YES- Replace speedometer the assembly.I NO Repairopen in the BLUMHTwiTe between the VSS and the speedometer.l
' t 2 .Put
the vehiclein neutralwith the ignitionswitch
o N { |) , |
t5.
Slowly rotateone wheel with the other wheel blocked. Does voltage pulse ttom 0 to about 5 V ot morc? YES Go to step 14. NO Replace VSS.I the
22-66
VSS Replacement
1. Removethe intakeresonator. 2. Disconnect 3P connectorfrom the vehicle the speed sensor{VSS)(A).
Removethe mounting bolt, then removethe VSS.

4 . lnstallthe VSS in the reverseorder of removal.
22-67
Exterior Lights
GomponentLocationIndex

HEADLIGHT RELAY 1 Test,page22-51
HEADLIGHT RELAY 2 Test,page22-5'l
BRAKEPEDALPOSITION Test,page22-84 Adjustment,page l9'6
swtTcH
0/
SIDETURN SIGNAL LIGHT page22-84 Replacement,
/
FRONT TURNSIGNAL LIGHT t, B u l bB e p l a c e m e np a g e2 2 8 1
HEADLIGHTS page22 79 Replacement, Adjustment.page22-78 page22-81 Eulb Replacement,
PARKING LIGHT p, B u l bR e p l a c e m e n t a g e2 2 - 8 1 FRONT SIDEMARKER LIGHT page22 83 Bulb Replacement,
22-68
-a-.,_ z
HIGHMOUNTBRAKE LIGHT page Replacement, 22-82
LICENSE PLATE LIGHTS page Replacement, 22-83
BACK.UPLIGHT page22-82 Replacement, TAILLIGHTSsnd BRAKELIGHTS page22-82 Replacement, REAR TURNSIGNALLIGHT page22-82 Beplacement,
REAR SIDEMARKER LIGHT page Replacement, 22-83
(cont'd)
22-69
Exterior Lights
ComponentLocationIndex(cont'dl
DAYTIME RUNNING LIGHTS RELAY {Canadal RED, REDryEL, [Wirecolors: I and LRED/BLK RED/BLU I Test,page22-51 BEAMCUTRELAY {Canadal_ _LOW Wirecolorsr REDMHT, RED/BLK, I and I LREDryEL RED/BLU Test,page22-51
DASH LIGHTSBRIGHTNESS CONTROLLER
. . i
' :' --,': -
' i,-'-'l
DRLINDICATOR LIGHT {Canadal

HIGH BEAM INDICATORLIGHT page22-63 Bulb Replacement,
COMBINATION LIGHT SWITCH page TesVReplacement, 22-80

oAYTIME RUNNING LIGHTSCONTROLUNIT lcanada) InputTest,page22-76
I t-
FUSE/ UNDER.DASH RELAY BOX
22-70
LET] FBOIII SIDE MAiKEE L.IGHT
f,IGHT TSONT
s]0E
MANXtF IJGIIT
IETT NEANSIDE MAircN IIGHT
I ucEr\6E I PI.ATE
|fiIli
I 8L.l(
_o
22-71
Lights Exterior
CircuitDiagram Canada
UNOEN HOOO FUSE/8ELAY BOX
N ol 9 l 8 0 A l
) to.o - i50Al
No.1'l
loa)
IT N o . ! 0S7 lusE (A r d.3hl
WHT ED
RED,I
I EAr
V
I 'l'
I
/', t-\ \ rc|'/moN . rcz/ swfrcH
I'2_ l
-/ l'lcli; *01
-- ,'orrro" .
) INDICAIOF
I I BU1 BED
vG2Horin0N{ll)
= .|
A DNL TIGHT luDl
) No12 i l7.5Al
\y
fifili{*1l,.H' I
tU
RE DAYTIME BUNNINC LIGHTS EfLAY
HT/BI
I I
In
12
RED/ BLU
I I
ll
--t
8 SLU/BID
RE
t0
t1
T
!3
SYSIIM UGHI
,{
oorr,",rr.,ro
3
I I
||MoS|UZEn CONTNOL UNIT RECEIVEB BI(
uctrrscournoLu,'r" J l
BI BI
{ r-
G8N
V Y
GNfl/FEO
17 Y
GRI\ /NED
I I
I
r\
88A(E I FiUrD 2 , LTVEL [./ SWITCH
f'
I
F\ PANKNG ; } BNAXE
+./ swrTcH
'nddoM
i
G301
i
cl.1 G501
\,
22-72
J
DASH LIGHTS
COMEINATION SWIqI LIGHT
LEFT PAfiX*'IG LIG}IT
TTFT TRONT 3r0E MABKER LIG}IT
BIGHT PANKNG LIGIIT
FIGIIT FBONT SIDE MAfircF LJGHT l5w)
LEFT TAIILGl T
LEFT BEAF SIDE LJGHT
RIGHT RIAF SIDI I/IAFrc8 UCHT
NEHI I LICENSE IAILUOHI I PLAII I LIGNTS (twr2l | 8LI
BLI(
BL](
G301
G301
G552
I
22-73
Lights Exterior
CircuitDiagram- BrakeLights
UiDENHOOD FUSE/NEUYBOX SATIISY \ r!o7l15A) I | ,r-T-v--rrni'citr
22-74
CircuitDiagram- Back-upLights
UiDEN H@DFUSI/8EIAY 80)(
22-75
Lights Exterior
LightsControlUnit InputTest- Canada DaytimeRunning
w s T h e D R Li n d i c a t o lri g h ti n t h e g a u g ea s s e m b l y i l l c o m e o n w h e n y o u t u r n t h e i g n i t i o n w i t c ht o O N ( l l )w i t h t h e the lt headlightswitch off and the parkingbrakese1. should go off when you turn on the headlightswitch and release parkingbrake.lf it comes on at any other time, do the control unit input test. r N O T EW h e nt h e d a y t i m er u n n i n gl i g h t sa r e o n ,t h e h i g h b e a mi n d i c a t ow i l l g l o w a t h a l fi t s n o r m a li n t e n s i t y . : 1. Removethe driver'sdashboardlower cover (seepage 20-60). l 4 2 , D i s c o n n e c t t hle P c o n n e c t o r ( Af)r o m t h e d a y t i m er u n n i n gl i g h t s c o n t r ou n i t ( B ) .
RED/BLU RED/BLU GRN/BLK
GNN/BLK GRN/ORN
BLU/RED
RED/YEL
YEL/RED
Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf the terminalsare bent,loose orcorroded, repairthem as necessary, and recheckthesystem. ' lf the terminalslook OK, go to step 4.
22-76
4. Makethese input tests at the connector, .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the input tests prove OK,the control unit must be faulty. Replaceit. Cavity
Wire Test condition RED/BLU U n d e a l l r conditions
12
YEL/RE D BLK
o N( r )
lgnitionswitch
10
U n d e ra l l conditions BLK U n d e ra l l conditions REDI/EL C o m b i n a t i o n light switch ON

/ =f\\
'11
3
5
6 8
Combination light switch ON {iD), and dimmer switch inHIGH RED/BLK C o m b i n a t i o n light switch ON (iD), and dimmer switch inHIGH G R N / B L K C o mb i n a t i o n light switch ON (iD), and dimmer switch inHIGH G R N / O R NParkingbrake l e v e ro u l l e d B L U / R E DC o m b i n a t i o n l i g h ts w i t c hO F F
RED/B LU
Possible causeif resultis not obtained Blown No. 14 (40A)fuse in the under-hood fuse/relaybox B l o w nN o . 3 { 1 0 A ) f u s en t h e i under-dash fuse/relaybox A n o p e ni n t h e w i r e Checkfor voltageto ground: B l o w nN o . l 2 ( 7 . 5 A ) f u s en t h e i Thereshould be batteryvoltage. under-dash fuse/relaybox An open in the wire C h e c k o r c o n t i n u i t yo g r o u n d : . P o o rg r o u n d{ G 5 0 ' 1 ) f t . An oDenin the wire T h e r es h o u l db e c o n t i n u i t v . . P o o rg r o u n d( G 5 0 1 ) Checkfor continuityto ground: ' A n o p e ni n t h e w i r e Thereshould be continuitv. Checkfor voltageto ground: B l o w nN o . 1 5 ( 1 5 A ) u s ei n t h e f Thereshould be batteryvoltage. under-hoodfuse/relaybox Faultyheadlightrelay 2 Faultycombinationlight switch An open in the wire Connecta jumper wire between B l o w nb u l b No.3 andNo.1terminals. Faultylow beam cut relay ) B o t hh e a d l i g h t ( H I G H a n d s Faultycombinationlight switch h i g h b e a mi n d i c a t o lri g h t Poor ground (G50'l ) s h o u l dc o m eo n . An open in the wire Connecta jumper wire between . B l o w nb u l b . Faultycombinationlight switch N o . 5 a n d N o . 1 1t e r m i n a l s . . Poor ground (G50'1 (t H I G H s h o u l d ) R i g h th e a d l i g h ) . A n o p e ni n t h e w i r e c o m eo n . Checkfor voltageto ground: Thereshould be batteryvoltage. f C h e c k o r c o n t i n u l t yo g r o u n d t T h e r es h o u l db e c o n t i n u i t y . . Faultycombinationlight switch . P o o rg r o un d { G 5 0 1 ) . A n o p e ni n t h e w i r e
Test:Desired result
C h e c k o r c o n t i n u i t yo g r o u n d : f t There should be continuitv. Checkfor voltageto ground: Thereshould be batteryvoltage. Attachto ground: T h e D R Li n d i c a t o lri g h ts h o u l d c o m eo n . Attachto ground: T h e b r a k es y s t e ml i g h ts h o u l d c o m eo n .
WHT/BLU lgnitionswitch
o N0 r )
t5
GR N / R E D lgnition switch
o N( | | )
Faultyparkingbrakeswitch A n o p e ni n t h e w i r e F a u l t y e a d l i g hr e l a y s h t Short to ground A n o o e ni n t h e w i r e . B l o w nN o . 1 0 ( 7 . 5 A f u s e i n t h e ) under-dash fuse/relaybox . FaultyDRLindicator . A n o o e ni n t h e w i r e Faultybrakesystem indicator A n o p e ni n t h e w i r e
22-77
Exterior Lights
HeadlightAdjustment
2. Parkthe vehicle7.5 m (25 ft) away from a wall or a screen(A). Headlights becomevery hot during use;do not touch them or any attachinghardwareimmediately afterthey have beenturned off. 7.5m {25ftl
Beforeadiustingthe headlights: . Park vehicle a levelsurface. the on . Make are surethetire pressures correct. . Thedriveror someone who weighs sameshould the sit in the driver's seat.
'1. Cleanthe outer lens so that you can seethe center of the headlights(A).
3 . O p e nt h e h o o d .
22-78
HeadlightReplacement
T u r nt h e l o w b e a m so n .
5
'1.
Removethe front bumper (seepage 20-85).
Determineifthe headlightsare aimed properly. Verticaladjustment: Measurethe height ofthe headlights(A).The lights should reflect52 mm (2.'1 below headljght in.) h e i g h t( B ) .
2 . Disconnect connectors(A)from the headlight the (B).
6. lf necessary, adjustthe headlights local to requirements turning the verticaladjuster. by Removethe five mounting bolts,then removethe corner upper beam (C)and headlightassembly. Installin the reverseorder of removal. 5 . After replacement, adjustthe headlights local to requirements.
22-79
Exterior Lights
CombinationLight Switch Test/Replacement
1. Removethe driver's dashboardlower cover (seepage 20-60). 2. Removethe steeringcolumn covers(seepage 17-9). 6 l 3 , D i s c o n n e c t t hle P c o n n e c t o r ( Af)r o m t h e c o m b i n a t i o ni g h ts w i t c h( B ) .
4 . Removethe tlvo screws,then slide out the combinationlight switch. 5 . Inspectthe connectorterminalsto be surethey are all makinggood contact. . lf the terminalsare bent, looseor corroded,repair them as necessa a nd recheck ry, the system. .lftheterminalslookOK,checkforcontinuitybetweentheterminalsineachswitchpositionaccordingtothe tables. - lf the continuityis not as specified,replacethe switch. Light switch:
\ Telmint
Position OFF
Headlight switch
12
13
LOW
HIGH OFF
o-o-o-
Passingswitch
ON
Turn signalswitch: \ Terminal Position 2
10
11
LEFT
NEUTRAL RIGHT
----o
o--
22-80
Bulb Replacement
Headlight:
1. Disconnect 3P connector(A)from the headlight. the 1 . R e m o v e h e i n n e rf e n d e r( s e ep a g e2 0 - 1 0 2 ) . t Headlight{high/low): 60/55 W 2. Disconnectthe connectors(A) from the lights.
FrontTurn SignalLight: Parking Light:
Frontturn signallight: Parking light:
21W 5W
A-
-'-+l
f-rI )/
2. Removethe rubbercover (B).

Pullthe retainingspring (C)away from the bulb (D), then removethe bulb. Installa new bulb in the reverseorder of removal. Make sure the notchesin the bulb align with the t a b sl n t h e h e a d l i g h t . Turn the bulb sockets(B) 45'counterclockwise to removethem from the headlighthousing.
4 . Installthe new bulb(s)in the reverseorder of
removat.
22-81
Exterior Lights
TaillightReplacement
(see page20-86). 1 . Remove rearbumper the
2 . Open tailgate, disconnect connectors the and the 1. Open the hatch. 2. Removethe plastictrim.
HighMount BrakeLight Replacement
(A)fromthetaillight (B). Brako/Taillight; 2115W TurnSignal Light: 21 W Back-up Light: 21W

3. Disconnectthe connectors(A)from the high 2P m o u n tb r a k el i g h t( B ) . High Mounl BrakeLight: 5W x 5
=\\ ili--- _\ \
, r B ---'a \ . t \r
\
Removethe mounting nuts and bolts,then remove t h et a i l l i g h t . Turn the bulb socket45' counterclockwise to removethe bulb socket. When installingthe taillight.checkthe gasket;if it is replaceit. distortedor stayscompressed, After installingthe taillight.run water over the taillightto make sure it does not leak. Carefullyremovethe high mount brakelight. 5 . lnstallthe light in the reverseorder of removal.
'
22-82
License PlateLight Replacement

1 . Removethe hatch lower trim panel (seepage20-
Side Marker Light Replacement

pry 1. Carefully the light(A)outofthe rearbumper, (B) anddisconnect 2Pconnector fromthe light. the Becareful to damage rearbumper. not the
Side Marker Light:
p P u l l t h el i c e n s e l a l el i g h ta s s e m b l y u t . a n d o disconnect 2P connector(A) from the light. the LicensePlateLight: 5Wx2
5W
+tiP't \-J
,^f , t lo \
'[-J^
' f l ^
\==-^
"/
3 . S e p a r a t eh e l e n s( B )a n d h o u s i n g( C ) , h e n r e m o v e t t
the bulb.
4 . l n s t a l l t h e i g h ti n t h e r e v e r s e r d e ro f r e m o v a l . l o
(A) 2 . Remove bulbsocket by turningit 45' the counterclockwise. reolace bulb. then the
22-83
ExteriorLights
BrakePedalPosition Switch Test
1. Disconnectthe4P connector(A) from the brake pedal positionswitch {B).
SideTurn SignalLight Replacement

NOTE:Be careful nol to damagethe fender. 1 . P u s ht h e r e t a i n i n g p r i n g( A ) .a n d r e m o v et h e s i d e s t u r n s i g n a l i g h t( B ) , Side Turn Signal Light: 5W
Checkfor continuitybetweenthe No. 1 and No. 2 termtnals. . T h e r es h o u l db e c o n t i n u i t y h e n t h e b r a k ep e d a l w rs presseo. . Thereshould be no continuitywhen the brake pedal is released. Checkfor continuitybetweenthe No. 3 and No. 4 terminals{with cruisecontrol). T h e r es h o u l db e n o c o n t i n u i t y h e n t h e b r a k e w pedal is pressed. T h e r es h o u l db e c o n t i n u i t y h e n t h e b r a k ep e d a l w is released. lf necessary, adjustor replacethe switch,or adjust t h e p e d a lh e i g h t( s e ep a g e1 9 - 6 ) . 2. Disconnect 2P connector{C)from the light. the
22-84
TurnSignal/Hazard Flasher
COMBINATION LIGHT/TURN SIGNAL SWITCH page Test, 22-80 page Beplacement, 22-80 TURNSIGNAL INDICATOR LIGHTS (lnthegauge assembly) page BulbReplacement, 22'63
WARNINGSWITCH HAZARD page Test, 22-88 page Replacement, 22-88
TURNSIGNAL/HAZARD RELAY page Input Test, 22-87
FUSE/RELAY BOX UNDER.DASH
22-85
Diagram Circuit
'No20lr0A USA No.2{ :Cmada l50A)
UNDff HOOD FUSUftIIY 8OX
DASH Ut\toEB TUSVRILAY 8OX
fiIGHT T
INDICATON IIGHT 11.1W)
FBONT
!
22-86
InputTest Relay TurnSignal/Hazard

u b re s 1 . R e m o v e t h e t u r n i g n a l / h a z a r d l a y( A )f r o m t h e u n d e r - d a sfh s e / r e l a y o x ( B ) .
000i0!1000
00u!u0
Inspectthe relay and fuse/relaybox socketterminalsto be sure they are all makinggood contact . lf the terminalsare bent.loose,or corroded,repairthem as necessary, and recheckthesystem. . lf the terminalslook OK, go to step 3. Make these input tests at the fuse/relaybox. .lfanvtestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . l f a l l t h e i n p u t t e s t s r o v eO K , t h e t u r ns i g n a l / h a z a rrd l a ym u s t b e f a u l t y . e p l a c et R i p e
Cavitv
1
il Possible cause resultis not obtained Test: Desired result . P o o r r o u n dG 2 0 1 ) ( g Checkfor continuityto ground: . An ooenin thewire Thereshould be continuiw. ' Blown No. 19 (7.5A) (ll) fuse in the for voltageto ground: Check lgnitionswitch ON fuse/relaybox under-dash Hazard warning switch Thereshould be batteryvoltage. . Faultyhazardwarning switch OFF . A n o o e ni n t h e w i r e . Blown No. 5 {10A)fuse in the ground: warning switch Checkfor voltageto Hazard fuse/relaybox under-hood Thereshould be batteryvoltage. ON . Faultyhazardwarning switch switch OFF lgnition . An ooen in the wire . P o o rg r o u n d( G 2 0 1G 3 0 1 , 5 0 1 , , (l l ) G C o n n e c N o . 2 t e r m i n a l t oN o . 3 t l g n i t i o n w i t c hO N s G502,G553) terminal: and turn signal switch . Faultyturn signalswitch in Rightor Left position R i g h to r l e f tt u r n s i g n a l i g h t s . A n o D e ni n t h e w i r e s h o u l dc o m e o n . . P o o rg r o u n d( G 2 0 1G 3 0 1 , 5 0 1 , , G l C o n n e c N o . 2 t e r m i n a t o N o .3 t lgnitionswitch OFF G502,G553) Hazard warning switch t e r m r n a l : . Faultyhazardwarning switch w H a z a r d a r n i n gl i g h t ss h o u l d ON . An open in lhe wire c o m eo n . Tesl condition U n d e ra l l c o n d i t i o n s
22-87
HazardWarningSwitch Test
1 . Removethe centerpanel (seepage 20-62). 2 . Disconnect 10Pconnector(A)from the hazard the w a r n i n gs w i t c h( B ) .
3 . Pushout the hazardwarning switch from behind

t h e c e n t e rp a n e l( C ) . 4 . Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. lf the continuityis not as specified, replacethe bulb ( D )o r t h e h a z a r d a r n i n gs w i t c h . w
Termin6l
;;;-_-\
OFF ON
10
22-88
Entry Light ControlSystem

LIGHT/SPOTLIGHTS CEILING Test,page22-96 page22-96 Replacement,
REAR CEILING LIGHT page Test, 22-96 page Replacement, 22-96

FRONTPASSENGER'S DOORSWITCH
KEYLIGHT IGNITION page 22-91 Test,

IGNITIONKEY SWITCH lest, page22-91 DRIVER'SDOORSWITCH HATCHLATCHSWITCH Test,page22-97
AREA LIGHT CARGO page 22-97 Test, page Replacement, 22 97
22-89
EntryLightControlSystem
CircuitDiagram
'No.20({0A) USA UiIOTf,HOOD fUSE/8ELAY BOX
EiIIpN SMTqI
lGlHoTin illl 0N nd STAnT 0D
CEILING UGHT
Y I
I
\
DtrVTN'S DOOR
(NOB s!t/tTc8
Locx
ORIVEBS DOOR SWITCH
PASSTNGERS DOOB SWITCH
i9r"..d l
I
22-90
BU
l'
IGNIlx)N KEY SWtTCH
j
J
G()t
lgnition KeySwitch Test

NOTE:For more key-inbeeperinformation,referto the circuitdiagram (seepage 22-90)and input test (see page 22-921. When the ignition key is in the ignition switchthe multiplexcontrol unit sensesground through the closedignition key switch.When you open the driver's door, the multiplexcontrol unit sensesground through the closeddoor switch and soundsthe beeper. 1. Removethe steeringcolumn upper and lower c o v e r s( s e ep a g e ' 1 7 - 9 ) . the 2. Disconnect 6P connector.
lgnition Key Light Test

1 . Removethe steeringcolumn upper and lower covers(seepage 17-9). the Disconnect 6P connector,
i'
/.'
The LEDshouldcome on when power is connected to to the No. 6 terminal and ground is connected N o .5 t e r m i n a l . lf the LEDdoes not come on, replacethe ignition swrtch.
3 . Checkfor continuitybetweenthe No. 1 and No. 2

termrnars. . There should be continuitywith the key in the ignition switch. . Thereshould be no continuitywith the key removedfrom the ignitionswitch. replacethe lf the continuityis not as specfied, ignition switch.
22-91
EntryLightControlSystem
Control Unit Input Test
1. Beforetesting,trou bleshootthe m u ltiplex control system (seepage22-172). 2. Removethe dashboardlower cover. 3. Disconnect under-dash the fuse/relaybox connectors. NOTE:All connectors are wire side of femaleterminals.
UNDER.DASH FUSE/RELAY CONNECTORIl7PI BOX K
UNDEB-DASIJ FUSE/RELAY BOX CONNECTOR {,I2PI O
GRN/RED UNDEB.DASH FUSE/RELAY CONNECTOR{18PI BOX P
6),/18.
GRN LT GRN/REO UNOER.DASH FUSE/REI"AY BOX CONNECTOB I8PI X
,/13
8ED/WHT WHT/BLK UNDER.DASH FUSE/RELAY CONNECTOR {13PI BOX Y
YEL/RED 4 . Inspectthe connectorand socketterminalsto be sure they are all making good contact. . lf the terminalsare bent, looseorcorroded, repairthem as necessary, and recheck system. the . lf the terminalslook OK, go to step 5.
22-92
I
make stilldisconnected, theseinputtestsat theconnector' 5. Withtheconnectors . lf anvtestindicates problem, the the then recheck system find andcorrect cause, a . lf allthe inpultestsproveOK,go to step6. Cavitv K2 result Test:Desired Test condition Wire between K2 the for allconditions Check continuity 8LU/ORN lJnder receiver and terminal the keyless No. unit5Pconnector 2 terminal: There shouldbecontinuitv. to GRN/RED C e j l i n gl i g h t s w i t c h i n Attach ground: light(s)should comeon. Ceiling middle position. Possible cquseil resultis not obtained
An open in the wire
o7
fusein the underhood BlownNo.3 (7.5A) Blownbulb light Faulty ceiling An ooenin the wire in ElownNo.3 (7.5A)fuse the underhood fuse/relay box ignition light(LED) key Faulty An ooenin the wire
X8
to r WHT/BLK U n d e a l l c o n d i t i o n s Attach ground: key comeon. lgnition lightshould
on connectors the under-dash box, theseinputtestsat the appropriate to the 6. Reconnect connectors the underdashfuse/relaV and make fuse/relay box. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. .lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder'dashfuse/relaYboxassemblY Cavitv P18
Wire RED
Test condition
H a t c ho p e n
result Test:Desired
C h e c kf o r v o l t a g et o g r o u n d : Thereshould be 1 V or less.
H a t c hc l o s e d Q3
to Check voltage ground: for There should 5 v or more. be

C h e c kf o r v o l t a g e t o g r o u n d : Thereshould be 1 V or less.
GRN
Driver's dooropen Driver's doorclosed
o4
door LTGRN/ Passenger's BED Passenger's door croseo RED^vHT lgnitionkey inserted intothe ignition
lgnitionkey removed from the ignition
X5
for to Check voltage ground: Thar. shoul.l 5 V or more. he to Check voltage ground: for be Thereshould 1 V or less. voltage ground: to Checkfor There should 5 Vor more. be Check voltage ground: for to There should 1 V or less. be
C h e c kf o r v o l t a g et o g r o u n d : Thereshould be 5 V or more.
Posq!!!c sq!!ej1!.9!!!!j Poorground(G552) latchswitch Fauhy hatch An openinthewire Faultyhatchlatchswitch Shorttooround Faulty drlver's doorswitch An oDen thewire in doorswitch Faulty driver's ' ' . . passenger's switch door Faulty An oneninthewire passenger's switch door Faulty Shor o oround Poorground(G401) key ignition switch Faulty An ooenin the wire
F a u l t yi g n i t i o n k e y s w i t c h Short to ground
Y8
doorlock YEURED Driver's knob switchlocked Driver's doorlock

kn6h cwirch Inl6cke.l
Check voltage ground: for to be There should 1 V or less. to Check voltage ground: for There should 5 V or more. be
Poorground{G501) Faulty driver's doorlockknobswitch An ooenin thewire Faulty driver's doorlockknobswitch Shortto oround
22-93
InteriorLights
CEILING LIGHT/SPOTLIGHTS page Test, 22-96 page Replacement, 22-96 REAR CEILING LIGHT page Test, 22-96 page Replacement, 22-96
v
HATCHLATCHSWITCH Test,page22-97 CARGO AREALIGHT fesl, page 22-97 page22-97 Replacement,
$
22-94
CircuitDiagram
STAB ctu[G
LIGHT
MUITIPLEX c0NTlot UIIIT
HATCH LATClI swtTcH
22-95
Interior Lights
CeilingLight/SpotlightsTest/ Replacement
1 . Turn the ceiling lighvspotlights switchesOFF. 2 . Carefullypry off the lens {A) wilh a small screwdnver, CeilingLight: Spotlight: 5W 5Wx2
RearCeilingLight Test/ Replacement

1 . Turn the light switch OFF. 2 . Carefullypry offthe lens (A) with a small screwdriver. CeilingLight: 8 W
x 1-0 mm 5x1.0mm
\A
3. Removethe two screwsand the housing(B). 4 . D i s c o n n e c h e 4 Pc o n n e c t o( C )f r o m t h e h o u s i n g . tt r 5. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
\ Terminal -----_l
il
A.
3. Removethe two mounting screws. 4. Disconnect 3P connector(B)from the housing the
{c).
P."lil;-
Checkfor continuitybetweenthe terminalsin each switch positionaccording the table. to

Terminal Position OFF 1
oFF celL,"ca,c", MIDDLE isoottiohts\ 'uir a}-+4 oN
re
-o -o
SPOTLIGHTS l I C e i l i n qi o h t r o F F - - i
ON
OFF
o
G-
(.F.O
MIDDLE ON
o
G -@- O
ON
L
OFF
lf the continuityis not as specified, checkthe bulb. l f t h e b u l bi s O K , r e p l a c eh e c e i l i n gl i g h v s p o t l ih t s . t g
lf the continuityis not as specified, checkthe bulb. l f t h e b u l b i s O K , r e p l a c eh e r e a rc e i l i n gl i g h t . t
22-96
CargoArea Light Test/Replacement Hatch Latch Switch Test

1 . Open the hatch. Carefullypry out the cargo area light (A). CargoArea Light: 5W the Disconnect 2P connector{A) from the hatch l a t c h( B ) , '1. Open the hatch. Removethe hatch lower trim panel (seepage 20-
s3).
Disconnect 2P connector(B)from the light. the Checkfor continuitybetweenthe No. 1 (+) and N o . 2 ( ) t e r m i n a l sT h e r es h o u l db e c o n t i n u i t y . . lf there is no continuitv,checkthe bulb. lf the bulb is OK, replacethe cargo area light. 4 . Checkfor continuitybetweenthe No. 1 and No. 2 terminals. . Thereshould be continuitywith the hatch open . Thereshould be no continuitywith the hatch ctoseo. lf the continuityis not as specified,replacethe hatch latch.
22-97
AudioSystem
AUOIO UNIT Removal/f nstallation, 22-100 Daoe pa-ge Connector Terminals, 22-101 RIGHT DOOB TWEETER page Replacement, 22-102
ROOFANTENNA page22-'1 Replacement, 03
ANTENNA SUB LEAD
DRIVER'S DOOR SPEAKER page Replacement, 22 102
LEFT REAR SPEAKER page Replacement, 22-102 RIGHT REAR SPEAKER page Replacement, 22-102
ANTENNA LEAD
22-98
CircuitDiagram
' No.20ioA) :USA
--------F
/ 8AT \
\ f!tACC /
WHT/FED
ACC HoTinACC lllmd0Nllll
AUDIO UflIT
DRIVER'S DOORSPEArcF
IEFITWEETER
PASSE!{GIF'S DOOB SPEAKES
SIGIITTWEETEB
LEFTFEAB SPEA(I8
NrcBTREAF SPEAKEF
22-99
AudioSystem
Audio Unit Removal/lnstallation
NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe dashboardand related parts. 1. Make sure you have the anti-theft code for the radio, then write down the frequencies the radio's for presetbuttons. 2. Removethe driver's dashboardlower cover (see page20-59). 3. Removethe two mounting bolts,then pull out the centerpanel (A). Removethe heatercontrol panel (seepage 21 38). R e m o v e h e f o u r m o u n t i n gb o l t sa n d t h e a u d i ou n i t t from the radio brackets.
!\,
7 . I n s t a l l t h e u d i ou n i ti n t h e r e v e r s e r d e ro f a o removal,and note these items: . Make sure the audio unit and A/C connectorsare pluggedin properly,and the antennalead is connectedproperly. . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets.
\v
4 . Disconnect audio connector(B)and antenna the lead (C),heatercontrol panelconnectors(D) and HAVCpush switch assembly(E),then removethe center panel.
22-100
Audio Unit Connector Replacement

Cavity 1
2 3
4 5
Wire YEUG RN YEURED

PNK
Connects to
Roof antenna ACC (Power) Not used Not used R i o h tr e a rs D e a k e(r+ I
6
7 8
BLU^/vHT
GRN/YEL
(+) LeftrearsDeaker
Front oassenqer's door sDeaker {+)/Riqht tweeter (+) Driver'sdoor speaker{ + )/Lefttweeter (+ ) Liqhts on siqnal Constantpower Not used Not used Not used
9 10
11
GRN/BLK RED/BLK WHT/RED
12
14
ta to
Notused BLU/YE L BLU/BLK GRY/RED LT GRN RED BLK

R i o h tr e a rs o e a k e ( r ( Left rear sDeaker door speaker( )/Riqhttweeter Front passenqer's { ( Driver'sdoor sDeaker )/Lefttweetr ( controller Dashliqhts briqhtness
11 18 19
20
( Gr o u n d G 5 0 3 )
AUDIOUNIT2OP CONNECTOR
22-101
AudioSystem
SpeakerReplacement
DoorSpeaker:
1 . R e m o v e h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) . t 2. Pullthe top of the speaker{A) straightout, just enoughto releasethe upper clip. lf you pull the speakerout too far, you will damagethe lower clips (C).Then lifi the speakerstraightup to release the lower clips.
Rear:
1 . Removethe speakercover (A).
2. Removethe three screws,then disconnect 2P the

connector(B)from the speaker(C).
3. Disconnect 2P connector(B),and removethe the speaKer.
Tweeter:
Carefullypry the tweeter (A) out of the mirror mount cover,then disconnect the 2P connector(B)from the tweeter.
'-----d
22-102
RoofAntennaReplacement
1. Removethe rear part of headliner(seepage20-54). 2, Disconnect antennalead connector(A) and 1P the connector(B)from the roof antenna(C).
3. Removethe mounting nut and the antenna.
22-103
RearWindow Defogger
*:Rearwindow defoggerswitch is built into the heatercontrol panel. UNDER.HOOD FUSE/RELAY BOX
t
REAR WINDOWDEFOGGER RELAY page Test, 22-51
REAR WINDOW DEFOGGER SWITCH+
NOISE CONDENSER page CapacityTest, 22 107
REAR WINDOWDEFOGGEB page 106 Function Test, 22
page22 106 Defogger Wire Repair,
J
22-104
Circuit Diagram
;Hl}lj.'fl,1fl1fi"
( BEATERcoNrf,oLpANrL \/ \iP
L
T f,rAiwrxDow ,74 DEfOGGES I SWrcfl

INDIATOR ILEDI
22-105
Rear WindowDefogger
Function Test
NOTE: . Be carefulnot to scratchor damagethe defogger wires with the testerprobe. . Beforetesting,checkthe No. 11 (30A)fuse in the fuse/relaybox and No. '14('10A) under-hood fuse in the under-dash fuse/relaybox. 1. Checkfor voltage betweenthe verticaI dividersand body ground with the ignitionswitch and defogger switch ON. There should be voltageas shown. . lf there is no voltage.checkfor: - faulty defoggerrelay. - an open in the BLK,BLK,/YEL, YEL/BLK or wire. - taulty heatercontrol panel. . lf there is batteryvoltage,goto step 2.
Defogger Wire Repair

NOTE:To make an effectiverepair,the brokensection m u s t b e n o l o n g e rt h a n o n e i n c h . 1. Lightly rub the area aroundthe brokensection(A) with fine steelwool, then clean it with alcohol.
2. Carefullymask above and below the brokenportion

of the defoggerwire (B)with transparent tape {C). Mix the silverconductivepaint thoroughly.Using a small brush,apply a heavy coat of paint extending about 1/8 inch on both sidesof the break.Allow 30 minutesto dry. 6V
2 . Checkfor continuitybetweenthe negativeterminal

( B )a n d b o d y g r o u n d . lf there is no continuity,checkfor: . a n o p e n i n t h e B L Kw i r e . . Poor body ground at the window antennacoil mounting bolt. Touchthe voltmeterpositiveprobe to the halfway point of each defoggerwire. and the negative probeto the negativeterminal, Thereshould be about 6 V with the ignitionswitch and the defoggerswitch ON. . l f t h e v o l t a g e s a s s p e c i f i e d , e d e f o g g e r w l r es i th i
Checkfor continuityin the repairedwire. 5 . Apply a secondcoat of paint in the same way. Let it dry 3 hours before removingthe tape.
oK.
. lf the voltage is not as specified,repairthe defoggerwire. - l f i t i s m o r et h a n 6 V , t h e r ei s a b r e a ki n t h e n e g a t i v e a l fo f t h e w i r e . h - lf it is lessthan 6 V, there is a breakin the positivehalf of the wire.
22-106
NoiseGondenser Test Capacity

1 . Removethe right rear side trim panel (seepage 2066). Disconnect 2P connector(A)from the noise the condenser. Noise condenser capacity: 0.47 a 0.09 microfarads Wiresideol female terminals
Use a commerciallyavailablecondensertester. Connectthe condenser tester probes,and the measurecondensercapacity.

4. lf it is not within the specification, replacethe noise
condenser.
22-107
Moonroof
MOONROOF SWITCH f e $ ,p a g e 2 - 1 1 2 2 R e p l a c e m ep a , e 2 - 1 2 ntg 2 T e s tp a g e 2 2 - 1 1 2 . page Replacement, 20-41

MOONROOFLIMIT SWITCH Test,page22-113
\|.
MOONROOF CONTROL UNIT page Input Test, 22-'l10
MOONROOFAUTO-STOPSWITCH Test,page22'113
MOONROOF OPEN RELAY GRN/YEL, GRN, I lwire colors: BLK LRED/YEL, andYEUGRNI page Test, 22-51 MOONROOF CLOSE RELAY GRN/BLK, GRN, I lwire colorsr BLK LGRN/WHT, and YEL/GRN I page Test, 22-51
22-108
CircuitDiagram
UNDIR OAS8 FUSE/NILAY MX No.20lOAl:US No.20150 :Canda )
A Clos.dfom lh ruto nop poshio. to lh doed porhion B Clo!.d in th lilt or do3.d poilion C : Clo!.d in anyop.n (io! riltl posirion D Clos.d in th tilt po6iiion
BL|(
+
G50t
I
G5{1
8LI
22-109
Moonroof
MoonroofControlUnit Input Test
(r p 1 . R e m o vte eh e a d l i n e s e e a g e 0 - 5 4 ) . h 2 (A) 2 . Disconnect 5Pconnector fromthecontrol the unit(B).
GRN/WHT
LT GRN
Wire sideof female erminals t
RED/YEL BLK Inspectthe connectorand socketterminalsto be sure they are all making good contact. . lf the terminalsare bent, looseor corroded,repairthem asnecessary. and recheckthesystem. . lf the terminalslook OK, go to step 4.
$ J
22-110
4- Reconnect moonrool the control unit5Pconnector, makethese and inputtests attheconnector. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the inputtestsproveOK,go to step5.
Caviiy
Wire
Test condition Underallconditions
Test:Desiredresuh Check continuity ground: for to There should continuity. be

C h e c kf o r v o l t a g e t o g r o u n d : There should be baftery voltage.
Possible caus6if result is not obtained Poorground(G501) An openin the wire BlownNo.6 (7.54)tuse the under in dashfuse/relaybox An openin the wire Poorground(G501) Faultymoonroof auto-stop switch An openinthewire Shorttoground Faulty moonroof auto-stop switch
5
,l
BLK
YEUGRN lgnition switch (ll) ON
LT GRN
lgnition switch (ll) ON Moonroofclosed

Moonroof open
C h e c kf o r v o l t a g et o g r o u n d : Thereshould be 1V or less.
Check voltage ground: for to Thereshouldbe batteryvoltage.
Disconnectthe moonroof control unit5Pconnector, makethese;nputtests the connector and at 'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the inputtests proveOK,the control unit mustbefaultv. Replace it.
Cavity
Wire
Test condition
Test:Desired rosult Connect jumperwire between a No, 3 and No.5 terminals. Moonroof motorshouldrun (opened).
Possible causeif resultis not obtained (G501) Poorground BlownNo.6 (7.5Aifuse the under' in dashfuse/relaybox BlownNo.7120Alfuse inthe under dashfuse/relay box Faulty moonroof openrelay Faulty moonroof closerelay Faulty moonrooJ motor A no p e n ; nh e w i r e t
RED//EL lgnition switch lll) ON
cRN,4/VHTl g n i t i o n s w i t c h O N ( l l )
Connect jumperwire between a No. Poorground(G501) 2 and No.5 terminals. BlownNo.6 (7.5Aifuse the under in I\,4oonroof motorshouldrun {closed). dashfuse/relay box ElownNo.7 (20A)fuse the under in dashfuse/relaybox Faulty moonroof openrelay Faulty moonrool closerelay Faultymoonroof motor An openin thewire
22-111
Moonroof
Switch Test/Replacement
'1 . Carefullypry the moonroof switch (A) out of the headlin r. e
Motor Test
r 1 . R e m o v e h e h e a d l i n e( s e ep a g e2 0 - 5 4 ) . t 2. Disconnect 2P connectorfrom the moonroof the motor.
5P 2. Disconnectthe connector(Blfrom the moonroof swtrcn. 3. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
Terminal \ --\ Pi.iti.. 1 4 5
3. Checkthe motor by connectingpower and ground accordinoto the table.

\ Terminal
pl.iri""---\
OPEN CLOSE
\7
(,
CLOSE TILT
OPEN
FO
lf the motor does not run. replaceit,
-o
NOTE:See closingforce check(seepage20-48)for motor clutchtest.
4 . lf the continuityis not as specified.replacethe moonroof switch.
22-112
Limit Switch Test

l . Removethe headliner(seepage 20-54).
Auto-stopSwitch Test
1 . Removethe headliner(seepage 20-54). 2 . Disconnect 2P connectorfrom the moonroof the auto-stopswitch.
2. Disconnect 4P connectorfrom the moonroof the

limit switch.
Checkfor continuily betweenthe terminalsin each switch positionaccordingto the table. NOTE: Turn the motor by hand with the wrench.
Terminal \ Position 1
Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. NOTE: . Turn the motor by hand with the wrench, . The auto-stoppositionis about 145 mm (5.75in.) from fully closed.
Terminal Position 1 2
TILT OPEN CLOSE
o-
o-
Botwoen AUTO-STOP andCLOSE

Between OPEN and AUTO.STOP
lf the continuityis not as specified,replacethe moonroof limit switch.
lf the continuityis not as specified,repairor replace the auto-stopswitch.
22-113
PowerMirrors
POWERMIRRORS Function Test,page22-116 page20-15 Replacement, ActuatorTest,page22-117 page22-1 18 ActuatorReplacemenl,
q3:.[
'\ \, -,''
j-' ',i. it .i/

'
---\,--,-'/
-:,)
-lo'
-o t:
,.'7
POWER MIRROR and MIRRORDEFOGGER SWITCH lesl, page22-111 page22-1 17 Replacement,
$r22-114
CircuitDiagram
'1 UiIDTS rcOD R]SE/RLAY 8OX ih.a i|0At :Usa
rcilmoN s1/vtTcH
UiD$ DASH N'SUnIIAY 8OX
22-115
PowerMirrors
FunctionTest
1. Removethe driver's pocket(seepage 20-60). 2. Reach through the pocketopening,and push out the power mirror switch (A). Left mirror 7 . C o n n e ctth e N o . 2 t e r m i n a t o t h e N o . l 0 t e r m i n a l , l a n dt h e N o . 5 ( o r N o . 1 2 )t e r m i n a t o t h e N o . 6 l t e r m i n a w i t h j u m p e rw i r e s .T h e l e f tm i r r o rs h o u l d l t i l t d o w n ( o r s w i n gl e f t ) w i t ht h e i g n i t i o n w i t c hO N s
, \
flr).
. l f t h e m i r r o r d o e sn o t t i l t d o w n ( o r d o e sn o t s w i n g (or left),checkfor an open in the GRN/WHT BLU/ Wl-lT)wirebetweenthe left mirror and the 13P conneclor,lf the wire is OK, checkthe left m irror actualor. . lf the mirror neithertiltsdown nor swings left. repair he BLU/BLK ire. t w . l f t h e m i r r o r w o r k sp r o p e r l yc h e c k t h e i r r o r , m
SWIICN,
RED B
Right mirror
W i r es i d eo f temale erminals t
WHT/RED RED/BLK RED/YEL
co r 3 . D i s c o n n e c t t h e ' 1 3 P n n e c t o( B )f r o m t h e s w i t c h . 4. Choosethe appropriate test basedon the symptom: . Both mirrors don't work, go to step 5. . Left mirror doesn'twork, go to step 7. . Rightmirror doesn'twork, go to step 8. . Defoggerdoesn'twork (Canada), to step 9. go Both mirrors
8 . C o n n e ctth e N o . 2 t e r m i n a l t ot h e N o . 1 1t e r m i n a l , l a n d t h e N o . 5 { o r N o . 1 3 )t e r m i n a t o t h e N o . 6 t e r m i n a w i t h j u m p e rw i r e s .T h e r i g h tm i r r o rs h o u l d l tilt down (or swing left)with the ignition switch ON ( ). . lf the mirror does not tilt down (or does not swing left),checkfor an open in the GRN/WHT(or WHT/ R E D ) w i r e e t w e e n h e r i g h tm i r r o ra n d t h e 1 3 P b t connector. lf the wire is OK, checkthe right mirror actuator. . l f t h e m i r r o r n e i t h e r t i l t s d o w n o r s w i n g sl e f t , repalrthe RED|YEL wire. ' l f t h e m i r r o r w o r k sp r o p e r l yc h e c k t h e i r r o r . m swrrcn. Defogger(Canada)
5. Checkfor voltage betweenthe No. 2 terminal and s b o d y g r o u n dw i t h t h e i g n i t l o n w i t c hO N ( l l ) . There should be batteryvoltage. . lf there is no batteryvoltage,checkfor: - b l o w n N o . 1 4 ( 1 0 A ) u s ei n t h e u n d e r ' d a s h f fuse/relaybox. - a n o p e ni n t h e B L K r y E L i r e . w . lf there is batteryvoltage,goto step 6. 6. Checkfor continuitybetweenthe No. 6 terminal a n d b o d yg r o u n d . T h e r es h o u l db e c o n t i n u i t y . . lf there is no continuity,checkfor: - a n o p e ni n t h e B L Kw i r e . - p o o r g r o u n d( G 5 0 1 ) . . lf there is continuity,checkboth mirrors i n d i v i d u a l l a s d e s c r i b e dn t h e n e x tc o l u m n . y i
w 9 . C o n n e ctth e N o . 1 a n d N o . I t e r m i n a l s i t h a jumper wire, and checkfor voltage betweenthe N o . 2 t e r m i n a lo f t h e m i r r o rc o n n e c t oa n d b o d y r ground.Thereshould be batteryvoltageand both s m i r r o r ss h o u l dw a r m u p w i t h t h e i g n i t i o n w i t c h
oN t).
. l f t h e r ei s n o v o l t a g eo r n e i t h e r w a r m s p , c h e c k u for: - a n o p e n i n t h e B L K I / E Lo r o R N w i r e . - b l o w n N o . 1 4 ( ' l 0 A ) f u s en t h e u n d e r - d a s h i fuse/relaybox. . l f o n l y o n e f a i l st o w a r m u p , c h e c k : - its defogger. - p o o r g r o u n d( G 5 0 1G 5 0 2 ) , . l f b o t hw a r m u p , c h e c k t h e d e f o g g e r s w i t c h .
22-116
PowerMirror Switch Test

1 . Removethe driver'spocket(seepage 20-60). 2 . Reachthrough the pocketopening,and push out the power mirror switch (A).
Power Mirror ActuatorTest

1 , Removethe door panel (seepage 20-4). 2 . Disconnect 6P connector(A) from the power the ( m i r r o ra c t u a t o r B ) .
3 . Disconnect 13Pconnector(B)f rom the switch. the

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. Mirror Switch: Checkactuatoroperationby connectingpower and ground accordingto the table.
2
CF
\.f9.-'"1L
Position
10
11
12
13
Terminal \ Position
UP
--o oo
TILTUP TILTDOWN SWINGLEFT
oG
-c) o-
o
-o
!
o
@
o o
@
oRIGHT
SWING RIGHT
-o o -o
UP
4. lf the mirror fails to work properly,replacethe mtrror actuator. DefoggerTest {Canada); 5. Checkor continuity etweenhe No.1and No.2 f b t terminalsof the 6P connector. Thereshould be continuity.lf there is no continuity,checkfor an open circuit.
"[T
RIGHT
Defogger Switch (Canadal:

\ Te.minal
il;;;
ON
OFF
tlf
5 . lf the continuityis not as specified,replacethe power mirror switch.
22-117
PowerMirrors
PowerMirror Actuator Replacement
'1. Removethe power mirror (seepage 20-15). 8. Removethe three Torx screws,and separate lhe actuator(A)from the mirror housing{B).
2 . Carefullyremovethe mirror holderfrom the mirror h o u s i n gG e n t l yp u l l i t o u t b y h a n d( s e ep a g e2 0 - 1 5 ) . .
3 . Disconnect connector. the 4 . Removethe cover,then removethe two Torx

screwsfrom the mirror connector. 5 . Recordthe terminal locationsand wire colors. 6 . Cut the wire harnesswith the wire cutter.
9 . Routethe wire harness{A) ofthe new actuator t t h r o u g ht h e h o l ei n t h e b r a c k e ( B ) .
7. Removethe three screws,and separate the mirror housinqfrom the mirror base.
J
22-118
10. lnsertthe terminalsinto the connectorin the o r i g i n a a r r a n g e m e na s s h o w nb e l o w . l t
MIRROR MIRROR LEFT CONNECTOR RIGHT CONNECTOR
*:Canada 'l'1.
in Reassemble the reverseorder of disassembly. Be carefulnot to breakthe mirror holderwhen reinstalling to the actuator. it
1 2 .R e i n s t a l l t h m i r r o ra s s e m b l y n t h e d o o r . e o
tJ.
Operatethe power mirror to ensuresmooth operation.
22-119
Horns
UNDER-HOOD FUSE/RELAY BOX
HORN RELAY page Test, 22-51
.-
:.."'
HORNSWITCH fesl, page22-122
HORNS Test,page22 122 B e p l a c e m e np a g e2 2 1 2 2 t,
CABLEREEL page23,119 Replacement,
*r
22-120
Diagram Gircuit
22-121
Horns
Horn Test/Replacement
1 . Removethe front bumper {seepage 20-85). Disconnect 1Pconnector(B),and removethe the horn (A).
Horn Switch Test

1 . Removethe steeringcolumn covers(seepage '179). Disconnecl dashboardwire harnessB 5P the connector(A) from the cable reel (B).
../.. |...:...., .
3 . Testthe horn by connectingbatterypower to the

terminal (A) and ground to the bracket(B).The horn s h o u l ds o u n d .
Using a jumper wire . connectthe dashboardwire harnessB 5P connector(A) No. 2 terminal to body g r o u n d. . lf the horns sound,goto step 4. . l f t h e h o r n sd o n o t s o u n d , h e c k t h e s et e m s : c i - Horn relay - N o . 7 ( 1 5 A ) f u s en t h e u n d e r - h o o f u s e / r e l a y i d box - Horns (see page 22-122). - An open in the wire 4. lf it fails to sound, replaceit.
22-122
I
wire B 4. Reconnect dashboard harness 5P the the connector anddisconnect hornswitch {A), (B). positive connector 1P wheelto the 1 . Usinga jumperwire,connent steering b o d yg r o u n d . the the between hornplateandthe 8 . Close contacts plate. contact . lf the hornssound, replacethe steering column. . l f t h eh o r n s d o o t s o u n dr,e p l a c e t hh o r na n d n e plate. contact
Using a jumperwire, connectthehorn switch positive1Pconnector(B)to ground . lf the horns sound,go to step 6. . l f t h e h o r n sd o n o t s o u n d ,r e p l a c e t h e c a b lr e e l . e the 6 , Reconnect horn switch positive1Pconector(B).
22-123
PowerWindows
I
al.l ' -f..--.-L - . : :
POWER WINDOWRELAY Iest, page 22-51
FRONT PASSENGER'S WINDOW MOTOR page Test, 22-132
DRIVER'S WINDOWMOTOR page Test, 22-129

POWERWINDOW MASIER SWITCH InputTest.Daqe22.126 Test,page22--128 page22-133 Replacement,
FRONTPASSENGER'S WINDOW SWITCH I n D u T e s l ,p a q e2 2 - 1 3 0 t page 22-132 f est, page22-133 Beplacement,
22-124
CircuitDiagram
'No.20il0A) : USA
8OI UNOERHMO FUSI/8tLAY
tGt'TtoitswtTcfi
--+r
U/
o'F
BTTYEL
lGl HOT 0N {ll) in tnd STABT {llll
WHT/BU
22-125
PowerWindows
MasterSwitch Input Test
NOTE: powerwindowcontrol The unitis builtintothe power windowmaster switch, andit onlycontrols driver's the windowoperations. 1. Remove windowmaster the switch{A)(seepage22-133). (B) 2. Disconnect 14P the connector from the master switch.
GRN/WHT
3. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf theterminals are bent, looseorcorroded, repairthem as necessary, and recheckthesystem. . lf the terminalslook OK, go to step 4.
22-126
maketheseinputtests attheconnector. 4. Withthe connectorstill disconnected, .lfanytestindicatesaproblem,findandcorrectthecause.thenrecheckthesystem. . l f a l l t h e i n p u t t e s t s r o v eO K ,g o t o s t e p5 . p
Cavity 10
14 11
Wire BLK
Test condition
result Test:Desired
Possible causeif result is not obtained . P o o r r o u n dG 5 0 ' 1 ) g { . An openin thewire

) B l o w nN o . 6 ( 7 . 5 A f u s e i n fuse/relay the under-dash box tuse Blown No. 22,23 l2OA) fuse/ in the under-dash relay Dox Faultypower window relay P o o rg r o u n d( G 2 0 1 ) An open in the wire . Faultydriver'swindow motor . An open in the wire
U n d e ra l l c o n d i t i o n s
Checkfor continuityto grouno: Thereshould be continuity. Checkfor voltageto ground: Thereshould be battery voltage.
GRN^,^/HT l g n i t i o n w i t c hO N ( l l ) s
GRN/BLK
RED/YEL C o n n e ctth e N o . RED/B LK
'l'1 and N o . 7 t e r m i n a l sa n d t h e , N o , 4 a n d N o . 1 4t e r m i n a l s , and turn the ignition switch
Checkfor driver'swindow molor operaflon: I t s h o u l dr u n ( t h ed r i v e r ' s w i n d o w m o v e sd o w n ) .
oN flr).
3 B L U / R E DConnectthe No. 2 and No. 1 Checkfor passenger's
t e r m i n a l sa n dt h e N o . 3 , , BLU/WHT a n d N o . 1 0t e r m i n a l sa n d t u r n t h e i g n i t i o n w i t c hO N s window motor operation: I t s h o u l dr u n ( t h e passenger's window moves oown). window Faultypassenger's motor Faultypassenger's window swatch An open in the wire
fir),
5. Reconnect 14Pconnectorto the switch,and performthe following input tests. the .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the input tests prove OK, the control unit must be faulty. Replace power window masterswitch. the
Cavity
Wire
Test condition
Test: Desired result
Possible cause if result is not obtained . Faultydriver'swindow molor . A n o p e ni n t h e w i r e
13
ORN
C o n n e ctth e N o . 1 1 a n d N o . 7 t e r m i n a l sa n d t h e , N o . 4 a n d N o . 1 4t e r m i n a l s , and turn the ignition switch
o N0 r ) .
Checkfor voltagebetween t h e N o . 1 3a n d N o . 1 4 termtnals: About6Vshouldbe with the driver's indicated window motor running.
22-127
Driver'sWindow Motor Test

Motor Test:
1 . Removethe door panel (seepage 20-4).
Pulser Test:
1 . Reconnect 4P connectorto the driver'swindow the motor, and reconnect 20Pconnectorto the the power window masterswitch. Connectthe test leadsof a voltmeterto the No, 3 and No. 4 terminalsof the driver'swindow motor 4P connector. Run the motor usingthe masterswitch.The voltmetershould read about 6 V. lf the voltageis not as specified, checkfor an open in the wires. lf the wires are OK, replacethe driver's window motor.
Disconnect 4P connector(A)from the driver's the window motor.
Testthe motor in each directionby connecting batterypower and ground accordingto the table. When the motor stops running,disconnectone lead immediatelv.
\ Terminal
il;;'-\
UP
DOWN
e
@
o e
4 . lf the motor does not run or fails to run smoothly, replacerL
22-129
PowerWindows
Passenger's Window Switch Input Test
1 . Removethe switch panel (seepage 20-4). 2 . Disconnect 5P connector(A)from the switch (B). the
'' "'"1.
BLU/WHT
GRN/BLK
Inputthe connectorand socketterminalsto be sure they are all making good contact. . lf theterminals are bent, looseor corroded,repairthem as necessary, and recheckthesystem. . lf the terminalslook OK, go to step 4.
4 . Reconnect the connector, and using a back probe, makethese input tests at the connector.lf any test indicatesa
problem,find and correctthe cause,then recheck the svstem,
Cavitv 3
Wire Test condition G R N / B L K lgnitionswitch ON

{l l )
Test:Desired result
Checkfor voltageto grouno: There should be battery voltage.
BLD,A/VHT lgnitionswitch ON
( ) At the master window switch, pressand hold down the passenger's switch BLU/RED lgnitionswitch ON (||) At the master window switch, p u l lu p a n d h o l d the passenger's switch
Checkfor voltageto ground: Thereshould be battery voltage.
Possible causeif resultis not obtained B l o w nN o . 6 ( 7 , 5 A ) f u s en t h e i under-dash fuse/relaybox B l o w nN o . 2 2 { 2 0 A ) f u s en t h e i under-dash fuse/relaybox Faultypower window relay An open in the wire P o o rq r o u n d( G 2 0 1 ) Faultymasterwindow switch An open in the wire
Checkfor voltageto grouno: Thereshould be battery voltage.
Faultymasterwindow switch An open in the wire
22-130
5. Disconnect 5Pconnector, make the and theseinputtests. Cavitv

1
Wire Test condition Test: Desired result RED Connectthe No. 2 Checkfor passenger's RED/BLU t e r m i n a t o t h e N o . window motor operation:lf l
Possible causeil resultis not obtained Faultymaster'swindow switch An open in the wire 1 t e r m i n a l a n dt h e should run (the passenger's , Faultypassenger's window N o .4 t e r m i n at o l window moves down), moror. t h e N o . 5 t e r m i n a l , There should be battery a n dt u r n t h e voltage. ignition switch ON {ll),and pressthe down button on the power window masterswitch for the passenger's window.
6. lf allthe tests prove OK, the switch must be faulty. Replace it.
22-131
PowerWindows
Passenger's Window Switch Test
1 . Removethe switch panel (seepage 20-4).
Removethe power window switch (A) from the doorpanel. Disconnect 5P connector(B)from the the passenger's power window switch.
Terminalside of m a l et e r m i n a l s
Passenger's Window Motor Test

1 . Removethe passenger's door panel (seepage204). Disconnect 2P connector(A)from the the passenger's power window motor.
tfiTtTtT;Etl '-r--r-,Jl l'

Testthe motor in each directionby connecting batterypower and ground accordingto the table. When the motor stops running,disconnect one l e a di m m e d i a t e l y .
\ \Torminal Poiition\ 1 Terminal Dl*;;;__\ 1
Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.
UP DOWN
UP
OFF
I o
o
o
DOWN
lf the motor does not run or fails to run smoothly, reptacert.
lf the continuityis not as specified,replacethe swtlcn.
22-132
MasterSwitch Replacement
'1. Removethe door grip (seepage 20-4).
Passenger's Window Switch Replacement

1 . Removethe door grip {seepage 20-4). 2 . Removethe power window switch (A) from the o o o rp a n e r .
2 . Removethe power window masterswitch (A)f rom t h e d o o rp a n e l .
3 . Disconnect 14Pconnector(B)from the switch. the

Removethe three screwsand the switch from the switch panel.
3 . Disconnect 5P connector(B)from the switch. lhe

4 . Removethe two screwsand the switch from the
switch panel.
22-133
Wipers/Washers
WINDSHIELD WIPER ARMS and LINKAGE page22-'145 Replacement,
WIPER/WASHER SWITCH Test,page22-140 Replacement,page 140 22
WINDSHIELD WIPER MOTOR Test,page22-'143 page22-145 Replacement,
INTERMITTENT WIPER CIRCUIT co u l l nt h em u l t i p l e x n t r o l n i t ) page Input Test, 22-138
22-134
WASHER TUBES page Replacement, 22-147
WASHER RESERVOIB page Replacement, 22'146
WASHERFLUIDLEVELSWITCH{Canada) TesI,page22-144 page22-144 Replacement,
REAR WINOOW WASHER MOTOR page Test, 22-144 page Replacement, 22 146
WINDSHIELD WASHER MOTOR fesl, page 144 22 page Beplacement, 22-146
CONDENSER page22 107 CapacityTest,
REAR WINDOWWIPER INTERMITTENT CONTROL UNIT page Input Test, 22'138
REAR WINDOWWIPER MOTOR f e$, page22-143 page 146 Replacement, 22
BEARWINDOWWIPER ARM page Replacement, 22 146
22-135
Wipers/Washers
CircuitDiagram Windshield
\ 1
IGNITIONSWITCN
'7{
HOOD FL]SE/8ELAY BOX UNOEN
U-I^--
F;^--il
I -':-;--u,Hr-
6\
o,f-''*""
MULTIPIIX coiln0L UNIT
L\'
\,!
22-136
CircuitDiagram RearWindow
No2olaoAl :USA
-;i BATTERY r--------------l No'g,soA, ro2o. | (-;1_=l----_--_fww{"-'
UI\IOIF H@OFUSE/RELAY MX
GNMOIIISW|ICH
/,^1\
\+y
I
lErHorb0Ni||l
andsra8r 0
ffAn w$tDow wtPEE INTE$'ITTEI'IT C{)NNOL UI'/IT
f---------------
li
22-137
Wipers/Washers
Rear WindowWiperIntermittent Gontrol Unit InputTest
1 . Remove rightrearsidetrim panel the {seepage20-51).
(A) the connector fromthe rearwindow.wiDer intermittent control unit(B). 2 . Disconnect 20P
Wire side of femaleterminals LTGRN/REO
WHT/RED WHT/RED
LT GRN
LT GRN/BLK
goodcontact. Inspect connector socket the and terminals be suretheyareall making to . lf theterminals bent,loose are orcorroded, repairthem necessary, recheckthe as and system. . lf theterminals lookOK,go to step4.
22-138
\
4. With the connectorstill disconnected, maketheseinput tests at the connecrors. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. ' lf all the input tests prove OK, the control unit must be faultv. Replace it.
Cavitv
Wire GRN BLK
Tesl condition lgnitionswitch ON
flr)
10
6 U n d e ra l l conditions
Test: Desired result Checkfor voltageto ground: Thereshould be battery voltaqe.
Possible causeif resultis not obtained
. B l o w n o . 9( 1 0 A ) f u sie t h e N n under-dash fuse/relay box . An openin thewire

Poor ground (G553) A n o p e ni n t h e w i r e B l o w nN o . 9 ( 1 0 A ) u s ei n t h e f under-dash fuse/relaybox Faultyrearwlndow wiper/ washer switch A n o p e ni n t h e w i r e
Check continuity for to grouno: Thereshould continuitv. be

Checkfor voltageto ground: Thereshould be battery vortage. Attachto groundl The rearwindow wiper motor s h o u l dr u n . Attachto ground: The rear window wiper motor s h o u l dr u n . Checkfor voltageto ground: Thereshould be battery voltage.
WHT/RED lgnitionswitch ON
( l l )a n d r e a r window washer switch ON lgnition switch ON ( l l )a n d r e a r window wiper switch ON lgnition switch ON
LT GRN/ RED LT GRN
flr)
20 LT GRN/ BLK
lgnitionswitch ON (ll)
B l o w nN o . 9 ( 1 0 A ) f u s en t h e i under-dash fuse/relaybox Faultyrearwindow wiper motor An open in the wire B l o w nN o . 9 ( 1 0 A ) u s ei n t h e f under-dash fuse/relaybox Faultyrearwindow wiper motor A n o D e ni n t h e w i r e
22-139
Wipers/Washers
Wiper/Washer Switch Test/Replacement
dashboard lowercover{seepage20-60). 1 . Remove driver's the (seepage17-9). Remove steering column covers the (A) switch Disconnecl 14P the connector fromthewiper/washer {B)
Removethe two screws,then pull out the wiper/washerswitch. Inspect the connectorterminalsto be sure they are all making good contact. . lf the terminalsare bent, looseor corroded,repairthem as necessary, and recheck system. the .lftheterminalslookOK,checkforcontinuitybetweentheterminalsineachswitchpositlonaccordingtothe tables, - lf the continuityis not as speciiied,replacethe switch.
Terminal Position OFF tNl LO
14
l2
12
11
o- -{ oo-
HI Mist switchON
Washor 3witch ON
22-140
ControlUnit InputTest
l . Beforetesting,troubleshoot the multiplexcontrol system lsee page22-jj2).
2 . Removethe dashboardlower cover, 3 . Disconnect under-dash the fuse/relaybox connectorsB, G, J, X and y

NOTE: connectors wire side of female terminals. All are UNDER-DASH FUSE/RELAY BOX CONNECTOR B I6PI UNDER.DASH FUSE/RELAY BOX CONNECTOR G {1OP) UNDER-DASH FUSE/RELAY BOX CONNECTOR J {8PI
WHT/BLU
l-,1l l
l-rl
\ BLU/RED
BLU/WHT
lslrlzlol
UNDER.DASH FUSE/RELAY BOX CONNECTORI8PI X
l-,1- llTtl F_j-JF-#
1 4 1 5 1 76 l 8 l
BLU/BLK 4. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf the terminalsare bent, looseor corroded,repairthem as necessary, and recheckthesystem. . l f t h e t e r m i n a l s r e O K ,g o t o s t e p5 . a
(cont'd)
22-141
Wipers/Washers
ControlUnit Input Test (cont'dl
the and make these input tests at the connector. 5. Reconnect connectors, .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . l f a l l t h e i n p u t t e s t s p r o v e O K , t h e m u l t i p l e x c o n t r o ln i tm u s t b e f a u l t y .R e p l a c eh e u n d e r - d a sfh s e / r e l a y o x u b t u assembly. Cavity J4 Test condition U n d e ra l l conditlons BLK U n d e ra l l conditions WHTiBLU lgnitionswitch ON { l l )a n d w a s h e r switch ON
Wire BLK
Test:Desired result
C h e c ko r v o l t a g eo g r o u n d : f t There hould e1V orless. s b Checkfor voltageto ground: T h e r es h o u l db e 1 V o r l e s s . Checkfor voltageto ground: Thereshould be battery vortage. Checkfor voltageto ground: There should be battery voltage.
Y6 BI
E'0
BLU/RED lgnitionswitch ON
( l l )a n d w i p e r switch OFF(wiper motor stopped)
G7
BLUA/VHT lgnitionswitch ON
( l l )a n d w i p e r si n p a r kp o s i t i o n
Checkfor voltageto ground: There should be battery voltage. Checkfor voltageto ground: There should be battery voltage.
x1
B L U / B L K l g n i t i o n w i t c hO N s
( l l )a n d w i p e r switch in INT
Possible if cause resultis not obtained . P o o rg r o u n d( G 5 0 1 ) . AnoDeninthewire . Poor ground (G502) . A n o D e ni n t h e w i r e Blown No. 20 (20A)fuse in the fuse/relaybox under-dash Faultywiper/washerswitch An open in the wire Blown No. 20 (20A)fuse in the under-dash fuse/relaybox Faultywiper/washerswitch w F a u l t y i n d s h i e l d i p e rm o t o r w An open in the wire i B l o w nN o . 2 0 ( 2 0 A ) f u s en t h e under-dash fuse/relaybox w F a u l t y i n d s h i e l d i p e rm o t o r w An ooen in the wire i B l o w nN o . 2 0 ( 2 0 A ) f u s en t h e under-dash fuse/relaybox Faultywiper/washerswitch An oDenin the wire
L
22-142
Wiper Motor Test

Windshield:
1. Open the hood,and carefullyremovethe cap nuts and the wiper arms. Make surethey do not touch the hood. 2, Removethe hood seal andcowl cover. e 3 . D i s c o n n e c t t h5 P c o n n e c t o( A ) f r o mt h e m o t o r ( B ) . r
RearWindow:
1. Open the hatch,and removethe hatchtrim panel (seepage 20-53). 2. Disconnectthe4P connector{A) from the motor {B).
Testthe motor by connectingbatterypower and ground accordingto the table. lf the motor does not run or fails to run smoothly,replaceit. Testthe motor by connectingbatterypower and ground accordingto the table. lf the motor does not run or fails to run smoothly,replaceit.
Terminal P-"-,tion 1 Telminal Battery Connected
LOWSPEED HIGHSPEED
5 . Testthe wiper motor park switch by connectingan a n a l o g o l t m e t e r e t w e e nh e N o , 5 ( + ) t e r m i n a l v b t a n d g r o u n d ,a n d r u n t h e m o t o ra t l o w o r h i g hs p e e d . T h ev o l t m e t e r h o u l di n d i c a t e 2V a n d 4 V o r l e s s s 1 alternately. it does not, replacethe motor. lf
4 . Testthe wiper motor park switch by connectingan a n a l o g o l t m e t e r e t w e e n h e N o .4 ( + ) t e r m i n a l v b t and ground, and run the motor. The voltmeter should indicate12 V and 4 V or lessalternatelv. it lf does not, reolacethe motor.
.l
J
22-143
Wipers/Washers
Washer MotorTest
1. Partiallyremovethe right inner fender (seepage 20-'t021. (A) 2. Disconnect 2P connectors from the washer the motors (B). 1 . Partiallyremovethe right innerfender (seepage 20-102). Disconnect 2P connector{A) from the washer the level switch.
WasherFluidLevelSwitch Test/ ReplacementCanada
Testthe washer motor by connectingbattery power and ground accordingto the lable.
3 . Removethe washer fluid level switchfrom the

Terminal
Battery
Connected
reservoir. N O T E F l u i dm a y f l o w o u t t h e o p e n i n g . : 4 . Checkfor continuitybetweenthe terminalsin each to float (B) positionaccording the table.
4. lf the motor does not run, replaceit,

Position
Terminal
FLOATUP FLOATDOWN
o- ---o
lf the continuityis not as specified.replacethe swtTcn.
22-144
WindshieldWiper Motor Replacement

1 . Open the hood. Removethe nuts (A) and the w i n d s h i e l d i p e ra r m s ( B ) . w 5 . S c r i b ea l i n e ( A )a c r o s s h e l i n ka n d w l n d s h i e l d t wiper linkageto show the original adjustment. ( S e p a r a t eh e w i n d s h i e l d i p e r l i n k a g e B )f r o m t h e t w w i p e r m o t o r( C ) . (3.2ksf.m,23 lbt.ft)
N.m
Removethe hood seal and cowl cover. Djsconnect 5P connector(A)from the wiper the motor (B).
9.8 N.m (1.0
Installin the reverseorder of removal,and note lhese items. Apply multipurposegreaseto the moving parts. Beforereinstalling wiper arms,turn the wiper the switch ON, then OFFto returnthe wiper shaftsto the oark oosition. lf necessary, replaceany damagedclips, Checkthe wioer motor oDeration.
R e m o v e h e b o l t s( C ) ,m o v ew i n d s h i e l d i p e r t w s l i n k a g e s s e m b l y D ) t o w a r d h e p a s s e n g e r 's i d e a t { of the vehicle until it slidesoff of the pin (E),then removethe assembly.
22-145
Wipers/Washers
RearWindow Wiper Motor Replacement
1 . Open the hatch,and removethe hatchtrim panel (seepage 20-53). Removethe mounting nut (A),the wiper arm (B) and the specialnut (C).
WasherReservoir Replacement
1 . Partiallyremovethe right inner fender.
(A) Disconnect 2P connectors irom the washer the motors (B) and level switch (Canada).
A 9.8N.m {1.0 kgf.m, 7.2rbf.ftl B 8 N.m 10.8 kgt.m, 6.0rbf.ft)
3 . Disconnecl tubes (C)from the washer motors. the

Removethe three bolts (A) and the washer reservoir(B).
the Disconnect 4Pconnector remove three the {A), thenremove rearwindow the mounting bolts(B), wiDermotor(C).
B
9.8 N.m
A 9.8 N.m (1.0kgt.m, 7.2 tbf.tt)
kgt.m,7.2lbf ftl {1.0
4 , Installin the reverseorder oI removal,and note
these items. Apply multipurposegreaseto the moving parts. the Beforereinstalling wiper arm, turn the wiper switch ON, then turn OFFto returnthe wiper shaft to the Darkoositon. lf necessary, replaceany damagedclips. Checkthe wiDer motor operation.
22-146
WasherTubesReplacement
1 . Remove rightinnerfender the {seepage20-102). 2 . Remove washer the nozzles clips, and thenremove tubes. the
<=>
r"-----------='
L-!
--==':?-
(cont'd)
22-147
Wipers/Washers
(cont'dl WasherTubesReplacement
. C t f 3 . I n s t a l il n t h e r e v e r s e o r d e r or e m o v a lT a k ec a r en o t t o p l n c h t h e w a s h e r t u b e s . h e c k h e w a s h e ro p er a t i o n .
22-148
Accessory PowerSocket
Circuit Diagram
AccessoryPower Socket Test/ Replacement
power socket(A) out 1 . Carefullypry the accessory from the centerlower cover. Disconnect 2P connector(B)from the socket. the
Inspectthe connectorterminalsto be sure they are all making good contact. . lf the terminalsare bent, loose orcorroded, repairthem as necessary, and recheck the system. . lf the terminalslook OK, go to step 4.
4 . Turn the ignition switchACC (l), and checkfor
voltage betweenthe No. 'l and No. 2 terminals. . Thereshould be batteryvoltage. . lf there is no baneryvoltage,checkfor: - p o o r g r o u n d{ G 5 0 2 ) . - an open in the wire. - b l o w n N o . 1 8 ( 1 5 A ) f u s en t h e u n d e r - d a s h i fuse/relaybox.
22-149
DoorLockSystem Keyless/Power
Test,page22-161 p P r o g r a m m i n g ,a g e2 2 - 1 6 1
DOOR DRIVER'S LOCKSWITCH page Test, 22-160

lnput Test,page22-153
RECEIVER UNIT
IGNITIONKEYSWITCH Test,page22-91
LOCK ACTUATOR PASSENGER'S DOOR page 158 22 Test,
UNIT MUTIPLEX CONTROL page 22-155 Input Test,
DRIVER'SDOORSWITCH
LOCK DRIVER'S DOOR SWTICH ACTUATOR/KNOB page Actuator Test, 22-158 page 160 Test, 22 Knob Switch
HATCHLATCHSWITCH Test,page22-97 HATCHLOOKACTUATOR Test,page22 159 PASSENGER'S DOORSWITCH
22-150
CircuitDiagram
UNOEE DASH fUSE/SELAYBOX
FUSE/RETIY 8OX UiDENHooD
-)
/ 8Ar \
cl-
lG1,/
lG1 in0N(lllaidSTAfft(llll HoT
l3 IT
I
UI'IDE8 DASH f USE/RETAY 80X MULTIPUX CONTNo! Uflfi
BLK
G502
000R Loc(KNOE
tl
xtY \"2
t'-F> Li___JDBt!'t8'S 000R 100( ACTUATOB
PASSTNGtrS 0008100( ACTUATOi
t
(cont'd)
22-151
Keyless/Power Door LockSystem

CircuitDiagram(cont'dl
\
HOOD UNDEN FU8E/BELAY MX l\br t15a) FUSE
HORN SWTCH
t"t J
UNDEN FUSE/8ELAY DAS}I 8OX
Y,,,
mMErNAllofl LIGHI SWITCH DFIVES'S DOOB TOCK 6WTCH
Df,IVEB'S 0008 swtrcH plo'.d l
tG tltot\t IGY stvrTcH
swlrol
HATCH LATCH
22-152
Keyless Receiver Unit Input Test

1. Removethe driver'sdashboardlower cover (seepage 20-59). 2 . R e m o v e h e a u d i ou n i t ( s e ep a g e2 2 - 1 0 0 ) . t 3. Disconnect 5P connector(A)from the keylessreceiverunit (B). the
WHT/RED Wiresideof female terminals e l 4 . I n s p e c t t h e c o n n e c t o r a n d s o c k e t t e r m i n a l s t o b e s u r e t h e y a rm a kli n gg o o dc o n t a c t . . lf the terminalsare bent.Iooseorcorroded, repairthem as necessary, and recheckthesystem. . lf the terminalsare OK, go to step 5.
t
(cont'd)
22-153

Keyless Receiver Unit Input Test (cont'dl
With the connectorstill disconnecled, makethe input test at the connector. .lftestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf the inputtest provesOK, goto step 6. Cavity
Wire Test condition BLU/ORN U n d e ra l l

conditions
Test:Desired result
Checkfor continuitybetween t h e N o . 2 t e r m i n a la n dt h e N o . 2 t e r m i n a lo f t h e under-dash fuse/relaybox connectorK { 17P). There should be continuitv.
Possible cause resultis not obtained il An open in the wire
Reconnect 5P connector,and make these input tests at the connector. the .lfanytestindicalesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the inputtests prove OK, replacethekeylessreceiverunit.
Cavitv
1
Wire BLK YEL
Test condition U n d e ra l l conditions lgnition switch
Test:Desired result
Checkfor voltageto ground: There should be 1 V or less. Checkfor voltageto ground: There should be battery voltaqe. Checkfor voltageto ground: There should be battery voltaqe.
o N( | | )
WHT/RED U n d e a l l r conditions
Possible causeif resultis not obtained . Poor ground (G502) . An oDenin the wire Blown No. 10 {7.5A)fuse in lhe fuse/relaybox under-dash An ooen in the wire ' B l o w nN o . 9 ( 1 0 A ) u s ei n t h e f fuse/relaybox under-hood . A n o o e ni n t h e w i r e
22-154
Control Unit Input Test

1. Beforetesting,trou bleshootthe m u ltiplexcontroI system (seepage 22-172). 2, Removethe dashboardlower cover. 3. Disconnect under-dash the fuse/relaybox connectors. NOTE:All connectors are wire side of female terminals. FUSE/RELAY BOX UNDER.DASH CONNECTOR{1itPl C UNDER.DASH FUSE/RELAY BOX CONNECTOR F I12P) BOX UNDER-OASH FUSE/RELAY CONNECTOR J {8PI
BLU FUSE/RELAY BOX UNDER.DASH CONNECTOR K {17PI BLU/ORN
BLU/RED UNDER.DASH FUSE/RELAY BOX CONNECTOR M Il2PI FUSE/RELAY BOX UNDER.OASH P I18PI CONNECTOR
YEL/BLKYEL/BLK YEL YEL

UNDER.DASH FUSE/RELAY BOX CONNECTOR(8P) O
YEL YEL/BLK FUSE/RELAY BOX UNDER.DASH Y {13P) CONNECTOR
UNDER-DAsH FUsE/neLeY sbx X (8P) CONNECTOR
,/1,/ 3
GRN
LT GRN/RED
RED/WHT
WHT/BLK YEL/RED WHT/GRN WHT/BLU
4. Inspectthe connectorand socketterminalsto be sure they are all making good contact. . lf the terminalsare bent, loose orcorroded, repairthem as necessary, and recheckthesystem. . lf the terminalslook OK, go to step 5.
(cont'd)
22-155

Control Unit Input Test (cont'dl
5. Reconnect connections the underdash all to fuse/relay and maketheseinputtestsat the appropriate box, connectors the under-dash on fuse/relay box. 'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the inputtests proveOK,goto step6.
Cavitv
c1'l
Wire 8LU
Test condition
Underall conditions
Test:Desiredresult Aftach ground: to Parking, marker, license side platelights, tajllights and should comeon. Attach ground: to Headlights should comeon. Check voltage ground: for to There shouldbe battery voltage. for Check voltage ground: to Thcreshoulnhc 1 V or lpqs
Attachto ground: The horns should sound.
Possible use result notobtained is ca if B l o w n o . 2( 1 5 A ) f u si e t h eu n d e r N n hoodfuse/relaybox Faulty taillight relay Faulty under-dash fuse/relay box
An onen in rhc wire
BLU/BEO Underall conditions
B l o w n o .1 5o r 1 7( 1 5 A ) f u si e t h e N n underhood fuse/relay box '1or 2 Faulty headlight relay

An ooen in the wire
J2
WHT/RED Underall conditions
B l o w n o . 9( 1 5 A ) f u si e t h eu n d e r N n hoodfuse/relay box
An oncn in thc wirc
BLK
J6 OBN
Underall conditaons
Under allconditions
Poorground(G501) An ooenin the wire BlownNo.7 (15A)fuse the under in hoodfuse/relay box Faulty hornrelay Faulty horns
An 6nen in rhe wire
J7 P18
Under all conditions
for Check voltage ground: to There should battery be voltage. Check voltage ground: for to There shouldbe 1 V or less. Check voltage groundl for to Thereshoul.l 5 V or more he
C h e c kf o r v o l t a g et o There should be 1 V C h e c kf o r v o l t a g e t o Thereshould be 5 V g.ound: or less ground: or more.
ElownNo.16(20A)fuse the under in hood fuse/relay box

An oocn in ihc wi.c
BED
H a t c ho p e n
Poorground(G552) Faultyhatchlatchswitch
An oncn in rhc wirF
H a t c hc l o s e d
Faulty hatch latch switch
GBN
Driver's dooropen Driver's doorclosed
o4
LT GRN /RED
Passenger's open door Passenger's closed door
for Check voltage ground: to There should 1 V or less. be

C h e c kf o r v o l t a g e t o g r o u n d l There should be sVor more C h e c kf o r v o l t a g e t o g r o u n d : There should be 1 V or less. C h e c kf o r v o l t a g e t o There should be 5 V C h e c kf o r v o l t a g e t o There should be 1 V C h e c kf o r v o l t a g e t o Ihere should be 5 V C h e c kf o r v o l t a g e t o There should be 1 V ground: or more. groundl or less. groundl or more. groundl or less.
X5
REDAVHT
lgnition key inserted into the ignitionswhch
Y1
lgnition removed key from rhe ionition switch WHT/BLK Driver's doorlockknob switchunlocked Driver's doorlockknob
Y8
YEURED Driver's doorlockknob

switch locked Driver's doorlockknob switch unlocked
. Faulty driver's doorswitch . An ooenin thewire Faulty driver's doorswitch Shortto oround passenger's switch Faulty door An ooeninthewire . Faulty passenger's switch door . Shortto oround Poorground{G401) Faulty ignition switch key An ooeninthewire Faulty ignition switch key Shortto oround (G50'l) Poorground Faulty driver's doorlockknobswitch An openin thewire Faulty driver's doorlockknobswitch Shortto oround (G50'l) Poorground Faulty driver's doorlockknobswitch
An oncn inihewire
Y10
WHT/GRN Drtver's door lock switch

unlocked
C h e c kf o r v o l t a g e t o g r o u n d : There should be 5Vor more C h e c kf o r v o l t a g e t o g r o u n d l There should be 1 V or less. C h e c kf o r v o l t a g e t o g r o u n d : Therc shorl.l be 5V or m6rp C h e c kf o r v o l t a g e t o g r o u n d : 'l There should be V or less. C h e c kt o r v o l t a g e t o g r o u n d : There should be 5Vor more
Driver's doorlockswitchin Y12
WHT/BLU Driver's doorlockswitch

locked Driver's doorlockswitchin
' Faulty driver's doorlockknobsw;tch . Shorr oround to (G501i Poorground Faulty driver's doorlockswitch An ooenin the wire Faulty driver's doorlockswitch Short to o rolrnd Poorground(G501) Faulty driver's doorlockswitch An oDenin the wire
F a u l t yd r i v e r ' s d o o r l o c k s w i t c h
22-156
6. Disconnect M, P,K andJ connectors the fromthe underdash fuse/relay and make theseinputtestsat the connectors. box, .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. .lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder-dashfuse/relayboxassembly. Cavitv K2
Wire Test condition BLU/ORN Underall conditions
M7 M9 M6 M8 P16 P17
YEUBLK
YEL
Connect terminal [,47 J7 to and lMgl terminal, Mg J4 lMTl terminalto Connect terminal M6 J7 to and lMSl terminal, M8 J4 lM6l terminalto Connect terminal P17 J7 to and lP16l terminal, P16 o l P 1 7 l t e r m i n a l tJ 4
Test:Desiredresult for Check continuitybetween the K2terminal andthe keyless receiver 5Pconnector unit disconnected: There should continuitv. be Check actuator operation: Thedriver's doorlockactuator should lock lunlockl operation: Check actuator The passenger's lock door should lock iunlockl actuator Check actuator operation: The hatchlockactuator should lock lunlockl
Pdsiblo c6useif resultis not obtaind
An openin the wire
Faulty driver's doorlockactuator An openin the wire passenger's lockactuator Faulty door An openin the wire . Faultyhatchlockactuator . An openin the wire
YEUBLK
YEL
YEL YEUBLK
22-157
I
Keyless/Power DoorLockSystem
Door LockActuatorTest
Driver's door:
1 . R e m o v e h e d r i v e r ' s o o r p a n e l( s e e p a g e 2 0 - 4 ) . t d 2. Disconnect 2P connectorfrom the actuator. the 2. Disconnect 2P connectorfrom the actuator, the
Passenger's door:
s 1 . R e m o v e h e p a s s e n g e r 'd o o r p a n e l( s e e p a g e 2 0 t 4).
Checkactuatoroperationby connectingpower and ground accordingto the table.To preventdamage to the actuator,apply batteryvoltageonly momenlanry.
\ Terminal 'l
Checkactuatoroperationby connectingpower and ground accordingto the table.To preventdamage to the actuator,apply batteryvoltageonly momenlanty.
\ Terminal P."I,l.;--\
ilil;lll
LOCK UNLOCK
e e
e e
LOCK UNLOCK
e e
e o
4 . lf the actuatordoes not operateas specified,
reprace rr.
lf the actuatordoes not operateas specified, reprace [,
22-158
Hatch Lock Actuator Test

1. Open the hatch. 2. Removethe hatch lower trim panel lsee page 2053). 3. Disconnect 2P connectorfrom the hatch lock the actualor.
Terminalside of m a l et e r m i n a l s
J
4. Checkactuatoroperationby connectingpower and ground accordingto the table.To preventdamage to the actuator,apply batteryvoltage only momentaflty.
\Terminal Po.irion\ 1
LOCK UNLOCK
22-159
Keyless/Power DoorLockSystem
Door LockKnob Switch Test
page20-4). 1 . Remove driver's the doorpanel(see Disconnect 3Pconnector fromthe actuator. the
Door LockSwitch Test

'1. Removethe driver'sdoor panel (seepage 20-4). Removethe two mounting screwsand the door lock switch.
Tr
NO
I
. t i
I
I
. l
( . 1
Checkfor continuitybetweenthe No. 1 and No. 2 term ana ls. . Thereshould be continuitywhen the door lock position. knob switch is in the LOCKED . Thereshould be no continuitywhen the door lock position. knob switch is in the UNLOCKED Checkfor continuitybetweenthe No. 2 and No. 3 termtnals. . Thereshould be continuitywhen the door lock position. knob switch is in the UNLOCKED . Thereshould be no continuitywhen the door lock position. knob switch is in the LOCKED 5. lf the continuityis not as specified,replacethe door locl(actuator.
Checkfor continuitybetweenthe terminals. . Thereshould be continuitybetweenthe No. 1 and No. 2 terminalswhen the door lock switch is position. in the LOCKED . Thereshould be continuitybetweenthe No. 2 and No. 3 terminalswhen the door lock switch is position. in the UNLOCKED lf the continuityis not as specified.replacethe door lock switch.
22-160
Transmitter Test
NOTE: . l f t h e d o o r su n l o c k o r l o c k w i t h t h e t r a n s m i t t e ru t b, the LEDon the transmitterdoes not come on, the LED is faulty. Replace transmitter, the . l f a n y d o o r i s o p e n ,y o u c a n n o t l o c k t h e d o o r w i t h t h e transmrtter. . lf you unlocked the doors with the transmitter,but do not open any of the doors within 30 seconds, the doors relockautomatically. . The doors do not lock or unlockwith the transmitterif the ignition key is insertedin the ignition switch. 1. Pressthe lock or unlock buttonfive or six times to resetthe transmitter. . lf the lockswork, the transmitteris OK. . lf the locksdon't work, go to step 2. 2. Open the transmitterand checkfor water damage. . lf you find any water damage,replacethe transmrtter. . lf there is no waterdamage,go to step 3. 3. Replace transmitterbattery(A)with a new one, the and try to lock and unlockthe doors with the transmitterby pressingthe lock or unlock button five or six times. . lf the doors lock and unlock,the transmifteris OK. . lf the doors don't lock and unlock,go to step 4.
Transmitter Programming
Storingtransmittercodes: The codes of up to three transmitterscan be storedin the keylessreceiverunit memory. (lf a fourth code is stored.the code which was input first will be erased.) NOTE:lt is importantto maintainthe time limits betweenthe steps.Make sure the doors and the hatch are closed. 1 . T u r nt h e i g n i t i o n w i t c hO N ( l l i . s 2. Within 1 to 4 sec.,push the transmitterlock or unlockbutton with the transmitteraimed at the receiverin the multiplexcontrol unit behindthe d r i v e r ' s i d eo f t h e d a s h . s 3. Within 1 to 4 sec.,turn the ignition switch OFF. 4. Within 1 to 4 sec.,turn the ignition switch ON (ll). 'l 5. Within to 4 sec.,push the transmitterlock or unlock buttonwith the transmitteraimed at the receiverin the multiplexcontrol unit behindthe d r i v e r ' s i d eo f t h e d a s h . s 6. Within 1 to 4 sec.,turn the ignitionswitch OFF. 7 . W i t h i n4 s e c . t u r n t h e i g n i t i o n w i t c hO N ( l l ) . , s 8. Within 1 to 4 sec.,push the transmitterlock or unlockbuttonwith the transmifteraimed at the receiverin the mupltiplexcontrol unit behindthe driver's side of the dash. 9. Within 1 to 4 sec.,turn the ignition switch OFF, '10. W i t h i n4 s e c . t u r n t h e i g n i t i o n w i t c hO N ( l l ) . , s 1 1 . W i t h i n1 t o 4 s e c . ,p u s ht h e t r a n s m i t t elro c ko r unlockbutton with the transmitteraimed at the r e c e i v e irn t h e m u l t i p l e x o n t r o lu n i t b e h i n d h e c t driver'sside of the dash. y 1 2 . C o n f i r m o u c a n h e a r t h es o u n do f t h e d o o r l o c k actuators. Within 1 to 4 sec.,push the transmitter lock or unlockbutton again, 13, Within 10 sec.,aim the transmitters(up to two additionalones)whose codesyou want to store at the receiver, and pressthe transmitterlock or unlockbuttons. Confirmthat you can hear the sound of the door lock actuatorsafter eachtransmittercode is stored. 1 4 . T u r nt h e i g n i t i o n w i t c hO F F ,a n d p u l l o u t t h e k e y . s '15. Confirm proper operationofthe transmitter.
4 . Reprogram transmitter, the then try to lock and unlockhedoors. t . l f t h e d o o r sl o c k a n du n l o c k . t h e t r a n s m i t t e rO K . is . l f t h e d o o r sd o n ' t l o c k a n du n l o c k r e p l a c e t h e , transmitter.
22-161
lmmobilizer System
INOICATOR LIGHT page 22 63 Bulb Replacement,
ECM page 11-4 Replacement, known-good testing, for Substitute p a g e1 1 - 5
UNIT.RECEIVER IMMOBILIZER CONTROL page Troubleshooting, 22-165 page Replacement, 22-167
TRANSPONDER (8uiltintothe ignition key)
22-162
SystemDescription
The vehicleis equippedwith an immobilizersystemthat will disablethe vehicleunlessthe proper ignition key is used. This system consistsof a transponderlocatedin the ignition key, an immobilizercontrol unit-receiver, indicator an l i g h t ,a n d t h e E C M . When the key is insertedin the ignition switch and turned to the ON {ll) position,the immobilizercontrol unit-receiver sendspower to the transponderin the ignition key.The transponder then sendsa coded signal backto the immobilizer control unit-receiver which then sendsa coded signalto the ECI\4. IMMOBILIZER CONTROL UNIT.RECEIVER
KEYCYLTNDER iEl'JUiliii'tlun"oona"|.r
lf the proper key has been used,the immobilizerindicatorlight will come on for about 2 seconds, then go off. lf the wrong key has been used or the code was not receivedor recognized the unit,the indicatorlight will come by on for about 2 seconds, then it will blink until the ignition switch is turned OFF. lf the ignition switch is turned OFF,the indicatorwill blinkfor about 5 secondsto signalthat the unit has reset correctly, then the indicatorwill go off. lf the customerhas lost his key,and cannot startthe engine,contactHondaCustomerRelations.
IMMOBILIZER INDICATOR LIGHT BLINKING PATTERN:
IGNITIONSWITCH
ON OFF
PROPER KEY INSERTED
INDICATOR LIGHT
ON
WRONGKEY INSERTED
INDICATOR ON LIGHT OFF
(| i.,
22-163
lmmobilizerSystem
CircuitDiagram
'
t
No20(LAl r USA
UNDTR rcOD FUSE/RELAY 8OX
rGNtTt0i/ swlrcH
lct HoT 0N{ll) in .ndSIAnT l|l)
F G N 8ELAY1
YEUBIJ(
0R8
itAWStY
tct
tGPl EC LGI
tGPz LG2
LG3
|M0CD
. PA8(II'IG DATA LIN( SMIG CONNECIOR SWITCH .8nA{E {0Lcl FTUID I!VEL SWTfi
22-164
Troubleshooting
Beforetroubleshooting immobilizersystem, the troubleshootany EClvl Diagnostic TroubleCodes(DTCS) ( s e ep a g e1 1 - 3 )a n d m a k es u r et h e E C Mh a s n o , malfunction. Note these items beforetroubleshooting: . Due to the actionof the immobilizersystem,the enginetakesslightly more time to startthan on a vehiclewithout an immobilizersystem. . When the system is normal,and the proper key is inserted, the indicatorlight comes on for 2 seconds, then it will go off. . If the indicatorstartstoblink after 2 seconds, if the or enginedoes not start.removeany other immobilizer keysor large key fobs on the key ring,then repeatthe startingprocedure. lf the engine still does not start,continuewith this procedure. 1. Turn the ignitionswitch ON {ll) with proper key. ls there battery voltage? 2. Checkto see if the immobilizerindicatorlight c o m e so n . Does the indicator light blink? YES Disconnect 7P connectorfrom the the immobilizercontrol unit-receiver, then go to step 9. NO Checkfor these problems,then go to step 3. . Blown No. 9 (10A)fusein the under-hood fuse/relaybox.I . An open in the wire betweenthe gaugeassembly a n d t h e i m m o b i l i z ec o n t r o lu n i t - r e c e i v e r . l r . A f a u l t yi m m o b i l i z eirn d i c a t o lri g h t , I . An open in the wire betweenthe gauge assembly and the under-hood fuse/relaybox.l Removethe driver'sdashboardlower cover (see page 20-59). Removethe steeringcolumn lower cover (seepage 11-9). 1 . Checkfor voltage betweenthe immobilizercontrol 7P unit-receiver connectorNo. 6 terminal and body ground with the ignition switch ON {ll). ls there battery voltage? YES- Go to step 8. NO Checkfor these problems: . B l o w nN o . 6 ( 1 5 A ) f u s en t h e u n d e r - h o o d i fuse/relaybox,I . F a u l t y G M - Fm a i n r e l a y1 , t P l . A n o p e ni n t h e Y E U B L K i r e . l w 5. Disconnect 7P connector(A)from the the (r i m m o b i l i z ec o n t r o lu n i t - r e c e i v e B ) , r
Checkfor voltage betweenthe immobilizercontrol unit-receiver connectorNo. 7 terminal and body 7P ground.
YES-Go to step 7. NO Checkfor these problems; . B l o w nN o . 9 { 1 0 A ) f u s en t h e u n d e r - h o o f u s e / i d relay box.l . An open in the WHT/RED wire.l
l
(cont'd)
22-165
lmmobilizer System
(cont'dl Troubleshooting
8. Checkfor voltage betvveen immobilizercontrol the unit-receiver connectorNo. 6 terminal and No. 1 7P rermlnat. ls thete battery voltage? YES Go to step 12. NO Checkfor these problems, . Open on the BRNI/ELwire.l . Faulty CM.I E 9. Removethe driver's dashboardlower cover (see page20-59). 10. Removethe steeringcolumn lower cover (seepage 17-9). the 11. Disconnect 7P connector(A) from the (B). immobilizercontrol unit-receiver Checkfor continuitybetweenthe immobilizer 7P control unit-receiver connectorNo. 2 terminal a n d E C Mt e r m i n a lE 2 7 . ls there continuity? Y E S - G o t o s t e p1 3 . w N O - R e p a i t h e o p e ni n t h e R E D / B L U i r e . I r
1 3 .Reconnect 7P connectorto the immobilizer the

control unit-receiver. 1 4 . Checkfor voltage betweenthe immobilizercontrol 7P unit-receiver connectorNo. 4 terminal and body ground with the parkingbrakelever pulled,then released. ls there 1 V or less,then 5 V or more? YES Replace the immobilizercontrol unit-receiver. After replacing the immobillzercontrol unitreceiver,rewritethe unit with a HondaPGM Tester.l NO Checkfor these problems: . Faultyparkingbrakeswitch or a poor body ground of the parkingbrakeswitch.l . R e p a i r h o r to r o p e ni n t h e G R N / O R N i r e .I w s
22-166
lmmobilizerControl Unit-Receiver Replacement

'L Removethe driver'sdashboardlower cover (see page20-59).
2 . Removethe steeringcolumn covers(seepage 17-
3 . Disconnect 7P connector(A)from the the

(B). immobilizercontrol unit-receiver
Removethe two screwsand the immobilizer control unit-receiver from the ignition key cylinder
(c).
5 . Installthe immobilizercontrol unit-receiver the in reverseorder of removal. 6 . After replacement, rewritethe unit with a Honda PGM Tester,then checkthe immobilizersystem.
22-167
MultiplexControlSystem
Index Location Component
LIGHT REAR CEILING page 22'96 Test,
LIGHT/SPOTLIGHTS Test,page22-96
lr,
ASSEMBLY GAUGE
IGNITION KEYLIGHT Test,page22'91
ECM
UNIT MULTIPLEX CONTROL {Builtinto the under-dash fus6/relav boxl page22'172 Troubleshooting, InputTest,page22-175
22-168
CircuitDiagram
' I'10.20 :usA {a0AJ UNDEf, DASH ib.a)l50A) :C.nd. FUSE/NEUYBOX BLI,'YEL
UiIDM HOOD IUSE/NEUY BOX --_to
IGNITiON SWITCH
/ BAI \ oJ\ tcl ./
MULTIPLEX c0NT80r tNsPECTror! CONNECIOF

HAICII LATCH SWITCH
G201
{cont'd)
22-169
CircuitDiagram(cont'd)
l'1o.3 tUSt l7.5AJ lln$.uidt hoodr itutefd4bor I
V
wHTPLU l0 t--t---
lrfl |
lE lnv*| > | ucHT

l Al l ' * ' t Y I'
LIGHT CIILING
I.l|MOBItEER @NTIOL UIIIT RECEIVEE
V I
I
22-170
SystemDescriptions
The MultiplexControlSystem hasfour internal functions: . M u l t i p l e x i n gs e n dm u l t i p l e i g n a l s v e rs h a r e d ( s o wtres) . Wake up/sleep(runsat full power only on demandto reducebatterydraw) . Fail-safe (fixesor ignoresfaulty signals) . Self-diagnosis (Mode 1 for the system,Mode 2 for i n p u tl i n e s ) The systemcontrolsthe functionof these circuits: . E n t r yl i g h t c o n t r o(l i g n i t i o n e y l i g h t a n d c e i t i n gi g h t ) k l . Wiper/washerintermittentwipe and park functions . Keyless/power door lock . Meter assembly, temperaturegauge,and indicator lights . HVAC(compressor and fan control) . Key-in eminder r . H e a d l i g hrte m i n d e r . Seatbeltreminder
MultiplexCommunication
To reducethe number of wire harnesses, digital signals a r e s e n tv i a s h a r e d u l t i p l e x o m m u n i c a t i o ln n e s m c i r a t h e r h a n s e n d i n g o r m a le l e c t r i c a l i g n a l s h r o u g h t n s t i n d i v i d u aw i r e s . l . The input signalsfrom each switch are convertedto digital signalsat the centralprocessingunit (CpU). . T h ed i g i t a l i g n a l s a r e s e n t f r o m t h e t r a n s m i t t i n g i t s un t o t h e r e c e i v i n g n i t a s s e r i a ls i g n a l s . u . The transmittedsignalis convertedto a switch signal at the receivingunit, and it operates the related componentor monitors a swltch. . There are exclusivecommunicalionlines between the ECM,the gauge assembly,and the under,dash fuse/relaybox.
Wake-up and Sleep

The multiplexcontrol system has "wake-up" and "sleep" functions parasiticdraw on the to decrease batterywhen the ignitionswitch is OFF. . ln the sleep mode,the multiplexcontrol unit stops functioning(communication and CPUcontrol)when it is not necessary the systemto operate. for . As soon as any operationis requested (for example,a door is unlocked), relatedcontrol unit in the sleep the mode immediatelywakes up and beginsto function. . When the ignition switch is turned OFF,and the driver'sor front passenger's door is opened,then closed,there is about a 10 seconddelay beforethe control unit goes from the wake-upmode to the sleep mode. . lf any door is open,the sleep mode will not function. . l f a k e y i s i n t h e i g n i t i o n w i t c h , h e s l e e pm o d ew i l l s t not function. . When in sleep mode,the draw is reducedfrom 70 80 mA to lessthan 10 mA.
Fail-safe
To preventimproper operation, the multiplexcontrol system has a fail-safe function.In the fail-safemode, the output signal js fixed when any part of the system malfunctions(for examplea faulty control unit or communicatioline). n Eachcontrol unit has a hardwarefail-safefunctionthat fixes the output signalwhen there is any CPU malfunction,and a softwarefail-safe functionthat i g n o r e s h e s i g n a l r o m t h e m a l f u n c t i o n i nc o n t r o lu n i t t f g and allowsthe systemto operatenormally.
22-171
/ar
Multiplex ControlSystem
Troubleshooting
Mode 1 Tset 1. Removethe driver's dashboardlower cover {see page 20-59). 2. Checkthe No. 9 ( 10A)fuse in the under-hoodfuse/ fuse in the underrelay box and the No. 10 (7.5A) fuse/relaybox. dash Are the fuses OK? YES-Go to step 2. c N O - F i n d a n d r e p a i r t h e a u s eo f t h e b l o w nf u s e . ! f s 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . l t h e d r i v e r ' s seatbeltis unbuckledthe seat belt reminderwill c h i m e6 t i m e s . 4. Set the ceiling light to the centerpositionand close a l l t h ed o o r s . 5. Connect the specialtoolto the multiplex inspection conneclor. 6. After about 5 secondsthe spotlightand ceiling light go should come on for 2 seconds, out, then blink on to show the system is now in mode for 0.2 second 1. Did the spotlight and ceiling light indicate mode 1? YES-Go to step 8. NO Go to step 7. 7. Checkfor continuitybetweenterminal 4ofthe fuse/relaybox connectorJ and body under-dash ground. ls there continuity? fuse/relaybox.l YES Replace the under-dash t r N O- R e p a i t h e o p e n i n t h e w i r e . l f h e w i r e i s o k , r e p a i rG 3 0 1 . 1 present, the spotlightand 8. lf ther are any DTCS lf ceiling light will blink to indicatethe DTC(S). more will be displayed than one DTCis present, the DTCS the in ascendingorder,lf there are no DTCS s p o t l i g h a n d c e i l i n gl i g h tw i l l n o t b l i n ka g a i na f t e r t the mode1 indication. Are there any DTCg? YES Go to step 9. NO Go to the Mode 2 test. in the DTC(S) the order indicated 9. Troubleshoot c u s i n gt h e f o l l o w i n g h a r t s . substituteit lf a faulty control unit is suspected, for with a known food part and recheck DTCS, . lf the DTC(s) go isstill present. to the next step listedfor the DTC. . lf the DTC(S) no longer presentreplacethe is originapart. l
22-172
I
Individual
Multiplex DTC
Probable Cause The multiplexcontrol unit cannot receivesignalsfrom the gauge assemDty.
'l
DTCs Multiplex DTC

1 , 2a n d3
Probable Cause
Short to ground on one of the
poweror ground the Faulty to gauge assembly
2 . Faultygauge assemblv 3 . Faultyunder-dash use/relay f

box The multiplexcontrol unit cannot receivesignalsfrom the ECM 1 Faultypower or ground to the ECM 2. Faulty CM E
?
& communication wires. ECMDTC Short to ground on the YELwire P0600 betweenthe PCMterminal E24 Simultane and the under-dash fuse/relay ously b o x t e r m i n a lE 1 0 2 . Short to ground on the WHT/
GRNwire betweenthe Gauge assemblyterminal A2 and under-dash fuse/relaybox t e r m i n a lK 1 0 1 a n d 6 Open in the communicationwire Simultane I Open in WHT/GRN wire o u sl y betweenthe under-dash fuse/ relay box terminal K10 and the GauqeassemblV terminal 42 2 a n d 5 O p e ni n t h e c o m m u n i c a t i o w i r e n S i m u l t a n e 1 Open in the YELwire between ously the under-dash fuse/relaybox t e r m i n a lE 1 0a n d E C Mt e r m i n a l
Faulty under-dash fuse/relay box
Internalfailure of the multiplex control unit 1 Faulty under-dash fuse/relay
box
5 The gaugeassemblycannot receive signalsfrom the multiplexcontrol u n i ta n d t h e E C M Faultypower or ground to the g a u g ea s s e m b t v q F a u l t y a u g ea s s e m b l v The ECMcannot receivesignals from multiplexcontrol unit and the gaugeassembty 1 Faultypower or ground to the ECM Faulty CM' E
I
6
replacinga FaultyECM/PCM make sure it has the latestsoftwarerevision.UDdateif necessary beforeswappingor replacing.
'Before
(cont'd)
22-173
MultiplexControlUnit Input Test

1 . Removethe driver'sdashboardlower cover (seepage20-59). 2 . Disconnect under-dash the fuse/relaybox connectors E, F, J, K, O, p, O, X and y. C, NOTE:All connectors wire side of female terminals. are CONNECTOR {14P} C CONNECTOR I13P) E CONNECTOR F {12P} GRN/RED {USAI (Canada) GRN/ORN CONNECTOR J {8PI WHT/RED
3
6 7
1 4 5 6
2 1
1 0) . / 12
GRN/ORN
BLU
YEL CONNECTOR O I12P)
GRN/RED
BLK coNNECTOR(18P) P
CONNECTOR K {17P)
1 8
2 10
5 15
7 17
/V
,/ l,/
GRN/RED
,/1,/l,/ 12
WHT/GBN
RED
CONNECTOR(8P} O LTGRN/RED GRN/ORN
CONNECTOR {8P) X WHT/BLK
CONNECTOR {13P) Y BRN/YEL
2 6 1
3
8
,/1,/
r0
12
BLU/RED BLU/RED
RED/WHT
BLK
{cont'd)
22-175
MultiplexControl Unit lnput Test (cont'd)
goodcontact and terminals be suretheyareall making to the 3. Inspect connector socket .lftheterminalsarebent,looseorcorroded,repairthemasnecessary,andrecheckthesystem . llthe terminals lookOK,go to step4. Cavitv
J4
Wire BLK BLK
Test condition
[ Jn d e r a l l c o n d i t i o n s lJnderall conditions
Test:Desired .esult {or 1o Check voltage ground:

Therc sholl.l he 1V or less
Y6 Y1
C h e c kf o r v o l t a g et o g r o u n d : There should bc 1 V or less.
lever brake BFNryEL Parking
Check voltage ground: for to voltage There shouldbe battery down,turn the indicator is system igntion switch (ll) whilethe Brake ON on forthe buldcheck. for to Check voltage ground: Thereshould 1V or lesswhenthe be
if Possible cause resullEqS!q!!e!!ed Poorground(G20'l) An ooenin the wire Poorground1G501) An ooenin thewire An openin thewire Shorttoground unit ABSmodulatorcontrol Faulty
J2
for to r WHT/RED U n d e a l l c o n d i t i o n s Check voltage groundi voltage. Thereshould baftery be
in BlownNo.9 (10A)fuse the under'hood box fuse/relay An oncnin rhc wire
connectors lhe underon inputtests atthe appropriate box,andmakesurethese underdashfuserelay 4. Reconnectthe connectorstothe box. dashfuse/relav . lf anytestindicates problem, the {ind andcorrect cause, the then recheck system a fuse/relay assembly box . lf alltheinputtestsproveOK,the multiplex the Replace under_dash control unit mustbe faulty. Cavitv
o3
GRN
Test condition dooropen Driver's Driver's doorclosed
Tesi: Oesired result

C h e c kf o r v o l t a g e t o g r o u n d : There should be 1 V or lessC h e c kf o r v o l t a g e t o g r o u n d : There should be 5 V or more. C h e c k. f o rv o l t a g e 1 0 g r o u n d : There should be 1 V or less.
O4
door LT GRN/RED Passenger's door Passenger's
for to Check voltage ground: There shouldbe 5 V or more.

C h e c kf o r v o l t a g et o g r o L r n d : Thereshorl.l be 1 V or less. C h e c kf o r v o l t a g e t o g r o u n d : There should be 5 V or more.
is Possible cause ifresult notobtained Faulty driver's doorswitch An ooenin the wire doorswitch Faulty driver's Shortto qround passenger's switch door Faulty An ooeninthewire passenger's switch door Faulty Shortto oround
F a u l t yp a r k i n gb r a k e s w i t c h . An ooen in thewire
osI]l
. l
lever brake GRN/ORN Parking GRN/ORN GRN/RED (USA) GRN/ORN (Canada)
4., F1 F8
. Faulty parking brake switch Shorttoground
o5
Q6
switchON (ll), C h e c kf o r v o l t a g et o g r o u n d : BLU/RED lgnition Thereshould be 1V or less. driver's seatbeltis {or to ON switch (ll) Check voltage ground: BLU/RED lgnition be Thereshould 6 V or more. driver's seatbeltis buckled. for to Check voltage ground: RED Theresho0ld 1V or lessbe
seatbeltswitch Faulty driver's G P o o r g r o u n(d 5 5 1 ) An oDen the wire in Faulty driver's seatbeltswitch Shorttoground Faulty hatchlatchswrtch Poorground(G552) An openin the wire
F a u l t yh a t c h l a t c hs w i t c h . F a u l t yi g n i t i o n k e y s w i t c h . Poorground (G401) . An open in the wire
P18
H",=
l g n i r i o nk e y i n t h e ignit on switch l g n r t r o nk e v o u r o { t h e
f-9*:li:'^:**:':s*:*
C h e c kf o r v o l i a g e t o g t o u n d : Thpre should be I V or lcss C h e c kf o r v o l l a g e t o g r o u n d :
X5
**6 I : [11y.'::i':::1"'
22-176
J
Cavitv X8 Wire WHT/BLK Test condition Test:Desiredresult Underallconditions Attach ground:The to ignition key lightshould comeon. Possible cause resuk notobtained if is BlownNo.3 (7.5A)fuse the under,hood in BlownLED An ooenin the wire ElownNo.3 (7.54)fuse the undeFhood in Faulty ceiling light An oDen the wire in BlownNo.2 (15Aifuse the under-hood in fuse/relaybox Faulty taillight relay An ooenin the wire Faulty brake fluidlevelswitch An openin thewire Faulty brake fluid levelswitch Shorttoground . An openor shortin thewire
o7
GRN/RED Ceiling lightswitchin A t t a c h t o g r o u n d : T h e c e i l i n g l i g h t , position, s p o t l i g h t ss h o u l d c o m e o n . the middle all doorsclosed BLU Underall conditions Attach ground: to Dashlights should
c]1
F8
GRN/RED
Brake fluidreservoir C h e c kf o r v o l t a g et o g r o u n d : float in down T h e r e s h o u l d b e l e s st h a n I V . position (brake fluid Brake lluid reservoir Check voltage ground: for to floatin up position There shouldbe 5 V or more. (brake fluidat full level) Under conditions C h e c kf o r v o l t a g et o g r o u n d : all
T h e r e s h o u l d b e b a t t e r yv o l t a g e i n t h e s l e e pm o d e a n d 3 T v o l t s w h e n
E10
YEL
K10
WHT/GRN Underall conditions Check voltage ground: for to There shouldbe battery voltage in the sleepmodeand3 Tvoltswhen
An openor shortin the wire
I J
22-177
I
Restraints
Restraints
Special Tools ............. 23-2
SeatBelts
Component Location Index ......................................... 23-3 Front SeatBeltReplacement ....................................... 23-4 Rear SeatBeltReplacement ........................................ 23-6 Inspection .................. 23-8 Child Seat Tether AnchorRemoval/lnstallation 23-9 ........
SRS(Supplemental Restraint Systeml

Component Location Index ......................................... 23-13 Precautions Procedures and ,,.,......... 23-14 General Troubleshooting Information ....................... 23-23 DTC Troubleshooting Index .............. 23-28 Symptom Troubleshooting Index............................... 23-30 System Description ................. ........... 23-31 Circuit Diagram ......... 23-34 DTC Troubleshooting ............... .......... 23-36 SRSIndicator Circuit Troubleshooting ....................... 23-105 Component eplace n(/ln pect n After R me s io Deployment ..............23-112 Driver's AirbagReplacement ............ 23-113 FrontPassenger's AirbagReplacement .....................14 23-1 SideAirbagReplacement .................. 23-115 A i r b a g i s p o s a.l . . . . . . . . . . . . . . . . . . . . . . D . . . . . . . . 2.3 - 1 1 6 . . R l C a b l e e eR e p l a c e m e n t . . . . . . . . . . . . . .2.3 . . . 1 9 . .-1 SRSUnitRepfacement ....................... 23-122 Sidefmpact Replacement Sensor ..........,.................... 23-123 OPDS UnitReplacement .................... 23-124 Frontfmpact Sensor Replacement .............................. 23-125
Restraints
SpecialTools
' 07HAZ-SG00500
DeploymentTool SCSServiceConnector r S R SI n f l a t o S i mu l a t o r L S R SS i m u l a t o r e a dC B a c k p r o bA d a p t e r 1 7 m m e , L S R SS i m u l a t o r e a dE L S R SS i m u l a t o r e a dF S R SS i m u l a t o r e a dH L
8t
oTPM-oo101oo
oTsM-TB4o114
O
o-'
oTTM-sz5o114
07TM-0010204
@ -1
o7xAz-s140200 07xAz-s230100
* 1 : I n c l u d e dn S R ST o o l S e t0 7 M M ' S M 5 0 0 0 8 i *2: Use with the stackingpatchcords from T/N 07SAZ-0010004, Backprobe Set.
Gl
ro
L .
23-2
SeatBelts
REAR CENTER BELT and REAR SEATBELTBUCKLES step1 on page 23-8 page Inspection, 23 9
SHOULDER ANCHOR ADJUSTER step8 on page 23-4 FRONT SEAT BELT page Replacement, 23-4 page 9 Inspection, 23
I
CHILDSEATTETHER ANCHORS Removal/lnstallation, page23-11
REAR BELT SEAT page Beplacement, 23.7 page Inspection, 23-9 FRONT SEAT BELT BUCKLES step1 on page 23'6
23-3
SeatBelts
FrontSeat Belt Replacement
are SRScomDonents locatedin this area.Reviewthe SRScomponentlocations(seepage23-13)and the (seepage23-14)in the SRS precautions and procedures sectionbefore performingrepairsor service, NOTE:Checkthe front seat beltsfor damage,and replacethem if necessary. careful not to damage Be them during removaland installation. 6. Removethe upper anchorcover {A),and remove t h e u p p e ra n c h o rb o l t( B ) . B 7/16-20 UNF 32N m (3.3 kgf.m,24lbt.ft)
Front Seat Belt

code for the radio, 1 . Make sure you have the anti-theft for then write down the frequencies the preset buttons. the Disconnect negativecablefrom the battery,and wait at least3 minutes beforebeginningwork.
3 . Slidethe front seatforward fully.

Removethe lower anchorcap (A),and removethe lower anchor bolt (B).
7. Disconnect seat belt tensionerconnector(A). the ET Removethe retractormounting self-tapping screw {B),and the retractorbolt (C),then remove the front seat belt (D) and retractor(E). 6x1.0mm kgf.m,2.5 lbf.ft) 3.4N m {0.35
5 . R e m o v e h e r e a rs i d et r i m p a n e l( s e e p a g e 2 0 - 5 1 ) . t
7/16-20 UNF 32 N.m(3.3 m,2irlbf.ft) kgf removethe front seat belt protecto 8. lf necessary, (F).
qt
23-4
the upper trim {seepage 20-50) 9 . Remove B-pillar anchor adjuster{A). 1 0 .Remove shoulder the
Upper anchor bolt construction:

UPPER ANCHOR BOLT UPPER ANCHOR
COLLAR
BUSHING
TOOTHED LOCK WASHER
Lower anchor bolt construction:

8 x 1.25mm
22 N.m(2.2 kgf.m, 16lbf.ftl 1 1 .Installtheseat belt in the reverseorder of removal, and note these items: . lf thethreads on the retractormounting selftapping ET screw are worn out, use an oversized ET self-tapping screw (P/N90133-SZ4-0030) for made specifically this application. . Checkthat the retractorlockingmechanism functions(seepage 23-9). . A s s e m b l eh e w a s h e r sc o l l a r s a n d b u s h i n g n o t , , the upper and lower anchorbolts as shown. . lf the seat belt tensionerhas been deployed replacethe front seat belt protectorwith a new one. . A p p l y l i q u i dt h r e a dl o c kt o t h e a n c h o rb o l t s beforereinstallation. . Beforeinstallingthe anchorbolts,make sure there are no twists or kinksin the front seat belt. . Make sure the seat belt tensionerconnectoris pluggedin properly. . Reconnect negativecableto the battery. the . Enterthe anti-theft code for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . Do the ECM/PCM idle learn procedure{seepage 11,139).
WASHER
BOLT LOWER ANCHOR
LOCKWASHER TOOTHED
{cont'd)
23-5
Seat Belts
(cont'd) Front Seat Belt Replacement
SeatBelt Buckle
1. Make sure you have the anti-theftcode for the radio, then write down the frequencies the preset for buttons. 2. Disconnect negativecablefrom the battery, the and wait at least3 minutesbefore beginningwork. 3. Removethe front seat (seepage 20-7'1). 4. Detachthe seat belt switch connectorclip (A),seat belt buckletensionerconnectorclip (B),and harness lip(C). c 7. Installthe bucklein the reverseorder of removal, and note these items: . Assemblethe washerson the centeranchor bolt as shown. . Apply liquid thread lockto the centeranchor bolt before reinstallation. . lf the seat belt tensionerhas been deployed, replacethe front seatbelt protectorwith a new one. . Apply liquid thread lockto the seat mounting bolts before reinstallation . Reconnect negativecableto the battery. the . Enterthe anti-theft code for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . Do the ECMiPCM idle learn procedure(seepage 11 _ 1 3 9 ) .
.-..:.a--
5. Removethe centeranchor bolt (A),and removethe seat belt buckle{B).
COLLAR
7/16-20 UNF 32N m {3.3 m,24lbf.ft) kgf 6. Pullthe seat belt switch/tensioner harness(C)out through the hole on the seattrack.
23-6
RearSeat Belt Replacement

NOTE:Checkthe rear seat beltsfor damage,and Be replacethem if necessary. carefulnot to damage l t h e m d u r i n gr e m o v a a n d i n s t a l l a t i o n . 5. Installtheseat belt in the reverseorder of removal, and note these items: . lf the threadson the retractormounting selftapping ET screw are worn out, use an oversized self-tapping screw (P/N90133-524-0030) ET o m a d es p e c i f i c a l lfy r t h i s a p p l i c a t i o n . . Apply liquid thread lockto the anchorbolt before reinstallation. ' Checkthat the retractorlockingmechanism functions{seepage 23-9). . Beforeinstallingthe anchor bolt, make sure there are no twists or kinksin the rear seat belt.
RearSeatBelt
( 1 . R e m o v e h e r e a rs e a tc u s h i o n s e ep a g e2 0 8 0 ) . t 2. Removethe lower anchor bolt {A}.
A 7/16-20UNF 32 N.m (3.3kgf.m, 24 tbf.ftl
t 3 , R e m o v e h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 ) . ET 4 . Removethe retractormounting self-tapping screw (A),and the retractorbolt (B),then remove the rear seat belt (C)and retractor{D). B 7/16-20 UNF
N m {3.3kgf.m,2irlbf.ft)
A 6x1.0mm 3.4 N.m {0.35kgl m,2.5 lbf.ftl
(cont'd)
23-7
SeatBelts
RearSeat Belt Replacement {cont'd)
CenterBelt and Seat Belt Buckles
1. Removethe seatcushion{seepage 20-80). 2. Removethe centeranchor bolts (A),and remove the seat belt buckles(B)and centerbeh (C). A 7/16-20 UNF 32N.m13.3 kgf.m, 24 tbt.ft) 7. Removethe seat belt guide (A)from the pin (B), and release the centerbelt (C)from the seat belt g ui d e .
'.;r'"
<i.. -"':'' "':
1-..i, ,
Removethe retractormounting bolt (A),and the retractorbolt (B),then removethe centerbelt (C) and retractor(D)from the seat-back frame (E).
A 6x1.0mm 9.8 N.m (1.0kgf m, 7.2 tbl.ttl
(seepage 20-80). 3. Removethe right seat-back 4. Removethe seat-back cover (seepage20-82). pad from the seat-back 5, Removethe seat-back frame (seestep 3 on page 20-81). 6. Removethe screw,and releasethe hooks (A),then removethe retractorcover (B). Fastener Location B
7/16-20 UNF kgf 32 N.m(3.3 m, 24 tbf.ftl
.:.',
t.)
23-8
I
9. lnstallthe seat belt and bucklesin the reverseorder of removal,and note these items: . Checkthat the retractorlockingmechanism functions(seestep 1 on page 23-10). . Assemblethe washerson the centeranchor bolt as shown (exceptcentershoulderbelt). . Apply liquidthread lock to the anchor bolts beforereinstallation. . Beforeinstallingthe centeranchor bolt, make sure there are no twlsts or kinksin the centerbelt, Canler anchor bolt construction:
Inspec'tion
with Forfrontseatbeltretractors seatbelttensioners. (see locations page23-13) reviewthe SRScomponent (see precautions procedures psge23-14) in and andthe performing repairs service. or the SRSsection before
Retractor,Front and Rear

checkthat the seat 1. Beforeinstallingthe retractor, can be pulled out freely. belt sure that the seat belt does not lockwhen the 2. l\4ake retractor(A) is leanedslowly up to 15'from the mounted position.The seat belt should lock when the retractoris leanedover 40'. Do not attemDtto disassemble retractor. the Front:
WASHER
Forward
lnside
Rear:
Forward
Inside
Replace seat belt with a new assemblyif there the any pan of is any abnormality.Do not disassemble the seat belt for any reason,
(cont'd)
23-9
Seat Belts
Inspection(cont'd)
RearCenter RetraEtor,
1. Beforeinstallingthe retractor, checkthat the seat belt can be pulled out freely. 2, Make sure that the seat belt does not lockwhen the retractor(A) is leanedslowly up to 15' from the mounted position.
In-vehicle
1. Checkthat the seat belt is not twisted or caught on anything. 2. After installingthe anchors.checkfor free movementon the anchorbolts. lf necessary, removethe anchor bolts and checkthat the washersand other partsare not damagedor i m p r o p e r l yn s t a l l e d . i 3. Checkthe seat beltsfor damageor discoloration. Cleanwith a shop towel if necessary. Use only soap and water to clean. NOTE:Dirt build-upin the loops of the upper anchorscan causethe seat beltsto retractslowly. Wipe the insideof the loops with a cleancloth i l d a m p e n e dn l s o p r o p ya l c o h o l . Checkthat the seat belt does not lockwhen pulled out slowly. The seatbelt is designedto lock only during a sudden stop or impact. For rearcentershoulderbelt,checkthat the seat i b e l tl o c k s h e n p u l l e do u t o v e r 4 0 0m m ( 1 5 . 7 n . ) w with the seat-back folded down. Make sure that the seat belt will retract automatically when released. 7 . For each passenger's seat belt, checkthe seat belt retractorlockingmechanismALR (automatic lockingretractor). This function is for securingchild seats. - 1 P u l l t h es e a tb e l ta l l t h e w a y o u t t o e n g a g e h e t ALR.The seat belt should retractwith a ratchetingsound, but not extend.This is normal. -2 To disengage the seat belt and the ALR, release a l l o w i t t o f u l l y r e t r a c tt,h e n p u l l t h es e a tb e l t out part-way.The seat belt should retractand extend normally. 8 . Replace seat belt with a new assemblyif there the is any abnormality.Do not disassemble any part of the seat belt for any reason.
lnside
Forward
3 , Leanthe retractorover 40', and make sure that the

seat belt does not lockwhen pulled out over 900 mm (35.4in.).Do not aftemptto disassemble the retractor. 4 . Replace seat belt with a new assemblyif there the is any abnormality.Do not disassemble any part of the seat belt for any reason.
\,J
23-10
ChildSeatTetherAnchorRemovaUlnstallation
Middle
1. Removethe child seattether anchorcover (A) in t h e r e a rt r i m p a n e l( B ) .
Side
1. Removethe rear bulkheadcoversfrom both sides ( s e ep a g e2 0 - 5 1 ) . 2. Removethe anchorbolt (A),then removethe child on seattether anchor (B)from behindthe seat-back each side ofthe cargo compartment.Do not removethe toothedwasher (C)from the tether anchor.
f-..- t"
.i..].-
,tltl
8 x 1.25mm 22 N m {2.2ksf.m, 16lbf.ft)
v\
t 2 . R e m o v e h e a n c h o rb o l t( C ) , h e n r e m o v et h e c h i l d t seattether anchor(D).Do not removethe toothed washer (E)from the tether anchor. a o 3 . I n s t a l l t h e n c h o ri n t h e r e v e r s e r d e ro f r e m o v a l .
m 8 x 1.25 m 22 N.m {2.2kgt m. 16lbfft)
i o l n s t a l l t h e n c h o r s n t h e r e v e r s e r d e ro f r e m o v a l . a
I J
23-11
sRs
Location Index Component
SRSINOICATOR page23-105 Troubleshooting, SIDEAIRBAG CUTOFFINDICATOR
LEFTFRONTIMPACTSENSOB RIGHTFRONTIMPACTSENSOR
AIRBAG DRIVER'S page 13 Replacement, 23-1 page 1'16 Disposal, 23
AIRBAG FRONTPASSENGER'S page23-1 14 Replacement, p, a g e2 3 ' 1 1 6 Disposal
BACK SEAT Replacement, page20-75 FRONT PASSENGER'S SIDE AIRBAG Replacement, page 3'1'15 2 Disposal, page 3'116 2
SENSOR/
CABLE REEL Beplacement, page 3-119 2
PASSENGER'S FRONT SEAT BELT TENSIONER Beplacement, page 23-4 Disposal, page 23-'116 OPDS UNIT page Initialization, 23-27 page Replacement, 23-124 SIOE PASSENGER'S
IMPACTSENSOR Replacement, p a g e2 3 - 1 2 3
ERASE MEMORY (MES} SIGNAL CONNECTOR I2PI
DATA LINK CONNECTOR (DLCI16P
SEAT FRONTPASSENGER'S BELTBUCKLETENSIONER
DRIVER'S SEATBELTTENSIONER page23 4 Replacement, D i s p o s a p,a g e2 3 - 1 1 6 l
23-13
sRs
Precautions and Procedures
General Precautions
Pleaseread the following precautions carefullybefore performingairbagsystem service.Observethe instructions describedin this manual.or the airbags could accidentally deploy and causedamageor injuries. . Exceptwhen performingelectricalinspections. alwaysturn the ignition switch OFF,disconnect the negativecablefrom the battery,and wait at least3 minutesbefore beginningwork. NOTE:The memory is not erasedeven if the ignition switch is turned OFFor the batterycablesare disconnected from the battery. . Use replacement pans which are manufactured the to same standardsand quality as the original parts.Do not installused SRSpartsfrom anothervehicle.Use only new pans when making SRS repairs. . Carefullyinspectany SRS part beforeyou installit. Do not installany part that shows signs of being droppedor improperlyhandled,such as dents,cracks, or deformation.
Steering-related Plecautions
CableReelAlignment . M i s a l i g n m e n t f t h e c a b l er e e lc o u l dc a u s ea n o p e ni n o t h e w i r i n g ,m a k i n gt h e S R Ss y s t e ma n d t h e h o r n s inoperative. Centerthe cable reelwheneverthe following is performed(seestep 6 on page23-121). Installation the steeringwheel of Installation the cable reel of I n s t a l l a t i oo f t h e s t e e r i n g o l u m n n c Other steering-related adjustmentor installation
. Do not disassemble cable reel. the . Do not apply greaseto the cable reel. . lf the cable reel shows any signs of damageor contamination. replaceit with a new one. For example,it does not rotatesmoothly.
. Beforeremoving any SRSparts (includingthe disconnection connectors), of alwaysdisconnect the SRSconnector. . Use only a digital multimeterto checkthe system.lf it is not a Honda multimeter,make sure its outout is 10 mA (0.01A) lesswhen switchedto the lowestvalue or in the ohmmeter range.A testerwith a higheroutput could causeaccidental deploymentand possible injury. . Do not put objectson the front passenger's airbag. . The original radio has a coded theft protectioncircuit. Be sure to get the customer'sradio code and write down the frequencies the radio's presetstations for beforedisconnecting batterycable. the . Beforereturningthe vehicleto the customer,enter the radio code.then enter the customer'sradio stationpresets, and set the clock.Do the engine control module (ECM)idle learn procedure(seepage 11-139).
\rc
23-14
AirbagHandling and Storage

an Do not disassemble airbag,lt has no serviceable parts.Oncean airbag has been deployed,it cannot be repairedor reused. For temporarystorageof an airbagduring service, observethe following precautions. . Storethe removedairbagwith the pad surfaceup. Never put anythingon the airbag.
. Store removed flat on the airbag a secure, surface (exceeding 200'Fi awayfrom any highheatsource
inspections the airbags, to Never perform electrical such as measuringresistance. Do not positionyourselfin front of the airbagduring or removal,inspection, replacement.
To preventdamageto the airbag,keep it free from or any oil, grease,detergent, water,
for Referto the scrappingprocedures disposalof a damaged irbag. a
(cont'd)
23-15
sRs
Precautions and Procedures {cont'dl
SRSUnit, Front lmpact Sensors,and Side lmpact Sensors
. Be careful not to bump or impactthe SRS unit, front impact sensors,or side impactsensorswheneverthe ignition switch is ON (ll),or for at least3 minules after the ignition switch is turned OFF. . During installation orreplacement,be carefulnotto bump (by impactwrench, hammer,etc.)the area aroundthe SRS unit, front impact sensors,and sjde impact sensor.The airbagscould accidentally deploy and causedamageor injury. . Do not disassemble SRS unit,front impactsensors, the or side impact sensors. . Turn the ignition switch OFF,disconnect the battery negativecable,and wait at least3 minules before beginninginstallation replacement the SBS unit, or of or disconnecting connectors the from the SRSunit. . Be sure the SRSunit,front impactsensors,and side impact sensorsare installedsecurely. with the mounting bolts torquedto 9.8 N.m (1.0kgf.m,7.2 lbf.ft) . Do not spill wateroroil on the SRSunit, front impact sensors, the side impact sensors, or and keepthem away from dust. . Store the SRS unit, front imDactsensorsand side impactsensorsin a cool (lessthan 104"F/40'C) and dry (lessthan 80 % relativehumidity,no moisture) area.
.j
After a collisionin which any airbagsor seat belt tensioners were deployed.replacethe SRSunit, front impact sensors,and other relatedcomponents(see page 23-112). After a collision in which a side airbag was deployed.replacethe side impact sensoron the deployedside and the SRS unit. After a collisionin which the airbagsor the side airbagsdid not deploy, inspectfor any damageor any deformationon the SRS unit, front impact sensors,and the side impact s e n s o r sl.f t h e r ei s a n y d a m a g e r e p l a c e h e S R Su n i t , t and/orthe sensors.
23-16
I
WiringPrecautions
Some of the SRSwiring can be identifiedby a special yellow outer covering,and the SRSconnectors can be identifiedby their yellow color. describedin this section. Observethe instructions . Neverattemptto modify. splice,or repairSRSwiring. l f t h e r ei s a n o p e no r d a m a g ei n S R Sw i r i n g ,r e p l a c e the harness.
Inspections Precautions Electrical for

. When using electricaltestequipment,insertthe probe of the tester into the wire side of the connector. Do not insertthe probe of the testerinto the terminal side of the connector,and do not tamper with the connector.
Use a U-shapedprobe.Do not insertthe probe forcibly.
Be sure to installthe harnesswires so they do not get Dinched interferewith other Darts. or
Use specifiedserviceconnectorsin tro u bleshooting. U s i n gi m p r o p e r o o l sc o ul d c a u s ea n e r r o ri n t contact. inspectiondue to poor metal-to-metal M a k es u r ea l l S R Sg r o u n dl o c a t i o n s r e c l e a n , n d a a groundsare securely fastenedfor optimum metal-tometal contact.Poorgroundingcan causeintermittent problemsthat are difficultto diagnose.
(cont'd)
23-17
sRs
(cont'dl Precautions and Procedures
Spring-loaded LockConnector
Some SRSsystemconnectorshave a spring-loaded lock. Front Airbag Connectors: Disconnecting To releasethe lock.pullthe spring-loaded sleeve(A) toward the stop (B)while holdingthe oppositehalf of the connector. Then pullthe connectorhalvesapart,Be sure to pull on the sleeveand not on lhe connector. Side Airbag Connector: Disconnecting ( T o r e l e a s eh e l o c k ,p u l l t h es p r i n g - l o a d es l e e v e A ) t d a n dt h e s l i d e r{ B )w h i l e h o l d i n g h e o p p o s i t e a l fo f t h e t h connector. Then pullthe connectorhalvesapart.Be sure to pull on the sleeveand not on the connectorhalf.
Connecting 1. To reconnect, hold the pawl-sideconnector,and presson the backof the sleeve-side connectorin the directionshown. As the two connectorhalves are pressedtogether,the sleeve(A) is pushedback by the pawl (C).Do not touch the sleeve.
Connecting Hold both connectorhalves,and pressthem firmly togetheruntil the projection(C)of the sleeveside connectorclicks.
When the connectorhalvesare completelV connected, the pawl is released, and the springloadedsleevelocksthe connector.
\ J
23-18
Backprobing Spring-loaded LockConnectors

When checkingvoltageor resistance this type of on connectorthe first time, you must removethe retainer to insertthe tester orobe from the wire side. NOTE:lt is not necessary reinstall to the removed retainer;theterminalswill stay lockedin the connector housrno.
Seatswith SideAirbags
"SIDEAIRBAG" label Seatswith side airbagshave a on the seat-back. Because componentpans (seat-back the cover,cushion,etc.)of seatswith and without airbags are different,make sure you installonly the correct parts. replacement
A To removethe retainer(A),inserta flat-tipscrewdriver (B) betweenthe connectorbody and the retainer, then Takecare not to breakthe carefullypry out the retainer. connector.
s W h e n c l e a n i n gd o n o t s a t u r a t e t h e e a t w i t hl i q u i d , , and do not sDravsteam on the seal cover. Do not reoalra torn or fraved seat-back ReDlace seat-back the cover. w i A f t e ra c o l l i s i o nn w h i c ht h e s i d ea i r b a g a s deployed,replacethe side airbagwith new parts.lf lf cushion is split, it must be replaced. the seat-back frame is deformed,it must be replaced. seat-back the on Never put aftermarket accessories the seat{covers, pads,seat heaters,lights,etc.).
(cont'd)
23-19
sRs
(cont'dl Precautions and Procedures
Disconnecting SystemConnectors
Beforeremoving a front airbag.side airbag,or other SRS relateddevices{the SRS unit,the cable reel,the front impact sensors, the side impact sensors, the seat belt buckletensioners, and the seat belt tensionerconnector), disconnecting connectors from relateddevices,or removingthe dashboardor the steeringcolumn, disconnect airbagconnectors the or the side airbagconnectors preventaccidental to deploVment. Turn the ignition switch OFF,disconnect the negativecablefrom the battery,and wait at least3 minutesbefore beginningthe following procedures. 'BeforedisconnectingSRSunitconnectorA(1)fromtheSRSunit,disconnectthedriver'sairbag4Pconnector(3). the front passenger's airbag4P connector(4),the driver'sseat belt tensioner2P connector(6),and the front passenger's seatbelt tensioner2P connector(7). '12), . Beforedisconnecting SRS unit connectorB (8)from the SRS unit, disconnect both side airbag2P connectors(11. (9, and both seat belt buckletensioner4P connectors 10). . Beforedisconnecting cable reel 4P connector(2),disconnect the the driver'sairbag4P connector(3). 'Beforedisconnectingthefloorwireharness4Pconnector(5),disconnectbothseatbelttensioner2Pconnectors (6.7).
23-20
1. Disconnect batterynegativecable,and wait at the least3 minutes. Driver's Airbag 2. Removethe accesspanel (A)from the steering wheel,then disconnecl the driver'sairbag 4P connector(B)from the cable reer.
Side Airbag 4. Disconnect both side airbag2P connectors(Alfrom the floor wire harness.
Front Passenger'sAirbag 3. Disconnect front passenger's the airbag4P connector(A)from dashboard wire harnessB.
(cont'd)
23-21
sRs
(cont'd) and Procedures Precautions
SeatBelt Tensioner 2P both 5. Disconnect seatbelttensioner connectors (A)fromthefloorwire harness
SRS Unit 7. Disconnect SRS unit connectorA, SRS unit connectorB, and/or SRS unit connectorC from the S R Su n i t .
Seat Belt Buckle Tensioner both seat belt buckletensioner4P 6. Disconnect connectors(A).
\ J
23-22

DTC(Diagnostic TroubleCodesl
The self-diagnostic function of the SRSsystem allows it to locatethe causesof system problemsand then store this informationin memory. For easiertroubleshooting, this data can be retrievedvia a data link circuit. . W h e ny o u t u r n t h e i g n i t i o n w i t c hO N ( l l ) ,t h e S R S s indicatorwill come on. lf it goes off after 6 seconds, the system is normal. . lf there is an abnormality, the svstem locatesand definesthe problem,storesthis informationin memory, and turns the SRS indicatoron. The data w i l l r e m a i ni n t h e m e m o r ye v e nw h e n t h e i g n i t i o n switch is turned off or if the batteryis disconnected. . When you connectthe HondaPGlMTesterto the 16P d a t al i n kc o n n e c t o( D L C ) t o h o r tt h e S C St e r m i n a l , r s a n d t u r n t h e i g n i t i o n w i t c hO N ( l l ) .t h e S R Si n d i c a t o r s will indicatethe diagnostic trouble code (DTC) the by n u m b e ro f b l i n k s . . When you connectthe HondaPGM Testerto the 16P (DLC), you can retrievethe DTCin data link Connector " t h e H o n d aS y s t e m s S R S " m e n u . . After readingand recordingthe DTC,proceedwith procedurefor th is code. the troubleshooting Precautions . U s eo n l y a d i g i t a lm u l t i m e t etro c h e c k h e s y s t e m . f t l it's not a Hondamultimeter,make sure its output is ) 1 0 m A ( 0 . 0 1 Ao r l e s sw h e n s w i t c h e do t h e s m a l l e s t t v a l u ei n t h e o h m m e t e rr a n g e A t e s t e r i t h a h i g h e r , w o u t p u tc o u l dd a m a g e h e a i r b a gc i r c u i t r c a u s e t o a c c i d e n t a l i r b a gd e p l o y m e na n d p o s s i b l en j u r y . a t i . Wheneverthe ignition switch is ON (ll),or has been turned OFFfor lessthan 3 minutes,be careful not to b u m pt h e S R Su n i Ut h e a i r b a g s o u l da c c i d e n t a l l y c d e p l o ya n d c a u s ed a m a g eo r i n j u r i e s . . Beforeyou removethe SRSharness,disconnect the driver's airbagconnector. front passenger's the airbagconnector,both side airbagconnectors, both seat belt buckletensionerconnectors, and both seat r b e l tt e n s i o n ec o n n e c t o r s . . Make sure the batteryis sufficiently charged.lf the batteryis dead or low, measuringvalueswon't be correct. . Do not touch a tester probe to the terminalsin the SRSunit or harnessconnectors, and do not connect t h e t e r m i n a l s i t h a j u m p e rw i r e . U s eo n l y t h e w backprobe and the HondaPGM Tester.Backprobe set spring loadedlocktype connectors correctly.
Reading DTC the

When the SRSindicatoris on, read the DTCusing either of the following methods: PGM Tester "SRS" Menu Method: Connectthe Honda PGM Tester{A)to the 16Pdata link connector{DLC)(B), follow the Tester'sDromptsin and "SRS" the menu. lf the Testerindicatesno DTC,no communication. DTC 3-6 to 3-'10, DTC4-6 to 4-10,DTC9-1,or DTC9-2, double-check usingthe "SCS" menu method. by
(cont'd)
23-23
sRs
Information(cont'd) GeneralTroubleshooting
PGM Tester "SCS" Menu Method {retrieving the flash codes): The SRSindicator(A) indicates the DTCby lhe number of blinkswhen the Honda PGM Tester(B) is connected ( to the DLC(datalink connector) 16P)(1). '1. Make sure the ionition switch is OFF. Readingthe main code:
I nc a s e f 1 - 1 0 o Count number blinks. the of Examplo:
*t**t*l*l
Maincodo= 1 + 1
1 . 2S r . 2S 1 . 2S 1 . 2 1 . 2 S S
Tester(B)to the DLC(C), 2. Connectthe HondaPGN4 "SCS" menu and follow the Tester'soromDtsin the ground the SCS line (seethe HondaPGM Tester to Manual). ODerator's
""_f]_flfl
+ 1 0 . 1s
/// t\\\
=3
In case 11..'15 ot Fourfastblinks countas 10. Add anyfunherblinks together shown. as Example:
,A
//lii\\ |
1.rs r.2s r.2s 1.2s *t* - L- - * l '
""ffi
Main code= 10 I
=12
3 . Make sure the SCS line is grounded,then turn the

ignitionswitch ON (ll).The SRS indicatorcomes on and then goes off. Then it will for about 6 seconds, blinkto indicatethe DTC(seethe table below).
4. Readthe DTC.
l n c a s eo f 2 0 o r m o r e T w o s e t s o f f o u r f a s t b l i n k sc o u n t a s 2 0 . A d d a n y f u n h e r b l i n k s t o g e t h e ra s s h o w n . Examplo:
0.1 s
0.1s
5 . Turn the ignition switch OFF,and wait for 10 seconds. the 6, Disconnect Honda PGMTesterfrom the DLC. 7. Do the troubleshootingprocedure the DTC. for Patteins of DTC Indications:
T h e D T C c o n s i s t so f a m a i n c o d e a n d s u b c o d e .
12s ,y'fl\,,. /[N *l- 12s *FtftffN*+fH-t-ff

Main code= 10 + 10
Readingthe subcode: Count number blinks. the of Example:

S: Second
s s 0.3 0.3 0.3s 0.3 0.3s 0.3s 0.3 s s
6S
25
35
o N [ l I t l - l - - -|- L [- - - l l oFFl
First emitting Main code Subcode
""ffi
S u b c o d e '3', lf the main code is DTC 3 4.
l**t**t*t*t*l
= 1 + 1 + 1 r ' 1 = 4
a n d t h e s u b c o d ei s
' 4 ' , r e c o r da
\ J
23-24
Includingthe most recentproblem,up to three differentDTCS can be indicated(seeexample 1 below). ln case of a continuousfailure,the DTCwill be indicatedrepeatedly {seeexample 1 below). In caseof an intermittentfailure,the SRS indicatorwill indicatethe DTCS one time, then it will stay on (seeexample 2 below). lf both a continuousand an intermittentfailure occur,both DTCS will be indicatedas continuousfailures. When the system is normal (no DTCS), SRS indicatorwill stay on (seeexample3). the lf the SRSindicatorcomes on continuouslywithout a DTC,there mav be a problemwith the svstem. lf the SRSindicatordoes not come on as indicatedabove,alwayscheckfor an open or a short to ground in the SCS circuitbeforetroubleshooting system. the Example of DTC Indications: 1. Continuous failure,SRSIndic6tor blink$likethis:
1 . 2S 1 , 2S
0.3 s
0.3s 0.3s
S: Second
ON
OFF Bulb check period
Main code l1l Subcode(3) Main code {11 Subcode{'l) Indications are lepeated DTC 2-l tn cese ot DTC1-3 DTC1-1 Most recentp.oblem continuous Sscond-mostrecent Third-mostrocent problem problem failure. 2. Intermittent failure, SRS lndicator blinks like this:
(21 Maincode Subcode l1)
ON
OFF Bulb check DTC 5-1 period (no failure|,SRSIndicatorblinks like this: 3. Normal lndicator stays on in case of i nterm ittent failu re.
ON
OFF Bulb chock period No DTC,systom is normal, the indicator stays on.
(cont'd)
23-25
sRs
Information(cont'dl Troubleshooting General
Memory Erasing DTG the
Specisl Tool Required SCSserviceconnector07PAz-0010100 To erasethe DTC(S)from SRSunit, use a Honda the TesterSRSVehicle PGMTester{seelhe HondaPGfM or SystemSupplement) the following procedure. 1. Make sure the ignition switch is OFF. 2. Connectthe SCSserviceconnector{A) to the MES 2P connector(B).Do not use a jumper wire.
Troubleshootinglntermittent Failures
lf there was a malfunction,but it doesn't recur.it will be storedin the memory as an intermittentfailure,and the SRS indicatorwill come on. After checkingthe DTC,troubleshootas follows: 1. Readthe DTC(see"Readingthe DTC"). "Erasingthe DTC 2. Erasethe DTCmemory (see Memory"). 3. With the shift lever in neutral,startthe engine,and letit idle.
4 . The SRSindicatorwill come on for about 6 seconds
and then go off. take a Shakethe wire harnessand the connectors. quick braking, test drive (quickacceleration, turn the steeringwheel fully left and cornering), '10 seconds.lf the right, and hold it there for 5 to problem recurs,the SRSindicatorwill come on. lf you can't duplicatethe intermittentfailure,the system is OK at this time.
07PAZ-0010100
s 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . 4. The SRS indicatorwill come on for about 6 seconds, and then go off. Removethe SCSserviceconnector from the MES connectorwithin 4 secondsafterthe indicatorgoes off. 5. The SRS indicatorwill come on again.Reconnect the SCSserviceconnectorto the MES connector within 4 secondsafter the indicatorcomes on. 6. When the SRSindicatorgoes off, removethe SCS serviceconnectorfrom the MES connectorwithin 4 seconds. 7 . T h e S R Si n d i c a t ow i l l b l l n kt w o t i m e s i n d i c a t i n g r that the memory has beenerased. 8. Turn the ignition switch OFF,and wait for seconds. '10
. s 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l )a g a i n T h e S R Sj s OK if the SRSindicatorcomes on for 6 secondsand then goes off.
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23-26
I
Initializing OPDS the Position Detection {Occupant System}Unit
Special Tool Required SCSserviceconnector07PAz-00'1 00 01 When a seat-back cover,seat-back cushion,and/or OPDSunit is replaced,initialize OPDSby following the the procedurebelow. NOTE:Make sure the front passenger's seat is dry. Set the seat-back the normal position,and make sure there is in nothing on the seat. l\4ake sure the ignition switch is OFF. 2. Connect the HondaPGM Tester(A)to the DLC(16P)(B),andfollowtheTester's prompts jn the ,,SCS,, menu to ground the SCSline (seethe Honda PGM TesterOperator'sManuaD. 3. Connectthe SCSserviceconnector(C)to the MES 2P connector(D).Do not use a iumoer wire. '1.
07PAZ-00r0100
4 . T u r nt h e i g n i t i o n w i t c hO N { l l ) . s 5. The SRS indicatorcomes on for about 6 secondsand goes off. Removethe SCSserviceconnectorfrom the MES connectorwithin 4 secondsafterthe SRSindicatorwent off. 6. The SRSindicatorcomes on again.Reconnect SCSserviceconnectorto the MES connectorwithin 4 seconds the afterthe SRS indicatorcomes on. 7. The SRSindicatorgoes off. Removethe SCSserviceconnectorfrom the MES connectorwithln 4 seconds. 8. Watch the sRS indicator. 'lftheindicatorblinkstwotimesandthenstayson,theOPDSisinitialized.buttheDTCSneedtobeerased. step 9, then erasethe DTCS. .lftheindicatorblinkstwotimesandthengoesoff,theOPDSunitisinitialized.Gotostep9. ' lf the indicatorstayson without first blinking.theOPDSis not initialized. Readthe DTC.lf DTC 15-'lis indicated, procedure. anotherDTCis indicated, to the appropriatepage in the DTC repeatthe initialization go lf Troubleshooting Index. 9. Turn the ignition switch off, and disconnect the PGM Tester.
SBS indic.ror
MES
I J
DISCONNECTED
23-27
sRs
Index DTCTroubleshooting
DTC
t- |
t .
Notes (seeDaqe23-36) (seeDaoe23-36 (seepage23-37) (seepaqe23-39 {seepaqe23-40 {seeoaoe23-42 (seeoaqe 23-42 (seepage23-43) (seepaqe23-45 (seepaqe 23-46 (seepage 23-48 (seepaqe 23-48 (seepage 23-49) (seeDaqe23-51 (seeoaoe 23-52 (seepaqe 23-54
t-5
1-4
t-5
2-1 2-2 2-3 2-4 2-5 3-1 3-2 3-3 3-4 3-5
21-1
2't-4
2't-5
4-'l
4-2 4-3
4-4 4-5
22-3 22-4 22-5

5-1
5-2
5-4
5-8 6-3 6-4

6-7 6-8
1-)
Detection ltem O D e ni n d r i v e r ' s i r b a qi n f l a t o r a Increased resistance driver'sairbaq inflator in resistance driver's airbag in Shon to anotherwire or decreased inflator Shortto Dowerin driver'sairbao inflator Shortto qround in driver'sairbaq inflator Open in front Dassenqer's airbaq inflator s I n c r e a s e r e s i s t a n cie f r o n tp a s s e n q e r 'a i r b a qi n t l a t o r d n resistance front passenger's in Short to anotherwire or decreased airbao inflator airbaq inflator Short to oower in front oassenoer's airbaq inflator Short to qround in front passenqer's ODenin driver'sseat belttensioner lncreased resistance driver's seat belt tensioner in in resistance driver'sseat belt Short to anotherwire or decreased tensioner Short to oower in driver'sseat belt tensioner Short to oround in driver'sseat belt tensioner resistance driver'sseat belt buckletensioner in ODenor increased resistance driver'sseat belt in Short to anotherwire or decreased buckletensioner Short to Dowerin driver'sseat belt buckletensioner Shon to oround in driver'sseat belt buckletensioner ODenin front oassenoer's seat belt tensioner in seat belttensioner lncreased resistance front oassenqer's resistance front passenger's in Short to anotherwire or decreased seat belt tensioner seat belt tensioner Shon to Dowerin front Dassenqer's Short to qround in front oassenoer's seat belt tensioner in seat belt buckle resislance front passenger's Open or increased tensioner in Short to anotherwire or decreasedresistance front passenger's seat belt buckletensioner seat belt buckletensioner Short to oower in front oassenqer's seatbelt buckletensioner Short to oround in front oassenoer's lnternalfailure of SRSunit NOTE: DTCS through 8-6,checkbattery/system Beforetroubleshooting 5-1 voltage.lf the voltage is low, repairthe charging system before troubleshootino SRS. the
(see page23-55)
(seepaqe 23-56) (seeoaqe23'57 {seepage23-58) {seepaqe23-58) {seepage23-60) lsee oaqe23-61 (seeDaqe23-63 (seepage 23-64) (seepage 23-65) (seepaqe 23-66 (seepaqe 23-68 (seepage23-69)
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7-3 8-1
a-2
8-4 8-5 8-6
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23-28
J
DTC 9-1
Detection ltem Internalfailure of the SRS unit. lf intermittent, could mean internal it failure of the unit or a faulty indicatorcircuit.Referto Troubleshooting Intermittent Failures(seepage 23-26). NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system voltage.lf the voltage is low, repairthe chargingsystem before troubleshooting e SRS. th Internalfailure of the SRSunit. lf intermittent, could mean internal it failure of the power supply (VB line).Referto Troubleshooting Intermittent Failures(seepage 23-26). NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system voltage.lf the voltage is low, repairthe chargingsystem or replace the btterybeforetroubleshooting SRS. the Faultydriver'sseat belt buckleswitch Notes (seepage23-69)
9-2
9-3 9-4 9-6 9-7

10-1
FaultLtglt passenger's beltbuckle seat switch

FaultyIeft front imDactsensor Faultyright front impact sensor Seat belt and seat belt buckletensioners(and airbag(s)) deployed D r i v e r ' s i d ea i r b a gd e p l o y e d s Seat belt and seat belt buckletensioners(and airbag(s)) and driver's s i d ea i r b a gd e p l o y e d Frontpassenqer's side airbaodeDloved Seat belt and seat belt buckletensioners(and airbag(s)) and front passenqer's side airbaq deDloved Driver'sand front passenqer's side al Seat belt and seat belt buckletensioners(and airbag(s)) and driver's and front passenger's side airbagsdeployed Open or increased resistance driver's side airbao inflator in Short to anotherwire or decreased resistance driver'sside airbao in inflator Short to power in driver'sside airbaq inflator Short to ground in driver's side airbaq inflator Open or increased resistance front passenger's in side airbag inflator Short to anotherwire or decreased resistance front passenger's in side airbag inflator Short to power in front passenqer's side airbaq inflator s S h o r tt o g r o u n di n f r o n t p a s s e n g e r 's i d ea i r b a qi n f l a t o r Internalfailure of the driver's side impactsensor N o s i g n a lf r o m t h e d r i v e r ' s i d ei m p a c ts e n s o r s
(seeDaqe23-71) lgqgfage 23-74) {see Daqe23-77) (seepaqe 23-79)
10-2
(see page23-69)
r0-3
'10-4
'10-5
l r
10-6
10-7 11-1
( s e ep a q e2 3 - 8 1 )
(see page23-82)
(seeoaqe 23-83) {seepaqe 23-85) (seepage 23-86) (seepage 23-87) {seeDaqezJ-uu} (seeoaqe 23-90) (seepage 23-70) ( s e ep a q e2 3 - 9 1 )
11-4
I t-5
12-4
Iz-5
13-1
- 7
13-4 14-1 i i 14-3 14-4 15-1 15-2 15-3
Faultypowersupplyto the df,rglllug t Opact s9I99L Internal failure ofthe frontpassenger's impact side sensor
N o s i g n a l r o m t h e f r o n t p a s s e n g e r 's i d ei m p a c ts e n s o r s f Faultypower supply to the front passenqer's side impact sensor F a u l t v P D Su n i to r O P D Sn o t i n i t i a l i z e d O Faultyside airbagcutoff indicatorcircuit FaultyOPDSsensor
(see page23-92) (seepage23-70)

(seepaqe 23-94) (seepage 23-95) ( s e ep a q e2 3 - 9 6 1 (seeDaqe23-99) (seeoaoe 23-104)
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23-29
SRS
Symptom
SRSindicatordoesn'tcome on SRSindicatorstayson when in "SCS" menu method Diagnosticprocedure (s r S R SI n d i c a t oT r o u b l e s h o o t i n g e e p a o e2 3 - 1 0 5 ) (see SRSIndicatorTroubleshooting step 1 on page 23-107) Also check for
Slde airbagcutoff indicatorstays o n a f t e rb u l bc h e c k( l f t h e indicatorstayson, it does not set a DTC).Side airbagcutoff indicatoris flashing
. M a k es u r en o t h i n g s o n t h e f r o n l i passenger's seat. . lf the side airbagcutoff indicator stayson after the ignition switch e i s t u r n e dO N ( l l ) ,i n i t i a l i z t h e OPDSunit (see page23-271. - lf the side airbagcutoff n i n d i c a t o o p e r a t e s o r m a l l Yt,h e r system is OK. - lf the side airbagcutoff indicatorstayson, replacethe n u F U 5 S e n S O r e e e C r OZ U l . {S S The sensor is part of the seatback Dad.
Inabilityto retrieveDTCswith the the PGM Tester.Retrieve flash codes usingthe SCSmenu method (seepage 23-24). DTC 15-2troubleshooting
t r J
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23-30
SystemDescription
SRSComponents
Airbags The SRSis a safetydevicewhich, when used with the seat belt, is designedto help protectthe driver and front passenger a frontal impact exceedinga certainset limit. The system consistsofthe SRS unit, includingsafing in sensorand impactsensor(A),the cable reel (B),the driver's airbag(C),the front passenger,s airbag (D).seat belt tensioners(l),seat belt buckletensioners(J), and front impactsensors(K). Sincethe driver'sand front passenger's airbagsusethe same sensors,both normally inflateat the same ttme. However,it is possiblefor only one airbagto inflate.This can occurwhen the severityof a collision is at the margin,or threshold,that determineswhether or not the airbagswill deploy.In such cases, the seat belt will provide sufficient protection, protectionofferedby the airbagwould be mininal. and the supplemental Side Airbags The side airbags(E)are in eachfront seat-back. They help protectthe upper torso of the driver or front seat passenger during a moderateto severeside impact.Side impact sensors(F) in each door sill and in the SRS unit detectsuch an impactand instantlyinflatethe driver'sor the passenger's side airbag.Only one side airbagwill deploy during a side impacl. lf the impact is on the passenger's side,the passenger's side airbagwill deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckletensionersare linkedwith the SRSairbagsto further increase the effectiveness of the seat belt. ln a front-endcollision,the tensionersinstantlyretractthe belt and bucklefirmly to securethe occupants in their seats. OPDS The side airbagsystemalso includesan occupantpositiondetectionsystem (OpDS). This systemconsistsof sensors ( G ) a n da n O P D Su n i t( H )i n t h e f r o n t p a s s e n g e r 's e a t - b a c k .h e O P D Su n i t s e n d so c c u p a nh e i g h la n d p o s i t i o n a t at o s T t d the SRS unit. lf the OPDSunit determinesthat the front passenger of small stature(for example,a child) and the is front passenger leaninginto the side airbag deploymentpath,the SRSunit will automatically is disablethe passenger's side airbag.The SRSunit will also disablethe airbagwhen the OPDSdetectscertainobiectson the seat.When the side airbag is disabled, the side airbagcutoff indicatoron the instrumentpanel alertsthe driver that the passenger's side airbagwill not deploy in a side impact.When the object is removed,or the passenger sits upright,the side airbag cutoff indicatorwill go off after a few seconds, alertingthe driver that the passenger's side airbagwill deploy in a side imDact.
(cont'd)
23-31
sRs
(cont'dl SystemDescription
SRSOperation
ignitesthe inflatorcharges.lf The main circuit in the SRS unit sensesand judgesthe force of impact and, if necessary. due to the impact,the voltage regulatorand the back-uppower batteryvoltage is too low or power is disconnected will keepvoltageat a constantlevel. circuit,respectively, For the SRS to operate: Seat Belt Tensioners and Seat Belt Buckle Tensioners (1)A front impact sensormust activateand send electricsignalsto the microprocessor. (2)The microprocessor must computethe signalsand send them to the tensioners. (3)The chargesmust ignite and deploy the tensioners. Driver's and Front Passenger'sAirbagls) (1)A front impactsensor musl activate. and send electricsignalsto the microprocessor. (2)The microprocessor must computethe signals.and dependingon the severityof the collisionand whetherthe seat belt buckleswilch is ON or OFF,it sendsthe appropriatesignalsto the airbag inflator(s). (3)The inflatorsthat receivedsignalsmust ignite and deploy the airbags. Side Airbaglsl ( 1)A side impact sensormust activate, and send electricsignalsto the microprocessor. (2)The microprocessor However,the must computethe signalsand send them to the side airbag inflator(s). that the tront side airbag if the OPDSunit determines cuts off the signalsto the front passenger's microprocessor passenger's head is in the deploymentpath of the side airbag. (3)The inflatorthat receivedthe signal must ignite and deploythe side airbag.
lw$ad..n sl
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T'
n0m S P gsfrlctR oXrVEr I S 9oEAiA$ SOtlr&G I
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sEctto
f'**)r !
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23-32
Self-diagnosis System A self-diagnosis circuitis built into the SRS uniUwhen the ignition switch is turned ON (ll),the SRS indicatorcomes on and goes off after about 6 secondsif the SRS is operatingnormally. lf the indicatordoes not come on, or does not go off after 6 seconds.or if il comes on while driving, it indicatesan abnormalityin the SRS.The SRSmust be inspected and repairedas soon as possible. For betterserviceability, SRSunit memory storesa DTCthat relatesto the causeof the malfunction,and the unit is the connected the data link circuit.This informationcan be read with the Honda PGM Testerwhen it is connectedto the to data link connector(DLc) (seepage 23-23).
23-33
SRS
CircuitDiagram
srarsftr rrl$0[n
rrssf c s
r-----Tr-i
i___':--_:"1
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23-34
J
tr ozr"* tr ul"ar
NJfl
t
|-(tzl
1i
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23-35
sRs
DTCTroubleshooting
AirbagInflator Openin Driver's DTC1-1: Resistance Driver's in Increased DTC1-2: AirbagInflator
Special Tools Required . SRS inflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON {ll),and checkthat the SRSindicatorcomes on for aboul 6 secondsand then goes off. Does the SBS indicator stay on? YES-Go to step 3. failure,system is OK at this time. NO Intermittent IntermittentFailures(see Go to Troubleshooting page 23-26). the 3. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. the 4. Disconnect driver's airbag4P connector(A) from the cable reel. airbag4P 10. Disconnect front passenger's the connectorfrom dashboardwire harnessB (seestep 3 o n p a g e2 3 - 2 1 ) . 11. Disconnect both seat belt tensioners2P connectors from the floor wire harness(seestep 5 on page236. Reconnect batterynegativecable. the 7. Erasethe DTCmemory. 8. Readthe DTC, ls DTC 1-1or DTC 1-2indicated? YES-Go to step 9. in resistance the driver's NO Open or increased airbag inflator;replacethe driver'sairbag (seepage 23-113).t the 9. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait ior 3 minutes.
22t.
t 1 2 . D i s c o n n e c t R Su n i tc o n n e c t oA ( 1 8 P ) f r o mh e S r Do SRSunit (seestep 7 on page 23-22). not disconnect specialtool from the cable reel. the
07sAz-TB4011A
07xaz-s230100
5. Connectthe SRS inflatorsimulator(2 Q and the simulatorlead F to the cable connectors) reet.
23-36
betweenthe No. 7 and the No. 13. Checkresistance t t e r m i n a l s n d b e t w e e n h e N o .6 a n dt h e N o . 1 5 a . r t e r m i n a l s f S R Su n i tc o n n e c t oA ( 1 8 P )T h e r e o s h o u l db e 2 . 0 3 . 0 0 . SRS UNIT CONNECTOR A I18P)
'16
DTC1-3:Shortto AnotherWire or Decreased in AirbagInflator Resistance Driver's

SpecialToolsRequired . SRS inflatorsimulator07SAZ-T8401 1A . SRSsimulatorlead F 07XAZ-S230100 1. ErasetheDTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes of{. Does the SRS indicator stay on? YES-Go to step 3.
terminals Wiresideof female failure,system is OK at this time. NO Intermittent Failures(see Intermittent Go to Troubleshooting page 23-261. the Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes, Disconnect driver'sairbag 4P connector(A) the from the cable reel.
ls the resistance as specilied? YES-Faulty SRS unit or poor contactat SRSunit and the SRSunit, checkthe connectorA (18P) connectionbetweenthe connectorand the SRS unit. lf the connectionis OK, replacethe SRSunit ( s e ep a g e2 3 - 1 2 2 ) . 1 resistance dashboard in NO-Open or increased wire harnessB orthe cable reel;replacethe cable reel.lf the problemstill present,replacedashboard wire harness . B
07sAz-T84011A
07xAz-s230100
ConnecttheSRSinflatorsimulator{2 0 and the simulatorlead F to the cable connectors) reel. Reconnect batterynegativecable. the 1 . Erasethe DTCmemory.
(cont'd)
23-37
sRs
8. Readthe DTC. Is DTC 1-3indicated? YES Go to step 9. NO Short in the driver'sairbag;replacethe driver's airbag (seepage 23-'l13).1 9. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 10. Disconnect front passenger's the airbag4P connectorfrom dashboardwire harnessB (seestep 3 o n p a g e2 3 - 2 1 ) . 1'1. Disconnect both seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 23SRSUNITCONNECTOR{18P) A GRN/WHT GRN/RED 14. Checkresistance betweenthe No. 7 and the No. 16 t e r m i n a l s n d b e t w e e n h e N o . 6 a n dt h e N o . 1 5 a t ( . t e r m i n a l s f S R Su n i tc o n n e c t o r A 1 8 P )T h e r e o should be an open circuit,or at least 1 M Q .
GRN/YEL
GRN/BLK
22t.
ls the rcsistance as specified? ( 1 2 . D i s c o n n e c t R Su n i tc o n n e c t o r A 1 8 P ) f r o mh e S t SRS unit (seestep 7 on page 23-221. 13. Disconnectthe specialtool from the cable reel. NO Go to step 15. Disconnect cable reelfrom dashboardwire the harnessB. Checkresistance betweenthe No,7 and the No. 16 terminalsand betweenthe No. 6 and the No. 15 terminalsof SRS unit connectorA (18P). Thereshould be an open circuit,or at least 1 M Q . ls the resistance as specified? YES Replace cable reel.I the N O - R e p l a c ed a s h b o a r d i r e h a r n e s s . l w B YES FaultySRS unit; replacethe SRS unit (see page 23-122],.a
IJ 23-38
Airbag DTC1-4: to in Short Power Driver's Inflator

SpecialToolsBequired . sRS inflatorsimulator07SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h a tt h e s t SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time. IntermittentFailures(see Go to Troubleshooting page 23-26). the 3. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes.
Readthe DTC. ls DTC 1-4indicated? YES-Go to step 9. NO-Short to power in the driver's airbag;replace 1 t h e d r i v e r ' s i r b a g( s e ep a g e2 3 - 1 3 ) . 1 a s tt 9 . T u r nt h e i g n i t i o n w i t c hO F F .D i s c o n n e c h e batterynegativecable,and wait for 3 minutes.
1 0 .Disconnect front passenger's the airbag4P

connectorfrom dashboardwire harnessB (seestep 3 o n p a g e2 3 ' 2 1 ) . 1 1 .Disconnect both seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 23221. t 1 2 . D i s c o n n e c t R Su n i tc o n n e c t oA ( 1 8 P ) f r o m h e S r SRSunit (seestep 7 on page 23-22). Disconnect specialtool from the cable reel. the 4. Disconnect driver'sairbag4P connector(A) the f r o m t h e c a b l er e e l .
't4. Reconnect batterynegativecable. the
07sAz-T84011A
( s C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 0 connectors) and the simulatorlead F to the cable reel. 6 . Reconnect batterynegativecable. the 1 . Erasethe DTCmemory.
(cont'd)
23-39
SRS
Turn the ignition switch ON {ll). 1 6 . Checkfor voltage betweenthe No. 7 terminal of ) S R Su n i tc o n n e c t oA ( 1 8 P a n d b o d y g r o u n d , h e r t N o . 1 6t e r m i n a a n d b o d y g r o u n d , h e N o . 6 l t t e r m i n a la n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l and body ground.Thereshould be 0.5 V or less. SRS UNIT CONNECTOR A {18P)
L
DTC1-5: Short Ground Driver's to in Airbag lnflator
Special Tools Required . SRS inflatorsimulator07SM-TB4011A . SRSsimulatorlead F 07XM-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthatthe SRS indicatorcomes on for about 6 secondsand then goes oIf. Does the SBS indicator stay on? YES Go to step 3. NO-lntermittent failure,system is OK at this time. Intermittent Failures(see Go to Troubleshooting page 23-26). 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Disconnect driver'sairbag 4P connector(A) the from the cable reel.
Wiresideol lemale terminals
Is the voltage as specilied? YES-Faulty SRS uniUreplacethe SRS unit (see page 23-122) .a NO Go to step 17. 1 1 . Turn the ignition switch OFF. 1 8 . Disconnect cable reel from dashboardwire the harnessB. 1 9 . Turn the ignition switch ON (ll).
07sAz-T84011A
20. Checkfor voltage betweenthe No. 7 terminal of

) r S R Su n i tc o n n e c t oA ( 1 8 P a n d b o d y g r o u n d , h e t N o . 1 6t e r m i n a la n d b o d y g r o u n d , h e N o . 6 t t e r m i n a la n d b o d y g r o u n d ,a n d t h e N o . 1 5t e r m i n a l and body ground.Thereshould be 0.5 V or less. ls the voltage as specitied? Y E S R e p l a c eh e c a b l er e e l . l t Reconnect batterynegativecable. the N O - R e p l a c ed a s h b o a r d i r e h a r n e s s . l w B 1 . Erasethe DTCmemory.
07xaz-s230100
( C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 0 s lead F to the cable connectors) and the simulator reet.
IJ
23-40
8. Readthe DTC. ls DTC 1-5 indicated? YES-Go to step 9. NO Short to ground in the driver's airbaginflator; 13).I replacethe driver's airbag(seepage 23-1 the 9. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. '10. front passenger's airbag 4P Disconnectthe wire harnessB (seestep connectorfrom dashboard 2 on page 23-21). 11. Disconnect both seat belt tensioner2P connectors from the floor wire harness (seestep 5 on page 23-
14. Checkresistance betweenthe No.7 terminal of SRS unit connectorA {18P)and body ground,the t N o . 1 6t e r m i n a la n d b o d y g r o u n d , h e N o . 6 t e r m i n a la n d b o d y g r o u n d .a n d t h e N o . 1 5t e r m i n a l and body ground.There should be an open circuit, o r a t l e a s t1 M Q . A I18PI CONNECTOR SRS UNIT GRN/WHT GRN/RED
22t.
fromthe 12. Disconnect SRSunit connectorA (18P) SRS unit (see step 7 on page 23-22],. t 1 3 . D i s c o n n e c t t hs p e c i a l t o o l f r o mh e c a b l er e e l . e terminals Wiresideof female ls the resistance as specified? YES-Faulty SRS unit; replacethe SRS unit {see page 23-1221 .f N O - G o t o s t e p1 5 . Disconnect cable reel from dashboardwire the B harness . 1 6 . Checkresistance betweenthe No.7 terminal of t a S R Su n i tc o n n e c t oA ( 1 8 P ) n d b o d y g r o u n d , h e r t N o . 1 6t e r m i n a a n d b o d y g r o u n d . h e N o , 6 l t e r m i n a a n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l l T a n d b o d y g r o u n d . h e r es h o u l db e a n o p e nc i r c u i t , or at least 1 fvlQ . ls the resistanceas specified? t Y E S R e p l a c eh e c a b l er e e l . I NO Replace dashboardwire harnessB.l
23-41
sRs
DTC 2-1:Openin FrontPassenger's Airbag Inflator DfC 2-2:Increased Resistance Front in Passenger's AirbagInflator
Special Tools Bequired . S R Si n f l a t o r i m u l a t o 0 7 S A Z - T 8 4 0 1 1 A s r . SRSsimulatorlead F 07XAZ-S230100 '1. Erasethe DTCmemory {seepage 23-26). Readthe DTC. ls DTC 2-1 or DTC 2-2 indicated? YES Go to step 9. NO-Open or increased resistance the front in passenger's airbag inflator;replacethe front p a s s e n g e r 'a i r b a g{ s e ep a g e2 3 - 1 1 4 ) . I s
9 . Turn the ignitionswitch OFF.Disconnect the

2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h a t t h e s t SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time, Go to Troubleshooting IntermittentFailures(see page 23-261. 3. Turn lhe ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Disconnect front passenger's the airbag 4P connector(A) from dashboardwire harnessB. 1 1 .Disconnect both seatbelt tensioner2P connectors from the floor wire harness(seestep 5 on page 2322). Disconnect SRS unit connectorA (18P) from the SRSunit (seestep 7 on page23-22). not Do disconnect specialtool from dashboardwire the harness . B
!.
batterynegativecable,and wait for 3 minutes.
1 0 .Disconnect driver'sairbag 4Pconnectorfrom the

the cable reel (seestep 2 on page 23-21],.
07sAz-T84011A
07xAz-s230100 5 . Connectthe SRS inflatorsimulator(2 0 connectors) and the simulatorlead F to dashboard wire harness . B 6 . Reconnect batterynegativecable. the 7 . Erasethe DTCmemory.
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23-42
13. Checkresistance betweenthe No. 4 and No. 13 t t e r m i n a l s n d b e t w e e nh e N o . 5 a n d N o . 1 4 a . t e r m i n a l s f S R Su n i tc o n n e c t oA ( 1 8 P )T h e r e o r s h o u l db e 2 . 0 3 . 0 Q .

A SRSUNITCONNECTOR {18P)
DTC2-3:Shortto AnotherWire or Decreased Passenger's Airbag Resistance Front in lnJlator

SpecialToolsRequired . S R Si n f l a t o r i m u l a t o 0 7 S A Z - T 8 4 0 1 ' 1 A s r . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-261. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) , a n d c h e c k t h a t t h e s SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on?
YES-Go to step 3. failure, system is OK at this time. NO Intermittent Failures{see Intermittent Go to Troubleshooting page23-26). the 3. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. airbag 4P 4. Disconnect front passenger's the connector(A) from dashboardwire harnessB.
ls the resistance as specified? YES FaultySRSunit or poor contactat SRS unit Checkthe connection;if the connectorA (18P). connectionis OK, replacethe SRSunit (seepage 23-1221.a in resistance dashboard NO Open or increased wire wire harnessB; replacedashboard B harness .I
07sAz-T84011A
07xAz-s230100
( s C o n n e ctth e S R Sl n f l a t o r i m u l a t o r 2 0 l a c o n n e c t o r s )n d t h e s i m u l a t o r e a dF t o d a s h b o a r d wire harness . B 6 . Reconnect batterynegativecable. the 7 . Erasethe DTCmemory.
T J
(cont'd)
23-43
sRs
Readthe DTC. ls DTC 2-3 indicated? YES Go to step9. NO-Short in the front passenger's airbag inflator; replacethe front passenger's airbag (seepage 231 1 4 )t . 9 . Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 13. Disconnectthe specialtool from dashboard wire harness . B 14. Checkresistance betweenthe No. 4 and No. 13 t e r m i n a l s n d b e t w e e n h e N o .5 a n d N o . 1 4 a t . t e r m i n a l s f S R Su n i tc o n n e c t oA ( 1 8 P )T h e r e o r s h o u l db e a n o p e nc i r c u i t o r a t l e a s t1 M Q . ,
SRSUNIT CONNECTOR I18P) A BLU/RED
qJ
'12. Disconnect SRS unit connectorA (18P) from the SRS u nit (see step 7 on page 23-22l. .
1 0 .Disconnect driver'sairbag 4P connectorfrom the

the cable reel {seestep 2 on page 23-21). 1 1 .Disconnect both seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 23221.
BLU/BLK Wiresideof female terminals
ls the resistance as specitied? YES FaultySRSunit; replacethe SRS unit (see page 23-122)'.a NO-Shon in dashboard ire harness ;replace w B dashboard ire harness .l w B
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23-44
DTC2-4:Shortto Powerin FrontPassenger's AirbagInflator

Special Tools Required . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off, Does the SRS indicatot stay on? YES-Go to step 3. failure,system is OK at this time. NO Intermittent lntermittentFailures(see Go to Troubleshooting page23-26). 3. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.
8. Readthe DTC. ls DTC 2-4 indicated? YES-Go to step 9. airbag NO-Short to power in the front passenger's airbag (see inflator;replacethe front passenger's p a g e2 3 - 1 1 4 ) . I 9. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnect driver's airbag4P connectorfrom the the cable reel (seestep 2 on page 23-21). both seatbelttensioner2P connectors 11. Disconnect from the floor wire harness(seestep 5 on page 2322).
airbag 4P 4. Disconnect front passenger's the wire harnessB. connector(A) from dashboard
07sAz-T84011A
07xAz-s230100
Connectthe SRSinflatorsimulator(2 Q and the simulatorlead F to dashboard connectors) B wireharness . the 6 . Reconnect batterynegativecable. 7 . Erasethe DTc memory.
{cont'd)
23-45
sRs
Disconnect SRSunit connectorA (18P) from the SRSunit (seestep 7 on page23-221.
DTC2-5:Shortto Groundin FrontPassenger's AirbagInflator

SpecialToolsRequired . SRSinflator simulator07SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26).
1 3 .Disconnect specialtool from dashboardwire the

harnessB. 1 4 . Reconnect batterynegativecable. the 1 5 . Turn the ignition switch ON (ll). t o . Checkfor voltage betweenthe No. 4 terminal of SRSunit connectorA (18P) and body ground,the N o . 1 3t e r m i n a a n d b o d y g r o u n d , h e N o . 5 l t terminal and body ground,and the No. 14 terminal and body ground.Thereshould be 0.5 V or less.
SRS UNIT CONNECTOB {18PI A
2. Turn the ignition switchON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures{see page 23-261. 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4, Disconnect front passenger's the airbag4P connector(A) from dashboardwire harnessB.
Wire side o{ {emaleterminals
ls the voltage specified? as YES Faulty SRSuniureplace SRSunit(see the page23-1221 .a NO-Short to powerin dashboard harness wire B; replace dashboard harness ! wire B.
07saz-T84011A
07xAz-s230100
5 . Connectthe SRSinflatorsimulator(2 Q connectors) and the simulatorlead F to dashboard wire harnessB.
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23-46
I
Reconnect batterynegativecable. the 7 . Erasethe DTCmemory. from the 12. Disconnect SRS unit connectorA (18P) SRS unit (seestep7 on page 23-221.
1 3 .Disconnectthespecialtool from dashboardwire

Readthe DTC. ls DTC 2-5 indicated? YES-Go to step 9. NO-Shon to ground in the front passenger's airbag airbaginflator;replacethe front passenger's ( s e ep a g e2 3 - 1 4 ) . 1 1 9 . Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. B harness .
't4. betweenthe No. 4 terminal of Checkresistance

SRS unit connectorA (18P)and body ground,the No. 13 terminal and body ground.the No. 5 a t e r m i n a a n d b o d y g r o u n d , n d t h e N o . 1 4t e r m i n a l l and body ground.Thereshould be an open circuit, o r a t l e a s tl M Q .
A SRSUNITCONNECTOR {18P}
BLU/RED
BLU/YEL
1 0 .Disconnect driver's airbag4P connectorfrom the

the cable reel {seestep 2 on page 23-21). 1 1 .Disconnect both seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 2322).
Wire side ol temaleterminals
ls the tesistanceas specitied? the YES Faulty SRSuniureplace SRSunit(see page23-122), .l wire harness B; NO Shortto groundin dashboard w s r e p l a cd a s h b o a r di r eh a r n e sB . l e
I
23-47
sRs
DTC3-1:Openin Driver's SeatBeltTensioner DTC3-2:Increased Resistance Driver's in SeatBeltTensioner
Special Tools Required . sRS inflatorsimulator07sAz-TB4011A . SRSsimulatorlead C 07TM-S25011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting lntermittentFailures(see page 23-26). 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Disconnect driver's seat belt tensioner2P the connector{A) trom the floor wire harness. NO-Open or increased resistance the driver's in seat belt tensioner;replacethe driver'sseat belt (seepage23-4).I L Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait Ior 3 minutes. 10. Disconnect floor wire harness4P connector the C403{A)from dashboardwire harnessB. 6. Reconnect batterynegativecable. the 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 3-1ot DTC 3-2 indicated? YES Go to step 9.
07sAz-T8401'lA
07sAz-T84011A
1 1 .Connectthe SRSinflatorsimulator(2 Q connectors) and simulatorlead F to dashboard wire harnessB.
1 2 . Reconnect batterynegativecable. the

07TAZ-52501'lA 5. ConnecttheSRSinflatorsimulator(2 0 connector) and simulatorlead C to the floor wire harness. Erasethe DTCmemory.
1 4 .Readthe DTC.
ls DTC 3-1 or DTC 3-2 indicated? YES Go to step 15. N O - O p e n o r i n c r e a s e de s i s t a n c ie t h e f l o o rw i r e r n harness;replacethe floor wire harness.l
t5.
Turn the ignition switch OFF.Disconnect the batterynegativecable.and wait for 3 minutes.
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23-48
I
to.
Oisconnect driver's airbagconnector(seestep the f airbag 2 on page 23-21), ront passenger's connector(seestep 3 on page 23-21),andfront passenger's seat belt tensionerconnector(seestep 5 on page 23-22).
DTC3-3:Shortto AnotherWire or Decreased in Resistance Driver's SeatBeltTensioner

SpecialToolsRequired . SRS inflatorsimulator07SAZ-T8401'1A . SRSsimulatorlead C 07TM-S25011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthatthe SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on?
from the 1 7 . Disconnect SRSunit connectorA (18P) Do SRSunit (seestep 7 on page 23-22). not disconnect the specialtool from dashboardwire harnessB. betweenthe No.8 terminal and 1 8 . Checkresistance r t h e N o . 1 7t e r m i n a o f S R Su n i tc o n n e c t oA ( 1 8 P ) . l T h e r es h o u l db e 2 . 0 - 3 . 0 Q . CONNECTOR A (18P) SRS UNIT RED/WHT
2
YES Go to step 3. NO-lntermittent failure,system is OK at this time, IntermittentFailures{see Go to Troubleshooting page 23-26). the Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. Disconnect driver'sseat belt tensioner2P the connector(A) from the floor wire harness.
i-4
\lel a;
10 1 l 1Z t 3
t 5 16
E a
I ]
RED/BLU terminals Wiresideof female
ls the resistance as specitied? YES FaultySRS unit or poor contactat SRSunit and the SRSunit. Checkthe connectorA (18P) connection; the connectionis OK, replacethe if SRSunit (seepage 23-'1221.a resistance dashboard in NO Open or increased B d w wire harness ;replace ashboard ire harness B,t
07TAZ-S25011A -T84011A
( s 5 . C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 0 c o n n e c t o r ) a n d s i m u l a t o r e a dC t o t h e f l o o rw i r e h a r n e s s . l
I
(cont'd)
23-49
sRs
6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 3-3 indicated? YES-Go to step L NO-Shon in the driver'sseat belt tensioner; replacethe driver's seat belt (seepage 23-4).1 L Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnect floor wire harness4P connectorC403 (A)from dashboardwire harnessB. 18. Disconnect specialtool from dashboardwire the harnessB. 1 9 . C h e c k e s i s t a n cb e t w e e n h e N o . 8 t e r m i n a a n d r e t l t h e N o . 1 7t e r m i n a o f S R Su n i tc o n n e c t oA ( ' l 8 P ) . l r Thereshould be an open circuit,or at least 1 l\4Q .
SRSUNIT CONNECTOR I18P) A
16. Disconnect driver'sairbagconnector(seestep the passenger's 2 on page23-211,lront airbag connector(seestep 3 on page 23-21), and front passenger's seat belt tensionerconnector(seestep 5 on page 23-22). ) 1 7 . D i s c o n n e c t R Su n i t c o n n e c t oA ( 1 8 P f r o m t h e S r SRSunit (seestep 7 on page 23-22:,.
RED/WHT
RED/BLU
07sAz-TB4or 1A
W i r es i d e f f e m a l ee r m i n a l s o t
ls the resistanceas specified? YES FaultySRS unit; replacethe SRSunit (see page 23-1221.a N O - S h o r ti n d a s h b o a r d i r e h a r n e s s ; r e p l a c e w B dashboard ire harness .l w B
1 1 .ConnecttheSRSinflatorsimulator(2 Q connectors) and simulatorlead F to dashboardwire harnessB. Reconnect batterynegativecable. the
1 3 .Erasethe DTCmemory. 1 4 .Readthe DTC.

ls DTC 3-3 indicated? YES-Go to step 15. NO Short in the floor wire harness;replacethe floor wire harness.l Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes.
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23-50
J
DTC3-4:Shortto Powerin Driver's SeatBelt Tensioner
SpecialToolsBequired . SRSlnflatorsimulator07SAZ-TB4011A . S R Ss i m u l a t o l e a dC 0 7 T M - S 2 5 0 1 1 A r . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-261. 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicatot stay on? YES- Go to step 3. NO Intermittent failure,system is OK at this time. Intermittent Failures(see Go to Troubleshooting page 23-261. the Turn the ignitionswitch OFF.Disconnect batterynegativecable,and wait for 3 minutes. Disconnect driver'sseat belt tensioner2P the connector(A)from the floorwire harness.
TB4O11A
6. Reconnect batterynegativecable. the 7. Erasethe DTCmemory. 8. Readthe DTC. Is DTC 3-4 indicated? YES- Go to step 9. NO-Short to power in the driver'sseat belt tensioner;replacethe driver'sseat belt ( s e ep a g e2 3 - 4 ) . 1 the L Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. floor wire harness4P connectorC403 10. Disconnect (A) from dashboard wire harnessB.
L ]
07sAz-T84011A
( s 1 1 .C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 0 wire and simlator lead F to dashboard connectors) B harness .
' t 2 .Reconnect batterynegativecable. the

Erasethe DTCmemory. 5. Connectthe SRSinflatorsimulator(2 !J connector) and simulatorlead C to the floor wire harness.
1 4 . Readthe DTC.
ls DTC 3-4 indicated? YES-- Go to step 15. N O - S h o n t o p o w e ri n t h e f l o o rw i r e h a r n e s s ; r e p l a c eh e f l o o rw i r e h a r n e s s . I t
tt T u r nt h e i g n i t i o n w i t c hO F F .D i s c o n n e c h e s batterynegativecable,and wait for 3 minutes.
(cont'd)
23-51
sRs
16. Disconnecl driver'sairbagconnector(seestep the 2 on page23-21l,Irontpassenger's airbag connector(seestep 3 on page 23-2'l), and front passenger's seat belt tensionerconnector(seestep 5 on page 23-221 . 17. Disconnect SRSunit connectorA (l8P)from the (see step 7 on page 23-22). SRS unit 18. Disconnect specialtoolfrom dashboardwire the harness . B 19. Reconnect batterynegativecable. the 20. Turn the ignition switch ON (ll), 21. Checkfor voltage betweenthe No. 8 terminal of SRSunit connectorA (18P) and body ground,and t h e N o . 1 7t e r m i n a la n d b o d yg r o u n d . h e r es h o u l d T be 0.5 V or less.
SRS UNIT CONNECTOR {18PI A
DTC3-5:Shortto Groundin Driver's SeatBelt Tensioner

Special Tools Required . sRS inflalor simularor07sAz-TB4011A . SRSsimulatorlead C 07TAZ-S25011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory {seepage23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-26). 3. Turn the ignitionswitch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4, Disconnect driver'sseat belt tensioner2P the connector(A) from the floor wire harness,
ls the voltageas specified? YES-Faulty SRSunit;replace SRSunit{see the page23-122], .a wire NO Shorttopowerin dashboard harness B; replace dashboard harness wire B.l
07TAZ-S25011A
-T84011A
5. Connectthe SRSinflatorsimulator(2 Q conneclor) and simulatorlead C to the floor wire harness.
L J
23-52
t
6. Reconnect batterynegativecable. the 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 3-5 indicated? YES-Go to step 9, NO Shortto ground in the driver'sseat belt tensioner;replacethe driver'sseat belt (seepage 23-4).I 9. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 10. Disconnect floor wire harness4P connectorC403 (A)from dashboard wire harnessB. 18. Disconnect specialtoolfrom dashboardwire the harnessB. 19. Checkresistance betweenthe No. 8 terminal of SRS unit connectorA (18P)and body ground, and t h e N o . 1 7t e r m i n a a n d b o d y g r o u n d . h e r es h o u l d l T be an open circuit,or at least 1 M Q .
A SRSUNIT CONNECTOR (18P)
16. Disconnectthedriver'sairbagconnector(seestep passenger's 2 on page23-211,lront airbag connector(seestep 3 on page 23-21), and front passenger's seat belt tensionerconnector(seestep 5 on page 23-22). 17, Disconnect SRS unit connectorA ('l8P)from the SRS unit (seestep 7 on page 23-221.
)
07sAz-T84011A
ls the resistance as specified? '11. ( C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 Q s connectors) and simulatorlead F to dashboardwire harness . B Reconnect batterynegativecable. the Erasethe DTCmemory. 1 4 . Readthe DTC. ls DTC 3-5 indicated? YES Go to step 15. NO-Short to ground in the floor wire harness; replacethe floor wire harness.l Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. Y E S - F a u l t yS R Su n i u r e p l a c eh e S R Su n i t{ s e e t page 23-122l,.a NO Short to ground in dashboard wire harnessB; replace ashboard ireharness .l d w B
23-53
sRs
DTC 21-1: Resistance Openor Increased in Tensioner Driver's SeatBeltBuckle
SpecialTools Required . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XAZ-S230100 1. ErasetheDTCmemory (seepage 23-261. 2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SBS indicatot stay on? YES Go to step3. NO-lntermittent failure,system is OK at this time. Intermittent Failures(see Go to Troubleshooting page 23-261. the 3. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. 4. Disconnect driver's seat belt buckletensioner the 4P connector(A) from the floor wire harness. 8. Readthe DTC. l s D T C 2 1 - 1i n d i c a t e d ? YES Go to step 9. NO Open or increased resistance the driver's in seat belt buckletensioner;replacethe driver'sseat b e l tb u c k l e . I 9. Turn the ignition switch OFF.Disconnect the batterynegativecable.and wait for 3 minutes. (see 10. Disconnect both side airbag2P connectors step 4 on page 23-2lland the front passenger's seat belt buckletensioner4P connector(seestep 6 . on page 23-22) 1 1 . D i s c o n n e c t R Su n i tc o n n e c t o B ( 1 8 P ) f r o mh e t S r SRSunit (seestep 7 on page 23'22).Do not the disconnect specialtool from the floor wire narness. 12. Checkresistance betweenthe No. 1 and No. 10 . t e r m i n a l s f S R Su n i tc o n n e c t oB ( 1 8 P )T h e r e o r s h o u l db e 2 . 0- 3 . 0 O . SRS UNIT CONNECTOR B Il8PI
GRN/YEL
l t ' ' A\ I' ? Y l r 0t l
1 5 t 6 17 t6
T I
GRN/BLK W i r e i d e ff e m a l t e r m i n a l s s o e
in{latorsimulator(2 Q connectors) 5. ConnecttheSRS and simulatorlead F to the Iloor wire harness. 6. Reconnect batterynegativecable. the 7. Erasethe DTCmemory.
ls the resistanceas specified? Y E S * F a u l t yS R Su n i to r p o o rc o n t a c a t S R Su n i t t ) c o n n e c t o B ( 1 8 P a n d t h e S R Su n i t .C h e c k h e r t connection; the connectionis OK, replacethe if SRS unit (seepage 23-122).a NO Open or increased resistance the floor wire in h a r n e s sr;e p l a c eh e f l o o rw i r e h a r n e s s . l t
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23-54
I
DTC 21-3: Short Another to Wireor Decreased Resistance Driver's in SeatBelt Euckle Tensioner
Special Tools Required . SRSinflatorsimulator07SAZ-T840't1A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (see page23-26). 2. Turn the ignition switch ON (ll),and checkthat the r S R Si n d i c a t o c o m e so n f o r a b o u t6 s e c o n d s n d a then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermittent failure.system is OK at this time. Go to Troubleshooting IntermittentFailureslsee page 23-26). Turn the ignitionswitch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. ( 1 1 . D i s c o n n e c t S Ru n i t c o n n e c t o r B 1 8 P ) f r o m t h e S SRS unit {seestep 7 on page 23-22l . '12. Disconnect specialtoolf rom the floor wire the harness. 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes, (see 10. Disconnect both side airbag2P connectors step 4 on page 23-21)and the front passenger's seat belt buckletensioner4P connector(seeslep 6 on page 23-22). 8. Readthe DTC. ls DTC 21-3 indicated? YES-Go to step 9. NO- Short in the driver'sseat belt buckle tensioner;replacethe driver's seat belt buckle.l
D i s c o n n e c h e d r i v e r ' s e a tb e l tb u c k l e e n s i o n e r tt s t 4P connector(A) from the floor wire harness.
13. Checkresistance betweenthe No. 1 and No. 10 . t e r m i n a l s f S R Su n i tc o n n e c t o B ( 1 8 P )T h e r e o r s h o u l db e a n o p e nc i r c u i t o r a t l e a s t1 M Q . ,

SRS UNIT CONNECTOR {18PI B
GRN/YEL
GRN/BLK
ls the resistanceas specified? C o n n e c t t h e R Si n f l a t o r i m u l a t o ( 2 i ) S s r c o n n e c t o r s )n d s i m u l a t o r e a dF t o t h e f l o o r a l w t r en a r n e s s . 6 . Reconnect batterynegativecable. the 7 . Erasethe DTCmemory. YES FaultySRS unit; replacethe SRSunit (see page 23-1221.a NO Short in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . l
23-55
sRs
(cont'dl DTC Troubleshootang
DTG 21-4: Shortto Powerin Driver's SeatBelt Buckle Tensioner
SpecialToolsRequired . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XM-S230100 1. Erasethe DTCmemory (seepage23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicatot stay on? YES-Go to step 3. NO Interminentfailure,system is OK at this time. IntermittentFailures(see Go to Troubleshooting page 23'26). the 3. Turn lhe ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. 4. Disconnect driver's seatbelt buckletensioner the 4P connector(A) from the floor wrre narness. Readthe DTC. ls DTC 21-4 indicated? YES Go to step 9. NO Shon to power in the driver'sseat belt buckle tensioner;replacethe driver's seatbelt buckle.l L Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. (see 1 0 .Disconnect both side airbag2P connectors step 4 on page 23-21)and the front passenger's seat belt buckletensioner4P connector(seestep 6 on page 23-22).
t,
.J
5 . ConnecttheSRSinflatorsimulator{2 0 and the simulatorlead F to the f loor connectors) wireharness. Reconnect batterynegativecable. the 7 . Erasethe DTCmemory.
\, .J
23-56
1 1 .Disconnect SRS unit connectorB (18P) from the SRSunit (seestep 7 on page 23-22). 1 2 . Disconnect specialtool from the floor wire the harness. Reconnect batterynegativecable. the 1 4 . Turn the ignitionswitch ON (ll). Checkfor voltage betweenthe No. 1 lerminal of SRSunit connectorB {18P)and body ground, and t h e N o . 1 0t e r m i n a la n d b o d y g r o u n d . h e r es h o u l d T be 0.5 V or less. SRS UNIT CONNECTOR B I18PI
DTC 21-5: Short Ground Driver's to in Seat BeltBuckle Tensioner

Special Tools Required . SRS inflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory {seepage 23-26}. 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES-Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting IntermittentFailures(see page 23-26). Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes.
J
ls the voltage specitied? as YES Faulty SRSunit;replace SRSunit(see the page23-1221 .f NO Shortto powerin thefloorwire harness; replace floorwire harness.l the
4 . Disconnect driver'sseat belt buckletensioner the 4P connector{A) from the floor wire harness.
( C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 Q s connectors) and simulatorlead F to the floor wire n ar n e s s . 6 . Reconnect batterynegativecable. the 7 . Erasethe DTCmemory.
(cont'd)
23-57
sRs
Readthe DTC. ls DTC 21-5 indicated? YES Go to step 9. NO Short to ground in the driver's seat belt buckletensioner;replacethe driver's seat belt buckle.l the 9 . Turn the ignitionswitch OFF.Disconnect batterynegativecable,and wait for 3 minutes. Special Tools Required . SRS inflatorsimulator07SM-T84011A . SRSsimulatorlead C 07TAZ-S25011A . SRSsimulatorlead F 07XAZ-S230100 'L Erasethe DTCmemory (seepage23-26). Turn the ignition switch ON {ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES-Go to step 3. NO- Intermittent failure,system is OK at this time. Intermittent Failures{see Go to Troubleshooting page23-26). Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. Disconnect front passenger's seat belt the tensioner2P connector(A) from the floor wire harness.
DTC4-1: Passenger's Belt Openin Front Seat renstoner DTC4-2:lncreased Resistance Front in Passenger's BeltTensioner Seat
1 0 .Disconnect both side airbag2P connectors(see

step 4 on page 23-21)andthe front passenger's seat belt buckletensioner4P connector(seestep 6 on page 23-221. from the 1 1 .Disconnect SRSunit connectorB (18P) (see step 7 on page 23-22) SRS unit
1 2 .Disconnect specialtool from the floor wire the

harness.
1 3 .Checkresistance betweenthe No. terminal of

SRS unit connectorB (18P)and body ground,and T t h e N o . 1 0t e r m i n a la n d b o d y g r o u n d . h e r es h o u l d b e a n o p e nc i r c u i t o r a t l e a s t1 M Q . , SRSUNITCONNECTOR{18PI B
'1
ls the tesistanceas specilied? YES Faulty SRSuniureplace SRSunit(see the page23-122) .a N O - S h o r t o g r o u n dn t h ef l o o rw i r eh a r n e s s ; i replace floorwire harness.l the
07TAZ-525011A
5. Connectthe SRS inflatorsimulator(2 0 connector) l a n d s i m u l a t o r e a dC t o t h e f l o o rw i r e h a r n e s s .
\ J
23-58
)
6. Reconnect batterynegativecable. the 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 4-1 or DTC 4-2 indicated? YES Go to step 9. NO-Open or increased resistance the front in passenger's seat belttensioner;replacethe front passenger's seat belt (seepage 23-4). t L Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 10, Disconnect floor wire harness4P connector the C403(A)from dashboard wire harnessB. 17. Disconnect SRS unit connectorA (18P) from the SRS unit (seestep 7 on page 23-22). not Do disconnect specialtool from dashboardwire the harnessB. 18. Checkresistance betweenthe No. 9 terminal and '18 the No. terminal of SRS unit connectorA (18P). T h e r es h o u l db e 2 . 0 - 3 . 0 Q .
SRS UNIT CONNECTOR {18P} A
15. Turn the ignition switch OFF.Disconnect the batterynegativecable.and wait for 3 minutes. '16. Disconnect driver'sairbagconnector{seestep the 2 on page23-211, tront passenger's airbag connector(seestep 3 on page 23-21), and driver's seat belt tensionerconnector(seestep 5 on page 23-221.
RED/YEL
1 2
3 4
5 15
1 0 11 12
l 6 1 7 r8l \t
)
07sAz-T840't 1A
r l
RED/BLK
ls the resistance as specitied? 1 1 .Connect the SRSinflatorsimulator(2 i) connectors) and simulatorlead F to dashboard wire harnessB. YES FaultySRS unit or poor contactat SRS unit connectorA (18P)and the SRS unit. Checkthe connection;if the connectionis OK, replacethe SRS unit (seepage 23-122l,.a NO-Open or increased resistance dashboard in wire harnessB; replacedashboard wire harness B.T
1 2 .Reconnect batterynegativecable. the

Erase the DTCmemory. 1 4 . Readthe DTC. ls DTC 4-l or DTC 4-2 indicated? YES-Go to step '15.
NO-Open or increased resistance the floor wire in harness;replacethe floor wire harness.I
I
23-59
sRs
DTC4-3:Shortto AnotherWire or Decreased Resistance FrontPassenger's Belt in Seat Tensioner
Special Tools Required . SRSinflatorsimulator07SAZ-TB40l1A . SRSsimulatorlead C 07TM-S25011A . SRSsimulatorlead F 07XAZ-S230100 1. ErasetheDTCmemory (seepage 23-26). 2. Turn the ignitionswitch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO Intermittent failure.system is OK at this time. lntermittentFailures(see Go to Troubleshooting page 23-26). 3. Turn the ignitionswitch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Disconnect front passenger's the seat belt tensioner2P connector(A)from the floor wire narness. 1 1 . onnectthe SRSinflatorsimulator(2 0 C wire connectors) and simulatorlead F to dashboard harnessB. Reconnect batterynegativecable. the
TB40,I1A
8. Readthe DTC. ls DTC 4-3 indicated? YES-Go to stepL NO-Short in the front passenger's seatbelt tensioner;replacethe front passenger's seat belt ( s e ep a g e2 3 - 4 ) . 1 9. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. '10. Disconnect floor wire harness4P connector the C403{A)from dashboardwire harnessB.
1 3 .Erasethe DTCmemory. 1 4 .Readthe DTC.

ls DTC 4-3 indicated?
07TAZ-S25011A
Y E S - G o t o s t e p1 5 . NO Short jn the floor wire harness;replacethe f l o o rw i r e h a r n e s s . I 1 5 .Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes.
Connectthe SRS inflatorsimulator(2 Q connector) and simulatorlead C to the floor wire harness. 6 . Reconnect batterynegativecable. the 7 . Erasethe DTCmemory.
\ J
23-60
16. Disconnectthe driver'sairbagconnector(seestep 2 on page23-211, front passenger's airbag connector(seestep 3 on page 23-21), and driver,s seat belt tensionerconnector(seestep 5 on page 23-221. 17. Disconnect SRSunit connectorA (18p)from the SRS unit (see step 7 on page 23-22). 18. Disconnect specialtool from dashboardwire the harnessB. 19. Checkresistance betweenthe No. 9 terminal and t h e N o . 1 8t e r m i n a o f S R Su n i tc o n n e c t oA ( 1 8 p ) . l r T h e r es h o u l db e a n o p e nc i r c u i t o r a t l e a s t1 M e . ,
SRSUNITCONNECTOR I18P} A
DTC4-4:Shortto Powerin FrontPassenger's SeatBeltTensioner

Special Tools Required . SRS inflatorsimulator07SAZ-T84011A . S R Ss i m u l a t o r e a dC 0 7 T A Z - S 2 5 0 1 1 A l . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON {ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO- Intermiftent failure.system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-261. 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Disconnectthe front passenger's seat belt tensioner2P connector(A)from the floor wire harness.
RED/YEL
2 3
4
10 t l 12 t 3 I
15 16 1 7
I 6] t
T
r8l \P
RED/BLK
ls the resistance specified? as YES-Faulty SRSunit;replace SRSunit(see the page 23-1221 .f NO-Short in dashboard harness replace wire B; d a s h b o a r di r eh a r n e sB .I w s
07TAZ-S2501'lA
5. Connectthe SRSinflatorsimulator(2 e connector) and simulatorlead C to the floor wire harness.
{cont'd)
23-61
sRs
the 6. Reconnect batterynegativecable. 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 4-4 indicated? YES Go to step 9. seat NO-Short to power in the front passenger's seat belt tensioner;replacethe front passenger's b e l t( s e ep a g e2 3 - 4 ) . I the 9. Turn the ignition switch OFF.Disconnect batterynegativecable.and wait for 3 minutes. '10.Disconnect floor wire harness4P connector C403(A)from dashboardwire harnessB. the 1 5 .Turn the ignitionswitch OFF.Disconnect batterynegativecable,and wait for 3 minutes.
t o . Disconnect the driver's airbagconnector(seestep
airbag tront passenger's 2 on page23-211, and drivefs connector(seestep 3 on page 23-21), seatbelt tensionerconnector(seestep 5 on page 23-22t. SRS unit connectorA ('l8P)trom the 1 1 . Disconnect SRS unit (seestep 7 on page 23-22). 1 8 . Disconnect specialtool from dashboardwire the harness . B the 1 9 . Reconnect batterynegativecable.
20. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 2 1 .Checkfor voltage betweenthe No. 9 terminal of

) r S R Su n i tc o n n e c t oA ( 1 8 P a n d b o d y g r o u n d ,a n d T l t h e N o . 1 8t e r m i n a a n d b o d y g r o u n d . h e r es h o u l d be 0.5 V or less. A SRSUNITCONNECTOR(18PI
t'
07sAz-TB4o11A
1 1 .Connectthe SRSinflatorsimulator(2 0 wire and simulatorlead F to dashboard connectors) B harness . the Reconnect batterynegativecable.
tJ.
terminals WiresideoJJemale
Is the voltageas specified? YES FaultySRSunit; replacethe SRS unit (see page 23'1221.a B w N O S h o r t t o p o w e ri n d a s h b o a r d i r e h a r n e s s ; B w replace ashboard ireharness .l d
Erasethe DTCmemory.
1 4 . Readthe DTC. ls DTC 4-4 indicated? Y E S - G o t o s t e p1 5 . NO- Short to power in the floor wire harness; replacethe floor wire harness.l
J 23-62
I
DTC4-5:Shortto Groundin FrontPassenger's SeatBeltTensioner
Special Tools Required . SRSinflatorsimulator07SAZ-TB40'11A . SRSsimulatorlead C 07TAZ-S25011A . SRSsimulatorlead F 07XAZ-S230100 1. ErasetheDTCmemory (seepage 23-26]|. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k t h a t t h e s SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? Y E S - G o t o s r e p3 . NO-lntermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-26l,. 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 8. Readthe DTC. ls DTC 4-5 indicated? YES-Go to step 9. NO Short to ground in the front passenger's seat belt tensioner;replacethe front passenger's seat b e l t( s e ep a g e2 3 - 4 ) . I 9. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 10. Disconnect floor wire harness4P connector the C403(Alfrom dashboardwire harnessB.
TB40t 1A
4. Disconnect front passenger's the seat belt tensioner2P connector(A) from the floor wire harness.
1 1 .Connectlhe SRS inflatorsimulator(2 e connectors) and simulatorlead F to dashboardwire harness . B 1 2 . Reconnect batterynegativecable. the Erasethe DTCmemory. 1 4 . Readthe DTC. 07TAZ-SZ501rA Connect the SRS inflatorsimulator(2 e connector) a n d s i m u l a t o r e a dC t o t h e f l o o rw i r e h a r n e s s . l Reconnect batterynegativecable. the 7 . Erasethe DTCmemory. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. ls DTC 4-5 indicated? YES Go to step 15. NO-Short to ground in the floor wire harness; r e p l a c eh e f l o o rw i r e h ar n e s s . l t
(cont'd)
23-63
sRs
16. Disconnect driver's airbagconnector(seestep the airbag front passenger's 2 on page 23-21), and driver's connector(seestep 3 on page 23-21). seat belt tensionerconnector(seestep 5 on page 23-22). t S r 1 7 . D i s c o n n e c t R Su n i tc o n n e c t oA ( 1 8 P ) f r o mh e SRSunit (seestep 7 on page 23-221. the 18. Disconnect specialtoolfrom dashboardwire harnessB. betweenthe No.9 terminal of 19. Checkresistance ) a S R Su n i tc o n n e c t oA ( 1 8 P a n d b o d y g r o u n d , n d r T t h e N o . l 8 t e r m i n a la n d b o d y g r o u n d . h e r es h o u l d . b e a n o p e nc i r c u i t o r a t l e a s t1 M Q .
A SRSUNITCONNECTOR {18P)
in Resistance DTC22-1: Openor Increased Tensioner FrontPassenger's BeltBuckle Seat

SpecialTools Required . SRSinflatorsimulator07SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTC memory (see page 23-261. 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes otf. Does the SRS indicator stay on? YES-Go to step 3. NO-lntermittent failure,system is OK at this time. Failures(see Intermittent Go to Troubleshooting page23-26). the 3. Turn the ignition switch oFF. Disconnect batterynegativecable,and wait for 3 minutes. seat belt buckle front passenger's 4. Disconnectthe tensioner4P connector(A)from the floor wire harness.
\,
w i r e s i d eo f l e m a l et e r m i n a l s
ls the rcsistance as specified? t S Y E S F a u l t y R Su n i Ur e p l a c eh e S R Su n i t ( s e e page 23-1221.1 wire harnessB; NO-Short to ground in dashboard B w replace ashboard ireharness .I d
( s 5 . C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 Q and the simulatorlead F to the floor connectors) w t r eh a r n e s s .
23-64
t
6. Reconnect bafterynegativecable. the 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 22-1 indicated? YES-Go to step 9. NO Open or increased resistance the front in passenger's seat belt buckletensioner;replacethe front passenger's seat belt buckle.l 9. Turn the ignitionswitch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 10. Disconnect both side airbag2P connectors(see step 4 on page23-21)and the driver's seat belt buckletensioner4P connector(seestep 6 on page 23-22). 1 1 . D i s c o n n e c t R Su n i tc o n n e c t oB ( 1 8 P ) f r o m h e S r t SRSunit (seestep 7 on page 23-22). not Do disconnect specialtool from the floor wire the harness. 1 2 . C h e c kr e s i s t a n cb e t w e e n h e N o . 2 a n d N o . 1 1 e t terminalsof SRS unit connectorB ('l8P). There s h o u l db e 2 . 0 3 . 0 0 .
SRSUNITCONNECTOR I,I8PI B
DTC22-3: Shortto AnotherWire or Decreased Resistance FrontPassenger's in SeatBeltBuckle Tensioner

SpecialToolsRequired . SRS inflatorsimulator07SAZ-TB4011A . SRSsimulator lead F 07XAZ,S230100 '1. Erasethe DTCmemory (seepage 23-26).
2. Turn the ignition switch ON fll), and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermiftent failure,system is OK at this time. Go to Troubleshooting IntermittentFailures(see page 23-26),. 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Disconnect front passenger's the seat belt buckle tensioner4P connector(A) from the floor wire harness.
)m
3
r5 r6 1T 1 8
W i r e i d e ff e m a l t e r m i n a l s s o e 5 . C o n n e ctth e S R Si n f l a t o r i m u l a t o ( 2 Q s r connectors) and the simulatorlead F to the floor w t r eh a r n e s s . 6. Reconnect batterynegativecable. the 7 . E r a s e h e D T Cm e m o r y . t
ls the resistance as specified? YES FaultySRS unit or poor contactat SRS unit ) c o n n e c t o B ( 1 8 P a n d t h e S R Su n i r .C h e c k h e r t connection; the connectionis OK, replacethe if SRSunit (seepage 23-122).a
I t
NO Open or increased resistance the floor wire in harness;replacethe floor wire harness.l {cont'd)
23-65
sRs
8. Readthe DTC. ls DTC 22-3 indicated? YES Go to slep 9. seat belt buckle NO-Short in the front passenger's seat belt tensioner;replacethe front passenger's buckle.l the 9. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. (see both side airbag2P connectors 10. Disconnect s t s t e p4 o n p a g e2 3 - 2 1 ) a n dh e d r i v e r ' s e a tb e l t buckletensioner4P connector(seestep 6 on page 23-22). '11. t r D i s c o n n e c t R Su n i tc o n n e c t oB { 1 8 P ) f r o m h e S SRS unit (seestep 7 on page23-221. the 12. Disconnect specialtool from the floor wire ha r n e s s . t e 1 3 . C h e c kr e s i s t a n cb e t w e e n h e N o . 2 a n d N o . 1 1 There terminalsof SRS unit connectorB ( 18P). 'l should be an open circuit,or at least M !) .
B SRSUNIT CONNECTOR {18P} GRN/RED
DTC22-4: Shortto Powerin FrontPassenger's Tensioner SeatBeltBuckle

SpecialToolsRequired . S R Si n f l a t o r i m u l a t o 0 7 S A Z - T B 4 0 1 1 A s r . S R Ss i m u l a t o r e a dF 0 7 X A z5 2 3 0 1 0 0 l 1. Erasethe DTCmemory (seep age23-26). t s 2 . T u r nt h e i g n i t i o n w i t c hO N { l l } ,a n d c h e c k h a tt h e a S R Si n d i c a t oc o m e so n f o r a b o u t6 s e c o n d s n d r then goes off. Does the SHS indicator stay on? YES Go to step 3. im N O I n l e r m i t t e n t f a i l u r e , s y s t es O K a t t h i s t i m e . Failures(see Intermittent Go to Troubleshooting page 23-261. the 3. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. seat belt buckle the 4. Disconnect front passenger's tensioner4P connector(A) from the floor wire narness.
GRN
terminals WiresideoI female ( s 5 . C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 ! J and simulatorlead F to the floor wire connectors) h ar n e s s .
ls the resistanceas specified? YES FaultySRSunit; replacethe SRS unit (see page 23'1221 .a NO Short in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . I
\ J
23-66
t
6. Reconnect batterynegativecable. the 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 22-4 indicated? YES Go to step g. NO-Short to power in the front passenger,s seat belt buckletensioner;replacethe front passenger,s seat belt buckle. ! 9. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes, 1 1 .Disconnect SRS unit connectorB (18P) from the SRS unit (seestep 7 on page 23-221.
1 0 .Disconnect both side airbag2P connectors(see

s t e p4 o n p a g e2 3 - 2 1 ) a n dh e d r i v e r ' s e a tb e l t t s buckletensioner4P connector(seestep 6 on page ,1_r'>\
' t 2 .Disconnect
harness.
t5.
the specialtool from the floor wire
Reconnect batterynegativecable. the
1 4 . Turn the ignition switch ON (ll). Checkfor voltage betweenthe No. 2 terminal of S R Su n i tc o n n e c t oB { 1 8 P ) n d b o d y g r o u n d , n d r a a t h e N o . 1 1t e r m i n a la n d b o d y g r o u n d . h e r es h o u l d T b e 0 . 5V o r I e s s . SRSUNIT CONNECTOR B I18P)
ls the voltageas specified? Y E S - F a u l t yS R Su n i t ;r e p l a c eh e S R Su n i t ( s e e t page 23-1221 .l NO Short to power in the floor wire harness; replacethe floor wire harness.l
23-67
sRs
DTC22-5: Shortto Groundin Front Tensioner Seat Passenger's BeltBuckle
SpecialTools Required . SRSinflatorsimulator07SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. failure,system is OK at this time. NO - Intermittent IntermittentFailures(see Go to Troubleshooting page 23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. front passenger's seat belt buckle 4. Disconnectthe tensioner4P connector(A)from the floor wire harness, 8. Readthe DTC. ls DTC 22-5 indicated? YES-Go to step 9. seat NO Short to ground in the front passenger's belt buckletensioner;replacethe front passenger's s e a tb e l tb u c k l e . l 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnect both side airbag2P connectors(see page 23-21) and the driver'sseat belt step 4 on buckletensioner4P connector(seestep 6 on page 23-22t. t r 1 1 . D i s c o n n e c t R Su n i tc o n n e c t oB ( 1 8 P l f r o m h e S SRS unit (see step 7 on page 23-221. the 12. Disconnect specialtool from the floor wire harness, 13. Checkresistance betweenthe No. 2 terminal of and body ground, and SRSunit connectorB (18P) the No, 11 terminal and body ground.Thereshould be an open circuit,or at least 1 M Q. g SRSUNITCONNECTOR{18PI
b U
5 . Connectthe SRSinflatorsimulator(2 Q and simulatorlead F to the floor wire connectors) narness. the 6 . Reconnect batterynegativecable. 1 . Erasethe DTCmemory.
ls the resistance as specified? YES-Faulty SRSunit; replacethe SRS unit (see page 23-1221 .a NO Short to ground in the floor wire harness; replacethe floor wire harness.l
!U
23-68
I
DTCs-1,5-2,5-4,s-8,6-3,6-4,6-7,6-8,7-1, 7-2,7-3, A-1,4-2, 8-4,8-5,8-6,9-1,9-2: 8-3, Internal Failure the SRSUnit of
NOTE:Beforetroubleshooting any of these DTCs,check voltage.lf the voltage is low, repair the battery/system the chargingsystem or replacethe batterybefore troubleshooting SRS.lf the battery/system the voltage is now OK, ask the customerif the batteryever went oeao, 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignitionswitch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicatot stay on? Y E S R e p l a c eh e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . 1 t NO Intermittent failure,system is OK at this time. Go to Troubleshooting lntermittentFailures(see page23-26).
DTC10-1, 10-2, 10-3, 10-4, 10-s,10-6, 10-7: Airbags, SideAirbags, and/or SeatBeltand Tensioners Deployed SeatBeltBuckle
The SRS unit must be replacedafter any airbagsand/or tensionershave deployed(seepage 23-122). !
I
23-69
SRS
DTC13-1, 13-2: Internal Failure the Driver's of Sidelmpact Sensor
1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicatot stay on? YES Replace driver's side impact sensor(see the page 23-123) .a NO Intermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-261.
DTC14-1, 14-2: Internal Failure ofthe Front Passenger's lmpact Side Sensor
1. Erasethe DTCmemory (seepage23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Replace the front passenger's side impact sensor (see page 23-123],.1 NO-lntermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-26).
I J
23-70
I
DTC9-3:Fau Driver's lty SeatBeltBuckle Switch
1. Erasethe DTCmemory (seepage 23 26). 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) , h e n b u c k l e n d s t a u n b u c k l eh e d r i v e r ' s e a tb e l ts e v e r atl i m e s . t s 3. Readthe DTC. ls DTC 9-3 indicated? YES Go to step 4. failure,system is OK at this time. NO Intermittent Go to Troubleshooting IntermittentFailures(see page 23-261.
4 . Turn the ignition switch OFF. 5 . Disconnect the driver's seat belt buckleswitch 3P
6. Bucklethe driver's seat belt. Checkresistance betweenthe No. 1 and No.3 terminalsofthe driver's seat belt buckleswitch 3P c o n n e c l o rT h e r es h o u l db e 0 1 ( J . . Checkresistance betweenthe No. 1 and No.2 Thereshould be terminalsof the same connector. a n o p e nc i r c u i t o r a t l e a s t1 M Q . , BUCKLE DRIVER'S SEAT BELT SWITCH 3PCONNECTOR
BLU/RED
connector(A)from the floor wire harness.
t
T e r m i n a li d e f m a l e e r m i n a l s t s o Ate the resistancereadings as specified? YES- Go to step 7. NO Replace driver'sseat belt buckleassembly, the t h e n c l e a rt h e D T C . I
I
(cont'd)
23-71
sRs
7, Unbucklethe driver'sseat belt. Checkresistance betweenthe No. 1 and No.2 terminalsofthe driver'sseat belt buckleswitch 3P c o n n e c t o rT h e r es h o u l db e 0 1 Q . . Checkresistance betweenthe No. 1 and No. 3 terminalsof the same connector. There should be an open circuit,or at least 1 M Q DRIVER'S SEAT BELT BUCKLE SWITCH CONNECTOR 3P 8. Checkresistance betweenthe No. 1 terminal ofthe floor wire harness3P connectorand bodv oround. '1 T h e r es h o u l db e 0 0.
FLOOR WIREHARNESS CONNECTOR 3P

ls the resistanceas specified? YES Go to step 9. N O O p e ni n t h e f l o o rw i r e h a r n e s s r p o o r g r o u n d o c o n n e c t i o n t G 5 5 1 . f G 5 5 ' 1s O K , r e p l a c eh e f l o o r a l i t w r r eh a r n e s s . l 9 . Disconnect negativecablefrom the battery. the
BLU/RED
T e r m i n a li d e I m a l e e r m i n a l s s o t ls the rcsistance as specified? YES Go to step 8. NO-Replace the driver'sseat belt buckleassembly, then clearthe DTC.I
1 0 . Disconnect SRS unit connectorC (8P)from the SRS unit {seestep 7 on page 23-22).
\ J
23-72
I
11. Checkresistance betweenthe No. 2 terminal of the floor wire harness3P connectorand body ground. Thereshould be an open circuit.or at least 1 fvlQ ,
FLOORWIRE HARNESS3P CONNECTOR
13. Checkresistance betweenthe No. 8 terminal of SRS unit connectorC (8P)and the No. 3 terminal of There should the floor wire harness3P connector. be0 1Q. UNITCONNECTORC FLOORWIRE HARNESS SRS I8P} 3PCONNECTOB
Wiresideot temale terminals
ls the resistance as specified? Y E S - G o t o s t e p1 2 . NO Short to ground in the floor wire harnessor multiplexcontrol unit. Replace faulty harnessor the part.I
ls the resistance as specitied? YES Go to step 14. NO Open in the floor wire harness;replacethe floor wire harness.l 1 4 . Checkresistance betweenthe No. 4 terminal of l S R Su n i tc o n n e c t oC ( 8 P ) n d t h e N o . 2 t e r m i n a o f r a There should the floor wire harness3P connector. be0-1 0.
FLOOR WIREHARNESS 3P CONNECTOR SRSUNITCONNECTOR IsPI C
1 2 .Checkresistance betweenthe No. 3 terminal of the

floor wire harness3P connectorand body ground. T h e r es h o u l db e a n o p e nc i r c u i to r a t l e a s t1 M Q . , FLOOR WIREHARNESS CONNECTOR 3P
LT GRN
Wiresideof female terminals ls the resistanceas specified? ls the resistance as specified? Y E S R e p l a c eh e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . 1 t YES Go to step 13. N O - S h o r t t o g r o u n di n t h e f l o o rw i r e harness; replacethe floor wire harness.I N O O p e ni n t h e f l o o rw i r e h a r n e s s r m u l t i p l e x o control unit, or poor connectionat the floor wire fuse/relaybox, and the harness, the under-dash multiplexcontrol unit. Checkthe connectionat the floor wire harness, the under-dash fuse/relaybox, and the multiplexcontrol unit. lf the connectionis OK, replacethe faulty harnessor part.l
23-73
SRS
DTC9-4:FaultyFrontPassenger's Belt Seat Buckle Switch
1. Erasethe DTCmemory {seepage 23-26). 2 . T u r nt h e i g n i t i o n w i t c hO N { l l ) ,t h e n b u c k l e n d s a unbucklethe front passenger's seat belt several times. 3. Readthe DTC. ls DTC 9-4 indicated? YES-Go to step 4. NO Intermittent failure,system is OK at this time. Intermiftent Go to Troubleshooting Failures{see page 23-26)'. 4. Turn the ignition switch OFF. 5. Disconnect front passenger's the seat belt buckle switch 3P connector(A) from the floor wire harness. Terminal of male side terminals Is the rcsistanceas specified? YES-Go to step 7. NO Replace front passenger's the seat belt buckle assembly, then clearthe DTC.I 6. Bucklethe front passenger's seat belt. Checkresistance betweenthe No. 1 and No.3 terminalsof the front passenger's seat belt buckle switch 3P connector. Thereshould be 0- 1 Q. Checkresistance betweenthe No. 1 and No.2 terminalsof the same connector. Thereshould be a n o o e nc i r c u i t o r a t l e a s t1 M Q . , FRONT PASSENGER'S BELT SEAT BUCKLE SWITCH CONNECTOR 3P BLU/RED
23-74
7. Unbucklethe front passenger's seat belt. Checkresistance betweenthe No. 1 and No. 2 terminalsof the front passenger's seat belt buckle T s w i t c h3 Pc o n n e c t o r . h e r es h o u l db e 0 1 ! ) . Checkresistance betweenthe No. 1 and No. 3 Thereshould be terminalsof the same connector. an oDencircuit,or at least 1 M Q FRONT PASSENGER'S BELT SEAT BUCKLE SWITCH CONNECTOR 3P
8. Checkresistance betweenthe No. 1 terminal ofthe floor wire harness3P connectorand body ground. T h e r e h o u l d e0 1 Q . s b
FLOORWIRE HARNESS3P CONNECTOR

Terminalside of maleterminals
ls the tesistance as specified? YES Go to step 9. NO-Open in the floor wire harnessor poor ground connectionat G551.lf G551is OK, replacethe floor wire harness.I 9 . Disconnect negativecablefrom the battery, the
Terminal of male side terminals ls the resistanceas specilied? YES Go to step 8. NO-Replace the front passenger's seat belt buckle assembly,then clearthe DTC.I
1 0 . Disconnect SRS unit connectorC (8P)from the SRS unit (see step 7 on page 23-22).
(cont'd)
23-75
sRs
1 1 . C h e c k e s i s t a n cb e t w e e n h e N o . 2 t e r m i n a o f t h e r e t l floor wire harness3P connectorand body ground. There should be an open circuit,or at least 1 M 0 . FLOOR WIRE HARNESS CONNECTOR 3P FLOORWIRE HARNESS SRS UNITCONNECTOR C (8P) 3PCONNECTOR 13. Checkresistance betweenthe No. 7 terminal of S R Su n i tc o n n e c t oC ( 8 P ) n d t h e N o . 3 t e r m i n a lo f r a the floor wire harness3P connector. T h e r es h o u l db e 0 - 1 Q .
Wiresideof female terminals Wiresideof female terminals ls the tesistance as specified? YES-Go to step 14. NO Open in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . I 1 4 . Checkresistance betweenthe No, 3 terminal of SRS unit connectorC (8P)and the No. 2 terminal of t h e f l o o rw i r e h a r n e s s Pc o n n e c t o f 3 T h e r e h o u l d e0 1 Q . s b
FLOOR WIREHARNESS 3P CONNECTOR SRS UNIT CONNECTOR ISPI C
ls the resistance as specified? Y E S - G o t o s t e p1 2 . NO-Short to ground in the floor wire harness; replacethe floor wire harness.I Checkresistance betweenthe No. 3 terminal of the floor wire harness3P connectorand body ground. There should be an open circuit,or at least 1 l\40 . FLOOR WIRE HABNESS CONNECTOR 3P
L J
Wiresideof temale terminals
ls the resistance as specified? Wiresideof female terminals Y E S - G o t o s t e p1 3 . NO Short to ground in the floor wire harness; replacethe floor wire harness.I ls the resistance as specified? Y E S R e p l a c eh e S R Su n i t( s e ep a g e2 3 - 1 2 2 ) . 1 t N O O p e nl n t h e f l o o rw l r e h a r n e s sr;e p l a c e t h e f l o o rw i r e h a r n e s s . l
\ J
23-76
DTC9-6:FaultyLeftFrontlmpactSensor
Special Tools Required . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead H 07YM-S3AA100 1. Erase the DTCmemory (seepage 23-26). 2. Turn the ignitionswitch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO Intermiftent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page23-26). 3. Turn the ignitionswitch OFF.Checkthe connections betweenSRS unit connectorA (18P) and the SRSunit. betweenthe engine compartmentwire harness2P connectorand the left front impactsensor{seepage23-13), and at connectorC401. Are the connections OK? YES Go to step 4. NO-Repair the poor connections and retest.lf DTC go 9-6 is still present, to step 4. Turn the ignition switch OFF.Disconnect the batterynegativecable.and wait for 3 minutes. Disconnect driver'sairbag4P connectorfrom the the cable reel (seestep 2 on page23-21).
8. Disconnect engine the compartment harness wire 2Pconnector fromthe leftfrontimpact sensor. {A)
from the 9 . Disconnect SRS unit connectorA {18P) SRSunit (seestep7 on page23-22J.
1 0 .Checkresistance betweenthe No. 10 and No. 11

There terminalsof SRSunit connectorA (18P). should be an oDencircuit.or at least 1 M 0 .
A SRSUNITCONNECTOR (18PI
2 3 5 6 7 8 9 10 t l 1Z t 3 15 16 17 1 8
RED
I T
ILK
ls the resistance as specitied? Disconnect front passenger's the airbag 4P wire harnessB {seestep connectorfrom dashboard 3 on page23-21). 7 . Disconnect both seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 2322). YES Go to step 11. N O - S h o r t i n t h e e n g i n e o m p a n m e nw i r e c t harnessor dashboard wire harnessB; replacethe f a u l t yh a r n e s s . I 1 1 .Reconnect batterynegativecable. the 12. Turn the ignition switch ON {ll).
{cont'd}
23-77
sRs
13. Check voltage between No. 10terminal SRS the of unitconnector (18P) bodyground. A and There shouid 'l V or less. be
SRS UNIT CONNECTOR {,I8P) A
16. Checkresistance betweenthe No. 10 and No. 11 terminalsof SRS unit connectorA (18P). There s h o u l db e 1 0 o r l e s s .
A SRS UNIT CONNECTOR Il8PI
10 11 12 l 3 t 4 15 1 6 1 1 t6
RED
Wire side oI femaleterminals
ls the voltage as specitied? YES-Go to step 14. NO-Short to power in the engine compartment wire harnessB; replace wire harnessor dashboard the faulty harness.l 1 4 . Turn the ignition switch OFF.
t5.
ls the rcsistance as specified? YES Faultyleft front impactsensoror SRS unit; replace the left front impact sensor (seepage 23-125). lf the problem is still present,replacethe SRSunit ( s e ep a g e2 3 - 1 2 2 ) . 1 NO-Poor connectionat C401,faulty engine compartmentwire harness,or faulty dashboard wire harnessB. InspectC401.lf it is OK, replacethe faulty harness.l
\y,
Connectthe SRS inflatorsimulator(jumper connector) and simulatorlead H to the engine compartmentwire harness2P connector(A).
07YAZ-S3AA100
07SAZ-TB,O11A
\."r1
23-78
DTC 9-7:Faulty Right Frontlmpact Sensor

Special Tools Bequired . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead H 07YM-S3AA100 1. Erasethe DTCmemory {seepage23-26). 2 . T u r nl h e i g n i t i o n w i t c hO N { l l ) ,a n d c h e c k t h a t t h e s SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting IntermittentFailures(see page 23-26). 3. Turn the ignitionswitch OFF.Checkthe connections betweenSRSunit connectorA (18P) and the SRSunit, betweenthe engine compartmentwire harness2P connectorand the right front impactsensor(seepage 23-13), and at connectorC401. Are the connections OK? YES-Go to step 4. NO Repairthe poor connections and retest.lf DTC go 9-7 is still present, to step 4.
4 . Turn the ignition switch OFF.Disconnect the
Disconnect enginecompartmentwire harness the 2P connector(A) from the right front impactsensor.
Disconnect SRSunit connectorA (18P) from the SRS unit (see step 7 on page 23-221.
'10.Checkresistance between
the No. 1 and No. 12 terminalsof SRSunit connectorA (18P). There should be an open circuit,or at least1 M 0.
SRS UNIT CONNECTOR (18PI A GRN F!t 1 t 2 ) l
I r o l r l r13
SLK
1 6 1 7 18
batterynegativecable,and wait for 3 minutes.

5 . Disconnect driver'sairbag4P connectorfrom the the cable reel {seestep 2 on page 23-21). ls the resistance as specified? Disconnect front passenger's the airbag4P connectorfrom the dashboardwire harness(see step 3 on page 23-21). 7 . Disconnect both seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page2322). Y E S G o t o s t e p1 1 . N O - S h o r t i n t h e e n g i n e o m p a n m e nw i r e c t harnessor dashboard wire harnessB; replacethe f a u l t yh a r n e s s , I 1 1 .Reconnect batterynegativecable. the T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
I
(cont'd)
23-79
sRs
13. Check voltage between No.1terminal the ofSRS unitconnector (18P) bodyground. A and There should 1 V or less. be
SRSUNIT CONNECTOR I18P} A
'12 16. Checkresistance betweenthe No. 1 and No. (18P). terminalsof SRS unit connectorA There s h o u l db e 1 O o r l e s s . SRS UNIT CONNECTOR A {18P) GRN
J_2 l r l r 1
tE.]I
/A
BLK Wiresideof female terminals
t 3 1 1 r5 16 1 1 t6
ls the voltage as specified? YES Go to step 14. NO-Short to power in the enginecompartment wire harnessor dashboard wire harnessB; replace the faulty harness.l 1 4 . Turn the ignition switch OFF. Connect the SRS inflatorsimulator(jumper connector) and simulatorlead H to the engine compartmentwire harness2P connector(A).
ls the resistance as specitied? YES Faultyright front impactsensoror SRS unit; replacethe rightfront sensor{seepage 23-125). lfthe problem is still present,replacethe SRS unit (see page 23-1221.a NO- Poorconnectionat C401,faulty engine compartmentwire harness, faulty dashboard or wire harnessB. lnspectC401.lf it is OK, replacethe faulty harness,I
L J
07YAZ-S3AA100
23-80
I
DTC11-1: Openor Increased Resistance in Driver's SideAirbagInflator
SpecialToolsRequired . S R Si n f l a t o r i m u l a t o 0 7 S M - T B 4 0 1 1 A s r . SRSsimulatorlead E 07XM-S140200 1. Erasethe DTCmemory (seepage 23-26), YES Go to step 9. 2. Tu rn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SBS indicatot stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-261. 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 9. Turn the ignitionswitch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 10. Disconnect front passenger's the side airbag 2P connector(seestep 4 on page 23-21)and both seat belt buckletensioner4P connectors(seestep 6 on page 23-221. NO-Open or increased resistance the driver's in side airbag inflator;replacethe driver's side a i r b a g( s e ep a g e2 3 - 1 ' 1 5 ) . 1 6. Reconnect batterynegativecable. the 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 11-1indicated?
4. Disconnect floor wire harness2P connector(A) the from the driver'sside airbag.
07sAz-T84011A
5. Connectthe SRSinflatorsimulator(2 Q connector) and simulatorlead E to the floor wire harness.
I
{cont'd)
23-81
sRs
' It . D i s c o n n e c t S R Su n i tc o n n e c t oB ( 1 8 P ) f r o mh e r t
SRS unit (seestep 7 on page 23-22). not Do disconnect specialtool from the floor wire the harness2P connector.
12
DTC11-3: Short Another to Wireor Decreased Resistance Driver's in SideAirbag lnflator

SpecialToolsRequired ' S R Si n f l a t o r i m u l a t o 0 7 S A Z - T 8 4 0 1 1 A s r . SRSsimulatorlead E o7XAZ-S140200 1. Erasethe DTCmemory (seepage 23 26).
Checkresistance betweenthe No.6 and No. 17 . t e r m i n a l s f S R Su n i tc o n n e c t oB ( 1 8 P )T h e r e o r s h o u l db e 2 . 0- 3 . 0 Q . SRS UNIT CONNECTOR B I18PI WHT/BLU
1
2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h a tt h e s t SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicatot stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-26). Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. Disconnect floor wire harness2P connector(A) the f r o m t h e d r i v e r ' s i d ea i r b a g . s
10 t l
15IdFFI \
rr--r-{ lTlslsl a
WHT/BLK Wiresideof female terminals
ls the resistance as specified? YES-Faulty SRS unit or poor contactat SRS unit ) c o n n e c t o B ( 1 8 P a n d t h e S R Su n i t .C h e c k h e r t connection; the connectionis OK, replacethe if SRS unit (seepage 23'1221.a NO Open or increasedresistance the floor wire in harness;replacethe floor wire harness.l
07sAz-T84011A
( C o n n e ctth e S R Si n f l a t o r i m u l a t o r 2 0 c o n n e c t o r ) s a n d s i m u l a t o r e a dE t o t h e f l o o rw i r e h a r n e s s . l Reconnect batterynegativecable. the 1 . Erasethe DTCmemory.
23-82
I
8. Readthe DTC. ls DTC 11-3indicated? YES-Go to step9. NO*Shon to anotherwire in the driver's side airbag inflator;replacethe driver'sside airbag (see p a g e2 3 - 1 1 5 ) . I 9. Turn the ignition switch OFF.Disconnect the batterynegativecable.and wait for 3 minutes. 10. Disconnectthe front passenger's side airbag2P connector(seestep 4 on page 23-21)and both seat (seestep 6 on belt buckletensioner4P connectors page 23-22l,. 11. Disconnect specialtool from the floor wire the harness2P connector. 1 2 . D i s c o n n e c t R Su n i tc o n n e c t oB { 1 8 P ) f r o m h e S r t SRSunit {seestep 7 on page23-221. Special Tools Required . SRS inflatorsimulator07SAZ-T84011A . SRSsimulatorlead E o7XAZ-S140200 1. Erasethe DTCmemory {seepage 23-261. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h a t t h e s t SRS indicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-26l,. 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Disconnect floor wire harness2P connector(A) the from the driver'sside airbag.
DTG11-4: Short Power Driver's to in Side AirbagInflator
13. Checkresistance betweenthe No.6 and No. 17 , t e r m i n a l s f S R Su n i tc o n n e c t oB ( 1 8 P )T h e r e o r s h o u l db e a n o p e nc i r c u i to r a t l e a s t1 M 0 . ,

SRSUNITCONNECTOR {18PI B
WHT/BLU
07sAz-TB4011A WHT/BLK Wiresideof female terminals 5 . C o n n e ctth e S R Si n f l a t o r i m u l a t o ( 2 0 c o n n e c t o r ) s r l a n d s i m u l a t o r e a dE t o t h e f l o o rw i r e h a r n e s s .
ls the resistance as specified? YES FaultySRSunit; replacethe SRS unit {see page23-'t221 .a N O S h o n t o a n o t h e r i r e i n t h e f l o o rw i r e w harness;replacethe floor wire harness.I
(cont'd)
23-83
sRs
negative 6. Reconnect battery the cable. 7. Erase DTC the memory, 8. Read DTC. the 1 3 .Checkfor voltage betweenthe No. 6 terminal of Is DTC 11-4 indicated? YES-Go to step9. NO Shortto powerin the driver's sideairbag (seepage inflator; replace driver's the sideairbag 23-115).t
9 . Turn the ignition swilch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. SRS unit connectorB (18P)and body ground,and betweenthe No. 17 terminal and body ground. Thereshould be 0.5 V or less.
SRSUNITCONNECTOR I18P) B
1 1 .Disconnect SRS unit connectorB (18P) from the SRSunit (seestep 7 on page 23-22l,.
' t 2 .T u r n
t h e i g n l t i o n w i t c hO N ( l l ) . s
' 1 0 Disconnect front passenger's . the side airbag2P

connector(seestep 4 on page 23-21)and both seat (seesteD6 on belt buckletensioner4P connectors page 23-221.
WHT/BLK
ls the voltage as specitied? YES- FaultySRSuniUreplacethe SRS unit (see page 23-1221.a NO Short to power in the floor wire harness; r e p l a c eh e f l o o rw i r e h a r n e s s . l t
U J
\.J
23-84
I
DTC11-5: Short Ground Driver's to in Side AirbagInflator
Special Tools Required . S R Si n f l a t o r i m u l a t o 0 7 S M - T 8 4 0 1 1 A s r ' SRSsimulatorlead E o7XAZ-S140200 '1. Erase the DTCmemory {seepage 23-26). 8. Readthe DTC. ls DTC 11-5indicated? YES Go to step 9. NO Short to ground in the driver'sside airbag inflator;replacethe driver'sside airbag (seepage 23-115).t 9. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 10. Disconnect front passenger's the side airbag2P connector(seestep 4 on page 23-21)andboth seat belt buckletensioner4P connectors(seestep 6 on page 23-221. ( 1 1 . D i s c o n n e c t S Ru n i t c o n n e c t o r B 1 8 P ) f r o m t h e S SRS unit (seestep 7 on page 23-22). '12. Checkresistance betweenthe No. 17 and No. 15 . t e r m i n a l s f S R Su n i tc o n n e c t oB ( 1 8 P )a n d o r '17 b e t w e e n h e N o . a n d N o . 1 6t e r m i n a l sT h e n t . checkresistance betweenthe No. 17 terminal and body ground.Thereshould be an open circuit,or at l e a s t1 M 0 .
SRSUNIT CONNECTOR I18P) B
2. Turn the ignitionswitch ON {ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-261. 3. Turn the ignitionswitch OFF.Disconnect the batterynegativecable,and wait for 3 minutes.
4. Disconnect floor wire harness2P connector(A) the from the driver'sside airbag.
WHT/BLK
07saz-TB,r011A
Wiresideof female terminals Connectthe SRSinflatorsimulator(2 Q connector) and simulatorlead E to the floor wire harness. 6 . Reconnect batterynegativecable. the 7 . Erasethe DTCmemory. NO-Short to ground in the floor wire harness; r e p l a c eh e f l o o rw i r e h a r n e s s . I t ls the resistance as specified? YES FaultySRSunit; replacethe SRS unit (see page 23-122).a
I
23-85
sRs
Resistance in DTG 12-1: Openor Increased Front Passenger's AirbagInflator Side
SpecialToolsRequired . S R Si n f l a t o r i m u l a t o 0 7 S A Z - T 8 4 0 1 1 A s r . SRSsimulatorlead E o7XAZ-S140200 1. Erasethe DTCmemory (seepage 23-26). YES Go to step L t 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h a tt h e s SRSindicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES Go to step 3. failure, system is OK at this time. NO - Intermittent lntermittentFailures(see Go to Troubleshooting page23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnect floor wire harness2P connector(A) the side airbag. from the front passenger's the 9 . Turn the ignition switch OFF.Disconnect batterynegativecable.and wait for 3 minutes. resistance the front in NO-Open or increased passenger's side airbag inflator;replacethe front p a s s e n g e r 's i d ea i r b a g( s e ep a g e2 3 - 1 5 ) . 1 s 1 Reconnect batterynegativecable. the 7 . Erasethe DTCmemory. Readthe DTC. ls DTC 12-l indicated?
'1 Disconnect driver'sside airbag2P connector 0. the

{seestep 4 on page 23-21)andboth seat belt buckle (seestep 6 on page 23-22). tensioner4P connectors
07xAz-s1A0200
the SRSinflatorsimulator(2 Q connector) 5. Connect l a n d s i m u l a t o r e a dE t o t h e f l o o rw i r e h a r n e s s .
I J
23-86
I
1't Disconnect . SRS unit connectorB ('l8P)from the
SRSunit (seestep 7 on page 23-22). not Do disconnect specialtool from the floor wire the h a r n e s s Pc o n n e c t o r . 2
DTC12-3: Short Another to Wireor Decreased Resistance Front in Passenger's SideAirbagInflator

SpecialToolsRequired . S R Si n f l a t o r i m u l a t o 0 7 S A Z - T 8 4 0 1 1 A s r . SRSsimulatorlead E o7XAZ-S140200 1. Erasethe DTCmemory (seep age 23-261.
1 2 .Checkresistance betweenthe No.7 and No. 18

. t e r m i n a l s f S R S u n i t c o n n e c t oB ( 1 8 P )T h e r e o r s h o u l db e 2 . 0 3 . 0 ( J . SRS UNIT CONNECTOR B {18P) WHT/RED
2. Tu rn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3.
WHT/GRN Wiresideof female terminals
NO - Intermittent failure,system is OK at this time. Go to Troubleshooting IntermittentFailures(see page 23-26). Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes.
4 . Disconnect the floor wire harness2P connector(A)
ls the resistanceas specified?
YES FaultySRSunit or poor contactat SRS unit c o n n e c t oB ( l 8 P )a n dt h e S R Su n i t .C h e c k h e r t connection;lf the connectionis OK, replacethe SRSunit (seepage 23-1221.a NO Open or increased resistance the floor wire in h a r n e s sr;e p l a c eh e f l o o rw i r e h a r n e s s . I t
from the front passenger's side airbag.
07xAz-s1A0200
5. Connectthe SRSinflatorsimulator(2 0 connector) a n d s i m u l a t o r e a dE t o t h e f l o o rw i r e h a r n e s s . l
(cont'd)
23-87
sRs
6. Reconnect batterynegativecable. the 7, Erasethe DTCmemory. 8. Readthe DTC. ls DTC 12-3indicated? 1. Erasethe DTCmemory (seepage 23-26). YES-Go to step I NO Short to anotherwire in the front passenger's side airbag inflator;replacethe front passenger's s i d ea i r b a g( s e ep a g e2 3 - l l 5 ) . 1 the 9. Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. 10. Disconnect driver's side airbag2P connector the (seestep 4 on page 23-21)and both seat belt buckle tensioner4P connectors(seestep 6 on page 23-22). '!1. t D i s c o n n e c h e s p e c i a l t o o l f r o mh e f l o o rw i r e tt harness2P connector. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h a t t h e s t SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. failure,system is OK at this time. NO- Intermittent Failures{see Intermittent Go to Troubleshooting page 23-26). the 3. Turn the ignition switch OFF.Disconnect banery negativecable,and wait for 3 minutes. 4. Disconnect floor wire harness2P connector(A) the from the front passenger's side airbag. Special Tools Required . sRS inflatorsimulator07sAz-TB4011A . SRSsimulatorlead E 07XM-S140200
DTC12-4: to in Passenger's Short Power Front SideAirbagInflator
SRS unit connectorB ('lSPlfromthe 12. Disconnect SRS unit {see step 7 on page 23-221. 13. Checkresistance betweenthe No.7 and No. 18 . r t e r m i n a l s f s R S u n i tc o n n e c t o B ( 1 8 P )T h e r e o , s h o u l db e a n o p e nc i r c u i t o r a t l e a s t1 M 0 . B I18P) SRS UNIT CONNECTOR WHT/RED
-r-'r-Jl
2 3
10 l l
' 8lel n
15
-T
i['tl,Bl S
07xAz-s1A0200
5. Connect the SRS inflatorsimulator(2 Q connector) a n d s i m ul a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s . WHT/GRN
terminals Wiresideof {emale
ls the resistance as specilied? S t Y E S F a u l t y R Su n i t ;r e p l a c eh e S R Su n i t{ s e e page 23-1221.a w N O S h o r tt o a n o l h e r i r e i n t h e f l o o rw i r e harness;replacethe floor wire harness.I
\.J
23-88
\
6. Reconnect batterynegativecable. the 7. Erasethe DTCmemory.
1?
1 1 .Disconnect SRS unit connectorB (18P) from the SRS unit (see step 7 on page 23-221. Turn the ignition switch ON (ll).
8. Readthe DTC.
1 3 .Checkfor voltage betweenthe No. 7 terminal of

ls DTC 12-4 indicated ? YES Go to step 9. NO-Short to power in the front passenger's side airbaginflator;replacethe front passenger's side a i r b a g( s e ep a g e2 3 - 1 1 5 t . ) 9. Turn the ignitionswilch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. '10. Disconnect driver'sside airbag2P connector the (seestep 4 on page 23-21) and both seat belt buckle tensioner 4P connectors (see step 6 on page 23-22l,. WHT/GRN SRS unit connectorB ( l8P) and body ground,and betweenthe No. 18terminal and body ground. T h e r es h o u l db e 0 . 5V o r l e s s .
SRSUNIT CONNECTOR I18P) B
ls the voltage as specified? YES FaultySRSunil; replacethe SRSunit (see page 23-1221 .a NO Short to power in the floor wire harness; r e p l a c eh e f l o o rw i r e h a r n e s s . l t
23-89
sRs
in DTC12-5: Short Ground Front to Passenger's AirbagInflator Side
SpecialToolsRequired . SRSinflatorsimulator07SAZ-T84011A . SRSsimulatorlead E o7XAZ-S140200 1. Erasethe DTCmemory (seepage23-26). YES Go to step9. 2. Turn the ignitionswitch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. failure,system is OK at this time. NO Intermittent Intermittent Failures(see Go to Troubleshooting page 23-261. 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnect floor wire harness2P connector(A) the from the front passenger's side airbag. the 9. Turn the ignitionswitch OFF.Disconnect batterynegativecable,and wait for 3 minutes. 10, Disconnectthe driver'sside airbag2P connector (see step 4 on page 23-211and both seat belt buckle lensioner4P connectors(seestep 6 onpage23-22). t 1 1 . D i s c o n n e c t R Su n i tc o n n e c t oB ( 1 8 P ) f r o mh e r S SRS unit (see step 7 on page 23-22). 12. Checkresistance betweenthe No. 15 and No. 18 ) r t e r m i n a l s f S R Su n i tc o n n e c t oB ( 1 8 P a n d o betweenthe No. 16 and No. 18 terminals.Then checkresistance betweenthe No. 18 terminal and body ground.Thereshould be an open circuit,or at l e a s t1 M Q . B {18PI SRS UNIT CONNECTOR
2 1 0 11
.t
6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 12-5indicated?
side NO-Short to ground in the front passenger's side airbaginflator;replacethe front passenger's 1 a i r b a g( s e ep a g e2 3 - 1 5 ) . 1
t6 1 7 1E
LTGRN/REDd i 116\l
9 Y 9
WHT/GRN
07xAz-s1A0200
5. Connectthe SRS inflatorsimulator(2 Q connector) and simulatorlead E to the floor wire harness.
GRY/RED
ls the resistanceas specified? YES FaultySRSunit; replacethe SRS unit (see page 23-1221.a N O - S h o r t t o g r o u n di n t h e f l o o rw i r e h a r n e s s ; r e p l a c eh e f l o o rw i r e h a r n e s s . l t
23-90
DTC13-3: Signalfrom the Driver's No Side lmpact Sensor

Special Tools Required . sRs inflatorsimularor07SAZ-TB4011A . SRSsimulatorlead H 07YM-S3AA100 1. ErasetheDTCmemory (seep age 23-261. 2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES- Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting lntermittentFailures(see page 23-261. 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Checkthe connectionbetweenthe floor wire harness2P connectorand the driver'sside impact sensor. ls the connectionOK? YES Go to step 5. NO-Replace the driver'sside impact sensorand/ or the floor harness, needed.I as
5. Disconnectthe driver's side airbagand front passenger's side airbag2P connectors(seestep 4 on page 23-21). Also disconnect both seat belt buckletensioner4P connectors(seestep 6 on page 23-22). 6. Disconnect floor wire harness2P connector{A} the from the driver'sside impact sensor.
07sAz-TB4011A
7. Connectthe SRS inflatorsimulator(2 Q connector) and simulatorlead H to the floor wire harness.
)
(cont'd)
23-91
sRs
B fromthe SRS 8. Disconnect unitconnector (18P) SRSunit(see step7 on page23-221. the 9. Check resistance between No.8 andNo.15 B There terminals sRSunitconnector ('l8P). of s h o u l d e0 1 . 0Q . b
B I18P) SRS UNIT CONNECTOR BRN/YEL
3
10 tl
l
FaultyPowerSupplyto the Driver's DTC13-4: Sensor Sidelmpact

1. Erasethe DTCmemory {seepage 23-261. 2. Turn the ignition switchON (ll),and checkthat the SRSlndicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO-lntermittent failure,system is OK at this time. Failures(see Intermittent Go to Troubleshooting page 23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnect driver'sside airbagand front the (seestep 4 passenger's side airbag2P connectors both seat belt on page23-21). Also disconnect buckletensioner4P connectors(seestep 6 on page 23-22).
:fr;f;l n \
l r or z r s l l |
LT GRN/RED
Is the resistance as specitied? YES Faultydriver'sside impact sensoror SRS unit; replacelhe driver'sside impactsensor(see page 23-123). the problem is still present,replace lf the SRSunit (seepage 23-122).1 t N O O p e ni n t h e f l o o rw i r e h a r n e s sr;e p l a c eh e floor wire harness.l
23-92
t
(A) 5. Disconnect floorwire harness connector the 2P fromthedriver's sideimpact sensor.
8. Checkresistance betweenlhe No.8 and No. l5 terminalsof SRSunil connectorB (18P). There should be an open circuit,or at least 1 M 0 .
SRSUNIT CONNECTOR {18P' B
BRN/YEL
2 3
10 11
1tr6l1tf;l \
LT GRN/RED
flliT;l
Wire side oI femaleterminals
Disconnect SRSunit connectorB (18P) from the SRS unit (see step 7 on page 23-22) 1 . Checkresistance betweenthe No. 8 terminal of SRS unit connectorB (18P) and body ground.There should be an open circuit,or at least 1 M Q .
ls the resistance as specitied? YES-Faulty driver's side impact sensoror SRS unit; replacethe driver'sside impact sensor(see page 23-1251.lf problem is still present,replace the t h e S R Su n i t( s e ep a g e 2 3 - 1 2 2 1 . a NO- Short in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . I
SRSUNITCONNECTOR{18PI B BRN/YEL
Wire side of femalete.minals
ls the resistance specitied? as YES-Go to step8. NO-Short to groundin thefloorwire harness; replace floorwire harness.I the
23-93
sRs
fromthe Front No DTC14-3: Signal Sensor Side Passenger's lmpact
SpecialToolsRequired . SRSinflatorsimulator07SAZ-TB401'lA . SRSsimulatorlead H 07YAZ'S3AA100 1. ErasetheDTCmemory (seepage 23-26). 2. Tu rn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES Go to step 3. failure,system is OK at this time. NO Intermittent Failures(see Intermittent Go to Troubleshooting page 23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Checkthe connectionbetweenthe floor wire harness2P connectorand the front passenger's side lmpact sensor. Is the connectionOK? YES-Go to step 5. NO- Poorcontactbetweenthe floor wire harness side impact 2P connectorand the front passenger's side impact sensor;replacethe front passenger's as sensorand/orthe floor harness, needed.
5 . Disconnectthedriver'sside airbagand front

passenger's side airbag2P connectors(seestep 4 Also disconnectboth seat belt on page 23-21). (seestep 6 on page buckletensioner4P connectors 23-22t. Disconnect floor wire harness2P connector{A) the side impact sensor. from the front passenger's
07sAz-TB4o11A
7. Connect the SRS inflatorsimulator(2 0 connector) and the simulatorlead H to the floor wire harness.
23-94
)
8. Disconnect SRSunit connectorB (18P)fromthe SRSunit (seestep 7 on page 23-221. 9. Checkresistance betweenthe No.9 and No. 16 terminalsof SRSunit connectorB (18P). There s h o u l db e 0 - 1 . 0 S 2 . SRS UNIT CONNECTOR B {18PI PNK/BLU
2 1 0 t1 3 0 t5
DTC14-4: FaultyPowerSupplyto the Front Passenger's lmpact Side Sensor

1. Erasethe DTCmemory (seepage23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-lntermittent failure,system is OK at this time. Go to Troubleshooting IntermittentFailures(see page 23-261. 3. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 4. Disconnectthe driver's side airbagand front passenger's side airbag2P connectors(seestep 4 on page 23-21). Also disconnectboth seat belt buckletensioner4P connectors(seestep 6 on page 23-22t. 5. Disconnect floor wire harness2P connector{A} the from the front passenger's side impact sensor.
l-u5l n
t-
iFf;l \
GRY/RED Wiresideol lemale terminals
ls the resistance as specified? YES-Faulty front passenger's side impact sensor or SRSunit; replacethe front passenger's side impactsensor(seepage 23-125). the problem is lf still present,replacethe SRS unit (seepage23-122). I NO-Open in the floor wire harness;replacethe floor wire harness. !
"-;s.\
\
\f r l/
\--)
- F.,=
Disconnecl SRS unit connectorB (18P) from the SRS unit (seestep 7 on page 23-22i.
I
(cont'd)
23-95
sRs
7. Checkresistance betweenthe No. 9 terminal of SRS unit connectorB (18P) and body ground.There should be an ooen circuit,or at least 1 N4 Q.
B SRSUNIT CONNECTOR {18PI
DTC15-1: Faulty OPDS Unit

NOTE: . An incorrectOPDSunit can causeDTC 15-1. . A n e w ( u n i n i t i a l i z e O)P D Su n i t i n s t a l l e d i t h a f a u l t y d w O P D Ss e n s o r a nc a u s eD T C 1 5 - 1 . c . lf you installa new OPDSunit and a new SRSunit at ( h t h e s a m et i m e , i n i t i a l i z te e O P D Sm a n u a l l y s e e page 23-27), not usethe HondaPGM Tester. do seat. 1. Make sure nothing is on the front passenger's 2. Initialize OPDSunit (seepage23-27). the 3. Erasethe DTCmemory (seepage 23-26]'.
PNK/BLU
4. Readthe DTC. Is DTC 15-1indicated? ls the tesistance as specilied? YES Go to step 5. YES Go to step 8. NO-Short to ground in the floor wire harness; replacethe floor wire harness.l betweenthe No.9 and No. 16 Checkresistance There terminalsof SRSunit connectorB (18P). should be an open circuit,or at least 1 M O . CONNECTOR B (18P) SRS UNIT NO Intermittent failure,system is OK at this time. Failures(see Intermittent Go to Troubleshooting page23-26). fuse/ Checkthe No. 9 (10A)fuse in the under-dash relay Dox, ls the tuse OK? YES Go to step 6. NO Go to step 9. Disconnect OPDSunit harness8P connector(A) from the OPDSunit (A) (seepage23-124).
2 10 tl
_-r
'18 sl /i
PNK/BLU
tltlis-l \
GRY/RED terminals Wiresideot female
ls the resistance as specified? side impactsensor YES-Faulty front passenger's side or SRS unit; replacethe front passenger's lf impact sensor{seepage 23-125). the problem is s t i l lp r e s e n tr,e p l a c eh e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . t I NO Short in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . l 7 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s
23-96
)
8. Checkfor voltage betweenthe No. 4 terminal of OPDSunit harness8P connectorand body ground. Thereshould be batteryvoltage.
OPDS UNIT HARNESS8P CONNECTOR
13. Disconnect OPDSunit harness8P connector(A) from the OPDSunit.
1 4 . Turn the ignition switch ON (ll) for 30 seconds, then turn it off. f C h e c k h e N o .9 ( 1 0 A ) u s e . t
ls there battery voltage? ls the f use OK? YES-Go to step 16. NO Open in the floor wire harnessor OPDSunit harness;replacethe faulty harness.I YES Short to ground in the OPDSunit; replacethe OPDSunit (seepage 23-1241.1 NO-Short to ground in the No. 9 (10A)fuse circuit (floor harness, OPDSharness); replacethe or affectedharness.I
to.
9 . R e p l a c eh e N o . 9 ( 1 0 A ) f u s en t h e u n d e r - d a s h t i fuse/relaybox.
1 0 .Turn the ignitionswitch ON (ll) for 30 seconds, then

turn it off. 1 1 .C h e c k h e N o . 9 ( 1 0 A ) f u s e . t ls the tuse OK?
Turn the ignition switch OFF.
1 1 . Checkresistance betweenthe No.8 terminal of OPDSunit harness8P connectorand body ground. '1.0 Thereshould be 0 Q.
OPDSUNIT HARNESS sPCONNECTOR
YES lntermittent failure,system is OK at this time. Go to Troubleshooting Intermiftent Failures(see page 23-26). NO Go to step 12. Replace No. 9 ('l0A)fuse. the
l4V-'l^l
TVjEl #
BLK
@ I
ls the resistance as specified? YES Go to step 18. NO Open in the floor wire harnessor OPDSunit h a r n e s so r p o o rg r o u n d( G 5 5 1 )l.f G 5 5 1i s O K , , replacethe faulty harness.I
)
(cont'd)
23-97
sRs
1 8 . Turn the ignition switch OFF.Disconnect the batterynegativecable.and wait for 3 minutes. 1 9 . Disconnect both side airbagconnectors(seestep 4 o n p a g e2 3 - 2 1 ) a n d o t hs e a tb e l tb u c k l e t e n s i o n e r b 4P connectors(seestep 6 on page23-22). 22. Checkresistance betweenthe No. 3 terminal of SRSunit connectorB (18P) and the No. 7 terminal of OPDSunit harness8P connector. Thereshould be0 1.0Q. SRSUNITCONNECTOR(18PI B GRN/ORN
20. Disconnect SRSunit connectorB (18P) from the

SRS unit (see step 7 on page 23-221. Checkresistance betweenthe No. 3 terminal of and body ground.There SRS unit connectorB (18P) should be an oDencircuit,or at least 1 MQ . SRSUNITCONNECTORI18PI B BLU
GRN/ORN Wire side of femaleterminals Wire side of femaleterminals OPOSUNIT HARNESS8P CONNECTOR
ls the resistance specitied? as YES Go to step23. NO Openin thefloorwire harness in the OPDS or unitharness; replace faultyharnessl the
Wiresideot temale terminals
Reconnect baftery the negative cable.

ls the resistance as specified? YES- Go to step 22. NO Short to ground in the floor wire harnessor OPDSunit harness;replacethe faulty harness.l
24. Turnthe ignition switch (ll). ON
23-98
25. Checkfor voltagebetweenthe No. 3 terminal of SRS unit connectorB (18P) and body ground.There s h o u l db e 0 . 5V o r l e s s .
B SRSUNITCONNECTOR (18P)
FaultySideAirbagCutoffIndicator DTC15-2: Circuit

1. Make sure nothing is on the front passenger's seat. 2. Erasethe DTCmemory (seepage 23-26]-. s 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) , a n d c h e c k t h a t t h e SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Turn the ignition switch OFF,and go to step
PNK
Wiresideof temale terminals NO Intermittent failure,system is OK at this time. IntermittentFailures(see Go to Troubleshooting page 23-26). NOTE:ThisDTCmay have been causedby turning t h e i g n i t i o n w i t c hO N ( l l ) w i t ht h e g a u g ea s s e m b l y s disconnected. T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k t h a t t h e s side airbagcutoff indicatorcomes on. Does the side airbag cutoft indicator come on? YES Go to step 5. NO Go to step 6. Make sure the side airbagcutoff indicatorgoes off after 5 seconds. Does the side airbag cutoff indicator go otf after 5 seconds? YES FaultyOPDSunit or SRS uniu replacethe lf OPDSunit (see page23-1241. the problem is still present,replacethe SRS unit (seepage 23-122).) NO Go to step 32. Turn the ignition switch OFF.
ls the voltageas specilied? YES Go to step 26. NO Short to power in the floor wire harnessor in the OPDSunit harness;replacethe faulty harness.l then 26. Replace OPDSunit (seepage 23-'124), the initialize system (seepage 23-27). the
2 7 . Erasethe DTCmemory,then checkfor DTC15-1.

ls DTC 15-l indicated? Y E S R e p l a c eh e S R Su n i t( s e ep a g e2 3 - 1 2 2 ) . 1 t NO The system is OK.l
{cont'd)
23-99
sRs
7. Checkthe No. 10 (7.5A)fusein the under-dash fuse/relaybox. ls the f use OK? YES Go to step 8. NO Replace fuse, then turn the ignition switch the ON (ll).lf the fuse blows again,checkfor a short in the No. 10 {7.5A)fuse circuit(ECMwire harness. floor harness, OPDSharness).1 or 8. Disconnect OPDSunit harness8P connector(A) the from the OPDSunit (seepage 23-124). 1 1 .Turn the ignltion switch OFF. 12. Disconnect dashboard the wire harness17P connectorK from the under-dash fuse/relaybox,
Turn the ignition switch ON (ll). 1 4 . Checkfor voltage betweenthe No. 3 terminal of the OPDSunit harness8P connectorand body ground. Thereshould be 0.5 V or less. OPDS UNITHABNESS CONNECTOR 8P
9 . Turn the ignitionswitch ON (ll). 1 0 .Checkfor voltage betweenthe No. 3 terminal of the
OPDSunit harness8P connectorand body ground. Thereshould be batteryvoltage.
OPDSUNtT HARNESS CONNECTOR 8P
ls the voltageas specitied? YES-Faulty OPDS unit;replace OPDS (see the unit page23-124) .a NO-Go to step15.
ls there battety voltage? Y E S G o t o s t e p1 1 . NO Go to step 23.
23-100
)
t5.
Turn the ignitionswitch OFF. Removethe gauge assembly(seepage 22-64). gaugeassemblyconnectorA from Then disconnect the gauge assembly.
1 9 . Turn the ignition switch OFF. 20. Disconnect floor wire harness6P connectorC509 (A)from the dashboardwire harness.
T u r nt h e i g n i t i o n w i t c hO N ( l l ) . s 1 7 . Turn the ignition switch ON (ll).
22. Checkfor voltage betweenthe No. 3 terminal of the

1 8 . Checkfor voltagebetweenthe No. 3 terminal of the OPDSunit harness8P connectorand body ground. Thereshould be 0.5 V or less. OPOS UNITHARNESS CONNECTOR 8P OPDSunit harness8P connectorand body ground. Thereshould be 0.5 V or less. OPDS UNIT HARNESS CONNECTOB 8P
\t
Wiresideof female terminals ls the voltage as specified? ls the voltageas specified? YES Short to power in the gaugeassembly; replacethe gaugeassembly.l NO Go to step 19. YES Short to power in dashboardwire harnessA; replacedashboardwire harnessA.l NO-Short to power in the floor wire harnessor in i t h e O P D Su n i t h a r n e s si;f t h e O P D Su n i t h a r n e s ss OK, replacethe floor wire harness.I
\,
(cont'd)
23-101
sRs
24. Removethe gaugeassembly(see page22-64l,. With the connectorsstill connected the gauge to '15 assembly,backprobe the No. terminal of gauge assemblyconnectorA (22P). Turn the ignition switch ON {ll). 2 9 . T u r nt h e i g n i t i o n w i t c hO N ( l l i s 3 0 . ' 0 2 m o d e l :C h e c k f o r v o l t a g e e t w e e nh e N o . 4 b t terminal of dashboardwire harnessA 6P connector C509and body ground.Thereshould be battery vorlage. '03 model: Checkfor voltagebetweenthe No. 5 terminal of dashboardwire harnessA 8P connector C509and body ground.Thereshould be battery vollage. '02 Model: OASHBOARD HARNESS6PCONNECTOF WIRE A A GAUGE ASSEMBLY CONNECTOR{22P)
26. Checkfor voltage betweenthe No. 15 terminal of

gauge assemblyconnectorA {22P) and body ground.Thereshould be batteryvoltage.
Terminalsideof male terminals
Wiresideof female terminals ls thete battery voltage? YES-Go to step 27. NO Go to step 31.
'03 Model: WIRE HARNESS 8PCONNECTOR A DASHBOARD
2 7 . Turn the ignitionswitch OFF. 28. Dlsconnect floor wire harness6P connectorC509
{A) from dashboardwire harness. s o t T e r m i n a li d e f m a l e e r m i n a l s ls there battety voltage? wire harness YES Poorcontactat the dashboard , A 6 P o r 8 P c o n n e c t oa n df l o o rw i r e h a r n e s sa n r o p e ni n t h e f l o o rw i r e h a r n e s so r a n o p e ni n t h e , i; O P D Su n i t h a r n e s sC h e c k h e c o n n e c t i o n f t h e . t connectionis OK, replacethe faulty harness.l NO Poor contactat gaugeassemblyconnectorA w A o { 2 2 P ) r a n o p e ni n d a s h b o a r d i r e h a r n e s s . if Checkgauge assemblyconnectorA {22P); the wire connections OK, replacedashboard are harness .I A
\ J
23-102
Checkfor voltagebetweenthe No. 2 terminal of ) g a u g ea s s e m b l y o n n e c t o B ( 2 2 P a n d b o d y c r ground.Thereshould be batteryvoltage. ASSEMBLY GAUGE CONNECTOR B {22P) YEL 1 2
32. Turn the ignitionswitch OFF. 33. Disconnect OPDSunit harness8P connector(A) the
f r o m t h e O P D Su n i t ( s e ep a g e2 3 -1 2 4 ) .
3 4
IJ
1t 12
,/1,/1,/)1 1
9 10 21 22
ls there battery voltage? YES Faultyside airbagcutoff indicatorcircuit; r e p l a c eh e g a u g ea s s e m b l y . l t NO Open in dashboard wire harnessA; replace dashboard ireharness .I w A
34. Turn the ignitionswitch ON (ll).

Does the slde airbag cutotf indicator come on? YES Go to step 35. NO FaultyOPDSunit; replacethe OPDSunit.l
3 5 . Turn the ignitionswitch OFF. 36. Removethe gaugeassembly(seepage 22-64).

gauge assemblyconnectorA from Then disconnect t h e g a u g ea s s e m b l y .
\,
(cont'd)
23-103
sRs
(cont'dl DTGTroubleshooting
37. Checkresistance betweenthe No. 15 terminal of gauge assemblyconnectorA (22P)and body ground.Thereshould be an open circuit,or at least 1M0. A GAUGE ASSEMBLY CONNECTORI22PI
J
Faulty DTC15-3: OPDS Sensor
1. Erasethe DTCmemory {seepage 23-261. 2 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d c h e c k h a tt h e s t SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO Intermittent failure,system is OK at this time. Go to Troubleshooting Intermittent Failures(see page 23-26).
ls the resistance as specified? YES-Short to ground in the side airbagcutoff indicatorcircuit;replacethe gaugeassembly.l NO Short to ground in the dashboardwire harnessA, floor wire harness,or OPDSunit harness;replacethe faulty harness.l
NOTE:Aftermarketdevices(fluorescent lights, laptop computers,etc.)used near the front passenger's seat-back can interferewith the seatbacksensorsand causea false DTC15-3.lf one of these deviceswas used,erasethe DTC,operatethe for devicenearthe seat-back, and recheck DTCs.lf DTC15-3is reset,eraseit, and do not usethe devicenearthe seat-back. 3 . Checkthe connectionat the OPDSsensorharness connectorand the OPDSunit connector. Are the connections OK? YES-Go to step 4. NO Reconnect OPDSsensorharness the connector, and clearthe DTC.I foam (seepage 4 . Replace the OPDSsensor/seat-back 20-141, initialize OPDS(seepage 23-27). and the Erasethe DTCmemory,then checkfor DTC15-3. ls DTC 15-3indicated? YES Replace OPDSunit (seepage 23-1241.a the NO The system is OK.l
23-104
SRSIndicator CircuitTroubleshooting
TheSRSIndicator Doesn't ComeOn
1. Turn the ignition switch ON (ll),and see if the other indicators come on {brakesystem,etc). Do the other indicatorscome on? YES Go to step 2. N O - G o t o s t e p8 . 2. Turn the ignition switch OFF,then removethe gauge assembly{see page22-641. Disconnect gauge assemblyconnectorA and B from the gauge assembly. Wiresideof female terminats Is the voltage as specified? Y E S - F a u l t yS R Si n d i c a t o c l r c u i t n t h e g a u g e r i assembly;replacethe gauge assembly.I 4. Checkfor voltage betweenthe No. l4terminal of gauge assemblyconnectorA (22P)and body ground within the first 6 secondsafter turning the ignition switch ON (ll).Thereshould be 8.5 V or less. GAUGE ASSEMBLY CONNECTORI22PI A
\9
N O - G o t o s t e p5 . Turn the ignition switch OFF.
Checkresistance betweenthe No. 12 terminal of gauge assemblyconnectorB (22P) and body g r o u n d . h e r es h o u l db e 0 1 . 0 Q . T GAUGE ASSEMBLY CONNECTOR B I22PI
3
BLK
11 12 l 3
/)x
9 10 21 22
1 1 1B
o.
Wiresideof female terminals Is the resistance as specified? YES Go to step 4.
l{,
N O O p e ni n t h e B L Kw i r e o f d a s h b o a r d i r e w h a r n e s s o r f a u l t yb o d y g r o u n dt e r m i n a l( G 5 0 1 )l.f A t h e b o d y g r o u n dt e r m i n a li s O K ,r e p l a c e a s h b o a r d d wireharness .I A (cont'd)
23-105
sRs
(cont'dl SRSIndicatorCircuitTroubleshooting
SRSunit connectorC (8P)from the SRS 6 . Disconnect unit {see step 7 on page 23-22). gaugeassemblyconnectorA (22P). 7 . Disconnect Connecta voltmeter betweenthe No, l4terminal of gauge assemblyconnectorA (22P) and body g r o u n d . u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d s T measurevoltage.There should be 0.5 V or less. A ASSEMBLY CONNECTOR{22P) GAUGE 9. Connecta voltmeterbetweenthe No.2 terminal of gauge assemblyconnectorB (22P)and body g r o u n d . u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d T s measurethe voltage.There should be battery voltaqe. B (22P} GAUGE ASSEMBLY CONNECTOR YEL 1
ll
2 12
,/
,/
,/x
6 11
o
9 10 21 22
terminals Wiresideof female ls the voltageas specitied? YES-Faulty SRSunit; replacethe SRSunit (see page23-'l22l.a NO-Short to power in the PNKwire of dashboard wire harnessA or in the floor wire harness;replace t h e f a u l t yh a r n e s s . l L Turn the ignition switch OFF.Checkthe No. 10 fuse/relaybox. {7.5A)fusein the under-dash ls the tuse blown? YES-Go to step 10. NO Go to step 9.
ls therc battery voltage? YES FaultySRSindicatorcircuitin the gauge assemblyor poor contactat gaugeassembly and the gaugeassembly;if the connectorB (22P) connectionis OK, replacethe gaugeassembly.l fuse/relaybox No. 10 NO Open in the under-dash (7.5A) fuse circuit,or open in the YELwire of fuse/ wire harnessA. lf the under-dash dashboard relay box is OK, replacelhe faulty harness.l fuse,then checkto see if 1 0 . Replace No. 10 (7.5A) the the indicatorscomes on. Do the indicators come on? YES The system is OK at thls time.l N O R e p a i t h e s h o r tt o g r o u n di n t h e u n d e r - d a s h r e f u s e / r e l a y o x N o . 1 0( 7 . 5 A ) f u sc i r c u i t . l b
23-106
I J
TheSRSlndicator StaysOn Whenln "SCS" MenuMethod
NOTE: . lf you cannot retrieveDTCSwiththe PGM Tester usingthe SRSmenu method.retrievethe flash codes with the Testerin SCS mode {seepage 23-24|,. . A new SRS unit must sensethe entire system is OK beforecompletingits initialself-test. The most common causeof an incompleteself-testis the failureto replaceall deployedpartsafter a collision, in particular, seat belt tensionersand seat belt buckle tenstoners. . An incompleteself-test preventsthe PGM Testerfrom retrievingDTCS, althoughflash codesare availablein the Tester'sSCSmode. 1. Erasethe DTCmemory usingthe MES connector (seepage 23-26). Does the SRS indicatorgo off while you are erasing the DTC memory? YES-Go to step 42. 6 . R e p l a c eh e N o . 1 3 ( 1 0 A ) u s e . t f 7. Turn the ignition switch OFF.Disconnect the batterynegativecable,and wait for 3 minutes. 8. Disconnect driver'sairbag 4P connector(see the step 2 on page 23-21). 9. Disconnect front passenger's the airbag4P connector(seestep 3 on page 23,21). 10. Disconnect both seatbelt tensioner2P connectors (seestep 5 on page 23-221. '11. D i s c o n n e c t S Ru n i t c o n n e c t o r A { 1 8 P ) f r o m t h e S SRS unit (see step 7 on page 23-22],. '12. Reconnect batterynegativecable. the
1 3 . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d w a i t f o r 3 0 s seconds. Then turn the ignition switch OFF. 1 4 . C h e c k t h e o . 1 3 ( ' 1 0 Af)u s e . N
ls the f use OK? NO Go to step 2. Checkthe No. '13{ 10A)fuse in the under-dash fuse/relaybox. l s t h e f u s eO K ? 1 5 . R e p l a c eh e N o . 1 3 ( 1 0 A ) u s e . t f YES--Goto step 19. NO Go to step 3. Y E S - S h o r t t o g r o u n di n t h e S R Su n i t ;r e p l a c eh e t SRS unit (seepage 23-122).a N O G o t o s t e p1 5 .
3 . R e p l a c e t h e o . 1 3( 1 0 A ) u s e . N f
T u r nt h e i g n i t i o n w i t c hO N ( l l ) ,a n d w a i t f o r 3 0 s seconds. Then turn the ignitionswitch OFF. C h e c k h e N o . 1 3( 1 0 A ) u s e . r f ls the f use OK? Y E S T h e s y s t e mi s O K a t t h i st i m e . I NO Go to step 6.
I
{cont'd)
23-107
sRs
(cont'd) SRSIndicatorCircuitTroubleshooting
'16. Disconnect dashboardwire harnessB connectorS fuse/relav from the under-dash bor.
24. Beconnect batterynegativecable. the

Connecta voltmeterbetweenthe No. 3 terminal of SRS unit connectorA (18P) and body ground.Turn the ignition switch ON (ll),and measurethe voltage. Thereshould be bafteryvoltage. A (18PI SRS UNIT CONNECTOR
PNK
1 1 . Turn the ignition switch ON {ll),and wait for 30 Then turn the ignition switch OFF, seconds. f t 1 8 .C h e c kh e N o . 1 3( 1 0 A ) u s e .
ls there battery voltage? ls the f use OK? YES Go to step 29. YES Short to ground in dashboardwire harness wire harnessB.I B; replacedashboard fuse/relay NO-Short to ground in the under-dash fuse/relaybox.l box; replacethe under-dash the 1 9 . Turn the ignition switch OFF.Disconnect batterynegativecable,and wait for 3 minutes. 20. Disconnect driver'sairbag 4P connector(see the step 2 on page 23-2'l). airbag 4P the 2 1 . Disconnect front passenger's connector(seestep 3 on page 23-21). NO Go to step 26.
26. Turn the ignition switch OFF.

dashboardwire harnessB connectorS 2 7 . Disconnect fuse/relavbox. from the under-dash
22. Disconnect both seat belttensioner2P connectors

(see step 5 on page 23-22). from the Disconnect SRS unit connectorA (18P) (see step 7 on page 23-22). SRS unit
23-108
I
28. Checkresistance betweenthe No. 3 terminal of SRSunit connectorA (18P) and the No. 2 terminal of dashboard wire harnessB connectorS. There s h o u l db e 0 1 . 0 0 . DASHBOARD WIRE HARNESS CONNECTOR B S
l
3 1 . C o n n e ctth e N o . 3 t e r m i n a lo f S R S u n i t c o n n e c t o r A (18P)and the No. 5 terminal of SRSunit connector C ( 8 P ) w i t h j u m p e rw i r e . a

SRS UNIT CONNECTOR I8P} C
Wire side of femaletermr n a s l
PNK
PNK T
l
a, uNrr CONNECTORI18P) SRS A

3 5 7 8 I
PNK Wire side of femaleterminals JUMPER WIRE A PNK SRSUNITCONNECTOR I18P)
1 0 11 12 l 3 1 4 1 5 16 1 1 l 8
Wiresideof female terminals 32. Turn the ignition switch ON (llf. ls the rcsistance as specified? 33. Checkthe SRS indicator. YES-Open in the under-dash fuse/relaybox or poor contactat dashboard wire harnessB connectors; checkthe connection.lf the connection is OK, replacethe under-dash fuse/relaybox.l NO-Open in dashboard wire harnessB; replace dashboard wire harnessB.I Did the SRS indicator go off? YES FaultySRS unit; replacethe SRS unit (see page 23-122l.a NO-Go to step 34. 34. Turn the ignition switch OFF. 35. Disconnect jumper wire betweenthe No. 3 the terminal of SRSunit connectorA (18P) and the No. 5 terminal of SRSunit connectorC (8P). 3 6 . C h e c k h e N o . 1 3 ( 1 0 A ) f u s en t h e u n d e r , d a s h t i fuse/relaybox. ls the f use OK? YES Go to step 40. NO Go to step 37. 3 7 . R e p l a c eh e N o . 1 3 { 1 0 A ) f u s e . t
29. Turn the ignitionswitch OFF. 30. Disconnect SRSunit connectorC {8P)from the SRS
unit (see step 7 on page 23-22],.
I
(cont'd)
23-109
sRs
(cont'dl SRSlndicatorGircuitTroubleshooting
then 38. Removethe gauge assembly(seepage 22-64), gauge assemblyconnectorA from the disconnect g a u g ea s s e m D l y , then 40. Removethe gauge assembly(seepage 22-64), gauge assemblyconnectorA from the disconnect g a u g ea s s e m b l y .
betweenthe No. 5 terminal of 3 9 . Checkresistance SRS unit connectorC (8P)and body ground.There should be an ooen circuit,or at least 1 fMQ ,
C SRSUNITCONNECTOR {8PI
4 1 . Checkresistance betweenthe No. 14 terminal of ) g a u g ea s s e m b l y o n n e c t oA ( 2 2 P a n dt h e N o . 5 c r Thereshould terminal of SRS unit connectorC (8P). 'l be 0 or less,
C SRS UNIT CONNECTOR (8P}
Wire side of lemale terminals CONNECTOR I22P) A GAUGEASSEMBLY
terminals Wiresideof lemale
ls the resbtance as specitied? ls the resistance as specitied? YES-Faulty SRS indicatorcircuit in the gauge t a s s e m b l yr;e p l a c eh e g a u g ea s s e m b l y . I o N O S h o r tt o g r o u n di n t h e f l o o rw i r e h a r n e s s r i n wire harnessA; replacethe faulty dashboard harness.l YES FaultySRS indicatorcircuitin the gauge assemblyor poor contactat gauge assembly lf checkthe connection. the connectorA (22P); connectionis OK, replacethe gauge assembly,I o N O O p e ni n t h e f l o o rw i r e h a r n e s s r i n dashboardwire harnessA; replacethe faulty harness. !
23-110
42. Turn the ignition switch OFF. 43. lf necessary, removethe SCSserviceconnector from the l\4ES connector. 4 4 . T u r nt h e i g n i t i o n w i t c hO N { l l } . s Does the SBS indicator come on for about 6 seconds and then go off? YES-The system is OK at this time. t
47. Check resistance between No.6 terminal the of SRSunitconnector (8P) C andbodyground. There s h o u l b e0 - 1 . 0 Q . d
SRS UNIT CONNECTOR I8P) C
2
0
BRN
n
NO Go to step 45. 4 5 . D i s c o n n e c t R Su n i tc o n n e c t oC ( 8 P ) r o m t h e S R S S r f unit (see step 7 on page 23-221. 46. Connectthe HondaPGM Tester{A) to the Data Link Connector(B),and follow the Tester'sprompts in the "SCS" menu (seethe Tester'soperating m a n ual ) .
ls the resistance as specified? YES FaultySRSunit or poor contactat SRS unit connectorC (8P); checkthe connection.lf the connectionis OK, replacethe SRS unit (seepage 23-1221.. NO Open in the SCS line betweenthe No.6 terminal of SRS unit connectorC (8P)and the No. 9 terminal (BRNwire) ofthe data link connector (DLC), open betweenthe No. 4 terminal of the or D L Ca n d b o d y g r o u n d .R e p a i r h e o p e nw i r e ( s ) . 1 t
.r9
,l
I
IL,
23-111
sRs
After Deployment ComponentReplacement/lnspection
NOTE:Beforedoing any SRS repairs.use the PGM referto the TesterSRSmenu method to checkfor DTCS; Indexfor the lessobvious DTCTroubleshooting front sensors,side deployedparts (seatbeit tensioners, airbagsensors,etc.) After a collisionwhere the seat belt tensioners deployed,replacethese items: ' Seat belt tensioners . Seat belt buckletensioners . S R Su n i t . Front impactsensors deployed. After a collisionwhere the front airbag(s) replacethese items: . S R Su n i t . Deployedairbag(s) . Seatbelt tensioners . Seat belt buckletensioners . Front impactsensors deployed, After a collisionwhere the side airbag{s) replacethese items: . S R Su n i t . D e p l o y e d i d ea i r b a g ( s ) s . Side impact senso(s)for the side(s) that deployed Duringthe repair process,inspectthese areas: . lnspectallthe SRSwire harnesses. Replace, don't repair,any damagedharnesses. . I n s p e c t t h e c a b l r e e l f o rh e a t d a m a g el.f t h e r ei s a n y e damage,replacethe cable reel. turn the Afterthe vehicleis completelyrepaired, ignitionswitch ON (ll).lf the SRSindicatorcomes on for about 6 secondsand then goes off, the SRSairbag system is OK. lf the indicatordoes not function properly, use the PGM TesterSRS Menu Methodto readthe DTC (seepage23-23). this doesn't retrieveany codes,use lf lf the Tester'sSCSmenu method (seepage23-24). you still cannot retrievea code,go to SRS IndicatorCircuit Troubleshooting.
\|J
23-112
Driver's Airbag Replacement

Removal
1. Disconnectthe batterynegativecable,and wait at least3 minutes beforebeginningwork. 2. Removethe accesspanel (A)from the steering wheel, then disconnect driver's airbag 4p the connector(B)from the cable reel.
Installation
1. Connectlhe horn switch connector(1P)to the driver'sairbag. 2. Placethe new driver'sairbag (A) inthesteering wheel, and secureit with new Torx bohs (B),and installthe maintenance cover (C).
a
9.8 N.m {1.0kgf.m,7.2 lbt.ft)
A \'l9
Removethe maintenance cover (A),then remove the two Torx bolts (B) using a Torx T3Obit.
Connect the cable reelto the driver's airbag4P connector(A),then installthe accesspanel (B)on the steeringwheel.
Disconnect horn switch connector(1P)(D). the 5 . Removethe driver'sairbag (C). 4. Connectthe batterynegativecable. 5 . After installingthe airbag,confirm proper system operation: . T u r nt h e i g n i t i o n w i t c hO N ( l l ) ;t h e S R Si n d i c a t o r s should come on for about 6 secondsand then go off. . Make sure the horn works.
lfc
23-113
sRs
AirbagReplacement FrontPassenger's
Removal
1. Disconnectthebatterynegativecable,and wait at least3 minutes before beginningwork, 2. Removethe glove box stops,and lower the glove box.
Installation
airbag(A) into the 1. Placethe new front passenger's Tightenthe front passenger's airbag dashboard. m o u n t i n gn u t s( B ) .
4P airbag the 3. Disconnect frontpassenger's (A) wire B. connector from dashboard harness
ft} kgf.m,7.2lbf 9.8N m {1.0 airbag4P connector Connectthe front passenger's ( A ) t od a s h b o a r d i r e h a r n e s s . w B
4 . Removethe three mounting nuts (A) from the
bracket.Coverthe lid and dashboardwith a cloth, and pry carefullywith a screwdriverto lift the front p a s s e n g e r 'a i r b a g( B )o u t o f t h e d a s h b o a r d . s a N O T E : T h e i r b a gl i d h a sp a w l so n i t s s i d ew h i c h aftachit to the dashboard.
Raisethe glove box, and reinstallthe stops. 4 . Reconnect batterynegativecable. the After installingthe airbag,confirm proper system s t o p e r a t i o nT u r nt h e i g n i t i o n w i t c hO N ( l l ) ; h e S R S ; indicatorshould come on for about 6 secondsand then go off.
trr
23-114
SideAirbag Replacement
NOTE: Review seatreplacement pro6edure the the in pertorming Bodysection before repairs service. or
Installation
NOTE: . l f t h e s i d ea i r b a gl i d i s s e c u r e d y a t a p e , r e m o v e l h e b rape. . Do not open the lid of the side airbagcover. . Use new mounting nuts tightenedto the specified torque. . Make sure that the seat-back cover is installed properly,lmproper installation may preventproper deployment. . Be sure to installthe harnesswires so that they are not pinchedor interferingwith other parts. 1. Placethe new side airbagon the seat-back frame (A).Tightenthe side airbag mounting nuts (B).
Removal
1. Disconnectthe battery negative cable, wait at and least minutes 3 before beginning work. 2. Disconnect sideairbag the harness 2P connector {A).
3 . Removethe seatassembly(seepage20-71)and
seat-back cover (seepage 20-75). Removethe mounting nut (A) and the side a i r b a g( B ) . 2. Installtheseat-back cover {seepage 20-75). 3. Installtheseat assembly(seepage 20-71), then connectthe side airbagharness2P connector. 4. Move the front seat and the seat-back through their full rangesof movement,making sure the harness wires are not pinchedor interfering with other parts. 5. Reconnect batterynegativecable. the 6. After installingthe side airbag,confirm proper system operation;Turnthe ignition switch ON (ll); t h e S R Si n d i c a t o s h o u l dc o m e o n f o r a b o u t6 r secondsand then go off.
l,o
23-115
sRs
Airbag Disposal
Special Tool Required Deployment tool 07HAz-SG00500 Beforescrappingany airbags,side airbags,seat belt tensioners, seat belt buckletensioners(including or the those in a whole vehicleto be scrapped), airbags, or side airbags,seat belt tensioners, seat belt buckle tensionersmust be deployed.lf the vehicleis still within the warranty period,the HondaDistrictService Managermust give approvaland/orspecialinstruction beforedeployingthe airbags,side airbags,seat belt Only afterthe or tensioners, seatbelt buckletensioners. or airbags,side airbags,seat belt tensioners, seat belt buckletensionershave been deployed(asthe resultof vehiclecollision,for example),can they be scrapped. and lf the airbags,side airbags,seat belt tensioners, seat belt buckletensionersappearintact(not deployed), treat them with extremecaution.Follow this Drocedure. Driver's Airbag: 4. Removethe accesspanelf rom the steeringwheel, then disconnect driver'sairbag4P connector the from the cable reel (seestep 2 on page 23-21). Front Passenger'sAirbag: 5. Lowerthe glove box,then disconnectthefront passenger's airbag 4P connectorfrom dashboard wire harnessB (seestep 3 on page 23-211. Side Airbag: from the the 6. Disconnect side airbag2P connectors floor wire harness(seestep 4 on page23-211. Seat belt tensioner: 7. Disconnect seat belt tensioner2P connectors the from the floor wire harness{seestep 5 on page 2322).Pullthe seat belt out all the way, and cut it off. Seat belt buckle tensioner: the 8, Disconnect seat belt buckletensioner4P from the floor wire harness(seestep 6 connectors on page 23-221.
Airbagsin the Vehicle Deploying

lf an SRSequippedvehicleis to be entirelyscrapped,its and seat belt airbags,side airbags.seat belt tensioners. buckletensionersshould be deolovedwhile still in the vehicle.The airbags,side airbags,seat belttensioners, and seat belt buckletensionersshould not be partsand should never be considered salvageable as installedin anothervehicle. the 1. Turn the ignition switch OFF,then disconnect batterynegativecable,and wait at least3 minutes. 2. Confirmthat each airbag,side airbag,or seat belt tensioneris securelymounted. I 3. Confirm that the specia tool isfunctioning properly by following the checkprocedureon the tool label.
$ J
23-116
9. Cut off each connector, strip the ends of the wires, and connectthe deploymenttool alligatorclips (A) to the wires. Placethe deploymenttool at least30 feet (10 meters)away from the vehicle. NOTE:The driver'sairbagand the front passenger's airbageach have four wires,two yellow and two red. Twist each Dairof unlikecoloredwires together,and connectan alligatorclip to each pair.
10. Connecta 12 volt batteryto the tool. . lf the green light on the tool comes on, the igniter circuit is defectiveand cannot deDlovthe component.Go to Disposalof Damaged ComDonents. . lf the red light on the tool comes on, the componentis readyto be deployed. 1 1 . P u s ht h e t o o l ' sd e p l o y m e ns w i t c h T h e a i r b a g s n d t . a tensionersshould deploy (deploymentis both h i g h l ya u d i b l e n d v i s i b l e a l o u d n o i s ea n d r a p i d a : inflationof the bag,followed by slow deflation). . lf the componentsdeploy and the green light on the tool comes on, continuewith this procedure. . lf a componentdoesn'tdeploy,yet the green Go light comes on, its igniter is defective. to Disposalof Damagedcomponents. . During deployment, the airbagscan becomehot enoughto burn you. Wait 30 minutesafter deploymentbeforetouchingthe airbags. 12. Disposeofthe completeairbag.No pan of it can be reused.Placeit in a sturdy plasticbag (A),and seal rt securery.
/ :
i'..-':
!
(cont'd)
23-117
sRs
Airbag Disposal(cont'dl
Deploying Components of the Vehicle Out
lf an intactairbagor tensionerhas been removedfrom a scrappedvehicle,or has beenfound defectiveor damagedduring transit,storage,or service,it should be deolovedas follows:
J
Deployment Tool Check
1. Connect yellowclipsto bothswitchprotector the handles thetool;connect toolto a battery. on the green 2. Push operation the switch: means tool is the OK;redmeans tool is faulty the 3. Disconnectthe battery the yellowclips. and
1. Confirmthat the specialtool isfunctioning properly by following the checkprocedureon this page or o n t h et o o ll a b e l . 2. Positionthe airbagface up, outdoors,on flat ground,at least30 feet (10 meters)from any obstacles DeoDle. or 3. Follow steps9 through 11 of the in-vehicle deploymentprocedure.
Disposalof DamagedComponents
1. lf installedin a vehicle,follow the removal procedurefor the driver'sairbag (seepage23-113), front passenger's airbag (seepage 23-114), side ( s e ep a g e2 3 - 1 1 5 ) .e a tb e l tt e n s i o n e ( s e e airbag s r page23-4),and seat belt buckletensioner. 2. In all cases.make a short circuit by cutting, stripping,and twisting togetherthe two inflator wires. NOTE;The driver'sand passenger's airbageach have four wires:twist each pair of like-colored wires together Package componentin the same packaging the that the new reolacement Dartcame in. Mark the outsideof the box "DAMAGEDAIRBAG ''DAMAGED NOT DEPLOYED'" SIDEAIRBAGNOT "DAMAGED DEPLOYED", SEATBELTTENSIONER NOT DEPLOYED" "DAlvlAGED or SEATBELT BUCKLE TENSIONER NOT DEPLOYED" it does so not get confusedwith your parts stock. Contactyour HondaDistrictServiceManagerfor how and where to return it for disposal.
I|J
23-118
CableReelReplacement
Removal
1 . M a k es u r et h e f r o n tw h e e l sa r e a l i g n e d t r a i g h t s ahead. Disconnect batterynegativecable,and wait at the least3 minutes. 6. Removethe dashboardlower cover (Ai.
3 . Removethe driver'sairbag{seepage 23-113). 4 . Disconnect connector(Al from the cruise the

control sevresumeswitch,then removethe s t e e r i n g h e e lb o l t( B ) . w
7 . Removethe column cover screws(A),then remove t h e c o l u m nc o v e r s( 8 , C ) .
)
5 . Align the front wheels straightahead,then remove the steeringwheel with a steeringwheel puller (see '17-6). step 3 on page Do not tap on the steeringwheel or steering c o l u m ns h a f t w h e nr e m o v i n g h e s t e e r i n g h e e l . t w
I,
(cont'd)
23-119
sRs
(cont'd) CableReelReplacement
Disconnect dashboardwire harness4P the connector(A)from the cable reel,then disconnect wire harness5P connector{B}from the dashboard the cable reel.
J
Installation
1. Beforeinstallingthe steeringwheel. align the front wheels straightahead. 2. lf not alreadydone, disconnect batterynegative the cable,and wait at least3 minutes. 3. Setthe cancelsleeve(A) so the projections(B)are v aligned ertically.
9 . R e l e a s t h e t a b ( B ) , h e n p u l l o f f t h e c a b l er e e l( A ) . e t
4 . Carefullyinstallthe cable reel (A) on the steering column shaft.Then connectlhe 5P connector{B) and the 4P connector(C).
J
23-120
)
8 . l n s t a l l t h e r i v e r ' s i r b a g( s e ep a g e2 3 - 1 1 3 ) . d a 9. Reconnect batterynegativecable. the 10. After installingthe cable reel,confirm proper syslem operalton: . Turn the ignition switch ON (ll);the SRS indicator should come on for about 6 secondsand then go off. . After the SRS indicatorhasturned off, turn the steeringwheel fully left and right to confirm the SRSindicatordoes not come on. . M a k es u r et h e h o r nw o r k s . . Make sure the cruisecontrolworks,
Installthe steeringcolumn covers. lf necessary, centerthe cable reel.{New replacement cable reelscome centered.) this by Do first rotatingthe cable reel clockwiseuntil it stops, Then rotateit counterclockwise labout 2 112lurns) untilthe arrow mark on the cable reel label Doints straightup.
A gn the projections the cable reel with the on noleson the steeringwheel, and installthe steering Ai\eelwith a new steeringwheel bolt (A).
) c
23-121
sRs
SRSUnit Replacement
Removal
'1. Disconnect batterynegativecable,and wait at the least3 minutesbefore beginningwork.
lnstallation
1 , I n s t a l l t h e e w S R Su n i t ( A ) w i t hT o r x b o l t s( B ) , h e n n t connectthe connectors{C)to the SRSuniu push them into positionuntil they clicks. NOTE: When tighteningthe Torx boltsto the specified torque, be carefulto turn them in so that their headsrest squarelyon the brackets.
9.8 N.m (1.0kgf m, 7.2 lbf ft)
2. Disconnect driver'sand front passenger's the airbagconnectors(seepage 23-21). 3. Disconnectthe side airbagconnectors(seepage 23-211. 4 . Disconnect both seat belt tensionerconnectors(see page 23-22)and both seat belt buckletensioner connectors {see page 23-221. Removethe dashboardcenterlower cover (see step 2 on page 20-57). Pull down the consolecarpeton the passenger's side,then removethe Torx bolt (A)from the SRS unit.
Reinstall dashboardcenterlower cover (see the step 2 on page 20-57). Reconnect driver'sand front passenger's the airbag connectors (see page 23-21]'. (seepage234. Reconnect the side airbagconnectors 211. (see Reconnect both seat belt tensionerconnectors page 23-221and both seat belt buckle tensioner connectors (see page 23-22). 7. Pull down the consolecarpeton the driver'sside, then disconnect connectors. Removethe Torx the bolts (A),then pull out the SRSunit.
6 . Reconnect batterynegativecable. the

7 . I n i t i a l i zte e O P D Su n i t ( s e ep a g e2 3 ' 2 7 ) . h
8 . After installingthe SRS unit,confirm propersystem

Turn the ignition switch ON (ll);the SRS operation: i n d i c a t o s h o u l dc o m eo n f o r a b o u t6 s e c o n d s n d r a then go off.
23-122
Side lmpact SensorReplacement

Removal
1. Disconnect batterynegativecable,and wait at the least3 minutesbefore beginningwork. 2. Disconnect appropriateside airbag2P the connector(seestep 4 on page 23-21). 3. Removethe seat assembly(seepage 20-71J. 4 . R e m o v e h e f r o n td o o rs i l l t r i ma n d t h e B - p i l l a r t lower trim panel (seepage 20-50). 5. Disconnect floor wire harness2P connector the from the side impact sensor. 6. Removethe Torx bolt (A) using a Torx T30 bit, then removethe side impact sensor(B).
lnstallation
1 . I n s t a ltlh e n e w s i d ei m p a c ts e n s o r i t h a n e w T o r x w bolt (A),then connectthe floor wire harness2P connector{B)to the side impact sensor{C).
2. Reconnect negativebatterycable. the 3 . After installingthe side impact sensor,confirm

proper system operation:Turnthe ignition switch r O N ( l l ) ; h e S R Si n d i c a t o s h o u l dc o m e o n f o r a b o u t t 6 secondsand then go off. Installall removed parts.
23-123
sRs
OPDSUnit Replacement
procedures the NOTE:Reviewthe seat replacement in body sectionbeforeperformingrepairsor service.
Installation
1. Placethe new OPDSunit (A) on the seat-back frame. Tightenthe two screws(B),and connectthe OPDS (C) unit harness8P and sensorconnectors to the OPDSunit. Reinstallthecover (D).
Removal
1. Disconnect batterynegativecable.and wait at the least3 minutesbefore beginningwork. 2. Disconnect passenger's the side airbag harness2P connector(seestep 4 on page23-2'll. 3. Removethe front passenger's seat assembly(see page20-71)andseat-back cover (seepage2O-15],. 4. Removethe cover (A),then disconnect the OPDS unit harness8P and sensorconnectors(B)from the OPDSunit.
2 . Installtheseat-back cover (seepage 20-75).

Installthe seat assembly(seepage20-71), then connectthe side airbag harness2P connector,
4. Reconnect the batterynegativecable.
Set the seat-back the normal position,and make in sure there is nothing on the front passenger's seat. Initialize OPDSunit (seepage 23-27). the 5. Removethe two screws(C)and the OPDSunit (D). 1 . After installingthe OPDSunit, confirm proper Turn the ignitionswitch ON (ll); system operation: the SRSindicatorshould come on for about 6 secondsand then go off.
23-124
Front lmpact SensorReplacement

Removal
1 . Disconnect batterynegativecable.and wait at the least3 minutesbefore beginningwork.
Installation
1. Installthe new front impact sensorwith new Torx bolts (A),then connectthe engine compartmentwire harness2P connector(B)to the front impactsensor
2 . Disconnect driver'sairbag4P connectorlsee the

step 2 on page23-21), front passenger's the airbag 4P connector(seestep 3 on page 23-21), both seat (seestep 5 on page belttensioner2P connectors 23-221, and both seat belt buckle4P connectors(see step 6 on page23-22). Removethe front inner fender (seepage 2O-1O21. Disconnect engine compartmentwire harness the 2P connector(A),and removethe two Torx bolts (B) using a Torx T30 bit, then removethe front impact sensor{C).
{c).
A 9.8N.m
(1.0kgf.m,7.2lbf.ftl
Reconnect batterynegativecable. the After installingthe front impact sensor,confirm proper system operation: Turn the ignition switch ON (ll);the SRS indicatorshould come on for about 6 secondsand then go off.
23-125

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Manual Service lndex

Back-up LightSwitch Test......................................................... 13'3 Back-up Li9ht3 Circuit Diagram

Meintenence section.................... 3 Section Gene.allnlormationsection........ Section1

Bumper,Front Removal/1nsra11ation ............................ 20 85 Bumper,Rear R e m o v a l / l n s t a l l a t i o.n . . . . . . . . . 2 0 . 8 6 .

EVAPControlSystm FuelFill Door Openet ComponentLocation Index ..............'11-170 B e p l a c e m e n t . . . . . . . . . . . ... . . . . . . . .2.0 . 1 0 9 . .

Test H.tch Lock Actuator Test 22-159

Test lgnition Switch Test .,,,.,.,.,,,,.,.,.

. . . . . . . . . . . . . . .2 2.-. 9.1 . .. . . ......22-53 License Plate Light R e p l a c e m e n t . . . . . . .-. . . . . . . . .....22-83

ReQ\ace$ent Hcadlights Diagram.............................. Circuit 22-71, 72 Headliner Removal/lnstallalion ............................ 20-54

MoonroofDreinChannel .0. . B e p l a c e m e n.t .. . . . . . . . . . . . . . . . . . . . . .2 . .3.9 . . . .

Manual Service lndex

Specifications (See section 2)

23-9 23-1 20-75 20-84

Radiatorand Condenser Fans CommonCircuit T r o u b l e s h o o l i n g . . . ........... . . . . . . . . . 2 1 9 2 RadialorCap Test..-.-... 10-3

SeatCover,Front Replacement SeatCushionCover,R6ar

StartingSystem Component Location Index...............-..... 4-3 CircuitDia9ram ........................................ 44

Secirculation ControlMotor Replacement Test.....

Retrigerant Oil Spark Plugs R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . 2.1 .-.6 . . - . . . . . . . . . . . . . .

Component Location Index................. 20-17

Thermostai Test ........................ 10 4 R e p l a c e m e n t . . . . . - . . . . . . . . . . . . . . . . . 1.0I. . . . . . .

Wiper/Washor Switch TesVReplacement .............................. 22-1 40 WireHarnesses

Timing/Cam Chain Auto-tensionel R e m o v a l / 1 n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -W9 1

Water Pump Inspection ........................... ....... 5 .. . . . 10 Replacement .-......................................... 10 5

UndeFdash Fuse/Rlay Box Removal/lnstaf ............................ lation 22-49 UpperArms R e m o v a l / | n s t a 1 1 a t i o n . . . . . . . .. .. ..1.8 - . . 2 . .. 3 .

Color Niqhthawk Black Pearl TaffetaWhite Satin Silver lvletallic M i l a n oR e d E u r oY e l i o wP e a r l

Chassis and PaintCodes- 2003Model

Vehicle ldentif ication Number {vlN}

Vehicle ldentificalion Numbe.lvlN)

Steering Wheel: DRIVER MODULE DANGER CABLEREEL CAUTION

SRS WARNING LABEL

Emission ControlLabel Under-hood

Families: Engine and Evaporative

2 HNX V O2.O VBP

2 HNX R OO99 AAH

Standards Service and Limits

lgnition coil plug Spark

12V 1 3-4 2 N G Kt Z F B 6 K 1 1 : DENSO: SKJ20DR-M11 1 . 0 1 . 1 m m ( 0 . 0 3 9 . 0 4 3n . ) 0 i in neutral: 8t2' ETDC 650150rpm at

o.o5 (0.002 mm in.)

Minimum Maximum vanatton

930kPa(9.5 kgflcmr, psi) 135 200kPa{2.0kgf/cm',28 psi)

primary Intake, Intake, Exhaust

(cold) clearance StemO.DS t e m - t o - g L r i dc l e a r a n c e e

height stem installed Valve springs length Free LD.

Exhaust lntake Exhaust lntake Exhaust lntake Exhaust

in.) 5.55mm (0.219 n 5 . 5 5 m { 0 . 2 1i9 . ) m

Exhaust Rocker arms Arm-to-shaft clearance

in.) 0.08mm (0.003 in.) 0.08mm (0.003

Measurement of I Warpage deck tsore diameter

SkirtO.D. 11mm (0.4in.)from at bottom of skirt

OiI(REKEN) OiI(FEDERAL I\4OG L) U pin Piston Pin'to-piston clearance Connecting rod

0.70mm (0.028 in.) 0.75mm (0.030 in.) 0.80mm 10.031 in.)

No. l journal No.2 journal N o .4 j o u r n a l No.5 journal No.3 journal

Rodjournal diameter Rod/main

Rod/main out iournal of,round E n dp l a y Runout . . - ' . : - - ' +

No.2 journal No.4 journal

No.3 journa/ Bodbearing clearance

q0rr034, -rn {O'o010 0-o01r|"tl 0.055 (0.0022 mm in.)

0.12mm (0.005 in.)

mm (0.784 in.) in.) 19.92 mm 19.938 19.950 10.78500.7854

in.) mm (0.0020 0.0032 0.050 0.082 in.) mm (0.0024 0.0047 0.060-0.120

in.i 0.10mm (0.004 in.) 0.15mm (0.006

LD. shaftbearings, Balancer